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Komatsu D32E-1 Shop Manual

Crawler tractor
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Table of Contents

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SHOP MANUAL
This material is proprietary to Komatsu and is not to be reproduced, used, or disclosed except in accordance with written
authorization from Komatsu.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
NOV 98
CRAWLER TRACTOR
D32E-1,P-1
SERIAL NUMBERS
D38E-1,P-1
D39E-1,P-1
COPYRIGHT 1998 KOMATSU AMERICA INTERNATIONAL COMPANY
CEBM003100
P075718
and up
P085799
and up
P095872
and up

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Summary of Contents for Komatsu D32E-1

  • Page 1 P095872 and up This material is proprietary to Komatsu and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously.
  • Page 3 PARTS BOOK - PAPER: ENGINE AND CHASSIS - D32E-1 & D32P-1 ....... .
  • Page 4 REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS COMPLETE FORM < < Komatsu America International Company AND RETURN TO 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887 COMPANY NAME PURCHASE ORDER NO.
  • Page 5 SECTION INDEX This shop manual includes information for locations, INTRODUCTION — SECTION 1 specifications, service/special tools, tolerances, pressures, lubricants and sealants, special torques, tests and adjust- MISCELLANEOUS — SECTION 2 ments, assembly tips and service bulletin references for various components of the machine. This shop manual is —...
  • Page 6 INDEX TO SECTIONS SECTION 1 - INTRODUCTION SECTION 7F - FINAL DRIVE SAFETY PRECAUTIONS ......2 GENERAL .
  • Page 7 INTRODUCTION SECTION 1 SAFETY PRECAUTIONS ....... 2 GENERAL ......... 2 BEFORE STARTING THE ENGINE .
  • Page 8 INTRODUCTION SAFETY PRECAUTIONS AVOID ACCIDENTS WORK SAFETY -- FOLLOW THESE RULES A CAREFUL MECHANIC IS THE BEST INSURANCE AGAINST AN ACCIDENT THIS SYMBOL IS USED THROUGHOUT THIS SHOP MANUAL TO CALL YOUR ATTENTION TO INSTRUCTIONS CONCERNING PERSONAL SAFETY. OBSERVE AND FOLLOW THESE INSTRUCTIONS.
  • Page 9 SAFETY PRECAUTIONS INTRODUCTION or its equipment. Follow all machine mounted safety signs before starting, operating, maintaining or servicing the machine. Be sure the area of the operator's compartment, all mounting steps and grab handles are free of oil, grease, loose objects, ice and mud to lessen the possibility of slipping. Remove or secure all maintenance and personal items so they will not interfere with the operator or jam the controls.
  • Page 10 INTRODUCTION SAFETY PRECAUTIONS A machine's weight and the vibration it creates can cause the edge of a high wall to collapse. Keep your machine back from the edges of banks and excavations. Operating in rough virgin terrain with such hazards as trees, logs, large rocks and brush is called pioneering. Be sure you know the operating techniques required.
  • Page 11 SAFETY PRECAUTIONS INTRODUCTION the parking brake. Turn off the electrical system master switch. Remove the key. Read and know your OPERATION & MAINTENANCE MANUAL and SHOP MANUAL before performing any work on the machine. Read ALL product graphics and safety precautions. Never work beneath the blade without proper blocking and/or a safety bar properly installed.
  • Page 12 INTRODUCTION SAFETY PRECAUTIONS Lower the blade before making hydraulic adjustments. To prevent personal injury, be sure personnel are not standing in the way of the blade when it is being lowered. Never allow anyone to walk under or be near unblocked raised equipment.
  • Page 13 SAFETY PRECAUTIONS INTRODUCTION traffic area. Park machine on level ground whenever possible. If you must park on a slope, park at right angles to the slope. Lock the transmission selector in neutral. Never leave the machine unattended with the engine running. When leaving the machine unattended, slowly lower all hydraulic equipment to the ground, shift the transmission selector into neutral and apply the neutral lock lever and shut off the engine.
  • Page 14 INTRODUCTION SAFETY PRECAUTIONS SAFETY PRODUCT GRAPHICS AND LOCATION SAFETY PRODUCT GRAPHIC LOCATION 1 - 8...
  • Page 15 SAFETY PRECAUTIONS INTRODUCTION 1. General Caution 4. Track Adjuster Caution (737 994 C3) (655 434 C2) 5. Pressurized Reservoir (2754 473 R3) 2. Door Caution (667 460 C2) 6. Safety Caution (1120 363 C2) 3. Instructional Caution (628 135 C4) 7.
  • Page 16 INTRODUCTION SERVICE INFORMATION This illustration shows the D32E-1 GENERAL Instructions contained in this shop manual are for information and guidance of the service personal who are responsible for the overhaul and repair of this machine. In this shop manual, the use of the terms left, right, front and rear must be understood to avoid confusion when following the instructions.
  • Page 17 Use the serial numbers when requesting or ordering parts. SERVICE TOOLS AND PARTS Information regarding service tools are listed is the individual sections. Always use genuine Komatsu service parts. Service parts are available through your local distributor. INSPECTION AND REPAIR Gasket and Seals Always use new gaskets and seals during assembly and installation.
  • Page 18 INTRODUCTION LOCTITE USAGE SURFACE PREPARATION Plain and Phosphate Coated Parts Clean surfaces where compounds are to be applied to remove heavy coating of oil, grease and dirt (rust or light oil film are not detrimental). Normal shop practice of cleaning or degreasing is adequate. Phosphate and oiled hardware is used in as received condition provided it is dry to touch.
  • Page 19 LOCTITE USAGE INTRODUCTION SETTING TIME (BEFORE PLACING IN OPERATION) Normal time for compound grades without use of any primer - 6 to 24 hours at room temperature with machined carbon steel parts. Higher temperatures will accelerate cure and lower temperatures will retard cure. Other base metals will provide more or less catalytic effect on cure.
  • Page 20 DIMENSIONS ......2 D32E-1 DIMENSIONS ....2 D32P-1 DIMENSIONS .
  • Page 21 MISCELLANEOUS DIMENSIONS D32E-1 DIMENSIONS 2 - 2...
  • Page 22 DIMENSIONS MISCELLANEOUS D32P-1 DIMENSIONS 2 - 3...
  • Page 23 MISCELLANEOUS DIMENSIONS D38E-1 DIMENSIONS 2 - 4...
  • Page 24 DIMENSIONS MISCELLANEOUS D38P-1 DIMENSIONS 2 - 5...
  • Page 25 MISCELLANEOUS DIMENSIONS D39E-1 DIMENSIONS 2 - 6...
  • Page 26 DIMENSIONS MISCELLANEOUS D39P-1 DIMENSIONS 2 - 7...
  • Page 27 MISCELLANEOUS SPECIFICATIONS D32E-1, D32P-1 SPECIFICATIONS D32E-1 D32P-1 WEIGHT 7133 kg (15725 lbs) 7782 kg (17155 lbs) Operating weight w/o operator BLADE 1173 kg (2586 lbs) 1245 kg (2744 lbs) Equipment weight (including cylinders) 1.2 m³ (1.6 yd³) 1.45 m³ (1.9 yd³)
  • Page 28 14217 kg (31343 lbs) Maximum drawbar pull 0.47 kg/cm² (6.8 psi) 0.31 kg/cm² (4.4 psi) Ground pressure ENGINE Komatsu S4D102E-1 Diesel Engine Model 60 kW (80 hp) @ 2500 RPM Flywheel horsepower 324 NCm (239 lbf ft) @ 1500 RPM Maximum torque 2.7 kW (12V)
  • Page 29 14832 kg (32699 lbs) Maximum drawbar pull 0.42 kg/cm² (6.1 psi) 0.33 kg/cm² (4.7 psi) Ground pressure ENGINE Komatsu S4D102E-1 Diesel Engine Model 67 kW (90 hp) @ 2500 RPM Flywheel horsepower 386 NCm (285 lbf ft) @ 1500 RPM Maximum torque 2.7 kW (12V)
  • Page 30 It is not our policy to approve lubricants or to guarantee oil performance in service. The responsibility of quality of the lubricant must remain with the supplier of the lubricant. When in doubt consult your Komatsu distributor. The lubricants specified for this machine are shown below.
  • Page 31 MISCELLANEOUS CAPACITIES AND LUBRICANTS HDTF Komatsu heavy duty transmission fluid or equivalent fluid meeting C-4 or TO-4 and must NOT contain viscosity index improver. Komatsu engine oil or multigrade diesel engine oil or engine oil API CF/CC or MIL-L-2104 with sulphated ash of 1.65%.
  • Page 32 Universal Joint Bolt - D32E-1, D32P-1, D38E-1 or D38P-1 ... . 5/16 ....
  • Page 33 MISCELLANEOUS SPECIAL TORQUES POSITION SIZE TORQUE Rear Engine Mount Bolts ........5/8 ....267 NCm (195 lbf ft) Front Idler Thrust Plate .
  • Page 34 For details of the fluid to use, see CAPACITIES AND LUBRI- Grease Cartridge CANTS. If any of the above tools are broken, please order them from your Komatsu distributor. When not using the tools, always put them in the appropriate tool box. 2 - 15...
  • Page 35 MISCELLANEOUS STANDARD TORQUES BOLT IDENTIFICATION CHART TYPE/CLASS DESCRIPTION HEAD MARKING Type 5 Three radial lines on top and none on side of head. Medium carbon steel Inch Thread quenched and tempered. Type 5.2 Three radial lines on top and none on side of head. Low carbon boron Inch Thread steel quenched and tempered.
  • Page 36 STANDARD TORQUES MISCELLANEOUS GRADE 5 AND 8 NON-PHOSPHATE COATED HARDWARE Recommended torque for all Standard Application Nuts and Bolts, provided; all thread surfaces are clean and lubricated with SAE-30 engine oil or joints are rigid, that is, no gaskets or compressible materials are used. When reusing nuts or bolts, use minimum torque values.
  • Page 37 MISCELLANEOUS STANDARD TORQUES GRADE 8 PHOSPHATE COATED HARDWARE STANDARD METRIC FASTENERS NOMINAL STANDARD TORQUE ± 10% NOMINAL STANDARD TORQUE THREAD THREAD ± 10% NC C m lbf ft NC C m MILLIMETERS lbf ft 5/16 7/16 9/16 1-1/8 1110 1-1/4 1565 1160 1-3/8...
  • Page 38 STANDARD TORQUES MISCELLANEOUS HYDRAULIC TUBES AND FITTINGS The torque figures are recommended for plain, cadmium or zinc plated fittings, dry or wet installations. Swivel nuts either swaged or brazed. Figures are for tube nuts used with 37E flared fittings and JIC - 37E seat O-Ring boss plugs and swivel nuts.
  • Page 39 BRAKES SECTION 4 GENERAL ......3 DESCRIPTION ......4 SPECIFICATIONS .
  • Page 40 BRAKES GENERAL EXTERNAL BRAKE CONTROLS 6. Main Brake Rod 11. Control Rod Boot 16. Clevis Pin 1. Shoes and Levers 7. Brake and Decel. Pedal 12. Boot Clamp 17. Equalizer Support 2. Brake Pad 8. Turnbuckle Rod 13. Return Spring 18.
  • Page 41 GENERAL BRAKES DESCRIPTION These machines are equipped with a disc and pad type brake system which can be applied manually or hydraulically. The brake and decelerator pedal manually actuates the brakes and the secondary brake pedal control the hydraulic system. This section covers the external portion of the pedal systems only with the hydraulic and internal portions covered in Section 7E.
  • Page 42 BRAKES BRAKE AND DECELERATOR PEDAL BRAKE PEDAL AND BRACKET 1. Brake Pedal 4. Lube Fitting 7. Roll Pin 2. Needle Bearing 5. Cross Shaft 3. Bearing Seal 6. Pedal Bracket 4 - 4...
  • Page 43 BRAKE AND DECELERATOR PEDAL BRAKES REMOVAL WARNING Be sure blade and any rear mounted equipment has been lowered to the ground or on suitable blocking. Turn the master switch to the off position and remove key or remove one of the cables from the master switch to prevent accidental starting.
  • Page 44 BRAKES BRAKE AND DECELERATOR PEDAL 2. Remove cross shaft (5) from bracket. 3. Remove pedal (1) from bracket. 4. Remove wiper seals (3) from each side of pedal and replace with new. 5. Drive out needle bearings (2) from each side of pedal. REMARK Needle bearing will be destroyed when removed from pedal.
  • Page 45 BRAKE AND DECELERATOR PEDAL BRAKES BRAKE PEDAL 4 - 7...
  • Page 46 BRAKES BRAKE AND DECELERATOR PEDAL 7. Position new wiper seal (3) in pedal (1). 8. Using a driver with a slightly larger diameter than wiper seal, press seal flush with outer surface of pedal. Repeat for remaining wiper seal. 9. Insert brake pedal (1) into bracket (6). 10.
  • Page 47 BRAKE AND DECELERATOR PEDAL BRAKES INSTALLATION 1. Insert brake pedal to dashboard. 2. Mount pedal and bracket to dashboard with hardware. Torque bolts to 92 NCm (70 lbf ft) ±10%. 3. Connect decelerator over travel rod (4) to brake pedal tang with clevis and new cotter pin (3).
  • Page 48 BRAKES BRAKE PAD BRAKE AND DECELERATOR PEDAL BRAKES EXPLODED VIEW OF BRAKE PAD 1. Final Bellcrank 5. Brake Pawl 9. Retaining Ring 13. Tension Spring 2. Needle Bearing 6. Flat Washer 10. Release Rod 3. Lube Fitting 7. Retaining Ring 11.
  • Page 49 BRAKE PAD BRAKES FLAT VIEW OF BRAKE PAD 4 - 11...
  • Page 50 BRAKE PAD BRAKES REMOVAL WARNING Be sure blade and any rear mounted equipment has been lowered to the ground or on suitable blocking. Turn the master switch to the off position and remove key or remove one of the cables from the master switch to prevent accidental starting.
  • Page 51 BRAKE PAD BRAKES 5. Remove brake pad mounting hardware. 6. Remove brake pad from machine. 7. If brake release rod assembly warrants repair, proceed as follows: Compress return spring (13) and drive out roll pin (12). Pull out release rod (10) and remove remaining parts (11 and 13). WARNING Spring loaded assembly.
  • Page 52 BRAKE PAD BRAKES 3. Remove spacer washer (6). 4. Slide final bellcrank (1) off mounting bracket shaft. 5. Remove small retaining ring (9). 6. Remove spacer washer (8). 4 - 14...
  • Page 53 BRAKE PAD BRAKES 7. Slide brake pawl (5) off mounting bracket shaft. 8. Remove inner retaining ring (9). 9. Position final bellcrank (1) in press. Using a drive of same or slightly smaller diameter, press both bearings out on same press.
  • Page 54 BRAKE PAD BRAKES FINAL BELLCRANK 4 - 16...
  • Page 55 BRAKE PAD BRAKES 11. Install inner retaining ring (9) to mounting bracket shaft. 12. Coat mounting bracket shaft with Never-Seez. Install brake pawl (5) on shaft. 13. Install spacer washer (8) on shaft. 14. Install outer retaining ring (9) to shaft. 4 - 17...
  • Page 56 BRAKE PAD BRAKES 15. Install final bellcrank (1) to mounting bracket shaft. 16. Install spacer washer (6) to mounting bracket shaft. 17. Install retaining ring (7) to mounting bracket shaft. INSTALLATION 1. Check mounting surface of brake pad at frame and remove all dirt and foreign debris.
  • Page 57 BRAKE PAD BRAKES 2. Install brake pad to machine. 3. Secure brake pad to main frame with mounting hardware. Torque bolts to 98 NCm (70 lbf ft) ±10%. 4. Secure turnbuckle rod to brake pad with clevis and new cotter pins.
  • Page 58 BRAKE PAD BRAKES 6. Secure final brake rod to brake pad with clevis and new cotter pins. 7. Install operator’s compartment floor plate and secure with hardware. Torque bolts to 38 NCm (28 lbf ft) ±10%. 4 - 20...
  • Page 59 BRAKES BRAKE SUPPORT BRACKET BRAKE SUPPORT BRACKET 1. Support Bracket 4. Lube Fitting 7. Brake Shaft 10. Throttle Control Bell- 2. Sealed Bearing 5. Grease Seal 8. Throttle Shaft crank 3. Main Bellcrank 6. Roll Pin 9. Decel Bellcrank 4 - 21...
  • Page 60 BRAKE SUPPORT BRACKET BRAKES BRAKE SUPPORT BRACKET 4 - 22...
  • Page 61 SERVICE DIAGNOSIS ....3 RADIATOR - D32E-1 & D32P-1 ... . 4 RADIATOR - D38E/P-1 &...
  • Page 62 COOLING GENERAL DESCRIPTION The cooling system used is a closed type system that permits operation at extreme angles without loss of coolant through the overflow pipe and also permits operation at higher engine temperatures without boiling. Extra care must be taken that all connections are tight. A centrifugal water pump circulates the coolant from the radiator lower tank through the cylinder head and crankcase water jackets, past the thermostat into the radiator upper tank and down through the tubes of the radiator core to the lower water tank where the cycle is repeated.
  • Page 63 COOLING SERVICE DIAGNOSIS GENERAL COMPLAINT PROBABLE CAUSE REMARKS Engine Overheating Add coolant to radiator and check cooling system for 1. Not enough coolant. leaks. Refer to the OPERATION & MAINTENANCE MANUAL. Review operating instructions per OPERATION & 2. Engine overloaded. MAINTENANCE MANUAL.
  • Page 64 COOLING RADIATOR RADIATOR AND CONNECTIONS - D32E-1 & D32P-1 1. Radiator 5. Hose Clamp 9. Drain Cock 13. Hose Fitting 2. Mounting Bracket 6. Inlet Hose 10. Top/Bottom Seal 14. Hose Clamp 3. Rubber Insulator 7. Hose Clamp 11. Side Seal 15.
  • Page 65 COOLING RADIATOR RADIATOR AND CONNECTIONS - D38E-1, D38P-1, D39E-1, D39P-1 1. Radiator 6. Inlet Hose 11. Side Seal 16. Vent Fitting 2. Mounting Bracket 7. Hose Clamp 12. Vent Hose 17. Hose 3. Rubber Insulator 8. Hose Clamp 13. Hose Fitting 18.
  • Page 66 COOLING RADIATOR 1. Reversible Fan 2. Front Cover 3. Mounting Bolt 4. Flat Washer 5. Fan Spacer 6. Blower Fan 7. Fan Spacer FANS 1. Upper Fan Shroud 2. Lower Fan Shroud 3. Right Fan Guard 4. Left Fan Guard FAN SHROUD AND GUARDS 6 - 6...
  • Page 67 RADIATOR COOLING REMOVAL WARNING Be sure blade and any rear mounted equipment has been lowered to the ground or on suitable blocking. Turn the master switch to the off position and remove key. WARNING Hot scalding coolant can spray out if the radiator cap is removed suddenly.
  • Page 68 COOLING RADIATOR 7. Install sling through pull hook on crankcase guard and position around lift cylinders. Attach hoist to sling. 8. From under machine, carefully remove hardware and slowly lower guard to ground. Pull guard out front of machine, attach hoist and remove.
  • Page 69 RADIATOR COOLING 13. Remove upper fan shroud. 14. Reversible Fan: Remove front cover. In side housing remove two bolts 180E apart and install M10 aligning studs. This will keep fan pulley in place on fan hub. Remove remaining bolts and lift fan with spacer from engine. 15.
  • Page 70 COOLING RADIATOR 19. Install two dNC eye bolts to holes in top tank. Connect hoist to eye bolts. 20. Remove hardware from mounting brackets. 21. Using hooked pry bar, carefully work mounting brackets from main frame. 22. Install dNF eye bolt to rubber insulator. Using a block of wood and pry bar, carefully remove insulator being cautious not to damage cylinder rod.
  • Page 71 RADIATOR COOLING EXPLODED VIEW OF RADIATOR 1. Core and Header 5. Left Side Bracket 9. Gasket Strip 13. Hose Clip 2. Top Tank 6. Bolting Bar 10. Core Support 14. Radiator Cap 3. Bottom Tank 7. Bolting Bar 11. Core Side 15.
  • Page 72 COOLING RADIATOR Callouts from exploded view correspond with callouts in following steps. 1. Position radiator on blocking as shown. Remove overflow hose (12), clips (13) and cap (14). 2. Remove sight glass (15) from top tank (2). 3. Remove hardware securing top tank (2) to left and right side brackets (4 and 5).
  • Page 73 RADIATOR COOLING 6. Remove top tank (2). 7. Remove top strip gaskets (9) and end gaskets (8) from core and header. 8. Mark left side bracket (5) as shown. 9. Using mechanics fingers to hold nut, remove inner hardware from bottom side bolting bar (6). 10.
  • Page 74 COOLING RADIATOR 12. Carefully slide left side bracket (5) out from core and header (1). 13. Check condition of core support (10) and core side (11) and replace as necessary. 14. Mark right side bracket (4) as shown. 15. Using mechanics fingers to hold nut, remove inner hardware from bottom side bolting bar (6).
  • Page 75 RADIATOR COOLING 18. Carefully slide left side bracket (5) out from core and header (1). 19. Check condition of core support (10) and core side (11) and replace as necessary. 20. Remove lower front and rear bolting bars (7). 21. Lift core and header (1) from bottom tank (3). 6 - 15...
  • Page 76 COOLING RADIATOR 22. Remove bottom strip gaskets (9) and end gaskets (8) from bottom tank (3). 23. Flush out the upper and lower tanks with water. Flush out the core with water under pressure, both inside and out. If the core is greasy, clean it with steam cleaning equipment.
  • Page 77 RADIATOR COOLING 4. Start right side bracket (4) into core and header (1) using a soft face mallet. 5. Insert aligning dowels and secure to bottom tank, bolts facing down. 6. Position side bolting bar (6) and secure with hardware, three inner bolts facing upward and two outer bolts facing down.
  • Page 78 COOLING RADIATOR 11. Position top tank (2) on core and header (1) and align to side brackets with pins. 12. Install left side bolting bar (6) and clip and mount with outer hardware, bolts facing up. Remove aligning pins and secure left side bracket (5) to top tank (2) with bolts facing up.
  • Page 79 RADIATOR COOLING 17. Torque all original mounting bolts to 18 NCm (13 lbf ft) ±10% or replacement mounting bolts to 21 NCm (16 lbf ft) ±10%. 18. Coat sight glass (15) with Loctite pipe sealant and install to top tank. 19.
  • Page 80 COOLING RADIATOR INSTALLATION 1. Remove and discard radiator side foam strips from each side. 2. Tape horn harness to side of frame. This will assist in installing radiator. 3. Install new bottom foam strip, flush with front edge of bottom tank evenly spaced between both ends.
  • Page 81 RADIATOR COOLING 7. Install stabilizing link (1) to radiator (2) over foam strip (3). Mark (4) foam at bottom of link. Remove link and cut slit in foam. 8. Install link and check it for fit up. Adjust as necessary. Remove link.
  • Page 82 COOLING RADIATOR 12. Install rubber insulator (1) to mounting bracket (2). 13. Install left mounting bracket with rubber insulator to frame and radiator using longer bolts. 14. Install right mounting bracket with rubber insulator to frame and radiator and carefully draw in using longer bolts. 15.
  • Page 83 RADIATOR COOLING 18. Install right radiator side foam strip to side main frame with back edge even with radiator. 19. Using small screwdriver tuck rear edge into radiator. 20. Install left radiator side foam strip (1) to side main frame with back edge even with radiator.
  • Page 84 COOLING RADIATOR 26. Install top fan shroud. Measure fan to shroud clearance and equalize gap around fan and secure shrouding. Torque bolts to 38 NCm (28 lbf ft) ±10%. 27. Install left and right fan guard. Torque bolts to 21 NCm (16 lbf ft) ±10%.
  • Page 85 RADIATOR COOLING 33. Install air inlet cap (1) to inlet pipe. Install hood rear mounting hardware (2) loosely. 34. From inside of engine compartment, install hood tie down brackets (3). Torque bolts to 10 NCm (8 lbf ft) ±10%. Install hook rod (1) and ball (2) to hood and bracket and tighten nut until ball compresses.
  • Page 86 DRIVE TRAIN SECTION 7 GENERAL ......2 SPECIFICATIONS ..... 2 DRIVE TRAIN SCHEMATIC .
  • Page 87 D32E-1 or D32P-1 ........
  • Page 89 DRIVE TRAIN GENERAL 7 - 4...
  • Page 90 GENERAL DRIVE TRAIN DRIVE TRAIN COMPONENTS 1. Engine 7. Transmission 13. Left Brake Disc 2. Flex Plate 8. Output Shaft and Pinion 14. Right Brake Disc 3. Torque Converter 9. Bevel Gear Carrier 15. Right Sprocket Drive 4. Drive Shaft 10.
  • Page 91 DRIVE TRAIN GENERAL Again, the charge pump flow is teed off the outlet elbow of the pressure filter and directed to the left brake pedal valve which releases the brake cylinder in the rear main frame. For a complete description of components, refer to Section Main pressure oil is directed out the F or R port and also out the 1 or 2 port of the transmission/steering valve.
  • Page 92 GENERAL DRIVE TRAIN PRESSURES i i Measurement Conditions ‚ Engine at full throttle ‚ Engine coolant temperature in operating range ‚ Drive train oil in operating range ‚ Hydraulic oil at operating range ‚ Safety lock lever in the unlocked (up) position ‚...
  • Page 93 DRIVE TRAIN GENERAL BRAKE CYLINDER RELEASE i i Measurement Conditions ‚ Engine at full throttle ‚ Engine coolant temperature in operating range ‚ Drive train oil in operating range ‚ Hydraulic oil at operating range ‚ Safety lock lever in the locked (down) position ‚...
  • Page 94 GENERAL DRIVE TRAIN STALL SPEEDS i i Measurement Conditions ‚ Engine at full throttle ‚ Engine coolant temperature in operating range ‚ Drive train oil in operating range ‚ Hydraulic oil at operating range ‚ Secondary brake pedal applied Converter Stall Connect digital optical tachometer.

