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KOMATSU GD500-2 SERIES SHOP MANUAL SEBM023AB07 – PDF DOWNLOAD
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Description
KOMATSU GD500-2 SERIES SHOP MANUAL SEBM023AB07 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU GD500-2 SERIES SHOP MANUAL SEBM023AB07 – PDF DOWNLOAD
Language : English
Pages : 849
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU GD500-2 SERIES SHOP MANUAL SEBM023AB07 – PDF DOWNLOAD
COVER............................................................................................................................. 1 CONTENTS.......................................................................................................................... 2 01 GENERAL........................................................................................................................ 16 GENERAL....................................................................................................................... 18 GENERAL VIEW (GD500R-2)................................................................................................... 19 OPERATOR'S COMPARTMENT (GD500R-2)......................................................................................... 20 GENERAL VIEW (GD505R-2)................................................................................................... 21 OPERATOR'S COMPARTMENT (GD505R-2)......................................................................................... 22 GENERAL VIEW (GD505A-2)................................................................................................... 23 OPERATOR'S COMPARTMENT (GD505A-2)......................................................................................... 25 SPECIFICATIONS............................................................................................................ 28 ENGINE SPECIFICATIONS..................................................................................................... 32 ENGINE ASSEMBLY DRAWING................................................................................................... 33 ENGINE PERFORMANCE CURVE.................................................................................................. 34 WEIGHT TABLE.............................................................................................................. 35 SERIAL NUMBER LOCATIONS................................................................................................... 37 OIL AND WATER CAPACITIES.................................................................................................. 43 MOTOR GRADER DESCRIPTION.................................................................................................. 52 GENERAL INSPECTION AND TEST............................................................................................... 55 GENERAL PRECAUTION FOR DISASSEMBLY........................................................................................ 57 GENERAL PRECAUTION FOR ASSEMBLY........................................................................................... 59 10 ENGINE......................................................................................................................... 65 11 STRUCTURE AND FUNCTION..................................................................................................... 65 STRUCTURE AND FUNCTION.................................................................................................... 66 ENGINE MOUNTING....................................................................................................... 67 RADIATOR.............................................................................................................. 68 FUEL TANK AND PIPING.................................................................................................. 69 ACCELERATOR CONTROL................................................................................................... 70 12 TESTING AND ADJUSTING...................................................................................................... 73 TESTING AND ADJUSTING..................................................................................................... 74 STANDARD FOR TESTING AND ADJUSTING.................................................................................... 75 TOOLS FOR TESTING AND ADJUSTING....................................................................................... 77 CRANKING METHOD ...................................................................................................... 78 INTAKE AND EXHAUST SYSTEM............................................................................................. 79 ENGINE................................................................................................................ 83 LUBRICATION SYSTEM.................................................................................................... 84 FUEL SYSTEM........................................................................................................... 85 COOLING SYSTEM........................................................................................................ 86 FUEL CONTROL LEVER STROKE............................................................................................. 87 ACCELERATOR PEDAL STROKE.............................................................................................. 88 13 DISASSEMBLY AND ASSEMBLY................................................................................................... 89 DISASSEMBLY AND ASSEMBLY.................................................................................................. 90 STARTING MOTOR........................................................................................................ 91 DISMOUNTING AND MOUNTING.......................................................................................... 91 ALTERNATOR............................................................................................................ 92 DISMOUNTING AND MOUNTING.......................................................................................... 92 FUEL INJECTION PUMP................................................................................................... 94 DISMOUNTING AND MOUNTING.......................................................................................... 94 WATER PUMP............................................................................................................ 95 DISMOUNTING ...................................................................................................... 95 MOUNTING.......................................................................................................... 96 OIL COOLER............................................................................................................ 99 DISMOUNTING AND MOUNTING.......................................................................................... 