Komatsu GD663A-2 Motor Grader Shop Manual SEN06779-02 – PDF DOWNLOAD 

Description

Komatsu GD663A-2 Motor Grader Shop Manual SEN06779-02 – PDF DOWNLOAD

FILE DETAILS:

Komatsu GD663A-2 Motor Grader Shop Manual SEN06779-02 – PDF DOWNLOAD 

Language : English
Pages : 524
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu GD663A-2 Motor Grader Shop Manual SEN06779-02 – PDF DOWNLOAD 

SERIAL NUMBERS 1001 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

TABLE OF CONTENTS:

Komatsu GD663A-2 Motor Grader Shop Manual SEN06779-02 – PDF DOWNLOAD 

SERIAL NUMBERS 1001 and up

Cover 1
CONTENTS 4
SAFETY 5
SAFETY NOTICE 5
FOREWORD 7
GENERAL 7
HOW TO READ THE SHOP MANUAL 8
HOISTING INSTRUCTIONS 9
COATING MATERIALS 10
STANDARD TIGHTENING TORQUE 12
ELECTRIC WIRE CODE 15
CONVERSION TABLE 16
01 SPECIFICATION 23
WEIGHT TABLE 24
TABLE OF OIL AND COOLANT QUANTITY 25
10 ENGINE 27
12 TESTING AND ADJUSTING 27
TABLE OF JUDGEMENT STANDARD VALUE 28
TESTING AND ADJUSTING TOOL LIST 30
ADJUSTING VALVE CLEARANCE 31
MEASURING COMPRESSION PRESSURE 32
TESTING AND ADJUSTING FUEL INJECTION TIMING 33
BLEEDING AIR FROM FUEL SYSTEM 34
ENGINE SPEED CONTROL 35
MEASURING EXHAUST GAS COLOR 37
TESTING AND ADJUSTING FAN BELT TENSION 38
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE 39
13 DISASSEMBLY AND ASSEMBLY 41
RADIATOR 42
REMOVAL 42
INSTALLATION 42
FUEL TANK (Incl HYDRAULIC TANK) ASSEMBLY 46
REMOVAL 46
INSTALLATION 50
20 POWER TRAIN 55
21 STRUCTURE AND FUNCTION 55
GENERAL 56
POWER TRAIN 58
HYDROSHIFT TRANSMISSION PIPING 60
HYDROSHIFT TRANSMISSION CONTROL 61
POWER TRAIN HYDRAULIC CIRCUIT SCHEMATICS 62
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 63
JOINT 64
PTO (POWER TAKE OFF) 65
HYDROSHIFT TRANSMISSION AND TRANSFER 67
HYDROSHIFT TRANSMISSION PUMP 74
TRANSMISSION CONTROL VALVE 76
FINAL DRIVE 84
DIFFERENTIAL LOCK PIPING 91
TANDEM DRIVE 92
22 TESTING AND ADJUSTING 95
TABLE OF JUDGEMENT STANDARD VALUE 96
TOOL LIST FOR TESTING AND ADJUSTING 97
INCHING PEDAL TRAVEL AND OPERATING FORCE 98
CHECKING OIL PRESSURE 100
MACHINE TYPE AND INCHING PRESSURE 101
TRANSMISSION CONTROL LEVER TRAVEL AND OPERATING FORCE 102
CHECKING DIFFERENTIAL LOCKING DEVICE OIL PRESSURE 103
23 DISASSEMBLY AND ASSEMBLY 105
TRANSMISSION PUMP 106
REMOVAL 106
INSTALLATION 106
TRANSMISSION PUMP (Incl FINAL DRIVE PUMP) ASSEMBLY 106
ASSEMBLY 106
INSTALLATION 106
ENGINE (Incl TRANSMISSION) ASSEMBLY 108
REMOVAL 108
INSTALLATION 112
PTO 116
DISASSEMBLY 116
ASSEMBLY 120
HYDROSHIFT TRANSMISSION 126
DISASSEMBLY 126
ASSEMBLY 142
TRANSFER ASSEMBLY 162
DISASSEMBLY 162
ASSEMBLY 166
TANDEM, FINAL DRIVE ASSEMBLY 172
REMOVAL (NON-DIFFERENTIAL TYPE AND NON-SPIN DIFFERENTIAL TYPE) 172
INSTALLATION (NON-DIFFERENTIAL TYPE AND NON-SPIN DIFFERENTIAL TYPE) 172
REMOVAL (WITH DIFFERENTIAL LOCK TYPE) 174
INSTALLATION (WITH DIFFERENTIAL LOCK TYPE) 174
FINAL DRIVE 176
DISASSEMBLY 176
ASSEMBLY 180
TANDEM, FINAL DRIVE ASSEMBLY 186
DISASSEMBLY 186
ASSEMBLY 190
SIDE CASE ASSEMBLY 198
