SEBM022104
MACHINE MODEL
SERIAL NUMBER
GD705A-4
23001 and up
•
•
This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. GD705A-4 mounts the S6D125-1 engine. For details of the engine, see the 6D125 Series Engine Shop Manual.
© 2007 All Rights Reserved Printed in Japan 06-07 (01)
00-1 (4)
GENERAL
CONTENTS No. of page
01 GENERAL ............................................................................................................................ 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD............................................ 10-1 20 TESTING AND ADJUSTING ........................................................................ 20-1 30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1 90 OTHERS ................................................................................................................................ 90-1
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GD705A-4
LIST OF REVISED PAGES
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GD705A-4
SAFETY
SAFETY NOTICE
SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
¤
To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 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, hand shield, 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 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, 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.
00-3
SAFETY
PRECAUTIONS DURING WORK 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 hitting 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 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
SAFETY NOTICE
19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
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 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.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
REVISED EDITION MARK
VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
W h en a m an u a l is r e vis ed , a n e d itio n ma rk ( ....) is recorded on the bottom of the pages.
Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models
REVISIONS
}
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.
FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5
00-6
123
Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
Symbol
Item
Remarks
¤
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
Tightening torque
Places that require special attention for the tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants, etc.
Oil, water
Places where oil, water or fuel must be added, and the capacity.
Drain
Places where oil or water m u s t b e d r a i n e d , a nd quantity to be drained.
s
4 3 2 5 6
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS HOISTING
¤ •
Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol
4
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.
WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter
★
Allowable load
mm
kN
tons
10 11.5 12.5 14 16 18 20 22.4 30 40 50 60
9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2
1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41% SAD00479
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
¤
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, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle portion of the hook.
00-7
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤ ¤
Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Disconnection 1) Release the residual pressure from the hydraulic tan k. Fo r d e tails , se e TES TIN G AN D ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-8
Type 1
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 3
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
•
•
Disassembly
Type 2
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Connection
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
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
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
LT-2
09940-00030
50 g
Polyethylene container
LT-3
790-129-9060 (Set of adhesive and hardening agent)
Adhesive: 1 kg Hardenin g agent: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-126-9120
75 g
Tube
Three bond 1735
790-129-9140
50 g
Polyethylene container
2g
Polyethylene container
Adhesives
Aron-alpha 201
790-129-9130
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
LG-1
790-129-9010
200 g
Tube
LG-5
790-129-9070
1 kg
Can
Main applications, featuresr •
Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.
•
Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroet hl ene and vi nyl chl oride), rubber, metal and non-metal.
• •
Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs.
•
Used as adhesive or sealant for metal, glass and plastic.
•
Used as sealant for machined holes.
•
Used as heat-resisting sealant for repairing engine.
• • •
Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods.
• •
Quick hardening type adhesive Quick cure type (max. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals.
• • •
Resistance to heat, chemicals Used at joint portions subject to high temperatures.
•
Used as adhesive or sealant for gaskets and packing of power train case, etc.
•
Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
•
Gasket sealant • LG-6
790-129-9020
200 g
Tube
• •
00-10
Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. mab Used as sealant for oil pan, final drive case, etc.
FOREWORD
Category
COATING MATERIALS
Komatsu code
Part No.
Q'ty
Container
Main applications, featuresr •
LG-7
790-129-9070
1g
Tube
Three bond 1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
•
Adhesives
Molybdenum disulphide lubricant
LM-P
09940-00040
200 g
•
Used as heat-resisting sealant for repairing engine.
•
Used as lubricant for sliding portion (to prevent from squeaking).
•
Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.
Tube •
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA
Various
Various
Molybdenum disulphide lubricant
SYG2-400M
400 g (10 per case)
Belows type
Grease
Various
Ftures: Silicon based, quick hardening type Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.
•
General purpose type
•
Used for normal temperature, light load bearing at places in contact with water or steam.
•
Used for places with heavy load
Various
00-11
FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter of bolt
Width across flats
mm
mm
6 8 10 12 14
10 13 17 19 22
16 18 20 22 24
24 27 30 32 36
27 30 33 36 39
41 46 50 55 60
Thread diameter of bolt
Width across flats
mm
mm
Nm
6 8 10 12
10 13 14 27
7.85 1.95 18.6 4.9 40.2 5.9 82.35 7.85
Nm
kgm
0 0 0 0 0 28.5 0 3 39 0 4 56 0 6 76 0 8.5 94.5 0 10.5 135 0 15 175 0 20 225 0 25 280 0 30 335 0 35
0 1.4 03 07 0 10 0 19 279 0 30 382 0 39 549 0 59 745 0 83 927 0 103 1320 0 140 1720 0 190 2210 0 240 2750 0 290 3290 0 340
1.35 0.15 3.2 0.3 6.7 0.7 11.5 1 18 2
13.2 31 66 113 177
kgm
0 0 0 0
0.8 1.9 4.1 8.4
0 0.2 0 0.5 0 0.6 0 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.
SAD00483
Thread diameter
Width across flat
mm
mm
Nm
kgm
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
24.5 4.9 49 19.6 78.5 19.6 137.3 29.4 176.5 29.4 196.1 49 245.2 49 294.2 49
2.5 0.5 5 2 8 2 14 3 18 3 20 5 25 5 30 5
00-12
Tightening torque
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
FOREWORD
STANDARD TIGHTENING TORQUE
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10 12 16
14 17 22
65.7 6.8 112 9.8 279 29
0 0 0
6.7 0.7 11.5 1 28.5 3
0
0 0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
14 20 24 33 42
Varies depending on type of connector.
34.3 4.9 93.1 9.8 142.1 19.6 421.4 58.8 877.1 132.3
0 0 0 0 0
3.5 0.5 9.5 1 14.5 2 43 6 89.5 13.5
Norminal No.
02 03, 04 05, 06 10, 12 14
0 0 0 0 0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
08 10 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 n 36 n n
7.35 1.47 11.27 1.47 17.64 1.96 22.54 1.96 29.4 4.9 39.2 4.9 49 4.9 68.6 9.8 107.8 14.7 127.4 19.6 151.9 24.5 210.7 29.4 323.4 44.1
0 0 0 0 0 0 0 0 0 0 0 0 0
0.75 0.15 1.15 0.15 1.8 0.2 2.3 0.2 3 0.5 4 0.5 5 0.5 7 1 11 1.5 13 2 15.5 2.5 21.5 3 33 4.5
Norminal No.
08 10 12 14 16 18 20 24 30 33 36 42 52
0 0 0 0 0 0 0 0 0 0 0 0 0
00-13
FOREWORD
STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE FOR 102 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
6 8 10 12
10 2 24 4 43 6 77 12
kgm
0 0 0 0
1.02 2.45 4.38 7.85
0 0.20 0 0.41 0 0.61 0 1.22
2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
6 8 10 12 14
8 2 10 2 12 2 24 4 36 5
kgm
0 0 0 0 0
0.81 1.02 1.22 2.45 3.67
0 0.20 0 0.20 0 0.20 0 0.41 0 0.51
3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter
Tightening torque
inch
Nm
1 / 16 1/8 1/4 3/8 1/2 3/4 1
3 1 8 2 12 2 15 2 24 4 36 5 60 9
kgm
0 0 0 0 0 0 0
0.31 0.81 1.22 1.53 2.45 3.67 6.12
0 0.10 0 0.20 0 0.20 0 0.41 0 0.41 0 0.51 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal size Width across of hose flats
Taper seal type
Face seal type
Nominal thread Thread size size - Threads per Root diameter (mm) (mm) (Reference) inch, Thread series
Range
Target
19
35 - 63 {3.5 - 6.5}
44 {4.5}
14
9 – - 18UNF 16
14.3
22
54 - 93 {5.5 - 9.5}
74 {4.5}
–
11 – - 16UN 16
17.5
24
59 - 98 {6.0 - 10.0}
78 {8.0}
18
–
–
04
27
84 - 132 {8.5 - 13.5}
103 {10.5}
22
13 – - 16UN 16
20.7
05
32
128 - 186 {13.0 - 19.0}
157 {16.0}
24
1 - 14UNS
25.4
06
36
177 - 245 {18.0 - 25.0}
216 {22.0}
30
3 1 – - 12UNF 16
30.3
(10)
41
177 - 245 {18.0 - 25.0}
216 {22.0}
33
–
–
(12)
46
197 - 294 {20.0 - 30.0}
245 {25.0}
36
–
–
(14)
55
246 - 343 {25.0 - 35.0}
294 {30.0}
42
–
–
02
03
00-14
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire Cable O.D. (mm)
Current rating (A)
Applicable circuit
0.88
2.4
12
Starting, lighting, signal etc.
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Norminal number
Number of strands
Dia. of strands (mm2)
Cross section (mm 2)
0.85
11
0.32
2
26
5
CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification
1
Primary
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
BW
RW
YR
GW
LW
2 Color White & Red Code
WB
3 Color White & Black Code 4
Auxiliary
WL
Color White & Blue Code
WG
5 Color White & Green Code 6 Color
n n
n n n n n n n n n n
White & Black Red & White Rellow & Red Green & White Blue & White BY
RB
YB
GR
LR
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR
RY
Black & Red Red & Yellow
n n n n
RG
YG
GY
LY
Yellow & Green
Green & Yellow
Blue & Yellow
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black RL
YW
GL
Red & Blue Yellow & White Green & Blue
n n 00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.
EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line from . (2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from . (3) Take the point where the two lines cross as . This point gives the value when converting from millimeters 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.
A B
C
C
A
B
B Millimeters to inches 1 mm = 0.03937 in
A
00-16
0
1
2
3
4
5
6
7
8
9
0 10 20 30 40
0 0.394 0.787 1.181 1.575
0.039 0.433 0.827 1.220 1.614
0.079 0.472 0.866 1.260 1.654
0.118 0.512 0.906 1.299 1.693
0.157 0.551 0.945 1.339 1.732
0.197 0.591 0.984 1.378 1.772
0.236 0.630 1.024 1.417 1.811
0.276 0.669 1.063 1.457 1.850
0.315 0.709 1.102 1.496 1.890
0.354 0.748 1.142 1.536 1.929
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
C
FOREWORD
CONVERSION TABLE
Millimeters to Inches 1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
0
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound 1 kg = 2.2046 lb
0
1
2
3
4
5
6
7
8
9
0
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon 1l = 0.2642 U.S. Gal
0
1
2
3
4
5
6
7
8
9
0
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
Liter to U.K. Gallon 1l = 0.21997 U.K. Gal
0
1
2
3
4
5
6
7
8
9
0
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb 1 kgm = 7.233 ft. lb
0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2
0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
FOREWORD
CONVERSION TABLE
Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F
°C
°F
°C
°F
°C
°F
°C
°F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
117.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 0
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-21
FOREWORD
UNITS
UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}
00-22
}.
GENERAL General assembly drawing . . . . . . . . . . . . . . . 01-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3 Weight table . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5 List of lubricant and water . . . . . . . . . . . . . . . . 01-6
GD705A-4
01-1
GENERAL
GENERAL ASSEMBLY DRAWING
12
GENERAL ASSEMBLY DRAWING
Unit: mm
Dimensions
01-2
A
B
C
9,270
3,365
2,800
GD705A-4
GENERAL
SPECIFICATIONS
12
Dimensions
Weight
SPECIFICATIONS
Model
GD705A-4
Serial Number
23,001 and up
Operating weight
kg
17,620
On front axle (27.7%)
kg
4,885
On rear axle (72.3%)
kg
12,735
Overall length
mm
9,270
Overall width
mm
2,800
Overall height
mm
3,365
Wheel base
mm
6,450
Rear wheel base
mm
1,730
Tread (Front)
mm
2,300
Tread (Rear)
mm
2,300
Ground clearance
mm
410
1st
km/h
3.9
2nd
km/h
5.2
3rd
km/h
7.6
4th
km/h
11.0
5th
km/h
15.2
6th
km/h
20.5
7th
km/h
30.0
8th
km/h
43.0
1st
km/h
4.1
2nd
km/h
5.6
3rd
km/h
8.1
4th
km/h
11.7
5th
km/h
16.2
6th
km/h
21.8
7th
km/h
31.9
8th
km/h
45.9
kN {kg}
100 {10,180}
Turning radius
m
7.5
Over turn angle
deg
35
Travel speed
Performance
Forward
Reverse
Maximum drawbar pull
GD705A-4
01-3
GENERAL
SPECIFICATIONS
Wheels
12 Model
GD705A-4
Serial Number
23,001 and up
Tire (Front)
16.00 - 24 - 12 PR 0.22MPa {2.2 kg/cm2}
Tire (Rear)
16.00 - 24 - 12 PR 0.22MPa {2.2 kg/cm2}
Rim (Front)
1,000 VA x 24 SDC
Rim (Rear)
1,000 VA x 24 SDC
Blade dimension (Length x Height x Thickness)
mm
4,320 x 700 x 25
mm
2 - 2,134 x 203 x 16
deg
360
[Standard]
deg
34
[Maximum]
deg
84
[Minimum]
deg
26
Cutting edge dimension Blade
(Number - Length x Width x Thickness) Turning angle Cutting angle
Engine model
Komatsu S6D125-1 Diesel Engine
type
4 cycle, water cooled, overhead valve, direct injection type with turbocharger
Cylinder number - bore x stroke
mm
6 - 125 x 150
Piston displacement
O {cc}
11.045 {11,045}
Performance
Engine
Dimension
Firing order Overall length
mm
1,556
Overall width
mm
877
Overall height
mm
1,703
Flywheel horsepower
kW/rpm {HP/rpm}
149/2,000 {200/2,000}
Maximum torque
Nm/rpm {kgm/rpm}
902/1,300 {92/1,300}
High idling
rpm
2,200 ± 50
Low idling
rpm
650 +- 050
g/kW·h {g/HP·h}
204 {152}
kg
1,175
Fuel consumptions ratio Dry weight 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
01-4
1-5-3-6-2-4
12V, 200Ah x 2
GD705A-4
GENERAL
LIST OF LUBRICANT AND WATER
LIST OF LUBRICANT AND WATER
∗ ASTM D975 No. 1
01-6 (4)
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%.
Fuel sulphur content
Change interval of oil in engine oil pan
0.5 to 1.0%
1/2 of regular interval
Above 1.0%
1/4 of regular interval
•
When starting the engine in atmospheric temperature of lower than 0°C, be sure to use engine oil of SAE10W, SAE10W-30 and SAE15W-40, even though an atmospheric temperature goes up 10°C or more in the day time.
•
Use API classification CD engine oil. If API classification CC is used, reduce the engine oil change interval to half.
•
There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table.
•
We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications.
Specific capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute
GD705A-4
01-7
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD Engine mounting ..............................................10-2 Radiator ...........................................................10-3 Fuel tank piping ...............................................10-4 Accelerator control ........................................... 10-5 Power train ......................................................10-6 Damper ............................................................10-8 PTO .................................................................10-9 HYDROSHIFT transmission .......................... 10-11 HYDROSHIFT transmission control valve .....10-22 HYDROSHIFT transmission piping ...............10-37 Lubrication relief valve ...................................10-38 Transmission pump .......................................10-39 Transmission control ......................................10-42 Drive shaft .....................................................10-44 Final drive ......................................................10-45 Tandem drive .................................................10-50 Steering piping ...............................................10-54 Steering wheel ...............................................10-58 Steering valve ................................................10-59 Steering system .............................................10-60 Steering pump ...............................................10-67 Steering cylinder ............................................10-70 Front axle .......................................................10-72 Wheel ............................................................10-78
GD705A-4
Brake piping .................................................. 10-80 Disc brake system ......................................... 10-82 Brake valve ................................................... 10-86 Relay valve .................................................... 10-90 Air governor ................................................... 10-92 Check valve ................................................... 10-94 Air reservoir ................................................... 10-95 Safety valve ................................................... 10-95 Pressure switch ............................................. 10-96 Automatic drain valve .................................... 10-98 Air drier ........................................................ 10-100 Air compressor ............................................ 10-102 Parking brake .............................................. 10-103 Parking brake control .................................. 10-106 Hydraulic piping ........................................... 10-108 Main control valve ....................................... 10-112 Pilot check valve ......................................... 10-116 DDV (Dual Demand Valve) ....................... 10-123-1 Flow divider valve ................................... 10-123-18 Hydraulic pump ........................................... 10-124 Circle rotation motor .................................... 10-127 Hydraulic cylinder ........................................ 10-130 Work equipment control .............................. 10-140 Work equipment .......................................... 10-142
10-1
STRUCTURE AND FUNCTION
ENGINE MOUNTING
12
ENGINE MOUNTING
10-2
1.
Bracket
2.
Lock plate
3.
Plate
4.
Shim
5.
Plate
6.
Dust indicator
GD705A-4
STRUCTURE AND FUNCTION
RADIATOR
12
RADIATOR
Radiator
GD705A-4
Core type: Model G6 Total radiation area: 46.89 m2
1.
Drain plug
2.
Radiator core
3.
Water filler cap
4.
Inlet hose
5.
Fan
6.
Outlet hose
10-3
STRUCTURE AND FUNCTION
FUEL TANK PIPING
12
FUEL TANK PIPING
Fuel tank capacity: 400 O
10-4
1.
Fuel tank
2.
Fuel filler cap
3.
Strainer
4.
Fuel line valve
5.
Drain cock
GD705A-4
STRUCTURE AND FUNCTION
ACCELERATOR CONTROL
12
ACCELERATOR CONTROL
1. 2. 3. 4. 5.
GD705A-4
Fuel control lever Parking brake lever Accelerator pedal Stopper for pedal Accelerator return spring
10-5
STRUCTURE AND FUNCTION
POWER TRAIN
12
POWER TRAIN
The power from the diesel engine (1) is transmitted to the HYDROSHIFT transmission (3) through the joint (2). In the HYDROSHIFT transmission in response to the load and the forward-reverse rotation direction, the clutch is selected and the power is transmitted to the final drive (6) through the drive shaft (5). Here, the power is separated into left and right perpendicular directions and transmitted to the tandem drive (7) through the rear axle. The tandem drive transmits the power to the wheel by a chain and the machine travels.
10-6
1.
Engine
2.
Joint
3.
HYDROSHIFT transmission
4.
Parking brake
5.
Drive shaft
6.
Final drive
7.
Tandem drive
GD705A-4
STRUCTURE AND FUNCTION
POWER TRAIN
12
GD705A-4
1.
Engine
2.
Joint
3.
HYDROSHIFT transmission
4.
Parking brake
5.
Drive shaft
6.
Final drive (with differential)
7.
Tandem drive
10-7
STRUCTURE AND FUNCTION
DAMPER
12
DAMPER
10-8
1.
Disc
2.
Bolt
3.
Washer
4.
Flywheel housing
5.
HYDROSHIFT transmission case
GD705A-4
STRUCTURE AND FUNCTION
PTO
12
PTO (POWER TAKE OFF)
1. 2.
GD705A-4
Joint bolt Joint bolt
10-9
STRUCTURE AND FUNCTION
PTO
12
3.
Gear (35 teeth)
7.
Gear
11. Snap ring
4.
Gear (57 teeth)
8.
Housing
12. Bearing
5.
Flywheel (137 teeth)
9.
Gear (52 teeth)
6.
Bolt
10. Gear
13. Cover 14. Gear 15. Snap ring 16. Bearing
10-10
GD705A-4
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION
12
HYDROSHIFT TRANSMISSION
GD705A-4
10-11
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION
12 The GD705A has a planetary type transmission which combines a planetary gear mechanism and disc clutch for 8 forward speeds and 8 reverse speeds. Out of the 8 sets of planetary gear type disc clutches, 3 clutches are fixed by oil pressure via the control valve to select one revolving direction and one revolving speed. The R clutch is for reverse travel and F clutch for forward travel. The correspondence between clutch combinations and speeds are as follows:
L
Reduction ratio Speed stage
RF4321LH
Total reduction ratio
Each speed ratio
F1
7.823
8.637
1.349
F2
5.798
6.398
F3
3.958
4.367
F4
2.758
3.043
F5
1.994
2.200
F6
1.478
1.631 1.113
Clutch
Speed
Clutch
Speed
F7
1.009
1st
1st speed
1st
5th speed
F8
0.703
2nd
2nd speed
2nd
6th speed
R1
7.341
3rd
3rd speed
3rd
7th speed
R2
4th
4th speed
4th
8th speed
1.
10-12
H
T/F
1.465 1.435 1.383 1.349 1.465
0.776
1.435
8.100
1.349
5.440
6.003
1.465
R3
3.714
4.098
R4
2.588
2.856
R5
1.871
2.065
R6
1.387
1.530
R7
0.947
1.045
1.465
R8
0.660
0.728
1.349
F, R housing
23. Shaft
2.
F piston
24. Cage
3.
4th planetary pinion shaft
25. Shaft
4.
Sleeve
26. Cage
5.
4th piston
27. Output shaft
6.
4th, 3rd housing
28. L carrier
7.
3rd piston
29. 1st carrier
8.
3rd, 4th carrier
30. 2nd carrier
9.
