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KOMATSU GD530A (W)-2B(C)Y, GD650A (W)-2B(C)Y, GD670A (W)-2B(C)Y MOTOR GRADER SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- KOMATSU GD530A (W)-2B(C)Y, GD650A (W)-2B(C)Y, GD670A (W)-2B(C)Y MOTOR GRADER SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:CEBM009900
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Description
KOMATSU GD530A (W)-2B(C)Y, GD650A (W)-2B(C)Y, GD670A (W)-2B(C)Y MOTOR GRADER SERVICE REPAIR MANUAL
KOMATSU GD530A (W)-2B(C)Y, GD650A (W)-2B(C)Y, GD670A (W)-2B(C)Y MOTOR GRADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GD530A (W)-2B(C)Y, GD650A (W)-2B(C)Y, GD670A (W)-2B(C)Y MOTOR GRADER SERVICE REPAIR MANUAL
- This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck.
- All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit.
- The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model.
- This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque.
- All torque specifications have æ10% tolerance unless otherwise specified. A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating. The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E).
- The three numbers represent the basic truck model. The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit.
- This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU GD530A (W)-2B(C)Y, GD650A (W)-2B(C)Y, GD670A (W)-2B(C)Y MOTOR GRADER SERVICE REPAIR MANUAL
MAIN MENU....................................................................................................... 0 COVER........................................................................................................... 1 CONTENTS........................................................................................................ 2 FOREWORD........................................................................................................ 8 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 GD530................................................................................................... 22 GD650/670............................................................................................... 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, I....... 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 - L.H. BANK.............................................................................. 70 CONTROL VALVES - R.H. 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 VALVES..............................................................................101 SCARIFIER...........................................................................................101 RIGHT AND LEFT BLADE LIFT...........................................................................102 FLOAT VALVE.........................................................................................104 BLADE SHIFT.........................................................................................104 CIRCLE REVERSE MOTOR................................................................................105 MOLDBOARD TILT......................................................................................106 ARTICULATION........................................................................................107 CIRCLE SIDE SHIFT...................................................................................108 LEANING WHEEL.......................................................................................110 OPTIONAL FLOAT VALVE................................................................................111 STEERING AND BRAKE CIRCUIT..................................................................................112 ALL-WHEEL-DRIVE CIRCUIT.....................................................................................115 NORMAL MODE.............................................................................................116 AGGRESSIVE MODE.........................................................................................118 HYDRAULIC OPERATION.....................................................................................119 ELECTRICAL OPERATION....................................................................................122 AWD CONTROLLER PROGRAMMING..............................................................................124 LOCK/UNLOCK DIFFERENTIAL PUMP...............................................................................126 CIRCLE REVERSE SLIP CLUTCH..................................................................................128 CIRCLE REVERSE GEAR CASE....................................................................................130 WITHOUT SLIP CLUTCH.....................................................................................130 WITH SLIP CLUTCH........................................................................................132 MOTOR INSTALLATION......................................................................................134 TANDEM CASE.................................................................................................136 LOCATION................................................................................................136 DESCRIPTION.............................................................................................136 NONPLANETARY FINAL DRIVE............................................................................136 PLANETARY FINAL DRIVE...............................................................................138 FINAL DRIVE IDENTIFICATION..............................................................................140 PART NUMBER TAG.....................................................................................140 TANDEM CASE MEASUREMENT.............................................................................140 SPECIFICATIONS..........................................................................................141 AWD GEARBOX ASSEMBLY........................................................................................141 AWD GEARBOX.............................................................................................142 FRONT AXLE ASSEMBLY.........................................................................................144 NON ALL-WHEEL-DRIVE FRONT AXLE..........................................................................144 AWD FRONT AXLE..........................................................................................146 FINAL DRIVE ASSEMBLY........................................................................................148 FINAL DRIVE WITHOUT PLANETARY REDUCTION.................................................................148 FINAL DRIVE WITH PLANETARY REDUCTION....................................................................150 NO-SPIN DIFFERENTIAL CASE ASSEMBLY..................................................................152 LOCK/UNLOCK DIFFERENTIAL CASE ASSEMBLY..............................................................154 INPUT QUILL ASSEMBLY................................................................................156 BRAKES..............................................................................................158 NO-SPIN DIFFERENTIAL BEARING QUILLS.................................................................160 LOCK/UNLOCK DIFFERENTIAL BEARING QUILLS.............................................................162 LOCK/UNLOCK DIFFERENTIAL ASSEMBLY...................................................................164 LOCK/UNLOCK DIFFERENTIAL CASE OIL LINE..............................................................166 NO-SPIN DIFFERENTIAL ASSEMBLY.......................................................................168 NO-SPIN DIFFERENTIAL................................................................................170 PLANETARY ASSEMBLY AND RING GEAR....................................................................172 NONPLANETARY FINAL DRIVE CROSS SECTION..................................................................174 PLANETARY REDUCTION FINAL DRIVE CROSS SECTION...........................................................175 MICO PARKING BRAKE..........................................................................................176 MICO PARKING BRAKE INSTALLATION.........................................................................177 PARKING BRAKE CALIPER...................................................................................178 MICO BRAKE VALVE............................................................................................180 BRAKE PEDAL LINKAGE.....................................................................................180 HYDRAULIC BRAKE LINES - WITHOUT