Complete service repair manual with Electrical Wiring Diagrams for Komatsu Motor Graders GD750A, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Motor Graders GD750A workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Total Pages: 1,401 pages
File Format: PDF
Language: English
CEBM002104 – Komatsu Motor Grader GD750A-1 Shop Manual.pdf
CEAM002402 – Komatsu Motor Grader GD750A-1 Operation & Maintenance Manual.pdf
MAIN SECTIONS
CEAM002402 – Motor Grader GD750A-1 Operation & Maintenance Manual….2
COVER PAGE….2
1. FORWARD….6
2. SAFETY INFORMATION….7
3. INTRODUCTION….8
3.1 INTENDED USE….8
3.2 FEATURES….8
3.3 BREAKING IN THE MACHINE….8
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….9
4.1 P.I.N. NUMBER LOCATIONS….9
4.2 ENGINE SERIAL NO. PLATE POSITION….10
4.3 TRANSMISSION SERIAL NO. PLATE POSITION….10
4.4 REAR AXLE SERIAL NO. PLATE POSITION….10
4.5 CAB ROPS/FOBS SERIAL NO. PLATE POSITION….11
4.6 GENERAL PART NO. PLATE….11
4.7 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….12
5. TABLE OF CONTENTS….13
SAFETY….21
6. GENERAL PRECAUTIONS….22
7. PRECAUTIONS DURING OPERATION….28
7.1 BEFORE STARTING ENGINE….28
7.2 OPERATING MACHINE….30
7.3 TRANSPORTATION….36
7.4 BATTERY….37
7.5 TOWING….40
7.6 TIRES….41
8. PRECAUTIONS FOR MAINTENANCE….43
8.1 BEFORE CARRYING OUT MAINTENANCE….43
8.2 DURING MAINTENANCE….47
9. POSITON FOR ATTACHING SAFETY LABELS….53
9.1 POSITION FOR ATTACHING SAFETY LABELS….53
OPERATION….63
10. GENERAL VIEW….64
10.1 GENERAL VIEW OF MACHINE….64
10.2 UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS….65
11. EXPLANATION OF COMPONENTS….66
11.1 STEERING CONSOLE CONTROLS AND GAUGES….66
11.2 RIGHT SIDE CONSOLE….74
11.3 MISCELLANEOUS CONTROLS….76
11.4 HEATER/AIR CONDITIONING CONTROLS….79
11.4.1 METHOD OF OPERATION….82
11.4.2 PRECAUTIONS WHEN USING AIR CONDITIONER….83
11.4.3 HANDLING DURING SEASON….83
11.4.4 HANDLING DURING OFF-SEASON….83
11.5 MISCELLANEOUS GAUGES AND VALVE….84
11.6 ACCESS COVERS, HOOD SIDES AND DOORS….85
11.7 CONTROL LEVERS AND PEDALS….88
11.8 CAP WITH LOCK….97
11.8.1 METHOD OF OPENING CAP WITH LOCK….97
11.8.2 METHOD OF CLOSING CAP WITH LOCK….97
11.9 ARTICULATE LOCK PIN….97
11.10 PARKING BRAKE….98
11.11 BACKUP ALARM….98
11.12 CIRCUIT BREAKERS….98
12. MACHINE OPERATION….100
12.1 WALK AROUND CHECK….100
12.2 TOWING….103
12.3 CHECKS BEFORE STARTING….104
12.3.1 CHECK COOLANT LEVEL, ADD COOLANT….105
12.3.2 CHECK MONITOR PANEL….105
12.3.3 CHECK FUEL LEVEL, ADD FUEL….106
