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SEBM022103

MACHINE MODEL SERIAL NUMBER


GD705A-4 23001 and up

• 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.
• GD705A-4 mounts the S6D125-1 engine.
For details of the engine, see the 6D125 Series Engine Shop Manual.

© 2002
All Rights Reserved
Printed in Japan 10-02 (01)
00-1
GENERAL

CONTENTS

No. of page
01 GENERAL ............................................................................................................................ 01-1

10 STRUCTURE, FUNCTION AND


MAINTENANCE STANDARD............................................ 10-1

20 TESTING AND ADJUSTING ........................................................................ 20-1

30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1

90 OTHERS ................................................................................................................................ 90-1

00-2 GD705A-4
LIST OF REVISED PAGES

The affected pages are indicated by using the fol- Mark Indication Action required
lowing marks. It is requested that necessary actions
be taken to these pages according to the table New Page to be added Add
below.
Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised


or made additions.

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of


Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
00-1 10-5 10-44 10-84 10-122
00-2 10-6 10-45 10-85 10-123-1
00-2-1 10-7 10-46 10-86 10-123-3
00-2-2 10-8 10-47 10-87 10-123-4
00-3 10-9 10-48 10-88 10-123-5
00-4 10-10 10-50 10-89 10-123-6
00-5 10-11 10-51 10-90 10-123-7
00-6 10-12 10-52 10-91 10-123-8
00-7 10-13 10-54 10-92 10-123-9
00-8 10-14 10-55 10-93 10-123-10
00-9 10-15 10-56 10-94 10-123-11
00-10 10-16 10-57 10-95 10-123-12
00-11 10-17 10-58 10-96 10-123-13
00-12 10-18 10-59 10-97 10-123-14
00-13 10-19 10-60 10-98 10-123-15
00-14 10-20 10-61 10-99 10-123-16
00-15 10-21 10-62 10-100 10-123-17
00-16 10-22 10-63 10-101 10-123-18
00-17 10-23 10-64 10-102 10-123-19
00-18 10-24 10-65 10-103 10-124
00-19 10-25 10-66 10-104 10-125
00-20 10-26 10-67 10-106 10-127
00-21 10-27 10-68 10-108 10-128
00-22 10-28 10-70 10-108-1 10-129
10-29 10-71 10-109 10-130
01-1 10-30 10-72 10-110 10-131
01-2 10-31 10-73 10-111 10-132
01-3 10-32 10-74 10-112 10-133
01-4 10-33 10-75 10-113 10-134
01-5 10-34 10-76 10-114 10-135
01-6 10-35 10-77 10-115 10-136
01-7 10-37 10-78 10-116 10-137
10-38 10-79 10-117 10-138
10-1 10-39 10-80 10-118 10-139
10-2 10-40 10-81 10-119 10-140
10-3 10-42 10-82 10-120 10-141
10-4 10-43 10-83 10-121 10-142

GD705A-4 00-2-1
LIST OF REVISED PAGES

Time of Time of Time of Time of Time of


Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
10-143 20-124 30-17 30-65 30-114
10-144 30-18 30-66 30-115
10-145 20-201 30-19 30-67 30-116
10-146 20-202 30-20 30-68 30-117
10-147 20-203 30-21 30-69 30-118
10-148 20-204 30-22 30-70 30-119
10-149 20-205 30-23 30-71 30-120
10-150 20-206 30-24 30-72 30-121
10-151 20-207 30-25 30-73 30-122
10-152 20-208 30-26 30-74 30-123
10-153 20-209 30-27 30-75 30-124
10-154 20-210 30-28 30-76 30-125
10-155 20-211 30-29 30-77 30-126
10-156 20-212 30-30 30-78 30-127
10-157 20-213 30-31 30-79 30-128
10-158 20-214 30-32 30-80 30-129
10-159 20-215 30-33 30-81 30-130
20-216 30-34 30-82 30-131
20-1 20-217 30-35 30-83 30-132
20-2 20-218 30-36 30-84 30-133
20-3 20-219 30-37 30-85 30-134
20-4 30-38 30-86 30-135
20-5 20-251 30-39 30-88 30-136
20-252 30-40 30-89 30-137
20-101 20-253 30-41 30-90 30-138
20-102 20-254 30-42 30-91 30-139
20-103 20-255 30-44 30-92 30-140
20-104 20-256 30-45 30-93 30-141
20-105 20-257 30-46 30-94 30-142
20-106 20-258 30-47 30-95 30-143
20-107 20-259 30-48 30-96 30-144
20-108 30-49 30-97 30-145
20-109 30-1 30-50 30-98
20-110 30-2 30-51 30-100 90-1
20-111 30-3 30-52 30-101 90-2
20-112 30-4 30-53 30-102 90-3
20-113 30-5 30-54 30-103 90-3-1
20-114 30-6 30-55 30-104 90-3-2
20-115 30-7 30-56 30-105 90-4
20-116 30-8 30-57 30-106 90-5
20-117 30-9 30-58 30-107 90-7
20-118 30-10 30-59 30-108 90-9
20-119 30-12 30-60 30-109 90-11
20-120 30-13 30-61 30-110
20-121 30-14 30-62 30-111
20-122 30-15 30-63 30-112
20-123 30-16 30-64 30-113

00-2-2 GD705A-4
SAFETY SAFETY NOTICE

SAFETY
SAFETY NOTICE

IMPORTANT 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 ¤ is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep


tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.

00-3
SAFETY SAFETY NOTICE

PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, 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 minimum of
gasoline when washing electrical parts.

00-4
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 judge-
ments. 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 fur-
ther 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 under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.

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" with "Causes" are also included in this section.

DISASSEMBLY AND ASSEMBLY


This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.

MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.

OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

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
FOREWORD HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:

Chassis volume: Issued for every machine model REVISIONS


Engine volume: Issued for each engine series
Revised pages are shown in the LIST OF REVISED

}
Electrical volume: Each issued as one
PAGES next to the CONTENTS page.
Attachments volume: · volume to cover all
models
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.

DISTRIBUTION AND UPDATING


Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
¤ Safety
Special safety precautions
are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order.
2. Following examples show how to read the page s Caution
tions or other precautions
for preserving standards
are necessary when per-

4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting

3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special

2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with

5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or

6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204

00-6
FOREWORD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

HOISTING

¤ Heavy parts (25 kg or more) must be lifted


Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and

4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol

• If a part cannot be smoothly removed from the


machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.

¤
but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.

★ The allowable load value is estimated to be one-


sixth or one-seventh of the breaking strength of
the rope used.

2) Sling wire ropes from the middle portion of the


hook.

00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, release


the residual pressure from the hydraulic tank.
Type 1

For details, see TESTING AND ADJUSTING,


Releasing residual pressure from hydraulic

¤
tank.

Even if the residual pressure is released from


the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.

Disconnection
1) Release the residual pressure from the hydrau-
lic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.

2) Hold adapter (1) and push hose joint (2) into


mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).

3) After hose joint (2) is pushed into adapter (3),


press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)

4) Hold hose adapter (1) or hose (5) and pull it out.


(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.

Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).

2) After inserting the hose in the mating adapter


perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.

00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly

3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.

• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection

00-9
FOREWORD COATING MATERIALS

COATING MATERIALS

★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.

Category Komatsu code Part No. Q'ty Container Main applications, featuresr

• Used to prevent rubber gaskets,


LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.

• Used in places requiring an imme-


diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oet hl ene and vi nyl chl oride),
rubber, metal and non-metal.

• Features: Resistance to heat and


LT-2 09940-00030 50 g Polyethylene chemicals
container • Used for anti-loosening and seal-
ant purpose for bolts and plugs.

Adhesive: • Used as adhesive or sealant for


790-129-9060 metal, glass and plastic.
(Set of 1 kg
Hardenin
LT-3 adhesive and Can
hardening g
agent:
agent)
500 g
Adhesives

Polyethylene • Used as sealant for machined


LT-4 790-129-9040 250 g holes.
container

Holtz • Used as heat-resisting sealant for


MH 705 790-126-9120 75 g Tube repairing engine.

• Quick hardening type adhesive


Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of met-
als, rubbers, plastics and woods.

• Quick hardening type adhesive


• Quick cure type (max. strength af-
Aron-alpha Polyethylene
201 790-129-9130 2g container ter 30 minutes)
• Used mainly for adhesion of rub-
bers, plastics and metals.

Loctite Polyethylene • Resistance to heat, chemicals


79A-129-9110 50 cc • Used at joint portions subject to
648-50 container
high temperatures.

• Used as adhesive or sealant for


LG-1 790-129-9010 200 g Tube gaskets and packing of power
train case, etc.

• Used as sealant for various


threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can • Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.

• Features: Silicon based, resist-


ance to heat, cold
• Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
• mab Used as sealant for oil pan,
final drive case, etc.

00-10
FOREWORD COATING MATERIALS

Category Komatsu code Part No. Q'ty Container Main applications, featuresr

• Ftures: Silicon based, quick hard-


ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.

Three bond • Used as heat-resisting sealant for


790-129-9090 100 g Tube repairing engine.
1211

• Used as lubricant for sliding por-


LM-G 09940-00051 60 g Can
tion (to prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
• Used as lubricant for linkage,
bearings, etc.

SYG2-400LI • General purpose type


SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI

SYG2-400CA • Used for normal temperature,


Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA

Molybdenum 400 g • Used for places with heavy load


disulphide SYG2-400M (10 per Belows type
lubricant case)

00-11
FOREWORD STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE


STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.

Thread diameter Width across


of bolt flats

mm mm Nm kgm

6 10 13.2 0 1.4 1.35 0 0.15


8 13 31 03 3.2 0 0.3
10 17 66 07 6.7 0 0.7
12 19 113 0 10 11.501
14 22 177 0 19 1802
16 24 279 0 30 28.5 0 3
18 27 382 0 39 39 0 4
20 30 549 0 59 56 0 6
22 32 745 0 83 76 0 8.5
24 36 927 0 103 94.5 0 10.5

27 41 1320 0 140 135 0 15


30 46 1720 0 190 175 0 20
33 50 2210 0 240 225 0 25
36 55 2750 0 290 280 0 30
39 60 3290 0 340 335 0 35

Thread diameter Width across


of bolt flats

mm mm Nm kgm

6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8

Sealing surface

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS


★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
SAD00483
the table below.
Thread diameter Width across flat Tightening torque

mm mm Nm kgm

14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0

00-12
FOREWORD STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS


★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS


★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter Width across flat Tightening torque


Norminal No.
mm mm Nm kgm

02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS


★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter Width across flat Tightening torque


Norminal No.
mm mm Nm kgm

08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0

00-13
FOREWORD STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 ENGINE SERIES


1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 0
10 2 1.02 0 0.20
8 0
24 4 2.45 0 0.41
10 0
43 6 4.38 0 0.61
12 0
77 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 8 20 0.81 0 0.20
8 0
10 2 1.02 0 0.20
10 0
12 2 1.22 0 0.20
12 0
24 4 2.45 0 0.41
14 0
36 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter Tightening torque
inch Nm kgm
1 / 16 3 10 0.31 0 0.10
1/8 8 20 0.81 0 0.20
1/4 0
12 2 1.22 0 0.20
3/8 0
15 2 1.53 0 0.41
1/2 0
24 4 2.45 0 0.41
3/4 0
36 5 3.67 0 0.51
1 0
60 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Nominal thread
Range Target Thread size size - Threads per Root diameter
(mm) (mm) (Reference)
inch, Thread series
9
02 19 35 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 – –
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 – –
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 – –

00-14
FOREWORD ELECTRIC WIRE CODE

ELECTRIC WIRE CODE


In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal


etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE

Circuits
Priori-
ty Classi- Charging Ground Starting Lighting Instrument Signal Other
fication

Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue

Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White

Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow

Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow

Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black

Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE

CONVERSION TABLE

METHOD OF USING THE CONVERSION TABLE


The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.

EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

B
Millimeters to inches

1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354


10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536

C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

00-16
FOREWORD CONVERSION TABLE

Millimeters to Inches
1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354


10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound
1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84


10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

00-17
FOREWORD CONVERSION TABLE

Liter to U.S. Gallon


1l = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378


10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

Liter to U.K. Gallon


1l = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980


10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

00-18
FOREWORD CONVERSION TABLE

kgm to ft. lb
1 kgm = 7.233 ft. lb

0 1 2 3 4 5 6 7 8 9

0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1


10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

00-19
FOREWORD CONVERSION TABLE

kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9

0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0


10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

00-20
FOREWORD CONVERSION TABLE

Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F

°C °F °C °F °C °F °C °F

–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8


–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8


–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8


–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0

–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8


–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0


–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0


–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0


–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

00-21
FOREWORD UNITS

UNITS

In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.

Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}

00-22
 GENERAL

General assembly drawing . . . . . . . . . . . . . . . 01-2


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
Weight table . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5
List of lubricant and water . . . . . . . . . . . . . . . . 01-6

GD705A-4 01-1
GENERAL GENERAL ASSEMBLY DRAWING

12
GENERAL ASSEMBLY DRAWING

Unit: mm

A B C

Dimensions 9,270 3,365 2,800

01-2 GD705A-4
GENERAL SPECIFICATIONS

12
SPECIFICATIONS

Model GD705A-4

Serial Number 23,001 and up

Operating weight kg 17,620


Weight

On front axle (27.7%) kg 4,885


On rear axle (72.3%) kg 12,735
Overall length mm 9,270
Overall width mm 2,800
Overall height mm 3,365
Dimensions

Wheel base mm 6,450


Rear wheel base mm 1,730
Tread (Front) mm 2,300
Tread (Rear) mm 2,300
Ground clearance mm 410
1st km/h 3.9
2nd km/h 5.2
3rd km/h 7.6
4th km/h 11.0
Forward
5th km/h 15.2
6th km/h 20.5
7th km/h 30.0
Travel speed

8th km/h 43.0


Performance

1st km/h 4.1


2nd km/h 5.6
3rd km/h 8.1
4th km/h 11.7
Reverse
5th km/h 16.2
6th km/h 21.8
7th km/h 31.9
8th km/h 45.9
Maximum drawbar pull kN {kg} 100 {10,180}
Turning radius m 7.5
Over turn angle deg 35

GD705A-4 01-3
GENERAL SPECIFICATIONS

12

Model GD705A-4

Serial Number 23,001 and up

Tire (Front) 16.00 - 24 - 12 PR 0.22MPa {2.2 kg/cm2}


Wheels

Tire (Rear) 16.00 - 24 - 12 PR 0.22MPa {2.2 kg/cm2}


Rim (Front) 1,000 VA x 24 SDC
Rim (Rear) 1,000 VA x 24 SDC
Blade dimension
(Length x Height x Thickness) mm 4,320 x 700 x 25
Cutting edge dimension
(Number - Length x Width x Thickness) mm 2 - 2,134 x 203 x 16
Blade

Turning angle deg 360


Cutting angle
[Standard] deg 34
[Maximum] deg 84
[Minimum] deg 26
Engine model Komatsu S6D125-1 Diesel Engine
4 cycle, water cooled, overhead valve, direct
type
injection type with turbocharger
Cylinder number - bore x stroke mm 6 - 125 x 150
Piston displacement O {cc} 11.045 {11,045}
Firing order 1-5-3-6-2-4
Overall length mm 1,556
Dimension

Overall width mm 877

Overall height mm 1,703

kW/rpm 149/2,000
Flywheel horsepower
{HP/rpm} {200/2,000}
Engine

Nm/rpm 902/1,300
Performance

Maximum torque
{kgm/rpm} {92/1,300}
High idling rpm 2,200 ± 50
Low idling rpm 650 +- 050
g/kW·h 204
Fuel consumptions ratio
{g/HP·h} {152}
Dry weight kg 1,175
Fuel oil Diesel fuel ASTM D975 No. 2 or No. 1
Fuel pump Bosch PE-P type
Governor Bosch RSV centrifugal, all speed
Alternator 24V, 35A
Starting motor 24V, 7.5 kW
Battery 12V, 200Ah x 2

01-4 GD705A-4
GENERAL WEIGHT TABLE

12
WEIGHT TABLE

Unit: kg

Model GD705A-4

Serial Number 23,001 and up

Drawbar shift cylinder assembly 43

Blade side shift cylinder assembly 72

Steering cylinder 11

Articulate cylinder 44

Ripper cylinder (dry) ---

Hydraulic tank (dry) 64

(KFP3223-23CFESE)
Hydraulic pump
10

(KFP3223CFMSE)
Circle reverse and ripper pump
5

(KFP2233CVKR)
Steering pump
8

(KFP3250AFMSSH)
Transmission pump
10

Circle rotation motor 19

GD705A-4 01-5
GENERAL LIST OF LUBRICANT AND WATER

12
LIST OF LUBRICANT AND WATER

AMBIENT TEMPERATURE CAPACITY


KIND OF
RESERVOIR -22 -4 14 32 50 68 86 104 122°F
FLUID Specified
-30 -20 -10 0 10 20 30 40 50°C

SAE30CD

SAE10WCD
Engine oil pan 30 O
SAE10W-30CD

SAE 15W-40CD
Engine oil

Transmission case 48 O

Final drive case SAE30CD 40 O

Tandem drive case SAE10WCD


105 O
(each)

SAE140

Circle reverse gear


Gear oil SAE90 12 O
case
SAE80

Hydraulic system Engine oil SAE10WCD 120 O

Brake
Brake tank SAE J-1703 
fluid

ASTM D975 No. 2


Diesel
Fuel tank 400 O
fuel

Cooling system Water Add antifreeze 55 O

ASTM D975 No. 1

01-6 GD705A-4
GENERAL LIST OF LUBRICANT AND WATER

12
REMARK
• When fuel sulphur content is less than 0.5%, change oil in the oil pan in accordance with the periodic
maintenance hours described in this manual.

Change oil according to the following table if fuel sulphur content is above 0.5%.

Change interval of oil in


Fuel sulphur content
engine oil pan

0.5 to 1.0% 1/2 of regular interval

Above 1.0% 1/4 of regular interval

• When starting the engine in atmospheric temperature of lower than 0°C, be sure to use engine oil of
SAE10W, SAE10W-30 and SAE15W-40, even though an atmospheric temperature goes up 10°C or more
in the day time.

• Use API classification CD engine oil. If API classification CC is used, reduce the engine oil change inter-
val to half.

• There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to
add single grade oil that matches the temperature in the table.

• We recommend Komatsu genuine oil which has been specifically formulated and approved for use in
engine and hydraulic work equipment applications.

Specific capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.

ASTM: American Society of Testing and Material


SAE: Society of Automotive Engineers
API: American Petroleum Institute

GD705A-4 01-7
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD

Engine mounting ..............................................10-2 Brake piping .................................................. 10-80


Radiator ...........................................................10-3 Disc brake system ......................................... 10-82
Fuel tank piping ...............................................10-4 Brake valve ................................................... 10-86
Accelerator control ........................................... 10-5 Relay valve .................................................... 10-90
Power train ......................................................10-6 Air governor ................................................... 10-92
Damper ............................................................10-8 Check valve ................................................... 10-94
PTO .................................................................10-9 Air reservoir ................................................... 10-95
HYDROSHIFT transmission .......................... 10-11 Safety valve ................................................... 10-95
HYDROSHIFT transmission control valve .....10-22 Pressure switch ............................................. 10-96
HYDROSHIFT transmission piping ...............10-37 Automatic drain valve .................................... 10-98
Lubrication relief valve ...................................10-38 Air drier ........................................................ 10-100
Transmission pump .......................................10-39 Air compressor ............................................ 10-102
Transmission control ......................................10-42 Parking brake .............................................. 10-103
Drive shaft .....................................................10-44 Parking brake control .................................. 10-106
Final drive ......................................................10-45 Hydraulic piping ........................................... 10-108
Tandem drive .................................................10-50 Main control valve ....................................... 10-112
Steering piping ...............................................10-54 Pilot check valve ......................................... 10-116
Steering wheel ...............................................10-58 DDV (Dual Demand Valve) ....................... 10-123-1
Steering valve ................................................10-59 Flow divider valve ................................... 10-123-18
Steering system .............................................10-60 Hydraulic pump ........................................... 10-124
Steering pump ...............................................10-67 Circle rotation motor .................................... 10-127
Steering cylinder ............................................10-70 Hydraulic cylinder ........................................ 10-130
Front axle .......................................................10-72 Work equipment control .............................. 10-140
Wheel ............................................................10-78 Work equipment .......................................... 10-142

GD705A-4 10-1
STRUCTURE AND FUNCTION ENGINE MOUNTING

12
ENGINE MOUNTING

1. Bracket
2. Lock plate
3. Plate
4. Shim
5. Plate
6. Dust indicator

10-2 GD705A-4
STRUCTURE AND FUNCTION RADIATOR

12
RADIATOR

Radiator Core type: Model G6 1. Drain plug


Total radiation area: 46.89 m2 2. Radiator core
3. Water filler cap
4. Inlet hose
5. Fan
6. Outlet hose

GD705A-4 10-3
STRUCTURE AND FUNCTION FUEL TANK PIPING

12
FUEL TANK PIPING

Fuel tank capacity: 400 O 1. Fuel tank


2. Fuel filler cap
3. Strainer
4. Fuel line valve
5. Drain cock

10-4 GD705A-4
STRUCTURE AND FUNCTION ACCELERATOR CONTROL

12
ACCELERATOR CONTROL

1. Fuel control lever


2. Parking brake lever
3. Accelerator pedal
4. Stopper for pedal
5. Accelerator return spring

GD705A-4 10-5
STRUCTURE AND FUNCTION POWER TRAIN

12
POWER TRAIN

The power from the diesel engine (1) is transmitted 1. Engine


to the HYDROSHIFT transmission (3) through the 2. Joint
joint (2). In the HYDROSHIFT transmission in
response to the load and the forward-reverse rota- 3. HYDROSHIFT transmission
tion direction, the clutch is selected and the power is 4. Parking brake
transmitted to the final drive (6) through the drive
5. Drive shaft
shaft (5).
Here, the power is separated into left and right per- 6. Final drive
pendicular directions and transmitted to the tandem 7. Tandem drive
drive (7) through the rear axle.
The tandem drive transmits the power to the wheel
by a chain and the machine travels.

