PDF Shop Manual Komatsu GD675-7E0 Motor Grader - 4 MB
This comprehensive shop manual contains all the necessary information for servicing and repairing the Komatsu GD675-7E0 Motor Grader.
It is the definitive guide for professional mechanics, offering step-by-step instructions, detailed diagrams, and technical specifications.
From the engine to the hydraulic system, every aspect of the machine is covered in depth.
Use this manual to perform accurate repairs and keep your motor grader in top working order.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
SEN06962-01
MOTOR GRADER GD675 -7E0
SERIAL NUMBERS 65001 and up
--- Page 3 ---
00 Index and Foreword Precautions When You Handle Hydraulic Equipment
Preventing Intrusion of Foreign Materials While You Refill
• During refilling with the hydraulic oil, do not let water enter
the electrical components.
• Clean the oil filler port and its around, refilling pump, oil
jug, or etc.
• Refilling by using an oil cleaning device is better method
since it can filtrate the contaminants accumulated in the oil
during storage.
Replace Hydraulic Oil While Its Temperature is High
• The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are
easily discharged from the circuit. Perform the replacement while oil temperature is high.
• Old hydraulic oil needs to be drained as much as possible when replacing.
NOTICE
Old hydraulic oil contaminates the new one if it is mixed since it contains contaminants and sludg-
es, and the service life of the hydraulic oil is shortened.
REMARK
Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the cir-
cuit.
Do Not Use the Hydraulic Oil and Lubricating Oil Again
Avoid reusing the hydraulic oil and lubricating oil which has been drained from the machine.
If reused, any foreign material may enter the hydraulic equipment, and it may cause a failure.
Flushing Operation
• Flushing is required to completely dislodge the contami-
nants and sludges, and existing oil containing those inside
the hydraulic circuit after disassembling and assembling,
and when replacing the oil with the new one.
• Normally, flushing is performed twice. Primary flushing is
performed by using the flushing oil (1) and the secondary
flushing is performed by using the specified hydraulic oil.
Cleaning Operation
Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic
device (pump, or control valve) or during operation of the machine.
GD675-7E0 00-47
--- Page 4 ---
00 Index and Foreword Abbreviation List
Abbreviation List
• This list of abbreviations includes the abbreviations for functions, devices, and parts which are used in the
shop manual.
• Commonly used abbreviations are not included.
• Special abbreviations which are not shown frequently are included in the text as additional information.
List of Abbreviations Used in the Text
Abbreviation Actual word spelled out Explanation
API American Petroleum Institute API is the abbreviation for American Petroleum Institute.
CAN is one of networks that communicate between the machine
CAN Controller Area Network
monitor and controllers.
Crankcase Depression Regula-
CDR valve CDR valve is a valve that is attached to the KCCV ventilator.
tor valve
CLSS is a hydraulic system that provides total control over the
Closed-center Load Sensing
CLSS pumps, valves, and actuators. When actuators are in neutral,
System
pump circuits are closed.
CRI is a function that is composed of the supply pump, common
CRI Common Rail Injection rail, and injector, and that controls the fuel injection rate and injec-
tion timing.
DEF Diesel Exhaust Fluid DEF is a urea solution that is used for the SCR system.
ECM is an electronic device that controls actuators adequately
ECM Electronic Control Module
with signals from sensors.
Electronic Control Modulation ECMV is a device that controls the connection and disconnection
ECMV
Valve of clutches of the transmission and brake.
Electronically Controlled Sus- ECSS is a function that decreases bucket vibration during travel
ECSS
pension System to reduce load spillage and operator's fatigue.
ECU is an electronic device that controls actuators adequately
ECU Electronic Control Unit
with signals from sensors.
EGR is a function that recirculates part of exhaust gas to the in-
EGR Exhaust Gas Recirculation
take side to control NOx emissions.
Electromagnetic Proportional EPC is a function that controls the pressure of the hydraulic circuit
EPC
Control in proportion to the electric current.