2nd housing
31. Shaft
1.103 (32/29)
10. 2nd piston
32. 3rd planetary pinion shaft
11. 2nd planetary piston shaft
33. F carrier
12. 1st housing
34. R carrier
13. 1st piston
35. Housing
14. 1st planetary pinion shaft
36. Input shaft
15. L housing
37. Cage
16. L piston
38. R planetary pinion shaft
17. L planetary pinion shaft
39. F planetary pinion shaft
18. H piston
40. Cover
19. Spring
41. R piston
20. Cage
42. Cage
21. Transfer case
43. Coupling
22. Cage
44. Shaft
1.435 1.383 1.349
GD705A-4
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION
12
PLANETARY GEAR SYSTEM Planetary gear system (structure) The planetary gear mechanism consists of sun gear A, planetary pinion B, ring gear C, and carrier D. The planetary pinion is supported by the carrier and meshes with the sun gear and the ring gear. When the ring gear is fixed, The sun gear A revolutions are transmitted to the planetary pinions B. The planetary pinions are meshed with the ring gear C. Since the ring gear is fixed, it cannot revolve as it is. Therefore, the planetary pinions revolve on their axes while revolving around the sun gear along the ring gear. At this time the torque of the sun gear becomes carrier D torque and is transmitted. The direction of rotation of the carrier is the same as that of the sun gear.
A. Sun gear B. Planetary pinion C. Ring gear D. Planetary carrier
When the carrier is fixed, The sun gear A revolutions are transmitted to the planetary pinions B. Because carrier D is fixed, the planetary pinions meshed with the sun gear revolve on their own axes at their positions. The ring gear C which is meshed with planetary pinions revolves in the opposite direction to the sun gear, and the sun gear torque becomes the torque of the ring gear and is transmitted. Combinations such as → Sun gear → Planetary pinion → Ring gear or carrier, is the structure of R.F. 3rd, 2nd, L clutches. However, for R clutch, the sun gear becomes the power source and transmits power to the ring gear, and for F, L clutch, the sun gear is the power source and transmits power to the carrier, and for 3rd and 2nd clutches the carrier is the power source and transmits power to 3rd and 2nd sun gears.
GD705A-4
10-13
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION
12
DISC CLUTCH In order to fix the ring gear a disc clutch made up of piston (26), plate (50), disc (51), pin (52), piston return spring (53), washer spring (54), etc., is installed. The internal teeth of the disc mesh with the external teeth of the ring gear. The plate is fixed in the direction of rotation by the meshing of the notched protrusions of the outer diameter and pins (52) fixed into the housing (6). The piston is also fixed in the direction of rotation in the same way.
Clutch "ENGAGED" (Fixed) Hydraulic oil from the control valve passes through the port of the housing (6) and transmits pressure to the back of the piston (26). The piston presses disc (51) and plate (50) and the friction stops the disc rotation, resulting in fixing ring gear G which is meshing with the interior teeth of the disc.
Clutch "DISENGAGED" (Released) When the hydraulic oil from the control valve is interrupted, the piston return spring (53) acts to return the piston (26) to its original position, the plate (50) and disc (51) friction is released and the ring gear G becomes neutral. The washer spring (54) installed between the pin (52) and the plate acts to return the piston more quickly when the clutch is disengaged, improve plate and disc separation and prevent the disc drag rotation.
10-14
GD705A-4
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION
12
ROTARY CLUTCH
Clutch "ENGAGED" (Fixed) Hydraulic oil from the control valve goes to the back of the piston (13) through the port of the cage (20). The piston force-presses disc (55) and plate (56). The clutch is engaged by meshing the internal teeth of the disc and the external teeth of the gear N and the external teeth of the plate and the internal teeth of the drum (2nd carrier, (10)). The gear and drum become one unit and revolve.
Clutch "DISENGAGED" (Released) When the hydraulic oil from the control valve is interrupted, the piston is returned by the disc spring (12). On the other hand, when the piston is returned to its original position, and the clutch is disengaged, the wave spring (57) between plates (56) separates plate and disc (55) completely, and prevents drag rotation.
GD705A-4
10-15
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION
12
10-16
GD705A-4
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION
12 Unit: mm No.
Check item
1
No. 1 sun gear-to-No. 1 planetary gear backlash
2
No. 2 sun gear-to-No. 2 planetary gear backlash
3
Criteria
Remedy
Standard clearance
Clearance limit
0.13 - 0.32
---
0.13 - 0.34
---
No. 3 sun gear-to-No. 3 planetary gear backlash
0.13 - 0.32
---
4
No. 4 sun gear-to-No. 4 planetary gear backlash
0.13 - 0.32
---
5
No. 5 sun gear-to-No. 5 planetary gear backlash
0.13 - 0.32
---
6
No. 6 sun gear-to-No. 6 planetary gear backlash
0.11 - 0.28
---
7
No. 7 sun gear-to-No. 7 planetary gear backlash
0.13 - 0.32
---
8
Drive gear-to-idle gear backlash
0.26 - 0.61
---
9
No. 1 planetary gear-to-No. 1 ring gear backlash
0.14 - 0.43
---
10
No. 2 planetary gear-to-No. 2 ring gear backlash
0.14 - 0.37
---
11
No. 3 planetary gear-to-No. 3 ring gear backlash
0.14 - 0.43
---
12
No. 4 planetary gear-to-No. 4 ring gear backlash
0.13 - 0.42
---
13
No. 5 planetary gear-to-No. 5 ring gear backlash
0.14 - 0.43
---
14
No. 6 planetary gear-to-No. 6 ring gear backlash
0.12 - 0.22
---
15
No. 7 planetary gear-to-No. 7 ring gear backlash
0.14 - 0.43
---
16
Thickness of No. 1 clutch disc
5
4.7
17
Thickness of No. 1 clutch plate
5
4.7
18
Thickness of No. 1 clutch
35
32.9
19
Thickness of No. 2 clutch disc
5
4.7
20
Thickness of No. 2 clutch plate
5
4.7
21
Thickness of No. 2 clutch
35
32.9
22
Thickness of No. 3 clutch disc
5
4.7
23
Thickness of No. 3 clutch plate
5
4.7
24
Thickness of No. 3 clutch
25
23.5
GD705A-4
Replace
10-17
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION
12
10-18
GD705A-4
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION
12
Unit: mm No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
5
4.7
Thickness of No. 4 clutch plate
5
4.7
27
Thickness of No. 4 clutch
25
23.5
28
Thickness of No. 5 clutch disc
5
4.7
29
Thickness of No. 5 clutch plate
5
4.7
30
Thickness of No. 5 clutch
15
14.1
31
Thickness of No. 6 clutch disc
5
4.7
32
Thickness of No. 6 clutch plate
5
4.7
33
Thickness of No. 6 clutch
25
23.5
34
Thickness of No. 7 clutch disc
5
4.7
35
Thickness of No. 7 clutch plate
5
4.7
36
Thickness of No. 7 clutch
45
42.3
37
Thickness of No. 8 clutch disc
5
4.7
38
Thickness of No. 8 clutch plate
5
4.7
39
Thickness of No. 8 clutch
35
32.9
40
No. 1 clutch disc-to-No. 1 ring gear backlash
0.29 - 0.67
---
41
No. 2 clutch disc-to-No. 2 ring gear backlash
0.29 - 0.67
---
42
No. 3 clutch disc-to-No. 3 ring gear backlash
0.29 - 0.67
---
43
No. 4 clutch disc-to-No. 4 ring gear backlash
0.29 - 0.67
---
44
No. 5 clutch disc-to-No. 5 ring gear backlash
0.29 - 0.67
---
45
No. 6 clutch disc-to-No. 6 ring gear backlash
0.19 - 0.54
---
46
No. 7 clutch disc-to-No. 7 ring gear backlash
0.29 - 0.67
---
47
No. 8 clutch disc-to-No. 8 ring gear backlash
0.29 - 0.54
---
25
Thickness of No. 4 clutch disc
26
GD705A-4
Replace
10-19
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION
12
10-20
GD705A-4
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION
12
Unit: mm No.
Check item
Criteria Standard size
48
No. 1 clutch spring
Remedy Repair limit
Free length x O.D.
Installed length
Installed load
Free length
Installed load
53 x
44
8.2 kg
51.7
7.0 kg
49
No. 2 clutch spring
53 x
47
5.5 kg
51.9
4.5 kg
50
No. 3 clutch spring
39.6 x
33
8.4 kg
38.6
7.1 kg
51
No. 4 clutch spring
39.6 x
33.5
7.8 kg
38.6
6.5 kg
52
No. 5 clutch spring
39.6 x
33
8.4 kg
38.6
7.1 kg
53
No. 6 clutch spring
39.6 x
34.5
6.5 kg
38.6
5.2 kg
54
No. 7 clutch spring
66 x
60
8.5 kg
64.9
7.9 kg
55
No. 8 clutch spring
6.5 x
5.5
143 kg
6.2
100 kg
Side clearance of planetary gear
Standard clearance
Clearance limit
56
0.35 - 0.80
1.5
0.25 - 0.60
---
57
Idler gear-to-driven gear backlash
GD705A-4
Replace
10-21
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION CONTROL VALVE
12
HYDROSHIFT TRANSMISSION CONTROL VALVE
10-22
1.
Lubrication oil pressure measuring plug
2.
Inching oil pressure measuring plug
3.
Pilot oil pressure measuring plug
4.
Main oil pressure measuring plug
5.
Relief valve (Lubrication and cooler by-pass)
6.
Shift valve lever (for F.R.)
7.
Shift valve lever (for Inching)
8.
Speed select control lever
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 position
N
1st
2nd
3rd
4th
5th
6th
7th
8th
Shift valve
Cut off
L 1st
L 2nd
L 3rd
L 4th
H 1st
H 2nd
H 3rd
H 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 pressure) is the same as the main circuit hydraulic pressure 2.5 MPa {25 kg/cm2}. The priority valve is in contact with the stopper.
2.
During gear changing When the main circuit oil pressure goes down below 1.4 MPa {14 kg/cm2}, the pilot circuit oil pressure is maintained at 1.4 MPa {14 kg/cm2} by the priority valve and the shift valve can reliably function.
10-26
GD705A-4
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION CONTROL VALVE
12
MODULATING VALVE AND QUICK RETURN VALVE The modulating valve and the quick return valve smoothly raise the main oil pressure when gear changing. By operating the clutch, shock at driving gear changing is eliminated and the production of peak torque in the power line is prevented.
1)
Immediately after gear changing (X point) Immediately after changing gears the main circuit (from the pump) oil flows into the piston of the operating clutch. Due to the flow of oil at this time, a difference in pressure is produced in the A-chamber and the Bchamber of the quick return valve (3), and the quick return valve moves to the left. At this time, the C-chamber of the modulating valve load piston port is connected to the drain circuit. By the force of spring (4) the modulating load piston (5), while draining the oil which has filled the C-chamber of the load piston port, returns to stroke end (right edge).
2)
While raising pressure (Y point) When the clutch piston fill with oil, the flow of oil almost completely stops. The pressure of the Achamber and B-chamber of the quick return valve (3) is almost the same. Due to this, the pressure difference (a > b) on the surface and b surface of the quick return valve causes the quick return valve to return the right. The circuit to the drain port D-chamber of the modulating valve load piston closes. At the same time the oil passed through the orifice (e) of the quick return valve pushes the modulating valve load piston (5) to the left. Then, due to the movement of the load piston, the spring (4) contracts and the relief pressure of the modulating valve gradually rises.
GD705A-4
10-27
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION CONTROL VALVE
12 3)
At set pressure 2.5 MPa {25kg/cm2} (Z point) When the modulating valve load piston touches the stopper, the increase in the oil pressure ceases. At this time the relief pressure is the set pressure 2.5 MPa {25 kg/cm2} of the modulating valve.
10-28
GD705A-4
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION CONTROL VALVE
12 FUNCTION SPEED STAGE CHANGING VALVE 1)
At neutral The pilot pressure applies on the A-chamber of the cutoff valve and because the C-chamber connects 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 lubricates the transmission and PTO, and is drained into the transmission case.
2)
At forward 1st speed The B-chamber and D-chamber of the back pressure side of the shift valve (1st) (H.L.) are each connected to the drain circuit and so a difference in pressure arises in the A-chamber and B-chamber, and the A-chamber and D-chamber. The 1st spool is pushed to the right and the H.L. spool is pushed to the left and since the F.R. spool is set in the F position, the oil pump is let to the 1st, L, F clutch.
GD705A-4
10-29
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION CONTROL VALVE
12
3)
Forward 8th speed Since the E-chamber of the back pressure side of the shift valve (4th) is connected to the drain circuit, a pressure difference arises between Achamber and E-chamber and the spool is pushed to the left. Since the F.R. spool is set on the F position, the oil from the pump flows into the 4th, H, F clutch
4)
At reverse 2nd speed Because the back pressure side of the shift valve (2nd), (H.L.) is connected to the drain circuit, a difference in pressure arises between the A-chamber and D-chamber, and the A-chamber and F-chamber. The H.L. spool is pushed to the left and the 2nd spool is pushed to the right. Since the F.R. spool is set in the R position, the oil from the pump is led to the 2nd, L, R clutch.
At other forward 2nd speed to 7th speed and reverse 1st speed and 3rd speed to 8th speed occur according to combinations in the above items 2 to 4. The combinations are as follows: Forward 2nd speed: 2nd, L, F Forward 3rd speed: 3rd, L, F Forward 4th speed: 4th, L, F Forward 5th speed: 1st, H, F Forward 6th speed: 2nd, H, F Forward 7th speed: 3rd, H, F Forward 8th speed: 4th, H, F Reverse 1st speed: 1st, L, R Reverse 3rd speed: 2nd, L, R Reverse 4th speed: 4th, L, R Reverse 5th speed: 1st, H, R Reverse 6th speed: 2nd, H, R Reverse 7th speed: 3rd, H, R Reverse 8th speed: 4th, H, R
10-30
GD705A-4
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION CONTROL VALVE
12 INCHING VALVE OPERATION 1)
Inching valve [OPEN] Tho oil from the pump passes through ports A and B, and then goes from the F-R spool to the F-R clutch. The return spring of the inching pedal pushes valve spool (2) and collar (3), and moves valve (1) to the left. Oil passes through orifice D and enters chamber C. It acts to push valve (1) to the right, but because of the tension of the return spring, valve (1) does not move.
2)
Inching valve [THROTTLED] When the inching pedal is depressed slightly, valve spool (2) moves to the right, so piston (4) pushes valve (1) to the right to a position where it balances the tension of springs (5), (6) and (7). In other words, the passage to port B is restricted, and the orifice E is connected to the drain port, so the hydraulic pressure of the F-R clutch is reduced, and the clutch is partially disengaged.
3)
Inching valve [CLOSED] When the inching is depressed fully, valve spool (2) moves fully to the right, so the tension of springs (5) and (6) becomes weaker. As a result, the hydraulic pressure of the F-R clutch drops to 0.04 - 0.54 MPa {0.4 - 0.55 kg/cm2}, and the clutch is completely disengaged.
GD705A-4
10-31
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION CONTROL VALVE
12 1.
HYDROSHIFT transmission control valve
10-32
GD705A-4
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION CONTROL VALVE
12 Unit: mm No.
Check item
Criteria Tolerance Standard size
1
Clearance between shift valve spool (3rd) and valve body
Remedy
Standard clearance
Clearance limit
Shaft
Hole
19
-0.035 -0.045
+0.013 0
0.035-0.058
0.08
2
Clearance between shift valve spool (1st) and valve body
19
-0.035 -0.045
+0.013 0
0.035-0.058
0.08
3
Clearance between shift valve spool (2nd) and valve body
19
-0.035 -0.045
+0.013 0
0.035-0.058
0.08
4
Clearance between shift valve spool (4th) and valve body
19
-0.035 -0.045
+0.013 0
0.035-0.058
0.08
5
Clearance between shift valve spool (H.L.) and valve body
19
-0.035 -0.045
+0.013 0
0.035-0.058
0.08
6
Clearance between valve spool (F.R.) and valve body
19
-0.035 -0.045
+0.013 0
0.035-0.058
0.08
7
Clearance between inching valve spool and valve body
10
-0.020 -0.030
+0.015 0
0.020-0.045
8
Clearance between inching valve and valve body
25
-0.035 -0.045
+0.013 0
0.035-0.058
9
Clearance between inching sleeve and inching valve spool
17.2
-0.035 -0.045
+0.018 0
0.035-0.063
10
Clearance between speed selector spool and valve body
14
-0.035 -0.045
+0.011 0
0.035-0.056
0.08
11
Clearance between priority valve and valve body
25
-0.035 -0.045
+0.013 0
0.035-0.058
0.08
12
Clearance between priority valve and valve spool
15
-0.020 -0.030
+0.018 0
0.020-0.048
0.08
13
Clearance between modulating valve and valve body
25
-0.035 -0.045
+0.013 0
0.035-0.058
0.08
14
Clearance between modulating valve and valve spool
15
-0.020 -0.030
+0.018 0
0.020-0.048
0.08
15
Clearance between valve and valve body
35
-0.035 -0.045
+0.016 0
0.035-0.061
0.08
16
Clearance between quick return valve and sleeve
12
-0.035 -0.045
+0.011 0
0.035-0.056
0.08
17
Clearance between lubrication valve and valve body
22
-0.035 -0.045
+0.013 0
0.035-0.058
0.10
18
Clearance between cooler by-pass valve and valve body
22
-0.035 -0.045
+0.013 0
0.035-0.058
0.10
19
Clearance between cut-off valve and valve body
19
-0.035 -0.045
+0.013 0
0.035-0.058
0.08
GD705A-4
Replace
10-33
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION CONTROL VALVE
12 2.
HYDROSHIFT transmission control valve spring
10-34
GD705A-4
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION CONTROL VALVE
12
Unit: mm No.
Check item
Criteria
Remedy
Standard size 1
Spool return spring
Repair limit
Free length x O.D.
Installed length
Installed load
Free length
Load
36.75 x 19.3
30.3
6.12 kg
36.1
5.51 kg
2
Inching valve spring
16.1 x
12.5
1.15 kg
3
Inching valve spring (Large)
50.2 x
33
4.02 kg
4
Inching valve spring (Small)
39 x
33
0.81 kg
5
Inching valve spring
26 x
18
0.66 kg
6
Priority valve spring
35 x 9.5
21
1.33 kg
34.3
1.26 kg
7
Priority valve spring
115.5 x 16.9
100
23.50 kg
114.7
22.3 kg
8
Modulating valve spring (Large)
86.7 x 23.2
65
27.03 kg
85.6
25.7 kg
9
Modulating valve spring (Small)
71.2 x 14.3
65
13.39 kg
70.9
12.7 kg
10
Lubrication valve spring
39.4 x 15.6
37
6.20 kg
39.0
5.27kg
11
Cooler by-pass valve spring
71.4 x 14.9
66
13.88 kg
70.6
11.8 kg
12
Cut-off valve spring
36.75 x
30
6.41 kg
36.1
5.79 kg
A
Length between selector valve and yoke
B
Clearance between nut and selector valve body
GD705A-4
51.4 (for reference) 0.1 - 0.3
10-35
STRUCTURE AND FUNCTION
HYDROSHIFT TRANSMISSION PIPING
12
HYDROSHIFT TRANSMISSION PIPING
1. 2. 3. 4. 5.
GD705A-4
Transfer HYDROSHIFT transmission control valve Engine Transmission pump (KFP3250AFMSSH) Oil filter
10-37
STRUCTURE AND FUNCTION
LUBRICATION RELIEF VALVE
12
LUBRICATION RELIEF VALVE
10-38
1.
Plug
2.
Spring
3.
Body
4.
Poppet
GD705A-4
STRUCTURE AND FUNCTION
TRANSMISSION PUMP
12
TRANSMISSION PUMP KFP3250AFMSSH
GD705A-4
1.
Drive gear
2.
Cover
3.
Body
4.
Mounting flange
5.
Driven gear
6.
Bushing
7.
Oil seal
8.
Snap ring
10-39
STRUCTURE AND FUNCTION
TRANSMISSION PUMP
12
Unit: mm No. 1. 2.
Check Item Diameter of gear shift
Criteria
Remedy
Standard size
Repair limit
---
24.895
---
6.676
Replace Replace mounting flange, cover, etc. Replace driven gear, drive gear Replace pump assembly
Pressure plate
Replace
3.
Wear of drive-in bushing
---
Teflon layer is worn and red copper color portion of base metal is exposed for more than 150o
4.
Depth of gear contact traces on bushing
---
Max. 0.12
---
10-40
Discharge (E010-CD: 50oC)
Speed (rpm)
Discharge MPa {kg/cm2}
Standard Discharge (O/min.)
Discharge limit
2,200
24.5 {25}
103
---
---
GD705A-4
STRUCTURE AND FUNCTION
TRANSMISSION CONTROL
12
TRANSMISSION CONTROL
10-42
GD705A-4
STRUCTURE AND FUNCTION
TRANSMISSION CONTROL
12
GD705A-4
1.
Inching pedal
5.
Lock lever (for shift lever)
2.
Wire (for F.R. control)
6.
Shift lever
3.
Wire (for inching)
7.
F.R. control side
4.
Stopper (for inching pedal)
8.
Inching control side
10-43
STRUCTURE AND FUNCTION
DRIVE SHAFT
12
DRIVE SHAFT
10-44
GD705A-4
STRUCTURE AND FUNCTION
FINAL DRIVE
12
FINAL DRIVE
1.
Shaft
15. Bevel pinion mounting bearing
2.
Bearing
16. Lock
3.
Sprocket
17. Nut
4.
Joint
18. Coupling
5.
Gear (42 teeth)
19. Bevel pinion (13 teeth)
6.
Shaft
20. Case
7.
Gear (17 teeth)
21. Housing
8.
Non-spin differential
22. Breather
9.
