Komatsu GD825A-2 Motor Grader Service Repair Shop Manual (11001 and up) - SEBM002307

This complete service repair workshop manual PDF download for the GD825A-2 Komatsu Motor Grader (SN: 11001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Machine Model : GD825A-2
Serial Numbers : 11001 and up
Engine : S6D140E-2


TABLE OF CONTENTS :

- GENERAL
- STRUCTURE AND FUNCTION
- TESTING AND ADJUSTING
- DISASSEMBLY AND ASSEMBLY
- MAINTENANCE STANDARD


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM002307
Total Pages : 937

GD825A-2 mount the S6D140-1 and S6D140E-2 engine.
For details of the engine, see the 6D140-1 and 6D140-2 Series Engine Shop Manual.


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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01 GENERAL
SPECIFICATION DIMENSION DRAWINGS
SPECIFICATIONS
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANTS

10 STRUCTURE AND FUNCTION
GENERAL
POWER TRAIN DIAGRAM
JOINT
HYDROSHIFT TRANSMISSION AND TRANSFER PIPING
HYDRAULIC CIRCUIT FOR POWER TRAIN
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
PTO (POWER TAKE OFF)
HYDROSHIFT TRANSMISSION AND TRANSFER
TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL
INCHING CONTROL
DRIVE SHAFT
FINAL DRIVE, DIFFERENTIAL LOCK AND UNLOCK PIPING
FINAL DRIVE
TANDEM DRIVE
STEERING PIPING
STEERING CIRCUIT SYSTEM
STEERING CIRCUIT DIAGRAM
STEERING VALVE
DOUBLE RELIEF VALVE
CHECK VALVE
EMERGENCY STEERING SYSTEM
FRONT AXLE
WHEEL
DISC BRAKE
PARKING BRAKE
BRAKE AIR PIPING
BRAKE AIR CIRCUIT SYSTEM
BRAKE AIR CIRCUIT DIAGRAM
AIR DRIER
AIR GOVERNOR
AIR TANK
SAFETY VALVE
AUTOMATIC DRAIN VALVE
CHECK VALVE
BRAKE VALVE
PARKING BRAKE SYSTEM
PARKING BRAKE SOLENOID VALVE
EXHAUST VALVE
SPRING CYLINDER
HYDRAULIC CONTROL PIPING
HYDRAULIC CIRCUIT SYSTEM
HYDRAULIC CIRCUIT DIAGRAM
CLOSED CENTER LOAD SENSING SYSTEM (CLSS)
HYDRAULIC PUMP
PRIORITY FLOW DIVIDER VALVE
SURGE PRESSURE ABSORBING VALVE
HYDRAULIC CONTROL VALVE
PRESSURE COMPENSATING MECHANISM OF HYDRAULIC CONTROL VALVE
BLADE LIFT SPEED ADJUSTMENT MECHANISM
PILOT CHECK VALVE
PILOT CHECK VALVE (WITH SAFETY VALVE)
CIRCLE ROTATION MOTOR
BLADE ACCUMULATOR SYSTEM
BLADE FLOAT SYSTEM
DRAWBAR AND LIFTER
BLADE
LIFTER BRACKET CONTROL PIPING
CIRCLE ROTATION GEAR
REAR MOUNT RIPPER
HYDRAULIC CONTROL LINKAGE
MAIN FRAME
AIR CONDITIONER
ELECTRICAL WIRING DIAGRAM
MONITOR PANEL, CLUSTER GAUGE AND PILOT LAMP
ELECTRICAL CIRCUIT DIAGRAM
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)
TRANSMISSION CONTROL SYSTEM
SENSORS
ENGINE STARTING CIRCUIT
ENGINE STOPPING CIRCUIT