10-6 GD705A-4
STRUCTURE AND FUNCTION POWER TRAIN

12

1. Engine
2. Joint
3. HYDROSHIFT transmission
4. Parking brake
5. Drive shaft
6. Final drive (with differential)
7. Tandem drive

GD705A-4 10-7
STRUCTURE AND FUNCTION DAMPER

12
DAMPER

1. Disc
2. Bolt
3. Washer
4. Flywheel housing
5. HYDROSHIFT transmission case

10-8 GD705A-4
STRUCTURE AND FUNCTION PTO

12
PTO (POWER TAKE OFF)

1. Joint bolt
2. Joint bolt

GD705A-4 10-9
STRUCTURE AND FUNCTION PTO

12

3. Gear (35 teeth) 7. Gear 11. Snap ring


4. Gear (57 teeth) 8. Housing 12. Bearing
5. Flywheel (137 teeth) 9. Gear (52 teeth) 13. Cover
6. Bolt 10. Gear 14. Gear
15. Snap ring
16. Bearing

10-10 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION

12
HYDROSHIFT TRANSMISSION

GD705A-4 10-11
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION

12
The GD705A has a planetary type transmission Reduction ratio
which combines a planetary gear mechanism and Speed Total Each speed
disc clutch for 8 forward speeds and 8 reverse stage RF4321LH T/F reduction ratio
speeds. ratio
Out of the 8 sets of planetary gear type disc
F1 7.823 8.637 1.349
clutches, 3 clutches are fixed by oil pressure via
the control valve to select one revolving direction F2 5.798 6.398
1.465
and one revolving speed. F3 3.958 4.367
The R clutch is for reverse travel and F clutch for 1.435
F4 2.758 3.043
forward travel. The correspondence between 1.383
clutch combinations and speeds are as follows: F5 1.994 2.200
1.349
F6 1.478 1.631
1.465
Clutch Speed Clutch Speed F7 1.009 1.113
1st 1st speed 1st 5th speed F8 0.703 1.103 0.776 1.435
2nd 2nd speed 2nd 6th speed R1 7.341 (32/29) 8.100 1.349
L H
3rd 3rd speed 3rd 7th speed R2 5.440 6.003 1.465
4th 4th speed 4th 8th speed R3 3.714 4.098
1.435
R4 2.588 2.856
1.383
R5 1.871 2.065
1.349
R6 1.387 1.530
R7 0.947 1.045 1.465
R8 0.660 0.728 1.349

1. F, R housing 23. Shaft


2. F piston 24. Cage
3. 4th planetary pinion shaft 25. Shaft
4. Sleeve 26. Cage
5. 4th piston 27. Output shaft
6. 4th, 3rd housing 28. L carrier
7. 3rd piston 29. 1st carrier
8. 3rd, 4th carrier 30. 2nd carrier
9. 2nd housing 31. Shaft
10. 2nd piston 32. 3rd planetary pinion shaft
11. 2nd planetary piston shaft 33. F carrier
12. 1st housing 34. R carrier
13. 1st piston 35. Housing
14. 1st planetary pinion shaft 36. Input shaft
15. L housing 37. Cage
16. L piston 38. R planetary pinion shaft
17. L planetary pinion shaft 39. F planetary pinion shaft
18. H piston 40. Cover
19. Spring 41. R piston
20. Cage 42. Cage
21. Transfer case 43. Coupling
22. Cage 44. Shaft

10-12 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION

12

PLANETARY GEAR SYSTEM


Planetary gear system (structure)
The planetary gear mechanism consists of sun
gear A, planetary pinion B, ring gear C, and car-
rier D.
The planetary pinion is supported by the carrier
and meshes with the sun gear and the ring gear.

When the ring gear is fixed,


The sun gear A revolutions are transmitted to the
planetary pinions B.
The planetary pinions are meshed with the ring
gear C.
Since the ring gear is fixed, it cannot revolve as it
is. Therefore, the planetary pinions revolve on
their axes while revolving around the sun gear
along the ring gear. At this time the torque of the
sun gear becomes carrier D torque and is trans- A. Sun gear
mitted. The direction of rotation of the carrier is B. Planetary pinion
the same as that of the sun gear. C. Ring gear
D. Planetary carrier
When the carrier is fixed,
The sun gear A revolutions are transmitted to the
planetary pinions B.
Because carrier D is fixed, the planetary pinions
meshed with the sun gear revolve on their own
axes at their positions. The ring gear C which is
meshed with planetary pinions revolves in the
opposite direction to the sun gear, and the sun
gear torque becomes the torque of the ring gear
and is transmitted.

Combinations such as → Sun gear → Planetary


pinion → Ring gear or carrier, is the structure of
R.F. 3rd, 2nd, L clutches. However, for R clutch,
the sun gear becomes the power source and
transmits power to the ring gear, and for F, L
clutch, the sun gear is the power source and trans-
mits power to the carrier, and for 3rd and 2nd
clutches the carrier is the power source and trans-
mits power to 3rd and 2nd sun gears.

GD705A-4 10-13
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION

12

DISC CLUTCH
In order to fix the ring gear a disc clutch made up
of piston (26), plate (50), disc (51), pin (52), piston
return spring (53), washer spring (54), etc., is
installed. The internal teeth of the disc mesh with
the external teeth of the ring gear.
The plate is fixed in the direction of rotation by the
meshing of the notched protrusions of the outer
diameter and pins (52) fixed into the housing (6).
The piston is also fixed in the direction of rotation
in the same way.

Clutch "ENGAGED" (Fixed)


Hydraulic oil from the control valve passes
through the port of the housing (6) and transmits
pressure to the back of the piston (26). The piston
presses disc (51) and plate (50) and the friction
stops the disc rotation, resulting in fixing ring gear
G which is meshing with the interior teeth of the
disc.

Clutch "DISENGAGED" (Released)


When the hydraulic oil from the control valve is
interrupted, the piston return spring (53) acts to
return the piston (26) to its original position, the
plate (50) and disc (51) friction is released and the
ring gear G becomes neutral.
The washer spring (54) installed between the pin
(52) and the plate acts to return the piston more
quickly when the clutch is disengaged, improve
plate and disc separation and prevent the disc
drag rotation.

10-14 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION

12

ROTARY CLUTCH

Clutch "ENGAGED" (Fixed)


Hydraulic oil from the control valve goes to the
back of the piston (13) through the port of the
cage (20).
The piston force-presses disc (55) and plate (56).
The clutch is engaged by meshing the internal
teeth of the disc and the external teeth of the gear
N and the external teeth of the plate and the inter-
nal teeth of the drum (2nd carrier, (10)).
The gear and drum become one unit and revolve.

Clutch "DISENGAGED" (Released)


When the hydraulic oil from the control valve is
interrupted, the piston is returned by the disc
spring (12).
On the other hand, when the piston is returned to
its original position, and the clutch is disengaged,
the wave spring (57) between plates (56) sepa-
rates plate and disc (55) completely, and prevents
drag rotation.

GD705A-4 10-15
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION

12

10-16 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION

12

Unit: mm

No. Check item Criteria Remedy

No. 1 sun gear-to-No. 1 planetary Standard clearance Clearance limit


1
gear backlash 0.13 - 0.32 ---
No. 2 sun gear-to-No. 2 planetary
2 0.13 - 0.34 ---
gear backlash
No. 3 sun gear-to-No. 3 planetary
3 0.13 - 0.32 ---
gear backlash
No. 4 sun gear-to-No. 4 planetary
4 0.13 - 0.32 ---
gear backlash
No. 5 sun gear-to-No. 5 planetary
5 0.13 - 0.32 ---
gear backlash
No. 6 sun gear-to-No. 6 planetary
6 0.11 - 0.28 ---
gear backlash
No. 7 sun gear-to-No. 7 planetary
7 0.13 - 0.32 ---
gear backlash

8 Drive gear-to-idle gear backlash 0.26 - 0.61 ---

No. 1 planetary gear-to-No. 1 ring


9 0.14 - 0.43 ---
gear backlash
No. 2 planetary gear-to-No. 2 ring
10 0.14 - 0.37 ---
gear backlash
No. 3 planetary gear-to-No. 3 ring
11 0.14 - 0.43 ---
gear backlash
No. 4 planetary gear-to-No. 4 ring Replace
12 0.13 - 0.42 ---
gear backlash
No. 5 planetary gear-to-No. 5 ring
13 0.14 - 0.43 ---
gear backlash
No. 6 planetary gear-to-No. 6 ring
14 0.12 - 0.22 ---
gear backlash
No. 7 planetary gear-to-No. 7 ring
15 0.14 - 0.43 ---
gear backlash

16 Thickness of No. 1 clutch disc 5 4.7

17 Thickness of No. 1 clutch plate 5 4.7

18 Thickness of No. 1 clutch 35 32.9

19 Thickness of No. 2 clutch disc 5 4.7

20 Thickness of No. 2 clutch plate 5 4.7

21 Thickness of No. 2 clutch 35 32.9

22 Thickness of No. 3 clutch disc 5 4.7

23 Thickness of No. 3 clutch plate 5 4.7

24 Thickness of No. 3 clutch 25 23.5

GD705A-4 10-17
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION

12

10-18 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION

12

Unit: mm

No. Check item Criteria Remedy

Standard clearance Clearance limit


25 Thickness of No. 4 clutch disc
5 4.7

26 Thickness of No. 4 clutch plate 5 4.7

27 Thickness of No. 4 clutch 25 23.5

28 Thickness of No. 5 clutch disc 5 4.7

29 Thickness of No. 5 clutch plate 5 4.7

30 Thickness of No. 5 clutch 15 14.1

31 Thickness of No. 6 clutch disc 5 4.7

32 Thickness of No. 6 clutch plate 5 4.7

33 Thickness of No. 6 clutch 25 23.5

34 Thickness of No. 7 clutch disc 5 4.7

35 Thickness of No. 7 clutch plate 5 4.7

36 Thickness of No. 7 clutch 45 42.3


Replace
37 Thickness of No. 8 clutch disc 5 4.7

38 Thickness of No. 8 clutch plate 5 4.7

39 Thickness of No. 8 clutch 35 32.9

No. 1 clutch disc-to-No. 1 ring


40 0.29 - 0.67 ---
gear backlash
No. 2 clutch disc-to-No. 2 ring
41 0.29 - 0.67 ---
gear backlash
No. 3 clutch disc-to-No. 3 ring
42 0.29 - 0.67 ---
gear backlash
No. 4 clutch disc-to-No. 4 ring
43 0.29 - 0.67 ---
gear backlash
No. 5 clutch disc-to-No. 5 ring
44 0.29 - 0.67 ---
gear backlash
No. 6 clutch disc-to-No. 6 ring
45 0.19 - 0.54 ---
gear backlash
No. 7 clutch disc-to-No. 7 ring
46 0.29 - 0.67 ---
gear backlash
No. 8 clutch disc-to-No. 8 ring
47 0.29 - 0.54 ---
gear backlash

GD705A-4 10-19
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION

12

10-20 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION

12

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length Installed Installed Installed


48 No. 1 clutch spring Free length
x O.D. length load load

53 x 44 8.2 kg 51.7 7.0 kg

49 No. 2 clutch spring 53 x 47 5.5 kg 51.9 4.5 kg

50 No. 3 clutch spring 39.6 x 33 8.4 kg 38.6 7.1 kg

51 No. 4 clutch spring 39.6 x 33.5 7.8 kg 38.6 6.5 kg

52 No. 5 clutch spring 39.6 x 33 8.4 kg 38.6 7.1 kg Replace

53 No. 6 clutch spring 39.6 x 34.5 6.5 kg 38.6 5.2 kg

54 No. 7 clutch spring 66 x 60 8.5 kg 64.9 7.9 kg

55 No. 8 clutch spring 6.5 x 5.5 143 kg 6.2 100 kg

Side clearance of planetary Standard clearance Clearance limit


56
gear 0.35 - 0.80 1.5

Idler gear-to-driven gear


57 0.25 - 0.60 ---
backlash

GD705A-4 10-21
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE

12
HYDROSHIFT TRANSMISSION CONTROL VALVE

1. Lubrication oil pressure measuring plug


2. Inching oil pressure measuring plug
3. Pilot oil pressure measuring plug
4. Main oil pressure measuring plug
5. Relief valve (Lubrication and cooler by-pass)
6. Shift valve lever (for F.R.)
7. Shift valve lever (for Inching)
8. Speed select control lever

10-22 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE

12

GD705A-4 10-23
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE

12

10-24 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE

12
1. Sleeve
2. Sleeve
3. Valve
4. Sleeve
5. Valve body
6. Shift valve (1st)
7. Valve body
8. Shift valve (2nd)
9. Stopper
10. Yoke
11. Shift valve (F,R)
12. Shift valve (Inching)
13. Spring
14. Valve
15. Sleeve
16. Washer
17. Stopper
18. Sleeve
19. Sleeve
20. Spring
21. Shift valve (H,L)
22. Valve body
23. Sleeve
24. Shift valve (3rd)
25. Cover
26. Valve
27. Spring
28. Valve
29. Priority valve
30. Spring
31. Sleeve
32. Cover
33. Spring
34. Valve
35. Modulating valve
36. Valve body
37. Sleeve
38. Quick return valve
39. Modulating valve
40. Stopper
41. Plug
42. Spring
43. Valve body
44. Lubrication valve
45. Spring
46. Cooler bypass valve

Control
N 1st 2nd 3rd 4th 5th 6th 7th 8th
position
Shift Cut L L L L H H H H
valve off 1st 2nd 3rd 4th 1st 2nd 3rd 4th

GD705A-4 10-25
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE

12

PRIORITY VALVE

FUNCTION
The priority valve keeps the hydraulic pressure (shift
valve operation hydraulic pressure) of the pilot circuit
constant at the specified pressure if the main circuit
hydraulic pressure decreases, to ensure operation of
the gear shift valve.

1. When neutral
The priority valve (1) is a relief valve with a set
pressure of 1.4 MPa {14 kg/cm2}.
When there is no gear changing, the pilot circuit
hydraulic pressure (shift valve hydraulic oil pres-
sure) is the same as the main circuit hydraulic
pressure 2.5 MPa {25 kg/cm2}. The priority valve
is in contact with the stopper.

2. During gear changing


When the main circuit oil pressure goes down
below 1.4 MPa {14 kg/cm2}, the pilot circuit oil
pressure is maintained at 1.4 MPa {14 kg/cm2} by
the priority valve and the shift valve can reliably
function.

10-26 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE

12

MODULATING VALVE AND QUICK RETURN


VALVE
The modulating valve and the quick return valve
smoothly raise the main oil pressure when gear
changing. By operating the clutch, shock at driving
gear changing is eliminated and the production of
peak torque in the power line is prevented.

1) Immediately after gear changing (X point)


Immediately after changing gears the main circuit
(from the pump) oil flows into the piston of the
operating clutch.
Due to the flow of oil at this time, a difference in
pressure is produced in the A-chamber and the B-
chamber of the quick return valve (3), and the
quick return valve moves to the left. At this time,
the C-chamber of the modulating valve load pis-
ton port is connected to the drain circuit. By the
force of spring (4) the modulating load piston (5),
while draining the oil which has filled the C-cham-
ber of the load piston port, returns to stroke end
(right edge).

2) While raising pressure (Y point)


When the clutch piston fill with oil, the flow of oil
almost completely stops. The pressure of the A-
chamber and B-chamber of the quick return valve
(3) is almost the same. Due to this, the pressure
difference (a > b) on the surface and b surface of
the quick return valve causes the quick return
valve to return the right. The circuit to the drain
port D-chamber of the modulating valve load pis-
ton closes. At the same time the oil passed
through the orifice (e) of the quick return valve
pushes the modulating valve load piston (5) to the
left. Then, due to the movement of the load pis-
ton, the spring (4) contracts and the relief pressure
of the modulating valve gradually rises.

GD705A-4 10-27
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE

12

3) At set pressure 2.5 MPa {25kg/cm2} (Z point)


When the modulating valve load piston touches
the stopper, the increase in the oil pressure
ceases. At this time the relief pressure is the set
pressure 2.5 MPa {25 kg/cm2} of the modulating
valve.

10-28 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE

12

FUNCTION

SPEED STAGE CHANGING VALVE

1) At neutral
The pilot pressure applies on the A-chamber of
the cutoff valve and because the C-chamber con-
nects with the drain circuit, the spool moves to the
right due to the difference in pressure between
the A-chamber and the C-chamber. The oil from
the pump does not operate each clutch, but lubri-
cates the transmission and PTO, and is drained
into the transmission case.

2) At forward 1st speed


The B-chamber and D-chamber of the back pres-
sure side of the shift valve (1st) (H.L.) are each
connected to the drain circuit and so a difference
in pressure arises in the A-chamber and B-cham-
ber, and the A-chamber and D-chamber. The 1st
spool is pushed to the right and the H.L. spool is
pushed to the left and since the F.R. spool is set in
the F position, the oil pump is let to the 1st, L, F
clutch.

GD705A-4 10-29
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE

12

3) Forward 8th speed


Since the E-chamber of the back pressure side of
the shift valve (4th) is connected to the drain cir-
cuit, a pressure difference arises between A-
chamber and E-chamber and the spool is pushed
to the left. Since the F.R. spool is set on the F
position, the oil from the pump flows into the 4th,
H, F clutch

4) At reverse 2nd speed


Because the back pressure side of the shift valve
(2nd), (H.L.) is connected to the drain circuit, a dif-
ference in pressure arises between the A-chamber
and D-chamber, and the A-chamber and F-cham-
ber.
The H.L. spool is pushed to the left and the 2nd
spool is pushed to the right. Since the F.R. spool
is set in the R position, the oil from the pump is
led to the 2nd, L, R clutch.

At other forward 2nd speed to 7th speed and reverse


1st speed and 3rd speed to 8th speed occur according
to combinations in the above items 2 to 4. The combi-
nations are as follows:
Forward 2nd speed: 2nd, L, F
Forward 3rd speed: 3rd, L, F
Forward 4th speed: 4th, L, F
Forward 5th speed: 1st, H, F
Forward 6th speed: 2nd, H, F
Forward 7th speed: 3rd, H, F
Forward 8th speed: 4th, H, F
Reverse 1st speed: 1st, L, R
Reverse 3rd speed: 2nd, L, R
Reverse 4th speed: 4th, L, R
Reverse 5th speed: 1st, H, R
Reverse 6th speed: 2nd, H, R
Reverse 7th speed: 3rd, H, R
Reverse 8th speed: 4th, H, R

10-30 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE

12
INCHING VALVE

OPERATION

1) Inching valve [OPEN]


Tho oil from the pump passes through ports A
and B, and then goes from the F-R spool to the F-R
clutch.
The return spring of the inching pedal pushes
valve spool (2) and collar (3), and moves valve (1)
to the left. Oil passes through orifice D and enters
chamber C. It acts to push valve (1) to the right,
but because of the tension of the return spring,
valve (1) does not move.

2) Inching valve [THROTTLED]


When the inching pedal is depressed slightly,
valve spool (2) moves to the right, so piston (4)
pushes valve (1) to the right to a position where it
balances the tension of springs (5), (6) and (7).
In other words, the passage to port B is restricted,
and the orifice E is connected to the drain port, so
the hydraulic pressure of the F-R clutch is
reduced, and the clutch is partially disengaged.

3) Inching valve [CLOSED]


When the inching is depressed fully, valve spool
(2) moves fully to the right, so the tension of
springs (5) and (6) becomes weaker. As a result,
the hydraulic pressure of the F-R clutch drops to
0.04 - 0.54 MPa {0.4 - 0.55 kg/cm2}, and the clutch
is completely disengaged.

GD705A-4 10-31
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE

12
1. HYDROSHIFT transmission control valve

10-32 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE

12

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Clearance
Standard size
clearance limit
Clearance between shift valve Shaft Hole
1
spool (3rd) and valve body
-0.035 +0.013
19 0.035-0.058 0.08
-0.045 0

Clearance between shift valve -0.035 +0.013


2 19 0.035-0.058 0.08
spool (1st) and valve body -0.045 0

Clearance between shift valve -0.035 +0.013


3 19 0.035-0.058 0.08
spool (2nd) and valve body -0.045 0

Clearance between shift valve -0.035 +0.013


4 19 0.035-0.058 0.08
spool (4th) and valve body -0.045 0

Clearance between shift valve -0.035 +0.013


5 19 0.035-0.058 0.08
spool (H.L.) and valve body -0.045 0

Clearance between valve spool -0.035 +0.013


6 19 0.035-0.058 0.08
(F.R.) and valve body -0.045 0

Clearance between inching valve -0.020 +0.015


7 10 0.020-0.045
spool and valve body -0.030 0

Clearance between inching valve -0.035 +0.013


8 25 0.035-0.058
and valve body -0.045 0

Clearance between inching sleeve -0.035 +0.018


9 17.2 0.035-0.063
and inching valve spool -0.045 0
Replace
Clearance between speed selector -0.035 +0.011
10 14 0.035-0.056 0.08
spool and valve body -0.045 0

Clearance between priority valve -0.035 +0.013


11 25 0.035-0.058 0.08
and valve body -0.045 0

Clearance between priority valve -0.020 +0.018


12 15 0.020-0.048 0.08
and valve spool -0.030 0

Clearance between modulating -0.035 +0.013


13 25 0.035-0.058 0.08
valve and valve body -0.045 0

Clearance between modulating -0.020 +0.018


14 15 0.020-0.048 0.08
valve and valve spool -0.030 0

Clearance between valve and -0.035 +0.016


15 35 0.035-0.061 0.08
valve body -0.045 0

Clearance between quick return -0.035 +0.011


16 12 0.035-0.056 0.08
valve and sleeve -0.045 0

Clearance between lubrication -0.035 +0.013


17 22 0.035-0.058 0.10
valve and valve body -0.045 0

Clearance between cooler by-pass -0.035 +0.013


18 22 0.035-0.058 0.10
valve and valve body -0.045 0

Clearance between cut-off valve -0.035 +0.013


19 19 0.035-0.058 0.08
and valve body -0.045 0

GD705A-4 10-33
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE

12
2. HYDROSHIFT transmission control valve spring

10-34 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE

12

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit


Free length Installed Installed Free
1 Spool return spring Load
x O.D. length load length
36.75 x 19.3 30.3 6.12 kg 36.1 5.51 kg

2 Inching valve spring 16.1 x 12.5 1.15 kg

3 Inching valve spring (Large) 50.2 x 33 4.02 kg

4 Inching valve spring (Small) 39 x 33 0.81 kg

5 Inching valve spring 26 x 18 0.66 kg

6 Priority valve spring 35 x 9.5 21 1.33 kg 34.3 1.26 kg

7 Priority valve spring 115.5 x 16.9 100 23.50 kg 114.7 22.3 kg

8 Modulating valve spring (Large) 86.7 x 23.2 65 27.03 kg 85.6 25.7 kg

9 Modulating valve spring (Small) 71.2 x 14.3 65 13.39 kg 70.9 12.7 kg

10 Lubrication valve spring 39.4 x 15.6 37 6.20 kg 39.0 5.27kg

11 Cooler by-pass valve spring 71.4 x 14.9 66 13.88 kg 70.6 11.8 kg

12 Cut-off valve spring 36.75 x 30 6.41 kg 36.1 5.79 kg

Length between selector valve


A 51.4 (for reference)
and yoke
Clearance between nut and
B 0.1 - 0.3
selector valve body

GD705A-4 10-35
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION PIPING

12
HYDROSHIFT TRANSMISSION PIPING

1. Transfer
2. HYDROSHIFT transmission control valve
3. Engine
4. Transmission pump (KFP3250AFMSSH)
5. Oil filter

GD705A-4 10-37
STRUCTURE AND FUNCTION LUBRICATION RELIEF VALVE

12
LUBRICATION RELIEF VALVE

1. Plug
2. Spring
3. Body
4. Poppet

10-38 GD705A-4
STRUCTURE AND FUNCTION TRANSMISSION PUMP

12
TRANSMISSION PUMP
KFP3250AFMSSH

1. Drive gear
2. Cover
3. Body
4. Mounting flange
5. Driven gear
6. Bushing
7. Oil seal
8. Snap ring

GD705A-4 10-39
STRUCTURE AND FUNCTION TRANSMISSION PUMP

12

Unit: mm

No. Check Item Criteria Remedy

Standard size Repair limit


1. Diameter of gear shift Replace
--- 24.895
2.
Pressure plate --- 6.676 Replace

Teflon layer is worn and Replace mount-


red copper color portion ing flange, cover,
3. Wear of drive-in bushing --- of base metal is exposed etc.
Replace driven
for more than 150o gear, drive gear

Depth of gear contact traces Replace pump


4. --- Max. 0.12
on bushing assembly

Discharge Standard
Speed Discharge
Discharge Discharge
---
(rpm) MPa {kg/cm2} (O/min.)
limit
---
(E010-CD: 50oC)
2,200 24.5 {25} 103 ---

10-40 GD705A-4
STRUCTURE AND FUNCTION TRANSMISSION CONTROL

12
TRANSMISSION CONTROL

10-42 GD705A-4
STRUCTURE AND FUNCTION TRANSMISSION CONTROL

12

1. Inching pedal 5. Lock lever (for shift lever)


2. Wire (for F.R. control) 6. Shift lever
3. Wire (for inching) 7. F.R. control side
4. Stopper (for inching pedal) 8. Inching control side

GD705A-4 10-43
STRUCTURE AND FUNCTION DRIVE SHAFT

12
DRIVE SHAFT

10-44 GD705A-4
STRUCTURE AND FUNCTION FINAL DRIVE

12
FINAL DRIVE

1. Shaft 15. Bevel pinion mounting bearing OUTLINE


2. Bearing 16. Lock • A non-spin differential system is
used for the differential.
3. Sprocket 17. Nut • The non-spin differential
4. Joint 18. Coupling system detects the difference
in rotation of the left and right
5. Gear (42 teeth) 19. Bevel pinion (13 teeth) rear wheels and automatically
switches between the
6. Shaft 20. Case
differential ON and differential
7. Gear (17 teeth) 21. Housing LOCK condition.
• When the machine is traveling
8. Non-spin differential 22. Breather
in a straight line (no difference
9. Rock plate 23. Filler tube in rotation), the differential is
kept locked; when the
10. Bevel gear (38 teeth) 24. Tube, oil level gauge
machine is turning (difference
11. Nut 25. Shim in rotation), the differential is
kept in the ON condition.
12. Gauge 26. Bolt
13. Bevel gear side housing 27. Support
14. Shim 28. Drain plug

GD705A-4 10-45
STRUCTURE AND FUNCTION FINAL DRIVE

12
NON-SPIN DIFFERENTIAL
1. Side gear
2. Clutch return spring
3. Holdout ring
4. Driven clutch
5. Spider
6. Center cam

SPIDER

DRIVEN CLUTCH

CENTER CAM

10-46 GD705A-4
STRUCTURE AND FUNCTION FINAL DRIVE

12

Principle of operation of non-spin


differential
1. When traveling in a straight line.
Left and right driven clutches (4) are meshed with
spider (5) and center cam (6), so the power passing
through the bevel gear passes from the spider
through the left and right driven clutches and
drives the left and right drive wheels at the same
speed.
There are cam teeth at the point where the driven
clutch meshes with the center cam, so there is no
backlash when they mesh.
There are clutch teeth at the portion where there is
meshing with the spider, so they mesh with a fixed
backlash.

