Shop Manual GD555-3C

SEBM020908
MACHINE MODEL SERIAL NUMBER

GD555-3C 00 50001 and up 00
GD655-3C 00 50001 and up 00
GD675-3C 00 50001 and up 00
• This shop manual may contain attachments and optional equipment that are not avail-
able in your area. Please consult your local Komatsu distributor for those items you
may require.
Materials and specifications are subject to change without notice.
• GD555-3C mounts the SA6D102E-1 or SAA6D102E-2 engine.
GD655-3C, GD675-3C mount the S6D114E-1, SA6D114E-1 or SAA6D114E-2 engine.
For details of the engine, see the 102 Series Engine Shop Manual and the 114 Series
Engine Shop Manual.
© 2006
All Rights Reserved 00-1
Printed in Japan 03-06 (01) (8)
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, 675-3C

(4)
The affected pages are indicated by using the following Mark Indication Action Required
marks. It is requested that necessary actions be taken to
New page to be added Add
these pages according to the table below.
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 (8) 10-1 (8) 10-46 (4) 10-98 (4) 10-147 (8)
00-2 (4) 10-2 (4) 10-47 (4) 10-99 (4) 10-148 (8)
00-2-1 (8) 10-3 (4) 10-48 (4) 10-100 (8) 10-149 (8)
00-2-2 (8) 10-4 (4) 10-49 (4) 10-101 (4) 10-150 (8)
00-2-3 (8) 10-5 (4) 10-50 (4) 10-102 (4) 10-152 (8)
00-3 10-6 (6) 10-52 (4) 10-103 (4) 10-153 (8)
00-4 10-7 (4) 10-53 (4) 10-104 (4) 10-154 (8)
00-5 10-7-1 (6) 10-54 (4) 10-105 (4) 10-155 (4)
00-6 10-7-2 (6) 10-55 (4) 10-106 (4) 10-156 (8)
00-7 10-8 (4) 10-56 (4) 10-107 (4) 10-157 (4)
00-8 10-9 (4) 10-58 (4) 10-108 (4) 10-158 (8)
00-9 10-10 (4) 10-59 (4) 10-110 (8) 10-159 (4)
00-10 10-11 (4) 10-60 (4) 10-111 (7) 10-160 (8)
00-11 10-12 (4) 10-61 (4) 10-112 (8) 10-161 (8)
00-12 10-13 (4) 10-62 (4) 10-113 (8) 10-162 (8)
00-13 10-14 (4) 10-64 (4) 10-114 (4) 10-163 (4)
00-14 10-15 (7) 10-65 (4) 10-115 (4) 10-164 (8)
00-15 10-16 (4) 10-66 (4) 10-116 (8) 10-165 (4)
00-16 10-17 (4) 10-68 (4) 10-117 (8) 10-166 (8)
00-17 10-18 (4) 10-69 (4) 10-118 (8) 10-167 (8)
00-18 10-19 (4) 10-71 (6) 10-119 (8) 10-169 (4)
00-19 10-20 (4) 10-72 (4) 10-120 (8) 10-170 (4)
00-20 10-21 (4) 10-73 (4) 10-121 (8) 10-171 (4)
00-21 10-22 (4) 10-74 (6) 10-122 (8) 10-173 (7)
00-22 10-23 (4) 10-75 (7) 10-123 (8) 10-174 (4)
10-24 (4) 10-76 (4) 10-124 (4) 10-175 (4)
10-25 (4) 10-77 (4) 10-125 (4) 10-177 (4)
01-1 (4) 10-26 (4) 10-78 (4) 10-126 (4) 10-178 (4)
01-2 (4) 10-27 (4) 10-79 (4) 10-127 (4) 10-179 (4)
01-3 (4) 10-28 (4) 10-80 (4) 10-128 (4) 10-181 (4)
01-4 (4) 10-29 (4) 10-81 (4) 10-129 (4) 10-182 (4)
01-5 (4) 10-30 (4) 10-82 (4) 10-130 (4) 10-183 (4)
01-6 (4) 10-31 (4) 10-83 (4) 10-132 (4) 10-185 (4)
01-7 (4) 10-32 (4) 10-84 (4) 10-133 (4) 10-186 (4)
01-8 (4) 10-33 (4) 10-85 (8) 10-134 (4) 10-187 (4)
01-9 (4) 10-34 (4) 10-86 (8) 10-135 (4) 10-188 (8)
01-10 (4) 10-35 (4) 10-87 (8) 10-136 (4) 10-189 (8)
01-11 (4) 10-36 (4) 10-88 (8) 10-137 (4) 10-190 (8)
01-12 (4) 10-37 (4) 10-89 (8) 10-138 (4) 10-191 (8)
01-13 (4) 10-38 (4) 10-90 (8) 10-139 (4) 10-192 (8)
01-14 (4) 10-39 (4) 10-91 (8) 10-140 (4) 10-193 (8)
01-15 (4) 10-40 (4) 10-92 (8) 10-141 (4) 10-194 (8)
01-16 (4) 10-41 (4) 10-93 (8) 10-142 (4) 10-195 (8)
01-17 (4) 10-42 (4) 10-94 (4) 10-143 (4) 10-196 (8)
01-18 (4) 10-43 (4) 10-95 (4) 10-144 (4) 10-197 (8)
10-44 (4) 10-96 (4) 10-145 (4) 10-198 (8)
10-45 (4) 10-97 (4) 10-146 (8) 10-199 (8)
GD555, 655, 675-3C 00-2-1

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10-200 (4) 10-264 (4) 20-125 (4) 20-248 (4) 20-380 (4)
10-201 (4) 10-265 (4) 20-126 (4) 20-249 (4) 20-381 (4)
10-202 (4) 10-266 (4) 20-127 (4) 20-250 (4) 20-382 (4)
10-203 (4) 10-267 (4) 20-128 (4) 20-251 (4) 20-383 (4)
10-204 (4) 10-268 (4) 20-129 (4) 20-252 (4) 20-384 (4)
10-205 (8) 10-269 (4) 20-130 (4) 20-253 (4) 20-385 (4)
10-206 (8) 10-270 (4) 20-131 (4) 20-254 (4) 20-386 (4)
10-207 (8) 10-271 (4) 20-132 (4) 20-255 (4) 20-387 (4)
10-208 (4) 10-272 (4) 20-133 (4) 20-388 (4)
10-209 (4) 10-273 (4) 20-134 (4) 20-301 (4) 20-389 (4)
10-210 (4) 10-274 (4) 20-135 (4) 20-302 (4) 20-390 (4)
10-212 (4) 20-136 (4) 20-303 (4) 20-391 (4)
10-213 (4) 20-304 (4) 20-392 (4)
10-214 (4) 20-1 (4) 20-201 (4) 20-305 (4) 20-393 (4)
10-215 (4) 20-2 (4) 20-202 (4) 20-306 (4) 20-394 (4)
10-216 (4) 20-3 (4) 20-203 (4) 20-307 (4) 20-395 (4)
10-217 (4) 20-4 (4) 20-204 (4) 20-308 (4) 20-396 (4)
10-218 (4) 20-5 (4) 20-205 (4) 20-309 (4) 20-397 (4)
10-219 (4) 20-6 (4) 20-206 (4) 20-310 (4) 20-398 (4)
10-221 (4) 20-7 (4) 20-207 (4) 20-311 (4) 20-399 (4)
10-222 (4) 20-8 (4) 20-208 (4) 20-312 (4) 20-400 (4)
10-223 (4) 20-9 (4) 20-209 (4) 20-313 (4) 20-401 (4)
10-224 (4) 20-10 (4) 20-210 (4) 20-314 (4) 20-402 (4)
10-225 (4) 20-11 (4) 20-211 (4) 20-315 (4) 20-403 (4)
10-226 (4) 20-12 (4) 20-212 (4) 20-316 (4) 20-404 (4)
10-227 (4) 20-13 (4) 20-213 (4) 20-317 (4) 20-405 (4)
10-228 (4) 20-14 (4) 20-214 (4) 20-318 (4) 20-406 (4)
10-229 (4) 20-15 (4) 20-215 (4) 20-319 (4) 20-407 (4)
10-230 (4) 20-16 (4) 20-216 (4) 20-320 (4) 20-408 (4)
10-231 (4) 20-17 (4) 20-217 (4) 20-321 (4) 20-409 (4)
10-232 (4) 20-18 (4) 20-218 (4) 20-410 (4)
10-233 (4) 20-19 (4) 20-219 (4) 20-351 (4) 20-411 (4)
10-234 (4) 20-20 (4) 20-220 (4) 20-352 (4) 20-412 (4)
10-236 (4) 20-21 (4) 20-222 (4) 20-354 (4) 20-413 (4)
10-237 (4) 20-223 (4) 20-355 (4) 20-414 (4)
10-238 (4) 20-101 (4) 20-224 (4) 20-356 (4) 20-415 (4)
10-239 (4) 20-102 (4) 20-225 (4) 20-357 (4) 20-416 (4)
10-240 (4) 20-103 (7) 20-226 (4) 20-358 (4) 20-417 (4)
10-242 (4) 20-104 (4) 20-227 (4) 20-359 (4) 20-418 (4)
10-243 (4) 20-105 (4) 20-228 (4) 20-360 (4) 20-419 (4)
10-244 (4) 20-106 (4) 20-229 (4) 20-361 (4) 20-420 (4)
10-245 (4) 20-107 (7) 20-230 (4) 20-362 (4) 20-421 (4)
10-247 (4) 20-108 (7) 20-231 (4) 20-363 (4) 20-422 (4)
10-248 (4) 20-109 (4) 20-232 (4) 20-364 (4) 20-423 (4)
10-249 (4) 20-110 (4) 20-233 (4) 20-365 (4) 20-424 (4)
10-250 (4) 20-111 (4) 20-234 (4) 20-366 (4) 20-425 (4)
10-251 (4) 20-112 (4) 20-235 (4) 20-367 (4) 20-426 (4)
10-252 (4) 20-113 (4) 20-236 (4) 20-368 (4) 20-427 (4)
10-253 (4) 20-114 (4) 20-237 (4) 20-369 (4) 20-428 (4)
10-254 (4) 20-115 (4) 20-238 (4) 20-370 (4) 20-429 (4)
10-255 (4) 20-116 (4) 20-239 (4) 20-371 (4) 20-430 (4)
10-256 (4) 20-117 (4) 20-240 (4) 20-372 (4) 20-431 (4)
10-257 (4) 20-118 (4) 20-241 (4) 20-373 (4)
10-258 (4) 20-119 (4) 20-242 (4) 20-374 (4) 20-451 (4)
10-259 (4) 20-120 (4) 20-243 (4) 20-375 (4) 20-452 (4)
10-260 (4) 20-121 (4) 20-244 (4) 20-376 (4) 20-453 (4)
10-261 (4) 20-122 (4) 20-245 (4) 20-377 (4) 20-454 (4)
10-262 (4) 20-123 (4) 20-246 (4) 20-378 (4) 20-455 (4)
10-263 (4) 20-124 (4) 20-247 (4) 20-379 (4) 20-456 (4)
00-2-2 GD555, 655, 675-3C

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20-457 (4) 30-22 (5) 30-81 (5) 30-140 (5)
20-458 (4) 30-23 (5) 30-82 (5) 30-141 (5)
20-459 (4) 30-24 (5) 30-83 (5)
20-460 (4) 30-25 (5) 30-84 (5)
20-461 (4) 30-26 (5) 30-85 (5) 90-1 (4)
20-462 (4) 30-27 (5) 30-86 (5) 90-3 (4)
20-463 (4) 30-28 (5) 30-87 (5) 90-5 (4)
30-29 (5) 30-88 (5) 90-7 (4)
20-501 (4) 30-30 (5) 30-89 (5) 90-9 (8)
20-502 (4) 30-31 (5) 30-90 (5) 90-11 (4)
20-503 (4) 30-32 (5) 30-91 (5) 90-13 (4)
20-504 (4) 30-33 (5) 30-92 (5) 90-15 (4)
20-505 (4) 30-34 (5) 30-93 (5) 90-17 (4)
20-506 (4) 30-35 (5) 30-94 (5) 90-19 (4)
20-507 (4) 30-36 (5) 30-95 (5) 90-21 (4)
20-508 (4) 30-37 (5) 30-96 (5) 90-23 (4)
20-509 (4) 30-38 (5) 30-97 (5) 90-25 (4)
20-510 (4) 30-39 (5) 30-98 (5) 90-27 (4)
20-511 (4) 30-40 (5) 30-99 (5) 90-29 (4)
20-512 (4) 30-41 (5) 30-100 (5) 90-31 (4)
20-513 (4) 30-42 (5) 30-101 (5) 90-33 (4)
20-514 (4) 30-43 (5) 30-102 (5) 90-35 (4)
20-515 (4) 30-44 (5) 30-103 (5)
20-516 (4) 30-45 (5) 30-104 (5)
20-517 (4) 30-46 (5) 30-105 (5)
20-518 (4) 30-47 (5) 30-106 (5)
20-519 (4) 30-48 (5) 30-107 (5)
20-520 (4) 30-49 (5) 30-108 (5)
20-521 (4) 30-50 (5) 30-109 (5)
20-522 (4) 30-51 (5) 30-110 (5)
20-523 (4) 30-52 (5) 30-111 (5)
20-524 (4) 30-53 (5) 30-112 (5)
20-525 (4) 30-54 (5) 30-113 (5)
20-526 (4) 30-55 (5) 30-114 (5)
20-527 (4) 30-56 (5) 30-115 (5)
20-528 (4) 30-57 (5) 30-116 (5)
20-529 (4) 30-58 (5) 30-117 (5)
30-59 (5) 30-118 (5)
30-60 (5) 30-119 (5)
30-1 (5) 30-61 (5) 30-120 (5)
30-2 (5) 30-62 (5) 30-121 (5)
30-3 (5) 30-63 (5) 30-122 (5)
30-4 (5) 30-64 (5) 30-123 (5)
30-5 (5) 30-65 (5) 30-124 (5)
30-6 (5) 30-66 (5) 30-125 (5)
30-8 (5) 30-67 (5) 30-126 (5)
30-9 (5) 30-68 (5) 30-127 (5)
30-10 (5) 30-69 (5) 30-128 (5)
30-11 (5) 30-70 (5) 30-129 (5)
30-12 (5) 30-71 (5) 30-130 (5)
30-13 (5) 30-72 (5) 30-131 (5)
30-14 (5) 30-73 (5) 30-132 (5)
30-15 (5) 30-74 (5) 30-133 (5)
30-16 (5) 30-75 (5) 30-134 (5)
30-17 (5) 30-76 (5) 30-135 (5)
30-18 (5) 30-77 (5) 30-136 (5)
30-19 (5) 30-78 (5) 30-137 (5)
30-20 (5) 30-79 (5) 30-138 (5)
30-21 (5) 30-80 (5) 30-139 (5)
GD555, 655, 675-3C 00-2-3

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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
available. Special safety precautions
k 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.
Places to be coated with
2
Item number Coat adhesives and lubricants,
(10. Structure and Function) etc.
Consecutive page number for
Places where oil, water or
5
each item.
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 SELECTION......................................................................................01- 17
GD555, 655, 675-3C 01-1

(4)
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING
(Unit: mm)
Item GD555-3C GD655-3C GD675-3C
A Overall length 8,350 8,595 8,611
Overall height (with full height cab) 3,330 3,350 3,350
B
Overall height (with low height cab) 3,100 3,120 3,120
C Overall width 2,525 2,550 2,550
01-2 GD555, 655, 675-3C

(4)
GENERAL SPECIFICATIONS
SPECIFICATIONS
GD555-3C
GD555-3C
Machine Model
VHP Engine
Serial Number 50001 – 51000 51001 and up
Machine weight 13,850 14,040
On front axle kg 3,950 4,000
On rear axle 9,900 10,040
Overall length 8,370 8,350
Overall width 2,525
Overall height (top of muffler) 2,980
Dimensions
Overall height (with ROPS cab) 3,100

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
6th 21.6
Travel speed
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} 77.7 {7,920} 78.7 {8,030}
Gradeability deg. 24
Min. Turning radius m 6.8
Static stability deg. 35
• VHP engine: Variable horsepower engine.
GD555, 655, 675-3C 01-3

(4)
GD555-3C
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}
Engine
Nm/rpm 606.3 to 741.6/1,400 575.4 to 728.6/1,500

Performance
Maximum torque
{kgm/rpm} {60.9 to 74.5/1,400} {58.7 to 74.3/1,500}
Max. speed at no load rpm 2,200 2,200
Min. speed at no load rpm 800 850
g/kWh 229.4 to 232.4 214.3
Fuel consumption 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
Automatic shifting, wet-type clutch
Multiple shaft
Power 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-row chain drive
Type Reverse Elliott, angle type
Front axle
Max. leaning angle deg. 16

Steering
Type Fully hydraulic type

Steering system
Steering angle deg. 49
Articulate angle deg. 23
01-4 GD555, 655, 675-3C

(4)
GD555-3C
Machine Model
VHP Engine
Serial Number 50001 and up
Tires (front) 13.00-24-10PR
Tires (rear) 13.00-24-10PR
Steering, operating
Tires
kPa
Inflation pressure (front) 275 {2.75}
{kg/cm2}
system
kPa
Inflation pressure (rear) 275 {2.75}
{kg/cm2}
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
MPa
Set pressure 206 {210}
{kg/cm2}
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

Hydraulic system
Cylinder bore mm 50 70 90
Piston rod outside diameter mm 35 35 50
Piston stroke mm 330 160 325
Blade Blade Blade Drawbar

Ripper
Type lift side shift tilt side shift
Double-acting piston type
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
Type
Cylinder bore mm 80
Piston rod outside diameter mm 50
Piston stroke mm 345
GD555, 655, 675-3C 01-5

(4)
Machine Model GD555-3C

Blade dimension (Length x Height x Thickness) 3,660 x 660 x 22
Cutting edge dimension
1,830 x 153 x 16 – 2
(Length x Width x Thickness – Number)
mm
Max. lift above ground 460
Max. cutting depth 635
Blade base 2,500
Blade
Blade load kN {kg} 68 {6,939} 68.5 {6,985}

Turning angle (with scarifier) deg. 360 (130)
Max. side shift distance (left) 625
mm
Max. side shift distance (right) 625
Cutting angle —
[Standard] deg. 37
[Adjustable] 32 to 81
01-6 GD555, 655, 675-3C

(4)
GD655-3C
GD655-3C
Machine Model Standard HP
VHP Engine
Engine
On rear axle 10,580 10,730
Overall length 8,595
Overall width 2,550
Overall height
3,120
Dimensions
(with ROPS cab)

Wheel base mm 6,070
Distance between centers of
1,535
tandem wheels
Tread (Front) 2,130
Tread (Rear) 2,130
1st 3.3
2nd 4.7
3rd 6.7
Forward
4th 9.7
km/h
5th 14.6
Travel speed
6th 21.2
7th 29.1
Performance
8th 42.1
1st 4.3 4.3
Reverse
2nd 8.8 8.8

km/h
3rd 18.1 18.1
4th 35.1 38.4
GD555, 655, 675-3C 01-7

(4)
GD655-3C
Machine Model Standard HP
VHP Engine
Engine
S6D114E-1 SA6D114E-1
Engine model SAA6D114E-2
Standard VHP
4-cycle, water 4-cycle, water cooled,
cooled, overhead valve,
overhead valve, direct-injection type
Type direct-injection type with turbocharger
Cylinder number
mm 6 - 114 x 135
- bore x stroke
Flywheel horse- kW/rpm 123/1,900 123.3 to 141.7/1,900
power {HP/rpm} {165/1,900} {165 to 190/1,900}
Engine
794.3 to 913.0/ 749.7 to 926.2/

Nm/rpm 793.4/1,300
Maximum torque 1,300 1,400
{kgm/rpm} {80.9/1,300}
Performance
{81.0 to 93.1/1,300} {76.4 to 94.4/1,400}

Max. speed at
rpm 2,200
no load
Min. speed at
rpm 800
no load
Fuel consumption g/kWh 159 218
ratio {g/HPh} {213.2} {162.8}
Starting motor 24 V, 7.5 kW 24 V, 7.5 kW
Alternator 24 V, 50 A 24 V, 60 A
Battery 12 V, 112 Ah x 2 12 V, 112 Ah x 2
Radiator type CF19-4 CF19-5
Torque converter
Multiple shaft
Power train

Transmission
Front
axle
Max. leaning
16
angle
Steering

Steering
system

01-8 GD555, 655, 675-3C

(4)
GD655-3C
Machine Model
Standard HP Engine VHP Engine
Steering, operating
Tires
kPa
{kg/cm2}
system
kPa
{kg/cm2}
Brakes

Hydraulic pump
Discharge at rated rpm l/min. 194
MPa
{kg/cm2}
Control valve


Hydraulic system

Ripper

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

(4)

1,829 x 153 x 16 – 2
mm
Blade base 2,600
Blade
Blade load kN {kg} 72.4 {7,378} 73.2 {7,469}

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

(4)
GD675-3C
GD675-3C
Machine Model
VHP Engine
On rear axle 11,150 11,310
Overall length 8,620 8,595
Overall width 2,550
Dimensions
Overall height (with ROPS cab) 3,115

Wheel base mm 6,070
Distance between centers of tandem wheels 1,535
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
2nd 8.8
Reverse km/h
3rd 18.1
4th 35.1
GD555, 655, 675-3C 01-11

(4)
GD675-3C
Machine Model
VHP Engine
Engine model SA6D114E-1 SAA6D114E-2
4-cycle, water cooled,
overhead valve,
Type
direct-injection type
Cylinder number - bore x stroke mm 6 - 114 x 135
kW/rpm 134.2 to 149.2/1,900
Flywheel horsepower
{HP/rpm} {180 to 200/1,900}
Engine
Nm/rpm 856.2 to 974.8/1,300 785 to 974.6/1,400

Performance
Maximum torque
{kgm/rpm} {86.1 to 98.0/1,300} {80.0 to 99.4/1,400}
Max. speed at no load rpm 2,200
Min. speed at no load rpm 800
g/kW•h 236.5 to 237.6 218.1
Fuel consumption ratio
{g/HP•h} {176.4 to 177.2} {162.7}
Starting motor 24V, 7.5 kW 24V, 7.5kW
Alternator 24V, 50A 24V, 60A
Battery 12V, 112Ah x 2 12V, 112Ah x 2
Radiator type CF19-4 CF19-5
Torque converter
Multiple shaft
Power train

Transmission
Front axle
Max. leaning angle 16

Steering

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

(4)
GD675-3C
Machine Model
VHP Engine
Steering, operating
Tires
kPa
{kg/cm2}
system
kPa
{kg/cm2}
Brakes

Hydraulic pump
Discharge at rated rpm l/min. 194
MPa
{kg/cm2}
Control valve


Hydraulic system

Ripper

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

(4)

1,830 x 153 x 16 – 2
mm
Blade base 2,600
Blade
Blade load kN {kg} 76.3 {7,777} 77.2 {7,872}

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

(4)
GENERAL WEIGHT TABLE
WEIGHT TABLE
k Use the weight table when handling individual parts or when transporting the entire machine.
Serial No. 50001 – 51000 Unit: kg

Machine model GD555-3C GD655-3C GD675-3C
Serial Number 50001 – 51000
Engine assembly (dry) 453 616 616
Radiator assembly (dry) 51 51 51
Transmission assembly (dry) 755 755 755
Transmission pump 9 9 9
Final drive assembly 1,012 1,012 1,012
Tandem drive (one side) 876 876 876
Front axle assembly, except leaning cylinder 418 548 548
Parking brake assembly 26 26 26
Wheel assembly (front) 138 x 2 151 x 2 179 x 2
Wheel assembly (rear) 138 x 4 151 x 4 179 x 4
Scarifier assembly 450 530 530
Hydraulic pump 49 49 49
Fuel tank and hydraulic tank (both dry) 160 160 160
Circle rotation motor 10 10 10
Steering cylinder assembly 12 x 2 12 x 2 12 x 2
Leaning cylinder assembly 11 15 15
Articulating cylinder assembly 25 x 2 25 x 2 25 x 2
Blade lift cylinder assembly 49 x 2 49 x 2 49 x 2
Blade side-shift cylinder assembly 48 48 48
Blade power tilt cylinder assembly 19 19 19
Drawbar side-shift cylinder assembly 32 32 32
Scarifier cylinder assembly 22 24 24
Drawbar assembly 538 557 557
Blade assembly 625 625 675
Circle gear 252 272 272
Circle rotation gear assembly 119 119 119
Front frame assembly 1,613 1,814 1,814
Rear frame assembly 883 980 980
Ripper 595 900 900
Operator's compartment assembly and controls 200 200 200
GD555, 655, 675-3C 01-15

(4)
GENERAL WEIGHT TABLE
Serial No. 51001 and up Unit: kg

Machine model GD555-3C GD655-3C GD675-3C
Engine assembly (dry) 550 750 750
Radiator assembly (dry) 115 115 115
Transmission assembly (dry) 755 755 755
Transmission pump 9 9 9
Final drive assembly 1,012 1,012 1,012
Tandem drive (one side) 876 876 876
Front axle assembly, except leaning cylinder 418 548 548
Parking brake assembly 26 26 26
Wheel assembly (front) 138 x 2 151 x 2 179 x 2
Wheel assembly (rear) 138 x 4 151 x 4 179 x 4
Scarifier assembly 450 530 530
Hydraulic pump 49 49 49
Fuel tank and hydraulic tank (both dry) 160 160 160
Circle rotation motor 10 10 10
Steering cylinder assembly 12 x 2 12 x 2 12 x 2
Leaning cylinder assembly 11 15 15
Articulating cylinder assembly 25 x 2 25 x 2 25 x 2
Blade lift cylinder assembly 49 x 2 49 x 2 49 x 2
Blade side-shift cylinder assembly 48 48 48
Blade power tilt cylinder assembly 19 19 19
Drawbar side-shift cylinder assembly 32 32 32
Scarifier cylinder assembly 22 24 24
Drawbar assembly 538 557 557
Blade assembly 625 625 675
Circle gear 252 272 272
Circle rotation gear assembly 119 119 119
Front frame assembly 1,613 1,814 1,814
Rear frame assembly 883 980 980
Ripper 595 900 900
Operator's compartment assembly and controls 200 200 200
01-16 GD555, 655, 675-3C

(4)
GENERAL FUEL, COOLANT, AND LUBRICANT SELECTION
FUEL, COOLANT, AND LUBRICANT SELECTION

According to temperature
Ambient temperature Capacity (l)
Reservoir Fluid
-22 -4 14 32 50 68 86 104 122ºF
-30 -20 -10 0 10 20 30 40 50ºC
Specified Refill
SAE30 CD
SAE10W CD
GD555-3C GD555-3C
16 14
SAE10W-30 CD
Engine oil pan
GD655-3C GD655-3C
SAE15W-40 CD
GD675-3C GD675-3C
24 19
Engine oil SAE5W-40 CD
SAE0W-30 CD
Transmission case SAE10W CD 60 45
Final drive case SAE30 CD 18 16
Tandem drive case

SAE10W CD 80 75
(each)
Circle reverse gear SAE90
• Shear-pin type Gear oil SAE80 4 4
• Slip-clutch type SAE75 7 7
SAE10W CD
Hydraulic system Engine oil 85 45
SAE5W-30 CD
ASTM D975 No. 2

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

(4)
GENERAL FUEL, COOLANT, AND LUBRICANT SELECTION
Remark
• When fuel sulphur content is less than 0.5%, change oil in the oil pan in accordance with the periodic main-
tenance hours described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.
Change interval of oil

Fuel sulphur content
in 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 0ºC, be sure to use engine oil of
SAE10W, SAE10W-30 and SAE15W-40, even though an atmospheric temperature goes up 10ºC or more
in the day time.
• Use API classification CD engine oil. If API classification CC is used, reduce the engine oil change interval
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, 675-3C

(4)
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
ACCELERATOR CONTROL LINKAGE ............ 10-2 WORK EQUIPMENT CONTROL...................10-200
ACCELERATOR PEDAL................................... 10-3 HYDRAULIC SYSTEM ..................................10-202
FAN DRIVE ....................................................... 10-4 HYDRAULIC TANK........................................10-208
POWER TRAIN DIAGRAM ............................... 10-5 SWIVEL JOINT..............................................10-209
TRANSMISSION HYDRAULIC PIPING............ 10-6 PILOT CHECK VALVE...................................10-212
TRANSMISSION HYDRAULIC PIPING............ 10-8 BLADE ACCUMULATOR, FLOAT VALVE .....10-217
TORQUE CONVERTER ................................... 10-9 SHUT-OFF VALVE.........................................10-221
TORQUE CONVERTER LOCK-UP VALVE BLADE FLOAT DEVICE ................................10-222
(ECMV) ...................................................... 10-14 CIRCLE ROTATION MOTOR ........................10-224
TRANSMISSION............................................. 10-17 HYDRAULIC CYLINDER...............................10-226
TRANSMISSION VALVE................................. 10-46 CIRCLE, DRAWBAR .....................................10-232
ECMV (ELECTRONIC CONTROL LIFTER BRACKET LOCK PIN.......................10-234
MODULATION VALVE).............................. 10-47 BLADE ...........................................................10-236
MAIN RELIEF VALVE ..................................... 10-52 CIRCLE ROTATION GEAR ...........................10-238
TRANSMISSION PUMP ................................. 10-55 SCARIFIER....................................................10-242
TRANSMISSION AND DIFFERENTIAL LOCK RIPPER .........................................................10-244
PUMP (WITH DIFFERENTIAL LOCK) ...... 10-56 MAIN FRAME ................................................10-247
FINAL DRIVE .................................................. 10-58 AIR CONDITIONER (IF EQUIPPED) ............10-248
TANDEM DRIVE ............................................. 10-64 ENGINE STARTING CIRCUIT ......................10-252
STEERING HYDRAULIC PIPING DRAWING 10-68 ENGINE STOP CIRCUIT...............................10-256
STEERING VALVE (Q/AMP MANUAL PREHEAT CIRCUIT ......................................10-258
ORBIT-ROLL TYPE).................................. 10-71 AUTOMATIC SHIFT CONTROL SYSTEM ....10-260
PRIORITY ACC GOVERNOR VALVE TRANSMISSION CONTROLLER..................10-261
(Serial No. 50001 – 51000) ....................... 10-78 MONITOR......................................................10-265
PRIORITY VALVE SENSORS .....................................................10-268
(Serial No. 51001 and up) ......................... 10-85
ACCUMULATOR PRESSURE GOVERNOR VALVE
(Serial No. 51001 and up) ......................... 10-92
FRONT AXLE ................................................. 10-94
BRAKE HYDRAULIC PIPING ......................... 10-98
BRAKE VALVE.............................................. 10-102
WHEEL BRAKE ............................................ 10-106
SLACK ADJUSTER ...................................... 10-107
ACCUMULATOR............................................10-110
PARKING BRAKE .......................................... 10-111
PARKING BRAKE AND
BANK CONTROL VALVE .........................10-112
WORK EQUIPMENT HYDRAULIC
PIPING DRAWING ...................................10-114
HYDRAULIC PUMP
(Serial No. 50001 – 51000) ..................... 10-124
HYDRAULIC PUMP
(Serial No. 51001 and up) ....................... 10-146
MAIN CONTROL VALVE .............................. 10-169
CLSS............................................................. 10-188
GD555, 655, 675-3C 10-1

(8)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCELERATOR CONTROL LINKAGE
ACCELERATOR CONTROL LINKAGE
Outline
• Operating the fuel control lever (1) pulls the 1. Fuel control lever
spring rod (2), which moves the lever (3) and ac- 2. Spring rod
celerator cable (9) to control the engine speed. 3. Lever
• Depressing the accelerator pedal (5) moves the 4. Rod.
rod (4), lever (3), and accelerator cable (9) to 5. Accelerator pedal
control the engine speed. When this situation 6. Decelerator pedal
happens, the spring of the spring rod (2) moves 7. Fuel injection pump
in the direction of the compression. 8. Fuel injection pump lever
• Releasing the accelerator pedal (5) and de- 9. Accelerator cable
pressing the decelerator pedal (rod) (6) cause
the lever (3) to rotate, reducing engine speed.
10-2 GD555, 655, 675-3C

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

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

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN DIAGRAM
POWER TRAIN DIAGRAM
• The power produced by diesel engine (5) goes 1. Cooling fan

to transmission (4) through torque converter 2. Hydraulic pump
with lock-up clutch (3). 3. Torque converter
• Transmission (4), with a multiple shaft mecha- 4. Transmission
nism and a hydraulic control unit combined, al- 5. Engine assembly
lows an easy selection of eight forward speeds 6. Drive shaft
and four reverse speeds. Through drive shaft 7. Final drive
(6), the power is transmitted from the transmis- 8. Tandem drive
sion to the final drive (7). Here, final drive (7) di- 9. Tire
rects the power to the right and left, and the 10. Wheel brake
power is transmitted to the left and right tandem 11. Shaft
drives (8) through shaft (11).
• Tandem drive (8) transmits the power to the
wheel by a chain and the machine travels.
GD555, 655, 675-3C 10-5

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION HYDRAULIC PIPING
TRANSMISSION HYDRAULIC PIPING

GD555-3C Serial No. 50001 – 51037
GD655-3C Serial No. 50001 – 51081
GD675-3C Serial No. 50001 – 51009
1. Engine assembly
2. Transmission assembly
3. Oil filter
4. Hydraulic pump
10-6 GD555, 655, 675-3C

(6)
5. Hose-oil cooler inlet port

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

(4)

GD555-3C Serial No. 51038 and up
1. Engine assembly
2. Transmission assembly
3. Oil filter
4. Return hose of oil in flywheel housing
5. Hydraulic pump
10-7-1 GD555, 655, 675-3C

(6)
6. Hose-oil cooler inlet port

7. Hose-oil cooler outlet port
8. Oil filter
9. Radiator and oil cooler
GD555, 655, 675-3C 10-7-2

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION CONTROL
TRANSMISSION CONTROL
1. Gearshift lever Gearshift lever positions

2. Transmission controller Reverse
Forward
Parking
Neutral
1 range (forward, reverse)
5 range (forward)
6 range (forward)
7 range (forward)
8 range (forward)
10-8 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
1. Pump Specifications:
2. PTO drive gear (No. of teeth: 70) Name: TCA38-10A
3. Outer race Type: 3 element, 1 stage, 2 phase
4. Output shaft (transmission input shaft) Stall torque ratio: 2.17
5. Stator shaft
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, 675-3C 10-9

(4)
10-10 GD555, 655, 675-3C

(4)
Unit: mm
No. Check item Criteria Remedy
Std. size Tolerance Repair limit

1 Pilot O.D. –0.010
71.954 71.7 Rebuild or
–0.040
replace
+0.025
2 Pilot seal ring I.D. 35 35.5
0
+0.089
3 Clutch housing seal ring I.D. 340 340.1
0
Replace
+0.081
4 Clutch piston seal ring I.D. 260 260.1
0
+0.040 Rebuild or
5 PTO drive gear seal ring O.D. 125 125.5
0 replace
–0.01
Clutch housing Width 5 4.5
6 –0.04
seal ring wear
Thickness 6 ±0.15 5.85
0
Stator shaft Width 3.95 3.56
7 –0.1
seal ring wear
Thickness 4.8 ±0.1 4.32
One-way clutch outer race +0.005
8 88.882 88.912
O.D. –0.008
Stator shaft one-way clutch +0.008
9 72.217 72.187
O.D. –0.005 Replace
+0.015
10 Bushing I.D. 72.32 72.4
0
0
11 Bushing thickness 5 4.9
–0.1
12 Clutch disc thickness 5 ±0.1 4.7
+0.030
13 Stator shaft seal ring I.D. 55 55.5
0
Backlash between PTO drive
14 0.160 to 0.407
gear and idler gear
GD555, 655, 675-3C 10-11

(4)
LOCK-UP CLUTCH
Lock-up clutch disengaged

• When the lock-up clutch is disengaged, the drive
case (13) and turbine (11) are separated, and 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 transmitted 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, forming
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 tur-
bine (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, 675-3C

(4)
OIL FLOW
• The oil supplied from the torque converter charg-

ing pump passes through the transmission 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 centrifugal force by the pump (1) and en-
ters the turbine (11), transmiting the energy of
the oil to the turbine. Because the turbine (11) is
fixed to the output shaft (4), the power is trans-
mitted to the output shaft. The oil from turbine
(11) is sent to the stator (8), entering the pump
again. However, part of the oil that returns from
between the turbine (11) and stator (8) to the out-
let port is routed to the oil cooler.
GD555, 655, 675-3C 10-13

(4)
TORQUE CONVERTER LOCK-UP VALVE
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD (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, 675-3C

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

(7)
During direct travel

(torque converter travel o direct travel)
1. When filling 2. Adjusting pressure

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

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
Serial No.: 50001 – 51000
1. Transmission control valve

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

(4)
1. Torque converter
2. Input shaft
3. FL clutch
4. Upper shaft
5. FH clutch
6. Lower shaft
7. 3rd clutch
8. Coupling
9. 4th clutch
10. Output shaft
11. 2nd clutch
12. 1st clutch
13. R clutch
14. Mounting coupling for fan pulley
15. Shaft for hydraulic pump drive
10-18 GD555, 655, 675-3C

(4)
1. Shaft for transmission charge pump

2. R idler gear (Number of teeth: 37)
3. Speedometer gear set
Unit: mm
Tolerance Standard Clearance

Std. size
Clearance between idler gear Shaft Hole clearance limit
4
and bearing
+0.018 0 –0.030 to
50
+0.002 –0.012 –0.002
Clearance between idler gear 0 +0.016 –0.006 to
5 90
bearing and case –0.015 –0.006 0.031
Clearance between pump +0.020 0 –0.032 to
6 50
drive shaft and bearing (F) +0.009 –0.012 –0.009
Clearance between pump
0 +0.030 0 to
7 drive shaft bearing and case 90 Replace
–0.015 0 0.045
(F)
8 70
drive shaft and bearing (R) +0.011 –0.015 –0.011
0 +0.030 0 to
9 drive shaft bearing and case 100
–0.015 0 0.045
(R)
Clearance between idler +0.032 0 –0.047 to
10 70
shaft and bearing +0.002 –0.015 –0.002
Clearance between idler gear 0 –0.025 –0.050 to
11 125
and bearing –0.018 –0.050 –0.007
GD555, 655, 675-3C 10-19

(4)
10-20 GD555, 655, 675-3C

(4)
Unit: mm

Std. size
Clearance between FL, R Shaft Hole clearance limit
1
clutch bearing and case (F)
0 +0.030 0 to
150
–0.018 0 0.048
Clearance between FL, R 0 +0.022 –0.013 to
2 100
clutch bearing and case (R) –0.015 –0.013 0.037
Clearance between FH, 1st 0 +0.030 0 to
3 100
clutch bearing and case (F) –0.015 0 0.045
Clearance between FH, 1st 0 +0.022 –0.013 to
4 110
Clearance between 2nd, 3rd 0 +0.026 –0.014 to
5 140
clutch bearing and case (F) –0.018 –0.014 0.044
6 130
Clearance between 4th clutch 0 +0.026 –0.014 to
7 140
bearing and case (F) –0.018 –0.014 0.044
Clearance between 4th clutch 0 +0.040
8 160 0 to 0.065
bearing and case (R) –0.025 0
Clearance between idler gear +0.018 0 –0.030 to
9 50
and bearing +0.002 –0.012 –0.002
Clearance between idler gear 0 +0.016 –0.006 to Replace
10 90
bearing and case –0.015 –0.006 0.031
Clearance between fan drive +0.025 0 –0.037 to
11 35
Clearance between fan drive 0 +0.030 0 to
12 80
shaft bearing and case –0.013 0 0.043
13 50
0 +0.030 0 to
–0.015 0 0.045
(F)
15 70
0 +0.030 0 to
–0.015 0 0.045
(R)
Standard size Tolerance Repair limit
Width of input shaft seal ring
groove +0.018
2.5 2.7
+0.010
17
Width 2.4 ±0.05 2.2
Wear of input
shaft seal ring 0
Thickness 1.7 1.5
–0.010
GD555, 655, 675-3C 10-21

(4)
Width of input shaft seal ring +0.076

3.2 3.5
groove 0
18 Width 3.1 ±0.05 2.8
Wear of input
shaft seal ring 0
Thickness 2.29 2.1
–0.010
Inside diameter of case seal +0.05
50 50.1
ring sliding portion 0
3.2 3.5
19 groove 0
Replace
Width 3.1 ±0.05 2.8
Wear of input
shaft seal ring 0
Thickness 2.29 2.1
–0.010
Outside diameter of output
0
20 coupling oil seal sliding por- 80 79.8
–0.074
tion
Outside diameter of fan pul-
0
21 ley coupling oil seal sliding 65 64.8
–0.074
portion
10-22 GD555, 655, 675-3C

(4)
Serial No.: 51001 and up
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, 675-3C 10-23

(4)
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
10-24 GD555, 655, 675-3C

(4)
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. Size
Clearance between idler gear Shaft Hole Clearance Limit
4
and bearing
+0.018 0 –0.030 to
50 —
+0.002 –0.012 –0.002
Clearance between idler gear 0 +0.016 –0.006 to
5 90 —
bearing and case –0.015 –0.006 0.031
6 50 —
0 +0.030 0 to
7 drive shaft bearing and case 90 — Replace
–0.015 0 0.045
(F)
8 70 —
0 +0.030 0 to
9 drive shaft bearing and case 100 —
–0.015 0 0.045
(R)
10 70 —
Clearance between idler gear 0 –0.038 –0.073 to
11 100 —
and bearing –0.015 –0.073 –0.023
GD555, 655, 675-3C 10-25

(4)
10-26 GD555, 655, 675-3C

(4)
Unit: mm

Std. Size
Clearance between FL, R Shaft Hole Clearance Limit
1
clutch bearing and case (F)
0 +0.030 0 to
150 —
–0.018 0 0.048
Clearance between FL, R 0 +0.022 –0.013 to
2 100 —
Clearance between FH, 1st 0 +0.030 0 to
3 100 —
clutch bearing and case (F) –0.015 0 0.045
Clearance between FH, 1st 0 +0.022 –0.013 to
4 110 —
5 140 —
6 130 —
Clearance between 4th 0 +0.026 –0.014 to
7 140 —
Clearance between 4th 0 +0.040 0 to
8 160 —
clutch bearing and case (R) –0.025 0 0.065
9 50 —
gear and bearing +0.002 –0.012 –0.002
Clearance between idler 0 +0.016 –0.006 to Replace
10 90 —
gear bearing and case –0.015 –0.006 0.031
Clearance between fan drive +0.025 0 –0.037 to
11 35 —
Clearance between fan drive 0 +0.030 0 to
12 80 —
shaft bearing and case –0.013 0 0.043
13 50 —
0 +0.030 0 to
–0.015 0 0.045
(F)
15 70 —
0 +0.030 0 to
–0.015 0 0.045
(R)
Standard Size Tolerance Repair Limit
Width of input shaft seal ring
groove +0.018
2.5 2.7
+0.010
17
Width 2.4 ±0.05 2.2
Wear of input
shaft seal ring 0
Thickness 1.7 1.5
–0.010
GD555, 655, 675-3C 10-27

(4)

3.2 3.5
groove 0
18 Width 3.1 ±0.05 2.8
Wear of input
shaft seal ring 0
Thickness 2.29 2.1
–0.010
Inside diameter of case seal +0.05
50 50.1
ring sliding portion 0
3.2 3.5
19 groove 0
Replace
Width 3.1 ±0.05 2.8
Wear of input
shaft seal ring 0
Thickness 2.29 2.1
–0.010
Outside diameter of output
0
20 coupling oil seal sliding por- 80 79.8
–0.074
tion
Outside diameter of fan pul-
0
21 ley coupling oil seal sliding 65 64.8
–0.074
portion
10-28 GD555, 655, 675-3C

(4)
OUTLINE Combination of clutches and reduction ratio

• The transmission is installed at the rear of the
Speed range Clutch used Reduction ratio
torque converter. The power from the torque
converter passes through the transmission input F1 FL x 1st 9.950
shaft and enters the transmission. F2 FH x 1st 6.865
• The transmission shifts the gear to FORWARD 1
to 8 or REVERSE 1 to 4, according to the combi- F3 FL x 2nd 4.879
nation of the FL, FH, and R clutches and the 4- F4 FH x 2nd 3.367
speed.
F5 FL x 3rd 2.222
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
GD555, 655, 675-3C 10-29

(4)
FH, 1st clutches
1. Idler gear (No. of teeth: 42) A : FH clutch oil port

2. 1st gear (No. of teeth: 26) B : 1st clutch oil port
3. 1st clutch C : Lubrication oil port
4. FH, 1st cylinder, idler gear (No. of teeth: 62)
5. FH clutch
6. FH gear (No. of teeth: 55)
7. Upper shaft
2nd and 3rd clutches
1. Idler gear (No. of teeth: 29) A. 2nd clutch oil port

2. 2nd gear (No. of teeth: 61) B. 3rd clutch oil port
3. 2nd clutch C. Lubrication oil port
4. 2nd, 3rd cylinder, idler gear (No. of teeth: 77)
5. 3rd clutch
6. 3rd gear (No. of teeth: 55, 41)
7. Lower shaft
10-30 GD555, 655, 675-3C

(4)
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
GD555, 655, 675-3C 10-31

(4)
FL - R clutches
Unit: mm

Std. size
Shaft Hole clearance limit
1 Clearance
between the 0 +0.180 0.050 to
piston and Inside 96.73 0.25
–0.050 +0.050 0.230
shaft (FL)
–0.300 +0.130 0.300 to
2 Outside 140 0.53
–0.350 0 0.480
Clearance 0 +0.180 0.050 to

3 Inside 96.73 0.25
between the –0.050 +0.050 0.230
piston and –0.300 +0.130 0.300 to
4 shaft (R) Outside 140 0.53
–0.350 0 0.480
Clearance between the FL, +0.030 0 –0.045 to
5 60 —
R shaft and bearing (F) +0.011 –0.015 –0.011
Clearance between the FL, +0.034 0 –0.049 to
6 55 —
R shaft and bearing (R) +0.021 –0.015 –0.021
Replace
Separator
7 Thickness 1.7 ±0. 05 1.6
plate
Distortion — 0.1 0.15
Thickness 2.2 ±0.08 1.9
8 Friction plate
Load of wave spring 1,010 N ±101 N 859 N
9
(height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
FL clutch thrust washer thick-
10 3 ±0.1 2.7
ness
R clutch thrust washer thick-
11 3 ±0.1 2.7
ness
12 FL gear end play 0.30 to 0.76
13 R gear end play 0.29 to 0.69
10-32 GD555, 655, 675-3C

(4)
FH and 1st clutches
Unit: mm

Std. size
1 Clearance
between pis- 0 +0.180 0.050 to
ton and shaft Inside 96.73 0.25
–0.050 +0.050 0.230
(FH)
–0.300 +0.130 0.300 to
2 Outside 145 0.53
–0.350 0 0.480

3 Inside 96.73 0.25
between –0.050 +0.050 0.230
piston and –0.200 +0.130 0.200 to
4 shaft (1st) Outside 164.93 0.42
–0.250 0 0.380
Clearance between the FH, +0.034 0 –0.049 to
5 55 —
1st shaft and bearing (F) +0.021 –0.015 –0.021
Clearance between the FH, +0.034 0 –0.049 to
6 60 —
1st shaft and bearing (R) +0.021 –0.015 –0.021
Replace
Separator
7 Thickness 1.7 ±0. 05 1.6
plate
Thickness 2.2 ±0.08 1.9
8 Friction plate
9
(height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
FH clutch thrust washer
10 3 ±0.1 2.7
thickness
1st clutch thrust washer
11 3 ±0.1 2.7
thickness
12 FH gear end play 0.39 to 0.79
13 1st gear end play 0.26 to 0.74
GD555, 655, 675-3C 10-33

(4)
2nd and 3rd clutches
Unit: mm

Std. size
1 Clearance
ton and shaft Inside 96.73 0.25
–0.050 +0.050 0.230
(3rd)
–0.200 +0.130 0.200 to
2 Outside 164.93 0.42
–0.250 0 0.380

3 Inside 96.73 0.25
between –0.050 +0.050 0.230
piston and –0.200 +0.130 0.200 to
4 shaft (2nd) Outside 164.93 0.42
–0.250 0 0.380
Clearance between 2nd, 3rd +0.030 0 –0.045 to
5 65 —
shaft and bearing (F) +0.011 –0.015 –0.011
Clearance between 2nd, 3rd +0.054 0 –0.069 to
6 60 —
shaft and bearing (R) +0.044 –0.015 –0.044
Replace
Separator
7 Thickness 1.7 ±0. 05 1.6
plate
Thickness 2.2 ±0.08 1.9
8 Friction plate
9
(height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
3rd clutch thrust washer
10 3 ±0.1 2.7
thickness
2nd clutch thrust washer
11 3 ±0.1 2.7
thickness
12 3rd gear end play 0.38 to 0.82
13 2nd gear end play 0.35 to 0.85
10-34 GD555, 655, 675-3C

(4)
4th clutches
Unit: mm

Std. size
1 Clearance
ton and cylin- Inside 96.73 0.25
–0.050 +0.050 0.230
der (4th)
–0.200 +0.130 0.200 to
2 Outside 164.93 0.42
–0.250 0 0.380
Clearance between 4th shaft +0.030 0 –0.045 to
3 65 —
and bearing (F) +0.011 –0.015 –0.011
Clearance between 4th shaft +0.030 0 –0.045 to
4 75 —
and bearing (R) +0.011 –0.015 –0.011
Separator
5 Thickness 1.7 ±0.05 1.6
plate
Thickness 2.2 ±0.08 1.9 Replace
6 Friction plate
Load of wave spring 1010 N ±101 N 859 N
7
(height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
Thickness of 4th clutch thrust
8 3 ±0.1 2.7
washer
Inside diameter of cylinder +0.030
70 70.1
seal ring sliding portion 0
4th shaft seal ring groove +0.076
3.2 3.5
9 width 0
Width 3.1 ±0.05 2.8
4th shaft seal
ring wear 0
Thickness 2.29 2.1
–0.10
4th cylinder idler gear end
10 0.30 to 0.70 mm
play
GD555, 655, 675-3C 10-35

(4)
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 be-
cause 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.
10-36 GD555, 655, 675-3C

(4)
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) passes
1st clutch (10) hold each clutch disc in position through the 1st clutch (10). From the 1st clutch
with the oil pressure applied to the piston. the power goes from 1st gear (13) to 2nd, 3rd cyl-
• The power from the torque converter is transmit- inder gear (19). The power flow continues
ted from the input shaft (1) through the FL clutch through the lower shaft (20), idler gear (21), out-
(2) to the FL gear (4). The power is then transmit- put gear (24), and finally to the output shaft (25).
ted to FH, 1st cylinder gear (11).
GD555, 655, 675-3C 10-37

(4)
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 then
with the oil pressure applied to the piston. transmitted from the 1st gear (13) to 2nd, 3rd cyl-
• The power from the torque converter is transmit- inder gear (19). Power then goes through the
ted from the input shaft (1) to the idler gear (6). lower shaft (20), idler gear (21), output gear (24),
The power continues to the FH gear (8) and and finally the output shaft (25).
passes through the FH clutch (9), and is then
transmitted to the FH, 1st cylinder gear (11).
10-38 GD555, 655, 675-3C

(4)
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 the
2nd clutch (17) hold each clutch disc in position 2nd clutch (17). Power continues to the 2nd, 3rd
with the oil pressure applied to the piston. cylinder gear (19) and lower shaft (20), and then
• The power from the torque converter is transmit- passes through the idler gear (21), output gear
ted from the input shaft (1) through the FL clutch (24), and to the output shaft (25).
(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).
GD555, 655, 675-3C 10-39

(4)
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 through
2nd clutch (17) hold each clutch disc in position the 2nd clutch (17), and to the 2nd, 3rd cylinder
with the oil pressure applied to the piston. gear (19) and lower shaft (20). Power is then
• The power from the torque converter is transmit- transmitted through the idler gear (21), output
ted from the input shaft (1) to the idler gear (6) gear (24), and finally to the output shaft (25).
and the FH gear (8) and then passes through the
FH clutch (9). Power is then transmitted through
the FH, 1st cylinder gear (11), upper shaft (12),
idler gear (14), and then to the 2nd gear (15).
10-40 GD555, 655, 675-3C

(4)
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 through
3rd clutch (18) hold each clutch disc in position the 3rd clutch (18) and then goes to the 2nd, 3rd
with the oil pressure applied to the piston. cylinder gear (19) and lower shaft (20). Power
• The power from the torque converter is transmit- then is transmitted through the idler gear (21),
ted from the input shaft (1) through the FL clutch output gear (24), and finally to the output shaft
(2) and then to the FL gear (4). Power is then (25).
(11) to the 3rd gear (16).
GD555, 655, 675-3C 10-41

(4)
Forward 6th
Operation
• In FORWARD 6th, the FH clutch (9) and 3rd
clutch (18) are engaged. The FH clutch (9) and
3rd clutch (18) hold each clutch disc in position
with the oil pressure applied to the piston.
• The power from the torque converter is transmit-
ted 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).
• With the 3rd clutch (18) engaged, the power
transmitted to the 3rd gear (16) passes through
the 3rd clutch (18) and then to the 2nd, 3rd cylin-
der gear (19) and lower shaft (20). Power is then
transmitted through the idler gear (21), output
gear (24), and finally to the output shaft (25).
10-42 GD555, 655, 675-3C

(4)
Forward 7th
Operation
• In FORWARD 7th, the FL clutch (2) and 4th
clutch (23) are engaged. The FL clutch (2) and
4th clutch (23) hold each clutch disc in position
ted from the input shaft (1) through the FL clutch
(2) and then to the FL gear (4). Power is then
(11) and 3rd gear (16) to the 4th cylinder gear
(22).
• With the 4th clutch (23) engaged, the power
transmitted to the 4th cylinder gear (22) goes
through the 4th clutch (23), and then to the out-
put shaft (25).
GD555, 655, 675-3C 10-43

(4)
Forward 8th
Operation
• In FORWARD 8th, the FH clutch (9) and 4th
clutch (23) are engaged. The FH clutch (9) and
4th clutch (23) hold each clutch disc in position
ted 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).
• With 4th clutch (23) engaged, the power trans-
mitted to the 4th cylinder gear (22) passes
through the 4th clutch (23), and finally to the out-
put shaft (25).
10-44 GD555, 655, 675-3C

(4)
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 clutch transmitted to the FH, 1st cylinder gear (11)
(10) hold each clutch disc in position with the oil passes through the 1st clutch (10), and goes
pressure applied to the piston. from 1st gear (13) to 2nd, 3rd cylinder gear (19).
• The power from the torque converter is transmit- The power is then transmitted through the lower
ted from the input shaft (1) through the R clutch shaft (20), idler gear (21), output gear (24), and
(3). Power to the R gear (5) is rotated in the op- fianlly to the output shaft (25).
posite direction by the R idler gear (7). The pow-
er is then transmitted through the idler gear (14)
and upper shaft (12) to the FH, 1st cylinder gear
(11).
GD555, 655, 675-3C 10-45

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION VALVE
TRANSMISSION VALVE
ECMV clutch actuation table

A : FL clutch oil pressure detection port
ECMV
B : R clutch oil pressure detection port FL FH R 1 2 3 4
Speed range
C : FH clutch oil pressure detection port
D : 1st clutch oil pressure detection port F1 Q Q
E : 2nd clutch oil pressure detection port F2 Q Q
F : 3rd clutch oil pressure detection port
G : 4th clutch oil pressure detection port F3 Q Q
F4 Q Q
1. ECMV (for FL clutch)
F5 Q Q
2. ECMV (for R clutch)
3. ECMV (for FH clutch) F6 Q Q
4. ECMV (for 1st clutch) F7 Q Q
5. ECMV (for 2nd clutch)
6. ECMV (for 3rd clutch) F8 Q Q
7. ECMV (for 4th clutch) R1 Q Q
8. Seat
R2 Q Q
9. Last chance filter
R3 Q Q
R4 Q Q
N
10-46 GD555, 655, 675-3C

(4)
ECMV (ELECTRONIC CONTROL MODU-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LATION 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
GD555, 655, 675-3C 10-47

(4)
ECMV FOR SPEED CLUTCH
Outline of ECMV
• The ECMV (Electronic Control Modulation Valve)
consists of two components: the pressure control
valve and the fill switch.
Pressure control valve

• The proportional solenoid receives the flow of
electricity sent from the transmission controller,
and the pressure control valve converts this into
hydraulic pressure.
Fill switch
• This detects when oil has filled the clutch. It has
the following functions.
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 controller
to inform the controller of the existence 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 proportional solenoid

• There is one proportional solenoid installed to
each ECMV.
It generates propulsion as shown in the diagram
on the right according to the command current
from the controller.
The propulsion generated by the proportional

solenoid acts on the pressure control valve
spool and generates oil pressure as shown in
the diagram on the right.
In this way, the command current is controlled
and the propulsion force varies to actuate the
pressure control valve and control the oil flow
and oil pressure.
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 pressure.
With this signal, the oil pressure starts to build
up.
10-48 GD555, 655, 675-3C

(4)
OPERATION OF ECMV
• The ECMV is controlled by the command current
from the transmission controller to the propor-
tional solenoid and the fill switch output signal.
The relationship between the ECMV propor-
tional solenoid command current and the clutch
input pressure and fill switch output signal is as
shown in the diagram on the right.
A range: Before gear shifting (drained)

B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
1. When gear shifting (during draining)

(Range A in graph).
When no current is flowing to proportional sole-
noid (1), pressure control valve spool (3) drains
the oil at clutch port A through drain port Dr.
When this happens, there is no hydraulic force
acting on pressure detection valve (4), so fill
switch (6) is turned OFF.
GD555, 655, 675-3C 10-49

(4)
2. When filling (when trigger command is input

to pressure control valve)
(Ranges B and C in graph)
When there is no oil inside the clutch, if electric
current is applied to proportional solenoid (1), a
hydraulic force balancing the force of the sole-
noid acts on chamber B, and pressure control
valve spool (3) moves to the left. As a result, the
circuit between pump port P 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.
3. Adjusting pressure (Range D in graph)

When electric current flows to proportional sole-
noid (1), the solenoid generates a propulsion
force proportional to the current.
The pressure is adjusted so that the total of this
propulsion force of the solenoid, the propulsion
force of the oil pressure at the clutch port, and
the reaction force of pressure control valve
spring (2) is balanced.
10-50 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MAIN RELIEF VALVE
MAIN RELIEF VALVE
1. Seat OUTLINE
2. Body Main relief valve
3. Piston • The main relief valve (6) sets the pressure of the
4. Torque converter relief valve transmission main port pressure in front of
5. Piston ECMV set pressure.
6. Main relief valve
Torque converter relief valve
A : Drain Port • The torque converter relief valve (4) protects the
B : To torque converter torque converter from abnormally high pressure.
C : Drain port It relieves the pressure when the pressure at the
D : Drain port inlet port of the torque converter goes above the
E : From pump specified pressure.
P1 : Main relief oil pressure detection port
P2 : Torque converter oil pressure relief detection
Specified pressure
port
Serial No. 50001 – 51000 51001 and up
2.37 MPa 2.47 MPa
Main relief pressure
{24.2 kg/cm2} {25.2 kg/cm2}
Torque converter inlet 0.91 MPa 0.91 MPa
port pressure {9.31 kg/cm2} {9.31 kg/cm2}
10-52 GD555, 655, 675-3C

(4)
Unit: mm

Std. size
Clearance between main Shaft Hole clearance limit
7
relief valve and valve body
–0.035 +0.013 0.035 to
28 0.08
–0.045 0 0.058
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 Free Permissi-
Main relief valve spring
9 length length load length ble load
(Outer)
226 N 224.6 N
108 82.5 104.8
{23.1 kg} {22.9 kg}
Main relief valve spring 290 N 287.3 N
10 108 82.5 104.8
(Inner) {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, 675-3C 10-53

(4)
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 circuit,
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.
Oil pressure at port A:
2.37 MPa {24.2 kg/cm2}
(Serial No.: 50001 – 51000)
2.47 MPa {25.2 kg/cm2}
(Serial No.: 51001 and up)
Torque converter operation

• The oil relieved from the main relief valve flows
from port C into the torque converter and simul-
taneously 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 en-
tering port D pushes the piston (9). This action
compresses the spring (3), moving the relief
valve (2) to the right to open the passage be-
tween port C and port E. The oil from port C is
now relieved to port E and merges with the trans-
mission lubrication circuit. The oil pressure at
port C is 0.91 MPa {9.31 kg/cm2}.
10-54 GD555, 655, 675-3C

(4)
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
2 0.067 to 0.125 0.20
and outside of diameter of
gear shaft Replace
Standard size Tolerance
3 Depth for knocking in pin 0
12
–0.5
Rotating torque of spline
4 2.9 to 6.9 Nm {0.3 to 0.7 kgm}
shaft
Standard
Rotating Delivery Standard
Discharge amount delivery
speed pressure amount limit
— Oil: EO10-CD amount —
Oil temperature: 45 – 55°C 15.2 MPa
2300 rpm 137 l/min 124 l/min
{155 kg/cm2}
GD555, 655, 675-3C 10-55

