Komatsu GD530A, AW SERIES GD650A, AW SERIES GD670A, AW SERIES Shop Manual CEBMG65194 – PDF DOWNLOAD
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Komatsu GD530A, AW SERIES GD650A, AW SERIES GD670A, AW SERIES Shop Manual CEBMG65194 – PDF DOWNLOAD
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Pages : 1053
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
Komatsu GD530A, AW SERIES GD650A, AW SERIES GD670A, AW SERIES Shop Manual CEBMG65194 – PDF DOWNLOAD
MACHINE MODEL
GD530A-1
GD530A-1 E
GD530A-2A
GD530A-2B
GD530A-2E
GD530A-2C
GD530AW-1
GD530AW-2A
GD530AW-2B
GD530AW-2E
GD530AW-2C
GD650A-1
GD650A-2
GD650A-2A
GD650A-2B
GD650A-2E
SERIAL NUMBER
20084OTHRU202000
201404
202002 al up
202002 & up
202002 & up
20084OTHRU202000
202002 84 up
202002 & up
202002 84 up
20084OTHRU202000
202001
202002 & up
202002 & up
202002 & up
MACHINE MODEL
GD650A-2C
GD650AW-I
GD650AW-2A
GD650AW-2B
GD650AW-2E
GD650AW-2C
GD670A-1
GD670A-2A
GD670A-2B
GD670A-2E
GD-670A-2C
GD670AW-1
GD670AW-2A
GD670AW-2B
GD670AW-2E
GD-670AW-2C
SERIAL NUMBER
20084OTHRU202000
202002 & up
202002 & up
202002 & up
20084OTHRU202000
202002 & up
202002 & up
202002 & up
20084OTHRU202000
202002 & up
202002 & up
202002 & up
TABLE OF CONTENTS:
Komatsu GD530A, AW SERIES GD650A, AW SERIES GD670A, AW SERIES Shop Manual CEBMG65194 – PDF DOWNLOAD
MAIN MENU 0
CONTENTS FOR CEBMG65194 2
A-01 50K – ARTICULATION JOINT ASSEMBLY 3
TABLE OF CONTENTS 5
INTRODUCTION 6
SERVICING 7
REMOVAL 7
DISASSEMBLY 12
CLEANING AND INSPECTION 14
REASSEMBLY 16
INSTALLATION 19
A-10 40K – CHAR-LYNN ORBITROL UNIT 23
TABLE OF CONTENTS 23
INTRODUCTION 26
SERVICING 28
REMOVAL 28
DISASSEMBLY 28
CLEANING INSPECTION 35
REASSEMBLY 37
INSTALLATION 42
C-11 40K R1 – TRANSMISSION POWER SHIFT (FUNK 2263E130B) 43
TABLE OF CONTENTS 45
SPECIAL TOOLS 46
CHANNEL SUPPORT TOOL 46
CLUTCH PACK REMOVAL TOOL 47
CLUTCH SPRING COMPRESSION TOOL 48
INTRODUCTION 49
OPERATION 49
RULES OF OPERATION 49
SERVICE 51
RECOMMENDED LUBRICANT AND FILTER CHANGE INTERVALS 52
GENERAL LOCATION OF COMPONENTS 53
VOLTAGE AND ELECTRICAL POWER REQUIREMENTS 54
CLUTCH SOLENOID VALVE REQUIREMENTS 54
PRESSURE AND FLOW CHECKS 55
SETTING THE CLUTCH PRESSURE 56
TRANSMISSION SCHEMATICS 57
TROUBLESHOOTING 58
FLYWHEEL DIMENSIONAL CHECKS 64
CONVERTER ASSEMBLY INSTALLATION INTO TRANSMISSION IF SEPARATED FROM TRANSMISSION 67
SERVICING 68
REMOVAL 68
TRANSMISSION 78
Disassembly 78
Transmission/Torque Converter Disassembly 78
Front Cover Disassembly 80
Main Case Disassembly 82
Torque Converter Disassembly (S/N 200417 Thru 202050) 86
Torque Converter Disassembly (S/N 202051 and UP) 88
Clutch Pack 1 and 5 Disassembly (First Stage) 90