EPC is a function that controls the pressure of the hydraulic circuit
EPC Electrical Pressure Control
in proportion to the electric current.
Falling Object Protective Struc-
FOPS FOPS is a structure that protects operators from falling objects.
ture
Global Navigation Satellite Sys-
GNSS GNSS is a general term for satellite positioning systems.
tem
GPS Global Positioning System GPS is one of satellite positioning systems.
IMA is a device that controls fuel intake volume at the inlet of the
IMA Inlet Metering Actuator
supply pump.
IMV is a device that controls fuel intake volume at the inlet of the
IMV Inlet Metering Valve
supply pump.
KOMATSU Closed Crankcase KCCV is a function that isolates oil from blowby gas in the engine
KCCV
Ventilation and returns the blowby gas to the intake side.
KCSF KOMATSU Catalyzed Soot Filter KCSF is a filter that catches soot in exhaust gas.
GD675-7E0 00-95
--- Page 5 ---
10 Structure and Function Component Parts of Urea SCR System
1: Connector 4: Level sensing part
2: Cover (If equipped) 5: Concentration sensing part
3: Temperature sensing part
Function of DEF Tank Sensor
• This sensor is installed to DEF tank and outputs DEF level, DEF concentration, and DEF temperature
through CAN communication.
• DEF level and DEF concentration are measured by using ultrasonic wave.
• When the tank is frozen or empty, DEF level and DEF concentration are not measured.
GD675-7E0 10-31
--- Page 6 ---
10 Structure and Function Component Parts of Cooling System
Function of Cooling Fan Motor
The cooling fan motor changes fluid movement from the pump into fan rotation movement.
Operation of Cooling Fan Motor
The shaft (1) is supported in the case (2) by the bearing (9).
The piston (5) is contained in each cylinder of the cylinder
block (6), and it can slide in the axial direction. The spherical
side of the shoe (4) is connected to the point of the piston (5),
so the shoe can swing. Also, the shoe (4) is connected, and it
can slide on the flat surface (A) of the thrust plate (3). The cyl-
inder block (6) is connected to the shaft (1) through the spline
(a). The cylinder block (7), piston (6), and shoe (5) rotate to-
gether with the shaft (1).
The angle between the vertical axis of the flat surface (A) of the
thrust plate (3) and the axis of the shaft (1) is called the swash
plate angle (b). The swash plate angle (b) is fixed at a given angle.
The hydraulic force from the pump pushes the piston (5) from the cylinder block (6). The thrust of the piston (5)
is applied to the thrust plate (3) through the shoe (4), and the force to push the thrust plate (3) (F2) and force to
slide on the thrust plate (F3) act on the plate by the force (F3) that the piston (5) slides on the thrust plate (3).
The piston (5) of the cylinder block (6) and the opposite end are connected to rotate relatively to the valve plate
(7) fixed to the case (2).
The valve plate (7) has holes, one of which is at a position where the hydraulic oil from the cylinder block (6)
flows in, and the other is at the position where the hydraulic oil is discharged to. The holes are connected to the
pump and hydraulic oil tanks.
The cylinder block (6) rotates. When the cylinder block (6) ro-
tates and the thrust plate (3) pushes the piston (5), hydraulic oil
is discharged.
GD675-7E0 10-79
--- Page 7 ---
10 Structure and Function Component Parts of Control System
KOMTRAX Terminal
Function of KOMTRAX Terminal
Model: TC630/TC635/TC330
1 2 3 4
5
G0000318
1: GPS antenna connection part 4: Communication antenna connection
2: Machine harness connection (070-18P) 5: LED lamp display
3: Machine harness connection (070-12P)
The KOMTRAX terminal is a device that transmits various pieces of machine information obtained from the net-
work signals and input signals and also the GPS position information via wireless communication. Information is
transmitted by the communication antenna.
The condition of the KOMTRAX terminal can be checked on the KOMTRAX Settings on the service mode of the
machine monitor.
KOMTRAX terminal cannot be used in countries or regions where there is no permission by law.