  • Page 95: Table Of Contents

    TORQUE CONVERTER SECTION 7B GENERAL ......2 DESCRIPTION ......2 OPERATION .

  • Page 96: Description

    TORQUE CONVERTER GENERAL DESCRIPTION The torque converter contains a single stage, single phase, three element converter assembly and a rear gear housing to drive the drive train charge and scavenge pump and the equipment pump. The torque converter performs two functions: it couples the engine to the transmission and multiplies engine torque.
  • Page 97 GENERAL TORQUE CONVERTER TORQUE CONVERTER OPERATION 1. Converter Assembly 7. Pump Gears 13. Output Shaft 2. Drive Plate 8. Stator 14. Ball Bearing 3. Impeller 9. Thrust Washers 15. Ball Bearing 4. Ground Sleeve Hub 10. Thrust Washers 16. Rear Gear Housing 5.

  • Page 98: Specifications

    SPECIFICATIONS Universal Joint Mounting Bolts - D32E-1, D32P-1, D38E-1 or D38P-1 ..... . . 33 NCm (24 lbf ft) Universal Joint Mounting Bolts - D39E-1 or D39P-1 ........57 NCm (42 lbf ft) Converter Mounting Bolts .
  • Page 99 REMOVAL TORQUE CONVERTER WARNING Be sure blade and any rear mounted equipment has been lowered to the ground or on suitable blocking. Turn the master switch to the off position and remove key. 1. Drain hydraulic reservoir. Refer to the OPERATION & MAINTE- NANCE MANUAL.
  • Page 100 TORQUE CONVERTER REMOVAL 5. From inside of engine compartment relieve tension off of tie down rod (1) and compression ball (2). Disconnect mounting bracket (3) hardware and remove bracket, rod and ball. Repeat for opposite side. 6. Remove air inlet cap (1) from inlet pipe. Remove hood rear mounting hardware (2).

  • Page 101: Removal

    REMOVAL TORQUE CONVERTER 12. Remove rear cover. 13. Disconnect front and rear light harness (1) from main harness (2). Cut tie strap (3) and remove from clip. 14. Attach four leg chain and hoist to ROPS lifting brackets. Remove mounting hardware and lift ROPS from machine. REMARK For a machine equipped with a cab, see Section 13 for cab removal.
  • Page 102 20. Disconnect instrument panel harness at bracket at rear of engine. 21. Disconnect dual harness lead. 22. Disconnect and remove engine shutoff solenoid. 23. D32E-1 or D32P-1: Disconnect wiring lead from switch at air cleaner outlet pipe. 7B - 8...
  • Page 103 24. D38E-1, D38P-1, D39E-1 or D39P-1: Disconnect wiring lead from switch at air cleaner outlet pipe. 25. D32E-1 or D32P-1: Disconnect elbow at air intake manifold. Cover inlet to engine manifold. 26. D38E-1, D38P-1, D39E-1 or D39P-1: Loosen hose clamp (1) at inlet of turbocharger (2) and remove hose (3) from turbo- charger.
  • Page 104 TORQUE CONVERTER REMOVAL 29. Install two ½NC eye bolts to dashboard and attach chain and hoist. 30. Remove three mounting bolts from each side and lift dashboard from machine. REMARK On some models there will be shims between dashboard and main frame.
  • Page 105 REMOVAL TORQUE CONVERTER 37. Disconnect, cap and plug pump to equipment valve hose at bottom port of equipment pump. 38. Disconnect drive train temperature lead at switch. Disconnect, cap and plug converter outlet switch tube adapter from elbow at bottom of torque converter. 39.
  • Page 106 TORQUE CONVERTER REMOVAL 43. Remove or reposition throttle linkage out of the way. 44. Remove access cover and barring tool cover. 45. Using barring tool, J38686 rotate engine so that all eight flywheel to flex plate bolts can be removed. 46.

  • Page 107: Complete Assembly

    DISASSEMBLY TORQUE CONVERTER COMPLETE ASSEMBLY EXPLODED VIEW OF COMPLETE ASSEMBLY 7B - 13...
  • Page 108 TORQUE CONVERTER DISASSEMBLY CROSS SECTION VIEW OF COMPLETE ASSEMBLY Legend for Exploded and Cross Section Views 1. Converter Housing 7. Retainer Gasket 13. Retaining Ring 2. Pump Drive Gear 8. Output Shaft 14. Converter Assembly 3. Output Yoke 9. Ball Bearing 15.
  • Page 109 DISASSEMBLY TORQUE CONVERTER 1. While retaining output yoke, remove hardware, lock plate and flex plate. REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 2. Remove one bearing retainer plate (6) bolt and install longer one that will allow output yoke (3) to be retained while removing yoke bolt.
  • Page 110 TORQUE CONVERTER DISASSEMBLY 9. Pull output shaft (8) with bearing (9) out from assembly. 10. Remove seal ring (10) from output shaft (8). 11. Check condition of bearing (9) and if replacement is necessary, position in press and remove. 12. Insert two ½NC eye bolts to pump mounting holes and connect hoist.

  • Page 111: Converter Assembly

    DISASSEMBLY TORQUE CONVERTER 15. Carefully pry pump drive gear (2) from converter assembly. 16. Remove front retaining ring (13). 17. Lift housing (1) off from converter assembly. 18. Drive oil seal (12) from housing (1) and discard. CONVERTER ASSEMBLY 1. Remove mounting hardware and impeller (3) from assembly. 2.
  • Page 112 TORQUE CONVERTER DISASSEMBLY EXPLODED VIEW OF CONVERTER ASSEMBLY 7B - 18...
  • Page 113 DISASSEMBLY TORQUE CONVERTER Legend for Exploded and Cross Section Views 1. Drive Housing 2. Ball Bearing 3. Impeller 4. Oil Seal Sleeve 5. Needle Bearing 6. Turbine 7. Stator 8. Thrust Washer 9. Thrust Bearing 10. Thrust Washer 11. O-Ring 12.
  • Page 114 TORQUE CONVERTER DISASSEMBLY 7. Remove inner thrust washer (8), thrust bearing (9) and outer thrust washer (10). 8. Install four bolts of sufficient length to drive housing (1). 9. Position a block of wood on bench. Turn drive housing (1) over and carefully bump on bench until turbine with bearing come free of housing.

  • Page 115: Rear Housing

    DISASSEMBLY TORQUE CONVERTER REAR HOUSING EXPLODED VIEW OF REAR HOUSING 7B - 21...
  • Page 116 TORQUE CONVERTER DISASSEMBLY Legend for Exploded and Cross Section Views 1. Hub Gasket 2. Ground Sleeve Hub 3. Ball Bearing 4. Pump Gear 5. Seal Ring 6. Retaining Ring 7. Retaining Ring 8. Rear Housing 9. Retainer Hub 10. Hub Gasket REMARK Callouts from exploded and cross section views correspond with callouts in following steps.
  • Page 117 DISASSEMBLY TORQUE CONVERTER 5. Remove retaining ring (6) from drive housing. 6. Remove bearing retaining ring (7) from other pump mounting side. 7. Drive gear (4) with bearing from housing. 8. Turn housing over and drive other bearing (3) out of housing. 9.

  • Page 118: Rear Housing

    TORQUE CONVERTER REASSEMBLY REAR HOUSING EXPLODED VIEW OF REAR HOUSING 7B - 24...
  • Page 119 REASSEMBLY TORQUE CONVERTER Legend for Exploded and Cross Section Views 1. Hub Gasket 2. Ground Sleeve Hub 3. Ball Bearing 4. Pump Gear 5. Seal Ring 6. Retaining Ring 7. Retaining Ring 8. Rear Housing 9. Retainer Hub 10. Hub Gasket REMARK Callouts from exploded and cross section views correspond with callouts in following steps.
  • Page 120 TORQUE CONVERTER REASSEMBLY 5. After hubs have reached room temperature, install hooked seal ring (5) to retainer hub. 6. Install retaining ring (6) into housing at one pump mounting area. 7. Finger press outer bearing (3) into housing up against retaining ring.
  • Page 121 REASSEMBLY TORQUE CONVERTER 13. Install retaining ring (6) into housing at other pump mounting area. 14. Finger press outer bearing (3) into housing up against retaining ring. 15. Position pump gear (4) in press. Press inner bearing (3) onto gear until it bottoms. 16.