99 NOZZLE HOLDER.........................................................................................................100 DISMOUNTING AND MOUNTING..........................................................................................100 TURBOCHARGER..........................................................................................................101 DISMOUNTING AND MOUNTING..........................................................................................101 RADIATOR..............................................................................................................102 DISMOUNTING AND MOUNTING..........................................................................................102 CYLINDER HEAD.........................................................................................................103 DISMOUNTING.......................................................................................................103 MOUNTING..........................................................................................................109 FUEL TANK.............................................................................................................115 DISMOUNTING.......................................................................................................115 MOUNTING..........................................................................................................118 ENGINE................................................................................................................123 DISMOUNTING.......................................................................................................123 MOUNTING..........................................................................................................130 DAMPER................................................................................................................137 DISMOUNTING.......................................................................................................137 MOUNTING..........................................................................................................138 20 POWER TRAIN....................................................................................................................139 21 STRUCTURE AND FUNCTION.....................................................................................................139 STRUCTURE AND FUNCTION....................................................................................................140 GENERAL (GD500R-2)....................................................................................................141 POWER TRAIN DIAGRAM (GD500R-2)........................................................................................142 GENERAL (GD505R-2 GD505A-2)...........................................................................................143 POWER TRAIN DIAGRAM (GD505R-2 GD505A-2)...............................................................................145 MAIN CLUTCH...........................................................................................................147 MAIN CLUTCH BOOSTER...................................................................................................152 MAIN CLUTCH CONTROL LINKAGE...........................................................................................155 INERTIA BRAKE (GD500R-2)..............................................................................................158 TRANSMISSION (GD500R-2)...............................................................................................160 TRANSMISSION CONTROL LINKAGE (GD500R-2)...............................................................................165 DAMPER (GD505-2)......................................................................................................166 HYDROSHIFT TRANSMISSION (GD505-2).....................................................................................167 HYDROSHIFT TRANSMISSION CONTROL VALVE (GD505-2).......................................................................179 HYDROSHIFT TRANSMISSION HYDRAULIC CONTROL (GD505-2)...................................................................185 HYDROSHIFT TRANSMISSION PIPING (GD505-2)..............................................................................187 HYDROSHIFT TRANSMISSION LUBRICATION (GD505-2).........................................................................188 LUBRICATING RELIEF VALVE (GD505-2)....................................................................................189 HYDROSHIFT TRANSMISSION CONTROL LINKAGE (GD505-2).....................................................................190 P.T.O (GD505-2).......................................................................................................193 TRANSMISSION AND MAIN CLUTCH PUMP (GD500R-2)..........................................................................194 TRANSMISSION PUMP (GD505-2)...........................................................................................195 DRIVE SHAFT...........................................................................................................196 FINAL DRIVE...........................................................................................................198 TANDEM DRIVE..........................................................................................................202 DIFFERENTIAL LOCK AND UNLOCK PIPING...................................................................................205 22 TESTING AND ADJUSTING......................................................................................................206 TESTING AND ADJUSTING.....................................................................................................207 MAIN CLUTCH (GD500R-2)................................................................................................208 TRANSMISSION CONTROL LEVER STROKE AND OPERATING FORCE (GD500R-2)......................................................212 INCHING PEDAL STROKE AND OPERATING FORCE (GD505-2)....................................................................213 HYDROSHIFT TRANSMISSION (GD505-2).....................................................................................214 TRANSMISSION CONTROL LEVER STROKE AND OPERATING FORCE.................................................................217 TROUBLE SHOOTING......................................................................................................219 DIAGNOSIS TOOL TABLE..............................................................................................220 TROUBLE SHOOTING..................................................................................................221 1. MAIN CLUTCH DOES NOT DISENGAGE CLEANLY (GEARS GRATE).......................................................221 2. MAIN CLUTCH SLIPS (GD500R-2)...............................................................................222 3. GEAR SLIPS OUT (GD500R-2)..................................................................................222 4. EXCESSIVE SHOCK IS FELT WHEN STARTING THE MACHINE OR SHIFTING TRANSMISSION SPEED (GD505-2).................222 5. TIME LAG IS EXCESSIVE WHEN STARTING THE MACHINE OR SHIFTING TRANSMISSION SPEED (GD505-2)...................223 6. MACHINE FAILS TO START (GD505-2)...........................................................................224 7. MACHINE TRAVELS SLOWLY OR DOES NOT START (AT EVERY SPEED POSITION).........................................225 23 DISASSEMBLY AND ASSEMBLY...................................................................................................226 DISASSEMBLY AND ASSEMBLY..................................................................................................227 MAIN CLUTCH ASSEMBLY..................................................................................................228 DISMOUNTING.......................................................................................................228 