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KOMATSU GD530A(W)-2 GD650A(W)-2 GD670A(W)-2 MOTOR GRADER SERVICE REPAIR MANUAL (SN:210098 and UP)KOMATSU GD530A(W) 2, GD650A(W) 2,GD670A(W) 2 – PDF DOWNLOAD
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- KOMATSU GD530A(W)-2 GD650A(W)-2 GD670A(W)-2 MOTOR GRADER SERVICE REPAIR MANUAL
- SERIAL NUMBER:210098 and UP
- PUBLICATION NUMBER:CEBM003902
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KOMATSU GD530A(W)-2 GD650A(W)-2 GD670A(W)-2 MOTOR GRADER SERVICE REPAIR MANUAL (SN:210098 and UP)KOMATSU GD530A(W) 2, GD650A(W) 2,GD670A(W) 2
KOMATSU GD530A(W)-2 GD650A(W)-2 GD670A(W)-2 MOTOR GRADER SERVICE REPAIR MANUAL (SN:210098 AND UP)KOMATSU GD530A(W) 2, GD650A(W) 2,GD670A(W) 2 – PDF DOWNLOAD:
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KOMATSU GD530A(W)-2 GD650A(W)-2 GD670A(W)-2 MOTOR GRADER SERVICE REPAIR MANUAL (SN:210098 and UP)KOMATSU GD530A(W) 2, GD650A(W) 2,GD670A(W) 2
- 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 GD530A(W)-2 GD650A(W)-2 GD670A(W)-2 MOTOR GRADER SERVICE REPAIR MANUAL (SN:210098 and UP)KOMATSU GD530A(W) 2, GD650A(W) 2,GD670A(W) 2
MAIN MENU....................................................................................................... 0 COVER........................................................................................................... 1 CONTENTS........................................................................................................ 2 FORWARD......................................................................................................... 5 SAFETY...................................................................................................... 13 SAFETY NOTICE........................................................................................... 15 IMPORTANT SAFETY NOTICE............................................................................. 15 GENERAL PRECAUTIONS................................................................................. 15 PREPARATIONS FOR WORK............................................................................... 15 PRECAUTIONS DURING WORK............................................................................. 15 GENERAL..................................................................................................... 15 HOW TO READ THE SHOP MANUAL................................................................................. 16 VOLUMES................................................................................................. 16 DISTRIBUTION AND UPDATING............................................................................... 16 FILING METHOD........................................................................................... 16 REVISED EDITION MARK.................................................................................... 16 REVISIONS............................................................................................... 16 SYMBOLS................................................................................................. 16 HOISTING INSTRUCTIONS....................................................................................... 17 HOISTING................................................................................................ 17 WIRE ROPES.............................................................................................. 17 COATING MATERIALS........................................................................................... 18 STANDARD TIGHTENING TORQUE.................................................................................. 20 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS............................................................ 20 TIGHTENING TORQUE OF HOSE NUTS.......................................................................... 21 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS................................................................. 21 TIGHTENING TORQUE FOR FLARED NUTS....................................................................... 21 ELECTRIC WIRE CODE.......................................................................................... 22 CLASSIFICATION BY THICKNESS............................................................................. 22 CLASSIFICATION BY COLOR AND CODE........................................................................ 22 CONVERSION TABLES........................................................................................... 23 METHOD OF USING THE CONVERSION TABLE.................................................................... 23 01 GENERAL...................................................................................................... 29 GENERAL ASSEMBLY DRAWING.................................................................................... 30 GD530................................................................................................... 30 GD650/670............................................................................................... 30 FUEL, COOLANT, AND LUBRICANTS............................................................................... 31 ACCORDING TO AMBIENT TEMPERATURE........................................................................ 31 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS........................................................ 31 ENGINE OIL SPECIFICATIONS............................................................................... 33 NORMAL OPERATION.................................................................................... 33 ARCTIC OPERATION.................................................................................... 33 TRANSMISSION, TORQUE CONVERTER AND OIL COOLER, TANDEM DRIVE CASES, FRONT-WHEEL-DRIVE GEAR CASE, I....... 34 REAR-DRIVE AXLE AND CIRCLE DRIVE BRAKE HOUSING OIL SPECIFICATIONS....................................... 34 DIESEL FUEL SPECIFICATIONS.............................................................................. 34 COOLANT SPECIFICATIONS.................................................................................. 35 GENERAL............................................................................................. 35 WATER............................................................................................... 35 ANTIFREEZE.......................................................................................... 35 SUPPLEMENTAL COOLANT ADDITIVES...................................................................... 37 MAINTENANCE OF SUPPLEMENTAL COOLANT ADDITIVES....................................................... 37 COOLANT TESTING FOR CONDITIONER CONCENTRATION....................................................... 37 REPLENISHING COOLANT CONDITIONER.................................................................... 37 SUPPLEMENTAL COOLANT ADDITIVE MAINTENANCE GUIDE..................................................... 38 COOLING SYSTEM TEST KIT............................................................................. 40 CIRCLE DRIVE GEAR CASE OIL SPECIFICATIONS (HDTF)........................................................ 40 10 STRUCTURE AND FUNCTION....................................................................................... 41 ORBITROL.................................................................................................... 45 TRANSMISSION POWER SHIFT.................................................................................... 47 OPERATION............................................................................................... 49 RECOMMENDED LUBRICANT AND FILTER CHANGE INTERVALS....................................................... 51 GENERAL LOCATION OF COMPONENTS.......................................................................... 53 ALL-WHEEL-DRIVE PUMP........................................................................................ 54 ROTARY GROUP............................................................................................ 56 EP2 HYDRAULIC CONTROL................................................................................... 58 INTERPRETATION OF TYPE CODES............................................................................ 60 CIRCLE REVERSE MOTOR........................................................................................ 61 CIRCLE REVERSE GEAR CASE MOTOR.......................................................................... 61 CIRCLE REVERSE MOTOR.................................................................................... 63 STEERING AND BRAKE PUMP..................................................................................... 65 STEERING AND BRAKE PUMP MOUNTING........................................................................ 65 STEERING AND BRAKE PUMP................................................................................. 66 SPECIFICATIONS...................................................................................... 68 AWD HYDRAULIC MOTOR......................................................................................... 69 OPERATION............................................................................................... 71 SPECIFICATIONS.......................................................................................... 72 HYDRAULIC OIL SWIVEL BLOCK.................................................................................. 73 FOUR WAY................................................................................................ 73 CONTROL VALVE MANIFOLDS..................................................................................... 