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KOMATSU GD705A-4 SHOP MANUAL SN23001 & UP – PDF DOWNLOAD
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Description
KOMATSU GD705A-4 SHOP MANUAL SN23001 & UP – PDF DOWNLOAD
FILE DETAILS:
KOMATSU GD705A-4 SHOP MANUAL SN23001 & UP – PDF DOWNLOAD
Language : English
Pages : 429
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU GD705A-4 SHOP MANUAL SN23001 & UP – PDF DOWNLOAD
MAIN MENU ....................................................................... 0 COVER............................................................................ 1 CONTENTS......................................................................... 2 SAFETY........................................................................... 5 SAFETY NOTICE................................................................ 5 GENERAL PRECAUTIONS...................................................... 5 PRECAUTIONS FOR WORK..................................................... 5 PRECAUTIONS DURING WORK.................................................. 6 FOREWARD......................................................................... 7 GENERAL...................................................................... 7 HOW TO READ THE SHOP MANUAL.................................................. 8 VOLUMES.................................................................. 8 DISTRIBUTION AND UPDATING................................................ 8 FILING METHOD............................................................ 8 REVISED EDITION MARK..................................................... 8 REVISIONS................................................................ 8 SYMBOLS.................................................................. 8 HOISTING INSTRUCTIONS........................................................ 9 HOISTING................................................................. 9 WIRE ROPES............................................................... 9 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER................... 10 COATING MATERIALS............................................................ 12 STANDARD TIGHTENING TORQUE................................................... 14 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS............................. 14 TIGHTENING TORQUE OF HOSE NUTS........................................... 15 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS.................................. 15 TIGHTENING TORQUE FOR FLARED NUTS........................................ 15 TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLTS AND NUTS)................. 16 TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)..................... 16 TIGHTENED TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS).................. 16 ELECTRIC WIRE CODE........................................................... 17 CLASSIFICATION BY THICKNESS.............................................. 17 CLASSIFICATION BY COLOR AND CODE......................................... 17 CONVERSION TABLES............................................................ 18 METHOD OF USING THE CONVERSION TABLE..................................... 18 UNITS........................................................................ 24 01 GENERAL....................................................................... 25 GENERAL ASSEMBLY DRAWING..................................................... 26 SPECIFICATIONS............................................................... 27 WEIGHT TABLE................................................................. 29 LIST OF LUBRICANT AND WATER.................................................. 30 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.................................. 32 ENGINE MOUNTING.............................................................. 33 RADIATOR..................................................................... 34 FUEL TANK PIPING............................................................. 35 ACCELERATOR CONTROL.......................................................... 36 POWER TRAIN.................................................................. 37 DAMPER....................................................................... 39 PTO (POWER TAKE OFF)......................................................... 40 HYDROSHIFT TRANSMISSION...................................................... 42 HYDROSHIFT TRANSMISSION CONTROL VALVE........................................ 53 HYDROSHIFT TRANSMISSION PIPING............................................... 68 LUBRICATION RELIEF VALVE..................................................... 69 TRANSMISSION PUMP............................................................ 70 TRANSMISSION CONTROL......................................................... 73 DRIVE SHAFT.................................................................. 75 FINAL DRIVE.................................................................. 76 TANDEM DRIVE................................................................. 81 STEERING PIPING.............................................................. 85 STEERING WHEEL............................................................... 89 STEERING VALVE (ORBIT ROLL TYPE)............................................. 90 STEERING SYSTEM.............................................................. 91 STEERING PUMP................................................................ 99 STEERING CYLINDER............................................................102 FRONT AXLE...................................................................104 WHEEL........................................................................110 BRAKE PIPING.................................................................112 DISC BRAKE SYSTEM............................................................114 BRAKE VALVE..................................................................118 RELAY VALVE..................................................................122 AIR GOVERNOR.................................................................124 CHECK VALVE..................................................................126 AIR RESERVOIR................................................................127 SAFETY VALVE.................................................................127 PRESSURE SWITCH..............................................................128 AUTOMATIC DRAIN VALVE........................................................130 AIR DRIER....................................................................132 AIR COMPRESSOR...............................................................134 