Clutch Pack 2 and 6 Disassembly (Second Stage) 93
Clutch Pack 3 and 4 Disassembly (Third Stage) 96
Control Valve Disassembly 100
Cleaning and Inspection 102
Reassembly 104
Front Cover Reassembly 104
Torque Converter Reassembly (S/N 200417 Thru 202050) 108
Torque Converter Reassembly (S/N 202051 and UP) 110
Clutch Pack 1 and 5 Reassembly (First Stage) 112
Clutch Pack 2 and 6 Reassembly (Second Stage) 117
Clutch Pack 3 and 4 Reassembly (Third Stage) 122
Control Valve Reassembly 128
Main Case Reassembly 130
Transmission/Torque Converter Reassembly 134
TRANSFER CASE 136
Disassembly 136
Cleaning and Inspection 137
Reassembly 138
INSTALLATION 141
SERVICING MACHINE AFTER TRANSMISSION OVERHAUL 152
STARTUP PROCEDURE 153
E-01 15K – ALL WHEEL DRIVE PUMP (REXROTH) 155
TABLE OF CONTENTS 157
INTRODUCTION 158
INTERPRETATION OF TYPE CODES 163
DIAGNOSTIC PORTS 164
TROUBLESHOOTING 166
SERVICING 169
REMOVAL 169
CHARGE PUMP (IN WARRANTY SERVICE) 171
Disassembly 171
Reassembly 172
SHAFT SEAL (IN WARRANTY SERVICE) 173
Disassembly 173
Reassembly 174
MAIN PUMP DISASSEMBLY (OUT OF WARRANTY SERVICE) 175
CLEANING AND INSPECTION 183
MAIN PUMP REASSEMBLY (OUT OF WARRANTY SERVICE) 185
INSTALLATION 194
TESTS AND ADJUSTMENTS 196
E-03 90K R1 – CIRCLE REVERSE MOTOR (DANFOSS) 197
TABLE OF CONTENTS 197
LOCATION ON MACHINE 199
DESCRIPTION 200
SERVICING 204
REMOVAL 204
DISASSEMBLY 204
CLEANING AND INSPECTION 210
REASSEMBLY 212
INSTALLATION 219
E-03 95K – CIRCLE REVERSE MOTOR P/N 1435 598 H91 (CHAR-LYNN) 220
TABLE OF CONTENTS 222
SPECIAL TOOLS 223
INTRODUCTION 227
SERVICING 228
REMOVAL 228
DISASSEMBLY 228
CLEANING AND INSPECTION 231
REASSEMBLY 233
INSTALLATION 236
TESTS AND ADJUSTMENTS 237
E-04 60K – STEERING & BRAKE PUMP (EATON MODEL 70422 RDU) 238
TABLE OF CONTENTS 240
LOCATION ON MACHINE 241
DESCRIPTION 241
SPECIFICATIONS 244
SERVICE DIAGNOSIS 245
SERVICE/SPECIAL TOOLS 247
PRESSURES 247
SPECIAL TORQUES 247
TESTS AND ADJUSTMENTS 247
START-UP PROCEDURE 247
SERVICING 249
REMOVAL 249
DISASSEMBLY 251
CLEANING AND INSPECTION 254
REASSEMBLY 257
INSTALLATION 259
E-13 30K – HYDRAULIC MOTOR (VICKERS) (ALL WHEEL DRIVE) 260
TABLE OF CONTENTS 262
LOCATION ON MACHINE 263
DESCRIPTION 263
OPERATION 264
SPECIFICATIONS 265
SERVICE DIAGNOSIS 266
SERVICE/SPECIAL TOOLS 268
SERVICING 270
REMOVAL 270
DISASSEMBLY 270
CLEANING AND INSPECTION 273
REASSEMBLY 275
INSTALLATION 279
TESTS AND ADJUSTMENTS 280
E-30 40K – HYDRAULIC OIL SWIVEL BLOCK (FOUR-WAY) 281
TABLE OF CONTENTS 283
SPECIAL TOOLS 284
INTRODUCTION 285
SERVICING 286
REMOVAL 286
DISASSEMBLY 287
CLEANING AND INSPECTION 288
REASSEMBLY 289
INSTALLATION 290
