Komatsu Motor Graders GD611A-1, GD611R-1, GD613A-1, GD615A-1, GD621A-1, GD622A-1, GD623A-1, GD661A-1, GD625A-1, GD625A-1A, GD625A-1B, GD625A-1C, GD663A-1, GDO663A-2, GD672A-1, GD621R-1, GD623R-1 Repair Service Manual + Operation & Maintenance
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Motor Graders GD611A-1, GD611R-1, GD613A-1, GD615A-1, GD621A-1, GD622A-1, GD623A-1, GD661A-1, GD625A-1, GD625A-1A, GD625A-1B, GD625A-1C, GD663A-1, GDO663A-2, GD672A-1, GD621R-1, GD623R-1, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Motor Grader GD610 & GD620 & GD660 & GD670 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: 664 + 130 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEBMG6150109 - Motor Grader GD610 & GD620 & GD660 & GD670 Shop Manual.pdf
SEAMG6150101 - Motor Grader GD625A-1 Operation & Maintenance Manual.pdf
GD621A, 611A, 661A, 621R, 623R, 611R, 613R-1 mount the S6D105-1 engine;
GD622A, 623A, 625A, 672A, 613A, 663A, 625A4-1C, 625A-1A mount the 6D125-1 engine;
GD615A-1 mount the $6D110-1 engine.
For details of the engines, see the 105 Series Shop Manual, 110 Series Shop Manual and 6D125 Series Shop Manual.
MAIN SECTIONS
COVER...1
CONTENTS...2
10 ENGINE...28
12 TESTING AND ADJUSTING...29
TABLE OF JUDGEMENT STANDARD VALUE...30
TESTING AND ADJUSTING TOOL LIST...35
ADJUSTING VALVE CLEARANCE...36
MEASURING COMPRESSION PRESSURE...38
TESTING AND ADJUSTING FUEL INJECTION TIMING...39
BLEEDING AIR FROM FUEL SYSTEM...41
ENGINE SPEED CONTROL...42
MEASURING EXHAUST GAS COLOR...45
TESTING AND ADJUSTING FAN BELT TENSION...47
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE...48
13 DISASSEMBLY AND ASSEMBLY...49
RADIATOR...50
REMOVAL...50
INSTALLATION...50
FUEL TANK(Incl.HYDRAULIC TANK)ASSEMBLY...54
REMOVAL...54
INSTALLATION...56
20 POWER TRAIN...60
21 STRUCTURE AND FUNCTION...61
GENERAL...62
POWER TRAIN...63
HYDROSHIFT TRANSMISSION PIPING...65
HYDROSHIFT TRANSMISSION CONTROL...66
POWER TRAIN HYDRAULIC CIRCUIT SCHEMATICS...67
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM...68
JOINT...69
PTO(POWER TAKE OFF)...70
HYDROSHIFT TRANSMISSION AND TRANSFER...71
HYDROSHIFT TRANSMISSION PUMP...77
TRANSMISSION CONTROL VALVE...79
FINAL DRIVE...87
DIFFERENTIAL LOCK PIPING...94
TANDEM DRIVE...96
22 TESTING AND ADJUSTING...98
TABLE OF JUDGEMENT STANDARD VALUE...99
TOOL LIST FOR TESTING AND ADJUSTING...101
INCHING PEDAL TRAVEL AND OPERATING FORCE...102
CHECKING OIL PRESSURE...105
MACHINE TYPE AND INCHING PRESSURE...106
TRANSMISSION CONTROL LEVER TRAVEL AND OPERATING FORCE...107
CHECKING DIFFERENTIAL LOCKING DEVICE OIL PRESSURE...108
23 DISASSEMBLY AND ASSEMBLY...109
TRANSMISSION PUMP...110
