Complete service repair manual with Electrical Wiring Diagrams for Komatsu Motor Graders GD611A-1, GD611R-1, GD613A-1, GD615A-1, GD621A-1, GD622A-1, GD623A-1, GD661A-1, GD625A-1, GD625A-1A, GD625A-1B, GD625A-1C, GD663A-1, GDO663A-2, GD672A-1, GD621R-1, GD623R-1, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Motor Grader GD610 & GD620 & GD660 & GD670 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SEBMG6150109 - Motor Grader GD610 & GD620 & GD660 & GD670 Shop Manual.pdf
SEAMG6150101 - Motor Grader GD625A-1 Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 664 + 130 pages
File Format: PDF
Language: English

GD621A, 611A, 661A, 621R, 623R, 611R, 613R-1 mount the S6D105-1 engine;
GD622A, 623A, 625A, 672A, 613A, 663A, 625A4-1C, 625A-1A mount the 6D125-1 engine;
GD615A-1 mount the $6D110-1 engine.
For details of the engines, see the 105 Series Shop Manual, 110 Series Shop Manual and 6D125 Series Shop Manual.

MAIN SECTIONS
SEAMG6150101 - Motor Grader GD625A-1 Operation & Maintenance Manual..2
  COVER..2
  FOREWORD..3
  BREAKING IN YOUR NEW MACHINE..4
  CONTENTS..5
  SAFETY HINTS..6
  GENERAL LOCATIONS AND SPECIFICATIONS..13
  INSTRUMENTS AND CONTROLS..14
  OPERATING THE AIR CONDITIONER..37
  CHECK BEFORE STARTING..38
  OPERATING YOUR MACHINE..43
  COLD WEATHER OPERATION..51
  OPERATING OF WORK EQUIPMENT..56
  REVERSING AND REPLACEMENT OF CUTTING EDGE AND END BIT..67
  CHANGING TIRES..69
  DRIVING ALONG ROAD..71
  HANDLING OF BATTERY..72
  TRANSPORTATION..75
  PERIODIC MAINTENANCE..76
    PRECAUTIONS FOR MAINTENANCE..77
    MAINTENANCE TABLE..80
    OIL FILLER AND LEVEL GAUGE POSITIONS..84
    EVERY 50 HOURS SERVICE..85
    INITIAL 250 HOURS SERVICE..86
    EVERY 250 HOURS SERVICE..86
    EVERY 500 HOURS SERVICE..95
    EVERY 1000 HOURS SERVICE..101
    EVERY 2000 HOURS SERVICE..108
    EVERY 4000 HOURS SERVICE..111
    WHEN REQUIRED..112
  ADJUSTMENT..118
  TROUBLE SHOOTING GUIDE..120
  STORAGE..124
  SERVICE METER..126
  MACHINE AND ENGINE SERIAL NUMBERS..127
  FUEL,COOLANT AND LUBRICANTS..128
SEBMG6150109 - Motor Grader GD610 & GD620 & GD660 & GD670 Shop Manual..132
  COVER..132
  CONTENTS..133
  10 ENGINE..159
    12 TESTING AND ADJUSTING..160
      TABLE OF JUDGEMENT STANDARD VALUE..161
      TESTING AND ADJUSTING TOOL LIST..166
      ADJUSTING VALVE CLEARANCE..167
      MEASURING COMPRESSION PRESSURE..169
      TESTING AND ADJUSTING FUEL INJECTION TIMING..170
      BLEEDING AIR FROM FUEL SYSTEM..172
      ENGINE SPEED CONTROL..173
      MEASURING EXHAUST GAS COLOR..176
      TESTING AND ADJUSTING FAN BELT TENSION..178
      MEASURING ENGINE OIL PRESSURE AND TEMPERATURE..179
    13 DISASSEMBLY AND ASSEMBLY..180
      RADIATOR..181
        REMOVAL..181
        INSTALLATION..181
      FUEL TANK(Incl.HYDRAULIC TANK)ASSEMBLY..185
        REMOVAL..185
        INSTALLATION..187
  20 POWER TRAIN..191
    21 STRUCTURE AND FUNCTION..192
      GENERAL..193
      POWER TRAIN..194
      HYDROSHIFT TRANSMISSION PIPING..196
      HYDROSHIFT TRANSMISSION CONTROL..197
      POWER TRAIN HYDRAULIC CIRCUIT SCHEMATICS..198
      POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM..199
      JOINT..200
      PTO(POWER TAKE OFF)..201
      HYDROSHIFT TRANSMISSION AND TRANSFER..202
      HYDROSHIFT TRANSMISSION PUMP..208
      TRANSMISSION CONTROL VALVE..210
      FINAL DRIVE..218