Rock plate
23. Filler tube
10. Bevel gear (38 teeth)
24. Tube, oil level gauge
11. Nut
25. Shim
12. Gauge
26. Bolt
13. Bevel gear side housing
27. Support
14. Shim
28. Drain plug
GD705A-4
OUTLINE • A non-spin differential system is used for the differential. • The non-spin differential system detects the difference in rotation of the left and right rear wheels and automatically switches between the differential ON and differential LOCK condition. • When the machine is traveling in a straight line (no difference in rotation), the differential is kept locked; when the machine is turning (difference in rotation), the differential is kept in the ON condition.
10-45
STRUCTURE AND FUNCTION
FINAL DRIVE
12 NON-SPIN DIFFERENTIAL 1.
Side gear
2.
Clutch return spring
3.
Holdout ring
4.
Driven clutch
5.
Spider
6.
Center cam
SPIDER
DRIVEN CLUTCH
CENTER CAM
10-46
GD705A-4
STRUCTURE AND FUNCTION
FINAL DRIVE
12
Principle of operation of non-spin differential 1.
When traveling in a straight line. Left and right driven clutches (4) are meshed with spider (5) and center cam (6), so the power passing through the bevel gear passes from the spider through the left and right driven clutches and drives the left and right drive wheels at the same speed. There are cam teeth at the point where the driven clutch meshes with the center cam, so there is no backlash when they mesh. There are clutch teeth at the portion where there is meshing with the spider, so they mesh with a fixed backlash.
2.
When traveling on a curve (turning left). When traveling on a curve, the outside drive wheel (right wheel) must turn faster than the inside drive wheel (left wheel). Because of this, the force received from the ground surface tries to make the left and right drive wheels (driven clutch) rotate at different speeds. Driven clutch (4) is meshed with spider (5) by teeth with a large backlash, so the force from the road surface tries to rotate the driven clutch (4R) at a different speed from the spider in the direction to remove the backlash. This force from the ground surface also acts at the same time on center cam (6) and the driven clutch cam teeth. It makes the cam tooth surface slide, and pushes the driven clutch to the outside. When the sliding of the cam tooth surface finishes, both cams are raised, so the meshing of the clutch teeth is completely disengaged and the right driven clutch can rotate freely. In this way, when the machine is traveling on a curve, the outside wheel becomes free and power is transmitted only to the inside wheel.
GD705A-4
10-47
STRUCTURE AND FUNCTION
FINAL DRIVE
12
Unit: mm No.
Check Item
Criteria
1
Preload of bevel pinion bearing
Starting torque: 11.8 - 15.7 Nm {1.2 - 1.6 kgm}
2
Preload of side bearing
3
Backlash between 2nd pinion and 2nd gear
4
10-48
Backlash between bevel pinion and bevel gear
Remedy
Starting torque: Item 1 + (2.9 - 3.9 Nm {0.3 - 0.4 kgm}) (after setting: measure at pinion shaft) Tolerance
Repair limit
0.24 - 0.60
1.6
0.3 - 0.4
1.4
Adjust
GD705A-4
STRUCTURE AND FUNCTION
TANDEM DRIVE
12
TANDEM DRIVE
★
Above 0°C: Use engine oil CLASS-CD SAE30 Below 10°C: Use engine oil CLASS-CD SAE10W Reduction ratio:
26 13
= 2.0
Lubrication amount: 105 O
10-50
1.
Cover
10. Spring
2.
Breather
11. Bearing
3.
Chain
12. Gear (105 teeth)
4.
Hub shaft
13. Plate (138 teeth)
5.
Bearing
14. Disk
6.
Shim
15. Tandem case
7.
Sprocket (26 teeth)
16. Cover
8.
Cage
17. Oil level gauge
9.
Piston
18. Drain plug
GD705A-4
STRUCTURE AND FUNCTION
TANDEM DRIVE
12 Power from the final drive is transmitted to the front and back rear wheels by chain. The tandem cases can swing up and down 13o each. All four rear wheels are in contact with the ground even when the ground is rough restricting the up-anddown movement of the blade to a minimum.
The movement of the blade of a motor grader when its rear wheel ride over an obstacle is as follows:
1.
When both left and right wheels ride over an object (height: H) at the same time, the center of the rear axle rise H/2 as right figure shows, and because the blade is situated about halfway between the front and rear axles, its movement further becomes H/4.
2.
When only one left rear wheel rides over an object (height: H), the rise at the center of rear axle is H/2 at its left end as right figure shows and H/4 at the center line of machine and on the real axle. The movement of the center part of the blade is half of that, which is H/8.
GD705A-4
10-51
STRUCTURE AND FUNCTION
TANDEM DRIVE
12
Unit: mm No.
Check Item
1
Preload of hub bearing
2
Extension of chain (10 links)
10-52
Criteria
Remedy
Starting torque: 19.6 - 24.5 Nm {2.0 - 2.5 kgm} Standard size
Repair limit
571.5
580
Adjust Replace
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. 2. 3. 4. 5.
Steering cylinder Steering pump (With flow priority valve) Steering valve (Orbit-roll type) Steering wheel Oil cooler
GD705A-4
10-57
STRUCTURE AND FUNCTION
STEERING WHEEL
12
STEERING WHEEL
The GD705-4 steering system features hydraulic control. A quantity of oil corresponding to the turn of the steering wheel (2) passes to the steering cylinder via a steering valve (Orbit roll type). The hydraulic oil is also used in the steering system.
10-58
1.
Steering valve
2.
Steering wheel
GD705A-4
STRUCTURE AND FUNCTION
STEERING VALVE
12
STEERING VALVE (ORBIT ROLL TYPE)
1.
Check valve
9.
Center ring
17. Ball
2.
Drive shaft
10. Needle bearing
18. Spring
3.
Under cover
11. Retainer
19. Valve
4.
Rotor
12. Ball
20. Adjusting screw
5.
Housing
13. Check seat
21. Locknut
6.
Control sleeve
14. Set screw
22. Plug
7.
Control spool
15. Housing
23. Plug
8.
Center pin
16. Valve seat
24. Ball
GD705A-4
10-59
STRUCTURE AND FUNCTION
STEERING SYSTEM
12
STEERING SYSTEM STRUCTURE
The steering system is of the fully hydraulic type and hydraulic oil is sent to the steering cylinder by this steering valve, oil flow being varied with turning angle of the steering wheel. The valve has a built-in hand pump, which makes it possible to suck oil directly from the tank so that necessary steering operation can be maintained in case of trouble of the oil pump or the engine. This valve is of the orbit roll type.
•
The lower end of the steering wheel shaft is spline-fitted to the top of the spool, which is inserted in the sleeve. The spool and the sleeve are joined to each other with the center pin (which does not contact to the spool when the steering wheel is at neutral position) and the center spring.
•
There is the drive shaft inside the spool. The upper end of the shaft is joined to the center pin and the lower end of it is spline-fitted to the hand pump rotor. The hand pump adjusts oil flow to the cylinder, depending on steering angle of the steering wheel, and also acts to supply oil to the cylinder in case of oil pump or engine trouble by utilizing turning force of the steering wheel to suck oil directly from the tank.
•
The valve body has four ports which connect to the oil pump, tank, steering cylinder head and steering cylinder bottom, respectively. The pump side port and the tank side port are connected to each other through the check valve, which permits the steering valve to suck oil directly from the tank in case of oil pump or engine trouble.
10-60
GD705A-4
STRUCTURE AND FUNCTION
STEERING SYSTEM
12
When the steering wheel is not manipulated, the center spring keeps the spool and the sleeve are stopped in the position at which the center pin is located to the center of the slotted hole in the spool. Under this condition, the ports that connect the sleeve to the steering cylinder and the hand pump are insulated from the lengthwise slots in the spool. While, the small holes in the spool bottom are aligned with those in the sleeve bottom. (Total 24 holes are provided by arranging twin holes at 12 places equally spaced around the circumference of spool or sleeve.) Oil from the pump enters the valve inlet port and flows through small holes in the sleeve and spool to the inside of the spool. The oil, in turn, flows through the slotted hole in the spool and the spring mounting portion to the valve outlet port, and is returned to the tank.
GD705A-4
10-61
STRUCTURE AND FUNCTION
STEERING SYSTEM
12 When steering wheel is manipulated (Turning to the left)
•
When the steering wheel is turned to the left, the rotation causes the spool spline-fitted to the steering wheel shaft to turn to the left. As the sleeve is joined to the spool with the center spring, the spring contracted by the spool causes a difference in turning angle between the spool and the sleeve depending on contraction of the spring. As the result, each port in the sleeve is connected to a lengthwise slit in the spool.
•
Oil from the pump enters the hand pump through the valve inlet port and returns to the sleeve. The oil, in turn, flows from a lengthwise slit in the spool, through the steering cylinder port in the sleeve to the steering cylinder. While, oil from the steering cylinder is forced to flow through the port in the sleeve and a lengthwise slit in the spool and returns to the tank.
•
Under this condition, the hand pump port in the sleeve and the steering cylinder port (on the leftsteering side) in the sleeve are connected to each other through the lengthwise slits in the spool. Also, the steering cylinder port (on the rightsteering side) in the sleeve is connected to the valve outlet port in the sleeve.
•
Under such a condition as mentioned above, the hand pump is rotated by hydraulic oil from the pump and acts as an oil motor to lighten steering wheel manipulating force. When the steering wheel is stopped turning, difference in turning angle between the sleeve and the spool is removed by return force of the center spring. The same condition as mentioned before under "When steering wheel is not manipulated" is recovered. Refer to page 10-64 for details of mutual relation between the hand pump ports (7 ports) and the sleeve ports (12 ports) which will be connected to each other when the steering wheel is turned to either direction.
10-62
GD705A-4
STRUCTURE AND FUNCTION
STEERING SYSTEM
12 When steering is made with the oil pump malfunctioning (Turning to the right)
•
When a motor grader is to be towed by another machine because of some trouble in the oil pump or the engine, keeping normal steering of the grader cannot be neglected to prevent accident. To satisfy this requirement, a built-in hand pump is provided on the bottom of the steering valve. When the steering system is normally supplied with hydraulic oil from the pump, the hand pump is only to control flow of oil, its rotation being supported by pressure of oil. When oil from the pump is stopped, the center pin comes into contact with an end of the slotted hole in the spool and, then, turning force of the steering wheel is used for driving the hand pump.
GD705A-4
•
Like as before-mentioned, a difference occurs in turning angle between the spool and the sleeve and, therefore, each port in the sleeve is connected to a lengthwise slit in the spool. The hand pump is rotated with turning of the steering wheel. The rotation causes the hand pump to suck oil directly from the tank, through the check valve provided between the valve outlet port and the inlet port, and to deliver oil to the steering cylinder.
•
The hand pump resemble trochoid pumps, but its ports are arranged on the root of teeth and each port acts as the inlet port and the outlet port alternatively. Oil suction and discharge operation of the hand pump is carried out by the combination of the seven ports in the hand pump and the 12 ports in the sleeve.
10-63
STRUCTURE AND FUNCTION
STEERING VALVE
CONNECTION BETWEEN HAND PUMP AND SLEEVE
•
•
The diagrams above show the connections with the sleeve ports used to connect the suction and discharge ports of the Girotor. If the steering wheel has been turned to the right, ports a, c, e, g, i, and k are connected by the vertical grooves in the spool to the pump side. At the same time, ports b, d, f, h, j, and l are connected to the head end of the left steering cylinder in the same way. In the condition in diagram above left, ports 1, 2, and 3 are the discharge ports of the Girotor set. They are connected to ports l, b, and d, so the oil is sent to the cylinder. Ports 5, 6, and 7 are connected and the oil flows in from the pump. If the steering wheel is turned 90°, the condition changes to the condition shown in diagram above right. In this case, ports 1, 2, and 3 are the suction ports, and are connected to ports i, k, and a. Ports 5, 6, and 7 are the discharge ports, and are connected to ports d, f, and h.
10-64
GD705A-4
STRUCTURE AND FUNCTION
•
In this way, the ports acting as the discharge ports of the hand pump are connected to the ports going to the steering cylinder, while the ports acting as the suction ports are connected to the pump circuit.
•
If the pump or engine fail, the suction and discharge of this hand pump is carried out forcibly and oil is sent to the steering cylinder, so it is possible to carry out steering.
STEERING VALVE
•
•
To carry out adjustment of the discharge amount to match the amount the steering wheel is turned, the oil from the pump always passes through this hand pump, and for each 1/7 turn of the steering wheel, the internal tooth gear of the hand pump advances by one tooth. An amount of oil equal to this movement is discharged, so the discharge oil amount is directly proportional to the amount the steering wheel is turned. If the pump or engine should fail, the condition is exactly the same, so the same amount of oil is discharged as when the pump is normal.
Differences between trochoid pump and steering pump hand pump •
Trochoid pump
•
The trochoid pump is divided into an inlet port and an outlet port, and when the shaft rotates as shown in the diagram above, oil is sucked in from the inlet port and discharged from the outlet port as shown in 2 - 6.
•
Steering pump hand pump
•
In the case of the hand pump, there are inlet ports and outlet ports at the bottom of the internal teeth of the stator, and when the shaft is rotated, the steering pump and port are connected as shown in 2 - 3 in the diagram above, and oil is sucked in. If the shaft rotated further, the steering cylinder and port are connected as shown in 5 - 6, and the oil is delivered to the cylinder. This action is carried out at each port.
GD705A-4
10-65
STRUCTURE AND FUNCTION
STEERING VALVE
Role of centering spring • Centering spring (4) consists of six X-shaped leaf springs. It is assembled between spool (10) and sleeve (9) as shown in the diagram on the right. When the steering wheel is turned, the spool compresses the spring, and a difference (angle variation) is generated in the turning angle of the spool and sleeve. As a result, the port of the spool and sleeve is connected and oil is sent to the cylinder. However, when the rotation of the steering wheel is stopped, the rotation of the hand pump also stops, so no more oil is sent to the cylinder, and the oil pressure rises. To prevent this, when the turning of the steering wheel is stopped, the action of the centering spring only allows it to turn by an amount equal to the difference in angle a of rotation (angle variation) of the sleeve and spool, so the steering wheel returns to the NEUTRAL position.
10-66
GD705A-4
STRUCTURE AND FUNCTION
STEERING PUMP
12
STEERING PUMP KFP2233CVKR (Pump with flow priority valve)
1.
Flow priority valve
2.
Mounting flange
3.
Body
4.
Bracket
5.
Drive gear
6.
Snap ring
7.
Oil seal
8.
Bushing
9.
Relief valve
A.
PF port
B.
EF port
GD705A-4
10-67
STRUCTURE AND FUNCTION
STEERING PUMP
12
Operation of flow priority valve 1. When pump discharge amount is less than control flow. The flow of oil from the pump passes through the orifice and flows to PF. When this happens, the pressure difference created on both sides of the orifice acts on the plunger in the direction to bend the spring, so the balance with the force of the spring prevents portion a of the plunger from opening to EF and ensures that all the oil flows to PF. 2. When pump discharge amount is more than control flow When the pump discharge amount is more than the set control flow, the pressure difference created on both sides of the orifice becomes greater, so the plunger moves, portion a opens, and the excess oil flows to EF. 3. When circuit on PF side is actuated When the circuit on the PF side is actuated and the pressure on the PF side rises, the difference in pressure between the IN side and the EF side causes the flow of oil to the EF side to increase and the flow of the oil to the PF side to decrease. When this happens, the pressure difference created on both sides of the orifice becomes smaller. Because of the relationship with the spring force, the plunger moves down, and throttles portion a until the pressure difference created on both sides of the orifice reaches the pressure needed to let the set amount of oil flow. This sends a constant amount of oil to the PF side.
10-68
GD705A-4
STRUCTURE AND FUNCTION
STEERING CYLINDER
12
STEERING CYLINDER
10-70
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
GD705A-4
STRUCTURE AND FUNCTION
STEERING CYLINDER
12
Unit: mm No.
Check item
Criteria Tolerance
Standard clearance
Clearance limit
+0.132 +0.006
0.036-0.274
0.6
Standard size 1
Clearance between piston rod and bushing
Remedy
Shaft
Hole
35
-0.030 -0.142
2
Clearance between piston rod support shaft and bushing
50
-0.050 -0.075
+0.041 +0.025
0.075-0.116
0.6
3
Clearance between cylinder bottom support and shaft bushing
47
0 -0.011
+0.007 -0.018
-0.018-0.018
0.6
GD705A-4
Replace bushing
10-71
STRUCTURE AND FUNCTION
FRONT AXLE
12
FRONT AXLE
Toe-in 8.2 ± 1.0 mm Camber 1.5o King pin tilting angle: 0o
10-72
1.
Tie rod
2.
Pitman arm
3.
Front axle
4.
Leaning rod
5.
Housing
6.
Hub shaft
7.
Hub nut
8.
King pin
9.
Bracket
10.
Nut
GD705A-4
STRUCTURE AND FUNCTION
FRONT AXLE
12 FUNCTION OF FRONT AXLE
1.
Steering Refer to section, "STEERING SYSTEM"
2.
Lessening blade angling and up-and-down movement The axle is fixed in the center with a center pin to the frame so that it can oscillate 13 degrees. This, like the tandem system, restricts the up-and-down movement of the blade to a minimum when one front wheel rides over an object or falls into a hole. When the front wheel rides over an object (height-H), the center point of the front axle rises H/2, as shown in drawing. Because of possible rocking of front axle blade movement rises only H/ 4 while holding its horizontal posture. Unless the whole oscillating range (left, right 13o) of the front axle is used, the blade moves up-and-down holding its horizontal posture.
3.
Prevention of side slipping of front wheels (leaning system) The front wheels can be tilted to the left or right. This is called the leaning system, and is to prevent the front wheel from slipping sidewards and to reduce the turning radius. Operations with blade at propulsion angle are frequent among grader operations. In proportion to the propulsion angle a side slipping force acts on the blade to cause side slipping.
Also the distribution of weight on the front and rear wheels is about 3:7, and when the blade cuts into the ground, the load on the front wheels decreases and it is easier for the front wheels to slip sideward. To counteract this side slipping, the front wheels are leaned to make them more resistant, and this changes the center of the load on the front axle and the center of gravity of the machine and prevents side slipping.
GD705A-4
10-73
STRUCTURE AND FUNCTION
FRONT AXLE
12 When the wheel is leaned that angle between the center line of the leaned tire and the perpendicular line is called the "Leaning angle." Leaning angle is the distance S= 2 x π x r covered by the tire as it advances, and the side with the greater load radius, in order to advance more than the side with the less load radius, advances in the direction of the leaning. Using this characteristic, the turning radius can be lessened when the leaning operation is carried out.
When backing, leaning should be reversed to the leaning for forward operation by turning a steering wheel in the same direction. Leaning angel is 16.5o.
Also, when there is no differential mechanism, even though the front wheels are steered, the rear wheels tend to go straight ahead and this causes the front wheels to slip little by little. Leaning prevents this. Also, the front wheels steering angle is increased by leaning. Explanation according to the drawing to the right: (In order to keep the explanation simple it will be down without steering.) When the front wheels are leaned to one side, O4 revolves 23o around 03 and comes to 04, and at the same time 02 also revolves around 03 and comes to 02. The tie-rod revolves around O1, but since its length is fixed, a clearance "O" is made. However, since O1, is fixed, the housing is pulled to the "O" and comes to the position "O" (O2). Since the front wheels are steered a little in the direction of leaning, the steering angle becomes a little bigger.
10-74
O1: Center of pitman arm ball joint O2: Center of tie-rod end pin O3: Center of mounting pin of housing O4: Center of cylinder rod
GD705A-4
STRUCTURE AND FUNCTION
FRONT AXLE
12
FRONT WHEEL ALIGNMENT In vehicles steered by the two front wheels, the wheels are fitted by a special method to ensure ease, stability, and accuracy in steering. This special fitting is called alignment, and has a very big influence on operation of the steering wheel. 1.
Camber The front wheels are fitted so that the top of the wheels are further away from the vehicle than the bottom of the wheels in contact with the ground. This slanting is called camber.
2.
Toe-in When seen from above, the distance A between the front of the front wheels is slightly less than the distance B between the rears. This is called toe-in. When vehicles travel with a camber angle, the force which tends to push the front wheels outwards increases the ground resistance of the wheels, resulting in less stable travel and greater tire wear. By fitting the wheels with a slight inward slant, however, this undesirable tendency can be eliminated. The difference between A and B of 3 to 7mm is called toe-in quantity.
3.
King pin angle of inclination The king pin is not exactly vertical to the ground but inclines slightly inwards. This angle is called the king pin angle of inclination. Together with the camber, this inclination shortens the trail for easier steering wheel operation. Since the front wheels turn during operation with the king pin center line as the center axis, the front wheels tend to be lifted up. This action, however, is also accompanied by a reaction which tends to return the wheels to the former position. When the grader turns a little and still is about to proceed straight ahead, releasing the steering wheel will generate the restoring force, and bring the steering wheel back to its former position. This angle is generally about 5o to 8o.
GD705A-4
10-75
STRUCTURE AND FUNCTION
FRONT AXLE
12 4.
Caster (The caster angle in grader is Oo.) Caster refers to the angle at which the king pin is fitted when the wheel is viewed from the side shown in the accompanying diagram. The angle is called the caster angle. If the king pin is fitted at an angle, the point of contact between the wheel and the ground will be behind the point where the extrapolated king pin center line meets the ground. This means that during travel, there is a force constantly pulling the wheels backward, depending on the ground resistance added to the point where the wheels are in contact with the ground. This backward force tends to keep the wheels directed straight ahead (directional property). This force also tends to return the steering wheel to the original position when the steering wheel is turned (restoring property). In automobiles, the caster angle is generally 1o to 3o. In graders, however, the angle is 0o
10-76
GD705A-4
STRUCTURE AND FUNCTION
FRONT AXLE
12
Unit: mm No.