MOUNTING..........................................................................................................230 MAIN CLUTCH CASE ASSEMBLY.............................................................................................232 DISASSEMBLY.......................................................................................................232 ASSEMBLY..........................................................................................................234 MAIN CLUTCH ASSEMBLY..................................................................................................236 DISASSEMBLY.......................................................................................................236 ASSEMBLY..........................................................................................................239 MAIN CLUTCH BOOSTER...................................................................................................242 DISASSEMBLY AND ASSEMBLY..........................................................................................242 TRANSMISSION ASSEMBLY.................................................................................................243 DISMOUNTING.......................................................................................................243 MOUNTING..........................................................................................................247 DISASSEMBLY.......................................................................................................251 ASSEMBLY..........................................................................................................258 SHIFTING FORK COVER ASSEMBLY..........................................................................................266 DISASSEMBLY.......................................................................................................266 ASSEMBLY..........................................................................................................268 DAMPER................................................................................................................270 DISMOUNTING.......................................................................................................270 MOUNTING..........................................................................................................271 DISASSEMBLY AND ASSEMBLY..........................................................................................272 P.T.O.(POWER TAKE OFF)................................................................................................273 DISASSEMBLY.......................................................................................................273 ASSEMBLY..........................................................................................................275 HYDROSHIFT TRANSMISSION...............................................................................................276 DISMOUNTING.......................................................................................................276 MOUNTING..........................................................................................................282 DISASSEMBLY.......................................................................................................289 ASSEMBLY..........................................................................................................305 CAGE AND REVERSE CARRIER ASSEMBLY.....................................................................................327 DISASSEMBLY.......................................................................................................327 ASSEMBLY..........................................................................................................330 1ST SPEED ROTARY CLUTCH...............................................................................................333 DISASSEMBLY.......................................................................................................333 ASSEMBLY..........................................................................................................336 HIGH SPEED ROTARY CLUTCH..............................................................................................339 DISASSEMBLY.......................................................................................................339 ASSEMBLY..........................................................................................................343 PLANETARY GEAR........................................................................................................346 DISASSEMBLY AND ASSEMBLY..........................................................................................346 HYDROSHIFT TRANSMISSION CONTROL VALVE.................................................................................347 DISMOUNTING.......................................................................................................347 MOUNTING..........................................................................................................349 TRANSMISSION CONTROL VALVE ASSEMBLY...................................................................................351 DISASSEMBLY.......................................................................................................351 ASSEMBLY..........................................................................................................352 HYDROSHIFT TRANSMISSION PUMP..........................................................................................357 DISMOUNTING AND MOUNTING..........................................................................................357 TANDEM AND FINAL DRIVE ASSEMBLY.......................................................................................358 DISMOUNTING.......................................................................................................358 MOUNTING..........................................................................................................360 FINAL DRIVE...........................................................................................................364 DISASSEMBLY.......................................................................................................364 ASSEMBLY..........................................................................................................370 BEVEL PINION..........................................................................................................392 DISASSEMBLY.......................................................................................................392 ASSEMBLY..........................................................................................................394 BEVEL GEAR AND SHAFT ASSEMBLY.........................................................................................398 DISASSEMBLY.......................................................................................................398 ASSEMBLY..........................................................................................................399 TANDEM CASE AND SPROCKET..............................................................................................406 DISMOUNTING.......................................................................................................406 MOUNTING..........................................................................................................410 CHAIN.................................................................................................................414 