74 OPTIONAL CONTROL LEVER (SCARIFIER)...................................................................... 76 OPTIONAL CONTROL LEVERS (AUXILIARY)..................................................................... 78 CONTROL VALVES - LEFT BANK.............................................................................. 80 CONTROL VALVES - R.H. BANK.............................................................................. 82 VALVE SECTION........................................................................................... 84 MAIN SYSTEM PUMP............................................................................................ 86 MAIN SYSTEM PUMP........................................................................................ 88 AWD HIC VALVE............................................................................................... 90 SOLENOID VALVE CARTRIDGE................................................................................ 92 ACCUMULATOR................................................................................................. 93 SPECIFICATIONS.......................................................................................... 94 BRAKE SYSTEM ACCUMULATORS............................................................................... 95 DRAWBAR LIFT AND DRAWBAR SIDE SHIFT ACCUMULATORS........................................................ 95 HYDRAULIC SYSTEM OVERVIEW................................................................................... 96 STANDARD GRADER......................................................................................... 96 MAIN HYDRAULIC CIRCUIT.............................................................................. 97 STEERING AND BRAKE HYDRAULIC CIRCUIT................................................................ 97 (INCLUDES LOCK PIN)................................................................................. 97 STANDARD GRADER WITH ALL WHEEL DRIVE (AWD).............................................................. 98 MAIN HYDRAULIC CIRCUIT.............................................................................. 99 ALL WHEEL DRIVE CIRCUIT............................................................................. 99 STEERING AND BRAKE HYDRAULIC CIRCUIT................................................................ 99 (INCLUDES LOCK PIN)................................................................................. 99 MAIN HYDRAULIC CIRCUIT......................................................................................101 SPOOL VALVE POSITIONS...................................................................................106 NEUTRAL (CENTER)....................................................................................106 PULLED (PRESSURIZED "B" PORT).......................................................................107 PUSHED (PRESSURIZED "A" PORT).......................................................................108 MAIN SYSTEM CONTROL VALVES..............................................................................110 SCARIFIER...........................................................................................110 RIGHT AND LEFT BLADE LIFT...........................................................................112 FLOAT VALVE.........................................................................................114 BLADE SHIFT.........................................................................................114 CIRCLE REVERSE MOTOR................................................................................115 MOLDBOARD TILT......................................................................................116 ARTICULATION........................................................................................118 CIRCLE SIDE SHIFT...................................................................................120 LEANING WHEEL.......................................................................................122 OPTIONAL FLOAT VALVE................................................................................123 STEERING AND BRAKE CIRCUIT..................................................................................124 ALL-WHEEL-DRIVE CIRCUIT.....................................................................................127 NORMAL MODE.............................................................................................128 AGGRESSIVE MODE.........................................................................................130 HYDRAULIC OPERATION.....................................................................................131 ELECTRICAL OPERATION....................................................................................134 AWD CONTROLLER PROGRAMMING..............................................................................136 LOCK/UNLOCK DIFFERENTIAL PUMP...............................................................................138 CIRCLE REVERSE SLIP CLUTCH..................................................................................140 CIRCLE REVERSE GEAR CASE....................................................................................142 WITHOUT SLIP CLUTCH.....................................................................................142 WITH SLIP CLUTCH........................................................................................144 MOTOR INSTALLATION......................................................................................146 TANDEM CASE.................................................................................................148 LOCATION................................................................................................148 DESCRIPTION.............................................................................................148 NONPLANETARY FINAL DRIVE............................................................................148 PLANETARY FINAL DRIVE...............................................................................150 FINAL DRIVE IDENTIFICATION..............................................................................152 PART NUMBER TAG.....................................................................................152 TANDEM CASE MEASUREMENT.............................................................................152 SPECIFICATIONS..........................................................................................154 AWD GEARBOX ASSEMBLY........................................................................................155 AWD GEARBOX.............................................................................................156 FRONT AXLE ASSEMBLY.........................................................................................158 NON ALL-WHEEL-DRIVE FRONT AXLE..........................................................................158 AWD FRONT AXLE..........................................................................................160 FINAL DRIVE ASSEMBLY........................................................................................162 FINAL DRIVE WITHOUT PLANETARY REDUCTION.................................................................162 FINAL DRIVE WITH PLANETARY REDUCTION....................................................................164 NO-SPIN DIFFERENTIAL CASE ASSEMBLY..................................................................166 INPUT QUILL ASSEMBLY................................................................................170 BRAKES..............................................................................................172 NO-SPIN DIFFERENTIAL BEARING QUILLS.................................................................174 LOCK/UNLOCK DIFFERENTIAL BEARING QUILLS.............................................................176 LOCK/UNLOCK DIFFERENTIAL ASSEMBLY...................................................................178 LOCK/UNLOCK DIFFERENTIAL CASE OIL LINE..............................................................180 NO-SPIN DIFFERENTIAL ASSEMBLY.......................................................................181 NOSPIN DIFFERENTIAL.................................................................................183 PLANETARY ASSEMBLY AND RING GEAR....................................................................184 NONPLANETARY FINAL DRIVE CROSS SECTION..................................................................186 PLANETARY REDUCTION FINAL DRIVE CROSS SECTION...........................................................187 MICO PARKING BRAKE..........................................................................................188 OPERATION...............................................................................................188 PARKING BRAKE INSTALLATION..............................................................................189 PARKING BRAKE CALIPER...................................................................................191 MICO BRAKE VALVE............................................................................................193 OPERATION...............................................................................................193 BRAKE PEDAL LINKAGE.....................................................................................193 HYDRAULIC BRAKE LINES - WITHOUT AWD.....................................................................195 HYDRAULIC BRAKE LINES - WITH AWD........................................................................197 BRAKE VALVE.............................................................................................199 PRE-DELIVERY PROCEDURES.....................................................................................201 