Complete service repair manual with Electrical Wiring Diagrams for Komatsu Motor Graders GD611A-1, GD611R-1, GD613A-1, GD615A-1, GD621A-1, GD622A-1, GD623A-1, GD661A-1, GD625A-1, GD625A-1A, GD625A-1B, GD625A-1C, GD663A-1, GDO663A-2, GD672A-1, GD621R-1, GD623R-1, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Motor Grader GD610 & GD620 & GD660 & GD670 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEBMG6150109 – Motor Grader GD610 & GD620 & GD660 & GD670 Shop Manual.pdf
SEAMG6150101 – Motor Grader GD625A-1 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 664 + 130 pages
File Format: PDF
Language: English
GD621A, 611A, 661A, 621R, 623R, 611R, 613R-1 mount the S6D105-1 engine;
GD622A, 623A, 625A, 672A, 613A, 663A, 625A4-1C, 625A-1A mount the 6D125-1 engine;
GD615A-1 mount the $6D110-1 engine.
For details of the engines, see the 105 Series Shop Manual, 110 Series Shop Manual and 6D125 Series Shop Manual.
MAIN SECTIONS
SEAMG6150101 – Motor Grader GD625A-1 Operation & Maintenance Manual..2
COVER..2
FOREWORD..3
BREAKING IN YOUR NEW MACHINE..4
CONTENTS..5
SAFETY HINTS..6
GENERAL LOCATIONS AND SPECIFICATIONS..13
INSTRUMENTS AND CONTROLS..14
OPERATING THE AIR CONDITIONER..37
CHECK BEFORE STARTING..38
OPERATING YOUR MACHINE..43
COLD WEATHER OPERATION..51
OPERATING OF WORK EQUIPMENT..56
REVERSING AND REPLACEMENT OF CUTTING EDGE AND END BIT..67
CHANGING TIRES..69
DRIVING ALONG ROAD..71
HANDLING OF BATTERY..72
TRANSPORTATION..75
PERIODIC MAINTENANCE..76
PRECAUTIONS FOR MAINTENANCE..77
MAINTENANCE TABLE..80
OIL FILLER AND LEVEL GAUGE POSITIONS..84
EVERY 50 HOURS SERVICE..85
INITIAL 250 HOURS SERVICE..86
EVERY 250 HOURS SERVICE..86
EVERY 500 HOURS SERVICE..95
EVERY 1000 HOURS SERVICE..101
EVERY 2000 HOURS SERVICE..108
EVERY 4000 HOURS SERVICE..111
WHEN REQUIRED..112
ADJUSTMENT..118
TROUBLE SHOOTING GUIDE..120
STORAGE..124
SERVICE METER..126
MACHINE AND ENGINE SERIAL NUMBERS..127
FUEL,COOLANT AND LUBRICANTS..128
SEBMG6150109 – Motor Grader GD610 & GD620 & GD660 & GD670 Shop Manual..132
COVER..132
CONTENTS..133
10 ENGINE..159
12 TESTING AND ADJUSTING..160
TABLE OF JUDGEMENT STANDARD VALUE..161
TESTING AND ADJUSTING TOOL LIST..166
ADJUSTING VALVE CLEARANCE..167
MEASURING COMPRESSION PRESSURE..169
TESTING AND ADJUSTING FUEL INJECTION TIMING..170
BLEEDING AIR FROM FUEL SYSTEM..172
ENGINE SPEED CONTROL..173
MEASURING EXHAUST GAS COLOR..176
TESTING AND ADJUSTING FAN BELT TENSION..178
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE..179
13 DISASSEMBLY AND ASSEMBLY..180
RADIATOR..181
REMOVAL..181
INSTALLATION..181
FUEL TANK(Incl.HYDRAULIC TANK)ASSEMBLY..185
REMOVAL..185
INSTALLATION..187
20 POWER TRAIN..191
21 STRUCTURE AND FUNCTION..192
GENERAL..193
POWER TRAIN..194
HYDROSHIFT TRANSMISSION PIPING..196
HYDROSHIFT TRANSMISSION CONTROL..197
POWER TRAIN HYDRAULIC CIRCUIT SCHEMATICS..198