Check item
Criteria Tolerance Standard size
1
Remedy
Standard clearance
Clearance limit
Shaft
Hole
50
-0.025 -0.064
+0.025 +0
0.025-0.089
1.0
Clearance between leaning pin and leaning rod bushing
2
Clearance between center pin bushing
60
-0.085 -0.110
-0.025 -0.050
0.035-0.085
1.0
3
Clearance between king pin and bushing
50
-0.025 -0.050
+0.025 +0
0.025-0.075
0.4
4
Axial clearance between knuckle and bracket (king pin)
Standard clearance
Interference limit
0.143 - 0.331
1.0
Replace
Tolerance Standard size 5
Clearance between axle end pin and bushing 45
6
Tie rod joint nut tightening torque
7
Preload of hub bearing
8
Hub nut tightening torque
GD705A-4
Replace bushing
Shaft
Hole
-0.085 -0.064
-0.025 +0
Standard interference
Interference limit
0.025 - 0.089
0.4
Replace bushing
216 - 304 Nm {22 - 31 kgm} Starting torque: 24.5 - 32.9 Nm {2.5 - 3.35 kgm}
Adjusting
491 ± 49 Nm {50 ± 5 kgm}
10-77
STRUCTURE AND FUNCTION
WHEEL
12
WHEEL FRONT WHEEL
10-78
Tire size
16.00 - 24 - 12PR
Rim size
10.00VA x 24SDC
Air pressure
0.22 MPa {2.2 kg/cm2}
1. 2. 3. 4.
Side ring Rim Tube Tire
GD705A-4
STRUCTURE AND FUNCTION
WHEEL
12 REAR WHEEL
Tire size
16.00 - 24 - 12PR
Rim size
10.00VA x 24SDC
Air pressure
0.22 MPa {2.2 kg/cm2}
GD705A-4
1. 2. 3. 4.
Side ring Rim Tube Tire
10-79
STRUCTURE AND FUNCTION
BRAKE PIPING
12
BRAKE PIPING
1. 2. 3. 4. 5. 6.
Disc brake housing Stop lamp switch Brake valve Air governor Drain cock Air reservoir
10-80
7. Low pressure switch 8. Check valve 9. Air compressor 10. Air dryer (OP) 11. Safety valve 12. Relay valve
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
1.
Air compressor
8.
Low pressure switch
2.
Air drier (If equipped)
9.
Pressure gauge
3.
Air governor
10.
Brake valve
4.
Air reservoir
11.
Stop lamp switch
5.
Safety valve
12.
Automatic drain (If equipped)
6.
Relay valve
13.
Disc brake
7.
Check valve
14.
Purge tank
GD705A-4
STRUCTURE AND FUNCTION
DISC BRAKE SYSTEM
12 STRUCTURE OF DISC BRAKE
Disc brakes are fitted on the four rear wheels and are actuated by air pressure. The motive force from the final drive rotates hub shaft (1), gear (2) and disc (4) inside cage (7). This rotation is transmitted to the tires which are fixed to the hub. Each brake consists of disc (4) which is meshed with plate (5) and gear (2) which are meshed with cage (7). The discs are cooled by the oil inside the tandem case.
GD705A-4
1.
Hub shaft
2.
Gear
3.
Support
4.
Disc
5.
Plate
6.
Spring
7.
Cage
8.
Piston
9.
Nut
10.
Bolt
10-83
STRUCTURE AND FUNCTION
DISC BRAKE SYSTEM
12
OPERATION 1.
Brake applied When the brake pedal is depressed, the air circuit is connected to chamber A of the disc brake. When the air pressure is greater than the pushing force of spring (6), piston (8) moves to the left, and pushes disc (4) and plate (5). Friction is generated between the disc (meshed with gear (2)) and the plate (meshed with cage (7)). This slows down the rotation of the disc and finally stops it. In other words, the brake is applied.
2.
Brake released When the brake is released, the air in chamber A is released. Spring (6) moves piston (8) back to the right, so the pushing force is reduced. This removes the friction between disc (4) and plate (5), and allows them to rotate freely. In other words, the brake is released.
10-84
GD705A-4
STRUCTURE AND FUNCTION
DISC BRAKE SYSTEM
12
Unit: mm No.
1
Check item
Criteria
Remedy
Standard size
Repair limit
3.8 ± 0.1
3.3 ± 0.1
Thickness of disc
2
Thickness of plate
2.3 ± 0.1
3
Total thickness between disc and plate
32.8 ± 1.1
30.3 ± 1.1
Standard size
Repair limit
4
Return spring
GD705A-4
Free length x O.D.
Installed length
Installed load
71 x
52
16.9
Free length
Replace
Installed load
10-85
STRUCTURE AND FUNCTION
BRAKE VALVE
12
BRAKE VALVE
1.
Brake pedal
2.
Plunger
3.
Piston
4.
Inlet valve
5.
Piston
6.
Inlet valve
7.
Rubber spring
A.
From air reservoir
B.
From air reservoir
C.
To R.H. relay valve
D.
To L.H. relay valve
10-86
GD705A-4
STRUCTURE AND FUNCTION
BRAKE VALVE
12
OPERATION 1.
Brake operating Upper part • When brake pedal (1) is depressed, the operating force pushes plunger (2) and rubber spring (7), and these transmit the operating force to piston (3). • When piston (3) moves down, it closes exhaust outlet (9). At the same time, it pushes down inlet valve (4) and air flows from air reservoir A to right relay valve C. Lower part • When inlet valve (4) opens, air flows to chamber "a" of piston (5). • The air pressure pushes piston (5) down and this closes exhaust outlet (10). At the same time, it pushes down inlet valve (6) and air flows from air reservoir B to left relay valve D to actuate the brake. • Only a small amount of air pressure is needed to move piston (5), so the movement of the lower valve occurs at almost the same time as the movement of the upper valve.
2.
Brake operation when lower side breaks down If there is any leakage of air at the lower side, the upper side operates normally but the lower side does not actuate the brake.
GD705A-4
10-87
STRUCTURE AND FUNCTION
BRAKE VALVE
12 3.
Brake operation when upper side breaks down • If there is any leakage of air at the upper side, piston (5) is pushed down mechanically when the brake pedal is depressed. Because of this, the lower side operates normally but the upper side does not actuate the brake.
4.
Balancing operation Upper part • If the air pressure in relay valve C and the space below piston (3) becomes high, piston (3) will push rubber spring (7) and move up to close inlet valve (4). • When this happens, exhaust outlet (9) remains closed, so the air pressure in the relay valve is maintained. As a result, the brake remains applied Lower part • When the air pressure at the top and bottom of piston (5) becomes the same, the piston moves down slightly under the force of the spring at the top of the piston and closes inlet valve (6). The exhaust valve is closed so the air pressure is maintained. As a result, the brake remains applied. • The pressure in the space in the upper part balances with the operating force of the pedal, and the pressure in the space in the lower part balances with the air pressure in the space in the upper part.
10-88
GD705A-4
STRUCTURE AND FUNCTION
BRAKE VALVE
12 •
•
5.
When piston (3) and (5) move their whole stoke inlet valves (4) and (6) are completely opened. As a result, the air pressure in the spaces in the upper part and lower part, and in the right and left relay valves are the same as the air pressure in the air reservoir. Therefore, until the piston moves its full stroke down, the braking effect is controlled by the amount the brake pedal is depressed.
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
1.
Exhaust valve seat
2.
Spring
3.
Cover
4.
Relay piston
5.
O-ring
6.
O-ring
7.
Valve guide
8.
Exhaust check
9.
Exhaust cover
10.
Inlet exhaust valve
11.
Spring
12.
Body
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 supplied to the brake chamber.
2.
When brake pedal is held in place The air pressure in chamber A at the top of the piston becomes equal to the air pressure in chamber B at the bottom of the piston. Spring (2) operates to push up relay piston (4), and spring (11) closes valve (10). In addition, exhaust port C stays closed at this position, so the pressure in lower chamber B is kept the same. If the pedal is depressed further and the pressure is increased, compressed air will be supplied to the disc brake until the pressure becomes equal again.
3.
When brake pedal is released The compressed air in chamber A at the top of relay piston (4) is released through the brake valve. When the pressure in chamber A drops, relay piston (4) is pushed up by the air pressure in chamber B. Exhaust port C opens, so the air in chamber B is released.
GD705A-4
10-91
STRUCTURE AND FUNCTION
AIR GOVERNOR
12
AIR GOVERNOR
1.
Cover
2.
Lock nut
3.
Spring upper seat
4.
Spring
5.
Body
6.
Spring guide
7.
Spring lower seat
8.
Spring lower seat
9.
O-ring
10. Spring 11. Washer 12. Spring 13. Pressure regulator valve 14. Exhaust stem 15. Piston 16. Adjust screw 17. Snap ring
The air governor is installed to prevent the pressure from rising too high. The reservoir port is connected to the air reservoir; the unloader port is connected to the unloader valve of the air compressor. The governor maintains the pressure inside the air reservoir within the specified range. If the pressure exceeds the specified limit, it stops the air compressor working. Specified pressure range: 0.68 - 0.86 MPa {6.9 - 8.8 kg/cm2}
10-92
GD705A-4
STRUCTURE AND FUNCTION
AIR GOVERNOR
12
OPERATION 1.
When pressure inside air reservoir is too low • The pressure at reservoir port A is too low, so piston (15) is pushed down by spring (4), and unloader port B is connected to the exhaust port. There is pressure on the unloader valve, so the compressor is working.
2.
When pressure inside air reservoir is too high • If the pressure at reservoir port A is too low, piston (15) is pushed up. • When the piston is pushed up, the exhaust port closes and valve (13) opens. Compressed air from reservoir port A flows to unloader port B. This actuates the unloader valve and makes the compressor run at idling. • When the pressure inside the air reservoir drops, the piston is pushed down by spring (4). • When the pressure drops below the lower limit, valve (13) closes and exhaust stem (14) opens. Air pressure at the unloader port passes through the exhaust stem and is released to the atmosphere. As a result, the compressor starts working again.
GD705A-4
10-93
STRUCTURE AND FUNCTION
CHECK VALVE
12
CHECK VALVE
1.
Body
2.
Disc valve
3.
Spring
4.
Screw cap
The check valve acts to prevent air in the air reservoir from flowing back to the air compressor when the air compressor is stopped. OPERATION When air flows into the check valve from the left, valve (2) leaks its seat and the air flows freely to the various ports. When air flows into the check valve from the right, valve (2) is pushed back into its seat by spring (3) and the air pressure. This shuts off the air flow.
10-94
GD705A-4
STRUCTURE AND FUNCTION
AIR RESERVOIR
12
AIR RESERVOIR
1.
Plate
2.
Plate
3.
Plate
4.
Boss
The air reservoir acts to store the compressed air produced by the air compressor. Maximum pressure: 0.93 MPa {9.5 kg/cm2} (Capacity 19O x 2)
SAFETY VALVE 1.
Valve seat
2.
Ball
3.
Release pin
4.
Spring
5.
Spring cage
6.
Lock nut
7.
Adjusting screw
The safety valve is installed in the air reservoir and acts to maintain safety in the air circuit. When the pressure inside the air reservoir exceeds 0.93 ± 0.03 MPa {9.5 ± 0.3 kg/cm2}, the safety valve releases compressed air to the atmosphere.
GD705A-4
10-95
STRUCTURE AND FUNCTION
PRESSURE SWITCH
12
PRESSURE SWITCH The pressure switch detects any change in the air pressure. In accordance with these changes, it switches the electric circuit on or off. PRESSURE SWITCH FOR AIR PRESSURE WARNING (LOW PRESSURE SWITCH) The contacts of this switch close when the air pressure inside the main tank drops below 0.41 MPa {4.2 kg/ cm2}. A warning buzzer then sounds to warn the operator of loss of braking power. If the warning buzzer sounds, the operator must stop the machine and wait until the air pressure rises again.
1.
Cover
5.
Gasket
2.
Contact plate
6.
Body
3.
Spring
7.
Piston cup
4.
Contact disc
8.
Contact plate
OPERATION Contacts in OFF position
Contacts in ON position
1.
2.
When pressure in air circuit is above 0.41 MPa {4.2 kg/cm2} The air pressure action on piston (2) is higher than the force of the spring, so piston (2) is pushed up. The electrical contacts are open, so no electric current flows in the warning buzzer circuit and the buzzer does not sound.
10-96
When pressure in air circuit is below 0.41 MPa {4.2 kg/cm2} The air pressure acting on piston (2) is lower than the force of the spring, so piston (2) is pushed down. The electrical contacts are closed, so electric current flows in the warning buzzer circuit and the buzzer sounds.
GD705A-4
STRUCTURE AND FUNCTION
PRESSURE SWITCH
12 PRESSURE SWITCH FOR STOP LAMP The switch acts to light up the stop lamp when the brake pedal is depressed. When the air pressure rises above 0.05 MPa {0.5 kg/cm2} the contacts close and the stop lamp lights up. This switch is at the outlet port of the brake valve. One switch each is installed in both the right and left brake circuits. OPERATION When the brake pedal is depressed, air pressure is connected to the lower side of diaphragm (4). When the air pressure rises above 0.05 MPa {0.5 kg/cm2}, the diaphragm compresses spring (2) and pushes plunger (3). This brings the points of the plunger and terminal into contact, and the stop lamps light up.
GD705A-4
1.
Terminal
2.
Spring
3.
Plunger
4.
Diaphragm
5.
Body
10-97
STRUCTURE AND FUNCTION
AUTOMATIC DRAIN VALVE
12
AUTOMATIC DRAIN VALVE (If equipped)
1.
Retainer
2.
Filter
3.
Body
4.
Plug
5.
Valve guide
6.
Inlet-Exhaust valve
7.
Cover
The automatic drain valve is installed at the bottom of the air reservoir. It acts to automatically drain any water which forms when the compressor air is cooled. OPERATION 1. When there is no air pressure inside the air reservoir, inlet-exhaust valve (6) is closed.
10-98
GD705A-4
STRUCTURE AND FUNCTION
AUTOMATIC DRAIN VALVE
12 2.
When air pressure enters the air reservoir, inletexhaust valve (6) opens even when the pressure is low. Air and water then enters chamber A. The inlet-exhaust valve stops open until the pressure inside the air reservoir reaches the maximum pressure (until the governor is cut-off).
3.
When the pressure in the air reservoir and the pressure in chamber A are equal, the spring action of valve guide (5) closes inlet-exhaust valve (6).
4.
When the pressure in the air reservoir drops, and the pressure in chamber A is about 0.03 MPa {0.3 kg/cm2}, inlet-exhaust valve (6) exhausts the air and water.
GD705A-4
10-99
STRUCTURE AND FUNCTION
AIR DRIER
12
AIR DRIER (If equipped)
DR-5 (With purge chamber)
10-100
1.
Purge chamber
6.
Oil filter
A.
From compressor
2.
Spring
7.
Valve
B.
To air tank
3.
Check valve
8.
Piston
C.
From air governor
4.
Drier cylinder
9.
Body
5.
Drying agent
10. Heater
GD705A-4
STRUCTURE AND FUNCTION
AIR DRIER
12 OPERATION 1. Dehumidifying When the compressor is working, air from the compressor enters port A of the air drier. The air then passes through oil filter (6) which is fitted with an oil mist separator. Here the fine drops of oil and particles of dust are removed before the air enters the drier cylinder. Any water still included in the air is removed by drying agent (5). When the air reaches the top of the drier cylinder, it is completely dry. This dry air then passes through check valve (3) and the purge chamber and is sent to the main tank.
2.
Restoring drying agent When the air pressure inside the circuit reaches the set pressure, the command from the governor switches the compressor to unloading. The same command is also received by the control ports of the air drier. Valve (7) opens and the air inside drier cylinder (4) is released to the atmosphere. Following this sudden drop in pressure, the dried air in the purge chamber passes through orifice "a." Because of the drop in pressure, the dry air expands and becomes super-dry air. As it flows back through the drier cylinder, it picks up water from drying agent and carries it out to the atmosphere. When the loading cycle starts again, the valve closes, and the cylinder returns to dehumidifying action.
GD705A-4
10-101
STRUCTURE AND FUNCTION
AIR COMPRESSOR
12
AIR COMPRESSOR
Bore x Stroke: 85 x 59.9 mm Piston displacement: 340 cc 1.
Crankcase
8.
Piston
15. Unloader valve
2.
O-ring
9.
Piston pin
16. Shim
3.
Bearing cover
10. Snap ring
17. Gasket
4.
Oil seal
11. Oil ring
18. Connecting rod
5.
Crankshaft
12. Second ring
19. O-ring
6.
Bearing
13. Top ring
20. Bushing
7.
Cylinder
14. Cylinder head
21. Drive gear
10-102
GD705A-4
STRUCTURE AND FUNCTION
PARKING BRAKE
12
PARKING BRAKE
GD705A-4
1.
Arm
2.
Support plate
3.
Drum
4.
Return spring
5.
Adjuster
10-103
STRUCTURE AND FUNCTION
PARKING BRAKE
12
Unit: mm No.
Check item
Criteria Standard size
1
Wear of brake drum I.D.
2
Wear of lining
3
Out of roundness of drum I.D.
10-104
Remedy Repair limit
304.8 +0.2 0
308
Clearance between lining face and rivet head face: Max. 0.5
Repair limit: 0.2
Replace drum Replace lining Turn or Replace
GD705A-4
STRUCTURE AND FUNCTION
PARKING BRAKE CONTROL
12
PARKING BRAKE CONTROL
10-106
1.
Parking brake lever
2.
Parking brake control wire
3.
Lever
GD705A-4
STRUCTURE AND FUNCTION
HYDRAULIC PIPING
HYDRAULIC PIPING HYDRAULIC TANK TO CONTROL VALVES STD spec.
1. Work equipment control valve (L.H.) 2. Work equipment control valve (R.H.) 3. Work equipment pump 4. Circle rotatin and ripper (attachment) pump 5. Return filter 6. Hydraulic tank 7. Circle rotation and ripper (attachment) valve (2-spool valve)
10-108
GD705A-4
STRUCTURE AND FUNCTION
HYDRAULIC PIPING
DDV (Dual Demand Valve) spec.
1. Work equipment control valve (R.H.) 2. Dual demand valve 3. Mode control valve 4. Circle rotation and ripper (attachment) pump 5. Work equipment pump 6. Flow divider valve 7. Work equipment control valve (L.H.) 8. Hydraulic tank 9. Return filter
GD705A-4
10-108-1
STRUCTURE AND FUNCTION
HYDRAULIC PIPING
12 BLADE LIFT AND LEANING
8.
Pilot check valve (for leaning)
9.
Pilot check valve (for drawbar shift)
10. Leaning cylinder 11. Pilot check valve (for L.H. blade lift) 12. Pilot check valve (for R.H. blade lift) 13. Articulate cylinder 14. Pilot check valve (for articulate) 15. Blade lift cylinder
GD705A-4
10-109
STRUCTURE AND FUNCTION
HYDRAULIC PIPING
12 BLADE SIDE SHIFT, CIRCLE ROTATION AND POWER TILT
19. Circle rotation motor 20. Pilot check valve (for power tilt) 21. Rotary joint 22. Blade side shift cylinder 23. Power tilt cylinder
10-110
GD705A-4
STRUCTURE AND FUNCTION
HYDRAULIC PIPING
12 RIPPER (If equipped)
24. Ripper control valve 25. Pilot check valve 26. Ripper cylinder
GD705A-4
10-111
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
12
MAIN CONTROL VALVE
3-Spool valve Left hand valve Articulate, Drawbar shift, Blade lift (L.H.)
10-112
1.
Articulate
2.
Drawbar
3.
Blade lift (L.H.)
4.
Check valve
5.
Relief valve
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
1.
Blade lift (R.H.) spool
2.
Leaning spool
3.
Blade shift spool
4.
Power tilt spool
5.
Check valve
6.
Relief valve
10-113
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
12 CIRCLE ROTATION
10-114
1.
Circle rotation spool
2.
Check valve
3.
Relief valve
GD705A-4
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
12 CIRCLE ROTATION AND RIPPER VALVE
GD705A-4
1.
Circle rotation spool
2.
Ripper spool
3.
Relief valve
4.
Check valve
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 suddenly 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 shuttering 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 reason a throttle has been provided at E position, so that, even if pressure at the cylinder bottom side fails, it has a damper effect so that the check valve does not close immediately.
10-116
GD705A-4
STRUCTURE AND FUNCTION
PILOT CHECK VALVE
12
(For Leaning, Drawbar)
1.
Pilot check valve
2.
Body
3.
Piston
4.
Pilot check valve
OPERATION When extending the cylinder, if the control valve is operated, the oil from the pump enters chamber A. It pushes the pilot check valve and the piston, and enters chamber C. This forms pressure at the bottom end. Because the pressure in chamber C rises and pushes the cylinder, the oil in chamber D passes through the pilot check valve and flows to chamber B. The cylinder then extends.
GD705A-4
10-117
STRUCTURE AND FUNCTION
PILOT CHECK VALVE
12
(For articulate)
1.
Piston
2.
Check valve
3.
Body
4.
Piston
5.
Check valve
A.
From control valve
B.
From control valve
C.
To cylinder head
D.
To cylinder bottom
Operation When the hydraulic cylinder tries to extend and the control valve is operated, the oil from the pump enters port A, opens check valve (5), and flows to port D. When pressure is generated, the oil from orifice a pushes up piston (1), then opens check valve (2), connects port C and port B, and the oil flows to the drain port. There is hunting when check valve (2) opens and closes according to the change in the pressure at the bottom end and head end, but even if the pressure at port A goes down, there is orifice a, so it has the effect of acting as a damper to prevent check valve (2) from closing immediately.
