Machine Model Serial Number: GD555-3A 10001 and Up GD655-3A 10001 and Up GD675-3A 10001 and Up

SEBM021010
MACHINE MODEL SERIAL NUMBER

GD555-3A 00 10001 and up 00
GD655-3A 00 10001 and up 00
GD675-3A 00 10001 and up 00
• This shop manual may contain attachments and optional equipment that are
not available in your area. Please consult your local Komatsu distributor for
those items you may require. Materials and specifications are subject to
change without notice
• GD555-3A mounts the SA6D102E-1 or SAA6D102E-2 engine.
GD655-3A, GD675-3A mounts the SA6D114E-1 or SAA6D114E-2 engine.
For details of the engine, see the 102 Series Engine Shop Manual and the 114
Series Engine Shop Manual.
© 2017
All Rights Reserved 00-1
Printed in Japan 12-17 (01) (10)
CONTENTS
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00
00-2 GD555, 655, 675-3A

(2)
The affected pages are indicated by using the following marks. It is Mark Indication Action Required
requested that necessary actions be taken to these pages accord-
ing to the table below. New page to be added Add
Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are not revised at this time.
LIST OF REVISED PAGES

j
Revision Revision Revision Revision Revision

Mark Pages Mark Pages Mark Pages Mark Pages Mark Pages
Number Number Number Number Number
00-1 (10) 10-4 10-51 10-102 (3) 10-152
00-2 (2) 10-5 10-52 (3) 10-103 (3) 10-153
00-2-1 (10) 10-6 (5) 10-53 (3) 10-104 10-154 (7)
00-2-2 (10) 10-7 10-54 (4) 10-105 (3) 10-155 (7)
00-2-3 (10) 10-7-1 (5) 10-55 (3) 10-106 (3) 10-156 (6)
00-3 10-7-2 (5) 10-56 (3) 10-108 (3) 10-157
00-4 10-8 (6) 10-57 (6) 10-109 (3) 10-158
00-5 10-9 10-58 10-110 (7) 10-159 (6)
00-6 10-10 10-59 (5) 10-111 (3) 10-160 (6)
00-7 10-11 10-60 10-112 (7) 10-161
00-8 10-12 10-61 10-113 (3) 10-162
00-9 10-13 10-62 (5) 10-114 (7) 10-163
00-10 10-14 10-63 (6) 10-115 (3) 10-164 (6)
00-11 10-15 10-64 10-116 (7) 10-165
00-12 10-16 10-65 10-117 (3) 10-166 (6)
00-13 10-17 10-66 (7) 10-118 (7) 10-168
00-14 10-18 10-67 (6) 10-119 (3) 10-169 (6)
00-15 10-19 10-68 (7) 10-120 (7) 10-170 (6)
00-16 10-20 10-69 (7) 10-121 (3) 10-171 (6)
00-17 10-21 10-70 (7) 10-122 (7) 10-172
00-18 10-22 10-71 (7) 10-123 (3) 10-173
00-19 10-23 10-72 (7) 10-124 10-174 (6)
00-20 10-24 10-74 (7) 10-125 10-175
00-21 10-25 10-75 (7) 10-126 10-176
00-22 10-26 10-76 (6) 10-127 10-177 (6)
10-27 10-77 10-128 10-178
01-1 (3) 10-28 10-78 10-129 10-179
01-2 (3) 10-29 10-79 10-130 10-180
01-3 (3) 10-30 10-80 (7) 10-131 10-182
01-4 (3) 10-31 10-81 10-132 10-183
01-5 (3) 10-32 10-82 10-133 10-184
01-6 (3) 10-33 10-83 (6) 10-134 10-185
01-7 (3) 10-34 (6) 10-84 10-135 10-186
01-8 (3) 10-35 10-85 10-136 10-188
01-9 (3) 10-36 10-86 (6) 10-137 10-189
01-10 (3) 10-37 10-87 (6) 10-138 10-190 (6)
01-11 (3) 10-38 10-88 (6) 10-139 (3) 10-191 (6)
01-12 (3) 10-39 10-89 (7) 10-140 (7) 10-193
01-13 (3) 10-40 10-90 10-141 (7) 10-194 (3)
01-14 (3) 10-41 10-91 10-142 10-195
01-15 (3) 10-42 10-92 (7) 10-143 (7) 10-195-1 (3)
01-16 (3) 10-43 10-94 (7) 10-144 10-195-2 (3)
01-17 (3) 10-44 (6) 10-95 10-145 10-196 (6)
01-18 (6) 10-45 (6) 10-96 10-146 (7) 10-197
10-46 (6) 10-97 (3) 10-147 10-197-1 (3)
10-1 (7) 10-47 10-98 10-148 10-197-2 (3)
10-2 (6) 10-48 10-99 10-149 (6) 10-197-3 (3)
10-3 10-50 10-100 10-150 10-198 (3)
GD555, 655, 675-3A 00-2-1

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10-199 (3) 20-122 (6) 20-236 (1) 20-374 (6) 20-431 (6)
10-199-1 (3) 20-123 (6) 20-237 (1) 20-375 (6) 20-432 (6)
10-199-2 (3) 20-124 (6) 20-238 (1) 20-376 (6) 20-433 (6)
10-200 20-125 (6) 20-239 (3) 20-377 (1) 20-434 (6)
10-201 20-126 (6) 20-240 (3) 20-378 (6) 20-435 (6)
10-202 (6) 20-126-1 (3) 20-241 (3) 20-379 (1) 20-436 (6)
10-203 20-126-2 (3) 20-242 (3) 20-380 (6) 20-437 (6)
10-204 (6) 20-127 (6) 20-243 (3) 20-381 (3) 20-451 (3)
10-205 (6) 20-128 (6) 20-244 (3) 20-381-1 (3) 20-452 (6)
10-206 (6) 20-129 (6) 20-245 (3) 20-381-2 (3) 20-453 (3)
10-207 (6) 20-130 (1) 20-246 (3) 20-382 (6) 20-454 (6)
10-208 (6) 20-131 (6) 20-247 (6) 20-383 (6) 20-455 (1)
10-209 (6) 20-132 (6) 20-248 (1) 20-384 (6) 20-456 (1)
10-210 (6) 20-133 (1) 20-249 (1) 20-385 (6) 20-457 (1)
10-211 20-134 (6) 20-250 (6) 20-386 (1) 20-458 (6)
10-212 20-201 (6) 20-251 (6) 20-387 (6) 20-459 (6)
10-213 20-202 (3) 20-301 (3) 20-388 (1) 20-460 (1)
10-214 20-203 (1) 20-302 (3) 20-389 (6) 20-461 (6)
20-204 (1) 20-303 (1) 20-390 (6) 20-462 (6)
20-1 (6) 20-205 (1) 20-303-1 (3) 20-391 (6) 20-463 (3)
20-2 (6) 20-206 (1) 20-303-2 (3) 20-392 (6) 20-464 (6)
20-3 (8) 20-207 (1) 20-304 (6) 20-393 (6) 20-501 (6)
20-4 (6) 20-208 (1) 20-305 (1) 20-394 (6) 20-502 (6)
20-5 (6) 20-209 (1) 20-305-1 (6) 20-395 (6) 20-503 (1)
20-6 (6) 20-210 (1) 20-305-2 (3) 20-396 (6) 20-504 (3)
20-7 (6) 20-211 (1) 20-306 (3) 20-397 (6) 20-505 (3)
20-8 (3) 20-212 (6) 20-307 (3) 20-398 (6) 20-505-1 (3)
20-9 (6) 20-214 (6) 20-308 (6) 20-399 (6) 20-505-2 (3)
20-10 (6) 20-215 (6) 20-309 (3) 20-400 (6) 20-506 (6)
20-11 (6) 20-216 (6) 20-310 (6) 20-401 (6) 20-507 (6)
20-12 (6) 20-217 (6) 20-311 (3) 20-402 (6) 20-508 (6)
20-13 (6) 20-218 (6) 20-312 (6) 20-403 (6) 20-509 (6)
20-14 (6) 20-219 (6) 20-313 (6) 20-404 (6) 20-510 (6)
20-15 (6) 20-219-1 (6) 20-314 (6) 20-405 (1) 20-511 (6)
20-16 (6) 20-219-2 (6) 20-315 (3) 20-406 (6) 20-512 (6)
20-17 (6) 20-219-3 (6) 20-316 (6) 20-407 (1) 20-513 (6)
20-18 (6) 20-219-4 (6) 20-317 (3) 20-408 (6) 20-514 (6)
20-19 (6) 20-219-5 (6) 20-351 (6) 20-409 (1) 20-515 (6)
20-101 (6) 20-219-6 (6) 20-352 (6) 20-410 (6) 20-516 (6)
20-102 (9) 20-220 (3) 20-353 (6) 20-411 (6) 20-517 (1)
20-103 (6) 20-221 (3) 20-354 (6) 20-412 (6) 20-518 (6)
20-104 (6) 20-222 (1) 20-355 (6) 20-413 (6) 20-519 (6)
20-105 (6) 20-223 (3) 20-356 (6) 20-414 (6) 20-520 (6)
20-106 (6) 20-223-1 (3) 20-358 (6) 20-415 (1) 20-521 (3)
20-107 (6) 20-223-2 (3) 20-359 (6) 20-416 (6) 20-522 (6)
20-108 (6) 20-223-3 (3) 20-360 (6) 20-417 (6) 20-522-1 (6)
20-109 (6) 20-223-4 (3) 20-361 (6) 20-418 (6) 20-523 (6)
20-110 (6) 20-224 (1) 20-362 (6) 20-419 (6) 20-524 (6)
20-111 (6) 20-225 (1) 20-363 (6) 20-420 (6) 20-525 (6)
20-112 (6) 20-226 (1) 20-364 (6) 20-421 (6) 20-526 (6)
20-113 (6) 20-227 (1) 20-365 (6) 20-422 (1)
20-114 (6) 20-228 (1) 20-366 (6) 20-423 (6)
20-115 (6) 20-229 (1) 20-367 (6) 20-424 (6) 30-1 (4)
20-116 (6) 20-230 (1) 20-368 (6) 20-425 (6) 30-2 (6)
20-117 (6) 20-231 (1) 20-369 (6) 20-426 (6) 30-3 (4)
20-118 (6) 20-232 (1) 20-370 (6) 20-427 (6) 30-4 (4)
20-119 (6) 20-233 (1) 20-371 (6) 20-428 (6) 30-5 (4)
20-120 (6) 20-234 (1) 20-372 (6) 20-429 (6) 30-6 (6)
20-121 (3) 20-235 (1) 20-373 (6) 20-430 (6) 30-8 (10)
00-2-2 GD555, 655, 675-3A

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30-9 (4) 30-61 (6) 30-113 (6)
30-10 (2) 30-62 (6) 30-114 (6)
30-11 (10) 30-63 (2) 30-115 (6)
30-12 (10) 30-64 (6) 30-116 (4)
30-13 (10) 30-65 (6) 30-117 (4)
30-14 (10) 30-66 (6) 30-118 (4)
30-15 (10) 30-67 (10) 30-119 (4)
30-16 (6) 30-68 (10) 30-120 (4)
30-17 (4) 30-69 (10) 30-121 (4)
30-18 (6) 30-70 (6) 30-122 (6)
30-19 (6) 30-71 (4) 30-123 (4)
30-20 (4) 30-72 (6) 30-124 (4)
30-21 (6) 30-73 (6) 30-125 (6)
30-22 (4) 30-74 (6) 30-126 (6)
30-23-1 (4) 30-75 (6)
30-23-2 (6) 30-76 (6) 90-1 (3)
30-23-3 (6) 30-77 (6) 90-2
30-23-4 (6) 30-78 (6) 90-3 (3)
30-23-5 (6) 30-79 (6) 90-4
30-23-6 (6) 30-80 (6) 90-5 (7)
30-23-7 (4) 30-81 (6) 90-7 (3)
30-24 (6) 30-82 (4) 90-9 (3)
30-25 (6) 30-83 (6) 90-11 (3)
30-26 (2) 30-84 (6) 90-13 (3)
30-27 (6) 30-84-1 (6) 90-15 (3)
30-28 (6) 30-84-2 (4) 90-17 (3)
30-29 (6) 30-84-3 (6) 90-19 (3)
30-30 (6) 30-84-4 (6) 90-21 (3)
30-31 (6) 30-85 (6) 90-23 (3)
30-32 (6) 30-86 (6) 90-25 (3)
30-33 (6) 30-87 (6) 90-27 (3)
30-34 (6) 30-88 (6) 90-29 (3)
30-35 (6) 30-89 (6) 90-31 (3)
30-36 (10) 30-90 (6)
30-37 (10) 30-91 (6)
30-38 (10) 30-92 (6)
30-39 (10) 30-92-1 (4)
30-40 (10) 30-92-2 (6)
30-41 (10) 30-92-3 (6)
30-42 (10) 30-92-4 (4)
30-43 (10) 30-93 (6)
30-44 (10) 30-94 (6)
30-45 (10) 30-95 (6)
30-46 (10) 30-96 (2)
30-47 (10) 30-97 (6)
30-48 (10) 30-98 (6)
30-49 (10) 30-99 (6)
30-49-1 (10) 30-100 (6)
30-50 (10) 30-102 (6)
30-51 (6) 30-103 (2)
30-52 (6) 30-104 (6)
30-53 (6) 30-105 (6)
30-54 (6) 30-106 (2)
30-55 (6) 30-107 (2)
30-56 (6) 30-108 (6)
30-57 (6) 30-109 (2)
30-58 (6) 30-110 (6)
30-59 (6) 30-111 (6)
30-60 (6) 30-112 (6)
GD555, 655, 675-3A 00-2-3

(10)
Safety Safety notice
Safety
Safety notice
Important safety notice

Proper service and repair is extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with the
situation.
General precautions
6. Decide a place in the repair workshop to keep
Mistakes in operation are extremely dangerous. tools and removed parts. Always keep the tools
Read the Operation and Maintenance Manual care- and parts in their correct places. Always keep
fully BEFORE operating the machine. the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the
1. Before carrying out any greasing or repairs, read areas provided for smoking. Never smoke while
all the precautions given on the decals which working.
are fixed to the machine.
Preparations for work
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose 7. Before adding oil or making any repairs, park
work clothes, or clothes with buttons missing. the machine on hard, level ground, and block
• Always wear safety glasses when hitting the wheels or tracks to prevent the machine
parts with a hammer. from moving.
• Always wear safety glasses when grinding
parts with a grinder, etc. 8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work.
9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your
fellow workers before starting any step of the 10. Remove all mud and oil from the steps or other
operation. Before starting work, hang UNDER places used to get on and off the machine.
REPAIR signs on the controls in the operator's Always use the handrails, ladders or steps when
compartment. getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
Safety Safety notice
Precautions during work 19. Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or
Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen
• When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out.
that they will not be damaged by contact with
Before disconnecting or removing components
other parts when the machine is being
of the oil, water or air circuits, first remove the
operated.
pressure completely from the circuit.
20. When installing high pressure hoses, make sure
12. The water and oil in the circuits are hot when the
that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get
dangerous, so be extremely careful when install-
burned.
ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carrying
that connecting parts are correctly installed.
out any work on the oil or water circuits.
21. When assembling or installing parts, always use
13. Before starting work, remove the leads from the
the specified tightening torques. When installing
battery. Always remove the lead from the nega-
protective parts such as guards, or parts which
tive (–) terminal first.
vibrate violently or rotate at high speed, be par-
ticularly careful to check that they are installed
14. When raising heavy components, use a hoist or
correctly.
crane.
Check that the wire rope, chains and hooks are
22. When aligning two holes, never insert your fin-
free from damage.
gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample
caught in a hole.
capacity.
Install the lifting equipment at the correct places.
23. When measuring hydraulic pressure, check that
Use a hoist or crane and operate slowly to pre-
the measuring tool is correctly assembled
vent the component from hitting any other part.
before taking any measurements.
Do not work with any part still raised by the hoist
or crane.
24. Take care when removing or installing the tracks
of track-type machines.
15. When removing covers which are under internal
When removing the track, the track separates
pressure or under pressure from a spring,
suddenly, so never let anyone stand at either
always leave two bolts in position on opposite
end of the track.
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16. When removing components, be careful not to

break or damage the wiring. Damaged wiring
may cause electrical fires.
17. When removing piping, stop the fuel or oil from

spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18. As a general rule, do not use gasoline to wash

parts. In particular, use only the minimum of gas-
oline when washing electrical parts.
00-4
Foreword General
Foreword
General
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make 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 service
workshop. 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 function

This 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 adjusting

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
Disassembly and assembly

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
Maintenance standard
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in “Structure and function”.
Others
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
Notice
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
Foreword General
How to read the shop manual Revised edition mark

W he n a m an ua l i s r ev i s e d, an e di t i on m a r k
Volumes ((1)(2)(3)....) is recorded on the bottom of the pages.
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
Revisions
Chassis volume: Issued for every machine model Revised pages are shown in the List of revised
Engine volume: Issued for each engine series pages next to the Contents page.
Each issued as one
Electrical volume:
volume to cover all
Attachments volume: Symbols
models
So that the shop manual can be of ample practical
use, important safety and quality portions are
These various volumes are designed to avoid dupli- marked with the following symbols.
cating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chas-
Symbol Item Remarks
sis, engine, electrical and attachment volumes be
k
available. Special safety precautions
Safety are necessary when
performing the work.
Distribution and updating Special technical
Any additions, amendments or other changes will be precautions or other
sent to KOMATSU distributors. Get the most up-to- a Caution precautions for preserving
date information before you start any work. standards are necessary
when performing the work.
Filing method Weight of parts of systems.
1. See the page number on the bottom of the page. Caution necessary when
4
File the pages in correct order. Weight selecting hoisting wire, or
when working posture is
2. Following examples show how to read the page
important, etc.
number.
Places that require special
3
Example 1 (Chassis volume): Tightening
attention for the tightening
torque
10 - 3 torque during assembly.
2
Places to be coated with
Item number Coat adhesives and lubricants,
(10. Structure and Function) etc.
Consecutive page number for
5
each item. Places where oil, water or
Oil, water fuel must be added, and
Example 2 (Engine volume): the capacity.
12 - 5 Places where oil or water
6
Drain must be drained, and
Unit number (1. Engine) quantity to be drained.
Item number
(2. Testing and Adjusting)
Consecutive page number for
each item.
3. Additional pages: Additional pages are indi-

cated by a hyphen (–) and number after the
page number. File as in the example.
Example:
10-4 20-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
Foreword Hoisting instructions
Hoisting instructions
Hoisting
Slinging near the edge of the hook may
k
cause the rope to slip off the hook during
Heavy parts (25 kg or more) must be lifted
hoisting, and a serious accident can result.
with a hoist, etc. In the Disassembly and
Hooks have maximum strength at the mid-
assembly section, every part weighing 25
dle portion.
kg or more is indicated clearly with the
symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks should
be made:
1) Check for removal of all bolts fastening the
part to the relative parts. 100% 88% 79% 71% 41%
2) Check for existence of another part causing SAD00479
interference with the part to be removed. 3) Do not sling a heavy load with one rope
alone, but sling with two or more ropes
Wire ropes symmetrically wound onto the load.
k
1) Use adequate ropes depending on the
Slinging with one rope may cause
weight of parts to be hoisted, referring to the
turning of the load during hoisting,
table below:
untwisting of the rope, or slipping of the
Wire ropes rope from its original winding position on
(Standard “Z” or “S” twist ropes the load, which can result in a dangerous
without galvanizing) accident.
Rope diameter Allowable load
mm kN tons 4) Do not sling a heavy load with ropes forming
10 9.8 1.0 a wide hanging angle from the hook.
11.5 13.7 1.4 When hoisting a load with two or more
12.5 15.7 1.6 ropes, the force subjected to each rope will
14 21.6 2.2 increase with the hanging angles. The table
16 27.5 2.8 below shows the variation of allowable load
18 35.3 3.6 kN {kg} when hoisting is made with two
20 43.1 4.4 ropes, each of which is allowed to sling up
22.4 54.9 5.6
to 9.8 kN {1000 kg} vertically, at various
30 98.1 10.0
hanging angles.
40 176.5 18.0
50 274.6 28.0 When two ropes sling a load vertically, up to
60 392.2 40.0 19.6 kN {2000 kg} of total weight can be
suspended. This weight becomes 9.8 kN
a The allowable load value is estimated to be {1000 kg} when two ropes make a 120?
one-sixth or one-seventh of the breaking hanging angle. On the other hand, two
strength of the rope used. ropes are subjected to an excessive force
as large as 39.2 kN {4000 kg} if they sling a
2) Sling wire ropes from the middle portion of 19.6 kN {2000 kg} load at a lifting angle of
the hook. 150°.
00-7
Foreword Method of disassembling, connecting push-pull type coupler
Method of disassembling, connecting push-pull type coupler

k Before carrying out the following work, release Type 1
the residual pressure from the hydraulic tank.
For details, see “Tes ting and adjus ting”,
Releasing residual pressure from hydraulic tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the
hydraulic tank. For details, see “Testing and
adjusting”, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
a The adapter can be pushed in about 3.5 mm.
a Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
a Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
a When the hose is pulled back, the rubber cap
portion moves toward the hose about 3.5
mm. This does not indicate abnormality,
however.
00-8
Foreword Method of disassembling, connecting push-pull type coupler
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding and push body (2) in straight until sliding
prevention ring (1) contacts contact surface a of prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever 2) Hold in the condition in Step 1), and push until
(4) to the right (clockwise). cover (3) contacts contact surface a of the
hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and pull 3) Hold in the condition in Steps 1) and 2), and pull
out whole body (2) to disconnect it. out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion and • Hold the mouthpiece of the tightening portion and
push body (2) in straight until sliding prevention push body (2) in straight until sliding prevention
ring (1) contacts contact surface a of the ring (1) contacts contact surface a of the
hexagonal portion at the male end to connect it. hexagonal portion at the male end to connect it.
Connection
00-9
Foreword Coating materials
Coating materials
a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used to prevent rubber gaskets, rubber

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
• Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperatures.
• Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive
Gasket case, etc.
sealant • Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three bond • Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
• Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
• Used as sealing material for transfer case
00-10
Foreword Coating materials
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to
LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
Foreword Standard tightening torque
Standard tightening torque

Standard tightening torque table (when using torque wrench)
a In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the
table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
Table of tightening torques for flared nuts

a In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below.
SAD00483
Thread diameter Width across flats Tightening torque

mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5
18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
Table of tightening torques for flared nuts

a In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table
below.
Thread diameter Width across flats Tightening torque

mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
Table of tightening torques for o-ring boss piping joints

a Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}
03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
Table of tightening torques for o-ring boss plugs

a Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flats Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
Tightening torque for 102 and 114 engine series

1) Bolt and nuts
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
2) Eye joints
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
3) Tapered screws
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
Tightening torque table for hoses (taper seal type and face seal type)
a Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
a Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
Nominal type
Width
size of
hose across flats Thread size Nominal thread size Root diameter
Range Target – Threads per inch, (mm)
(mm) (Reference)
Thread series
9
34 – 54 {3.5 – 5.5} 44 {4.5} — – 18UN 14.3
16
02 19
34 – 63 {3.5 – 6.5} 44 {4.5} 14 — —
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} — – 16UN 17.5
16
03
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 — —
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 – 12UN 30.2
16
(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 — —
00-14
Foreword Electric wire code
Electric wire code

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
Classification by thickness
Copper wire
Norminal Cable O.D. Current rating
Number of Dia. of Cross section Applicable circuit
number (mm) (A)
strands strands (mm2) (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
Classification by color and code

Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Code W B B R Y G L
1 Primary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
White & White & Red & Rellow & Green & Blue &
Color —
Red Black White Red White White
Code WB — BY RB YB GR LR
3
White & Black & Red & Yellow & Green & Blue &
Color —
Black Yellow Black Black Red Yellow
Code WL — BR RY YG GY LY
4 Auxiliary
White & Black & Red & Yellow & Green & Blue &
Color —
Blue Red Yellow Green Yellow Yellow
Code WG — — RG YL GB LB
5
White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6
Yellow & Green &
Color — — — Red & Blue —
White Blue
00-15
Foreword Conversion table
Conversion table
Method of using the conversion table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
Example
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
(A) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-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 of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
Foreword Units
Units
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
01 GENERAL
General assembly drawing . . . . . . . . . . . . . . . 01-2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
Weight table . . . . . . . . . . . . . . . . . . . . . . . . . . 01-15
Fuel, coolant, and lubricant . . . . . . . . . . . . . . 01-17
GD555, 655, 675-3A 01-1

(3)
GENERAL GENERAL ASSEMBLY DRAWING
12
GENERAL ASSEMBLY DRAWING
Unit:mm
Item GD555-3A GD655-3A GD675-3A
A Overall length 8,350 8,595 8,595
B Overall height (Without cab at top of muffler) 2,980 3,000 3,000
Overall height (With full height cab) 3,330 3,350 3,350

C
Overal height (With low height cab) 3,100 3,120 3,120
D Overall width 2,525 2,550 2,550
01-2 GD555, 655, 675-3A

(3)
GENERAL SPECIFICATIONS
12
SPECIFICATIONS
GD555-3A
GD555-3A
Machine Model
VHP Engine
Serial Number 10001 – 11000 11001 and up
Machine weight (Without cab) 13,050 13,100

On front axle kg 3,780 3,740
On rear axle 9,270 9,360
Overall length 8,350
Overall width 2,525
Overall height (top of muffler) 2,980
Dimensions
Overall height (with ROPS cab) 3,330

Wheel base mm 5,850
Distance between centers of tandem wheels 1,535
Tread (Front) 2,130
Tread (Rear) 2,130
Ground clearance 350
1st 3.3
2nd 4.8
3rd 6.8
4th 9.8
Forward km/h
5th 14.9
Travel speed
6th 21.6
7th 29.6
Performance
8th 42.9
1st 4.4 4.4
2nd 8.9 9.0
Reverse km/h
3rd 18.7 19.7
4th 36.1 39.1
Maximum drawbar pull kN {kg} 72.7 {7,416} 73.5 {7,490}
Gradeability deg 24
Min. Turning radius m 6.9
Static stability deg 35
• VHP engine: variable horsepower engine
GD555, 655, 675-3A 01-3

(3)
GD555-3A
Machine Model
VHP Engine
Engine model SA6D102E-1 SAA6D102E-2
4-cycle, water cooled,
overhead valve,
Type
direct-injection type
with turbocharger and aftercooler
Cylinder number - bore x stroke mm 6 - 102 x 120
Piston displacement l{cc} 5.88 {5,880}

kW/rpm 104.4 to 119.3/2,000
Flywheel horsepower
{HP/rpm} {140 to 160/2,000}
Nm/rpm 606 to 741/1,400 576 to 729/1,500
Maximum torque
Engine
{kgm/rpm} {61.8 to 75.6/1,400} {58.7 to 74.3/1,500}

Performance
2,200 2,200
Max. speed at no load rpm
800 850
Min. speed at no load rpm
g/kWh 229.4 to 232.4 214.3
Fuel consumptions ratio
{g/HPh} {171.1 to 173.3} {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

3-element, single-stage
Torque converter
Wet disc for lock-up
Multiple shaft
Drive train
Fully automatic electric, automatic shifting type,

Transmission
pump force feed type
8 forward speeds, 4 reverse speeds
Reduction gear Spiral bevel gear, single-stage reduction
Rear axle Fully floating tandem type
Tandem Double-strand chain drive
Type Reverse Elliott, angle type

Front
axle
deg.
Max. leaning angle 16
Steering
Type Fully hydraulic type
Steering angle deg 49

Steering
system
Articulate angle deg 23
01-4 GD555, 655, 675-3A

(3)
GD555-3A
Machine Model
VHP Engine
Tires (front) 13.00-24-10PR

Steering, operating
Tires (rear) 13.00-24-10PR

Tires
kPa {kg/cm2}
system
Inflation pressure (front) 275 {2.75}
Inflation pressure (rear) kPa {kg/cm2} 275 {2.75}
Main brake Rear 4-wheel braking, multiple-disc wet type

Brakes
Parking brake Dry disc type
Type x no. Komatsu LPV90 Variable swash plate type x 1

Hydraulic pump
Discharge l/min. 205
Set pressure MPa {kg/cm2} 20.6 {210}

Control valve
Type x no. 4-spool type x 2 (CLSS)
Control method Hydraulic type
Steering Leaning Articulating

Steering related cylinders
Type Double-acting piston type
Cykinder bore mm 50 70 90
Hydraulic system
Piston rod outside diameter mm 35 35 50
Piston stroke mm 330 160 325
Blade Drawbar
Blade lift side shift Blade tilt side shift Ripper

Work equipment cylinders
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
Scarifier —
Cylinder bore mm 80
—
Piston rod outside diameter mm 50
Piston stroke mm 345
GD555, 655, 675-3A 01-5

(3)
Machine Model GD555-3A
Blade dimension (Length x Height x Thickness) 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 mm 460
Max. cutting depth 815
Blade base 2,500
Blade load kN {kg} 64.7 {6,601} 64.1 {6,531}

Blade
Turning angle (with scarifier) deg 360 (130)
Max. side shift distance (left) (Moving distance by cylinder +

Quantity of bolt adjustment) 625 + 195
mm
Max. side shift distance (right) (Moving distance by cylinder +
Quantity of bolt adjustment)\ 625 + 195
Cutting angle
[Standard] 37
deg
[Adjustable] 32 to 81
01-6 GD555, 655, 675-3A

(3)
GD655-3A
GD655-3A
Machine Model
VHP Engine
On rear axle 9,940 10,060
Overall width 2,550

Dimensions
Wheel base mm 6,070
Tread (Front) 2,130
Tread (Rear) 2,130
1st 3.3
2nd 4.7
3rd 6.7
4th 9.7
Forward km/h
5th 14.6
6th 21.2
Travel speed
7th 29.1
Performance
8th 42.1
1st 4.3 4.3
2nd 8.8 8.8

Reverse km/h
3rd 19.3 19.3
4th 38.3 38.4
Gradeability deg 24
GD555, 655, 675-3A 01-7

(3)
GD655-3A
Machine Model
VHP Engine

overhead valve,
Type direct-injection type
Piston displacement l {cc} 8.27 {8,270}
kW/rpm 123.3 to 141.7/1,900

Flywheel horsepower {HP/rpm} {165 to 190/1,900}
Nm/rpm 804 to 926/1,300 749 to 926/1,400

Engine
Performance
Maximum torque {kgm/rpm} {82.0 to 94.4/1,300} {76.4 to 94.4/1,400}
Max. speed at no load rpm 2,200
Min. speed at no load rpm 800
g/kWh 227.4 218.3

Fuel consumptions ratio {g/HPh} {169.61} {162.8}
Starting motor 24V, 7.5 kW 24V, 7.5 kW
Alternator 24V, 50A 24V, 60A
Battery 12V, 112Ah x 2 12V, 112Ah x 2
Radiator type CF19-4 CF19-5
Torque converter Wet disc for lock-up
Multiple shaft
Drive train
Transmission pump force feed type

8 Forward speeds, 4 reverse speeds

Front
axle

Steering

Steering
system
01-8 GD555, 655, 675-3A

(3)
GD655-3A
Machine Model
VHP Engine

Steering, operating

Tires
kPa {kg/cm2}
system

Brakes

Hydraulic
pump

Control

valve

Steering related

cylinders
Cylinder bore mm 50 80 90

Hydraulic system
Blade Drawbar
Blade lift side Blade tilt side shift Ripper
shift

Piston stroke mm 1,160 1,250 300 585 540
Scarifier —
Cylinder bore mm 90
—
GD555, 655, 675-3A 01-9

(3)
Blade base 2,600
Blade load kN {kg} 69.7 {7,102} 68.8 {7,015}

Blade

mm
Cutting angle
[Standard] 37
deg
01-10 GD555, 655, 675-3A

(3)
GD675-3A
GD675-3A
Machine Model
VHP Engine
On rear axle 10,510 10,640
Overall width 2,550

Dimensions
Wheel base mm 6,070
Tread (Front) 2,130
Tread (Rear) 2,130
1st 3.3
2nd 4.7
3rd 6.7
4th 9.7
Forward km/h
5th 14.6
6th 21.2
Travel speed
7th 29.1
Performance
8th 42.1
1st 4.3 4.3
2nd 8.8 8.8

Reverse km/h
3rd 18.1 19.3
4th 35.1 38.3
Gradeability deg 24
GD555, 655, 675-3A 01-11

(3)
GD675-3A
Machine Model
VHP Engine

overhead valve,
Type direct-injection type
Piston displacement l {cc} 8.27 {8,270}
kW/rpm 134.2 to 149.2/1,900

Flywheel horsepower {HP/rpm} {180 to 200/1,900}
Nm/rpm 856 to 975/1,300 785 to 975/1,400

Engine
Performance
Maximum torque {kgm/rpm} {87.3 to 99.4/1,300} {80.0 to 99.4/1,400}
Max. speed at no load rpm 2,200
Min. speed at no load rpm 800
g/kWh 236.5 218.1

Fuel consumptions ratio {g/HPh} {176.4} {162.7}
Starting motor 24V, 7.5 kW 24V, 7.5 kW
Alternator 24V, 50A 24V, 60A
Battery 12V, 112Ah x 2 12V, 112Ah x 2
Radiator type CF19-4 CF19-5
Torque converter Wet disc for lock-up
Multiple shaft
Drive train
Transmission pump force feed type

8 forward speeds, 4 reverse speeds

Front
axle

Steering

Steering
system
01-12 GD555, 655, 675-3A

(3)
GD675-3A
Machine Model
VHP Engine

Steering, operating

Tires
kPa {kg/cm2}
system

Brakes

Hydraulic
pump

Control

valve

Steering related

cylinders
Cylinder bore mm 50 80 90

Hydraulic system
Blade Draw-
Blade lift side Blade tilt bar side Ripper
shift shift

Piston stroke mm 1,160 1,250 300 585 540
Scarifier —
Cylinder bore mm 90
—
GD555, 655, 675-3A 01-13

(3)
Blade base 2,600
Blade load kN {kg} 73.6 {7,504} 72.6 {7,399}

Blade

mm
Cutting angle
[Standard] 37
deg
01-14 GD555, 655, 675-3A

(3)
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
k Use the weight table when handling individual parts or when transporting the entire machine.
Unit: kg
Machine Model GD555-3A GD655-3A GD675-3A
Serial Number 10001 – 11000
Engine assembly (dry) 453 616 616
Radiator assembly (dry) 51 74 74
Transmission assembly (dry) 755 755 755
Transmission pump 15 15 15
Final drive assembly 682 682 682
Tandem drive (one side) 904 904 904
Front axle assembly, except leaning cylinder 418 548 548
Parking brake assembly 13 13 13
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 550 620 620
Hydraulic pump 49 49 49
Fuel tank and hydraulic tank (both dry)(With bracket) 201 201 201
Circle rotation motor 10 10 10
Steering cylinder assembly 12 x 2 12 x 2 12 x 2
Leaning cylinder assembly 12 15 15
Articulating cylinder assembly 25 x 2 25 x 2 25 x 2
Blade lift cylinder assembly 53 x 2 53 x 2 53 x 2
Blade side-shift cylinder assembly 48 48 48
Blade power tilt cylinder assembly 19 19 19
Drawbar side-shift cylinder assembly 33 33 33
Scarifier cylinder assembly 22 24 24
Drawbar assembly 604 670 670
Blade assembly 713 713 713
Circle gear 644 680 680
Circle rotation gear assembly 119 119 119
Front frame assembly 1,988 2,150 2,150
Rear frame assembly 872 1,002 1,002
Ripper 595 900 900
Operator’s compartment assembly and controls and chair 306 306 306
GD555, 655, 675-3A 01-15

(3)
GENERAL WEIGHT TABLE
k Use the weight table when handling individual parts or when transporting the entire machine.
Unit: kg
Machine Model GD555-3A GD655-3A GD675-3A
Serial Number 11001 and up
Engine assembly (dry) 550 750 750
Radiator assembly (dry) 115 115 115
Transmission assembly (dry) 755 755 755
Transmission pump 15 15 15
Final drive assembly 682 682 682
Tandem drive (one side) 904 904 904
Front axle assembly, except leaning cylinder 418 548 548
Parking brake assembly 13 13 13
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 550 620 620
Hydraulic pump 49 49 49
Fuel tank and hydraulic tank (both dry)(With bracket) 201 201 201
Circle rotation motor 10 10 10
Steering cylinder assembly 12 x 2 12 x 2 12 x 2
Leaning cylinder assembly 12 15 15
Articulating cylinder assembly 25 x 2 25 x 2 25 x 2
Blade lift cylinder assembly 53 x 2 53 x 2 53 x 2
Blade side-shift cylinder assembly 48 48 48
Blade power tilt cylinder assembly 19 19 19
Drawbar side-shift cylinder assembly 33 33 33
Scarifier cylinder assembly 22 24 24
Drawbar assembly 604 670 670
Blade assembly 713 713 713
Circle gear 644 680 680
Circle rotation gear assembly 119 119 119
Front frame assembly 1,988 2,150 2,150
Rear frame assembly 872 1,002 1,002
Ripper 595 900 900
Operator’s compartment assembly and controls and chair 306 306 306
01-16 GD555, 655, 675-3A

(3)
GENERAL FUEL, COOLANT, AND LUBRICANT
12
FUEL, COOLANT, AND LUBRICANT
AMBIENT TEMPERATURE CAPACITY (l)

KIND OF
RESERVOIR FLUID -22 -4 14 32 50 68 86104122ºF
-30 -20 -10 0 10 20 30 4050ºC Specified Refill
SAE30 CD
SAE10W CD
GD555-3A GD555-3A
SAE10W-30 CD 16 14
Engine oil pan GD655-3A GD655-3A
SAE15W-40 CD GD675-3A GD675-3A
24 19
SAE5W-40 CD
Engine oil SAE0W-30 CD
Transmission case SAE10W CD 60 45
Final drive case SAE30 CD 18 16
Tandem drive case SAE10W CD 80 75

(each)
SAE10W CD
Hydraulic system 85 45
SAE5W-30 CD
Circle reverse gear SAE90
• Shear-pin type Gear oil SAE80 4 4
• Slip-clutch type SAE75 7 7
ASTM D975 No. 2

Fuel tank Diesel fuel 340 –
1
Cooling system Coolant Add antifreeze 44 44
1. ASTM D975 No. 1
GD555, 655, 675-3A 01-17

(3)
GENERAL FUEL, COOLANT, AND LUBRICANT
12
REMARK
• When fuel sulphur content is less than 0.5%, change oil in the oil pan in accordance with the periodic
maintenance hours described in Operation & Maintenance manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.
Change interval of oil in

Fuel sulphur content
engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
• When starting the engine in atmospheric temperature of lower than 0°C, be sure to use engine oil of
SAE10W, SAE10W-30 and SAE15W-40, even though an atmospheric temperature goes up 10°C or more
in the day time.
• Use API classification CD engine oil. If API classification CC is used, reduce the engine oil change inter-
val in half.
• There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to
add single grade oil that matches the temperature in the table.
• We recommend Komatsu genuine oil, which has been specifically formulated and approved for use in
engine and hydraulic work equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
01-18 GD555, 655, 675-3A

(6)
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
Accelerator control linkage . . . . . . . . . . . . . . . 10-2 Main frame . . . . . . . . . . . . . . . . . . . . . . . . . . 10-193

Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . 10-3 Air conditioner (if equipped) . . . . . . . . . . . . 10-194
Fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Engine starting circuit. . . . . . . . . . . . . . . . . . 10-196
Power train diagram . . . . . . . . . . . . . . . . . . . . 10-5 Engine stop circuit . . . . . . . . . . . . . . . . . . . . 10-198
Transmission hydraulic piping . . . . . . . . . . . . 10-6 Preheat circuit . . . . . . . . . . . . . . . . . . . . . . 10-199-1
Transmission control . . . . . . . . . . . . . . . . . . . . 10-8 Automatic shift control system . . . . . . . . . . 10-200
Torque converter . . . . . . . . . . . . . . . . . . . . . . . 10-9 Transmission controller . . . . . . . . . . . . . . . . 10-201
Torque converter lock-up valve (ECMV). . . . 10-14 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-206
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210
Transmission valve . . . . . . . . . . . . . . . . . . . . 10-39
ECMV
(Electronic Control Modulation Valve)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
Main relief valve . . . . . . . . . . . . . . . . . . . . . . . 10-44
Transmission pump . . . . . . . . . . . . . . . . . . . . 10-47
Transmission and differential lock pump. . . 10-48
Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
Tandem drive . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
Steering hydraulic piping drawing . . . . . . . . 10-58
Steering valve
(Q/amp Manual Orbit-roll Type)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
Priority valve. . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
Accumulator pressure governor valve . . . . . 10-74
Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
Brake hydraulic piping . . . . . . . . . . . . . . . . . . 10-80
Brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
Slack adjuster . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . 10-89
Wheel brake . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . 10-91
Parking brake and bank control valve . . . . . 10-92
Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . 10-102
Main control valve . . . . . . . . . . . . . . . . . . . . 10-124
CLSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-139
Work equipment control . . . . . . . . . . . . . . . 10-152
Hydraulic system . . . . . . . . . . . . . . . . . . . . . 10-154
Hydraulic tank. . . . . . . . . . . . . . . . . . . . . . . . 10-157
Swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
Pilot check valve . . . . . . . . . . . . . . . . . . . . . . 10-159
Blade accumulator, float valve . . . . . . . . . . 10-164
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
Blade float device . . . . . . . . . . . . . . . . . . . . . 10-168
Circle rotation motor . . . . . . . . . . . . . . . . . . 10-170
Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . 10-172
Circle drawbar . . . . . . . . . . . . . . . . . . . . . . . 10-178
Lifter bracket lock pin. . . . . . . . . . . . . . . . . . 10-180
Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
Circle rotation gear . . . . . . . . . . . . . . . . . . . 10-184
Scarifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188
Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190
GD555, 655, 675-3A 10-1

(7)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCELERATOR CONTROL LINKAGE
ACCELERATOR CONTROL LINKAGE
Outline 1. Fuel control lever

• Operating fuel control lever (1) pulls spring 2. Spring rod
rod (2), which moves lever (3) and accelerator 3. Lever
cable (9) to control the engine speed. 4. Rod.
5. Accelerator pedal
6. Decelerator pedal
• Depressing accelerator pedal (5) moves rod
7. Fuel injection pump
(4), lever (3), and accelerator cable (9) to con-
8. Fuel injection pump lever
trol the engine speed. When this situation
9. Accelerator cable
happens, the spring of spring rod (2) moves
in the direction of the compression.
• Releasing accelerator pedal (5) and depress-

ing decelerator pedal (rod) (6) cause lever (3)
to rotate, reducing engine speed.
10-2 GD555, 655, 675-3A

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCELERATOR PEDAL
ACCELERATOR PEDAL
1. Pedal
2. Stopper bolt
3. Cable
4. Potentiometer
GD555, 655, 675-3A 10-3

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FAN DRIVE
FAN DRIVE
1. Transmission Outline
2. Radiator • The fan drive is installed at the top of trans-
3. Fan drive pulley mission (1). The fan is driven by V-belt (4)
4. V-belt through drive pulley (6) at the front face of
5. Tension pulley transmission (1). This drive pulley (6) is
6. Drive pulley driven through a gear by the torque converter
input shaft.
10-4 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN DIAGRAM
POWER TRAIN DIAGRAM
SWG00981
• The power produced by diesel engine (5) 1. Cooling fan

goes to transmission (4) through torque con- 2. Hydraulic pump
verter with lock-up clutch (3). 3. Torque converter
4. Transmission
5. Engine assembly
• Transmission (4), with a multiple shaft mecha-
6. Drive shaft
nism and a hydraulic control unit combined,
7. Final drive
allows an easy selection of eight forward
8. Tandem drive
speeds and four reverse speeds. Through
9. Tire
drive shaft (6), the power is transmitted from
10. Wheel brake
the transmission to the final drive (7). Here,
11. Shaft
final drive (7) directs the power to the right
and left, and the power is transmitted to the
left and right tandem drives (8) through shaft
(11).
• Tandem drive (8) transmits the power to the

wheel by a chain and the machine travels.
GD555, 655, 675-3A 10-5

STRUCTURE, FUNCTION AND MAINTENANCE STANDARDTRANSMISSION HYDRAULIC PIPING
TRANSMISSION HYDRAULIC PIPING

GD555-3A Serial No. 10001 – 11048
GD655-3A Serial No. 10001 – 11026
GD675-3A Serial No. 10001 – 11015
1. Engine assembly 3. Oil filler

2. Transmission assembly 4. Transmission pump
10-6 GD555, 655, 675-3A

(5)
5. Hose - oil cooler inlet port 7. Transmission oil filter

6. Hose - oil cooler outlet port 8. Radiator and oil cooler
GD555, 655, 675-3A 10-7


GD555-3A Serial No. 11049 and up
1. Engine assembly 3. Oil filler

2. Transmission controller 4. Return hose of oil in flywheel housing
5. Transmission pump
10-7-1 GD555, 655, 675-3A

(5)
6. Hose - oil cooler inlet port 8. Transmission oil filter

7. Hose - oil cooler outlet port 9. Radiator and oil cooler
GD555, 655, 675-3A
GD555, 655, 675-3A 10-7-2

(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION CONTROL
TRANSMISSION CONTROL
1. Gearshift lever
2. Transmission controller
GEARSHIFT LEVER POSITIONS
[1] Reverse [7] 3 range (forward, reverse)

[2] Forward [8] 4 range (forward, reverse)
[3] Parking [9] 5 range (forward)
[4] Neutral [10] 6 range (forward)
[5] 1 range (forward, reverse) [11] 7 range (forward)
[6] 2 range (forward, reverse) [12] 8 range (forward)
10-8 GD555, 655, 675-3A

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
1. Pump Specifications:
2. PTO drive gear (No. of teeth: 70)
3. Outer race Name: TCA38-10A
4. Output shaft (transmission input shaft) Type: 3 element, 1 stage, 2 phase
5. Stator shaft Stall torque ratio: 2.17
6. Lock-up clutch piston
7. Lock-up clutch housing (No. of teeth: 72)
8. Stator
9. Pilot
10. Freewheel
11. Turbine
12. Lock-up clutch disc
13. Drive case
GD555, 655, 675-3A 10-9

10-10 GD555, 655, 675-3A

Unit: mm
No. Check Criteria Remedy
Std. Tolerance Repair
Size Limit
1 Pilot O.D. 71.954 -0.010 71.7 Rebuild or

-0.040 replace
2 Pilot seal ring I.D. 35 +0.025 35.5

0
3 Clutch housing seal ring I.D. 340 +0.089 340.1

0
Replace
4 Clutch piston seal ring I.D. 260 +0.081 260.1
0
5 PTO drive gear seal ring O.D. 125 +0.040 125.5 Rebuild or
0 replace
Clutch housing seal ring wear Width 5 -0.01 4.5

-0.04
6
Thickness 6 ±0.15 5.85
0
Stator shaft seal ring wear Width 3.95 -0.1 3.56
7
Thickness 4.8 ±0.1 4.32
8 +0.005
One-way clutch outer race O.D. 88.882 -0.008 88.912
9 +0.008
Stator shaft one-way clutch O.D. 72.217 -0.005 72.187 Replace
10 +0.015
Bushing I.D. 72.32 0 72.4
11 0
Bushing thickness 5 -0.1 4.9
12 Clutch disc thickness 5 ±0.1 4.7
13 +0.030
Stator shaft seal ring I.D. 55 0 55.5
14 Backlash between PTO drive gear and idler gear 0.160 to 0.407
GD555, 655, 675-3A 10-11

LOCK-UP CLUTCH
LOCK-UP CLUTCH DISENGAGED
• When the lock-up clutch is disengaged, the
drive case (13) and turbine (11) are separated,
and the torque converter functions as normal.
The power generated by the engine passes

through the flywheel, is transmitted to lock-
up clutch housing (7) and rotates drive case
(13) and pump (1) as one unit.
The power from the pump uses oil as a

medium, rotates turbine (11), and is transmit-
ted to output shaft (4), which forms one unit
with the turbine.
LOCK-UP CLUTCH ENGAGED

• When the lock-up clutch is engaged, the drive
case (13) and turbine (11) are engaged, form-
ing one unit. The stator (8) is rotated by the
rotation of 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)
as one unit. In addition, the drive case (13)
and turbine (11) are engaged by the clutch.
Thus, the power is transmitted directly to the
turbine and output shaft (4), without using oil.
10-12 GD555, 655, 675-3A

OIL FLOW
• The oil supplied from the torque converter
charging pump passes through the transmis-
sion valve and enters the inlet port (A). The oil
then passes through the oil passage in the
stator shaft (5) and PTO drive gear (2) and
flows from between the pump (1) and stator
(8) to the pump (1). The oil is given centrifu-
gal force by the pump (1) and enters the tur-
bine (11), transmitting the energy of the oil to
the turbine. Because the turbine (11) is fixed
to the output shaft (4), the power is transmit-
ted to the output shaft. The oil from turbine
(11) is sent to the stator (8), entering the pump
again. However, part of the oil that returns
from between the turbine (11) and stator (8) to
the outlet port is routed to the oil cooler.
GD555, 655, 675-3A 10-13

TORQUE CONVERTER LOCK-UP
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VALVE (ECMV)
TORQUE CONVERTER LOCK-UP VALVE (ECMV)
A. To clutch 1. Connector for proportional solenoid

P. From pump 2. ECMV (for torque converter lock-up clutch)
T. Drain 3. Seat
Dr. Drain 4. Connector for fill switch
P1. Clutch oil pressure detection port 5. Fill switch
P2. Pilot oil pressure detection port 6. Oil pressure detection valve
7. Pressure control valve spool
8. Proportional solenoid
10-14 GD555, 655, 675-3A

ECMV FOR LOCK-UP CLUTCH

Outline Operation
• This valve acts to set the lock-up clutch oil During torque converter travel
pressure to the set pressure, and also to • When transmission is in torque converter
switch the lock-up clutch. travel, no current flows to the proportional
If forms a modulation wave pattern, so the solenoid (1).
lock-up clutch is engaged smoothly to reduce Pressure control valve (3) drains the oil at
the shock when shifting gear. In addition, it clutch port A through drain port Dr and can-
prevents generation of peak torque in the cels the lock-up clutch.
power train. As a result, it provides a comfort- When this happens, there is no oil pressure
able ride for the operator and greatly acting on oil pressure detection valve (4), so
increases the durability of the power train. fill switch (6) is OFF.
GD555, 655, 675-3A 10-15

DURING DIRECT TRAVEL

(TORQUE CONVERTER TRAVEL ➞ DIRECT TRAVEL)
1. When filling 2. Adjusting pressure

When the transmission is in direct travel When the electric current flows to the propor-
(lock-up), if electric current is applied to pro- tional solenoid (1), the solenoid generates a
portional solenoid (1) by the electric signal, a propulsion force proportional to the current.
hydraulic force balancing with the force of the The pressure is adjusted so that the total of
solenoid acts on chamber B, and pressure this propulsion force of the solenoid, the pro-
control valve spool (3) moves to the left. pulsion force of the oil pressure at the clutch
As a result, the circuit between pump port P port, and the reaction force of pressure con-
and clutch port A opens, and oil starts to fill trol valve spring (2) is balanced.
the clutch. When the clutch is filled with oil, To reduce the shock when shifting gear, the
fill switch (6) is turned ON. lock-up clutch oil pressure is temporarily low-
ered to 0 MPa {0 kg/cm²} when the gear is
shifted.
10-16 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
1. Transmission control valve 4. Dipstick tube mounting port

2. Transmission case 5. Torque converter lock-up valve
3. Strainer mounting port 6. Main relief, torque converter relief valve
GD555, 655, 675-3A 10-17

1. Torque converter 9. 4th clutch

2. Input shaft 10. Output shaft
3. FL clutch 11. 2nd clutch
4. Upper shaft 12. 1st clutch
5. FH clutch 13. R clutch
6. Lower shaft 14. Mounting coupling for fan pulley
7. 3rd clutch 15. Shaft for hydraulic pump drive
8. Coupling
10-18 GD555, 655, 675-3A

1. Shaft for the transmission charge pump

2. R idler gear (Number of teeth: 37)
3. Speedometer gear set
Unit: mm
No. Check Item Criteria Remedy
Std. Tolerance Standard Clearance

Size Clearance Limit
Shaft Hole
Clearance between idler gear and +0.018 0 -0.030 to —
4 bearing 50 +0.002 -0.012 -0.002
Clearance between idler gear bear- 0 +0.016 -0.006 to —
5 ing and case 90 -0.015 -0.006 0.031
Clearance between pump drive +0.020 0 -0.032 to —
6 shaft and bearing (F) 50 +0.009 -0.012 -0.009
Clearance between pump drive 0 +0.030 0 to — Replace
7 shaft bearing and case (F) 90 -0.015 0 0.045
Clearance between pump drive +0.030 0 -0.045 to —
8 shaft and bearing (R) 70 +0.011 -0.015 -0.011
Clearance between pump drive 0 +0.030 0 to —
9 shaft bearing and case (R) 100 -0.015 0 0.045
Clearance between idler shaft and +0.032 0 -0.047 to —
10 bearing 70 +0.002 -0.015 -0.002
Clearance between idler gear and 0 -0.038 -0.073 to —
11 bearing 100 -0.015 -0.073 -0.023
GD555, 655, 675-3A 10-19

10-20 GD555, 655, 675-3A

Unit: mm

Clearance between FL, R clutch bear- Size Shaft Hole Clearance Limit
1 ing and case (F)
150 0 +0.030 0 to —
-0.018 0 0.048
2 Clearance between FL, R clutch bear- 100 0 +0.022 -0.013 to —
ing and case (R) -0.015 -0.013 0.037
Clearance between FH, 1st clutch 0 +0.030 0 to
3 bearing and case (F) 100 -0.015 0 0.045 —
4 Clearance between FH, 1st clutch 110 0 +0.022 -0.013 to —

bearing and case (R) -0.015 -0.013 0.037
5 Clearance between 2nd, 3rd clutch 140 0 +0.026 -0.014 to —
bearing and case (F) -0.018 -0.014 0.044
Clearance between 2nd, 3rd clutch 0 +0.026 -0.014 to
6 bearing and case (R) 130 -0.018 -0.014 0.044 —
7 Clearance between 4th clutch bearing 140 0 +0.026 -0.014 to —

and case (F) -0.018 -0.014 0.044
8 Clearance between 4th clutch bearing 160 0 +0.040 0 to —
and case (R) -0.025 0 0.065
Clearance between idler gear and +0.018 0 -0.030 to
9 bearing 50 +0.002 -0.012 -0.002 —
10 Clearance between idler gear bearing 90 0 +0.016 -0.006 to —

and case -0.015 -0.006 0.031
11 Clearance between fan drive shaft 35 +0.025 0 -0.037 to —
and bearing +0.009 -0.012 -0.009
Clearance between fan drive shaft 0 +0.030 0 to
12 bearing and case 80 -0.013 0 0.043 —
13 Clearance between pump drive shaft 50 +0.020 0 -0.032 to —

and bearing (F) +0.009 -0.012 -0.009
14 Clearance between pump drive shaft 90 0 +0.030 0 to —
bearing and case (F) -0.015 0 0.045 Replace
Clearance between pump drive shaft +0.030 0 -0.045 to
15 and bearing (R) 70 +0.011 -0.015 -0.011 —
16 Clearance between pump drive shaft 110 0 +0.030 0 to —

bearing and case (R) -0.015 0 0.045
Standard Tolerance Repair
Size Limit
Width of input shaft seal ring groove
+0.018
2.5 +0.010 2.7
17
Width 2.4 ±0.05 2.2
Wear of input shaft seal
ring Thickness 1.7 0 1.5
-0.010
+0.076
Width of input shaft seal ring groove 3.2 0 3.5
18 Width 3.1 ±0.05 2.8
ring 0
Thickness 2.29 -0.010 2.1
Inside diameter of case seal ring slid- +0.05
ing portion 50 0 50.1
+0.076
Width of input shaft seal ring groove 3.2 0 3.5
19
Width 3.1 ±0.05 2.8
ring 0
Thickness 2.29 -0.010 2.1
Outside diameter of output coupling 0

20 oil seal sliding portion 80 -0.074 79.8
Outside diameter of fan pulley cou- 0

21 pling oil seal sliding portion 65 -0.074 64.8
GD555, 655, 675-3A 10-21

Outline Combination of clutches and reduction ratio

• The transmission is installed at the rear of the Speed range Clutch Used
Reduction
torque converter. The power from the torque Ratio
converter passes through the transmission F1 FL x 1st 9.950
input shaft and enters the transmission. F2 FH x 1st 6.865
F3 FL x 2nd 4.879
• The transmission shifts the gear to FORWARD F4 FH x 2nd 3.367
1 to 8 or REVERSE 1 to 4, according to the
combination of the FL, FH, and R clutches and F5 FL x 3rd 2.222
the 4-speed. F6 FH x 3rd 1.533
F7 FL x 4th 1.118
F8 FH x 4th 0.772
R1 R x 1st 7.549
R2 R x 2nd 3.702
R3 R x 3rd 1.686
R4 R x 4th 0.848
CLUTCHES
FL, R CLUTCHES
1. R gear (number of teeth: 25) A. R clutch oil port

2. R clutch B. FL clutch oil port
3. FL, R cylinder C. Lubrication oil port
4. FL clutch D. Lock-up clutch oil port
5. FL gear (number of teeth: 28)
6. Idler gear (number of teeth: 36)
7. Input shaft
10-22 GD555, 655, 675-3A

FH, 1st CLUTCHES
1. Idler gear (No. of teeth: 42) 6. FH gear (No. of teeth: 55)

2. 1st gear (No. of teeth: 26) 7. Upper shaft
3. 1st clutch A. FH clutch oil port
4. FH, 1st cylinder, idler gear (No. of teeth: 62) B. 1st clutch oil port
5. FH clutch C. Lubrication oil port
2nd and 3rd CLUTCHES
1. Idler gear (No. of teeth: 29) 6. 3rd gear (No. of teeth: 55, 41)
2. 2nd gear (No. of teeth: 61) 7. Lower shaft
3. 2nd clutch A. 2nd clutch oil port
4. 2nd, 3rd cylinder, idler gear (No. of teeth: 77) B. 3rd clutch oil port
5. 3rd clutch C. Lubrication oil port
GD555, 655, 675-3A 10-23

4th CLUTCHES
1. Output gear (No. of teeth: 44) A. 4th clutch oil port

2. 4th clutch B. Lubrication oil port
3. 4th cylinder, idler gear (No. of teeth: 42) C. Lubrication oil port
4. Output shaft
10-24 GD555, 655, 675-3A

FL - R CLUTCHES
Unit: mm

Size Shaft Hole Clearance Limit
1
0 +0.180 0.050 to
Inside 96.73 -0.050 +0.050 0.230 0.25
Clearance between the
piston and shaft (FL) -0.300 +0.130 0.300 to
2 Outside 140 -0.350 0 0.480 0.53
0 +0.180 0.050 to
3 Inside 96.73 -0.050 +0.050 0.230 0.25
Clearance between the
piston and shaft (R) -0.300 +0.130 0.300 to
4 Outside 140 -0.350 0 0.480 0.53
Clearance between the FL, R shaft +0.030 0 -0.045 to

5 and bearing (F) 60 +0.011 -0.015 -0.011 —
Clearance between the FL, R shaft +0.034 0 -0.049 to

6 and bearing (R) 55 +0.021 -0.015 -0.021 —
Replace
Standard Repair
Size Tolerance Limit
7 Separator plate Thickness 1.7 ±0.05 1.6
Distortion — 0.1 0.15
Thickness 2.2 ±0.08 1.9
8 Friction plate
1010 N ±101 N 859 N
9 Load of wave spring (height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
10 FL clutch thrust washer thickness 3 ±0.1 2.7
11 R clutch thrust washer thickness 3 ±0.1 2.7
12 FL gear end play 0.30 to 0.76
13 R gear end play 0.29 to 0.69
GD555, 655, 675-3A 10-25

FH and 1st CLUTCHES
Unit: mm

1
Inside 96.73 0 +0.180 0.050 to 0.25
Clearance between -0.050 +0.050 0.230
piston and shaft (FH) -0.300 +0.130 0.300 to
2 Outside 145 0.53
-0.350 0 0.480
3 Inside 96.73 0 +0.180 0.050 to 0.25

Clearance between -0.050 +0.050 0.230
piston and shaft (1st) -0.200 +0.130 0.200 to
4 Outside 164.93 0.42
-0.250 0 0.380
5 Clearance between the FH, 1st 55 +0.034 0 -0.049 to —

shaft and bearing (F) +0.021 -0.015 -0.021
6 Clearance between the FH, 1st 60 +0.034 0 -0.049 to —

shaft and bearing (R) +0.021 -0.015 -0.021 Replace
Size Limit
7 Separator plate
Thickness 1.7 ±0.05 1.6
Thickness 2.2 ±0.08 1.9
8 Friction plate
9 Load of wave spring 1010 N ±101 N 859 N

(height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
10 FH clutch thrust washer thickness 3 ±0.1 2.7
11 1st clutch thrust washer thickness 3 ±0.1 2.7
12 FH gear end play 0.39 to 0.79
13 1st gear end play 0.26 to 0.74
10-26 GD555, 655, 675-3A

2nd and 3rd CLUTCHES
Unit: mm

1
0 +0.180 0.050 to
Inside 96.73 -0.050 +0.050 0.230 0.25
Clearance between
piston and shaft (3rd) -0.200 +0.130 0.200 to
2 Outside 164.93 -0.250 0 0.380 0.42
0 +0.180 0.050 to
3 Inside 96.73 -0.050 +0.050 0.230 0.25
Clearance between
piston and shaft (2nd) -0.200 +0.130 0.200 to
4 Outside 164.93 -0.250 0 0.380 0.42
Clearance between 2nd, 3rd shaft +0.030 0 -0.045 to

5 and bearing (F) 65 +0.011 -0.015 -0.011 —
Clearance between 2nd, 3rd shaft +0.054 0 -0.069 to

6 and bearing (R) 60 +0.044 -0.015 -0.044 —
Replace
Standard Repair
Size Tolerance Limit
Thickness 2.2 ±0.08 1.9
8 Friction plate
Load of wave spring 1010 N ±101 N 859 N
9 (height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
10 3rd clutch thrust washer thickness 3 ±0.1 2.7
11 2nd clutch thrust washer thickness 3 ±0.1 2.7
12 3rd gear end play 0.38 to 0.82
13 2nd gear end play 0.35 to 0.85
GD555, 655, 675-3A 10-27

4th CLUTCHES
Unit: mm

Shaft Hole
1 0 +0.180 0.050 to
Clearance between Inside 96.73 0.25
-0.050 +0.050 0.230
piston and cylin-
2 der (4th) Outside 164.93 -0.200 +0.130 0.200 to 0.42
-0.250 0 0.380
Clearance between 4th shaft and +0.030 0 -0.045 to
3 bearing (F) 65 +0.011 -0.015 -0.011 —
4 Clearance between 4th shaft and 75 +0.030 0 -0.045 to —

bearing (R) +0.011 -0.015 -0.011
Size Limit
Replace
Thickness 2.2 ±0.08 1.9
6 Friction plate
7 Load of wave spring 1010 N ±101 N 859 N
(height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
Thickness of 4th clutch thrust
8 washer 3 ±0.1 2.7
Inside diameter of cylinder seal +0.030
ring sliding portion 70 0 70.1
+0.076
4th shaft seal ring groove width 3.2 0 3.5
9
Width 3.1 ±0.05 2.8
4th shaft seal ring
wear 0
Thickness 2.29 -0.10 2.1
10 4th cylinder idler gear end play 0.30 to 0.70 mm
10-28 GD555, 655, 675-3A

CLUTCH OPERATION
When operated:
• The oil from the transmission valve passes
through the oil passage inside the shaft (1)
and goes to the rear face of the piston (6) to
actuate the piston.
• Actuating the piston (6) causes the separator

plate (2) to press the clutch disc (3) and com-
bines the shaft (1) and clutch gear (4) as one
unit to transmit the motive force.
• Oil is drained from the oil drain hole (5) at this

time, but does not affect the clutch operation
because less oil is drained than supplied. The
oil drain hole (5) is only in the 2nd, 3rd, and
4th clutches.
When not actuated:

• If the oil from the transmission valve is turned
off, the pressure acting on the rear face of the
piston (6) drops. The piston then returns to its
original position by the wave spring (7). Thus,
the shaft (1) and clutch gear (4) disengage or
separate. When the clutch is disengaged, the
oil at the rear face of the piston is drained by
centrifugal force through the oil drain hole
(5). This situation prevents the clutch from
remaining partially engaged.
GD555, 655, 675-3A 10-29

POWER FLOW
FORWARD 1st
Operation
• In FORWARD 1st, the FL clutch (2) and 1st • The 1st clutch (10) is engaged, so the power
clutch (10) are engaged. The FL clutch (2) and transmitted to FH, 1st cylinder gear (11)
1st clutch (10) hold each clutch disc in position passes through the 1st clutch (10). From the
with the oil pressure applied to the piston. 1st clutch the power goes from 1st gear (13)
to 2nd, 3rd cylinder gear (19). The power flow
• The power from the torque converter is trans- continues through the lower shaft (20), idler
mitted from the input shaft (1) through the FL gear (21), output gear (24), and finally to the
clutch (2) to the FL gear (4). The power is then output shaft (25).
transmitted to FH, 1st cylinder gear (11).
10-30 GD555, 655, 675-3A

FORWARD 2nd
Operation
• In FORWARD 2nd, the FH clutch (9) and 1st • With the 1st clutch (10) engaged, the power
clutch (10) are engaged. The FH clutch (9) and transmitted to the FH, 1st cylinder gear (11)
1st clutch (10) hold each clutch disc in position passes through the 1st clutch (10). Power is
with the oil pressure applied to the piston. then transmitted from the 1st gear (13) to 2nd,
3rd cylinder gear (19). Power then goes
• The power from the torque converter is trans- through the lower shaft (20), idler gear (21),
mitted from the input shaft (1) to the idler output gear (24), and finally the output shaft
gear (6). The power continues to the FH gear (25).
(8) and passes through the FH clutch (9), and
is then transmitted to the FH, 1st cylinder gear
(11).
GD555, 655, 675-3A 10-31

FORWARD 3rd
Operation
• In FORWARD 3rd, the FL clutch (2) and 2nd • With the 2nd clutch (17) engaged, the power
clutch (17) are engaged. The FL clutch (2) and transmitted to 2nd gear (15) passes through
2nd clutch (17) hold each clutch disc in posi- the 2nd clutch (17). Power continues to the
tion with the oil pressure applied to the pis- 2nd, 3rd cylinder gear (19) and lower shaft
ton. (20), and then passes through the idler gear
(21), output gear (24), and to the output shaft
• The power from the torque converter is trans- (25).
mitted from the input shaft (1) through the FL
clutch (2) and then to the FL gear (4). Power is
then transmitted through the FH, 1st cylinder
gear (11), upper shaft (12), and idler gear (14),
and goes to the 2nd gear (15).
10-32 GD555, 655, 675-3A

FORWARD 4th
Operation
• In FORWARD 4th, the FH clutch (9) and 2nd • With the 2nd clutch (17) engaged, the power
clutch (17) are engaged. The FH clutch (9) and transmitted to the 2nd gear (15) passes
2nd clutch (17) hold each clutch disc in posi- through the 2nd clutch (17), and to the 2nd,
tion with the oil pressure applied to the pis- 3rd cylinder gear (19) and lower shaft (20).
ton. Power is then transmitted through the idler
gear (21), output gear (24), and finally to the
• The power from the torque converter is trans- output shaft (25).
mitted from the input shaft (1) to the idler
gear (6) and the FH gear (8) and then passes
through the FH clutch (9). Power is then trans-
mitted through the FH, 1st cylinder gear (11),
upper shaft (12), idler gear (14), and then to
the 2nd gear (15).
GD555, 655, 675-3A 10-33

FORWARD 5th
Operation
• In FORWARD 5th, the FL clutch (2) and 3rd • With the 3rd clutch (18) engaged, the power
clutch (18) are engaged. The FL clutch (2) and transmitted to the 3rd gear (16) passes
3rd clutch (18) hold each clutch disc in posi- through the 3rd clutch (18) and then goes to
tion with the oil pressure applied to the pis- the 2nd, 3rd cylinder gear (19) and lower shaft
ton. (20). Power is then transmitted through the
idler gear (21), output gear (24), and finally to
• The power from the torque converter is trans- the output shaft (25).
gear (11) to the 3rd gear (16).
10-34 GD555, 655, 675-3A

(6)
FORWARD 6th
Operation
• In FORWARD 6th, the FH clutch (9) and 3rd • With the 3rd clutch (18) engaged, the power
clutch (18) are engaged. The FH clutch (9) and transmitted to the 3rd gear (16) passes
3rd clutch (18) hold each clutch disc in posi- through the 3rd clutch (18) and then to the
tion with the oil pressure applied to the pis- 2nd, 3rd cylinder gear (19) and lower shaft
ton. (20). Power is then transmitted through the
idler gear (21), output gear (24), and finally to
• The power from the torque converter is trans- the output shaft (25).
mitted from the input shaft (1) and then to the
idler gear (6) and FH gear (8). Power then
passes through the FH clutch (9) to the FH, 1st
cylinder gear (11) and then to the 3rd gear
(16).
GD555, 655, 675-3A 10-35

FORWARD 7th
Operation
• In FORWARD 7th, the FL clutch (2) and 4th • With the 4th clutch (23) engaged, the power
clutch (23) are engaged. The FL clutch (2) and transmitted to the 4th cylinder gear (22) goes
4th clutch (23) hold each clutch disc in posi- through the 4th clutch (23), and then to the
tion with the oil pressure applied to the pis- output shaft (25).
ton.
• The power from the torque converter is trans-

gear (11) and 3rd gear (16) to the 4th cylinder
gear (22).
10-36 GD555, 655, 675-3A

FORWARD 8th
Operation
• In FORWARD 8th, the FH clutch (9) and 4th • With 4th clutch (23) engaged, the power
clutch (23) are engaged. The FH clutch (9) and transmitted to the 4th cylinder gear (22)
4th clutch (23) hold each clutch disc in posi- passes through the 4th clutch (23), and finally
tion with the oil pressure applied to the pis- to the output shaft (25).
ton.
• The power from the torque converter is trans-

mitted from the input shaft (1) to the idler
gear (6) and FH gear (8). Power then passes
through the FH clutch (9) and FH, 1st cylinder
gear (11) and 3rd gear (16) to the 4th cylinder
gear (22).
GD555, 655, 675-3A 10-37

REVERSE 1st
Operation
• In REVERSE 1st, the R clutch (3) and 1st clutch • With the 1st clutch (10) engaged, the power
(10) are engaged. The R clutch (3) and 1st transmitted to the FH, 1st cylinder gear (11)
clutch (10) hold each clutch disc in position passes through the 1st clutch (10), and goes
with the oil pressure applied to the piston. from 1st gear (13) to 2nd, 3rd cylinder gear
(19). The power is then transmitted through
• The power from the torque converter is trans- the lower shaft (20), idler gear (21), output
mitted from the input shaft (1) through the R gear (24), and finally to the output shaft (25).
clutch (3). Power to the R gear (5) is rotated in
the opposite direction by the R idler gear (7).
The power is then transmitted through the
idler gear (14) and upper shaft (12) to the FH,
1st cylinder gear (11).
10-38 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION VALVE
TRANSMISSION VALVE
A. FL clutch oil pressure detection port ECMV clutch actuation table

B. R clutch oil pressure detection port ECMV FL FH R 1 2 3 4
C. FH clutch oil pressure detection port Speed Range
D. 1st clutch oil pressure detection port F1 O O
E. 2nd clutch oil pressure detection port F2 O O
F. 3rd clutch oil pressure detection port
F3 O O
G. 4th clutch oil pressure detection port
F4 O O
1. ECMV (for FL clutch) F5 O O
2. ECMV (for R clutch) F6 O O
3. ECMV (for FH clutch)
F7 O O
4. ECMV (for 1st clutch)
5. ECMV (for 2nd clutch) F8 O O
6. ECMV (for 3rd clutch) R1 O O
7. ECMV (for 4th clutch) R2 O O
8. Seat
R3 O O
9. Last chance filter
R4 O O
N
GD555, 655, 675-3A 10-39

ECMV (ELECTRONIC CONTROL
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MODULATION VALVE)
ECMV (ELECTRONIC CONTROL MODULATION VALVE)
A. To clutch 1. Connector for fill switch

P. From pump 2. Connector for proportional solenoid
T. Drain 3. Oil pressure detection valve
Dr. Drain 4. Fill switch
P1. Clutch oil pressure detection port 5. Proportional solenoid
P2. Pilot oil pressure detection port 6. Pressure control valve spool
10-40 GD555, 655, 675-3A

ECMV FOR SPEED CLUTCH

Outline of ECMV ECMV and proportional solenoid
• The ECMV (Electronic Control Modulation • There is one proportional solenoid installed
Valve) consists of two components: the pres- to each ECMV.
sure control valve and the fill switch. It generates propulsion as shown in the dia-
Pressure control valve gram below according to the command cur-
• The proportional solenoid receives the flow of rent form the controller.
electricity sent from the transmission control- The propulsion generated by the proportional
ler, and the pressure control valve converts solenoid acts on the pressure control valve
this into hydraulic pressure. spool and generates oil pressure as shown in
the diagram below.
Fill switch
In this way, the command current is con-
• This detects when oil has filled the clutch. It trolled and the propulsion force varies to
has the following functions. actuate the pressure control valve and control
the oil flow and oil pressure.
1) When the clutch is filled with oil, it sends
a signal (fill signal) to the controller to
inform the controller that the filling is
completed.
2) While oil pressure is applied to the clutch,

it outputs a signal (fill signal) to the con-
troller to inform the controller of the exist-
ence of the oil pressure.
A range: Before gear shifting (drained)
B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
ECMV and fill switch

• There is one fill switch installed to each
ECMV.
When the filling of the clutch is completed,
the fill switch is turned on by the clutch pres-
sure. With this signal, the oil pressure starts
to build up.
GD555, 655, 675-3A 10-41

OPERATION OF ECMV
• The ECMV is controlled by the command cur- 1. When gear shifting (during draining)
rent from the transmission controller to the (Range A in graph).
proportional solenoid and the fill switch out- When no current is flowing to proportional
put signal. solenoid (1), pressure control valve spool (3)
The relationship between the ECMV propor- drains the oil at clutch port A through drain
tional solenoid command current and the port Dr.
clutch input pressure and fill switch output When this happens, there is no hydraulic
signal is as shown in the diagram below. force acting on pressure detection valve (4),
so fill switch (6) is turned OFF.
A range: Before gear shifting (drained)

B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
10-42 GD555, 655, 675-3A

2. When filling (when trigger command is 3. Adjusting pressure (Range D in graph)

input to pressure control valve) When electric current flows to proportional
(Ranges B and C in graph) solenoid (1), the solenoid generates a propul-
When there is no oil inside the clutch, if elec- sion force proportional to the current.
tric current is applied to proportional solenoid The pressure is adjusted so that the total of
(1), a hydraulic force balancing the force of this propulsion force of the solenoid, the pro-
the solenoid acts on chamber B, and pressure pulsion force of the oil pressure at the clutch
control valve spool (3) moves to the left. port, and the reaction force of pressure con-
As a result, the circuit between pump port P trol valve spring (2) is balanced.
and clutch port A opens, and oil starts to fill
the clutch. When the clutch is filled with oil,
fill switch (6) is turned ON.
GD555, 655, 675-3A 10-43

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MAIN RELIEF VALVE
MAIN RELIEF VALVE
1. Seat Outline
2. Body
3. Piston Main relief valve
4. Torque converter relief valve • The main relief valve (6) sets the pressure of
5. Piston the transmission main port pressure in front
6. Main relief valve of ECMV set pressure.
A. Drain Port Torque converter relief valve

B. To torque converter
• The torque converter relief valve (4) protects
C. Drain port
the torque converter from abnormally high
D. Drain port
pressure. It relieves the pressure when the
E. From pump
pressure at the inlet port of the torque con-
verter goes above the specified pressure.
P1. Main relief oil pressure detection port
P2. Torque converter oil pressure relief detection
port
Specified Pressure
2.47 MPa
Main relief pressure
{25.2 kg/cm2}
Torque converter inlet 0.91 MPa

port pressure {9.31 kg/cm2}
10-44 GD555, 655, 675-3A

(6)
Unit: mm
Std. Standard Clearance

Tolerance
7 Clearance between main Shaft Hole
relief valve and valve body 0.035 to
28 -0.035 +0.013 0.08
0.058
-0.045 0
Clearance between torque -0.035 +0.013 0.035 to
8 converter relief valve and 22 0.08
-0.045 0 0.058
valve body
Standard Size Repair Limit Replace
Free Installed Installed Permissible
Free Length
9 Length Length Load Load
Main relief-
valve spring 226 N 224.6 N
Outer 108 82.5 104.8
{23.1 kg} {22.9 kg}
290 N 287.3 N
10 Inner 108 82.5 104.8
{29.6 kg} {29.3 kg}
Torque converter relief valve 153.0 N 145.1 N
11 50 42 48.5
spring {15.6 kg} {14.8 kg}
GD555, 655, 675-3A 10-45

(6)
MAIN RELIEF VALVE OPERATION

• The oil from the hydraulic pump passes
through the filter and then enters port A of
the main relief valve. The oil then passes
through the orifice a and enters port B. When
the oil from the pump fills the circuit, the oil
pressure increases.
• As the oil pressure increases within the cir-

cuit, the oil entering port B pushes the piston
(4). The reaction compression compresses
the spring and moves the main relief valve (6)
to the left in the direction of the arrow. This
action opens the passage between port A and
port C. The oil from the pump is relieved from
port A to port C and flows from port C into
the torque converter. The oil pressure at port
A is 2.47 MPa (25.2 kg/cm2).
TORQUE CONVERTER OPERATION

• The oil relieved from the main relief valve
flows from port C into the torque converter
and simultaneously passes through orifice b
and enters port D.
• As oil fills the torque converter circuit, the oil

pressure in the circuit increases. Thus, the oil
entering port D pushes the piston (9). This
action compresses the spring (3), moving the
relief valve (2) to the right to open the pas-
sage between port C and port E. The oil from
port C is now relieved to port E and merges
with the transmission lubrication circuit. The
oil pressure at port C is 0.91 MPa {9.31 kg/
cm2}.
10-46 GD555, 655, 675-3A

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION PUMP
TRANSMISSION PUMP
SAR(2)63
Unit: mm
Standard Clearance Clearance Limit

1 Side clearance
0.13 to 0.18 0.22
Clearance between inside

diameter of plain bearing and
2 0.067 to 0.125 0.20
outside of diameter of gear
shaft Replace
Standard size Tolerance

3 Depth for knocking in pin 0
12
-0.5
4 Rotating torque of spline shaft 2.9 to 6.9 Nm {0.3 to 0.7 kgm}
Standard Standard
Rotating Delivery
Discharge amount delivery amount
speed pressure
amount limit
— —
Oil: EO10-CD 15.2 MPa
2300 rpm 137 l/min 124 l/min
Oil temperature: 45 to 55 °C {155 kg/cm2}
GD555, 655, 675-3A 10-47

TRANSMISSION AND
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL LOCK PUMP
TRANSMISSION AND DIFFERENTIAL LOCK PUMP

(WITH DIFFERENTIAL LOCK)
SAR(2)63 + SBR(1)10
Unit: mm
Model Standard Clearance Clearance Limit
1 Side clearance SAR(2)63 0.13 to 0.18 0.22
SBR(1)10 0.10 to 0.15 0.19
Clearance between inside SAR(2)63 0.067 to 0.125 0.20

diameter of plain bearing and
2 Replace
outside of diameter of gear SBR(1)10 0.064 to 0.119 0.20
shaft
Model Standard Size Tolerance Repair Limit
3 Depth for knocking in pin SAR(2)63 12

0
—
SBR(1)10 10 -0.5
4 Rotating torque of spline shaft 4.9 to 11.8 Nm {0.5 to 1.2 kgm}
Delivery Standard Delivery

Rotating
Pressure Delivery Amount
Model Speed
Discharge amount [MPa {kg/cm2}] Amount Limit
(rpm) —
— Oil: EO10-CD (l/min) (l/min)
Oil temperature: 45 ~ 55 °C
SAR(2)63 15.2 {155} 137 124
2,300
SBR(1)10 20.6 {210} 20 19
10-48 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
STANDARD FINAL DRIVE (NO DIFFERENTIAL)
S_G00934
23B-22-34000
1. Cage 6. Sprocket (12 teeth)

2. Coupling 7. Breather
3. Bevel pinion (12 teeth) 8. Drain plug
4. Bevel gear (43 teeth) 9. Oil filler tube
5. Shaft
10-50 GD555, 655, 675-3A

Unit: mm
No. Check item Criteria Remedy
10 Preload of bevel Starting rotation torque: 8.7 to 11.7 Nm {0.89 to 1.19 kgm}
pinion bearing
11 Preload of bevel gear Starting rotation torque: Item 10 + 0.7 to 1.5 Nm {0.07 to 0.15 kgm}
bearing (after setting, measure at pinion bearing) Adjust
Backlash between bevel Standard size

12
pinion and bevel gear 0.25 to 0.33
GD555, 655, 675-3A 10-51

PLANETARY FINAL DRIVE (WITH DIFFERENTIAL LOCK)

1. For serial No. 11001 and up
1. Shaft (Number of teeth: 24) 10 Gear (Number of teeth: 10)

2. Coupling 11. Gear (Number of teeth: 20)
3. Bevel pinion (Number of teeth: 12) 12. Gear (Number of teeth: 66)
4. Bevel gear (Number of teeth: 43) 13. Gear (Number of teeth: 20)
5. Shaft 14. Breather
6. Sprocket (Number of teeth: 20) 15. Drain plug
7. Plate 16. Solenoid valve for differential lock-up
8. Disc 17. Oil supply pipe
9. Piston 18. Grease fitting ( 1)
10-52 GD555, 655, 675-3A

(3)
Unit: mm
No. Check item Criteria Remedy
Preload of bevel
19 pinion bearing Starting rotation torque: 8.7 to 11.7 Nm {0.89 to 1.19 kgm}
Preload of bevel gear

