PREVENTIVE MAINTENANCE

MOTOR GRADER
PT PUTRA PERKASA ABADI
 PREVENTIVE MAINTENANCE
GD 755-5R
NAMA : AHMAD KHAIRUDIN
NRP : 22001802
TEMPAT TL : LAMPUNG, 15 SEPTEMBER 1991
JABATAN : TECHNICAL INSTRUKTUR
DEPARTEMENT : PPA ACADEMY

PT. PUTRA PERKASA ABADI

SITE BUKIT ASAM
Selama Pelatihan
Sebelum Pelatihan

Sebelum Pelatihan …
Tujuan Pelatihan

Setelah menyelesaikan pelatihan, peserta harus dapat

melakukan & memahami :
1. Product Knowledge
2. Preventive maintenance
3. Structure & Function Engine & Power Train System
4. Structure & Function Hydraulic & Electric System
5. Structure & function Brake & Fan
 Nama Perusahaan : Putra Perkasa Abadi
Profil Perusahaan Bidang Usaha : Mining Contractor
Profil Perusahaan Tahun Berdiri : Tahun 2002

Project : 1. Site MHU – Kaltim 4. Site BIB – Kalsel 7. BUKIT ASAM

2. Site ABP – Kaltim 5. Site SKS – Kalteng 8.MIP
3. Site KJB – Kaltim 6. Site MLP – Kendari (Sulsel)
VISI :
Menjadi 3 besar kontraktor pertambangan batubara di Indonesia.

MISI :
❖Memberikan nilai tambah pelayanan kepada customer dengan pengoperasian yang baik di bidang
pertambangan terbuka dan pemindahan material.
❖Menghasilkan nilai tambah ekonomi yang maksimum kepada pemegang saham dan kepada
stakeholder (semua pihak terkait) .
❖Memberikan perbaikan secara terus-menerus dan meneyeluruh di perusahaan melalui proses
engineering dengan menggunakan sistem manajemen mutu, lingkungan dan K3 berdasarkan ISO9001,
ISO 14001, ISO 45001, SMK3 PP No50 Tahun 2012, Kepmen ESDM No 1827 Tahun 2018 sebagai acuan
Nilai Inti PT PutraNILAI INTI PERUSAHAAN
Perkasa Abadi

1. Ketaqwaan kepada Tuhan Yang Maha Esa

2. Integritas
3. Kerjasama Team
4. Kreatifitas
5. Semangat untuk Menang
6. Kesempurnaan Kerja
 MAINTENANCE

Tujuan Maintenance :

1. High Physichal Availability

2. Best Performance
3. Reduce repair cost akibat unschedule break down
Kegiatan Maintenance Meliputi :

 1. Pengontrolan Unit
 2. Penggantian terhadap komponen yang rusak
 3. Penyetelan komponen agar standart
 4. Pengetesan unit
 Klasifikasi Maintenance
10 Hrs
Periodic Inspection
50 Hrs

Periodic Maintenance 250 Hrs

500 Hrs
Periodic Service
1000 Hrs
Engine Overhaul
2000Hrs
Torque Convrter
Preventive Maintenance Schedule Overhaul
Overhaul

Etc.

Monitoring
Maintenance Schedule repair
Inspection
Program
Condition Based
Service News
Counter Measure
Repair & Adjustment
Corrective Factory Modification
Maintenance Program
Breakdown Maintenance
 Maintenance

Periodic Maintenance adalah pelaksanaan service yang

dilakukan setelah alat bekerja untuk jumlah jam operasi
tertentu.

Periodic Maintenace terbagi 2 (dua) yaitu :

1. Periodic Inspection
Inspeksi harian atau pemeriksaan harian (daily 10
H) mingguan (weekly 50 H) sebelum unit mulai
dioperasikan.

2.Periodic Service
suatu usaha untuk mencegah timbulnya
kerusakan pada suatu alat yang dilakukan secara
berkala atau continue dengan interval pelaksanaan
yang telah ditentukan berdasarkan service
meter/Hours Meter

Kegagalan karena
pengaruh maintenance
✓Poor lubrication Practices,
✓Faulty repairs,
✓Slow response time,
✓Ineffective PM,
✓Inadequate routine
maintenance,
✓Etc.
Faktor Kegagalan Maintenance
Kegagalan tanpa
pengaruh maintenance
✓ Operator error,
✓ Mechanical design,
✓ Sabotage,
✓ Poor training,
✓ Material defect,
✓ Improper application,
✓ Poor environment,
✓ Etc.
 Apa yang dilakukan saat
Maintenance/Service ?

Maintenance merupakan suatu usaha atau tindakan reparasi

yang dilakukan untuk menjaga agar kondisi dan
performance unit selalu dalam keadaan prima dan siap untuk
beroperasi untuk meningkatkan daya produksi, serta
meningkatkan ketahanan umur unit. Yang dilakukan pada
saat SERVICE adalah :

INTI
1. Visual Check MAINTENANCE
2. Replace & Repair adalah BERSIH
3. Testing & Adjusting
Management Backlog

Terminologi Backlog Strategi Backlog

✓Unschedule Breakdown ✓Backlog Analisis

✓Lead time job lama ✓Back log scheduling
✓Down time tinggi ✓Backlog organisasi
✓Kerusakan tidak urgent ✓Backlog monitoring system
PAP
Hose dan Wiring
New Product Service Training for GD755-5R
GENERAL VIEW

1.Counter Weight
2.Front Wheel
3.Blade
4.Rear Wheel
5.Ripper
6.Engine
7.Cabin
8.Left Lift Cylinder
9.Right Lift Cylinder
DIMENSI UNIT
 SAA6D125E-5 Komatsu Engine
GD705-5 GD705A-4 GD755-5R
MODEL
Tier 3 Equivalent Tier 0 Tier 2 Equivalent
Engine Model SAA6D114E-3 S6D125 SAA6D125E-5
Gross Power 194kW (260HP) 157kW (211HP) 216kW (294HP)
Net Power 186kW (250HP) 149kW (200HP) 213kW (290HP)
Torque Converter introduced on Komatsu Grader
Torque Converter
with Lock-up clutch
1. PTO drive gear (number of teeth: 70)
2. Pump
3. Drive case
4. Stator
5. Turbine
6. Damper
7. Lockup clutch piston
8. Lockup clutch housing (number of teeth: 72)
9. Pilot T/M E/G
10. Boss
11. Disc
12. One-way clutch
13. Race
14. Guide
15. Stator shaft
Counter shaft Transmission with
ECMV PTO driven gear

PTO idler gear

Output shaft torque
converter

Input shaft
Output shaft

FL clutch

Upper shaft
Output shaft
FH clutch

Lower shaft

3rd clutch

Output shaft
Coupling

4th clutch
New Monitor Panel
Electric Pedals
Front frame mount Cabin
Stretched Wheelbase & Short Turning
Radius
CLSS Hydraulic System
Center
Hydraulic System Outline
Full hydraulic Brake System
Productivity and Fuel Saving
Circle Drive Gear / Circle Reverse Gear

Shear Pin
Battery Location
Easy Fueling from the Ground
New Product Service Training for GD755-5
Outline and
Operation

3, Operation related

Service Planning Dept.

Techno Training Center
 Selectable Transmission Modes
Two unique transmission modes are specially developed for the new machine.
It enables the operator to select either the manual mode (direct mode) or the
auto mode (torque converter mode) for optimum performance.

Manual Mode Auto Mode

⚫Direct drive in all gears
⚫Works the same way as conventional power
shift ma chine
⚫Constant machine speed
⚫More economical operation
⚫ With torque converter in F1-F4 gears,
easy to operate the motor grader,
⚫ Maximum productivity at any application,
⚫ Easy traveling and high maneuverability
with automatic gear shifting.

