Komatsu Motor Grader GD825A Repair Service Manual + Operation Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Motor Grader GD825A , with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Motor Grader GD825A 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: 2,717 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
01 GENERAL...47
SPECIFICATION DIMENSION DRAWINGS ...48
SPECIFICATIONS ...50
WEIGHT TABLE ...53
FUEL, COOLANT AND LUBRICANTS ...54
10 STRUCTURE AND FUNCTION...57
GENERAL ...58
POWER TRAIN DIAGRAM ...59
JOINT ...60
HYDROSHIFT TRANSMISSION AND TRANSFER PIPING...61
HYDRAULIC CIRCUIT FOR POWER TRAIN ...62
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN ...63
PTO (POWER TAKE OFF) ...66
HYDROSHIFT TRANSMISSION AND TRANSFER ...68
TRANSMISSION CONTROL VALVE ...76
TRANSMISSION CONTROL ...104
INCHING CONTROL ...112
DRIVE SHAFT ...113
FINAL DRIVE, DIFFERENTIAL LOCK AND UNLOCK PIPING...114
FINAL DRIVE...116
TANDEM DRIVE ...119
STEERING PIPING ...121
STEERING CIRCUIT SYSTEM ...122
STEERING CIRCUIT DIAGRAM ...123
STEERING VALVE ...124
DOUBLE RELIEF VALVE ...128
CHECK VALVE ...129
EMERGENCY STEERING SYSTEM ...130
FRONT AXLE ...131
WHEEL ...135
DISC BRAKE ...138
PARKING BRAKE ...140
BRAKE AIR PIPING...142
BRAKE AIR CIRCUIT SYSTEM ...143
BRAKE AIR CIRCUIT DIAGRAM ...144
AIR DRIER ...145
AIR GOVERNOR ...147
AIR TANK ...149
SAFETY VALVE ...149
AUTOMATIC DRAIN VALVE ...150
CHECK VALVE ...152
BRAKE VALVE ...153
PARKING BRAKE SYSTEM ...157
PARKING BRAKE SOLENOID VALVE ...158
EXHAUST VALVE ...159
SPRING CYLINDER ...160
HYDRAULIC CONTROL PIPING ...161
HYDRAULIC CIRCUIT SYSTEM ...169
HYDRAULIC CIRCUIT DIAGRAM ...171
CLOSED CENTER LOAD SENSING SYSTEM (CLSS) ...183
HYDRAULIC PUMP ...187
PRIORITY FLOW DIVIDER VALVE ...192
SURGE PRESSURE ABSORBING VALVE ...198
HYDRAULIC CONTROL VALVE ...201
PRESSURE COMPENSATING MECHANISM OF HYDRAULIC CONTROL VALVE ...205
BLADE LIFT SPEED ADJUSTMENT MECHANISM ...211
PILOT CHECK VALVE ...213
PILOT CHECK VALVE (WITH SAFETY VALVE) ...215
CIRCLE ROTATION MOTOR ...217
BLADE ACCUMULATOR SYSTEM ...220
BLADE FLOAT SYSTEM ...222
DRAWBAR AND LIFTER ...223
BLADE ...227
LIFTER BRACKET CONTROL PIPING ...229
CIRCLE ROTATION GEAR...230
REAR MOUNT RIPPER ...232
HYDRAULIC CONTROL LINKAGE ...233
MAIN FRAME...235
AIR CONDITIONER...237
ELECTRICAL WIRING DIAGRAM...240
MONITOR PANEL, CLUSTER GAUGE AND PILOT LAMP ...245
ELECTRICAL CIRCUIT DIAGRAM...247
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) ...275
TRANSMISSION CONTROL SYSTEM ...281
SENSORS...287
ENGINE STARTING CIRCUIT...294
ENGINE STOPPING CIRCUIT...302
20 TESTING AND ADJUSTING...309
STANDARD VALUE TABLE FOR ENGINE ...311
STANDARD VALUE TABLE FOR CHASSIS ...314
TOOL LIST FOR TESTING AND ADJUSTING ...320
TESTING AND ADJUSTING VALVE CLEARANCE ...322
MEASURING COMPRESSION PRESSURE ...323
TESTING AND ADJUSTING FUEL INJECTION TIMING ...324
MEASURING BLOW-BY PRESSURE ...328
MEASURING ENGINE OIL PRESSURE ...329
MEASURING EXHAUST GAS COLOR ...330
MEASURING EXHAUST GAS TEMPERATURE...331
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) ...332
TESTING AND ADJUSTING BELT TENSION ...333
PROCEDURE FOR ADJUSTING THE ENGINE STOP MOTOR CABLE ...336
ADJUSTING ACCELERATOR CONTROL ...337
INCHING PEDAL TRAVEL AND OPERATING FORCE ...338
MEASURING TRANSMISSION OIL PRESSURE...339
CHECKING DIFFERENTIAL LOCKING DEVICE OIL PRESSURE ...341
STEERING SYSTEM...342
CHECKING TIRE RUNOUT ...343
CHECKING AIR PRESSURE OF TIRE ...343
CHECKING TOE-IN ...344
INSTALLATION OF ARTICULATE CENTER PINS...345
CHECKING WEAR OF BRAKE DISC ...346
CHECKING PARKING BRAKE ...346
