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Komatsu Dump Truck HD255 Repair Service Manual

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Dump Truck HD255, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Dump Truck HD255 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.

SEBM00911 – Komatsu Dump Truck HD255-5 Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 613 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
COVER…1
CONTENTS…2
LIST OF REVISED PAGES…3
SAFETY…7
SAFETY NOTICE…7
FOREWORD…9
GENERAL…9
HOW TO READ THE SHOP MANUAL…10
HOISTING INSTRUCTIONS…11
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER…12
COATING MATERIALS…14
STANDARD TIGHTENING TORQUE…16
ELECTRIC WIRE CODE…19
CONVERSION TABLE…20
UNITS…26
01 GENERAL…27
DIMENSIONS…28
SPECIFICATIONS…30
WEIGHT TABLE…36
LIST OF LUBRICANTS AND COOLANT…37
10 STRUCTURE AND FUNCTION…39
RADIATOR, TORQUE CONVERTER AND BRAKE OIL COOLER, AND AFTERCOOLER…40
POWER TRAIN SKELETON…42
HYDRAULIC CIRCUIT DIAGRAM FOR TORQUE CONVERTER, TRANSMISSION, AND BRAKE COOLING…44
TORQUE CONVERTER…46
MAIN RELIEF VALVE…48
TORQUE CONVERTER VALVE…50
TRANSMISSION…55
TRANSMISSION VALVE…60
ECMV (ELECTRONIC CONTROL MODULATION VALVE)…61
FRONT AXLE…66
REAR AXLE…67
DIFFERENTIAL…68
FINAL DRIVE…69
FRONT BRAKE…70
REAR BRAKE…71
PARKING BRAKE…72
STEERING COLUMN…74
STEERING LINKAGE…76
DEMAND VALVE…77
CROSSOVER RELIEF VALVE…80
STEERING VALVE…81
FRONT SUSPENSION CYLINDER…82
REAR SUSPENSION CYLINDER…83
AIR GOVERNOR…84
SAFETY VALVE…86
CHECK VALVE…86
DOUBLE CHECK VALVE…87
HAND BRAKE VALVE (RETARDER CONTROL VALVE)…88
BRAKE VALVE…90
PARKING BRAKE CONTROL VAVLE…93
BRAKE RELAY VALVE…95
BRAKE RELAY VALVE (ACTS ALSO AS EMERGENCY RELAY)…97
PARKING BRAKE RELAY VALVE…104
PARKING BRAKE QUICK RELEASE VALVE…106
SPRING CYLINDER…107
SLACK ADJUSTER…108
FRONT BRAKE CHAMBER…109
REAR BRAKE CHAMBER…110
AIR DRIER (DRYING AGENT TYPE)…111
AIR SYSTEM DIAGRAM…113
HOIST VALVE…114
HOIST CYLINDER…115
AUTOMATIC SHIFT CONTROL SYSTEM…116
AUTOMATIC RETARDER VALVE…126
HORN VALVE…128
WIPER SWITCH…128
SENSORS, SWITCHES…129
METER LAMPS…140
20 TESTING AND ADJUSTING…151
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…152
STANDARD VALUE TABLE FOR CHASSIS…155
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM…163
TESTING AND ADJUSTING…175
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING…176
SKETCHES OF SPECIAL TOOLS…178
ADJUSTING VALVE CLEARANCE…180
MEASURING COMPRESSION PRESSURE…182
MEASURING BLOW-BY…184
TESTING AND ADJUSTING ALTERNATOR BELT TENSION AND FAN BELT TENSION…186
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION…187
MEASURING ENGINE SPEED…188
MEASURING ENGINE OIL PRESSURE…190
MEASURING BOOST PRESSURE…191
MEASURING EXHAUST GAS TEMPERATURE…192
MEASURING EXHAUST GAS COLOR…193
TESTING AND ADJUSTING FUEL INJECTION TIMING…194
BLEEDING AIR FROM FUEL INJECTION PUMP…196
HANDLING EQUIPMENT IN FUEL CIRCUIT…197
RELEASING REMAINING PRESSURE IN FUEL SYSTEM…197
MEASURING FUEL PRESSURE…198
BLEEDING AIR FROM FUEL CIRCUIT…199
REDUCED CYLINDER MODE OPERATION FOR ENGINE…201
CHECKING FOR LEAKAGE IN FUEL CIRCUIT…202
ADJUSTING ENGINE STOP MOTOR CABLE…203
ADJUSTING ACCELERATOR PEDAL…204
ADJUSTING ENGINE SPEED SENSOR…205
TESTING OIL PRESSURE OF TORQUE CONVERTER VALVE…206
TESTING TORQUE CONVERTER STALL SPEED…207
TESTING BRAKE PRESSURE…208
BLEEDING AIR FROM BRAKE CIRCUIT…209
TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE…210
TESTING WEAR OF FRONT BRAKE PAD…211
TESTING WEAR OF REAR BRAKE DISC…212
TESTING AND ADJUSTING SUSPENSION CYLINDER…213
TESTING AND ADJUSTING AIR GOVERNOR SET PRESSURE…218
INSPECTION OF AIR DRIER (DESICCANT TYPE)…219
ADJUSTING HOIST LEVER LINKAGE…221
ADJUSTING BODY POSITIONER…222
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT…223
BLEEDING AIR FROM HYDRAULIC CYLINDER (STEERING CYLINDER)…226
EMERGENCY TRAVEL WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM…227
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM…228
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS…234
PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT…236
PM CLINIC CHECK SHEET…237
TROUBLESHOOTING…241
POINTS TO REMEMBER WHEN TROUBLESHOOTING…242
SEQUENCE OF EVENTS IN TROUBLESHOOTING…243
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…244
CHECKS BEFORE TROUBLESHOOTING…252
TYPE OF CONNECTOR AND POSITION OF INSTALLATION (SERIAL NO. 1001-1200)…254
CONNECTOR PIN ARRANGEMENT DIAGRAM (SERIAL NO. 1001-1200)…258
TYPE OF CONNECTOR AND POSITION OF INSTALLATION (SERIAL NO. 1201-1599)…262
CONNECTOR PIN ARRANGEMENT DIAGRAM (SERIAL NO. 1201-1599)…266
TYPE OF CONNECTOR AND POSITION OF INSTALLATION (SERIAL NO. 1601 AND UP)…270
CONNECTOR PIN ARRANGEMENT DIAGRAM (SERIAL NO. 1601 AND UP)…274
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS …280
METHOD OF USING JUDGEMENT TABLE…303
METHOD OF USING TROUBLESHOOTING CHARTS…304
METHOD OF LED DISPLAY FOR TRANSMISSION CONTROLLER…306
HOW TO DELETE FAILURE CODES FOR TRANSMISSION CONTROLLER AND ENGINE CONTROLLER…310
ACTION TAKEN BY TRANSMISSION CONTROLLER AND PROBLEMS ON MACHINE…312
TROUBLESHOOTING OF ENGINE SYSTEM (D MODE)…361
METHOD OF USING TROUBLESHOOTING CHART…362
D-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…366
D-2 ENGINE DOES NOT START…367
(1) ENGINE DOES NOT TURN…367
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)…368
(3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)…369
D-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…370
D-4 ENGINE STOPS DURING OPERATIONS…371
D-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…372
D-6 ENGINE LACKS OUTPUT (NO POWER)…373
D-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…374
D-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…375
D-9 OIL BECOMES CONTAMINATED QUICKLY…376
D-10 FUEL CONSUMPTION IS EXCESSIVE…377
D-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…378
D-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…379
D-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…380
D-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…381
D-15 ABNORMAL NOISE IS MADE…382
D-16 VIBRATION IS EXCESSIVE…383
TROUBLESHOOTING OF ENGINE SYSTEM (D MODE)…385
POINTS TO REMEMBER WHEN TROUBLESHOOTING…386
METHOD OF USING TROUBLESHOOTING CHARTS…387
D-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…390
D-2 ENGINE DOES NOT START…391
D-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…394
D-4 ENGINE STOPS DURING OPERATIONS…395
D-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…396
D-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…397
D-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…398
D-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…399
D-9 OIL BECOMES CONTAMINATED QUICKLY…400
D-10 FUEL CONSUMPTION IS EXCESSIVE…401
D-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)…402
D-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…403
D-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…404
D-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…405
D-15 ABNORMAL NOISE IS MADE…406
D-16 VIBRATION IS EXCESSIVE…407
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (G MODE)…409
ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING…411
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED…414
ENGINE CONTROLLER RELATED JUDGEMENT TABLE…422
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM…424
G-1 ERROR CODE [C01b] [ABNORMALITY IN NE REVOLUTION SENSOR SYSTEM]…426
G-2 ERROR CODE [C01C] [ABNORMALITY IN G REVOLUTION SENSOR SYSTEM]…427
G-3 ERROR CODE [C020] [ABNORMALITY IN MODEL SELECTION SYSTEM]…428
G-4 ERROR CODE [C022] [OVERRUN]…429
G-5 ERROR CODE [C023] [OVERHEAT]…429
G-6 ERROR CODE [C024] [DROP IN OIL PRESSURE]…430
G-7 ERROR CODE [C030] [ABNORMALITY IN IDLING VALIDATION SIGNAL SYSTEM]…431
G-8 ERROR CODE [C031] [ABNORMALITY IN ACCELERATOR SENSOR SYSTEM]…433
G-9 ERROR CODE [C034] [ABNORMALITY IN HIGH ENGINE COOLANT TEMPERATURE SENSOR SYSTEM]…435
G-10 ERROR CODE [C036] [ABNORMALITY IN OIL PRESSURE SWITCH SYSTEM]…436
G-11 ERROR CODE [C03C] [ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM]…438
G-12 ERROR CODE [C03d] [ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM]…439
G-13 ERROR CODE [C050] [ABNORMALITY IN PREHEATING RELAY CONNECTING POINT SYSTEM]…440
G-14 ERROR CODE [C051] [ABNORMALITY IN PREHEATING RELAY COIL SYSTEM]…441
G-15 ERROR CODE [C054] [SHORT CIRCUIT IN STARTING SWITCH C SYSTEM]…442
G-16 ERROR CODE [C056] [POWER SOURCE SYSTEM ABNORMALITY 1]…443
G-17 ERROR CODE [C057] [POWER SOURCE SYSTEM ABNORMALITY 2]…445
G-18 ERROR CODE [C05A] [ABNORMALITY IN FUEL INJECTION QUANTITY CONTROL SWITCH SIGNAL]…446
G-19 ERROR CODE [C06A] [ABNORMALITY IN LOW ENGINE COOLANT TEMPERATURE SENSOR SYSTEM]…446
G-20 ERROR CODE [C070] [EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM]…447
G-21 ERROR CODE [C071] [EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM]…448
G-22 ERROR CODE [C074] [DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM]…449
G-23 ERROR CODE [C075] [DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM]…450
G-24 ERROR CODE [C077] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM]…451
G-25 ERROR CODE [C079] [COMMON RAIL HIGH FUEL PRESSURE ABNORMALITY 1] ERROR CODE [C07A] [COMMON RAIL HIGH FUEL PRESSURE ABNORMALITY 2]…452
G-26 ERROR CODE [C07C] [FUEL SUPPLY PUMP NON-FORCE FEED 1] ERROR CODE [C07b] [FUEL SUPPLY PUMP NON-FORCE FEED 2]…453
G-27 ERROR CODE [C07d] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE]…455
G-28 ERROR CODE [C080] [DEFECTIVE CONTROLLER]…455
G-29 ERROR CODE [C081] [DISCONNECTION IN NO.1 FUEL INJECTOR <A> SYSTEM]…456
G-30 ERROR CODE [C082] [DISCONNECTION IN NO.2 FUEL INJECTOR <E> SYSTEM]…457
G-31 ERROR CODE [C083] [DISCONNECTION IN NO.3 FUEL INJECTOR <C> SYSTEM]…458
G-32 ERROR CODE [C084] [DISCONNECTION IN NO.4 FUEL INJECTOR <F> SYSTEM]…459
G-33 ERROR CODE [C085] [DISCONNECTION IN NO.5 FUEL INJECTOR <B> SYSTEM]…460
G-34 ERROR CODE [C086] [DISCONNECTION IN NO.6 FUEL INJECTOR <D> SYSTEM]…461
G-35 ERROR CODE [C08A] [SHORT CIRCUIT IN NO.1 <A>, NO.2 <E>, NO.3 <C> FUEL INJECTOR SYSTEM]…462
G-36 ERROR CODE [C08b] [SHORT CIRCUIT IN NO.4 <F>, NO.5 <B>, NO.6 <D> FUEL INJECTOR SYSTEM]…465
TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM FOR START/STOP SYSTEM (ENG MODE)…469
SERIAL NO.:1001-1599…470
ENG-1 ENGINE DOES NOT START (FUEL INJECTION PUMP STOP LEVER STAYS AT STOP POSITION)…470
ENG-2 ENGINE DOES NOT STOP (FUEL INJECTION PUMP STOP LEVER STAYS AT RUN POSITION)…477
SERIAL NO.:1601 AND UP…482
ENG-1 ENGINE DOES NOT START (STARTING MOTOR DOES NOT ROTATE)…482
ENG-2 ENGINE DOES NOT START OR IT HUNTS (RUNS ROUGH)…486
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)…487
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM…489
JUDGMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS…490
A-1 ABNORMALITY IN POWER SOURCE…492
a) [ ][DEFECTIVE CONTROLLER POWER SOURCE]IS DISPLAYED(ALL LEDS OFF)…492
b) [0.1](DROP IN VOLTAGE OF CONTROLLER)IS DISPLAYED…496
c) [0.2](DROP IN VOLTAGE OF SOLENOID)IS DISPLAYED…497
A-2 [0.3](NEUTRAL SAFETY)IS DISPLAYED…499
A-3 CONTROLLER SYSTEM…501
a) [ . ][ONLY DOT LIGHTS UP] OR [0.4](DATA ERROR)IS DISPLAYED…501
b) [0.5](DOUBLE ENGAGEMENT FOR CLUTCH)IS DISPLAYED…501
A-4 [0.6](DISCONNECTION,SHORT CIRCUIT,SHORT CIRCUIT WITH GROUND IN TRANSMISSION CUT RELAY)IS DISPLAYED…502
A-5 [0.8](DISCONNECTION,SHORT CIRCUIT,SHORT CIRCUIT WITH GROUND IN AUTOMATIC RETARDER SOLENOID)IS DISPLAYED…506
A-6 [0.9](DISCONNECTION,SHORT CIRCUIT,SHORT CIRCUIT WITH GROUND IN EXHAUST BRAKE SOLENOID)IS DISPLAYED…510
A-7 SPEED SENSOR SYSTEM…514
a) [1.0](DISCONNECTION IN ENGINE SPEED SENSOR) OR [6.0](DEFECTIVE OUTPUT OF ENGINE SPEED SENSOR)…514
b) [1.1](DISCONNECTION IN TRANSMISSION INPUT SHAFT SPEED SENSOR) OR [6.1](DEFECTIVE OUTPUT OF TRANSMISSION INPUT SHAFT SPEED SENSOR)…517
c) [1.2](DISCONNECTION IN TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR) OR [6.2](DEFECTIVE OUTPUT OF TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR)…518
d) [1.3](DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR) OR [6.3](DEFECTIVE OUTPUT OF TRANSMISSION OUTPUT SHAFT SPEED SENSOR)…519
A-8 SLIPPING CLUTCH OR SPEED SENSOR SYSTEM…520
a) [2.1][DEFECTIVE LOCK-UP CLUTCH SYSTEM] IS DISPLAYED…520
b) [2.2][FAILURE IN HI CLUTCH OR INPUT SHAFT SPEED SENSOR SYSTEM] OR [2.3][FAILURE IN LO CLUTCH OR INPUT SHAFT SPEED SENSOR SYSTEM] IS DISPLAYED…520
c) [2.4][FAILURE IN 1ST CLUTCH OR OUTPUT SHAFT SPEED SENSOR SYSTEM] OR [2.5][FAILURE IN 2ND CLUTCH OR OUTPUT SHAFT SPEED SENSOR SYSTEM] OR [2.6][FAILURE IN 3RD CLUTCH OR OUTPUT SHAFT SPEED SENSOR SYSTEM] OR [2.8][FAILURE IN R CLUTCH OR OUTPUT SHAFT SPEED SENSOR SYSTEM] IS DISPLAYED…520
A-9 [A.1]ABNORMALITY IN MODEL SELECTION SIGNAL IS DISPLAYED…521
A-10 ABNORMALITY IN SHIFT LEVER SYSTEM…522
a) [0.7][SHORT CIRCUIT WITH 12V OUTPUT CIRCUIT] IS DISPLAYED…522
b) [1.5][SHORT CIRCUIT,SHORT CIRCUIT WITH GROUND IN LEVER SIGNAL SYSTEM] IS DISPLAYED…523
c) [1.6][DISCONNECTION IN LEVER SIGNAL SYSTEM] IS DISPLAYED…527
A-11 [A.1][DISCONNECTION IN ACCELERATOR SIGNAL,DEFECTIVE ADJUSTMENT,DISCONNECTED LINK] IS DISPLAYED…529
A-12 [1.9][SHORT CIRCUIT WITH GROUND IN TRANSMISSION VALVE OIL TEMPERATURE SENSOR] IS DISPLAYED…533
A-13 PRESSURE CONTROL VALVE SYSTEM…534
a) [3.1][DEFECTIVE LOCK-UP CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ] OR [3.2][DEFECTIVE HI CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ]…534
a) [3.3][DEFECTIVE LO CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ] OR [3.4][DEFECTIVE 1ST CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ]…534
a) [3.5][DEFECTIVE 2ND CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ] OR [3.6][DEFECTIVE 3RD CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ]…534
a) [3.8][DEFECTIVE R CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ] IS DISPLAYED…534
b) [4.1][DEFECTIVE LOCK-UP CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ] OR [4.2][DEFECTIVE HI CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ]…535
b) [4.3][DEFECTIVE LO CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ] OR [4.4][DEFECTIVE 1ST CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ]…535
b) [4.5][DEFECTIVE 2ND CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ] OR [4.6][DEFECTIVE 3RD CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ]…535
b) [4.8][DEFECTIVE R CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ] IS DISPLAYED…535
b1) CHECKING FILL SIGNAL SYSTEM…535
b2) CHECKING WHEN [4.2] OR [4.3] IS DISPLAYED…536
b3) CHECKING WHEN [4.4] OR [4.6] OR [4.8] IS DISPLAYED…536
