KOMATSU GD825A-2 SHOP MANUAL SEBM002311 – PDF DOWNLOAD

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KOMATSU GD825A-2 SHOP MANUAL SEBM002311 – PDF DOWNLOAD

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KOMATSU GD825A-2 SHOP MANUAL SEBM002311 – PDF DOWNLOAD

Language : English
Pages : 968
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

KOMATSU GD825A-2 SHOP MANUAL SEBM002311 – PDF DOWNLOAD

COVER..................................................................................................................................................  1
01 GENERAL............................................................................................................................................. 49
	Specification dimension drawings................................................................................................................... 50
	Specifications..................................................................................................................................... 52
	Weight table....................................................................................................................................... 55
	Fuel, coolant and lubricants....................................................................................................................... 56
10 STRUCTURE AND FUNCTION.............................................................................................................................. 59
	General............................................................................................................................................ 60
	Power train diagram................................................................................................................................ 61
	Joint.............................................................................................................................................. 62
	HYDROSHIFT transmission and transfer piping........................................................................................................ 63
	Hydraulic circuit for power train.................................................................................................................. 64
	Hydraulic circuit diagram for power train.......................................................................................................... 65
	PTO (Power Take Off)............................................................................................................................... 68
	HYDROSHIFT transmission and transfer............................................................................................................... 70
	Transmission control valve......................................................................................................................... 80
	Transmission control...............................................................................................................................108
	Inching control....................................................................................................................................116
	Drive shaft........................................................................................................................................117
	Final drive, differential lock and unlock piping...................................................................................................118
	Final drive........................................................................................................................................120
	Tandem drive.......................................................................................................................................123
	Steering piping....................................................................................................................................125
	Steering circuit system............................................................................................................................126
	Steering circuit diagram...........................................................................................................................127
	Steering valve.....................................................................................................................................128
	Double relief valve................................................................................................................................132
	Check valve........................................................................................................................................133
	Emergency steering system..........................................................................................................................134
	Front axle.........................................................................................................................................135
	Wheel..............................................................................................................................................140
	Disc brake.........................................................................................................................................143
	Parking brake......................................................................................................................................145
	Brake air piping...................................................................................................................................147
	Brake air circuit system...........................................................................................................................148
	Brake air circuit diagram..........................................................................................................................149
	Air drier..........................................................................................................................................150
	Air governor.......................................................................................................................................152
	Air tank...........................................................................................................................................154
	Safety valve.......................................................................................................................................154
	Automatic drain valve..............................................................................................................................155
	Check valve........................................................................................................................................157
	Brake valve........................................................................................................................................158
	Parking brake system...............................................................................................................................162
	Parking brake solenoid valve.......................................................................................................................163
	Exhaust valve......................................................................................................................................164
	Spring cylinder....................................................................................................................................165
	Hydraulic control piping...........................................................................................................................166
	Hydraulic circuit system...........................................................................................................................174
	Hydraulic circuit diagram..........................................................................................................................176
	Closed center load sensing system (CLSS)...........................................................................................................188
	Hydraulic pump.....................................................................................................................................192
	Priority flow divider valve........................................................................................................................197
	Surge pressure absorbing valve.....................................................................................................................203
	Hydraulic control valve............................................................................................................................206
	Pressure compensating mechanism of hydraulic control valve.........................................................................................210
	Blade lift speed adjustment mechanism..............................................................................................................216
	Pilot check valve..................................................................................................................................218
	Pilot check valve (with safety valve)..............................................................................................................220
	Circle rotation motor..............................................................................................................................222