2. When traveling on a curve (turning left).


When traveling on a curve, the outside drive wheel
(right wheel) must turn faster than the inside drive
wheel (left wheel).
Because of this, the force received from the
ground surface tries to make the left and right
drive wheels (driven clutch) rotate at different
speeds. Driven clutch (4) is meshed with spider (5)
by teeth with a large backlash, so the force from
the road surface tries to rotate the driven clutch
(4R) at a different speed from the spider in the
direction to remove the backlash.
This force from the ground surface also acts at the
same time on center cam (6) and the driven clutch
cam teeth. It makes the cam tooth surface slide,
and pushes the driven clutch to the outside.
When the sliding of the cam tooth surface finishes,
both cams are raised, so the meshing of the clutch
teeth is completely disengaged and the right
driven clutch can rotate freely. In this way, when
the machine is traveling on a curve, the outside
wheel becomes free and power is transmitted only
to the inside wheel.

GD705A-4 10-47
STRUCTURE AND FUNCTION FINAL DRIVE

12

Unit: mm

No. Check Item Criteria Remedy

1 Preload of bevel pinion bearing Starting torque: 11.8 - 15.7 Nm {1.2 - 1.6 kgm}

2 Starting torque: Item 1 + (2.9 - 3.9 Nm {0.3 - 0.4 kgm})


Preload of side bearing
(after setting: measure at pinion shaft)

Backlash between 2nd pinion Tolerance Repair limit Adjust


3
and 2nd gear 0.24 - 0.60 1.6

4 Backlash between bevel pinion


0.3 - 0.4 1.4
and bevel gear

10-48 GD705A-4
STRUCTURE AND FUNCTION TANDEM DRIVE

12
TANDEM DRIVE

★ Above 0°C: Use engine oil CLASS-CD SAE30


Below 10°C: Use engine oil CLASS-CD SAE10W

26
Reduction ratio: = 2.0
13

Lubrication amount: 105 O

1. Cover 10. Spring


2. Breather 11. Bearing
3. Chain 12. Gear (105 teeth)
4. Hub shaft 13. Plate (138 teeth)
5. Bearing 14. Disk
6. Shim 15. Tandem case
7. Sprocket (26 teeth) 16. Cover
8. Cage 17. Oil level gauge
9. Piston 18. Drain plug

10-50 GD705A-4
STRUCTURE AND FUNCTION TANDEM DRIVE

12

Power from the final drive is transmitted to the front


and back rear wheels by chain.
The tandem cases can swing up and down 13o each.
All four rear wheels are in contact with the ground
even when the ground is rough restricting the up-and-
down movement of the blade to a minimum.

The movement of the blade of a motor grader when its


rear wheel ride over an obstacle is as follows:

1. When both left and right wheels ride over an


object (height: H) at the same time, the center of
the rear axle rise H/2 as right figure shows, and
because the blade is situated about halfway
between the front and rear axles, its movement
further becomes H/4.

2. When only one left rear wheel rides over an object


(height: H), the rise at the center of rear axle is H/2
at its left end as right figure shows and H/4 at the
center line of machine and on the real axle.
The movement of the center part of the blade is
half of that, which is H/8.

GD705A-4 10-51
STRUCTURE AND FUNCTION TANDEM DRIVE

12

Unit: mm

No. Check Item Criteria Remedy

1 Preload of hub bearing Starting torque: 19.6 - 24.5 Nm {2.0 - 2.5 kgm} Adjust

Standard size Repair limit


2 Extension of chain (10 links) Replace
571.5 580

10-52 GD705A-4
STRUCTURE AND FUNCTION STEERING PIPING

12
STEERING PIPING
-

10-54 GD705A-4
STRUCTURE AND FUNCTION STEERING PIPING

12

GD705A-4 10-55
STRUCTURE AND FUNCTION STEERING PIPING

12

10-56 GD705A-4
STRUCTURE AND FUNCTION STEERING PIPING

12

1. Steering cylinder
2. Steering pump
(With flow priority valve)
3. Steering valve
(Orbit-roll type)
4. Steering wheel
5. Oil cooler

GD705A-4 10-57
STRUCTURE AND FUNCTION STEERING WHEEL

12
STEERING WHEEL

The GD705-4 steering system features hydraulic control. 1. Steering valve


A quantity of oil corresponding to the turn of the steer- 2. Steering wheel
ing wheel (2) passes to the steering cylinder via a steer-
ing valve (Orbit roll type). The hydraulic oil is also used
in the steering system.

10-58 GD705A-4
STRUCTURE AND FUNCTION STEERING VALVE

12
STEERING VALVE (ORBIT ROLL TYPE)

1. Check valve 9. Center ring 17. Ball


2. Drive shaft 10. Needle bearing 18. Spring
3. Under cover 11. Retainer 19. Valve
4. Rotor 12. Ball 20. Adjusting screw
5. Housing 13. Check seat 21. Locknut
6. Control sleeve 14. Set screw 22. Plug
7. Control spool 15. Housing 23. Plug
8. Center pin 16. Valve seat 24. Ball

GD705A-4 10-59
STRUCTURE AND FUNCTION STEERING SYSTEM

12
STEERING SYSTEM
STRUCTURE

The steering system is of the fully hydraulic type and


hydraulic oil is sent to the steering cylinder by this
steering valve, oil flow being varied with turning angle
of the steering wheel. The valve has a built-in hand
pump, which makes it possible to suck oil directly
from the tank so that necessary steering operation can
be maintained in case of trouble of the oil pump or the
engine.
This valve is of the orbit roll type.

• The lower end of the steering wheel shaft is


spline-fitted to the top of the spool, which is
inserted in the sleeve. The spool and the sleeve
are joined to each other with the center pin (which
does not contact to the spool when the steering
wheel is at neutral position) and the center spring.

• There is the drive shaft inside the spool. The


upper end of the shaft is joined to the center pin
and the lower end of it is spline-fitted to the hand
pump rotor. The hand pump adjusts oil flow to
the cylinder, depending on steering angle of the
steering wheel, and also acts to supply oil to the
cylinder in case of oil pump or engine trouble by
utilizing turning force of the steering wheel to suck
oil directly from the tank.

• The valve body has four ports which connect to


the oil pump, tank, steering cylinder head and
steering cylinder bottom, respectively. The pump
side port and the tank side port are connected to
each other through the check valve, which permits
the steering valve to suck oil directly from the tank
in case of oil pump or engine trouble.

10-60 GD705A-4
STRUCTURE AND FUNCTION STEERING SYSTEM

12

When the steering wheel is not manipulated, the cen-


ter spring keeps the spool and the sleeve are stopped
in the position at which the center pin is located to the
center of the slotted hole in the spool. Under this con-
dition, the ports that connect the sleeve to the steering
cylinder and the hand pump are insulated from the
lengthwise slots in the spool. While, the small holes in
the spool bottom are aligned with those in the sleeve
bottom. (Total 24 holes are provided by arranging
twin holes at 12 places equally spaced around the cir-
cumference of spool or sleeve.)
Oil from the pump enters the valve inlet port and flows
through small holes in the sleeve and spool to the
inside of the spool. The oil, in turn, flows through the
slotted hole in the spool and the spring mounting por-
tion to the valve outlet port, and is returned to the
tank.

GD705A-4 10-61
STRUCTURE AND FUNCTION STEERING SYSTEM

12

When steering wheel is manipulated (Turning to the left)

• When the steering wheel is turned to the left, the • Oil from the pump enters the hand pump through
rotation causes the spool spline-fitted to the the valve inlet port and returns to the sleeve. The
steering wheel shaft to turn to the left. As the oil, in turn, flows from a lengthwise slit in the
sleeve is joined to the spool with the center spool, through the steering cylinder port in the
spring, the spring contracted by the spool causes sleeve to the steering cylinder. While, oil from the
a difference in turning angle between the spool steering cylinder is forced to flow through the port
and the sleeve depending on contraction of the in the sleeve and a lengthwise slit in the spool and
spring. As the result, each port in the sleeve is returns to the tank.
connected to a lengthwise slit in the spool.

• Under this condition, the hand pump port in the • Under such a condition as mentioned above, the
sleeve and the steering cylinder port (on the left- hand pump is rotated by hydraulic oil from the
steering side) in the sleeve are connected to each pump and acts as an oil motor to lighten steering
other through the lengthwise slits in the spool. wheel manipulating force. When the steering
Also, the steering cylinder port (on the right- wheel is stopped turning, difference in turning
steering side) in the sleeve is connected to the angle between the sleeve and the spool is
valve outlet port in the sleeve. removed by return force of the center spring. The
same condition as mentioned before under "When
steering wheel is not manipulated" is recovered.
Refer to page 10-64 for details of mutual relation
between the hand pump ports (7 ports) and the
sleeve ports (12 ports) which will be connected to
each other when the steering wheel is turned to
either direction.

10-62 GD705A-4
STRUCTURE AND FUNCTION STEERING SYSTEM

12

When steering is made with the oil pump mal-


functioning (Turning to the right)

• When a motor grader is to be towed by another • Like as before-mentioned, a difference occurs in


machine because of some trouble in the oil pump turning angle between the spool and the sleeve
or the engine, keeping normal steering of the and, therefore, each port in the sleeve is
grader cannot be neglected to prevent accident. connected to a lengthwise slit in the spool. The
To satisfy this requirement, a built-in hand pump hand pump is rotated with turning of the steering
is provided on the bottom of the steering valve. wheel. The rotation causes the hand pump to
When the steering system is normally supplied suck oil directly from the tank, through the check
with hydraulic oil from the pump, the hand pump valve provided between the valve outlet port and
is only to control flow of oil, its rotation being the inlet port, and to deliver oil to the steering
supported by pressure of oil. cylinder.
When oil from the pump is stopped, the center pin
comes into contact with an end of the slotted hole • The hand pump resemble trochoid pumps, but its
in the spool and, then, turning force of the steer- ports are arranged on the root of teeth and each
ing wheel is used for driving the hand pump. port acts as the inlet port and the outlet port
alternatively. Oil suction and discharge operation
of the hand pump is carried out by the
combination of the seven ports in the hand pump
and the 12 ports in the sleeve.

GD705A-4 10-63
STRUCTURE AND FUNCTION STEERING VALVE

CONNECTION BETWEEN HAND PUMP AND SLEEVE

• The diagrams above show the connections with


the sleeve ports used to connect the suction and
discharge ports of the Girotor.
• If the steering wheel has been turned to the right,
ports a, c, e, g, i, and k are connected by the ver-
tical grooves in the spool to the pump side. At the
same time, ports b, d, f, h, j, and l are connected
to the head end of the left steering cylinder in the
same way.
In the condition in diagram above left, ports 1, 2,
and 3 are the discharge ports of the Girotor set.
They are connected to ports l, b, and d, so the oil
is sent to the cylinder.
Ports 5, 6, and 7 are connected and the oil flows
in from the pump.
If the steering wheel is turned 90°, the condition
changes to the condition shown in diagram
above right. In this case, ports 1, 2, and 3 are the
suction ports, and are connected to ports i, k,
and a. Ports 5, 6, and 7 are the discharge ports,
and are connected to ports d, f, and h.

10-64 GD705A-4
STRUCTURE AND FUNCTION STEERING VALVE

• In this way, the ports acting as the discharge • To carry out adjustment of the discharge amount
ports of the hand pump are connected to the to match the amount the steering wheel is
ports going to the steering cylinder, while the turned, the oil from the pump always passes
ports acting as the suction ports are connected to through this hand pump, and for each 1/7 turn of
the pump circuit. the steering wheel, the internal tooth gear of the
hand pump advances by one tooth. An amount of
• If the pump or engine fail, the suction and dis- oil equal to this movement is discharged, so the
charge of this hand pump is carried out forcibly discharge oil amount is directly proportional to
and oil is sent to the steering cylinder, so it is pos- the amount the steering wheel is turned.
sible to carry out steering. • If the pump or engine should fail, the condition is
exactly the same, so the same amount of oil is
discharged as when the pump is normal.

Differences between trochoid pump and steering


pump hand pump

• Trochoid pump

• The trochoid pump is divided into an inlet port


and an outlet port, and when the shaft rotates as
shown in the diagram above, oil is sucked in from
the inlet port and discharged from the outlet port
as shown in 2 - 6.

• Steering pump hand pump

• In the case of the hand pump, there are inlet


ports and outlet ports at the bottom of the internal
teeth of the stator, and when the shaft is rotated,
the steering pump and port are connected as
shown in 2 - 3 in the diagram above, and oil is
sucked in.
If the shaft rotated further, the steering cylinder
and port are connected as shown in 5 - 6, and the
oil is delivered to the cylinder.
This action is carried out at each port.

GD705A-4 10-65
STRUCTURE AND FUNCTION STEERING VALVE

Role of centering spring


• Centering spring (4) consists of six X-shaped leaf
springs.
It is assembled between spool (10) and sleeve
(9) as shown in the diagram on the right.
When the steering wheel is turned, the spool
compresses the spring, and a difference (angle
variation) is generated in the turning angle of the
spool and sleeve.
As a result, the port of the spool and sleeve is
connected and oil is sent to the cylinder.
However, when the rotation of the steering wheel
is stopped, the rotation of the hand pump also
stops, so no more oil is sent to the cylinder, and
the oil pressure rises.
To prevent this, when the turning of the steering
wheel is stopped, the action of the centering
spring only allows it to turn by an amount equal
to the difference in angle a of rotation (angle var-
iation) of the sleeve and spool, so the steering
wheel returns to the NEUTRAL position.

10-66 GD705A-4
STRUCTURE AND FUNCTION STEERING PUMP

12
STEERING PUMP
KFP2233CVKR (Pump with flow priority valve)

1. Flow priority valve


2. Mounting flange
3. Body
4. Bracket
5. Drive gear
6. Snap ring
7. Oil seal
8. Bushing
9. Relief valve

A. PF port
B. EF port

GD705A-4 10-67
STRUCTURE AND FUNCTION STEERING PUMP

12

Operation of flow priority valve


1. When pump discharge amount is less than control flow.
The flow of oil from the pump passes through the orifice and flows to PF.
When this happens, the pressure difference created on both sides of the orifice
acts on the plunger in the direction to bend the spring, so the balance with the
force of the spring prevents portion a of the plunger from opening to EF and
ensures that all the oil flows to PF.

2. When pump discharge amount is more than control flow


When the pump discharge amount is more than the set control flow, the pressure
difference created on both sides of the orifice becomes greater, so the plunger
moves, portion a opens, and the excess oil flows to EF.

3. When circuit on PF side is actuated


When the circuit on the PF side is actuated and the pressure on the PF side rises,
the difference in pressure between the IN side and the EF side causes the flow of
oil to the EF side to increase and the flow of the oil to the PF side to decrease.
When this happens, the pressure difference created on both sides of the orifice
becomes smaller. Because of the relationship with the spring force, the plunger
moves down, and throttles portion a until the pressure difference created on both
sides of the orifice reaches the pressure needed to let the set amount of oil flow.
This sends a constant amount of oil to the PF side.

10-68 GD705A-4
STRUCTURE AND FUNCTION STEERING CYLINDER

12
STEERING CYLINDER

1. Snap ring
2. Cylinder head
3. Dust seal
4. Ring
5. Back-up ring
6. O-ring
7. Bushing
8. Rod packing
9. Piston rod
10. Cylinder
11. Piston
12. Piston ring
13. Wear ring
14. Nut

10-70 GD705A-4
STRUCTURE AND FUNCTION STEERING CYLINDER

12

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Clearance
Standard size
clearance limit
Clearance between piston rod and Shaft Hole
1
bushing
-0.030 +0.132
35 0.036-0.274 0.6
-0.142 +0.006 Replace
bushing
Clearance between piston rod -0.050 +0.041
2 50 0.075-0.116 0.6
support shaft and bushing -0.075 +0.025

Clearance between cylinder bot- 0 +0.007


3 47 -0.018-0.018 0.6
tom support and shaft bushing -0.011 -0.018

GD705A-4 10-71
STRUCTURE AND FUNCTION FRONT AXLE

12
FRONT AXLE

Toe-in 8.2 ± 1.0 mm 1. Tie rod


Camber 1.5o 2. Pitman arm
King pin tilting angle: 0o 3. Front axle
4. Leaning rod
5. Housing
6. Hub shaft
7. Hub nut
8. King pin
9. Bracket
10. Nut

10-72 GD705A-4
STRUCTURE AND FUNCTION FRONT AXLE

12
FUNCTION OF FRONT AXLE

1. Steering
Refer to section, "STEERING SYSTEM"

2. Lessening blade angling and up-and-down


movement
The axle is fixed in the center with a center pin to
the frame so that it can oscillate 13 degrees. This,
like the tandem system, restricts the up-and-down
movement of the blade to a minimum when one
front wheel rides over an object or falls into a
hole. When the front wheel rides over an object
(height-H), the center point of the front axle rises
H/2, as shown in drawing. Because of possible
rocking of front axle blade movement rises only H/
4 while holding its horizontal posture. Unless the
whole oscillating range (left, right 13o) of the front
axle is used, the blade moves up-and-down hold-
ing its horizontal posture.

3. Prevention of side slipping of front wheels


(leaning system)
The front wheels can be tilted to the left or right.
This is called the leaning system, and is to prevent
the front wheel from slipping sidewards and to
reduce the turning radius.
Operations with blade at propulsion angle are fre-
quent among grader operations. In proportion to
the propulsion angle a side slipping force acts on
the blade to cause side slipping.

Also the distribution of weight on the front and


rear wheels is about 3:7, and when the blade cuts
into the ground, the load on the front wheels
decreases and it is easier for the front wheels to
slip sideward.
To counteract this side slipping, the front wheels
are leaned to make them more resistant, and this
changes the center of the load on the front axle
and the center of gravity of the machine and pre-
vents side slipping.

GD705A-4 10-73
STRUCTURE AND FUNCTION FRONT AXLE

12

When the wheel is leaned that angle between the


center line of the leaned tire and the perpendicular
line is called the "Leaning angle."
Leaning angle is the distance S= 2 x π x r covered
by the tire as it advances, and the side with the
greater load radius, in order to advance more than
the side with the less load radius, advances in the
direction of the leaning.
Using this characteristic, the turning radius can be
lessened when the leaning operation is carried
out.

When backing, leaning should be reversed to the


leaning for forward operation by turning a steer-
ing wheel in the same direction.
Leaning angel is 16.5o.

Also, when there is no differential mechanism,


even though the front wheels are steered, the rear
wheels tend to go straight ahead and this causes
the front wheels to slip little by little. Leaning pre-
vents this. Also, the front wheels steering angle is
increased by leaning.
Explanation according to the drawing to the right:
(In order to keep the explanation simple it will be
down without steering.)
When the front wheels are leaned to one side, O4
revolves 23o around 03 and comes to 04, and at the
same time 02 also revolves around 03 and comes
to 02.
The tie-rod revolves around O1, but since its O1: Center of pitman arm ball joint
length is fixed, a clearance "O" is made. However, O2: Center of tie-rod end pin
since O1, is fixed, the housing is pulled to the "O" O3: Center of mounting pin of housing
and comes to the position "O" (O2). O4: Center of cylinder rod
Since the front wheels are steered a little in the
direction of leaning, the steering angle becomes a
little bigger.

10-74 GD705A-4
STRUCTURE AND FUNCTION FRONT AXLE

12

FRONT WHEEL ALIGNMENT


In vehicles steered by the two front wheels, the wheels
are fitted by a special method to ensure ease, stability,
and accuracy in steering. This special fitting is called
alignment, and has a very big influence on operation
of the steering wheel.

1. Camber
The front wheels are fitted so that the top of the
wheels are further away from the vehicle than the
bottom of the wheels in contact with the ground.
This slanting is called camber.

2. Toe-in
When seen from above, the distance A between
the front of the front wheels is slightly less than
the distance B between the rears.
This is called toe-in.
When vehicles travel with a camber angle, the
force which tends to push the front wheels out-
wards increases the ground resistance of the
wheels, resulting in less stable travel and greater
tire wear. By fitting the wheels with a slight
inward slant, however, this undesirable tendency
can be eliminated. The difference between A and
B of 3 to 7mm is called toe-in quantity.

3. King pin angle of inclination


The king pin is not exactly vertical to the ground
but inclines slightly inwards. This angle is called
the king pin angle of inclination.
Together with the camber, this inclination short-
ens the trail for easier steering wheel operation.
Since the front wheels turn during operation with
the king pin center line as the center axis, the front
wheels tend to be lifted up. This action, however,
is also accompanied by a reaction which tends to
return the wheels to the former position. When
the grader turns a little and still is about to pro-
ceed straight ahead, releasing the steering wheel
will generate the restoring force, and bring the
steering wheel back to its former position. This
angle is generally about 5o to 8o.

