Komatsu Motor Graders GD500R, GD505R, GD505A, GD510, GD520 Repair Service Manual + Operation Maintenance Manuals
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Motor Graders GD500R, GD505R, GD505A, GD510, GD520, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Motor Graders GD500R, GD505R, GD505A, GD510, GD520 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 2,936 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
COVER...1
CONTENTS...2
10 ENGINE...25
12 TESTING AND ADJUSTING...26
TABLE OF JUDGEMENT STANDARD VALUE...27
TESTING AND ADJUSTING TOOL LIST...31
ADJUSTING VALVE CLEARANCE...32
MEASURING COMPRESSION PRESSURE...34
TESTING AND ADJUSTING FUEL INJECTION TIMING...36
BLEEDING AIR-FROM FUEL SYSTEM...39
ENGINE SPEED CONTROL...40
13 DISASSEMBLY AND ASSEMBLY...41
RADIATOR...42
REMOVAL...42
INSTALLATION...42
RADIATOR ASSEMBLY...44
REMOVAL...44
INSTALLATION...44
FUEL TANK(INCL.HYDRAULIC TANK)ASSEMBLY...46
REMOVAL...46
INSTALLATION...48
20 POWER TRAIN...54
21 STRUCTURE AND FUNCTION...55
GENERAL...56
POWER TRAIN...57
HYDROSHIFT TRANSMISSION PIPING...59
HYDROSHIFT TRANSMISSION CONTROL...60
POWER TRAIN HYDRAULIC CIRCUIT SCHEMATICS...61
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM...62
PTO...63
HYDROSHIFT TRANSMISSION...65
TRANSFER...70
TRANSMISSION CONTROL VALVE...72
POWER TRAIN...80
MAIN CLUTCH...81
TRANSMISSION...82
HYDROSHIFT TRANSMISSION PUMP...84
FINAL DRIVE...86
FINAL DRIVE,DIFFERENTIAL LOCK AND UNLOCK PIPING...94
TANDEM DRIVE...96
22 TESTING ADJUSTING...98
TABLE OF JUDGEMENT STANDARD VALUE...99
TOOL LIST FOR TESTING AND ADJUSTING...100
INCHING PEDAL TRAVEL AND OPERATING FORCE...101
MAIN CLUTCH...103
TRANSMISSION CONTROL LEVER TRAVEL AND OPERATING FORCE...106
CHECKING OIL PRESSURE...107
MACHINE TYPE AND INCHING PRESSURE...109
TRANSMISSION CONTROL LEVER TRAVEL AND OPERATING FORCE...110
CLEARANCE DIFFERENTIAL LOCKING DEVICE OIL PRESSURE...111
23 DISASSEMBLY AND ASSEMBLY...112
ENGINE(INCL.TRANSMISSION)ASSEMBLY...113
REMOVAL...113
INSTALLATION...117
MAIN CLUTCH ASSEMBLY...135
REMOVAL...135
INSTALLATION...135
MAIN CLUTCH CASE ASSEMBLY...137
DISASSEMBLY...137
ASSEMBLY...137
MAIN CLUTCH ASSEMBLY...139
DISASSEMBLY...139
ASSEMBLY...139
MAIN CLUTCH BOOSTER ASSEMBLY...141
DISASSEMBLY...141
ASSEMBLY...141
TRANSMISSION ASSEMBLY...143
REMOVAL...143
INSTALLATION...147
DISASSEMBLY...151
ASSEMBLY...157
SHIFTING FORK COVER ASSEMBLY...163
DISASSEMBLY...163
ASSEMBLY...163
TRANSMISSION...165
DISASSEMBLY...165
ASSEMBLY...178
LOW SPEED ROTATING CLUTCH...194
DISASSEMBLY...194
ASSEMBLY...197
INTERMEDIATE SHAFT ROTATING CLUTCH...200
DISASSEMBLY...200
ASSEMBLY...203
CAGE AND CARRIER...206
DISASSEMBLY...206
ASSEMBLY...207
TRANSMISSION CASE...208
DISASSEMBLY...208
ASSEMBLY...209
PLANETARY GEAR...210
DISASSEMBLY...210
ASSEMBLY...210
TRANSMISSION PUMP...211
REMOVAL...211
INSTALLATION...211
TANDEM AND FINAL DRIVE...215