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM..199
JOINT..200
PTO(POWER TAKE OFF)..201
HYDROSHIFT TRANSMISSION AND TRANSFER..202
HYDROSHIFT TRANSMISSION PUMP..208
TRANSMISSION CONTROL VALVE..210
FINAL DRIVE..218
DIFFERENTIAL LOCK PIPING..225
TANDEM DRIVE..227
22 TESTING AND ADJUSTING..229
TABLE OF JUDGEMENT STANDARD VALUE..230
TOOL LIST FOR TESTING AND ADJUSTING..232
INCHING PEDAL TRAVEL AND OPERATING FORCE..233
CHECKING OIL PRESSURE..236
MACHINE TYPE AND INCHING PRESSURE..237
TRANSMISSION CONTROL LEVER TRAVEL AND OPERATING FORCE..238
CHECKING DIFFERENTIAL LOCKING DEVICE OIL PRESSURE..239
23 DISASSEMBLY AND ASSEMBLY..240
TRANSMISSION PUMP..241
REMOVAL..241
INSTALLATION..241
ENGINE(Incl.TRANSMISSION)ASSEMBLY..243
REMOVAL..243
INSTALLATION..247
PTO..267
DISASSEMBLY..267
ASSEMBLY..271
HYDROSHIFT TRANSMISSION..277
DISASSEMBLY..277
ASSEMBLY..293
TRANSFER ASSEMBLY..313
DISASSEMBLY..313
ASSEMBLY..317
TANDEM AND FINAL DRIVE..323
REMOVAL..323
INSTALLATION..323
TANDEM,FINAL DRIVE ASSEMBLY..325
REMOVAL..325
INSTALLATION..325
FINAL DRIVE..329
DISASSEMBLY..329
ASSEMBLY..333
TANDEM,FINAL DRIVE ASSEMBLY..339
DISASSEMBLY..339
ASSEMBLY..343
SIDE CASE ASSEMBLY..351
DISASSEMBLY..351
ASSEMBLY..351
BEVEL GEAR ASSEMBLY..353
DISASSEMBLY..353
ASSEMBLY..353
PINION ASSEMBLY..363
DISASSEMBLY..363
ASSEMBLY..363
24 MAINTENANCE STANDARD..365
PTO,HYDROSHIFT TRANSMISSION AND TRANSFER..366
HYDROSHIFT TRANSMISSION CONTROL VALVE..368
TRANSMISSION PUMP..374
FINAL DRIVE..376
TANDEM DRIVE..378
40 STEERING SYSTEM..379
41 STRUCTURE AND FUNCTION..380
STEERING PIPING..381
STEERING CIRCUIT DIAGRAM..382
STEERING CONTROL VALVE..383
FRONT AXLE..388
STEERING CYLINDER..394
WHEEL..395
42 TESTING AND ADJUSTING..399
TABLE OF JUDGEMENT STANDARD..400
TOOL LIST FOR TESTING AND ADJUSTING..402
CHECKING STEERING WHEEL..403
CHECKING TIRE RUNOUT..404
CHECKING TIRE INFLATION PRESSURE..404
CHECKING TOE-IN..405
43 DISASSEMBLY AND ASSEMBLY..406
FRONT AXLE ASSEMBLY..407
REMOVAL..407
INSTALLATION..407
FRONT AXLE ASSEMBLY..409
DISASSEMBLY..409
ASSEMBLY..415
STEEREMBLY VALVE..421
DISASSEMBLY..421
ASSEMBLY..425
DOUBLE RELIEF VALVE..429
DISASSEMBLY..429
ASSEMBLY..429
44 MAINTENANCE STANDARD..431
FRONT AXLE..432
STEERING CYLINDER..438
50 BRAKE SYSTEM..439
51 STRUCTURE AND FUNCTION..440
BRAKE PIPING..441
BRAKE CIRCUIT DIAGRAM..442
BOOST MASTER..443
AIR BRAKE PIPING..446
AIR BRAKE CIRCUIT SCHEMATICS..448
AIR BRAKE CIRCUIT DIAGRAM..449
BRAKE VALVE..452
AIR COMPRESSOR..456
AIR GOVERNOR..457
CHECK VALVE..458
AIR TANK..459
SAFETY VALVE..459
AUTOMATIC DRAIN VALVE(IF EQUIPPED)..460
AIR DRIER(IF EQUIPPED)..462
WHEEL BRAKE..464
PARKING BRAKE..467
52 TESTING AND ADJUSTING..468
TABLE OF JUDGEMENT STANDARD VALUE..469
TOOL LIST FOR TESTING AND ADJUSTING..469
CHECKING BRAKE PEDAL..470
AIR BLEEDING FROM BRAKE CIRCUIT..472