PRE-UNLOADING CHECKS....................................................................................201 RECORD THE SERIAL NUMBERS...............................................................................202 COMPONENT SERIAL NUMBER LOCATION........................................................................203 OPERATION AND MAINTENANCE MANUAL........................................................................205 REVIEW THE TEXT WITH OWNER/OPERATOR.....................................................................205 INSPECT THE MACHINE AND ATTACHMENTS.....................................................................205 INSPECT THE PRODUCT GRAPHICS (decals)...................................................................205 20 TESTING, ADJUSTING AND TROUBLESHOOTING.......................................................................207 STANDARD VALUE TABLES.......................................................................................212 TABLE OF JUDGEMENT STANDARD VALUE.......................................................................213 FOR ENGINE ON TEST BENCH............................................................................213 FOR ENGINE IN CHASSIS...............................................................................215 IN CHASSIS..........................................................................................216 IN CHASSIS (CONTINUED)..............................................................................217 IN CHASSIS (CONTINUED)..............................................................................218 TESTING AND ADJUSTING TOOL LIST.....................................................................221 TRANSMISSION POWER SHIFT....................................................................................222 VOLTAGE AND ELECTRICAL POWER REQUIREMENTS...............................................................222 CLUTCH SOLENOID VALVE REQUIREMENTS..................................................................223 PRESSURE AND FLOW CHECKS................................................................................223 FLOW RATES..........................................................................................223 SETTING THE CLUTCH PRESSURE.........................................................................224 TROUBLESHOOTING.........................................................................................224 FLYWHEEL DIMENSIONAL CHECKS.............................................................................229 FLYWHEEL DIMENSIONS.................................................................................230 CHECKING FOR THE CORRECT PILOT SLEEVE LENGTH........................................................231 ALL-WHEEL-DRIVE PUMP........................................................................................232 REXROTH.................................................................................................232 DIAGNOSTIC PORTS....................................................................................232 TROUBLESHOOTING.....................................................................................235 CIRCLE REVERSE MOTOR........................................................................................238 TESTS AND ADJUSTMENTS...................................................................................238 STEERING AND BRAKE PUMP.....................................................................................239 SERVICE DIAGNOSIS.......................................................................................239 STEERING AND BRAKE PUMP TEST............................................................................240 SPECIFICATION.......................................................................................240 PROCEDURE...........................................................................................241 STARTUP PROCEDURE.......................................................................................242 AWD HYDRAULIC MOTOR.........................................................................................243 TROUBLESHOOTING.........................................................................................244 FOUR-WAY SWIVEL BLOCK.......................................................................................245 CONTROL VALVE MANIFOLDS.....................................................................................246 TROUBLESHOOTING.........................................................................................246 MAIN SYSTEM PUMP............................................................................................248 TROUBLESHOOTING.........................................................................................248 HYDRAULIC CYLINDERS.........................................................................................250 TROUBLESHOOTING.........................................................................................250 FRONT WHEEL ALIGNMMENT AND TURNING RADIUS ADJUSTMENT....................................................251 PROCEDURE...........................................................................................251 PRESSURE TESTING HYDRAULIC CYLINDERS....................................................................254 BALL AND SOCKET SHIMMING ADJUSTMENT.....................................................................254 ACCUMULATORS................................................................................................255 PRECHARGE...............................................................................................255 PRESSURES...........................................................................................255 TESTS AND ADJUSTMENTS...............................................................................255 PROCEDURE FOR ACCUMULATORS UP TO 3000 PSI...........................................................256 PROCEDURE FOR ACCUMULATORS UP TO 5000 PSI...........................................................257 HYDRAULIC CIRCUITS..........................................................................................258 RELIEVING ACCUMULATOR PRESSURE..........................................................................259 SETTING RELIEF VALVES...................................................................................259 GENERAL DIAGNOSIS PROCEDURE.............................................................................260 HEAT PROBLEMS...........................................................................................260 SPECIAL TOOLS...........................................................................................261 TROUBLESHOOTING CHARTS..................................................................................262 MAIN SYSTEM PUMP....................................................................................262 RIGHT AND LEFT CONTROL VALVE........................................................................262 MOLDBOARD TILT CYLINDER.............................................................................264 BLADE SHIFT CYLINDER................................................................................264 CIRCLE REVERSE MOTOR................................................................................265 HYDRAULIC PRESSURE TESTS................................................................................266 QUICK-REFERENCE PRESSURE CHART......................................................................267 MAIN HYDRAULIC SYSTEM SPECIFICATIONS....................................................................268 TEST PORT LOCATIONS.................................................................................268 TEST PROCEDURE: Low-Pressure Standby................................................................269 TEST PROCEDURE: High-Pressure Standby...............................................................270 STEERING AND BRAKE SYSTEM PRESSURE TEST.................................................................271 STEERING AND BRAKE SYSTEM SPECIFICATION.............................................................271 TEST PORT LOCATION..................................................................................271 TEST PROCEDURE......................................................................................271 AWD SYSTEM TEST.........................................................................................272 AWD SYSTEM FUNCTIONAL TEST..........................................................................274 AWD HYDRAULIC SYSTEM PRESSURE TEST..................................................................277 AWD ELECTRICAL SYSTEM TESTS.........................................................................279 PROBLEMS................................................................................................289 Problem 1. Test lamp does not light.................................................................289 Problem 2. Test lamp blinks green when in reverse...................................................290 Problem 3. Test lamp blinks red.....................................................................291 Problem 4. No change between the normal mode and aggressive mode....................................291 Problem 5. System appears to lack power.............................................................292 Problem 6. Wheels turn when in neutral..............................................................292 Problem 7. Wheels don't turn either direction.......................................................293 Problem 8. Wheels do not turn