CHECKING WORK EQUIPMENT CONTROL LEVER TRAVEL AND OPERATING FORCE ...347
CHECKING HYDRAULIC OIL TEMPERATURE ...347
CHECKING WORK EQUIPMENT HYDRAULIC PRESSURE ...348
ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE ...348
MEASURING HYDRAULIC DRIFT ...349
CHARGING BLADE ACCUMULATOR WITH GAS ...350
ADJUSTING BLADE LIFT SPEED ...351
BLEEDING AIR FROM HYDRAULIC PUMP ...352
ADJUSTING SLIP LOAD OF CIRCLE ROTATION CLUTCH ...353
ADJUSTING CLEARANCE OF F AND R SWITCHES ...357
ADJUSTING SHIFT POTENTIOMETER ...358
ADJUSTING INCHING POTENTIOMETER ...359
ADJUSTING SPEEDOMETER MODULE OF MACHINE MONITOR ...360
TROUBLESHOOTING...362
POINTS TO REMEMBER WHEN TROUBLESHOOTING ...363
SEQUENCE OF EVENTS IN TROUBLESHOOTING ...364
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT...365
CHECKS BEFORE TROUBLESHOOTING...374
ELECTRICAL CIRCUIT SYSTEM DIAGRAM ...375
CONNECTOR TYPES AND MOUNTING LOCATIONS...391
ELECTRICAL WIRING DIAGRAM...401
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...405
T- BRANCH BOX AND T- BRANCH ADAPTER TABLE...441
METHOD OF USING TROUBLESHOOTING CHARTS...444
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE...446
TROUBLESHOOTING OF ENGINE (S MODE)...450
S-1 Starting performance is poor (Starting always takes time) ...451
S-2 Engine does not start ...452
1) Engine does not turn...452
2) Engine turns but no exhaust gas comes out (Fuel is not being injected)...453
3) Exhaust gas comes out but engine does not start (Fuel is being injected)...454
S-3 Engine does not pick up smoothly (Follow-up is poor) ...455
S-4 Engine stops during operations ...456
S-5 Engine does not rotate smoothly (hunting) ...457
S-6 Engine lacks output (no power) ...458
S-7 Exhaust gas is black (incomplete combustion) ...459
S-8 Oil consumption is excessive (or exhaust gas is blue)...460
S-9 Oil becomes contaminated quickly ...461
S-10 Fuel consumption is excessive ...462
S-11 Oil is in cooling water, or water spurts back, or water level goes down ...463
S-12 Oil pressure lamp lights up (drop in oil pressure) ...464
S-13 Oil level rises...465
S-14 Water temperature becomes too high (overheating) ...466
S-15 Abnormal noise is made...467
S-16 Vibration is excessive...468
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (M MODE)...470
M-1 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR...471
M-2 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT GO OUT...471
M-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH...472
M-4 PREHEATING OPERATION IS NOT BEING USED BUT PREHEATING DISPLAY LIGHTS UP...474
M-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH (but there is no abnormality with engine or CHECK items)...476
M-6 BUZZER DOES NOT SOUND FOR 1 MINUTE WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) ...482
M-7 THERE IS NO ABNORMALITY DISPLAYED ON MONITOR, BUT BUZZER SOUNDS ...482
M-8 MONITOR PANEL LIGHTING DOES NOT LIGHT UP...483
M-9 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED; SERVICE METER CONTINUES TO MOVE WHEN ENGINE IS STOPPED...485
M-10 COOLANT TEMPERATURE GAUGE DISPLAYS ABNORMALLY LOW TEMPERATURE...486
M-11 COOLANT TEMPERATURE GAUGE DOES NOT GIVE A DISPLAY ...487
M-12 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL ...488
M-13 FUEL GAUGE DOES NOT GIVE ANY DISPLAY ...488
M-14 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY...489
M-15 TURN SIGNAL INDICATOR PILOT LAMP DOES NOT LIGHT UP ...490
M-16 HIGH BEAM PILOT LAMP DOES NOT LIGHT UP...491
TROUBLESHOOTING CHART FOR ELECTRONIC (ENGINE, PARKING BRAKE, TRANSMISSION CONTROL) (E MODE)...493
E-1 Engine does not start (starting motor works)...494
