Komatsu GD535-5 Motor Grader Shop Manual KEBM665002

Description

• Model List:
  • GD535-5 Motor Grader

• 1. Notice of revision
• 2. Index and foreword
• 2.1. Index and foreword
• 2.1.1. Table of contents
• 2.1.2. Acronyms
• 2.1.3. Foreword and general information
• 3. Specification
• 3.1. Specification
• 3.1.1. Contents
• 3.1.2. Acronyms
• 3.1.3. Specifications
• 4. Structure and function
• 4.1. Structure and function
• 4.1.1. Contents
• 4.1.2. Acronyms
• 4.1.3. Engine and cooling system
• 4.1.4. Power train system
• 4.1.5. Steering system
• 4.1.6. Brake system
• 4.1.7. Undercarriage and frame
• 4.1.8. Hydraulic system
• 4.1.9. Work equipment system
• 4.1.10. Cab and its attachments
• 4.1.11. Electrical system
• 5. Standard value table
• 5.1. Standard value table
• 5.1.1. Contents
• 5.1.2. Acronyms
• 5.1.3. Standard value table
• 6. Testing and adjusting
• 6.1. Testing and adjusting
• 6.1.1. Contents
• 6.1.2. Acronyms
• 6.1.3. Tools for testing, adjusting, and troubleshooting
• 6.1.4. Engine and cooling system
• 6.1.5. Power train
• 6.1.6. Steering system
• 6.1.7. Brake system
• 6.1.8. Hydraulic system
• 6.1.9. Work equipment
• 6.1.10. Electrical system
• 6.1.11. Pm Clinic
• 7. Troubleshooting
• 7.1. Troubleshooting
• 7.1.1. Contents
• 7.1.2. Acronyms
• 7.1.3. Information related to troubleshooting
• 7.1.4. Troubleshooting by failure code (display of code)
• 7.1.5. Troubleshooting of electrical system (Emode)
• 7.1.6. Troubleshooting of hydraulic and mechanical system (Hmode)
• 7.1.7. Troubleshooting of engine (Smode)
• 8. Disassembly and assembly
• 8.1. Contents
• 8.2. Acronyms
• 8.3. Related information on disassembly and assembly
• 8.3.1. How to read this manual
• 8.3.2. Coating materials list
• 8.3.3. Special tool list
• 8.3.4. Sketches of special tools
• 8.4. Engine and cooling system
• 8.4.1. Removal and installation of supply pump assembly
• 8.4.2. Removal and installation of injector assembly
• 8.4.3. Removal and installation of cylinder head assembly
• 8.4.4. Removal and installation of air conditioner compressor belt
• 8.4.5. Removal and installation of alternator belt
• 8.4.6. Removal and installation of engine front oil seal
• 8.4.7. Removal and installation of engine rear oil seal
• 8.4.8. Removal and installation of cooling fan pump assembly
• 8.4.9. Removal and installation of cooling fan and fan motor assembly
• 8.4.10. Removal and installation of radiator assembly
• 8.4.11. Removal and installation of aftercooler assembly
• 8.4.12. Removal and installation of power train oil cooler assembly
• 8.4.13. Removal and installation of fuel tank assembly
• 8.4.14. Removal and installation of engine hood assembly
• 8.4.15. Removal and installation of air conditioner compressor assembly
• 8.5. Power train
• 8.5.1. Removal and installation of engine, transmission, and torque converter assembly
• 8.5.2. Disconnection and connection of engine, transmission, and torque converter assembly
• 8.5.3. Disassembly and assembly of torque converter assembly
• 8.5.4. Disassembly and assembly of transmission assembly
• 8.5.5. Removal and installation of tandem drive and final drive assembly
• 8.5.6. Disassembly and assembly of tandem drive assembly
• 8.5.7. Disassembly and assembly of differential assembly
• 8.5.8. Disassembly and assembly of final drive assembly
• 8.6. Steering system
• 8.6.1. Removal and installation of Orbitrol valve assembly
• 8.7. Brake system