20 bearing Starting rotation torque: Item 18 + 0.7 to 1.5 Nm {0.07 to 0.15 kgm} Adjust
Backlash between bevel Standard size

21 pinion and bevel gear 0.25 to 0.33
GD555, 655, 675-3A 10-53

(3)
Outline
• When the motor grader works with its blade
at a propulsion angle or its body inclined, its
front part is pushed to the right or left by the
reaction force. Since it must travel straight,
resisting the reaction force, it is not equipped
with a differential.
• Since the motor grader is articulated, its rear
wheels are slipped sideways rather frequently
when it turns. To increase the durability of the
rear wheels, an optional final drive having a
differential can be installed.
• The optional final drive has a differential lock-
up mechanism, which can be controlled with
the switch from the operator’s seat.
Operation (with differential lock-up)

• The power transmitted from the engine to the
transmission passes through the meshing of
bevel pinion (1) and bevel gear (2), and is
then transmitted shaft (3) o (4) o sprocket
(5).
The differential is switched between ON and

LOCK (OFF) by using hydraulic power to push
together or separate disc (6) and plate (7).
• Even when the differential lock is switched

ON, if the machine is travelling at high speed
(F6-F8), the controller acts to automatically
cancel the differential lock.
10-54 GD555, 655, 675-3A

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TANDEM DRIVE
TANDEM DRIVE
FOR STANDARD FINAL DRIVE
1. Breather 5. Plate
2. Hub shaft 6. Oil level plug
3. Sprocket (45 teeth) 7. Drain plug
4. Disc
Unit: mm
8 Hub bearing preload Turning torque: 11 to 16 Nm {1.15 to 1.65 kgm} Adjust
Extension of chain Size Repair limit

9 (10 links) Replace
317.5 322.26
GD555, 655, 675-3A 10-55

(3)
FOR PLANETARY FINAL DRIVE
1. Breather 5. Plate
2. Hub shaft 6. Oil level plug
3. Sprocket (20 teeth) 7. Drain plug
4. Disc
Unit: mm
8 Hub bearing preload Turning torque: 11 to 16 Nm {1.15 to 1.65 kgm} Adjust
Extension of chain Size Repair limit

9 (10 links) Replace
508.0 515.62
10-56 GD555, 655, 675-3A

(3)
Outline
Power from the final drive is transmitted to the
front and back rear wheels by chain.
The tandem cases can swing up 12° and down
13° each. All four wheels are in contact with the
ground even when the ground is rough restrict-
ing the up-and-down movement of the blade to a
minimum.
Operation
The movement of the blade of a motor grader
when its rear wheel rides over an obstacle as fol-
lows:
1. When both left and right wheels ride over an

object (height: H) at the same time, the center
of the rear axle rises H/2 as right figure
shows, and because the blade is situated
about halfway between the front and rear
axles, its movement further becomes H/4.
2. When only one left rear wheel rides over an

object (height: H), the rise at the center of rear
axle is H/2 at its left end as right figure shows
and H/4 at the center line of machine and on
the real axle.
The movement of the center part of the blade
is half of that, which is H/8.
GD555, 655, 675-3A 10-57

(6)
STEERING HYDRAULIC PIPING
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRAWING
STEERING HYDRAULIC PIPING DRAWING
1. Steering valve 5. Hydraulic tank

2. Steering wheel 6. Hydraulic pump
3. Priority valve 7. Steering cylinder
4. Accumulator charge valve
10-58 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING VALVE (Q/AMP MANUAL
STEERING VALVE (Q/AMP MANUAL ORBIT-ROLL TYPE)
1. Gland 8. Drive shaft

2. Valve body 9. Sleeve
3. Check valve 10. Spool
4. Gerotor 11. Center pin
5. Spacer 12. Center spring
6. Cover
7. Spacer
GD555, 655, 675-3A 10-59

(5)
STEERING VALVE (Q/AMP MANUAL
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ORBIT-ROLL TYPE)
Outline
The Q/Amp manual Orbit-roll used on this 1. Variable ratio steering function
machine has a flow amplification function. This The amount of oil pushed out of the steering
function is provided by the structure of the Orbit- pump, in other words, the steering discharge
roll valve and orifice. With this, the steering pump amount, varies according to the steering
speed range varies to change the steering dis- wheel speed. When the steering wheel is
charge amount; in particular, at high speed it has turned at low speed, the steering discharge is
the characteristic of providing an amplified flow small; and when the steering wheel is turned
above the metering amount of the Gerotor (Vari- at high speed, the steering discharge is large.
able ratio steering function).
For this reason, when the machine is travel-
The Gerotor used for this function has the following at high speed, if the steering wheel is
ing features. turned at low speed, the steering discharge is
• Fine compensation of the steering is possible small. This makes fine compensation of the
at high speed to ensure stable steering. steering possible, and enables superior travel
• Quick turns are possible when the machine is at high speed.
traveling at low speed or when it is stationary.
When the machine is stationary or traveling
• Emergency steering is possible with the
at low speed, if the steering wheel is turned at
Orbit-roll control used independently.
high speed, a large steering discharge is eas-
ily ensured, so quick turns are possible.
10-60 GD555, 655, 675-3A

2. Flow amplification function

• In addition to the metering by the Gerotor
of the conventional Orbit-roll, there is a
variable internal orifice with a bypass
flow control function, so this makes it
possible to send a large oil flow to the
steering cylinder. In this way, even with a
small Orbit-roll, a large amount of oil can
be sent to the steering cylinder when trav-
eling at high speed.
3. Q/Amp manual Orbit-roll

• An Orbit-roll with an emergency steering
function using a Q/Amp Orbit-roll is called
a Q/Amp manual Orbit-roll. To achieve
this function, the oil does not pass
through the metering (Orbit-roll) but uses
the characteristics of a bypass orifice
(characteristics of flow amplification ori-
fice AA) and closes the hole during emer-
gency steering (valve at maximum flow
position).
• This type of Orbit-roll has great merits
when it is used in the steering system of
medium sized machines.
• Normally, only an Orbit-roll with a small
discharge volume can achieve actual
emergency steering when the Orbit-roll is
used independently. When selecting an
Orbit-roll with a large discharge volume, it
is necessary to provide an emergency
source of pressure oil.
With this Q/Amp manual Orbit-roll, the
system is simplified, and as a result, the
reliability is improved.
Steering lock-to-lock characteristics

(Variable capacity steering system of Q/Amp steering speed)
SWG00982
GD555, 655, 675-3A 10-61

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING VALVE (Q/AMP MANUAL
STRUCTURE
• The shaft connected to the steering wheel
meshes with the spline at the top of the spool
and the spool (10) is fitted inside the sleeve
(9). In addition, the spool and sleeve are con-
nected by the center pin (7) (not touching the
spool when the steering wheel is not being
used).
• The top of drive shaft (3) is engaged with cen-

ter pin (7) and made one with sleeve (9). The
bottom of drive shaft (3) is engaged with the
spline of rotor (1) of the Gerotor set (combina-
tion of rotor (1) and stator (11)).
• Four ports in the valve body connect to the

pump circuit, tank circuit, and circuits to the
head and bottom ends of the steering cylin-
ders. Also, a check valve inside the body con-
nects the port at the pump end and the port at
the tank end. Thus, if the engine or pump fail,
oil can be sucked in directly from the tank
because of this check valve.
10-62 GD555, 655, 675-3A

(5)
CONNECTION BETWEEN THE HAND PUMP AND SLEEVE
• The diagrams above show the connections

with the sleeve ports connecting the suction
and discharge ports of the Gerotor.
• When turning the wheel to the right, the verti-

cal grooves in the spool connect ports a, c, e,
g, i, and k to the pump side. Simultaneously,
ports b, d, f, h, j, and l connect to the head end
of the steering cylinder in the same way.
• In the diagram above left, ports 1, 2, 3 are the

discharge ports and connect to ports l, b, and
d. Thus, the oil is sent to the cylinder.
• Turning the steering wheel 90° changes the

condition to that shown in the diagram above
right. Ports 1, 2, and 3 are suction ports and
connect to ports i, k, and a. Ports 5, 6, and 7
are discharge ports and connect to ports d, f,
and h.
GD555, 655, 675-3A 10-63

(6)
• In this way, the ports acting as the discharge • Adjust the discharge amount to match the
ports of the hand pump connect to the ports amount while turning the steering wheel. The
going to the steering cylinder. And the ports oil from this pump always passes through
acting as suction ports connect to the pump this hand pump. For each 1/7 turn of the steer-
circuit. ing wheel, the internal tooth gear of the hand
• If the pump or engine fails, the suction and pump advances by one tooth. An amount of
discharge of this hand pump is performed oil equal to this movement is discharged.
forcibly and oil is sent to the steering cylinder. Thus, the discharge oil amount is directly pro-
Thus, it is still possible to steer the machine. portional to the amount the steering wheel is
turned. If the pump or engine fail, the condi-
tion is exactly the same. Thus, the same
amount of oil is discharged as when the
Differences between the trochoid pump is normal.
pump and steering pump hand pump
Trochoid pump
• The trochoid pump is divided into an inlet

port and an outlet port. When the shaft
rotates as shown above, oil is sucked in from
the inlet port and discharged from the outlet
port as shown in stage 2 and 6.
Steering pump hand pump
• With the hand pump, inlet and outlet ports

exist at the bottom of the internal teeth of the
stator. Rotating the shaft connects the steer-
ing pump and port as shown in stage 2 and 3
above. Also, oil is sucked in. Rotating the
shaft further, the steering cylinder and port
connect as shown in stage 5 and 6 above. The
oil is delivered to the cylinder. This action is
performed at each port.
10-64 GD555, 655, 675-3A

ROLE OF THE CENTERING SPRING

• The centering spring (4) consists of four X-
shaped leaf springs and two flat leaf springs.
It is assembled between the spool (10) and
sleeve (9) as shown in the diagram on the
right.
• Turning the wheel, the spool compresses the

spring. A difference (angle variation) is gener-
ated in the turning angle of the spool and
sleeve. As a result, the spool port and sleeve
connect and oil is directed to the cylinder.
However, when the steering wheel is
stopped, the hand pump rotation stops also.
Thus, oil is no longer sent to the cylinder and
the oil pressure increases. To prevent this sit-
uation, when the steering wheel is stopped,
the action of the centering spring only allows
it to turn by an amount equal to the angle
variation of the sleeve and spool. Thus, the
steering wheel returns to the NEUTRAL posi-
tion.
GD555, 655, 675-3A 10-65

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PRIORITY VALVE
PRIORITY VALVE
SWG00983
1. Relief valve P: From pump

2. Orifice EF: To accumulator pressure governor valve
3. Spring (To work equipment circuit)
4. Spool CF1: To accumulator pressure governor valve
5. Orifice (To brake circuit)
6. Orifice CF2: To steering valve
7. Fitting face of accumulator pressure governor LS1: To accumulator pressure governor valve
valve (To pilot circuit)
LS2: To accumulator pressure governor valve
(To pilot circuit)
T: To accumulator pressure governor valve
(To hydraulic tank)
10-66 GD555, 655, 675-3A

(7)
SWG00984
Outline
• If the hydraulic systems for both the work
equipment and steering and brake are cov-
ered by one pump, all the oil flow is con-
sumed by the work equipment circuit. Thus,
there is a lack of oil for the steering and brake
circuit. To prevent this dangerous situation, a
valve is installed to ensure that priority is
given to the oil flow to the steering and brake
circuit.
• If a large flow of oil is sent to the steering cir-

cuit even when the steering is at neutral, the
oil flow to the work equipment circuit will be
reduced and poor efficiency results. To pre-
vent this situation and to ensure a quick
response when operating the steering, this
valve keeps the steering circuit oil flow to a
minimum (approx. 1 l/min) when the steering
is at neutral. And to send the rest of the oil to
the work equipment circuit. In addition, this
valve is a load-sensing type that ensures the
necessary flow even when operating the
steering.
• The built-in relief valve regulates the steering

circuit pressure to prevent generation of
abnormal pressure.
GD555, 655, 675-3A 10-67

(6)
OPERATION
1. When engine is stopped
Spool (1) is pushed to the right by spring (2).
In this condition, port (CF) is opened to the
maximum and port (EF) is closed.
2. When engine is started (steering and
main control valves at neutral)
The oil from the pump flows from port (A) to
port (CF) and to the steering and brake line,
but the steering valve is closed, so the pres-
sure at port (CF) rises.
The oil in chamber (A) from the pump passes
through orifice (a) in spool (1), enters cham-
ber (B), and pushes spool (1) to the left.
The steering valve is closed, so the oil at port
(CF) flows to the brake accumulator line and
charges the brake accumulator. The accumu-
lator charge pressure passes through the LS
and PLS lines and is transmitted to the servo
valve of the pump. The pump then supplies
the necessary oil flow and pressure. The
accumulator charge oil flow is controlled by
orifice (e). When the accumulator pressure
rises and the charging is completed, the gov-
ernor valve is opened.
The oil from orifice (b) flows in chamber (C)
and is drained through orifice c and steering
valve. The flow rate in the LS circuit is about
1 l/min.
When this flow from port (CF) passes through
orifices (e) and (b), a difference in pressure of
approx. 0.98 MPa {10 kg/cm2} is formed on
both sides of the orifices. The pressure in
chamber (B) = pressure in chamber (C) + 0.98
MPa {10 kg/cm2}, so spool (1) is pushed to the
left and tries to close portion (d).
If the area of the opening at portion (d)
becomes smaller, the oil flow in the drain cir-
cuit passing through orifice (b) becomes
smaller, so the differential pressure on both
sides of orifice (b) becomes smaller. Spool (1)
is pushed to the right by spring (2), and the
opening at portion (d) again opens. When the
oil flow becomes larger, the spool again
moves to the left. This is repeated until a bal-
ance is reached.
The forces acting on chamber (B) and cham-
ber (C) are as follows:
• Force in left direction (converted to hydrau-
lic force): PB (= 1.57 MPa {16 kg/cm2})
• Force in right direction: PC + 0.98 MPa
{10 kg/cm2} (= 1.57 MPa {16 kg/cm2})
(0.98 MPa {10 kg/cm2} is the hydraulic
force converted for spring (2))
10-68 GD555, 655, 675-3A

(7)
3. Steering operated (accumulator not

charged, main control valve at neutral)
When the steering wheel is turned, port (CF)
and the steering cylinder are connected.
When this happens, the pressure in chamber
(C) becomes higher, and spool (1) is pushed
to the right by spring (2). The area of the
opening of portion (d) becomes larger, so the
oil from the pump passes through port (CF)
when the steering wheel is being turned, and
the necessary oil flow goes from the steering
valve to the steering cylinder.
If the steering wheel is turned quickly, and the
area of the variable throttle in the steering
valve becomes larger, the difference in pres-
sure on both sides of the variable throttle
inside the steering valve becomes smaller,
and the pressure in the LS circuit rises. (The
pressure in chamber (B) drops.)
At the same time, the oil pressure in chamber
(C) also rises, so spool (1) is moved further to
the right, and the area of the opening of por-
tion (d) also becomes larger. This sends a
large oil flow to the steering cylinder.
On the other hand, if the steering wheel is
turned slowly, the throttle of the variable ori-
fice becomes smaller, so the differential pres-
sure on both sides of the variable throttle
inside the steering valve becomes larger. The
pressure in chamber (B) then becomes larger
than the pressure in chamber (C), so spool (1)
is pushed to the left, and the area of the open-
ing of portion (d) becomes smaller to match
the flow of oil needed for the steering valve. It
becomes balanced in this position.
In other words, spool (1) moves in accor-
dance with the flow of oil needed for port (CF)
to maintain the differential pressure between
chamber (C) and chamber (B) at 0.98 MPa {10
kg/cm2}, and adjusts the opening of portion
(d). (In this way, all the oil not needed for the
steering can be sent to port (EF).)
When the oil from port (CF) enters the steer-
ing cylinder and load is applied, the pressure
in the circuit rises. This signal becomes PLS
and is fed back to the pump servo valve. The
angle of the swash plate in the pump is
changed to increase the discharge amount,
and to increase the pressure in the circuit. In
this way, the PLS circuit acts to detect the
hydraulic load on the steering and feeds back
this information to the pump.
GD555, 655, 675-3A 10-69

(7)
4. Steering cylinder at end of stroke

When the steering cylinder reaches the end of
its stroke, and the operator continues to turn
the steering wheel, the flow of oil to the cylin-
der is stopped regardless of the opening of
the steering valve.
There is no flow of oil, so the CF and LS pres-
sure rise together with the pressure at pump
port (P), and at the same time, pressure
chamber (B) and chamber (C) also rise, and
spool (1) is moved to the right.
If pressure chamber (C) goes above 15.21
MPa {155 kg/cm2}, steering relief valve opens
and drains the oil in chamber (C). Because of
this flow of oil, a difference in pressure on
both sides of orifices (b) and (e) is created,
and pressure chamber (C) becomes lower
than pressure chamber (B).
As a result, spool (1) moves to the left to a
position where the oil flow inside the spool is
1 l/min. Spool (1) stabilizes at a position
where portion (d) of the spool is throttled, and
this prevents the large loss of oil if the circuit
is relieved.
If spool (1) moves too far to the left, portion
(d) is closed and the oil stops flowing. The
flow of oil through orifice (b) stops, so pres-
sure chamber (C) and pressure chamber (B)
become the same, and spool (1) is moved
again to the right by spring (2) to open por-
tion (d).
Because of this repeated action, the pressure
in the steering circuit is maintained at a maxi-
mum of 15.21 MPa {155 kg/cm2}.
5. Steering valve at neutral, work equip-
ment control lever operated
If the work equipment control lever is oper-
ated, pressure PA changes to 1.96 – 24.5 MPa
{20 – 250 kg/cm 2}. However, the steering valve
is at neutral, so the condition is the same as
in Section 2. "When engine is started (steer-
ing and main control valves at neutral)", and
the force acting on spool (1) is constant
regardless of pressure PA.
If pressure PA rises, the pressure at port (CF)
also rises momentarily, and the amount of oil
flowing through orifice (b) increases. A large
difference in pressure is created, so spool (1)
is pushed to the left, and the area of the open-
ing of portion (d) becomes smaller. The oil
flow is automatically adjusted so that only 1 l/
min. flows.
10-70 GD555, 655, 675-3A

(7)
6. Steering, work equipment operated

simultaneously
1) When the load on steering circuit is
higher than the load on the work equip-
ment circuit, the actuation condition is the
same as in Section 3, "Steering operated
(main control valve at neutral)".
Port (CF) is at the same pressure as cham-
ber (A), and port (EF) is throttled by por-
tion (I) until it balances at the same
pressure as the pressure needed for the
work equipment. In other words, the oil
pressure in the main circuit for the pump
is sent to the steering circuit.
2) When the load on the steering circuit is

less than the load on the work equipment
circuit, circuit (CF) satisfies the demand of
the amount of oil and oil pressure for the
steering, but compared with port (CF),
when the pressure at port (EF) is higher,
the flow of oil passing through portion (d)
increases and the pressure in chamber (B)
rises.
As a result, spool (1) moves to the left,
and the area of the opening at portion (d)
becomes smaller. It balances so that the
pressure and oil flow matches the needs
of port (CF). In other words, the pressure
and oil flow needed for the steering circuit
is supplied to the steering circuit by prior-
ity regardless of the pressure in the work
equipment circuit.
GD555, 655, 675-3A 10-71

(7)
7. When brake accumulator is being

charged
When the brake is operated, the pressure
inside the brake accumulator goes down. If
the pressure goes down to 9.42 MPa {96 kg/
cm2}, the brake accumulator pressure gover-
nor valve closes, the flow of oil from orifice
(c) to the steering valve stops, and the LS
pressure rises. After this, the procedure is the
same as when the engine is started, and the
charging of oil pressure to the brake accumu-
lator is completed.
8. Steering and brake accumulator charg-

ing actuated at same time
1) If the load in the steering circuit is higher
than the load in the brake accumulator
charge circuit, the load in the steering cir-
cuit for normal travel becomes lower than
5.89 MPa {60 kg/cm2}. Operating the steer-
ing when the machine is stationary may
create such a situation, but after a few
seconds, the accumulator charging will be
completed, so in reality there is almost no
effect.
2) When load in brake charge circuit is
higher than load in steering circuit
This pattern is normal when both circuits
are operated at the same time. The steer-
ing valve discharges an amount of oil to
match the operating angle of the steering,
so when an oil flow matching the operat-
ing angle of the steering is sent to the
steering cylinder. The steering valve then
automatically closes and this gives an
operating feeling that is the same as with
normal operations.
10-72 GD555, 655, 675-3A

(7)
ACCUMULATOR PRESSURE
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD GOVERNOR VALVE
ACCUMULATOR PRESSURE GOVERNOR VALVE
1. Pressure governor valve EF1: To left main control valve

2. Solenoid (For releasing LS pressure) EF2: To right main control valve
3. Accumulator shuttle valve A1: To brake control
4. Fitting face of priority valve A2: To brake control
LSS: From steering valve
LSP1:From parking and bank control valve
LSP2:From LS pressure reducing valve
T: To hydraulic tank
EF: From priority valve

CF1: From priority valve
LS1: From priority valve
LS2: From priority valve
T: From priority valve
10-74 GD555, 655, 675-3A

(7)
ACCUMULATOR PRESSURE
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD GOVERNOR VALVE
Outline
• The accumulator pressure governor valve is
connected to the priority valve and used as a
path for the oil from the priority valve to the
main control valve and control the oil flow to
the brake circuit.
• The oil flowing in the brake circuit is distrib-

uted by the accumulator shuttle valve to the
front and rear brake circuits to heighten the
pressure in the brake accumulator. The accu-
mulator charge pressure is transmitted by the
pressure governor valve to the servo valve of
the hydraulic pump. If it lowers to 9.36 MPa
{95.4 kg/cm2}, it is raised. If it is raised to 13.38
MPa {14.1 kg/cm2}, it is stopped rising.
• The LS pressure relief valve is installed to

improve the startability of the engine (particu-
larly in the cold season). While the starting
motor is running, the solenoid operates to
drain the oil sent by the hydraulic pump to
the servo valve to reduce the load on the
pump.
GD555, 655, 675-3A 10-75

(7)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FRONT AXLE
FRONT AXLE
1. Tie rod Specifications:

2. Steering cylinder Toe-in: -5 – 0 mm
3. Support axle Camber: 0°
4. Leaning rod
5. Leaning cylinder
6. Bracket
7. Hub shaft
10-76 GD555, 655, 675-3A

(6)
Unit: mm

Size Tolerance Clearance Limit
8 Clearance between center pin and Shaft Hole
bushing 0.130 to
55 -0.030 +0.174 3.0
0.250
-0.076 +0.100
-0.025 +0.142 0.105 to
GD555 40 -0.064 +0.080 0.206 2.0
Clearance between king
9 pin and bushing Replace
GD655 -0.025 +0.164 0.145 to bushing
GD675 45 -0.064 +0.120 0.228 2.0
-0.025 +0.161 0.143 to

GD555 40 -0.064 +0.118 0.225 0.6
Clearance between axle
10 end pin and bushing GD655 -0.025 +0.164 0.145 to
GD675 45 -0.064 +0.120 0.228 2.0
Clearance between ball joint and -0.060 +0.020 0.060 to

11 bushing 55 -0.090 0 0.110 1.0
GD555 Start to rotate: 147 to 196 Nm {15 to 20 kgm}

12 Preload of hub bearing GD655 Adjust
GD675 Start to rotate: 78.5 to 117.7 Nm {8 to 12 kgm}
GD555, 655, 675-3A 10-77

FUNCTION OF FRONT AXLE

1. Lessening blade angling and up-and-
down movement
• The front axle is fixed in the center with a
center pin to the frame so that it can oscil-
late 16 degrees. This, like the tandem sys-
tem, restricts the up-and-down
movement of the blade to a minimum
41F017
when one front wheel rides over an object
S_G00944
or falls into a hole. When the front wheel
rides over an object (height-H), the center
point of the front axle rises H/2, as shown
in drawing. Because of possible rocking of
front axle blade movement rises only H/4
while holding its horizontal posture.
Unless the whole oscillating range (left,
right 16°) of the front axle is used, the
blade moves up-and-down holding its
horizontal posture.
2. Prevention of side slipping of front

wheels (leaning system)
• The front wheels can be tilted to the left or
right. This is called the leaning system,
and is to prevent the front wheel from
slipping sidewards and to reduce the
turning radius. 41F018
S_G00945
Operations with blade at propulsion angle
are frequent among grader operations. In
proportion to the propulsion angle a side
slipping force acts on the blade to cause
side slipping.
• Also, the distribution of weight on the

front and rear wheels is about 3:7, and
when the blade cuts into the ground, the
load on the front wheels decreases and it
is easier for the front wheels to slip
sideward.
To counteract this side slipping, the front 41F019
wheels are leaned to make them more S_G00946
resistant, and this changes the center of
the load on the front axle and the center
of gravity of the machine and prevents
side slipping.
10-78 GD555, 655, 675-3A

• When the wheel is leaned that angle between

the center line of the leaned tire and the per-
pendicular line is called the "Leaning angle".
Leaning angle is the distance S=2 x π x r cov-
ered by the tire as it advances, and the side
41F020
with the greater load radius, in order to
S_G00947
advance more than the side with the less load
radius, advances in the direction of the lean-
ing.
Using this characteristic, the turning radius
can be lessened when the leaning operation
is carried out.
• When backing, leaning should be reversed to

the leaning for forward operation by turning a
steering wheel in the same direction.
Leaning angle is 16°
GD555, 655, 675-3A 10-79

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE HYDRAULIC PIPING
BRAKE HYDRAULIC PIPING
S_G00948
23B-43-42600
1. Wheel brake (front) 5. Stop lamp switch

2. Wheel brake (rear) 6. Brake valve
3. Accumulator (front) 7. Accumulator pressure governor valve
4. Accumulator (rear) 8. Priority valve
10-80 GD555, 655, 675-3A

(7)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE HYDRAULIC PIPING
S_G00949
23B-43-42600
9. Slack adjuster (front)

10. Slack adjuster (rear)
GD555, 655, 675-3A 10-81

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
1. Piston A: To rear slack adjuster

2. Spool B: To front slack adjuster
3. Spool PA: To accumulator
PB: To accumulator
T: To hydraulic tank
10-82 GD555, 655, 675-3A

Unit: mm
Standard Clearance
Std. Tolerance Clearance Limit
Clearance between Size
4 pedal mounting hole Shaft Hole
and bracket hole 0.175 to
-0.025 +0.013 0.25
— 0.025
-0.075 0
Clearance between -0.025 +0.013 0.175 to
5 — 0.25
roller and pin -0.075 0 0.025
Size Tolerance Repair Limit
Outside diameter of
6 0
roller 30 29.2
-0.5
Free Length
7 Control spring Length Height Load Load
80 N
54.5 49.7 33.4 —
{8.1kg}
8 Control spring 29.1 — — 28.7 —
60.8 N
9 Return spring 86.2 58 78 —
{6.2 kg}
17.7 N
10 Spring 17 16.5 16.2 —
{1.8 kg}
16.7 N
11 Return spring 31.5 19.5 28 —
{1.7 kg}
GD555, 655, 675-3A 10-83

(6)
Operation
1. Depressing the brake pedal.

Depressing the brake pedal causes the piston
(1) and spring (2) to make the spools (3, 4)
move down. The port a (port b) close and oil
now flows from port PA to port A and port PB
and port B. Oil then flows from port A (port B)
to the rear (front) slack adjuster and actuate
the brakes. When this happens, the slack
adjuster makes the flow of oil to the left and
right brakes the same to ensure the same
braking effect on both the left and right sides.
2. When the operation is in balance at the

rear (front) brake.
When the brake cylinder fills with oil and the
pressure between port PA (port PB) and port
A (port B) increase, the oil entering port e
(port f) from orifice c (orifice d) of spool (3)
(spool 4) up against the spring (2), and port
PA (port PB) and port A (port B) are shut off.
When this situation happens, drain port a
remains closed. Thus, the oil entering the rear
(front) slack adjuster is held and the brake
remains actuated.
10-84 GD555, 655, 675-3A

3. Releasing the brake.

Removing the force from the pedal removes
the force at the piston (1). This action causes
back pressure from the brake cylinder and the
force of the spool return spring to move the
spools (3, 4) up. Drain port a (port b) now
opens. The oil from the slack adjuster flows to
the hydraulic tank return circuit and the brake
released.
GD555, 655, 675-3A 10-85

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
1. Bleeder Specifications:
2. Check valve Piston actuation pressure:
3. Piston 0.01 ± 0.01 MPa {0.1 ± 0.1 kg/cm2}
A. Inlet port Check valve cracking pressure:

B. Outlet port
0.93 ± 0.05 MPa {9.5 ± 0.5 kg/cm2}
Check valve closing pressure:

Function
0.6 ± 0.05 MPa {6.0 ± 0.5 kg/cm2}
• The slack adjuster is installed in the brake oil
line from the brake valve to the brake piston.
The slack adjuster provides a fixed time lag
when applying the brakes.
• It also fixes the quantity of oil fed by each
application of the brake to prevent generation
of peak pressure.
Unit: mm

Tolerance
Clearance between body
4 Shaft Hole
and piston 0.030 to
— -0.030 +0.074 0.25
0.150
-0.076 0
Free Length
5 Slack adjuster spring Length Height Load Load
43.2 N
198 38 — —
{4.4 kg}
66.7 N
6 Spring 38.8 33 — —
{6.8 kg}
10-86 GD555, 655, 675-3A

(6)
Operation
1. Brake pedal depressed.
• Before the brake pedal is depressed, piston

(4) is returned by stroke S (full stroke). If the
brake pedal is depressed, the oil discharged
from the brake valve flows through port P of
the slack adjuster into right and left cylinders
(2) and moves pistons (4) to the right and left
by stroke S.
• As a result, brake piston (7) moves by stroke

S. At this time, the clearance between the
brake piston and disc is reduced to zero (0)
but no braking force is generated.
• If the brake pedal is depressed further and the

oil discharged from the brake valve exceeds
the set oil pressure, check valve (3) opens and
pressure is applied as braking force to port C.
Accordingly, the time lag made when the
brake is applied is kept constant.
GD555, 655, 675-3A 10-87

(6)
2. Brake pedal released.
• If the brake pedal is released, return spring (8)

of the brake returns piston (4) by the distance
equivalent to the oil in stroke S and the brake
is released.
In other words, return stroke T of brake piston
(7) is decided by the quantity of the oil in
stroke S of the slack adjuster and the time lag
of the brake is kept constant, regardless of the
wear of the brake disc.
10-88 GD555, 655, 675-3A

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR
ACCUMULATOR
1. Valve assembly Specifications:

2. Top cover Gas used: Nitrogen gas
3. Cylinder Gas capacity: 3000 cc
4. Piston Charging pressure (at 20° ± 5 °C):
3.4 ± 0.1 MPa {35 ± 1.0 kg/cm2}
Function
The accumulator is installed between the pres-
sure governor valve and brake valve. Cylinder (3)
is charged with nitrogen gas. Even after the
engine stops, braking force is kept by the pres-
sure of the nitrogen gas compressed by free pis-
ton (4). The compressibility of the nitrogen gas
absorbs the pulsating pressure from the hydrau-
lic pump.
GD555, 655, 675-3A 10-89

(7)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WHEEL BRAKE
WHEEL BRAKE
1. Guide pin
2. Brake piston
Unit: mm
Size Repair Limit

3 Disc thickness 3.8 ± 0.1 3.3 ± 0.1
4 Plate thickness 2.3 ± 0.08 —
5 Total thickness of disc and plate 26.7 ± 0.8 24.7 ±0.8
Replace
Standard Size Repair Limit
Free Length Installed Installed Load Installed Load

Length
6 Return spring 76.5 60.5 75.0 654 N

{66.7 kg}
10-90 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
1. Piston Outline
2. Adjustment bolt • The parking brake is a disc type, and is
3. Caliper installed to the final drive.
4. Disc • The parking brake is applied mechanically by
the force of the spring inside the caliper, and
is released by hydraulic force.
• The parking brake caliper is secured to the
final drive case. The disc is installed to the
final drive coupling and rotates together with
the coupling.
Unit: mm
5 Disc thickness 10.4 9.4

Replace
9.5
6 Pad thickness (Remaining thickness
12.5 when pad groove has
disappeared)
GD555, 655, 675-3A 10-91

PARKING BRAKE AND BANK
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
PARKING BRAKE AND BANK CONTROL VALVE
S_G00950
23B-61-42100
1. Solenoid valve for bank control Outline

2. Solenoid valve for parking brake The parking brake control valve has the solenoid
AP : From accumulator valves for parking brake and bank control.
B1 : To bank control cylinder If the solenoid for the parking brake is turned on,
B2 : To bank control cylinder hydraulic oil is supplied to the parking brake to
QC : To parking brake release the parking brake.
ST : (Plugged) If the solenoid for the bank control is turned on,
BR : (Plugged) hydraulic oil is supplied to the bank control cylin-
T1 : (Plugged) der to move the lock pin in the pulling out direc-
T2 : To hydraulic tank tion.
T3 : To accumulator pressure governor valve
T4 : (Plugged)
10-92 GD555, 655, 675-3A

(7)
WORK EQUIPMENT HYDRAULIC
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PIPING DRAWING
WORK EQUIPMENT HYDRAULIC PIPING DRAWING

MAIN PIPING (1/2)
S_G00951
23B-60-42200
1. Main control valve (left) 5. LS pressure reducing valve

2. Main control valve (right) 6. Priority valve
3. Hydraulic tank 7. Accumulator pressure governor valve
4. Hydraulic pump
10-94 GD555, 655, 675-3A

(7)
MAIN PIPING (2/2)
S_G00952
23B-60-4220
GD555, 655, 675-3A 10-95

HIGH PRESSURE PIPING (1/3)
10-96 GD555, 655, 675-3A

1. Pilot check valve - drawbar shift

2. Pilot check valve - leaning
3. Pilot check valve - articulate
4. Pilot check valve - right blade lift
5. Main control valve - right
6. Articulate cylinder
7. Main control valve
8. Pilot check valve - left blade lift
9. Pilot check valve - blade tip
10. Blade lift cylinder
GD555, 655, 675-3A 10-97

(3)
1. Swivel joint
2. Drawbar side-shift cylinder
3. Blade tilt cylinder
10-98 GD555, 655, 675-3A

LIFTER LOCK PIPING
SWG00992
1. Parking and bank control valve Function

2. Bank pin The lifter bracket (3) is fixed by the bank pin (2).
3. Lifter bracket When setting in the bank cutting position, oper-
ate control lever. This uses hydraulic oil to push
piston. The pin can be removed and the bracket
can be rotated.
GD555, 655, 675-3A 10-99

BANK PIN
SWG00993
1. Pin 4. Shaft
2. Piston 5. Case
3. Cover 6. Bushing
10-100 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
TYPE: LPV90
PA : Pump discharge The main pump consists of one unit formed

PA1 : Pump pressure detection port by the pump, servo piston, PC valve, and LS
PA2 : LS pump pressure port valve.
PA3 : Drain port The explanation in STRUCTURE, FUNCTION
PDA : Pump air bleed AND MAINTENANCE STANDARD is divided
PD1 : Pump drain into two parts: the pump and the PC valve +
PD2 : Pump drain LS valve.
PEN : Control pressure detection port
PLS : LS pressure input
PS : Pump suction
10-102 GD555, 655, 675-3A

(3)
1. Shaft 6. Piston
2. Cradle 7. Cylinder block
3. Case 8. Valve plate
4. Rocker cam 9. Spring
5. Shoe 10.Servo piston
GD555, 655, 675-3A 10-103

(3)
PUMP
Function
• The engine rotation and torque transmitted to
the pump shaft is converted into hydraulic
energy, and pressurized oil is discharged
according to the load.
• It is possible to change the discharge amount
by changing the swash plate angle.
Structure
• Cylinder block (7) is supported to shaft (1) by • Piston (6) carries out relative movement in
spline a, and shaft (1) is supported by the the axial direction inside each cylinder cham-
front and rear bearings. ber of cylinder block (7).
• The tip of piston (6) is a concave ball, and • Cylinder block (7) seals the pressure oil to
shoe (5) is caulked to it to form one unit. Pis- valve plate (8) and carries out relative rota-
ton (6) and shoe (5) form a spherical bearing. tion. This surface is designed so that the oil
• Rocker cam (4) has flat surface A, and shoe pressure balance is maintained at a suitable
(5) is always pressed against this surface level.
while sliding in a circular movement. Rocker The oil inside each cylinder chamber of cylin-
cam (4) brings high pressure oil at cylindrical der block (7) is sucked in and discharged
surface B with cradle (2), which is secured to through valve plate (8).
the case and forms a static pressure bearing
when it slides.
10-104 GD555, 655, 675-3A

Operation
1. Operation of pump
i. Cylinder block (7) rotates together with
shaft (1), and shoe (5) slides on flat sur-
face A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle
between center line X of rocker cam (4)
and the axial direction of cylinder block
(7) changes. (Angle is called the swash
plate angle.)
ii. Center line X of rocker cam (4) maintains

swash plate angle in relation to the axial
direction of cylinder block (7), and flat sur-
face A moves as a cam in relation to shoe
(5).
In this way, piston (6) slides on the inside
of cylinder block (7), so a difference
between volumes E and F is created
inside cylinder block (7). The suction and
discharge is carried out by this difference
F - E.
In other words, when cylinder block (7)
rotates and the volume of chamber E
becomes smaller, the oil is discharged
during that stroke.
At the same time the volume of chamber
F becomes larger, and as the volume
becomes bigger, the oil is sucked in.
(The diagram shows chamber F at the end
of the suction process and chamber E at
the end of the discharge process.)
iii. If center line X of rocker cam (4) is in line
with the axial direction of cylinder block
(7) (swash plate angle = 0), the difference
between volumes E and F inside cylinder
block (7) becomes 0, so the pump does
not carry out any suction or discharge of
oil. (In actual fact, the swash plate angle
never becomes 0.)
iv. In other words, there is a proportional
relationship between swash plate angle
and the pump discharge amount.
GD555, 655, 675-3A 10-105

(3)
2. Control of discharge amount

• If the swash plate angle becomes larger, the
difference between volumes E and F
becomes larger and discharge amount Q
increases. Swash plate angle is changed by
servo piston (1).
• Servo piston (1) moves in reciprocating direc-
tions according to the signal pressure from
the PC and LS valves. This straight move-
ment is transmitted to rocker cam (4). Rocker
cam (4) supported on the cylindrical surface
of cradle (2) slides in rotational directions.
• Servo piston (1) has different pressure receiv-
ing areas on its top and bottom. Main pump
discharge pressure (self pressure) PA is con-
stantly led in the pressure chamber on the
small-diameter piston side (upper side).
• LS valve output pressure PEN is led in the
pressure chamber on the large-diameter pis-
ton side (lower side).
• The movement of servo piston (1) is con-
trolled by the difference between pressure PA
on the small-diameter piston side and pres-
sure PEN on the large-diameter piston side
and the ratio of the pressure receiving area of
the small-diameter piston to that of the large-
diameter piston.
10-106 GD555, 655, 675-3A

(3)
PC VALVE, LS VALVE, SERVO PISTON
PA: Pump discharge pressure PC valve LS valve

PA2: LS pump pressure inlet 4. Piston 11.Plug
PA3: Drain 5. Spring 12.Sleeve
PLS: LS pressure inlet 6. Seat 13.Spring
7. Spring 14.Spool
Servo piston 8. Spool
1. Servo piston 9. Sleeve
2. Lever 10.Plug
3. Spring
10-108 GD555, 655, 675-3A

(3)
LS VALVE
Function
• The LS valve controls the pump discharge
amount according to the amount of move-
ment of the control lever, that is the oil flow
demanded by the actuator.
• The LS valve detects the oil flow demanded
by the actuator from the differential pressure
∆PLS between inlet pressure PA2 of the con-
trol valve and control valve outlet pressure
PLS and controls main pump discharge
amount Q. (PA2 is called the LS pump pres-
sure, PLS is called the LS pressure, and ∆PLS
is called the LS differential pressure.)
• In other words, the pressure loss (= LS differ-
ential pressure ∆PLS) generated by the oil
flowing from the pump through the open area
of the control valve spool is detected. Pump
discharge amount Q is so controlled that this
pressure loss will remain constant to supply
oil from the pump according to the demand
of the actuator.
• Main pump discharge pressure PA, LS pump
pressure PA2, and LS pressure PLS are led in
the LS valve. The relationship between LS
differential pressure ∆PLS and pump dis-
charge amount Q changes as shown in the
figure on the right.
GD555, 655, 675-3A 10-109

(3)
Operation
1. When control valve is at HOLD position
10-110 GD555, 655, 675-3A

(7)
• LS pressure PLS from the control valve outlet

is led in spring chamber a of the LS valve. LS
pump pressure PA2 at the control valve inlet
is lead in chamber b at the sleeve end on the
opposite side.
• The position of spool (14) is determined by
the resultant of "LS pressure PLS and force of
spring (13)" and the level of pump pressure
PA2.
• Before the engine is started, servo piston (1)
is pushed down (toward the maximum swash
plate angle side) by spring (3).
• After the engine is started, if all the control
valves are in neutral, no oil flows to the outlet
side of the control valves and LS pressure
PLS is 0 MPa {0 kg/cm2}. (Spring chamber a
is connected through the control valve spool
to the drain circuit.) At this time, LS pump
pressure PA2 is kept at the unload pressure
of about 2.8 MPa {29 kg/cm2}.
• Accordingly, spool (14) is pushed to the right
and ports c and d are connected and pump
pressure PA is led through port d into cham-
ber X on the large diameter side of servo pis-
ton (1).
• Pump pressure PA is constantly led in cham-
ber Y on the small diameter side of servo pis-
ton (1). Since the force applied to the large
diameter side is larger because of the area
difference between both ends of servo piston
(1), servo piston (1) moves toward the mini-
mum swash plate angle side (upper side).
GD555, 655, 675-3A 10-111

(3)
2. When opening area of control valve is maximum (lever operated fully)
10-112 GD555, 655, 675-3A

(7)
• If the control lever is moved to the stroke end

and the open area of the control valve is
increased, LS differential pressure ∆PLS
between LS pump pressure PA2 and LS pres-
sure PLS is reduced.
• LS pressure PLS led in spring chamber a of
the LS valve becomes near LS pump pressure
PA2 and spool (14) is pushed to the left by
the resultant of "LS pressure PLS and force of
spring (13)". As a result, port c is closed and
ports d and e are connected.
• Accordingly, the oil applied to chamber X on
the large diameter side of servo piston (1)
flows through ports d and e to port f of the PC
valve.
• Since the oil in port f of the PC valve is
drained through the piston into the pump
case at this time, the drain pressure is also
applied to chamber X on the large diameter
side of servo piston (1).
• Consequently, servo piston (1) is moved
toward the maximum swash plate angle side
(lower side) by pump pressure PA applied to
chamber Y on the small diameter side.
GD555, 655, 675-3A 10-113

(3)
3. When opening area of control valve is small (small movement of lever)
10-114 GD555, 655, 675-3A

(7)
• When the control lever is operated finely or

set in the HOLD position and the open area of
the control valve is reduced, LS differential
pressure ∆PLS between LS pump pressure
PA2 and LS pressure PLS is increased.
• At this time, the mechanism operates as
described in "1. When control valve is at
HOLD position". LS pump pressure PA2
pushes spool (14) to the right and servo pis-
ton (1) moves toward the minimum swash
plate angle side (upper side).
• In other words, on the basis of the LS set dif-
ferential pressure of 2.35 MPa {24 kg/cm2} for
the LS valve and in the range from the HOLD
position of the control valve to the minimum
open area of the control valve (in the fine con-
trol operation), when LS differential pressure
∆PLS is higher than 2.35 MPa {24 kg/cm2}, the
swash plate angle reduces. When the open
area of the control valve increases and LS dif-
ferential pressure ∆PLS lowers below 2.35
MPa {24 kg/cm2}, the swash plate angle
increases.
GD555, 655, 675-3A 10-115

(3)
4. When pump flow is amount demanded by control valve
10-116 GD555, 655, 675-3A

(7)
PC VALVE
• Let the pressure receiving area on the large
diameter side of servo piston (1) be A1, the Function
pressure receiving area on the small diameter • When discharge pressure PA rises and the
side be A2, the pressure applied on the large open area of the control valve is wide, the LS
diameter side be PEN, and the pressure valve increases pump discharge amount Q.
applied on the small diameter side be PA. At this time, the PC valve controls discharge
• When the oil flow from the pump reaches the amount Q so that it will not exceed a certain
flow rate demanded by the control valve, LS level according to discharge pressure PA.
pump pressure PA2 applied to port b of the That is, the PC valve performs approximate
LS valve is balanced with the resultant of "LS equal horsepower control so that the pump
pressure PLS and the force of spring (13)" absorption horsepower will not exceed the
applied to spring chamber a and spool (14) is engine horsepower.
stopped at an almost intermediate point.
• In other words, when the load increases and
• As a result, ports c, d, and e are opened pump discharge pressure PA rises during
almost equally. Then, some of the pump oil work, pump discharge amount Q is reduced.
from port c flows in port d and the other is When pump discharge pressure PA lowers,
drained through port e into the tank case. pump discharge amount is increased.
Accordingly, the pressure of this oil is
• The relationship between pump discharge
reduced to about 1/2 and applied to chamber
pressure PA and pump discharge amount Q
X on the large diameter side of servo piston
is shown below.
(1).
• At this time, since the relationship of the pres-
sure receiving areas of servo piston (1) is as
A2 : A1 = 1 : 2, the ratio of pressure PA to
pressure PEN applied to both ends of servo
piston (1) is 2 : 1. Accordingly, the same force
is applied to both ends of servo piston (1),
and then servo piston (1) is stopped at the
current position and the oil flow demanded
by the control valve is balanced with the
pump discharge.
• The spring force is so adjusted that PA2 –
PLS will be ∆PLS and will approximately
equal 2.35 MPa {24 kg/cm2} to determine the
balancing point of spool (14).
• In other words, when the open area of the
control valve is 1/2, the swash plate angle is
also 1/2, and when the open area of the con-
trol valve is 1/4, the swash plate angle is also
1/4. The pump discharge is changed accord-
ing to the open area of the control valve by
keeping LS differential pressure ∆PLS at 2.35
MPa {24 kg/cm2}.
• For example, if the spool is balanced at 1/4 of
the open area of the control valve and then
the open area of the control valve is increased
to 3/4, LS differential pressure ∆PLS lowers
temporarily. Accordingly, the LS valve oper-
ates to increase the pump discharge. After
the swash plate angle increases to 3/4, how-
ever, LS differential pressure ∆PLS rises to
2.35 MPa {24 kg/cm2} and the spool is bal-
anced at this point.
GD555, 655, 675-3A 10-117

(3)
Operation
1. When actuator load is large (pump discharge pressure PA is high)
10-118 GD555, 655, 675-3A

(7)
• When the load on the actuator increases and

pump discharge pressure PA rises, spool (8)
is pushed to the left because of the relation-
ship between the sectional areas of parts S1
and S2 of the spool (S1 > S2).
• As a result, ports f and g are connected and
pump discharge pressure PA flows through
port g to port f and port f is disconnected
from the drain circuit.
• If the LS valve increases the pump discharge
amount, spool (14) of the LS valve moves to
the left and ports d and e are connected.
• As a result, pump discharge pressure PA
from port f of the PC valve flows through port
e of the LS valve to port d, and then flows in
chamber X on the large diameter side of
servo piston (1) to stop servo piston (1).
• If pump discharge pressure PA rises further,
spool (8) moves to the left and servo piston
(1) is moved by the pressure in chamber X on
the large diameter side toward minimum
swash plate angle side (upper side).
• If servo piston (1) moves up, piston (4) is
moved through lever (2) to the right. Accord-
ingly, springs (5) and (7) are compressed and
they push back spool (8) to the right.
• If spool (8) is pushed back to the right and
ports f and g are disconnected, servo piston
(1) stops moving up.
• At this time, servo piston (1) stops higher
(nearer to the minimum swash plate angle)
than when the pump discharge pressure is
low.
GD555, 655, 675-3A 10-119

(3)
2. When actuator load becomes smaller (pump discharge pressure PA drops)
10-120 GD555, 655, 675-3A

(7)
• When the load on the actuator is reduced and

pump discharge pressure PA lowers, spool
(8) is pushed back to the right by the forces of
springs (5) and (7).
• As a result, ports g and f are disconnected
and port f is connected to the drain circuit.
• At this time, if the LS valve increases the
pump discharge amount, the PC valve does
not limit the oil flow. Accordingly, as
explained in the section of the LS valve, the
oil in chamber X on the large diameter side of
servo piston (1) flows through ports d and e
of the LS valve and port f of the PC valve to
the drain circuit.
• As a result, servo piston (1) is moved by the
pressure in chamber Y on the small diameter
side toward the maximum swash plate angle
side (lower side).
GD555, 655, 675-3A 10-121

(3)
3. Action of spring
10-122 GD555, 655, 675-3A

(7)
• The forces of springs (5) and (7) of the PC

valve vary with the swash plate angle of the
pump.
• If servo piston (1) moves, lever (2) moves and
piston (4) moves to the right or left according
to the turning direction of lever (2).
• If piston (4) moves to the right, springs (5)
and (7) are compressed first. If piston (4)
moves to the right further, spring (5) touches
seat (6) and only spring (7) works as a spring.
That is, the forces of springs (5) and (7)
change as piston (4) compresses or releases
those springs.
• The pump absorption torque curve showing
the relationship between pump discharge
pressure PA and discharge amount Q is bro-
ken as shown in the following figure, since
the spring constants of springs (5) and (7) are
different.
• In other words, if pump discharge pressure
PA rises, pump discharge amount Q is
reduced, and if pump discharge pressure PA
lowers, pump discharge amount Q is
increased.
GD555, 655, 675-3A 10-123

(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE

LEFT 4-SPOOL VALVE (1/3)
P : Pump port (from main pump) A2 : To blade shift cylinder bottom

PP : PP port (to main pump) B2 : To blade shift cylinder head
LS : LS port (to main pump) A3 : To circle motor
T : Tank port (to tank) B3 : To circle motor
TS : Seal drain port (to tank) A4 : To blade tilt cylinder bottom
A1 : To left blade lift cylinder bottom B4 : To blade tilt cylinder head
B1 : To left blade lift cylinder head
10-124 GD555, 655, 675-3A

GD555, 655, 675-3A 10-125

1. Spool (blade tilt) 9. Pressure compensation valve R (blade tilt)

2. Spool (circle) 10. Pressure compensation valve R (circle)
3. Spool (blade shift) 11. Pressure compensation valve R (blade shift)
4. Spool (Left blade lift) 12. Pressure compensation valve R (left blade lift)
5. Pressure compensation valve F (left blade lift) 13. LS bypass plug
6. Pressure compensation valve F (blade shift) 14. Unload valve
7. Pressure compensation valve F (circle) 15. Safety-suction valve
8. Pressure compensation valve F (blade tilt)
Unit: mm
Free Length x Installed Installed Free Installed

OD Length Load Length Load
34.8 N 27.9 N
16 Spool return spring 56.27 x 20.1 25.4 —
{3.55 kg} {2.84 kg}
Replace
Spool return spring (cir- 34.8 N 27.9 N
17 87.7 x 19.7 25.4 — spring if
cle) {3.55 kg} {2.84 kg}
damaged or
Pressure compensation 6.9 N 5.52 N deformed
18 23 x 8.4 15 —
valve spring (R) {0.7 kg} {0.56 kg}
Pressure compensation 7.45 N 5.98 N

19 15.4 x 6 8 —
valve spring (F) {0.76 kg} {0.61 kg}
137 N 110 N
20 Unload valve spring 35.25 x 19 20.5 —
{14 kg} {11.2 kg}
10-126 GD555, 655, 675-3A

RIGHT 4-SPOOL VALVE (1/3)
P : Pump port (from main pump) A2 : To leaning shift cylinder head

PP : PP port (to main pump) B2 : To leaning shift cylinder bottom
LS : LS port (to main pump) A3 : To articulating cylinder head
T : Tank port (to tank) B3 : To articulating cylinder bottom
TS : Seal drain port (to tank) A4 : To drawbar shift cylinder head
A1 : To right blade lift cylinder bottom B4 : To drawbar shift cylinder bottom
B1 : To left blade lift cylinder head
GD555, 655, 675-3A 10-127

10-128 GD555, 655, 675-3A

1. Spool (right blade lift) 8. Pressure compensation valve F (drawbar shift)

2. Spool (leaning) 9. Pressure compensation valve R (drawbar shift)
3. Spool (articulating) 10. Pressure compensation valve R (articulating)
4. Spool (drawbar shift) 11. Pressure compensation valve R (leaning)
5. Pressure compensation valve F (right blade lift) 12. Pressure compensation valve R (right blade
6. Pressure compensation valve F (leaning) lift)
7. Pressure compensation valve F (articulating) 13. LS relief valve
14. Main relief valve
Unit: mm

Replace
34.8 N 27.8 N
56.27 x 20.1 25.4 — spring if
15 Spool return spring {3.55 kg} {2.84 kg}
damaged or
16 23 x 8.4 15 —

17 15.4 x 6 8 —
GD555, 655, 675-3A 10-129

LEFT 5-SPOOL VALVE (SCARIFIER SPECIFICATION) (1/3)
P : Pump port (from main pump) A2 : To left blade lift cylinder bottom
PP : PP port (to main pump) B2 : To left blade lift cylinder head
LS : LS port (to right valve LS port) A3 : To blade shift cylinder bottom
T : Tank port (to tank) B3 : To blade shift cylinder head
TS : Seal drain port (to tank) A4 : To circle motor
A1 : To scarifier cylinder bottom B4 : To circle motor
B1 : To scarifier cylinder head A5 : To blade tilt cylinder bottom
B5 : To blade tilt cylinder head
10-130 GD555, 655, 675-3A

GD555, 655, 675-3A 10-131

1. Spool (blade tilt) 10. Pressure compensation valve F (blade tilt)

2. Spool (circle) 11. Pressure compensation valve R (blade tilt)
3. Spool (blade shift) 12. Pressure compensation valve R (circle)
4. Spool (left blade lift) 13. Pressure compensation valve R (blade shift)
5. Spool (scarifier) 14. Pressure compensation valve R (left blade lift)
6. Pressure compensation valve F (scarifier) 15. Pressure compensation valve (scarifier)
Unit: mm

19 Spool return spring 34.8 N 27.9 N

56.27 x 20.1 25.4 —
{3.55 kg} {2.84 kg}
Replace
20 87.7 x 19.7 25.4 — spring if
cle) {3.55 kg} {2.84 kg}
damaged or
21 23 x 8.4 15 —

22 15.4 x 6 8 —
137 N 110 N
{14 kg} {11.2 kg}
10-132 GD555, 655, 675-3A

LEFT 5-SPOOL VALVE (RIPPER SPECIFICATION) (1/3)

GD555-3A
LS : LS port (to right valve LS port) A3 : To blade shift cylinder bottom
A1 : To ripper cylinder bottom B4 : To circle motor
B1 : To ripper cylinder head A5 : To blade tilt cylinder bottom
GD555, 655, 675-3A 10-133


GD555-3A
10-134 GD555, 655, 675-3A


GD555-3A
1. Spool (blade tilt) 10. Pressure compensation valve F (blade tilt)

2. Spool (circle) 11. Pressure compensation valve R (blade tilt)
3. Spool (blade shift) 12. Pressure compensation valve R (circle)
4. Spool (left blade lift) 13. Pressure compensation valve R (blade shift)
5. Spool (ripper) 14. Pressure compensation valve R (left blade lift)
6. Pressure compensation valve F (ripper) 15. Pressure compensation valve (ripper)
Unit: mm


56.27 x 20.1 25.4 —
{3.55 kg} {2.84 kg}
Replace
21 87.7 x 19.7 25.4 — spring if
cle) {3.55 kg} {2.84 kg}
damaged or
22 23 x 8.4 15 —

23 15.4 x 6 8 —
137 N 110 N
{14 kg} {11.2 kg}
GD555, 655, 675-3A 10-135


GD655, GD675-3A
LS : LS port (to main pump) A3 : To blade shift cylinder bottom
A1 : To ripper cylinder bottom B4 : To circle motor
B1 : To ripper cylinder head A5 : To blade tilt cylinder bottom
10-136 GD555, 655, 675-3A


GD655, GD675-3A
GD555, 655, 675-3A 10-137


GD655, GD675-3A
1. Spool (blade tilt) 11. Pressure compensation valve R (blade tilt)

2. Spool (circle) 12. Pressure compensation valve R (circle)
3. Spool (blade shift) 13. Pressure compensation valve R (blade shift)
4. Spool (left blade lift) 14. Pressure compensation valve R (left blade lift)
5. Spool (ripper) 15. Pressure compensation valve (ripper)
6. Pressure compensation valve F (ripper) 16. LS bypass plug
7. Pressure compensation valve F (left blade lift) 17. Unload valve
8. Pressure compensation valve F (blade shift) 18. Safety-suction valve
10. Pressure compensation valve F (blade tilt)
Unit: mm


56.27 x 20.1 25.4 —
{3.55 kg} {2.84 kg}
Replace
21 87.7 x 19.7 25.4 — spring if
cle) {3.55 kg} {2.84 kg}
damaged or
22 23 x 8.4 15 —

23 15.4 x 6 8 —
137 N 110 N
{14 kg} {11.2 kg}
10-138 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
CLSS
1. OUTLINE OF CLSS
Features Structure
CLSS stands for Closed center Load Sensing • The CLSS consists of a variable capacity sin-
System, and has the following features. gle piston pump, control valve, and actuators.
1) Fine control not influenced by load. • The pump body consists of the main pump,
2) Control enabling digging even with fine the PC valve and LS valve.
control.
3) Ease of compound operation ensured by
flow divider function using area of open-
ing of spool during compound opera-
tions.
4) Energy saving using variable pump con-
trol.
GD555, 655, 675-3A 10-139

(3)
2. BASIC PRINCIPLE
1) Control of pump swash plate angle
• The pump swash plate angle (pump • If LS differential pressure (∆PLS)
discharge amount) is controlled so becomes lower than the set pressure
that LS differential pressure (∆PLS) of the LS valve, the pump swash plate
(the difference between pump pres- becomes larger; if it becomes higher
sure (PP) and control valve outlet port than the set pressure of the LS valve,
LS pressure (PLS)) (load pressure of the pump swash plate becomes
actuator) is constant. smaller.
(LS pressure (∆PLS) = Pump discharge ★ For details of the operation, see
pressure (PP) - LS pressure (PLS)) HYDRAULIC PUMP.
10-140 GD555, 655, 675-3A

(7)
2) Pressure compensation control

• Valves (pressure compensation valves) are installed on the inlet side of the control valves to bal-
ance the load. When the actuators are operated simultaneously, pressure difference (∆P)
between the upstream (inlet) of the spool of each valve and downstream (outlet) is kept con-
stant by the pressure compensation valves, regardless of the load (pressure). Accordingly, the
oil flow from the pump is distributed (compensated) in proportion to the open areas (S1) and
(S2) of the operated valves.
GD555, 655, 675-3A 10-141

(7)
3. FUNCTIONS AND OPERATION OF EACH VALVE

Hydraulic circuits and names of valves
SWG00879
S_G00962
1. Unload valve 4. Pressure compensation valve

2. LS relief valve 5. Safety suction valve
3. Main relief valve 6. LS pressure reducing valve
10-142 GD555, 655, 675-3A

UNLOAD VALVE
1) When control valve is at HOLD
Function
• When the control valve is at HOLD, pump dis-
charge amount Q discharged by the mini-
mum swash plate angle is released to the
tank circuit. When this happens, pump dis-
charge pressure PP is set to 2.9 MPa
{30 kg/cm2} by spring (2) inside the valve.
LS pressure PLS: 0 MPa {0 kg/cm2}.
Operation
• At the left end of the spool (1), pump pressure PP : Pump circuit
PP is acting on area S1, and at the right end PLS : LS circuit
of spool (1), pump pressure PP is acting on T : Tank circuit
area S2, and LS pressure PLS is acting on A : To valves
area S3. B : To pump LS valve
• When the control valve is at HOLD, LS pres-
sure PLS is not generated, so only pump dis-
charge pressure PP has any effect, and PP is
set by the load of spring (2).
• As pump discharge pressure PP rises and
becomes PP x S1 = PP x S2 + spring force of
spring (2), spool (1) is moved to the right.
Pump circuit PP is then connected to tank cir-
cuit T through the drill hole.
• In this way, pump discharge pressure PP is
set to 2.9 MPa {30 kg/cm2}.
GD555, 655, 675-3A 10-143

(7)
2) During fine control of control valve operation

Function
• During the fine control of the control valve,
when the demand flow for the actuator is
within the amount discharged by the mini-
mum swash plate angle of the pump, pump
discharge pressure PP is set to LS pressure
PLS + 2.9 MPa {30 kg/cm2}. When the differ-
ence in pressure between pump discharge
pressure PP and LS pressure PLS reaches the
load of spring (2) (2.9 MPa {30 kg/cm2}), the
unload valve opens, so LS differential pres-
sure ∆PLS becomes 2.9 MPa {30 kg/cm2}.
Operation
• When fine control is carried out on the control PP : Pump circuit
valve, LS pressure PLS is generated and acts PLS : LS circuit
on area S3 at the right end of spool (1). When T : Tank circuit
this happens, the area of the opening of the A : To valves
control valve spool is small, so there is a big B : To pump LS valve
difference between LS pressure PLS and
pump discharge pressure PP.
• When the difference in pressure between
pump discharge pressure PP and LS pressure
PLS reaches the load of spring (2), spool (1)
moves to the right, and pump circuit PP and
tank circuit T are connected.
• In other words, pump discharge pressure PP
is set to a pressure equal to the force of
spring (2) (2.9 MPa {30 kg/cm2}) + LS pressure
PLS, and LS differential pressure ∆PLS
becomes 2.9 MPa {30 kg/cm2}.
10-144 GD555, 655, 675-3A

3) When control valve is operated

Function
• When the control valve is being operated and
the demand flow for the actuator becomes
greater than the pump discharge from the
minimum swash plate angle, the flow of the
oil out to tank circuit T is shut off, and all the
pump discharge amount Q flows to the actua-
tor circuit.
Operation
• When the control valve is operated to a larger PP : Pump circuit
stroke, LS pressure PLS is generated and acts PLS : LS circuit
on area S3 at the right end of spool (1). When T : Tank circuit
this happens, the area of the opening of the A : To valves
control valve spool is large, so the difference B : To pump LS valve
between LS pressure PLS and pump dis-
charge pressure PP is small.
• For this reason, the difference in pressure
between pump discharge pressure PP and LS
pressure PLS does not reach the load of
spring (2) (2.9 MPa {30 kg/cm2}), so spool (1)
is pushed to the left by spring (2).
• As a result, pump circuit PP and tank circuit T
are shut off, and all the pump discharge
amount Q flows to the actuator circuit.
GD555, 655, 675-3A 10-145

INTRODUCTION OF LS PRESSURE
Function
• The LS pressure is the actuator load pressure
at the outlet port end of the control valve.
• It actually reduces pump pressure PP at
reducing valve (3) of the pressure compensa-
tion valve to the same pressure as actuation
circuit pressure A, and sends it to the LS cir-
cuit PLS.
Operation
• When spool (1) is operated, pump pressure • Actuator circuit pressure PA (=A) acts on the
PP flows from flow control valve (2) and left end of reducing valve (3); the reduced
notch a in a spool (1) through bridge passage pump pressure PP acts on the other end.
b to actuator circuit A. • As a result, reducing valve (3) is balanced at a
• At the same time, reducing valve (3) also position where actuator circuit pressure PA
moves to the right, so pump pressure PP has and the pressure of spring chamber PLS1 are
its pressure reduced by the pressure loss at the same. Pump pressure PP reduced at
notch C. It is introduced to LS circuit PLS, and notch C becomes actuator circuit pressure A
then goes to spring chamber PLS1. and is taken to LS circuit pressure PLS.
• When it happens, LS circuit PLS is connected
to tank circuit T from LS bypass plug (4) (see
the section on the LS bypass plug).
10-146 GD555, 655, 675-3A

(7)
PRESSURE COMPENSATION VALVE

Function
• During compound operations, if the load
pressure becomes lower than the other actua-
tor and the oil flow tries to increase, compen-
sation is received. (When this happens, the
other actuator being used for compound
operation (right side) is at a higher load than
the actuator on this side (left side).)
Operation
• If the load pressure of the other actuator • Flow control valve (2) and reducing valve (1)
(right side) becomes higher during com- are balanced in position where the difference
pound operations, the oil flow in actuator cir- in pressure between PLS and PA acting on
cuit A on this side (left side) tries to increase. both ends of reducing valve (2) and the pres-
• If this happens, the LS pressure PLS of the sure loss between PP and PPA on both sides
other actuator acts on spring chamber PLS1, of flow control valve (2) are the same.
and reducing valve (1) and flow control valve • In this way, the pressure difference between
(2) are pushed to the left (←). upstream pressure PPA and downstream
• Flow control valve (2) throttles the area of pressure PA of both spools used during com-
opening between pump circuit PP and spool pound operations is the same, so the pump
upstream PPA, and pressure loss is gener- flow is divided in proportions to the area of
ated between PP and PPA. opening of notch a of each spool.
GD555, 655, 675-3A 10-147

LS BYPASS PLUG
Function
• It releases the residual pressure of LS pres-
sure PLS.
• It makes the speed of the rise in pressure of
LS pressure PLS more gentle. In addition,
with this discarded throttled flow, it creates a
pressure loss in the throttled flow of the spool
or shuttle valve, and increases the stability by
lowering the effective LS differential pres-
sure.
Operation
• The pressurized oil for LS circuit PLS passes PP : Pump circuit
from clearance filter a (formed by the clear- PLS: LS circuit
ance between LS bypass plug (1) and the T : Tank circuit
valve body) through orifice b and flows to the A : To valves
bank circuit T. B : To pump LS valve
10-148 GD555, 655, 675-3A

LS RELIEF VALVE
A : L.H. control valve (unload section)

B : R.H. control valve (LS relief section)
Function Operation
• Even if the LS orifice functions, if another • If the LS circuit pressure PLS goes up and
actuator is relieved in compound operation, reaches the set pressure of LS relief valve (1),
the actuator speed is lower than in single PLS is kept constant.
operation. • When this happens, the pump circuit PP is
• When another actuator is relieved, if the set to PLS + the spring force of unload valve
speed lowers remarkably, the working perfor- (2).
mance is lowered. To prevent this, the LS • The relief amount of pump circuit PP flows
relief valve is employed. from unload valve (2) to circuit T. (Pump mini-
• A small pilot relief valve installed to the LS mum swash plate angle flow).
circuit controls the maximum pressure. • Relief valve (3) is a backup for the LS relief
• The unload valve works as a relief valve valve and has the function of a surge absorp-
installed to the main control valve and tion valve.
relieves the oil.
• In addition, since the LS differential pressure
equivalent to the set pressure of the unload
valve is secured, the actuator speed does not
lower even if another actuator is relieved.
GD555, 655, 675-3A 10-149

(6)
LS REDUCING VALVE
A : To main control valve

B : To pump LS port
C : From steering valve LS port
D : From steering valve P port
E : To pump PP port
FUNCTION OPERATION
• The LS differential pressure (∆PLS) of the • Pump pressure PCF and LS pressure PLS (st)
main control valve and the steering valve are are brought in from the steering valve.
set to different values; the value for the main • The PCF pressure is taken as the base pres-
control valve is higher. sure, and LS pressure PLS (v) reduced from
• If the steering is operated with this circuit, the PLS (st) by the load of spring (1) is taken to
pump discharges the maximum flow. The the main control valve.
excess oil is relieved by the unload valve of • Check valve (2) is installed to prevent the PP
the main control valve, so there is a large pressure when the work equipment is oper-
energy loss. To prevent this, the steering LS ated from entering the steering valve.
pressure is reduced and is set to the same
value as the LS differential pressure of the
main control valve. This reduces the loss.
10-150 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL
WORK EQUIPMENT CONTROL
1. Steering adjustment knob Outline

2. R.H. blade lift lever Steering tilt mechanism:
3. Leaning lever Rotate the steering adjustment knob (1) to release
4. Articulation lever the lock. Set steering to a suitable position, and
5. Drawbar shift lever then tighten the lever.
6. Blade rotation lever
7. Blade tilt lever Console box tilt mechanism:
8. Blade shift lever Depress the console box tilt pedal (11) and adjust
9. Ripper, scarifier lever the console box. The tilt angle can be adjusted
10. L.H. blade lift lever steplessly to a maximum of 24°.
11. Steering control tilt pedal
In this way, it is possible for the operator to set
the steering and control levers to the optimum
position.
10-152 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL
GD555, 655, 675-3A 10-153

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
STRUCTURE OF SYSTEM
Outline of System
1. Hydraulic pump
1) The hydraulic oil inside the hydraulic tank 3) The pressure loss caused by flow resis-
passes through the hydraulic pump and is tance in the piping varies according to the
sent to the priority valve. temperature. At low temperature, the nec-
2) The hydraulic pump is the source of essary control pressure may be lacking,
hydraulic power for the steering brake, and the necessary flow may not be pro-
work equipment, parking brake, and bank vided. But to prevent this, pressure PP
control lock pin. When there is a demand which is close to each piece of equipment
from the equipment, it generates an oil is brought to the hydraulic pump, and the
flow of the necessary amount and pres- pressure generated by the hydraulic
sure to match the demands of the equip- pump is controlled so that the differential
ment. pressure between PP and LS is 2.35 MPa
=LS pressure + control pressure {24 kg/cm2}.
2.35 MPa {24 kg/cm2}
At neutral, the steering LS pressure
0.8 to 1.1 MPa {8 to 11 kg/cm2} + 2.35 MPa
{24 kg/cm2} + pressure loss in piping =
3.24 to 3.63 MPa (33 to 37 kg/cm2}.
10-154 GD555, 655, 675-3A

(7)
4) In addition, it checks the pressure and dis- 3. Brake circuit

charge amount of the hydraulic pump,
and ensures the resilience of the engine 1) The oil that is given priority and ensured
when there is compound operation or for the circuit has its pressure raised to
when there is excessive load caused by the necessary pressure by the priority
PQ control when controlling at PQ = con- valve and is charged in the brake accumu-
stant value. lators inside the piping of the two sys-
tems.
5) When there are no demands for oil from 2) If the brake is used and the pressure goes
the steering or work equipment (the sys- down to 9.36 MPa {95 kg/cm2} the accu-
tem is at neutral), the swash plate in the mulator pressure governor valve is actu-
hydraulic pump is held at a position ated and the brake accumulator is
where a fixed minimum flow is discharged to the specified pressure of 13.4
charged so that the hydraulic pump can MPa {137 kg/cm2}.
respond swiftly to any rapid operation of 3) Even after the engine is stopped, braking
the steering wheel or work equipment. is possible for a limited time using the
pressure inside the brake accumulator.
2. Steering circuit 4) When the brake accumulator pressure
goes down, the force releasing the park-
1) The priority valve is provided to ensure
ing brake is reduced and the parking
the necessary oil flow and to give priority
brake is automatically applied by the
to the oil flow in the steering brake sys-
force of the spring. If the machine is
tem, which is closely related to safety,
stopped for a certain time, the parking
rather than to the work equipment.
brake is automatically applied, and it can
2) The steering valve is an energy saving
only be released by starting the engine.
closed center type which lets the hydrau-
5) In postures such as the bank cut posture
lic oil flow only when necessary. When
or shoulder reach posture, when chang-
the steering is not being operated, it stops
ing the posture of the work equipment,
the flow of oil.
the lifter lock pin is removed and
When the steering wheel is operated, the
installed. When doing this, the accumula-
pressure (LS pressure) passes through
tor is also used as the source of hydraulic
the accumulator pressure governor valve
power.
→ LS pressure regulator valve, and goes
6) The brakes are the most important
to the servo valve of the hydraulic pump
devices for ensuring safety, so charging
to ensure the necessary flow. It also gen-
always starts immediately after the
erates pressure so that Pb = LS pressure
engine is started. But particularly when
+ 2.35 MPa {24 kg/cm2} + pressure loss in starting in cold weather, if the accumula-
piping. At the same time, the LS pressure tor is charged during the starting opera-
is transmitted to the priority valve tion, there will be an excessive load on
through the accumulator pressure gover- the hydraulic pump, and this will make it
nor valve. Priority is given to the steering difficult to start the engine. To prevent
circuit by keeping the spool at a position this, an electromagnetic LS pressure
where it can provide the necessary oil release valve is installed in the accumula-
flow to the steering circuit, regardless of tor pressure governor valve. This cancels
whether there is any demand for oil from the charging of the accumulator when the
the work equipment. starting motor is cranking and makes it
3) The steering valve is a Q-Amp type that easier to start the engine.
provides good control at high speed and
can also ensure the steering ability if the
engine should stall or if any problem
should occur in the variable pump.
4) The maximum pressure in the steering
circuit is determined by the relief valve
inside the priority valve. It is different
from the hydraulic pressure for the work
equipment.
GD555, 655, 675-3A 10-155

(7)
4. LS pressure regulator valve

1) To improve the response when the steer- 3) At the hydraulic relief, the upper limit for
ing is operated suddenly and to ensure a the LS pressure is determined by the LS
quick response for the work equipment, a relief valve. The control valve is a closed
specified minimum flow of oil is dis- center load sensing valve, and has a pro-
charged from the hydraulic pump, so an portional flow and proportional dividing
unload valve is installed to the control pressure compensation function. It also
valve. has a built-in unload valve, LS relief valve,
2) When the steering is operated, the steer- a surge absorption valve. This gives it the
ing LS pressure rises and the pump dis- following features.
charge pressure is increased. For this • The operating effort is light and the
reason, the steering Pb pressure also lever travel is short
rises, but the function of the priority valve • It is possible to adjust each work
sends the excess oil used for the steering equipment to the optimum cylinder
to the control valve. When this happens, if set speed.
the control valve is open, this excess oil
• The raise and lower speeds (cylinder
flow is relieved by the unload valve and
extending and retracting speeds) are
returns to the tank. This causes an energy
the same, so the height can be
loss, so when the steering brake is
adjusted.
charged and the oil is not being used for
the work equipment, a signal is sent to • There is a wide fine control range.
the unload valve. The control valve is set • A constant movement position can be
to on-load and shuts off the flow of oil obtained, regardless of the load.
back to the hydraulic tank to prevent loss • The work equipment can be operated
of energy. with small movements of the lever
3) The internal shuttle valve transmits the and fine control is easy.
higher of the steering brake charge LS • Operations are certain even during
pressure and the work equipment LS simultaneous operations.
pressure to the pump to make it possible • Simultaneous operations are possi-
to carry out simultaneous operations. ble even when there is lack of oil.
4) The excess oil flow for the steering brake
• Other work equipment moves even
is sent to the control valve.
when there is hydraulic relief.
When used in combination with the CLSS
5. Control valve
hydraulic pump, it has the following fea-
1) The control valve is closed center type, so tures.
at neutral when the work equipment is • The work equipment speed is fixed,
not being used, the hydraulic oil returns regardless of the engine speed.
from the unload valve to the hydraulic • The neutral loss is reduced.
tank. The unload pressure 3.1 MPa {32 kg/
• The relief loss is reduced.
cm2} when the engine is at low idle and
• There is little problem of the engine
3.4 MPa {35 kg/cm2} when it is at full stalling even during compound opera-
throttle. tions or when there is a large load.
2) When the work equipment control valve
lever is operated, the pressure at the
valve inlet side is transmitted to the
hydraulic pump as Pb. At the same time,
the maximum pressure for the work
equipment load passes through the LS
line and is transmitted to the hydraulic
pump, so the necessary oil flow is sent
from the hydraulic pump.
10-156 GD555, 655, 675-3A

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
1. Filter
2. Filter by-pass
3. Oil filler
4. Oil filler strainer
5. Strainer
GD555, 655, 675-3A 10-157

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWIVEL JOINT
SWIVEL JOINT
1. Plug a. Blade tilt cylinder head

2. Plate b. Blade tilt cylinder bottom
3. Cover c. Blade shift cylinder head
4. Shaft d. Blade shift cylinder bottom
5. Rotor
10-158 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PILOT CHECK VALVE
PILOT CHECK VALVE

For blade lift (left), leaning, articulating, and drawbar shift
1. Piston
2. Check valve
3. Body
4. Piston
5. Check valve
A: From control valve

B: From control valve
C: To cylinder head
D: To cylinder bottom
Operation
When the hydraulic cylinder is extended, the con-
trol valve operates and oil flows from the pump
to port A, opening the check valve (5). Oil now
flows to port D. Pressurized oil from orifice a
pushes the piston (1) up, opening the check valve
(2). Ports C and B now connect and the oil flows
to the drain port.
Hunting occurs when the check valve (2) opens

and closes, compensating for pressure changes
at the bottom and head end. If the pressure at
port A decreases, orifice a acts as a damper to
prevent the check valve (2) from closing immedi-
ately.
GD555, 655, 675-3A 10-159

(6)
For blade lift (right)

1. Check valve
2. Plug
3. Body
4. Piston
5. Relief valve
SWG00783
The check valve with safety valve prevents

hydraulic drift of the cylinder and also protects
the cylinder from abnormal pressure caused by
external force.
When the blade lift is raised to the maximum
position and the drawbar is shifted to the side,
the drawbar stopper and lifter come into contact.
SWG00785
The check valve with safety valve installed to the
blade lift cylinder (left) acts to prevent damage to
the work equipment caused by this contact.
Operation
When the lever is operated to retract the cylinder,
oil from the pump enters chamber A1 and
pushes check valve (1). It then passes through
chamber B1 and flows to the chamber at the
head of the cylinder to push the cylinder piston.
The oil at the cylinder bottom end flows back
through chamber B2 and chamber A2 and
returns to the tank.
When the lever is operated to extend the cylinder,
the oil from the pump enters chamber A2 and
flows through chamber B2 to the cylinder bottom
end. As the pressure in chambers A2 and B2
rises, piston (4) is pushed. This pushes open
check valve (1), and the oil at the cylinder head
flows from chamber B1 through the throttle of
check valve (1). It then flows from chamber A1
back to the tank.
If there is any shock to the work equipment dur-
ing operations, and the pressure in chamber B1
rises to an abnormal pressure of 28.4 MPa
{290 kg/cm2} or more, relief valve (5) is pushed
open and the oil flows to chamber B2. This raises
the work equipment and relieves the shock.
10-160 GD555, 655, 675-3A

(6)
For ripper (GD555-3A)
1. Piston
2. Check valve
SWG00884 SWG00885
Operation
When the control valve is operated to lower the
ripper, pressure is generated at the bottom end of
the ripper cylinder. This pressure passes through
a throttle valve and pushes piston (1). This opens
pilot check valve (2), and the oil in chamber C at
the cylinder head returns to the tank. The ripper
hold pressure is acting on the head end of the rip- SWG00886
per cylinder. When it pushes open check valve
(2), the oil in chamber C suddenly escapes to
chamber A, and the pressure at the bottom
drops.
When this happens, if there is no throttle at the
pilot valve, the check valve will always open and
close according to the changes in the pressure at
the bottom and head ends. This will cause ripper
chattering. To prevent this a throttle is installed at
E which acts as a damper, so even if the pressure
at the bottom end drops, the check valve will not
close immediately.
GD555, 655, 675-3A 10-161

For blade tilt - ripper (GD655, 675-3A)

1. Check valve
2. Piston
3. Body
4. Check valve
5. Relief valve
SWG00887 SWG00888
The check valve with safety valve prevents

hydraulic drift of the cylinder and also protects
the cylinder from abnormal pressure caused by
external force
Operation
When the lever is operated to extend the cylinder, SWG00889
oil from the pump enters chamber A1 and
pushes piston (2) and check valve (4). It then
passes through chamber B1 and flows to the
chamber at the bottom end of the cylinder. The
oil at the cylinder head flows back through cham-
ber B2 and chamber A2 and returns to the tank.
When the lever is operated to retract the cylinder,
the oil from the pump enters chamber A2. As the
pressure in chamber A2 rises, check valve (1) is
pushed. This pushes open check valve (1), and
the oil flows to the cylinder head from chamber
B2.
If shock causes abnormal pressure of over
For blade tilt: 24.5 MPa {250 kg/cm2},
For ripper: 21.5 MPa {219 kg/cm2} in chamber B2,
it pushes open relief valve (5) and oil flows to
chamber B1 to relieve the shock.
10-162 GD555, 655, 675-3A

For scarifier
SWG00783 SWG00784
The check valve with safety valve prevents 1. Check valve

hydraulic drift of the cylinder, and also protects 2. Plug
the cylinder from abnormal pressure caused by 3. Body
external force. 4. Piston
5. Relief valve
Operation
Operating the lever to retract the cylinder, oil A1: From control valve
from the pump enters chamber A1 and pushes A2: From control valve
check valve (1). Oil then passes through chamber B1: To cylinder head
B1 and flows to the chamber at the head of the B2: To cylinder bottom
cylinder to push the cylinder piston. The oil at the
bottom of the cylinder flows back through cham-
ber B2 and chamber A2 and returns to the tank.
Operating the lever to extend the cylinder, oil

from the pump enters chamber A2 and flows
through chamber B2 to the bottom of the cylin-
der. As pressure increases in chambers A2 and
B2, pressure pushes the piston (4) and opens the
check valve (1). The oil at the cylinder head flows
from chamber B1 through the throttle of check
valve (1). It then flows from chamber A1 back to
the tank.
If there is any shock to the work equipment dur-
ing operations, and the pressure in chamber B1
rises to an abnormal pressure of 24.5 MPa {250
kg/cm2} or more, relief valve (5) is pushed open
and the oil flows to chamber B2. This raises the
work equipment and relieves the shock.
GD555, 655, 675-3A 10-163

BLADE ACCUMULATOR, FLOAT
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VALVE
BLADE ACCUMULATOR, FLOAT VALVE
Outline
• The blade accumulator prevents excessive • The blade float can be used in clearing fresh
load and pushing up by the blade in propul- snow. It allows only the weight of the work
sion works on roads where there are many equipment to push against the snow, making
buried rocks. In this way, it improves durabil- it possible to carry out operations following
ity of the work equipment and blade, and the ups and downs on the road surface,
reduces operator fatigue. allowing fresh snow to be cleared effectively
The blade accumulator can also be used at high speed, while increasing the safety of
effectively in snow-clearing operations on the operation.
compacted snow. It is possible to carry out
operations following the ups and downs on
the road surface, so the snow can be cleared
smoothly.
For blade lift (left)
SXG00780
1. Body A: From main control valve

