Komatsu GD705A-4 Motor Grader Shop Manual SEBM022104

Description

• Model List:
  • GD705A-4 Motor Grader

• 0.0.1. GENERAL PRECAUTIONS
• 0.0.2. PRECAUTIONS FOR WORK
• 0.0.3. PRECAUTIONS DURING WORK
• 1. FOREWARD
• 1.1. GENERAL
• 1.2. HOW TO READ THE SHOP MANUAL
• 1.2.1. VOLUMES
• 1.2.2. DISTRIBUTION AND UPDATING
• 1.2.3. FILING METHOD
• 1.2.4. REVISED EDITION MARK
• 1.2.5. REVISIONS
• 1.2.6. SYMBOLS
• 1.3. HOISTING INSTRUCTIONS
• 1.3.1. HOISTING
• 1.3.2. WIRE ROPES
• 1.4. METHOD OF DISASSEMBLING, CONNECTING PUSHPULL TYPE COUPLER
• 1.5. COATING MATERIALS
• 1.6. STANDARD TIGHTENING TORQUE
• 1.6.1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
• 1.6.2. TIGHTENING TORQUE OF HOSE NUTS
• 1.6.3. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
• 1.6.4. TIGHTENING TORQUE FOR FLARED NUTS
• 1.6.5. TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLTS AND NUTS)
• 1.6.6. TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)
• 1.6.7. TIGHTENED TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS)
• 1.7. ELECTRIC WIRE CODE
• 1.7.1. CLASSIFICATION BY THICKNESS
• 1.7.2. CLASSIFICATION BY COLOR AND CODE
• 1.8. CONVERSION TABLES
• 1.8.1. METHOD OF USING THE CONVERSION TABLE
• 1.9. UNITS
• 2. GENERAL
• 2.1. GENERAL ASSEMBLY DRAWING
• 2.2. SPECIFICATIONS
• 2.3. WEIGHT TABLE
• 2.4. LIST OF LUBRICANT AND WATER
• 3. STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
• 3.1. ENGINE MOUNTING
• 3.2. RADIATOR
• 3.3. FUEL TANK PIPING
• 3.4. ACCELERATOR CONTROL
• 3.5. POWER TRAIN
• 3.6. DAMPER
• 3.7. PTO (POWER TAKE OFF)
• 3.8. HYDROSHIFT TRANSMISSION
• 3.9. HYDROSHIFT TRANSMISSION CONTROL VALVE
• 3.10. HYDROSHIFT TRANSMISSION PIPING
• 3.11. LUBRICATION RELIEF VALVE
• 3.12. TRANSMISSION PUMP
• 3.13. TRANSMISSION CONTROL
• 3.14. DRIVE SHAFT
• 3.15. FINAL DRIVE
• 3.16. TANDEM DRIVE
• 3.17. STEERING PIPING
• 3.18. STEERING WHEEL
• 3.19. STEERING VALVE (ORBIT ROLL TYPE)
• 3.20. STEERING SYSTEM
• 3.21. STEERING PUMP
• 3.22. STEERING CYLINDER
• 3.23. FRONT AXLE
• 3.24. WHEEL
• 3.25. BRAKE PIPING
• 3.26. DISC BRAKE SYSTEM
• 3.27. PRESSURE SWITCH
• 3.28. AUTOMATIC DRAIN VALVE
• 3.29. AIR DRIER
• 3.30. AIR COMPRESSOR
• 3.31. PARKING BRAKE
• 3.32. PARKING BRAKE CONTROL
• 3.33. HYDRAULIC PIPING
• 3.34. MAIN CONTROL VALVE
• 3.35. PILOT CHECK VALVE
• 3.36. DDV (DUAL DEMAND VALVE)
• 3.37. FLOW DIVIDER VALVE
• 3.38. HYDRAULIC PUMP
• 3.39. CIRCLE ROTATION MOTOR
• 3.40. HYDRAULIC CYLINDER
• 3.41. WORK EQUIPMENT CONTROL
• 3.42. WORK EQUIPMENT
• 4. TESTING AND ADJUSTING
• 4.1. STANDARD VALUE TABLE FOR ENGINE
• 4.2. STANDARD VALUE TABLE FOR CHASSIS
