Komatsu GD750A-1 Motor Grader Shop Manual CEBM002104 – PDF DOWNLOAD

Description

Komatsu GD750A-1 Motor Grader Shop Manual CEBM002104 – PDF DOWNLOAD

FILE DETAILS:

Komatsu GD750A-1 Motor Grader Shop Manual CEBM002104 – PDF DOWNLOAD

Language : English
Pages : 1066
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu GD750A-1 Motor Grader Shop Manual CEBM002104 – PDF DOWNLOAD

• SERIAL NUMBERS GD750A-1 – 7001 and up

MAIN MENU 0
COVER 1
CONTENTS 2
00 FORWARD 14
SAFETY 15
SAFETY NOTICE 15
GENERAL PRECAUTIONS 15
PREPARATIONS FOR WORK 15
PRECAUTIONS DURING WORK 15
GENERAL 17
HOW TO READ THE SHOP MANUAL 18
VOLUMES 18
DISTRIBUTION AND UPDATING 18
FILING METHOD 18
REVISED EDITION MARK 18
REVISIONS 18
SYMBOLS 18
HOISTING INSTRUCTIONS 19
HOISTING 19
WIRE ROPES 19
COATING MATERIALS 20
STANDARD TORQUE REQUIREMENTS 21
STANDARD TORQUE REQUIREMENTS OF BOLTS AND NUTS 21
TYPE 1, 5, AND 8 NON-PHOSPHATE COATED HARDWARE 22
TYPE 8 PHOSPHATE COATED HARDWARE 22
HOSE CLAMP TORQUE VALUES 23
TORQUE REQUIREMENTS OF SPLIT FLANGE BOLTS 23
O-RING SEAL FITTING TORQUE VALUES 24
TORQUE REQUIREMENTS FOR FLAIRED NUTS 24
ELECTRIC WIRE CODE 25
CLASSIFICATION BY THICKNESS 25
CLASSIFICATION BY COLOR AND CODE 25
CONVERSION TABLES 26
METHOD OF USING THE CONVERSION TABLE 26
MILLIMETERS TO INCHES 26
MILLIMETERS TO INCHES 27
KILOGRAM TO POUND 27
LITER TO U S GALLON 28
LITER TO U K GALLON 28
KM/CM² TO LB/IN² 29
KG/CM² TO LB/IN² 30
TEMPERATURE 31
01 GENERAL 32
GENERAL ASSEMBLY DRAWING 33
WEIGHT TABLE 34
FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 35
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS 35
ENGINE OIL SPECIFICATIONS 37
NORMAL OPERATION 37
ARCTIC OPERATION 37
TRANSMISSION, TORQUE CONVERTER AND OIL COOLER, TANDEM DRIVE CASES, FRONT WHEEL DRIVE GEAR CASE 38
REAR DRIVE AXLE AND CIRCLE DRIVE BRAKE HOUSING OIL SPECIFICATIONS 38
DIESEL FUEL SPECIFICATION 38
COOLANT SPECIFICATIONS 39
GENERAL 39
ANTIFREEZE 39
SUPPLEMENTAL COOLANT ADDITIVES 40
CIRCLE DRIVE GEAR CASE OIL SPECIFICATION (HDTF) 43
10 STRUCTURE AND FUNCTION 44
GENERAL 48
JOINT 49
TORQUE CONVERTER LUBE CIRCUIT 50
HYDRAULIC CIRCUITS FOR POWER TRAIN 51
GEARS 51
1ST GEAR 52
2ND GEAR 52
3RD GEAR 53
4TH GEAR 53
5TH GEAR 54
6TH GEAR 54
7TH GEAR 55
8TH GEAR 55
R1 GEAR 56
R2 GEAR 57
R3 GEAR 58
R4 GEAR 59
TORQUE CONVERTER/TRANSMISSION 60
SIDE VIEW 60
TORQUE CONVERTER 61
THEORY OF OPERATION 61
RULES OF OPERATION 62
CONNECTOR PINOUTS 62
TRANSMISSION, DF 250 63
TRANSMISSION DIAGRAM 64
OPERATION 66
RULES OF OPERATION 67
CONTROL VALVE (S/N A7003-A7007 69
CONTROL VALVE (S/N A7008 AND UP) 70
PRESSURE AND TEMPERATURE CHECK PORTS (S/N A7003-A7007) 71
OPERATING CONDITONS (S/N A7003-A7007) 71
PORT PRESSURES (S/N A7003-A7007) 71
PRESSURE AND TEMPERATURE CHECK PORTS (S/N A7008 AND UP) 72
OPERATING CONDITIONS (S/N A7008 AND UP) 72
PORT PRESSURES (S/N A7008 AND UP) 72
PIPING DIAGRAM, CHARGE PUMP TO CONTROL VALVE 73