PARKING BRAKE................................................................135 PARKING BRAKE CONTROL........................................................138 HYDRAULIC PIPING.............................................................140 MAIN CONTROL VALVE...........................................................145 PILOT CHECK VALVE............................................................149 DDV (DUAL DEMAND VALVE)......................................................157 FLOW DIVIDER VALVE...........................................................175 HYDRAULIC PUMP...............................................................176 CIRCLE ROTATION MOTOR........................................................179 HYDRAULIC CYLINDER...........................................................182 WORK EQUIPMENT CONTROL.......................................................192 WORK EQUIPMENT...............................................................194 20 TESTING AND ADJUSTING.........................................................213 STANDARD VALUE TABLE FOR ENGINE..............................................214 STANDARD VALUE TABLE FOR CHASSIS.............................................215 TESTING AND ADJUSTING........................................................218 TESTING AND ADJUSTING TOOL LIST (FOR ENGINE).............................219 TESTING AND ADJUSTING VALVE CLEARANCE....................................220 MEASURING COMPRESSION PRESSURE...........................................221 MEASURING BLOW-BY........................................................222 TESTING AND ADJUSTING FAN BELT TENSION...................................223 TESTING AND ADJUSTING FUEL INJECTION TIMING..............................224 INCHING PEDAL STROKE AND OPERTING FORCE..................................226 HYDROSHIFT TRANSMISSION..................................................227 TRANSMISSION CONTROL LEVER STROKE AND OPERATING FORCE....................229 ADJUSTING F/R CONTROL CABLE..............................................230 ADJUSTING TRANSMISSION CONTROL LINKAGE...................................231 STEERING WHEEL...........................................................233 CHECKING TIRE PLAY.......................................................234 CHECKING TIRE AIR PRESSURE...............................................234 CHECKING TOE-IN..........................................................235 CHECKING PARKING BRAKE LEVER STROKE AND OPERATING FORCE..................237 CHECKING WEAR OF BRAKE DISC..............................................238 CHECKING HYDRAULIC OIL PRESSURE..........................................239 CHECKING HYDRAULIC OIL TEMPERATURE.......................................240 WORK EQUIPMENT CONTROL LEVER STROKE AND OPERATING FORCE..................241 HYDRAULIC DRIFT OF BLADE.................................................241 MEASURING BLADE SINKING AMOUNT...........................................241 TROUBLESHOOTING..............................................................242 POINTS TO REMEMBER WHEN TROUBLESHOOTING..................................243 SEQUENCE OF EVENTS IN TROUBLESHOOTING....................................244 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.........................245 CHECKS BEFORE TROUBLESHOOTING............................................253 CONNECTOR TYPES AND MOUNTING LOCATIONS...................................254 CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS................................257 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)............................261 E-1 ENGINE DOES NOT START............................................262 E-2 ELECTRIC SYSTEM DOES NOT WORK....................................265 E-3 SERVICE METER DOES NOT WORK......................................266 E-4 WATER TEMPERATURE GUAGE INDICATES ABNORMALLY HIGH TEMPERATURE....267 E-5 WATER TEMPERATURE GUAGE DOES NOT WORK............................267 E-6 FUEL GUAGE ALWAYS INDICATES FULL.................................268 E-7 FUEL GUAGE DOES NOT WORK.........................................268 E-8 ENGINE OIL PRESSURE GUAGE INDICATES ABNORMALLY HIGH PRESSURE.....269 E-9 ENGINE OIL PRESSURE GUAGE DOES NOT WORK..........................269 30 DISASSEMBLY AND ASSEMBLY......................................................270 ALTERNATOR ASSEMBLY..........................................................272 REMOVAL AND INSTALLATION.................................................272 STARTING MOTOR AND ASSEMBLY..................................................273 REMOVAL AND INSTALLATION.................................................273 OIL COOLER ASSMBLY...........................................................273 REMOVAL AND INSTALLATION.................................................273 HYDROSHIFT TRANSMISSION OIL COOLER ASSEMBLY..................................274 REMOVAL AND INSTALLATION.................................................274 WATER PUMP ASSEMBLY..........................................................275 REMOVAL AND INSTALLATION.................................................275 FUEL INJECTION PUMP ASSEMBLY.................................................276 REMOVAL AND INSTALLATION.................................................276 AIR COMPRESSOR ASSEMBLY......................................................277 REMOVAL AND INSTALLATION.................................................277 TURBOCHARGER ASSEMBLY........................................................278 REMOVAL AND INSTALLATION.................................................278 NOZZLE HOLDER ASSEMBLY.......................................................279 REMOVAL AND INSTALLATION.................................................279 CYLINDER HEAD ASSEMBLY.......................................................281 REMOVAL..................................................................281 INSTALLATION.............................................................287 RADIATOR ASSEMBLY............................................................293 REMOVAL..................................................................293 INSTALLATION.............................................................295 FUEL TANK ASSEMBLY (INC. HYDRAULIC TANK).....................................297 REMOVAL..................................................................297 INSTALLATION.............................................................299 ENGINE ASSEMBLY (INC. TRANSMISSION)..........................................301 REMOVAL..................................................................301 