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GD535-5 | SN: B10001-UP | Komatsu | Heavy Equipment Manual PDF

Page 1


MOTORGRADER

Hydraulicdrivefanspecification

SERIALNUMBERSB10001andup

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00Indexandforeword

Tableofcontents 1

00Indexandforeword

Tableofcontents.........................................................................................................................................00-2

Acronyms..................................................................................................................................................00-12

Forewordandgeneralinformation............................................................................................................00-17

Safetynotice..........................................................................................................................................00-17

Howtoreadtheshopmanual................................................................................................................00-22

Explanationoftermsformaintenancestandard....................................................................................00-24

Handlingofelectricequipmentandhydrauliccomponents....................................................................00-26

Handlingofconnectorsnewlyusedforengines....................................................................................00-35

Howtoreadelectricwirecode...............................................................................................................00-38

Precautionswhencarryingoutwork......................................................................................................00-41

Methodofdisassemblingandconnectingpush-pulltypecoupler..........................................................00-44

Standardtighteningtorquetable............................................................................................................00-47

Conversiontable....................................................................................................................................00-51

01Specification

Acronyms....................................................................................................................................................01-3

Specifications..............................................................................................................................................01-8

Specificationdrawing...............................................................................................................................01-8

Specifications.........................................................................................................................................01-10

Weighttable...........................................................................................................................................01-16

Tableoffuel,coolant,andlubricants......................................................................................................01-17

10Structureandfunction

Acronyms....................................................................................................................................................10-4

Engineandcoolingsystem.........................................................................................................................10-9

Coolingsystem........................................................................................................................................10-9

Coolingfanmotor...................................................................................................................................10-11

Powertrainsystem...................................................................................................................................10-19

Powertrainsystemdrawing...................................................................................................................10-19

Powertrainpipingdrawing.....................................................................................................................10-20

Transmissioncontrol..............................................................................................................................10-21

Torqueconverter....................................................................................................................................10-22

Transmission..........................................................................................................................................10-25

Transmissioncontrolvalve.....................................................................................................................10-44

ECMV.....................................................................................................................................................10-46

Mainreliefvalveandtorqueconverterreliefvalve.................................................................................10-53

Frontaxle...............................................................................................................................................10-55

Rearaxle................................................................................................................................................10-58

Differential(Non-differentialspecification).............................................................................................10-59

Differential(Differentiallockspecification).............................................................................................10-61

Differentiallocksolenoidvalve...............................................................................................................10-64

Finaldrive..............................................................................................................................................10-65

Tandemdrive.........................................................................................................................................10-67

Steeringsystem........................................................................................................................................10-69

Steeringpipingdrawing..........................................................................................................................10-69

Priorityvalve..........................................................................................................................................10-70

Steeringvalve........................................................................................................................................10-75

Brakesystem............................................................................................................................................10-82

Hydraulicpipingdrawingofbrakesystem.............................................................................................10-82

Brakevalve............................................................................................................................................10-83

Brakecircuitaccumulator.......................................................................................................................10-88

Brakecircuitaccumulatorchargevalve.................................................................................................10-89

Wheelbrake...........................................................................................................................................10-95

Parkingbrakesolenoidvalveandlifterlockpinsolenoidvalve.............................................................10-96

Parkingbrake.........................................................................................................................................10-97

Undercarriageandframe..........................................................................................................................10-98

Frame.....................................................................................................................................................10-98

Tire.........................................................................................................................................................10-99

Hydraulicsystem.....................................................................................................................................10-100

Hydraulicsystem..................................................................................................................................10-100

Hydraulicpipingdrawingofworkequipment.......................................................................................10-102

Workequipmentcontrol.......................................................................................................................10-104

Hydraulictank......................................................................................................................................10-105

Workequipmentpumpandsteeringpump..........................................................................................10-106

Powertrainpump.................................................................................................................................10-107

Powertrainpumpanddifferentiallockpump.......................................................................................10-108

Brakeandcoolingfanpump................................................................................................................10-109

Controlvalve.........................................................................................................................................10-110

Functionsandvalveoperations............................................................................................................10-112

Hydrauliccylinder..................................................................................................................................10-113

Swiveljoint............................................................................................................................................10-114

Pilotcheckvalve...................................................................................................................................10-115

Workequipmentsystem.........................................................................................................................10-124

Circleanddrawbar...............................................................................................................................10-124