F1 to F8

R1 to R4

T/C mode selector switch

Manual Mode and Auto mode
Manual mode Auto mode

T/C state

L/U state
(Direct mode)

T/C changes to
L/U mode as
machine speed
increases

Auto Gear
Shift
 Manual Mode and Auto mode

The Decal can be found

on the right side of cabin.
ECMV OUTLINE GEAR ECMV Reduction
SPEED FL FH R 1st 2nd 3rd 4th
Ratio

N - - - - - - -

F1 O O 6.773
F2 O O 4.787
F3 O O 3.499
F4 O O 2.473
F5 O O 1.771
F6 O O 1.251
F7 O O 0.900
F8 O O 0.636
R1 O O 5.957
R2 O O 3.077
R3 O O 1.557
R4 O O 0.791
Performance Curve 1
12km/hr
 Engine Stall Prevention Function ( Manual Mode)
As load increases further, the engine may stall.
The engine stall prevention function will work just before the engine stalls,it automatically
changes to auto mode (with torque converter) to avoid engine stalling.

GD705-5/GD755-5R transmission control condition

Torque converter operation

Lock-up operation

46
Engine Stall Prevention Function

A If the load increases, the engine speed will go down.

B If the load increases further, the engine may stall.

C Just before the engine stalls, it automatically changes to

Auto mode ( with torque converter) to avoid stalling.

D When the load decreases and travel speed has

recovered, it automatically returns back to manual mode.

During manual mode:

When engine speed goes down to 600rpm,
the controller deactivates the lock up function
and goes to T/C drive to prevent stall.

When the engine recovers to 1000rpm and

t/c slip is less than 100, L/U is restored and
machine goes back to manual mode.
Selectable Working Modes
 Variable Horse Power Control -1
The transmission controller and engine controller exchange signals using CAN communication.
The engine power mode switching always takes place after gear shift is completed.

4 stage VHPC
Variable Horse Power Control

ECO : 120 kW (161 HP)

LOW : 150 kW (201 HP)
MID : 165 kW (221 HP)
HIGH : 186 kW (250 HP)
Variable Horse Power Control - 2

Engine torque
Engine speed

150kW

165kW
186kW
Constant Speed Operation
Constant Speed
Operation
 Ultra low-speed control ( Creep Mode)
In this mode, travel speed is maintained at 1 km/h. This mode is used for light
load work such as final finishing work.

Condition of Ultra low speed mode (Creep Mode )

Mode T/M Lever Accel Inching
Machine Switch
Manu Auto Pedal Pedal

GD705-5 X X O F1 RELEASED RELEASED

GD755-5R O O O F1 RELEASED RELEASED

In case F1 manual and both pedals are released,

the speed is at 1.6 – 1.7 km/h (engine 825 rpm)

Note for GD755-5R Creep Mode Operation:

When using the creep mode switch on finishing work, it
Creep Mode Switch is advisable to use it in T/C Auto mode. If used in Manu
Mode and the creep mode switch is reset, a shock on
the machine may occur because the lock-up is
engaged thus a trace of the blade may be left on the
finished surface.
GD755-5R
Skip Shift Function (Shifting Down) - Overrun protection Function
To protect the engine, transmission and hydraulic pump, the torque converter lock-up
condition is controlled to protect overrun.

Conditions:
When input shaft speed is≧ 3000rpm
When engine speed is ≧ 2650rpm Overrun!!!!

Overrun Prevention Action

Speed
Phenomenon Mode Action
Range
F1-F7 Shifts up regardless of the mode to
R1-R3 L/U protect the pump and engine

Overrun F1-F7 L/U is applied to make use of

T/C
R1-R3 engine braking and then shifts up.
F8 Change to T/C mode.
L/U
R4
 Directional Inhibit Function(F, R)
To protect the transmission, there is a function to prevent transmission gear shift from
wrong operation of F or R even when the gear shift lever is operated.

When traveling in reverse at a speed of more than 4 km/h, even if gear shift lever is operated
to F1 or any position of Forward, transmission will not be shifted to immediately to travel
forward. The engine speed is lowered to reduce the travel speed, and then travel speed goes
to below 4.0 km/h, the transmission is shifted to Forward.

Same function from F to R as well.

This is a same concept which is programed on HD dump trucks.

But different concept from WA-6/7 wheel loaders.

Smartly utilize this function, GD705-5 can be operated more efficiently,

minimizing cycle time by quick directional change.

Forward

Less than Less than

4.0km/h 4.0km/h

F1 F4 Reverse
 Skip Shift Function (Overrun Prevention)
As part of the overrun protection function ,the transmission
skip shift down function is applied..

The controller determines the real time speed of the machine and calculates the
applicable shift down gear speed according to the graph ( refer to shift down graph).

The first shift down happens on a gear lower then continuous to shift skipping 2 gear
speeds at a time until it reaches the applicable gear speed.

For example: Shift lever position: F8 F2 (Machine speed 12km/hr)

F8
According to the diagram the F4 speed F8 F2
range is applicable basing on the 12km/hr
F7 actual machine speed.

Even though the desired speed according

F5 to the shift lever is F2, it is not achieved
since the shift down function is computed
by the controller according to actual
F4 machine speed basing on the shift down
graph. (refer to shift down graph) F8 F7 F5 F4
F2
Engine starting aid cock
GD705-5 Structure and Function

Cab Controls

Service Planning Dept.

Techno Training Center
Controls and Gauges Overview
Monitor
Dimmer switch
Work Equipment control lever Differential lock Switch
Work Equipment
control lever

Machine monitor
mode selector Switch 2
Turn Signal
Machine monitor lever
mode selector Switch 1

Horn button
Brake
Steering Wheel pedal
Accelerator
pedal

Steering console tilt pedal

Gears
shift lever

Inching pedal

Right side
console
Monitor Panel
Monitor Panel 1 Head lamp high beam
pilot lamp Working lamp
pilot lamp
Turn Signal pilot lamp Turn signal
pilot lamp
Engine
tachometer Shift Indicator

T/C oil temp gauge

Fuel
gauge
Coolant temperature gage

Character display

Speedometer

Centralized Blade P mode

Lift arm
warning lamp accumulator pilot lamp
lock pin
pilot lamp
pilot lamp
Monitor Panel 2
Parking brake
pilot lamp Brake oil
Torque converter oil Engine water Engine oil Engine
temperature caution pressure temperature reheating
pressure
lamp caution lamp caution lamp pilot lamp
Battery charge circuit caution lamp
caution lamp

RPM
set pilot
lamp

Cooling fan
caution lamp Economy
Water Hydraulic oil operation display
Maintenance Differential oil
separator temperature lamp
caution lamp temperature
monitor caution lamp
caution lamp
Inching clutch
Differential lock overheat caution
pilot lamp lamp
Caution Items
If the monitor lights up during travel , inspect the location of the problem quickly and take the necessary action.
Parking brake
pilot lamp

Cooling fan
Water Maintenance caution lamp
separator caution lamp
monitor
 Caution Items
PARKING BRAKE PILOT LAMP
This monitor lights up when the parking brake has been applied.

MAINTENANCE CAUTION LAMP

Lights up approximately 30 seconds after the system check has been completed if the oil change time is close.
It flashes when there are less than 30 hours to the replacement time, and after the replacement time has
passed, it stays on.
This lamp also lights up when the air cleaner element is clogged.

WATER SEPARATOR MONITOR

This monitor lights up in red to inform the operator that the water
separator is full of water. If monitor lights up in red, stop the engine and drain the water from the water separator.