AWD.....................................................................182 HYDRAULIC BRAKE LINES - WITH AWD........................................................................184 BRAKE VALVE.............................................................................................186 TILT STEERING CONSOLE.......................................................................................188 EXPLODED VIEW OF TILT STEERING CONSOLE..................................................................190 20 TESTING, ADJUSTING AND TROUBLESHOOTING.......................................................................193 STANDARD VALUE TABLES.......................................................................................197 TABLE OF JUDGEMENT STANDARD VALUE.......................................................................197 ENGINE IN CHASSIS.......................................................................................198 CHASSIS.................................................................................................200 TOOL LIST...........................................................................................206 TRANSMISSION POWER SHIFT....................................................................................207 TRANSMISSION SHIFTER....................................................................................207 VOLTAGE AND ELECTRICAL POWER REQUIREMENTS...............................................................209 CLUTCH SOLENOID VALVE REQUIREMENTS..................................................................210 PRESSURE AND FLOW CHECKS................................................................................210 FLOW RATES..........................................................................................210 SETTING THE CLUTCH PRESSURE.........................................................................211 FLYWHEEL DIMENSIONAL CHECKS.............................................................................211 FLYWHEEL DIMENSIONS.................................................................................212 CHECKING FOR THE CORRECT PILOT SLEEVE LENGTH........................................................213 AWD PUMP....................................................................................................214 REXROTH.................................................................................................214 DIAGNOSTIC PORTS....................................................................................214 CIRCLE REVERSE MOTOR........................................................................................215 TESTS AND ADJUSTMENTS...................................................................................215 STEERING AND BRAKE PUMP.....................................................................................216 PROCEDURE...............................................................................................216 STARTUP PROCEDURE.......................................................................................217 AWD HYDRAULIC MOTOR.........................................................................................218 FOUR-WAY SWIVEL BLOCK.......................................................................................218 FRONT AXLE AND GEARBOX......................................................................................219 FRONT WHEEL ALIGNMENT AND TURNING RADIUS ADJUSTMENT.....................................................219 HYDRAULIC CYLINDERS.........................................................................................221 PRESSURE TESTING HYDRAULIC CYLINDERS....................................................................221 BALL AND SOCKET SHIMMING ADJUSTMENT.........................................................................221 ACCUMULATORS................................................................................................222 PRECHARGE...............................................................................................222 TESTS AND ADJUSTMENTS...................................................................................222 PROCEDURE FOR ACCUMULATORS UP TO 3000 psi...............................................................223 PROCEDURE FOR ACCUMULATORS UP TO 5000 psi...............................................................224 HYDRAULIC CIRCUITS..........................................................................................225 RELIEVING ACCUMULATOR PRESSURE..........................................................................226 SETTING RELIEF VALVES...................................................................................226 GENERAL DIAGNOSIS PROCEDURE.............................................................................227 HEAT PROBLEMS...........................................................................................227 SPECIAL TOOLS...........................................................................................228 HYDRAULIC PRESSURE TESTS................................................................................228 QUICK-REFERENCE PRESSURE CHART......................................................................229 MAIN HYDRAULIC SYSTEM SPECIFICATIONS....................................................................230 TEST PORT LOCATIONS.................................................................................230 TEST PROCEDURE: LOW-PRESSURE STANDBY................................................................231 TEST PROCEDURE: HIGH-PRESSURE STANDBY...............................................................232 STEERING AND BRAKE SYSTEM PRESSURE TEST.................................................................233 STEERING AND BRAKE SYSTEM SPECIFICATION.............................................................233 TEST PORT LOCATION..................................................................................233 TEST PROCEDURE......................................................................................233 AWD SYSTEM TEST.........................................................................................234 AWD SYSTEM FUNCTIONAL TEST..........................................................................235 AWD HYDRAULIC SYSTEM PRESSURE TEST..................................................................238 ALL-WHEEL-DRIVE PUMP....................................................................................239 ADJUSTMENT..........................................................................................239 RELIEF VALVES.......................................................................................241 HYDRAULIC CENTERING ADJUSTMENT PROCEDURE............................................................244 MECHANICAL CENTERING ADJUSTMENT PROCEDURE...........................................................246 AWD HYDRAULIC SYSTEM FILTERING PROCEDURE................................................................247 AWD ELECTRICAL SYSTEM TESTS.........................................................................248 LOCK/UNLOCK DIFFERENTIAL RELIEF VALVE.......................................................................257 REAR AXLE COOLING SYSTEM................................................................................257 FINAL DRIVE ASSEMBLY........................................................................................258 WITH NoSPIN AND LOCK/UNLOCK DIFFERENTIAL................................................................258 NO SPIN TEST........................................................................................258 BRAKE DISC INSPECTION...............................................................................259 TANDEM CASE.................................................................................................260 TANDEM CHAIN WEAR LIMITS................................................................................260 SPECIFICATIONS......................................................................................260 PROCEDURE...........................................................................................260 SPROCKET WEAR (NON-PLANETARY ONLY)......................................................................262 OIL.....................................................................................................262 SINGLE AND DOUBLE STRAND CHAINS.........................................................................262 ROAD TEST...........................................................................................262 CIRCLE ADJUSTMENT...........................................................................................264 FOUR