gd675-3c (aps) shop manual

2006 All Rights Reserved 00-1Printed in Japan 03-06 (01) (8)

SEBM020908

This shop manual may contain attachments and optional equipment that are not avail-able in your area. Please consult your local Komatsu distributor for those items youmay 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 SeriesEngine Shop Manual.

MACHINE MODEL SERIAL NUMBERGD555-3C 00 50001 and up 00GD655-3C 00 50001 and up 00GD675-3C 00 50001 and up 00

CONTENTS

00-2 GD555, 655, 675-3C (4)

No. of page

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

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

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

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

90 OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-100

GD555, 655, 675-3C 00-2-1(8)

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

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LIST OF REVISED PAGES

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00-3

Safety Safety notice

SafetySafety notice

General precautions

Mistakes in operation are extremely dangerous.Read the Operation and Maintenance Manual care-fully BEFORE operating the machine.

1. Before carrying out any greasing or repairs, readall the precautions given on the decals whichare fixed to the machine.

2. When carrying out any operation, always wearsafety shoes and helmet. Do not wear loosework 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 atrained, experienced welder carry out the work.When carrying out welding work, always wearwelding gloves, apron, hand shield, cap andother clothes suited for welding work.

4. When carrying out any operation with two ormore workers, always agree on the operatingprocedure before starting. Always inform yourfellow workers before starting any step of theoperation. Before starting work, hang UNDERREPAIR signs on the controls in the operator'scompartment.

5. Keep all tools in good condition and learn thecorrect way to use them.

6. Decide a place in the repair workshop to keeptools and removed parts. Always keep the toolsand parts in their correct places. Always keepthe work area clean and make sure that there isno dirt or oil on the floor. Smoke only in theareas provided for smoking. Never smoke whileworking.

Preparations for work

7. Before adding oil or making any repairs, parkthe machine on hard, level ground, and blockthe wheels or tracks to prevent the machinefrom moving.

8. Before starting work, lower blade, ripper, bucketor any other work equipment to the ground. Ifthis is not possible, insert the safety pin or useblocks to prevent the work equipment from fall-ing. In addition, be sure to lock all the controllevers and hang warning signs on them.

9. When disassembling or assembling, support themachine with blocks, jacks or stands beforestarting work.

10. Remove all mud and oil from the steps or otherplaces used to get on and off the machine.Always use the handrails, ladders or steps whengetting on or off the machine. Never jump on oroff the machine. If it is impossible to use thehandrails, ladders or steps, use a stand to pro-vide safe footing.

Important safety noticeProper service and repair is extremely important for safe machine operation. The service and repairtechniques 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 specificpurpose.

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

00-4

Safety Safety notice

Precautions during work

11. When removing the oil filler cap, drain plug orhydraulic pressure measuring plugs, loosenthem slowly to prevent the oil from spurting out.Before disconnecting or removing componentsof the oil, water or air circuits, first remove thepressure completely from the circuit.

12. The water and oil in the circuits are hot when theengine is stopped, so be careful not to getburned.Wait for the oil and water to cool before carryingout any work on the oil or water circuits.

13. Before starting work, remove the leads from thebattery. Always remove the lead from the nega-tive () terminal first.

14. When raising heavy components, use a hoist orcrane.Check that the wire rope, chains and hooks arefree from damage.Always use lifting equipment which has amplecapacity.Install the lifting equipment at the correct places.Use a hoist or crane and operate slowly to pre-vent the component from hitting any other part.Do not work with any part still raised by the hoistor crane.

15. When removing covers which are under internalpressure or under pressure from a spring,always leave two bolts in position on oppositesides. Slowly release the pressure, then slowlyloosen the bolts to remove.

16. When removing components, be careful not tobreak or damage the wiring. Damaged wiringmay cause electrical fires.

17. When removing piping, stop the fuel or oil fromspilling out. If any fuel or oil drips onto the floor,wipe it up immediately. Fuel or oil on the floorcan cause you to slip, or can even start fires.

18. As a general rule, do not use gasoline to washparts. In particular, use only the minimum of gas-oline when washing electrical parts.

19. Be sure to assemble all parts again in their origi-nal places.Replace any damaged parts with new parts. When installing hoses and wires, be sure

that they will not be damaged by contact withother parts when the machine is beingoperated.

20. When installing high pressure hoses, make surethat they are not twisted. Damaged tubes aredangerous, so be extremely careful when install-ing tubes for high pressure circuits. Also, checkthat connecting parts are correctly installed.

21. When assembling or installing parts, always usethe specified tightening torques. When installingprotective parts such as guards, or parts whichvibrate violently or rotate at high speed, be par-ticularly careful to check that they are installedcorrectly.

22. When aligning two holes, never insert your fin-gers or hand. Be careful not to get your fingerscaught in a hole.

23. When measuring hydraulic pressure, check thatthe measuring tool is correctly assembledbefore taking any measurements.

24. Take care when removing or installing the tracksof track-type machines.When removing the track, the track separatessuddenly, so never let anyone stand at eitherend of the track.

00-5

Foreword General

ForewordGeneralThis shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman anaccurate understanding of the product and by showing him the correct way to perform repairs and make judge-ments. 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 serviceworkshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-ther divided into the each main group of components.

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

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

Disassembly and assemblyThis section explains the procedures for removing, installing, disassembling and assembling each com-ponent, as well as precautions for them.

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

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

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

00-6

Foreword General

How to read the shop manual

VolumesShop manuals are issued as a guide to carrying outrepairs. They are divided as follows:

Chassis volume: Issued for every machine modelEngine volume: Issued for each engine series

These various volumes are designed to avoid dupli-cating the same information. Therefore, to deal withall repairs for any model , it is necessary that chas-sis, engine, electrical and attachment volumes beavailable.

Distribution and updatingAny additions, amendments or other changes will besent to KOMATSU distributors. Get the most up-to-date information before you start any work.

Filing method1. See the page number on the bottom of the page.

File the pages in correct order.

2. Following examples show how to read the pagenumber.

Example 1 (Chassis volume):

Example 2 (Engine volume):

3. Additional pages: Additional pages are indi-cated by a hyphen () and number after thepage number. File as in the example.

Example:

Revised edition markWhen a manual is rev ised, an edi t ion mark((1)(2)(3)....) is recorded on the bottom of the pages.

RevisionsRevised pages are shown in the List of revisedpages next to the Contents page.

SymbolsSo that the shop manual can be of ample practicaluse, important safety and quality portions aremarked with the following symbols.

Electrical volume: Attachments volume:

Each issued as one volume to cover all models

10 - 3

Item number (10. Structure and Function)Consecutive page number for each item.

12 - 5

Unit number (1. Engine) Item number (2. Testing and Adjusting)Consecutive page number for each item.

10-4

Added pages

20-20310-4-1 12-203-110-4-2 12-203-210-5 12-204

Symbol Item Remarks

k SafetySpecial safety precautions are necessary when performing the work.

a Caution

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

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

3 Tightening torquePlaces that require special attention for the tightening torque during assembly.

2 CoatPlaces to be coated with adhesives and lubricants, etc.

5 Oil, waterPlaces where oil, water or fuel must be added, and the capacity.

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

00-7

Foreword Hoisting instructions

Hoisting instructionsHoisting

If a part cannot be smoothly removed from themachine by hoisting, the following checks shouldbe made:1) Check for removal of all bolts fastening the

part to the relative parts.2) Check for existence of another part causing

interference with the part to be removed.

Wire ropes1) Use adequate ropes depending on the

weight of parts to be hoisted, referring to thetable below:

a The allowable load value is estimated to beone-sixth or one-seventh of the breakingstrength of the rope used.

2) Sling wire ropes from the middle portion ofthe hook.

Slinging near the edge of the hook maycause the rope to slip off the hook duringhoisting, and a serious accident can result.Hooks have maximum strength at the mid-dle portion.