TESTING AND ADJUSTMENTS 291
E-32 35K – CONTROL VALVE MANIFOLDS (HUSCO 5000C SERIES) 292
TABLE OF CONTENTS 294
INTRODUCTION 295
TROUBLESHOOTING 307
SERVICING 310
REMOVAL 310
DISASSEMBLY 313
Disassembly of Control Valve Bank 313
Disassembly of Valve Section 315
Valve Section Identification 315
CLEANING AND INSPECTION 317
REASSEMBLY 319
Reassembly of Valve Section 319
Reassembly of Control Valve Bank 321
INSTALLATION 323
E-32 45K – MAIN SYSTEM PUMP 325
TABLE OF CONTENTS 325
INTRODUCTION 327
TROUBLESHOOTING 332
SERVICING 334
REMOVAL 334
DISASSEMBLY 336
CLEANING AND INSPECTION 344
REASSEMBLY 345
INSTALLATION 353
E-32 90K – ALL WHEEL DRIVE HYDRAULIC INTEGRATED CIRCUIT (HIC) VALVE 356
TABLE OF CONTENTS 358
INTRODUCTION 359
TROUBLESHOOTING 365
SERVICING 366
REMOVAL 366
DISASSEMBLY 367
HIC Valve Disassembly 367
Solenoid Cartridge Disassembly 369
CLEANING AND INSPECTION 370
REASSEMBLY 372
Solenoid Cartridge Reassembly 372
HIC Valve Reassembly 373
INSTALLATION 375
E-33 00K R1 – HYDRAULIC CYLINDERS 376
TABLE OF CONTENTS 378
INTRODUCTION 380
SERVICE DIAGNOSIS 380
SPECIAL TORQUES 381
TESTS AND ADJUSTMENTS 382
FRONT WHEEL ALIGNMENT & TURNING RADIUS ADJUSTMENT 382
HYDRAULIC PRESSURE TESTING FOR CYLINDERS 385
BALL AND SOCKET SHIMMING ADJUSTMENT 386
SERVICING 387
CLEANING AND INSPECTION 387
STEERING CYLINDERS 388
Removal 388
Disassembly 389
Cleaning and Inspection 389
Reassembly 389
Installation 391
LEANING WHEEL CYLINDER 392
Removal 392
Disassembly 393
Cleaning and Inspection 393
Reassembly 393
Installation 395
MOLDBOARD TILT CYLINDERS 396
Removal 396
Disassembly 397
Cleaning and Inspection 397
Reassembly 397
Installation 399
MOLDBOARD SIDE SHIFT CYLINDER 400
Removal 400
Disassembly 402
Cleaning and Inspection 402
Reassembly 402
Installation 404
DRAWBAR SIDE SHIFT CYLINDER (R H BLADE SUSPENSION ONLY) 406
Removal 406
Disassembly 407
Cleaning and Inspection 407
Reassembly 407
Installation 409
DRAWBAR SIDE SHIFT CYLINDER (R H & L H BIAS BLADE SUSPENSION ONLY) 410
Removal 410
Disassembly 411
Cleaning and Inspection 411
Reassembly 411
Installation 413
DRAWBAR LIFT CYLINDERS (R H BLADE SUSPENSION ONLY) 414
Removal 414
Disassembly 416
Cleaning and Inspection 416
Reassembly 416
Installation 418
DRAWBAR LIFT CYLINDERS (R H & L H BIAS BLADE SUSPENSION ONLY) 420
Removal 420
Disassembly 422
Cleaning and Inspection 422
Reassembly 422
Installation 424
SCARIFIER CYLINDERS 426
Removal 426
Disassembly 428
Cleaning and Inspection 428
Reassembly 428
Installation 430
LOCK PIN CYLINDER (R H & L H BIAS BLADE SUSPENSION ONLY) 431
Removal 431
Disassembly 432
Cleaning and Inspection 432
Reassembly 432