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
TOOL LIST FOR TESTING AND ADJUSTING
TESTING AND ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
MEASURING BLOW-BY PRESSURE
MEASURING ENGINE OIL PRESSURE
MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS TEMPERATURE
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
TESTING AND ADJUSTING BELT TENSION
PROCEDURE FOR ADJUSTING THE ENGINE STOP MOTOR CABLE
ADJUSTING ACCELERATOR CONTROL
INCHING PEDAL TRAVEL AND OPERATING FORCE
MEASURING TRANSMISSION OIL PRESSURE
CHECKING DIFFERENTIAL LOCKING DEVICE OIL PRESSURE
STEERING SYSTEM
CHECKING TIRE RUNOUT
CHECKING AIR PRESSURE OF TIRE
CHECKING TOE-IN
INSTALLATION OF ARTICULATE CENTER PINS
CHECKING WEAR OF BRAKE DISC
CHECKING PARKING BRAKE
CHECKING WORK EQUIPMENT CONTROL LEVER TRAVEL AND OPERATING FORCE
CHECKING HYDRAULIC OIL TEMPERATURE
CHECKING WORK EQUIPMENT HYDRAULIC PRESSURE
ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
MEASURING HYDRAULIC DRIFT
CHARGING BLADE ACCUMULATOR WITH GAS
ADJUSTING BLADE LIFT SPEED
BLEEDING AIR FROM HYDRAULIC PUMP
ADJUSTING SLIP LOAD OF CIRCLE ROTATION CLUTCH
ADJUSTING CLEARANCE OF F AND R SWITCHES
ADJUSTING SHIFT POTENTIOMETER
ADJUSTING INCHING POTENTIOMETER
ADJUSTING SPEEDOMETER MODULE OF MACHINE MONITOR
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
CHECKS BEFORE TROUBLESHOOTING
ELECTRICAL CIRCUIT SYSTEM DIAGRAM
CONNECTOR TYPES AND MOUNTING LOCATIONS
ELECTRICAL WIRING DIAGRAM
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T- BRANCH BOX AND T- BRANCH ADAPTER TABLE
METHOD OF USING TROUBLESHOOTING CHARTS
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
TROUBLESHOOTING OF ENGINE (S MODE)
S-1 Starting performance is poor (Starting always takes time)
S-2 Engine does not start
1) Engine does not turn
2) Engine turns but no exhaust gas comes out (Fuel is not being injected)
3) Exhaust gas comes out but engine does not start (Fuel is being injected)
S-3 Engine does not pick up smoothly (Follow-up is poor)
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly (hunting)
S-6 Engine lacks output (no power)
S-7 Exhaust gas is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust gas is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in cooling water, or water spurts back, or water level goes down
S-12 Oil pressure lamp lights up (drop in oil pressure)
S-13 Oil level rises
S-14 Water temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (M MODE)
M-1 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR
M-2 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT GO OUT
M-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH
M-4 PREHEATING OPERATION IS NOT BEING USED BUT PREHEATING DISPLAY LIGHTS UP
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)
M-6 BUZZER DOES NOT SOUND FOR 1 MINUTE WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED)
M-7 THERE IS NO ABNORMALITY DISPLAYED ON MONITOR, BUT BUZZER SOUNDS
M-8 MONITOR PANEL LIGHTING DOES NOT LIGHT UP
M-9 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED; SERVICE METER CONTINUES TO MOVE WHEN ENGINE IS STOPPED
M-10 COOLANT TEMPERATURE GAUGE DISPLAYS ABNORMALLY LOW TEMPERATURE
M-11 COOLANT TEMPERATURE GAUGE DOES NOT GIVE A DISPLAY
M-12 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL
M-13 FUEL GAUGE DOES NOT GIVE ANY DISPLAY
M-14 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY
M-15 TURN SIGNAL INDICATOR PILOT LAMP DOES NOT LIGHT UP
M-16 HIGH BEAM PILOT LAMP DOES NOT LIGHT UP