DISMOUNTING.......................................................................................................414 MOUNTING..........................................................................................................417 WHEEL BRAKE AND SPROCKET..............................................................................................420 DISMOUNTING.......................................................................................................420 MOUNTING..........................................................................................................422 DISASSEMBLY.......................................................................................................428 ASSEMBLY..........................................................................................................431 24 MAINTENANCE STANDARD.......................................................................................................435 MAINTENANCE STANDARD......................................................................................................437 MAIN CLUTCH (GD500R-2)................................................................................................438 TRANSMISSION (GD500R-2)...............................................................................................442 HYDROSHIFT TRANSMISSION (GD505-2).....................................................................................444 HYDROSHIFT TRANSMISSION CONTROL VALVE (GD505-2).......................................................................449 TRANSMISSION AND MAIN CLUTCH PUMP (GD500R-2)..........................................................................454 HYDROSHIFT TRANSMISSION PUMP (GD505-2)................................................................................455 FINAL DRIVE...........................................................................................................456 TANDEM DRIVE..........................................................................................................458 40 STEERING SYSTEM................................................................................................................460 41 STRUCTURE AND FUNCTION.....................................................................................................460 STRUCTURE AND FUNCTION....................................................................................................461 STEERING PIPING.......................................................................................................462 STEERING PIPING DIAGRAM...............................................................................................466 STEERING WHEEL........................................................................................................468 STEERING VALVE........................................................................................................469 FLOW CONTROL VALVE....................................................................................................476 STEERING PUMP.........................................................................................................481 STEERING CYLINDER.....................................................................................................482 FRONT AXLE............................................................................................................483 WHEELS................................................................................................................489 42 TESTING AND ADJUSTING......................................................................................................498 TESTING AND ADJUSTING.....................................................................................................499 CHECKING STEERING WHEEL PLAY..........................................................................................500 CHECKING STEERING WHEEL OPERATING FORCE...............................................................................500 CHECKING TIRE PLAY....................................................................................................501 CHECKING AIR PRESSURE OF TIRE.........................................................................................501 CHECKING TOE-IN.......................................................................................................502 TROUBLE SHOOTING......................................................................................................503 STEERING WHEEL DRAGS OR IS HARD TO TURN...........................................................................504 43 DISASSEMBLY AND ASSEMBLY...................................................................................................505 DISASSEMBLY AND ASSEMBLY..................................................................................................506 FRONT AXLE............................................................................................................507 DISMOUNTING.......................................................................................................507 MOUNTING..........................................................................................................511 FLOW CONTROL VALVE....................................................................................................515 DISMOUNTING AND MOUNTING..........................................................................................515 STEERING CYLINDER.....................................................................................................517 DISMOUNTING AND MOUNTING..........................................................................................517 DISASSEMBLY AND ASSEMBLY..........................................................................................519 STEERING PUMP.........................................................................................................520 DISMOUNTING AND MOUNTING..........................................................................................520 44 MAINTENANCE STANDARD.......................................................................................................521 MAINTENANCE STANDARD......................................................................................................523 STEERING PUMP.........................................................................................................524 STEERING CYLINDER.....................................................................................................526 FRONT AXLE............................................................................................................527 50 BRAKE SYSTEM...................................................................................................................529 51 STRUCTURE AND FUNCTION.....................................................................................................529 STRUCTURE AND FUNCTION....................................................................................................530 BRAKE PIPING..........................................................................................................531 BRAKE PIPING DIAGRAM..................................................................................................533 HYDROMASTER...........................................................................................................534 MASTER CYLINDER.......................................................................................................536 WHEEL BRAKE