Komatsu MOTOR GRADER GD610, GD620, GD660, GD670 Series Shop Manual PDF

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Komatsu MOTOR GRADER GD610, GD620, GD660, GD670 Series Shop Manual – PDF DOWNLOAD

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Komatsu MOTOR GRADER GD610, GD620, GD660, GD670 Series Shop Manual – PDF DOWNLOAD

Language : English
Pages :706
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu MOTOR GRADER GD610 GD620  GD660 GD670 Series Shop Manual – PDF DOWNLOAD

MACHINE MODEL
SERIAL No.
COMPONENT TYPE
MACHINE MODEL
SERIAL No.
COMPONENT TYPE
GD621A-1 10001 and up
GD622A-1 20001 and up
GD621R-1 10001 and up
GD623R-1 30001 and up
GD623A-1 30001 and up
GD611R-1
10001 and up
GD625A-1 50001 and up
GD613R-1 30001 and up
GD672A-1 20001 and up
GD615A-1 50001 and up
GD611A-1 10001 and up
GD613A-1 30001 and up
GD661A-1 10001 and up
GD625A-1C 60001 and up GD625A-1A 60001 and up GD625A-1B 65001 and up
Q See table of applicable components.
GD663A-1 30001 and up
GD663A-2 1001 and up

FOREWORD
GENERAL

• 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 the following
  chapters; these chapters are further divided into the each main group of components.

TABLE OF CONTENTS:

Komatsu MOTOR GRADER GD610 GD620  GD660 GD670 Series Shop Manual – PDF DOWNLOAD

MACHINE MODEL
SERIAL No.
COMPONENT TYPE
MACHINE MODEL
SERIAL No.
COMPONENT TYPE
GD621A-1 10001 and up
GD622A-1 20001 and up
GD621R-1 10001 and up
GD623R-1 30001 and up
GD623A-1 30001 and up
GD611R-1
10001 and up
GD625A-1 50001 and up
GD613R-1 30001 and up
GD672A-1 20001 and up
GD615A-1 50001 and up
GD611A-1 10001 and up
GD613A-1 30001 and up
GD661A-1 10001 and up
GD625A-1C 60001 and up GD625A-1A 60001 and up GD625A-1B 65001 and up
Q See table of applicable components.
GD663A-1 30001 and up
GD663A-2 1001 and up