ENGAGEMENT OVERRIDE VALVE (EOV) 74
ELECTRONIC CONTROL UNIT (ECU) 74
THEORY OF OPERATION 74
TROUBLESHOOTING INTRODUCTION 75
PROPORTIONAL VALVES 76
FUNCTION OF PROPORTIONAL VALVES 76
PROPORTIONAL VALVE CONNECTOR PINOUT 77
TRANSIENT VOLTAGE PROTECTION (TVP) MODULE 78
ENGINE SPEED MAGNETIC PICKUP (MPU) (INPUT SPEED) 78
TRANSMISSION OUTPUT SPEED MPU 78
CYLINDER MAGNETIC PICKUP SENSOR MPU 79
SHIFT LEVER 79
GEAR/DIAGNOSTIC INDICATOR 79
INCHING PEDAL 80
THROTTLE POSITION SENSOR 80
MISCELLANEOUS INPUT FUNCTION SWITCHES 81
PARK BRAKE 81
WIRING HARNESS 81
CALIBRATION 81
CLUTCH CALIBRATION EIGHT FORWARD SPEEDS AND FOUR REVERSE 82
SYSTEM REQUIREMENTS 83
VOLTAGE 83
WIRING 83
ECU MOUNTING 84
GLOSSARY 85
TRANSMISSION CONTROL 87
SELECTOR LEVER 87
OPERATIONAL ERROR CODE IDENTIFICATION 89
INCHING CONTROL 91
DRIVE SHAFT 92
FINAL DRIVE, DIFFERENTIAL LOCK AND UNLOCK PIPING 93
FINAL DRIVE 95
FINAL DRIVE 96
DIFFERENTIAL OPERATION 96
DIFFERENTIAL LOCK CAPTURE SYSTEM 98
DIFFERENTIAL LOCK VALVE 98
TANDEM DRIVE 99
STEERING 101
STEERING PIPING 101
STEERING CIRCUIT DIAGRAM 102
STEERING VALVE (ORBITROL TYPE) 103
OUTLINE 104
STRUCTURE 104
FUNCTION OF CENTER SPRING 106
STEERING UNIT PORTS 107
EMERGENCY STEERING SYSTEM 107
FRONT AXLE 108
WHEEL 109
STANDARD WHEEL 109
OPTIONAL WHEEL 109
BRAKES 111
SERVICE BRAKE 111
PARKING BRAKE 112
BRAKE PIPING 113
BRAKE CIRCUIT PIPING 115
BRAKE VALVE 117
COMBINATION/PARK BRAKE BLOCK VALVE 119
PIPING 121
HYDRAULIC TANK PIPING 121
HYDRAULIC CONTROL PIPING 123
REAR MOUNT RIPPER CONTROL PIPING 125
HYDRAULIC CIRCUIT DIAGRAM 126
CONTROL VALVE 126
PUMP AND RESERVOIR 128
CLOSED CENTER LOAD SENSING SYSTEM (CLSS) 130
MAIN HYDRAULIC CIRCUIT 134
PRINCIPLE OF OPERATION OF A PISTON PUMP 135
FUNCTION 135
OPERATION 135
OPERATION OF THE HYDRAULIC PUMP 135
FUNCTION 135
MAIN HYDRAULIC PUMP 136
PRIORITY VALVE 139
RH & LH BLADE LIFT CYLINDER 147
BLADE SHIFT CYLINDER 150
CIRCLE REVERSE MOTOR 150
MOLDBOARD TILT CYLINDER 151
ARTICULATION CYLINDERS 152
CIRCLE SIDE SHIFT CYLINDER 154
WHEEL LEAN CYLINDER 155
FLOAT VALVE FOR AUXILIARY FUNCTION (OPTIONAL) 156
HYDRAULIC CONTROL VALVE 157
L H VALVE BANK 157
R H VALVE BANK 158
PRESSURE COMPENSATING MECHANISM OF HYDRAULIC CONTROL VALVE 159
CIRCLE ROTATION MOTOR 162
CIRCLE ROTATION GEAR 163
BLADE ACCUMULATOR SYSTEM 164
DRAW BAR AND LIFTER 165
BLADE 167
BLADE SUPPORT 168
BLADE LIFT ASSEMBLY 169
HYDRUALIC CONTROL LEVER LINKAGE 171
RIPPER 173
MAIN FRAME 175
MONITOR PANEL, GAUGES AND SIDE PANELS 177
MONITOR PANEL AND GAUGES 177
UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS 179
SIDE PANELS 180
DRIVER’S RIGHT SIDE PANEL 180
DRIVER’S LEFT SIDE PANEL 180
ELECTRICAL WIRING 181
ELECTRICAL CONNECTIONS 187
ELECTRICAL SCHEMATIC 202
CAB AREA 202
ENGINE AREA 204
TRANSMISSION HARNESS 206
SWITCH PANEL HARNESS 208
DASH CONSOLE AREA 210
MAIN HARNESS 212
20 TESTING, ADJUSTING AND TROUBLESHOOTING 214
