Komatsu 830B, 850B, 870B Motor Grader Shop Manual CEBM011200 – PDF DOWNLOAD

Description

Komatsu 830B, 850B, 870B Motor Grader Shop Manual CEBM011200 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 830B, 850B, 870B Motor Grader Shop Manual CEBM011200 – PDF DOWNLOAD

Language : English
Pages :930
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 830B, 850B, 870B Motor Grader Shop Manual CEBM011200 – PDF DOWNLOAD

SERIAL NUMBERS
830B              203163
830C              202753
850B              202575
850C              202727
870B             202599   and UP
870C             202775

• This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
  understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
  understand the contents of this manual and use it to full effect at every opportunity.
• This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
  ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
  group of components.

GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this
section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

TABLE OF CONTENTS:

Komatsu 830B, 850B, 870B Motor Grader Shop Manual CEBM011200 – PDF DOWNLOAD

SERIAL NUMBERS
830B              203163
830C              202753
850B              202575
850C              202727
870B             202599   and UP
870C             202775

MAIN MENU 0
CONTENTS 2
FOREWORD 5
SAFETY 5
SAFETY NOTICE 5
IMPORTANT SAFETY NOTICE 5
GENERAL PRECAUTIONS 5
PREPARATIONS FOR WORK 5
PRECAUTIONS DURING WORK 6
GENERAL 7
HOW TO READ THE SHOP MANUAL 8
VOLUMES 8
DISTRIBUTION AND UPDATING 8
FILING METHOD 8
REVISED EDITION MARK 8
REVISIONS 8
SYMBOLS 8
HOISTING INSTRUCTIONS 9
HOISTING 9
WIRE ROPES 9
COATING MATERIALS 10
STANDARD TIGHTENING TORQUE 12
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 12
TIGHTENING TORQUE OF HOSE NUTS 13
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 13
TIGHTENING TORQUE FOR FLARED NUTS 13
ELECTRIC WIRE CODE 14
CLASSIFICATION BY THICKNESS 14
CLASSIFICATION BY COLOR AND CODE 14
CONVERSION TABLES 15
METHOD OF USING THE CONVERSION TABLE 15
01 GENERAL 21
GENERAL ASSEMBLY DRAWING 22
830 22
850/870 22
FUEL, COOLANT, AND LUBRICANTS 23
ACCORDING TO AMBIENT TEMPERATURE 23
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS 23
ENGINE OIL SPECIFICATIONS 25
NORMAL OPERATION 25
ARCTIC OPERATION 25
TRANSMISSION, TORQUE CONVERTER AND OIL COOLER, TANDEM DRIVE CASES, FRONT-WHEEL-DRIVE GEAR CASE, IF EQUIPPED, AND HYDRAULIC SYSTEM OIL SPECIFICATIONS 26
REAR-DRIVE AXLE AND CIRCLE DRIVE BRAKE HOUSING OIL SPECIFICATIONS 26
DIESEL FUEL SPECIFICATIONS 26
COOLANT SPECIFICATIONS 27
GENERAL 27
WATER 27
ANTIFREEZE 27
SUPPLEMENTAL COOLANT ADDITIVES 29