A-14 FLOW DETECTION VALVE SYSTEM…537
[5.1][DISCONNECTION IN LOCK-UP CLUTCH FLOW CONTROL VALVE SYSTEM] OR [5.2][DISCONNECTION IN HI CLUTCH FLOW CONTROL VALVE SYSTEM]…537
[5.3][DISCONNECTION IN LO CLUTCH FLOW CONTROL VALVE SYSTEM] OR [5.4][DISCONNECTION IN 1ST CLUTCH FLOW CONTROL VALVE SYSTEM]…537
[5.5][DISCONNECTION IN 2ND CLUTCH FLOW CONTROL VALVE SYSTEM] OR [5.6][DISCONNECTION IN 3RD CLUTCH FLOW CONTROL VALVE SYSTEM]…537
[5.8][DISCONNECTION IN R CLUTCH FLOW CONTROL VALVE SYSTEM] IS DISPLAYED…537
A-15 PRESSURE CONTEOL SOLENOID SYSTEM…538
a) [7.1][SHORT CIRCUIT IN LOCK-UP CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [7.2][SHORT CIRCUIT IN HI CLUTCH PRESSURE CONTROL SOLENOID SYSTEM]…538
a) [7.3][SHORT CIRCUIT IN LO CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [7.4][SHORT CIRCUIT IN 1ST CLUTCH PRESSURE CONTROL SOLENOID SYSTEM]…538
a) [7.5][SHORT CIRCUIT IN 2ND CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [7.6][SHORT CIRCUIT IN 3RD CLUTCH PRESSURE CONTROL SOLENOID SYSTEM]…538
a) [7.8][SHORT CIRCUIT IN R CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] IS DISPLAYED…538
b) [9.1][SHORT CIRCUIT IN LOCK-UP CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [9.2][SHORT CIRCUIT IN HI CLUTCH PRESSURE CONTROL SOLENOID SYSTEM]…540
b) [9.3][SHORT CIRCUIT IN LO CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [9.4][SHORT CIRCUIT IN 1ST CLUTCH PRESSURE CONTROL SOLENOID SYSTEM]…540
b) [9.5][SHORT CIRCUIT IN 2ND CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [9.6][SHORT CIRCUIT IN 3RD CLUTCH PRESSURE CONTROL SOLENOID SYSTEM]…540
b) [9.8][SHORT CIRCUIT IN R CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] IS DISPLAYED…540
A-16 PRESSURE SENSOR SYSTEM…542
a) [8.1][DEFECTIVE OUTPUT OF TORQUE CONVERTER INLET PRESSURE SENSOR] OR [8.3][DEFECTIVE OUTPUT OF TORQUE CONVERTER INLET PRESSURE SENSOR] IS DISPLAYED…542
b) [8.2][DEFECTIVE OUTPUT OF TORQUE CONVERTER OUTLET PRESSURE SENSOR] OR [8.4][DEFECTIVE OUTPUT OF TORQUE CONVERTER OUTLET PRESSURE SENSOR] IS DISPLAYED…543
ELECTRICAL CIRCUIT DIAGRAM FOR A MODE SYSTEM…544
TROUBLESHOOTING FOR METER PANEL SYSTEM (E MODE)…557
E-1 WATER TEMPERATURE GAUGE GIVES NO DISPLAY OR GIVES ABNORMAL DISPLAY…558
a) GIVES NO DISPLAY…558
b) GIVES ABNORMAL DISPLAY…558
E-2 TORQUE CONVERTER OIL TEMPERATURE GAUGE GIVES NO DISPLAY OR GIVES ABNORMAL DISPLAY…560
a) GIVES NO DISPLAY…560
b) GIVES ABNORMAL DISPLAY…560
E-3 RETARDER OIL TEMPERATURE GAUGE GIVES NO DISPLAY OR GIVES ABNORMAL DISPLAY…562
a) GIVES NO DISPLAY…562
b) GIVES ABNORMAL DISPLAY…562
E-4 FUEL GAUGE GIVES NO DISPLAY OR GIVES ABNORMAL DISPLAY…564
a) GIVES NO DISPLAY…564
b) GIVES ABNORMAL DISPLAY…564
E-5 SERVICE METER DOES NOT MOVE (SERIAL NO.:1001-1599)…566
E-6 SERVICE METER AND TACHOMETOR DOES NOT MOVE (SERIAL NO.:1601 AND UP)…567
TROUBLESHOOTING FOR PILOT LAMP SYSTEM(F MODE)…569
F-1 ABNORMALITY IN LIGHTING UP OF RETARDER PILOT LAMP…570
F-2 ABNORMALITY IN LIGHTING UP OF PARKING BRAKE PILOT LAMP…576
F-3 ABNORMALITY IN LIGHTING UP OF FRONT BRAKE OIL LEVEL PILOT LAMP…582
F-4 ABNORMALITY IN LIGHTING UP OF REAR BRAKE CAUTION LAMP…588
F-5 ABNORMALITY IN LIGHTING UP OF ENGINE OIL PRESSURE PILOT LAMP…594
F-6 ABNORMALITY IN LIGHTING UP OF BATTERY CHARGE CAUTION LAMP…598
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE SYSTEM…604
TROUBLESHOOTING OF AIR SYSTEM ON MACHINE AIR COMPRESSOR(C MODE)…607
TROUBLESHOOTING OF AIR SYSTEM ON MACHINE AIR COMPRESSOR…608
BASIC AIR CIRCUIT OF AIR COMPRESSOR…608
C-1 AIR PRESSURE DOES NOT RISE AT ALL…609
C-2 AIR PRESSURE DOES NOT RISE TO SPECIFIED PRESSURE RANGE(GREEN RANGE OF AIR GAUGE)…610
C-3 AIR PRESSURE RISES BUT CHARGING TAKES A LONG TIME…611
C-4 AIR BLOWS OUT FROM SAFETY VALVE…612
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS(H MODE)…613
METHOD OF USING MATRIX TROUBLESHOOTING TABLES…614
H-1 MACHINE DOES NOT START…616
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)…618
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS)…618
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING…619
H-5 TRANSMISSION DOES NOT SHIFT UP…619
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING…620
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR…626
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH…628
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW…629
H-10 FRONT BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE…630
H-11 REAR BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE…631
H-12 STEERING WHEEL IS HEAVY…632
H-13 STEERING WHEEL DOES NOT WORK…633
H-14 STEERING WHEEL VIBRATES…633
H-15 HOIST CYLINDER LACKS LIFTING FORCE(LIFTING SPEED)…634
H-16 HOIST CYLINDER DOES NOT WORK…635
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY…636
TROUBLESHOOTING OF ARSC [AUTOMATIC RETARDER SPEED CONTROLLER] SYSTEM (R MODE)…637
OUTLINE…638
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM…642
R-1 0.1 (ABNORMALITY IN POWER SOURCE VOLTAGE) IS DISPLAYED…644
R-2 1.0 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED…645
R-3 1.3 (DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM) IS DISPLAYED…646
R-4 1.5 (FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED…647
R-5 1.7 (FAILURE IN ACCELERATOR SIGNAL SYSTEM) IS DISPLAYED…648
R-6 1.8 (FAILURE IN SUSPENSION PRESSURE SENSOR "LEFT" SYSTEM) IS DISPLAYED…649
R-7 1.9 (FAILURE IN SUSPENSION PRESSURE SENSOR "RIGHT" SYSTEM) IS DISPLAYED…650
R-8 4.2 (DISCONNECTION IN EXHAUST BRAKE SELECTOR SIGNAL SYSTEM) IS DISPLAYED…651
R-9 4.3 (DISCONNECTION IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED…652
R-10 4.4 (DISCONNECTION IN READY LAMP SYSTEM) IS DISPLAYED…653
R-11 4.5 (DISCONNECTION IN PANEL CAUTION AND BUZZER SYSTEM) IS DISPLAYED…654
R-12 5.2 (SHORT CIRCUIT WITH GROUND IN EXHAUST BRAKE SELECTOR SIGNAL OUTPUT SYSTEM) IS DISPLAYED…655
R-13 5.3 (SHORT CIRCUIT WITH GROUND IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED…656
R-14 5.4 (SHORT CIRCUIT WITH GROUND IN READY OUTPUT CIRCUIT SYSTEM) IS DISPLAYED…657
R-15 5.5 (SHORT CIRCUIT WITH GROUND IN PANEL CAUTION LAMP AND BUZZER OUTPUT SYSTEM) IS DISPLAYED…658
R-16 6.0 (FAILURE IN ENGINE SPEED SYSTEM) IS DISPLAYED…659
R-17 7.0 (DISCONNECTION IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED…660
R-18 7.1 (DISCONNECTION IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED…661
R-19 7.2 (DISCONNECTION IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED…662
R-20 7.3 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED…663
R-21 7.4 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED…664
R-22 7.5 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED…665
R-23 8.1 (SHORT CIRCUIT WITH GROUND IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED…666
R-24 8.3 (DISCONNECTION IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED…667
R-25 8.5 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE REMAINS OPEN) IS DISPLAYED…668
R-26 8.7 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE DOES NOT OPEN) IS DISPLAYED…669
R-27 8.9 (SHORT CIRCUIT WITH GROUND IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED…670
R-28 9.0 (DISCONNECTION IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED…671
R-29 9.1 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (REMAINS OPEN)) IS DISPLAYED…672
R-30 9.2 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (DOES NOT OPEN)) IS DISPLAYED…673
R-31 9.3 (DISCONNECTION IN SYSTEM SWITCH SYSTEM) IS DISPLAYED…674
R-32 9.4 (SHORT CIRCUIT WITH GROUND IN SYSTEM SWITCH SYSTEM) IS DISPLAYED…675
R-33 9.5 (DISCONNECTION, SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED SETTING SWITCH SYSTEM) IS DISPLAYED…676
R-101 SET SPEED CANNOT BE SET…677
R-102 FAILURE CODE IS ALWAYS CLEARED (CONTROLLER DISPLAY WINDOW ALWAYS SHOWS "–") OR FAILURE CODE CANNOT BE CLEARED…680
R-103 EFFECT OF RETARDER IS TOO STRONG WHEN MACHINE IS EMPTY, OR TOO WEAK WHEN MACHINE IS LOADED (DOES NOT JUDGE LOADED/UNLOADED CONDITION PROPERLY)…681
R-104 ABNORMALITY APPEARS IN OTHER CONTROLLER…681
R-105 WHEN TRAVELING DOWNHILL, EVEN WHEN SET SPEED IS EXCEEDED, NO CONTROL IS CARRIED OUT…682
R-106 MONITOR LAMP (BUZZER) STAYS ON (OR OFF)…683
R-107 READY LAMP DOES NOT LIGHT UP (OR STAYS LIGHTED UP)…684
R-108 EXHAUST BRAKE DOES NOT WORK PROPERLY [EXHAUST BRAKE IS ACTUATED WHEN EXHAUST BRAKE SWITCH IS OFF; OR EXHAUST BRAKE IS NOT ACTUATED WHEN EXHAUST BRAKE SWITCH IS ON]…686
R-109 RETARDER LAMP DOES NOT LIGHT UP, OR STAYS LIGHTED UP…688
R-110 TRAVEL SPEED DISPLAY ALWAYS GIVES DISPLAY (OR DOES NOT GIVE ANY DISPLAY)…689
30 DISASSEMBLY AND ASSEMBLY…691
SPECIAL TOOL LIST…694
SKETCHES OF SPECIAL TOOLS…698
STARTING MOTOR…700
REMOVAL AND INSTALLATION…700
ALTERNATOR…701
REMOVAL AND INSTALLATION…701
ENGINE OIL COOLER…702
REMOVAL AND INSTALLATION…702
FUEL INJECTION PUMP…703
REMOVAL AND INSTALLATION…703
FUEL SUPPLY PUMP…704
REMOVAL…704
INSTALLATION…706
AIR COMPRESSOR…708
REMOVAL AND INSTALLATION…708
AIR CONDITIONER COMPRESSOR …710
REMOVAL AND INSTALLATION…710
AIR CONDITIONER CONDENSER…712
REMOVAL AND INSTALLATION…712
WATER PUMP…713
REMOVAL AND INSTALLATION…713
AFTERCOOLER CORE…714
REMOVAL AND INSTALLATION…714
EXHAUST BRAKE CYLINDER…715
REMOVAL AND INSTALLATION…715
TURBOCHARGER…716
REMOVAL AND INSTALLATION…716
NOZZLE HOLDER…717
REMOVAL AND INSTALLATION…717
FUEL INJECTOR…718
REMOVAL…718
INSTALLATION…720
NOZZLE TIP…722
REMOVAL…722
INSTALLATION…724
CYLINDER HEAD…726
REMOVAL…726
INSTALLATION…728
ENGINE FRONT SEAL…739
REMOVAL…739
INSTALLATION…740
ENGINE REAR SEAL…742
REMOVAL…742
INSTALLATION…743
ENGINE…746
REMOVAL…746
INSTALLATION…749
RADIATOR…754
REMOVAL…754
INSTALLATION…756
OIL COOLER…761
REMOVAL AND INSTALLATION…761
OUTPUT SHAFT…762
REMOVAL AND INSTALLATION…762
DISASSEMBLY…763
ASSEMBLY…765
TORQUE CONVERTER, TRANSMISSION…769
REMOVAL …769
INSTALLATION…771
DISCONNECTION…773
CONNECTION…774
TORQUE CONVERTER…775
DISASSEMBLY…775
ASSEMBLY…781
PTO…787
DISASSEMBLY…787
ASSEMBLY…788
TRANSMISSION…790
DISASSEMBLY…790
ASSEMBLY…808
TRANSMISSION CONTROL VALVE (ECMV)…827
REMOVAL AND INSTALLATION…827
TRANSMISSION, MAIN RELIEF VALVE…828
REMOVAL AND INSTALLATION…828
DIFFERENTIAL…829
REMOVAL…829
INSTALLATION…830
DISASSEMBLY…831
ASSEMBLY…834
FRONT WHEEL…842
REMOVAL AND INSTALLATION…842
REAR WHEEL…843
REMOVAL AND INSTALLATION…843
FRONT BRAKE CALIPER PAD…844
REMOVAL AND INSTALLATION…844
FRONT BRAKE CALIPER…845
REMOVAL AND INSTALLATION…845
DISASSEMBLY…846
ASSEMBLY…847
FRONT WHEEL HUB…849
DISASSEMBLY…849
ASSEMBLY…850
FINAL DRIVE CARRIER…853
REMOVAL AND INSTALLATION…853
DISASSEMBLY AND ASSEMBLY…854
REAR WHEEL BRAKE …855
REMOVAL…855
INSTALLATION…857
REAR BRAKE…859
DISASSEMBLY…859
ASSEMBLY…861
FRONT SUSPENSION CYLINDER…864
REMOVAL…864
INSTALLATION…865
DISASSEMBLY…866
ASSEMBLY…867
REAR SUSPENSION CYLINDER…868
REMOVAL AND INSTALLATION…868
DISASSEMBLY…869
ASSEMBLY…870
AIR GOVERNOR…871
REMOVAL AND INSTALLATION…871
DISASSEMBLY AND ASSEMBLY…872
BRAKE VALVE…873
REMOVAL AND INSTALLATION…873
DISASSEMBLY…874
ASSEMBLY…876
PARKING BRAKE SPRING CYLINDER…878
REMOVAL AND INSTALLATION…878
PARKING BRAKE CHAMBER…879
DISASSEMBLY…879
ASSEMBLY…880
FRONT BRAKE CHAMBER…881
REMOVAL AND INSTALLATION…881
DISASSEMBLY…882
ASSEMBLY…884
REAR BRAKE CHAMBER…886
REMOVAL AND INSTALLATION…886
DISASSEMBLY…887
ASSEMBLY…891
SLACK ADJUSTER…894
REMOVAL AND INSTALLATION…894
DISASSEMBLY AND ASSEMBLY…895
AIR DRIER (DESICCANT TYPE)…896
REMOVAL AND INSTALLATION…896
DISASSEMBLY AND ASSEMBLY…897
TRANSMISSION CONTROL, RETARDER BRAKE COOLING PUMP AND HOIST, STEERING PUMP…914
REMOVAL AND INSTALLATION…914
EMERGENCY STEERING MOTOR PUMP…915
REMOVAL AND INSTALLATION…915
STEERING VALVE…916
REMOVAL AND INSTALLATION…916
DISASSEMBLY…917
ASSEMBLY…922
DEMAND VALVE…930
REMOVAL AND INSTALLATION…930
DISASSEMBLY AND ASSEMBLY…931
RELIEF VALVE…932
DISASSEMBLY AND ASSEMBLY…932
HOIST VALVE…933
REMOVAL AND INSTALLATION…933
DISASSEMBLY…934
ASSEMBLY…935
STEERING CYLINDER…936
REMOVAL AND INSTALLATION…936
DISASSEMBLY…937
ASSEMBLY…939
HOIST CYLINDER…941
REMOVAL AND INSTALLATION…941
DISASSEMBLY…942
ASSEMBLY…945
DUMP BODY…948
REMOVAL AND INSTALLATION…948
SHIM OF DUMP BODY…949
PROCEDURE FOR ADJUSTING…949
TRANSMISSION CONTROLLER…950
REMOVAL AND INSTALLATION…950
ENGINE CONTROLLER…951
REMOVAL AND INSTALLATION…951
SHIFT INDICATOR CONTROLLER…952
REMOVAL AND INSTALLATION…952
PARKING BRAKE SHOE…953
REMOVAL …953
INSTALLATION…954
40 MAINTENANCE STANDARD…955
DAMPER…957
TORQUE CONVERTER…958
TRANSMISSION…960
MAIN RELIEF VALVE…963
TRANSMISSION VALVE, ECMV…964
FRONT AXLE…965
DIFFERENTIAL…967
FINAL DRIVE…970
FRONT BRAKE…971
REAR BRAKE…972
PARKING BRAKE…974
REAR BRAKE CHAMBER…975
FRONT BRAKE CHAMBER…976
SLACK ADJUSTER…977
HYDRAULIC PUMP…978
STEERING, HOIST PUMP…979
STEERING CYLINDER…980
DEMAND VAVLE…981
CROSSOVER RELIEF VALVE…981
HOIST VALVE…982
HOIST CYLINDER…983
STEERING LINKAGE…984
REAR AXLE SUPPORT…985
FRONT SUSPENSION CYLINDER…986
REAR SUSPENSION CYLINDER…987
90 OTHERS…989
AIR CIRCUIT DIAGRAM (STANDARD SPECIFICATION SERIAL NO.:1001-1200)…991
AIR CIRCUIT DIAGRAM (STANDARD SPECIFICATION SERIAL NO.:1201-1600)…993
AIR CIRCUIT DIAGRAM (EMERGENCY BRAKE SPECIFICATION SERIAL NO.:1001-1200)…995
AIR CIRCUIT DIAGRAM (EMERGENCY BRAKE SPECIFICATION SERIAL NO.:1201-1600)…997
AIR CIRCUIT DIAGRAM (EMERGENCY BRAKE SPECIFICATION SERIAL NO.:1601 AND UP)…999
HYDRAULIC CIRCUIT DIAGRAM FOR TORQUE CONVERTER, TRANSMISSION, AND BRAKE COOLING…1001
STEERING, HOIST HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO.:1001-1200)…1003
STEERING, HOIST HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO.:1201 AND UP)…1005
ELECTRIC CIRCUIT DIAGRAM (1/2) (SERIAL NO.:1001-1200)…1007
ELECTRIC CIRCUIT DIAGRAM (2/2) (SERIAL NO.:1001-1200)…1009
ELECTRIC CIRCUIT DIAGRAM (1/2) (SERIAL NO.:1201-1600)…1011
ELECTRIC CIRCUIT DIAGRAM (2/2) (SERIAL NO.:1201-1600)…1013
ELECTRIC CIRCUIT DIAGRAM (1/4) (SERIAL NO.:1601-1685)…1015
ELECTRIC CIRCUIT DIAGRAM (2/4) (SERIAL NO.:1601-1685)…1017
ELECTRIC CIRCUIT DIAGRAM (3/4) (SERIAL NO.:1601-1685)…1019
ELECTRIC CIRCUIT DIAGRAM (4/4) (SERIAL NO.:1601-1685)…1021
ELECTRIC CIRCUIT DIAGRAM (1/4) (SERIAL NO.:1686 AND UP)…1023
ELECTRIC CIRCUIT DIAGRAM (2/4) (SERIAL NO.:1686 AND UP)…1025
ELECTRIC CIRCUIT DIAGRAM (3/4) (SERIAL NO.:1686 AND UP)…1027
ELECTRIC CIRCUIT DIAGRAM (4/4) (SERIAL NO.:1686 AND UP)…1029
ELECTRIC CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM…1031
ELECTRIC CIRCUIT DIAGRAM OF AIR CONDITIONER (SERIAL NO.:1001-1200)…1033
ELECTRIC CIRCUIT DIAGRAM OF AIR CONDITIONER (SERIAL NO.: 1201 – 1600)…1034
ELECTRIC CIRCUIT DIAGRAM OF AIR CONDITIONER (SERIAL NO.: 1601 AND UP)…1035