TESTING AND ADJUSTING 218
SPECIAL TOOLS 219
MEASURING ENGINE PERFORMANCE 230
ENGINE SPEEDS 230
ENGINE RATING 230
INTAKE MANIFOLD PRESSURE 230
INTAKE AIR RESTRICTION 230
LUBRICATING OIL PRESSURE 230
FUEL FILTER INLET RESTRICTION 230
BLOW-BY PRESSURE 230
EXHAUST BACK PRESSURE 230
COOLANT TEMPERATURE 230
VALVE CLEARANCE 230
EXHAUST GAS COLOR 230
ENGINE DRIVE BELT TENSION 230
STANDARD VALUE TABLE FOR ENGINE – IN CHASSIS 231
STANDARD VALUE TABLE FOR CHASSIS 232
ELECTRONIC SYSTEM CHECK VALUE TABLE 235
ADJUSTING ACCELERATOR/DECELERATOR CONTROL PEDAL 237
PEDAL START ADJUSTMENT 237
PEDAL LIMIT STOP ADJUSTMENT 237
HEEL PIECE LIMIT STOP ADJUSTMENT 237
FINAL INSPECTION OF SYSTEM 237
INCHING PEDAL 238
TRANSMISSION 239
TO READ DIAGNOSTIC TEST FOR TRANSMISSION AND MACHINE 239
ECU DIAGNOSTIC SOFTWARE 240
CLUTCH CALIBRATION 266
TRANSMISSION HARNESS 267
CONTROL SIGNALS REQUIRED FROM GEAR SHIFT LEVER POSITIONS 275
MAIN CONNECTOR PINOUT 275
SUCTION LEAK TEST 276
CLUTCH PACK PRESSURE CHECK (S/N A7003-A7007) 277
CLUTCH PACK PRESSURE CHECK (S/N A7008 AND UP) 279
SOLENOID VALVE OPERATION 282
CLUTCH SOLENOID VOLTAGE REQUIREMENTS 282
TEST SOLENOIDS 283
STEERING SYSTEM PRESSURE CHECK 288
FRONT WHEEL ALIGNMENT AND TURNING RADIUS ADJUSTMENT 289
STARTING POINT 289
PROCEDURE 289
CHECK AND ADJUST FRONT WHEEL “TOE IN” 290
SYNCHRONIZE STEERING CYLINDER 291
BRAKE SYSTEM 293
CHECKING BRAKE ACCUMULATOR CHARGE 293
SERVICE (FOOT) BRAKE CHECK – OPERATOR 294
CHECKING SERVICE (FOOT) BRAKE PRESSURE 294
FINAL DRIVE BRAKE BLEEDING 296
CHECKING AND ADJUSTING WHEEL BRAKE 296
PARKING BRAKE 297
CHECKING THE PARKING BRAKE 297
ADJUSTING THE PARKING BRAKE 297
PARKING/EMERGENCY BRAKE BLEEDING 297
CHECKING WORK EQUIPMENT CONTROL LEVER 299
CHECK AND ADJUSTMENT OF WORK EQUIPMENT CONTROL LEVER TRAVEL 299
CHECK AND ADJUSTMENT OF EACH WORK EQUIPMENT CONTROL LEVER OPERATING FORCE 299
CHECKING HYDRAULIC OIL TEMPERATURE 300
HYDRAULIC PRESSURE CHECKS 301
TEST PROCEDURE 301
MEASURING HYDRAULIC DRIFT 304
EXTENSION BLADE CYLINDER (IF EQUIPPED) 304
RETRACTION OF BLADE CYLINDER 304
EXTENSION OF RIPPER CYLINDER (IF EQUIPPED) 304
RETRACTION OF RIPPER CYLINDER (IF EQUIPPED) 304
CUSHION BLADE ACCUMULATOR 305
CHECKING AND SERVICE 305
BLEEDING AIR FROM HYDRAULIC PUMP 306
CAB HEATER OPERATION TEST 307
AIR CONDITIONER 307
OPERATION TEST 307
SERVICE 308
CHECK AND ADJUST TIRE PRESSURE 310
FUNCTIONAL ROAD TEST 311
AXLE ASSEMBLY 313
AXLE VERTICAL MOVEMENT CHECK 313
AIR TEST AXLE ASSEMBLY 314
DIFFERENTIAL ASSEMBLY 315
AIR TEST DIFFERENTIAL LOCK CAPTURE SYSTEM 315
OIL TEST DIFFERENTIAL LOCK CAPTURE SYSTEM 316
TEST DIFFERENTIAL LOCK SEALING RINGS WITH AIR BOOST SYSTEM 317
DIFFERENTIAL LOCK FUNCTION TEST 318
CHECK CARRIER BACKLASH 319
CHECK RING GEAR AND PINION TOOTH CONTACT PATTERN 319
TROUBLESHOOTING 320
POINTS TO REMEMBER WHEN TROUBLESHOOTING 321
PROCEDURE FOR TROUBLESHOOTING 323