MAINTENANCE OF SUPPLEMENTAL COOLANT ADDITIVES 29
COOLANT TESTING FOR CONDITIONER CONCENTRATION 29
REPLENISHING COOLANT CONDITIONER 29
SUPPLEMENTAL COOLANT ADDITIVE MAINTENANCE GUIDE 30
COOLING SYSTEM TEST KIT 32
CIRCLE DRIVE GEAR CASE OIL SPECIFICATIONS (HDTF) 32
10 STRUCTURE AND FUNCTION 33
STEERING (ORBITROL) CONTROL VALVE 36
TRANSMISSION POWER SHIFT 38
TRANSMISSION SHIFTER 38
RECOMMENDED LUBRICANT AND FILTER CHANGE INTERVALS 41
GENERAL LOCATION OF COMPONENTS 43
ALL-WHEEL-DRIVE PUMP 44
ROTARY GROUP 46
EP2 HYDRAULIC CONTROL 48
INTERPRETATION OF TYPE CODES 50
CIRCLE REVERSE MOTOR 52
CIRCLE REVERSE GEAR CASE MOTOR 52
CIRCLE REVERSE MOTOR 54
STEERING AND BRAKE PUMP 56
STEERING AND BRAKE PUMP MOUNT 56
STEERING AND BRAKE PUMP 58
SPECIFICATIONS 59
AWD HYDRAULIC MOTOR 60
SPECIFICATIONS 62
HYDRAULIC OIL SWIVEL BLOCK 63
FOUR WAY 63
CONTROL VALVE MANIFOLDS 64
OPTIONAL CONTROL LEVER (SCARIFIER) 66
OPTIONAL CONTROL LEVERS (AUXILIARY) 68
CONTROL VALVES – LH BANK 70
CONTROL VALVES – RH BANK 72
VALVE SECTION 74
MAIN SYSTEM PUMP MOUNT 76
MAIN SYSTEM PUMP 78
AWD HIC VALVE 80
SOLENOID VALVE CARTRIDGE 84
ACCUMULATOR 85
SPECIFICATIONS 86
BRAKE SYSTEM ACCUMULATORS 87
DRAWBAR LIFT AND DRAWBAR SIDE SHIFT ACCUMULATORS 87
HYDRAULIC SYSTEM OVERVIEW 88
STANDARD GRADER 88
MAIN HYDRAULIC CIRCUIT 89
STEERING AND BRAKE HYDRAULIC CIRCUIT (INCLUDES LOCK PIN) 89
STANDARD GRADER WITH ALL WHEEL DRIVE (AWD) 90
MAIN HYDRAULIC CIRCUIT 91
ALL WHEEL DRIVE CIRCUIT 91
STEERING AND BRAKE HYDRAULIC CIRCUIT (INCLUDES LOCK PIN) 91
MAIN HYDRAULIC CIRCUIT 92
SPOOL VALVE POSITIONS 97
NEUTRAL (CENTER) 97
PULLED (PRESSURIZED “B” PORT) 98
PUSHED (PRESSURIZED “A” PORT) 99
MAIN SYSTEM CONTROL VALVES101
SCARIFIER101
RIGHT AND LEFT BLADE LIFT102
FLOAT VALVE104
BLADE SHIFT104
CIRCLE REVERSE MOTOR105
MOLDBOARD TILT106
ARTICULATION107
CIRCLE SIDE SHIFT108
LEANING WHEEL110
OPTIONAL FLOAT VALVE111
STEERING AND BRAKE CIRCUIT112
ALL-WHEEL-DRIVE CIRCUIT115
NORMAL MODE116
AGGRESSIVE MODE118
HYDRAULIC OPERATION119
ELECTRICAL OPERATION122
AWD CONTROLLER PROGRAMMING124
LOCK/UNLOCK DIFFERENTIAL PUMP126
CIRCLE REVERSE SLIP CLUTCH128
CIRCLE REVERSE GEAR CASE130
WITHOUT SLIP CLUTCH130
WITH SLIP CLUTCH132
MOTOR INSTALLATION134
TANDEM CASE136
LOCATION136
DESCRIPTION136
NONPLANETARY FINAL DRIVE136
PLANETARY FINAL DRIVE138
FINAL DRIVE IDENTIFICATION140
PART NUMBER TAG140
TANDEM CASE MEASUREMENT140
SPECIFICATIONS141
AWD GEARBOX ASSEMBLY141
AWD GEARBOX142
FRONT AXLE ASSEMBLY144
NON ALL-WHEEL-DRIVE FRONT AXLE144
AWD FRONT AXLE146
FINAL DRIVE ASSEMBLY148
FINAL DRIVE WITHOUT PLANETARY REDUCTION148
FINAL DRIVE WITH PLANETARY REDUCTION150
NO-SPIN DIFFERENTIAL CASE ASSEMBLY152
LOCK/UNLOCK DIFFERENTIAL CASE ASSEMBLY154