INSTALLATION.............................................................306 HYDROSHIFT TRANSMISSION ASSEMBLY.............................................313 DISASSEMBLY..............................................................313 ASSEMBLY.................................................................323 CAGE AND REVERSE CARRIER ASSEMBLY............................................334 DISASSEMBLY AND ASSEMBLY.................................................334 1ST SPEED AND 2ND SPEED CARRIER ASSEMBLY.....................................335 DISASSEMBLY..............................................................335 ASSEMBLY.................................................................336 HIGH REVOLUTION CLUTCH ASSEMBLY..............................................337 DISASSEMBLY..............................................................337 ASSEMBLY.................................................................338 PLANETARY GEAR...............................................................339 DISASSEMBLY AND ASSEMBLY.................................................339 HYDROSHIFT TRANSMISSION PUMP ASSEMBLY........................................340 REMOVAL AND INSTALLATION.................................................340 TANDEM AND FINAL DRIVE ASSEMBLY..............................................341 REMOVAL..................................................................341 INSTALLATION.............................................................342 FINAL DRIVE ASSEMBLY.........................................................343 DISASSEMBLY..............................................................343 ASSEMBLY.................................................................349 BEVEL GEAR ASSEMBLY..........................................................357 DISASSEMBLY..............................................................357 ASSEMBLY.................................................................360 BEVEL PINION ASSEMBLY........................................................363 REMOVAL..................................................................363 INSTALLATION.............................................................364 DISASSEMBLY..............................................................366 ASSEMBLY.................................................................367 SPROCKET ASSEMBLY............................................................369 REMOVAL..................................................................369 INSTALLATION.............................................................371 CHAIN........................................................................373 REMOVAL..................................................................373 INSTALLATION.............................................................375 FRONT AXLE ASSEMBLY..........................................................377 REMOVAL..................................................................377 INSTALLATION.............................................................379 STEERING PUMP ASSEMBLY.......................................................381 REMOVAL AND INSTALLATION.................................................381 STEERING CYLINDER ASSEMBLY...................................................382 REMOVAL AND INSTALLATION.................................................382 WHEEL BRAKE ASSEMBLY.........................................................383 DISASSEMBLY..............................................................383 ASSEMBLY.................................................................385 HYDRAULIC TANK...............................................................387 REMOVAL AND INSTALLATION.................................................387 HYDRAULIC PUMP ASSEMBLY......................................................388 REMOVAL AND INSTALLATION.................................................388 HYDRAULIC CONTROL VALVE ASSEMBLY.............................................389 REMOVAL..................................................................389 INSTALLATION.............................................................390 BLADE LIFT CYLINDER ASSEMBLY.................................................391 REMOVAL AND INSTALLATION.................................................391 DRAWBAR SHIFT CYLINDER ASSEMBLY..............................................392 REMOVAL AND INSTALLATION.................................................392 BLADE SIDE SHIFT CYLINDER ASSEMBLY...........................................393 REMOVAL..................................................................393 INSTALLATION.............................................................394 LEANING CYLINDER ASSEMBLY....................................................395 REMOVAL AND INSTALLATION.................................................395 ARTICULATE CYLINDER ASSEMBLY.................................................396 REMOVAL AND INSTALLATION.................................................396 POWER TILT CYLINDER ASSEMBLY.................................................397 REMOVAL AND INSTALLATION.................................................397 HYDRAULIC CYLINDER ASSEMBLY..................................................398 DISASSEMBLY..............................................................398 ASSEMBLY.................................................................401 BLADE ASSEMBLY...............................................................408 REMOVAL AND INSTALLATION.................................................408 CIRCLE ROTATION GEAR AND HYDRAULIC MOTOR ASSEMBLY............................409 REMOVAL AND INSTALLATION.................................................409 DISASSEMBLY..............................................................410 ASSEMBLY.................................................................412 90 OTHERS........................................................................416 HYDRAULIC CIRCUIT DIAGRAM (STD SPEC.)........................................417 HYDRAULIC CIRCUIT DIAGRAM (DDV SPEC.)........................................419 HYDROSHIFT TRANSMISSION CONTROL CIRCUIT DIAGRAM..............................421 ELECTRICAL CIRCUIT DIAGRAM (1/2).............................................422 ELECTRICAL CIRCUIT DIAGRAM (2/2).............................................424 ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER...............................426 ELECTRICAL CIRCUIT DIAGRAM FOR CAB...........................................428
DESCRIPTION:
KOMATSU GD705A-4 SHOP MANUAL SN23001 & UP – PDF DOWNLOAD
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together
S.S 12/12/24