10-118
GD705A-4
STRUCTURE AND FUNCTION
PILOT CHECK VALVE
12
(For power tilt)
1.
Pilot check valve
2.
Body
3.
Piston
4.
Pilot check valve
5.
Spool
6.
Poppet
The check and safety valve acts to prevent hydraulic drift of the cylinder, and also protects the cylinder from abnormal pressure generated by external force. Operation • When the blade is lowered and the control valve is actuated, the oil from the pump enters chamber A2, pushes the pilot check valve and the piston, and then enters chamber B2. This oil causes the oil pressure at the bottom of the cylinder to rise. • When the oil pressure in chamber B2 (bottom) rises, it pushes the cylinder, and the oil in chamber B1 passes through the pilot check valve, flows to chamber A1, and the cylinder extends. • If the pressure exceeds 24.52 MPa {250 kg/ cm2}, the oil from chamber B1 pushes the poppet and flows again to chamber B2.
GD705A-4
10-119
STRUCTURE AND FUNCTION
PILOT CHECK VALVE
12
(For Ripper (if equipped))
The check valve with safety valve prevents hydraulic drift of the cylinder. At the same time, it protects the cylinder from abnormal pressure inside the cylinder caused by external force. OPERATION When extending the blade, the oil from the pump passes through chamber A and flows to chamber C. The pressure at the bottom rises and pushes the cylinder. When the cylinder is pushed, the oil in chamber B1 passes through the pilot valve and flows to chamber B. When the oil pressure is more that 24.6 MPa {250 kg/cm2} the oil from chamber D pushes the poppet and flows back to chamber C. When the ripper lever is moved to the LOWER position, the oil from the pump passes through chamber A2 and pushes pilot check valve (4). It then passes through chamber B2 and flows to the chamber at the bottom end of the cylinder, and extends the cylinder to
10-120
lower the ripper. The oil at the head end of the cylinder flows back through chamber A1 and chamber B1, and returns to the tank. When the ripper lever is moved to the RAISE position, the oil from the pump passes from chamber A1 through chamber B1 and flows to the chamber at the head end of the cylinder. When this happens, the pressure in chambers A1 and B1 rises. As the pressure rises, piston (3) is pushed, and check valve (4) is pushed open. The oil at the bottom end of the cylinder flows through the restriction in check valve (4) and returns through chamber A2 to the tank. The cylinder retracts and the ripper rises. When the ripper is operated, if there is abnormal ripper pressure of over 24.6 MPa {250 kg/cm2}, generated in chamber B1, relief valve poppet (6) is pushed down. The oil flows to chamber B2 and raises the ripper to relieve the shock.
GD705A-4
STRUCTURE AND FUNCTION
PILOT CHECK VALVE
12
(For Blade lift L.H. Scarifier (if equipped))
It is installed on the left blade lift and the scarifier cylinders.
1.
Pilot valve
2.
Check valve
3.
Sleeve
4.
Adjusting screw
5.
Lock nut
6.
Sleeve
7.
Poppet
A safety valve is installed on the check valve not only to prevent natural falling of the cylinder and vacuum developing at the cylinder bottom side, but also to preserve the cylinder against abnormal pressure from outside forces.
OPERATION Using blade lift cylinder (left) as an example, when trying to lower the blade, when the control valve is operated, pressure develops in the cylinder bottom side of the blade lift cylinder. The pressure passing through the throttle forces the pilot valve (1) 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 suddenly 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 shuttering 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 reason a throttle has been provided at E position, so that, even if pressure at the cylinder bottom side fails, it has a damper effect so that the check valve does not close immediately.
GD705A-4
10-121
STRUCTURE AND FUNCTION
PILOT CHECK VALVE
12 A safety valve poppet (7) has been installed to preserve the cylinder when high hydraulic pressures arises in the cylinder head side of the cylinder because of interference from the work equipment or external force. When high hydraulic pressure (about 24.6 MPa {250 kg/cm2}) arises to C, oil flows through the drill hole in the spool (6) to open the safety valve poppet (7) to flow to the cylinder bottom side of the cylinder.
10-122
GD705A-4
STRUCTURE AND FUNCTION
DDV (DUAL DEMAND VALVE)
DDV (DUAL DEMAND VALVE)
1. Mode control valve 2. Cable 3. Lever
The DDV (dual demand valve) consists of two demand valves. The No. 1 demand valve, when in neutral, maintains the delivery from each pump at a constant level even if the engine speed is low. Because of this, even if the engine speed drops, the work equipment can be moved at the usual speed. For finishing operations, the mode control valve can be set to the ON position to obtain a speed for the work equipment to match the machine speed. The No. 2 demand valve sends a constant flow of oil to the circle control valve when the engine speed is midrange or above. Any unnecessary oil is unloaded. This prevents any increase in loss of power and in this way improves fuel consumption. When starting in low temperatures, the mode control valve can be set to the UNLOAD position. This improves the ease of starting by unloading the oil delivered by the pump without sending it through the work equipment valve.
10-123-1
GD705A-4
STRUCTURE AND FUNCTION
DDV (DUAL DEMAND VALVE)
MODE CONTROL VALVE
This valve acts to switch the DDV to its various positions: NEUTRAL, ON, UNLOAD. ★ For details of the operation of the DDV (dual dema nd v al ve ) , se e DDV (D UAL D EM AND VALVE).
10-123-3
1. Spool 2. Body 3. Screw MA. From dual demand valve MB. To dual demand valve F. Passage T. To tank
GD705A-4
STRUCTURE AND FUNCTION
DDV (DUAL DEMAND VALVE)
Unit: mm No.
4
Check Item
Clearance between spool and valve body
Criteria Tolerance
Standard size
shaft
14
—
Remedy
Hole
Standard clearance
Clearance limit
—
—
—
Standard size 5
6
Spool return spring
Detent spring
GD705A-4
Repair limit
Free length x O.D.
Installed length
Installed load
Free length
Installed load
53.3 x 23.3
10
329.0N {33.5kg}
—
78.5N {8kg}
30.7 x 7.7
5
226N {23kg}
—
39.2N {4kg}
—
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 chamber 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 chamber D. It then divides into two oil flows. One passes through chamber E, passage F, chamber A and chamber B and goes to DDV port Pi. The other is drained from chamber E to the tank.
10-123-5
GD705A-4
STRUCTURE AND FUNCTION
DDV (DUAL DEMAND VALVE)
DUAL DEMAND VALVE
OPERATION PRINCIPLES OF DDV The oil from the hydraulic tank is delivered to DDV from each pump (pumps 1, 2, and 3). The DDV distributes the oil to the V1 port (to L.H. and R.H. hydraulic control valve), V2 port (to circle rotation control valve) and T port according to the engine speed.
GD705A-4
1. Pipe 2. Cover 3. Spring 4. Spool 5. Body 6. Plug 7. Cover 8. Cover 9. Spring 10. Spool 11. Spring 12. Plug (Orifice 1) 13. Plug (Orifice 2)
10-123-6
STRUCTURE AND FUNCTION
DDV (DUAL DEMAND VALVE)
SYSTEM HYDRAULIC CIRCUIT
10-123-7
GD705A-4
STRUCTURE AND FUNCTION
PRECONDITIONS The explanation given so far assumes the control flow rates of the first and second demand valves to be QA and QB, respectively. In actuality, however, speeds N1 through N6 vary because of the flow control limits (illustrated) of the first and second demand valves.
DDV (DUAL DEMAND VALVE)
PRINCIPLE OF OPERATION WHEN USED WITH MODE CONTROL VALVE •
•
•
GD705A-4
Position a (NEUTRAL) See explanation of DDV operation principle, items 1 through 10. Position b (ON) This position causes pump speed change in proportion to the engine speed. Since the pump discharge varies in proportion to the travel speed as with the conventional grader, fine control at a low travel speed at the time of road surface finishing operation is possible, This position is advantageous in improving the finishing speed. Position c (UNLOAD) This position causes unloading of pump discharge P1 through the mode control valve. Since unloading of the oil from all pumps (P1, P2 and P3) is carried out bypassing operation valves, the load at the time of engine starting is small, resulting in improvement of startabilty.
10-123-8
STRUCTURE AND FUNCTION
DDV (DUAL DEMAND VALVE)
Distribution to each port is as follows: 1. When the engine speed is N1 or below: (Fig. 1) The total volume of the oil from pumps 1, 2 and 3 flows to the V1 port.
10-123-9
GD705A-4
STRUCTURE AND FUNCTION
DDV (DUAL DEMAND VALVE)
2. When the engine speed is from N1 up to N2: (Fig. 2) The total volume of the oil from pumps 1 and 2 flows to the V1 port. ∆Q (Q1 + Q2 + Q3 – QA) out of the oil from pump 3 flows to the V2 port.
GD705A-4
10-123-10
STRUCTURE AND FUNCTION
DDV (DUAL DEMAND VALVE)
3. When the engine speed is N2: (Fig. 3) The total volume of oil from pumps 1 and 2 flows to the V1 port, and the total volume of oil discharged from pump 3 flows to the V2 port.
10-123-11
GD705A-4
STRUCTURE AND FUNCTION
DDV (DUAL DEMAND VALVE)
4. When the engine speed is between N2 and N3: (Fig. 4) The total volume of the oil from pump 1 and a part (QA – Q1) of the oil from pump 2 flow to the V1 port. The total volume oil from pump 3 and ∆Q (Q1 + Q2 – QA) out of the oil from pump 3 flows to the V2 port.
GD705A-4
10-123-12
STRUCTURE AND FUNCTION
DDV (DUAL DEMAND VALVE)
5. When the engine speed is between N3 and N4: a. Same as item 4 when the oil flowing to the V1 port is used. b. When the oil flowing to the V1 port is not used and is led to the C0 port: (Fig. 5) The total volume of the oil from pumps 1 and 2 and a part of the oil (QB – Q1 – Q2) from pump 3 flows to the V2 port and ∆Q (Q1 + Q2 + Q3 – QB) out of the oil from pump 3 flows to the T port (for unloading).
10-123-13
GD705A-4
STRUCTURE AND FUNCTION
DDV (DUAL DEMAND VALVE)
6. When the engine speed is N4: a. Same as item 4 when the oil flowing to the V1 port is used. b. When the oil flowing to the V1 port is not used and is led to the C0 port: (Fig. 6) The total volume of oil from pumps 1 and 2 flows to the V2 port and the total volume of oil from pump 3 flows to the T port.
GD705A-4
10-123-14
STRUCTURE AND FUNCTION
DDV (DUAL DEMAND VALVE)
7. When the engine speed is between N4 and N5: a. Same as item 4 when the oil flowing to the V1 port is used. b. When the oil flowing of the V1 port is not used and is led to the C0 port: (Fig. 7) The total volume of oil from pump 1 and a part of oil (OB – Q1) from pumps 2 flows to the V2 port. The total volume of the oil from pump 3 and ∆Q = Q1 + Q2 – QB) of the oil from a part (∆ pump 2 flows to the T port.
10-123-15
GD705A-4
STRUCTURE AND FUNCTION
DDV (DUAL DEMAND VALVE)
8. When the engine speed is between N5 and N6: a. When the oil flowing to the V1 port is used: (Fig. 8) The total volume of oil from pump 1 and a part (QA – Q1) of the oil from pump 2 flows to the V1 port. ∆Q = Q1 + Q2 – QA) of the oil from A part (∆ pump 2 and a part (QA + QB – Q1 – Q2) of the oil from pump 3 flows to the V2 port. ∆Q = Q1 + Q2 + Q3 – QA – QB) of A part (∆ the oil from pump 3 flows to the T port. b. Same as 7 (b) when the oil flowing to the V1 port is not used and is led to the C0 port.
GD705A-4
10-123-16
STRUCTURE AND FUNCTION
DDV (DUAL DEMAND VALVE)
9. When the engine speed is N6 or above: a. When the oil flowing to the V1 port is used: (Fig. 9) The total volume of the oil from pump 1 flows to the V1 port. The total volume of the oil ∆Q = Q2 + Q3 – QB) from pump 2 and a part (∆ from pump 3 flows to the T port.
10-123-17
GD705A-4
STRUCTURE AND FUNCTION
DDV (DUAL DEMAND VALVE)
b. When the oil flowing to the V1 port is not used and is led to the C0 port: (Fig. 10) The total volume of the oil from pump 1 flows to the V1 port → C0 port. The total volume ∆Q = Q1 + of the oil from pump 3 and a part (∆ Q2 – QB) of the oil from pump 2 flows to the T port. Therefore, the total volume of oil from pump 1 and a part (QB – Q1) of the oil from pump 2 flows to the V2 port.
GD705A-4
10-123-18
STRUCTURE AND FUNCTION
FLOW DIVIDER VALVE
FLOW DIVIDER VALVE
1. O-ring 2. Plug 3. Snap ring 4. Sleeve 5. Piston 6. Housing
The oil from the DDV enters chamber A and is divided according to a constant flow ratio. It then passes through throttles B1 and B2, then through chambers C1 and C2, and goes to the hydraulic control valve.
10-123-19
GD705A-4
STRUCTURE AND FUNCTION
HYDRAULIC PUMP
12
HYDRAULIC PUMP FOR WORK EQUIPMENT (KFP3223-23CFESE)
10-124
1.
Drive gear
8.
Drive gear
2. 3.
Snap ring
9.
Cover
Oil seal
10. Driven gear
4.
Flange
11. Center plate
5.
Gear case
12. Driven gear
6.
Coupling
13. Bushing
7.
Gear case
GD705A-4
STRUCTURE AND FUNCTION
HYDRAULIC PUMP
12
Unit: mm No.
Check Item
1.
Diameter of gear shaft
2.
Pressure plate
Criteria
Remedy
Standard size
Repair limit
---
24.895
---
6.676
Replace Replace mounting flange, cover, etc. Replace driven gear, drive gear Replace pump assembly
Replace
Wear of drive-in bushing
---
4.
Depth of gear contact traces on housing
---
Max. 0.12
---
Discharge
3.
Teflon layer is worn and red copper color portion of base metal is exposed for more than 150o
GD705A-4
Front pump (L.H. control valve) (EO10-CD: 50oC)
Rear pump (R.H. control valve) (EO10-CD: 50oC)
Speed (rpm)
Discharge pressure MPa {kg/cm2}
Standard discharge (O/min.)
Discharge limit (O/min.)
2,340
17.2 {175}
49
---
2,340
17.2 {175}
49
---
---
10-125
STRUCTURE AND FUNCTION
CIRCLE ROTATION MOTOR
12
CIRCLE ROTATION MOTOR
Orbit motor is used for circle rotation motor; the machine is mounted with this motor on drawbar. Star gear (6) turns with high hydraulic pressure, thereby rotating output shaft (1) which turns together with the star gear (6) and the main drive shaft (5). This output shaft is connected to circle rotation gear case. Since star gear (6) engages with disc valve drive shaft (8), disc valve (9) also turns, thus changing the position where the hydraulic oil to Geroler (7) enters.
1.
Output shaft
7.
Geroler housing
2.
Flange
8.
Disc valve drive shaft
3.
Oil seal
9.
Disc valve
4.
Taper roller bearing
10. Check valve
5.
Main drive shaft
11. Valve plate
6.
Star gear
12. Pump housing
HYDRAULIC PUMP TYPE GD705A-4 Roller
37.5 mm
Theoretical oil quantity
246 cc/rev.
Rated speed
603 rpm
Instantaneous maximum torque
68.5 kgm
Instantaneous maximum pressure
17.2 MPa (175 kg/cm2)
Weight
GD705A-4
18.8 kg
10-127
STRUCTURE AND FUNCTION
CIRCLE ROTATION MOTOR
12
Disc valve (9) is furnished with twelve oil holes; the oil of high pressure flows through six oil holes, and the other oil holes serve as a drain port. Disc valve (9) contacts the valve plate (11) with seven oil holes. These oil holes in the valve plate (11) are connected to the chamber made up of star gear (6) and Geroler (7). The oil of high pressure, which has entered to each travelling motor, goes into the chamber via the disc valve (9) and valve plate (11). When the oil of high pressure flows into the chamber, the star gear (6) starts running with the hydraulic pressure. When the star gear (6) rotates, disc valve (9) turns. Thus, the position where the high-pressure oil is delivered to the chamber, is shifted in regular sequence.
10-128
GD705A-4
STRUCTURE AND FUNCTION
CIRCLE ROTATION MOTOR
12 The star gear (6) rotates on its own axis and it also revolves around the center of Geroler. The rotation of star gear (6) is transmitted to the output shaft via the main drive shaft.
When star gear (6) makes 1/7 of a rotation left-ward on its own axis, it makes 6/7 of a revolution right-ward. Namely, when the star gear makes one revolution, it rotates 1/6 of a rotation on its own axis. As a result, compared with general hydraulic motors (the difference from the orbit motor can be understood more easily when compared with the trochoid motor), this orbit more makes available a torque 6 times as large as that possible with hydraulic motors. In addition, the rotating speed of the orbit motor can be reduced to as low as 1/6 speed of hydraulic motors. Nevertheless, the orbit motor is designed to be of the compact type.
GD705A-4
10-129
STRUCTURE AND FUNCTION
HYDRAULIC CYLINDER
12
HYDRAULIC CYLINDER BLADE LIFT CYLINDER
1.
Cap
2.
Cylinder head
3.
Cylinder
4.
Piston
5.
Wear ring
6.
Piston nut
7.
Bushing
8.
Piston ring
9.
Piston rod
10. Rod packing 11. Bushing 12. Dust seal
10-130
GD705A-4
STRUCTURE AND FUNCTION
HYDRAULIC CYLINDER
12 BLADE SIDE SHIFT CYLINDER
1.
Bushing
2.
Cylinder head
3.
Cylinder
4.
Piston
5.
Wear ring
6.
Piston nut
7.
Piston ring
8.
Piston rod
9.
Rod packing
10. Bushing 11. Dust seal 12. Bushing
GD705A-4
10-131
STRUCTURE AND FUNCTION
HYDRAULIC CYLINDER
12 DRAWBAR SHIFT CYLINDER
1.
Cap
2.
Cylinder head
3.
Cylinder
4.
Piston
5.
Wear ring
6.
Piston nut
7.
Piston ring
8.
Piston rod
9.
Rod packing
10. Bushing 11. Dust seal
10-132
GD705A-4
STRUCTURE AND FUNCTION
HYDRAULIC CYLINDER
12 LEANING CYLINDER
1.
Cylinder head
2.
Cylinder
3.
Piston
4.
Wear ring
5.
Piston nut
6.
Bushing (bottom side)
7.
Piston ring
8.
Piston rod
9.
Rod packing
10. Bushing 11. Dust seal 12. Bushing (head side)
GD705A-4
10-133
STRUCTURE AND FUNCTION
HYDRAULIC CYLINDER
12 ARTICULATE CYLINDER
POWER TILT CYLINDER 1.
Cylinder head
2.
Cylinder
3.
Piston
4.
Wearing
5.
Piston nut
6.
Bushing (bottom side)
7.
Piston ring
8.
Piston rod
9.
Rod packing
10. Bushing 11. Dust seal 12. Bushing (head side)
10-134
GD705A-4
STRUCTURE AND FUNCTION
HYDRAULIC CYLINDER
12 SCARIFIER CYLINDER (If equipped)
1.
Cylinder head
2.
Cylinder
3.
Piston
4.
Wearing
5.
Piston nut
6.
Bushing (bottom side)
7.
Piston ring
8.
Piston rod
9.
Rod packing
10. Bushing 11. Dust seal 12. Bushing (head side)
GD705A-4
10-135
STRUCTURE AND FUNCTION
HYDRAULIC CYLINDER
12 RIPPER CYLINDER
10-136
1.
Cylinder
2.
Piston
3.
Wearing
4.
Piston nut
5.
Piston ring
6.
Rod packing
7.
Bushing
8.
Dust seal
9.
Bushing (head side)
GD705A-4
STRUCTURE AND FUNCTION
HYDRAULIC CYLINDER
12
OUTLINE The hydraulic cylinder is a mechanism for converting fluid energy into mechanical energy for linear drive purposes. The cylinder has oil inlets and outlets at both head end (piston rod end) and the bottom end, and by applying oil pressure to both ends, the oil is alternately forced in and out of the cylinder resulting in the piston and piston rod being moved back and forth. Cylinders with this kind of action are referred to as double-acting cylinders and are used in motor grader.
STRUCTURE AND FUNCTION Cylinder Cylinders are made of steel piping with a base welded to the bottom. The inside of the piping is finished by honing in order to prevent oil leakage and abrasion with the packing. Cylinder head The cylinder head of motor grader is secured to the cylinder by cutting a thread into the head and screwing 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 cylinder oil through the gab between the cylinder head and piston rod. In addition, a dust seal is employed to prevent grit adhering to the piston rod from being carried into the cylinder when the rod is pushed in.
GD705A-4
10-137
STRUCTURE AND FUNCTION
HYDRAULIC CYLINDER
12
Unit: mm No.