Installation 434
ARTICULATION CYLINDERS 435
Removal 435
Disassembly 436
Cleaning and Inspection 436
Reassembly 436
Installation 438
E-33 10K – ACCUMULATORS (P/N 1285 352 H91, 1279 537 H & 1233 789 H91) 439
TABLE OF CONTENTS 440
LOCATION ON MACHINE 441
BRAKE SYSTEM ACCUMULATORS 441
DRAWBAR LIFT AND DRAWBAR SIDE SHIFT ACCUMULATORS 441
DESCRIPTION 442
OPERATION 443
BRAKE SYSTEM ACCUMULATORS 443
DRAWBAR LIFT AND DRAWBAR SIDE SHIFT ACCUMULATORS 443
SPECIFICATIONS 443
SERVICE/SPECIAL TOOLS 445
PRESSURES 445
SPECIAL TORQUES 445
TESTS AND ADJUSTMENTS 445
PRE-CHARGING 445
SERVICING 448
MAINTENANCE 448
PRE-CHARGE CHECKING PROCEDURE 449
REMOVAL (BRAKE SYSTEM) 450
REMOVAL (DRAWBAR LIFT AND DRAWBAR SIDE SHIFT) 451
DISASSEMBLY 452
CLEANING AND INSPECTION 453
REPAIR AND REPLACEMENT 454
REASSEMBLY 455
INSTALLATION (BRAKE SYSTEM) 456
INSTALLATION (DRAWBAR LIFT AND DRAWBAR SIDE SHIFT) 456
E-33 80K – TROUBLESHOOTING AND ADJUSTMENT MANUAL 457
TABLE OF CONTENTS 459
SPECIAL TOOLS 460
INTRODUCTION 461
SETTING RELIEF VALVES 461
GENERAL DIAGNOSIS PROCEDURE 463
HEAT PROBLEMS 463
HYDRAULIC TEST PORT CONNECTIONS 464
HYDRAULIC SYSTEM OVERVIEW 466
QUICK REFERENCE PRESSURE CHART 467
HYDRAULIC SCHEMATICS 468
STANDARD GRADER 470
STANDARD GRADER WITH ALL WHEEL DRIVE (AWD) 472
DETAILED HYDRAULIC SYSTEMS 475
MAIN HYDRAULIC CIRCUIT 475
Main System Pump Troubleshooting Chart 485
R H & L H Control Valve Troubleshooting Chart 485
Main Hydraulic System Specification 488
Test Port Locations 488
Test Procedure 489
Main System Control Valve Functions 491
Scarifier Cylinders 491
R H & L H Blade Lift Cylinders 493
Blade Shift Cylinder 496
Circle Reverse Motor 497
Moldboard Tilt Cylinders 498
Articulation Cylinders 500
Circle Side Shift Cylinder 502
Leaning Wheel Cylinder 504
Float Valve for Optional Function 505
STEERING AND BRAKE CIRCUIT (INCLUDES LOCK PIN) 506
Steering and Brake System Pressure Tests 510
Steering and Brake System Specification 510
Test Port Locations 510
Test Procedure 510
ALL WHEEL DRIVE CIRCUIT 511
Introduction 511
Hydraulic Operation 514
Electrical Operation 520
AWD Controller Programming 522
Final Drive Planetary/Non-Planetary Identification 524
Part Number Tag 524
Physical Measurement of Tandem Case 524
Testing and Troubleshooting 526
AWD System Functional Test 528
AWD Hydraulic System Pressure Tests 530
AWD Electrical System Tests 533
Sensor Test and Adjustment 540
Problems 542
Problem 1 Test lamp does not light (“AWD System Functional Test”Step 3 A) 542
Problem 2 Test lamp blinks green when in reverse (“AWD System Functional Test” Step 3 A) 543
Problem 3 Test lamp blinks red (“AWD System Functional Test” Step 3 A) 544