INPUT QUILL ASSEMBLY156
BRAKES158
NO-SPIN DIFFERENTIAL BEARING QUILLS160
LOCK/UNLOCK DIFFERENTIAL BEARING QUILLS162
LOCK/UNLOCK DIFFERENTIAL ASSEMBLY164
LOCK/UNLOCK DIFFERENTIAL CASE OIL LINE166
NO-SPIN DIFFERENTIAL ASSEMBLY168
NO-SPIN DIFFERENTIAL170
PLANETARY ASSEMBLY AND RING GEAR172
NONPLANETARY FINAL DRIVE CROSS SECTION174
PLANETARY REDUCTION FINAL DRIVE CROSS SECTION175
MICO PARKING BRAKE176
MICO PARKING BRAKE INSTALLATION177
PARKING BRAKE CALIPER178
MICO BRAKE VALVE180
BRAKE PEDAL LINKAGE180
HYDRAULIC BRAKE LINES – WITHOUT AWD182
HYDRAULIC BRAKE LINES – WITH AWD184
BRAKE VALVE186
TILT STEERING CONSOLE188
EXPLODED VIEW OF TILT STEERING CONSOLE190
20 TESTING, ADJUSTING AND TROUBLESHOOTING193
CIRCLE ADJUSTMENT264
FOUR SHOES264
VERTICAL ADJUSTMENT265
PINION ADJUSTMENT266
CIRCLE REVERSE SLIP CLUTCH268
CIRCLE ADJUSTMENT268
SLIP CLUTCH ADJUSTMENT269
ENGINE AND TRANSMISSION GEAR RANGE TEST270
PARKING BRAKE CALIPER271
PERROT PARKING BRAKE ADJUSTMENT271
BRAKE PRESSURE WARNING SWITCHES271
LOW BRAKE PRESSURE WARNING SWITCH272
PARKING BRAKE PRESSURE SWITCH272
BLEEDING THE CALIPER’S273
MICO PARKING BRAKE ADJUSTMENT274
BRAKE VALVES275
MICO BRAKE VALVE275
BRAKE PEDAL BUMPER ADJUSTMENT275
BRAKE PEDAL FREE HEIGHT275
BRAKE PEDAL STOP276
PRESSURE TEST277
STANDARD VALUE TABLES197
TABLE OF JUDGEMENT STANDARD VALUE197
ENGINE IN CHASSIS198
CHASSIS200
TOOL LIST206
TRANSMISSION POWER SHIFT207
TRANSMISSION SHIFTER207
VOLTAGE AND ELECTRICAL POWER REQUIREMENTS209
CLUTCH SOLENOID VALVE REQUIREMENTS210
PRESSURE AND FLOW CHECKS210
FLOW RATES210
SETTING THE CLUTCH PRESSURE211
FLYWHEEL DIMENSIONAL CHECKS211
FLYWHEEL DIMENSIONS212
CHECKING FOR THE CORRECT PILOT SLEEVE LENGTH213
AWD PUMP214
REXROTH214
DIAGNOSTIC PORTS214
CIRCLE REVERSE MOTOR215
TESTS AND ADJUSTMENTS215
STEERING AND BRAKE PUMP216
PROCEDURE216
STARTUP PROCEDURE217
AWD HYDRAULIC MOTOR218
FOUR-WAY SWIVEL BLOCK218
FRONT AXLE AND GEARBOX219
FRONT WHEEL ALIGNMENT AND TURNING RADIUS ADJUSTMENT219
HYDRAULIC CYLINDERS221
PRESSURE TESTING HYDRAULIC CYLINDERS221
BALL AND SOCKET SHIMMING ADJUSTMENT221
ACCUMULATORS222
PRECHARGE222
TESTS AND ADJUSTMENTS222
PROCEDURE FOR ACCUMULATORS UP TO 3000 psi223
PROCEDURE FOR ACCUMULATORS UP TO 5000 psi224
HYDRAULIC CIRCUITS225
RELIEVING ACCUMULATOR PRESSURE226
SETTING RELIEF VALVES226
GENERAL DIAGNOSIS PROCEDURE227
HEAT PROBLEMS227
SPECIAL TOOLS228
HYDRAULIC PRESSURE TESTS228
QUICK-REFERENCE PRESSURE CHART229
MAIN HYDRAULIC SYSTEM SPECIFICATIONS230
TEST PORT LOCATIONS230
TEST PROCEDURE: LOW-PRESSURE STANDBY231
TEST PROCEDURE: HIGH-PRESSURE STANDBY232
STEERING AND BRAKE SYSTEM PRESSURE TEST233
STEERING AND BRAKE SYSTEM SPECIFICATION233
TEST PORT LOCATION233
TEST PROCEDURE233