Blade....................................................................................................................................................10-126

Lifter.....................................................................................................................................................10-128

Circlerotationmotor.............................................................................................................................10-130

Circlerotationgear...............................................................................................................................10-132

Testingexhaustgastemperature...........................................................................................................30-20

Testingexhaustgascolor......................................................................................................................30-22

Adjustingvalveclearance......................................................................................................................30-24

Testingcompressionpressure...............................................................................................................30-26

Testingblowbypressure........................................................................................................................30-29

Testingengineoilpressure....................................................................................................................30-30

Handlingfuelsystemdevices................................................................................................................30-31

Releasingremainingpressurefromfuelsystem....................................................................................30-32

Testingfuelpressure..............................................................................................................................30-33

Bleedingairfromfuelcircuit...................................................................................................................30-34

Testingfuelcircuitforleakage................................................................................................................30-35

Handlingcylindercutoutmodeoperation...............................................................................................30-36

Handlingno-injectioncrankingoperation...............................................................................................30-37

Handlingvoltagecircuitofenginecontroller..........................................................................................30-38

Testingmuffler(mainbody)andstackedmufflerforloosenessanddamage........................................30-39

Testingmufflerfunction..........................................................................................................................30-40

Testinginstalledconditionofcylinderheadsandmanifolds..................................................................30-41

Testingofenginepipingfordamageandlooseness..............................................................................30-42

Testingfueldischarge,returnrate,andleakage....................................................................................30-43

Testingandadjustingairconditionercompressorbelttension..............................................................30-47

Checkingandreplacingalternatorbelt..................................................................................................30-49

Checkingandreplacingauto-tensioner.................................................................................................30-51

Powertrain................................................................................................................................................30-54

Testingpowertrainoilpressure.............................................................................................................30-54

Adjustingtransmissionspeedsensor....................................................................................................30-68

Retrievalofdisabledmachineduetotransmissionvalvefailure...........................................................30-71

Flushingprocedurefortorqueconverterandtransmissioncircuits........................................................30-74

Testingandadjustingtoe-in...................................................................................................................30-76

Testingandadjustingdifferentiallockoilpressure(differentiallockspecification).................................30-78

Steeringsystem........................................................................................................................................30-80

Testingandadjustingsteeringoilpressure............................................................................................30-80

Testingoilleakageofsteeringcylinder..................................................................................................30-81

Bleedingairfromsteeringcircuit............................................................................................................30-82

Brakesystem............................................................................................................................................30-83

Releasingremainingpressurefrombrakecircuit...................................................................................30-83

Testingandadjustingbrakeoilpressure................................................................................................30-84

Bleedingairfrombrakecircuit...............................................................................................................30-87

Testingwearofwheelbrakedisc...........................................................................................................30-88

Testingandadjustingparkingbrakepad................................................................................................30-89

Releasingparkingbrakemanually.........................................................................................................30-92

Chargingbrakeaccumulatorwithgas....................................................................................................30-93

Hydraulicsystem.......................................................................................................................................30-95

Testingworkequipmentoilpressure......................................................................................................30-95

Testinglifterlockpincircuitpressure.....................................................................................................30-97

Testingcoolingfanspeed......................................................................................................................30-99

Testingcoolingfancircuitoilpressure.................................................................................................30-100

Testingoilleakageofworkequipmentcylinder....................................................................................30-102

Bleedingairfromworkequipmentcircuit.............................................................................................30-105

Workequipment......................................................................................................................................30-106

Adjustingdrawbarballjointclearance.................................................................................................30-106

Testingandadjustingcircleguideclearance.......................................................................................30-107

Testingandadjustingslipclutchtypecircledrive................................................................................30-109

Electricalsystem......................................................................................................................................30-111

Procedurefortestingdiodes.................................................................................................................30-111

Specialfunctionsofmachinemonitor..................................................................................................30-113

Handlinghigh-voltagecircuitofenginecontroller................................................................................30-162

KOMTRAXterminalstart-upprocedure...............................................................................................30-163

Adjustingrearviewcameraangle.........................................................................................................30-167

Handlebatterydisconnectswitch........................................................................................................30-169

Preparatoryworkfortroubleshootingofelectricalsystemfailure........................................................30-170 PmClinic.................................................................................................................................................30-172

PmClinic..............................................................................................................................................30-172

40Troubleshooting

Acronyms....................................................................................................................................................40-8