forward...............................................................295 Problem 9. Wheels do not turn in reverse............................................................296 Problem 10. Wheels do not stop......................................................................296 ALL-WHEEL-DRIVE PUMP....................................................................................297 ADJUSTMENT..........................................................................................297 RELIEF VALVES.......................................................................................298 HYDRAULIC CENTERING ADJUSTMENT PROCEDURE............................................................301 MECHANICAL CENTERING ADJUSTMENT PROCEDURE...........................................................304 AWD HYDRAULIC SYSTEM FILTERING PROCEDURE................................................................305 LOCK/UNLOCK DIFFERENTIAL RELIEF VALVE.......................................................................306 REAR AXLE COOLING SYSTEM................................................................................306 CIRCLE REVERSE SLIP CLUTCH..................................................................................307 CIRCLE ADJUSTMENT.......................................................................................307 SLIP CLUTCH ADJUSTMENT..................................................................................309 ENGINE AND TRANSMISSION GEAR RANGE TEST.................................................................310 TANDEM CASE.................................................................................................311 SINGLE AND DOUBLE STRAND CHAINS.........................................................................311 ROAD TEST...........................................................................................312 GEARBOX ASSEMBLY............................................................................................313 ALL WHEEL DRIVE.........................................................................................313 FRONT WHEEL ALIGNMENT AND TURNING RADIUS ADJUSTMENT.....................................................313 PROCEDURE...........................................................................................314 FRONT AXLE ASSEMBLY.........................................................................................317 PROCEDURE...............................................................................................318 FINAL DRIVE ASSEMBLY........................................................................................321 WITH NoSPIN AND LOCK/UNLOCK DIFFERENTIAL................................................................321 TROUBLESHOOTING.....................................................................................321 NoSPIN TEST.........................................................................................322 BRAKE DISC INSPECTION...............................................................................323 CIRCLE ADJUSTMENT...........................................................................................324 FOUR SHOES..............................................................................................324 VERTICAL ADJUSTMENT.................................................................................325 PINION ADJUSTMENT...................................................................................326 PARKING BRAKE CALIPER.......................................................................................328 TROUBLESHOOTING.........................................................................................328 PERROT PARKING BRAKE ADJUSTMENT.........................................................................329 MICO PARKING BRAKE ADJUSTMENT...........................................................................330 BRAKE VALVES................................................................................................331 REXROTH BRAKE VALVE.....................................................................................331 FREE PEDAL CLEARANCE................................................................................331 BRAKE PEDAL STOP....................................................................................332 FULL BRAKE VALVE STROKE.............................................................................333 MICO BRAKE VALVE........................................................................................334 BRAKE PEDAL BUMPER ADJUSTMENT.......................................................................334 BRAKE PEDAL FREE HEIGHT.............................................................................334 BRAKE PEDAL STOP....................................................................................335 PRESSURE TEST.......................................................................................336 PREDELIVERY PROCEDURES......................................................................................337 CHECKS AND ADJUSTMENTS..................................................................................337 FAN BELT TENSION....................................................................................337 AIR CLEANER SYSTEM..................................................................................337 AIR INDUCTION PRESSURE CHECK........................................................................338 SERVICE INDICATOR SAFETY FILTER.....................................................................339 RADIATOR HOSES......................................................................................340 FUEL LINES AND FITTINGS.............................................................................341 WATER TRAP..........................................................................................341 TRANSMISSION FLUID LEVEL............................................................................341 TRANSMISSION FILL PLUG..............................................................................342 HYDRAULIC OIL TANK LEVEL............................................................................342 HYDRAULIC OIL AND FUEL TANK FILL POINT..............................................................343 TANDEM CASE OIL LEVEL...............................................................................343 TANDEM CASE BREATHER/FILL POINT.....................................................................343 CIRCLE REVERSE OIL LEVEL............................................................................344 CIRCLE REVERSE FILL POINT...........................................................................344 REAR AXLE OIL LEVEL.................................................................................345 REAR AXLE OIL FILL POINT............................................................................345 FUEL TANK DRAIN PLUG................................................................................345 GREASE ZERKS........................................................................................346 MOLDBOARD SLIDE RAILS...............................................................................346 CONTROL LEVER LINKAGES..............................................................................347 CONTROL VALVE LINKAGES..............................................................................347 OIL LEVEL - AWD FRONT WHEEL GEAR....................................................................348 ENGINE OIL LEVEL AND FILL POINT.....................................................................348 BATTERY WATER LEVEL.................................................................................349 ENGINE COOLANT......................................................................................349 ENGINE SPEED TABLE......................................................................................350 ENGINE SPEED CHECK PROCEDURE............................................................................351 THROTTLE ADJUSTMENT PROCEDURE...........................................................................352 HYDRAULIC PRESSURE TESTS................................................................................355 QUICK-REFERENCE PRESSURE CHART......................................................................356 MAIN HYDRAULIC SYSTEM SPECIFICATIONs....................................................................357 TEST PORT LOCATIONS.................................................................................357 TEST PROCEDURE: Low-Pressure Standby................................................................358 TEST PROCEDURE: High-Pressure Standby...............................................................359 STEERING AND BRAKE SYSTEM PRESSURE TEST.................................................................360 STEERING AND BRAKE SYSTEM SPECIFICATION.............................................................360 TEST PORT LOCATION..................................................................................360 TEST PROCEDURE......................................................................................360 AWD HYDRAULIC SYSTEM PRESSURE TEST......................................................................361 AWD SYSTEM SPECIFICATION............................................................................361 TEST PORT LOCATIONS.................................................................................361 TEST PROCEDURE......................................................................................362 CLUTCH PACK PRESSURE CHECK..............................................................................363 