3) Do not sling a heavy load with one ropealone, but sling with two or more ropessymmetrically wound onto the load.

k Slinging with one rope may causeturning of the load during hoisting,untwisting of the rope, or slipping of therope from its original winding position onthe load, which can result in a dangerousaccident.

4) Do not sling a heavy load with ropes forminga wide hanging angle from the hook.When hoisting a load with two or moreropes, the force subjected to each rope willincrease with the hanging angles. The tablebelow shows the variation of allowable loadkN {kg} when hoisting is made with tworopes, each of which is allowed to sling upto 9.8 kN {1000 kg} vertically, at varioushanging angles.When two ropes sling a load vertically, up to19.6 kN {2000 kg} of total weight can besuspended. This weight becomes 9.8 kN{1000 kg} when two ropes make a 120?hanging angle. On the other hand, tworopes are subjected to an excessive forceas large as 39.2 kN {4000 kg} if they sling a19.6 kN {2000 kg} load at a lifting angle of150.

k Heavy parts (25 kg or more) must be liftedwith a hoist, etc. In the Disassembly andassembly section, every part weighing 25kg or more is indicated clearly with thesymbol

Wire ropes(Standard Z or S twist ropes

without galvanizing)Rope diameter Allowable load

mm kN tons10

11.512.514161820

22.430405060

9.813.715.721.627.535.343.154.998.1

176.5274.6392.2

1.01.41.62.22.83.64.45.6

10.018.028.040.0

4

SAD00479

41%71%79%88%100%

00-8

Foreword Method of disassembling, connecting push-pull type coupler

Method of disassembling, connecting push-pull type couplerk Before carrying out the following work, release

the residual pressure from the hydraulic tank.For details, see Testing and adjusting,Releasing residual pressure from hydraulic tank.

k Even if the residual pressure is released fromthe hydraulic tank, some hydraulic oil flows outwhen the hose is disconnected. Accordingly,prepare an oil receiving container.

Disconnection1) Release the residual pressure from the

hydraulic tank. For details, see Testing andadjusting, Releasing residual pressure fromhydraulic tank.

2) Hold adapter (1) and push hose joint (2) intomating 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 itclicks. (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.

Connection1) Hold hose adapter (1) or hose (5) and insert it in

mating adapter (3), aligning them with eachother. (See Fig. 4)a Do not hold rubber cap portion (4).

2) After inserting the hose in the mating adapterperfectly, pull it back to check its connectingcondition. (See Fig. 5)a When the hose is pulled back, the rubber cap

portion moves toward the hose about 3.5mm. This does not indicate abnormality,however.

Type 1

00-9

Foreword Method of disassembling, connecting push-pull type coupler

Type 2 Type 3D

isas

sem

bly

1) Hold the mouthpiece of the tightening portionand push body (2) in straight unti l s l id ingprevention ring (1) contacts contact surface a ofthe hexagonal portion at the male end.

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

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

1) Hold the mouthpiece of the tightening portionand push body (2) in straight unti l sl idingprevention ring (1) contacts contact surface a ofthe hexagonal portion at the male end.

2) Hold in the condition in Step 1), and push untilcover (3) contacts contact surface a of thehexagonal portion at the male end.

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

Con

nect

ion

Hold the mouthpiece of the tightening portion andpush body (2) in straight until sliding preventionring (1) contacts contact surface a of thehexagonal portion at the male end to connect it.

Hold the mouthpiece of the tightening portion andpush body (2) in straight until sliding preventionring (1) contacts contact surface a of thehexagonal portion at the male end to connect it.

00-10

Foreword Coating materials

Coating materialsa The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly

and assembly are listed below.a For coating materials not listed below, use the equivalent of products shown in this list.

Category Komatsu code Part No. Qty Container Main applications, features

Adhesives

LT-1A 790-129-9030 150 g Tube Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.

LT-1B 790-129-9050 20 g (2 pcs.)Polyethylene

container

Used in places requiring an immediately effective, strong adhesive.Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal.

LT-2 09940-00030 50 g Polyethylene container

Features: Resistance to heat and chemicals

Used for anti-loosening and sealant purpose for bolts and plugs.

LT-3790-129-9060

(Set of adhesive and hardening

agent)

Adhesive: 1 kg

Hardening agent: 500 g

Can

Used as adhesive or sealant for metal, glass and plastic.

LT-4 790-129-9040 250 g Polyethylene container Used as sealant for machined holes.

Holtz MH 705 790-126-9120 75 g Tube

Used as heat-resisting sealant for repairing engine.

Three bond 1735 790-129-9140 50 g

Polyethylene container

Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals,

rubbers, plastics and woods.

Aron-alpha 201 790-129-9130 2 g


Quick hardening type adhesive Quick cure type

(max. strength after 30 minutes) Used mainly for adhesion of rubbers,

plastics and metals.

Loctite 648-50 79A-129-9110 50 cc


Resistance to heat, chemicals Used at joint portions subject to high

temperatures.

Gasket sealant

LG-1 790-129-9010 200 g Tube Used as adhesive or sealant for gaskets and packing of power train case, etc.

LG-5 790-129-9080 1 kg Can Used as sealant for various threads, pipe

joints, flanges. Used as sealant for tapered plugs,

elbows, nipples of hydraulic piping.

LG-6 790-129-9020 200 g Tube

Features: Silicon based, resistance to heat, cold

Used as sealant for flange surface, tread. Used as sealant for oil pan, final drive

case, etc.

LG-7 790-129-9070 1 kg Tube

Features: Silicon based, quick hardening type

Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.

Three bond 1211 790-129-9090 100 g Tube

Used as heat-resisting sealant for repairing engine.

Three bond 1207B 419-15-18131 100 g Tube

Features: Silicone type, heat resistant, vibration resistant, and impact resistant sealing material

Used as sealing material for transfer case

00-11

Foreword Coating materials

Molybdenum disulphide lubricant

LM-G 09940-00051 60 g Can Used as lubricant for sliding portion (to prevent from squeaking).

LM-P 09940-00040 200 g Tube Used to prevent seizure or scuffling of the

thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings,

etc.

Grease

G2-LI

SYG2-400LISYG2-350LISYG2-400LI-ASYG2-160LISYGA-160CNLI

Various Various

General purpose type

G2-CA

SYG2-400CASYG2-350CASYG2-400CA-ASYG2-160CASYGA-160CNCA

Various Various

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

Molybdenum disulphide greaseLM-G (G2-M)

SYG2-400MSYG2-400M-ASYGA-16CNM

400 g 10400 g 20

16 kg

Bellows typeBellows type

Can

Used for heavy load portion

Hyper White Grease G2-TG0-T (*)*: For use in

cold district

SYG2-400T-ASYG2-16CNTSYG0-400T-A (*)SYG0-16CNT (*)

400 g16 kg

Bellows typeCan

Seizure resistance and heat resistance higher than molybdenum disulfide grease

Since this grease is white, it does not stand out against machine body.

Biogrease G2BG2-BT (*)*: For high

temperature and large load

SYG2-400BSYGA-16CNBSYG2-400BT (*)SYGA-16CNBT (*)

400 g16 kg

Bellows typeCan

Since this grease is decomposed by bacteria in short period, it has less effects on microorganisms, animals, and plants.

Primer

SUNSTAR PAINT PRIMER 580 SUPER

417-926-3910

20 ml Glass container

Adhe

sive

for c

ab g

lass

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

SUNSTAR GLASS PRIMER 580 SUPER

20 ml Glass container Used as primer for glass side

(Using limit: 4 months)

SUNSTAR PAINT PRIMER 435-95

22M-54-27230 20 ml Glass container Used as primer for painted surface on

cab side (Using limit: 4 months)

SUNSTAR GLASS PRIMER 435-41

22M-54-27240 150 ml Can Used as primer for black ceramic-

coated surface on glass side and for hard polycarbonate-coated surface(Using limit: 4 months)

SUNSTAR SASH PRIMER GP-402

22M-54-27250 20 ml Glass container Used as primer for sash (Alumite).