Komatsu Dump Truck HD255 Repair Service Manual

INSTANT DOWNLOAD

Posted on June 8, 2025 by admin

Komatsu Motor Grader GD825A Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Motor Grader GD825A , with all the technical information to maintain, diagnose, repair, and 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.

SEAM021400 – Motor Grader GD825A-2 Operation & Maintenance Manual.pdf
SEAM021403T – Motor Grader GD825A-2 Operation & Maintenance Manual.pdf
SEAM02350100 – Motor Grader GD825A-1 Operation & Maintenance Manual.pdf
SEBM002308 – Motor Grader GD825A-2 Shop Manual.pdf
SEBM02350106 – Motor Grader GD825A-1 Shop Manual.pdf
TEN00012-00 – Motor Grader GD825A-2 Operation & Maintenance Manual.pdf
TEN00334-02 – Motor Grader GD825A-2 Operation & Maintenance Manual.pdf

Total Pages: 2,717 pages
File Format: PDF
Language: English

MAIN SECTIONS
SEAM021400 – Motor Grader GD825A-2 Operation & Maintenance Manual….2
COVER….2
1. FOREWORD….3
2. SAFETY INFORMATION….4
3. INTRODUCTION….5
3.1 INTENDED USE….5
3.2 FEATURES….5
3.3 BREAKING IN THE MACHINE….5
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….6
4.1 MACHINE SERIAL NO. PLATE POSITION….6
4.2 ENGINE SERIAL NO. PLATE POSITION….6
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….6
5. CONTENTS….7
SAFETY….11
6. GENERAL PRECAUTIONS….12
7. PRECAUTIONS DRING OPERATION….18
7.1 BEFORE STARTING ENGINE….18
7.2 AFTER STARTING ENGINE….20
7.3 TRANSPORTATION….27
7.4 BATTERY….28
7.5 TOWING….30
8. PRECAUTIONS FOR MAINTENANCE….31
8.1 BEFORE CARRYING OUT MAINTENANCE….31
8.2 DURING MAINTENANCE….35
8.3 TIRES….41
9. POSITION FOR ATTACHING SAFETY LABELS….43
OPERATION….49
10. GENERAL VIEW….50
10.1 GENERAL VIEW OF MACHINE….50
10.2 GENERAL VIEW OF CONTROLS AND GAUGES….51
11. EXPLANATION OF COMPONENTS….53
11.1 MONITOR PANEL….53
11.2 CLUSTER GAUGE AND PILOT LAMPS….65
11.3 SWITCHES….66
11.4 CONTROL LEVERS AND PEDALS….72
11.5 DUST INDICATOR….79
11.6 ARTICULATE LOCK PIN….79
11.7 FUSE BOX….79
11.8 OPERATOR'S CAB LIFT MACHANISM….80
11.9 BACKUP ALARM….80
11.10 FRONT GLASS….81
11.11 TOOL BAG….82
11.12 STORAGE BOX….82
11.13 STORAGE NET….82
11.14 QUICK-FILL FUEL FILLER….82
11.15 AIR CONDITIONER….83
12. OPERATION….87
12.1 CHECKS BEFORE STARTING ENGINE….87
12.2 STARTING ENGINE….102
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….104
12.4 TRAVELING POSTURE FOR MACHINE….105
12.5 MOVING MACHINE….106
12.6 SHIFTING GEAR….107
12.7 SHIFTING BETWEEN FOREWARD AND REVERSE….108
12.8 STOPPING MACHINE….109
12.9 TURNING MACHINE….110
12.10 OPERATING WORK EQUIPMENT….112
12.11 WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….115
12.12 PRECAUTIONS FOR OPERATION….141
12.13 ADJUSTING WORK EQUIPMENT POSTURE….143
12.14 PARKING MACHINE….144
12.15 CHECK AFTER FINISHING WORK….145
12.16 STOPPING ENGINE….146
12.17 CHECK AFTER STOPPING ENGINE….146
12.18 LOCKING….147
12.19 HANDLING THE TIRES….148
12.20 HANDLING BLADE ACCUMULATOR….149
12.21 HANDLING BLADE FLOAT….151
13. TRANSPORTATION….153
13.1 LOADING, UNLOADING WORK….153
13.2 PRECAUTIONS FOR LOADING….154
13.3 PRECAUTIONS FOR TRANSPORTATION….154
14. COLD WEATHER OPERATION….155
14.1 PRECAUTIONS FOR LOW TEMPERATURE….155
14.2 CAUTIONS AFTER COMPLETION OF WORK….157
14.3 AFTER COLD WEATHER….157
15. LONG-TERM STORAGE….158
15.1 BEFORE STORAGE….158
15.2 DURING STORAGE….158
15.3 AFTER STORAGE….158
16. TROUBLESHOOTING….159
16.1 AFTER RUNNING OUT OF FUEL….159
16.2 WHEN LEANING PIPING IS DAMAGED….159
16.3 TOWING THE MACHINE….160
16.4 IF BATTERY IS DISCHARGED….164
16.5 OTHER TROUBLE….168
MAINTENANCE….173
17. GUIDES TO MAINTENANCE….174
18. OUTLINES OF SERVICE….176
18.1 OUTLINE OF OIL, FUEL, COOLANT….176
18.2 RELATING TO ELECTRIC SYSTEM….179
19. WEAR PARTS LIST….180
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….181
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….185
21.1 INTRODUCTION OF NECESSARY TOOLS….185
21.2 TORQUE LIST….186
22. PERIODIC REPLACEMENT OF CRITICAL PARTS….187
23. MAINTENANCE SCHEDULE CHART….190
23.1 MAINTENANCE SCHEDULE CHART….190
24. SERVICE PROCEDURE….194
24.1 INITIAL 250 HOURS SERVICE….194
24.2 WHEN REQUIRED….195
24.3 CHECK BEFORE STARTING….208
24.4 EVERY 50 HOURS SERVICE….214
24.5 EVERY 250 HOURS SERVICE….215
24.6 EVERY 500 HOURS SERVICE….230
24.7 EVERY 1000 HOURS SERVICE….239
24.8 EVERY 2000 HOURS SERVICE….250
24.9 EVERY 4000 HOURS SERVICE….256
SPECIFICATIONS….257
25. SPECIFICATIONS….258
OPTIONS, ATTACHMENTS….261
26. HANDLING EMERGENCY STEERING DEVICE….262
26.1 CHECKS….262
SEAM021403T – Motor Grader GD825A-2 Operation & Maintenance Manual….265
COVER….265
1.FOREWORD….266
2.SAFETY INFORMATION….269
3.INTRODUCTION….270
4.LOCATION OF PLATES,TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR….271
5.CONTENTS….272
SAFETY….275
6.GENERAL PRECAUTIONS….276
7.PRECAUTIONS DURING OPERATION….282
7.1 BEFORE STARTING ENGINE….282
7.2 AFTER STARTING ENGINE….284
7.3 TRANSPORTATION….291
7.4 BATTERY….292
7.5 TOWING….294
8.PRECAUTIONS FOR MAINTENANCE….295
8.1 BEFORE CARRYING OUT MAINTENANCE….295
8.2 DURING MAINTENANCE….299
8.3 TIRES….305
9.POSITION FOR ATTACHING SAFETY LABELS….307
OPERATION….312
10.GENERAL VIEW….313
10.1 GENERAL VIEW OF MACHINE….313
10.2 GENERAL VIEW OF CONTROLS AND GAUGES….314
11.EXPLANATION OF COMPONENTS….316
11.1 MONITOR PANEL….316
11.2 CLUSTER GAUGE AND PILOT LAMPS….328
11.3 SWITCHES….329
11.4 CONTROL LEVERS AND PEDALS….335
11.5 DUST INDICATOR….342
11.6 ARTICULATE LOCK PIN….342
11.7 FUSE BOX….342
11.8 OPERATOR'S CAB LIFT MECHANISM….343
11.9 BACKUP ALARM….343
11.10 FRONT GLASS….344
11.11 TOOL BAG….345
11.12 STORAGE BOX….345
11.13 STORAGE NET….345
11.14 QUICK-FILL FUEL FILLER….345
11.15 AIR CONDITIONER….346
12.OPERATION….350
12.1 CHECK BEFORE STARTING ENGINE….350
12.2 STARTING ENGINE….365
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….367
12.4 TRAVELING POSTURE FOR MACHINE….368
12.5 MOVING MACHINE ….369
12.6 SHIFTING GEAR….370
12.7 SHIFTING BETWEEN FORWARD AND REVERSE….371
12.8 STOPPING MACHINE….372
12.9 TURNING MACHINE….373
12.10 OPERATING WORK EQUIPMENT….375
12.11 WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….378
12.12 PRECAUTIONS FOR OPERATION ….404
12.13 ADJUSTING WORK EQUIPMENT POSTURE….407
12.14 PARKING MACHINE….408
12.15 CHECK AFTER FINISHING WORK….409
12.16 STOPPING ENGINE….410
12.17 CHECK AFTER STOPPING ENGINE….410
12.18 LOCKING ….411
12.19 HANDLING THE TIRES….411
12.20 HANDLING BLADE ACCUMULATOR….412
12.21 HANDLING BLADE FLOAT ….414
13.TRANSPORTATION….416
13.1 LOADING, UNLOADING WORK….416
13.2 PRECAUTIONS FOR LOADING….417
13.3 PRECAUTIONS FOR TRANSPORTATION….417
14.COLD WEATHER OPERATION….418
14.1 PRECAUTIONS FOR LOW TEMPERATURE….418
14.2 CAUTIONS AFTER COMPLETION OF WORK….420
14.3 AFTER COLD WEATHER….420
15.LONG-TERM STORAGE….421
15.1 BEFORE STORAGE….421
15.2 DURING STORAGE….421
15.3 AFTER STORAGE….421
16.TROUBLESHOOTING….422
16.1 AFTER RUNNING OUT OF FUEL….422
16.2 WHEN LEANING PIPING IS DAMAGED….422
16.3 TOWING THE MACHINE….423
16.4 IF BATTERY IS DISCHARGED….427
16.5 OTHER TROUBLE….431
MAINTENANCE….439
17.GUIDES TO MAINTENANCE….440
18.OUTLINES OF SERVICE….442
18.1 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ….442
18.2 RELATING OF ELECTRIC SYSTEM….445
19.WEAR PARTS LIST….446
20.USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….447
21.STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….451
21.1 INTRODUCTION OF NECESSARY TOOLS….451
21.2 TORQUE LIST….452
22.PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….453
23.MAINTENANCE SCHEDULE CHART….456
23.1 MAINTENANCE SCHEDULE CHART….456
24.SERVICE PROCEDURE….460
24.1 INITIAL 250 HOURS SERVICE….460
24.2 WHEN REQUIRED….461
24.3 CHECKS BEFORE STARTING….474
24.4 EVERY 50 HOURS SERVICE….480
24.5 EVERY 250 HOURS SERVICE….481
24.6 EVERY 500 HOURS SERVICE….496
24.7 EVERY 1000 HOURS SERVICE….505
24.8 EVERY 2000 HOURS SERVICE….516
24.9 EVERY 4000 HOURS SERVICE….522
SPECIFICATIONS….523
25.SPECIFICATIONS….524
OPTIONS,ATTACHMENTS….526
26.HANDLING EMERGENCY STEERING DEVICE….527
26.1 CHECKS….527
SEAM02350100 – Motor Grader GD825A-1 Operation & Maintenance Manual….530
SEBM002308 – Motor Grader GD825A-2 Shop Manual….648
COVER….648
CONTENTS….649
01 GENERAL….694
SPECIFICATION DIMENSION DRAWINGS ….695
SPECIFICATIONS ….697
WEIGHT TABLE ….700
FUEL, COOLANT AND LUBRICANTS ….701
10 STRUCTURE AND FUNCTION….704
GENERAL ….705
POWER TRAIN DIAGRAM ….706
JOINT ….707
HYDROSHIFT TRANSMISSION AND TRANSFER PIPING….708
HYDRAULIC CIRCUIT FOR POWER TRAIN ….709
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN ….710
PTO (POWER TAKE OFF) ….713
HYDROSHIFT TRANSMISSION AND TRANSFER ….715
TRANSMISSION CONTROL VALVE ….723
TRANSMISSION CONTROL ….751
INCHING CONTROL ….759
DRIVE SHAFT ….760
FINAL DRIVE, DIFFERENTIAL LOCK AND UNLOCK PIPING….761
FINAL DRIVE….763
TANDEM DRIVE ….766
STEERING PIPING ….768
STEERING CIRCUIT SYSTEM ….769
STEERING CIRCUIT DIAGRAM ….770
STEERING VALVE ….771
DOUBLE RELIEF VALVE ….775
CHECK VALVE ….776
EMERGENCY STEERING SYSTEM ….777
FRONT AXLE ….778
WHEEL ….782
DISC BRAKE ….785
PARKING BRAKE ….787
BRAKE AIR PIPING….789
BRAKE AIR CIRCUIT SYSTEM ….790
BRAKE AIR CIRCUIT DIAGRAM ….791
AIR DRIER ….792
AIR GOVERNOR ….794
AIR TANK ….796
SAFETY VALVE ….796
AUTOMATIC DRAIN VALVE ….797
CHECK VALVE ….799
BRAKE VALVE ….800
PARKING BRAKE SYSTEM ….804
PARKING BRAKE SOLENOID VALVE ….805
EXHAUST VALVE ….806
SPRING CYLINDER ….807
HYDRAULIC CONTROL PIPING ….808
HYDRAULIC CIRCUIT SYSTEM ….816
HYDRAULIC CIRCUIT DIAGRAM ….818
CLOSED CENTER LOAD SENSING SYSTEM (CLSS) ….830
HYDRAULIC PUMP ….834
PRIORITY FLOW DIVIDER VALVE ….839
SURGE PRESSURE ABSORBING VALVE ….845
HYDRAULIC CONTROL VALVE ….848
PRESSURE COMPENSATING MECHANISM OF HYDRAULIC CONTROL VALVE ….852
BLADE LIFT SPEED ADJUSTMENT MECHANISM ….858
PILOT CHECK VALVE ….860
PILOT CHECK VALVE (WITH SAFETY VALVE) ….862
CIRCLE ROTATION MOTOR ….864
BLADE ACCUMULATOR SYSTEM ….867
BLADE FLOAT SYSTEM ….869
DRAWBAR AND LIFTER ….870
BLADE ….874
LIFTER BRACKET CONTROL PIPING ….876
CIRCLE ROTATION GEAR….877
REAR MOUNT RIPPER ….879
HYDRAULIC CONTROL LINKAGE ….880
MAIN FRAME….882
AIR CONDITIONER….884
ELECTRICAL WIRING DIAGRAM….887
MONITOR PANEL, CLUSTER GAUGE AND PILOT LAMP ….892
ELECTRICAL CIRCUIT DIAGRAM….894
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) ….922
TRANSMISSION CONTROL SYSTEM ….928
SENSORS….934
ENGINE STARTING CIRCUIT….941
ENGINE STOPPING CIRCUIT….949
20 TESTING AND ADJUSTING….956
STANDARD VALUE TABLE FOR ENGINE ….958
STANDARD VALUE TABLE FOR CHASSIS ….961
TOOL LIST FOR TESTING AND ADJUSTING ….967
TESTING AND ADJUSTING VALVE CLEARANCE ….969
MEASURING COMPRESSION PRESSURE ….970
TESTING AND ADJUSTING FUEL INJECTION TIMING ….971
MEASURING BLOW-BY PRESSURE ….975
MEASURING ENGINE OIL PRESSURE ….976
MEASURING EXHAUST GAS COLOR ….977
MEASURING EXHAUST GAS TEMPERATURE….978
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) ….979
TESTING AND ADJUSTING BELT TENSION ….980
PROCEDURE FOR ADJUSTING THE ENGINE STOP MOTOR CABLE ….983
ADJUSTING ACCELERATOR CONTROL ….984
INCHING PEDAL TRAVEL AND OPERATING FORCE ….985
MEASURING TRANSMISSION OIL PRESSURE….986
CHECKING DIFFERENTIAL LOCKING DEVICE OIL PRESSURE ….988
STEERING SYSTEM….989
CHECKING TIRE RUNOUT ….990
CHECKING AIR PRESSURE OF TIRE ….990
CHECKING TOE-IN ….991
INSTALLATION OF ARTICULATE CENTER PINS….992
CHECKING WEAR OF BRAKE DISC ….993
CHECKING PARKING BRAKE ….993
CHECKING WORK EQUIPMENT CONTROL LEVER TRAVEL AND OPERATING FORCE ….994
CHECKING HYDRAULIC OIL TEMPERATURE ….994
CHECKING WORK EQUIPMENT HYDRAULIC PRESSURE ….995
ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE ….995
MEASURING HYDRAULIC DRIFT ….996
CHARGING BLADE ACCUMULATOR WITH GAS ….997
ADJUSTING BLADE LIFT SPEED ….998
BLEEDING AIR FROM HYDRAULIC PUMP ….999
ADJUSTING SLIP LOAD OF CIRCLE ROTATION CLUTCH ….1000
ADJUSTING CLEARANCE OF F AND R SWITCHES ….1004
ADJUSTING SHIFT POTENTIOMETER ….1005
ADJUSTING INCHING POTENTIOMETER ….1006
ADJUSTING SPEEDOMETER MODULE OF MACHINE MONITOR ….1007
TROUBLESHOOTING….1009
POINTS TO REMEMBER WHEN TROUBLESHOOTING ….1010
SEQUENCE OF EVENTS IN TROUBLESHOOTING ….1011
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT….1012
CHECKS BEFORE TROUBLESHOOTING….1021
ELECTRICAL CIRCUIT SYSTEM DIAGRAM ….1022
CONNECTOR TYPES AND MOUNTING LOCATIONS….1038
ELECTRICAL WIRING DIAGRAM….1048
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS….1052
T- BRANCH BOX AND T- BRANCH ADAPTER TABLE….1088
METHOD OF USING TROUBLESHOOTING CHARTS….1091
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE….1093
TROUBLESHOOTING OF ENGINE (S MODE)….1097
S-1 Starting performance is poor (Starting always takes time) ….1098
S-2 Engine does not start ….1099
1) Engine does not turn….1099
2) Engine turns but no exhaust gas comes out (Fuel is not being injected)….1100
3) Exhaust gas comes out but engine does not start (Fuel is being injected)….1101
S-3 Engine does not pick up smoothly (Follow-up is poor) ….1102
S-4 Engine stops during operations ….1103
S-5 Engine does not rotate smoothly (hunting) ….1104
S-6 Engine lacks output (no power) ….1105
S-7 Exhaust gas is black (incomplete combustion) ….1106
S-8 Oil consumption is excessive (or exhaust gas is blue)….1107
S-9 Oil becomes contaminated quickly ….1108
S-10 Fuel consumption is excessive ….1109
S-11 Oil is in cooling water, or water spurts back, or water level goes down ….1110
S-12 Oil pressure lamp lights up (drop in oil pressure) ….1111
S-13 Oil level rises….1112
S-14 Water temperature becomes too high (overheating) ….1113
S-15 Abnormal noise is made….1114
S-16 Vibration is excessive….1115
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (M MODE)….1117
M-1 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR….1118
M-2 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT GO OUT….1118
M-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH….1119
M-4 PREHEATING OPERATION IS NOT BEING USED BUT PREHEATING DISPLAY LIGHTS UP….1121
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)….1123
M-6 BUZZER DOES NOT SOUND FOR 1 MINUTE WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) ….1129
M-7 THERE IS NO ABNORMALITY DISPLAYED ON MONITOR, BUT BUZZER SOUNDS ….1129
M-8 MONITOR PANEL LIGHTING DOES NOT LIGHT UP….1130
M-9 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED; SERVICE METER CONTINUES TO MOVE WHEN ENGINE IS STOPPED….1132
M-10 COOLANT TEMPERATURE GAUGE DISPLAYS ABNORMALLY LOW TEMPERATURE….1133
M-11 COOLANT TEMPERATURE GAUGE DOES NOT GIVE A DISPLAY ….1134
M-12 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL ….1135
M-13 FUEL GAUGE DOES NOT GIVE ANY DISPLAY ….1135
M-14 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY….1136
M-15 TURN SIGNAL INDICATOR PILOT LAMP DOES NOT LIGHT UP ….1137
M-16 HIGH BEAM PILOT LAMP DOES NOT LIGHT UP….1138
TROUBLESHOOTING CHART FOR ELECTRONIC (ENGINE, PARKING BRAKE, TRANSMISSION CONTROL) (E MODE)….1140
E-1 Engine does not start (starting motor works)….1141
E-2 Starting motor does not turn. ….1141
E-3 Parking brake does not work ….1146
E-4 Parking brake cannot be released ….1146
E-5 Speed range does not change when transmission lever is switched between F1and F8 or between R1and R8 ….1148
E-6 Transmission does not shift to 1st (F and R). ….1154
E-7 Transmission does not shift to 2nd (F and R). ….1154
E-8 Transmission does not shift to 3rd (F and R). ….1154
E-9 Transmission does not shift to 4th (F and R). ….1155
E-10 Transmission does not shift to 5th (F and R). ….1155
E-11 Transmission does not shift to 6th (F and R). ….1155
E-12 Transmission does not shift to 7th (F and R). ….1156
E-13 Transmission does not shift to 8th (F and R). ….1156
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (ET MODE)….1157
LED DISPLAY FOR TRANSMISSION CONTROLLER….1158
ET-1 [A1] (Short circuit in 1st solenoid) is displayed ….1164
ET-2 [A2] (Short circuit in 2nd solenoid) is displayed ….1165
ET-3 [A3} (Short circuit in 3rd solenoid) is displayed….1166
ET-4 [A4] (Short circuit in 4th solenoid) is displayed ….1167
ET-5 [A5] (Short circuit in High/Low solenoid) is displayed ….1168
ET-6 [A7] (Short circuit in FORWARD/REVERSE solenoid) is displayed ….1170
ET-7 [b1] (Disconnection in 1st solenoid) is displayed ….1172
ET-8 [b2] (Disconnection in 2nd solenoid) is displayed ….1173
ET-9 [b3] (Disconnection in 3rd solenoid) is displayed ….1174
ET-10 [b4] (Disconnection in 4th solenoid) is displayed ….1175
ET-11 [b5] (Disconnection in Low solenoid) is displayed ….1176
ET-12 [b6] (Disconnection in High solenoid) is displayed ….1177
ET-13 [b7] (Disconnection in FORWARD solenoid) is displayed ….1178
ET-14 [b8] (Disconnection in REVERSE solenoid) is displayed ….1179
ET-15 [c1] (Disconnection in inching potentiometer) is displayed ….1180
ET-16 [c2] (Failure in shift potentiometer 1) is displayed ….1181
ET-17 (Failure in shift potentiometer 2) is displayed ….1182
ET-18 [d1] (Failure in F and R switches) is displayed ….1183
ET-19 [d4] (Disconnection in engine speed sensor) is displayed ….1185
ET-20 [d5] (Disconnection in speed sensor) is displayed ….1186
ET-21 [d6] (Failure in transmission oil temperature sensor) is displayed ….1187
ET-22 [E0] (Drop in power source voltage) is displayed ….1188
ET-23 [E1] (Short circuit in parking brake) is displayed ….1190
ET-24 [E2] or [F2] (Short circuit, disconnection in parking brake lamp) is displayed ….1191