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION AND DIFFERENTIAL LOCK
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
Rotating torque of spline

4 4.9 to 11.8 Nm {0.5 to 1.2 kgm}
shaft
Delivery Standard Delivery
Rotating
pressure delivery amount
Model speed —
Discharge amount [MPa amount limit
(rpm)
— Oil: EO10-CD {kg/cm2}] (l/min) (l/min)
Oil temperature: 45 – 55°C
SAR(2)63 15.2 {155} 137 124
2300
SBR(1)10 20.6 {210} 20 19
10-56 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
STANDARD FINAL DRIVE (NON-SPIN DIFFERENTIAL)
1. Cage 6. Shaft
2. Non-spin differential 7. Sprocket (12 teeth)
3. Coupling 8. Breather
4. Bevel pinion (12 teeth) 9. Drain plug
5. Bevel gear (43 teeth) 10. Oil filler tube
10-58 GD555, 655, 675-3C

(4)
Unit: mm
Preload of bevel pinion

11 Starting rotation torque: 8.7 to 11.7 Nm {0.89 to 1.19 kgm}
bearing
Starting rotation torque:
Preload of bevel gear
12 (Item 11) + 0.7 to 1.5 Nm {0.07 to 0.15 kgm} Adjust
bearing
(after setting, measure at pinion bearing)
Backlash between bevel Standard size

13
pinion and bevel gear 0.25 to 0.33
GD555, 655, 675-3C 10-59

(4)
PLANETARY FINAL DRIVE (WITH DIFFERENTIAL LOCK)
1: For serial No. 51001 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 (Serial No.: 51001 and up)
10-60 GD555, 655, 675-3C

(4)
Unit: mm
Preload of bevel pinion

19 Starting rotation torque: 8.7 to 11.7 Nm {0.89 to 1.19 kgm}
bearing
Preload of bevel gear Starting rotation torque:
20 Adjust
bearing ( Item 19) + 0.7 to 1.5 Nm {0.07 to 0.15 kgm}
Backlash between bevel Standard size

21
pinion and bevel gear 0.25 to 0.33
GD555, 655, 675-3C 10-61

(4)
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 dif-
ferential 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 dif-
ferential lock.
10-62 GD555, 655, 675-3C

(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

Size Repair limit
9 Extension of chain (10 links) Replace
317.5 322.26
10-64 GD555, 655, 675-3C

(4)
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

Size Repair limit
9 Extension of chain (10 links) Replace
508.0 515.62
GD555, 655, 675-3C 10-65

(4)
Outline
Power from the final drive is transmitted to the front
and back rear wheels by chain.
The tandem cases can swing up and down 13°
each. All four wheels are in contact with the ground
even when the ground is rough restricting 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 follows:
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.
10-66 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING HYDRAULIC PIPING DRAWING
STEERING HYDRAULIC PIPING DRAWING

Serial No.: 50001 – 51000
1. Steering valve
2. Steering wheel
3. Priority valve
4. Hydraulic tank
5. Hydraulic pump
10-68 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. Steering valve 5. Hydraulic tank

2. Steering wheel 6. Hydraulic pump
3. Priority valve 7. Steering cylinder
4. Accumulator charge valve
GD555, 655, 675-3C 10-69

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING VALVE (Q/AMP MANUAL ORBIT-
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, 675-3C 10-71

(6)
STEERING VALVE (Q/AMP MANUAL
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ORBIT-ROLL TYPE)
OUTLINE 1. Variable ratio steering function

The Q/Amp manual Orbit-roll used on this machine The amount of oil pushed out of the steering
has a flow amplification function. This function is pump, in other words, the steering discharge
provided by the structure of the Orbit-roll valve and amount, varies according to the steering wheel
orifice. With this, the steering pump speed range speed. When the steering wheel is turned at low
varies to change the steering discharge amount; in speed, the steering discharge is small; and
particular, at high speed it has the characteristic of when the steering wheel is turned at high speed,
providing an amplified flow above the metering the steering discharge is large.
amount of the Gerotor (Variable ratio steering func-
tion). For this reason, when the machine is traveling at
high speed, if the steering wheel is turned at low
The Gerotor used for this function has the following speed, the steering discharge is small. This
features. makes fine compensation of the steering possi-
• Fine compensation of the steering is possible at ble, and enables superior travel at high speed.
high speed to ensure stable steering.
• Quick turns are possible when the machine is When the machine is stationary or traveling at
traveling at low speed or when it is stationary. low speed, if the steering wheel is turned at high
• Emergency steering is possible with the Orbit-roll speed, a large steering discharge is easily
control used independently. ensured, so quick turns are possible.
10-72 GD555, 655, 675-3C

(4)
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 cyl-
inder when traveling 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 character-
istics of a bypass orifice (characteristics of
flow amplification orifice AA) and closes the
hole during emergency 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 dis-
charge volume can achieve actual emergen-
cy steering when the Orbit-roll is used
independently. When selecting an Orbit-roll
with a large discharge volume, it is neces-
sary to provide an emergency source of
pressure oil.
With this Q/Amp manual Orbit-roll, the sys-
tem is simplified, and as a result, the reliabil-
ity is improved.
Steering lock-to-lock characteristics

(Variable capacity steering system of Q/Amp steering speed)
GD555, 655, 675-3C 10-73

(4)
STRUCTURE
• The shaft connected to the steering wheel mesh-
es with the spline at the top of the spool and the
spool (10) is fitted inside the sleeve (9). In addi-
tion, the spool and sleeve are connected 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 center

pin (7) and made one with sleeve (9). The bot-
tom of drive shaft (3) is engaged with the spline
of rotor (1) of the Gerotor set (combination of ro-
tor (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 cylinders. Also, a
check valve isnide the body connects 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 di-
rectly from the tank because of this check valve.
10-74 GD555, 655, 675-3C

(6)
CONNECTION BETWEEN HAND PUMP AND SLEEVE
• The diagrams above show the connections with

the sleeve ports connecting the suction and dis-
charge ports of the Gerotor.
• When turning the wheel to the right, the vertical
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 i 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 con-
dition 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.
• In this way, the ports acting as the discharge
ports of the hand pump connect to the ports go-
ing to the steering cylinder. And the ports acting
as suction ports connect to the pump circuit.
• If the pump or engine fails, the suction and dis-
charge of this hand pump is performed forcibly
and oil is sent to the steering cylinder. Thus, it is
still possible to steer the machine.
GD555, 655, 675-3C 10-75

(7)
• Adjust the discharge amount to match the

amount while turning the steering wheel. The oil
from this pump always passes through this hand
pump. For each 1/7 turn of the steering wheel,
the internal tooth gear of the hand pump advanc-
es by one tooth. An amount of oil equal to this
movement is discharged. Thus, the discharge oil
amount is directly proportional to the amount the
steering wheel is turned. If the pump or engine
fail, the condition is exactly the same. Thus, the
same amount of oil is discharged as when the
pump is normal.
DIFFERENCES BETWEEN TROCHOID 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 steering 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.
10-76 GD555, 655, 675-3C

(4)
ROLE OF 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 generat-
ed 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 in-
creases.
To prevent this situation, 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 NEU-
TRAL position.
GD555, 655, 675-3C 10-77

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PRIORITY ACC GOVERNOR VALVE
PRIORITY ACC GOVERNOR VALVE

Serial No. 50001 – 51000
1. Orifice T : To hydraulic tank P1 : (plugged)

2. Bypass compensator spool S1 : (plugged) P2 : From hydraulic pump
3. Orifice LSP1 (IN): From bank control CF : Orbit-roll valve
4. Flow fuse shuttle valve B1 : (plugged) LSP1 (OUT): (plugged)
5. Relief valve B2 : (plugged) LSP2 : From hydraulic tank
6. Pilot unloader valve EF2 : To right control valve LSS : From Orbit-roll valve
7. Shuttle valve A/P1 : To bank control
8. Orifice A1 : To brake control
9. Check valve A2 : To brake control
10. Filter CF6 : (plugged)
11. Check valve EF1 : To left control valve
10-78 GD555, 655, 675-3C

(4)
OUTLINE
• If the hydraulic systems for both the work equip- to the work equipment circuit will be reduced and
ment and steering are covered by one pump, all poor efficiency results. To prevent this situation
the oil flow is consumed by the work equipment and to ensure a quick response when operating
circuit. Thus, there is a lack of oil for the steering the steering, this valve keeps the steering circuit
circuit. To prevent this dangerous situation, a oil flow to a minimum (approx. 1 l/min) when the
valve is installed to ensure that priority is given to steering is at neutral. And to send the rest of the
the oil flow to the steering circuit. oil to the work equipment circuit. In addition, this
valve is a load-sensing type that ensures the
• If a large flow of oil is sent to the steering circuit necessary flow even when operating the steer-
even when the steering is at neutral, the oil flow ing.
Valve circuit diagram
GD555, 655, 675-3C 10-79

(4)
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 maxi-
mum 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 the steering, but the steering valve is
closed, so the pressure at port CF rises.
The oil in chamber A from the pump passes
through orifice a in spool (1), enters chamber 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 accumula-
tor charge pressure passes through the LS and
PLS lines and is transmitted to the servo valve
of the pump. The pump then supplies the neces-
sary 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 governor valve is opened.
When this flow from port CF passes through ori-
fices 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 = pres-
sure 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 circuit passing
through orifice b becomes smaller, so the differ-
ential 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 balance is reached.
The forces acting on chamber B and chamber C
are as follows:
• Force in left direction (converted to hydraulic
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))
10-80 GD555, 655, 675-3C

(4)
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 cyl-
inder.
If the steering wheel is turned quickly, and the
area of the variable throttle in the steering valve
becomes larger, the difference in pressure on
both sides of the variable throttle inside the
steering valve becomes smaller, and the pres-
sure 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 portion 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 orifice
becomes smaller, so the differential pressure on
steering valve becomes larger. The pressure in
chamber B then becomes larger than the pres-
sure in chamber C, so spool (1) is pushed to the
left, and the area of the opening 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 accordance
with the flow of oil needed for port CF to main-
tain 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 steering
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 pres-
sure 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, 675-3C 10-81

(4)
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 cylinder is
stopped regardless of the opening of the steer-
ing valve.
There is no flow of oil, so the CF and LS pres-
sures rise together with the pressure at pump
port P, and at the same time, pressures cham-
ber 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/cm 2 }, 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 cham-
ber C becomes lower than pressure chamber B.
As a result, spool (1) moves to the left to a posi-
tion where the oil flow inside the spool is 1 l/
min. Spool (1) stabilizes at a position where por-
tion 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 pressure chamber C
and pressure chamber B become the same, and
spool (1) is moved again to the right by spring
(2) to open portion d.
Because of this repeated action, the pressure in
the steering circuit is maintained at a maximum
of 15.21 MPa {155 kg/cm2}.
5. Steering valve at neutral, work equipment

control lever operated
If the work equipment control lever is operated,
pressure A changes to 1.96 – 24.5 MPa {20 –
250 kg/cm2}. However, the steering valve is at
neutral, so the condition is the same as in Sec-
tion 2. "When engine is started (steering and
main control valves at neutral)", and the force
acting on spool (1) is constant regardless of
pressure A.
If pressure A 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 opening of portion d
becomes smaller. The oil flow is automatically
adjusted so that only 1 l/min flows.
10-82 GD555, 655, 675-3C

(4)
6. Steering, work equipment operated simulta-

neously
1) When the load on steering circuit is higher
than the load on the work equipment circuit,
the actuation condition is the same as in
Section 3, "Steering operated (accumulator
not charged, main control valve at neutral)".
2) Port CF is at the same pressure as chamber
A, and port EF is throttled by portion l until it
balances at the same pressure as the pres-
sure needed for the work equipment. In
other words, the oil pressure in the main cir-
cuit for the pump is sent to the steering cir-
cuit.
3) When the load on steering circuit is less

circuit CF satisfies the demand for the
amount of oil and oil pressure for the steer-
ing, 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 sup-
plied to the steering circuit by priority
regardless of the pressure in the work
equipment circuit.
GD555, 655, 675-3C 10-83

(4)
7. When brake accumulator is being charged

When the brake is operated, the pressure inside
the brake accumulator goes down. If the pres-
sure goes down to 9.42 MPa {96 kg/cm 2 }, the
governor valve for charging the brake accumula-
tor 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 accumulator is completed.
8. Steering and brake accumulator charging ac-

tuated 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 circuit
for normal travel becomes lower than 5.89
MPa {60 kg/cm 2 }. Operating the steering
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 steering
valve discharges an amount of oil to match
the operating angle of the steering, so when
an oil flow matching the operating 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.
10-84 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PRIORITY VALVE
PRIORITY VALVE
Serial No. 51001 and up
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 LS1 : To accumulator pressure governor valve
governor valve (To pilot circuit)
LS2 : To accumulator pressure governor valve
(To pilot circuit)
T : To accumulator pressure governor valve
(To hydraulic tank)
GD555, 655, 675-3C 10-85

(8)
OUTLINE
• If the hydraulic systems for both the work equip-

ment and steering and brake are covered by one
pump, all the oil flow is consumed 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 en-
sure 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 circuit

even when the steering is at neutral, the oil flow
to the work equipment circuit will be reduced and
poor efficiency results. To prevent 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 steer-
ing.
• The built-in relief valve regulates the steering cir-

cuit pressure to prevent generation of abnormal
pressure.
10-86 GD555, 655, 675-3C

(8)
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 maxi-
mum 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 pressure at port
(CF) rises.
The oil in chamber (A) from the pump passes
through orifice (a) in spool (1), enters chamber
(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 accumula-
tor charge pressure passes through the LS and
PLS lines and is transmitted to the servo valve
of the pump. The pump then supplies the neces-
sary 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 governor 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/cm 2}, 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 circuit passing
through orifice (b) becomes smaller, so the dif-
ferential pressure on both sides of orfice (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 balance is reached.
The forces acting on chamber (B) and chamber
(C) are as follows:
• Force in left direction (converted to hydraulic
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))
GD555, 655, 675-3C 10-87

(8)
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 steer-
ing 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 pressure on
steering valve becomes smaller, and the pres-
sure 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 portion
(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 orifice
becomes smaller, so the differential pressure on
steering valve becomes larger. The pressure in
chamber (B) then becomes larger than the pres-
sure in chamber (C), so spool (1) is pushed to
the left, and the area of the opening of portion
(d) becomes smaller to match the flow of oil
needed for the steering valve. It becomes bal-
anced in this position.
In other words, spool (1) moves in accordance

with the flow of oil needed for port (CF) to main-
tain 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 steering

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 pres-
sure 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.
10-88 GD555, 655, 675-3C

(8)
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 cylinder is
stopped regardless of the opening of the steer-
ing 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 cham-
ber (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/cm 2 }, 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 pois-
tion where the oil flow inside the spool is 1 l/
min. Spool (1) stabilizes at a position where por-
tion (d) of the spool is throttled, and this pre-
vents 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 pressure chamber
(C) and pressure chamber (B) become the
same, and spool (1) is moved again to the right
by spring (2) to open portion (d).
Because of this repeated action, the pressure in
the steering circuit is maintained at a maximum
of 15.21 MPa {155 kg/cm2}.
5. Steering valve at neutral, work equipment

control lever operated
If the work equipment control lever is operated,
pressure (PA) changes to 1.96 – 24.5 MPa {20 –
250 kg/cm2 }. However, the steering valve is at
neutral, so the condition is the same as in Sec-
tion 2. "When engine is started (steering 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 dif-
ference in pressure is created, so spool (1) is
pushed to the left, and the area of the opening of
portion (d) becomes smaller. The oil flow is auto-
matically adjusted so that only 1 l/min. flows.
GD555, 655, 675-3C 10-89

(8)
6. Steering, work equipment operated simulta-

neously
1) When the load on steering circuit is higher
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 portion
(I) until it balances at the same pressure as
the pressure needed for the work equip-
ment. In other words, the oil pressure in the
main circuit for the pump is sent to the steer-
ing circuit.
2) When the load on the steering circuit is less

circuit (CF) satisfies the demand for the
amount of oil and oil pressure for the steer-
ing, 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 sup-
plied to the steering circuit by priority
regardless of the pressure in the work
equipment circuit.
10-90 GD555, 655, 675-3C

(8)
7. When brake accumulator is being charged

When the brake is operated, the pressure inside
the brake accumulator goes down. If the pres-
sure goes down to 9.42 MPa {96 kg/cm2 }, the
brake accumulator pressure governor 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 accumulator is completed.
8. Steering and brake accumulator charging ac-

tuated 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 circuit
for normal travel becomes lower than 5.89
MPa {60 kg/cm 2 }. Operating the steering
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 steering
valve discharges an amount of oil to match
the operating angle of the steering, so when
an oil flow matching the operating 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.
GD555, 655, 675-3C 10-91

(8)
ACCUMULATOR PRESSURE GOVERNOR
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 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
10-92 GD555, 655, 675-3C

(8)
ACCUMULATOR PRESSURE GOVERNOR
Outline
• The accumulator pressure governor valve is con-
nected 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 distributed
by the accumulator shuttle valve to the front and
rear brake circuits to heighten the pressure in the
brake accumulator. The accumulator 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 im-
prove the startability of the engine (particularly in
the cold season). While the starting motor is run-
ning, the solenoid operates to drain the oil sent
by the hydraulic pump to the servo valve to re-
duce the load on the pump.
GD555, 655, 675-3C 10-93

(8)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FRONT AXLE
FRONT AXLE
1. Tie rod Specifications:

2. Steering cylinder Toe-in: –5 mm
3. Support axle Camber: 0°
4. Leaning rod
5. Bracket
6. Hub shaft
10-94 GD555, 655, 675-3C

(4)
Unit: mm
Standard
size
Clearance between center clearance limit
7 Shaft Hole
pin and bushing
55 –0.030 +0.197 0.167 to
3.0
–0.076 +0.137 0.273
–0.025 +0.142 0.105 to
Clearance GD555 40 2.0
–0.064 +0.080 0.206
8 between king Replace
pin and bushing GD655 –0.025 +0.142 0.105 to bushing
45 2.0
GD675 –0.064 +0.080 0.206
Clearance –0.025 +0.161 0.143 to

GD555 40 0.6
between axle –0.064 +0.118 0.225
9
end pin and GD655 –0.025 +0.142 0.105 to
bushing 45 2.0
GD675 –0.064 +0.080 0.206
Clearance between ball joint –0.060 +0.020 0.060 to
10 55 1.0
and bushing –0.090 +0.020 0.110
GD555 Start to rotate: 147 to 196 Nm {15 to 20 kgm}
Preload of hub
11 GD655
bearing Start to rotate: 78.5 to 117.7 Nm {8 to 12 kgm}
GD675
Adjust
GD555 314 to 608 Nm {32 to 62 kgm}
Hub nut tighten-
12 GD655
ing torque 490 to 608 Nm {50 to 62 kgm}
GD675
GD555, 655, 675-3C 10-95

(4)
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 oscillate
16°. This, like the tandem system, restricts
the up-and-down movement of the blade to a
minimum when one front wheel rides over an
object 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 rock-
ing of front axle blade movement rises only
H/4 while holding its horizontal posture. Un-
less 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.
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
wheels are leaned to make them more
resistant, and this changes the center of the
load on the front axle and the center of grav-
ity of the machine and prevents side slip-
ping.
10-96 GD555, 655, 675-3C

(4)
• When the wheel is leaned that angle be-

tween the center line of the leaned tire and
the perpendicular line is called the "Leaning
angle". Leaning angle is the distance S=2 x
x x r covered by the tire as it advances, and
the side with the greater load radius, in order
to advance more than the side with the less
load radius, advances in the direction of the
leaning.
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 turn-
ing a steering wheel in the same direction.
Leaning angle is 16°
GD555, 655, 675-3C 10-97

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE HYDRAULIC PIPING
BRAKE HYDRAULIC PIPING

Serial No.: 50001 – 51000
10-98 GD555, 655, 675-3C

(4)
1. Priority ACC governor valve

2. Air breather
3. Slack adjuster
4. Wheel brake
5. Accumulator
6. Stop lamp switch
7. Brake valve
GD555, 655, 675-3C 10-99

(4)
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
10-100 GD555, 655, 675-3C

(8)
9. Slack adjuster (front)

10. Slack adjuster (rear)
GD555, 655, 675-3C 10-101

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
1. Piston
2. Spool
3. Spool
A : To rear slack adjuster

B : To front slack adjuster
PA : To accumulator
PB : To accumulator
T : To hydraulic tank
10-102 GD555, 655, 675-3C

(4)
Unit: mm
Standard Tolerance Standard Clearance

Clearance between pedal size Shaft Hole clearance limit
4
mounting hole and bracket
–0.025 +0.013 0.175 to
— 0.25
–0.075 +0.013 0.025
Clearance between roller and –0.025 +0.013 0.175 to
5 — 0.25
pin –0.075 +0.013 0.025
Size Tolerance Repair limit
6 Outside diameter of roller 0
30 29.2
–0.5
Replace
7 Control spring length height load length ble load
80 N
54.5 49.7 33.4 —
{8.1 kg}
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, 675-3C 10-103

(4)
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.
10-104 GD555, 655, 675-3C

(4)
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, 675-3C 10-105

(4)
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 —
Total thickness of disc and
5 26.7 ± 0.8 24.7 ± 0.8
plate
Replace
Free Installed Installed
Installed load
6 Return spring length height load
654 N
76.5 60.5 75.0
{66.7 kg}
10-106 GD555, 655, 675-3C

(4)
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:

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

Clearance between body and size Shaft Hole clearance limit
4
piston
–0.030 +0.074 0.030 to
— 0.25
–0.076 +0.074 0.150
Replace
5 Slack adjuster spring length height load length ble load
43.2 N
198 38 — —
{4.4 kg}
66.7 N
6 Spring 38.8 33 — —
{6.8 kg}
GD555, 655, 675-3C 10-107

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SLACK ADJUSTER
OPERATION
1. Brake pedal depressed.

• Before depressing the brake pedal, the pis-
ton is returned by the distance of stroke S
(full stroke). Depressing the brake pedal dis-
charges the oil from the brake valve and
flows from port P of the slack adjuster. The
oil is then divided to the left and right cylin-
ders (2). The force of the oil moves the piston
(4) by stroke S to the left and right.
• Depressing the brake pedal moves the brake

piston (7) a distance of stroke S. In this con-
dition, the closer the clearance between the
brake piston and the disc is to zero (0), the
greater the braking force becomes.
• Depressing the brake pedal further and the

oil pressure discharged from the brake valve
goes above the set pressure, the check
valve opens (3) opens and the pressure ap-
plied to port C acts as the braking force.
Thus, when the brake is applied, the time lag
is a fixed value.
2. Brake pedal released.

• Releasing the brake pedal causes the piston
(4) to return by action of the brake return
spring (8) by an amount equivalent to the oil
for stroke S. Thus, the brake releases. In oth-
er words, the return stroke T of brake piston
(7) is determined by the amount of oil for
stroke S of the slack adjuster. The time lag of
the brake is always kept constant, regard-
less of disc brake wear.
10-108 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR
ACCUMULATOR
1. Valve assembly Specifications:

2. Top cover Gas used: Nitrogen
3. Cylinder Amount of gas: 3000 cc
4. Piston Gas charging pressure (at 20 ± 5°C):
3.4 ± 0.1 MPa {35 ± 1.0 kg/cm2}
Function:
The accumulator is installed between the pressure
governor valve and brake valve. Cylinder (3) is
charged with nitrogen gas. Even after the engine
stops, braking force is kept by the pressure of the
nitrogen gas compressed by free piston (4). The
compressibility of the nitrogen gas absorbs the pul-
sating pressure from the hydraulic pump.
10-110 GD555, 655, 675-3C

(8)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
1. Piston Outline:
2. Adjustment bolt • The parking brake is a disc type, and is installed to
3. Caliper the final drive.
4. Disc • The parking brake is applied mechanically by the
force of the spring inside the caliper, and is re-
leased 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 thinkness
10.4 9.4
Replace
9.5
6 Pad thickness 12.5 (Remaining thickness when
pad groove has disappeared)
GD555, 655, 675-3C 10-111

(7)
PARKING BRAKE AND BANK CONTROL
PARKING BRAKE AND BANK CONTROL VALVE

Serial No.: 50001 – 51000
DS1 : Solenoid valve for bank control Outline

DS2 : Solenoid valve for parking brake The parking brake control valve has the solenoid
B1 : To bank control cylinder valves for parking brake and bank control.
B2 : To bank control cylinder If the solenoid for the parking brake is turned on,
T5 : From mine control valve hydraulic oil is supplied to the parking brake to release
AP : From hydraulic control valve the parking brake.
BR : To parking brake If the solenoid for the bank control is turned on,
hydraulic oil is supplied to the bank control cylinder to
move the lock pin in the pulling out direction.
10-112 GD555, 655, 675-3C

(8)
PARKING BRAKE AND BANK CONTROL
1. Solenoid valve for bank control Outline

2. Solenoid valve for parking brake The parking brake control valve has the solenoid
valves for parking brake and bank control.
AP : From accumulator If the solenoid for the parking brake is turned on,
B1 : To bank control cylinder hydraulic oil is supplied to the parking brake to release
B2 : To bank control cylinder the parking brake.
QC : To parking brake If the solenoid for the bank control is turned on,
ST : (Plugged) hydraulic oil is supplied to the bank control cylinder to
BR : (Plugged) move the lock pin in the pulling out direction.
T1 : (Plugged)
T2 : To hydraulic tank
T3 : To accumulator pressure governor valve
T4 : (Plugged)
GD555, 655, 675-3C 10-113

(8)
WORK EQUIPMENT HYDRAULIC PIPING
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRAWING
WORK EQUIPMENT HYDRAULIC PIPING DRAWING

MAIN PIPING (1/2)
Serial No.: 50001 – 51000
1. Priority ACC governer valve
10-114 GD555, 655, 675-3C

(4)
MAIN PIPING (2/2)
1. Shut-off valve
2. Hydraulic tank
3. Hydraulic pump
GD555, 655, 675-3C 10-115

(4)
MAIN PIPING (1/2)
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
10-116 GD555, 655, 675-3C

(8)
MAIN PIPING (2/2)
GD555, 655, 675-3C 10-117

(8)
HIGH PRESSURE PIPING (1/3)
Left side
10-118 GD555, 655, 675-3C

(8)
Right side
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, 675-3C 10-119

(8)
1. Swivel joint
2. Drawbar side-shift cylinder
3. Blade tilt cylinder
10-120 GD555, 655, 675-3C

(8)
LIFTER LOCK PIPING
Serial No.: 50001 – 51000
1. Parking and bank control valve
GD555, 655, 675-3C 10-121

(8)
1. Parking and bank control valve Function

2. Bank pin The lifter bracket (3) is fixed by the bank pin (2). When
3. Lifter bracket setting in the bank cutting position, operate control
lever. This uses hydraulic oil to push piston. The pin
can be removed and the bracket can be rotated.
10-122 GD555, 655, 675-3C

(8)
BANK PIN
1. Pin 4. Shaft
2. Piston 5. Case
3. Cover 6. Bushing
GD555, 655, 675-3C 10-123

(8)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
Serial No. 50001 – 51000
PA : Pump discharge • The main pump consists of one unit formed by the
PA1 : Pump pressure detection port pump, servo piston, PC valve, and LS valve.
PA2 : LS pump pressure input The explanation of structure and function is divided
PA3 : Drain port into two parts: the pump and PC valve + LS valve.
PDA : Pump air bleed
PD1 : Pump drain
PD2 : Pump drain
PEN : Control pressure detection port
PLS : LS pressure input
PM : Drain port
PS : Pump suction
10-124 GD555, 655, 675-3C

(4)
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, 675-3C 10-125

(4)
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 the
spline a, and shaft (1) is supported by the front axial direction inside each cylinder chamber of
and rear bearings. cylinder block (7).
• The tip of piston (6) is a concave ball, and shoe • Cylinder block (7) seals the pressure oil to valve
(5) is caulked to it to form one unit. Piston (6) and plate (8) and carries out relative rotation. This
shoe (5) form a spherical bearing. surface is designed so that the oil pressure bal-
• Rocker cam (4) has flat surface A, and shoe (5) ance is maintained at a suitable level.
is always pressed against this surface while slid- The oil inside each cylinder chamber of cylinder
ing in a circular movement. Rocker cam (4) block (7) is sucked in and discharged through
brings high pressure oil at cylindrical surface B valve plate (8).
with cradle (2), which is secured to the case and
forms a static pressure bearing when it slides.
10-126 GD555, 655, 675-3C

(4)
OPERATION
1. Operation of pump
i) Cylinder block (7) rotates together with shaft
(1), and shoe (5) slides on flat surface 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 cylider 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 surface
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
volume E and F is created inside cylinder
block (7). The suction and discharge is car-
ried 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 dur-
ing that stroke.
At the same time, the volume of chamber F
b e c o m e s l a r g e r, a n d a s t h e v o l u m e
becomes larger, 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 vol-
umes 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 rela-
tionship between swash plate angle and
the pump discharge amount.
GD555, 655, 675-3C 10-127

(4)
2. Control of discharge amount

• If swash plate angle becomes larger, the dif-
ference in volumes E and F becomes larger and
discharge amount Q increases.
Swash plate angle is changed by servo pis-
ton (10).
• Servo piston (10) moves in a reciprocal move-
ment ( ) according to the command from the PC
and LS valve.
• This straight line movement is transmitted to
rocker cam (4), and rocker cam (4), which is sup-
ported by the cylindrical surface to cradle (2),
moves in a rotating motion on the cylindrical sur-
face in the ( ) direction.
• With servo piston (10), the area receiving the
pressure is different at the top and bottom, so
main pump discharge pressure (self pressure)
PP is always connected to the pressure chamber
at the small diameter piston end (top).
Output pressure Pen of the LS vale is brought to
the pressure chamber at the large diameter pis-
ton end (bottom).
The relationship in the size of pressure PP at
the small diameter piston end and pressure Pen
at the large diameter piston end, and the ratio
between the pressure-receiving area at the
small diameter piston end and the large diame-
ter piston end controls the movement of servo
piston (10).
10-128 GD555, 655, 675-3C

(4)
PC VALVE, LS VALVE, SERVO PISTON
PA2 : LS pump pressure inlet port

PA3 : Drain port
PLS : LS pressure inlet port
PM : Drain port
PP : Pump discharge port
Servo piston PC valve LS valve

1. Servo piston 4. Piston 12. Plug
2. Lever 5. Spring 13. Sleeve
3. Spring
6. Seat 14. Spring
7. Spring 15. Piston
8. Piston
9. Sleeve
10. Piston
11. Plug
GD555, 655, 675-3C 10-129

(4)
LS VALVE
Function
• The LS valve controls the pump discharge
amount according to the amount of movement 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 EPLS
between input pressure Pa2 of the control valve
(downstream pressure of self-pressure reducing
valve) and control valve outlet pressure PLS,
and controls main pump discharge amount Q.
(Pa2 is called the LS pump pressure, PLS is
called the LS pressure, and EPLS is called the
LS differential presure.)
• In other words, the pressure loss (= LS differen-
tial pressure EPLS) generated by the flow of oil
from the pump passing through opening area of
the control valve spool is detected.
By controlling pump discharge amount Q so that
this pressure loss remains constant, a pump dis-
charge amount is supplied in accordance with
the demands of the control valve by controlling
pump discharge amount Q.
• Main pump discharge pressure PP, LS pump
pressure Pa2, and LS pressure PLS are brought
to the LS valve.
The relationship between pump discharge
amount Q and LS differential pressure EPLS
changes as shown in the diagram on the right.
10-130 GD555, 655, 675-3C

(4)
Operation
1. When control valve is at HOLD position
10-132 GD555, 655, 675-3C

(4)
• The LS pressure PLS is brought from the control

valve outlet port to spring chamber a of the LS
valve. LS pump pressure Pa2 at the control valve
inlet port is brought to the chamber b at the tip of
the sleeve on the opposite side.
• The position of piston (15) is determined by the
size of pump pressure Pa2 and the combined
force of LS pressure PLS + force of spring (14).
• Before the engine is started, servo piston (1) is
pushed down (direction of minimum swash plate
angle) by spring (3).
• After the engine is started, if all the control valves
are at the neutral position, no pressure oil flows
to the control valve outlet port, so LS pressure
PLS is 0 MPa {0 kg/cm2}.
(Spring chamber a is connected to the drain cir-
cuit through the control valve spool.)
At the same time, LS pump pressure Pa2 is held
at the unload pressure of approx. 2.8 MPa {29
kg/cm2}.
• For this reason, piston (15) is pushed to the right
( ), port c and port d are interconnected, and
pump pressure PP is brought from port d to
chamber X at the large diameter end of servo
piston (1).
• Pump pressure PP is always supplied to cham-
ber Y at the small diameter end of servo piston
(1), but the force applied to the large diameter
end of servo piston (1) is greater because of the
difference in area at both ends of the piston, so
servo piston (1) moves up in the direction of the
minimum swash plate angle ( ).
GD555, 655, 675-3C 10-133

(4)
2. When opening area of control valve is maximum (lever operated fully)
10-134 GD555, 655, 675-3C

(4)
• When the control lever is operated fully, that is,

when the area of opening of the control valve be-
comes larger, the difference between LS pump
pressure Pa2 and LS pressure PLS (LS differen-
tial pressure PLS) becomes smaller.
• LS pressure PLS brought to spring chamber a of
the LS valve becomes close to LS pump pres-
sure Pa2, and piston (15) is pushed to the left
( ) by the combined force of LS pressure PLS
+ force of spring (14). This closes port c and in-
terconnects port d and port e.
• As a result, the pressurized oil acting on cham-
ber X at the large diameter end of servo piston
(1) flows from port d to port e and is connected to
port f of the PC valve.
• At this point, port f of the PC valve is drained in-
side the pump case through the inside of the pis-
ton, so the pressure in chamber X at the large
diameter end of servo piston (1) also becomes
the drain pressure.
• Because of this, servo piston (1) is moved down
in the direction of the maximum swash plate an-
gle ( ) by pump pressure PP acting on chamber
Y at the small diameter end of the piston.
GD555, 655, 675-3C 10-135

(4)
3. When opening area of control valve is small (small movement of lever)
10-136 GD555, 655, 675-3C

(4)
• When the control lever is operated in small

movements, or when it is operated to the HOLD
position (in other words, when the area of open-
ing of the control valve becomes smaller), the dif-
ference between LS pump pressure Pa2 and LS
pressure PLS (in other words, LS pressure
EPLS) becomes larger.
• When this happens, the movement is the same
as for [1. When control valve is at HOLD posi-
tion]: LS pump pressure Pa2 pushes piston (14)
to the right ( ), so servo piston (1) is moved up
in the direction of the minimum swash plate an-
gle ( ).
In other words, the basic LS set differential pres-
sure of the LS valve is taken as 2.35 MPa {24
kg/cm2}. In the range from the neutral position of
the control valve to the small area of opening of
the control valve (fine control), in the area where
the LS differential pressure EPLS is more than
2.35 MPa {24 kg/cm 2 }, the pump swash plate
angle moves in the minimum direction.
If the area of opening of the control valve is fur-
ther increased, and LS differential pressure
EPLS goes below 2.35 MPa {24 kg/cm2 }, the
pump swash plate angle is moved in the maxi-
mum direction.
GD555, 655, 675-3C 10-137

(4)
4. When pump flow is amount demanded by control valve
10-138 GD555, 655, 675-3C

(4)
PC VALVE
• Let us take the area receiving the pressure at the Function

large diameter end of servo piston as A1, the • When discharge pressure PP becomes higher,
area receiving the pressure at the small diameter the area of opening of the control valve becomes
end as A2, the pressure acting on the large pis- larger, and even if the LS valve tries to increase
ton diameter end as Pen, and the pressure act- pump discharge amount Q, the PC valve carries
ing on the small piston diameter end as PP. out control to prevent any increase above fixed
• When the flow of oil from the pump reaches the discharge amount Q to match discharge pres-
flow demanded by the control valve, LS pump sure PP. It carries out approximate horsepower
pressure Pa2 acting on port b of the LS valve control to prevent the hydraulic horsepower ab-
and the combined force of LS pressure PLS + sorbed by the pump from exceeding the engine
force of spring (14) acting on spring chamber a horsepower.
are balanced, so piston (15) stops at almost the • In other words, if the load during operations be-
central position. comes larger and pump discharge pressure PP
• As a result, port c, port d, and port e open ap- rises, pump discharge amount Q is reduced; and
proximately the same amount, so the pump pres- if pump discharge pressure PP goes down,
sure flows from port c to port d. pump discharge amount Q is increased.
Part flows from port e to the tank case and is • The relationship between pump discharge pres-
drained, so the pressure is reduced by approx. sure PP and pump discharge amount Q is as
1/2 and flows to chamber X at the large diame- shown in the diagram below.
ter end of servo piston (1).
• At this point, the relationship between the area
receiving the pressure at both ends of piston (1)
is A2 : A1 = 1 : 2, so the pressure applied to both
ends of servo piston (1) becomes PP : Pen = 2 :
1. This makes the force acting on both ends of
servo piston (1) 1 : 1, so servo piston (1) stops in
that position and the pump discharge amount is
balanced with the oil flow demanded by the con-
trol valve.
• The force of the spring is adjusted so that Pa2 –
PLS = EPLS
E = 2.35 MPa {24 kg/cm2} at the point
where piston (15) is balanced.
• In other words, when the area of opening of con-
trol valve is 1/2, the pump swash plate angle is
also 1/2, and when the area of opening of control
valve is 1/4, the pump swash plate angle is also
1/4. LS differential pressure EPLS is always
held at 1.96 MPa {20kg/cm2}, so the pump dis-
charge amount is in accordance with the area of
opening of the control valve.
• For example, after balancing at an area of open-
ing 1/4 of the control valve, LS differential pres-
sure EPLS will drop momentarily. As a result,
the LS valve is actuated and the pump discharge
amount is increased, but when the pump swash
plate angle rises to 3/4, the LS differential pres-
sure EPLS rises to 2.35 MPa {24 kg/cm2}, so it
is balanced in this position.
GD555, 655, 675-3C 10-139

(4)
Operation
1. When actuator load is large (pump discharge pressure PP is high)
10-140 GD555, 655, 675-3C

(4)
• When the load on the actuator becomes high and

pump discharge pressure PP rises, piston (8) is
pushed to the left ( ) because of the relation-
ship between the cross-sectional area of piston
portions S1 and S2 (S1 > S2).
• As a result, port f and port g are interconnected,
pump pressure PP flows from port g to port f, and
at the same time, port f and the drain circuit are
shut off.
• If the LS valve takes action to increase the pump
discharge amount, spool (15) of the LS valve is
moved to the left ( ) and port d and port e are
interconnected.
• As a result, pump pressure PP from port f of the
PC valve flows from port e of the LS valve to port
d, enters chamber X at the large diameter end of
servo piston (1), and stops the movement of ser-
vo piston (1).
• If pump discharge pressure PP rises further, pis-
ton (8) moves to the left ( ) and servo piston (1)
moves up in the direction of the minimum swash
plate angle ( ) because of the pressure in
chamber X at the large diameter end.
• When servo piston (1) moves up ( ), piston (4)
is moved to the right ( ) through lever (2). As a
result, springs (5) and (7) are moved in the direc-
tion of compression and piston (8) is pushed
back to the right.
• When piston (8) is pushed back to the right and
port f and port g are shut off, servo piston (1)
stops moving ( ).
• The position where servo piston (1) stops is high-
er (closer to the minimum swash plate angle)
than when the pump discharge pressure is low.
GD555, 655, 675-3C 10-141

(4)
2. When actuator load becomes smaller (pump discharge pressure PP drops)
10-142 GD555, 655, 675-3C

(4)
• When the load on the actuator becomes smaller

and pump discharge pressure PP drops, piston
(8) is pushed to the right ( ) by the force of
springs (5) and (7).
• As a result, port g and port f are shut off, and at
the same time, port f is connected to the drain cir-
cuit.
• When this happens, if the LS valve is acting to in-
crease the pump discharge pressure, the limit of
the PC valve disappears, so the pressurized oil
in chamber X at the large diameter end of servo
piston (1) passes from port d of LS valve to port
e, and flows from port f of the PC valve to the
drain circuit as explained in the section on the LS
valve.
• For this reason, servo piston (1) is moved down
in the direction of the maximum swash plate an-
gle ( ) by the pressure in chamber Y at the
small diameter end.
GD555, 655, 675-3C 10-143

(4)
3. Action of spring
10-144 GD555, 655, 675-3C

(4)
• The spring load of springs (5) and (7) in the PC

valve is changed by the swash plate angle.
• When servo piston (1) moves, lever (2) moves,
and piston (5) moves to the right or left according
to the direction of rotation of lever (2).
• If piston (4) moves to the right ( ), spring (5)
and spring (7) are compressed. If it moves fur-
ther to the right ( ), spring (5) contacts seat (6),
so only spring (7) functions as a spring.
In other words, the spring load is changed by
piston (5) extending or contracting springs (5)
and (7).
• The pump absorption torque curve, which shows
the relationship between pump discharge pres-
sure PP and discharge amount Q, is a bent curve
as shown in the diagram on the right because
springs (5) and (7) have different spring loads.
• In other words, if pump discharge pressure PP
increases, pump discharge amount Q is re-
duced; and if pump discharge pressure PP goes
down, pump discharge amount Q is increased.
GD555, 655, 675-3C 10-145

(4)
HYDRAULIC PUMP
PA : Pump discharge a The main pump consists of one unit formed by the
PA1 : Pump pressure detection port pump, servo piston, PC valve, and LS valve.
PA2 : LS pump pressure port The explanation in STRUCTURE, FUNCTION
PA3 : Drain port AND MAINTENANCE STANDARD is divided into
PDA : Pump air bleed two parts: the pump and the PC valve + LS valve.
PD1 : Pump drain
PD2 : Pump drain
PEN : Control pressure detection port
PLS : LS pressure input
PS : Pump suction
10-146 GD555, 655, 675-3C

(8)
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, 675-3C 10-147

(8)
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 the
spline a, and shaft (1) is supported by the front axial direction inside each cylinder chamber of
and rear bearings. cylinder block (7).
• The tip of piston (6) is a concave ball, and shoe • Cylinder block (7) seals the pressure oil to valve
(5) is caulked to it to form one unit. Piston (6) and plate (8) and carries out relative rotation. This
shoe (5) form a spherical bearing. surface is designed so that the oil pressure bal-
• Rocker cam (4) has flat surface A, and shoe (5) ance is maintained at a suitable level.
is always pressed against this surface while slid- • The oil inside each cylinder chamber of cylinder
ing in a circular movement. Rocker cam (4) block (7) is sucked in and discharged through
brings high pressure oil at cylindrical surface B valve plate (8).
with cradle (2), which is secured to the case and
forms a static pressure bearing when it slides.
10-148 GD555, 655, 675-3C

(8)
Operation
1. Operation of pump
i) Cylinder block (7) rotates together with shaft
(1), and shoe (5) slides on flat surface 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 surface
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 car-
ried 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 dur-
ing that stroke.
At the same time the volume of chamber F
b e c o m e s l a r g e r, a n d a s t h e v o l u m e
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 vol-
umes 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 rela-
tionship between swash plate angle and
the pump discharge amount.
GD555, 655, 675-3C 10-149

(8)
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 movement 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 receiving
areas on its top and bottom. Main pump dis-
charge pressure (self pressure) PA is constantly
led in the pressure chamber on the small-diame-
ter piston side (upper side).
• LS valve output pressure PEN is led in the pres-
sure chamber on the large-diameter piston side
(lower side).
• The movement of servo piston (1) is controlled
by the difference between pressure PA on the
small-diameter piston side and pressure 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.
10-150 GD555, 655, 675-3C

(8)
PC VALVE, LS VALVE, SERVO PISTON
PA : Pump discharge pressure

PA2 : LS pump pressure inlet
PA3 : Drain
PLS : LS pressure inlet
Servo piston PC valve LS valve

1. Servo piston 4. Piston 11. Plug
2. Lever 5. Spring 12. Sleeve
3. Spring 6. Seat 13. Spring
7. Spring 14. Spool
8. Spool
9. Sleeve
10. Plug
10-152 GD555, 655, 675-3C

(8)
LS VALVE
Function
• The LS valve controls the pump discharge
amount according to the amount of movement 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 EPLS
between inlet pressure PA2 of the control valve
and control valve outlet pressure PLS and con-
trols main pump discharge amount Q. (PA2 is
called the LS pump pressure, PLS is called the
LS pressure, and EPLS is called the LS differ-
ential pressure.)
• In other words, the pressure loss (= LS differen-
tial pressure EPLS) generated by the oil flowing
from the pump through the open area of the con-
trol 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 differ-
ential pressure EPLS and pump discharge
amount Q changes as shown in the figure on the
right.
GD555, 655, 675-3C 10-153

(8)
Operation
1. When control valve is at HOLD position
10-154 GD555, 655, 675-3C

(8)
• 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 un-
load 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 chamber X on the
large diameter side of servo piston (1).
• Pump pressure PA is constantly led in chamber
Y on the small diameter side of servo piston (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 minimum swash plate angle
side (upper side).
GD555, 655, 675-3C 10-155

(4)
2. When opening area of control valve is maximum (lever operated fully)
10-156 GD555, 655, 675-3C

(8)
• If the control lever is moved to the stroke end and

the open area of the control valve is increased,
LS differential pressure EPLS between LS
pump pressure PA2 and LS pressure PLS is re-
duced.
• 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 result-
ant 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 cham-
ber 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, 675-3C 10-157

(4)
3. When opening area of control valve is small (small movement of lever)
10-158 GD555, 655, 675-3C

(8)
• When the control lever is operated finely or set in

the HOLD position and the open area of the con-
trol valve is reduced, LS differential pressure
EPLS between LS pump pressure PA2 and LS
pressure PLS is increased.
• At this time, the mechanism operates as de-
scribed in "1. When control valve is at HOLD po-
sition". LS pump pressure PA2 pushes spool
(14) to the right and servo piston (1) moves to-
ward the minimum swash plate angle side (upper
side).
• In other words, on the basis of the LS set differ-
ential pressure of 2.35 MPa {24 kg/cm2} for the
LS valve and in the range from the HOLD posi-
tion of the control valve to the minimum open
area of the control valve (in the fine control oper-
ation), when LS differential pressure EPLS 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 differential pres-
sure EPLS lowers below 2.35 MPa {24 kg/cm2},
the swash plate angle increases.
GD555, 655, 675-3C 10-159

(4)
4. When pump flow is amount demanded by control valve
10-160 GD555, 655, 675-3C

(8)
PC VALVE
Function
• Let the pressure receiving area on the large di- • When discharge pressure PA rises and the open
ameter side of servo piston (1) be A1, the pres- area of the control valve is wide, the LS valve in-
sure receiving area on the small diameter side be creases pump discharge amount Q. At this time,
A2, the pressure applied on the large diameter the PC valve controls discharge amount Q so
side be PEN, and the pressure applied on the that it will not exceed a certain level according to
small diameter side be PA. discharge pressure PA. That is, the PC valve
• When the oil flow from the pump reaches the flow performs approximate equal horsepower control
rate demanded by the control valve, LS pump so that the pump absorption horsepower will not
pressure PA2 applied to port b of the LS valve is exceed the engine horsepower.
balanced with the resultant of "LS pressure PLS • In other words, when the load increases and
and the force of spring (13)" applied to spring pump discharge pressure PA rises during work,
chamber a and spool (14) is stopped at an al- pump discharge amount Q is reduced. When
most intermediate point. pump discharge pressure PA lowers, pump dis-
• As a result, ports c, d, and e are opened almost charge amount is increased.
equally. Then, some of the pump oil from port c • The relationship between pump discharge pres-
flows in port d and the other is drained through sure PA and pump discharge amount Q is shown
port e into the tank case. Accordingly, the pres- below.
sure of this oil is reduced to about 1/2 and ap-
plied to chamber X on the large diameter side of
servo piston (1).
• At this time, since the relationship of the pressure
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 EPLS and will approximately equal 2.35
MPa {24 kg/cm 2 } 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 control valve is 1/
4, the swash plate angle is also 1/4. The pump
discharge is changed according to the open area
of the control valve by keeping LS differential
pressure EPLS 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 EPLS lowers temporarily.
Accordingly, the LS valve operates to increase
the pump discharge. After the swash plate angle
increases to 3/4, however, LS differential pres-
sure EPLS rises to 2.35 MPa {24 kg/cm2} and
the spool is balanced at this point.
GD555, 655, 675-3C 10-161

(8)
Operation
1. When actuator load is large (pump discharge pressure PA is high)
10-162 GD555, 655, 675-3C

(8)
• When the load on the actuator increases and

pump discharge pressure PA rises, spool (8) is
pushed to the left because of the relationship be-
tween 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 an-
gle side (upper side).
• If servo piston (1) moves up, piston (4) is moved
through lever (2) to the right. Accordingly,
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, 675-3C 10-163

(4)
2. When actuator load becomes smaller (pump discharge pressure PA drops)
10-164 GD555, 655, 675-3C

(8)
• 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 sec-
tion 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 pres-
sure in chamber Y on the small diameter side to-
ward the maximum swash plate angle side
(lower side).
GD555, 655, 675-3C 10-165

(4)
3. Action of spring
10-166 GD555, 655, 675-3C

(8)
• 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) com-
presses or releases those springs.
• The pump absorption torque curve showing the
relationship between pump discharge pressure
PA and discharge amount Q is broken 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, 675-3C 10-167

(8)
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
GD555, 655, 675-3C 10-169

(4)
10-170 GD555, 655, 675-3C

(4)
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 Installed Installed Free Installed
16 Spool return spring x OD length load length load
34.8 N 27.9 N
56.27 x 20.1 25.4 —
{3.55 kg} {2.84 kg}
Replace
34.8 N 27.9 N
17 Spool return spring (circle) 87.7 x 19.7 25.4 — spring if
{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}
GD555, 655, 675-3C 10-171

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

PP : PP port (to main pump) B2 : To leaning 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, 675-3C 10-173

(7)
10-174 GD555, 655, 675-3C

(4)
1. Spool (right blade lift) 9. Pressure compensation valve R (drawbar shift)

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

Replace
34.8 N 27.8 N
56.27 x 20.1 25.4 — spring if
{3.55 kg} {2.84 kg}
damaged or
16 23 x 8.4 15 —
17 15.4 x 6 8 —
GD555, 655, 675-3C 10-175

(4)
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
GD555, 655, 675-3C 10-177

(4)
10-178 GD555, 655, 675-3C

(4)
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

34.8 N 27.9 N
56.27 x 20.1 25.4 —
{3.55 kg} {2.84 kg}
Replace
Spool return spring 34.8 N 27.9 N
20 87.7 x 19.7 25.4 — spring if
(circle) {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}
GD555, 655, 675-3C 10-179

(4)
LEFT 5-SPOOL VALVE (RIPPER SPECIFICATION) (1/3)
GD555-3C
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, 675-3C 10-181

(4)
GD555-3C
10-182 GD555, 655, 675-3C

(4)
GD555-3C
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

34.8 N 27.9 N
56.27 x 20.1 25.4 —
{3.55 kg} {2.84 kg}
Replace
34.8 N 27.9 N
20 Spool return spring (circle) 87.7 x 19.7 25.4 — spring if
{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}
GD555, 655, 675-3C 10-183

(4)
GD655, GD675-3C
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
GD555, 655, 675-3C 10-185

(4)
GD655, GD675-3C
10-186 GD555, 655, 675-3C

(4)
GD655, GD675-3C
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

34.8 N 27.9 N
56.27 x 20.1 25.4 —
{3.55 kg} {2.84 kg}
Replace
34.8 N 27.9 N
21 Spool return spring 87.7 x 19.7 25.4 — spring if
{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, 675-3C 10-187

(4)
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 single
System, and has the following features. piston pump, control valve, and actuators.
1) Fine control not influenced by load. • The pump body consists of the main pump, the
2) Control enabling digging even with fine con- PC valve and LS valve.
trol.
3) Ease of compound operation ensured by
flow divider function using area of opening
of spool during compound operations.
4) Energy saving using variable pump control.
10-188 GD555, 655, 675-3C

(8)
2. BASIC PRINCIPLE
1) Control of pump swash plate angle

• The pump swash plate angle (pump dis-
charge amount) is controlled so that LS
differential pressure (EPLS) (the differ-
ence between pump pressure (PP) and
control valve outlet port LS pressure
(PLS)) (load pressure of actuator) is con-
stant.
(LS pressure (EPLS) = Pump dis-
charge pressure (PP) – LS pressure
(PLS))
• If LS differential pressure (EPLS) be-
comes lower than the set pressure of the
LS valve, the pump swash plate be-
comes larger; if it becomes higher than
the set pressure of the LS valve, the
pump swash plate becomes smaller.
a For details of the operation, see HY-
DRAULIC PUMP.
GD555, 655, 675-3C 10-189

(8)
2) Pressure compensation control

• Valves (pressure compensation valves) are installed on the inlet side of the control valves to balance
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 constant 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.
10-190 GD555, 655, 675-3C

(8)
3. FUNCTIONS AND OPERATION OF EACH VALVE
HYDRAULIC CIRCUITS AND NAMES OF VALVES
1. Unload valve 5. Safety-suction valve

2. LS relief valve 6. LS pressure reducing valve
4. Pressure compensation valve
GD555, 655, 675-3C 10-191

(8)
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 minimum
swash plate angle is released to the tank circuit.
When this happens, pump discharge pressure
PP is set to 2.9 MPa {30 kg/cm2} by spring (2) in-
side the valve.
LS pressure PLS: 0 MPa {0 kg/cm2}.
Operation
• At the left end of the spool (1), pump pressure PP PP : Pump circuit
is acting on area S1, and at the right end of spool PLS : LS circuit
(1), pump pressure PP is acting on area S2, and T : Tank circuit
LS pressure PLS is acting on area S3. A : To valves
• When the control valve is at HOLD, LS pressure B : To pump LS valve
PLS is not generated, so only pump discharge
pressure PP has any effect, and PP is set by the
load of spring (2).
• As pump discharge pressure PP rises and be-
comes 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 circuit T through the
drill hole.
• In this way, pump discharge pressure PP is set
to 2.9 MPa {30 kg/cm2}.
10-192 GD555, 655, 675-3C

(8)
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 minimum swash plate
angle of the pump, pump discharge pressure PP
is set to LS pressure PLS + 2.9 MPa {30 kg/cm2}.
When the difference 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
pressure EPLS 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 on PLS : LS circuit
area S3 at the right end of spool (1). When this T : Tank circuit
happens, the area of the opening of the control A : To valves
valve spool is small, so there is a big difference B : To pump LS valve
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 EPLS becomes 2.9
MPa {30 kg/cm2}.
GD555, 655, 675-3C 10-193

(8)
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 actuator 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 con- A : To valves
trol valve spool is large, so the difference be- B : To pump LS valve
tween LS pressure PLS and pump discharge
pressure PP is small.
• For this reason, the difference in pressure be-
tween 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.
10-194 GD555, 655, 675-3C

(8)
INTRODUCTION OF LS PRESSURE
Function to the same pressure as actuation circuit pres-
• The LS pressure is the actuator load pressure at sure A, and sends it to the LS circuit PLS.
the outlet port end of the control valve.
• It actually reduces pump pressure PP at reduc-
ing valve (3) of the pressure compensation valve
Operation
• When spool (1) is operated, pump pressure PP • Actuator circuit pressure PA (=A) acts on the left
flows from flow control valve (2) and notch a in a end of reducing valve (3); the reduced pump
spool (1) through bridge passage b to actuator pressure PP acts on the other end.
circuit A. • As a result, reducing valve (3) is balanced at a
• At the same time, reducing valve (3) also moves position where actuator circuit pressure PA and
to the right, so pump pressure PP has its pres- the pressure of spring chamber PLS1 are the
sure reduced by the pressure loss at notch C. It same. Pump pressure PP reduced at notch C be-
is introduced to LS circuit PLS, and then goes to comes actuator circuit pressure A and is taken to
spring chamber PLS1. 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).
GD555, 655, 675-3C 10-195

(8)
PRESSURE COMPENSATION VALVE

Function
• During compound operations, if the load pres-
sure becomes lower than the other actuator and
the oil flow tries to increase, compensation is re-
ceived. (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 (right • In this way, the pressure difference between up-
side) becomes higher during compound opera- stream pressure PPA and downstream pressure
tions, the oil flow in actuator circuit A on this side PA of both spools used during compound opera-
(left side) tries to increase. tions is the same, so the pump flow is divided in
• If this happens, the LS pressure PLS of the other proportions to the area of opening of notch a of
actuator acts on spring chamber PLS1, and re- each spool.
ducing valve (1) and flow control valve (2) are
pushed to the left (i).
• Flow control valve (2) throttles the area of open-
ing between pump circuit PP and spool upstream
PPA, and pressure loss is generated between
PP and PPA.
• Flow control valve (2) and reducing valve (1) are
balanced in position where the difference in pres-
sure between PLS and PA acting on both ends
of reducing valve (2) and the pressure loss be-
tween PP and PPA on both sides of flow control
valve (2) are the same.
10-196 GD555, 655, 675-3C

(8)
LS BYPASS PLUG
Function
• It releases the residual pressure of LS pressure
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 pressure.
Operation
• The pressurized oil for LS circuit PLS passes PP : Pump circuit
from clearance filter a (formed by the clearance PLS : LS circuit
between LS bypass plug (1) and the valve body) T : Tank circuit
through orifice b and flows to the bank circuit T. A : To valves
B : To pump LS valve
GD555, 655, 675-3C 10-197

(8)
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 actua- • If the LS circuit pressure PLS goes up and reach-
tor is relieved in compound operation, the actua- es the set pressure of LS relief valve (1), PLS is
tor speed is lower than in single operation. kept constant.
• When another actuator is relieved, if the speed • When this happens, the pump circuit PP is set to
lowers remarkably, the working performance is PLS + the spring force of unload valve (2).
lowered. To prevent this, the LS relief valve is • The relief amount of pump circuit PP flows from
employed. unload valve (2) to circuit T. (Pump minimum
• A small pilot relief valve installed to the LS circuit swash plate flow).
controls the maximum pressure. • Relief valve (3) is a backup for the LS relief valve
• The unload valve works as a relief valve installed and has the function of a surge absorption valve.
to the main control valve and 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.
10-198 GD555, 655, 675-3C

(8)
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 (EPLS) of the main • Pump pressure PCF and LS pressure PLS (st)
control valve and the steering valve are set to dif- are brought in from the steering valve.
ferent values; the value for the main control valve • The PCF pressure is taken as the base pressure,
is higher. and LS pressure PLS (v) reduced from PLS (st)
• If the steering is operated with this circuit, the by the load of spring (1) is taken to the main con-
pump discharges the maximum flow. The excess trol valve.
oil is relieved by the unload valve of the main • Check valve (2) is installed to prevent the PP
control valve, so there is a large energy loss. To pressure when the work equipment is operated
prevent this, the steering LS pressure is reduced from entering the steering valve.
and is set to the same value as the LS differential
pressure of the main control valve. This reduces
the loss.
GD555, 655, 675-3C 10-199

(8)
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.
10-200 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL
GD555, 655, 675-3C 10-201

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
Serial No.: 50001 – 51000
STRUCTURE OF SYSTEM
OUTLINE OF SYSTEM
1. Hydraulic pump 3) The pressure loss caused by flow resistance

1) The hydraulic oil inside the hydraulic tank in the piping varies according to the temper-
passes through the hydraulic pump and is ature. At low temperature, the necessary
sent to the priority ACC governor valve. control pressure may be lacking, and the
2) The hydraulic pump is the source of hydrau- necessary flow may not be provided. But to
lic power for the steering brake, work equip- prevent this, pressure PP which is close to
ment, parking brake, and bank control lock each piece of equipment is brought to the
pin. When there is a demand from the hydraulic pump, and the pressure generated
equipment, it generates an oil flow of the by the hydraulic pump is controlled so that
necessary amount and pressure to match the differential pressure between PP and LS
the demands of the equipment. is 2.35 MPa {24 kg/cm2}.
(= LS pressure + control pressure 4) In addition, it checks the pressure and dis-
2.35 MPa {24 kg/cm2} charge amount of the hydraulic pump, and
At neutral, the steering LS pressure ensures the resilience of the engine when
0.80 – 1.1 MPa {8 – 11 kg/cm2} + 2.35 MPa there is compound operation or when there
{24 kg/cm2} + pressure loss in piping = is excessive load caused by the PQ control
3.24 – 3.63 MPa {33 – 37 kg/cm2}. when controlling at PQ = constant value.
10-202 GD555, 655, 675-3C