COOLING FAN CAUTION LAMP

This monitor warns about abnormality in the fan control system.
If the monitor lights up in orange, be sure to perform the inspection and maintenance after finishing the work.
Emergency Stop Items -1
Brake oil Engine water Engine oil
pressure temperature pressure
Battery charge circuit caution lamp caution lamp caution lamp
caution lamp

Hydraulic oil
Torque converter oil Differential oil temperature
temperature caution temperature caution caution lamp
lamp
lamp
Inching clutch
overheat caution
lamp
 Emergency Stop Items - 2
ENGINE WATER TEMPERATURE CAUTION LAMP
This monitor warns the operator that the engine coolant temperature has risen.
When it lights up, "E02 ENGINE OVERHEAT" is displayed on the character display at the same time, and the
engine output is automatically limited. (Engine is de-rated)
Run the engine under no load at a mid-range speed until the lamp goes out.

BATTERY CHARGE CIRCUIT CAUTION LAMP

When the engine is running, this monitor informs the operator that there is an abnormality in the charging
system.

When it lights up, "E03 CHECK RIGHT NOW" is displayed on the character display at the same time.
Move the machine immediately to a safe place, stop the machine, then stop the engine and inspect the charging
system.

ENGINE OIL PRESSURE CAUTION LAMP

This monitor warns the operator that the engine lubricating oil pressure has dropped.

When it lights up, "E03 CHECK RIGHT NOW" is displayed on the character display at the same time, and the
engine output is automatically limited.
Move the machine immediately to a safe place, stop the machine, then stop the engine and carry out inspection.

BRAKE OIL PRESSURE CAUTION LAMP

This monitor lights up if the oil pressure in the brake circuit goes below the specified value. When the engine is
stopped, the centralized warning lamp does not light up and the alarm buzzer does not sound.
After starting the engine, if the brake oil pressure is still below the specified value even after 30 seconds have
passed, "E03 CHECK RIGHT NOW" is displayed on the character display at the same time.
Move the machine immediately to a safe place, stop the machine, then stop the engine and carry out inspection.
Emergency Stop Items - 3
TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP
This monitor (5) warns the operator that the torque converter oil temperature has risen.
When it lights up, "E02 TC OVERHEAT" is displayed on the character display at the same time.
Move the machine immediately to a safe place, stop the machine, then move the gear shift lever to P (Parking)
and run the engine under no load at a mid-range speed until the lamp goes out.

DIFFERENTIAL OIL TEMPERATURE CAUTION LAMP

This monitor (6) warns the operator that the differential oil temperature has risen.
When the lamp lights up, "E02 DIFF OVERHEAT" is displayed on
the character display at the same time. Cancel the differential lock, move the machine to a safe place, set the
gear shift lever to the P (PARKING) position, and run at the engine at low speed under no
load until the lamp goes out.

HYDRAULIC OIL TEMPERATURE CAUTION LAMP

This monitor (7) warns the operator that the hydraulic oil temperature rose. When the lamp lights up, "E02 HYD
OVERHEAT" is displayed on the character display at the same time. Place the machine still in a safe place,
stop the engine, and check.

INCHING CLUTCH OVERHEAT CAUTION LAMP

This monitor warns the operator that the clutch temperature in the transmission rose due to partially applied
clutch operations.

Measures to be taken when the inching clutch overheat caution lamp lights up
1. Set the gear shift lever to N (NEUTRAL) position immediately.
2. Release the inching pedal.
3. Depress the brake pedal.
4. Even after the inching clutch overheat caution lamp goes out, keep the engine running at medium speed
(1200 to 1400 rpm) for at least 1 minute, placing the gear shift lever in N (NEUTRAL) position, to cool down the
clutch.
 Pilot Display -1
When starting switch is ON, the pilot display lights up when display items are functioning.

Head lamp high

beam pilot lamp

Turn Signal Working lamp

Engine reheating
pilot lamp pilot lamp
pilot lamp
Turn signal
pilot lamp

RPM set
pilot lamp

Centralized P mode Economy

warning lamp pilot lamp operation display lamp

Differential lock Inching clutch overheat

Blade Lift arm pilot lamp caution lamp
accumulator lock pin
pilot lamp pilot lamp
 Pilot Display -2
ENGINE PREHEATING PILOT LAMP
This monitor (1) lights up when the engine preheating electrical heater is actuated.
When the starting switch is turned to the ON position in cold areas, this lamp lights up. It goes out after 5 - 45
seconds to inform the operator that the preheating has been completed.
In addition, this monitor lights up when the starting switch is turned to the HEAT position.

DIFFERENTIAL LOCK PILOT LAMP

This monitor lights up when the differential lock switch is set to differential lock.

TURN SIGNAL PILOT LAMP

This monitor flashes at the same time when the turn signal lamp (hazard display lamp) flashes.

HEAD LAMP HIGH BEAM PILOT LAMP

This monitor lights up when the head lamp is set to high beam.

WORKING LAMP PILOT LAMP

(if equipped)
This monitor lights up when the working lamp is turned on.
 Pilot Display -3
BLADE ACCUMULATOR PILOT LAMP
(if equipped)
This monitor lights up when the blade accumulator switch is pressed to the accumulator side.

LIFT ARM LOCK PIN PILOT LAMP

This monitor lights up when the lift arm lock switch is pressed (pin removal).

RPM SET PILOT LAMP

This monitor lights up when the RPM SET switch is pushed to the front (SET/ACCEL) and the opening angle of
the accelerator is set.
The lamp also lights up if the brake pedal or accelerator pedal are depressed and the setting is temporarily
cancelled after the setting has been made.

ECONOMY OPERATION DISPLAY LAMP

This monitor lights up during economy operations. As this monitor lights up and goes out in conjunction with the
accelerator pedal, use it as an indicator of energy saving operations.

P MODE PILOT LAMP

This monitor lights up when the P mode is selected. Use the power mode selector switch to
select the P mode.
Meters 1
ENGINE TACHOMETER
This meter (2) indicates the engine speed.

ENGINE COOLANT TEMPERATURE GAUGE

This meter shows the engine coolant temperature. During operations, the indicator should be in
green range (B). If it enters red range (C) during operations, at the same time, the alarm buzzer
sounds, the centralized warning lamp lights up, and "E02 ENGINE OVERHEAT" is displayed on the
character display. Run the engine under no load at a mid-range speed and wait until the indicator
enters the green range. In addition, when the indicator enters the red range, the engine output
is automatically limited.

ARTICULATION GAUGE
This meter shows the angle between the front frame and rear frame.

TORQUE CONVERTER OIL TEMPERATURE GAUGE

This meter shows the torque converter oil temperature. During operations, the indicator should be in
green range (B). If it enters red range (C) during operations, at the same time, the
alarm buzzer sounds, the centralized warning lamp lights up, and "E02 TC OVERHEAT" is
displayed on the character display. Run the engine under no load at a mid-range speed and wait
until the indicator enters the green range.
Meters 2
FUEL GAUGE
This meter (6) shows the fuel level in the fuel tank.
During operations, the indicator should be in green range (B).
If it enters red range (A) during operations, it indicates that the
remaining amount of fuel is low. If it comes close to the red range,
add fuel as soon as possible.

SHIFT INDICATOR
This meter (7) indicates the shift range (speed range) of the transmission.
When the gear shift lever is at N (Neutral) or P (Parking), the shift range (1 to 8) is not indicated.