ET-25 [E3] or [F3] (Shot-t circuit, disconnection in differential lock relay) is displayed ….1192
ET-26 [E4] or [F4] (Short circuit, disconnection in backup buzzer relay) is displayed ….1194
ET-27 [E5} or {F5] (Short circuit, disconnection in caution lamp) is displayed ….1196
ET-28 [E6] or [F6] (Short circuit, disconnection in alarm buzzer relay) is displayed ….1197
ET-29 [E7] or [F7] (Short circuit, disconnection in starting motor relay) is displayed ….1199
ET-30 [F1] (Disconnection in parking brake) is displayed ….1201
TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM (H MODE)….1209
STANDARDS FOR MEASURING HYDRAULIC PRESSURE, AND JUDGEMENT VALUES….1210
TABLE OF FAILURE MODES AND CAUSES….1212
HYDRAULIC PRESSURE MEASUREMENT AND FILTER MOUNTING POSITIONS….1214
H-1 Abnormal noise is made (from around pump). ….1216
H-2 Relief sound is heard (when not operating). ….1216
H-3 Hydraulic oil overheats (when not operating). ….1216
H-4 Work equipment does not move when control lever is operated (steering at neutral). ….1217
H-5 Work equipment is slow, lacks power. ….1218
H-6 There is excessive hydraulic drift of work equipment. ….1219
H-7 Steering wheel does not turn (work equipment at neutral). ….1219
H-8 Turning speed is slow, lacks power (work equipment at neutral). ….1220
H-9 Feeling when operating steering wheel is strange. ….1220
30 DISASSEMBLY AND ASSEMBLY….1221
HOW TO READ THIS MANUAL….1223
COATING MATERIALS LIST….1225
SPECIAL TOOL LIST ….1228
STARTING MOTOR….1230
REMOVAL AND INSTALLATION….1230
ALTERNATOR….1230
REMOVAL AND INSTALLATION….1230
NOZZLE HOLDER….1232
REMOVAL AND INSTALLATION….1232
FUEL INJECTION PUMP….1233
REMOVAL AND INSTALLATION….1233
WATER PUMP….1234
REMOVAL….1234
INSTALLATION ….1235
ENGINE OIL COOLER CORE ….1236
REMOVAL AND INSTALLATION ….1236
TURBOCHARGER….1237
REMOVAL AND INSTALLATION ….1237
AIR COMPRESSOR….1238
REMOVAL AND INSTALLATION ….1238
CYLINDER HEAD ….1239
REMOVAL….1239
INSTALLATION….1243
ENGINE (INCL. TRANSMISSION) ….1246
REMOVAL….1246
INSTALLATION….1253
RADIATOR….1261
REMOVAL….1261
INSTALLATION….1263
FUEL TANK ….1265
REMOVAL….1265
INSTALLATION….1266
PTO….1268
DISASSEMBLY….1268
ASSEMBLY….1273
TRANSMISSION….1278
REMOVAL….1278
INSTALLATION….1282
DISASSEMBLY….1286
ASSEMBLY….1294
TRANSFER….1309
DISASSEMBLY….1309
ASSEMBLY ….1312
TRANSMISSION CONTROL VALVE….1316
DISASSEMBLY….1316
ASSEMBLY….1318
HYDROSHIFT TRANSMISSION PUMP….1320
REMOVAL AND INSTALLATION….1320
TANDEM AND FINAL DRIVE….1321
REMOVAL….1321
INSTALLATION….1323
FINAL DRIVE….1325
DISASSEMBLY….1325
ASSEMBLY….1334
BEVEL GEAR….1346
DISASSEMBLY ….1352
ASSEMBLY….1349
BEVEL PINION….1352
DISASSEMBLY….1352
ASSEMBLY….1353
FRONT AXLE ….1354
REMOVAL….1354
INSTALLATION ….1356
DISASSEMBLY….1358
ASSEMBLY….1361
STEERING VALVE ….1366
DISASSEMBLY….1366
ASSEMBLY ….1369
WHEEL BRAKE….1373
DISASSEMBLY….1373
ASSEMBLY….1375
AIR TANK ….1378
REMOVAL AND INSTALLATION….1378
HYDRAULIC TANK ….1379
REMOVAL AND INSTALLATION….1379
HYDRAULIC PUMP ….1380
REMOVAL….1380
INSTALLATION….1381
DISASSEMBLY ….1383
ASSEMBLY ….1397
HYDRAULIC CONTROL VALVE ….1420
REMOVAL….1420
INSTALLATION….1421
MAIN CONTROL VALVE ….1423
DISASSEMBLY….1423
ASSEMBLY….1425
CIRCLE ROTATION MOTOR ….1427
DISASSEMBLY….1427
ASSEMBLY….1430
DRAWBAR SHIFT CYLINDER, BLADE LIFT CYLINDER, LIFTER GUIDE….1446
REMOVAL….1446
INSTALLATION….1448
ARTICULATE CYLINDER….1450
REMOVAL AND INSTALLATION ….1450
REAR MOUNT RIPPER CYLINDER….1451
REMOVAL AND INSTALLATION….1451
HYDRAULIC CYLINDER Serial No.: 11001 – 12502….1452
DISASSEMBLY….1452
ASSEMBLY….1454
HYDRAULIC CYLINDER Serial No.: 12503 and up….1457
DISASSEMBLY….1457
ASSEMBLY….1461
CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR ….1465
REMOVAL….1465
INSTALLATION….1466
DISASSEMBLY….1469
ASSEMBLY….1472
BLADE….1484
REMOVAL AND INSTALLATION….1484
CIRCLE AND DRAWBAR….1487
REMOVAL AND INSTALLAITON….1487
DISASSEMBLY….1488
ASSEMBLY….1490
REAR MOUNT RIPPER….1501
REMOVAL….1501
INSTALLATION….1502
METHOD LIFTING UP ROPS CAB….1503
INSTALLATION OF ROPS….1505
ROPS CAB….1506
REMOVAL….1506
INSTALLATION….1510
DISCONNECTION AND CONNECTION OF ARTICULATE SECTION Serial No.: 11001 – 12502….1515
Disconnection….1515
Connection….1518
DISCONNECTION AND CONNECTION OF ARTICULATE SECTION Serial No.: 12503 and up….1520
Disconnection….1520
Connection….1523
40 MAINTENANCE STANDARD….1526
HYDROSHIFT TRANSMISSION AND TRANSFER….1527
TRANSMISSION PUMP ….1531
TRANSMISSION CONTROL VALVE ….1533
TRANSMISSION SOLENOID VALVE ….1539
FINAL DRIVE ….1542
DIFFERENTIAL LOCK-UP PUMP ….1543
TANDEM DRIVE….1544
FRONT AXLE ….1545
STEERING CYLINDER….1549
DISC BRAKE….1550
PARKING BRAKE….1551
SPRING CYLINDER ….1552
HYDRAULIC CONTROL VALVE ….1553
HYDRAULIC CYLINDER….1557
HYDRAULIC PUMP ….1561
DRAWBAR AND LIFTER ….1563
BLADE ….1567
CIRCLE ROTATION GEAR….1569
RIPPER….1571
FRAME ….1572
SEBM02350106 – Motor Grader GD825A-1 Shop Manual….1574
TEN00012-00 – Motor Grader GD825A-2 Operation & Maintenance Manual….2182
COVER….2182
FOREWORD….2183
FOREWORD….2184
SAFETY INFORMATION….2187
INTENDED USE….2189
DIRECTIONS OF MACHINE….2189
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND….2190
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….2190
ENGINE SERIAL NO. PLATE POSITION….2190
SERVICE METER POSITION….2191
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….2191
CONTENTS….2192
SAFETY….2195
SAFETY INFORMATION….2196
SAFETY LABELS….2198
POSITION FOR ATTACHING SAFETY LABELS….2199
SAFETY LABELS….2200
GENERAL PRECAUTIONS….2206
SAFETY RULES….2206
IF ABNORMALITIES ARE FOUND….2206
CLOTHING AND PERSONAL PROTECTIVE ITEMS….2206
FIRE EXTINGUISHER AND FIRST AID KIT….2206
SAFETY FEATURES….2206
KEEP MACHINE CLEAN….2207
INSIDE OPERATOR'S COMPARTMENT….2207
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT….2207
HANDRAILS AND STEPS….2208
MOUNTING AND DISMOUNTING….2208
DO NOT GET CAUGHT IN ARTICULATED PORTION….2209
PREVENTION OF BURNS….2209
FIRE PREVENTION….2210
ACTION IF FIRE OCCURS….2210
WINDOW WASHER LIQUID….2211
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)….2211
PRECAUTIONS FOR ATTACHMENTS….2211
UNAUTHORIZED MODIFICATION….2211
SAFETY AT WORKSITE….2212
WORKING ON LOOSE GROUND….2212
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES….2212
ENSURE GOOD VISIBILITY….2213
VENTILATION FOR ENCLOSED AREAS….2213
CHECKING SIGNALMAN'S SIGNALS AND SIGNS….2213
EMERGENCY ESCAPE FROM OPERATOR'S CAB….2213
ASBESTOS DUST HAZARD PREVENTION….2213
PRECAUTIONS DURING OPERATION….2214
STARTING ENGINE….2214
CHECKS BEFORE STARTING ENGINE, ADJUST….2214
PRECAUTIONS WHEN STARTING….2214
PRECAUTIONS IN COLD AREAS….2215
OPERATION….2216
CHECKS BEFORE STARTING OPERATION….2216
PRECAUTIONS BEFORE MOVING OFF….2216
PRECAUTIONS WHEN TRAVELING….2217
PRECAUTIONS WHEN TRAVELING ON SLOPES….2218
PRECAUTIONS WHEN OPERATIONS ON SLOPES….2218
PROHIBITED OPERATIONS….2218
PRECAUTIONS WHEN OPERATING….2218
OPERATE CAREFULLY ON SNOW….2219
PARKING MACHINE….2219
TRANSPORTATION….2220
LOADING AND UNLOADING….2220
SHIPPING….2220
BATTERY….2221
BATTERY HAZARD PREVENTION….2221
STARTING WITH BOOSTER CABLES….2222
TOWING….2223
WHEN TOWING….2223
PRECAUTIONS FOR MAINTENANCE….2224
WARNING TAG….2224
KEEP WORK PLACE CLEAN AND TIDY….2224
APPOINT LEADER WHEN WORKING WITH OTHERS….2224
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE….2225
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….2226
PROPER TOOLS….2226
ACCUMULATOR….2227
PERSONNEL….2227
ATTACHMENTS….2227
WORK UNDER THE MACHINE….2227
NOISE….2227
PRECAUTIONS WHEN USING HAMMER….2228
REPAIR WELDING….2228
REMOVING BATTERY TERMINAL….2228
PROHIBITED TO DISASSEMBLE BANK CONTROL LOCK PIN….2228
PRECAUTIONS WITH HIGH-PRESSURE OIL….2228
HANDLING HIGH-PRESSURE HOSES….2229
WASTE MATERIALS….2229
MAINTENANCE OF AIR CONDITIONER….2229
COMPRESSED AIR….2229
PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS….2229
PRECAUTIONS WITH TIRES….2230
HANDLING TIRES….2230
PRECAUTIONS WHEN STORING TIRE….2230
OPERATIONS….2231
GENERAL VIEW….2232
GENERAL VIEW OF MACHINE….2232
GENERAL VIEW OF CONTROLS AND GAUGES….2233
EXPLANATION OF COMPONENTS….2236
MONITOR PANEL….2236
METERS AND LAMPS….2249
SWITCHES….2250
CONTROL LEVERS, PEDALS….2259
DUST INDICATOR….2268
ARTICULATE LOCK PIN….2268
FUSE BOX….2269
OPERATOR'S CAB LIFT MECHANISM….2270
BACKUP ALARM….2270
FRONT GLASS….2271
TOOL BAG….2272
STORAGE BOX….2272
QUICK-FILL FUEL FILLER….2272
OPERATION….2273
CHECK BEFORE STARTING ENGINE….2273
STARTING ENGINE….2288
OPERATIONS, CHECKS AFTER STARTING ENGINE….2291
STOPPING ENGINE….2293
CHECK AFTER STOPPING ENGINE….2293
TRAVELING POSTURE FOR MACHINE….2294
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….2295
TURNING MACHINE….2301
OPERATING WORK EQUIPMENT….2303
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….2308
PRECAUTIONS WHEN OPERATION….2336
ADJUSTING WORK EQUIPMENT POSTURE….2340
PARKING MACHINE….2341
CHECKS AFTER COMPLETION OF OPERATION….2343
LOCKING….2343
HANDLING THE TIRES….2344
HANDLING BLADE ACCUMULATOR….2345
HANDLING BLADE FLOAT….2347
TRANSPORTATION….2349
LOADING, UNLOADING WORK….2349
PRECAUTIONS FOR LOADING….2350
COLD WEATHER OPERATION….2351
PRECAUTIONS FOR LOW TEMPERATURE….2351
CAUTIONS AFTER COMPLETION OF WORK….2352
AFTER COLD WEATHER….2352
LONG-TERM STORAGE….2353
BEFORE STORAGE….2353
DURING STORAGE….2353
AFTER STORAGE….2353
TROUBLESHOOTING….2354
AFTER RUNNING OUT OF FUEL….2354
WHEN LEANING PIPING IS DAMAGED….2354
TOWING THE MACHINE….2355
IF BATTERY IS DISCHARGED….2358
OTHER TROUBLE….2361
TRANSMISSION CONTROLLER….2366
MAINTENANCE….2371
GUIDES TO MAINTENANCE….2372
OUTLINES OF SERVICE….2374
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….2374
RELATING TO ELECTRIC SYSTEM….2376
WEAR PARTS….2377
WEAR PARTS LIST….2377
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO….2378
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….2382
TORQUE LIST….2382
PERIODIC REPLACEMENT OF CRITICAL PARTS….2383
CRITICAL PARTS….2383
MAINTENANCE SCHEDULE CHART….2384
MAINTENANCE SCHEDULE CHART….2384
SERVICE PROCEDURE….2386
INITIAL 250 HOURS SERVICE (only after the first 250 hours)….2386
REPLACE FUEL FILTER CARTRIDGE….2411
CHANGE OIL IN TRANSMISSION CASE….2421
CHANGE OIL IN FINAL DRIVE CASE….2422
CHANGE OIL IN CIRCLE REVERSE GEAR CASE….2428
CHANGE OIL IN HYDRAULIC TANK….2424
REPLACE RETURN FILTER ELEMENT AND CLEAN SUCTION STRAINER IN HYDRAULIC TANK….2423
CHANGE OIL IN TANDEM DRIVE CASE….2429
CHECK CIRCLE GUIDE CLEARANCE, ADJUST….2413
CHECK, ADJUST SLIP LOAD FOR DRY-TYPE CLUTCH FOR BLADE ROTATION GEAR….2417
CHECK ENGINE VALVE CLEARANCE, ADJUST….2431
WHEN REQUIRED….2387
CLEAN INSIDE OF COOLING SYSTEM….2387
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….2389
CHECK ELECTRICAL INTAKE AIR HEATER….2391
REVERSE AND REPLACE THE END BITS AND CUTTING EDGES….2391
REPLACING RIPPER POINT….2392
CHECK INCHING PEDAL….2392
CLEAN ELEMENT OF AIR CONDITIONER FRESH AIR FILTER….2392
CLEAN ELEMENT OF AIR CONDITIONER RECIRCULATION AIR FILTER….2393
CHECK REFRIGERANT (GAS) LEVEL….2394
SELECTION AND INSPECTION OF TIRES….2394
INSPECTING CORROSION, WEAR OF WHEEL RIM, LOCK RING, SIDE RING….2395
CHECK BEFORE STARTING….2396
EVERY 50 HOURS SERVICE….2397
LUBRICATING….2397
INSPECT WEAR OF BLADE GUIDE….2397
EVERY 250 HOURS SERVICE….2398
LUBRICATING….2398
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….2400
CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL….2401
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….2402
CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL….2402
CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE, ADD OIL….2403
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL….2403
CHECK LEVEL OF BATTERY ELECTROLYTE….2404
CHECK BALL JOINT CLEARANCE, ADJUST….2406
CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT….2406
CHECK FAN BELT TENSION, ADJUST….2407
CHECK ALTERNATOR BELT TENSION, ADJUST….2408
CHECK AIR CONDITIONER BELT TENSION, ADJUST….2409
CHECK, ADJUST FOOT BRAKE….2410
EVERY 500 HOURS SERVICE….2411
REPLACE FUEL FILTER CARTRIDGE….2411
CLEAN, CHECK RADIATOR FINS….2412
CHECK CIRCLE GUIDE CLEARANCE, ADJUST….2413
CHECK PARKING BRAKE LEVEL STROKE, ADJUST….2416
CHECK, ADJUST SLIP LOAD FOR DRY-TYPE CLUTCH FOR BLADE ROTATION GEAR….2417
EVERY 1000 HOURS SERVICE….2419
GREASE DRIVE SHAFT….2419
GREASE FAN PULLEY AND TENSION PULLEY….2419
REPLACE TRANSMISSION OIL FILTER ELEMENT….2420
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER….2421
CHANGE OIL IN FINAL DRIVE CASE, CLEAN STRAINER….2422
REPLACE RETURN FILTER ELEMENT AND CLEAN SUCTION STRAINER IN HYDRAULIC TANK….2423
CHANGE OIL IN HYDRAULIC TANK….2424
CHECK LOOSENESS IN DRAWBAR FRONT BALL JOINT AND BALL STUD….2425
CHECK TOE-IN, ADJUST….2425
CHECK FRONT WHEEL BEARING PLAY, ADJUST….2426
REPLACE CORROSION RESISTOR CARTRIDGE….2427
CHECK FOR LOOSE ROPS MOUNT BOLTS….2427
REPLACING AIR DRYER DESICCANT….2427
EVERY 2000 HOURS SERVICE….2428
CHANGE OIL IN FRONT WHEEL BEARING….2428
CHANGE OIL IN CIRCLE REVERSE GEAR CASE….2428
CHANGE OIL IN TANDEM DRIVE CASE….2429
CLEAN ENGINE BREATHER ELEMENT….2429
CLEAN BREATHER….2430
CLEAN AND INSPECT INCHING POTENTIOMETER SENSOR….2431
CHECK ALTERNATOR, STARTING MOTOR….2431
CHECK ENGINE VALVE CLEARANCE, ADJUST….2431
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER….2431
CHECK PLAY OF TURBOCHARGER ROTOR….2431
CLEAN, CHECK TURBOCHARGER….2431
EVERY 4000 HOURS SERVICE….2432
CHECK WATER PUMP….2432
CHECK VIBRATION DAMPER….2432
CHECK FAN PULLEY AND TENSION PULLEY….2432
SPECIFICATIONS….2433
SPECIFICATIONS….2434
ATTACHMENTS, OPTIONS….2437
HANDLING EMERGENCY STEERING DEVICE….2438
CHECKING….2438
AIR CONDITIONER….2439
LOCATIONS AND FUNCTIONS OF CONTROL PANEL….2439
METHOD OF OPERATION….2441
PRECAUTIONS WHEN USING….2441
HANDLING AIR-SUSPENSION SEAT….2442
ADJUST OPERATOR'S SEAT….2442
INDEX….2445
TEN00334-02 – Motor Grader GD825A-2 Operation & Maintenance Manual….2449
COVER….2449
FOREWORD….2450
FOREWORD….2451
SAFETY INFORMATION….2452
INTENDED USE….2454
DIRECTIONS OF MACHINE….2454
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….2455
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….2455
ENGINE SERIAL NO. PLATE POSITION….2455
SERVICE METER POSITION….2456
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….2456
CONTENTS….2457
SAFETY….2460
SAFETY INFORMATION….2461
SAFETY LABELS….2463
POSITION FOR ATTACHING SAFETY LABELS….2464
SAFETY LABELS….2465
GENERAL PRECAUTIONS….2471
PRECAUTIONS DURING OPERATION….2479
STARTING ENGINE….2479
OPERATION….2481
TRANSPORTATION….2485
BATTERY….2486
TOWING….2488
PRECAUTIONS FOR MAINTENANCE….2489
PRECAUTIONS WITH TIRES….2495
OPERATION….2496
GENERAL VIEW….2497
GENERAL VIEW OF MACHINE….2497
GENERAL VIEW OF CONTROLS AND GAUGES….2498
EXPLANATION OF COMPONENTS….2501
MONITOR PANEL….2501
METERS AND LAMPS….2514
SWITCHES….2515
CONTROL LEVERS, PEDALS….2524
DUST INDICATOR….2533
ARTICULATE LOCK PIN….2533
FUSE BOX….2534
OPERATOR'S CAB LIFT MECHANISM….2536
BACKUP ALARM….2536
FRONT GLASS….2537
TOOL BAG….2538
STORAGE BOX….2538
QUICK-FILL FUEL FILLER….2538
OPERATION….2539
CHECK BEFORE STARTING ENGINE….2539
STARTING ENGINE….2554
OPERATIONS, CHECKS AFTER STARTING ENGINE….2557
STOPPING ENGINE….2559
CHECK AFTER STOPPING ENGINE….2559
TRAVELING POSTURE FOR MACHINE….2560
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….2561
TURNING MACHINE….2567
OPERATING WORK EQUIPMENT….2569
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….2574
PRECAUTIONS WHEN OPERATION….2602
ADJUSTING WORK EQUIPMENT POSTURE….2606
PARKING MACHINE….2607
CHECKS AFTER COMPLETION OF OPERATION….2609
LOCKING….2609
HANDLING THE TIRES….2610
HANDLING BLADE ACCUMULATOR….2611
HANDLING BLADE FLOAT….2613
TRANSPORTATION….2615
STEPS FOR TRANSPORTATION….2615
LOADING, UNLOADING WORK….2615
PRECAUTIONS FOR LOADING….2616
COLD WEATHER OPERATION….2617
PRECAUTIONS FOR LOW TEMPERATURE….2617
CAUTIONS AFTER COMPLETION OF WORK….2618
AFTER COLD WEATHER….2618
LONG-TERM STORAGE….2619
BEFORE STORAGE….2619
DURING STORAGE….2619
AFTER STORAGE….2619
TROUBLESHOOTING….2620
AFTER RUNNING OUT OF FUEL….2620
WHEN LEANING PIPING IS DAMAGED….2620
TOWING THE MACHINE….2621
IF BATTERY IS DISCHARGED….2624
OTHER TROUBLE….2627
TRANSMISSION CONTROLLER….2632
MAINTENANCE….2636
GUIDES TO MAINTENANCE….2637
OUTLINES OF SERVICE….2639
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….2639
RELATING TO ELECTRIC SYSTEM….2642
WEAR PARTS….2643
WEAR PARTS LIST….2643
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….2644
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….2649
TORQUE LIST….2649
PERIODIC REPLACEMENT OF CRITICAL PARTS….2650
CRITICAL PARTS….2650
MAINTENANCE SCHEDULE CHART….2651
MAINTENANCE SCHEDULE CHART….2651
SERVICE PROCEDURE….2653
INITIAL 250 HOURS SERVICE (only after the first 250 hours)….2653
WHEN REQUIRED….2654
CHECK BEFORE STARTING….2664
EVERY 50 HOURS SERVICE….2665
EVERY 250 HOURS SERVICE….2666
EVERY 500 HOURS SERVICE….2679
EVERY 1000 HOURS SERVICE….2687
EVERY 2000 HOURS SERVICE….2696
EVERY 4000 HOURS SERVICE….2700
SPECIFICATIONS….2702
SPECIFICATIONS….2703
ATTACHMENTS, OPTIONS….2706
HANDLING EMERGENCY STEERING DEVICE….2707
CHECKING….2707
AIR CONDITIONER….2708
LOCATIONS AND FUNCTIONS OF CONTROL PANEL….2708
METHOD OF OPERATION….2710
PRECAUTIONS WHEN USING….2710
HANDLING AIR-SUSPENSION SEAT….2711
ADJUST OPERATOR'S SEAT….2711
INDEX….2714