(4)
5) When there are no demands for oil from the 3. Brake circuit
steering or work equipment (the system is at 1) The oil that is given priority and ensured for
neutral), the swash plate in the hydraulic the circuit has its pressure raised to the nec-
pump is held at a position where a fixed essary pressure by the priority ACC gover-
minimum flow is discharged so that the nor valve and is charged in the brake
hydraulic pump can respond swiftly to any accumulators inside the piping of the two
rapid operation of the steering or work systems.
equipment. 2) If the brake is used and the pressure goes
down to 9.32 MPa {96 kg/cm2}, the priority
2. Steering circuit ACC governor valve is actuated and the
1) The priority ACC governor valve is provided brake accumulator is charged to the speci-
to ensure the necessary oil flow and to give fied pressure of 13.4 MPa {137 kg/cm2}.
priority to the oil flow in the steering brake 3) Even after the engine is stopped, braking is
system, which is closely related to safety, possible for a limited time using the pres-
rather than to the work equipment. sure inside the brake accumulator.
2) The steering valve is an energy-saving, 4) When the brake accumulator pressure goes
closed center type which lets the hydraulic down, the force releasing the parking brake
oil flow only when necessary. When the is reduced and the parking brake is auto-
steering is not being operated, it stops the matically applied by the force of the spring.
flow of oil. If the machine is stopped for a certain time,
When the steering wheel is operated, the the parking brake is automatically applied,
pressure (LS pressure) passes through the and it can only be released by starting the
priority ACC governor valve o LS pressure engine.
regulator valve, and goes to the servo valve 5) In postures such as the bank cut posture or
of the hydraulic pump to ensure the neces- shoulder reach posture, when changing the
sary flow. It also generates pressure so that posture of the work equipment, the lifter lock
Pb = LS pressure + 2.35 MPa {24 kg/cm2} + pin is removed and installed.
pressure loss in piping. At the same time, When doing this, the accumulator is also
the LS pressure is transmitted to the priority used as the source of hydraulic power.
ACC governor valve. Priority is given to the 6) The brakes are the most important devices
steering circuit by keeping the spool at a for ensuring safety, so charging always
position where it can provide the necessary starts immediately the engine is started. But
oil flow to the steering circuit, regardless of particularly when starting in cold weather, if
whether there is any demand for oil from the the accumulator is charged during the start-
work equipment. ing operation, there will be an excessive
3) The steering valve is a Q-Amp type that pro- load on the hydraulic pump, and this will
vides good control at high speed and engine make it difficult to start the engine. To pre-
should stall or if any problem should occur in vent this, an electromagnetic LS pressure
the variable pump. release valve is installed. This cancels the
4) The maximum pressure in the steering cir- charging of the accumulator when the start-
cuit is determined by the relief valve inside ing motor is cranking and makes it easier to
the priority ACC governor valve. It is differ- start the engine.
ent from the hydraulic pressure for the work
equipment.
GD555, 655, 675-3C 10-203

(4)
4. LS pressure regulator valve 5. Control valve

1) To improve the response when the steering 1) The control valve is a closed center type, so
is operated suddenly and to ensure a quick at neutral when the work equipment is not
response for the work equipment, a speci- being used, the hydraulic oil returns from
fied minimum flow of oil is discharged from the unload valve to the hydraulic tank. The
the hydraulic pump, so an unload valve is unload pressure is 3.1 MPa {32 kg/cm 2 }
installed to the control valve. when the engine is at low idling and 3.5
2) When the steering is operated, the steering MPa {35 kg/cm2} when it is at full throttle.
LS pressure rises and the pump discharge 2) When the work equipment control valve
is increased. For this reason, the steering lever is operated, the pressure at the valve
Pb pressure also rises, but the function of inlet side is transmitted to the hydraulic
the priority ACC governor valve sends the pump as Pb. At the same time, the maxi-
excess oil used for the steering to the con- mum pressure for the work equipment load
trol valve. When this happens, if the control passes through the LS line and is transmit-
valve is open, this excess oil flow is relieved ted to the hydraulic pump, so the necessary
by the unload valve and returns to the tank. oil flow is sent from the hydraulic pump.
This causes an energy loss, so when the 3) At hydraulic relief, the upper limit for the LS
steering brake is charged and the oil is not pressure is determined by the LS relief
being used for the work equipment, a signal valve. The control valve is a closed center
is sent to the unload valve. The control valve load sensing valve, and has a proportional
is set to on-load and shuts off the flow of oil flow and proportional dividing pressure com-
back to the hydraulic tank to prevent loss of pensation function. It also has a built-in
energy. unload valve, LS relief valve, and surge
3) The internal shuttle valve transmits the absorption valve. This gives it the following
higher of the steering brake charge LS pres- features.
sure and the work equipment LS pressure to • The operating effort is light and the lever
the pump to make is possible to carry out travel is short.
simultaneous operations. • It is possible to adjust each work equip-
4) The excess oil flow for the steering brake is ment to the optimum cylinder set speed.
sent to the control valve. • The raise and lower speeds (cylinder ex-
tending and retracting speeds) are the
same, so the height can be adjusted.
• There is a wide fine control range.
• A constant movement position can be
obtained, regardless of the load.
• The work equipment can be operated
with small movements of the lever and
fine control is easy.
• Operations are certain even during si-
multaneous operations.
• Simultaneous operations are possible
even when there is a lack of oil.
• Other work equipment moves even
when there is hydraulic relief.
• When used in combination with the
CLSS hydraulic pump, it has the follow-
ing features.
• The work equipment speed is fixed, re-
gardless of the engine speed.
• The neutral loss is reduced.
• The relief loss is reduced.
• There is little problem of the engine stall-
ing even during compound operations or
when there is a large load.
10-204 GD555, 655, 675-3C

(4)
STRUCTURE OF SYSTEM
OUTLINE OF SYSTEM
1. Hydraulic pump
1) The hydraulic oil inside the hydraulic tank 3) The pressure loss caused by flow resistance
passes through the hydraulic pump and is in the piping varies according to the temper-
sent to the priority valve. ature. At low temperature, the necessary
2) The hydraulic pump is the source of hydrau- control pressure may be lacking, and the
lic power for the steering brake, work equip- necessary flow may not be provided. But to
ment, parking brake, and bank control lock prevent this, pressure PP which is close to
pin. When there is a demand from the each piece of equipment is brought to the
equipment, it generates an oil flow of the hydraulic pump, and the pressure generated
necessary amount and pressure to match by the hydraulic pump is controlled so that
the demands of the equipment. the differential pressure between PP and LS
=LS pressure + control pressure is 2.35 MPa {24 kg/cm2}.
2.35 MPa {24 kg/cm2} 4) In addition, it checks the pressure and dis-
At neutral, the steering LS pressure charge amount of the hydraulic pump, and
0.8 to 1.1 MPa {8 to 11 kg/cm2} + 2.35 MPa ensures the resilience of the engine when
{24 kg/cm2} + pressure loss in piping = 3.24 there is compound operation or when there
to 3.63 MPa (33 to 37 kg/cm2}. is excessive load caused by PQ control
when controlling at PQ = constant value.
GD555, 655, 675-3C 10-205

(8)
5) When there are no demands for oil from the 3. Brake circuit
steering or work equipment (the system is at 1) The oil that is given priority and ensured for
neutral), the swash plate in the hydraulic the circuit has its pressure raised to the nec-
pump is held at a position where a fixed essary pressure by the priority valve and is
minimum flow is discharged so that the charged in the brake accumulators inside
hydraulic pump can respond swiftly to any the piping of the two systems.
rapid operation of the steering wheel or 2) If the brake is used and the pressure goes
work equipment. down to 9.36 MPa {95 kg/cm2} the accumu-
lator pressure governor valve is actuated
2. Steering circuit and the brake accumulator is charged to the
1) The priority valve is provided to ensure the specified pressure of 13.4 MPa {137 kg/
necessary oil flow and to give priority to the cm2}.
oil flow in the steering brake system, which 3) Even after the engine is stopped, braking is
is closely related to safety, rather than to the possible for a limited time using the pres-
work equipment. sure inside the brake accumulator.
2) The steering valve is an energy saving 4) When the brake accumulator pressure goes
closed center type which lets the hydraulic down, the force releasing the parking brake
oil flow only when necessary. When the is reduced and the parking brake is auto-
steering is not being operated, it stops the matically applied by the force of the spring.
flow of oil. If the machine is stopped for a certain time,
When the steering wheel is operated, the the parking brake is automatically applied,
pressure (LS pressure) passes through the and it can only be released by starting the
accumulator pressure governor valve o LS engine.
pressure regulator valve, and goes to the 5) In postures such as the bank cut posture or
servo valve of the hydraulic pump to ensure shoulder reach posture, when changing the
the necessary flow. It also generates pres- posture of the work equipment, the lifter lock
sure so that Pb = LS pressure + 2.35 MPa pin is removed and installed. When doing
{24 kg/cm2} + pressure loss in piping. At the this, the accumulator is also used as the
same time, the LS pressure is transmitted to source of hydraulic power.
the priority valve through the accumulator 6) The brakes are the most important devices
pressure governor valve. Priority is given to for ensuring safety, so charging always
the steering circuit by keeping the spool at a starts immediately after the engine is
position where it can provide the necessary started. But particularly when starting in cold
oil flow to the steering circuit, regardless of weather, if the accumulator is charged dur-
whether there is any demand for oil from the ing the starting operation, there will be an
work equipment. excessive load on the hydraulic pump, and
3) The steering valve is a Q-Amp type that pro- this will make it difficult to start the engine.
vides good control at high speed and can To prevent this, an electromagnetic LS pres-
also ensure the steering ability if the engine sure release valve is installed in the accu-
should stall or if any problem should occur in mulator pressure governor valve. This
the variable pump. cancels the charging of the accumulator
4) The maximum pressure in the steering cir- when the starting motor is cranking and
cuit is determined by the relief valve inside makes it easier to start the engine.
the priority valve. It is different from the
hydraulic pressure for the work equipment.
10-206 GD555, 655, 675-3C

(8)
4. LS pressure regulator valve 5. Control valve

1) To improve the response when the steering 1) The control valve is closed center type, so at
is operated suddenly and to ensure a quick neutral when the work equipment is not
response for the work equipment, a speci- being used, the hydraulic oil returns from
fied minimum flow of oil is discharged from the unload valve to the hydraulic tank. The
the hydraulic pump, so an unload valve is unload pressure 3.1 MPa {32 kg/cm2} when
installed to the control valve. the engine is at low idle and 3.5 MPa {35 kg/
2) When the steering is operated, the steering cm2} when it is at full throttle.
LS pressure rises and the pump discharge 2) When the work equipment control valve
pressure is increased. For this reason, the lever is operated, the pressure at the valve
steering Pb pressure also rises, but the inlet side is transmitted to the hydraulic
function of the priority valve sends the pump as Pb. At the same time, the maxi-
excess oil used for the steering to the con- mum pressure for the work equipment load
trol valve. When this happens, if the control passes through the LS line and is transmit-
valve is open, this excess oil flow is relieved ted to the hydraulic pump, so the necessary
by the unload valve and returns to the tank. oil flow is sent from the hydraulic pump.
This causes an energy loss, so when the 3) At the hydraulic relief, the upper limit for the
steering brake is charged and the oil is not LS pressure is determined by the LS relief
being used for the work equipment, a signal valve. The control valve is a closed center
is sent to the unload valve. The control valve load sensing valve, and has a proportional
is set to on-load and shuts off the flow of oil flow and proportional dividing pressure com-
back to the hydraulic tank to prevent loss of pensation function. It also has a built-in
energy. unload valve, LS relief valve, a surge
3) The internal shuttle valve transmits the absorption valve. This gives it the following
higher of the steering brake charge LS pres- features.
sure and the work equipment LS pressure to • The operating effort is light and the lever
the pump to make it possible to carry out travel is short.
simultaneous operations. • It is possible to adjust each work equip-
4) The excess oil flow for the steering brake is ment to the optimum cylinder set speed.
sent to the control valve. • The raise and lower speeds (cylinder ex-
tending and retracting speeds) are the
same, so the height can be adjusted.
• There is a wide fine control range.
• A constant movement position can be
obtained, regardless of the load.
• The work equipment can be operated
with small movements of the lever and
fine control is easy.
• Operations are certain even during si-
multaneous operations.
• Simultaneous operations are possible
even when there is lack of oil.
• Other work equipment moves even
when there is hydraulic relief.
When used in combination with the CLSS
hydraulic pump, it has the following fea-
tures.
• The work equipment speed is fixed, re-
gardless of the engine speed.
• The neutral loss is reduced.
• The relief loss is reduced.
• There is little problem of the engine stall-
ing even during compound operations or
when there is a large load.
GD555, 655, 675-3C 10-207

(8)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
1. Filter
2. Filter by-pass
3. Oil filler
4. Oil filler strainer
5. Strainer
10-208 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWIVEL JOINT
SWIVEL JOINT
Serial No.: 50001 – 51000
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. Roter
GD555, 655, 675-3C 10-209

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 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
10-210 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PILOT CHECK VALVE
PILOT CHECK VALVE

For blade lift (right), leaning, articulating, 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 control
valve is operated and oil from the pump enters port
A, opens check valve (5), and flows to port D. When
pressure is generated, the oil from orifice a pushes
up piston (1), then opens check valve (2), connects
port C and port B, and flows to the drain port.
Hunting occurs when check valve (2) opens and
closes to compensate for changes in the pressure at
the bottom end and head end, but even if the pres-
sure at port A goes down, orifice a is provided, so
there is a damper effect to prevent check valve (2)
from closing immediately.
10-212 GD555, 655, 675-3C

(4)
For blade lift (left)
1. Check valve
2. Plug
3. Body
4. Piston
5. Relief valve
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 posi-
tion and the drawbar is shifted to the side, the draw-
bar stopper and lifter come into contact.
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 during
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 equip-
ment and relieves the shock.
GD555, 655, 675-3C 10-213

(4)
For ripper (GD555-3C)
1. Piston
2. Check valve
Operation
When the control valve is operated to lower the rip-
per, 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 cyl-
inder head returns to the tank. The ripper hold pres-
sure is acting on the head end of the ripper 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 bot-
tom and head ends. This will cause ripper chatter-
ing. To prevent this, a throttle is installed at E which
acts as a damper, so even if the pressure at the bot-
tom end drops, the check valve will not close imme-
diately.
10-214 GD555, 655, 675-3C

(4)
For blade tilt, ripper (GD655, 675-3C)
1. Check valve
2. Piston
3. Body
4. Check valve
5. Relief valve

Operation
When the lever is operated to extend the cylinder, oil
from the pump enters chamber A1 and pushes pis-
ton (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 chamber 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 form 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.
GD555, 655, 675-3C 10-215

(4)
For scarifier
1. Check valve
2. Piston
3. Body
4. Check valve
5. Relief valve
A1:From control valve

A2:From control valve
B1:To cylinder head
B2:To cylinder bottom

Operation
Operating the lever to retract the cylinder, oil from
the pump enters chamber A1 and pushes check
valve (1). Oil 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 bottom of the
cylinder flows back through chamber B2 and cham-
ber 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 cylinder. As pres-
sure 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 during
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 equip-
ment and relieves the shock.
10-216 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BLADE ACCUMULATOR, FLOAT VALVE
BLADE ACCUMULATOR, FLOAT VALVE

OUTLINE
• The blade accumulator prevents excessive load • The blade float can be used in clearing fresh
and pushing up by the blade in propulsion work snow. It allows only the weight of the work equip-
on roads where there are many buried rocks. In ment to push against the snow, making it possi-
this way, it improves the durability of the work ble to carry out operations following the ups and
equipment and blade, and reduces operator fa- downs on the road surface, allowing fresh snow
tigue. to be cleared effectively at high speed, while in-
The blade accumulator can also be used effec- creasing the safety of the operation.
tively in snow-clearing operations on compacted
snow. It is possible to carry out operations fol-
lowing the ups and downs on the road surface,
so the snow can be cleared smoothly.
FOR BLADE LIFT (LEFT)
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
GD555, 655, 675-3C 10-217

(4)
FOR BLADE LIFT (RIGHT)
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
10-218 GD555, 655, 675-3C

(4)
ACCUMLATOR
For blade float
1. Valve assembly
2. Top cover
3. Cylinder
4. Cylinder
Specifications
Gas used: Nitrogen gas
Amount of gas: 1,000 cc
Gas charging pressure: 2.0 ± 0.1 MPa
{20 ± 1.0 kg/cm2} (at 20 ± 5°C)
Function
When oil pressure is applied to the blade cylinder,
the pressure oil flows to the accumulator through the
solenoid valve and the oil flows into cylinder (4).
Thereby, nitrogen gas is compressed and piston
mov es upper side. Cons equently, the shock
imposed on the blade cylinder is reduced by the
compressible amount of the nitrogen gas.
When the oil pressure in the blade cylinder drops,
the piston moves to lower side by the gas pressure
in cylinder (3), and the oil in cylinder (4) sends to the
blade cylinder until the oil pressure in the cylinder
balances to that in blade cylinder circuit. The flow of
oil in the accumulator hydraulic circuit is repeated
smoothly to reduce the shock imposed on the blade.
GD555, 655, 675-3C 10-219

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SHUT-OFF VALVE
SHUT-OFF VALVE
Serial No.: 50001 – 51000
1. Connector Function
2. Filter When the engine is started, this valve temporarily
3. Spring stops the charging of the accumulator in the brake
4. Spool circuit. This reduces the load on the engine and
5. Solenoid makes it easier to start the engine.
Specifications
Max. pressure A: 20.6 MPa {210 kg/cm2}
B: 15.7 MPa {160 kg/cm2}
Max. flow: 20 l/min
GD555, 655, 675-3C 10-221

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BLADE FLOAT DEVICE
BLADE FLOAT DEVICE
10-222 GD555, 655, 675-3C

(4)
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 condi-
tion.
• When the blade float and accumulator switch (1)
is pushed to FLOAT position, and the blade lift le-
ver is operated to the RAISE or LOWER position,
proximity switch (4) turns the blade float and ac-
cumulator switch (1), and the blade returns to
normal RAISE or LOWER condition, and this
condition maintained. If the blade lift lever is re-
turned to the N position, the blade is placed in
floating condition.
a If the blade and accumulator switch (1) is
pushed to FLOAT position with the blade raised,
the blade will suddenly drop.
GD555, 655, 675-3C 10-223

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CIRCLE ROTATION MOTOR
CIRCLE ROTATION MOTOR
1. Output shaft
2. Flange
3. Shaft seal
4. Taper roller bearing for heavy loads
5. Main drive
6. O-ring
7. Giroller
8. Valve drive
9. Wear compensation mechanism valve
10. PF1/2 rolling port
11. Check valve
12. Valve plate
10-224 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CIRCLE ROTATION MOTOR
Outline
The circle rotation motor is a small, compact low-
speed torque motor and the giroller carries out plan-
etary motion. Therefore, it can provide the same
torque as other types of hydraulic motors using a
mechanical reduction 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 sta-
ble performance over long periods.
A taper roller bearing for heavy loads is assembled
to the output shaft, so it can withstand high radial
loads and high thrust loads.
Operation
The high-pressure oil flowing into the motor passes
through disc valve (1), enters giroller (2), and the
star of giroller (2) moves in a planetary motion. Of
this planetary motion, only the rotation is taken off by
main drive (3) to rotate output shaft (4).
When this happens, disc valve (1) is driven by valve
drive (4). The relationship between the positions of
the 12 ports of disc valve (1) and the 7 ports (5) of
the valve plate changes, and the position of the
hydraulic oil flowing to giroller (2) changes in turn.
GD555, 655, 675-3C 10-225

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
GD555-3C
Unit: mm

size Shaft Hole clearance limit
–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
Clearance Drawbar –0.025 +0.152 0.032 to
45 0.539
between shift –0.087 +0.007 0.239 Replace
1
piston rod and bushing
–0.025 +0.132 0.031 to
bushing 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
10-226 GD555, 655, 675-3C

(4)
Unit: mm

–0.06 +0.02 0.06 to

Steering 55 1.0
–0.09 +0.02 0.11
–0.05 +0.1 0.05 to
Blade lift 80 1.0
–0.15 +0.1 0.25
Blade side –0.025 +0.142 0.105 to
40 1.0
shift –0.064 +0.080 0.206
80 1.0
between pis- shift –0.15 +0.1 0.25
2
ton rod support
–0.025 +0.142 0.104 to
and bushing 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 –0.012 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 0.13 to Replace
Ripper 55 1.0 bushing
–0.076 +0.100 0.25
–0.025 –0.012 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 +0.062 0.204
Blade side –0.025 +0.142 0.105 to
40 1.0
shift –0.064 +0.080 0.206
80 1.0
between cylin- shift –0.15 +0.10 0.25
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
Articulate 50 1.0
ing –0.064 +0.080 0.206
–0.025 –0.012 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, 675-3C 10-227

(4)
Unit: mm
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
618 ± 61.8 Nm {63 ± 6.3 kgm} (width across flats: 41)
shift
Drawbar
Piston nut 618 ± 61.8 Nm {63 ± 6.3 kgm} (width across flats: 41)
shift
4 tightening
torque Leaning 412 ± 41.2 Nm {42 ± 4.2 kgm} (width across flats: 36)
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
588 ± 58.8 Nm {60 ± 6 kgm}
shift
Drawbar
Cylinder head 588 ± 58.8 Nm {60 ± 6 kgm}
shift
5 tightening
torque Leaning 539 ± 53.9 Nm {55 ± 5.5 kgm}
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}
10-228 GD555, 655, 675-3C

(4)
GD655, 675-3C
Unit: mm

–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
45 0.539
between shift –0.087 +0.007 0.239 Replace
1
piston rod and bushing
–0.025 +0.132 0.031 to
bushing Leaning 40 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
–0.030 +0.163 0.036 to
Ripper 55 0.567
–0.104 +0.006 0.267
GD555, 655, 675-3C 10-229

(4)
Unit: mm

–0.06 +0.02 0.06 to

Steering 55 1.0
–0.09 +0.02 0.11
–0.05 +0.1 0.05 to
Blade lift 80 1.0
–0.15 +0.1 0.25
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 0.05 to
between 80 1.0
shift –0.15 +0.1 0.25
2 piston rod
support and –0.025 +0.142 0.104 to
Leaning 50 1.0
bushing –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 –0.012 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 0.13 to Replace
Ripper 60 1.0 bushing
–0.076 +0.100 0.25
–0.025 –0.012 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 +0.062 0.204
Blade side –0.025 +0.142 0.105 to
40 1.0
shift –0.064 +0.080 0.206
80 1.0
between shift –0.15 +0.10 0.25
cylinder bottom
–0.025 +0.142 0.105 to
3 (yoke, support Leaning 45 1.0
–0.064 +0.080 0.206
ball joint,
support) and –0.025 +0.142 0.105 to
Articulate 50 1.0
bushing –0.064 +0.080 0.206
–0.025 –0.012 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
10-230 GD555, 655, 675-3C

(4)
Unit: mm
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
618 ± 61.8 Nm {63 ± 6.3 kgm} (width across flats: 41)
shift
Drawbar
Piston nut 618 ± 61.8 Nm {63 ± 6.3 kgm} (width across flats: 41)
shift
4 tightening
torque Leaning 618 ± 61.8 Nm {63 ± 6.3 kgm} (width across flats: 41)
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 ± 77 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
588 ± 58.8 Nm {60 ± 6 kgm}
shift
Drawbar
Cylinder head 588 ± 58.8 Nm {60 ± 6 kgm}
shift
5 tightening
torque Leaning 588 ± 58.8 Nm {60 ± 6 kgm}
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, 675-3C 10-231

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CIRCLE, DRAWBAR
CIRCLE, DRAWBAR
10-232 GD555, 655, 675-3C

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

Wear of drawbar ball joint size Shaft Hole clearance ance limit Adjust or
21
end replace
–0.050 +0.100 0.050 to
150 —
–0.100 +0.100 0.200
–0.030 +0.174 0.130 to
Clearance GD555 75 0.6
–0.076 +0.100 0.250 Replace
22 between yoke
GD655 –0.030 +0.220 0.190 to bushing
and bushing 75 0.6
GD675 –0.076 +0.160 0.296
Standard clearance Clearance limit Replace

23 Axial clearance of yoke yoke or
0.8 to 1.3 2.0 bushing
Clearance between circle Adjust or
24 0 to 3.0 1.0 to 2.0
and drawbar replace
GD555, 655, 675-3C 10-233

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LIFTER BRACKET LOCK PIN
LIFTER BRACKET LOCK PIN
The lifter bracket is fixed by bank pin (3). When set- 1. Parking, bank control valve
ting in the bank cutting position, operate control 2. Lifter
lever. This uses hydraulic oil to push piston (4). The 3. Bank pin
pin can be removed and the bracket can then be 4. Piston
rotated. 5. Bushing
6. Case
10-234 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BLADE
BLADE
1. Adjuster 3. Drawbar side-shift cylinder

2. Blade tilt cylinder 4. Blade side-shift cylinder
10-236 GD555, 655, 675-3C

(4)
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 cut-
ting angle of the blade. Adjustment can be made
freely between 32° and 81° using a single lever.
The guide acts as a bushing for the sliding parts
when shifting the blade to the side. If the clear-
ance from the sliding parts is too large and the
finishing accuracy cannot be obtained, adjust the
shims or replace the guide.
Unit: mm

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 Wear of blade Height 368 364
Replace
7b rail Thickness 25 21
8a Height 8 5
Wear of blade
rail guide Width of
8b 25 33
groove
GD555, 655, 675-3C 10-237

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CIRCLE ROTATION GEAR
CIRCLE ROTATION GEAR
1. Drain plug
2. Worm wheel
3. Oil filler plug
4. Joint
5. Shear pin
6. Worm gear
10-238 GD555, 655, 675-3C

(4)
Unit: mm

Std. Size
Clearance between worm Shaft Hole clearance limit
7
wheel shaft and bushing Replace
+0.291 +0.057 0.281 to
75 0.4 bushing
+0.077 +0.010 0.02
Clearance between worm +0.035 +0.057 0.052 to
8 75 0.4
wheel shaft and bushing +0.005 +0.010 0.025
Backlash between worm and Standard clearance Clearance limit

9 Replace
worm wheel 0.3 to 0.4 2.0
Cleaarance between pinion
10 0.1 to 0.5 0.6 Adjust
gear and wear plate
11 Pinion gear wear Replace
25 20
Starting torque: 2.9 to 7.8 Nm (0.3 to 0.8 kgm)
12 Wormshaft bearing preload Adjust
when worm wheel is not meshed
GD555, 655, 675-3C 10-239

(4)
With slip clutch
1. Floating seal Outline

2. Shaft • The circle rotation gear is driven by an oil motor
3. Case connected to worm gear shaft (12).
4. Worm wheel • Pinion gear shaft (2) has a clutch mechanism,
5. Plate and if an abnormal rotating force is transmitted
6. Disc from the blade, disc (6) slips to prevent breakage
7. Spring of the blade.
8. Cover • The clutch pressure of this clutch mechanism is
9. Shim adjusted by the thickness of shim (9).
10. Pinion gear
11. Drain plug
12. Worm gear shaft
13. Oil motor
10-240 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SCARIFIER
SCARIFIER
10-242 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SCARIFIER
1. Lift arm
2. Scarifier cylinder
3. Scarifier body
4. Wedge
Unit: mm
Standard size Repair limit Replace

5 Tooth wear
450 330 tooth
Replace
6 Point tooth wear 450 407
point
GD555, 655, 675-3C 10-243

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RIPPER
RIPPER
GD555-3C
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 per-
forms heavy-duty digging work that cannot be
done by the scarifier.
Unit: mm

Std. size
Clearance between pin and Shaft Hole clearance limit
4
bushing
–0.025 +0.142 0.105 to
50 0.5
–0.050 +0.080 0.192
Clearance between pin and –0.025 +0.046 0.025 to
5 60 0.5 Replace
bushing –0.055 +0.046 0.101
Clearance between trunnion –0.100 +0.174 0.200 to
6 60 0.5
and bushing –0.174 +0.100 0.348
7 Point wear
198 123
10-244 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RIPPER
GD655-3C, GD675-3C
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 per-
forms heavy-duty digging work that cannot be
done by the scarifier.
Unit: mm

Std. size
Clearance between pin and Shaft Hole clearance limit
4
bushing
–0.025 +0.142 0.105 to
50 0.5
–0.050 +0.080 0.292
Clearance between pin and –0.030 +0.054 0.03 to
5 60 0.5 Replace
bushing –0.076 +0.054 0.13
Clearance between trunnion –0.100 +0.174 0.200 to
6 60 0.5
and bushing –0.174 +0.100 0.348
7 Point wear
290 150
GD555, 655, 675-3C 10-245

(4)
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, 675-3C 10-247

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER (IF EQUIPPED)
AIR CONDITIONER (IF EQUIPPED)

AIR CONDITIONER PIPING
Serial No.: 50001 – 51000
1. Condenser
2. Air conditioner compressor
3. Receiver-dryer
10-248 GD555, 655, 675-3C

(4)
4. Air conditioner unit

4a. Hot water heater
4b. Evaporator
4c. Blower unit
GD555, 655, 675-3C 10-249

(4)
1. Condenser
2. Air conditioner compressor
3. Receiver-dryer
10-250 GD555, 655, 675-3C

(4)
4. Air conditioner unit

4a. Hot water heater
4b. Evaporator
4c. Blower unit
GD555, 655, 675-3C 10-251

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE STARTING CIRCUIT
ENGINE STARTING CIRCUIT

Serial No.: 50001 – 51000
Function Operation
• To ensure safety while starting the engine, a • When the starting switch is turned to the ON po-
neutral safety circuit is used. This circuit makes it sition, electricity flows from the switch BR termi-
impossible to start the engine, if the gearshift le- nal to the battery relay. The battery relay points
ver is not at the P (PARK) position. now close. In addition, electricity flows from the
• After starting the engine, pressurized oil is stored ACC terminal of the switch to the holding coil of
in the brake circuit accumulator. However, this the fuel shut-off solenoid to supply fuel.
process is temporarily canceled while starting • When the gearshift lever is at the P (PARK) posi-
the engine to reduce the load on the engine, tion, electricity flows from gearshift lever terminal
making it easier to start the engine. 6 to the coil of the neutral relay. Electricity now
flows through contacts 3 and 5 of the neutral re-
lay.
• If the gearshift lever is not in the P (PARK) posi-
tion, the flow of electricity from the gearshift lever
terminal 6 is stopped. Thus, no electricity flows to
the neutral relay and the engine starting circuit is
not energized.
10-252 GD555, 655, 675-3C

(4)
• When the starting switch is turned to the START

position, electricity flows from terminal C at the
switch to terminals 3 and 5 of the starter relay
and then to ground, completing the circuit. The
engine now starts. Electrical current also flows
from terminal C of the switch to the starter sole-
noid. The storage of pressurized oil in the accu-
mulator is temporarily canceled.
• After the engine starts, electricity flows from the
neutral relay to the fuel shut-off relay and closes
the fuel shut-off relay contact. Electrical current
now flows to the pull-in coil of the fuel shut-off so-
lenoid. The system is now set to the maximum
fuel supply condition.
• When the starting switch is returned to the ON
position, the flow of electric current from terminal
C of the switch is stopped, the starting motor re-
lay points open, and the flow of electric current to
the starting motor is blocked. At the same time,
the fuel shut-off relay contacts open and the fuel
shut-off solenoid returns to the normal fuel sup-
ply condition. In addition, the power supply is
shut off from the starter solenoid. Thus, the sys-
tem returns to the normal condition and the hy-
draulic pump starts and pressure is stored in the
accumulator.
GD555, 655, 675-3C 10-253

(4)
Function Operation
• The neutral safety circuit is employed to secure • If the starting switch is turned from the OFF posi-
safety when the engine is started. This circuit al- tion to the START position, a current flows from
lows the engine to start only when the gearshift starting switch terminal BR to the battery relay to
lever is in the P (Parking) position. "close" the contacts of the battery relay.
• When the engine is started, storing pressure in • The current flows in the holding coil of the sole-
the accumulator of the brake circuit is canceled noid to supply fuel. It also flows in the fuel shut-
temporarily to reduce the load of the hydraulic off timer to "close" the contacts of the fuel shut-
pump on the engine for the ease of starting of the off relay for about 3 seconds. Then, the current
engine. also flows in the pull-in coil of the fuel shut-off so-
In addition, the engine start auxiliary switch is lenoid to supply the fuel at the maximum rate so
installed to reduce the load on the engine and that the engine will be started easily.
stabilize the engine rotation when the engine is • If the gearshift lever is in the P (Parking) position,
started at low temperature. a current flows from gearshift lever terminal 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 (Parking)
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 starting
switch terminal C to the engine startup solenoid
to temporarily cancel storing pressure in the
brake accumulator so that the load on the engine
will be reduced and the engine will be started
easily.
10-254 GD555, 655, 675-3C

(4)
• After the engine is started, if the starting switch is

turned to the ON position, the current flowing
from starting switch terminal C is turned OFF,
and the current flowing through neutral relay ter-
minals 1 and 2 to the starting motor is turned off
consequently.
The current flowing in the engine startup sole-
noid is turned OFF, the solenoid is returned to
the normal state, and the hydraulic pump starts
storing pressure in the accumulator.
• A current keeps flowing from starting switch ter-
minal 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 solenoid. Accordingly, the fuel
supplied normally.
• If the engine start auxiliary switch is held even af-
ter the engine is started in when the temperature
is low, a current flows from neutral relay terminal
3 through terminal 4 to the engine startup sole-
noid to reduce the load of the hydraulic pump on
the engine while the switch is held.
GD555, 655, 675-3C 10-255

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT

Serial No.: 50001 – 51000
Function
• Turning the starting switch to the OFF position
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.
10-256 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE STOP CIRCUIT
Function
• Turning the starting switch to the OFF position
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.
GD555, 655, 675-3C 10-257

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PREHEAT CIRCUIT
PREHEAT CIRCUIT
Serial No.: 50001 – 51000
Operation
• Turning the starting switch to the PREHEAT po-
sition, electricity flows from switch terminal BR to
the battery relay to ground. The battery 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 bat-
tery relay to the heater relay to the preheater to
ground. The circuit is complete and the engine is
heated.
• Simultaneously, current now flows from terminal
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 preheating pilot
lamp to ground for a fixed period of time. The cir-
cuit is now complete and the preheating pilot
lamp lights up.
10-258 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PREHEAT CIRCUIT
Operation
• If the starting switch is set in the PREHEAT posi-
tion, 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 pre-
heated.
• At this time, another current flows from starting
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, 675-3C 10-259

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SHIFT CONTROL SYSTEM
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 signals from oth-
er switches and sensors. The transmission con-
troller automatically shifts the transmission to the
most suitable speed range. In addition to shift
control the transmission controller also drives
and controls the torque converter lock-up sole-
noid.
10-260 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER
Outline
• This transmission controller controls the system
using a built-in computer, which has the following
functions:
• Upshifts and downshifts in relation to the pedal
angle.
• 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 Q Q
F2 Q Q
F3 Q Q
F4 Q Q
F5 Q Q
F6 Q Q
F7 Q Q
F8 Q Q
R1 Q Q
R2 Q Q
R3 Q Q
R4 Q Q
GD555, 655, 675-3C 10-261

(4)
GEARSHIFT LEVER POSITION
Gearshift lever position 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 converter pat-
tern changes.
• When the transmission mode switch is in in “MODE 1”, the gear is shifted manually at each lever position.
• When the transmission mode switch is in in “MODE 2”, the gear is shifted manually at the lever positions of
F1 – F4 and R1 – R4 but shifted automatically at the lever positions of F5 – F8 according to the travel speed.
(Automatic gearshifting)
MODE 1
LEVER Speed Range
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 A
MODE 2
LEVER Speed Range
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
10-262 GD555, 655, 675-3C

(4)
Gearshifting diagram
• Gearshifting range
• As the transmission mode selector switch is operated, the gearshift pattern changes.
GD555, 655, 675-3C 10-263

(4)
OVERRUN PREVENTION FUNCTION
Automatic gearshift wiring diagram • When shifting gears suddenly, the transmission
• Transmission mode switch: Mode 2 may enter a speed range that does not match the
• Lever position: F5 – F8 position of the lever. This action prevents the en-
gine from overrunning. When this situation oc-
curs, a short warning sound is given to warn the
operator. Reducing the machine’s travel speed
automatically shifts the transmission to the posi-
tion selected by the lever.
Ultra low-speed travel control

• When the gearshift lever is at F1, the transmis-
sion is in the torque converter mode, the acceler-
ator pedal is not depressed, and if the travel
speed is less than 1.8 km/h (1.1 mph), the trans-
mission 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, switching
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
10-264 GD555, 655, 675-3C

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR
MONITOR
MONITOR PANEL
1. Engine water temperature gauge 13. Differential oil temperature caution lamp
2. Turn signal pilot lamp (if equipped)
3. Speedometer 14. Differential control pilot lamp (if equipped)
4. Turn signal pilot lamp 15. AWD pilot lamp (if equipped)
5. Fuel gauge 16. Working pilot lamp (if equipped)
6. Message center 17. Blade accumulator pilot lamp (if equipped)
7. Engine oil pressure caution lamp 18. Preheating pilot lamp
8. Battery charge caution lamp 19. Blade float pilot lamp (if equipped)
9. Electric circuit monitor of transmission system 20. Head lamp beam pilot lamp
caution lamp 21. Parking brake pilot lamp
10. Brake oil pressure caution lamp 22. Torque converter oil temperature gauge
11. Torque converter oil temperature caution lamp (if equipped)
12. Lift arm lock pilot lamp 23. Articulate meter
GD555, 655, 675-3C 10-265

(4)
MONITOR ITEMS DISPLAY
Category Symbol Item indicated Indicated range Description
Differential oil temperature More than 120° C
Torque converter oil temperature More than 110° C
Max. 4.17 MPa

Brake oil pressure
{42.5 kg/cm2}
Off when normal, lights up
Caution
when problem detected
Off when normal, lights
Monitor transmission electrical
up when problem
circuit
detected
When charge is defec-

Battery charge
tive
Max. 82 kPa
Engine oil pressure
{0.837 kg/cm2}
Turn signal indicator When operated
Parking brake When operated Lights up when operated
Pilot Head lamp beam When operated
Lights up when blade accu-

Blade float When operated mulator/float switch is at
FLOAT
While starting, lights up for

When electricity flows in
Engine preheating approx. 20 seconds when
the preheating circuit
the switch is at HEAT
10-266 GD555, 655, 675-3C

(4)
Category Symbol Item indicated Indicated range Description
Lights up when blade accu-

Blade accumulator When operated mulator/float switch is at
ACCUMULATOR
Working lamp When operated
Pilot AWD When operated Lights up when operated
Differential control When operated
Lift arm lock When cancelled Lights up when not locked
• Displays while starting

switch is ON
— Engine water temperature
• Indicator shows engine
water temperature

— Articulate switch is ON
• Indicator shows angle
Gauges

— Fuel
switch is ON

switch is ON
— Torque converter oil temperature
• Indicator shows torque
converter oil temperature

switch is ON
Speedometer — Speedometer
• Indicator shows vehicle
speed
Digital display:
Message
— Message center displays speed range,
center
error code, travel speed
GD555, 655, 675-3C 10-267

(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS
SENSORS
Engine water temperature sensor
Torque converter oil temperature sensor (for monitor panel)
Serial No.: 50001 – 51000
1. Connector
2. Sensor
Temperature (°C) 50 ± 0.2 60 ± 0.2 80 ± 0.2 100 ± 0.3 106 ± 0.3 120 ± 0.3
Resistance (z) 80 ± 10 56.3 ± 5 29.5 ± 2.5 16.5 ± 0.9 14.3 ± 0.5 10 ± 0.3
Function
• The engine water temperature sensor is installed
to the engine cylinder block. As the engine tem-
perature changes, so does the sensor’s resist-
ance. The gauge on the monitor panel moves to
indicate the engine temperature.
• The torque converter oil temperature sensor is
installed to the torque converter hydraulic piping.
The sensor sends a signal to the monitor panel.
If the value is above the set value, the warning
lamp lights.
10-268 GD555, 655, 675-3C

(4)
1. Connector
2. Plug
3. Thermistor
Temperature (°C) 50 ± 0.2 60 ± 0.2 80 ± 0.2 100 ± 0.3 106 ± 0.3 120 ± 0.3
Resistance (z) 80 ± 10 56.3 ± 5 29.5 ± 2.5 16.5 ± 0.9 14.3 ± 0.5 10 ± 0.3
Function
• The engine water temperature sensor is installed
to the engine cylinder block. As the engine tem-
perature changes, so does the sensor’s resist-
ance. The gauge on the monitor panel moves to
indicate the engine temperature.
• The torque converter oil temperature sensor is
installed to the torque converter outlet port on the
transmission. If it senses the torque converter
outlet oil temperature, its resistance changes.
The resistance is converted into 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 pres-
sure) drops below a specified value, the switch
turns ON. This action causes the brake oil pres-
sure lamp to light up and warn of a problem.
GD555, 655, 675-3C 10-269

(4)
Transmission speed sensor
1. Sensor Function
2. Locknut • Two transmission-speed sensors are screwed
3. Wiring harness into the transmission case: one sensor detects
4. Connector 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 control-
ler. This information controls the transmission.
Differential oil temperature sensor
1. Sensor Function
2. Wiring harness • The differential oil temperature sensor is a bimet-
3. Connector al type. It detects the temperature of the oil in the
differential case. If the oil temperature exceeds
120°C, the switch turns ON. This signal is sent to
the transmission controller and is also used to
control the transmission.
10-270 GD555, 655, 675-3C

(4)
Hydraulic oil temperature sensor
Transmission oil temperature sensor
Torque converter oil temperature sensor (for transmission controller)
1. Thermistor Function
2. Plug • The hydraulic oil sensor, transmission oil temper-
3. Wiring harness ature sensor, and torque converter oil tempera-
4. Connector ture sensor are installed at the hydraulic tank.
These sensors use a thermistor to detect the
temperature. The sensors connect to the trans-
mission controller and used to control the trans-
mission.
Articulation sensor
1. Lever Function
• The articulation sensor is installed to the center
of the frame. This sensor uses a variable resis-
tor. The resistor’s resistance varies according to
lever movement. The amount of resistance de-
termines the angle displayed on the gauge,
which is located on the monitor panel.
GD555, 655, 675-3C 10-271

(4)
Fuel level gauge sensor

Serial No.: 50001 – 51000
2. Variable resistor • The fuel gauge is installed on the side of the fuel
3. Gear tank. The float moves up and down, according to
4. Float the fuel level. Float movement is sent through a
gear and adjusts a variable resistor’s resistance.
The voltage signal is adjusted according to the
resistance and then transmitted to the fuel level
display. Thus, the display reflects the fuel level
within the fuel tank.
10-272 GD555, 655, 675-3C

(4)
1. Float Function
2. Arm • The fuel gauge sensor is installed to the rear side
3. Variable resistor of the fuel tank and its float moves up and down
4. Connector 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 indi-
cates the fuel level in the fuel tank.
GD555, 655, 675-3C 10-273

(4)
ACCELERATOR PEDAL POTENTIOMETER
2. Case • This sensor is installed to the accelerator pedal.
3. Shaft The sensor detects the pedal angle when de-
4. Element pressing the pedal.
5. Bearing • Inside the potentiometer, the pedal angle is con-
6. Contact verted into a voltage signal. A variable resistor
7. Mold adjusts the 5 volt source signal as the pedal an-
gle changes. The adjusted voltage signal is now
sent to the transmission controller.
10-274 GD555, 655, 675-3C

(4)
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE ............................................................................................................................ 20-2

STANDARD VALUE TABLE FOR ENGINE.............................................................................................. 20-2
STANDARD VALUE TABLE FOR CHASSIS............................................................................................ 20-6
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM.................................................................... 20-13
TESTING AND ADJUSTING ...................................................................................................................... 20-101
TROUBLESHOOTING ................................................................................................................................ 20-201
a 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 service limit 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 opera-
tion to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k 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.
k When working with other workers, always use signals and do not let unauthorized people near the ma-
chine.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed
when the water is still hot, the water will spurt out and cause burns.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
GD555, 655, 675-3C 20-1

(4)
TESTING AND ADJUSTING STANDARD VALUE TABLE
STANDARD VALUE TABLE

STANDARD VALUE TABLE FOR ENGINE
Machine model GD555-3C

Serial No. 50001 – 51000
Engine Standard machine VHP specification machine
Item Measurement condition Unit SA6D102E-1 SA6D102E-1
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 ± 50 800 ± 50 800 ± 50 800 ± 50
Rated speed 2,000 2,000 2,000 2,000
Exhaust temperature All speed
°C — — 385 to 485 —
(turbine inlet temp.) (intake air temp. 20° C)
kPa 130 to 150
Intake resistance At rated output — — —
{mm Hg} {975 to 1,125}
Sudden acceleration Bosch — — Max. 5.5 Max. 6.5
Exhaust gas color
High idle index — — Max. 1.0 Max. 2.0
Valve clearance Intake valve 0.25 — 0.25 —
mm
(cold) Exhaust valve 0.51 — 0.51 —
At rated output
Blowby pressure
(SAE 15W-40 oil) Coolant temperature: kPa 0.65 3.3 0.65 3.3
Operating range {mmH2O} {66} {337} {66} {337}
Coolant temperature:
Operating range
Oil pressure MPa 0.4 Max. 0.27 0.4 Max. 0.27
At rated output
(SAE 15W-40 oil) {kg/cm2} {4.1} {2.8} {4.1} {2.8}
0.19 Max. 0.07 0.19 Max. 0.07
At low idle
{1.9} {0.7} {1.9} {0.7}
Whole speed range
Oil temperature Max. 127 Max. 127 Max. 127 Max. 127
(inside oil pan)
Fuel injection timing Before T.D.C. degrees — — 12.5 to 14.5 —
Max. 11 or Max. 11 or
New belt Deflection when pressed 12 to 13 12 to 13
Fan belt Min. 14 Min.14
with finger force of mm
tension When adjusting Max. 13 or Max. 13 or
approx. 59 N {6 kg}. 14 to 16 14 to 16
belt tension Min. 17 Min. 17
20-2 GD555, 655, 675-3C

(4)
GD555-3C GD655-3C
51001 and up 50001 – 51000 51001 and up
VHP specification machine Standard machine VHP specification machine VHP specification machine
SAA6D102E-2 S6D114E-1 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
850 ± 50 850 ± 50 850 ± 50 850 ± 50 850 ± 50 850 ± 50 800 ± 100 800 ± 100
2,000 2,000 1,900 1,900 1,900 1,900 1,900 1,900
550 to 650 — — — 375 to 475 — 450 to 550 —
Max. 3.7 Max. 6.2 140 to 160 Max. 3.7 Max. 6.2
— — —
{380} {635} {1,050 to 1,200} {380} {635}
Max. 4.5 Max. 5.5 — — Max. 4.5 Max. 5.5 Max. 6.5 Max. 8.5
Max. 1.0 Max. 2.0 — — Max. 1.0 Max. 2.0 Max. 1.0 Max. 2.0
0.25 — 0.3 — 0.3 — 0.30 —
0.51 — 0.61 — 0.61 — 0.56 —
0.49 2.0 0.9 4.5 0.9 4.5 1.0 2.0

{50} {200} {92} {460} {92} {460} {100} {200}
0.39 to 0.64 Min. 0.25 0.4 Max. 0.27 0.4 Max. 0.27 0.29 to 0.49 Min. 0.21
{4.0 to 6.5} {2.6} {4.1} {2.8} {4.1} {2.8} {3.0 to 5.0} {2.1}
Min. 0.15 Min. 0.09 0.19 Max. 0.07 0.16 Max. 0.07 Min. 0.12 Min. 0.07
{1.5} {0.9} {1.97} {0.7} {1.6} {0.7} {1.2} {0.7}
80 to 110 Max. 120 Max. 127 Max. 127 Max. 127 Max. 127 80 to 110 Max. 120
9.5 to 10.5 — — — 13 to 15 — 7.5 to 9.5 —

Max. 11 or Max. 11 or Max. 11 or Max. 11 or
12 to 13 12 to 13 12 to 13 12 to 13
Min. 14 Min. 14 Min. 14 Min. 14
Max. 13 or Max. 13 or Max. 13 or Max. 13 or
14 to 16 14 to 16 14 to 16 14 to 16
Min. 17 Min. 17 Min. 17 Min. 17
GD555, 655, 675-3C 20-3

(4)
Machine model GD675-3C

Serial No. 50001 – 51000
Engine Standard machine VHP specification machine
Item Measurement condition Unit S6D114E-1 SA6D114E-1
Standard Permissible Standard Permissible
Engine speed High idle rpm 2,200 ± 50 2,200 ± 50 2,200 ± 50 2,200 ± 50
Low idle 800 ± 50 800 ± 50 800 ± 50 800 ± 50
Rated speed 1,900 1,900 1,900 1,900
Exhaust temperature All speed
°C — — 365 to 465 —
(turbine inlet temp.) (intake air temp. 20° C)
kPa 160 to 180
Intake resistance At rated output — — —
{mm Hg} {1,200 to 1,350}
Sudden acceleration Bosch — — Max. 4.5 Max. 5.5
Exhaust gas color
High idle index — — Max. 1.0 Max. 2.0
Valve clearance Intake valve 0.3 — 0.3 —
mm
(cold) Exhaust valve 0.61 — 0.61 —
At rated output
Blowby pressure
(SAE 15W-40 oil) Coolant temperature: kPa 2.0 4.5 2.0 4.5
Operating range {mmH2O} {204} {460} {204} {460}
Coolant temperature:
Operating range
Oil pressure MPa 0.4 Max. 0.27 0.4 Max. 0.27
At rated output
(SAE 15W-40 oil) {kg/cm2} {4.1} {2.8} {4.1} {2.8}
0.16 Max. 0.07 0.16 Max. 0.07
At low idle
{1.6} {0.7} {1.6} {0.7}
Whole speed range
Oil temperature Max. 127 Max. 127 Max. 127 Max. 127
(inside oil pan)
Fuel injection timing Before T.D.C. degrees — — 13 to 15 —
Max. 11 or Max. 11 or
New belt Deflection when pressed 12 to 13 12 to 13
Fan belt Min. 14 Min. 14
with finger force of mm
tension When adjusting Max. 13 or Max. 13 or
approx. 59 N {6 kg}. 14 to 16 14 to 16
belt tension Min. 17 Min. 17
20-4 GD555, 655, 675-3C

(4)
GD675-3C
51001 and up
VHP specification machine
SAA6D114E-2
Standard Permissible
value value
2,200 ± 50 2,200 ± 50
800 ± 100 800 ± 100
1,900 1,900
490 to 550 —
Max. 3.7 Max. 6.2

{380} {635}
Max. 6.5 Max. 8.5
Max. 1.0 Max. 2.0
0.30 —
0.56 —
1.0 2.0
{100} {200}
0.29 to 0.49 Min. 0.21

{3.0 to 5.0} {2.1}
Min. 0.12 Min. 0.07
{1.2} {0.7}
80 to 110 Max. 120
7.5 to 9.5 —
Max. 11 or
12 to 13
Min. 14
Max. 13 or
14 to 16
Min. 17
GD555, 655, 675-3C 20-5

(4)
STANDARD VALUE TABLE FOR CHASSIS
Cate-
Item Measurement conditions Unit Standard value
gory
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
NoP Engine speed stopped, travel at tip of lever 35 ± 5
N o F1 Engine speed stopped, travel at tip of lever 30 ± 5
1o2 Engine speed stopped, travel at tip of lever 30 ± 5
Travel
3o4 Engine speed stopped, travel at tip of lever mm 30 ± 5

Gearshift lever 5o6 Engine speed stopped, travel at tip of lever 30 ± 5
N o R1 Engine speed stopped, travel at tip of lever 30 ± 5
Max. 30
Fuel control lever Max. value at tip of lever to just before end of travel
{Max. 3}
Operating effort at a position 150 mm from center of Max. 90
Accelerator pedal
Operating effort
pedal rotation. Max. value just before end of travel. {Max. 9}

Operating effort at a position 150 mm from center of N 60 to 90
Inching pedal
pedal rotation. Max. value just before end of travel. {kg} {6 to 9}
Operating effort at a 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
188 ±5
(when not operated)
Inching pedal height Height from floor surface to tip of pedal. mm
104 ± 5
(when operated)
Inching pedal play 0
Others
STD 1,505 ± 100

GD555
Run engine at full throttle, set to VHP 1,580 ± 100
R4, depress the brake pedal,
STD 1,615 ± 100
Transmission slippage release the inching pedal. Measure GD655 rpm
VHP 1,700 ± 100
time taken for engine speed to
enter specified range. STD 1,660 ± 100
GD675
VHP 1,730 ± 100
20-6 GD555, 655, 675-3C

(4)
Standard value Permissible value

Cate-
Item Measurement conditions Unit GD655-3C
gory GD555-3C —
GD675-3C
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
5th 14.9 ± 0.8 14.6 ± 0.7 —
Flat, dry road surface:
6th • Oil temperature and pressure 21.6 ± 1.1 21.2 ± 1.1 —
Travel speed
7th within operating range 29.6 ± 1.5 29.1 ± 1.5 —

• Engine at the rated speed km/h
8th • Work equipment unloaded 42.9 ± 2.1 42.1 ± 2.1 —
1st • Tires inflated to the specified 4.4 ± 0.2 4.3 ± 0.2 —
pressure
( 1) 8.9 ± 0.5
2nd 8.8 ± 0.5 —
( 2) 9.0 ± 0.5
Reverse ( 1) 18.7 ± 1.0 ( 1) 18.1 ± 1.0
3rd —
( 2) 19.7 ± 1.0 ( 2) 19.1 ± 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:
Travel
Leaning • Measure at the tip of the lever.

mm 22 ± 5 —
control lever • Measure travel from neutral to
end of travel.
Controls
Operating effort
Engine stopped:
Leaning • Measure at center of lever N
Max. 24.5 {2.5} —
control lever grip. {kg}
• Max. value to end of travel
Engine stopped:
Play • Pedal movement in direction mm Max. 5 Max. 5
Brake pedal performance
of operation
Engine stopped:
Travel mm 66 ± 4 66 ± 10
• Measure at the tip of the pedal
Brake
Brake oil Hydraulic oil temperature: MPa

pressure 45 to 50°C {kg/cm2} 3.9 +0.1 +1
–0.31 {40 –3 } 3.9 +0.1 +1
–0.31 {40 –3 }
Max. 13
Stopping When braking from a speed of
m Max. 11 (SAE standard =
distance 32 km/h (20 mph)
Max. 15.1 m)
1. For serial No. 50001 – 51000

2. For serial No. 51001 and up
GD555, 655, 675-3C 20-7

(4)
Standard value Permissible value

Cate-
Item Measurement conditions Unit GD655-3C
gory GD555-3C —
GD675-3C
Raise front tires 50 to 100 mm
from ground.
Steering wheel • Turn the steering wheel and
mm 0 to 10 —
play then measure the distance to
the point where the wheels
start to turn to side.
Raise front tires 50 to 100 mm
from ground. Check the point
Steering
where the steering wheel starts

to turn, then turn steering wheel
fully and measure the distance
Lock-to-lock to the point where the steering — 5 to 9.5 —
wheel stops turning.
• Turn the steering wheel at 120
rpm
• Check distance to both left
and right
Steering wheel Engine at low idle when travel- N
Max. 49 {5} —
operating effort ling in F1. {kg}
20-8 GD555, 655, 675-3C

(4)
Cate-
Item Measurement conditions Unit Standard value Permissible value
gory
Put dial gauge in contact with
Tire runout mm Max. 7 —
sidewall of both front and rear
GD555-3C: 13.00-24-10 PR 275 {2.75}
kPa
Tire inflation pressure GD655-3C: 14.00-24-10 PR 250 {2.50} —
Steering
Wheel
{kg/cm2}
GD675-3C: 14.00-24-12 PR 275 {2.75}
Camber degree 0 —
Flat, paved road surface
Toe-in mm -5 ± 1 —
• Angle of knuckle bracket
Leaning angle degree 21.7 —
Blade lift lever (right, left) 22 ± 5 —
Blade side shift lever 22 ± 5 —
Drawbar shift lever 22 ± 5 —
Engine stopped:
Circle rotation lever 22 ± 5 —
Travel
• Measure at tip of lever

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

Circle rotation lever —
• Measure at center of lever N {2.5}
grip {kg} Max. 24.5
Power tilt lever • Max. value to end of travel —
{2.5}
Max. 24.5
Articulation lever —
{2.5}
Max. 24.5
Scarifier lever —
{2.5}
Max. 24.5
Ripper lever —
{2.5}
9.4 + 1.0 9.4 ± 1
Accumulator
Charge cut-in pressure Engine at low idle:

MPa {93.6 + 10} {93.6 ± 10}
• Hydraulic oil temperature:
{kg/cm2} 13.4 + 0.5 13.4 ± 1
Charge cut-out pressure 40 to 55°C
{136.5 + 5} {136.5 ± 10}
GD555, 655, 675-3C 20-9

(4)
GD655-3C
GD555-3C
Cate- GD675-3C
Item Measurement conditions Unit
gory Std. Permis. Std. Permis.
Engine full throttle: Left
Raise Oil temp. 40 ± 5°C 2.7 ± 0.4 4 2.7 ± 0.4 4
Blade lifting Independent op. Right
speed Make a mark on the cylin- Left
Lower der rod and operate it 350 2.7 ± 0.4 4 2.7 ± 0.4 4
mm. Right
Blade side- Engine full throttle:
shift speed Left Oil temp. 40 ± 5°C. 6.9 ± 0.8 9 6.9 ± 0.8 9
with circle Set height of bottom edge of
movement Right blade to 100 mm with blade at 7.5 ± 0.8 10 7.5 ± 0.8 10
(drawbar) center as standard condition
Work equipment speed
Blade side- Engine full throttle:

shift speed Left Oil temp. 40 ± 5°C 9.1 ± 1.0 11 9.1 ± 1.0 11
compared to Set height of bottom edge of
circle blade to 100 mm with blade at Seconds
Right 9.1 ± 1.0 11 9.1 ± 1.0 11
(blade shift) center as standard condition
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°
( 1)
Engine full throttle: 3
1.8 ± 0.3
Oil temp. 40 ± 5°C Raise 1.6 ± 0.3 3
Make a mark on the cylin- ( 2)
Work equipment
2
der rod and operate it the 1.1 ± 0.2
Scarifier lifting speed
distance shown below: ( 1)
GD555: 200 mm 3
1.8 ± 0.3
GD655: 180 mm Lower 1.6 ± 0.3 3
GD675: 180 mm ( 2)
3
1.5 ± 0.3
Engine stopped:
Oil temp. 40 ± 5°C
Blade drift Downward movement of cylinder 10 20 10 20
when blade is suspended at right
angle
Engine stopped:
Scarifier drift 10 20 10 20
Downward movement of cylinder
when scarifier is suspended
Hydraulic drift
Engine stopped: mm/

Oil temp. 40 ± 5°C 10 min.
Chassis drift when Downward movement of cylinder
20 35 20 35
pushed up with blade after blade is lowered to ground
and used to raise front wheels
from ground
Engine stopped:
Chassis drift when
Downward movement of cylinder
pushed up with scari- 20 35 20 35
after scarifier is lowered to ground
fier
and used to raise front wheels
from ground
1. For serial No. 50001 – 51000

20-10 GD555, 655, 675-3C

(4)
GD655-3C
GD555-3C
Cate- GD675-3C
Item Measurement conditions Unit
gory Std. Permis. Std. Permis.
Work Engine full throttle: 20.6 ± 1 20.6 ± 1
Work equip- — —
equip. Oil temperature: 45 to 50°C MPa {210 ± 10} {210 ± 10}
ment hydrau-
Hydraulic pressure
lic pressure Steer- Operate blade lift cylinder to {kg/cm2} 15.1 ± 0.4 15.1 ± 0.4
raise — —
ing {154 ± 4} {154 ± 4}
Engine at low idle (800 rpm)
Hydraulic Work
Oil temperature: 45 to 50°C 76 — 76 —
pump dis- equip.
Work equipment
Rotate circle l/min.

charge
amount Engine full throttle
Trans. 130 — 130 —
Oil temperature: 45 to 50°C
Spool travel Circle: 5 Circle: 5
mm — —
Main control valve
(one side) 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, 675-3C 20-11

(4)
Cate-
Item Measurement conditions Unit GD555-3C GD655-3C, GD675-3C
gory
Spool travel Circle: 5 Circle: 5
Main control valve
mm
(one side) Others: 6 Others: 6
Engine stopped Circle: Circle:

Spool oper- N Max. 109.8 {11.2} Max. 109.8 {11.2}
ating effort {kg} Others: Others:
Max. 73.5 {7.5} Max. 73.5 {7.5}
Unload pres- Hydraulic oil temperature:
2.8 +0.98 {29 + 10} 2.8 + 0.98 {29 + 10}
sure 45 to 50°C
Inlet oil
0.74 ± 0.15 {7.5 ± 1.5} 0.74 ± 0.15 {7.5 ± 1.5}
pressure
Outlet oil
Torque converter
Oil temperature: 60 to 80°C 0.59 ± 0.1 {6 ± 1.0} 0.59 ± 0.1 {6 ± 1.0}

Hydraulic pressure
pressure
Lock-up
2.01 ± 0.15 {20.5 ± 1.5} 2.01 ± 0.15 {20.5 ± 1.5}
pressure
Low
Main relief
2.24 ± 0.1 {22.9 ± 1.0} 2.24 ± 0.1 {22.9 ± 1.0}

pressure
idle Oil temperature: 60 to 80°C MPa

High Engine full throttle {kg/cm2}
2.37 ± 0.1 {24.2 ± 1.0} 2.37 ± 0.1 {24.2 ± 1.0}
idle
FL 2.25 ± 0.2 {23 ± 2.0} 2.25 ± 0.2 {23 ± 2.0}
Control valve set pressure
R 2.25 ± 0.2 {23 ± 2.0} 2.25 ± 0.2 {23 ± 2.0}