AWD SYSTEM TEST234
AWD SYSTEM FUNCTIONAL TEST235
AWD HYDRAULIC SYSTEM PRESSURE TEST238
ALL-WHEEL-DRIVE PUMP239
ADJUSTMENT239
RELIEF VALVES241
HYDRAULIC CENTERING ADJUSTMENT PROCEDURE244
MECHANICAL CENTERING ADJUSTMENT PROCEDURE246
AWD HYDRAULIC SYSTEM FILTERING PROCEDURE247
AWD ELECTRICAL SYSTEM TESTS248
LOCK/UNLOCK DIFFERENTIAL RELIEF VALVE257
REAR AXLE COOLING SYSTEM257
FINAL DRIVE ASSEMBLY258
WITH NoSPIN AND LOCK/UNLOCK DIFFERENTIAL258
NO SPIN TEST258
BRAKE DISC INSPECTION259
TANDEM CASE260
TANDEM CHAIN WEAR LIMITS260
SPECIFICATIONS260
PROCEDURE260
SPROCKET WEAR (NON-PLANETARY ONLY)262
OIL262
SINGLE AND DOUBLE STRAND CHAINS262
ROAD TEST262
TROUBLESHOOTING279
HYDRAULIC CIRCUITS281
PROBLEMS281
Problem 1 Test lamp does not light281
Problem 2 Test lamp blinks green when in reverse282
Problem 3 Test lamp blinks red283
Problem 4 No change between the normal mode and aggressive mode283
Problem 5 System appears to lack power284
Problem 6 Wheels turn when in neutral284
Problem 7 Wheels don’t turn either direction285
Problem 8 Wheels do not turn forward286
Problem 9 Wheels do not turn in reverse287
Problem 10 Wheels do not stop287
RIGHT AND LEFT CONTROL VALVE288
MOLDBOARD TILT CYLINDER290
BLADE SHIFT CYLINDER290
HYDRAULIC CYLINDERS290
CIRCLE REVERSE MOTOR291
AWD PUMP292
AWD HYDRAULIC MOTOR296
STEERING AND BRAKE PUMP297
CONTROL VALVE MANIFOLDS298
MAIN SYSTEM PUMP299
TRANSMISSION POWER SHIFT301
TRANSMISSION SHIFTER301
TANDEM CASE305
SINGLE AND DOUBLE STRAND CHAINS305
FINAL DRIVE ASSEMBLY306
WITH NoSPIN AND LOCK/UNLOCK DIFFERENTIAL306
PARKING BRAKE CALIPER307
PREDELIVERY PROCEDURES309
PREDELIVERY PROCEDURES311
CHECKS AND ADJUSTMENTS311
FAN BELT TENSION311
AIR CLEANER SYSTEM311
AIR INDUCTION PRESSURE CHECK312
TEST PROCEDURE312
SERVICE INDICATOR SAFETY FILTER313
RADIATOR HOSES314
FUEL LINES AND FITTINGS315
WATER TRAP315
TRANSMISSION FLUID LEVEL315
TRANSMISSION FILL PLUG315
HYDRAULIC OIL TANK LEVEL315
HYDRAULIC OIL AND FUEL TANK FILL POINT316
TANDEM CASE OIL LEVEL316
TANDEM CASE BREATHER/FILL POINT316
CIRCLE REVERSE OIL LEVEL316
CIRCLE REVERSE FILL POINT317
REAR AXLE OIL LEVEL317
REAR AXLE OIL FILL POINT317
FUEL TANK DRAIN PLUG317
GREASE ZERKS318
MOLDBOARD SLIDE RAILS318
CONTROL LEVER LINKAGES318
CONTROL VALVE LINKAGES318
OIL LEVEL – AWD FRONT WHEEL GEAR319
ENGINE OIL LEVEL AND FILL POINT319
BATTERY WATER LEVEL319
ENGINE COOLANT319
ENGINE SPEED TABLE320
ENGINE SPEED CHECK PROCEDURE321
THROTTLE ADJUSTMENT PROCEDURE322
HYDRAULIC PRESSURE TESTS325
QUICK-REFERENCE PRESSURE CHART326
MAIN HYDRAULIC SYSTEM SPECIFICATIONs327
TEST PORT LOCATIONS327
PUMP-OUTLET LINE PRESSURE (TEST PORT 1)327
LOAD-SENSOR LINE PRESSURE (TEST PORT 2)327
TEST PROCEDURE: Low-Pressure Standby328
