Komatsu Motor Grader GD750A-1 service & repair manual

Description Komatsu Motor Grader GD750A-1 service & repair manual

Komatsu Motor Grader GD750A-1 pdf workshop service repair manual + operation & maintenance manual

Serial number 7001 and up

MANUAL CONTENT:
GENERAL
GENERAL ASSEMBLY DRAWING
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
ENGINE OIL SPECIFICATIONS
NORMAL OPERATION
ARCTIC OPERATION
TRANSMISSION, TORQUE CONVERTER AND OIL COOLER, TANDEM DRIVE CASES, FRONT
WHEEL DRIVE GEAR CASE, IF EQUIPPED AND HYDRAULIC SYSTEM OIL SPECIFICATIONS
REAR DRIVE AXLE AND CIRCLE DRIVE BRAKE HOUSING OIL SPECIFICATIONS
DIESEL FUEL SPECIFICATIONS
COOLANT SPECIFICATIONS
GENERAL
ANTIFREEZE
SUPPLEMENTAL COOLANT ADDITIVES
CIRCLE DRIVE GEAR CASE OIL SPECIFICATIONS (HDTF)

STRUCTURE AND FUNCTION
GENERAL
JOINT
TORQUE CONVERTER LUBE CIRCUIT
HYDRAULIC CIRCUITS FOR POWER TRAIN
GEARS
TORQUE CONVERTER / TRANSMISSION
TORQUE CONVERTER
THEORY OF OPERATION
RULES OF OPERATION
CONNECTOR PINOUTS
TRANSMISSION, DF 250
TRANSMISSION DIAGRAM
RULES OF OPERATION
CONTROL VALVE (S/N A7003 - A7007)
CONTROL VALVE (S/N A7008 and up)
PRESSURE AND TEMPERATURE
OPERATING CONDITIONS (S/N A7003 - A7007)
PORT PRESSURES (S/N A7003 - A7007)
PRESSURE AND TEMPERATURE CHECK PORTS (S/N A7008 and up)
OPERATING CONDITIONS (S/N A7008 and up)
PORT PRESSURES (S/N A7008 and up)
PIPING DIAGRAM, CHARGE PUMP TO CONTROL VALVE
ENGAGEMENT OVERRIDE VALVE (EOV)
ELECTRONIC CONTROL UNIT (ECU)
THEORY OF OPERATION
TROUBLESHOOTING INTRODUCTION
PROPORTIONAL VALVES
FUNCTION OF PROPORTIONAL VALVES
PROPORTIONAL VALVE CONNECTOR PINOUT
TRANSIENT VOLTAGE PROTECTION (TVP) MODULE
ENGINE SPEED MAGNETIC PICKUP (MPU) (INPUT SPEED)
TRANSMISSION OUTPUT SPEED MPU
CYLINDER MAGNETIC PICKUP SENSOR MPU
SHIFT LEVER
GEAR/DIAGNOSTIC INDICATOR
INCHING PEDAL
THROTTLE POSITION SENSOR
MISCELLANEOUS INPUT FUNCTION SWITCHES
PARK BRAKE
WIRING HARNESS
CALIBRATION
CLUTCH CALIBRATION EIGHT FORWARD SPEEDS AND FOUR REVERSE
SYSTEM REQUIREMENTS
VOLTAGE
WIRING
ECU MOUNTING
GLOSSARY
TRANSMISSION CONTROL
SELECTOR LEVER
OPERATIONAL ERROR CODE IDENTIFICATION
INCHING CONTROL
DRIVE SHAFT
FINAL DRIVE, DIFFERENTIAL LOCK AND UNLOCK PIPING
FINAL DRIVE
DIFFERENTIAL OPERATION
DIFFERENTIAL LOCK CAPTURE SYSTEM
DIFFERENTIAL LOCK VALVE
TANDEM DRIVE
STEERING
STEERING PIPING
STEERING CIRCUIT DIAGRAM
STEERING VALVE (Orbitrol type)
OUTLINE
STRUCTURE
FUNCTION OF CENTER SPRING
STEERING UNIT PORTS
EMERGENCY STEERING SYSTEM
FRONT AXLE
WHEEL
STANDARD WHEEL
OPTIONAL WHEEL
BRAKES
SERVICE BRAKE
PARKING BRAKE
BRAKE PIPING
BRAKE CIRCUIT DIAGRAM
BRAKE VALVE
COMBINATION / PARK BRAKE BLOCK VALVE
PIPING
HYDRAULIC TANK PIPING
HYDRAULIC CONTROL PIPING
REAR MOUNT RIPPER CONTROL PIPING
HYDRAULIC CIRCUIT DIAGRAM
CONTROL VALVE
PUMP AND RESERVOIR
CLOSED CENTER LOAD SENSING SYSTEM (CLSS)
MAIN HYDRAULIC CIRCUIT
PRINCIPLE OF OPERATION OF A PISTON PUMP
FUNCTION
OPERATION
OPERATION OF THE HYDRAULIC PUMP
FUNCTION
MAIN HYDRAULIC PUMP
PRIORITY VALVE
RH & LH BLADE LIFT CYLINDER
BLADE SHIFT CYLINDER
CIRCLE REVERSE MOTOR
MOLDBOARD TILT CYLINDER
ARTICULATION CYLINDERS
CIRCLE SIDE SHIFT CYLINDER
WHEEL LEAN CYLINDER
FLOAT VALVE FOR AUXILIARY FUNCTION (OPTIONAL)
HYDRAULIC CONTROL VALVE
LH VALVE BANK
RH VALVE BANK
PRESSURE COMPENSATING MECHANISM OF HYDRAULIC CONTROL VALVE
CIRCLE ROTATION MOTOR
CIRCLE ROTATION GEAR
BLADE ACCUMULATOR SYSTEM
DRAWBAR AND LIFTER
BLADE
BLADE SUPPORT
BLADE LIFT ASSEMBLY
HYDRAULIC CONTROL LEVER LINKAGE
RIPPER
MAIN FRAME
MONITOR PANEL, GAUGES AND SIDE PANELS
MONITOR PANEL AND GAUGES
UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS
SIDE PANELS
DRIVER’S RIGHT SIDE PANEL
DRIVER’S LEFT SIDE PANEL
ELECTRICAL WIRING
ELECTRICAL CONNECTIONS
ELECTRICAL SCHEMATIC
CAB AREA
ENGINE AREA
TRANSMISSION HARNESS
SWITCH PANEL HARNESS
DASH CONSOLE AREA
MAIN HARNESS