Transmission
FH 2.25 ± 0.2 {23 ± 2.0} 2.25 ± 0.2 {23 ± 2.0}

Oil temperature: 60 to 80°C
1st 2.25 ± 0.2 {23 ± 2.0} 2.25 ± 0.2 {23 ± 2.0}
Engine at full throttle
2nd 2.25 ± 0.2 {23 ± 2.0} 2.25 ± 0.2 {23 ± 2.0}
3rd 2.25 ± 0.2 {23 ± 2.0} 2.25 ± 0.2 {23 ± 2.0}
4th 2.25 ± 0.2 {23 ± 2.0} 2.25 ± 0.2 {23 ± 2.0}
( 1)
GD655-3C
STD: 1,615 ± 100
( 1) VHP:
STD: 1,505 ± 100 Base power 1,610 ± 100
High power 1,700 ± 100
Oil temperature: 60 to 80°C VHP:
Base power 1,470 ± 100 GD675-3C
Engine coolant temperature: High power 1,580 ± 100 STD: 1,660 ± 100
Engine speed
operating range VHP:

Engine speed Base power 1,665 ± 100
at torque con- Run engine at full throttle, set to R4, rpm High power 1,730 ± 100
verter stall depress the brake pedal and then
release the inching pedal. ( 2)
GD655-3C
Measure engine speed when VHP:
engine stalls. ( 2) Base power 1,559 ± 100
VHP: High power 1,665 ± 100
Base power 1,378 ± 100
High power 1,552 ± 100 GD675-3C
VHP:
Base power 1,593 ± 100
High power 1,698 ± 100
1. For serial No. 50001 – 51000

20-12 GD555, 655, 675-3C

(4)
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Sys- Connec- Inspection Measurement

Component Judgement table
tem tor No. method condition
If the condition is as shown in the table below, the
condition is normal.
1. Turn starting switch
Switch Between T1 (7), (13) - chassis OFF
T1 Measure
power 2. Insert the T-adapter.
T2 voltage Between T2 (1), (12) - chassis
source 20 to 30V 3. Turn starting switch
Between T1 (7), (13) - (6), (12) ON
Between T1 (7), (12) - (11), (21)
If the condition is as shown in the table below, the 1. Turn starting switch
condition is normal. OFF
Measure
S-NET 2. Insert the T-adapter.
voltage
Between (4), (12) - chassis 4 to 8V 3. Turn starting switch
ON
VHP condition is normal. OFF
Measure
select T3B 2. Insert the T-adapter.
voltage VHP spec. Between (2) Max. 1V
switch 3. Turn starting switch
Transmission control related
Without VHP spec. and chassis 20 to 30V ON

Controller
AWD condition is normal. OFF

Measure
select 2. Insert the T-adapter.
voltage AWD spec. Between (3) Max. 1V
Without AWD spec. and chassis 20 to 30V ON
Inching OFF
Measure
select Inching pedal spec. Between Max. 1V 2. Insert the T-adapter.
voltage
switch (20) and 3. Turn starting switch
Without inching
chassis 20 to 30V ON
pedal spec.
T3A
Differen- condition is normal.
OFF
tial lock Measure
Differential spec. Max. 1V 2. Insert the T-adapter.
select voltage Between(10) 3. Turn starting switch
switch Without differential and chassis 20 to 30V ON
spec.
Type condition is normal.
OFF
select Measure
T5 Standard spec. Max. 1V 2. Insert the T-adapter.
switch voltage Between (5) 3. Turn starting switch
(spare) Without standard and chassis 20 to 30V ON
spec.
GD555, 655, 675-3C 20-13

(4)

Gearshift lever at OFF
Forward Measure 20 to 30V
(F1) thru (F8) Between 2. Insert the T-adapter
switch voltage
(10) and 3. Turn starting switch
Gearshift lever at
chassis ON
any position except Max. 1V
above.
T5
Reverse Measure 20 to 30V
(R1) thru (R4) Between 2. Insert the T-adapter
switch voltage
Gearshift lever at
chassis ON
above.
Neutral Measure 20 to 30V
Neutral or Park 2. Insert the T-adapter
signal voltage
Between (8) 3. Turn starting switch

Gearshift lever at and chassis ON
above.
Controller
T3A
Drive lever Measure
any position except Between 20 to 30V 2. Insert the T-adapter
(A) voltage
Neutral or Park (18) and 3. Turn starting switch
chassis ON
Gearshift lever at
Max. 1V
Neutral or Park
Gearshift lever at
OFF
Drive lever Measure (F1), (F5) thru (F7) 20 to 30V
2. Insert the T-adapter
(B) voltage and (R1) thru (R3) Between (7) 3. Turn starting switch
above.
T5
Gearshift lever at
OFF
Drive lever Measure (F1) thru (F5) and 20 to 30V
Between 2. Insert the T-adapter
(C) voltage (R1)
Gearshift lever at chassis ON
above.
20-14 GD555, 655, 675-3C

(4)

Drive Measure 20 to 30V
(F1) thru (F3) 2. Insert the T-adapter
lever (D) voltage Between (8) 3. Turn starting switch
above.
T5 Gearshift lever at
OFF
Drive Measure (F3) thru (F6) and 20 to 30V
lever (E) voltage (R1), (R2)
Gearshift lever at chassis ON
above.
Reset Measure
switch resistance Reset switch ON Between (9) Max. 1 z
Reset switch OFF and chassis Min. 1 z ON

Memory Initialize switch OFF
Controller
Measure Max. 1 z
reset (memory reset) 2. Insert the T-adapter
resistance Between (11)
Initialize switch and chassis ON
(Initialize learning Min. 1 z
function or OFF)
T3A If the condition is as shown in the table below, the
Initialize switch
OFF
Initialize Measure (Initialize learning Max. 1 z
switch resistance function)
Initialize switch chassis ON
(memory reset or Min. 1 z
OFF)
condition is normal. 1. Turn starting switch
OFF
Lockup Measure T/C lock-up switch
Between 20 to 30V 2. Insert the T-adapter
switch voltage ON
T/C lock-up switch chassis ON
Max. 1V
OFF
T5
OFF
Differen- Measure Differential switch
20 to 30V 2. Insert the T-adapter
tial switch voltage ON Between (9) 3. Turn starting switch
Differential switch and chassis ON
Max. 1V
OFF
GD555, 655, 675-3C 20-15

(4)

OFF
Hi set Measure Potentiometer set
T3B Max. 1 z 2. Insert the T-adapter
switch resistance switch HI Between (1) 3. Turn starting switch
Potentiometer set and chassis ON
Min. 1 z
switch LOW
OFF
Low set Measure Potentiometer set
T5 Between Max. 1 z 2. Insert the T-adapter
switch resistance switch HI or OFF
Potentiometer set chassis ON
Min. 1 z
switch LOW or OFF
Between (7) and (16) 4.75 to 5.25V
Between (3) and (16) 0.5 to 4.75V

Between (3) and (16) at low idle 1.0 to 2.0V 1. Turn starting switch
Controller
Accelera-
Between (3) and (16) at high idle 2.4 to 4.3V OFF
tor potenti- Measure
ometer voltage The above table shows the specified value for the 3. Turn starting switch
signal voltage for a potentiometer that allows the control- ON
ler to recognize the dial range correctly. When
adjusting the potentiometer, allow a margin for the
error judgement range. At low idle, adjust within
the range of 1.0 to 2.0V. The error judgement
T3A range is potentiometer <0.5V or potentiometer
voltage > 4.5V.
Between (7) and (16) 4.75 to 5.25V
Between (13) and (16) 0.5 to 4.75V 1. Turn starting switch
Inching Between (13) and (16), inching OFF
Measure 0.8 to 1.6V 2. Insert the T-adapter
potentiom- pedal not depressed (min. travel)
voltage
eter signal 3. Turn starting switch
Between (13) and (16), inching ON
3.2 to 4.0V
pedal depressed (max. travel)
At minimum travel, adjust within the range of 0.8 to
1.6V. The error judgement range is potentiometer
<0.5V or potentiometer voltage > 4.5V.
20-16 GD555, 655, 675-3C

(4)

Transmis- If the condition is as shown in the table below, the 1. Turn starting switch
sion input condition is normal. Measure with AC range. OFF
Measure
shaft T5 2. Insert the T-adapter
voltage
speed Between (2) and (1) 0.5V 3. Turn starting switch
sensor ON
Transmis- If the condition is as shown in the table below, the 1. Turn starting switch
sion out- condition is normal. Measure with AC range. OFF
T4 Measure
put shaft 2. Insert the T-adapter
T5 voltage
speed Between T4 (1) and T5 (1) 0.5V 3. Turn starting switch
sensor ON
2. Disconnect the con-
At (F1), (F3), (F5),
FL clutch Measure Max. 1 z nector
T36 and (F7)
fill switch resistance Between (1) 3. Connect the
and chassis T-adapter
At any position
Min. 1 z 4. Turn starting switch
except above
ON

At (F2), (F4), (F6),
FH clutch Measure Max. 1 z nector
T37 and (F8)
T-adapter
Controller
At any position and chassis

except above
ON
At (R1) thru (R4) Max. 1 z
R clutch Measure nector
T38
At any position and chassis T-adapter
Min. 1 z
except above 4. Turn starting switch
ON
At (F1), (F2), and
1st clutch Measure Max. 1 z nector
T39 (R1)
At any position
except above
ON
At (F3), (F4), and
2nd clutch Measure Max. 1 z nector
T40 (R2)
At any position
except above
ON
GD555, 655, 675-3C 20-17

(4)

3rd clutch fill Measure At (F5), (F6), and
T41 Max. 1 z nector
switch resistance (R3) Between (1) 3. Connect the
Min. 1 z
except above 4. Start engine
4th clutch fill Measure At (F7), (F8), and
T42 Max. 1 z nector
switch resistance (R2) Between (1) 3. Connect the
Min. 1 z
except above 4. Start engine
OFF
At F1 to F4, (R1) to
Lock-up clutch Measure (R2)
T43 Max. 1 z nector
fill switch resistance T/C lock-up switch Between (1)
3. Connect the
ON and chassis T-adapter
T/C lock-up switch 4. Manual mode
Min. 1 z
OFF
FL Measure 2. Disconnect the con-
T24 Between (1) and (2) 5 to15 z
solenoid resistance nector
3. Connect the
Between (1) and chassis Min. 1 z
T-adapter
FH Measure 2. Disconnect the con-
3. Connect the
T-adapter
R Measure 2. Disconnect the con-
3. Connect the
T-adapter
1st Measure 2. Disconnect the con-
3. Connect the
T-adapter
20-18 GD555, 655, 675-3C

(4)

2nd Measure 2. Disconnect the con-
3. Connect the
T-adapter
3rd Measure 2. Disconnect the con-
3. Connect the
T-adapter
4th Measure 2. Disconnect the con-
3. Connect the
T-adapter
Lock-up Measure 2. Disconnect the con-
3. Connect the
T-adapter
T/C output
Measure 2. Disconnect the con-
hydraulic T34 25°C normal temp. 3.5 to 4.0 kz
resistance Between (1) nector
temp. sensor
and (2) 38.5 to 47.0 3. Connect the
100°C
kz T-adapter
T/M hydraulic Measure 2. Disconnect the con-
T35 25°C normal temp. 3.5 to 4.0 kz
temp. sensor resistance Between (1) nector
100°C
kz T-adapter
Hydraulic Measure 2. Disconnect the con-
E5 25°C normal temp. 3.5 to 4.0 kz
temp. sensor resistance Between (1) nector
100°C
kz T-adapter
GD555, 655, 675-3C 20-19

(4)

condition is normal. Measure with AC range. OFF
Transmission
input shaft T32 500 to 1,000
resistance Between (1) and (2) nector
speed sensor z
3. Connect the
Between (1), (2), and chassis Min. 1 z T-adapter
1. Screw the transmission input shaft speed sensor
Transmission
in until it contacts the ring gear, then turn back 1/
input shaft — Adjust —
2 to 1 turn.
speed sensor
2. Works normally after above adjustment.
condition is normal. Measure with AC range. OFF
Transmission
output shaft T33 500 to 1,000
resistance Between (1) and (2) nector
z
speed sensor
3. Connect the
Transmission
in until it contacts the ring gear, then turn back 1/
output shaft — Adjust —
2 to 1 turn.
speed sensor
Engine speed Measure 2. Disconnect the con-
T46 500 to 1,000
sensor resistance Between (1) and (2) nector
z
3. Connect the
Engine speed in until it contacts the ring gear, then turn back 1/
— Adjust —
sensor 2 to 1 turn.
Engine start Measure 2. Disconnect the con-
B20 Between (1) and (2) 0.5 to 1.0 z
3. Connect the
Between (1), (2), and chassis Min. 1 z
T-adapter
20-20 GD555, 655, 675-3C

(4)

Lifter lock Measure
FL7
solenoid resistance Between (1) and (2) 40 to 60 z
Parking brake Measure 2. Disconnect the con-
FL8 Between (1) and (2) 40 to 60 z
3. Connect the
T-adapter
Accumulator Measure 2. Disconnect the con-
solenoid (left) resistance nector
3. Connect the
T-adapter
Accumulator Measure 2. Disconnect the con-
solenoid (right) resistance nector
3. Connect the
T-adapter
Float solenoid FL11 Measure 2. Disconnect the con-
Between (1) and (2) 20 to 30 z
(right) FL12 resistance nector
3. Connect the
T-adapter
Float solenoid FL13 Measure 2. Disconnect the con-
Between (1) and (2) 20 to 30 z
(left) FL14 resistance nector
3. Connect the
T-adapter
Articulate angle: 0° 80 to 100 z OFF
Articulator Measure 2. Disconnect the con-
FL6
sensor resistance Articulate angle: Between (1) 180 to 200 z nector
Left 23° 3. Connect the
and (2)
Articulate angle: T-adapter
5 to 15 z
Right 23°
GD555, 655, 675-3C 20-21

(4)
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 NITROGEN GAS FOR BRAKE, WORK EQUIPMENT ACCUMULATOR .............................. 20-124
TESTING AND ADJUSTING CIRCLE GUIDE CLEARANCE ..................................................................... 20-125
TESTING AND ADJUSTING SLIP CLUTCH-TYPE ROTARY DEVICE...................................................... 20-127
MEMORIZING IDLE AND FULL POSITION PROCEDURE ....................................................................... 20-129
INITIAL LEARNING METHOD FOR TRANSMISSION CONTROLLER ..................................................... 20-130
DIODE CHECKING PROCEDURE............................................................................................................. 20-132
MOVING MACHINE WHEN TRANSMISSION VALVE FAILS..................................................................... 20-133
ADJUSTING CAB STOPPER BOLT ........................................................................................................... 20-135
GD555, 655, 675-3C 20-101

(4)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

Check or
Symbol Part No. Part Name Remarks
measurement item
1 799-203-8001 Multi-tachometer Digital display
Engine speed A L: 60 to 2,000 rpm
2 795-790-2500 Adapter H: 60 to 19,999 rpm
Coolant and oil temperature B 799-101-1502 Digital temperature gauge –99.9 to 1,299°C
Pressure gauge
799-101-5002 Hydraulic tester 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
799-261-1203 Digital hydraulic tester 58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic gauge 1.0 MPa {10 kg/cm2}
799-101-5160 RC 1/8
3 Nipple
799-101-5220 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
790-261-1311
14 x 1.5 (R.C. 1/8)
6 790-261-1321 Adapter
14 x 1.5 (R.C. 1/8)
790-261-1331
14 x 1.5 (R.C. 1/8)
Discoloration 0 to 70 per-
1 799-201-9000 Handy smoke checker
cent (with standard color)
Exhaust color D
Discoloration % x 1/10 =
2 Commercially available Smoke meter
Bosch index
0 to 4,900 Pa
1 799-201-1504 Blowby checker
{0 to 500 mm H2O}
Orifice diameter:
Blowby pressure E 799-201-1511
7.67 mm (114 engine)
2 Nozzle
Orifice diameter:
795-790-1950
5.613 mm (102 engine)
79A-264-0021 0 to 294 N {0 to 30 kg}
Operating effort F Push-pull scale
79A-261-0091 0 to 490 N {0 to 50 kg}
Stroke G Commercially available Scale —
Troubleshooting of wiring 799-601-2500 —

H T-adapter assembly
harnesses and sensors 799-601-9200 For DT series
Measuring voltage and resis-
I Commercially available Tester —
tance values
Charging accumulator J 792-610-1700 Charging tool —
Procedure for moving
machine when transmission K 794-423-1190 Plug —
valve fails
20-102 GD555, 655, 675-3C

(4)
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR

• When measuring in the field where is no air or 2. Connect the air hose of the probe hose acceler-
electric power supply, use tool D1; when record- ator switch to the tool D2.
ing formal data, use tool D2. a Keep the air pressure supply below 1.47
a Increase the coolant temperature to the operat- MPa {15 kg/cm2}.
ing temperature range before measuring.
3. Connect the power cord to the AC 100V socket.
Measuring with D1 a When connecting the cord, check that the
power switch of tool D2 is OFF.
1. Install the filter paper to tool D1.
2. Insert the exhaust gas suction port into the

exhaust pipe.
3. Accelerate the engine suddenly while simulta-

neously 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.
a 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 simulta-

neously depressing the accelerator pedal of tool
D2 to collect the exhaust gas color on the filter.
Measuring with D2 7. Place the filter paper used to catch the exhaust
gas color on top of at least 10 sheets of unused
1. Insert the probe into the outlet port of the filter paper inside the filter paper holder.
exhaust pipe (1) and tighten the clip to secure
the probe to the exhaust pipe. 8. Read the value shown.
GD555, 655, 675-3C 20-103

(7)
TESTING AND ADJUSTING MEASURING BLOWBY PRESSURE
MEASURING BLOWBY PRESSURE

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

the blowby pressure.
k Take care not to touch the hot or rotating

parts during measurement.
a The regular blowby pressure is measured while

the engine is running at the rated output.
• In the field, perform a stall operation for an ap-
proximate value.
20-104 GD555, 655, 675-3C

(4)
MEASURING ENGINE OIL PRESSURE
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE OIL MEASURING ENGINE SPEED

PRESSURE
a Increase the coolant temperature to the operat- k Do not to touch any hot parts when handling the
ing temperature range before measuring. measuring tools.
1. Remove the pressure measurement sensor (1) a Measure the engine speed per listed conditions:
then install the oil pressure gauge C2 (0.98 MPa a. Coolant temperature: operating range.
{10kg/cm2}). b. Power train oil temperature: 60 to 80°C.
c. Hydraulic temperature: 45 to 55°C
GD555-3C
1. Remove the cap of the speed pickup port.
2. Install the adapter assembly A2 to the speed

pickup port, then install the tachometer sensor
and connect to the body A1.
GD655-3C, GD675-3C
2. Start the engine and measure the oil pressure at

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

(4)
TESTING AND ADJUSTING TESTING FAN BELT TENSION
TESTING FAN BELT TENSION

3. Start the engine and measure the engine speed 1. Testing belt tension
at high and low idle. Measure the deflection A of the belt when the
k When measuring the engine speed, be

belt is pressed with a force of approx. 98N {10
kg} at a point midway between the fan pulley
careful not to touch the rotating or hot parts. and tension pulley.
a When measuring items other than above (torque
converter stall), see the measurement proce-
dure for each item.
(Unit: mm)
MODEL GD555 GD655, 675
Belt Deflection A Deflection A
New belt 12.2 to 13.3 11.8 to 12.8
After adjusting
14.7 to 16.0 14.0 to 15.6
tension
2. Adjusting the belt tension

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

(4)
TESTING AIR CONDITIONER COMPRESSOR BELT TENSION
TESTING AND ADJUSTING MEASURING TORQUE CONVERTER STALL SPEED
TESTING AIR CONDITIONER MEASURING TORQUE CON-

COMPRESSOR BELT TEN- VERTER STALL SPEED
SION
1. Testing belt tension k Do not touch the hot parts when measuring. And
Measure the deflection a of the belt when the ensure that no one is near the machine during
belt is pressed with a force of approx. 98N {10 the procedure.
kg} at a point midway between the fan pulley
and tension pulley. a Measure the torque converter stall speed under
the following conditions:
• Coolant temperature: within operating range
• Power train oil temperature: 60 to 80°C
• Hydraulic oil temperature: 45 to 55°C
1. Remove the cap from the engine speed pick-up

port, install the adapter assembly A2 and multi-
tachometer sensor , then connect to the main
body A1.
BELT DEFLECTION a (mm)

New belt 15 to 16
After adjusting 17 to 19
2. Adjusting the belt tension

1) Loosen the locknut (1), then turn the adjust-
ment bolt (2) and move the compressor (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 gear lever to TOP reverse speed (R4).
4. Measure the speed when the accelerator pedal

or the regulator lever is set to the full throttle
position.
a Measure when the engine speed is stable.
GD555, 655, 675-3C 20-107

(7)
TESTING AND ADJUSTING CHECKING CLUTCH OIL PRESSURE
CHECKING CLUTCH OIL PRESSURE

k Set the front frame and rear frame facing
straight to the front, then secure in position with
the lock pin.
k Raise the tandem drive with a hydraulic jack and

raise the 4 rear wheels off the ground.
k Set the blade at right angles to the chassis and

lower the blade completely to the ground.
k The oil is hot, so be careful not to burn yourself.
k Stop the engine before removing or installing

the plug or pressure gauge.
a Oil temperature when measuring: 60 to 80°C
1. Checking transmission modulating oil pressure

(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 C1.
All gauges: 5.88 MPa {60 kg/cm2}
Oil pres- Oil pres-

Plug No. Plug No.
sure circuit sure circuit
1 FL clutch 5 R clutch
2 FH clutch 6 3rd clutch ECMV clutch actuation table
3 1st clutch 7 4th clutch ECMV
4 2nd clutch — — FL FH R 1st 2nd 3rd 4th
Speed
Plug size: Rc1/8 or 1/4 Range
F1
3) Run the engine at low idle and shift the
F2
gearshift lever to the speed range (oil pres-
sure circuit) to be measured. F3
4) Run the engine at full throttle and measure
F4
the clutch pressure of that circuit.
F5
F6
F7
F8
R1
R2
R3
R4
N
20-108 GD555, 655, 675-3C

(7)
TESTING AND ADJUSTING CHECKING TORQUE CONVERTER OIL PRESSURE
CHECKING TORQUE CONVERTER OIL PRESSURE

k Set the front frame and rear frame facing 3. Torque converter outlet port pressure
straight to the front, then secure in position with 1) Measurement port: 3 (Rc 1/8)
the lock pin. 2) Start the engine and measure the pressure
k Raise the tandem drive with a hydraulic jack and

at low idle and high idle.
raise the 4 rear wheels off the ground. 4. Torque converter lock-up port pressure
k Set the blade at right angles to the chassis and

1) Measurement port: 4 (Rc 1/4)
2) Start the engine and measure the pressure
lower the blade completely to the ground. at high and low idle.
k The oil is at high temperature, so be careful not
to burn yourself.
k Stop the engine before removing or installing

the plug or pressure gauge.
a Oil temperature: 60 to 80°C
1. Main relief pressure

2. Torque converter inlet port pressure

GD555, 655, 675-3C 20-109

(4)
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).
a When positioning the sensor tip in con- a When positioning the sensor tip in con-
tact with the gear, tighten lightly by hand tact with the gear, tighten lightly by hand
and check that the sensor in contact. and check that it is in contact. Never use
Never use a wrench or any other tool a wrench or any other tool to tighten the
when tightening. 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 to 1.13 mm
3) Tighten the locknut (3) from 49.0 to 68.6 Nm
{5 to 7 kgm}
a Tighten the sensor carefully to prevent
excessive force being applied to the sen-
sor wiring.
a 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.
{5 to 7 kgm}
a Tighten the sensor carefully to prevent
excessive force being applied to the sen-
sor wiring.
tip.
20-110 GD555, 655, 675-3C

(4)
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).
a When positioning the sensor tip in con-
tact with the gear, tighten lightly by hand
and check that sensor is in contact. Nev-
er use a wrench or any other tool to tight-
en the sensor.
2) When the sensor (5) contacts the gear (2),

turn the sensor out 1/2 to 1 turn.
{5 to 7 kgm}
a Tighten carefully and take action to pre-
vent any excessive force from being ap-
plied to the sensor wiring.
tip.
GD555, 655, 675-3C 20-111

(4)
TESTING AND ADJUSTING FLUSHING TORQUE CONVERTER, TRANSMISSION CIRCUIT
FLUSHING TORQUE CONVERTER, TRANSMISSION CIRCUIT

a Metal particles and other dirt in the torque con- 2) Travel or perform the actual operations for
verter and transmission hydraulic circuit will at least 20 minutes.
reduce the torque converter and transmission a Use all the speed ranges (FORWARD,
life, and will cause internal damage. To prevent REVERSE, and 1st – 8th).
this situation, flush the system to remove the dirt 3) Repeat the procedure in Step 4.1 and run
in the hydraulic circuit. the engine at low idle for approx. 20 min-
utes.
1. Flush the circuit, if the following conditions
apply. 5. Replace the flushing element.
1) If there has been any breakage of the torque 1) Using the procedure in Step 2.1, replace the
converter, transmission, or hydraulic equip- flushing element with the standard element
ment, and metal particles are circulating in (714-07-28711).
the hydraulic circuit. 2) Add oil and check the level again.
2) When the torque converter and transmis-
sion have been overhauled or repaired. 6. Replace the transmission fail-safe filter.
1) Remove the mounting bolt (3) of the filter
2. Cleaning the filter assembly (2), then remove the filter assem-
1) After removing the filter, remove the drain bly.
plug (1) and drain the system. 2) Remove the element (4) and replace it with
a new element.
a 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).
a Coat the outside circumference of the O-
ring with a small amount of grease.
3 Case bolts:
4) Install the case (5).
34.3 to 44.1 Nm {3.5 to 4.5 kgm}

5) Install the filter assembly (2).
2) Remove the transmission oil filter, clean the

inside, then reinstall the element for a sec-
ond 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.
5 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, without oper-
ating the gearshift lever.
a From time to time, increase the engine
speed to approx. 1,500 rpm.
a If the ambient temperature is low and the
engine water temperature gauge does
not enter the green range, continue the
warming-up operation longer.
20-112 GD555, 655, 675-3C

(4)
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.

a Dimension A: 75 mm
2) Set the installed length of pedal (2) to dimension B.
a Dimension B: 193 mm
3) Set the installed length of cable (3) to dimensions C and D.
Unit: mm
Serial No. GD555-3C GD655, 675-3C

50001 – 51000 51001 and up 50001 – 51000 51001 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.
a 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).
a Dimension E of rod (4) (standard length): 459 mm
6) Turn back the stopper bolt (1) one-half turn and lock in position.
GD555, 655, 675-3C 20-113

(4)
TESTING AND ADJUSTING TESTING BRAKE DISC
TESTING BRAKE DISC

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

(4)
TESTING AND ADJUSTING TESTING AND ADJUSTING PARKING BRAKE PAD CLEARANCE
TESTING AND ADJUSTING PARKING BRAKE PAD CLEARANCE

k Stop the machine on flat ground and put blocks 8) Tighten the bolt (8) until it contacts the ure-
under the front wheels. thane spring (10), then tighten the bolt an
additional 1/2 turn.
1. Checking the parking brake pad clearance 9) Tighten nut (7) from 242 to 302 Nm {24.7 to
1) Start the engine, charge the accumulator 30.8 kgm}. Target: 272 Nm {27.7 kgm}
with hydraulic oil, then stop the engine. 10) Loosen the adjustment bolt (9) to adjust so
2) Turn the engine starting switch to the ON that the total clearance (a + b) between the
position and set the gearshift lever to the N disc and pads is from 0.5 to 0.8 mm.
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 adjusting the
parking brake pad clearance below to adjust
the clearance.
a Total clearance for new part (a + b): 0.5
to 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 and b) between the disc (2)
and pads (1) is uniform. Torque the double
nut (5) from 24.1 to 30.1 Nm {2.46 to 3.07
kgm} Target: 27.1 Nm {2.76 kgm}
12) Secure the adjustment bolt (9) with the lock-
nut (4) torqued from 102.8 to 128.2 Nm
{10.5 to 13.1 kgm}. Target: 115.5 Nm {11.8
kgm}.
2. Adjusting the parking brake pad clearance 13) Check the clearance between the disc (2)
1) Start the engine, charge the accumulator and pads (1) again.
with hydraulic oil, then stop the engine. 14) Install the plug (3).
2) Turn the engine start switch ON and set the 15) Set the gearshift lever to the P position and
gearshift lever to the N position. check that the clearance between the pads
3) Measure parking brake pad (1) thickness. (1) and disc (2) is removed.
k If the adjustment procedure for steps 3) thru

• 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 (4). 15) takes longer than 15 minutes, perform
5) Loosen the double nut (5), then loosen the the adjustment procedure continuously af-
bolt (6) five turns. ter completing the proce-dure in steps 1)
6) After loosening the nut (7), loosen the bolt and 2).
(8) three turns.
7) Tighten the bolt (9) so that the front and rear 16) Turn the engine start switch OFF.
pads (1) contact disc (2).
GD555, 655, 675-3C 20-115

(4)
TESTING ACCUMULATOR CHARGE PRESSURE
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT OIL
TESTING ACCUMULATOR TESTING AND ADJUSTING

CHARGE PRESSURE WORK EQUIPMENT OIL
PRESSURE
a Hydraulic oil temperature: 45 to 55°C k Stop the engine, loosen the oil filler cap slowly
k Stop the engine and depress the brake pedal

to release the pressure inside the hydraulic
tank.
slowly at least 30 times to release the pressure
inside the accumulator circuit. a Oil temperature when measuring: 45 to 55°C
1. Remove the accumulator inlet port pressure 1. Measuring unload oil pressure
switch (1) (Rc 1/4), then install tool C1 (39.2 1) Remove the pressure measurement plug (1)
MPa {400 kg/cm2}). (M10 x 1.25).
2) Fit the nipple C3, then install the oil pressure
2. Measure the accumulator charge cut-out pres- gauge C1 (5.9 MPa {60 kg/cm2}).
sure. Start the engine, run the engine at low 3) Run the engine at full throttle and measure
idling, and measure the rise in pressure. The the oil pressure with all levers at HOLD.
point where the pressure stops rising is the cut-
out pressure. 2. Measuring work equipment pressure (relief
pressure)
3. Measure the accumulator charge cut-in pres- 1) Remove the pressure measurement plug (1)
sure. Start the engine, run the engine at low idle, (M10 x 1.25).
wait for the accumulator charge cut-out, then 2) Fit the nipple C3, then install the oil pressure
depress and release the brake repeatedly to gauge C1 (39.2 MPa {400 kg/cm2}).
lower the pressure. The point where the pres- 3) Run the engine at full throttle and measure
sure starts to rise again is the cut-in pressure. 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 repeatedly,
then run the engine at low idling. The initial pres-
sure 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 caution buzzer
sounds before the brake pedal is pressed 10
times, check the accumulator gas pressure.
• For the method of checking the accumulator
gas pressure, see Procedure for Charging
Accumulator for Brake and Work Equipment
with Nitrogen Gas.
20-116 GD555, 655, 675-3C

(4)
TESTING AND ADJUSTING TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTING LS

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

15.1 MPa {154 kg/cm2}
2) After adjusting, tighten the locknut (3) from
68.6 to 78.5 Nm {7 to 8 kgm}
a After completing the adjustment, use the mea-

surement procedure above to check the oil pres-
sure again.
3) Connect the differential pressure gauge C4.
a Connect the LS pump pressure (1) to the high-

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

(4)
TESTING AND ADJUSTING TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE
4) Set to the conditions in Table 1, and meas- 4) Set to the conditions in Table 1, and meas-
ure the LS differential pressure. ure the LS pump pressure.
a Read the gauge indicator while standing
Table 1 directly in front of it.
5) Set to the conditions in Table 1, and meas-
Differential
ure the LS pressure.
Accelerator Operation pressure
MPa {kg/cm2} a Read the gauge indicator while standing
directly in front of it.
2.84 to 3.9 LS differential pressure = (LS pump pres-
Full Levers at neutral
{29 to 40} sure) – (LS pressure)
Blade lever 2.35 ± 0.1
Full
(operate fully to raise) {24 ± 1} Adjusting the LS valve
2. Measuring with an oil pressure gauge When measuring the differential pressure under the
a Measure with the same gauge. above conditions and the pressure is not within the
1) Remove the high-pressure (1) and low-pres- standard value, adjust as follows.
sure (2) oil measurement plugs.
1. To adjust the differential pressure, loosen the
locknut (2) and turn the screw (3)
• CLOCKWISE to increase pressure
• COUNTERCLOCKWISE to decrease pres-
sure
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}
a Always measure the differential pressure
while adjusting.
2) Fit the elbow C5 and nipple C3.
3) Connect the differential pressure gauge C1

(39.2 MPa {400 kg/cm2}).
a Use a gauge with a scale in units of 1.0
MPa {10 kg/cm2}.
20-118 GD555, 655, 675-3C

(4)
ADJUSTING PC VALVE
TESTING AND ADJUSTING BLEEDING AIR FROM HYDRAULIC CIRCUIT
ADJUSTING PC VALVE BLEEDING AIR FROM

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

113 Nm {9 to 11.5 kgm}.
Serial No. 50001 – 51000
2. Bleeding air from the pump circuit

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

(4)
TESTING AND ADJUSTING MEASURING INTERNAL CYLINDER LEAKAGE
MEASURING INTERNAL
CYLINDER LEAKAGE
3. Bleeding air from the hydraulic cylinder a If the hydraulic drift of the work equipment is not
1) Start the engine and run at idle for approx. 5 within the standard value, measure the amount
minutes. of leakage inside the cylinder as follows to judge
2) Run the engine at low idle, and raise and if cause of the hydraulic drift is in the cylinder or
lower the boom 4 to 5 times in succession. in the control valve.
a Operate the piston rod to approx. 100 mm • If the amount of leakage is within the stand-
before the end of its stroke. Do not relieve ard value, the problem is with the control
the circuit under any circumstances. valve.
3) Run the engine at full throttle and repeat • If the amount of leakage is not within the
Step 2). After that, run the engine at low idle standard value, the problem is with the cylin-
and operate the piston rod to the end of its der.
stroke to relieve the circuit. a Oil temperature when measuring: 45 to 55°C.
4) Repeat Steps 2) and 3) to bleed the air from
all the cylinders. 1. Fully extend the cylinder rod to be measured,
then stop the engine.
a 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.
k 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 bottom end
of the cylinder.
4. Wait 30 seconds, then measure the amount of

oil that leaks during the next minute.
a Minimum leakage: 10 cc
BLADE LIFT CYLINDER

L.H. R.H.
20-120 GD555, 655, 675-3C

(4)
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, 675-3C 20-121

(4)
TESTING AND ADJUSTING MEASURING STEERING, BRAKE OIL PRESSURE
MEASURING STEERING, BRAKE OIL PRESSURE

k Stop the machine on flat ground, apply the park- 2) Fit the nipple C3, then install the oil pressure
ing brake, and lower the blade completely to the gauge C1 (5.88 MPa {60 kg/cm2}).
k Stop the engine, loosen the oil filler cap slowly

ground.
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.
2) Fit the nipple C3, then install the oil pressure
gauge C1 (39.2 MPa {400 kg/cm2}).
3) Run the engine at full throttle, and measure
the oil pressure after relieving the left or
right steering circuits (operate to end of the
stroke).
3) Measure the oil pressure after depressing
the brake pedal.
a After measuring the oil pressure, install the
plug and bleed the air from the system.
2. Measuring the brake circuit pressure

a 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, 675-3C

(4)
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE PIPING
BLEEDING AIR FROM BRAKE PIPING

k Stop the machine on flat ground and put blocks 2. Bleeding the air between the slack adjuster and
under the front wheels. the brake
1) Install the vinyl tube (4) to the tip of the air
a Start the engine and charge the accumulator. bleed valve (3).
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 bub-
bles exit with the oil discharged from the air
bleed valve (3).
2) Depress the brake pedal and loosen the air 4) Bleed the air from the brake air bleed valves
bleed valve (1) 3/4 turns, then close the at four places on the left and right.
valve and release the pedal.
3) Continue this procedure until no more bub-
bles 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, 675-3C 20-123

(4)
CHARGING NITROGEN GAS FOR BRAKE,
TESTING AND ADJUSTING WORK EQUIPMENT ACCUMULATOR
CHARGING NITROGEN GAS FOR BRAKE, WORK EQUIPMENT

ACCUMULATOR
1. Before charging with gas, check that the oil 8. Open the valve of the nitrogen cylinder slowly
pressure is completely released. and charge the cylinder (bladder) with nitrogen
a If the oil pressure is not released, it is impos- gas.
sible to charge with the nitrogen gas. a While doing this step, close the nitrogen cyl-
inder valve from time to time, wait for the
2. Turn the charging assembly handle (1) counter- charging assembly pressure gauge to be-
clockwise and raise it to the point where it stops. come stable, and check the displayed pres-
sure.
3. 3. Turn the bleed plug handle (2) counterclock-
wise to open it. 9. When the gas is charged to the specified pres-
sure, close the valve of the nitrogen cylinder
securely.
a If the pressure in the cylinder is too high, turn
the handle (2) counterclockwise gradually to
release the excessive pressure.
1) Accumulator (721-32-10240, 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)}
4. Remove the cap from the gas valve (1), then Px: Pressure of charged gas
assemble the charging assembly to the gas t: Gas temperature when charging
valve (2). (nearly ambient temperature)
35: Specified gas pressure
2) Accumulator (721-32-10250, capacity: 1 l):

• 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
5. Connect the nitrogen cylinder and charging
assembly with hose assembly (3). 10. Turn the handle (1) counterclockwise. Return
the gas valve piston to its original position.
6. Open the nitrogen cylinder valve slightly, take Then, turn the handle (2) counterclockwise to
care that the gas does not discharge quickly, release the gas remaining inside the hose and
and let the gas flow at a pressure from 0.20 to charging assembly.
0.29 MPa {2 to 3 kg/cm2}. When the gas starts to
exit from the handle (2), turn the handle (2) 11. Remove the charging assembly from the accu-
clockwise to stop the gas from escaping. mulator.
7. Turn the handle (1) slowly clockwise to push the

piston of the gas valve (1).
20-124 GD555, 655, 675-3C

(4)
TESTING AND ADJUSTING TESTING AND ADJUSTING CIRCLE GUIDE CLEARANCE
TESTING AND ADJUSTING

CIRCLE GUIDE CLEARANCE
12. Use water or soapy water to check that the gas k If the following conditions occur during adjust-
is not leaking from the gas valve (1). Install the ment, replace the circle guide.
cap and valve guard. • When clearance R between the circle and circle
a After charging with nitrogen gas, check the guide is lost.
charge pressure about a week later to verify • When the clearance between the tip (or root) of
pressure is maintaining. After that, check the teeth of the circle gear and the root (or tip) of
once every month or once every six months, the teeth of the pinion gear of the circle rotation
according to the conditions of use. Note that gear becomes zero (0).
when the check is performed, the pressure
will go down. Thus, add a slight charge to re- Testing
place the pressure that is lost. 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 figure.
Standard clearance QF (front): 0 mm
QC (center): 0.7 mm ([*1])
QR (rear): 1.5 mm
or QF = QR = 1 mm
(*1: Except GD555-3)
Adjusting
1. Adjusting clearance in top-to-bottom direction
Raise the blade, remove the bolts (1), (5), and
(9), and circle guides (2), (6), and (10).
Adjust with shims.
a Standard shim thickness: 5.5 mm
(Shim thickness: 1 mm, 0.5 mm)
GD555, 655, 675-3C 20-125

(4)
TESTING AND ADJUSTING TESTING AND ADJUSTING CIRCLE GUIDE CLEARANCE
2) Adjust clearance D between the end face of

the flange at the bottom of the circle rota-
tion 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)
3) When QF=0, tighten locknut (4), then

tighten bolt (1) from 490.3 to 608 Nm {50 to
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.
a 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 GD555-3)
2. Adjusting clearance in front-to-rear direction
a Push open left and right circle guides (6) uni-
1) Bring the blade lightly into contact with the
formly.
ground. Loosen the bolt (1) and locknut (4).
3) When QR=0, turn the bolt (11) back 1/4 turn,
Extend the bolt (3). Push the circle guide (2)
and tighten the locknut (12). Turn back the
open to make QF=0.
circle guide (10) until it contacts the bolt
a Push open the left and right circle guides (2)
(11). Then tighten the bolt (9) from 490.3 to
uniformly.
608 Nm {50 to 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 to 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 bolt (7).
Tighten the bolt (5) from 490.3 to 608 Nm
{50 to 62 kgm}. (*: Except GD555-3)
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.
20-126 GD555, 655, 675-3C

(4)
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
3. Press the blade against the ground and raise not rotated, the clutch is slipping.
the front wheel to lock the circle or fix the blade
end. Adjusting
• How to raise the front wheel 1. When clutch does not slip
1) Lower the blade to the ground and extend 1) Remove bolts (4) and holder (5) and add 1
the blade lift cylinder until the front wheels shim 0.2 mm thick (6).
are raised. 2) Install holder (5) and tighten bolts (4).
3 Bolt (4):
2) Apply the parking brake.
110.5 ± 12.5 Nm {11.25 ± 1.25 kgm}
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).
a After the shim is adjusted, the clutch
must not slip.
GD555, 655, 675-3C 20-127

(4)
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
• After the clutch disc is replaced with new one,
3) Check the clutch for slipping according to run in the clutch according to the following proce-
the "testing" procedure. dure.
4) Repeat steps 1) - 3) until the clutch does not a When installing the disc, apply oil GO #90 to
slip and set the clutch to the critical slipping its both sides.
point. 1) Set the clutch to the critical slipping point
5) At the critical slipping point, remove 1 shim according to adjusting steps 1 and 2.
0.2 mm thick (6). 2) Add 1 shim 0.2 mm thick so that the clutch
a After the shim is adjusted, the clutch will slip.
must not 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 slip-
ping for 3.5 - 4.0 seconds.
4) Repeat step 2) by 20 - 25 times at intervals
of 3 minutes.
k If the clutch housing temperature ex-

ceeds 50 °C, stop the work until it low-
k If the clutch stops slipping during the

ers to the normal temperature.
work, add 1 shim 0.2 mm thick.
5) Wait until the clutch is cooled to the normal

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.
20-128 GD555, 655, 675-3C

(4)
TESTING AND ADJUSTING MEMORIZING IDLE AND FULL POSITION PROCEDURE
MEMORIZING IDLE AND FULL POSITION PROCEDURE

Accelerator, inching potentiometer 2. Memorizing the full position
1) Depress the accelerator pedal and inching
a If the accelerator pedal assembly, accelerator pedal fully.
linkage and inching pedal assembly have been 2) Turn the start switch to the ON position.
removed or replaced, perform the operation to 3) Push the potentiometer set switch (1) up for
memorize the idle position and full position after at least 1 second.
installing. a If the buzzer sounds continuously for 2 sec-
a For the accelerator, perform the operation after onds, the value for the accelerator and inch-
adjusting the accelerator control linkage. ing potentiometer full position has been
stored correctly.
1. Memorizing the idle position a If the buzzer sounds three times in a cycle of
1) Release the accelerator pedal and inching 1 second ON, 1 second OFF, the setting has
pedal, and leave the pedal free. not been stored in memory.
2) Set the regulator lever to the idling position.
3) Turn the start switch to the ON position. Measuring voltage
4) Push the potentiometer set switch (1) down
Potentiometer
for at least 1 second. Pedal Connector
voltage
a If the buzzer sounds continuously for 2 sec-
onds, the value for the accelerator and inch- Accelerator T9 C to B 2.42 to 4.3
ing potentiometer idling position has been Inching T8 C to B 3.2 to 4.0
stored cor-rectly.
a 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
Potentiometer
Pedal Connector
voltage
Accelerator T9 C to B 1 to 2
Inching T8 C to B 0.8 to 1.6
GD555, 655, 675-3C 20-129

(4)
TESTING AND ADJUSTING INITIAL LEARNING METHOD FOR TRANSMISSION CONTROLLER
INITIAL LEARNING METHOD FOR TRANSMISSION

CONTROLLER
• The transmission controller is equipped with a 2. Resetting learned data
self-compensating learning function that corrects a Do as follows to return all the previously
to a fixed level the differences in operating feel- learned control data in the controller to the
ing caused by the individual differences in the hy- default values.
dr aulic val ves and maintains a constant 1) Check that the starting switch is at the OFF
gearshifting feeling by compensating for the position.
changes in the transmission clutches caused by 2) Turn the starting switch ON. (Do not start
wear. the engine.)
• If the transmission is overhauled or replaced, or 3) Push memory set/learning function initializ-
the hydraulic valves are replaced, the transmis- ing switch (1) down for at least 1 second,
sion controller still has the control command val- then turn the starting switch OFF.
ues learned to match the previous transmission.
For this reason, transmission shock, abnormal 3. Method for learning correction for individual dif-
noise, or defective operating feeling may occur. ferences in valves
• After operating the machine for a short time, the • When correcting the individual differences in the
controller will learn the condition of the new valves, do as follows. The correction operation is
transmission and will gradually return to the opti- for three types of clutch: FL, FH, and R.
mum condition, but if it is desired to reset the 1) Start the engine and run it at low idling.
condition quickly and to carry out learning again, (Depress the accelerator pedal, then let it
it is possible to carry out resetting of the learned back fully.)
data, learning of correction of individual valve dif- 2) Push memory set/learning function initializ-
ferences, and initial learning of stabilized trans- ing switch (1) up, then within 0.8 seconds,
mission feeling as follows. push the reset switch. Hold it in this condition
for at least 1 second, then release the switch.
1. Preparation of machine for learning of correction
for individual differences in valves and initial
learning of transmission feeling stabilization
• It is necessary to carry out the learning operation
at the specified oil temperature, so do as follows
to raise the oil temperature.
1) Depress the brake pedal fully, set the gear-
shift lever to R4, stall the torque converter,
and raise the transmission oil temperature.
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.) 3) The learning of the correction for individual
2) Raise the machine and set it on a stand to differences in the valves will start and
keep the rear wheels off the ground [FWL1] - [REV3] will be displayed on mes-
3) Operate the gearshift lever as follows to cir- sage center (3).
culate the oil fully through the transmission
valves and the whole of the case.
P o N o F1 o F2 o F3 o F4 o N o R1 o
R2 o R3 o R4 o N
4) Use the above operation to raise the oil tem-
perature to 50 – 60°C.
5) Set to N, run the engine at idling for 3 min-
utes, check again that the oil is at the speci-
fied level, then turn the engine starting
switch OFF.
20-130 GD555, 655, 675-3C

(4)
TESTING AND ADJUSTING INITIAL LEARNING METHOD FOR TRANSMISSION CONTROLLER
Item Display Item Display Item Display

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

the controller LED during the correction of the in-
dividual differences in the valves.
4) The corrected values are saved in the con-
troller memory and the correction learning
function is automatically completed.
5) When the correction learning is completed,
the message center returns to the normal
display.
6) Turn the start switch OFF.
4. Initial learning method for stabilized transmis-

sion feeling
• To adjust the controller learning control data for
each clutch from the default settings to the opti-
mum values, always carry out resetting of the
learned data and learning of the correction for in-
dividual differences in the valves, then do as fol-
lows.
1) Start the engine and run at low idling.
2) Set the transmission mode switch to [Mode
1].
3) Operate the gearshift lever as follows three
times in succession:
P o N o F1 o F2 o F3 o F5 o F3 o F2 o
F1 o N o R1 o R2 o R3 o R4 o R3 o R2
o R1 o N
a When doing this, hold each speed range for
at least 3 seconds, then shift to the next
speed range.
GD555, 655, 675-3C 20-131

(4)
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, in-
cluding the diode.
• Use a digital tester with a range for measuring di-
odes.
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 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 displayed. 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.
20-132 GD555, 655, 675-3C

(4)
TESTING AND ADJUSTING MOVING MACHINE WHEN TRANSMISSION VALVE FAILS
MOVING MACHINE WHEN TRANSMISSION VALVE FAILS

a If the machine cannot be moved because of a 3. Depending on the direction for moving the
failure in any part of the transmission valve sys- machine (forward or reverse), remove the fol-
tem (electrical system, solenoid valves, spools, lowing 2 ECMV sooenoids (3) and install Plug K.
etc.), it is possible to move the machine by • FORWARD: F L solenoid and 2nd solenoid
installing Plug K. • REVERSE: R solenoid and 2nd solenoid
k Plug K is only for emergency use when the ma- a If there is any mistake in the selection of the
chine cannot be moved by any other means be- solenoid to remove, there is danger that the
cause of a failure in the transmission control transmission may be damaged.
valve system. Do not install plate N to the ECMV a Install Plug K with the protruding surface fac-
except when there has been a failure and it is ing the ECMV. Check also that there is an O-
necessary to move the machine from a danger- ring installed to the mating surface.
ous working area to a safe place for repairs. a Be careful not to let any dirt or mud get inside
k When carrying out this operation, keep strictly to
the removed solenoid or valve.
the procedure and pay careful attention to safe-
ty when moving the machine.
k To prevent the machine from moving, lower the
work equipment completely to the ground, apply
the parking brake, and put blocks under the
tires.
k Carry out operation with the engine stopped.
k Be careful not to burn yourself if the oil is hot.
1. Remove valve cover (1) at front of transmission.

a Clean around the ECMV and remove all dirt
and dust.
2. Disconnect wiring connectors (2). (14 places)
GD555, 655, 675-3C 20-133

(4)
TESTING AND ADJUSTING MOVING MACHINE WHEN TRANSMISSION VALVE FAILS
4. Depress the brake pedal securely.

5. Start the engine, release the parking brake, then
release the brake pedal gradually to allow the
machine to start, then move the machine.
k Remove the blocks under the tires.
k When the engine is started, the transmission is
also engaged to start the machine. To ensure
safety when starting the engine, check carefully
that the direction of travel and area around the
machine are safe. Always keep the brake pedal
depressed when starting.
k After moving the machine, stop the engine, ap-
ply the parking brake, and put blocks under the
tires.
20-134 GD555, 655, 675-3C

(4)
TESTING AND ADJUSTING ADJUSTING CAB STOPPER BOLT
ADJUSTING CAB STOPPER BOLT

1. Remove 4 stopper bolts (1). (Top, bottom, left, 5. Check clearance a between door handle (5) and
right) cab (surface of glass).
• Clearance a = 8 mm
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.
a If the adjustment of the 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

2. Check that door striker (3) is properly set and is mounting of door striker (3) out from the surface
not angled to the left or right. of door glass (6) by an amount equal to clear-
ance a - 8 mm. Fit the door to the cab again and
3. Fit door striker (3) to lock (4) on the cab. check that clearance a is 8 mm.
4. Check that the centers of door striker (3) and 9. If the center of door striker (3) is not aligned,
lock (4) on cab are aligned. remove door link cover (2) and move door
striker (3) up or down to set it in the center.
10. Install 4 stopper bolts (1). (Top, bottom, left,

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
condition is correct.
a If there is a clearance at portion C, go to Step
15.
GD555, 655, 675-3C 20-135

(4)
TESTING AND ADJUSTING ADJUSTING CAB STOPPER BOLT
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).
a Remove 20Y-54-11611 (length below head:

42 mm) and install 23A-952-1430 (length be-
low head: 32 mm)
14. Fit door striker (3) to lock (4) on the cab, and
check again that there is a clearance at portion
C of door glass (6) and the rubber tip.
15. Turn the stopper bolt and put it in contact with

the surface of door glass (6). (Clearance at por-
tion C = 0)
16. With the clearance of stopper bolt (1) = 0, turn

the bolt 3 turn to the left (to move it out from the
surface of the glass).
20-136 GD555, 655, 675-3C

(4)
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 ............................................................................. 20-213
CONNECTOR ARRANGEMENT DIAGRAM .............................................................................................. 20-222
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-230
MESSAGE CENTER DISPLAY AND TABLE ERROR CODES .................................................................. 20-251
USING THE TROUBLESHOOTING CHARTS............................................................................................ 20-255
GD555, 655, 675-3C 20-201

(4)
TROUBLESHOOTING TROUBLESHOOTING POINTS TO REMEMBER
TROUBLESHOOTING POINTS TO REMEMBER

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fit-
ted.
k 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.
k 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.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
k 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 connect 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.
1. When carrying out troubleshooting, do not hurry 3) Check the travel of the control levers.
to disassemble the components. If components 4) Check the stroke of the control valve spool.
are disassembled immediately after a failure 5) Other maintenance items can be checked
occurs: externally, so check any item that is consid-
• Parts that have no connection with the failure ered to be necessary.
or other unnecessary parts will be disassem-
bled. 4. Confirming the failure.
• It will become impossible to find the cause of Confirm the extent of the failure yourself, and
the failure. judge whether to handle it as a real failure or as
It will also cause a waste of man hours, parts, or a problem with the method of operation, etc.
oil and grease. At the same time, it will also lose a When operating the machine to re-enact the
the confidence of the user or operator. For this troubleshooting symptoms, do not carry out
reason, when carrying out troubleshooting, it is any investigation or measurement that may
necessary to carry out thorough prior investiga- make the problem worse.
tion and to carry out troubleshooting in accor-
dance with the fixed procedure. 5. Troubleshooting
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 exactly.
2) Was there anything strange about the a The basic procedure for troubleshooting is
machine before the failure occurred? as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or infor-
4) Under what conditions did the failure occur? mation.
5) Had any repairs been carried out before the
failure? When were these repairs carried 6. Measures to remove root cause of failure.
out? Even if the failure is repaired, if the root cause of
6) Has the same kind of failure occurred the failure is not repaired, the same failure will
before? occur again.
To prevent this, always investigate why the
3. Check before troubleshooting. problem occurred. Then, remove the root cause.
1) Check the oil level.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
20-202 GD555, 655, 675-3C

(4)
TROUBLESHOOTING TROUBLESHOOTING SEQUENCE
TROUBLESHOOTING SEQUENCE
GD555, 655, 675-3C 20-203

(4)
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 electric equip-
ment
1) Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors 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, dur-
ing inspection and repair operations they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
Main failures occurring in wiring harness

1) 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 connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidation of the contact surfaces.
2) Defective compression or soldering of con-

nectors
The pins of the male and female connectors
are in contact at the compressed terminal or
soldered portion, but there is excessive
force on the wiring, and the plating peels to
cause improper connection or breakage.
20-204 GD555, 655, 675-3C

(4)
3) Disconnections in wiring
If the wiring is held and tugged and the con-
nectors are pulled apart, or components are
lifted with a crane with the wiring still con-
nected, 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 wiring may be bro-
ken.
4) High pressure water entering a connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector depending on the direction of the
water jet. The connector is designed to pre-
vent water from entering, but if water does
enter, it is difficult for it to be drained. There-
fore, if water should get into the connector,
the pins will be short-circuited by the water,
so if any water gets in, immediately dry the
connector or take other appropriate action
before passing electricity through it.
5) 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.
a When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
a If there is water or oil present, it will in-
crease the contamination of the points,
so clean with air until all water and oil
has been removed.
GD555, 655, 675-3C 20-205

(4)
2) Removing, installing, and drying connectors

and wiring harnesses
• Disconnecting connectors
1) 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 connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never try to pull apart with one hand.
2) When removing the connectors from the
clips, pull the connector in a parallel direc-
tion to the clip.
a If the connector is twisted to the left and
right or up and down, the housing may
break.
3) 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 portion.
a If the machine is left for a long time, it is
particularly easy for improper contact to
occur, so always cover the connector.
20-206 GD555, 655, 675-3C

(4)
• Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
faulty contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
a 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 con-
nector, warm the inside of the wiring with
a dryer, but be careful not to make it too
hot as this will cause short circuits.
a If there is any damage or breakage, re-
place the connector.
Since the DT 8-pole and 12-pole heavy duty
wire connectors have 2 latches respectively,
push them in until they click 2 times.
a 1: Male connector, 2: Female connector
• Normal locking state (Horizontal): a,
b, d
• Incomplete locking state (Diagonal):
c
2) Assemble the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with a lock stopper:
Push in the connector until the stopper
clicks into position.
3) 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 wir-
ing harness is misaligned, or the clamp is
out of position, adjust it to its correct posi-
tion.
a When blowing with dry air, there is dan-
ger that the oil in the air may cause im-
proper contact, so clean with properly
filtered air.
4) 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, 675-3C 20-207

(4)
• 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 fol-

lows:
1) Disconnect the connector and wipe off the
water with a dry cloth.
a If the connector is blown dry with air,
there is the risk that oil in the air may
cause a faulty contact, so avoid blowing
with air.
2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
a 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.
3) Carry out a continuity test on the connector.