TEST PROCEDURE: High-Pressure Standby329
STEERING AND BRAKE SYSTEM PRESSURE TEST330
STEERING AND BRAKE SYSTEM SPECIFICATION330
TEST PORT LOCATION330
PUMP PRESSURE (TEST PORT 1)330
TEST PROCEDURE330
AWD HYDRAULIC SYSTEM PRESSURE TEST331
AWD SYSTEM SPECIFICATION331
TEST PORT LOCATIONS331
CHARGE PUMP PRESSURE331
REVERSE PRESSURE (TEST PORT 1)331
FOREWARD PRESSURE (TEST PORT 2)331
TEST PROCEDURE332
CLUTCH PACK PRESSURE CHECK333
TIRES AND RIMS334
TIRE INFLATION334
TIRE PRESSURES334
RIM CENTERING334
CONTROL VALVE OPERATION336
CONTROL LEVERS – RIGHT BANK336
CONTROL LEVERS – LEFT BANK337
OPTIONAL EQUIPMENT339
LIGHTING339
WARNING LIGHTS339
YARD TEST339
BRAKE VALVES340
MICO BRAKE VALVE340
BRAKE PEDAL BUMPER ADJUSTMENT340
BRAKE PEDAL FREE HEIGHT340
BRAKE PEDAL STOP341
PRESSURE TEST342
PARKING BRAKE CALIPER343
PERROT PARKING BRAKE ADJUSTMENT343
MICO PARKING BRAKE ADJUSTMENT344
30 DISASSEMBLY AND ASSEMBLY345
METHOD OF USING MANUAL353
PRECAUTIONS DURING OPERATION354
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK354
PRECAUTIONS WHEN CLEANING AND INSPECTING355
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK356
PRECAUTIONS WHEN COMPLETING THE OPERATIONS356
OTHER PRECAUTIONS357
SPECIAL TOOL LIST358
SKETCHES OF SPECIAL TOOLS359
TRANSMISSION359
CHANNEL SUPPORT TOOL359
CLUTCH PACK REMOVAL TOOL360
CLUTCH SPRING COMPRESSION TOOL361
CIRCLE REVERSE MOTOR (PARKER)362
SPECIAL BEARING MANDREL TOOL362
CIRCLE REVERSE MOTOR (CHAR-LYNN)363
ASSEMBLY BULLET TOOL363
SEAL BULLET TOOL363
SEAL INSTALLATION TOOL364
HYDRAULIC MOTOR365
SHAFT BEARING REMOVAL / INSTALLATION TOOL365
HOUSING BEARING RACE REMOVAL TOOL366
BEARING RACE INSTALLATION TOOL366
SHAFT SEAL DRIVER TOOL367
HYDRAULIC OIL SWIVEL BLOCK – 4 WAY368
SWIVEL BLOCK SEAL TOOL368
CIRCLE REVERSE SLIP CLUTCH369
CIRCLE SLIP CLUTCH GAUGE TOOL369
TANDEM CASE370
WHEEL KNOCKER TOOL370
AXLE LIFTING TOOL370
AXLE ROLLING TORQUE TOOL371
SPREADER BAR AND CHAINS371
AWD – GEARBOX ASSEMBLY373
SEAL INSTALLATION TOOL373
AWD – MOTOR (VICKERS-EATON)374
SPECIAL SHAFT BEARING REMOVAL AND INSTALLATION TOOLS374
HOUSING BEARING RACE REMOVAL TOOL374
SPECIAL BEARING RACE INSTALLATION TOOL375
SHAFT SEAL DRIVER375
FINAL DRIVE ASSEMBLY376
SPREADER BAR AND CHAINS376
DIFFERENTIAL BACKLASH TOOL (DR08-111)377
ARTICULATION JOINT379
REMOVAL380
DISASSEMBLY384
ASSEMBLY386
INSTALLATION389
ENGINE HOOD, FRONT & REAR COWLING392
REMOVAL392
INSTALLATION395
FUEL TANK AND HYDRAULIC TANK398
REMOVAL398
INSTALLATION399
TRANSMISSION SHIFTER400
REMOVAL400
INSTALLATION400
TRANSMISSION POWER SHIFT401
REMOVAL401
DISASSEMBLY404
FRONT COVER DISASSEMBLY406
MAIN CASE DISASSEMBLY408
TORQUE CONVERTER DISASSEMBLY410
CLUTCH PACK 1 AND 5 DISASSEMBLY (FIRST STAGE)412