• 8.7.1. Disassembly and assembly of wheel brake assembly
• 8.8. Undercarriage and frame
• 8.8.1. Removal and installation of center hinge pin
• 8.9. Hydraulic system
• 8.9.1. Removal and installation of hydraulic tank, battery, and frame assembly
• 8.9.2. Removal and installation of hydraulic tank assembly
• 8.9.3. Removal and installation of control valve assembly
• 8.9.4. Disassembly and assembly of hydraulic cylinder assembly
• 8.10. Work equipment
• 8.10.1. Removal and installation of blade assembly
• 8.10.2. Removal and installation of circle drawbar assembly
• 8.10.3. Removal and installation of circle rotation gear assembly
• 8.10.4. Disassembly and assembly of circle rotation gear assembly
• 8.11. Cab and its attachments
• 8.11.1. Removal and installation of operators cab assembly
• 8.11.2. Removal and installation of operator cab glass (adhered glass)
• 8.11.3. Removal and installation of floor frame assembly
• 8.11.4. Removal and installation of operators cab and floor frame assembly
• 8.11.5. Removal and installation of air conditioner unit assembly
• 8.11.6. Removal and installation operators seat
• 8.11.7. Removal and installation seat belt
• 8.12. Electrical system
• 8.12.1. Removal and installation of engine controller assembly
• 8.12.2. Removal and installation of machine monitor assembly
• 8.12.3. Removal and installation of transmission controller assembly
• 8.12.4. Removal and installation of rearview camera
• 8.12.5. Removal and installation of KOMTRAX terminal assembly
• 8.13. Disassembly and assembly
• 9. Maintenance standard
• 9.1. Maintenance standard
• 9.1.1. Contents
• 9.1.2. Acronyms
• 9.1.3. Engine and cooling system
• 9.1.4. Power train system
• 9.1.5. Steering system
• 9.1.6. Brake system
• 9.1.7. Undercarriage and frame
• 9.1.8. Hydraulic system
• 9.1.9. Work equipment
• 10. Appendix
• 10.1. Appendix
• 10.1.1. Contents
• 10.1.2. Acronyms
• 10.1.3. Air conditioner system
• 10.1.4. Component parts of air conditioner system
• 10.1.5. Testing air leakage (duct)
• 10.1.6. Check temperature control function
• 10.1.7. Testing fresh/recirc air changeover
• 10.1.8. Test evaporator temperature sensor
• 10.1.9. Test relays
• 10.1.10. Check blower AMP
• 10.1.11. Connection of service tool
• 11. Diagrams and drawings
• 11.1. Contents
• 11.2. Acronyms
• 11.3. Hydraulic diagrams and drawings
• 11.3.1. Symbols used in hydraulic circuit diagrams
• 11.4. Hydraulic circuit diagram
• 11.4.1. Hydraulic circuit diagram (1/2)
• 11.4.2. Hydraulic circuit diagram (2/2)
• 11.5. Power train hydraulic circuit diagram
• 11.5.1. Power train hydraulic circuit diagram
• 11.6. Electrical diagrams and drawings
• 11.6.1. Symbols used in electric circuit diagrams
• 11.6.2. Chassis electric circuit diagram
• 11.6.3. Floor electric circuit diagram
• 11.7. Chassis electric circuit diagram
• 11.7.1. Chassis electric circuit diagram (1/5)
• 11.7.2. Chassis electric circuit diagram (2/5)
• 11.7.3. Chassis electric circuit diagram (3/5)
• 11.7.4. Chassis electric circuit diagram (4/5)
• 11.7.5. Chassis electric circuit diagram (5/5)
• 11.7.6. Floor electric circuit diagram (1/7)
• 11.7.7. Floor electric circuit diagram (2/7)
• 11.7.8. Floor electric circuit diagram (3/7)
• 11.7.9. Floor electric circuit diagram (4/7)
• 11.7.10. Floor electric circuit diagram (5/7)
• 11.7.11. Floor electric circuit diagram (6/7)
• 11.7.12. Floor electric circuit diagram (7/7)