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

(4)
3) Handling control box

1) 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.
2) Do not open the cover of the control box
unless necessary.
3) Do not place objects on top of the control

box.
4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
5) Do not leave the control box in a place
where it is exposed to rain.
6) 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)
7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
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.
a Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a 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.
a If there is any change, there is probably defective contact in the circuit.
GD555, 655, 675-3C 20-209

(4)
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 disassem-
bling 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. Disas-
sembly and maintenance of hydraulic equip-
ment 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 enter-
ing. 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 environ-
mental regulation for any disposal of oil.
4) Do not let any dirt, or dust get in during refill-

ing 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 clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-210 GD555, 655, 675-3C

(4)
5) Change hydraulic oil when the temperature

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 con-
taminants 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 sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he
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, 675-3C 20-211

(4)
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
4. Check hydraulic oil strainer — Clean, drain
Lubricating oil, coolant
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

2. Check battery electrolyte level — Add or replace
Electrics, electrical equipment
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 Disconnect
—
leaking 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
— Replace
ON, OFF)
20-212 GD555, 655, 675-3C

(4)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

Serial No. 50001 – 51000
Connector
Connector
Address
Address
No. of
No. of
pins
No.
pins
Type Mounting location
No.
AC1 SWP 12 Air-con unit G-9 BR12 Relay 5 Neutral relay Q-5
AC3 SWP 14 Air-con unit X-3 BR13 Relay 6 Front work lamp relay R-3
AC4 SWP 16 Air-con unit W-2 P-4
BR14 Relay 5 Rear work lamp relay
AC5 — 16 Air-con control unit U-7 R-3
AC6 — 20 Air-con control unit U-8 BR15 Relay 5 Float cancel relay (R.H.) R-4
AC8 — 7 Air-con intake duct W-2 BR16 Relay 5 Float cancel relay (L.H.) R-3
B1 DT2 (G) 12 Intermediate connector D-8 BR18 KES 4 Front wiper switch N-4
B2 DT2 (Gr) 12 Intermediate connector C-8 BR19 KES 6 Preheat timer relay R-4
B3 DT2 (Br) 12 Intermediate connector C-8 BR20 KES 4 Flasher R-4
B4 DT2 (B) 8 Intermediate connector A-8 BR21 DT2 2 Buzzer (B) P-1
B5 DT2 (G) 8 Intermediate connector C-9 BR22 M 2 Buzzer (A) Q-1
B6 L 2 Intermediate connector D-8 BR23 DT2 2 Lifter lock switch Q-5
B7 DT2 (Br) 8 Intermediate connector C-9 Work lamp switch
BR24 DT2 2 O-4
(If equipped)
B8 DT2 (B) 12 Intermediate connector B-9
Fog lamp switch
B9 DT2 (Gr) 8 Intermediate connector B-9 BR25 DT2 2 O-5
(If equipped)
B10 DT2 (G) 8 Intermediate connector B-9
BR26 VCH 8 Hazard lamp switch O-5
Intermediate connector
B11 L 2 B-8 BR27 VCH 8 Head lamp switch P-5
(battery relay)
BR28 DT2 3 Accumulator float switch N-4
B12 L 2 B-8 BT30 TERMINAL 1 GND D-7
(starter motor)
B13 DT2 2 Brake lamp switch D-7 BT31 TERMINAL 1 Starter switch (B) P-5
B14 DT2 2 Brake lamp switch D-7 BT32 TERMINAL 1 Starter switch (Br) P-5
Window washer BT33 TERMINAL 1 Starter switch (R1) P-5
B15 KES 2 G-3 BT34 TERMINAL 1 Starter switch (C) P-5
(Front upper)
Window washer BT35 TERMINAL 1 Starter switch (ACC) P-5
B16 KES 2 G-3
(Front lower) BT36 TERMINAL 1 Horm relay M-3
B17 KES 2 Window washer (Rear) G-3 BT37 TERMINAL 1 Horm relay N-3
B18 DT2 3 Float cancel switch (R.H.) D-6 BT38 TERMINAL 1 Horm relay N-3
B19 DT2 3 Float cancel switch (L.H.) E-4 1-pin
BT41 1 Switch panel lamp P-5
B20 DT2 2 Engine start solenoid G-9 connector
Diode 1-pin
B21 DT2 2 H-9 BT42 1 Cigar lighter Q-5
(Engine start up solenoid) connector
B22 DT1 4 Intermediate connector B-8 1-pin
BT43 1 Cigar lighter Q-5
B23 L 1 Fuse box K-6 connector
B24 DT2 (B) 8 Intermediate connector L-6 1-pin
BT44 1 Accumulator float switch —
connector
B25 DT2 (B) 12 Intermediate connector L-6
1-pin
BR1 DT2 2 Diode (Battery relay) M-5 BT45 1 Accumulator float switch —
connector
BR2 DT2 2 Diode (Battery relay) M-5
1-pin
BR3 DT2 2 Diode (Buzzer) N-4 BT46 1 Accumulator float switch —
connector
BR4 Relay 5 Alternator relay Q-1 C1 DT2 (G) 8 Intermediate connector G-4
BR5 Relay 5 Charge lamp relay Q-1 C2 DT2 (Gr) 8 Intermediate connector H-4
BR6 Relay 5 Back-up alarm relay R-3 Intermediate connector
BR7 Relay 5 Differential relay R-2 C3 DT2 6 H-4
(Wiper)
BR8 Relay 5 VHP relay R-2 C4 DT1 3 Heater (If equipped) H-4
Accumulator hydraulic C5 — 9 Radio (If equipped) U-8
BR9 Relay 5 R-2
pressure relay C6 KES 2 Speaker (R.H.) V-8
BR10 Relay 5 Brake pump relay R-3 C7 KES 2 Speaker (L.H.) X-7
BR11 Relay 5 Parking brake relay P-5 C8 KES 6 Rear wiper switch X-4
GD555, 655, 675-3C 20-213

(4)
Connector
Connector
Address
Address
No. of
No. of
pins
pins
No.
No.
Type Mounting location Type Mounting location
C9 KES 6 Front lower wiper switch X-3 Diode

E8 DT2 2 J-6
C10 KES 2 Room lamp switch T-7 (Fuel shut-off relay)
C11 M 2 Fan switch (front) X-4 E9 (PKD) 3 Fuel shut-off solenoid J-7
C12 M 2 Fan switch (rear) X-5 E10 DT2 3 VHP valve J-7
C13 M 2 Defroster fan (front) U-2 E11 DT2 2 Diode (VHP valve) J-7
C14 M 2 Defroster fan (rear) X-6 Engine oil pressure
E12 DT2 3 J-6
C15 KES 4 Front wiper motor S-4 switch
C16 KES 4 Rear wiper motor W-7 Accumulator hydraulic
E13 DT2 3 H-4
pressure switch (R.H.)
Front lower wiper motor
C17 KES 4 T-2 Accumulator hydraulic
(R.H.) E14 DT2 3 H-4
pressure switch (L.H.)
Front lower wiper motor
C18 KES 4 U-2 E15 DT2 6 Joint connector J-5
(L.H.)
Front lower wiper motor E16 DT2 4 Intermediate connector I-4
C19 Relay 5 V-2 Diff. thermostat sensor
relay (R.H.) E17 DT2 2 H-4
C20 M 2 Beacon switch X-5 (If equipped)
Work lamp relay Diff. lock solenoid
C21 Relay 5 V-2 E18 DT2 2 I-4
(If equipped) (If equipped)
Work lamp switch 1-pin Hydraulic thermo sensor
C22 KES 3 X-6 E95 1 —
(If equipped) connector for T/C
C23 M 2 Work lamp (If equipped) T-7 1-pin
ET39 1 Fuel sensor J-8
connector
C24 M 2 Work lamp (If equipped) S-6
ET40 TERMINAL 1 Gnd J-6
ET41 TERMINAL 1 Battery (-) J-6
ET42 TERMINAL 1 Battery (+) J-6
Head lamp (R.H.)
C27 M 3 S-3 ET43 TERMINAL 1 Battery (-) G-9
(If equipped)
Head lamp (L.H.) ET44 TERMINAL 1 Battery (+) G-9
C28 M 3 S-5 ET45 TERMINAL 1 Battery relay K-3
(If equipped)
C29 M 2 Power (24V) (Spare) X-6 ET46 TERMINAL 1 Battery relay K-2
C30 KES 2 Spot lamp (If equipped) V-8 ET47 TERMINAL 1 Slow blow fuse I-2
Intermediate connector ET48 TERMINAL 1 Slow blow fuse J-2
C31 M 2 U-2
(Defroster fan, front) ET49 TERMINAL 1 Battery relay K-2
Intermediate connector ET50 TERMINAL 1 Starter motor H-9
C32 M 2 X-6
(Defroster fan, rear) ET51 TERMINAL 1 Starter motor (Gnd) I-9
Combination lamp (R.H.) ET52 TERMINAL 1 Gnd J-7
C33 M 3 T-3
(If equipped) ET53 TERMINAL 1 Starter motor (B) H-9
Combination lamp (L.H.) ET54 TERMINAL 1 Grid heater relay J-2
C34 M 3 S-6
(If equipped)
ET55 TERMINAL 1 Grid heater relay I-3
1-pin
CT35 1 Beacon S-5 ET56 TERMINAL 1 Grid heater J-7
connector
ET58 TERMINAL 1 Battery relay K-3
CT41 TERMINAL 1 Gnd X-3
ET59 TERMINAL 1 Slow blow fuse I-2
E1 DT2 2 Alternator H-9
Thermostat sensor
E2 X 2 H-9 ET62 TERMINAL 1 Battery relay K-3
(GD655, 675)
Thermostat sensor ET63 TERMINAL 1 Slow blow fuse H-9
E2 X 2 I-9 ET64 TERMINAL 1 Battery relay L-3
(GD555)
E3 DT2 2 Intermediate connector J-8 ET65 TERMINAL 1 Alternator (B) M-8
Hydraulic thermo sensor ET66 TERMINAL 1 Alternator (I terminal) M-8
E4 X 2 J-7
for T/C (If equipped) ET67 TERMINAL 1 Alternator (E) M-8
Hydraulic thermo sensor ET68 TERMINAL 1 Slow blow fuse I-2
E5 DT2 2 J-7
for AWD (If equipped) ET69 TERMINAL 1 Slow blow fuse I-2
E6 DT2 2 Diode (Starter relay) J-4 ET70 TERMINAL 1 Fuel shut-off relay J-5
E7 DT2 2 Diode (Grid heater relay) I-3 ET71 TERMINAL 1 Fuel shut-off relay I-5
ET72 TERMINAL 1 Starter relay K-2
20-214 GD555, 655, 675-3C

(4)
Connector
Connector
Address
Address
No. of
No. of
pins
pins
No.
No.
ET73 TERMINAL 1 Starter relay J-4 Front work lamp (spare)

FL28 M 2 B-5
ET74 TERMINAL 1 Starter motor (C) H-9 (R.H.)
ET75 TERMINAL 1 Battery relay (+) J-4 Front work lamp (spare)
FL29 M 2 B-1
ET76 TERMINAL 1 Battery relay (–) K-4 (L.H.)
ET77 TERMINAL 1 Gnd I-5 FP1 DT2 (Gr) 12 Meter assembly D-8
ET80 TERMINAL 1 Starter relay K-2 FP2 DT2 (B) 12 Warning module (L.H.) D-8
ET81 TERMINAL 1 Starter relay J-4 FP3 DT2 (Br) 12 Warning module (R.H.) E-9
ET82 TERMINAL 1 Grid heater relay I-4 FP6 DT2 (B) 12 Intermediate connector B-7
ET83 TERMINAL 1 Grid heater relay J-2 FP7 DT2 (Gr) 8 Intermediate connector B-8
1-pin FP8 DT2 (Br) 12 Intermediate connector A-8
ET88 1 Aircon compressor J-7 FP9 KES 1 Service meter D-7
connector
ET89 TERMINAL 1 Battery (–) J-6 FP10 DT2 4 Message center E-9
ET90 TERMINAL 1 Fuel shut-off relay I-5 FP11 DT2 3 Turn signal switch D-8
ET91 TERMINAL 1 Fuel shut-off relay I-5 FP12 DT2 3 Dimmer switch D-8
ET92 TERMINAL 1 Gnd (Engine) J-6 Differential switch
FP13 DT2 2 D-8
ET93 TERMINAL 1 Gnd (Engine) J-5 (If equipped)
ET94 TERMINAL 1 Gnd (Alternator) I-4 AWD on/off switch
FP14 DT2 2 D-8
(If equipped)
FB18 DT2 3 Intermediate connector —
AWD auto/manual switch
FL1 M 3 Head lamp (R.H.) B-5 FP15 DT2 2 D-8
(If equipped)
FL2 M 3 Head lamp (L.H.) A-2
FP16 DT2 6 AWD auto/manual switch E-9
FL3 DT2 (B) 8 Intermediate connector A-4
Front wheel rev. tuning
FL4 DT2 (B) 12 Intermediate connector D-6 FP17 DT2 3 E-9
potentiometer
FL5 DT2 (Br) 8 Intermediate connector D-6 FP18 DT2 3 Intermediate connector E-9
FL6 DT2 2 Articulate sensor E-5 1-pin
FL7 (PKD) 2 Lifter lock solenoid F-4 FT6 1 Horn (L.H.) F-4
connector
FL8 (PKD) 2 Parking brake solenoid F-4 1-pin
FT7 1 Horn (R.H.) E-5
Accumulator solenoid connector
FL9 DT2 2 C-6
(R.H.) FT10 TERMINAL 1 Floor (Floor) E-5
Accumulator solenoid FT11 TERMINAL 1 Gnd (front frame) F-4
FL10 DT2 2 E-2
(L.H.) FT12 TERMINAL 1 Gnd (front frame) D-7
FL11 DT2 2 Float solenoid (R.H.) B-5 FT13 TERMINAL 1 Gnd (rear frame) J-5
FL12 DT2 2 Float solenoid (R.H.) C-6 FT16 TERMINAL 1 Articulate sensor (–) —
FL13 DT2 2 Float solenoid (L.H.) D-2 FT17 TERMINAL 1 Articulate sensor (G) —
FL14 DT2 2 Float solenoid (L.H.) C-6 1-pin Speed meter
FL15 DT2 2 Diode (solenoid) C-1 FT18 1 D-9
connector (If equipped)
FL16 DT2 2 Diode (solenoid) F-3 1-pin
FT19 1 T/C HYD temp. gauge —
FL17 DT2 2 Diode (solenoid) D-1 connector
FL18 DT2 2 Diode (solenoid) D-1 1-pin
FT20 1 Water temperature gauge D-9
E- connector
FL19 DT2 2 Diode (solenoid)
20 1-pin
FT21 1 Fuel gauge D-9
E- connector
FL20 DT2 2 Diode (solenoid)
20 1-pin
FT22 1 Articulate gauge D-9
FL21 DT2 4 Intermediate connector C-6 connector
FL22 M 3 Combination lamp (R.H.) A-5 FT23 TERMINAL 1 T/C HYD temp. gauge (B) D-9
FL23 M 3 Combination lamp (L.H.) A-2 FT24 TERMINAL 1 T/C HYD temp. gauge (T) D-9
FL24 M 2 Fog (If equipped) A-4 FT25 TERMINAL 1 T/C HYD temp. gauge (E) D-9
FL25 M 2 Fog (If equipped) A-3 Water temperature gauge
FT26 TERMINAL 1 D-9
(B)
Front work lamp (R.H.)
FL26 M 2 E-5 Water temperature gauge
(If equipped) FT27 TERMINAL 1 D-9
(T)
Front work lamp (L.H.)
FL27 M 2 F-4 Water temperature gauge
(If equipped) FT28 TERMINAL 1 D-9
(E)
GD555, 655, 675-3C 20-215

(4)
Connector
Connector
Address
Address
No. of
No. of
pins
pins
No.
No.
FT29 TERMINAL 1 Fuel gauge (B) D-9 T20 DT2 (B) 12 Intermediate connector Q-9
FT30 TERMINAL 1 Fuel gauge (T) D-9 T21 DT2 6 Intermediate connector Q-9
FT31 TERMINAL 1 Fuel gauge (E) D-9 T22 DT2 (Gr) 12 Intermediate connector Q-9
FT32 TERMINAL 1 Articulate gauge (E) D-9 Intermediate connector
T23 DT2 3
1-pin (for MF controller)
FT33 1 Articulate gauge (B) D-9
connector T24 DT2 2 FL solenoid R-8
1-pin T25 DT2 2 FH solenoid R-8
FT34 1 Articulate gauge (T) D-9
connector T26 DT2 2 R solenoid R-8
1-pin T27 DT2 2 1st solenoid R-7
FT35 1 Articulate gauge D-9
connector T28 DT2 2 2nd solenoid R-7
1-pin T29 DT2 2 3rd solenoid R-7
FT37 1 Horn switch F-9
connector
T30 DT2 2 4th solenoid R-6
H1 M 2 Heater F-9
T31 DT2 2 Lockup solenoid N-9
OP1 M 1 If equipped F-9
Transmission input shaft
OP2 M 1 If equipped F-9 T32 DT2 2 R-9
speed sensor
RL1 DT2 (Br) 8 Intermediate connector J-8 Transmission output
RL2 M 6 Combination lamp (R.H.) I-9 T33 DT2 2 Q-6
shaft speed sensor
RL3 M 6 Combination lamp (L.H.) J-8 T/C hydraulic temp. sen-
T34 DT2 2 R-8
Rear work lamp sor
RL4 M 2 I-9
(If equipped) T/M hydraulic temp. sen-
T35 DT2 2 R-6
Rear work lamp sor
RL5 M 2 J-8
(If equipped) T36 DT2 2 FL clutch fill switch R-8
RT1 M 1 License lamp J-8 T37 DT2 2 FH clutch fill switch R-7
RT2 TERMINAL 1 Back-up alarm J-8 T38 DT2 2 R clutch fill switch R-8
RT3 TERMINAL 1 Back-up alarm I-9 T39 DT2 2 1st clutch fill switch R-7
1-pin Rear work lamp T40 DT2 2 2nd clutch fill switch R-7
RT4 1 —
connector (If equipped) T41 DT2 2 3rd clutch fill switch R-6
1-pin Rear work lamp T42 DT2 2 4th clutch fill switch R-6
RT5 1 —
connector (If equipped)
T43 DT2 2 Lockup clutch fill switch N-8
T1 MIC 13 T/M controller N-3
T44 DT2 6 Intermediate connector A-8
T46 DT2 2 Engine riv. sensor Q-9
T3A 040 20 T/M controller N-2
T47 DT2 6 Joint connector P-9
T3B 040 16 T/M controller N-3
T4 040 12 T/M controller N-3
T49 DT2 6 Joint connector Q-9
T5 MIC 17 T/M controller Q-5
Connector for flash ROM
T6 DT2 4 D-7 TT1 TERMINAL 1 Potentiometer set switch R-4
writer
TT2 TERMINAL 1 Potentiometer set switch R-4
Connector for
T7 DT2 6 O-1 TT3 TERMINAL 1 Potentiometer set switch R-4
specification selection
T8 DT2 3 Inching potentiometer P-1 TT4 TERMINAL 1 Intialize switch R-5
Accelerator TT5 TERMINAL 1 Intialize switch R-5
T9 DT2 3 O-1
potentiometer TT6 TERMINAL 1 Intialize switch R-5
T10 DT2 (G) 12 For floor harness A-7 TT7 TERMINAL 1 Reset switch Q-5
T11 DT2 (Gr) 8 Intermediate connector A-8 TT8 TERMINAL 1 Reset switch R-5
T12 DT2 6 Intermediate connector C-8 TT9 TERMINAL 1 Gnd (Floor) D-8
T13 DRC 24 Shift lever N-3
T14 DT2 2 T/C lockup 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
T19 DT2 (Gr) 12 Intermediate connector A-9
20-216 GD555, 655, 675-3C

(4)
Connector
Connector
Address
Address
No. of
No. of
pins
No.
pins
No.
AC1 SWP 12 Air-con unit (If equipped) G-9 BR10 Relay 5 Brake pump relay R-3
AC3 SWP 14 Air-con unit (If equipped) X-3 BR11 Relay 5 Parking brake relay P-5
AC4 SWP 16 Air-con unit (If equipped) W-2 BR12 Relay 6 Neutral relay Q-5
Air-con control unit (If BR13 Relay 6 Front work lamp relay R-3
AC5 — 16 U-7
equipped) P-5
BR14 Relay 5 Rear work lamp relay
Air-con control unit (If R-3
AC6 — 20 U-8
equipped) BR15 Relay 5 Float cancel relay (R.H.) R-4
Air-con intake duct (If BR16 Relay 5 Float cancel relay (L.H.) R-3
AC8 — 7 W-2
equipped) BR18 KES 4 Front wiper switch N-4
B1 DT2 (G) 12 Intermediate connector D-8 BR19 KES 6 Preheat timer relay R-4
B2 DT2 (Gr) 12 Intermediate connector C-8 BR20 KES 4 Flasher R-4
B3 DT2 (Br) 12 Intermediate connector C-8 BR21 DT2 2 Buzzer (B) P-1
B4 DT2 (B) 8 Intermediate connector A-8 BR22 M 2 Buzzer (A) Q-1
B5 DT2 (G) 8 Intermediate connector C-9 BR23 DT2 2 Lift lock switch Q-5
B6 L 2 Intermediate connector D-8 Work lamp switch
BR24 DT2 2 O-4
B7 DT2 (Br) 8 Intermediate connector D-9 (If equipped)
B8 DT2 (B) 12 Intermediate connector B-9 BR25 DT2 2 Fog lamp (If equipped) O-5
B9 DT2 (Gr) 8 Intermediate connector B-9 BR26 (VCH) 8 Hazard lamp switch O-5
B10 DT2 (G) 8 Intermediate connector B-9 BR27 (VCH) 8 Head lamp switch P-5
Intermediate connector BR28 DT2 3 Accumulator float switch N-4
B11 L 2 B-8
(Battery relay) BT30 TERMINAL 1 GND D-7
Intermediate connector BT31 TERMINAL 1 Starter switch (B) P-5
B12 L 2 B-8
(Battery relay) BT32 TERMINAL 1 Starter switch (BR) P-5
B13 DT2 2 Brake lamp switch D-7 BT33 TERMINAL 1 Starter switch (R1) P-5
Window washer (Front BT34 TERMINAL 1 Starter switch (C) P-5
B15 KES 2 G-3
upper) (If equipped)
BT35 TERMINAL 1 Starter switch (ACC) P-5
Window washer (Front
B16 KES 2 G-3 BT36 TERMINAL 1 Horn relay M-3
lower) (If equipped)
BT37 TERMINAL 1 Horn relay N-3
Window washer (Rear)
B17 KES 2 G-3 BT38 TERMINAL 1 Horn relay N-3
(If equipped)
B18 DT2 3 Float cancel switch (R.H.) D-6 1-pin
BT41 1 Switch panel lamp P-5
connector
B19 DT2 3 Float cancel switch (L.H.) E-5
1-pin
B20 DT2 2 Engine start solenoid G-9 BT42 1 Cigar lighter O-5
connector
Diode (Engine start up
B21 DT2 2 H-9 1-pin
solenoid) BT43 1 Cigar lighter O-5
connector
B22 DT1 4 Intermediate connector B-8
C1 DT2 (G) 8 Intermediate connector G-4
B23 L 1 Fuse box K-7
C2 DT2 (Gr) 8 Intermediate connector G-4
B24 DT2 (B) 8 Intermediate connector L-6
B25 DT2 (B) 12 Intermediate connector L-6 C3 DT2 6 H-4
(Wiper)
B26 DT2 2 Diode — Glass heater
B27 DT2 2 Diode — C4 DT1 3 H-4
(If equipped)
BR1 DT2 2 Diode (Battery relay) M-5 C5 — 9 Radio (If equipped) U-8
BR2 DT2 2 Diode (Battery relay) M-5 Speaker (R.H.)
C6 KES 2 V-8
BR3 DT2 2 Diode (Buzzer) N-4 (If equipped)
BR4 Relay 5 Alternator relay Q-1 Speaker (L.H.)
C7 KES 2 X-7
BR5 Relay 5 Charge lamp relay Q-1 (If equipped)
BR6 Relay 5 Buck-up alarm relay R-3 Rear wiper switch
C8 KES 6 X-4
BR7 Relay 5 Differential relay R-2 (If equipped)
BR8 Relay 5 VHP relay — Front lower wiper switch
C9 KES 6 X-3
(If equipped)
Accumulator hydraulic
BR9 Relay 5 R-2
pressure relay
GD555, 655, 675-3C 20-217

(4)
Connector
Connector
Address
Address
No. of
No. of
pins
pins
No.
No.
Room lamp switch Hydraulic thermostat sen-

C10 KES 2 T-7 E4 X 2 J-7
(If equipped) sor for T/C (If equipped)
Fan switch (Front) Hydraulic thermostat sen-
C11 M 2 X-4 E5 DT2 2 J-7
(If equipped) sor for AWD (If equipped)
Fan switch (Rear) Diode (Starter safety
C12 M 2 X-5 E6 DT2 2 J-4
(If equipped) relay) (GD555)
Defroster fan (Front) Starter motor
C13 M 2 U-2 E6 DT2 2 X-3
(If equipped) (GD655, 675)
Defroster fan (Rear) E7 DT2 2 Diode (Grid heater relay) I-3
C14 M 2 X-6
(If equipped) Diode
E8 DT2 2 J-6
Front wiper motor (Fuel shut-off solenoid)
C15 KES 4 S-4
(If equipped) Fuel shut-off solenoid
E9 DT 3 J-7
Rear wiper motor (GD655, 675)
C16 KES 4 W-7
(If equipped) E10 DT2 3 VHM valve —
Front lower wiper motor E11 DT2 2 Diode (VHP valve) J-7
C17 KES 4 T-2
(L.H.) (If equipped) Engine oil pressure
Front lower wiper motor E12 (PKD) 3 J-7
C18 KES 4 U-2 switch
(R.H.) (If equipped) Accumulator hydraulic
Front lower wiper motor E13 DT2 3 H-4
C19 Relay 5 V-2 pressure switch (R.H.)
relay (R.H.) (If equipped) Accumulator hydraulic
Beacon switch E14 DT2 3 H-4
C20 M 2 X-5 pressure switch (L.H.)
(If equipped) E15 DT2 6 Joint connector J-5
Work lamp relay E16 DT2 4 Intermediate connector I-4
C21 Relay 5 V-2
(If equipped)
Differential thermostat
Work lamp switch (If E17 DT2 2 H-4
C22 KES 3 X-6 sensor (If equipped)
equipped)
Differential lock solenoid
C23 M 2 Work lamp (If equipped) T-7 E18 DT2 2 H-4
(If equipped)
C24 M 2 Work lamp (If equipped) S-6 E20 DT 4 Fuel shut-off timer J-5
C25 M 2 Work lamp (If equipped) S-6 E21 DT 2 Fuel shut-off relay I-5
C26 M 2 Work lamp (If equipped) S-5 ET39 DT2 2 Fuse sensor J-8
Head lamp (R.H.) ET40 TERMINAL 1 GND J-6
C27 M 3 S-3
(If equipped)
ET41 TERMINAL 1 Battery (–) J-6
Head lamp (L.H.)
C28 M 3 S-5 ET42 TERMINAL 1 Battery (+) J-5
(If equipped)
ET43 TERMINAL 1 Battery (–) G-9
C29 M 2 Power (24V) (Spare) X-6
ET44 TERMINAL 1 Battery (+) G-9
C30 KES 2 Spot lamp (If equipped) V-8
ET45 TERMINAL 1 Battery relay K-3
C31 M 2 U-2 ET46 TERMINAL 1 Battery relay K-2
(Defroster fan, front)
Intermediate connector ET47 TERMINAL 1 Slow blow fuse I-2
C32 M 2 X-6 ET48 TERMINAL 1 Slow blow fuse J-2
(Defroster fan, rear)
Combination lamp (R.H.) ET49 TERMINAL 1 Battery relay K-3
C33 M 3 T-3
(If equipped) ET50 TERMINAL 1 Starter motor H-9
Combination lamp (L.H.) ET51 TERMINAL 1 Starter motor (GND) I-9
C34 M 3 S-6
(If equipped) ET52 TERMINAL 1 GND I-9
1-pin ET53 TERMINAL 1 Starter motor (B) H-9
CT35 1 Beacon (If equipped) S-5
connector
ET54 TERMINAL 1 Grid heater relay J-2
CT41 TERMINAL 1 GND X-3
ET55 TERMINAL 1 Grid heater relay I-3
E1 DT2 2 Alternator H-9
ET56 TERMINAL 1 Grid heater J-7
Thermostat sensor
E2 X 2 I-9 ET58 TERMINAL 1 Battery relay K-3
(GD555)
Thermostat sensor
E2 X 2 H-9 ET60 TERMINAL 1 Slow blow fuse I-2
(GD655, 675)
E3 DT2 2 Intermediate connector J-8 ET62 TERMINAL 1 Battery relay K-3
ET63 TERMINAL 1 Slow blow fuse H-9
20-218 GD555, 655, 675-3C

(4)
Connector
Connector
Address
Address
No. of
No. of
pins
pins
No.
No.
ET64 TERMINAL 1 Battery relay L-3 FL21 DT2 4 Intermediate connector C-6
ET65 TERMINAL 1 Alternator (B) M-8 FL22 M 3 Combination lamp (R.H.) A-5
ET66 TERMINAL 1 Alternator (I terminal) M-8 FL23 M 3 Combination lamp (L.H.) A-2
ET67 TERMINAL 1 Alternator (E) M-8 Front work lamp (R.H.)
FL26 M 2 E-5
ET68 TERMINAL 1 Slow blow fuse I-2 (If equipped)
ET70 TERMINAL 1 Fuel shut-off relay J-5 Front work lamp (L.H.)
FL27 M 2 F-4
ET71 TERMINAL 1 Fuel shut-off relay I-5 (If equipped)
Starter safety relay (B) Front work lamp (Spare)
ET72 TERMINAL 1 K-2 FL28 M 2 B-5
(GD555) (R.H.)
Starter safety relay (C) Front work lamp (Spare)
ET73 TERMINAL 1 J-4 FL29 M 2 B-1
(GD555) (L.H.)
ET74 TERMINAL 1 Starter motor (C) H-9 FP1 DT2 (Gr) 12 Meter assembly D-8
ET75 TERMINAL 1 Battery relay (+) J-4 FP2 DT2 (B) 12 Warning module (L.H.) D-8
ET76 TERMINAL 1 Battery relay (–) K-4 FP3 DT2 (Br) 12 Warning module (R.H.) E-9
ET77 TERMINAL 1 GND I-5 FP6 DT2 (B) 12 Intermediate connector B-7
Starter safety relay (E) FP7 DT2 (Gr) 8 Intermediate connector B-8
ET81 TERMINAL 1 J-4 FP8 DT2 (Br) 12 Intermediate connector A-8
(GD555-3A)
ET82 TERMINAL 1 Grid heater relay I-4 FP9 KES 2 Service meter D-7
ET83 TERMINAL 1 Grid heater relay J-2 FP10 DT2 4 Message center E-9
ET88 TERMINAL 1 Aircon compressor J-7 FP11 DT2 3 Turn signal switch D-8
ET89 TERMINAL 1 Battery (–) J-6 FP12 DT2 3 Dimmer switch D-8
ET92 TERMINAL 1 GND (Engine) J-6 Differential switch
FP13 DT2 2 D-8
ET93 TERMINAL 1 GND (Engine) J-5 (If equipped)
ET94 TERMINAL 1 GND (Alternator) I-4 FP19 DT2 2 Engine start up switch E-9
Fuel shut-off solenoid 1-pin
ET97 TERMINAL 1 J-7 FT6 1 Horn (L.H.) F-4
(GND) (GD555) connector
Fuel shut-off solenoid 1-pin
ET98 TERMINAL 1 J-7 FT7 1 Horn (R.H.) E-5
(PULL) (GD555) connector
Fuel shut-off solenoid FT10 TERMINAL 1 GND (Floor) E-5
ET99 TERMINAL 1 J-7 FT11 TERMINAL 1 GND (Front frame) F-4
(COMM) (GD555)
FL1 M 3 Head lamp (R.H.) B-5 FT12 TERMINAL 1 GND (Front frame) D-7
FL2 M 3 Head lamp (L.H.) A-2 FT13 TERMINAL 1 GND (Rear frame) J-5
FL3 DT2(B) 8 Intermediate connector A-4 FT16 TERMINAL 1 Articulate sensor (-) —
FL4 DT2(B) 12 Intermediate connector D-6 FT17 TERMINAL 1 Articulate sensor (G) —
FL5 DT2(Br) 8 Intermediate connector C-6 1-pin Speed meter
FT18 1 D-9
FL6 DT2 2 Articulate sensor D-6 connector (If equipped)
FL7 DT2 2 Lifter lock solenoid F-4 1-pin T/C Hydraulic
FT19 1 —
connector temperature gauge
FL8 DT2 2 Parking brake solenoid F-4
1-pin
Accumulator solenoid FT20 1 Water temperature gauge D-9
FL9 DT2 2 B-6 connector
(R.H.)
1-pin
Accumulator solenoid FT21 1 Fuel gauge D-9
FL10 DT2 2 E-2 connector
(L.H.)
T/C Hydraulic
FL11 DT2 2 Float solenoid (R.H.) B-5 FT23 TERMINAL 1 D-9
temperature gauge (B)
FL12 DT2 2 Float solenoid (R.H.) C-6
T/C Hydraulic
FL13 DT2 2 Float solenoid (L.H.) D-2 FT24 TERMINAL 1 D-9
temperature gauge (T)
FL14 DT2 2 Float solenoid (L.H.) C-6 T/C Hydraulic tempera-
FL15 DT2 2 Diode (Solenoid) C-1 FT25 TERMINAL 1 D-9
ture gauge (E)
FL16 DT2 2 Diode (Solenoid) F-3 Water temperature gauge
FT26 TERMINAL 1 D-9
FL17 DT2 2 Diode (Solenoid) D-1 (B)
FL18 DT2 2 Diode (Solenoid) D-1 Water temperature gauge
FT27 TERMINAL 1 D-9
FL19 DT2 2 Diode (Solenoid) E-2 (T)
FL20 DT2 2 Diode (Solenoid) E-2
GD555, 655, 675-3C 20-219

(4)
Connector
Connector
Address
Address
No. of
No. of
pins
pins
No.
No.
Water temperature gauge T20 DT2(B) 12 Intermediate connector Q-9

FT28 TERMINAL 1 D-9
(E) T21 DT2 6 Intermediate connector Q-9
FT29 TERMINAL 1 Fuel gauge (B) D-9 T22 DT2(Gr) 12 Intermediate connector Q-9
FT30 TERMINAL 1 Fuel gauge (T) D-9 T24 DT2 2 FL solenoid R-8
FT31 TERMINAL 1 Fuel gauge (E) D-9 T25 DT2 2 FH solenoid R-8
FT32 TERMINAL 1 Articulate gauge (E) D-9 T26 DT2 2 R solenoid R-8
1-pin T27 DT2 2 1st solenoid R-7
FT33 1 Articulate gauge (B) D-9
connector T28 DT2 2 2nd solenoid R-7
1-pin T29 DT2 2 3rd solenoid R-7
FT34 1 Articulate gauge (T) D-9
connector
T30 DT2 2 4th solenoid R-6
1-pin
FT37 1 Horn switch E-9 T31 DT2 2 Lockup solenoid N-9
connector
Transmission input shaft
H1 M 1 Heater F-9 T32 DT2 2 R-9
speed sensor
OP1 M 1 If equipped F-9
Transmission output
OP2 M 1 If equipped F-9 T33 DT2 2 Q-6
shaft speed sensor
RL1 DT2 (Br) 8 Intermediate connector J-8 T/C hydraulic tempera-
RL2 M 6 Combination lamp (R.H.) I-9 T34 DT2 2 R-8
ture sensor
RL3 M 6 Combination lamp (L.H.) J-8 T/M hydraulic tempera-
T35 DT2 2 R-6
Rear work lamp ture sensor
RL4 M 2 I-9
(If equipped) T36 DT2 2 FL clutch fill switch R-8
Rear work lamp T37 DT2 2 FH clutch fill switch R-7
RL5 M 2 J-8
(If equipped) T38 DT2 2 R clutch fill switch R-8
Intermediate connector T39 DT2 2 1st clutch fill switch R-7
RL6 M 2 J-8
(license lamp)
T40 DT2 2 2nd clutch fill switch R-7
RL7 X 2 License lamp —
T41 DT2 2 3rd clutch fill switch R-6
RT1 M 2 J-8 T42 DT2 2 4th clutch fill switch R-6
(license lamp)
T43 DT2 2 Lockup clutch fill switch N-8
RT2 TERMINAL 1 Back-up alarm J-8
RT3 TERMINAL 1 Back-up alarm I-9
T46 DT2 2 Engine riv. sensor R-9
T3A 040 20 T/M controller N-2
T3B 040 16 T/M controller N-3
T50 DT2 6 Joint connector R-9
T4 040 12 T/M controller N-3
T5 MIC 17 T/M controller Q-5
Connector for flash ROM
T6 DT2 4 D-7 TT3 TERMINAL 1 Potentiometer set switch R-4
writer
Converter for specified TT4 TERMINAL 1 Initialize switch R-5
T7 DT2 6 O-1
selection TT5 TERMINAL 1 Initialize switch R-5
T8 DT2 3 Inching potentiometer P-1 TT6 TERMINAL 1 Initialize switch R-5
Accelerator TT7 TERMINAL 1 Reset switch Q-5
T9 DT2 3 O-1
potentiometer TT8 TERMINAL 1 Reset switch R-5
T10 DT2 (G) 12 Intermediate connector A-7 TT9 TERMINAL 1 GND (Floor) D-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
20-220 GD555, 655, 675-3C

(4)
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
CONNECTOR ARRANGEMENT DIAGRAM

Serial No. 50001 – 51000
20-222 GD555, 655, 675-3C

(4)
GD555, 655, 675-3C 20-223

(4)
20-224 GD555, 655, 675-3C

(4)
GD555, 655, 675-3C 20-225

(4)
20-226 GD555, 655, 675-3C

(4)
GD555, 655, 675-3C 20-227

(4)
20-228 GD555, 655, 675-3C

(4)
GD555, 655, 675-3C 20-229

(4)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a 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 T-adapter Part
Male (Female Housing) Female (Male Housing)
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
3 799-601-7030
4 BWP04705 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
20-230 GD555, 655, 675-3C

(4)
SWP-Type Connector
Number
Number
BWP04708
BWP04707
6 799-601-7050
BWP04710
8 BWP04709 799-601-7060
BWP04711
12 BWP04712 799-601-7310
BWP04713 BWP04714
14 799-601-7070
GD555, 655, 675-3C 20-231

(4)
SWP-Type Connector
Number
Number
16 BWP04715 799-601-7320
BWP04716

Terminal part number: Terminal part number:
— —
• Grommet: black • Grommet: black
Terminal part number: Terminal part number:
— —
• Grommet: red • Grommet: red
20-232 GD555, 655, 675-3C

(4)
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
799-601-7340
8 BWP04725 BWP04726
GD555, 655, 675-3C 20-233

(4)
S-Type Connector
Number
Number
BWP04728
8 BWP04727 799-601-7140
10
BWP04729 BWP04730 799-601-7150
(White)
12
BWP04731 BWP04732 799-601-7350
(White)
16
BWP04733 BWP04734 799-601-7330
(White)
20-234 GD555, 655, 675-3C

(4)
S-Type Connector
Number
Number
10 BWP04736
BWP04735 —
(Blue)
— —
12
BWP04737 BWP04738 799-601-7160
(Blue)
16
BWP04739 BWP04740 799-601-7170
(Blue)
GD555, 655, 675-3C 20-235

(4)
MIC-Type Connector
Number
Number
Body Part Number: 79A-222-2640 Body Part Number: 79A-222-2630
7 —
(Quantity: 5 pieces) (Quantity: 5 pieces)
11 —
BWP04742
BWP04741
5 799-601-2710

BWP04743 BWP04744
9 799-601-2950

BWP04745 BWP04746
13 799-601-2720

20-236 GD555, 655, 675-3C

(4)
MIC-Type Connector
Number
Number
BWP04748
BWP04747
17 799-601-2730

BWP04749 BWP04750
21 799-601-2740

—
GD555, 655, 675-3C 20-237

(4)
AMP040-Type Connector
Number
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
a Terminal Part Number: 79A-222-3470 (For all numbers of pins).
20-238 GD555, 655, 675-3C

(4)
AMP070-Type Connector
Number
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, 675-3C 20-239

(4)
L-Type Connector
Number
Number
2 —
— —
PA-Type Connector
Number
Number
9 —
— —
BENDIX MS-Type Connector

Number
Number
10 799-601-3460
— —
20-240 GD555, 655, 675-3C

(4)
KES1 Automobile-Type Connector

Number
Number
2 —
Part Number: 08027-10210 (Natural color) Part Number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
GD555, 655, 675-3C 20-241

(4)
KES1 Automobile-Type Connector

Number
Number
8 —
08027-10820 (Black) 08027-10870 (Black)
Socket-Type Connector for Relay

Number
Number
5 799-601-7360
— —
6 799-601-7370
— —
F-Type Connector
Number
Number
4 —
— —
20-242 GD555, 655, 675-3C

(4)
[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, 675-3C 20-243

(4)

(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
20-244 GD555, 655, 675-3C

(4)

(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, 675-3C 20-245

(4)

(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
20-246 GD555, 655, 675-3C

(4)

(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, 675-3C 20-247

(4)
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

20-248 GD555, 655, 675-3C

(4)
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
12
12G:799-601-9130
12BR:799-601-9140

GD555, 655, 675-3C 20-249

(4)
No.of DTM Series connector

pins Body (plug) Body (receptacle) 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)
20-250 GD555, 655, 675-3C

(4)
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.T (version of software)
[3] Gear (speed range) [7] M7TT (display in miles)
[4] Err (error code) [8] M8TT (display in kilometers)
2) When pressing the mode button (2), the mode display changes in the following sequence:
[1] o [2] o [3] o [4] o [5] o [6] o [7] o [8]
3) Starting switch ON display

• It remembers the content (mode) of the display when the starting switch is OFF.
• Turning the start 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 [RpmT]: Displays this mode for 3 seconds, then changes to the engine speed display.
( [RpmT] is an example, the mode is the mode when the start switch is turned off)
iii) Displays the engine speed in [TTT] 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 [TTT] and maintains this mode until the mode button is pressed.
GD555, 655, 675-3C 20-251

(4)
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 [TTTT] for 3 seconds, then changes to engine speed display.
iii) Displays [RpmT] for 2 seconds, then changes to the engine speed display.
iv) Continues to display the engine speed in [TTT].
• When the speed range changes
The speed range is displayed for 3 seconds, then the display changes to the engine speed dis-
play and continues to display the engine speed.
• When the 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 errors 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 [RpmT]

i) Displays [RpmT] for 3 seconds, then changes to the engine speed display.
ii) Displays the engine speed in [TTTT] 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 [T880]. (The T 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 [TTTT] and maintains this mode until the mode button is
pressed.
Speed range Display Speed range Display Speed range Display

P [T - P - 1] F4 [TTF4] R1 [TTR1]
N [T - N -] F5 [TTF5] R2 [TTR2]
F1 [TTF1] F6 [TTF6] R3 [TTR3]
F2 [TTF2] F7 [TTF7] R4 [TTR4]
F3 [TTF3] F8 [TTF8]
4) Mode display [ErrT]

i) Displays [ErrT] for 3 seconds, then changes to the error display.
ii) Displays the error code in [TTTT] and maintains this mode until the mode button is pressed.
• If there is no error, the display shows [ETT].
• If there is an error, the display shows [ETEE]. 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. (EE 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.
20-252 GD555, 655, 675-3C

(4)
5) Mode display [Lum.]

i) Displays [Lum.] for 3 seconds, then changes to the engine speed display.
ii) Displays the brightness in [TTTT] and maintains this mode until the mode button is pressed.
• Each time the scroll button (3) is pressed, the display changes
• [100%] o [ 50%] o [ 25%] o [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 T]

i) Displays [Ver T] for 3 seconds, then changes to the program No. display.
ii) Displays the program No. in [PEEE] and maintains this mode until the mode button is
pressed. (EEE shows the program No. For example: P5R2)
7) Mode display [M7TT]

i) Displays [M7TT] for 3 seconds, then changes to the travel speed (miles) display.
ii) Displays [MPHT] for 3 seconds, then changes to the travel speed display.
iii) Displays the travel speed (miles) in two digits in [EEM.], and maintains this mode until the
mode button is pressed.
8) Mode display [M8TT]

i) Displays [M8TT] for 3 seconds, then changes to the travel speed (km/h) display.
ii) Displays [kmPHT] for 3 seconds, then changes to the travel speed display.
iii) Displays the travel speed (kilometers) in two digits in [EEkm], 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 T] modes.
GD555, 655, 675-3C 20-253

(4)
2. Table of error codes

A1 Short circuit in the FL solenoid system Short circuit with power source, or the neutral signal
E2
system disconnected
A2 Short circuit in the FH solenoid system
Short circuit with power source, or the parking signal
A3 Short circuit in the R solenoid system E3
system disconnected
A4 Short circuit in the 1st, 3rd solenoid system Short circuit with power source, or the logic A signal
E4
A5 Short circuit in the 2nd, 4th solenoid system system disconnected
A8 Short circuit in the lock-up solenoid system Short circuit with power source, or the logic B signal
E5
system disconnected
b1 FL solenoid system disconnected
Short circuit with power source, or the logic C signal
b2 FH solenoid system disconnected E6
system disconnected
b3 R solenoid system disconnected Short circuit with power source, or the logic D signal
E7
b4 1st solenoid system disconnected system disconnected
b5 2nd solenoid system disconnected Short circuit with power source, or the logic E signal
E8
system disconnected
b6 3rd solenoid system disconnected
Short circuit with ground in the FL clutch pressure
b7 4th solenoid system disconnected F1
switch signal system
b8 Lock-up solenoid system disconnected Short circuit with ground in the FH clutch pressure
F2
C0 Drop in power supply voltage switch signal system
C1 Engine speed sensor system disconnected Short circuit with ground in the R clutch pressure
F3
Short circuit with power source, or accelerator
C3 Short circuit with ground in the 1st clutch pressure
potentiometer system disconnected F4
Short circuit with power source, or inching potenti-
C4 Short circuit with ground in the 2nd clutch pressure
ometer system disconnected. F5
Short circuit with power source, or transmission oil
C5 Short circuit with ground in the 3rd clutch pressure
temperature sensor system disconnected F6
Short circuit with power source, or torque converter
C6 Short circuit with ground in the 4th clutch pressure
outlet oil temperature sensor system disconnected F7
Short or open circuit of power source in the hydrau-
C7 Short circuit with ground in the lock-up clutch pres-
lic oil temperature sensor system F8
sure switch signal system
Transmission input speed sensor system discon-
C8 FL clutch pressure switch signal system discon-
nected 91
nected
Transmission output speed sensor system discon-
C9 FH clutch pressure switch signal system discon-
nected 92
nected
Short circuit with power source, or differential oil
d1 R clutch pressure switch signal system discon-
temperature warning lamp system disconnected 93
nected
Short circuit with power source, or transmission
d2 (torque converter outlet) oil temperature warning 1st clutch pressure switch signal system discon-
94
lamp system disconnected nected
Short circuit with power source, or alarm buzzer 2nd clutch pressure switch signal system discon-
d4 95
system disconnected nected
Short circuit with power source, or warning lamp 3rd clutch pressure switch signal system discon-
d5 96
system disconnected nected
Short circuit with power source, or differential con- 4th clutch pressure switch signal system discon-
d6 97
trol relay system disconnected nected
Short circuit with power source, or VHP relay sys- Lock-up clutch pressure switch signal system dis-
d7 98
tem disconnected connected
Short circuit with power source, or F (Forward), R

E1
(Reverse) system disconnected
20-254 GD555, 655, 675-3C

(4)
TROUBLESHOOTING USING THE TROUBLESHOOTING CHARTS
USING THE TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No. Component
E-QQ Troubleshooting of electrical system
T-QQ Troubleshooting of transmission controller system
H-QQ Troubleshooting of hydraulic, mechanical system
M-QQ Troubleshooting of 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 apply to all items are given at the top of the page
under the title and marked with (a).
The common precautions marked (a) at the page top are not given below each item, but must always
be followed when performing the check.
Example: a Before troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on 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 troubleshooting
table is not divided into sections, start troubleshooting from the first check item in the flow chart.
Example: a) Turning the start 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
Yes not indicate 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 a 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 judge-
ment 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, measurement,
and the judgement values. If this preparatory work is neglected, or the method of operation or han-
dling 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, 675-3C 20-255

(4)
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
ELECTRICAL CIRCUIT DIAGRAM ............................................................................................................ 20-302

E-1 Engine does not start..................................................................................................................... 20-306
E-2 Engine does not stop ..................................................................................................................... 20-316
E-3 Engine preheating pilot lamp does not glow .................................................................................. 20-318
E-4 Electrical components do not work ................................................................................................ 20-320
GD555, 655, 675-3C 20-301

(4)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM

For engine start, stop, preheat, charge
Serial No. 50001 – 51000
20-302 GD555, 655, 675-3C

(4)
GD555, 655, 675-3C 20-303

(4)
20-304 GD555, 655, 675-3C

(4)
GD555, 655, 675-3C 20-305

(4)
TROUBLESHOOTING E-1
E-1 Engine does not start
A) Starter mortor does not turn
Serial No. 50001 – 51000
20-306 GD555, 655, 675-3C

(4)
TROUBLESHOOTING E-1
E-1 A) Related electrical circuit diagram
GD555, 655, 675-3C 20-307

(4)
TROUBLESHOOTING E-1
A) Starter mortor does not turn
20-308 GD555, 655, 675-3C

(4)
TROUBLESHOOTING E-1
E-1 A) Related electrical circuit diagram
GD555, 655, 675-3C 20-309

(4)
TROUBLESHOOTING E-1
B) Engine starter solenoid does not work
E-1 B) Related electrical circuit diagram
Serial No. 50001 – 51000
20-310 GD555, 655, 675-3C

(4)
TROUBLESHOOTING E-1
GD555, 655, 675-3C 20-311

(4)
TROUBLESHOOTING E-1
C) Fuel shut-off solenoid does not work
Serial No. 50001 – 51000

• Set the gearshift lever to the P position before starting the troubleshooting process.
20-312 GD555, 655, 675-3C

(4)
TROUBLESHOOTING E-1
E-1 C) Related electrical circuit diagram
GD555, 655, 675-3C 20-313

(4)
TROUBLESHOOTING E-1
C) Fuel shut-off solenoid does not work

• Set the gearshift lever to the P position before starting the troubleshooting process.
20-314 GD555, 655, 675-3C

(4)
TROUBLESHOOTING E-1
E-1 C) Related electrical circuit diagram
GD555, 655, 675-3C 20-315

(4)
TROUBLESHOOTING E-2
E-2 Engine does not stop
Serial No. 50001 – 51000
E-2 Related electrical circuit diagram
20-316 GD555, 655, 675-3C

(4)
TROUBLESHOOTING E-2
GD555, 655, 675-3C 20-317

(4)
TROUBLESHOOTING E-3
E-3 Engine preheating pilot lamp does not glow
a Check that the pilot lamp is not defective.
20-318 GD555, 655, 675-3C

(4)
TROUBLESHOOTING E-3
Serial No. 50001 – 51000
GD555, 655, 675-3C 20-319

(4)
TROUBLESHOOTING E-4
E-4 Electrical components do not work
a Verify that normal battery voltage exists.
20-320 GD555, 655, 675-3C

(4)
TROUBLESHOOTING E-4
Serial No. 50001 – 51000
GD555, 655, 675-3C 20-321

(4)
TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM
(T MODE)
TRANSMISSION-CONTROLLER SYSTEM JUDGEMENT TABLE............................................................ 20-354

CONTROLLER ACTION WHEN PROBLEMS OCCUR WITH THE MACHINE.......................................... 20-358
ELECTRICAL CIRCUIT DIAGRAM ............................................................................................................ 20-378
T-1 Failure code [A1]............................................................................................................................ 20-382
T-2 Failure code [A2]............................................................................................................................ 20-383
T-3 Failure code [A3]............................................................................................................................ 20-384
T-4 Failure code [A4]............................................................................................................................ 20-385
T-5 Failure code [A5]............................................................................................................................ 20-386
T-6 Failure code [A8]............................................................................................................................ 20-387
T-7 Failure code [b1] ............................................................................................................................ 20-388
T-8 Failure code [b2] ............................................................................................................................ 20-389
T-9 Failure code [b3] ............................................................................................................................ 20-390
T-10 Failure code [b4] .......................................................................................................................... 20-391
T-11 Failure code [b5] .......................................................................................................................... 20-392
T-12 Failure code [b6] .......................................................................................................................... 20-393
T-13 Failure code [b7] .......................................................................................................................... 20-394
T-14 Failure code [b8] .......................................................................................................................... 20-395
T-15 Failure code [C0].......................................................................................................................... 20-396
T-16 Failure code [C1].......................................................................................................................... 20-397
T-17 Failure code [C3].......................................................................................................................... 20-398
T-18 Failure code [C4].......................................................................................................................... 20-400
T-19 Failure code [C5].......................................................................................................................... 20-402
T-20 Failure code [C6].......................................................................................................................... 20-403
T-21 Failure code [C7].......................................................................................................................... 20-404
T-22 Failure code [C8].......................................................................................................................... 20-405
T-23 Failure code [C9].......................................................................................................................... 20-406
T-24 Failure code [d1] .......................................................................................................................... 20-407
T-25 Failure code [d2] .......................................................................................................................... 20-408
T-26 Failure code [d4] .......................................................................................................................... 20-409
T-27 Failure code [d5] .......................................................................................................................... 20-410
T-28 Failure code [d6] .......................................................................................................................... 20- 411
T-29 Failure code [d7] .......................................................................................................................... 20-412
T-30 Failure code [E1].......................................................................................................................... 20-413
T-31 Failure code [E2].......................................................................................................................... 20-414
T-32 Failure code [E3].......................................................................................................................... 20-415
T-33 Failure code [E4].......................................................................................................................... 20-417
T-34 Failure code [E5].......................................................................................................................... 20-417
T-35 Failure code [E6].......................................................................................................................... 20-418
T-36 Failure code [E7].......................................................................................................................... 20-419
T-37 Failure code [E8].......................................................................................................................... 20-419
T-38 Failure code [F1] .......................................................................................................................... 20-421
GD555, 655, 675-3C 20-351

(4)
TROUBLESHOOTING
T-39 Failure code [F2] .......................................................................................................................... 20-421

T-40 Failure code [F3] .......................................................................................................................... 20-422
T-41 Failure code [F4] .......................................................................................................................... 20-423
T-42 Failure code [F5] .......................................................................................................................... 20-423
T-43 Failure code [F6] .......................................................................................................................... 20-424
T-44 Failure code [F7] .......................................................................................................................... 20-424
T-45 Failure code [F8] .......................................................................................................................... 20-425
T-46 Failure code [91] .......................................................................................................................... 20-426
T-47 Failure code [92] .......................................................................................................................... 20-426
T-48 Failure code [93] .......................................................................................................................... 20-427
T-49 Failure code [94] .......................................................................................................................... 20-428
T-50 Failure code [95] .......................................................................................................................... 20-428
T-51 Failure code [96] .......................................................................................................................... 20-429
T-52 Failure code [97] .......................................................................................................................... 20-429
T-53 Failure code [98] .......................................................................................................................... 20-431
20-352 GD555, 655, 675-3C

(4)
TROUBLESHOOTING TRANSMISSION-CONTROLLER SYSTEM JUDGEMENT TABLE
TRANSMISSION-CONTROLLER SYSTEM JUDGEMENT TABLE

Self-diagnostic display
(problem displayed)
Short circuit to the power source in the 2nd, 4th solenoid circuit
Short circuit to the power source in the 1st, 3rd solenoid circuit
Failure location
Short circuit to the 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 2nd solenoid circuit
Open circuit in the 3rd solenoid circuit
Open circuit in the 4th solenoid circuit

Open circuit in the 1st solenoid circuit
Open circuit in the FH solenoid circuit
Open circuit in the FL solenoid circuit
Open circuit in the R solenoid circuit

Failure code
Failure mode
Transmission controller error

A1 A2 A3 A4 A5 A8 b1 b2 b3 b4 b5 b6 b7
1. Travel is impossible
2. Autoshifting is not performed Q Q Q Q Q Q Q Q Q Q
3. Downshifts, regardless of travel speed
4. Upshifts, regardless of travel speed
5. Excessive gearshift shock Q Q Q Q Q Q Q Q Q Q Q Q Q
6. Abnormal gearshifting speed when traveling in the
automode
7. Engine speed not displayed on the message center
8. Inching does not function normally Q Q Q
9. Modulation clutch control does not function Q Q Q Q Q Q Q Q Q Q Q Q Q
T- T- T- T- T- T- T- T- T- T- T- T- T-
Troubleshooting code when an error code is displayed
1 2 3 4 5 6 7 8 9 10 11 12 13
20-354 GD555, 655, 675-3C

(4)
T-
Open circuit in the lock-up solenoid circuit
14
Q
Q
T-
Power supply voltage reduced
15
Q
T-
Engine speed sensor system
16
T-
Accelerator potentiometer system
17
Q
GD555, 655, 675-3C

T-
Inching potentiometer system
18
TROUBLESHOOTING
Q
Q
T-
Transmission oil temperature sensor system
19
T-
Torque converter outlet oil temperature system
20
T-
Hydraulic oil temperature sensor system (opt)
21
Q
T-
Transmission input speed sensor system
22
Transmission output speed sensor system
Q
Q
Q
Q
Q
T-
23
T-
Differential oil temperature lamp system (opt)
24
b8 C0 C1 C3 C4 C5 C6 C7 C8 C9 d1
T-
Torque converter outlet oil temperature lamp system (opt)
25
d2
T-
Alarm buzzer A system
26
d4
T-
Warning lamp system
27
d5
(problem displayed)
T-
Differential control relay system
28
d6
T-
VHP solenoid relay system (opt)
29
d7
Q
T-
F (forward), R (reverse) signal system
30
Q
T-
Neutral signal system
31
Q
T-
Parking signal system
32
Q
T-
Logic A signal system
33
Q
T-
Logic B signal system
34
Q
T-
Logic C signal system
35
Q
T-
Logic D signal system
36
Q
T-
Logic E signal system
37
E1 E2 E3 E4 E5 E6 E7 E8
(4)
—
Stop lamp signal system
20-355
TROUBLESHOOTING TRANSMISSION-CONTROLLER SYSTEM JUDGEMENT TABLE
(problem displayed)
Short circuit to ground in the FL clutch pressure switch signal system

Failure location
Learning function initialize switch system

Differential selection switch system
Failure code Differential selector switch system
Inching selection switch system

Model selection switch system
AWD selection switch system

VHP selection switch system
Memory reset switch system

High set switch system
Lock-up switch system
Low set switch system
Reset switch system

Failure mode

— — — — — — — — — — — — F1
1. Travel is impossible Q
2. Autoshifting is not performed
3. Downshifts, regardless of travel speed
4. Upshifts, regardless of travel speed
5. Excessive gearshift shock
6. Abnormal gearshifting speed when traveling in the
automode
7. Engine speed not displayed on the message center
8. Inching does not function normally Q
9. Modulation clutch control does not function
T-
Troubleshooting code when an error code is displayed
38
20-356 GD555, 655, 675-3C

(4)
Q
Q
Q
T-
Open circuit in the FL clutch pressure switch signal system
46
91
Q
Q
T-
Short circuit to ground in the FH clutch pressure switch signal system
39
F2
Q
Q
Q
T-
Open circuit in the FH clutch pressure switch signal system
47
92
Q
Q
T-
Short circuit to ground in the R clutch pressure switch signal system
40
F3
Q
Q
Q
GD555, 655, 675-3C

T-
Open circuit in the R clutch pressure switch signal system
48
93
TROUBLESHOOTING
T-
Short circuit to ground in the 1st clutch pressure switch signal system
41
F4
Q
Q
T-
Open circuit in the 1st clutch pressure-switch signal system
49
94
Q
T-
Short circuit to ground in the 2nd clutch pressure switch signal system
42
F5
Q
Q
T-
Open circuit in the 2nd clutch pressure switch signal system
50
95
Q
T-
Short circuit to ground in the 3rd clutch pressure switch signal system
43
F6
(problem displayed)

Q
Q
T-
Open circuit in the 3rd clutch pressure switch signal system
51
96
Q
T-
Short circuit to ground in the 4th clutch pressure switch signal system
44
F7
Q
Q
T-
Open circuit in the 4th clutch pressure switch signal system
52
97
T-
Short circuit to ground in the lock-up clutch pressure switch signal system
45
F8
T-
Open circuit in the lock-up clutch pressure switch signal system
53
98
Troubleshooting code when no error code is displayed
H-11
(4)
20-357
TROUBLESHOOTING CONTROLLER ACTION WHEN PROBLEMS OCCUR WITH THE MACHINE
CONTROLLER ACTION WHEN PROBLEMS OCCUR WITH THE

MACHINE
Fail-
System Normal condition
No. ure Nature of the problem
problem (volts, amps and ohms)
code
1. Defective FL solenoid
2. Short circuit to ground, short circuit to power source in the wiring har-
Resistance between T2
ness between T2 (female) (7) and T24 (female) (1)
Short circuit to (female) (7) and (17):
3. Short circuit to the power source in the wiring harness between T2
the power source 5 to 15 z
1 A1 (female) (17) and T24 (female) (2)
in the FL solenoid Voltage between T2 (17)
4. Short circuit in the wiring harness between T2 (female) (7) and T24
circuit and chassis at neutral:
(female) (1) and wiring harness between T2 (female) (17) and T24
Less than 0.1 V
(female) (2)
5. Defective transmission controller
1. Defective FH solenoid.
2. Short circuit to ground, short circuit to power source in wiring harness Resistance between T2
Short circuit to between T2 (female) (8) and T25 (female) (1) (female) (8) and (18):
the power source 3. Short circuit to the power source in the wiring harness between T2 5 to 15 z
2 A2
in FH solenoid (female) (18) and T25 (female) (2) Voltage between T2 (18)
system 4. Short circuit in wiring harness between T2 (female) (8) and T25 (female) and chassis at neutral:
(1); and between T2 (female) (18) and T25 (female) (2) Less than 0.1 V
1. Defective R solenoid
2. Short circuit to ground, short circuit to power source in wiring harness Resistance between T2
Short circuit to between T2 (female) (9) and T26 (female) (1) (female) (9) and (19):
the power source 3. Short circuit to power source in wiring harness between T2 (female) (19) 5 to 15 z
3 A3
in the R solenoid and T26 (female) (2) Voltage between T2 (19)
system 4. Short circuit in wiring harness between T2 (female) (9) and T26 (female) and chassis at neutral:
(1); and between T2 (female) (19) and T26 (female) (2) Less than 0.1 V
1. Defective 1st or 3rd solenoid

2. Short circuit to ground, short circuit to power source in wiring harness
(female) (2) and (13):
between T2 (female) (2) and T27 (female) (1) or T2 (female) (3) and T29
5 to 15 z
(female) (1)
Voltage between T2 (13)
Short circuit to and chassis at neutral:
(female) (13) and T27 (female) (2) or T2 (female) (14) and T29 (female)
power source in Less than 0.1 V
4 A4 (2)
1st, 3rd solenoid Resistance between T2
4. Short circuit in wiring harness between T2 (female) (2) and T27 (female)
system (female) (3) and (14):
(1); and between T2 (female) (13) and T27 (female) (2)
5 to 15 z
5. Short circuit in the wiring harness between T2 (female) (3) and T29
(female) (1) and wiring harness between T2 (female) (14) and T29
and chassis at neutral:
(female) (2)
Less than 0.1 V
1. Defective 2nd or 4th solenoid
(female) (4) and (15):
2. Short circuit to ground, short circuit to power source in the wiring har-
5 to 15 z
ness between T2 (female) (4) and T28 (female) (1) or T2 (female) (5)
and T30 (female) (1)
Short circuit to and chassis at neutral:
3. Short circuit to power source in wiring harness between T2 (female) (15)
power source in Less than 0.1 V
5 A5 and T28 (female) (2) or T2 (female) (16) and T30 (female) (2)
the 2nd, 4th sole- Resistance between T2
noid system (female) (5) and (16):
5 to 15 z
and chassis at neutral:
Less than 0.1 V
20-358 GD555, 655, 675-3C

(4)
Trouble-
Controller action after Problem with the Code dis- Warning Alarm Warning
Memory shooting
detecting the problem machine played lamp buzzer chime
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-
Q Q Q Q Q T-1
F5, F6: F5 ble to travel in
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-
Q Q Q Q Q T-2
F6, F7: F6 ble to travel in
F8: F8 F2, F4, F6, F8
R: 1st thru 4th
After alarm buzzes for 2 seconds, chimes
sound continuously
N, F1 - F8: 1st - 4th solenoids OFF
Big transmission
R1: R1
shock, but possi-
R2: R2 Q Q Q Q Q T-3
ble to travel in
R3: R3
R1, R2, R3, R4
R4: R4
After alarm buzzes for 2 seconds,
chimes sound continuously
Big transmission
Turns 1st thru 4th solenoid outputs OFF shock, but possi-
After alarm buzzes for 2 seconds, chimes ble to travel in Q Q Q Q Q T-4
sound continuously F1, F2, F5, F6,
R1, R3
Big transmission
Turns 1st thru 4th solenoid outputs OFF shock, but possi-
After alarm buzzes for 2 seconds, chimes ble to travel in Q Q Q Q Q T-5
sound continuously F3, F4, F7, F8,
R2, R4
GD555, 655, 675-3C 20-359

