Komatsu GD700-4 Series Motor Grader Shop Manual SEBM023E0404 PDF
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Komatsu GD700-4 Series Motor Grader Shop Manual SEBM023E0404 – PDF DOWNLOAD
MACHINE MODEL SERIAL No.
- GD705R-4 16001 and up
- GD705A-4 21001 and up
Description
Komatsu GD700-4 Series Motor Grader Shop Manual SEBM023E0404 – PDF DOWNLOAD
FILE DETAILS:
Komatsu GD700-4 Series Motor Grader Shop Manual SEBM023E0404 – PDF DOWNLOAD
Language : English
Pages : 715
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu GD700-4 Series Motor Grader Shop Manual SEBM023E0404 – PDF DOWNLOAD
MACHINE MODEL SERIAL No.
- GD705R-4 16001 and up
- GD705A-4 21001 and up
COVER . 1
CONTENTS 2
01 GENERAL 21
MOTOR GRADER NUMBERING CODE . 22
GENERAL VIEW 23
OPERATOR’S COMPARTMENT 24
SPECIFICATIONS 29
ENGINE ASSEMBLY . 33
WEIGHT TABLE 41
SERIAL NUMBER LOCATIONS . 43
LIST OF LUBRICANT AND WATER . 45
MOTOR GRADER DESCRIPTION 46
10 ENGINE . 49
11 STRUCTURE AND FUNCTION . 49
ENGINE MOUNTING . 50
RADIATOR 52
FUEL TANK AND PIPING 54
ACCELERATOR CONTROL . 56
12 TESTING AND ADJUSTING 58
TESTING AND ADJUSTING DATA 59
TESTING AND ADJUSTING TOOL LIST . 60
TESTING AND ADJUSTING VALVE CLEARANCE . 61
MEASURING COMPRESSION PRESSURE . 62
MEASURING BLOW-BY . 63
TESTING AND ADJUSTING FAN BELT TENSION 63
TESTING AND ADJUSTING FUEL INJECTION TIMING . 64
13 DISASSEMBLY AND ASSEMBLY . 66
ALTERNATOR ASSEMBLY . 67
REMOVAL AND INSTALLATION 67
STARTING MOTOR ASSEMBLY . 69
REMOVAL AND INSTALLATION 69
OIL COOLER ASSEMBLY . 69
REMOVAL AND INSTALLATION 69
HYDROSHIFT TRANSMISSION OIL COOLER ASSEMBLY . 70
REMOVAL AND INSTALLATION 70
WATER PUMP ASSEMBLY . 72
REMOVAL AND INSTALLATION 72
FUEL INJECTION PUMP ASSEMBLY 74
REMOVAL AND INSTALLATION 74
AIR COMPRESSOR ASSEMBLY . 76
REMOVAL AND INSTALLATION 76
TURBOCHARGER ASSEMBLY . 77
REMOVAL AND INSTALLATION 77
NOZZLE HOLDER ASSEMBLY 78
REMOVAL AND INSTALLATION 78
CYLINDER HEAD ASSEMBLY 80
REMOVAL . 80
INSTALLATION 85
RADIATOR ASSEMBLY .107
REMOVAL .107
INSTALLATION 109
FUEL TANK ASSEMBLY (INCL . HYDRAULIC TANK) 115
REMOVAL .115
INSTALLATION 117
ENGINE ASSEMBLY (INCL . TRANSMISSION) .123
REMOVAL .123
INSTALLATION 130
20 POWER TRAIN 150
21 STRUCTURE AND FUNCTION .150
GENERAL .151
POWER TRAIN DIAGRAM .153
DAMPER 155
PTO .157
HYDROSHIFT TRANSMISSION .159
HYDROSHIFT TRANSMISSION CONTROL VALVE .170
HYDROSHIFT TRANSMISSION CONTROL CIRCUIT DIAGRAM .181
HYDROSHIFT TRANSMISSION CONTROL .182
HYDROSHIFT TRANSMISSION PIPING 185
LUBRICATION RELIEF VALVE 187
TRANSMISSION PUMP .188
HYDROSHIFT TRANSMISSION CONTROL LINKAGE .189
DRIVE SHAFT .193
FINAL DRIVE .194
DIFFERENTIAL LOCK AND UNLOCK PIPING .198
TANDEM DRIVE 202
22 TESTING AND ADJUSTING 205
TABLE OF JUDGEMENT STANDARD VALUE .206
INCHING PEDAL STROKE AND OPERATING FORCE 207
HYDROSHIFT TRANSMISSION .208
TRANSMISSION CONTROL LEVER STROKE AND OPERATING FORCE .212
23 DISASSEMBLY AND ASSEMBLY .213
DAMPER 214
REMOVAL AND INSTALLATION 214
HYDROSHIFT TRANSMISSION ASSEMBLY 216
DISASSEMBLY .216
ASSEMBLY 231
CAGE AND REVERSE CARRIER ASSEMBLY .308
DISASSEMBLY AND ASSEMBLY 308