CLUTCH PACK 2 AND 6 DISASSEMBLY (SECOND STAGE)414
CLUTCH PACK 3 AND 4 DISASSEMBLY (THIRD STAGE)416
CONTROL VALVE DISASSEMBLY418
REASSEMBLY420
FRONT COVER REASSEMBLY420
TORQUE CONVERTER ASSEMBLY424
CLUTCH PACK 1 AND 5 REASSEMBLY (FIRST STAGE)426
CLUTCH PACK 2 AND 6 REASSEMBLY (SECOND STAGE)429
CLUTCH PACK 3 AND 4 REASSEMBLY (THIRD STAGE)432
CONTROL VALVE ASSEMBLY436
MAIN CASE REASSEMBLY437
TRANSMISSION/TORQUE CONVERTER REASSEMBLY440
INSTALLING THE CONVERTER INTO THE TRANSMISSION442
TRANSFER CASE443
DISASSEMBLY443
ASSEMBLY445
INSTALLATION448
SERVICING THE MACHINE AFTER A TRANSMISSION OVERHAUL452
STARTUP PROCEDURE452
ALL WHEEL DRIVE (AWD)452
ALL-WHEEL-DRIVE PUMP453
REMOVAL453
SHAFT SEAL (IN-WARRANTY SERVICE)455
CHARGE PUMP (IN-WARRANTY SERVICE)456
CONTROL PISTON COVER (IN-WARRANTY SERVICE)457
LEFT COVER457
RIGHT COVER458
REPLACING THE VALVES (IN-WARRANTY SERVICE)459
BOOST PRESSURE VALVE459
RELIEF VALVE459
PRESSURE CUT-OFF VALVE459
CONTROL DEVICE (IN-WARRANTY SERVICE)460
REGULATOR VALVE (IN-WARRANTY SERVICE)461
REBUILDING THE PUMP (OUT-OF-WARRANTY SERVICE)462
TORQUE VALUES479
TIGHTENING TORQUES FOR SHAFT BOLTS (METRIC ISO STANDARD THREAD)479
TIGHTENING TORQUES FOR LOCKING SCREWS VSTI (METRIC ISO FINE THREAD)479
TIGHTENING TORQUE FOR SEAL LOCK NUTS VSTI (METRIC ISO STANDARD THREAD)480
TIGHTENING TORQUES FOR CROSS-SLOTTED LENS HEAD SCREWS DIN 7985 (METRIC ISO STANDARD THREAD)480
INSTALLATION481
CIRCLE REVERSE MOTOR482
CHAR-LYNN (MACHINE S/N 202309 TO 203192)482
REMOVAL482
DISASSEMBLY482
ASSEMBLY484
INSTALLATION486
PARKER (MACHINE S/N 203193 AND UP)488
EXPLODED ASSEMBLY VIEW488
REMOVAL490
DISASSEMBLY490
ASSEMBLY499
ONE PIECE STATOR CONSTRUCTION508
FINAL CHECKS509
INSTALLATION509
STEERING (ORBITOL) VALVE510
REMOVAL510
DISASSEMBLY510
ASSEMBLY515
INSTALLATION519
STEERING AND BRAKE PUMP520
REMOVAL520
DISASSEMBLY521
ASSEMBLY524
INSTALLATION526
HYDRAULIC MOTOR527
REMOVAL527
DISASSEMBLY528
SPECIAL INSPECTION AREAS532
ASSEMBLY534
INSTALLATION537
4-WAY SWIVAL VALVE BLOCK538
REMOVAL538
DISASSEMBLY539
ASSEMBLY540
INSTALLATION542
CONTROL VALVE MANIFOLDS544
REMOVAL544
DISASSEMBLY547
CONTROL VALVE BANK547
VALVE SECTION549
VALVE SECTION IDENTIFICATION550
ASSEMBLY551
VALVE SECTION551
CONTROL VALVE BANK552
INSTALLATION553
MAIN SYSTEM PUMP555
REMOVAL555
DISASSEMBLY556
ASSEMBLY562
INSTALLATION568
HYDRAULIC INTEGRATED CIRCUIT VALVE569
REMOVAL569
DISASSEMBLY570
HIC VALVE570
SOLENOID CARTRIDGE DISASSEMBLY571
ASSEMBLY572
SOLENOID CARTRIDGE REASSEMBLY572
HIC VALVE573
INSTALLATION574
HYDRAULIC CYLINDERS575
BALL AND SOCKET SHIMMING ADJUSTMENT575
SPECIAL TORQUES576
CLEANING AND INSPECTION576
STEERING CYLINDERS577
REMOVAL577
DISASSEMBLY578
ASSEMBLY579