SHOES..............................................................................................264 VERTICAL ADJUSTMENT.................................................................................265 PINION ADJUSTMENT...................................................................................266 CIRCLE REVERSE SLIP CLUTCH..................................................................................268 CIRCLE ADJUSTMENT.......................................................................................268 SLIP CLUTCH ADJUSTMENT..................................................................................269 ENGINE AND TRANSMISSION GEAR RANGE TEST.................................................................270 PARKING BRAKE CALIPER.......................................................................................271 PERROT PARKING BRAKE ADJUSTMENT.........................................................................271 BRAKE PRESSURE WARNING SWITCHES.........................................................................271 LOW BRAKE PRESSURE WARNING SWITCH...................................................................272 PARKING BRAKE PRESSURE SWITCH.......................................................................272 BLEEDING THE CALIPER’S..................................................................................273 MICO PARKING BRAKE ADJUSTMENT...........................................................................274 BRAKE VALVES................................................................................................275 MICO BRAKE VALVE........................................................................................275 BRAKE PEDAL BUMPER ADJUSTMENT.......................................................................275 BRAKE PEDAL FREE HEIGHT.............................................................................275 BRAKE PEDAL STOP....................................................................................276 PRESSURE TEST.......................................................................................277 TROUBLESHOOTING.............................................................................................279 HYDRAULIC CIRCUITS......................................................................................281 PROBLEMS............................................................................................281 Problem 1. Test lamp does not light.............................................................281 Problem 2. Test lamp blinks green when in reverse...............................................282 Problem 3. Test lamp blinks red.................................................................283 Problem 4. No change between the normal mode and aggressive mode................................283 Problem 5. System appears to lack power.........................................................284 Problem 6. Wheels turn when in neutral..........................................................284 Problem 7. Wheels don't turn either direction...................................................285 Problem 8. Wheels do not turn forward...........................................................286 Problem 9. Wheels do not turn in reverse........................................................287 Problem 10. Wheels do not stop..................................................................287 RIGHT AND LEFT CONTROL VALVE........................................................................288 MOLDBOARD TILT CYLINDER.............................................................................290 BLADE SHIFT CYLINDER................................................................................290 HYDRAULIC CYLINDERS.................................................................................290 CIRCLE REVERSE MOTOR................................................................................291 AWD PUMP............................................................................................292 AWD HYDRAULIC MOTOR.................................................................................296 STEERING AND BRAKE PUMP.............................................................................297 CONTROL VALVE MANIFOLDS.............................................................................298 MAIN SYSTEM PUMP....................................................................................299 TRANSMISSION POWER SHIFT................................................................................301 TRANSMISSION SHIFTER................................................................................301 TANDEM CASE.............................................................................................305 SINGLE AND DOUBLE STRAND CHAINS.....................................................................305 FINAL DRIVE ASSEMBLY....................................................................................306 WITH NoSPIN AND LOCK/UNLOCK DIFFERENTIAL............................................................306 PARKING BRAKE CALIPER...................................................................................307 PREDELIVERY PROCEDURES......................................................................................311 CHECKS AND ADJUSTMENTS..................................................................................311 FAN BELT TENSION....................................................................................311 AIR CLEANER SYSTEM..................................................................................311 AIR INDUCTION PRESSURE CHECK........................................................................312 SERVICE INDICATOR SAFETY FILTER.....................................................................313 RADIATOR HOSES......................................................................................314 FUEL LINES AND FITTINGS.............................................................................315 WATER TRAP..........................................................................................315 TRANSMISSION FLUID LEVEL............................................................................315 TRANSMISSION FILL PLUG..............................................................................315 HYDRAULIC OIL TANK LEVEL............................................................................315 HYDRAULIC OIL AND FUEL TANK FILL POINT..............................................................316 TANDEM CASE OIL LEVEL...............................................................................316 TANDEM CASE BREATHER/FILL POINT.....................................................................316 CIRCLE REVERSE OIL LEVEL............................................................................316 CIRCLE REVERSE FILL POINT...........................................................................317 REAR AXLE OIL LEVEL.................................................................................317 REAR AXLE OIL FILL POINT............................................................................317 FUEL TANK DRAIN PLUG................................................................................317 GREASE ZERKS........................................................................................318 MOLDBOARD SLIDE RAILS...............................................................................318 CONTROL LEVER LINKAGES..............................................................................318 CONTROL VALVE LINKAGES..............................................................................318 OIL LEVEL - AWD FRONT WHEEL GEAR....................................................................319 ENGINE OIL LEVEL AND FILL POINT.....................................................................319 BATTERY WATER LEVEL.................................................................................319 ENGINE COOLANT......................................................................................319 ENGINE SPEED TABLE......................................................................................320 ENGINE SPEED CHECK PROCEDURE............................................................................321 THROTTLE ADJUSTMENT PROCEDURE...........................................................................322 HYDRAULIC PRESSURE TESTS................................................................................325 QUICK-REFERENCE PRESSURE CHART......................................................................326 MAIN HYDRAULIC SYSTEM SPECIFICATIONs....................................................................327 