REMOVAL...215
INSTALLATION...215
TANDEM,FINAL DRIVE ASSEMBLY...217
REMOVAL...217
INSTALLATION...217
FINAL DRIVE...221
DISASSEMBLY...221
ASSEMBLY...225
TANDEM,FINAL DRIVE ASSEMBLY...231
DISASSEMBLY...231
ASSEMBLY...235
SIDE CASE ASSEMBLY...243
DISASSEMBLY...243
ASSEMBLY...243
BEVEL GEAR ASSEMBLY...245
DISASSEMBLY...245
ASSEMBLY...245
PINION ASSEMBLY...255
DISASSEMBLY...255
ASSEMBLY...255
24 MAINTENANCE STANDARD...257
PTO...258
MAIN CLUTCH...262
TRANSMISSION...265
HYDROSHIFT TRANSMISSION...266
TRANSFER...270
HYDROSHIFT TRANSMISSION CONTROL VALVE...272
TRANSMISSION PUMP...277
FINAL DRIVE...279
TANDEM DRIVE...283
40 STEERING SYSTEM...284
41 STRUCTURE AND FUNCTION...285
STEERING PIPING...286
STEERING CIRCUIT DIAGRAM...287
STEERING CONTROL VALVE...288
FRONT AXLE...293
STEERING CYLINDER...298
WHEEL...299
42 TESTING AND ADJUSTING...303
TABLE OF JUDGEMENT STANDARD...304
TOOL LIST FOR TESTING AND ADJUSTING...305
CHECKING STEERING WHEEL...306
CHECKING TIRE RUNOUT...307
CHECKING TIRE INFLATION PRESSURE...307
CHECKING TOE-IN...308
43 DISASSEMBLY AND ASSEMBLY...309
FRONT AXLE ASSEMBLY...310
REMOVAL...310
INSTALLATION...310
FRONT AXLE ASSEMBLY...312
DISASSEMBLY...312
ASSEMBLY...318
STEERING VALVE...324
DISASSEMBLY...324
ASSEMBLY...328
DOUBLE RELIEF VALVE...332
DISASSEMBLY...332
ASSEMBLY...332
44 MAINTENANCE STANDARD...334
FRONT AXLE...335
STEERING CYLINDER...339
50 BRAKE SYSTEM...340
51 STRUCTURE AND FUNCTION...341
BRAKE PIPING...342
BRAKE CIRCUIT DIAGRAM...343
BOOST MASTER...344
BRAKE AIR PIPING...347
AIR BRAKE CIRCUIT SCHEMATICS...348
AIR BRAKE CIRCUIT DIAGRAM...349
BRAKE VALVE...350
AIR COMPRESSOR...354
AIR GOVERNOR...355
CHECK VALVE...356
AIR TANK...357
SAFETY VALVE...357
AUTOMATIC DRAIN VALVE...358
AIR DRIER...360
WHEEL BRAKE...362
PARKING BRAKE...365
52 TESTING AND ADJUSTING...367
TABLE OF JUDGEMENT STANDARD VALUE...368
TOOL LIST FOR TESTING AND ADJUSTING...368
CHECKING BRAKE PEDAL...369
AIR BLEEDING FROM BRAKE CIRCUIT...371
CHECKING PARKING BRAKE LEVER...372
CHECKING WEAR OF BRAKE DISC...373
53 DISASSEMBLY AND ASSEMBLY...374
WHEEL BRAKE...375
REMOVAL...375
INSTALLATION...375
WHEEL BRAKE ASSEMBLY...377
REMOVAL...377
INSTALLATION...377
DISASSEMBLY...381
ASSEMBLY...385
BOOST MASTER...391
DISASSEMBLY...391
ASSEMBLY...393
PARKING BRAKE...395
REMOVAL AND DISASSEMBLY...395
INSTALLATION AND ASSEMBLY...395
54 MAINTENANCE STANDARD...398
WHEEL BRAKE...399
PARKING BRAKE...401
BOOST MASTER...403
60 HYDRAULIC SYSTEM...404
61 STRUCTURE AND FUNCTION...405
HYDRAULIC CONTROL PIPING...406
HYDRAULIC CONTROL LINKAGE...417
BLADE ACCUMULATOR SYSTEM ...419
HYDRAULIC CIRCUIT DIAGRAM...421
FLOW DIVIDER...424
HYDRAULIC PUMP...425
CIRCLE ROTATION MOTOR...427
WORK EQUIPMENT CONTROL VALVE...433
PILOT CHECK VALVE...440
HYDRAULIC CYLINDER...444
63 DISASSEMBLY AND ASSEMBLY...447
HYDRAULIC PUMP(INCL.STEERING PUMP)...448
REMOVAL...448
INSTALLATION...448