Check item
Criteria Tolerance Standard size
1
Clearance between piston rod and bushing
Standard clearance
Clearance limit
55
-0.100 -0.174
+0.163 +0.006
0.106-0.337
0.6
Blade side shift
55
-0.100 -0.174
+0.163 +0.006
0.106-0.337
0.6
Drawbar shift
55
-0.100 -0.174
+0.163 +0.006
0.106-0.337
0.6
Leaning
45
-0.030 -0.019
+0.007 +0.152
0.026-0.182
0.6
Articulate
55
-0.100 -0.174
+0.163 +0.006
0.106-0.337
0.6
Power tilt
50
-0.030 -0.142
+0.164 +0.007
0.037-0.306
0.6
70
-0.100 -0.174
+0.271 +0.075
0.175-0.445
0.6
55
-0.100 -0.174
+0.163 +0.006
0.106-0.337
0.6
Blade lift
90
-
-
-
-
Blade side shift
50
-0.050 (-0.025) -0.15 (-0.064)
+0.142 +0.080
0.130-0.292 (0.105-0.250)
1.0
Drawbar shift
90
-
-
-
-
Leaning
50
-0.025 -0.064
+0.142 +0.080
0.105-0.206
1.0
Articulate
60
-0.030 -0.076
+0.174 +0.100
0.130-0.350
1.0
Power tilt
60
0 -0.019
0 -0.015
0-0.004
0.6
75
+0.035 0
+0.174 +0.100
0.065-0.174
1.0
50
-0.025 -0.064
+0.142 +0.080
0.105-0.206
1.0
(If equipped) Scarifier (If equipped)
2
Hole
Blade lift
Ripper
Clearance between piston rod support shift (ball joint) and bushing (rod end)
Shaft
Remedy
Ripper (If equipped) Scarifier (If equipped)
Replace
Replace
(): For serial No. 21086 and up
10-138
GD705A-4
STRUCTURE AND FUNCTION
HYDRAULIC CYLINDER
12 Unit: mm No.
Check item
Criteria Tolerance Standard size
3
Clearance between cylinder bottom yoke (Support, support shaft, support ball joint) and bushing (rod end)
Standard clearance
Clearance limit
70
-0.100 -0.174
+0.271 +0.095
0.195-0.445
1.0
Blade side shift
70
-0.100 -0.174
+0.271 +0.095
0.195-0.445
1.0
(Blade side shift)
(50)
(+0.025 +0.064)
(+0.142 +0.080)
(0.105-0.206)
(1.0)
Drawbar shift
90
-
-
-
-
Leaning
50
-0.025 -0.064
+0.163 +0.006
0.031-0.227
1.0
Articulate
60
-0.030 -0.076
+0.174 +0.100
0.130-0.350
1.0
Power tilt
75
-0.100 -0.174
+0.074 0
0.100-0.248
1.0
90
-0.035 0
+0.207 +0.120
0.085-0.207
1.0
50
-0.025 -0.064
+0.142 +0.080
0.105-0.206
1.0
Replace
(If equipped) Scarifier (If equipped)
Tightening torque for piston nut
Hole
Blade lift
Ripper
4
Shaft
Remedy
Blade lift
1422 ± 142 Nm {145 ± 14.5 kgm} (785 ± 78.5 Nm {80 ± 8 kgm})
Blade side shift
1422 ± 142 Nm {145 ± 14.5 kgm} (785 ± 78.5 Nm {80 ± 8 kgm})
Drawbar shift
1422 ± 142 Nm {145 ± 14.5 kgm} (785 ± 78.5 Nm {80 ± 8 kgm})
Leaning
1079 ± 107 Nm {110 ± 11.0 kgm} (785 ± 78.5 Nm {80 ± 8 kgm})
Articulate
1422 ± 142 Nm {145 ± 14.5 kgm}
Power tilt
1422 ± 142 Nm {145 ± 14.5 kgm}
Ripper (If equipped) Scarifier (If equipped)
3972 ± 397 Nm {405 ± 40.5 kgm}
1422 ± 142 Nm {145 ± 14.5 kgm} Retighten
5
Tightening torque for cylinder head
Blade lift
677 ± 67.5 Nm {69 ± 6.9 kgm}
Blade side shift
677 ± 67.5 Nm {69 ± 6.9 kgm}
Drawbar shift
677 ± 67.5 Nm {69 ± 6.9 kgm}
Leaning
677 ± 67.5 Nm {69 ± 6.9 kgm}
Articulate
932 ± 93.2 Nm {95 ± 9.5 kgm}
Power tilt
785 ± 83.4 Nm {80 ± 8.5 kgm}
Ripper (If equipped) Scarifier (If equipped)
927 ± 103 Nm {94.5 ± 10.5 kgm}
677 ± 67.5 Nm {69 ± 6.9 kgm} (): For serial No. 21086 and up
GD705A-4
10-139
STRUCTURE AND FUNCTION
WORK EQUIPMENT CONTROL
12
WORK EQUIPMENT CONTROL
OUTLINE • Turn tilt lever (5) of the tilt mechanism for the steering wheel and instrument panel to release the lock, set the steering wheel to the desired position, then turn the lever again to lock the tilt. Tilt angle: 10° (stepless)
1.
Blade lift (R.H.) lever
9.
2.
Leaning lever
10. Blade lift (L.H.) lever
3.
Blade side shift lever
11. Work equipment control lever
4.
Power tilt lever
12. Work equipment control lever
5.
Scarifier lever (if equipped)
13. Console box tilt pedal
6.
Steering wheel tilt lever
14. Dowel pin
•
7.
Articulate lever
15. Control valve (for circle reverse)
8.
Circle rotation lever
Tilt mechanism for console box. • When tilt pedal (12) is depressed, dowel pin (13) 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
Drawbar shift lever
GD705A-4
STRUCTURE AND FUNCTION
WORK EQUIPMENT CONTROL
12
GD705A-4
10-141
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12
WORK EQUIPMENT DRAWBAR
1.
Shim
2.
Ball joint
3.
Nut
4.
Drawbar
5.
Guide
6.
Shim
7.
Bolt
8.
Guide
9.
Shim
10. Bolt 11. Bolt
10-142
GD705A-4
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12 CIRCLE ROTATION GEAR
★
Use CLASS-CD SAE90 gear oil for all seasons.
The circle rotation gear is driven by an oil motor through coupling (3). The joint (11) and circle pinion gear (6) are connected by a shear pin (10). If an abnormal torque is transmitted from the blade, the shear pin (10) is cut through at (a) and prevents breakage of blade system.
1.
Drain plug
2.
Worm gear
3.
Coupling
4.
Case
5.
Worm wheel
6.
Gear (circle pinion gear)
7.
Shaft
8.
Plate
9.
Bolt
10. Shear pin 11. Joint 12. Pin 13. Lock plate 14. Oil filler plug
GD705A-4
10-143
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12 LIFTER
10-144
1.
Bracket (Upper)
2.
Shim
3.
Bolt
4.
Bracket (Lower)
5.
Yoke
6.
Pin
7.
Busing
8.
Pin
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
1.
Bank lock solenoid valve
2.
Pin
3.
Piston
4.
Spring
5.
Air tube
GD705A-4
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12 REAR MOUNT RIPPER (If equipped)
Ripper lifting height and digging height can be adjusted with hydraulic cylinder (1). Since the point tips cut into the ground under the load of the ripper’s heavy weight, the ripper easily performs heavy-duty digging work which cannot be done by the scarifier. Two kinds of points are selectively used: A short point for heavy-duty work and a long point for ordinary work.
GD705A-4
1.
Ripper cylinder
2.
Pin
3.
Bracket
4.
Shank pin
5.
Shank
6.
Point
10-147
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12 SCARIFIER (If equipped)
The lifting height and digging depth of the scarifier can be changed by moving the connecting holes (a), (b) and (c) of the rod (5) and pipe (6). Also, the digging angle, lifting height and digging depth of the scarifier teeth (8) can be changed by moving bolt (9) into holes (e), (f) or (g) on the scarifier body. When in (g) position especially, the blade can be revolved 360o, when the scarifier teeth are extracted and the scarifier raised up.
1.
Scarifier cylinder
2.
Arm
3.
Scarifier lift arm
4.
Pin
5.
Rod
6.
Pipe
7.
Scarifier body
8.
Scarifier teeth
9.
Bolt
10. Wedge 11. Pin
10-148
GD705A-4
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12 BLADE ACCUMULATOR SYSTEM (If equipped)
1.
Bolt
6.
Bolt
11. Tube
2.
Bolt
7.
Accumulator
12. Bracket
3.
Pilot check valve
8.
Clip
13. Nipple
4.
Solenoid valve
9.
Valve
5.
Cover
10. Nipple
GD705A-4
14. Tube 15. Bracket
10-149
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12
10-150
GD705A-4
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12
GD705A-4
10-151
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12
FUNCTION When oil pressure is applied from the blade cylinder, the pressurized oil flows to the accumulator through the solenoid valve, pushing valve (6). This in turn pushes valve (4), allowing the oil to flow into shell (2) from the blade cylinder. Thereby, bladder (3) is compressed. Consequently, the shock imposed on the blade cylinder is reduced by the compressible amount of the bladder. When the oil pressure in the cylinder drops, the
10-152
bladder expands by the gas pressure in bladder (3), allowing the oil in the shell to drain out until the oil pressure in the shell balances that from the blade cylinder side. At this time, valve (5) on the underside of the accumulator closes throttling the return oil. This prevents the oil in shell (2) from flowing out abruptly and prevents the bladder from striking against the inside of the shell. The flow of oil in the accumulator hydraulic circuit is repeated smoothly to reduce the shock imposed on the blade.
GD705A-4
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12
INSTALLATION PROCEDURE 1. 2.
3. 4.
Install valve (9) and elbow on accumulator body (7). Hold the accumulator body with clip (8) and temporarily attach the accumulator body to the frame with bolts (6) and washers. Temporarily attach solenoid valve bracket (12) to the frame bracket (15) with bolts (2) and washers. Connect nipple (13), which has nipples for tubes (14) and (11) on the underside of solenoid valve bracket, to nipple in advance, and tighten them together.
GD705A-4
5.
6. 7.
Since the system is set up according to this procedure must be provided on each side of the frame, follow the above procedure again to form the same system on the other side of the frame. After connecting the piping, tighten the temporarily attached portions positively. Secure solenoid valve (4) to the solenoid valve bracket (12).
10-153
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12 DRAWBAR
Unit: mm No.
Check item
Criteria Tolerance Standard size
1
Wear of drawbar ball joint end
Shaft
Hole
-0.05 -0.15
+0.1 0
150
2
Clearance between circle and drawbar
10-154
Remedy
Standard clearance
Clearance limit
0.05-0.25
-
Standard clearance
Clearance limit
1.5
1.0 - 2.0
GD705A-4
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12 BLADE LIFTER EQUIPMENT
Unit: mm No.
Check item
Criteria Tolerance
Standard clearance
Clearance limit
+0.071 +0.001
0.037-0.161
0.6
+0.074 0
0.100-0.248
1.0
Standard size 1
Shaft
Hole
85
-0.036 -0.090
70
-0.100 -0.174
Clearance between yoke and bushing
2
Clearance between blade side shift cylinder bottom side yoke and bushing
3
Wear of lifter
4
Axial clearance of yoke
GD705A-4
Remedy
Standard thickness of shim: 2
Replace
Replace
Standard clearance
Clearance limit
0.3 - 0.8
1.7
Replace
10-155
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12 CIRCLE ROTATION GEAR
Unit: mm No.
Check item
Criteria
Remedy
Tolerance
Standard clearance
Repair
+0.057 +0.010
0.040-0.117
0.3
+0.226 0.069
0.035-0.221
0.3
Standard size 1
Shaft
Hole
65
-0.030 -0.060
65
-0.035 -0.005
Clearance between worm gear shaft and bushing
2
Clearance between worm gear shaft and bushing
3
Backlash between worm and worm wheel
4
Clearance between pinion and wear plate
5
Wear of pinion gear
Standard clearance
Clearance limit
0.3 - 0.5
2.0
0.1 - 0.5
0.6
Standard size
Repair limit
25
20
Replace
Replace
Adjust
Replace
Starting torque 0.5 - 1.0 kgm
6
Preload of worm shaft bearing
7
Tightening torque of filter plug
93.2 122.6 Nm {9.5 - 12.5 kgm}
8
Tightening torque of drain plug
93.2 122.6 Nm {9.5 - 12.5 kgm}
10-156
limit
(when worm wheel is not meshed)
Adjust
GD705A-4
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12 SCARIFIER (If equipped)
Unit: mm No.
Check item
Criteria Tolerance
Standard clearance
Clearance limit
+0.207 +0.120
0.156-0.297
0.7
+0.1 0
0.05-0.25
0.5
Standard size 1
2
3
Clearance between shaft and bushing
Wear of ball joint
Wear of tooth
GD705A-4
Remedy
Shaft
Hole
110
-0.036 -0.090
70
-0.05 -0.015
Standard size
Repair limit
Standard
450
330
With point tooth
450
410
Replace bushing
Adjust shim
Replace tooth
10-157
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12 REAR MOUNT RIPPER (If equipped)
Unit: mm No.
Check item
Criteria Tolerance Standard size
1
Clearance between
Remedy
Standard clearance
Clearance limit
Shaft
Hole
60
-0.025 -0.055
+0.046 0
0.025-0.101
0.5
Replace
pin and bushing
2
Clearance between pin and bushing
60
-0.025 -0.055
+0.046 0
0.025-0.101
0.5
Replace
3
Clearance between pin and bushing
75
-0.030 -0.076
+0.089 +0.035
0.065-0.165
0.5
Replace
4
Wear of point
10-158
Standard size
Repair limit
290
150
Replace
GD705A-4
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12 BLADE AND CIRCLE
Unit: mm No.
Check item
1
Clearance between blade shift cylinder support yoke and adjuster
Criteria Tolerance Standard size
80 2
Wear of cutting edge
3
Wear of side edge
4
Wear of blade rail
5
Wear of blade rail guide
Shaft
Hole
-0.030 -0.076
+0.030 0
Remedy
Standard clearance
Clearance limit Replace
0.030-0.106
0.5
Max. 10 mm (from blade base) Clearance limit: Side face 25 Max. 10 mm (from blade base) Replace
GD705A-4
Repair limit:
Height 105 Thickness 22
Repair limit: 10
10-159
20 TESTING AND ADJUSTING 12 STANDARD VALUE TABLE Standard value table for engine . . .20-2 Standard value table for chassis . .20-3 TESTING AND ADJUSTING. . . . . . .20-101 TROUBLESHOOTING . . . . . . . . . . . .20-201
★ 1.
2.
3.
Note the following when making judgments using the standard value tables for testing, adjusting or troubleshooting. 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. 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. 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 unauthorized 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 GD705A-4
Engine model
S6D125-1
Item Engine speed
Necessary starting speed
Condition, etc.
Standard value
High idling speed
rpm
2200 ± 50
---
Low idling speed
rpm
650 +50 0
---
0oC
rpm
Min. 100
---
-20oC (Using starting aid)
rpm
Min. 85
---
Max. 2.94 {300}
Max. 7.48 {762}
Intake resistance
All speed
Intake pressure
All speed
kPa {mmHg}
Min. 61.2 {460}
Min. 53.2 {400}
oC
Max. 600
Max. 650
Max. 4.0
---
At high idling
Bosch scale
Max. 1.0
---
Intake valve
mm
0.33
0.33
mm
0.71
0.71
MPa {kg/cm2}
31.4 - 3.53 {32 - 36}
---
(rpm)
(240 - 260)
kPa {mmH2O}
Max. 1.47 {150}
1.96 {200}
MPa
0.294 - 0.491 {3.0 - 5.0}
0.206 {2.1}
{kg/cm2}
Min. 0.157 {1.6}
0.069 {0.7}
Exhaust temperature Exhaust gas color
Engine body
Valve clearance at 20oC
Compression pressure (SAE30)
Oil pressure (SAE30, Oil temperature:
All speed (intake air temp.: 20oC) Quick acceleration
Exhaust valve Oil temperature: 40 - 60oC (Engine speed)
Blow-by pressure (SAE30)
At high idling (Water temperature operating range)
Cooling system
Fuel system
At high idling
20-2 1
Permissible value
Unit
kPa {mmH2O}
Lubrication system
Intake and exhaust system
Performance
Category
Machine model
Min. 80oC) At low idling
(Water temperature operating range)
{kg/cm2}
MPa
Oil temperature
All speed (Oil in oil pan)
oC
80 - 110
120
Oil consumption ratio
At continuous rated output (Ratio to fuel consumption)
%
Max. 0.5
1.0
Fuel injection pressure
Nozzle tester
MPa {kg/cm2}
24.5 {250}
22.1 {225}
Fuel injection timing
B.T.D.C.
Degree
26 ± 1
26 ± 1
Opening pressure (Differential pressure)
MPa
0.069 ± 0.010 {0.7 ± 0.1}
0.069 ± 0.010 {0.7 ± 0.1}
Radiator pressure valve function Fan speed Fan belt tension
At rated rpm At high idling speed Deflect when pushed with a force of 6 kg
{kg/cm2} rpm mm
---
---
1,870
---
13
10 - 16
GD705A-4
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
12
STANDARD VALUE TABLE FOR CHASSIS Machine model Category
Test condition
Standard value
Fuel control lever
Amount of movement from center of lever knob from slow to full rotation
110 ± 10 mm
Accelerator pedal
Amount of movement in up-down direction
48 ± 10 mm
Inching pedal
Amount of movement in up-down direction
55 ± 10 mm
Parking brake lever
Ability to hold in stopped condition on 1/5 incline paved surface
Stroke
Item
Gear shift lever
Engine stopped, stoke of tip of lever
55 ± 10 mm
1→2
Engine stopped, stoke of tip of lever
50 ± 10 mm
2→3
Engine stopped, stoke of tip of lever
45 ± 10 mm
3→4
Engine stopped, stoke of tip of lever
45 ± 10 mm
4→5
Engine stopped, stoke of tip of lever
45 ± 10 mm
5→6
Engine stopped, stoke of tip of lever
45 ± 10 mm
6→7
Engine stopped, stoke of tip of lever
45 ± 10 mm
Operating force Heat balance
Engine stopped, stoke of tip of lever
Fuel control lever
88.3 ± 19.6 N {9 ± 2 kg}
Accelerator pedal (depression force)
Maximum value until just before stroke end
98.1 ± 19.6 N {10 ± 2 kg}
Inching pedal
Maximum value until just before stoke end
68.6 ± 19.6 N {7 ± 2 kg}
Brake pedal (depression force)
Measured with wheels completely locked
Max. 294 N {Max. 30 kg}
Parking brake lever
Ability to hold in stopped condition on 1/5 incline paved surface
Max. 196 N {Max. 20 kg}
Gear shift lever
Maximum value until just before stoke end
Max. 49 N {Max. 5 kg}
Engine cooling water
•
Oil and water levels are normal
Max. 100oC
Engine oil temperature
•
Air temperature 40oC conversion
Max. 120oC
Transmission oil temperature
•
Performed at a continuous traction (F-2)
Max. 120oC
Final drive oil temperature
•
On a concrete road surface
Max. 120oC
Tandem case oil temperature
•
Using thermistor
Max. 120oC
Hydraulic oil temperature
•
Performed with thermostat open
Max. 120oC
Height of inching pedal (during operation) Others
45 ± 10 mm
Maximum value at tip of lever until just before stroke end
Height of inching pedal (when not operating)
120 ± 5 mm Height from the floor to the center of the stopper mounting bolt
Inching pedal play
Transmission operating
GD705A-4
Within range of 2 - 3 notches
N→1
7→8
Power train
GD705A-4
15 ± 1 mm 0 mm
At engine full rotation, F-6, using both the parking brake and the wheel brake, the engine should stop within the ruled value when the inching pedal is released.
Within 3.0 sec.
20-3 1
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
12 Machine model Category
Item
GD705A-4 Test condition
20-4 1
Operating force
5.35 turns ± 50 degrees
Leaning lever
Travel at the tip of the lever
45 ± 10 mm
Articulation lever
Travel at the tip of the lever
40 ± 10 mm
Steering wheel (turning direction)
When traveling at engine slow rotation, F-1
Max. 50 N {Max. 5 kg}
Leaning lever
Maximum value until just before stroke end
Max. 50 N {Max. 5 kg}
Articulation lever
Maximum value until just before stroke end
Max. 50 N {Max. 5 kg}
Tire vibration
Measure tire side surface of both front and rear wheels with dial gauge
Max. 7 mm
Front wheel
0.343 ± 0.020 MPa
Rear wheel
{3.5 ± 0.2 kg/cm2}
Camber
Level paved surface
1.5 degree ± 50%
Toe in
Level paved surface
8.5 ± 1.5 mm
Leaning angle
Level paved surface
23.5 ± 2 degrees
Wheel bearing band temperature
Measure at surface of wheel cap after traveling 10 km
Max. 40oC
Steering wheel play
At engine slow rotation, and with the tires floating measured at the outside circumference of the steering wheel
10 - 12 mm
Tire air pressure
Wheels
Steering system
Stroke
Steering wheel turning angle
Standard value
GD705A-4
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
12 Machine model Category
Work equipment
Operating force
40 ± 10 mm
Blade side shift
Engine stopped, stroke at the tip of the lever
40 ± 10 mm
Drawbar shift
Engine stopped, stroke at the tip of the lever
40 ± 10 mm
Circle rotation
Engine stopped, stroke at the tip of the lever
45 ± 10 mm
Power tilt
Engine stopped, stroke at the tip of the lever
45 ± 10 mm
Work equipment control lever
Maximum value until just before stroke end
Max. 49 N {Max. 5 kg}
1. Blade 1-1. Blade lifting speed (rising)
Oil temperature: 40 ± 5oC When engine at rated rotation, the speed of lifting or lowering the blade with the lower edge of the blade 50 - 150 mm above ground.