  • Page 122: Converter Assembly

    TORQUE CONVERTER REASSEMBLY CONVERTER ASSEMBLY EXPLODED VIEW OF CONVERTER ASSEMBLY 7B - 28...
  • Page 123 REASSEMBLY TORQUE CONVERTER Legend for Exploded and Cross Section Views 1. Drive Housing 2. Ball Bearing 3. Impeller 4. Oil Seal Sleeve 5. Needle Bearing 6. Turbine 7. Stator 8. Thrust Washer 9. Thrust Bearing 10. Thrust Washer 11. O-Ring 12.
  • Page 124 TORQUE CONVERTER REASSEMBLY 4. Place impeller (3) in press. Start spur gear on splines and shore up press. 5. Coat oil seal sleeve mounting area with Loctite #609 and bottom sleeve with gear and press. Remove gear. 6. Locate heavy mark on drive housing (1) and mark line to side. 7.
  • Page 125 REASSEMBLY TORQUE CONVERTER 9. Install outer thrust washer (10), smaller OD, into turbine. 10. Install thrust bearing (9) onto thrust washer. 11. Install inner thrust washer (8), larger OD, onto thrust bearing. 12. Install stator (7), indented end, in turbine onto thrust and bearing.
  • Page 126 TORQUE CONVERTER REASSEMBLY 17. Aligning marks on impeller (3) to drive housing (1), install impeller and secure with hardware. Torque to 49 to 58 NCm (36 to 43 lbf ft). COMPLETE ASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps.
  • Page 127 REASSEMBLY TORQUE CONVERTER EXPLODED VIEW OF COMPLETE ASSEMBLY 7B - 33...
  • Page 128 TORQUE CONVERTER REASSEMBLY CROSS SECTION VIEW OF COMPLETE ASSEMBLY Legend for Exploded and cross Section views 1. Converter Housing 6. Bearing Retainer 11. Cover Gasket 16. Port Plug 2. Pump Drive Gear 7. Retainer Gasket 12. Oil Seal 17. Port Plug 3.
  • Page 129 REASSEMBLY TORQUE CONVERTER 5. Attach eye bolts and hoist to converter housing (1) and lower over converter assembly (14) being careful not to damage oil seal. 6. Install retaining ring (13) in lower groove on impeller hub. 7. Install pump drive spur gear (2) to impeller hub. 8.
  • Page 130 TORQUE CONVERTER REASSEMBLY 10. Install four aligning studs DR04-720, to converter housing. 11. Install ½NC eye bolts to pump mounting flanges and lower rear housing (15) over studs to converter housing (1). 12. Reposition eye bolts as shown and install mounting hardware. Torque bolts to 49 to 58 NCm (36 to 43 lbf ft).
  • Page 131 REASSEMBLY TORQUE CONVERTER 15. Install gasket (7) to housing. Position solder at three equidis- tant spots on bearing (9) outer race. 16. Install bearing retainer (6) being careful not to dislodge solder from bearing race. Torque bolts to 49 to 58 NCm (36 to 43 lbf ft).
  • Page 132 TORQUE CONVERTER REASSEMBLY 21. Install output yoke (3), flat washer (4) and hardware. Install eye bolts and bolt and secure with pry bars. Torque bolt to 73 to 88 NCm (54 to 65 lbf ft). 22. Install fittings with new o-rings to rear housing at marked positions.
  • Page 133 INSTALLATION TORQUE CONVERTER 1. Position converter in frame. Slide up on dowels aligning con- verter nose with flywheel pilot bore. Secure with half of the metric bolts. Remove lifting tool and dowels. Install remaining mounting bolts and torque all to 43 NCm (32 lbf ft). 2.
  • Page 134 11. Connect pump to equipment valve hose to bottom port of equipment pump. 12. Install drive shaft with mounting hardware. Torque D32E-1, D32P-1, D38E-1 or D38P-1 bolts to 33 NCm (24 lbf ft). Torque D39E-1 or D39P-1 bolts to 57 NCm (42 lbf ft).
  • Page 135 19. At right side, connect hose (1) to foot brake valve (2). 20. At left side, connect two hoses (1 and 2) to foot brake valve (3). 21. D32E-1 or D32P-1; Remove cover from inlet manifold and connect elbow. 7B - 41...
  • Page 136 22. D38E-1, D38P-1, D39E-1 or D39P-1; Remove cover from turbocharger (2) and connect hose (3) and secure with hose clamp (1). 23. D32E-1 or D32P-1; Apply electrical sealing grease, Grafo 112-X to wiring lead and connect to switch at air cleaner outlet pipe.
  • Page 137 INSTALLATION TORQUE CONVERTER 27. Connect pump control rod (1) and over travel decelerator (2) to throttle control (3). Torque bolt to 10 NCm (8 lbf ft) ±10%. 28. Install dash brace bar to left side of machine. Torque bolts to 92 NCm (70 bf ft) ±10%.
  • Page 138 TORQUE CONVERTER INSTALLATION 33. Connect front and rear light harness (1) to main harness (2). Tie strap (3) and insert in clip. 34. Position rear cover in place and secure with hardware. Torque bolts to 92 NCm (70 lbf ft) ±10%. 35.
  • Page 139 INSTALLATION TORQUE CONVERTER 38. Install hood to machine. Remove eye bolts from hood. 39. Install air inlet cap (1) to inlet pipe. Install hood rear mounting hardware (2) loosely. 40. From inside of engine compartment, install hood tie down brackets (3). Torque bolts to 10 NCm (8 lbf ft) ±10%. Install hook rod (1) and ball (2) to hood and bracket and tighten nut until ball compresses.
  • Page 140 TRANSMISSION SECTION 7C GENERAL ........2 THEORY OF OPERATION .
  • Page 141 TRANSMISSION GENERAL CROSS SECTION VIEW OF TRANSMISSION 1. Transmission Case 8. Output Shaft 15. 2nd Speed Gear 2. Transmission Cover 9. Directional Clutch Manifold 16. 3rd Speed Gear 3. Mounting O-Ring 10. Reverse Gear 17. Countershaft 4. Output Shaft Manifold 11.
  • Page 142 GENERAL TRANSMISSION DESCRIPTION The transmission is designed to provide high speed shifting by use of hydraulically actuated clutch packs. It has three forward and three reverse speeds. Gears are mounted on four shafts; directional (input) shaft (12), range (output) shaft (8), countershaft (17) and reverse idler shaft (18).
  • Page 143 TRANSMISSION GENERAL 2nd Speed Forward Engine power and torque are delivered through the converter and drive shaft to the directional (input) shaft (A). As the forward clutch pack is activated, it engages the forward gear (B) and rotates it in the same direction as the shaft. The countershaft (C), through the 3rd speed drive gear (D), is rotated in the opposite direction.
  • Page 144 GENERAL TRANSMISSION 3rd Speed Reverse Engine power and torque are delivered through the torque converter and drive shaft to the directional (input) shaft (A). As the reverse clutch pack is activated, it engages the reverse gear (B) and rotates it in the same direction as the shaft.
  • Page 145 TRANSMISSION REMOVAL WARNING Be sure blade and any rear mounted equipment has been lowered to the ground or on suitable blocking. Turn the master switch to the off position and remove key. 1. Drain hydraulic reservoir. Refer to the OPERATION & MAINTE- NANCE MANUAL.
  • Page 146 REMOVAL TRANSMISSION 5. From inside of engine compartment relieve tension off of tie down rod (1) and compression ball (2). Disconnect mounting bracket (3) hardware and remove bracket, rod and ball. Repeat for opposite side. 6. Remove air inlet cap (1) from inlet pipe. Remove hood rear mounting hardware (2).
  • Page 147 TRANSMISSION REMOVAL 12. Remove rear cover. 13. Disconnect front and rear light harness (1) from main harness (2). Cut tie strap (3) and remove from clip. 14. Attach four leg chain and hoist to ROPS lifting brackets. Remove mounting hardware and lift ROPS from machine. REMARK For a machine equipped with a cab, see Section 13 for cab removal.
  • Page 148 20. Disconnect instrument panel harness at bracket at rear of engine. 21. Disconnect dual harness lead. 22. Disconnect and remove fuel shutoff solenoid. 23. D32E-1 or D32P-1; Disconnect wiring lead from switch at air cleaner outlet pipe. 7C - 9...
  • Page 149 24. D38E-1, D38P-1, D39E-1 or D39P-1; Disconnect wiring lead from switch at air cleaner outlet pipe. 24. D32E-1 or D32P-1: Disconnect elbow at air intake manifold. Cover inlet to engine manifold. 25. D38E-1, D38P-1, D39E-1 or D39P-1: Loosen hose clamp (1) at inlet of turbocharger (2) and remove hose (3) from turbo- charger.
  • Page 150 REMOVAL TRANSMISSION 28. Install two ½NC eye bolts to dashboard and attach chain and hoist. 29. Remove three mounting bolts from each side and lift dashboard from machine. REMARK On some models there will be shims between dashboard and main frame. Keep shims with sides they were removed from. On machines with cabs, the dashboard will come off with the cab.
  • Page 151 TRANSMISSION REMOVAL 35. Replace cover and unclip harness from fuel tank. 36. Remove back up alarm mounting hardware. 37. Flip over alarm and remove wire leads. 38. Close fuel shut off valve (1). Disconnect and cap hose (2). Disconnect and cap fuel return hose (3). 7C - 12...
  • Page 152 REMOVAL TRANSMISSION 39. Install lifting bracket to front of fuel tank and attach hoist.. 40. Remove mounting hardware and spacers, then remove fuel tank from machine. 41. Disconnect battery cable (1) and ground cable (2) from discon- nect switch (3). Remove battery cable from machine. 42.
  • Page 153 TRANSMISSION REMOVAL 43. Disconnect throttle cable (1) from overtravel rod (2). 44. At lower left side of seat support disconnect throttle cable from support. 45. Remove hardware and seat support from machine. 46. Disconnect right side brake and clutch hoses (1) at fittings on rear main frame cover.
  • Page 154 REMOVAL TRANSMISSION 47. Disconnect left side brake and clutch hoses (1) at fittings on rear main frame cover. Disconnect pressure hose at (2) top inlet screen fitting (3) at neutral start valve. Remove return hose (4) from bottom fitting at neutral start valve. 48.
  • Page 155 TRANSMISSION REMOVAL 52. Disconnect drive train pressure filter hoses and position outside of box. 53. Disconnect wire lead at pressure filter. Remove from clamp on box wall. 54. Mark reed valve switches, squeeze housing and disconnect. 55. Unclip transmission pressure switch. 56.
  • Page 156 REMOVAL TRANSMISSION 59. Attach chain and hoist to lifting bracket. Remove mounting hardware and remove from machine. Keep shims in positions they were removed. 60. Remove two hoses at inlet tee on main regulator valve. 61. Remove hose from outlet port of charge and scavenge pump. 62.
  • Page 157 TRANSMISSION REMOVAL 63. Feed hydraulic box harness out. Unclip remaining harness from rear main frame cover and reservoir box and position out of the way. 64. Remove drive train dipstick. 65. Remove dipstick and filler tube. 66. Remove lower filler tube. 7C - 18...
  • Page 158 REMOVAL TRANSMISSION 67. Plug port. 68. Remove two crossover tubes. 69. Disconnect and cap four hoses from tubes. 70. Remove upper and lower rear tubes from valve bank. 71. Disconnect rear equipment suction tube from fitting. 72. Disconnect suction tube assembly from pump and remove. 7C - 19...
  • Page 159 TRANSMISSION REMOVAL 73. Disconnect and remove brake rod. 74. Disconnect valve bank inlet hose from tube. 75. Remove drive shaft. 76. Disconnect and remove pump to rear mainframe hose. 77. Disconnect cooler outlet hose from front of transmission. Position out of the way. 78.
  • Page 160 REMOVAL TRANSMISSION 80. Disconnect hoses at suction strainer and position out of the way. Cap ports on strainer. Remove strainer and mounting bracket from machine. 81. Install a ½NC eye bolt (1) at top of transmission (2) and attach hoist. Remove mounting hardware. Work transmission away from rear main frame face and remove from machine.
  • Page 161 TRANSMISSION COMPLETE ASSEMBLY EXPLODED VIEW OF COMPLETE ASSEMBLY 7C - 22...
  • Page 162 REMARK Callouts from exploded view correspond with callouts in the following steps. 1. D32E-1, D32P-1, D38E-1 or D38P-1: Remove mounting bolt and spacer securing pinion gear to output shaft. 1. D39E-1 or D39P-1: Remove mounting bolt and spacer securing pinion gear to output shaft.
  • Page 163 TRANSMISSION COMPLETE ASSEMBLY 6. Remove rate of rise valve (27). Discard mounting gasket. Refer to RATE OF RISE VALVE for service. 7. If necessary, remove orifice strainer (28) from manifold plate. 8. Remove valve manifold (29) from transmission housing. Discard manifold gasket.
  • Page 164 COMPLETE ASSEMBLY TRANSMISSION 13. Attach eye bolt to range (output) shaft (15) and remove. Refer to RANGE (OUTPUT) SHAFT for service. 14. Attach eye bolt to directional (input) shaft (3) and remove. Refer to DIRECTIONAL (INPUT) SHAFT for service. 15. Attach eye bolt to countershaft (11) and remove. Refer to COUNTERSHAFT for service.
  • Page 165 TRANSMISSION COMPLETE ASSEMBLY 18. Remove drive shaft yoke. 19. Pry oil seal (10) from housing. 20. Carefully tap down on directional shaft manifold (5) to free up retaining ring (9). Remove ring. 21. Remove shims (8). 22. Install manifold tool, DR04-721-1, to directional shaft manifold (5).
  • Page 166 COMPLETE ASSEMBLY TRANSMISSION 26. Tap on range clutch manifold (18) to free up retaining ring (21), then remove ring. 27. Remove shims (20). 28. Install port plug in range shaft manifold (18). Using a long drift on port plug from inside housing, remove manifold. 29.
  • Page 167 TRANSMISSION COMPLETE ASSEMBLY 34. Using a suitable driver, remove bearing cup from input shaft bore. Using same driver, remove bearing cup from countershaft bore. REASSEMBLY REMARK Callouts from exploded view correspond with callouts in following steps. 1. If removed, install new bearing cups in rear cover. Bottom new cups in their bores.
  • Page 168 COMPLETE ASSEMBLY TRANSMISSION 6. Install shaft retainer and bolt and torque to 325 NCm (240 lbf ft) ±10%. 7. Using a dial indicator, check reverse idler gear (14) for end play. These bearings are non adjustable. The idle gear should turn freely with 0 to 0.25 mm (0 to 0.010 in) end play.
  • Page 169 TRANSMISSION COMPLETE ASSEMBLY 14. Apply Loctite #515 to mating surface of rear cover (2). Loop around bolt holes. 15. Using four legged chain lower transmission housing (1), over shafts, aligning dowel pins with holes. Install hardware finger tight. 16. Turn assembly over on its side. Torque mounting bolts to 92 NCm (70 lbf ft) ±10%.
  • Page 170 COMPLETE ASSEMBLY TRANSMISSION 22. Refit bridge tool to countershaft. Install extension adapter to torque wrench. Position dial indicator on threaded rod of tool and set to zero. Pull up on countershaft with 58 NCm (43 lbf ft) and read and record indicator movement. ÷...
  • Page 171 TRANSMISSION COMPLETE ASSEMBLY 29. Remove bridge tool. Lightly tap down on directional (input) shaft to attempt to achieve zero end play. 30. Refit bridge tool to directional (input) shaft. Install extension adapter on torque wrench. Position dial indicator on threaded rod of tool and set to zero.
  • Page 172 COMPLETE ASSEMBLY TRANSMISSION 35. Install long bolt to range (output) shaft and tap down on shaft while rotating. 36. Install retaining ring (21) WITHOUT shims, into groove in transmission housing. 37. Install bridge tool DR04-721-3, as follows; Thread rod into range (output) shaft lifting threads. Lock nut against shaft.
  • Page 173 TRANSMISSION COMPLETE ASSEMBLY 42. Install new oil seal (10) flush with transmission housing. 43. Install two aligning studs DR04-720, to transmission housing. Position gasket (30) over studs. 44. Install valve manifold (29) over studs. Apply Loctite #262 to two mounting bolts and install. 45.
  • Page 174 COMPLETE ASSEMBLY TRANSMISSION 50. Install range selector valve (25) over studs. Apply Loctite #262 to top bolts and install. Remove studs and install two bottom bolts with Loctite #262. Torque bolts to 38 NCm (28 lbf ft) ±10%. 51. Install aligning dowels DR04-721-4, to bottom main regulator valve mounting bolt holes.
  • Page 175 57. Install pinion gear on splines. 58. Coat mounting bolt threads with clean oil. 59. D32E-1, D32P-1, D38E-1 or D38P-1: Secure pinion gear to range (output) shaft with bolt and spacer. 60. D39E-1 or D39P-1: Secure pinion gear to range (output) shaft with bolt and spacer.
  • Page 176 COMPLETE ASSEMBLY TRANSMISSION 61. Secure range (output) shaft on tool with large wrench. Torque pinion gear mounting bolt to 434 NCm (320 lbf ft) . 62. Remove tool from range (output) shaft manifold (18). 63. Install adapter fitting (22) with new o-ring to range (output) shaft manifold.
  • Page 177 TRANSMISSION DIRECTIONAL (INPUT) SHAFT GENERAL CROSS SECTION VIEW OF DIRECTIONAL (INPUT) SHAFT 7C - 38...
  • Page 178 DIRECTIONAL (INPUT) SHAFT TRANSMISSION EXPLODED VIEW OF DIRECTIONAL (INPUT) SHAFT 7C - 39...
  • Page 179 TRANSMISSION DIRECTIONAL (INPUT) SHAFT 1. Input Shaft 8. Return Spring 15. Seal Ring 2. Thrust Race 9. Hub and Drum Kit 16. Friction Disc 3. Thrust Bearing 10. Retaining Ring 17. Separator Plate 4. Needle Bearing 11. Clutch Piston 18. Support Plate 5.
  • Page 180 DIRECTIONAL (INPUT) SHAFT TRANSMISSION 7. Remove inner thrust race (2). 8. Remove reverse gear and hub (20) from directional (input) shaft. 9. Remove needle bearing (4). 10. Remove outer thrust race (2). 11. Remove thrust bearing (3). 12. Remove inner thrust race (2). 13.
  • Page 181 TRANSMISSION DIRECTIONAL (INPUT) SHAFT 15. Turn assembly over in stand and support with metal bars. Install bearing puller arrangement on forward gear and hub. Activate ram to unseat bearing press fit. Remove puller arrangement after press fit is unseated. 16. Remove bearing cone from directional (input) shaft. 17.
  • Page 182 DIRECTIONAL (INPUT) SHAFT TRANSMISSION 23. Remove outer thrust race (2). 24. Remove thrust bearing (3). 25. Remove inner thrust race (2). 26. Using retaining ring pliers, retract captured retaining ring (19) and remove with support plate (18). 27. Remove friction discs (16) and separator plates (17). 28.
  • Page 183 TRANSMISSION DIRECTIONAL (INPUT) SHAFT 31. Remove spring (8). REMARK Check spring(s) for damage and fatigue against those values shown in spring criterion. 32. Remove inner spring retainer (7). 33. Turn assembly over in stand seal ring groove side up (reverse). Remove retaining ring (6) from shaft.
  • Page 184 DIRECTIONAL (INPUT) SHAFT TRANSMISSION 39. Using compressed air in lower (forward) groove port, unseat piston from clutch hub and drum. REMARK Wear eye protection when using air under pressure. Limit air pressure to 206 kPa (30 psi). 40. Raise assembly and remove piston (11). 41.
  • Page 185 TRANSMISSION DIRECTIONAL (INPUT) SHAFT 3. Install one retaining ring (10) in groove in hub and drum. 4. Position hub and drum in press. Align dowel pin in shaft with notched spline of hub and drum. 5. Press shaft into hub and drum bottoming against retaining ring. 6.
  • Page 186 DIRECTIONAL (INPUT) SHAFT TRANSMISSION 11. Turn assembly over in stand and support with bars. Coat lead in chamfers of hub and drum with clean oil. Spline piston in hub and press in place being careful not to damage piston rings. Using wooden dowels, carefully bottom piston into hub and drum.
  • Page 187 TRANSMISSION DIRECTIONAL (INPUT) SHAFT 19. Position retaining ring (6) on shaft. 20. Position assembly in press and install spring compressor tool DR04-721-6 on spring retainer (7). Activate press to move retainer below retaining ring (6). Install ring in groove on shaft. Slowly let off press until spring (8) is held by retainer.
  • Page 188 DIRECTIONAL (INPUT) SHAFT TRANSMISSION 25. Retract retaining ring (19) and install two #6-32 screws in support plate (18). 26. Install support plate (18) into assembly. 27. Retract retaining ring (19) and remove four screws. Carefully let off retaining ring until it seats in groove in drum. 28.
  • Page 189 TRANSMISSION DIRECTIONAL (INPUT) SHAFT 32. Install forward gear and hub (5) aligning all six friction disc. 33. Install inner thrust race (2). 34. Install thrust bearing (3) to race. Coat bearing needles with clean oil. 35. Install outer thrust race (2). 36.
  • Page 190 DIRECTIONAL (INPUT) SHAFT TRANSMISSION 40. Alternately install friction disc and separator plates ending with friction disc (16). A total of six friction discs and five separator plates are to be used. 41. Position captured retaining ring (19) into support plate (18). Install two #6-32 screws at opposite side of retaining ring opening.
  • Page 191 TRANSMISSION DIRECTIONAL (INPUT) SHAFT 45. Install inner thrust race (2). 46. Install thrust bearing (3) to race. Coat bearing needles with clean oil. 47. Install outer thrust race (2). 48. Install reverse gear and hub (20) aligning all six friction discs. 49.
  • Page 192 DIRECTIONAL (INPUT) SHAFT TRANSMISSION 53. Install bearing spacer (21). 54. Heat bearing cone to 135EC (275EF) for 45 minutes. Install on shaft and bottom. To insure cone is seated, keep pressure against cone until it cools. 55. Install four new manifold seal rings to shaft. 7C - 53...
  • Page 193 TRANSMISSION COUNTERSHAFT GENERAL EXPLODED AND CROSS SECTION VIEWS OF COUNTERSHAFT 1. Countershaft 3. 2nd Speed Gear 5. Retaining Ring 2. 3rd Speed Gear 4. 1st Speed Gear 7C - 54...
  • Page 194 COUNTERSHAFT TRANSMISSION DISASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 1. Install bearing puller arrangement to 2nd speed gear (3). Activate ram to unseat bearing press fit. Remove puller arrange- ment and bearing after press fit is unseated. 2.
  • Page 195 TRANSMISSION COUNTERSHAFT 2. Install 3rd speed gear (2). 3. Install retaining ring (5) to top groove in countershaft. 4. Heat bearing cone to 135EC (275EF) for 45 minutes. Install on shaft and bottom. To insure cone is seated, keep pressure against cone until it cools.
  • Page 196 RANGE (OUTPUT) SHAFT TRANSMISSION GENERAL EXPLODED VIEW OF RANGE (OUTPUT) SHAFT 7C - 57...
  • Page 197 TRANSMISSION RANGE (OUTPUT) SHAFT CROSS SECTION VIEW OF RANGE (OUTPUT) SHAFT 7C - 58...
  • Page 198 RANGE (OUTPUT) SHAFT TRANSMISSION 1. Output Shaft 10. Lube Sleeve 19. Separator Plate 28. Retaining Ring 2. Bearing Spacer 11. Hub and Drum Kit 20. Support Plate 29. Seal Ring 3. Retaining Ring 12. Retaining Ring 21. Captured Retaining Ring 30.
  • Page 199 TRANSMISSION RANGE (OUTPUT) SHAFT 7. Remove needle bearing (6). 8. Remove thrust races (4) and bearing (5). 9. Using retaining ring pliers, retract captured retaining ring (21) and remove with support plate (20). 10. Remove friction discs (18) and separator plates (19). 11.
  • Page 200 RANGE (OUTPUT) SHAFT TRANSMISSION 13. Remove 1st pack compressing tool. 14. Remove retaining ring (32) from shaft. 15. Remove ring spacer (31). 16. Remove seal ring (29) from under 1st speed piston housing (30). 17. Position blocking under 1st speed drum (32). Using retaining ring pliers, retract captured retaining ring (21) and remove.
  • Page 201 TRANSMISSION RANGE (OUTPUT) SHAFT 21. Remove seal ring (29) from groove in shaft. 22. Position assembly in press and install spring compressor tool DR04-721-6 on lube sleeve (10). Activate press to move retainer below retaining ring (28). Move ring out of groove and up on shaft.
  • Page 202 RANGE (OUTPUT) SHAFT TRANSMISSION 29. Remove thrust races (4) and bearing (5). 30. Using retaining ring pliers, compact captured retaining ring (21) and remove with support plate (20). 31. Remove seven friction discs (18) and six separator plates (19). 32. Position assembly in press and install spring compressor tool DR04-721-6 on spring retainer (7).
  • Page 203 TRANSMISSION RANGE (OUTPUT) SHAFT 37. Turn assembly over in press and install spring compressor tool DR04-721-6 on spring retainer (7). Activate press to move retainer below retaining ring (6). Move ring out of groove and up on shaft. Slowly let off press until spring (8) fully decompresses. WARNING Spring loaded assembly.
  • Page 204 RANGE (OUTPUT) SHAFT TRANSMISSION 45. If hub and drum (11) is to be remove from output shaft (1), remove retaining rings (12) from each side. 46. Position assembly in press and separate shaft (1) from hub and drum (11). 47. Remove piston seal (14) and seal ring (15) from each side of hub and drum.
  • Page 205 TRANSMISSION RANGE (OUTPUT) SHAFT 51. Remove piston seal (14) and seal ring (15) from 1st piston housing (30). 52. Remove piston seal (23) and seal ring (24 ) from 1st speed piston (22). 53. Install puller arrangement to bearing and remove. REASSEMBLY REMARK Callouts from exploded and cross section views correspond with...
  • Page 206 RANGE (OUTPUT) SHAFT TRANSMISSION 2. Position hub and drum (11) in press. Align dowel pin in shaft (1) with notched spline of hub and drum. 3. Press shaft (1) into hub and drum (11) bottoming against retaining ring. 4. Using compressed air through port of bottom groove, ascertain that piston apply ports align.
  • Page 207 TRANSMISSION RANGE (OUTPUT) SHAFT 10. Coat lead in chamfers of hub and drum with clean oil. Spline piston (13) in hub and press in place being careful not to damage piston rings. 11. Install lube sleeve (10). 12. Install piston return spring (9). 13.
  • Page 208 RANGE (OUTPUT) SHAFT TRANSMISSION 18. Install new piston seal (14) over seal ring into groove at hub and drum (11). 19. Coat lead in chamfers of hub and drum with clean oil. Spline piston (22) in hub and press in place being careful not to damage piston rings.