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 324
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT 324
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS 328
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 329
CHECKS BEFORE TROUBLESHOOTING 331
HANDLING CONNECTORS 332
PRECAUTIONS WHEN TROUBLESHOOTING 333
1 SAFETY 333
2 METHODS FOR TROUBLESHOOTING 333
3 PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING 335
PREVENTING RECURRENCE OF TROUBLE 336
HYDRAULIC EQUIPMENT 336
ENGINE TROUBLESHOOTING 338
CHASSIS TROUBLESHOOTING 339
ELECTRICAL SYSTEM TROUBLESHOOTING 341
TRANSMISSION SYSTEM DIAGNOSTICS 342
TRANSMISSION TROUBLESHOOTING INTRODUCTION 342
DIAGNOSTIC CHART 343
HYDRAULIC SYSTEM DIAGNOSTICS 346
HEAT PROBLEMS 346
STEERING AND BRAKE PUMP DIAGNOSTIC CHART 347
PARKING/EMERGENCY BRAKE DIAGNOSTIC CHART 348
MAIN SYSTEM PUMP DIAGNOSTIC CHART 349
RH&LH CONTROL VALVE DIAGNOSTIC CHART 350
HYDRAULIC CYLINDERS GENERAL DIAGNOSTIC CHART 351
BLADE SHIFT CYLINDER DIAGNOSTIC CHART 352
BLADE TILT CYLINDER DIAGNOSTIC CHART 352
BLADE LIFT CYLINDER DIAGNOSTIC CHART 352
CIRCLE REVERSE MOTOR DIAGNOSTIC CHART 353
TANDEM CASE DIAGNOSTIC CHART 354
FINAL DRIVE DIAGNOSTIC CHART 355
SHIFT LEVER ERROR CODES 356
INSTRUMENT PANEL TROUBLESHOOTING/FAULT CODES 357
INSTRUMENT PANEL 360
FAULT CODES EXPLANATION 361
AXLE AND DIFFERENTIAL 471
30 DISASSEMBLY AND ASSEMBLY 474
METHOD OF USING MANUAL 484
WHEN REMOVING OR INSTALLING UNIT ASSEMBLIES 484
GENERAL PRECAUTIONS 484
LISTING OF SPECIAL TOOLS 485
PRECAUTIONS WHEN CARRYING OUT OPERATION 485
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK 485
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK 487
PRECAUTIONS WHEN COMPLETING THE OPERATIONS 488
CLEANING AND INSPECTION 489
SPECIAL TOOL LIST 491
ENGINE COWLING & DOORS 493
REMOVAL 493
INSTALLATION 495
RADIATOR HOOD 496
REMOVAL 496
INSTALLATION 497
FUEL/HYDRAULIC TANK HOOD 498
REMOVAL 498
INSTALLATION 498
BATTERY 499
REMOVAL 499
INSTALLATION 500
RADIATOR/OIL COOLER 501
REMOVAL 501
INSTALLATION 504
FUEL/HYDRAULIC TANK 505
REMOVAL 505
INSTALLATION 509
REMOVAL OF HYDRAULIC TANK 510
INSTALLATION OF HYDRAULIC TANK 510
FAN 511
REMOVAL 511
INSTALLATION 513
EXHAUST SYSTEM 514
REMOVAL 514
INSTALLATION 516
DRIVE SHAFT 517
REMOVAL 517
INSTALLATION 517
ENGINE (INC TRANSMISSION) 518
REMOVAL 518
INSTALLATION 524
TRANSMISSION 525
REMOVAL 525
INSTALLATION 528
TORQUE CONVERTER TO ENGINE FLYWHEEL DIMENSIONS 531
TORQUE CONVERTER, 14 INCH WITH LOCKUP 532
REMOVAL 534
DISASSEMBLE AND ASSEMBLE STATOR ASSEMBLY 539
INSTALLATION 552
LEAK TEST TORQUE CONVERTER ASSEMBLY 553
TORQUE CONVERTER, LOCK UP VALVE 554
DISASSEMBLE AND ASSEMBLE LOCKUP CONTROL VALVE GROUP 555
REMOVAL 556
DISASSEMBLE AND ASSEMBLE PROPORTIONAL SOLENOID VALVE 557
INSTALLATION 558
CHARGE PUMP 560
DISASSEMBLE SUCTION TUBE GROUP 560
REMOVE SUCTION TUBE ASSEMBLY 561
ASSEMBLE SUCTION TUBE GROUP 562