CONTROL LINKAGE...........................................................................................537 WHEEL BRAKE...........................................................................................................538 DISC BRAKE SYSTEM.....................................................................................................542 BRAKE VALVE...........................................................................................................547 RELAY VALVE...........................................................................................................551 AIR GOVERNOR..........................................................................................................553 CHECK VALVE...........................................................................................................555 AIR RESERVOIR.........................................................................................................556 SAFETY VALVE..........................................................................................................556 PRESSURE SWITCH.......................................................................................................557 AUTOMATIC DRAIN VALVE.................................................................................................559 AIR DRIER.............................................................................................................561 BLADE ACCUMULATOR SYTEM...............................................................................................563 PARKING BRAKE CONTROL LINKAGE.........................................................................................569 PARKING BRAKE.........................................................................................................571 52 TESTING AND ADJUSTING......................................................................................................572 TESTING AND ADJUSTING.....................................................................................................573 CHECKING BRAKE PEDAL HEIGHT...........................................................................................574 CHECKING BRAKE PEDAL PLAY.............................................................................................574 CHECKING BRAKE PEDAL DEPRESSION HEIGHT................................................................................575 BLEEDING AIR INSIDE BRAKE PIPING......................................................................................576 CHECKING BRAKE PEDAL OPERATING FORCE..................................................................................577 CHECKING PARKING BRAKE LEVER STROKE...................................................................................578 CHECKING PARKING BRAKE OPERATING FORCE................................................................................579 CHECKING WEAR OF BRAKE DISC...........................................................................................580 53 DISASSEMBLY AND ASSEMBLY...................................................................................................581 DISASSEMBLY AND ASSEMBLY..................................................................................................582 WHEEL AND WHEEL BRAKE ASSEMBLY........................................................................................583 DISMOUNTING.......................................................................................................583 MOUNTING..........................................................................................................585 WHEEL BRAKE ASSEMBLY..................................................................................................587 DISASSEMBLY.......................................................................................................587 ASSEMBLY..........................................................................................................590 BRAKE MASTER CYLINDER.................................................................................................594 DISMOUNTING.......................................................................................................594 MOUNTING..........................................................................................................596 HYDROMASTER...........................................................................................................598 DISMOUNTING AND MOUNTING..........................................................................................598 DISASSEMBLY.......................................................................................................599 ASSEMBLY..........................................................................................................601 PARKING BRAKE.........................................................................................................603 DISMOUNTING AND ASSEMBLY..........................................................................................603 54 MAINTENANCE STANDARD.......................................................................................................604 MAINTENANCE STANDARD......................................................................................................606 WHEEL BRAKE...........................................................................................................607 PARKING BRAKE.........................................................................................................610 60 HYDRAULIC SYSTEM...............................................................................................................611 61 STRUCTURE AND FUNCTION.....................................................................................................611 STRUCTURE AND FUNCTION....................................................................................................612 HYDRAULIC CONTROL PIPING..............................................................................................613 HYDRAULIC PIPING DIAGRAM..............................................................................................632 HYDRAULIC CIRCUIT DIAGRAM.............................................................................................633 HYDRAULIC CONTROL VALVE(4-SPOOL)......................................................................................642 HYDRAULIC CONTROL VALVE(5-SPOOL)......................................................................................644 PILOT CHECK VALVE.....................................................................................................654 CIRCLE REVOLUTION HYDRAULIC CIRCUIT (GD500R,505A-2)...................................................................661 CIRCLE REVOLUTION HYDRAULIC CIRCUIT (GD505R-2)........................................................................666 HYDRAULIC PUMP........................................................................................................669 CIRCLE REVERSE MOTOR..................................................................................................679 HYDRAULIC CYLINDER....................................................................................................682 HYDRAULIC CONTROL LINKAGE.............................................................................................687 62 TESTING AND ADJUSTING......................................................................................................693 TESTING AND