TESTING, ADJUSTING AND TROUBLESHOOTING
TESTING AND ADJUSTING
SPECIAL TOOLS
MEASURING ENGINE PERFORMANCE
ENGINE SPEEDS
ENGINE RATING
INTAKE MANIFOLD PRESSURE
INTAKE AIR RESTRICTION
LUBRICATING OIL PRESSURE
FUEL FILTER INLET RESTRICTION
BLOW-BY PRESSURE
EXHAUST BACK PRESSURE
COOLANT TEMPERATURE
VALVE CLEARANCE
EXHAUST GAS COLOR
ENGINE DRIVE BELT TENSION
STANDARD VALUE TABLE FOR ENGINE - In Chassis
STANDARD VALUE TABLE FOR CHASSIS
ELECTRONIC SYSTEM CHECK VALUE TABLE
ADJUSTING ACCELERATOR / DECELERATOR CONTROL PEDAL
PEDAL START ADJUSTMENT
PEDAL LIMIT STOP ADJUSTMENT
HEEL PIECE LIMIT STOP ADJUSTMENT
FINAL INSPECTION OF THE SYSTEM
INCHING PEDAL
TRANSMISSION
DIAGNOSTIC FOR TRANSMISSION
ECU DIAGNOSTIC SOFTWARE
CLUTCH CALIBRATION
TRANSMISSION HARNESS
CONTROL SIGNALS REQUIRED FROM GEAR SHIFT LEVER POSITIONS
MAIN CONNECTOR PINOUT
SUCTION LEAK TEST
CLUTCH PACK PRESSURE CHECK (S/N A7003 - A7007)
CLUTCH PACK PRESSURE CHECK (S/N A7008 and up)
SOLENOID VALVE OPERATION
CLUTCH SOLENOID VOLTAGE REQUIREMENTS
TEST SOLENOIDS
STEERING SYSTEM PRESSURE CHECK
FRONT WHEEL ALIGNMENT AND TURNING RADIUS ADJUSTMENT
STARTING POINT
PROCEDURE
CHECK AND ADJUST FRONT WHEEL “TOE IN”
SYNCHRONIZE STEERING CYLINDER
BRAKE SYSTEM
CHECKING BRAKE ACCUMULATOR CHARGE
SERVICE (FOOT) BRAKE CHECK - OPERATOR
CHECKING SERVICE (FOOT) BRAKE PRESSURE
FINAL DRIVE BRAKE BLEEDING
CHECKING AND ADJUSTING WHEEL BRAKE
PARKING BRAKE
CHECKING THE PARKING BRAKE
ADJUSTING THE PARKING BRAKE
PARKING / EMERGENCY BRAKE BLEEDING
CHECKING WORK EQUIPMENT CONTROL LEVER
CHECK AND ADJUSTMENT OF WORK EQUIPMENT CONTROL LEVER TRAVEL
CHECK AND ADJUSTMENT OF EACH WORK EQUIPMENT CONTROL LEVER
OPERATING FORCE
CHECKING HYDRAULIC OIL TEMPERATURE
HYDRAULIC PRESSURE CHECKS
TEST PROCEDURE
MEASURING HYDRAULIC DRIFT
EXTENSION OF BLADE CYLINDER
RETRACTION OF BLADE CYLINDER
EXTENSION OF RIPPER CYLINDER (if equipped)
RETRACTION OF RIPPER CYLINDER (if equipped)
CUSHION BLADE ACCUMULATOR
CHECKING AND SERVICE
BLEEDING AIR FROM HYDRAULIC PUMP
CAB HEATER OPERATION TEST
AIR CONDITIONER
OPERATION TEST
SERVICE
CHECK AND ADJUST TIRE PRESSURE
FUNCTIONAL ROAD TEST
AXLE ASSEMBLY
AXLE VERTICAL MOVEMENT CHECK
AIR TEST AXLE ASSEMBLY
DIFFERENTIAL ASSEMBLY
AIR TEST DIFFERENTIAL LOCK CAPTURE SYSTEM
OIL TEST DIFFERENTIAL LOCK CAPTURE SYSTEM
TEST DIFFERENTIAL LOCK SEALING RINGS WITH AIR BOOST SYSTEM
DIFFERENTIAL LOCK FUNCTION TEST
CHECK CARRIER BACKLASH
CHECK RING GEAR AND PINION TOOTH CONTACT PATTERN
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
PROCEDURE FOR TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT
CHECKS BEFORE TROUBLESHOOTING
HANDLING CONNECTORS
PRECAUTIONS WHEN TROUBLESHOOTING
SAFETY
METHODS FOR TROUBLESHOOTING
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR
ASSEMBLING PARTS DURING TROUBLESHOOTING
PREVENTING RECURRENCE OF TROUBLE
HYDRAULIC EQUIPMENT
ENGINE TROUBLESHOOTING