GD705A-4 10-75
STRUCTURE AND FUNCTION FRONT AXLE

12

4. Caster (The caster angle in grader is Oo.)


Caster refers to the angle at which the king pin is
fitted when the wheel is viewed from the side
shown in the accompanying diagram. The angle
is called the caster angle.
If the king pin is fitted at an angle, the point of
contact between the wheel and the ground will be
behind the point where the extrapolated king pin
center line meets the ground. This means that
during travel, there is a force constantly pulling
the wheels backward, depending on the ground
resistance added to the point where the wheels
are in contact with the ground. This backward
force tends to keep the wheels directed straight
ahead (directional property).
This force also tends to return the steering wheel
to the original position when the steering wheel is
turned (restoring property).
In automobiles, the caster angle is generally 1o to
3o.
In graders, however, the angle is 0o

10-76 GD705A-4
STRUCTURE AND FUNCTION FRONT AXLE

12

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Clearance
Standard size
clearance limit
Clearance between leaning pin Shaft Hole
1
and leaning rod bushing
-0.025 +0.025
50 0.025-0.089 1.0
-0.064 +0 Replace
bushing
Clearance between center pin -0.085 -0.025
2 60 0.035-0.085 1.0
bushing -0.110 -0.050

Clearance between king pin and -0.025 +0.025


3 50 0.025-0.075 0.4
bushing -0.050 +0

Standard clearance Interference limit


Axial clearance between knuckle
4 Replace
and bracket (king pin)
0.143 - 0.331 1.0

Tolerance
Standard Interference
Standard size
interference limit
Clearance between axle end pin Shaft Hole Replace
5
and bushing bushing
-0.085 -0.025
45 0.025 - 0.089 0.4
-0.064 +0

6 Tie rod joint nut tightening torque 216 - 304 Nm {22 - 31 kgm}

7 Preload of hub bearing Starting torque: 24.5 - 32.9 Nm {2.5 - 3.35 kgm} Adjusting

8 Hub nut tightening torque 491 ± 49 Nm {50 ± 5 kgm}

GD705A-4 10-77
STRUCTURE AND FUNCTION WHEEL

12
WHEEL
FRONT WHEEL

1. Side ring
Tire size 16.00 - 24 - 12PR
2. Rim
3. Tube
Rim size 10.00VA x 24SDC
4. Tire

Air pressure 0.22 MPa {2.2 kg/cm2}

10-78 GD705A-4
STRUCTURE AND FUNCTION WHEEL

12
REAR WHEEL

1. Side ring
Tire size 16.00 - 24 - 12PR
2. Rim
3. Tube
Rim size 10.00VA x 24SDC
4. Tire

Air pressure 0.22 MPa {2.2 kg/cm2}

GD705A-4 10-79
STRUCTURE AND FUNCTION BRAKE PIPING

12
BRAKE PIPING

1. Disc brake housing 7. Low pressure switch


2. Stop lamp switch 8. Check valve
3. Brake valve 9. Air compressor
4. Air governor 10. Air dryer (OP)
5. Drain cock 11. Safety valve
6. Air reservoir 12. Relay valve

10-80 GD705A-4
STRUCTURE AND FUNCTION BRAKE PIPING

12

GD705A-4 10-81
STRUCTURE AND FUNCTION DISC BRAKE SYSTEM

12
DISC BRAKE SYSTEM
DISC BRAKE PIPING CIRCUIT DIAGRAM

1. Air compressor 8. Low pressure switch


2. Air drier (If equipped) 9. Pressure gauge
3. Air governor 10. Brake valve
4. Air reservoir 11. Stop lamp switch
5. Safety valve 12. Automatic drain (If equipped)
6. Relay valve 13. Disc brake
7. Check valve 14. Purge tank

10-82 GD705A-4
STRUCTURE AND FUNCTION DISC BRAKE SYSTEM

12
STRUCTURE OF DISC BRAKE

Disc brakes are fitted on the four rear wheels and are 1. Hub shaft
actuated by air pressure. 2. Gear
The motive force from the final drive rotates hub shaft
(1), gear (2) and disc (4) inside cage (7). This rotation 3. Support
is transmitted to the tires which are fixed to the hub. 4. Disc
Each brake consists of disc (4) which is meshed with
5. Plate
plate (5) and gear (2) which are meshed with cage (7).
The discs are cooled by the oil inside the tandem 6. Spring
case. 7. Cage
8. Piston
9. Nut
10. Bolt

GD705A-4 10-83
STRUCTURE AND FUNCTION DISC BRAKE SYSTEM

12

OPERATION
1. Brake applied
When the brake pedal is depressed, the air circuit
is connected to chamber A of the disc brake.
When the air pressure is greater than the pushing
force of spring (6), piston (8) moves to the left, and
pushes disc (4) and plate (5). Friction is generated
between the disc (meshed with gear (2)) and the
plate (meshed with cage (7)). This slows down the
rotation of the disc and finally stops it. In other
words, the brake is applied.

2. Brake released
When the brake is released, the air in chamber A
is released. Spring (6) moves piston (8) back to
the right, so the pushing force is reduced. This
removes the friction between disc (4) and plate
(5), and allows them to rotate freely. In other
words, the brake is released.

10-84 GD705A-4
STRUCTURE AND FUNCTION DISC BRAKE SYSTEM

12

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit


1 Thickness of disc
3.8 ± 0.1 3.3 ± 0.1

2 Thickness of plate 2.3 ± 0.1

Total thickness between


3 32.8 ± 1.1 30.3 ± 1.1
disc and plate Replace

Standard size Repair limit

Free length Installed Installed Installed


4 Return spring Free length
x O.D. length load load

71 x 52 16.9

GD705A-4 10-85
STRUCTURE AND FUNCTION BRAKE VALVE

12
BRAKE VALVE

1. Brake pedal
2. Plunger
3. Piston
4. Inlet valve
5. Piston
6. Inlet valve
7. Rubber spring

A. From air reservoir


B. From air reservoir
C. To R.H. relay valve
D. To L.H. relay valve

10-86 GD705A-4
STRUCTURE AND FUNCTION BRAKE VALVE

12

OPERATION
1. Brake operating
Upper part
• When brake pedal (1) is depressed, the
operating force pushes plunger (2) and rubber
spring (7), and these transmit the operating
force to piston (3).
• When piston (3) moves down, it closes
exhaust outlet (9). At the same time, it pushes
down inlet valve (4) and air flows from air
reservoir A to right relay valve C.
Lower part
• When inlet valve (4) opens, air flows to
chamber "a" of piston (5).
• The air pressure pushes piston (5) down and
this closes exhaust outlet (10). At the same
time, it pushes down inlet valve (6) and air
flows from air reservoir B to left relay valve D
to actuate the brake.
• Only a small amount of air pressure is needed
to move piston (5), so the movement of the
lower valve occurs at almost the same time as
the movement of the upper valve.

2. Brake operation when lower side breaks


down
If there is any leakage of air at the lower side, the
upper side operates normally but the lower side
does not actuate the brake.

GD705A-4 10-87
STRUCTURE AND FUNCTION BRAKE VALVE

12

3. Brake operation when upper side breaks


down
• If there is any leakage of air at the upper side,
piston (5) is pushed down mechanically when
the brake pedal is depressed. Because of this,
the lower side operates normally but the
upper side does not actuate the brake.

4. Balancing operation
Upper part
• If the air pressure in relay valve C and the
space below piston (3) becomes high, piston
(3) will push rubber spring (7) and move up to
close inlet valve (4).
• When this happens, exhaust outlet (9)
remains closed, so the air pressure in the
relay valve is maintained. As a result, the
brake remains applied
Lower part
• When the air pressure at the top and bottom
of piston (5) becomes the same, the piston
moves down slightly under the force of the
spring at the top of the piston and closes inlet
valve (6). The exhaust valve is closed so the
air pressure is maintained. As a result, the
brake remains applied.
• The pressure in the space in the upper part
balances with the operating force of the
pedal, and the pressure in the space in the
lower part balances with the air pressure in
the space in the upper part.

10-88 GD705A-4
STRUCTURE AND FUNCTION BRAKE VALVE

12

• When piston (3) and (5) move their whole


stoke inlet valves (4) and (6) are completely
opened. As a result, the air pressure in the
spaces in the upper part and lower part, and
in the right and left relay valves are the same
as the air pressure in the air reservoir.
• Therefore, until the piston moves its full
stroke down, the braking effect is controlled
by the amount the brake pedal is depressed.

5. Pedal released
Upper part
• If the pressure on the pedal is reduced, and
the operating pressure is removed from the
top of the piston, the piston moves up
because of the air pressure at the bottom of
the piston and the force of the piston return
spring. As a result, the passage to exhaust
port (9) is opened and the compressed air in
the relay valve is released to the atmosphere.
Lower part
• If the pressure on the pedal is reduced, and
the compressed air at the top of piston (5) is
released, the air pressure at the bottom of
piston (5) pushes piston (5) up. Exhaust port
(10) is opened and the compressed air in the
relay valve is released to the atmosphere.

GD705A-4 10-89
STRUCTURE AND FUNCTION RELAY VALVE

12
RELAY VALVE

1. Exhaust valve seat


2. Spring
3. Cover
4. Relay piston
5. O-ring
6. O-ring
7. Valve guide
8. Exhaust check
9. Exhaust cover
10. Inlet exhaust valve
11. Spring
12. Body

10-90 GD705A-4
STRUCTURE AND FUNCTION RELAY VALVE

12

OPERATION
1. When brake pedal is depressed
Compressed air enters chamber A at the top of
relay piston (4) and pushes the relay piston down.
Because of this, exhaust valve seat (1) closes
exhaust port C and pushes open valve (10).
When the valve opens, compressed air from the
air reservoir passes through the valve and is sup-
plied to the brake chamber.

2. When brake pedal is held in place


The air pressure in chamber A at the top of the
piston becomes equal to the air pressure in cham-
ber B at the bottom of the piston. Spring (2) oper-
ates to push up relay piston (4), and spring (11)
closes valve (10). In addition, exhaust port C
stays closed at this position, so the pressure in
lower chamber B is kept the same. If the pedal is
depressed further and the pressure is increased,
compressed air will be supplied to the disc brake
until the pressure becomes equal again.

3. When brake pedal is released


The compressed air in chamber A at the top of
relay piston (4) is released through the brake
valve. When the pressure in chamber A drops,
relay piston (4) is pushed up by the air pressure in
chamber B. Exhaust port C opens, so the air in
chamber B is released.

GD705A-4 10-91
STRUCTURE AND FUNCTION AIR GOVERNOR

12
AIR GOVERNOR

1. Cover
2. Lock nut
3. Spring upper seat
4. Spring
5. Body
6. Spring guide
7. Spring lower seat
8. Spring lower seat
9. O-ring
10. Spring
11. Washer
12. Spring
13. Pressure regulator valve
14. Exhaust stem
15. Piston
16. Adjust screw
17. Snap ring

The air governor is installed to prevent the pressure from


rising too high. The reservoir port is connected to the air
reservoir; the unloader port is connected to the unloader
valve of the air compressor. The governor maintains the
pressure inside the air reservoir within the specified range.
If the pressure exceeds the specified limit, it stops the air
compressor working.

Specified pressure range: 0.68 - 0.86 MPa {6.9 - 8.8 kg/cm2}

10-92 GD705A-4
STRUCTURE AND FUNCTION AIR GOVERNOR

12

OPERATION
1. When pressure inside air reservoir is too low
• The pressure at reservoir port A is too low, so
piston (15) is pushed down by spring (4), and
unloader port B is connected to the exhaust
port. There is pressure on the unloader valve,
so the compressor is working.

2. When pressure inside air reservoir is too


high
• If the pressure at reservoir port A is too low,
piston (15) is pushed up.
• When the piston is pushed up, the exhaust
port closes and valve (13) opens.
Compressed air from reservoir port A flows to
unloader port B. This actuates the unloader
valve and makes the compressor run at idling.
• When the pressure inside the air reservoir
drops, the piston is pushed down by spring
(4).
• When the pressure drops below the lower
limit, valve (13) closes and exhaust stem (14)
opens.
Air pressure at the unloader port passes
through the exhaust stem and is released to
the atmosphere. As a result, the compressor
starts working again.

GD705A-4 10-93
STRUCTURE AND FUNCTION CHECK VALVE

12
CHECK VALVE

1. Body
2. Disc valve
3. Spring
4. Screw cap

The check valve acts to prevent air in the air reservoir


from flowing back to the air compressor when the air
compressor is stopped.

OPERATION
When air flows into the check valve from the left, valve
(2) leaks its seat and the air flows freely to the various
ports.
When air flows into the check valve from the right,
valve (2) is pushed back into its seat by spring (3) and
the air pressure. This shuts off the air flow.

10-94 GD705A-4
STRUCTURE AND FUNCTION AIR RESERVOIR

12
AIR RESERVOIR

1. Plate
2. Plate
3. Plate
4. Boss

The air reservoir acts to store the compressed air


produced by the air compressor.
Maximum pressure: 0.93 MPa {9.5 kg/cm2} (Capac-
ity 19O x 2)

SAFETY VALVE
1. Valve seat
2. Ball
3. Release pin
4. Spring
5. Spring cage
6. Lock nut
7. Adjusting screw

The safety valve is installed in the air reservoir


and acts to maintain safety in the air circuit.
When the pressure inside the air reservoir
exceeds 0.93 ± 0.03 MPa {9.5 ± 0.3 kg/cm2}, the
safety valve releases compressed air to the
atmosphere.

GD705A-4 10-95
STRUCTURE AND FUNCTION PRESSURE SWITCH

12
PRESSURE SWITCH

The pressure switch detects any change in the air


pressure. In accordance with these changes, it
switches the electric circuit on or off.

PRESSURE SWITCH FOR AIR PRESSURE


WARNING (LOW PRESSURE SWITCH)

The contacts of this switch close when the air pressure


inside the main tank drops below 0.41 MPa {4.2 kg/
cm2}. A warning buzzer then sounds to warn the oper-
ator of loss of braking power.
If the warning buzzer sounds, the operator must stop
the machine and wait until the air pressure rises again.

1. Cover 5. Gasket
2. Contact plate 6. Body
3. Spring 7. Piston cup
4. Contact disc 8. Contact plate

OPERATION
Contacts in OFF position Contacts in ON position

1. When pressure in air circuit is above 0.41 2. When pressure in air circuit is below 0.41
MPa {4.2 kg/cm2} MPa {4.2 kg/cm2}
The air pressure action on piston (2) is higher than The air pressure acting on piston (2) is lower than
the force of the spring, so piston (2) is pushed up. the force of the spring, so piston (2) is pushed
The electrical contacts are open, so no electric cur- down.
rent flows in the warning buzzer circuit and the The electrical contacts are closed, so electric cur-
buzzer does not sound. rent flows in the warning buzzer circuit and the
buzzer sounds.

10-96 GD705A-4
STRUCTURE AND FUNCTION PRESSURE SWITCH

12

PRESSURE SWITCH FOR STOP LAMP


The switch acts to light up the stop lamp when the
brake pedal is depressed. When the air pressure rises
above 0.05 MPa {0.5 kg/cm2} the contacts close and the
stop lamp lights up.
This switch is at the outlet port of the brake valve.
One switch each is installed in both the right and left
brake circuits.

OPERATION
When the brake pedal is depressed, air pressure is
connected to the lower side of diaphragm (4). When
the air pressure rises above 0.05 MPa {0.5 kg/cm2}, the
diaphragm compresses spring (2) and pushes plunger
(3). This brings the points of the plunger and terminal
into contact, and the stop lamps light up.

1. Terminal
2. Spring
3. Plunger
4. Diaphragm
5. Body

GD705A-4 10-97
STRUCTURE AND FUNCTION AUTOMATIC DRAIN VALVE

12
AUTOMATIC DRAIN VALVE
(If equipped)

1. Retainer
2. Filter
3. Body
4. Plug
5. Valve guide
6. Inlet-Exhaust valve
7. Cover

The automatic drain valve is installed at the bottom of


the air reservoir. It acts to automatically drain any
water which forms when the compressor air is cooled.

OPERATION
1. When there is no air pressure inside the air reser-
voir, inlet-exhaust valve (6) is closed.

10-98 GD705A-4
STRUCTURE AND FUNCTION AUTOMATIC DRAIN VALVE

12

2. When air pressure enters the air reservoir, inlet-


exhaust valve (6) opens even when the pressure is
low. Air and water then enters chamber A. The
inlet-exhaust valve stops open until the pressure
inside the air reservoir reaches the maximum
pressure (until the governor is cut-off).

3. When the pressure in the air reservoir and the


pressure in chamber A are equal, the spring
action of valve guide (5) closes inlet-exhaust valve
(6).

4. When the pressure in the air reservoir drops, and


the pressure in chamber A is about 0.03 MPa {0.3
kg/cm2}, inlet-exhaust valve (6) exhausts the air
and water.

GD705A-4 10-99
STRUCTURE AND FUNCTION AIR DRIER

12
AIR DRIER
(If equipped)

DR-5 (With purge chamber)

1. Purge chamber 6. Oil filter A. From compressor


2. Spring 7. Valve B. To air tank
3. Check valve 8. Piston C. From air governor
4. Drier cylinder 9. Body
5. Drying agent 10. Heater

10-100 GD705A-4
STRUCTURE AND FUNCTION AIR DRIER

12

OPERATION
1. Dehumidifying
When the compressor is working, air from the
compressor enters port A of the air drier. The air
then passes through oil filter (6) which is fitted
with an oil mist separator. Here the fine drops of
oil and particles of dust are removed before the air
enters the drier cylinder. Any water still included
in the air is removed by drying agent (5). When
the air reaches the top of the drier cylinder, it is
completely dry. This dry air then passes through
check valve (3) and the purge chamber and is sent
to the main tank.

2. Restoring drying agent


When the air pressure inside the circuit reaches
the set pressure, the command from the governor
switches the compressor to unloading. The same
command is also received by the control ports of
the air drier. Valve (7) opens and the air inside
drier cylinder (4) is released to the atmosphere.
Following this sudden drop in pressure, the dried
air in the purge chamber passes through orifice
"a." Because of the drop in pressure, the dry air
expands and becomes super-dry air. As it flows
back through the drier cylinder, it picks up water
from drying agent and carries it out to the atmo-
sphere.
When the loading cycle starts again, the valve
closes, and the cylinder returns to dehumidifying
action.

GD705A-4 10-101
STRUCTURE AND FUNCTION AIR COMPRESSOR

12
AIR COMPRESSOR

Bore x Stroke: 85 x 59.9 mm


Piston displacement: 340 cc

1. Crankcase 8. Piston 15. Unloader valve


2. O-ring 9. Piston pin 16. Shim
3. Bearing cover 10. Snap ring 17. Gasket
4. Oil seal 11. Oil ring 18. Connecting rod
5. Crankshaft 12. Second ring 19. O-ring
6. Bearing 13. Top ring 20. Bushing
7. Cylinder 14. Cylinder head 21. Drive gear

10-102 GD705A-4
STRUCTURE AND FUNCTION PARKING BRAKE

12
PARKING BRAKE

1. Arm
2. Support plate
3. Drum
4. Return spring
5. Adjuster

GD705A-4 10-103
STRUCTURE AND FUNCTION PARKING BRAKE

12

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit


Replace
1 Wear of brake drum I.D.
+0.2 drum
304.8 0 308

Replace
2 Wear of lining Clearance between lining face and rivet head face: Max. 0.5
lining

Turn or
3 Out of roundness of drum I.D. Repair limit: 0.2
Replace

10-104 GD705A-4
STRUCTURE AND FUNCTION PARKING BRAKE CONTROL

12
PARKING BRAKE CONTROL

1. Parking brake lever


2. Parking brake control wire
3. Lever

10-106 GD705A-4
STRUCTURE AND FUNCTION HYDRAULIC PIPING

HYDRAULIC PIPING
HYDRAULIC TANK TO CONTROL VALVES

STD spec.

1. Work equipment control valve (L.H.)


2. Work equipment control valve (R.H.)
3. Work equipment pump
4. Circle rotatin and ripper (attachment) pump
5. Return filter
6. Hydraulic tank
7. Circle rotation and ripper (attachment) valve
(2-spool valve)

10-108 GD705A-4
STRUCTURE AND FUNCTION HYDRAULIC PIPING

DDV (Dual Demand Valve) spec.

1. Work equipment control valve (R.H.)


2. Dual demand valve
3. Mode control valve
4. Circle rotation and ripper (attachment) pump
5. Work equipment pump
6. Flow divider valve
7. Work equipment control valve (L.H.)
8. Hydraulic tank
9. Return filter

GD705A-4 10-108-1
STRUCTURE AND FUNCTION HYDRAULIC PIPING

12
BLADE LIFT AND LEANING

8. Pilot check valve (for leaning)


9. Pilot check valve (for drawbar shift)
10. Leaning cylinder
11. Pilot check valve (for L.H. blade lift)
12. Pilot check valve (for R.H. blade lift)
13. Articulate cylinder
14. Pilot check valve (for articulate)
15. Blade lift cylinder

GD705A-4 10-109
STRUCTURE AND FUNCTION HYDRAULIC PIPING

12
BLADE SIDE SHIFT, CIRCLE ROTATION AND POWER TILT

19. Circle rotation motor


20. Pilot check valve (for power tilt)
21. Rotary joint
22. Blade side shift cylinder
23. Power tilt cylinder

10-110 GD705A-4
STRUCTURE AND FUNCTION HYDRAULIC PIPING

12
RIPPER (If equipped)

24. Ripper control valve


25. Pilot check valve
26. Ripper cylinder

GD705A-4 10-111
STRUCTURE AND FUNCTION MAIN CONTROL VALVE

12
MAIN CONTROL VALVE

3-Spool valve
Left hand valve
Articulate, Drawbar shift, Blade lift (L.H.)

1. Articulate
2. Drawbar
3. Blade lift (L.H.)
4. Check valve
5. Relief valve

10-112 GD705A-4
STRUCTURE AND FUNCTION MAIN CONTROL VALVE

12
4-Spool valve
Right hand valve
Blade lift (R.H.), Leaning, Blade shift, Power tilt

1. Blade lift (R.H.) spool


2. Leaning spool
3. Blade shift spool
4. Power tilt spool
5. Check valve
6. Relief valve

GD705A-4 10-113
STRUCTURE AND FUNCTION MAIN CONTROL VALVE

12
CIRCLE ROTATION

1. Circle rotation spool


2. Check valve
3. Relief valve

10-114 GD705A-4
STRUCTURE AND FUNCTION MAIN CONTROL VALVE

12
CIRCLE ROTATION AND RIPPER VALVE

1. Circle rotation spool


2. Ripper spool
3. Relief valve
4. Check valve

GD705A-4 10-115
STRUCTURE AND FUNCTION PILOT CHECK VALVE

12
PILOT CHECK VALVE
(For Blade lift R.H.)

1. Pilot valve
2. Check valve
3. Sleeve

OPERATION
Using blade lift cylinder (right) as an example, when
trying to lower the blade, when the control valve is
operated, pressure develops in the cylinder bottom
side of the blade lift cylinder. The pressure passing
the throttle forces the pilot valve (1) downwards and
opens the pilot check valve and returns air and oil at
the head of the cylinder to the tank. Pressure to hold
the blade acts in the blade lift cylinder head side and
pushes the check valve (2).
At the instant the check valve opens, oil escapes sud-
denly from chamber C to chamber A and pressure at
the cylinder bottom side falls.
At this time, if there was no throttle in the pilot valve,
the pilot valve would be constantly opening and shut-
tering in response to the changes in pressure at the
cylinder bottom side and the head side which would
give rise to the phenomena of chattering. For this rea-
son a throttle has been provided at E position, so that,
even if pressure at the cylinder bottom side fails, it has
a damper effect so that the check valve does not close
immediately.