  • Page 209 TRANSMISSION RANGE (OUTPUT) SHAFT 26. Slowly let off press until spring (9) is held by retainer (8). Turn assembly over in press and repeat steps 24 through 26 for remaining side. WARNING Spring loaded assembly. Assembly must be held to install spring.
  • Page 210 RANGE (OUTPUT) SHAFT TRANSMISSION 32. Install support plate (20) into assembly. 33. Retract retaining ring (21) and remove four screws. Carefully let off retaining ring until it seats in groove in drum. 34. Install inner thrust race (4). 35. Install thrust bearing (5) to race. Coat bearing needles with clean oil.
  • Page 211 TRANSMISSION RANGE (OUTPUT) SHAFT 40. Install thrust bearing (5) to race. Coat bearing needles with clean oil. 41. Install outer thrust race (4). 42. Install retaining ring (3) up against step on output shaft. 43. Seat bearing spacer (2) on outer thrust race against retaining ring.
  • Page 212 RANGE (OUTPUT) SHAFT TRANSMISSION 48. Position captured retaining ring (21) into support plate (20). Install two #6-32 screws at opposite side of retaining ring opening. 49. Retract retaining ring (21) and install two #6-32 screws in support plate (20). 50. Install support plate (20) into assembly. 51.
  • Page 213 TRANSMISSION RANGE (OUTPUT) SHAFT 54. Install outer thrust race (4). 55. Install 2nd speed gear and hub (25) aligning all seven friction discs. 56. Install needle bearing (6) inside 2nd speed gear and hub. Coat bearing needles with clean oil. 57.
  • Page 214 RANGE (OUTPUT) SHAFT TRANSMISSION 62. Install inner thrust race (4). 63. Install thrust bearing (5) to race. Coat bearing needles with clean oil. 64. Install outer thrust race (4). 65. Install retaining ring (3) into groove against outer thrust race. 66.
  • Page 215 TRANSMISSION RANGE (OUTPUT) SHAFT 70. Position assembly in press and install spring compressor tool DR04-721-6 on lube sleeve (10). Activate press to move retainer below retaining ring groove. Install retaining ring (28) in groove on shaft. Slowly let off press until spring is held by lube sleeve.
  • Page 216 RANGE (OUTPUT) SHAFT TRANSMISSION 77. Position 1st speed drum (33), installed retaining ring side down, on clutch stand. Insert 1st speed housing (30), bearing end down, up against retaining ring. 78. Coat lead in chamfers of hub and drum with clean oil. Spline piston (22) in housing and press in place being careful not to damage piston rings.
  • Page 217 TRANSMISSION RANGE (OUTPUT) SHAFT 83. Retract retaining ring (21) and install two #6-32 screws in support plate (20). 84. Install support plate (20) into assembly. 85. Retract retaining ring (21) and remove four screws. Carefully let off retaining ring until it seats in groove in drum. 86.
  • Page 218 RANGE (OUTPUT) SHAFT TRANSMISSION 90. Start retaining ring (32) on shaft and position next to ring spacer (31). Install compression tool, DR04-721-7, and move clutch assembly down until retaining ring can be inserted into groove on shaft. Insert. Remove tool. 7C - 79...
  • Page 219 TRANSMISSION REVERSE IDLER SHAFT GENERAL EXPLODED AND CROSS SECTION VIEWS OF REVERSE IDLER SHAFT 1. Reverse Idler Shaft 3. Cone Spacer 5. Reverse Idler Gear 7. Mounting Bolt 2. Double Bearing 4. Bearing Cup Spacer 6. Shaft Retainer 8. Seal Ring 7C - 80...
  • Page 220 REVERSE IDLER SHAFT TRANSMISSION DISASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 1. Remove seal ring (8) from reverse idler shaft (1). 2. Remove reverse idler gear (5) with outer tapered roller bearing (2) cone.
  • Page 221 TRANSMISSION REVERSE IDLER SHAFT 2. Install inner tapered roller bearing (2) on reverse idler shaft (1) and bottom against step. 3. Install bearing cone spacer (3). 4. Install reverse idler gear (5) on inner tapered roller bearing cone. 5. Install outer tapered roller bearing (2) cone. 6.
  • Page 222 MAIN REGULATOR VALVE TRANSMISSION EXPLODED VIEW OF MAIN REGULATOR VALVE 7C - 83...
  • Page 223 TRANSMISSION MAIN REGULATOR VALVE CROSS SECTION VIEW OF MAIN REGULATOR VALVE 1. Valve Housing 6. Check Ball Spring 11. Main Spool Shim 16. O-Ring 2. Main Spool Assy 7. Spring Guide Pin 12. Lube Spool 17. End Cover 3. Check Ball 8.
  • Page 224 MAIN REGULATOR VALVE TRANSMISSION SPECIFICATIONS Spring Criteria: Main Spool Valve Check Ball Spring (4): Free Length ..............21.13 mm (0.832 in) Test Length .
  • Page 225 TRANSMISSION MAIN REGULATOR VALVE 2. Remove bolts and lock washers from end cover (17). Slowly back off vise allowing springs to decompress. WARNING Spring loaded assembly. Assembly must be held to relieve spring pressure. Use extreme caution when disassembling. 3. Remove lube spool spring (15). Identify spring for ease of testing and reassembly.
  • Page 226 MAIN REGULATOR VALVE TRANSMISSION 6. Remove converter spool (13) with spring shims (10). Keep removed amount of shims with spool. REMARK A total quantity of 5 shims can used under spool spring. Each shim added or deleted will raise or lower converter pressure by 24 kPa (3.5 psi).
  • Page 227 TRANSMISSION MAIN REGULATOR VALVE 10. Remove main spool assembly (2) with spring shims (11). Keep removed amount of shims with spool. REMARK A total quantity of 3 shims can used under spool spring. Each shim added or deleted will raise or lower main pressure by 34 kPa (5 psi).
  • Page 228 MAIN REGULATOR VALVE TRANSMISSION 2. Install new o-rings (16) into bottom of housing and bolt bottom end cover (17) in place. Torque bolts to 21 NCm (16 lbf ft) ±10%. Install new o-rings (16) into top of housing (1). 3. Install main spool assembly (2) with same amount of shims (11) that were removed.
  • Page 229 TRANSMISSION MAIN REGULATOR VALVE 6. Install main outer spring (8). 7. Install converter spool (13) with spring shims (10) that were removed with spool. REMARK A total quantity of 5 shims can used under spool spring. Each shim added or deleted will raise or lower converter or pressure by 24 kPa (3.5 psi).
  • Page 230 MAIN REGULATOR VALVE TRANSMISSION 10. Install lube spool spring (15). 11. Position valve and end cover (17) in vise. 12. Slowly compress vise and install mounting hardware. Torque bolts to 21 NCm (16 lbf ft) ±10%. WARNING Spring loaded assembly. Assembly must be held to install spring.
  • Page 231 TRANSMISSION RANGE SELECTOR VALVE EXPLODED VIEW OF RANGE SELECTOR VALVE 7C - 92...
  • Page 232 RANGE SELECTOR VALVE TRANSMISSION CROSS SECTION VIEW OF RANGE SELECTOR VALVE 1. Valve Housing 4. Directional Spool - Long 7. Small O-ring 2. Speed Spool Return Spring 5. Directional Spool - Short 8. End Cover 3. Speed Spool 6. Large O-Ring 9.
  • Page 233 TRANSMISSION RANGE SELECTOR VALVE SPECIFICATIONS Spring Criteria: Speed or Directional Selector Spool Spring (2); Free Length ..............49.01 mm (1.933 in) Test Length .
  • Page 234 RANGE SELECTOR VALVE TRANSMISSION 4. Remove directional spool return spring (2) from housing bore. REMARK Check spring for damage and fatigue against those values shown in specifications. 5. Remove short directional spool (5) from housing bore. REMARK Spool is to be kept with housing bore side that it was removed from.
  • Page 235 TRANSMISSION RANGE SELECTOR VALVE 8. Remove remaining speed spool (3) from housing bore. REMARK Spool is to be kept with housing bore side that it was removed from. 9. Remove large (6) and small (7) o-rings from each end of housing.
  • Page 236 RANGE SELECTOR VALVE TRANSMISSION 4. Install end cover and secure with hardware. Torque bolts to 21 NCm (16 lbf ft) ±10%. 5. Install short directional spool (5) into its housing bore. 6. Install directional spool return spring (2) into spool. 7.
  • Page 237 TRANSMISSION RANGE SELECTOR VALVE 8. Install remaining speed spool (3) into its housing bore. 9. Install end cover (8) and secure with hardware. Torque bolts to 21 NCm (16 lbf ft) ±10%. WARNING Spring loaded assembly. Assembly must be held to install spring.
  • Page 238 RATE OF RISE VALVE TRANSMISSION CROSS SECTION VIEW OF RATE OF RISE VALVE A. Main Pressure Oil E. Main Oil Pressure to Directional Spool B. Orificed Main Pressure Oil F. Main Oil Pressure to Range Spools C. Drain Port G. Internal Passage D.
  • Page 239 TRANSMISSION RATE OF RISE VALVE Theory of Operation RATE OF RISE VALVE IN NEUTRAL POSITION A. Main Pressure Oil E. Main Oil Pressure to Directional Spool B. Orificed Main Pressure Oil F. Main Oil Pressure to Range Spools C. Drain Port G.
  • Page 240 RATE OF RISE VALVE TRANSMISSION DURING A SHIFT SEQUENCE SPOOL SHIFTED, MODULATING PISTON STILL IN NEUTRAL POSITION A. Main Pressure Oil E. Main Oil Pressure to Directional Spool B. Orificed Main Pressure Oil F. Main Oil Pressure to Range Spools C.
  • Page 241 TRANSMISSION RATE OF RISE VALVE SEQUENCE SPOOL SHIFTED, MODULATING PISTON SHIFTED TO LEFT A. Main Pressure Oil E. Main Oil Pressure to Directional Spool B. Orificed Main Pressure Oil F. Main Oil Pressure to Range Spools C. Drain Port G. Internal Passage D.
  • Page 242 RATE OF RISE VALVE TRANSMISSION EXPLODED VIEW OF RATE OF RISE VALVE 7C - 103...
  • Page 243 TRANSMISSION RATE OF RISE VALVE CROSS SECTION VIEW OF RATE OF RISE VALVE 5. Inner Piston Spring 9. Dowel Pin 13. Tube Spacer 1. Valve Housing 6. Reducing Spool 10. Sequence Spool Spacer 14. End Cover Gasket 2. Modulating Piston 7.
  • Page 244 RATE OF RISE VALVE TRANSMISSION DISASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 1. While holding down on end cover (16), slowly let off mounting bolts until all spring tension is released. Then remove cover. WARNING Spring loaded assembly.
  • Page 245 TRANSMISSION RATE OF RISE VALVE 6. Remove dowel pin (9) from housing bore. 7. Remove outer piston spring (4) from housing bore. REMARK Check spring for damage and fatigue against those values shown in specifications. 8. Remove piston spring retainer (3) from housing bore. 9.
  • Page 246 RATE OF RISE VALVE TRANSMISSION 12. Remove and discard end cover gasket (14). 13. Remove reducing spool (6) from housing bore. 14. Remove reducing spool spring (7) from housing bore. REMARK Check spring for damage and fatigue against those values shown in specifications.
  • Page 247 TRANSMISSION RATE OF RISE VALVE 2. Install sequence spool (8) into housing bore. 3. Install reducing spool spring (7) into housing bore. 4. Seat reducing spool (6) in housing bore. 5. Insert aligning studs DR04-720, to housing. Install new end cover gasket (14) to housing.
  • Page 248 RATE OF RISE VALVE TRANSMISSION 7. Install modulating piston (2) into housing bore. 8. Install inner piston spring (5) into modulating piston in housing bore. 9. Install piston spring retainer (3) over spring. 10. Install outer piston spring (4) over retainer. 11.
  • Page 249 TRANSMISSION RATE OF RISE VALVE 14. Install sequence spool spring (12) inside tube spacer. 15. Insert aligning studs DR04-720, to housing. Install new end cover gasket (14) to housing. 16. Install end cover (16) over aligning studs and secure with four bolts.
  • Page 250 INSTALLATION TRANSMISSION 1. Remove caps from fittings. Using lock ring pliers, remove retaining ring. 2. Remove hardware and seal flange. 3. Remove connector boot. 4. Remove long connector from cylinder. Repeat Steps 1 through 4 for remaining four fittings. 5. Remove hardware and side, front and back stiffeners. 6.
  • Page 251 Step 9, within 0.025 mm (0.001 in). Torque trans- mission mounting bolts to 352 to 406 NCm (260 to 300 lbf ft). 11. D32E-1, D32P-1, D38E-1 or D38P-1 12. D39E-1 or D39P-1 7C - 112...
  • Page 252 INSTALLATION TRANSMISSION 13. With pressure source in place, install brake cylinder (5)to base plates and torque mounting bolts to 92 NCm (70 lbf ft) ±10%. Screw both adjustment bolts (4) out until they just make contact with equalizer bar. Secure with locknuts (3) and torque to 92 NCm (70 lbf ft).
  • Page 253 TRANSMISSION INSTALLATION 21. Using lock ring pliers, install ring over boot and under lip. 22. Install lower filler tube. 23. Install upper filler tube. 24. Install suction strainer and bracket and secure with hardware. Torque bolts to 38 NCm (28 lbf ft) ±10%. Connect and tighten hoses at strainer fittings.
  • Page 254 27. Install cooler outlet hose to front of transmission. 28. Install pump to rear mainframe hose. 29. Install drive shaft and secure with bolts. D32E-1, D32P-1, D38E-1 or D38P-1; Torque bolts to 33 NCm (24 lbf ft). D39E-1 or D39P-1; Torque bolts to 57 NCm (42 lbf ft).
  • Page 255 TRANSMISSION INSTALLATION 32. Install rear suction tube to fitting at reservoir. 33. Connect front suction tube to equipment pump. Connect front suction tube to rear suction tube with rubber hose and clamps. 34. Install upper and lower rear tubes at valve bank. 35.
  • Page 256 INSTALLATION TRANSMISSION 38. Feed harness into hydraulic reservoir box. Reclip harness to reservoir box and rear main frame cover. 39. Apply electrical sealing grease, Grafo 112-X to wire leads and connect to horn (1) switch and equipment (2) filter switch. Reclip to box wall.
  • Page 257 TRANSMISSION INSTALLATION 42. Position battery box in place on fender with shims that were removed with it and secure with hardware finger tight. REMARK When installing battery box, make sure crossover tubes at left front of rear frame clear bottom floor plate of box. Tubes go inside box.
  • Page 258 INSTALLATION TRANSMISSION 48. Apply electrical sealing grease, Grafo 112-X to wire lead and connect to drive train pressure filter. Reclamp to box wall. Reclamp wiring harness to inside of battery box. 49. Connect hoses drive train pressure filter. 50. Connect reverse (1) and 1st speed (2) hoses to fittings at bottom and side of trans/steer valve.
  • Page 259 TRANSMISSION INSTALLATION 54. Install return hose (4) to bottom fitting at neutral start valve. Connect pressure hose to (2) top inlet screen fitting (3) at neutral start valve. Connect left side brake and clutch hoses (1) to fittings on rear main frame cover. 55.
  • Page 260 INSTALLATION TRANSMISSION 58. Connect throttle cable (1) to overtravel rod (2). 59. Install tube brackets to front seat support. Torque center dNC bolt to 38 NCm (28 lbf ft) ±10% and right ½NC bolts to 92 NCm (70 lbf ft) ±10%. Torque front seat support hardware to 38 NCm (28 lbf ft) ±10%.
  • Page 261 TRANSMISSION INSTALLATION 62. Remove lifting bracket from front of fuel tank. 63. Connect fuel return hose (3) to fitting at tank. Connect fuel supply hose (2) to shut off valve (1). Open valve. 64. Apply electrical sealing grease, Grafo 112-X to wire leads and connect at back of alarm.
  • Page 262 INSTALLATION TRANSMISSION 66. Remove cover and feed harness through grommet to fuel level sender switch. Reclip harness to tank. 67. Apply electrical sealing grease, Grafo 112-X to wire leads and connect to switch. 68. Install cover with new gasket and secure with hardware. Torque to 21 NCm (16 lbf ft) ±10%.
  • Page 263 See Section 13 for cab reassembly. 74. At left side, connect two hoses (1 and 2) to foot brake valve (3). 75. D32E-1 or D32P-1; Remove cover from inlet manifold and connect elbow. 76. D38E-1, D38P-1, D39E-1 or D39P-1; Remove cover from turbocharger (2) and connect hose (3) and secure with hose clamp (1).
  • Page 264 INSTALLATION TRANSMISSION 77. D32E-1 or D32P-1; Apply electrical sealing grease, Grafo 112-X to wiring lead and connect to switch at air cleaner outlet pipe. 78. D38E-1, D38P-1, D39E-1 or D39P-1; Apply electrical sealing grease, Grafo 112-X to wiring lead and connect to switch at air cleaner outlet pipe.
  • Page 265 TRANSMISSION INSTALLATION 83. Install dash brace bar to right side of machine. Torque bolts to 92 NCm (70 bf ft) ±10%. 84. Install final brake rod (1) to bellcrank (2). 85. Using a rolling floor jack, install transmission guard to machine and secure with hardware.
  • Page 266 INSTALLATION TRANSMISSION 88. Position rear cover in place and secure with hardware. Torque bolts to 92 NCm (70 lbf ft) ±10%. 89. Install operators compartment floor plate. Torque bolts to 38 NCm (28 lbf ft) ±10%. 90. Install floor mat. 91.
  • Page 267 TRANSMISSION INSTALLATION 94. From inside of engine compartment, install hood tie down brackets (3). Torque bolts to 10 NCm (8 lbf ft) ±10%. Install hook rod (1) and ball (2) to hood and bracket and tighten nut until ball compresses. Repeat for other side. Torque hood rear mounting hardware to 92 NCm (70 lbf ft) ±10%.
  • Page 268 TRANSMISSION/STEERING VALVE TRANSMISSION EXPLODED VIEW OF TRANSMISSION/STEERING VALVE 7C - 129...
  • Page 269 TRANSMISSION TRANSMISSION/STEERING VALVE CROSS SECTION VIEW OF TRANSMISSION/STEERING VALVE 7C - 130...
  • Page 270 TRANSMISSION/STEERING VALVE TRANSMISSION 1. Valve Body 18. ½NC Hex Nut 35. Detent Ball 2. Expander Plug 19. Dowel Pin 36. Range Detent Spring 3. Port Plug 20. Dowel Pin 37. Detent Guide 4. Steering Spool 21. Range Cam 38. Detent Guide Plug 5.
  • Page 271 Cam Ring (28) Working System (Generous Amount) ....KOMATSU Super Grease - 1400120H91 Universal Joint (31) (Liberal Amount in Joint Area) ....KOMATSU Super Grease - 1400120H91 Magnet Brass Screw (42) .
  • Page 272 TRANSMISSION/STEERING VALVE TRANSMISSION REMOVAL WARNING Be sure blade and any rear mounted equipment has been lowered to the ground or on suitable blocking. Turn the master switch to the off position and remove key. 1. Open battery door. Remove inner pin and remove door from battery box.
  • Page 273 TRANSMISSION TRANSMISSION/STEERING VALVE 5. Remove trans/steer valve inlet (1) and outlet (2) hoses. REMARK Tag, cap and plug all disconnected hoses, tubing and fittings. 6. Disconnect 1st speed hose from fitting at side of trans/steer valve. 7. Disconnect wires at back up alarm switch. 8.
  • Page 274 TRANSMISSION/STEERING VALVE TRANSMISSION 13. Move control lever inward and loosen jam nut. Unthread control handle and remove nut. 14. Remove boot and clamp. 15. Install a small ID, large OD washer (1) to valve shaft and secure with jam nut (2). REMARK When valve is removed, it has to be tilted forward so that ceramic magnet on switch arm clears reed (1,2,3) switch housing.
  • Page 275 TRANSMISSION TRANSMISSION/STEERING VALVE 4. Remove motion lever (26) from bearing housing. 5. Drive outer bearing (29) from housing 6. Remove two internal retaining rings (30) from bearing housing. Drive remaining inner bearing (29) from housing. 7. Cut and remove tie straps (33) from joint boot (32). 8.
  • Page 276 TRANSMISSION/STEERING VALVE TRANSMISSION 10. Remove spool rocker end (12) and jam nut (13) from each spool. 11. With switch arm (40) position out of the way, remove dowel pin (34) connecting universal joint (31) to range spool. 12. Remove universal joint (31). 13.
  • Page 277 TRANSMISSION TRANSMISSION/STEERING VALVE 15. Remove brass screw (42) and ceramic magnet (41) from switch arm (40). 16. Remove detent guide plug (38)and discard o-ring (39). WARNING Spring loaded assembly. Use extreme caution when disas- sembling. 17. Remove spring (36), detent guide (37) and detent ball (35). 18.
  • Page 278 TRANSMISSION/STEERING VALVE TRANSMISSION 20. Remove remaining two mounting bolts. 21. Let off each nut until all spring tension is relieved. WARNING Spring loaded assembly. Use extreme caution when disas- sembling. 22. Remove threaded rods and bottom cover (22) from valve. 23.
  • Page 279 TRANSMISSION TRANSMISSION/STEERING VALVE 25. Remove inner spring (6). 26. Remove pick up spacer (5) from each steering spool (4). 27. Remove forward reverse spring (10) at each directional spool in valve body. 28. Remove two steering spools (4) from valve body. 7C - 140...
  • Page 280 TRANSMISSION/STEERING VALVE TRANSMISSION 29. From under valve body, push directional spool (8) up and out of valve body. Repeat for remaining spool. 30. Install two nuts on directional spool (8) and position in vise. Remove Loctited nut from spool. 31. Remove spring retaining washer (9) from spool. 32.
  • Page 281 TRANSMISSION TRANSMISSION/STEERING VALVE 35. If necessary, remove dowel pin(s) (19 and/or 20). 36. Remove top thrust washer (16). 37. Remove thrust bearing (15). 38. Remove bottom thrust washer (16). 39. Remove and discard range selector wiper seal (46) from valve body.
  • Page 282 TRANSMISSION/STEERING VALVE TRANSMISSION 40. Remove and discard steering spool wiper seal (44) and direc- tional spool wiper seal (45) from valve body. 41. Remove orifice plugs (24) from bottom cover (22). 42. Discard all software and replace with new. REASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps.
  • Page 283 TRANSMISSION TRANSMISSION/STEERING VALVE 3. Install new wiper seal (46), with U cup portion facing down, to center spool bore in valve body. 4. Install bottom thrust washer (16) to range selector spool. 5. Lightly coat thrust bearing (15) with clean oil and install on thrust washer.
  • Page 284 TRANSMISSION/STEERING VALVE TRANSMISSION 10. Position valve body (1) bottom side facing up in vise. Install range selector spool (14) into body using a slight turning motion to aid spool to pass through wiper seal. 11. With directional spool nutted in vise, install spring retainer washer (9).
  • Page 285 TRANSMISSION TRANSMISSION/STEERING VALVE 15. Install forward reverse springs (10) in recessed bores. 16. Install pick up spacers (5) over steering spools (4) with recessed area towards valve body. 17. Install inner springs (6) to steering spools. 18. Install outer springs (7) to steering spools. 7C - 146...
  • Page 286 TRANSMISSION/STEERING VALVE TRANSMISSION 19. Check alignment of range selector spool as follows: Position bottom cover (22) with offset dowel pin hole to dowel pin (25). Align spool range cam dowel pins with offset recess in bottom cover. 20. Install two dNC threaded rods to valve body. 21.
  • Page 287 TRANSMISSION TRANSMISSION/STEERING VALVE 24. Torque mounting hardware to 38 NCm (28 lbf ft). 25. Apply clean grease to detent ball (35) to hold it in guide (37). Install guide with ball, spring (36) and cap with plug (38) with new o-ring (39). Torque plug to 20 NCm (15 lbf ft). 26.
  • Page 288 TRANSMISSION/STEERING VALVE TRANSMISSION 28. Slide switch arm (40) over universal joint, making sure that magnet (41) is on top side of arm and locking bolt (43) is aligned with counter sunk hole in universal joint. 29. Slide universal joint over range spool making sure that switch arm points to cast indentation in valve body.
  • Page 289 TRANSMISSION TRANSMISSION/STEERING VALVE 32. Apply Komatsu Super Grease to universal joint. 33. Install boot (32) over universal joint (31) and secure with tie straps (33). 34. Install jam nuts (13) and spool rocker ends (12) to each spool. 35. Start dowel pin (34) into universal joint.
  • Page 290 40. Install motion lever (26) and align with dowel pin (34). Drive pin into universal joint so that it completely clears bearing housing. ADJUSTMENT 1. Apply a generous amount of Komatsu Super Grease to cam ring surface. 2. Run all four spool rocker ends (12) up against cam plate until motion lever (26) is vertical with no free play between cam ring and rocker ends.
  • Page 291 TRANSMISSION TRANSMISSION/STEERING VALVE 3. Move motion lever fully in all directions to seat range selector spool against needle bearing. Recheck for free play between cam ring and rocker ends and correct as necessary. 4. Tighten jam nuts to spool rocker ends. INSTALLATION 1.
  • Page 292 TRANSMISSION/STEERING VALVE TRANSMISSION 7. Install left steering brake (1) and clutch (2) tubes to fittings at front of trans/steer valve. Connect hoses (3 and 4) to tubes and secure with clamp (5). REMARK Left brake and clutch tubes have a M23 hex nut at valve fittings. 8.
  • Page 293 TRANSMISSION TRANSMISSION/STEERING VALVE 14. Install battery mounting pad. 15. Install battery with negative terminal forward. 16. Install battery hold down clamp with hardware. 17. Position battery door in place and secure with hardware. Connect door link. 7C - 154...
  • Page 294 SPECIFICATIONS D32E-1, D32P-1, D38E-1 or D38P-1: Yoke Size ................. . 3C Bolt Torque - 5/16NF .
  • Page 295 5. Position drive shaft yoke to transmission input shaft and slide in being careful not to damage oil seal. Align front spider to converter yoke and secure with bolts. Torque bolts, D32E-1, D32P-1, D38E-1 or D38P-1 to 33 NCm (24 lbf ft) or D39E-1 or D39P-1 to 57 NCm (42 lbf ft).
  • Page 296 DRIVE SHAFT TRANSMISSION 8. Install front (1) and side (2) floor mat retainer angles at each side of machine. Torque bolts to 38 NCm (28 lbf ft) ±10%. 7C - 157...
  • Page 297 STEERING DRIVE SECTION 7E GENERAL ......2 DESCRIPTION ......2 OPERATION .
  • Page 298 STEERING DRIVE GENERAL DESCRIPTION This steering system combines a planetary gear type drive, hydraulically applied clutch and brake discs and a spring applied hydraulic released brake cylinder - that doubles as a parking brake - all located in the rear main frame. Steering is operated by the transmission/steering valve.