2. Piston B: From main control valve
3. Check valve C: To cylinder head
4. Check valve D: To cylinder bottom
5. Piston
10-164 GD555, 655, 675-3A

(6)
BLADE ACCUMULATOR, FLOAT
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VALVE
For blade lift (right)
SXG00781
1. Body A: From main control valve

2. Check valve B: From main control valve
3. Piston C: To cylinder head
4. Piston D: To cylinder bottom
5. Check valve
GD555, 655, 675-3A 10-165

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR
ACCUMULATOR
For blade float
1. Valve assembly
2. Top cover
3. Cylinder
4. Cylinder
Specifications
Gas used: Nitrogen gas
Gas capacity: 1000 cc
Charging pressure:
2.0 ± 0.1 MPa {20 ± 1.0 kg/cm2} (at 20°C ± 5°C)
Function
If high pressure is generated in the blade cylinder
by a shock, the high-pressure oil flows through
the solenoid valve to the accumulator and then
enters cylinder (4) and presses the piston up to
compress the nitrogen gas in cylinder (3). As a
result, the shock applied to the blade cylinder is
damped by the nitrogen gas pressure in cylinder
(3). If the oil pressure in the blade cylinder low-
ers, the piston moves down to discharge the oil
until the nitrogen gas pressure is balanced with
the pressure in the blade cylinder circuit. This
operation is repeated smoothly in the accumula-
tor hydraulic circuit to damp the shocks applied
to the blade.
10-166 GD555, 655, 675-3A

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BLADE FLOAT DEVICE
BLADE FLOAT DEVICE
SWG00892
SWG00893
10-168 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BLADE FLOAT DEVICE
1. Blade float and accumulator switch

2. Blade accumulator, float valve
3. Blade lift cylinder
4. Proximity switch
5. Blade lift control valve
6. Pilot check valve
Outline
• When the lift lever is at N position, and the
blade float and accumulator switch (1) is
pushed to FLOAT position, blade accumulator,
float valve (2) is actuated, and the bottom and
head ends of the blade lift cylinder (3) are
connected to the drain circuit. This sets the
blade in a float condition.
• When the blade float and accumulator switch
(1) is pushed to FLOAT position, and the blade
lift lever is operated to the RAISE or LOWER
position, proximity switch (4) turns the blade
float and accumulator switch (1), and the
blade returns to normal RAISE or LOWER con-
dition, and this condition maintained. If the
blade lift lever is returned to the N position,
the blade is placed in floating condition.
★ If the blade float and accumulator switch (1) is
pushed to FLOAT position with the blade
raised, the blade will suddenly stop.
GD555, 655, 675-3A 10-169

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CIRCLE ROTATION MOTOR
CIRCLE ROTATION MOTOR
SWG00894
1. Output shaft 7. Gerotor

2. Flange 8. Valve drive
3. Shaft seal 9. Wear compensation mechanism valve
4. Taper roller bearing for heavy loads 10.PF 1/2 rolling port
5. Main drive 11.Check valve
6. O-ring 12.Valve plate
10-170 GD555, 655, 675-3A

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CIRCLE ROTATION MOTOR
Outline
• The circle rotation motor is a small, compact
low-speed torque motor and the giroller car-
ries out planetary motion. Therefore, it can
provide the same torque as other types of
hydraulic motors using a mechanical reduc-
tion gear when the reduction ratio is 1:6.
A hydraulic balance type disc valve is used
for the valve mechanism. A high-precision
giroller is used, so leakage is small.
The valve parts are assembled independently
from the power transmission mechanism, so
accurate valve timing can always be
obtained, providing stable performance over
long periods.
A taper roller bearing for heavy loads is
assembled to the output shaft, so it can with-
stand high radial loads and high thrust loads.
Operation
The high pressure oil flowing into the motor
passes through disc valve (1), enter giroller (2),
and the start of giroller (2) moves in a planetary
motion. Of this planetary motion, only the rota-
tion is taken off by main drive (3) to rotate output
shaft (4).
When this happens, disc valve (1) is driven by SWG00895
valve drive. The relationship between the posi-
tions of the 12 ports of disc valve (1) and the 7
ports (5) of the valve plate changes, and the posi-
tion of the hydraulic oil flowing to giroller (2)
changes in turn.
GD555, 655, 675-3A 10-171

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
GD555-3A
SJG00896
Unit: mm
Standard Tolerance Standard Clearance

-0.025 +0.132 0.031 to

Steering 35 0.519
-0.087 +0.006 0.219
-0.025 +0.164 0.032 to
Blade lift 50 0.551
-0.087 +0.007 0.251
Blade side -0.025 +0.164 0.032 to
50 0.551
shift -0.087 +0.007 0.251
Drawbar -0.025 +0.152 0.032 to
Clearance 45 0.539
shift -0.087 +0.007 0.239 Replace
1 between piston bushing
rod and bushing -0.025 +0.132 0.031 to
Leaning 35 0.519
-0.087 +0.006 0.219
-0.025 +0.164 0.032 to
Articulate 50 0.551
-0.087 +0.007 0.251
-0.025 +0.132 0.031 to
Blade tilt 40 0.519
-0.087 +0.006 0.219
-0.025 +0.164 0.032 to
Scarifier 50 0.551
-0.087 +0.007 0.251
-0.025 +0.164 0.032 to
Ripper 50 0.551
-0.087 +0.007 0.251
10-172 GD555, 655, 675-3A

GD555-3A
Unit: mm

-0.06 +0.02
Steering 55 0.06 to 0.11 1.0
-0.09 0
-0.05 +0.1
Blade lift 80 0.05 to 0.25 1.0
-0.15 0
Blade side -0.025 +0.142 0.105 to
40 1.0
shift -0.064 +0.080 0.206
Clearance Drawbar -0.05 +0.1
80 0.05 to 0.25 1.0
between piston shift -0.15 0
2 rod support and
bushing -0.025 +0.142 0.104 to
Leaning 45 1.0
-0.064 +0.080 0.206
-0.025 +0.142 0.104 to
Articulate 50 1.0
-0.064 +0.080 0.206
-0.025 0 0.013 to
Blade tilt 40 1.0
-0.064 -0.012 0.064
-0.025 +0.142 0.105 to
Scarifier 50 1.0
-0.064 +0.080 0.206
-0.030 +0.174 Replace
Ripper 55 0.13 to 0.25 1.0 bushing
-0.076 +0.100
-0.025 0 0.013 to
Steering 35 1.0
-0.064 -0.012 0.064
-0.080 +0.062 0.080 to
Blade lift 45 1.0
-0.142 0 0.204
Blade side -0.025 +0.142 0.105 to
40 1.0
shift -0.064 +0.080 0.206
80 0.05 to 0.25 1.0
between cylin- shift -0.15 0
der bottom -0.025 +0.142 0.105 to
3 (yoke, support Leaning 40 1.0
-0.064 +0.080 0.206
ball joint, sup-
port) and bush- -0.025 +0.142 0.105 to
ing Articulate 50 1.0
-0.064 +0.080 0.206
-0.025 0 0.013 to
Blade tilt 40 1.0
-0.064 -0.012 0.064
-0.025 +0.142 0.105 to
Scarifier 50 1.0
-0.064 +0.080 0.206
-0.100 +0.174 0.200 to
Ripper 60 1.0
-0.174 +0.100 0.348
GD555, 655, 675-3A 10-173

GD555-3A
Steering 245 ± 24.5 Nm {25 ± 2.5 kgm} (width across flats: 30)
Blade lift 647 ± 64.7 Nm {66 ± 6.6 kgm} (width across flats: 41)
Blade side shift 618 ± 61.8 Nm {63 ± 6.3 kgm} (width across flats: 41)
Drawbar shift 618 ± 61.8 Nm {63 ± 6.3 kgm} (width across flats: 41)
Piston nut tighten-
4 Leaning 412 ± 41.2 Nm {42 ± 4.2 kgm} (width across flats: 36)
ing torque
Articulate 1420 ± 142 Nm {145 ± 14.5 kgm} (width across flats: 55)
Blade tilt 647 ± 64.7 Nm {66 ± 6.6 kgm} (width across flats: 41)
Scarifier 618 ± 61.8 Nm {63 ± 6.3 kgm} (width across flats: 41)
Ripper 1080 ± 108 Nm {110 ± 11 kgm} (width across flats: 50)
Retighten
Steering 392 ± 39.2 Nm {40 ± 4 kgm}
Blade lift 588 ± 58.8 Nm {60 ± 6 kgm}
Blade side shift 588 ± 58.8 Nm {60 ± 6 kgm}
Drawbar shift 588 ± 58.8 Nm {60 ± 6 kgm}
Cylinder head tight-
5 Leaning 539 ± 53.9 Nm {55 ± 5.5 kgm}
ening torque
Articulate 677 ± 67.7 Nm {69 ± 6.9 kgm}
Blade tilt 588 ± 58.8 Nm {60 ± 6 kgm}
Scarifier 588 ± 58.8 Nm {60 ± 6 kgm}
Ripper 785 ± 78.5 Nm {80 ± 8 kgm}
10-174 GD555, 655, 675-3A

(6)
GD655, 675-3A
SJG00896
Unit: mm

Steering 35 -0.025 +0.132 0.031 to 0.519

-0.087 +0.006 0.219
Blade lift 50 -0.025 +0.164 0.032 to 0.551

-0.087 +0.007 0.251
Blade side 50 -0.025 +0.164 0.032 to 0.551
shift -0.087 +0.007 0.251
Clearance Drawbar 45 -0.025 +0.152 0.032 to 0.539

1 between piston shift -0.087 +0.007 0.239 Replace
rod and bushing bushing
Leaning 40 -0.025 +0.132 0.031 to 0.519
-0.087 +0.006 0.219
Articulate 50 -0.025 +0.164 0.032 to 0.551

-0.087 +0.007 0.251
Blade tilt 40 -0.025 +0.132 0.031 to 0.519

-0.087 +0.006 0.219
Scarifier 50 -0.025 +0.164 0.032 to 0.551

-0.087 +0.007 0.251
Ripper 55 -0.030 +0.163 0.036 to 0.567

-0.104 +0.006 0.267
GD555, 655, 675-3A 10-175

GD655, 675-3A
Unit: mm

-0.06 +0.02
Steering 55 -0.09 0 0.06 to 0.11 1.0
-0.05 +0.1
Blade lift 80 -0.15 0 0.05 to 0.25 1.0
Blade side -0.025 +0.142 0.105 to

shift 40 -0.064 +0.080 0.206 1.0

between piston shift 80 -0.15 0 0.05 to 0.25 1.0
2 rod support and
bushing -0.025 +0.142 0.104 to
Leaning 50 -0.064 +0.080 0.206 1.0
-0.025 +0.142 0.104 to

Articulate 50 -0.064 +0.080 0.206 1.0
-0.025 0 0.013 to
Blade tilt 40 -0.064 -0.012 0.064 1.0
-0.025 +0.142 0.105 to

Scarifier 50 -0.064 +0.080 0.206 1.0
-0.030 +0.174 Replace

Ripper 60 -0.076 +0.100 0.13 to 0.25 1.0 bushing
-0.025 0 0.013 to
Steering 35 -0.064 -0.012 0.064 1.0
-0.080 +0.062 0.080 to

Blade lift 45 -0.142 0 0.204 1.0
Blade side -0.025 +0.142 0.105 to

shift 40 -0.064 +0.080 0.206 1.0

shift 80 -0.15 0 0.05 to 0.25 1.0
between cylin-
der bottom -0.025 +0.142 0.105 to
3 (yoke, support Leaning 45 -0.064 +0.080 0.206 1.0
ball joint, sup-
port) and bush- -0.025 +0.142 0.105 to
ing Articulate 50 -0.064 +0.080 0.206 1.0
-0.025 0 0.013 to
Blade tilt 40 -0.064 -0.012 0.064 1.0
-0.025 +0.142 0.105 to

Scarifier 50 -0.064 +0.080 0.206 1.0
-0.100 +0.174 0.200 to

Ripper 60 -0.174 +0.100 0.348 1.0
10-176 GD555, 655, 675-3A

GD655, 675-3A
Steering 245 ± 24.5 Nm {25 ± 2.5 kgm} (width across flats: 30)
Blade lift 647 ± 64.7 Nm {66 ± 6.6 kgm} (width across flats: 41)
Blade side shift 618 ± 61.8 Nm {63 ± 6.3 kgm} (width across flats: 41)
Drawbar shift 618 ± 61.8 Nm {63 ± 6.3 kgm} (width across flats: 41)
Piston nut tighten-
4 Leaning 618 ± 61.8 Nm {63 ± 6.3 kgm} (width across flats: 41)
ing torque
Articulate 1420 ± 142 Nm {145 ± 14.5 kgm} (width across flats: 55)
Blade tilt 647 ± 64.7 Nm {66 ± 6.6 kgm} (width across flats: 41)
Scarifier 785 ± 78.5 Nm {80 ± 8 kgm} (width across flats: 46)
Ripper 1770 ± 177 Nm {180 ± 18 kgm} (width across flats: 60)
Retighten
Steering 392 ± 39.2 Nm {40 ± 4 kgm}
Blade lift 588 ± 58.8 Nm {60 ± 6 kgm}
Blade side shift 588 ± 58.8 Nm {60 ± 6 kgm}
Drawbar shift 588 ± 58.8 Nm {60 ± 6 kgm}
Cylinder head tight-
5 Leaning 588 ± 58.8 Nm {60 ± 6 kgm}
ening torque
Articulate 677 ± 67.7 Nm {69 ± 6.9 kgm}
Blade tilt 588 ± 58.8 Nm {60 ± 6 kgm}
Scarifier 677 ± 67.7 Nm {69 ± 6.9 kgm}
Ripper 981 ± 98.1 Nm {100 ± 10 kgm}
GD555, 655, 675-3A 10-177

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CIRCLE, DRAWBAR
CIRCLE, DRAWBAR
SWG00897
10-178 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CIRCLE, DRAWBAR
1. Circle Outline
2. Drawbar • The drawbar is an important piece of equip-
3. Blade tilt cylinder ment which supports the circle and blade. If
4. Drawbar side-shift cylinder ball joint (6) is worn, use shim (5) to adjust
5. Shim the clearance at the joint so that there is no
6. Ball joint excessive play.
7. Lifter bracket (Upper) • When adjusting the clearance at the contact
8. Shim portions of guides (15), (18), and (20), adjust
9. Lifter bracket (Lower) with shims (14), (17), and (19), and adjustment
10. Yoke bolt (13).
11. Pin • There are two cylinders installed in the lifter
12. Bushing for moving the blade devices. Brackets (7) and
13. Adjustment bolt (9) are installed by the guide, which is welded
14. Shim to the main frame. They can be revolved by
15. Guide revolving the guide by extracting a pin (11)
16. Bolt controlled from the operator’s seat. There are
17. Shim four insertion holes altogether for the pin
18. Guide stopping revolution. Holes b, c and d, e are
19. Shim used for the blade to make a bank cut to left
20. Guide or right. At other times, holes a are used.
• These a get used much more than the other
holes and bushing (12) is used in it to make
the clearance between the pin and the hole at
a minimum. (This clearance amplifies the up
and down movement of the blade.) Also, the
clearance between the bracket and the guide
welded to the frame can be adjusted with
shims (8).
Unit: mm

Size Shaft Hole Clearance Limit Adjust or
replace
Wear of drawbar ball -0.050 +0.100 0.050 to
21 joint end 150 -0.100 0 0.200 —
Clearance -0.030 +0.174 0.130 to

GD555 75 -0.076 +0.100 0.250 0.6
between the Replace
22 yoke and bushing
GD655 -0.030 +0.220 0.190 to
bushing GD675 75 -0.076 +0.160 0.296 0.6
Standard Clearance Clearance Limit Replace

23 yoke or
Axial clearance of yoke 0.8 to 1.3 2.0 bushing
Clearance between the Adjust or
24 circle and drawbar 0 to 3.0 1.0 to 2.0 replace
GD555, 655, 675-3A 10-179

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LIFTER BRACKET LOCK PIN
LIFTER BRACKET LOCK PIN
SWG00898
The lifter bracket is fixed by bank pin (3). When 1. Parking, bank control valve
setting in the bank cutting position, operate con- 2. Lifter
trol lever. This uses hydraulic oil to push piston 3. Bank pin
(4). The pin can be removed and the bracket can 4. Piston
then be rotated. 5. Bushing
6. Case
10-180 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BLADE
BLADE
1. Adjuster 3. Drawbar side-shift cylinder

2. Blade tilt cylinder 4. Blade side-shift cylinder
10-182 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BLADE
Function
• Side edge installed to the blade is designed
so that it can be used twice by turning it
upside down and moving it to the other (left
or right) side.
• A power tilt device is installed to adjust the
cutting angle of the blade. Adjustment can be
made freely between 32° and 81° using a sin-
gle lever. The guide acts as a bushing for the
sliding parts when shifting the blade to the
side. If the clearance from the sliding parts is
too large and the finishing accuracy cannot
be obtained, adjust the shims or replace the
guide.
Unit: mm
Size Repair Limit

5 Wear of cutting edge From blade holder: 32 From blade holder: 10
6 Wear of side edge From blade holder: 48 From blade holder: 25
7a Height 368 364
Wear of blade rail Replace
7b Thickness 25 21
8a Height 8 5
Wear of blade rail
guide Width of
8b groove 25 33
GD555, 655, 675-3A 10-183

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CIRCLE ROTATION GEAR
CIRCLE ROTATION GEAR
1. Drain plug 4. Joint

2. Worm wheel 5. Shear pin
3. Oil filler plug 6. Worm gear
10-184 GD555, 655, 675-3A

Unit: mm

7 Shaft Hole
Replace
Clearance between worm 75 -0.030 +0.057 0.040 to 0.4 bushing
wheel shaft and bushing -0.060 +0.010 0.117
8 Clearance between worm 75 +0.035 +0.291 0.112 to 0.4

wheel shaft and bushing +0.005 +0.077 0.296
Standard Clearance Clearance Limit
Backlash between worm and Replace
9 0.3 to 0.4 2.0
worm wheel
10 Clearance between pinion 0.1 to 0.5 0.6 Adjust

gear and wear plate
Replace
11 Pinion gear wear 25 20
12 Wormshaft bearing preload Starting torque: 2.9 to 7.8 Nm {0.3 to 0.8 kgm} Adjust
when worm wheel is not meshed
GD555, 655, 675-3A 10-185

With slip clutch
SWG00899
1. Floating seal Outline

2. Shaft • The circle rotation gear is driven by an oil
3. Case motor connected to worm gear shaft (12).
4. Worm wheel • Pinion gear shaft (2) has a clutch mechanism,
5. Plate and if abnormal rotating force is transmitted
6. Disc from the blade, disc (6) slips to prevent break-
7. Spring age of the blade.
8. Cover
• The clutch pressure of this clutch mechanism
9. Shim
is adjusted by the thickness of shim (9).
10. Pinion gear
11. Drain plug
12. Worm gear shaft
13. Oil motor
10-186 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SCARIFIER
SCARIFIER
10-188 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SCARIFIER
1. Lift arm
2. Scarifier cylinder
3. Scarifier body
4. Wedge
Unit: mm

Replace tooth
5 Tooth wear 450 330
6 Point tooth wear 450 407 Replace point
GD555, 655, 675-3A 10-189

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RIPPER
RIPPER
GD555-3A
SWG00900
1. Bracket Outline
2. Ripper cylinder • Ripper lifting height and digging depth can be
3. Shank controlled with ripper cylinder (2). Since the
point tips cut into the ground under the load
of the ripper’s heavy weight, the ripper easily
performs heavy-duty digging work that can-
not be done by the scarifier
Unit: mm
Standard Standard
Tolerance Clearance Limit
Size Clearance
4 Clearance between pin and bushing Shaft Hole
50 -0.025 +0.142 0.105 to 0.192 0.5
-0.050 +0.080
5 Clearance between pin and bushing 60 -0.025 +0.046 0.025 to 0.101 0.5 Replace
-0.055 0
6 Clearance between trunnion and bush- 60 -0.100 +0.174 0.200 to 0.348 0.5
ing -0.174 +0.100
7 Point wear
198 123
10-190 GD555, 655, 675-3A

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RIPPER
GD655, 675-3A
SJG00901
1. Bracket Outline
2. Rod • Ripper lifting height and digging depth can be
3. Shank controlled with ripper cylinder (4). Since the
4. Ripper cylinder point tips cut into the ground under the load
of the ripper’s heavy weight, the ripper easily
performs heavy-duty digging work that can-
not be done by the scarifier.
Unit: mm
Standard Standard
Tolerance Clearance Limit
Size Clearance
5 Clearance between pin and bushing Shaft Hole
50 -0.025 +0.142 0.105 to 0.192 0.5
-0.050 +0.080
-0.030 +0.054 Replace
6 Clearance between pin and bushing 60 0.03 to 0.13 0.5
-0.076 0
Clearance between trunnion and bush- -0.100 +0.174
7 ing 60 -0.174 +0.100 0.200 to 0.348 0.5

8 Point wear
290 150
GD555, 655, 675-3A 10-191

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MAIN FRAME
MAIN FRAME
1. Articulate cylinder
2. Front frame
3. Rear frame
4. Upper center pin
5. Lower center pin
GD555, 655, 675-3A 10-193

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER (IF EQUIPPED)
AIR CONDITIONER (IF EQUIPPED)

AIR CONDITIONER PIPING
Serial No.: 10001 – 11000
1. Condenser
2. Air conditioner compressor
3. Receiver-dryer
10-194 GD555, 655, 675-3A

(3)
4. Air conditioner unit

4a. Hot water heater
4b. Evaporator
4c. Blower unit
GD555, 655, 675-3A 10-195

Serial No.: 11001 and up
1. Condenser
2. Air conditioner compressor
3. Receiver-dryer
10-195-1 GD555, 655, 675-3A

(3)
4. Air conditioner unit

4a. Hot water heater
4b. Evaporator
4c. Blower unit
GD555, 655, 675-3A 10-195-2

(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE STARTING CIRCUIT
ENGINE STARTING CIRCUIT

Serial No.: 10001 – 11000
Function
• To ensure safety while starting the engine, a • If the gearshift lever is not in the P (PARK)
neutral safety circuit is used. This circuit position, the flow of electricity from the gear-
makes it impossible to start the engine, if the shift lever terminal 6 is stopped. Thus, no
gearshift lever is not at the P (PARK) position. electricity flows to the neutral relay and the
engine starting circuit is not energized.
• After starting the engine, pressurized oil is
stored in the brake circuit accumulator. How-
ever, this process is temporarily canceled
while starting the engine to reduce the load
on the engine, making it easier to start the
engine.
Operation
• When the starting switch is turned to the ON
position, electricity flows from the switch BR
terminal to the battery relay. The battery relay
points now close. In addition, electricity flows
from the ACC terminal of the switch to the
holding coil of the fuel shut-off solenoid to
supply fuel.
• When the gearshift lever is at the P (PARK)

position, electricity flows from gearshift lever
terminal 6 to the coil of the neutral relay. Elec-
tricity now flows through contacts 3 and 5 of
the neutral relay.
10-196 GD555, 655, 675-3A

(6)
• If the starting switch is turned to the START • If the starting switch is returned to the ON
position, a current flows from starting switch position, the current flowing in the starting
terminal C through the neutral relay terminals switch terminal C is cut-out and the contact of
3 – 5 and starting motor relay to ground, and the starting motor relay is "opened" to cut out
the contact of the starting motor relay is the current flowing in the starting motor. At
closed. As a result, a circuit is formed by the this time, the contact of the fuel shut-off relay
battery, battery relay, starting motor relay, is also "opened" and the fuel shut-off solenoid
starting motor, and ground to supply the cur- is returned to the normal fuel supply state.
rent to the starting motor. • The engine start-up solenoid is turned off and
• At this time, a current also flows from the the hydraulic pump charges the brake accu-
neutral relay to the fuel shut-off relay to mulator while the engine is running.
"close" the contact of the fuel shut-off relay.
As a result, the current flows in the pull-in coil
of the fuel shut-off solenoid to supply the fuel
most, then the engine starts.
• A current flows from starting switch terminal
C to the engine start-up solenoid to cancel
charging the brake accumulator temporarily
and lower the hydraulic pump load on the
engine.
GD555, 655, 675-3A 10-197

Function
• The neutral safety circuit is employed to
secure safety when the engine is started. This
circuit allows the engine to start only when
the gearshift lever is in the P (Parking) posi-
tion.
• When the engine is started, storing pressure
in the accumulator of the brake circuit is can-
celed temporarily to reduce the load of the
hydraulic pump on the engine for the ease of
starting of the engine.
In addition, the engine start auxiliary switch is
installed to reduce the load on the engine and
stabilize the engine rotation when the engine
is started at low temperature.
10-197-1 GD555, 655, 675-3A

(3)
Operation
• If the starting switch is turned from the OFF
position to the START position, a current
flows from starting switch terminal BR to the
battery relay to "close" the contacts of the bat-
tery relay.
• The current flows in the holding coil of the
solenoid to supply fuel. It also flows in the
fuel shut-off timer to "close" the contacts of
the fuel shut-off relay for about 3 seconds.
Then, the current also flows in the pull-in coil
of the fuel shut-off solenoid to supply the fuel
at the maximum rate so that the engine will
be started easily.
• If the gearshift lever is in the P (Parking) posi-
tion, a current flows from gearshift lever ter-
minal 6 to the neutral relay coil to connect
contacts 1 and 2 of the neutral relay.
While the gearshift lever is not in the P (Park-
ing) position, the current does not flow from
gearshift lever terminal 6. Accordingly, any
current does not flow in the neutral relay coil
and the starting circuit is not formed.
• A current flows from starting switch terminal
C through neutral relay terminals 1 and 2 to
the starting motor to start the engine.
• At this time, another current flows from start-
ing switch terminal C to the engine startup
solenoid to temporarily cancel storing pres-
sure in the brake accumulator so that the load
on the engine will be reduced and the engine
will be started easily.
GD555, 655, 675-3A 10-197-2

(3)
• After the engine is started, if the starting

switch is turned to the ON position, the cur-
rent flowing from starting switch terminal C is
turned OFF, and the current flowing through
neutral relay terminals 1 and 2 to the starting
motor is turned off consequently.
The current flowing in the engine startup
solenoid is turned OFF, the solenoid is
returned to the normal state, and the hydrau-
lic pump starts storing pressure in the accu-
mulator.
• A current keeps flowing from starting switch
terminal ACC to the holding coil of the fuel
shut-off solenoid. The fuel shut-off timer
turns OFF the current flowing in the fuel shut-
off relay coil, and then any current does not
flow in the pull-in coil of the fuel shut-off sole-
noid. Accordingly, the fuel supplied normally.
• If the engine start auxiliary switch is held even
after the engine is started in when the tem-
perature is low, a current flows from neutral
relay terminal 3 through terminal 4 to the
engine startup solenoid to reduce the load of
the hydraulic pump on the engine while the
switch is held.
10-197-3 GD555, 655, 675-3A

(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT

Serial No.: 10001 – 11000
Function
• Turning the starting switch to the OFF posi-
tion stops the current flow from terminal ACC
of the switch to the fuel shut-off solenoid. The
fuel shut-off solenoid now stops the fuel flow
to the engine, stopping the engine.
10-198 GD555, 655, 675-3A

(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE STOP CIRCUIT
Operation
• If the starting switch is set in the OFF position,
a current flowing from starting switch termi-
nal ACC to the fuel shut-off solenoid is turned
OFF. As a result, the fuel shut-off solenoid
stops supplying fuel and the engine stops.
GD555, 655, 675-3A 10-199

(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PREHEAT CIRCUIT
PREHEAT CIRCUIT
Serial No.: 10001 – 11000
Operation
• Turning the starting switch to the PREHEAT
position, electricity flows from switch termi-
nal BR to the battery relay to ground. The bat-
tery relay contacts close. In addition, current
now flows from terminal R1 of the switch to
the heater relay to ground, closing the heater
relay contacts. As a result, current flows from
the battery to the battery relay to the heater
relay to the preheater to ground. The circuit is
complete and the engine is heated.
• Simultaneously, current now flows from ter-

minal R1 of the switch to terminal 3 of the
timer. The timer is now actuated. Current now
flows from terminal 1 of the timer to the pre-
heating pilot lamp to ground for a fixed
period of time. The circuit is now complete
and the preheating pilot lamp lights up.
10-199-1 GD555, 655, 675-3A

(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PREHEAT CIRCUIT
Operation
• If the starting switch is set in the PREHEAT
position, a current flows from starting switch
terminal BR through the battery relay to the
ground, and the battery relay contacts are
"closed".
At this time, a current flows from starting
switch terminal R1 through the heater relay to
the ground, and the heater relay contacts are
"closed".
As a result, the circuit from the battery
through the battery relay, heater relay, and
preheater to the ground is formed, and the
engine is preheated.
• At this time, another current flows from start-
ing switch terminal R1 to timer terminal 3 to
turn the timer ON.
Then, a current flows through the fuse, pre-
heater pilot lamp, and timer to the ground
and the pilot lamp lights up for a certain
period (about 20 seconds).
GD555, 655, 675-3A 10-199-2

(3)
AUTOMATIC SHIFT CONTROL SYS-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TEM
AUTOMATIC SHIFT CONTROL SYSTEM

SYSTEM DIAGRAM
Outline
• The automatic shift control system receives
the shift position signal from the gearshift
lever, the transmission speed signal, and sig-
nals from other switches and sensors. The
transmission controller automatically shifts
the transmission to the most suitable speed
range. In addition to shift control the trans-
mission controller also drives and controls
the torque converter lock-up solenoid.
10-200 GD555, 655, 675-3A

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER
Outline
• This transmission controller controls the sys- • Upshifts and downshifts in relation to the
tem using a built-in computer, which has the pedal angle.
following functions: • Drives and controls the torque converter lock-
up solenoid.
• Installed separately from the gearshift lever.
Clutches used
ECMV
Speed range Low High R 1st 2nd 3rd 4th
F1 O O
F2 O O
F3 O O
F4 O O
F5 O O
F6 O O
F7 O O
F8 O O
R1 O O
R2 O O
R3 O O
R4 O O
GD555, 655, 675-3A 10-201

GEARSHIFT LEVER POSITION

Gearshift lever positions and automatic gearshifting range
• The gearshifting range for each gearshift lever position is as shown in the chart below.
• As the transmission mode selector switch is operated, the gearshift pattern and lock-up/torque con-
verter pattern changes.
• When the transmission mode switch is in "MODE 1", the gear is shifted manually at each lever position.
• When the transmission mode switch is in "MODE2", the gear is shifted manually at the lever positions
of F1 – F4 and R1 – R4 but shifted automatically at the lever positions F5 – F8 according to the travel
speed. (Automatic gearshifting)
MODE 1
Speed Range
LEVER
POSITION N F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4
N A
F1 B
F2 B
F3 B
F4 B
F5 B
F6 B
F7 B
F8 B
R1 B
R2 B
R3 A
R4 B
MODE 2
Speed Range
LEVER
POSITION N F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4
N A
F1 A
F2 A
F3 A
F4 A
F5 A C
F6 A C C
F7 A C C C
F8 A C C C C
R1 A
R2 A
R3 A
R4 A
A = Does not lockup

B = Locks up
C = Locks up automatically
10-202 GD555, 655, 675-3A

(6)
Gearshifting diagram
• Gearshifting range
• As the transmission mode selector switch is
operated, the gearshift pattern changes.
SWG00803
GD555, 655, 675-3A 10-203

AUTOMATIC GEARSHIFT WIRING DIAGRAM

• Transmission mode selector switch: Mode 2
• Lever position: F5 - F8
SXG00903
10-204 GD555, 655, 675-3A

(6)
OVERRUN PREVENTION FUNCTION

• When shifting gears suddenly, the transmis-
sion may enter a speed range that does not
match the position of the gearshift lever. This
action prevents the engine from overrunning.
When this situation occurs, a short warning
sound is given to warn the operator. Reduc-
ing the machine’s travel speed automatically
shifts the transmission to the position
selected by the gearshift lever.
ULTRA LOW-SPEED TRAVEL CONTROL

• When the gearshift lever is at F1, the trans-
mission is in the torque converter mode, the
accelerator pedal is not depressed, and if the
travel speed is less than 1.8 km/h (1.1 mph),
the transmission enters the ultra low-speed
travel control mode and maintains the travel
speed at 1 km/h.
VHP SPECIFICATION MACHINE

• With the VHP specification machine, switch-
ing between the standard output and high
output of the engine is possible, as shown in
the diagram below, by turning the lock-up
switch ON/OFF.
Lock-up Switch
OFF ON
F1
Standard output
F2 Standard output
F3
F4
F5
High output
F6 High output
F7
F8
GD555, 655, 675-3A 10-205

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR
MONITOR
MONITOR PANEL
S_G00965
1. Turn-signal pilot lamp 13. Lift arm lock pilot lamp

2. Engine coolant temperature gauge 14. Torque converter oil temperature caution
3. Articulate meter lamp
4. Parking brake pilot lamp 15. Brake oil pressure caution lamp
5. Head lamp high beam pilot lamp 16. Electric circuit monitor of transmission
6. Blade float pilot lamp (if equipped) system caution lamp
7. Preheating pilot lamp 17. Battery charge caution lamp
8. Blade accumulator pilot lamp (if equipped) 18. Engine oil pressure caution lamp
9. Working lamp pilot lamp (if equipped) 19. Message center
10. AWD pilot lamp (if equipped) 20. Fuel gauge
11. Differential control pilot lamp (if equipped) 21. Speedometer (if equipped)
12. Differential oil temperature caution lamp 22. Torque converter oil temperature gauge
(if equipped) (if equipped)
10-206 GD555, 655, 675-3A

(6)
MONITOR ITEMS DISPLAY
Category Symbol Item indicated Indicated range Description
Differential oil tem- More than 120° C

perature {248° F}
Torque converter oil More than 110° C

temperature {230° F}
Max. 4.17 MPa

Brake oil pressure {42.5 kg/cm2}
Off when normal,
Caution lights up when prob-
lem detected
Off when normal,

Monitor transmission lights up when
electrical circuit problem detected
When charge is
Battery charge defective
Max. 82 kPa
Engine oil pressure {0.837 kg/cm2}
Turn signal indicator When operated
Parking brake When operated Lights up when oper-

ated
Pilot
Head lamp beam When operated
Lights up when blade

Blade float When operated accumulator/float
switch is at FLOAT
GD555, 655, 675-3A 10-207

(6)
While starting, lights

When electricity up for approx. 20 sec-
Engine preheating flows in the preheat- onds when the switch
ing circuit is at HEAT
Lights up when blade

accumulator/float
Blade accumulator When operated switch is at ACCUMU-
LATOR
When operated
Working lamp
Pilot
When operated Lights up when oper-

AWD
ated
When operated
Differential control
Lights up when not

Lift arm lock When cancelled locked
• Displays while
starting switch is
Engine coolant tem- ON
— perature • Indicator shows
engine coolant
temperature
• Displays while
starting switch is
— Articulate ON
• Indicator shows
angle
Gauges
• Displays while
— Fuel starting switch is
ON
• Displays while
starting switch is
Torque converter oil ON
— temperature • Indicator shows
torque converter
oil temperature
10-208 GD555, 655, 675-3A

(6)
• Displays while
starting switch is
Speedometer — Speedometer ON
• Indicator shows
vehicle speed
Digital display:
displays speed range,
Message center — Message center error code, travel
speed
GD555, 655, 675-3A 10-209

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS
SENSORS
ENGINE COOLANT TEMPERATURE SENSOR
TORQUE CONVERTER OIL TEMPERATURE SENSOR
SWG00995
1. Connector 3. Thermistor
2. Plug
Temperature °C 50 ± 0.2 60 ± 0.2 80 ± 0.2 100 ± 0.3 106 ± 0.3 120 ± 0.3
Ohms 80 ± 10 56.3 ± 5 29.5 ± 2.5 16.5 ± 0.9 14.3 ± 0.5 10 ± 0.3
Function
• The engine coolant temperature sensor is • The torque converter oil temperature sensor
installed to the engine cylinder block. As the is installed to the torque converter outlet port
engine temperature changes, so does the on the transmission. If it senses the torque
sensor’s resistance. The gauge on the moni- converter outlet oil temperature, its resistance
tor panel moves to indicate the engine tem- changes. The resistance is converted into
perature. temperature and displayed on the monitor
panel.
BRAKE OIL PRESSURE SWITCH
1. Pressure sensor Function

2. Cable • This electronic switch uses a semiconductor.
3. Connector When the brake oil pressure (accumulator
pressure) drops below a specified value, the
switch turns ON. This action causes the brake
oil pressure lamp to light up and warn of a
problem.
10-210 GD555, 655, 675-3A

(6)
TRANSMISSION SPEED SENSOR
1. Sensor Function
2. Locknut • Two transmission-speed sensors are screwed
3. Wiring harness into the transmission case: one sensor
4. Connector detects transmission input shaft speed and
the other sensor detects output shaft speed.
• Gears are installed to the transmission input

shaft and output shaft. When the tip of a gear
tooth passes the sensor, an electrical pulse is
generated, which is detected by the sensor.
The speed is calculated by the transmission
controller. This information controls the
transmission.
DIFFERENTIAL OIL TEMPERATURE SENSOR
1. Sensor Function
2. Wiring harness • The differential oil temperature sensor is a
3. Connector bimetal type. It detects the temperature of the
oil in the differential case. If the oil tempera-
ture exceeds 120° C (248° F), the switch turns
ON. This signal is sent to the transmission
controller and is also used to control the
transmission.
GD555, 655, 675-3A 10-211

HYDRAULIC OIL SENSOR
TRANSMISSION OIL TEMPERATURE SENSOR
TORQUE CONVERTER OIL TEMPERATURE SENSOR
S_G00969
1. Thermistor Function
2. Plug • The hydraulic oil sensor, transmission oil
3. Wiring harness temperature sensor, and torque converter oil
4. Connector temperature sensor are installed at the
hydraulic tank. These sensors use a ther-
mistor to detect the temperature. The sensors
connect to the transmission controller and
used to control the transmission.
ARTICULATION SENSOR
1. Lever Function
• The articulation sensor is installed to the cen-
ter of the frame. This sensor uses a variable
resistor. The resistor’s resistance varies
according to lever movement. The amount of
resistance determines the angle displayed on
the gauge, which is located on the monitor
panel.
10-212 GD555, 655, 675-3A

FUEL GAUGE SENSOR
S_G00970
23B-06-42650
1. Float Function
2. Arm • The fuel gauge sensor is installed to the rear
3. Variable resistor side of the fuel tank and its float moves up
4. Connector and down according to the fuel level in the
tank.
The float moves the variable resistor and
changes its resistance through the arm.
The change of the resistance is converted into
a change of voltage is transmitted to the fuel
level gauge, then the fuel level gauge pointer
indicates the fuel level in the fuel tank.
GD555, 655, 675-3A 10-213

ACCELERATOR PEDAL POTENTIOMETER
1. Connector Function
2. Case • This sensor is installed to the accelerator
3. Shaft pedal. The sensor detects the pedal angle
4. Element when depressing the pedal.
5. Bearing • Inside the potentiometer, the pedal angle is
6. Contact converted into a voltage signal. A variable
7. Mold resistor adjusts the 5 volt source signal as the
pedal angle changes. The adjusted voltage
signal is now sent to the transmission con-
troller.
10-214 GD555, 655, 675-3A

20 TESTING AND ADJUSTING
Standard value table

Standard value table for engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
Standard value table for chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4
Standard value table for electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11
Testing and adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-201
★ Note the following when making judgements using the standard value tables for testing, adjusting,
or troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the
machine from the factory and is given for reference. It is used as a guideline for judging the progress
of wear after the machine has been operated, and as a reference value when carrying out repairs.
2. The permissible value given in the tables is the estimated value for the shipped machine based on
the results of various tests. It is used for reference together with the state of repair and the history of
operation to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground,
insert the safety pins, and use blocks to prevent the machine from moving.
When working with other workers, always use signals and do not let unauthorized people near
the machine.
When checking the coolant level, always wait for the coolant to cool down. If the radiator cap is
removed when the coolant is still hot, the coolant will spurt out and cause burns.
Be careful not to get caught in the fan, fan belt or other rotating parts.
GD555, 655, 675-3A 20-1

(6)
TESTING AND ADJUSTING STANDARD VALUE TABLE
STANDARD VALUE TABLE

STANDARD VALUE TABLE FOR ENGINE
Machine Model GD555-3A GD555-3A

Serial No. 10001 – 11000 11001 and up
Engine VHP Specification Machine VHP Specification Machine
Item Measurement Conditions Unit SA6D102E-1 SAA6D102E-2
Standard Permissible Standard Permissible
Value Value Value Value
Engine speed High idle rpm 2,200 ± 50 2,200 ± 50 2,200 ± 50 2,200 ± 50

Low idle 800 ± 100 800 ± 100 850 ± 50 850 ± 50
Rated speed 2,000 2,000 2,000 2,000
Exhaust
temperature At rated output
°C 385 – 485 — 550 – 650 —
(Intake air temp. 20 °C)
(Turbine inlet temp.)
kPa Max. 3.7 Max. 6.2 Max. 3.7 Max. 6.2
Intake resistance At rated output
{mm Aq} {380} {635} {380} {635}
Sudden acceleration Bosch Max. 6.0 Max. 7.0 Max. 4.5 Max. 5.5
Exhaust gas color
High idle index Max. 1.0 Max. 2.0 Max. 1.0 Max. 2.0
Valve clearance Intake valve 0.25 — 0.25 —

(Cold) mm
Exhaust valve 0.51 — 0.51 —
At rated output
Blowby pressure Coolant temperature: kPa 0.65 3.3 0.49 2.0
(SAE 15W-40 oil) {mmH2O} {66} {337} {50} {200}
Operating range
Coolant temperature:
Operating range
Oil pressure MPa 0.4 Min. 0.27 0.39 – 0.64 Min. 0.25
At rated output
(SAE 15W-40 oil) {kg/cm2} {4.1} {2.8} {4.0 – 6.5} {2.6}
0.19 Min. 0.07 Min 0.15 Min. 0.09
At low idle {1.9} {0.7} {1.5} {0.9}
Oil temperature Whole speed range °C Max. 127 Max. 127 80 – 110 Max. 120
(Inside oil pan)
Fuel injection timing Before top dead center degrees 12.5 – 14.5 — 9.5 – 10.5 —
New 12 – 13 Max. 11 or 12 – 13 Max. 11 or
belt Min. 14 Min. 14
Deflection when pressed with
Fan belt When finger force of approx. mm
tension adjust- Max. 13 or Max. 13 or
98 N {10 kg} 14 – 16 14 – 16
ing belt Min. 17 Min. 17
tension
20-2 GD555, 655, 675-3A

(6)
GD655-3A GD655-3A GD675-3A GD675-3A

10001 - 11000 11001 and up 10001 – 11000 11001 and up
VHP Specification Machine VHP Specification Machine VHP Specification Machine VHP Specification Machine
SA6D114E-1 SAA6D114E-2 SA6D114E-1 SAA6D114E-2
Standard Permissible Standard Permissible Standard Permissible Standard Permissible
Value Value Value Value Value Value Value Value
2,200 ± 50 2,200 ± 50 2,200 ± 50 2,200 ± 50 2,200 ± 50 2,200 ± 50 2,200 ± 50 2,200 ± 50
800 ± 100 800 ± 100 800 ± 100 800 ± 100 800 ± 100 800 ± 100 800 ± 100 800 ± 100
1,900 1,900 1,900 1,900 1,900 1,900 1,900 1,900
375 – 475 — 450 – 550 — 365 – 465 — 490 – 550 —
Max. 3.7 Max. 6.2 Max. 3.7 Max. 6.2 Max. 3.7 Max. 6.2 Max. 3.7 Max. 6.2
{380} {635} {380} {635} {380} {635} {380} {635}
0.30 — 0.30 — 0.30 — 0.30 —
0.61 — 0.56 — 0.61 — 0.56 —
0.9 4.5 1.57 2.55 2.0 4.5 1.57 2.55

{92} {460} {160} {260} {204} {460} {160} {260}
0.4 Min. 0.27 0.29 – 0.49 Min. 0.21 0.4 Min. 0.27 0.29 – 0.49 Min. 0.21
{4.1} {2.8} {3.0 – 5.0} {2.1} {4.1} {2.8} {3.0 – 5.0} {2.1}
0.16 Min. 0.07 Min. 0.12 Min. 0.07 0.16 Min. 0.07 Min 0.12 Min. 0.07
{1.6} {0.7} {1.2} {0.7} {1.6} {0.7} {1.2} {0.7}
Max. 127 Max. 127 80 – 110 Max. 120 Max. 127 Max. 127 80 – 110 Max. 120
13 – 15 — 7.5 – 9.5 — 13 – 15 — 7.5 – 9.5 —

Max. 11 or Max. 11 or Max. 11 or Max. 11 or
12 – 13 Min. 14 12 – 13 Min. 14 12 – 13 Min. 14 12 – 13 Min. 14
Max. 13 or Max. 13 or 14 – 16 Max. 13 or 14 – 16 Max. 13 or

14 – 16 14 – 16
Min. 17 Min. 17 Min. 17 Min. 17
GD555, 655, 675-3A 20-3

(8)
STANDARD VALUE TABLE FOR CHASSIS
Category Item Measurement Conditions Unit Standard Value

Amount of movement at center of lever knob when
Fuel control lever 216 ± 10
moved from LOW
Accelerator pedal Amount of up-down movement at tip of pedal 60 ± 10
Inching pedal Amount of up-down movement at tip of pedal 44 ± 10
NP Engine speed stopped, travel at tip of lever 35 ± 5
N  F1 Engine speed stopped, travel at tip of lever 30 ± 5
12 Engine speed stopped, travel at tip of lever 30 ± 5
Travel
34 Engine speed stopped, travel at tip of lever mm 30 ± 5

Gearshift
lever 56 Engine speed stopped, travel at tip of lever 30 ± 5
N  R1 Engine speed stopped, travel at tip of lever 30 ± 5
Max. 35
Fuel control lever Max. value at tip of lever just before end of travel {Max. 3.5}
Accelerator pedal Operating effort at position 150 mm from center of Max. 90

pedal rotation. Max. value just before end of travel. {Max. 9}
Operating
effort
Operating effort at position 150 mm from center of N 60 – 95

Inching pedal
pedal rotation. Max. value just before end of travel. {kg} {6 – 9.5}
Operating effort at position 150 mm from center of 275 ± 28
Brake pedal pedal rotation. Measure with wheels fully locked. {28.1 ± 2.8}
Gearshift lever Measure at center of lever grip. Max. value just before Max. 45
(Including parking brake lever) end of travel {Max. 4.5}
Inching pedal height
(When not operated) 188 ± 5
Inching pedal height Height from floor surface to tip of pedal. mm 104 ± 5
(When operated)
Others
Inching pedal play 0

Run engine at full throttle, set to R4, GD555 1,580 ± 100
depress the brake pedal, release the inch-
Transmission slippage ing pedal. Measure time taken for engine GD655 rpm 1,700 ± 100
speed to enter specified range. GD675 1,730 ± 100
20-4 GD555, 655, 675-3A

(6)
Standard Value
Cate- Measurement
gory Item Conditions Unit GD655-3A Permissible Value
GD555-3A
GD675-3A
1st 3.3 ± 0.2 3.3 ± 0.2 —
2nd 4.8 ± 0.3 4.7 ± 0.3 —
3rd 6.8 ± 0.4 6.7 ± 0.4 —
4th 9.8 ± 0.5 9.7 ± 0.5 —
Forward Flat, dry road surface:
5th • Oil temperature and pres- 14.9 ± 0.8 14.6 ± 0.7 —
sure within operating
Travel speed
6th 21.6 ± 1.1 21.2 ± 1.1 —

range
7th 29.6 ± 1.5 29.1 ± 1.5 —
• Engine at the rated speed km/h
8th • Work equipment 42.9 ± 2.1 42.1 ± 2.1 —
unloaded
1st 4.4 ± 0.2 4.3 ± 0.2 —
• Tires inflated to the speci-
fied pressure (*1) 8.9 ± 0.5
2nd (*2) 9.0 ± 0.5 8.8 ± 0.5 —
Reverse (*1) 18.7 ± 1.0 (*1) 18.1 ± 1.0
3rd —
(*2) 19.7 ± 1.0 (*2) 19.3 ± 1.0
(*1) 36.1 ± 2.0 (*1) 35.1 ± 2.0
4th —
(*2) 39.1 ± 2.0 (*2) 38.4 ± 2.0
Engine stopped:
• Measure at the tip of the
Travel
Leaning lever.
control lever mm 22 ± 5 —
• Measure travel from neu-
tral to end of travel.
Controls
Operating effort
Engine stopped:
• Measure at center of lever
Leaning grip. N Max. 24.5
control lever —
{kg} {2.5}
• Max. value to end of
travel
Engine stopped:
Play • Pull the pedal to this side, Max. 5 Max. 5
Brake pedal performance
then measure.
mm
Engine stopped:
Travel • Measure at the tip of the 66 ± 4 66 ± 10
Brake
pedal.
Hydraulic oil temperature:
Brake oil MPa 3.9 –+0.1
+1
3.9 –+0.1
+1
45 – 50°C 0.31 {40 – 3 } 0.31 {40 –3 }
pressure {113° – 122°F} {kg/cm2}
Stopping When braking from a speed Max. 13

of 35 km/h m Max. 11 (SAE standard =
distance
{21.7 mph} Max. 15.1 m)
*1. For Serial No. 10001 – 11000

*2. For Serial No. 11001 and up
GD555, 655, 675-3A 20-5

(6)
Standard Value
Cate- Measurement
gory Item Conditions Unit GD655-3A Permissible Value
GD555-3A
GD675-3A
Raise front tires 50 to 100 mm
from the ground.
• Turn the steering wheel and
Steering wheel play then measure the distance to mm 0 – 10 —
the point where the wheels
start to turn to side.
Raise front tires 50 to 100 mm
from the ground. Check the
Steering
point where the steering wheel

starts to turn, then turn steering
wheels fully and measure the
Lock-to-lock distance to the point where the — 5 – 9.5 —
steering wheel stops turning.
• The result depends on the
steering speed.
• Check distance to both left
and right.
Steering wheel Engine at low idle when travel- N Max. 49
operating effort ling in F1. {kg} {5} —
20-6 GD555, 655, 675-3A

(6)
Cate- Measurement
gory Item Conditions Unit Standard Value Permissible Value
Put dial gauge in contact with

Tire runout mm Max. 7 —
sidewall of both front and rear
GD555-3A 13.00-24-10 PR 270 {2.75}
kPa
Steering
Tire inflation pressure GD655-3A 14.00-24-10 PR 245 {2.50} —

Wheel
{kg/cm 2}
GD675-3A 14.00-24-12 PR 270 {2.75}
Camber Flat, paved road surface degree 0 —
Toe-in mm 0 – –5 —
Leaning angle • Angle of knuckle bracket degree 21.7 —
Blade lift lever (Right,
22 ± 5 —
left)
Blade side shift lever 22 ± 5 —
Drawbar shift lever Engine stopped: 22 ± 5 —
Travel
Circle rotation lever • Measure at tip of lever 22 ± 5 —

• Measure travel from Neu- mm
Power tilt lever tral to end of travel 22 ± 5 —
Articulation lever 22 ± 5 —
Scarifier lever 22 ± 5 —
Ripper lever 22 ± 5 —
Blade lift lever (Right, Max. 24.5
left) {2.5} —
Controls
Max. 24.5
Blade side shift lever —
{2.5}
Max. 24.5
Drawbar shift lever {2.5} —
Operating effort
Circle rotation lever Engine stopped: Max. 24.5 —

• Measure at center of lever N {2.5}
grip {kg} Max. 24.5
Power tilt lever • Max. value to end of travel —
{2.5}
Articulation lever Max. 24.5 —

{2.5}
Max. 24.5
Scarifier lever —
{2.5}
Max. 24.5
Ripper lever —
{2.5}
+1.0
Accumulator
Charge cut-in pressure 9.4 0 9.4 ± 1

Engine at low idle: {93.6
+10 {93.6 ± 10}
MPa 0 }
• Hydraulic oil temperature:
{kg/cm 2} +0.5
45 – 55°C 13.4 0 13.4 ± 1
Charge cut-out pressure +5
{136.5 0 } {136.5 ± 10}
GD555, 655, 675-3A 20-7

(6)
GD555-3A GD655-3A, GD675-3A

Cate- Measurement
gory Item Conditions Unit Std. Permis. Permis.
Value Value Std. Value Value
Engine full throttle: Left
Raise Oil temp. 40 ± 5 °C 2.7 ± 0.4 4 2.7 ± 0.4 4
Blade Right
lifting Independent op.
Make a mark on the Left
speed
Lower cylinder rod and 2.7 ± 0.4 4 2.7 ± 0.4 4
operate it 350 mm. Right
Blade Left 6.9 ± 0.8 9 6.9 ± 0.8 9
sideshift
speed Engine full throttle:
with cir- Oil temp. 40 ± 5 °C
cle Set height of bottom edge of
move- Right blade to 100 mm with blade at 7.5 ± 0.8 10 7.5 ± 0.8 10
ment center as standard condition.
Work equipment speed
(Draw-
bar)
Blade Left 9.1 ± 1.0 11 9.1 ± 1.0 11
sideshift
speed Engine full throttle: Seconds
Oil temp. 40 ± 5 °C
com-
pared to Set height of bottom edge of
Right blade to 100 mm with blade at 9.1 ± 1.0 11 9.1 ± 1.0 11
circle
(Blade center as standard condition.
shift)
Engine full throttle:
Blade rotation
speed Oil temp. 40 ± 5 °C 8.8 ± 1.3 12 8.8 ± 1.3 12
Time taken to turn 90°
Work equipment
Engine stopped: (*1) 1.8 ± 0.3 3

Make mark on the Raise 1.6 ± 0.3 3
cylinder rod and (*2) 1.1 ± 0.2 2
Scarifier lifting
speed operate it the dis-
tance shown below: (*1) 1.8 ± 0.3 3
GD555 → 200 mm Lower 1.6 ± 0.3 3
GD655 → 180 mm
GD675 → 180 mm (*2) 1.5 ± 0.3 3
Engine stopped:
Blade drift Downward movement of cyl- 10 20 10 20
inder when blade is sus-
pended at right angle.
Engine stopped:
Scarifier drift Downward movement of cyl- 10 20 10 20
inder when scarifier is sus-
Hydraulic drift
pended.
Engine stopped: mm/
Oil temp. 40 ± 5 °C 10Min.
Chassis drift Downward movement of cyl-
when pushed up inder when blade after blade 20 35 20 35
with blade is lowered to ground and
used to raise front wheels
from ground.
Engine stopped:
Chassis drift
Downward movement of cyl-
when pushed up inder after scarifier is lowered 20 35 20 35
with scarifier
to ground and used to raise
front wheels from ground.
*1. For Serial No. 10001 – 11000

20-8 GD555, 655, 675-3A

(3)
GD555-3A GD655-3A, GD675-3A

Cate- Measurement
gory Item Conditions Unit Permis. Permis.
Std. Value Value Std. Value Value
Work Work Engine full throttle: 20.6 ± 1 — 20.6 ± 1 —

equip. equip. • Oil temperature: {210 ± 10} {210 ± 10}
hydrau- 45 – 50 °C MPa
{kg/cm2}
Hydraulic pressure
lic pres- Steer- • Operate blade lift cylinder 15.1 ± 1.0 15.1 ± 1.0
— —
sure ing {154 ± 10} {154 ± 10}
to raise
Engine at low idle (800 rpm):
Work • Oil temperature:
Hydrau- 76 — 76 —
Work equipment
lic pump equip. 45 – 50 °C

dis- • Rotate circle l/min.
charge
amount Engine full throttle:
Trans. • Oil temperature: 130 — 130 —
45 – 50 °C
Spool travel Circle: 5 Circle: 5
Main control valve
(One side) mm Others: 6 — Others: 6 —
Circle: Circle:
Engine stopped Max. 109.8 Max. 109.8
Spool operating N {11.2} {11.2}
— —
effort {kg} Others: Others:
Max. 73.5 Max. 73.5
{7.5} {7.5}
GD555, 655, 675-3A 20-9

(6)
Cate- Measurement GD655-3A,

gory Item Conditions Unit GD555-3A GD675-3A
Spool travel Circle: 5 Circle: 5
Main control valve
(One side) mm Others: 6 Others: 6
Engine stopped Circle: Max. 109.8 {11.2} Circle: Max. 109.8 {11.2}
Spool oper- N
ating effort {kg}
Others: Max. 73.5 {7.5} Others: Max. 73.5 {7.5}
Hydraulic oil temperature: 2.8 ± 0.98 2.8 ± 0.98

Unload pressure
45 – 50°C {29 ± 10} {29 ± 10}
Inlet oil Max. 0.9 Max. 0.9
pressure {Max. 9.3} {Max. 9.3}
Outlet oil Oil temperature: 60 – 80°C 0.59 ± 0.1 0.59 ± 0.1
pressure {6 ± 1.0} {6 ± 1.0}
Torque converter
Lock-up 2.01 ± 0.15 2.01 ± 0.15

pressure {20.5 ± 1.5} {20.5 ± 1.5}
Hydraulic pressure
Low 2.32 ± 0.2 2.32 ± 0.2

Main relief pressure
idle {23.7 ± 2.0} {23.7 ± 2.0}
Oil temperature: 60 – 80°C

High Engine full throttle 2.46 ± 0.2 2.46 ± 0.2
idle {25.1 ± 2.0} {25.1 ± 2.0}
MPa
{kg/cm2}
FL 2.25 ± 0.2 2.25 ± 0.2

{23 ± 2.0} {23 ± 2.0}
2.25 ± 0.2 2.25 ± 0.2
Control valve set pressure
R
{23 ± 2.0} {23 ± 2.0}
2.25 ± 0.2 2.25 ± 0.2
FH
Transmission
{23 ± 2.0} {23 ± 2.0}

Oil temperature: 60 – 80°C
2.25 ± 0.2 2.25 ± 0.2
1st {23 ± 2.0} {23 ± 2.0}
Engine full throttle
2nd 2.25 ± 0.2 2.25 ± 0.2
{23 ± 2.0} {23 ± 2.0}
3rd 2.25 ± 0.2 2.25 ± 0.2

{23 ± 2.0} {23 ± 2.0}
2.25 ± 0.2 2.25 ± 0.2
4th
{23 ± 2.0} {23 ± 2.0}
Oil temperature: 60 – 80°C (*1) (*1)
Engine coolant tempera- Base power 1,470 ± 100 GD655-3A
ture: High power 1,580 ± 100 Base power 1,610 ± 100
Operating range High power 1,700 ± 100
Run engine at full throttle,
GD675-3A
Engine speed
set to R4, depress the brake

pedal and then release the Base power 1,655 ± 100
Engine speed at inching pedal. Measure High power 1,730 ± 100
torque converter engine speed when engine rpm
stall stalls. (*2) (*2)
Base power 1,378 ± 100 GD655-3A

High power 1,552 ± 100 Base power 1,559 ± 100
High power 1,665 ± 100
GD675-3A
Base power 1,593 ± 100
High power 1,698 ± 100
*1. For Serial No. 10001 – 11000

20-10 GD555, 655, 675-3A

(6)
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Sys- Connector Inspection Measurement

tem Component No. Method Judgement Table Condition
If the condition is shown in the table below, the 1. Turn starting
condition is normal. switch OFF
Switch Between T1 (7), (13) – chassis 2. Insert the
T1 Measure T-adapter
power T2 voltage
source Between T2 (1), (12) – chassis
20 – 30 V 3. Turn starting
Between T1 (7), (13) – (6), (12) switch ON
Between T2 (7), (12) – (11), (21)
Measure 2. Insert the
S-NET
voltage T-adapter
Between (4), (12) – chassis 4–8V 3. Turn starting
switch ON

VHP select Measure 2. Insert the
T3B
switch voltage Between (2) – T-adapter
VHP spec Max. 1 V
Transmission control related
chassis 3. Turn starting

switch ON

Controller

AWD select Measure AWD spec. Max. 1 V 2. Insert the
switch voltage Between (3) – T-adapter
Without AWD chassis 3. Turn starting
spec. 20 – 30 V
switch ON

Inching Measure 2. Insert the
select switch voltage Inching pedal Between (20) – T-adapter
Max. 1 V 3. Turn starting
spec. chassis
switch ON
T3A
Differential Measure Differential 2. Insert the
lock select spec. Max. 1 V
voltage Between (10) – T-adapter
switch
Without differ-
20 – 30 V switch ON
ential spec.
Type select Standard spec. Max. 1 V 2. Insert the
switch T5 Measure
(spare)
Without stan- chassis 3. Turn starting
20 – 30 V
dard spec. switch ON
GD555, 655, 675-3A 20-11

(6)

Gearshift lever 2. Insert the
Forward Measure 20 – 30 V
switch voltage at (F1) thru (F8) T-adapter
Between (10) – 3. Turn starting
Gearshift lever chassis
at any position Max. 1 V switch ON
except above.
T5
Reverse Measure 20 – 30 V
switch voltage at (R1) thru (R4) T-adapter
Between (14) –
Gearshift lever chassis 3. Turn starting
except above.
Neutral Measure at Neutral or 20 – 30 V T-adapter
signal voltage Park Between (8) – 3. Turn starting
Gearshift lever chassis switch ON
at any position Max. 1 V
except above.
T3A If the condition is shown in the table below, the 1. Turn starting
at any position
Controller
Drive lever Measure 20 – 30 V T-adapter

(A) voltage except Neutral 3. Turn starting
or Park Between (18) –
chassis switch ON
Gearshift lever
except above.
Drive lever Measure at (F1), (F5) thru 20 – 30 V T-adapter
(B) voltage (F7) and (R1) 3. Turn starting
thru (R3) Between (7) –
chassis switch ON
Gearshift lever
except above.
T5
Drive lever Measure at (F1) thru (F5) 20 – 30 V T-adapter
(C) voltage and (R1) Between (15) – 3. Turn starting
except above.
Drive lever Measure 20 – 30 V
(D) voltage at (F1) thru (F3) T-adapter
Between (8) – 3. Turn starting
Gearshift lever chassis
except above.
20-12 GD555, 655, 675-3A

(6)

Drive lever Measure at (F3) thru (F6) 20 – 30 V T-adapter
(E) voltage and (R1), (R2) Between (16) – 3. Turn starting
T5 except above
Measure Reset switch 2. Insert the
Reset switch Max. 1 Ω
resistance ON T-adapter
Between (9) –
Reset switch
Min. 1 MΩ switch ON
OFF
Transmission Control Related
Initialize switch 2. Insert the

Memory Measure Max. 1 Ω
(Memory reset) T-adapter
reset switch resistance Between (11) – 3. Turn starting
Initialize switch
(Initialize learn- chassis switch ON
Controller
Min. 1 MΩ
ing function or
OFF)
T3A
Initialize switch 2. Insert the
Initialize Measure (Initialize learn- Max. 1 Ω T-adapter
switch resistance ing function) Between (13) – 3. Turn starting
Initialize switch chassis switch ON
(Memory reset Min. 1 MΩ
or OFF)
Measure Mode switch is 2. Insert the
Mode switch 1 20 – 30 V
Mode switch is
2 Max. 1 V switch ON
T5
Differential Measure Differential 2. Insert the
20 – 30 V
switch voltage switch ON Between (9) – T-adapter
Differential
Max. 1 V switch ON
switch OFF
GD555, 655, 675-3A 20-13

(6)

Potentiometer 2. Insert the
Hi set switch T3B
Measure Max. 1 Ω
resistance set switch HI T-adapter
Between (1) –
Potentiometer chassis 3. Turn starting
set switch Min. 1 MΩ switch ON
LOW or OFF
Potentiometer 2. Insert the
Low set T5 Measure set switch HI Min. 1 Ω T-adapter
switch resistance or OFF Between (12) 3. Turn starting
Potentiometer – chassis switch ON
set switch Max. 1 MΩ
LOW

Between (7) – (16) 4.75 – 5.25 V 2. Insert the
T-adapter
Between (3) – (16) 0.5 – 4.75 V
Controller
3. Turn starting
Between (3) – (16) at low idle 1.0 – 2.0 V switch ON
Accelerator
Measure Between (3) – (16) at high idle 2.4 – 4.3 V
potentiome-
ter signal voltage
The above table shows the specified value for
the voltage for the potentiometer that allows the
controller to recognize the dial range correctly.
When adjusting the potentiometer, allow a mar-
gin for the error judgement range. At low idle,
adjust within the range of 1.0 to 2.0 V. The error
judgement range is potentiometer < 0.5 V or
T3A potentiometer voltage > 4.5 V
Between (7) – (16) 4.75 – 5.25 V 2. Insert the
T-adapter
Between (13) – (16) 0.5 – 4.75 V
3. Turn starting
Inching Between (13) – (16) inching switch ON
potentiome- Measure pedal not depressed (Min. 0.8 – 1.6 V
voltage travel)
ter signal
Between (13) – (16) inching
3.2 – 4.0 V
pedal depressed (Max. travel)
At minimum travel, adjust within the range of 0.8
to 1.6 V. The error judgement range is potentiom-
eter < 0.5 V or potentiometer voltage > 4.5 V.
20-14 GD555, 655, 675-3A

(6)

If the condition is as shown in the table below, 1. Turn starting
Transmis- the condition is normal. Measure with AC range. switch OFF
sion input Measure 2. Insert the
T5
shaft speed voltage
sensor Between (2) – (1) 0.5 V T-adapter
3. Start engine
If the condition is as shown in the table below, 1. Turn starting

the condition is normal. Measure with AC range. switch OFF
Transmis- 2. Insert the
sion output T4 Measure T-adapter
shaft speed T5 voltage 3. Start the
sensor Between T4 (1) – T5 (1) 0.5 V engine and
operate the
gear shift lever

At (F1), (F3), 2. Disconnect the
(F5), and (F7) Max. 1 Ω
connector
FL clutch fill Measure 3. Connect the
T36
switch resistance Between (1) – T-adapter
At any posi- chassis 4. Start the
tion except Min. 1 MΩ engine and
above operate the
gear shift lever

(F6), and (F8) Max. 1 Ω
connector
FH clutch fill Measure 3. Connect the

T37
Controller

above operate the
gear shift lever

At (R1) thru 2. Disconnect the
(R4) Max. 1 Ω
connector
R clutch fill Measure 3. Connect the
T38
above operate the
gear shift lever

and (R1) Max. 1 Ω
connector
1st clutch fill Measure 3. Connect the
T39
above operate the
gear shift lever

and (R2) Max. 1 Ω
connector
2nd clutch Measure 3. Connect the
T40
fill switch resistance Between (1) – T-adapter
above operate the
gear shift lever
GD555, 655, 675-3A 20-15

(6)

and (R3) Max. 1 Ω
connector
3rd clutch fill Measure 3. Connect the
switch T41 resistance Between (1) – T-adapter
above operate the
gear shift lever

and (R4) Max. 1 Ω
connector
4th clutch fill Measure 3. Connect the
T42
above operate the
gear shift lever

At (F1) to (F8), 2. Disconnect the
(R1) to (R2) connector
Max. 1 Ω
Mode switch 3. Connect the

is 1
Lockup clutch fill Measure T-adapter
switch T43 resistance Between (1) – 4. Mode selector
chassis switch: Mode 1
At (R3), (R4) 5. Start the
Mode switch Min. 1 MΩ
engine and
is 1
operate the
gear shift lever

Measure Between (1) – (2) 5 – 15 Ω 2. Disconnect the
FL solenoid T24 resistance connector
Between (1) – chassis Min. 1 MΩ 3. Connect the
T-adapter

FH solenoid T25
resistance connector
3. Connect the
Between (1) – chassis Min. 1 MΩ
T-adapter

R solenoid T26 resistance connector
3. Connect the
T-adapter

1st solenoid T27 resistance connector
3. Connect the
T-adapter
20-16 GD555, 655, 675-3A

(6)

2nd solenoid T28
3. Connect the
T-adapter

3rd solenoid T29
3. Connect the
T-adapter

4th solenoid T30
3. Connect the

T-adapter

Lock-up solenoid T31
T-adapter

T/C output Measure 25 °C 2. Disconnect the
hydraulic temper- T34 normal temp. 38 – 48 kΩ
resistance Between (1) – connector
ature sensor
(2) 3. Connect the
100 °C 3.7 – 4.0 kΩ T-adapter

T/M hydraulic Measure 25 °C 2. Disconnect the
temperature sen- T35 38 – 48 kΩ
resistance normal temp. Between (1) – connector
sor
(2) 3. Connect the
100 °C 3.7 – 4.0 kΩ T-adapter

Hydraulic temper- Measure 25 °C 2. Disconnect the
E5 38 – 48 kΩ
ature sensor resistance normal temp. Between (1) – connector
(2) 3. Connect the
100 °C 3.7 – 4.0 kΩ T-adapter
GD555, 655, 675-3A 20-17

(6)

condition is normal. Measure with AC range. switch OFF
Transmission Between (1) – (2) 500 – 1,000 Ω 2. Disconnect the
input shaft speed T32 Measure
sensor
Between (1), (2), – chassis Min. 1 MΩ 3. Connect the
T-adapter
1. Screw the transmission input shaft speed sen-

Transmission sor in until it contacts the ring gear, then turn
input shaft speed — Adjust —
back 1/2 to 1 turn.
sensor
2. Works normally after above adjustment.

condition is normal. Measure with AC range. switch OFF
Transmission Between (1) – (2) 500 – 1,000 Ω 2. Disconnect the
Measure
output shaft T33
speed sensor
3. Connect the
Between (1), (2), – chassis Min. 1 MΩ
T-adapter
1. Screw the transmission output shaft speed

Transmission sensor in until it contacts the ring gear, then
output shaft — Adjust —
turn back 1/2 to 1 turn.
speed sensor

Engine speed Measure Between (1) – (2) 500 – 1,000 Ω 2. Disconnect the
sensor T46 resistance connector
3. Connect the
Between (1), (2), – chassis Min. 1 MΩ
T-adapter
1. Screw the transmission input shaft speed sen-

Engine speed sor in until it contacts the ring gear, then turn
sensor — Adjust back 1/2 to 1 turn. —

Engine start sole- Measure Between (1) – (2) 0.5 – 1.0 Ω 2. Disconnect the
B20
noid resistance connector
3. Connect the
T-adapter
20-18 GD555, 655, 675-3A

(6)

Lifter lock sole- Measure Between (1) – (2) 40 – 60 Ω 2. Disconnect the
noid FL7 resistance connector
T-adapter

Parking brake Measure Between (1) – (2) 40 – 60 Ω 2. Disconnect the
solenoid FL8 resistance connector
T-adapter

Accumulator Measure Between (1) – (2) 20 – 30 Ω 2. Disconnect the
solenoid (Left) FL9 resistance connector
3. Connect the
T-adapter

Accumulator Measure Between (1) – (2) 20 – 30 Ω 2. Disconnect the
FL10
solenoid (Right) resistance connector
T-adapter

Float solenoid FL11 Measure Between (1) – (2) 20 – 30 Ω 2. Disconnect the
(Right) FL12 resistance connector
3. Connect the
T-adapter

Float solenoid FL13 Measure Between (1) – (2) 20 – 30 Ω 2. Disconnect the
(Left) FL14 resistance connector
3. Connect the
T-adapter

Articulate 2. Disconnect the
80 – 100 Ω
angle: 0° connector
Articulator sensor FL6 Measure Articulate 3. Connect the
resistance angle: Between (1) – 180 – 200 Ω T-adapter
Left 23° (2)
Articulate
angle: 5 – 15 Ω
Right 23°
GD555, 655, 675-3A 20-19

(6)
TESTING AND ADJUSTING
Tools for testing, adjusting, and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-102

Measuring exhaust color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-103
Measuring blowby pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-104
Measuring engine oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
Measuring engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
Testing fan belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
Testing air conditioner compressor belt tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-107
Measuring torque converter stall speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-107
Checking clutch oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-108
Checking torque converter oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-109
Adjusting speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110
Flushing torque converter, transmission circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-112
Adjusting accelerator control linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-113
Testing brake disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-114
Testing and adjusting parking brake pad clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-115
Testing accumulator charge pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
Testing and adjusting work equipment oil pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
Testing and adjusting LS differential pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-117
Adjusting PC valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
Bleeding air from hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
Measuring internal cylinder leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120
Measuring steering, brake oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-122
Bleeding air from brake piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-123
Charging brake, work equipment accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-124
Testing and adjusting circle guide clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-125
Testing and adjusting slip clutch-type rotary device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-126-1
Memorizing idle and full position procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-127
Initial learning method for transmission controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-128
Diode checking procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130
Moving machine when transmission valve fails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-131
Adjusting cab stopper bolt (if equipped with cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-133
GD555, 655, 675-3A 20-101

(6)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUST-

ING, AND TROUBLESHOOTING
Check or Measure-
Symbol Part Number Part Name Remarks
ment Item
1 799-203-8001 Multi-tachometer Digital display
Engine speed A L: 60 – 2,000 rpm
2 795-790-2500 Adapter H: 60 – 19,999 rpm
Coolant and oil
B 799-101-1502 Digital temperature gauge -99.9 – 1,299 °C
temperature
Pressure gauge
799-101-5002 Hydraulic tester 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester 58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic gauge 1.0 MPa {10 kg/cm2}
799-101-5160 • Nipple RC 1/8
3
799-101-5220 Nipple M10 x 1.25
Oil pressure C 4 799-401-2701 Differential pressure gauge DC 12 V
5 790-261-1231 Elbow M10 x 1.25 (RC 1/8)
Both male and female 14 x 1.5
790-261-1311
(RC 1/8)
Both male and female 14 x 1.5
6 790-261-1321 Adapter (RC 1/8)
790-261-1331 Both male and female 14 x 1.5

(RC 1/8)
1 799-201-9000 Handy smoke checker Discoloration 0 – 70 percent
Exhaust color D (with standard color)
2 Commercially Smoke meter Discoloration % x 1/10
available = Bosch index
1 799-201-1504 Blowby checker 0 to 4,900 Pa {0 – 500 mm H2O}
orifice diameter: 7.67 mm
799-201-1511 • Nozzle
Blowby pressure E (114 engine)
2
orifice diameter: 5.613 mm
795-790-1950 Nozzle (102 engine)
79A-264-0021 0 – 294 N {0 – 30 kg}
Operating effort F Push-pull scale
79A-261-0091 0 – 490 N {0 – 30 kg}
Commercially
Stroke G Scale —
available
Troubleshooting of 799-601-2500 —
wiring harness and H T-adapter assembly
sensors 799-601-9200 For DT series
Measuring volt- Commercially
age and resis- I Tester —
tance values available
Charging accumu- J 792-610-1700 Charging tool —

lator
Procedure for
moving machine
K 794-423-1190 Plug —
when transmission
valve fails
20-102 GD555, 655, 675-3A

(9)
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR

• When measuring in the field where there is 2. Connect the air hose of the probe hose accel-
no air or electric power supply, use tool D1; erator switch to the tool D2.
when recording formal data, use tool D2. ★ Keep the air pressure supply below 1.47 MPa
★ Increase the coolant temperature to the oper- {15 kg/cm 2}.
ating temperature range before measuring.
3. Connect the power cord to the AC 100 V
MEASURING WITH D1 socket.
★ When connecting the cord, check that the
1. Install the filter paper to tool D1. power switch of tool D2 is OFF.
2. Insert the exhaust gas suction port into the
exhaust pipe.
3. Accelerate the engine suddenly while simul-
taneously operating the handle of tool D1.
4. Remove the filter paper and compare it with
the scale supplied to judge the condition.
4. Loosen the cap nut of the suction pump and

fit the filter paper.
★ Fit the filter paper securely so that exhaust
gas cannot leak.
5. Turn the power switch of tool D2 ON.

6. Accelerate the engine suddenly while simul-
taneously depressing the accelerator pedal of
MEASURING WITH D2 tool D2 to collect the exhaust gas color on the
filter.
1. Insert the probe [1] into the outlet port of the 7. Place the filter paper used to catch the
exhaust pipe (1) and tighten the clip to secure exhaust gas color on top of at least 10 sheets
the probe to the exhaust pipe. of unused filter paper inside the filter paper
holder.
8. Read the value shown.
GD555, 655, 675-3A 20-103

(6)
TESTING AND ADJUSTING MEASURING BLOWBY PRESSURE
MEASURING BLOWBY PRESSURE

★ Before measuring the blowby pressure, • If it is impossible to run the engine at the
heighten the coolant temperature to the oper- rated power or perform a stall operation,
ating range. measure while the engine is running at high
idle. The value obtained in this case is about
1. Connect the nozzle E2 of the blowby checker 80 percent of the blowby pressure at the rated
E1 to the end of the engine breather hose (1). output.
★ The blowby pressure may vary largely with

the engine condition. If the measured value is
judged abnormal, check for oil consumption
increase, bad exhaust gas color, oil deteriora-
tion, high speed of oil deterioration, etc.,
which are related to the abnormal blowby
pressure.
2. Connect the nozzle E2 to the blowby checker

E1.
3. Run the engine at the rated output and mea-

sure the blowby pressure.
Take care not to touch the hot or rotat-

ing parts during measurement.
★ The regular blowby pressure is measured

while the engine is running at the rated out-
put.
• In the field, perform a stall operation for an

approximate value.
20-104 GD555, 655, 675-3A

(6)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL MEASURING ENGINE SPEED

PRESSURE
Do not touch any hot parts when han-
★ Increase the coolant temperature to the oper- dling the measuring tools.
ating temperature range before measuring.
★ Measure the engine speed per listed condi-
1. Remove the pressure measurement sensor tions:
(1), then install the oil pressure gauge C2 a. Coolant temperature: operating range.
(0.98 MPa {10 kg/cm2}). b. Power train oil temperature: 60 – 80°C
c. Hydraulic temperature: 45 – 55°C
GD555-3A
1. Remove the cap of the speed pickup port.
2. Install the adapter assembly A2 to the speed
pickup port, then install the tachometer sen-
sor [1] and connect to the body A1.
GD655-3A, GD675-3A
2. Start the engine and measure the oil pressure

at low idle and the rated speed.
GD555, 655, 675-3A 20-105

(6)
TESTING AND ADJUSTING TESTING FAN BELT TENSION
3. Start the engine and measure the engine TESTING FAN BELT TENSION
speed at high and low idle.
1. Testing belt tension
When measuring the engine speed, be Measure the deflection A of the belt when the
careful not to touch the rotating or hot belt is pressed with a force of approx.
parts. 98 N {10 kg} at a point midway between the
fan pulley and tension pulley.
★ When measuring items other than above

(torque converter stall), see the measurement
procedure for each item.
GD655-3A, GD675-
Model GD555-3A
3A
Belt Deflection A mm Deflection A mm
New belt 12.2 – 13.3 11.8 – 12.8
After adjusting
14.7 – 16.0 14.0 – 15.6
tension
2. Adjusting the belt tension

1) Loosen the nut (1).
2) Loosen the locknut (2), then turn the
adjustment nut (3) to adjust the belt ten-
sion.
3) After adjusting the belt tension, tighten
the nut (1) and then the locknut (2).
20-106 GD555, 655, 675-3A

(6)
TESTING AND ADJUSTING TESTING AIR CONDITIONER COMPRESSOR BELT TENSION
TESTING AIR CONDITIONER MEASURING TORQUE CON-

COMPRESSOR BELT TENSION VERTER STALL SPEED
1. Testing belt tension Do not touch the hot parts when mea-
Measure the deflection a of the belt when the suring. And ensure that no one is near
belt is pressed with a force of approx. the machine during the procedure.
98 N {10 kg} at a point midway between the Apply chocks to the tires.
fan pulley and tension pulley.
★ Measure the torque converter stall speed under

the following conditions:
• Coolant temperature: operating range.
• Power train oil temperature: 60 – 80°C
• Hydraulic temperature: 45 – 55°C
★ Avoid stalling for more than 20 seconds so that the
torque converter oil temperature will not exceed
120°C.
1. Remove the cap from the engine speed pick-up

port, install the adapter assembly A2 and multita-
chometer sensor [1], then connect to the main
body A1.
Belt Deflection a mm
New belt 15 – 16
After adjusting 17 – 19
2. Adjusting belt tension.

1) Loosen the locknut (1), then turn the
adjustment bolt (2) and move the com-
pressor (4) with the shaft (3) at the center
to adjust the belt tension.
2) After adjusting the belt tension, tighten
the locknut (1).
2. Start the engine and run at low idle.