INSTALL SUCTION TUBE 563
CHARGE PUMP GROUP 564
REMOVE CHARGE PUMP GROUP 564
REMOVE DRIVEN GEAR AND BEARING ASSEMBLY 565
DISASSEMBLE & ASSEMBLE CHARGE PUMP WITH AUXILIARY PUMP DRIVE DISCONNECT 566
INSTALL CHARGE PUMP TO FRONT COVER 569
FRONT COVER 570
DISASSEMBLE FRONT COVER GROUP 571
REMOVE FRONT COVER AND INPUT ASSEMBLY 572
DISASSEMBLE INPUT ASSEMBLY 574
DISASSEMBLE FRONT COVER 575
REMOVE AND DISASSEMBLE DRIVEN GEARS 576
ASSEMBLE DRIVEN GEARS AND BEARINGS (CHARGE PUMP SIDE) 576
REMOVE IDLER GEARS AND DISASSEMBLE 577
ASSEMBLE IDLER GEARS 577
REMOVE MAGNETIC PICKUP 578
ASSEMBLE INPUT ASSEMBLY 579
INSTALL OIL SEAL AND BALL BEARING 580
INSTALL IDLER GEARS AND BEARING ASSEMBLIES 580
INSTALL IDLER SHAFTS 581
INSTALL DRIVEN GEAR ASSEMBLY 582
INSTALL MAGNETIC PICKUP 583
ASSEMBLE FRONT COVER GROUP 584
ASSEMBLE CONVERTER INPUT SHAFT AND STATOR TUBE 585
INSTALL FRONT COVER ASSEMBLY TO MAIN CASE FRONT HOUSING 586
CONTROL VALVE 587
REMOVE AND INSTALL WIRING HARNESS 587
REMOVE CONTROL VALVE GROUP 588
DISASSEMBLE AND ASSEMBLE CONTROL VALVE 589
INSTALL CONTROL VALVE GROUP 590
BOLT TIGHTENING SEQUENCE AND TORQUE SPECIFICATIONS 591
PIPING DIAGRAM, CONVERTER DRIVEN TRANSMISSION 592
PRESSURE AND TEMPERATURE CHECK PORTS 593
MAIN CASE FRONT HOUSING 595
REMOVE AND INSTALL DIPSTICK ASSEMBLY 596
REMOVE OUTPUT YOKE 597
REMOVE INTERNAL DISCONNECT 597
INSTALL INTERNAL DISCONNECT 600
DISASSEMBLE AND ASSEMBLE GROUND DRIVEN PUMP 603
INSTALL GROUND DRIVEN PUMP 605
DISASSEMBLE AND ASSEMBLE FRONT HOUSING 606
REMOVE FRONT HOUSING 607
DISASSEMBLE FRONT HOUSING 608
REMOVE BORE SLEEVES 608
INSTALL BORE SLEEVES 609
REMOVE LUBE RELIEF VALVE 610
INSTALL LUBE RELIEF VALVE 610
REMOVE BEARING CUP 610
INSTALL BEARING CUP 611
REMOVE OIL SEAL 611
INSTALL OIL SEAL 611
INSTALL FRONT HOUSING TO REAR HOUSING 612
GEAR RATIO GROUP 613
REMOVE MAGNETIC PICKUP FROM REAR HOUSING 613
REMOVE OUTPUT GROUP 613
REMOVE OUTPUT GROUP (NO DISCONNECT) AND OIL TROUGH 615
DISASSEMBLE AND ASSEMBLE OUTPUT GROUP (WITH INTERNAL DISCONNECTION 616
DISASSEMBLE OUTPUT GROUP WITH INTERNAL DISCONNECT 617
ASSEMBLE OUTPUT GROUP WITH DISCONNECT 618
REMOVE ALL CLUTCH STAGE ASSEMBLIES 620
SECOND STAGE CLUTCH ASSEMBLY 622
THIRD STAGE CLUTCH ASSEMBLY 623
FOURTH STAGE CLUTCH ASSEMBLY 624
FIFTH STAGE CLUTCH ASSEMBLY 625
DISASSEMBLE CLUTCH STAGE ASSEMBLY 626
ASSEMBLE CLUTCH STAGE ASSEMBLY 630
SIZING SEAL RINGS 634
INSTALL STAGE ASSEMBLIES INTO REAR HOUSING 635
INSTALL OUTPUT GROUP AND OIL TROUGH 636
MAIN CASE REAR HOUSING 638
REAR HOUSING COMPONENT IDENTIFICATION 639
FIRST STAGE COVER GROUP 640
REMOVE FIRST STAGE COVER GROUP 640
INSTALL FIRST STAGE COVER GROUP 641
REMOVE BEARING RETAINER 642
DISASSEMBLE BEARING RETAINER 643
ASSEMBLE BEARING RETAINER 644
REMOVE AND INSTALL BEARING CUP 644
INSTALL BEARING RETAINER 645
SETTING END PLAY OF OUTPUT GROUP ASSEMBLY 646
PARKING BRAKE 649
REBUILD CRITERIA 650