COVER 1
CONTENTS 2
10 ENGINE 29
12 TESTING AND ADJUSTING 31
TABLE OF JUDGEMENT STANDARD VALUE 32
TESTING AND ADJUSTING TOOL LIST 37
ADJUSTING VALVE CLEARANCE 38
MEASURING COMPRESSION PRESSURE 40
TESTING AND ADJUSTING FUEL INJECTION TIMING 41
BLEEDING AIR FROM FUEL SYSTEM 43
ENGINE SPEED CONTROL 44
MEASURING EXHAUST GAS COLOR 48
TESTING AND ADJUSTING FAN BELT TENSION 50
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE 51
13 DISASSEMBLY AND ASSEMBLY 53
RADIATOR 54
REMOVAL 54
INSTALLATION 54
FUEL TANK(InclHYDRAULIC TANK)ASSEMBLY 58
REMOVAL 58
INSTALLATION 60
20 POWER TRAIN 65
21 STRUCTURE AND FUNCTION 67
GENERAL 68
POWER TRAIN 69
HYDROSHIFT TRANSMISSION PIPING 72
HYDROSHIFT TRANSMISSION CONTROL 73
POWER TRAIN HYDRAULIC CIRCUIT SCHEMATICS 74
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 75
JOINT 76
PTO(POWER TAKE OFF) 77
HYDROSHIFT TRANSMISSION AND TRANSFER 78
HYDROSHIFT TRANSMISSION PUMP 84
TRANSMISSION CONTROL VALVE 86
FINAL DRIVE 94
DIFFERENTIAL LOCK PIPING102
TANDEM DRIVE104
22 TESTING AND ADJUSTING107
TABLE OF JUDGEMENT STANDARD VALUE108
TOOL LIST FOR TESTING AND ADJUSTING111
INCHING PEDAL TRAVEL AND OPERATING FORCE112
CHECKING OIL PRESSURE115
MACHINE TYPE AND INCHING PRESSURE116
TRANSMISSION CONTROL LEVER TRAVEL AND OPERATING FORCE117
CHECKING DIFFERENTIAL LOCKING DEVICE OIL PRESSURE118
23 DISASSEMBLY AND ASSEMBLY119
TRANSMISSION PUMP120
REMOVAL120
INSTALLATION120
ENGINE(InclTRANSMISSION)ASSEMBLY122
REMOVAL122
INSTALLATION126
PTO146
DISASSEMBLY146
ASSEMBLY150
HYDROSHIFT TRANSMISSION156
DISASSEMBLY156
ASSEMBLY172
TRANSFER ASSEMBLY192
DISASSEMBLY192
ASSEMBLY196
TANDEM AND FINAL DRIVE202
REMOVAL202
INSTALLATION202
TANDEM,FINAL DRIVE ASSEMBLY204
REMOVAL204
INSTALLATION204
FINAL DRIVE208
DISASSEMBLY208
ASSEMBLY212
TANDEM,FINAL DRIVE ASSEMBLY218
DISASSEMBLY218
ASSEMBLY222
SIDE CASE ASSEMBLY230
DISASSEMBLY230
ASSEMBLY230
BEVEL GEAR ASSEMBLY232
DISASSEMBLY232
ASSEMBLY232
PINION ASSEMBLY242
DISASSEMBLY242
ASSEMBLY242
24 MAINTENANCE STANDARD245
PTO,HYDROSHIFT TRANSMISSION AND TRANSFER246
HYDROSHIFT TRANSMISSION CONTROL VALVE249
TRANSMISSION PUMP256
FINAL DRIVE258
TANDEM DRIVE260
40 STEERING SYSTEM261
41 STRUCTURE AND FUNCTION263
STEERING PIPING264
STEERING CIRCUIT DIAGRAM265
STEERING CONTROL VALVE266
FRONT AXLE271
STEERING CYLINDER277
WHEEL278
42 TESTING AND ADJUSTING283
TABLE OF JUDGEMENT STANDARD284
TOOL LIST FOR TESTING AND ADJUSTING287
CHECKING STEERING WHEEL288
CHECKING TIRE RUNOUT289
CHECKING TIRE INFLATION PRESSURE289
CHECKING TOE-IN290
43 DISASSEMBLY AND ASSEMBLY291
FRONT AXLE ASSEMBLY292
REMOVAL292
INSTALLATION292
FRONT AXLE ASSEMBLY294
DISASSEMBLY294
ASSEMBLY300
STEEREMBLY VALVE306
DISASSEMBLY306
ASSEMBLY310
DOUBLE RELIEF VALVE314
DISASSEMBLY314
ASSEMBLY314
44 MAINTENANCE STANDARD317