(4)
Fail-
code problem (volts, amps and ohms)
1. Defective lock-up solenoid

2. Short circuit to ground, short circuit to power source in the wiring har- Resistance between T2
Short circuit to ness between T2 (female) (10) and T31 (female) (1) (female) (7) and (17):
the power source 3. Short circuit to power source in the wiring harness between T2 (female) 5 to 15 z
6 A8
in the lock-up (20) and T31 (female) (2) Voltage between T2 (17)
solenoid system 4. Short circuit in wiring harness between T2 (female) (10) and T31 and chassis at neutral:
(female) (1); and between T2 (female) (20) and T31 (female) (2) Less than 0.1 V
1. Defective FL solenoid Resistance between T2
2. Defective contact or open circuit in the wiring harness between T2 (female) (8) and (18):
Open circuit in
(female) (7) and T24 (female) (1) 5 to 15 z
7 b1 the FL solenoid
3. Short circuit to ground in wiring harness between T2 (female) (17) and Voltage between T2 (18)
circuit
T24 (female) (2) and chassis at neutral:
4. Defective transmission controller Less than 0.1 V
1. Defective FH solenoid Resistance between T2
2. Defective contact or open circuit in wiring harness between T2 (female) (female) (9) and (19):
Open circuit in
(8) and T25 (female) (1) 5 to 15 z
8 b2 the FH solenoid
circuit
1. Defective R solenoid Resistance between T2
Open circuit in
(9) and T26 (female) (1) 5 to 15 z
9 b3 the R solenoid
system
1. Defective 1st solenoid Resistance between T2
Open circuit in
(2) and T27 (female) (1) 5 to 15 z
10 b4 the 1st solenoid
system
1. Defective 2nd solenoid Resistance between T2
Open circuit in
(4) and T28 (female) (1) 5 to 15 z
11 b5 the 2nd solenoid
system
1. Defective 3rd solenoid Resistance between T2
Open circuit in
(3) and T29 (female) (1) 5 to 15 z
12 b6 the 3rd solenoid
system
1. Defective 4th solenoid Resistance between T2
Open circuit in
(5) and T30 (female) (1) 5 to 15 z
13 b7 the 4th solenoid
system
1. Defective lock-up solenoid
Voltage between T1 (7), (13)
Open circuit in 2. Defective contact or open circuit in wiring harness between T2 (female)
– chassis: 19 to 30V
14 b8 the lock-up sole- (10) and T31 (female) (1)
Voltage between T2 (1), (12)
noid system 3. Short circuit to ground in wiring harness between T2 (female) (20) and
– chassis: 19 to 30 V
T31 (female) (2)
1. Defective contact or open circuit in wiring harness between T1
(female) (7), (13), T2 (1), (12) - T11 (male) (1)
2. Defective contact or open circuit in wiring harness between T1 (female) Resistance between T4
Power source
15 C0 (6), (12), T2 (11), (21) - chassis (female) (7) and T5 (female)
voltage reduced
3. Defective contact or open circuit in wiring harness between T11 (female) (1): 500 to 1000 z
(11) and battery relay
20-360 GD555, 655, 675-3C

(4)
Trouble-
Memory shooting
code
Turns lock-up solenoid output OFF

Lock-up is
After alarm buzzes for 2 seconds, chimes Q Q Q Q Q T-6
always applied
sound continuously
Does not travel in

No action F1, F3, F5, F7 Q Q Q Q Q T-7
(coasts)
Cannot travel in
No action F2, F4, F6, F8 Q Q Q Q Q T-8
(coasts)
Does not travel in

No action Q Q Q Q Q T-9
reverse (coasts)
Cannot travel in
F1, F2, R1
Cannot travel in
F3, F4, R2
Does not travel in

F5, F6, R3
Cannot travel in
F7, F8, R4
Always torque
converter drive
(lock-up is not
applied)
All solenoid outputs OFF (sets to Neutral) Stays in N Q Q Q — Q T-15
GD555, 655, 675-3C 20-361

(4)
Fail-
1. Defective engine speed sensor

2. Defective contact or open circuit in wiring harness between T4 (female)
Open circuit in
(7) and T46 (female) (1) Voltage between T3A (13)
16 C1 the engine speed
3. Defective contact or open circuit in wiring harness between T5 (female) and (16): 0.5 to 4.75 V
sensor system
(1) and T46 (female) (2)
1. Defective accelerator potentiometer
Short circuit to 2. Short circuit to power source in wiring harness between T3A (female) (3)
the power source and T9 (female) (B)
Voltage between T3A (13)
17 C3 in the accelerator 3. Defective contact, open circuit, short circuit, short circuit to ground, or
and (16): 0.5 to 4.75 V
potentiometer short circuit to power source in wiring harness between T3A (female) (7)
system and T9 (female) (A)
Voltage between T3A
1. Defective accelerator potentiometer
(female) (11), T34 (female)
2. Defective contact or open circuit in the wiring harness between T3A
Open circuit in (1) and chassis: Max. 4.75 V
(female) (16) and T9 (female) (3)
the accelerator Resistance between T34
18 C3 3. Contact of wiring harness between T3A (female) (3) and T9 (female) (B)
potentiometer (male) (1) and (2):
with wiring harness between T3A (female) (7) and T9 (female) (A), or
system 25°C (normal temperature):
contact with power source wiring harness
3.5 to 4.0 z
100°C: 38.5 to 47.0 z
Voltage between T3A
1. Defective inching potentiometer
Short circuit to 2. Short circuit to power source in wiring harness between T3A (female)
(1) and chassis: Max. 4.75
the power source (13) and T8 (female) (B)
19 C4 in inching potenti- 3. Defective contact, open circuit, short circuit, short circuit to ground, or
(male) (1) and (2):
ometer system short circuit to the power source in the wiring harness between T3A
25°C (normal temperature):
(opt) (female) (7) and T8 (female) (A)
3.5 to 4.0 z
100°C: 38.5 to 47.0 z
Voltage between T3A
1. Defective inching potentiometer
Open circuit in (1) and chassis: Max. 4.75 V
(female) (16) and T8 (female) (C)
the inching Resistance between T35
20 C4 3. Contact of wiring harness between T3A (female) (13) and T8 (female)
potentiometer cir- (male) (1) and (2):
(B) with wiring harness between T3A (female) (7) and T8 (female) (A),
cuit (opt) 25°C (normal temperature):
or contact with power source wiring harness
3.5 to 4.0 z
100°C: 38.5 to 47.0 z
Voltage between T3A
Short circuit to
1. Defective transmission oil temperature sensor (1) and chassis: Max. 4.75 V
the power source
2. Short circuit to ground, short circuit, or short circuit to the power source Resistance between T35
21 C5 in the transmis-
in wiring harness between T3A (female) (1) and T35 (female) (1) (male) (1) and (2):
sion oil tempera-
3. Defective transmission controller 25°C (normal temperature):
ture sensor circuit
3.5 to 4.0 z
100°C: 38.5 to 47.0 z
Voltage between T3A
1. Defective transmission oil temperature sensor (female) (2), E5 (female) (1)
Open circuit in 2. Defective contact or open circuit in the wiring harness between T3A and chassis: Max. 4.75 V
the transmission (female) (1) and T35 (female) (1) Resistance between E5
22 C5
oil temperature 3. Defective contact or open circuit in the wiring harness between T35 (male) (1) and (2):
sensor circuit (female) (2) and chassis 25°C (normal temperature):
4. Defective transmission controller 3.5 to 4.0 z
100°C: 38.5 to 47.0 z
Voltage between T3A
Short circuit to (female) (2), E5 (female) (1)
the power source 1. Defective torque converter outlet oil temperature sensor and chassis: Max. 4.75 V
in the torque con- 2. Short circuit to ground, short circuit, or short circuit to the power source Resistance between E5
23 C6
verter outlet oil in the wiring harness between T3A (female) (11) and T34 (female) (1) (male) (1) and (2):
temperature sen- 3. Defective transmission controller 25°C (normal temperature):
sor system 3.5 to 4.0 z
100°C: 38.5 to 47.0 z
20-362 GD555, 655, 675-3C

(4)
Trouble-
Memory shooting
code
Engine speed not displayed on message None in

Q Q — — Q T-16
center particular
Calculates for the accelerator at low

Reduced power Q Q — — Q T-17
position
Calculates for the accelerator at low

Reduced power Q Q — — Q T-17
position
Inching
No inching output Q Q — — Q T-18
impossible
Inching
No inching output Q Q — — Q T-18
impossible
Outputs with oil temperature map for less Normal

Q Q — — Q T-19
than 20°C operation
Outputs with oil temperature map for less Normal

Q Q — — Q T-19
than 20°C operation
No action Normal operation Q Q — — Q T-20
GD555, 655, 675-3C 20-363

(4)
Fail-
Voltage between T3A

1. Defective torque converter outlet oil temperature sensor (female) (1), T35 (female)
Open circuit in
2. Defective contact or open circuit in the wiring harness between T3A (1) and chassis: Max. 4.75 V
the torque con-
(female) (11) and T34 (female) (1) Resistance between T35
24 C6 verter outlet oil
3. Defective contact or open circuit in the wiring harness between T34 (male) (1) and (2):
temperature sen-
(female) (2) and chassis 25°C (normal temperature):
sor system
100°C: 38.5 to 47.0 z
Voltage between T3A
(female) (2), E5 (female) (1)
Short circuit to
1. Defective hydraulic oil temperature sensor and chassis: Max. 4.75 V
power source in
2. Short circuit to ground, short circuit, or short circuit to the power source Resistance between E5
25 C7 hydraulic oil tem-
in the wiring harness between T3A (female) (2) and E5 (female) (1) (male) (1) and (2):
perature sensor
3. Defective transmission controller 25°C (normal temperature):
system (opt)
3.5 to 4.0 z
100°C: 38.5 to 47.0 z
Voltage between T3A
1. Defective hydraulic oil temperature sensor (female) (2), E5 (female) (1)
Open circuit in 2. Defective contact or open circuit in wiring harness between T3A and chassis: Max. 4.75 V
hydraulic oil tem- (female) (2) and E5 (female) (1) Resistance between E5
26 C7
perature sensor 3. Defective contact or open circuit in wiring harness between E5 (female) (male) (1) and (2):
system (opt) (2) and chassis 25°C (normal temperature):
100°C: 38.5 to 47.0 z
1. Defective transmission input shaft speed sensor
Resistance between T5 (2)
the transmission (2) and T32 (female) (1)
27 C8 and (1):
input speed sen- 3. Defective contact or open circuit in wiring harness between T5 (female)
500 to 1000 z
sor system (1) and T32 (female) (2)
1. Defective transmission output shaft speed sensor
the transmission (2) and T33 (female) (1)
28 C9 and T5 (1):
output speed 3. Defective contact or open circuit in wiring harness between T5 (female)
500 to 1000 z
sensor system (1) and T33 (female) (2)
Short circuit to
power source in 1. Defective differential oil temperature warning lamp
Voltage between T1 (1) and
the differential oil 2. Short circuit to power source in wiring harness between T1 (female) (1)
29 d1 chassis: When output is
temperature and FP3 (female) (4)
OFF: Max. 1 V
warning lamp 3. Defective transmission controller
system (opt)
Open circuit in
1. Defective differential oil temperature warning lamp
the differential oil Voltage between T1 (1) and
2. Defective contact or open circuit in wiring harness between T1 (female)
30 d1 temperature chassis: When output is ON:
(1) and FP3 (female) (4)
warning lamp 17 to 30 V
system (opt)
Short circuit to
power source in 1. Defective transmission (torque converter outlet) oil temperature warning
transmission lamp Voltage between T1 (3) and
31 d2 (torque converter 2. Short circuit to power source in wiring harness between T1 (female) (3) chassis: When output is
outlet) oil temper- and FP3 (female) (6) OFF: Max. 1 V
ature warning 3. Defective transmission controller
lamp system
Open circuit in
1. Defective transmission (torque converter outlet) oil temperature warning
the transmission
lamp Voltage between T1 (3) and
(torque converter
32 d2 2. Defective contact or open circuit in wiring harness between T1 (female) chassis: When output is ON:
outlet) oil temper-
(3) and FP3 (female) (6) 17 to 30 V
ature warning
lamp system
20-364 GD555, 655, 675-3C

(4)
Trouble-
Memory shooting
code
No action Normal operation Q Q Q Q Q T-22
When starting switch is ON and gearshift

Travel impossi-
lever kept at N, possible up to 2nd; when
ble after stop- Q Q Q Q Q T-23
traveling, taken as N until starting switch is
ping the machine
turned OFF
Differential oil
temperature
Differential oil temperature warning lamp
warning lamp Q Q — — Q T-24
output OFF
stays on and
does not go out
Warning lamp
does not light up
Differential oil temperature warning lamp
when the differ- Q Q — — Q T-24
output OFF
ential oil temper-
ature is abnormal
Torque converter
outlet port oil
Torque converter outlet port oil temperature temperature
Q Q — — Q T-25
warning lamp output OFF warning lamp
stays on and
does not go out
Warning lamp
does not light up
when transmis-
Torque converter outlet port oil temperature
sion oil tempera- Q Q — — Q T-25
warning lamp output OFF
ture problems
exist (torque con-
verter outlet port)
GD555, 655, 675-3C 20-365

(4)
Fail-
Short circuit to
1. Defective alarm buzzer (alarm buzzer A)
power source in Voltage between T1 (9) and
2. Short circuit to power source in wiring harness between T1 (female) (9)
33 d4 alarm buzzer chassis: When output is
and BR22 (female) (1)
(alarm buzzer A) OFF: Max. 1 V
system
1. Defective alarm buzzer (alarm buzzer A)
the alarm buzzer (9) and BR22 (female) (1)
34 d4 chassis: When output is ON:
(alarm buzzer A) 3. Defective contact or open circuit in wiring harness between BR22
17 to 30 V
system (female) (2) and chassis
Short circuit to
1. Defective warning lamp
35 d5 the transmission chassis: When output is
(female) (5) and FP3 (female) (7)
control warning OFF: Max. 1 V
lamp system
Open circuit in 1. Defective warning lamp
the transmission 2. Defective contact or open circuit in the wiring harness between T1
control warning (female) (5) and FP3 (female) (7)
17 to 30 V
lamp system 3. Defective transmission controller
Short circuit to
1. Defective differential control relay
2. Short circuit to power source in the wiring harness between T1 (female)
37 d6 the differential chassis: When output is
(11) and BR7 (female) (1)
control relay sys- OFF: Max. 1 V
tem
1. Defective differential control relay
Open circuit in 2. Defective contact or open circuit in the wiring harness between T1
the differential (female) (11) and BR7 (female) (1)
control relay sys- 3. Defective contact or open circuit in the wiring harness between BR7
17 to 30 V
tem (female) (2) and chassis
Short circuit to
1. Defective VHP solenoid relay Voltage between T1 (2) and
the power source
2. Short circuit to the power source in the wiring harness between T1 chassis: When output is
39 d7 in VHP solenoid
(female) (2) and BR8 (female) (1) OFF (except for VHP specifi-
relay system
3. Defective transmission controller cation): Max. 1 V
(opt)
1. Defective VHP solenoid relay
Open circuit in 2. Defective contact or open circuit in the wiring harness between T1 Voltage between T1 (2) and
the VHP sole- (female) (2) and BR8 (female) (1) chassis: When output is ON
40 d7
noid relay sys- 3. Defective contact or open circuit in the wiring harness between BR8 (VHP specification):
tem (opt) (female) (2) and chassis 17 to 30 V
Short circuit to 1. Defective gearshift lever Voltage between T5 (6) and
the power source 2. Short circuit to the power source in the wiring harness between T5 chassis: Except when gear-
41 E1
in the F (Forward) (female) (6) and T13 (female) (7) shift lever is at [F1] to [F8]:
signal circuit 3. Defective transmission controller Max. 1 V
1. Defective gearshift lever Voltage between T5 (6) and
Open circuit in
2. Defective contact or open circuit in the wiring harness between T5 chassis: When gearshift
42 E1 the F (Forward)
(female) (6) and T13 (female) (7) lever is at [F1] to [F8]:
signal circuit
3. Defective transmission controller 20 to 30 V
Short circuit to 1. Defective gearshift lever Voltage between T5 (14)
the power source 2. Short circuit to power source in wiring harness between T5 (female) (14) and chassis: Except when
43 E1
in R (Reverse) and T13 (female) (13) gearshift lever is in [R1] to
signal system 3. Defective transmission controller [R4]: Max. 1 V
1. Defective gearshift lever Voltage between T5 (14)
Open circuit in
2. Defective contact or open circuit in wiring harness between T5 (female) and chassis: When gear-
44 E1 the R (Reverse)
(14) and T13 (female) (13) shift lever is at [R1] to [R4]:
signal system
3. Defective transmission controller 20 to 30 V
20-366 GD555, 655, 675-3C

(4)
Trouble-
Memory shooting
code
Alarm buzzer
Alarm buzzer output OFF Q Q — Q Q T-26
does not stop
Alarm buzzer
Alarm buzzer output OFF Q Q — Q Q T-26
does not sound
Warning lamp
Warning lamp output OFF stays lit and does Q — — Q Q T-27
not go out
Warning lamp
Warning lamp output OFF Q — — Q Q T-27
does not light up
Normal differen-
Differential control relay output OFF Q Q — Q Q T-28
tial condition
Normal differen-
Differential control relay output OFF Q Q — Q Q T-28
tial lock condition
Normal VHP con-

VHP solenoid relay output OFF Q Q — Q Q T-29
dition
Does not change

VHP solenoid relay output OFF Q Q — Q Q T-29
to VHP
achine coasts,
F and R signals input at same time o N Q Q Q Q Q T-30
and then stops
Impossible to
No action travel in FOR- Q Q Q Q Q T-30
WARD
Machine coasts,
F and R signals input at same time o N Q Q Q Q Q T-30
and then stops
Impossible to
No action travel in Q Q Q Q Q T-30
REVERSE
GD555, 655, 675-3C 20-367

(4)
Fail-
Short circuit to 1. Defective gearshift lever Voltage between T3A (8)

the power source 2. Short circuit to power source in wiring harness between T3A (female) (8) and chassis: Except when
45 E2
in the neutral sig- and T13 (female) (2) gearshift lever is in Neutral,
nal system 3. Defective transmission controller Park: Max. 1 V
1. Defective gearshift lever Voltage between T3A (8)
Open circuit in
2. Defective contact or open circuit in wiring harness between T3A and chassis: When gear-
46 E2 the neutral signal
(female) (8) and T13 (female) (2) shift lever is in Neutral, Park-
system
3. Defective transmission controller ing: 20 to 30 V
1. Defective parking brake relay
2. Short circuit to the power source in the wiring harness between T3A
Short circuit to Voltage between T3A (9)
(female) (9) and BR11 (female) (6)
power source in and chassis: Except when
47 E3 3. Short circuit to the power source in the wiring harness between T13
parking signal gearshift lever is in Park:
system Max. 1 V
5. Defective gearshift lever
1. Defective parking brake relay
Voltage between T3A (9)
Open circuit in 3. Defective contact or open circuit in the wiring harness between T13
and chassis: When gear-
48 E3 the parking signal (female) (10) and BR11 (female) (1)
shift lever is in Park:
system 4. Defective contact or open circuit in the wiring harness between BR11
20 to 30 V
(female) (2) and chassischassis
6. Defective gearshift lever
Short circuit to
2. Short circuit to power source in wiring harness between T3A (female) and chassis: When gear-
49 E4 power source in
(18) and T13 (female) (4) shift lever is in Park, Neutral:
logic A system
3. Defective transmission controller Max. 1 V
Open circuit in 2. Defective contact or open circuit in the wiring harness between T3A and chassis: Except when
50 E4
logic A system (female) (18) and T13 (female) (4) gearshift lever is in Park,
3. Defective transmission controller Neutral: 20 to 30 V
Short circuit to
2. Short circuit to the power source in the wiring harness between T5 chassis: Except when gear-
51 E5 the power source
(female) (7) and T13 (female) (5) shift lever is in [F1], [F5] -
in logic B system
3. Defective transmission controller [F7], [R1] - [R3]: Max. 1 V
Open circuit in 2. Defective contact or open circuit in wiring harness between T5 (female) chassis: When gearshift
52 E5
logic B system (7) and T13 (female) (5) lever is at [F1], [F5] - [F7],
3. Defective transmission controller [R1] - [R3]: 20 to 30 V
Short circuit to
2. Short circuit to power source in wiring harness between T5 (female) (15) and chassis: Except when
and T13 (female) (12) gearshift lever is at [F1] -
logic C system
3. Defective transmission controller [F5], [R1]: Max. 1 V
Open circuit in
2. Defective contact or open circuit in wiring harness between T5 (female) and chassis: When gear-
54 E6 the logic C sys-
(15) and T13 (female) (12) shift lever is at [F1] - [F5],
tem
3. Defective transmission controller [R1]: 20 to 30 V
Short circuit to
2. Short circuit to power source in the wiring harness between T5 (female) chassis: Except when gear-
55 E7 the power source
(8) and T13 (female) (18) shift lever is at [F1] - [F3]:
in logic D system
3. Defective transmission controller Max. 1 V
Open circuit in 2. Defective contact or open circuit in wiring harness between T5 (female) chassis: When gearshift
56 E7
logic D system (8) and T13 (female) (18) lever is at [F1] - [F3]: 20 to
3. Defective transmission controller 30 V
20-368 GD555, 655, 675-3C

(4)
Trouble-
Memory shooting
code
Machine coasts,
N, P, and other signals input at same time
and then stops
oN Q Q Q Q Q T-31
After stopping,
N and other signals input at same time o N
cannot travel
No F, R, N signals o N Cannot travel Q Q Q Q Q T-31
Danger that
machine will
move when the
No action Q Q — Q Q T-32
lever is operated
and the parking
brake will seize
When machine
stops, it does not
move when oper-
ating the lever.
No action Shifts to Neutral Q Q — Q Q T-32
during travel
when accelera-
tor pedal is being
depressed
Set to Neutral Cannot travel Q Q — Q Q T-33
GD555, 655, 675-3C 20-369

(4)
Fail-

Short circuit to
2. Short circuit to power source in wiring harness between T5 (female) (16) and chassis: Except when
and T13 (female) (3) gearshift lever is at [F3] -
logic E system
3. Defective transmission controller [F6], [R1], [R2]: Max. 1 V
Open circuit in 2. Defective contact or open circuit in wiring harness between T5 (female) and chassis: When gear-
58 E8
logic E system (16) and T13 (female) (3) shift lever is at [F3] - [F6],
3. Defective transmission controller [R1], [R2]: 20 to 30 V
Short circuit to 1. Defective stop lamp or stop lamp relay Voltage between T3A (19)
power source in 2. Short circuit to power source in wiring harness between T3A (female) and chassis: When output is
59 —
stop lamp signal (19) and BR10 (female) (5) or RL1 (female) (3) OFF (brake pedal not being
system 3. Defective transmission controller depressed): Max. 1 V
1. Defective stop lamp or stop lamp relay Voltage between T3A (19)
Open circuit in
2. Defective contact or open circuit in wiring harness between T3A and chassis: When output is
60 — the stop lamp sig-
(female) (19) and BR10 (female) (5) or RL1 (female) (3) ON (brake pedal being
nal system
3. Defective transmission controller depressed): 17 to 30 V
Short circuit to 1. Defective differential switch chassis:
ground in differ- 2. Short circuit to ground, short circuit, or short circuit to power source in When differential selector
61 —
ential selector wiring harness between T5 (female) (9) and FP13 (female) (2) switch is ON: 20 to 30 V
switch system 3. Defective transmission controller When differential selector
switch is OFF: Max. 1 V
Open circuit in 1. Defective differential switch chassis:
the differential 2. Defective contact or open circuit in the wiring harness between T5 When differential selector
62 —
selector switch (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
1. Defective lock-up switch and chassis:
Short circuit to
2. Short circuit to the ground, short circuit, or short circuit to power source When lock-up switch is ON:
63 — ground in lock-up
in wiring harness between T5 (female) (17) and T14 (female) (2) 20 to 30 V
switch system
3. Defective transmission controller When lock-up switch is OFF:
Max. 1 V
Open circuit in 1. Defective lock-up switch and chassis:
the differential 2. Defective contact or open circuit in the wiring harness between T5 When lock-up switch is ON:
64 —
lock-up switch (female) (17) and T14 (female) (2) 20 to 30 V
system 3. Defective transmission controller When lock-up switch is OFF:
Max. 1 V
1. Defective low set switch and chassis:
Short circuit to
2. Short circuit to ground, short circuit, or short circuit to power source in When potentiometer switch
65 — ground in low set
wiring harness between T5 (female) (12) and TT (terminal) (4) is at LOW: Max. 1 z
switch system
3. Defective transmission controller When potentiometer switch
is at HIGH OFF: Min. 1 Mz
1. Defective low set switch and chassis:
Open circuit in
2. 2. Defective contact or open circuit in wiring harness between T5 When potentiometer switch
66 — the low set switch
(female) (12) and TT (terminal) (4) is at LOW: Max. 1 z
system
3. 3. Defective transmission controller When potentiometer switch
is at HIGH OFF: Min. 1 Mz
Short circuit to Resistance between T5 (5)
ground in the 1. Short circuit to ground, short circuit, or short circuit to the power source and chassis:
67 —
model selection in the wiring harness between T5 (female) (5) and T7 (female) (1) STD specification: Max. 1 z
switch system Specification: Min. 1 MC
Open circuit in Resistance between T5 (5)
the model selec- 1. Defective contact or open circuit in the wiring harness between T5 and chassis:
68 —
tion switch sys- (female) (5) and T7 (female) (1) STD specification: Max. 1 z
tem Specification: Min.1 Mz
20-370 GD555, 655, 675-3C

(4)
Trouble-
Memory shooting
code
Sets to neutral Cannot travel Q Q — Q Q T-37
Sets to neutral Cannot travel Q Q — Q Q T-37
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 mode
No action — — — — — —
when in F1 - F4
or R1 - R4
Always enters
torque converter
No action — — — — — —
mode when in F1
- F4 or R1 - R4
If a short circuit exists when turning the

start switch to ON, the setting does not Normal operation — — — — — —
work
No action Normal operation — — — — — —
If reset switch is not turned OFF (at least 1

sec) o ON (at least 1 sec) o OFF (at least
Normal operation — — — — — —
1 second), does not enter the selection
mode Normal

sec) o ON (at least 1 sec) o OFF (at least Normal operation — — — — — —
1 sec), does not enter selection mode
GD555, 655, 675-3C 20-371

(4)
Fail-

Short circuit to and chassis:
ground in differ- 1. Short circuit to ground, short circuit, or short circuit to the power source When differential selection
69 —
ential selection in wiring harness between T3A (female) (10) and T7 (female) (2). switch is ON: Max. 1 z
switch system When differential selection
switch is OFF: Min. 1 Mz
Open circuit in and chassis:
the differential 1. Defective contact or open circuit in the wiring harness between T3A When differential selection
70 —
selection switch (female) (10) and T7 (female) (2). switch is ON: Max. 1 z
system When differential selection
switch is OFF: Min. 1 Mz
Resistance between T3A
Short circuit to (20) and chassis:
ground in inching 1. Short circuit to ground, short circuit, or short circuit to power source in With inching specification:
71 —
selection switch wiring harness between T3A (female) (20) and T7 (female) (4). Max. 1 z
system Without inching specifica-
tion: Min. 1 Mz
Resistance between T3A
Open circuit in (20) and chassis:
the inching selec- 1. Defective contact or open circuit in the wiring harness between T3A With inching specification:
72 —
tion switch sys- (female) (20) and T7 (female) (4). Max. 1 z
tem Without inching specifica-
tion: Min. 1 Mz
Resistance between T3B (1)
and chassis:
Short circuit to
1. Short circuit to ground, short circuit, or short circuit to power source in When potentiometer switch
73 — ground in high set
wiring harness between T3B (female) (1) and TT (terminal) (3). is at HIGH: Max. 1 z
switch system
When potentiometer switch
is at LOW OFF: Min. 1 Mz
and chassis:
Open circuit in
1. Defective contact or open circuit in the wiring harness between T3B When potentiometer switch
74 — the high set
(female) (1) and TT (terminal) (3). is at HIGH: Max. 1 z
switch system
When potentiometer switch
is at LOW OFF: Min. 1 Mz
ground in the 1. Short circuit to ground, short circuit, or short circuit to power source in When reset switch is ON:
75 —
reset switch sys- wiring harness between T3B (female) (9) and TT (terminal) (8). Max. 1 z
tem When reset switch is OFF:
Min. 1 Mz
and chassis:
Open circuit in
1. Defective contact or open circuit in the wiring harness between T3B When reset switch is ON:
76 — the reset switch
(female) (9) and TT (terminal) (8) Max. 1 z
system
When reset switch is OFF:
Min. 1 Mz
ground in VHP 1. Short circuit to ground, short circuit, or short circuit to power source in With VHP specification:
77 —
selection switch wiring harness between T3B (female) (2) and T7 (female) (3) Max. 1 z
system Without VHP specification:
Min. 1 Mz
Open circuit in and chassis:
the VHP selec- 1. Defective contact or open circuit in wiring harness between T3B With VHP specification:
78 —
tion switch sys- (female) (2) and T7 (female) (3) Max. 1 z
tem Without VHP specification:
Min. 1 Mz
20-372 GD555, 655, 675-3C

(4)
Trouble-
Memory shooting
code
If the reset switch is not turned OFF (at

least 1 sec) o ON (at least 1 sec) o OFF
(at least 1 sec), does not enter differential
mode

(at least 1 sec), does not enter differential
mode

(at least 1 sec), does not enter inching
mode

(at least 1 sec), does not enter inching
mode
If potentiometer voltage is not ± 0.1V, the

setting does not work. If there is a short cir-
cuit when the start switch is turned ON, the
setting does not work.

1 sec), does not enter VHP mode

1 sec), does not enter VHP mode
GD555, 655, 675-3C 20-373

(4)
Fail-

Short circuit to
and chassis:
ground in AWD 1. Short circuit to ground, short circuit, or short circuit to power source in
79 — AWD specification: Max. 1 z
selection switch wiring harness between T3B (female) (3) and T7 (female) (5)
Except AWD specification:
system
Min. 1 Mz
Open circuit in
and chassis:
the AWD selec- 1. Defective contact or open circuit in the wiring harness between T3B
80 — AWD specification: Max. 1 z
tion switch sys- (female) (3) and T7 (female) (5)
Except AWD specification:
tem
Min. 1 Mz
Resistance between T3B
(11) and chassis:
Short circuit to
Initialize switch at [Memory
ground in mem- 1. Short circuit to ground, short circuit, or short circuit to power source in
81 — set]: Max. 1 z
ory reset switch wiring harness between T3B (female) (11) and TT (terminal) (6)
Initialize switch at [Initialize
system
learning function] or OFF:
Min. 1 Mz
(11) and chassis:
Open circuit in Initialize switch at [Memory
1. Defective contact or open circuit in wiring harness between T3B
82 — the memory reset set]: Max. 1 z
(female) (11) and TT (terminal) (6)
switch system Initialize switch at [Initialize
learning function] or OFF:
Min. 1 Mz
Short circuit to
(13) and chassis:
ground in learn-
1. Short circuit to ground, short circuit, or short circuit to power source in Initialize switch at [Initialize
83 — ing function ini-
wiring harness between T5 (female) (13) and TT (terminal) (4) learning function]: Max. 1 z
tialize switch
Initialize switch at [Memory
system
set] or OFF: Min. 1 Mz
Open circuit in (13) and chassis:
learning function 1. Defective contact or open circuit in wiring harness between T5 (female) Initialize switch at [Initialize
84 —
initialize switch (13) and TT (terminal) (4) learning function]: Max. 1 z
system Initialize switch at [Memory
set] or OFF: Min. 1 Mz
Short circuit to 1. Defective FL clutch pressure switch
and chassis:
ground in FL 2. Short circuit to ground in wiring harness between T3B (female) (5) and
85 F1 At F1, F3, F5, F7: Max. 1 z
clutch pressure T36 (female) (1)
Except F1, F3, F5, F7:
switch system 3. Defective transmission controller
Min. 1 Mz
Open circuit in 1. Defective FL clutch pressure switch
and chassis:
the FL clutch 2. Defective contact or open circuit in wiring harness between T3B
86 91 At F1, F3, F5, F7: Max. 1 z
pressure switch (female) (5) and T36 (female) (1)
system 3. Defective transmission controller
Min. 1 Mz
Short circuit to 1. Defective FH clutch pressure switch
(13) and chassis:
ground in the FH 2. Short circuit to ground in the wiring harness between T3B (female) (13)
87 F2 At F2, F4, F6, F8: Max. 1 z
clutch pressure and T37 (female) (1)
Min. 1 Mz
Open circuit in 1. Defective FH clutch pressure switch
(13) and chassis:
the FH clutch 2. Defective contact or open circuit in the wiring harness between T3B
88 92 At F2, F4, F6, F8: Max. 1 z
Min. 1 Mz
Short circuit to 1. Defective R clutch pressure switch Resistance between T3B (6)
ground in the R 2. Short circuit to ground in the wiring harness between T3B (female) (6) and chassis:
89 F3
clutch pressure and T38 (female) (1) At R1 - R4 : Max. 1 z
switch system 3. 3. Defective transmission controller Except R1 - R4: Min. 1 Mz
20-374 GD555, 655, 675-3C

(4)
Trouble-
Memory shooting
code

1 sec), does not enter AWD mode

1 sec), does not enter AWD mode

1 sec), error code is not deleted

1 sec), error code is not deleted
If learning function initialize switch is not

turned OFF (at least 1 sec) o ON (at least
1 sec) o OFF (at least 1 sec), potentiome-
ter set value, trigger time, learning value,
model selection values cannot be deleted
from memory
If learning function initialize switch is not
turned OFF (at least 1 sec) o ON (at least
1 sec) o OFF (at least 1 sec), potentiome-
ter set value, trigger time, learning value,
model selection values cannot be deleted
from memory
Sets to neutral Sets to neutral Q Q Q Q Q T-38
Gearshift shock
Sets to rapid raise mode Q Q — — Q T-46
Gearshift timelag
Gearshift shock
Gearshift timelag
GD555, 655, 675-3C 20-375

(4)
Fail-
Open circuit in 1. Defective R clutch pressure switch Resistance between T3B

the R clutch pres- 2. Defective contact or open circuit in the wiring harness between T3B (13) and chassis:
90 93
sure switch sys- (female) (6) and T38 (female) (1) At R1 - R4: Max. 1 z
tem 3. Defective transmission controller Except R1 - R4: Min. 1 Mz
Short circuit to 1. Defective 1st clutch pressure switch
(14) and chassis:
ground in 1st 2. Short circuit to ground in the wiring harness between T3B (female) (14)
91 F4 At F1, F2, R1: Max. 1 z
clutch pressure and T39 (female) (1)
Except F1, F2, R1:
Min. 1 Mz
Open circuit in 1. Defective 1st clutch pressure switch
(14) and chassis:
the 1st clutch 2. Defective contact or open circuit in wiring harness between T3B
92 94 At F1, F2, R1: Max. 1 z
Except F1, F2, R1:
Min. 1 Mz
Short circuit to 1. Defective 2nd clutch pressure switch
and chassis:
ground in the 2nd 2. Short circuit to ground in wiring harness between T3B (female) (7) and
93 F5 At F3, F4, R2: Max. 1 z
Except F3, F4, R2:
Min. 1 Mz
Open circuit in 1. Defective 2nd clutch pressure switch
and chassis:
the 2nd clutch 2. Defective contact or open circuit in wiring harness between T3B
94 95 At F3, F4, R2: Max. 1 z
Except F3, F4, R2:
Min. 1 Mz
Short circuit to 1. Defective 3rd clutch pressure switch
(15) and chassis:
ground in 3rd 2. Short circuit to ground in wiring harness between T3B (female) (15) and
95 F6 At F5, F6, R3: Max. 1 z
Except F5, F6, R3:
Min. 1 Mz
Open circuit in 1. Defective 3rd clutch pressure switch
(15) and chassis:
the 3rd clutch 2. Defective contact or open circuit in the wiring harness between T3B
96 96 At F5, F6, R3: Max. 1 z
Except F5, F6, R3:
Min. 1 Mz
Short circuit to 1. Defective 4th clutch pressure switch
and chassis:
ground in the 4th 2. Short circuit to ground in wiring harness between T3B (female) (8) and
97 F7 At F7, F8, R4: Max. 1 z
Except F7, F8, R4:
Min. 1 Mz
Open circuit in 1. Defective 4th clutch pressure switch
and chassis:
the 4th clutch 2. Defective contact or open circuit in wiring harness between T3B
98 97 At F7, F8, R4: Max. 1 z
Except F7, F8, R4:
Min. 1 Mz
Short circuit to
1. Defective lock-up clutch pressure switch (16) and chassis:
ground in the
2. Short circuit to ground in wiring harness between T3B (female) (16) and When lock-up switch is ON:
99 F8 lock-up clutch
T43 (female) (1) Max. 1 z
pressure switch
3. Defective transmission controller When lock-up switch is OFF:
system
Min. 1 Mz
Open circuit in 1. Defective lock-up clutch pressure switch (16) and chassis:
the lock-up clutch 2. Defective contact or open circuit in wiring harness between T3B When lock-up switch is ON:
100 98
pressure switch (female) (16) and T43 (female) (1) Max. 1 z
system 3. Defective transmission controller When lock-up switch is
OFF: Min. 1 Mz
20-376 GD555, 655, 675-3C

(4)
Trouble-
Memory shooting
code
Gearshift shock
Gearshift timelag
Set to neutral Set to neutral Q Q Q Q Q T-41
Gearshift shock
Gearshift timelag
Gearshift shock
Gearshift timelag
Gearshift shock
Gearshift timelag
Gearshift shock
Gearshift timelag
Gearshift shock
Gearshift timelag
GD555, 655, 675-3C 20-377

(4)
ELECTRICAL CIRCUIT DIAGRAM

For the transmission control system
Serial No. 50001 – 51000
20-378 GD555, 655, 675-3C

(4)
TROUBLESHOOTING
GD555, 655, 675-3C 20-379

(4)
TROUBLESHOOTING
20-380 GD555, 655, 675-3C

(4)
TROUBLESHOOTING
GD555, 655, 675-3C 20-381

(4)
TROUBLESHOOTING T-1
T-1 Failure code [A1]
Short circuit with power source, ground, or FL solenoid system
T-1 Related electrical circuit diagram
20-382 GD555, 655, 675-3C

(4)
TROUBLESHOOTING T-2
Short circuit with power source, ground, or FH solenoid circuit
T-2 Related electrical circuit
GD555, 655, 675-3C 20-383

(4)
TROUBLESHOOTING T-3
Short circuit with power source, R solenoid circuit, or ground
20-384 GD555, 655, 675-3C

(4)
TROUBLESHOOTING T-4
Short circuit with power source, 1st or 3rd solenoid circuit, or ground
GD555, 655, 675-3C 20-385

(4)
TROUBLESHOOTING T-5
Short circuit with power source, 2nd or 4th solenoid system, or ground
20-386 GD555, 655, 675-3C

(4)
TROUBLESHOOTING T-6
Short circuit with power source, lockup solenoid circuit, or ground
GD555, 655, 675-3C 20-387

(4)
TROUBLESHOOTING T-7
T-7 Failure code [b1]
Open FL solenoid circuit
20-388 GD555, 655, 675-3C

(4)
TROUBLESHOOTING T-8
Open FH solenoid circuit
GD555, 655, 675-3C 20-389

(4)
TROUBLESHOOTING T-9
Open R solenoid circuit
20-390 GD555, 655, 675-3C

(4)
TROUBLESHOOTING T-10
Open 1st solenoid circuit
GD555, 655, 675-3C 20-391

(4)
Open 2nd solenoid circuit
20-392 GD555, 655, 675-3C

(4)
Open 3rd solenoid circuit
GD555, 655, 675-3C 20-393

(4)
Open 4th solenoid circuit
20-394 GD555, 655, 675-3C

(4)
Open lock-up solenoid circuit
GD555, 655, 675-3C 20-395

(4)
T-15 Failure code [C0]
Power supply voltage reduced

a 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.
a When the battery is normal.
20-396 GD555, 655, 675-3C

(4)
Open engine-speed sensor circuit
GD555, 655, 675-3C 20-397

(4)
Short circuit with power source or open accelerator potentiometer circuit
20-398 GD555, 655, 675-3C

(4)
Table 1
T3A T9 Voltage
0.5 to 4.75V
0.5 to 1.6 V (low idle)
Between (3) and (16) Between (B) and (C)
2.1 V at low idle to
4.75 V at high idle
Between (7) and (16) Between (A) and (C) 4.75 to 5.25 V
a The above table shows the specified potentiometer voltage. The controller interprets the voltage as the
throttle angle. When adjusting the potentiometer, leave a margin of error for the judgment field. At low idle,
adjust the potentiometer so that voltage is from 1.3 to 1.6 V.
GD555, 655, 675-3C 20-399

(4)
Short circuit with power source or open inching potentiometer circuit
20-400 GD555, 655, 675-3C

(4)
Table 1
T3A T8 Voltage
0.5 to 4.75V
0.5 to 1.6 V
Between (13) and (16) Between (B) and (C) (inching pedal not depressed)
2.1 V when inching pedal not depressed to
4.75 V when inching pedal fully depressed
Between (7) and (16) Between (A) and (C) 4.75 to 5.25 V
a The above table shows the specified potentiometer voltage. The controller interprets the voltage as the
throttle angle. When adjusting the potentiometer, leave a margin of error for the judgment field. At low idle,
adjust the potentiometer so that voltage is from 1.3 to 1.6 V.
GD555, 655, 675-3C 20-401

(4)
Short circuit with the power source or open circuit in the transmission oil temperature sensor
circuit
20-402 GD555, 655, 675-3C

(4)
Short circuit with the power source or open circuit in the torque converter outlet oil tempera-
ture sensor circuit
GD555, 655, 675-3C 20-403

(4)
Short circuit with the power source or open circuit in the hydraulic oil temperature circuit
20-404 GD555, 655, 675-3C

(4)
Open circuit in the transmission input shaft speed sensor circuit
GD555, 655, 675-3C 20-405

(4)
Open circuit in the transmission output shaft speed sensor circuit
20-406 GD555, 655, 675-3C

(4)
T-24 Failure code [d1]
Short circuit with power source or open circuit in the differential oil temperature warning lamp
circuit
GD555, 655, 675-3C 20-407

(4)
Short circuit to the power source or open circuit in the transmission oil temperature warning
lamp circuit
20-408 GD555, 655, 675-3C

(4)
Short circuit to the power source or open circuit in the buzzer alarm system
Note 1: k Always apply the parking brake.
GD555, 655, 675-3C 20-409

(4)
Short circuit with the power source or open circuit in the transmission control warning lamp
system
20-410 GD555, 655, 675-3C

(4)
Short circuit with power source or open circuit in the differential control relay system
GD555, 655, 675-3C 20-411

(4)
Short circuit to the power source or open circuit in the VHP relay circuit
20-412 GD555, 655, 675-3C

(4)
T-30 Failure code [E1]
Short circuit with the power source or open circuit in the F (for-ward), R (reverse) system
GD555, 655, 675-3C 20-413

(4)
Short circuit with the power source or open circuit in the neutral signal circuit
T-30, T-31 Related electrical circuit diagram
20-414 GD555, 655, 675-3C

(4)
Short circuit with the power source or open circuit in the parking signal circuit
GD555, 655, 675-3C 20-415

(4)
20-416 GD555, 655, 675-3C

(4)
TROUBLESHOOTING T-33, T-34
Short circuit with the power source or open circuit in the logic A signal circuit
Short circuit with the power source or open circuit in the logic B signal circuit
GD555, 655, 675-3C 20-417

(4)
Short circuit with the power source or open circuit in the logic C signal circuit
T-33, T-34, T-35 Related electrical circuit diagram
20-418 GD555, 655, 675-3C

(4)
Short circuit with the power source or open circuit in the logic D signal system
Short circuit with the power source or open circuit in the logic E signal system
GD555, 655, 675-3C 20-419

(4)
T-36, T-37 Related electrical circuit diagram
20-420 GD555, 655, 675-3C

(4)
T-38 Failure code [F1]
Short circuit with ground in the FL clutch pressure switch signal circuit
Short circuit with ground in the FH clutch pressure switch signal circuit
GD555, 655, 675-3C 20-421

(4)
Short circuit with ground in the R clutch pressure switch signal circuit
20-422 GD555, 655, 675-3C

(4)
Short circuit to ground in the 1st clutch pressure switch circuit
Short circuit to ground in the 2nd clutch pressure switch circuit
GD555, 655, 675-3C 20-423

(4)
Short circuit to ground in the 3rd clutch pressure switch circuit
Short circuit with ground in 4th clutch pressure switch system
T-41, T-42, T-43, T-44 Related electrical circuit diagram
20-424 GD555, 655, 675-3C

(4)
Short circuit to ground in the lock-up clutch pressure switch circuit
GD555, 655, 675-3C 20-425

(4)
T-46 Failure code [91]
Open circuit in the FL clutch pressure switch circuit
Open circuit in the FH clutch pressure switch circuit
20-426 GD555, 655, 675-3C

(4)
Open circuit in the R clutch pressure switch circuit
GD555, 655, 675-3C 20-427

(4)
Open circuit in the 1st clutch pressure switch circuit
Open circuit in the 2nd clutch pressure switch circuit
20-428 GD555, 655, 675-3C

(4)
Open circuit in the 3rd clutch pressure switch circuit
Open circuit in the 4th clutch pressure switch circuit
GD555, 655, 675-3C 20-429

(4)
T-49, T-50, T-51, T-52 Related electrical circuit diagram
20-430 GD555, 655, 675-3C

(4)
Open circuit in the lock-up clutch pressure switch circuit
GD555, 655, 675-3C 20-431

(4)
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................................................................... 20-459
H-12 Transmission does not shift-up or shift-down .............................................................................. 20-460
H-13 Machine is slow or lacks power when traveling........................................................................... 20-460
H-14 Torque converter lock-up malfunction, cannot be actuated or canceled ..................................... 20-461
H-15 Excessive time lag when starting or shifting gear........................................................................ 20-461
H-16 Torque converter oil temperature is high ..................................................................................... 20-462
H-17 Braking force is insufficient.......................................................................................................... 20-463
GD555, 655, 675-3C 20-451

(4)
TROUBLESHOOTING FAILURE TABLE: MODES AND CAUSES
FAILURE TABLE: MODES AND CAUSES

Left Right
Pump control control
valve valve
Cause of failure
Hydraulic cylinder
Slow return valve

Pilot check valve
Main relief valve
LS relief valve
Unload valve
Pump proper
Circle motor
Failure mode
PC valve
Strainer
Spool
Spool
All work equipment is slow or lacks power Q Q Q Q Q
No work equipment moves Q Q Q
Excessive drop in engine speed, or engine stalls Q Q
Abnormal noise is generated Q Q
Work equipment
Excessive blade drift Q Q

Impossible to raise the machine using the blade Q Q Q Q Q Q Q
Lack of actuating power in articulating, drawbar shift,
Q Q Q Q Q Q Q
scarifier, leaning, blade shift cylinders (Left, right)
Excessive leaning cylinder drift (Tires lean) Q Q Q
Impossible to rotate the circle Q Q Q Q Q Q
Excessive scarifier drift
Machine does not move in either FORWARD or
REVERSE
Transmission does not upshift or downshift
Machine is slow or lacks In all speed ranges

power when traveling In certain speed ranges
Travel
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, 675-3C

(4)
Q
Circle rotator
ment
Work
equip-
Q
Shear pin
Loose piping connection or clamp, cracked hose
Q
Q
Q
Transmission proper
GD555, 655, 675-3C

Q
Q
TROUBLESHOOTING
Defective transmission main relief valve
Q
Q
Q
Q
Defective transmission clutch
Q
Q
Q
Torque converter proper
Q
Q
Q
Defective torque converter relief valve
Q
Q
Q
Defective torque converter lock-up clutch
Q
Q
Defective transmission pump
Q
Q
Air sucked into transmission pump suction circuit
Q
Q
Clogged strainer
Q
Q
Q
Q
Q
Defective ECMV valve
Q
Defective differential or final drive
Q
Brake valve
Q
Piston/disc/plate
Q
Accumulator charge circuit
Q
Accumulator
Braking device
Q
Slack adjuster
Q
Q
Q
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-17
H-16
H-15
H-14
H-12
H-10
H-13b
H-13a
(4)
20-453
TROUBLESHOOTING H-1
H-1 All work equipment is slow or lacks power
20-454 GD555, 655, 675-3C

(4)
TROUBLESHOOTING H-2, H-3
H-2 No work equipment moves
H-3 Excessive drop in engine speed, or engine stalls
GD555, 655, 675-3C 20-455

(4)
H-4 Abnormal noise generated around the pump
H-5 Excessive blade drift
Standard drift: Fewer than 10 mm after 10 minutes
20-456 GD555, 655, 675-3C

(4)
H-6 Impossible to raise front of machine using the blade
H-7 Lack of actuating power in the articulating, drawbar shift, scarifier, leaning, and
blade shift cylinders (left, right)
GD555, 655, 675-3C 20-457

(4)
H-8 Excessive leaning cylinder drift (tires lean)
Standard drift: Fewer than 10 mm after 10 minutes
H-9 Impossible to rotate the circle
a Check that dirt or an object doesn’t exist between the pinion and circle.
a Check that the specified circle guide clearance exists.
20-458 GD555, 655, 675-3C

(4)
H-10 Excessive scarifier drift
H-11 Machine does not move in either forward or reverse
GD555, 655, 675-3C 20-459

(4)
H-12 Transmission does not shift-up or shift-down
Before troubleshooting, operate the gearshift lever to each speed range to determine the speed ranges where
the transmission does not shift-up or shift-down.
H-13 Machine is slow or lacks power when traveling
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.
b) Travel is slow or lacks power in certain speed ranges: Refer to troubleshooting H-11.
20-460 GD555, 655, 675-3C

(4)
H-14 Torque converter lock-up malfunction, cannot be actuated or canceled
• If the torque converter lock-up does not work, the maximum speed is reduced; if it cannot be canceled, the
engine stalls when starting or stopping the machine.
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.
GD555, 655, 675-3C 20-461

(4)
TROUBLESHOOTING H-16
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.
20-462 GD555, 655, 675-3C

(4)
TROUBLESHOOTING H-17
H-17 Braking force is insufficient
a Carry out the following troubleshooting when the steering system and work equipment operate normally.
GD555, 655, 675-3C 20-463

(4)
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 lights up.................................................................................... 20-508
M-2 Transmission controller caution lamp lights up ............................................................................. 20-509
M-3 Transmission oil temperature caution lamp lights up .................................................................... 20-509
M-4 Differential oil temperature caution lamp lights up (opt) ................................................................ 20-510
M-5 Bank pin caution lamp lights up .................................................................................................... 20- 511
M-6 Brake oil pressure caution lamp lights up ..................................................................................... 20-512
M-7 Battery charge caution lamp lights up ........................................................................................... 20-513
M-8 Preheating display does not light up ............................................................................................. 20-514
M-9 High beam display does not light up ............................................................................................. 20-515
M-10 Working lamp display does not light up (opt) .............................................................................. 20-516
M-11 Differential lock actuation display does not light up (opt) ............................................................ 20-517
M-12 Accumulator actuation display does not light up ......................................................................... 20-518
M-13 Float actuation display does not light up ..................................................................................... 20-518
M-14 Parking brake display does not light up ...................................................................................... 20-520
M-15 Turn signal lamp display does not flash ...................................................................................... 20-521
M-16 Articulation gauge does not work ................................................................................................ 20-522
M-17 Fuel gauge does not work........................................................................................................... 20-524
M-18 Engine water temperature gauge does not work ........................................................................ 20-526
M-19 Torque converter temperature gauge does not work (Opt) ......................................................... 20-527
M-20 Message center does not work ................................................................................................... 20-528
M-21 Service meter does not work....................................................................................................... 20-529
GD555, 655, 675-3C 20-501

(4)
TROUBLESHOOTING FAILURE TABLE: MODES AND CAUSES
Torque converter oil temperature gauge

Cause of the failure
Water temperature gauge
Transmission controller
Relay, flasher, timer
ArticulatIion gauge
Message center
Wiring harness
Nature of the failure
Fuel gauge
Fuse
Engine oil pressure caution lamp lights up when the engine is started Q
Transmission controller abnormality caution lamp lights up Q Q
Transmission oil temperature caution lamp lights up Q Q
Caution
Differential oil temperature caution lamp lights up (opt) Q Q

Bank pin caution lamp lights up Q
Brake oil pressure caution lamp lights up Q
Battery charge caution lamp lights up when the engine is started Q Q
Preheating display does not light up when preheating is operated Q Q
High beam display does not light up Q Q
Actuation display
Working lamp display does not light up (opt) Q Q Q

Differential lock actuation display does not light up (opt) Q Q Q
Accumulator actuation display does not light up Q Q
Float actuation display does not light up Q Q
Parking brake display does not light up Q Q Q
Turn signal lamp display does not flash Q Q Q
Articulation gauge does not work Q Q
Fuel gauge does not work Q Q
Gauges
Engine water temperature gauge does not work Q Q

Torque converter temperature gauge does not work (opt) Q Q
Message center does not work (opt) Q Q Q
Service meter does not work Q
20-502 GD555, 655, 675-3C

(4)
Q
Leakage of oil from engine oil pressure piping
Q
Shifter
Q
Starting switch
Q
Q
Engine oil pressure sensor (switch)
GD555, 655, 675-3C

Q
Transmission oil temperature sensor
TROUBLESHOOTING
Q
Coolant temperature sensor
Q
Alternator
Q
Accumulator oil pressure switch
Q
Buzzer
Q
Head lamp switch
Q
Q
Q
Q
Q
Q
Q
Q
Bulb
Q
Service meter
Q
Fuel level sensor (fuel sensor)
Q
Torque converter oil temperature sensor
Q
Q Articulation sensor
Differential oil temperature sensor
Q
Turn switch, hazard switch
Q
Q
Float / accumulator switch
Q
Lifter lock switch
Q
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-21
M-20
M-19
M-18
M-17
M-16
M-15
M-14
M-13
M-12
M-10
(4)
20-503
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM

Serial No. 50001 – 51000
20-504 GD555, 655, 675-3C

(4)
GD555, 655, 675-3C 20-505

(4)
20-506 GD555, 655, 675-3C

(4)
GD555, 655, 675-3C 20-507

(4)
TROUBLESHOOTING M-1
M-1 Engine oil pressure caution lamp lights up
When the engine is started
M-1 Related electrical circuit diagram
20-508 GD555, 655, 675-3C

(4)
TROUBLESHOOTING M-2, M-3
M-2 Transmission controller caution lamp lights up
M-3 Transmission oil temperature caution lamp lights up
GD555, 655, 675-3C 20-509

(4)
TROUBLESHOOTING M-4
M-4 Differential oil temperature caution lamp lights up (opt)
20-510 GD555, 655, 675-3C

(4)
TROUBLESHOOTING M-5
M-5 Bank pin caution lamp lights up
GD555, 655, 675-3C 20-511

(4)
TROUBLESHOOTING M-6
M-6 Brake oil pressure caution lamp lights up
20-512 GD555, 655, 675-3C

(4)
TROUBLESHOOTING M-7
M-7 Battery charge caution lamp lights up
After starting the engine
GD555, 655, 675-3C 20-513

(4)
TROUBLESHOOTING M-8
M-8 Preheating display does not light up
When operating the preheating
20-514 GD555, 655, 675-3C

(4)
TROUBLESHOOTING M-9
M-9 High beam display does not light up
GD555, 655, 675-3C 20-515

(4)
TROUBLESHOOTING M-10
M-10 Working lamp display does not light up (opt)
20-516 GD555, 655, 675-3C

(4)
M-11 Differential lock actuation display does not light up (opt)
GD555, 655, 675-3C 20-517

(4)
M-12 Accumulator actuation display does not light up
M-13 Float actuation display does not light up
20-518 GD555, 655, 675-3C

(4)
M-12, M-13 Related electrical circuit diagram
GD555, 655, 675-3C 20-519

(4)
M-14 Parking brake display does not light up
Brake released when light is on
20-520 GD555, 655, 675-3C

(4)
M-15 Turn signal lamp display does not flash
GD555, 655, 675-3C 20-521

(4)
M-16 Articulation gauge does not work
20-522 GD555, 655, 675-3C

(4)
Serial No. 50001 – 51000
GD555, 655, 675-3C 20-523

(4)
M-17 Fuel gauge does not work
Serial No. 50001 – 51000
20-524 GD555, 655, 675-3C

(4)
GD555, 655, 675-3C 20-525

(4)
M-18 Engine water temperature gauge does not work
20-526 GD555, 655, 675-3C

(4)
M-19 Torque converter temperature gauge does not work (Opt)
GD555, 655, 675-3C 20-527

(4)
M-20 Message center does not work
20-528 GD555, 655, 675-3C

(4)
M-21 Service meter does not work
GD555, 655, 675-3C 20-529

(4)
30 DISASSEMBLY AND
ASSEMBLY
METHOD OF USING MANUAL...................... 30- 3 REMOVAL OF TRANSMISSION

PRECAUTIONS WHEN CARRYING OUT ASSEMBLY...............................................30- 36
OPERATION ............................................. 30- 5 INSTALLATION OF TRANSMISSION
SPECIAL TOOL LIST ..................................... 30- 8 ASSEMBLY...............................................30- 38
SKETCHES OF SPECIAL TOOLS ................. 30- 11 DISASSEMBLY OF TORQUE CONVERTER
REMOVAL OF ENGINE HOOD ASSEMBLY ASSEMBLY...............................................30- 41
(SERIAL NO.: 50001 – 51000).................. 30- 16 ASSEMBLY OF TORQUE CONVERTER
INSTALLATION OF ENGINE HOOD ASSEMBLY ASSEMBLY...............................................30- 43
(SERIAL NO.: 50001 – 51000).................. 30- 17 DISASSEMBLY OF TRANSMISSION
REMOVAL OF ENGINE HOOD ASSEMBLY ASSEMBLY...............................................30- 47
(SERIAL NO.: 51001 AND UP) ................. 30- 17 ASSEMBLY OF TRANSMISSION
INSTALLATION OF ENGINE HOOD ASSEMBLY ASSEMBLY...............................................30- 63
(SERIAL NO.: 51001 AND UP) ................. 30- 18 REMOVAL OF FINAL DRIVE ASSEMBLY.....30- 84
REMOVAL OF RADIATOR ASSEMBLY INSTALLATION OF FINAL DRIVE
(SERIAL NO.: 50001 – 51000).................. 30- 19 ASSEMBLY...............................................30- 87
INSTALLATION OF RADIATOR ASSEMBLY DISASSEMBLY OF FINAL DRIVE
REMOVAL OF RADIATOR ASSEMBLY ASSEMBLY OF FINAL DRIVE ASSEMBLY...30- 90
(SERIAL NO.: 51001 AND UP) ................. 30- 21 DISASSEMBLY OF FINAL BRAKE CASE .....30- 93
INSTALLATION OF RADIATOR ASSEMBLY ASSEMBLY OF FINAL BRAKE CASE ...........30- 94
(SERIAL NO.: 51001 AND UP) ................. 30- 23 DISASSEMBLY OF SIDE CASE ....................30- 96
REMOVAL OF FUEL TANK, HYDRAULIC TANK, ASSEMBLY OF SIDE CASE ..........................30- 97
AND COOLING WATER SUB TANK ASSEMBLY DISASSEMBLY OF DIFFERENTIAL GEAR
INSTALLATION OF FUEL TANK, HYDRAULIC ASSEMBLY OF DIFFERENTIAL GEAR
TANK, AND COOLING WATER SUB TANK ASSEMBLY...............................................30-100
ASSEMBLY DISASSEMBLY OF BEVEL GEAR ................30-103
(SERIAL NO.: 50001 – 51000).................. 30- 26 ASSEMBLY OF BEVEL GEAR ......................30-104
REMOVAL OF FUEL TANK, HYDRAULIC TANK, DISASSEMBLY OF BEVEL PINION
AND COOLING WATER SUB TANK ASSEMBLY ASSEMBLY...............................................30-105
(SERIAL NO.: 51001 AND UP) ................. 30- 28 ASSEMBLY OF BEVEL PINION
INSTALLATION OF FUEL TANK, HYDRAULIC ASSEMBLY...............................................30-106
TANK, AND COOLING WATER SUB TANK REMOVAL OF OPERATOR'S CAB
ASSEMBLY ASSEMBLY...............................................30-107
(SERIAL NO.: 51001 AND UP) ................. 30- 30 INSTALLATION OF OPERATOR'S CAB
REMOVAL OF ENGINE ASSEMBLY ............. 30- 31 ASSEMBLY...............................................30-109
INSTALLATION OF ENGINE ASSEMBLY...... 30- 32 REMOVAL OF OPERATOR'S CAB FLOOR ..30- 111
REMOVAL OF ENGINE ASSEMBLY, INSTALLATION OF OPERATOR'S
TRANSMISSION ASSEMBLY CAB FLOOR .............................................30- 113
AS ONE UNIT ........................................... 30- 34 REMOVAL OF STEERING VALVE
INSTALLATION OF ENGINE ASSEMBLY, (ORBIT-ROLL) ..........................................30- 115
TRANSMISSION ASSEMBLY INSTALLATION OF STEERING VALVE
AS ONE UNIT ........................................... 30- 35 (ORBIT-ROLL) ..........................................30- 115
GD555, 655, 675-3C 30-1