REMOVAL 650
DISASSEMBLY 650
PRE-ASSEMBLY 652
ASSEMBLY 652
INSTALLATION 654
DIFFERENTIAL & FINAL DRIVE 658
GENERAL REPAIR PROCEDURES 658
INSPECTION BEFORE DISASSEMBLY 658
HEATING BEARING CONES 658
CLEANING AND INSPECTION 658
BEARINGS 658
SHAFTS 659
GEARS AND PLANETARY ASSEMBLIES 659
FASTENERS AND TIGHTENING 659
ASSEMBLY 659
SEALING INSTRUCTIONS 660
DISASSEMBLY 660
CLEANING 660
APPLICATION AND ASSEMBLY 660
LOCATION ON MACHINE 663
EXPLODED VIEW OF FINAL DRIVE WITH PLANETARY REDUCTION 663
EXPLODED VIEW OF DIFFERENTIAL CASE ASSEMBLY 665
EXPLODED VIEW OF INPUT QUILL ASSEMBLY 667
TANDEM DRIVE WITH PLANETARY FINAL DRIVE 669
DIFFERENTIAL LOCK/UNLOCK ASSEMBLY 671
DIFFERENTIAL LOCK/UNLOCK HYDRAULIC SYSTEM 673
PLANETARY ASSEMBLY AND RING GEAR 675
FINAL DRIVE & TANDEMS WITH PLANETARY 677
CROSS SECTION OF PLANETARY REDUCTION AXLE 679
SERVICE/SPECIAL/FABRICATED TOOLS 680
REMOVAL 686
INPUT HOUSING/CASE COVER 689
ESSENTIAL OR RECOMMENDED TOOLS 689
INSTALL AXLE IN REPAIR STAND 691
REMOVE INPUT HOUSING/COVER 692
CROSS – SECTIONAL VIEW – INPUT HOUSING/COVER 693
EXPLODED VIEW – INPUT HOUSING/COVER 694
DISASSEMBLE INPUT HOUSING/COVER AND BEVEL PINION SHAFT 695
ASSEMBLE INPUT HOUSING/COVER AND BEVEL PINION SHAFT 697
DETERMINE DIFFERENTIAL DRIVE SHAFT CONE POINT SHIM PACK 698
CONTINUE ASSEMBLY OF INPUT HOUSING/COVER 699
INSTALL INPUT HOUSING/COVER 702
DIFFERENTIAL HOUSING 703
ESSENTIAL OR RECOMMENDED TOOLS 703
OTHER MATERIAL 704
SPECIFICATIONS 704
INSTALL AXLE IN REPAIR STAND 705
REMOVE DIFFERENTIAL 706
CROSS-SECTIONAL VIEW – DIFFERENTIAL WITH DIFFERENTIAL LOCK 708
DISASSEMBLE, INSPECT, AND ASSEMBLE DIFFERENTIAL 709
INSTALL DIFFERENTIAL 714
ADJUST DIFFERENTIAL PRELOAD 716
ADJUST DIFFERENTIAL BACKLASH 717
FINAL DRIVE/PLANETARY CARRIER 719
ESSENTIAL OR RECOMMENDED TOOLS 719
OTHER MATERIAL 721
SPECIFICATIONS 721
INSTALL AXLE IN REPAIR STAND 722
REMOVE FINAL DRIVE ASSEMBLIES 723
INSTALL FINAL DRIVE ASSEMBLIES 724
CROSS-SECTIONAL VIEW – FINAL DRIVE AND AXLE ASSEMBLY 725
EXPLODED VIEW – AXLE SHAFT AND HOUSING 726
DISASSEMBLY FINAL DRIVE 727
EXPLODED VIEW – FINAL DRIVE PLANETARY CARRIER 729
DISASSEMBLE PLANET PINION CARRIER 730
INSPECT PLANET PINION COMPONENTS 731
ASSEMBLE PLANET PINION CARRIER 732
REMOVE AXLE HOUSING 733
DISASSEMBLE AND ASSEMBLE AXLE HOUSING 733
DISASSEMBLE, INSPECT, AND ASSEMBLE AXLE SHAFT 734
INSTALL AXLE HOUSING 737
ADJUST AXLE BEARINGS 738
TANDEM DRIVE CASE 741
SPECIAL TOOLS 743
REMOVAL 744
INSTALLATION 746
SERVICE BRAKES 748
CUT VIEWS & CROSS-SECTIONAL OF SERVICE BRAKES 748
REMOVAL 751
ASSEMBLY 754
FRONT AXLE 759
EXPLODED VIEW 759
REMOVAL 761
DISASSEMBLY 763
ASSEMBLY 766
INSTALLATION 773
BLADE 775
REMOVAL 775
INSTALLATION 775
CIRCLE & DRAWBAR ASSEMBLY 776
REMOVAL 776
INSTALLATION 776
DISASSEMBLY 777
ASSEMBLY 782
REBUILDING TEETH 786
LIFTER GUIDE, DRAWBAR SHIFT & BLADE LIFT CYLINDERS 787
DRAWBAR SHIFT CYLINDER 789