Problem 4 No change between normal mode and aggressive mode (“AWD System Functional Test” Step 3 B) 544
Problem 5 System appears to lack power (“AWD System Functional Test” Step 3 B) 545
Problem 6 Wheels turn when in neutral (“AWD System Functional Test” Step 4 A) 545
Problem 7 Wheels don’t turn either direction (“AWD System Functional Test” Step 5 A, 6 A) 546
Problem 8 Wheels do not turn forward (“AWD System Functional Test” Step 5 A) 547
Problem 9 Wheels do not turn in reverse (“AWD System Functional Test” Step 6 A) 548
Problem 10 Wheels do not stop (“AWD System Functional Test” Step 5 8, 5 C 5 D, 5 E, 5 F, 6 B, 6 C 6 D, 6 E, 6 F) 548
All Wheel Drive Pump Adjustment Procedure 549
All Wheel Drive Pump Adjustment Procedure for Relief Valves 550
Hydraulic Centering Adjustment Procedure 555
Mechanical Centering Adjustment Procedure 556
Filtering Procedure for “AWD” Hydraulic System 558
E-34 00K – REAR AXLE COOLING AND LOCK/UNLOCK DIFFERENTIAL PUMP 559
TABLE OF CONTENTS 561
INTRODUCTION 562
SERVICING 564
REMOVAL 564
DISASSEMBLY 566
CLEANING AND INSPECTION 568
REASSEMBLY 570
INSTALLATION 572
TESTS AND ADJUSTMENTS 573
LOCK/UNLOCK DIFFERENTIAL RELIEF VALVE ADJUSTMENT 573
REAR AXLE COOLING SYSTEM 573
F-01 20K R1 – CIRCLE REVERSE SLIP CLUTCH 575
TABLE OF CONTENTS 577
INTRODUCTION 578
SPECIAL TOOLS 580
SERVICING 581
REMOVAL 581
DISASSEMBLY 582
CLEANING AND INSPECTION 585
REASSEMBLY 587
INSTALLATION 593
RETROFITTING A STANDARD CIRCLE GEAR CASE WITH A SLIP CLUTCH 595
FOR CIRCLE P/N 1430 851 H92 595
CIRCLE IDENTIFICATION 595
RETROFITTING INSTRUCTIONS 595
TESTS AND ADJUSTMENTS 598
CIRCLE ADJUSTMENT 598
SLIP CLUTCH ADJUSTMENT TEST 600
Spring Scale Test 600
Engine and Transmission Gear Range Test 601
F-01 30K – CIRCLE REVERSE GEAR CASE 603
TABLE OF CONTENTS 605
INTRODUCTION 606
SERVICING 610
DISASSEMBLY 610
CLEANING AND INSPECTION 617
REASSEMBLY 619
F-11 80K R1 – TANDEM CASE (SINGLE AND DOUBLE STRAND CHAINS) 627
TABLE OF CONTENTS 629
LOCATION ON MACHINE 630
DESCRIPTION 630
FINAL DRIVE PLANETARY/NON-PLANETARY IDENTIFICATION 633
Part Number Tag 634
Physical Measurement of Tandem Case 634
SPECIFICATIONS 635
SERVICE DIAGNOSIS 636
SERVICE/SPECIAL TOOLS 637
WHEEL KNOCKER TOOL 638
AXLE LIFTING TOOL 639
AXLE ROLLING TORQUE TOOL 640
SPREADER BAR AND CHAINS 641
TOLERANCES 642
LUBRICANTS AND SEALANTS 642
SPECIAL TORQUES 642
TESTS AND ADJUSTMENTS 642
ROAD TESTING 642
SERVICING 643
REMOVAL 643
DISASSEMBLY 647
CLEANING AND INSPECTION 648
REASSEMBLY 650
INSTALLATION 652
G-01 13K R3 – GEARBOX ASSEMBLY (ALL WHEEL DRIVE) 655
TABLE OF CONTENTS 657
DESCRIPTION 657