TIRES AND RIMS..........................................................................................364 TIRE INFLATION......................................................................................364 TIRE PRESSURES......................................................................................364 RIM CENTERING.......................................................................................365 CONTROL VALVE OPERATION.................................................................................366 CONTROL LEVERS - RIGHT BANK.........................................................................367 CONTROL LEVERS - LEFT BANK..........................................................................368 OPTIONAL EQUIPMENT......................................................................................369 LIGHTING............................................................................................369 WARNING LIGHTS......................................................................................369 YARD TEST...............................................................................................369 BRAKE VALVES............................................................................................370 REXROTH BRAKE VALVE.................................................................................370 MICO BRAKE VALVE....................................................................................373 PARKING BRAKE CALIPER...................................................................................376 PERROT PARKING BRAKE ADJUSTMENT.....................................................................376 MICO PARKING BRAKE ADJUSTMENT.......................................................................377 30 DISASSEMBLY AND ASSEMBLY.....................................................................................379 ARTICULATION JOINT ASSEMBLY.................................................................................386 SERVICING...............................................................................................387 DISASSEMBLY.........................................................................................392 CLEANING AND INSPECTION.............................................................................394 ASSEMBLY............................................................................................395 INSTALLATION........................................................................................398 ORBITROL....................................................................................................402 REMOVAL.................................................................................................402 DISASSEMBLY.............................................................................................402 CLEANING AND INSPECTION.................................................................................408 ASSEMBLY................................................................................................409 INSTALLATION............................................................................................415 TRANSMISSION POWER SHIFT....................................................................................416 SPECIAL TOOLS...........................................................................................271 CHANNEL SUPPORT TOOL................................................................................416 CLUTCH PACK REMOVAL TOOL............................................................................417 CLUTCH SPRING COMPRESSION TOOL......................................................................418 REMOVAL.................................................................................................419 DISASSEMBLY.............................................................................................430 FRONT COVER DISASSEMBLY.............................................................................432 MAIN CASE DISASSEMBLY...............................................................................434 TORQUE CONVERTER DISASSEMBLY........................................................................436 CLUTCH PACK 1 AND 5 DISASSEMBLY (first stage).......................................................438 CLUTCH PACK 2 AND 6 DISASSEMBLY (second stage)......................................................440 CLUTCH PACK 3 AND 4 DISASSEMBLY (third stage).......................................................442 CONTROL VALVE DISASSEMBLY...........................................................................444 CLEANING AND INSPECTION.................................................................................445 CLEANING............................................................................................445 INSPECTION..........................................................................................446 REASSEMBLY..............................................................................................447 FRONT COVER REASSEMBLY..............................................................................447 TORQUE CONVERTER ASSEMBLY...........................................................................449 CLUTCH PACK 1 AND 5 REASSEMBLY (first stage)........................................................451 Reassemble the first clutch pack as follows:........................................................451 CLUTCH PACK 2 AND 6 REASSEMBLY (second stage).......................................................455 CLUTCH PACK 3 AND 4 REASSEMBLY (third stage)........................................................458 CONTROL VALVE REASSEMBLY............................................................................462 MAIN CASE REASSEMBLY................................................................................463 TRANSMISSION/TORQUE CONVERTER REASSEMBLY............................................................466 INSTALLING THE CONVERTER INTO THE TRANSMISSION..........................................................467 TRANSFER CASE...............................................................................................468 DISASSEMBLY.............................................................................................468 ASSEMBLY................................................................................................470 INSTALLATION............................................................................................472 SERVICING THE MACHINE AFTER A TRANSMISSION OVERHAUL.....................................................259 STARTUP PROCEDURE.......................................................................................483 ALL WHEEL DRIVE (AWD)...............................................................................483 ALL-WHEEL-DRIVE PUMP........................................................................................484 REMOVAL.................................................................................................232 SHAFT SEAL (IN-WARRANTY SERVICE)........................................................................486 CHARGE PUMP (IN-WARRANTY SERVICE).......................................................................488 CONTROL PISTON COVER (IN-WARRANTY SERVICE)..............................................................490 LEFT COVER..........................................................................................490 RIGHT COVER.........................................................................................491 REPLACING THE VALVES (IN-WARRANTY SERVICE)..............................................................493 BOOST PRESSURE VALVE................................................................................493 RELIEF VALVE........................................................................................493 PRESSURE CUT-OFF VALVE..............................................................................494 CONTROL DEVICE (IN-WARRANTY SERVICE)....................................................................495 REGULATOR VALVE (IN-WARRANTY SERVICE)...................................................................496 REBUILDING THE PUMP (OUT-OF-WARRANTY SERVICE)...........................................................497 TORQUE VALUES...........................................................................................522 Tightening torques for shaft bolts (Metric ISO Standard Thread).....................................522 Tightening torques for locking screws VSTI (Metric ISO fine thread).................................523 Tightening torque for seal lock nuts VSTI (Metric ISO standard thread)..............................523 Tightening torques for cross-slotted lens head screws DIN 7985 (Metric ISO standard thread).........524 INSTALLATION............................................................................................525 CIRCLE REVERSE MOTOR (DANFOSS)..............................................................................527 REMOVAL.................................................................................................527 DISASSEMBLY.............................................................................................527 CLEANING AND INSPECTION.................................................................................533 ASSEMBLY................................................................................................534 INSTALLATION............................................................................................544 CIRCLE REVERSE MOTOR (CHAR-LYNN)............................................................................545 