Komatsu Motor Grader GD510 GD520 Series Shop Manual SEBMG5250108 – PDF DOWNLOAD

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Komatsu Motor Grader GD510 GD520 Series Shop Manual SEBMG5250108 – PDF DOWNLOAD

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Komatsu Motor Grader GD510 GD520 Series Shop Manual SEBMG5250108 – PDF DOWNLOAD

Language : English
Pages :696
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Motor Grader GD510 GD520 Series Shop Manual SEBMG5250108 – PDF DOWNLOAD

MACHINE MODEL
SERIAL No.
GD521A-1
10001 and up
GD522A-1
20001 and up
GD523A-1
30001 and up
GD525A-1
50001 and up
GD511A-1
10001 and up
GD513A-1
30001 and up
GD521R-1
10001 and up
GD523R-1
30001 and up
GD511R-1
10001 and up
GD513R-1
30001 and up
GD510R-1
15001 and up
GD515A-1
50001 and up
GD525A-1C
60001 and up
GD525A-1A
50001 and up
GD525A-1B
55001 and up

FORDWORD

• This shop manual has been prepared as an aid to improve the quality of repairs by
  giving the serviceman an accurate understanding of the product and by showing him the correct
  way to perform repairs and make judgements. Make sure you understand the contents of this manual
  and use it to full effect at every opportunity.
• This shop manual mainly contains the necessary technical information for operations performed in
  a service workshop. For ease of understanding, the manual is divided into chapters for each
  main group of components; these chapters are further divided into the following sections.

TABLE OF CONTENTS:

Komatsu Motor Grader GD510 GD520 Series Shop Manual SEBMG5250108 – PDF DOWNLOAD

COVER 1
CONTENTS 2
10 ENGINE 27
12 TESTING AND ADJUSTING 29
TABLE OF JUDGEMENT STANDARD VALUE 30
TESTING AND ADJUSTING TOOL LIST 34
ADJUSTING VALVE CLEARANCE 35
MEASURING COMPRESSION PRESSURE 37
TESTING AND ADJUSTING FUEL INJECTION TIMING 39
BLEEDING AIR-FROM FUEL SYSTEM 42
ENGINE SPEED CONTROL 43
13 DISASSEMBLY AND ASSEMBLY 45
RADIATOR 46
REMOVAL 46
INSTALLATION 46
RADIATOR ASSEMBLY 48
REMOVAL 48
INSTALLATION 48
FUEL TANK(INCLHYDRAULIC TANK)ASSEMBLY 50
REMOVAL 50
INSTALLATION 52
20 POWER TRAIN 59
21 STRUCTURE AND FUNCTION 61
GENERAL 62
POWER TRAIN 63
HYDROSHIFT TRANSMISSION PIPING 66
HYDROSHIFT TRANSMISSION CONTROL 67
POWER TRAIN HYDRAULIC CIRCUIT SCHEMATICS 68
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 69
PTO 70
HYDROSHIFT TRANSMISSION 73
TRANSFER 79
TRANSMISSION CONTROL VALVE 82
POWER TRAIN 90
MAIN CLUTCH 91
TRANSMISSION 92
HYDROSHIFT TRANSMISSION PUMP 94
FINAL DRIVE 96
FINAL DRIVE,DIFFERENTIAL LOCK AND UNLOCK PIPING106
TANDEM DRIVE108
22 TESTING ADJUSTING111
TABLE OF JUDGEMENT STANDARD VALUE112
TOOL LIST FOR TESTING AND ADJUSTING113
INCHING PEDAL TRAVEL AND OPERATING FORCE114
MAIN CLUTCH116
TRANSMISSION CONTROL LEVER TRAVEL AND OPERATING FORCE119
CHECKING OIL PRESSURE120
MACHINE TYPE AND INCHING PRESSURE122
TRANSMISSION CONTROL LEVER TRAVEL AND OPERATING FORCE123
CLEARANCE DIFFERENTIAL LOCKING DEVICE OIL PRESSURE124
23 DISASSEMBLY AND ASSEMBLY125
ENGINE(INCLTRANSMISSION)ASSEMBLY126
REMOVAL126
INSTALLATION130
MAIN CLUTCH ASSEMBLY148
REMOVAL148
INSTALLATION148
MAIN CLUTCH CASE ASSEMBLY150
DISASSEMBLY150
ASSEMBLY150
MAIN CLUTCH ASSEMBLY152
DISASSEMBLY152
ASSEMBLY152
MAIN CLUTCH BOOSTER ASSEMBLY154
DISASSEMBLY154
ASSEMBLY154
TRANSMISSION ASSEMBLY156
REMOVAL156
INSTALLATION160
DISASSEMBLY164
ASSEMBLY170
SHIFTING FORK COVER ASSEMBLY176
DISASSEMBLY176
ASSEMBLY176
TRANSMISSION178
DISASSEMBLY178
ASSEMBLY191
LOW SPEED ROTATING CLUTCH207
DISASSEMBLY207
ASSEMBLY210
INTERMEDIATE SHAFT ROTATING CLUTCH213
DISASSEMBLY213
ASSEMBLY216
CAGE AND CARRIER219
DISASSEMBLY219
ASSEMBLY220
TRANSMISSION CASE221
DISASSEMBLY221
ASSEMBLY222
PLANETARY GEAR223
DISASSEMBLY223
ASSEMBLY223
TRANSMISSION PUMP224
REMOVAL224
INSTALLATION224
TANDEM AND FINAL DRIVE228
REMOVAL228
INSTALLATION228
TANDEM,FINAL DRIVE ASSEMBLY230
REMOVAL230
INSTALLATION230
FINAL DRIVE234
DISASSEMBLY234
ASSEMBLY238
TANDEM,FINAL DRIVE ASSEMBLY244
DISASSEMBLY244
ASSEMBLY248
SIDE CASE ASSEMBLY256
DISASSEMBLY256
ASSEMBLY256
BEVEL GEAR ASSEMBLY258
DISASSEMBLY258
ASSEMBLY258
PINION ASSEMBLY268
DISASSEMBLY268
ASSEMBLY268
24 MAINTENANCE STANDARD271
PTO272
MAIN CLUTCH276
TRANSMISSION279
HYDROSHIFT TRANSMISSION280
TRANSFER284
HYDROSHIFT TRANSMISSION CONTROL VALVE287
TRANSMISSION PUMP292
FINAL DRIVE294
TANDEM DRIVE299
40 STEERING SYSTEM301
41 STRUCTURE AND FUNCTION303
STEERING PIPING304
STEERING CIRCUIT DIAGRAM305
STEERING CONTROL VALVE306
FRONT AXLE311
STEERING CYLINDER317
WHEEL318
42 TESTING AND ADJUSTING323