      DIFFERENTIAL LOCK PIPING..225
      TANDEM DRIVE..227
    22 TESTING AND ADJUSTING..229
      TABLE OF JUDGEMENT STANDARD VALUE..230
      TOOL LIST FOR TESTING AND ADJUSTING..232
      INCHING PEDAL TRAVEL AND OPERATING FORCE..233
      CHECKING OIL PRESSURE..236
      MACHINE TYPE AND INCHING PRESSURE..237
      TRANSMISSION CONTROL LEVER TRAVEL AND OPERATING FORCE..238
      CHECKING DIFFERENTIAL LOCKING DEVICE OIL PRESSURE..239
    23 DISASSEMBLY AND ASSEMBLY..240
      TRANSMISSION PUMP..241
        REMOVAL..241
        INSTALLATION..241
      ENGINE(Incl.TRANSMISSION)ASSEMBLY..243
        REMOVAL..243
        INSTALLATION..247
      PTO..267
        DISASSEMBLY..267
        ASSEMBLY..271
      HYDROSHIFT TRANSMISSION..277
        DISASSEMBLY..277
        ASSEMBLY..293
      TRANSFER ASSEMBLY..313
        DISASSEMBLY..313
        ASSEMBLY..317
      TANDEM AND FINAL DRIVE..323
        REMOVAL..323
        INSTALLATION..323
      TANDEM,FINAL DRIVE ASSEMBLY..325
        REMOVAL..325
        INSTALLATION..325
      FINAL DRIVE..329
        DISASSEMBLY..329
        ASSEMBLY..333
      TANDEM,FINAL DRIVE ASSEMBLY..339
        DISASSEMBLY..339
        ASSEMBLY..343
      SIDE CASE ASSEMBLY..351
        DISASSEMBLY..351
        ASSEMBLY..351
      BEVEL GEAR ASSEMBLY..353
        DISASSEMBLY..353
        ASSEMBLY..353
      PINION ASSEMBLY..363
        DISASSEMBLY..363
        ASSEMBLY..363
    24 MAINTENANCE STANDARD..365
      PTO,HYDROSHIFT TRANSMISSION AND TRANSFER..366
      HYDROSHIFT TRANSMISSION CONTROL VALVE..368
      TRANSMISSION PUMP..374
      FINAL DRIVE..376
      TANDEM DRIVE..378
  40 STEERING SYSTEM..379
    41 STRUCTURE AND FUNCTION..380
      STEERING PIPING..381
      STEERING CIRCUIT DIAGRAM..382
      STEERING CONTROL VALVE..383
      FRONT AXLE..388
      STEERING CYLINDER..394
      WHEEL..395
    42 TESTING AND ADJUSTING..399
      TABLE OF JUDGEMENT STANDARD..400
      TOOL LIST FOR TESTING AND ADJUSTING..402
      CHECKING STEERING WHEEL..403
      CHECKING TIRE RUNOUT..404
      CHECKING TIRE INFLATION PRESSURE..404
      CHECKING TOE-IN..405
    43 DISASSEMBLY AND ASSEMBLY..406
      FRONT AXLE ASSEMBLY..407
        REMOVAL..407
        INSTALLATION..407
      FRONT AXLE ASSEMBLY..409
        DISASSEMBLY..409
        ASSEMBLY..415
      STEEREMBLY VALVE..421
        DISASSEMBLY..421
        ASSEMBLY..425
      DOUBLE RELIEF VALVE..429
        DISASSEMBLY..429
        ASSEMBLY..429
    44 MAINTENANCE STANDARD..431
      FRONT AXLE..432
      STEERING CYLINDER..438
  50 BRAKE SYSTEM..439
    51 STRUCTURE AND FUNCTION..440
      BRAKE PIPING..441
      BRAKE CIRCUIT DIAGRAM..442
      BOOST MASTER..443
      AIR BRAKE PIPING..446
      AIR BRAKE CIRCUIT SCHEMATICS..448
      AIR BRAKE CIRCUIT DIAGRAM..449
      BRAKE VALVE..452
      AIR COMPRESSOR..456
      AIR GOVERNOR..457
      CHECK VALVE..458
      AIR TANK..459
      SAFETY VALVE..459
      AUTOMATIC DRAIN VALVE(IF EQUIPPED)..460
      AIR DRIER(IF EQUIPPED)..462
      WHEEL BRAKE..464
      PARKING BRAKE..467
    52 TESTING AND ADJUSTING..468
      TABLE OF JUDGEMENT STANDARD VALUE..469
      TOOL LIST FOR TESTING AND ADJUSTING..469
      CHECKING BRAKE PEDAL..470
      AIR BLEEDING FROM BRAKE CIRCUIT..472
      CHECKING PARKING BRAKE LEVER..473
      CHECKING WEAR OF BRAKE DISC..474