The KOMTRAX terminal has LED lamps and 7-segment LED used for inspection and troubleshooting on its dis-
play section.
REMARK
Each country or region has different communication method (communication company). The KOMTRAX termi-
nal has built-in communication devices that are applicable to each country or region.
To use KOMTRAX terminal in a different country, authorization in the country where the machine is used is pos-
sibly required. For details, consult the person responsible for KOMTRAX at your local Komatsu distributor.
Input and Output Signals of KOMTRAX Terminal
070-18P “L80A”
Pin No. Signal name Input and output signals
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 CAN (C)_H Input and output
11 CAN (C)_L Input and output
GD675-7E0 10-127
--- Page 8 ---
10 Structure and Function Component Parts of Hydraulic System
Sectional View (G-G, H-H, J-J, K-K)
1: Pilot check valve (blade power tilt cylinder) 5: Centralized safety valve
2: EPC valve 6: Cylinder pressure release plug (centralized circuit)
3: Suction valve (blade side-shift cylinder bottom) 7: Centralized safety valve filter
4: Suction valve (blade side-shift cylinder head) 8: Pump circuit filter
GD675-7E0 10-175
--- Page 9 ---
10 Structure and Function Component Parts of Power Train System
↓
FL clutch gear (5)
↓
FH, 1st cylinder gear (12)
↓
Upper shaft (13)
↓
Upper gear (15)
↓
2nd clutch gear (16)
↓
2nd clutch (18)
↓
2nd, 3rd ring gear (20)
↓
Lower shaft (21)
↓
Lower gear (22)
↓
Output gear (25)
↓
Transmission output shaft (27)
GD675-7E0 10-223
--- Page 10 ---
10 Structure and Function Cross Slope System
Cross Slope System
Machines with cross slope system
System Diagram of Cross Slope System
2 a a 7
3 a 8
4 a 9
5 10
1
6 11
12
13
14
G0089839
a: CAN signal
1: Work equipment controller 8: Auto/manual switch (L.H.)
2: Machine IMU 9: Target cross slope increase switch
3: Drawbar IMU 10: Target cross slope decrease switch
4: Blade rotation angle sensor 11: Preset 1 selection switch
5: Work equipment electric lever 12: Preset 2 selection switch
6: Cross slope activation switch 13: Slope match activation switch
7: Auto/manual switch (R.H.) 14: Work equipment EPC valve
Function of Cross Slope System
The cross slope system automatically control the blade to the desired cross slope set by the operator.
REMARK
For the operation method of the cross slope, see the “Operation and Maintenance Manual”.
GD675-7E0 10-271
--- Page 11 ---
20 Standard Value Table Standard Value Table for Engine: GD675-7E0
Standard Value Table for Engine
Standard Value Table for Engine: GD675-7E0
Engine: SAA6D107E-3
Performance
Standard value
Item Test condition Unit Failure criterion
for new machine
• Engine coolant tempera- Power mode: P r/min 2100 to 2200 2100 to 2200
ture: 80 to 90 ˚C mode {rpm} {2100 to 2200} {2100 to 2200}
• Hydraulic oil temperature:
45 to 55 ˚C
Engine speed
at high idle • Torque converter oil tem-
Power mode: E r/min 1820 to 1920 1820 to 1920
perature: 60 to 80 ˚C
mode {rpm} {1820 to 1920} {1820 to 1920}
• Accelerator pedal: Push
the pedal fully to the
stroke end
• Engine coolant temperature: 80 to 90 ˚C
• Hydraulic oil temperature: 45 to 55 ˚C
Engine speed r/min 760 to 860 760 to 860
at low idle • Torque converter oil temperature: 60 to 80
{rpm} {760 to 860} {760 to 860}
˚C
• Accelerator pedal: Not pushed
Air Intake and Exhaust System
Standard value
Item Test condition Unit Failure criterion
for new machine
• Engine coolant temperature: 60 to 100 ˚C
• Hydraulic oil temperature: 45 to 55 ˚C
Boost pres- kPa Min. 120 Min. 100
sure • Torque converter oil temperature: 60 to
{mmHg} {Min. 900} {Min. 750}
80 °C
• T/C Stall mode
• Engine coolant temperature: 60 to 100 ˚C
• Hydraulic oil temperature: 45 to 55 ˚C