Adhesive

SUNSTAR PENGUINE SUPER 560

22M-54-27210 320 mlEcocart (Special

container)

Used as adhesive for glass.(Using limit: 6 months)

SUNSTAR PENGUINE SEAL 580 SUPER S or W

417-926-3910 320 ml Polyethylene container

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)

Sika Japan, Sikaflex 256HV 20Y-54-39850 310 ml


Used as adhesive for glass.(Using limit: 6 months)

Caulking material

SUNSTAR PENGUINE SEAL No. 2505

417-926-3920 320 ml Polyethylene container Used to seal joints of glass parts.


SEKISUI SILICONE SEALANT

20Y-54-55130 333 ml Polyethylene container Used to seal front window.


GE TOSHIBA SILICONES TOSSEAL 381

22M-54-27220 333 ml Cartridge Used to seal joint of glasses.

Translucent white seal.(Using limit: 12 months)

Category Komatsu code Part No. Qty Container Main applications, features

00-12

Foreword Standard tightening torque

Standard tightening torqueStandard 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.

Table of tightening torques for flared nutsa In the case of flared nuts for which there is no

special instruction, tighten to the torque given inthe table below.

Thread diameter of bolt

Width across flats

Tightening torque

mm mm Nm kgm

68

101214

1013171922

11.8 14.727 3459 7498 123

153 190

1.2 1.52.8 3.5

6 7.510 12.5

15.5 19.5

1618202224

2427303236

235 285320 400455 565610 765785 980

23.5 29.533 41

46.5 5862.5 78

80 100

2730333639

4146505560

1150 14401520 19101960 24502450 30402890 3630

118 147155 195200 250250 310295 370

Thread diameter of bolt

Width across flats

Tightening torque

mm mm Nm kgm

68

1012

10131427

5.9 9.813.7 23.534.3 46.174.5 90.2

0.6 1.01.4 2.43.5 4.77.6 9.2

SAD00483

Sealing surface

Thread diameter Width across flats Tightening torque

mm mm Nm kgm

1418222430333642

1924273236414655

24.5 4.949 19.6

78.5 19.6137.3 29.4176.5 29.4196.1 49245.2 49294.2 49

2.5 0.55 28 2

14 318 320 525 530 5

00-13


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

below.

Table of tightening torques for o-ring boss piping jointsa Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Table of tightening torques for o-ring boss plugsa Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter Width across flats Tightening torque

mm mm Nm kgm

101216

141722

59 7498 123

235 285

6 7.510 12.5

23.5 29.5

Norminal No.Thread diameter Width across flats Tightening torque (Nm {kgm})

mm mm Range Target

0203, 0405, 0610, 12

14

1420243342

Varies depending on type of connector.

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}

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

Norminal No.Thread diameter Width across flats Tightening torque (Nm {kgm})

mm mm Range Target

08101214161820243033364252

08101214161820243033364252

14171922242730323236

5.88 8.82 {0.6 0.9}9.8 12.74 {1.0 1.3}14.7 19.6 {1.5 2.0}19.6 24.5 {2.0 2.5}24.5 34.3 {2.5 3.5}34.3 44.1 {3.5 4.5}44.1 53.9 {4.5 5.5}58.8 78.4 {6.0 8.0}

93.1 122.5 {9.5 12.5}107.8 147.0 {11.0 15.0}127.4 176.4 {13.0 18.0}181.3 240.1 {18.5 24.5}274.4 367.5 {28.0 37.5}

7.35 {0.75}11.27 {1.15}17.64 {1.8}22.54 {2.3}

29.4 {3.0}39.2 {4.0}49.0 {5.0}68.6 {7.0}

107.8 {11.0}124.4 {13.0}151.9 {15.5}210.7 {21.5}323.4 {33.0}

00-14


Tightening torque for 102 and 114 engine series1) Bolt and nuts

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.

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

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

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.

Thread diameter Tightening torque

mm Nm kgm

68

1012

10 224 443 677 12

1.02 0.202.45 0.414.38 0.617.85 1.22


mm Nm kgm

68

101214

8 210 212 224 436 5

0.81 0.201.02 0.201.22 0.202.45 0.413.67 0.51


inch Nm kgm

1 / 161 / 81 / 43 / 81 / 23 / 4

1

3 18 2

12 215 224 436 560 9

0.31 0.100.81 0.201.22 0.201.53 0.202.45 0.413.67 0.516.12 0.92

Nominal size of hose

Width across flats

Tightening torque (Nm {kgm}) Taper seal type Face seal type

Range Target Thread size (mm)Nominal thread size Threads per inch,

Thread seriesRoot diameter

(mm) (Reference)

02 1934 54 {3.5 5.5} 44 {4.5} 9 18UN 14.31634 63 {3.5 6.5} 44 {4.5} 14

0322 54 93 {5.5 9.5} 74 {7.5} 11 16UN 17.51624 59 98 {6.0 10.0} 78 {8.0} 18

04 27 84 132 {8.5 13.5} 103 {10.5} 22 13 16UN 20.61605 32 128 186 {13.0 19.0} 157 {16.0} 24 1 14UNS 25.4

06 36 177 245 {18.0 25.0} 216 {22.0} 30 1 3 12UN 30.216(10) 41 177 245 {18.0 25.0} 216 {22.0} 33

(12) 46 197 294 {20.0 30.0} 245 {25.0} 36

(14) 55 246 343 {25.0 35.0} 294 {30.0} 42

00-15

Foreword Electric wire code

Electric wire codeIn 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

Classification by color and code

Norminal number

Copper wireCable O.D.

(mm)Current rating

(A) Applicable circuitNumber of strands

Dia. of strands (mm2)

Cross section (mm2)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

PriorityCircuits

Charging Ground Starting Lighting Instrument Signal OtherClassification

1 PrimaryCode W B B R Y G L

Color White Black Black Red Yellow Green Blue

2

Auxiliary

Code WR BW RW YR GW LW

Color White & Red White & Black

Red & White

Rellow & Red

Green & White

Blue & White

3Code WB BY RB YB GR LR

Color White & Black Black & Yellow

Red & Black

Yellow & Black

Green & Red

Blue & Yellow

4Code WL BR RY YG GY LY

Color White & Blue Black &

RedRed & Yellow

Yellow & Green

Green & Yellow

Blue & Yellow

5Code WG RG YL GB LB

Color White & Green Red & Green

Yellow & Blue

Green & Black

Blue & Black

6Code RL YW GL

Color Red & Blue Yellow & WhiteGreen &

Blue

00-16

Foreword Conversion table

Conversion tableMethod of using the conversion table

The Conversion Table in this section is provided to enable simple conversion of figures. For details of themethod 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 inches1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

00.3940.7871.1811.575

1.9692.3622.7563.1503.543

0.0390.4330.8271.2201.614

2.0082.4022.7953.1893.583

0.0790.4720.8661.2601.654

2.0472.4412.8353.2283.622

0.1180.5120.9061.2991.693

2.0872.4802.8743.2683.661

0.1570.5510.9451.3391.732

2.1262.5202.9133.3073.701

0.1970.5910.9841.3781.772

(C)

2.5592.9533.3463.740

0.2360.6301.0241.4171.811

2.2052.5982.9923.3863.780

0.2760.6691.0631.4571.850

2.2442.6383.0323.4253.819

0.3150.7091.1021.4961.890

2.2832.6773.0713.4653.858

0.3540.7481.1421.5361.929

2.3232.7173.1103.5043.898

2.165

(B)

(A)