1ST SPEED AND 2ND SPEED CARRIER ASSEMBLY 309
DISASSEMBLY .309
ASSEMBLY 310
HIGH REVOLUTION CLUTCH ASSEMBLY .311
DISASSEMBLY .311
ASSEMBLY 312
PLANETARY GEAR 313
DISASSEMBLY AND ASSEMBLY 313
HYDROSHIFT TRANSMISSION CONTROL VALVE .314
REMOVAL .314
INSTALLATION 315
HYDROSHIFT TRANSMISSION PUMP ASSEMBLY .316
REMOVAL AND INSTALLATION 316
TANDEM AND FINAL DRIVE ASSEMBLY .318
REMOVAL .318
INSTALLATION 319
FINAL DRIVE ASSEMBLY 322
DISASSEMBLY .322
ASSEMBLY 327
BEVEL GEAR ASSEMBLY .347
DISASSEMBLY .347
ASSEMBLY 348
BEVEL PINION ASSEMBLY .355
REMOVAL .355
INSTALLATION 357
DISASSEMBLY .359
ASSEMBLY 360
TANDEM CASE AND SPROCKET 361
REMOVAL .361
INSTALLATION 364
SPROCKET ASSEMBLY .367
REMOVAL .367
INSTALLATION 369
CHAIN .371
REMOVAL .371
INSTALLATION 373
WHEEL BRAKE AND SPROCKET ASSEMBLY .375
REMOVAL .375
INSTALLATION 375
DISASSEMBLY .376
ASSEMBLY 379
24 MAINTENANCE STANDARD .382
DAMPER 383
HYDROSHIFT TRANSMISSION .384
HYDROSHIFT TRANSMISSION CONTROL VALVE .394
HYDROSHIFT TRANSMISSION PUMP 402
FINAL DRIVE .404
TANDEM DRIVE 406
40 STEERING SYSTEM 408
41 STRUCTURE AND FUNCTION .408
STEERING PIPING 409
STEERING WHEEL 411
STEERING SYSTEM .413
FLOW CONTROL VALVE 419
STEERING PUMP .423
STEERING CYLINDER .424
FRONT AXLE 426
WHEEL .432
42 TESTING AND ADJUSTING 442
TABLE OF JUDGEMENT STANDARD VALVE .443
STEERING WHEEL 444
CHECKING TIRE PLAY 445
CHECKING TOE-IN .446
43 DISASSEMBLY AND ASSEMBLY .448
FRONT AXLE ASSEMBLY .449
REMOVAL .449
INSTALLATION 453
STEERING PUMP ASSEMBLY 461
REMOVAL AND INSTALLATION 461
STEERING CYLINDER ASSEMBLY 462
REMOVAL AND INSTALLATION 462
44 MAINTENANCE STANDARD 463
STEERING PUMP .464
STEERING CYLINDER .466
FRONT AXLE 468
50 BRAKE SYSTEM .470
51 STRUCTURE AND FUNCTION .470
BRAKE PIPING DIAGRAM 471
BRAKE PIPING .472
HYDROMASTER .473
WHEEL BRAKE .475
BRAKE AIR PIPING 476
DISK BRAKE SYSTEM .478
BRAKE VALVE .482
RELAY VALVE .486
AIR GOVERNOR 488
CHECK VALVE .490
AIR RESERVOIR .491
SAFETY VALVE 491
PRESSURE SWITCH .492
AUTOMATIC DRAIN VALVE .494
AIR DRIER .496
AIR COMPRESSOR 498
PARKING BRAKE .499
PARKING BRAKE CONTROL .500
52 TESTING AND ADJUSTING 502
CHECKING BRAKE PEDAL HEIGHT .503
CHECKING BRAKE PEDAL PLAY .503
CHECKING BRAKE PEDAL OPERATING FORCE 503
CHECKING BRAKE PEDAL DEPRESSION HEIGHT 504
CHECKING PARKING BRAKE LEVER STROKE AND OPERATING FORCE 505
BLEEDING AIR INSIDE BRAKE PIPING .506
CHECKING WEAR OF BRAKE DISC .507
53 DISASSEMBLY AND ASSEMBLY .508
HYDROMASTER .509
DISASSEMBLY .509
ASSEMBLY 511
WHEEL BRAKE ASSEMBLY 513
DISASSEMBLY .513
ASSEMBLY 515
BRAKE MASTER CYLINDER ASSEMBLY 517
REMOVAL .517
INSTALLATION 517
54 MAINTENANCE STANDARD .518
WHEEL BRAKE .519
DISC BRAKE 520
PARKING BRAKE .521
60 HYDRAULIC SYSTEM .523
61 STRUCTURE AND FUNCTION .523
HYDRAULIC CONTROL PIPING 524
HYDRAULIC SYSTEM DIAGRAM 538
HYDRAULIC CIRCUIT DIAGRAM .540
HYDRAULIC CONTROL VALVE .550
DDV (DUAL DEMAND VALVE) .561
FLOW DIVIDER VALVE 577
PILOT CHECK VALVE .578
DOUBLE RELIEF VALVE .583
HYDRAULIC PUMP 584
CIRCLE ROTATION MOTOR .593
HYDRAULIC CYLINDER 596
62 TESTING AND ADJUSTING 604
CHECKING HYDRAULIC OIL TEMPERATURE 605