1-2. Blade lifting speed (lowering) 1-3. Speed of cross-feed by circle move - left 1-4. Speed of cross-feed by circle movement - right Performance
Standard value
Engine stopped, stroke at the tip of the lever
1-5. Speed of side shift in rotation to circle - left 1-6. Speed of side shift in rotation to circle - right 1-7. Turning speed by circle rotation
GD705A-4
Test condition
Blade lift left, right Work equipment control lever
Stroke
Item
GD705A-4
When engine at rated rotation and the height of the lower edge of the blade 100 mm, speed of left and right side shifting by a level circle movement of 200 mm under standard position. When engine at rated rotation and the height of the lower edge of the blade 100 mm, speed of the left and right side shifting in rotation to a circle of a level distance of 200 mm under standard position.
210 ± 8.4 mm/s 140 ± 5.6 mm/s 120 ± 4.8 mm/s 180 ± 7.2 mm/s 140 ± 5.6 mm/s 220 ± 8.8 mm/s
Angle speed with engine at rated rotation speed
14.5 ± 0.87 degrees/s
1-8. Hydraulic drift of blade (hanging down)
Amount of lowering of cylinder when the blade is suspended symmetrically perpendicular to the machine
Max. 10 mm / 10 min
1-9. Hydraulic drift of machine (support by blade)
Amount of cylinder sinking when the lower edge of the blade is in contact with the ground and the front wheels floating.
Max. 20 mm / 10 min
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
1
Engine speed
2
Battery S.G.
3
Freezing temperature of cooling water
4
Water temperature, oil temperature, air intake temperature
Fault finding tool
Part No.
Remarks
Multi-meter
799-203-8000
Digital reading, pressure sensing type 60 - 19,999 rpm
Battery coolant tester
795-500-1000
1.100 - 1.300 -5 to -50oC
Thermistor temperature gauge
799-101-1502
-99.9 - 1299oC
5
Exhaust temperature
6
Lubrication oil pressure
0 - 0.98 MPa {0 - 10 kg/cm2}
7
Fuel pressure
0 - 1.96 MPa {0 - 20 kg/cm2}
8
Intake pressure, exhaust pressure
9
Blow-by pressure
0 - 9.81 kPa {0 - 1,000 mmH2O}
10
Intake resistance
-9.81 - 0 kPa {-1,000 - 0 mmH2O}
11
Compression pressure
Engine pressure measuring kit
799-101-5002
Compression gauge
795-502-1590
Adapter
795-502-1360
0 - 199 kPa {0 - 1,500 mmHg}
{0 - 70 kg/cm2}
12
Blow-by pressure
Blow-by checker
799-201-1504
0 - 4.91 kPa {0 - 500 mmH2O}
13
Valve clearance
Feeler gauge
795-125-1360
Intake 0.33 mm, Exhaust 0.71 mm
14
Exhaust gas color
Handy smoke checker
799-201-9000
Dirtiness 0 - 70% with standard color (Dirtiness% x 1/10 = Bosch scale)
15
Water and fuel content in oil
Engine oil checker
799-201-6000
Provided with 0.1 and 0.2% water content standard samples
16
Fuel injection pressure Fuel injection nozzle spray condition
Nozzle tester
Commercially available
0 - 2.94 MPa {0 - 300 kg/cm2}
17
Coolant quality
Water quality tester
799-202-7001
PH, nitrite ion concentration
18
Pressure valve function Leakage in cooling water system
Radiator cap tester
799-202-9001
0 - 0.196 MPa {0 - 2 kg/cm2}
19
Radiator blockage (wing speed)
Anemometer (Air speed gauge)
799-202-2001
0 - 40 m/s
20
Engine cranking
Cranking kit
795-610-1000
Engine with DC24V starting motor
21
Electrical circuit
Tester
Commercially available
Current, Voltage, Resistance
20-102 1
GD705A-4
TESTING AND ADJUSTING
TESTING AND ADJUSTING VALVE CLEARANCE
12
TESTING AND ADJUSTING VALVE CLEARANCE Special tool
A ★
Part Number
Part Name
Q’ty
795-125-1360
Feeler gauge
1
Adjust clearance between rocker lever and top of crosshead to following valve. Intake valve (at 20oC)
Exhaust valve (at 20oC)
0.33 mm
0.71 mm
1.
When adjusting the valve clearance for cylinders No. 3 to 6, remove air cleaner.
2.
Remove cylinder head cover.
3.
Rotate the crankshaft in the normal direction to align pointer (2) with the 1.6 TOP mark or crankshaft damper (1). When rotating, check the movement of the intake valves of No. 1 cylinder and No. 6 cylinder. Set with No. 1 cylinder at compression top dead center. ★ When No. 1 cylinder is at compression top dead center, the intake valve of No. 6 cylinder opens.
4.
When No. 1 cylinder is at compression top dead center, adjust the valves marked •. Then rotate the crankshaft one turn in the normal direction, set No. 6 cylinder to compression top dead center, and adjust the valves marked o.
5.
To adjust, insert tool A between rocker lever (3) and crosshead (4) and turn adjustment screw (5) until clearance is a sliding fit.
6.
Tighten locknut (6) to hold adjustment screw in position. Locknut: 66.15 ± 7.35 Nm {6.75 ± 0.75
★
kgm} After adjusting No. 1 Cylinder at compression top dead center, it is also possible to turn the crankshaft 120o each time and adjust the valve clearance of each cylinder according to the firing order. •
★
Firing order: 1 - 5 - 3 - 6 - 2 - 4
After tightening the locknut, check the clearance again.
GD705A-4
20-103 1
TESTING AND ADJUSTING
MEASURING COMPRESSION PRESSURE
12
MEASURING COMPRESSION PRESSURE
Special tools Part Number
Part Name
Q’ty
A
795-502-1360
Adapter
1
B
795-502-1590
Compression gauge
1
★
Warm up the engine (oil temperature: 40 - 60oC) before measuring the compression pressure.
1.
Adjust valve clearance
2.
Remove spill tube (1), then disconnect fuel injection tube (2) and remove nozzle holder assembly (3). ★ When removing the nozzle holder assembly, use the mounting bolt of the spill pipe and lever the nozzle holder assembly out with a bar.
3.
Install tool A in mount of nozzle holder assembly, and tighten to specified torque. Mounting bolt: 24.5 ± 4.9 Nm {2.5 ± 0.5 kgm}
4.
Connect tool B to adapter.
5.
Place fuel control lever (4) in NO INJECTION position. Crank engine with starting motor and measure compression pressure. ★ Measure the compression pressure at the point where the compression gauge indicator remains steady. ★ If the adapter mount is coated with a small amount of oil, leakage is reduced. If the fuel control lever is not set to the NO INJECTION position, the engine will start. When measuring the compression pressure, be careful not to touch the exhaust manifold or muffler, or to get caught in rotating parts.
20-104 1
GD705A-4
TESTING AND ADJUSTING
MEASURING BLOW-BY
12
MEASURING BLOW-BY Special tools A
Part Number
Part Name
799-201-1504
Blow-by checker
Q’ty 1
1.
Measuring blow-by Connect tool A to breather hose. ★ Check that the oil filler and dipstick are properly sealed. 2. Precautions when measuring blow-by ★ Measure blow-by with the engine properly warmed up (oil temperature: 60oC) and running 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 condition 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 discoloration 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 alternator 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 tension. 2.
Check each pulley for damage, wear of V-groove, and wear of the V-belt. Be particularly careful to check that the V-belt does not contact the bottom of the V-groove.
3.
If the belt has elongated and there is no more allowance for adjustment, or it the belt is cut or cracked, replace the belt.
4.
When adjusting the V-belt, tighten nut (1) or (2) (the nut in the opposite direction from the direction to move the alternator), then move the alternator. When the position is fixed, tighten the other nut and the fulcrum nut (3) to hold alternator (4) in position.
5.
If the V-belt has been replaced, adjust again after operating for 1 hour.
20-106 1
GD705A-4
TESTING AND ADJUSTING
TESTING AND ADJUSTING FUEL INJECTION TIMING
12
TESTING AND ADJUSTING FUEL INJECTION TIMING When installing the fuel injection pump on the engine, test and adjust the fuel injection timing as follows: • Aligning match mark Use this method when the fuel injection pump is put back on the same engine without being repaired. • Delivery check method Use this method when replacing or installing a repaired fuel injection pump. ★ Set the No. 1 cylinder to top dead center when testing and adjusting. 1.
Testing and adjusting by aligning match mark 1) Set the No. 1 cylinder to top dead center, then rotate the crankshaft 30o-40o in the reverse direction. Next, rotate the crankshaft in the normal direction and align the fuel injection line on crankshaft damper (1) with pointer (2). 2) ★
Check that line "a" on the injection pump and line "b" on the coupling are aligned. If the lines are not aligned, loosen nut (3). Move the coupling to align the lines, then tighten the nut. Nut: 60.8 ± 2.0 Nm {6.2 ± 0.2 kgm}
2.
Testing and adjusting fuel injection timing by delivery check. 1) Disconnect fuel injection tube (4) on No. 1 cylinder. 2) Remove delivery valve holder (5).
GD705A-4
20-107 1
TESTING AND ADJUSTING
TESTING AND ADJUSTING FUEL INJECTION TIMING
12 3) 4)
5)
3.
Remove spring (6) and delivery valve (7), then install delivery valve holder (5) again. Place fuel control lever at FULL position, then operated priming pump and rotate crankshaft slowly in normal direction. Check point where fuel stops flowing from delivery valve holder. Check that fuel injection timing line on crankshaft damper and pointer are aligned at point where fuel stops flowing. ★ BEYOND injection timing line: Timing RETARDED ★ BEFORE injection timing line: Timing ADVANCED
If the test shows that the fuel injection timing in incorrect, adjust as follows. 1) Set the No. 1 cylinder to top dead center, the rotate the crankshaft 30o-40o in the reverse direction. 2)
Next, rotate the crankshaft in the normal direction and align the fuel injection line on the crankshaft damper with the pointer correctly.
3)
Loosen nut (3) in oblong hole of mounting flange of fuel injection pump. Operate priming pump and rotate flange at pump end a little at a time. Stop at point where fuel stops flowing from delivery valve holder.
4)
Tighten nut in oblong hole of mounting flange of fuel injection pump. ★ After tightening the nut, check again that the fuel injection timing is correct.
20-108 1
GD705A-4
TESTING AND ADJUSTING
INCHING PEDAL
12
INCHING PEDAL INCHING PEDAL STROKE AND OPERATING FORCE INCHING PEDAL STROKE CHECK Use convex rule 1 to measure the length of the movement from up to down from beginning to end of depressing inching pedal (1).
INCHING PEDAL OPERATING FORCE CHECK Use push-pull scale 2 to measure the maximum value in the stroke to just before the inching pedal stroke end.
GD705A-4
20-109 1
TESTING AND ADJUSTING
HYDROSHIFT TRANSMISSION
12
HYDROSHIFT TRANSMISSION Special tool A
Part Number
Part Name
Q’ty
799-101-5002
Hydraulic tester
1
TRANSMISSION PILOT OIL PRESSURE CHECK 1. Remove measuring plug (2) and attach hydraulic gauge A (5.88 MPa {60 kg/cm2}). 2. Start engine and measure pilot oil pressure of transmission.
TRANSMISSION OIL PRESSURE CHECK (MODULATING PRESSURE) 3. Remove measuring plug (3) and attach oil pressure gauge A (5.88 MPa {60 kg/cm2}). 4. Start engine and measure pilot oil pressure of transmission. ★ To confirm modulating set pressure only, it is necessary to start the engine. ★ To confirm clutch pressure for each gear shift (except F and R) start engine and measure with the inching pedal depressed.
TRANSMISSION LUBRICATION PRESSURE CHECK 1. Remove measuring plug (2) and attach hydraulic gauge A (25 kg/cm2). 2. Start engine and measure lubricating oil pressure of transmission. Unit MPa {kg/cm2} Measurement check items
Standard value
Plug (2)
Pilot oil pressure
1.422 ± 0.049 {14.5 ± 0.5}
Plug (3)
Modulating pressure
2.501 ± 0.147 {25.5 ± 1.5}
Plug (1)
Lubrication oil pressure
0.245 ± 0.147 {2.5 ± 1.5}
20-110 1
GD705A-4
TESTING AND ADJUSTING
HYDROSHIFT TRANSMISSION
12 TRANSMISSION OIL PRESSURE ADJUSTMENT (MODULATING PRESSURE) ★ If oil pressure is outside standard value, adjust according to the following procedure: 1.
Remove transmission control valve assembly (4).
2.
Remove cover (5) and remove valve (6).
3.
Increase or decrease shims (7) and adjust tension of spring (8). ★ Increase shims and oil pressure rises. Decrease shims and oil pressure falls. ★ Standard shim thickness: 1.0 mm ★ Kind of shim: 0.5 mm
4.
After adjustment, confirm that transmission oil pressure (modulating pressure) is within standard value, following procedure of TRANSMISSION OIL PRESSURE CHECK (MODULATING PRESSURE).
GD705A-4
20-111 1
TESTING AND ADJUSTINGTRANSMISSION CONTROL LEVER STROKE AND OPERATING FORCE 12
TRANSMISSION CONTROL LEVER STROKE AND OPERATING FORCE STROKE CHECK AND ADJUSTMENT Use convex rule 1 to measure the stoke of the gear shift lever at the tip of each lever between each gear shift. ★ Measure with engine stopped. ★ The stroke of gear shift lever is determined by the working distance of the lever notch on the transmission side. However, the neutral position of the gear shift lever is determined by adjusting rod (2) and cable (3) without removing the gear shift lever guide.
OPERATING FORCE CHECK AND ADJUSTMENT Use push-pull scale 2 to measure maximum value in the stroke to just before the stroke end of each gear at the gear shift lever (1) tip. ★ Measure with engine stopped. ★ The operating force of the gear shift lever is determined on transmission side. However, when the operating force is above standard value, check the movement of connecting rod. If it is normal, disassemble the transmission side and check the operating condition of the movement of the spool.
20-112 1
GD705A-4
TESTING AND ADJUSTING
ADJUSTING F/R CONTROL CABLE
12
ADJUSTING F/R CONTROL CABLE
1.
Set screwed-in length (L1) of yoke (3) of the cable at the transmission end to11 mm, then tighten the nut.
2.
Install yoke (4) to the cable at the control lever end. Screwed in length (l2): 25 mm
3.
Install the cable to the machine, and adjust the position of locknut C to apply slight tension to the cable.
GD705A-4
20-113 1
TESTING AND ADJUSTING
ADJUSTING TRANSMISSION CONTROL LINKAGE
12
ADJUSTING TRANSMISSION CONTROL LINKAGE
1.
Set rods (2), (3), and (4) to the following length. A:
Approx. 115 mm
B:
520 mm
C:
413.5 mm
2.
Install each rod to the intermediate lever. ★ When installing rod (2) to control lever (1), align with the position of punch mark A.
3.
Adjust the length of rod (2) so that control lever (1) and the neutral position of the transmission lever are aligned.
20-114 1
GD705A-4
TESTING AND ADJUSTING
ADJUSTING TRANSMISSION CONTROL LINKAGE
12 4.
Check that the transmission shifts correctly to each gear position. ★ If the movement of control lever (1) to each gear position differs greatly from the mark on the control lever guide, move the mounting position of rod (2) to control lever (1). ★ It is possible to adjust the stroke of the cable by changing the mounting position of the end rod.
GD705A-4
20-115 1
TESTING AND ADJUSTING
STEERING WHEEL
12
STEERING WHEEL
CHECKING STEERING WHEEL PLAY Standard play: 10 to 12 mm When the play of the steering wheel is outside the standard value or vibrates abnormally or pulls, replace the steering valve assembly.
CHECKING STEERING WHEEL OPERATING FORCE
Using push-pull scale 1, measure the operating force of the steering wheel. ★ Measure operating force of the steering wheel with the engine idling and with the wheels on the ground.
20-116 1
GD705A-4
TESTING AND ADJUSTING
TIRE
12 TIRE
CHECKING TIRE PLAY FRONT WHEEL CHECK 1.
2.
Start the engine and raise the front wheel off the ground, using the blade or scarifier as a jack. Use dial gauge 1 to measure the tire play while rotating the tire (1) by hand.
REAR WHEEL CHECK 1. Start the engine and raise four wheels by operating the blade. 2.
Insert block 2 in place at rear side of chassis.
3.
Use dial gauge 1 to measure the tire play while rotating the tire (2) by hand. Measure with engine stopped.
CHECKING TIRE AIR PRESSURE Use tire gauge 1 to measure the air pressure of front and rear wheels.
GD705A-4
20-117 1
TESTING AND ADJUSTING
CHECKING TOE-IN
12
CHECKING TOE-IN
CHECKING TOE-IN 1.
Put steering and leaning in central position and park the machine on a level surface. ★ Park the machine after it has moved a few meters straight forward.
2.
Use convex rule to measure the height from tire tread level to the center of the shaft.
3.
Mark the center of the width of both left and right tires at the height attained in item 2.
4.
Use convex rule to measure distance A between the marks on the left and right tires.
5.
Advance the machine slowly and move the marks on the front of the tires to the back. Stop the machine when these marks are the same distance from the tire tread level to the center of the shaft.
6.
Use the convex rule to measure distance B between the marks on the left and right tires.
7.
Standard of toe-in: B - A = 8.5 ± 1.5 mm
20-118 1
GD705A-4
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) tierods equally. ★ Adjust with the front axle horizontal without any leaning.
GD705A-4
20-119 1
TESTING AND ADJUSTING
CHECKING PARKING BRAKE LEVER STROKE AND OPERATING
12
CHECKING PARKING BRAKE LEVER STROKE AND OPERATING FORCE STROKE CHECK Use convex rule to measure the travel of parking brake lever tip from bottom to top.
STROKE ADJUSTMENT Adjust with engine stopped. 1.
Insert driver through adjusting hole of parking brake drum, rotate adjusting gear in the direction of the arrow until lining and drum contact tightly, then return 8 ratchets.
2.
After adjusting the lining and drum clearance, pull the parking brake lever and adjust the cable so that the notched section is in the 2 to 3 ratchet range.
3.
After adjustment, it is possible to keep the machine stopped on a 1/5 paved gradient by pulling the parking lever.
OPERATING FORCE CHECK Use push-pull scale to check the operating force by hanging it on the front end of the parking brake lever and lifting it up.
20-120 1
GD705A-4
TESTING AND ADJUSTING
CHECKING WEAR OF BRAKE DISC
12
CHECKING WEAR OF BRAKE DISC 1.
Remove plug (1) of checking hole and peep through from directing above the checking hole.
2.
Depress brake pedal push piston (2) against plate (3) and to compress disc (4).
3.
Confirm that length A in the diagram at right is not O. In other words, confirm that a portion of the disc can be seen through the checking hole.
GD705A-4
20-121 1
TESTING AND ADJUSTING
CHECKING HYDRAULIC OIL PRESSURE
12
CHECKING HYDRAULIC OIL PRESSURE CHECKING Special tool required A
Part Number
Part Name
Q’ty
799-101-5002
Hydraulic tester
1
Stop the engine, then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1.
★
2.
Remove measurement plugs (1) and (2), and install oil pressure gauge A (34.3 MPa {350 kg/ cm2}). To prevent the oil from spurting out when the plugs are removed, set the control lever in the operated position when removing. Start the engine, and when the temperature of the hydraulic oil is within a range of 40 ± 5oC, operate the lever of the circuit to be measured, and measure the relief pressure.
ADJUSTING ★
If the oil pressure is not within the standard value (17.2 MPa {175 kg/cm2}), adjust as follows.
1.
Loosen nut (3), turn adjustment screw (4), and adjust the pressure of internal spring (5). To INCREASE the oil pressure, turn CLOCKWISE To DECREASE the oil pressure, turn COUNTERCLOCKWISE Amount of change in pressure for one turn of adjustment screw: Approx. 5.3 MPa {54 kg/cm2}
★ ★
2.
After adjusting, check that the oil pressure within the standard value.
20-122 1
is
GD705A-4
TESTING AND ADJUSTING
CHECKING HYDRAULIC OIL TEMPERATURE
12
CHECKING HYDRAULIC OIL TEMPERATURE Special tool A 1.
Part Number
Part Name
Q’ty
795-500-1300
Thermister
1
Remove hydraulic oil tank cap (1) and remove strainer. When removing cap, loosen the oil filler cap slowly to release the remaining oil pressure in the hydraulic tank.
2.
Insert sensor into filling port and measure oil temperature with thermistor gauge A.
GD705A-4
20-123 1
TESTING AND ADJUSTING
WORK EQUIPMENT CONTROL LEVER STROKE AND OPERATING
12
WORK EQUIPMENT CONTROL LEVER STROKE AND OPERATING FORCE WORK EQUIPMENT CONTROL LEVER STROKE CHECK AND ADJUSTMENT Use a convex rule 1 and measure the operating length from the center of the knob of lever (1). ★ Measure with engine stopped. ★ The stroke of work equipment control lever is determined by the spool stroke of the control valve, but the neutral position of each lever is adjusted by each rod. CHECK AND ADJUSTMENT OF EACH WORK EQUIPMENT CONTROL LEVER OPERATING FORCE Use push-pull scale 2 to measure maximum value from the tip of lever (1) to just before the stroke end. ★ Measure with engine stopped. ★ The operating force of the work equipment control lever is determined by the spring load of the spool on the control valve side. When the operating force is outside standard value, check the movement of the connecting rod. If it is normal, disassemble the control valve and check the movement of the spool.
HYDRAULIC DRIFT OF BLADE 1. 2.
3.
Start the engine and after the pressure test, bring hydraulic oil temperature to the 40 ± 5oC range. Raise the blade 300mm from the ground and at right angles to the machine and equidistant to right and left. Stop the engine and leave for 10 minutes. Use a convex rule 1 to measure the amount the cylinder piston rod has dropped.