TEST PORT LOCATIONS.................................................................................327 TEST PROCEDURE: Low-Pressure Standby................................................................328 TEST PROCEDURE: High-Pressure Standby...............................................................329 STEERING AND BRAKE SYSTEM PRESSURE TEST.................................................................330 STEERING AND BRAKE SYSTEM SPECIFICATION.............................................................330 TEST PORT LOCATION..................................................................................330 TEST PROCEDURE......................................................................................330 AWD HYDRAULIC SYSTEM PRESSURE TEST......................................................................331 AWD SYSTEM SPECIFICATION............................................................................331 TEST PORT LOCATIONS.................................................................................331 TEST PROCEDURE......................................................................................332 CLUTCH PACK PRESSURE CHECK..............................................................................333 TIRES AND RIMS..........................................................................................334 TIRE INFLATION......................................................................................334 TIRE PRESSURES......................................................................................334 RIM CENTERING.......................................................................................334 CONTROL VALVE OPERATION.................................................................................336 CONTROL LEVERS - RIGHT BANK.........................................................................336 CONTROL LEVERS - LEFT BANK..........................................................................337 OPTIONAL EQUIPMENT......................................................................................339 LIGHTING............................................................................................339 WARNING LIGHTS......................................................................................339 YARD TEST...............................................................................................339 BRAKE VALVES............................................................................................340 MICO BRAKE VALVE....................................................................................340 PARKING BRAKE CALIPER...................................................................................343 PERROT PARKING BRAKE ADJUSTMENT.....................................................................343 MICO PARKING BRAKE ADJUSTMENT.......................................................................344 30 DISASSEMBLY AND ASSEMBLY.....................................................................................345 METHOD OF USING MANUAL......................................................................................353 PRECAUTIONS DURING OPERATION................................................................................354 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK..............................................................354 PRECAUTIONS WHEN CLEANING AND INSPECTING................................................................355 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK.........................................................356 PRECAUTIONS WHEN COMPLETING THE OPERATIONS..............................................................356 OTHER PRECAUTIONS.......................................................................................357 SPECIAL TOOL LIST...........................................................................................358 SKETCHES OF SPECIAL TOOLS...................................................................................359 TRANSMISSION............................................................................................359 CHANNEL SUPPORT TOOL................................................................................359 CLUTCH PACK REMOVAL TOOL............................................................................360 CLUTCH SPRING COMPRESSION TOOL......................................................................361 CIRCLE REVERSE MOTOR (PARKER)...........................................................................362 SPECIAL BEARING MANDREL TOOL........................................................................362 CIRCLE REVERSE MOTOR (CHAR-LYNN)........................................................................363 ASSEMBLY BULLET TOOL................................................................................363 SEAL BULLET TOOL....................................................................................363 SEAL INSTALLATION TOOL..............................................................................364 HYDRAULIC MOTOR.........................................................................................365 SHAFT BEARING REMOVAL / INSTALLATION TOOL...........................................................365 HOUSING BEARING RACE REMOVAL TOOL...................................................................366 BEARING RACE INSTALLATION TOOL......................................................................366 SHAFT SEAL DRIVER TOOL..............................................................................367 HYDRAULIC OIL SWIVEL BLOCK - 4 WAY......................................................................368 SWIVEL BLOCK SEAL TOOL..............................................................................368 CIRCLE REVERSE SLIP CLUTCH..............................................................................369 CIRCLE SLIP CLUTCH GAUGE TOOL.......................................................................369 TANDEM CASE.............................................................................................370 WHEEL KNOCKER TOOL..................................................................................370 AXLE LIFTING TOOL...................................................................................370 AXLE ROLLING TORQUE TOOL............................................................................371 SPREADER BAR AND CHAINS.............................................................................371 AWD - GEARBOX ASSEMBLY..................................................................................373 SEAL INSTALLATION TOOL..............................................................................373 AWD - MOTOR (VICKERS-EATON).............................................................................374 SPECIAL SHAFT BEARING REMOVAL AND INSTALLATION TOOLS................................................374 HOUSING BEARING RACE REMOVAL TOOL...................................................................374 SPECIAL BEARING RACE INSTALLATION TOOL..............................................................375 SHAFT SEAL DRIVER...................................................................................375 FINAL DRIVE ASSEMBLY....................................................................................376 SPREADER BAR AND CHAINS.............................................................................376 DIFFERENTIAL BACKLASH TOOL (DR08-111)...............................................................377 ARTICULATION JOINT..........................................................................................379 REMOVAL.................................................................................................380 DISASSEMBLY.............................................................................................384 ASSEMBLY................................................................................................386 INSTALLATION............................................................................................389 ENGINE HOOD, FRONT & REAR COWLING...........................................................................392 REMOVAL.................................................................................................392 INSTALLATION............................................................................................395 FUEL TANK AND HYDRAULIC TANK................................................................................398 REMOVAL.................................................................................................398 