• 4.3. TESTING AND ADJUSTING
• 4.3.1. TESTING AND ADJUSTING TOOL LIST (FOR ENGINE)
• 4.3.2. TESTING AND ADJUSTING VALVE CLEARANCE
• 4.3.3. MEASURING COMPRESSION PRESSURE
• 4.3.4. MEASURING BLOWBY
• 4.3.5. TESTING AND ADJUSTING FAN BELT TENSION
• 4.3.6. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 4.3.7. INCHING PEDAL STROKE AND OPERTING FORCE
• 4.3.8. HYDROSHIFT TRANSMISSION
• 4.3.9. TRANSMISSION CONTROL LEVER STROKE AND OPERATING FORCE
• 4.3.10. ADJUSTING F/R CONTROL CABLE
• 4.3.11. ADJUSTING TRANSMISSION CONTROL LINKAGE
• 4.3.12. STEERING WHEEL
• 4.3.13. CHECKING TIRE PLAY
• 4.3.14. CHECKING TIRE AIR PRESSURE
• 4.3.15. CHECKING TOEIN
• 4.3.16. CHECKING PARKING BRAKE LEVER STROKE AND OPERATING FORCE
• 4.3.17. CHECKING WEAR OF BRAKE DISC
• 4.3.18. CHECKING HYDRAULIC OIL PRESSURE
• 4.3.19. CHECKING HYDRAULIC OIL TEMPERATURE
• 4.3.20. WORK EQUIPMENT CONTROL LEVER STROKE AND OPERATING FORCE
• 4.3.21. HYDRAULIC DRIFT OF BLADE
• 4.3.22. MEASURING BLADE SINKING AMOUNT
• 4.4. TROUBLESHOOTING
• 4.4.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 4.4.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 4.4.3. POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• 4.4.4. CHECKS BEFORE TROUBLESHOOTING
• 4.4.5. CONNECTOR TYPES AND MOUNTING LOCATIONS
• 4.4.6. CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS
• 4.4.7. TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
• 4.4.7.1. E1 ENGINE DOES NOT START
• 4.4.7.2. E2 ELECTRIC SYSTEM DOES NOT WORK
• 4.4.7.3. E3 SERVICE METER DOES NOT WORK
• 4.4.7.4. E4 WATER TEMPERATURE GUAGE INDICATES ABNORMALLY HIGH TEMPERATURE
• 4.4.7.5. E5 WATER TEMPERATURE GUAGE DOES NOT WORK
• 4.4.7.6. E6 FUEL GUAGE ALWAYS INDICATES FULL
• 4.4.7.7. E7 FUEL GUAGE DOES NOT WORK
• 4.4.7.8. E8 ENGINE OIL PRESSURE GUAGE INDICATES ABNORMALLY HIGH PRESSURE
• 4.4.7.9. E9 ENGINE OIL PRESSURE GUAGE DOES NOT WORK
• 5. DISASSEMBLY AND ASSEMBLY
• 5.1. ALTERNATOR ASSEMBLY
• 5.1.1. REMOVAL AND INSTALLATION
• 5.2. STARTING MOTOR AND ASSEMBLY
• 5.2.1. REMOVAL AND INSTALLATION
• 5.3. OIL COOLER ASSMBLY
• 5.3.1. REMOVAL AND INSTALLATION
• 5.4. HYDROSHIFT TRANSMISSION OIL COOLER ASSEMBLY
• 5.4.1. REMOVAL AND INSTALLATION
• 5.5. WATER PUMP ASSEMBLY
• 5.5.1. REMOVAL AND INSTALLATION
• 5.6. FUEL INJECTION PUMP ASSEMBLY
• 5.6.1. REMOVAL AND INSTALLATION
• 5.7. AIR COMPRESSOR ASSEMBLY
• 5.7.1. REMOVAL AND INSTALLATION
• 5.8. TURBOCHARGER ASSEMBLY
• 5.8.1. REMOVAL AND INSTALLATION
• 5.9. NOZZLE HOLDER ASSEMBLY
• 5.9.1. REMOVAL AND INSTALLATION
• 5.10. CYLINDER HEAD ASSEMBLY
• 5.10.1. REMOVAL
• 5.10.2. INSTALLATION
• 5.11. RADIATOR ASSEMBLY