3. Depress the brake pedal. Stop the engine and
move the gearshift lever to TOP reverse speed R4.
★ If the gear speed is not R4, the machine may move
and the clutch may be damaged, even if the brake
pedal is pressed fully.
4. Measure the speed when the accelerator pedal or
the regulator lever is set to the full throttle position.
★ Measure when the engine speed is stable.
GD555, 655, 675-3A 20-107

(6)
TESTING AND ADJUSTING CHECKING CLUTCH OIL PRESSURE
CHECKING CLUTCH OIL PRESSURE
Set the front frame and rear frame fac-

ing straight to the front, then secure in
position with the lock pin.
Raise the tandem drive with a hydrau-

lic jack and raise the 4 rear wheels off
the ground.
Set the blade a right angles to the

chassis and lower the blade com-
pletely to the ground.
The oil is hot, so be careful not to burn

yourself.
Stop the engine before removing or

installing the plug or pressure gauge.
★ Oil temperature when measuring: 60 – 80 °C
1. Checking transmission modulating oil pres-

sure (Clutch circuit oil pressure)
1) Measure the main relief oil pressure and
check that it is normal.
2) Remove the plugs (1) thru (7) from the
places to be measured, then install tool
ECMV clutch actuation table
C1.
ECMV
All gauges: 5.88 MPa {60 kg/cm2} FL FH R 1st 2nd 3rd 4th
Speed
Range
Oil Pressure Oil Pressure
Plug No. Circuit Plug. No. Circuit F1 { {
1 FL clutch 5 R clutch F2 { {
2 FH clutch 6 3rd clutch F3 { {
3 1st clutch 7 4th clutch F4 { {
4 2nd clutch — — F5 { {
F6 { {
Plug size: RC 1/8 or 1/4 F7 { {
F8 { {
3) Run the engine at low idle and shift the R1 { {
gearshift lever to the speed range (oil R2 { {
pressure circuit) to be measured.
R3 { {
4) Run the engine at full throttle and mea-
sure the clutch pressure of that circuit. R4 { {
N
20-108 GD555, 655, 675-3A

(6)
TESTING AND ADJUSTING CHECKING TORQUE CONVERTER OIL PRESSURE
CHECKING TORQUE CONVERTER OIL PRESSURE

3. Torque converter outlet port pressure
1) Measurement port: 3 (Rc 1/8)
Set the front frame and rear frame fac- 2) Start the engine and measure the pres-
ing straight to the front, then secure in sure at low idle and high idle.
position with the lock pin.
4. Torque converter lock-up port pressure
Raise the tandem drive with a hydrau- 1) Measurement port: 4 (Rc 1/4)
lic jack and raise the 4 rear wheels off 2) Start the engine and measure the pres-
the ground. sure at high and low idle.
Set the blade at right angles to the

chassis and lower the blade com-
pletely to the ground.
The oil is hot, so be careful not to burn

yourself.
Stop the engine before removing or

installing the plug or pressure gauge.
1. Main relief pressure

2) Start the engine and measure the pres-
sure at low idle and high idle.
2. Torque converter inlet port pressure

2) Start the engine and measure the pres-
sure at low idle and high idle.
GD555, 655, 675-3A 20-109

(6)
TESTING AND ADJUSTING ADJUSTING SPEED SENSOR
ADJUSTING SPEED SENSOR

1. Engine speed sensor 2. Transmission input shaft speed sensor
1) Screw the sensor (1) in by hand until the 1) Screw the sensor (4) in by hand until the
sensor tip contacts the gear (2). sensor tip contacts the gear (2).
★ When positioning the sensor tip in contact ★ When positioning the sensor tip in contact
with the gear, tighten lightly by hand and with the gear, tighten lightly by hand and
check that the sensor is in contact. Never use check that it is in contact. Never use a wrench
a wrench or any other tool when tightening. or any other tool to tighten the sensor.
2) When the sensor (4) tip contacts the gear

(2), screw the sensor out 1/2 to 1 turn.
Standard clearance a: 0.68 – 1.13 mm
3) Tighten the locknut (3) from
49.0 – 68.6 Nm {5 – 7 kgm}
★ Tighten the sensor carefully to prevent exces-

sive force being applied to the sensor wiring.
★ Be careful not to scratch the sensor tip or let
any iron filings or powder stick to the tip.
2) When the sensor (1) tip contacts the gear

(2), screw the sensor out 1/2 to 1 turn.
49.0 – 68.6 Nm {5 – 7 kgm}

20-110 GD555, 655, 675-3A

(6)
TESTING AND ADJUSTING ADJUSTING SPEED SENSOR
3. Transmission output shaft speed sensor

1) Screw the sensor (5) in by hand until the
sensor tip contacts the gear (2).
★ When positioning the sensor tip in contact

with the gear, tighten lightly by hand and
check that the sensor is in contact. Never use
a wrench or any other tool when tightening.
2) When the sensor (5) contacts the gear (2),

screw the sensor out 1/2 to 1 turn.
49.0 – 68.6 Nm {5 – 7 kgm}

GD555, 655, 675-3A 20-111

(6)
TESTING AND ADJUSTING FLUSHING TORQUE CONVERTER, TRANSMISSION CIRCUIT
FLUSHING TORQUE CONVERTER, TRANSMISSION CIRCUIT

★ Metal particles and other dirt in the torque ★ If the ambient temperature is low and the
converter and transmission hydraulic circuit engine coolant temperature gauge does not
will reduce the torque converter and trans- enter the green range, continue the warming-
mission life, and will cause internal damage. up operation longer.
To prevent this situation, flush the system to 2) Travel or perform the actual operations
remove the dirt in the hydraulic circuit. for at least 20 minutes.
★ Use all the speed ranges (FORWARD,
1. Flush the circuit, if the following conditions REVERSE, and 1st thru 8th).
apply.
3) Repeat the procedure in Step 4.1 and run
1) If there has been any breakage of the
the engine at low idle for approx. 20 min-
torque converter, transmission, or
utes.
hydraulic equipment, and metal particles
5. Replace the flushing element.
are circulating in the hydraulic circuit.
1) Using the procedure in Step 2.1, replace
2) When the torque converter and transmis-
the flushing element with the standard
sion have been overhauled or repaired.
element (714-07-28711).
2. Cleaning the filter
2) Add oil and check the level again.
1) After removing the filter, remove the
6. Replace the transmission fail-safe filter.
drain plug (1) and drain the system.
1) Remove the mounting bolt (3) of the filter
assembly (2), then remove the filter
assembly.
2) Remove the element (4) and replace it
with a new element.
★ If there is any dirt inside the filter case (5),
wash the case.
3) Install a new O-ring (6) to the outside cir-
cumference of the case (5).
★ Coat the outside circumference of the O-ring
with a small amount of grease.
4) Install the case (5).
Case bolts: 34.3 – 44.1 Nm {3.5 – 4.5 kgm}
5) Install the filter assembly (2).
2) Remove the transmission oil filter, clean
the inside, then reinstall the element for a
second flushing.
3. Fill the transmission case with oil.

• Add fresh oil through the oil filler port to the
specified level, and run the engine to circulate
the oil through the system. Then check the
level again.
Transmission case: 45 l
4. Perform the flushing as follows.
1) After starting the engine, run the engine
for approx. 20 minutes at low idle, with-
out operating the gearshift lever.
★ From time to time, increase the engine speed
to approx. 1,500 rpm.
20-112 GD555, 655, 675-3A

(6)
TESTING AND ADJUSTING ADJUSTING ACCELERATOR CONTROL LINKAGE
ADJUSTING ACCELERATOR CONTROL LINKAGE
1. Procedure for adjusting the accelerator pedal:

• Remove the floor mat to adjust.
1) Set the installed height of the stopper bolt (1) to dimension A.
Dimension A: 75 mm
2) Set the installed length of pedal (2) to dimension B.

Dimension B: 193 mm
3) Set the installed length of cable (3) to dimensions C and D.

(Unit : mm)
Serial No. GD555-3A GD655, 675-3A
Item 10001 – 11000 11001 and up 10001 – 11000 11001 and up
Dimension C 289 290 289 290
Dimension D 322.5 280 331.5 332
4) Adjust the rod length (4) so that the idle speed is 800 to 850 rpm.
Dimension E of rod (4) (standard length): 459 mm
5) Depress the pedal (2) until it contacts the stopper bolt (1), and adjust the rod length (4) so that the
engine governor lever (5) is at the end of its stroke (engine high idle: 2,200 ± 50 rpm).
Dimension E of rod (4) (standard length): 459 mm
6) Turn back the stopper bolt (1) one-half turn and lock in position.
(Prevent the engine governor from hitting against the engine strongly.)
GD555, 655, 675-3A 20-113

(6)
TESTING AND ADJUSTING TESTING BRAKE DISC
2. Procedure for adjusting the regulator lever TESTING BRAKE DISC

★ Adjust the accelerator pedal before adjusting
the regulator lever. Stop the machine on flat ground and
1) Set the installed length of the spring unit put blocks under the front wheels.
(6) to dimension F.
Dimension F: 290 mm
1. Remove the rear wheel assembly. For details,
2) Adjust with the stopper bolt (8) so that the
see REMOVAL OF REAR WHEEL ASSEMBLY.
speed changes from idle speed to
2. Apply the brake, remove the cap (1), then
2,200 ± 50 rpm when operating the regu-
push in the pin (2).
lator lever (7).
3. Measure the height of the pin tip (2) and the
guide end face (3).
Height (new part): 1.8 – 2.0 mm
4. If the pin tip (2) and the guide end face (3) are
level, replace the disc.
20-114 GD555, 655, 675-3A

(6)
TESTING AND ADJUSTING TESTING AND ADJUSTING PARKING BRAKE PAD CLEARANCE
TESTING AND ADJUSTING PARKING BRAKE PAD CLEARANCE

7) Tighten the bolt (9) so that the front and
the rear pads (1) contact disc (2).
Stop the machine on flat ground and put 8) Tighten the bolt (8) until it contacts the
blocks under the front wheels. urethane spring (10), then tighten the bolt
an additional 1/2 turn.
9) Tighten the nut (7) from 242 – 302 Nm
1. Checking the parking brake pad clearance {24.7 – 30.8 kgm}.
1) Start the engine, charge the accumulator Target: 272 Nm {27.7 kgm}
with hydraulic oil, then stop the engine. 10) Loosen the adjustment bolt (9) to adjust
2) Turn the engine starting switch to the ON so that the total clearance (a+b) between
position and set the gearshift lever to the the disc and pads is from 0.5 – 0.8 mm.
N position.
3) Measure the front and rear clearances (a
and b) between the parking brake pad (1)
and disc (2).
4) If the total clearance (a+b) is more than
2.5 mm, follow the procedure for adjust-
ing the parking brake pad clearance
below to adjust the clearance.
★ Total clearance new part (a+b): 0.5 – 0.8 mm
11) Position the bolt tip (6) in contact with the

bracket (11). Turn the bolt and adjust so
that the clearance (a+b) between the disc
(2) and pads (1) is uniform. Torque the
double nut (5) from 24.1 – 30.1 Nm {2.46
– 3.07 kgm}
Target: 27.1 Nm {2.76 kgm}
12) Secure the adjustment bolt (9) with the
locknut (4) torqued from
2. Adjusting the parking brake pad clearance 102.8 – 128.2 Nm {10.5 – 13.1 kgm}.
1) Start the engine, charge the accumulator Target: 115.5 Nm {11.8 kgm}
with hydraulic oil, then stop the engine. 13) Check the clearance between the disc (2)
2) Turn the starting switch ON and set the and pads (1) again.
gearshift lever to the N position. 14) Install the plug (3).
3) Measure the parking brake pad (1) thick- 15) Set the gearshift lever to the P position
ness. and check that the clearence between the
pads (1) and disc (2) is removed.
• If thickness is 3 mm or more: Use again
• If thickness is less than 3 mm: Replace
4) Remove the plug (3); loosen the locknut If the adjustment procedure for Steps
(4). 3) thru 15) takes longer than 15 min-
5) Loosen the double nut (5), then loosen the utes, perform the adjustment proce-
bolt (6) five turns. dure continuously after completing the
6) After loosening the nut (7), loosen the bolt procedure in Steps 1) and 2).
(8) three turns.
16) Turn the engine starting switch OFF.
GD555, 655, 675-3A 20-115

(6)
TESTING AND ADJUSTING TESTING ACCUMULATOR CHARGE PRESSURE
TESTING ACCUMULATOR TESTING AND ADJUSTING

CHARGE PRESSURE WORK EQUIPMENT OIL PRES-
SURE
★ Hydraulic oil temperature: 45 – 55 °C
Stop the engine, loosen the oil filler

Stop the engine and depress the brake cap slowly to release the pressure
pedal slowly at least 30 times to inside the hydraulic tank.
release the pressure inside the accu-
mulator circuit.
1. Remove the accumulator inlet port pressure 1. Measuring unload oil pressure
switch (1) (Rc 1/4), then install tool C1 1) Remove the pressure measurement plug
{39.2 MPa or 400 kg/cm2}. (1) (M10 x 1.25).
2. Measure the accumulator charge cut-out pres- 2) Fit the nipple C3, then install the oil pres-
sure. Start the engine, run the engine at low sure gauge C1 (5.9 MPa {60 kg/cm2}).
idle, and measure the rise in pressure. The 3) Run the engine at full throttle and mea-
point where the pressure stops rising is the cut- sure the oil pressure with all levers at
out pressure. HOLD.
3. Measure the accumulator charge cut-in pres- 2. Measuring work equipment pressure (relief
sure. Start the engine, run the engine at low pressure)
idle, wait for the accumulator charge cut-out, 1) Remove the pressure measurement plug
then depress and release the brake repeatedly
(1) (M10 x 1.25).
to lower the pressure. The point where the
2) Fit the nipple C3, then install the oil pres-
pressure starts to rise again is the cut-in pres-
sure. sure gauge C1 (39.2 MPa {400 kg/cm2}).
3) Run the engine at full throttle and mea-
sure the relief pressure; operate the blade
lift lever to the RAISE position.
4. After stopping the engine, press and release

the brake pedal slowly at least 20 times repeat-
edly, then run the engine at low idle. The initial
pressure at this time is the accumulator gas
charge pressure, which is
3.4 ± 0.1 MPa {35 ± 1.0 kg/cm2}.
5. Charge fully (to the cut-out pressure) with the
engine at full throttle, then stop the engine.
Turn the starting switch to the ON position and
press and release the brake pedal repeatedly.
At this time, if the low brake oil pressure cau-
tion buzzer sounds before the brake pedal is
pressed 10 times, check the accumulator gas
pressure.
• For the method of checking the accumula-
tor gas pressure, see Procedure for Charg-
ing Accumulator for Brake and Work
Equipment with Nitrogen Gas.
20-116 GD555, 655, 675-3A

(6)
TESTING AND ADJUSTING TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE
ADJUSTING TESTING AND ADJUSTING LS

1. Adjusting the LS relief valve DIFFERENTIAL PRESSURE
★ If the work equipment oil pressure is not nor-
1. Measuring LS differential pressure with the
mal, adjust the LS relief valve (2) as follows.
main relief differential pressure gauge
1) Loosen the locknut (3) and turn the adjust- i. Remove the high-pressure (1) and
ment screw (4) as follows. low-pressure (2) measurement plugs.
• To INCREASE the pressure, turn CLOCKWISE.
• To DECREASE the pressure, turn COUNTER-
CLOCKWISE.
ii. Fit the elbow C5 and nipple C3.
★ One turn of the adjustment screw equals

15.1 MPa {154 kg/cm2}.
2) After adjusting, tighten the locknut (3)
from 68.6 – 78.5 Nm {7 – 8 kgm}.
★ After completing the adjustment, use the
measurement procedure above to check the
oil pressure again.
iii. Connect the differential pressure

gauge C4.
★ Connect the LS pump pressure (1) to the

high-pressure side of the differential pressure
gauge and LS pressure (2) to the low-pres-
sure side.
GD555, 655, 675-3A 20-117

(6)
TESTING AND ADJUSTING TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE
iv. Set to the conditions in Table 1, and ★ Read the gauge indicator while standing
measure the LS differential pressure. directly in front of it.
v. Set to the conditions in Table 1, and
Table 1
measure the LS pressure.
Differential
Accelerator Operation Pressure ★ Read the gauge indicator while standing
MPa {kg/cm2} directly in front of it.
2.84 – 3.9
Full Levers at neutral LS differential pressure = (LS pump pressure) –
{29 – 40}
Blade lever
(LS pressure)
2.35 ± 0.1
Full (Operate fully to {24 ± 1}
raise)
ADJUSTING LS VALVE
2. Measuring with an oil pressure gauge When measuring the differential pressure under
★ Measure with the same gauge. the above conditions and the pressure is not
i. Remove the high-pressure (1) and within the standard value, adjust as follows.
low-pressure (2) oil measurement
plugs. 1. To adjust the differential pressure, loosen the
locknut (2) and turn the screw (3).
• To INCREASE the pressure, turn CLOCKWISE.
• To DECREASE the pressure, turn COUNTER-
CLOCKWISE.
One turn of the adjustment screw equals 1.3 MPa
{13.3 kg/cm2}.
2. After adjusting, tighten the locknut (2) to 49 –
63.7 Nm {5 – 6.5 kgm}.
Note: Always measure the differential pressure

while adjusting.
ii. Fit the elbow C5 and nipple C3.
iii. Connect the differential pressure

gauge C1 (39.2 MPa {400 kg/cm2}).
★ Use a gauge with a scale in units of 9.8 MPa
{10 kg/cm2}.
iv. Set to the conditions in Table 1, and
measure the LS pump pressure.
20-118 GD555, 655, 675-3A

(6)
TESTING AND ADJUSTING ADJUSTING PC VALVE
ADJUSTING PC VALVE BLEEDING AIR FROM HYDRAU-

LIC CIRCUIT
★ If the load becomes high and the engine
speed drops, or the engine speed remains
1. Bleeding air from the pump
normal and the work equipment becomes
1) Loosen the air bleed plug (1), and bleed
slower, but the pump discharge pressure and the air from the pump.
the LS differential pressure are normal, adjust
★ When air no longer is discharged with the oil,
the PC valves as follows.
the air bleeding operation is completed.
2) Tighten the plug (1) from 14.7 – 19.6 Nm
1. Loosen the locknut (1) and turn the sleeve (2)
{1.5 – 2.0 kgm}.
to adjust as follows.
★ Precautions when starting the engine
• If the work equipment speed is slow, turn
CLOCKWISE. After completing the above procedure and
• If the engine speed drops, turn COUN- starting the engine, run the engine at low idle
TERCLOCKWISE for 10 minutes.
★ Turning the sleeve clockwise increases
the pump absorption torque.
★ Turn the adjustment sleeve within a range
of 180° to the left or right.
2. After adjusting, tighten the locknut (1) to 88 –
113 Nm {9 – 11.5 kgm}.
2. Bleeding air from the pump circuit

1) Start the engine, remove the plugs (1) and
(2), and bleed the air.
★ When air no longer is discharged with the
oil, the air bleeding operation is com-
pleted.
2) Tighten the plugs (1) and (2).
GD555, 655, 675-3A 20-119

(6)
TESTING AND ADJUSTING MEASURING INTERNAL CYLINDER LEAKAGE
3. Bleeding air from the hydraulic cylinder MEASURING INTERNAL CYLIN-

1) Start the engine and run at low idle for
approx. 5 minutes. DER LEAKAGE
2) Run the engine at low idle, and raise and
lower the boom 4 to 5 times in succes- ★ If the hydraulic drift of the work equipment is
sion. not within the standard value, measure the
amount of leakage inside the cylinder as fol-
★ Operate the piston rod to approx. 100 mm
lows to judge if the cause of the hydraulic
before the end of its stroke. Do not relieve
drift is in the cylinder or in the control valve.
the circuit under any circumstances.
3) Run the engine at full throttle and repeat • If the amount of leakage is within the stan-
Step 2). After that, run the engine at low dard value, the problem is with the control
idle and operate the piston rod to the end valve.
of its stroke to relieve the circuit. • If the amount of leakage is not within the
4) Repeat Steps 2) and 3) to bleed the air standard value, the problem is with the cylin-
from all the cylinders. der.
1. Fully extend the cylinder rod to be measured,
then stop the engine.
★ When measuring the blade lift and the scari-
fier cylinders, lower the work equipment to
the ground, remove the joint at the rod end
from the work equipment, then extend the
cylinder.
2. Disconnect the piping at the head end, and
block the piping (1) at the chassis end with a
blind plug.
Be careful not to disconnect the piping

at the bottom end.
3. Start the engine, then run the engine at high

idle and apply the relief pressure to the bot-
tom end of the cylinder.
4. Wait 30 seconds, then measure the amount of
oil that leaks during the next minute.
★ Minimum leakage: 10 cc
BLADE LIFT CYLINDER
L.H. R.H.
20-120 GD555, 655, 675-3A

(6)
TESTING AND ADJUSTING MEASURING INTERNAL CYLINDER LEAKAGE
BLADE SHIFT CYLINDER LEANING CYLINDER
POWER TILT CYLINDER ARTICULATION CYLINDER
R.H. L.H.
DRAWBAR SHIFT CYLINDER
RIPPER CYLINDER
GD555, 655, 675-3A 20-121

(3)
TESTING AND ADJUSTING MEASURING STEERING, BRAKE OIL PRESSURE
MEASURING STEERING, BRAKE OIL PRESSURE

sure gauge C1 (5.88 MPa {60 kg/cm2}).
Stop the machine on flat ground,
apply the parking brake, and lower the
blade completely to the ground.
Stop the engine, loosen the oil filler

cap slowly to release the pressure
inside the hydraulic tank.
1. Measuring the steering circuit pressure

1) Remove the oil pressure measurement
plug, 10 x 1.25, (1) at the front of the
pump.
sure gauge C1 (39.2 MPa {400 kg/cm2}).
3) Run the engine at full throttle, and mea-
sure the oil pressure after relieving the
left or right steering circuits (operate to 3) Measure the oil pressure after depressing
the end of the stroke). the brake pedal.
★ After measuring the oil pressure, install
the plug and bleed the air from the sys-
tem.
2. Measuring the brake circuit pressure

★ After charging the brake accumulator fully
with oil pressure, stop the engine.
1) Remove the air bleed plug (2) (Rc 1/4).
20-122 GD555, 655, 675-3A

(6)
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE PIPING
BLEEDING AIR FROM BRAKE PIPING

2. Bleeding the air between the slack adjuster
and the brake
Stop the machine on flat ground and 1) Install the vinyl tube (4) to the tip of the air
put blocks under the front wheels. bleed valve (3).
★ Start the engine and charge the accumulator.
1. Bleeding the air between the brake valve and

the slack adjuster
1) Open the battery cover, then install vinyl
tube (2) to the tip of air bleed valve (1) at
the top face of the slack adjuster.
2) Depress the brake pedal and loosen the

air bleed valve (3) 3/4 turns, then close the
valve and release the pedal.
3) Continue this procedure until no more
bubbles exit with the oil discharged from
the air bleed valve (3).
4) Bleed the air from the brake air bleed
valves at four places on the left and right.
2) Depress the brake pedal and loosen the

air bleed valve (1) 3/4 turns, then close the
valve and release the pedal.
3) Continue this procedure until no more
bubbles exit with the oil discharged from
the air bleed valve (1).
4) Bleed the air from the slack adjuster air
bleed valves at 2 places on the left and
right.
GD555, 655, 675-3A 20-123

(6)
TESTING AND ADJUSTING CHARGING BRAKE, WORK EQUIPMENT ACCUMULATOR
CHARGING BRAKE, WORK EQUIPMENT ACCUMULATOR

WITH NITROGEN GAS 8. Open the valve of the nitrogen cylinder slowly
and charge the cylinder (bladder) with the
1. Before charging with gas, check that the oil nitrogen gas.
pressure is completely released. ★ While doing this step, close the nitrogen
★ If the oil pressure is not released, it is cylinder valve from time to time, wait for
impossible to charge with the nitrogen the charging assembly pressure gauge to
gas. become stable, and check the displayed
2. Turn the charging assembly handle [1] coun- pressure.
terclockwise and raise it to the point where it 9. When the gas is charged to the specified
stops. pressure, close the valve of the nitrogen cylin-
3. Turn the bleed plug handle [2] counterclock- der securely.
wise to open it. ★ If the pressure in the cylinder is too high,
turn the handle [2] counterclockwise grad-
ually to release the excessive pressure.
1) Accumulator (721-32-10241, capacity: 3 l):
• Specified pressure at 20 ± 5 °C: 3.4 ± 0.1 MPa
{35 ± 1.0 kg/cm2}
• The relationship between the temperature
and pressure of the charged gas at the time of
charging is as follows.
Px = 35(kg/cm2) x {273 + t(°C)}/{273 + 20(°C)}
Px: Pressure of charged gas

t: Gas temperature when charging
(nearly ambient temperature)
4. Remove the cap from the gas valve (1), then 35: Specified gas pressure
assemble the charging assembly to the gas 2) Accumulator (721-32-10251, capacity: 1 l):
valve (1). • Specified pressure at 20 ± 5 °C: 2.0 ± 0.1 MPa
{20 ± 1.0 kg/cm2}
• The relationship between the temperature
and pressure of the charged gas at the time of
charging is as follows.
Px = 20(kg/cm2) x {273 + t(°C)}/{273 + 20(°C)}
Px: Pressure of charged gas
t: Gas temperature when charging
(nearly ambient temperature)
20: Specified gas pressure
10. Turn the handle [1] counterclockwise. Return
the gas valve piston to its original position.
Then, turn the handle [2] counterclockwise to
5. Connect the nitrogen cylinder and charging release the gas remaining inside the hose and
assembly with hose assembly [3]. charging assembly.
6. Open the nitrogen cylinder valve slightly, take 11. Remove the charging assembly from the
care that the gas does not discharge quickly, accumulator.
and let the gas flow at a pressure from
0.20 – 0.29 MPa {2 – 3 kg/cm2}. When the gas
starts to exit from the handle [2], turn the han-
dle [2] clockwise to stop the gas from escap-
ing.
7. Turn the handle [1] slowly clockwise to push
the piston of the gas valve (1).
20-124 GD555, 655, 675-3A

(6)
TESTING AND ADJUSTING TESTING AND ADJUSTING CIRCLE GUIDE CLEARANCE
12. Use water or soapy water to check that the TESTING AND ADJUSTING CIR-
gas is not leaking from the gas valve (1).
Install the cap and valve guard. CLE GUIDE CLEARANCE
★ After charging with nitrogen gas, check the If the following conditions occur dur-
charge pressure about a week later to verify ing adjustment, replace the circle
pressure is maintaining. After that, check guide.
once every month or once every six months,
according to the conditions of use. Note that • When clearance R between the circle and cir-
when the check is performed, the pressure cle guide is lost.
will go down. Thus, add a slight charge to
• When the clearance between the tip (or root)
replace the pressure that is lost.
of the teeth of the circle gear and the root (or
tip) of the teeth of the pinion gear of the circle
rotation gear becomes zero (0).
TESTING
1. Testing clearance in top-to-bottom direction
• Let the blade hang and measure clearance P
between the top face of the circle and the bot-
tom face of the drawbar as shown in the dia-
gram.
Standard clearance P: 1.5 ± 0.5 mm
2. Checking clearance in front-to-rear direction
• Leave the blade hanging down, apply force to
the rear, then measure clearance Q between
the circle and circle guide as shown in the fig-
ure.
Standard clearance QF (front): 0 mm
QC (center): 0.7 mm ([*1])
QR (rear): 1.5 mm
or QF = QR = 1 mm
(*1: Except GD555-3A)
ADJUSTING
1. Adjusting clearance in top-to-bottom direc-
tion
i. Raise the blade, remove the bolts [1],
[5], and [9], and circle guides [2], [6],
and [10].
Adjust with shims.
★ Standard shim thickness: 5.5 mm
(Shim thickness: 1 mm, 0.5 mm)
GD555, 655, 675-3A 20-125

(6)
TESTING AND ADJUSTING TESTING AND ADJUSTING CIRCLE GUIDE CLEARANCE
3) When QF = 0, tighten locknut [4], then

tighten bolt [1] from 490.3 – 608 Nm
{50 – 62 kgm}
3. Adjusting clearance in left-to-right direction
1) Loosen the bolt [9] and locknut [12],
extend bolt [11], and push the circle guide
[10] open to make QR = 0.
★ Push open the left and right circle guides
[10] uniformly.
2) Loosen the bolt [5] and locknut [8]. Extend
the bolt [7], and push the circle guide [6]
open to make QC = 0.
(*: Except GD555-3A)
★ Push open left and right circle guides [6]
uniformly.
3) When QR = 0, turn the bolt [11] back 1/4
turn, and tighten the locknut [12]. Turn
back the circle guide [10] until it contacts
the bolt [11]. Then tighten the bolt [9]
from 490.3 – 608 Nm {50 – 62 kgm}.
4) The standard clearance between the tip of
the teeth of the circle gear and the root of
the teeth of the pinion gear of the rotation
gear is from 1.5 – 3.0 mm.
5) When QC = 0, turn the bolt [7] back 1/2
turn and tighten locknut [8]. Turn back the
circle guide [6] until it contacts the bolts
[7]. Tighten the bolt [5] from 490.3 – 608
Nm {50 – 62 kgm}.
(*: Except GD555-3A)
6) Check that the circle guide rotates even
when the work equipment is set to the 90°
high bank position on the left and right.
2. Adjusting clearance in front-to-rear direction
1) Bring the blade lightly into contact with
the ground. Loosen the bolt [1] and lock-
nut [4]. Extend the bolt [3]. Push the circle
guide [2] open to make QF = 0.
★ Push open the left and right circle guides
[2] uniformly.
2) Adjust clearance D between the end face
of the flange at the bottom of the circle
rotation gear and the sliding surface on
the inside diameter of the circle.
Standard clearance at D:
15 to 17 mm (shear pin type)
20 to 22 mm (slip clutch type)
20-126 GD555, 655, 675-3A

(6)
TESTING AND ADJUSTING TESTING AND ADJUSTING SLIP CLUTCH-TYPE ROTARY DEVICE
TESTING AND ADJUSTING

SLIP CLUTCH-TYPE ROTARY
DEVICE
TESTING
1. Remove bolts (1) and cover (2).
2. Check that you can see the internal teeth of

worm wheel (3) through the hole at P.
4. Run the engine at full throttle and operate the

circle rotation lever slowly to see if the clutch
slips.
• Check by rotation of worm wheel (3).
• If worm wheel (3) rotates and the blade
does not rotated, the clutch is slipping.
ADJUSTING
1. When clutch does not slip
1) Remove bolts (4) and holder (5) and add 1
3. Press the blade against the ground and raise shim 0.2 mm thick (6).
the front wheel to lock the circle or fix the 2) Install holder (5) and tighten bolts (4).
blade end.
3 Bolt (4):
• How to raise the front wheel 110.5 ± 12.5 Nm {11.25 ± 1.25 kgm}
1) Lower the blade to the ground and extend
the blade lift cylinder until the front
wheels are raised.
2) Apply the parking brake.
3) Check the clutch for slipping according to

the "testing" procedure.
4) Repeat steps 1) - 3) until the clutch slips
and set the clutch to the critical slipping
point.
5) If the clutch comes to slip, remove 1 shim
0.2 mm thick (6).
After the shim is adjusted, the clutch must
not slip.
GD555, 655, 675-3A 20-126-1

(3)
TESTING AND ADJUSTING TESTING AND ADJUSTING SLIP CLUTCH-TYPE ROTARY DEVICE
2. When clutch slips 3. Installation of cover

1) Remove bolts (4) and holder (5), and then 1) Install cover (2) and tighten bolts (1).
3 Bolt (1):
remove 1 shim 0.2 mm thick (6).
2) Install holder (5) and tighten bolts (4).
3 Bolt (4):
65.7 ± 6.8 Nm {6.7 ± 0.7 kgm}
110.5 ± 12.5 Nm {11.25 ± 1.25 kgm}
RUNNING IN CLUTCH
3) Check the clutch for slipping according to • After the clutch disc is replaced with new one,
the "testing" procedure. run in the clutch according to the following
4) Repeat steps 1) - 3) until the clutch does procedure.
not slip and set the clutch to the critical When installing the disc, apply oil GO #90
slipping point. to its both sides.
5) At the critical slipping point, remove 1 1) Set the clutch to the critical slipping point
shim 0.2 mm thick (6). according to adjusting steps 1 and 2.
After the shim is adjusted, the clutch must 2) Add 1 shim 0.2 mm thick so that the
not slip. clutch will slip.
3) Slip the clutch for 3.5 - 4.0 seconds.
• Run the engine at full throttle.
• The clutch rotates 1 turn while it is
slipping for 3.5 - 4.0 seconds.
4) Repeat step 2) by 20 - 25 times at intervals
of 3 minutes.
If the clutch housing tempera-

ture exceeds 50 °C, stop the
work until it lowers to the nor-
mal temperature.
If the clutch stops slipping dur-
ing the work, add 1 shim 0.2
mm thick.
5) Wait until the clutch is cooled to the nor-

mal temperature.
6) Set the clutch to the critical slipping point
again (according to steps 1 and 2).
7) Remove 1 shim 0.2 mm thick so that the
clutch will not slip.
20-126-2 GD555, 655, 675-3A

(3)
TESTING AND ADJUSTING MEMORIZING IDLE AND FULL POSITION PROCEDURE
MEMORIZING IDLE AND FULL POSITION PROCEDURE

ACCELERATOR, INCHING POTENTIOMETER
★ If the accelerator pedal assembly, accelerator 2. Memorizing the full position
linkage and inching pedal assembly have 1) Depress the accelerator pedal and inching
been removed or replaced, perform the oper- pedal fully.
ation to memorize the idle position and full 2) Turn the starting switch to the ON posi-
position after installing. tion.
★ For the accelerator, perform the operation 3) Push the potentiometer set switch (1) up
after adjusting the accelerator control linkage. for at least 1 second.
★ If the buzzer sounds continuously for 2
1. Memorizing the idle position
seconds, the value for the accelerator and
1) Release the accelerator pedal and inching
inching potentiometer full position has
pedal, and leave the pedal free.
been stored correctly.
2) Set the regulator lever to the idle position.
3) Turn the starting switch to the ON posi- ★ If the buzzer sounds three times in a cycle
tion. of 1 second ON, 1 second OFF, the setting
4) Push the potentiometer set switch (1) has not been stored in memory.
down for at least 1 second.
★ If the buzzer sounds continuously for 2 sec- Measuring voltage
onds, the value for the accelerator and inch- Pedal Connector
Potentiometer
Voltage
ing potentiometer idle position has been
stored correctly. Accelerator T9 C to B 2.42 – 4.3
Inching T8 C to B 3.2 – 4.0
★ If the buzzer sounds three times in a cycle of 1
second ON, 1 second OFF, the setting has not
been stored in memory.
Measuring voltage
Pedal Connector Potentiometer
Voltage
Accelerator T9 C to B 1–2
Inching T8 C to B 0.8 – 1.6
GD555, 655, 675-3A 20-127

(6)
TESTING AND ADJUSTING INITIAL LEARNING METHOD FOR TRANSMISSION CONTROLLER
INITIAL LEARNING METHOD FOR TRANSMISSION CONTROLLER

• The transmission controller has a self-correct- 5) Set to N, run the engine at low idle for 3
ing and learning function which reduces the minutes, check again that the oil is at the
difference in the operation feeling caused by specified oil level, then turn the engine
the individual difference of the hydraulic starting switch OFF.
valves to a certain level and keeps the gear- 2. Resetting learned data
shifting feeling constant even if the transmis- ★ Do as follows to return all the previously
sion clutch is worn. learned control data in the controller to
• If the transmission is overhauled or replaced, the default values.
or the hydraulic valves are replaced, the 1) Check that the starting switch is at the
transmission controller still has the control OFF position.
command values learned to match the previ- 2) Turn the starting switch ON. (Do not start
ous transmission. For this reason, transmis- the engine.)
sion shock, abnormal noise, or defective 3) Push the memory set/learning function
operating feeling may occur. initializing switch (1) down for at least 1
• After operating the machine for a short time, second, then turn the starting switch OFF.
the controller will learn the condition of the 3. Method for learning correction for individual
new transmission and will gradually return to differences in valves
the optimum condition, but if it is desired to • When correcting the individual differences in
reset the condition quickly and to carry out the valves, do as follows. The correction oper-
resetting of the learned data, learning of cor- ation is for three types of clutch: FL, FH, and
rection of individual valve differences, and R.
initial learning of stabilized transmission feel- 1) Start the engine and run it at low idle.
ing as follows. (Depress the accelerator pedal, then let it
1. Preparation of machine for learning of correc- back fully.)
tion for individual differences in valves and 2) Push memory set/learning function initial-
initial learning of transmission feeling stabili- izing switch (1) up, then within 0.8 sec-
zation. onds, push the reset switch. Hold it in this
• It is necessary to carry out the learning opera- condition for at least 1 second, then
tion at the specified oil temperature, so do as release the switch.
follows to raise the oil temperature.
1) Depress the brake pedal fully, set the
gearshift lever to R4, stall the torque con-
verter, and raise the transmission oil tem-
perature. During the stall operation, keep
the gearshift lever at R4 and do not shift
to any other speed range. (If the stall
operation is carried out in any speed
range other than R4, there is danger that
the machine may pitch or the clutch may
be damaged.)
2) Raise the machine and set it on a stand to
keep the rear wheels off the ground.
3) Operate the gearshift lever as follows to
circulate the oil fully through the trans-
mission valves and the whole of the case.
P → N → F1 → F2 → F3 → F4 → N → R1 →
R2 → R3 → R4 → N
4) Use the above operation to raise the oil
temperature to 50 – 60 °C.
20-128 GD555, 655, 675-3A

(6)
TESTING AND ADJUSTING INITIAL LEARNING METHOD FOR TRANSMISSION CONTROLLER
3) The learning of the correction for individ- 2) Set the transmission mode switch to
ual differences in the valves will start and [Mode 1].
[FWL1] - [REV3] will be displayed on mes- 3) Operate the gearshift lever as follows
sage center (3). three times in succession:
P → N → F1 → F2 → F3 → F4 → F3 → F2 →
F1 → N → R1 → R2 → R3 → R4 → R3 → R2
→ R1 → N
★ When doing this, hold each speed range for
at least 3 seconds, then shift to the next speed
range.
Dis- Dis- Dis-

Item Item Item
play play play
1st 1st 1st
time FWL1 time FWH1 time REV1
for FL for FH for R
2nd 2nd 2nd
for FL for FH for R
3rd 3rd 3rd
for FL for FH for R
• The transmission oil temperature is displayed

on the controller LED during the correction of
the individual differences in the valves.
4) The corrected values are saved in the con-
troller memory and the correction learn-
ing function is automatically completed.
5) When the correction learning is com-
pleted, the message center returns to the
normal display.
6) Turn the starting switch OFF.
4. Initial learning method for stabilized trans-
mission feeling
• To adjust the controller learning control data
for each clutch from the default settings to the
optimum values, always carry out resetting of
the learned data and learning of the correc-
tion for individual differences in the valves,
then do as follows.
1) Start the engine and run at low idle.
GD555, 655, 675-3A 20-129

(6)
TESTING AND ADJUSTING DIODE CHECKING PROCEDURE
DIODE CHECKING PROCEDURE

• Use the following procedure to check the
diode as an individual part and the wiring
harness, including the diode.
• Use a digital tester with a range for measur-
ing diodes.
1. Put the red (+) test pin in contact with the
diode’s anode P, and the black (-) test pin in
contact with the cathode N.
★ A mark exists on the diode surface that shows
the direction of continuity.
2. If a normal tester is switched to the diode
range, the internal battery voltage is dis-
played.
The value indicates the following.
• No change: No continuity
• Changes: Continuity exists (normal) (Note)
• The value is 0 or near 0: Short circuit inside
the diode.
Note: With silicon diodes, a value between

0.450 and 0.600 is displayed.
20-130 GD555, 655, 675-3A

(1)
TESTING AND ADJUSTING MOVING MACHINE WHEN TRANSMISSION VALVE FAILS
MOVING MACHINE WHEN TRANSMISSION VALVE FAILS

★ If the machine cannot be moved because of a 2. Disconnect wiring connectors (2). (14 places)
failure in any part of the transmission valve
system (electrical system, solenoid valves,
spools, etc.), it is possible to move the
machine by installing Plug K.
Installation of plugs K to the ECMV is a

means to move the machine from a
dangerous job site to a safe place
where you can repair it when you can-
not move it at any gear speed because
of breakage of the transmission control
valve. Accordingly, use this method
only when the transmission control
valve is broken.
When carrying out this operation, keep

strictly to the procedure and pay care-
ful attention to safety when moving the
machine.
To prevent the machine from moving,

lower the work equipment to the
ground, apply the parking brake, and
put blocks under the tires.
Carry out operation with the engine

stopped.
Be careful not to burn yourself if the oil

is hot.
1. Remove valve cover (1) at front of transmis-

sion.
★ Clean around the ECMV and remove all
dirt and dust.
GD555, 655, 675-3A 20-131

(6)
TESTING AND ADJUSTING MOVING MACHINE WHEN TRANSMISSION VALVE FAILS
3. Depending on the direction for moving the 4. Depress the brake pedal securely.
machine (forward or reverse), remove the fol- 5. Start the engine, release the parking brake,
lowing 2 ECMV solenoids (3) and install Plug then release the brake pedal gradually to
K. allow the machine to start, then move the
• FORWARD: FL solenoid and 2nd solenoid machine.
• REVERSE: R solenoid and 2nd solenoid
★ If there is any mistake in the selection of Remove the blocks under the tires.
the solenoid to remove, there is danger
that the transmission may be damaged.
★ Install Plug K with the protruding surface When the engine is started, the trans-
facing the ECMV. Check also that there is mission is also engaged to start the
an O-ring installed to the mating surface. machine. To ensure safety when start-
★ Be careful not to let any dirt or mud get ing the engine, check carefully that the
inside the removed solenoid or valve. direction of travel and area around the
machine are safe. Always keep the
brake pedal depressed when starting.
After moving the machine, stop the

engine, apply the parking brake, and
put blocks under the tires.
20-132 GD555, 655, 675-3A

(6)
TESTING AND ADJUSTING ADJUSTING CAB STOPPER BOLT (IF EQUIPPED WITH CAB)
ADJUSTING CAB STOPPER BOLT (IF EQUIPPED WITH CAB)

1. Remove 4 stopper bolts (1). (Top, bottom, left,
right).
6. If clearance a is 8 mm, door striker (3) is not

angled to the left or right, and the center of door
striker (3) is aligned, the adjustment of door
striker (3) is correct.
★ If the adjustment of striker is correct, go on to
Step 10.
7. If the striker is angled to the left or right, install
door striker (3) so that installation height b from
the surface of door glass (6) is uniform.
• Installation height b: 67 ± 1 mm (standard)
8. If clearance a is less than 8 mm, move the mount-
ing of door striker (3) out from the surface of door
glass (6) by an amount equal to clearance a is 8
mm.
Fit the door to the cab again and check that clear-
ance a is 8 mm.
2. Check that door striker (3) is properly set and 9. If the center of door striker (3) is not aligned,
is not angled to the left or right. remove door link cover (2) and move door striker
3. Fit door striker (3) to lock (4) on the cab. (3) up or down to set it in the center.
4. Check that the centers of door striker (3) and 10. Install 4 stopper bolts (1). (Top, bottom, left,
lock (4) on cab are aligned. right).
11. Screw stopper bolts (1) fully into the cab, then fit
door striker (3) to lock (4) on the cab.
12. If there is a clearance at portion C of door glass
(6) and the rubber tip of stopper bolt (1), the con-
dition is correct.
★ If there is a clearance at portion C, go to Step
15.
13. If there is no clearance at portion C of door glass
(6) and the rubber tip of stopper bolt (1) (when
the rubber tip is pushed against the glass sur-
face), replace stopper bolt (1).
5. Check clearance a between door handle (5)

and cab (surface of glass).
• Clearance a = 8 mm
GD555, 655, 675-3A 20-133

(1)
TESTING AND ADJUSTING ADJUSTING CAB STOPPER BOLT (IF EQUIPPED WITH CAB)
★ Remove 20Y-54-11611 (length below

head: 42 mm) and install 23A-952-1430
(length below head: 32 mm)
14. Fit door striker (3) to lock (4) on the cab, and
check again that there is a clearance at por-
tion C of door glass (6) and rubber tip.
15. Turn the stopper bolt and put it in contact
with the surface of door glass (6). (Clearance
at portion C = 0)
16. With the clearance of stopper bolt (1) = 0, turn
the bolt 3 turns to the left (to move it out from
the surface of the glass).
20-134 GD555, 655, 675-3A

(6)
TROUBLESHOOTING
Troubleshooting points to remember . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-202

Troubleshooting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-203
Points to remember when performing maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-204
Checks before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-212
Connector types and mounting locations (Serial No. 10001 – 11000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-214
Connector types and mounting locations (Serial No. 11001 and up) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-219-1
Connector arrangement diagram (Serial No. 10001 – 11000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220
Connector arrangement diagram (Serial No. 11001 and up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-223-1
Connection table for connector pin numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-224
Message center display and table error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-247
Using troubleshooting charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-251
Troubleshooting of electrical system (E mode). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-301
Troubleshooting of transmission controller system (T mode). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-351
Troubleshooting of hydraulic and mechanical system (H mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-451
Troubleshooting of main monitor system (M mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-501
GD555, 655, 675-3A 20-201

(6)
TROUBLESHOOTING TROUBLESHOOTING POINTS TO REMEMBER
TROUBLESHOOTING POINTS TO REMEMBER

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are
securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns,
so wait for the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the
machine. However, a short cut to effective troubleshooting is to ask the operator various questions to form
some idea of possible causes of the failure that would produce the reported symptoms.
2) Check for any external leakage of oil from
1. When carrying out troubleshooting, do not the piping or hydraulic equipment.
hurry to disassemble the components. If com- 3) Check the travel of the control levers.
ponents are disassembled immediately after a 4) Check the stroke of the control valve spool.
failure occurs: 5) Other maintenance items can be checked
• Parts that have no connection with the fail- externally, so check any item that is consid-
ure or other unnecessary parts will be dis- ered to be necessary.
assembled. 4. Confirming the failure.
• It will become impossible to find the cause Confirm the extent of the failure yourself, and
of the failure. judge whether to handle it as a real failure or as
a problem with the method of operation, etc.
It will also cause a waste of man hours, parts,
or oil and grease. At the same time, it will also When operating the machine to re-enact
lose the confidence of the user or operator. For the troubleshooting symptoms, do not
this reason, when carrying out troubleshoot- carry out any investigation or measure-
ing, it is necessary to carry out thorough prior ment that may make the problem worse.
investigation and to carry out troubleshooting 5. Troubleshooting
in accordance with the fixed procedure. Use the results of the investigation and inspec-
2. Points to ask the user or operator. tion in Steps 2 - 4 to narrow down the causes of
1) Have any other problems occurred apart the failure, then use the troubleshooting flow-
from the problem that has been reported? chart to locate the position of the failure
2) Was there anything strange about the exactly.
machine before the failure occurred? The basic procedure for troubleshooting is
3) Did the failure occur suddenly, or were as follows.
there problems with the machine condition 1) Start from the simple points.
before this? 2) Start from the most likely points.
4) Under what conditions did the failure 3) Investigate other related parts or infor-
occur? mation.
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure.
failure? When were these repairs carried Even if the failure is repaired, if the root cause
out? of the failure is not repaired, the same failure
6) Has the same kind of failure occurred will occur again.
before? To prevent this, always investigate why the
problem occurred. Then, remove the root
3. Check before troubleshooting. cause.
1) Check the oil level.
20-202 GD555, 655, 675-3A

(3)
TROUBLESHOOTING TROUBLESHOOTING SEQUENCE
TROUBLESHOOTING SEQUENCE
GD555, 655, 675-3A 20-203

b
TROUBLESHOOTING POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE
POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be
carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed
at improving the quality of repairs. For this purpose, it gives sections on 'Handling electric equipment'
and 'Handling hydraulic equipment' (particularly hydraulic oil).
1. PRECAUTIONS WHEN HANDLING ELEC-
TRIC EQUIPMENT
1) Handling wiring harnesses and connec-
tors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protector or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations they
are frequently removed and installed again, so
they are likely to suffer deformation or dam-
age. For this reason, it is necessary to be
extremely careful when handling wiring har-
nesses.
Main failures occurring in wiring harness

➀ Faulty contact of connectors
(faulty contact between male and female).
Problems with faulty contact are likely to
occur because the male connector is not
properly inserted into the female connec-
tor, or because one or both of the connec-
tors is deformed or the position is not
correctly aligned, or because there is corro-
sion or oxidation of the contact surfaces.
➁ Defective compression or soldering of con-

nectors
The pins of the male and female connec-
tors are in contact at the compressed ter-
minal or soldered portion, but there is
excessive force on the wiring, and the plat-
ing peels to cause improper connection or
breakage.
20-204 GD555, 655, 675-3A

b
12 ➂ Disconnections in wiring
If the wiring is held and tugged and the
connectors are pulled apart, or compo-
nents are lifted with a crane with the wiring
still connected, or a heavy object hits the
wiring, the crimping compression of the
connectors to the wire may be loosened, or
the soldering may be damaged, or the wir-
ing may be broken.
➃ High pressure water entering a connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector depending on the direction
of the water jet. The connector is designed
to prevent water from entering, but if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the con-
nector, the pins will be short-circuited by
the water, so if any water gets in, immedi-
ately dry the connector or take other appro-
priate action before passing electricity
through it.
➄ Oil, grease or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, and this
will cause a defective contact. If there is oil
or grease or dirt stuck to the connector,
wipe it off with a dry cloth or blow dry with
air, and spray it with a contact restorer.
★ When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
★ If there is water or oil present, it will
increase the contamination of the
points, so clean with air until all water
and oil has been removed.
GD555, 655, 675-3A 20-205

b
2) Removing, installing, and drying connec-

tors and wiring harnesses
• Disconnecting connectors
➀ Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female con-
nectors in each hand and pull apart. For
connectors which have a lock stopper,
press down the stopper with your thumb
and pull the connectors apart.
★ Never try to pull apart with one hand.
➁ When removing the connectors from the
clips, pull the connector in a parallel direc-
tion to the clip.
★ If the connector is twisted to the left
and right or up and down, the housing
may break.
➂ Action to take after removing connectors.

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector por-
tion.
★ If the machine is left for a long time, it
is particularly easy for improper con-
tact to occur, so always cover the con-
nector.
20-206 GD555, 655, 675-3A

b
• Connecting connectors
➀ Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating
portion).
2) Check that there is no deformation,
faulty contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or
breakage to the outside of the connec-
tor.
★ If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry
cloth. If any water has gotten inside the
connector, warm the inside of the wir-
ing with a dryer, but be careful not to
make it too hot as this will cause short
circuits.
★ If there is any damage or breakage,
replace the connector.
Since the DT 8-pole and 12-pole heavy duty
wire connectors have 2 latches respec-
tively, push them in until they click 2 times.
★ 1: Male connector, 2: Female connector
• Normal locking state (Horizontal):
a, b, d
• Incomplete locking state (Diago-
nal): c
➁ Assemble the connector securely.
Align the position of the connector cor-
rectly, then insert it securely.
For connectors with a lock stopper:
Push in the connector until the stopper
clicks into position.
➂ Correct any protrusion of the boot and any
misalignment of the wiring harness.
For connectors fitted with boots, correct
any protrusion or the boot. In addition, if
the wiring harness is misaligned, or the
clamp is out of position, adjust it to its cor-
rect position.
★ When blowing with dry air, there is
danger that the oil in the air may cause
improper contact, so clean with prop-
erly filtered air.
12 ➃ When the wiring harness clamp of the con-

nector has been removed, always return it
to its original condition and check that
there is no looseness of the clamp.
GD555, 655, 675-3A 20-207

b
• Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high pressure
water or steam directly on the wiring harness.
If water gets directly on the connector, do as

follows:
➀ Disconnect the connector and wipe off the
water with a dry cloth.
★ If the connector is blown dry with air,
there is the risk that oil in the air may
cause a faulty contact, so avoid blow-
ing with air.
• ➁ Dry the inside of the connector with a

dryer.
If water gets inside the connector, use a
dryer to dry the connector.
★ Hot air from the dryer can be used, but
be careful not to make the connector or
related parts too hot, as this will cause
deformation or damage to the connec-
tor.
➂ Carry out a continuity test on the connec-

tor.
After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins TEP01357
caused by water.
★ After completely drying the connector,
spray it with contact restorer and reas-
semble.
20-208 GD555, 655, 675-3A

b
3) Handling control box

➀ The control box contains a microcomputer
and electronic control circuits.
This controls all of the electronic circuits on
the machine, so be extremely careful when
handling the control box.
➁ Do not open the cover of the control box
unless necessary.
➂ Do not place objects on top of the control

box.
➃ Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
➄ Do not leave the control box in a place
where it is exposed to rain.
➅ Do not place the control box on oil, water,

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand)
➆ Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the control box. Fit an
arc welding ground close to the welding
point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality
displays will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or
current), move the related wiring and connectors several times and check that there is no change
in the reading of the tester.
★ If there is any change, there is probably defective contact in the circuit.
GD555, 655, 675-3A 20-209

b
3. Points to remember when handling

hydraulic equipment
With the increase in pressure and precision of

hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic cir-
cuit. When adding hydraulic oil, or when disas-
sembling or assembling hydraulic equipment, it is
necessary to be particularly careful.
1) Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2) Disassembly and maintenance work in

the field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there
is danger of dust entering the equipment. It is
also difficult to confirm the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dust proof workshop, and the perfor-
mance should be confirmed with special test
equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tape, or
vinyl bags to prevent any dirt or dust from
entering. Never leave any openings opened or
blocked with a rag, this could cause particles or
dirt to get into the system.
Drain all oil into a container and not unto the
ground and be sure to follow the proper envi-
ronmental regulation for any disposal of oil.
4) Do not let any dirt, or dust get in during

refilling operations.
Be careful not to let any dirt or dust get in
when refilling with hydraulic oil. Always keep
the oil filler and the area around it clean, and
also use clean pumps and oil containers. If an
oil cleaning device is used, it is possible to fil-
ter out the dirt that has collected during stor-
age, so this is an even more effective method.
20-210 GD555, 655, 675-3A

b
5) Change hydraulic oil when the tempera-

ture is high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together
with the oil, so it is best to change the oil when
it is still warm. When changing the oil, as much
as possible of the old hydraulic oil must be
drained out. (Do not drain the oil from the
hydraulic tank; but drain the oil from the filter
and from the drain plug in the circuit.) If any
old oil is left, the contaminants and sludge in it
will mix with the new oil and will shorten the
life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and
secondary flushing is carried out with the spec-
ified hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment
(pump, control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultra fine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
GD555, 655, 675-3A 20-211

(1)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item Action
Value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
Lubricating oil, coolant
4. Check hydraulic oil strainer — Clean, drain

5. Check the transmission oil level strainer — Add oil
6. Check the final drive oil level — Add oil
7. Check the tandem drive oil level — Add oil
8. Check the circle reverse gear oil level — Add oil
9. Check the engine oil level (Oil pan oil level), oil type — Add oil
10. Check the coolant level — Add coolant
11. Check the dust indicator for clogging — Clean or replace
12. Check the hydraulic filter — Replace
1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
equipment
Electrical
2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
3. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
1. Check for abnormal noise, smell — Repair

mechanical
equipment
Hydraulic,
2. Check for oil leakage — Repair
3. Carry out air bleeding — Bleed air

1. Check battery voltage (Engine stopped) 20 — 30 V Replace
Electrics, electrical equipment
2. Check battery electrolyte level — Add or replace

3. Check for discolored, burnt, exposed wiring — Replace
4. Check for missing wiring clamps, hanging wire — Repair
5. Check for water leaking on wiring (Pay particular attention to water leak- Disconnect
—
ing on connectors or terminals) connector and dry
6. Check for blown, corroded fuses — Replace
After running for
7. Check alternator voltage (Engine running at 1/2 throttle or above) several minutes: Replace
27.5 – 29.5 V
8. Sound of actuation of battery relay (When starting switch is turned ON,
— Replace
OFF)
20-212 GD555, 655, 675-3A

(6)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

Serial No : 10001 – 11000
Connector
Type No. of Pins Mounting Location Address
No.
AC1 SWP 12 Air conditioner unit (If equipped) G-9
AC3 SWP 14 Air conditioner unit (If equipped) X-3
AC4 SWP 16 Air conditioner unit (If equipped) W-2
AC5 — 16 Air conditioner control unit (If equipped) U-7
AC8 — 7 Air conditioner intake duct (If equipped) W-2
B1 DT2(G) 12 Intermediate connector D-8
B2 DT2(Gr) 12 Intermediate connector C-8
B3 DT2(Br) 12 Intermediate connector C-8
B4 DT2(B) 8 Intermediate connector A-8
B5 DT2(G) 8 Intermediate connector C-9
B6 L 2 Intermediate connector D-8
B7 DT2(Br) 8 Intermediate connector D-9
B8 DT2(B) 12 Intermediate connector B-9
B9 DT2(Gr) 8 Intermediate connector B-9
B10 DT2(G) 8 Intermediate connector B-9
B11 L 2 Intermediate connector (Battery relay) B-8
B13 DT2 2 Brake lamp switch D-7
B15 KES 2 Window washer (Front upper) (If equipped) G-3
B16 KES 2 Window washer (Front lower) (If equipped) G-3
B17 KES 2 Window washer (Rear) (If equipped) G-3
B18 DT2 3 Float cancel switch (R.H.) D-6
B19 DT2 3 Float cancel switch (L.H.) E-5
B20 DT2 2 Engine start solenoid G-9
B21 DT2 2 Diode (Engine start up solenoid) H-9
B22 DT1 4 Intermediate connector B-8
B23 L 1 Fuse box K-7
B24 DT2(B) 8 Intermediate connector L-6
BR1 DT2 2 Diode (Battery relay) M-5
BR3 DT2 2 Diode (Buzzer) N-4
BR4 Relay 5 Alternator relay Q-1
BR5 Relay 5 Charge lamp relay Q-1
BR6 Relay 5 Back-up alarm relay R-3
BR7 Relay 5 Differential relay R-2
BR8 Relay 5 VHP relay —
BR9 Relay 5 Accumulator hydraulic pressure relay R-2
BR10 Relay 5 Brake pump relay R-3
BR11 Relay 5 Parking brake relay P-5
BR12 Relay 5 Neutral relay Q-5
BR13 Relay 6 Front work lamp relay R-3
BR14 Relay 5 Rear work lamp relay P-5, R-3
BR15 Relay 5 Float cancel relay (R.H.) R-4
BR16 Relay 5 Float cancel relay (L.H.) R-3
BR18 KES 4 Front wiper switch N-4
BR19 KES 6 Preheat timer relay R-4
BR20 KES 4 Flasher R-4
BR21 DT2 2 Buzzer (B) P-1
BR22 M 2 Buzzer (A) Q-1
BR23 DT2 2 Lift lock switch Q-5
BR24 DT2 2 Work lamp switch (If equipped) O-4
BR25 DT2 2 Fog lamp (If equipped) O-5
20-214 GD555, 655, 675-3A

(6)
Connector
No. Type No. of Pins Mounting Location Address
BR26 (VCH) 8 Hazard lamp switch O-5

BR27 (VCH) 8 Head lamp switch P-5
BR28 DT2 3 Accumulator float switch N-4
BT30 TERMINAL 1 GND D-7
BT31 TERMINAL 1 Starting switch (B) P-5
BT32 TERMINAL 1 Starting switch (BR) P-5
BT33 TERMINAL 1 Starting switch (R1) P-5
BT34 TERMINAL 1 Starting switch (C) P-5
BT35 TERMINAL 1 Starting switch (ACC) P-5
BT36 TERMINAL 1 Horn relay M-3
BT37 TERMINAL 1 Horn relay N-3
BT41 1-pin connector 1 Switch panel lamp P-5
BT42 1-pin connector 1 Cigar lighter O-5
C1 DT2(G) 8 Intermediate connector G-4
C2 DT2(Gr) 8 Intermediate connector G-4
C3 DT2 6 Intermediate connector (Wiper) H-4
C4 DT1 3 Glass heater (If equipped) H-4
C5 — 9 Radio (If equipped) U-8
C6 KES 2 Speaker (R.H.) (If equipped) V-8
C7 KES 2 Speaker (L.H.) (If equipped) X-7
C8 KES 6 Rear wiper switch (If equipped) X-4
C9 KES 6 Front lower wiper switch (If equipped) X-3
C10 KES 2 Room lamp switch (If equipped) T-7
C11 M 2 Fan switch (Front) (If equipped) X-4
C12 M 2 Fan switch (Rear) (If equipped) X-5
C13 M 2 Defroster fan (Front) (If equipped) U-2
C14 M 2 Defroster fan (Rear) (If equipped) X-6
C15 KES 4 Front wiper motor (If equipped) S-4
C16 KES 4 Rear wiper motor (If equipped) W-7
C17 KES 4 Front lower wiper motor (L.H.) (If equipped) T-2
C18 KES 4 Front lower wiper motor (R.H.) (If equipped) U-2
C19 Relay 5 Front lower wiper motor relay (R.H.) (If equipped) V-2
C20 M 2 Beacon switch (If equipped) X-5
C21 Relay 5 Work lamp relay (If equipped) V-2
C22 KES 3 Work lamp switch (If equipped) X-6
C23 M 2 Work lamp (If equipped) T-7
C24 M 2 Work lamp (If equipped) S-6
C27 M 3 Head lamp (If equipped) S-3
C28 M 3 Head lamp (If equipped) S-5
C29 M 2 Power (24V) (Spare) X-6
C30 KES 2 Spot lamp (If equipped) V-8
C31 M 2 Intermediate connector (Defroster fan, front) U-2
C32 M 2 Intermediate connector (Defroster fan, rear) X-6
C33 M 3 Combination lamp (R.H.) (If equipped) T-3
C34 M 3 Combination lamp (L.H.) (If equipped) S-6
CT35 1-pin connector 1 Beacon (If equipped) S-5
CT41 TERMINAL 1 GND X-3
E1 DT2 2 Alternator H-9
E2 X 2 Thermostat sensor (GD655, 675-3A) H-9
E2 X 2 Thermostat sensor (GD555-3A) I-9
E3 DT2 2 Intermediate connector J-8
E4 X 2 Hydraulic thermostat sensor for T/C (If equipped) J-7
E5 DT2 2 Hydraulic thermostat sensor for AWD (If equipped) J-7
GD555, 655, 675-3A 20-215

(6)
Connector
E6 DT2 2 Diode (Starter relay) J-4

E7 DT2 2 Diode (Grid heater relay) I-3
E8 DT2 2 Diode (Fuel shut-off solenoid) J-6
E9 (PKD) 3 Fuel shut-off solenoid J-7
E10 DT2 3 VHM valve —
E11 DT2 2 Diode (VHP valve) J-7
E12 (PKD) 3 Engine oil pressure switch J-7
E13 DT2 3 Accumulator hydraulic pressure switch (R.H.) H-4
E14 DT2 3 Accumulator hydraulic pressure switch (L.H.) H-4
E15 DT2 6 Joint connector J-5
E16 DT2 4 Intermediate connector I-4
E17 DT2 2 Differential thermostat sensor (If equipped) H-4
E18 DT2 2 Differential lock solenoid (If equipped) H-4
ET39 DT2 2 Fuse sensor J-8
ET40 TERMINAL 1 GND J-6
ET41 TERMINAL 1 Battery (-) J-6
ET42 TERMINAL 1 Battery (+) J-5
ET43 TERMINAL 1 Battery (-) G-9
ET44 TERMINAL 1 Battery (+) G-9
ET45 TERMINAL 1 Battery relay K-3
ET47 TERMINAL 1 Slow blow fuse I-2
ET48 TERMINAL 1 Slow blow fuse J-2
ET50 TERMINAL 1 Starting motor H-9
ET51 TERMINAL 1 Starting motor (GND) I-9
ET52 TERMINAL 1 GND I-9
ET53 TERMINAL 1 Starting motor (B) H-9
ET54 TERMINAL 1 Grid heater relay J-2
ET55 TERMINAL 1 Grid heater relay I-3
ET56 TERMINAL 1 Grid heater J-7
ET63 TERMINAL 1 Slow blow fuse H-9
ET64 TERMINAL 1 Battery relay L-3
ET65 TERMINAL 1 Alternator (B) M-8
ET66 TERMINAL 1 Alternator (I terminal) M-8
ET67 TERMINAL 1 Alternator (E) M-8
ET70 TERMINAL 1 Fuel shut-off relay J-5
ET71 TERMINAL 1 Fuel shut-off relay I-5
ET72 TERMINAL 1 Starter relay K-2
ET73 TERMINAL 1 Starter relay J-4
ET74 TERMINAL 1 Starting motor (C) H-9
ET75 TERMINAL 1 Battery relay (+) J-4
ET76 TERMINAL 1 Battery relay (-) K-4
ET80 TERMINAL 1 Starter relay K-2
ET81 TERMINAL 1 Starter relay J-4
ET88 X 1 Air conditioner compressor J-7
20-216 GD555, 655, 675-3A

(6)
Connector

ET92 TERMINAL 1 GND (Engine) J-6
ET94 TERMINAL 1 GND (Alternator) I-4
FL1 M 3 Head lamp (R.H.) B-5
FL2 M 3 Head lamp (L.H.) A-2
FL3 DT2(B) 8 Intermediate connector A-4
FL4 DT2(B) 12 Intermediate connector D-6
FL5 DT2(Br) 8 Intermediate connector C-6
FL6 DT2 2 Articulate sensor D-6
FL7 DT2 2 Lifter lock solenoid F-4
FL8 DT2 2 Parking brake solenoid F-4
FL9 DT2 2 Accumulator solenoid (R.H.) B-6
FL10 DT2 2 Accumulator solenoid (L.H.) E-2
FL11 DT2 2 Float solenoid (R.H.) B-5
FL12 DT2 2 Float solenoid (R.H.) C-6
FL13 DT2 2 Float solenoid (L.H.) D-2
FL14 DT2 2 Float solenoid (L.H.) C-6
FL15 DT2 2 Diode (Solenoid) C-1
FL16 DT2 2 Diode (Solenoid) F-3
FL17 DT2 2 Diode (Solenoid) D-1
FL19 DT2 2 Diode (Solenoid) E-2
FL21 DT2 4 Intermediate connector C-6
FL22 M 3 Combination lamp (R.H.) A-5
FL23 M 3 Combination lamp (L.H.) A-2
FL26 M 2 Front work lamp (R.H.) (If equipped) E-5
FL27 M 2 Front work lamp (L.H.) (If equipped) F-4
FL28 M 2 Front work lamp (Spare) (R.H.) B-5
FL29 M 2 Front work lamp (Spare) (L.H.) B-1
FP1 DT2(Gr) 12 Meter assembly D-8
FP2 DT2(B) 12 Warning module (L.H.) D-8
FP3 DT2(Br) 12 Warning module (R.H.) E-9
FP6 DT2(B) 12 Intermediate connector B-7
FP7 DT2(Gr) 8 Intermediate connector B-8
FP8 DT2(Br) 12 Intermediate connector A-8
FP9 KES 2 Service meter D-7
FP10 DT2 4 Message center E-9
FP11 DT2 3 Turn signal switch D-8
FP12 DT2 3 Dimmer switch D-8
FP13 DT2 2 Differential switch (If equipped) D-8
FT6 1-pin connector 1 Horn (L.H.) F-4
FT7 1-pin connector 1 Horn (R.H.) E-5
FT10 TERMINAL 1 GND (Floor) E-5
FT11 TERMINAL 1 GND (Front frame) F-4
FT12 TERMINAL 1 GND (Front frame) D-7
FT13 TERMINAL 1 GND (Rear frame) J-5
FT16 TERMINAL 1 Articulate sensor (-) —
FT17 TERMINAL 1 Articulate sensor (G) —
FT18 1-pin connector 1 Speed meter (If equipped) D-9
FT19 1-pin connector 1 T/C Hydraulic temperature gauge —
FT20 1-pin connector 1 Coolant temperature gauge D-9
FT21 1-pin connector 1 Fuel gauge D-9
FT22 1-pin connector 1 Articulate gauge D-9
FT23 TERMINAL 1 T/C Hydraulic temperature gauge (B) D-9
FT24 TERMINAL 1 T/C Hydraulic temperature gauge (T) D-9
GD555, 655, 675-3A 20-217

(6)
Connector
FT25 TERMINAL 1 T/C Hydraulic temperature gauge (E) D-9

FT26 TERMINAL 1 Coolant temperature gauge (B) D-9
FT27 TERMINAL 1 Coolant temperature gauge (T) D-9
FT28 TERMINAL 1 Coolant temperature gauge (E) D-9
FT29 TERMINAL 1 Fuel gauge (B) D-9
FT30 TERMINAL 1 Fuel gauge (T) D-9
FT31 TERMINAL 1 Fuel gauge (E) D-9
FT32 TERMINAL 1 Articulate gauge (E) D-9
FT33 1-pin connector 1 Articulate gauge (+) D-9
FT34 1-pin connector 1 Articulate gauge (G) D-9
FT35 1-pin connector 1 Articulate gauge D-9
FT37 1-pin connector 1 Horn switch E-9
H1 M 1 Heater F-9
OP1 M 1 If equipped F-9
RL1 DT2(Br) 8 Intermediate connector J-8
RL2 M 6 Combination lamp (R.H.) I-9
RL3 M 6 Combination lamp (L.H.) J-8
RL4 M 2 Rear work lamp (If equipped) I-9
RL5 M 2 Rear work lamp (If equipped) J-8
RT1 M 2 License lamp J-8
RT2 TERMINAL 1 Back-up alarm J-8
RT3 TERMINAL 1 Back-up alarm I-9
T1 MIC 13 T/M controller N-3
T3A 040 20 T/M controller N-2
T3B 040 16 T/M controller N-3
T4 040 12 T/M controller N-3
T5 MIC 17 T/M controller Q-5
T6 DT2 4 Connector for flash ROM writer D-7
T7 DT2 6 Converter for specified selection O-1
T8 DT2 3 Inching potentiometer P-1
T9 DT2 3 Accelerator potentiometer O-1
T10 DT2(G) 12 Intermediate connector A-7
T11 DT2(Gr) 8 Intermediate connector A-8
T12 DT2 6 Intermediate connector C-8
T13 DRC 24 Shift lever N-3
T14 DT2 2 T/C switch N-4
T15 DT2 2 Intermediate connector N-4
T16 DT2(Br) 12 Intermediate connector A-9
T17 DT2(B) 8 Intermediate connector A-9
T18 DT2 6 Intermediate connector A-8
T20 DT2(B) 12 Intermediate connector Q-9
T21 DT2 6 Intermediate connector Q-9
T22 DT2(Gr) 12 Intermediate connector Q-9
T24 DT2 2 FL solenoid R-8
T25 DT2 2 FH solenoid R-8
T26 DT2 2 R solenoid R-8
T27 DT2 2 1st solenoid R-7
T28 DT2 2 2nd solenoid R-7
T29 DT2 2 3rd solenoid R-7
T30 DT2 2 4th solenoid R-6
T31 DT2 2 Lockup solenoid N-9
T32 DT2 2 Transmission input shaft speed sensor R-9
T33 DT2 2 Transmission output shaft speed sensor Q-6
T34 DT2 2 T/C hydraulic temperature sensor R-8
20-218 GD555, 655, 675-3A

(6)
Connector
T35 DT2 2 T/M hydraulic temperature sensor R-6

T36 DT2 2 FL clutch fill switch R-8
T37 DT2 2 FH clutch fill switch R-7
T38 DT2 2 R clutch fill switch R-8
T39 DT2 2 1st clutch fill switch R-7
T40 DT2 2 2nd clutch fill switch R-7
T41 DT2 2 3rd clutch fill switch R-6
T42 DT2 2 4th clutch fill switch R-6
T43 DT2 2 Lockup clutch fill switch N-8
T46 DT2 2 Engine revolution sensor R-9
T47 DT2 6 Joint connector P-9
T49 DT2 6 Joint connector Q-9
T50 DT2 6 Joint connector R-9
TT1 TERMINAL 1 Potentiometer set switch R-4
TT4 TERMINAL 1 Initialize switch R-5
TT7 TERMINAL 1 Reset switch Q-5
TT8 TERMINAL 1 Reset switch R-5
TT9 TERMINAL 1 GND D-8
GD555, 655, 675-3A 20-219

(6)
CONNECTOR TYPES AND MOUNTING LOCATIONS

Serial No : 11001 and up
Connector
Type No. of Pins Mounting Location Address
No.
AC1 SWP 12 Air conditioner unit (If equipped) G-9
AC3 SWP 14 Air conditioner unit (If equipped) X-3
AC4 SWP 16 Air conditioner unit (If equipped) W-2
AC8 — 7 Air conditioner intake duct (If equipped) W-2
B1 DT2(G) 12 Intermediate connector D-8
B2 DT2(Gr) 12 Intermediate connector C-8
B3 DT2(Br) 12 Intermediate connector C-8
B4 DT2(B) 8 Intermediate connector A-8
B5 DT2(G) 8 Intermediate connector C-9
B6 L 2 Intermediate connector D-8
B7 DT2(Br) 8 Intermediate connector D-9
B8 DT2(B) 12 Intermediate connector B-9
B9 DT2(Gr) 8 Intermediate connector B-9
B10 DT2(G) 8 Intermediate connector B-9
B15 KES 2 Window washer (Front upper) (If equipped) G-3
B16 KES 2 Window washer (Front lower) (If equipped) G-3
B17 KES 2 Window washer (Rear) (If equipped) G-3
B18 DT2 3 Float cancel switch (R.H.) D-6
B19 DT2 3 Float cancel switch (L.H.) E-5
B20 DT2 2 Engine start solenoid G-9
B21 DT2 2 Diode (Engine start up solenoid) H-9
B22 DT1 4 Intermediate connector B-8
B23 L 1 Fuse box K-7
B26 DT2 2 Diode —
B27 DT2 2 Diode —
BR3 DT2 2 Diode (Buzzer) N-4
BR4 Relay 5 Alternator relay Q-1
BR5 Relay 5 Charge lamp relay Q-1
BR6 Relay 5 Back-up alarm relay R-3
BR7 Relay 5 Differential relay R-2
BR8 Relay 5 VHP relay —
BR9 Relay 5 Accumulator hydraulic pressure relay R-2
BR10 Relay 5 Brake pump relay R-3
BR11 Relay 5 Parking brake relay P-5
BR12 Relay 6 Neutral relay Q-5
BR13 Relay 6 Front work lamp relay R-3
BR14 Relay 5 Rear work lamp relay P-5, R-3
BR15 Relay 5 Float cancel relay (R.H.) R-4
BR16 Relay 5 Float cancel relay (L.H.) R-3
BR18 KES 4 Front wiper switch N-4
BR19 KES 6 Preheat timer relay R-4
BR20 KES 4 Flasher R-4
BR21 DT2 2 Buzzer (B) P-1
BR22 M 2 Buzzer (A) Q-1
BR23 DT2 2 Lift lock switch Q-5
20-219-1 GD555, 655, 675-3A

(6)
Connector
BR24 DT2 2 Work lamp switch (If equipped) O-4

BR25 DT2 2 Fog lamp (If equipped) O-5
BR26 (VCH) 8 Hazard lamp switch O-5
BR27 (VCH) 8 Head lamp switch P-5
BR28 DT2 3 Accumulator float switch N-4
BT30 TERMINAL 1 GND D-7
BT31 TERMINAL 1 Starting switch (B) P-5
BT32 TERMINAL 1 Starting switch (BR) P-5
BT33 TERMINAL 1 Starting switch (R1) P-5
BT34 TERMINAL 1 Starting switch (C) P-5
BT35 TERMINAL 1 Starting switch (ACC) P-5
BT36 TERMINAL 1 Horn relay M-3
BT41 1-pin connector 1 Switch panel lamp P-5
C1 DT2(G) 8 Intermediate connector G-4
C2 DT2(Gr) 8 Intermediate connector G-4
C3 DT2 6 Intermediate connector (Wiper) H-4
C4 DT1 3 Glass heater (If equipped) H-4
C5 — 9 Radio (If equipped) U-8
C6 KES 2 Speaker (R.H.) (If equipped) V-8
C7 KES 2 Speaker (L.H.) (If equipped) X-7
C8 KES 6 Rear wiper switch (If equipped) X-4
C9 KES 6 Front lower wiper switch (If equipped) X-3
C10 KES 2 Room lamp switch (If equipped) T-7
C11 M 2 Fan switch (Front) (If equipped) X-4
C12 M 2 Fan switch (Rear) (If equipped) X-5
C13 M 2 Defroster fan (Front) (If equipped) U-2
C14 M 2 Defroster fan (Rear) (If equipped) X-6
C15 KES 4 Front wiper motor (If equipped) S-4
C16 KES 4 Rear wiper motor (If equipped) W-7
C17 KES 4 Front lower wiper motor (L.H.) (If equipped) T-2
C18 KES 4 Front lower wiper motor (R.H.) (If equipped) U-2
C19 Relay 5 Front lower wiper motor relay (R.H.) (If equipped) V-2
C20 M 2 Beacon switch (If equipped) X-5
C21 Relay 5 Work lamp relay (If equipped) V-2
C22 KES 3 Work lamp switch (If equipped) X-6
C23 M 2 Work lamp (If equipped) T-7
C27 M 3 Head lamp (R.H.) (If equipped) S-3
C28 M 3 Head lamp (L.H.) (If equipped) S-5
C29 M 2 Power (24V) (Spare) X-6
C30 KES 2 Spot lamp (If equipped) V-8
C31 M 2 Intermediate connector (Defroster fan, front) U-2
C32 M 2 Intermediate connector (Defroster fan, rear) X-6
C33 M 3 Combination lamp (R.H.) (If equipped) T-3
C34 M 3 Combination lamp (L.H.) (If equipped) S-6
CT35 1-pin connector 1 Beacon (If equipped) S-5
CT41 TERMINAL 1 GND X-3
E1 DT2 2 Alternator H-9
E2 X 2 Thermostat sensor (GD555-3A) I-9
E2 X 2 Thermostat sensor (GD655, 675-3A) H-9
E3 DT2 2 Intermediate connector J-8
GD555, 655, 675-3A 20-219-2

(6)
Connector
E4 X 2 Hydraulic thermostat sensor for T/C (If equipped) J-7

E5 DT2 2 Hydraulic thermostat sensor for AWD (If equipped) J-7
E6 DT2 2 Diode (Starter safety relay) (GD555-3A) J-4
E6 DT2 2 Starting motor (GD655, 675-3A) X-3
E7 DT2 2 Diode (Grid heater relay) I-3
E8 DT2 2 Diode (Fuel shut-off solenoid) J-6
E9 DT 3 Fuel shut-off solenoid (GD655, 675-3A) J-7
E10 DT2 3 VHM valve —
E11 DT2 2 Diode (VHP valve) J-7
E12 (PKD) 3 Engine oil pressure switch J-7
E13 DT2 3 Accumulator hydraulic pressure switch (R.H.) H-4
E14 DT2 3 Accumulator hydraulic pressure switch (L.H.) H-4
E15 DT2 6 Joint connector J-5
E16 DT2 4 Intermediate connector I-4
E17 DT2 2 Differential thermostat sensor (If equipped) H-4
E18 DT2 2 Differential lock solenoid (If equipped) H-4
E20 DT 4 Fuel shut-off timer J-5
E21 DT 2 Fuel shut-off relay I-5
ET39 DT2 2 Fuse sensor J-8
ET40 TERMINAL 1 GND J-6
ET42 TERMINAL 1 Battery (+) J-5
ET43 TERMINAL 1 Battery (-) G-9
ET44 TERMINAL 1 Battery (+) G-9
ET48 TERMINAL 1 Slow blow fuse J-2
ET50 TERMINAL 1 Starting motor H-9
ET51 TERMINAL 1 Starting motor (GND) I-9
ET53 TERMINAL 1 Starting motor (B) H-9
ET56 TERMINAL 1 Grid heater J-7
ET63 TERMINAL 1 Slow blow fuse H-9
ET64 TERMINAL 1 Battery relay L-3
ET65 TERMINAL 1 Alternator (B) M-8
ET66 TERMINAL 1 Alternator (I terminal) M-8
ET67 TERMINAL 1 Alternator (E) M-8
ET72 TERMINAL 1 Starter safety relay (B) (GD555-3A) K-2
ET73 TERMINAL 1 Starter safety relay (C) (GD555-3A) J-4
ET74 TERMINAL 1 Starting motor (C) H-9
ET75 TERMINAL 1 Battery relay (+) J-4
ET76 TERMINAL 1 Battery relay (-) K-4
ET81 TERMINAL 1 Starter safety relay (E) (GD555-3A) J-4
20-219-3 GD555, 655, 675-3A

(6)
Connector
ET88 X 1 Air conditioner compressor J-7

ET94 TERMINAL 1 GND (Alternator) I-4
ET97 TERMINAL 1 Fuel shut-off solenoid (GND) (GD555-3A) J-7
ET98 TERMINAL 1 Fuel shut-off solenoid (PULL) (GD555-3A) J-7
ET99 TERMINAL 1 Fuel shut-off solenoid (COMM) (GD555-3A) J-7
FL1 M 3 Head lamp (R.H.) B-5
FL2 M 3 Head lamp (L.H.) A-2
FL3 DT2(B) 8 Intermediate connector A-4
FL4 DT2(B) 12 Intermediate connector D-6
FL5 DT2(Br) 8 Intermediate connector C-6
FL6 DT2 2 Articulate sensor D-6
FL7 DT2 2 Lifter lock solenoid F-4
FL8 DT2 2 Parking brake solenoid F-4
FL9 DT2 2 Accumulator solenoid (R.H.) B-6
FL10 DT2 2 Accumulator solenoid (L.H.) E-2
FL11 DT2 2 Float solenoid (R.H.) B-5
FL12 DT2 2 Float solenoid (R.H.) C-6
FL13 DT2 2 Float solenoid (L.H.) D-2
FL14 DT2 2 Float solenoid (L.H.) C-6
FL15 DT2 2 Diode (Solenoid) C-1
FL16 DT2 2 Diode (Solenoid) F-3
FL21 DT2 4 Intermediate connector C-6
FL22 M 3 Combination lamp (R.H.) A-5
FL23 M 3 Combination lamp (L.H.) A-2
FL26 M 2 Front work lamp (R.H.) (If equipped) E-5
FL27 M 2 Front work lamp (L.H.) (If equipped) F-4
FL28 M 2 Front work lamp (Spare) (R.H.) B-5
FL29 M 2 Front work lamp (Spare) (L.H.) B-1
FP1 DT2(Gr) 12 Meter assembly D-8
FP2 DT2(B) 12 Warning module (L.H.) D-8
FP3 DT2(Br) 12 Warning module (R.H.) E-9
FP6 DT2(B) 12 Intermediate connector B-7
FP7 DT2(Gr) 8 Intermediate connector B-8
FP8 DT2(Br) 12 Intermediate connector A-8
FP9 KES 2 Service meter D-7
FP10 DT2 4 Message center E-9
FP11 DT2 3 Turn signal switch D-8
FP12 DT2 3 Dimmer switch D-8
FP13 DT2 2 Differential switch (If equipped) D-8
FP19 DT2 2 Engine start up switch E-9
FT6 1-pin connector 1 Horn (L.H.) F-4
FT7 1-pin connector 1 Horn (R.H.) E-5
FT10 TERMINAL 1 GND (Floor) E-5
FT11 TERMINAL 1 GND (Front frame) F-4
FT12 TERMINAL 1 GND (Front frame) D-7
FT13 TERMINAL 1 GND (Rear frame) J-5
FT16 TERMINAL 1 Articulate sensor (-) —
FT17 TERMINAL 1 Articulate sensor (G) —
FT18 1-pin connector 1 Speed meter (If equipped) D-9
GD555, 655, 675-3A 20-219-4

