Komatsu GD610 Series Install guide

SEBMG6150109
© 2011 7
All Rights Reserved
Printed in Japan 08-11(01) 00-1
o
GD663A-2 1001 and up
For GD663A-2, see pages prepared for GD623A-1 except two descriptions below.
1) Front axle (page 41-9) 1. Steering cylinder has both types of single cylinder and dual cylinder.
2) For rear mount ripper, see page 74-9.
~IBI@JF
KOMA1sU
GD610,
GD620
SERIES
GD660,
GD670
SERIES
MACHINE SERIAL No. COMPONENT MACHINE SERIAL No. COMPONENT
MODEL
TYPE
MODEL
TYPE
GD621A-1 10001
and
up
A GD621
R-1
10001 and
up
K
GD622A-1 20001
and
up
B GD623R-1 30001 and up L
GD623A-1 30001
and
up
C GD611R-1 10001 and up
M
GD625A-1 50001
and
up
D GD613R-1 30001 and up N
GD672A-1 20001 and
up
E GD615A-1 50001 and up p
GD611A-1 10001
and
up
F GD625A-1C 60001 and up
a
GD613A-1 30001
and
up
G GD625A-1A 60001 and
up}
See
table
of
GD661A-1 10001
and
up
H applicable
GD625A-1 B 65001 and up components.
GD663A-1 30001
andup
J
•
This
shop
manual
may
contain
attachments
and
optional
equipment
that
are
not
available
in
your
area. Please
consult
your
local
Komatsu
distributor
for
those
items
you
may
require.
Materials
and
specifications
are
subject
to
change
without
notice.
• GD621A, 611A, 661A,
621R,
623R, 611R,
613R-1
mount
the S6D105-1 engine;
•
GD622A, 623A, 625A, 672A, 613A, 663A, 625A-1C, 625A-1A
mount
the 6D125-1 engine;
GD615A-1
mount
the S6D110-1 engine.
For details
of
the engines,
see
the
105
Series Shop Manual, 110 Series Shop Manual
and 6D125 Series Shop Manual.

CONTENTS
No. of page
10 ENGINE
12 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
13 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
20 POWER TRAIN
21 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 -1
22 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1
23 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1
24 MAINTENANCE STANDA RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-1
40 STEERING SYSTEM
41 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 -1
42 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-1
43 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-1
44 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44- 1
50 BRAKE SYSTEM
51 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 -1
52 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-1
53 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-1
54 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54-1
60 HYDRAULIC SYSTEM
61 STRUCTUREANDFUNCTION .................................................... 61-1
62 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62-1
63 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-1
64 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64-1
70 WORK EQUIPMENT
71 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 -1
72 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-1
73 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-1
74 MAINTENANCE STANDA
RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-1
80 ELECTRIC AND ELECTRONIC SYSTEM
81 STRUCTURE AND FUNCTION .................................................... 81-1
82 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-1
90 OTHERS ................................................... .. ................... 90-1
AIR
CONDITIONER.................................................................. 90-2
00-2
®
GD610, 620
GD660, 670
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GD660, 670
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Mark
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Time
of
revision
GD610, 620
GD660, 670
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SAFETY
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
SAFETY NOTICE
Proper service and repair is
extremely
important
for
safe machine operation. The
service and repair techniques recommended
by
Komatsu and described in
this
manual
are both effective and safe. Some
of
these techniques require the use
of
tools
specially
designed
by
Komatsu
for
the specific purpose.
To prevent
injury
to
workers,
the
symbol
A
is used
to
mark
safety precautions in
this
manual. The cautions accompanying these symbols should always be
followed
care-
fully.
If
any dangerous situation arises
or
may
possibly arise,
first
consider safety, and
take the necessary actions
to
deal
with
the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read
the Operation and Maintenance Manual
carefully
BEFORE
operating the machine.
1.
Before carrying
out
any greasing
or
repairs,
read all the precautions given on the decals
which are fixed
to
the machine.
2.
When carrying
out
any operation, always
wear safety shoes and helmet. Do
not
wear
loose
work
clothes,
or
clothes
with
buttons
missing.
• Always wear safety glasses when hitting
parts
with
a hammer.
• Always wear safety glasses when grind-
ing parts
with
a grinder, etc.
3.
If welding repairs are needed, always have a
trained, experienced
welder
carry
out
the
work. When carrying
out
welding
work, al-
ways
wear
welding
gloves,
apron,
hand
shield, cap and other clothes suited
for
weld-
ing work.
4.