SERVICE/SPECIAL TOOLS 660
INSTALLATION OF TWO PIECE SEAL 660
TESTS AND ADJUSTMENTS 666
FRONT WHEEL ALIGNMENT & TURNING RADIUS ADJUSTMENT 666
SERVICING 669
REMOVAL 669
DISASSEMBLY 673
CLEANING AND INSPECTION 683
REASSEMBLY 685
INSTALLATION 696
G-01 15K – FRONT AXLE ASSEMBLY 701
TABLE OF CONTENTS 703
DESCRIPTION 704
FRONT AXLE TORQUE VALUES 708
TESTS AND ADJUSTMENTS 710
FRONT WHEEL ALIGNMENT & TURNING RADIUS ADJUSTMENT 710
SERVICING 713
REMOVAL 713
DISASSEMBLY 716
CLEANING AND INSPECTION 722
REASSEMBLY 724
INSTALLATION 731
G-09 30K R1 – FINAL DRIVE ASSEMBLY (JOHN DEERE TeamMate II) WITH PLANETARY AND NON-PLANETARY REDUCTION (NoSPIN & LOCK/UNLOCK DIF 734
TABLE OF CONTENTS 736
LOCATION ON MACHINE 739
DESCRIPTION 739
SERVICE DIAGNOSIS 757
NoSPIN 758
BRAKE DISC INSPECTION 760
SERVICE/SPECIAL TOOLS 761
SPREADER BAR AND CHAINS 761
DIFFERENTIAL BACKLASH TOOL (DR08-111) 762
LUBRICANTS AND SEALANTS 763
SPECIAL TORQUES 763
TESTS AND ADJUSTMENTS 763
PARKING BRAKE BLEEDING 763
PARKING BRAKE ADJUSTMENT 764
FINAL DRIVE BRAKE BLEEDING 765
ROAD TESTING 766
SERVICING 767
REMOVAL 767
DISASSEMBLY GENERAL 772
DISASSEMBLY OF PLANETARY CARRIER 772
DISASSEMBLY OF NON-PLANETARY CARRIER 778
DISASSEMBLY OF DIFFERENTIAL BRAKE PISTONS 782
DISASSEMBLY OF INPUT QUILL ASSEMBLY 783
DISASSEMBLY OF DIFFERENTIAL CASE WITH NoSPlN DIFFERENTIAL 785
Disassembly of NoSPlN Differential Quills 785
Disassembly of Ring Gear and NoSPlN Differential 785
Disassembly of Miscellaneous NoSPlN Differential Items 786
DISASSEMBLY OF DIFFERENTIAL CASE WITH LOCK/UNLOCK DIFFERENTIAL 787
Disassembly of Lock/Unlock Differential Quills 787
Disassembly of Ring Gear and Lock/Unlock Differential 788
Disassembly of Differential Pinions 792
Disassembly of Miscellaneous Lock/Unlock Differential Items 792
CLEANING AND INSPECTION 793
REASSEMBLY GENERAL 797
REASSEMBLY OF DIFFERENTIAL CASE WITH NoSPIN DIFFERENTIAL 798
Reassembly of NoSPIN Differential Miscellaneous Items 798
Reassembly of Ring Gear and NoSPlN Differential 798
Preload Adjustment of NoSPlN Differential Quills 799
REASSEMBLY OF DIFFERENTIAL CASE WITH LOCK/UNLOCK DIFFERENTIAL 801
Reassembly of Lock/Unlock Differential Miscellaneous Items 801
Reassembly of Ring Gear and Lock/Unlock Differential 801
Preload Adjustment of Lock/Unlock Differential Quills 806
PINION GEAR CONE POINT ADJUSTMENT 809
PINION GEAR ENDPLAY ADJUSTMENT 812
PINION GEAR INPUT QUILL INSTALLATION AND BACKLASH ADJUSTMENT 812
RING GEAR AND PINION ROLLING PATTERN CHECK 813
FINAL ASSEMBLY OF DIFFERENTIAL CASE 814
REASSEMBLY OF DIFFERENTIAL BRAKE PISTONS 815
REASSEMBLY OF NON-PLANETARY CARRIER 816
REASSEMBLY OF PLANETARY CARRIER 824