INSTALLATION............................................................................................399 TRANSMISSION SHIFTER........................................................................................400 REMOVAL.................................................................................................400 INSTALLATION............................................................................................400 TRANSMISSION POWER SHIFT....................................................................................401 REMOVAL.................................................................................................401 DISASSEMBLY.............................................................................................404 FRONT COVER DISASSEMBLY.............................................................................406 MAIN CASE DISASSEMBLY...............................................................................408 TORQUE CONVERTER DISASSEMBLY........................................................................410 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 DISASSEMBLY...........................................................................418 REASSEMBLY..............................................................................................420 FRONT COVER REASSEMBLY..............................................................................420 TORQUE CONVERTER ASSEMBLY...........................................................................424 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 ASSEMBLY..............................................................................436 MAIN CASE REASSEMBLY................................................................................437 TRANSMISSION/TORQUE CONVERTER REASSEMBLY............................................................440 INSTALLING THE CONVERTER INTO THE TRANSMISSION..........................................................442 TRANSFER CASE...............................................................................................443 DISASSEMBLY.............................................................................................443 ASSEMBLY................................................................................................445 INSTALLATION............................................................................................448 SERVICING THE MACHINE AFTER A TRANSMISSION OVERHAUL.....................................................452 STARTUP PROCEDURE.......................................................................................452 ALL WHEEL DRIVE (AWD)...............................................................................452 ALL-WHEEL-DRIVE PUMP........................................................................................453 REMOVAL.................................................................................................453 SHAFT SEAL (IN-WARRANTY SERVICE)........................................................................455 CHARGE PUMP (IN-WARRANTY SERVICE).......................................................................456 CONTROL PISTON COVER (IN-WARRANTY SERVICE)..............................................................457 LEFT COVER..........................................................................................457 RIGHT COVER.........................................................................................458 REPLACING THE VALVES (IN-WARRANTY SERVICE)..............................................................459 BOOST PRESSURE VALVE................................................................................459 RELIEF VALVE........................................................................................459 PRESSURE CUT-OFF VALVE..............................................................................459 CONTROL DEVICE (IN-WARRANTY SERVICE)....................................................................460 REGULATOR VALVE (IN-WARRANTY SERVICE)...................................................................461 REBUILDING THE PUMP (OUT-OF-WARRANTY SERVICE)...........................................................462 TORQUE VALUES...........................................................................................479 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 INSTALLATION............................................................................................481 CIRCLE REVERSE MOTOR........................................................................................482 CHAR-LYNN (MACHINE S/N 202309 TO 203192)................................................................482 REMOVAL.............................................................................................482 DISASSEMBLY.........................................................................................482 ASSEMBLY............................................................................................484 INSTALLATION........................................................................................486 PARKER (MACHINE S/N 203193 AND UP)......................................................................488 EXPLODED ASSEMBLY VIEW..............................................................................488 REMOVAL.............................................................................................490 DISASSEMBLY.........................................................................................490 ASSEMBLY............................................................................................499 ONE PIECE STATOR CONSTRUCTION.......................................................................508 FINAL CHECKS........................................................................................509 INSTALLATION........................................................................................509 STEERING (ORBITOL) VALVE....................................................................................510 REMOVAL.................................................................................................510 DISASSEMBLY.............................................................................................510 ASSEMBLY................................................................................................515 INSTALLATION............................................................................................519 STEERING AND BRAKE PUMP.....................................................................................520 REMOVAL.................................................................................................520 DISASSEMBLY.............................................................................................521 ASSEMBLY................................................................................................524 INSTALLATION............................................................................................526 HYDRAULIC MOTOR.............................................................................................527 REMOVAL.................................................................................................527 DISASSEMBLY.............................................................................................528 SPECIAL INSPECTION AREAS............................................................................532 ASSEMBLY................................................................................................534 INSTALLATION............................................................................................537 4-WAY SWIVAL VALVE BLOCK....................................................................................538 REMOVAL.................................................................................................538 DISASSEMBLY.............................................................................................539 ASSEMBLY................................................................................................540 INSTALLATION............................................................................................542 CONTROL VALVE MANIFOLDS.....................................................................................544 REMOVAL.................................................................................................544 DISASSEMBLY.............................................................................................547 CONTROL VALVE BANK..................................................................................547 VALVE SECTION.......................................................................................549 