00-17


Millimeters to Inches1 mm = 0.03937 in

Kilogram to Pound1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

00.3940.7871.1811.575

1.9692.3622.7563.1503.543

0.0390.4330.8271.2201.614

2.0082.4022.7953.1893.583

0.0790.4720.8661.2601.654

2.0472.4412.8353.2283.622

0.1180.5120.9061.2991.693

2.0872.4802.8743.2683.661

0.1570.5510.9451.3391.732

2.1262.5202.9133.3073.701

0.1970.5910.9841.3781.772

2.1652.5592.9533.3463.740

0.2360.6301.0241.4171.811

2.2052.5982.9923.3863.780

0.2760.6691.0631.4571.850

2.2442.6383.0323.4253.819

0.3150.7091.1021.4961.890

2.2832.6773.0713.4653.858

0.3540.7481.1421.5361.929

2.3232.7173.1103.5043.898

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

022.0544.0966.1488.18

110.23132.28154.32176.37198.42

2.2024.2546.3068.3490.39

112.44134.48156.53178.57200.62

4.4126.4648.5070.5592.59

114.64136.69158.73180.78202.83

6.6128.6650.7172.7594.80

116.85138.89160.94182.98205.03

8.8230.8651.9174.9697.00

119.05141.10163.14185.19207.24

11.0233.0755.1277.1699.21

121.25143.30165.35187.39209.44

13.2335.2757.3279.37

101.41

123.46145.51167.55189.60211.64

15.4337.4859.5381.57

103.62

125.66147.71169.76191.80213.85

17.6439.6861.7383.78

105.82

127.87149.91171.96194.01216.05

19.8441.8963.9385.98

108.03

130.07152.12174.17196.21218.26

00-18


Liter to U.S. Gallon1l = 0.2642 U.S. Gal

Liter to U.K. Gallon1l = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

02.6425.2837.925

10.567

13.20915.85018.49221.13423.775

0.2642.9065.5488.189

10.831

13.47316.11518.75621.39824.040

0.5283.1705.8128.454

11.095

13.73716.37919.02021.66224.304

0.7933.4346.0768.718

11.359

14.00116.64319.28521.92624.568

1.0573.6986.3408.982

11.624

14.26516.90719.54922.19024.832

1.3213.9636.6049.246

11.888

14.52917.17119.81322.45525.096

1.5854.2276.8699.510

12.152

14.79517.43520.07722.71925.361

1.8494.4917.1339.774

12.416

15.05817.70020.34122.98325.625

2.1134.7557.397

10.03912.680

15.32217.96420.60523.24725.889

2.3785.0197.661

10.30312.944

15.58618.22820.87023.51126.153

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

02.2004.3996.5998.799

10.99813.19815.39817.59819.797

0.2202.4204.6196.8199.019

11.28113.41815.61817.81820.017

0.4402.6404.8397.0399.239

11.43813.63815.83818.03720.237

0.6602.8605.0597.2599.459

11.65813.85816.05818.25720.457

0.8803.0805.2797.4799.679

11.87814.07816.27818.47720.677

1.1003.3005.4997.9699.899

12.09814.29816.49818.69720.897

1.3203.5205.7197.919

10.119

12.31814.51816.71818.91721.117

1.5403.7405.9398.139

10.339

12.52814.73816.93819.13721.337

1.7603.9506.1598.359

10.559

12.75814.95817.15819.35721.557

1.9804.1796.3798.579

10.778

12.97815.17817.37819.57721.777

00-19


kgm to ft. lb1 kgm = 7.233 ft. lb

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

100110120130140

150160170180190

072.3

144.7217.0289.3

361.7434.0506.3578.6651.0

723.3795.6868.0940.3

1012.6

1084.91157.31129.61301.91374.3

7.279.6

151.9224.2296.6

368.9441.2513.5585.9658.2

730.5802.9875.2947.5

1019.9

1092.21164.51236.81309.21381.5

14.586.8

159.1231.5303.8

376.1448.5520.8593.1665.4

737.8810.1882.4954.8

1027.1

1099.41171.71244.11316.41388.7

21.794.0

166.4238.7311.0

383.4455.7528.0600.3672.7

745.0817.3889.7962.0

1034.3

1106.61179.01251.31323.61396.0

28.9101.3173.6245.9318.3

390.6462.9535.2607.6679.9

752.2824.6896.9969.2

1041.5

1113.91186.21258.51330.91403.2

36.2108.5180.8253.2325.5

397.8470.2542.5614.8687.1

759.5831.8904.1976.5

1048.8

1121.11193.41265.81338.11410.4

43.4115.7188.1260.4332.7

405.1477.4549.7622.0694.4

766.7839.0911.4983.7

1056.0

1128.31200.71273.01345.31417.7

50.6123.0195.3267.6340.0

412.3484.6556.9629.3701.6

773.9846.3918.6990.9

1063.2

1135.61207.91280.11352.61424.9

57.9130.2202.5274.9347.2

419.5491.8564.2636.5708.8

781.2853.5925.8998.2

1070.5

1142.81215.11287.51359.81432.1

65.1137.4209.8282.1354.4

426.8499.1571.4643.7716.1

788.4860.7933.1

1005.41077.7

1150.01222.41294.71367.01439.4

00-20


kg/cm2 to lb/in21kg/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

100110120130140

150160170180190

200210220230240

0 142.2 284.5 426.7 568.9

711.2 853.4 995.611381280

14221565170718491991

21342276241825602702

28452987312932713414

14.2 156.5 298.7 440.9 583.2

725.4 867.6

101011521294

14371579172118632005

21482290243225742717

28593001314332863428

28.4 170.7 312.9 455.1 597.4

739.6 881.8

102411661309

14511593173518772020

21622304244625892731

28733015315833003442

42.7 184.9 327.1 469.4 611.6

753.8 896.1

103811811323

14651607174918922034

21762318246026032745

28873030317233143456

56.9 199.1 341.4 483.6 625.8

768.1 910.3

105311951337

14791621176419062048

21902333247526172759

29013044318633283470

71.1 213.4 355.6 497.8 640.1

782.3 924.5

106712091351

14931636177819202062

22052347248926312773

29163058320033433485

85.3 227.6 369.8 512.0 654.3

796.5 938.7108112231365

15081650179219342077

22192361250326462788

29303072321433573499

99.6 241.8 384.0 526.3 668.5

810.7 953.0109512371380

15221664180619492091

22332375251826602802

29443086322933713513

113.8 256.0 398.3 540.5 682.7

825.0 967.2110912521394

15361678182119632105

22472389253226742816

29583101324333853527

128.0 270.2 412.5 554.7 696.9

839.2 981.4112412661408

15501693183519772119

22622404254626882830

29733115325733993542

00-21


TemperatureFahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centi-grade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-umn 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 ofFahrenheit 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 ofCentigrade values, and read the corresponding Fahrenheit temperature on the right.

1C = 33.8FC F C F C F C F

40.437.234.431.728.9

28.327.827.226.726.1

25.625.024.423.923.3

22.822.221.721.120.6

20.019.418.918.317.8

17.216.716.115.615.0

14.413.913.312.812.2

4035302520

1918171615

1413121110

98765

4321

0

12345

6789

10

40.031.022.013.0

4.0

2.20.4

1.43.25.0

6.88.6

10.412.214.0

15.817.619.421.223.0

24.826.628.430.232.0

33.835.637.439.241.0

42.844.646.448.250.0

11.711.110.610.0

9.4

8.98.37.87.26.7

6.15.65.04.43.9

3.32.82.21.71.1

0.600.61.11.7

2.22.83.33.94.4

5.05.66.16.77.2

1112131415

1617181920

2122232425

2627282930

3132333435

3637383940

4142434445

51.853.655.457.259.0

60.862.664.466.268.0

69.871.673.475.277.0

78.880.682.484.286.0

87.889.691.493.295.0

96.898.6

100.4102.2104.0

105.8107.6109.4111.2113.0

7.88.38.99.4

10.0

10.611.111.712.212.8

13.313.914.415.015.6

16.116.717.217.818.3

18.919.420.020.621.1

21.722.222.823.323.9

24.425.025.626.126.7

4647484950

5152535455

56575859

0

6162636465

6667686970

7172737475

7677787980

114.8116.6118.4120.2122.0

123.8125.6127.4129.2131.0

132.8134.6136.4138.2140.0

141.8143.6145.4147.2149.0

150.8152.6154.4156.2158.0

159.8161.6163.4165.2167.0

168.8170.6172.4174.2176.0

27.227.828.328.929.4

30.030.631.131.732.2

32.833.333.934.435.0

35.636.136.737.237.8

40.643.346.148.951.7

54.457.260.062.765.6

68.371.173.976.779.4

8182838485

8687888990

9192939495

96979899

100

105110115120125

130135140145150

155160165170175

117.8179.6181.4183.2185.0

186.8188.6190.4192.2194.0

195.8197.6199.4201.2203.0

204.8206.6208.4210.2212.0

221.0230.0239.0248.0257.0

266.0275.0284.0293.0302.0

311.0320.0329.0338.0347.0

00-22

Foreword Units

04-05

UnitsIn 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}

GD555, 655, 675-3C 01-1(4)