REMOVAL...110
INSTALLATION...110
ENGINE(Incl.TRANSMISSION)ASSEMBLY...112
REMOVAL...112
INSTALLATION...116
PTO...136
DISASSEMBLY...136
ASSEMBLY...140
HYDROSHIFT TRANSMISSION...146
DISASSEMBLY...146
ASSEMBLY...162
TRANSFER ASSEMBLY...182
DISASSEMBLY...182
ASSEMBLY...186
TANDEM AND FINAL DRIVE...192
REMOVAL...192
INSTALLATION...192
TANDEM,FINAL DRIVE ASSEMBLY...194
REMOVAL...194
INSTALLATION...194
FINAL DRIVE...198
DISASSEMBLY...198
ASSEMBLY...202
TANDEM,FINAL DRIVE ASSEMBLY...208
DISASSEMBLY...208
ASSEMBLY...212
SIDE CASE ASSEMBLY...220
DISASSEMBLY...220
ASSEMBLY...220
BEVEL GEAR ASSEMBLY...222
DISASSEMBLY...222
ASSEMBLY...222
PINION ASSEMBLY...232
DISASSEMBLY...232
ASSEMBLY...232
24 MAINTENANCE STANDARD...234
PTO,HYDROSHIFT TRANSMISSION AND TRANSFER...235
HYDROSHIFT TRANSMISSION CONTROL VALVE...237
TRANSMISSION PUMP...243
FINAL DRIVE...245
TANDEM DRIVE...247
40 STEERING SYSTEM...248
41 STRUCTURE AND FUNCTION...249
STEERING PIPING...250
STEERING CIRCUIT DIAGRAM...251
STEERING CONTROL VALVE...252
FRONT AXLE...257
STEERING CYLINDER...263
WHEEL...264
42 TESTING AND ADJUSTING...268
TABLE OF JUDGEMENT STANDARD...269
TOOL LIST FOR TESTING AND ADJUSTING...271
CHECKING STEERING WHEEL...272
CHECKING TIRE RUNOUT...273
CHECKING TIRE INFLATION PRESSURE...273
CHECKING TOE-IN...274
43 DISASSEMBLY AND ASSEMBLY...275
FRONT AXLE ASSEMBLY...276
REMOVAL...276
INSTALLATION...276
FRONT AXLE ASSEMBLY...278
DISASSEMBLY...278
ASSEMBLY...284
STEEREMBLY VALVE...290
DISASSEMBLY...290
ASSEMBLY...294
DOUBLE RELIEF VALVE...298
DISASSEMBLY...298
ASSEMBLY...298
44 MAINTENANCE STANDARD...300
FRONT AXLE...301
STEERING CYLINDER...307
50 BRAKE SYSTEM...308
51 STRUCTURE AND FUNCTION...309
BRAKE PIPING...310
BRAKE CIRCUIT DIAGRAM...311
BOOST MASTER...312
AIR BRAKE PIPING...315
AIR BRAKE CIRCUIT SCHEMATICS...317
AIR BRAKE CIRCUIT DIAGRAM...318
BRAKE VALVE...321
AIR COMPRESSOR...325
AIR GOVERNOR...326
CHECK VALVE...327
AIR TANK...328
SAFETY VALVE...328
AUTOMATIC DRAIN VALVE(IF EQUIPPED)...329
AIR DRIER(IF EQUIPPED)...331
WHEEL BRAKE...333
PARKING BRAKE...336
52 TESTING AND ADJUSTING...337
TABLE OF JUDGEMENT STANDARD VALUE...338
TOOL LIST FOR TESTING AND ADJUSTING...338
CHECKING BRAKE PEDAL...339
AIR BLEEDING FROM BRAKE CIRCUIT...341
CHECKING PARKING BRAKE LEVER...342
CHECKING WEAR OF BRAKE DISC...343
53 DISASSEMBLY AND ASSEMBLY...344
BOOST MASTER...345
DISASSEMBLY ...345
ASSEMBLY...347
WHEEL BRAKE...349
REMOVAL...349
INSTALLATION...349
DISASSEMBLY...351
ASSEMBLY...351
WHEEL BRAKE...353
REMOVAL...353
INSTALLATION...353
DISASSEMBLY...357
ASSEMBLY...361
54 MAINTENANCE STANDARD...373
WHEEL BRAKE...374
PARKING BRAKE...376