	Blade accumulator system...........................................................................................................................225
	Blade float system.................................................................................................................................227
	Drawbar and lifter.................................................................................................................................228
	Blade..............................................................................................................................................232
	Lifter bracket control piping......................................................................................................................234
	Circle rotation gear...............................................................................................................................235
	Rear mount ripper..................................................................................................................................237
	Hydraulic control linkage..........................................................................................................................238
	Main Frame.........................................................................................................................................240
	Air conditioner....................................................................................................................................242
	Electrical wiring diagram..........................................................................................................................245
	Monitor panel, cluster gauge and pilot lamp........................................................................................................251
	Electrical circuit diagram.........................................................................................................................254
	Electrical vehicle monitoring system (EVMS)........................................................................................................295
	Transmission control system........................................................................................................................301
	Sensors............................................................................................................................................308
	Engine starting circuit............................................................................................................................316
	Engine stopping circuit............................................................................................................................324
20 TESTING AND ADJUSTING...............................................................................................................................331
	Standard value table for engine....................................................................................................................333
	Standard value table for testing and adjusting, failure judgment of chassis........................................................................336
	Tool list for testing and adjusting................................................................................................................342
	Testing and adjusting valve clearance..............................................................................................................344
	Measuring compression pressure.....................................................................................................................345
	Testing and adjusting fuel injection timing........................................................................................................346
	Measuring blow-by pressure.........................................................................................................................350
	Measuring engine oil pressure......................................................................................................................351
	Measuring exhaust gas color........................................................................................................................352
	Measuring exhaust gas temperature..................................................................................................................353
	Measuring intake air pressure (boost pressure).....................................................................................................354
	Testing and adjusting fan belt tension.............................................................................................................356
	Testing and adjusting alternator belt tension......................................................................................................358
	Procedure for adjusting the engine stop motor cable................................................................................................360
	Adjusting accelerator control......................................................................................................................361
	Inching pedal travel and operating force...........................................................................................................362
	HYDROSHIFT transmission............................................................................................................................363
	Checking differential locking device oil pressure..................................................................................................366
	Steering system....................................................................................................................................367
	Checking tire runout...............................................................................................................................368
	Checking air pressure of tire......................................................................................................................368
	Checking toe-in....................................................................................................................................369
	Installation of articulate center pins.............................................................................................................370
	Checking wear of brake disc........................................................................................................................371
	Checking parking brake.............................................................................................................................371
	Checking work equipment control lever travel and operating force...................................................................................372
	Checking hydraulic oil temperature.................................................................................................................372
	Checking work equipment hydraulic pressure.........................................................................................................373
	Adjusting work equipment hydraulic pressure........................................................................................................373
	Measuring hydraulic drift..........................................................................................................................374
	Charging blade accumulator with gas................................................................................................................375
	Adjusting blade lift speed.........................................................................................................................376
	Bleeding air from hydraulic pump...................................................................................................................377
	Adjusting slip load of circle rotation clutch......................................................................................................378
	Adjusting speedometer module of machine monitor....................................................................................................385
TROUBLESHOOTING........................................................................................................................................387
	Points to remember when troubleshooting............................................................................................................388
	Sequence of events in troubleshooting..............................................................................................................389
	Handling of electric equipment and hydraulic component.............................................................................................390
	Checks before troubleshooting......................................................................................................................400
	Electrical circuit system diagram..................................................................................................................401
	Connector types and mounting locations.............................................................................................................417
	Electrical wiring diagram..........................................................................................................................427
	Connection table for connector pin numbers.........................................................................................................431