10-116 GD705A-4
STRUCTURE AND FUNCTION PILOT CHECK VALVE

12

(For Leaning, Drawbar)

1. Pilot check valve


2. Body
3. Piston
4. Pilot check valve

OPERATION
When extending the cylinder, if the control valve is
operated, the oil from the pump enters chamber A.
It pushes the pilot check valve and the piston, and
enters chamber C. This forms pressure at the bottom
end. Because the pressure in chamber C rises and
pushes the cylinder, the oil in chamber D passes
through the pilot check valve and flows to chamber B.
The cylinder then extends.

GD705A-4 10-117
STRUCTURE AND FUNCTION PILOT CHECK VALVE

12

(For articulate)

1. Piston
2. Check valve
3. Body
4. Piston
5. Check valve

A. From control valve


B. From control valve
C. To cylinder head
D. To cylinder bottom

Operation
When the hydraulic cylinder tries to extend
and the control valve is operated, the oil from
the pump enters port A, opens check valve
(5), and flows to port D.
When pressure is generated, the oil from ori-
fice a pushes up piston (1), then opens
check valve (2), connects port C and port B,
and the oil flows to the drain port.

There is hunting when check valve (2) opens


and closes according to the change in the
pressure at the bottom end and head end, but
even if the pressure at port A goes down,
there is orifice a, so it has the effect of acting
as a damper to prevent check valve (2) from
closing immediately.

10-118 GD705A-4
STRUCTURE AND FUNCTION PILOT CHECK VALVE

12

(For power tilt)

1. Pilot check valve


2. Body
3. Piston
4. Pilot check valve
5. Spool
6. Poppet

The check and safety valve acts to prevent hydrau-


lic drift of the cylinder, and also protects the cylin-
der from abnormal pressure generated by
external force.

Operation
• When the blade is lowered and the control
valve is actuated, the oil from the pump
enters chamber A2, pushes the pilot check
valve and the piston, and then enters
chamber B2. This oil causes the oil pressure
at the bottom of the cylinder to rise.
• When the oil pressure in chamber B2
(bottom) rises, it pushes the cylinder, and the
oil in chamber B1 passes through the pilot
check valve, flows to chamber A1, and the
cylinder extends.
• If the pressure exceeds 24.52 MPa {250 kg/
cm2}, the oil from chamber B1 pushes the
poppet and flows again to chamber B2.

GD705A-4 10-119
STRUCTURE AND FUNCTION PILOT CHECK VALVE

12

(For Ripper (if equipped))

The check valve with safety valve prevents hydraulic lower the ripper. The oil at the head end of the cylin-
drift of the cylinder. At the same time, it protects the der flows back through chamber A1 and chamber B1,
cylinder from abnormal pressure inside the cylinder and returns to the tank.
caused by external force. When the ripper lever is moved to the RAISE position,
OPERATION the oil from the pump passes from chamber A1
When extending the blade, the oil from the pump through chamber B1 and flows to the chamber at the
passes through chamber A and flows to chamber C. head end of the cylinder. When this happens, the
The pressure at the bottom rises and pushes the cylin- pressure in chambers A1 and B1 rises. As the pres-
der. When the cylinder is pushed, the oil in chamber sure rises, piston (3) is pushed, and check valve (4) is
B1 passes through the pilot valve and flows to cham- pushed open. The oil at the bottom end of the cylinder
ber B. When the oil pressure is more that 24.6 MPa flows through the restriction in check valve (4) and
returns through chamber A2 to the tank. The cylinder
{250 kg/cm2} the oil from chamber D pushes the pop-
retracts and the ripper rises.
pet and flows back to chamber C.
When the ripper is operated, if there is abnormal rip-
When the ripper lever is moved to the LOWER posi- per pressure of over 24.6 MPa {250 kg/cm2}, generated
tion, the oil from the pump passes through chamber in chamber B1, relief valve poppet (6) is pushed down.
A2 and pushes pilot check valve (4). It then passes The oil flows to chamber B2 and raises the ripper to
through chamber B2 and flows to the chamber at the relieve the shock.
bottom end of the cylinder, and extends the cylinder to

10-120 GD705A-4
STRUCTURE AND FUNCTION PILOT CHECK VALVE

12

(For Blade lift L.H. Scarifier (if equipped))

It is installed on the left blade lift and the scarifier cyl- 1. Pilot valve
inders. 2. Check valve
3. Sleeve
4. Adjusting screw
5. Lock nut
6. Sleeve
7. Poppet

A safety valve is installed on the check valve not only


to prevent natural falling of the cylinder and vacuum
developing at the cylinder bottom side, but also to pre-
serve the cylinder against abnormal pressure from
outside forces.

OPERATION
Using blade lift cylinder (left) as an example,
when trying to lower the blade, when the control valve
is operated, pressure develops in the cylinder bottom
side of the blade lift cylinder. The pressure passing
through the throttle forces the pilot valve (1) down-
wards and opens the pilot check valve and returns air
and oil at the head of the cylinder to the tank. Pres-
sure to hold the blade acts in the blade lift cylinder
head side and pushes the check valve (2).
At the instant the check valve opens, oil escapes sud-
denly from chamber C to chamber A and pressure at
the cylinder bottom side falls.
At this time, if there was no throttle in the pilot valve,
the pilot valve would be constantly opening and shut-
tering in response to the changes in pressure at the
cylinder bottom side and the head side which would
give rise to the phenomena of chattering. For this rea-
son a throttle has been provided at E position, so that,
even if pressure at the cylinder bottom side fails, it has
a damper effect so that the check valve does not close
immediately.

GD705A-4 10-121
STRUCTURE AND FUNCTION PILOT CHECK VALVE

12

A safety valve poppet (7) has been installed to pre-


serve the cylinder when high hydraulic pressures
arises in the cylinder head side of the cylinder because
of interference from the work equipment or external
force. When high hydraulic pressure (about 24.6 MPa
{250 kg/cm2}) arises to C, oil flows through the drill
hole in the spool (6) to open the safety valve poppet
(7) to flow to the cylinder bottom side of the cylinder.

10-122 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)

DDV (DUAL DEMAND VALVE)

1. Mode control valve


2. Cable
3. Lever

The DDV (dual demand valve) consists of two de-


mand valves.
The No. 1 demand valve, when in neutral, maintains
the delivery from each pump at a constant level even
if the engine speed is low. Because of this, even if
the engine speed drops, the work equipment can be
moved at the usual speed. For finishing operations,
the mode control valve can be set to the ON position
to obtain a speed for the work equipment to match
the machine speed.
The No. 2 demand valve sends a constant flow of oil
to the circle control valve when the engine speed is
midrange or above. Any unnecessary oil is unload-
ed. This prevents any increase in loss of power and
in this way improves fuel consumption.
When starting in low temperatures, the mode control
valve can be set to the UNLOAD position. This im-
proves the ease of starting by unloading the oil deliv-
ered by the pump without sending it through the work
equipment valve.

10-123-1 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)

MODE CONTROL VALVE

This valve acts to switch the DDV to its various posi- 1. Spool
tions: NEUTRAL, ON, UNLOAD. 2. Body
3. Screw
★ For details of the operation of the DDV (dual de-
ma nd v al ve ) , se e DDV (D UAL D EM AND MA. From dual demand valve
VALVE). MB. To dual demand valve
F. Passage
T. To tank

10-123-3 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)

Unit: mm

No. Check Item Criteria Remedy

Standard Tolerance Standard Clearance


Clearance between spool size shaft Hole clearance limit
4
and valve body
14 — — — —

Standard size Repair limit



Free length Installed Installed Installed
Free length
5 Spool return spring x O.D. length load load

329.0N 78.5N
53.3 x 23.3 10 —
{33.5kg} {8kg}

226N 39.2N
6 Detent spring 30.7 x 7.7 5 —
{23kg} {4kg}

GD705A-4 10-123-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)

OPERATION

1. NEUTRAL
When the DDV lever is placed in the NEUTRAL
position, the oil from DDV port Po enters cham-
ber D. It then passes through chamber C and
flows from chamber B to DDV port Pi.

2. ON
When the DDV lever is placed in the ON position,
the oil from DDV port Pi enters chamber B. It
then flows from chamber A through passage F to
chamber E and is drained to the tank.

3. UNLOAD
When the DDV lever is placed in the UNLOAD
position, the oil from DDV port Po enters cham-
ber D. It then divides into two oil flows. One
passes through chamber E, passage F, chamber
A and chamber B and goes to DDV port Pi. The
other is drained from chamber E to the tank.

10-123-5 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)

DUAL DEMAND VALVE

OPERATION PRINCIPLES OF DDV 1. Pipe


The oil from the hydraulic tank is delivered to DDV 2. Cover
from each pump (pumps 1, 2, and 3). 3. Spring
The DDV distributes the oil to the V1 port (to L.H. and 4. Spool
R.H. hydraulic control valve), V2 port (to circle rota- 5. Body
tion control valve) and T port according to the engine 6. Plug
speed. 7. Cover
8. Cover
9. Spring
10. Spool
11. Spring
12. Plug (Orifice 1)
13. Plug (Orifice 2)

GD705A-4 10-123-6
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)

SYSTEM HYDRAULIC CIRCUIT

10-123-7 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)

PRECONDITIONS PRINCIPLE OF OPERATION WHEN USED


The explanation given so far assumes the control WITH MODE CONTROL VALVE
flow rates of the first and second demand valves to • Position a (NEUTRAL)
be QA and QB, respectively. In actuality, however, See explanation of DDV operation principle,
speeds N1 through N6 vary because of the flow con- items 1 through 10.
trol limits (illustrated) of the first and second demand • Position b (ON)
valves. This position causes pump speed change in pro-
portion to the engine speed.
Since the pump discharge varies in proportion to
the travel speed as with the conventional grader,
fine control at a low travel speed at the time of
road surface finishing operation is possible, This
position is advantageous in improving the finish-
ing speed.
• Position c (UNLOAD)
This position causes unloading of pump dis-
charge P1 through the mode control valve.
Since unloading of the oil from all pumps (P1, P2
and P3) is carried out bypassing operation
valves, the load at the time of engine starting is
small, resulting in improvement of startabilty.

GD705A-4 10-123-8
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)

Distribution to each port is as follows:

1. When the engine speed is N1 or below:


(Fig. 1)
The total volume of the oil from pumps 1, 2 and
3 flows to the V1 port.

10-123-9 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)

2. When the engine speed is from N1 up to N2:


(Fig. 2)
The total volume of the oil from pumps 1 and 2
flows to the V1 port. ∆Q (Q1 + Q2 + Q3 – QA)
out of the oil from pump 3 flows to the V2 port.

GD705A-4 10-123-10
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)

3. When the engine speed is N2: (Fig. 3)


The total volume of oil from pumps 1 and 2 flows
to the V1 port, and the total volume of oil dis-
charged from pump 3 flows to the V2 port.

10-123-11 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)

4. When the engine speed is between N2 and


N3: (Fig. 4)
The total volume of the oil from pump 1 and a
part (QA – Q1) of the oil from pump 2 flow to the
V1 port. The total volume oil from pump 3 and
∆Q (Q1 + Q2 – QA) out of the oil from pump 3
flows to the V2 port.

GD705A-4 10-123-12
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)

5. When the engine speed is between N3 and


N4:
a. Same as item 4 when the oil flowing to the
V1 port is used.
b. When the oil flowing to the V1 port is not
used and is led to the C0 port: (Fig. 5)
The total volume of the oil from pumps 1 and
2 and a part of the oil (QB – Q1 – Q2) from
pump 3 flows to the V2 port and ∆Q (Q1 + Q2
+ Q3 – QB) out of the oil from pump 3 flows
to the T port (for unloading).

10-123-13 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)

6. When the engine speed is N4:


a. Same as item 4 when the oil flowing to the
V1 port is used.
b. When the oil flowing to the V1 port is not
used and is led to the C0 port: (Fig. 6)
The total volume of oil from pumps 1 and 2
flows to the V2 port and the total volume of
oil from pump 3 flows to the T port.

GD705A-4 10-123-14
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)

7. When the engine speed is between N4 and


N5:
a. Same as item 4 when the oil flowing to the
V1 port is used.
b. When the oil flowing of the V1 port is not
used and is led to the C0 port: (Fig. 7)
The total volume of oil from pump 1 and a
part of oil (OB – Q1) from pumps 2 flows to
the V2 port.
The total volume of the oil from pump 3 and
∆Q = Q1 + Q2 – QB) of the oil from
a part (∆
pump 2 flows to the T port.

10-123-15 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)

8. When the engine speed is between N5 and


N6:
a. When the oil flowing to the V1 port is used:
(Fig. 8)
The total volume of oil from pump 1 and a
part (QA – Q1) of the oil from pump 2 flows
to the V1 port.
A part (∆∆Q = Q1 + Q2 – QA) of the oil from
pump 2 and a part (QA + QB – Q1 – Q2) of
the oil from pump 3 flows to the V2 port.
A part (∆ ∆Q = Q1 + Q2 + Q3 – QA – QB) of
the oil from pump 3 flows to the T port.
b. Same as 7 (b) when the oil flowing to the V1
port is not used and is led to the C0 port.

GD705A-4 10-123-16
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)

9. When the engine speed is N6 or above:


a. When the oil flowing to the V1 port is used:
(Fig. 9)
The total volume of the oil from pump 1 flows
to the V1 port. The total volume of the oil
from pump 2 and a part (∆∆Q = Q2 + Q3 – QB)
from pump 3 flows to the T port.

10-123-17 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)

b. When the oil flowing to the V1 port is not


used and is led to the C0 port: (Fig. 10)
The total volume of the oil from pump 1 flows
to the V1 port → C0 port. The total volume
∆Q = Q1 +
of the oil from pump 3 and a part (∆
Q2 – QB) of the oil from pump 2 flows to the
T port. Therefore, the total volume of oil from
pump 1 and a part (QB – Q1) of the oil from
pump 2 flows to the V2 port.

GD705A-4 10-123-18
STRUCTURE AND FUNCTION FLOW DIVIDER VALVE

FLOW DIVIDER VALVE

1. O-ring
2. Plug
3. Snap ring
4. Sleeve
5. Piston
6. Housing

The oil from the DDV enters chamber A and is divid-


ed according to a constant flow ratio. It then passes
through throttles B1 and B2, then through chambers
C1 and C2, and goes to the hydraulic control valve.

10-123-19 GD705A-4
STRUCTURE AND FUNCTION HYDRAULIC PUMP

12
HYDRAULIC PUMP
FOR WORK EQUIPMENT (KFP3223-23CFESE)

1. Drive gear 8. Drive gear


2. Snap ring 9. Cover
3. Oil seal 10. Driven gear
4. Flange 11. Center plate
5. Gear case 12. Driven gear
6. Coupling 13. Bushing
7. Gear case

10-124 GD705A-4
STRUCTURE AND FUNCTION HYDRAULIC PUMP

12

Unit: mm

No. Check Item Criteria Remedy

Standard size Repair limit


1. Diameter of gear shaft Replace
--- 24.895
2. Pressure plate --- 6.676 Replace

Teflon layer is worn and red Replace mount-


copper color portion of base ing flange, cover,
3. Wear of drive-in bushing ---
metal is exposed for more etc.
Replace driven
than 150o gear, drive gear
Depth of gear contact traces Replace pump
4. --- Max. 0.12
on housing assembly
Discharge Standard Discharge
Speed pressure discharge limit
Front pump (rpm)
MPa {kg/cm2} (O/min.) (O/min.)
(L.H. control valve)
Discharge

(EO10-CD: 50oC)
--- 2,340 17.2 {175} 49 --- ---

Rear pump
(R.H. control valve) 2,340 17.2 {175} 49 ---
(EO10-CD: 50oC)

GD705A-4 10-125
STRUCTURE AND FUNCTION CIRCLE ROTATION MOTOR

12
CIRCLE ROTATION MOTOR

Orbit motor is used for circle rotation motor; the 1. Output shaft 7. Geroler housing
machine is mounted with this motor on drawbar. Star 2. Flange 8. Disc valve drive shaft
gear (6) turns with high hydraulic pressure, thereby
rotating output shaft (1) which turns together with the 3. Oil seal 9. Disc valve
star gear (6) and the main drive shaft (5). 4. Taper roller bearing 10. Check valve
This output shaft is connected to circle rotation gear
5. Main drive shaft 11. Valve plate
case. Since star gear (6) engages with disc valve drive
shaft (8), disc valve (9) also turns, thus changing the 6. Star gear 12. Pump housing
position where the hydraulic oil to Geroler (7) enters.

HYDRAULIC PUMP TYPE


GD705A-4

Roller 37.5 mm

Theoretical oil quantity 246 cc/rev.

Rated speed 603 rpm

Instantaneous maximum torque 68.5 kgm

Instantaneous maximum pressure 17.2 MPa (175 kg/cm2)

Weight 18.8 kg

GD705A-4 10-127
STRUCTURE AND FUNCTION CIRCLE ROTATION MOTOR

12

Disc valve (9) is furnished with twelve oil holes; the oil
of high pressure flows through six oil holes, and the
other oil holes serve as a drain port. Disc valve (9)
contacts the valve plate (11) with seven oil holes.
These oil holes in the valve plate (11) are connected to
the chamber made up of star gear (6) and Geroler (7).
The oil of high pressure, which has entered to each
travelling motor, goes into the chamber via the disc
valve (9) and valve plate (11). When the oil of high
pressure flows into the chamber, the star gear (6)
starts running with the hydraulic pressure. When the
star gear (6) rotates, disc valve (9) turns. Thus, the
position where the high-pressure oil is delivered to the
chamber, is shifted in regular sequence.

10-128 GD705A-4
STRUCTURE AND FUNCTION CIRCLE ROTATION MOTOR

12
The star gear (6) rotates on its own axis and it also
revolves around the center of Geroler. The rotation of
star gear (6) is transmitted to the output shaft via the
main drive shaft.

When star gear (6) makes 1/7 of a rotation left-ward on


its own axis, it makes 6/7 of a revolution right-ward.
Namely, when the star gear makes one revolution, it
rotates 1/6 of a rotation on its own axis. As a result,
compared with general hydraulic motors (the differ-
ence from the orbit motor can be understood more
easily when compared with the trochoid motor), this
orbit more makes available a torque 6 times as large
as that possible with hydraulic motors. In addition,
the rotating speed of the orbit motor can be reduced
to as low as 1/6 speed of hydraulic motors. Neverthe-
less, the orbit motor is designed to be of the compact
type.

GD705A-4 10-129
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER

12
HYDRAULIC CYLINDER
BLADE LIFT CYLINDER

1. Cap
2. Cylinder head
3. Cylinder
4. Piston
5. Wear ring
6. Piston nut
7. Bushing
8. Piston ring
9. Piston rod
10. Rod packing
11. Bushing
12. Dust seal

10-130 GD705A-4
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER

12
BLADE SIDE SHIFT CYLINDER

1. Bushing
2. Cylinder head
3. Cylinder
4. Piston
5. Wear ring
6. Piston nut
7. Piston ring
8. Piston rod
9. Rod packing
10. Bushing
11. Dust seal
12. Bushing

GD705A-4 10-131
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER

12
DRAWBAR SHIFT CYLINDER

1. Cap
2. Cylinder head
3. Cylinder
4. Piston
5. Wear ring
6. Piston nut
7. Piston ring
8. Piston rod
9. Rod packing
10. Bushing
11. Dust seal

10-132 GD705A-4
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER

12
LEANING CYLINDER

1. Cylinder head
2. Cylinder
3. Piston
4. Wear ring
5. Piston nut
6. Bushing (bottom side)
7. Piston ring
8. Piston rod
9. Rod packing
10. Bushing
11. Dust seal
12. Bushing (head side)

GD705A-4 10-133
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER

12
ARTICULATE CYLINDER

POWER TILT CYLINDER

1. Cylinder head
2. Cylinder
3. Piston
4. Wearing
5. Piston nut
6. Bushing (bottom side)
7. Piston ring
8. Piston rod
9. Rod packing
10. Bushing
11. Dust seal
12. Bushing (head side)

10-134 GD705A-4
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER

12
SCARIFIER CYLINDER (If equipped)

1. Cylinder head
2. Cylinder
3. Piston
4. Wearing
5. Piston nut
6. Bushing (bottom side)
7. Piston ring
8. Piston rod
9. Rod packing
10. Bushing
11. Dust seal
12. Bushing (head side)

GD705A-4 10-135
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER

12
RIPPER CYLINDER

1. Cylinder
2. Piston
3. Wearing
4. Piston nut
5. Piston ring
6. Rod packing
7. Bushing
8. Dust seal
9. Bushing (head side)

10-136 GD705A-4
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER

12

OUTLINE
The hydraulic cylinder is a mechanism for converting
fluid energy into mechanical energy for linear drive
purposes. The cylinder has oil inlets and outlets at
both head end (piston rod end) and the bottom end,
and by applying oil pressure to both ends, the oil is
alternately forced in and out of the cylinder resulting
in the piston and piston rod being moved back and
forth.
Cylinders with this kind of action are referred to as
double-acting cylinders and are used in motor grader.

STRUCTURE AND FUNCTION


Cylinder
Cylinders are made of steel piping with a base welded
to the bottom. The inside of the piping is finished by
honing in order to prevent oil leakage and abrasion
with the packing.

Cylinder head
The cylinder head of motor grader is secured to the
cylinder by cutting a thread into the head and screw-
ing it into the cylinder.
The cylinder head has a center hole through which the
piston rod is passed. This hole is fitted with a bronze
bushing to prevent the piston rod from rubbing
directly against the cylinder head.
This section is also packed to prevent leakage of cylin-
der oil through the gab between the cylinder head and
piston rod. In addition, a dust seal is employed to pre-
vent grit adhering to the piston rod from being carried
into the cylinder when the rod is pushed in.