12.3..4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL….106
12.3.5 CHECK ELECTRIC WIRING….107
12.3.6 DRAIN WATER AND SEDIMENT IN FUEL TANK….107
12.3.7 CHECK VOLTMETER….108
12.3.8 CHECK FOR SEDIMENT AND WATER IN THE WATER SEPARATOR….108
12.3.9 CHECK LAMPS FOR SWITCHING, DIRT AND DAMAGE….108
12.3.10 CHECK REAR VIEW MIRROR FOR POSITIONING, DIRT AND DAMAGE….108
12.3.11 CHECK HORN AND BACKUP ALARM….108
12.3.12 DO THE INTRUMENTS FUNCTION NORMALLY….108
12.3.13 CHECK THE SEAT BELT FOR NORMAL FUNCTION….108
12.3.14 CHECK THE DOOR LOCKS FOR NORMAL FUNCTION….108
12.3.15 CHECK THE WINDSHIELD WIPER, WINDOW WASHER AND DEFROSTER FOR NORMAL FUNCTION. CHECK FOR SUFFICIENT WASHER FLUID LEVE….109
12.3.16 CHECK FOR MISSING GUARDS, OR PROTECTIVE EQUIPMENT. DO NOT OPERATE UNIT IF ANY ARE MISSING….109
12.3.17 GENERAL SAFETY….109
12.4 REMOVAL OF ARTICULATION PIN….109
12.5 ENTERING OPERATOR&’S CAB….109
12.6 ADJUSTMENTS BEFORE OPERATION….110
12.6.1 ADJUST OPERATOR&’S SEAT….110
12.6.2 SEAT BELT….111
12.6.3 ADJUSTING POSITION OF STEERING WHEEL AND GAUGE PANEL….112
12.6.4 ADJUSTING MIRRORS….112
12.7 OPERATIONS AND CHECKS BEFORE STARTING ENGINE….113
12.8 STARTING ENGINE….115
12.8.1 NORMAL STARTING….115
12.8.2 STARTING IN COLD WEATHER: USING ETHER INJECTOR (OPTIONAL)….116
12.8.3 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE….118
12.8.4 STARTING PROCEDURES AFTER CHANGING FUEL FILTERS….118
12.8.5 STARTING PROCEDURES AFTER RUNNING OUT OF FUEL….119
12.9 OPERATIONS AND CHECKS AFTER STARTING ENGINE….120
12.9.1 ENGINE WARM UP….120
12.9.2 WHILE WARMING UP – ENGINE RUNNING ABOVE IDLE….120
12.9.3 COLD WEATHER START UP….121
12.9.4 HYDRAULIC SYSTEM COLD WEATHER START UP….121
12.10 TRAVELING POSTURE FOR MACHINE….122
12.11 MOVING MACHINE….123
12.12 SHIFTING GEARS….124
12.12.1 ACCELERATION….124
12.12.2 DECELERATION….124
12.13 SHIFTING BETWEEN FORWARD AND REVERSE….125
12.14 STOPPING MACHINE….126
12.15 TURNING MACHINE….127
12.15.1 LEANING OPERATION….127
12.15.2 ARTICULATING OPERATION….128
12.16 OPERATING WORK EQUIPMENT….129
12.16.1 OPERATING BLADE….129
12.16.2 OPERATING DRAWBAR SIDE SHIFT….132
12.16.3 OPERATING RIPPER….133
12.16.4 PROPULSION ANGLE OF BLADE….133
12.16.5 RH & LH 90 DEGREE BLADE SUSPENSION….134
12.17 WORK APPLICATION….136
12.17.1 LEVELING GROUND TO RIGHT….136
12.17.2 LEVELING GROUND TO LEFT….137
12.17.3 DIGGING RIGHT V-DITCHES….138
12.17.4 DIGGING LEFT V-DITCHES….140
12.18 RIGHT DITCH FINISHING….142
12.19 LEFT DITCH FINISHING….143