INSTALLATION580
LEANING WHEEL CYLINDER581
REMOVAL581
DISASSEMBLY582
ASSEMBLY583
INSTALLATION584
MOLDBOARD TILT CYLINDERS585
REMOVAL585
DISASSEMBLY586
ASSEMBLY587
INSTALLATION588
MOLDBOARD SIDE SHIFT CYLINDER589
REMOVAL589
DISASSEMBLY590
ASSEMBLY590
INSTALLATION591
DRAWBAR SIDE SHIFT CYLINDER (RH BLADE SUSPENSION ONLY)592
REMOVAL592
DISASSEMBLY593
ASSEMBLY594
INSTALLATION595
DRAWBAR SIDE SHIFT CYLINDER (RH & LH BIAS BLADE SUSPENSION)596
REMOVAL596
DISASSEMBLY596
ASSEMBLY598
INSTALLATION599
DRAWBAR LIFT CYLINDERS (RH BLADE SUSPENSION ONLY)600
REMOVAL600
DISASSEMBLY601
ASSEMBLY602
INSTALLATION603
DRAWBAR LIFT CYLINDERS (RH & LH BIAS BLADE SUSPENSION ONLY)604
REMOVAL604
TRUNNION BUSHING REPLACEMENT605
DISASSEMBLY606
ASSEMBLY607
INSTALLATION608
SCARIFIER CYLINDERS610
REMOVAL610
DISASSEMBLY611
ASSEMBLY612
INSTALLATION613
LOCK PIN CYLINDER (RH & LH BIAS BLADE SUSPENSION ONLY)615
REMOVAL615
DISASSEMBLY616
ASSEMBLY617
INSTALLATION618
ARTICULATION CYLINDERS619
REMOVAL619
DISASSEMBLY620
ASSEMBLY621
INSTALLATION622
ACCUMULATORS623
MAINTENANCE623
CHECKING THE PRECHARGE623
ACCUMULATORS WITH PARKER VALVE P/N 5323640000624
ACCUMULATORS WITH PARKER VALVE P/N 6124330000624
REMOVAL (BRAKE SYSTEM)625
REMOVAL (DRAWBAR LIFT AND DRAWBAR SIDE SHIFT)626
DISASSEMBLY627
REPAIR AND REPLACEMENT628
ASSEMBLY628
INSTALLATION (BRAKE SYSTEM)629
INSTALLATION (DRAWBAR LIFT AND DRAWBAR SIDE SHIFT)629
LOCK/UNLOCK DIFFERENTIAL PUMP630
REMOVAL630
DISASSEMBLY631
REPAIR AND REPLACEMENT632
REASSEMBLY633
INSTALLATION634
ADJUSTING DIFFERENTIAL PUMP BELT TENSION635
V-BELT ADJUSTMENT635
OPTIONAL V-BELT ADJUSTMENT635
CIRCLE REVERSE SLIP CLUTCH636
REMOVAL636
GENERAL EXPLOSION VIEW637
DISASSEMBLY639
ASSEMBLY641
INSTALLATION646
RETROFITTING A STANDARD CIRCLE GEAR CASE WITH A SLIP CLUTCH647
CIRCLE IDENTIFICATION647
RETROFITTING INSTRUCTIONS647
CIRCLE REVERSE GEAR CASE649
DISASSEMBLY649
ASSEMBLY655
TANDEM CASE663
SINGLE AND DOUBLE STRAND CHAINS663
REMOVAL663
DISASSEMBLY667
ASSEMBLY668
INSTALLATION670
AWD – GEARBOX ASSEMBLY673
TWO-PIECE SEAL INSTALLATION673
REMOVAL678
DISASSEMBLY682
ASSEMBLY689
INSTALLATION698
AWD MOTOR (VICKERS/EATON)703
REMOVAL703
DISASSEMBLY703
REMOVAL OF FRONT SHAFT BEARING706
REPLACE ALL PARTS THAT DO NOT MEET THE FOLLOWING SPECIFICATIONS706
ASSEMBLY707
INSTALLATION710
FRONT AXLE ASSEMBLY711
REMOVAL711
DISASSEMBLY713
ASSEMBLY717
INSTALLATION724
FINAL DRIVE ASSEMBLY727
NoSPIN AND LOCK/UNLOCK DIFFERENTIALS727
PARKING BRAKE BLEEDING727
FINAL DRIVE BRAKE BLEEDING727
ROAD TESTING728
REMOVAL728
GENERAL DISASSEMBLY733
DISASSEMBLY OF THE PLANETARY CARRIER733
DISASSEMBLY OF THE NONPLANETARY CARRIER737
DISASSEMBLY OF THE DIFFERENTIAL BRAKE PISTONS740
DISASSEMBLY OF THE INPUT QUILL ASSEMBLY741