• Torque converter oil temperature: 60 to 80
Exhaust tem-
˚C °C Max. 650 Max. 700
perature
• T/C Stall mode
• Full speed range (ambient temperature
20 °C)
• Engine coolant tempera- Engine outlet Bosch in-
- Max. 2.2
ture: 60 to 100 ˚C (VGT to KDPF) dex
• Accelerator pedal: Push
Exhaust gas
fully to the stroke end SCR outlet (ex-
color Bosch in-
(High idle) haust pipe out- - Max. 0.5
dex
• After it is kept for 5 sec- let)
onds at normal condition
Valve clear- Engine coolant temperature: Intake valve mm 0.25 0.152 to 0.381
ance Normal temperature Exhaust valve mm 0.51 0.381 to 0.762
GD675-7E0 20-3
--- Page 12 ---
30 Testing and Adjusting Examine Exhaust Gas Temperature
REMARK
For the procedure for the torque converter stall, see “Examine Engine Speed”.
2) After the exhaust gas temperature increases to approximately 670 ˚C, set the blade lift cylinder control
lever to NEUTRAL. Check the exhaust gas temperature when the torque converter alone is stalled.
REMARK
• As the exhaust temperature decreases from the full stall, check the temperature in a stable condi-
tion.
• If the exhaust temperature does not decrease but increase, make the set temperature at full stall
higher.
3) When the check is completed, immediately lift your right foot off the accelerator pedal.
4) Set the directional selector switch to the NEUTRAL (N) position. Set the parking brake switch ON.
NOTICE
Do not operate the directional selector switch while you push the accelerator pedal. Large gear
shift shock will occur. It will be a cause to make the service life of the machine short.
Restoration
7. Stop the engine.
k Immediately after the engine is stopped, the parts and oil become very hot and can cause burn
injury. Do the work after the temperature dropped.
8. Remove the sensor A2.
9. Install the pickup plug (5).
Pickup plug (5): Seizure prevention compound (LC-G)
Pickup plug (5): 3.9 to 6.9 Nm {0.4 to 0.7 kgm}
10. Install the heat insulation plate (4) with the bolts (3) (8 pieces).
11. Close the covers (1) and (2) on the left side of the machine. Restore the machine.
GD675-7E0 30-31
--- Page 13 ---
30 Testing and Adjusting Examine and Adjust Air Conditioner Compressor Belt Tension
Examine and Adjust Air Conditioner Compressor Belt Tension
Obey the procedures that follow to inspect and adjust the tension of the air conditioner compressor belt.
k Place the machine on a level ground, and lower the work equipment fully to the ground.
k Set the parking brake switch to the ON position, the work equipment lock switch to the LOCK state,
and the steering control lever enable switch to the DISABLE state. Then, stop the engine.
k Chock the tires to prevent machine movement.
For standard values, see Standard Value Table,“Standard Value Table for Engine”.
How to Examine Air Conditioner Compressor Belt Tension
*
1. Push a point between the drive pulley (A) and the compressor pulley (B) with your finger (approximately
98.1 N {10.0 kg}). Pull the belt to make sag c 19 to 20.5 mm (15.5 to 17 mm for a new belt).
New belts usually show initial stretch. Thus, adjust the belt every 2 to 3 days.
2. Check each pulley for breakage. Inspect the V-groove for wear. Inspect the V-belt for wear.
Carefully examine and make sure that the V-belt does not touch the bottom of the V-groove.
How to Adjust Air Conditioner Compressor Belt Tension
NOTICE
• Check each pulley for breakage. Inspect the V-groove for wear. Inspect the V-belt for wear. Carefully
examine and make sure that the V-belt does not touch the bottom of the V-groove.
• Replace the belt with a new one if the belt is stretched and has no allowance for adjustment or has
slipping sound or whine because of cuts or cracks in the belt.