Komatsu Motor Grader GD825A Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 8, 2025June 8, 2025 by admin

Komatsu Motor Graders GD750A Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Motor Graders GD750A, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Motor Graders GD750A 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.

Total Pages: 1,401 pages
File Format: PDF
Language: English

CEBM002104 – Komatsu Motor Grader GD750A-1 Shop Manual.pdf
CEAM002402 – Komatsu Motor Grader GD750A-1 Operation & Maintenance Manual.pdf

MAIN SECTIONS
CEAM002402 – Motor Grader GD750A-1 Operation & Maintenance Manual….2
COVER PAGE….2
1. FORWARD….6
2. SAFETY INFORMATION….7
3. INTRODUCTION….8
    3.1 INTENDED USE….8
    3.2 FEATURES….8
    3.3 BREAKING IN THE MACHINE….8
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….9
    4.1 P.I.N. NUMBER LOCATIONS….9
    4.2 ENGINE SERIAL NO. PLATE POSITION….10
    4.3 TRANSMISSION SERIAL NO. PLATE POSITION….10
    4.4 REAR AXLE SERIAL NO. PLATE POSITION….10
    4.5 CAB ROPS/FOBS SERIAL NO. PLATE POSITION….11
    4.6 GENERAL PART NO. PLATE….11
    4.7 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….12
5. TABLE OF CONTENTS….13
SAFETY….21
    6. GENERAL PRECAUTIONS….22
    7. PRECAUTIONS DURING OPERATION….28
      7.1 BEFORE STARTING ENGINE….28
      7.2 OPERATING MACHINE….30
      7.3 TRANSPORTATION….36
      7.4 BATTERY….37
      7.5 TOWING….40
      7.6 TIRES….41
    8. PRECAUTIONS FOR MAINTENANCE….43
      8.1 BEFORE CARRYING OUT MAINTENANCE….43
      8.2 DURING MAINTENANCE….47
    9. POSITON FOR ATTACHING SAFETY LABELS….53
      9.1 POSITION FOR ATTACHING SAFETY LABELS….53
OPERATION….63
    10. GENERAL VIEW….64
      10.1 GENERAL VIEW OF MACHINE….64
      10.2 UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS….65
    11. EXPLANATION OF COMPONENTS….66
      11.1 STEERING CONSOLE CONTROLS AND GAUGES….66
      11.2 RIGHT SIDE CONSOLE….74
      11.3 MISCELLANEOUS CONTROLS….76
      11.4 HEATER/AIR CONDITIONING CONTROLS….79
        11.4.1 METHOD OF OPERATION….82
        11.4.2 PRECAUTIONS WHEN USING AIR CONDITIONER….83
        11.4.3 HANDLING DURING SEASON….83
        11.4.4 HANDLING DURING OFF-SEASON….83
      11.5 MISCELLANEOUS GAUGES AND VALVE….84
      11.6 ACCESS COVERS, HOOD SIDES AND DOORS….85
      11.7 CONTROL LEVERS AND PEDALS….88
      11.8 CAP WITH LOCK….97
        11.8.1 METHOD OF OPENING CAP WITH LOCK….97
        11.8.2 METHOD OF CLOSING CAP WITH LOCK….97
      11.9 ARTICULATE LOCK PIN….97
      11.10 PARKING BRAKE….98
      11.11 BACKUP ALARM….98
      11.12 CIRCUIT BREAKERS….98
    12. MACHINE OPERATION….100
      12.1 WALK AROUND CHECK….100
      12.2 TOWING….103
      12.3 CHECKS BEFORE STARTING….104
        12.3.1 CHECK COOLANT LEVEL, ADD COOLANT….105
        12.3.2 CHECK MONITOR PANEL….105
        12.3.3 CHECK FUEL LEVEL, ADD FUEL….106
        12.3..4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL….106
        12.3.5 CHECK ELECTRIC WIRING….107
        12.3.6 DRAIN WATER AND SEDIMENT IN FUEL TANK….107
        12.3.7 CHECK VOLTMETER….108
        12.3.8 CHECK FOR SEDIMENT AND WATER IN THE WATER SEPARATOR….108
        12.3.9 CHECK LAMPS FOR SWITCHING, DIRT AND DAMAGE….108
        12.3.10 CHECK REAR VIEW MIRROR FOR POSITIONING, DIRT AND DAMAGE….108
        12.3.11 CHECK HORN AND BACKUP ALARM….108
        12.3.12 DO THE INTRUMENTS FUNCTION NORMALLY….108
        12.3.13 CHECK THE SEAT BELT FOR NORMAL FUNCTION….108
        12.3.14 CHECK THE DOOR LOCKS FOR NORMAL FUNCTION….108
        12.3.15 CHECK THE WINDSHIELD WIPER, WINDOW WASHER AND DEFROSTER FOR NORMAL FUNCTION. CHECK FOR SUFFICIENT WASHER FLUID LEVE….109
        12.3.16 CHECK FOR MISSING GUARDS, OR PROTECTIVE EQUIPMENT. DO NOT OPERATE UNIT IF ANY ARE MISSING….109
        12.3.17 GENERAL SAFETY….109
      12.4 REMOVAL OF ARTICULATION PIN….109
      12.5 ENTERING OPERATOR&’S CAB….109
      12.6 ADJUSTMENTS BEFORE OPERATION….110
        12.6.1 ADJUST OPERATOR&’S SEAT….110
        12.6.2 SEAT BELT….111
        12.6.3 ADJUSTING POSITION OF STEERING WHEEL AND GAUGE PANEL….112
        12.6.4 ADJUSTING MIRRORS….112
      12.7 OPERATIONS AND CHECKS BEFORE STARTING ENGINE….113
      12.8 STARTING ENGINE….115
        12.8.1 NORMAL STARTING….115
        12.8.2 STARTING IN COLD WEATHER: USING ETHER INJECTOR (OPTIONAL)….116
        12.8.3 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE….118
        12.8.4 STARTING PROCEDURES AFTER CHANGING FUEL FILTERS….118
        12.8.5 STARTING PROCEDURES AFTER RUNNING OUT OF FUEL….119
      12.9 OPERATIONS AND CHECKS AFTER STARTING ENGINE….120
        12.9.1 ENGINE WARM UP….120
        12.9.2 WHILE WARMING UP – ENGINE RUNNING ABOVE IDLE….120
        12.9.3 COLD WEATHER START UP….121
        12.9.4 HYDRAULIC SYSTEM COLD WEATHER START UP….121
      12.10 TRAVELING POSTURE FOR MACHINE….122
      12.11 MOVING MACHINE….123
      12.12 SHIFTING GEARS….124
        12.12.1 ACCELERATION….124
        12.12.2 DECELERATION….124
      12.13 SHIFTING BETWEEN FORWARD AND REVERSE….125
      12.14 STOPPING MACHINE….126
      12.15 TURNING MACHINE….127
        12.15.1 LEANING OPERATION….127
        12.15.2 ARTICULATING OPERATION….128
      12.16 OPERATING WORK EQUIPMENT….129
        12.16.1 OPERATING BLADE….129
        12.16.2 OPERATING DRAWBAR SIDE SHIFT….132
        12.16.3 OPERATING RIPPER….133
        12.16.4 PROPULSION ANGLE OF BLADE….133
        12.16.5 RH & LH 90 DEGREE BLADE SUSPENSION….134
      12.17 WORK APPLICATION….136
        12.17.1 LEVELING GROUND TO RIGHT….136
        12.17.2 LEVELING GROUND TO LEFT….137
        12.17.3 DIGGING RIGHT V-DITCHES….138
        12.17.4 DIGGING LEFT V-DITCHES….140
      12.18 RIGHT DITCH FINISHING….142
      12.19 LEFT DITCH FINISHING….143
      12.20 FINISHING RIGHT ROAD SHOULDER….144
      12.21 FINISHING LEFT ROAD SHOULDER….144
      12.22 CONSTRUCTING ROAD – METHOD OF MAKING V-DITCH….145
      12.23 FLAT-BOTTOM DITCH….149
      12.24 CONSTRUCTING ROAD – METHOD FOR MAKING FLAT BOTTOM DITCH….151
      12.25 FINISHING WITH GRADER FOR DITCHES WHERE WET ROAD SHOULDER IS LOOSE….154
      12.26 LEVELING 3:1 SLOPE FACE….154
      12.27 BANK CUTTING METHOD – RIGHT SIDE….154
      12.28 EXTREME SIDE REACH….158
      12.29 RIPPER OPERATIONS – WITH FRAME STRAIGHT….159
      12.30 PRECAUTIONS FOR OPERATION….160
        12.30.1 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS….160
        12.30.2 PRECAUTIONS WHEN USING ARTICULATED STEERING….160
        12.30.3 PRECAUTIONS WHEN TRAVELING ON ROADS….161
        12.30.4 CAUTIONS IN OPERATION OF WORK EQUIPMENT….161
      12.31 ADJUSTING WORK EQUIPMENT POSTURE….161
        12.31.1 BLADE PROTRUSION….161
      12.32 PARKING MACHINE….162
      12.33 CHECK AFTER FINISHING WORK….163
      12.34 STOPPING ENGINE….163
      12.35 CHECK AFTER STOPPING ENGINE….164
      12.36 LOCKING….164
      12.37 TIRES….165
        12.37.1 PRECAUTIONS WHEN HANDLING TIRES….165
        12.37.2 DIRECTION OF TIRE TREADS….165
        12.37.3 TIRE MATCHING….165
      12.38 BLADE ACCUMULATOR….166
        12.38.1 OPERATION….166
        12.38.2 FEATURES….167
      12.39 HANDLING BLADE FLOAT….167
        12.39.1 OPERATION….167
        12.39.2 FEATURES….168
    13. TRANSPORTATION….169
      13.1 GENERAL….171
        13.1.1 TRUCK….171
        13.1.2 RAILROAD FLATCAR….171
        13.1.3 DRIVING….171
      13.2 MOVING A DISABLED MACHINE….172
      13.3 METHODS OF TOWING….172
        13.3.1 METHOD ONE….173
        13.3.2 METHOD TWO….174
        13.3.3 METHOD THREE….174
    14. OPERATION UNDER UNUSUAL CONDITIONS….176
      14.1 OPERATION IN EXTREME COLD….176
        14.1.1 COLD WEATHER STARTING AID (OPTIONAL)….177
        14.1.2 ENGINE BLOCK HEATER (OPTIONAL)….178
      14.2 BATTERY….178
        14.2.1 CHARGING….179
        14.2.2 AFTER CHARGING….180
      14.3 AFTER COLD WEATHER….180
      14.4 OPERATION IN EXTREME HEAT….180
      14.5 OPERATION IN DUSTY OR SANDY AREAS….181
      14.6 OPERATION IN RAINY OR HUMID CONDITIONS….182
      14.7 OPERATION IN SALT WATER AREAS….182
      14.8 OPERATION AT HIGH ALTITUDES….183
    15. MACHINE STORAGE….184
      15.1 PREPARING FOR STORAGE….184
      15.2 SERVICING MACHINE DURING STORAGE….187
        15.2.1 ONE-MONTH REPETITIVE SERVICE PERIOD….187
        15.2.2 SIX MONTH REPETITIVE SERVICE PERIOD….187
      15.3 PREPARING FOR OPERATION….188
      15.4 ROLLOVER PROTECTIVE STRUCTURE….189
      15.5 THEFT DETERRENT PRACTICES….190
        15.5.1 ACTION TO DISCOURAGE THEFT AND VANDALISM….190
        15.5.2 ACTIONS TO AID IN RECOVERY OF STOLEN MACHINES….190
    16. TROUBLESHOOTING….192
      16.1 ETHER STARTING….192
        16.1.1 FLUID CYLINDER….192
        16.1.2 ATOMIZERS….192
        16.1.3 TUBING….192
        16.1.4 ELECTRIC VALVE….193
        16.1.5 REASSEMBLY….193
      16.2 AFTER RUNNING OUT OF FUEL….193
      16.3 WHEN LEANING PIPING IS DAMAGED….194
        16.3.1 HOW TO USE LEANING STOPPER….194
      16.4 IF BATTERY IS DISCHARGED….195
        16.4.1 STARTING ENGINE WITH BOOSTER CABLE….196
      16.5 OTHER TROUBLE….198
        16.5.1 ELECTRICAL SYSTEM….198
        16.5.2 CHASSIS….199
        16.5.3 ENGINE….202
        16.5.4 INSTRUMENT PANEL….204
        16.5.5 FAULT CODES EXPLANATION….207
        16.5.6 SHIFT LEVER ERROR CODES….220
MAINTENANCE….221
    17. GUIDES TO MAINTENANCE….222
    18. OUTLINES OF SERVICE….225
      18.1 OUTLINE OF OIL, FUEL, COOLANT….225
        18.1.1 OIL….225
        18.1.2 FUEL….226
        18.1.3 COOLANT….226
        18.1.4 GREASE….227
        18.1.5 STORING OIL AND FUEL….227
        18.1.6 FILTERS….227
      18.2 RELATING TO ELECTRIC SYSTEM….228
        18.2.1 BATTERIES….229
        18.2.2 BATTERY – GENERAL MAINTENANCE….230
        18.2.3 CLEANING THE BATTERIES….231
        18.2.4 CONVENTIONAL ANTIMONY (LEAD-ACID) BATTERY….231
        18.2.5 LOW MAINTENANCE BATTERY….231
        18.2.6 MAINTENANCE FREE BATTERY….231
        18.2.7 BATTERY CHARGING….231
    19. WEAR PARTS LIST….238
    20. FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….240
      20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS….240
      20.2 ENGINE OIL SPECIFICATIONS….242
        20.2.1 NORMAL OPERATION….242
        20.2.2 ARCTIC OPERATION….243
      20.3 TRANSMISSION, TORQUE CONVERTER AND OIL COOLER, TANDEM DRIVE CASES….243
      20.4 HYDRAULIC SYSTEM OIL SPECIFICATIONS….243
      20.5 REAR DRIVE AXLE AND CIRCLE DRIVE BRAKE HOUSING OIL SPECIFICATIONS….243
      20.6 DIESEL FUEL SPECIFICATIONS….243
      20.7 COOLANT SPECIFICATIONS….244
        20.7.1 GENERAL….244
        20.7.2 ANTIFREEZE….245
        20.7.3 SUPPLEMENTAL COOLANT ADDITIVES….246
      20.8 CIRCLE DRIVE GEAR CASE OIL SPECIFICATIONS (HDTF)….251
    21 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….252
      21.1 INTRODUCTION OF NECESSARY TOOLS….252
      21.2 TORQUE VALUES FOR STANDARD METRIC FASTENERS….253
      21.3 TORQUE VALUES FOR STANDARD ENGLISH FASTENERS….254
        21.3.1 TYPE 1, 5 AND 8 NON-PHOSPHATE COATED HARDWARE….254
        21.3.2 TYPE 8 PHOSPHATE COATED HARDWARE….255
        21.3.3 TORQUE VALUES FOR HOSE CLAMPS….256
        21.3.4 TORQUE VALUES FOR SPLIT FLANGE CONNECTIONS….256
        21.3.5 O-RING FACE SEAL FITTING TORQUE….257
    22. PERIODIC REPLACEMENT OF CRITICAL PARTS….258
    23. MAINTENANCE SCHEDULE CHART….259
      23.1 MAINTENANCE SCHEDULE CHART….259
    24. SERVICE PROCEDURES….264
      24.1 PERIODIC SERVICE CHART….265
      24.2 WHEN REQUIRED….266
        24.2.1 ETHER STARTING AID….266
        24.2.2 CIRCUIT BREAKERS….266
        24.2.3 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES….266
        24.2.4 REPLACING RIPPER TOOTH….267
        24.2.5 MOLDBOARD SLIDE….268
        24.2.6 CHECK CIRCLE GUIDE CLEARANCE, ADJUST….268
        24.2.7 MOLDBOARD ACCUMULATOR (IF EQUIPPED)….272
        24.2.8 WIPER BLADES….272
        24.2.9 CIRCLE SLIP CLUTCH, LEVEL AND FILL PLUGS….272
        24.2.10 CIRCLE REVERSE GEAR CASE – WET TYPE BRAKE ADJUSTING….273
        24.2.11 INCHING PEDAL – INSPECTING….273
        24.2.12 TRANSMISSION CLUTCH – CALIBRATION….274
        24.2.13 TORQUE CONVERTER LOCK UP – CHECK….274
      24.3 CHECK BEFORE STARTING ENGINE….275
      24.4 EVERY SHIFT/10 HOURS SERVICE….276
        24.4.1 BRAKES – CHECK….276
        24.4.2 WARNING LIGHT – CHECK….276
        24.4.3 GAUGES – CHECK….276
        24.4.4 BACKUP ALARM – CHECK….276
        24.4.5 OPERATIONAL LIGHTS – CHECK….276
        24.4.6 RADIATOR COOLANT LEVEL – CHECK….277
        24.4.7 RADIATOR DEBRIS – CHECK….278
        24.4.8 FUEL/WATER SEPARATOR – DRAIN….278
        24.4.9 FUEL TANK FUEL/WATER TRAP – DRAIN….278
        24.4.10 FUEL TANK – CHECK….279
        24.4.11 ENGINE AIR CLEANER – CHECK….279
        24.4.12 TRANSMISSION OIL LEVEL TRANSMISSION DIPSTICK….282
        24.4.13 HYDRAULIC OIL TANK LEVEL HYDRAULIC OIL TANK SIGHT GAGE….283
        24.4.14 BLADE SLIDE RAILS….283
        24.4.15 ENGINE OIL DIPSTICK & FILL CAP….284
        24.4.16 CIRCLE TEETH….284
        24.4.17 CIRCLE TOP & BOTTOM….284
        24.4.18 ENGINE FAN BLADE….285
      24.5 EVERY 50 MAN HOURS/WEEKLY SERVICE….286
        24.5.1 AXLE AND FRONT STEERING LINKAGE….286
        24.5.2 STEERING LINKAGE & CYLINDER PINS….286
        24.5.3 THE ROD & LEANING WHEEL ROD CYLINDER….287
        24.5.4 DRAWBAR BALL JOINT….287
        24.5.5 ARTICULATION BEARINGS….288
        24.5.6 RIPPER LINKAGE….288
        24.5.7 CIRCLE REVERSE CASE OIL LEVEL….289
        24.5.8 CAB AIR FILTERS (IF EQUIPPED)….289
        24.5.9 TIRES….289
        24.5.10 TANDEM CASES, BREATHER….290
        24.5.11 TANDEM CASES, FILL PLUG….290
        24.5.12 TANDEM CASES, OIL LEVEL PLUG….290
        24.5.13 HYDRAULIC OIL FILTER….290
        24.5.14 TRANSMISSION FILTER….291
        24.5.15 BATTERY….292
        24.5.16 MACHINE….292
      24.6 100 HOURS INITIAL SERVICE….293
        24.6.1 LOCK/UNLOCK AXLE FILTER….293
        24.6.2 REAR AXLE, SUCTION SCREEN….293
        24.6.3 REAR AXLE DIFFERENTIAL….293
      24.7 EVERY 250 HOURS/MONTHLY SERVICE….294
        24.7.1 AIR INTAKE HOSES & CLAMPS….294
        24.7.2 COOLANT SYSTEM HOSES & CLAMPS….294
        24.7.3 REAR AXLE, OIL LEVEL….294
        24.7.4   ENGINE OIL & FILTER CHANGE….295
        24.7.5 COOLANT CORROSION RESISTER CARTRIDGE….296
        24.7.6 CIRCLE REVERSE CASE BREATHER….296
        24.7.7 CONTROL LEVER LINKAGES….296
        24.7.8 CONTROL VALVE LINKAGES….297
        24.7.9 BRAKE ACCUMULATOR GAS PRESSURE….297
        24.7.10 BANK CONTROL GUIDE….297
        24.7.11 RIPPER CYLINDERS (IF EQUIPPED)….297
        24.7.12 LIFT CYLINDER CAP….298
        24.7.13 LIFT CYLINDER TRUNNIONS….298
        24.7.14 LIFT CYLINDER TRUNNION SHAFTS….298
        24.7.15 CIRCLE SIDE SHIFT CYLINDER….298
        24.7.16 BLADE PITCH CYLINDER….299
        24.7.17 ARTICULATION CYLINDERS….299
        24.7.18 WHEEL HUB BOLTS….299
        24.7.19 WHEEL BRAKE….300
        24.7.20 AIR CONDITIONER BELT….301
      24.8 EVERY 500 HOUR/THREE MONTHS SERVICE….302
        24.8.1 COOLANT PROTECTION….302
        24.8.2 FUEL FILTER….302
        24.8.3 PARKING BRAKE….304
        24.8.4 FUEL TANK, FILTER SCREEN (STRAINER)….304
        24.8.5 TRANSMISSION FILTER….304
        24.8.6 WHEEL BRAKE….304
        24.8.7 BLADE ACCUMULATORS….304
      24.9 EVERY 1000 HOURS/SIX MONTHS SERVICE….305
        24.9.1 DRAWBAR, FRONT BALL JOINT….305
        24.9.2 ROPS MOUNT BOLTS….305
        24.9.3 HYDRAULIC OIL FILTER….305
        24.9.4 TRANSMISSION OIL….305
        24.9.5 DRIVE SHAFT….306
        24.9.6 LOCK/UNLOCK AXLE FILTER….306
        24.9.7 FRONT WHEEL BEARING….307
        24.9.8 TOE-IN….307
        24.9.9 ENGINE DRIVE & ALTERNATOR BELTS….309
        24.9.10 FAN BELT….310
        24.9.11 ALTERNATOR BELT….311
        24.9.12 AIR CONDITIONER BELT….311
      24.10 EVERY 1500 HOURS SERVICE….312
        24.10.1 ENGINE VALVES AND INJECTORS….312
        24.10.2 TURBOCHARGER MOUNTING NUTS….312
        24.10.3 ENGINE MOUNT BOLTS….312
        24.10.4 WATER PUMP….312
        24.10.5 ENGINE….312
      24.11 EVERY 2000 HOUR/ONE YEAR SERVICE….313
        24.11.1 TANDEM DRIVE CASE….313
        24.11.2 HYDRAULIC TANK RETURN FILTER AND SUCTION STRAINER….314
        24.11.3 HYDRAULIC TANK….315
        24.11.4 HYDRAULIC TANK FILTER BREATHER CAP….318
        24.11.5 REAR AXLE….318
        24.11.6 CIRCLE DRIVE….318
        24.11.7 FRONT WHEEL BEARING….318
        24.11.8 LOCK/UNLOCK OF SUCTION SCREEN….319
        24.11.19 VALVES & INJECTORS….319
        24.11.10 CAB PRESSURIZER FILTER….320
        24.11.11 ACCUMULATORS….320
        24.11.12 BATTERIES….320
      24.12 EVERY 4000 HOURS/TWO YEAR SERVICE….321
        24.12.1 RADIATOR COOLANT….321
        24.12.2 REFRIGERANT (GAS) IN AIR CONDITIONER CHECKING LEVEL….325
      24.13 EVERY 6000 HOURS/THREE YEAR SERVICE….327
        24.13.1 INJECTORS….327
        24.13.2 FUEL PUMP….327
        24.13.3 TURBOCHARGER….327
        24.13.4 FAN HUB….327
        24.13.5 IDLER PULLEY….327
        24.13.6 VIBRATION DAMPER….327
SPECIFICATIONS….329
    25. GD750A-1….330
      25.1 WEIGHT….331
      25.2 TRANSMISSION AND TORQUE CONVERTER PERFORMANCE….331
      25.3 LIQUID CAPACITIES….331
      25.4 ENGINE….332
      25.5 HYDRAULIC….332
      25.6 CIRCLE….332
      25.7 DRAWBAR….333
      25.8 MOLDBOARD….333
      25.9 BLADE RANGE….333
      25.10 FRONT AXLE….333
      25.11 AXLE REAR….334
      25.12 STEERING….334
      25.13 TANDEM DRIVE….334
      25.14 WHEELS, FRONT AND REAR….334
      25.15 BRAKES….334
      25.16 OPERATOR&’S COMPARTMENT….334
CEBM002104 – Motor Grader GD750A-1 Shop Manual….335

Komatsu Motor Graders GD750A Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 8, 2025 by admin

Komatsu Motor Graders GD705, GD705A Workshop Service Repair Manuals

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Motor Graders GD705, GD705A, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Motor Graders GD705, GD705A 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.

SEAM234Y01 – Motor Grader GD705A-3 Operation & Maintenance Manual.pdf
SEAM036701 – Motor Grader GD705A-4 Operation & Maintenance Manual.pdf
SEBM022104 – Motor Grader GD705A-4 Shop Manual.pdf
SEN06489-03 – Motor Grader GD705-5 Shop Manual.pdf