SPECIAL TOOLS...........................................................................................313 SEAL INSTALLATION TOOL..............................................................................546 ASSEMBLY BULLET TOOL................................................................................547 SEAL BULLET TOOL....................................................................................548 REMOVAL.................................................................................................549 DISASSEMBLY.............................................................................................549 CLEANING AND INSPECTION.................................................................................551 ASSEMBLY................................................................................................311 INSTALLATION............................................................................................555 STEERING AND BRAKE PUMP.....................................................................................556 REMOVAL.................................................................................................556 DISASSEMBLY.............................................................................................557 CLEANING AND INSPECTION.................................................................................560 ASSEMBLY................................................................................................562 INSTALLATION............................................................................................564 HYDRAULIC MOTOR.............................................................................................565 SPECIAL SERVICE TOOLS...................................................................................565 SHAFT BEARING REMOVAL/INSTALLATION TOOL.............................................................565 HOUSING BEARING RACE REMOVAL TOOL...................................................................566 BEARING RACE INSTALLATION TOOL......................................................................330 SHAFT SEAL DRIVER TOOL..............................................................................567 REMOVAL.................................................................................................568 DISASSEMBLY.............................................................................................569 CLEANING AND INSPECTION.................................................................................573 ASSEMBLY................................................................................................576 INSTALLATION............................................................................................579 HYDRAULIC OIL SWIVEL BLOCK - 4 WAY..........................................................................580 SPECIAL TOOLS...........................................................................................334 SWIVEL BLOCK SEAL TOOL..............................................................................580 REMOVAL.................................................................................................581 DISASSEMBLY.............................................................................................582 CLEANING AND INSPECTION.................................................................................583 ASSEMBLY................................................................................................583 INSTALLATION............................................................................................585 CONTROL VALVE MANIFOLDS.....................................................................................586 REMOVAL.................................................................................................586 DISASSEMBLY.............................................................................................589 CONTROL VALVE BANK..................................................................................589 VALVE SECTION.......................................................................................591 VALVE SECTION IDENTIFICATION........................................................................592 CLEANING AND INSPECTION.................................................................................593 ASSEMBLY................................................................................................594 VALVE SECTION.......................................................................................594 CONTROL VALVE BANK..................................................................................337 INSTALLATION............................................................................................338 MAIN SYSTEM PUMP............................................................................................355 REMOVAL.................................................................................................355 DISASSEMBLY.............................................................................................357 CLEANING AND INSPECTION.................................................................................609 REASSEMBLY..............................................................................................610 INSTALLATION............................................................................................617 HYDRAULIC INTEGRATED CIRCUIT VALVE..........................................................................619 REMOVAL.................................................................................................619 DISASSEMBLY.............................................................................................620 HIC VALVE...........................................................................................620 SOLENOID CARTRIDGE DISASSEMBLY......................................................................347 CLEANING AND INSPECTION.................................................................................622 ASSEMBLY................................................................................................623 SOLENOID CARTRIDGE REASSEMBLY.......................................................................623 HIC VALVE...........................................................................................624 INSTALLATION............................................................................................349 HYDRAULIC CYLINDERS.........................................................................................627 CLEANING AND INSPECTION.................................................................................627 STEERING CYLINDERS......................................................................................628 REMOVAL.............................................................................................628 DISASSEMBLY.........................................................................................629 CLEANING AND INSPECTION.............................................................................629 ASSEMBLY............................................................................................630 INSTALLATION........................................................................................631 LEANING WHEEL CYLINDER..................................................................................632 REMOVAL.............................................................................................632 DISASSEMBLY.........................................................................................633 CLEANING AND INSPECTION.............................................................................633 ASSEMBLY............................................................................................634 INSTALLATION........................................................................................634 MOLDBOARD TILT CYLINDERS................................................................................636 REMOVAL.............................................................................................636 DISASSEMBLY.........................................................................................637 CLEANING AND INSPECTION.............................................................................637 ASSEMBLY............................................................................................638 INSTALLATION........................................................................................639 MOLDBOARD SIDE SHIFT CYLINDER...........................................................................640 REMOVAL.............................................................................................640 DISASSEMBLY.........................................................................................642 CLEANING AND INSPECTION.............................................................................642 ASSEMBLY............................................................................................642 INSTALLATION........................................................................................643 DRAWBAR SIDE SHIFT CYLINDER (R.H. BLADE SUSPENSION ONLY)................................................645 REMOVAL.............................................................................................645 DISASSEMBLY.........................................................................................646 CLEANING AND INSPECTION.............................................................................646 ASSEMBLY............................................................................................647 