CENTRALIZED WARNING LAMP

When the machine is in any of the following conditions, this lamp lights up and the alarm buzzer
sounds intermittently at the same time:
⚫When an abnormality occurs in any emergency stop item
⚫When action code "E02" or "E03" is displayed on the character display
⚫When attempting to start the engine while the gear shift lever is not in the P position
⚫When the clutch temperature rises during inching operations

SPEEDOMETER
This meter (1) indicates the travel speed of the machine.
When it is changed to the shift indicator display, the shift position
is displayed.
SWITCH GD 825-2
Right Side Control Panel

Gear
shift lever

Right side
console
 Right Side Control Panel Switches Transmission mode
Blade accumulator
selector switch
Hazard lamp switch switch

Gear Shift lever

RPM SET mode Front working

selector switch Lamp switch

Rear working
Lamp switch

Front lamp
switch

Power mode
selector switch

Lift arm
lock switch Cigarette
lighter

RPM SET switch Starting switch

 Console Switches -1
RPM SET SWITCH
Use this switch when setting or adjusting the angle of the accelerator.
Position (A) SET/ACCEL
If this switch is pushed forward when the accelerator pedal has been depressed to give the necessary
engine speed, the opening angle of the accelerator at that point is maintained and the RPM SET pilot lamp
on the machine monitor lights up. Once the accelerator opening angle has been set, if the front of the switch
is pushed, the accelerator opening angle will increase by approximately 7% each time the switch is pressed.
If the front of the switch is kept pushed, the opening angle will increase 50% each second.

Position (B) RESUME/DECEL

Once the accelerator opening angle has been set, if the back of the switch is pushed, the accelerator
opening angle will decrease by approximately 7% each time the switch is pressed.
If the back of the switch is kept pushed, the opening angle will decrease 50% each second.
Once the accelerator opening angle has been set in the Auto mode, if the back of the switch is pushed in the
temporary cancel condition, the accelerator opening angle will be restored to the position before the
temporary cancel.

RPM SET MODE SELECTOR SWITCH

This switch is used to switch the power for the RPM SET system ON-OFF and to select the RPM SET mode.

Position (A): The automatic mode is selected and the indicator on the (A) side of the switch lights up.

Position (B): OFF

The electric power for the RPM SET system is shut off and the indicator of the switch goes out.

Position (C): The manual mode is selected and the indicator on the (C) side of the switch lights up.
 Console Switches -2
FRONT LAMP SWITCH
Use this switch to light up the front lamps, side clearance lamps and tail lamps.
Position (A): Front lamps light up in addition to lamps at position (B).
Position (B): Side clearance lamps and tail lamps light up
Position (C): OFF

FRONT WORKING LAMP SWITCH

This switch is used to light up the front working lamp.
Position (A): Working lamp lights up
Position (B): OFF

BLADE ACCUMULATOR SWITCH

This switch is used to actuate the blade accumulator.
Position (A): Blade accumulator ON
Position (B): OFF
REMARK:
The blade accumulator is effective in leveling road surfaces on jobsites where there are many rocks or when
clearing compressed snow.

CIGARETTE LIGHTER
This cigarette lighter is used to light cigarettes. When the
cigarette lighter is pushed in, it will return to its original position after
several seconds, so pull it out and use it to light your cigarette
 Console Switches
-3
STARTING SWITCH
Starting switch is used to start or stop the engine.
(A): OFF position (B): ON position (C): START position (D): HEAT position

POWER MODE SELECTOR SWITCH

This switch can be used to switch the engine output to match the purpose of the operation.
When the P mode is selected, the P mode pilot lamp on the machine monitor lights up.
Position (A): E mode (use this mode when operating or when traveling on flat ground)
Position (B): P mode (use this mode when traveling at high speeds or when travelling on uphill)

TRANSMISSION MODE SELECTOR SWITCH

By using this switch ,changeover between torque converter Auto mode and Manual mode can be carried
out.

LIFT ARM LOCK SWITCH

This switch is used to remove or insert the lifter lock pin. This switch is used when setting the blade to the
bank cut posture or shoulder reach posture. Press the switch to remove the pin, and press the switch again
to return the switch and insert the pin. A cover is provided to prevent accidental operations. Before
pressing the switch, open the cover.

HAZARD LAMP SWITCH

Use this switch (only in emergencies such as the case when
having to park on a road due to a failure, etc.
Position (A): All turn signal lamps and turn signal pilot lamps flash.
Position (B): OFF
 Other Switches

MACHINE MONITOR MODE SELECTOR SWITCH 2

This switch (11) is used to switch the function of the character display.
The basic operations are as follows.
Position (A): Use this position when going to the next screen or advancing the
cursor or going up to the next number when inputting numerals.
Position (B): Use this position when going back to the previous screen or returning
the cursor or going down

MACHINE MONITOR MODE SELECTOR SWITCH 1

This switch (12) is used to switch the function of the
character display.
When the switch is released, it automatically returns to
its original position.
The basic operation is as follows.
Position (A): Use this position to select (confirm) each
mode or operation.
Position (B): Use this position to cancel each mode or
operation.
DIFFERENTIAL LOCK SWITCH
Used to actuate the differential lock
 GEAR SHIFT LEVER
Use this lever to select the transmission speeds.
The transmission has 8 FORWARD and 4 REVERSE speeds,
and the gear is shifted simply by setting the gear shift lever to the
desired position. By setting the gear shift lever to P (PARKING)
position, the parking brake is applied and the parking brake pilot
lamp lights up.

Parking

Neutral

Reverse speeds
R,R2,R3, R Max

Forward Speeds
F1,F2,F3,F4,F5,F6,F7,F8
Pedals ACCELERATOR PEDAL
This pedal adjusts the engine speed.

BRAKE PEDAL
This pedal is used to apply the wheel brakes.
Inching pedal
Accelerator pedal

Brake pedal
Pedals - Inching Pedal
Long time inching operations raise the clutch temperature excessively and cause the seizure or
abnormal wear. In case the clutch temperature rose excessively during inching operations,
the inching clutch overheat caution is issued.
(The inching clutch overheat caution lamp and the centralized warning lamp light up, and the
alarm buzzer sounds intermittently.)

Avoid the following operations as they possibly cause issuance of the inching clutch overheat caution:
1)Continuous use of the inching pedal for a long time. As a target, the continuation of using the
inching pedal is within 10 seconds.

2) Operation of continuously repeated "depression" and "release" of the inching pedal within
a short time. Issuance of the inching clutch overheat caution is likely to indicate that large loads are applied.

3) Operation of the inching pedal while large loads are applied.

Issuance of the inching clutch overheat caution is likely to indicate that large loads are applied. In this case, take such measures
as lowering the engine speed, lightening loads on the blade, etc. When driving the machine or driving downhill, do not drive it by
inertia with the inching pedal depressed. This pedal cuts off the power from the engine. When depressing the pedal, the power is
cut off.
Use this pedal when stopping the machine, starting the machine off, or when shifting the direction between forward and reverse.
When the transmission is in F1 to F4 or in R1 or R2, operating this pedal makes it possible to make fine movements of the
machine, which are suitable for light load operations such as road surface finishing.

REMARK
⚫It is not necessary to operate the inching pedal when shifting gears.
When making gear shifts, operate the gear shift lever, not depressing the inching pedal.
⚫The duration of inching operations until issuance of the inching overheat caution, if issued, is uncertain.
 Work Equipment Control
RIPPER/SCARIFIER POWER TILT ARTICULATE
CONTROL CONTROL CONTROL

DRAWBAR LEANING
LEFT BLADE BLADE SIDE BLADE ROTATION RIGHT
SIDE SHIFT CONTROL CONTROL
LIFT CYLINDER SHIFT CONTROL LEVER BLADE LIFT
CONTROL CONTROL CONTROL
MAINTENANCE SEE OMM
 GD755-5R Structure and Function

Power Train

Service Planning Dept.