Total Pages: 1,543 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
SEAM036701 – Motor Grader GD705A-4 Operation & Maintenance Manual…2
COVER…2
FOREWORD…3
FOREWORD…4
SAFETY INFORMATION…7
INTRODUCTION…9
INTENDED USE…9
DIRECTIONS OF MACHINE…9
LOCATION OF PLATES,TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR…10
MACHINE SERIAL NO.PLATE POSITION…10
ENGINE SERIAL NO.PLATE POSITION…10
SERVICE METER POSITION…11
TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR…11
CONTENTS…12
SAFETY…15
SAFETY LABELS…16
POSITION FOR ATTACHING SAFETY LABELS…16
SAFETY LABELS…17
GENERAL PRECAUTIONS…21
PRECAUTIONS DURING OPERATION…30
BEFORE STARTING ENGINE…30
AFTER STARTING ENGINE…32
TRANSPORTATION…37
BATTERY…38
TOWING…40
PRECAUTIONS FOR MAINTENANCE…41
BEFORE CARRYING OUT MAINTENANCE…41
DURING MAINTENANCE…43
PRECAUTIONS WITH TIRES…48
OPERATION…49
GENERAL VIEW…50
GENERAL VIEW OF MACHINE…50
GENERAL VIEW OF CONTROLS AND GAUGES…51
EXPLANATION OF COMPONENTS…53
METERS AND LAMPS…53
SWITCHES…57
CONTROL LEVERS,PEDALS…62
DUST INDICATOR…70
ARTICULATE LOCK PIN…70
FUSE BOX…70
OPERATION…72
CHECK BEFORE STARTING ENGINE…72
STARTING ENGINE…86
OPERATIONS,CHECKS AFTER STARTING ENGINE…90
STOPPING ENGINE…92
CHECK AFTER STOPPING ENGINE…93
TRAVELING POSTURE FOR MACHINE…93
MOVING MACHINE OFF(FORWARD,REVRESE,SHIFTING GEAR),STOPPING…94
TURNING MACHINE…100
OPERATING WORK EQUIPMENT…103
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER…107
PRECAUTIONS WHEN OPERATION…127
ADJUSTING WORK EQUIPMENT POSTURE…130
PARKING MACHINE…137
CHECKS AFTER COMPLETION OF OPERATION…139
LOCKING(IF EQUIPPED WITH CAB)…139
HANDLING THE TIRES…139
TRANSPORTATION…140
LOADING, UNLOADING WORK…140
PRECAUTIONS FOR LOADING…140
COLD WEATHER OPERATION…141
PRECAUTIONS FOR LOW TEMPERATURE…141
CAUTIONS AFTER COMPLETION OF WORK…143
AFTER COLD WEATHER…143
LONG-TERM STORAGE…144
BEFORE STORAGE…144
DURING STORAGE…144
AFTER STORAGE…144
TROUBLESHOOTING…145
AFTER RUNNING OUT OF FUEL…145
WHEN LEANING PIPING IS DAMAGED…146
TOWING THE MACHINE…147
IF BATTERY IS DISCHARGED…149
OTHER TROUBLE…153
MAINTENANCE…158
GUIDE TO MAINTENANCE…159
OUTLINES OF SERVICE…161
OUTLINE OF OIL, FUEL, COOLANT…161
RELATING TO ELECTRIC SYSTEM…163
WEAR PARTS LIST…164
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…165
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…165
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…169
TORQUE LIST…169
PERIODIC REPLACEMENT OF CRITICAL PARTS…170
CRITICAL PARTS…170
MAINTENANCE SCHEDULE CHART…171
MAINTENANCE SCHEDULE CHART…171
SERVICE PROCEDURE…174
INITIAL 250 HOURS SERVICE…174
WHEN REQUIRED…175
CLEAN INSIDE OF COOLING SYSTEM…175
CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT…178
CHECK ELECTRICAL INTAKE AIR HEATER…180
REPLACE THE CUTTING EDGES,REVERSE AND REPLACE END BIT…180
CHECK INCHING PEDAL…180
CHECK DISC BRAKE…181
SELECTION AND INSPECTION OF TIRES…183
CHECK BEFORE STARTING…185
EVERY 50 HOURS SERVICE…186
LUBRICATING…186
EVERY 250 HOURS SERVICE…187
LUBRICATING…187
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…190
CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL…192
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…193
CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL…194
CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE,ADD OIL…194
CHECK OIL LEVEL IN HYDRAULIC TANK,ADD OIL…195
CHECK LEVEL OF BATTERY ELECTROLYTE…196
CHECK BALL JOINT CLEARANCE,ADJUST…196
CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT…197
CHECK PARKING BRAKE LEVER STROKE,ADJUST…198
CHECKING WHEEL RIM,LOCK RING AND SIDE RING FOR CORROSION AND WEAR…199
CHECK FAN BELT TENSION,ADJUST…199
EVERY 500 HOURS SERVICE…200
REPLACE FUEL FILTER CARTRIDGE…200
REPLACE TRANSMISSION OIL FILTER ELEMENT…201
CLEAN,CHECK RADIATOR FINS…201
CHECK CIRCLE GUIDE CLEARANCE,ADJUST…202
EVERY 1000 HOURS SERVICE…204
GREASE DRIVE SHAFT…204
CHANGE OIL IN TRANSMISSION CASE,CLEAN STRAINER…205
CHANGE OIL IN FINAL DRIVE CASE…206
CHANGE OIL IN CIRCLE REVERSE GEAR CASE…207
CHANGE OIL PIN HYDRAULIC TANK,REPLACE FILTER ELEMENT AND CLEAN STRAINER…208
CHECK LOOSENESS IN DRAWBAR FRONT BALL JOINT…209
CHECK TOE-IN,ADJUST…210
REPLACE CORROSION RESISTOR CARTRIDGE…211
CHECK FRONT WHEEL BEARING PLAY,ADJUST…211
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…211
CHECK PLAY OF TURBOCHARGER ROTOR…211
EVERY 2000 HOURS SERVICE…212
CHANGE OIL IN FRONT WHEEL BEARING…212
CHANGE OIL IN TANDEM DRIVE CASE…212
CHECK ALTERNATOR,STARTING MOTOR…212
CHECK ENGINE VALVE CLEARANCE,ADJUST…212
CHECK VIBRATION DAMPER…212
CLEAN,CHECK TURBOCHARGER…213
CLEAN ENGINE BREATHER ELEMENT…213
EVERY 4000 HOURS SERVICE…214
CHECK WATER PUMP…214
SPECIFICATIONS…215
SPECIFICATIONS…216
OPTIONS,ATTACHMENTS…217
HANDLING BLADE ACCUMULATOR…218
FEATURES OF BLADE ACCUMULATOR…218
METHOD OF OPERATING BLADE ACCUMULATOR…219
INDEX…220
SEAM234Y01 – Motor Grader GD705A-3 Operation & Maintenance Manual…223
COVER…223
FOREWORD…224
BREAKING IN YOUR NEW MACHINE…225
CONTENTS…226
SAFETY HINTS…227
GENERAL LOCATIONS…239
OPERATOR'S COMPARTMENT…241
INSTRUMENTS AND CONTROLS…243
CHECK BEFORE STARTING…262
OPERATING YOUR MACHINE…270
COLD WEATHER OPERATION…281
WORKS TO BE CARRIED OUT BY A MOTOR GRADER…286
OPERATING OF WORK EQUIPMENT…291
REVERSING AND REPLACEMENT OF CUTTING EDGE AND END BIT…304
CHANGING TIRES…306
DRIVING ALONG ROAD…308
HANDLING OF BATTERY…309
TRANSPORTATION…312
MAINTENANCE…314
PERIODIC MAINTENANCE…315
PRECAUTIONS FOR MAINTENANCE…316
MAINTENANCE TABLE…323
EVERY 50 HOURS SERVICE…331
INITIAL 250 HOURS SERVICE…332
EVERY 250 HOURS SERVICE…332
EVERY 500 HOURS SERVICE…344
EVERY 1000 HOURS SERVICE…348
EVERY 2000 HOURS SERVICE…357
EVERY 4000 HOURS SERVICE…361
WHEN REQUIRED…362
ADJUSTMENT…368
TROUBLE SHOOTING GUIDE…369
WEAR PARTS…373
STORAGE…374
SERVICE METER…376
MACHINE AND ENGINE SERIAL NUMBERS…377
SPECIFICATIONS…378
FUEL AND LUBRICANTS…380
SEBM022104 – Motor Grader GD705A-4 Shop Manual…383
COVER…383
CONTENTS…384
SAFETY…387
SAFETY NOTICE…387
GENERAL PRECAUTIONS…387
PRECAUTIONS FOR WORK…387
PRECAUTIONS DURING WORK…388
FOREWARD…389
GENERAL…389
HOW TO READ THE SHOP MANUAL…390
VOLUMES…390
DISTRIBUTION AND UPDATING…390
FILING METHOD…390
REVISED EDITION MARK…390
REVISIONS…390
SYMBOLS…390
HOISTING INSTRUCTIONS…391
HOISTING…391
WIRE ROPES…391
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER…392
COATING MATERIALS…394
STANDARD TIGHTENING TORQUE…396
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS…396
TIGHTENING TORQUE OF HOSE NUTS…397
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS…397
TIGHTENING TORQUE FOR FLARED NUTS…397
TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLTS AND NUTS)…398
TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)…398
TIGHTENED TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS)…398
ELECTRIC WIRE CODE…399
CLASSIFICATION BY THICKNESS…399
CLASSIFICATION BY COLOR AND CODE…399
CONVERSION TABLES…400
METHOD OF USING THE CONVERSION TABLE…400
UNITS…406
01 GENERAL…407
GENERAL ASSEMBLY DRAWING…408
SPECIFICATIONS…409
WEIGHT TABLE…411
LIST OF LUBRICANT AND WATER…412
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…414
ENGINE MOUNTING…415
RADIATOR…416
FUEL TANK PIPING…417
ACCELERATOR CONTROL…418
POWER TRAIN…419
DAMPER…421
PTO (POWER TAKE OFF)…422
HYDROSHIFT TRANSMISSION…424
HYDROSHIFT TRANSMISSION CONTROL VALVE…435
HYDROSHIFT TRANSMISSION PIPING…450
LUBRICATION RELIEF VALVE…451
TRANSMISSION PUMP…452
TRANSMISSION CONTROL…455
DRIVE SHAFT…457
FINAL DRIVE…458
TANDEM DRIVE…463
STEERING PIPING…467
STEERING WHEEL…471
STEERING VALVE (ORBIT ROLL TYPE)…472
STEERING SYSTEM…473
STEERING PUMP…481
STEERING CYLINDER…484
FRONT AXLE…486
WHEEL…492
BRAKE PIPING…494
DISC BRAKE SYSTEM…496
BRAKE VALVE…500
RELAY VALVE…504
AIR GOVERNOR…506
CHECK VALVE…508
AIR RESERVOIR…509
SAFETY VALVE…509
PRESSURE SWITCH…510
AUTOMATIC DRAIN VALVE…512
AIR DRIER…514
AIR COMPRESSOR…516
PARKING BRAKE…517
PARKING BRAKE CONTROL…520
HYDRAULIC PIPING…522
MAIN CONTROL VALVE…527
PILOT CHECK VALVE…531
DDV (DUAL DEMAND VALVE)…539
FLOW DIVIDER VALVE…557
HYDRAULIC PUMP…558
CIRCLE ROTATION MOTOR…561
HYDRAULIC CYLINDER…564
WORK EQUIPMENT CONTROL…574
WORK EQUIPMENT…576
20 TESTING AND ADJUSTING…595
STANDARD VALUE TABLE FOR ENGINE…596
STANDARD VALUE TABLE FOR CHASSIS…597
TESTING AND ADJUSTING…600
TESTING AND ADJUSTING TOOL LIST (FOR ENGINE)…601
TESTING AND ADJUSTING VALVE CLEARANCE…602
MEASURING COMPRESSION PRESSURE…603
MEASURING BLOW-BY…604
TESTING AND ADJUSTING FAN BELT TENSION…605
TESTING AND ADJUSTING FUEL INJECTION TIMING…606
INCHING PEDAL STROKE AND OPERTING FORCE…608
HYDROSHIFT TRANSMISSION…609
TRANSMISSION CONTROL LEVER STROKE AND OPERATING FORCE…611
ADJUSTING F/R CONTROL CABLE…612
ADJUSTING TRANSMISSION CONTROL LINKAGE…613
STEERING WHEEL…615
CHECKING TIRE PLAY…616
CHECKING TIRE AIR PRESSURE…616
CHECKING TOE-IN…617
CHECKING PARKING BRAKE LEVER STROKE AND OPERATING FORCE…619
CHECKING WEAR OF BRAKE DISC…620
CHECKING HYDRAULIC OIL PRESSURE…621
CHECKING HYDRAULIC OIL TEMPERATURE…622
WORK EQUIPMENT CONTROL LEVER STROKE AND OPERATING FORCE…623
HYDRAULIC DRIFT OF BLADE…623
MEASURING BLADE SINKING AMOUNT…623
TROUBLESHOOTING…624
POINTS TO REMEMBER WHEN TROUBLESHOOTING…625
SEQUENCE OF EVENTS IN TROUBLESHOOTING…626
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…627
CHECKS BEFORE TROUBLESHOOTING…635
CONNECTOR TYPES AND MOUNTING LOCATIONS…636
CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS…639
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…643
E-1 ENGINE DOES NOT START…644
E-2 ELECTRIC SYSTEM DOES NOT WORK…647
E-3 SERVICE METER DOES NOT WORK…648
E-4 WATER TEMPERATURE GUAGE INDICATES ABNORMALLY HIGH TEMPERATURE…649
E-5 WATER TEMPERATURE GUAGE DOES NOT WORK…649
E-6 FUEL GUAGE ALWAYS INDICATES FULL…650
E-7 FUEL GUAGE DOES NOT WORK…650
E-8 ENGINE OIL PRESSURE GUAGE INDICATES ABNORMALLY HIGH PRESSURE…651
E-9 ENGINE OIL PRESSURE GUAGE DOES NOT WORK…651
30 DISASSEMBLY AND ASSEMBLY…652
ALTERNATOR ASSEMBLY…654
REMOVAL AND INSTALLATION…654
STARTING MOTOR AND ASSEMBLY…655
REMOVAL AND INSTALLATION…655
OIL COOLER ASSMBLY…655
REMOVAL AND INSTALLATION…655
HYDROSHIFT TRANSMISSION OIL COOLER ASSEMBLY…656
REMOVAL AND INSTALLATION…656
WATER PUMP ASSEMBLY…657
REMOVAL AND INSTALLATION…657
FUEL INJECTION PUMP ASSEMBLY…658
REMOVAL AND INSTALLATION…658
AIR COMPRESSOR ASSEMBLY…659
REMOVAL AND INSTALLATION…659
TURBOCHARGER ASSEMBLY…660
REMOVAL AND INSTALLATION…660
NOZZLE HOLDER ASSEMBLY…661
REMOVAL AND INSTALLATION…661
CYLINDER HEAD ASSEMBLY…663
REMOVAL…663
INSTALLATION…669
RADIATOR ASSEMBLY…675
REMOVAL…675
INSTALLATION…677
FUEL TANK ASSEMBLY (INC. HYDRAULIC TANK)…679
REMOVAL…679
INSTALLATION…681
ENGINE ASSEMBLY (INC. TRANSMISSION)…683
REMOVAL…683
INSTALLATION…688
HYDROSHIFT TRANSMISSION ASSEMBLY…695
DISASSEMBLY…695
ASSEMBLY…705
CAGE AND REVERSE CARRIER ASSEMBLY…716
DISASSEMBLY AND ASSEMBLY…716
1ST SPEED AND 2ND SPEED CARRIER ASSEMBLY…717
DISASSEMBLY…717
ASSEMBLY…718
HIGH REVOLUTION CLUTCH ASSEMBLY…719
DISASSEMBLY…719
ASSEMBLY…720
PLANETARY GEAR…721
DISASSEMBLY AND ASSEMBLY…721
HYDROSHIFT TRANSMISSION PUMP ASSEMBLY…722
REMOVAL AND INSTALLATION…722
TANDEM AND FINAL DRIVE ASSEMBLY…723
REMOVAL…723
INSTALLATION…724
FINAL DRIVE ASSEMBLY…725
DISASSEMBLY…725
ASSEMBLY…731
BEVEL GEAR ASSEMBLY…739
DISASSEMBLY…739
ASSEMBLY…742
BEVEL PINION ASSEMBLY…745
REMOVAL…745
INSTALLATION…746
DISASSEMBLY…748
ASSEMBLY…749
SPROCKET ASSEMBLY…751
REMOVAL…751
INSTALLATION…753
CHAIN…755
REMOVAL…755
INSTALLATION…757
FRONT AXLE ASSEMBLY…759
REMOVAL…759
INSTALLATION…761
STEERING PUMP ASSEMBLY…763
REMOVAL AND INSTALLATION…763
STEERING CYLINDER ASSEMBLY…764
REMOVAL AND INSTALLATION…764
WHEEL BRAKE ASSEMBLY…765
DISASSEMBLY…765
ASSEMBLY…767
HYDRAULIC TANK…769
REMOVAL AND INSTALLATION…769
HYDRAULIC PUMP ASSEMBLY…770
REMOVAL AND INSTALLATION…770
HYDRAULIC CONTROL VALVE ASSEMBLY…771
REMOVAL…771
INSTALLATION…772
BLADE LIFT CYLINDER ASSEMBLY…773
REMOVAL AND INSTALLATION…773
DRAWBAR SHIFT CYLINDER ASSEMBLY…774
REMOVAL AND INSTALLATION…774
BLADE SIDE SHIFT CYLINDER ASSEMBLY…775
REMOVAL…775
INSTALLATION…776
LEANING CYLINDER ASSEMBLY…777
REMOVAL AND INSTALLATION…777
ARTICULATE CYLINDER ASSEMBLY…778
REMOVAL AND INSTALLATION…778
POWER TILT CYLINDER ASSEMBLY…779
REMOVAL AND INSTALLATION…779
HYDRAULIC CYLINDER ASSEMBLY…780
DISASSEMBLY…780
ASSEMBLY…783
BLADE ASSEMBLY…790
REMOVAL AND INSTALLATION…790
CIRCLE ROTATION GEAR AND HYDRAULIC MOTOR ASSEMBLY…791
REMOVAL AND INSTALLATION…791
DISASSEMBLY…792
ASSEMBLY…794
90 OTHERS…798
HYDRAULIC CIRCUIT DIAGRAM (STD SPEC.)…799
HYDRAULIC CIRCUIT DIAGRAM (DDV SPEC.)…801
HYDROSHIFT TRANSMISSION CONTROL CIRCUIT DIAGRAM…803
ELECTRICAL CIRCUIT DIAGRAM (1/2)…804
ELECTRICAL CIRCUIT DIAGRAM (2/2)…806
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER…808
ELECTRICAL CIRCUIT DIAGRAM FOR CAB…810
SEN06489-03 – Motor Grader GD705-5 Shop Manual…812
Cover…812
Notice of revision…814
00 Index and foreword…822
Foreword and general information…834
Safety notice…834
How to read the shop manual…839
Explanation of terms for maintenance standard…841
Handling of electric equipment and hydraulic components…843
Handling of connectors newly used for engines…852
How to read electric wire code…855
Precautions when carrying out work…858
Method of disassembling and connecting push-pull type coupler…861
Standard tightening torque table…864
List of Abbreviation…868
Conversion table…872
01 Specification…878
Specification drawing…880
Specifications…882
Weight table…888
Table of fuel, coolant and lubricants…889
10 Structure and function…892
Engine and cooling system…895
Cooling system…895
Cooling fan motor…897
Power train system…904
Power train system drawing…904
Power train piping drawing…905
Transmission control…906
Torque converter…907
Transmission…911
Transmission control valve…931
ECMV…933
Main relief and torque converter relief valve…940
Front axle…942
Final drive…945
Differential…948
Differential lock solenoid valve…950
Tandem drive…951
Steering system…954
Steering piping diagram…954
Priority valve…955
Steering valve…961
Brake system…969
Brake hydraulic piping diagram…969
Brake valve…970
Slack adjuster…975
Accumulator (for brake)…977
Charge valve…978
Wheel brake…983
Parking brake and bank control valve…984
Parking brake…985
Undercarriage and frame…986
Frame…986
Tire…987
Hydraulic system…988
Hydraulic system…988
Work equipment hydraulic component layout…991
Work equipment control…994
Hydraulic tank…996
Main pump…997
Power train pump…1009
Control valve…1011
CLSS…1020
Functions and operation by valve…1023
Swivel joint…1033
Pilot check valve…1034
Separately installed safety valve…1038
Accumulator (for blade)…1039
Work equipment…1041
Circle and drawbar…1041
Blade…1043
Lifter…1045
Circle rotation motor…1047
Circle rotation gear…1049
Cab…1051
Cab…1051
Electrical system…1053
Machine monitor…1053
Automatic shift control system…1056
Transmission controller…1064
Engine controller…1067
KOMTRAX system…1070
Starting engine circuit…1075
Stopping engine circuit…1077
Preheating circuit…1078
Engine power mode select circuit…1079
Cooling fan control function…1080
Sensor…1084
20 Standard value table…1096
Standard value table…1098
Standard value table for engine…1098
Standard value table for machine…1100
Machine posture and procedure for measuring performance…1108
30 Testing and adjusting…1110
Related information on testing and adjusting…1113
Tools for testing and adjusting…1113
Sketch of tools for testing and adjusting…1116
Engine and cooling system…1117
Testing engine speed…1117
Testing boost pressure…1120
Testing exhaust gas temperature…1122
Testing exhaust gas color…1124
Testing and adjusting valve clearance…1126
Testing compression pressure…1129
Testing blowby pressure…1133
Testing engine oil pressure…1134
Handling equipment of fuel system devices…1135
Releasing remaining pressure from fuel system…1135
Testing fuel pressure…1136
Testing fuel return rate and leakage…1141
Bleeding air from fuel circuit…1144
Testing fuel circuit for leakage…1145
Handling cylinder cutout mode operation…1146
Handling no-injection cranking operation…1146
Testing muffler (main body) and stuck muffler for looseness and damage…1147
Testing muffler function…1147
Testing installed condition of cylinder heads and manifolds…1147
Testing of engine piping for damage and looseness…1147
Testing and adjusting air conditioner compressor belt tension…1148
Replacing alternator belt…1149
Power train…1150
Testing power train oil pressure…1150
Adjusting transmission speed sensor…1163
Retrieval of disabled machine due to transmission valve failure…1166
Flushing procedure for torque converter and transmission circuits…1169
Testing and adjusting toe-in…1171
Testing and adjusting differential lock oil pressure…1172
Steering system…1175
Testing and adjusting steering oil pressure…1175
Testing oil leakage of steering cylinder…1176
Bleeding air from steering circuit…1176
Brake system…1177
Testing and adjusting brake oil pressure…1177
Releasing remaining pressure from brake circuit…1181
Bleeding air from brake circuit…1182
Testing wear of wheel brake disc…1183
Testing and adjusting parking brake…1184
Parking brake emergency releasing procedure…1186
Procedure for charging brake accumulator with nitrogen gas…1187
Hydraulic system…1190
Testing and adjusting work equipment oil pressure…1190
Testing and adjusting pump LS differential pressure…1193
Testing lift arm lock cylinder circuit oil pressure…1195
Testing oil leakage of work equipment cylinder…1196
Bleeding air from work equipment circuit…1199
Testing cooling fan pump circuit oil pressure…1200
Work equipment system…1202
Adjusting drawbar ball joint clearance…1202
Testing and adjusting circle guide clearance…1203
Adjusting circle rotation gear…1205
Procedure for charging blade accumulator with nitrogen gas…1208
Electrical system…1209
Special functions of machine monitor…1209
KOMTRAX terminal start-up procedure (ORBCOMM)…1257
Lamp indication of KOMTRAX terminal (ORBCOMM)…1262
KOMTRAX terminal start-up procedure (GPRS)…1265
Lamp indication of KOMTRAX terminal (GPRS)…1268
Handling voltage circuit of engine controller…1271
Testing diodes…1272
Pm Clinic…1273
Pm Clinic service…1273
40 Troubleshooting…1280
General information on troubleshooting…1287
Points to remember when troubleshooting…1287
Sequence of events in troubleshooting…1288
Checks before troubleshooting…1289
Preparation work for troubleshooting of electrical system…1310
Classification and procedures for troubleshooting…1313
Failure codes table…1314
Failure and troubleshooting numbers…1321
Information in troubleshooting table…1323
Troubleshooting method for open circuit in wiring harness of pressure sensor system…1325
Connector list and layout…1327
Connection table for connector pin numbers…1341
T- branch box and T- branch adapter table…1377
Locations of fuses…1380
Troubleshooting by failure code…1382
Failure code [1500L0] TORQFLOW transmission: Double engagement…1382
Failure code [15G0MW] Transmission R clutch: Slip…1383
Failure code [15H0MW] Transmission FH clutch: Slip…1384
Failure code [15J0MW] Transmission FL clutch: Slip…1384
Failure code [15K0MW] Transmission 1st clutch: Slip…1385
Failure code [15L0MW] Transmission 2nd clutch: Slip…1386
Failure code [15M0MW] Transmission 3rd speed clutch: Slip…1387
Failure code [15N0MW] Transmission 4th clutch: Slip…1388
Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command signal is OFF…1389
Failure code [15SBMA] ECMV R clutch: Malfunction…1391
Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command signal is OFF…1393
Failure code [15SCMA] ECMV FH clutch: Malfunction…1395
Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command signal is OFF…1397
Failure code [15SDMA] ECMV FL clutch: Malfunction…1399
Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command signal is OFF…1401
Failure code [15SEMA] ECMV 1st clutch: Malfunction…1403
Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command signal is OFF…1405
Failure code [15SFMA] ECMV 2nd clutch: Malfunction…1407
Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command signal is OFF…1409
Failure code [15SGMA] ECMV 3rd clutch: Malfunction…1411
Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command signal is OFF…1413
Failure code [15SHMA] ECMV 4th clutch: Malfunction…1415
Failure code [15SJMA] ECMV lockup clutch: Malfunction…1417
Failure code [15U0NT] Inching clutch: Overheating…1417
Failure code [2G42ZG] Front accumulater: Oil pressure drop…1418
Failure code [2G43ZG] Rear accumulater: Pressure drop…1418
Failure code [AA1ANX] Air cleaner: Clogging…1419
Failure code [AB00L6] Alternator; Engine start and stop signals are not matched…1421
Failure code [AB00MA] Alternator: Malfunction…1423
Failure code: [B@BAZG] Derating in speed due to engine oil pressure drop…1425
Failure code: [B@BCNS] Engine coolant overheat…1425
Failure code [B@BEBF] Water in fuel error…1426
Failure code: [B@CENS] Torque converter oil overheat…1427
Failure code: [B@CKNS] Differential case: Overheat…1429
Failure code: [B@HANS] Hydraulic oil: Overheating…1431
Failure code [CA111] Engine controller internal error…1433
Failure code [CA115] Engine Ne, Bkup speed sensor error…1434
Failure code [CA122] Charge pressure sensor high error…1435
Failure code [CA123] Charge pressure sensor low error…1437
Failure code [CA131] Throttle sensor high error…1439
Failure code [CA132] Throttle sensor low error…1441
Failure code [CA144] Coolant sensor high error…1443
Failure code [CA145] Coolant sensor low error…1445
Failure code [CA153] Charge temperature sensor high error…1447
Failure code [CA154] Charge temperature sensor low error…1449
Failure code [CA155] Speed derating error by high charge temperature…1451
Failure code [CA187] Sensor power supply 2 low error…1453
Failure code [CA221] Atmospheric pressure sensor high error…1455
Failure code [CA222] Atmospheric pressure sensor low error…1457
Failure code [CA227] Sensor power supply 2 high error…1459
Failure code [CA234] Engine overspeed…1459
Failure code [CA238] Ne speed sensor power supply error…1460
Failure code [CA271] IMV/IMA: Short circuit…1461
Failure code [CA272] IMV/IMA open circuit…1463
Failure code [CA281] Abnormal supply pump pressure balance…1465
Failure code [CA322] Injector #1 (L#1) open/short…1467
Failure code [CA323] Injector #5 (L#5) open/short…1469
Failure code [CA324] Injector #3 (L#3) open/short…1471
Failure code [CA325] Injector #6 (L#6) open/short…1473
Failure code [CA331] Injector #2 (L#2) open/short…1475
Failure code [CA332] Injector #4 (L#4) open/short…1477
Failure code [CA342] Data compatibility error in engine controller…1479
Failure code [CA351] Injector drive circuit error…1480
Failure code [CA352] Sensor power supply 1 low error…1481
Failure code [CA386] Sensor power supply 1 high error…1482
Failure code [CA428] Water-in-fuel sensor high error…1483
Failure code [CA429] Water-in-fuel sensor low error…1485
Failure code [CA431] Idle validation switch error…1487
Failure code [CA432] Idle validation action error…1491
Failure code [CA435] Engine oil pressure switch error…1494
Failure code [CA441] Power supply voltage low error…1495
Failure code [CA442] Power supply voltage high error…1497
Failure code [CA449] Common rail pressure high error 2…1498
Failure code [CA451] Common rail pressure sensor high error…1499
Failure code [CA452] Common rail pressure sensor low error…1501
Failure code [CA488] Torque derating error by high charge temperature…1503
Failure code [CA553] Common rail pressure high error 1…1504
Failure code [CA559] Rail Press Low Error…1505
Failure code [CA689] Eng Ne Speed Sensor Error…1507
Failure code [CA731] Eng Bkup Speed Sens Phase Error…1509
Failure code [CA757] All continuous data lost error…1510
Failure code [CA778] Eng Bkup Speed Sensor Error…1511
Failure code [CA1633] KOMNET (CAN communication) error…1514
Failure code [CA2185] Throttle sensor power supply high error…1515
Failure code [CA2186] Throttle sensor power supply low error…1517
Failure code [CA2249] Supply pump pressure low error 2…1519
Failure code [CA2265] Fuel Feed Pump Open Error…1521
Failure code [CA2266] Fuel Feed Pump Short Error…1523
Failure code [CA2311] Abnormality in IMV (IMA) solenoid…1524
Failure code [CA2555] Intake heater relay open circuit…1525
Failure code [CA2556] Intake heater relay short circuit…1527
Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit in wiring harness…1529
Failure code [D160KB] Backup lamp relay: Ground fault…1531
Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault…1533
Failure code [D5ZHL6] C terminal signal: Signal does not match to actual engine state…1535
Failure code [DAFRKR] CAN communication failure (monitor panel)…1537
Failure code [DAQ0KK] Transmission controller: Power supply voltage low error (input)…1539
Failure code [DAQOKT] Transmission controller: Non-volatile memory error…1541
Failure code [DAQ2KK] Transmission controller load power line: Power supply voltage drop (input)…1543
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement…1545
Failure code [DAQRKR] Transmission controller CAN communication: Communication error…1547
Failure code [DAQRMA] Transmission controller option setting: Malfunction…1551
Failure code [DB2RKR] Engine controller CAN communication: Communication error…1552
Failure code [DD1PKB] RPM set switch power supply short circuit…1559
Failure code [DD1QKB] RPM set mode switch short circuit…1561
Failure code [DDB6L4] Transmission gearshift lever: Parking brake signal error…1563
Failure code [DDTHKA] Fill switch for FH clutch: Open circuit…1566
Failure code [DDTJKA] Fill switch for FL clutch: Open circuit…1566
Failure code [DDTKKA] Fill switch for 1st clutch: Open circuit…1567
Failure code [DDTLKA] Fill switch for 2nd clutch: Open circuit…1567
Failure code [DDTMKA] Fill switch for 3rd clutch: Open circuit…1568
Failure code [DDTNKA] Fill switch for R clutch: Open circuit…1569
Failure code [DDTPKA] Fill switch for 4th clutch: Open circuit…1570
Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input…1571
Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel direction signal error…1575
Failure code [DGF1KX] Transmission oil temperature sensor: Input signal out of range…1577
Failure code [DGH2KB] Hydraulic oil temperature sensor: Ground fault…1579
Failure code [DGT1KX] Torque converter oil temperature sensor: Input signal out of range…1581
Failure code [DGT7KB] Differential oil temperature sensor: Ground fault…1583
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor…1585
Failure code [DHT5L6] Failure of T/C Oil Press Sensor…1587
Failure code [DJF1KA] Fuel level sensor: Open circuit…1589
Failure code [DK70KX] Inching pedal angle sensor: Input signal out of range…1591
Failure code [DKD0KX] Articulation angle sensor: Input signal out of range…1593
Failure code [DLF1KA] Transmission input shaft speed sensor: Open circuit…1595
Failure code [DLF1LC] Transmission input shaft speed sensor: Speed signal does not match…1596
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Open circuit…1597
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Speed signal does not match…1598
Failure code [DLM3KA] Fan speed sensor: Open circuit…1599
Failure code [DLM3LC] Fan speed sensor: Short circuit…1600
Failure code [DLM3MB] Radiator Fan Control Mismatch…1601
Failure code [DLT3KA] Transmission output shaft speed sensor: Open circuit…1602
Failure code [DV00KB] Buzzer: Short circuit…1603
Failure code [DW4BKA] Parking brake solenoid valve: Open circuit…1605
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit…1607
Failure code [DX16KA] Fan motor EPC solenoid: Open circuit…1608
Failure code [DX16KB] Fan motor EPC solenoid: Short circuit…1609
Failure code [DX16KY] Fan motor EPC solenoid: Short circuit to power supply line…1611
Failure code [DXH1KA] Lockup ECMV solenoid: Open circuit…1613
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit…1614
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit to power supply line…1615
Failure code [DXH2KA] FH clutch ECMV solenoid: Open circuit…1617
Failure code [DXH2KB] FH clutch ECMV solenoid: Short circuit…1618
Failure code [DXH2KY] FH clutch ECMV solenoid: Short circuit to power supply line…1619
Failure code [DXH3KA] FL clutch ECMV solenoid: Open circuit…1621
Failure code [DXH3KB] FL clutch ECMV solenoid: Short circuit…1622
Failure code [DXH3KY] FL clutch ECMV solenoid: Short circuit to power supply line…1623
Failure code [DXH4KA] 1st clutch ECMV solenoid: Open circuit…1625
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit…1626
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit to power supply line…1627
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open circuit…1629
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit…1630
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit to power supply line…1631
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open circuit…1633
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit…1634
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit to power supply line…1635
Failure code [DXH7KA] R clutch ECMV solenoid: Open circuit…1637
Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit…1638
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit to power supply line…1639
Failure code [DXHHKA] 4th clutch ECMV solenoid: Open circuit…1641
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit…1642
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit to power supply line…1643
Troubleshooting of electrical system (E-mode)…1645
E-1 Engine does not start (Starting motor does not turn)…1645
E-2 Preheating does not work…1651
E-3 When starting switch is turned to ON position, machine monitor displays nothing…1656
E-4 When starting switch is turned to ON position, machine monitor does not reach standard screen…1659
E-5 When starting switch is turned to ON position, caution monitor flashes or lights up, or machine monitor does not display correct screen…1659
E-6 Emergency stop monitor lights up while engine is running…1660
E-7 Speedometer or engine tachometer does not indicate correctly…1664
E-8 Engine coolant temperature gauge does not indicate correctly…1665
E-9 Articulation angle indicator does not indicate correctly…1667
E-10 Torque converter oil temperature gauge does not indicate correctly…1669
E-11 Fuel level gauge does not indicate correctly…1671
E-12 Character display does not display correctly…1673
E-13 Centralized warning lamp does not light up or does not go off…1675
E-14 Alarm buzzer does not sound or does not stop sounding…1677
E-15 Machine monitor mode selector switch does not work…1679
E-16 Transmission mode does not switch…1683
E-17 Engine mode does not switch…1685
E-18 Differential lock function does not work or cannot be reset [for machine with differential lock specification]…1687
E-19 Lift arm lock pin does not lock lift arm or does not unlock it [for machine with lift arm specification]…1691
E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator specification]…1693
E-21 Horn does not sound or does not stop sounding…1697
E-22 Backup alarm does not sound or does not stop sounding…1699
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off…1702
E-24 Working lamp does not light up or does not go off…1709
E-25 Fog lamp does not light up or does not go off…1715
E-26 Turn signal lamp and hazard lamp do not flash…1717
E-27 Stop lamp does not light up or does not go off…1723
E-28 Backup lamp does not light up or does not go off…1725
E-29 Windshield wiper does not operate…1727
E-30 Window washer does not operate…1735
E-31 KOMTRAX system does not operate correctly…1739
Troubleshooting for hydraulic and mechanical system (H-mode)…1743
Information described in troubleshooting table (H-mode)…1743
H-1 Engine speed drops significantly or engine stalls…1744
H-2 Machine does not move off (both forward and reverse)…1745
H-3 Gear speed does not shift…1746
H-4 Travel speed or power is low…1747
H-5 Torque converter lockup does not operate or is not canceled…1749
H-6 Machine starts or gear speed shifts with long time lag…1750
H-7 Torque converter oil temperature is high…1751
H-8 Differential lock function does not operate or is not canceled…1752
H-9 Steering speed or power is insufficient…1753
H-10 Steering wheel does not move…1754
H-11 Wheel brakes do not work or are weak…1755
H-12 Wheel brakes are not released or drag…1756
H-13 Parking brake does not work or it is weak…1757
H-14 Parking brake (including emergency release system) is not released or drags…1758
H-15 All work equipment operates slowly or lacks power…1759
H-16 All work equipments do not operate…1760
H-17 Unusual noise is heard from around hydraulic pump…1761
H-18 Blade lift speed or power is low…1762
H-19 Hydraulic drift of lifted blade is large…1763
H-20 Drawbar side shift speed or power is low…1764
H-21 Blade cross slide speed or power is low…1765
H-22 Power tilt speed or power is low…1766
H-23 Articulate speed or power is low…1767
H-24 Leaning speed or power is insufficient…1768
H-25 Hydraulic drift (tilting) of leaning is large…1769
H-26 Blade does not rotate…1770
H-27 Lift arm lock pin is not locked or is not canceled…1771
H-28 Blade accumulator does not operate or is not canceled [blade accumulator specifications]…1772
H-29 Fan rotation is abnormal (such as excessive noise or vibration of fan, or overheating)…1773
H-30 Unusual noise is heard from around fan…1774
Troubleshooting of engine (S-mode)…1776
Method of using troubleshooting charts…1776
S-1 Starting performance is poor…1779
S-2 Engine does not start…1780
S-3 Engine does not pick up smoothly…1783
S-4 Engine stops during operations…1784
S-5 Engine does not rotate smoothly…1785
S-6 Engine lacks output (or lacks power)…1786
S-7 Exhaust smoke is black (incomplete combustion)…1787
S-8 Oil consumption is excessive (or exhaust smoke is blue)…1788
S-9 Oil becomes contaminated quickly…1789
S-10 Fuel consumption is excessive…1790
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)…1791
S-12 Oil pressure drops…1792
S-13 Oil level rises (water, fuel in oil)…1793
S-14 Coolant temperature becomes too high (overheating)…1794
S-15 Abnormal noise is made…1795
S-16 Vibration is excessive…1796
Shop Manual…1798
50 Disassembly and assembly…1798
Related information on disassembly and assembly…1801
How to read this manual…1801
Coating materials list…1803
Special tools list…1807
Sketches of special tools…1812
Engine and cooling system…1846
Removal and installation of fuel supply pump assembly…1846
Removal and installation of fuel injector assembly…1849
Removal and installation of cylinder head assembly…1858
Removal and installation of engine front oil seal assembly…1871
Removal and installation of engine rear oil seal assembly…1874
Removal and installation of cooling fan pump assembly…1879
Removal and installation of cooling fan and fan motor assembly…1881
Removal and installation of radiator assembly…1886
Removal and installation of aftercooler assembly…1890
Removal and installation of power train oil cooler assembly…1893
Removal and installation of fuel tank assembly…1896
Removal and installation of engine hood assembly…1900
Power train…1902
Removal and installation of engine and transmission assembly…1902
Disconnection and connection of transmission and torque converter assembly from/to engine…1910
Disassembly and assembly of transmission assembly…1912
Disassembly and assembly of torque converter assembly…1951
Removal and installation of tandem drive and final drive assembly…1963
Disassembly and assembly of tandem drive assembly…1967
Disassembly and assembly of final drive assembly…1973
Steering system…1992
Removal and installation of steering valve (Orbitrol) assembly…1992
Disassembly and assembly of steering valve (Orbitrol)…1998
Brake system…2009
Disassembly and assembly of wheel brake assembly…2009
Undercarriage and frame…2017
Removal and installation of center hinge pin…2017
Hydraulic system…2030
Removal and installation of hydraulic tank, battery and frame assembly…2030
Removal and installation of hydraulic tank assembly…2035
Removal and installation of control valve assembly…2038
Disassembly and assembly of control valve assembly…2044
Disassembly and assembly of hydraulic cylinder assembly…2047
Work equipment…2051
Removal and installation of blade assembly…2051
Disassembly and assembly of circle drawbar assembly…2053
Removal and installation of circle rotation gear assembly…2056
Disassembly and assembly of circle rotation gear assembly…2059
Removal and installation of ripper assembly…2066
Cab and its attachments…2067
Removal and installation of operator's cab assembly…2067
Removal and installation of floor frame assembly…2079
Removal and installation of operator's cab glass (adhered window glass)…2083
Removal and installation of air conditioner unit assembly…2093
Electrical system…2099
Removal and installation of engine controller assembly…2099
Removal and installation of starting motor…2101
Removal and installation of battery…2103
Removal and installation of machine monitor assembly…2105
Removal and installation of transmission controller assembly…2107
Removal and installation of KOMTRAX terminal assembly (ORBCOMM)…2109
Removal and installation of KOMTRAX terminal assembly (GPRS)…2111
60 Maintenance standard…2114
Engine and cooling system…2116
Engine mount and transmission mount…2116
Cooling system…2117
Cooling fan motor…2118
Power train system…2121
Torque converter…2121
Transmission…2124
Transmission control valve…2133
ECMV…2134
Main relief valve and torque converter relief valve…2136
Front axle…2137
Final drive…2140
Differential…2143
Tandem drive…2145
Brake system…2147
Slack adjuster…2147
Wheel brake…2148
Parking brake…2149
Undercarriage and frame…2150
Frame…2150
Hydraulic system…2151
Main pump…2151
Power train pump…2155
Control valve…2157
Hydraulic cylinder…2166
Work equipment…2169
Circle and drawbar…2169
Blade…2171
Lifter…2173
Circle rotation gear…2174
80 Appendix…2176
Air conditioner…2178
Precautions for refrigerant…2178
Air conditioner components…2179
Structure and function of refrigeration system…2181
Overview of refrigeration system…2182
Air conditioner unit…2183
Compressor…2186
Condenser…2187
Receiver drier…2188
Air conditioner control panel…2189
Procedure for check and troubleshooting…2191
Circuit diagram and layout of connector pins…2193
System diagram…2195
Detail of air conditioner unit…2197
Parts and connectors layout…2199
Testing air leakage (ducts)…2201
Check with self-diagnosis (control panel display)…2203
Testing temperature control…2204
Testing Fresh/Recirc air changeover…2205
Testing evaporator temperature sensor…2206
Testing relays…2207
Testing blower amp…2208
Troubleshooting Chart 1…2209
Troubleshooting Chart 2…2211
Information in troubleshooting table…2213
Troubleshooting for power supply system (Air conditioner does not operate)…2215
Troubleshooting of compressor and refrigerant system (Air is not cooled)…2217
Troubleshooting for blower motor system (Air does not come out or air flow is improper)…2221
Troubleshooting for temperature control…2223
Troubleshooting for FRESH/RECIRC air changeover…2225
Troubleshooting with gauge pressure…2227
Connection of service tool…2229
Precautions for disconnecting and connecting air conditioner piping…2231
Handling compressor oil…2233
90 Diagrams and drawings…2236
Hydraulic diagrams and drawings…2238
Symbols used in hydraulic circuit diagrams…2238
Hydraulic circuit diagram…2240
Electrical diagrams and drawings…2242
Symbols used in electric circuit diagrams…2242
Electrical circuit diagram…2246
Index…2255