INSTALLATION........................................................................................648 DRAWBAR SIDE SHIFT CYLINDER (R.H. & L.H. BIAS BLADE SUSPENSION).........................................649 REMOVAL.............................................................................................649 DISASSEMBLY.........................................................................................649 CLEANING AND INSPECTION.............................................................................650 ASSEMBLY............................................................................................650 INSTALLATION........................................................................................651 DRAWBAR LIFT CYLINDERS (R.H. BLADE SUSPENSION ONLY).....................................................652 REMOVAL.............................................................................................652 DISASSEMBLY.........................................................................................653 CLEANING AND INSPECTION.............................................................................654 ASSEMBLY............................................................................................654 INSTALLATION........................................................................................655 DRAWBAR LIFT CYLINDERS (R.H. & L.H. BIAS BLADE SUSPENSION ONLY).........................................657 REMOVAL.............................................................................................657 DISASSEMBLY.........................................................................................659 CLEANING AND INSPECTION.............................................................................660 ASSEMBLY............................................................................................660 INSTALLATION........................................................................................661 SCARIFIER CYLINDERS.....................................................................................663 REMOVAL.............................................................................................663 DISASSEMBLY.........................................................................................664 CLEANING AND INSPECTION.............................................................................665 ASSEMBLY............................................................................................665 INSTALLATION........................................................................................666 LOCK PIN CYLINDER (R.H. & L.H. BIAS BLADE SUSPENSION ONLY)..............................................668 REMOVAL.............................................................................................668 DISASSEMBLY.........................................................................................669 CLEANING AND INSPECTION.............................................................................669 ASSEMBLY............................................................................................669 INSTALLATION........................................................................................670 ARTICULATION CYLINDERS..................................................................................671 REMOVAL.............................................................................................671 DISASSEMBLY.........................................................................................672 CLEANING AND INSPECTION.............................................................................673 ASSEMBLY............................................................................................673 INSTALLATION........................................................................................674 ACCUMULATORS................................................................................................675 MAINTENANCE.............................................................................................675 CHECKING THE PRECHARGE..................................................................................675 Accumulators with Parker valve p/n 5323640000.......................................................676 Accumulators with Parker valve p/n 6124330000.......................................................677 REMOVAL (BRAKE SYSTEM)..................................................................................677 REMOVAL (DRAWBAR LIFT AND DRAWBAR SIDE SHIFT)...........................................................678 DISASSEMBLY.............................................................................................680 CLEANING AND INSPECTION.................................................................................681 REPAIR AND REPLACEMENT..............................................................................681 ASSEMBLY................................................................................................681 INSTALLATION (BRAKE SYSTEM).............................................................................682 INSTALLATION (DRAWBAR LIFT AND DRAWBAR SIDE SHIFT)......................................................682 LOCK/UNLOCK DIFFERENTIAL PUMP...............................................................................683 REMOVAL.................................................................................................683 DISASSEMBLY.............................................................................................685 CLEANING AND INSPECTION.................................................................................686 REPAIR AND REPLACEMENT..............................................................................687 REASSEMBLY..............................................................................................687 INSTALLATION............................................................................................687 CIRCLE REVERSE SLIP CLUTCH..................................................................................689 SPECIAL TOOLS...........................................................................................689 CIRCLE SLIP CLUTCH GAUGE TOOL.......................................................................689 REMOVAL.................................................................................................690 DISASSEMBLY.............................................................................................691 CLEANING AND INSPECTION.................................................................................693 ASSEMBLY................................................................................................695 INSTALLATION............................................................................................702 RETROFITTING A STANDARD CIRCLE GEAR CASE WITH A SLIP CLUTCH.............................................704 CIRCLE IDENTIFICATION...............................................................................704 RETROFITTING INSTRUCTIONS...........................................................................704 CIRCLE REVERSE GEAR CASE....................................................................................706 DISASSEMBLY.............................................................................................706 CLEANING AND INSPECTION.................................................................................713 ASSEMBLY................................................................................................714 TANDEM CASE.................................................................................................218 SINGLE AND DOUBLE STRAND CHAINS.........................................................................722 SERVICE/SPECIAL TOOLS...................................................................................722 WHEEL KNOCKER TOOL..................................................................................218 AXLE LIFTING TOOL...................................................................................218 AXLE ROLLING TORQUE TOOL............................................................................218 SPREADER BAR AND CHAINS.............................................................................724 REMOVAL.................................................................................................219 DISASSEMBLY.............................................................................................220 CLEANING AND INSPECTION.................................................................................220 ASSEMBLY................................................................................................732 INSTALLATION............................................................................................221 GEARBOX ASSEMBLY - AWD......................................................................................738 SERVICE/SPECIAL TOOLS...................................................................................738 SEAL INSTALLATION TOOL..............................................................................738 TWO-PIECE SEAL INSTALLATION.........................................................................738 REMOVAL.................................................................................................743 DISASSEMBLY.............................................................................................748 CLEANING AND INSPECTION.................................................................................757 ASSEMBLY................................................................................................758 