CHECKING PARKING BRAKE LEVER..473
CHECKING WEAR OF BRAKE DISC..474
53 DISASSEMBLY AND ASSEMBLY..475
BOOST MASTER..476
DISASSEMBLY ..476
ASSEMBLY..478
WHEEL BRAKE..480
REMOVAL..480
INSTALLATION..480
DISASSEMBLY..482
ASSEMBLY..482
WHEEL BRAKE..484
REMOVAL..484
INSTALLATION..484
DISASSEMBLY..488
ASSEMBLY..492
54 MAINTENANCE STANDARD..504
WHEEL BRAKE..505
PARKING BRAKE..507
BOOST MASTER..508
60 HYDRAULIC SYSTEM..509
61 STRUCTURE AND FUNCTION..510
HYDRAULIC PIPING..511
HYDUAULIC CONTROL..521
BLADE ACCUMULATOR SYSTEM(IF EQUIPPED)..523
HYDRAULIC CIRCUIT DIAGRAM..525
OIL COOLING FLOW..529
HYDRAULIC PUMP..530
CIRCLE ROTATION MOTOR..532
CONTROL VALVE..538
FLOW DIVIDER..544
PILOT CHECK VALVE..545
FLOW CONTROL VALVE..549
HYDRAULIC CYLINDER..550
62 TESTING AND ADJUSTING..553
TROUBLESHOOTING(CIRCLE ROTATION MOTOR)..554
63 DISASSEMBLY AND ASSEMBLY..555
HYDRAULIC PUMP(Incl.STEERING PUMP)..556
REMOVAL..556
INSTALLATION..556
BLADE LIFT CYLINDER..558
REMOVAL..558
INSTALLATION..558
DRAWBAR SHIFT CYLINDER..560
REMOVAL..560
INSTALLATION..560
BLADE SIDE SHAFT CYLINDER..562
REMOVAL..562
INSTALLATION..562
ARTICULATE CYLINDER..564
REMOVAL..564
INSTALLATION..564
SCARIFIER CYLINDER..566
REMOVAL..566
INSTALLATION..566
POWER TILT CYLINDER..568
REMOVAL..568
INSTALLATION..568
REAR MOUNT RIPPER CYLINDER..568
REMOVAL..568
INSTALLATION..568
HYDRAULIC CYLINDER..570
DISASSEMBLY..570
ASSEMBLY..574
CIRCLE ROTATION MOTOR..582
DISASSEMBLY..582
ASSEMBLY..588
64 MAINTENANCE STANDARD..602
HYDRAULIC PUMP..603
CONTROL VALVE..605
HYDRAULIC CYLINDER..609
70 WORK EQUIPMENT..613
71 STRUCTURE AND FUNCTION..614
DRAWBAR AND LIFTER..615
BLADE..619
CIRCLE ROTATION GEAR..623
FRAME..625
SCARIFIER(IF EQUIPPED)..626
REAR MOUNTING RIPPER(IF EQUIPPED)..627
72 TESTING AND ADJUSTING..628
TABLE OF JUDGEMENT STANDARD..629
TOOL LIST FOR TESTING AND ADJUSTING..632
CHECKING CONTROL LEVER..633
CHECKING HYDRAULIC OIL TEMPERATURE..634
CHECKING HYDRAULIC OIL PRESSURE..634
HYDRAULIC DRIFT..636
CHARGING BLADE ACCUMULATOR WITH GAS..637
ADJUSTMENT OF CIRCLE GUIDE..638
73 DISASSEMBLY AND ASSEMBLY..639
BLADE ASSEMBLY..640
REMOVAL..640
INSTALLATION..640
CIRCLE ROTATION GEAR..642
REMOVAL..642
INSTALLATION..642
DISASSEMBLY..644
ASSEMBLY..646
REAR MOUNT RIPPER ASSEMBLY..648
REMOVAL..648
INSTALLATION..648
CIRCLE ROTATION GEAR ASSEMBLY..648
REMOVAL..648
INSTALLATION..648
DISASSEMBLY..650
ASSEMBLY..656
74 MAINTENANCE STANDARD..662
DRAWBAR AND LIFTER..663
BLADE..665
CIRCLE ROTATION GEAR..666
SCARIFIER(IF EQUIPPED)..668
REAR MOUNT RIPPER(IF EQUIPPED)..669
80 ELECTRIC AND ELECTRONIC SYSTEM..672
81 STRUCTURE AND FUNCTION..673
ELECTRICAL CIRCUIT DIAGRAM..674
CIRCUIT DIAGRAM OF CAB..679
ELECTRONIC VEHICLE MONITORING SYSTEM(EVMS)..681
ADJUSTING SPEEDOMETER MODULE(IF EQUIPPED)..689
82 TESTING AND ADJUSTING..690
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE..691