	T-branch box and T-branch adapter table............................................................................................................467
	Method of using troubleshooting charts.............................................................................................................470
	Details of troubleshooting and troubleshooting procedure...........................................................................................472
	TROUBLESHOOTING OF ENGINE (S MODE).................................................................................................................477
		S-1  Starting performance is poor (Starting always takes time).................................................................................478
		S-2  Engine does not start.....................................................................................................................479
			(1) Engine does not turn...................................................................................................................479
			(2) Engine turns but no exhaust gas comes out (Fuel is not being injected).................................................................480
			(3) Exhaust gas comes out but engine does not start (Fuel is being injected)...............................................................481
		S-3  Engine does not pick up smoothly (Follow-up is poor)......................................................................................482
		S-4  Engine stops during operations............................................................................................................483
		S-5  Engine does not rotate smoothly (hunting).................................................................................................484
		S-6  Engine lacks output (no power)............................................................................................................485
		S-7  Exhaust gas is black (incomplete combustion)..............................................................................................486
		S-8  Oil consumption is excessive (or exhaust gas is blue).....................................................................................487
		S-9  Oil becomes contaminated quickly..........................................................................................................488
		S-10  Fuel consumption is excessive............................................................................................................489
		S-11  Oil is in cooling water, or water spurts back, or water level goes down..................................................................490
		S-12  Oil pressure lamp lights up (drop in oil pressure).......................................................................................491
		S-13  Oil level rises..........................................................................................................................492
		S-14  Water temperature becomes too high (overheating).........................................................................................493
		S-15  Abnormal noise is made...................................................................................................................494
		S-16  Vibration is excessive...................................................................................................................495
	TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (M MODE)............................................................................497
		M-1.  When starting switch is turned ON, monitor panel display does not appear.................................................................498
		M-2.  When starting switch is turned ON, monitor panel display does not go out.................................................................498
		M-3.  When starting switch is turned ON (engine stopped), check items flash....................................................................499
		M-4.  Preheating operation is not being used but preheating display lights up..................................................................501
		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)....504
		M-6.  Buzzer does not sound for 1 minute when starting switch is turned ON (engine stopped)....................................................511
		M-7.  There is no abnormality displayed on monitor, but buzzer sounds..........................................................................511
		M-8.  Monitor panel lighting does not light up.................................................................................................512
		M-9.  Service meter does not move after engine is started / Service meter continues to move when engine is stopped.............................515
		M-10.  Coolant temperature gauge displays abnormally low temperature...........................................................................516
		M-11.  Coolant temperature gauge does not give a display.......................................................................................517
		M-12.  Fuel level gauge always displays FULL...................................................................................................518
		M-13.  Fuel gauge does not give any display....................................................................................................518
		M-14.  Speedometer display does not work normally..............................................................................................519
		M-15.  Turn signal indicator pilot lamp does not light up......................................................................................520
		M-16.  High beam pilot lamp does not light up..................................................................................................521
	TROUBLESHOOTING CHART FOR ELECTRONIC (ENGINE, PARKING BRAKE, TRANSMISSION CONTROL) (E MODE)........................................................523
		E-1  Engine does not start (starting motor works)..............................................................................................524
		E-2  Starting motor does not turn..............................................................................................................524
		E-3  Parking brake does not work...............................................................................................................530
		E-4  Parking brake cannot be released..........................................................................................................530
		E-5  Transmission does not shift when transmission lever is moved to a position between F1 and F8, or R1 and R8................................532
		E-6  Transmission does not shift to 1st (F and R)..............................................................................................542
		E-7  Transmission does not shift to 2nd (F and R)..............................................................................................542
		E-8  Transmission does not shift to 3rd (F and R)..............................................................................................542
		E-9  Transmission does not shift to 4th (F and R)..............................................................................................543
		E-10  Transmission does not shift to 5th (F and R).............................................................................................543
		E-11  Transmission does not shift to 6th (F and R).............................................................................................543
		E-12  Transmission does not shift to 7th (F and R).............................................................................................544
		E-13  Transmission does not shift to 8th (F and R).............................................................................................544
	TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (ET MODE)........................................................................................545
		LED display for transmission controller........................................................................................................546
		ET-1  [A1] (Short circuit in 1st solenoid) is displayed........................................................................................552
		ET-2  [A2] (Short circuit in 2nd solenoid) is displayed........................................................................................553
		ET-3  [A3] (Short circuit in 3rd solenoid) is displayed........................................................................................554
		ET-4  [A4] (short circuit in 4th solenoid) is displayed........................................................................................555
		ET-5  [A5] (Short circuit in High/Low solenoid) is displayed...................................................................................556
		ET-6  [A7] (Short circuit in FORWARD/REVERSE solenoid) is displayed............................................................................558
		ET-7  [b1] (Disconnection in 1st solenoid) is displayed........................................................................................560
		ET-8  [b2] (Disconnection in 2nd solenoid) is displayed........................................................................................561