Komatsu Motor Graders GD705, GD705A Workshop Service Repair Manuals

INSTANT DOWNLOAD

Posted on June 8, 2025 by admin

Komatsu Motor Graders GD655-3E0, GD675-3E0 Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Motor Graders GD655-3E0, GD675-3E0, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Motor Graders GD655-3E0, GD675-3E0 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.

SEN01775-05 – Motor Grader GD655-3E0, GD675-3E0 Shop Manual.pdf
TEN00149-05 – Motor Grader GD655-3E0 Operation & Maintenance Manual.pdf
TEN00150-05 – Motor Grader GD675-3E0 Operation & Maintenance Manual.pdf
TEN00448-00 – Motor Grader GD655-3E0 Operation & Maintenance Manual.pdf
TEN00449-01 – Motor Grader GD675-3E0 Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 2,261 pages
File Format: PDF
Language: English

SEN01775-05 – Motor Grader GD655-3E0, GD675-3E0 Shop Manual….2
COVER….2
00 Index and foreword….0
Index….3
Composition of shop manual….4
Table of contents….6
Foreword and general information….17
Safety notice….18
How to read the shop manual….23
Explanation of terms for maintenance standard….25
Handling electric equipment and hydraulic component….27
How to read electric wire code….39
Precautions when carrying out operation….42
Method of disassembling and connecting push-pull type coupler….45
Standard tightening torque table….48
Conversion table….52
01 Specification….0
Specification and technical data….58
Specification and technical data….59
General assembly drawing….59
Specifications….60
Weight table….68
Fuel, coolant, and lubricant selection….69
10 Structure, function and maintenance standard….0
Engine and cooling system….72
Engine and cooling system….73
Cooling line….73
Fan drive….74
Power train….76
Power train….77
Power train diagram….77
Transmission hydraulic piping….78
Transmission control….79
Torque converter….80
Torque converter control valve….85
Transmission….86
Transmission control valve….106
ECMV….108
Main relief valve and torque converter relief valve….114
Final drive….116
Steering system….123
Steering system….124
Steering hydraulic piping drawing….124
Steering valve (Q/Amp manual Orbit-roll type)….125
Priority valve….132
Accumulator pressure governor valve….140
Front axle….142
Brake system….147
Brake system….148
Blake hydraulic piping….148
Brake valve….150
Wheel brake….154
Slack adjuster….155
Accumulator….157
Parking brake….158
Parking brake and bank control valve….159
Undercarriage and frame….161
Undercarriage and frame….162
Tandem drive….162
Main frame….165
Hydraulic system….167
Hydraulic system….168
Work equipment hydraulic piping drawing….168
Hydraulic pump….175
Main control valve….196
CLSS….205
Work equipment….218
Work equipment….220
Work equipment control….220
Hydraulic system….222
Hydraulic tank….225
Swivel joint….226
Pilot check valve….227
Blade accumulator, float valve….231
Blade float device….234
Circle rotation motor….236
Hydraulic cylinder….238
Circle, drawbar….240
Blade….242
Circle rotation gear….244
Scarifier….247
Ripper….249
Cab and its attachments….251
Cab and its attachments….252
Air conditioner (If equipped)….252
Electrical system….255
Electrical system….256
Engine starting circuit….256
Engine stop circuit….258
Preheat circuit….259
Automatic shift control system….260
Transmission controller….261
Monitor….267
Sensors….270
Communication controller….276
KOMTRAX terminal system (if equipped)….277
20 Standard value table….0
Standard service value table….280
Standard service value table….281
Standard value table for engine….281
Standard value table for chassis….282
30 Testing and adjusting….0
Testing and adjusting, Part 1….289
Testing and adjusting, Part 1….291
Tools for testing, adjusting and troubleshooting….291
Measuring exhaust color….294
Measuring exhaust temperature….295
Measuring intake air pressure (boost pressure)….297
Measuring blowby pressure….299
Measuring engine oil pressure….300
Measuring engine speed….301
Testing fan belt tension….301
Testing air conditioner compressor belt tension….302
Measuring torque converter stall speed….303
Checking clutch oil pressure….304
Checking torque converter oil pressure….305
Adjusting speed sensor….306
Flushing torque converter and transmission circuit….308
Testing brake disc….309
Testing and adjusting parking brake….310
Method for emergency release of parking brake….312
Testing and adjusting parking brake pad clearance….313
Testing accumulator charge pressure….314
Testing and adjusting work equipment oil pressure….315
Testing and adjusting LS differential pressure….316
Adjusting PC valve….318
Bleeding air from hydraulic circuit….319
Measuring internal cylinder leakage….320
Testing and adjusting differential lock oil pressure [Differential lock specification]….322
Measuring steering and brake oil pressure….324
Bleeding air from brake piping….325
Charging nitrogen gas for brake, work equipment accumulator….326
Testing and adjusting circle guide clearance….328
Testing and adjusting slip clutch type rotary device….330
Memorizing idle and full position procedure….332
Initial learning method for transmission controller….333
Inspection procedure of diode….335
Testing and adjusting, Part 2….337
Testing and adjusting, Part 2….338
Special functions of machine monitor (EMMS)….338
Self-diagnosis display of gear shift lever….363
Handling of high-voltage circuit of engine controller….364
Preparatory work for troubleshooting for electrical equipment system….365
Moving machine when transmission valve fails….366
Adjusting cab stopper bolt….368
How to start operation of KOMTRAX terminal….370
Lamp display of KOMTRAX terminal….373
Pm-clinic….376
40 Troubleshooting….0
Failure code table and fuse locations….384
Failure code table and fuse locations….385
Failure code table….385
Fuse locations….389
General information on troubleshooting….394
General information on troubleshooting….395
Points to remember when troubleshooting….395
Sequence of events in troubleshooting….396
Testing before troubleshooting….397
Classification and procedures of troubleshooting….398
Connection table for connector pin numbers….399
T- branch box and T- branch adapter table….435
Troubleshooting by failure code, Part 1….440
Troubleshooting by failure code, Part 1….442
Failure code [(DF1000)] Neutral safety….442
Failure code [2G42ZG] Decrease of accumulator oil pressure (Front)….443
Failure code [2G43ZG] Decrease of accumulator oil pressure (Rear)….444
Failure code [AB00L6] Signal of alternator disagrees with operating state of engine….445
Failure code [AB00MA] Malfunction of alternator….447
Failure code [B@BAZG] Engine oil pressure too low….449
Failure code [B@BCNS] Engine overheat….450
Failure code [B@CENS] Torque converter oil temperature too high….451
Failure code [B@CKNS] Differential oil overheat….452
Failure code [CA111] Abnormality in controller….453
Failure code [CA115] Abnormality in engine Ne and Bkup speed sensors….454
Failure code [CA122] Charge pressure sensor too high….455
Failure code [CA123] Charge pressure sensor too low….457
Failure code [CA131] Throttle sensor too high….459
Failure code [CA132] Throttle sensor too low….461
Failure code [CA144] Coolant temperature sensor too high….463
Failure code [CA145] Coolant temperature sensor too low….465
Failure code [CA153] Charge temperature sensor too high….467
Failure code [CA154] Charge temperature sensor too low….469
Failure code [CA155] Charge temperature too high and engine speed derated….471
Failure code [CA187] Sensor power source 2 too low….472
Failure code [CA221] Atmospheric pressure sensor too high….474
Failure code [CA222] Atmospheric pressure sensor too low….476
Failure code [CA227] Sensor power source 2 too high….478
Failure code [CA234] Engine over speed….480
Failure code [CA238] Abnormal power source for Ne speed sensor….481
Failure code [CA271] Short circuit in fuel pump actuator….482
Failure code [CA272] Disconnection in fuel pump actuator….484
Failure code [CA281] Abnormal supply pump pressure balance….486
Failure code [CA322] Disconnection or short circuit in injector No.1….487
Failure code [CA323] Disconnection or short circuit in injector No.5….489
Failure code [CA324] Disconnection or short circuit in injector No.3….491
Failure code [CA325] Disconnection or short circuit in injector No.6….493
Failure code [CA331] Disconnection or short circuit in injector No.2….495
Failure code [CA332] Disconnection or short circuit in injector No.4….497
Troubleshooting by failure code, Part 2….500
Troubleshooting by failure code, Part 2….502
Failure code [CA342] Abnormality in engine controller data consistency….502
Failure code [CA351] Abnormality in injector drive circuit….503
Failure code [CA352] Sensor power source 1 too low….505
Failure code [CA386] Sensor power source 1 too high….507
Failure code [CA428] Water detection sensor too high….509
Failure code [CA429] Water detection sensor too low….511
Failure code [CA435] Abnormality in engine oil pressure switch….513
Failure code [CA441] Power supply voltage too low….515
Failure code [CA442] Power supply voltage too high….517
Failure code [CA449] Common rail pressure too high (2)….519
Failure code [CA451] Common rail pressure sensor too high….523
Failure code [CA452] Common rail pressure sensor too low….525
Failure code [CA488] Charge temperature too high and torque derated….527
Failure code [CA553] Common rail pressure too high (1)….528
Failure code [CA559] Supply pump no pressure (1)….529
Failure code [CA689] Abnormality in engine Ne speed sensor….531
Failure code [CA731] Abnormality in engine Bkup speed sensor phase1….533
Failure code [CA757] Loss of all engine controller data….535
Failure code [CA778] Abnormality in engine Bkup speed sensor….537
Failure code [CA1633] Abnormality in KOMNET….539
Failure code [CA2185] Accelerator pedal sensor power source too high….541
Failure code [CA2186] Accelerator pedal sensor power source too low….543
Failure code [CA2249] Supply pump no pressure (2)….545
Failure code [CA2265] Disconnection in electric lift pump….547
Failure code [CA2266] Short circuit in electric lift pump….549
Failure code [CA2311] Abnormal resistance in IMV solenoid….551
Failure code [CA2555] Disconnection in air intake heater relay….553
Failure code [CA2556] Short circuit in air intake heater relay….555
Troubleshooting by failure code, Part 3….558
Troubleshooting by failure code, Part 3….561
Failure code [D19CKZ] Disconnection or short circuit in differential control relay….561
Failure code [D19KKZ] Differential lock-up relay : Disconnection….563
Failure code [DAQ0KK] Power source voltage of transmission controller too low….567
Failure code [DAQSKR] Communication controller cannot recognize S-NET….568
Failure code [DB2RKR] Communication lost engine controller….569
Failure code [DBF0KK] Power source voltage of communication controller too low….571
Failure code [DBF2KK] Voltage of 24 V solenoid power supply system too low….573
Failure code [DBFRKR] Communication lost communication controller….575
Failure code [DD1PKB] Power supply line short in RPM set switch….577
Failure code [DD1QKB] Short circuit in RPM set mode switch….579
Failure code [DDTGKA] Disconnection in lock-up clutch fill switch….581
Failure code [DDTGKB] Fill signal is ON when command current is OFF (lock-up clutch fill switch)….582
Failure code [DDTHKA] Disconnection in FH clutch fill switch….583
Failure code [DDTHKB] Fill signal is ON when command current is OFF (FH clutch fill switch)….584
Failure code [DDTJKA] Disconnection in FL clutch fill switch….585
Failure code [DDTJKB] Fill signal is ON when command current is OFF (FL clutch fill switch)….586
Failure code [DDTKKA] Disconnection in 1st clutch fill switch….587
Failure code [DDTKKB] Fill signal is ON when command current is OFF (1st clutch fill switch)….589
Failure code [DDTLKA] Disconnection in 2nd clutch fill switch….591
Failure code [DDTLKB] Fill signal is ON when command current is OFF (2nd clutch fill switch)….593
Failure code [DDTMKA] Disconnection in 3rd clutch fill switch….595
Failure code [DDTMKB] Fill signal is ON when command current is OFF (3rd clutch fill switch)….597
Failure code [DDTNKA] Disconnection in R clutch fill switch….599
Failure code [DDTNKB] Fill signal is ON when command current is OFF (R clutch fill switch)….600
Failure code [DDTPKA] Disconnection in 4th clutch fill switch….601
Failure code [DDTPKB] Fill signal is ON when command current is OFF (4th clutch fill switch)….603
Failure code [DF10KA] Disconnection in transmission shift lever switch….605
Failure code [DF10KB] Short circuit in transmission shift lever switch….609
Failure code [DGF1KX] Transmission oil temperature out of range….613
Failure code [DGT1KX] Torque converter oil temperature out of range….615
Failure code [DJF1KA] Disconnection in fuel level sensor….617
Failure code [DK10KX] Input of accelerator pedal potentiometer out of normal range….619
Failure code [DK70KX] Input of inching pedal potentiometer out of normal range….621
Failure code [DKD0KA] Disconnection in articulate sensor….623
Failure code [DLE2KA] Disconnection in engine speed sensor….625
Failure code [DLF1KA] Disconnection in transmission input speed sensor….626
Failure code [DLT3KA] Disconnection in transmission output speed sensor….627
Failure code [DV00KB] Short circuit in caution buzzer….628
Failure code [DW4BKA] Disconnection in parking brake relay….629
Failure code [DXH1KA] Disconnection in lock-up ECMV solenoid….631
Failure code [DXH1KY] Power supply line short in lock-up ECMV solenoid….632
Failure code [DXH2KA] Disconnection in FH clutch ECMV solenoid….633
Failure code [DXH2KY] Power supply line short in FH clutch ECMV solenoid….635
Failure code [DXH3KA] Disconnection in FL clutch ECMV solenoid….637
Failure code [DXH3KY] Power supply line short in FL clutch ECMV solenoid….639
Failure code [DXH4KA] Disconnection in 1st clutch ECMV solenoid….641
Failure code [DXH4KY] Power supply line short in 1st, 3rd clutch ECMV solenoid….642
Failure code [DXH5KA] Disconnection in 2nd clutch ECMV solenoid….643
Failure code [DXH5KY] Power supply line short in 2nd, 4th clutch ECMV solenoid….644
Failure code [DXH6KA] Disconnection in 3rd clutch ECMV solenoid….645
Failure code [DXH7KA] Disconnection in R clutch ECMV solenoid….646
Failure code [DXH7KY] Power supply line short in R clutch ECMV solenoid….647
Failure code [DXHHKA] Disconnection in 4th clutch ECMV solenoid….649
Troubleshooting of electrical system (E-mode)….652
Troubleshooting of electrical system (E-mode)….654
Contents of troubleshooting table….654
E-1 Engine does not start at all or does not start easily….655
E-2 Transmission mode does not change….662
E-3 Differential lock function does not work or is not reset [Differential lock specification]….664
E-4 Wheel brake does not work normally….667
E-5 Parking brake does not work or is not reset….669
E-6 Lift arm lock pin is not locked or reset [Lift arm specification]….671
E-7 Blade accumulator function does not work or is not reset [Blade accumulator and float specification]….674
E-8 Blade float function does not work or is not reset [Blade accumulator and float specification]….677
E-9 When starting switch is turned ON, machine monitor does not operate normally….684
E-10 When starting switch is turned ON, machine monitor is not reset to ordinary display….686
E-11 When starting switch is turned ON, caution item lights up….687
E-12 While engine is running, emergency stop item lights up….688
E-13 Indication of speedometer and engine tachometer is abnormal….697
E-14 Indication of engine coolant temperature gauge is abnormal….698
E-15 Indication of articulate gauge is abnormal….700
E-16 Indication of torque converter oil temperature gauge is abnormal….701
E-17 Indication of fuel level gauge is abnormal….702
E-18 Display of character display is abnormal….704
E-19 Centralized warning lamp does not light up or go off….705
E-20 Alarm buzzer does not sound or stop….706
E-21 Machine monitor mode selector switch does not function….708
E-22 Headlamp, clearance lamp and tail lamp do not light up or go off….711
E-23 Working lamp does not light up or go off….716
E-24 Turn signal lamp and hazard lamp do not blink or go off….720
E-25 Brake lamp does not light up or go off….725
E-26 Backup lamp does not light up or go off….727
E-27 Backup buzzer does not sound or stop….728
E-28 Air conditioner does not work or stop….729
E-29 KOMTRAX system does not operate normally….732
Troubleshooting of hydraulic and mechanical system (H-mode)….735
Troubleshooting of hydraulic and mechanical system (H-mode)….737
Contents of troubleshooting table….737
H-1 Excessive drop in engine speed, or engine stalls….738
H-2 Machine does not move in either forward or reverse direction….739
H-3 Transmission does not shift up or shift down….740
H-4 Machine is slow or lacks power when traveling….741
H-5 Torque converter lockup function cannot be actuated or canceled….743
H-6 Excessive time lag when starting or shifting gear….744
H-7 Torque converter oil temperature is high….745
H-8 Differential lock function is not operated or reset [Differential lock specification]….747
H-9 Machine is slow or lacks power when steering….748
H-10 Wheel brake does not work normally….749
H-11 Parking brake is not applied or released….750
H-12 All work equipment is slow or lacks power….751
H-13 No work equipment moves….752
H-14 Abnormal noise generated around pump….753
H-15 Blade is slow or lacks power in lifting….754
H-16 Excessive blade drift….755
H-17 Drawbar side shift operation is slow or lacks power….756
H-18 Blade side shift operation is slow or lacks power….757
H-19 Power tilt operation is slow or lacks power….758
H-20 Articulate operation is slow or lacks power….759
H-21 Leaning operation is slow or lacks power….760
H-22 Excessive drift of leaning….761
H-23 Blade does not rotate….762
H-24 Lift arm lock pin is not locked or reset [Lift arm specification]….763
H-25 Blade accumulator function is not operated or reset [Blade accumulator and float specification]….764
H-26 Blade float function is not operated or reset [Blade accumulator and float specification]….765
Troubleshooting of engine (S-mode)….767
Troubleshooting of engine (S-mode)….769
Method of using troubleshooting charts….769
S-1 Starting performance is poor….772
S-2 Engine does not start….773
S-3 Engine does not pick up smoothly….776
S-4 Engine stops during operations….777
S-5 Engine does not rotate smoothly….778
S-6 Engine lacks output (or lacks power)….779
S-7 Exhaust smoke is black (incomplete combustion)….780
S-8 Oil consumption is excessive (or exhaust smoke is blue)….781
S-9 Oil becomes contaminated quickly….782
S-10 Fuel consumption is excessive….783
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)….784
S-12 Oil pressure drops….785
S-13 Oil level rises (water, fuel in oil)….786
S-14 Coolant temperature becomes too high (overheating)….787
S-15 Abnormal noise is made….788
S-16 Vibration is excessive….789
50 Disassembly and assembly….0
General information on disassembly and assembly….791
How to read this manual….792
How to read this manual….792
Coating materials list….794
Special tool list….797
Sketches of special tools….802
Engine and cooling system….809
Engine and cooling system….810
Removal and installation of fuel supply pump assembly….810
Removal and installation of fuel injector assembly….813
Removal and installation of cylinder head assembly….818
Removal and installation of engine front seal….831
Removal and installation of engine rear seal….835
Removal and installation of engine assembly….841
Removal and installation of fuel tank, hydraulic tank and coolant sub tank assembly….845
Removal and installation of air conditioner condenser….849
Removal and installation of oil cooler assembly….852
Removal and installation of aftercooler assembly….854
Removal and installation of radiator assembly….857
Removal and installation of engine hood….860
Power train, Part 1….865
Power train, Part 1….866
Removal and installation of engine and transmission assembly….866
Removal and installation of transmission assembly….872
Disassembly and assembly of torque converter assembly….878
Disassembly and assembly of transmission assembly….885
Power train, Part 2….923
Power train, Part 2….924
Removal and installation of final drive assembly….924
Disassembly and assembly of final drive assembly….929
Disassembly and assembly of final brake case assembly….934
Disassembly and assembly of side case assembly (For standard final drive)….938
Disassembly and assembly of bevel gear assembly….941
Disassembly and assembly of bevel gear shaft….945
Disassembly and assembly of bevel pinion assembly….947
Steering system….950
Steering system….951
Removal and installation of steering valve (Orbit-roll)….951
Disassembly and assembly of steering valve….952
Hydraulic system….963
Hydraulic system….964
Disassembly and assembly of work equipment control valve assembly….964
Disassembly and assembly of hydraulic cylinder assembly….967
Work equipment….972
Work equipment….973
Removal and installation of blade assembly….973
Removal and installation of circle drawbar assembly….974
Removal and installation of blade circle gear assembly….976
Removal and installation of blade circle rotation gear assembly (with shear pin)….978
Disassembly and assembly of blade circle rotation gear assembly (with shear pin)….980
Disassembly and assembly of circle rotation gear assembly (with slip clutch)….984
Cab and its attachments….990
Cab and its attachments….991
Removal and installation of operator's cab assembly….991
Removal and installation of floor frame assembly….993
Disassembly and assembly of operator’s seat assembly….996
Removal and installation of operator's cab glass (stuck glass)….1005
Removal and installation of air conditioner unit assembly….1011
Electrical system….1014
Electrical system….1015
Removal and installation of machine monitor assembly….1015
Removal and installation of engine controller assembly….1016
Removal and installation of transmission controller assembly….1017
Removal and installation of KOMTRAX controller assembly….1018
Removal and installation of COMMUNICATION controller assembly….1019
90 Diagrams and drawings….0
Hydraulic diagrams and drawings….1021
Hydraulic diagrams and drawings….1022
Power train hydraulic circuit diagram….1022
Brake hydraulic circuit….1024
Hydraulic circuit diagram (1/2)….1025
Hydraulic circuit diagram (2/2)….1026
Electrical diagrams and drawings….1028
Electrical diagrams and drawings….1029
Electrical circuit diagram (1/6)….1029
Electrical circuit diagram (2/6)….1030
Electrical circuit diagram (3/6)….1031
Electrical circuit diagram (4/6)….1032
Electrical circuit diagram (5/6)….1033
Electrical circuit diagram (6/6)….1034
Connector arrangement diagram….1035
TEN00149-05 – Motor Grader GD655-3E0 Operation & Maintenance Manual….1037
COVER….1037
FOREWORD….1038
BEFORE READING THIS MANUAL….1039
SAFETY INFORMATION….1040
INTENDED USE….1041
USE OF MACHINE….1041
DIRECTIONS OF MACHINE….1041
VISIBILITY FROM OPERATOR'S SEAT….1042
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1043
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….1043
EPA REGULATIONS, ENGINE NUMBER PLATE….1043
SERVICE METER POSITION….1044
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1044
CONTENTS….1045
SAFETY….1048
SAFETY INFORMATION….1049
SAFETY LABELS….1052
POSITION FOR ATTACHING SAFETY LABELS….1053
SAFETY LABELS….1054
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….1059
PRECAUTIONS BEFORE STARTING OPERATION….1059
PREPARATIONS FOR SAFE OPERATION….1059
FIRE PREVENTION….1061
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….1062
DO NOT GET CAUGHT IN WORK EQUIPMENT….1064
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….1064
UNAUTHORIZED MODIFICATION….1065
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….1065
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….1065
PRECAUTIONS FOR OPERATION….1066
PRECAUTIONS FOR JOBSITE….1066
STARTING ENGINE….1068
OPERATION….1071
TRANSPORTATION….1075
TOWING….1076
PRECAUTIONS FOR MAINTENANCE….1077
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….1077
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….1082
TIRES….1087
OPERATION….1090
GENERAL VIEW….1091
GENERAL VIEW OF MACHINE….1091
GENERAL VIEW OF CONTROLS AND GAUGES….1092
EXPLANATION OF COMPONENTS….1095
MONITOR PANEL….1095
OTHER FUNCTIONS OF MACHINE MONITOR….1113
SWITCHES….1118
CONTROL LEVERS, PEDALS….1132
DUST INDICATOR….1142
ARTICULATE LOCK PIN….1142
FUSE BOX….1143
SLOW BLOW FUSE….1144
CIRCUIT BREAKER….1144
HANDLING BATTERY DISCONNECTOR SWITCH….1145
OPERATION….1146
CHECK BEFORE STARTING ENGINE….1146
STARTING ENGINE….1160
OPERATIONS, CHECKS AFTER STARTING ENGINE….1163
STOPPING ENGINE….1164
CHECK AFTER STOPPING ENGINE….1164
TRAVELING POSTURE FOR MACHINE….1165
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….1166
TURNING MACHINE….1175
OPERATING WORK EQUIPMENT….1178
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….1184
PRECAUTIONS WHEN OPERATION….1205
ADJUSTING WORK EQUIPMENT POSTURE….1209
PARKING MACHINE….1218
CHECKS AFTER COMPLETION OF OPERATION….1220
LOCKING….1221
HANDLING THE TIRES….1221
TRANSPORTATION….1222
STEPS FOR TRANSPORTATION….1222
LOADING, UNLOADING WORK….1222
PRECAUTIONS FOR LOADING….1223
COLD WEATHER OPERATION….1224
PRECAUTIONS FOR LOW TEMPERATURE….1224
CAUTIONS AFTER COMPLETION OF WORK….1225
AFTER COLD WEATHER….1225
LONG-TERM STORAGE….1226
BEFORE STORAGE….1226
DURING STORAGE….1226
AFTER STORAGE….1226
TROUBLESHOOTING….1227
AFTER RUNNING OUT OF FUEL….1227
WHEN LEANING PIPING IS DAMAGED….1228
TOWING THE MACHINE….1229
IF BATTERY IS DISCHARGED….1231
OTHER TROUBLE….1235
MAINTENANCE….1242
GUIDES TO MAINTENANCE….1243
OUTLINES OF SERVICE….1245
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….1245
RELATING TO ELECTRIC SYSTEM….1249
WEAR PARTS….1250
WEAR PARTS LIST….1250
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….1251
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1252
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….1253
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….1254
TORQUE LIST….1254
PERIODIC REPLACEMENT OF CRITICAL PARTS….1255
CRITICAL PARTS….1255
MAINTENANCE SCHEDULE CHART….1256
MAINTENANCE SCHEDULE CHART….1256
SERVICE PROCEDURE….1258
INITIAL 250 HOURS SERVICE (only after the first 250 hours)….1258
WHEN REQUIRED….1259
CHECK BEFORE STARTING….1274
EVERY 50 HOURS SERVICE….1275
EVERY 250 HOURS SERVICE….1276
EVERY 500 HOURS SERVICE….1290
EVERY 1000 HOURS SERVICE….1298
EVERY 2000 HOURS SERVICE….1307
EVERY 4000 HOURS SERVICE….1312
EVERY 8000 HOURS SERVICE….1314
SPECIFICATIONS….1316
SPECIFICATIONS….1317
ATTACHMENTS, OPTIONS….1320
HANDLING BLADE ACCUMULATOR….1321
FEATURES OF BLADE ACCUMULATOR….1321
METHOD OF OPERATING BLADE ACCUMULATOR….1322
AM/FM RADIO-CASSETTE STEREO….1323
EXPLANATION OF COMPONENTS….1323
METHOD OF OPERATION….1328
PRECAUTIONS WHEN USING….1331
AIR CONDITIONER….1332
LOCATIONS AND FUNCTIONS OF CONTROL PANEL….1332
METHOD OF OPERATION….1335
PRECAUTIONS WHEN USING….1336
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….1336
HANDLING AIR-SUSPENSION SEAT….1337
ADJUST OPERATOR'S SEAT….1337
HANDLING MACHINES EQUIPPED WITH KOMTRAX….1339
BASIC PRECAUTIONS….1339
INDEX….1340
TEN00150-05 – Motor Grader GD675-3E0 Operation & Maintenance Manual….1344
COVER….1344
FOREWORD….1345
BEFORE READING THIS MANUAL….1346
SAFETY INFORMATION….1347
INTENDED USE….1348
USE OF MACHINE….1348
DIRECTIONS OF MACHINE….1348
VISIBILITY FROM OPERATOR'S SEAT….1349
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1350
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….1350
EPA REGULATIONS, ENGINE NUMBER PLATE….1350
SERVICE METER POSITION….1351
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1351
CONTENTS….1352
SAFETY….1355
SAFETY INFORMATION….1356
SAFETY LABELS….1359
POSITION FOR ATTACHING SAFETY LABELS….1360
SAFETY LABELS….1361
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….1366
PRECAUTIONS BEFORE STARTING OPERATION….1366
PREPARATIONS FOR SAFE OPERATION….1366
FIRE PREVENTION….1368
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….1369
DO NOT GET CAUGHT IN WORK EQUIPMENT….1371
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….1371
UNAUTHORIZED MODIFICATION….1372
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….1372
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….1372
PRECAUTIONS FOR OPERATION….1373
PRECAUTIONS FOR JOBSITE….1373
STARTING ENGINE….1375
OPERATION….1378
TRANSPORTATION….1382
TOWING….1383
PRECAUTIONS FOR MAINTENANCE….1384
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….1384
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….1389
TIRES….1394
OPERATION….1397
GENERAL VIEW….1398
GENERAL VIEW OF MACHINE….1398
GENERAL VIEW OF CONTROLS AND GAUGES….1399
EXPLANATION OF COMPONENTS….1402
MONITOR PANEL….1402
OTHER FUNCTIONS OF MACHINE MONITOR….1420
SWITCHES….1425
CONTROL LEVERS, PEDALS….1439
DUST INDICATOR….1449
ARTICULATE LOCK PIN….1449
FUSE BOX….1450
SLOW BLOW FUSE….1451
CIRCUIT BREAKER….1451
HANDLING BATTERY DISCONNECTOR SWITCH….1452
OPERATION….1453
CHECK BEFORE STARTING ENGINE….1453
STARTING ENGINE….1467
OPERATIONS, CHECKS AFTER STARTING ENGINE….1470
STOPPING ENGINE….1471
CHECK AFTER STOPPING ENGINE….1471
TRAVELING POSTURE FOR MACHINE….1472
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….1473
TURNING MACHINE….1482
OPERATING WORK EQUIPMENT….1485
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….1491
PRECAUTIONS WHEN OPERATION….1512
ADJUSTING WORK EQUIPMENT POSTURE….1516
PARKING MACHINE….1525
CHECKS AFTER COMPLETION OF OPERATION….1527
LOCKING….1528
HANDLING THE TIRES….1528
TRANSPORTATION….1529
STEPS FOR TRANSPORTATION….1529
LOADING, UNLOADING WORK….1529
PRECAUTIONS FOR LOADING….1530
COLD WEATHER OPERATION….1531
PRECAUTIONS FOR LOW TEMPERATURE….1531
CAUTIONS AFTER COMPLETION OF WORK….1532
AFTER COLD WEATHER….1532
LONG-TERM STORAGE….1533
BEFORE STORAGE….1533
DURING STORAGE….1533
AFTER STORAGE….1533
TROUBLESHOOTING….1534
AFTER RUNNING OUT OF FUEL….1534
WHEN LEANING PIPING IS DAMAGED….1535
TOWING THE MACHINE….1536
IF BATTERY IS DISCHARGED….1538
OTHER TROUBLE….1542
MAINTENANCE….1549
GUIDES TO MAINTENANCE….1550
OUTLINES OF SERVICE….1552
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….1552
RELATING TO ELECTRIC SYSTEM….1556
WEAR PARTS….1557
WEAR PARTS LIST….1557
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….1558
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1559
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….1560
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….1561
TORQUE LIST….1561
PERIODIC REPLACEMENT OF CRITICAL PARTS….1562
CRITICAL PARTS….1562
MAINTENANCE SCHEDULE CHART….1563
MAINTENANCE SCHEDULE CHART….1563
SERVICE PROCEDURE….1565
INITIAL 250 HOURS SERVICE (only after the first 250 hours)….1565
WHEN REQUIRED….1566
CHECK BEFORE STARTING….1581
EVERY 50 HOURS SERVICE….1582
EVERY 250 HOURS SERVICE….1583
EVERY 500 HOURS SERVICE….1597
EVERY 1000 HOURS SERVICE….1605
EVERY 2000 HOURS SERVICE….1614
EVERY 4000 HOURS SERVICE….1619
EVERY 8000 HOURS SERVICE….1621
SPECIFICATIONS….1623
SPECIFICATIONS….1624
ATTACHMENTS, OPTIONS….1627
HANDLING BLADE ACCUMULATOR….1628
FEATURES OF BLADE ACCUMULATOR….1628
METHOD OF OPERATING BLADE ACCUMULATOR….1629
AM/FM RADIO-CASSETTE STEREO….1630
EXPLANATION OF COMPONENTS….1630
METHOD OF OPERATION….1635
PRECAUTIONS WHEN USING….1638
AIR CONDITIONER….1639
LOCATIONS AND FUNCTIONS OF CONTROL PANEL….1639
METHOD OF OPERATION….1642
PRECAUTIONS WHEN USING….1643
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….1643
HANDLING AIR-SUSPENSION SEAT….1644
ADJUST OPERATOR'S SEAT….1644
HANDLING MACHINES EQUIPPED WITH KOMTRAX….1646
BASIC PRECAUTIONS….1646
INDEX….1647
TEN00448-00 – Motor Grader GD655-3E0 Operation & Maintenance Manual….1651
COVER….1651
FOREWORD….1652
BEFORE READING THIS MANUAL….1653
SAFETY INFORMATION….1654
INTENDED USE….1655
USE OF MACHINE….1655
DIRECTIONS OF MACHINE….1655
VISIBILITY FROM OPERATOR'S SEAT….1656
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1657
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….1657
EPA REGULATIONS, ENGINE NUMBER PLATE….1657
SERVICE METER POSITION….1658
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1658
CONTENTS….1659
SAFETY….1662
SAFETY INFORMATION….1663
SAFETY LABELS….1666
POSITION FOR ATTACHING SAFETY LABELS….1667
SAFETY LABELS….1668
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….1674
PRECAUTIONS BEFORE STARTING OPERATION….1674
PREPARATIONS FOR SAFE OPERATION….1674
FIRE PREVENTION….1676
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….1677
DO NOT GET CAUGHT IN WORK EQUIPMENT….1679
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….1679
UNAUTHORIZED MODIFICATION….1680
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….1680
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….1680
PRECAUTIONS FOR OPERATION….1681
PRECAUTIONS FOR JOBSITE….1681
STARTING ENGINE….1683
OPERATION….1686
TRANSPORTATION….1690
TOWING….1691
PRECAUTIONS FOR MAINTENANCE….1692
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….1692
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….1697
TIRES….1702
OPERATION….1704
GENERAL VIEW….1705
GENERAL VIEW OF MACHINE….1705
GENERAL VIEW OF CONTROLS AND GAUGES….1706
EXPLANATION OF COMPONENTS….1709
MONITOR PANEL….1709
OTHER FUNCTIONS OF MACHINE MONITOR….1727
SWITCHES….1732
CONTROL LEVERS, PEDALS….1746
DUST INDICATOR….1756
ARTICULATE LOCK PIN….1756
FUSE BOX….1757
SLOW BLOW FUSE….1758
CIRCUIT BREAKER….1758
HANDLING BATTERY DISCONNECTOR SWITCH….1759
OPERATION….1760
CHECK BEFORE STARTING ENGINE….1760
STARTING ENGINE….1774
OPERATIONS, CHECKS AFTER STARTING ENGINE….1777
CHECK AFTER STOPPING ENGINE….1778
TRAVELING POSTURE FOR MACHINE….1779
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….1780
TURNING MACHINE….1789
OPERATING WORK EQUIPMENT….1792
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….1798
PRECAUTIONS WHEN OPERATION….1819
ADJUSTING WORK EQUIPMENT POSTURE….1823
PARKING MACHINE….1832
CHECKS AFTER COMPLETION OF OPERATION….1834
LOCKING….1835
HANDLING THE TIRES….1835
TRANSPORTATION….1836
STEPS FOR TRANSPORTATION….1836
LOADING, UNLOADING WORK….1836
PRECAUTIONS FOR LOADING….1837
COLD WEATHER OPERATION….1838
PRECAUTIONS FOR LOW TEMPERATURE….1838
CAUTIONS AFTER COMPLETION OF WORK….1839
AFTER COLD WEATHER….1839
LONG-TERM STORAGE….1840
BEFORE STORAGE….1840
DURING STORAGE….1840
AFTER STORAGE….1840
TROUBLESHOOTING….1841
AFTER RUNNING OUT OF FUEL….1841
WHEN LEANING PIPING IS DAMAGED….1842
TOWING THE MACHINE….1843
IF BATTERY IS DISCHARGED….1845
OTHER TROUBLE….1849
MAINTENANCE….1856
GUIDES TO MAINTENANCE….1857
OUTLINES OF SERVICE….1859
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….1859
RELATING TO ELECTRIC SYSTEM….1863
WEAR PARTS….1864
WEAR PARTS LIST….1864
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….1865
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1866
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….1867
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….1868
TORQUE LIST….1868
PERIODIC REPLACEMENT OF CRITICAL PARTS….1869
CRITICAL PARTS….1869
MAINTENANCE SCHEDULE CHART….1870
MAINTENANCE SCHEDULE CHART….1870
SERVICE PROCEDURE….1872
INITIAL 250 HOURS SERVICE (only after the first 250 hours)….1872
WHEN REQUIRED….1873
CHECK BEFORE STARTING….1888
EVERY 50 HOURS SERVICE….1889
EVERY 250 HOURS SERVICE….1890
EVERY 500 HOURS SERVICE….1904
EVERY 1000 HOURS SERVICE….1912
EVERY 2000 HOURS SERVICE….1921
EVERY 4000 HOURS SERVICE….1926
EVERY 8000 HOURS SERVICE….1928
SPECIFICATIONS….1930
SPECIFICATIONS….1931
ATTACHMENTS, OPTIONS….1934
HANDLING BLADE ACCUMULATOR….1935
FEATURES OF BLADE ACCUMULATOR….1935
METHOD OF OPERATING BLADE ACCUMULATOR….1936
AM/FM RADIO-CASSETTE STEREO….1937
EXPLANATION OF COMPONENTS….1937
METHOD OF OPERATION….1942
PRECAUTIONS WHEN USING….1945
AIR CONDITIONER….1946
LOCATIONS AND FUNCTIONS OF CONTROL PANEL….1946
METHOD OF OPERATION….1949
PRECAUTIONS WHEN USING….1950
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….1950
HANDLING AIR-SUSPENSION SEAT….1951
ADJUST OPERATOR'S SEAT….1951
HANDLING MACHINES EQUIPPED WITH KOMTRAX….1953
BASIC PRECAUTIONS….1953
INDEX….1954
TEN00449-01 – Motor Grader GD675-3E0 Operation & Maintenance Manual….1958

Komatsu Motor Graders GD655-3E0, GD675-3E0 Repair Service Manuals

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