  • Page 299: General

    GENERAL STEERING DRIVE STEERING DRIVE 1. Brake Equalizer Bar 6. Brake Lever 11. Sprocket Pinion Shaft 16. Clutch End of Piston 2. Bar Pivot Pin 7. Cylinder Base Plate 12. Clutch Shoe 17. Return Spring 3. Brake Actuator Bar 8. Brake Shoe 13.
  • Page 300 STEERING DRIVE REMOVAL WARNING Be sure blade and any rear mounted equipment has been lowered to the ground or on suitable blocking. Turn the master switch to the off position and remove key. 1. Drain hydraulic reservoir. Refer to the OPERATION & MAINTE- NANCE MANUAL.

  • Page 301: Removal

    REMOVAL STEERING DRIVE 6. Remove rear cover. 7. Disconnect front and rear light harness (1) from main harness (2). Cut tie strap (3) and remove from clip. 8. Attach four leg chain and hoist to ROPS lifting brackets. Remove mounting hardware and lift ROPS from machine. REMARK For a machine equipped with a cab, see Section 13 for cab removal.
  • Page 302 STEERING DRIVE REMOVAL 10. Disconnect final brake rod (1) from bellcrank (2). 11. Remove armrest and brackets from each side of machine. 12. Connect sling and hoist to seat. Remove front and rear hard- ware and lift seat from machine. 13.
  • Page 303 REMOVAL STEERING DRIVE 16. Replace cover and unclip harness from fuel tank. 17 Remove back up alarm mounting hardware. 18. Flip over alarm and remove wire leads. 19. Close fuel shut off valve (1). Disconnect and cap hose (2). Disconnect and cap fuel return hose (3). 7E - 7...
  • Page 304 STEERING DRIVE REMOVAL 20. Install lifting bracket to front of fuel tank and attach hoist.. 21. Remove mounting hardware and spacers, then remove fuel tank from machine. 22. Disconnect battery cable (1) and ground cable (2) from discon- nect switch (3). Remove battery cable from machine. 23.
  • Page 305 REMOVAL STEERING DRIVE 24. Disconnect throttle cable (1) from overtravel rod (2). 25. At lower left side of seat support disconnect throttle cable from support. 26. Remove hardware and seat support from machine. 27. Disconnect right side brake and clutch hoses (1) at fittings on rear main frame cover.
  • Page 306 STEERING DRIVE REMOVAL 28. Disconnect left side brake and clutch hoses (1) at fittings on rear main frame cover. Disconnect pressure hose at (2) top inlet screen fitting (3) at neutral start valve. Remove return hose (4) from bottom fitting at neutral start valve. 29.
  • Page 307 REMOVAL STEERING DRIVE 33. Disconnect drive train pressure filter hoses and position outside of box. 34. Disconnect wire lead at pressure filter. Remove from clamp on box wall. 35. Mark reed valve switches, squeeze housing and disconnect. 36. Unclip transmission pressure switch. 37.
  • Page 308 STEERING DRIVE REMOVAL 40. Attach chain and hoist to lifting bracket. Remove mounting hardware and remove from machine. Keep shims in positions they were removed. 41. Remove two hoses at inlet tee on main regulator valve. 42. Remove hose from outlet port of charge and scavenge pump. 43.
  • Page 309 REMOVAL STEERING DRIVE 44. Feed hydraulic box harness out. Unclip remaining harness from rear main frame cover and reservoir box and position out of the way. 45. Remove drive train dipstick. 46. Remove dipstick and filler tube. 47. Remove lower filler tube and plug port. 7E - 13...
  • Page 310 STEERING DRIVE DISASSEMBLY EXPLODED VIEW OF STEERING DRIVE 7E - 14...
  • Page 311 DISASSEMBLY STEERING DRIVE EXPLODED VIEW OF STEERING DRIVE SHOES AND LEVERS 7E - 15...
  • Page 312 STEERING DRIVE DISASSEMBLY CROSS SECTION VIEW OF STEERING DRIVE 7E - 16...
  • Page 313 DISASSEMBLY STEERING DRIVE 1. Planet Gear Carrier 14. Carrier Shim 27. Back Up Shoe 40. Long Connector 2. Retaining Ring 15. Sun Gear 28. Arm Return Spring 41. Seal Flange 3. Planet Gear 16. Retaining Ring 29. Adjustment Screw 42. Connector Boot 4.
  • Page 314 STEERING DRIVE DISASSEMBLY 10. Remove retaining ring (28) from left steering arm (22) and left brake arm (24). Repeat for remaining side (items 23 and 25). 11. Remove left steering arm (22) and left brake arm (24). Repeat for remaining side (items 23 and 25). 12.
  • Page 315 DISASSEMBLY STEERING DRIVE 16. Remove clevis pin and brake actuator bar (46). 17. Detach steering cylinder (44) mounting hardware. 18. Remove steering cylinder (44) from mounting plate. As a rule, spring pin (39) will stay with mounting plate. Repeat for remain- ing side.
  • Page 316 STEERING DRIVE DISASSEMBLY 23. Remove thrust washers (21). 24. Remove left front eccentric shaft (20). 25. Remove left front apply shoe (19). Remove left rear eccentric shaft and apply shoe. Refer to BRAKE/STEERING SHOES in this section for service. 26. Remove thrust washers (21) from bottom front and rear of frame.
  • Page 317 DISASSEMBLY STEERING DRIVE 30. Remove outer retaining ring (16) from sun gear at both side. 31. Remove clutch disc (17) from each side. 32. Remove rear apply shoe (27) from each side. 33. Remove sun gear (15) from each side. 34.
  • Page 318 STEERING DRIVE DISASSEMBLY 38. Remove ring gear carrier (10) from rear main frame. 39. Position gear carrier (10) in press. Using properly sized plates, press down on planet gear carrier to unseat bearing cup. 40. Remove assembly from press. Remove planet gear carrier (1 through 7).
  • Page 319 DISASSEMBLY STEERING DRIVE 43. Remove pinion gear (8) mounting hardware. 44. Remove pinion gear (8) from transmission output (range) shaft. 7E - 23...
  • Page 320 STEERING DRIVE BRAKE CYLINDER EXPLODED VIEW OF BRAKE CYLINDER 7E - 24...
  • Page 321 BRAKE CYLINDER STEERING DRIVE CROSS SECTION VIEW OF BRAKE CYLINDER 7E - 25...

  • Page 322: Disassembly

    STEERING DRIVE BRAKE CYLINDER 1. Cylinder Body 5. Cylinder Piston 9. Spring Retainer 13. Wear Ring 2. Cylinder Support 6. ½NC Connector Nut 10. ½NC Retainer Bolt 14. Piston Seal 3. Piston Rod 7. Inner Spring 11. Rod Seal 15. O-ring 4.
  • Page 323 BRAKE CYLINDER STEERING DRIVE 5. Turn assembly over in vise and clamp along flats of piston rod (3). Start to loosen retainer bolt (10) until all tension is relieved off of inner an outer springs. WARNING Spring loaded assembly. Use extreme caution when disas- sembling.
  • Page 324 STEERING DRIVE BRAKE CYLINDER REASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 1. Install o-ring (15) in piston. For ease of assembly, soak piston seal ring (14) in water heated to 82 to 93EC (180 to 200EF) until it is pliable.
  • Page 325 BRAKE CYLINDER STEERING DRIVE 9. Install stop bolt (4) and lock nut to piston rod. 10. Install rod seal (11), back up ring (12) and wear ring (13) to body bore. 11. Coat all seals with a liberal layer of clean oil. Install assembly to cylinder body being careful not to cut or clip seals in cylinder body.
  • Page 326 STEERING DRIVE STEERING CYLINDER EXPLODED AND CROSS SECTION VIEWS OF STEERING CYLINDER 7E - 30...

  • Page 327: Disassembly

    STEERING CYLINDER STEERING DRIVE 1. Cylinder Housing 4. Piston Seal 7. O-Ring 2. Cylinder Piston and Rods 5. O-Ring 8. Quad Ring 3. End Cap 6. Quad Ring 9. Retaining Ring DESCRIPTION Steering cylinders are a double acting, double rod type that control engaging and disengaging of the brake or clutch plates.
  • Page 328 STEERING DRIVE STEERING CYLINDER 5. Remove piston/rod (2) from housing. 6. Remove quad ring (6) from cylinder housing. 7. Remove piston seal (4) and o-ring (5) from piston/rod. 8. Remove o-ring (7) from end cap. 9. Remove quad ring (8) from inside of end cap. 10.