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

01 GENERAL

01-2 GD555, 655, 675-3C

GENERAL GENERAL ASSEMBLY DRAWING

(4)

GENERAL ASSEMBLY DRAWING

(Unit: mm)

Item GD555-3C GD655-3C GD675-3C

A Overall length 8,350 8,595 8,611

BOverall height (with full height cab) 3,330 3,350 3,350

Overall height (with low height cab) 3,100 3,120 3,120

C Overall width 2,525 2,550 2,550

GD555, 655, 675-3C 01-3

GENERAL SPECIFICATIONS

(4)

SPECIFICATIONS

GD555-3C

VHP engine: Variable horsepower engine.

Machine ModelGD555-3C

VHP Engine

Serial Number 50001 51000 51001 and up

Machine weight

kg

13,850 14,040

On front axle 3,950 4,000

On rear axle 9,900 10,040

Dim

ensi

ons

Overall length

mm

8,370 8,350

Overall width 2,525

Overall height (top of muffler) 2,980

Overall height (with ROPS cab) 3,100

Wheel base 5,850

Distance between centers of tandem wheels 1,535

Tread (Front) 2,130

Tread (Rear) 2,130

Ground clearance 350

Pe

rfo

rma

nce

Travel speed

Forward

1st

km/h

3.3

2nd 4.8

3rd 6.8

4th 9.8

5th 14.9

6th 21.6

7th 29.6

8th 42.9

Reverse

1st

km/h

4.4 4.4

2nd 8.9 9.0

3rd 18.7 19.7

4th 36.1 39.1

Maximum drawbar pull kN {kg} 77.7 {7,920} 78.7 {8,030}

Gradeability deg. 24

Min. Turning radius m 6.8

Static stability deg. 35

01-4 GD555, 655, 675-3C


(4)


VHP Engine


Eng

ine

Engine model SA6D102E-1 SAA6D102E-2

Type

4-cycle, water cooled,overhead valve,

direct-injection typewith turbocharger and aftercooler

Cylinder number - bore x stroke mm 6 - 102 x 120

Piston displacement l {cc} 5.88 {5,880}

Pe

rfor

man

ce

Flywheel horsepowerkW/rpm

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

Maximum torqueNm/rpm

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

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

Max. speed at no load rpm 2,200 2,200

Min. speed at no load rpm 800 850

Fuel consumption ratiog/kWh

{g/HPh}229.4 to 232.4

{171.1 to 173.3}214.3

{159.7}

Starting motor 24 V, 7.5 kW 24 V, 5.5 kW

Alternator 24 V, 50 A

Battery 12 V, 112 Ah x 2

Radiator type CF19-4

Po

we

r tr

ain

Torque converter3-element, single-stage

Automatic shifting, wet-type clutch

Transmission

Multiple shaftFully automatic electric, automatic shifting type,

pump force feed type8 forward speeds, 4 reverse speeds

Reduction gear Spiral bevel gear, single-stage reduction

Rear axle Fully floating tandem type

Tandem Double-row chain drive

Ste

erin

g

Fro

nt a

xle Type Reverse Elliott, angle type

Max. leaning angle deg. 16

Ste

erin

g s

yste

m Type Fully hydraulic type

Steering angle deg. 49

Articulate angle deg. 23

GD555, 655, 675-3C 01-5


(4)


VHP Engine

Serial Number 50001 and up

Ste

erin

g,

ope

ratin

gsy

ste

m Tir

es

Tires (front) 13.00-24-10PR

Tires (rear) 13.00-24-10PR

Inflation pressure (front)kPa

{kg/cm2}275 {2.75}

Inflation pressure (rear)kPa

{kg/cm2}275 {2.75}

Bra

kes Main brake Rear 4-wheel braking, multiple-disc wet type

Parking brake Dry disc type

Hyd

rau

lic s

yste

m

Hyd

rau

lic p

ump Type x no. Komatsu LPV90 Variable swash plate type x 1

Discharge l/min. 205

Set pressureMPa

{kg/cm2}206 {210}

Con

trol

va

lve

Type x no. 4-spool type x 2 (CLSS)

Control method Hydraulic type

Ste

eri

ng r

ela

ted

cyl

ind

ers Steering Leaning Articulating

Type Double-acting piston type

Cylinder bore mm 50 70 90

Piston rod outside diameter mm 35 35 50

Piston stroke mm 330 160 325

Wo

rk e

qui

pm

ent

cyl

inde

rs

Type

Bladelift

Bladeside shift

Bladetilt

Drawbarside shift

Ripper

Double-acting piston type

Cylinder bore mm 80 80 80 80 100

Piston rod outside diameter mm 50 50 40 45 50

Piston stroke mm 1,160 1,250 300 585 600

TypeScarifier


Cylinder bore mm 80

Piston rod outside diameter mm 50

Piston stroke mm 345

01-6 GD555, 655, 675-3C


(4)

Machine Model GD555-3C


Bla

de

Blade dimension (Length x Height x Thickness)

mm

3,660 x 660 x 22

Cutting edge dimension(Length x Width x Thickness Number)

1,830 x 153 x 16 2

Max. lift above ground 460

Max. cutting depth 635

Blade base 2,500

Blade load kN {kg} 68 {6,939} 68.5 {6,985}

Turning angle (with scarifier) deg. 360 (130)

Max. side shift distance (left)mm

625

Max. side shift distance (right) 625

Cutting angle

deg.

[Standard] 37

[Adjustable] 32 to 81

GD555, 655, 675-3C 01-7


(4)

GD655-3C

Machine Model

GD655-3C

Standard HPEngine

VHP Engine


Machine weight

kg

14,800 15,000


On rear axle 10,580 10,730

Dim

ens

ion

s

Overall length

mm

8,595

Overall width 2,550


Overall height(with ROPS cab)

3,120

Wheel base 6,070

Distance between centers of tandem wheels

1,535

Tread (Front) 2,130

Tread (Rear) 2,130


Per

form

anc

e

Tra

vel s

pee

d Fo

rwar

d

1st

km/h

3.3

2nd 4.7

3rd 6.7

4th 9.7

5th 14.6

6th 21.2

7th 29.1

8th 42.1

Re

vers

e

1st

km/h

4.3 4.3

2nd 8.8 8.8

3rd 18.1 18.1

4th 35.1 38.4





01-8 GD555, 655, 675-3C


(4)

Machine Model

GD655-3C

Standard HP Engine

VHP Engine


Eng

ine

Engine modelS6D114E-1Standard

SA6D114E-1VHP

SAA6D114E-2

4-cycle, water cooled,

overhead valve,direct-injection typewith turbocharger


direct-injection typewith turbochargerand aftercooler

Type

Cylinder number- bore x stroke

mm 6 - 114 x 135


Pe

rfo

rma

nce

Flywheel horse-power

kW/rpm{HP/rpm}

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

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


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

794.3 to 913.0/1,300

{81.0 to 93.1/1,300}

749.7 to 926.2/1,400

{76.4 to 94.4/1,400}

Max. speed atno load

rpm 2,200

Min. speed atno load

rpm 800

Fuel consumption ratio

g/kWh{g/HPh}

159{213.2}

218{162.8}

Starting motor 24 V, 7.5 kW 24 V, 7.5 kW

Alternator 24 V, 50 A 24 V, 60 A

Battery 12 V, 112 Ah x 2 12 V, 112 Ah x 2

Radiator type CF19-4 CF19-5

Po

we

r tr

ain



Transmission






Ste

eri

ng

Fro

nta

xle

Type Reverse Elliott, angle type

Max. leaning angle

16

Ste

erin

gsy

ste

m

Type Fully hydraulic type



GD555, 655, 675-3C 01-9


(4)