    53 DISASSEMBLY AND ASSEMBLY..475
      BOOST MASTER..476
        DISASSEMBLY ..476
        ASSEMBLY..478
      WHEEL BRAKE..480
        REMOVAL..480
        INSTALLATION..480
        DISASSEMBLY..482
        ASSEMBLY..482
      WHEEL BRAKE..484
        REMOVAL..484
        INSTALLATION..484
        DISASSEMBLY..488
        ASSEMBLY..492
    54 MAINTENANCE STANDARD..504
      WHEEL BRAKE..505
      PARKING BRAKE..507
      BOOST MASTER..508
  60 HYDRAULIC SYSTEM..509
    61 STRUCTURE AND FUNCTION..510
      HYDRAULIC PIPING..511
      HYDUAULIC CONTROL..521
      BLADE ACCUMULATOR SYSTEM(IF EQUIPPED)..523
      HYDRAULIC CIRCUIT DIAGRAM..525
      OIL COOLING FLOW..529
      HYDRAULIC PUMP..530
      CIRCLE ROTATION MOTOR..532
      CONTROL VALVE..538
      FLOW DIVIDER..544
      PILOT CHECK VALVE..545
      FLOW CONTROL VALVE..549
      HYDRAULIC CYLINDER..550
    62 TESTING AND ADJUSTING..553
      TROUBLESHOOTING(CIRCLE ROTATION MOTOR)..554
    63 DISASSEMBLY AND ASSEMBLY..555
      HYDRAULIC PUMP(Incl.STEERING PUMP)..556
        REMOVAL..556
        INSTALLATION..556
      BLADE LIFT CYLINDER..558
        REMOVAL..558
        INSTALLATION..558
      DRAWBAR SHIFT CYLINDER..560
        REMOVAL..560
        INSTALLATION..560
      BLADE SIDE SHAFT CYLINDER..562
        REMOVAL..562
        INSTALLATION..562
      ARTICULATE CYLINDER..564
        REMOVAL..564
        INSTALLATION..564
      SCARIFIER CYLINDER..566
        REMOVAL..566
        INSTALLATION..566
      POWER TILT CYLINDER..568
        REMOVAL..568
        INSTALLATION..568
      REAR MOUNT RIPPER CYLINDER..568
        REMOVAL..568
        INSTALLATION..568
      HYDRAULIC CYLINDER..570
        DISASSEMBLY..570
        ASSEMBLY..574
      CIRCLE ROTATION MOTOR..582
        DISASSEMBLY..582
        ASSEMBLY..588
    64 MAINTENANCE STANDARD..602
      HYDRAULIC PUMP..603
      CONTROL VALVE..605
      HYDRAULIC CYLINDER..609
  70 WORK EQUIPMENT..613
    71 STRUCTURE AND FUNCTION..614
      DRAWBAR AND LIFTER..615
      BLADE..619
      CIRCLE ROTATION GEAR..623
      FRAME..625
      SCARIFIER(IF EQUIPPED)..626
      REAR MOUNTING RIPPER(IF EQUIPPED)..627
    72 TESTING AND ADJUSTING..628
      TABLE OF JUDGEMENT STANDARD..629
      TOOL LIST FOR TESTING AND ADJUSTING..632
      CHECKING CONTROL LEVER..633
      CHECKING HYDRAULIC OIL TEMPERATURE..634
      CHECKING HYDRAULIC OIL PRESSURE..634
      HYDRAULIC DRIFT..636
      CHARGING BLADE ACCUMULATOR WITH GAS..637
      ADJUSTMENT OF CIRCLE GUIDE..638
    73 DISASSEMBLY AND ASSEMBLY..639
      BLADE ASSEMBLY..640
        REMOVAL..640
        INSTALLATION..640
      CIRCLE ROTATION GEAR..642
        REMOVAL..642
        INSTALLATION..642
        DISASSEMBLY..644
        ASSEMBLY..646
      REAR MOUNT RIPPER ASSEMBLY..648
        REMOVAL..648
        INSTALLATION..648
      CIRCLE ROTATION GEAR ASSEMBLY..648
        REMOVAL..648
        INSTALLATION..648
        DISASSEMBLY..650
        ASSEMBLY..656
    74 MAINTENANCE STANDARD..662
      DRAWBAR AND LIFTER..663
      BLADE..665
      CIRCLE ROTATION GEAR..666
      SCARIFIER(IF EQUIPPED)..668
      REAR MOUNT RIPPER(IF EQUIPPED)..669
  80 ELECTRIC AND ELECTRONIC SYSTEM..672
    81 STRUCTURE AND FUNCTION..673
      ELECTRICAL CIRCUIT DIAGRAM..674
      CIRCUIT DIAGRAM OF CAB..679