FRONT AXLE318
STEERING CYLINDER324
50 BRAKE SYSTEM325
51 STRUCTURE AND FUNCTION327
BRAKE PIPING328
BRAKE CIRCUIT DIAGRAM329
BOOST MASTER330
AIR BRAKE PIPING334
AIR BRAKE CIRCUIT SCHEMATICS336
AIR BRAKE CIRCUIT DIAGRAM337
BRAKE VALVE340
AIR COMPRESSOR344
AIR GOVERNOR345
CHECK VALVE346
AIR TANK347
SAFETY VALVE347
AUTOMATIC DRAIN VALVE(IF EQUIPPED)348
AIR DRIER(IF EQUIPPED)350
WHEEL BRAKE352
PARKING BRAKE355
52 TESTING AND ADJUSTING357
TABLE OF JUDGEMENT STANDARD VALUE358
TOOL LIST FOR TESTING AND ADJUSTING358
CHECKING BRAKE PEDAL359
AIR BLEEDING FROM BRAKE CIRCUIT363
CHECKING PARKING BRAKE LEVER364
CHECKING WEAR OF BRAKE DISC365
53 DISASSEMBLY AND ASSEMBLY367
BOOST MASTER368
DISASSEMBLY 368
ASSEMBLY370
WHEEL BRAKE372
REMOVAL372
INSTALLATION372
DISASSEMBLY374
ASSEMBLY374
WHEEL BRAKE378
REMOVAL378
INSTALLATION378
DISASSEMBLY382
ASSEMBLY386
54 MAINTENANCE STANDARD399
WHEEL BRAKE400
PARKING BRAKE402
BOOST MASTER403
60 HYDRAULIC SYSTEM405
61 STRUCTURE AND FUNCTION407
HYDRAULIC PIPING408
HYDUAULIC CONTROL418
BLADE ACCUMULATOR SYSTEM(IF EQUIPPED)420
HYDRAULIC CIRCUIT DIAGRAM423
OIL COOLING FLOW427
HYDRAULIC PUMP428
CIRCLE ROTATION MOTOR430
CONTROL VALVE436
FLOW DIVIDER442
PILOT CHECK VALVE443
FLOW CONTROL VALVE447
HYDRAULIC CYLINDER449
62 TESTING AND ADJUSTING453
TROUBLESHOOTING(CIRCLE ROTATION MOTOR)454
63 DISASSEMBLY AND ASSEMBLY455
HYDRAULIC PUMP(InclSTEERING PUMP)456
REMOVAL456
INSTALLATION456
BLADE LIFT CYLINDER458
REMOVAL458
INSTALLATION458
DRAWBAR SHIFT CYLINDER460
REMOVAL460
INSTALLATION460
BLADE SIDE SHAFT CYLINDER462
REMOVAL462
INSTALLATION462
ARTICULATE CYLINDER464
REMOVAL464
INSTALLATION464
SCARIFIER CYLINDER466
REMOVAL466
INSTALLATION466
POWER TILT CYLINDER468
REMOVAL468
INSTALLATION468
REAR MOUNT RIPPER CYLINDER468
REMOVAL468
INSTALLATION468
HYDRAULIC CYLINDER470
DISASSEMBLY470
ASSEMBLY474
CIRCLE ROTATION MOTOR482
DISASSEMBLY482
ASSEMBLY488
64 MAINTENANCE STANDARD503
HYDRAULIC PUMP504
CONTROL VALVE506
HYDRAULIC CYLINDER510
70 WORK EQUIPMENT515
71 STRUCTURE AND FUNCTION517
DRAWBAR AND LIFTER518
BLADE522
CIRCLE ROTATION GEAR526
FRAME528
SCARIFIER(IF EQUIPPED)529
REAR MOUNTING RIPPER(IF EQUIPPED)530
72 TESTING AND ADJUSTING531
TABLE OF JUDGEMENT STANDARD532
TOOL LIST FOR TESTING AND ADJUSTING536
CHECKING CONTROL LEVER537
CHECKING HYDRAULIC OIL TEMPERATURE538
CHECKING HYDRAULIC OIL PRESSURE538
HYDRAULIC DRIFT540
CHARGING BLADE ACCUMULATOR WITH GAS541
ADJUSTMENT OF CIRCLE GUIDE542
73 DISASSEMBLY AND ASSEMBLY543
BLADE ASSEMBLY544
REMOVAL544
INSTALLATION544
CIRCLE ROTATION GEAR546
REMOVAL546
INSTALLATION546
DISASSEMBLY548
ASSEMBLY550
REAR MOUNT RIPPER ASSEMBLY552
REMOVAL552
INSTALLATION552
CIRCLE ROTATION GEAR ASSEMBLY552
REMOVAL552
INSTALLATION552
DISASSEMBLY554
ASSEMBLY560
74 MAINTENANCE STANDARD567