(5)
DISASSEMBLY AND ASSEMBLY
STANDARD INTEGRAL ORBIT-ROLL ..........30- 116

DISASSEMBLY OF STEERING VALVE.........30- 118
ASSEMBLY OF STEERING VALVE...............30-121
REMOVAL OF BLADE ASSEMBLY ...............30-126
INSTALLATION OF BLADE ASSEMBLY .......30-126
REMOVAL OF CIRCLE DRAWBAR
ASSEMBLY...............................................30-127
INSTALLATION OF CIRCLE DRAWBAR
ASSEMBLY...............................................30-128
REMOVAL OF BLADE CIRCLE GEAR
ASSEMBLY ..............................................30-129
INSTALLATION OF BLADE CIRCLE GEAR
ASSEMBLY ..............................................30-130
REMOVAL OF BLADE CIRCLE ROTATION GEAR
ASSEMBLY (WITH SHEAR PIN)..............30-131
INSTALLATION OF BLADE CIRCLE ROTATION
GEAR ASSEMBLY (WITH SHEAR PIN) ..30-132
DISASSEMBLY OF BLADE CIRCLE ROTATION
GEAR ASSEMBLY (WITH SHEAR PIN) ..30-133
ASSEMBLY OF BLADE CIRCLE ROTATION GEAR
ASSEMBLY (WITH SHEAR PIN) .............30-135
DISASSEMBLY OF CIRCLE ROTATING GEAR
ASSEMBLY (WITH SLIP CLUTCH)..........30-137
ASSEMBLY OF CIRCLE ROTATING GEAR
ASSEMBLY (WITH SLIP CLUTCH)..........30-139
30-2 GD555, 655, 675-3C

(5)
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 installation proce-
dure it applies to.
(Example)
REMOVAL OF QQQQ ASSEMBLY .............................Title of operation
k ................................................................................Precautions related to safety when carrying out the
operation
1. XXXX (1) .................................................................Step in operation
a.............................................................................Technique or important point to remember when
removing XXXX (1).
2. EEEE (2): ............................................................ , Indicates that a technique is listed for use dur-
ing installation
3. TTTT assembly (3)
6.......................................................................Quantity of oil or water drained
INSTALLATION OF QQQQ 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 EEEE (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 precautions
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 opera-
tion procedure, see the SPECIAL TOOLS LIST given in this manual.
GD555, 655, 675-3C 30-3

(5)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
4. General tightening torque table (when using torque wrench)

a 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

a 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

a 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, 675-3C

(5)
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 general pre-
cautions 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 discon-
necting 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.
a 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, 675-3C 30-5

(5)
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 portion
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 se-
curely.
• 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.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hy-
draulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idling.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cyl-
inder 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.
a 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 water to the specified level. Run the engine
to circulate the water through the system. Then check the water 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 reassem-
bling the parts.
a 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, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured).
a Necessity: t: Cannot be substituted, should always be installed (used).
q: Very convenient if available, can be substituted with commercially available part.
a 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.
a Tools marked Q in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPE-
CIAL TOOLS).
New/remodel
Necessity
Symbol
Sketch
Qty.
Component Part No. Part Name Nature of work, remarks
Removal, installation of cylin-

1 709-331-1110 Wrench t 1
der head
Disassembly, assembly 2 795-799-2250 Installer t 1 Press fitting of front oil seal
A
of engine
795-799-1390 Remover t 1 Removal, installation of injec-
3
795-799-1131 Gear t 1 tion pump
790-501-5000 Repair stand q 1
790-501-5200 Repair stand q 1
Disassembly, assembly of
1 790-901-2110 Bracket q 1
toruqe converter
793-310-2131 Plate q 1
793-310-2141 Plate q 1
Disassembly, assembly
C Removal, installation of start-
of torque converter 2 792-390-1210 Wrench t 1
ing motor shaft round nut
790-201-2740 Spacer t 1
3 Press fitting of bearing
790-201-2750 Spacer t 1
Removal, installation of PTO
4 790-102-1871 Wrench t 1
bearing locknut
790-201-2740 Spacer t 1
1 Press fitting of clutch bearing
790-201-2750 Spacer t 1
2 790-101-5201 Push tool kit t 1 Press fitting of clutch bearing
Press fitting of clutch F2 & R
3 797T-423-1320 Push tool t 1 Q
bearing
794T-423-1130 Push tool t 1 N Q
Press fitting of case oil seal at
4 790-101-5221 Grip t 1
pulley end
01010-51225 Bolt t 1
Disassembly, assembly 794T-423-1130 Push tool t 1
D
of transmission 794T-423-1140 Spacer t 1 N Q Press fitting of case dust seal
5
790-101-5221 Grip t 1 at pulley end
01010-51225 Bolt t 1
794T-423-1110 Push tool t 1 N Q
Press fitting of coupling cage
6 790-101-5221 Grip t 1
oil seal
01010-51225 Bolt t 1
Press fitting of coupling cage
7 794T-423-1120 Spacer t 1 N Q
dust seal
8 794T-423-1180 Push tool t 1 N Q Press fitting of coupling cover
30-8 GD555, 655, 675-3C

(5)
New/remodel
Necessity
Symbol
Sketch
Qty.
9 793-310-2100 Lifting tool t 1 Lifting of clutch assembly

Disassembly, assembly Centering transmission and
D 10 792-271-2000 Centering tool t 1
of transmission final drive
11 799-301-1600 Oil leak tester t 1 Checking actuation of piston
790-201-2850 Spacer t 1
Press fitting of bevel pinion
1 790-201-2230 Plate t 1
bearing inner race
790-201-2740 Spacer t 1
790-101-5401 Push tool kit t 1
Disassembly, assembly
J 790-101-5441 Plate 1
of final drive 2 Press fitting of flange oil seal
790-101-5421 Grip 1
01010-51240 Bolt 1
Press fitting of drive shaft col-
3 794T-422-1110 Push tool t 1 N Q
lar, bearing
1 792-571-1600 Chain puller t 1 Removal, installation of chain
790-101-5551 Plate 1
2 Press fitting of oil seal to cage
Disassembly, assembly 790-101-5421 Grip 1
K
of tandem drive 01010-51240 Bolt 1
794T-425-1110 Push tool t 1 N Q Press fitting of drive shaft
3
794T-659-1110 Push tool t 1 bearing inner race
4 799-301-1600 Oil leak tester t 1 Checking actuation of piston
796-765-1110 Push tool (GD555) t 1
790-201-2220 Plate t 1 Press fitting of shaft bearing
1
793T-659-1110 Push tool (GD655) t 1 Q inner race
790-201-2240 Plate t 1
Disassembly, assembly 790-101-5491 Plate (GD555) 1
H
of axle 790-101-5421 Grip 1
01010-51240 Bolt 1
2 Press fitting of housing oil seal
790-101-5531 Plate (GD655) 1
790-101-5421 Grip 1
01010-51240 Bolt 1
1 791-342-1310 Wrench t 1 Removal, installation of cover
Disassembly, assembly 790-720-1000 Expander t 1
of bank pin Removal, installation of piston
2 796-720-1740 Ring t 1
ring
07281-00809 Clamp t 1
V Press fitting of worm bearing
3 796-460-1110 Push tool t 1
inner race
Disassembly, assembly 794T-470-1110 Push tool t 1 N Q
of circle rotation
4 790-101-5221 Grip t 1 Press fitting of houising oil seal
01010-51225 Bolt t 1
GD555, 655, 675-3C 30-9

(5)
New/remodel
Necessity
Symbol
Sketch
Qty.
790-502-1003 Cylinder repair stand t 1 Disassembly, assembly of

1
790-101-1102 Hydraulic pump t 1 hydraulic cylinder
Removal, installation of cylin-
2 790-102-2303 Wrench assembly t 1
der round head
790-201-1731 Push tool 1
790-201-1741 Push tool 1
790-201-1751 Push tool 1 Press fitting of cylinder head
3
790-201-1761 Push tool 1 coil bushing
790-201-1771 Push tool 1
790-201-5021 Grip 1
01010-50816 Bolt 1
790-201-1540 Plate 1
790-201-1550 Plate 1
790-201-1560 Plate 1 Installation of cylinder head
4
790-201-1570 Plate 1 dust seal
Disassembly, assembly 790-201-1580 Plate 1
U
of hydraulic system
790-101-5021 Grip 1
01010-50816 Bolt 1
790-720-1000 Expander t 1
796-720-1620 Ring t 1
07281-00609 Clamp t 1
796-720-1740 Ring t 1
07281-00809 Clamp t 1
796-720-1640 Ring t 1
Installation of cylinder piston
5 07281-00909 Clamp t 1
ring
796-720-1650 Ring t 1
07281-01029 Clamp t 1
796-720-1660 Ring t 1
07281-01159 Clamp t 1
796-720-1670 Ring t 1
07281-01279 Clamp t 1
796-460-1210 Stopper t 1 Removal, installation of
6
23B-60-32121 Rodd t 1 hydraulic pump
799-703-1200 Service tool kit t 1
799-703-1100 Vacuum pump (100 V) t 1
Discharging and charging air
Air conditioner assembly X 799-703-1110 Vacuum pump (220 V) t 1
conditioner refrigerant gas
799-703-1120 Vacuum pump (240 V) t 1
799-703-1400 Gas leak tester t 1
30-10 GD555, 655, 675-3C

(5)
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-6
D-4
GD555, 655, 675-3C 30-11

(5)
H-1
J-3
30-12 GD555, 655, 675-3C

(5)
D-8
D-3
GD555, 655, 675-3C 30-13

(5)
K-3
V-4
30-14 GD555, 655, 675-3C

(5)
D-7
D-5
GD555, 655, 675-3C 30-15

(5)
DISASSEMBLY AND ASSEMBLY REMOVAL OF ENGINE HOOD ASSEMBLY
REMOVAL OF ENGINE HOOD

ASSEMBLY
Serial No.: 50001 – 51000 4. Loosen clamp (9) of hose (8) connecting air
cleaner (6) and precleaner (7), then remove
1. Remove battery ground wire (1) from terminal. hose (8) from air cleaner (6).
2. Remove connectors of left and right working 5. Loosen mounting bolts of clamp (11) of air con-
lamp and license lamp (2) on inside. ditioner hose (10) and remove clamp (11).
Loosen mounting bolts of radiator guard (3) and Loosen mounting bolts of guard (12) and
remove guard. remove guard (12).
a The clearance between the hood and opera-
tor's cab is small, and it is difficult to remove
the hood, so remove the guard at this point.
3. Remove left and right mounting bolts (5) (front:

4, center: 4, rear: 6) of hood assembly (4).
6. Install 4 eyebolts to hood assembly (4), then

lift off hood assembly (4).
4 Hood assembly: 340 kg
30-16 GD555, 655, 675-3C

(5)
INSTALLATION OF ENGINE HOOD ASSEMBLY
DISASSEMBLY AND ASSEMBLY REMOVAL OF ENGINE HOOD ASSEMBLY
INSTALLATION OF ENGINE REMOVAL OF ENGINE HOOD

HOOD ASSEMBLY ASSEMBLY
Serial No.: 50001 – 51000 Serial No.: 51001 and up
a Carry out installation in the reverse order of re- k Disconnect the cable from the negative (–) ter-
moval. 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).
3. Disconnect air duct (5).
4. Disconnect clamp (7) of air conditioner hose (6).
5. Remove guard (8).

a Since the space between the hood and oper-
ator's cab is narrow for work, remove the
guard.
GD555, 655, 675-3C 30-17

(5)
DISASSEMBLY AND ASSEMBLY INSTALLATION OF ENGINE HOOD ASSEMBLY
INSTALLATION OF ENGINE
HOOD ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
6. Remove mounting bolts (10) of hood assembly

(9).
a Front: 4 bolts, center: 4 bolts, rear: 6 bolts
7. Using eyebolts [1], lift off hood assembly (11).
4 Hood assembly: 340 kg
30-18 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY REMOVAL OF RADIATOR ASSEMBLY
REMOVAL OF RADIATOR
ASSEMBLY
Serial No.: 50001 – 51000 3. Remove hoses (8) and (9) of hydraulic oil cooler.
a Fit male and female plugs into the hoses and
a Remove the engine hood assembly. (For details, nipples after removing them.
see REMOVAL OF ENGINE HOOD ASSEM-
BLY.)
1. Loosen radiator drain plug (1) and drain coolant

into container.
a 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.
a The hydraulic cooler forms one unit at the

bottom surface of the radiator, so drain the 4. Remove mounting bolts of fan guard (10), then
hydraulic oil. remove fan guard (10).
6
Install lifting tool to radiator lifting hook, sling
Hydraulic oil: 45 l radiator, then remove bolts of mounts (13) at
bottom of radiator, and lift off radiator assembly
(14).
a Release the gas before removing the air
conditioner condenser hose.
a Fit male and female plugs into the hoses af-
ter 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.
GD555, 655, 675-3C 30-19

(5)
DISASSEMBLY AND ASSEMBLY INSTALLATION OF RADIATOR ASSEMBLY
INSTALLATION OF
RADIATOR ASSEMBLY
Serial No.: 50001 – 51000 3. Install hydraulic oil cooler hoses (8) and (9).
Tighten hydraulic tank drain plug (2).
1. Install lifting tool to radiator assembly (14), Add hydraulic oil to the specified level.
raise radiator assembly (14), then set at fixed
position on top of main frame.
4 Radiator assembly:
Approx. 80 kg
4. Tighten radiator drain plug (1). Insert lower

hose (5) to tube at engine end and radiator end,
then tighten clamp (6).
2. Sling radiator assembly (14), install cushion 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).
5. Install upper tank hose (3), then tighten clamp

(4). Install sub tank hose (7) to radiator cap end.
30-20 GD555, 655, 675-3C

(5)
REMOVAL OF RADIATOR
ASSEMBLY
6. Fill radiator (14) with water through sub tank cap Serial No.: 51001 and up
(15) to FULL level.
a Start the engine, raise the temperature until a The method of removing the radiator, aftercool-
the thermostat opens, then circulate the er, and air conditioner condenser assembly to-
coolant and check the level again. gether is described below.
5 Coolant: 42 l 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.
5. Disconnect hose (3) between the radiator and

sub tank.
6. Disconnect radiator inlet hose (4) from the radia-

tor side.
GD555, 655, 675-3C 30-21

(5)
7. Disconnect radiator outlet hose (5) from the radi-

ator side.
14. Remove fan shroud (13), and then remove air

conditioner condenser (14) and aftercooler (15)
8. Disconnect torque converter oil cooler hoses (6) from radiator (16).
4
and (7).
Radiator: 120 kg
4
9. Disconnect 2 air conditioner tubes (8).
Aftercooler: 25 kg
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.
13. Remove radiator assembly (10).

a Take care not to damage the radiator core.
4 Radiator assembly (Radiator, aftercooler,

and air conditioner condenser): 150 kg
30-22 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY INSTALLATION OF RADIATOR ASSEMBLY
INSTALLATION OF
RADIATOR ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
3 Aftercooler hose clamp:

10.5 ± 0.5 Nm {107 ± 5 kgcm}
3 Radiator hose clamp:

8.8 ± 0.5 Nm {90 ± 5 kgcm}
• 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.
• Refilling with water

Close the radiator cap, and add water through
the water filler of the sub tank to the full level at
the center of the cooling water gauge. Run the
engine and warm up the water. Then, check the
water level again.
• Charging air conditioner with refrigerant gas

Using tool X, charge the air conditioner circuit
with refrigerant (R134a).
GD555, 655, 675-3C 30-23

(5)
REMOVAL OF FUEL TANK, HYDRAULIC TANK,
DISASSEMBLY AND ASSEMBLY AND COOLING WATER SUB TANK ASSEMBLY
REMOVAL OF FUEL TANK,

HYDRAULIC TANK, AND
COOLING WATER SUB TANK
ASSEMBLY
Serial No.: 50001 – 51000 3. Loosen clamp (8) of coolant circulation hose (7)
so that tube inside tank can come out. Loosen
a Remove the engine hood assembly. (For details, clamp (10) of hose (9) between engine and sub
see REMOVAL OF ENGINE HOOD ASSEM- tank, then remove hose (9). Loosen 2 mounting
BLY.) bolts of tube (11) and remove tube.
1. Loosen fuel tank drain cock (1) and drain fuel

into container.
Loosen coolant drain plug (2) and drain coolant
into container.
a 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 sensor, and
remove clamps (16) of wiring harness. 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
30-24 GD555, 655, 675-3C

(5)
5. Remove hoses (19), (20), and (21) installed to

hydraulic tank. Loosen clamp (23) of pump suc-
tion hose (22), then remove hose.
Loosen clamp (24) and pull out hose (25).
Remove tank drain hose (26). Disconnect con-
nector of sensor (27).
nipples after removing them. Cover any hos-
es 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 hydraulic
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.
a Fit male and female plugs into the hoses af-
ter 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
7. Install eyebolts to tank, sling tank, then remove

2 front and rear mounting bolts (36) at right side
of tank mount (35). Remove clamps (38) of wir-
ing harness (37) at bottom of tank.
GD555, 655, 675-3C 30-25

(5)
INSTALLATION OF FUEL TANK, HYDRAULIC TANK,
INSTALLATION OF FUEL
TANK, HYDRAULIC TANK,
AND COOLING WATER SUB
TANK ASSEMBLY
Serial No.: 50001 – 51000 3. Tighten mounting bolts of tank (42) and tank
mount (39). Install drain hose (26) and tube
a When assembling, be extremely careful not to (31). Pass hose (25) through clamp (24) and
cause failures due to dirt, rust, or scratches. tighten bolt. Install hoses (21), (20), and (19).
a At places where there is double clamping of the Install pump suction hose (22), and tighten
hoses, assemble so that the screws are at 180° clamp (23).
to each other.
a Install the hoses carefully so that there is no
twisting.
a 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).
30-26 GD555, 655, 675-3C

(5)
5. Install hose (14) and secure with clamp. Install 7. Tighten drain plug (3) of hydraulic tank. Tighten
connector of fuel sensor (15), and secure wiring coolant drain plug (2).
harness (44) with clamps (16). Insert tube (13) a Fill with hydraulic oil through the oil filler.
5
in tank and install to tank with mounting bolts.
Insert hose (12) in radiator (42) and tighten with Hydraulic tank:
clamp (45). 45 l (Total oil volume: 85 l)
a Fill with coolant. Fill the radiator with water
from the sub tank cap to the FULL level.
5 Total water 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 portion of cir-
culation tube (6), and tighten clamp (5).
a Some intermediate clamps of the hoses and 8. Tighten drain valve (1) of fuel tank and fill with
wiring harnesses are at places where it is dif- fuel through fuel filler.
5
ficult to install, so be sure to install them all
properly. Fuel tank: 352 l
9. Install engine hood assembly. (For details, see

INSTALLATION OF ENGINE HOOD ASSEM-
BLY.)
GD555, 655, 675-3C 30-27

(5)
REMOVAL OF FUEL TANK,

HYDRAULIC TANK, AND
COOLING WATER SUB TANK
ASSEMBLY
Serial No.: 51001 and up 6. Disconnect water 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 7. Disconnect water hoses (7) and (9).
4. Remove the engine hood assembly. For details, 8. Disconnect tube (11) from the fuel tank.
see REMOVAL, INSTALLATION OF ENGINE
HOOD ASSEMBLY.
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 water tube (13).
11. Disconnect water hose (14) from the sub tank.
12. Disconnect fuel level sensor wiring connector

(15) and wire clamp (16).
13. Disconnect water hose (18) from reservoir tank

(17).
30-28 GD555, 655, 675-3C

(5)
17. Using eyebolts, sling the tank assembly tempo-

rarily and remove 2 mounting bolts (36) from
tank assembly right bracket (35).
18. Remove the wire clamp from the tank bottom

and disconnect wiring harness (37).
14. Disconnect hoses (19), (20), (21), (22), (25), and

(26) from the hydraulic tank.
a Plug the disconnected hoses and nipples.
15. Disconnect wiring connector (27).
19. Remove tank assembly mounting bolts (41)

from tank assembly left bracket (39).
a If the tank assembly is disconnected from
mounting bolts (40), it will interfere with the
work equipment pump when it is lifted up.
Accordingly, do not disconnect the tank as-
sembly from mounting bolts (40).
16. Disconnect hoses (28) and (29), tubes (30) and

(31), and breather (33) from the hydraulic tank.
GD555, 655, 675-3C 30-29

(5)
INSTALLATION OF FUEL
TANK, HYDRAULIC TANK,
AND COOLING WATER SUB
TANK ASSEMBLY
20. Lift off fuel tank, hydraulic tank, and cooling Serial No.: 51001 and up
water sub tank assembly together with the right
bracket. • Carry out installation in the reverse order to re-
a Check that all the wires and pipes are dis- moval.
connected.
4
• Refilling with oil (Hydraulic tank)
Fuel tank, hydraulic tank, and cooling Add oil through the oil filler to the specified level.
water sub tank assembly: 200 kg 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 water

Close the radiator cap, and add water through
the water filler of the sub tank to the full level at
the center of the cooling water gage. Run the
engine and warm up the water. Then, check the
water level again.
30-30 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY REMOVAL OF ENGINE ASSEMBLY
REMOVAL OF ENGINE
ASSEMBLY
1. Remove engine hood assembly. 5. Remove 2 mounting bolts of mounting bracket

(For details, see REMOVAL OF ENGINE HOOD (12) of remote hose (11) for engine oil drain,
ASSEMBLY.) then remove hose clamp (13), and remove
hose.
2. Remove fuel tank and hydraulic tank.
(For details, see REMOVAL OF FUEL TANK,
HYDRAULIC TANK.)
3. Remove fuel hose (1), accelerator wire (2), elec-

tric wiring harnesses (3), air conditioner hose
(4), and battery ground from engine block.
a Release the air conditioner gas before re-
moving air conditioner hose (4).
6. Use stable stand under rear of transmission

to prevent transmission from tilting when sepa-
rating 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, 675-3C 30-31

(5)
DISASSEMBLY AND ASSEMBLY INSTALLATION OF ENGINE ASSEMBLY
ASSEMBLY
8. Remove all 12 mounting bolts (18) from mating 1. Raise engine assembly (16), align with mount-
surface of transmission assembly (17) and ing face of transmission, then fit spline portion.
engine assembly (16). a When installing, be careful not to damage
the O-ring.
4 Engine assembly: 850 kg
9. Using forcing tap bolt (2-10x1.5), disconnect

engine assembly (16) from transmission assem-
bly, then raise and set on stable stand.
4
2. Keep engine assembly (16) raised and tighten
Engine assembly: 850 kg bolts to specified torque at mounting surface
with transmission (17).
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.
30-32 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY INSTALLATION OF ENGINE ASSEMBLY
4. Install mounting bracket (12) of remote hose 7. Install fuel tank and hydraulic tank.
(11) for engine oil drain. Install hose clamp (13). (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.)
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.
6. Install fuel hose (1), accelerator wire (2), electric

wiring harnesses (3), and air conditioner hose
(4), then install battery ground to engine block.
a 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.
GD555, 655, 675-3C 30-33

(5)
REMOVAL OF ENGINE ASSEMBLY, TRANSMISSION
DISASSEMBLY AND ASSEMBLY ASSEMBLY AS ONE UNIT
REMOVAL OF ENGINE
ASSEMBLY, TRANSMISSION
ASSEMBLY AS ONE UNIT
1. Remove engine hood assembly. 6. After lifting engine and transmission assembly,
(For details, see REMOVAL OF ENGINE HOOD put a stable stand under engine mount portion
ASSEMBLY.) (3). (A stand of height approx. 630 mm is
needed.)
2. Remove fuel tank and hydraulic tank. a Use a strong and stable stand.
HYDRAULIC TANK, COOLANT SUB TANK.)
3. Remove transmission related accessories.

(For details, see REMOVAL OF TRANSMIS-
SION ASSEMBLY.)
4. Remove engine related accessories.

( For detai ls, see RE MOVAL O F ENGINE
ASSEMBLY.)
a Do not loosen the mounting bolts at the mat-
ing surface of the engine assembly and
transmission assembly.
Sling the engine and transmission assem-
bly, then loosen and remove the mounting 7. Set stable stand under bottom of torque con-
bolts at the mating surface of the engine and verter case of transmission, sling engine assem-
transmission. bly (4), then remove all 12 bolts of mount portion
of engine and transmission. Using forcing tap
5. Loosen and remove 2 mounting bolts of engine bolts (2–10x1.5), disconnect engine assembly
mount (1) and 4 mounting bolts of transmission and put it on stable stand.
mount (2), then lift off engine and transmission
assembly.
4 Engine, transmission assembly:

Approx. 1850 kg
30-34 GD555, 655, 675-3C

(5)
INSTALLATION OF ENGINE ASSEMBLY, TRANS-
DISASSEMBLY AND ASSEMBLY MISSION ASSEMBLY AS ONE UNIT
ASSEMBLY, TRANSMISSION
ASSEMBLY AS ONE UNIT
1. Set transmission assembly (5) on stable stand 3. Raise engine and transmission assembly, and
with torque converter case at bottom, and align with specified position on main frame.
secure in position. Raise engine assembly (4) Align bolt holes of engine mount (1) and trans-
and mate transmission assembly (5). mission mount (2) with holes in frame, then
a When mating, be careful not to damage the install mounting bolts and tighten to specified
O-ring or let it fall out. torque.
2. Install bolts to mating portion of transmission 4. Install engine related accessories.

assembly (5) and engine assembly (4), and (For details, see INSTALLATION OF ENGINE
tighten to specified torque. ASSEMBLY.)
5. Install transmission related accessories.

(For details, see INSTALLATION OF TRANS-
MISSION ASSEMBLY.
6. Install fuel tank and hydraulic tank.

(For details, see INSTALLATION OF FUEL
TANK, HYDRAULIC TANK, COOLANT SUB
TANK.)

HOOD ASSEMBLY.)
GD555, 655, 675-3C 30-35

(5)
DISASSEMBLY AND ASSEMBLY REMOVAL OF TRANSMISSION ASSEMBLY
REMOVAL OF TRANSMISSION
ASSEMBLY
1. Remove engine hood assembly.
(For details, see REMOVAL OF ENGINE HOOD
ASSEMBLY.)
2. Remove fuel tank, hydraulic tank, and coolant

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.
a 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 mounting 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 cannot
be removed)
5. Remove hoses (6), (7), and (8) of pump (5) at

pump end. Remove connectors of speed sen-
sor system wiring harness (9).
nipples after removing them.
a Cover the removed connectors with a nylon
bag to prevent the entry of dust or water.
30-36 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY REMOVAL OF TRANSMISSION ASSEMBLY
8. Remove 4 mounting bolts (18) (2 each on left 10. Using forcing tap bolts (2–10x1.5), disconnect
and right). transmission assembly (21) from engine assem-
bly (20), and put on stable stand.
a Place a stable stand under the bottom sur-
face of the transmission and the bottom sur-
face of the torque converter case.
Remove hydraulic oil suction hose (22) and
oil supply tube (23).
11. Remove transmission accessories. Remove hoses

2 (24) and (25) of pump (10), remove mounting
bolts of pump, then lift off pump (10). Remove suc-
tion tube (26) of pump (5). Remove 2 hoses (27),
then lift off pump (5).
4 Hydraulic pump: Approx. 60 kg
4
9. Place stable stand under engine flywheel so that
there is no clearance. Install eyebolts and Transmission pump: Approx. 20 kg
sling transmission. Remove all 12 bolts (19) at
mating surface of engine assembly and trans-
mission assembly.
a 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. 1,000 kg
GD555, 655, 675-3C 30-37

(5)
DISASSEMBLY AND ASSEMBLY INSTALLATION OF TRANSMISSION ASSEMBLY
INSTALLATION OF
TRANSMISSION ASSEMBLY
12. Remove fan pulley assembly (28), belt (29) and 1. Install mounting bracket (33), then install pulley
hose (30), then remove electric control system (32).
cover (31). Remove pulley (32).
4 Fan pulley assembly: Approx. 40 kg
2. Install electric control system cover (31), then

install hose (30).
Raise fan pulley assembly (28) and install, then
13. Remove mounting bracket (33). Make transmis- install fan belt (29).
sion into individual part (34) to make it possible a For details of adjusting the fan belt, see
to carry out overhaul. TESTING AND ADJUSTING.
4 Fan pulley assembly:

Approx. 40 kg
30-38 GD555, 655, 675-3C

(5)
3. Raise pump (5) and install, then install suction 5. Raise transmission assembly (21) and install to
tube (26) and 2 hoses (27). engine assembly (20).
a When installing the hoses, tighten temporar- a Be careful not to damage the O-ring at the
ily, then adjust the angle and position and mating face of the transmission and engine
tighten fully so that there is no twisting of the when installing.
4
hoses.
4
Transmission assembly:
Transmission pump: Approx. 20 kg Approx. 1000 kg
4. Raise hydraulic pump (10) and install, then 6. Keep engine raised and install mounting bolts to
install hoses (24) and (25). Install hydraulic oil engine (20). Install 2 bolts (18) each of trans-
suction hose (22), then install oil supply tube mission bracket on left and right (total: 4).
(23).
4 Hydraulic pump: Approx. 60 kg
7. Install hydraulic oil hose (15) under radiator.

Install filter (16), then install 2 filter hoses (17).
GD555, 655, 675-3C 30-39

(5)
8. Install hoses (11), (12), (13), and (14) to hydrau- 11. Tighten drain plug (1) to specified torque. Fill
lic pump (10). with oil through oil filler (35).
a Oil used: EO 10-CD
5 Specified oil level: 45 l
9. Install hoses (6), (7), and (8) to pump (5). Install

connectors of speed sensor system wiring har-
ness (9).
12. Install fuel tank and hydraulic tank.
(For details, see INSTALLATION OF FUEL TANK,
HYDRAULIC TANK, COOLANT SUB TANK.)
a Transmission oil level check
Fill with oil to the correct level (as specified
above).
a After installation and proper fill of the fuel, hy-
draulic, and coolant tanks, start the engine
and bleed the air from the pump piping, then
run the engine at low idling and check the
transmission oil level. If the oil is not up to
the specified level, add oil.

10. Install universal joint (2) to flange with bolts. (For details, see INSTALLATION OF ENGINE
Install cable (3) of speedometer with nut (4). HOOD ASSEMBLY.)
30-40 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY
DISASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
1. Pilot 3) Using puller , remove torque converter
1) Set torque converter assembly (1) on work lock-up housing (7).
stand with pilot side at the top.
2) Remove mounting bolts (2), and using forc-
ing screws, remove pilot (3).
4) Remove bearing (8) from housing (7).

5) Remove piston (9) from housing (7).
2. Torque converter lock-up housing

1) Remove snap ring (4), then remove spacer
(5).
6) Remove seal ring (10) from piston (9).

7) Remove seal ring (11) from housing (7).
2) Remove housing mounting bolts (6).
GD555, 655, 675-3C 30-41

(5)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY
3. Drive case ii) Remove snap ring (17) from stator (16).
1) Remove disc (12). iii) Remove bushings (18) and (19), then
2) Remove mounting bolts (22), then using remove flywheel (20) from race (21).
eyebolts , remove drive case (23).
6. Stator shaft
4. Turbine assembly 1) Using tool C2, remove nut (25).
Remove turbine assembly (24).
2) Remove spacer (29).

5. Stator assembly 3) Turn over pump and stator shaft assembly
1) Remove stator assembly (13). (26), support gear (27) with block , then
a Rotate to the right as seen from the top remove stator shaft (28) with push tool .
and pull up.
2) Disassembly of stator assembly
i) Remove snap ring (14), then remove
race and flywheel assembly (15) from
stator (16).
4) Remove seal ring (30) from stator shaft (28).
30-42 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TORQUE CONVERTER ASSEMBLY
ASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
7. Disassembly of pump assemble a Wash all the parts clean and check that there is
1) Remove mounting bolts (31), then push no dirt or damage before assembling.
bearing (32) from opposite side, and remove a Check that the snap ring is securely fitted in the
together with gear (27) from pump assembly groove.
(35).
1. Pump assembly
1) Install collar (34) to gear (27).
a Align the bolt holes.
2) Install bearing (32) to collar (34).
2) Remove bearing (32) from gear (27).

3) Using forcing screws , remove collar (34)
from gear (27).
3) Set gear (27) and bearing (32) to pump (35),
3 Mounting bolt:
and tighten mounting bolts (31).
66.15 ± 7.35 N·m {6.75 ± 0.75 kgm}
GD555, 655, 675-3C 30-43

(5)
2. Stator shaft 3. Stator assembly
2 Outside circumference of seal ring:

1) Install seal ring (30) to stator shaft (28). 1) Assembly of stator assembly
i) Assemble flywheel (20) to race (21),
Grease (G2-LI) then expand fit bushings (18) and (19).
a Coat the sliding surface of the bushing
and flywheel with engine oil.
a Be careful not to damage the plug of the
flywheel.
2) Set stator shaft (28) on work stand, and

install to pump assembly (35).
a Press fit the inner race end of the bear-
ing.
3) Install spacer (29). ii) Install snap ring (17) to stator (16).
2 Nut: Thread tightener (LT-2)

4) Using tool C2, tighten nut (25). iii) Fit race and flywheel assembly (15) to
3 Nut:
stator (16), then install snap ring (14).
161.8 ± 14.7 N·m {16.5 ± 1.5 kgm}
30-44 GD555, 655, 675-3C

(5)
2) Rotate stator assembly (13) to right (clock- 5. Drive case

wise) to install. 1) Using eyebolt , install drive case (23).
a Check the direction of rotation of the sta-
2 Mounting bolt:
2) Tighten mounting bolts (22).
tor from the turbine end (input end).
• Clockwise: Free
3 Mounting bolt:
Thread tightener (LT-2)
• Counterclockwise: Locked
a If the direction of rotation of the stator is 53.9 ± 4.9 N·m {5.5 ± 0.5 kgm}
not as given above, reverse the race and 3) Install disc (12).
freewheel assembly, reassemble the
stator assembly, then check the direc-
tion of rotation again.
6. Torque converter lock-up housing

1) Install seal ring (11) to housing (7) and
2 Outside circumference of seal ring:

install seal ring (10) to piston (9).
4. Turbine assembly
Install turbine assembly (24). Grease (G2-LI)
2) Install piston (9) to housing (7).

3) Using eyebolts , install housing (7).
4) Temporarily assemble several mounting
bolts(6).
GD555, 655, 675-3C 30-45

(5)
5) Install bearing (8) with push tool . 7. Pilot
2 Mounting bolt: Thread tightener (LT-2)

a Press fit the outer race and inner race at Install pilot (3), then tighten mounting bolts (2).
3 Mounting bolt:
the same time.
66.15 ± 7.35 N·m {6.75 ± 0.75 kgm}
6) Fit spacer (5) and install snap ring (4).

a Check that the snap ring is securely fit-
ted in the groove.
2 Mounting bolt:
3 Mounting bolt:
66.15 ± 7.35 N·m {6.75 ± 0.75 kgm}
30-46 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION ASSEMBLY
DISASSEMBLY OF 2. Piston pump assembly

Sling pump assembly (5), then remove mount-
TRANSMISSION ASSEMBLY ing bolts and lift off.
k Set blocks securely to transmission assembly

(1), then sling the assembly to prevent it from
falling over.
3. Gear pump assembly

1) Remove suction tube (6).
2) Sling gear pump assembly (7), remove
mounting bolts, then remove.
1. Fan assembly
1) Turn fan belt adjustment screw (2) and
loosen fan belt tension, then remove fan belt
(3).
4. Oil lubrication hoses, tube

1) Remove hoses (8) and (9).
2) Remove tube (10).
2) Sling fan bracket, remove mounting bolts, 5. Transmission mount (right)

then remove fan assembly (4). Remove transmission mount (right) (11).
6. Speed sensor (for detection of transmission

output shaft speed)
Remove speed sensor (12).
GD555, 655, 675-3C 30-47

(5)
7. Fan pulley 13. Lubrication tube, block assembly

Remove fan pulley (13). Remove lubrication tube and block assembly
(28).
8. Transmission mount (left)
Remove transmission mount (left) (14).
9. Return hose, valve cover

1) Remove hose (15).
2) Remove valve cover (16).
14. Worm gear assembly (for speedometer)

Remove worm gear assembly (30).
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).
15. Coupling, retainer
1) Remove coupling (31).
2) Remove mounting bolts, then using forcing
screws, remove retainer (32).
30-48 GD555, 655, 675-3C

(5)
3) Remove dust seal (33) and oil seal (29) from 3) Remove valve assembly (37) from valve
retainer (32). seat (38).
16. Torque converter relief valve assembly 18. Oil lubrication tubes
1) Remove 4 mounting bolts, then remove Remove tubes (39) and (40).
torque converter relief valve assembly (34).
19. Cover, breather

17. Torque converter lock-up valve assembly, oil 1) Remove cover (41).
pressure tube 2) Remove breather (42).
1) Remove oil pressure tube (36).
2) Remove mounting bolts at valve seat end, 20. Speed sensor (for detection of engine speed)
then remove valve assembly (37) together Remove speed sensor (43).
with seat (38).
GD555, 655, 675-3C 30-49

(5)
21. Oil block (torque converter oil outlet) 3) Remove mounting bolts of valve seat, then
Remove oil block (44). using eyebolts , remove valve assembly
(50).
22. Speed sensor (for detection of transmission
input shaft speed)
Remove speed sensor (45).
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 .
24. Transmission cover assembly

1) Remove mounting bolts of cover assembly
(52), then using forcing screws , discon-
nect from transmission case.
2) Remove filter (47) and case (48).

a Use forcing screws when removing case
(48).
30-50 GD555, 655, 675-3C

(5)
2) Using eyebolts , remove cover assembly 4) Remove dust seal (59) and oil seal (35).
(52). 5) Remove snap ring (60), then remove bear-
a Using lever block, adjust so that clearing (61) from cover.
ance from transmission case is uniform.
26. Idler gear (for REVERSE)

3) Remove outer races (53) and (54) and bear- Serial No.: 50001 – 51000
ing (55) from cover (52). 1) Remove bolt (62), then remove plate (63).
2) Using gear puller , remove bearing (64)
together with gear (65).
25. Fan drive shaft

1) Remove bolt (56), then remove plate (49).
2) Remove flange (57). 3) Remove bearing (64) and snap ring (66)
3) Knock out shaft (58) and remove. from gear (65).
from shaft.
a There is a collar under the bearing.
GD555, 655, 675-3C 30-51

(5)
26. Idler gear (for REVERSE) 2) Using 2 wire ropes, remove 4th speed
Serial No.: 51001 and up clutch assembly (69).
1) Remove bolt (62), then remove plate (63).
together with gear (65).
3) Disassembly of 4th speed clutch assembly

i) Remove seal ring (70).
ii) Using press, remove bearing (71) and
3) Remove bearing (64) from gear (65). gear (72).
4) Remove spacer (66), bearing (64), and a Hold the gear and push shaft (73).
spacer (97) from shaft. a The clutch assembly will fall, so use
a There is a collar under the bearing. cushioning material to catch it.
iii) Remove snap ring (74) from shaft (73).

27. 4th speed clutch assembly
1) Remove oil guides (67) and (68).
30-52 GD555, 655, 675-3C

(5)
iv) Using press, remove bearing (75) at vii) Push in end plate (81) with bar handle
clutch end, spacer (76), thrust washer , and remove snap ring (82).
(77), and clutch assembly (78) from viii) Remove bar handle, then remove end
shaft (73). plate (81).
a Hold the drum end of clutch assembly ix) Remove 7 plates (83), 6 springs (84),
(78) and push shaft (73). and 6 discs (85) in turn.
a The shaft will fall, so use cushioning ma- a Store the discs and plates in a flat place
terial to catch it. to prevent them from warping.
v) Remove thrust washer (77) and seal x) Remove piston assembly (86).
ring (79) from shaft (73). a The piston cannot be removed if it is at
vi) Remove needle bearing (80) from 4th an angle, so set it horizontal to remove it.
speed clutch gear (137). a Be careful not to use force when remov-
ing. This will scratch the inside surface
of the cylinder.
xi) Remove seal rings (87) and (88) from
piston assembly (86).
GD555, 655, 675-3C 30-53

(5)
28. 2nd, 3rd speed clutch assembly v) Remove 3rd speed clutch gear (96).
1) Using gear puller , remove bearing (90) vi) Remove needle bearing (80) from 3rd
and gear (91) of 1st speed shaft. speed clutch gear (96).
a 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).
vii) Push in end plate (81) with push tool ,

and remove snap ring (82).
viii) Remove end plate (81).
3) Disassembly of 2nd, 3rd speed clutch

assembly
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.
a Store the discs and plates in a flat place
to prevent them from warping.
iii) Using bearing race puller , remove

bearing (95) at 3rd speed end.
iv) Remove spacer (76) and thrust washer
(77).
30-54 GD555, 655, 675-3C

(5)
x) Remove thrust washer (77). xvi) Push in end plate (81) with bearing race
xi) Remove piston assembly (86). puller and forcing screws , then
a The piston cannot be removed if it is at remove snap ring (82) and end plate
an angle, so set it horizontal to remove it. (81).
a Be careful not to use force when remov-
of the cylinder.
xii) Remove seal rings (87) and (88) from
xvii)Remove 15 plates (83), 14 springs (84),

to prevent them from warping.
xiii) Using gear puller , remove 2nd speed

inner race (98) and intermediate gear
(99), then remove snap ring (89) from
gear (99).
xviii)Remove thrust washer (77) and piston

assembly (101).
a If the piston is at an angle, it will not
come out, so set it horizontally and re-
move it.
xiv) Remove thrust washer (77) and 2nd a Do not use force to remove it. The inside
speed clutch gear (100). surface of the cylinder will be damaged.
xv) Remove needle bearing (80) from 2nd xix) Remove seal rings (87) and (88) from
speed clutch gear (100). piston assembly (101).
GD555, 655, 675-3C 30-55

(5)
29. 1st, FH clutch assembly, REVERSE, FL clutch iv) Push in end plate (81) with push tool ,
assembly and remove snap ring (82).
1) Using eyebolt , remove 1st, FH clutch v) Remove end plate (81).
assembly (102) and REVERSE, FL clutch vi) Remove 6 plates (83), 5 springs (84),
assembly (103) at the same time. and 5 discs (85) in turn.
a The gears of the two sets of clutch assem- a Store the discs and plates in a flat place
blies cross, so both sets must be raised at to prevent them from warping.
the same time in order to remove them.
a Raise both types of clutch assemblies per-
pendicularly.
2) Disassembly of 1st, FH clutch assembly

a The intermediate gear and bearing at the
tip of the 1st gear shaft were removed in
Step 29.
ii) Remove snap ring (104) and thrust
washer (77).
iii) Remove 1st speed clutch gear (105),
then remove needle bearing (80).
vii) Remove thrust washer (77).

viii) Remove piston assembly (86).
a The piston cannot be removed if it is at
an angle, so set it horizontal to remove it.
a Be careful not to use force when remov-
of the cylinder.
ix) Remove seal rings (87) and (88) from
30-56 GD555, 655, 675-3C

(5)
x) Pull out FH gear (106) with forcing xiii) Remove 13 plates (83), 12 springs (84),
screws , then remove together with and 12 discs (85) in turn.
bearing (107), spacer (108), and thrust a Store the discs and plates in a flat place
washer (77). to prevent them from warping.
xi) Remove thrust bearing (109) and nee- xiv) Remove piston assembly (110).
dle bearing (80) from FH clutch gear a There is a sleeve on the inside, so it can
(106). be removed smoothly.
xii) Push in end plate (81) with bar handle xv) Remove seal rings (112) and (88) from
, and remove snap ring (82). Remove piston assembly (110).
bar handle, then remove end plate (81). xvi) Remove snap ring (111), then remove
sleeve (137) from piston assembly.
GD555, 655, 675-3C 30-57

(5)
3) Disassembly of R, FL clutch assembly vi) Remove thrust bearing (109).

i) Remove seal rings (70) and (113).
vii) Push in end plate (81) with bar handle

ii) Remove bearing (114) and gear (115) at , and remove snap ring (82). Remove
FL clutch end with bearing race puller handle, then remove end plate (81).
.
iii) Remove snap ring (116), then remove
thrust washer (77).
viii) Remove 9 plates (83), 8 springs (84),

iv) Remove FL clutch gear (117). to prevent them from warping.
v) Remove needle bearing (80) from gear
(117).
30-58 GD555, 655, 675-3C

(5)
ix) Remove piston assembly (118).

a There is a sleeve on the inside, so it can
be removed smoothly.
xiv) Remove thrust bearing (109).

xv) Push in end plate (81) with bar handle
, and remove snap ring (82). Remove
x) Remove seal rings (120) and (88) from handle, then remove end plate (81).
piston assembly.
xi) Remove snap ring (111), then remove
sleeve (119).
xvi) Remove 9 plates (83), 8 springs (84),

xii) Using bearing race puller , remove R to prevent them from warping.
clutch gear (121), bearing (122), spacer
(108), and thrust washer (123).
xiii) Remove needle bearing (124) from R
clutch gear (121).
GD555, 655, 675-3C 30-59

(5)
xvii)Remove piston assembly (118). 2) Remove 8 torque converter assembly

a There is a sleeve on the inside, so it can mounting bolts (123) from under case.
be removed smoothly. 3) Using eyebolts , remove torque converter
assembly (127) from transmission case.
xviii)Remove seal rings (120) and (88) from

piston assembly. 31. Idler gear (procedure is same for both sets,
xix) Remove snap ring (111), then remove procedure given below is for fan drive shaft
sleeve (119). end)
1) Turn over transmission case and set securely
on block.
2) Use wrench with claw to remove nut
(128).
a Hold it at the gear end to prevent it from
rotating.
30. Torque converter assembly

1) Set transmission case (126) securely on
block (height: min. 400 mm).
3) To remove, knock out gear (129) from end

where nut is fitted.
30-60 GD555, 655, 675-3C

(5)
4) Remove snap ring (125), then remove 3) Remove gear (135) and spacer (142).
spacer (146), bearing (131), and outer race
(132).
4) Remove bearing (137) from shaft (140).
5) Remove bearing (136) and spacer (139)

from gear (129).
5) Remove bearing (143), then remove outer

race (144).
32. Hydraulic pump drive gear (procedure is

same for both sets, procedure given below is
for piston pump end)
1) Remove snap ring (138).
2) Using puller , pull out shaft (140).
a Support the shaft to prevent the spacer
and gear from falling when the shaft
comes out.
GD555, 655, 675-3C 30-61

(5)
33. Outer race (for FH clutch shaft)

Remove outer race (145) from transmission
case.
30-62 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION ASSEMBLY
ASSEMBLY OF TRANSMIS-
SION ASSEMBLY
a Wash all the parts clean and check that there is 3) Install snap ring (138).
no dirt or damage before assembling. a Check that the snap ring is fitted secure-
ly in the groove.
1. Outer race
Install outer race (145) to transmission case.
4) Install bearing (143) and outer race (144) in

order.
2. Hydraulic pump drive gear (procedure is
same for both sets, procedure given below is
for piston pump end)
1) Install bearing (137) to shaft (140).
3. Idler gear (procedure is same for both sets,

procedure given below is for fan drive shaft
end)
a Match the production No. of the inner and
2) Assemble gear (135) and spacer (142) in outer races and the spacer, and assemble
case, then install shaft (140). the bearing as a set.
a Tap the tip of the shaft. 1) Using push tool, press fit bearing (136) to
gear (129), then install spacer (139).
GD555, 655, 675-3C 30-63

(5)
2) Install outer race (132) to case. 4. Torque converter assembly

1) Set transmission case (126) on block with
torque converter side at the top.
a The mounting bolts for the torque con-
verter assembly are tightened temporar-
ily from below, so use a block at least
400 mm in height.
3) Assemble gear (124) to outer race of case.

4) Install bearing (126) to gear (124).
a Hold at the gear end.
5) Fit spacer (146) and install snap ring (125).
a Check that the snap ring is fitted secure-
ly in the groove.
2) Check position of oil hole and fit guide bolt
to stator shaft.
a Make a mark by the hole where the
guide bolt is inserted.
3) Using eyebolts , install torque converter
assembly (127).
a Mesh the torque converter PTO gear
and idler gear.
4) Install 2 – 3 mounting bolts temporarily from
below.
6) Use wrench with claw to tighten nut
2 Nut: Thread tightener (LT-2)

(128).
3 Nut: 353 ± 39 N·m {36 ± 4 kgm}

a After tightening the nut, drop 6 cc of en-
gine oil (EO-30) on the nut, rotate about
10 times, then check the tightening
torque again.
30-64 GD555, 655, 675-3C

(5)
5) Turn over transmission case (121) and set ii)

Assemble seal rings (120) and (88) to
to block . piston.
a Be careful to assemble the seal ring with
the side receiving the pressure facing in
the correct direction.
a Replace the seal ring with a new part.
2 Mounting bolt:
3 Mounting bolt:
110.5 ± 12.5 N·m {11.25 ± 1.25 kgm} iii) Install piston assembly (118) to cylinder
portion.
a When installing the piston assembly,
coat the contact surface and the inside
and outside circumference of the seal
ring with transmission oil.
5. R.FL clutch assembly, 1st. FH clutch assembly

1) Assembly of R.FL clutch assembly
i) Set sleeve (119) to piston, then install
snap ring (111).
ly in the groove. iv) Assemble 9 plates (83), 9 springs (84),
a Soak the discs for at least 2 minutes in
clean transmission oil before assembling.
a Be careful not to let the springs and
discs overlap.
GD555, 655, 675-3C 30-65

(5)
v) Assemble end plate (81), then push in x) Using push tool , press fit bearing
with bar handle and install snap ring (122) to shaft.
(82). a After press fitting the bearing, check that
a Check that the snap ring is fitted secure- there is no clearance between the end
ly in the groove. face of the bearing and the spacer.
a After press fitting the bearing, check
clearance "e" between the thrust washer
and the spacer.
a Clearance: 0.29 – 0.69 mm
vi) Install thrust bearing (109).

a Insert the thick race to the clutch end.
vii) Assemble needle bearing (124) to R
clutch gear (121).
xi) Set sleeve (119) to piston, then install
snap ring (111).
ly in the groove.
viii) Align inner teeth of discs and install R

clutch gear (121).
a 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 in-
stalling.
ix) Install thrust washer (123) and spacer
(108).
30-66 GD555, 655, 675-3C

(5)
xii) Assemble seal rings (120) and (88) to xv) Assemble end plate (81), then push in
piston. with bar handle and install snap ring
a Be careful to assemble the seal ring with (82).
the side receiving the pressure facing in a Check that the snap ring is fitted secure-
the correct direction. ly into the groove.
xvi) Install thrust bearing (109).

xiii) Install piston assembly (118) to cylinder a Insert the thick race to the clutch end.
portion. xvii)Assemble needle bearing (80) to FL
a When installing the piston assembly, clutch gear (117).
xviii)Align inner teeth of disc and install FL

clutch gear (117).
xiv) Assemble 9 plates (83), 9 springs (84), to the left, right, up, and down to align
and 8 discs (85) in turn. the teeth of the gear and discs when in-
a Soak the discs for at least 2 minutes in stalling.
clean transmission oil before assembling.
discs overlap.
GD555, 655, 675-3C 30-67

(5)
xix) Install thrust washer (77) and snap ring

(116).
xx) Install gear (115), and using push tool,
press fit bearing (114) to shaft.
a After press fitting the bearing, check that
there is no clearance between the end
face of the gear and the bearing.
clearance ""e"" between the thrust wash-
er and the gear.
2) Assembly of 1st. FH clutch assembly

i) Set sleeve (137) to piston, then install
snap ring (111).
ly in the groove.
xxi) Install seal rings (70) and (113) to shaft.

a Coat the outer circumference of the seal
ring with grease (G2-LI), and be careful
to install it uniformly.
ii)
Install seal rings (112) and (88) to piston
assembly (110).
a Be careful to assemble the seal ring with
xxii)Using tool D11, pump in air through oil

hole in shaft and check operation of
clutch.
a If the gear at the end where the air is
pumped in is held in position, the clutch
is working normally.
a Air pressure:
0.5 – 0.6 MPa {5.0 – 6.0 kg/cm2}
30-68 GD555, 655, 675-3C

(5)
iii) Install piston assembly (110) to cylinder vi) Install thrust bearing (109).
portion. a Insert the thick race to the clutch end.
a 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

clutch gear (106).
iv) Assemble 13 plates (83), 13 springs a Move the gear carefully a little at a time
(84), and 12 discs (85) in turn. to the left, right, up, and down to align
a Soak the discs for at least 2 minutes in the teeth of the gear and discs when in-
clean transmission oil before assem- stalling.
bling.
discs overlap.
v) Assemble end plate (81), then push in

with bar handle and install snap ring
(82).
ly in the groove.
GD555, 655, 675-3C 30-69

(5)
ix) Install thrust washer (77) and spacer

(108).
x) Using push tool, install bearing (107).
face of the bearing and the spacer.
a After press fitting the bearing, check the
clearance between the thrust washer
and the spacer.
xiv) Assemble 6 plates (83), 6 springs (84),

clean transmission oil before assem-
bling.
discs overlap.
xi) Assemble seal rings (88) and (87) to

a Be careful to assemble the piston with
xv) Assemble end plate (81).

xvi) Push end plate with push tool , then
install snap ring (82).
ly in the groove.
xvii)Assemble needle bearing (80) to 1st
speed clutch gear (105).
xii) Install piston assembly (86) to cylinder

portion.
xiii) Install thrust washer (77).
30-70 GD555, 655, 675-3C

(5)
xviii)Align inner teeth of disc and install 1st

stalling.
xix) Fit thrust washer (77) and install snap
ring (104).
xx) Install seal ring (70) to shaft.
6. 2nd, 3rd speed clutch assembly

1) Assembly of 2nd, 3rd speed clutch assem-
bly
i) Assemble seal rings (88) and (87) to
xxi) Using tool D11, pump in air through oil

clutch.
a If the gear at the end where the air is
pumped in is held in position, the clutch
a Air pressure:
0.5 – 0.6 MPa {5.0 – 6.0 kg/cm2}
ii) Install piston assembly (101) to cylinder

portion.
iii) Install thrust washer (77).
3) Using eyebolts , install 1st. FH clutch

assembly (102) and REVERSE. FL clutch
assembly (103) at same time.
a Raise both clutch assemblies perpendic-
ularly.
a If it is difficult to insert the 1st. FH clutch
assembly, remove the outer race from
the transmission case end, then assem-
ble to the shaft bearing and install.
GD555, 655, 675-3C 30-71

(5)
iv) Assemble 15 plates (83), 15 springs

(84), and 14 discs (85) in turn.
bling.
discs overlap.
x) Fit snap ring (89) to intermediate gear

(99), then install to shaft.
xi) Using press, install inner race (98).
a After press fitting the inner race, check
that there is no clearance between the
end face of the gear and the inner race.
a After press fitting the inner race, check
v) Assemble end plate (81). clearance "e" between the gear and the
vi) Push in with bearing race puller and thrust washer.
forcing screws , and install snap ring a Clearance: 0.35 – 0.85 mm
(82).
ly in the groove.
vii) Install needle bearing (80) to 2nd speed
clutch gear (100).
xii) Assemble seal rings (88) and (87) to

viii) Align inner teeth of disc and install 2nd a Replace the seal ring with a new part.
stalling.
ix) Install thrust washer (77).
30-72 GD555, 655, 675-3C

(5)
xiii) Install piston assembly (86) to cylinder

portion.
xiv) Install thrust washer (77).
xix) Align inner teeth of disc and install 3rd

stalling.
xx) Install thrust washer (77) and spacer
xv) Assemble 8 plates (83), 8 springs (84), (76).
bling.
discs overlap.
xxi) Using press, install bearing (95).

face of the spacer and the bearing.
a After press fitting the bearing, check the
xvi) Install end plate (81). and the spacer.
xvii)Push in end plate with push tool , and a Clearance: 0.38 – 0.82 mm
install snap ring (82).
ly in the groove.
xviii)Assemble needle bearing (80) to 3rd
GD555, 655, 675-3C 30-73

(5)
xxii)Install speedometer worm gear (94), 3) Install gear (91) to 1st speed clutch shaft.
2 Bolt: Thread tightener (LT-2)

and tighten bolts (93). 4) Using push tool , install bearing (90).
3 Bolt:
277 ± 32 N·m {28.25 ± 3.25 kgm} face of the bearing and the spacer.
xxiii)Install seal ring (70) to shaft. a After press fitting the bearing, check
and the spacer.
xxiv)Using tool D11, pump in air through oil

clutch.
a If the gear at the end where the air is 7. 4th speed clutch assembly
pumped in is held in position, the clutch 1) Assembly of 4th speed clutch assembly
is working normally. i) Assemble seal rings (88) and (87) to
a Air pressure: piston assembly (86).
0.5 – 0.6 MPa {5.0 – 6.0 kg/cm2} a Be careful to assemble the piston with
2) Using 2 wire ropes, install 2nd, 3rd speed

clutch assembly (92).
30-74 GD555, 655, 675-3C

(5)
ii) Assemble piston assembly (86) to cylin-

der portion of 4th speed clutch gear.
iii) Install needle bearing (80) to 4th speed
clutch gear (78).
ix) Turn over 4th speed clutch and shaft

assembly, and assemble 7 plates (83), 7
springs (84), and 6 discs (85) in turn.
a It is unstable, so support by hand.
bling.
iv) Install thrust washer (77) and seal ring discs overlap.
(79) to shaft (73).
v) Set with spline of shaft (73) at the top
and support with block.
a It is unstable, so support it by hand.
vi) Install 4th speed clutch gear (137) to
shaft (73).
a 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 and install
snap ring (82).
ly in the groove.
viii) Press fit bearing (75) to shaft.

face of the spacer and the bearing.
clearance "e" between the spacer and
the bearing.
GD555, 655, 675-3C 30-75

(5)
xi) Install snap ring (74) to tip of shaft (73) xv) Using tool D11, pump in air through oil
on opposite side from clutch. hole in shaft and check operation of
a Check that the snap ring is fitted secure- clutch.
ly in the groove. a If the gear at the end where the air is
xii) Install gear (72). pumped in is held in position, the clutch
a Air pressure:
0.5 – 0.6 MPa {5.0 – 6.0 kg/cm2}
xiii) Using press, press fit bearing (71).

face of the bearing and the gear. 2) Using 2 wire ropes, install 4th speed clutch
xiv) Install seal ring (70). assembly (69).
3) Install oil guides (68) and (67).
30-76 GD555, 655, 675-3C

(5)
8. Idler gear (for REVERSE) 8. Idler gear (for REVERSE)

Serial No.: 50001 – 51000 Serial No.: 51001 and up
1) Fit snap ring (66) to gear (65) and install 1) Using the push tool, install outer race (64a)
bearing (64). to gear (65).
a Press fit the outer race of the bearing. a 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.
a Install the spacer with the largely cut in-
side down.
3) Push bearing (64) with spacer (66) and the
push tool to install it to the shaft.
a Align the match mark on the bearing with
that on the outer race installed to the
gear.
2) Install collar (97) to shaft.

3) Assemble gear (65) and bearing (64) into
one unit, then shrink fit to install.
a Shrink-fitting temperature: 100 – 120°
a To prevent damage to the rolling surface
of the bearing, do not hit the bearing un-
der any circumstances.
4) Align the match marks and install gear (65),

then install bearing (64) with the push tool.

4) Fit plate (63) and tighten bolts (62).
3 Bolt:
277 ± 32 N·m {28.25 ± 3.25 kgm}
GD555, 655, 675-3C 30-77

(5)
5) Check that there is clearance a of 0.15 – 4) Install oil seal (35) and dust seal (59).
0.91 mm between the end face of bearing a Coat the area between the oil seal lip
(64) and that of the shaft. surface and oil seal and dust seal with

6) Install plate (63) and tighten bolts (62). silicon grease.
3 Bolt:
(Three Bond 1855 or equivalent)
110.5 ± 12.5 N·m {11.25 ± 1.25 kgm}
5) Install flange (57).