      ELECTRONIC VEHICLE MONITORING SYSTEM(EVMS)..681
      ADJUSTING SPEEDOMETER MODULE(IF EQUIPPED)..689
    82 TESTING AND ADJUSTING..690
      TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE..691
      CIRCUIT DIAGRAM..694
      CONNECTOR POSITION FOR TROUBLESHOOTING..696
      POSITION OF CONNECTOR(D TYPE)..702
      POSITION OF CONNECTOR(P,Q TYPE)..708
      CONNECTOR TERMINAL NUMBERS..718
      PROCEDURE FOR TROUBLESHOOTING..723
      CHECKS BEFORE TROUBLESHOOTING..724
      METHOD OF USING TROUBLESHOOTING CHART..725
      TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM(M1 TO M-18)(D TYPE)..727
        M-1 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL DISPLAY DOES NOT APPEAR...728
          a) NONE OF MONITOR PANEL WORKS..728
          b) PART OF MONITOR PANEL DOES NOT WORK..728
        M-2 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL DISPLAY DOES NOT GO OUT..728
        M-3 WHEN STARTING SWITCH IS TURNED ON,(DO NOT START ENGINE),CHECK BEFORE STARTING ITEMS FLASH OR PREHEATING ITEM LIGHTS UP...729
          a) COOLANT LEVEL..729
          b) ENGINE OIL LEVEL..729
          c) PREHEATER..730
        M-4 WHEN STARTING SWITCH IS TURNED ON,(ENGINE STARTED),CHECK BEFORE STARTING ITEMS FLASH...731
          a) ALTERNATOR SYSTEM..731
          b) ENGINE OIL PRESSURE CIRCUIT..731
        M-5 WHEN STARTING SWITCH IS TURNED ON,(DO NOT START ENGINE),CAUTION ITEMS FLASH..732
        M-6 WHEN STARTING SWITCH IS ON(ENGINE STARTED),CAUTION ITEMS FLASH..733
          a) ENGINE OIL PRESSURE..733
          b) COOLANT LEVEL..733
          c) COOLANT TEMPERATURE..734
          d) BATTERY CHARGE..734
          e) FINAL OIL TEMPERATURE..735
          f) AIR PRESSURE..735
          g) PARKING BRAKE..736
        M-7 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK..737
        M-8 NO DISPLAY IS GIVEN FOR FUEL LEVEL..737
        M-9 ENGINE COOLANT TEMPERATURE IS HIGH,BUT LOWEST LEVEL DISPLAYED..738
        M-10 ENGINE COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY..738
        M-11 TURN SIGNAL LAMPS,HIGH BEAM LIGHT UP ABNORMALLY,OR DO NOT LIGHT UP..739
          a) PILOT DISPLAY OF TURN SIGNAL LAMP(RIGHT)LIGHTS UP..739
          b) PILOT DISPLAY OF TURN SIGNAL LAMP(LEFT)LIGHTS UP..739
          c) PILOT DISPLAY OF TURN SIGNAL LAMP(RIGHT)DOES NOT LIGHT UP..739
          d) PILOT DISPLAY OF TURN SIGNAL LAMP(LEFT)DOES NOT LIGHT UP..740
          e) HIGHT BEAM PILOT LAMP DOES NOT LIGHT UP..740
          f) HIGH BEAM PILOT LAMP DOES NOT GO OUT..740
        M-12 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY..741
        M-13 WHEN ENGINE IN STARTED,SERVICE METER DOES NOT MOVE,WHEN ENGINE IN STOPPED,SERVICE METER MOVES..742
          a) SERVICE METER DOES NOT MOVE..742
          b) SERVICE METER DOES NOT STOP MOVING..742
        M-14 MONITOR PANEL LAMPS DO NOT LIGHT UP..743
          a) NO LAMPS ON PANEL LIGHT UP..743
          b) SOME LAMPS ON PANEL DO NOT LIGHT UP..743
        M-15 CENTRAL WARNING LAMP DOES NOT GO OUT..744
          a) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING LAMP LIGHTS UP INTERMITTENTLY..744
          b) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY..744
        M-16 CENTRAL WARNING BUZZER DOES NOT STOP..745
          a) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY..745
          b) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY..745