VALVE SECTION IDENTIFICATION........................................................................550 ASSEMBLY................................................................................................551 VALVE SECTION.......................................................................................551 CONTROL VALVE BANK..................................................................................552 INSTALLATION............................................................................................553 MAIN SYSTEM PUMP............................................................................................555 REMOVAL.................................................................................................555 DISASSEMBLY.............................................................................................556 ASSEMBLY................................................................................................562 INSTALLATION............................................................................................568 HYDRAULIC INTEGRATED CIRCUIT VALVE..........................................................................569 REMOVAL.................................................................................................569 DISASSEMBLY.............................................................................................570 HIC VALVE...........................................................................................570 SOLENOID CARTRIDGE DISASSEMBLY......................................................................571 ASSEMBLY................................................................................................572 SOLENOID CARTRIDGE REASSEMBLY.......................................................................572 HIC VALVE...........................................................................................573 INSTALLATION............................................................................................574 HYDRAULIC CYLINDERS.........................................................................................575 BALL AND SOCKET SHIMMING ADJUSTMENT.....................................................................575 SPECIAL TORQUES.........................................................................................576 CLEANING AND INSPECTION.................................................................................576 STEERING CYLINDERS......................................................................................577 REMOVAL.............................................................................................577 DISASSEMBLY.........................................................................................578 ASSEMBLY............................................................................................579 INSTALLATION........................................................................................580 LEANING WHEEL CYLINDER..................................................................................581 REMOVAL.............................................................................................581 DISASSEMBLY.........................................................................................582 ASSEMBLY............................................................................................583 INSTALLATION........................................................................................584 MOLDBOARD TILT CYLINDERS................................................................................585 REMOVAL.............................................................................................585 DISASSEMBLY.........................................................................................586 ASSEMBLY............................................................................................587 INSTALLATION........................................................................................588 MOLDBOARD SIDE SHIFT CYLINDER...........................................................................589 REMOVAL.............................................................................................589 DISASSEMBLY.........................................................................................590 ASSEMBLY............................................................................................590 INSTALLATION........................................................................................591 DRAWBAR SIDE SHIFT CYLINDER (R.H. BLADE SUSPENSION ONLY)................................................592 REMOVAL.............................................................................................592 DISASSEMBLY.........................................................................................593 ASSEMBLY............................................................................................594 INSTALLATION........................................................................................595 DRAWBAR SIDE SHIFT CYLINDER (R.H. & L.H. BIAS BLADE SUSPENSION).........................................596 REMOVAL.............................................................................................596 DISASSEMBLY.........................................................................................596 ASSEMBLY............................................................................................598 INSTALLATION........................................................................................599 DRAWBAR LIFT CYLINDERS (R.H. BLADE SUSPENSION ONLY).....................................................600 REMOVAL.............................................................................................600 DISASSEMBLY.........................................................................................601 ASSEMBLY............................................................................................602 INSTALLATION........................................................................................603 DRAWBAR LIFT CYLINDERS (R.H. & L.H. BIAS BLADE SUSPENSION ONLY).........................................604 REMOVAL.............................................................................................604 TRUNNION BUSHING REPLACEMENT........................................................................605 DISASSEMBLY.........................................................................................606 ASSEMBLY............................................................................................607 INSTALLATION........................................................................................608 SCARIFIER CYLINDERS.....................................................................................610 REMOVAL.............................................................................................610 DISASSEMBLY.........................................................................................611 ASSEMBLY............................................................................................612 INSTALLATION........................................................................................613 LOCK PIN CYLINDER (R.H. & L.H. BIAS BLADE SUSPENSION ONLY)..............................................615 REMOVAL.............................................................................................615 DISASSEMBLY.........................................................................................616 ASSEMBLY............................................................................................617 INSTALLATION........................................................................................618 ARTICULATION CYLINDERS..................................................................................619 REMOVAL.............................................................................................619 DISASSEMBLY.........................................................................................620 ASSEMBLY............................................................................................621 INSTALLATION........................................................................................622 ACCUMULATORS................................................................................................623 MAINTENANCE.............................................................................................623 CHECKING THE PRECHARGE..................................................................................623 ACCUMULATORS WITH PARKER VALVE P/N 5323640000.......................................................624 ACCUMULATORS