When carrying
out
any operation
with
two
or
more workers, always agree on the oper-
ating procedure before starting. Always in-
form
your
fellow
workers before starting any
step
of
the operation. Before starting work,
hang UNDER
REPAIR
signs on the controls
in the operator's compartment.
5.
Keep all tools in good condition and learn
the correct
way
to
use them.
6.
Decide a place in the repair
workshop
to
keep
tools
and removed parts.
Always
keep
the
tools
and parts in
their
correct places.
Always
keep the
work
area clean and make
sure
that
there is no
dirt
or
oil on
the
floor.
Smoke
only
in the areas provided
for
smok-
ing. Never smoke
while
working.
PREPARATIONS FOR WORK
7.
Before adding oil
or
making any repairs,
park the machine on hard, level
ground,
and
block the wheels
or
tracks
to
prevent
the
machine
from
moving.
8.
Before starting work,
lower
blade, ripper,
bucket
or
any other
work
equipment
to
the
ground.
If
this is
not
possible, insert the
safety pin
or
use blocks
to
prevent
the
work
equipment
from
falling. In addition, be sure
to
lock all the control levers and hang
warn-
ing signs on them.
9.
When disassembling
or
assembling,
support
the machine
with
blocks, jacks
or
stands
before starting work.
10. Remove all
mud
and oil
from
the steps
or
other places used
to
get
on and
off
the
ma-
chine.
Always
use
the
handrails, ladders
or
steps
when
getting on
or
off
the machine.
Never
jump
on
or
off
the machine. If
it
is
impossible
to
use
the
handrails, ladders
or
steps, use a stand
to
provide safe
footing.
00-3
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SAFETY
PRECAUTIONS DURING WORK
11.
When
removing
the oil
filler
cap, drain plug
or
hydraulic
pressure
measuring
plugs,
loosen
them
slowly
to
prevent the oil
from
spurting
out.
Before disconnecting
or
removing
compo-
nents
of
the
oil,
water
or
air
circuits,
first
remove
the
pressure
completely
from
the
circuit.
12. The
water
and oil in the circuits are
hot
when
the engine is stopped, so be careful
not
to
get
burned.
Wait
for
the oil and
water
to
cool before
carrying
out
any
work
on
the
oil
or
water
circuits.
13. Before starting work, remove the leads
from
the
battery.
Always
remove
the
lead
from
the
negative
(-)
terminal
first.
14.
When
raising heavy components, use a
hoist
or
crane.
Check
that
the
wire
rope, chains and hooks
are free
from
damage.
Always
use
lifting
equipment
which
has
ample
capacity.
Install the
lifting
equipment
at
the
correct
places. Use a
hoist
or
crane and operate
slowly
to
prevent
the
component
from
hit-
ting
any
other
part. Do
not
work
with
any
part
still raised
by
the
hoist
or
crane.
15.
When
removing
covers
which
are
under
in-
ternal pressure
or
under
pressure
from
a
spring, always leave
two
bolts in
position
on opposite sides.
Slowly
release
the
pres-
sure, then
slowly
loosen the bolts
to
remove.
16.
When
removing
components, be careful
not
to
break
or
damage the
wiring.
Damaged
wiring
may
cause electrical fires.
17.
When
removing
piping,
stop
the
fuel
or
oil
from
spilling
out.
If
any
fuel
or
oil drips
onto
the
floor,
wipe
it
up
immediately. Fuel
or
oil
on
the
floor
can cause
you
to
slip,
or
can
even start fires.
18. As a general rule,
do
not
use gasoline
to
wash
parts. In particular, use
only
the
mini-
mum
of
gasoline
when
washing
electrical
parts.
00-4
SAFETY NOTICE
19.
Be
sure
to
assemble all parts again in
their
original places.
Replace any damaged parts
with
new
parts.
• When installing hoses and wires, be sure
that
they
will
not
be damaged
by
contact
with
other
parts when the machine is be-
ing operated.
20. When installing high pressure hoses, make
sure
that
they
are
not
twisted. Damaged
tubes are dangerous, so be extremely care-
ful
when
installing tubes
for
high pressure
circuits. Also, check
that
connecting parts
are correctly installed.
21. When assembling
or
installing parts, always
use
the
specified
tightening
torques. When
installing protective parts such
as
guards,
or
parts
which
vibrate
violently
or
rotate at
high speed, be particularly careful
to
check
that
they
are installed correctly.
22.
When aligning
two
holes, never insert
your
fingers
or
hand.
Be
careful
not
to
get
your
fingers caught in a hole.
23. When measuring hydraulic pressure, check
that
the measuring
tool
is correctly assem-
bled before taking any measurements.