CIRCUIT DIAGRAM..694
CONNECTOR POSITION FOR TROUBLESHOOTING..696
POSITION OF CONNECTOR(D TYPE)..702
POSITION OF CONNECTOR(P,Q TYPE)..708
CONNECTOR TERMINAL NUMBERS..718
PROCEDURE FOR TROUBLESHOOTING..723
CHECKS BEFORE TROUBLESHOOTING..724
METHOD OF USING TROUBLESHOOTING CHART..725
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM(M1 TO M-18)(D TYPE)..727
M-1 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL DISPLAY DOES NOT APPEAR…728
a) NONE OF MONITOR PANEL WORKS..728
b) PART OF MONITOR PANEL DOES NOT WORK..728
M-2 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL DISPLAY DOES NOT GO OUT..728
M-3 WHEN STARTING SWITCH IS TURNED ON,(DO NOT START ENGINE),CHECK BEFORE STARTING ITEMS FLASH OR PREHEATING ITEM LIGHTS UP…729
a) COOLANT LEVEL..729
b) ENGINE OIL LEVEL..729
c) PREHEATER..730
M-4 WHEN STARTING SWITCH IS TURNED ON,(ENGINE STARTED),CHECK BEFORE STARTING ITEMS FLASH…731
a) ALTERNATOR SYSTEM..731
b) ENGINE OIL PRESSURE CIRCUIT..731
M-5 WHEN STARTING SWITCH IS TURNED ON,(DO NOT START ENGINE),CAUTION ITEMS FLASH..732
M-6 WHEN STARTING SWITCH IS ON(ENGINE STARTED),CAUTION ITEMS FLASH..733
a) ENGINE OIL PRESSURE..733
b) COOLANT LEVEL..733
c) COOLANT TEMPERATURE..734
d) BATTERY CHARGE..734
e) FINAL OIL TEMPERATURE..735
f) AIR PRESSURE..735
g) PARKING BRAKE..736
M-7 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK..737
M-8 NO DISPLAY IS GIVEN FOR FUEL LEVEL..737
M-9 ENGINE COOLANT TEMPERATURE IS HIGH,BUT LOWEST LEVEL DISPLAYED..738
M-10 ENGINE COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY..738
M-11 TURN SIGNAL LAMPS,HIGH BEAM LIGHT UP ABNORMALLY,OR DO NOT LIGHT UP..739
a) PILOT DISPLAY OF TURN SIGNAL LAMP(RIGHT)LIGHTS UP..739
b) PILOT DISPLAY OF TURN SIGNAL LAMP(LEFT)LIGHTS UP..739
c) PILOT DISPLAY OF TURN SIGNAL LAMP(RIGHT)DOES NOT LIGHT UP..739
d) PILOT DISPLAY OF TURN SIGNAL LAMP(LEFT)DOES NOT LIGHT UP..740
e) HIGHT BEAM PILOT LAMP DOES NOT LIGHT UP..740
f) HIGH BEAM PILOT LAMP DOES NOT GO OUT..740
M-12 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY..741
M-13 WHEN ENGINE IN STARTED,SERVICE METER DOES NOT MOVE,WHEN ENGINE IN STOPPED,SERVICE METER MOVES..742
a) SERVICE METER DOES NOT MOVE..742
b) SERVICE METER DOES NOT STOP MOVING..742
M-14 MONITOR PANEL LAMPS DO NOT LIGHT UP..743
a) NO LAMPS ON PANEL LIGHT UP..743
b) SOME LAMPS ON PANEL DO NOT LIGHT UP..743
M-15 CENTRAL WARNING LAMP DOES NOT GO OUT..744
a) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING LAMP LIGHTS UP INTERMITTENTLY..744
b) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY..744
M-16 CENTRAL WARNING BUZZER DOES NOT STOP..745
a) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY..745
b) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY..745
M-17 EMERGENCY ITEM OR NON-EMERGENCY ITEMS IS FLASHING,BUT WARNING LAMP DOES NOT FLASH..746