BLADE LIFT CYLINDER...450
REMOVAL...450
INSTALLATION...450
DRAWBAR SHIFT CYLINDER...452
REMOVAL...452
INSTALLATION...452
ARTICULATE CYLINDER...452
REMOVAL...452
INSTALLATION...452
BLADE SIDE SHIFT CYLINDER...454
REMOVAL...454
INSTALLATION...454
BLADE SIDE SHIFT CYLINDER ASSEMBLY...456
REMOVAL...456
INSTALLATION...456
SCARIFIER CYLINDER ASSEMBLY...458
REMOVAL...458
INSTALLATION...458
LEANING CYLINDER...458
REMOVAL...458
INSTALLATION...458
POWER TILT CYLINDER...460
REMOVAL...460
INSTALLATION...460
REAR MOUNT RIPPER CYLINDER ASSEMBLY...460
REMOVAL...460
INSTALLTION...460
HYDRAULIC CYLINDER ASSEMBLY...462
DISASSEMBLY...462
ASSEMBLY...466
CIRCLE ROTATION MOTOR...474
DISASSEMBLY...474
ASSEMBLY...480
64 MAINTENANCE STANDARD...494
HYDRAULIC PUMP...495
HYDRAULIC CONTROL VALVE...497
HYDRAULIC CYLINDER...501
70 WORK EQUIPMENT...507
71 STRUCTURE AND FUNCTION...508
DRAWBAR AND LIFTER...509
BLADE...513
CIRCLE ROTATION GEAR...517
SCARIFIER...518
REAR MOUNT RIPPER...519
FRAME...520
72 TESTING AND ADJUSTING...522
TABLE OF JUDGEMENT STANDARD VALUE...523
TOOL LIST FOR TESTING AND ADJUSTING...527
CHECKING CONTROL LEVER...528
CHECKING HYDRAULIC OIL TRMPERATURE...529
CHECKING HYDRAULIC OIL PRESSURE...529
HYDRAULIC DRIFT...531
CHARGING BLADE ACCUMULATOR WITH GAS...532
ADJUSTMENT OF CIRCLE GUIDE...533
73 DISASSEMBLY AND ASSEMBLY...534
BLADE ASSEMBLY...535
REMOVAL...535
INSTALLTION...535
CIRCLE ROTATION GEAR...537
REMOVAL...537
INSTALLATOIN...537
DISASSEMBLY...539
ASSEMBLY...541
REAR MOUNT RIPPER ASSEMBLY...543
REMOVAL...543
INSTALLATION...543
74 MAINTENANCE STANDARD...545
DRAWBAR AND LIFTER...546
BLADE...550
CIRCLE ROTATION GEAR...551
SCARIFIER...552
REAR MOUNT RIPPER...553
80 ELECTRIC AND ELECTRONIC SYSTEM...554
81 STRUCTURE AND FUNCTION...555
ELECTRICAL CIRCUIT DIAGRAM...556
CIRCUIT DIAGRAM OF CAB...560
ELECTRONIC VEHICLE MONITORING SYSTEM(EVMS)...562
ADJUSTING SPEEDOMETER MODULE OF MACHINE MONITOR...567
82 TESTING AND ADJUSTING...572
TABLE OF MONITOR REFERENCE VALUES...573
ELECTRICAL WIRING DIAGRAM...576
POSITION OF CONNECTOR...578
CONNECTOR TERMINAL NUMBER...586
PRECAUTION WHEN HANDLING CONNECTOR...591
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART...593
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (D TYPE) (M-1 TO M-18)...594
M-1 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL DISPLAY DOES NOT APPEAR...595
a) NONE OF MONITOR PANEL WORKS...595
b) PART OF MONITOR PANEL DOES NOT WORK...595
M-2 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL DISPLAY DOES NOT GO OUT...595
a) MONITOR MODULE DOES NOT GO OUT ...595
b) GAUGE MODULE DOES NOT GO OUT ...595
c) SPEEDOMETER MODULE DOES NOT GO OUT ...595
M-3 WHEN STARTING SWITCH IS TURNED ON,(DO NOT START ENGINE),CHECK BEFORE STARTING ITEMS FLASH OR PREHEATING ITEM LIGHTS UP...596
a) COOLANT LEVEL...596
b) ENGINE OIL LEVEL...596
c) PREHEATER...597