  • Page 329: Reassembly

    STEERING CYLINDER STEERING DRIVE REASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 1. Install new quad ring (8) into end cap. Make sure ring sits squarely in groove. 2. Install new o-ring (7) at outer groove on end cap. 3.
  • Page 330 STEERING DRIVE STEERING CYLINDER 7. Coat piston seal on piston/rod with a liberal layer of clean oil. Install piston/rod to cylinder housing being careful not to cut or clip piston seal or quad ring in cylinder housing. 8. Coat internal quad ring in end cap (3) with a liberal layer of clean oil.
  • Page 331 MOUNTING PLATE STEERING DRIVE SECTION VIEW OF CYLINDER PLATE 32. Left Mounting Plate 35. Right Mounting Plate 33. Dowel Pin 36. Dowel Pin 34. Needle Bearing 37. Needle Bearing 7E - 35...
  • Page 332 STEERING DRIVE MOUNTING PLATE SERVICE REMARK For removal of mounting plate, refer to DISASSEMBLY and follow steps to mounting plate removal. 1. Position mounting plate in press with bearing over open area. Apply press and remove bearing. 2. Position mounting plate in press with bearing over closed area. Apply press and install bearing flush with both edges of plate.

  • Page 333: Mounting Plate

    MOUNTING PLATE STEERING DRIVE 5. Measure pin height and correct as necessary. REMARK For installation of mounting plate, refer to REASSEMBLY and follow steps from mounting plate installation to end. 7E - 37...
  • Page 334 STEERING DRIVE BRAKE/STEERING SHOES EXPLODED VIEW OF BRAKE OR STEERING SHOES 7E - 38...
  • Page 335 BRAKE/STEERING SHOES STEERING DRIVE SECTION VIEW OF BRAKE OR STEERING SHOES 7E - 39...

  • Page 336: Service

    STEERING DRIVE BRAKE/STEERING SHOES Apply Shoe Assembly 3. Mounting Screw 5. Back Up Shoe 1. Apply Shoe 4. Needle Bearing 6. Shoe Lining 2. Shoe Lining Back Up Shoe Assembly 7. Mounting Screw SPECIFICATIONS Mating Surfaces Degreaser ............Cleaning Solvent Mating Surfaces Set Up .

  • Page 337: Brake/Steering Shoes

    BRAKE/STEERING SHOES STEERING DRIVE 5. Degrease mating surfaces of lining and shoe with cleaning solvent. Apply Loctite Primer "T" and Plastic Gasket or #568 per Section 1 or instructions that come with material. Allow an adequate period for fixture time. Apply Loctite #262 to threads of screws (3) and install.
  • Page 338 STEERING DRIVE BRAKE/STEERING SHOES REMARK For installation of brake or steering shoes, refer to REASSEMBLY and follow steps from brake or steering shoes installation to end. 7E - 42...

  • Page 339: Service

    BEARING CARRIER STEERING DRIVE SERVICE REMARK For removal of brake carrier, refer to DISASSEMBLY and follow steps to brake carrier removal. 11. Tapered Roller Bearing 12. Bearing Carrier 13. Carrier Bushing 1. Install puller arrangement to bearing cone (11). Apply ram to puller arrangement and unseat bearing cone.
  • Page 340 STEERING DRIVE BEARING CARRIER 4. Apply coat of Loctite #609 to outside diameter of bushing (13). 5. Position bearing carrier (12) in press, bearing surface facing up. Start chamfered edge of bushing (13) into carrier and secure with press. Apply press and install bushing 0.76 to 2.03 mm (0.03 to 0.08 in) below edge of carrier.

  • Page 341: Bearing Carrier

    BEARING CARRIER STEERING DRIVE 8. Heat bearing cone (11) to 135EC (275EF) for 45 minutes. Install on bearing carrier (12) and bottom. To insure cone is seated, keep pressure against cone until it cools. REMARK For installation of brake carrier, refer to REASSEMBLY and follow steps from brake carrier installation to end.

  • Page 342: Service

    STEERING DRIVE PLANET GEAR CARRIER SERVICE REMARK For removal of planet gear carrier, refer to DISASSEMBLY and follow steps to planet gear carrier removal. 1. Planet Gear Carrier 5. Needle Bearing Spacer 2. Retaining Ring 6. Planet Gear Shaft 3. Planet Gear 7.

  • Page 343: Planet Gear Carrier

    PLANET GEAR CARRIER STEERING DRIVE 6. Liberally coat planet gear (3) bore with amber grease. Position shaft (6) in gear. Install bottom row of bearing needles (4) around shaft (qty. 20). 7. Install bearing needle spacer (5) and press bottom row of needle bearings down into gear.
  • Page 344 STEERING DRIVE REASSEMBLY EXPLODED VIEW OF STEERING DRIVE 7E - 48...
  • Page 345 REASSEMBLY STEERING DRIVE EXPLODED VIEW OF STEERING DRIVE SHOES AND LEVERS 7E - 49...
  • Page 346 STEERING DRIVE REASSEMBLY CROSS SECTION VIEW OF STEERING DRIVE 7E - 50...
  • Page 347 REASSEMBLY STEERING DRIVE 1. Planet Gear Carrier 14. Carrier Shim 27. Back Up Shoe 40. Long Connector 2. Retaining Ring 15. Sun Gear 28. Arm Return Spring 41. Seal Flange 3. Planet Gear 16. Retaining Ring 29. Adjustment Screw 42. Connector Boot 4.
  • Page 348 STEERING DRIVE REASSEMBLY 4. Install remaining planet gear carrier assembly with retaining ring end down. 5. Reposition assembly in press, bevel gear end up. Place bearing cup (11) in carrier. Using suitable push plate, apply press and install cup flush with edge of carrier. 6.
  • Page 349 8. Install pinion gear on splines. 9. Coat mounting bolt threads with clean oil. 10. D32E-1, D32P-1 D38E-1 or D38P-1: Secure pinion gear to range (output) shaft with bolt and spacer. 10. D39E-1 or D39P-1: Secure pinion gear to range (output) shaft with bolt and spacer.
  • Page 350 STEERING DRIVE REASSEMBLY 11. Secure tool with socket and breaker bar. 12. Torque pinion gear mounting bolt to 434 NCm(320 lbf ft). 13. Remove tool from range (output) shaft manifold. Install adapter fitting with new o-ring to range (output) shaft manifold. Install hose fitting with new o-ring and attach hose.
  • Page 351 Step 14, within 0.025 mm (0.001 in). Torque trans mounting bolts to 352 to 406 NCm (260 to 300 lbf ft). D32E-1, D32P-1, D38E-1 or D38P-1 7E - 55...
  • Page 352 STEERING DRIVE REASSEMBLY D39E-1 or D39P-1 22. Back out both left side bridge bolts ¼ in. Position dial indicator on heel of ring gear. Check backlash with dimension recorded from Step 14. To decrease backlash, turn right bridge bolts in. To increase backlash, turn left bridge bolts in.
  • Page 353 REASSEMBLY STEERING DRIVE 25. Apply a thorough coat of clean oil to carrier bearings. Rotate ring gear carrier five or six revolutions for proper seating. Using a torque wrench (lbf in scale), read and record ring gear carrier rolling torque. Reading not to exceed 13.5 NCm (120 lbf in). ‚...
  • Page 354 STEERING DRIVE REASSEMBLY 30. Install drive shoe adjustment screw (29) (both sides) partially into rear main frame. 31. Install clutch back up shoe (27) onto dowels in rear main frame. 32. Install sun gear (15) with inner retaining ring (16) into bearing carrier (12) meshing with three planet gears.
  • Page 355 REASSEMBLY STEERING DRIVE 38. Install top thrust washer (21) to eccentric shaft. Repeat Steps 35 through 38 for remaining side. 39. Position brake disc (18) in rear main frame on both sides. 40. Install final drive to both sides. Refer to SECTION 7F. 41.
  • Page 356 STEERING DRIVE REASSEMBLY 46. Install eccentric shaft (20) through apply shoe engaging bearing in rear main frame. 47. Install top thrust washer (21). 48. Install left mounting plate (32) over eccentric shafts engaging dowel pins in rear main frame. 49. Install plate mounting spacers (38) at each outside corner. 50.
  • Page 357 REASSEMBLY STEERING DRIVE 53. Position brake actuator bar (46) in brake rod clevis (45) and secure with clevis and new cotter pins. 54. Position brake actuator bar (46) in place in rear main frame and secure with pivot pin (49). 55.
  • Page 358 STEERING DRIVE REASSEMBLY 58. Install retaining ring (26) at all four arms. 59. Install adjustment tool (DR06-582) on rear main frame. 60. Set combination square at 195.6 ±0.76 mm (7.70 ±0.03 in). Clean off mounting area on face of rear main frame. Position square at rear nose of steering cylinder.
  • Page 359 STEERING DRIVE Secure ad hardware. Torque bolts to 38 N m (28 lbf ft) ±10%. Repeat Steps 59 through 62 for right side of machine. Adjustment tool is reversible by moving adjusting bolt block to 63. Turn adjusting from left brake arm (24) and cylinder rod. Repeat for right side. Avoid over tightening, which will cause erroneous adjustment.
  • Page 360 STEERING DRIVE REASSEMBLY 65. Rotate brake shoe adjustment screw (31) ¼ turn counterclock- wise. Check that there is a 3 mm (0.12 in) gap between brake arm (24) and piston end. 66. Install tool DR06-583, to adjusting screw lock nut (B). 67.
  • Page 361 REASSEMBLY STEERING DRIVE 72. Install front, back and side stiffeners and secure with hardware. Remove aligning studs and install remaining hardware. Torque bolts to 55 NCm (41 lbf ft). 73. Install long connector, with new o-ring, to cylinder port. 74. Install boot down over connector against cover. 75.
  • Page 362 STEERING DRIVE REASSEMBLY 78. Install upper filler tube. 7E - 66...
  • Page 363 INSTALLATION STEERING DRIVE 1. Install inner rock deflector and secure with hardware. Torque bolts to 267 NCm (195 lbf ft). 2. Attach sling and hoist to sprocket install sprocket to carrier securing with hardware. 3. Torque bolts to 455 NCm (335 lbf ft). Remove sling and hoist. 4.
  • Page 364 STEERING DRIVE INSTALLATION 8. Feed harness into hydraulic reservoir box. Reclip harness to reservoir box and rear main frame cover. 9. Apply electrical sealing grease, Grafo 112-X to wire leads and connect to horn (1) switch and equipment (2) filter switch. Reclip to box wall.
  • Page 365 INSTALLATION STEERING DRIVE 12. Position battery box in place on fender with shims that were removed with it and secure with hardware finger tight. REMARK When installing battery box, make sure crossover tubes at left front of rear frame clear bottom floor plate of box. Tubes go inside box.
  • Page 366 STEERING DRIVE INSTALLATION 18. Apply electrical sealing grease, Grafo 112-X to wire lead and connect to drive train pressure filter. Reclamp to box wall. Reclamp wiring harness to inside of battery box. 19. Connect hoses drive train pressure filter. 20. Connect reverse (1) and 1st speed (2) hoses to fittings at bottom and side of trans/steer valve.
  • Page 367 INSTALLATION STEERING DRIVE 24. Install return hose (4) to bottom fitting at neutral start valve. Connect pressure hose to (2) top inlet screen fitting (3) at neutral start valve. Connect left side brake and clutch hoses (1) to fittings on rear main frame cover. 25.
  • Page 368 STEERING DRIVE INSTALLATION 28. Connect throttle cable (1) to overtravel rod (2). 29. Install tube brackets to front seat support. Torque center dNC bolt to 38 NCm (28 lbf ft) ±10% and right ½NC bolts to 92 NCm (70 lbf ft) ±10%. Torque front seat support hardware to 38 NCm (28 lbf ft) ±10%.
  • Page 369 INSTALLATION STEERING DRIVE 32. Remove lifting bracket from front of fuel tank. 33. Connect fuel return hose (3) to fitting at tank. Connect fuel supply hose (2) to shut off valve (1). Open valve. 34. Apply electrical sealing grease, Grafo 112-X to wire leads and connect at back of alarm.
  • Page 370 STEERING DRIVE INSTALLATION 36. Remove cover and feed harness through grommet to fuel level sender switch. Reclip harness to tank. 37. Apply electrical sealing grease, Grafo 112-X to wire leads and connect to switch. 38. Install cover with new gasket and secure with hardware. Torque to 21 NCm (16 lbf ft) ±10%.