		ET-9  [b3] (Disconnection in 3rd solenoid) is displayed........................................................................................562
		ET-10  [b4] (Disconnection in 4th solenoid) is displayed.......................................................................................563
		ET-11  [b5] (Disconnection in Low solenoid) is displayed.......................................................................................564
		ET-12  [b6] (Disconnection in High solenoid) is displayed......................................................................................565
		ET-13  [b7] (Disconnection in FORWARD solenoid) is displayed...................................................................................566
		ET-14  [b8] (Disconnection in REVERSE solenoid) is displayed...................................................................................567
		ET-15  [c1] (Disconnection in inching potentiometer) is displayed..............................................................................568
		ET-16  [c2] (Failure in shift potentiometer 1) is displayed....................................................................................569
		ET-17  [c3] (Failure in shift potentiometer 2) is displayed....................................................................................570
		ET-18  [d1] (Failure in F and R switches) is displayed.........................................................................................571
		ET-19  [d4] (Disconnection in engine speed sensor) is displayed................................................................................574
		ET-20  [d5] (Disconnection in speed sensor) is displayed.......................................................................................575
		ET-21  [d6] (Failure in transmission oil temperature sensor) is displayed......................................................................576
		ET-22  [E0] (Drop in power source voltage) is displayed........................................................................................577
		ET-23  [E1] (Short circuit in parking brake) is displayed......................................................................................579
		ET-24  [E2] or [F2] (Short circuit, disconnection in parking brake lamp) is displayed..........................................................580
		ET-25  [E3] or [F3] (Short circuit, disconnection in differential lock relay) is displayed.....................................................581
		ET-26  [E4] or [F4] (Short circuit, disconnection in backup buzzer relay) is displayed.........................................................583
		ET-27  [E5] or [F5] (Short circuit, disconnection in caution lamp) is displayed................................................................585
		ET-28  [E6] or [F6] (Short circuit, disconnection in alarm buzzer relay) is displayed..........................................................586
		ET-29  [E7] or [F7] (Short circuit, disconnection in starting motor relay) is displayed........................................................588
		ET-30  [F1] (Disconnection in parking brake) is displayed......................................................................................590
		ET-31  [C4] (Disconnection in rotary switch photo-interrupter) is displayed....................................................................592
		ET-32  [C5] (Abnormality in rotary switch photo-interrupter) is displayed......................................................................593
	TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM (H MODE)................................................................................................597
		STANDARDS FOR MEASURING HYDRAULIC PRESSURE, AND JUDGEMENT VALUES...............................................................................598
		TABLE OF FAILURE MODES AND CAUSES..............................................................................................................600
		HYDRAULIC PRESSURE MEASUREMENT AND FILTER MOUNTING POSITIONS...................................................................................602
		H-1  Abnormal noise is made (from around pump).................................................................................................604
		H-2  Relief sound is heard (when not operating)................................................................................................604
		H-3  Hydraulic oil overheats (when not operating)..............................................................................................604
		H-4  Work equipment does not move when control lever is operated (steering at neutral).........................................................605
		H-5  Work equipment is slow, lacks power.......................................................................................................606
		H-6  There is excessive hydraulic drift of work equipment......................................................................................607
		H-7  Steering wheel does not turn (work equipment at neutral)..................................................................................607
		H-8  Turning speed is slow, lacks power (work equipment at neutral)............................................................................608
		H-9  Feeling when operating steering wheel is strange..........................................................................................608
30 DISASSEMBLY AND ASSEMBLY............................................................................................................................609
	HOW TO READ THIS MANUAL............................................................................................................................611
	COATING MATERIAL LIST..............................................................................................................................613
	SPECIAL TOOL LIST..................................................................................................................................616
	STARTING MOTOR.....................................................................................................................................618
		Removal and Installation.......................................................................................................................618
	ALTERNATOR.........................................................................................................................................618
		Removal and Installation.......................................................................................................................618
	NOZZLE HOLDER......................................................................................................................................620
		Removal and Installation.......................................................................................................................620
	FUEL INJECTION PUMP................................................................................................................................621
		Removal and Installation.......................................................................................................................621
	WATER PUMP.........................................................................................................................................622
		Removal and Installation.......................................................................................................................622
	ENGINE OIL COOLER CORE.............................................................................................................................624
		Removal and Installation.......................................................................................................................624
	TURBOCHARGER.......................................................................................................................................625
		Removal and Installation.......................................................................................................................625
	AIR COMPRESSOR.....................................................................................................................................626
		Removal and Installation.......................................................................................................................626
	CYLINDER HEAD......................................................................................................................................627
		Removal........................................................................................................................................627
		Installation...................................................................................................................................631
	ENGINE (INCL. TRANSMISSION)........................................................................................................................634
		Removal........................................................................................................................................634
		Installation...................................................................................................................................641
	RADIATOR...........................................................................................................................................649