12.20 FINISHING RIGHT ROAD SHOULDER….144
12.21 FINISHING LEFT ROAD SHOULDER….144
12.22 CONSTRUCTING ROAD – METHOD OF MAKING V-DITCH….145
12.23 FLAT-BOTTOM DITCH….149
12.24 CONSTRUCTING ROAD – METHOD FOR MAKING FLAT BOTTOM DITCH….151
12.25 FINISHING WITH GRADER FOR DITCHES WHERE WET ROAD SHOULDER IS LOOSE….154
12.26 LEVELING 3:1 SLOPE FACE….154
12.27 BANK CUTTING METHOD – RIGHT SIDE….154
12.28 EXTREME SIDE REACH….158
12.29 RIPPER OPERATIONS – WITH FRAME STRAIGHT….159
12.30 PRECAUTIONS FOR OPERATION….160
12.30.1 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS….160
12.30.2 PRECAUTIONS WHEN USING ARTICULATED STEERING….160
12.30.3 PRECAUTIONS WHEN TRAVELING ON ROADS….161
12.30.4 CAUTIONS IN OPERATION OF WORK EQUIPMENT….161
12.31 ADJUSTING WORK EQUIPMENT POSTURE….161
12.31.1 BLADE PROTRUSION….161
12.32 PARKING MACHINE….162
12.33 CHECK AFTER FINISHING WORK….163
12.34 STOPPING ENGINE….163
12.35 CHECK AFTER STOPPING ENGINE….164
12.36 LOCKING….164
12.37 TIRES….165
12.37.1 PRECAUTIONS WHEN HANDLING TIRES….165
12.37.2 DIRECTION OF TIRE TREADS….165
12.37.3 TIRE MATCHING….165
12.38 BLADE ACCUMULATOR….166
12.38.1 OPERATION….166
12.38.2 FEATURES….167
12.39 HANDLING BLADE FLOAT….167
12.39.1 OPERATION….167
12.39.2 FEATURES….168
13. TRANSPORTATION….169
13.1 GENERAL….171
13.1.1 TRUCK….171
13.1.2 RAILROAD FLATCAR….171
13.1.3 DRIVING….171
13.2 MOVING A DISABLED MACHINE….172
13.3 METHODS OF TOWING….172
13.3.1 METHOD ONE….173
13.3.2 METHOD TWO….174
13.3.3 METHOD THREE….174
14. OPERATION UNDER UNUSUAL CONDITIONS….176
14.1 OPERATION IN EXTREME COLD….176
14.1.1 COLD WEATHER STARTING AID (OPTIONAL)….177
14.1.2 ENGINE BLOCK HEATER (OPTIONAL)….178
14.2 BATTERY….178
14.2.1 CHARGING….179
14.2.2 AFTER CHARGING….180
14.3 AFTER COLD WEATHER….180
14.4 OPERATION IN EXTREME HEAT….180
14.5 OPERATION IN DUSTY OR SANDY AREAS….181
14.6 OPERATION IN RAINY OR HUMID CONDITIONS….182
14.7 OPERATION IN SALT WATER AREAS….182
14.8 OPERATION AT HIGH ALTITUDES….183
15. MACHINE STORAGE….184
15.1 PREPARING FOR STORAGE….184
15.2 SERVICING MACHINE DURING STORAGE….187
15.2.1 ONE-MONTH REPETITIVE SERVICE PERIOD….187
15.2.2 SIX MONTH REPETITIVE SERVICE PERIOD….187
15.3 PREPARING FOR OPERATION….188
15.4 ROLLOVER PROTECTIVE STRUCTURE….189
15.5 THEFT DETERRENT PRACTICES….190
15.5.1 ACTION TO DISCOURAGE THEFT AND VANDALISM….190
15.5.2 ACTIONS TO AID IN RECOVERY OF STOLEN MACHINES….190
16. TROUBLESHOOTING….192
16.1 ETHER STARTING….192
16.1.1 FLUID CYLINDER….192
16.1.2 ATOMIZERS….192