Standard HP Engine VHP Engine


Ste

erin

g,

ope

ratin

gsy

ste

m Tir

es




{kg/cm2}250 {2.5}


{kg/cm2}250 {2.5}

Bra



Hyd

rau

lic s

yste

m

Hyd

rau

lic p


Discharge at rated rpm l/min. 194

Set pressureMPa

{kg/cm2}206 {210}

Con

trol

va

lve



Ste

eri

ng r

ela

ted

cyl

ind






Wo

rk e

qui

pm

ent

cyl

inde

rs

Type

Bladelift

Bladeside shift

Bladetilt

Drawbarside shift

Ripper




Piston stroke mm 1,160 1,250 300 585 540

TypeScarifier


Cylinder bore mm 90



01-10 GD555, 655, 675-3C


(4)



Bla

de


mm

3,660 x 660 x 22


1,829 x 153 x 16 2



Blade base 2,600

Blade load kN {kg} 72.4 {7,378} 73.2 {7,469}



625


Cutting angle

deg.

[Standard] 37


GD555, 655, 675-3C 01-11


(4)

GD675-3C


VHP Engine


Machine weight

kg

15,600 15,810


On rear axle 11,150 11,310

Dim

en

sion

s

Overall length

mm

8,620 8,595

Overall width 2,550


Overall height (with ROPS cab) 3,115

Wheel base 6,070

Distance between centers of tandem wheels 1,535

Tread (Front) 2,130

Tread (Rear) 2,130


Per

form

anc

e

Travel speed

Forward

1st

km/h

3.3

2nd 4.7

3rd 6.7

4th 9.7

5th 14.6

6th 21.2

7th 29.1

8th 42.1

Reverse

1st

km/h

4.3

2nd 8.8

3rd 18.1

4th 35.1





01-12 GD555, 655, 675-3C


(4)


VHP Engine


Eng

ine

Engine model SA6D114E-1 SAA6D114E-2

Type


direct-injection typewith turbocharger and aftercooler

Cylinder number - bore x stroke mm 6 - 114 x 135


Pe

rfor

man

ce

Flywheel horsepowerkW/rpm

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


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

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

Max. speed at no load rpm 2,200

Min. speed at no load rpm 800

Fuel consumption ratiog/kWh

{g/HPh}236.5 to 237.6

{176.4 to 177.2}218.1

{162.7}

Starting motor 24V, 7.5 kW 24V, 7.5kW

Alternator 24V, 50A 24V, 60A

Battery 12V, 112Ah x 2 12V, 112Ah x 2

Radiator type CF19-4 CF19-5

Po

we

r tr

ain



Transmission






Ste

erin

g

Fro

nt a

xle Type Reverse Elliott, angle type

Max. leaning angle 16

Ste

erin

g s

yste

m Type Fully hydraulic type



GD555, 655, 675-3C 01-13


(4)


VHP Engine


Ste

erin

g,

ope

ratin

gsy

ste

m Tir

es




{kg/cm2}275 {2.75}


{kg/cm2}275 {2.75}

Bra



Hyd

rau

lic s

yste

m

Hyd

rau

lic p


Discharge at rated rpm l/min. 194

Set pressureMPa

{kg/cm2}206 {210}

Con

trol

va

lve



Ste

eri

ng r

ela

ted

cyl

ind






Wo

rk e

qui

pm

ent

cyl

inde

rs

Type

Bladelift

Bladeside shift

Bladetilt

Drawbarside shift

Ripper




Piston stroke mm 1,160 1,250 300 585 540

TypeScarifier


Cylinder bore mm 90



01-14 GD555, 655, 675-3C


(4)



Bla

de


mm

3,660 x 660 x 25


1,830 x 153 x 16 2



Blade base 2,600

Blade load kN {kg} 76.3 {7,777} 77.2 {7,872}



625


Cutting angle

deg.

[Standard] 37


GD555, 655, 675-3C 01-15

GENERAL WEIGHT TABLE

(4)

WEIGHT TABLE

k Use the weight table when handling individual parts or when transporting the entire machine.Serial No. 50001 51000 Unit: kg

Machine model GD555-3C GD655-3C GD675-3C

Serial Number 50001 51000

Engine assembly (dry) 453 616 616

Radiator assembly (dry) 51 51 51

Transmission assembly (dry) 755 755 755

Transmission pump 9 9 9

Final drive assembly 1,012 1,012 1,012

Tandem drive (one side) 876 876 876

Front axle assembly, except leaning cylinder 418 548 548

Parking brake assembly 26 26 26

Wheel assembly (front) 138 x 2 151 x 2 179 x 2

Wheel assembly (rear) 138 x 4 151 x 4 179 x 4

Scarifier assembly 450 530 530

Hydraulic pump 49 49 49

Fuel tank and hydraulic tank (both dry) 160 160 160

Circle rotation motor 10 10 10

Steering cylinder assembly 12 x 2 12 x 2 12 x 2

Leaning cylinder assembly 11 15 15

Articulating cylinder assembly 25 x 2 25 x 2 25 x 2

Blade lift cylinder assembly 49 x 2 49 x 2 49 x 2

Blade side-shift cylinder assembly 48 48 48

Blade power tilt cylinder assembly 19 19 19

Drawbar side-shift cylinder assembly 32 32 32

Scarifier cylinder assembly 22 24 24

Drawbar assembly 538 557 557

Blade assembly 625 625 675

Circle gear 252 272 272

Circle rotation gear assembly 119 119 119

Front frame assembly 1,613 1,814 1,814

Rear frame assembly 883 980 980

Ripper 595 900 900

Operator's compartment assembly and controls 200 200 200

01-16 GD555, 655, 675-3C

GENERAL WEIGHT TABLE

(4)

Serial No. 51001 and up Unit: kg

Machine model GD555-3C GD655-3C GD675-3C


Engine assembly (dry) 550 750 750

Radiator assembly (dry) 115 115 115

Transmission assembly (dry) 755 755 755

Transmission pump 9 9 9

Final drive assembly 1,012 1,012 1,012

Tandem drive (one side) 876 876 876

Front axle assembly, except leaning cylinder 418 548 548

Parking brake assembly 26 26 26

Wheel assembly (front) 138 x 2 151 x 2 179 x 2

Wheel assembly (rear) 138 x 4 151 x 4 179 x 4

Scarifier assembly 450 530 530

Hydraulic pump 49 49 49

Fuel tank and hydraulic tank (both dry) 160 160 160

Circle rotation motor 10 10 10

Steering cylinder assembly 12 x 2 12 x 2 12 x 2

Leaning cylinder assembly 11 15 15

Articulating cylinder assembly 25 x 2 25 x 2 25 x 2

Blade lift cylinder assembly 49 x 2 49 x 2 49 x 2

Blade side-shift cylinder assembly 48 48 48

Blade power tilt cylinder assembly 19 19 19

Drawbar side-shift cylinder assembly 32 32 32

Scarifier cylinder assembly 22 24 24

Drawbar assembly 538 557 557

Blade assembly 625 625 675

Circle gear 252 272 272

Circle rotation gear assembly 119 119 119

Front frame assembly 1,613 1,814 1,814

Rear frame assembly 883 980 980

Ripper 595 900 900

Operator's compartment assembly and controls 200 200 200

GD555, 655, 675-3C 01-17

GENERAL FUEL, COOLANT, AND LUBRICANT SELECTION

(4)