(6)
Connector
FT19 1-pin connector 1 T/C Hydraulic temperature gauge —

FT20 1-pin connector 1 Coolant temperature gauge D-9
FT21 1-pin connector 1 Fuel gauge D-9
FT23 TERMINAL 1 T/C Hydraulic temperature gauge (B) D-9
FT24 TERMINAL 1 T/C Hydraulic temperature gauge (T) D-9
FT25 TERMINAL 1 T/C Hydraulic temperature gauge (E) D-9
FT26 TERMINAL 1 Coolant temperature gauge (B) D-9
FT27 TERMINAL 1 Coolant temperature gauge (T) D-9
FT28 TERMINAL 1 Coolant temperature gauge (E) D-9
FT29 TERMINAL 1 Fuel gauge (B) D-9
FT30 TERMINAL 1 Fuel gauge (T) D-9
FT31 TERMINAL 1 Fuel gauge (E) D-9
FT32 TERMINAL 1 Articulate gauge (E) D-9
FT33 1-pin connector 1 Articulate gauge (+) D-9
FT34 1-pin connector 1 Articulate gauge (G) D-9
FT37 1-pin connector 1 Horn switch E-9
H1 M 1 Heater F-9
RL1 DT2(Br) 8 Intermediate connector J-8
RL2 M 6 Combination lamp (R.H.) I-9
RL3 M 6 Combination lamp (L.H.) J-8
RL4 M 2 Rear work lamp (If equipped) I-9
RL5 M 2 Rear work lamp (If equipped) J-8
RL6 M 2 Intermediate connector (license lamp) J-8
RL7 X 2 License lamp —
RT1 M 2 Intermediate connector (license lamp) J-8
RT2 TERMINAL 1 Back-up alarm J-8
RT3 TERMINAL 1 Back-up alarm I-9
T3A 040 20 T/M controller N-2
T3B 040 16 T/M controller N-3
T4 040 12 T/M controller N-3
T5 MIC 17 T/M controller Q-5
T6 DT2 4 Connector for flash ROM writer D-7
T7 DT2 6 Converter for specified selection O-1
T8 DT2 3 Inching potentiometer P-1
T9 DT2 3 Accelerator potentiometer O-1
T10 DT2(G) 12 Intermediate connector A-7
T12 DT2 6 Intermediate connector C-8
T13 DRC 24 Shift lever N-3
T14 DT2 2 T/C switch N-4
T15 DT2 2 Intermediate connector N-4
T16 DT2(Br) 12 Intermediate connector A-9
T17 DT2(B) 8 Intermediate connector A-9
T20 DT2(B) 12 Intermediate connector Q-9
T21 DT2 6 Intermediate connector Q-9
T22 DT2(Gr) 12 Intermediate connector Q-9
T24 DT2 2 FL solenoid R-8
T25 DT2 2 FH solenoid R-8
T26 DT2 2 R solenoid R-8
T27 DT2 2 1st solenoid R-7
20-219-5 GD555, 655, 675-3A

(6)
Connector
T28 DT2 2 2nd solenoid R-7

T29 DT2 2 3rd solenoid R-7
T30 DT2 2 4th solenoid R-6
T31 DT2 2 Lockup solenoid N-9
T32 DT2 2 Transmission input shaft speed sensor R-9
T33 DT2 2 Transmission output shaft speed sensor Q-6
T34 DT2 2 T/C hydraulic temperature sensor R-8
T35 DT2 2 T/M hydraulic temperature sensor R-6
T36 DT2 2 FL clutch fill switch R-8
T37 DT2 2 FH clutch fill switch R-7
T38 DT2 2 R clutch fill switch R-8
T39 DT2 2 1st clutch fill switch R-7
T40 DT2 2 2nd clutch fill switch R-7
T41 DT2 2 3rd clutch fill switch R-6
T42 DT2 2 4th clutch fill switch R-6
T43 DT2 2 Lockup clutch fill switch N-8
T46 DT2 2 Engine revolution sensor R-9
T49 DT2 6 Joint connector Q-9
T50 DT2 6 Joint connector R-9
TT7 TERMINAL 1 Reset switch Q-5
TT8 TERMINAL 1 Reset switch R-5
TT9 TERMINAL 1 GND D-8
GD555, 655, 675-3A 20-219-6

(6)
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
CONNECTOR ARRANGEMENT DIAGRAM

Serial No. : 10001 – 11000
20-220 GD555, 655, 675-3A

(3)
GD555, 655, 675-3A 20-221

(3)
20-222 GD555, 655, 675-3A

(1)
GD555, 655, 675-3A 20-223

(3)
CONNECTOR ARRANGEMENT DIAGRAM

Serial No. : 11001 and up
20-223-1 GD555, 655, 675-3A

(3)
GD555, 655, 675-3A 20-223-2

(3)
20-223-3 GD555, 655, 675-3A

(3)
GD555, 655, 675-3A 20-223-4

(3)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

The terms male and female refer to the pins while the terms male housing and female housing refer to
the mating portion of the housing.
X-Type Connector
Number
of Pins Male (Female Housing) Female (Male Housing) T-adapter Part
Number
1 Part Number: 08055-00181 Part Number: 08055-00191 799-601-7010
BWP04702
2 799-601-7020
Part Number: 08055-00282 Part Number: 08055-00292
BWP04703
3 799-601-7030
BWP04704
BWP04705
4 BWP04706 799-601-7040

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
• Wire size: 0.85 • Wire size: 0.85
— • Grommet: black • Grommet: black —
• Quantity: 20 pieces • Quantity: 20 pieces
Terminal part number: 79A-222-3380 Terminal part number: 79A-222-3410
— • Grommet: red • Grommet: red —
20-224 GD555, 655, 675-3A

(1)
SWP-Type Connector
Number
Number
BWP04708
BWP04707
6 799-601-7050
BWP04709 BWP04710
8 799-601-7060
BWP04711
BWP04712
12 799-601-7310
BWP04713 BWP04714
14 799-601-7070
GD555, 655, 675-3A 20-225

b
SWP-Type Connector
Number
Number
BWP04715
16 BWP04716 799-601-7320

Terminal part number: Terminal part number:
— • Grommet: black • Grommet: black —
Terminal part number: Terminal part number:
— • Grommet: red • Grommet: red —
20-226 GD555, 655, 675-3A

b
M-Type Connector
Number
Number
1 Part Number: 08056-00171 Part Number: 08056-00181 799-601-7080
BWP04718
2 BWP04717 799-601-7090
3 BWP04719 BWP04720 799-601-7110
4 BWP04721 BWP04722 799-601-7120
6 BWP04723 BWP04724 799-601-7130
799-601-7390
8 BWP04725 BWP04726
GD555, 655, 675-3A 20-227

b
S-Type Connector
Number
of Pins T-adapter Part
Male (Female Housing) Female (Male Housing) Number
BWP04728
8 BWP04727 799-601-7140
10 (White) BWP04729 BWP04730 799-601-7150
12 (White) BWP04731 BWP04732 799-601-7350
16 (White) BWP04733 BWP04734 799-601-7330
20-228 GD555, 655, 675-3A

b
S-Type Connector
Number
BWP04736
10 (Blue) BWP04735 —
— —
12 (Blue) BWP04737 BWP04738 799-601-7160
16 (Blue) BWP04739 BWP04740 799-601-7170
GD555, 655, 675-3A 20-229

b
MIC-Type Connector
Number
Number
7 Body Part Number: 79A-222-2640 Body Part Number: 79A-222-2630 —
(Quantity: 5 pieces) (Quantity: 5 pieces)
Body Part Number: 79A-222-2680 Body Part Number: 79A-222-2670
11 (Quantity: 5 pieces) (Quantity: 5 pieces) —
BWP04742
BWP04741
5 799-601-2710

BWP04743 BWP04744
9 799-601-2950

BWP04745 BWP04746
13 799-601-2720

20-230 GD555, 655, 675-3A

b
MIC-Type Connector
Number
BWP04748
BWP04747
17 799-601-2730

BWP04749 BWP04750
21 799-601-2740

Body Part Number: 79A-222-2770 Body Part Number: 79A-222-2760 —
GD555, 655, 675-3A 20-231

b
AMP040-Type Connector
Number
BWP04752
8 BWP04751 799-601-7180
— Housing Part Number: 79A-222-3430
12 BWP04753 BWP047544 799-601-7190
16 BWP04755 BWP04756 799-601-7210
20 BWP04757 BWP04758 799-601-7220
★ Terminal Part Number: 79A-222-3470 (For all numbers of pins).
20-232 GD555, 655, 675-3A

b
AMP070-Type Connector
Number
BWP04760
10 BWP04759 799-601-7510
— Part Number: 08195-10210
12 BWP04761 BWP04762 799-601-7520
— Part Number: 08195-12210
14 BWP04763 BWP04764 799-601-7530
— Part Number: 08195-14210
18 BWP04765 BWP04766 799-601-7540
— Part Number: 08195-18210
20 BWP04767 BWP04768 799-601-7550
— Part Number: 08195-20210
GD555, 655, 675-3A 20-233

b
L-Type Connector
Number
BWP04770
2 BWP04769 —
— —
PA-Type Connector
Number
BWP04772
9 BWP04771 —
— —
BENDIX MS-Type Connector

Number
Number
BWP04774
10 BWP04773 799-601-3460
— —
20-234 GD555, 655, 675-3A

b
KES1 Automobile-Type Connector

Number
BWP04776
BWP04775
2 —
Part Number: 08027-10210 (Natural color) Part Number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 BWP04777 BWP04778 —
BWP04779 BWP04780
4 —
08027-10420 (Black) 08027-10470 (Black)
BWP04781 BWP04782
6 —
08027-10620 (Black) 08027-10670 (Black)
GD555, 655, 675-3A 20-235

b
KES1 Automobile-Type Connector

Number
BWP04784
BWP04783
8 —
08027-10820 (Black) 08027-10870 (Black)
20-236 GD555, 655, 675-3A

b
Socket-Type Connector for Relay

Number
BWP04786
5 BWP04785 799-601-7360
— —
BWP04788
6 BWP04787 799-601-7370
— —
GD555, 655, 675-3A 20-237

b
F-Type Connector
Number
BWP04786
BWP04785
4 —
— —
20-238 GD555, 655, 675-3A

b
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
GD555, 655, 675-3A 20-239

(3)

(shell
size T-adapter
code) Part No.
799-601-9230
18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

799-601-9230
Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

799-601-9240
18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

799-601-9240
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
20-240 GD555, 655, 675-3A

(3)

(shell
size T-adapter
code) Part No.
799-601-9250
24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

799-601-9250
Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
GD555, 655, 675-3A 20-241

(3)

(shell
size T-adapter
code) Part No.
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
20-242 GD555, 655, 675-3A

(3)

(shell
size T-adapter
code) Part No.
Pin (male termial) Pin (female terminal)
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
GD555, 655, 675-3A 20-243

(3)
DT Series connector
No.of
pins Body (receptacle) T-adapter
Body (plug)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
20-244 GD555, 655, 675-3A

(3)
No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
12GR: 799-601-9110
12B: 799-601-9120
10
12G: 799-601-9130
12BR: 799-601-9140
GD555, 655, 675-3A 20-245

(3)
DTM Series connector

No.of
pins T-adapter Part
No.
799-601-9010
2
Part No.: 08192-02200 Part No.: 08192-02100
DTHD Series connector

No.of
pins T-adapter Part
No.
2 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
20-246 GD555, 655, 675-3A

(3)
TROUBLESHOOTING MESSAGE CENTER DISPLAY AND TABLE ERROR CODES
MESSAGE CENTER DISPLAY AND TABLE ERROR CODES
1. Display function of the message center (1)

1) Content of mode display (8 modes displayed with 4 digits)
[1] Auto [5] Lum. (monitor illumination brightness)
[2] Rpm (engine speed) [6] Ver. ❏ (version of software)
[3] Gear (speed range) [7] M7 ❏ ❏ (display in miles)
[4] Err (error code) [8] M8 ❏ ❏ (display in kilometers)
2) When pressing the mode button (2), the mode display changes in the following sequence:
[1] → [2] → [3] → [4] → [5] → [6] → [7] → [8]
3) Starting switch ON display
• It remembers the content (mode) of the display when the starting switch is OFF.
• Turning the starting switch ON starts with the mode saved in memory when the switch was
OFF.
i. Displays [V1.4]: The display goes out immediately and changes to the mode display.
ii. Displays [Rpm ❏]: Displays this mode for 3 seconds, then changes to the engine speed display.
([Rpm ❏] is an example, the mode is mode when the starting switch is turned OFF)
iii. Displays the engine speed in [❏ ❏ ❏] and maintains this mode until the mode button is
pressed.
iv. Press the mode button.
v. Displays [Gear]: Displays this mode for 3 seconds, then changes to the engine speed display.
vi. Displays the speed range in [❏ ❏ ❏] and maintains this mode until the mode button is
pressed.
GD555, 655, 675-3A 20-247

(6)
4) Display time and display

1) Mode display [Auto]
i) Displays [Auto] for 3 seconds, then changes to the engine speed display.
ii) Displays the engine speed in [❏ ❏ ❏ ❏] for 3 seconds, then changes to engine speed dis-
play.
iii) Displays [Rpm ❏] for 2 seconds, then changes to the engine speed display.
iv) Continues to display the engine speed in [❏ ❏ ❏].
• When the speed range changes
The speed range is displayed for 3 seconds, then the display changes to the engine speed
display and continues to display the engine speed.
• When the engine speed range changes during the speed range display
Even if the previous speed range display is shown for less than 3 seconds, the display
shows the next speed range.
• If the error occurs (priority given to error display)
Even if the speed range or engine speed is being displayed, the display changes to the error
code display and continues to display it.
If multiple error codes occur at the same time, the error codes are displayed in sequence for
2 seconds each.
• When the error is removed
Display returns to the speed range display.
2) Mode display [Rpm ❏]
i) Displays [Rpm ❏] for 3 seconds, then changes to the engine speed display.
ii) Displays the engine speed in [❏ ❏ ❏ ❏] and maintains this mode until the mode button
is pressed.
• The display is shown with four digits; If the speed is 1794 rpm, the value is rounded and dis-
played as [1790]; If the speed is 878 rpm, it is displayed as [❏ 880]. (The ❏ indicates a blank.)
3) Mode display [Gear]
i) Displays [Gear] for 3 seconds, then changes to the engine speed display.
ii) Displays the engine speed in [❏ ❏ ❏ ❏] and maintains this mode until the mode button
is pressed.
Speed Range Display Speed Range Display Speed Range Display

P [❏ - P - 1] F4 [❏ ❏ F4] R1 [❏ ❏ R1]
N [❏ - N -] F5 [❏ ❏ F5] R2 [❏ ❏ R2]
F1 [❏ ❏ F1] F6 [❏ ❏ F6] R3 [❏ ❏ R3]
F2 [❏ ❏ F2] F7 [❏ ❏ F7] R4 [❏ ❏ R4]
F3 [❏ ❏ F3] F8 [❏ ❏ F8]
4) Mode display [Err ❏]

i) Displays [Err ❏] for 3 seconds, then changes to the error display.
ii) Displays the error code in [❏ ❏ ❏ ❏] and maintains this mode until the mode button is
pressed
• If there is no error, the display shows [E ❏ ❏].
• If there is an error, the display shows [E ❏ ∆ ∆]. If there are multiple errors, the display
shows the error for 2 seconds, then displays the next error, and continues to display
each error for 2 seconds each. (∆ ∆ indicates the error code.)
iii) A maximum of 32 error codes can be displayed in the order of occurrence (the display at the
present point of operation). (The error code for the transmission controller is also displayed
at the same time with the LED.)
iv) When the error code is displayed, the electric circuit monitor for the transmission system on
the monitor panel also lights up at the same time.
20-248 GD555, 655, 675-3A

(1)
5) Mode display [Lum.]

i) Displays [Lum.] for 3 seconds, then changes to the engine speed display.
ii) Displays the brightness in [❏ ❏ ❏ ❏] and maintains this mode until the mode button is
pressed.
• Each time the scroll button (3) is pressed, the display changes
[100%] → [50%] → [25%] → [100%]
• The brightness data is not stored in memory; when the starting switch is turned ON, it
always starts from 100%.
6) Mode display [Ver ❏]
i) Displays [Ver ❏] for 3 seconds, then changes to the program No. display.
ii) Displays the program No. in [P ∆ ∆ ∆] and maintains this mode until the mode button is
pressed. (∆ ∆ ∆ shows the program No. For example: P5R2)
7) Mode display [M7 ❏ ❏]
i) Displays [M7 ❏ ❏] for 3 seconds, then changes to the travel speed (miles) display.
ii) Displays [MPH ❏] for 3 seconds, then changes to the travel speed display.
iii) Displays the travel speed (miles) in two digits in [∆ ∆ M], and maintains this mode until the
mode button is pressed.
8) Mode display [M8 ❏ ❏]
i) Displays [M8 ❏ ❏] for 3 seconds, then changes to the travel speed (km/h) display.
ii) Displays [kmPH ❏] for 3 seconds, then changes to the travel speed display.
iii) Displays the travel speed (kilometers) in two digits in [∆ ∆ km], and maintains this mode
until the mode button is pressed.
5) The error codes can be displayed on the message center only for the [Auto] and [Err ❏] modes.
GD555, 655, 675-3A 20-249

(1)
2. Table of error codes
A1 Short circuit in the FL solenoid system E2 Hot short, or the neutral signal system disconnected
A2 Short circuit in the FH solenoid system E3 Hot short, or the parking signal system disconnected
A3 Short circuit in the R solenoid system E4 Hot short, or the logic A signal system disconnected
A4 Short circuit in the 1st, 3rd solenoid system E5 Hot short, or the logic B signal system disconnected
A5 Short circuit in the 2nd, 4th solenoid system E6 Hot short, or the logic C signal system disconnected
A8 Short circuit in the lock-up solenoid system E7 Hot short, or the logic D signal system disconnected
b1 FL solenoid system disconnected E8 Hot short, or the logic E signal system disconnected
b2 FH solenoid system disconnected Short circuit with ground in the FL clutch pressure
F1
switch signal system
b3 R solenoid system disconnected
Short circuit with ground in the FH clutch pressure
b4 1st solenoid system disconnected F2 switch signal system
b5 2nd solenoid system disconnected Short circuit with ground in the R clutch pressure
F3
b6 3rd solenoid system disconnected switch signal system
b7 4th solenoid system disconnected Short circuit with ground in the 1st clutch pressure
F4
b8 Lock-up solenoid system disconnected
Short circuit with ground in the 2nd clutch pressure
C0 Drop in power supply voltage F5
C1 Engine speed sensor system disconnected Short circuit with ground in the 3rd clutch pressure
F6
Hot short, or accelerator potentiometer system dis- switch signal system
C3
connected Short circuit with ground in the 4th clutch pressure
F7
Hot short, or inching potentiometer system discon- switch signal system
C4
nected Short circuit with ground in the lock-up clutch pres-
F8 sure switch signal system
Hot short, or transmission oil temperature sensor
C5
system disconnected FL clutch pressure switch signal system discon-
91 nected
Hot short, or torque converter outlet oil temperature
C6
sensor system disconnected FH clutch pressure switch signal system discon-
92
Short or open circuit of power source in the hydrau- nected
C7
lic oil temperature sensor system 93 R clutch pressure switch signal system disconnected
Transmission input speed sensor system discon- 1st clutch pressure switch signal system discon-
C8 94
nected nected
Transmission output speed sensor system discon- 2nd clutch pressure switch signal system discon-
C9 95
nected nected
d1 Hot short, or differential oil temperature warning 3rd clutch pressure switch signal system discon-
lamp system disconnected 96 nected
d2 Hot short, or transmission (Torque converter outlet) 4th clutch pressure switch signal system discon-
oil temperature warning lamp system disconnected 97 nected
d4 Hot short, or alarm buzzer system disconnected Lock-up clutch pressure switch signal system dis-
98 connected
d5 Hot short, or warning lamp system disconnected
d6 Hot short, or differential control relay system dis-

connected
d7 Hot short, or VHP relay system disconnected
Hot short, or F (Forward), R (Reverse) system dis-
E1
connected
20-250 GD555, 655, 675-3A

(6)
TROUBLESHOOTING USING TROUBLESHOOTING CHARTS
USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No. Component
E - {{ Troubleshooting the electrical system
T - {{ Troubleshooting the transmission controller system
H - {{ Troubleshooting the hydraulic, mechanical system
M - {{ Troubleshooting the machine monitor system
2. Using the troubleshooting flow chart

1) Troubleshooting code number and problem
The title at the top of the troubleshooting chart gives the troubleshooting code and problem with
the machine. Example: Abnormal buzzer
2) General precautions
When troubleshooting the problem, precautions that will apply to all items are given at the top of
the page under the title and marked with (★).
The common precautions marked (★) at the page top are not given below each item, but must
always be followed when performing the check.
Example: ★ Before troubleshooting, check that all the related connectors are properly inserted.
★ Always connect any disconnected connectors before going on to the next step.
3) Distinguishing the conditions
Even with the same failure mode (problem), the method of troubleshooting may differ according to
the model, component, or problem. In such cases, the failure mode is further divided into sections
marked with small letters. For example, a) go to the appropriate troubleshooting section. If the trou-
bleshooting table is not divided into sections, start troubleshooting from the first check item in the
flow chart.
Example: a) Turning the starting switch ON (3 sec.) and the buzzer does not sound
b) Buzzer always sounds
4) Follow the troubleshooting chart
Check or measure the item described inside the box. Answer the question YES or NO.
NO
According to the answer, follow either the YES line or the NO line to the next box.
Note: The number at the top right corner of the box is an index number; it does not indi-
YES cate the order to follow.
•
Following the YES or NO lines, according to the check or measurement result, will lead to the
Cause column. Check the cause and take the action given in the Remedy column on the right.
• To the left of the box is another box formed with a gray line. The gray line box contains the
methods for inspection or measurement, and the judgement values. If the judgement values to
the left of the box are correct or the answer to the question inside the box is YES, follow the YES
line; if the judgement value is incorrect, or the answer to the question is NO, follow the NO line.
• The data inside the gray line box gives the preparatory work needed for inspection, measure-
ment, and the judgement values. If this preparatory work needed is neglected, or the method of
operation or handling is mistaken, there is danger that it may cause an incorrect judgement or
equipment damage. Therefore, before starting the inspection or measurement, always read the
instructions carefully, and start the work in order from the first item.
5) Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin number.
When troubleshooting, see this chart for the location for the inspection and measurement of the
wiring connector in the troubleshooting flow chart.
GD555, 655, 675-3A 20-251

(6)
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
Electrical circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-302

E-1 Engine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-304
E-2 Engine does not stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-312
E-3 Engine preheating pilot Lamp does not glow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-314
E-4 Electrical components do not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-316
GD555, 655, 675-3A 20-301

(3)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM

FOR ENGINE START, STOP, PREHEAT, CHARGE
Serial No.: 10001 – 11000
20-302 GD555, 655, 675-3A

(3)
GD555, 655, 675-3A 20-303

(1)
20-303-1 GD555, 655, 675-3A

(3)
GD555, 655, 675-3A 20-303-2

(3)
TROUBLESHOOTING E-1
E-1 ENGINE DOES NOT START
A) STARTING MOTOR DOES NOT TURN

Serial No.: 10001 – 11000
Cause Remedy
1
• Is battery voltage a mini-

mum of 20 V?
NO Lack of battery Charge or
• Is specific gravity of the
capacity replace
electrolyte a minimum of
1.26?
YES
2
• Turn starting switch When turning the starting NO

switch OFF, does the relay Go to E-4
ON and then OFF make a noise?
YES
3
Does the starting motor pin- NO

ion sound like it engages the
flywheel?
YES
Defective con-
4 tact or open cir-
cuit in the
• Turn starting switch Is the voltage 24 V between NO wiring harness
Repair or
starter terminal B and chas- between the
to the ON position replace
sis? battery positive
(+) and starting
YES motor terminal
B
Defective start-
Replace
ing motor
• Turn starting switch Is the voltage from 20 to 30 V NO

Defective start-
to the START posi- between starting switch ter- Replace
minal C and chassis? ing switch
tion
YES
Defective con-
tact or open in
the wiring har- Repair or
ness between replace
starting switch
terminal C, neu-
tral safety relay,
and starter relay
terminal (E6)
20-304 GD555, 655, 675-3A

(6)
TROUBLESHOOTING E-1
E-1 A) RELATED ELECTRICAL CIRCUIT DIAGRAM
GD555, 655, 675-3A 20-305

(1)
TROUBLESHOOTING E-1
A) STARTING MOTOR DOES NOT TURN

Cause Remedy
1
• Is battery voltage a mini-

mum of 20 V?
NO Lack of battery Charge or
• Is specific gravity of the
capacity replace
electrolyte a minimum of
1.26?
YES
2
• Turn starting switch When turning the starting NO

switch OFF, does the relay Go to E-4
ON and then OFF make a noise?
YES
3
Does the starting motor pin- NO

ion sound like it engages the
flywheel?
YES
4 Defective con-
tact or open cir-
cuit in the
• Turn starting switch Is the voltage 24 V between NO wiring harness
Repair or
starter terminal B and chas- between the
to the ON position sis? battery positive replace
(+) and starting
motor terminal
YES
B
Defective start-
ing motor Replace
• Turn starting switch Is the voltage from 20 to 30 V NO

Defective start-
to the START posi- between starting switch ter- ing switch Replace
tion minal C and chassis?
YES
Defective con-
tact or open in
the wiring har- Repair or
ness between replace
starting switch
terminal C, neu-
tral safety relay
and E6 (female)
20-305-1 GD555, 655, 675-3A

(6)
TROUBLESHOOTING E-1
E-1 A) RELATED ELECTRICAL CIRCUIT DIAGRAM
GD555, 655, 675-3A 20-305-2

(3)
TROUBLESHOOTING E-1
B) ENGINE STARTER SOLENOID DOES NOT WORK

Cause Remedy
1 Defective con-
tact or open cir-
• From 20 to 30 V cuit in the
• Turn starting switch Is the voltage between the NO wiring harness Replace the wir-
engine start up solenoid ter-
to the START posi- minal and chassis normal? between the ing harness
tion starting switch
terminal C and
YES B20 (Female) (1)
2 Defective con-
• Maximum 1 tact or open cir-
• Turn starting switch Is the resistance between NO cuit in the
B20 (Female) (2) and chassis wiring harness Replace the wir-
to the OFF position ing harness
normal? between B20
• Disconnect B20 (Female) (2) and
chassis
YES
Defective
engine start up Replace
solenoid
E-1 B) RELATED ELECTRICAL CIRCUIT DIAGRAM
Serial No.: 10001 – 11000
20-306 GD555, 655, 675-3A

(3)
TROUBLESHOOTING E-1
GD555, 655, 675-3A 20-307

(3)
TROUBLESHOOTING E-1
C) FUEL SHUT-OFF SOLENOID DOES NOT WORK

Seral No.: 10001 – 11000
• Set the gearshift lever to the P position before starting the troubleshooting process.
Cause Remedy
1
Defective contact or open
• From 20 – 30 V NO circuit in the wiring harness
Is the voltage between E9 (A) and between E9 (Female) (A) Repair or
• The starting switch is ON chassis normal? and BT35 (Terminal C), or replace
defective starting switch
YES
2
• From 20 – 30 V
Is the voltage between E9 (B) and NO
• The starting switch is at
chassis normal?
the START position
YES
• Maximum 1 Ω Open circuit in the wiring

Is the resistance between E9 (C) and NO harness between E9 Repair or
• Turn starting switch OFF chassis normal? (Female) (C) and chassis replace
• Disconnect E9 ground
YES Defective fuel shut-off sole- Replace

noid
4
• From 20 – 30 V NO
Is the voltage between ET90 and
• Turn starting switch to
chassis normal?
the START position
YES
5
• Maximum 1 Ω NO Open circuit in the wiring

Is the resistance between ET91 and Repair or
harness between E15
• Turn starting switch OFF chassis normal? (Male) (2) and ET91 replace
YES
6
• From 20 – 30 V NO Open circuit in the wiring

Is the voltage between ET70 and Repair or
chassis normal? harness between ET62 and replace
• Turn starting switch ON ET70
YES
Open circuit in the wiring
harness between E9 (B) and Repair or
ET71, or a defective fuel replace
shut-off relay
7
• From 20 – 30 V circuit in the wiring harness
Is the voltage between neutral relay NO between BR12 (Female) (1) Repair or
• Turn starting switch to
BR12 (1) and chassis normal? and gearshift lever T13 replace
the START position (Female) (6), or a defective
gearshift lever T13
YES

circuit in the wiring harness
between the neutral relay Repair or
BR12 (Female) (5) and replace
ET90, or a defective neutral
relay
20-308 GD555, 655, 675-3A

(6)
TROUBLESHOOTING E-1
E-1 C) RELATED ELECTRICAL CIRCUIT DIAGRAM
GD555, 655, 675-3A 20-309

(3)
TROUBLESHOOTING E-1
C) FUEL SHUT-OFF SOLENOID DOES NOT WORK

Seral No.: 11001 and up
• Set the gearshift lever to the P position before starting the troubleshooting process.
Cause Remedy
1
• From 20 – 30 V NO circuit in the wiring harness
Is the voltage between E9 (B) and between E9 (Female) (B) Repair or
• The starting switch is ON chassis normal? and BT35 (Terminal ACC), replace
or defective starting switch
YES
2
• From 20 – 30 V Is the voltage between E9 (A) and NO

• The starting switch is ON chassis normal?
YES
• Maximum 1 Ω Defective contact or open

Is the resistance between E9 (C) and NO circuit in the wiring harness Repair or
• Turn starting switch OFF chassis normal? between E9 (Female) (C) replace
• Disconnect E9 and chassis ground
YES Defective fuel shut-off sole- Replace

noid
4
• From 20 – 30 V NO Defective contact or open

Is the voltage between ET70 and Repair or
circuit in the wiring harness
• Turn starting switch ON chassis normal? between ET70 and ET62 replace
YES
5
When fuel shut-off relay is replaced, NO

does condition become normal?
YES
Defective fuel shut-off relay Replace
Disconnection or defective
When fuel shut-off timer is replaced, NO contact in wiring harness Repair or
does condition become normal? between ET71 - E9 (female) replace
(A)
YES
Defective fuel shut-off timer Replace
20-310 GD555, 655, 675-3A

(6)
TROUBLESHOOTING E-1
E-1 C) RELATED ELECTRICAL CIRCUIT DIAGRAM
GD555, 655, 675-3A 20-311

(3)
TROUBLESHOOTING E-2
E-2 ENGINE DOES NOT STOP

Serial No.: 10001 – 11000
Cause Remedy
1 Defective con-
tact with 24 V
• Maximum 1 V wiring harness Repair or
Is the voltage between E9 (A) NO between the replace
• Turn starting switch
and chassis normal? starting switch
OFF terminal ACC
(BT35) and E9
YES (Female) (A)
Defective fuel
shut-off sole- Replace
noid
E-2 RELATED ELECTRICAL CIRCUIT DIAGRAM
20-312 GD555, 655, 675-3A

(6)
TROUBLESHOOTING E-2

Cause Remedy
1 Defective con-
tact with 24 V
• Maximum 1 V wiring harness Repair or
Is the voltage between E9 (B) NO between the replace
• Turn starting switch
and chassis normal? starting switch
OFF terminal ACC
(BT35) and E9
YES (Female) (B)
Defective fuel
shut-off sole- Replace
noid
E-2) RELATED ELECTRICAL CIRCUIT DIAGRAM
GD555, 655, 675-3A 20-313

(6)
TROUBLESHOOTING E-3
E-3 ENGINE PREHEATING PILOT LAMP DOES NOT GLOW

★ Check that the pilot lamp is not defective.
Cause Remedy
1
• Minimum 20 V
• Turn starting switch Is the voltage between NO
heater relay terminal (ET82)
to the HEAT posi- and chassis normal?
tion
YES
2
Defective contact or
• Minimum 20 V open circuit in the wir-
• Turn starting switch Is the voltage between timer NO ing harness between
Repair or
relay BR19 (3) and chassis the starting switch ter-
to the HEAT posi- normal? minal R1 and the timer replace
tion relay BR19 (Female)
(3)
YES
3
• Maximum 1 Ω open circuit in the wir-
Is the resistance between NO
• Turn starting switch timer relay BR19 (6) and ing harness between Repair or
the timer relay BR19 replace
to the OFF position chassis normal?
(Female) (6) and chas-
sis ground
YES
4
• Maximum 1 V
• Turn starting switch Is the voltage between timer NO
to the HEAT posi- relay BR19 (1) and chassis Defective timer relay Replace
tion normal?
• Use T-adapter
YES Defective contact or

open circuit in the wir-
ing harness between Repair or
the battery relay ET58, replace
pilot lamp, timer relay
BR19 (Female) (1)
5
• Minimum 20 V
• Turn starting switch Is the voltage between start- NO
ing switch R1 and chassis
to the HEAT posi- normal?
tion
Repair or
ing harness between
starting switch R1 and replace
6 heater relay ET82
• Minimum 20 V
• Turn starting switch Is the voltage between start- NO
ing switch B and chassis nor- Go to E-4
to the HEAT posi- mal?
tion
YES
Defective starting
Replace
switch
20-314 GD555, 655, 675-3A

(6)
TROUBLESHOOTING E-3

Serial No.: 10001 – 11000
GD555, 655, 675-3A 20-315

(3)
TROUBLESHOOTING E-4
E-4 ELECTRICAL COMPONENTS DO NOT WORK

★ Verify that normal battery voltage exists.
Cause Remedy
1
• Turn starting switch Does the battery relay make NO
ON ↔ OFF an actuation sound?
YES
2
• Minimum 20 V Is the voltage between bat- NO

• Turn starting switch tery relay terminal ET58 and Defective battery relay Replace
ON chassis normal?

replace
battery relay terminal
ET58 and fuse box
3
Is the voltage between start- open circuit in the wir-
NO ing harness between Repair or
• Minimum 20 V ing switch terminal B (BT31)
the battery relay ET46 replace
and chassis normal? and starting switch
terminal B (BT31)
YES
4
• Minimum 20 V Is the voltage between bat- NO

• Turn starting switch tery relay ET75 and chassis
ON normal?
YES
5
• Maximum 1 Ω Is the resistance between bat- NO open circuit in the wir-
• Turn starting switch tery relay ET76 and chassis ing harness between Repair or
replace
OFF normal? battery relay ET76 and
chassis
YES
Defective battery relay Replace
• Minimum 20 V Is the voltage between start- NO Defective starting

• Turn starting switch ing switch BR (BT32) and Replace
chassis normal? switch
ON
YES
battery ET75 and start- replace
ing switch terminal BR
(BT32)
20-316 GD555, 655, 675-3A

(6)
TROUBLESHOOTING E-4

Serial No.: 10001 – 11000
GD555, 655, 675-3A 20-317

(3)
TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM
(T MODE)
Transmission controller system judgement table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-352

Controller action when problems occur with the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-358
Electrical circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-380
T-1 Error Code [A1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-382
T-2 Error Code [A2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-383
T-3 Error Code [A3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-384
T-4 Error Code [A4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-385
T-5 Error Code [A5] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-387
T-6 Error Code [A8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-389
T-7 Error Code [b1]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-390
T-8 Error Code [b2]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-391
T-9 Error Code [b3]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-392
T-10 Error Code [b4]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-393
T-11 Error Code [b5]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-394
T-12 Error Code [b6]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-395
T-13 Error Code [b7]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-396
T-14 Error Code [b8]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-397
T-15 Error Code [C0]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-398
T-16 Error Code [C1]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-399
T-17 Error Code [C3]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-400
T-18 Error Code [C4]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402
T-19 Error Code [C5]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-404
T-20 Error Code [C6]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-406
T-21 Error Code [C7]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-408
T-22 Error Code [C8]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-410
T-23 Error Code [C9]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-411
T-24 Error Code [d1]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-412
T-25 Error Code [d2]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-413
T-26 Error Code [d4]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-414
T-27 Error Code [d5]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-416
T-28 Error Code [d6]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-417
T-29 Error Code [d7]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-418
T-30 Error Code [E1]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-419
T-31 Error Code [E2]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-420
T-32 Error Code [E3]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-421
T-33 Error Code [E4]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-423
T-34 Error Code [E5]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-424
T-35 Error Code [E6]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-425
T-36 Error Code [E7]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-426
T-37 Error Code [E8]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-427
T-38 Error Code [F1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-428
T-39 Error Code [F2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-428
T-40 Error Code [F3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-429
T-41 Error Code [F4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-430
T-42 Error Code [F5] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-430
T-43 Error Code [F6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-431
T-44 Error Code [F7] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-431
T-45 Error Code [F8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-432
T-46 Error Code [91] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-433
T-47 Error Code [92] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-433
T-48 Error Code [93] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-434
T-49 Error Code [94] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-435
T-50 Error Code [95] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-435
T-51 Error Code [96] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-436
T-52 Error Code [97] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-436
T-53 Error Code [98] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-437
GD555, 655, 675-3A 20-351

(6)
TROUBLESHOOTING TRANSMISSION CONTROLLER SYSTEM JUDGEMENT TABLE
TRANSMISSION CONTROLLER SYSTEM JUDGEMENT TABLE

Self-diagnostic Display (Problem Displayed)
Short circuit to power source in the 2nd, 4th solenoid circuit

Short circuit to power source in the 1st, 3rd solenoid circuit
Short circuit to power source in the lock-up solenoid circuit

Short circuit to the power source in the FH solenoid circuit
Short circuit to the power source in the FL solenoid circuit
Short circuit to power source in the R solenoid circuit
Open circuit in the FH solenoid circuit

Open circuit in the FL solenoid circuit
Failure location
Open circuit in the R solenoid circuit

Error code
Failure mode
Transmission Controller Error
A1 A2 A3 A4 A5 A8 b1 b2 b3
1. Travel is impossible
2. Autoshifting is not performed { { { { { {
3. Downshifts, regardless of travel speed
4. Upshifts, regardless of travel speed
5. Excessive gearshift lock { { { { { { { { {
6. Abnormal gearshifting speed when traveling in the automode
7. Engine speed not displayed on the message center
8. Inching does not function normally { { {
9. Modulation clutch control does not function { { { { { { { { {
Troubleshooting code when an error code is displayed T-1 T-2 T-3 T-4 T-5 T-6 T-7 T-8 T-9
20-352 GD555, 655, 675-3A

(6)
Open circuit in the 1st solenoid circuit
{
{
{
b4
T-10
Open circuit in the 2nd solenoid circuit
{
{
{
b5
T-11
Open circuit in the 3rd solenoid circuit
{
{
{
b6
T-12
Open circuit in the 4th solenoid circuit
{
{
{
b7
T-13
GD555, 655, 675-3A

TROUBLESHOOTING
Open circuit in the lock-up solenoid circuit
b8
T-14
Power supply voltage reduced
{
{
C0
T-15
Engine speed sensor system
{
C1
T-16
Accelerator potentiometer system
C3
T-17
Inching potentiometer system
{
C4
T-18
Transmission oil temperature sensor system
{
{
C5
T-19
Torque converter outlet oil temperature system
C6
T-20
Hydraulic oil temperature sensor system (Opt.)
C7
T-21
Transmission input speed sensor system
{
C8
T-22
Transmission output speed sensor system
{
{
{
{
{
C9
T-23
Differential oil temperature lamp system (Opt.)

d1
T-24
Torque converter outlet oil temperature lamp system (Opt.)
d2
T-25
Alarm buzzer A system
d4
T-26
Warning lamp system
d5
T-27
Differential control relay system
d6
T-28
VHP solenoid relay system (Opt.)
d7
T-29
F (Forward), R (Reverse) signal system
{
E1
T-30
20-353
(6)
Failure location
Differential selector switch system

Stop lamp signal system
Parking signal system
Logic A signal system
Logic D signal system

Neutral signal system
Logic B signal system
Logic C signal system
Logic E signal system

Error code
Failure mode
E2 E3 E4 E5 E6 E7 E8 — —
1. Travel is impossible { { { { { { {
2. Autoshifting is not performed
5. Excessive gearshift lock
8. Inching does not function normally
9. Modulation clutch control does not function
Troubleshooting code when an error code is displayed T-31 T-32 T-33 T-34 T-35 T-36 T-37
20-354 GD555, 655, 675-3A

(6)
Lock-up switch system
—
Low set switch system
—
Model selection switch system
—
Differential selector switch system
GD555, 655, 675-3A

TROUBLESHOOTING
Inching selector switch system
—
High set switch system
—
Reset switch system
—
VHP selection switch system
—
AWD selection switch system
—
Memory reset switch system
—
Learning function initialize switch system
—
Short circuit to ground in the FL clutch pressure switch signal system
{
{
F1
T-38
Open circuit in the FL clutch pressure switch signal system
{
{
{
91
T-46
Short circuit to ground in the FH clutch pressure switch signal system
{
{
F2
T-39
Self-diagnostic Display (Problem displayed)
Open circuit in the FH clutch pressure switch signal system
{
{
{
92
T-47
Short circuit to ground in the R clutch pressure switch signal system
{
{
F3
T-40
Open circuit in the R clutch pressure switch signal system
{
{
{
93
T-48
Short circuit to ground in the 1st clutch pressure switch signal system
{
F4
T-41
Open circuit in the 1st clutch pressure switch signal system
{
{
94
T-49
Short circuit to ground in the 2nd clutch pressure switch signal system
{
F5
T-42
Open circuit in the 2nd clutch pressure switch signal system
{
{
95
T-50
20-355
(6)
Short circuit to ground in the lock-up clutch pressure switch signal system
Short circuit to ground in the 3rd clutch pressure switch signal system
Short circuit to ground in the 4th clutch pressure switch signal system
Open circuit in the lock-up clutch pressure switch signal system

Open circuit in the 3rd clutch pressure switch signal system
Open circuit in the 4th clutch pressure switch signal system
Troubleshooting code when no error code is displayed

Failure location
Error code
Failure mode
F6 96 F7 97 F8 98
1. Travel is impossible { { H-11
2. Autoshifting is not performed
5. Excessive gearshift lock { {
8. Inching does not function normally { {
9. Modulation clutch control does not function { {
Troubleshooting code when an error code is displayed T-43 T-51 T-44 T-52 T-45 T-53
20-356 GD555, 655, 675-3A

(6)
TROUBLESHOOTING CONTROLLER ACTION WHEN PROBLEMS OCCUR WITH MACHINE
CONTROLLER ACTION WHEN PROBLEMS OCCUR WITH MACHINE
Error System Normal Condition (Volts, Amps,

No. Nature of the Problem
Code Problem and Ohms)
1. Defective FL solenoid. • Resistance between T2

2. Short circuit to ground, short circuit to power source in the (Female) (7) and (17): 5 to
wiring harness between T2 (Female) (7) and T24 (Female) 15 Ω
Short circuit (1).
to the power 3. Short circuit to the power source in the wiring harness • Voltage between T2 (17) and
1 A1 source in the chassis at neutral:
FL solenoid between T2 (Female) (17) and T24 (Female) (2).
system. 4. Short circuit in the wiring harness between T2 (Female) (7) Max. 0.1 V
and T24 (Female) (1) and wiring harness between T2
(Female) (17) and T24 (Female) (2).
5. Defective transmission controller.
1. Defective FH solenoid. • Resistance between T2

Short circuit (1).
2 A2 source in the chassis at neutral:
FH solenoid between T2 (Female) (18) and T25 (Female) (2).
and T25 (Female) (1); and between T2 (Female) (18) and
T25 (Female) (2).
1. Defective R solenoid. • Resistance between T2

Short circuit (1).
3 A3 source in the
R solenoid between T2 (Female) (19) and T26 (Female) (2). chassis at neutral:
and T26 (Female) (1); and between T2 (Female) (19) and
T26 (Female) (2).
1. Defective 1st or 3rd solenoid. • Resistance between T2

2. Short circuit to ground, short circuit to power source in (Female) (2) and (13): 5 to
(1) or T2 (Female) (3) and T29 (Female) (1).
• Voltage between T2 (13) and
3. Short circuit to the power source in the wiring harness
chassis at neutral:
Short circuit between T2 (Female) (13) and T27 (Female) (2) or T2
to the power Max. 0.1 V
4 A4 source in the
1st, 3rd sole- 4. Short circuit in wiring harness between T2 (Female) (2) and • Resistance between T2
noid system. T27 (Female) (1); and between T2 (Female) (13) and T27 (Female) (3) and (14): 5 to
(Female) (2). 15 Ω
5. Short circuit in the wiring harness between T2 (Female) (3)
chassis at neutral:
Max. 0.1 V
1. Defective 2nd or 4th solenoid. • Resistance between T2

2. Short circuit to ground, short circuit to power source in (Female) (4) and (15): 5 to
(1) or T2 (Female) (5) and T30 (Female) (1).
3. Short circuit to the power source in the wiring harness
Short circuit chassis at neutral:
to the power between T2 (Female) (15) and T28 (Female) (2) or T2
Max. 0.1 V
source in the (Female) (16) and T30 (Female) (2).
5 A5 2nd, 4th 4. Short circuit in wiring harness between T2 (Female) (4) and • Resistance between T2
solenoid sys- T28 (Female) (1); and between T2 (Female) (15) and T28 (Female) (5) and (16): 5 to
tem.
(Female) (2). 15 Ω
5. Short circuit in the wiring harness between T2 (Female) (5)
chassis at neutral:
Max. 0.1 V
20-358 GD555, 655, 675-3A

(6)
Trouble-
Controller Action After Detecting the Problem With Code Warning Alarm Warning
Problem the Machine Displayed Lamp Buzzer Chime Memory shooting
Code
Turns FL, FH, R solenoid outputs OFF.

Lever command when at:
N: 1st – 4th solenoids OFF
F1, F2: F1
Big transmission
F3, F4: F3 shock, but possi-
F5, F6: F5 ble to travel in { { { { { T-1
F7, F8: F7 F1, F3, F5, F7.
R: 1st thru 4th solenoids OFF
After alarm buzzes for 2 seconds,
chimes sound continuously.

N, F1: S solenoid OFF
F2, F3: F2
Big transmission
F4, F5: F4 shock, but possi-
F6, F7: F6 ble to travel in { { { { { T-2
F8: F8 F2, F4, F6, F8.
R: 1st thru 4th solenoids OFF

N, F1 – F8: 1st – 4th solenoids OFF
R1: R1 Big transmission
R2: R2 shock, but possi- { { { { { T-3
ble to travel in
R3: R3 R1, R2, R3, R4.
R4: R4
Big transmission
Turns 1st thru 4th solenoid outputs
OFF. shock, but possi-
ble to travel in { { { { { T-4
chimes sound continuously. F1, F2, F5, F6,
R1, R3.
Turns 1st thru 4th solenoid outputs Big transmission

shock, but possi-
OFF.
After alarm buzzes for 2 seconds, ble to travel in { { { { { T-5
F3, F4, F7, F8, R2,
R4.
GD555, 655, 675-3A 20-359

(6)
No. Error System Nature of the Problem Normal Condition (Volts, Amps,
1. Defective lock-up solenoid. • Resistance between T2

2. Short circuit to ground, short circuit to power source in the wir- (Female) (10) and (20): 5 to
ing harness between T2 (Female) (10) and T31 (Female) (1). 15 Ω
Short circuit
to the power 3. Short circuit to power source in the wiring harness between T2 • Voltage between T2 (20) and
6 A8 source in the (Female) (20) and T31 (Female) (1). chassis at neutral:
lock-up sole- 4. Short circuit in wiring harness between T2 (Female) (10) and
noid system. Max. 0.1 V
T31 (Female) (1); and between T2 (Female) (20) and T31
(Female) (2).
1. Defective FL solenoid. • Resistance between T2

2. Defective contact or open circuit in the wiring harness between (Female) (7) and (17): 5 to 15 Ω
Open circuit T2 (Female) (7) and T24 (Female) (1).
7 b1 in the FL sole- • Voltage between T2 (17) and
noid circuit. 3. Short circuit to ground in wiring harness between T2 (Female) chassis at neutral:
(17) and T24 (Female) (2). Max. 0.1 V
1. Defective FH solenoid. • Resistance between T2

Open circuit 2. Defective contact or open circuit in the wiring harness between (Female) (8) and (18): 5 to 15 Ω
in the FH T2 (Female) (8) and T25 (Female) (1).
8 b2 • Voltage between T2 (18) and
solenoid cir- 3. Short circuit to ground in wiring harness between T2 (Female)
cuit. chassis at neutral:
(18) and T25 (Female) (2).
Max. 0.1 V
1. Defective R solenoid. • Resistance between T2

2. Defective contact or open circuit in the wiring harness between (Female) (9) and (19): 5 to 15 Ω
Open circuit T2 (Female) (9) and T26 (Female) (1).
9 b3 in the R sole- • Voltage between T2 (19) and
noid system. 3. Short circuit to ground in wiring harness between T2 (Female) chassis at neutral:
(19) and T26 (Female) (2). Max. 0.1 V
1. Defective 1st solenoid. • Resistance between T2

in the 1st T2 (Female) (2) and T27 (Female) (1).
10 b4 • Voltage between T2 (13) and
solenoid sys- 3. Short circuit to ground in wiring harness between T2 (Female)
tem. chassis at neutral:
(13) and T27 (Female) (2).
Max. 0.1 V
1. Defective 2nd solenoid. • Resistance between T2

in the 2nd T2 (Female) (4) and T28 (Female) (1). • Voltage between T2 (15) and
11 b5 solenoid sys- 3. Short circuit to ground in wiring harness between T2 (Female) chassis at neutral:
tem. (15) and T28 (Female) (2). Max. 0.1 V
1. Defective 3rd solenoid. • Resistance between T2

in the 3rd T2 (Female) (3) and T29 (Female) (1).
12 b6 solenoid sys- 3. Short circuit to ground in wiring harness between T2 (Female) • Voltage between T2 (14) and
tem. (14) and T29 (Female) (2). chassis at neutral:
4. Defective transmission controller. Max. 0.1 V
1. Defective 4th solenoid. • Resistance between T2

in the 4th T2 (Female) (5) and T30 (Female) (1). • Voltage between T2 (16) and
13 b7 solenoid sys- 3. Short circuit to ground in wiring harness between T2 (Female) chassis at neutral:
tem. (16) and T30 (Female) (2). Max. 0.1 V
1. Defective lock-up solenoid. • Resistance between T2

Open circuit 2. Defective contact or open circuit in wiring harness between T2 (Female) (10) and (20): 5 to
in the lock-up (Female) (10) and T31 (Female) (1). 15 Ω
14 b8
solenoid sys- 3. Short circuit to ground in wiring harness between T2 (Female) • Voltage between T2 (20) and
tem. (20) and T31 (Female) (2). chassis at neutral:
4. Defective transmission controller. Max. 0.1 V
1. Defective contact or open circuit in wiring harness between T1 • Voltage between T1 (7), (13) –
(Female) (7), (13), T2 (1), (12) – T11 (Male) (1). chassis: 19 to 30 V
Power source 2. Defective contact or open circuit in wiring harness between T1
15 C0 voltage (Female) (6), (12), T2 (11), (21) – chassis. • Voltage between T2 (1), (12) –
reduced. 3. Defective contact or open circuit in wiring harness between chassis: 19 to 30 V
T11 (Female) (11) and battery relay.
20-360 GD555, 655, 675-3A

(6)
Controller Action After Detecting the Problem With the Code Warning Alarm Warning Trouble-
Problem Machine Displayed Lamp Buzzer Chime Memory shooting
Code
Turns lock-up solenoid output OFF. Lock-up is always

After alarm buzzes for 2 seconds, chimes applied. { { { { { T-6
sound continuously.
Does not travel in

No action. F1, F3, F5, F7 { { { { { T-7
(Coasts).
Does not travel in

No action. F2, F4, F6, F8 { { { { { T-8
(Coasts).
Does not travel in

No action. reverse (Coasts). { { { { { T-9
No action. Cannot travel in { { { { { T-10

F1, F2, R1.
No action. Cannot travel in { { { { { T-11

F3, F4, R2.
Does not travel

No action. F5, F6, R3. { { { { { T-12
Cannot travel in
No action. F7, F8, R4. { { { { { T-13
Always torque
converter drive
No action. (Lock-up is not { { { { { T-14
applied).
All solenoid outputs OFF (Sets to Neu- Stays in N. { { { — { T-15

tral).
GD555, 655, 675-3A 20-361

(6)

1. Defective engine speed sensor. • Resistance between T4

Open circuit 2. Defective contact or open circuit in wiring harness (Female) (7) and T5 (Female)
in the engine between T4 (Female) (7) and T46 (Female) (1). (1): 500 to 1000 Ω
16 C1
speed sensor 3. Defective contact or open circuit in wiring harness
system. between T5 (Female) (1) and T46 (Female) (2).
1. Defective accelerator potentiometer. • Voltage between T3A (13) and

Short circuit 2. Short circuit to power source in wiring harness between (16): 0.5 to 4.75 V
to the power T3A (Female) (3) and T9 (Female) (B).
source in the
17 C3 3. Defective contact, open circuit, short circuit, short circuit to
accelerator
potentiome- ground, or short circuit to power source in wiring harness
ter system. between T3A (Female) (7) and T9 (Female) (A).
1. Defective accelerator potentiometer. • Voltage between T3A (13) and

2. Defective contact or open circuit in the wiring harness (16): 0.5 to 4.75 V
Open circuit between T3A (Female) (16) and T9 (Female) (3).
in the accel- 3. Contact of wiring harness between T3A (Female) (3) and
18 C3 erator poten-
tiometer T9 (Female) (B) with wiring harness between T3A (Female)
system. (7) and T9 (Female) (A), or contact with power source wir-
ing harness.
1. Defective inching potentiometer. • Voltage between T3A (13) and

Short circuit (16): 0.5 to 4.75 V
to the power 2. Short circuit to power source in wiring harness between
source in T3A (Female) (13) and T8 (Female) (B).
19 C4 inching 3. Defective contact, open circuit, short circuit, short circuit to
potentiome- ground, or short circuit to the power source in the wiring
ter system
(Opt). harness between T3A (Female) (7) and T8 (Female) (A).
1. Defective inching potentiometer. • Voltage between T3A (13) and

2. Defective contact or open circuit in the wiring harness (16): 0.5 to 4.75 V
Open circuit
in the inch- between T3A (Female) (16) and T8 (Female) (C).
ing potenti- 3. Contact of wiring harness between T3A (Female) (13) and
20 C4
ometer T8 (Female) (B) with wiring harness between T3A (Female)
system (7) and T8 (Female) (A), or in contact with power source
(Opt).
wiring harness.
• Voltage between T3A

Short circuit (Female) (11), T34 (Female)
to the power 1. Defective transmission oil temperature sensor.
source in the (1) and chassis: Max. 4.75 V
2. Short circuit to ground, short circuit, or short circuit to the
transmis- • Resistance between T34
21 C5 power source in wiring harness between T3A (Female) (1)
sion oil tem- (Male) (1) and (2):
perature and T35 (Female) (1).
25 °C (Normal temperature):
sensor cir- 3. Defective transmission controller.
cuit. 3.5 – 4.0 Ω
100 °C: 38.5 – 47.0 Ω
• Voltage between T3A

1. Defective transmission oil temperature sensor. (Female) (11), T34 (Female)
Open circuit
in the trans- 2. Defective contact or open circuit in the wiring harness (1) and chassis: Max. 4.75 V
mission oil between T3A (Female) (1) and T35 (Female) (1). • Resistance between T34
22 C5
temperature 3. Defective contact or open circuit in the wiring harness (Male) (1) and (2):
sensor cir- between T35 (Female) (2) and chassis. 25 °C (Normal temperature):
cuit.
4. Defective transmission controller. 3.5 – 4.0 Ω
100 °C: 38.5 – 47.0 Ω
20-362 GD555, 655, 675-3A

(6)
Trouble-
Memory shooting
Problem the Machine Displayed Lamp Buzzer Chime Code
Engine speed not displayed on mes- None in particu-

sage center. lar. { { — — { T-16
Calculates for the accelerator at low Reduced power. { { — — { T-17

position.
Calculates for the accelerator at low

Reduced power. { { — — { T-17
position.
Inching impossi-
No inching output. { { — — { T-18
ble.
Inching impossi-
No inching output. ble. { { — — { T-18
Outputs with oil temperature map for Normal opera-

{ { — — { T-19
less than 20 °C. tion.
Outputs with oil temperature map for Normal opera-

{ { — — { T-19
less than 20 °C. tion.
GD555, 655, 675-3A 20-363

(6)

Short circuit • Voltage between T3A

to the power 1. Defective torque converter outlet oil temperature sensor. (Female) (1), T35 (Female) (1)
source in the 2. Short circuit to ground, short circuit, or short circuit to the and chassis: Max. 4.75 V
torque con- • Resistance between T35
23 C6 power source in the wiring harness between T3A (Female)
verter outlet (Male) (1) and (2):
oil tempera- (11) and T34 (Female) (1). 25 °C (Normal temperature):
ture sensor 3. Defective transmission controller. 3.5 – 4.0 Ω
system. 100 °C: 38.5 – 47.0 Ω
Open circuit 1. Defective torque converter outlet oil temperature sensor. • Voltage between T3A
(Female) (1), T35 (Female) (1)
in the torque 2. Defective contact or open circuit in the wiring harness
converter and chassis: Max. 4.75 V
between T3A (Female) (11) and T34 (Female) (1). • Resistance between T35
24 C6 outlet oil
temperature 3. Defective contact or open circuit in wiring harness (Male) (1) and (2):
sensor sys- between T34 (Female) (2) and chassis. 25 °C (Normal temperature):
tem. 3.5 – 4.0 Ω
4. Defective transmission controller. 100 °C: 38.5 – 47.0 Ω
Short circuit • Voltage between T3A

1. Defective hydraulic oil temperature sensor. (Female) (2), E5 (Female) (1)
to the power
source in the 2. Short circuit to ground, short circuit, or short circuit to the and chassis: Max. 4.75 V
• Resistance between E5 (Male)
25 C7 hydraulic oil power source in the wiring harness between T3A (Female)
temperature (1) and (2):
(2) and E5 (Female) (1). 25 °C (Normal temperature):
sensor sys-
tem (Opt). 3. Defective transmission controller. 3.5 – 4.0 Ω
100 °C: 38.5 – 47.0 Ω
1. Defective hydraulic oil temperature sensor. • Voltage between T3A

Open circuit (Female) (2), E5 (Female) (1)
in the 2. Defective contact or open circuit in the wiring harness and chassis: Max. 4.75 V
hydraulic oil between T3A (Female) (2) and E5 (Female) (1). • Resistance between E5 (Male)
26 C7 temperature 3. Defective contact or open circuit in wiring harness (1) and (2):
sensor sys- between E5 (Female) (2) and chassis. 25 °C (Normal temperature):
tem (Opt). 3.5 – 4.0 Ω
4. Defective transmission controller. 100 °C: 38.5 – 47.0 Ω
1. Defective transmission input shaft speed sensor. • Resistance between T5 (2)

Open circuit and (1): 500 – 1000 Ω
in the trans- 2. Defective contact or open circuit in wiring harness
mission between T5 (Female) (2) and T32 (Female) (1).
27 C8 input speed 3. Defective contact or open circuit in wiring harness
sensor sys- between T5 (Female) (1) and T32 (Female) (2).
tem.
1. Defective transmission output shaft speed sensor. • Resistance between T4 (1)

Open circuit and T5 (1): 500 – 1000 Ω
in the trans- 2. Defective contact or open circuit in wiring harness
mission out- between T4 (Female) (2) and T33 (Female) (1).
28 C9 put speed 3. Defective contact or open circuit in wiring harness
sensor sys- between T5 (Female) (1) and T33 (Female) (2).
tem.
Short circuit • Voltage between T1 (1) and

to power chassis: When output is OFF:
source in the 1. Defective differential oil temperature warning lamp. Max. 1 V
differential 2. Short circuit to power source in wiring harness between
29 d1 oil tempera- T1 (Female) (1) and FP3 (Female) (4).
ture warning 3. Defective transmission controller.
lamp system
(Opt).
Open circuit • Voltage between T1 (1) and

in the differ- 1. Defective differential oil temperature warning lamp. chassis: When output is ON:
ential oil 17 to 30 V
2. Defective contact or open circuit in wiring harness
30 d1 temperature
warning between T1 (Female) (1) and FP3 (Female) (4).
lamp system 3. Defective transmission controller.
(Opt).
Short circuit Voltage between T1 (3) and

to power chassis:
source in the • When output is OFF: Max. 1 V
transmis- 1. Defective transmission (Torque converter outlet) oil tem-
sion (Torque perature warning lamp.
31 d2 converter 2. Short circuit to power source in wiring harness between
outlet) oil T1 (Female) (3) and FP3 (Female) (6).
temperature
warning 3. Defective transmission controller.
lamp sys-
tem.
20-364 GD555, 655, 675-3A

(6)
Trouble-
Memory shooting
No action. Normal opera- { { — — { T-20

tion.
Normal opera-
No action. tion. { { — — { T-20

tion.

tion.
Normal opera-
No action. { { { { { T-22
tion.
When starting switch is ON and gear- Travel impossi-

shift lever kept at N, possible up to ble after stop-
2nd; when travelling, taken as N until ping the { { { { { T-23
starting switch is turned OFF. machine.
Differential oil
temperature
Differential oil temperature warning warning lamp { { — — { T-24
lamp output OFF.
stays on and
does not go out.
Warning lamp
does not light up
Differential oil temperature warning when the differ-
lamp output OFF. ential oil tem- { { — — { T-24
perature is
abnormal.
Torque con-
verter outlet port
Torque converter outlet port oil tem- oil temperature
{ { — — { T-25
perature warning lamp output OFF. warning lamp
stays on and
does not go out.
GD555, 655, 675-3A 20-365

(6)

Open circuit Voltage between T1 (3) and

in the trans- 1. Defective transmission (Torque converter outlet) oil tem- chassis:
mission perature warning lamp. • When output is ON: 17 to 30 V
(Torque con-
32 d2 2. Defective contact or open circuit in wiring harness between
verter outlet)
oil tempera- T1 (Female) (3) and FP3 (Female) (6).
ture warning 3. Defective transmission controller.
lamp system.

to power 1. Defective alarm buzzer (Alarm buzzer A). chassis:
source in the 2. Short circuit to power source in wiring harness between T1 • When output is OFF: Max. 1 V
33 d4 alarm buzzer
(Alarm (Female) (9) and BR22 (Female) (1).
buzzer A) 3. Defective transmission controller.
system.
1. Defective alarm buzzer (Alarm buzzer A). Voltage between T1 (9) and
Open circuit chassis:
in the alarm 2. Defective contact or open circuit in wiring harness between
T1 (Female) (9) and BR22 (Female) (1). • When output is ON: 17 to 30 V
buzzer
34 d4
(Alarm 3. Defective contact or open circuit in wiring harness between
buzzer A) BR22 (Female) (2) and chassis.
system.

to power 1. Defective warning lamp. chassis:
source in the 2. Short circuit to the power source in the wiring harness • When output is OFF: Max. 1 V
35 d5 transmis-
sion control between T1 (Female) (5) and FP3 (Female) (7).
warning 3. Defective transmission controller.
lamp system.
Open circuit 1. Defective warning lamp. Voltage between T1 (5) and

in the trans- 2. Defective contact or open circuit in the wiring harness chassis:
36 d5 mission con- • When output is ON: 17 to 30 V
trol warning between T1 (Female) (5) and FP3 (Female) (7).
lamp system. 3. Defective transmission controller.

to power 1. Defective differential control relay. chassis:
source in the 2. Short circuit to the power source in the wiring harness • When output is OFF: Max. 1 V
37 d6 differential between T1 (Female) (11) and BR7 (Female) (1).
control relay 3. Defective transmission controller.
system.
1. Defective differential control relay. Voltage between T1 (11) and

Open circuit 2. Defective contact or open circuit in the wiring harness chassis:
in the differ- between T1 (Female) (11) and BR7 (Female) (1). • When output is ON: 17 to 30 V
38 d6 ential con-
trol relay 3. Defective contact or open circuit in the wiring harness
system. between BR7 (Female) (2) and chassis.

to power 1. Defective VHP solenoid relay. chassis:
source in the 2. Short circuit to the power source in the wiring harness • When output is OFF:
39 d7
VHP solenoid between T1 (Female) (2) and BR8 (Female) (1). (Except for VHP specification):
relay system 3. Defective transmission controller. Max. 1 V
(Opt).
1. Defective VHP solenoid relay. Voltage between T1 (2) and

in the VHP • When output is ON:
between T1 (Female) (2) and BR8 (Female) (1).
40 d7 solenoid (VHP specification): 17 to 30 V
relay system 3. Defective contact or open circuit in the wiring harness
(Opt). between BR8 (Female) (2) and chassis.
Short circuit 1. Defective gearshift lever. Voltage between T5 (6) and

to power 2. Short circuit to the power source in the wiring harness chassis:
41 E1 source in the • Except when gearshift lever is
F (Forward) between T5 (Female) (6) and T13 (Female) (7). at [F1] to [F8]: Max. 1 V
signal circuit. 3. Defective transmission controller.
Open circuit 1. Defective gearshift lever. Voltage between T5 (6) and

in the F (For- 2. Defective contact or open circuit in the wiring harness chassis:
42 E1 • When gearshift lever is at [F1]
ward) signal between T5 (Female) (6) and T13 (Female) (7).
circuit. to [F8]: 20 to 30 V
20-366 GD555, 655, 675-3A

(6)
Trouble-
Problem the Machine Displayed Lamp Buzzer Chime Memory shooting
Code
Warning lamp
does not light up
when transmis-
Torque converter outlet port oil tem- sion oil tempera-
{ { — — { T-25
perature warning lamp output OFF. ture problems
exist (Torque
converter outlet
port).
Alarm buzzer
Alarm buzzer output OFF. { — { { { T-26
does not stop.
Alarm buzzer
Alarm buzzer output OFF. { — { { { T-26
does not sound.
Warning lamp
Warning lamp output OFF. stays lit and { — — { { T-27
does not go out.
Warning lamp
Warning lamp output OFF. does not light { — — { { T-27
up.
Normal differen-
Differential control relay output OFF. tial condition. { { — { { T-28
Normal differen-
Differential control relay output OFF. tial lock condi- { { — { { T-28
tion.
VHP solenoid relay output OFF. Normal VHP { { — { { T-29

condition.
VHP solenoid relay output OFF. Does not change { { — { { T-29

to VHP.
F and R signals input at the same time Machine coasts, { { { { { T-30

→ N. and then stops.
Impossible to
No action. travel in FOR- { { { { { T-30
WARD.
GD555, 655, 675-3A 20-367

(6)


to power 1. Defective gearshift lever. chassis: Except when gearshift
source in the 2. Short circuit to the power source in the wiring harness lever is at [R1] to [R4]: Max. 1 V
43 E1 R (Reverse) between T5 (Female) (14) and T13 (Female) (13).
signal sys- 3. Defective transmission controller.
tem.
Open circuit 1. Defective gearshift lever. Voltage between T5 (14) and

in the R 2. Defective contact or open circuit in the wiring harness chassis: When gearshift lever is
44 E1 (Reverse) at [R1] to [R4]: 20 to 30 V
signal sys- between T5 (Female) (14) and T13 (Female) (13).
tem. 3. Defective transmission controller.
Short circuit 1. Defective gearshift lever. Voltage between T3A (8) and
to power 2. Short circuit to the power source in the wiring harness chassis: Except when gearshift
45 E2 source in the lever is in Neutral, Park:
neutral sig- between T3A (Female) (8) and T13 (Female) (2). Max. 1 V
nal system. 3. Defective transmission controller.
Open circuit 1. Defective gearshift lever. Voltage between T3A (8) and
in the neutral 2. Defective contact or open circuit in the wiring harness chassis: When gearshift lever is
46 E2 in Neutral, Park: 20 to 30 V
signal sys- between T3A (Female) (8) and T13 (Female) (2).
1. Defective parking brake relay. Voltage between T3A (9) and

2. Short circuit to the power source in the wiring harness chassis: Except when gearshift
Short circuit lever is in Park: Max. 1 V
to power between T3A (Female) (9) and BR11 (Female) (6).
47 E3 source in the 3. Short circuit to the power source in the wiring harness
parking sig- between T13 (Female) (10) and BR11 (Female) (1).
nal system.
5. Defective gearshift lever.
1. Defective parking brake relay. Voltage between T3A (9) and

2. Defective contact or open circuit in the wiring harness chassis: When gearshift lever is
in Park: 20 to 30 V
between T3A (Female) (9) and BR11 (Female) (6).
Open circuit 3. Defective contact or open circuit in the wiring harness
48 E3 in the park-
ing signal between T13 (Female) (10) and BR11 (Female) (1).
system 4. Defective contact or open circuit in the wiring harness
between BR11 (Female) (2) and chassis.
6. Defective gearshift lever.
Short circuit 1. Defective gearshift lever. Voltage between T3A (18) and
to power 2. Short circuit to the power source in the wiring harness chassis: When gearshift lever is
49 E4 source in the in Park, Neutral:
logic A sys- between T3A (Female) (18) and T13 (Female) (4). Max. 1 V
1. Defective gearshift lever. Voltage between T3A (18) and

Open circuit 2. Defective contact or open circuit in the wiring harness chassis: Except when gearshift
50 E4 in the logic A lever is in Park, Neutral: 20 to 30
system between T3A (Female) (18) and T13 (Female) (4). V

51 E5 source in the lever is in [F1], [F5] – [F7], [R1] –
logic B sys- between T5 (Female) (7) and T13 (Female) (5). [R3]: Max. 1 V
1. Defective gearshift lever. Voltage between T5 (7) and

Open circuit 2. Defective contact or open circuit in the wiring harness chassis: When gearshift lever is
52 E5 in the logic B in [F1], [F5] – [F7], [R1] – [R3]:
system between T5 (Female) (7) and T13 (Female) (5). 20 to 30 V

53 E6 source in the lever is in [F1] – [F5], [R1]:
logic C sys- between T5 (Female) (15) and T13 (Female) (12). Max. 1 V

Open circuit 2. Defective contact or open circuit in the wiring harness chassis: When gearshift lever is
54 E6 in the logic C in [F1] – [F5], [R1]: 20 to 30 V
20-368 GD555, 655, 675-3A

(6)
Trouble-
Memory shooting
F and R signals input at the same time Machine coasts,

→ N. and then stops. { { { { { T-30
Impossible to
No action. travel in { { { { { T-30
REVERSE.
N, P, and other signals input at same Machine coasts,

time → N and then stops.
{ { { { { T-31
N and other signals input at the same After stopping,
time → N. cannot travel.
No F, R, N signals → N. Cannot travel. { { { { { T-31
Danger that
machine will
move when the
No action. lever is oper- { { — { { T-32
ated and the
parking brake
will seize.
When machine
stops, it does
not move when
operating the
lever.
No action. Shifts to Neutral { { — { { T-32
during travel
when accelera-
tor pedal is
being
depressed.
Set to Neutral. Cannot travel. { { — { { T-33
GD555, 655, 675-3A 20-369

(6)


logic D sys- between T5 (Female) (8) and T13 (Female) (18). in [F1] – [F3]: Max. 1 V

56 E7 in the logic D • When gearshift lever is in [F1]
system. between T5 (Female) (8) and T13 (Female) (18). – [F3]: 20 to 30 V

logic E sys- between T5 (Female) (16) and T13 (Female) (3). in [F3] – [F6], [R1], [R2]:
tem. 3. Defective transmission controller. Max. 1 V

58 E8 in the logic E • When gearshift lever is in [F3]
– [F6], [R1], [R2]: 20 to 30 V
Short circuit 1. Defective stop lamp or stop lamp relay. Voltage between T3A (19) and
59 — source in the • When output is OFF (Brake
stop lamp between T3A (Female) (19) and BR10 (Female) (5) or RL1
pedal is not being depressed):
signal sys- (Female) (3). Max. 1 V
1. Defective stop lamp or stop lamp relay. Voltage between T3A (19) and
60 — in the stop • When output is ON (Brake
lamp signal between T3A (Female) (19) and BR10 (Female) (5) or RL1
pedal is being depressed):
system. (Female) (3). 17 to 30 V
Short circuit 1. Defective differential switch. Voltage between T1 (11) and

to ground in 2. Short circuit to ground, short circuit, or short circuit to chassis:
61 — the differen- • When differential selector
tial selector power source in harness between T5 (Female) (9) and FP13
switch is ON: 20 to 30 V
switch sys- (Female) (2). • When differential selector
tem. 3. Defective transmission controller. switch is OFF: Max. 1 V
Voltage between T1 (11) and

Open circuit 1. Defective differential switch.
in the differ- chassis:
2. Defective contact or open circuit in the wiring harness • When differential selector
62 — ential selec-
tor switch between T5 (Female) (9) and FP13 (Female) (2). switch is ON: 20 to 30 V
system. 3. Defective transmission controller. • When differential selector
switch is OFF: Max. 1 V
Short circuit 1. Defective lock-up switch. Voltage between T5 (17) and

to ground in 2. Short circuit to ground, short circuit, or short circuit to chassis:
the differen- • When lock-up switch is ON:
63 — tial lock-up power source in harness between T5 (Female) (17) and T14
20 to 30 V
switch sys- (Female) (2). • When lock-up switch is OFF:
tem. 3. Defective transmission controller. Max. 1 V
Open circuit Voltage between T5 (17) and

1. Defective lock-up switch. chassis:
in the differ- 2. Defective contact or open circuit in the wiring harness
64 — ential lock-up • When lock-up switch is ON:
switch sys- between T5 (Female) (17) and T14 (Female) (2). 20 to 30 V
tem. 3. Defective transmission controller. • When lock-up switch is OFF:
Max. 1 V
20-370 GD555, 655, 675-3A

(6)
Trouble-
Memory shooting
Shock becomes
Takes no action. greater when — — — — — —
decelerating.
Takes no action. None. — — — — — —
Differential lock
No action. may be applied. — — — — — —
Differential lock
No action. always applied. — — — — — —
Always enters
the lock-up
No action. mode when in — — — — — —
F1 – F4 or R1 –
R4.
Always enters
torque con-
No action. verter mode — — — — — —
when in F1 – F4
or R1 – R4
GD555, 655, 675-3A 20-371

(6)

Short circuit 1. Defective low set switch. Resistance between T5 (12) and
2. Short circuit to ground, short circuit, or short circuit to chassis:
to ground in
65 — low set power source in wiring harness between T5 (Female) (12) • When potentiometer switch is
LOW: Max. 1 Ω
switch sys- and TT1 (Terminal) (4). • When potentiometer switch is
tem. HIGH, OFF: Min. 1 M Ω
Resistance between T5 (12) and

Open circuit 1. Defective low set switch. chassis:
in the low set 2. Defective contact or open circuit in wiring harness • When potentiometer switch is
66 —
switch sys- between T5 (Female) (12) and TT1 (Terminal) (4). LOW: Max. 1 Ω
tem. 3. Defective transmission controller. • When potentiometer switch is
HIGH, OFF: Min. 1 M Ω
Short circuit Resistance between T5 (5) and

to ground in 1. Short circuit to ground, short circuit, or short circuit to the chassis:
the model • STD specification: Max. 1 Ω
67 — power source in the wiring harness between T5 (Female)
selection • Specification: Min. 1 M Ω
switch sys- (5) and T7 (Female) (1).
tem.
Open circuit Resistance between T5 (5) and

in the model 1. Defective contact or open circuit in the wiring harness chassis:
68 — selection • STD specification: Max. 1 Ω
switch sys- between T5 (Female) (5) and T7 (Female) (1). • Specification: Min. 1 Ω
tem.

69 — the differen- power source in the wiring harness between T3A (Female) • When differential selection
tial selection switch is ON: Max. 1 Ω
switch sys- (10) and T7 (Female) (2). • When differential selection
tem. switch is OFF: Min. 1 M Ω
Open circuit Resistance between T5 (9) and

chassis:
in the differ- 1. Defective contact or open circuit in the wiring harness
70 — ential selec- • When differential selection
between T3A (Female) (10) and T7 (Female) (2). switch is ON: Max. 1 Ω
tion switch • When differential selection
system. switch is OFF: Min. 1 M Ω
Short circuit Resistance between T3A (20)

to ground in 1. Short circuit to ground, short circuit, or short circuit to the and chassis:
71 — the inching power source in the wiring harness between T3A (Female) • With inching specification:
selection Max. 1 Ω
switch sys- (20) and T7 (Female) (4). • Without inching specifica-
tem. tion: Min. 1 MΩ
Open circuit Resistance between T3A (20)

and chassis:
in the inch- 1. Defective contact or open circuit in the wiring harness
72 — ing selection • With inching specification:
switch sys- between T3A (Female) (20) and T7 (Female) (4). Max. 1 Ω
• Without inching specifica-
tem.
tion: Min. 1 MΩ
20-372 GD555, 655, 675-3A

(6)
Trouble-
Memory shooting
If a short circuit exists when turning

the starting switch to ON, the setting Normal opera- — — — — — —
tion.
does not work.
No action. Normal opera- — — — — — —

tion.
If reset switch is not turned OFF (At

least 1 sec.) → ON (At least 1 sec.) → Normal opera-
OFF (At least 1 sec.), does not enter tion. — — — — — —
selection mode.

— — — — — —
OFF (At least 1 sec.), does not enter tion.
selection mode.

least 1 sec.) → ON (At least 1 sec.) → Normal opera- — — — — — —
differential mode.

differential mode.

OFF (At least 1 sec.), does not enter tion. — — — — — —
inching mode.

— — — — — —
inching mode.
GD555, 655, 675-3A 20-373

(6)

Resistance between T3B (1) and

Short circuit chassis:
to ground in 1. Short circuit to ground, short circuit, or short circuit to the
• When potentiometer switch is
73 — the high set power source in the wiring harness between T3B (Female)
switch sys- at HIGH: Max. 1 Ω
(1) and TT (Terminal) (3). • When potentiometer switch is
tem.
at LOW, OFF: Min. 1 MΩ

in the high 1. Defective contact or open circuit in the wiring harness • When potentiometer switch is
74 —
set switch between T3B (Female) (1) and TT (Terminal) (3). at HIGH: Max. 1 Ω
system. • When potentiometer switch is
at LOW, OFF: Min. 1 MΩ

Short circuit chassis:
to ground in 1. Short circuit to ground, short circuit, or short circuit to the
• When reset switch is ON:
75 — the reset power source in the wiring harness between T3B (Female)
switch sys- Max. 1 Ω
(9) and TT (Terminal) (8). • When reset switch is OFF:
tem.
Min. 1 MΩ

in the reset 1. Defective contact or open circuit in the wiring harness • When reset switch is ON:
76 —
switch sys- between T3B (Female) (9) and TT (Terminal) (8). Max. 1 Ω
tem. • When reset switch is OFF:
Min. 1 MΩ
Short circuit Resistance between T3B (2) and

the VHP • With VHP specification:
77 — power source in the wiring harness between T3B (Female)
selection Max. 1 Ω
switch sys- (2) and T7 (Female) (3). • Without VHP specification:
tem. Min. 1 MΩ

in the VHP 1. Defective contact or open circuit in the wiring harness • With VHP specification:
78 — selection
switch sys- between T3B (Female) (2) and T7 (Female) (3). Max. 1 Ω
tem. • Without VHP specification:
Min. 1 MΩ

the AWD
79 — power source in the wiring harness between T3B (Female) • AWD specification: Max. 1 Ω
selection
switch sys- (3) and T7 (Female) (5). • Except AWD specification:
tem. Min. 1 MΩ
Open circuit Resistance between T3B (3) and

in the AWD chassis:
1. Defective contact or open circuit in the wiring harness
80 — selection • AWD specification: Max. 1 Ω
switch sys- between T3B (Female) (3) and T7 (Female) (5).
• Except AWD specification:
tem. Min. 1 MΩ
Resistance between T3B (11)

Short circuit and chassis:
to ground in 1. Short circuit to ground, short circuit, or short circuit to the • Initialize switch at [Memory
81 — the memory power source in the wiring harness between T3B (Female) set]: Max. 1 Ω
reset switch (11) and TT6 (Terminal) (6). • Initialize switch at [Initialize
system. learning function] or OFF:
Min. 1 MΩ
20-374 GD555, 655, 675-3A

(6)
Trouble-
Memory shooting
If potentiometer voltage is not ± 0.1 V,

the setting does not work. If there is a
Normal opera-
short circuit when the starting switch — — — — — —
tion.
is turned ON, the setting does not
work.
Normal opera-
No action. — — — — — —
tion.
Normal opera-
No action. — — — — — —
tion.
Normal opera-
No action. — — — — — —
tion.

— — — — — —
VHP mode.

— — — — — —
VHP mode.

— — — — — —
AWD mode.

— — — — — —
AWD mode.