		Removal........................................................................................................................................649
		Installation...................................................................................................................................651
	FUEL TANK..........................................................................................................................................653
		Removal........................................................................................................................................653
		Installation...................................................................................................................................654
	PTO................................................................................................................................................656
		Disassembly....................................................................................................................................656
		Assembly.......................................................................................................................................661
	TRANSMISSION.......................................................................................................................................666
		Removal........................................................................................................................................666
		Installation...................................................................................................................................670
		Disassembly....................................................................................................................................674
		Assembly.......................................................................................................................................682
	TRANSFER...........................................................................................................................................697
		Disassembly....................................................................................................................................697
		Assembly.......................................................................................................................................700
	TRANSMISSION CONTROL VALVE.........................................................................................................................704
		Disassembly....................................................................................................................................704
		Assembly.......................................................................................................................................706
	HYDROSHIFT TRANSMISSION PUMP.......................................................................................................................708
		Removal and Installation.......................................................................................................................708
	TANDEM AND FINAL DRIVE.............................................................................................................................709
		Removal........................................................................................................................................709
		Installation...................................................................................................................................711
	FINAL DRIVE........................................................................................................................................713
		Disassembly....................................................................................................................................713
		Assembly.......................................................................................................................................722
	BEVEL GEAR.........................................................................................................................................734
		Disassembly....................................................................................................................................734
		Assembly.......................................................................................................................................737
	BEVEL PINION.......................................................................................................................................740
		Disassembly....................................................................................................................................740
		Assembly.......................................................................................................................................741
	FRONT AXLE.........................................................................................................................................742
		Removal........................................................................................................................................742
		Installation...................................................................................................................................744
		Disassembly....................................................................................................................................746
		Assembly.......................................................................................................................................749
	STEERING VALVE.....................................................................................................................................755
		Disassembly....................................................................................................................................755
		Assembly.......................................................................................................................................758
	WHEEL BRAKE........................................................................................................................................766
		Removal........................................................................................................................................762
		Installation...................................................................................................................................764
		Disassembly....................................................................................................................................766
		Assembly.......................................................................................................................................768
	AIR TANK...........................................................................................................................................771
		Removal and Installation.......................................................................................................................771
	HYDRAULIC TANK.....................................................................................................................................772
		Removal and Installation.......................................................................................................................772
	HYDRAULIC PUMP.....................................................................................................................................773
		Removal........................................................................................................................................773
		Installation...................................................................................................................................774
		Disassembly....................................................................................................................................776
		Assembly.......................................................................................................................................790
	HYDRAULIC CONTROL VALVE............................................................................................................................813
		Removal........................................................................................................................................813
		Installation...................................................................................................................................814
	MAIN CONTROL VALVE.................................................................................................................................816
		Disassembly....................................................................................................................................816
		Assembly.......................................................................................................................................818
	CIRCLE ROTATION MOTOR..............................................................................................................................820
		Disassembly....................................................................................................................................820
		Assembly.......................................................................................................................................823