MEASURING BLADE SINKING AMOUNT 1. 2.
3.
Start engine after the pressure test, bring hydraulic oil temperature to the 40 ± 5oC range. Lower blade until its bottom edge touches the ground, push the cylinder and float the front wheels about 300mm off the ground. Stop the engine and leave for 10 minutes. Use a convex rule 1 to measure at the cylinder the amount of sinkage.
20-124 1
GD705A-4
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.
2.
3.
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of man-hours, parts, oil or grease, and at the same time also lose the confidence of the user or operator. For this reason when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine’s condition before this? 4) Under what condition did the failure occurred? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Had the same kind of failure occurred before? Checks before troubleshooting 1) Check the oil level. 2) Check for external oil leaks from the piping or hydraulic equipment. 3) Check the travel of the control levers.
20-202 1
4) 5)
4.
5.
6.
Check the stroke of the control valve spool. Other maintenance items can be checked externally, so check any item that is consider to be necessary.
Confirming failure • Confirm the extent of the failure yourself, and judge whether to handle it as a real failure, or as a problem with the method of operation, etc. ★ When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting • Use the result of the investigation and inspection in items 2 - 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly ★ The basic procedure for troubleshooting is as follows: 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. Measure to remove root cause of failure • Even if he failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then remove the root cause.
GD705A-4
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
GD705A-4
20-203
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic equipment" (particularly gear oil and hydraulic oil). 1. Points to remember when handling electric equipment 1) Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.
2) Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
20-204
GD705A-4
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
4) High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. 5) Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. ★ When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. ★ If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
GD705A-4
20-205
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
2) Removing, installing, and drying connectors and wiring harnesses •
Disconnecting connectors 1) Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. ★ Never pull with one hand. 2) When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. ★ If the connector is twisted up and down or to the left or right, the housing may break.
3) Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. ★ If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
20-206
GD705A-4
TROUBLESHOOTING
•
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Connecting connectors 1) Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage 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 connector, 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, replace the connector. 2) Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. 3) Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. ★ If the connector cannot be corrected easily, remove the clamp and adjust the position. 4) If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
•
Connecting connectors (DT type connector) Since the DT 8-pole and 12-pole DT type connectors have 2 latches respectively, push them in until they click 2 times. 1. Male connector, 2. Female connector • Normal locking state (Horizontal):a, b, d • Incomplete locking state (Diagonal):c
GD705A-4
20-207
TROUBLESHOOTING
•
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1) Disconnect the connector and wipe off the water with a dry cloth. ★ If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air. 2) Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. ★ Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
3) Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. ★ After completely drying the connector, blow it with contact restorer and reassemble.
20-208
GD705A-4
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Handling control box 1) The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. 2) Do not open the cover of the control box unless necessary.
3) Do not place objects on top of the control box. 4) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 5) During rainy weather, do not leave the control box in a place where it is exposed to rain.
6) Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 7) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.
2. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connect connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. ★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. ★ If there is any change, there is probably defective contact in that circuit.
GD705A-4
20-209
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3. Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1) Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2) Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment. 3) Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. 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, collect it and ask the customer to dispose of it, or take it back with you for disposal.
4) Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
20-210
GD705A-4
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
5) Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 6) Flushing operations After disassembling and assembling the equipment, 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 secondary 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 circuit. The oil cleaning equipment is used to remove the ultrafine (about 3µ) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.
GD705A-4
20-211
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING Judgement value
Action
1. Check fuel level, type of fuel 2. Check for impurities in fuel 3. Check hydraulic oil level 4. Check hydraulic oil strainer 5. Check engine oil level (oil pan oil level) 6. Check coolant level 7. Check dust indicator for clogging 8. Check hydraulic filter
— — — — — — — —
Add fuel Clean, drain Add oil Clean, drain Add oil Add water Clean or replace Replace
1. Check for looseness, corrosion of battery terminal, wiring 2. Check for looseness, corrosion of alternator terminal, wiring 3. Check for looseness, corrosion of starting motor terminal, wiring
— — —
Tighten or replace Tighten or replace Tighten or replace
1. Check for abnormal noise, smell 2. Check for oil leakage 3. Carry out air bleeding
— — —
Repair Repair Bleed air
Electrics, electrical equipment
Hydraulic, Electrical mechanical equipment equipment
Lubricating oil, coolant
Item
20 – 30V Replace 1. Check battery voltage (engine stopped) Add or replace — 2. Check battery electrolyte level Replace — 3. Check for discolored, burnt, exposed wiring Repair — 4. Check for missing wiring clamps, hanging wiring Disconnect — 5. Check for water leaking on wiring (be particularly careful attention connector and dry to water leaking on connectors or terminals) Replace — 6. Check for blown, corroded fuses Replace 7. Check alternator voltage (engine running at 1/2 throttle or above) After running for several minutes : 27.5 – 29.5V Replace — 8. Check operating sound of battery relay (when switch is turned ON/OFF)
20-212
GD705A-4
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATIONS
12
CONNECTOR TYPES AND MOUNTING LOCATIONS ★
---
1-pin conn. 1-pin conn.
Intermediate connector (R.H. console box) (air conditioner)
1
Air drier
1
Backup alarm Intermediate connector (R.H. console box) (Wiper, caution lamp) Intermediate connector (R.H. console box) Intermediate connector (R.H. console box) Intermediate connector (R.H. console box)
---
CN-25
Automobile conn.
---
---
---
Mounting location
address
---
4
Type
No. of Pins
X
Connector No.
A24
Mounting location
address
Type
No. of Pins
Connector No.
The Address column in the table shows the address in the connector arrangement drawing (3 dimensional drawing).
3
Turn signal lamp switch
---
---
---
Speedometer
CN-39
SWP
16
Intermediate connector (Bottom right of fuel tank)
A6
H7
CN-40
SWP
12
Intermediate connector (Bottom right of fuel tank)
A6
G6
---
1-pin conn.
1
Fuel level sensor
---
G6
CN-44
X
2
Starting motor
---
H7
CN-45
1-pin conn.
1
Engine water temp. sensor
D8
CN-C1
X
4
Door
X
1
FR
X
1
FU
X
1
---
1-pin conn.
1
Horn switch
---
CN-46
Econoseal
2
Parking brake switch
L3
H2
YPC
4
Car heater switch (Main heater)
---
CN-50
SWP
12
Intermediate connector (Rear left of rear frame)
B9
CNM58
Automobile conn.
4
Turn signal & hazard relay
G6
---
Terminal
1
Pressure switch of air pressure alarm (L.H.)
---
OP
X
1
---
---
Terminal
1
RAD
X
3
H7
---
Terminal
1
---
1-pin conn.
1
---
---
Terminal
1
YOBI
X
1
H7
CN-53
CN-1
SWP
6
C2
CN-54
CN-2
SWP
12
A5
CN-57
CN-4 CN-5
YPC YPC
3 2
Intermediate connector (R.H. console box) (Spare) Intermediate connector (Front frame) Intermediate connector (Bottom right of fuel tank) Bank switch Caution lamp switch
L8 L8
CN-63 CN-64
CN-6
YPC
3
Head lamp switch
L8
CN-101
CN-7 CN-8 CN-9 CN-10 CN-11
2 2 2 2 5
Front working lamp switch Fog lamp switch Rear working lamp switch Lamp switch (spare) Caution lamp relay
L8 L8 L8 L7 L6
CN-102 CN-201 CN-202 CN-203 CN-204
1
Buzzer
L6
1
Buzzer
L5
CN-15
YPC YPC YPC YPC Relay 1-pin conn. 1-pin conn. Relay
5
L4
CN-18
SWP
16
CN-20
SWP
16
CN-23
YPC
2
Engine stop motor relay Intermediate connector (Bottom right of fuel tank) Intermediate connector (Bottom right of fuel tank) Accumulator switch
CN-13 CN-14
GD705A-4
Intermediate connector (R.H. console box) (OP) Intermediate connector (R.H. console box) (Radio) License lamp
Automobile conn. Automobile conn.
Pressure switch of air pressure alarm (L.H.) Pressure switch of air pressure alarm (R.H.) Pressure switch of air pressure alarm (R.H.)
-------
4
Combination lamp (Left rear)
A9
4
Combination lamp (Right rear)
A8
SWP
8
Engine stop motor
A6
X X Automobile conn. YPC X X X SWP
2 3
Stop lamp switch Solenoid valve for bank
B5 D6
3
Head lamp dimmer switch
---
3 3 3 2 2
Head lamp switch Head lamp Head lamp Engine oil pressure switch Caution lamp
L7 ---------
A6 --L7
20-213 1
TROUBLESHOOTING
20-214 1
CONNECTOR TYPES AND MOUNTING LOCATIONS
GD705A-4
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATIONS
12
GD705A-4
20-215 1
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ★
The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing.
No.of pins
X type connector Male (female housing)
Female (male housing)
2
3
4
20-216 1
GD705A-4
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 No.of pins
SWP type connector Male (female housing)
Female (male housing)
6
8
12
14
16
GD705A-4
20-217 1
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 No.of pins
Automobile connector Male (female housing)
Female (male housing)
2
3
4
6
8
20-218 1
GD705A-4
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
No.of pins
Relay connector Female (female housing)
Relay (male housing)
5
6
GD705A-4
20-219 1
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 12
E-1 Engine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-252 E-2 Electric system does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-255 E-3 Service meter does not work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-256 E-4 Water temperature gauge indicates abnormally high temperature. . . . . . . . . . . . . . . . . . . . 20-257 E-5 Water temperature gauge does not work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-257 E-6 Fuel gauge always indicates FULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-258 E-7 Fuel gauge does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-258 E-8 Engine oil pressure gauge indicates abnormally high pressure . . . . . . . . . . . . . . . . . . . . . . 20-259 E-9 Engine oil pressure gauge does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-259
GD705A-4
20-251 1
TROUBLESHOOTING
E-1
E-1 12
E-1 Engine does not start ★ ★ ★
Check that the fuse is normal before starting troubleshooting. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
a) Starting motor does not turn
Cause 4
YES Is voltage between starting motor terminal B and chassis normal? 3
YES Is there sound of starting motor pinion engaging? 2
5
When starting YES switch is turned OFF, is sound heard from battery relay?
Is voltage between starting switch terminal C and chassis No normal?
YES Defective starting motor
Replace
Defective contact or disconnection in wiring harness between battery NO (+) and starting motor terminal B
Repair or replace
Defective contact, or YES disconnection in wiring or harness between starting Repair replace switch terminal C starting motor terminal S
Defective starting switch
• Starting switch ON → OFF.
1
• Turn starting switch ON. • Approx. 24V
Remedy
Replace
NO • Turn starting switch to START. • 20 - 30 V
Is voltage and electrolyte specific gravity of battery normal?
Go to E-2 NO
• Voltage: Min. 20V • Electrolyte specific gravity: Min. 1.26
NO
Lack of battery capacity
Charge or replace
E-1 a) Related electric circuit
20-252 1
GD705A-4
TROUBLESHOOTING
E-1
12 b) Engine stop motor does not work Cause 2
YES
Defective engine stop motor
Remedy Replace
Is there continuity between CN-57 (female)(3) and (7)?
YES
• Starting switch OFF. • Disconnect CN-57
NO
3
YES
1
Defective relay, or broken wire or contact failure in Repair or replace the wire harness
Defective engine stop motor
Replace
Is there continuity between CN-57 (female)(5) and (7)?
Is the voltage of CN-57 (female) (4) 20 - 30 volts?
• Starting switch OFF. • Disconnect CN-57
NO
NO
Repair or Defective relay, or broken replace wire or contact failure in the wire harness
Broken wire or contact failure in the wire harness between battery Repair relay and CN-57 (female) (4)
E1 b) Related electric circuit diagram (When starting engine)
GD705A-4
20-253 1
TROUBLESHOOTING
E-1
12 E1 b) Related electric circuit diagram (When stopping engine)
20-254 1
GD705A-4
TROUBLESHOOTING
E-2
E-2 12
E-2 Electric system does not work ★
Before starting troubleshooting, check that the battery voltage is normal. Cause 2
YES
Is the voltage YES between the terminal RM of battery relay and chassis normal? • Starting switch ON. • 20V or more.
NO 5
1 Does the battery relay make a sound when the starting switch is turned OFF?
4 Is the voltage YES between the terminal BR of the battery relay and chassis normal?
• Starting switch ON → OFF.
• Starting switch ON. • 20V or more
3 Is the voltage between the terminal B of the NO starting switch and chassis normal?
Is the resistance YES between the terminal RE of the battery relay and chassis normal?
• Starting switch ON. • 20V or more NO
Broken wire or contact failure in the wire harness between the terminal RM of the battery relay - fuse box
Repair or replace
Defective battery relay
Replace
Defective battery relay
Replace
YES
Broken wire or contact failure in the wire Repair or harness between the NO terminal RE of the battery replace relay and chassis
• 1 Ω or less
6 Is the voltage between the terminal BR of the NO starting switch and chassis normal? • Starting switch ON. • 20V or more
Remedy
Broken wire or contact failure in the wire YES harness between the terminal BR of the starting switch terminal BR of the battery relay.
NO
Repair or replace
Defective starting switch
Replace
Broken wire or contact failure in the wire harness between battery - terminal B of the starting switch
Repair or replace
E-2 Related electric circuit diagram
GD705A-4
20-255 1
TROUBLESHOOTING
E-3
E-3 12
E-3 Service meter does not work Cause 2
YES Defective service meter
1
Is the voltage YES between the terminal of the service meter and chassis normal? • Start engine • 10 - 14 V
Is the voltage between the terminal R of the alternator and chassis normal? • Start engine • 10 - 14 V
Remedy
NO
NO
Replace
Broken wire, contact failure or short circuit to the ground in the wire harness between the termi- Repair or replace nal R of the alternator the connector CN-18B (female) (10) - the terminal of the service meter
Defective alternator
Replace
E-3 Related electric circuit diagram
20-256 1
GD705A-4
TROUBLESHOOTING
E-4, E-5
E-4, E-5 12
E-4 Water temperature gauge indicates abnormally high temperature Cause YES
1
3
Does the water temperature gauge indicate minimum when the connector of the sensor is disconnected?
2
Is the voltage YES between the connector CN-18B (female) (7) and chassis normal?
• Disconnect the connector of the water temperature sensor • Turn the starting switch ON.
Is the resistance between the connector CN-18B NO (female) (7) and chassis normal?
YES
• Disconnect the con- NO nector CN-18B and the connector of the water temperature sensor • Starting switch ON. • 1V or less
• Starting switch OFF. • Disconnect the connector CN-18B and the connector of the water temperature NO sensor • 1 MΩ Ω or more
Does the water temperature gauge indicate maximum when the connector (female) of the water temperature sensor is touched to the chassis? • Disconnect the connector of the water temperature sensor • Touch the connector (female) of the water temperature sensor to the chassis • Turn the starting switch ON.
Defective water temperature sensor
Replace
Defective water temperature gauge
Replace
Wire harness between the connector CN-18B (female) (7) - the connector (female) of the water Repair or temperature sensor replace touches the wire harness between the connector CN-18B (female) (7) - fuse box (No. 2) (13)
Wire harness between connector CN-18B (female) (7) - the Repair or connector (female) of the replace water temperature sensor touches the chassis
E-5 Water temperature gauge does not work 1
YES
Cause Defective water temperature sensor
2
YES
Is the resistance between the connector CN-18B (female) (7) - chassis normal when NO the connector (female) of the water temperature sensor is touched to the chassis? • Disconnect the connector CN-18B and the connector of the water temperature sensor. • Starting switch OFF.
Remedy
NO
Broken wire or contact failure in the wire harness between the connector of CN-18 (female) (7) - the connector (female) of the water temperature sensor
Defective water temperature gauge
Remedy Replace
Repair or replace
Repair or replace
E-4, E-5 Related electric circuit diagram
GD705A-4
20-257 1
TROUBLESHOOTING
E-6, E-7
E-6, E-7 12
E-6 Fuel gauge always indicates FULL Cause YES
1
3
Does the fuel gauge indicate EMPTY when the connector of the fuel level sensor is disconnected?
2
Is the voltage YES between the connector CN-20B (female) (15) and chassis normal?
• Disconnect the connector of the fuel level sensor • Turn the starting switch ON. • Wait 1 minute
Is the resistance between the connector CN-20B NO (female) (15) and chassis normal?
E-7 Fuel gauge does not work 1 Does the fuel gauge indicate FULL when the connector of the fuel level sensor is touched to the chassis? • Disconnect the connector of the fuel level sensor • Touch the connector (female) of the fuel level sensor to the chassis • Turn the starting switch ON. • Wait 1 minute
YES
2
YES
Is the resistance between the connector CN-20B (female) (15) and chassis norNO mal when the connector (female) of the fuel level sensor is touched to the chassis? • Starting switch OFF. • Disconnect the connector CN-20B and the connector of the fuel level sensor • 1 Ω or less
NO
Defective fuel level sensor
Replace
Defective fuel gauge
Replace
YES
• Disconnect the con- NO nector CN-20B and the connector of the fuel level sensor. • Turn starting switch ON. • 1V or less
• Starting switch OFF. • Disconnect the connector CN-20B and NO the connector of the fuel level sensor • 1 MΩ Ω or more
Remedy
Inner contact in the wire harness between the con- Repair or replace nector CN-20B (female) (2) - fuse box (No. 2) (13)
Wire harness between the connector CN-20B (female) (15) - the Repair or connector (female) of the replace fuel level sensor touches the chassis
Cause
Remedy
Defective fuel level sensor
Replace
Broken wire or contact failure in the wire harness between the connector CN-20B (female) (15) - the connector (female) of the fuel level sensor
Repair or replace
Defective fuel level gauge
Replace
E-6, E-7 Related electric circuit diagram
20-258 1
GD705A-4
TROUBLESHOOTING
E-8, E-9
E-8, E-9 12
E-8 Engine oil pressure gauge indicates abnormally high pressure Cause YES
1
YES
Does the engine oil pressure gauge indicate minimum when the connector (CN-203) of the engine oil pressure sensor is disconnected?
Remedy
Defective engine oil pressure sensor
Replace
Defective engine oil pressure gauge
Replace
2 Wire harness between the connector CN-18B (female) (15) - the connector (female) of the engine oil pressure sensor touches the chassis Repair or or wire harness between the replace connector CN-18B (female) (11) - the connector CN-203 (female) (2) has a contact with wire harness between the connector CN-203 (female) (1) chassis
Is the resistance between the connector CN-18B (female) (11) and chassis normal?
• Disconnect the connector (CN203) of the engine oil pressure sensor. • Turn the starting switch to ON.
• Starting switch OFF. • Disconnect the connector (CN203) of the engine oil pressure sensor. • 1 MΩ Ω or more
NO
E-9 Engine oil pressure gauge does not work Cause 1 Does the engine oil pressure gauge indicate maximum when the connector (female) of the engine oil pressure sensor touches the chassis? • Disconnect the connector of the engine oil pressure sensor. • Touch the connector (female) of the engine oil pressure sensor to the chassis. • Turn the starting switch to ON.
YES
Defective engine oil presReplace sure sensor
3
2 Is there resistance between the connector CN-203 NO (female) (1) and the chassis? • Starting switch OFF. • Disconnect the connector (CN203) of the engine oil pressure sensor. • 1 Ω or less
Is the resistance between the connecYES tor CN-18B (female) (11) and chassis normal when the connector CN-203 (female) (2) is touched to chassis?
YES
NO
NO
Remedy
Defective engine oil pressure gauge
Replace
Broken wire or contact failure in the wire harness between the connector CN-18B (female) (11) - the connector CN203 (female) (2)
Repair or replace
Broken wire or contact failure in the wire haror ness between the engine Repair replace oil pressure connector (CN-203) - chassis
E-8, E-9 Related electric circuit diagram
GD705A-4
20-259 1
90 OTHERS Hydraulic circuit diagram (STD spec.) ...............................................................................................90-2 Hydraulic circuit diagram (DDV spec.) ........................................................................................... 90-3-1 HYDROSHIFT transmission control circuit diagram ..........................................................................90-4 Electrical circuit diagram (1/2) ...........................................................................................................90-5 Electrical circuit diagram (2/2) ...........................................................................................................90-7 Electrical circuit diagram for Air Conditioner ......................................................................................90-9 Electrical circuit diagram for Cab .....................................................................................................90-11
GD705A-4
90-1
OTHERS
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM STD spec.
90-2
GD705A-4
OTHERS
HYDRAULIC CIRCUIT DIAGRAM
12
GD705A-4
90-3
OTHERS
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM DDV spec.
90-3-1
GD705A-4
OTHERS
HYDRAULIC CIRCUIT DIAGRAM
GD705A-4
90-3-2
OTHERS
HYDRAULIC CIRCUIT DIAGRAM
121 HYDROSHIFT TRANSMISSION CONTROL CIRCUIT DIAGRAM
90-4
GD705A-4
STRUCTURE AND FUNCTION
ELECTRICAL CIRCUIT DIAGRAM (1/2)
ELECTRICAL CIRCUIT DIAGRAM (1/2)
GD705A-4
90-5
STRUCTURE AND FUNCTION
ELECTRICAL CIRCUIT DIAGRAM (2/2)
ELECTRICAL CIRCUIT DIAGRAM (2/2) 12
GD705A-4
90-7
STRUCTURE AND FUNCTION
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER
GD705A-4
90-9
OTHERS
ELECTRICAL CIRCUIT DIAGRAM FOR CAB
ELECTRICAL CIRCUIT DIAGRAM FOR CAB 12
GD705-A4
90-11