Komatsu GD825A-2 Motor Grader Shop Manual SEBM002309

Description

• Model List:
  • GD825A-2 Motor Grader

• 1. COVER
• 2. CONTENTS
• 3. Notice of revision
• 4. FORWORD
• 4.1. Safety notice
• 4.2. How to read the shop manual
• 4.3. Explanation of terms for maintenance standard
• 4.4. Handling of electric equipment and hydraulic component
• 4.5. Handling of connectors newly used for engines
• 4.6. How to read electric wire code
• 4.7. Precautions when carrying out operation
• 4.8. Method of disassembling and connecting pushpull type coupler
• 4.9. Standard tightening torque table
• 4.10. Conversion table
• 5. GENERAL
• 5.1. Specification dimension drawings
• 5.2. Specifications
• 5.3. Weight table
• 5.4. Fuel, coolant and lubricants
• 6. STRUCTURE AND FUNCTION
• 6.1. General
• 6.2. Power train diagram
• 6.3. Joint
• 6.4. HYDROSHIFT transmission and transfer piping
• 6.5. Hydraulic circuit for power train
• 6.6. Hydraulic circuit diagram for power train
• 6.7. PTO (Power Take Off)
• 6.8. HYDROSHIFT transmission and transfer
• 6.9. Transmission control valve
• 6.10. Transmission control
• 6.11. Inching control
• 6.12. Drive shaft
• 6.13. Final drive, differential lock and unlock piping
• 6.14. Final drive
• 6.15. Tandem drive
• 6.16. Steering piping
• 6.17. Steering circuit system
• 6.18. Steering circuit diagram
• 6.19. Steering valve
• 6.20. Double relief valve
• 6.21. Check valve
• 6.22. Emergency steering system
• 6.23. Front axle
• 6.24. Wheel
• 6.25. Disc brake
• 6.26. Parking brake
• 6.27. Brake air piping
• 6.28. Brake air circuit system
• 6.29. Brake air circuit diagram
• 6.30. Air drier
• 6.31. Air governor
• 6.32. Air tank
• 6.33. Safety valve
• 6.34. Automatic drain valve
• 6.35. Check valve
• 6.36. Brake valve
• 6.37. Parking brake system
• 6.38. Parking brake solenoid valve
• 6.39. Exhaust valve
• 6.40. Spring cylinder
• 6.41. Hydraulic control piping
• 6.42. Hydraulic circuit system
• 6.43. Hydraulic circuit diagram
• 6.44. Closed center load sensing system (CLSS)
• 6.45. Hydraulic pump
• 6.46. Priority flow divider valve
• 6.47. Surge pressure absorbing valve
• 6.48. Hydraulic control valve
• 6.49. Pressure compensating mechanism of hydraulic control valve
• 6.50. Blade lift speed adjustment mechanism
• 6.51. Pilot check valve
• 6.52. Pilot check valve (with safety valve)
• 6.53. Circle rotation motor
• 6.54. Blade accumulator system
• 6.55. Blade float system
• 6.56. Drawbar and lifter
• 6.57. Blade
• 6.58. Lifter bracket control piping
• 6.59. Circle rotation gear
• 6.60. Rear mount ripper
• 6.61. Hydraulic control linkage
• 6.62. Main Frame
• 6.63. Air conditioner
• 6.64. Electrical wiring diagram
• 6.65. Monitor panel, cluster gauge and pilot lamp
• 6.66. Electrical circuit diagram
• 6.67. Electrical vehicle monitoring system (EVMS)
• 6.68. Transmission control system
• 6.69. Sensors
• 6.70. Engine starting circuit
• 6.71. Engine stopping circuit
• 7. TESTING AND ADJUSTING
• 7.1. Standard value table for engine
• 7.2. Standard value table for chassis
• 7.3. Tool list for testing and adjusting
• 7.4. Testing and adjusting valve clearance
• 7.5. Measuring compression pressure
• 7.6. Testing and adjusting fuel injection timing
• 7.7. Measuring blowby pressure
• 7.8. Measuring engine oil pressure
• 7.9. Measuring exhaust gas color
• 7.10. Measuring exhaust gas temperature
• 7.11. Measuring intake air pressure (boost pressure)
• 7.12. Testing and adjusting belt tension
• 7.13. Procedure for adjusting the engine stop motor cable
• 7.14. Adjusting accelerator control
• 7.15. Inching pedal travel and operating force
• 7.16. HYDROSHIFT transmission
• 7.17. Checking differential locking device oil pressure
• 7.18. Steering system
• 7.19. Checking tire runout
• 7.20. Checking air pressure of tire
• 7.21. Checking toein
• 7.22. Installation of articulate center pins
• 7.23. Checking wear of brake disc
• 7.24. Checking parking brake