Techno Training Center
POWER TRAIN 825-2
INCHING VALVE (INCHING VALVE WITH MODULATING VALVE)
Fungsi
· Inching valve with modulation digunakan untuk
1. Saat pedal inching tidak diinjak
mengurangi kejutan atau hentakan saat pedal
inching digerakkan

2. Saat pedal inching diinjak sebagian

 General View
The power from engine is transmitted to
transmission through torque converter.
Transmission is of counter-shaft type,
controlled hydraulically
(8 forward and 4 reverse gear speeds).
The power from transmission is transmitted
to final drives through drive shaft.

The power after the speed is reduced in final

drives is transmitted to tandem drives
through shafts.
The power from shafts are transmitted to
hub shafts by the chains in tandem drives.
The power transmitted to hub shafts is
transmitted to tires to travel the machine.
Powertrain Piping Diagram

1. Transmission oil filler port/ oil level check port

2. Power train oil cooler inlet hose
3. Power train oil cooler
4.Power train branch hose
5. Power train 2nd pump outlet hose
6. Power train oil filter outlet hose
7.Power train 1st pump outlet hose
8. Power train oil filter
9. Torque converter outlet hose
10. Power train oil cooler outlet hose
11. Power train 1st pump
12. Power train pump inlet tube
13. Transmission
14. Power train 2nd pump
Powertrain Hydraulic Circuit
Diagram
 Transmission Control
The transmission is controlled by an
Electronic controller located inside the
operators cab. The controller is mounted
beneath the covers, on the left side of
the cab.

We see the gear shift lever located on

the right side console.
Also notice the mode selector switch,
which gives the operator the ability to
select either the manual, lock-up clutch
mode, or the automatic, torque converter
mode.

The controller communicates with

sensors that monitor the operations of
the transmission. The communication
network also includes the electronic
controller for the engine, and the
electronic monitor. The ideal
transmission operation, will then be
controlled, using the inputs from all these
components.
Transmission Sensors
Torque Converter oil
temperature sensor Torque Converter oil
pressure sensor

Transmission
intermediate shaft
Transmission oil speed sensor
temperature sensor

Transmission input
shaft speed sensor

Transmission shaft
output speed sensor
Transmission Sensors
Refer to shop manual for complete the procedures
Adjusting transmission speed sensor

Installation angle
adjustment range Gear
Sensor

Nut
Sensor
0.75 to 1.5 mm

Check that the signal from each speed sensor is inputted normally with the
"real time monitoring function" of the machine monitor.
For the operating method, see "Special functions of machine monitor".
Monitoring code (all TRANSMISSION1):

Input shaft: 31200-T/M SPEED: IN

Intermediate shaft: 31300-T/M SPEED: MID1
Output shaft: 31400-T/M SPEED: OUT

You cannot check the speed of other than the input shaft unless actually
driving the machine or running wheel idle off ground.
Powertrain Pump
The triple type gear pump consists of the power train charge pump, power train lubrication pump, and differential
lock pump. It is installed to the PTO shaft of the torque converter and driven by the shaft to supply oil pressure to
the torque converter, transmission and differential lock circuits.

Power train charge pump Power train lubrication pump Differential lock pump
Torque Converter
1. PTO drive gear (number of teeth: 70)
2. Pump
3. Drive case
4. Stator
5. Turbine
6. Damper
7. Lockup clutch piston
8. Lockup clutch housing (number of teeth: 72)
9. Pilot
10. Boss
11. Disc
12. One-way clutch
13. Race
14. Guide
15. Stator shaft
 oil outlet
Torque Converter Oil Flow
The oil flows through the main relief valve and its
pressure is reduced to below the set pressure by
the torque converter relief valve. The oil then
flows through inlet port (A) and the oil passage of
stator shaft (1) and guide (2) to pump (3).

The oil is given centrifugal force by pump (3) and

flows into turbine (4) to transmit its energy to
turbine (4).

The oil from turbine (4) is sent to stator (5) and

flows into pump (3) again. And part of the oil
flows through the space between turbine (4) and
stator (5) to outlet port (B). The oil is then con-
ducted to the oil cooler for cooling and used for
lubricating the transmission.

oil inlet
Torque Converter (Power
Flow1)
Torque Converter mode
( Lock-up is disengaged)
Drive case (3), boss (10) and turbine (9) are disconnected
and the torque converter works as an ordinary torque
converter.

Engine power

Flywheel (1)

Clutch housing (2)

Drive case (3), pump (5) and PTO drive gear (6) rotate
together

Oil is used as a medium

Turbine (9) and turbine boss (10)

Transmission input shaft (11)

The power transmitted to PTO drive gear (6) is

used as power for driving the hydraulic pumps
after being transmitted through PTO idler gear (7).
Torque Converter (Power Flow 2)
Direct Mode
( Lock-up is engaged)

Drive case (3), damper (8), boss (10) and turbine (9)
are connected and the lockup function works.

Engine power

Flywheel (1)

Clutch housing (2)

Drive case (3), pump (5) and PTO drive gear (6) rotate
together

Lockup clutch (4)

Damper (8)

Boss (10)

Transmission input shaft (11) The power transmitted to PTO

drive gear (6) is used as power for driving the hydraulic pumps
after being transmitted through PTO drive gear (6).
 1- Torque Converter Valve
Torque converter relief valve
The torque converter relief valve maintains the torque
converter inlet pressure below the set pressure to protect
the torque converter from abnormally high pressure.
Set pressure: 1.02 MPa {10.4 kg/cm2} (cracking pressure)
Main relief valve
The main relief valve maintains the pressure in the transmission
hydraulic circuit below the set pressure.
Set pressure: 2.78 MPa {28.4 kg/cm2}
(Engine at rated speed)

From powertrain oil Torque Converter

filter valve

To oil
Cooler

A: Drain (torque converter relief)

B: Drain
C: From pump
D: Drain
E: To torque converter
P1: Main relief pressure pickup port
P2: Torque converter relief pressure pickup port
Operation of Main Relief Valve
The oil from the hydraulic pump flows to port
(C) through the filter. Then it flows to chamber
(F) through orifice (a) in main relief valve (1).
When the oil pressure in the circuit increases
beyond the set pressure, the oil in chamber (F)
pushes piston (2) and the reaction force of the
movement pushes main relief valve (1) leftward.
This connects ports (C) and (E). Then, the oil
from the pump flows through port (E) into the
torque converter.
Operation of T/C Relief Valve

The oil relieved through the main relief

valve flows through port (E) into the
torque converter.

It also flows through orifice (b) in torque

converter relief valve (3) into chamber
(G).

When the oil pressure to the torque

converter goes beyond the set pressure,
the oil conducted to chamber (G) pushes
piston (4) and the resulting pushing force
pushes torque converter relief valve (3)
rightward. This connects ports (E) and
(A).

Then, the oil in port (E) is drained through

port
(A).
Transmission-2 PTO driven gear

PTO idler gear

Output shaft torque
The transmission installed is a converter
"forward 8-gear range and
reverse 4-gear range" R clutchv
transmission which consists of Input shaft
the counter-shaft type, constant Output shaft
mesh spur gear mechanisms and
the disc clutches. FL clutch
1st clutchv
The transmission selects a
rotating direction and Upper shaft
Output shaft
rotating speed by fixing the FH clutchv
counter-shaft type, constant
mesh spur gear mechanisms and 3rd clutchv
two out of seven sets of disc Lower shaft
clutches with the oil pressure by
ECMV operation
2nd clutch

Output shaft
Coupling

4th clutch
Clutch Pack (principle)
Clutch Combination
The transmission transfers the power received by the
transmission input shaft to the output shaft while
changing the gear speed (forward 1st - 8th or
reverse 1st - 4th) by any combination of the FL, FH,
R clutches and four speed clutches
Disc Clutch Operation