INSTALLATION............................................................................................769 FRONT AXLE ASSEMBLY.........................................................................................774 REMOVAL.................................................................................................774 DISASSEMBLY.............................................................................................777 CLEANING AND INSPECTION.................................................................................782 ASSEMBLY................................................................................................783 INSTALLATION............................................................................................793 FINAL DRIVE ASSEMBLY........................................................................................796 NoSPIN AND LOCK/UNLOCK DIFFERENTIALS....................................................................796 SERVICE/SPECIAL TOOLS...................................................................................796 SPREADER BAR AND CHAINS.............................................................................796 DIFFERENTIAL BACKLASH TOOL (DR08-111)...............................................................798 PARKING BRAKE BLEEDING..............................................................................799 FINAL DRIVE BRAKE BLEEDING..........................................................................799 ROAD TESTING............................................................................................800 REMOVAL.................................................................................................800 GENERAL DISASSEMBLY.....................................................................................806 DISASSEMBLY OF THE PLANETARY CARRIER................................................................806 DISASSEMBLY OF THE NONPLANETARY CARRIER.............................................................812 DISASSEMBLY OF THE DIFFERENTIAL BRAKE PISTONS.......................................................816 DISASSEMBLY OF THE INPUT QUILL ASSEMBLY.............................................................817 DISASSEMBLY OF THE DIFFERENTIAL CASE WITH NoSPIN DIFFERENTIAL.......................................819 DISASSEMBLY OF DIFFERENTIAL CASE WITH LOCK/UNLOCK DIFFERENTIAL......................................821 CLEANING AND INSPECTION.................................................................................828 NoSPIN DIFFERENTIAL INSPECTION......................................................................829 LOCK/UNLOCK DIFFERENTIAL INSPECTION.................................................................829 PARKING BRAKE MOUNTING BRACKET..........................................................................830 DIFFERENTIAL ASSEMBLY...................................................................................831 NoSPIN DIFFERENTIAL CASE ASSEMBLY...................................................................832 LOCK/UNLOCK DIFFERENTIAL CASE ASSEMBLY..............................................................836 PINION GEAR ADJUSTMENTS.................................................................................845 PINION GEAR CONE POINT ADJUSTMENT...................................................................845 PINION GEAR ENDPLAY ADJUSTMENT......................................................................847 PINION GEAR BACKLASH ADJUSTMENT.....................................................................848 FINAL ASSEMBLY......................................................................................850 ASSEMBLY OF THE DIFFERENTIAL BRAKE PISTONS..............................................................852 NONPLANETARY CARRIER ASSEMBLY...........................................................................854 PLANETARY CARRIER ASSEMBLY..............................................................................862 INSTALLATION............................................................................................868 CIRCLE TOOTH REBUILD........................................................................................874 REBUILDING THE TEETH....................................................................................874 MICO PARKING BRAKE CALIPER..................................................................................875 REMOVAL.................................................................................................875 BRAKE LINING REPLACEMENT................................................................................878 DISASSEMBLY.............................................................................................878 CLEANING AND INSPECTION.................................................................................880 ASSEMBLY................................................................................................881 INSTALLATION............................................................................................883 REXROTH BRAKE VALVE.........................................................................................885 REMOVAL.................................................................................................885 DISASSEMBLY.............................................................................................888 CLEANING AND INSPECTION.................................................................................889 ASSEMBLY................................................................................................890 INSTALLATION............................................................................................891 40 MAINTENANCE STANDARD.........................................................................................893 FINAL DRIVE.................................................................................................894 NO SPIN DIFFERENTIAL CASE ASSEMBLY..........................................................................895 NO SPIN DIFFERENTIAL ASSEMBLY...............................................................................896 FINAL DRIVE AND TANDEMS.....................................................................................897 TANDEM DRIVE................................................................................................898 BRAKE VALVE.................................................................................................899 STEERING CYLINDER...........................................................................................900 LEANING WHEEL CYLINDER......................................................................................901 MOLDBOARD TILT CYLINDER.....................................................................................902 MOLDBOARD SIDE SHIFT........................................................................................903 DRAWBAR SIDE SHIFT CYLINDER.................................................................................904 DRAWBAR LIFT CYLINDER.......................................................................................905 SCARIFIER CYLINDER..........................................................................................906 ARTICULATION CYLINDER.......................................................................................907 RIPPER CYLINDER.............................................................................................908 LUG NUTS....................................................................................................909 FRONT AXLE..................................................................................................910 POWER TILT MOLDBOARD CARRIER................................................................................911 FRAME.......................................................................................................912 DRAWBAR AND CIRCLE..........................................................................................913 DRAWBAR LIFT................................................................................................914 ENGINE AND TRANSMISSION.....................................................................................915 DRIVE LINE..................................................................................................916 ALTERNATOR..................................................................................................917 90 DIAGRAMS AND SCHEMATICS......................................................................................919 HYDRAULIC DIAGRAM (SHEET 1 OF 2)............................................................................920 HYDRAULIC DIAGRAM (SHEET 2 OF 2)............................................................................921 ELECTRICAL DEG-20109 Page 1 of 2 (Sheet 1 of 5).............................................................922 DEG-20109 Page 1 OF 2 (Sheet 2 of 5)........................................................................923 DEG-20109 Page 1 of 2 (Sheet 3 of 5)........................................................................924 DEG-20109 Page 1 of 2 (Sheet 4 of 5)........................................................................925 DEG-20109 Page 1 of 2 (Sheet 5 of 5)........................................................................926 DEG-20109 Page 2 of 2 (Sheet 1 of 2)........................................................................927 DEG-20109 Page 2 of 2 (Sheet 2 of t)........................................................................928
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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