63 DISASSEMBLY AND ASSEMBLY .606
HYDRAULIC TANK 607
REMOVAL AND INSTALLATION 607
HYDRAULIC PUMP ASSEMBLY .608
REMOVAL AND INSTALLATION 608
HYDRAULIC CONTROL VALVE ASSEMBLY 610
REMOVAL .610
INSTALLATION 611
BLADE LIFT CYLINDER ASSEMBLY 614
REMOVAL AND INSTALLATION 614
DRAWBAR SHIFT CYLINDER ASSEMBLY .615
REMOVAL AND INSTALLATION 615
BLADE SIDE SHIFT CYLINDER ASSEMBLY 616
REMOVAL .616
INSTALLATION 617
LEANING CYLINDER ASSEMBLY .620
REMOVAL AND INSTALLATION 620
ARTICULATE CYLINDER ASSEMBLY 622
REMOVAL AND INSTALLATION 622
POWER TILT CYLINDER ASSEMBLY 623
REMOVAL AND INSTALLATION 623
HYDRAULIC CYLINDER ASSEMBLY .624
DISASSEMBLY .624
ASSEMBLY 627
64 MAINTENANCE STANDARD .634
HYDRAULIC CONTROL VALVE .635
HYDRAULIC PUMP 641
HYDRAULIC CYLINDER 643
70 WORK EQUIPMENT .647
71 STRUCTURE AND FUNCTION .647
DRAWBAR .648
BLADE AND CIRCLE 650
CIRCLE ROTATION GEAR 652
LIFTER 654
LIFTER BRACKET CONTROL 656
REAR MOUNT RIPPER .659
SCARIFIER .660
MAIN FRAME 662
HYDRAULIC CONTROL LINKAGE .664
BLADE ACCUMULATOR SYSTEM 670
72 TESTING AND ADJUSTING 675
INSPECTION TABLE 676
WORK EQUIPMENT CONTROL LEVER STROKE AND OPERATING FORCE .677
HYDRAULIC DRIFT OF BLADE 677
MEASURING BLADE SINKING AMOUNT 677
CHECKING HYDRAULIC OIL PRESSURE .678
ADJUSTING OIL PRESSURE 679
CHARGING BLADE ACCUMULATOR WITH GAS .680
73 DISASSEMBLY AND ASSEMBLY .681
BLADE ASSEMBLY 682
REMOVAL AND INSTALLATION 682
CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR ASSEMBLY .683
REMOVAL AND INSTALLATION 683
DISASSEMBLY .684
ASSEMBLY 686
74 MAINTENANCE STANDARD .689
BLADE AND CIRCLE 690
DRAWBAR .692
BLADE LIFTER BRACKET 694
CIRCLE ROTATION GEAR 696
SCARIFIER .698
REAR MOUNT RIPPER .700
80 ELECTRICAL SYSTEM 701
81 ELECTRIC SYSTEM 701
BATTERY HANDLING 702
ELECTRIC WIRE CODE 703
ELECTRICAL WIRING DIAGRAM .704
ELECTRICAL CIRCUIT DIAGRAM 708
ELECTRICAL CIRCUIT DIAGRAM FOR CAB 714
WIRING DIAGRAM FOR CAB 715
DESCRIPTION:
Komatsu GD700-4 Series Motor Grader Shop Manual SEBM023E0404 – PDF DOWNLOAD
MACHINE MODEL SERIAL No.
- GD705R-4 16001 and up
- GD705A-4 21001 and up
Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
Always wear safety glasses when hitting. parts with a hammer.
Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the op- erating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
PREPARATIONS FOR WORK:
7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
9. When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out.
Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned.
Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal first.
14. When raising heavy components, use a hoist or crane.
Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity.
Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane.
15. When removing covers which are under internal pressure or under pressure from a spring, 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 on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
18. As a general rule, do not use gasoline to wash parts. In particular, use only the mini- mum of gasoline when washing electrical parts.
G.B 28/12/24
