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• 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
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
GD705A-4 00-2-1
LIST OF REVISED PAGES
00-2-2 GD705A-4
SAFETY SAFETY NOTICE
SAFETY
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.
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.
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
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:
}
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.
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
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
¤
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°.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤
tank.
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.
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).
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
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
00-11
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
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
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
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
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
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
00-14
FOREWORD ELECTRIC WIRE CODE
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)
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
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
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
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
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
0 1 2 3 4 5 6 7 8 9
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
0 1 2 3 4 5 6 7 8 9
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
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
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
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
GD705A-4 01-1
GENERAL GENERAL ASSEMBLY DRAWING
12
GENERAL ASSEMBLY DRAWING
Unit: mm
A B C
01-2 GD705A-4
GENERAL SPECIFICATIONS
12
SPECIFICATIONS
Model GD705A-4
GD705A-4 01-3
GENERAL SPECIFICATIONS
12
Model GD705A-4
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
Steering cylinder 11
Articulate cylinder 44
(KFP3223-23CFESE)
Hydraulic pump
10
(KFP3223CFMSE)
Circle reverse and ripper pump
5
(KFP2233CVKR)
Steering pump
8
(KFP3250AFMSSH)
Transmission pump
10
GD705A-4 01-5
GENERAL LIST OF LUBRICANT AND WATER
12
LIST OF LUBRICANT AND WATER
SAE30CD
SAE10WCD
Engine oil pan 30 O
SAE10W-30CD
SAE 15W-40CD
Engine oil
Transmission case 48 O
SAE140
Brake
Brake tank SAE J-1703
fluid
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%.
• 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.
GD705A-4 01-7
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
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
GD705A-4 10-3
STRUCTURE AND FUNCTION FUEL TANK PIPING
12
FUEL TANK PIPING
10-4 GD705A-4
STRUCTURE AND FUNCTION ACCELERATOR CONTROL
12
ACCELERATOR CONTROL
GD705A-4 10-5
STRUCTURE AND FUNCTION POWER TRAIN
12
POWER TRAIN
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
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
10-12 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION
12
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.
10-14 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION
12
ROTARY CLUTCH
GD705A-4 10-15
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION
12
10-16 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION
12
Unit: mm
GD705A-4 10-17
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION
12
10-18 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION
12
Unit: mm
GD705A-4 10-19
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION
12
10-20 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION
12
Unit: mm
GD705A-4 10-21
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE
12
HYDROSHIFT TRANSMISSION CONTROL VALVE
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.
10-26 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE
12
GD705A-4 10-27
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE
12
10-28 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE
12
FUNCTION
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.
GD705A-4 10-29
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE
12
10-30 GD705A-4
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE
12
INCHING VALVE
OPERATION
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
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
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
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
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
GD705A-4 10-43
STRUCTURE AND FUNCTION DRIVE SHAFT
12
DRIVE SHAFT
10-44 GD705A-4
STRUCTURE AND FUNCTION FINAL DRIVE
12
FINAL DRIVE
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
GD705A-4 10-47
STRUCTURE AND FUNCTION FINAL DRIVE
12
Unit: mm
1 Preload of bevel pinion bearing Starting torque: 11.8 - 15.7 Nm {1.2 - 1.6 kgm}
10-48 GD705A-4
STRUCTURE AND FUNCTION TANDEM DRIVE
12
TANDEM DRIVE
26
Reduction ratio: = 2.0
13
10-50 GD705A-4
STRUCTURE AND FUNCTION TANDEM DRIVE
12
GD705A-4 10-51
STRUCTURE AND FUNCTION TANDEM DRIVE
12
Unit: mm
1 Preload of hub bearing Starting torque: 19.6 - 24.5 Nm {2.0 - 2.5 kgm} Adjust
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
10-58 GD705A-4
STRUCTURE AND FUNCTION STEERING VALVE
12
STEERING VALVE (ORBIT ROLL TYPE)
GD705A-4 10-59
STRUCTURE AND FUNCTION STEERING SYSTEM
12
STEERING SYSTEM
STRUCTURE
10-60 GD705A-4
STRUCTURE AND FUNCTION STEERING SYSTEM
12
GD705A-4 10-61
STRUCTURE AND FUNCTION STEERING SYSTEM
12
• 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
GD705A-4 10-63
STRUCTURE AND FUNCTION STEERING VALVE
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.