DISASSEMBLY 198
ASSEMBLY 198
BEVEL GEAR ASSEMBLY 200
DISASSEMBLY 200
ASSEMBLY 200
DISASSEMBLY (DIFFERENTIAL TYPE) 202
ASSEMBLY (DIFFERENTIAL TYPE) 206
PINION ASSEMBLY 210
DISASSEMBLY 210
ASSEMBLY 210
24 MAINTENANCE STANDARD 213
PTO, HYDROSHIFT TRANSMISSION AND TRANSFER 214
HYDROSHIFT TRANSMISSION CONTROL VALVE 217
TRANSMISSION PUMP 220
FINAL DRIVE 222
TANDEM DRIVE 224
40 STEERING SYSTEM 225
41 STRUCTURE AND FUNCTION 225
STEERING PIPING 226
STEERING CIRCUIT DIAGRAM 227
STEERING CONTROL VALVE (Orbitrol type) 228
FRONT AXLE 233
STEERING CYLINDER 236
WHEEL 237
42 TESTING AND ADJUSTING 241
TABLE OF JUDGEMENT STANDARD 242
TOOL LIST FOR TESTING AND ADJUSTING 243
CHECKING STEERING WHEEL 244
CHECKING TIRE RUNOUT 245
CHECKING TIRE INFLATION PRESSURE 245
CHECKING TOE-IN 246
43 DISASSEMBLY AND ASSEMBLY 247
FRONT AXLE ASSEMBLY 248
REMOVAL 248
INSTALLATION 248
DISASSEMBLY 250
ASSEMBLY 256
STEEREMBLY VALVE 262
DISASSEMBLY 262
ASSEMBLY 266
DOUBLE RELIEF VALVE 270
DISASSEMBLY 270
ASSEMBLY 270
44 MAINTENANCE STANDARD 273
FRONT AXLE 274
STEERING CYLINDER 276
50 BRAKE SYSTEM 277
51 STRUCTURE AND FUNCTION 277
BRAKE PIPING 278
BRAKE CIRCUIT DIAGRAM 279
BOOST MASTER 280
AIR BRAKE CIRCUIT DIAGRAM 283
AIR BRAKE CIRCUIT SCHEMATICS 284
BRAKE VALVE 286
AIR COMPRESSOR 290
AIR GOVERNOR 291
CHECK VALVE 292
AIR TANK 293
SAFETY VALVE 293
AUTOMATIC DRAIN VALVE (IF EQUIPPED) 294
AIR DRIER (IF EQUIPPED) 296
WHEEL BRAKE 298
PARKING BRAKE 301
52 TESTING AND ADJUSTING 303
TABLE OF JUDGEMENT STANDARD VALUE 304
TOOL LIST FOR TESTING AND ADJUSTING 304
CHECKING BRAKE PEDAL 305
AIR BLEEDING FROM BRAKE CIRCUIT 308
CHECKING PARKING BRAKE LEVER 309
CHECKING WEAR OF BRAKE DISC 310
53 DISASSEMBLY AND ASSEMBLY 311
BOOST MASTER 312
DISASSEMBLY 312
ASSEMBLY 314
WHEEL BRAKE 316
REMOVAL 316
INSTALLATION 316
DISASSEMBLY 318
ASSEMBLY 318
BRAKE SHOE 320
DISASSEMBLY 320
ASSEMBLY 320
WHEEL BRAKE ASSEMBLY 322
REMOVAL (WET TYPE DISC BRAKE TYPE) 322
INSTALLATION (WET TYPE DISC BRAKE TYPE) 322
DISASSEMBLY (WET TYPE DISC BRAKE TYPE) 326
ASSEMBLY (WET TYPE DISC BRAKE TYPE) 330
DISASSEMBLY (DRY TYPE DRUM BRAKE TYPE) 334
ASSEMBLY (DRY TYPE DRUM BRAKE TYPE) 336
PARKING BRAKE 340
REMOVAL AND DISASSEMBLY 340
INSTALLATION AND ASSEMBLY 340
54 MAINTENANCE STANDARD 343
WHEEL BRAKE 344
PARKING BRAKE 346
BOOST MASTER 347
60 HYDRAULIC SYSTEM 349
61 STRUCTURE AND FUNCTION 349
HYDRAULIC PIPING 350
HYDUAULIC CONTROL 360
HYDRAULIC CIRCUIT DIAGRAM 362
HYDRAULIC PUMP 364
CIRCLE ROTATION MOTOR 365
CONTROL VALVE 368
FLOW DIVIDER 372
PILOT CHECK VALVE 373
FLOW CONTROL VALVE 377
HYDRAULIC CYLINDER 378
62 TESTING AND ADJUSTING 381
TROUBLESHOOTING (Circle rotation motor) 382
63 DISASSEMBLY AND ASSEMBLY 383
HYDRAULIC PUMP (Incl STEERING PUMP) 384
REMOVAL 384
INSTALLATION 384
BLADE LIFT CYLINDER 386
REMOVAL 386
INSTALLATION 386
DRAWBAR SHIFT CYLINDER 388
REMOVAL 388
INSTALLATION 388
BLADE SIDE SHAFT CYLINDER 390
REMOVAL 390
INSTALLATION 390
BLADE SIDE SHAFT CYLINDER ASSEMBLY 392
REMOVAL 392