E-2 Starting motor does not turn. ...494
E-3 Parking brake does not work ...499
E-4 Parking brake cannot be released ...499
E-5 Speed range does not change when transmission lever is switched between F1and F8 or between R1and R8 ...501
E-6 Transmission does not shift to 1st (F and R). ...507
E-7 Transmission does not shift to 2nd (F and R). ...507
E-8 Transmission does not shift to 3rd (F and R). ...507
E-9 Transmission does not shift to 4th (F and R). ...508
E-10 Transmission does not shift to 5th (F and R). ...508
E-11 Transmission does not shift to 6th (F and R). ...508
E-12 Transmission does not shift to 7th (F and R). ...509
E-13 Transmission does not shift to 8th (F and R). ...509
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (ET MODE)...510
LED DISPLAY FOR TRANSMISSION CONTROLLER...511
ET-1 [A1] (Short circuit in 1st solenoid) is displayed ...517
ET-2 [A2] (Short circuit in 2nd solenoid) is displayed ...518
ET-3 [A3} (Short circuit in 3rd solenoid) is displayed...519
ET-4 [A4] (Short circuit in 4th solenoid) is displayed ...520
ET-5 [A5] (Short circuit in High/Low solenoid) is displayed ...521
ET-6 [A7] (Short circuit in FORWARD/REVERSE solenoid) is displayed ...523
ET-7 [b1] (Disconnection in 1st solenoid) is displayed ...525
ET-8 [b2] (Disconnection in 2nd solenoid) is displayed ...526
ET-9 [b3] (Disconnection in 3rd solenoid) is displayed ...527
ET-10 [b4] (Disconnection in 4th solenoid) is displayed ...528
ET-11 [b5] (Disconnection in Low solenoid) is displayed ...529
ET-12 [b6] (Disconnection in High solenoid) is displayed ...530
ET-13 [b7] (Disconnection in FORWARD solenoid) is displayed ...531
ET-14 [b8] (Disconnection in REVERSE solenoid) is displayed ...532
ET-15 [c1] (Disconnection in inching potentiometer) is displayed ...533
ET-16 [c2] (Failure in shift potentiometer 1) is displayed ...534
ET-17 (Failure in shift potentiometer 2) is displayed ...535
ET-18 [d1] (Failure in F and R switches) is displayed ...536
ET-19 [d4] (Disconnection in engine speed sensor) is displayed ...538
ET-20 [d5] (Disconnection in speed sensor) is displayed ...539
ET-21 [d6] (Failure in transmission oil temperature sensor) is displayed ...540
ET-22 [E0] (Drop in power source voltage) is displayed ...541
ET-23 [E1] (Short circuit in parking brake) is displayed ...543
ET-24 [E2] or [F2] (Short circuit, disconnection in parking brake lamp) is displayed ...544
ET-25 [E3] or [F3] (Shot-t circuit, disconnection in differential lock relay) is displayed ...545
ET-26 [E4] or [F4] (Short circuit, disconnection in backup buzzer relay) is displayed ...547
ET-27 [E5} or {F5] (Short circuit, disconnection in caution lamp) is displayed ...549
ET-28 [E6] or [F6] (Short circuit, disconnection in alarm buzzer relay) is displayed ...550
ET-29 [E7] or [F7] (Short circuit, disconnection in starting motor relay) is displayed ...552
ET-30 [F1] (Disconnection in parking brake) is displayed ...554
TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM (H MODE)...562
STANDARDS FOR MEASURING HYDRAULIC PRESSURE, AND JUDGEMENT VALUES...563
TABLE OF FAILURE MODES AND CAUSES...565
HYDRAULIC PRESSURE MEASUREMENT AND FILTER MOUNTING POSITIONS...567
H-1 Abnormal noise is made (from around pump). ...569
H-2 Relief sound is heard (when not operating). ...569
H-3 Hydraulic oil overheats (when not operating). ...569
H-4 Work equipment does not move when control lever is operated (steering at neutral). ...570
H-5 Work equipment is slow, lacks power. ...571
H-6 There is excessive hydraulic drift of work equipment. ...572
H-7 Steering wheel does not turn (work equipment at neutral). ...572