DRAWBAR AND LIFTER568
BLADE570
CIRCLE ROTATION GEAR571
SCARIFIER(IF EQUIPPED)573
REAR MOUNT RIPPER(IF EQUIPPED)574
80 ELECTRIC AND ELECTRONIC SYSTEM577
81 STRUCTURE AND FUNCTION579
ELECTRICAL CIRCUIT DIAGRAM580
CIRCUIT DIAGRAM OF CAB585
ELECTRONIC VEHICLE MONITORING SYSTEM(EVMS)588
ADJUSTING SPEEDOMETER MODULE(IF EQUIPPED)596
82 TESTING AND ADJUSTING597
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE598
CIRCUIT DIAGRAM601
CONNECTOR POSITION FOR TROUBLESHOOTING604
POSITION OF CONNECTOR(D TYPE)610
POSITION OF CONNECTOR(P,Q TYPE)616
CONNECTOR TERMINAL NUMBERS627
PROCEDURE FOR TROUBLESHOOTING632
CHECKS BEFORE TROUBLESHOOTING633
METHOD OF USING TROUBLESHOOTING CHART634
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM(M1 TO M-18)(D TYPE)637
M-1 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL DISPLAY DOES NOT APPEAR638
a) NONE OF MONITOR PANEL WORKS638
b) PART OF MONITOR PANEL DOES NOT WORK638
M-2 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL DISPLAY DOES NOT GO OUT638
M-3 WHEN STARTING SWITCH IS TURNED ON,(DO NOT START ENGINE),CHECK BEFORE STARTING ITEMS FLASH OR PREHEATING ITEM LIGHTS UP639
a) COOLANT LEVEL639
b) ENGINE OIL LEVEL639
c) PREHEATER640
M-4 WHEN STARTING SWITCH IS TURNED ON,(ENGINE STARTED),CHECK BEFORE STARTING ITEMS FLASH641
a) ALTERNATOR SYSTEM641
b) ENGINE OIL PRESSURE CIRCUIT641
M-5 WHEN STARTING SWITCH IS TURNED ON,(DO NOT START ENGINE),CAUTION ITEMS FLASH642
M-6 WHEN STARTING SWITCH IS ON(ENGINE STARTED),CAUTION ITEMS FLASH643
a) ENGINE OIL PRESSURE643
b) COOLANT LEVEL643
c) COOLANT TEMPERATURE644
d) BATTERY CHARGE644
e) FINAL OIL TEMPERATURE645
f) AIR PRESSURE645
g) PARKING BRAKE646
M-7 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK647
M-8 NO DISPLAY IS GIVEN FOR FUEL LEVEL647
M-9 ENGINE COOLANT TEMPERATURE IS HIGH,BUT LOWEST LEVEL DISPLAYED648
M-10 ENGINE COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY648
M-11 TURN SIGNAL LAMPS,HIGH BEAM LIGHT UP ABNORMALLY,OR DO NOT LIGHT UP649
a) PILOT DISPLAY OF TURN SIGNAL LAMP(RIGHT)LIGHTS UP649
b) PILOT DISPLAY OF TURN SIGNAL LAMP(LEFT)LIGHTS UP649
c) PILOT DISPLAY OF TURN SIGNAL LAMP(RIGHT)DOES NOT LIGHT UP649
d) PILOT DISPLAY OF TURN SIGNAL LAMP(LEFT)DOES NOT LIGHT UP650
e) HIGHT BEAM PILOT LAMP DOES NOT LIGHT UP650
f) HIGH BEAM PILOT LAMP DOES NOT GO OUT650
M-12 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY651
M-13 WHEN ENGINE IN STARTED,SERVICE METER DOES NOT MOVE,WHEN ENGINE IN STOPPED,SERVICE METER MOVES652
a) SERVICE METER DOES NOT MOVE652
b) SERVICE METER DOES NOT STOP MOVING652
M-14 MONITOR PANEL LAMPS DO NOT LIGHT UP653
a) NO LAMPS ON PANEL LIGHT UP653
b) SOME LAMPS ON PANEL DO NOT LIGHT UP653
M-15 CENTRAL WARNING LAMP DOES NOT GO OUT654
a) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING LAMP LIGHTS UP INTERMITTENTLY654
b) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY654
M-16 CENTRAL WARNING BUZZER DOES NOT STOP655
a) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY655
b) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY655
M-17 EMERGENCY ITEM OR NON-EMERGENCY ITEMS IS FLASHING,BUT WARNING LAMP DOES NOT FLASH656
M-18 EMERGENCY ITEM IS FLASHING,BUT ALARM BUZZER DOES NOT SOUND657
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM(M1 TO M-22)(P,Q TYPE)665
M-1 MONITOR PANEL PILOT LAMPS DO NOT LIGHT UP FOT 3 SECONDS WHEN STARTING SWITCH IS TURNED ON666
a) NO LAMPS ON MONITOR PANEL(MONITOR MODULE)LIGHT UP666
b) NO LAMPS ON MONITOR PANEL(SPEEDOMETER MODULE)LIGHT UP666
c) SOME LAMPS ON MONITOR PANEL DO NOT LIGHT UP666
M-2 WHEN STARTING SWITCH IS TURNED ON,ALL MONITOR PANEL LAMPS LIGHT UP BUT DO NOT GO OUT666
M-3 WHEN STARTING SWITCH IS TURNED ON(WITH ENGINE STOPPED),CHECK ITEMS FLASH668
a) RADIATOR WATER LEVEL FLASHES668
b) ENGINE OIL LEVEL FLASHES669
M-4 PREHEATING IS NOT BEING CARRIED OUT,BUT PREHEATING DISPLAY FLASHES670
M-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,CHECK ITEMS FLASH671
a) ALTERNATOR SYSTEM671
b) ENGINE OIL PRESSURE SYSTEM672
M-6 WHEN STARTING SWITCH IS TURNED ON WITH ENGINE STOPPED CAUTION ITEMS FLASH674
M-7 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,CAUTION ITEMS FLASH678
a) ENGINE OIL PRESSURE FLASHES678
b) RADIATOR WATER LEVEL FLASHES680
c) ENGINE WATER TEMPERATURE FLASHES680
d) CHARGE FLASHES681
e) FINAL DRIVE OIL TEMPERATURE FLASHES682
f) AIR PRESSURE FLASHES683
g) PARKING BRAKE FLASHES684
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 SOUND685
M-9 THERE IS NO ABNORMALITY ON MONITOR DISPLAY,BUT ALARM BUZZER SOUNDS685
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 UP686
M-11 THERE IS NO ABNORMALITY ON MONITOR DISPLAY,BUT WARNING LAMP LIGHTS UP686
M-12 MONITOR PANEL LIGHTING DOES NOT LIGHT UP688
a) NO PANEL LIGHTING LIGHTS UP688
b) PART OF PANEL LIGHTING DOES NOT LIGHT UP688
M-13 SERVICE METER DOES NOT MOVE WHEN ENGINE IS STARTED;OR SERVICE METER MOVES WHEN ENGINE IS STOPPED(FOR MACHINES WITH SPEEDOMETER)689
a) SERVICE METER DOES NOT MOVE WHEN ENGINE IS STARTED689
b) SERVICE METER MOVES WHEN ENGINE IS STOPPED689
M-14 ENGINE WATER TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE691
M-15 ENGINE WATER TEMPERATURE GAUGE SHOWS NO DISPLAY691
M-16 FUEL GAUGE ALWAYS SHOWS FULL692
M-17 NO DISPLAY IS GIVEN FOR FUEL LEVEL GAUGE692
M-18 HIGH BEAM DOES NOT LIGHT UP694
M-19 HIGH BEAM STAYS LIGHTED UP694
M-20 TURN SIGNAL INDICATOR DOES NOT LIGHT UP696
M-21 TURN SIGNAL INDICATOR STAYS LIGHTED UP697
M-22 SPEED DISPLAY STAYS AT “0” AND DOES NOT MOVE699
90 OTHERS701
AIR CONDITIONER702

IMAGES PREVIEW OF THE MANUAL:

S.M 21/12/24