INSTALLATION 830
H-03 00K R1 – CIRCLE ADJUSTMENT (FOUR SHOE) 836
TABLE OF CONTENTS 838
INTRODUCTION 838
REBUILDING TEETH 839
VERTICAL ADJUSTMENT 840
PINION ADJUSTMENT 841
Y-02 00K – METRIC CONVERSIONS 1044
TABLE OF CONTENTS 1046
METRIC CONVERSIONS 1047
AREA 1047
DENSITY (Mass Density) 1047
FORCE 1047
FORCE PER LENGTH 1048
HEAT 1048
LENGTH 1048
MASS (WEIGHT) 1049
POWER 1049
PRESSURE 1049
TEMPERATURE 1049
TEMPERATURE INTERVAL OR TOLERANCE 1049
VOLUME 1051
TORQUE 1051
VELOCITY 1052
K-04 20K R1 – PARKING BRAKE CALIPER (PERROT P/N 40 023 002) 844
TABLE OF CONTENTS 845
LOCATION ON MACHINE 846
DESCRIPTION 846
OPERATION 849
SERVICE DIAGNOSIS 851
LUBRICANTS AND SEALANTS 852
TESTS AND ADJUSTMENTS 852
PARKING/EMERGENCY BRAKE BLEEDING 852
PARKING/EMERGENCY BRAKE ADJUSTMENT 853
SERVICING 853
REMOVAL 853
Method One 854
Method Two 854
Method Three 854
DISASSEMBLY 856
CLEANING AND INSPECTION 857
REASSEMBLY 858
INSTALLATION 858
K-04 30K – PARKING BRAKE CALIPER (MICO) 860
TABLE OF CONTENTS 862
INTRODUCTION 863
OPERATION 867
TROUBLESHOOTING 869
SERVICING 870
REMOVAL 870
Method One 870
Method Two 871
Method Three 871
BRAKE LINING REPLACEMENT 872
DISASSEMBLY 872
CLEANING AND INSPECTION 875
REASSEMBLY 877
INSTALLATION 879
TESTS AND ADJUSTMENTS 880
PARKING/EMERGENCY BRAKE BLEEDING 880
PARKING/EMERGENCY BRAKE ADJUSTMENT 881
K-11 10K R2 – BRAKE VALVE (REXROTH) 882
TABLE OF CONTENTS 884
LOCATION ON MACHINE 885
DESCRIPTION 885
OPERATION 890
LUBRICANTS AND SEALANTS 890
SPECIAL TORQUES 891
TESTS AND ADJUSTMENTS 891
BRAKE PEDAL ADJUSTMENT 891
FINAL DRIVE BRAKE BLEEDING 893
SERVICING 894
REMOVAL 894
DISASSEMBLY 895
CLEANING AND INSPECTION 895
REASSEMBLY 896
INSTALLATION 896
K-11 30K R1 – BRAKE VALVE (MICO) 898
TABLE OF CONTENTS 900
DESCRIPTION 901
OPERATION 905
SERVICING 905
REMOVAL 905
DISASSEMBLY 907
CLEANING AND INSPECTION 908
REASSEMBLY 910
INSTALLATION 911
TESTS AND ADJUSTMENTS 912
FINAL DRIVE BRAKE BLEEDING 912
BRAKE PEDAL ADJUSTMENT 912
L-01 45K – WIRING DIAGRAMS 916
Foldout No 1 Electrical Wiring Diagram 1 of 2 918
Foldout No 1 Electrical Wiring Diagram 2 of 2 923
Foldout No 2 Electrical Wiring Diagram 1 of 3 928
Foldout No 2 Electrical Wiring Diagram 2 of 3 933
Foldout No 2 Electrical Wiring Diagram 3 of 3 938
Foldout No 3 Electrical Wiring Diagram 1 of 3 943
Foldout No 3 Electrical Wiring Diagram 2 of 3 948
Foldout No 3 Electrical Wiring Diagram 3 of 3 953
N-01 35K R1 – PRE-DELIVERY PROCEDURES 958
TABLE OF CONTENTS 960
PRE-UNLOADING CHECKS 962
RECORD SERIAL NUMBERS 963
GENERAL INSTRUCTIONS 965
OPERATION AND MAINTENANCE MANUAL 965
REVIEW TEXT WITH OWNER/OPERATOR 965