• Trochoid pump
GD705A-4 10-65
STRUCTURE AND FUNCTION STEERING VALVE
10-66 GD705A-4
STRUCTURE AND FUNCTION STEERING PUMP
12
STEERING PUMP
KFP2233CVKR (Pump with flow priority valve)
A. PF port
B. EF port
GD705A-4 10-67
STRUCTURE AND FUNCTION STEERING PUMP
12
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
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
GD705A-4 10-71
STRUCTURE AND FUNCTION FRONT AXLE
12
FRONT AXLE
10-72 GD705A-4
STRUCTURE AND FUNCTION FRONT AXLE
12
FUNCTION OF FRONT AXLE
1. Steering
Refer to section, "STEERING SYSTEM"
GD705A-4 10-73
STRUCTURE AND FUNCTION FRONT AXLE
12
10-74 GD705A-4
STRUCTURE AND FUNCTION FRONT AXLE
12
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.
GD705A-4 10-75
STRUCTURE AND FUNCTION FRONT AXLE
12
10-76 GD705A-4
STRUCTURE AND FUNCTION FRONT AXLE
12
Unit: mm
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
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
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
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
GD705A-4 10-79
STRUCTURE AND FUNCTION BRAKE PIPING
12
BRAKE PIPING
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
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
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
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.
GD705A-4 10-87
STRUCTURE AND FUNCTION BRAKE VALVE
12
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
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
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.
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
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.
GD705A-4 10-93
STRUCTURE AND FUNCTION CHECK VALVE
12
CHECK VALVE
1. Body
2. Disc valve
3. Spring
4. Screw cap
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
SAFETY VALVE
1. Valve seat
2. Ball
3. Release pin
4. Spring
5. Spring cage
6. Lock nut
7. Adjusting screw
GD705A-4 10-95
STRUCTURE AND FUNCTION PRESSURE SWITCH
12
PRESSURE SWITCH
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
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
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
GD705A-4 10-99
STRUCTURE AND FUNCTION AIR DRIER
12
AIR DRIER
(If equipped)
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.
GD705A-4 10-101
STRUCTURE AND FUNCTION AIR COMPRESSOR
12
AIR COMPRESSOR
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
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
10-106 GD705A-4
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING
HYDRAULIC TANK TO CONTROL VALVES
STD spec.
10-108 GD705A-4
STRUCTURE AND FUNCTION HYDRAULIC PIPING
GD705A-4 10-108-1
STRUCTURE AND FUNCTION HYDRAULIC PIPING
12
BLADE LIFT AND LEANING
GD705A-4 10-109
STRUCTURE AND FUNCTION HYDRAULIC PIPING
12
BLADE SIDE SHIFT, CIRCLE ROTATION AND POWER TILT
10-110 GD705A-4
STRUCTURE AND FUNCTION HYDRAULIC PIPING
12
RIPPER (If equipped)
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
GD705A-4 10-113
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
12
CIRCLE ROTATION
10-114 GD705A-4
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
12
CIRCLE ROTATION AND RIPPER 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
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
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.
10-118 GD705A-4
STRUCTURE AND FUNCTION PILOT CHECK VALVE
12
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
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
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
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
10-122 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)
10-123-1 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND 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
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)
GD705A-4 10-123-6
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)
10-123-7 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)
GD705A-4 10-123-8
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)
10-123-9 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)
GD705A-4 10-123-10
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)
10-123-11 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)
GD705A-4 10-123-12
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)
10-123-13 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)
GD705A-4 10-123-14
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)
10-123-15 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)
GD705A-4 10-123-16
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)
10-123-17 GD705A-4
STRUCTURE AND FUNCTION DDV (DUAL DEMAND VALVE)
GD705A-4 10-123-18
STRUCTURE AND FUNCTION FLOW DIVIDER VALVE
1. O-ring
2. Plug
3. Snap ring
4. Sleeve
5. Piston
6. Housing
10-123-19 GD705A-4
STRUCTURE AND FUNCTION HYDRAULIC PUMP
12
HYDRAULIC PUMP
FOR WORK EQUIPMENT (KFP3223-23CFESE)
10-124 GD705A-4
STRUCTURE AND FUNCTION HYDRAULIC PUMP
12
Unit: mm
(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.
Roller 37.5 mm
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.
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
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.