— — — — — —
OFF (At least 1 sec.), error code is not tion.
deleted.
GD555, 655, 675-3A 20-375

(6)


Open circuit and chassis:
in the mem- • Initialize switch at [Memory
1. Defective contact or open circuit in the wiring harness set]: Max. 1 Ω
82 — ory reset
switch sys- between T3B (Female) (11) and TT (Terminal) (6). • Initialize switch at [Initialize
tem. learning function] or OFF:
Min. 1 MΩ

to ground in chassis:
1. Short circuit to ground, short circuit, or short circuit to the • Initialize switch at [Initialize
the learning
83 — power source in the wiring harness between T5 (Female) learning function]: Max. 1 Ω
function ini-
tialize switch (13) and TT (Terminal) (4). • Initialize switch at [Memory
system. set] or OFF: Min. 1 M Ω
Open circuit Resistance between T3B (13)

in the learn- and chassis:
ing function 1. Defective contact or open circuit in the wiring harness • Initialize switch at [Initialize
84 — learning function]: Max. 1 Ω
initialize between T5 (Female) (13) and TT (Terminal) (4).
switch sys- • Initialize switch at [Memory
tem. set] or OFF: Min. 1 M Ω

to ground in 1. Defective FL clutch pressure switch. chassis:
85 F1
the FL clutch 2. Short circuit to ground in wiring harness between T3B • At F1, F3, F5, F7: Max. 1 Ω
pressure (Female) (5) and T36 (Female) (1). • Except F1, F3, F5, F7:
switch sys- 3. Defective transmission controller. Min. 1 MΩ
tem.
Open circuit 1. Defective FL clutch pressure switch. Resistance between T3B (5) and
in the FL chassis:
2. Defective contact or open circuit in wiring harness • At F1, F3, F5, F7: Max. 1 Ω
86 91 clutch pres-
sure switch between T3B (Female) (5) and T36 (Female) (1). • Except F1, F3, F5, F7:
system. 3. Defective transmission controller. Min. 1 MΩ
Short circuit Resistance between T3B (13)

to ground in 1. Defective FH clutch pressure switch. and chassis:
87 F2 the FH clutch 2. Short circuit to ground in wiring harness between T3B • At F2, F4, F6, F8: Max. 1 Ω
pressure (Female) (13) and T37 (Female) (1). • Except F2, F4, F6, F8:
switch sys- 3. Defective transmission controller. Min. 1 MΩ
tem.
Open circuit 1. Defective FH clutch pressure switch. Resistance between T3B (13)
in the FH and chassis:
2. Defective contact or open circuit in wiring harness • At F2, F4, F6, F8: Max. 1 Ω
88 92 clutch pres-
sure switch between T3B (Female) (13) and T37 (Female) (1). • Except F2, F4, F6, F8:
system. 3. Defective transmission controller. Min. 1 MΩ

to ground in 1. Defective R clutch pressure switch. chassis:
the R clutch 2. Short circuit to ground in wiring harness between T3B • At R1 – R4: Max. 1 Ω
89 F3
pressure (Female) (6) and T38 (Female) (1). • Except R1 – R4: Min. 1 M Ω
switch sys- 3. Defective transmission controller.
tem.
Open circuit 1. Defective R clutch pressure switch. Resistance between T3B (6) and
in the R 2. Defective contact or open circuit in wiring harness chassis:
90 93 clutch pres- • At R1 – R4: Max. 1 Ω
sure switch between T3B (Female) (6) and T38 (Female) (1).
• Except R1 – R4: Min. 1 M Ω
system. 3. Defective transmission controller.

to ground in 1. Defective 1st clutch pressure switch. and chassis:
the 1st clutch 2. Short circuit to ground in wiring harness between T3B • At F1, F2, R1: Max. 1 Ω
91 F4
pressure (Female) (14) and T39 (Female) (1). • Except F1, F2, R1: Min. 1 M Ω
tem.
20-376 GD555, 655, 675-3A

(6)
Trouble-
Memory shooting

OFF (At least 1 sec.), error code is not tion.
deleted.
If learning function initialize switch is

not turned OFF (At least 1 sec.) → ON
(At least 1 sec.) → OFF (At least 1 sec.), Normal opera-
potentiometer set value, trigger time, tion. — — — — — —
learning value, model selection values
cannot be deleted from memory.
If learning function initialize switch is

not turned OFF (At least 1 sec.) → ON
(At least 1 sec.) → OFF (At least 1 sec.), Normal opera-
potentiometer set value, trigger time, tion. — — — — — —
learning value, model selection values
cannot be deleted from memory.
Sets to Neutral. Set to Neutral. { { { { { T-38
Gearshift shock.
Sets to rapid raise mode. Gearshift { { — — { T-46
timelag.
Gearshift shock.
Sets to rapid raise mode. { { — — { T-47
Gearshift
timelag.
Gearshift shock.
timelag.
GD555, 655, 675-3A 20-377

(1)

Open circuit 1. Defective 1st clutch pressure switch. Resistance between T3B (14)
in the 1st 2. Defective contact or open circuit in wiring harness and chassis:
92 94 clutch pres- • At F1, F2, R1: Max. 1 Ω
• Except F1, F2, R1: Min. 1 M Ω

to ground in 1. Defective 2nd clutch pressure switch. chassis:
the 2nd 2. Short circuit to ground in wiring harness between T3B • At F3, F4, R2: Max. 1 Ω
93 F5
clutch pres- (Female) (7) and T40 (Female) (1). • Except F3, F4, R2: Min. 1 M Ω
sure switch 3. Defective transmission controller.
system.
Open circuit 1. Defective 2nd clutch pressure switch. Resistance between T3B (7) and
in the 2nd 2. Defective contact or open circuit in wiring harness chassis:

to ground in 1. Defective 3rd clutch pressure switch. and chassis:
the 3rd 2. Short circuit to ground in wiring harness between T3B • At F5, F6, R3: Max. 1 Ω
95 F6
clutch pres- (Female) (15) and T41 (Female) (1). • Except F5, F6, R3: Min. 1 M Ω
sure switch 3. Defective transmission controller.
system.
Open circuit 1. Defective 3rd clutch pressure switch. Resistance between T3B (15)
in the 3rd 2. Defective contact or open circuit in wiring harness and chassis:

to ground in 1. Defective 4th clutch pressure switch. chassis:
the 4th clutch 2. Short circuit to ground in wiring harness between T3B • At F7, F8, R4: Max. 1 Ω
97 F7 pressure (Female) (8) and T42 (Female) (1). • Except F7, F8, R4: Min. 1 M Ω
tem.
Open circuit 1. Defective 4th clutch pressure switch. Resistance between T3B (8) and
in the 4th 2. Defective contact or open circuit in wiring harness chassis:

to ground in 1. Defective lock-up clutch pressure switch. and chassis:
the lock-up 2. Short circuit to ground in wiring harness between T3B • When lock-up switch is ON:
99 F8 Max. 1 Ω
clutch pres- (Female) (16) and T43 (Female) (1).
sure switch 3. Defective transmission controller. • When lock-up switch is OFF:
system. Min. 1 MΩ

Open circuit 1. Defective lock-up clutch pressure switch. and chassis:
in the lock-up 2. Defective contact or open circuit in wiring harness • When lock-up switch is ON:
100 98 clutch pres- Max. 1 Ω
system. 3. Defective transmission controller. • When lock-up switch is OFF:
Min. 1 MΩ
20-378 GD555, 655, 675-3A

(6)
Trouble-
Memory shooting
Gearshift shock.
Gearshift
timelag.
Gearshift shock.
Gearshift
timelag.
Gearshift shock.
timelag.
Gearshift shock.
Gearshift
timelag.
Gearshift shock.
timelag.
GD555, 655, 675-3A 20-379

(1)
ELECTRICAL CIRCUIT DIAGRAM

FOR TRANSMISSION CONTROL SYSTEM
Serial No.: 10001 – 11000
20-380 GD555, 655, 675-3A

(6)
GD555, 655, 675-3A 20-381

(3)
20-381-1 GD555, 655, 675-3A

(3)
GD555, 655, 675-3A 20-381-2

(3)
TROUBLESHOOTING T-1
T-1 ERROR CODE [A1]
HOT SHORT, GROUND, OR FL SOLENOID SYSTEM
Cause Remedy
1
• Between (1) and (2): 5 to 15 Ω

• Between (1), (2) and chassis: Is the resistance normal
between T24 (Male) (1) NO
Min. 1 MΩ Defective FL solenoid Replace
and (2), and between (1),
• Turn starting switch OFF (2) and the chassis?
• Disconnect T24
YES
2
Short circuit with
• Min. 1 MΩ chassis ground in
Is the resistance normal NO
• Turn starting switch OFF between T2 (Female) (7) wiring harness Repair or
between T2 (Female) replace
• Disconnect T2 and T24 and the chassis?
(7) and T24 (Female)
(1)
YES
3
Short circuit in wiring
• 5 to 15 Ω harness between T2
Is the resistance normal NO (Female) (7) and T24 Repair or
• Turn starting switch OFF between T2 (Female) (7)
and (17)? (Female) (1), and T2 replace
• Disconnect T2 (Female) (17) and T24
(Female) (2)
YES
4
• Turn starting switch ON Hot short in wiring

Is the voltage normal NO harness between T2 Repair or
• Disconnect T2 and T24 between T2 (Female) (7)
(Female) (7) and T24 replace
• Max. 1 V and the chassis? (Female) (1)
YES
5

Is the voltage normal NO
• Disconnect T2 and T24 between T2 (Female) (17) harness between T2 Repair or
• Max. 1 V and the chassis?
(Female) (2)
YES Defective transmis-

Replace
sion controller
T-1 RELATED ELECTRICAL CIRCUIT DIAGRAM
20-382 GD555, 655, 675-3A

(6)
TROUBLESHOOTING T-2
T-2 ERROR CODE [A2]

HOT SHORT, GROUND, OR FH SOLENOID SYSTEM
Cause Remedy
1

between T25 (Male) (1) NO Defective FH sole-
Min. 1 MΩ Replace
and (2), and between (1), noid
• Disconnect T25
YES
2
Short circuit with
Is the resistance normal NO wiring harness Repair or
• Turn starting switch OFF between T2 (Female) (8) between T2 (Female) replace
(1)
YES
3 Short circuit in the
wiring harness
• 5 to 15 Ω Is the resistance normal between T2 (Female)
NO (8) and T25 (Female) Repair or
(1) and wiring har- replace
• Disconnect T2 and (18)? ness between T2
(Female) (18) to T25
(Female) (2)
YES
4

(Female) (1)
YES
5

• Disconnect T2 and T25 between T2 (Female) (18) (Female) (18) and replace
T25 (Female) (2)
YES Defective transmis- Replace

sion controller
GD555, 655, 675-3A 20-383

(6)
TROUBLESHOOTING T-3
T-3 ERROR CODE [A3]
HOT SHORT, GROUND, OR R SOLENOID CIRCUIT
Cause Remedy
1

Min. 1 MΩ Defective R solenoid Replace
• Disconnect T26
YES
2
Short circuit with
(1)
YES
wiring harness
NO (9) – T26 (Female) (1) Repair or
and wiring harness replace
• Disconnect T2 and (19)? between T2 (Female)
(19) – T26 (Female)
(2)
YES
4

(Female) (1)
YES
5

• Disconnect T2 and T26 between T2 (Female) (19) (Female) (19) and T26 replace
(Female) (2)

sion controller
20-384 GD555, 655, 675-3A

(6)
TROUBLESHOOTING T-4
T-4 ERROR CODE [A4]

HOT SHORT, 1ST OR 3RD SOLENOID CIRCUIT, OR GROUND
Cause Remedy
1
• Between (1) and (2): 5 to 15 Ω Is the resistance normal

• Between (1), (2) and chassis: between T27 (Male) (1) NO
Min. 1 MΩ and (2), T29 (Male) (1) and Defective 1st or 3rd Replace
solenoid
• Turn starting switch OFF (2) and between (1), (2)
• Disconnect T2, T27, and T29 and the chassis?
YES
2
Short circuit with
chassis ground in
• Min. 1 MΩ Is the resistance normal NO wiring harness
Repair or
• Turn starting switch OFF between T2 (Female) (2), between T2 (Female) replace
• Disconnect T2, T27, and T29 (3) and the chassis? (2) and T27 (Female)
(1) or T2 (Female) (3)
and T29 (Female) (1)
YES

3 harness between T2
(Female) (2) – T27
(Female) (1); T2
• 5 to 15 Ω Is the resistance normal NO (Female) (3) – T29
Repair or
• Turn starting switch OFF between T2 (Female) (2) – (Female) (1) and wir-
• Disconnect T2 (13), T2 (Female) (3) – (14)? ing harness between replace
T2 (Female) (13) –
T27 (Female) (2); T2
YES (Female) (14) – T29
(Female) (2)
4
Hot short in wiring
• Turn starting switch ON harness between T2
Is the voltage normal NO (Female) (2) and T27 Repair or
• Disconnect T2, T27, and T29 between T2 (Female) (2),
(Female) (1) or T2 replace
• Max. 1 V (3) and the chassis? (Female) (3) and T29
(Female) (1)
YES
5
Hot short in wiring
• Disconnect T2, T27, and T29 between T2 (Female) (13), (Female) (13) and T27 Repair or
• Max. 1 V (14) and the chassis?
(Female) (14) and T29
(Female) (2)

Replace
sion controller
GD555, 655, 675-3A 20-385

(6)
TROUBLESHOOTING T-4
20-386 GD555, 655, 675-3A

(1)
TROUBLESHOOTING T-5
T-5 ERROR CODE [A5]

HOT SHORT, 2ND OR 4TH SOLENOID SYSTEM, OR GROUND
Cause Remedy
1
• Between (1) and (2): 5 to 15 Ω Is the resistance normal

• Between (1), (2) and chassis: between T28 (Male) (1) NO
Min. 1 MΩ and (2), T30 (Male) (1) and Defective 2nd or 4th Replace
solenoid
• Turn starting switch OFF (2) and between (1), (2)
• Disconnect T2, T28, and T30 and the chassis?
YES
2
Short circuit with
chassis ground in
• Min. 1 MΩ Is the resistance normal NO wiring harness
Repair or
• Turn starting switch ON between T2 (Female) (4), between T2 (Female) replace
• Disconnect T2, T28, and T30 (5) and the chassis? (4) and T28 (Female)
(1) or T2 (Female) (5)
and T30 (Female) (1)
YES

3 harness between T2
(Female) (4) – T28
(Female) (1); T2
• 5 to 15 Ω Is the resistance normal NO (Female) (5) – T30
Repair or
• Turn starting switch OFF between T2 (Female) (4) – (Female) (1) and wir-
• Disconnect T2 (15), T2 (Female) (5) – (16)? ing harness between replace
T2 (Female) (15), T28
(Female) (2); T2
YES (Female) (16) – T30
(Female) (2)
4
Hot short in wiring
Is the voltage normal NO (Female) (4) and T28 Repair or
• Disconnect T2, T28, and T30 between T2 (Female) (4),
• Max. 1 V (5) and the chassis? (Female) (5) and T30
(Female) (1)
YES
5
Hot short in wiring
• Disconnect T2, T28, and T30 between T2 (Female) (15), (Female) (15) and T28 Repair or
• Max. 1 V (16) and the chassis?
(Female) (2).

Replace
sion controller.
GD555, 655, 675-3A 20-387

(6)
TROUBLESHOOTING T-5
20-388 GD555, 655, 675-3A

(1)
TROUBLESHOOTING T-6
T-6 ERROR CODE [A8]

HOT SHORT, LOCK-UP SOLENOID SYSTEM, OR GROUND
Cause Remedy
1

between T31 (Male) (1) NO Defective lock-up
Min. 1 MΩ Replace
and (2), and between (1), solenoid
• Disconnect T31
YES
2
Short circuit with
(1)
YES
wiring harness
NO (10) – T31 (Female) Repair or
(1) and wiring har- replace
• Disconnect T2 and (20)? ness between T2
(Female) (20) to T31
(Female) (2)
YES
4

(Female) (1)
YES
5

• Disconnect T2 and T31 between T2 (Female) (20) (Female) (20) and T31 replace
(Female) (2)

sion controller
GD555, 655, 675-3A 20-389

(6)
TROUBLESHOOTING T-7
T-7 ERROR CODE [B1]
OPEN FL SOLENOID CIRCUIT
Cause Remedy
1

Min. 1 MΩ Defective FL solenoid Replace
• Disconnect T24
YES
2
• Max. 1 Ω Is the resistance normal NO open circuit in wir-
• Turn starting switch OFF between T2 (Female) (17) ing harness between Repair or
replace
• Disconnect T2 and T24 and T24 (Female) (2)? T2 (Female) (17) and
T24 (Female) (2)
YES
3
Short circuit between
• Min. 1 MΩ Is the resistance normal NO ground and wiring
Repair or
• Turn starting switch OFF between T2 (Female) (17) harness T2 (Female)
• Disconnect T2 and T24 and the chassis? (17) and T24 (Female) replace
(2)
YES
4
• Max. 1 Ω Is the resistance normal NO open circuit in wir- Repair or
• Turn starting switch OFF between T2 (Female) (7) ing harness between
replace
T24 (Female) (1)

sion controller Replace
20-390 GD555, 655, 675-3A

(6)
TROUBLESHOOTING T-8
T-8 ERROR CODE [B2]
OPEN FH SOLENOID CIRCUIT
Cause Remedy
1

between T25 (Male) (1) NO Defective FH sole-
Min. 1 MΩ Replace
• Disconnect T25
YES
2
replace
T25 (Female) (2)
YES
3
Short circuit to
• Min. 1 MΩ Is the resistance normal NO ground in wiring har-
Repair or
• Turn starting switch OFF between T2 (Female) (18) ness between T2
• Disconnect T2 and T25 and the chassis? (Female) (18) and T25 replace
(Female) (2)
YES
4
replace
T25 (Female) (1)

GD555, 655, 675-3A 20-391

(6)
TROUBLESHOOTING T-9
T-9 ERROR CODE [B3]
OPEN R SOLENOID CIRCUIT
Cause Remedy
1

Min. 1 MΩ Defective R solenoid Replace
• Disconnect T26
YES
2
replace
T26 (Female) (2)
YES
3
Short circuit to
Repair or
(Female) (2)
YES
4
replace
T26 (Female) (1)

20-392 GD555, 655, 675-3A

(6)
TROUBLESHOOTING T-10
T-10 ERROR CODE [B4]
OPEN 1ST SOLENOID CIRCUIT
Cause Remedy
1

between T27 (Male) (1) NO Defective 1st sole-
Min. 1 MΩ Replace
• Disconnect T27
YES
2
replace
T27 (Female) (2)
YES
3
Short circuit to
Repair or
(Female) (2)
YES
4
replace
T27 (Female) (1)

GD555, 655, 675-3A 20-393

(6)
OPEN 2ND SOLENOID CIRCUIT
Cause Remedy
1

between T28 (Male) (1) NO Defective 2nd sole-
Min. 1 MΩ Replace
• Disconnect T28
YES
2
replace
T28 (Female) (2)
YES
3
Short circuit to
Repair or
(Female) (2)
YES
4
replace
T28 (Female) (1)

20-394 GD555, 655, 675-3A

(6)
OPEN 3RD SOLENOID CIRCUIT
Cause Remedy
1

between T29 (Male) (1) NO Defective 3rd sole-
Min. 1 MΩ Replace
• Disconnect T29
YES
2
replace
T29 (Female) (2)
YES
3
Short circuit to
Repair or
(Female) (2)
YES
4
replace
T29 (Female) (1)

GD555, 655, 675-3A 20-395

(6)
OPEN 4TH SOLENOID CIRCUIT
Cause Remedy
1

between T30 (Male) (1) NO Defective 4th sole-
Min. 1 MΩ Replace
• Disconnect T30
YES
2
replace
T30 (Female) (2)
YES
3
Short circuit to
Repair or
(Female) (2)
YES
4
replace
T30 (Female) (1)

20-396 GD555, 655, 675-3A

(6)
OPEN LOCK-UP SOLENOID CIRCUIT
Cause Remedy
1

between T31 (Male) (1) NO Defective lock-up
Min. 1 MΩ Replace
and (2), and between (1), solenoid
• Disconnect T31
YES
2
replace
T31 (Female) (2)
YES
3
Short circuit to
Repair or
(Female) (2)
YES
4
replace
T31 (Female) (1)

GD555, 655, 675-3A 20-397

(6)
T-15 ERROR CODE [C0]
POWER SUPPLY VOLTAGE REDUCED

★ When fuse I-(7) is normal.
If it is blown, check for a short circuit to ground in the wiring harness between the fuse and inside the
controller.
★ When the battery is normal.
Cause Remedy
1
Is the resistance normal
• 20 to 30 V between T1 (Female) (7), NO
• Connect T-adapter to T1 and T2 (13) – (6), (12), and T2
• Turn starting switch ON (Female) (1), (12) – (11),
(21)?

2
• 20 to 30 V Is the voltage normal NO
between T11 (Female) (1)
• Turn starting switch ON and chassis? Defective contact or
open circuit in wir-
YES ing harness between Repair or
T1 (Female) (7), (13), replace
T2 (Female) (1), (12) –
T11 (Male) (1)
3
• Max. 1 Ω Is the resistance normal open circuit in wir-
between T1 (Female) (6), NO ing harness between Repair or
• Turn starting switch OFF (12), T2 (Female) (11), (21) T1 (Female) (6), (12), replace
• Disconnect T1 and T2 – chassis? T2 (Female) (11), (21)
– chassis
YES open circuit in wir-
Repair or
ing harness between
replace
T11 (Female) (1) and
Battery relay
20-398 GD555, 655, 675-3A

(6)
OPEN ENGINE SPEED SENSOR CIRCUIT
Cause Remedy
1
• Between (1) and (2):

500 to 1000 Ω Is the resistance normal
• Between (1), (2) and chassis: between T46 (Male) (1) NO Defective engine Replace
Min 1 MΩ and (2), and between (1), speed sensor
• Turn starting switch OFF (2) and chassis?
• Disconnect T46
YES
2
• Max. 1 Ω Is the resistance normal NO disconnection in wir-
Repair or
• Turn starting switch OFF between T4 (Female) (7) ing harness between replace
T46 (Female) (1)
YES
3
• Max. 1 Ω Is the resistance normal NO disconnection in wir-
Repair or
• Turn starting switch OFF between T5 (Female) (1) ing harness between replace
T46 (Female) (2)

Replace
sion controller
GD555, 655, 675-3A 20-399

(6)
HOT SHORT OR OPEN ACCELERATOR POTENTIOMETER CIRCUIT
Cause Remedy
1
• Min. 1 MΩ Is the resistance normal NO Short circuit with

• Turn starting switch OFF between T3A (Female) (7), T9 ground or short circuit Repair or
in wiring harness replace
• Disconnect T3A and T9 (Female) (A), and the chassis?
between T3A (Female)
(7) and T9 (Female) (A)
YES
2
• Max. 1 Ω Defective contact or

• Turn starting switch OFF Is the resistance normal NO disconnection in wiring Repair or
between T3A (Female) (7) and harness between T3A replace
• Disconnect T3A and T9 the chassis? (Female) (7) and T9
• Ground T9 (Female) (A) to chassis (Female) (A)
YES
3

• Turn starting switch OFF Is the resistance normal NO open circuit in wiring Repair or
between T3A (Female) (3) and harness between T3A
• Disconnect T3A and T9 replace
the chassis? (Female) (3) and T9
• Ground T9 (Female) (B) to chassis (Female) (B)
YES
4
Is the voltage between T3A (3) NO Defective accelerator
• Turn starting switch OFF – (16), T3A (7) – (16) as shown Replace
potentiometer
in Table 1?
YES
5
• Max. 1 Ω When T9 (Female) (C) is Defective contact or

• Turn starting switch OFF grounded to chassis, is resis- NO open circuit in wiring Repair or
tance normal between T3A harness between T3A
(Female) (16) and the chassis (Female) (16) and T9
• Ground T9 (Female) (C) to chassis ground? (Female) (C)
YES
6
Is the voltage between T3A (3) NO
• Turn starting switch ON and (16) as shown in Table 1?
YES Defective transmission Replace

controller
7 Wiring harness
(3) and T9 (Female) (B)
• Max: 0.5 V When T9 is disconnected, is NO in contact with wiring
• Disconnect T9 voltage between T3A (3) and harness between T3A Repair or
replace
• Turn starting switch ON (16) normal? (Female) (7) and T9
(Female) (A), or with
wiring harness at
power source end
YES Defective accelerator Replace
potentiometer
20-400 GD555, 655, 675-3A

(6)
Table 1
T3A T9 Voltage
0.5 to 4.75 V
0.5 to 1.6 V (Low idle)

Between (3) and (16) Between (B) and (C)
2.1 V (Low idle)
to
4.75 V (High idle)
Between (7) and (16) Between (A) and (C) 4.75 to 5.25 V
★ The above table shows the specified potentiometer voltage. The controller interprets the voltage as the throttle angle. When adjust-
ing the potentiometer, leave a margin of error for the judgement field. At low idle, adjust the potentiometer so that voltage is from
1.3 to 1.6 V.
GD555, 655, 675-3A 20-401

(6)
HOT SHORT OR OPEN INCHING POTENTIOMETER CIRCUIT
Cause Remedy
1
• Min. 1 MΩ Is the resistance normal NO Short circuit with

• Turn starting switch OFF between T3A (Female) (7), T8 ground or short circuit Repair or
in wiring harness replace
• Disconnect T3A and T8 (Female) (A), and the chassis?
(7) and T8 (Female) (A)
YES
2

• Turn starting switch OFF Is the resistance normal NO disconnection in wiring Repair or
between T3A (Female) (7) and harness between T3A replace
• Disconnect T3A and T8 the chassis? (Female) (7) and T8
• Ground T8 (Female) (A) to chassis (Female) (A)
YES
3

• Turn starting switch OFF Is the resistance normal NO open circuit in wiring Repair or
between T3A (Female) (13) harness between T3A
and the chassis? (Female) (13) and T8
• Ground T8 (Female) (B) to chassis (Female) (B)
YES
4
Is the voltage between T3A NO Defective inching
• Turn starting switch ON (13) – (16), T3A (7) – (16) as Replace
potentiometer
shown in Table 1?
YES
5
• Max. 1 Ω When T8 (Female) (C) is Defective contact or

• Turn starting switch OFF grounded to chassis, is resis- NO open circuit in wiring Repair or
tance normal between T3A harness between T3A
(Female) (16) and the chassis (Female) (16) and T8
• Ground T8 (Female) (C) to chassis ground? (Female) (C)
YES
6
Is the voltage between T3A NO
• Turn starting switch ON (13) and (16) as shown in
Table 1?
controller
7 Wiring harness
(13) and T8 (Female) (B)
• Max: 0.5 V When T8 is disconnected, is NO in contact with wiring Repair or
• Disconnect T8 voltage between T3A (13) and harness between T3A replace
• Turn starting switch ON (16) normal? (Female) (7) and T8
(Female) (A), or with
wiring harness at
power source end
YES Defective inching Replace
potentiometer
20-402 GD555, 655, 675-3A

(6)
Table 1
T3A T9 Voltage
0.5 to 4.75 V
0.5 to 1.6 V (Inching pedal not depressed)

Between (13) and (16) Between (B) and (C)
2.1 V (Inching pedal not depressed)
to
4.75 V (Inching pedal fully depressed)
Between (7) and (16) Between (A) and (C) 4.75 to 5.25 V
★ The above table shows the specified potentiometer voltage. The controller interprets the voltage as the throttle angle. When adjust-
ing the potentiometer, leave a margin of error for the judgement field. At low idle, adjust the potentiometer so that voltage is from
1.3 to 1.6 V.
GD555, 655, 675-3A 20-403

(6)
HOT SHORT OR OPEN CIRCUIT IN THE TRANSMISSION OIL TEMPERATURE

SENSOR CIRCUIT
Cause Remedy
1
3.5 to 4.0 kΩ
(Normal temp. 25 °C) Is the resistance normal
38.5 to 47.0 kΩ (Temp. 100 °C) NO Defective transmis-
between T35 (Male) (1)
sion oil temperature Replace
• Between (1), (2) and chassis: and (2), and between (1), sensor
Min. 1 MΩ (2) and the chassis?
• Turn starting switch OFF
• Disconnect T35
YES
2
Short circuit with
• Min. 1 MΩ ground or short cir-
Is the resistance normal NO cuit in the wiring har- Repair or
• Turn starting switch OFF between T3A (Female) (1) ness between T3A replace
• Disconnect T3A and T35 and the chassis?
(Female) (1)
YES
• Max. 1 V Hot short in the wir-

Is the voltage normal NO ing harness between Repair or
• Turn starting switch ON between T3A (Female) (1)
and the chassis? T3A (Female) (1) and replace
• Disconnect T3A and T35 T35 (Female) (1)
YES
4
• Max. 1 Ω Is the resistance normal open circuit in the
NO wiring harness Repair or
between T3A replace
• Disconnect T3A and T35 and T35 (Female) (1)? (Female) (1) and T35
(Female) (1)
YES
5
• Max. 1 Ω open circuit in the
between T35 replace
• Disconnect T35 and the chassis?
(Female) (2) and
chassis

Replace
sion controller.
20-404 GD555, 655, 675-3A

(6)
GD555, 655, 675-3A 20-405

(1)
HOT SHORT OR OPEN CIRCUIT IN THE TORQUE CONVERTER OUTLET OIL TEM-
PERATURE SENSOR CIRCUIT
Cause Remedy
1
3.5 to 4.0 kΩ
(Normal temp. 25°C) Is the resistance normal
38.5 to 47.0 kΩ (100°C) NO Defective torque con-
between T34 (Male) (1)
verter outlet oil tem- Replace
• Between (1), (2) and chassis: and (2), and between (1), perature sensor
Min. 1 MΩ (2) and the chassis?
• Disconnect T34
YES
2
Short circuit with
• Disconnect T3A and T34 and the chassis?
(Female) (1)
YES

and the chassis? T3A (Female) (11) replace
• Disconnect T3A and T34 and T34 (Female) (1)
YES
4
between T3A replace
• Disconnect T3A and T34 and T34 (Female) (1)? (Female) (11) and T34
(Female) (1)
YES
5
between T34 replace
• Disconnect T34 and the chassis?
(Female) (2) and
chassis

Replace
sion controller.
20-406 GD555, 655, 675-3A

(6)
GD555, 655, 675-3A 20-407

(1)
HOT SHORT OR OPEN CIRCUIT IN THE HYDRAULIC OIL TEMPERATURE SEN-

SOR CIRCUIT
Cause Remedy
1
3.5 to 4.0 kΩ
(Normal temp. 25 °C) Is the resistance normal
Defective hydraulic
38.5 to 47.0 kΩ (Temp. 100 °C) between E5 (Male) (1) and NO
oil temperature sen- Replace
• Between (1), (2) and chassis: (2), and between (1), (2) sor
Min. 1 MΩ and the chassis?
• Disconnect E5
YES
2
Short circuit with
• Disconnect T3A and E5 and the chassis?
(Female) (2) and E5
(Female) (1)
YES
3
Is the voltage normal
• Max. 1 V between T3A (Female) (2) NO Hot short in the wir-
• Turn starting switch OFF and the chassis, and
between T3B (Female) (10) T3A (Female) (2) and replace
• Disconnect T3A and E5 E5 (Female) (1)
and the chassis?
YES
4
• Turn starting switch OFF between T3A (Female) (2)
between T3A replace
• Disconnect T3A and E5 and E5 (Female) (1)?
(Female) (2) and E5
(Female) (1)
YES
5
• Max. 1 Ω Is the resistance normal NO open circuit in the
Repair or
• Turn starting switch OFF between E5 (Female) (2) wiring harness replace
• Disconnect E5 and the chassis? between E5 (Female)
(2) and chassis

Replace
sion controller.
20-408 GD555, 655, 675-3A

(6)
GD555, 655, 675-3A 20-409

(1)
OPEN CIRCUIT IN THE TRANSMISSION INPUT SHAFT SPEED SENSOR CIRCUIT
Cause Remedy
1

• Between (1), (2) and chassis: NO Defective transmis-
between T32 (Male) (1) sion input shaft Replace
Min. 1 MΩ and (2), and between (1),
speed sensor
• Disconnect T32
YES
2
• Disconnect T5 and T32 and T32 (Female) (1)?
(1)
YES
3
• Disconnect T5 and T32 and T32 (Female) (2)? (1) and T32 (Female)
(2)

sion controller. Replace
20-410 GD555, 655, 675-3A

(6)

OPEN CIRCUIT IN THE TRANSMISSION OUTPUT SHAFT SPEED SENSOR CIR-
CUIT
Cause Remedy
1

• Between (1), (2) and chassis: between T33 (Male) (1) NO Defective transmis-
sion output shaft Replace
Min. 1 MΩ and (2), and between (1),
speed sensor
• Disconnect T33
YES
2
(1)
YES
3
and T33 (Female) (2)? between T5 (Female) replace
• Disconnect T5 and T33 (1) and T33 (Female)
(2)

sion controller.
GD555, 655, 675-3A 20-411

(6)
T-24 ERROR CODE [d1]
HOT SHORT OR OPEN CIRCUIT IN THE DIFFERENTIAL OIL TEMPERATURE

WARNING LAMP CIRCUIT
Cause Remedy
1
After interchanging the NO
• Turn starting switch ON lamps, does the display go
out?
YES
Defective lamp Replace

• Turn starting switch ON between T1 (Female) (1)
and chassis? T1 (Female) (1) and replace
• Disconnect T1 and FP3 FP3 (Female) (4)
YES
3
• Disconnect T1 and FP3 and FP3 (Female) (4)? (1) and FP3 (Female)
(4)

20-412 GD555, 655, 675-3A

(6)
HOT SHORT OR OPEN CIRCUIT IN THE TRANSMISSION OIL TEMPERATURE

WARNING LAMP CIRCUIT
Cause Remedy
1
After interchanging the NO
• Turn starting switch ON lamps, does the display go
out?
YES

YES
3
(6)

GD555, 655, 675-3A 20-413

(6)
HOT SHORT OR OPEN CIRCUIT IN THE BUZZER ALARM SYSTEM
Cause Remedy
1

• Interchange BR22 (Male) and
BR21 (Male)
• Start the engine, then depress When BR21 and connector
the brake pedal repeatedly until are interchanged, does
the buzzer sounds, signaling alarm buzzer A sound? NO
that the brake accumulator
pressure has been relieved.
• See Note 1 below.
YES
Defective alarm
buzzer A Replace
2

• Turn starting switch OFF Is the voltage normal NO ing harness between Repair or
• Disconnect T1 and BR22 T1 (Female) (9) and replace
and chassis?
• Turn starting switch ON BR22 (Female) (1)
YES
3
Is the voltage normal
wiring harness Repair or
• Turn starting switch OFF between BR22 (Female) (2) between BR22 replace
• Disconnect BR22 and chassis? NO
(Female) (2) and
chassis
YES
4
and BR22 (Female) (1)? NO between T1 (Female) replace
• Disconnect T1 and BR22 (9) and BR22
(Female) (1)

sion controller
Note 1:
Always apply the parking brake.
20-414 GD555, 655, 675-3A

(6)
GD555, 655, 675-3A 20-415

(1)
HOT SHORT OR OPEN CIRCUIT IN THE TRANSMISSION CONTROL WARNING

LAMP SYSTEM
Cause Remedy
1
When the lamps are inter- NO
• Turn starting switch ON changed, does the display
go out?
YES

YES
3
(7)

20-416 GD555, 655, 675-3A

(6)
HOT SHORT OR OPEN CIRCUIT IN THE DIFFERENTIAL CONTROL RELAY SYS-

TEM
Cause Remedy
1
After replacing the BR7

• Replace the BR7 relay with relay with another relay, NO
another known good relay does the condition become
normal?
YES Defective differential

Replace
control relay
• Max. 1 Ω Hot short in the wir-

T1 (Female) (11) and replace
• Disconnect T1 and BR7 and BR7 (Female) (1)?
BR7 (Female) (1)
YES
3
• Turn starting switch OFF between BR7 (Female) (2)
and chassis? between BR7 replace
• Disconnect BR7 (Female) (2) and
chassis
YES
4

• Turn starting switch OFF Is the voltage normal NO ing harness between Repair or
and chassis? BR7 (Female) (1)
• Turn starting switch ON

GD555, 655, 675-3A 20-417

(6)
HOT SHORT OR OPEN CIRCUIT IN THE VHP RELAY SYSTEM
Cause Remedy
1
After replacing the BR8

• Replace the BR8 relay with relay with another relay, NO
another known good relay does the condition become
normal?
YES
Defective VHP relay Replace
2
• Disconnect T1 and BR8 and BR8 (Female) (1)?
(2) and BR8 (Female)
(1)
YES
3
• Turn starting switch OFF between BR8 (Female) (2)
between BR8 replace
• Disconnect BR8 and chassis? (Female) (2) and
chassis
YES
4

• Turn starting switch OFF Is the voltage normal NO
between T1 (Female) (2) ing harness between Repair or
and chassis?
• Turn starting switch ON BR8 (Female) (1)

Replace
sion controller
20-418 GD555, 655, 675-3A

(6)
T-30 ERROR CODE [E1]
HOT SHORT OR OPEN CIRCUIT IN THE F (FORWARD), R (REVERSE) SYSTEM
Cause Remedy
1
Short circuit with the
• Max. 1 V power source in the
• Turn starting switch OFF Is the voltage normal NO wiring harness
Repair or
between T5 (Female) (6), between T5 (Female)
• Disconnect T5 and T13 (14) and chassis? (6) – T13 (Female) (7) replace
• Turn starting switch ON or T5 (Female) (14) –
T13 (Female) (13)
YES
2 Defective contact or
open circuit in the
• Max. 1 Ω wiring harness
between T5 (Female) (6) – NO between T5 (Female) Repair or
• Turn starting switch OFF T13 (Female) (7), T5
(6) – T13 (Female) (7) replace
• Disconnect T5 and T13 (Female) (14) – T13
(Female) (13)? or T5 (Female) (14) –
T13 (Female) (13)
YES
3
• 20 to 30 V Is the voltage normal

Defective gearshift
• Turn starting switch ON between T13 (Female) (7) lever Replace
• Gearshift lever: [F1] to [F8] and (19), (20), (23)? NO
YES
4
• 20 to 30 V Is the voltage normal

Defective gearshift
• Turn starting switch ON between T13 (Female) (13) Replace
– (19), (20), (23)? NO lever
• Gearshift lever: [R1] to [R4]

sion controller
GD555, 655, 675-3A 20-419

(6)
HOT SHORT OR OPEN CIRCUIT IN THE NEUTRAL SIGNAL CIRCUIT
Cause Remedy
1
• Turn starting switch OFF Is the voltage normal NO wiring harness Repair or
between T3A (Female) (8)
• Disconnect T3A and T13 and chassis? between T13 replace
• Turn starting switch ON (Female) (2) – T3A
(Female) (8)
YES
2
between T13 replace
• Disconnect T3A and T13 and T13 (Female) (2)?
(Female) (2) – T3A
(Female) (8)
YES
3
• 20 to 30 V Is the voltage normal NO Defective gearshift

• Gearshift lever: [N] and (19), (20), (23)?

Replace
sion controller
T-30, T-31 RELATED ELECTRICAL CIRCUIT DIAGRAM
20-420 GD555, 655, 675-3A

(6)
HOT SHORT OR OPEN CIRCUIT IN THE PARKING SIGNAL CIRCUIT

Cause Remedy
1
When the BR11 relay is inter- NO

• Replace BR11 with a known good relay changed with another relay, does
the condition become normal?
YES Defective parking brake

relay Replace
• Max. 1 V Short circuit to the power

• Turn starting switch OFF Is the voltage normal between NO source in the wiring har-
T3A (Female) (9) and the chassis ness between T3A Repair or
• Disconnect T3A and BR11 replace
ground? (Female) (9) and BR11
• Turn starting switch ON (Female) (6)
YES
3
• Max. 1 Ω Is the resistance normal between NO

circuit in wiring harness Repair or
• Turn starting switch OFF T3A (Female) (9) and BR11 between T3A (Female) (9) replace
• Disconnect T3A and BR11 (Female) (6)? and BR11 (Female) (6)
YES
4
• Max. 1 V Short circuit to the power

• Turn starting switch OFF Is the voltage between T13 NO source in the wiring har- Repair or
(Female) (10) and chassis nor- ness between T13
• Disconnect T13 and BR11 mal? (Female) (10) and BR11 replace
• Turn starting switch ON (Female) (1)
YES
5
• Max. 1 Ω Is resistance normal between T13 NO

circuit in the wiring har- Repair or
• Turn starting switch OFF (Female) (10) and BR11 (Female)
ness T13 (Female) (10) and replace
• Disconnect T13 and BR11 (1)? BR11 (Female) (1)
YES
6
Defective contact or dis-

• Max. 1 Ω Is resistance normal between NO connection in wiring har-
• Turn starting switch OFF BR11 (Female) (2) and the chas- ness between BR11 Repair or
• Disconnect BR11 sis? (Female) (2) and the chas- replace
sis
YES
7
• 20 to 30 V NO
Is voltage normal between T13
• Turn starting switch ON Defective gearshift lever Replace
(Female) (10) and (19), (20), (23)?
• Gearshift lever: [Parking]

controller
GD555, 655, 675-3A 20-421

(6)
20-422 GD555, 655, 675-3A

(1)
HOT SHORT OR OPEN CIRCUIT IN THE LOGIC A SIGNAL CIRCUIT
Cause Remedy
1
between T3A (Female) (18)
• Disconnect T3A and T13 and chassis? between T3A replace
• Turn starting switch ON (Female) (18) and T13
(Female) (4)
YES
2
between T3A replace
• Disconnect T3A and T13 and T13 (Female) (4)?
(Female) (4)
YES
3
• Max. 1 V
• Turn starting switch ON Is the voltage normal NO Defective gearshift
between T13 (Female) (4) – lever Replace
• Gearshift lever: [Parking] and (19), (20), (23)?
[Neutral]

Replace
sion controller
GD555, 655, 675-3A 20-423

(6)
HOT SHORT OR OPEN CIRCUIT IN THE LOGIC B SIGNAL CIRCUIT
Cause Remedy
1
• Disconnect T3A and T13 and chassis? between T5 (Female) replace
• Turn starting switch ON (7) and T13 (Female)
(5)
YES
2
(5)
YES
3

• Turn starting switch ON between T13 (Female) (5) – lever Replace
• Gearshift lever: [F5] – [F7] (19), (20), (23)?

Replace
sion controller
20-424 GD555, 655, 675-3A

(6)
HOT SHORT OR OPEN CIRCUIT IN THE LOGIC C SIGNAL CIRCUIT
Cause Remedy
1
• Disconnect T5 and T13 and chassis? between T5 (Female) replace
(12)
YES
2
(12)
YES
3

• Gearshift lever: [F1] – [F5], [R1] – (19), (20), (23)?

Replace
sion controller
T-33, T-34, T-35 RELATED ELECTRICAL CIRCUIT DIAGRAM
GD555, 655, 675-3A 20-425

(6)
HOT SHORT OR OPEN CIRCUIT IN THE LOGIC D SIGNAL CIRCUIT
Cause Remedy
1
(18)
YES
2
(18)
YES
3

• Gearshift lever: [F1] – [F3] – (19), (20), (23)?

Replace
sion controller
20-426 GD555, 655, 675-3A

(6)
HOT SHORT OR OPEN CIRCUIT IN THE LOGIC E SIGNAL CIRCUIT
Cause Remedy
1
(3)
YES
2
(3)
YES
3
• 20 to 30 V
• Turn starting switch ON Is the voltage normal NO Defective gearshift
between T13 (Female) (3) – lever Replace
• Gearshift lever: [F3] – [F6], [R1], (19), (20), (23)?
[R2]

Replace
sion controller
T-36, T-37 RELATED ELECTRICAL CIRCUIT DIAGRAM
GD555, 655, 675-3A 20-427

(6)
T-38 ERROR CODE [F1]
SHORT CIRCUIT WITH GROUND IN THE FL CLUTCH PRESSURE SWITCH SIGNAL

CIRCUIT
Cause Remedy
1
• Min. 1 MΩ Is the resistance normal NO Defective FL clutch

• Turn starting switch OFF between T36 (Male) (1) pressure switch Replace
• Disconnect T36 and chassis?
YES
2
Short circuit with
• Min. 1 MΩ Is the resistance normal NO ground in the wiring
Repair or
• Turn starting switch OFF between T3B (Female) (5) harness between T3B
replace
• Disconnect T3B and T36 and chassis? (Female) (5) and T36
(Female) (1)

sion controller
SHORT CIRCUIT WITH GROUND IN THE FH CLUTCH PRESSURE SWITCH SIG-

NAL CIRCUIT
Cause Remedy
1
• Min. 1 MΩ Is the resistance normal NO Defective FH clutch

• Turn starting switch OFF between T37 (Male) (1) Replace
and chassis? pressure switch
• Disconnect T37
YES
2
Short circuit with
• Min. 1 MΩ Is the resistance normal NO ground in the wiring Repair or
replace
(Female) (1)

Replace
sion controller
20-428 GD555, 655, 675-3A

(6)
SHORT CIRCUIT WITH GROUND IN THE R CLUTCH PRESSURE SWITCH SIGNAL

CIRCUIT
Cause Remedy
1
• Min. 1 MΩ Is the resistance normal NO Defective R clutch

• Turn starting switch OFF between T38 (Male) (1) pressure switch Replace
YES
2
Short circuit with
Repair or
replace
(Female) (1)

sion controller
GD555, 655, 675-3A 20-429

(6)
SHORT CIRCUIT WITH GROUND IN THE 1ST CLUTCH PRESSURE SWITCH CIR-
CUIT
Cause Remedy
1
• Min. 1 MΩ Is the resistance normal NO Defective 1st clutch

• Turn starting switch OFF between T39 (Female) (1) pressure switch Replace
YES
2
Short circuit with
Repair or
replace
(Female) (1)

sion controller
SHORT CIRCUIT WITH GROUND IN THE 2ND CLUTCH PRESSURE SWITCH CIR-
CUIT
Cause Remedy
1
• Min. 1 MΩ Is the resistance normal NO Defective 2nd clutch

• Turn starting switch OFF between T40 (Female) (1) Replace
and chassis? pressure switch
• Disconnect T40
YES
2
Short circuit with
• Min. 1 MΩ Is the resistance normal NO ground in the wiring Repair or
replace
(Female) (1)

Replace
sion controller
20-430 GD555, 655, 675-3A

(6)
SHORT CIRCUIT WITH GROUND IN THE 3RD CLUTCH PRESSURE SWITCH CIR-
CUIT
Cause Remedy
1
• Min. 1 MΩ Is the resistance normal NO Defective 3rd clutch
• Turn starting switch OFF between T41 (Female) (1) pressure switch Replace
YES
2
Short circuit with
• Min. 1 MΩ Is the resistance normal ground in the wiring
NO Repair or
• Turn starting switch OFF between T3B (Female) (15) harness between T3B replace
(Female) (1)

Replace
sion controller
SHORT CIRCUIT WITH GROUND IN THE 4TH CLUTCH PRESSURE SWITCH CIR-
CUIT
Cause Remedy
1
• Min. 1 MΩ Is the resistance normal NO Defective 4th clutch
• Turn starting switch OFF between T42 (Female) (1) Replace
pressure switch
YES
2
Short circuit with
• Min. 1 MΩ Is the resistance normal ground in the wiring
NO Repair or
replace
(Female) (1)

T-41, T-42, T-43, T-44 RELATED ELECTRICAL CIRCUIT DIAGRAM
GD555, 655, 675-3A 20-431

(6)
SHORT CIRCUIT WITH GROUND IN THE LOCK-UP CLUTCH PRESSURE SWITCH

SIGNAL CIRCUIT
Cause Remedy
1
• Min. 1 MΩ Is the resistance normal NO Defective lock-up

• Turn starting switch OFF between T43 Male) (1) and clutch pressure Replace
• Disconnect T43 chassis? switch
YES
2
Short circuit with
Repair or
replace
(Female) (1)

sion controller
20-432 GD555, 655, 675-3A

(6)
T-46 ERROR CODE [91]
OPEN CIRCUIT IN THE FL CLUTCH PRESSURE SWITCH CIRCUIT
Cause Remedy
1
• Turn starting switch OFF between T3B (Female) (5)
and T36 (Female) (1)? NO between T3B replace
• Disconnect T3B and T36 (Female) (5) and T36
(Female) (1)
YES
2
• Disconnect T36 Is code [91] displayed
when T36 (Female) (1) – NO Defective FL clutch
• Start engine Replace
chassis ground is pressure switch
• Gearshift lever: [F1] [F3] [F5] grounded?
[F7]


OPEN CIRCUIT IN THE FH CLUTCH PRESSURE SWITCH CIRCUIT
Cause Remedy
1
• Turn starting switch OFF between T3B (Female) (13) wiring harness Repair or
between T3B replace
• Disconnect T3B and T37 and T37 (Female) (1)?
(Female) (1)
YES
2
• Disconnect T37 Is code [92] displayed
when T37 (Female) (1) – NO Defective FH clutch
• Start engine chassis ground is pressure switch Replace
• Gearshift lever: [F2] [F4] [F6] grounded?
[F8]

Replace
sion controller
GD555, 655, 675-3A 20-433

(6)
OPEN CIRCUIT IN THE R CLUTCH PRESSURE SWITCH CIRCUIT
Cause Remedy
1
and T38 (Female) (1)? between T3B replace
(Female) (1)
YES
2
• Turn starting switch ON Is code [93] displayed

• Disconnect T38 when T38 (Female) (1) – NO Defective R clutch
Replace
• Start engine chassis ground is pressure switch
• Gearshift lever: [R1] thru [R4] grounded?

20-434 GD555, 655, 675-3A

(6)
OPEN CIRCUIT IN THE 1ST CLUTCH PRESSURE SWITCH CIRCUIT
Cause Remedy
1
(Female) (1)
YES
2

• Disconnect T39 when T39 (Female) (1) – NO Defective 1st clutch
Replace
• Start engine chassis ground is pressure switch
• Gearshift lever: [F1] [F2] [R1] grounded?


OPEN CIRCUIT IN THE 2ND CLUTCH PRESSURE SWITCH CIRCUIT
Cause Remedy
1
• Turn starting switch OFF between T3B (Female) (7) wiring harness Repair or
between T3B replace
• Disconnect T3B and T40 and T40 (Female) (1)?
(Female) (1)
YES
2

• Disconnect T40 when T40 (Female) (1) – NO Defective 2nd clutch
chassis ground is pressure switch Replace
• Start engine
• Gearshift lever: [F3] [F4] [ [R2] grounded?

Replace
sion controller
GD555, 655, 675-3A 20-435

(6)

OPEN CIRCUIT IN THE 3RD CLUTCH PRESSURE SWITCH CIRCUIT
Cause Remedy
1
• Max. 1 Ω Is the resistance normal NO open circuit in the wir- Repair or
• Turn starting switch OFF between T3B (Female) (15) ing harness between
• Disconnect T3B and T41 and T41 (Female) (1)? T3B (Female) (15) and replace
T41 (Female) (1)
YES
2

• Disconnect T41 Is code [96] displayed when NO
Defective 3rd clutch
T41 (Female) (1) – chassis pressure switch
Replace
• Start engine ground is grounded?
• Gearshift lever: [F5] [F6] [R3]

sion controller

OPEN CIRCUIT IN THE 4TH CLUTCH PRESSURE SWITCH CIRCUIT
Cause Remedy
1
• Max. 1 Ω Is the resistance normal NO open circuit in the wir- Repair or
• Turn starting switch OFF between T3B (Female) (8) ing harness between replace
• Disconnect T3B and T42 and T42 (Female) (1)? T3B (Female) (8) and
T42 (Female) (1)
YES
2

• Disconnect T42 Is code [97] displayed when NO Defective 4th clutch
T42 (Female) (1) – chassis Replace
• Start engine pressure switch
ground is grounded?
• Gearshift lever: [F7] [F8] [R4]

Replace
sion controller
T-49, T-50, T-51, T-52 RELATED ELECTRICAL CIRCUIT DIAGRAM
20-436 GD555, 655, 675-3A

(6)
OPEN CIRCUIT IN THE LOCK-UP CLUTCH PRESSURE SWITCH CIRCUIT
Cause Remedy
1
(Female) (1)
YES
2

• Disconnect T43 when T43 (Female) (1) – NO Defective lock-up
clutch pressure Replace
• Start engine chassis ground is
switch
• Turn the lock-up switch ON grounded?

GD555, 655, 675-3A 20-437

(6)
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM
(H MODE)
Failure table: modes and causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-452

H-1 All work equipment is slow or lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-454
H-2 No work equipment moves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-455
H-3 Excessive drop in engine speed, or engine stalls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-455
H-4 Abnormal noise generated around the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-456
H-5 Excessive blade drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-456
H-6 Impossible to raise front of machine using the blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-457
H-7 Lack of actuating power in the articulating, drawbar shift, scarifier, leaning, and blade shift
cylinders (left, right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-457
H-8 Excessive leaning cylinder drift (tires lean) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-458
H-9 Impossible to rotate the circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-458
H-10 Excessive scarifier drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-459
H-11 Machine does not move in either FORWARD or REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-460
H-12 Transmission does not upshift or downshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-461
H-13 Machine is slow or lacks power when travelling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-461
H-14 Torque converter lock-up malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-462
H-15 Excessive time lag when starting or shifting gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-462
H-16 Torque converter oil temperature is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-463
H-17 Braking force is insufficient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-464
GD555, 655, 675-3A 20-451

(3)
TROUBLESHOOTING FAILURE TABLE: MODES AND CAUSES
FAILURE TABLE: MODES AND CAUSES
Pump Left control Right control

valve valve
Cause of Failure
Hydraulic cylinder
Slow return valve

Main relief valve
Pilot check valve

Failure mode
LS relief valve
Unload valve
Pump proper
Circle motor
PC valve
Strainer
Spool
Spool
All work equipment is slow or lacks power { { { { {
No work equipment moves { { {
Excessive drop in engine speed, or engine stalls { {
Work equipment
Abnormal noise is generated { {

Excessive blade drift { {
Impossible to raise the machine using the blade { { { { { { {
Lack of actuating power in articulating, drawbar shift, scari- { { { { { { {
fier, leaning, blade shift cylinders (Left, right)
Excessive leaning cylinder drift (Tires lean) { {
Impossible to rotate the circle { { { { { {
Excessive scarifier drift { {
Machine does not move in either FORWARD or REVERSE
Transmission does not upshift or downshift
In all
speed
ranges
Machine is slow or lacks power when traveling
Travel
In certain
speed
ranges
Torque converter lock-up cannot be actuated or cancelled
Excessive time lag when starting or shifting gear
Torque converter oil temperature is high
Braking force is insufficient
20-452 GD555, 655, 675-3A

(6)
{
Circle rotator
Work
ment
equip-
{
Shear pin
Loose piping connection or clamp, cracked hose
{
{
{
Transmission proper
GD555, 655, 675-3A

{
{
Defective transmission main relief valve
TROUBLESHOOTING
{
{
{
{
Defective transmission clutch
{
{
{
Torque converter proper
{
{
{
Defective torque converter relief valve
{
{
{
Defective torque converter lock-up clutch
{
{
Defective transmission pump
{
{
Air sucked into transmission pump suction circuit
{
{
Clogged strainer
{
{
{
{
{
Defective ECMV valve
{
Defective differential or final drive
{
Brake valve
{
Piston/disc/plate
{
Accumulator charge circuit
{
Accumulator
Braking device
{
Slack adjuster
{
{
{
Drop in engine performance
Troubleshooting code
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-14
H-10
H-17
H-16
H-15
H-12
H-13a
H-13b
20-453
(3)
TROUBLESHOOTING H-1
H-1 ALL WORK EQUIPMENT IS SLOW OR LACKS POWER
Cause Remedy
1
Does abnormal noise come from NO
the pump?
YES
2
Are the pipe connections loose

between the hydraulic tank and NO
the pump, or any cracks in the
hose?
Tighten,
YES Loose piping replace
connection,
packing,
cracked hose
hose
3
Excessive metal particles in the NO
pump discharge filter?
YES Abnormal pump Repair or
wear replace
4
Is the hydraulic tank strainer NO Pump perfor- Replace
clogged? mance reduced
YES Clogged suction Clean or
strainer replace
5
• 20.6 MPa {210 kg/cm2} Is the main relief pressure nor- NO
• Engine at full throttle mal?
YES Defective unload
valve (Left con- Replace
trol valve)
6
Is the condition normal after NO

adjusting the main relief pres-
sure?
YES Improper relief Repair or

pressure adjust-
replace
ment
7
Is the condition normal after NO
Go to Item 3 –
adjusting the LS relief valve?
YES LS relief pres-

Repair or
sure incorrectly
adjusted replace
20-454 GD555, 655, 675-3A

(6)
TROUBLESHOOTING H-2, H-3
H-2, H-3
H-2 NO WORK EQUIPMENT MOVES
Cause Remedy
1
After removing the main pump

Defective main
• 20.6 MPa {210 kg/cm2} pressure plug and then cranking NO
pump or defec-
Repair or
• Engine at full throttle the engine, does oil come out of tive PTO replace
the plug opening?
YES
2
After cleaning or replacing the NO Defective unload

main relief valve, does the condi- valve (Left con- Replace
tion become normal? trol valve)
YES Defective main

Adjust
relief valve
H-3 EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS
Cause Remedy
1
Is the throttle inside the servo NO
clogged?
YES Clogged throttle
inside the servo Clean
Does the condition become nor- NO

mal after replacing the PC valve?
Defective PC Adjust or
YES valve or incor- replace
rect PC valve the PC
adjustment valve

mal after replacing the main See the Engine
Shop Manual
pump assembly?
YES Replace
Defective servo the main
piston
pump
GD555, 655, 675-3A 20-455

b
H-4, H-5
H-4 ABNORMAL NOISE GENERATED AROUND THE PUMP
Cause Remedy
1
Add
Is the hydraulic tank oil level cor- NO Lack of hydraulic hydrau-
rect? oil
lic oil
YES
2
NO
Is the strainer clogged?
YES
Clogged strainer Clean

mal after tightening the piping
between the tank and the pump?
YES Loose piping

clamp Tighten
Inspect
again,
4 Operate for a depend-
Are metal particles found in the NO short time and ing on
watch for any the
drained hydraulic oil? change in symp- changes
toms in the
symp-
toms
YES
Defective pump Replace
H-5 EXCESSIVE BLADE DRIFT

Standard drift: Fewer than 10 mm after 10 minutes
Cause Remedy
1
• Max. 10 cc/min
• Engine at the rated
Is the hydraulic cylinder leak- NO Defective cylin-
speed Replace
age normal? der packing
• Relief at end of the
stroke (Extended)
YES Defective check Replace check

valve valve assembly
20-456 GD555, 655, 675-3A

b
H-6, H-7
H-6 IMPOSSIBLE TO RAISE FRONT OF MACHINE USING THE
BLADE
Cause Remedy
1
Is the condition normal in Trou- NO Same as Trou-
bleshooting H-1? bleshooting H-1
YES
2
NO Defective actua-
Control valve spool Does the control valve spool tion of the con- Repair or
stroke: 6.0 ± 5.0 mm move normally? replace
trol valve spool
YES Defective pack-

ing inside the Replace
cylinder
H-7 LACK OF ACTUATING POWER IN THE ARTICULATING,

DRAWBAR SHIFT, SCARIFIER, LEANING, AND BLADE SHIFT
CYLINDERS (LEFT, RIGHT)
Cause Remedy
1
Is the condition normal in Trou- NO Same as Trou-
bleshooting H-1? bleshooting H-1
YES
2
Control valve spool Does the control valve spool NO Defective actua- Repair or
tion of the con-
stroke: 6.0 ± 5.0 mm move normally? replace
trol valve spool
YES Defective pack-

ing inside the Replace
cylinder
GD555, 655, 675-3A 20-457

(1)
H-8, H-9
H-8 EXCESSIVE LEANING CYLINDER DRIFT (TIRES LEAN)
Cause Remedy
1
• Max. 10 cc/min
• Engine at the rated
speed Is the hydraulic cylinder leakage NO Defective cylin- Replace
normal? der packing
stroke (Extended)
Replace
YES check
Defective check
valve valve
assem-
bly
H-9 IMPOSSIBLE TO ROTATE THE CIRCLE

★ Check that dirt or an object doesn’t exist between the pinion and circle.
★ Check that the specified circle guide clearance exists.
Cause Remedy
1
Is the condition normal in Trou- NO
bleshooting H-1? Go to H-1
YES
2
NO
Is the shear pin broken?
YES
Broken shear pin Replace
3
Open the circle reverse gear NO
Defective motor Replace
case. Is the gear broken?
YES Defective circle Repair or
reverse replace
20-458 GD555, 655, 675-3A

(6)
TROUBLESHOOTING H-10
H-10 EXCESSIVE SCARIFIER DRIFT
Cause Remedy
1
• Max. 10 cc/min
• Engine at full throttle Is the hydraulic cylinder leakage NO Defective cylin-
normal? der packing Replace
stroke (Extended)
Replace
YES check
Defective check valve
valve
assem-
bly
GD555, 655, 675-3A 20-459

(6)
H-11 MACHINE DOES NOT MOVE IN EITHER FORWARD OR

REVERSE
Cause Remedy
1
• 2.37 ± 0.1 MPa
{24.2 ± 1 kg/cm2} Is the transmission main relief NO
• Engine at full throttle pressure normal?
• Gearshift lever: N
YES
2
• 0.59 ± 0.1 MPa
{6 ± 1 kg/cm2} Is the torque converter outlet NO
• Gearshift lever: N
YES Defective trans- Repair or
mission replace

Defective torque Repair or
mal after replacing the torque
converter relief valve? converter replace
YES Defective torque

Repair or
converter relief
replace
valve
4
Is abnormal noise generated NO
from around the pump?
YES
5
Is the transmission case strainer NO Air sucked into
the pump suc- Repair
clogged?
tion circuit
YES Clean or
Clogged strainer replace

Defective trans- Repair or
mal after replacing the main
relief valve? mission pump replace
YES Defective trans-

Repair or
mission main
relief valve replace
20-460 GD555, 655, 675-3A

(1)
H-12, H-13
H-12 TRANSMISSION DOES NOT UPSHIFT OR DOWNSHIFT
Before troubleshooting, operate the gearshift lever to each speed range to determine the speed ranges
where the transmission does not upshift or downshift.
Cause Remedy
1
• 2.06 – 2.45 MPa

NO
{21 – 25 kg/cm2} Is the clutch pressure normal?
• Engine at full throttle

Repair or
mission clutch replace
disc, plate
Does the condition become nor- NO Defective trans-

Repair or
mal after changing the ECMV mission clutch replace
with another ECMV? piston seal

mission ECMV replace
H-13 MACHINE IS SLOW OR LACKS POWER WHEN TRAVELLING

Before troubleshooting, operate the gearshift lever to each speed range to check if the travel is slow or
lacks power in all speed ranges, or if it is only in certain speed ranges.
a) Travel is slow or lacks power in all speed ranges
• Check that the brake is not dragging before troubleshooting. The machine should move after the
gearshift lever is at F4 and the engine is at low idle.
Cause Remedy
1
• 2.06 – 2.45 MPa

NO
{21 – 25 kg/cm2} Is each clutch pressure normal? Go to H-12
• Engine at full throttle
YES
Serial No.: 10001 – 11000
• GD555-3A 2
Engine perfor-
VHP: 1580 ± 100 rpm Is the torque converter stall NO mance reduced
• GD655-3A speed normal? (See Engine
VHP: 1700 ± 100 rpm Shop Manual)
YES
• GD675-3A
VHP: 1730 ± 100 rpm
3
Is the torque converter lock-up NO
• GD555-3A Go to H-14
actuated?
VHP: 1552 ± 100 rpm
• GD655-3A
VHP: 1665 ± 100 rpm YES Defective differ-
ential or final Repair or
• GD675-3A replace
drive
VHP: 1698 ± 100 rpm
b) Travel is slow or lacks power in certain speed ranges: Refer to Troubleshooting H-11.
GD555, 655, 675-3A 20-461

(6)
H-14, H-15
H-14 TORQUE CONVERTER LOCK-UP MALFUNCTION
CANNOT BE ACTUATED OR CANCELLED
• If the torque converter lock-up does not work, the maximum speed is reduced; if it cannot be cancelled,
the engine stalls when starting or stopping the machine.
Cause Remedy
• When actuated:
2.01± 0.15 MPa 1
{20.5 ± 1.5 kg/cm2} Is the torque converter lock-up NO
• When cancelled: pressure normal?
Defective torque
0 MPa {0 kg/cm2} YES converter lock- Repair or
• Engine at full throttle up clutch disc, replace
plate
Defective torque
After changing the ECMV with NO converter lock- Repair or
another one, does the condition up clutch piston replace
become normal?
seal
YES Defective torque

Repair or
converter lock- replace
up ECMV
H-15 EXCESSIVE TIME LAG WHEN STARTING OR SHIFTING GEAR

• Before troubleshooting, operate the gearshift lever to each speed range to determine the speed ranges
where excessive time lag exists.
• Check that the travel speed is normal before troubleshooting.
Cause Remedy
1
• 2.06 – 2.45 MPa Defective trans-
NO Repair or
{21 – 25 kg/cm2} Is the clutch pressure normal? mission clutch
replace
• Engine at full throttle piston seal
YES
2
After replacing the clutch ECMV, NO

does the condition become nor-
mal?

mission clutch
replace
ECMV
3
NO Defective trans-
Is the torque converter lock-up mission clutch Repair or
actuated? replace
valve spool

Repair or
mission clutch replace
disc, plate
20-462 GD555, 655, 675-3A

(6)
H-16 TORQUE CONVERTER OIL TEMPERATURE IS HIGH

• Verify that the torque converter oil temperature is high before troubleshooting.
• Check that the brake is not dragging before troubleshooting. The machine should move when the gear-
shift lever is at F4 and the engine is at low idle.
Cause Remedy
• 2.37 ± 0.1 MPa 1
{24.2 ± 1 kg/cm2} Is the transmission main relief NO
Go to H-12
• Gearshift lever: N YES
2
Is the torque converter stall NO
See Table 1 below. speed normal?
Defective engine
YES coolant system
(See Engine
Shop Manual)
• 0.59 ± 0.1 MPa {6 ± 1 3

kg/cm2} Is the torque converter outlet NO
• Gearshift lever: N YES
4
Is the torque converter lock-up NO
Go to H-14
actuated?
mission replace
After replacing the torque con- NO

verter relief valve, does the con- Defective torque Repair or
converter replace
dition become normal?
Table 1 YES Defective torque

converter relief Repair or
Serial No.: 10001 – 11000 replace
valve
• GD555-3A
VHP: 1580 ± 100 rpm
• GD655-3A
VHP: 1700 ± 100 rpm
• GD675-3A
VHP: 1730 ± 100 rpm
• GD555-3A
VHP: 1552 ± 100 rpm
• GD655-3A
VHP: 1665 ± 100 rpm
• GD675-3A
VHP: 1698 ± 100 rpm
GD555, 655, 675-3A 20-463

(3)
H-17 BRAKING FORCE IS INSUFFICIENT

★ Carry out the following troubleshooting when the steering system and work equipment operate nor-
mally.
Cause Remedy
1
• See TESTING AND Is wear of brake disc and plate in NO Wear of disc and
Replace
ADJUSTING. standard range? plate
YES
2
NO
Is air in brake circuit?
YES Air in brake cir-

cuit Bleed air
3
• 3.9 +0.1
–0.31 MPa
NO
Is brake circuit pressure normal?
{40 +1
–3 kg/cm 2}
YES
• Cut-in pressure:
9.4 ± 1 MPa 4
{93.5 ± 10 kg/cm2} Is accumulator charge pressure NO
• Cut-out pressure: normal?
13.4 ± 1 MPa YES
{136.5 ± 10 kg/cm 2} Charge
5 accumu-
lator
When accumulator charge valve NO Defective accu- with gas
is adjusted, is trouble repaired? mulator (See
TEST-
ING AND
ADJUST-
ING)
YES Defective adjust-

ment of charge Adjust
circuit
Does brake valve operate nor- NO Defective opera- Clean or

tion of brake
mally? replace
valve
YES Leakage through

brake piston seal Replace
7
Defective opera-
Does slack adjuster operate nor- NO Clean or
mally? tion of slack repair
adjuster
YES Distortion of disc

Replace
and plate
20-464 GD555, 655, 675-3A

(6)
TROUBLESHOOTING OF
MAIN MONITOR SYSTEM
(M MODE)
Failure table: modes and causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-502

Electrical circuit diagram for main monitor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-504
M-1 Engine oil pressure caution lamp glows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-506
M-2 Transmission controller caution lamp glows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-507
M-3 Transmission oil temperature caution lamp glows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-507
M-4 Differential oil temperature caution lamp glows (opt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-508
M-5 Bank pin caution lamp glows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-509
M-6 Brake oil pressure caution lamp glows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510
M-7 Battery charge caution lamp glows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-511
M-8 Preheating display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-512
M-9 High Beam display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-513
M-10 Working lamp display does not light up (opt). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
M-11 Differential lock actuation display does not light up (opt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-515
M-12 Accumulator actuation display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-516
M-13 Float actuation display does not light up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-516
M-14 Parking brake display does not light up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-518
M-15 Turn signal lamp does not flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-519
M-16 Articulation gauge does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-520
M-17 Fuel gauge does not work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-522
M-18 Engine coolant temperature gauge does not work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-523
M-19 Torque converter temperature gauge does not work (opt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-524
M-20 Message center does not work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-525
M-21 Service meter does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-526
GD555, 655, 675-3A 20-501

(6)
TROUBLESHOOTING FAILURE TABLE: MODES AND CAUSES
Torque converter oil temperature gauge

Cause of the failure
Coolant temperature gauge
Transmission controller
Relay, flasher, timer
Articulation gauge
Wiring harness
Nature of the failure
Fuel gauge
Fuse
Engine oil pressure caution lamp lights up when the engine is started {
Transmission controller abnormality caution lamp lights up { {
Transmission oil temperature caution lamp lights up { {

Caution
Differential oil temperature caution lamp lights up (Opt) { {
Bank pin caution lamp lights up {
Brake oil pressure caution lamp lights up {
Battery charge caution lamp lights up when the engine is started { {
Preheating display does not light up when preheating is operated { {
High beam display does not light up { {

Actuation display
Working lamp display does not light up (Opt) { { {
Differential lock actuation display does not light up (Opt) { { {
Accumulator actuation display does not light up { {
Float actuation display does not light up { {
Parking brake display does not light up { { {
Turn signal lamp display does not flash { { {
Articulation gauge does not work { {
Fuel gauge does not work { {
{ {
Gauges
Engine coolant temperature gauge does not work
Torque converter temperature gauge does not work (Opt) { {
Message center does not work (Opt) { {
Service meter does not work {
20-502 GD555, 655, 675-3A

(6)
Message center
!
Leakage of oil from engine oil pressure piping
!
Shifter
!
Starting switch
GD555, 655, 675-3A

Engine oil pressure sensor (Switch)
!
!
TROUBLESHOOTING
Transmission oil temperature sensor
!
Coolant temperature sensor
!
Alternator
!
Accumulator oil pressure switch
!
Buzzer
!
Head lamp switch
!
Bulb
!
!
!
!
!
!
!
!
Service meter
!
Fuel level sensor (Fuel sensor)
!
Torque converter oil temperature sensor
!
Articulation sensor
!
Differential oil temperature sensor
!
Turn switch, hazard switch
!
Float/accumulator switch
!
!
Lifter lock switch
!
Differential lock switch

!
Troubleshooting code
M-9
M-8
M-7
M-6
M-5
M-4
M-3
M-2
M-1
M-11
M-19
M-14
M-10
M-21
M-20
M-18
M-17
M-16
M-15
M-13
M-12
20-503
(1)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM

Serial No.: 10001 – 11000
20-504 GD555, 655, 675-3A

(3)
GD555, 655, 675-3A 20-505

(3)
20-505-1 GD555, 655, 675-3A

(3)
GD555, 655, 675-3A 20-505-2

(3)
TROUBLESHOOTING M-1
M-1 ENGINE OIL PRESSURE CAUTION LAMP GLOWS
WHEN THE ENGINE IS STARTED
Cause Remedy
1
Does the caution lamp go Hot short in wiring

• Disconnect E12 out after removing the NO harness between FP3 Repair or
• Turn starting switch ON engine oil pressure switch (female) (8) – E12 replace
connector (E12)? (female) (C)
YES
2
Does the caution lamp NO Defective engine oil

• Turn starting switch ON light up when the starting Replace
pressure switch
switch is turned ON?
YES
3
Does the caution lamp NO

• Turn starting switch START light up after the engine No problem (Normal)
starts?
Check the hydraulic

piping (Drop in oil
YES level, oil leakage, Repair or
deterioration of oil, replace
defective engine oil
pressure switch)
M-1 RELATED ELECTRICAL CIRCUIT DIAGRAM
20-506 GD555, 655, 675-3A

(6)
TROUBLESHOOTING M-2
M-2 TRANSMISSION CONTROLLER CAUTION LAMP GLOWS
Cause Remedy
1
Defective transmis-
sion or 24 V wiring
Check the transmission NO contact the wiring Repair or
• Turn starting switch ON controller error code, can- harness between FP3 replace
cel alarm.
(Female) (7) and T1
(Female) (5)
YES Transmission con- Repair
troller error canceled
M-3 TRANSMISSION OIL TEMPERATURE CAUTION LAMP GLOWS
Cause Remedy
1
Defective transmis-
• Disconnect T35 Does the caution lamp go sion controller or hot
• Turn starting switch ON out after removing the NO short in wiring Repair or
(Engine and transmission must transmission oil tempera- harness between FP3 replace
be cold). ture sensor T35? (female) (6) – T1
(female) (3)

sion oil temperature Replace
sensor
GD555, 655, 675-3A 20-507

(6)
TROUBLESHOOTING M-4
M-4 DIFFERENTIAL OIL TEMPERATURE CAUTION LAMP GLOWS

(OPT)
Cause Remedy
Does the caution lamp go

• Disconnect E17 out after removing the dif-
• Turn starting switch ON ferential oil temperature NO
sensor E17?
YES Defective differential

oil temperature sen- Replace
sor
2
24 V wiring contacts
• Max. 1 V the wiring harness
Is voltage normal between NO between FP3 Repair or
E17 (1) and the chassis? (Female) (4) and T1 replace
• Connect the T-adapter (Female) (1), or
defective controller
YES
Short circuit to
ground in the wiring Repair or
harness between T3
replace
(Female) (10) and E17
(Female) (1)
20-508 GD555, 655, 675-3A

(6)
TROUBLESHOOTING M-5
M-5 BANK PIN CAUTION LAMP GLOWS
Cause Remedy
1
Is the lifter lock switch NO
being pressed?
YES Turn start-
Normal if lamp lights
ing switch
up, switch still ON OFF
2
• Disconnect BR23 Does the caution lamp NO Defective lifter lock
glow after removing BR23? switch Replace
YES
24 V wiring contacts
the wiring harness Repair or
between FP3
replace
(Female) (3) and
BR23 (Female) (2)
GD555, 655, 675-3A 20-509

(6)
TROUBLESHOOTING M-6
M-6 BRAKE OIL PRESSURE CAUTION LAMP GLOWS
Cause Remedy
1
If only the lamp
glows, defective
Does the buzzer sound at NO buzzer A, also 24 V Repair or
• Turn starting switch ON the same time the lamp wiring contacts wir-
replace
glows? ing harness between
FP3 (Female) (2) and
B1 (Female) (5)
YES
2
• Turn starting switch to the Does the lamp glow and NO

START position and start the the buzzer sound after Normal (Oil pressure
is charged)
engine starting the engine?
YES Defective accumula-

tor oil pressure Replace
switch
20-510 GD555, 655, 675-3A

(6)
TROUBLESHOOTING M-7
M-7 BATTERY CHARGE CAUTION LAMP GLOWS
AFTER STARTING THE ENGINE
Cause Remedy
• 20 – 30 V open circuit in the
• Turn starting switch to START wiring harness
Is the voltage normal NO between BR5 Repair or
and start the engine between BR5 (1) and the
chassis? (Female) (1) and replace
• Possible to the connect T- alternator terminal I,
adapter to B7 (3) or a defective alter-
nator
YES
Defective relay BR5 Replace
GD555, 655, 675-3A 20-511

(6)
TROUBLESHOOTING M-8
M-8 PREHEATING DISPLAY DOES NOT LIGHT UP
WHEN OPERATING THE PREHEATING
Cause Remedy
open circuit in the
• 20 – 30 V wiring harness
• Connect T-adapter to the B3 Is the voltage normal NO between B3 (Female) Repair or
between B3 (1), B8 (4) and
and B8 connectors the chassis? (1), B8 (Female) (4) – replace
• Turn starting switch to HEAT B7 (Female) (4) –
BT33, or defective
starting switch
YES
2
• 20 – 30 V open circuit in the
Is the voltage normal NO wiring harness Repair or
• Connect T-adapter between FP2 (10) and the
between FP2 replace
• Turn starting switch to HEAT chassis?
(Female) (10) and FP7
(1)
YES
3
• Turn starting switch OFF between FP2 (Female) (2) between FP2 replace
• Disconnect FP2 and BR19 and BR19 (Female) (1)?
(Female) (2) and
BR19 (Female) (1)
YES Blown bulb, or defec-

Replace
tive timer
20-512 GD555, 655, 675-3A

(6)
TROUBLESHOOTING M-9
M-9 HIGH BEAM DISPLAY DOES NOT LIGHT UP
Cause Remedy
1
• Turn starting switch ON Do the low-beam head NO
• Head lamp switch ON lamps illuminate?
YES
2 Open circuit in the
wiring harness
After turning the dimmer between FP12
switch to HI, do the high- NO (Female) (C) – FP8 Repair or
• Dimmer switch on HI beam head lamps illumi- (Male) (7), FP2 replace
nate? (Female) (1), or
defective dimmer
switch
YES
Blown pilot lamp
Replace
bulb
3 Defective head lamp

switch, or open cir-
NO cuit in the wiring har- Repair or
• Head lamp switch: SMALL Does the small lamp glow?
ness between BR27 replace
(Female) (5) and fuse
box, blown fuse
open circuit in the
YES wiring harness Replace
between BR27
(Female) (6) and FP12
(Female) (A)
GD555, 655, 675-3A 20-513

(6)
TROUBLESHOOTING M-10
M-10 WORKING LAMP DISPLAY DOES NOT LIGHT UP (OPT)
Cause Remedy
1
• Turn starting switch ON NO

Does the working lamp
• Turn the working lamp switch
light up?
ON
YES
2
• 20 – 30 V Defective contact or
• Connect T-adapter open circuit in the
• Turn starting switch ON between FP2 (3) and the wiring harness Repair or
between FP6 (Male) replace
• Turn the working lamp switch chassis?
(6) and FP2 (Female)
ON (3)
YES Blown pilot lamp
Replace
bulb
3
Open circuit in the
• 20 – 30 V Is the voltage normal NO wiring harness
Repair or
• Connect T-adapter between B2 (8) and the between B2 (Female) replace
• Turn starting switch ON chassis? (8) and the fuse box,
or a blown fuse
YES
Defective BR13 relay,
Repair or
or defective working
lamp switch replace
20-514 GD555, 655, 675-3A

(6)
M-11 DIFFERENTIAL LOCK ACTUATION DISPLAY DOES NOT LIGHT

UP (OPT)
Cause Remedy
• 20 – 30 V
• Connect T-adapter Is the voltage normal NO
between FP2 (5) and the
• Turn starting switch ON chassis?
• Turn the differential switch ON

Replace
bulb
Defective BR7 relay,

or defective trans-
• 20 – 30 V mission controller.
• Connect T-adapter Is the voltage normal NO Open circuit in the Repair or
between B1 (3) and the transmission control- replace
• Turn the differential switch ON ler wiring harness, or
a defective differen-
tial switch
open circuit in the
YES wiring harness Repair or
between B1 (Female) replace
(3) – FP6 (1) – FP2
(Female) (5)
GD555, 655, 675-3A 20-515

(6)
M-12 ACCUMULATOR ACTUATION DISPLAY DOES NOT LIGHT UP
Cause Remedy
1
• 20 – 30 V
• Turn starting switch ON between FP2 (6) and the
• Turn the accumulator switch chassis?
ON
Replace
bulb
2 Defective accumula-
• 20 – 30 V tor float switch, or
• Connect T-adapter open circuit in the
• Turn starting switch ON between B5 (2) and the wiring harness Repair or
between BR28 replace
• Turn the accumulator switch chassis?
(Female) (A) – B5
ON (Male) (2), blown
fuse
open circuit in the
YES wiring harness Repair or
between B5 (Female) replace
(2) – FP6 (11) – FP2
(Female) (6)
M-13 FLOAT ACTUATION DISPLAY DOES NOT LIGHT UP
Cause Remedy
1
• 20 – 30 V
between FP2 (7) and the
• Turn float switch ON
YES Blown pilot lamp Replace

bulb
2
Defective accumula-
• 20 – 30 V tor float switch, or
• Connect T-adapter Is the voltage normal NO open circuit in the Repair or
between B5 (5) and the
• Turn starting switch ON wiring harness replace
chassis? between BR28
• Turn float switch ON
(Female) (C) – B5
(Male) (5), blown fuse
YES open circuit in the
between BR28 replace
(Female) (C) – B5
(Male) (5) – FP6 (9) –
FP2 (Female) (7)
20-516 GD555, 655, 675-3A

(6)
M-12, M-13 RELATED ELECTRICAL CIRCUIT DIAGRAM
GD555, 655, 675-3A 20-517

(1)
M-14 PARKING BRAKE DISPLAY DOES NOT LIGHT UP
BRAKE RELEASED WHEN LIGHT IS ON
Cause Remedy
• 20 – 30 V Is the voltage normal NO

• Gearshift lever: [P] between FP2 (8) and the
YES Blown pilot lamp Replace

bulb
2 Defective BR11 relay,

or disconnection in
• 20 – 30 V wiring harness
• Connect T-adapter Is the voltage normal NO between BR4 (Male) Repair or
between B4 (4) and the
• Gearshift lever: [P] (4) – BR11 (Female) replace
chassis? (6), BR11 (Female) (3)
– B4 (1) – fuse, blown
fuse
YES disconnection in wir-
replace
B4 (Female) (4) and
FP2 (Female) (8)
20-518 GD555, 655, 675-3A

(6)
M-15 TURN SIGNAL LAMP DISPLAY DOES NOT FLASH
Cause Remedy
1
After turning the hazard NO