ADJUSTING.....................................................................................................694 CHECKING HYDRAULIC OIL TEMPERATURE....................................................................................695 CHECKING HYDRAULIC OIL PRESSURE.......................................................................................696 ADJUSTING HYDRAULIC OIL PRESSURE......................................................................................698 MEASURING BLADE NATURAL LOWERING RATE.................................................................................699 MEASURING BLADE SINKING AMOUNT........................................................................................699 MEASURING SCARIFIER (O.P.) NATURAL LOWERING RATE......................................................................699 MEASURING SCARIFIER (O.P.) SINKING MOUNT..............................................................................699 TROUBLE SHOOTING......................................................................................................700 DIAGNOSIS TOOL TABLE..............................................................................................701 1. HYDRAULIC DRIFT OF BLADE OR SCARIFIER CYLINDER IS LARGE ...................................................702 2. BLADE OR SCARIFIER LIFTING CYLINDER LACKS FORCE ENOUGH TO RAISE THE FRONT END OF MACHINE...................703 3. DRAWBAR-SHIFT,SCARIFIER L.H. AND R.H. BLADE LIFT CYLINDER OR ARTICULATE CYLINDERS LACKS OPERATING FORCE....704 4. HYDRAULIC DRIFT OF LEANING CYLINDER IS LARGE...............................................................705 5. CIRCLE CANNOT BE ROTATED...................................................................................706 6. CIRCLE MOTOR SPEED IS LOW..................................................................................707 63 DISASSEMBLY AND ASSEMBLY...................................................................................................708 DISASSEMBLY AND ASSEMBLY..................................................................................................709 HYDRAULIC PUMP........................................................................................................710 DISMOUNTING AND MOUNTING..........................................................................................710 CONTORL VALVE.........................................................................................................711 DISMOUNTING.......................................................................................................711 MOUNTING..........................................................................................................712 4-SPOOL VALVE ASSEMBLY................................................................................................719 DISASSEMBLY.......................................................................................................719 ASSEMBLY..........................................................................................................720 MAIN RELIEF VALVE ASSEMBLY............................................................................................721 DISASSEMBLY AND ASSEMBLY..........................................................................................721 CONFLUENT VALVE (SWITCH VALVE AND QUICK DRAIN VALVE)..................................................................722 DISMOUNTING AND MOUNTING..........................................................................................722 DISASSEMBLY.......................................................................................................723 ASSEMBLY..........................................................................................................724 CHECK VALVE AND QUICK DRAIN VALVE ASSEMBLY............................................................................725 DISMOUNTING AND MOUNTING..........................................................................................725 DISASSEMBLY AND ASSEMBLY..........................................................................................727 BLADE LIFT CYLINDER...................................................................................................728 DISMOUNTING AND MOUNTING..........................................................................................728 BLADE SIDE SHIFT CYLINDER.............................................................................................729 DISMOUNTING.......................................................................................................729 MOUNTING..........................................................................................................730 DRAWBAR SHIFT CYLINDER................................................................................................733 DISMOUNTING AND MOUNTING..........................................................................................733 LEANING CYLINDER......................................................................................................734 DISMOUNTING AND MOUNTING..........................................................................................734 ARTICULATE CYLINDER ASSEMBLY..........................................................................................735 DISMOUNTING AND MOUNTING..........................................................................................735 HYDRAULIC CYLINDER ASSEMBLY...........................................................................................736 DISASSEMBLY.......................................................................................................736 ASSEMBLY..........................................................................................................739 64 MAINTENANCE STANDARD.......................................................................................................748 MAINTENANCE STANDARD......................................................................................................750 HYDRAULIC CONTROL VALVE...............................................................................................751 HYDRAULIC PUMP........................................................................................................756 BLADE LIFT CYLINDER...................................................................................................759 BLADE SIDE SHIFT CYLINDER.............................................................................................760 DRAWBAR SHIFT CYLINDER................................................................................................761 LEANING CYLINDER......................................................................................................762 SCARIFIER CYLINDER (OP)...............................................................................................763 ARTICULATE CYLINDER (GD505A-2)........................................................................................764 70 WORK EQUIPMENT.................................................................................................................765 71 STRUCTURE AND FUNCTION.....................................................................................................765 STRUCTURE AND FUNCTION....................................................................................................766 DRAWBAR...............................................................................................................767 BLADE AND