The oil sent from the transmission valve flows through the oil
The oil sent from the transmission valve is stopped and the oil
passage in shaft (1) to the back of piston (5) and moves
pressure on the back of piston (5) decreases.
piston (5).
Piston (5) is returned to its original position by wave spring (6),
As piston (5) moves, it presses separator plate (2) and
and shaft (1) and clutch gear (4) are disconnected.
friction plate (3) against each other. As a result, shaft (1) and
clutch gear (4) get together and transmit the power. Although
When the clutch is disengaged, the oil on the back of the
some oil is drained through oil drain hole (a) at this time, it
piston is drained by the centrifugal force through oil drain hole
does not affect the operation of the clutch since its quantity is
(a) to prevent partial engagement of the clutch.
little for the supply of oil.
Clutch Pack -1
Clutch Pack -2
Clutch Pack -3
Clutch Pack -4
When travelling @ Forward 3rd Speed
FL clutch (3) and 2nd clutch (18) are fixed hydraulically

.
Power from torque converter

Input shaft (1)

FL and R cylinders (2)

FL clutch (3)

FL clutch gear (5) (20)

FH and 1st cylinders(12)

Upper shaft (13)

Upper gear (15)

2nd clutch gear (16)

2nd clutch (18)

2nd and 3rd cylinders

4th cylinder (25)

Output shaft (26)

 When travelling @ Reverse 1st gear
Speed
R clutch (4) and 1st clutch (11) are fixed hydraulically.

Power from torque converter

Input shaft (1)

FL and R cylinders (2)

R clutch (4)

R clutch gear (6)

R idler gear (8)

(Output rotation is reversed through R idler gear (8).

Upper gear (15)

Upper shaft (13)

FH and 1st cylinders (12)

1st clutch (11)

1st clutch gear (14)

2nd and 3rd cylinders (20)

4th cylinder (25)

Output shaft (26)

 ECMV ( Electronic Control Modulation Valve)

A: FL clutch oil pressure pickup port

B: FH clutch oil pressure pickup port
C: R clutch oil pressure pickup port
D: 1st clutch oil pressure pickup port
E: 2nd clutch oil pressure pickup port
F: 3rd clutch oil pressure pickup port
G: 4th clutch oil pressure pickup port
H: Lockup clutch oil pressure pickup port

1. FL clutch ECMV
2. FH clutch ECMV
3. R clutch ECMV
4. 1st clutch ECMV
5. 2nd clutch ECMV
6. 3rd clutch ECMV
7. 4th clutch ECMV
8. Lockup clutch ECMV
9. Seat
10. Last chance filter
 ECMV OUTLINE
GEAR ECMV The oil from the pump flows to the
transmission case through the oil filter
SPEED FL FH R 1st 2nd 3rd 4th and then the flow diverges, one
flowing toward the main relief circuit and
N - - - - - - -
another toward the clutch operating
F1
circuit.
O O
F2
The oil regulated by the main relief valve
O O flowed in the clutch operating circuit,
F3
operates the clutch through
O O the last chance filter. The oil relieved by
F4
the main relief valve is supplied to the
O O torque converter.
F5
O O When the transmission gear is shifted,
F6
the ECMV increases the clutch oil
O O pressure smoothly according to
F7
the command current from the
O O transmission controller to reduce the gear
F8
shifting shocks. The ECMV
O O keeps the clutch pressure constant
R1
during travel.
O O
R2
When the FL, FH, or R, and one of 1st to
O O 4th ECMVs are selected, the pressure
R3
regulated oil is supplied
O O to the selected clutches and the desired
R4
gear range is obtained.
O O
 ECMV (Electronic Control Modulation
3 Different Types of ECMV
Valve)

Identification Color To Drain

From pump To Tank

Name plate

To
To Clutch
Clutch
 ECMV Operation ( F,R, 1,2,3,4)

Before shifting gear During filling

While no current is flowing to the proportional solenoid
(1), pressure control valve (3) drains the
oil from clutch port (A) through drain port (T).
Fill switch (5) is turned "OFF" at this time since
the oil pressure is not applied to pressure sensor
valve (4).
When the current flows to proportional solenoid (1) while there is
no oil in the clutch, the hydraulic force balanced with the solenoid
force is applied to chamber (B) to push pressure control valve (3)
to the left. As a result, pump port (P) is connected to clutch port
(A) and the oil starts filling the clutch. When the clutch is filled
with the oil, oil pressure sensing valve (4) operates and fill
switch (5) is turned "ON".
 ECMV ( Electronic Control Modulation Valve) ( F,R, 1,2,3,4)

Range A: Before shifting gear (oil is drained.)

Range B: Filling phase
Range C: Pressure adjusting phase
Range D: Filling phase (during triggering)
Point E: Start of filling
Point F: End of filling
 ECMV Operation (Lock-up)
When clutch is "disengaged" (released)
While no current is flowing to the proportional solenoid
(1), pressure control valve (3) drains the
oil from clutch port (A) through drain port (T).
When clutch is "engaged" (locked)
When the current flows to proportional solenoid (1), the hydraulic
force balanced with the solenoid force is applied to chamber (B) to
push pressure control valve (3) to the left. As a result, pump port (P)
and clutch port (A) are opened and the oil starts filling the clutch.
If the clutch is filled with oil, the thrust of the solenoid is balanced
with the sum of the thrust generated by the oil pressure in clutch
port and the reaction force of pressure control valve spring (2), thus
the pressure is adjusted.
 ECMV Operation ( Lock-up Clutch)
This valve is used to adjust the clutch oil pressure to the set
pressure and select a clutch. Since the pressure application
characteristics to the clutch are designed as the modulation
waveform, the lockup clutch is engaged smoothly and the gear
shift shocks are reduced. In addition, occurrence of a peak
torque in the power train is prevented. As a result, the operator
comfort improves and the power train durability increases.

Name Proportional
plate solenoid

A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch pressure pickup port
Pressure Test Ports
Measuring positions of each oil pressure on the
transmission.

⚫ Place the machine on a level ground,

⚫ Set the gear shift lever to P position and chock the tires.
⚫ Torque converter oil temperature: 60 to 80°C
 Differential and Final
Drive
Shaft Planetary carrier Sun gear Ring gear Planetary gear
Sprocket

Output Output

Coupling

INPUT
 Differential lock mechanism
When the motor grader levels the ground while
turning, the rear wheels slip more because of the
difference between tracks.
In this case, the differential lock type of final drive
has effects to lengthen the service life of the
tires.
Differential
Pinion gear Shaft case Side gear

Bevel Bevel
pinion gear
Differential Lock Operation
While differential lock is operating
qWhen the load resistance exerted on the
tandem drive wheels on only one side
decreases (in the mud etc.), only those
wheels rotate and consequently the power
cannot be transmitted. Differential
case

To make travel possible under this

condition, differential lock (7) is operated to
lock pinion gear (6) and the power is
transmitted to both axle shafts(8) evenly.

Side gear
 Differential Lock Components

Breather

Adjustable
Oil filter pipe
relief valve

Differential lock valve outlet

pressure can be is adjusted by
the relief valve.
Differential oil Final drive oil temperature: 60 to 80°C
Drain plug Differential
temp switch Rated speed (1,950 rpm)
lock solenoid When differential lock is operated.
Standard value:
2.70 to 3.09 MPa
27.5 to 31.5 kg/cm2
Tandem Drive
The tandem drive assemblies receives
the power from the final drive to the four
rear wheels of the motor grader. Each
tandem drive can oscillate thus keeping
the amount of level distortion on the
blade at minimum.

The long wheel base of the motor grader

( 6800 mm) also helps in minimizing the
blade movement on the ground that is
helpful in finishing related jobs

Since the tandem case can rock up and

down 15 degrees respectively, the rear
four wheels are kept on the ground even if
it is uneven, thus the blade moves up and
down less.
 Tandem Drive
There are two tandem drive assemblies on the motor grader. One for each side of the machine. The tandem
drives are powered by the output shaft of the final drive. The tandem drives transfer that power to the wheel
brake assemblies, for turning the wheels. Chains are used as the mechanism for transferring the power.