DISASSEMBLY AND ASSEMBLY
When removing or installing unit assemblies
General precautions
Listing of special tools
PRECAUTIONS WHEN CARRYING OUT OPERATION
Precautions when carrying out removal work
Precautions when carrying out installation work
Precautions when completing the operations
CLEANING AND INSPECTION
SPECIAL TOOL LIST
ENGINE COWLING & DOORS
RADIATOR HOOD
FUEL / HYDRAULIC TANK HOOD
BATTERY
RADIATOR / OIL COOLER
FUEL / HYDRAULIC TANK
INSTALLATION OF HYDRAULIC TANK
FAN
EXHAUST SYSTEM
DRIVE SHAFT
ENGINE (INC. TRANSMISSION)
INSTALLATION
TRANSMISSION
TORQUE CONVERTER, LOCK UP VALVE
FRONT COVER
CONTROL VALVE
MAIN CASE FRONT HOUSING
GEAR RATIO GROUP
MAIN CASE REAR HOUSING
FINAL DRIVE / PLANETARY CARRIER
TANDEM DRIVE CASE
SERVICE BRAKES
BLADE
CIRCLE & DRAWBAR ASSEMBLY
LIFTER GUIDE, DRAWBAR SHIFT & BLADE LIFT CYLINDERS
PUSH BLOCK (COUNTERWEIGHT)
RIPPER
CIRCLE REVERSE MOTOR
HYDRAULIC TANK
HYDRAULIC PUMP

MAINTENANCE STANDARD
GENERAL BOLT TORQUE VALUES
ENGINE MOUNT
TRANSMISSION / TORQUE CONVERTER MOUNT
DRIVE SHAFT
FINAL DRIVE & TANDEM DRIVE
BRAKES
SERVICE BRAKE
PARKING BRAKE
PUSH BLOCK
FRONT AXLE
RIPPER
MAIN FRAME
FUEL & HYDRAULIC TANK MOUNT
CAB MOUNT BOLTS
BATTERY & BOX MOUNTING
RADIATOR MOUNTING
HYDRAULIC CONTROL LINKAGE
PRIORITY VALVE
RETURN / PARK BRAKE VALVE
BLADE ACCUMULATOR BRACKET
BLADE
BLADE SUPPORT
BLADE LIFT ASSEMBLY
DRAWBAR
CIRCLE ROTATION GEAR
REAR AXLE ASSEMBLY

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