REMOVAL 789
INSTALLATION 789
BLADE LIFT CYLINDERS 790
REMOVAL 790
INSTALLATION 791
LIFTER GUIDE (SADDLE) 792
REMOVAL 792
INSTALLATION 793
PUSH BLOCK (COUNTERWEIGHT) 795
REMOVAL 795
INSTALLATION 795
RIPPER 797
RIPPER CYLINDER 799
REMOVAL 799
INSTALLATION 799
RIPPER 800
REMOVAL 800
INSTALLATION 800
CIRCLE REVERSE MOTOR 801
REMOVAL 803
INSTALLATION 803
DISASSEMBLY AND INSPECTION 804
ASSEMBLY 812
FINAL CHECKS 822
ROTOR SET COMPONENT ASSEMBLY PROCEDURES 824
ONE PIECE STATOR CONSTRUCTION 824
HYDRAULIC TANK 825
STRAINER 825
REMOVAL 825
INSTALLATION 825
HYDRAULIC FILTER 826
REMOVAL 826
INSTALLATION 826
HYDRAULIC PUMP 827
MAIN SYSTEM PUMP 827
REMOVAL 827
INSTALLATION 828
DISASSEMBLY 829
INSPECT PARTS FOR WEAR 834
ASSEMBLY 835
START UP PROCEDURE 837
CHARGE PUMP 838
STEERING & BRAKE SYSTEM PUMP 839
REMOVAL 839
INSTALLATION 840
DISASSEMBLY 841
INSPECT PARTS FOR WEAR 846
ASSEMBLY 847
START UP PROCEDURE 849
DIFFERENTIAL LOCK/UNLOCK PUMP 850
ACCUMULATOR 851
CUSHION (BLADE) ACCUMULATOR 852
REMOVAL 852
DISASSEMBLY 854
CLEANING 854
INSPECTION 854
REPAIR AND REPLACEMENT 854
ASSEMBLY 854
INSTALLATION 855
BRAKE ACCUMULATOR 857
REMOVAL 857
DISASSEMBLY 859
CLEANING 859
INSPECTION 859
REPAIR AND REPLACEMENT 859
ASSEMBLY 859
INSTALLATION 860
SWIVEL BLOCK (FOUR WAY) 861
REMOVAL 861
DISASSEMBLY 863
CLEANING AND INSPECTION 864
ASSEMBLY 865
INSTALLATION 867
TESTING AND ADJUSTMENTS 867
CONTROL VALVE MANIFOLDS 868
SERVICING 876
REMOVAL 876
DISASSEMBLY 880
DISASSEMBLY OF CONTROL VALVE BANK 880
DISASSEMBLY OF VALVE SECTION 882
VALVE SECTION IDENTIFICATION 882
CLEANING AND INSPECTION 883
ASSEMBLY 884
REASSEMBLY OF VALVE SECTION 884
REASSEMBLY OF CONTROL VALVE BANK 886
INSTALLATION 887
CIRCLE REVERSE GEAR 889
REMOVAL OF CIRCLE REVERSE MOTOR 889
INSTALLATION 889
SERVICING 893
DISASSEMBLY 893
ASSEMBLY 895
HYDRAULIC CYLINDER 898
HYDRAULIC CYLINDER TORQUES AND PRESSURES 898
STEERING CYLINDER 899
REMOVAL 899
INSTALLATION 900
DISASSEMBLY 902
CLEANING AND INSPECTION 902
ASSEMBLY 902
LEANING WHEEL CYLINDER 904
REMOVAL 904
INSTALLATION 905
DISASSEMBLY 908
CLEANING AND INSPECTION 908
ASSEMBLY 909
BLADE TILT CYLINDER 910
REMOVAL 910
INSTALLATION 910
DISASSEMBLY 912
CLEANING AND INSPECTION 912
ASSEMBLY 913
BLADE SIDE SHIFT CYLINDER 914
REMOVAL 914
INSTALLATION 914
DISASSEMBLY 915
CLEANING AND INSPECTION 915
ASSEMBLY 916
DRAWBAR (BLADE) LIFT CYLINDER 917
REMOVAL 917
INSTALLATION 917
DISASSEMBLY 918
CLEANING AND INSPECTION 918
ASSEMBLY 919
DRAWBAR SHIFT CYLINDER 920
REMOVAL 920
INSTALLATION 920
DISASSEMBLY 921
CLEANING AND INSPECTION 921
ASSEMBLY 922
RIPPER CYLINDER 923
REMOVAL 923
INSTALLATION 923
DISASSEMBLY 924
CLEANING AND INSPECTION 924
ASSEMBLY 925
ARTICULATION CYLINDER 926
REMOVAL 926
INSTALLATION 927
DISASSEMBLY 930
CLEANING AND INSPECTION 930
ASSEMBLY 931
LOCK PIN CYLINDER 932
REMOVAL 932
INSTALLATION 932
DISASSEMBLY 934
CLEANING AND INSPECTION 934