24. Take care
when
removing
or
installing the
tracks
of
track-type machines.
When
removing
the
track,
the
track sepa-
rates suddenly, so never let anyone stand at
either end
of
the track.
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FOREWORD
GENERAL
FOREWORD
GENERAL
This shop manual has been prepared
as
an aid
to
improve
the
quality
of
repairs
by
giving
the
serviceman an accurate understanding
of
the
product
and
by
showing
him
the
correct
way
to
perform
repairs and make judgements. Make sure
you
understand the contents
of
this
manual and use
it
to
full
effect at every
opportunity.
This shop manual
mainly
contains
the
necessary technical
information
for
operations
performed
in a
service workshop. For ease
of
understanding,
the
manual is divided
into
the
following
chapters; these
chapters are
further
divided
into
the
each
main
group
of
components.
STRUCTURE AND FUNCTION
This section explains
the
structure and
function
of
each component. It serves
not
only
to
give
an
understanding
of
the structure,
but
also serves
as
reference material
for
troubleshooting.
TESTING AND ADJUSTING
This section explains checks
to
be made before and after
performing
repairs,
as
well
as
adjustments
to
be made at
completion
of
the
checks and repairs.
Troubleshooting charts correlating "Problems"
to
"Causes" are also included in
this
section.
DISASSEMBLV AND ASSEMBLV
This section explains the
order
to
be
followed
when
removing,
installing, disassembling
or
assembling each component,
as
well
as
precautions
to
be taken
for
these operations.
MAINTENANCE STANDARD
This section gives the
judgement
standards
when
inspecting disassembled parts.
NOTICE
The
specifications
contained
in
this
shop
manual
are
subject
to
change
at
any
time
and
without
any
advance
notice.
Use
the
specifications
given
in
the
book
with
the
latest
date.
00-5
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FOREWORD
HOW TO
READ
THE
SHOP MANUAL
VOLUMES
Shop
manuals are issued
as
a
guide
to
carrying
out
repairs. They are divided
as
follows:
Chassis volume:
Issued
for
every machine model
Engine volume:
Issued
for
each engine series
Electrical volume:
lEach issued
as
one
Attachments volume:
volume
to
cover all
models
These various
volumes
are designed
to
avoid
duplicating
the
same
information.
Therefore,
to
deal
with
all repairs
for
any
model
,
it
is neces-
sary
that
chassis, engine, electrical and attach-
ment
volumes
be available.
DISTRIBUTION AND UPDATING
Any
additions, amendments
or
other
changes
will
be sent
to
KOMATSU distributors. Get the
most
up-to-date information before
you
start any
work.
FILING METHOD
1. See
the
page
number
on the
bottom
of
the
page. File
the
pages in correct order.
2.
Following
examples
show
how
to
read the
page number.
Example 1 (Chassis volume):
10
-3
4=
Item
number
(10. Structure
and Function)
Consecutive page
number
for
each item.
Example 2 (Engine volume):
12 -5
t
Unit
number
(1.
Engine)
Item
number
(2.
Testing and
Adjusting)
Consecutive page
number
for
each item.
3.
Additional
pages:
Additional
pages are indi-
cated
by
a hyphen (-) and
number
after
the
page
number.
File as in
the
example.
Example:
10-4 12-203
10-4-1
_j-
r--12-203-1
10-4-2 Added pages
-L
12-203-2
10-5 12-204
00-6
HOW TO
READ
THE
SHOP MANUAL
REVISED EDITION MARK
When a
manual
is revised, an
edition
mark
(G)(g)@
....)
is recorded on the
bottom
of
the
pages.
REVISIONS
Revised pages are
shown
in the LIST
OF
RE-
VISED PAGES
next
to
the
CONTENTS page.
SYMBOLS
So
that
the shop manual can be
of
ample prac-
tical use,
important
safety and
quality
portions
are marked
with
the
following
symbols.
Symbol Item
Remarks
•
Special safety precautions are
Safety necessary when
performing
the work.
Special technical precautions
*
or
other
precautions
for
pre-
Caution serving standards are neces-
sary
when
performing
the
work.
Weight
of
parts
of
systems.
~
Caution necessary when se-
Weight
lecting hoisting wire,
or
when
working posture
is
important,
etc.
~
Tightening Places
that
require special at-
tention
for
the
tightening
torque torque
during
assembly.
~
Coat Places
to
be coated
with
ad-
hesives and lubricants, etc.
6w
Places where oil, water
or
fuel
Oil,
water
must
be added, and the ca-
pacity.
•
Places
where
oil
or
water
' • '
Drain
must
be drained, and quan-
tity
to
be drained.
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