BOOST MASTER...377
60 HYDRAULIC SYSTEM...378
61 STRUCTURE AND FUNCTION...379
HYDRAULIC PIPING...380
HYDUAULIC CONTROL...390
BLADE ACCUMULATOR SYSTEM(IF EQUIPPED)...392
HYDRAULIC CIRCUIT DIAGRAM...394
OIL COOLING FLOW...398
HYDRAULIC PUMP...399
CIRCLE ROTATION MOTOR...401
CONTROL VALVE...407
FLOW DIVIDER...413
PILOT CHECK VALVE...414
FLOW CONTROL VALVE...418
HYDRAULIC CYLINDER...419
62 TESTING AND ADJUSTING...422
TROUBLESHOOTING(CIRCLE ROTATION MOTOR)...423
63 DISASSEMBLY AND ASSEMBLY...424
HYDRAULIC PUMP(Incl.STEERING PUMP)...425
REMOVAL...425
INSTALLATION...425
BLADE LIFT CYLINDER...427
REMOVAL...427
INSTALLATION...427
DRAWBAR SHIFT CYLINDER...429
REMOVAL...429
INSTALLATION...429
BLADE SIDE SHAFT CYLINDER...431
REMOVAL...431
INSTALLATION...431
ARTICULATE CYLINDER...433
REMOVAL...433
INSTALLATION...433
SCARIFIER CYLINDER...435
REMOVAL...435
INSTALLATION...435
POWER TILT CYLINDER...437
REMOVAL...437
INSTALLATION...437
REAR MOUNT RIPPER CYLINDER...437
REMOVAL...437
INSTALLATION...437
HYDRAULIC CYLINDER...439
DISASSEMBLY...439
ASSEMBLY...443
CIRCLE ROTATION MOTOR...451
DISASSEMBLY...451
ASSEMBLY...457
64 MAINTENANCE STANDARD...471
HYDRAULIC PUMP...472
CONTROL VALVE...474
HYDRAULIC CYLINDER...478
70 WORK EQUIPMENT...482
71 STRUCTURE AND FUNCTION...483
DRAWBAR AND LIFTER...484
BLADE...488
CIRCLE ROTATION GEAR...492
FRAME...494
SCARIFIER(IF EQUIPPED)...495
REAR MOUNTING RIPPER(IF EQUIPPED)...496
72 TESTING AND ADJUSTING...497
TABLE OF JUDGEMENT STANDARD...498
TOOL LIST FOR TESTING AND ADJUSTING...501
CHECKING CONTROL LEVER...502
CHECKING HYDRAULIC OIL TEMPERATURE...503
CHECKING HYDRAULIC OIL PRESSURE...503
HYDRAULIC DRIFT...505
CHARGING BLADE ACCUMULATOR WITH GAS...506
ADJUSTMENT OF CIRCLE GUIDE...507
73 DISASSEMBLY AND ASSEMBLY...508
BLADE ASSEMBLY...509
REMOVAL...509
INSTALLATION...509
CIRCLE ROTATION GEAR...511
REMOVAL...511
INSTALLATION...511
DISASSEMBLY...513
ASSEMBLY...515
REAR MOUNT RIPPER ASSEMBLY...517
REMOVAL...517
INSTALLATION...517
CIRCLE ROTATION GEAR ASSEMBLY...517
REMOVAL...517
INSTALLATION...517
DISASSEMBLY...519
ASSEMBLY...525
74 MAINTENANCE STANDARD...531
DRAWBAR AND LIFTER...532
BLADE...534
CIRCLE ROTATION GEAR...535
SCARIFIER(IF EQUIPPED)...537
REAR MOUNT RIPPER(IF EQUIPPED)...538
80 ELECTRIC AND ELECTRONIC SYSTEM...541
81 STRUCTURE AND FUNCTION...542
ELECTRICAL CIRCUIT DIAGRAM...543
CIRCUIT DIAGRAM OF CAB...548
ELECTRONIC VEHICLE MONITORING SYSTEM(EVMS)...550
ADJUSTING SPEEDOMETER MODULE(IF EQUIPPED)...558
82 TESTING AND ADJUSTING...559
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE...560
CIRCUIT DIAGRAM...563
CONNECTOR POSITION FOR TROUBLESHOOTING...565