• When you replace the V-belt, adjust it again after operating for 1 hour.
• When adjusting the V-belt, use a wrench. Do not push the compressor directly with a bar.
1. Open covers (1) and (2) on the right side of the machine.
GD675-7E0 30-79
--- Page 14 ---
30 Testing and Adjusting Clean DEF Tank
Refilling DEF
25. Refill the DEF tank with DEF in accordance with the procedures that follow.
26. Make sure that the drain plug (7) is securely closed.
27. Install the cover (2) with the bolts (1) (4 pieces).
28. Disconnect remote breather hose B from breather hose
(5).
29. Connect breather hose (5) to breather block (6).
30. Refill the DEF tank with new DEF.
DEF tank: 37 l
NOTICE
DEF freezes at -11 ˚C. When adding DEF where the am-
bient temperature is -11 ˚C or below, add until it rea-
ches the lowest line. For adding DEF, see Operation
and Maintenance Manual, “CHECK AdBlue® LEVEL
AND ADD IT”.
Check the refilling amount of DEF through sight gauge.
GD675-7E0 30-127
--- Page 15 ---
30 Testing and Adjusting Examine and Adjust Differential Lock Hydraulic Oil Pressure
5. Set the differential lock switch to the ON position.
REMARK
When the differential lock activates, the differential lock pi-
lot lamp comes on.
*
Check procedure
6. Check the oil pressure when the accelerator pedal is pushed to the stroke end (high idle).
See Standard Value Table, “Standard Value Table for Machine” for standard values.
Restoration
7. Stop the engine.
k Immediately after the engine is stopped, the parts and oil become very hot and can cause burn
injury. Wait for the temperature to go down, and then start the work.
8. Remove the gauge A1, the nipple A2, the joint A4, the O-ring A5, and elbow D.
9. Install pickup plug (2). Restore the machine.
Pickup plug (2): 9.8 to 12.7 Nm {1.0 to 1.3 kgm}
How to Adjust Differential Lock Oil Pressure
If the pump discharged pressure or the valve outlet pressure
during differential lock is not normal, adjust differential lock re-
lief valve (3) in accordance with the procedures that follow.
1. Remove the orange cap.
2. Loosen the lock nut (5) with the adjustment screw (4)
fixed.
3. Turn the adjustment screw (4) to adjust the oil pressure.
• Clockwise turn: Pressure increases.
• Counterclockwise turn: Pressure decreases.
REMARK
Quantity of pressure adjustment for each turn of adjust-
ment screw (4): 3.7 MPa {37.8 kg/cm2} *
4. While the adjustment screw (4) is fixed, tighten the locknut
(5).
Lock nut (5): 10 to 15 Nm {1.0 to 1.5 kgm}
After the adjustment is completed, inspect again to make sure that the pump discharged pressure and valve
outlet pressure are normal in response to “TEST DIFFERENTIAL LOCK OIL PRESSURE”.
GD675-7E0 30-175
--- Page 16 ---
30 Testing and Adjusting Examine and Adjust Work Equipment Oil Pressure
How to Examine Work Equipment Relief Pressure
Examine Work Equipment Relief Pressure (Cylinder)
Setting the testing device
1. Remove bolts (1) (6 pieces). Remove cover (2) on the right
side of the machine.
2. Remove the pickup plug of pump discharged pressure
pickup port (P1C).
3. Install the nipple C, and connect the gauge A1 in the hy-
draulic tester A.
Nipple C: 19.6 to 27.4 Nm {2.0 to 2.8 kgm}
REMARK
The gauge in the digital hydraulic tester B can be used in
place of the gauge A1.