TROUBLESHOOTING CHART FOR ELECTRONIC (ENGINE, PARKING BRAKE, TRANSMISSION CONTROL) (E MODE)
E-1 Engine does not start (starting motor works).
E-2 Starting motor does not turn.
E-3 Parking brake does not work
E-4 Parking brake cannot be released
E-5 Speed range does not change when transmission lever is switched between F1and F8 or between R1and R8
E-6 Transmission does not shift to 1st (F and R).
E-7 Transmission does not shift to 2nd (F and R).
E-8 Transmission does not shift to 3rd (F and R).
E-9 Transmission does not shift to 4th (F and R).
E-10 Transmission does not shift to 5th (F and R).
E-11 Transmission does not shift to 6th (F and R).
E-12 Transmission does not shift to 7th (F and R).
E-13 Transmission does not shift to 8th (F and R).
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (ET MODE)
LED DISPLAY FOR TRANSMISSION CONTROLLER
ET-1 [A1] (Short circuit in 1st solenoid) is displayed
ET-2 [A2] (Short circuit in 2nd solenoid) is displayed
ET-3 [A3} (Short circuit in 3rd solenoid) is displayed
ET-4 [A4] (Short circuit in 4th solenoid) is displayed
ET-5 [A5] (Short circuit in High/Low solenoid) is displayed
ET-6 [A7] (Short circuit in FORWARD/REVERSE solenoid) is displayed
ET-7 [b1] (Disconnection in 1st solenoid) is displayed
ET-8 [b2] (Disconnection in 2nd solenoid) is displayed
ET-9 [b3] (Disconnection in 3rd solenoid) is displayed
ET-10 [b4] (Disconnection in 4th solenoid) is displayed
ET-11 [b5] (Disconnection in Low solenoid) is displayed
ET-12 [b6] (Disconnection in High solenoid) is displayed
ET-13 [b7] (Disconnection in FORWARD solenoid) is displayed
ET-14 [b8] (Disconnection in REVERSE solenoid) is displayed
ET-15 [c1] (Disconnection in inching potentiometer) is displayed
ET-16 [c2] (Failure in shift potentiometer 1) is displayed
ET-17 (Failure in shift potentiometer 2) is displayed
ET-18 [d1] (Failure in F and R switches) is displayed
ET-19 [d4] (Disconnection in engine speed sensor) is displayed
ET-20 [d5] (Disconnection in speed sensor) is displayed
ET-21 [d6] (Failure in transmission oil temperature sensor) is displayed
ET-22 [E0] (Drop in power source voltage) is displayed
ET-23 [E1] (Short circuit in parking brake) is displayed
ET-24 [E2] or [F2] (Short circuit, disconnection in parking brake lamp) is displayed
ET-25 [E3] or [F3] (Shot-t circuit, disconnection in differential lock relay) is displayed
ET-26 [E4] or [F4] (Short circuit, disconnection in backup buzzer relay) is displayed
ET-27 [E5} or {F5] (Short circuit, disconnection in caution lamp) is displayed
ET-28 [E6] or [F6] (Short circuit, disconnection in alarm buzzer relay) is displayed
ET-29 [E7] or [F7] (Short circuit, disconnection in starting motor relay) is displayed
ET-30 [F1] (Disconnection in parking brake) is displayed
TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM (H MODE)
STANDARDS FOR MEASURING HYDRAULIC PRESSURE, AND JUDGEMENT VALUES
TABLE OF FAILURE MODES AND CAUSES
HYDRAULIC PRESSURE MEASUREMENT AND FILTER MOUNTING POSITIONS
H-1 Abnormal noise is made (from around pump).
H-2 Relief sound is heard (when not operating).
H-3 Hydraulic oil overheats (when not operating).
H-4 Work equipment does not move when control lever is operated (steering at neutral).
H-5 Work equipment is slow, lacks power.
H-6 There is excessive hydraulic drift of work equipment.
H-7 Steering wheel does not turn (work equipment at neutral).
H-8 Turning speed is slow, lacks power (work equipment at neutral).
H-9 Feeling when operating steering wheel is strange.