GD705A-4 10-137
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER

12

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Clearance
Standard size
clearance limit
Shaft Hole

-0.100 +0.163
Blade lift 55 0.106-0.337 0.6
-0.174 +0.006

Blade side -0.100 +0.163


55 0.106-0.337 0.6
shift -0.174 +0.006

Drawbar -0.100 +0.163


55 0.106-0.337 0.6
shift -0.174 +0.006

Clearance between -0.030 +0.007


1 Leaning 45 0.026-0.182 0.6 Replace
piston rod and bushing -0.019 +0.152

-0.100 +0.163
Articulate 55 0.106-0.337 0.6
-0.174 +0.006

-0.030 +0.164
Power tilt 50 0.037-0.306 0.6
-0.142 +0.007

Ripper -0.100 +0.271


70 0.175-0.445 0.6
(If equipped) -0.174 +0.075

Scarifier -0.100 +0.163


55 0.106-0.337 0.6
(If equipped) -0.174 +0.006

Blade lift 90 - - - -

Blade side -0.050 (-0.025) +0.142 0.130-0.292


50 1.0
shift -0.15 (-0.064) +0.080 (0.105-0.250)

Drawbar
90 - - - -
shift

-0.025 +0.142
Leaning 50 0.105-0.206 1.0
-0.064 +0.080
Clearance between
piston rod support shift
2 -0.030 +0.174 Replace
(ball joint) and bushing Articulate 60 0.130-0.350 1.0
(rod end) -0.076 +0.100

0 0
Power tilt 60 0-0.004 0.6
-0.019 -0.015

Ripper +0.035 +0.174


75 0.065-0.174 1.0
(If equipped) 0 +0.100

Scarifier -0.025 +0.142


50 0.105-0.206 1.0
(If equipped) -0.064 +0.080

(): For serial No. 21086 and up

10-138 GD705A-4
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER

12
Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Clearance
Standard size
clearance limit
Shaft Hole

-0.100 +0.271
Blade lift 70 0.195-0.445 1.0
-0.174 +0.095

Blade side -0.100 +0.271


70 0.195-0.445 1.0
shift -0.174 +0.095

(Blade side (+0.025 (+0.142


(50) (0.105-0.206) (1.0)
shift) +0.064) +0.080)

Clearance between Drawbar


cylinder bottom yoke 90 - - - -
shift
3 (Support, support shaft, Replace
support ball joint) and -0.025 +0.163
bushing (rod end) Leaning 50 0.031-0.227 1.0
-0.064 +0.006

-0.030 +0.174
Articulate 60 0.130-0.350 1.0
-0.076 +0.100

-0.100 +0.074
Power tilt 75 0.100-0.248 1.0
-0.174 0

Ripper -0.035 +0.207


90 0.085-0.207 1.0
(If equipped) 0 +0.120

Scarifier -0.025 +0.142


50 0.105-0.206 1.0
(If equipped) -0.064 +0.080

Blade lift 1422 ± 142 Nm {145 ± 14.5 kgm} (785 ± 78.5 Nm {80 ± 8 kgm})

Blade side
1422 ± 142 Nm {145 ± 14.5 kgm} (785 ± 78.5 Nm {80 ± 8 kgm})
shift

Drawbar
1422 ± 142 Nm {145 ± 14.5 kgm} (785 ± 78.5 Nm {80 ± 8 kgm})
shift

Leaning 1079 ± 107 Nm {110 ± 11.0 kgm} (785 ± 78.5 Nm {80 ± 8 kgm})
Tightening torque for
4
piston nut Articulate 1422 ± 142 Nm {145 ± 14.5 kgm}

Power tilt 1422 ± 142 Nm {145 ± 14.5 kgm}

Ripper
3972 ± 397 Nm {405 ± 40.5 kgm}
(If equipped)

Scarifier
1422 ± 142 Nm {145 ± 14.5 kgm}
(If equipped)
Retighten
Blade lift 677 ± 67.5 Nm {69 ± 6.9 kgm}

Blade side
677 ± 67.5 Nm {69 ± 6.9 kgm}
shift

Drawbar
677 ± 67.5 Nm {69 ± 6.9 kgm}
shift

Leaning 677 ± 67.5 Nm {69 ± 6.9 kgm}


Tightening torque for
5
cylinder head Articulate 932 ± 93.2 Nm {95 ± 9.5 kgm}

Power tilt 785 ± 83.4 Nm {80 ± 8.5 kgm}

Ripper
927 ± 103 Nm {94.5 ± 10.5 kgm}
(If equipped)

Scarifier
677 ± 67.5 Nm {69 ± 6.9 kgm}
(If equipped)

(): For serial No. 21086 and up

GD705A-4 10-139
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL

12
WORK EQUIPMENT CONTROL

OUTLINE 1. Blade lift (R.H.) lever 9. Drawbar shift lever


• Turn tilt lever (5) of the tilt
mechanism for the steering 2. Leaning lever 10. Blade lift (L.H.) lever
wheel and instrument panel to 3. Blade side shift lever 11. Work equipment control lever
release the lock, set the steering
wheel to the desired position, 4. Power tilt lever 12. Work equipment control lever
then turn the lever again to lock
the tilt. 5. Scarifier lever (if equipped) 13. Console box tilt pedal
Tilt angle: 10° (stepless) 6. Steering wheel tilt lever 14. Dowel pin

• Tilt mechanism for console box. 7. Articulate lever 15. Control valve (for circle reverse)
• When tilt pedal (12) is
depressed, dowel pin (13) 8. Circle rotation lever
comes out and it is possible
to adjust the angle of the
console box.
• When the pedal is released,
the dowel pin holds the
console box in position.
Tilt angle: 30° (5 stages)

10-140 GD705A-4
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL

12

GD705A-4 10-141
STRUCTURE AND FUNCTION WORK EQUIPMENT

12
WORK EQUIPMENT
DRAWBAR

1. Shim
2. Ball joint
3. Nut
4. Drawbar
5. Guide
6. Shim
7. Bolt
8. Guide
9. Shim
10. Bolt
11. Bolt

10-142 GD705A-4
STRUCTURE AND FUNCTION WORK EQUIPMENT

12
CIRCLE ROTATION GEAR

★ Use CLASS-CD SAE90 gear oil for all seasons.

The circle rotation gear is driven by an oil motor 1. Drain plug


through coupling (3). 2. Worm gear
The joint (11) and circle pinion gear (6) are connected
by a shear pin (10). If an abnormal torque is transmit- 3. Coupling
ted from the blade, the shear pin (10) is cut through at 4. Case
(a) and prevents breakage of blade system.
5. Worm wheel
6. Gear (circle pinion gear)
7. Shaft
8. Plate
9. Bolt
10. Shear pin
11. Joint
12. Pin
13. Lock plate
14. Oil filler plug

GD705A-4 10-143
STRUCTURE AND FUNCTION WORK EQUIPMENT

12
LIFTER

1. Bracket (Upper)
2. Shim
3. Bolt
4. Bracket (Lower)
5. Yoke
6. Pin
7. Busing
8. Pin

10-144 GD705A-4
STRUCTURE AND FUNCTION WORK EQUIPMENT

12
BLADE AND CIRCLE

1. Bracket
2. Support
3. Blade shift cylinder
4. Blade
5. End bit
6. Power tilt cylinder
7. Adjuster
8. Cutting edge
9. Yoke
10. Guide
11. Nut
12. Bolt

GD705A-4 10-145
STRUCTURE AND FUNCTION WORK EQUIPMENT

12
LIFTER BRACKET CONTROL

1. Bank lock solenoid valve


2. Pin
3. Piston
4. Spring
5. Air tube

10-146 GD705A-4
STRUCTURE AND FUNCTION WORK EQUIPMENT

12
REAR MOUNT RIPPER (If equipped)

Ripper lifting height and digging height can be 1. Ripper cylinder


adjusted with hydraulic cylinder (1). Since the point 2. Pin
tips cut into the ground under the load of the ripper’s
heavy weight, the ripper easily performs heavy-duty 3. Bracket
digging work which cannot be done by the scarifier. 4. Shank pin
Two kinds of points are selectively used: A short point
5. Shank
for heavy-duty work and a long point for ordinary
work. 6. Point

GD705A-4 10-147
STRUCTURE AND FUNCTION WORK EQUIPMENT

12
SCARIFIER (If equipped)

The lifting height and digging depth of the scarifier 1. Scarifier cylinder
can be changed by moving the connecting holes (a), 2. Arm
(b) and (c) of the rod (5) and pipe (6).
Also, the digging angle, lifting height and digging 3. Scarifier lift arm
depth of the scarifier teeth (8) can be changed by mov- 4. Pin
ing bolt (9) into holes (e), (f) or (g) on the scarifier
5. Rod
body. When in (g) position especially, the blade can
be revolved 360o, when the scarifier teeth are 6. Pipe
extracted and the scarifier raised up. 7. Scarifier body
8. Scarifier teeth
9. Bolt
10. Wedge
11. Pin

10-148 GD705A-4
STRUCTURE AND FUNCTION WORK EQUIPMENT

12
BLADE ACCUMULATOR SYSTEM (If equipped)

1. Bolt 6. Bolt 11. Tube


2. Bolt 7. Accumulator 12. Bracket
3. Pilot check valve 8. Clip 13. Nipple
4. Solenoid valve 9. Valve 14. Tube
5. Cover 10. Nipple 15. Bracket

GD705A-4 10-149
STRUCTURE AND FUNCTION WORK EQUIPMENT

12

10-150 GD705A-4
STRUCTURE AND FUNCTION WORK EQUIPMENT

12

GD705A-4 10-151
STRUCTURE AND FUNCTION WORK EQUIPMENT

12

FUNCTION bladder expands by the gas pressure in bladder (3),


When oil pressure is applied from the blade cylinder, allowing the oil in the shell to drain out until the oil
the pressurized oil flows to the accumulator through pressure in the shell balances that from the blade cyl-
the solenoid valve, pushing valve (6). This in turn inder side. At this time, valve (5) on the underside of
pushes valve (4), allowing the oil to flow into shell (2) the accumulator closes throttling the return oil. This
from the blade cylinder. Thereby, bladder (3) is com- prevents the oil in shell (2) from flowing out abruptly
pressed. and prevents the bladder from striking against the
Consequently, the shock imposed on the blade cylin- inside of the shell.
der is reduced by the compressible amount of the The flow of oil in the accumulator hydraulic circuit is
bladder. repeated smoothly to reduce the shock imposed on
When the oil pressure in the cylinder drops, the the blade.

10-152 GD705A-4
STRUCTURE AND FUNCTION WORK EQUIPMENT

12

INSTALLATION PROCEDURE

1. Install valve (9) and elbow on accumulator body 5. Since the system is set up according to this proce-
(7). dure must be provided on each side of the frame,
2. Hold the accumulator body with clip (8) and tem- follow the above procedure again to form the
porarily attach the accumulator body to the frame same system on the other side of the frame.
with bolts (6) and washers. 6. After connecting the piping, tighten the tempo-
3. Temporarily attach solenoid valve bracket (12) to rarily attached portions positively.
the frame bracket (15) with bolts (2) and washers. 7. Secure solenoid valve (4) to the solenoid valve
4. Connect nipple (13), which has nipples for tubes bracket (12).
(14) and (11) on the underside of solenoid valve
bracket, to nipple in advance, and tighten them
together.

GD705A-4 10-153
STRUCTURE AND FUNCTION WORK EQUIPMENT

12
DRAWBAR

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Clearance
Standard size
clearance limit
Wear of drawbar ball joint Shaft Hole
1
end
-0.05 +0.1
150 0.05-0.25 -
-0.15 0

Standard clearance Clearance limit


Clearance between circle
2
and drawbar
1.5 1.0 - 2.0

10-154 GD705A-4
STRUCTURE AND FUNCTION WORK EQUIPMENT

12
BLADE LIFTER EQUIPMENT

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Clearance
Standard size
clearance limit
Clearance between yoke and Shaft Hole
1
bushing
-0.036 +0.071
85 0.037-0.161 0.6 Replace
-0.090 +0.001

Clearance between blade side


-0.100 +0.074
2 shift cylinder bottom side 70 0.100-0.248 1.0
-0.174 0
yoke and bushing

3 Wear of lifter Standard thickness of shim: 2 Replace

Standard clearance Clearance limit


4 Axial clearance of yoke Replace
0.3 - 0.8 1.7

GD705A-4 10-155
STRUCTURE AND FUNCTION WORK EQUIPMENT

12
CIRCLE ROTATION GEAR

Unit: mm

No. Check item Criteria Remedy

Tolerance Repair
Standard
Standard size
clearance limit
Clearance between worm gear Shaft Hole
1
shaft and bushing
-0.030 +0.057 Replace
65 0.040-0.117 0.3
-0.060 +0.010

Clearance between worm gear -0.035 +0.226


2 65 0.035-0.221 0.3
shaft and bushing -0.005 0.069

Standard clearance Clearance limit


Backlash between worm and
3 Replace
worm wheel
0.3 - 0.5 2.0

Clearance between pinion and


4 0.1 - 0.5 0.6 Adjust
wear plate

Standard size Repair limit


5 Wear of pinion gear Replace
25 20

Starting torque 0.5 - 1.0 kgm


6 Preload of worm shaft bearing Adjust
(when worm wheel is not meshed)

7 Tightening torque of filter plug 93.2 122.6 Nm {9.5 - 12.5 kgm}

Tightening torque of drain


8 93.2 122.6 Nm {9.5 - 12.5 kgm}
plug

10-156 GD705A-4
STRUCTURE AND FUNCTION WORK EQUIPMENT

12
SCARIFIER (If equipped)

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Clearance
Standard size
clearance limit
Clearance between shaft and Shaft Hole Replace
1
bushing bushing
-0.036 +0.207
110 0.156-0.297 0.7
-0.090 +0.120

-0.05 +0.1
2 Wear of ball joint 70 0.05-0.25 0.5 Adjust shim
-0.015 0

Standard size Repair limit


Replace
3 Wear of tooth Standard 450 330
tooth
With point tooth 450 410

GD705A-4 10-157
STRUCTURE AND FUNCTION WORK EQUIPMENT

12
REAR MOUNT RIPPER (If equipped)

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Clearance
Standard size
Clearance between clearance limit
Shaft Hole
1 Replace
pin and bushing
-0.025 +0.046
60 0.025-0.101 0.5
-0.055 0

Clearance between pin and -0.025 +0.046


2 60 0.025-0.101 0.5 Replace
bushing -0.055 0

Clearance between pin and -0.030 +0.089


3 75 0.065-0.165 0.5 Replace
bushing -0.076 +0.035

Standard size Repair limit


4 Wear of point Replace
290 150

10-158 GD705A-4
STRUCTURE AND FUNCTION WORK EQUIPMENT

12
BLADE AND CIRCLE

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Clearance
Standard size
Clearance between blade shift clearance limit
Shaft Hole
1 cylinder support yoke and Replace
adjuster
-0.030 +0.030
80 0.030-0.106 0.5
-0.076 0

2 Wear of cutting edge Max. 10 mm (from blade base)

3 Wear of side edge Clearance limit: Side face 25


Max. 10 mm (from blade base)
Replace
Repair limit: Height 105
4 Wear of blade rail Thickness 22

5 Wear of blade rail guide Repair limit: 10

GD705A-4 10-159
20 TESTING AND ADJUSTING

12

STANDARD VALUE TABLE


Standard value table for engine . . .20-2
Standard value table for chassis . .20-3

TESTING AND ADJUSTING. . . . . . .20-101


TROUBLESHOOTING . . . . . . . . . . . .20-201

★ Note the following when making judgments using the standard value tables for testing, adjusting or
troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine
from the factory and is given for reference. It is used as a guideline for judging the progress of wear after
the machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the stat of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.

When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset
the safety pins, and use blocks to prevent the machine from moving.

When carrying out work together with other workers, always use signals and do not let unautho-
rized people near the machine.

When checking the water level, always wait for the water to cool down. If the radiator cap is
removed when the water is still hot, the water will spurt out and cause burns.

Be careful not to get caught in the fan, fan belt or other rotating parts.

GD705A-4 20-1
1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE

12
STANDARD VALUE TABLE FOR ENGINE

Machine model GD705A-4

Engine model S6D125-1


Cate- Permissible
Item Condition, etc. Unit Standard value
gory value
High idling speed rpm 2200 ± 50 ---
Performance

Engine speed +50


Low idling speed rpm 650 0 ---

0oC rpm Min. 100 ---


Necessary starting speed
-20oC (Using starting aid) rpm Min. 85 ---
kPa Max. 2.94 Max. 7.48
Intake resistance All speed
{mmH2O} {300} {762}
Intake and exhaust system

kPa Min. 61.2 Min. 53.2


Intake pressure All speed
{mmHg} {460} {400}
All speed oC
Exhaust temperature Max. 600 Max. 650
(intake air temp.: 20oC)
Quick acceleration Bosch Max. 4.0 ---
Exhaust gas color
At high idling scale Max. 1.0 ---
Intake valve mm 0.33 0.33
Valve clearance at 20oC
Exhaust valve mm 0.71 0.71
MPa 31.4 - 3.53
Compression pressure Oil temperature: 40 - 60oC
{kg/cm2}
Engine body

{32 - 36} ---


(SAE30)
(Engine speed) (rpm) (240 - 260)
At high idling
Blow-by pressure kPa Max. 1.47 1.96
(Water temperature operating
(SAE30) {mmH2O} {150} {200}
range)
MPa 0.294 - 0.491 0.206
At high idling
Oil pressure (Water {kg/cm2} {3.0 - 5.0} {2.1}
Lubrication system

(SAE30, Oil temperature: temperature


operating
Min. 80oC) range) MPa Min. 0.157 0.069
At low idling
{kg/cm2} {1.6} {0.7}
All speed oC
Oil temperature 80 - 110 120
(Oil in oil pan)
At continuous rated output
Oil consumption ratio % Max. 0.5 1.0
(Ratio to fuel consumption)
MPa 24.5 22.1
system

Fuel injection pressure Nozzle tester


Fuel

{kg/cm2} {250} {225}


Fuel injection timing B.T.D.C. Degree 26 ± 1 26 ± 1
Radiator pressure Opening pressure MPa 0.069 ± 0.010 0.069 ± 0.010
Cooling system

valve function (Differential pressure) {kg/cm2} {0.7 ± 0.1} {0.7 ± 0.1}


At rated rpm --- ---
Fan speed rpm
At high idling speed 1,870 ---
Deflect when pushed with a force
Fan belt tension mm 13 10 - 16
of 6 kg

20-2 GD705A-4
1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

12
STANDARD VALUE TABLE FOR CHASSIS

Machine model GD705A-4


Cate-
Item Test condition Standard value
gory
Amount of movement from center of lever knob
Fuel control lever 110 ± 10 mm
from slow to full rotation

Accelerator pedal Amount of movement in up-down direction 48 ± 10 mm

Inching pedal Amount of movement in up-down direction 55 ± 10 mm

Ability to hold in stopped condition on 1/5 incline Within range of


Parking brake lever
paved surface 2 - 3 notches
N→1 Engine stopped, stoke of tip of lever 55 ± 10 mm
Stroke

1→2 Engine stopped, stoke of tip of lever 50 ± 10 mm

2→3 Engine stopped, stoke of tip of lever 45 ± 10 mm

3→4 Engine stopped, stoke of tip of lever 45 ± 10 mm


Gear shift lever
4→5 Engine stopped, stoke of tip of lever 45 ± 10 mm

5→6 Engine stopped, stoke of tip of lever 45 ± 10 mm

6→7 Engine stopped, stoke of tip of lever 45 ± 10 mm

7→8 Engine stopped, stoke of tip of lever 45 ± 10 mm


Maximum value at tip of lever until just before 88.3 ± 19.6 N
Fuel control lever
stroke end {9 ± 2 kg}
Accelerator pedal 98.1 ± 19.6 N
Maximum value until just before stroke end
(depression force) {10 ± 2 kg}
Operating force
Power train

68.6 ± 19.6 N
Inching pedal Maximum value until just before stoke end
{7 ± 2 kg}
Brake pedal Max. 294 N
Measured with wheels completely locked
(depression force) {Max. 30 kg}
Ability to hold in stopped condition on 1/5 incline Max. 196 N
Parking brake lever
paved surface {Max. 20 kg}
Max. 49 N
Gear shift lever Maximum value until just before stoke end
{Max. 5 kg}
Engine cooling water • Oil and water levels are normal Max. 100oC
Engine oil temperature • Air temperature 40oC conversion Max. 120oC
Heat balance

Transmission oil temperature • Performed at a continuous traction (F-2) Max. 120oC


Final drive oil temperature • On a concrete road surface Max. 120oC
Tandem case oil temperature • Using thermistor Max. 120oC
Hydraulic oil temperature • Performed with thermostat open Max. 120oC
Height of inching pedal
120 ± 5 mm
(when not operating)
Height of inching pedal Height from the floor to the center of the stopper
mounting bolt 15 ± 1 mm
(during operation)
Others

Inching pedal play 0 mm

At engine full rotation, F-6, using both the parking


brake and the wheel brake, the engine should
Transmission operating Within 3.0 sec.
stop within the ruled value when the inching
pedal is released.

GD705A-4 20-3
1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

12
Machine model GD705A-4
Cate-
Item Test condition Standard value
gory

Steering wheel turning angle 5.35 turns ± 50 degrees


Stroke

Leaning lever Travel at the tip of the lever 45 ± 10 mm

Articulation lever Travel at the tip of the lever 40 ± 10 mm

Steering wheel
Operating force

When traveling at engine slow rotation, F-1 Max. 50 N {Max. 5 kg}


(turning direction)

Leaning lever Maximum value until just before stroke end Max. 50 N {Max. 5 kg}
Steering system

Articulation lever Maximum value until just before stroke end Max. 50 N {Max. 5 kg}

Measure tire side surface of both front and rear


Tire vibration Max. 7 mm
wheels with dial gauge
Front wheel 0.343 ± 0.020 MPa
Tire air pressure
Rear wheel {3.5 ± 0.2 kg/cm2}
Camber Level paved surface 1.5 degree ± 50%
Wheels

Toe in Level paved surface 8.5 ± 1.5 mm


Leaning angle Level paved surface 23.5 ± 2 degrees
Wheel bearing band Measure at surface of wheel cap after traveling
temperature 10 km Max. 40oC

At engine slow rotation, and with the tires float-


Steering wheel play ing measured at the outside circumference of 10 - 12 mm
the steering wheel

20-4 GD705A-4
1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

12
Machine model GD705A-4
Cate-
Item Test condition Standard value
gory

Work equipment Blade lift left, right Engine stopped, stroke at the tip of the lever 40 ± 10 mm

Blade side shift Engine stopped, stroke at the tip of the lever 40 ± 10 mm
control lever
Stroke

Drawbar shift Engine stopped, stroke at the tip of the lever 40 ± 10 mm

Circle rotation Engine stopped, stroke at the tip of the lever 45 ± 10 mm

Power tilt Engine stopped, stroke at the tip of the lever 45 ± 10 mm


Operating
force

Work equipment control lever Maximum value until just before stroke end Max. 49 N {Max. 5 kg}

1. Blade Oil temperature: 40 ± 5oC 210 ± 8.4 mm/s


1-1. Blade lifting speed (rising)
Work equipment

When engine at rated rotation, the speed of lifting


1-2. Blade lifting speed or lowering the blade with the lower edge of the
140 ± 5.6 mm/s
(lowering) blade 50 - 150 mm above ground.
1-3. Speed of cross-feed by cir- When engine at rated rotation and the height of 120 ± 4.8 mm/s
cle move - left the lower edge of the blade 100 mm, speed of left
1-4. Speed of cross-feed by cir- and right side shifting by a level circle movement
of 200 mm under standard position. 180 ± 7.2 mm/s
cle movement - right
Performance

1-5. Speed of side shift in rota- When engine at rated rotation and the height of
140 ± 5.6 mm/s
tion to circle - left the lower edge of the blade 100 mm, speed of the
1-6. Speed of side shift in rota- left and right side shifting in rotation to a circle of
tion to circle - right a level distance of 200 mm under standard posi- 220 ± 8.8 mm/s
tion.
1-7. Turning speed by circle
Angle speed with engine at rated rotation speed 14.5 ± 0.87 degrees/s
rotation
1-8. Hydraulic drift of blade Amount of lowering of cylinder when the blade is
(hanging down) suspended symmetrically perpendicular to the Max. 10 mm / 10 min
machine
1-9. Hydraulic drift of machine Amount of cylinder sinking when the lower edge
(support by blade) of the blade is in contact with the ground and the Max. 20 mm / 10 min
front wheels floating.

