Komatsu Motor Grader GD663A-2 service & repair manual

Description Komatsu Motor Grader GD663A-2 service & repair manual

Komatsu Motor Grader GD663A-2 pdf workshop service repair manual

Serial numbers:
1001 and up

Technical documentation, specifications, troubleshooting, maintenance, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
SAFETY
SAFETY NOTICE

FOREWORD
GENERAL
HOW TO READ THE SHOP MANUAL
HOISTING INSTRUCTIONS
COATING MATERIALS
STANDARD TIGHTENING TORQUE
ELECTRIC WIRE CODE
CONVERSION TABLE

SPECIFICATION
WEIGHT TABLE
TABLE OF OIL AND COOLANT QUANTITY

ENGINE
TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE
TESTING AND ADJUSTING TOOL LIST
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
BLEEDING AIR FROM FUEL SYSTEM
ENGINE SPEED CONTROL
MEASURING EXHAUST GAS COLOR
TESTING AND ADJUSTING FAN BELT TENSION
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE

DISASSEMBLY AND ASSEMBLY
RADIATOR
FUEL TANK (Incl. HYDRAULIC TANK) ASSEMBLY

POWER TRAIN
STRUCTURE AND FUNCTION
GENERAL
POWER TRAIN
HYDROSHIFT TRANSMISSION PIPING
HYDROSHIFT TRANSMISSION CONTROL
POWER TRAIN HYDRAULIC CIRCUIT SCHEMATICS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
JOINT
PTO (POWER TAKE OFF)
HYDROSHIFT TRANSMISSION AND TRANSFER
HYDROSHIFT TRANSMISSION PUMP
TRANSMISSION CONTROL VALVE
FINAL DRIVE
DIFFERENTIAL LOCK PIPING
TANDEM DRIVE

TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE
TOOL LIST FOR TESTING AND ADJUSTING
INCHING PEDAL TRAVEL AND OPERATING FORCE
CHECKING OIL PRESSURE
MACHINE TYPE AND INCHING PRESSURE
TRANSMISSION CONTROL LEVER TRAVEL AND OPERATING FORCE
CHECKING DIFFERENTIAL LOCKING DEVICE OIL PRESSURE

DISASSEMBLY AND ASSEMBLY
TRANSMISSION PUMP
TRANSMISSION PUMP (Incl. FINAL DRIVE PUMP) ASSEMBLY
ENGINE (Incl. TRANSMISSION) ASSEMBLY
PTO
HYDROSHIFT TRANSMISSION
TRANSFER ASSEMBLY
TANDEM, FINAL DRIVE ASSEMBLY
FINAL DRIVE
TANDEM, FINAL DRIVE ASSEMBLY
SIDE CASE ASSEMBLY
BEVEL GEAR ASSEMBLY
PINION ASSEMBLY

MAINTENANCE STANDARD
PTO, HYDROSHIFT TRANSMISSION AND TRANSFER
HYDROSHIFT TRANSMISSION CONTROL VALVE
TRANSMISSION PUMP
FINAL DRIVE
TANDEM DRIVE

STEERING SYSTEM
STRUCTURE AND FUNCTION
STEERING PIPING
STEERING CIRCUIT DIAGRAM
STEERING CONTROL VALVE (Orbitrol type)
FRONT AXLE
STEERING CYLINDER
WHEEL

TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD
TOOL LIST FOR TESTING AND ADJUSTING
CHECKING STEERING WHEEL
CHECKING TIRE RUNOUT
CHECKING TIRE INFLATION PRESSURE
CHECKING TOE-IN

DISASSEMBLY AND ASSEMBLY
FRONT AXLE ASSEMBLY
STEEREMBLY VALVE
DOUBLE RELIEF VALVE

MAINTENANCE STANDARD
FRONT AXLE
STEERING CYLINDER

BRAKE SYSTEM
STRUCTURE AND FUNCTION
BRAKE PIPING
BRAKE CIRCUIT DIAGRAM
BOOST MASTER
AIR BRAKE CIRCUIT DIAGRAM
AIR BRAKE CIRCUIT SCHEMATICS
BRAKE VALVE
AIR COMPRESSOR
AIR GOVERNOR
CHECK VALVE
AIR TANK
SAFETY VALVE
AUTOMATIC DRAIN VALVE (IF EQUIPPED)
AIR DRIER (IF EQUIPPED)
WHEEL BRAKE
PARKING BRAKE

TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE
TOOL LIST FOR TESTING AND ADJUSTING
CHECKING BRAKE PEDAL
AIR BLEEDING FROM BRAKE CIRCUIT
CHECKING PARKING BRAKE LEVER
CHECKING WEAR OF BRAKE DISC

DISASSEMBLY AND ASSEMBLY
BOOST MASTER
WHEEL BRAKE
BRAKE SHOE
WHEEL BRAKE ASSEMBLY
PARKING BRAKE

MAINTENANCE STANDARD
WHEEL BRAKE
PARKING BRAKE
BOOST MASTER

HYDRAULIC SYSTEM
STRUCTURE AND FUNCTION
HYDRAULIC PIPING
HYDUAULIC CONTROL
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC PUMP
CIRCLE ROTATION MOTOR
CONTROL VALVE
FLOW DIVIDER
PILOT CHECK VALVE
FLOW CONTROL VALVE
HYDRAULIC CYLINDER

TESTING AND ADJUSTING
TROUBLESHOOTING (Circle rotation motor)

DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (Incl. STEERING PUMP)
BLADE LIFT CYLINDER
DRAWBAR SHIFT CYLINDER
BLADE SIDE SHAFT CYLINDER
BLADE SIDE SHAFT CYLINDER ASSEMBLY
ARTICULATE CYLINDER
SCARIFIER CYLINDER ASSEMBLY
LEANING CYLINDER
POWER TILT CYLINDER (if equipped)
REAR MOUNT RIPPER CYLINDER ASSEMBLY (if equipped)
HYDRAULIC CYLINDER ASSEMBLY
CIRCLE ROTATION MOTOR

MAINTENANCE STANDARD
HYDRAULIC PUMP
CONTROL VALVE
HYDRAULIC CYLINDER

WORK EQUIPMENT
STRUCTURE AND FUNCTION
DRAWBAR AND LIFTER
BLADE
CIRCLE ROTATION GEAR
FRAME
SCARIFIER (if equipped)
REAR MOUNT RIPPER (if equipped)

TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD
TOOL LIST FOR TESTING AND ADJUSTING
CHECKING CONTROL LEVER
CHECKING HYDRAULIC OIL TEMPERATURE
CHECKING HYDRAULIC OIL PRESSURE
HYDRAULIC DRIFT
ADJUSTMENT OF CIRCLE GUIDE

DISASSEMBLY AND ASSEMBLY
BLADE ASSEMBLY
CIRCLE ROTATION GEAR
REAR MOUNT RIPPER ASSEMBLY (if equipped)

MAINTENANCE STANDARD
DRAWBAR AND LIFTER
BLADE
CIRCLE ROTATION GEAR
SCARIFIER (If equipped)
REAR MOUNT RIPPER (If equipped)

ELECTRIC AND ELECTRONIC SYSTEM
STRUCTURE AND FUNCTION
ELECTRICAL CIRCUIT DIAGRAM
INDICATION ON PANEL

TESTING AND ADJUSTING
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE
POSITION OF CONNECTOR
CONNECTOR TERMINAL NUMBERS
PROCEDURE FOR TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHART
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (M-1 to M-12)

OTHERS
AIR CONDITIONER (if equipped)

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