WITH PARKER VALVE P/N 6124330000.......................................................624 REMOVAL (BRAKE SYSTEM)..................................................................................625 REMOVAL (DRAWBAR LIFT AND DRAWBAR SIDE SHIFT)...........................................................626 DISASSEMBLY.............................................................................................627 REPAIR AND REPLACEMENT..................................................................................628 ASSEMBLY................................................................................................628 INSTALLATION (BRAKE SYSTEM).............................................................................629 INSTALLATION (DRAWBAR LIFT AND DRAWBAR SIDE SHIFT)......................................................629 LOCK/UNLOCK DIFFERENTIAL PUMP...............................................................................630 REMOVAL.................................................................................................630 DISASSEMBLY.............................................................................................631 REPAIR AND REPLACEMENT..................................................................................632 REASSEMBLY..............................................................................................633 INSTALLATION............................................................................................634 ADJUSTING DIFFERENTIAL PUMP BELT TENSION............................................................635 V-BELT ADJUSTMENT...................................................................................635 OPTIONAL V-BELT ADJUSTMENT..........................................................................635 CIRCLE REVERSE SLIP CLUTCH..................................................................................636 REMOVAL.................................................................................................636 GENERAL EXPLOSION VIEW..................................................................................637 DISASSEMBLY.............................................................................................639 ASSEMBLY................................................................................................641 INSTALLATION............................................................................................646 RETROFITTING A STANDARD CIRCLE GEAR CASE WITH A SLIP CLUTCH.............................................647 CIRCLE IDENTIFICATION...............................................................................647 RETROFITTING INSTRUCTIONS...........................................................................647 CIRCLE REVERSE GEAR CASE....................................................................................649 DISASSEMBLY.............................................................................................649 ASSEMBLY................................................................................................655 TANDEM CASE.................................................................................................663 SINGLE AND DOUBLE STRAND CHAINS.........................................................................663 REMOVAL.................................................................................................663 DISASSEMBLY.............................................................................................667 ASSEMBLY................................................................................................668 INSTALLATION............................................................................................670 AWD - GEARBOX ASSEMBLY......................................................................................673 TWO-PIECE SEAL INSTALLATION.............................................................................673 REMOVAL.................................................................................................678 DISASSEMBLY.............................................................................................682 ASSEMBLY................................................................................................689 INSTALLATION............................................................................................698 AWD MOTOR (VICKERS/EATON)...................................................................................703 REMOVAL.................................................................................................703 DISASSEMBLY.............................................................................................703 REMOVAL OF FRONT SHAFT BEARING......................................................................706 REPLACE ALL PARTS THAT DO NOT MEET THE FOLLOWING SPECIFICATIONS.....................................706 ASSEMBLY................................................................................................707 INSTALLATION............................................................................................710 FRONT AXLE ASSEMBLY.........................................................................................711 REMOVAL.................................................................................................711 DISASSEMBLY.............................................................................................713 ASSEMBLY................................................................................................717 INSTALLATION............................................................................................724 FINAL DRIVE ASSEMBLY........................................................................................727 NoSPIN AND LOCK/UNLOCK DIFFERENTIALS....................................................................727 PARKING BRAKE BLEEDING..............................................................................727 FINAL DRIVE BRAKE BLEEDING..........................................................................727 ROAD TESTING............................................................................................728 REMOVAL.................................................................................................728 GENERAL DISASSEMBLY.....................................................................................733 DISASSEMBLY OF THE PLANETARY CARRIER................................................................733 DISASSEMBLY OF THE NONPLANETARY CARRIER.............................................................737 DISASSEMBLY OF THE DIFFERENTIAL BRAKE PISTONS.......................................................740 DISASSEMBLY OF THE INPUT QUILL ASSEMBLY.............................................................741 DISASSEMBLY OF THE DIFFERENTIAL CASE WITH NoSPIN DIFFERENTIAL.......................................743 DISASSEMBLY OF DIFFERENTIAL CASE WITH LOCK/UNLOCK DIFFERENTIAL......................................745 NoSPIN DIFFERENTIAL INSPECTION......................................................................751 LOCK/UNLOCK DIFFERENTIAL INSPECTION.................................................................751 PARKING BRAKE MOUNTING BRACKET..........................................................................752 DIFFERENTIAL ASSEMBLY...................................................................................753 NoSPIN DIFFERENTIAL CASE ASSEMBLY...................................................................754 LOCK/UNLOCK DIFFERENTIAL CASE ASSEMBLY..............................................................758 PINION GEAR ADJUSTMENTS.................................................................................765 PINION GEAR CONE POINT ADJUSTMENT...................................................................765 PINION GEAR ENDPLAY ADJUSTMENT......................................................................767 PINION GEAR BACKLASH ADJUSTMENT.....................................................................768 FINAL ASSEMBLY......................................................................................771 ASSEMBLY OF THE DIFFERENTIAL BRAKE PISTONS..............................................................773 NONPLANETARY CARRIER ASSEMBLY...........................................................................775 PLANETARY CARRIER ASSEMBLY..............................................................................782 INSTALLATION............................................................................................787 REPLACING 6C FLANGE DRIVE SHAFT WITH 7C FLANGE DRIVE SHAFT..........................................788 CIRCLE