  • Page 371: Reassembly

    INSTALLATION STEERING DRIVE 42. Using a rolling floor jack, install transmission guard to machine and secure with hardware. Torque bolts to 92 NCm (70 lbf ft) ±10%. 43. Using hoist, install ROPS on machine securing with hardware (nuts inward) and torque to 822 ±47 NCm (605 ±35 lbf ft). REMARK For a machine equipped with a cab, see Section 13 for cab reassembly.
  • Page 372 STEERING DRIVE INSTALLATION 46. Adjust length of final brake rod (1) so that stop (2) on bellcrank is in contact with mounting bracket (3). Adjust length of main brake link (4) so that top of brake decelerator or brake pedal (5) is 137 mm (5.4 in) (6) from floor (7) as shown.
  • Page 373 INSTALLATION STEERING DRIVE 50. Verify brake adjustment as follows: Connect a portable pump to quick-disconnect fitting in battery box and apply 260 PSI to brake cylinder to release brakes. With throttle lever in high idle position, brake pedal depressed and transmission in first gear. Release brake pedal and start machine rolling.
  • Page 374 STEERING DRIVE BRAKE ADJUSTMENT REMARK Following procedures are to be performed with brake pedal in up, released position unless noted otherwise. 1. Remove front (1) and rear (2) floor mat retainer angles from each side of machine. 2. Remove floor mat. 3.
  • Page 375 BRAKE ADJUSTMENT STEERING DRIVE 6. Rotate (shorten) brake rod (2) until brake pedal free play is eliminated. Lock jam nuts (1). 7. Connect a portable pump to quick-disconnect fitting in battery box and apply 260 PSI to brake cylinder to release brakes. 7.
  • Page 376 STEERING DRIVE BRAKE ADJUSTMENT 9. With transmission in first gear and engine at full throttle, foot brake (A) must stall tracks and at . 71 (B) to 94 (C) mm (2.8 to 3.7 in) from floor plate. If dimension is not obtained, repeat Steps 2 through 6 until it is.
  • Page 377 BRAKE CYLINDER VALVE STEERING DRIVE GENERAL BRAKE CYLINDER VALVE 7E - 81...
  • Page 378 STEERING DRIVE BRAKE CYLINDER VALVE 1. Spool Wiper 7. Outer Metering Spring 13. O-ring 2. Valve Housing 8. End Cover 14. Port Plug 3. Input Spool 9. Spool Return Spring 15. Inner Metering Spring 4. Metering Spool 10. Seal Retainer 16.
  • Page 379 BRAKE CYLINDER VALVE STEERING DRIVE REMOVAL WARNING Be sure blade and any rear mounted equipment has been lowered to the ground or on suitable blocking. Turn the master switch to the off position and remove key. 1. Remove engine left side door. 2.
  • Page 380 STEERING DRIVE BRAKE CYLINDER VALVE 5. Remove return spring. 6. Remove linkage from valve spool. REMARK Tag, cap and plug all disconnected hoses, tubing and fittings. 7. At left side, disconnect two hoses (1 and 2) at foot brake valve (3).
  • Page 381 BRAKE CYLINDER VALVE STEERING DRIVE DISASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 1. Remove two end cover bolts (11) and washers (12) across from each other. Install longer bolts in place. Remove remaining two end cover bolts.
  • Page 382 STEERING DRIVE BRAKE CYLINDER VALVE REASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 1. Install retainer washer (6) and spool stop (5) to spool. 2. Install spool (3) and return spring (9) into valve housing. 3.
  • Page 383 BRAKE CYLINDER VALVE STEERING DRIVE INSTALLATION 1. Install valve to dashboard and secure with hardware. Torque bolts to 21 NCm (16 lbf ft) ±10%. 2. At left side, connect two hoses (1 and 2) to foot brake valve (3). 3. At right side, connect hose (1) to foot brake valve (2). 4.
  • Page 384 STEERING DRIVE BRAKE CYLINDER VALVE 7. Install fuel filter mounting bracket with filter to dashboard. Torque bolts to 21 NCm (16 lbf ft) ±10%. Install dashbrace on left side of machine. Torque bolts to 92 NCm (70 lbf ft) ±10%. Install (2) cable ties for fuel filter hoses and harness.
  • Page 385 DISASSEMBLY ......7 D32E-1, D32P-1, D38E-1 OR D38P-1 ..8 D39E-1 OR D39P-1 ....11 REASSEMBLY .
  • Page 386 FINAL DRIVE GENERAL CROSS SECTION VIEW OF FINAL DRIVE 7F - 2...
  • Page 387 D32E-1 or D38E-1 ........
  • Page 388 FINAL DRIVE GENERAL SERVICE DIAGNOSIS PROBABLE CAUSE REMEDY Final Drive Overheating Improper or insufficient lubricant. Use proper grade and amount of lubricant. Refer to OPERATION & MAINTENANCE MANUAL. Bearing seizure or damaged bearings. Remove final drive and inspect. Noise Improper, dirty or insufficient lubricant. Use proper grade and amount of lubricant.
  • Page 389 REMOVAL FINAL DRIVE REMARK Following procedure is for removal of final drive on one side of machine. Procedure is identical for opposite side. WARNING This procedure requires extreme caution. Use suitable blocking equipment while under confines of machine. WARNING Be sure blade and any rear mounted equipment has been lowered to the ground or on suitable blocking.
  • Page 390 FINAL DRIVE REMOVAL 9. Remove bolts (1) and rear rigid crossbar cap (2). 10. D32E-1, D32P-1, D38E-1 or D38P-1; Reinstall top front cap bolt (1) as a safety measure. Remove four final drive to main frame bolts (2) spacer plate (3).
  • Page 391 FINAL DRIVE DISASSEMBLY EXPLODED VIEW OF FINAL DRIVE 1. O-Ring 6. Spacer 11. Cover 15. Pinion 20. Drain Plug 2. Carrier Shaft 7. Shim 12. Housing 16. Outer Bearing 21. Bottom Cover 3. Seal 8. Washer 12a Filler Plug 17. Inner Bearing 22.
  • Page 392 FINAL DRIVE DISASSEMBLY D32E-1, D32P-1, D38E-1 OR D38P-1 REMARK Callouts from exploded view correspond with callouts in following steps 1. Rest final drive on bench with main frame mounting face down. Assemble safety restraint. 2. Replace two top corner bolts of bottom cover with ½NCx7 bolts.
  • Page 393 DISASSEMBLY FINAL DRIVE 7. Remove sprocket carrier bolt (9), and washer (8) and shim pack (7). REMARK Heat may have to be applied to bolt for removal. 8. Install alignment rod DR10-821 in end of sprocket carrier shaft and bridge over rod and secure to housing. 9.
  • Page 394 FINAL DRIVE DISASSEMBLY 15. Remove oil seal (19) from housing by driving a screwdriver through flange of seal and prying out of housing. 16. Remove retaining ring (18) from housing. 17. Install puller arrangement and draw out pinion shaft (15) with bearing cones and inner cup.
  • Page 395 DISASSEMBLY FINAL DRIVE 22. Install puller arrangement and remove bearing (4) from sprocket carrier shaft. 23. If necessary to replace bearing spacer (6), heat and remove. Press fit requires destroying spacer. 24. If necessary, remove studs from housing. D39E-1 OR D39P-1 REMARK Callouts from exploded view correspond with callouts in following steps...
  • Page 396 FINAL DRIVE DISASSEMBLY 5. Remove sprocket carrier retaining screw (14) and jam nut. Discard retainer screw and replace with new. REMARK Assembly shown rotated for clarity. 6. Position a wedge between housing and sprocket drive gear (13) to prevent gear from rotating. Loosen sprocket carrier bolt (9). REMARK Heat may have to be applied to bolt for removal.
  • Page 397 DISASSEMBLY FINAL DRIVE 11. Thread in puller screws to draw shaft from sprocket drive gear. When shaft groove is visible between gear and housing, reposition lifting strap as shown. 12. Remove sprocket carrier shaft from housing. 13. Install lifting strap through top relief hole in sprocket drive gear and support gear with hoist.
  • Page 398 FINAL DRIVE DISASSEMBLY 17. Remove o-ring (1) from drive pinion face of housing. 18. Remove oil seal (19) from housing by tapping OD of seal toward center and prying out of housing. 19. Remove retaining ring (18) from housing. 20. Following are two possible ways of removal: A) Install a slide hammer in pinion shaft (15).
  • Page 399 DISASSEMBLY FINAL DRIVE 22. Install puller arrangement and remove bearing (4) from sprocket carrier shaft. 23. If necessary to replace bearing spacer (6), heat and remove. Press fit requires destruction of spacer during removal. 24. Install puller arrangement and remove outer bearing (16) from drive pinion.
  • Page 400 REASSEMBLY FINAL DRIVE EXPLODED VIEW OF FINAL DRIVE 1. O-Ring 6. Spacer 11. Cover 15. Pinion 20. Drain Plug 2. Carrier Shaft 7. Shim 12. Housing 16. Outer Bearing 21. Bottom Cover 3. Seal 8. Washer 12a Filler Plug 17. Inner Bearing 22.
  • Page 401 REASSEMBLY FINAL DRIVE D32E-1, D32P-1, D38E-1 OR D38P-1 REMARK Callouts from exploded view correspond with callouts in following steps 1. Block final drive housing in a horizontal position with rear main frame mating face up. Check height of two mounting studs for 65 mm (2.56 in) dimension.
  • Page 402 FINAL DRIVE REASSEMBLY 9. Install sprocket carrier shaft inner (5) and outer (4) bearing cups in housing and using a driver, bottom cups. With lifting strap, position sprocket drive gear (13) in housing with retainer screw hole facing up. Install gear retaining tool DR10-820 to housing and torque bolts to 95 NCm (70 lbf ft).
  • Page 403 REASSEMBLY FINAL DRIVE 16. Assemble and tighten new retainer screw (14) and jam nut (20). Torque retainer screw to 17 NCm (150 lbf in) and jam nut to 80 NCm (60 lbf ft). Continue to lower housing to seat. Remove alignment bridge from housing and pin from shaft.
  • Page 404 FINAL DRIVE REASSEMBLY 22. D32E-1 or D38E-1: Assemble two ¾NF bolts in opposite holes of sprocket carrier shaft (2). Position pry bar to prevent shaft rotation. Torque sprocket carrier shaft retainer bolt to 305 NCm (225 lbf ft). D32P-1 or D38P-1: Assemble two ¾NC bolts in opposite holes of sprocket carrier shaft (2).
  • Page 405 REASSEMBLY FINAL DRIVE 6. Attempt to insert 2.769 mm (0.109 in) retaining ring (18). If possible to insert ring, bump cup back against ring with slide hammer. If shaft rotates freely assembly is complete. 7. Position indicator against bearing cone (17). Set to zero. 8.
  • Page 406 FINAL DRIVE REASSEMBLY 14. Assemble and tighten new retainer screw (14) and jam nut (20). Torque retainer screw to 17 NCm (150 lbf in) and jam nut to 80 NCm (60 lbf ft). Continue to lower housing to seat. Remove gear shims and alignment bridge.
  • Page 407 REASSEMBLY FINAL DRIVE 22. Assemble carrier shaft cover (11) and gasket (10). Secure with hardware. Torque bolts to 60 NCm (45 lbf ft) ±10%. 23. Carefully work shaft oil seal (19) (spring garter facing out) down pinion shaft, being careful not to cut sealing lip surface. Using a suitable driver, press pinion shaft seal flush with surface.
  • Page 408 FINAL DRIVE METAL TYPE FACE SEALS SEAL INSPECTION 1. Check condition of rubber seal rings. If any sign of wear, scratches, nicks, cuts, etc. replace complete seal. Inspect condition of metal ring seal surfaces as follows. Highly polished surfaces of rings must be free of chips, pocks and deep scratches.
  • Page 409 REASSEMBLY FINAL DRIVE SEAL INSTALLATION REMARK Cleanliness is critical when handling seals. Never handle seal with greasy, oily or dirty hands. Do not drop, bump or roughly handle seals. 1. Remove any corrosion or hardened material that may exist on surface (1) that contact rubber rings.
  • Page 410 Section 7E. Install and trim corks in two puller screw holes. 7. D32E-1, D32P-1, D38E-1 or D38P-1; From under machine, remove front cap bolt (2). Place spacer plate (3) in place and install main frame to final drive bolts (1) (qty. four). Torque all to 730 NCm (540 lbf ft).
  • Page 411 INSTALLATION FINAL DRIVE 9. Install inner rock deflector (2) and bolts (1) and torque to 267 NCm (195 lbf ft). 10. Attach eye bolt (1) to hole in sprocket, attach hoist (2) and install sprocket to carrier. Install bolts (3) and torque to 455 NCm (335 lbf ft).
  • Page 412 ELECTRICAL SECTION 8 GENERAL ......2 DESCRIPTION ......2 SPECIFICATIONS .
  • Page 413 ELECTRICAL GENERAL DESCRIPTION The electrical system used on this machine is a 12 volt negative ground system. Warm or Cold Start - Both of these systems have one twelve volt battery. All electrical service is controlled by a master disconnect switch located in a recess in the operators seat front support panel.
  • Page 416 HYDRAULICS SECTION 10 GENERAL ......2 DESCRIPTION ......3 OPERATION .
  • Page 417 HYDRAULICS GENERAL HYDRAULIC SYSTEM 10 - 2...
  • Page 418 GENERAL HYDRAULICS 1. Hydraulic Reservoir 6. Blade Lift Section 11. Anti-Cav Valve 16. Blade Angle Cylinders 2. Suction Strainer 7. Blade Tilt Section 12. ¼ Orifice Check 17. Ripper Cylinders 13. c Orifice Check 3. Gear Pump 8. Blade Angle Section 18.
  • Page 419 Blade Angle Cylinder; D32E-1, D32P-1, D38E-1 or D38P-1 ..... 0.85 to 3.4 cm³/min (0.052 to 0.021 in³/min) D39E-1 or D39P-1 ........1.2 to 4.7 cm³/min (0.073 to 0.28 in³/min) Blade Drift .
  • Page 420 GENERAL HYDRAULICS WORK EQUIPMENT i i Measurement Conditions ‚ Engine at full throttle ‚ Engine coolant temperature in operating range ‚ Hydraulic oil at operating range ‚ Safety lock lever in the locked (down) position ‚ Brake and decelerator pedal locked System Relief Valve Test 1.
  • Page 421 HYDRAULICS GENERAL Cylinder Drift Test The problem of cylinder drift can be traced to two main causes, internal or external leakage. External leakage is not detailed here, since it can be visually located. Internal leakage is not always readily pin pointed to its source and may require a series of tests to isolate the problem.
  • Page 422 GENERAL HYDRAULICS Cylinder Time Cycle Before performing the cylinder time cycle test, perform the CYLIN- DER DRIFT TEST to insure that the control valve and the cylinders are performing satisfactorily. If there is no excessive drift when the blade lift control is in the hold position, but slow lift speed, slow response or low power is present in the raise position, the problem could be either the hydraulic pump or the main pressure relief valve.
  • Page 423 HYDRAULICS GENERAL BLADE EQUIPMENT LEVER i i Measurement Conditions ‚ Engine stopped ‚ Mounted equipment lowered to the ground Raise, Lower and Float Travel Using scale, measure the travel distances from; hold to raise, hold to lower and hold to float at the center top of the lever knob. Raise, Lower and Float Effort Using push pull scale at the base of the knob, measure the maximum effort required when moving the lever from hold to...
  • Page 424 GENERAL HYDRAULICS Angle Degrees Using an angle gauge, measure travel distances in degrees from; hold to right angle and hold to left angle at the center top of the lever knob. Angle Effort Using a torque measuring device, measure the maximum effort required when moving the lever hold to right angle and hold to left angle.
  • Page 425 PUMPS SECTION 10A CHARGE AND SCAVENGE PUMP ..2 GENERAL ......3 REMOVAL .
  • Page 426 PUMPS CHARGE AND SCAVENGE PUMP EXPLODED VIEW OF CHARGE AND SCAVENGE PUMP 10A - 2...
  • Page 427 Type ................Dual Element Gear D32E-1, D32P-1, D38E- or D38P-1 Rated Capacity @ 1977 RPM;...
  • Page 428 PUMPS CHARGE AND SCAVENGE PUMP REMOVAL WARNING Be sure blade and any rear mounted equipment has been lowered to the ground or on suitable blocking. Turn the master switch to the off position and remove key to prevent accidental starting. 1.
  • Page 429 CHARGE AND SCAVENGE PUMP PUMPS 6. Disconnect and cap lines at top and bottom of pump and allow pump to drain into suitable container. Remove mounting hardware and lift pump out of machine. DISASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps.
  • Page 430 PUMPS CHARGE AND SCAVENGE PUMP 8. Remove section o-ring (6) from front plate. 9. Remove back up gasket (11) from front plate. 10. Remove protector gasket (10) from front plate. 11. Remove diaphragm seal (9) from front plate. 12. Turn front plate over. Remove retaining ring (4) from front plate. 13.
  • Page 431 CHARGE AND SCAVENGE PUMP PUMPS 16. Remove front diaphragm (12). 17. Remove idler gear and shaft (19). 18. Tap on front housing (17) and center housing (20) to loosen from dowel pins. Remove front housing. 19. Remove center housing (20) with drive gear and shaft (18). Keyed rear gear will most likely stay with assembly.
  • Page 432 PUMPS CHARGE AND SCAVENGE PUMP 24. Turn center section over. Remove back up gasket (11). 25. Remove protector gasket (10). 26. Remove diaphragm seal (9). 27. Remove section o-ring (6). 28. Remove rear diaphragm (14) from pump. 29. Remove rear gears (22). 30.
  • Page 433 CHARGE AND SCAVENGE PUMP PUMPS INSPECTION 1. Tie bolts (1 and 2), seal repair kit (4 through 14) and seal retainer washer (25) are only serviced parts. If any other part other than these need replacement, replace complete pump. 2. Clean all parts and dry thoroughly with compressed air. Inspect edges and faces of gears for scoring or roughness.
  • Page 434 PUMPS CHARGE AND SCAVENGE PUMP 6. Position protector gasket (10) over diaphragm seal. Using dull tool, carefully press gasket into diaphragm seal and bottom. Use air to blow any gasket particles which may have been trimmed off during seating of gasket. 7.
  • Page 435 CHARGE AND SCAVENGE PUMP PUMPS 14. Install driven gear and shaft (19). 15. Aligning match marks, install front housing (17) over gears on dowel pins. 16. Install front diaphragm (12), bronze face down to shafts. 17. Using a dull tool, tuck the diaphragm seal (9) into grooves of front plate so the open part of "U"...
  • Page 436 PUMPS CHARGE AND SCAVENGE PUMP 22. Aligning match marks, install front plate (3) over dowels to front housing. 23. Install tie bolts (1 and 2) and torque to 54 to 68 NCm (40 to 50 lbf ft). 24. Start oil seal (5) over shaft into front plate. 25.
  • Page 437 CHARGE AND SCAVENGE PUMP PUMPS 30. Install new mounting o-ring to pump. INSTALLATION 1. Install pump to torque converter being careful not to damage o- ring and secure with hardware. Torque bolts to 92 NCm (70 lbf ft) ±10%. Reconnect lines at pump. 2.
  • Page 438 PUMPS EQUIPMENT PUMP EXPLODED VIEW OF EQUIPMENT PUMP 10A - 14...
  • Page 439 D32E-1, D32P-1, D38E-1 or D38P-1 @ 1977 RPM ....... . .
  • Page 440 PUMPS EQUIPMENT PUMP REMOVAL WARNING Be sure blade and any rear mounted equipment has been lowered to the ground or on suitable blocking. Turn the master switch to the off position and remove key. 1. Drain hydraulic reservoir. Refer to the OPERATION & MAINTE- NANCE MANUAL.
  • Page 441 EQUIPMENT PUMP PUMPS 6. Disconnect and cap lines at top and bottom of pump and allow pump to drain into suitable container. Remove hardware and lift pump out of machine. DISASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps.
  • Page 442 PUMPS EQUIPMENT PUMP 6. Remove back up gasket (7) from front plate. 7. Remove protector gasket (6) from front plate. 8. Remove diaphragm seal (4) from front plate. 9. Turn front plate over and rest on wooden blocks. Using a punch drift, remove shaft seal (5) from front plate.
  • Page 443 EQUIPMENT PUMP PUMPS 14. Remove thrust plate (9) and section o-ring (3) from back plate (17). INSPECTION 1. Tie bolts (10 and 11) and seal repair kit (1 through 9) are only serviced parts. If any other part other than these need replace- ment, replace complete pump.
  • Page 444 PUMPS EQUIPMENT PUMP 6. Using a dull tool, tuck the diaphragm seal (4) into grooves of front plate so the open part of "U" section is down. 7. Position protector gasket (6) over diaphragm seal. Using dull tool, carefully press gasket into diaphragm seal and bottom. Use air to blow any gasket particles which may have been trimmed off during seating of gasket.
  • Page 445 EQUIPMENT PUMP PUMPS 12. Install mounting bolts (10 and 11) and torque to 54 to 68 NCm (40 to 50 lbf ft). 13. Start oil seal (5) over shaft into front plate. 14. Using a deep well socket, bottom seal into front plate. 15.
  • Page 446 PUMPS EQUIPMENT PUMP 2. Using rolling floor jack, install transmission guard to machine and secure with hardware. Torque bolts to 92 NCm (70 lbf ft) ±10%. 3. Install operators compartment floor plate. Torque bolts to 38 NCm (28 lbf ft) ±10%. 4.
  • Page 447 CONTROL VALVE SECTION 10B REMOVAL ......2 COMPLETE ASSEMBLY ....10 DISASSEMBLY .
  • Page 448 CONTROL VALVE REMOVAL WARNING Be sure blade and any rear mounted equipment has been lowered to the ground or on suitable blocking. Turn the master switch to the off position and remove key. 1. Drain hydraulic reservoir. Refer to the OPERATION & MAINTE- NANCE MANUAL.
  • Page 449 REMOVAL CONTROL VALVE 6. Disconnect front and rear light harness (1) from main harness (2). Cut tie strap (3) and remove from clip. 7. Attach four leg chain and hoist to ROPS lifting brackets. Remove mounting hardware and lift ROPS from machine. REMARK For a machine equipped with a cab, see Section 13 for cab removal.
  • Page 450 CONTROL VALVE REMOVAL 11. Disconnect battery cable (1) and ground cable (2) from discon- nect switch (3). Remove battery cable from machine. 12. Release tube brackets from front seat support. 13. Disconnect throttle cable (1) from overtravel rod (2). 14. At lower left side of seat support disconnect throttle cable from support.
  • Page 451 REMOVAL CONTROL VALVE 15. Remove hardware and seat support from machine. 16. Remove right front access cover. 17. Open reservoir door. Disconnect door lock from inside cavity. 18. Remove door hinge inside mounting hardware and lift door from machine. 19. Remove drive train dipstick. 10B - 5...