FUEL, COOLANT, AND LUBRICANT SELECTION

According to temperature

Reservoir FluidAmbient temperature Capacity (l)

-22 -4 14 32 50 68 86 104 122F-30 -20 -10 0 10 20 30 40 50C Specified Refill

Engine oil pan

Engine oil

GD555-3C16

GD655-3CGD675-3C

24

GD555-3C14

GD655-3CGD675-3C

19

SAE30 CD

SAE10W CD

SAE10W-30 CD

SAE15W-40 CD

SAE5W-40 CD

SAE0W-30 CD

Transmission case 60 45SAE10W CD

Final drive case 18 16SAE30 CD

Tandem drive case (each)

80 75SAE10W CD

Gear oil

Circle reverse gear SAE90

Shear-pin type SAE80 4 4

Slip-clutch type SAE75 7 7

Hydraulic system Engine oil 85 45SAE10W CD

SAE5W-30 CD

Fuel tank Diesel fuel 340 ASTM D975 No. 2

Cooling system Coolant Add antifreeze 44 44

ASTM D975 No. 1

01-18 GD555, 655, 675-3C

GENERAL FUEL, COOLANT, AND LUBRICANT SELECTION

(4)

Remark When fuel sulphur content is less than 0.5%, change oil in the oil pan in accordance with the periodic main-

tenance hours described in this manual.

Change oil according to the following table if fuel sulphur content is above 0.5%.

When starting the engine in atmospheric temperature of lower than 0C, be sure to use engine oil ofSAE10W, SAE10W-30 and SAE15W-40, even though an atmospheric temperature goes up 10C or morein the day time.

Use API classification CD engine oil. If API classification CC is used, reduce the engine oil change intervalin half.

There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to addsingle grade oil that matches the temperature in the table.

We recommend Komatsu genuine oil, which has been specifically formulated and approved for use in engineand 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 MaterialSAE: Society of Automotive EngineersAPI: American Petroleum Institute

Fuel sulphur contentChange interval of oil

in engine oil pan

0.5 to 1.0% 1/2 of regular interval

Above 1.0% 1/4 of regular interval

GD555, 655, 675-3C 10-1(8)

ACCELERATOR CONTROL LINKAGE ............ 10-2ACCELERATOR PEDAL................................... 10-3FAN DRIVE ....................................................... 10-4POWER TRAIN DIAGRAM............................... 10-5TRANSMISSION HYDRAULIC PIPING............ 10-6TRANSMISSION HYDRAULIC PIPING............ 10-8TORQUE CONVERTER ................................... 10-9TORQUE CONVERTER LOCK-UP VALVE

(ECMV)...................................................... 10-14TRANSMISSION............................................. 10-17TRANSMISSION VALVE................................. 10-46ECMV (ELECTRONIC CONTROL

MODULATION VALVE).............................. 10-47MAIN RELIEF VALVE ..................................... 10-52TRANSMISSION PUMP ................................. 10-55TRANSMISSION AND DIFFERENTIAL LOCK

PUMP (WITH DIFFERENTIAL LOCK) ...... 10-56FINAL DRIVE.................................................. 10-58TANDEM DRIVE ............................................. 10-64STEERING HYDRAULIC PIPING DRAWING 10-68STEERING VALVE (Q/AMP MANUAL

ORBIT-ROLL TYPE).................................. 10-71PRIORITY ACC GOVERNOR VALVE

(Serial No. 50001 51000) ....................... 10-78PRIORITY VALVE

(Serial No. 51001 and up) ......................... 10-85ACCUMULATOR PRESSURE GOVERNOR VALVE

(Serial No. 51001 and up) ......................... 10-92FRONT AXLE ................................................. 10-94BRAKE HYDRAULIC PIPING......................... 10-98BRAKE VALVE.............................................. 10-102WHEEL BRAKE ............................................ 10-106SLACK ADJUSTER ...................................... 10-107ACCUMULATOR............................................10-110PARKING BRAKE..........................................10-111PARKING BRAKE AND

BANK CONTROL VALVE .........................10-112WORK EQUIPMENT HYDRAULIC

PIPING DRAWING ...................................10-114HYDRAULIC PUMP

(Serial No. 50001 51000) ..................... 10-124HYDRAULIC PUMP

(Serial No. 51001 and up) ....................... 10-146MAIN CONTROL VALVE .............................. 10-169CLSS............................................................. 10-188

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

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

10-2 GD555, 655, 675-3C

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCELERATOR CONTROL LINKAGE

(4)

ACCELERATOR CONTROL LINKAGE

Outline Operating the fuel control lever (1) pulls the

spring rod (2), which moves the lever (3) and ac-celerator cable (9) to control the engine speed.

Depressing the accelerator pedal (5) moves therod (4), lever (3), and accelerator cable (9) tocontrol the engine speed. When this situationhappens, the spring of the spring rod (2) movesin the direction of the compression.

Releasing the accelerator pedal (5) and de-pressing the decelerator pedal (rod) (6) causethe lever (3) to rotate, reducing engine speed.

1. Fuel control lever2. Spring rod3. Lever4. Rod.5. Accelerator pedal6. Decelerator pedal7. Fuel injection pump8. Fuel injection pump lever9. Accelerator cable

GD555, 655, 675-3C 10-3

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCELERATOR PEDAL

(4)

ACCELERATOR PEDAL

1. Pedal2. Stopper bolt3. Cable4. Potentiometer

10-4 GD555, 655, 675-3C

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FAN DRIVE

(4)

FAN DRIVE

1. Transmission Outline The fan drive is installed at the top of transmis-

sion (1). The fan is driven by V-belt (4) throughdrive pulley (6) at the front face of transmission(1). This drive pulley (6) is driven through a gearby the torque converter input shaft.

2. Radiator3. Fan drive pulley4. V-belt5. Tension pulley6. Drive pulley

GD555, 655, 675-3C 10-5

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN DIAGRAM

(4)

POWER TRAIN DIAGRAM

The power produced by diesel engine (5) goesto transmission (4) through torque converterwith lock-up clutch (3).

Transmission (4), with a multiple shaft mecha-nism and a hydraulic control unit combined, al-lows an easy selection of eight forward speedsand four reverse speeds. Through drive shaft(6), the power is transmitted from the transmis-sion to the final drive (7). Here, final drive (7) di-rects the power to the right and left, and thepower is transmitted to the left and right tandemdrives (8) through shaft (11).

Tandem drive (8) transmits the power to thewheel by a chain and the machine travels.

1. Cooling fan2. Hydraulic pump3. Torque converter4. Transmission5. Engine assembly6. Drive shaft7. Final drive8. Tandem drive9. Tire

10. Wheel brake11. Shaft

10-6 GD555, 655, 675-3C

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION HYDRAULIC PIPING

(6)

TRANSMISSION HYDRAULIC PIPINGGD555-3C Serial No. 50001 51037GD655-3C Serial No. 50001 51081GD675-3C Serial No. 50001 51009

1. Engine assembly2. Transmission assembly3. Oil filter4. Hydraulic pump

GD555, 655, 675-3C 10-7


(4)

5. Hose-oil cooler inlet port6. Hose-oil cooler outlet port7. Oil filter8. Radiator and oil cooler

10-7-1 GD555, 655, 675-3C


(6)

TRANSMISSION HYDRAULIC PIPINGGD555-3C Serial No. 51038 and upGD655-3C Serial No. 51082 and upGD675-3C Serial No. 51010 and up

1. Engine assembly2. Transmission assembly3. Oil filter4. Return hose of oil in flywheel housing5. Hydraulic pump

GD555, 655, 675-3C 10-7-2


(6)

TRANSMISSION HYDRAULIC PIPING

6. Hose-oil cooler inlet port7. Hose-oil cooler outlet port8. Oil filter9. Radiator and oil cooler

10-8 GD555, 655, 675-3C

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION CONTROL

(4)