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
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
-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
Blade lift 90 - - - -
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
10-138 GD705A-4
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER
12
Unit: mm
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
-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
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}
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
Ripper
927 ± 103 Nm {94.5 ± 10.5 kgm}
(If equipped)
Scarifier
677 ± 67.5 Nm {69 ± 6.9 kgm}
(If equipped)
GD705A-4 10-139
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL
12
WORK EQUIPMENT CONTROL
• 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
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
10-146 GD705A-4
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
REAR MOUNT RIPPER (If equipped)
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)
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
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
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
10-154 GD705A-4
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
BLADE LIFTER EQUIPMENT
Unit: mm
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
GD705A-4 10-155
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
CIRCLE ROTATION GEAR
Unit: mm
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
10-156 GD705A-4
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
SCARIFIER (If equipped)
Unit: mm
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
GD705A-4 10-157
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
REAR MOUNT RIPPER (If equipped)
Unit: mm
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
10-158 GD705A-4
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
BLADE AND CIRCLE
Unit: mm
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
GD705A-4 10-159
20 TESTING AND ADJUSTING
12
★ 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
20-2 GD705A-4
1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
STANDARD VALUE TABLE FOR CHASSIS
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
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
Operating force
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}
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
Work equipment control lever Maximum value until just before stroke end Max. 49 N {Max. 5 kg}
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
13 Valve clearance Feeler gauge 795-125-1360 Intake 0.33 mm, Exhaust 0.71 mm
17 Coolant quality Water quality tester 799-202-7001 PH, nitrite ion concentration
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
• Firing order: 1 - 5 - 3 - 6 - 2 - 4
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
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.
20-106 GD705A-4
1
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
12
GD705A-4 20-107
1
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
12
20-108 GD705A-4
1
TESTING AND ADJUSTING INCHING PEDAL
12
INCHING PEDAL
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
20-110 GD705A-4
1
TESTING AND ADJUSTING HYDROSHIFT TRANSMISSION
12
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
20-112 GD705A-4
1
TESTING AND ADJUSTING ADJUSTING F/R CONTROL CABLE
12
ADJUSTING F/R CONTROL CABLE
GD705A-4 20-113
1
TESTING AND ADJUSTING ADJUSTING TRANSMISSION CONTROL LINKAGE
12
ADJUSTING TRANSMISSION CONTROL LINKAGE
20-114 GD705A-4
1
TESTING AND ADJUSTING ADJUSTING TRANSMISSION CONTROL LINKAGE
12
GD705A-4 20-115
1
TESTING AND ADJUSTING STEERING WHEEL
12
STEERING WHEEL
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.
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.
GD705A-4 20-117
1
TESTING AND ADJUSTING CHECKING TOE-IN
12
CHECKING TOE-IN
CHECKING TOE-IN
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
STROKE ADJUSTMENT
20-120 GD705A-4
1
TESTING AND ADJUSTING CHECKING WEAR OF BRAKE DISC
12
GD705A-4 20-121
1
TESTING AND ADJUSTING CHECKING HYDRAULIC OIL PRESSURE
12
CHECKING HYDRAULIC OIL PRESSURE
CHECKING
ADJUSTING
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
GD705A-4 20-123
1
TESTING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER STROKE AND OPERATING
12
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.
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
GD705A-4 20-203
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
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.
GD705A-4 20-205
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• 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.
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.
GD705A-4 20-207
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
20-208 GD705A-4
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
GD705A-4 20-209
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
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.
20-210 GD705A-4
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
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
Judgement
Item Action
value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
Lubricating oil,
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.
20-216 GD705A-4
1
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
12
14
16
GD705A-4 20-217
1
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
20-218 GD705A-4
1
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
GD705A-4 20-219
1
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
12
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.
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)?
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)
GD705A-4 20-253
1
TROUBLESHOOTING E-1
12
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
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?
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
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
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
GD705A-4 20-259
1
90 OTHERS
GD705A-4 90-1
OTHERS HYDRAULIC CIRCUIT DIAGRAM
90-2 GD705A-4
OTHERS HYDRAULIC CIRCUIT DIAGRAM
12
GD705A-4 90-3
OTHERS HYDRAULIC CIRCUIT DIAGRAM
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)
GD705A-4 90-5
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM (2/2)
GD705A-4 90-7
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER
GD705A-4 90-9
OTHERS ELECTRICAL CIRCUIT DIAGRAM FOR CAB
GD705-A4 90-11