• Turn starting switch ON switch ON, does either
side (Left or right) flash?
YES
2
After turning the signal NO

switch ON, does either
side (Left or right) flash?
YES
3
Defective flasher, dis-
Does either combination connection in wiring
NO harness between
lamp (Front and rear)
flash? BR26 (female) (2), (5)
Repair or
- BR20 (female) (4) or replace
between BR20
YES (female) (3) - B3 (3) -
fuse or breakage of
fuse
4
• Defective turn sig-
• 20 – 30 V nal switch or hazard
• Connect T-adapter Is the voltage normal NO switch
between FP1 (7), (8) and
• Turn starting switch ON the chassis? • Disconnection or
• Hazard switch: ON defective contact in
wiring harness
between FP1 Repair or
YES
(female) (8) - FP11 replace
(female) (C), FP6
(male) (5) (RH) or
between FP1
(female) (7) - FP11
(female) (B), FP6
(male) (3) (LH)
Pilot lamp bulb

blown on the side Replace
which does not flash
GD555, 655, 675-3A 20-519

(6)
TROUBLESHOOTING M-15, M-16
M-16 ARTICULATION GAUGE DOES NOT WORK
Cause Remedy
1
• 20 – 30 V Is the voltage normal NO open circuit in the
between FT33 and the wiring harness Repair or
• Turn starting switch ON replace
chassis? between FT33 and
FP1 (Male) (5)
YES
2
Open circuit in the
• 20 – 170 Ω Is the resistance normal NO wiring harness
Repair or
• Turn starting switch OFF between FT17 and the between FT16 and
chassis? GND, or defective replace
• Disconnect FT17
articulation sensor
YES
3
Open circuit or short
• 20 – 170 Ω Is the resistance normal NO circuit to ground in Repair or
• Turn starting switch OFF between FP1 (Female) (2) the wiring harness
replace
• Disconnect FP1 and the chassis? between FP1
(Female) (2) and FT17
YES
Defective articula-
Replace
tion gauge
20-520 GD555, 655, 675-3A

(6)

Serial No.: 10001 – 11000
Serial No.: 11001and up
GD555, 655, 675-3A 20-521

(3)
M-17 FUEL GAUGE DOES NOT WORK

Serial No.: 10001 – 11000
Cause Remedy
1
Repair or
between FT29 and the wiring harness
FP1 (Male) (5)
YES
2
• 10 – 100 Ω Is the resistance normal NO

• Turn starting switch OFF between ET39 (male) (1) Defective fuel sensor Replace
• Disconnect ET39 and the chassis?
YES
3
• 10 – 100 Ω circuit to ground in
Is the resistance normal NO the wiring harness Repair or
• Disconnect FP1 and the chassis?
(Female) (3) and
ET39 (female)
YES
Defective fuel gauge Replace
20-522 GD555, 655, 675-3A

(6)

Cause Remedy
1
between FT29 and the wiring harness Repair or
FP1 (Male) (5)
YES
2
• 10 – 100 Ω Is the resistance normal NO Repair or

• Turn starting switch OFF between ET39 (male)(1) Defective fuel sensor
and the chassis? replace
• Disconnect ET39
YES
3
• Turn the starting switch OFF between FP1 (Female) (3)
between FP1 replace
• Disconnect FP1 and the chassis? (Female) (3) and
ET39 (female)(1)
YES
Defective fuel gauge Replace
GD555, 655, 675-3A 20-522-1

(6)
M-18 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT WORK
Cause Remedy
1
Is the voltage normal Open circuit in the

• 20 – 30 V NO wiring harness Repair or
between FT26 and the
• Turn starting switch ON between FT26 and replace
chassis? FP1 (Male) (5)
YES
2
Open circuit in the
• 10 – 100 Ω wiring harness
• Turn starting switch OFF between E2 (Male) (1) and between E2 (Female) Repair or
(2) and GND, or a replace
• Disconnect E2 the chassis?
defective coolant
temperature sensor
YES
3
• Disconnect FP1 and the chassis?
(Female) (1) and E2
(Female) (1)
YES Defective coolant

Replace
temperature gauge
GD555, 655, 675-3A 20-523

(6)
M-19 TORQUE CONVERTER TEMPERATURE GAUGE DOES NOT

WORK (OPT)
Cause Remedy
1
• 20 – 30 V Is the voltage normal NO Open circuit in the wir- Repair or

between FT23 and the chas- ing harness between
• Turn starting switch ON sis? FT23 and FP1 (Male) (5) replace
YES
2
Open circuit in the wir-
• 10 – 100 Ω Is the resistance normal NO
ing harness between E4
(Female) (2) and GND, Repair or
• Turn starting switch OFF between E4 (Male) (1) and the or a defective torque replace
• Disconnect E4 chassis? converter oil tempera-
ture sensor
YES
3

• 10 – 100 Ω Is the resistance normal NO circuit to ground in the Repair or
• Turn starting switch OFF between FP1 (Female) (6) and wiring harness between replace
• Disconnect FP1 the chassis? FP1 (Female) (6) and E4
(Female) (1)
YES Defective torque con-

verter oil temperature Replace
gauge
20-524 GD555, 655, 675-3A

(6)
M-20 MESSAGE CENTER DOES NOT WORK
Cause Remedy
1
open circuit in the
• 20 – 30 V Is the voltage normal NO wiring harness Repair or
between FP10 (Female) (1)
• Turn starting switch ON between FP10 replace
and the chassis? (Female) (1) – FP7 (1)
– fuse
YES
2
• Max. 1 Ω between FP10 (Female) (2) NO Resistance of more
• Turn starting switch OFF and T4 (Female) (3), than 1 MΩ in the wir- Repair or
between FP10 (Female) (3) replace
• Disconnect FP10 and T4 ing harness
and T4 (Female) (4),
between FP10 (Female) (4)
and T4 (Female) (10)?
Defective message
YES center, or defective
Replace
transmission control-
ler
GD555, 655, 675-3A 20-525

(6)
M-21 SERVICE METER DOES NOT WORK
Cause Remedy
1
• 20 – 30 V Open circuit in the

• Turn starting switch ON Is the voltage normal NO wiring harness Repair or
between E12 (Female) (A) between E12
(Engine oil pressure lamp lights replace
and the chassis? (Female) (A) and the
up) fuse
YES
2
Open circuit in the
• Max. 1 Ω Is the resistance normal NO wiring harness
between FP9 (Female) (1) between FP9 Repair or
• Turn starting switch OFF replace
and the chassis? (Female) (1) and FP7
(Male) (8)
YES
3
• 20 – 30 V
• Turn starting switch to START Is the voltage normal NO Defective engine oil
and start the engine between B10 (3) and the Replace
chassis? pressure switch
(Engine oil pressure lamp lights
up)
YES
4
Open circuit in the
• 20 – 30 V Is the voltage normal NO wiring harness Repair or
• Turn starting switch to START between FP9 (2) and the between FP9
replace
and start the engine chassis? (Female) (2) and B10
(Female) (3)
YES Defective service

meter Replace
20-526 GD555, 655, 675-3A

(6)
30 DISASSEMBLY AND ASSEMBLY
Method of using manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3

Precautions when carrying out operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
Special tool list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
Sketches of special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
Removal of engine hood assembly (Serial No.10001 – 11000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
Installation of engine hood assembly (Serial No.10001 – 11000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
Removal of engine hood assembly (Serial No.11001 and up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
Installation of engine hood assembly (Serial No.11001 and up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
Removal of radiator assembly (Serial No.10001 – 11000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
Installation of radiator assembly (Serial No.10001 – 11000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
Removal of radiator assembly (Serial No.11001 and up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
Installation of radiator assembly (Serial No.11001 and up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21
Removal of fuel tank, hydraulic tank, and coolant sub tank (Serial No.10001 – 11000). . . . . . . . . . . . . . . 30-22
Installation of fuel tank, hydraulic tank, and coolant sub tank (Serial No.10001 – 11000) . . . . . . . . . . . 30-23-1
Removal of fuel tank, hydraulic tank, and coolant sub tank (Serial No.11001 and up) . . . . . . . . . . . . . 30-23-3
Installation of fuel tank, hydraulic tank, and coolant sub tank (Serial No.11001 and up) . . . . . . . . . . . 30-23-5
Removal of engine assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23-6
Installation of engine assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
Removal of engine assembly, transmission assembly as one unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
Installation of engine assembly, transmission assembly as one unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
Removal of transmission assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27
Installation of transmission assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
Disassembly of torque converter assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
Assembly of torque converter assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33
Disassembly of transmission assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36
Assembly of transmission assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
Removal of final drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70
Installation of final drive assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-73
Disassembly of final drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75
Assembly of final drive assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
Disassembly of final brake case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
Assembly of final brake case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
Disassembly of side case assembly (for standard final drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-82
Assembly of side case assembly (for standard final drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-83
Disassembly of side case (for planetary final drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84-1
Assembly of side case (for planetary final drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84-3
Disassembly of differential gear assembly (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85
Assembly of differential gear assembly (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-86
Disassembly of bevel gear assembly (for standard final drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-89
Assembly of bevel gear assembly (for standard final drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-89
Disassembly of bevel gear (for planetary final drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92-1
Assembly of bevel gear (for planetary final drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92-2
Disassembly of bevel pinion assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92-4
Assembly of bevel pinion assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-93
Removal of operator's cab assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-94
Installation of operator's cab assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-95
Removal of operator's cab floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-97
Installation of operator's cab floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98
Removal of steering valve (orbit-roll). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100
Installation of steering valve (orbit-roll) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100
Standard integral orbit-roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102
Disassembly of steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104
Assembly of steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106
Removal of blade assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-111
Installation of blade assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-111
GD555, 655, 675-3A 30-1

(4)
DISASSEMBLY AND
ASSEMBLY
Removal of circle drawbar assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112

Installation of circle drawbar assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113
Removal of blade circle rotation gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114
Installation of blade circle rotation gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115
Removal of blade circle rotation gear (with shear pin). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
Installation of blade circle rotation gear (with shear pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-117
Disassembly of circle rotation gear (with shear pin). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118
Assembly of circle rotation gear (with shear pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-120
Disassembly of circle rotation gear (with slip clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-122
Assembly of circle rotation gear (with slip clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-124
30-2 GD555, 655, 675-3A

(6)
DISASSEMBLY AND
ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
1) When removing or installing a unit assembly, the order of work and techniques used are given for
the removal operation; the order of work for the installation operation is not given.
2) Any special techniques applying only to the installation procedure are marked , and the same
mark is placed after the relevant step in the removal procedure to indicate which step in the installa-
tion procedure it applies to.
(Example)
REMOVAL OF ASSEMBLY........................... Title of operation
k ................................................................................... Precautions related to safety when carrying out
the operation
1. X X X X (1) ................................................................ Step in operation
+ ................................................................................ Technique or important point to remember when
removing XXXX (1).
2. (2):............................................................. Indicates that a technique is listed for use
during installation
3. assembly (3)
6.......................................................................... Quantity of oil or water drained
INSTALLATION OF ASSEMBLY .................. Title of operation

• Carry out installation in the reverse order to removal.
.................................................................................. Technique used during installation
+....................................................................................... Technique or important point to remember when
installing (2)
• Adding water, oil ...................................................... Step in operation
+ ................................................................................ Point to remember when adding water or oil
5 ............................................................................ Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are
given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these pre-
cautions when carrying out the operation.
3. Listing of special tools

1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the
operation procedure, see the SPECIAL TOOLS LIST given in this manual.
GD555, 655, 675-3A 30-3

(4)
DISASSEMBLY AND
ASSEMBLY METHOD OF USING MANUAL
4. General tightening torque table (when using torque wrench)

+ For metric nuts and bolts without specified torque, tighten to the torque given in the table below.
Thread Diameter Width Across Flats
mm mm Nm kgm
6 10 13.2 ± 1.4 1.35 ± 0.15
8 13 31.4 ± 2.9 3.2 ± 0.3
10 17 65.7 ± 6.8 6.7 ± 0.7
12 19 112 ± 9.8 11.5 ± 1.0

14 22 177 ± 19 18.0 ± 2.0
16 24 279 ± 29 28.5 ± 3
18 27 383 ± 39 39 ± 4
20 30 549 ± 58 56 ± 6
22 32 745 ± 78 76 ± 8
24 36 927 ± 98 94.5 ± 10
27 41 1320 ± 140 135 ± 15
30 46 1720 ± 190 175 ± 20
33 50 2210 ± 240 225 ± 25

36 55 2750 ± 290 280 ± 30
39 60 3280 ± 340 335 ± 35
5. Table of tightening torques for flared nuts

+ For flared nuts without specified torque, tighten to the torque given in the table below.
Thread Diameter Width Across Flats Tightening Torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5
18 24 49 ± 9.8 5±1
22 27 78.5 ± 9.8 8±1
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
6. Table of tightening torques for split flanged bolts

+ For split flange bolts without specified torque, tighten to the torque given in the table below.
Thread Diameter Width Across Flats Tightening Torque
mm mm Nm kgm
10 14 65.7 ± 6.8 6.7 ± 0.7
12 17 112 ± 98 11.5 ± 1
16 22 279 ± 29 28.5 ± 3
30-4 GD555, 655, 675-3A

(4)
DISASSEMBLY AND
ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the gen-
eral precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
★ Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal number Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes

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

(4)
DISASSEMBLY AND
ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
★ When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the
engine to circulate the coolant through the system. Then check the coolant level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed, always bleed the air from the system after
reassembling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-6 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

★ Tools with part number 79T-- cannot be supplied (they are items to be locally manufac-
tured).
★ Necessity: ■: Cannot be substituted, should always be installed (used).
●: Very convenient if available, can be substituted with commercially available part.
★ New/remodel: N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available for other
models.
Blank: Tools already available for other models, used without any modification.
★ Tools marked  in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPE-
CIAL TOOLS).
Neces New/
Component Symbol Part No. Part Name Qty. Sketch Nature of work, remarks
sity remodel
Removal, installation of cylin-
1 709-331-1110 Wrench ■ 1
der head
Disassem-
bly, assem-
A 2 795-799-2250 Installer ■ 1 Press fitting of front oil seal
bly of
engine 795-799-1390 Remover ■ 1 Removal, installation of injec-
3
795-799-1131 Gear ■ 1 tion pump
790-501-5000 Repair stand ● 1

790-501-5200 Repair stand ● 1
Disassembly, assembly of
1 790-901-2110 Bracket ● 1
torque converter
793-310-2131 Plate ● 1
Disassem-
bly, assem- 793-310-2141 Plate ● 1
bly of C
Removal, installation of start-
torque con- 2 792-390-1210 Wrench ■ 1 ing motor shaft round nut
verter
790-201-2740 Spacer ■ 1
3 Press fitting of bearing
790-201-2750 Spacer ■ 1
■ Removal, installation of PTO

4 790-102-1871 Wrench 1
bearing locknut
790-201-2740 Spacer ■ 1
1 Press fitting of clutch bearing
790-201-2750 Spacer ■ 1
2 790-101-5201 Push tool kit ■ 1 Press fitting of clutch bearing
Press fitting of clutch F2 & R
3 797T-423-1320 Push tool ■ 1 
bearing
797T-423-1130 Push tool ■ 1 N 
4 790-101-5221 Grip ■ 1 Press fitting of case oil seal at
pulley end
01010-51225 Bolt ■ 1
794T-423-1130 Push tool ■ 1
Disassem- 794T-423-1140 Spacer ■ 1 N  Press fitting of case dust seal
bly, assem- 5
bly of D 790-101-5221 Grip ■ 1 at pulley end
transmis-
sion 01010-51225 Bolt ■ 1
794T-114-1210 Push tool ■ 1 N 
6 01010-51240 Bolt ■ 1 Press fitting of coupling cage
790-101-5421 Grip ■ 1 oil seal and dust seal
7 794T-114-1230 Spacer ■ 1 N 
8 794T-423-1180 Push tool ■ 1 N  Press fitting of coupling cover
9 793-310-2100 Lifting tool ■ 1 Lifting of clutch assembly
Centering transmission and
10 792-271-2000 Centering tool ■ 1 final drive
11 799-301-1600 Oil leak tester ■ 1 Checking actuation of piston
30-8 GD555, 655, 675-3A

(10)
DISASSEMBLY
AND ASSEMBLY SPECIAL TOOL LIST
Neces New/ Nature of work,

Component Symbol Part No. Part Name sity Qty. remodel Sketch remarks
790-201-2850 Spacer Q 1
Press fitting of bevel
1 790-201-2230 Plate Q 1 pinion bearing inner
race
790-201-2740 Spacer Q 1
Disassem- 790-101-5401 Push tool kit Q 1
bly, assem-
bly of final J 790-101-5441 Plate 1 Press fitting of flange
drive 2 oil seal
790-101-5421 Grip 1
01010-51240 Bolt 1
3 794T-422-1110 Push tool Q 1 N !

Press fitting of drive
shaft collar, bearing
Removal, installation of
1 792-571-1600 Chain puller Q 1 chain
790-101-5401 Push tool kit Q 1
790-101-5551 Plate 1 Press fitting of oil seal
Disassem- 2
bly, assem- 790-101-5421 Grip 1 to cage
bly of K
tandem 01010-51240 Bolt 1
drive
794T-425-1110 Push tool Q 1 N ! Press fitting of drive
3
794T-659-1110 Push tool Q 1 shaft bearing inner race
Checking actuation of
4 799-301-1600 Oil leak tester Q 1 piston
796-765-1110 Push tool (GD555) Q 1
790-201-2220 Plate Q 1 Press fitting of shaft
1
793T-659-1110 Push tool (GD655) Q 1 ! bearing inner race
790-201-2240 Plate Q 1
Disassem- 790-101-5491 Plate (GD555) 1
bly, assem- H
bly of axle 790-101-5421 Grip 1
01010-51240 Bolt 1 Press fitting of housing
2
790-101-5401 Push tool kit Q 1 oil seal
790-101-5531 Plate (GD655) 1

790-101-5421 Grip 1
01010-51240 Bolt 1
1 791-342-1310 Wrench Q 1 Removal, installation of

cover
Disassem-
bly, assem- 790-720-1000 Expander Q 1
bly of bank Removal, installation of
pin 2 796-720-1740 Ring Q 1
piston ring
07281-00809 Clamp Q 1
V
Press fitting of worm
3 796-460-1110 Push tool Q 1 bearing inner race
Disassem-
bly, assem- 794T-470-1110 Push tool Q 1 N !
bly of circle Press fitting of housing
rotation 4 790-101-5221 Grip Q 1 oil seal
01010-51225 Bolt Q 1
790-502-1003 Cylinder repair stand Q 1 Disassembly, assembly
1
790-101-1102 Hydraulic pump Q 1 of hydraulic cylinder
2 790-102-2303 Wrench assembly Q 1 Removal, installation of

cylinder round head
Disassem-
bly, assem- 790-201-1731 Push tool 1
bly of U 790-201-1741 Push tool 1
hydraulic
system 790-201-1751 Push tool 1
3 Press fitting of cylinder
790-201-1761 Push tool 1 head coil bushing
790-201-1771 Push tool 1

790-201-5021 Grip 1
01010-50816 Bolt 1
GD555, 655, 675-3A 30-9

(2)
DISASSEMBLY AND
ASSEMBLY SPECIAL TOOL LIST
Component Symbol Part No. Part Name Neces Qty. New/ Sketch Nature of work,
sity remodel remarks
790-201-1540 Plate 1
790-201-1550 Plate 1
790-201-1560 Plate 1 Installation of cylinder
4 head dust seal
790-201-1570 Plate 1
790-201-1580 Plate 1
790-101-5021 Grip 1
01010-50816 Bolt 1
790-720-1000 Expander Q 1
796-720-1000 Ring Q 1
Disassem- 07281-00609 Clamp Q 1
bly, assem-
bly of U 796-720-1740 Ring Q 1
hydraulic
system 07281-00809 Clamp Q 1
796-720-1640 Ring Q 1
5 07281-00909 Clamp Q 1 Installation of cylinder
piston ring
796-720-1650 Ring Q 1
07281-01029 Clamp Q 1
796-720-1660 Ring Q 1
07281-01159 Clamp Q 1
796-720-1670 Ring Q 1
07281-01279 Clamp Q 1
796-460-1210 Stopper Q 1 Removal, installation
6
23B-60-32121 Rod Q 1 of hydraulic pump
799-703-1200 Service tool kit Q 1

799-703-1100 Vacuum pump (100V) Q 1
Air condi- Discharging and charg-
tioner X 799-703-1110 Vacuum pump (220V) Q 1 ing air conditioner
assembly refrigerant gas
799-703-1120 Vacuum pump (240V) Q 1
799-703-1400 Gas leak tester Q 1
30-10 GD555, 655, 675-3A

(4)
DISASSEMBLY AND
ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
D-3
D-4
GD555, 655, 675-3A 30-11

(10)
DISASSEMBLY
AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
D-5
D-6
30-12 GD555, 655, 675-3A

(10)
DISASSEMBLY AND
D-7
D-8
GD555, 655, 675-3A 30-13

(10)
DISASSEMBLY
AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
H-1
J-3
30-14 GD555, 655, 675-3A

(10)
DISASSEMBLY AND
K-3
V-4
GD555, 655, 675-3A 30-15

(10)
DISASSEMBLY AND
ASSEMBLY REMOVAL OF ENGINE HOOD ASSEMBLY
REMOVAL OF ENGINE HOOD

ASSEMBLY
Serial No. 10001 – 11000
1. Remove battery ground wire (1) from termi-

nal.
5. Loosen mounting bolts of clamp (11) of air

conditioner hose (10) and remove clamp (11).
Loosen mounting bolts of guard (12) and
remove guard (12).
★ The clearance between the hood and
operator's cab is small, and it is difficult to
remove the hood, so remove the guard at
this point.
2. Remove connectors of left and right working
lamp and license lamp (2) on inside.
Loosen mounting bolts of radiator guard (3)
and remove guard.
6. Install 4 eyebolts [1] to hood assembly (4),

then lift off hood assembly (4).
4 Hood assembly: 340 kg
3. Remove left and right mounting bolts (5)
(front: 4, center: 4, rear: 6) of hood assembly
(4).
INSTALLATION OF ENGINE
HOOD ASSEMBLY
Serial No. 10001 – 11000
4. Loosen clamp (9) of hose (8) connecting air
cleaner (6) and precleaner (7), then remove ★ Carry out installation in the reverse order of
hose (8) from air cleaner (6). removal.
30-16 GD555, 655, 675-3A

(6)
DISASSEMBLY AND
ASSEMBLY REMOVAL OF ENGINE HOOD ASSEMBLY
REMOVAL OF ENGINE HOOD

ASSEMBLY
Serial No. 11001 and up
k Disconnect the cable from the negative (-) ter-

minal of the battery.
1. Disconnect the wiring connectors of backup

buzzer (1), right and left working lamps (2),
and license lamp (3) from inside.
2. Remove radiator guard (4).
6. Remove mounting bolts (10) of hood assem-

bly (9).
★ Front: 4 bolts, center: 4 bolts, rear: 6 bolts
3. Disconnect air duct (5).
7. Using eyebolts [1], lift off hood assembly (11).

4 Hood assembly: 340 kg
4. Disconnect clamp (7) of air conditioner hose

(6).
5. Remove guard (8).

★ Since the space between the hood and
operator's cab is narrow for work, remove
the guard.
INSTALLATION OF ENGINE
HOOD ASSEMBLY
★ Carry out installation in the reverse order to

removal.
GD555, 655, 675-3A 30-17

(4)
DISASSEMBLY AND
ASSEMBLY REMOVAL OF RADIATOR ASSEMBLY
REMOVAL OF RADIATOR ASSEMBLY

Serial No. 10001 – 11000
★ Remove the engine hood assembly. (For 3. Remove hoses (8) and (9) of hydraulic oil
details, see REMOVAL OF ENGINE HOOD cooler.
ASSEMBLY.) ★ Fit male and female plugs into the hoses
and nipples after removing them.
1. Loosen radiator drain plug (1) and drain cool-
ant into container.
If the coolant contains anti-freeze, handle
it as a harmful substance. Do not dispose
of it illegally.
6 Coolant: 42 l
Loosen hydraulic tank drain plug (2) and
drain the hydraulic oil into a container.
★ The hydraulic cooler forms one unit at the
bottom surface of the radiator, so drain
the hydraulic oil.
6 Hydraulic oil: 45 l
4. Remove mounting bolts of fan guard (10),

then remove fan guard (10).
Install lifting tool [2] to radiator lifting hook,
sling radiator, then remove bolts of mounts
(13) at bottom of radiator, and lift off radiator
assembly (14).
★ Release the gas before removing the air
conditioner condenser hose.
★ Fit male and female plugs into the hoses
after removing them.
4 Radiator assembly: Approx. 80 kg
2. Loosen clamp (4) of radiator upper hose (3) at

radiator end, then remove hose (3). Loosen
clamp (6) of lower hose (5), then remove
lower hose (5). Remove hose (7) from sub
tank at radiator cap end.
30-18 GD555, 655, 675-3A

(6)
DISASSEMBLY AND
ASSEMBLY INSTALLATION OF RADIATOR ASSEMBLY
INSTALLATION OF RADIATOR ASSEMBLY

Serial No. 10001 – 11000
1. Install lifting tool [2] to radiator assembly (14), 4. Tighten radiator drain plug (1). Insert lower
raise radiator assembly (14), then set at fixed hose (5) to tube at engine end and radiator
position on top of main frame. end, then tighten clamp (6).
4 Radiator assembly: Approx. 80 kg
5. Install upper tank hose (3), then tighten clamp

(4). Install sub tank hose (7) to radiator cap
2. Sling radiator assembly (14), install cushion
end.
to left and right mounts (13) of radiator, then
tighten with bolts.
Install 2 air conditioner condenser hoses (11).
Install mounting bolts of fan guard (10) to
each place, and install fan guard (10).
6. Fill radiator (14) with coolant through sub

tank cap (15) to FULL level.
★ Start the engine, raise the temperature
until the thermostat opens, then circulate
the coolant and check the level again.
5
3. Install hydraulic oil cooler hoses (8) and (9).
Tighten hydraulic tank drain plug (2). Coolant : 42 l
Add hydraulic oil to the specified level.
GD555, 655, 675-3A 30-19

(6)
DISASSEMBLY AND
ASSEMBLY REMOVAL OF RADIATOR ASSEMBLY
REMOVAL OF RADIATOR ASSEMBLY

★ The method of removing the radiator, after- 7. Disconnect radiator outlet hose (5) from the
cooler, and air conditioner condenser assem- radiator side.
bly together is described below.
1. Drain the coolant.

6 Coolant: 44 l
2. Drain the transmission oil.

6 Transmission case: 45 l
3. Using tool X, collect air conditioner gas

(R134a).
4. Disconnect inlet air hose (1) and outlet air

hose (2) from the aftercooler.
8. Disconnect torque converter oil cooler hoses
5. Disconnect hose (3) between the radiator and (6) and (7).
sub tank.
9. Disconnect 2 air conditioner tubes (8).
6. Disconnect radiator inlet hose (4) from the

radiator side. 10. Remove fan guard (9).
11. Sling radiator assembly (10) temporarily and

remove 2 radiator stays (11), 1 on each side.
12. Remove 2 radiator mounting bolts (12), 1 on

each side.
30-20 GD555, 655, 675-3A

(4)
DISASSEMBLY AND
ASSEMBLY INSTALLATION OF RADIATOR ASSEMBLY
13. Remove radiator assembly (10). INSTALLATION OF RADIATOR

★ Take care not to damage the radiator
core. ASSEMBLY
4 Radiator assembly (Radiator, after-
cooler, and air conditioner con- • Carry out installation in the reverse order to
denser): 150 kg removal.
3 Aftercooler hose clamp:

10.5 ± 0.5 Nm {107 ± 5 kgm}
3 Radiator hose clamp:

8.8 ± 0.5 Nm {90 ± 5 kgm}
• Refilling with oil (Transmission)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
14. Remove fan shroud (13), and then remove air • Refilling with coolant
conditioner condenser (14) and aftercooler Close the radiator cap, and add coolant
(15) from radiator (16). through the coolant filler of the sub tank to
4 Radiator: 120 kg
the full level at the center of the coolant
gauge. Run the engine and warm up the
4 Aftercooler: 25 kg coolant. Then, check the coolant level again.
• Charging air conditioner with refriger-

ant gas
Using tool X, charge the air conditioner cir-
cuit with refrigerant (R134a).
GD555, 655, 675-3A 30-21

(6)
DISASSEMBLY AND REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLANT
ASSEMBLY SUB TANK
REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLANT SUB

TANK
Serial No. 10001 – 11000
★ Remove the engine hood assembly. (For 3. Loosen clamp (8) of coolant circulation hose
details, see REMOVAL OF ENGINE HOOD (7) so that tube inside tank can come out.
ASSEMBLY.) Loosen clamp (10) of hose (9) between engine
and sub tank, then remove hose (9). Loosen 2
1. Loosen fuel tank drain cock (1) and drain fuel mounting bolts of tube (11) and remove tube.
into container.
Loosen coolant drain plug (2) and drain cool-
ant into container.
★ If the coolant contains anti-freeze, handle
it as a harmful substance. Do not dispose
of it illegally.
6 Coolant: 42 l
4. Loosen clamp of radiator upper hose (12) and

remove hose. Pull out (remove) tube (13).
Remove clamp of hose (14), then remove
hose. Disconnect connector (15) of fuel sen-
sor, and remove clamps (16) of wiring har-
ness. Remove hose (18) of reserve tank (17).
2. Loosen hydraulic tank drain plug (3) and drain

hydraulic oil into container.
Loosen clamp (5) of hose (4) from bottom of
coolant sub tank, then remove hose (4) from
main circulation circuit tube (6).
6 Hydraulic tank : 45 l
30-22 GD555, 655, 675-3A

(4)
DISASSEMBLY AND REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLANT
ASSEMBLY SUB TANK
5. Remove hoses (19), (20), and (21) installed to 7. Install eyebolts to tank, sling tank, then
hydraulic tank. Loosen clamp (23) of pump remove 2 front and rear mounting bolts (36)
suction hose (22), then remove hose. at right side of tank mount (35). Remove
Loosen clamp (24) and pull out hose (25). clamps (38) of wiring harness (37) at bottom
Remove tank drain hose (26). Disconnect con- of tank.
nector of sensor (27).
+ Fit male and female plugs into the hoses
and nipples after removing them. Cover
any hoses that cannot be fitted with
plugs.
8. Do not remove mounting bolts (40) at left side

(39) of tank mount. Remove bolts (41) at tank
mounting portion at the top of tank mount.
(When tank is raised, mount contacts hydrau-
lic pump and tank cannot be removed.)
6. Remove hoses (28) and (29), then remove 2
mounting bolts of tube (30). Loosen mounting
nut (32) of tube (31), then remove elbow.
Loosen mounting bolts of clamp (34) of
breather (33), then remove clamp.
+ Fit male and female plugs into the hoses
after removing them.
9. After raising and moving tank assembly (42),

remove tank mount from main frame, and
install to bottom surface of tank (43), then
place on stable horizontal surface.
4 Tank assembly : 200 kg
GD555, 655, 675-3A 30-23

(4)
DISASSEMBLY INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLANT SUB
AND ASSEMBLY TANK
INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLANT

SUB TANK
Serial No. 10001 – 11000
+ When assembling, be extremely careful not 3. Tighten mounting bolts of tank (42) and tank
to cause failures due to dirt, rust, or mount (39). Install drain hose (26) and tube
scratches. (31). Pass hose (25) through clamp (24) and
+ At places where there is double clamping of tighten bolt. Install hoses (21), (20), and (19).
the hoses, assemble so that the screws are at Install pump suction hose (22), and tighten
180° to each other. clamp (23).
+ Install the hoses carefully so that there is no
twisting.
+ Coat the blind plugs with LT-2A.
1. Install eyebolts to tank (42), raise to a suitable

height, remove left side of tank mount (39),
then tighten temporarily to mounting position
on main frame.
Raise tank (42) and set to mounting position
on main frame, insert bolts in right side of
tank mount, then temporarily tighten left side
mount to tank.
4 Tank assembly : 200 kg
4. Install hoses (28) and (29). Install tube (30)
and tighten clamp (34) of breather (33) with
bolt.
2. Tighten mounting bolts of tank mount (35)

fully. Secure wiring harness (37) with clamps
(38). Install hose (18) to reserve tank (17).
30-23-1 GD555, 655, 675-3A

(4)
AND ASSEMBLY TANK
5. Install hose (14) and secure with clamp. Install 7. Tighten drain plug (3) of hydraulic tank.
connector of fuel sensor (15), and secure wir- Tighten coolant drain plug (2).
ing harness (44) with clamps (16). Insert tube ★ Fill with hydraulic oil through the oil filler.
5
(13) in tank and install to tank with mounting
Hydraulic tank :
bolts. Insert hose (12) in radiator (42) and
45 l (Total oil volume: 85 l)
tighten with clamp (45).
★ Fill with coolant. Fill the radiator with
coolant from the sub tank cap to the FULL
level.
5 Total coolant volume: 42 l
6. Insert hose (7) in tube inside tank, then

tighten clamp (8). Insert hose (9) in tube and
tighten clamp (10). Insert hose (4) in joint por-
tion of circulation tube (6), and tighten clamp
(5). 8. Tighten drain valve (1) of fuel tank and fill
★ Some intermediate clamps of the hoses with fuel through fuel filler.
5
and wiring harnesses are at places where
it is difficult to install, so be sure to install Fuel tank : 352 l
them all properly.
9. Install engine hood assembly. (For details,

see INSTALLATION OF ENGINE HOOD
ASSEMBLY.)
GD555, 655, 675-3A 30-23-2

(6)
DISASSEMBLY
AND ASSEMBLY REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLANT SUB TANK
REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLANT SUB

TANK
Serial No. 11001 and up 6. Disconnect coolant hoses (4) and (6).
k Disconnect the cable from the negative (-) ter-

minal of the battery.
1. Drain the coolant.

6 Coolant: 44 l
2. Drain the fuel.

6 Fuel tank: 340 l (When full)
3. Drain the hydraulic oil.

6 Hydraulic tank: 45 l
4. Remove the engine hood assembly. For 7. Disconnect coolant hoses (7) and (9).
details, see REMOVAL, INSTALLATION OF
ENGINE HOOD ASSEMBLY. 8. Disconnect tube (11) from the fuel tank.
5. Remove aftercooler inlet hose and tube (1)

and outlet hose and tube (2).
9. Disconnect radiator upper hose (12) from the

fuel tank side.
10. Remove coolant tube (13).
11. Disconnect coolant hose (14) from the sub

tank.
12. Disconnect fuel level sensor wiring connector

(15) and wire clamp (16).
30-23-3 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLANT SUB TANK
13. Disconnect coolant hose (18) from reservoir 18. Remove the wire clamp from the tank bottom
tank (17). and disconnect wiring harness (37).
14. Disconnect hoses (19), (20), (21), (22), (25), 19. Remove tank assembly mounting bolts (41)
and (26) from the hydraulic tank. from tank assembly left bracket (39).
★ Plug the disconnected hoses and nipples. ★ If the tank assembly is disconnected from
mounting bolts (40), it will interfere with
15. Disconnect wiring connector (27). the work equipment pump when it is lifted
up. Accordingly, do not disconnect the
tank assembly from mounting bolts (40).
16. Disconnect hoses (28) and (29), tubes (30) and

(31), and breather (33) from the hydraulic
tank. 20. Lift off fuel tank, hydraulic tank, and coolant
sub tank assembly together with the right
bracket.
★ Check that all the wires and pipes are dis-
connected.
4 Fuel tank, hydraulic tank, and
coolant sub tank assembly:
200 kg
17. Using eyebolts, sling the tank assembly tem-

porarily and remove 2 mounting bolts (36)
from tank assembly right bracket (35).
GD555, 655, 675-3A 30-23-4

(6)
AND ASSEMBLY TANK
INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLANT

SUB TANK
• Carry out installation in the reverse order to

removal.
• Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
• Refilling with fuel (Fuel tank)

Add fuel through the fuel filler.
• Refilling with coolant

Close the radiator cap, and add coolant
through the coolant filler of the sub tank to
the full level at the center of the coolant
gauge. Run the engine and warm up the
coolant. Then, check the coolant level again.
30-23-5 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY REMOVAL OF ENGINE ASSEMBLY
REMOVAL OF ENGINE ASSEMBLY

1. Remove engine hood assembly. 5. Remove 2 mounting bolts of mounting
(For details, see REMOVAL OF ENGINE HOOD bracket (12) of remote hose (11) for engine oil
ASSEMBLY.) drain, then remove hose clamp (13), and
remove hose.
2. Remove fuel tank and hydraulic tank.
(For details, see REMOVAL OF FUEL TANK,
HYDRAULIC TANK, COOLANT SUB TANK.)
3. Remove fuel hose (1), accelerator wire (2),

electric wiring harnesses (3), air conditioner
hose (4), and battery ground from engine
block.
★ Release the air conditioner gas before
removing air conditioner hose (4).
6. Use stable stand [1] under rear of transmis-

sion to prevent transmission from tilting
when separating from engine.
4. Remove wiring harness (6) of starting motor

(5). Remove wiring harness (8) of alternator
(7). Loosen clamps of coolant system hoses
(9) and (10), and remove hoses.
7. Sling engine assembly, and loosen left

mounting bolts (14) and right mounting bolts
(15), then remove.
GD555, 655, 675-3A 30-23-6

(6)
DISASSEMBLY
AND ASSEMBLY REMOVAL OF ENGINE ASSEMBLY
8. Remove all 12 mounting bolts (18) from mat-

ing surface of transmission assembly (17) and
engine assembly (16).
9. Using forcing tap bolt (2-10x1.5), disconnect

engine assembly (16) from transmission
assembly, then raise and set on stable stand.
4 Engine assembly : 850 kg
30-23-7 GD555, 655, 675-3A

(4)
DISASSEMBLY
AND ASSEMBLY INSTALLATION OF ENGINE ASSEMBLY
INSTALLATION OF ENGINE 4. Install mounting bracket (12) of remote hose

(11) for engine oil drain. Install hose clamp
ASSEMBLY (13).
1. Raise engine assembly (16), align with

mounting face of transmission, then fit spline
portion.
★ When installing, be careful not to damage
the O-ring.
4 Engine assembly : 850 kg
5. Install wiring harness (6) of starting motor (5).

Install wiring harness (8) of alternator (7).
Install coolant hose (10) and tighten clamp.
Insert tube (19) in hose (9), and tighten clamp
to specified torque.
2. Keep engine assembly (16) raised and tighten

bolts to specified torque at mounting surface
with transmission (17).
6. Install fuel hose (1), accelerator wire (2), elec-

tric wiring harnesses (3), and air conditioner
hose (4), then install battery ground to engine
block.
★ After assembling the air conditioner hose,
use the compressor to charge with gas to
the specified pressure. After charging,
check that there is no leakage of gas.
3. Keep engine assembly raised, align positions
of holes for frame on left side (14) and right
side (15) of engine mount, install mounting
bolts, then tighten to specified torque.
7. Install fuel tank and hydraulic tank.

(For details, see INSTALLATION OF FUEL
TANK, HYDRAULIC TANK, COOLANT SUB
TANK.)
8. Install engine hood assembly.
(For details, see INSTALLATION OF ENGINE
HOOD ASSEMBLY.)
REMOVAL & INSTALLATION OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT
30-24 GD555, 655, 675-3A

(6)
DISASSEMBLY REMOVAL & INSTALLATION OF ENGINE ASSEMBLY, TRANSMISSION AS-
AND ASSEMBLY SEMBLY AS ONE UNIT
REMOVAL OF ENGINE ASSEM- 7. Set stable stand [1] under bottom of torque
converter case of transmission, sling engine
BLY, TRANSMISSION ASSEM- assembly (4), then remove all 12 bolts of
BLY AS ONE UNIT mount portion of engine and transmission.
1. Remove engine hood assembly. Using forcing tap bolts (2-10x1.5), disconnect
(For details, see REMOVAL OF ENGINE HOOD engine assembly and put it on stable stand.
ASSEMBLY.)
2. Remove fuel tank and hydraulic tank.
HYDRAULIC TANK, COOLANT SUB TANK.)
3. Remove transmission related accessories.
(For details, see REMOVAL OF TRANSMIS-
SION ASSEMBLY.)
4. Remove engine related accessories.
(For details, see REMOVAL OF ENGINE
ASSEMBLY.)
★ Do not loosen the mounting bolts at the
mating surface of the engine assembly
and transmission assembly.
Sling the engine and transmission assem-
bly, then loosen and remove the mount-
ing bolts at the mating surface of the INSTALLATION OF ENGINE
engine and transmission.
5. Loosen and remove 2 mounting bolts of ASSEMBLY, TRANSMISSION
engine mount (1) and 4 mounting bolts of ASSEMBLY AS ONE UNIT
transmission mount (2), then lift off engine
and transmission assembly. 1. Set transmission assembly (5) on stable stand
4 Engine, transmission assembly:
[1] with torque converter case at bottom, and
secure in position. Raise engine assembly (4)
Approx. 1850 kg
and mate transmission assembly (5).
★ When mating, be careful not to damage
the O-ring or let it fall out.
6. After lifting engine and transmission assem-

bly, put a stable stand under engine mount
portion (3). (A stand of height approx. 630
REMOVAL & INSTALLATION OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT
mm is needed.)
★ Use a strong and stable stand.
GD555, 655, 675-3A 30-25

(6)
DISASSEMBLY REMOVAL & INSTALLATION OF ENGINE ASSEMBLY, TRANSMISSION AS-
AND ASSEMBLY SEMBLY AS ONE UNIT
2. Install bolts to mating portion of transmission

assembly (5) and engine assembly (4), and
tighten to specified torque.
3. Raise engine and transmission assembly, and

align with specified position on main frame.
Align bolt holes of engine mount (1) and
transmission mount (2) with holes in frame,
then install mounting bolts and tighten to
specified torque.
4. Install engine related accessories.

ASSEMBLY.)
5. Install transmission related accessories.
(For details, see INSTALLATION OF TRANS-
MISSION ASSEMBLY.
TANK.)
HOOD ASSEMBLY.)
30-26 GD555, 655, 675-3A

(2)
DISASSEMBLY
AND ASSEMBLY REMOVAL OF TRANSMISSION ASSEMBLY
REMOVAL OF TRANSMISSION 5. Remove hoses (6), (7), and (8) of pump (5) at
pump end. Remove connectors of speed sen-
ASSEMBLY sor system wiring harness (9).
1. Remove engine hood assembly. and nipples after removing them.
(For details, see REMOVAL OF ENGINE HOOD ★ Cover the removed connectors with a
ASSEMBLY.) nylon bag to prevent the entry of dust or
2. Remove fuel tank, hydraulic tank, and coolant water.
sub tank assembly.
HYDRAULIC TANK, COOLANT SUB TANK).
3. Remove drain plug (1) of transmission oil
tank, and drain into container.
5 Transmission oil: Approx. 45 l
6. Remove hoses (11), (12), (13), and (14)

installed to hydraulic pump (10) at pump end.
★ Fit male and female plugs in the hoses
and nipples after removing them.
4. Loosen mounting bolts of universal joint (2)

and remove joint from flange. Loosen mount-
ing nut (4) of speedometer cable (3), then
remove cable.
7. Remove hydraulic hose (15) under radiator.

Remove filter (16), then remove 2 filter hoses
(17). (Because right side mounting bolts can-
not be removed)
GD555, 655, 675-3A 30-27

(6)
DISASSEMBLY
AND ASSEMBLY REMOVAL OF TRANSMISSION ASSEMBLY
8. Remove 4 mounting bolts (18) (2 each on left

and right).
9. Place stable stand under engine flywheel so

that there is no clearance. Install eyebolts [1]
and sling transmission. Remove all 12 bolts
(19) at mating surface of engine assembly
and transmission assembly.
★ When installing the eyebolts, install 2 at
the fan end and 2 at the torque converter
end, and lift at 4 points.
4 Transmission assembly:
Approx. 1000 kg
12. Remove fan pulley assembly (28), belt (29)
and hose (30), then remove electric control
system cover (31). Remove pulley (32).
4 Fan pulley assembly:
Approx. 40 kg
10. Using forcing tap bolts (2-10x1.5), disconnect

transmission assembly (21) from engine
assembly (20), and put on stable stand.
★ Place a stable stand under the bottom sur-
face of the transmission and the bottom
surface of the torque converter case.
Remove hydraulic oil suction hose (22) and 13. Remove mounting bracket (33). Make trans-
oil supply tube (23). mission into individual part (34) to make it
11. Remove transmission accessories. Remove possible to carry out overhaul.
hoses 2 (24) and (25) of pump (10), remove
mounting bolts of pump, then lift off pump
(10). Remove suction tube (26) of pump (5).
Remove 2 hoses (27), then lift off pump (5).
4 Hydraulic pump:
Approx. 60 kg
4 Transmission pump:
Approx. 20 kg
30-28 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY INSTALLATION OF TRANSMISSION ASSEMBLY
INSTALLATION OF TRANSMISSION ASSEMBLY

1. Install mounting bracket (33), then install pul- 4. Raise hydraulic pump (10) and install, then
ley (32). install hoses (24) and (25). Install hydraulic oil
suction hose (22), then install oil supply tube
(23).
4 Hydraulic pump:
Approx. 60 kg
2. Install electric control system cover (31), then

install hose (30).
Raise fan pulley assembly (28) and install,
then install fan belt (29).
★ For details of adjusting the fan belt, see
TESTING AND ADJUSTING. 5. Raise transmission assembly (21) and install
4 Fan pulley assembly:

to engine assembly (20).
★ Be careful not to damage the O-ring at the
Approx. 40 kg mating face of the transmission and
engine when installing.
4 Transmission assembly:
Approx. 1000 kg
3. Raise pump (5) and install, then install suction

tube (26) and 2 hoses (27).
★ When installing the hoses, tighten tempo-
rarily, then adjust the angle and position
and tighten fully so that there is no twist- 6. Keep engine raised and install mounting bolts
ing of the hoses. to engine (20). Install 2 bolts (18) each of
4 Transmission pump:
transmission bracket on left and right (total:
4).
Approx. 20 kg
GD555, 655, 675-3A 30-29

(6)
DISASSEMBLY
AND ASSEMBLY INSTALLATION OF TRANSMISSION ASSEMBLY
7. Install hydraulic oil hose (15) under radiator. 11. Tighten drain plug (1) to specified torque. Fill
Install filter (16), then install 2 filter hoses (17). with oil through oil filler (35).
★ Oil used: EO 10-CD
5 Specified oil level: 45 l
8. Install hoses (11), (12), (13), and (14) to

hydraulic pump (10).

TANK.)
★ Transmission oil level check
Fill with oil to the correct level (as speci-
fied above).
★ After installation and proper fill of the
fuel, hydraulic, and coolant tanks, start
the engine and bleed the air from the
pump piping, then run the engine at low
9. Install hoses (6), (7), and (8) to pump (5).
idle and check the transmission oil level. If
Install connectors of speed sensor system
the oil is not up to the specified level, add
wiring harness (9).
oil.
HOOD ASSEMBLY.)
10. Install universal joint (2) to flange with bolts.

Install cable (3) of speedometer with nut (4).
30-30 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY

1. Pilot 4) Remove bearing (8) from housing (7).
1) Set torque converter assembly (1) on 5) Remove piston (9) from housing (7).
work stand with pilot side at the top.
2) Remove mounting bolts (2), and using
forcing screws, remove pilot (3).
6) Remove seal ring (10) from piston (9).

7) Remove seal ring (11) from housing (7).
2. Torque converter lock-up housing
1) Remove snap ring (4), then remove
spacer (5).
3. Drive case
1) Remove disc (12).
2) Remove housing mounting bolts (6). 2) Remove mounting bolts (22), then using
eyebolts [2], remove drive case (23).
3) Using puller [1], remove torque converter

lock-up housing (7).
GD555, 655, 675-3A 30-31

(6)
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY
4. Turbine assembly 6. Stator shaft

Remove turbine assembly (24). 1) Using tool C2, remove nut (25).
5. Stator assembly 2) Remove spacer (29).

1) Remove stator assembly (13). 3) Turn over pump and stator shaft assem-
★ Rotate to the right as seen from the bly (26), support gear (27) with block [3],
top and pull up. then remove stator shaft (28) with push
2) Disassembly of stator assembly tool [4].
i) Remove snap ring (14), then remove
race and freewheel assembly (15)
from stator (16).
4) Remove seal ring (30) from stator shaft

(28).
7. Disassembly of pump assembly
ii) Remove snap ring (17) from stator 1) Remove mounting bolts (31), then push
(16). bearing (32) from opposite side, and
iii) Remove bushings (18) and (19), then remove together with gear (27) from
remove freewheel (20) from race (21). pump assembly (35).
30-32 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY ASSEMBLY OF TORQUE CONVERTER ASSEMBLY
2) Remove bearing (32) from gear (27). 2. Stator shaft

3) Using forcing screws [5], remove collar 1) Install seal ring (30) to stator shaft (28).
2 Outside circumference of seal ring:
(34) from gear (27).
Grease (G2-LI)
ASSEMBLY OF TORQUE CON-

VERTER ASSEMBLY 2) Set stator shaft (28) on work stand, and
install to pump assembly (35).
★ Press fit the inner race end of the
★ Wash all the parts clean and check that
there is no dirt or damage before assem- bearing.
bling. 3) Install spacer (29).
★ Check that the snap ring is securely fitted
in the groove.
1. Pump assembly
1) Install collar (34) to gear (27).
★ Align the bolt holes.
2) Install bearing (32) to collar (34).
4) Using tool C2, tighten nut (25).

2 Nut: Thread tightener (LT-2)
3 Nut: 161.8 ± 14.7 Nm
{16.5 ± 1.5 kgm}
3) Set gear (27) and bearing (32) to pump
(35), and tighten mounting bolts (31).
3 Mounting bolt: 66.15 ± 7.35 Nm
{6.75 ± 0.75 kgm}
GD555, 655, 675-3A 30-33

(6)
DISASSEMBLY
2) Rotate stator assembly (13) to right (clock-

3. Stator assembly wise) to install.
1) Assembly of stator assembly ★ Check the direction of rotation of the
i) Assemble freewheel (20) to race (21), stator from the turbine end (input
then expand fit bushings (18) and (19). end).
★ Coat the sliding surface of the bush- • Clockwise: Free
ing and flywheel with engine oil. • Counterclockwise: Locked
★ Be careful not to damage the plug of ★ If the direction of rotation of the stator
the freewheel. is not as given above, reverse the race
and freewheel assembly, reassemble
the stator assembly, then check the
direction of rotation again.
ii) Install snap ring (17) to stator (16).
4. Turbine assembly
Install turbine assembly (24).
iii) Fit race and flywheel assembly (15) to

stator (16), then install snap ring (14).
5. Drive case
1) Using eyebolt [2], install drive case (23).
2) Tighten mounting bolts (22).
2 Mounting bolt:
Thread tightener (LT-2)
{5.5 ± 0.5 kgm}
3) Install disc (12).
30-34 GD555, 655, 675-3A

(6)
DISASSEMBLY
6. Torque converter lock-up housing 6) Fit spacer (5) and install snap ring (4).
1) Install seal ring (11) to housing (7) and ★ Check that the snap ring is securely
install seal ring (10) to piston (9). fitted in the groove.
2 Outside circumference of seal ring:
Grease (G2-LI)
7) Tighten mounting bolts (6).

2 Mounting bolt:
2) Install piston (9) to housing (7). Thread tightener (LT-2)
3) Using eyebolts [2], install housing (7).
4) Temporarily assemble several mounting
bolts (6). {6.75 ± 0.75 kgm}
7. Pilot
5) Install bearing (8) with push tool [6]. Install pilot (3), then tighten mounting bolts
★ Press fit the outer race and inner race (2).
2 Mounting bolt:
at the same time.

{6.75 ± 0.75 kgm}
GD555, 655, 675-3A 30-35

(6)
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY OF TRANSMISSION ASSEMBLY
DISASSEMBLY OF TRANS-
MISSION ASSEMBLY Set blocks securely to transmission assem-
bly (1), then sling the assembly to prevent
it from falling over.
Special tools
New/remodel
Necessity
Sketch
Qty.
Symbol Part No. Part Name
790-201-2740 Spacer ■ 1
1
790-201-2750 Spacer ■ 1
2 790-101-5201 Push tool kit ■ 1
3 797T-423-1320 Push tool ■ 1 
797T-423-1130 Push tool ■ 1 N 
4 790-101-5221 Grip ■ 1
01010-51225 Bolt ■ 1
794T-423-1130 Push tool ■ 1 1. Fan assembly
794T-423-1140 Spacer ■ 1 N  1) Turn fan belt adjustment screw (2) and
5 loosen fan belt tension, then remove fan
D 790-101-5221 Grip ■ 1
belt (3).
01010-51225 Bolt ■ 1
794T-114-1210 Push tool ■ 1 N 
6 01010-51240 Bolt ■ 1
790-101-5421 Grip ■ 1
7 794T-114-1230 Spacer ■ 1 N 
8 794T-423-1180 Push tool ■ 1 N 
9 793-310-2100 Lifting tool ■ 1
10 792-271-2000 Centering tool ■ 1
11 799-301-1600 Oil leak tester ■ 1
2) Sling fan bracket, remove mounting bolts,

then remove fan assembly (4).
30-36 GD555, 655, 675-3A

(10)
DISASSEMBLY
2. Piston pump assembly 7. Fan pulley

Sling pump assembly (5), then remove Remove fan pulley (13).
mounting bolts and lift off. 8. Transmission mount (left)
Remove transmission mount (left) (14).
9. Return hose, valve cover
1) Remove hose (15).
2) Remove valve cover (16).
3. Gear pump assembly

1) Remove suction tube (6).
2) Sling gear pump assembly (7), remove
mounting bolts, then remove.
10. Oil lubrication tubes, wiring harness
1) Remove tubes (17), (18), (19), (20), (21),
(22), and (27), then remove block (23).
2) Remove wiring harness (24).
11. Oil temperature sensor (for transmission oil)
Remove oil temperature sensor (25).
12. Strainer
Remove strainer (26).
4. Oil lubrication hoses, tube

1) Remove hoses (8) and (9).
2) Remove tube (10).
5. Transmission mount (right)
Remove transmission mount (right) (11).
6. Speed sensor (for detection of transmission
output shaft speed)
Remove speed sensor (12).
13. Lubrication tube, block assembly
Remove lubrication tube and block assembly
(28).
GD555, 655, 675-3A 30-37

(10)
DISASSEMBLY
14. Worm gear assembly (for speedometer) 16. Torque converter relief valve assembly
Remove worm gear assembly (30). 1) Remove 4 mounting bolts, then remove torque
converter relief valve assembly (34).
17. Torque converter lock-up valve assembly, oil pres-

sure tube
15. Coupling, retainer
1) Remove oil pressure tube (36).
1) Remove coupling (31).
2) Remove mounting bolts at valve seat end,
2) Remove mounting bolts, then using forc- then remove valve assembly (37) together
ing screws, remove retainer (32). with seat (38).
3) Remove valve assembly (37) from valve seat

(38).
3) Remove dust seal (33) and oil seal (29)
from retainer (32).
18. Oil lubrication tubes

Remove tubes (39) and (40).
30-38 GD555, 655, 675-3A

(10)
DISASSEMBLY
19. Cover, breather 2) Remove filter (47) and case (48).

1) Remove cover (41). ★ Use forcing screws when removing case
2) Remove breather (42). (48).
20. Speed sensor (for detection of engine speed)
3) Remove mounting bolts of valve seat,

then using eyebolts [3], remove valve
21. Oil block (torque converter oil outlet) assembly (50).
Remove oil block (44).
input shaft speed)
4) Remove ECMV (51) from valve seat.
23. Transmission control valve assembly

1) Face transmission assembly (46) to side
so that valve assembly is at the top, then
set on block [2].
GD555, 655, 675-3A 30-39

(10)
DISASSEMBLY
24. Transmission cover assembly 25. Fan drive shaft

1) Remove mounting bolts of cover assem- 1) Remove bolt (56), then remove plate (49).
bly (52), then using forcing screws [4], dis- 2) Remove flange (57).
connect from transmission case. 3) Knock out shaft (58) and remove.
2) Using eyebolts [5], remove cover assem- 4) Remove dust seal (59) and oil seal (35).
bly (52). 5) Remove snap ring (60), then remove bear-
★ Using lever block, adjust so that clearing (61) from cover.
ance from transmission case is uni-
form.
26. Idler gear (for REVERSE)

1) Remove bolt (62), then remove plate (63).
3) Remove outer races (53) and (54) and 2) Using gear puller [6], remove bearing (64)
bearing (55) from cover (52). together with gear (65).
30-40 GD555, 655, 675-3A

(10)
DISASSEMBLY
3) Remove bearing (64) from gear (65). 3) Disassembly of 4th speed clutch assem-
4) Remove spacer (66), bearing (64), and bly
spacer (97) from shaft. i) Remove seal ring (70).
★ There is a collar under the bearing. ii) Using press, remove bearing (71) and
gear (72).
★ Hold the gear and push shaft (73).
★ The clutch assembly will fall, so use
cushioning material to catch it.
CWG10604
27. 4th speed clutch assembly

1) Remove oil guides (67) and (68).
iii) Remove snap ring (74) from shaft (73).
2) Using 2 wire ropes, remove 4th speed

clutch assembly (69).
iv) Using press, remove bearing (75) at

clutch end, spacer (76), thrust washer
(77), and clutch assembly (78) from
shaft (73).
GD555, 655, 675-3A 30-41

(10)
DISASSEMBLY
★ Hold the drum end of clutch assembly ix) aRemove 7 plates (83), 6 springs (84),
(78) and push shaft (73). and 6 discs (85) in turn.
★ The shaft will fall, so use cushioning ★ Store the discs and plates in a level
material to catch it. ground to prevent them from distor-
tion.
x) Remove piston assembly (86).

v) Remove thrust washer (77) and seal ★ The piston cannot be removed if it is
ring (79) from shaft (73). at an angle, so set it horizontal to
vi) Remove needle bearing (80) from 4th remove it.
speed clutch gear (137). ★ Be careful not to use force when
removing. This will scratch the inside
surface of the cylinder.
xi) Remove seal rings (87) and (88) from
piston assembly (86).
vii) Push in end plate (81) with bar handle

[7], and remove snap ring (82).
viii) Remove bar handle, then remove end 28. 2nd, 3rd speed clutch assembly
plate (81). 1) Using gear puller [8], remove bearing (90)
and gear (91) of 1st speed shaft.
★ Remove this because the 2nd speed
clutch gear is in contact with gear (91)
and cannot be removed.
2) Using 2 wire ropes, remove 2nd and 3rd
speed clutch assemblies (92).
30-42 GD555, 655, 675-3A

(10)
DISASSEMBLY
3) Disassembly of 2nd, 3rd speed clutch vii) Push in end plate (81) with push tool
assembly [10], and remove snap ring (82).
i) Remove seal ring (70). viii)Remove end plate (81).
ii) Remove bolt (93), then remove worm
gear (94) for speedometer.
ix) Remove 8 plates (83), 7 springs (84),

and 7 discs (85) in turn.
★ Store the discs and plates in a level
iii) Using bearing race puller [9], remove
ground to prevent them from distor-
bearing (95) at 3rd speed end.
tion.
iv) Remove spacer (76) and thrust
washer (77).
x) Remove thrust washer (77).

xi) Remove piston assembly (86).
v) Remove 3rd speed clutch gear (96). ★ The piston cannot be removed if it is
vi) Remove needle bearing (80) from 3rd at an angle, so set it horizontal to
speed clutch gear (96). remove it.
★ Be careful not to use force when
removing. This will scratch the inside
surface of the cylinder.
xii) Remove seal rings (87) and (88) from
GD555, 655, 675-3A 30-43

(10)
DISASSEMBLY
xiii)Using gear puller [11], remove 2nd xvii)Remove 15 plates (83), 14 springs
speed inner race (98) and intermedi- (84), and 14 discs (85) in turn.
ate gear (99), then remove snap ring ★ Store the discs and plates in a level
(89) from gear (99). ground to prevent them from distor-
tion.
xviii)Remove thrust washer (77) and pis-

xiv)Remove thrust washer (77) and 2nd ton assembly (101).
speed clutch gear (100). ★ If the piston is at an angle, it will not
xv) Remove needle bearing (80) from 2nd come out, so set it horizontally and
speed clutch gear (100). remove it.
★ Do not use force to remove it. The
inside surface of the cylinder will be
damaged.
xix) Remove seal rings (87) and (88) from
xvi)Push in end plate (81) with bearing

race puller [12] and forcing screws
[13], then remove snap ring (82) and
29. 1st, FH clutch assembly, REVERSE, FL clutch
end plate (81). assembly
1) Using eyebolt [14], remove 1st, FH clutch
assembly (102) and REVERSE, FL clutch
assembly (103) at the same time.
★ The gears of the two sets of clutch assem-
blies cross, so both sets must be raised at
the same time in order to remove them.
★ Raise both types of clutch assemblies per-
pendicularly.
30-44 GD555, 655, 675-3A

(10)
DISASSEMBLY
2) Disassembly of 1st, FH clutch assembly vii) Remove thrust washer (77).

★ The intermediate gear and bearing at viii)Remove piston assembly (86).
the tip of the 1st gear shaft were ★ The piston cannot be removed if it is
removed in Step 29. at an angle, so set it horizontal to
i) Remove seal ring (70). remove it.
ii) Remove snap ring (104) and thrust ★ Be careful not to use force when
washer (77). removing. This will scratch the inside
iii) Remove 1st speed clutch gear (105), surface of the cylinder.
then remove needle bearing (80). ix) Remove seal rings (87) and (88) from
iv) Push in end plate (81) with push tool

[10], and remove snap ring (82). x) Pull out FH gear (106) with forcing
v) Remove end plate (81). screws [15], then remove together
vi) Remove 6 plates (83), 5 springs (84), with bearing (107), spacer (108), and
and 5 discs (85) in turn. thrust washer (77).
tion.
xi) Remove thrust bearing (109) and nee-

dle bearing (80) from FH clutch gear
(106).
GD555, 655, 675-3A 30-45

(10)
DISASSEMBLY
xii) Push in end plate (81) with bar handle xv) Remove seal rings (112) and (88) from
[7], and remove snap ring (82). piston assembly (110).
Remove bar handle, then remove end xvi) Remove snap ring (111), then remove
plate (81). sleeve (137) from piston assembly.
xiii)Remove 13 plates (83), 12 springs 3) Disassembly of R, FL clutch assembly

(84), and 12 discs (85) in turn. i) Remove seal rings (70) and (113).
tion.
ii) Remove bearing (114) and gear (115)

at FL clutch end with bearing race
puller [16].
xiv)Remove piston assembly (110). iii) Remove snap ring (116), then remove
★ There is a sleeve on the inside, so it thrust washer (77).
can be removed smoothly.
30-46 GD555, 655, 675-3A

(10)
DISASSEMBLY
iv) Remove FL clutch gear (117). viii)Remove 9 plates (83), 8 springs (84),
v) Remove needle bearing (80) from and 8 discs (85) in turn.
gear (117). ★ Store the discs and plates in a level
tion.
vi) Remove thrust bearing (109).
ix) Remove piston assembly (118).

★ There is a sleeve on the inside, so it
vii) Push in end plate (81) with bar handle

Remove handle, then remove end
plate (81).
x) Remove seal rings (120) and (88) from
piston assembly.
xi) Remove snap ring (111), then remove
sleeve (119).
GD555, 655, 675-3A 30-47

(10)
DISASSEMBLY
xii) Using bearing race puller [17], xvi) Remove 9 plates (83), 8 springs (84),
remove R clutch gear (121), bearing and 8 discs (85) in turn.
(122), spacer (108), and thrust washer ★ Store the discs and plates in a level
(123). ground to prevent them from distor-
xiii)Remove needle bearing (124) from R tion.
clutch gear (121).
xvii)Remove piston assembly (118).

★ There is a sleeve on the inside, so it
xiv)Remove thrust bearing (109).

xv) Push in end plate (81) with bar handle
Remove handle, then remove end xviii)Remove seal rings (120) and (88)
plate (81). from piston assembly.
xix) Remove snap ring (111), then remove
sleeve (119).
30-48 GD555, 655, 675-3A

(10)
DISASSEMBLY
30. Torque converter assembly 3) To remove, knock out gear (129) from end
1) Set transmission case (126) securely on where nut is fitted.
block [18] (height: min. 400 mm).
4) Remove snap ring (125), then remove

2) Remove 8 torque converter assembly spacer (146), bearing (131), and outer race
mounting bolts (123) from under case. (132).
3) Using eyebolts [19], remove torque con-
verter assembly (127) from transmission
case.
5) Remove bearing (136) and spacer (139)

from gear (129).
31. Idler gear (procedure is same for both sets,

procedure given below is for fan drive shaft
end)
1) Turn over transmission case and set
securely on block.
2) Use wrench [21] with claw to remove nut
(128).
★ Hold it at the gear end to prevent it
from rotating.
GD555, 655, 675-3A 30-49

(10)
DISASSEMBLY
32. Hydraulic pump drive gear (procedure is 5) Remove bearing (143), then remove outer
same for both sets, procedure given below is race (144).
for piston pump end)
1) Remove snap ring (138).
2) Using puller [20], pull out shaft (140).
★ Support the shaft to prevent the
spacer and gear from falling when the
shaft comes out.
33. Outer race (for FH clutch shaft)

Remove outer race (145) from transmission
case.
3) Remove gear (135) and spacer (142).
4) Remove bearing (137) from shaft (140)
30-49-1 GD555, 655, 675-3A

(10)
DISASSEMBLY
AND ASSEMBLY ASSEMBLY OF TRANSMISSION ASSEMBLY
ASSEMBLY OF TRANSMISSION
3) Install snap ring (138).
ASSEMBLY ★ Check that the snap ring is fitted
securely in the groove.
★ Wash all the parts clean and check that there
is no dirt or damage before assembling.
1. Outer race
Install outer race (145) to transmission case.
2. Hydraulic pump drive gear (procedure is

same for both sets, procedure given below is
for piston pump end)
1) Using push tool, install bearing (137) to
shaft (140).
2) Assemble gear (135) and spacer (142) in

case, then install shaft (140).
★ Tap the tip of the shaft.
30-50 GD555, 655, 675-3A

(10)
DISASSEMBLY
4) Install bearing (143) and outer race (144) 3) Assemble gear (124) to outer race of case.
in order. 4) Install bearing (126) to gear (124).
★ Hold at the gear end.
5) Fit spacer (146) and install snap ring (125).
★ Check that the snap ring is fitted
3. Idler gear (procedure is same for both sets,

procedure given below is for fan drive shaft
end)
★ Match the production No. of the inner and
outer races and the spacer, and assemble 6) Use wrench [21] with claw to tighten nut
the bearing as a set. (128).
2 Nut: Thread tightener (LT-2)
1) Using push tool, press fit bearing (136) to
gear (129), then install spacer (139).
3 Nut: 353 ± 39 Nm {36 ± 4 kgm}
★ After tightening the nut, drop 6 cc of
engine oil (EO-30) on the nut, rotate
about 10 times, then check the tight-
ening torque again.
2) Install outer race (132) to case.
GD555, 655, 675-3A 30-51

(6)
DISASSEMBLY
4. Torque converter assembly 6) Tighten mounting bolts (123).

2 Mounting bolt:
1) Set transmission case (126) on block [18]
with torque converter side at the top.
★ The mounting bolts for the torque
converter assembly are tightened 3 Mounting bolt: 110.5 ± 12.5 Nm
temporarily from below, so use a {11.25 ± 1.25 kgm}
block at least 400 mm in height.
5. R.FL clutch assembly, 1st.FH clutch assembly

2) Check position of oil hole and fit guide 1) Assembly of R.FL clutch assembly
bolt [22] to stator shaft. i) Set sleeve (119) to piston, then install
★ Make a mark by the hole where the snap ring (111).
guide bolt is inserted. ★ Check that the snap ring is fitted
3) Using eyebolts [19], install torque con- securely in the groove.
verter assembly (127).
★ Mesh the torque converter PTO gear
and idler gear.
4) Install 2 - 3 mounting bolts temporarily
from below.
ii) Assemble seal rings (120) and (88) to

piston.
★ Be careful to assemble the seal ring
with the side receiving the pressure
facing in the correct direction.
5) Turn over transmission case (121) and set ★ Replace the seal ring with a new part.
to block [18].
30-52 GD555, 655, 675-3A

(6)
DISASSEMBLY
iii) Install piston assembly (118) to cylin- ★ Insert the thick race to the clutch end.
der portion. vii) Assemble needle bearing (124) to R
★ When installing the piston assembly, clutch gear (121).
coat the contact surface and the inside
and outside circumference of the seal
ring with transmission oil.
viii)Align inner teeth of discs and install R

clutch gear (121).
★ Move the gear carefully a little at a
iv) Assemble 9 plates (83), 9 springs (84), time to the left, right, up, and down to
and 8 discs (85) in turn. align the teeth of the gear and discs
★ Soak the discs for at least 2 minutes in when installing.
clean transmission oil before assem- ix) Install thrust washer (123) and spacer
bling. (108).
★ Be careful not to let the springs and
discs overlap.
x) Using push tool [23], press fit bearing

(122) to shaft.
v) Assemble end plate (81), then push in ★ After press fitting the bearing, check
with bar handle [7] and install snap that there is no clearance between the
ring (82). end face of the bearing and the
★ Check that the snap ring is fitted spacer.
securely in the groove. ★ After press fitting the bearing, check
clearance "e" between the thrust
washer and the spacer.
★ Clearance "e": 0.29 - 0.69 mm
vi) Install thrust bearing (109).
GD555, 655, 675-3A 30-53

(6)
DISASSEMBLY
xi) Set sleeve (119) to piston, then install xiv)Assemble 9 plates (83), 9 springs (84),
snap ring (111). and 8 discs (85) in turn.
★ Check that the snap ring is fitted ★ Soak the discs for at least 2 minutes in
securely in the groove. clean transmission oil before assem-
bling.
discs overlap.
xii) Assemble seal rings (120) and (88) to

piston.
★ Be careful to assemble the seal ring
with the side receiving the pressure xv) Assemble end plate (81), then push in
facing in the correct direction. with bar handle [7] and install snap
★ Replace the seal ring with a new part. ring (82).
securely into the groove.
xiii)Install piston assembly (118) to cylin-

der portion.
★ When installing the piston assembly, xvi)Install thrust bearing (109).
coat the contact surface and the inside ★ Insert the thick race to the clutch end.
and outside circumference of the seal xvii)Assemble needle bearing (80) to FL
ring with transmission oil. clutch gear (117).
30-54 GD555, 655, 675-3A

(6)
DISASSEMBLY
xviii)Align inner teeth of disc and install xxi)Install seal rings (70) and (113) to
FL clutch gear (117). shaft.
★ Move the gear carefully a little at a ★ Coat the outer circumference of the
time to the left, right, up, and down to seal ring with grease (G2-LI), and be
align the teeth of the gear and discs careful to install it uniformly.
when installing.
xxii)Using tool D11, pump in air through

oil hole in shaft and check operation
xix)Install thrust washer (77) and snap
of clutch.
ring (116).
★ If the gear at the end where the air is
xx) Install gear (115), and using push tool,
pumped in is held in position, the
press fit bearing (114) to shaft.
clutch is working normally.
★ After press fitting the bearing, check
that there is no clearance between the ★ Air pressure: 0.5 - 0.6 MPa
end face of the gear and the bearing. {5.0 - 6.0 kg/cm²}
washer and the gear.
★ Clearance "e": 0.30 - 0.76 mm
2) Assembly of 1st. FH clutch assembly

i) Set sleeve (137) to piston, then install
snap ring (111).
GD555, 655, 675-3A 30-55

(6)
DISASSEMBLY
ii) Install seal rings (112) and (88) to pis- v) Assemble end plate (81), then push in
ton assembly (110). with bar handle [7] and install snap
★ Be careful to assemble the seal ring ring (82).
with the side receiving the pressure ★ Check that the snap ring is fitted
facing in the correct direction. securely in the groove.
★ Replace the seal ring with a new part.
iii) Install piston assembly (110) to cylin- vi) Install thrust bearing (109).
der portion. ★ Insert the thick race to the clutch end.
★ When installing the piston assembly, vii) Assemble needle bearing (80) to FH
coat the contact surface and the inside clutch gear (106).
viii)Align inner teeth of disc and install FH

iv) Assemble 13 plates (83), 13 springs clutch gear (106).
(84), and 12 discs (85) in turn. ★ Move the gear carefully a little at a
★ Soak the discs for at least 2 minutes in time to the left, right, up, and down to
clean transmission oil before assem- align the teeth of the gear and discs
bling. when installing.
discs overlap.
30-56 GD555, 655, 675-3A

(6)
DISASSEMBLY
ix) Install thrust washer (77) and spacer xii) Install piston assembly (86) to cylin-
(108). der portion.
x) Using push tool, install bearing (107). ★ When installing the piston assembly,
★ After press fitting the bearing, check coat the contact surface and the inside
that there is no clearance between the and outside circumference of the seal
end face of the bearing and the ring with transmission oil.
spacer. xiii)Install thrust washer (77).
the clearance "e" between the thrust
★ Clearance "e": 0.39 - 0.79 mm
xiv)Assemble 6 plates (83), 6 springs (84),

★ Soak the discs for at least 2 minutes in
clean transmission oil before assem-
bling.
xi) Assemble seal rings (88) and (87) to discs overlap.
★ Be careful to assemble the piston with
the side receiving the pressure facing
in the correct direction.
xv) Assemble end plate (81).

xvi)Push end plate with push tool [10],
then install snap ring (82).
xvii)Assemble needle bearing (80) to 1st
speed clutch gear (105).
GD555, 655, 675-3A 30-57

(6)
DISASSEMBLY
xviii)Align inner teeth of disc and install 3) Using eyebolts [14], install 1st. FH clutch
1st speed clutch gear (105). assembly (102) and REVERSE FL clutch
★ Move the gear carefully a little at a assembly (103) at same time.
time to the left, right, up, and down to ★ Raise both clutch assemblies perpen-
align the teeth of the gear and discs dicularly.
when installing. ★ If it is difficult to insert the 1st. FH
xix)Fit thrust washer (77) and install snap clutch assembly, remove the outer
ring (104). race from the transmission case end,
xx) Install seal ring (70) to shaft. then assemble to the shaft bearing
★ Coat the outer circumference of the and install.
seal ring with grease (G2-LI), and be
careful to install it uniformly.
6. 2nd, 3rd speed clutch assembly

1) Assembly of 2nd, 3rd speed clutch assem-
xxi)Using tool D11, pump in air through bly
oil hole in shaft and check operation i) Assemble seal rings (88) and (87) to
of clutch. piston assembly (101).
★ If the gear at the end where the air is ★ Be careful to assemble the piston with
pumped in is held in position, the the side receiving the pressure facing
clutch is working normally. in the correct direction.
★ Air pressure: 0.5 - 0.6 MPa {5.0 - 6.0 ★ Replace the seal ring with a new part.
kg/cm²}
ii) Install piston assembly (101) to cylin-

der portion.
★ When installing the piston assembly,
coat the contact surface and the inside
30-58 GD555, 655, 675-3A

(6)
DISASSEMBLY
iii) Install thrust washer (77). viii) Align inner teeth of disc and install 2nd
★ Move the gear carefully a little at a time
to the left, right, up, and down to align
the teeth of the gear and discs when
installing.
ix) Install thrust washer (77).
iv) Assemble 15 plates (83), 15 springs

(84), and 14 discs (85) in turn.
bling.
x) Fit snap ring (89) to intermediate gear
discs overlap.
(99), then install to shaft.
xi) Using press, install inner race (98).
★ After press fitting the inner race, check
that there is no clearance between the
end face of the gear and the inner race.
★ After press fitting the inner race, check
clearance "e" between the gear and the
thrust washer.
★ Clearance "e": 0.35 - 0.85 mm
v) Assemble end plate (81).

vi) Push in with bearing race puller [12]
and forcing screws [13], and install
snap ring (82).
vii) Install needle bearing (80) to 2nd
xii) Assemble seal rings (88) and (87) to pis-
ton assembly (86).
★ Be careful to assemble the piston with
the side receiving the pressure facing in
the correct direction.
GD555, 655, 675-3A 30-59

(6)
DISASSEMBLY
xiii)Install piston assembly (86) to cylin- xix)Align inner teeth of disc and install
der portion. 3rd speed clutch gear (96).
★ When installing the piston assembly, ★ Move the gear carefully a little at a
coat the contact surface and the inside time to the left, right, up, and down to
and outside circumference of the seal align the teeth of the gear and discs
ring with transmission oil. when installing.
xiv)Install thrust washer (77). xx) Install thrust washer (77) and spacer
(76).
xv) Assemble 8 plates (83), 8 springs (84),

clean transmission oil before assem- xxi)Using press, install bearing (95).
bling. ★ After press fitting the bearing, check
★ Be careful not to let the springs and that there is no clearance between the
discs overlap. end face of the spacer and the bear-
ing.
the clearance "e" between the thrust
★ Clearance "e": 0.38 - 0.82 mm
xvi)Install end plate (81).

xvii)Push in end plate with push tool [10],
and install snap ring (82).
xviii)Assemble needle bearing (80) to 3rd
30-60 GD555, 655, 675-3A

(6)
DISASSEMBLY
xxii)Install speedometer worm gear (94), 3) Install gear (91) to 1st speed clutch shaft.
and tighten bolts (93). 4) Using push tool [24], install bearing (90).
2 Bolt: Thread tightener (LT-2)
3 Bolt: 277 ± 32 Nm
end face of the bearing and the
{28.25 ± 3.25 kgm} spacer.
xxiii)Install seal ring (70) to shaft.
★ Clearance "e": 0.26 - 0.74 mm
xxiv)Using tool D11, pump in air through

oil hole in shaft and check operation
of clutch.
★ If the gear at the end where the air is 7. 4th speed clutch assembly
pumped in is held in position, the 1) Assembly of 4th speed clutch assembly
clutch is working normally. i) Assemble seal rings (88) and (87) to
★ Air pressure: 0.5 - 0.6 MPa {5.0 - 6.0 piston assembly (86).
kg/cm²} ★ Be careful to assemble the piston with
the side receiving the pressure facing
in the correct direction.
2) Using 2 wire ropes, install 2nd, 3rd speed

clutch assembly (92).
GD555, 655, 675-3A 30-61

(6)
DISASSEMBLY
ii) Assemble piston assembly (86) to cyl- viii) Press fit bearing (75) to shaft.
inder portion of 4th speed clutch gear. ★ After press fitting the bearing, check
★ When installing the piston assembly, that there is no clearance between the
coat the contact surface and the inside end face of the spacer and the bearing.
and outside circumference of the seal ★ After press fitting the bearing, check
ring with transmission oil. clearance "e" between the spacer and
iii) Install needle bearing (80) to 4th the bearing.
speed clutch gear (78). ★ Clearance "e": 0.3 - 0.7 mm
ix) Turn over 4th speed clutch and shaft

assembly, and assemble 7 plates (83), 7
iv) Install thrust washer (77) and seal ring springs (84), and 6 discs (85) in turn.
(79) to shaft (73). ★ It is unstable, so support by hand.
★ Coat the outer circumference of the ★ Soak the discs for at least 2 minutes in
bling.
v) Set with spline of shaft (73) at the top discs overlap.
and support with block.
★ It is unstable, so support it by hand.
vi) Install 4th speed clutch gear (137) to
shaft (73).
★ The piston assembly will fall out, so
be careful.
vii) Install thrust washer (77) and spacer
(76).
x) Assemble end plate (81), then push in

end plate with bar handle [7] and install
snap ring (82).
30-62 GD555, 655, 675-3A

(6)
DISASSEMBLY
xi) Install snap ring (74) to tip of shaft (73) 2) Using 2 wire ropes, install 4th speed
on opposite side from clutch. clutch assembly (69).
xii) Install gear (72).
3) Install oil guides (68) and (67).
xiii)Using press, press fit bearing (71).

end face of the bearing and the gear.
xiv)Install seal ring (70).
★ Coat the outer circumference of the
8. Idler gear (for REVERSE)

1) Using the push tool, install outer race
(64a) to gear (65).
★ Check the manufacturer numbers and
match symbols of the inner and outer
races of the bearing and make "match
marks".
2) Install spacer (97) to the shaft.
★ Install the spacer with the largely cut
inside down.
xv) Using tool D11, pump in air through 3) Push bearing (64) with spacer (66) and the
oil hole in shaft and check operation push tool to install it to the shaft.
of clutch. ★ Align the match mark on the bearing
★ If the gear at the end where the air is with that on the outer race installed to
pumped in is held in position, the the gear.
clutch is working normally.
★ Air pressure: 0.5 - 0.6 MPa
{5.0 - 6.0 kg/cm²}
CWG10605
GD555, 655, 675-3A 30-63

(2)
DISASSEMBLY
4) Align the match marks and install gear 2) Install shaft (58) to cover.
(65), then install bearing (64) with the 3) Install snap ring (60).
push tool. ★ Check that the snap ring (60) is fitted
CWG10606
5) Check that there is clearance a of 0.15 -

0.91 mm between the end face of bearing
4) Install oil seal (35) and dust seal (59).
(64) and that of the shaft.
★ Coat the area between the oil seal lip
6) Install plate (63) and tighten bolts (62).
surface and oil seal and dust seal with
silicon grease.
3 Bolt: 98 – 123 Nm
(Three Bond 1855 or equivalent)
{10 – 12.5 kgm}
CWG10607
5) Install flange (57).

9. Fan drive shaft 6) Fit plate (49) and tighten bolts (56).
1) Using push tool [28], press fit bearing (61)
to shaft (58).
3 Bolt: 110.5 ± 12.5 Nm
{11.25 ± 1.25 kgm}
30-64 GD555, 655, 675-3A

(6)
DISASSEMBLY
10. Transmission cover assembly 3) Using eyebolts [5] and lever block, raise
1) Install bearing (55) and outer races (54) transmission assembly (52) horizontally.
and (53) to transmission cover (52) with 4) Align outer race and bearing of cover with
push tool. each clutch shaft, align spline of fan drive
shaft at same time, then lower cover
assembly (52) slowly and install.
5) Tighten mounting bolts of cover assem-
bly (52).
{11.25 ± 1.25 kgm}
2) See diagram below and coat transmission

case with gasket sealant.
2 Mating face of front cover:
Gasket sealant
(Three Bond 1207B or equivalent)
★ Be careful not to let the gasket sealant 11. Transmission control valve assembly
be squeezed inside the case; be care- 1) Install ECMV (51) to valve seat.
ful not to coat with too much gasket
sealant.
★ Check that there are no scratches or
damage to the front cover.
2) Using eyebolts [3] and guide bolt [21], set

control valve assembly (50) to transmis-
sion case, and tighten temporarily with
mounting bolts.
GD555, 655, 675-3A 30-65

(6)
DISASSEMBLY
3) Install case (48) and filter (47) for 2nd, 3rd 14. Speed sensor (for detection of engine speed)
speed clutch, then tighten mounting Install speed sensor (43).
bolts. ★ Screw it in until it contacts the gear
★ The bolts are of different lengths, so lightly, then turn it back 1/2 - 1 turn and
be careful to install at the correct tighten with the locknut.
3 Locknut: 58.8 ± 9.8 Nm
place.
{6.0 ± 1.0 kgm}
15. Cover, breather
1) Install breather (42).
2) Install cover (41).

input shaft speed)
1) Set transmission assembly (46) securely
on block [2] with torque converter side at
top.
16. Oil lubrication tubes
Install tubes (40) and (39).
3 Joint bolt: 11.25 ± 1.45 Nm
{1.15 ± 0.15 kgm}
2) Install speed sensor (45).