INSPECT MACHINE AND ATTACHMENTS 965
PRODUCT GRAPHICS (DECALS) 965
LUBRICATION 966
TORQUES 969
TORQUE VALUES FOR STANDARD ENGLISH FASTENERS 969
BOLT IDENTIFICATION CHART 969
TYPE 1, 5 AND 8 NON-PHOSPHATE COATED HARDWARE 969
TYPE 8 PHOSPHATE COATED HARDWARE 970
TORQUE VALUES FOR STANDARD METRIC FASTENERS 971
TORQUE VALUES FOR HOSE CLAMPS 972
TORQUE VALUES FOR SPLIT FLANGE CONNECTIONS 972
TORQUE VALUES FOR HYDRAULIC TUBES AND FITTINGS 973
SPECIFIC BOLT TORQUES 974
ENGINE CHECKS 985
ADJUST FAN BELT TENSION 986
CHECK AND TIGHTEN AIR CLEANER CONNECTIONS 986
PERFORM AIR INDUCTION PRESSURE CHECKS 987
General 987
Test Procedure 987
Service Indicator Safety Filter Check 988
Assembly Tips 989
CHECK AND TIGHTEN RADIATOR HOSES 990
CHECK ALL FUEL LINES AND FITTINGS 990
ENGINE SPEEDS 991
ENGINE SPEED TABLE 991
ENGINE SPEED CHECK PROCEDURE 992
THROTTLE ADJUSTMENT PROCEDURE 993
PRESSURE TESTS 995
HYDRAULIC PRESSURE CHECKS 995
QUICK REFERENCE PRESSURE CHART 996
MAIN HYDRAULIC SYSTEM TESTING AND ADJUSTMENT PROCEDURE 997
Main Hydraulic System Specification 997
Test Port Locations 997
Test Procedure 997
STEERING AND BRAKE SYSTEM PRESSURE TESTS 1000
Steering and Brake System Specification 1000
Test Port Locations 1000
Test Procedure 1000
AWD HYDRAULIC SYSTEM PRESSURE TESTS 1001
All Wheel Drive System Specification 1001
Test Port Locations 1001
Test Procedure 1001
CLUTCH PACK PRESSURE CHECK 1003
CHECKS AND ADJUSTMENTS 1004
TIRE INFLATION 1009
CONTROL LEVER LINKAGE 1010
RIM CENTERING 1010
HYDRAULIC WET BRAKES 1011
PARKING/EMERGENCY BRAKE 1017
TESTING 1019
CONTROL VALVE ASSEMBLY OPERATION 1019
R H CONTROL LEVER BANK (STANDARD MACHINE) 1020
Circle Shift 1020
Articulation 1020
Wheel Lean 1020
R H Blade Lift 1020
L H CONTROL LEVER BANK (STANDARD MACHINE) 1020
L H Blade Lift 1020
Auxiliary/Optional (Scarifier or Ripper) 1020
Blade Shift 1020
Blade Tilt 1020
Circle Rotation 1020
OPTIONAL LIGHTING EQUIPMENT 1021
OPTIONAL WARNING EQUIPMENT 1021
YARD AND/OR ROAD TEST 1021
X-01 00K – SUSPENSION SEAT 1022
TABLE OF CONTENTS 1022
SERVICING 1024
GENERAL 1024
COMPLETE ASSEMBLY 1025
LOWER SUSPENSION 1029
SEAT ADJUSTER 1033
Y-01 00K – GENERAL TORQUE VALUES 1035
TABLE OF CONTENTS 1035
INTRODUCTION 1037
TORQUE VALUES FOR STANDARD ENGLISH FASTENERS 1038
BOLT IDENTIFICATION CHART 1038
TYPE 1, 5 AND 8 NON-PHOSPHATE COATED HARDWARE 1038
TYPE 1, 5 AND 8 NON-PHOSPHATE COATED HARDWARE – CONTINUED 1039
TYPE 8 PHOSPHATE COATED HARDWARE 1040
TORQUE VALUES FOR STANDARD METRIC FASTENERS 1041
TORQUE VALUES FOR HOSE CLAMPS 1042
TORQUE VALUES FOR SPLIT FLANGE CONNECTIONS 1042
TORQUE VALUES FOR HYDRAULIC TUBES AND FITTINGS 1043
S.V 14/12/24