Informationrelatedtotroubleshooting......................................................................................................40-13

Pointstorememberwhentroubleshooting............................................................................................40-13

Howtoproceedintroubleshooting........................................................................................................40-14

Checksbeforetroubleshooting..............................................................................................................40-15

Inspectionprocedurebeforetroubleshooting.........................................................................................40-17

Troubleshootingprocedure....................................................................................................................40-32

Failurecodelist......................................................................................................................................40-34

Symptomsandtroubleshootingnumbers..............................................................................................40-42

Informationdescribedintroubleshootingtable......................................................................................40-45

Diagnosisofopenharnessinpressuresensorsystem.........................................................................40-47

Connectorlistandlayout.......................................................................................................................40-49

Connectorpinlayout..............................................................................................................................40-63

T-boxandT-adapterlist.........................................................................................................................40-99

Locationsoffuses................................................................................................................................40-104

Troubleshootingbyfailurecode(displayofcode)...................................................................................40-107

Failurecode[1500L0]DoubleEngagementofT/MClutches..............................................................40-107 Failurecode[15G0MW]FailureofR-ClutchSystem...........................................................................40-108 Failurecode[15H0MW]FailureofClutchSystem(FH).......................................................................40-109 Failurecode[15J0MW]FailureofClutchSystem(FL).........................................................................40-110 Failurecode[15K0MW]FailureofClutchSystem(1st)........................................................................40-111 Failurecode[15L0MW]FailureofClutchSystem(2nd).......................................................................40-112 Failurecode[15M0MW]FailureofClutchSystem(3rd).......................................................................40-113 Failurecode[15N0MW]FailureofClutchSystem(4th)........................................................................40-114 Failurecode[15SBL1]ReleaseTroubleofECMV(R)..........................................................................40-115 Failurecode[15SBMA]MalfunctionofECMV(R)................................................................................40-117 Failurecode[15SCL1]ReleaseTroubleofECMV(FH).......................................................................40-119 Failurecode[15SCMA]MalfunctionofECMV(FH).............................................................................40-121 Failurecode[15SDL1]ReleaseTroubleofECMV(FL).......................................................................40-123 Failurecode[15SDMA]MalfunctionofECMV(FL).............................................................................40-125 Failurecode[15SEL1]ReleaseTroubleofECMV(1st)......................................................................40-127 Failurecode[15SEMA]MalfunctionofECMV(1st).............................................................................40-129 Failurecode[15SFL1]ReleaseTroubleofECMV(2nd).....................................................................40-131 Failurecode[15SFMA]MalfunctionofECMV(2nd)............................................................................40-133 Failurecode[15SGL1]ReleaseTroubleofECMV(3rd)......................................................................40-135 Failurecode[15SGMA]MalfunctionofECMV(3rd)............................................................................40-137

Failurecode[15SHL1]ReleaseTroubleofECMV(4th)......................................................................40-139

Failurecode[15SHMA]MalfunctionofECMV(4th).............................................................................40-141

Failurecode[15SJMA]MalfunctionofECMV(L/U).............................................................................40-143 Failurecode[15U0NT]OverloadofInchingClutch.............................................................................40-144 Failurecode[2G42ZG]AccumulatorOilPressureLow(Front)...........................................................40-145

Failurecode[2G43ZG]AccumulatorOilPressureLow(Rear)............................................................40-147

Failurecode[989L00]EngineControllerLockCaution1....................................................................40-149

Failurecode[989M00]EngineControllerLockCaution2...................................................................40-150

Failurecode[989N00]EngineControllerLockCaution3....................................................................40-151

Failurecode[AB00KE]ChargeVoltageLow.......................................................................................40-152

Failurecode[AB00KY]HotShortofAlternatorRTerminal..................................................................40-153

Failurecode[B@BAZG]Deratinginspeedduetoengineoilpressuredrop.......................................40-154

Failurecode[B@BCNS]EngineOverheat..........................................................................................40-155

Failurecode[B@CENS]T/COilTemp.Overheat...............................................................................40-156

Failurecode[B@CKNS]DIFFOilTemp.Overheat.............................................................................40-157

Failurecode[B@HANS]HYDOilTemp.Overheat..............................................................................40-159

Failurecode[CA111]EngineNE,controllerinternalerror...................................................................40-161

Failurecode[CA115]EngineNE,Bkupspeedsensorerror................................................................40-162

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