DISASSEMBLY OF THE DIFFERENTIAL CASE WITH NoSPIN DIFFERENTIAL743
DISASSEMBLY OF DIFFERENTIAL CASE WITH LOCK/UNLOCK DIFFERENTIAL745
NoSPIN DIFFERENTIAL INSPECTION751
LOCK/UNLOCK DIFFERENTIAL INSPECTION751
PARKING BRAKE MOUNTING BRACKET752
DIFFERENTIAL ASSEMBLY753
NoSPIN DIFFERENTIAL CASE ASSEMBLY754
LOCK/UNLOCK DIFFERENTIAL CASE ASSEMBLY758
PINION GEAR ADJUSTMENTS765
PINION GEAR CONE POINT ADJUSTMENT765
PINION GEAR ENDPLAY ADJUSTMENT767
PINION GEAR BACKLASH ADJUSTMENT768
FINAL ASSEMBLY771
ASSEMBLY OF THE DIFFERENTIAL BRAKE PISTONS773
NONPLANETARY CARRIER ASSEMBLY775
PLANETARY CARRIER ASSEMBLY782
INSTALLATION787
REPLACING 6C FLANGE DRIVE SHAFT WITH 7C FLANGE DRIVE SHAFT788
CIRCLE TOOTH REBUILD794
REBUILDING THE TEETH794
MICO PARKING BRAKE CALIPER795
REMOVAL795
BRAKE LINING REPLACEMENT797
DISASSEMBLY797
ASSEMBLY801
INSTALLATION804
BRAKE VALVE805
REMOVAL805
DISASSEMBLY808
ASSEMBLY810
INSTALLATION811
SEAT813
GENERAL SPECIFICATIONS813
COMPLETE ASSEMBLY815
DISASSEMBLY816
ASSEMBLY818
LOWER SUSPENSION819
DISASSEMBLY820
INSPECTION AND REPAIR822
ASSEMBLY822
SEAT ADJUSTER823
DISASSEMBLY824
ASSEMBLY824
TILT STEERING CONSOLE825
DISASSEMBLY825
ASSEMBLY833
AIR CONDITIONING842
AIR CONDITIONING SYSTEM ELECTRICAL DIAGRAM842
AIR CONDITIONING SYSTEM DIAGRAM843
AIR CONDITIONING COMPRESSOR844
REMOVAL844
INSTALLATION844
COMPRESSOR CLUTCH SERVICE845
RECEIVER/DRYER850
SERVICE850
REMOVAL850
INSTALLATION850
CONDENSER851
REMOVAL851
INSTALLATION851
AIR CONDITIONER/HEATER UNIT852
ELECTRICAL DIAGRAM852
ASSEMBLY DIAGRAM853
REMOVAL855
INSTALLATION855
ASSEMBLY856
AIR CONDITIONING SYSTEM CHARGING PROCEDURE879
CHECKING COMPRESSOR OIL LEVEL881
40 MAINTENANCE STANDARD883
FINAL DRIVE884
NO SPIN DIFFERENTIAL CASE ASSEMBLY885
NO SPIN DIFFERENTIAL ASSEMBLY886
FINAL DRIVE AND TANDEMS887
TANDEM DRIVE888
BRAKE VALVE889
STEERING CYLINDER890
LEANING WHEEL CYLINDER891
MOLDBOARD TILT CYLINDER892
MOLDBOARD SIDE SHIFT893
DRAWBAR SIDE SHIFT CYLINDER894
DRAWBAR LIFT CYLINDER895
SCARIFIER CYLINDER896
ARTICULATION CYLINDER897
RIPPER CYLINDER898
LUG NUTS899
FRONT AXLE900
POWER TILT MOLDBOARD CARRIER901
FRAME902
DRAWBAR AND CIRCLE903
DRAWBAR LIFT904
ENGINE AND TRANSMISSION905
DRIVE LINE906
ALTERNATOR907
CAB MOUNT908
90 OTHERS909
ORIGINAL ELECTRICAL DIAGRAM (Sheet 1 of 3)911
ORIGINAL ELECTRICAL DIAGRAM (Sheet 2 of 3)913
ORIGINAL ELECTRICAL DIAGRAM (Sheet 3 of 3)915
REVISED ELECTRICAL DIAGRAM (Sheet 1 Part 1 of 2)917
REVISED ELECTRICAL DIAGRAM (Sheet 1 Part 2 of 2)919
REVISED ELECTRICAL DIAGRAM (Sheet 2)921
800 TRANSMISSION WITH AWD DIAGRAM923
HYDRAULIC CIRCUIT DIAGRAM (Sheet 1 of 2)925
HYDRAULIC CIRCUIT DIAGRAM (Sheet 2 of 2)927

IMAGES PREVIEW OF THE MANUAL:

S.M 15/12/24