Komatsu GD530A,AW & GD650A,AW & GD67OA,AW & GD530A(W)-2 & GD650A(W)-2 & GD670A(W)-2 & GD530A(W)-2B(C)Y & GD650A(W)-2B(C)Y & GD670A(W)-2B(C)Y Motor Graders Repair Service Manual + Operation & Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu GD530A, GD530AW, GD530A-2, GD530AW-2, GD530A-2BY, GD530A-2CY, GD530AW-2BY, GD530AW-2CY, GD650A, GD650AW, GD650A-2, GD650AW-2, GD650A-2BY, GD650A-2CY, GD650AW-2BY, GD650AW-2CY, GD67OA, GD67OAW, GD670A-2, GD670AW-2, GD670A-2BY, GD670A-2CY, GD670AW-2BY, GD670AW-2CY Motor Graders , with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Motor Graders GD530A,AW & GD650A,AW & GD67OA,AW & GD530A(W)-2 & GD650A(W)-2 & GD670A(W)-2 & GD530A(W)-2B(C)Y & GD650A(W)-2B(C)Y & GD670A(W)-2B(C)Y workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 3,764 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEBMG65194 - Motor Grader GD530A,AW & GD650A,AW & GD67OA,AW Shop Manual.pdf
CEBM003902 - Motor Grader GD530A(W)-2 & GD650A(W)-2 & GD670A(W)-2 Shop Manual.pdf
CEBM009900 - Motor Grader GD530A(W)-2B(C)Y & GD650A(W)-2B(C)Y & GD670A(W)-2B(C)Y Shop Manual.pdf
CEAM009700 - Motor Grader GD530A(W)-2B(C)Y & GD650A(W)-2B(C)Y & GD670A(W)-2B(C)Y Operation & Maintenance Manual.pdf
CEAMG65040 - Motor Grader GD530A(W)-2 & GD650A(W)-2 & GD670A(W)-2 Operation & Maintenance Manual.pdf
CEAM003900 - Motor Grader with Emissionized Engine GD530A-2EY,AW-2EY & GD650A-2EY,AW-2EY & GD670A-2EY,AW-2EY Operation & Maintenance Manual.pdf
MAIN SECTIONS
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