TABLE OF JUDGEMENT STANDARD324
TOOL LIST FOR TESTING AND ADJUSTING325
CHECKING STEERING WHEEL326
CHECKING TIRE RUNOUT327
CHECKING TIRE INFLATION PRESSURE327
CHECKING TOE-IN328
43 DISASSEMBLY AND ASSEMBLY329
FRONT AXLE ASSEMBLY330
REMOVAL330
INSTALLATION330
FRONT AXLE ASSEMBLY332
DISASSEMBLY332
ASSEMBLY338
STEERING VALVE344
DISASSEMBLY344
ASSEMBLY348
DOUBLE RELIEF VALVE352
DISASSEMBLY352
ASSEMBLY352
44 MAINTENANCE STANDARD355
FRONT AXLE356
STEERING CYLINDER360
50 BRAKE SYSTEM361
51 STRUCTURE AND FUNCTION363
BRAKE PIPING364
BRAKE CIRCUIT DIAGRAM365
BOOST MASTER366
BRAKE AIR PIPING369
AIR BRAKE CIRCUIT SCHEMATICS370
AIR BRAKE CIRCUIT DIAGRAM371
BRAKE VALVE372
AIR COMPRESSOR376
AIR GOVERNOR377
CHECK VALVE378
AIR TANK379
SAFETY VALVE379
AUTOMATIC DRAIN VALVE380
AIR DRIER382
WHEEL BRAKE384
PARKING BRAKE387
52 TESTING AND ADJUSTING389
TABLE OF JUDGEMENT STANDARD VALUE390
TOOL LIST FOR TESTING AND ADJUSTING390
CHECKING BRAKE PEDAL391
AIR BLEEDING FROM BRAKE CIRCUIT395
CHECKING PARKING BRAKE LEVER396
CHECKING WEAR OF BRAKE DISC397
53 DISASSEMBLY AND ASSEMBLY399
WHEEL BRAKE400
REMOVAL400
INSTALLATION400
WHEEL BRAKE ASSEMBLY402
REMOVAL402
INSTALLATION402
DISASSEMBLY406
ASSEMBLY410
BOOST MASTER418
DISASSEMBLY418
ASSEMBLY420
PARKING BRAKE422
REMOVAL AND DISASSEMBLY422
INSTALLATION AND ASSEMBLY422
54 MAINTENANCE STANDARD425
WHEEL BRAKE426
PARKING BRAKE428
BOOST MASTER431
60 HYDRAULIC SYSTEM433
61 STRUCTURE AND FUNCTION435
HYDRAULIC CONTROL PIPING436
HYDRAULIC CONTROL LINKAGE448
BLADE ACCUMULATOR SYSTEM 450
HYDRAULIC CIRCUIT DIAGRAM453
FLOW DIVIDER457
HYDRAULIC PUMP458
CIRCLE ROTATION MOTOR460
WORK EQUIPMENT CONTROL VALVE466
PILOT CHECK VALVE474
HYDRAULIC CYLINDER478
63 DISASSEMBLY AND ASSEMBLY481
HYDRAULIC PUMP(INCLSTEERING PUMP)482
REMOVAL482
INSTALLATION482
BLADE LIFT CYLINDER484
REMOVAL484
INSTALLATION484
DRAWBAR SHIFT CYLINDER486
REMOVAL486
INSTALLATION486
ARTICULATE CYLINDER486
REMOVAL486
INSTALLATION486
BLADE SIDE SHIFT CYLINDER488
REMOVAL488
INSTALLATION488
BLADE SIDE SHIFT CYLINDER ASSEMBLY490
REMOVAL490
INSTALLATION490
SCARIFIER CYLINDER ASSEMBLY492
REMOVAL492
INSTALLATION492
LEANING CYLINDER492
REMOVAL492
INSTALLATION492
POWER TILT CYLINDER494
REMOVAL494
INSTALLATION494
REAR MOUNT RIPPER CYLINDER ASSEMBLY494
REMOVAL494
INSTALLTION494
HYDRAULIC CYLINDER ASSEMBLY496
DISASSEMBLY496
ASSEMBLY500
CIRCLE ROTATION MOTOR508
DISASSEMBLY508
ASSEMBLY514
64 MAINTENANCE STANDARD529
HYDRAULIC PUMP530
HYDRAULIC CONTROL VALVE532
HYDRAULIC CYLINDER536
70 WORK EQUIPMENT543
71 STRUCTURE AND FUNCTION545
DRAWBAR AND LIFTER546
BLADE550
CIRCLE ROTATION GEAR554
SCARIFIER555
REAR MOUNT RIPPER556
FRAME557
72 TESTING AND ADJUSTING559
TABLE OF JUDGEMENT STANDARD VALUE560
TOOL LIST FOR TESTING AND ADJUSTING565
CHECKING CONTROL LEVER566
CHECKING HYDRAULIC OIL TRMPERATURE567
CHECKING HYDRAULIC OIL PRESSURE567
HYDRAULIC DRIFT569
CHARGING BLADE ACCUMULATOR WITH GAS570
ADJUSTMENT OF CIRCLE GUIDE571
73 DISASSEMBLY AND ASSEMBLY573
BLADE ASSEMBLY574
REMOVAL574