6) Fit plate (49) and tighten bolts (56).
3 Bolt:
9. Fan drive shaft
1) Using push tool , press fit bearing (61) to
shaft (58). 110.5 ± 12.5 N·m {11.25 ± 1.25 kgm}
2) Install shaft (58) to cover. 10. Transmission cover assembly

3) Install snap ring (60). 1) Install bearing (55) and outer races (54) and
a Check that the snap ring is fitted secure- (53) to transmission cover (52) with push
ly in the groove. tool.
30-78 GD555, 655, 675-3C

(5)
2) See diagram below and coat transmission 11. Transmission control valve assembly
2 Mating face of front cover:

case with gasket sealant. 1) Install ECMV (51) to valve seat.
Gasket sealant
(Three Bond 1207B or equivalent)
a Be careful not to let the gasket sealant
be squeezed inside the case; be careful
not to coat with too much gasket sealant.
a Check that there are no scratches or
damage to the front cover.
2) Using eyebolts and guide bolt , set con-

trol valve assembly (50) to transmission
case, and tighten temporarily with mounting
bolts.
3) Using eyebolts and lever block, raise

transmission assembly (52) horizontally.
4) Align outer race and bearing of cover with
each clutch shaft, align spline of fan drive
shaft at same time, then lower cover assem-
bly (52) slowly and install.
5) Tighten mounting bolts of cover assembly
3 Mounting bolt:
(52).
110.5 ± 12.5 Nm {11.25 ± 1.25 kgm}

3) Install case (48) and filter (47) for 2nd, 3rd
speed clutch, then tighten mounting bolts.
a The bolts are of different lengths, so be
careful to install at the correct place.
GD555, 655, 675-3C 30-79

(5)
12. Speed sensor (for detection of transmission 15. Cover, breather

input shaft speed) 1) Install breather (42).
1) Set transmission assembly (46) securely on 2) Install cover (41).
block with torque converter side at top.
16. Oil lubrication tubes
3 Joint bolt:
2) Install speed sensor (45). Install tubes (40) and (39).
a Screw it in until it contacts the gear light-
ly, then turn it back 1/2 – 1 turn and tight- 11.25 ± 1.45 N·m {1.15 ± 0.15 kgm}
3 Locknut:
en with the locknut.
58.8 ± 9.8 N·m {6.0 ± 1.0 kgm}
13. Oil block (torque converter oil outlet)

Install oil block (44).
17. Torque converter lock-up valve, oil pressure

tube
1) Install valve (37) to valve seat (38).
14. Speed sensor (for detection of engine speed)

Install speed sensor (43).
a Screw it in until it contacts the gear lightly,
then turn it back 1/2 – 1 turn and tighten with
3 Locknut:
the locknut.
58.8 ± 9.8 N·m {6.0 ± 1.0 kgm}
30-80 GD555, 655, 675-3C

(5)
2) Install lock-up valve (37) and seat as one 2) Install retainer (32) to case.
unit. 3) Install coupling (31).
3) Install oil pressure tube (36).
20. Worm gear assembly (for speedometer)

18. Torque converter relief valve Install worm gear (30).
1) Install torque converter relief valve assem-
3 Mounting bolt:
bly (34), then tighten 4 mounting bolts.
49 ± 4.9 N·m {5.0 ± 0.5 kgm}
21. Oil lubrication tube, block assembly

Install oil lubrication tube and block assembly
(28).
19. Coupling, retainer

1) Install oil seal (29) and dust seal (33) to
retainer (32).
a Coat the area between the oil seal lip
surface and oil seal and dust seal with
silicon grease.
(Three Bond 1855 or equivalent)
GD555, 655, 675-3C 30-81

(5)
22. Strainer 28. Speed sensor (for detection of transmission

Install strainer (26). output shaft speed)
Install speed sensor (12).
23. Oil temperature sensor (for transmission oil) a Screw it in until it contacts the gear lightly,
Install oil temperature sensor (25). then turn it back 1/2 – 1 turn and tighten with
3 Lock-nut:
the locknut.
24. Oil lubrication tube, wiring harness
1) Install wiring harness (24). 58.8 ± 9.8 N·m {6.0 ± 1.0 kgm}
2) Install block (23).
3) Install tubes (22), (21), (20), (19), (18), (17), 29. Transmission mount (right)
3 Joint bolt:
and (27). Install transmission mount (right) (11).
49 ± 4.9 N·m {5.0 ± 0.5 kgm}
30. Lubrication tube, lubrication hoses

1) Install hoses (9) and (8).
3 Joint bolt:
25. Valve cover, return hose 2) Install tube (10).
1) Install valve cover (16).
2) Install hose (15). 29.4 ± 4.9 N·m {3.0 ± 0.5 kgm}
26. Transmission mount (left)

Install transmission mount (left) (14).
27. Fan pulley

Install fan pulley (13).
30-82 GD555, 655, 675-3C

(5)
31. Gear pump assembly 2) Install fan belt (3), then turn adjustment
1) Install gear pump assembly (7), then tighten screw (2) and adjust fan belt.
mounting bolts.
2) Install suction tube (6).
32. Piston pump assembly

1) Raise piston pump assembly (5) with wire
rope and install, then tighten mounting bolts.
33. Fan assembly

1) Raise bracket portion of fan assembly (4),
set to transmission case, then tighten
mounting bolts.
GD555, 655, 675-3C 30-83

(5)
DISASSEMBLY AND ASSEMBLY REMOVAL OF FINAL DRIVE ASSEMBLY
REMOVAL OF FINAL DRIVE

ASSEMBLY
a To prepare for disassembly and assembly of the 4. Lower work equipment (1) to ground.
final drive assembly, jack up the machine and
support it with strong, stable stands.
a The height of the bottom surface of the main
frame must be approx. 1000 mm.
1. Set stand to front of front frame.
5. Set blocks under 4 rear wheels.
2. Set stand to center of main frame.
6. Remove engine hood assembly.

(For details, see REMOVAL OF ENGINE HOOD
ASSEMBLY.)
7. Drain final drive oil. (Non-spin differential type)

Loosen drain plug (2) and drain oil into con-
3. Set stand to rear of frame. tainer. Remove breather hose (4), then remove
a Lower ripper to ground. oil filler tube (9).
6 EO 30: 17 l
30-84 GD555, 655, 675-3C

(5)
7. Drain differential oil. (With differential lock type) 9. Loosen mounting bolts of universal joint (6)
Loosen drain plug (2) and drain oil into con- between transmission and differential, remove
tainer. Remove differential lock and 2 tempera- universal joint (6), then remove brake hose (7).
ture 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).
a 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 stable pos-
ture where there is no danger. (Remove 4 rear
wheels.)
a 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 be-
fore removing the wheel.
a 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 inter-

mediate thread portion (9). (With differntial lock
type)
GD555, 655, 675-3C 30-85

(5)
12. Remove cover (10) of electric relay system box. 14. After raising final drive assembly (13), use a
(Because mounting bolts and nuts of final drive crane and forklift truck together. Insert forks of
assembly cannot be removed.) lift truck from right side (or left side) of final drive
Remove left and right batteries (11). and remove lifting tool from fork. With left side
of final drive raised, operate crane slowly and
drive lift truck in reverse. When tip of forks is
holding tandem case on left side, check that
forks can support final drive, then remove lifting
tool on left side and use lift truck to remove to
outside of machine. Then raise with crane and
set on stable stand.
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
30-86 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY INSTALLATION OF FINAL DRIVE ASSEMBLY
INSTALLATION OF FINAL
DRIVE ASSEMBLY
1. Raise final drive assembly (13), bring as close
as possible to frame at side of machine (on
either left or right side), then remove lifting tool
at frame side. Use lift truck from opposite side
of machine to support tandem case on side
where lifting tool has been removed, then oper-
ate crane and lift truck together to place at spec-
ified position.
4 Final drive assembly: 2,750 kg
4. Install oil filler tube of final drive to intermediate

thread portion (9), then remove oil filler cap (17)
and fill with oil. (Non-spin differential type)
5 EO 30: 17 l
2. Raise final drive assembly (13), and align posi-

tion of mounting bolt holes.
a To ensure safety during the operation, set a
stand of a height equal to the bottom surface
of the case.
4. Install 2 differential lock solenoid connectors

and 2 oil temperature sensor connectors (3).
Install other 2 hoses (4). Tighten drain plug (2).
(With differential lock type)
3. Keep raised with crane, tighten mounting bolts

(12) and nuts (14) (2 each at left, right, front,
rear: total 8), and install final drive assembly to
main frame.
a Insert the bolts from below, install the nuts
from above, then tighten the bolts from be-
3 Mounting bolt:
low.
2 Mounting bolt:
927 – 1133 N·m {94.5 – 115.5 kgm}
GD555, 655, 675-3C 30-87

(5)
DISASSEMBLY AND ASSEMBLY INSTALLATION OF FINAL DRIVE ASSEMBLY
5. Install universal joint (6) between differential and 8. Install oil filler tube of differential to intermediate
transmission. Install parking brake hose (7). thread portion (9), then remove oil filler cap (17)
a Install the hoses without twisting or interfer- and fill with oil.
5
ence.
EO 30: 17 l
6. Install electric relay system box cover (10) and

left and right batteries (11). 9. Raise wheel (5) and install to final case, then
a After completing the operation, install the tighten 2 nuts and 8 bolts.
battery cables immediately before starting a When lifting the wheel, use a sling and fit it to
the engine. the center of the tire so that the tire does not
3 Mounting bolt:
come out, then lift the wheel.
392 – 490 N·m {40 – 50 kgm}

Target: 441 N·m {45 kgm}
7. Install hoses (8) to front, rear, left, and right of

final brake. Install step (15) and cover (16).

HOOD ASSEMBLY.)
30-88 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FINAL DRIVE ASSEMBLY
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
1. Loosen tandem case oil drain plug (1) and drain 4. Extend cotter pin (8) and pull it out, then remove
oil into container. Remove non-slip pad (2) on plate (9) and push master pin (10) to remove.
step, then remove chain removal covers (3) (2
places at the top) and side covers (4) (inside,
outside, front, rear: 4 places).
6 Tandem case: 80 l
5. Remove chain (11) from sprocket, then pull out

and remove.
2. Using hand pump , 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 , shorten chain.
GD555, 655, 675-3C 30-89

(5)
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FINAL DRIVE ASSEMBLY
7. Raise tandem case (13), remove bolts mounting

to side case (14), then disconnect from side
ASSEMBLY OF FINAL DRIVE
case and set on stable stand. ASSEMBLY
1. Raise final brake case (12) and install front, rear,
3 Mounting bolt:
left, and right.
245 – 309 N·m {26 – 31.5 kgm}
2 Mounting bolt: Coat with LG-1

Target: 277 N·m {28.2 kgm}
8. Raise side case assembly (14), remove bolts

mounting to differential (15), then disconnect
from differential and set on stable stand.
4 Side case: 310 kg
2. Raise right side case (14) and install to tandem
3 Mounting bolt:
case (13).
245 – 309 N·m {26 – 31.5 kgm}
2 Mounting bolt: Coat with LG-1

9. Raise differential 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 mount-
ing to tandem case (13), then disconnect from
tandem case and set on stable stand.
4 Differential: 320 kg
30-90 GD555, 655, 675-3C

(5)
3. Install shaft (16) to side case planetary gear 5. Raise tandem case (13) and install to side case
3 Mounting bolt:
(17), raise differential assembly (15), and install (14).
to side case.
a If the shaft spline does not match, rotate the 245 – 309 N·m {26 – 31.5 kgm}
3 Mounting bolt: 2 Mounting bolt: Coat with LG-1

parking brake disc to align. Target: 277 N·m {28.2 kgm}
245 – 309 N·m {26 – 31.5 kgm}
2 Fitting face of side case:

Adhesive (LOCTITE 515)
6. Insert chain (11) in tandem case (13), and mesh

tip portion with sprocket. Rotate disc of center
brake, wind chain on, then align with master pin
mounting hole (4).
4. Raise left side case (14) and install shaft (16),
then install to differential assembly (15).
a If the shaft spline does not match, rotate the
3 Mounting bolt:
parking brake disc to align.
245 – 309 N·m {26 – 31.5 kgm}

7. Using tool , shorten chain, then install master

pin (10).
GD555, 655, 675-3C 30-91

(5)
8. Install plate (9), then install cotter pin (8) and 11. Tighten drain plug (1) of tandem case, and fill
connect chain. with oil through oil filler (18).
a Assemble the chain so that the front is on the a After filling with oil, rotate the final drive input
inside of the machine and the rear is on the coupling 7 turns, and rotate the disc 1/2 turn
3 Drain plug:
outside. to immerse it in oil.
58.8 – 78.4 N·m {6.0 – 8.0 kgm}

Target: 68.6 N·m {7.0 kgm}
5 Tandem case EO 30: 80 l
9. Use hand pump to release pad of parking

brake (5), then install.
12. After refilling with oil, coat top surface of tandem

case (13), front, rear, left, and right chain mount-
ing holes, covers (3) and gasket (19) with gasket
2 Mounting bolt and gasket:

sealant.
Coat with LG-1
10. Install parking brake. For details of procedure

for adjusting, see TESTING AND ADJUSTING.
a For details of procedure for adjusting parking

brake mount, see TESTING AND ADJUST-
ING.
30-92 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FINAL BRAKE CASE
DISASSEMBLY OF FINAL
BRAKE CASE
1. Remove and install final brake case assembly. 5. Remove guide (14), then remove spring (15).
For details, see REMOVAL, INSTALLATION OF Remove piston (16).
FINAL BRAKE ASSEMBLY.
a 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.
3. Remove brake plate (6) and disc (7).
4. Remove gear (8), then remove shaft (9) from

cage (10).
Remove bearing (11), seal (12), and spacer (13)
from shaft (9).
GD555, 655, 675-3C 30-93

(5)
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FINAL BRAKE CASE
ASSEMBLY OF FINAL BRAKE

CASE
1. Insert O-ring and spacer to shaft (9), press fit oil 4. Coat piston insertion portion inside cage (10)
2 Cage: Coat with G2-LI.

seal (17), then press fit bearing (11). with grease, and assemble piston (16).
a Oil seal space: Fill 80% with grease (G2-LI)
a Bearing: Coat with EO 30.
5. Install brake spring (15) to piston with guide

2. Put cage (10) on stable stand and install disc (14).
wear gauge (18). a Installed length: 60.5 mm
Installed load: 735 N {75 kg}
Free length: 76.5 mm
2 Groove portion of piston and O-ring:

3. Assemble O-ring (19) to brake piston (16).
Coat with G2-LI. 6. Tighten guide (14) to specified torque, and
3 Guide: 49 N·m {5 kgm}

check torque with torque wrench H.
a Guide thread portion: Coat with LT-2.
30-94 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FINAL BRAKE CASE
7. Install cage (10) to shaft (9). Install bleeder (20),
3 Plug: 68.7 ± 9.8 N·m {7 ± 1 kgm}

then install plug (21).
a Before installing bleeder (20), insert mount-

ing bolts (22) connecting to the tandem.
11. Insert collar, and press fit bearing (24).

a Coat the bearing with EO 30.
8. Assemble collar first, then install gear (8).
12. Insert collar and install sprocket (4), then insert
3 Mounting bolt:
shim (3) and install holder (2), then tighten bolt (1).
98 – 123 N·m {10 – 12.5 kgm}

9. Assemble brake plates (6) and discs (7) in turn. a Using push-pull gauge , measure the start-
a Plates: 5 (outside teeth), discs: 4 (inside ing torque of the shaft. Adjust with shims so
teeth) that the preload of the left and right bearings
is within a range of shaft starting torque +11
– 16 N·m {1.15 – 1.65 kgm}.
a Types of shim: 0.1, 0.2, 0.5 mm
10. Install O-rings (23) to inside and outside of cage

(5), then install cage (5) to cage (10).
a For details of adjusting the disc wear gauge,

see TESTING AND ADJUSTING.
GD555, 655, 675-3C 30-95

(5)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF SIDE CASE
DISASSEMBLY OF SIDE CASE

1. Raise side case (1), set sprocket at bottom, then 4. Set side case (1) to press stand, and use press
set on stable stand. Remove center shaft bolt to remove shaft together with bearing. Using
(2), remove plate (3), then remove shim. Lift off press in same way, remove bearing from shaft.
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
5. Remove dowel pin of cage (14) and flange (13),

lift off flange (13), then remove 2 bushings (15).
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).
6. Remove mounting bolts of side case (1) and

cage (14), lift off cage, then remove oil seal (16).
3. Remove collar (10), then remove inside sprocket

(11). Using ring pliers , remove snap ring (12).
30-96 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF SIDE CASE
ASSEMBLY OF SIDE CASE

1. Install oil seal (16) to cage (14), and fill with 4. Knock dowel pins in cage (14) and flange (13)
2 Oil seal lip:

grease. and secure.
Fill 50% of space with G2-LI
5. Coat shaft (20) and bearing (21) with EO-30,

press fit to side case, then install snap ring (12)
2. Install cage (14) to side case (1), coat split with ring pliers .
washer with LM-P, assemble, then install plate
2 Split washer: LM-P

(17) and tighten with bolts (18).
3 Mounting bolt:
98 – 123 N·m {10 – 12.5 kgm}
6. Turn over side case, install ring gear (6), then

secure with 4 dowel pins (22).
3. Install 2 bushings (15) to outside of flange (13),

and assemble collar and oil seal to inside.
Install O-rings (19) to inside and outside of top
2 Oil seal lip:

of flange (13), and insert in side case (1).
GD555, 655, 675-3C 30-97

(5)
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF SIDE CASE
7. Install collar (23), then install eyebolts to plane- 9. Raise side case (1), turn over, and put on stable
tary gear (4), raise planetary gear, and install. stand. Install inside sprocket (11) and insert col-
4
lar (10).
Planetary gear: 45 kg
10. Install to outside sprocket (9), then install shim

8. Insert shim (24) and plate (3), and tighten bolt (2). (25) and plate (8), and tighten bolt (7).
a Install the same thickness of adjustment a Install the same thickness of adjustment
shim as was removed. shim as was removed.
3 Bolt: 490 – 608 N·m {50 – 62 kgm}

Types of shim: 0.1, 0.2, 0.5 mm Types of shim: 0.1, 0.2, 0.5 mm
Target: 549 N·m {56 kgm}
2 Mounting bolt:
3 Bolt: 98 – 123 N·m {10 – 12.5 kgm}

11. Tighten bolt (7) to specified torque.
30-98 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY
DISASSEMBLY OF DIFFEREN-
TIAL GEAR ASSEMBLY
1. Put differential gear case assembly (1) on stable 4. Sling bevel gear (11), and remove left and right
stand, and remove oil supply tube (2), solenoid mounting bolts of bearing gauge (12). Install
valve (3), hose (4), oil temperature sensor (5), guide bolt to differential, screw in forcing screws
and cover (6). Raise differential (1), turn over, (13), then pull out gauge and remove.
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).
2. Remove mounting bolts of parking brake (7), 4 Bevel gear: 90 kg

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, 675-3C 30-99

(5)
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY
ASSEMBLY OF DIFFERENTIAL
GEAR ASSEMBLY
1. Put differential case (15) on stable stand, raise 3. Using guide bolt, install shim (14) on left side.
bevel gear assembly (11), and assemble. Keep Assemble bearing (18) to cage (12), then install
bevel gear raised, and use a guide bolt to install to differential case (15).
shims (14) on right side. a Install the same thickness of adjustment
a Install the same thickness of adjustment shim as was removed.
shim as was removed. a Types of shim: 0.05, 0.1, 0.2, 0.5 mm
a Types of shim: 0.05, 0.1, 0.2, 0.5 mm (The Part Nos. for the left and right shims
4
are different.)
Bevel gear assembly: 90 kg
4. Tighten mounting bolts of right cage (12) to
3 Mounting bolt:
2. Assemble bearing inside cage (16), then insert specified torque.
in spider case (17) and install to differential case
(15). 98 – 113 N·m {10 – 11.5 kgm}
a Coat the bearing roller with EO 30. Target: 111 N·m {11.3 kgm}
Tighten mounting bolts of left cage (16) to speci-
3 Mounting bolt:
fied torque.
98 – 123 N·m {10 – 12.5 kgm}
2 Mounting bolt: Thread tightener (LT-2)

30-100 GD555, 655, 675-3C

(5)
5. Raise pinion assembly (8) and install to differen- 7. Coat coupling mounting bolts (22) with thread
tial case. Install shim (19) to flange portion. tightener, install shim (23) and holder (24), then
(Standard shim thickness: 1.5) tighten bolts (22) to specified torque.
a Types of shim: 0.05, 0.1, 0.2, 0.5 mm (Standard shim thickness: 2.0 mm)
2 Mounting bolt:
3 Mounting bolt:
245 – 309 N·m {25 – 31.5 kgm}

6. Tighten mounting bolts of pinion assembly (8) to

specified torque.
Install coupling (21) to parking brake disc (7),
3 Mounting bolt:
then install to pinion shaft (20).
98 – 123 N·m {10 – 12.5 kgm}

Target: 111 N·m {11.3 kgm} 8. To adjust backlash of bevel gear and pinion
gear, set dial gauge in position, then change
thickness of shim at pinion gear and differential
case mount to adjust.
a Select a shim and adjust.
a Backlash: 0.25 – 0.33 mm
GD555, 655, 675-3C 30-101

(5)
9. To adjust preload and backlash of bevel gear 10. Install nipple (10) for differential lock, then install
and side bearing, use push-pull gauge , and tube (9).
change thickness of shim at left and right of
cage to adjust.
a Adjust the preload with the bevel pinion
meshed. Select shims to adjust so that the
preload is 0.7 – 1.5 N·m {0.07 – 0.15 kgm}
added to the starting torque of the bevel pin-
ion, and the backlash is 0.25 – 0.33 mm.
11. Coat inside of cover (6) with LG-1, and install

gasket, then install cover with bolts. Install mag-
net assembly, spring, and O-ring to oil supply
tube (2), then install solenoid valve (3), oil tem-
perature sensor (5), and hose (4), and tighten
2 Solenoid valve mounting bolt:

drain plug (25) to specified torque.
2 Hose elbow mounting thread:

a The tooth contact is as shown in the diagram Coat with LG-1
below.
2 Cover: Coat with LG-1

A: 46 – 58% of tooth width; Coat with LT-2
3 Cover mounting bolt:

B: 28 – 40% of tooth width
98 – 123 N·m {10 – 12.5 kgm}
3 Oil supply tube mounting bolt:

59 – 74 N·m {6 – 7.5 kgm}
3 Drain plug:
55.8 – 78.4 N·m {6 – 8.0 kgm}

Target: 68.6 N·m {7.0 kgm}
30-102 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF BEVEL GEAR
DISASSEMBLY OF BEVEL
GEAR
1. Remove mounting bolts of brake cage (1), then 4. Remove spider gear assembly (10).
remove cage.
5. Remove 12 bolts of bevel gear case (7), then

2. Remove plate (2), disc (3), gear (4), washer (5), pull out dowel pin (11), and separate bevel gear
and piston (6). (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, 675-3C 30-103

(5)
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF BEVEL GEAR
ASSEMBLY OF BEVEL GEAR
1. Tighten bolts to bevel gear case (7) and bevel 3. Install gear (9) to spider assembly. Install 2
gear (12) temporarily, and knock 4 dowel pins rings (13) to outside of spider gear case (8),
(11) and tighten bolts. then install washer to inside case, and tighten
a After knocking in the dowel pin, caulk at 2 case (8) with bolts.
3 Mounting bolt:
places. a Coat the outside and side surfaces of the
3 Mounting bolt:
ring with LM-P.
157 – 198 N·m {16 – 20 kgm}
Target: 117 N·m {18 kgm} 98 – 123 N·m {10 – 12.5 kgm}
2. Turn over bevel gear case (7) and install spider

gear assembly (10). 4. Turn over bevel gear case (7), assemble seal to
a Coat the inside surface of the bushing of the piston (6), and install.
spider gear with EO 30. a Be careful to assemble the seal facing in the
correct direction.
a Seal direction diagram
30-104 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF BEVEL PINION ASSEMBLY
DISASSEMBLY OF BEVEL
PINION ASSEMBLY
5. Install gear (4), and install plates (2), then install 1. Remove mounting bolts of coupling (1). Remove
discs (3). Install plates and discs in turn. coupling (1), then remove holder, shim, and O-
a Coat both sides of the plates and discs with ring.
EO 30.
2. Set pinion assembly (2) on press stand, and fit

6. Install washer (5) to cage (1). Assemble cage jig to top of shaft (3), then push out shaft (3) with
(1) to bevel gear case, and knock in 4 dowel press.
pins. a When the pinion shaft is removed, the cage
and top bearing will also come off at the
same time.
7. Install cage (1) and tighten with bolts to bevel
3 Mounting bolt:
gear case (7) to specified torque.
3. Remove bearing (4) of pinion shaft (3).
98 – 123 N·m {10 – 12.5 kgm}
GD555, 655, 675-3C 30-105

(5)
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF BEVEL PINION ASSEMBLY
ASSEMBLY OF BEVEL PINION

ASSEMBLY
1. Press fit bearing (4) to pinion shaft (3) with press 3. Install deflector and coupling (1), assemble O-
2 Bearing: Coat with EO 30 2 Mating surface of coupling and seal:

. ring, shim, and holder, then tighten bolts (6).
2 Coupling mounting bolt:

Coat with G2-LI.
3 Coupling mounting bolt:

245 – 309 N·m {25 – 31.5 kgm}

2. Press fit cage (5) and bearing to pinion shaft (3),
2 Bearing: Coat with EO 30

and install seal (6).
2 Oil seal lip:

4. Install torque wrench to coupling mounting

bolt, and measure starting torque.
a Starting torque:
8.73 – 10.69 N·m {0.89 – 1.19 kgm}
30-106 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY REMOVAL OF OPERATOR'S CAB ASSEMBLY
REMOVAL OF OPERATOR'S
CAB ASSEMBLY
1. Remove right side (1) and left side (2) of cover 4. Loosen mounting clamp of air conditioner vent
under cab door. hose (10), then remove hose. Disconnect con-
a There are 2 washer tanks installed to the nectors (12) of electrical system wiring har-
rear left cover. nesses (11).
a Cover the removed connectors with a nylon
bag to prevent the entry of dust or water.
2. Disconnect connectors of motor wiring harness

(5) and hose (4) of washer tank (3).
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 mounting
bolts of left and right step portions of floor at
same time.
4 Operator's cab: Approx. 700 kg

a The 2 mounting bolts at the rear left contact
the case under the floor, so when removing
or installing the cap without removing them,
be careful not to cause damage.
3. Remove operator's seat (6). Remove controller

box (7). Loosen mounting clamp of air condi-
tioner vent hoses (8) and (9), then remove
hoses.
GD555, 655, 675-3C 30-107

(5)
DISASSEMBLY AND ASSEMBLY REMOVAL OF OPERATOR'S CAB ASSEMBLY
6. Remove mounting box (16) of rear air condi-

tioner vent hose (15).
7. Left cover (17) and right cover (18) of work

equipment control levers contact when cap is
removed, so remove cover mounting bolts and
leave covers free.
8. Raise operator's cab assembly (19) and put on

stable stand, horizontally.
4 Operator's cab assembly:

Approx. 700 kg
30-108 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY INSTALLATION OF OPERATOR'S CAB ASSEMBLY
INSTALLATION OF OPERA-
TOR'S CAB ASSEMBLY
1. Install 4 eyebolts to top of operator's cab, raise 3. Insert mounting bolts in left cover (17) and right
cab assembly (19), then set in specified position cover (18) of work equipment control lever.
on cab floor.
4 Operator's cab assembly:

Approx. 700 kg
4. Install box (16) for mounting air conditioner

hose.
2. Keep cab raised, align position of left and right

mounting bolt holes of mounts (13) and (14),
then install bolts and tighten temporarily. Tem-
porarily 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.
a The 2 mounting bolts at the rear left protrude,
so be careful not to damage them.
5. Tighten air conditioner hose (10) with mounting

clamp. Install connectors (12) to electric wiring
harness (11).
a After mating the connectors, check that they
are securely locked.
GD555, 655, 675-3C 30-109

(5)
DISASSEMBLY AND ASSEMBLY INSTALLATION OF OPERATOR'S CAB ASSEMBLY
6. Install air conditioner hoses (8) and (9) and 9. Carry out shower test to check that no water is
tighten clamp. Install controller box (7). Install entering cab from door seal of cab (19), weather
operator's seat (6). strip, and seals.
Check that the wiper works smoothly and stops
at the specified position.
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.
8. Install right (1) and left (2) covers under cab

door.
30-110 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY REMOVAL OF OPERATOR'S CAB FLOOR
REMOVAL OF OPERATOR'S
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.
5. Remove steering filter (7) together with mount-

ing bracket (8).
3. Disconnect connectors of transmission system

wiring harnesses (3) and (4) under right floor.
a Cover the connectors with a nylon bag.
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 mounting bracket
from under floor and remove.
a Before removing the hoses, mark each hose
and its partner with a number to prevent any
mistake when installing.
4. Remove left and right floor mounts (5). Remove nipples after removing them.
ground connection (6). At same time, discon-
nect wiring harness connector CN-B20 (for
improvement of engine starting ability) from
under rear left floor.
GD555, 655, 675-3C 30-111

(5)
DISASSEMBLY AND ASSEMBLY REMOVAL OF OPERATOR'S CAB FLOOR
7. Remove 3 hoses (11) inside orbit motor from 9. Remove mounting cover (16) of speedometer
under left side of floor. (15), then loosen mounting nut (18) of cable (17)
of speedometer (15) from rear, and pull out
cable (17) from bottom side of post stand to bot-
tom surface of floor.
a Wind the cable and nut with plastic tape to
make it easier to remove.
8. Release air conditioner gas, remove cover

under operator's seat, then remove hoses (12)
and (13). Cover mouthpiece, remove hose
clamps under floor, pull down hoses (12) and
(13), loosen hose clamps under floor at rear left
of heater hose (14), remove 2 intermediate 10. Install eyebolts to floor assembly, then lift off
clamps, then remove 2 hoses.. floor assembly (19).
a Prepare a stable stand, set the assembly
horizontally on the stand, and check that
there is no obstruction of the accessories in-
stalled under the floor.
4 Floor assembly: Approx. 260 kg
30-112 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY INSTALLATION OF OPERATOR'S CAB FLOOR
INSTALLATION OF
OPERATOR'S CAB FLOOR
1. Install eyebolts to floor assembly (19), raise floor
assembly, set in position on frame, align holes
for mounting bolts of floor assembly, then lower
assembly and put in contact with frame.
a The 2 mounting bolts at the rear left of the
floor protrude, so be careful not to damage
them.
4 Floor assembly: Approx. 260 kg
4. Pull up air conditioner hoses (12) and (13) from

under floor and install, then install intermediate
clamp of hose to bottom surface of floor. Install
2 heater hoses (14), then install 2 hose interme-
diate clamps to bottom surface of floor.
a Install the hoses without twisting or interfer-
ence.
a After completing the assembly at all points,
fill the air conditioner with gas.
2. Tighten left and right mounting bolts of floor
mount (5) to specified torque. Install chassis
ground connection (6), then install wiring har-
ness connector B20 at rear bottom left. (For
improving ease of starting engine.)
5. Connect 3 hoses (11) inside orbit motor under

floor on left side.
3. Pass cable (17) of speedometer (15) through

center of post stand from under floor, pull up to
meter, insert in rear of meter, then tighten nut
(18). Install mounting cover (16) of meter (15).
a It is easier to pass the cable through if the in-
termediate cover of the post stand is re-
moved.
GD555, 655, 675-3C 30-113

(5)
DISASSEMBLY AND ASSEMBLY INSTALLATION OF OPERATOR'S CAB FLOOR
6. Connect accelerator wire to accelerator linkage 8. Install connectors of transmission system wiring
(10), and install bracket and wire to bottom sur- harnesses (3) and (4).
face of floor. Install hoses (9) of brake line sys- a After mating connectors, check that they are
tem. securely locked.
a Install the hoses without twisting.
9. Connect right control valve (1) and left control

a Adjustment procedure for accelerator control valve (2) to rod of work equipment control lever
1) Set height of pedal stopper bolt to 75 mm with roll pins, then insert beta pin.
from top surface of floor.
2) Set height of pedal to 193 mm, then adjust
length of rod so that engine low idling speed
is 850 ± 50 rpm.
3) Adjust length of rod so that engine governor
lever reaches end of stroke (engine 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 idling (800 ± 50
rpm) to full throttle (2200 ± 50 rpm).
10. Install operator's cab.
7. Install steering filter (7) and bracket (8). (For details, see INSTALLATION OF OPERA-
TOR'S CAB.)
a For details of bleeding air from brake line,

see TESTING AND ADJUSTING.
30-114 GD555, 655, 675-3C

(5)
REMOVAL OF STEERING VALVE (ORBIT-ROLL)
DISASSEMBLY AND ASSEMBLY INSTALLATION OF STEERING VALVE (ORBIT-ROLL)
REMOVAL OF STEERING INSTALLATION OF STEERING

VALVE (ORBIT-ROLL) VALVE (ORBIT-ROLL)
1. Remove cover (1) of post stand, then remove a Carry out installation of the steering valve in the
gauge mounting cover (2), and remove wiring reverse order of removal.
harness and cable of each gauge.
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), and
separate.
GD555, 655, 675-3C 30-115

(5)
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
30-116 GD555, 655, 675-3C

(5)
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, 675-3C 30-117

(5)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF STEERING VALVE
DISASSEMBLY OF STEERING
VALVE
a When disassembling the valve, cleanliness is ex- 3. Remove spacer (5) inside spline on inside of
tremely important. Carry out the work in a clean star of Gerotor (4).
place. Remove Gerotor (4). Be careful not to drop star
a Before removing the piping, remove all dirt and from ring of outer circumference of Gerotor.
dust from around the ports and joints on the out- Remove O-ring (22) from Gerotor.
side circumference of the motor.
a 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 pos-
k Be extremely careful not to injure yourself on the

sible.
edges of sleeves, spools, housing, and other

machined parts.
1. Put end cap (3) at the top, fit side face of hous-
ing between copper sheets in vice , and be
careful not to tighten vice too strongly.
4. Remove drive (8), then remove spacer plate (7).

Remove O-ring (23) from housing.
2. Remove 6 screws (1) and 1 retainer screw (2),

then remove end cap (3). Remove O-ring (22)
from end cap (3).
5. Using flat-headed screwdriver, remove adapter

screw (39). Remove housing from vice, set
upside down, then remove ball (40).
a Be careful not to drop or lose the ball.
30-118 GD555, 655, 675-3C

(5)
6. Set housing upside down, remove 2 springs

(31), 2 retainer lugs (30), and 2 balls (32).
a Be careful not to drop or lose the parts.
9. Remove 2 race bearings (15) and thrust needle

(16).
7. Set on clean cloth with flange surface of housing

facing up to prevent damage to finished surface.
Use flat-headed screwdriver to raise tip of
k The retaining ring may fly out from the housing,

retaining ring (20), then remove from housing.
so always wear protective glasses.
10. Push spline portion inside spool with thumb and

remove spool and sleeve assembly from oppo-
site side of housing flange. When doing this, be
careful not to let outside diameter of sleeve get
caught in inside diameter of housing.
a Depending on the assembly of sleeve and
spool, it may not work properly if it is assem-
8. Set housing on clean cloth with axial line of bled 180° from the proper direction, so make
valve horizontal. marks to show the position of spool and

Turn spool and sleeve assembly to set sleeve sleeve (43). Remove pin (12).
pin in horizontal position, then push out spool
and sleeve assembly slightly, and remove seal so always wear protective glasses.
gland bushing (21) from housing.
Remove oil seal and dust seal from gland bush-
ing.
a When removing the seal, be careful not to
damage the seal gland bushing.
GD555, 655, 675-3C 30-119

(5)
11. Push out spool inside sleeve slightly, and DISASSEMBLY OF OVERLOAD RELIEF VALVE
remove centering spring (13) carefully by hand • Using hexagonal wrench (width across flats: 3/16
from spool. 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).
a The valve seat is stuck to the housing and cannot
be removed.
12. Rotate spool slowly and pull out spool (11) from
sleeve (10).
Remove O-ring from housing.
DISASSEMBLY OF STEERING RELIEF VALVE

• Using hexagonal wrench (width across flats: 3/16
inch), remove plug (28). Remove O-ring (29)
from plug. Using tweezers, remove spring (27)
and poppet (26).
a The valve seat is stuck to the housing and cannot
be removed.
30-120 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF STEERING VALVE
ASSEMBLY OF STEERING
VALVE
a Check all the joining parts. k The centering spring may fly out from the spool,
Parts with gouges or burrs will cause leakage of so always wear protective glasses.
oil, so replace them with new parts. Wash all
metal parts with clean solvent 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
k Be extremely careful not to injure yourself on the

with a file.
edges of sleeves, spools, housing, and other

machined parts.
a As a basic rule, assemble new O-rings and seal
after disassembling. Coat the O-rings with a
small amount of clean grease before assembling. 3. Set housing on clean cloth with axial line of
a The O-rings in front of or behind the spacer plate valve horizontal. Insert spool and sleeve
are of very similar sizes, so check the part assembly from opposite end of housing to
number before opening the seal kit, and be ex- flange end. In this condition, check that spool
tremely careful not to mix them. and sleeve assembly rotates smoothly inside
housing.
1. Turn spool (11) and insert slowly into sleeve a When inserting spool and sleeve assembly,
(10). Grip spline portion of spool and check that be careful not to insert it at an angle and get
spool rotates smoothly inside sleeve. Align it caught. Keep the pin at near the horizontal
mark made when disassembling. position, and rotate slightly to left and right to
insert.
a Insert so that the end face of the spool and
sleeve assembly is level with the end face of
the housing. If it is inserted further, the pin
will fall inside the housing, so stop inserting
when the end face is level.
2. Align 2 spring grooves at 180° in spool and

sleeve, then stand on a horizontal plate. Insert
spring insertion tool (Part No.: 60057) in spring
groove, then fit centering spring to insertion tool
so that notched portions at both ends are at bot-
tom.
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.
GD555, 655, 675-3C 30-121

(5)
4. Place housing on clean flat surface, then a The diagram below is the standard seal
assemble O-ring (17). specification drawing.
Assemble 2 race bearings (15) and thrust nee-
dle (16). Always insert thrust needle between
race bearings.
6. After assembling seals, rotate seal gland bush-

ing (21) and insert to spool. Tap with plastic
hammer to insert to specified position.
a There are two types of seal: Teflon seal and Assemble retaining ring (20) to housing.
standard seal. a Push open with a flat-headed screwdriver so
that the whole circumference of the retaining

5. Assemble dust seal (19) to seal gland bushing ring fits securely in the groove in the housing.
(21). Assemble dust seal so that flat surface is
at seal gland bushing end. Assemble oil seal so always wear protective glasses.
(18) to seal gland bushing.
a Assemble the oil seal carefully so that there
is no twisting or deformation.
a The diagram below is the Teflon seal speci-
fication drawing; (44) is the distinguishing
groove.
a Seal assembly drawing

Screwdriver , dust seal (19), retaining ring
(20), seal gland bushing (21), oil seal (18),
O-ring (17)
30-122 GD555, 655, 675-3C

(5)
ASSEMBLY OF STEERING RELIEF VALVE ASSEMBLY OF ANTI-CAVITATION CHECK VALVE

• Assemble O-ring (29) to plug (28). • Grip the port surface and side surface of the
Using tweezers, assemble spring (27) and pop- housing lightly in a vice. Fit copper sheets in the
pet (26) to housing. vice, and be careful not to tighten the vice too
Using hexagonal wrench (width across flats: 3/ strongly.
16 inch), assemble plug (28) to housing. 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.
a Be careful not to drop or lose the ball. Be
careful of the assembly direction of the re-
tainer plug.
ASSEMBLY OF OVERLOAD RELIEF VALVE

• Assemble O-ring (38) to plug (37). Fit grease to
ball holder (35) and install ball (34).
Using tweezers, assemble ball holder (35) and
spring (36) to housing. Using hexagonal wrench
(width across flats: 3/16 inch), assemble plug
(37) to housing. ASSEMBLY OF GEROTOR END
a The size of the overload valve ball and the • Grip the port surface and side surface of the
anti- cavitation check valve ball is different, housing lightly in a vice. (45): 25 mm. Fit copper
so be careful not to mix them. sheets in the vice, and be careful not to tighten
the vice too strongly.
GD555, 655, 675-3C 30-123

(5)
• Of the 7 bolt holes in the end face of the housing, • Assemble O-ring (22) to Gerotor (4).
insert ball (40) in the holes shown in the drawing.
Assemble adapter screw (39) in holes in same
drawing.
• Set O-ring end at end face of Gerotor (4) at spac-

er plate (7) side, align concave portions (48) of
Gerotor star teeth with pin (12), align with mark
• Assemble O-ring (23) to housing. drawn on end face of drive (8), and assemble.
Set spacer plate (7) on top and align position of When doing this, check carefully that lines A, B,
bolt holes. C, and D are parallel as shown in diagram
a The pitch diameter of the bolt holes and oil below.
holes is different. a Turn Gerotor ring to align bolt holes. Do not
remove mating of drive and Gerotor star.
a The above procedure is important for align-
ing the valve timing.
• Turn spool and sleeve assembly and set pin (12)

and port surface (46) of housing in parallel. In-
sert drive (8) into portion (47), then mate drive
yoke and pin (12). To carry out positioning ex-
actly, use a felt pen to draw line on end face of
drive (8) parallel to pin.
30-124 GD555, 655, 675-3C

(5)
• Assemble spacer (5) to spline inside Gerotor a After tightening to torque given below, install
star. handle to spool and check that spool rotates.
a Do not assemble spacers to 51 cc/rev and 69
cc/rev discharge capacity Orbit-rolls. As- Screw tightening torque
semble 2 spacers to 184 cc/rev discharge
Discharge capacity Tightening torque
capacity Orbit-roll.
(cc/rev) (N·m {kgm})
Assemble O-ring (22) to end cap (3), set on
top of Gerotor, then align bolt holes. Coat 6 51 – 230 22.6 {2.3}
screws (1) and thread of retainer screw 277 23.5 {2.4}
assembly (2) with oil, then assemble to end 369 – 737 28.4 {2.9}
cap.
Install retainer screw assemblies to bolt
holes where adapter screws have already List of capacities and spacers
been assembled. Tighten 7 screws to
Discharge Discharge Spacer
torque of approx. 1.5 kgfm, then tighten in
capacity symbol capacity (cc/rev) thickness (mm)
order to following torque.
A 51
B 69
C 96 3.6
D 120 6.1
E 159 12.2
12.2
G 184
3.6
K 230 22.0
M 277 24.4
P 369 41.1
S 461 53.7
T 553 66.4
• Order for tightening end cap mounting screws is U 737 91.8
as shown in diagram below.
GD555, 655, 675-3C 30-125

(5)
REMOVAL OF BLADE ASSEMBLY
DISASSEMBLY AND ASSEMBLY INSTALLATION OF BLADE ASSEMBLY
REMOVAL OF BLADE INSTALLATION OF BLADE

ASSEMBLY ASSEMBLY
k Start the engine, operate the work equipment 1. Raise center of blade (1), and install right tip of
control levers, raise blade so that bottom is ap- blade to adjuster. Extend blade side shift cylin-
prox. 100 mm from ground, set stable stand to der rod fully, and move position of lifting wire
match height under circle, then lower. while pushing in blade to point where it is possi-
ble to connect cylinder rod.
1. Operate blade control lever and shift blade (1) a Do not coat the rail at the rear of the blade
fully to left. Sling blade, remove mounting bolts with grease.
4
of blade side shift cylinder rod (2), remove rod
head, then operate control lever to retract cylin- Blade assembly: Approx. 755 kg
der rod fully. (differs according to blade)
a After completing operation of the control le-
ver, stop the engine and lock the lever.
2. Install cylinder rod (2) to blade (1) and tighten

mounting bolts to specified torque. Remove
2 Cylinder rod pin hole: Coat with G2-LI

2. Sling blade (1), move position of wire to center stand from under circle.
of blade while pushing blade out, then lift off.
4 Blade assembly: Approx. 755 kg

(differs according to blade)
30-126 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY REMOVAL OF CIRCLE DRAWBAR ASSEMBLY
REMOVAL OF CIRCLE
DRAWBAR ASSEMBLY
1. Remove blade assembly. 4. Disconnect 2 motor hoses (11), 2 side cylinder
For details, see REMOVAL OF BLADE ASSEM- hoses (9), and 2 swivel hoses (10).
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 draw-
bar (1) horizontal, set stand under blade mount-
i ng b r a c k e t, t h e n l ow e r b l a d e . Re m o v e
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-
nect rod (4) from drawbar (1).
5. Sling circle and drawbar, remove mounting 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).
nipples.
GD555, 655, 675-3C 30-127

(5)
DISASSEMBLY AND ASSEMBLY INSTALLATION OF CIRCLE DRAWBAR ASSEMBLY
INSTALLATION OF CIRCLE
DRAWBAR ASSEMBLY
1. Raise circle drawbar assembly and set in posi- 3. Install 2 side cylinder hoses (9), 2 swivel hoses
tion. Insert stud ball (12) at tip of drawbar at (10), and 2 motor hoses (11).
front frame mount, install holder (13) and shim a Install the clamp at right angles to the hose
(14) placed in front of ball, then tighten nut to so that there is no twisting.
specified torque.
a Types of shim: 0.29 mm x 16
2 When assembling stud ball:

Standard shim thickness: 4 – 4.64
2 After assembling stud ball:

Coat with LM-P
3 Mounting nut:
Fill with G2-LI
588.4 – 1029.5 N·m {60 – 105 kgm}
4 Circle drawbar assembly:

Approx. 1,250 kg
4. Install side cylinder hoses (6) and (7), then

install clamp (8).
2. Install cap (3) of drawbar side shift cylinder (2) to

ball joint and tighten bolt to specified torque.
Install left and right caps (5) of blade cylinder
rod (4) to ball joint of drawbar (1) and tighten
2 Ball joint portion: Coat with LM-P

bolt to specified torque. 5. Install blade assembly.
(For details, see INSTALLATION OF BLADE
ASSEMBLY.)
30-128 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY REMOVAL OF BLADE CIRCLE GEAR ASSEMBLY
REMOVAL OF BLADE CIRCLE

GEAR ASSEMBLY
1. Remove blade assembly. 4. Raise lock plate of mounting bolt of pinion gear
( F o r d e t a i l s , s e e R E M O VA L O F B L A D E (13) of circle rotating gear, loosen bolt, remove
ASSEMBLY.) plate (14), shim (15), and joint (19) then remove
pinion gear (13).
2. Operate drawbar side shift control lever, and set a When the bolt is removed, the pinion gear
center of drawbar at bottom surface of front will fall under its own weight, so support it by
frame. Operate blade control lever to set draw- hand when removing.
bar (1) horizontal, set stand to match height
under blade mounting bracket, then lower. Dis-
connect 2 hoses (3) of blade side shift cylinder
(2). Sling cylinder (2), remove 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).
nipples.
4 Side shift cylinder assembly:

Approx. 50 kg
5. Sling circle rotating gear, loosen mounting 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 rotating gear: Approx. 135 kg
3. Disconnect hoses (8) and (9) of power tilt cylin-

der (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
GD555, 655, 675-3C 30-129

(5)
DISASSEMBLY AND ASSEMBLY INSTALLATION OF BLADE CIRCLE GEAR ASSEMBLY
INSTALLATION OF BLADE
CIRCLE GEAR ASSEMBLY
1. Raise circle rotating gear (17) to mounting posi- 3. Install power tilt cylinder mounting bracket (12)
tion at bottom surface of drawbar (18). Align with mounting bolts. Raise power tilt cylinder
mounting bolt position of circle rotating guide (7), install to bracket (12), install pins (10) and
(16), install 6 guides (16), and tighten temporar- (11), fit lock plate, then tighten bolts to tightening
ily. torque. Install hoses (8) and (9).
4
After adjust, tighten fully.
a For details of method for adjusting circle, see Power tilt cylinder assembly:
TESTING AND ADJUSTING. Approx. 20 kg
a After adjusting all parts, check that that all a After installing the bracket, put a stand that
nuts and bolts are tightened to the specified matches the height under the bottom surface
3 Guide mounting bolt:

tightening torque. of the bracket.
2 Circle teeth, guide, top surface of

490 – 608 Nm {50 – 62 kgm}
circle, 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 support (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 rotat-
ing gear, install plate (14) and shim (15), then
tighten mounting bolts to specified torque, bend
lock plate of bolt securely, and lock.
a When installing the pinion gear, be careful
not to let it fall.
(shim thickness: 3 mm)
5. Install blade assembly.

(For details, see INSTALLATION OF BLADE
ASSEMBLY.)
a After completion of the operation, check that
each component works properly.
30-130 GD555, 655, 675-3C

(5)
REMOVAL OF BLADE CIRCLE ROTATION GEAR
DISASSEMBLY AND ASSEMBLY ASSEMBLY (WITH SHEAR PIN)
REMOVAL OF BLADE CIRCLE

ROTATION GEAR ASSEMBLY
(WITH SHEAR PIN)
k Stop the engine and operate the circle rotation 4. Lift off circle gear assembly (3).
control lever to release the residual pressure in
the piping.
1. Disconnect 2 hoses (2) from circle motor (1).

a Plug the removed hoses and nipples.
2. Drive out dowel pin (4) from underside and

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).
a Raise lock plate (5) of the mounting bolts of
holder (6) and remove the mounting bolts.
a When removing the bolts, hold pinion gear
(9) with the hand so that it will not fall.
a Check the thickness and quantity of shims
(7).
GD555, 655, 675-3C 30-131

(5)
INSTALLATION OF BLADE CIRCLE ROTATION
DISASSEMBLY AND ASSEMBLY GEAR ASSEMBLY (WITH SHEAR PIN)
INSTALLATION OF BLADE
ASSEMBLY (WITH SHEAR PIN)
4. Install pinion gear (9), joint (8), and shim (7) in
3 Mounting bolt:
order.
911 – 1,029 Nm {93 – 105 kgm}
5. Install holder (6) with the mounting bolts and
2 Plate (11), pinion gear, and contact

bend lock plate (5) securely.
1. Install pinion gear (9) and joint (8) and fix them face of shaft:
temporarily. Lubricant containing molybdenum
2 Filling for part c at top of pinion gear:

disulfide (LM-P)
2. Measure clearance b between the ends of shaft
(10) and joint (8), and then select shims 0.1 – Grease (G2-LI).
0.5 mm thicker than b.
• Standard shim thickness: 3 mm
• Kinds of shim thickness: 0.2 mm, 0.5 mm,
1.0 mm
3. Make clearance a of the same dimension

between plate (11) and pinion gear (9).
30-132 GD555, 655, 675-3C

(5)
DISASSEMBLY OF BLADE
ASSEMBLY (WITH SHEAR PIN)
1. Draining oil 5. Worm gear and bearing assembly
Remove the drain plug and drain the oil from the 1) Remove worm gear and bearing assembly
circle rotation gear case. (9).
6 Quantity of oil: Approx. 4 l
2. Disconnection of circle rotation gear and

motor
Remove mounting bolts (2) and disconnect cir-
cle rotation gear assembly (3) and motor assem-
bly (4).
a Take care not to drop or lose the motor shaft
key.
3. Cover
Remove cover (5).
2) Remove 2 bearings (11) from shaft (10).
4. Housing
Remove housing (7) and shim (8) from case (6).
a Check the thickness and quantity of shims 6. Worm wheel shaft assembly
(8). 1) Remove worm wheel shaft assembly (12).
a Remove washer (18).
GD555, 655, 675-3C 30-133

(5)
2) Remove gear (14) from shaft (13).

a Remove washer (17).
30-134 GD555, 655, 675-3C

(5)
ASSEMBLY OF BLADE CIRCLE

ROTATION GEAR ASSEMBLY
(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),
2) Install worm gear and bearing assembly (9) press fit bushing (15) to case (6).
to case (6). 2) Using push tool kit (85 mm), press fit oil seal
2 Oil seal lip: Grease (G2-LI)

(16).
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).
a Adjust the shim so that the rotating a Install washer (17).
torque of the worm shaft will be 2.94 –
7.8 Nm {0.3 – 0.8 kgm} to give a preload
to the bearing.
a When measuring the rotating torque,
check that the worm gear is not meshed
with the worm wheel gear.
• Types of shim: 0.1, 0.2, 1.0 mm
2) Check the quantity of the shims, loosen the
bolts on the housing side, and pull the hous-
ing out of the case a little.
a Remove the worm gear and bearing as-
sembly from the outer race of the bear-
ing.
GD555, 655, 675-3C 30-135

(5)
4) Install worm wheel shaft assembly (12).

a Matching the teeth of the worm wheel
gear and worm wheel, tighten the nuts
on the housing side.
a Install washers (17) and (18) to the top
and bottom of the worm wheel shaft as-
sembly.
6. Cover
2 Bolts at 2 through parts of case tap on

Set the O-ring and install cover (5).
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).
a Install the key to the motor assembly shaft.
a Install cover (5) so that oil filler plug (19) will
3 Oil filler plug:

be positioned as shown in the illustration.
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
3 Drain plug:
Circle rotation gear case: 4 l
32.36 – 44.13 Nm {3.3 – 4.5 kgm}
30-136 GD555, 655, 675-3C

(5)
DISASSEMBLY AND ASSEMBLY ASSEMBLY (WITH SLIP CLUTCH)
DISASSEMBLY OF CIRCLE
ROTATING GEAR ASSEMBLY
(WITH SLIP CLUTCH)
1. Remove 2 hoses (2) of circle motor (1). Knock 3. Install eyebolt to circle rotating gear assembly
out 2 dowel pins (4) of circle rotating gear from (3), then raise and set on strong, stable stand.
bottom. Remove 6 mounting bolts of circle Loosen 4 mounting bolts of circle motor (1) and
rotating gear from bottom. remove motor. Loosen 8 mounting bolts of
a Fit male and female plugs into the hoses and cover (8) of circle rotating gear assembly (3),
nipples. then remove cover.
4 Circle rotating 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 pinion gear
(5). It will fall out, so remove it quickly. 4. Pull out 8 mounting bolts of housing (9), then
a When raising the lock plate, support the pin- using 2 forcing screws (10), remove housing.
ion gear by hand to prevent it from falling out
when it is removed.
GD555, 655, 675-3C 30-137

(5)
DISASSEMBLY AND ASSEMBLY ASSEMBLY (WITH SLIP CLUTCH)
5. Remove 3 bolts of circle gear shaft, then remove 8. Separate circle gear (17) and shaft (14).
plate (11) and collar (12). Remove 4 mounting Remove spacer (18) under shaft.
nuts of worm gear bearing cage (13), then
remove cage together with shim.
9. Remove worm gear (19) from gear case, then

remove 2 left and right bearings (20). Turn over
6. Install eyebolts to circle gear shaft (14), and lift gear case, remove oil seal (21), then remove
off gear assembly. Remove belleville spring bushing (22).
(15) and collar (16).
7. Remove 5 plates (18) and 6 discs (19) from cir-

cle gear (17) in order.
30-138 GD555, 655, 675-3C

(5)
ASSEMBLY OF CIRCLE ROTATING GEAR ASSEM-
DISASSEMBLY AND ASSEMBLY BLY (WITH SLIP CLUTCH)
ASSEMBLY OF CIRCLE
ROTATING GEAR ASSEMBLY
(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).
a 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.
a NOTICE: When assembling, coat the whole
surface of the discs (front and rear faces)
with GO#90 oil.
GD555, 655, 675-3C 30-139

(5)
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 tighten shim (25).
nut. a Types of shim: 0.2, 0.5 mm
a To apply the preload to the bearing, adjust
with shims so that the friction torque of the
worm shaft is 2.9 – 7.85 N·m {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).
(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.
a 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
8. Install plate (18) and belleville spring (15) to cir- of cage (9).
cle gear (17), then install lifting tool to shaft,
raise gear assembly, and assemble to gear
case. Using forcing screws, hold housing (9),
and install to gear case.
a When installing housing (9), set with oval
hole (24) in housing facing oil level gauge
side of gear case (rear of machine), then in-
2 Only 2 mounting bolts of cover at

stall. (Relationship with oil filler plug)
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.
a Install the gear case securely to the motor
before installing.
30-140 GD555, 655, 675-3C

(5)
12. Raise circle gear assembly and install to draw- 13. Knock in 2 dowel pins (4), and install 2 hoses (2)
bar, then install pinion gear (5) from bottom, to circle motor (1). Tighten drain plug, remove
install shim (27) and lock plate (6) with 2 bolts, oil filler plug (26), then fill with oil. After filling
install stopper plate (7) to bolt, then tighten to with oil, tighten fully.
specified torque. a After knocking in the dowel pin, caulk the cir-
a Bend lock plate (7) fully to lock in position, cumference at 2 places.
then tighten mounting bolts of rotation as- a When adding oil, set the rotating gear hori-
sembly to specified tightening torque. zontal, and add oil until oil comes out from
3 Drain plug:
a When installing the pinion gear, be careful level plug hole.
not to drop it.
3 Oil filler plug:

a Types of shim at pinion gear portion: 0.2, 0.5, 32.36 – 44.13 N·m {3.3 – 4.5 kgm}
3 4 bolts at dowel pin mounts at front

1.0 mm (Standard: 3.0 mm).
73.5 – 122.6 N·m {7.5 – 12.5 kgm}
5
and rear of machine:
3 2 bolts at left and right of machine:

911.4 – 1029 N·m {93 – 105 kgm} GO #90: Approx. 7 l
490.3 – 608 N·m {50 – 62 kgm}
a For details of the procedure for adjusting the

slip clutch, see TESTING AND ADJUSTING
GD555, 655, 675-3C 30-141

(5)
90 OTHERS
TRANSMISSION HYDRAULIC CIRCUIT (Serial No.: 50001 – 51000) ........................................................90- 3

TRANSMISSION HYDRAULIC CIRCUIT (Serial No.: 51001 and up) ..........................................................90- 5
HYDRAULIC CIRCUIT DIAGRAM (Serial No.: 50001 – 51000)...................................................................90- 7
HYDRAULIC CIRCUIT DIAGRAM (1/2) (Serial No.: 51001 and up) ............................................................90- 9
HYDRAULIC CIRCUIT DIAGRAM (2/2) (Serial No.: 51001 and up) ...........................................................90- 11
ELECTRICAL CIRCUIT DIAGRAM (1/6) (Serial No.: 50001 – 51000) .........................................................90- 13
ELECTRICAL CIRCUIT DIAGRAM (1/6) (Serial No.: 51001 and up) ...........................................................90- 25
GD555, 655, 675-3C 90-1

(4)
TRANSMISSION HYDRAULIC CIRCUIT (Serial No.: 50001 – 51000)
Serial No.: 50001 – 51000
2. Strainer
3. Transmission pump
4. Oil filter
6. Torque converter relief valve
7. Torque converter
8. Oil cooler
9. Transmission lubrication
10. PTO lubrication
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 clutch lubrication
34. R clutch lubrication
35. FH clutch lubrication
GD555, 655, 675-3C 90-3

(4)
TRANSMISSION HYDRAULIC CIRCUIT (Serial No.: 51001 and up)
2. Strainer
3. Transmission pump
4. Oil filter
6. Torque converter relief valve
7. Torque converter
8. Oil cooler
9. Transmission lubrication
10. PTO lubrication
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 clutch lubrication
34. R clutch lubrication
35. FH clutch lubrication
GD555, 655, 675-3C 90-5

(4)
HYDRAULIC CIRCUIT DIAGRAM (Serial No.: 50001 – 51000)
Serial No.: 50001 – 51000
GD555, 655, 675-3C 90-7

(4)
HYDRAULIC CIRCUIT DIAGRAM (1/2) (Serial No.: 51001 and up)
GD555, 655, 675-3C 90-9

(8)
HYDRAULIC CIRCUIT DIAGRAM (2/2) (Serial No.: 51001 and up) 1. For GD655, 675-3C: Serial No. 50001 – 51000
2. For GD655, 675-3C: Serial No. 51001 and up
GD555, 655, 675-3C 90-11

(4)
ELECTRICAL CIRCUIT DIAGRAM (1/6) (Serial No.: 50001 – 51000)
Serial No.: 50001 – 51000
GD555, 655, 675-3C 90-13

(4)
Serial No.: 50001 – 51000
GD555, 655, 675-3C 90-15

(4)
Serial No.: 50001 – 51000
GD555, 655, 675-3C 90-17

(4)
Serial No.: 50001 – 51000
GD555, 655, 675-3C 90-19

(4)
Serial No.: 50001 – 51000
GD555, 655, 675-3C 90-21

(4)
Serial No.: 50001 – 51000
GD555, 655, 675-3C 90-23

(4)
ELECTRICAL CIRCUIT DIAGRAM (1/6) (Serial No.: 51001 and up)
GD555, 655, 675-3C 90-25

(4)
GD555, 655, 675-3C 90-27

(4)
GD555, 655, 675-3C 90-29

(4)
GD555, 655, 675-3C 90-31

(4)
GD555, 655, 675-3C 90-33

(4)
GD555, 655, 675-3C 90-35

(4)

Shop Manual GD555-3C

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Shop Manual GD555-3C

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SEBM020908

MACHINE MODEL SERIAL NUMBER

GD655-3C 00 50001 and up 00

GD675-3C 00 50001 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, 675-3C

( ) Page to be deleted Discard

Pages having no marks are not revised at this

LIST OF REVISED PAGES

Revision Revision Revision Revision Revision

GD555, 655, 675-3C 00-2-1

00-2-2 GD555, 655, 675-3C

GD555, 655, 675-3C 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

–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0