H-8 Turning speed is slow, lacks power (work equipment at neutral). ...573
H-9 Feeling when operating steering wheel is strange. ...573
30 DISASSEMBLY AND ASSEMBLY...574
HOW TO READ THIS MANUAL...576
COATING MATERIALS LIST...578
SPECIAL TOOL LIST ...581
STARTING MOTOR...583
REMOVAL AND INSTALLATION...583
ALTERNATOR...583
REMOVAL AND INSTALLATION...583
NOZZLE HOLDER...585
REMOVAL AND INSTALLATION...585
FUEL INJECTION PUMP...586
REMOVAL AND INSTALLATION...586
WATER PUMP...587
REMOVAL...587
INSTALLATION ...588
ENGINE OIL COOLER CORE ...589
REMOVAL AND INSTALLATION ...589
TURBOCHARGER...590
REMOVAL AND INSTALLATION ...590
AIR COMPRESSOR...591
REMOVAL AND INSTALLATION ...591
CYLINDER HEAD ...592
REMOVAL...592
INSTALLATION...596
ENGINE (INCL. TRANSMISSION) ...599
REMOVAL...599
INSTALLATION...606
RADIATOR...614
REMOVAL...614
INSTALLATION...616
FUEL TANK ...618
REMOVAL...618
INSTALLATION...619
PTO...621
DISASSEMBLY...621
ASSEMBLY...626
TRANSMISSION...631
REMOVAL...631
INSTALLATION...635
DISASSEMBLY...639
ASSEMBLY...647
TRANSFER...662
DISASSEMBLY...662
ASSEMBLY ...665
TRANSMISSION CONTROL VALVE...669
DISASSEMBLY...669
ASSEMBLY...671
HYDROSHIFT TRANSMISSION PUMP...673
REMOVAL AND INSTALLATION...673
TANDEM AND FINAL DRIVE...674
REMOVAL...674
INSTALLATION...676
FINAL DRIVE...678
DISASSEMBLY...678
ASSEMBLY...687
BEVEL GEAR...699
DISASSEMBLY ...705
ASSEMBLY...702
BEVEL PINION...705
DISASSEMBLY...705
ASSEMBLY...706
FRONT AXLE ...707
REMOVAL...707
INSTALLATION ...709
DISASSEMBLY...711
ASSEMBLY...714
STEERING VALVE ...719
DISASSEMBLY...719
ASSEMBLY ...722
WHEEL BRAKE...726
DISASSEMBLY...726
ASSEMBLY...728
AIR TANK ...731
REMOVAL AND INSTALLATION...731
HYDRAULIC TANK ...732
REMOVAL AND INSTALLATION...732
HYDRAULIC PUMP ...733
REMOVAL...733
INSTALLATION...734
DISASSEMBLY ...736
ASSEMBLY ...750
HYDRAULIC CONTROL VALVE ...773
REMOVAL...773
INSTALLATION...774
MAIN CONTROL VALVE ...776
DISASSEMBLY...776
ASSEMBLY...778
CIRCLE ROTATION MOTOR ...780
DISASSEMBLY...780
ASSEMBLY...783
DRAWBAR SHIFT CYLINDER, BLADE LIFT CYLINDER, LIFTER GUIDE...799
REMOVAL...799
INSTALLATION...801
ARTICULATE CYLINDER...803
REMOVAL AND INSTALLATION ...803
REAR MOUNT RIPPER CYLINDER...804
REMOVAL AND INSTALLATION...804
HYDRAULIC CYLINDER Serial No.: 11001 - 12502...805
DISASSEMBLY...805
ASSEMBLY...807
HYDRAULIC CYLINDER Serial No.: 12503 and up...810
DISASSEMBLY...810
ASSEMBLY...814
CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR ...818
REMOVAL...818
INSTALLATION...819
DISASSEMBLY...822
ASSEMBLY...825
BLADE...837
REMOVAL AND INSTALLATION...837
CIRCLE AND DRAWBAR...840
REMOVAL AND INSTALLAITON...840
DISASSEMBLY...841
ASSEMBLY...843
REAR MOUNT RIPPER...854
REMOVAL...854
INSTALLATION...855
METHOD LIFTING UP ROPS CAB...856
INSTALLATION OF ROPS...858
ROPS CAB...859
REMOVAL...859
INSTALLATION...863
DISCONNECTION AND CONNECTION OF ARTICULATE SECTION Serial No.: 11001 - 12502...868
Disconnection...868
Connection...871
DISCONNECTION AND CONNECTION OF ARTICULATE SECTION Serial No.: 12503 and up...873
Disconnection...873
Connection...876
40 MAINTENANCE STANDARD...879
HYDROSHIFT TRANSMISSION AND TRANSFER...880
TRANSMISSION PUMP ...884
TRANSMISSION CONTROL VALVE ...886
TRANSMISSION SOLENOID VALVE ...892
FINAL DRIVE ...895
DIFFERENTIAL LOCK-UP PUMP ...896
TANDEM DRIVE...897
FRONT AXLE ...898
STEERING CYLINDER...902
DISC BRAKE...903
PARKING BRAKE...904
SPRING CYLINDER ...905
HYDRAULIC CONTROL VALVE ...906
HYDRAULIC CYLINDER...910
HYDRAULIC PUMP ...914
DRAWBAR AND LIFTER ...916
BLADE ...920
CIRCLE ROTATION GEAR...922
RIPPER...924
FRAME ...925