16.1.3 TUBING….192
16.1.4 ELECTRIC VALVE….193
16.1.5 REASSEMBLY….193
16.2 AFTER RUNNING OUT OF FUEL….193
16.3 WHEN LEANING PIPING IS DAMAGED….194
16.3.1 HOW TO USE LEANING STOPPER….194
16.4 IF BATTERY IS DISCHARGED….195
16.4.1 STARTING ENGINE WITH BOOSTER CABLE….196
16.5 OTHER TROUBLE….198
16.5.1 ELECTRICAL SYSTEM….198
16.5.2 CHASSIS….199
16.5.3 ENGINE….202
16.5.4 INSTRUMENT PANEL….204
16.5.5 FAULT CODES EXPLANATION….207
16.5.6 SHIFT LEVER ERROR CODES….220
MAINTENANCE….221
17. GUIDES TO MAINTENANCE….222
18. OUTLINES OF SERVICE….225
18.1 OUTLINE OF OIL, FUEL, COOLANT….225
18.1.1 OIL….225
18.1.2 FUEL….226
18.1.3 COOLANT….226
18.1.4 GREASE….227
18.1.5 STORING OIL AND FUEL….227
18.1.6 FILTERS….227
18.2 RELATING TO ELECTRIC SYSTEM….228
18.2.1 BATTERIES….229
18.2.2 BATTERY – GENERAL MAINTENANCE….230
18.2.3 CLEANING THE BATTERIES….231
18.2.4 CONVENTIONAL ANTIMONY (LEAD-ACID) BATTERY….231
18.2.5 LOW MAINTENANCE BATTERY….231
18.2.6 MAINTENANCE FREE BATTERY….231
18.2.7 BATTERY CHARGING….231
19. WEAR PARTS LIST….238
20. FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….240
20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS….240
20.2 ENGINE OIL SPECIFICATIONS….242
20.2.1 NORMAL OPERATION….242
20.2.2 ARCTIC OPERATION….243
20.3 TRANSMISSION, TORQUE CONVERTER AND OIL COOLER, TANDEM DRIVE CASES….243
20.4 HYDRAULIC SYSTEM OIL SPECIFICATIONS….243
20.5 REAR DRIVE AXLE AND CIRCLE DRIVE BRAKE HOUSING OIL SPECIFICATIONS….243
20.6 DIESEL FUEL SPECIFICATIONS….243
20.7 COOLANT SPECIFICATIONS….244
20.7.1 GENERAL….244
20.7.2 ANTIFREEZE….245
20.7.3 SUPPLEMENTAL COOLANT ADDITIVES….246
20.8 CIRCLE DRIVE GEAR CASE OIL SPECIFICATIONS (HDTF)….251
21 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….252
21.1 INTRODUCTION OF NECESSARY TOOLS….252
21.2 TORQUE VALUES FOR STANDARD METRIC FASTENERS….253
21.3 TORQUE VALUES FOR STANDARD ENGLISH FASTENERS….254
21.3.1 TYPE 1, 5 AND 8 NON-PHOSPHATE COATED HARDWARE….254
21.3.2 TYPE 8 PHOSPHATE COATED HARDWARE….255
21.3.3 TORQUE VALUES FOR HOSE CLAMPS….256
21.3.4 TORQUE VALUES FOR SPLIT FLANGE CONNECTIONS….256
21.3.5 O-RING FACE SEAL FITTING TORQUE….257
22. PERIODIC REPLACEMENT OF CRITICAL PARTS….258
23. MAINTENANCE SCHEDULE CHART….259
23.1 MAINTENANCE SCHEDULE CHART….259
24. SERVICE PROCEDURES….264
24.1 PERIODIC SERVICE CHART….265
24.2 WHEN REQUIRED….266
24.2.1 ETHER STARTING AID….266
24.2.2 CIRCUIT BREAKERS….266
24.2.3 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES….266