★ Screw it in until it contacts the gear
lightly, then turn it back 1/2 - 1 turn
and tighten with the locknut.
3 Locknut: 58.8 ± 9.8 Nm
17. Torque converter lock-up valve, oil pressure
{6.0 ± 1.0 kgm}
tube
13. Oil block (torque converter oil outlet) 1) Install valve (37) to valve seat (38).
Install oil block (44).
30-66 GD555, 655, 675-3A

(6)
DISASSEMBLY
2) Install lock-up valve (37) and seat as one 3) Using tools D6 and D7, press fit dust seal
unit. (33).
3) Install oil pressure tube (36). ★ Press fit so that dimension (b) will be
30 ± 0.2 mm.
★ Install the dust seal so that its lip faces
outward.
18. Torque converter relief valve

1) Install torque converter relief valve
assembly (34), then tighten 4 mounting
bolts.
3 Mounting bolt: 49 ± 4.9 Nm
4) Apply and fill the grease according to the
following procedure.
{5.0 ± 0.5 kgm} Part a: Apply the grease (G2-S or G2-LI) to
the lip ends (4 places).
Part b: Fill 40 to 60% of the clearances
"between the main lip and dust lip of oil
seal", "between the dust seal and oil seal",
and "between the double lips of dust seal"
with the grease (G2-S or G2-LI).
★ Take care not to apply too much
grease because it may be mistaken for
oil leakage.
★ Wipe off any protruded liquid gasket
inside and outside of the lip.
Part c: Grease may protrude to the clear-
ance between the oil seal and dust seal.
19. Coupling, retainer

1) Thinly apply gasket sealant (LG-5) to the
oil seal fitting face of retainer (32).
2) Using tool D6, press fit oil seal (29) to
retainer (32) until dimension (a) becomes
as follows.
★ Dimension (a) is 38 ± 0.2 mm.
GD555, 655, 675-3A 30-67

(10)
DISASSEMBLY
5) Install retainer (32) to case. 3 Joint bolt: 49 ± 4.9 Nm

6) Install coupling (31). {5.0 ± 0.5 kgm}
20. Worm gear assembly (for speedometer)

Install worm gear (30).
25. Valve cover, return hose

1) Install valve cover (16).
2) Install hose (15).
26. Transmission mount (left)
Install transmission mount (left) (14).
21. Oil lubrication tube, block assembly
27. Fan pulley
Install oil lubrication tube and block assembly
Install fan pulley (13).
(28).

22. Strainer
output shaft speed)
Install strainer (26).
Install speed sensor (12).
23. Oil temperature sensor (for transmission oil)
★ Screw it in until it contacts the gear
Install oil temperature sensor (25).
lightly, then turn it back 1/2 - 1 turn and
24. Oil lubrication tube, wiring harness
tighten with the locknut.
3 Locknut: 58.8 ± 9.8 Nm
1) Install wiring harness (24).
2) Install block (23).
3) Install tubes (22), (21), (20), (19), (18), (17), {6.0 ± 1.0 kgm}
and (27).
30-68 GD555, 655, 675-3A

(10)
DISASSEMBLY
29. Transmission mount (right) 32. Piston pump assembly

Install transmission mount (right) (11). Raise piston pump assembly (5) with wire
rope and install, then tighten mounting bolts.
30. Lubrication tube, lubrication hoses

1) Install hoses (9) and (8). 33. Fan assembly
2) Install tube (10). 1) Raise bracket portion of fan assembly (4),
3 Joint bolt: 29.4 ± 4.9 Nm
set to transmission case, then tighten
mounting bolts.
{3.0 ± 0.5 kgm}
31. Gear pump assembly 2) Install fan belt (3), then turn adjustment
1) Install gear pump assembly (7), then screw (2) and adjust fan belt.
tighten mounting bolts.
2) Install suction tube (6).
GD555, 655, 675-3A 30-69

(10)
DISASSEMBLY
AND ASSEMBLY REMOVAL OF FINAL DRIVE ASSEMBLY
REMOVAL OF FINAL DRIVE ASSEMBLY

★ To prepare for disassembly and assembly of 4. Lower work equipment (1) to ground.
the final drive assembly, jack up the machine
and support it with strong, stable stands.
★ The height of the bottom surface of the main
frame must be approx. 1000 mm.
1. Set stand [2] to front of front frame.
5. Set blocks [5] under 4 rear wheels.
2. Set stand [3] to center of main frame.
6. Remove engine hood assembly.

(For details, see REMOVAL OF ENGINE HOOD
ASSEMBLY.)
7. Drain final drive oil.(No differential type)

3. Set stand [4] to rear of frame. Loosen drain plug (2) and drain oil into con-
★ Lower ripper to ground. tainer. Remove breather hose (4), then,
remove oil filler tube (9).
6 EO 30: 17 l
CWG10608
30-70 GD555, 655, 675-3A

(6)
DISASSEMBLY
7. Drain differential oil. (With differential lock 9. Loosen mounting bolts of universal joint (6)
type) between transmission and final drive, remove
Loosen drain plug (2) and drain oil into con- universal joint (6), then remove brake hose
tainer. Remove differential lock and 2 temper- (7).
ature connectors (3), then remove 2 hoses
and hose (4).
6 EO 30: 17 l
10. Sling final drive assembly, and disconnect

brake hoses (8) (front, rear, left, right: 4).
★ Fit male and female plugs into the hoses.
8. Sling wheel (5), loosen 2 wheel nuts and 8
bolts, then lift off wheel, and place it in a sta-
ble posture where there is no danger.
(Remove 4 rear wheels.)
★ When the wheel is removed, the tandem
case will tilt, so insert a stand of a height
equal to the bottom surface of the case
before removing the wheel.
★ When lifting the wheel, use a sling and fit
it to the center of the tire so that the tire
does not come out, then lift the wheel.
11. Remove oil filler tube of differential from

intermediate thread portion (9). (With differ-
ential lock type)
GD555, 655, 675-3A 30-71

(4)
DISASSEMBLY
12. Remove cover (10) of electric relay system 14. Using a crane and a forklift, take final drive
box. assembly (13) out of the chassis.
(Because mounting bolts and nuts of final 1) While hanging the final drive assembly,
drive assembly cannot be removed.) support its one side with the forklift and
Remove left and right batteries (11). remove the sling on that side.
2) While hanging the opposite side to the
forklift, move the forklift back.
★ Adjust the crane according to the
movement of the forklift.
3) When you can support the bottom of the
tandem drive on the crane side with the
fork tip, remove the sling.
4) Pull the final drive assembly out of the
chassis with the forklift.
13. Raise final drive assembly, remove bolts (12)

mounting assembly to main frame (2 each at
left, right, front, rear: total 8), then lower.
4 Final drive assembly: 2750 kg
30-72 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY INSTALLATION OF FINAL DRIVE ASSEMBLY
INSTALLATION OF FINAL DRIVE ASSEMBLY

1. Raise final drive assembly (13), bring as close ★ Insert the bolts from below, install the
as possible to frame at side of machine (on nuts from above, then tighten the bolts
either left or right side), then remove lifting from below.
3 Mounting bolt: 927 - 1133 Nm
tool at frame side. Use lift truck from opposite
side of machine to support tandem case on
{94.5 - 115.5 kgm}
2 Mounting bolt:
side where lifting tool has been removed,
then operate crane and lift truck together to
place at specified position. Thread tightener (LT-2)
4 Final drive assembly: 2750 kg
4. Install oil filler tube of final drive to intermedi-

ate thread portion (9), then remove oil filler
2. Raise final drive assembly (13), and align cap (17) and fill with oil. (No differential type)
5
position of mounting bolt holes.
EO 30: 17 l
★ To ensure safety during the operation, set
a stand of a height equal to the bottom
surface of the case.
CWG10609
4. Install 2 differential lock solenoid connectors

and 2 oil temperature sensor connectors (3).
Install other 2 hoses (4). Tighten drain plug
3. Keep raised with crane, tighten mounting (2). (With diffrential lock type)
bolts (12) and nuts (14) (2 each at left, right,
front, rear: total 8), and install final drive
assembly to main frame.
GD555, 655, 675-3A 30-73

(6)
DISASSEMBLY
AND ASSEMBLY INSTALLATION OF FINAL DRIVE ASSEMBLY
5. Install universal joint (6) between final drive 8. Install oil filler tube of differential to interme-
and transmission. Install parking brake hose diate thread portion (9), then remove oil filler
(7). cap (17) and fill with oil.
5
★ Install the hoses without twisting or inter-
EO 30: 17 l
ference.
9. Raise wheel (5) and install to final case, then

6. Install electric relay system box cover (10)
and left and right battery (11). tighten 2 nuts and 8 bolts.
★ When lifting the wheel, use a sling and fit
★ After completing the operation, install the
it to the center of the tire so that the tire
battery cables immediately before start-
does not come out, then lift the wheel.
3 Mounting bolt:
ing the engine.
392 - 490 Nm {40 – 50 kgm}

Target: 441 Nm {45 kgm}
7. Install hoses (8) to front, rear, left, and right of

final brake. Install step (15) and cover (16).

HOOD ASSEMBLY.)
30-74 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY OF FINAL DRIVE ASSEMBLY
DISASSEMBLY OF FINAL DRIVE ASSEMBLY

1. Loosen tandem case oil drain plug (1) and
drain oil into container. Remove non-slip pad
(2) on step, then remove chain removal cov-
ers (3) (2 places at the top) and side covers (4)
(inside, outside, front, rear: 4 places).
6 Tandem case: 83 l CWG10610
5. Remove chain (9) from sprocket, then pull out

and remove.
2. Using hand pump [5], release parking brake

(5), then remove pad and rotate disc (6) to
align master chain portion (7) with removal
hole.
6. Raise final brake case assembly (12), then

remove mounting bolts, and remove case
assembly.
4 Final brake case: 200 kg
3. Using tool [A], shorten chain.
4. Extend cotter pin (8) and pull it out, then

remove plate (11) and push master pin (10) to
remove.
GD555, 655, 675-3A 30-75

(6)
DISASSEMBLY
AND ASSEMBLY ASSEMBLY OF FINAL DRIVE ASSEMBLY
7. Raise tandem case (13), remove bolts mount- ASSEMBLY OF FINAL DRIVE
ing to side case (14), then disconnect from
side case and set on stable stand. ASSEMBLY
1. Raise final brake case (12) and install front,
rear, left, and right.
{26 - 31.5 kgm}
Target: 277 Nm {28.2 kgm}
2 Mounting bolt: Coat with LG-1
8. Raise side case assembly (14), remove bolts

mounting to final drive (15), then disconnect
from differential and set on stable stand.
2. Raise right side case (14) and install to tan-

dem case (13).
CWG10611
{26 - 31.5 kgm}

9. Raise final drive assembly (15), remove bolts

mounting to side case (14), then disconnect
from side case and set on stable stand. Raise
right side of side case (14), remove bolts
mounting to tandem case (13), then discon-
nect from tandem case and set on stable
stand.
4 Differential: 320 kg
CWG10612
30-76 GD555, 655, 675-3A

(6)
DISASSEMBLY
3. Install shaft (16), raise final drive assembly 5. Raise tandem case (13) and install to side
(15), and install to side case. case (14).
★ If the shaft spline does not match, rotate
the parking brake disc to align.
{26 - 31.5 kgm}
{26 - 31.5 kgm}
2 Fitting face of side case:
Adhesive (LOCTITE 515)
CWG10612
6. Insert chain (9) in tandem case (13), and mesh

tip portion with sprocket. Rotate disc of center
4. Raise left side case (14) and install shaft (16), brake, wind chain on, then align with master
then install to final drive assembly (15). pin mounting hole (4).
★ If the shaft spline does not match, rotate
the parking brake disc to align.
{26 - 31.5 kgm}
CWG10614
CWG10613
GD555, 655, 675-3A 30-77

(6)
DISASSEMBLY
7. Using tool [A], shorten chain, then install 11. Tighten drain plug (1) of tandem case, and fill
master pin (10). with oil through oil filler (18).
★ After filling with oil, rotate the final drive
8. Install plate (11), then install cotter pin (8) and input coupling 7 turns, and rotate the disc
connect chain. 1/2 turn to immerse it in oil.
3 Drain plug: 58.8 – 78.4 Nm
★ Assemble the chain so that the front is on
the inside of the machine and the rear is
{6.0 – 8.0 kgm}
on the outside.
5 Tandem case EO 30: 83 l
CWG10610
9. Use hand pump [5] to release pad of parking

brake (5), then install.
12. After refilling with oil, coat top surface of tan-
dem case (13), front, rear, left, and right chain
mounting holes, covers (3) and gasket (19)
with gasket sealant.
2 Case and both sides of cover:
Three Bond 1207B
10. Install parking brake. For details of procedure

for adjusting, see TESTING AND ADJUSTING.
★ For details of procedure for adjusting

parking brake mount, see TESTING AND
ADJUSTING.
30-78 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY & ASSEMBLY OF FINAL BRAKE CASE
DISASSEMBLY OF FINAL 5. Remove guide (14), then remove spring (15).

Remove piston (16).
BRAKE CASE
1. Remove and install final brake case assembly.
For details, see REMOVAL, INSTALLATION
OF FINAL BRAKE ASSEMBLY.
★ Set on a stable stand with the sprocket
side at the top.
2. Remove mounting bolts (1), then remove
holder (2), shim (3), sprocket (4), and cage (5)
in order.
★ The collar is installed to the sprocket end
of the case assembly on the opposite
side. Turn over the sprocket.
ASSEMBLY OF FINAL BRAKE

CASE
CWG10615 1. Insert O-ring and spacer to shaft (9), press fit
oil seal (17), then press fit bearing (11).
★ Oil seal space: Fill 80% with grease (G2-LI)
★ Bearing: Coat with EO 30.
3. Remove brake plate (6) and disc (7).
2. Put cage (10) on stable stand and install disc

wear gauge (18).
4. Remove gear (8), then remove shaft (9) from

cage (10).
Remove bearing (11), seal (12), and spacer
(13) from shaft (9).
GD555, 655, 675-3A 30-79

(6)
DISASSEMBLY
AND ASSEMBLY ASSEMBLY OF FINAL BRAKE CASE
3. Assemble O-ring (19) to brake piston (16). 6. Tighten guide (14) to specified torque, and
2 Groove portion of piston and O-ring:
check torque with torque wrench [7].
Coat with G2-LI 3 Guide: 49 Nm {5 kgm}
★ Guide thread portion: Coat with LT-2.
4. Coat piston insertion portion inside cage (10)

with grease, and assemble piston (16).
2 Cage: Coat with G2-LI
7. Install cage (10) to shaft (9). Install bleeder
(20), then install plug (21).
3 Plug: 68.7 ± 9.8 Nm {7 ± 1 kgm}
★ Before installing bleeder (20), insert
mounting bolts (22) connecting to the tan-
dem.
5. Install brake spring (15) to piston with guide

(14).
★ Installed length: 60.5 mm
Installed load: 735 Nm {75 kg}
Free length: 76.5 mm
8. Assemble collar first, then install gear (8).
30-80 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY ASSEMBLY OF FINAL BRAKE CASE
9. Assemble brake plates (6) and discs (7) in 12. Insert collar and install sprocket (4), then
turn. insert shim (3) and install holder (2), then
★ Plates: 5 (outside teeth), discs: 4 (inside tighten bolt (1).
3 Mounting bolt:
teeth)
98 - 123 Nm {10 - 12.5 kgm}
★ Using push-pull gauge [4], measure the
starting torque of the shaft. Adjust with
shims so that the preload of the left and
right bearings is within a range of shaft
starting torque + 11 - 16 Nm {1.15 - 1.65
kgm}.
★ Types of shim: t = 0.1, 0.2, 0.5 mm
10. Install O-rings (23) to inside and outside of

CWG10616
cage (5), then install cage (5) to cage (10).
CWG10617
11. Insert collar, and press fit bearing (24).

★ Coat the bearing with EO 30.
★ For details of adjusting the disc wear

gauge, see TESTING AND ADJUSTING.
GD555, 655, 675-3A 30-81

(6)
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY OF SIDE CASE ASSEMBLY
DISASSEMBLY OF SIDE CASE ASSEMBLY

(FOR STANDARD FINAL DRIVE)
1. Sprocket 3. Cage
1) Place side case assembly (1) on a stable 1) Turn over the side case assembly and
stand with the sprocket side up. remove bolts (11) and holder (12).
2) Remove bolt (2) and plate (3). 2) Sling cage (13) and remove it from flange
★ Check the thickness and quantity of (14).
the shims.
3) Remove sprocket (4) and collars (5) and
(6).
CWG10621
CWG10618
4. Flange
1) Remove bushing (15), oil seals (16) and
(17), and thrust washer (18) from flange
2. Shaft (14).
1) Remove snap ring (7).
2) Turn over the side case assembly. Using
a press, remove shaft (8).
CWG10619
3) Remove bearing (9) and collar (10) from

shaft (8).
CWG10620
30-82 GD555, 655, 675-3A

(4)
DISASSEMBLY
AND ASSEMBLY ASSEMBLY OF SIDE CASE ASSEMBLY
ASSEMBLY OF SIDE CASE ASSEMBLY

(FOR STANDARD FINAL DRIVE)
★ Clean the all parts and check them for dirt or 2. Cage
damage before installing. 1) Sling cage (13) and install it to flange (14).
2 Bushing contact surface:
1. Flange
Lubricant containing molybde-
1) Install thrust washer (18) to flange (14).
2 Both sides of thrust washer:
num disulfide (LM-P)
2) Install holder (12) with 10 mounting bolts
Lubricant containing molybde- (11).
3 Mounting bolt:
2) Using push tool [1], press fit oil seal (17).
2 Space of oil seal lip (To be filled
98 – 123 Nm {10 – 12.5 kgm}
up to 50%):
Grease (G2-LI)
CWG10621
3. Shaft
1) Using push tool [2], install collar (10) to
shaft (8).
3) Similarly to step 2), press fit oil seal (16). 2) Using push tool [3], install bearing (9) to
2 Space of oil seal lip (To be filled

shaft (8).
up to 50%): Grease (G2-LI) 2 Bearing roller: Engine oil (EO30)

4) Press fit flange (14) to bushing (15).
2 Bushing contact surface:
Lubricant containing molybde-
CWG10624
GD555, 655, 675-3A 30-83

(6)
DISASSEMBLY
AND ASSEMBLY ASSEMBLY OF SIDE CASE ASSEMBLY
3) Press fit shaft (8) to flange (14).

4) Install snap ring (7).
CWG10626
4. Sprocket
1) Install collars (6) and (5) and sprocket (4)
to the shaft.
2) Insert a shim so that clearance "a"
between the sprocket and plate will be
0.23 – 0.58 mm, and then install plate (3)
and mounting bolt (2).
2 Bearing roller: Adhesive (LT-2)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
CWG10627
30-84 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY OF SIDE CASE
DISASSEMBLY OF SIDE CASE

(FOR PLANETARY FINAL DRIVE)
1. Raise side case (1), set sprocket at bottom, 3. Remove collar (10), then remove inside
then set on stable stand. Remove center sprocket (11). Using ring pliers [1], remove
shaft bolt (2), remove plate (3), then remove snap ring (12).
shim. Lift off planetary gear (4). Pull out 4
roll pins (5), then remove ring gear (6).
4 Side case assembly: 310 kg
4 Planetary gear: 45 kg
4. Set side case (1) to press stand, and use press

[2] to remove shaft together with bearing.
Using press in same way, remove bearing
from shaft.
2. Raise side case (1) and turn over to set

sprocket at the top, then set on stable stand.
Remove bolt (7), remove plate (8), then
remove shim. Remove outside sprocket (9).
5. Remove dowel pin of cage (14) and flange

(13), lift off flange (13), then remove 2 bush-
ings (15).
GD555, 655, 675-3A 30-84-1

(6)
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY OF SIDE CASE
6. Remove mounting bolts of side case (1) and

cage (14), lift off cage, then remove oil seal
(16).
30-84-2 GD555, 655, 675-3A

(4)
DISASSEMBLY
AND ASSEMBLY ASSEMBLY OF SIDE CASE
ASSEMBLY OF SIDE CASE

1. Install oil seal (16) to cage (14), and fill with 3. Install 2 bushings (15) to outside of flange
grease. (13), and assemble collar and oil seal to
2 Oil seal lip:
inside. Install O-rings (19) to inside and out-
side of top of flange (13), and insert in side
Fill 50% of space with G2-LI
case (1).
2 Oil seal lip:
Fill 80% of space with G2-LI
2. Install cage (14) to side case (1), coat split

washer with LM-P, assemble, then install
plate (17) and tighten with bolts (18).
2 Split washer: LM-P
4. Knock dowel pins in cage (14) and flange (13)
3 Mounting bolt: 98 – 123 Nm

and secure.
{10 – 12.5 kgm}

5. Coat shaft (20) and bearing (21) with EO-30,

press fit to side case, then install snap ring
(12) with ring pliers [1].
GD555, 655, 675-3A 30-84-3

(6)
DISASSEMBLY
AND ASSEMBLY ASSEMBLY OF SIDE CASE
6. Turn over side case, install ring gear (6), then 9. Raise side case (1), turn over, and put on sta-
secure with 4 dowel pins (22). ble stand. Install inside sprocket (11) and
insert collar (10).
7. Install collar (23), then install eyebolts to plan-

etary gear (4), raise planetary gear, and 10. Install to outside sprocket (9), then install
install. shim (25) and plate (8), and tighten bolt (7).
4 Planetary gear: 45 kg
★ Install the same thickness of adjustment
shim as was removed.
Types of shim: 0.1, 0.2, 0.5 mm
8. Insert shim (24) and plate (3), and tighten bolt

(2).
11. Tighten bolt (7) to specified torque.
3 Bolt:
shim as was removed. 98 – 123 Nm {10 – 12.5 kgm}
Types of shim: 0.1, 0.2, 0.5 mm Target: 111 Nm {11.3 kgm}
3 Bolt: 490 – 608 Nm {50 – 62 kgm}
2 Mounting bolt:
30-84-4 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY (IF EQUIPPED)
DISASSEMBLY OF DIFFEREN- 4. Sling bevel gear (11), and remove left and
right mounting bolts of bearing gauge (12).
TIAL GEAR ASSEMBLY (IF Install guide bolt to differential, screw in forc-
EQUIPPED) ing screws (13), then pull out gauge and
remove.
1. Put differential gear case assembly (1) on sta-
ble stand, and remove oil supply tube (2),
solenoid valve (3), hose (4), oil temperature
sensor (5), and cover (6). Raise differential (1),
turn over, and put parking brake disc facing
up.
4 Differential gear assembly: 320 kg
5. Lift off bevel gear (11). Remove left and right

bearing gauges (12) and shims (14).
4 Bevel gear: 90 kg
2. Remove mounting bolts of parking brake (7),

then remove disc. Remove mounting bolts of
pinion (8), and lift off pinion.
4 Pinion: 35 kg
3. Raise differential (1), turn over, remove brake

tube (9), then remove nipple (10).
GD555, 655, 675-3A 30-85

(6)
DISASSEMBLY
AND ASSEMBLY ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY (IF EQUIPPED)
ASSEMBLY OF DIFFERENTIAL 3. Using guide bolt, install shim (14) on left side.
Assemble bearing (18) to cage (12), then
GEAR ASSEMBLY (IF install to differential case (15).
EQUIPPED) ★ Install the same thickness of adjustment
1. Put differential case (15) on stable stand, raise ★ Types of shim: t = 0.05, 0.1, 0.2, 0.5 mm
bevel gear assembly (11), and assemble. (The Part Nos. for the left and right shims
Keep bevel gear raised, and use a guide bolt are different.)
to install shims (14) on right side.
★ Types of shim: t = 0.05, 0.1, 0.2, 0.5 mm
4 Bevel gear assembly: 90 kg
4. Tighten mounting bolts of right cage (12) to

specified torque.
3 Mounting bolt:
98 - 113 Nm {10 - 11.5 kgm}
2. Assemble bearing inside cage (16), then
insert in spider case (17) and install to differ- Tighten mounting bolts of left cage (16) to
ential case (15). specified torque.
3 Mounting bolt:
★ Coat the bearing roller with EO 30.
98 - 123 Nm {10 - 12.5 kgm}

2 Mounting bolt: Thread tightener (LT-2)
30-86 GD555, 655, 675-3A

(6)
DISASSEMBLY
5. Raise pinion assembly (8) and install to differ- 7. Coat coupling mounting bolts (22) with thread
ential case. Install shim (19) to flange portion. tightener, install shim (23) and holder (24),
(Standard shim thickness: 1.5) then tighten bolts (22) to specified torque.
★ Shim thickness: t = 0.05, 0.1, 0.2, 0.5 mm (Standard shim thickness: 2.0 mm)
★ Types of shim: t = 0.1, 0.2, 0.5 mm
2 Mounting bolt: Thread tightener (LT-2)
3 Mounting bolt:
245 - 309 Nm {25 - 31.5 kgm}
6. Tighten mounting bolts of pinion assembly

(8) to specified torque.
Install coupling (21) to parking brake disc (7),
then install to pinion shaft (20).
3 Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm} 8. To adjust backlash of bevel gear and pinion
Target: 111 Nm {11.3 kgm} gear, set dial gauge [3] in position, then
change thickness of shim at pinion gear and
differential case mount to adjust.
★ Select a shim and adjust.
★ Backlash: 0.25 - 0.33
GD555, 655, 675-3A 30-87

(6)
DISASSEMBLY
9. To adjust preload and backlash of bevel gear 11. Coat inside of cover (6) with LG-1, and install
and side bearing, use push-pull gauge [4], gasket, then install cover with bolts. Install
and change thickness of shim at left and right magnet assembly, spring, and O-ring to oil
of cage to adjust. supply tube (2), then install solenoid valve (3),
★ Adjust the preload with the bevel pinion oil temperature sensor (5), and hose (4), and
meshed. Select shims to adjust so that the tighten drain plug (25) to specified torque.
2 Solenoid valve mounting bolt:
preload is 0.7 - 1.5 Nm {0.07 - 0.15 kgm}
added to the starting torque of the bevel
Coat with LG-1
2 Hose elbow mounting thread:
pinion, and the backlash is 0.25 - 0.33.
Coat with LT-2

2 Cover: Coat with LG-1
3 Cover mounting bolt:
98 - 123 N m {10 - 12.5 kgm}
3 Oil supply tube mounting bolt:
59 - 74 Nm {6 - 7.5 kgm}
3 Drain plug:
55.8 - 78.4 Nm {6 - 8.0 kgm}}
★ The tooth contact is as shown in the dia-
gram below.
A: 46 - 58% of tooth width;
B: 28 - 40% of tooth width
10. Install nipple (10) for differential lock, then

install tube (9).
30-88 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY OF BEVEL GEAR ASSEMBLY
DISASSEMBLY OF BEVEL ASSEMBLY OF BEVEL GEAR

GEAR ASSEMBLY ASSEMBLY
(FOR STANDARD FINAL DRIVE) (FOR STANDARD FINAL DRIVE)
1. Bevel pinion assembly 1. Bevel gear assembly

1) Set bevel gear case assembly (1) on the 1) Wind wires around bevel gear assembly
block with the bevel pinion assembly up. (5). Sling the assembly and set it to the
2) Remove 6 mounting bolts (2) and lift off installation position in the case.
bevel pinion assembly (3). ★ Install the assembly with the bevel
★ Check the thickness and quantity of gear on the left of the machine body.
the shims. 2) Install the removed shims with cages (7)
and (6).
★ Apply preload to the side bearing of the
bevel gear assembly after installing the
bevel pinion assembly.
CWG10628
CWG10630
2. Bevel gear assembly

1) Set the bevel gear assembly on the block
with the bevel pinion assembly side
down.
k Since the bevel gear assembly is not
2. Bevel pinion assembly
1) Set case assembly (1) on the block with
stable, fix the block securely.
the bevel pinion assembly side up.
2) Remove cover (4). 2) Install the removed shims and bevel pin-
3) Wind wires around the shaft of bevel gear ion assembly (3) and tighten bolts (2).
assembly (5) and sling the shaft. Remove
cages (6) and (7) and bevel gear assembly
(5). {10 – 12.5 kgm}
★ Check the thickness and quantity of
the shims.
CWG10631
CWG10629
GD555, 655, 675-3A 30-89

(6)
DISASSEMBLY
AND ASSEMBLY ASSEMBLY OF BEVEL GEAR ASSEMBLY
3. Adjusting
1) If bevel pinion is too far from center line 2) If bevel pinion is too close to center line of
of bevel gear. bevel gear.
Contact is at the small end of the convex Contact is at the small end of the concave
tooth face of the bevel gear and at the big tooth face of the bevel gear and the big
end of the concave tooth face. end of the convex tooth face.
• Procedure for adjustment • Procedure for adjustment

Reduce the thickness of the shims at Increase the thickness of the shims at
the mounting face of the bevel pinion the mounting face of the bevel pinion
assembly to move the pinion shaft in assembly to move the pinion in direc-
direction A, nearer to the bevel gear. tion A, away from the bevel gear.
Change the shim thickness at the cov- Change the shim thickness at the cov-
ers at both ends to move the bevel ers at both ends to move the bevel
gear in direction B by the same gear in direction B by the same
amount that the bevel pinion has amount that the bevel pinion has
moved in direction A. Check the tooth moved in direction A. Check the tooth
contact pattern backlash. contact pattern and backlash.
30-90 GD555, 655, 675-3A

(6)
DISASSEMBLY
★ When inserting the shims, loosen the

mounting bolts of the bevel pinion
assembly and tap the tip of the pinion
gear to knock out the shims that can
be removed.
★ When adjusting the bevel gear to the
right or left, do not change the pre-
load of the bearing. Adjust by moving
the same thickness of shims at the
covers at both ends.
3) Testing and adjusting
Adjust the preload of the taper roller bear-
ing, and the backlash and tooth contact
between the bevel gear and bevel pinion. ★ If the result of the inspection
★ Adjust the rotating starting torque shows that the correct tooth con-
8.7 - 11.7 Nm {0.89 - 1.19 kgm} (value tact is not being obtained, adjust
of the preload on the pinion unit) of again as follows.
the bevel pinion assembly as an indi- ii) Measuring backlash
vidual part. Put fuse wire [1] (approx φ 1.5 mm)
★ Install the bevel pinion assembly to between the teeth of the bevel gear
the case with the same thickness of and bevel pinion and fix in position
shims as was removed during disas- with sellotape. Rotate the bevel gear
sembly. and then measure the thickness of the
fuse wire with micrometer [2].
★ Carry out the adjustment of the pre-
load and the adjustment of backlash
and tooth contact at the same time.
★ Measure the starting torque of the
bevel gear assembly with the bevel
gear and bevel pinion meshed.
i) Adjusting tooth contact
Coat the tooth face of the bevel pinion
lightly with red lead (minimum).
Rotate the bevel gear forward and
backward and inspect the pattern left
on the teeth.
★ Tooth contact should be checked
with no load on the bevel pinion.
The tooth contact pattern should
be located 28 - 40 mm from the
small end of the bevel gear. It
should be in the center of the
tooth height. If the gears are
adjusted to this pattern, the tooth
contact will be correct when load
is applied.
GD555, 655, 675-3A 30-91

(6)
DISASSEMBLY
★ Stick the fuse wire in the center of

the bevel gear height (about 21
mm from the small end) and mea-
sure at least three points around
the gear.
★ Backlash: 0.25 – 0.33 mm
iii) Measuring preload
Install torque wrench [3] to bolt of pin-
ion assembly, then measure starting
torque.
★ Adjust so that the starting torque
8.7 – 11.7 Nm {0.89 – 1.19 kgm} of
the pinion assembly as an individ-
ual part is increased by 0.7 – 1.5
Nm {0.07 – 0.15 kgm}.
4. Cover
After adjusting, install cover (4).
2 Fitting face of cover:
Gasket sealant (ThreeBond 1207B)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
CWG10632
30-92 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY OF BEVEL GEAR
DISASSEMBLY OF BEVEL GEAR

1. Remove mounting bolts of brake cage (1), 4. Remove spider gear assembly (10).
then remove cage.
5. Remove 12 bolts of bevel gear case (7), then

2. Remove plate (2), disc (3), gear (4), washer pull out dowel pin (11), and separate bevel
(5), and piston (6). gear (12) and case (7).
3. Turn over bevel gear (7), and install spider

case (8). Remove bolts, then remove case.
Remove washer, then remove gear (9).
GD555, 655, 675-3A 30-92-1

(4)
DISASSEMBLY
AND ASSEMBLY ASSEMBLY OF BEVEL GEAR
ASSEMBLY OF BEVEL GEAR

1. Tighten bolts to bevel gear case (7) and bevel

gear (12) temporarily, and knock 4 dowel pins
(11) and tighten bolts.
★ After knocking in the dowel pin, caulk at 2
places.
{16 – 20 kgm}
4. Turn over bevel gear case (7), assemble seal

to piston (6), and install.
★ Be careful to assemble the seal facing in
the correct direction.
2. Turn over bevel gear case (7) and install spi-

der gear assembly (10).
★ Coat the inside surface of the bushing of
the spider gear with EO 30.
★ Seal direction diagram
3. Install gear (9) to spider assembly. Install 2

rings (13) to outside of spider gear case (8),
then install washer to inside case, and tighten
case (8) with bolts.
★ Coat the outside and side surfaces of the
ring with LM-P.
{10 – 12.5 kgm}
30-92-2 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY ASSEMBLY OF BEVEL GEAR
5. Install gear (4), and install plates (2), then

install discs (3). Install plates and discs in
turn.
★ Coat both sides of the plates and discs
with EO 30.
6. Install washer (5) to cage (1). Assemble cage

(1) to bevel gear case, and knock in 4 dowel
pins.
7. Install cage (1) and tighten with bolts to bevel

gear case (7) to specified torque.
{10 – 12.5 kgm}
GD555, 655, 675-3A 30-92-3

(6)
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY OF BEVEL PINION ASSEMBLY
DISASSEMBLY OF BEVEL PINION ASSEMBLY

1. Remove mounting bolts of coupling (1).
Remove coupling (1), then remove holder,
shim, and O-ring.
2. Set pinion assembly (2) on press stand, and

fit jig to top of shaft (3), then push out shaft
(3) with press.
★ When the pinion shaft is removed, the
cage and top bearing will also come off at
the same time.
3. Remove bearing (4) of pinion shaft (3).
30-92-4 GD555, 655, 675-3A

(4)
DISASSEMBLY
AND ASSEMBLY ASSEMBLY OF BEVEL PINION ASSEMBLY
ASSEMBLY OF BEVEL PINION 3. Install deflector and coupling (1), assemble O-

ring, shim, and holder, then tighten bolts (6).
2 Mating surface of coupling and seal:
ASSEMBLY
1. Press fit bearing (4) to pinion shaft (3) with Coat with G2-LI
press [2]. 2 Coupling mounting bolt:
2 Bearing: Coat with EO 30 Thread tightener (LT-2)
3 Coupling mounting bolt:
245 - 309 Nm {25 - 31.5 kgm}
★ Types of shim: t = 0.1, 0.2, 0.5 mm
2. Press fit cage (5) and bearing to pinion shaft

(3), and install seal (6).
2 Bearing: Coat with EO 30
2 Oil seal lip:
Fill 80% of space with G2-LI 4. Install torque wrench [7] to coupling mount-
ing bolt, and measure starting torque.
★ Starting torque: 8.73 - 10.69 Nm
{0.89 - 1.19 kgm}
GD555, 655, 675-3A 30-93

(6)
DISASSEMBLY
AND ASSEMBLY REMOVAL OF OPERATOR'S CAB ASSEMBLY
REMOVAL OF OPERATOR'S 4. Loosen mounting clamp of air conditioner

vent hose (10), then remove hose. Disconnect
CAB ASSEMBLY connectors (12) of electrical system wiring
harnesses (11).
1. Remove right side (1) and left side (2) of cover ★ Cover the removed connectors with a
under cab door. nylon bag to prevent the entry of dust or
★ There are 2 washer tanks installed to the water.
rear left cover.
5. Install 4 eyebolts to top of operator's cab, and

sling. Remove left and right mounting bolts of
cab mounts (13) and (14). Remove 8 mount-
2. Disconnect connectors of motor wiring har- ing bolts of left and right step portions of
ness (5) and hose (4) of washer tank (3). floor at same time.
4 Operator's cab: Approx. 700 kg
★ The 2 mounting bolts at the rear left con-
tact the case under the floor, so when
removing or installing the cab without
removing them, be careful not to cause
damage.
3. Remove operator's seat (6). Remove control-

ler box (7). Loosen mounting clamp of air
conditioner vent hoses (8) and (9), then
remove hoses.
6. Remove mounting box (16) of rear air condi-

tioner vent hose (15).
30-94 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY INSTALLATION OF OPERATOR'S CAB ASSEMBLY
7. Left cover (17) and right cover (18) of work 2. Keep cab raised, align position of left and
equipment control levers contact when cap is right mounting bolt holes of mounts (13) and
removed, so remove cover mounting bolts (14), then install bolts and tighten tempo-
and leave covers free. rarily. Temporarily tighten mounting bolts of
left and right step portions of floor, put cab in
contact with floor, tighten mounting bolts
fully, then tighten floor bolts fully.
★ The 2 mounting bolts at the rear left pro-
trude, so be careful not to damage them.
8. Raise operator's cab assembly (19) and put

on stable stand, horizontally.
4 Operator's cab assembly:
Approx. 700 kg
3. Insert mounting bolts in left cover (17) and

right cover (18) of work equipment control
lever.
INSTALLATION OF OPERA-
TOR'S CAB ASSEMBLY
1. Install 4 eyebolts to top of operator's cab,
raise cab assembly (19), then set in specified
4. Install box (16) for mounting air conditioner
position on cab floor.
4 Operator's cab assembly:
hose.
Approx. 700 kg
GD555, 655, 675-3A 30-95

(6)
DISASSEMBLY
AND ASSEMBLY INSTALLATION OF OPERATOR'S CAB ASSEMBLY
5. Tighten air conditioner hose (10) with mount- 8. Install right (1) and left (2) covers under cab
ing clamp. Install connectors (12) to electric door.
wiring harness (11).
★ After mating the connectors, check that
they are securely locked.
9. Carry out shower test to check that no water

is entering cab from door seal of cab (19),
weather strip, and seals.
6. Install air conditioner hoses (8) and (9) and Check that the wiper works smoothly and
tighten clamp. Install controller box (7). Install stops at the specified position.
operator's seat (6). Check that the head lamps and combination
lamp light up.
Check that the door opens and closes
smoothly without any squeaking or play.
7. Install cover (installed to washer tank (3)) to

mounting position, then install hoses (4) of
washer tank (3) and connectors (5) of electric
wiring harness.
30-96 GD555, 655, 675-3A

(2)
DISASSEMBLY
AND ASSEMBLY REMOVAL OF OPERATOR'S CAB FLOOR
REMOVAL OF OPERATOR'S 5. Remove steering filter (7) together with

mounting bracket (8).
CAB FLOOR
1. Remove operator's cab assembly.
For details, see REMOVAL OF OPERATOR'S
CAB ASSEMBLY.
2. Pull out roll pin of spool (3) portion of right (1)
and left (2) control valves, and disconnect rod
of work equipment control lever.
6. Disconnect hoses (9) from brake line, and at

same time, pull out roll pin and disconnect
wire of accelerator linkage (10) from linkage
of lever. Then, loosen 2 bolts of wire mount-
ing bracket from under floor and remove.
★ Before removing the hoses, mark each
hose and its partner with a number to pre-
vent any mistake when installing.
3. Disconnect connectors of transmission sys- ★ Fit male and female plugs into the hoses
tem wiring harness (3) and (4) under right and nipples after removing them.
floor.
★ Cover the connectors with a nylon bag.
7. Remove 3 hoses (11) inside orbit motor from

4. Remove left and right floor mounts (5). under left side of floor.
Remove ground connection (6). At same time,
disconnect wiring harness connector CN-B20
(for improvement of engine starting ability)
from under rear left floor.
GD555, 655, 675-3A 30-97

(6)
DISASSEMBLY
AND ASSEMBLY INSTALLATION OF OPERATOR'S CAB FLOOR
8. Release air conditioner gas, remove cover 10. Install eyebolts to floor assembly, then lift off
under operator's seat, then remove hoses floor assembly (19).
(12) and (13). Cover mouthpiece, remove ★ Prepare a stable stand, set the assembly
hose clamps under floor, pull down hoses horizontally on the stand, and check that
(12) and (13), loosen hose clamps under floor there is no obstruction of the accessories
at rear left of heater hose (14), remove 2 inter- installed under the floor.
4 Floor assembly: Approx. 260 kg
mediate clamps, then remove 2 hoses.
9. Remove mounting cover (16) of speedometer

(15), then loosen mounting nut (18) of cable INSTALLATION OF OPERA-
(17) of speedometer (15) from rear, and pull
out cable (17) from bottom side of post stand
TOR'S CAB FLOOR
to bottom surface of floor.
★ Wind the cable and nut with plastic tape 1. Install eyebolts to floor assembly (19), raise
floor assembly, set in position on frame, align
to make it easier to remove.
holes for mounting bolts of floor assembly,
then lower assembly and put in contact with
frame.
★ The 2 mounting bolts at the rear left of the
floor protrude, so be careful not to dam-
age them.
4 Floor assembly: Approx. 260 kg
30-98 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY INSTALLATION OF OPERATOR'S CAB FLOOR
2. Tighten left and right mounting bolts of floor 5. Connect 3 hoses (11) inside orbit motor under
mount (5) to specified torque. Install chassis floor on left side.
ground connection (6), then install wiring har-
ness connector B20 at rear bottom left. (For
improving ease of starting engine.)
6. Connect accelerator wire to accelerator link-

3. Pass cable (17) of speedometer (15) through age (10), and install bracket and wire to bot-
center of post stand from under floor, pull up to tom surface of floor. Install hoses (9) of brake
meter, insert in rear of meter, then tighten nut line system.
(18). Install mounting cover (16) of meter (15). ★ Install the hoses without twisting.
★ It is easier to pass the cable through if the
intermediate cover of the post stand is
removed.
★ Adjustment procedure for accelerator

4. Pull up air conditioner hoses (12) and (13) from control
under floor and install, then install intermediate
1) Set height of pedal stopper bolt to 75 mm
clamp of hose to bottom surface of floor. Install
from top surface of floor.
2 heater hoses (14), then install 2 hose interme-
2) Set height of pedal to 193 mm, then
diate clamps to bottom surface of floor.
adjust length of rod so that engine low
★ Install the hoses without twisting or interfer-
idle speed is 850 ± 50 rpm.
ence.
3) Adjust length of rod so that engine gover-
★ After completing the assembly at all points,
nor lever reaches end of stroke (engine
fill the air conditioner with gas.
full throttle 2200 ± 50 rpm) when pedal is
depressed until it contacts stopper bolt.
4) Loosen stop bolt 1/2 turn and fix it in posi-
tion. (Set so that engine governor lever
does not contact engine end strongly.)
5) Adjust length of rod so that regulator
lever can change speed from low idle (800
± 50 rpm) to full throttle (2200 ± 50 rpm).
GD555, 655, 675-3A 30-99

(6)
DISASSEMBLY
AND ASSEMBLY REMOVAL & INSTALLATION OF STEERING VALVE (ORBIT-ROLL)
REMOVAL & INSTALLATION OF STEERING VALVE (ORBIT-ROLL)
7. Install steering filter (7) and bracket (8). REMOVAL OF STEERING

VALVE (ORBIT-ROLL)
1. Remove cover (1) of post stand, then remove
gauge mounting cover (2), and remove wiring
harness and cable of each gauge.
8. Install connectors of transmission system wir-

ing harness (3) and (4).
★ After mating connectors, check that they
are securely locked.
2. Remove 5 hoses (4) installing to Orbit-roll (3).
3. Remove mounting bolts of Orbit-roll (3), then

remove Orbit-roll (3) and steering shaft (5),
9. Connect right control valve (1) and left control
and separate.
valve (2) to rod of work equipment control
lever with roll pins, then insert beta pin.
INSTALLATION OF STEERING
10. Install operator's cab. VALVE (ORBIT-ROLL)
(For details, see INSTALLATION OF OPERA-
TOR'S CAB.) ★ Carry out installation of the steering valve
in the reverse order of removal.
★ For details of bleeding air from brake line,
see TESTING AND ADJUSTING.
30-100 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY STANDARD INTEGRAL ORBIT-ROLL
STANDARD INTEGRAL ORBIT-

ROLL
Tools needed for disassembly and assembly
(1) Torque wrench (torque capacity: 49 Nm {5 kgm}) (7) Plastic hammer
(2) 5/12 in - 12 point socket (8) Small amount of grease
(3) Flat-headed screwdriver (large) (9) Vice
(4) Flat-headed screwdriver (small) (10) Oil-based felt pen
(5) Spring insertion tool (P/N: 600057) (11) Tweezers
(6) 3/16 in hexagonal wrench
30-102 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY STANDARD INTEGRAL ORBIT-ROLL
Part Part name Q’ty Remarks

No.
1 Screw 6
2 Retainer screw assembly 1
3 End cap 1
4 Gerotor 1
5 Spacer 1
6 Spacer (1)
7 Spacer plate 1
8 Drive 1
9 Housing 1
10 Sleeve 1
11 Spool 1
12 Pin 1
Centering spring 6 For standard input torque specification
13
Centering spring 4 For low input torque specification
14 Flat spring (2) Only for low input torque specification
15 Race bearing 2
16 Thrust needle 1
17 O-ring 1
18 Oil seal 1 X-ring or Teflon seal
19 Dust seal 1
20 Retaining ring 1
21 Seal gland bushing 1
22 O-ring 2 Part No.: 5776
23 O-ring 1 Part No.: BA0098A
24 Inlet check valve sub assembly 1 (Cannot be disassembled)
25 Valve seat 1 (Cannot be disassembled)
26 Poppet 1
27 Spring 1
28 Plug 1
29 O-ring 1
30 Retainer plug 2
31 Spring 2
32 Ball 2
33 Valve seat 2 (Cannot be disassembled)
34 Ball 2
35 Ball holder 2
36 Spring 2
37 Plug 2
38 O-ring 2
39 Adapter screw 1
40 Ball 1
41 Name plate 1
42 Rivet 2
Seal kit (X-ring) Part No.: BA0271A

Seal kit (Teflon seal) Part No.: BA0273A
GD555, 655, 675-3A 30-103

(2)
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY OF STEERING VALVE
DISASSEMBLY OF STEERING 3. Remove spacer (5) inside spline on inside of

star of Gerotor (4).
VALVE Remove Gerotor (4). Be careful not to drop
star from ring of outer circumference of Gero-
★ When disassembling the valve, cleanli- tor. Remove O-ring (22) from Gerotor.
ness is extremely important. Carry out the
work in a clean place.
★ Before removing the piping, remove all
dirt and dust from around the ports and
joints on the outside circumference of the
motor.
★ In the following explanation diagrams, it
is not absolutely necessary to hold the
unit in a vice, but it is recommended to
use a vice as far as possible.
Be extremely careful not to injure yourself

on the edges of sleeves, spools, housing,
and other machined parts.
4. Remove drive (8), then remove spacer plate
1. Put end cap (3) at the top, fit side face of (7). Remove O-ring (23) from housing.
housing between copper sheets in vice [8],
and be careful not to tighten vice too
strongly.
5. Using flat-headed screwdriver, remove

adapter screw (39). Remove housing from
vice, set upside down, then remove ball (40).
2. Remove 6 screws (1) and 1 retainer screw (2), ★ Be careful not to drop or lose the ball.
then remove end cap (3). Remove O-ring (22)
from end cap (3).
30-104 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY OF STEERING VALVE
6. Set housing upside down, remove 2 springs 9. Remove 2 race bearings (15) and thrust nee-
(31), 2 retainer plugs (30), and 2 balls (32). dle (16).
★ Be careful not to drop or lose the parts.
10. Push spline portion inside spool with thumb

7. Set on clean cloth with flange surface of and remove spool and sleeve assembly from
housing facing up to prevent damage to fin- opposite side of housing flange. When doing
ished surface. Use flat-headed screwdriver to this, be careful not to let outside diameter of
raise tip of retaining ring (20), then remove sleeve get caught in inside diameter of hous-
from housing. ing.
★ Depending on the assembly of sleeve and
The retaining ring may fly out from the spool, it may not work properly if it is
housing, so always wear protective glasses. assembled 180° from the proper direc-
tion, so make marks to show the position
of spool and sleeve (43). Remove pin (12).
The retaining ring may fly out from the

housing, so always wear protective glasses.
8. Set housing on clean cloth with axial line of

valve horizontal.
Turn spool and sleeve assembly to set sleeve
pin in horizontal position, then push out spool
and sleeve assembly slightly, and remove
seal gland bushing (21) from housing.
Remove oil seal and dust seal from gland 11. Push out spool inside sleeve slightly, and
bushing. remove centering spring (13) carefully by
★ When removing the seal, be careful not to hand from spool.
damage the seal gland bushing.
GD555, 655, 675-3A 30-105

(6)
DISASSEMBLY
AND ASSEMBLY ASSEMBLY OF STEERING VALVE
12. Rotate spool slowly and pull out spool (11) ASSEMBLY OF STEERING
from sleeve (10).
Remove O-ring from housing. VALVE
★ Check all the joining parts.
Parts with gouges or burrs will cause leak-
age of oil, so replace them with new
parts. Wash all metal parts with clean sol-
vent and blow dry with compressed air. If
they are wiped with rags or paper, pieces
of cloth or paper will stick to the parts or
get inside the valves. This will cause the
hydraulic system to become dirty, so do
not wipe with cloth or paper.
Do not polish parts with sandpaper or
modify with a file.
DISASSEMBLY OF STEERING RELIEF VALVE
Be extremely careful not to injure yourself
• Using hexagonal wrench (width across on the edges of sleeves, spools, housing,
flats: 3/16 inch), remove plug (28). and other machined parts.
Remove O-ring (29) from plug. Using
tweezers, remove spring (27) and poppet ★ As a basic rule, assemble new O-rings
(26). and seal after disassembling. Coat the O-
★ The valve seat is stuck to the housing and rings with a small amount of clean grease
cannot be removed. before assembling.
★ The O-rings in front of or behind the
spacer plate are of very similar sizes, so
check the part number before opening the
seal kit, and be extremely careful not to
mix them.
1. Turn spool (11) and insert slowly into sleeve
(10). Grip spline portion of spool and check
that spool rotates smoothly inside sleeve.
Align mark made when disassembling.
DISASSEMBLY OF OVERLOAD RELIEF

VALVE
• Using hexagonal wrench (width across

flats: 3/16 inch), remove plugs (37) (2
places). Remove O-ring (38) from plug.
Using tweezers, remove 2 springs (36), 2
ball holders (35), and 2 balls (34).
★ The valve seat is stuck to the housing and
cannot be removed.
30-106 GD555, 655, 675-3A

(2)
DISASSEMBLY
2. Align 2 spring grooves at 180° in spool and 4. Place housing on clean flat surface, then
sleeve, then stand on a horizontal plate. Insert assemble O-ring (17).
spring insertion tool (Part No.: 60057) in spring Assemble 2 race bearings (15) and thrust nee-
groove, then fit centering spring to insertion dle (16). Always insert thrust needle between
tool so that notched portions at both ends are at race bearings.
bottom.
When doing this, it is easier to insert if spool is
lifted up slightly from sleeve. Hold centering
spring at opposite end with a finger and com-
press it to push it into spool sleeve groove.
When doing this, slide insertion tool at same
speed as pushing in spring. After inserting, align
end of spring with outside diameter of sleeve.
Insert sleeve pin into hole in sleeve, and align
both ends of pin with outside diameter of
sleeve.
The centering spring may fly out from the

spool, so always wear protective glasses. ★ There are two types of seal: Teflon seal
and standard seal.
5. Assemble dust seal (19) to seal gland bushing
(21). Assemble dust seal so that flat surface is
at seal gland bushing end. Assemble oil seal
(18) to seal gland bushing.
★ Assemble the oil seal carefully so that
there is no twisting or deformation.
★ The diagram below is the Teflon seal
specification drawing; (44) is the distin-
guishing groove.
3. Set housing on clean cloth with axial line of

valve horizontal. Insert spool and sleeve assem-
bly from opposite end of housing to flange end.
In this condition, check that spool and sleeve
assembly rotates smoothly inside housing.
★ When inserting spool and sleeve assembly,
be careful not to insert it at an angle and get
it caught. Keep the pin at near the horizontal
position, and rotate slightly to left and right
to insert.
★ Insert so that the end face of the spool and ★ The diagram below is the standard seal
sleeve assembly is level with the end face of specification drawing.
the housing. If it is inserted further, the pin
will fall inside the housing, so stop inserting
when the end face is level.
GD555, 655, 675-3A 30-107

(2)
DISASSEMBLY
6. After assembling seals, rotate seal gland bush-

ASSEMBLY OF OVERLOAD RELIEF VALVE
ing (21) and insert to spool. Tap with plastic
hammer to insert to specified position. • Assemble O-ring (38) to plug (37). Fit grease
Assemble retaining ring (20) to housing.
to ball holder (35) and install ball (34).
★ Push open with a flat-headed screwdriver so Using tweezers, assemble ball holder (35) and
that the whole circumference of the retain-
spring (36) to housing. Using hexagonal
ing ring fits securely in the groove in the
wrench (width across flats: 3/16 inch), assem-
housing. ble plug (37) to housing.
The retaining ring may fly out from the ★ The size of the overload valve ball and the
housing, so always wear protective anti- cavitation check valve ball is differ-
glasses. ent, so be careful not to mix them.
★ Seal assembly drawing

Screwdriver [9], dust seal (19), retaining ring
(20), seal gland bushing (21), oil seal (18), O- ASSEMBLY OF ANTI-CAVITATION CHECK
ring (17) VALVE
• Grip the port surface and side surface of the

housing lightly in a vice. Fit copper sheets in
the vice, and be careful not to tighten the vice
too strongly.
Of the 7 bolt holes in the end face of the hous-
ing, insert 1 each of spring (31), retainer plug
(30), and ball (32) in the 2 holes shown in the
drawing.
★ Be careful not to drop or lose the ball. Be
careful of the assembly direction of the
retainer plug.
ASSEMBLY OF STEERING RELIEF VALVE

• Assemble O-ring (29) to plug (28).
Using tweezers, assemble spring (27) and pop-
pet (26) to housing.
Using hexagonal wrench (width across flats: 3/
16 inch), assemble plug (28) to housing.
30-108 GD555, 655, 675-3A

(6)
DISASSEMBLY
ASSEMBLY OF GEROTOR END • Turn spool and sleeve assembly and set pin
(12) and port surface (46) of housing in paral-
• Grip the port surface and side surface of the lel. Insert drive (8) into portion (47), then mate
housing lightly in a vice. (45): 25 mm. Fit cop- drive yoke and pin (12). To carry out position-
per sheets in the vice, and be careful not to ing exactly, use a felt pen to draw line on end
tighten the vice too strongly. face of drive (8) parallel to pin.
• Of the 7 bolt holes in the end face of the hous- • Assemble O-ring (22) to Gerotor (4).
ing, insert ball (40) in the holes shown in the
drawing. Assemble adapter screw (39) in
holes in same drawing.
• Assemble O-ring (23) to housing.

Set spacer plate (7) on top and align position
of bolt holes.
★ The pitch diameter of the bolt holes and
oil holes is different.
GD555, 655, 675-3A 30-109

(2)
DISASSEMBLY
• Set O-ring end at end face of Gerotor (4) at • Order for tightening end cap mounting
spacer plate (7) side, align concave portions screws is as shown in diagram below.
(48) of Gerotor star teeth with pin (12), align
with mark drawn on end face of drive (8), and
assemble.
When doing this, check carefully that lines A,
B, C, and D are parallel as shown in diagram
below.
★ Turn Gerotor ring to align bolt holes. Do
not remove mating of drive and Gerotor
star.
★ The above procedure is important for
aligning the valve timing.
★ After tightening to torque given below,

install handle to spool and check that
spool rotates.
Screw tightening torque
Discharge capacity Tightening torque
(cc/rev) (Nm {kgm})
51 - 230 22.6 {2.3}
277 23.5 {2.4}
369 - 737 28.4 {2.9}

• Assemble spacer (5) to spline inside Gerotor
star.
★ Do not assemble spacers to 51 cc/rev and List of capacities and spacers
69 cc/rev discharge capacity Orbit-rolls.
Discharge Discharge Spacer thickness
Assemble 2 spacers to 184 cc/rev dis- capacity symbol capacity (cc/rev) (mm)
charge capacity Orbit-roll.
Assemble O-ring (22) to end cap (3), set A 51 –
on top of Gerotor, then align bolt holes. B 69 –
Coat 6 screws (1) and thread of retainer C 96 3.6
screw assembly (2) with oil, then assem- D 120 6.1
ble to end cap.
E 159 12.2
Install retainer screw assemblies to bolt
holes where adapter screws have already 12.2
G 184
been assembled. Tighten 7 screws to 3.6
torque of approx. 14.7 Nm {1.5 kgm}, then K 230 22.0
tighten in order to following torque. M 277 24.4
P 369 41.1
S 461 53.7
T 553 66.4
U 737 91.8
30-110 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY REMOVAL & INSTALLATION OF BLADE ASSEMBLY
REMOVAL & INSTALLATION OF BLADE ASSEMBLY
REMOVAL OF BLADE ASSEM- INSTALLATION OF BLADE

BLY ASSEMBLY
1. Raise center of blade (1), and install right tip
Start the engine, operate the work equip-
ment control levers, raise blade so that bot- of blade to adjuster. Extend blade side shift
tom is approx. 100 mm from ground, set cylinder rod fully, and move position of lifting
stable stand to match height under circle, wire while pushing in blade to point where it
then lower. is possible to connect cylinder rod.
★ Do not coat the rail at the rear of the blade
1. Operate blade control lever and shift blade (1) with grease.
4 Blade assembly: Approx. 755 kg
fully to left. Sling blade, remove mounting
bolts of blade side shift cylinder rod (2),
remove rod head, then operate control lever (differs according to blade)
to retract cylinder rod fully.
★ After completing operation of the control
lever, stop the engine and lock the lever.
2. Install cylinder rod (2) to blade (1) and tighten

mounting bolts to specified torque. Remove
stand from under circle.
2. Sling blade (1), move position of wire to cen- 2 Cylinder rod pin hole: Coat with G2-LI
ter of blade while pushing blade out, then lift
off.
4 Blade assembly: Approx. 755 kg
(differs according to blade)
GD555, 655, 675-3A 30-111

(6)
DISASSEMBLY
AND ASSEMBLY REMOVAL OF CIRCLE DRAWBAR ASSEMBLY
REMOVAL OF CIRCLE DRAW- 4. Disconnect 2 motor hoses (11), 2 side cylinder

hoses (9), and 2 swivel hoses (10).
BAR ASSEMBLY
1. Remove blade assembly.
For details, see REMOVAL OF BLADE ASSEM-
BLY.
2. Operate drawbar side shift control lever, and
set center of drawbar to bottom surface of
front frame. Operate blade control lever to set
drawbar (1) horizontal, set stand under blade
mounting bracket, then lower blade. Remove
mounting bolts of cap (3) at bottom of side
shift cylinder (2), and disconnect cylinder (2)
from drawbar (1).
Remove mounting bolts of left and right caps
(5), and of blade cylinder rod (4), then discon-
5. Sling circle and drawbar, remove mounting
nect rod (4) from drawbar (1).
nut of mounting holder (13) of stud ball (12) at
tip of drawbar, raise circle drawbar assembly,
then remove from front frame.
4 Circle drawbar assembly:
Approx. 1250 kg
3. Disconnect hoses (6) and (7) of drawbar side

shift cylinder, and remove clamp (8).
and nipples.
30-112 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY INSTALLATION OF CIRCLE DRAWBAR ASSEMBLY
INSTALLATION OF CIRCLE 3. Install 2 side cylinder hoses (9), 2 swivel

hoses (10), and 2 motor hoses (11).
DRAWBAR ASSEMBLY ★ Install the clamp at right angles to the
hose so that there is no twisting.
1. Raise circle drawbar assembly and set in
position. Insert stud ball (12) at tip of drawbar
at front frame mount, install holder (13) and
shim (14) placed in front of ball, then tighten
nut to specified torque.
★ Types of shim: t = 0.29 mm x 16
Standard shim thickness: 4 - 4.64 mm
2 When assembling stud ball:
Coat with LM-P
2 After assembling stud ball:
Fill with G2-LI
3 Mounting nut:
588.4 - 1029.5 Nm {60 - 105 kgm}
4 Circle drawbar assembly:
4. Install side cylinder hoses (6) and (7), then
install clamp (8).
Approx. 1250 kg
5. Install blade assembly.

2. Install cap (3) of drawbar side shift cylinder (For details, see INSTALLATION OF BLADE
(2) to ball joint and tighten bolt to specified ASSEMBLY.)
torque. Install left and right caps (5) of blade
cylinder rod (4) to ball joint of drawbar (1) and
tighten bolt to specified torque.
2 Ball joint portion: Coat with LM-P
GD555, 655, 675-3A 30-113

(6)
DISASSEMBLY
AND ASSEMBLY REMOVAL OF BLADE CIRCLE ROTATION GEAR
REMOVAL OF BLADE CIRCLE 4. Raise lock plate of mounting bolt of pinion

gear (13) of circle rotation gear, loosen bolt,
ROTATION GEAR remove holder (14), shim (15), and joint (19)
then remove pinion gear (13).
1. Remove blade assembly. ★ When the bolt is removed, the pinion gear
(For details, see REMOVAL OF BLADE will fall under its own weight, so support
ASSEMBLY.) it by hand when removing.
2. Operate drawbar side shift control lever, and
set center of drawbar at bottom surface of
front frame. Operate blade control lever to set
drawbar (1) horizontal, set stand to match
height under blade mounting bracket, then
lower. Disconnect 2 hoses (3) of blade side
shift cylinder (2). Sling cylinder (2), remove
CWG10633
bottom bolt and washer, then lift off cylinder.
Loosen left and right mounting nuts of
adjuster (4) and remove. Loosen mounting
bolts of cover (5) and remove, then remove
rod (6).
and nipples.
4 Side shift cylinder assembly: 5. Sling circle rotation gear, loosen mounting
Approx. 50 kg bolts and adjustment bolts of circle rotating
guide (16), remove 6 guides (16), raise circle
gear (17), lower below drawbar (18), and
remove.
4 Circle rotation gear: Approx. 135 kg
3. Disconnect hoses (8) and (9) of power tilt cyl-

inder (7). Sling cylinder (7), then remove lock
plate and bolt of pins (10) and (11), and lift off
cylinder. Remove mounting bolts of cylinder
mounting bracket (12), then remove bracket.
4 Power tilt cylinder assembly:
Approx. 20 kg
30-114 GD555, 655, 675-3A

(6)
DISASSEMBLY
AND ASSEMBLY INSTALLATION OF BLADE CIRCLE ROTATION GEAR
INSTALLATION OF BLADE CIR- 3. Install power tilt cylinder mounting bracket

(12) with mounting bolts. Raise power tilt cyl-
CLE ROTATION GEAR inder (7), install to bracket (12), install pins
(10) and (11), fit lock plate, then tighten bolts
1. Raise circle rotation gear (17) to mounting to tightening torque. Install hoses (8) and (9).
4 Power tilt cylinder assembly:
position at bottom surface of drawbar (18).
Align mounting bolt position of circle rotating
guide (16), install 6 guides (16), and tighten Approx. 20 kg
temporarily. ★ After installing the bracket, put a stand
After adjust, tighten fully. that matches the height under the bottom
★ For details of method for adjusting circle, surface of the bracket.
see TESTING AND ADJUSTING.
★ After adjusting all parts, check that all
nuts and bolts are tightened to the speci-
fied tightening torque.
3 Guide mounting bolt: 490 – 608 Nm
{50 – 62 kgm}
2 Circle teeth, guide, top surface of cir-
cle, surface in contact with guide:
Coat with LM-P
4 Circle rotation gear: Approx. 135 kg
4. Install rod (6) to bracket (12). Install left and

right adjusters (4) to support (19) and rod (6)
of circle gear (17), then tighten nuts and
secure. Install 2 covers (5) to rod (6) and sup-
port (19). Raise blade side shift cylinder (2),
install bottom end to right adjuster (4), then
install 2 hoses (3).
4 Side shift cylinder: Approx. 50 kg
2. Install pinion gear (13), joint (19) of circle rota-

tion gear, install holder (14) and shim (15),
then tighten mounting bolts to specified
torque, bend lock plate of bolt securely, and
lock.
★ When installing the pinion gear, be care-
ful not to let it fall.
★ Types of shim: 0.2, 0.5, 1.0 mm
(shim thickness: 3 mm)
5. Install blade assembly.

(For details, see INSTALLATION OF BLADE
ASSEMBLY.)
★ After completion of the operation, check
CWG10633 that each component works properly.
GD555, 655, 675-3A 30-115

(6)
DISASSEMBLY
AND ASSEMBLY REMOVAL OF BLADE CIRCLE ROTATION GEAR
REMOVAL OF BLADE CIRCLE ROTATION GEAR

(WITH SHEAR PIN)
k Stop the engine and operate the circle rota- 4. Lift off circle gear assembly (3).
tion control lever to release the residual pres-
sure in the piping.
1. Disconnect 2 hoses (2) from circle motor (1).
★ Plug the removed hoses and nipples.
2. Drive out dowel pin (4) from underside and

CWG10635
remove the 4 mounting bolts of circle gear
assembly (3) from underside.
3. Remove holder (6) and shim (7), and then

remove joint (8) and pinion gear (9).
★ Raise lock plate (5) of the mounting bolts
of holder (6) and remove the mounting
bolts.
★ When removing the bolts, hold pinion
gear (9) with the hand so that it will not
fall.
★ Check the thickness and quantity of shims
(7).
CWG10634
30-116 GD555, 655, 675-3A

(4)
DISASSEMBLY
AND ASSEMBLY INSTALLATION OF BLADE CIRCLE ROTATION GEAR
INSTALLATION OF BLADE CIRCLE ROTATION GEAR

(WITH SHEAR PIN)
5. Install holder (6) with the mounting bolts and
3 Mounting bolt:
bend lock plate (5) securely.
911 – 1,029 Nm {93 – 105 kgm} 2 Plate (11), pinion gear, and contact
face of shaft:
Lubricant containing molybdenum
disulfide (LM-P)
2 Filling for part c at top of pinion gear:
1. Install pinion gear (9) and joint (8) and fix
them temporarily.
Grease (G2-LI)
2. Measure clearance b between the ends of
shaft (10) and joint (8), and then select shims
0.1 – 0.5 mm thicker than b.
• Standard shim thickness: 3 mm
• Kinds of shim thickness: 0.2, 0.5, 1.0 mm
3. Make clearance a of the same dimension CWG10637

between plate (11) and pinion gear (9).
CWG10636
4. Install pinion gear (9), joint (8), and shim (7) in

order.
GD555, 655, 675-3A 30-117

(4)
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY OF CIRCLE ROTATION GEAR
DISASSEMBLY OF CIRCLE ROTATION GEAR

(WITH SHEAR PIN)
1. Draining oil 5. Worm gear and bearing assembly

Remove the drain plug and drain the oil from 1) Remove worm gear and bearing assem-
the circle rotation gear case. bly (9).
6 Quantity of oil: Approx. 4 l
2. Disconnection of circle rotation gear

and motor
Remove mounting bolts (2) and disconnect
circle rotation gear assembly (3) and motor
assembly (4).
+ Take care not to drop or lose the motor
shaft key.
3. Cover
Remove cover (5).
2) Remove 2 bearings (11) from shaft (10).
CWG10638
.
4. Housing
Remove housing (7) and shim (8) from case
(6).
+ Check the thickness and quantity of shims 6. Worm wheel shaft assembly
(8). 1) Remove worm wheel shaft assembly (12).
+ Remove washer (18).
30-118 GD555, 655, 675-3A

(4)
DISASSEMBLY
2) Remove gear (14) from shaft (13).

+ Remove washer (17).
GD555, 655, 675-3A 30-119

(4)
DISASSEMBLY
AND ASSEMBLY ASSEMBLY OF CIRCLE ROTATION GEAR
ASSEMBLY OF CIRCLE ROTATION GEAR

(WITH SHEAR PIN)
1. Worm gear and bearing assembly

1) Press fit 2 bearings (11) to worm gear
(10).
3. Worm wheel shaft assembly

1) Using push tool kits (70 mm and 73 mm),
press fit bushing (15) to case (6).
2) Install worm gear and bearing assembly 2) Using push tool kit (85 mm), press fit oil
(9) to case (6). seal (16).
2 Oil seal lip: Grease (G2-LI)
2. Housing
1) Set the O-ring to housing (7) and install
them to the case, inserting shim (8). 3) Install gear (14) to shaft (13).
+ Adjust the shim so that the rotating + Install washer (17).
torque of the worm shaft will be 2.94 –
7.8 Nm {0.3 – 0.8 kgm} to give a pre-
load to the bearing.
+ When measuring the rotating torque,
check that the worm gear is not
meshed with the worm wheel gear.
• Kinds of shim thickness: 0.1 mm, 0.2
mm, 1.0 mm
2) Check the quantity of the shims, loosen
the bolts on the housing side, and pull the
housing out of the case a little.
+ Remove the worm gear and bearing
assembly from the outer race of the
bearing.
30-120 GD555, 655, 675-3A

(4)
DISASSEMBLY
4) Install worm wheel shaft assembly (12).

★ Matching the teeth of the worm wheel
gear and worm wheel, tighten the
nuts on the housing side.
★ Install washers (17) and (18) to the top
and bottom of the worm wheel shaft
assembly.
6. Cover
Set the O-ring and install cover (5).
2 Bolts at 2 through parts of case tap on
worm gear side: Adhesive (LT-2)
4. Connection of circle rotation gear and

motor assembly
Matching circle rotation gear (3) and motor
assembly (4), install mounting bolts (2).
★ Install the key to the motor assembly
shaft.
★ Install cover (5) so that oil filler plug (19)

CWG10638 will be positioned as shown in the illustra-
tion.
3 Oil filler plug: 73.55 – 122.58 Nm
{7.5 – 12.5 kgm}
5. Refilling with oil

Tighten drain plug (1) and add gear oil to the
specified level.
5 Circle rotation gear case: 4 l
3 Drain plug:
32.36 – 44.13 Nm {3.3 – 4.5 kgm}
GD555, 655, 675-3A 30-121

(4)
DISASSEMBLY
DISASSEMBLY OF CIRCLE ROTATION GEAR

(WITH SLIP CLUTCH)
1. Remove 2 hoses (2) of circle motor (1). Knock 3. Install eyebolt to circle rotation gear assem-
out 2 dowel pins (4) of circle rotation gear bly (3), then raise and set on strong, stable
from bottom. Remove 6 mounting bolts of stand. Loosen 4 mounting bolts of circle
circle rotation gear from bottom. motor (1) and remove motor. Loosen 8
★ Fit male and female plugs into the hoses mounting bolts of cover (8) of circle rotation
and nipples. gear assembly (3), then remove cover.
4 Circle rotation gear assembly:
Approx. 125 kg
2. Raise stopper plates for mounting bolts of

lock plate (6) and pinion gear, then remove
bolts. Remove lock plate (6) and take out pin-
ion gear (5). It will fall out, so remove it 4. Pull out 8 mounting bolts of housing (9), then
using 2 forcing screws (10), remove housing.
quickly.
★ When raising the lock plate, support the
pinion gear by hand to prevent it from
falling out when it is removed.
5. Remove 3 bolts of circle gear shaft, then

remove plate (11) and collar (12). Remove 4
mounting nuts of worm gear bearing cage
(13), then remove cage together with shim.
30-122 GD555, 655, 675-3A

(6)
DISASSEMBLY
6. Install eyebolts to circle gear shaft (14), and 9. Remove worm gear (19) from gear case, then
lift off gear assembly. Remove belleville remove 2 left and right bearings (20). Turn
spring (15) and collar (16). over gear case, remove oil seal (21), then
remove bushing (22).
7. Remove 5 plates (18) and 6 discs (19) from cir-

cle gear (17) in order.
8. Separate circle gear (17) and shaft (14).

Remove spacer (18) under shaft.
GD555, 655, 675-3A 30-123

(4)
DISASSEMBLY
ASSEMBLY OF CIRCLE ROTATION GEAR

(WITH SLIP CLUTCH)
1. Press fit bushing (22) to circle gear insertion 4. Press fit bearing (20) to worm gear (19).
portion of gear case. Turn over gear case and
press fit oil seal (21).
+ Coat the shaft seal surface of seal (21)
with G2-LI and bushing (22) with LM-P.
5. Assemble worm gear (19) to gear case.
2. Assemble circle gear (17), shaft (14), and

spacer (18).
6. Install bearing cage (13) to gear case.
3. Assemble plates (18) and discs (19) to circle

gear (17) in order.
+ NOTICE: When assembling, coat the
whole surface of the discs (front and rear
faces) with GO#90 oil.
30-124 GD555, 655, 675-3A

(4)
DISASSEMBLY
7. Install nuts to mounting bolts of bearing cage 9. Install collar (12), then install bolts to housing
(13), set to condition where shim (23) adjust- (9), and tighten to specified torque. Assemble
ment is possible, then adjust shim and shim (25).
tighten nut. ★ Types of shim: 0.2, 0.5 mm
★ To apply the preload to the bearing,
adjust with shims so that the friction
torque of the worm shaft is 2.9 – 7.85 Nm
{0.3 – 0.8 kgm}.
When measuring the rotating torque, the
worm and worm wheel must not be
meshed (measure before assembling
worm and worm wheel).
★ Types of shim: 0.1, 0.2, 1.0 mm
(Shim adjustment: 1.65 mm)
10. Install lock plate (11) to gear shaft, and

tighten 3 bolts to specified torque. Install
gear case cover (8), then install bolt and
tighten to specified torque.
★ When installing cover (8), set position of
oil filler plug (26) at oil level gauge side of
gear case (rear of machine), then install.
Make sure that oval hole in housing (9) is
aligned. If it is not aligned, change
mounting position of cage (9).
8. Install plate (18) and belleville spring (15) to
circle gear (17), then install lifting tool to
shaft, raise gear assembly, and assemble to
gear case. Using forcing screws, hold hous-
ing (9), and install to gear case.
★ When installing housing (9), set with oval
hole (24) in housing facing oil level gauge
side of gear case (rear of machine), then
install. (Relationship with oil filler plug)
2 Only 2 mounting bolts of cover at
case tap hole:
Coat with thread tightener (LT-2)
11. Assemble circle motor (1) to worm gear, and

tighten 4 mounting bolts to specified torque.
★ Install the gear case securely to the motor
before installing.
GD555, 655, 675-3A 30-125

(6)
DISASSEMBLY
12. Raise circle gear assembly and install to 13. Knock in 2 dowel pins (4), and install 2 hoses
drawbar, then install pinion gear (5) from bot- (2) to circle motor (1). Tighten drain plug,
tom, install shim (27) and lock plate (6) with 2 remove oil filler plug (26), then fill with oil.
bolts, install stopper plate (7) to bolt, then After filling with oil, tighten fully.
tighten to specified torque. ★ After knocking in the dowel pin, caulk the
★ Bend lock plate (7) fully to lock in position, circumference at 2 places.
then tighten mounting bolts of rotation ★ When adding oil, set the rotating gear
assembly to specified tightening torque. horizontal, and add oil until oil comes out
★ When installing the pinion gear, be care- from level plug hole.
3 Drain plug: 32.36 – 44.13 Nm
ful not to drop it.
★ Types of shim at pinion gear portion:
{3.3 – 4.5 kgm}
3 Oil filler plug: 73.5 – 122.6 Nm
0.2, 0.5, 1.0 mm (Standard: 3.0 mm).
3 4 bolts at dowel pin mounts at
{7.5 – 12.5 kgm}
5
front and rear of machine:
911.4 – 1029 Nm {93 – 105 kgm} GO #90: Approx. 7 l
3 2 bolts at left and right of
machine:
490.3 - 608 Nm {50 - 62 kgm}
★ For details of the procedure for adjusting

the slip clutch, see TESTING AND
ADJUSTING
30-126 GD555, 655, 675-3A

(6)
90 OTHERS
Transmission hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-2

Brake oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
Hydraulic circuit diagram (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5
Hydraulic circuit diagram (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7
Electrical circuit diagram (1/6) (Serial No.: 10001 – 11000) . . . . . . . . . . . . . . . . . . . . . . . 90-9
Electrical circuit diagram (2/6) (Serial No.: 10001 – 11000) . . . . . . . . . . . . . . . . . . . . . . 90-11
Electrical circuit diagram (1/6) (Serial No.: 11001 and up) . . . . . . . . . . . . . . . . . . . . . . . 90-21
GD555, 655, 675-3A 90-1

(3)
OTHERS TRANSMISSION HYDRAULIC CIRCUIT
TRANSMISSION HYDRAULIC CIRCUIT
90-2 GD555, 655, 675-3A

OTHERS TRANSMISSION HYDRAULIC CIRCUIT
1. Transmission case
2. Strainer
3. Transmission pump
4. Oil filter
5. Main relief valve
6. Torque converter relief valve
7. Torque converter
8. Oil cooler
9. Transmission lubrication
10. PTO lubrication
11. Last chance filter
12. Lock-up clutch ECMV
13. FL clutch ECMV
14. R clutch ECMV
15. FH clutch ECMV
16. 1st clutch ECMV
17. 2nd clutch ECMV
18. 3rd clutch ECMV
19. 4th clutch ECMV
20. Fill switch
21. Pressure control valve
22. Lock-up clutch
23. FL clutch
24. R clutch
25. FH clutch
26. 1st clutch
27. 2nd clutch
28. 3rd clutch
29. 4th clutch
30. FL clutch lubrication dividing piston
31. R clutch lubrication dividing piston
32. FH clutch lubrication dividing piston
33. FL cllutch lubrication
34. R clutch lubrication
35. FH clutch lubrication
GD555, 655, 675-3A 90-3

(3)
OTHERS BRAKE OIL CIRCUIT
BRAKE OIL CIRCUIT
SWG00994
1. Hydraulic tank 8. Brake cylinder (front)

2. Main pump 9. Slack adjuster (rear)
3. Priority valve + Accumulator charge valve 10. Brake cylinder (rear)
4. Check valve 11. Accumulator (rear, parking brake)
5. Accumulator (front) 12. Parking and bank control valve
6. Brake valve 13. Parking brake
7. Slack adjuster (front)
90-4 GD555, 655, 675-3A

HYDRAULIC CIRCUIT DIAGRAM (1/2)
GD555, 655, 675-3A 90-5

(7)
HYDRAULIC CIRCUIT DIAGRAM (2/2)
1. For GD655, 675-3A: Serial No. 10001 – 11000

2. For GD655, 675-3A: Serial No. 11001 and up
GD555, 655, 675-3A 90-7

(3)
ELECTRICAL CIRCUIT DIAGRAM (1/6) (Serial No.: 10001 – 11000)
GD555, 655, 675-3A 90-9

(3)
GD555, 655, 675-3A 90-11

(3)
GD555, 655, 675-3A 90-13

(3)
GD555, 655, 675-3A 90-15

(3)
GD555, 655, 675-3A 90-17

(3)
GD555, 655, 675-3A 90-19

(3)
ELECTRICAL CIRCUIT DIAGRAM (1/6) (Serial No.: 11001 and up)
GD555, 655, 675-3A 90-21

(3)
GD555, 655, 675-3A 90-23

(3)
GD555, 655, 675-3A 90-25

(3)
GD555, 655, 675-3A 90-27

(3)
GD555, 655, 675-3A 90-29

(3)
GD555, 655, 675-3A 90-31

(3)

Machine Model Serial Number: GD555-3A 10001 and Up GD655-3A 10001 and Up GD675-3A 10001 and Up

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Machine Model Serial Number: GD555-3A 10001 and Up GD655-3A 10001 and Up GD675-3A 10001 and Up

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SEBM021010

MACHINE MODEL SERIAL NUMBER

GD655-3A 00 10001 and up 00

GD675-3A 00 10001 and up 00

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD. 10-1

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

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

00-2 GD555, 655, 675-3A

Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

Revision Revision Revision Revision Revision

GD555, 655, 675-3A 00-2-1

00-2-2 GD555, 655, 675-3A

GD555, 655, 675-3A 00-2-3

Important safety notice

16. When removing components, be careful not to

17. When removing piping, stop the fuel or oil from

18. As a general rule, do not use gasoline to wash

Structure and function

Testing and adjusting

Disassembly and assembly

How to read the shop manual Revised edition mark

3. Additional pages: Additional pages are indi-

• If a part cannot be smoothly removed from the

Method of disassembling, connecting push-pull type coupler

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rubber

Standard tightening torque

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

Table of tightening torques for flared nuts

Thread diameter Width across flats Tightening torque

Table of tightening torques for flared nuts

Thread diameter Width across flats Tightening torque

Table of tightening torques for o-ring boss piping joints

Thread diameter Width across flats Tightening torque (Nm {kgm})

Table of tightening torques for o-ring boss plugs

Thread diameter Width across flats Tightening torque (Nm {kgm})

Tightening torque for 102 and 114 engine series

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

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

Electric wire code

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

Classification by color and code

Millimeters to inches (B)

Liter to U.S. Gallon

Liter to U.K. Gallon

–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0