TOOTH REBUILD........................................................................................794 REBUILDING THE TEETH....................................................................................794 MICO PARKING BRAKE CALIPER..................................................................................795 REMOVAL.................................................................................................795 BRAKE LINING REPLACEMENT................................................................................797 DISASSEMBLY.............................................................................................797 ASSEMBLY................................................................................................801 INSTALLATION............................................................................................804 BRAKE VALVE.................................................................................................805 REMOVAL.................................................................................................805 DISASSEMBLY.............................................................................................808 ASSEMBLY................................................................................................810 INSTALLATION............................................................................................811 SEAT........................................................................................................813 GENERAL SPECIFICATIONS..................................................................................813 COMPLETE ASSEMBLY.......................................................................................815 DISASSEMBLY.........................................................................................816 ASSEMBLY............................................................................................818 LOWER SUSPENSION........................................................................................819 DISASSEMBLY.........................................................................................820 INSPECTION AND REPAIR...............................................................................822 ASSEMBLY............................................................................................822 SEAT ADJUSTER...........................................................................................823 DISASSEMBLY.........................................................................................824 ASSEMBLY............................................................................................824 TILT STEERING CONSOLE.......................................................................................825 DISASSEMBLY.............................................................................................825 ASSEMBLY................................................................................................833 AIR CONDITIONING............................................................................................842 AIR CONDITIONING SYSTEM ELECTRICAL DIAGRAM..............................................................842 AIR CONDITIONING SYSTEM DIAGRAM.........................................................................843 AIR CONDITIONING COMPRESSOR.............................................................................844 REMOVAL.............................................................................................844 INSTALLATION........................................................................................844 COMPRESSOR CLUTCH SERVICE...........................................................................845 RECEIVER/DRYER..........................................................................................850 SERVICE.............................................................................................850 REMOVAL.............................................................................................850 INSTALLATION........................................................................................850 CONDENSER...............................................................................................851 REMOVAL.............................................................................................851 INSTALLATION........................................................................................851 AIR CONDITIONER/HEATER UNIT.............................................................................852 ELECTRICAL DIAGRAM..................................................................................852 ASSEMBLY DIAGRAM....................................................................................853 REMOVAL.............................................................................................855 INSTALLATION........................................................................................855 ASSEMBLY............................................................................................856 AIR CONDITIONING SYSTEM CHARGING PROCEDURE..............................................................879 CHECKING COMPRESSOR OIL LEVEL...........................................................................881 40 MAINTENANCE STANDARD.........................................................................................883 FINAL DRIVE.................................................................................................884 NO SPIN DIFFERENTIAL CASE ASSEMBLY..........................................................................885 NO SPIN DIFFERENTIAL ASSEMBLY...............................................................................886 FINAL DRIVE AND TANDEMS.....................................................................................887 TANDEM DRIVE................................................................................................888 BRAKE VALVE.................................................................................................889 STEERING CYLINDER...........................................................................................890 LEANING WHEEL CYLINDER......................................................................................891 MOLDBOARD TILT CYLINDER.....................................................................................892 MOLDBOARD SIDE SHIFT........................................................................................893 DRAWBAR SIDE SHIFT CYLINDER.................................................................................894 DRAWBAR LIFT CYLINDER.......................................................................................895 SCARIFIER CYLINDER..........................................................................................896 ARTICULATION CYLINDER.......................................................................................897 RIPPER CYLINDER.............................................................................................898 LUG NUTS....................................................................................................899 FRONT AXLE..................................................................................................900 POWER TILT MOLDBOARD CARRIER................................................................................901 FRAME.......................................................................................................902 DRAWBAR AND CIRCLE..........................................................................................903 DRAWBAR LIFT................................................................................................904 ENGINE AND TRANSMISSION.....................................................................................905 DRIVE LINE..................................................................................................906 ALTERNATOR..................................................................................................907 CAB MOUNT...................................................................................................908 90 OTHER........................................................................................................909 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 DIAGRAM...........................................................................923 HYDRAULIC CIRCUIT DIAGRAM (SHEET 1 OF 2)....................................................................925 HYDRAULIC CIRCUIT DIAGRAM (SHEET 2 OF 2)....................................................................927
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