INSTALLTION574
CIRCLE ROTATION GEAR576
REMOVAL576
INSTALLATOIN576
DISASSEMBLY578
ASSEMBLY580
REAR MOUNT RIPPER ASSEMBLY582
REMOVAL582
INSTALLATION582
74 MAINTENANCE STANDARD585
DRAWBAR AND LIFTER586
BLADE590
CIRCLE ROTATION GEAR591
SCARIFIER592
REAR MOUNT RIPPER593
80 ELECTRIC AND ELECTRONIC SYSTEM595
81 STRUCTURE AND FUNCTION597
ELECTRICAL CIRCUIT DIAGRAM598
CIRCUIT DIAGRAM OF CAB602
ELECTRONIC VEHICLE MONITORING SYSTEM(EVMS)604
ADJUSTING SPEEDOMETER MODULE OF MACHINE MONITOR609
82 TESTING AND ADJUSTING615
TABLE OF MONITOR REFERENCE VALUES616
ELECTRICAL WIRING DIAGRAM620
POSITION OF CONNECTOR622
CONNECTOR TERMINAL NUMBER630
PRECAUTION WHEN HANDLING CONNECTOR635
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART637
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (D TYPE) (M-1 TO M-18)639
M-1 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL DISPLAY DOES NOT APPEAR640
a) NONE OF MONITOR PANEL WORKS640
b) PART OF MONITOR PANEL DOES NOT WORK640
M-2 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL DISPLAY DOES NOT GO OUT640
a) MONITOR MODULE DOES NOT GO OUT 640
b) GAUGE MODULE DOES NOT GO OUT 640
c) SPEEDOMETER MODULE DOES NOT GO OUT 640
M-3 WHEN STARTING SWITCH IS TURNED ON,(DO NOT START ENGINE),CHECK BEFORE STARTING ITEMS FLASH OR PREHEATING ITEM LIGHTS UP641
a) COOLANT LEVEL641
b) ENGINE OIL LEVEL641
c) PREHEATER642
M-4 WHEN STARTING SWITCH IS TURNED ON,(ENGINE STARTED),CHECK BEFORE STARTING ITEMS FLASH643
a) ALTERNATOR SYSTEM643
b) ENGINE OIL PRESSURE CIRCUIT643
M-5 WHEN STARTING SWITCH IS TURNED ON,(DO NOT START ENGINE),CAUTION ITEMS FLASH644
M-6 WHEN STARTING SWITCH IS ON(ENGINE STARTED),CAUTION ITEMS FLASH645
a) ENGINE OIL PRESSURE645
b) COOLANT LEVEL645
c) COOLANT TEMPERATURE646
d) BATTERY CHARGE646
e) FINAL OIL TEMPERATURE647
f) AIR PRESSURE647
g) PARKING BRAKE648
M-7 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK649
M-8 NO DISPLAY IS GIVEN FOR FUEL LEVEL649
M-9 ENGINE COOLANT TEMPERATURE IS HIGH,BUT LOWEST LEVEL DISPLAYED650
M-10 ENGINE COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY 650
M-11 TURN SIGNAL LAMPS,HIGH BEAM LIGHT UP ABNORMALLY,OR DO NOT LIGHT UP651
a) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) LIGHT UP651
b) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) LIGHT UP651
c) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHTS UP651
d) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) DOES NOT LIGHTS UP652
e) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP652
f) HIGH BEAM PILOT LAMP DOES NOT GO OUT 652
M-12 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY653
M-13 WHEN ENGINE IS STARTED,SERVICE METER DOES NOT MOVEWHEN ENGINE IS STOOPED,SERVICE METER MOVES654
a) SERVICE METER DOES NOT MOVE654
b) SERVICE METER DOES NOT STOP MOVING654
M-14 MONITOR PANEL LAMPS DO NOT LIGHT UP655
a) NO LAMPS ON PANEL LIGHT UP655
b) SOME LAMPS ON PANEL DO NOT LIGHT UP655
M-15 CENTRAL WARNING LAMP DOES NOT GO OUT656
a) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING LAMP LIGHTS UP INTERMITTENTLY656
b) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY656
M-16 CENTRAL WARNING BUZZER DOES NOT STOP657
a) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY657
b) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY657
M-17 EMERGENCY ITEM OR NON-EMERGENCY ITEMS IS FLASHING,BUT WARNING LAMP DOES NOT FLASH658
M-18 EMERGENCY ITEM IS FLASHING,BUT ALARM BUZZER DOES NOT SOUND659
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM(M,N TYPE) (M-1 TO M-22)667
M-1 MONITOR PANEL PILOT LAMPS DO NOT LIGHT UP FOT 3 SECONDS WHEN STARTING SWITCH IS TURNED ON668
a) NO LAMPS ON MONITOR PANEL (MONITOR MODULE) LIGHT UP668
b) NO LAMPS ON MONITOR PANEL (SPEEDOMETER MODULE) LIGHT UP668
c) SOME LAMPS ON MONITOR PANEL DO NOT LIGHT UP668
M-2 WHEN STARTING SWITCH IS TURNED ON,ALL MONITOR PANEL LAMPS LIGHT UP BUT DO NOT GO OUT668
M-3 WHEN STARTING SWITCH IS TURNED ON (WITH ENGINE STOPPED),CHECK ITEMS FLASH670
a) RADIATOR WATER LEVEL FLASHES670
b) ENGINE OIL LEVEL FLASHES671
M-4 PREHEATING IS NOT BEING CARRIED OUT,BUT PREHEATING DISPLAY FLASHES672
M-5 WHEN STARTING SWTICH IS TURNED ON AND ENGINE IS STARTED,CHECK ITEMS FLASH673
a) ALTERNATOR SYSTEM673
b) ENGINE OIL PRESSURE SYSTEM674
M-6 WHEN STARTING SWITCH IS TURNED ON (WITH ENGINE STOPPED),CAUTION ITEMS FLASH675
M-7 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,CAUTION ITEMS FLASH677
a) ENGINE OIL PRESSURE FLASHES677
b) RADIATOR WATER LEVEL FLASHES678
c) ENGINE WATER TEMPERATURE FLASHES678
d) CHARGE FLASHES679
e) FINAL DRIVE OIL TEMPERATURE FLASHES680
f) AIR PRESSURE FLASHES681
g) PARKING BRAKE FLASHES682
M-8 FOR ONE SECOND AFTER STARTING SWITCH IS TURNED ON (ENGINE STOPPED),ALARM BUZZER DOES NOT SOUNDCAUTION ITEM LAMPS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND683
M-9 THERE IS NO ABNORMALITY ON MONITOR DISPLAY,BUT ALARM BUZZER SOUNDS683
M-10 FOR TWO SECONDS AFTER STARTING SWITCH IS TURNED ON (ENGINE STOPPED),WARNING LAMP DOES NOT LIGHT UPCAUTION ITEM LAMPS ARE FLASHING BUT WARNING LAMP DOES NOT LIGHT UP684
M-11 THERE IS NO ABNORMALITY ON MONITOR DISPLAY,BUT WARNING LAMP LIGHTS UP684
M-12 MONITOR PANEL LIGHTING DOES NOT LIGHT UP686
a) NO PANEL LIGHTIN LIGHTS UP686
b) PART OF PANEL LIGHTING DOES NOT LIGHT UP686
M-13 SERVICE METER DOES NOT MOVE WHEN ENGINE IS STARTED;OR SERVICE METER MOVES WHEN ENGINE IS STOPPED(FOR MACHINES WITH SPEEDOMETER)687
a) SERVICE METER DOES NOT MOVE WHEN ENGINE IS STARTED687
b) SERVICE METER MOVES WHEN ENGINE IS STOPPED687
M-14 ENGINE WATER TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE689
M-15 ENGINE WATER TEMPERATURE GAUGE SHOWS NO DISPLAY689
M-16 FUEL GAUGE ALWAYS SHOWS FULL690
M-17 NO DISPLAY IS GIVEN FOR FUEL LEVEL GAUGE690
M-18 HIGH BEAM DOES NOT LIGHT UP692
M-19 HIGH BEAM STAYS LIGHTED UP692
M-20 TURN SIGNAL INDICATOR DOES NOT LIGHT UP693
M-21 TURN SIGNAL INDICATOR STAYS LIGHTED UP693
M-22 SPEED DISPLAY STAYS AT “0” AND DOES NOT MOVE695

IMAGES PREVIEW OF THE MANUAL:

S.M 14/12/24