24.2.4 REPLACING RIPPER TOOTH….267
24.2.5 MOLDBOARD SLIDE….268
24.2.6 CHECK CIRCLE GUIDE CLEARANCE, ADJUST….268
24.2.7 MOLDBOARD ACCUMULATOR (IF EQUIPPED)….272
24.2.8 WIPER BLADES….272
24.2.9 CIRCLE SLIP CLUTCH, LEVEL AND FILL PLUGS….272
24.2.10 CIRCLE REVERSE GEAR CASE – WET TYPE BRAKE ADJUSTING….273
24.2.11 INCHING PEDAL – INSPECTING….273
24.2.12 TRANSMISSION CLUTCH – CALIBRATION….274
24.2.13 TORQUE CONVERTER LOCK UP – CHECK….274
24.3 CHECK BEFORE STARTING ENGINE….275
24.4 EVERY SHIFT/10 HOURS SERVICE….276
24.4.1 BRAKES – CHECK….276
24.4.2 WARNING LIGHT – CHECK….276
24.4.3 GAUGES – CHECK….276
24.4.4 BACKUP ALARM – CHECK….276
24.4.5 OPERATIONAL LIGHTS – CHECK….276
24.4.6 RADIATOR COOLANT LEVEL – CHECK….277
24.4.7 RADIATOR DEBRIS – CHECK….278
24.4.8 FUEL/WATER SEPARATOR – DRAIN….278
24.4.9 FUEL TANK FUEL/WATER TRAP – DRAIN….278
24.4.10 FUEL TANK – CHECK….279
24.4.11 ENGINE AIR CLEANER – CHECK….279
24.4.12 TRANSMISSION OIL LEVEL TRANSMISSION DIPSTICK….282
24.4.13 HYDRAULIC OIL TANK LEVEL HYDRAULIC OIL TANK SIGHT GAGE….283
24.4.14 BLADE SLIDE RAILS….283
24.4.15 ENGINE OIL DIPSTICK & FILL CAP….284
24.4.16 CIRCLE TEETH….284
24.4.17 CIRCLE TOP & BOTTOM….284
24.4.18 ENGINE FAN BLADE….285
24.5 EVERY 50 MAN HOURS/WEEKLY SERVICE….286
24.5.1 AXLE AND FRONT STEERING LINKAGE….286
24.5.2 STEERING LINKAGE & CYLINDER PINS….286
24.5.3 THE ROD & LEANING WHEEL ROD CYLINDER….287
24.5.4 DRAWBAR BALL JOINT….287
24.5.5 ARTICULATION BEARINGS….288
24.5.6 RIPPER LINKAGE….288
24.5.7 CIRCLE REVERSE CASE OIL LEVEL….289
24.5.8 CAB AIR FILTERS (IF EQUIPPED)….289
24.5.9 TIRES….289
24.5.10 TANDEM CASES, BREATHER….290
24.5.11 TANDEM CASES, FILL PLUG….290
24.5.12 TANDEM CASES, OIL LEVEL PLUG….290
24.5.13 HYDRAULIC OIL FILTER….290
24.5.14 TRANSMISSION FILTER….291
24.5.15 BATTERY….292
24.5.16 MACHINE….292
24.6 100 HOURS INITIAL SERVICE….293
24.6.1 LOCK/UNLOCK AXLE FILTER….293
24.6.2 REAR AXLE, SUCTION SCREEN….293
24.6.3 REAR AXLE DIFFERENTIAL….293
24.7 EVERY 250 HOURS/MONTHLY SERVICE….294
24.7.1 AIR INTAKE HOSES & CLAMPS….294
24.7.2 COOLANT SYSTEM HOSES & CLAMPS….294
24.7.3 REAR AXLE, OIL LEVEL….294
24.7.4 ENGINE OIL & FILTER CHANGE….295
24.7.5 COOLANT CORROSION RESISTER CARTRIDGE….296
24.7.6 CIRCLE REVERSE CASE BREATHER….296
24.7.7 CONTROL LEVER LINKAGES….296
24.7.8 CONTROL VALVE LINKAGES….297
24.7.9 BRAKE ACCUMULATOR GAS PRESSURE….297
24.7.10 BANK CONTROL GUIDE….297
24.7.11 RIPPER CYLINDERS (IF EQUIPPED)….297
24.7.12 LIFT CYLINDER CAP….298