M-4 WHEN STARTING SWITCH IS TURNED ON,(ENGINE STARTED),CHECK BEFORE STARTING ITEMS FLASH...598
a) ALTERNATOR SYSTEM...598
b) ENGINE OIL PRESSURE CIRCUIT...598
M-5 WHEN STARTING SWITCH IS TURNED ON,(DO NOT START ENGINE),CAUTION ITEMS FLASH...599
M-6 WHEN STARTING SWITCH IS ON(ENGINE STARTED),CAUTION ITEMS FLASH...600
a) ENGINE OIL PRESSURE...600
b) COOLANT LEVEL...600
c) COOLANT TEMPERATURE...601
d) BATTERY CHARGE...601
e) FINAL OIL TEMPERATURE...602
f) AIR PRESSURE...602
g) PARKING BRAKE...603
M-7 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK...604
M-8 NO DISPLAY IS GIVEN FOR FUEL LEVEL...604
M-9 ENGINE COOLANT TEMPERATURE IS HIGH,BUT LOWEST LEVEL DISPLAYED...605
M-10 ENGINE COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY ...605
M-11 TURN SIGNAL LAMPS,HIGH BEAM LIGHT UP ABNORMALLY,OR DO NOT LIGHT UP...606
a) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) LIGHT UP...606
b) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) LIGHT UP...606
c) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHTS UP...606
d) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) DOES NOT LIGHTS UP...607
e) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP...607
f) HIGH BEAM PILOT LAMP DOES NOT GO OUT ...607
M-12 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY...608
M-13 WHEN ENGINE IS STARTED,SERVICE METER DOES NOT MOVE.WHEN ENGINE IS STOOPED,SERVICE METER MOVES...609
a) SERVICE METER DOES NOT MOVE...609
b) SERVICE METER DOES NOT STOP MOVING...609
M-14 MONITOR PANEL LAMPS DO NOT LIGHT UP...610
a) NO LAMPS ON PANEL LIGHT UP...610
b) SOME LAMPS ON PANEL DO NOT LIGHT UP...610
M-15 CENTRAL WARNING LAMP DOES NOT GO OUT...611
a) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING LAMP LIGHTS UP INTERMITTENTLY...611
b) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY...611
M-16 CENTRAL WARNING BUZZER DOES NOT STOP...612
a) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY...612
b) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY...612
M-17 EMERGENCY ITEM OR NON-EMERGENCY ITEMS IS FLASHING,BUT WARNING LAMP DOES NOT FLASH...613
M-18 EMERGENCY ITEM IS FLASHING,BUT ALARM BUZZER DOES NOT SOUND...614
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM(M,N TYPE) (M-1 TO M-22)...622
M-1 MONITOR PANEL PILOT LAMPS DO NOT LIGHT UP FOT 3 SECONDS WHEN STARTING SWITCH IS TURNED ON...623
a) NO LAMPS ON MONITOR PANEL (MONITOR MODULE) LIGHT UP...623
b) NO LAMPS ON MONITOR PANEL (SPEEDOMETER MODULE) LIGHT UP...623
c) SOME LAMPS ON MONITOR PANEL DO NOT LIGHT UP...623
M-2 WHEN STARTING SWITCH IS TURNED ON,ALL MONITOR PANEL LAMPS LIGHT UP BUT DO NOT GO OUT...623
M-3 WHEN STARTING SWITCH IS TURNED ON (WITH ENGINE STOPPED),CHECK ITEMS FLASH...625
a) RADIATOR WATER LEVEL FLASHES...625
b) ENGINE OIL LEVEL FLASHES...626
M-4 PREHEATING IS NOT BEING CARRIED OUT,BUT PREHEATING DISPLAY FLASHES...627
M-5 WHEN STARTING SWTICH IS TURNED ON AND ENGINE IS STARTED,CHECK ITEMS FLASH...628