POSITION OF CONNECTOR(D TYPE)...571
POSITION OF CONNECTOR(P,Q TYPE)...577
CONNECTOR TERMINAL NUMBERS...587
PROCEDURE FOR TROUBLESHOOTING...592
CHECKS BEFORE TROUBLESHOOTING...593
METHOD OF USING TROUBLESHOOTING CHART...594
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM(M1 TO M-18)(D TYPE)...596
M-1 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL DISPLAY DOES NOT APPEAR...597
a) NONE OF MONITOR PANEL WORKS...597
b) PART OF MONITOR PANEL DOES NOT WORK...597
M-2 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL DISPLAY DOES NOT GO OUT...597
M-3 WHEN STARTING SWITCH IS TURNED ON,(DO NOT START ENGINE),CHECK BEFORE STARTING ITEMS FLASH OR PREHEATING ITEM LIGHTS UP...598
a) COOLANT LEVEL...598
b) ENGINE OIL LEVEL...598
c) PREHEATER...599
M-4 WHEN STARTING SWITCH IS TURNED ON,(ENGINE STARTED),CHECK BEFORE STARTING ITEMS FLASH...600
a) ALTERNATOR SYSTEM...600
b) ENGINE OIL PRESSURE CIRCUIT...600
M-5 WHEN STARTING SWITCH IS TURNED ON,(DO NOT START ENGINE),CAUTION ITEMS FLASH...601
M-6 WHEN STARTING SWITCH IS ON(ENGINE STARTED),CAUTION ITEMS FLASH...602
a) ENGINE OIL PRESSURE...602
b) COOLANT LEVEL...602
c) COOLANT TEMPERATURE...603
d) BATTERY CHARGE...603
e) FINAL OIL TEMPERATURE...604
f) AIR PRESSURE...604
g) PARKING BRAKE...605
M-7 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK...606
M-8 NO DISPLAY IS GIVEN FOR FUEL LEVEL...606
M-9 ENGINE COOLANT TEMPERATURE IS HIGH,BUT LOWEST LEVEL DISPLAYED...607
M-10 ENGINE COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY...607
M-11 TURN SIGNAL LAMPS,HIGH BEAM LIGHT UP ABNORMALLY,OR DO NOT LIGHT UP...608
a) PILOT DISPLAY OF TURN SIGNAL LAMP(RIGHT)LIGHTS UP...608
b) PILOT DISPLAY OF TURN SIGNAL LAMP(LEFT)LIGHTS UP...608
c) PILOT DISPLAY OF TURN SIGNAL LAMP(RIGHT)DOES NOT LIGHT UP...608
d) PILOT DISPLAY OF TURN SIGNAL LAMP(LEFT)DOES NOT LIGHT UP...609
e) HIGHT BEAM PILOT LAMP DOES NOT LIGHT UP...609
f) HIGH BEAM PILOT LAMP DOES NOT GO OUT...609
M-12 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY...610
M-13 WHEN ENGINE IN STARTED,SERVICE METER DOES NOT MOVE,WHEN ENGINE IN STOPPED,SERVICE METER MOVES...611
a) SERVICE METER DOES NOT MOVE...611
b) SERVICE METER DOES NOT STOP MOVING...611
M-14 MONITOR PANEL LAMPS DO NOT LIGHT UP...612
a) NO LAMPS ON PANEL LIGHT UP...612
b) SOME LAMPS ON PANEL DO NOT LIGHT UP...612
M-15 CENTRAL WARNING LAMP DOES NOT GO OUT...613
a) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING LAMP LIGHTS UP INTERMITTENTLY...613
b) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY...613
M-16 CENTRAL WARNING BUZZER DOES NOT STOP...614
a) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY...614
b) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY...614
M-17 EMERGENCY ITEM OR NON-EMERGENCY ITEMS IS FLASHING,BUT WARNING LAMP DOES NOT FLASH...615
M-18 EMERGENCY ITEM IS FLASHING,BUT ALARM BUZZER DOES NOT SOUND...616
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM(M1 TO M-22)(P,Q TYPE)...624
M-1 MONITOR PANEL PILOT LAMPS DO NOT LIGHT UP FOT 3 SECONDS WHEN STARTING SWITCH IS TURNED ON...625
a) NO LAMPS ON MONITOR PANEL(MONITOR MODULE)LIGHT UP...625
b) NO LAMPS ON MONITOR PANEL(SPEEDOMETER MODULE)LIGHT UP...625
c) SOME LAMPS ON MONITOR PANEL DO NOT LIGHT UP...625
M-2 WHEN STARTING SWITCH IS TURNED ON,ALL MONITOR PANEL LAMPS LIGHT UP BUT DO NOT GO OUT...625
M-3 WHEN STARTING SWITCH IS TURNED ON(WITH ENGINE STOPPED),CHECK ITEMS FLASH...627
a) RADIATOR WATER LEVEL FLASHES...627
b) ENGINE OIL LEVEL FLASHES...628
M-4 PREHEATING IS NOT BEING CARRIED OUT,BUT PREHEATING DISPLAY FLASHES...629
M-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,CHECK ITEMS FLASH...630
a) ALTERNATOR SYSTEM...630
b) ENGINE OIL PRESSURE SYSTEM...631
M-6 WHEN STARTING SWITCH IS TURNED ON WITH ENGINE STOPPED CAUTION ITEMS FLASH...633
M-7 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,CAUTION ITEMS FLASH...637
a) ENGINE OIL PRESSURE FLASHES...637
b) RADIATOR WATER LEVEL FLASHES...639
c) ENGINE WATER TEMPERATURE FLASHES...639
d) CHARGE FLASHES...640
e) FINAL DRIVE OIL TEMPERATURE FLASHES...641
f) AIR PRESSURE FLASHES...642
g) PARKING BRAKE FLASHES...643
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...644
M-9 THERE IS NO ABNORMALITY ON MONITOR DISPLAY,BUT ALARM BUZZER SOUNDS...644
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...645
M-11 THERE IS NO ABNORMALITY ON MONITOR DISPLAY,BUT WARNING LAMP LIGHTS UP...645
M-12 MONITOR PANEL LIGHTING DOES NOT LIGHT UP...647
a) NO PANEL LIGHTING LIGHTS UP...647
b) PART OF PANEL LIGHTING DOES NOT LIGHT UP...647
M-13 SERVICE METER DOES NOT MOVE WHEN ENGINE IS STARTED;OR SERVICE METER MOVES WHEN ENGINE IS STOPPED.(FOR MACHINES WITH SPEEDOMETER)...648
a) SERVICE METER DOES NOT MOVE WHEN ENGINE IS STARTED...648
b) SERVICE METER MOVES WHEN ENGINE IS STOPPED...648
M-14 ENGINE WATER TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE...650
M-15 ENGINE WATER TEMPERATURE GAUGE SHOWS NO DISPLAY...650
M-16 FUEL GAUGE ALWAYS SHOWS FULL...651
M-17 NO DISPLAY IS GIVEN FOR FUEL LEVEL GAUGE...651
M-18 HIGH BEAM DOES NOT LIGHT UP...653
M-19 HIGH BEAM STAYS LIGHTED UP...653
M-20 TURN SIGNAL INDICATOR DOES NOT LIGHT UP...655
M-21 TURN SIGNAL INDICATOR STAYS LIGHTED UP...656
M-22 SPEED DISPLAY STAYS AT "0" AND DOES NOT MOVE...658
90 OTHERS...660
AIR CONDITIONER...661