24.7.13 LIFT CYLINDER TRUNNIONS….298
24.7.14 LIFT CYLINDER TRUNNION SHAFTS….298
24.7.15 CIRCLE SIDE SHIFT CYLINDER….298
24.7.16 BLADE PITCH CYLINDER….299
24.7.17 ARTICULATION CYLINDERS….299
24.7.18 WHEEL HUB BOLTS….299
24.7.19 WHEEL BRAKE….300
24.7.20 AIR CONDITIONER BELT….301
24.8 EVERY 500 HOUR/THREE MONTHS SERVICE….302
24.8.1 COOLANT PROTECTION….302
24.8.2 FUEL FILTER….302
24.8.3 PARKING BRAKE….304
24.8.4 FUEL TANK, FILTER SCREEN (STRAINER)….304
24.8.5 TRANSMISSION FILTER….304
24.8.6 WHEEL BRAKE….304
24.8.7 BLADE ACCUMULATORS….304
24.9 EVERY 1000 HOURS/SIX MONTHS SERVICE….305
24.9.1 DRAWBAR, FRONT BALL JOINT….305
24.9.2 ROPS MOUNT BOLTS….305
24.9.3 HYDRAULIC OIL FILTER….305
24.9.4 TRANSMISSION OIL….305
24.9.5 DRIVE SHAFT….306
24.9.6 LOCK/UNLOCK AXLE FILTER….306
24.9.7 FRONT WHEEL BEARING….307
24.9.8 TOE-IN….307
24.9.9 ENGINE DRIVE & ALTERNATOR BELTS….309
24.9.10 FAN BELT….310
24.9.11 ALTERNATOR BELT….311
24.9.12 AIR CONDITIONER BELT….311
24.10 EVERY 1500 HOURS SERVICE….312
24.10.1 ENGINE VALVES AND INJECTORS….312
24.10.2 TURBOCHARGER MOUNTING NUTS….312
24.10.3 ENGINE MOUNT BOLTS….312
24.10.4 WATER PUMP….312
24.10.5 ENGINE….312
24.11 EVERY 2000 HOUR/ONE YEAR SERVICE….313
24.11.1 TANDEM DRIVE CASE….313
24.11.2 HYDRAULIC TANK RETURN FILTER AND SUCTION STRAINER….314
24.11.3 HYDRAULIC TANK….315
24.11.4 HYDRAULIC TANK FILTER BREATHER CAP….318
24.11.5 REAR AXLE….318
24.11.6 CIRCLE DRIVE….318
24.11.7 FRONT WHEEL BEARING….318
24.11.8 LOCK/UNLOCK OF SUCTION SCREEN….319
24.11.19 VALVES & INJECTORS….319
24.11.10 CAB PRESSURIZER FILTER….320
24.11.11 ACCUMULATORS….320
24.11.12 BATTERIES….320
24.12 EVERY 4000 HOURS/TWO YEAR SERVICE….321
24.12.1 RADIATOR COOLANT….321
24.12.2 REFRIGERANT (GAS) IN AIR CONDITIONER CHECKING LEVEL….325
24.13 EVERY 6000 HOURS/THREE YEAR SERVICE….327
24.13.1 INJECTORS….327
24.13.2 FUEL PUMP….327
24.13.3 TURBOCHARGER….327
24.13.4 FAN HUB….327
24.13.5 IDLER PULLEY….327
24.13.6 VIBRATION DAMPER….327
SPECIFICATIONS….329
25. GD750A-1….330
25.1 WEIGHT….331
25.2 TRANSMISSION AND TORQUE CONVERTER PERFORMANCE….331
25.3 LIQUID CAPACITIES….331
25.4 ENGINE….332
25.5 HYDRAULIC….332
25.6 CIRCLE….332
25.7 DRAWBAR….333
25.8 MOLDBOARD….333
25.9 BLADE RANGE….333
25.10 FRONT AXLE….333
25.11 AXLE REAR….334
25.12 STEERING….334
25.13 TANDEM DRIVE….334
25.14 WHEELS, FRONT AND REAR….334
25.15 BRAKES….334
25.16 OPERATOR&’S COMPARTMENT….334
CEBM002104 – Motor Grader GD750A-1 Shop Manual….335
Komatsu Motor Graders GD750A Repair Service Manuals