• 7.25. Checking work equipment control lever travel and operating force
• 7.26. Checking hydraulic oil temperature
• 7.27. Checking work equipment hydraulic pressure
• 7.28. Adjusting work equipment hydraulic pressure
• 7.29. Measuring hydraulic drift
• 7.30. Charging blade accumulator with gas
• 7.31. Adjusting blade lift speed
• 7.32. Bleeding air from hydraulic pump
• 7.33. Adjusting slip load of circle rotation clutch
• 7.34. Adjusting speedometer module of machine monitor
• 7.35. TROUBLESHOOTING
• 7.35.1. Points to remember when troubleshooting
• 7.35.2. Sequence of events in troubleshooting
• 7.35.3. Handling of electric equipment and hydraulic component
• 7.35.4. Checks before troubleshooting
• 7.35.5. Electrical circuit system diagram
• 7.35.6. Connector types and mounting locations
• 7.35.7. Electrical wiring diagram
• 7.35.8. Connection table for connector pin numbers
• 7.35.9. Tbranch box and Tbranch adapter table
• 7.35.10. Method of using troubleshooting charts
• 7.35.11. Details of troubleshooting and troubleshooting procedure
• 7.35.12. TROUBLESHOOTING OF ENGINE (S MODE)
• 7.35.13. TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (M MODE)
• 7.35.14. TROUBLESHOOTING CHART FOR ELECTRONIC (ENGINE, PARKING BRAKE, TRANSMISSION CONTROL) (E MODE)
• 7.35.15. TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (ET MODE)
• 7.35.16. TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM (H MODE)
• 8. DISASSEMBLY AND ASSEMBLY
• 8.1. HOW TO READ THIS MANUAL
• 8.2. COATING MATERIAL LIST
• 8.3. SPECIAL TOOL LIST
• 8.4. STARTING MOTOR
• 8.4.1. Removal and Installation
• 8.5. ALTERNATOR
• 8.5.1. Removal and Installation
• 8.6. NOZZLE HOLDER
• 8.6.1. Removal and Installation
• 8.7. FUEL INJECTION PUMP
• 8.7.1. Removal and Installation
• 8.8. WATER PUMP
• 8.8.1. Removal and Installation
• 8.9. ENGINE OIL COOLER CORE
• 8.9.1. Removal and Installation
• 8.10. TURBOCHARGER
• 8.10.1. Removal and Installation
• 8.11. AIR COMPRESSOR
• 8.11.1. Removal and Installation
• 8.12. CYLINDER HEAD
• 8.12.1. Removal
• 8.12.2. Installation
• 8.13. ENGINE (INCL. TRANSMISSION)
• 8.14. TRANSMISSION CONTROL VALVE
• 8.14.1. Disassembly
• 8.14.2. Assembly
• 8.15. HYDROSHIFT TRANSMISSION PUMP
• 8.15.1. Removal and Installation
• 8.16. TANDEM AND FINAL DRIVE
• 8.16.1. Removal and Installation
• 8.17. HYDRAULIC TANK
• 8.17.1. Removal and Installation
• 8.18. HYDRAULIC CONTROL VALVE
• 8.18.1. Removal
• 8.18.2. Installation
• 8.19. MAIN CONTROL VALVE
• 8.19.1. Disassembly
• 8.19.2. Assembly
• 8.20. CIRCLE ROTATION MOTOR
• 8.20.1. Disassembly
• 8.20.2. Assembly
• 8.21. DRAWBAR SHIFT CYLINDER, BLADE LIFT CYLINDER, LIFTER GUIDE
• 8.21.1. Removal
• 8.21.2. Installation
• 8.22. ARTICULATE CYLINDER
• 8.22.1. Removal and Installation
• 8.23. REAR MOUNT RIPPER CYLINDER
• 8.23.1. Removal and Installation
• 8.24. HYDRAULIC CYLINDER
• 8.24.1. Serial No. 11001 12502
• 8.24.2. Serial No. 12503 and up
• 8.25. CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR
• 8.25.1. Removal and installation
• 8.26. CIRCLE AND DRAWBAR
• 8.26.1. Removal and Installation
• 8.26.2. Disassembly
• 8.26.3. Assembly
• 8.27. REAR MOUNT RIPPER
• 8.27.1. Removal
• 8.27.2. Installation
• 8.28. METHOD FOR LIFTING UP ROPS CAB
• 8.29. INSTALLATION OF ROPS
• 8.30. ROPS cab
• 8.30.1. Removal
• 8.30.2. Installation
• 8.31. DISCONNECTION AND CONNECTION OF ARTICULATE SECTION
• 8.31.1. Serial No. 11001 12502
• 8.31.2. Serial No. 12503 and up
• 9. MAINTENANCE STANDARD
• 9.1. HYDROSHIFT transmission and transfer
• 9.2. Transmission pump
• 9.3. Transmission control valve
• 9.4. Transmission solenoid valve
• 9.5. Final drive
• 9.6. Differential lockup pump
• 9.7. Tandem drive
• 9.8. Front axle
• 9.9. Steering cylinder
• 9.10. Disc brake
• 9.11. Parking brake
• 9.12. Spring cylinder
• 9.13. Hydraulic control valve
• 9.14. Hydraulic cylinder
• 9.15. Hydraulic pump
• 9.16. Drawbar and lifter
• 9.17. Blade
• 9.18. Circle rotation gear
• 9.19. Ripper
• 9.20. Frame