GD705A-4 20-5
1
TESTING AND ADJUSTING

12
Testing and adjusting tool list (For engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-102
Testing and adjusting valve clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-103
Measuring compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-104
Measuring blow-by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
Testing and adjusting fan belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
Testing and adjusting fuel injection timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-107
Inching pedal stroke and operating force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-109
HYDROSHIFT transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110
Transmission control lever stroke and operating force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-112
Adjusting F/R Control cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-113
Adjusting transmission control linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-114
Steering wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
Checking tire play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-117
Checking tire air pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-117
Checking toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-118
Checking parking brake lever stroke and operating force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120
Checking wear of brake disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121
Checking hydraulic oil pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-122
Checking hydraulic oil temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-123
Checking work equipment control lever stroke and operating force . . . . . . . . . . . . . . . . . . . . . . 20-124
Hydraulic drift of blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-124
Measuring blade sinking amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-124

GD705A-4 20-101
1
TESTING AND ADJUSTING TESTING AND ADJUSTING TOOL LIST

12
TESTING AND ADJUSTING TOOL LIST
(For engine)

No. Testing and measuring item Fault finding tool Part No. Remarks

Digital reading, pressure sensing


1 Engine speed Multi-meter 799-203-8000
type 60 - 19,999 rpm

2 Battery S.G. 1.100 - 1.300


Battery coolant tester 795-500-1000
3 Freezing temperature of cooling water -5 to -50oC

Water temperature, oil temperature,


4
air intake temperature Thermistor temperature
gauge
799-101-1502 -99.9 - 1299oC
5 Exhaust temperature

6 Lubrication oil pressure 0 - 0.98 MPa {0 - 10 kg/cm2}

7 Fuel pressure 0 - 1.96 MPa {0 - 20 kg/cm2}

Engine pressure measur-


8 Intake pressure, exhaust pressure 799-101-5002 0 - 199 kPa {0 - 1,500 mmHg}
ing kit

9 Blow-by pressure 0 - 9.81 kPa {0 - 1,000 mmH2O}

10 Intake resistance -9.81 - 0 kPa {-1,000 - 0 mmH2O}

Compression gauge 795-502-1590


11 Compression pressure {0 - 70 kg/cm2}
Adapter 795-502-1360

12 Blow-by pressure Blow-by checker 799-201-1504 0 - 4.91 kPa {0 - 500 mmH2O}

13 Valve clearance Feeler gauge 795-125-1360 Intake 0.33 mm, Exhaust 0.71 mm

Dirtiness 0 - 70% with standard color


14 Exhaust gas color Handy smoke checker 799-201-9000
(Dirtiness% x 1/10 = Bosch scale)

Provided with 0.1 and 0.2% water


15 Water and fuel content in oil Engine oil checker 799-201-6000
content standard samples

Fuel injection pressure Commercially


16 Nozzle tester 0 - 2.94 MPa {0 - 300 kg/cm2}
Fuel injection nozzle spray condition available

17 Coolant quality Water quality tester 799-202-7001 PH, nitrite ion concentration

Pressure valve function


18 Radiator cap tester 799-202-9001 0 - 0.196 MPa {0 - 2 kg/cm2}
Leakage in cooling water system

Anemometer
19 Radiator blockage (wing speed) 799-202-2001 0 - 40 m/s
(Air speed gauge)

20 Engine cranking Cranking kit 795-610-1000 Engine with DC24V starting motor

Commercially
21 Electrical circuit Tester Current, Voltage, Resistance
available

20-102 GD705A-4
1
TESTING AND ADJUSTING TESTING AND ADJUSTING VALVE CLEARANCE

12

TESTING AND ADJUSTING VALVE CLEARANCE


Special tool

Part Number Part Name Q’ty


A 795-125-1360 Feeler gauge 1

★ Adjust clearance between rocker lever and top of


crosshead to following valve.

Intake valve (at 20oC) Exhaust valve (at 20oC)


0.33 mm 0.71 mm

1. When adjusting the valve clearance for cylinders


No. 3 to 6, remove air cleaner.
2. Remove cylinder head cover.
3. Rotate the crankshaft in the normal direction to
align pointer (2) with the 1.6 TOP mark or crank-
shaft damper (1). When rotating, check the move-
ment of the intake valves of No. 1 cylinder and No.
6 cylinder. Set with No. 1 cylinder at compression
top dead center.
★ When No. 1 cylinder is at compression top
dead center, the intake valve of No. 6 cylinder
opens.

4. When No. 1 cylinder is at compression top dead


center, adjust the valves marked •. Then rotate the
crankshaft one turn in the normal direction, set
No. 6 cylinder to compression top dead center,
and adjust the valves marked o.

5. To adjust, insert tool A between rocker lever (3)


and crosshead (4) and turn adjustment screw (5)
until clearance is a sliding fit.

6. Tighten locknut (6) to hold adjustment screw in


position.

Locknut: 66.15 ± 7.35 Nm {6.75 ± 0.75


kgm}
★ After adjusting No. 1 Cylinder at compression top
dead center, it is also possible to turn the crank-
shaft 120o each time and adjust the valve clear-
ance of each cylinder according to the firing order.

• Firing order: 1 - 5 - 3 - 6 - 2 - 4

★ After tightening the locknut, check the clearance


again.

GD705A-4 20-103
1
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE

12
MEASURING COMPRESSION PRESSURE

Special tools
Part Number Part Name Q’ty
A 795-502-1360 Adapter 1
B 795-502-1590 Compression gauge 1

★ Warm up the engine (oil temperature: 40 - 60oC)


before measuring the compression pressure.

1. Adjust valve clearance

2. Remove spill tube (1), then disconnect fuel injec-


tion tube (2) and remove nozzle holder assembly
(3).
★ When removing the nozzle holder assembly,
use the mounting bolt of the spill pipe and
lever the nozzle holder assembly out with a
bar.
3. Install tool A in mount of nozzle holder assembly,
and tighten to specified torque.

Mounting bolt: 24.5 ± 4.9 Nm {2.5 ±


0.5 kgm}
4. Connect tool B to adapter.

5. Place fuel control lever (4) in NO INJECTION posi-


tion.
Crank engine with starting motor and measure
compression pressure.
★ Measure the compression pressure at the
point where the compression gauge indicator
remains steady.
★ If the adapter mount is coated with a small
amount of oil, leakage is reduced.

If the fuel control lever is not set to the


NO INJECTION position, the engine will
start.

When measuring the compression


pressure, be careful not to touch the
exhaust manifold or muffler, or to get
caught in rotating parts.

20-104 GD705A-4
1
TESTING AND ADJUSTING MEASURING BLOW-BY

12
MEASURING BLOW-BY

Special tools
Part Number Part Name Q’ty
A 799-201-1504 Blow-by checker 1

1. Measuring blow-by
Connect tool A to breather hose.
★ Check that the oil filler and dipstick are prop-
erly sealed.
2. Precautions when measuring blow-by
★ Measure blow-by with the engine properly
warmed up (oil temperature: 60oC) and run-
ning at rated output.
• When measuring in the field, a similar value
will be obtained at stall speed.
• If it is impossible to run the engine at rated
output or at stall speed, measure at high
idling.
The blow-by value obtained at high idling will
be about 80% of the value at rated output.
★ Blow-by varies greatly according to the condi-
tion of the machine, so if the value obtained is
considered abnormal, check for factors
related to defective blow-by. These factors
include excessive oil consumption, defective
exhaust gas color, deterioration and early dis-
coloration of oil.

GD705A-4 20-105
1
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION

12
TESTING AND ADJUSTING FAN BELT TENSION

TESTING
The deflection should be approx. 10 mm when the fan
belt is pushed at a point midway between the alterna-
tor pulley and fan pulley with a force of approx. 59 N
(6 kgf).

ADJUSTING
1. Loosen nuts (1) and (2), and alternator fulcrum nut
(3), then move alternator (4) to adjust the belt ten-
sion.

2. Check each pulley for damage, wear of V-groove,


and wear of the V-belt. Be particularly careful to
check that the V-belt does not contact the bottom
of the V-groove.

3. If the belt has elongated and there is no more


allowance for adjustment, or it the belt is cut or
cracked, replace the belt.

4. When adjusting the V-belt, tighten nut (1) or (2)


(the nut in the opposite direction from the direc-
tion to move the alternator), then move the alter-
nator.
When the position is fixed, tighten the other nut
and the fulcrum nut (3) to hold alternator (4) in
position.

5. If the V-belt has been replaced, adjust again after


operating for 1 hour.

20-106 GD705A-4
1
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

12

TESTING AND ADJUSTING


FUEL INJECTION TIMING
When installing the fuel injection pump on the engine,
test and adjust the fuel injection timing as follows:
• Aligning match mark
Use this method when the fuel injection pump is
put back on the same engine without being
repaired.
• Delivery check method
Use this method when replacing or installing a
repaired fuel injection pump.
★ Set the No. 1 cylinder to top dead center when test-
ing and adjusting.
1. Testing and adjusting by aligning match mark
1) Set the No. 1 cylinder to top dead center, then
rotate the crankshaft 30o-40o in the reverse
direction. Next, rotate the crankshaft in the
normal direction and align the fuel injection
line on crankshaft damper (1) with pointer (2).

2) Check that line "a" on the injection pump and


line "b" on the coupling are aligned.
★ If the lines are not aligned, loosen nut (3).
Move the coupling to align the lines, then
tighten the nut.

Nut: 60.8 ± 2.0 Nm {6.2 ± 0.2 kgm}

2. Testing and adjusting fuel injection timing by


delivery check.
1) Disconnect fuel injection tube (4) on No. 1 cyl-
inder.
2) Remove delivery valve holder (5).

GD705A-4 20-107
1
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

12

3) Remove spring (6) and delivery valve (7), then


install delivery valve holder (5) again.
4) Place fuel control lever at FULL position, then
operated priming pump and rotate crankshaft
slowly in normal direction. Check point
where fuel stops flowing from delivery valve
holder.
5) Check that fuel injection timing line on crank-
shaft damper and pointer are aligned at point
where fuel stops flowing.
★ BEYOND injection timing line:
Timing RETARDED
★ BEFORE injection timing line:
Timing ADVANCED

3. If the test shows that the fuel injection tim-


ing in incorrect, adjust as follows.
1) Set the No. 1 cylinder to top dead center, the
rotate the crankshaft 30o-40o in the reverse
direction.

2) Next, rotate the crankshaft in the normal


direction and align the fuel injection line on
the crankshaft damper with the pointer cor-
rectly.

3) Loosen nut (3) in oblong hole of mounting


flange of fuel injection pump. Operate prim-
ing pump and rotate flange at pump end a lit-
tle at a time. Stop at point where fuel stops
flowing from delivery valve holder.

4) Tighten nut in oblong hole of mounting


flange of fuel injection pump.
★ After tightening the nut, check again that
the fuel injection timing is correct.

20-108 GD705A-4
1
TESTING AND ADJUSTING INCHING PEDAL

12
INCHING PEDAL

INCHING PEDAL STROKE


AND OPERATING FORCE
INCHING PEDAL STROKE CHECK

Use convex rule 1 to measure the length of the move-


ment from up to down from beginning to end of
depressing inching pedal (1).

INCHING PEDAL OPERATING FORCE CHECK

Use push-pull scale 2 to measure the maximum value


in the stroke to just before the inching pedal stroke end.

GD705A-4 20-109
1
TESTING AND ADJUSTING HYDROSHIFT TRANSMISSION

12
HYDROSHIFT TRANSMISSION

Special tool
Part Number Part Name Q’ty
A 799-101-5002 Hydraulic tester 1

TRANSMISSION PILOT OIL PRESSURE CHECK


1. Remove measuring plug (2) and attach hydraulic
gauge A (5.88 MPa {60 kg/cm2}).
2. Start engine and measure pilot oil pressure of
transmission.

TRANSMISSION OIL PRESSURE CHECK (MODU-


LATING PRESSURE)
3. Remove measuring plug (3) and attach oil pres-
sure gauge A (5.88 MPa {60 kg/cm2}).
4. Start engine and measure pilot oil pressure of
transmission.
★ To confirm modulating set pressure only, it is
necessary to start the engine.
★ To confirm clutch pressure for each gear shift
(except F and R) start engine and measure
with the inching pedal depressed.

TRANSMISSION LUBRICATION PRESSURE


CHECK
1. Remove measuring plug (2) and attach hydraulic
gauge A (25 kg/cm2).
2. Start engine and measure lubricating oil pressure
of transmission.

Unit MPa {kg/cm2}


Measurement check items Standard value
1.422 ± 0.049
Plug (2) Pilot oil pressure
{14.5 ± 0.5}
2.501 ± 0.147
Plug (3) Modulating pressure
{25.5 ± 1.5}
0.245 ± 0.147
Plug (1) Lubrication oil pressure
{2.5 ± 1.5}

20-110 GD705A-4
1
TESTING AND ADJUSTING HYDROSHIFT TRANSMISSION

12

TRANSMISSION OIL PRESSURE ADJUSTMENT


(MODULATING PRESSURE)
★ If oil pressure is outside standard value, adjust
according to the following procedure:

1. Remove transmission control valve assembly (4).

2. Remove cover (5) and remove valve (6).

3. Increase or decrease shims (7) and adjust tension


of spring (8).
★ Increase shims and oil pressure rises.
Decrease shims and oil pressure falls.
★ Standard shim thickness: 1.0 mm
★ Kind of shim: 0.5 mm

4. After adjustment, confirm that transmission oil


pressure (modulating pressure) is within standard
value, following procedure of TRANSMISSION
OIL PRESSURE CHECK (MODULATING PRES-
SURE).

GD705A-4 20-111
1
TESTING AND ADJUSTINGTRANSMISSION CONTROL LEVER STROKE AND OPERATING FORCE

12

TRANSMISSION CONTROL
LEVER STROKE AND OPERAT-
ING FORCE
STROKE CHECK AND ADJUSTMENT

Use convex rule 1 to measure the stoke of the gear


shift lever at the tip of each lever between each gear
shift.
★ Measure with engine stopped.
★ The stroke of gear shift lever is determined by the
working distance of the lever notch on the transmis-
sion side. However, the neutral position of the gear
shift lever is determined by adjusting rod (2) and
cable (3) without removing the gear shift lever
guide.

OPERATING FORCE CHECK AND ADJUSTMENT


Use push-pull scale 2 to measure maximum value in
the stroke to just before the stroke end of each gear at
the gear shift lever (1) tip.
★ Measure with engine stopped.
★ The operating force of the gear shift lever is deter-
mined on transmission side. However, when the
operating force is above standard value, check the
movement of connecting rod. If it is normal, disas-
semble the transmission side and check the operat-
ing condition of the movement of the spool.

20-112 GD705A-4
1
TESTING AND ADJUSTING ADJUSTING F/R CONTROL CABLE

12
ADJUSTING F/R CONTROL CABLE

1. Set screwed-in length (L1) of yoke (3) of the cable


at the transmission end to11 mm, then tighten the
nut.

2. Install yoke (4) to the cable at the control lever


end.
Screwed in length (l2): 25 mm

3. Install the cable to the machine, and adjust the


position of locknut C to apply slight tension to the
cable.

GD705A-4 20-113
1
TESTING AND ADJUSTING ADJUSTING TRANSMISSION CONTROL LINKAGE

12
ADJUSTING TRANSMISSION CONTROL LINKAGE

1. Set rods (2), (3), and (4) to the following length.


A: Approx. 115 mm
B: 520 mm
C: 413.5 mm

2. Install each rod to the intermediate lever.


★ When installing rod (2) to control lever (1),
align with the position of punch mark A.

3. Adjust the length of rod (2) so that control lever


(1) and the neutral position of the transmission
lever are aligned.

20-114 GD705A-4
1
TESTING AND ADJUSTING ADJUSTING TRANSMISSION CONTROL LINKAGE

12

4. Check that the transmission shifts correctly to


each gear position.
★ If the movement of control lever (1) to each
gear position differs greatly from the mark on
the control lever guide, move the mounting
position of rod (2) to control lever (1).
★ It is possible to adjust the stroke of the
cable by changing the mounting position of
the end rod.

GD705A-4 20-115
1
TESTING AND ADJUSTING STEERING WHEEL

12
STEERING WHEEL

CHECKING STEERING WHEEL PLAY

Standard play: 10 to 12 mm
When the play of the steering wheel is outside the
standard value or vibrates abnormally or pulls, replace
the steering valve assembly.

CHECKING STEERING WHEEL OPERATING FORCE

Using push-pull scale 1, measure the operating force


of the steering wheel.
★ Measure operating force of the steering wheel
with the engine idling and with the wheels on the
ground.

20-116 GD705A-4
1
TESTING AND ADJUSTING TIRE

12
TIRE
CHECKING TIRE PLAY
FRONT WHEEL CHECK

1. Start the engine and raise the front wheel off the
ground, using the blade or scarifier as a jack.

2. Use dial gauge 1 to measure the tire play while


rotating the tire (1) by hand.

REAR WHEEL CHECK


1. Start the engine and raise four wheels by operat-
ing the blade.
2. Insert block 2 in place at rear side of chassis.
3. Use dial gauge 1 to measure the tire play while
rotating the tire (2) by hand.

Measure with engine stopped.

CHECKING TIRE AIR


PRESSURE

Use tire gauge 1 to measure the air pressure of front


and rear wheels.

GD705A-4 20-117
1
TESTING AND ADJUSTING CHECKING TOE-IN

12
CHECKING TOE-IN

CHECKING TOE-IN

1. Put steering and leaning in central position and


park the machine on a level surface.
★ Park the machine after it has moved a few
meters straight forward.

2. Use convex rule to measure the height from tire


tread level to the center of the shaft.

3. Mark the center of the width of both left and right


tires at the height attained in item 2.

4. Use convex rule to measure distance A between


the marks on the left and right tires.

5. Advance the machine slowly and move the marks


on the front of the tires to the back. Stop the
machine when these marks are the same distance
from the tire tread level to the center of the shaft.

6. Use the convex rule to measure distance B


between the marks on the left and right tires.

7. Standard of toe-in: B - A = 8.5 ± 1.5 mm

20-118 GD705A-4
1
TESTING AND ADJUSTING CHECKING TOE-IN

12

TOE-IN ADJUSTMENT
★ When toe-in is out-side standard value, adjust it
according to the following procedure:
Loosen mounting nuts (1), apply wrench to the
notch section (2), turn left and right tie-rods, and
adjust to within standard value.
★ Toe-in increases when tie-rod is turned in the
direction of the arrow, and decreases when it is
turned in the opposite direction.
★ Adjust length of the left and right (C and D) tie-
rods equally.
★ Adjust with the front axle horizontal without any
leaning.

GD705A-4 20-119
1
TESTING AND ADJUSTING CHECKING PARKING BRAKE LEVER STROKE AND OPERATING

12

CHECKING PARKING
BRAKE LEVER STROKE
AND OPERATING FORCE
STROKE CHECK

Use convex rule to measure the travel of parking brake


lever tip from bottom to top.

STROKE ADJUSTMENT

Adjust with engine stopped.

1. Insert driver through adjusting hole of parking


brake drum, rotate adjusting gear in the direction
of the arrow until lining and drum contact tightly,
then return 8 ratchets.

2. After adjusting the lining and drum clearance, pull


the parking brake lever and adjust the cable so
that the notched section is in the 2 to 3 ratchet
range.

3. After adjustment, it is possible to keep the


machine stopped on a 1/5 paved gradient by pull-
ing the parking lever.

OPERATING FORCE CHECK

Use push-pull scale to check the operating force by


hanging it on the front end of the parking brake lever
and lifting it up.

20-120 GD705A-4
1
TESTING AND ADJUSTING CHECKING WEAR OF BRAKE DISC

12

CHECKING WEAR OF BRAKE


DISC

1. Remove plug (1) of checking hole and peep


through from directing above the checking hole.

2. Depress brake pedal push piston (2) against plate


(3) and to compress disc (4).

3. Confirm that length A in the diagram at right is


not O. In other words, confirm that a portion of
the disc can be seen through the checking hole.

GD705A-4 20-121
1
TESTING AND ADJUSTING CHECKING HYDRAULIC OIL PRESSURE

12
CHECKING HYDRAULIC OIL PRESSURE
CHECKING

Special tool required


Part Number Part Name Q’ty
A 799-101-5002 Hydraulic tester 1

Stop the engine, then loosen the oil filler cap


slowly to release the pressure inside the
hydraulic tank.

1. Remove measurement plugs (1) and (2), and


install oil pressure gauge A (34.3 MPa {350 kg/
cm2}).
★ To prevent the oil from spurting out when the
plugs are removed, set the control lever in the
operated position when removing.

2. Start the engine, and when the temperature of


the hydraulic oil is within a range of 40 ± 5oC,
operate the lever of the circuit to be measured,
and measure the relief pressure.

ADJUSTING

★ If the oil pressure is not within the standard value


(17.2 MPa {175 kg/cm2}), adjust as follows.

1. Loosen nut (3), turn adjustment screw (4), and


adjust the pressure of internal spring (5).
★ To INCREASE the oil pressure, turn CLOCKWISE
To DECREASE the oil pressure, turn COUNTER-
CLOCKWISE
★ Amount of change in pressure for one turn of
adjustment screw: Approx. 5.3 MPa {54 kg/cm2}

2. After adjusting, check that the oil pressure is


within the standard value.

20-122 GD705A-4
1
TESTING AND ADJUSTING CHECKING HYDRAULIC OIL TEMPERATURE

12

CHECKING HYDRAULIC
OIL TEMPERATURE

Special tool
Part Number Part Name Q’ty
A 795-500-1300 Thermister 1

1. Remove hydraulic oil tank cap (1) and remove


strainer.

When removing cap, loosen the oil filler


cap slowly to release the remaining oil
pressure in the hydraulic tank.

2. Insert sensor into filling port and measure oil tem-


perature with thermistor gauge A.

GD705A-4 20-123
1
TESTING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER STROKE AND OPERATING

12

WORK EQUIPMENT CONTROL


LEVER STROKE AND OPERAT-
ING FORCE
WORK EQUIPMENT CONTROL LEVER STROKE
CHECK AND ADJUSTMENT

Use a convex rule 1 and measure the operating length


from the center of the knob of lever (1).
★ Measure with engine stopped.
★ The stroke of work equipment control lever is deter-
mined by the spool stroke of the control valve, but
the neutral position of each lever is adjusted by each
rod.

CHECK AND ADJUSTMENT OF EACH WORK


EQUIPMENT CONTROL LEVER OPERATING FORCE
Use push-pull scale 2 to measure maximum value from
the tip of lever (1) to just before the stroke end.
★ Measure with engine stopped.
★ The operating force of the work equipment control
lever is determined by the spring load of the spool
on the control valve side. When the operating force
is outside standard value, check the movement of
the connecting rod. If it is normal, disassemble the
control valve and check the movement of the spool.

HYDRAULIC DRIFT OF
BLADE
1. Start the engine and after the pressure test, bring
hydraulic oil temperature to the 40 ± 5oC range.
2. Raise the blade 300mm from the ground and at right
angles to the machine and equidistant to right and
left.
3. Stop the engine and leave for 10 minutes.
Use a convex rule 1 to measure the amount the
cylinder piston rod has dropped.

MEASURING BLADE SINK-


ING AMOUNT
1. Start engine after the pressure test, bring hydraulic
oil temperature to the 40 ± 5oC range.
2. Lower blade until its bottom edge touches the
ground, push the cylinder and float the front wheels
about 300mm off the ground.
3. Stop the engine and leave for 10 minutes.
Use a convex rule 1 to measure at the cylinder the
amount of sinkage.