TRANSMISSION CONTROL

1. Gearshift lever Gearshift lever positions2. Transmission controller Reverse

ForwardParkingNeutral1 range (forward, reverse)2 range (forward, reverse)3 range (forward, reverse)4 range (forward, reverse)5 range (forward)6 range (forward)7 range (forward)8 range (forward)

GD555, 655, 675-3C 10-9

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER

(4)

TORQUE CONVERTER

1. Pump Specifications:Name: TCA38-10AType: 3 element, 1 stage, 2 phaseStall torque ratio:2.17

2. PTO drive gear (No. of teeth: 70)3. Outer race4. Output shaft (transmission input shaft)5. Stator shaft6. Lock-up clutch piston7. Lock-up clutch housing (No. of teeth: 72)8. Stator9. Pilot

10. Freewheel11. Turbine12. Lock-up clutch disc13. Drive case

10-10 GD555, 655, 675-3C


(4)

GD555, 655, 675-3C 10-11


(4)

Unit: mm

No. Check item Criteria Remedy

1 Pilot O.D.

Std. size Tolerance Repair limit

Rebuild or replace

71.9540.0100.040

71.7

2 Pilot seal ring I.D. 35+0.025

035.5

3 Clutch housing seal ring I.D. 340+0.089

0340.1

Replace

4 Clutch piston seal ring I.D. 260+0.081

0260.1

5 PTO drive gear seal ring O.D. 125+0.040

0125.5

Rebuild or replace

6Clutch housing seal ring wear

Width 50.010.04

4.5

Replace

Thickness 6 0.15 5.85

7Stator shaft seal ring wear

Width 3.950

0.13.56

Thickness 4.8 0.1 4.32

8One-way clutch outer race O.D.

88.882+0.0050.008

88.912

9Stator shaft one-way clutch O.D.

72.217+0.0080.005

72.187

10 Bushing I.D. 72.32+0.015

072.4

11 Bushing thickness 50

0.14.9

12 Clutch disc thickness 5 0.1 4.7

13 Stator shaft seal ring I.D. 55+0.030

055.5

14Backlash between PTO drive gear and idler gear

0.160 to 0.407

10-12 GD555, 655, 675-3C


(4)

LOCK-UP CLUTCH

Lock-up clutch disengaged When the lock-up clutch is disengaged, the drive

case (13) and turbine (11) are separated, and thetorque converter functions as normal.The power generated by the engine passesthrough the flywheel, is transmitted to lock-upclutch 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 outputshaft (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, formingone unit. The stator (8) is rotated by the rotationof the pump (1) and turbine (11).Engine power is transmitted through the fly-wheel and through the lock-up clutch housing(7), rotating the drive case (13) and pump (1) asone unit. In addition, the drive case (13) and tur-bine (11) are engaged by the clutch. Thus, thepower is transmitted directly to the turbine andoutput shaft (4), without using oil.

GD555, 655, 675-3C 10-13


(4)

OIL FLOW

The oil supplied from the torque converter charg-ing pump passes through the transmission valveand enters the inlet port (A). The oil then passesthrough the oil passage in the stator shaft (5) andPTO drive gear (2) and flows from between thepump (1) and stator (8) to the pump (1). The oilis given centrifugal force by the pump (1) and en-ters the turbine (11), transmiting the energy ofthe oil to the turbine. Because the turbine (11) isfixed to the output shaft (4), the power is trans-mitted to the output shaft. The oil from turbine(11) is sent to the stator (8), entering the pumpagain. However, part of the oil that returns frombetween the turbine (11) and stator (8) to the out-let port is routed to the oil cooler.

10-14 GD555, 655, 675-3C

STRUCTURE, FUNCTION AND MAINTENANCE STANDARDTORQUE CONVERTER LOCK-UP VALVE

(ECMV)

(4)

TORQUE CONVERTER LOCK-UP VALVE (ECMV)

A : To clutch 1. Connector for proportional solenoidP : From pump 2. ECMV (for torque converter lock-up clutch)T : Drain 3. SeatDr : Drain 4. Connector for fill switchP1 : Clutch oil pressure detection port 5. Fill switchP2 : Pilot oil pressure detection port 6. Oil pressure detection valve

7. Pressure control valve spool8. Proportional solenoid

GD555, 655, 675-3C 10-15


(ECMV)

(7)

ECMV FOR LOCK-UP CLUTCH

Outline This valve acts to set the lock-up clutch oil pres-

sure to the set pressure, and also to switch thelock-up clutch.It forms a modulation wave pattern, so the lock-up clutch is engaged smoothly to reduce theshock when shifting gear. In addition, it preventsgeneration of peak torque in the power train. Asa result, it provides a comfortable ride for theoperator and greatly increases the durability ofthe 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 clutchport A through drain port Dr and cancels thelock-up clutch.When this happens, there is no oil pressure act-ing on oil pressure detection valve (4), so fillswitch (6) is OFF.

10-16 GD555, 655, 675-3C


(ECMV)

(4)

During direct travel (torque converter travel oooo direct travel)

1. When fillingWhen the transmission is in direct travel (lock-up), if electric current is applied to proportionalsolenoid (1) by the electric signal, a hydraulicforce balancing with the force of the solenoidacts on chamber B, and pressure control valvespool (3) moves to the left.As a result, the circuit between pump port P andclutch port A opens, and oil starts to fill theclutch. When the clutch is filled with oil, fill switch(6) is turned ON.

2. Adjusting pressureWhen the electric current flows to the propor-tional solenoid (1), the solenoid generates a pro-pulsion force proportional to the current.The pressure is adjusted so that the total of thispropulsion force of the solenoid, the propulsionforce of the oil pressure at the clutch port, andthe reaction force of pressure control valvespring (2) is balanced.To reduce the shock when shifting gear, thelock-up clutch oil pressure is temporarily low-ered to 0 MPa {0 kg/cm2} when the gear isshifted.

GD555, 655, 675-3C 10-17

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION

(4)

TRANSMISSION

Serial No.: 50001 51000

1. Transmission control valve2. Transmission case3. Strainer mounting port4. Dipstick tube mounting port5. Torque converter lock-up valve6. Main relief, torque converter relief valve

10-18 GD555, 655, 675-3C


(4)

1. Torque converter2. Input shaft3. FL clutch4. Upper shaft5. FH clutch6. Lower shaft7. 3rd clutch8. Coupling9. 4th clutch

10. Output shaft11. 2nd clutch12. 1st clutch13. R clutch14. Mounting coupling for fan pulley15. Shaft for hydraulic pump drive

GD555, 655, 675-3C 10-19


(4)

Unit: mm

1. Shaft for transmission charge pump2. R idler gear (Number of teeth: 37)3. Speedometer gear set

No. Check item Criteria Remedy

4Clearance between idler gear and bearing

Std. sizeTolerance Standard

clearanceClearance

limit

Replace

Shaft Hole

50+0.018+0.002

00.012

0.030 to 0.002

5Clearance between idler gear bearing and case

900

0.015+0.0160.006

0.006 to 0.031

6Clearance between pump drive shaft and bearing (F)

50+0.020+0.009

00.012

0.032 to 0.009

7Clearance between pump drive shaft bearing and case (F)

900

0.015+0.030

00 to

0.045

8Clearance between pump drive shaft and bearing (R)

70+0.030+0.011

00.015

0.045 to 0.011

9Clearance between pump drive shaft bearing and case (R)

1000

0.015+0.030

00 to

0.045

10Clearance between idler shaft and bearing

70+0.032+0.002

00.015

0.047 to 0.002

11Clearance between idler gear and bearing

1250

0.0180.0250.050

0.050 to 0.007

10-20 GD555, 655, 675-3C


(4)

GD555, 655, 675-3C 10-21

STRUCTURE, FUNCTION AND MAINTENAN

gd675-3c (aps) shop manual

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