Brake oil
line

Torque from the final drive is transferred

to the to the wheel hub through chains.
Wheel There are two chains on each tandem
Chain brake hub drive case
Tandem
Case
Chain

Wheel

Chain
 Tandem Drive
The tandem case can rock up and down 15 degrees respectively, the rear four
wheels are kept on the ground even if it is uneven, thus the blade moves up and
down less.
※ When the rear wheels of the motor grader ride on a bump, the blade moves as follows.

1. If both of the right and left wheels ride on the
bump (height: H), the height at the center between
the rear hub shafts is H/2. Since the blade is located
at almost the center between the front and rear axles,
the height of the blade is H/4.
2. If only the left one of the rear wheels rides on the
bump (height: H), the height at the center between
the rear hub shafts is H/2, and it is H/4 at the center
of the chassis on the rear hub shafts and H/8 at the
center of the blade.
 Ref No. :0605-70-00E

GD705-5
Hydraulic system overview

133
 System diagram

Hydraulic system is powered by two pumps, one is a variable piston pump, LPV90
for Steering and Work equipment and another one is a gear pump, SAR40134for Fan,
Brake, Bank pin and Parking brake.
Brake circuit

135
 Cooling fan circuit

As this cooling fan system is powered by the gear pump which capacity is fixed,
fan speed is controlled by drain amount of oil from the supplied amount.
136
During charging to the accumulator, fan speed goes down for few seconds.
Main pump( LPV90 )

137
Steering circuit

138
 LS regulation valve

(( example ))
When LS(st) = 100K, Pcf(Pb) = 100+24 = 124K
Unload valve set = 100-8 + 34 = 126
Pump pressure = 124 + piping loss 139
Unload valve is closed.
Control valve ( CLSS-DB12 )

9 spool valve with Ripper

BRAKE AIR CIRCUIT SYSTEM
 Ref No. :0605-72-00E
GD705-5 Brake system

Brake & Cooling fan pump

142
Brake circuit

143
Engine starting aid cock

144
Accumulator charge valve function

P
PA
145
Accumulator charge valve

Right side of Engine

146
Accumulator charge valve ports &
sections
Adjusting R2
relief valve
varies both cut-
in and cut out
P pressures.
P Turn clockwise to increase
Turn counter clockwise to decrease
one turn : 2.49 MPa ( 25.4 Kg/cm2 )

PA T

147
Cut-in state When Accumulator pressure is
low

148
Cut-out state When Accumulator pressure is
high

149
Accumulator

Behind Cabin

150
Brake valve

151
Brake pedal is depressed

152
 Brake pedal depressed & balanced

F & R pressures become same

balancing to Spring(4) force.

153
When one side brake failed

154
Brake pedal released

155
Slack adjuster when pedal is depressed (1)

156
Slack adjuster when pedal is depressed (2)

157
Slack adjuster when pedal is depressed (3)

158
Slack adjuster when pedal is released

159
Wheel brake

160
Brake disc wear check

161

From Operation & Maintenance manual

Parking brake & bank pin circuit

This diagram shows the condition that

162
the both solenoid valves are turned ON.
Parking brake & bank pin control

Right side of Engine

163
Parking brake structure

164
Same as GD755-5R
Pad thickness & clearance

★ See Shop manual in detail for

the clearance adjustment.

165
Parking brake emergency releasing

166
Same as GD755-5R
GD705-5 Cooling system

167
Cooling system

168
Brake and Cooling fan pump

169
Fan motor

EPC valve

170
Cooling fan circuit

As this cooling fan system is powered by the gear pump which capacity is fixed,
fan speed is controlled by drain amount of oil from the supplied amount.
171
During charging to the accumulator, fan speed goes down for few seconds.
Flow control

172
Flow control

173
Flow control

174
Typical failure code(1)

175
Typical failure code(2)

176
Fan speed 100% / 70% mode
Monitor panel operation (Service mode)
Choose “INITIALIZE” by >
in Service mode ➔◇

➔INPUT “7641” ➔◇

➔Choose the mode by >

Depress Acceleration pedal
to Max.
Left figure is the actual speed and
right figure is the target speed of
100%. As the machine was still very
cold, the actual one showed low value.

70 % mode was chosen

➔◇

The speed can be adjusted

by the cursor < or > for up
and down.
70% speed is the most
frequently used zone
during actual jobs.
Annex.

As this cooling fan system is powered by the gear pump which capacity is fixed,
fan speed is controlled by drain amount of oil from the supplied amount.
During charging to the accumulator, fan speed goes down for few seconds.
179
 Ref No. :0605-73-00E

GD705-5 Steering system

March 2014
Techno Training Center

180
 Main pump( LPV90 )

181

Same page from Hydraulic overview

Steering circuit

182

Same page with Hydraulic overview

Priority valve

183
Priority valve function

184
Priority valve circuit

•The priority valve functions to give oil

flow priority to the steering system, that
is closely related to safety, over the work
equipment.
•Only when enough flow is supplied or
Steering is not used, the rest oil is
provided to the work equipment.
• Difference pressure, ( Pump – Steering
LS pressure ) pushes the spool to left
against the spring force and open
passage to the work equipment.

•LS relief valve decides Steering circuit

maximum pressure ( LS relief + 24K ).
185
When engine is started

186
When machine is steered

187
When Work equipment is operated

188
Simultaneously operation(1)

189
Simultaneously operation(2)

190
 Steering valve - structure

191
There are grooves on the There are holes on the
spool. sleeve.
Role of Center spring

192
Steering valve - operation

There are holes on the

sleeve and the bottom ones
are connected with Pump.
2nd ones from bottom are
connected with the gerotor.
The holes on top are for left
steering and 2nd ones from
top are right steering.

The spool has vertical

grooves and respective
groove makes connection
with the holes of the sleeve
when Steering wheel is
turned as the angular
difference was explained
on the previous page.
193

Page from Wheel loader training course

Connection of Hand pump & Sleeve

194
Steering valve

In the steering spool, there is

a bypass line in addition to
the metering line. When
steering is operated quickly,
this bypass line amplifies flow
to the steering cylinders. This
structure enables fine control
when slow and faster steering
when quick turning.
195
Q/Amp. characteristics

A small Orbit-roll can perform fine control

and quick steering when necessary with the
Q/Amp. Type one. This is an unique feature
196
on Motor Grader.
 Ref No. :0605-74-00E

GD705-5 Hydraulic equipment

March 2014
Techno Training
197
Center
Hydraulic component layout (1)

198
Hydraulic component layout (2)

199
Hydraulic component layout (3)

200
Hydraulic component layout (4)

The spools of the control valve are

moved by mechanical linkage
connected with control levers.

201
Hydraulic tank

202
 Main pump( LPV90 )

See Annex 1.

Same
page from
203
Hydraulic
overview
Main pump outside

P1C

204
Main pump section
Ball

The Ball contacts with

the lever of205Servo PC
valve (next page).
Servo valve section

Ball

Lever(1) contacts with

the ball on the rocker
206
arm of Main pump.
LS and PC valve function

ΔPLS
= 24K

Q = C X A X √ ΔPLS
C : co-efficient, A : area of passage 207
LS valve principle
Same page from GD755-5R text
•LS (Load Sensing ) valve
controls Pump discharge
amount as much as
required from Steering and
Work equipment.
•PA2(Pp), a kind of Pump
pressure but it is fed back
from Control valve together
with PLS to supply the
required flow amount
precisely.
•Discharge amount
generates ΔPLS when oil
passes Control valve and
LS valve keeps it in
constant and the amount is
controlled proportionally to
lever stroke or steering
speed. 208
See Annex 2.
LS valve function

PA2
PLS
PA

209

Same page from GD755-5R text

LS valve - neutral

When all levers are in neutral, LS

pressure leaks through LS bypass and
lowers to zero.
Meanwhile , Pump discharges oil and
the oil is drains from Unload valve.
The Unload pressure pushes LS valve
to right and the Pump pressure goes
into Servo piston large area.
Thus Servo piston moves until the
minimum stopper.