	DRAWBAR SHIFT CYLINDER, BLADE LIFT CYLINDER, LIFTER GUIDE..........................................................................................839
		Removal........................................................................................................................................839
		Installation...................................................................................................................................841
	ARTICULATE CYLINDER................................................................................................................................843
		Removal and Installation.......................................................................................................................843
	REAR MOUNT RIPPER CYLINDER.........................................................................................................................844
		Removal and Installation.......................................................................................................................844
	HYDRAULIC CYLINDER.................................................................................................................................845
		Serial No. 11001 - 12502.......................................................................................................................845
			Disassembly................................................................................................................................845
			Assembly...................................................................................................................................847
		Serial No. 12503 and up........................................................................................................................850
			Disassembly................................................................................................................................850
			Assembly...................................................................................................................................854
	CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR.......................................................................................................858
		Removal........................................................................................................................................858
		Installation...................................................................................................................................859
		Disassembly....................................................................................................................................862
		Assembly.......................................................................................................................................865
	BLADE..............................................................................................................................................877
		Removal and installation.......................................................................................................................877
	CIRCLE AND DRAWBAR.................................................................................................................................880
		Removal and Installation.......................................................................................................................880
		Disassembly....................................................................................................................................881
		Assembly.......................................................................................................................................883
	REAR MOUNT RIPPER..................................................................................................................................894
		Removal........................................................................................................................................894
		Installation...................................................................................................................................895
	METHOD FOR LIFTING UP ROPS CAB.....................................................................................................................896
	INSTALLATION OF ROPS...............................................................................................................................898
	ROPS cab...........................................................................................................................................899
		Removal........................................................................................................................................899
		Installation...................................................................................................................................903
	DISCONNECTION AND CONNECTION OF ARTICULATE SECTION.................................................................................................908
		Serial No. 11001 - 12502.......................................................................................................................908
			Disconnection..............................................................................................................................908
			Connection.................................................................................................................................911
		Serial No. 12503 and up........................................................................................................................913
			Disconnection..............................................................................................................................913
			Connection.................................................................................................................................916
40 MAINTENANCE STANDARD................................................................................................................................919
	HYDROSHIFT transmission and transfer...............................................................................................................920
	Transmission pump..................................................................................................................................926
	Transmission control valve.........................................................................................................................928
	Transmission solenoid valve........................................................................................................................934
	Final drive........................................................................................................................................937
	Differential lock-up pump..........................................................................................................................938
	Tandem drive.......................................................................................................................................939
	Front axle.........................................................................................................................................940
	Steering cylinder..................................................................................................................................944
	Disc brake.........................................................................................................................................945
	Parking brake......................................................................................................................................946
	Spring cylinder....................................................................................................................................947
	Hydraulic control valve............................................................................................................................948
	Hydraulic cylinder.................................................................................................................................952
	Hydraulic pump.....................................................................................................................................956
	Drawbar and lifter.................................................................................................................................958
	Blade..............................................................................................................................................962
	Circle rotation gear...............................................................................................................................964
	Ripper.............................................................................................................................................966
	Frame..............................................................................................................................................967

DESCRIPTION:

KOMATSU GD825A-2 SHOP MANUAL SEBM002311 – PDF DOWNLOAD

General precautions 
1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
5) Only qualified workers must carry out work and operation which require license or qualification.
6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places

S.S 26/12/24