20-124 GD705A-4
1
TROUBLESHOOTING

12
Points to remember when troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-202
Sequence of events in troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-203
Points to remember when carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-204
Checks before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-212
Connector types and mounting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-213
Connection table for connector pin numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-216
Troubleshooting of electrical system (E mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-251

GD705A-4 20-201
1
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING

12
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow
any unauthorized persons to come near.
If the radiator cap is removed when the engine is hot, hot water may spurt out and cause severe burns, so wait
for the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the
internal pressure first. When installing measuring equipment, be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of
possible causes of the failure that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry 4) Check the stroke of the control valve spool.
to disassemble the components. 5) Other maintenance items can be checked
If components are disassembled immediately externally, so check any item that is consider
after failure occurs: to be necessary.
• Parts that have no connection with the failure
or other unnecessary parts will be disassem- 4. Confirming failure
bled. • Confirm the extent of the failure yourself, and
• It will become impossible to find the cause of judge whether to handle it as a real failure, or
the failure. as a problem with the method of operation,
It will also cause a waste of man-hours, parts, oil etc.
or grease, and at the same time also lose the con- ★ When operating the machine to reenact
fidence of the user or operator. the troubleshooting symptoms, do not
For this reason when carrying out troubleshoot- carry out any investigation or measure-
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in ment that may make the problem worse.
accordance with the fixed procedure. 5. Troubleshooting
2. Points to ask user or operator • Use the result of the investigation and inspec-
1) Have any other problems occurred apart from tion in items 2 - 4 to narrow down the causes
the problem that has been reported? of failure, then use the troubleshooting flow-
2) Was there anything strange about the chart to locate the position of the failure
machine before the failure occurred? exactly
3) Did the failure occur suddenly, or were there ★ The basic procedure for troubleshooting
problems with the machine’s condition before is as follows:
this? 1) Start from the simple points.
4) Under what condition did the failure 2) Start from the most likely points.
occurred?
3) Investigate other related parts or informa-
5) Had any repairs been carried out before the
tion.
failure?
When were these repairs carried out? 6. Measure to remove root cause of failure
6) Had the same kind of failure occurred before? • Even if he failure is repaired, if the root cause
3. Checks before troubleshooting of the failure is not repaired, the same failure
will occur again.
1) Check the oil level.
To prevent this, always investigate why the
2) Check for external oil leaks from the piping or
problem occurred. Then remove the root
hydraulic equipment.
cause.
3) Check the travel of the control levers.

20-202 GD705A-4
1
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

GD705A-4 20-203
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE


To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic
equipment" (particularly gear oil and hydraulic oil).

1. Points to remember when handling electric


equipment

1) Handling wiring harnesses and connectors


Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.

Main failures occurring in wiring harness


1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.

2) Defective crimping or soldering of connec-


tors
The pins of the male and female connectors
are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.

20-204 GD705A-4
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.

4) High-pressure water entering connector


The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water
should get into the connector, the pins will
be short-circuited by the water, so if any
water gets in, immediately dry the connector
or take other appropriate action before
passing electricity through it.

5) Oil or dirt stuck to connector


If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
tact restorer.
★ When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
★ If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before
cleaning with compressed air.

GD705A-4 20-205
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

2) Removing, installing, and drying connectors


and wiring harnesses

• Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
★ Never pull with one hand.

2) When removing from clips


When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
★ If the connector is twisted up and down
or to the left or right, the housing may
break.

3) Action to take after removing connectors


After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
★ If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.

20-206 GD705A-4
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

• Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
★ If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
★ If there is any damage or breakage, re-
place the connector.

2) Fix the connector securely.


Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.

3) Correct any protrusion of the boot and any


misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wir-
ing harness is misaligned, or the clamp is
out of position, adjust it to its correct posi-
tion.
★ If the connector cannot be corrected
easily, remove the clamp and adjust the
position.

4) If the connector clamp has been removed,


be sure to return it to its original position.
Check also that there are no loose clamps.

• Connecting connectors (DT type connector)


Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal):a, b, d
• Incomplete locking state (Diagonal):c

GD705A-4 20-207
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

• Drying wiring harness


If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure water
or steam directly on the wiring harness.

If water gets directly on the connector, do as fol-


lows.
1) Disconnect the connector and wipe off the
water with a dry cloth.
★ If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.

2) Dry the inside of the connector with a dryer.


If water gets inside the connector, use a
dryer to dry the connector.
★ Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.

3) Carry out a continuity test on the connector.


After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
★ After completely drying the connector,
blow it with contact restorer and reas-
semble.

20-208 GD705A-4
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) Handling control box


1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2) Do not open the cover of the control box
unless necessary.

3) Do not place objects on top of the control


box.
4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
5) During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.

6) Do not place the control box on oil, water, or


soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc
welding ground close to the welding point.

2. Points to remember when troubleshooting electric circuits


1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
★ If there is any change, there is probably defective contact in that circuit.

GD705A-4 20-209
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3. Points to remember when handling hydraulic


equipment

With the increase in pressure and precision of


hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic cir-
cuit. When adding hydraulic oil, or when disassem-
bling or assembling hydraulic equipment, it is
necessary to be particularly careful.

1) Be careful of the operating environment.


Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.

2) Disassembly and maintenance work in the


field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be confirmed with special test
equipment.

3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.

4) Do not let any dirt or dust get in during refill-


ing operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.

20-210 GD705A-4
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

5) Change hydraulic oil when the temperature


is high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the con-
taminants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic oil.

6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.

7) Cleaning operations
After repairing the hydraulic equipment (pump,
c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.

GD705A-4 20-211
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Action
value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
Lubricating oil,

3. Check hydraulic oil level — Add oil


coolant

4. Check hydraulic oil strainer — Clean, drain


5. Check engine oil level (oil pan oil level) — Add oil
6. Check coolant level — Add water
7. Check dust indicator for clogging — Clean or replace
8. Check hydraulic filter — Replace
mechanical equipment

1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace


Hydraulic, Electrical

2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace


3. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
equipment

1. Check for abnormal noise, smell — Repair


2. Check for oil leakage — Repair
3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 20 – 30V Replace
2. Check battery electrolyte level — Add or replace
Electrics, electrical equipment

3. Check for discolored, burnt, exposed wiring — Replace


4. Check for missing wiring clamps, hanging wiring — Repair
5. Check for water leaking on wiring (be particularly careful attention — Disconnect
to water leaking on connectors or terminals) connector and dry
6. Check for blown, corroded fuses — Replace
7. Check alternator voltage (engine running at 1/2 throttle or above) After Replace
running for
several
minutes :
27.5 – 29.5V
8. Check operating sound of battery relay — Replace
(when switch is turned ON/OFF)

20-212 GD705A-4
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

12
CONNECTOR TYPES AND MOUNTING LOCATIONS
★ The Address column in the table shows the address in the connector arrangement drawing (3 dimensional draw-
ing).
Connector

Connector
address

address
No. of

No. of
Pins

Pins
No.

No.
Type Mounting location Type Mounting location

Intermediate connector
Automobile
A24 X 4 (R.H. console box) --- CN-25 3 Turn signal lamp switch ---
conn.
(air conditioner)
1-pin
--- 1 Air drier --- --- --- --- Speedometer
conn.
1-pin Intermediate connector
--- 1 Backup alarm --- CN-39 SWP 16 A6
conn. (Bottom right of fuel tank)
Intermediate connector
Intermediate connector
CN-C1 X 4 (R.H. console box) (Wiper, H7 CN-40 SWP 12 A6
(Bottom right of fuel tank)
caution lamp)
Intermediate connector 1-pin
Door X 1 G6 --- 1 Fuel level sensor ---
(R.H. console box) conn.
Intermediate connector
FR X 1 G6 CN-44 X 2 Starting motor ---
(R.H. console box)
Intermediate connector 1-pin
FU X 1 H7 CN-45 1 Engine water temp. sensor D8
(R.H. console box) conn.
1-pin
--- 1 Horn switch --- CN-46 Econoseal 2 Parking brake switch L3
conn.
Car heater switch (Main Intermediate connector
H2 YPC 4 --- CN-50 SWP 12 B9
heater) (Rear left of rear frame)
Auto-
CN- Pressure switch of air pressure
mobile 4 Turn signal & hazard relay G6 --- Terminal 1 ---
M58 alarm (L.H.)
conn.
Intermediate connector Pressure switch of air pressure
OP X 1 --- --- Terminal 1 ---
(R.H. console box) (OP) alarm (L.H.)
Intermediate connector Pressure switch of air pressure
RAD X 3 H7 --- Terminal 1 ---
(R.H. console box) (Radio) alarm (R.H.)
1-pin Pressure switch of air pressure
--- 1 License lamp --- --- Terminal 1 ---
conn. alarm (R.H.)
Intermediate connector Automobile
YOBI X 1 H7 CN-53 4 Combination lamp (Left rear) A9
(R.H. console box) (Spare) conn.
Intermediate connector Automobile
CN-1 SWP 6 C2 CN-54 4 Combination lamp (Right rear) A8
(Front frame) conn.
Intermediate connector
CN-2 SWP 12 A5 CN-57 SWP 8 Engine stop motor A6
(Bottom right of fuel tank)
CN-4 YPC 3 Bank switch L8 CN-63 X 2 Stop lamp switch B5
CN-5 YPC 2 Caution lamp switch L8 CN-64 X 3 Solenoid valve for bank D6
Automobile
CN-6 YPC 3 Head lamp switch L8 CN-101 3 Head lamp dimmer switch ---
conn.
CN-7 YPC 2 Front working lamp switch L8 CN-102 YPC 3 Head lamp switch L7
CN-8 YPC 2 Fog lamp switch L8 CN-201 X 3 Head lamp ---
CN-9 YPC 2 Rear working lamp switch L8 CN-202 X 3 Head lamp ---
CN-10 YPC 2 Lamp switch (spare) L7 CN-203 X 2 Engine oil pressure switch ---
CN-11 Relay 5 Caution lamp relay L6 CN-204 SWP 2 Caution lamp ---
1-pin
CN-13 1 Buzzer L6
conn.
1-pin
CN-14 1 Buzzer L5
conn.
CN-15 Relay 5 Engine stop motor relay L4
Intermediate connector
CN-18 SWP 16 A6
(Bottom right of fuel tank)
Intermediate connector
CN-20 SWP 16 ---
(Bottom right of fuel tank)
CN-23 YPC 2 Accumulator switch L7

GD705A-4 20-213
1
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

20-214 GD705A-4
1
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

12

GD705A-4 20-215
1
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating
portion of the housing.

No.of X type connector


pins Male (female housing) Female (male housing)

20-216 GD705A-4
1
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12

No.of SWP type connector


pins Male (female housing) Female (male housing)

12

14

16

GD705A-4 20-217
1
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12

No.of Automobile connector


pins Male (female housing) Female (male housing)

20-218 GD705A-4
1
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12

No.of Relay connector


pins Female (female housing) Relay (male housing)

GD705A-4 20-219
1
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
12

E-1 Engine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-252


E-2 Electric system does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-255
E-3 Service meter does not work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-256
E-4 Water temperature gauge indicates abnormally high temperature. . . . . . . . . . . . . . . . . . . . 20-257
E-5 Water temperature gauge does not work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-257
E-6 Fuel gauge always indicates FULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-258
E-7 Fuel gauge does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-258
E-8 Engine oil pressure gauge indicates abnormally high pressure . . . . . . . . . . . . . . . . . . . . . . 20-259
E-9 Engine oil pressure gauge does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-259

GD705A-4 20-251
1
TROUBLESHOOTING E-1

12
E-1
E-1 Engine does not start
★ Check that the fuse is normal before starting troubleshooting.
★ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Always connect any disconnected connectors before going on to the next step.

a) Starting motor does not turn Cause Remedy


4 YES
Defective starting motor Replace

YES Is voltage between


starting motor
terminal B and chassis
normal?
Defective contact or
3 disconnection in wiring
harness between battery Repair or
replace
NO (+) and starting motor
• Turn starting switch terminal B
YES Is there sound of ON.
starting motor • Approx. 24V
pinion engaging?
Defective contact, or
2 5 YES disconnection in wiring
harness between starting Repair
or
replace
switch terminal C -
When starting starting motor terminal S
YES switch is turned Is voltage between
OFF, is sound starting switch
terminal C and chassis
heard from No normal?
battery relay?
Defective starting switch Replace
1 • Starting switch NO
ON → OFF. • Turn starting switch
to START.
Is voltage and
• 20 - 30 V
electrolyte
specific gravity
of battery
normal? Go to E-2
NO

• Voltage: Min. Lack of battery capacity Charge or


NO replace
20V
• Electrolyte
specific grav-
ity: Min. 1.26

E-1 a) Related electric circuit

20-252 GD705A-4
1
TROUBLESHOOTING E-1

12
b) Engine stop motor does not work

Cause Remedy
2 YES
Defective engine stop
Replace
motor

Is there continuity
between CN-57
(female)(3) and (7)?

Defective relay, or broken


wire or contact failure in Repair or
• Starting switch replace
NO the wire harness
OFF.
YES • Disconnect CN-57

3 YES
Defective engine stop
Replace
1 motor
Is there continuity
between CN-57
Is the voltage of (female)(5) and (7)?
CN-57 (female) (4) Repair or
20 - 30 volts? Defective relay, or broken replace
wire or contact failure in
• Starting switch the wire harness
NO
OFF.
• Disconnect CN-57
Broken wire or contact
failure in the wire har-
ness between battery Repair
NO relay and CN-57 (female)
(4)

E1 b) Related electric circuit diagram (When starting engine)

GD705A-4 20-253
1
TROUBLESHOOTING E-1

12

E1 b) Related electric circuit diagram (When stopping engine)

20-254 GD705A-4
1
TROUBLESHOOTING E-2

12
E-2
E-2 Electric system does not work
★ Before starting troubleshooting, check that the battery voltage is normal.
Cause Remedy

Broken wire or contact


2 YES failure in the wire Repair or
harness between the replace
terminal RM of the
Is the voltage battery relay - fuse box
YES between the
terminal RM of
battery relay and
chassis normal?
Defective battery relay Replace
• Starting switch NO
ON.
• 20V or more. 5 YES
Defective battery relay Replace
Is the resistance
1 YES between the
terminal RE of the
battery relay and
Does the battery chassis normal? Broken wire or contact
relay make a 4 failure in the wire
sound when the Repair or
harness between the
starting switch is • 1 Ω or less NO terminal RE of the battery replace
turned OFF? Is the voltage relay and chassis
YES between the
terminal BR of the
• Starting switch battery relay and Broken wire or contact
ON → OFF. chassis normal? failure in the wire
6 YES harness between the
Repair or
terminal BR of the replace
• Starting switch starting switch -
ON. Is the voltage terminal BR of the
3 • 20V or more between the battery relay.
terminal BR of the
NO starting switch and
Is the voltage chassis normal?
between the
terminal B of the Defective starting switch Replace
NO starting switch and • Starting switch NO
chassis normal? ON.
• 20V or more
• Starting switch
ON. Broken wire or contact
• 20V or more failure in the wire
Repair or
harness between battery
NO replace
- terminal B of the
starting switch

E-2 Related electric circuit diagram

GD705A-4 20-255
1
TROUBLESHOOTING E-3

12
E-3
E-3 Service meter does not work

Cause Remedy

2 YES
Defective service meter Replace
Is the voltage
YES between the
terminal of the
service meter and Broken wire, contact fail-
chassis normal? ure or short circuit to the
1 ground in the wire har-
ness between the termi- Repair or
• Start engine NO nal R of the alternator - replace
Is the voltage • 10 - 14 V the connector CN-18B
between the termi- (female) (10) - the termi-
nal R of the alter- nal of the service meter
nator and chassis
normal?

Defective alternator Replace


• Start engine NO
• 10 - 14 V

E-3 Related electric circuit diagram

20-256 GD705A-4
1
TROUBLESHOOTING E-4, E-5

12
E-4, E-5
E-4 Water temperature gauge indicates abnormally high temperature
Cause Remedy
YES
Defective water
Replace
temperature sensor

1 3 YES
Defective water
Replace
temperature gauge
Does the water
Is the voltage
temperature gauge
indicate minimum YES between the con-
nector CN-18B Wire harness between
when the connec-
(female) (7) and the connector CN-18B
tor of the sensor is
chassis normal? (female) (7) - the connec-
disconnected? 2 tor (female) of the water
Repair or
temperature sensor
• Disconnect the • Disconnect the con- NO replace
touches the wire harness
connector of the Is the resistance nector CN-18B and between the connector
water tempera- between the con- the connector of the CN-18B (female) (7) - fuse
ture sensor nector CN-18B water temperature box (No. 2) (13)
• Turn the starting NO (female) (7) and sensor
switch ON. chassis normal? • Starting switch ON.
• 1V or less
• Starting switch OFF. Wire harness between
• Disconnect the con- connector CN-18B
nector CN-18B and (female) (7) - the Repair or
the connector of the connector (female) of the replace
water temperature NO water temperature
sensor sensor touches the
• 1 MΩΩ or more chassis

E-5 Water temperature gauge does not work Cause Remedy


1 YES
Defective water Replace
temperature sensor
Does the water
temperature gauge
indicate maximum
when the connec- Broken wire or contact
2 YES failure in the wire har-
tor (female) of the Repair or
ness between the con- replace
water temperature Is the resistance nector of CN-18 (female)
sensor is touched between the connec- (7) - the connector
to the chassis? tor CN-18B (female) (7) (female) of the water
- chassis normal when temperature sensor
• Disconnect the NO
the connector (female)
connector of the
of the water tempera-
water tempera-
ture sensor is touched
ture sensor
to the chassis?
• Touch the con- Defective water Repair or
nector (female) • Disconnect the con- NO temperature gauge replace
of the water nector CN-18B and
temperature the connector of the
sensor to the water temperature
chassis sensor.
• Turn the starting • Starting switch OFF.
switch ON.

E-4, E-5 Related electric circuit diagram

GD705A-4 20-257
1
TROUBLESHOOTING E-6, E-7

12
E-6, E-7
E-6 Fuel gauge always indicates FULL
Cause Remedy
YES
Defective fuel level
Replace
sensor

1 3 YES
Defective fuel gauge Replace
Does the fuel
Is the voltage
gauge indicate
EMPTY when the YES between the con-
nector CN-20B
connector of the
(female) (15) and
fuel level sensor is
chassis normal? Inner contact in the wire
disconnected? 2
harness between the con- Repair or
• Disconnect the • Disconnect the con- NO nector CN-20B (female) replace
connector of the Is the resistance nector CN-20B and (2) - fuse box (No. 2) (13)
fuel level sensor between the con- the connector of the
• Turn the starting nector CN-20B fuel level sensor.
switch ON. NO (female) (15) and • Turn starting switch
• Wait 1 minute chassis normal? ON.
• 1V or less Wire harness between
• Starting switch OFF. the connector CN-20B
(female) (15) - the Repair or
• Disconnect the con- connector (female) of the replace
nector CN-20B and NO fuel level sensor touches
the connector of the the chassis
fuel level sensor
• 1 MΩΩ or more

E-7 Fuel gauge does not work Cause Remedy


1 YES
Defective fuel level sen- Replace
Does the fuel sor
gauge indicate
FULL when the 2 YES Broken wire or contact
connector of the Repair or
failure in the wire har- replace
fuel level sensor is Is the resistance ness between the con-
touched to the between the connec- nector CN-20B (female)
chassis? tor CN-20B (female) (15) - the connector
(15) and chassis nor- (female) of the fuel level
• Disconnect the NO sensor
mal when the connec-
connector of the
tor (female) of the fuel
fuel level sensor
level sensor is touched
• Touch the con-
to the chassis?
nector (female) Defective fuel level
of the fuel level Replace
• Starting switch OFF. NO gauge
sensor to the • Disconnect the con-
chassis nector CN-20B and
• Turn the starting the connector of the
switch ON. fuel level sensor
• Wait 1 minute • 1 Ω or less

E-6, E-7 Related electric circuit diagram

20-258 GD705A-4
1
TROUBLESHOOTING E-8, E-9

12
E-8, E-9
E-8 Engine oil pressure gauge indicates abnormally high pressure
Cause Remedy
YES
Defective engine oil
Replace
pressure sensor

1 YES
Defective engine oil
Replace
pressure gauge
Does the engine oil
pressure gauge
indicate minimum
when the connec-
2
tor (CN-203) of the
engine oil pressure Wire harness between
sensor is discon- Is the resistance the connector CN-18B
nected? between the con- (female) (15) - the
nector CN-18B connector (female) of the
• Disconnect the (female) (11) and engine oil pressure
connector (CN- chassis normal? sensor touches the
203) of the chassis
or Repair or
engine oil pres-
• Starting switch NO wire harness between the replace
sure sensor. connector CN-18B
• Turn the starting OFF.
• Disconnect the (female) (11) - the
switch to ON. connector CN-203
connector (CN- (female) (2) has a contact
203) of the with wire harness
engine oil pres- between the connector
sure sensor. CN-203 (female) (1) -
• 1 MΩΩ or more chassis

E-9 Engine oil pressure gauge does not work


Cause Remedy
1 YES
Defective engine oil pres-
Replace
3 sure sensor
Does the engine oil
pressure gauge Is the resistance
indicate maximum YES
between the connec- Defective engine oil
when the connec- pressure gauge Replace
2 YES tor CN-18B (female)
tor (female) of the (11) and chassis nor-
engine oil pressure mal when the connec-
sensor touches the Is there resistance tor CN-203 (female) (2)
chassis? between the con- is touched to chassis?
nector CN-203 Broken wire or contact
• Disconnect the NO (female) (1) and failure in the wire har-
connector of the ness between the con- Repair or
the chassis? nector CN-18B (female) replace
engine oil pres- NO
(11) - the connector CN-
sure sensor. 203 (female) (2)
• Touch the con- • Starting switch
nector (female) OFF.
of the engine oil • Disconnect the
pressure sensor connector (CN-
to the chassis. 203) of the
engine oil pres- Broken wire or contact
• Turn the starting failure in the wire har-
sure sensor.
switch to ON. ness between the engine Repair or
• 1 Ω or less NO oil pressure connector
replace
(CN-203) - chassis

E-8, E-9 Related electric circuit diagram

GD705A-4 20-259
1
90 OTHERS

Hydraulic circuit diagram (STD spec.) ...............................................................................................90-2


Hydraulic circuit diagram (DDV spec.) ........................................................................................... 90-3-1
HYDROSHIFT transmission control circuit diagram ..........................................................................90-4
Electrical circuit diagram (1/2) ...........................................................................................................90-5
Electrical circuit diagram (2/2) ...........................................................................................................90-7
Electrical circuit diagram for Air Conditioner ......................................................................................90-9
Electrical circuit diagram for Cab .....................................................................................................90-11

GD705A-4 90-1
OTHERS HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM


STD spec.

90-2 GD705A-4
OTHERS HYDRAULIC CIRCUIT DIAGRAM
12

GD705A-4 90-3
OTHERS HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM


DDV spec.

90-3-1 GD705A-4
OTHERS HYDRAULIC CIRCUIT DIAGRAM

GD705A-4 90-3-2
OTHERS HYDRAULIC CIRCUIT DIAGRAM
121
HYDROSHIFT TRANSMISSION CONTROL CIRCUIT DIAGRAM

90-4 GD705A-4
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM (1/2)

ELECTRICAL CIRCUIT DIAGRAM (1/2)

GD705A-4 90-5
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM (2/2)

ELECTRICAL CIRCUIT DIAGRAM (2/2)


12

GD705A-4 90-7
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER

ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER

GD705A-4 90-9
OTHERS ELECTRICAL CIRCUIT DIAGRAM FOR CAB

ELECTRICAL CIRCUIT DIAGRAM FOR CAB


12

GD705-A4 90-11