        M-17 EMERGENCY ITEM OR NON-EMERGENCY ITEMS IS FLASHING,BUT WARNING LAMP DOES NOT FLASH..746
        M-18 EMERGENCY ITEM IS FLASHING,BUT ALARM BUZZER DOES NOT SOUND..747
      TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM(M1 TO M-22)(P,Q TYPE)..755
        M-1 MONITOR PANEL PILOT LAMPS DO NOT LIGHT UP FOT 3 SECONDS WHEN STARTING SWITCH IS TURNED ON..756
          a) NO LAMPS ON MONITOR PANEL(MONITOR MODULE)LIGHT UP..756
          b) NO LAMPS ON MONITOR PANEL(SPEEDOMETER MODULE)LIGHT UP..756
          c) SOME LAMPS ON MONITOR PANEL DO NOT LIGHT UP..756
        M-2 WHEN STARTING SWITCH IS TURNED ON,ALL MONITOR PANEL LAMPS LIGHT UP BUT DO NOT GO OUT..756
        M-3 WHEN STARTING SWITCH IS TURNED ON(WITH ENGINE STOPPED),CHECK ITEMS FLASH..758
          a) RADIATOR WATER LEVEL FLASHES..758
          b) ENGINE OIL LEVEL FLASHES..759
        M-4 PREHEATING IS NOT BEING CARRIED OUT,BUT PREHEATING DISPLAY FLASHES..760
        M-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,CHECK ITEMS FLASH..761
          a) ALTERNATOR SYSTEM..761
          b) ENGINE OIL PRESSURE SYSTEM..762
        M-6 WHEN STARTING SWITCH IS TURNED ON WITH ENGINE STOPPED CAUTION ITEMS FLASH..764
        M-7 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,CAUTION ITEMS FLASH..768
          a) ENGINE OIL PRESSURE FLASHES..768
          b) RADIATOR WATER LEVEL FLASHES..770
          c) ENGINE WATER TEMPERATURE FLASHES..770
          d) CHARGE FLASHES..771
          e) FINAL DRIVE OIL TEMPERATURE FLASHES..772
          f) AIR PRESSURE FLASHES..773
          g) PARKING BRAKE FLASHES..774
        M-8 FOR ONE SECOND AFTER STARTING SWITCH IS TURNED ON(ENGINE STOPPED),ALARM BUZZER DOES NOT SOUND.CAUTION ITEM LAMPS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND..775
        M-9 THERE IS NO ABNORMALITY ON MONITOR DISPLAY,BUT ALARM BUZZER SOUNDS..775
        M-10 FOR TWO SECONDS AFTER STARTING SWITCH IS TURNED ON(ENGINE STOPPED),WARNING LAMP DOES NOT LIGHT UP.CAUTION ITEM LAMPS ARE FLASHING BUT WARNING LAMP DOES NOT LIGHT UP...776
        M-11 THERE IS NO ABNORMALITY ON MONITOR DISPLAY,BUT WARNING LAMP LIGHTS UP..776
        M-12 MONITOR PANEL LIGHTING DOES NOT LIGHT UP..778
          a) NO PANEL LIGHTING LIGHTS UP..778
          b) PART OF PANEL LIGHTING DOES NOT LIGHT UP..778
        M-13 SERVICE METER DOES NOT MOVE WHEN ENGINE IS STARTED;OR SERVICE METER MOVES WHEN ENGINE IS STOPPED.(FOR MACHINES WITH SPEEDOMETER)..779
          a) SERVICE METER DOES NOT MOVE WHEN ENGINE IS STARTED..779
          b) SERVICE METER MOVES WHEN ENGINE IS STOPPED..779
        M-14 ENGINE WATER TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE..781
        M-15 ENGINE WATER TEMPERATURE GAUGE SHOWS NO DISPLAY..781
        M-16 FUEL GAUGE ALWAYS SHOWS FULL..782
        M-17 NO DISPLAY IS GIVEN FOR FUEL LEVEL GAUGE..782
        M-18 HIGH BEAM DOES NOT LIGHT UP..784
        M-19 HIGH BEAM STAYS LIGHTED UP..784
        M-20 TURN SIGNAL INDICATOR DOES NOT LIGHT UP..786
        M-21 TURN SIGNAL INDICATOR STAYS LIGHTED UP..787
        M-22 SPEED DISPLAY STAYS AT "0" AND DOES NOT MOVE..789
  90 OTHERS..791
    AIR CONDITIONER..792

Komatsu Motor Graders GD611A, GD611R, GD613A, GD615A, GD621A, GD622A, GD623A, GD661A, GD625A, GD663A, GD672A, GD621R, GD623R Repair Service Manuals