M-18 EMERGENCY ITEM IS FLASHING,BUT ALARM BUZZER DOES NOT SOUND..747
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM(M1 TO M-22)(P,Q TYPE)..755
M-1 MONITOR PANEL PILOT LAMPS DO NOT LIGHT UP FOT 3 SECONDS WHEN STARTING SWITCH IS TURNED ON..756
a) NO LAMPS ON MONITOR PANEL(MONITOR MODULE)LIGHT UP..756
b) NO LAMPS ON MONITOR PANEL(SPEEDOMETER MODULE)LIGHT UP..756
c) SOME LAMPS ON MONITOR PANEL DO NOT LIGHT UP..756
M-2 WHEN STARTING SWITCH IS TURNED ON,ALL MONITOR PANEL LAMPS LIGHT UP BUT DO NOT GO OUT..756
M-3 WHEN STARTING SWITCH IS TURNED ON(WITH ENGINE STOPPED),CHECK ITEMS FLASH..758
a) RADIATOR WATER LEVEL FLASHES..758
b) ENGINE OIL LEVEL FLASHES..759
M-4 PREHEATING IS NOT BEING CARRIED OUT,BUT PREHEATING DISPLAY FLASHES..760
M-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,CHECK ITEMS FLASH..761
a) ALTERNATOR SYSTEM..761
b) ENGINE OIL PRESSURE SYSTEM..762
M-6 WHEN STARTING SWITCH IS TURNED ON WITH ENGINE STOPPED CAUTION ITEMS FLASH..764
M-7 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,CAUTION ITEMS FLASH..768
a) ENGINE OIL PRESSURE FLASHES..768
b) RADIATOR WATER LEVEL FLASHES..770
c) ENGINE WATER TEMPERATURE FLASHES..770
d) CHARGE FLASHES..771
e) FINAL DRIVE OIL TEMPERATURE FLASHES..772
f) AIR PRESSURE FLASHES..773
g) PARKING BRAKE FLASHES..774
M-8 FOR ONE SECOND AFTER STARTING SWITCH IS TURNED ON(ENGINE STOPPED),ALARM BUZZER DOES NOT SOUND.CAUTION ITEM LAMPS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND..775
M-9 THERE IS NO ABNORMALITY ON MONITOR DISPLAY,BUT ALARM BUZZER SOUNDS..775
M-10 FOR TWO SECONDS AFTER STARTING SWITCH IS TURNED ON(ENGINE STOPPED),WARNING LAMP DOES NOT LIGHT UP.CAUTION ITEM LAMPS ARE FLASHING BUT WARNING LAMP DOES NOT LIGHT UP…776
M-11 THERE IS NO ABNORMALITY ON MONITOR DISPLAY,BUT WARNING LAMP LIGHTS UP..776
M-12 MONITOR PANEL LIGHTING DOES NOT LIGHT UP..778
a) NO PANEL LIGHTING LIGHTS UP..778
b) PART OF PANEL LIGHTING DOES NOT LIGHT UP..778
M-13 SERVICE METER DOES NOT MOVE WHEN ENGINE IS STARTED;OR SERVICE METER MOVES WHEN ENGINE IS STOPPED.(FOR MACHINES WITH SPEEDOMETER)..779
a) SERVICE METER DOES NOT MOVE WHEN ENGINE IS STARTED..779
b) SERVICE METER MOVES WHEN ENGINE IS STOPPED..779
M-14 ENGINE WATER TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE..781
M-15 ENGINE WATER TEMPERATURE GAUGE SHOWS NO DISPLAY..781
M-16 FUEL GAUGE ALWAYS SHOWS FULL..782
M-17 NO DISPLAY IS GIVEN FOR FUEL LEVEL GAUGE..782
M-18 HIGH BEAM DOES NOT LIGHT UP..784
M-19 HIGH BEAM STAYS LIGHTED UP..784
M-20 TURN SIGNAL INDICATOR DOES NOT LIGHT UP..786
M-21 TURN SIGNAL INDICATOR STAYS LIGHTED UP..787
M-22 SPEED DISPLAY STAYS AT "0" AND DOES NOT MOVE..789
90 OTHERS..791
AIR CONDITIONER..792
Komatsu Motor Graders GD611A, GD611R, GD613A, GD615A, GD621A, GD622A, GD623A, GD661A, GD625A, GD663A, GD672A, GD621R, GD623R Repair Service Manuals