a) ALTERNATOR SYSTEM...628
b) ENGINE OIL PRESSURE SYSTEM...629
M-6 WHEN STARTING SWITCH IS TURNED ON (WITH ENGINE STOPPED),CAUTION ITEMS FLASH...630
M-7 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,CAUTION ITEMS FLASH...632
a) ENGINE OIL PRESSURE FLASHES...632
b) RADIATOR WATER LEVEL FLASHES...633
c) ENGINE WATER TEMPERATURE FLASHES...633
d) CHARGE FLASHES...634
e) FINAL DRIVE OIL TEMPERATURE FLASHES...635
f) AIR PRESSURE FLASHES...636
g) PARKING BRAKE FLASHES...637
M-8 FOR ONE SECOND AFTER STARTING SWITCH IS TURNED ON (ENGINE STOPPED),ALARM BUZZER DOES NOT SOUND.CAUTION ITEM LAMPS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND...638
M-9 THERE IS NO ABNORMALITY ON MONITOR DISPLAY,BUT ALARM BUZZER SOUNDS...638
M-10 FOR TWO SECONDS AFTER STARTING SWITCH IS TURNED ON (ENGINE STOPPED),WARNING LAMP DOES NOT LIGHT UP.CAUTION ITEM LAMPS ARE FLASHING BUT WARNING LAMP DOES NOT LIGHT UP...639
M-11 THERE IS NO ABNORMALITY ON MONITOR DISPLAY,BUT WARNING LAMP LIGHTS UP...639
M-12 MONITOR PANEL LIGHTING DOES NOT LIGHT UP...641
a) NO PANEL LIGHTIN LIGHTS UP...641
b) PART OF PANEL LIGHTING DOES NOT LIGHT UP...641
M-13 SERVICE METER DOES NOT MOVE WHEN ENGINE IS STARTED;OR SERVICE METER MOVES WHEN ENGINE IS STOPPED.(FOR MACHINES WITH SPEEDOMETER)...642
a) SERVICE METER DOES NOT MOVE WHEN ENGINE IS STARTED...642
b) SERVICE METER MOVES WHEN ENGINE IS STOPPED...642
M-14 ENGINE WATER TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE...644
M-15 ENGINE WATER TEMPERATURE GAUGE SHOWS NO DISPLAY...644
M-16 FUEL GAUGE ALWAYS SHOWS FULL...645
M-17 NO DISPLAY IS GIVEN FOR FUEL LEVEL GAUGE...645
M-18 HIGH BEAM DOES NOT LIGHT UP...647
M-19 HIGH BEAM STAYS LIGHTED UP...647
M-20 TURN SIGNAL INDICATOR DOES NOT LIGHT UP...648
M-21 TURN SIGNAL INDICATOR STAYS LIGHTED UP...648
M-22 SPEED DISPLAY STAYS AT "0" AND DOES NOT MOVE...650
COVER...1
FOREWORD...2
BREAKING IN YOUR NEW MACHINE...3
CONTENTS...4
SAFETY HINTS...5
GENERAL LOCATIONS...9
OPERATOR'S COMPARTMENT...11
INSTRUMENTS AND CONTROLS...13
CHECK BEFORE STARTING...24
OPERATING YOUR MACHINE...31
WORKS TO BE CARRIED OUT BY A MOTOR GRADER...45
OPERATING OF WORK EQUIPMENT...49
REPLACEMENT OF CUTTING EDGE AND END BIT...61
CHANGING TIRES...62
DRIVING ALONG ROAD...64
HANDLING OF BATTERY...65
TRANSPORTATION...68
PERIODIC MAINTENANCE...70
GENERAL PRECAUTIONS FOR MAINTENANCE...71
PERIODICAL REPLACEMENT OF SAFETY PARTS...73
MAINTENANCE TABLE...74
EVERY 50 HOURS SERVICE...82
EVERY 250 HOURS SERVICE...85
EVERY 500 HOURS SERVICE...99
EVERY 1000 HOURS SERVICE...103
EVERY 2000 HOURS SERVICE...111
EVERY 4000 HOURS SERVICE...116
WHEN REQUIRED...117
ADJUSTMENT...123
TROUBLE SHOOTING GUIDE...127
WEAR PARTS...130
COLD WEATHER OPERATION...131
STORAGE...136
SERVICE METER...138
MACHINE AND ENGINE SERIAL NUMBERS...139
SPECIFICATIONS...140
FUEL AND LUBRICANTS...142