30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOL LIST
STARTING MOTOR
REMOVAL AND INSTALLATION
ALTERNATOR
REMOVAL AND INSTALLATION
NOZZLE HOLDER
REMOVAL AND INSTALLATION
FUEL INJECTION PUMP
REMOVAL AND INSTALLATION
WATER PUMP
REMOVAL
INSTALLATION
ENGINE OIL COOLER CORE
REMOVAL AND INSTALLATION
TURBOCHARGER
REMOVAL AND INSTALLATION
AIR COMPRESSOR
REMOVAL AND INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
ENGINE (INCL. TRANSMISSION)
REMOVAL
INSTALLATION
RADIATOR
REMOVAL
INSTALLATION
FUEL TANK
REMOVAL
INSTALLATION
PTO
DISASSEMBLY
ASSEMBLY
TRANSMISSION
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRANSFER
DISASSEMBLY
ASSEMBLY
TRANSMISSION CONTROL VALVE
DISASSEMBLY
ASSEMBLY
HYDROSHIFT TRANSMISSION PUMP
REMOVAL AND INSTALLATION
TANDEM AND FINAL DRIVE
REMOVAL
INSTALLATION
FINAL DRIVE
DISASSEMBLY
ASSEMBLY
BEVEL GEAR
DISASSEMBLY
ASSEMBLY
BEVEL PINION
DISASSEMBLY
ASSEMBLY
FRONT AXLE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
STEERING VALVE
DISASSEMBLY
ASSEMBLY
WHEEL BRAKE
DISASSEMBLY
ASSEMBLY
AIR TANK
REMOVAL AND INSTALLATION
HYDRAULIC TANK
REMOVAL AND INSTALLATION
HYDRAULIC PUMP
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
HYDRAULIC CONTROL VALVE
REMOVAL
INSTALLATION
MAIN CONTROL VALVE
DISASSEMBLY
ASSEMBLY
CIRCLE ROTATION MOTOR
DISASSEMBLY
ASSEMBLY
DRAWBAR SHIFT CYLINDER, BLADE LIFT CYLINDER, LIFTER GUIDE
REMOVAL
INSTALLATION
ARTICULATE CYLINDER
REMOVAL AND INSTALLATION
REAR MOUNT RIPPER CYLINDER
REMOVAL AND INSTALLATION
HYDRAULIC CYLINDER Serial No.: 11001 - 12502
DISASSEMBLY
ASSEMBLY
HYDRAULIC CYLINDER Serial No.: 12503 and up
DISASSEMBLY
ASSEMBLY
CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
BLADE
REMOVAL AND INSTALLATION
CIRCLE AND DRAWBAR
REMOVAL AND INSTALLAITON
DISASSEMBLY
ASSEMBLY
REAR MOUNT RIPPER
REMOVAL
INSTALLATION
METHOD LIFTING UP ROPS CAB
INSTALLATION OF ROPS
ROPS CAB
REMOVAL
INSTALLATION
DISCONNECTION AND CONNECTION OF ARTICULATE SECTION Serial No.: 11001 - 12502
Disconnection
Connection
DISCONNECTION AND CONNECTION OF ARTICULATE SECTION Serial No.: 12503 and up
Disconnection
Connection

40 MAINTENANCE STANDARD
HYDROSHIFT TRANSMISSION AND TRANSFER
TRANSMISSION PUMP
TRANSMISSION CONTROL VALVE
TRANSMISSION SOLENOID VALVE
FINAL DRIVE
DIFFERENTIAL LOCK-UP PUMP
TANDEM DRIVE
FRONT AXLE
STEERING CYLINDER
DISC BRAKE
PARKING BRAKE
SPRING CYLINDER
HYDRAULIC CONTROL VALVE
HYDRAULIC CYLINDER
HYDRAULIC PUMP
DRAWBAR AND LIFTER
BLADE
CIRCLE ROTATION GEAR
RIPPER
FRAME

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