This function is important for easy

starting Engine by minimizing
rotating resistance.

210

Same page from GD755-5R text

 PC valve principle

Servo control pressure is generated by PC valve

first in the upper stream and then it is increased
further more according to lever stroke.
So horsepower control is the first and then secondly
lever stroke control is carried out by LS valve if
necessary.
211

Same as GD755-5R text

PC valve function

•When Pump pressure, PA goes up, it pushes

PC valve spool to right retracting the spring
and PA enters to Servo piston large area.
Servo control pressure goes up and Servo
piston moves to left.
PA •As Servo piston is interconnected with PC
valve spool by the follow-up mechanism, the
Servo piston movement pushes back PC valve
spool and stops in the balanced position.
•Pump discharge amount is decreased
according to P-Q diagram.

212

Same as GD755-5R text

PC valve control
When pump pressure is low

213
PC valve control
When pump pressure is high

214
PC valve control
balanced

After Spool(3) moves left

or right, swash plate angle
changes and the
movement is fed back by
the ball to Lever(1).
The lever changes
Spring(2) force and the
spool(3) returns to the
balanced position. Thus
the swash plate angle is
controlled according to the
pump pressure.

215
Control valve ( CLSS-DB12 )

216
CLSS DB12
•Closed center D type
control valve is employed.
LS pressure is generated by
the reducing valve of
Pressure Compensation
valve .
•Pressure compensation
valve is located Before
spool, so called DB12.
•Pump pressure, PP is fed
back from the control valve.
•Pump discharge amount is
controlled by the higher LS
pressure, from Steering or
Work equipment chosen in
the LS regulation valve.
•LS regulation valve
provides reduced Pump
pressure to LS circuit of the
control valve when only
steering is operated. This
function is to close Unload
valve for saving energy by
stopping drain to tank and
makes loaded condition for
good response of Work
equipment.
•Maximum217circuit pressure
is adjusted by LS relief
valve.
Control valve ( CLSS-DB12 )
Spool diameter is 12 mm
and Pressure
Compensation valve is
located before spool.

Maximum set pressure is

adjusted by LS relief valve
not by Main relief valve
which is named by Surge
pressure absorbing valve.
LS relief = 216K
Pump line = 216+24
= 240 to
218
216+Unload 34 = 250K
Control valve outside view

Pump pressure,
PP and LS
pressure, LS are
fed back to Pump
LS219valve.
Control valve
Centralized safety valve
Filter Centralized safety valve for
• Blade lift RH head & bottom
• Drawbar shift head & bottom
• Power tilt head
• Blade shift head & bottom
• Blade lift LH head & bottom
• Ripper head
Individual port safety valves for
• Blade lift RH & LH bottoms

To lower blade
lifting force that
was too strong

Suction valves for

• Blade shift head & bottom
Line to Centralized safety valve

220
Control valve spools

Spools are moved by

mechanical linkage
connected to control levers.

As the figure shows neutral

position, all pump line is
closed at the spools, so
called “ Closed Center ”.

221
Control valve
Pressure Compensation valves

The relief pressure should be

adjusted by the LS relief
valve not by Main relief valve.

222
Control valve
Pressure release plugs(1)

The plug(37) is for Blade and other work

equipment to be lowered to ground
when hydraulic pressure is lost.
The plug(39) is for Ripper(opt.).

223
Control valve
Pressure release plugs(2)

224
From Operation & Maintenance manual
Control valve
LH Blade lift Pilot check valve

225
Control valve
Pilot check valves

Ripper(opt.) circuit
is also equipped
with Pilot check
valve.

226
View from top

Pp, to Pump
Pilot
check
valves Centralized
safety valve

T1, to Tank
T2, to Tank
TS

227
 View from left side
Pressure Centralized safety valve Pp, Pump
release plug pressure pick
(Blade) up port

Pressure
release plug
(Ripper)
P2
From Pump

T2 to
Tank

LS pressure pick
up port

LS relief valve
Port relief valve(Blade lift LH) 228
 View from right side

Unload valve
& LS bypass
valve(bottom)

Port relief
Main relief valve ( Blade
valve lift RH )

229
View from rear side

Pp, to Pump

T2, to Tank

LS pressure
to Pump

P2 230
From Pump
Unload valve - neutral

231

Same with GD755-5R

Unload valve - operated

232

Same with GD755-5R

LS pressure introduction

233

Same with GD755-5R

LS pressure introduction
Pressure Compensation valve - balancing

234
Pressure compensation valve
control principle
1. Pump discharge amount is
controlled by the higher LS pressure
and Pump pressure becomes 2.4
MPa higher than the LS pressure.
2. The higher LS pressure is generated
by the reducing valve and the same
pressure goes to the lower side and
Pump LS valve. It throttles the Pump
pressure passage of the lower side.
3. Pump pressure is reduced and
balanced.
4. ΔP becomes same on both sides.
Flow rate Q = C X S X √ΔP
Flow rates are controlled
proportionally to lever strokes that
make open area, S1 and S2.

At this moment higher LS pressure is 10

MPa and the lower one is 5 MPa,
answer the following questions ;

Q1 : How much is Pump pressure ?

Q2 : How much is the reduced
235
Pump
pressure?
Same with GD755-5R
Pressure compensation valve operation

236

Same with GD755-5R

LS bypass valve

237

Same with GD755-5R

 LS relief valve

Maximum set pressure is adjusted by LS relief valve not by Main relief

valve which is named by Surge pressure absorbing valve.
LS relief = 216K
Pump line = 216+ ΔPLS 24 = 240K to 238

216+Unload 34 = 250K
 LS regulation valve circuit

(( example ))
When LS(st) = 100K, Pcf(Pb) = 100+24 = 124K
Unload valve set = 100-8 + 34 = 126
Pump pressure = 124 + piping loss 239

Unload valve is closed.

Same page with Hydraulic overview
LS regulation valve

Under the cabin and

left side of the machine

240
Hydraulic cylinder

241

Same with GD755-5R

Blade accumulator

242
Blade accumulator

243

Same with GD755-5R

Swivel joint

244
Pilot check valve
neutral position

Note : The holding

pressure is introduced to
the Centralized safety
valve( see Slide 22).
So if the safety valve
has leakage, hydraulic
drift happens.
245
Pilot check valve
operation

246
Separately installed
safety & suction valves

247
Circle rotation motor

248
Annex 1.
Why Pp is fed back to Pump?

249
 Annex 2.

(simplified image)

250
 Ref No. :0605-75-00E

GD705-5 Work equipment

March 2014
Techno Training
251
Center
Circle and Drawbar

252
Circle adjustment guide
Circle gear

Circle rotation
gear

Adjustment
bolts

253
Guide bushing
Guide
Adjusting clearance
Blade circle guide

Before adjustment, put the blade in the air and

pulled backward.

254

Same page from GD755-5R

Blade

Blade rail

Guide

255
Circle rotation gear

256

Same page from GD755-5R

Adjusting circle rotation gear
Testing
Testing posture

Stopping block

257

Same page from GD755-5R

 Adjusting circle rotation gear
adjustment

258

Same page from GD755-5R

Lifter and bank pin

B-B section shows the condition when the

bank pin is pulled out by the switch turning
on.

259