ASSEMBLY 934
STEERING UNIT 937
DISASSEMBLY 937
ASSEMBLY 944
ARTICULATION INDICATOR 949
REMOVAL 949
INSTALLATION 949
ADJUSTMENT 949
ARTICULATION JOINT 950
DISASSEMBLY 952
CLEANING AND INSPECTION 954
ASSEMBLY 955
SEAT 958
GENERAL SPECIFICATIONS 958
COMPLETE ASSEMBLY 959
DISASSEMBLY 960
REASSEMBLY 962
LOWER SUSPENSION 963
DISASSEMBLY 964
INSPECTION AND REPAIR 966
ASSEMBLY 966
SEAT ADJUSTER 967
DISASSEMBLY 967
ASSEMBLY 967
AIR CONDITIONING 969
AIR CONDITIONING SYSTEM ELECTRICAL DIAGRAM 969
AIR CONDITIONING SYSTEM DIAGRAM 970
AIR CONDITIONING COMPRESSOR 971
REMOVAL 971
INSTALLATION 971
COMPRESSOR BELT TENSION 971
RECEIVER/DRYER 972
SERVICE 972
REMOVAL 972
INSTALLATION 972
CONDENSER 973
REMOVAL 973
INSTALLATION 973
AIR CONDITIONER/HEATER UNIT 974
ELECTRICAL DIAGRAM 974
ASSEMBLY DIAGRAM 975
REMOVAL 977
INSTALLATION 977
ASSEMBLY 978
AIR CONDITIONING SYSTEM CHARGING PROCEDURE 1001
CHECKING COMPRESSOR OIL LEVEL 1003
CAB 1005
CAB AND OPERATOR’S PLATFORM MOUNTING DIAGRAM 1005
REMOVAL 1006
INSTALLATION 1006
STEERING CONSOLE 1007
ASSEMBLY 1008
STEERING CONSOLE WIRING 1009
STEERING CONSOLE CONTROL LEVERS 1011
ASSEMBLY 1012
STEERING COLUMN 1013
STEERING CONTROL ASSEMBLY 1015
STEERING CONSOLE INSTRUMENT PANEL 1017
RH SIDE CONSOLE 1019
CONSOLE SWITCH PANEL 1019
DISASSEMBLY 1020
ASSEMBLY 1020
TRANSMISSION CONTROLS 1021
DISASSEMBLY 1022
ASSEMBLY 1022
ACCELERATOR/DECELERATOR CONTROL LINKAGE 1023
PEDAL TO INJECTOR PUMP 1023
ASSEMBLY INSTRUCTION 1024
HAND THROTTLE 1025
ASSEMBLY INSTRUCTIONS 1026
40 MAINTENANCE STANDARD 1028
GENERAL BOLT TORQUE VALUES 1030
ENGINE MOUNT 1031
TRANSMISSION/TORQUE CONVERTER MOUNT 1032
DRIVE SHAFT 1033
FINAL DRIVE & TANDEM DRIVE 1034
BRAKES 1035
SERVICE BRAKE 1035
PARKING BRAKE 1036
PUSH BLOCK 1037
FRONT AXLE 1039
RIPPER 1041
MAIN FRAME 1043
FUEL & HYDRAULIC TANK MOUNT 1045
CAB MOUNT BOLTS 1046
BATTERY & BOX MOUNTING 1047
RADIATOR MOUNTING 1049
HYDRAULIC CONTROL LINKAGE 1051
PRIORITY VALVE 1052
RETURN/PARK BRAKE VALVE 1053
BLADE ACCUMULATOR BRACKET 1054
BLADE 1055
BLADE SUPPORT 1057
BLADE LIFT ASSEMBLY 1059
DRAWBAR 1061
CIRCLE ROTATION GEAR 1063
REAR AXLE ASSEMBLY 1064

DESCRIPTION:

Komatsu GD750A-1 Motor Grader Shop Manual CEBM002104 – PDF DOWNLOAD

• SERIAL NUMBERS GD750A-1 – 7001 and up

GENERAL PRECAUTIONS:
Mistakes in operation are extremely dangerous. Read the OPERATION & 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 operating 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.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

PREPARATIONS FOR WORK:
7. Before adding oil or making 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 b 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, support 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.

PRECAUTIONS DURING WORK:
11. When removing the oil filler cap, drain plug a 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.

G.B  14/12/24