Setting of test condition
4. Start the engine.
GD675-7E0 30-223
--- Page 17 ---
30 Testing and Adjusting Set and Adjust Each Equipment
Contents of work Required setting/adjustment Reference
Zero point adjustment for articulate an- ADJUSTMENT MENU (Zero Point Adjustment
gle For Art Angle)
Work equipment control lever adjust- ADJUSTMENT MENU (Work Equipment Control
Work equipment con- ment Lever Adjustment)
troller is replaced
IMU adjustment (*1) ADJUSTMENT MENU (IMU Adjustment)
Blade rotation angle sensor adjustment ADJUSTMENT MENU (Blade rotation angle sen-
(*1) sor adjustment)
ADJUSTMENT MENU (RH Blade Lift Cylinder
Control Lever Adjustment)
ADJUSTMENT MENU (LH Blade Lift Cylinder
Control Lever Adjustment)
ADJUSTMENT MENU (Blade Side Shift Control
Lever Adjustment)
ADJUSTMENT MENU (Blade Rotation Control
Lever Adjustment)
ADJUSTMENT MENU (Power Tilt Control Lever
Work equipment control Work equipment control lever adjust- Adjustment)
lever is replaced ment ADJUSTMENT MENU (Drawbar Side Shift Con-
trol Lever Adjustment)
ADJUSTMENT MENU (Leaning Control Lever
Adjustment)
ADJUSTMENT MENU (Articulate Control Lever
Adjustment)
ADJUSTMENT MENU (Ripper/scarifier Control
Lever Adjustment)
ADJUSTMENT MENU (Attachment Control Lev-
er Adjustment)
ADJUSTMENT MENU (Machine IMU Parameter
Setting)
IMU initial setting
IMU is replaced (*1) ADJUSTMENT MENU (Drawbar IMU Parameter
Setting)
IMU adjustment ADJUSTMENT MENU (IMU Adjustment)
IMU is removed/instal- ADJUSTMENT MENU (IMU Adjustment)
IMU adjustment
led (*1)
Blade rotation angle
ADJUSTMENT MENU (Blade rotation angle sen-
sensor is replaced, re- Blade rotation angle sensor adjustment
sor adjustment)
moved/installed (*1)
*1: For cross slope specification
If you get the feedback or request from user which seems to be applicable to an item in the table below, do the
setting or adjustment on the machine monitor.
Feedback/request Setting/adjustment Reference
To change the unit dis-
play on the speedome- Unit setting DEFAULT SETTING MENU (Unit Selection)
ter
Travel speed display is
Tire size compensation DEFAULT SETTING MENU (Option Selection)
too fast or too slow
GD675-7E0 30-271
--- Page 18 ---
30 Testing and Adjusting Set and Operate Machine Monitor
Items that Can be Selected with Maintenance Mode Setting
Code Item
00 Maintenance Mode Change
49 Air Cleaner Cleaning or Change Interval
60 Coolant Change Interval
41 Fuel Prefilter Change Interval
01 Engine Oil Change Interval
02 Engine Oil Filter Change Interval
13 T/M Oil Filter Change Interval
03 Fuel Main Filter Change Interval
12 T/M Oil Change Interval
15 Axle Oil Change Interval
04 Hydraulic Oil Filter Change Interval
30 Hyd Oil Pilot Filter Change
87 Diff. Lock Oil Filter Change
10 Hydraulic Oil Change Interval
37 Circle Drive Oil Change Interval
99 Restore All to Default Value
Maintenance Mode Change (Code: 00)
3. Select “Maintenance Mode Change”. On the screen, select
the item with the switches on the switch panel.
UP switch (10): Moves the selection up by one item.
DOWN switch (11): Moves the selection down by one item.
RETURN switch (12): Cancels the selection. The screen
moves back to the “Maintenance Mode Setting” screen.
ENTER switch (13): Validates the selection.
*
GD675-7E0 30-319
--- Page 19 ---
30 Testing and Adjusting Set and Operate Machine Monitor
4. On the “Adjustment Value Check” screen, push the EN-
TER switch (13) again to reset.
ENTER switch (13): Resets the setting.
*
5. After you do the reset, make sure that the initialization D
state (a) is “1: Learning Not Done Yet” and push the RE-
TURN switch (12).
RETURN switch (12): The screen moves back to the “Ad-
justment” screen.