INSTALLATION 392
ARTICULATE CYLINDER 392
REMOVAL 392
INSTALLATION 392
SCARIFIER CYLINDER ASSEMBLY 394
REMOVAL 394
INSTALLATION 394
LEANING CYLINDER 394
REMOVAL 394
INSTALLATION 394
POWER TILT CYLINDER (if equipped) 396
REMOVAL 396
INSTALLATION 396
REAR MOUNT RIPPER CYLINDER ASSEMBLY (if equipped) 396
REMOVAL 396
INSTALLATION 396
HYDRAULIC CYLINDER ASSEMBLY 398
DISASSEMBLY 398
ASSEMBLY 402
CIRCLE ROTATION MOTOR 410
DISASSEMBLY 410
ASSEMBLY 416
64 MAINTENANCE STANDARD 427
HYDRAULIC PUMP 428
CONTROL VALVE 430
HYDRAULIC CYLINDER 432
70 WORK EQUIPMENT 435
71 STRUCTURE AND FUNCTION 435
DRAWBAR AND LIFTER 436
BLADE 438
CIRCLE ROTATION GEAR 441
FRAME 442
SCARIFIER (if equipped) 443
REAR MOUNT RIPPER (if equipped) 444
72 TESTING AND ADJUSTING 445
TABLE OF JUDGEMENT STANDARD 446
TOOL LIST FOR TESTING AND ADJUSTING 447
CHECKING CONTROL LEVER 448
CHECKING HYDRAULIC OIL TEMPERATURE 449
CHECKING HYDRAULIC OIL PRESSURE 449
HYDRAULIC DRIFT 450
ADJUSTMENT OF CIRCLE GUIDE 451
73 DISASSEMBLY AND ASSEMBLY 453
BLADE ASSEMBLY 454
REMOVAL 454
INSTALLATION 454
CIRCLE ROTATION GEAR 456
REMOVAL 456
INSTALLATION 456
DISASSEMBLY 458
ASSEMBLY 460
REAR MOUNT RIPPER ASSEMBLY (if equipped) 462
REMOVAL 462
INSTALLATION 462
74 MAINTENANCE STANDARD 465
DRAWBAR AND LIFTER 466
BLADE 468
CIRCLE ROTATION GEAR 469
SCARIFIER (If equipped) 470
REAR MOUNT RIPPER (If equipped) 471
80 ELECTRIC AND ELECTRONIC SYSTEM 473
81 STRUCTURE AND FUNCTION 473
ELECTRICAL CIRCUIT DIAGRAM 475
INDICATION ON PANEL 482
82 TESTING AND ADJUSTING 483
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE 484
POSITION OF CONNECTOR 486
CONNECTOR TERMINAL NUMBERS 500
PROCEDURE FOR TROUBLESHOOTING 504
CHECKS BEFORE TROUBLESHOOTING 505
METHOD OF USING TROUBLESHOOTING CHART 506
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (M-1 to M-12) 509
M-1 WHEN STARTING SWITCH IS TURNED (DO NOT START ENGINE), CAUTION ITEMS DO NOT LIGHT UP 510
a) (ENGINE OIL PRESSURE) DO NOT LIGHT 510
b) (BATTERY CHARGE) DO NOT LIGHT UP 511
M-2 (FLUID LEVEL OF CHECKS BEFORE STARTING ITEMS AND ENGINE ARE CORRECT)
WHEN STARTING SWITCH IS ON (ENGINE STARTED), CAUTION ITEMS LIGHT UP 512
a) (ENGINE OIL PRESSURE) LIGHT UP 512
b) (BATTERY CHARGE) LIGHT UP 512
M-3 WHILE PARKING BRAKE LEVER IS OPERATED, CAUTION LAMP DOES NOT LIGHT UP 513
M-4 WHILE PARKING BRAKE LEVER IS NOT OPERATED, CAUTION LAMP LIGHTS UP 513
M-5 FUEL TANK IS NOT FULL BUT FUEL GAUGE SHOWS FULL 515
M-6 FUEL TANK IS NOT EMPTY BUT FUEL GAUGE SHOWS EMPTY 515
M-7 ENGINE COOLANT TEMPERATURE IS LOW, BUT TEMPERATURE GAUGE SHOWS HIGHEST LEVEL 516
M-8 ENGINE COOLANT TEMPERATURE IS HIGH, BUT TEMPERATURE GAUGE SHOWS LOWEST LEVEL 516
M-9 WHEN ENGINE IS STARTED, SERVICE METER DOES NOT MOVE 517
M-10 WHEN ENGINE IS STOPPED, SERVICE METER MOVES 517
M-11 AIR PRESSURE IS LOW, BUT PRESSURE GAUGE SHOWS HIGHEST LEVEL 518
M-12 AIR PRESSURE IS HIGH, BUT PRESSURE GAUGE SHOWS LOWEST LEVEL 518
90 OTHERS 519
AIR CONDITIONER (if equipped) 520

S.V  21/12/24