CIRCLE......................................................................................................769 LIFTER................................................................................................................772 LIFTER BRACKET CONTROL PIPING.........................................................................................775 CIRCLE REVERSE GEAR...................................................................................................776 SCARIFIER (O.P).......................................................................................................778 MAIN FRAME............................................................................................................780 72 TESTING AND ADJUSTING......................................................................................................783 TESTING AND ADJUSTING.....................................................................................................784 WORK EQUIPMENT CONTROL LEVER STROKE AND OPERATING FORCE...............................................................785 73 DISASSEMBLY AND ASSEMBLY...................................................................................................786 DISASSEMBLY AND ASSEMBLY..................................................................................................787 BLADE.................................................................................................................788 DISMOUNTING AND MOUNTING..........................................................................................788 CIRCLE REVERSE GEAR AND MOTOR.........................................................................................789 DISMOUNTING AND MOUNTING..........................................................................................789 DISASSEMBLY.......................................................................................................791 ASSEMBLY..........................................................................................................794 74 MAINTENANCE STANDARD.......................................................................................................798 MAINTENANCE STANDARD......................................................................................................800 BLADE AND CIRCLE......................................................................................................801 BLADE LIFTER BRACKET..................................................................................................804 CIRCLE REVERSE GEAR...................................................................................................806 SCARIFIER (O.P).......................................................................................................808 90 OTHERS.........................................................................................................................810 91 ELECTRICAL SYSTEM..........................................................................................................810 ELECTRICAL SYSTEM.........................................................................................................811 BATTERY HANDLING......................................................................................................812 ELECTRIC WIRE CODE....................................................................................................813 ELECTRICAL WIRING DIAGRAM.............................................................................................814 ELECTRICAL CIRCUIT DIAGRAM............................................................................................822 TROUBLE SHOOTING......................................................................................................826 1-1 ELECTRIC SYSTEM DOES NOT OPERATE AT ALL (EXCEPT PARKING LAMP).................................................827 1-2 CRANKING SPEED IS TOO LOW TO START THE ENGINE.................................................................828 1-3 PINION CLICK IS HEARD WHEN STARTING SWITCH IS TURNED TO "START",BUT STARTING MOTOR DOES NOT ROTATE............829 2-1 BATTERY IS FREQUENTLY NEEDS CHARGE,THUS MAKING THE ENGINE HARD TO START.......................................830 3-1 PARKING LAMP DOES NOT LIGHT...................................................................................832 3-2 ALL THE INSTRUMENT PANEL LAMPS,FRONT MARKER LAMPS,TAIL LAMPS AND HEAD LAMPS DO NOT LIGHT......................833 3-3 FRONT MARKER LAMP AND TAIL LAMP DO NOT LIGHT..................................................................834 3-4 HEAD LAMP DOES NOT LIGHT......................................................................................835 3-5 TURN SIGNAL LAMP DOES NOT LIGHT...............................................................................836 3-6 BACKUP HORN DOES NOT SOURD OR BACK-UP LAMP DOES NOT LIGHT.....................................................838 3-7 TROUBLESHOOTING OTHER ACCESSORY CIRCUITS......................................................................839 92 INSPECTION TABLE...........................................................................................................840 POWER TRAIN...............................................................................................................841 STEERING SYSTEM...........................................................................................................843 HYDRAULIC SYSTEM,WORK EQUIPMENT...........................................................................................844
DESCRIPTION:
KOMATSU GD500-2 SERIES SHOP MANUAL SEBM023AB07 – PDF DOWNLOAD
Introduction
This shop manual has been prepared as an aid to improve the quality of repairs by providing the serviceman with an accurate understanding of the product and by guiding them on the correct way to perform repairs and make judgments. Ensure you understand the contents of this manual and use it to its full potential at every available opportunity.
This shop manual has been prepared as an aid to improve the quality of repairs by providing the serviceman with an accurate understanding of the product and by guiding them on the correct way to perform repairs and make judgments. Ensure you understand the contents of this manual and use it to its full potential at every available opportunity.
Organization
This shop manual contains the necessary technical information for operations performed in a service workshop.
This shop manual contains the necessary technical information for operations performed in a service workshop.
For ease of understanding, the manual is divided into chapters, each covering a main group of components. These chapters are further divided into the following sections:
1. Structure and Function
This section explains the structure and function of each component. It not only provides an understanding of the structure but also serves as reference material for troubleshooting.
2. Testing and Adjusting
This section describes the checks to be performed before and after carrying out repairs, as well as the adjustments to be made upon completing these checks and repairs. Troubleshooting charts correlating “Diagnoses” to “Causes” are also included in this section.
3. Disassembly and Assembly
This section provides step-by-step instructions for removing, installing, disassembling, or assembling each component. It also highlights the precautions to be taken during these operations.
4. Maintenance Standards
This section outlines the judgment standards for inspecting disassembled parts.
S.S 30/12/24