• 5.11.1. REMOVAL
• 5.11.2. INSTALLATION
• 5.12. FUEL TANK ASSEMBLY (INC. HYDRAULIC TANK)
• 5.12.1. REMOVAL
• 5.12.2. INSTALLATION
• 5.13. ENGINE ASSEMBLY (INC. TRANSMISSION)
• 5.13.1. REMOVAL
• 5.13.2. INSTALLATION
• 5.14. HYDROSHIFT TRANSMISSION ASSEMBLY
• 5.14.1. DISASSEMBLY
• 5.14.2. ASSEMBLY
• 5.15. CAGE AND REVERSE CARRIER ASSEMBLY
• 5.15.1. DISASSEMBLY AND ASSEMBLY
• 5.16. T SPEED AND 2ND SPEED CARRIER ASSEMBLY
• 5.16.1. DISASSEMBLY
• 5.16.2. ASSEMBLY
• 5.17. HIGH REVOLUTION CLUTCH ASSEMBLY
• 5.17.1. DISASSEMBLY
• 5.17.2. ASSEMBLY
• 5.18. PLANETARY GEAR
• 5.18.1. DISASSEMBLY AND ASSEMBLY
• 5.19. HYDROSHIFT TRANSMISSION PUMP ASSEMBLY
• 5.19.1. REMOVAL AND INSTALLATION
• 5.20. TANDEM AND FINAL DRIVE ASSEMBLY
• 5.20.1. REMOVAL
• 5.20.2. INSTALLATION
• 5.21. FINAL DRIVE ASSEMBLY
• 5.21.1. DISASSEMBLY
• 5.21.2. ASSEMBLY
• 5.22. BEVEL GEAR ASSEMBLY
• 5.22.1. DISASSEMBLY
• 5.22.2. ASSEMBLY
• 5.23. BEVEL PINION ASSEMBLY
• 5.23.1. REMOVAL
• 5.23.2. INSTALLATION
• 5.23.3. DISASSEMBLY
• 5.23.4. ASSEMBLY
• 5.24. SPROCKET ASSEMBLY
• 5.25. FRONT AXLE ASSEMBLY
• 5.25.1. REMOVAL
• 5.25.2. INSTALLATION
• 5.26. STEERING PUMP ASSEMBLY
• 5.26.1. REMOVAL AND INSTALLATION
• 5.27. STEERING CYLINDER ASSEMBLY
• 5.27.1. REMOVAL AND INSTALLATION
• 5.28. WHEEL BRAKE ASSEMBLY
• 5.28.1. DISASSEMBLY
• 5.28.2. ASSEMBLY
• 5.29. HYDRAULIC TANK
• 5.29.1. REMOVAL AND INSTALLATION
• 5.30. HYDRAULIC PUMP ASSEMBLY
• 5.30.1. REMOVAL AND INSTALLATION
• 5.31. HYDRAULIC CONTROL VALVE ASSEMBLY
• 5.31.1. REMOVAL
• 5.31.2. INSTALLATION
• 5.32. BLADE LIFT CYLINDER ASSEMBLY
• 5.32.1. REMOVAL AND INSTALLATION
• 5.33. DRAWBAR SHIFT CYLINDER ASSEMBLY
• 5.33.1. REMOVAL AND INSTALLATION
• 5.34. BLADE SIDE SHIFT CYLINDER ASSEMBLY
• 5.34.1. REMOVAL
• 5.34.2. INSTALLATION
• 5.35. LEANING CYLINDER ASSEMBLY
• 5.35.1. REMOVAL AND INSTALLATION
• 5.36. ARTICULATE CYLINDER ASSEMBLY
• 5.36.1. REMOVAL AND INSTALLATION
• 5.37. POWER TILT CYLINDER ASSEMBLY
• 5.37.1. REMOVAL AND INSTALLATION
• 5.38. HYDRAULIC CYLINDER ASSEMBLY
• 5.38.1. DISASSEMBLY
• 5.38.2. ASSEMBLY
• 5.39. BLADE ASSEMBLY
• 5.39.1. REMOVAL AND INSTALLATION
• 5.40. CIRCLE ROTATION GEAR AND HYDRAULIC MOTOR ASSEMBLY
• 5.40.1. REMOVAL AND INSTALLATION
• 5.40.2. DISASSEMBLY
• 5.40.3. ASSEMBLY
• 6. OTHERS
• 6.1. HYDRAULIC CIRCUIT DIAGRAM (STD SPEC.)
• 6.2. HYDRAULIC CIRCUIT DIAGRAM (DDV SPEC.)
• 6.3. HYDROSHIFT TRANSMISSION CONTROL CIRCUIT DIAGRAM
• 6.4. ELECTRICAL CIRCUIT DIAGRAM (1/2)
• 6.5. ELECTRICAL CIRCUIT DIAGRAM (2/2)
• 6.6. ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER
• 6.7. ELECTRICAL CIRCUIT DIAGRAM FOR CAB