  • Page 452 CONTROL VALVE REMOVAL 20. Remove filler tube from rear cover and cap opening. REMARK Mark, cap and plug all disconnected lines. 21. Disconnect four hoses at tubes. 22. RIPPER: Disconnect hoses at valve and position out of the way. 23. Disconnect top tube (1) from angle section valve and remove. Disconnect bottom tube (2) from angle section valve and remove.
  • Page 453 REMOVAL CONTROL VALVE 29. Through access cover disconnect inlet tube at elbow. 30. Disconnect tube inlet tube from hose and remove. 31. Loosen jam nut at outlet elbow. 32. Remove reservoir breather (1) and filler cap (2). 33. Remove filter and switch lead from header. 34.
  • Page 454 CONTROL VALVE REMOVAL 37. Remove boot and mounting. 38. Remove forward lower mounting bolt. 39. Remove remaining and carefully remove from machine. 40. Position control valve in vise 41. Disconnect lift link from spool. Discard cotter pin and replace with new. 10B - 8...
  • Page 455 REMOVAL CONTROL VALVE 42. Disconnect tilt link from spool. Discard cotter pin and replace with new. 43. Disconnect angle link from spool. Discard cotter pin and replace with new. 44. Remove mounting hardware and lift linkage assembly from control valve. 10B - 9...
  • Page 456 CONTROL VALVE COMPLETE ASSEMBLY DISASSEMBLY 1. Position valve bank on bench. Remove nuts (7) and slide inlet cover (1) off tie bolts. 2. Slide blade lift section (3) off tie bolts. Remove and discard between section o-rings. 3. Slide blade tilt section (4) off tie bolts. Remove and discard between section o-rings.
  • Page 458 CONTROL VALVE COMPLETE ASSEMBLY 10B - 12...
  • Page 459 COMPLETE ASSEMBLY CONTROL VALVE 5 If equipped, slide ripper section (8) off tie bolts. Remove and discard between section o-rings. REASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 1. Position outlet cover (6) with tie bolts (7) facing up. Install new between section o-ring kit.
  • Page 460 CONTROL VALVE COMPLETE ASSEMBLY 4. Install blade tilt section (4) down over bolts on top of end cover. Install new between section o-ring kit. 5. Install blade lift section (3) down over bolts on top of end cover. Install new between section o-ring kit. Install inlet cover (1) and secure with nuts.
  • Page 462 CONTROL VALVE SYSTEM RELIEF VALVE 10B - 16...
  • Page 463 SYSTEM RELIEF VALVE CONTROL VALVE DISASSEMBLY 1. Remove system relief valve (2) from inlet cover (1). REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 2. Position relief valve in vise, adjusting end up. 3. While holding adjusting screw (7), remove jam nut (6). 4.
  • Page 464 CONTROL VALVE SYSTEM RELIEF VALVE 9. Remove o-ring (15) and back up ring (16) from main poppet (3) and discard. 10. Remove o-ring (12) from end cap (5) and discard. 11. Remove o-ring (11) from adjusting screw (7) and discard. 12.
  • Page 465 SYSTEM RELIEF VALVE CONTROL VALVE 5. Install main poppet (3) with filter screen (1) into valve body. 6. Install main poppet spring (18). 7. Install end cap (5). 8. Install pilot poppet (8) and spring (19). 9. Install adjusting screw (7) half way into end cap. REMARK Final adjustment of system relief valve will have to be made with control valve reinstalled into machine.
  • Page 466 CONTROL VALVE BLADE LIFT SECTION CROSS SECTION VIEW OF DETENT POSITIONER 10B - 20...
  • Page 468 CONTROL VALVE BLADE LIFT SECTION 10B - 22...
  • Page 469 BLADE LIFT SECTION CONTROL VALVE DISASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 1. Position valve section in vise. Remove hardware and detent housing (10). 2. Install shipping/retainer plate, 1299240H1, (7) over spool spring retainer and secure with bolts.
  • Page 470 CONTROL VALVE BLADE LIFT SECTION 9. Remove detent ball follower (19) and detent spring (20). 10. Remove section spool (8) from valve body. 11. Remove anti-cavitation valve (3) from valve body. Disassemble as follows: Separate check poppet (3/7), poppet spring (3/8), check ball retainer (3/10) and check ball (3/9) from body (3/6).
  • Page 472 CONTROL VALVE BLADE LIFT SECTION 10B - 26...
  • Page 473 BLADE LIFT SECTION CONTROL VALVE 2. Install anti-cavitation valve (3) at housing end as follows. Install check poppet (3/7) and poppet spring (3/8) into valve bore. Install check ball retainer (3/10) with new back up rings (3/4) and o-ring seal (3/5) into valve bore. Install check ball (3/9) into retainer in valve bore.
  • Page 474 CONTROL VALVE BLADE LIFT SECTION 7. Install detent sleeve (15) engaging seal ring (16) in bottom groove. 8. Coat four detent balls (21) with grease and position in holes in spool. 9. Position retainers (12 and 14) and spring (13) on spool. 10.
  • Page 476 CONTROL VALVE BLADE TILT SECTION 10B - 30...
  • Page 477 BLADE TILT SECTION CONTROL VALVE DISASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 1. Position blade tilt section in vise. Remove hardware and spool positioner housing (9). 2. Install shipping/retainer plate, 1299240H1, (6) over spool spring retainer and secure with bolts.
  • Page 478 CONTROL VALVE BLADE TILT SECTION LOAD CHECK VALVE 1. O-ring Seal 4. Back Up Ring 7. Check Poppet 2. Back Up Ring 5. O-ring Seal 8. Check Poppet Spring 3. O-ring Seal 6. Valve Body 10B - 32...
  • Page 479 BLADE TILT SECTION CONTROL VALVE Install check ball body (2/6) with new o-ring seal (2/1), back up ring (2/2), o-ring seal (2/3), back up rings (2/4) and o-ring seal (2/5) into valve bore. 2. Insert spool (7) into bore and remove collar (10). 3.
  • Page 480 CONTROL VALVE BLADE ANGLE OR RIPPER SECTION DISASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 1. Position blade angle or ripper section in vise. Remove hardware and spool positioner housing (9). 2. Install shipping/retainer plate, 1299240H1, (6) over spool spring retainer and secure with bolts.
  • Page 482 CONTROL VALVE BLADE ANGLE OR RIPPER SECTION 10B - 36...
  • Page 483 BLADE ANGLE OR RIPPER SECTION CONTROL VALVE ANTI-CAVITATION VALVE 1. O-ring Seal 5. O-ring Seal 9. Check Ball 2. Back Up Ring 6. Check Ball Body 10. Check Ball Retainer 3. O-ring Seal 7. Check Poppet 4. Back Up Ring 8.
  • Page 484 CONTROL VALVE BLADE ANGLE OR RIPPER SECTION Install check ball retainer (2/10) with new back up rings (2/4) and o-ring seal (2/5) into valve bore. Install check ball (2/9) into retainer in valve bore. Install check ball body (2/6) with new o-ring seal (2/1), back up ring (2/2) and o-ring seal (2/3) into valve bore.
  • Page 485 INSTALLATION CONTROL VALVE 1. With spool seals flush in bore install linkage and secure with hardware. Torque bolts to 10 NCm (8 lbf ft) ±10%. 2. Attach linkage links to valve spools with pin and new cotter. 3. Position assembly in reservoir box and secure with hardware. Torque bolts to 21 NCm (16 lbf ft) ±10%.
  • Page 486 CONTROL VALVE INSTALLATION 7. Secure filter header to mounting bracket with hardware. Torque bolts to 38 NCm (28 lbf ft) ±10%. Connect elbow to reservoir inlet. 8. Install new filter to header, refer to OPERATION & MAINTE- NANCE MANUAL. Apply electrical sealing grease, Grafo 112-X to header lead and connect to terminal.
  • Page 487 INSTALLATION CONTROL VALVE 15. Connect lower then upper tubes to control valve. 16. Connect crossover tubes to installed tubes. 17. Fish bottom tilt tube (2) through box and connect to control valve. Fish top tilt tube (1) through box and connect to control valve.
  • Page 488 CONTROL VALVE INSTALLATION 23. Position door in place and secure hinge to reservoir. Torque bolts to 38 NCm (28 lbf ft) ±10%. 24. Connect door locking mechanism to box. 25. Install right access panel. Torque bolts to 38 NCm (28 lbf ft) ±10%.
  • Page 489 INSTALLATION CONTROL VALVE 28. Connect throttle cable (1) to overtravel rod (2). 29. Install tube brackets to front seat support. Torque center dNC bolt to 38 NCm (28 lbf ft) ±10% and right ½NC bolts to 92 NCm (70 lbf ft) ±10%. Torque front seat support hardware to 38 NCm (28 lbf ft) ±10%.
  • Page 490 CONTROL VALVE INSTALLATION 32. Install seat and secure with hardware. Torque bolts to 38 NCm (28 lbf ft) ±10%. 33. Install armrests and bracket. Torque bolts to 38 NCm (28 lbf ft) ±10%. 34. Using hoist, install ROPS on machine securing with hardware (nuts inward) and torque to 822 ±47 NCm (605 ±35 lbf ft).
  • Page 491 INSTALLATION CONTROL VALVE 47. Install operators compartment floor plate. Torque bolts to 38 NCm (28 lbf ft) ±10%. 48. Install floor mat. 49. Install front (1) and side (2) floor mat retainer angles at each side of machine. Torque bolts to 38 NCm (28 lbf ft) ±10%. 50.
  • Page 492 CYLINDERS SECTION 10C BLADE EQUIPMENT ....2 SPECIFICATIONS ..... 3 REMOVAL .
  • Page 493 CYLINDERS BLADE EQUIPMENT EXPLODED AND CROSS SECTION VIEWS OF BLADE LIFT, TILT OR ANGLE CYLINDER 10C - 2...
  • Page 494 Tilt Cylinder - ALL ..........88.9 x 144.272 mm (3.5 x 5.68 in) Angle Cylinder - D32E-1, D32P-1, D38E-1, or D38P-1 ..... 76.2 x 352.044 mm (3 x 13.86 in) Angle Cylinder - D39E-1 or D39P-1 .
  • Page 495 CYLINDERS BLADE EQUIPMENT 2. Using retainer tool, relieve torque on gland retainer. Refer to SPECIFICATIONS for tool number. 3. Remove rod end anchor bolt. 4. Using ½NC eye bolt, remove rod end pin. 5. Remove piston end anchor bolt. Cylinder may have to be jockeyed around to allow bolt clearance.
  • Page 496 BLADE EQUIPMENT CYLINDERS 6. Using ½NC eye bolt, remove piston end pin. 7. Attach hoist and sling to cylinder and remove. DISASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 1. Mount cylinder in vise. Remove port plug and allow to drain into a suitable container.
  • Page 497 CYLINDERS BLADE EQUIPMENT 3. Unthread gland retainer (1) and position out at end of rod. 4. Pull rod (15) with gland (2) and piston (13), out of cylinder barrel. 5. Position rod in vise. Break torque on piston lock nut. 6.
  • Page 498 BLADE EQUIPMENT CYLINDERS 9. Remove and discard wear rings (9) from piston. 10. Cut piston seal ring (10) and remove and discard. 11. Remove and discard o-ring (11) from piston. 12. Remove and discard back up ring (7) from gland. 13.
  • Page 499 CYLINDERS BLADE EQUIPMENT 17. Remove and discard o-ring (6) from gland. 18. Remove and discard wear ring (12) from gland. 19. If not already done, discard all o-rings, seals and rings. Clean all remaining parts in solvent and dry thoroughly with compressed air.
  • Page 500 Tilt - ALL ....597 to 651 NCm (440 to 480 lbf ft) Angle - D32E-1 or D32P-1 . . . 448 to 502 NCm (330 to 370 lbf ft) Angle - D38E-1 or D38P-1 .
  • Page 501 CYLINDERS BLADE EQUIPMENT INSTALLATION REMARK Installation of cylinders are similar with tilt cylinder shown. 1. Using hoist and sling, position cylinder in place on machine. 2. Install mounting pin using eye bolt to align anchor bolt mounting holes. 3. Install anchor bolt and secure with nut. Torque bolt to 60 NCm (45 lbf ft) ±10%.
  • Page 502 BLADE EQUIPMENT CYLINDERS 5. Install anchor bolt and secure with nut. Torque bolt to 60 NCm (45 lbf ft) ±10%. 6. Using retainer tool, make sure gland retainer is up to torque value given in SPECIFICATIONS, using the following formula. R = T L ÷...
  • Page 503 CYLINDERS RIPPER EXPLODED AND CROSS SECTION VIEWS OF RIPPER CYLINDER 10C - 12...
  • Page 504 RIPPER CYLINDERS 8. O-Ring 1. Retainer Ring 15. Lock Nut 2. Cylinder Gland 9. Wear Ring 16. Rod Bushing 3. Rod Wiper 17. Cylinder Rod 10. Seal Ring 4. Rod Seal 18. Barrel Bushing 11. O-Ring 19. Cylinder Barrel 5. Buffer Ring 12.
  • Page 505 CYLINDERS RIPPER DISASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 1. Position cylinder in vise. Pull out rod to drain remaining oil into suitable container. Using a 3 in. spanner wrench, rotate gland (2) and remove retainer ring (1).
  • Page 506 RIPPER CYLINDERS 7. Remove gland (2) from rod. 8. Remove and discard wear rings (9) from piston. 9. Cut, remove and discard seal ring (10) from piston. 10. Remove and discard o-ring (11) from piston. 11. Remove and discard back up ring (7) from gland. 12.
  • Page 507 CYLINDERS RIPPER 13. Pop out and discard rod wiper (3) from gland. 14. Remove and discard rod seal (4) from gland. 15. Remove and discard buffer ring (5) from gland. 16. Remove and discard o-ring (6) from gland. 17. Remove and discard wear ring (12) from gland. BUSHINGS Cylinder Barrel 1.
  • Page 508 RIPPER CYLINDERS 2. Position bushing in barrel and using suitable driver, press in flush with edge of barrel. Turn over barrel and repeat for remaining bushing. Cylinder Rod 1. Position rod in press and remove both bushings at same time. 2.
  • Page 509 CYLINDERS RIPPER 3. Work buffer ring (5), with lip facing in, into groove under o-ring. 4. Install rod seal (4) with expander (o-ring) facing towards wear ring. Squeeze sides of seal together and start into groove. Work remainder in with thumbs. 5.
  • Page 510 RIPPER CYLINDERS 10. For ease of assembly, soak piston seal ring (10) in water heated to 82 to 93EC (180 to 200EF) until it is pliable. Install heated seal ring into piston groove over inner o-ring, using shim stock, wrapped around end of piston. 11.
  • Page 511 POWER SECTION 12 ENGINE ....... 2 STANDARD VALUE TABLE D32E AND D32P ....2 D38E AND D38P .
  • Page 512 POWER ENGINE STANDARD VALUE TABLE FOR ENGINE - D32E AND D32P Machine models D32E-1/P-1 Engine model 4D102E-1 Standard value for Item Measurement condition Unit Service limit value new machine ‚ High idle 2650 to 2780 2650 to 2780 Engine speeds ‚...
  • Page 513 ENGINE POWER STANDARD VALUE TABLE FOR ENGINE - D38E AND D38P Machine models D38E-1/P-1 Engine model S4D102E-1 Standard value for Item Measurement condition Unit Service limit value new machine ‚ High idle 2600 to 2770 2600 to 2770 Engine speeds ‚...
  • Page 514 POWER ENGINE STANDARD VALUE TABLE FOR ENGINE - D39E AND D39P Machine models D39E-1/P-1 Engine model S4D102E-1 Standard value for Item Measurement condition Unit Service limit value new machine ‚ High idle 2350 to 2465 2350 to 2465 Engine speeds ‚...
  • Page 515 ENGINE POWER REMOVAL WARNING Be sure blade and any rear mounted equipment has been lowered to the ground or on suitable blocking. Turn the master switch to the off position and remove key. 1. Drain hydraulic reservoir. Refer to the OPERATION & MAINTE- NANCE MANUAL.
  • Page 516 POWER ENGINE 5. From inside of engine compartment relieve tension from the tie down rod (1) and compression ball (2). Disconnect mounting bracket (3) hardware and remove bracket, rod and ball. Repeat for opposite side. 6. Remove air inlet cap (1) from inlet pipe. Remove hood rear mounting hardware (2).
  • Page 517 ENGINE POWER 12. Install sling (1) through pull hook on crankcase guard and position around lift cylinders. Attach hoist to sling. 13. From under machine, carefully remove hardware and slowly lower guard to ground. Pull guard out front of machine, attach hoist and remove.
  • Page 518 POWER ENGINE 18. Remove upper fan shroud. 19. Through access hole in frame disconnect and remove radiator lower hose. REMARK Lower radiator shroud removed for clarity. 20. Remove rear cover. 21. Disconnect front and rear light harness (1) from main harness (2).
  • Page 519 ENGINE POWER 23. Using a rolling floor jack, remove transmission guard from under machine 24. Disconnect final brake rod (1) from bellcrank (2). 25. Remove dash brace bar from right side of machine. 26. Cut cable tie holding hoses to left dash brace. Remove fuel filter mounting block from dashboard and roll forward.
  • Page 520 POWER ENGINE 30. D32E-1 or D32P-1; Disconnect wiring lead from switch at air cleaner outlet pipe. 30. D38E-1, D38P-1, D39E-1 or D39P-1; Disconnect wiring lead from switch at air cleaner outlet pipe. 31. D32E-1 or D32P-1: Disconnect elbow at air intake manifold.
  • Page 521 ENGINE POWER REMARK Tag, cap and plug all disconnected hoses, tubing and fittings. 32. At left side, disconnect two hoses (1 and 2) at foot brake valve (3). 33. At right side, disconnect remaining hose (1) at foot brake valve (2).
  • Page 522 POWER ENGINE 40. Disconnect, cap and plug front half of reservoir to pump hose at top port of equipment pump. 41. Remove mounting hardware and drive shaft. 42. Disconnect, cap and plug pump to equipment valve hose at bottom port of equipment pump. 43.
  • Page 523 ENGINE POWER 47. Disconnect and remove battery cable at cranking motor terminal. 48. Unclip battery cable from converter housing and position out of the way. 49. Disconnect rear harness from mounting block. 50. Disconnect, plug and cap fuel inlet (1) and outlet (2) lines. 12 - 13...
  • Page 524 POWER ENGINE 51. Remove horn and bracket from main frame. 52. Disconnect wiring lead at horn terminal. 53. Unclip horn harness at top and bottom corners of radiator. Tape a feeder line of sufficient length to horn harness. From engine side of radiator, pull horn harness through. Remove feeder line from harness position out of the way.
  • Page 525 ENGINE POWER 56. Remove front engine mounting bolt from each side of machine. 57. Using hoist and load leveler, slowly remove engine with torque converter from machine carefully checking for snagging or binding. Place engine on work stand. For further detailed information, refer to the ENGINE SHOP MANUAL.
  • Page 526 POWER ENGINE ENGINE MOUNTING - D32E-1 OR D32P-1 ENGINE MOUNTING - D38E-1, D38P-1, D39E-1 OR D39P-1 12 - 16...
  • Page 527 ENGINE POWER INSTALLATION 1. Clean rear mounting surface at each side of machine. Install aligning stud (1) to mount. Over stud position bottom portion of new bushing (2) with spacer (3). REMARK Make from eNCx5 bolt 24 883 R1 by removing Aligning stud : head and cutting a slot in its place.
  • Page 528 POWER ENGINE REMARK Install bushing and hardware on one side of engine at a time. 5. Install top portion of new front bushing (1) over spacer. Remove aligning stud. Secure with hardware. Repeat for remaining rear side. 6. Torque front engine mounting bolts to 92 NCm (70 lbf ft). 7.
  • Page 529 ENGINE POWER 9. Tape feeder line to horn harness. From blade side of radiator, pull horn harness through. Remove feeder line from harness. Clip horn harness at top and bottom corners of radiator. 10. Apply electrical sealing grease, Grafo 112-X to terminal and connect to horn.
  • Page 530 POWER ENGINE 14. Connect battery cable to converter housing and toque bolts to 46 NCm (34 lbf ft) ±10%. 15. Apply electrical sealing grease, Grafo 112-X to battery cable and connect at cranking motor terminal. Torque nut to 16 NCm (12 lbf ft) ±10%.
  • Page 531 20. Connect pump to equipment valve hose to bottom port of equipment pump. 21. Install drive shaft with mounting hardware. Torque D32E-1, D32P-1, D38E-1 or D38P-1 bolts to 33 NCm (24 lbf ft). Torque D39E-1 or D39P-1 bolts to 57 NCm (42 lbf ft).
  • Page 532 28. At right side, connect hose (1) to foot brake valve (2). 29. At left side, connect two hoses (1 and 2) to foot brake valve (3). 30. D32E-1 or D32P-1; Remove cover from inlet manifold and connect elbow. 31. D38E-1, D38P-1, D39E-1 or D39P-1; Remove cover from turbocharger (2) and connect hose (3) and secure with hose clamp (1).
  • Page 533 ENGINE POWER 33. D38E-1, D38P-1, D39E-1 or D39P-1; Apply electrical sealing grease, Grafo 112-X to wiring lead and connect to switch at air cleaner outlet pipe. 34. Connect dual harness lead. 35. Connect instrument panel harness to bracket at rear of engine. 26.
  • Page 534 POWER ENGINE 40. Using a rolling floor jack, install transmission guard to machine and secure with hardware. Torque bolts to 92 NCm (70 lbf ft) ±10%. 41. Using hoist, install ROPS on machine securing with hardware (nuts inward) and torque to 822 ±47 NCm (605 ±35 lbf ft). REMARK For a machine equipped with a cab, see Section 13 for cab reassembly.
  • Page 535 ENGINE POWER 44. Install radiator guard. Torque bolts to 92 NCm (70 lbf ft) ±10%. 45. Position crankcase guard under machine. 46. Install sling (1) through pull hook on crankcase guard and position around lift cylinders. Attach hoist to sling and lift guard in place and secure.
  • Page 536 POWER ENGINE 49. Install front (1) and side (2) floor mat retainer angles at each side of machine. Torque bolts to 38 NCm (28 lbf ft) ±10%. 50. Install hood to machine. Remove eye bolts from hood. 51. Install air inlet cap (1) to inlet pipe. Install hood rear mounting hardware (2) loosely.
  • Page 537 ENGINE POWER 42. Install engine right side door. Torque bolts to 38 NCm (28 lbf ft) ±10%. 43. Refill hydraulic and drive train systems with proper fluid, refer to the OPERATION & MAINTENANCE MANUAL. 12 - 27...
  • Page 538 POWER THROTTLE ADJUSTMENT Adjust brake and decelerator pedal (1) to the specified height. Adjust bolt (2) so that threaded tab (3) of throttle control bellcrank is vertical. Place throttle lever (4) in detented LOW IDLE position. Adjust stop bolt (5) so that it just contacts throttle lever and lock in place.
  • Page 540 POWER THROTTLE 12 - 30...
  • Page 541 THROTTLE POWER FUEL CONTROL LINKAGE i i Measurement Conditions ‚ Engine stopped ‚ Safety lock lever in the locked (down) position ‚ Mounted equipment lowered to the ground Lever Travel Measure travel distance with scale from low idle to high idle at the center tip of the lever knob.
  • Page 542 UNDERCARRIAGE SECTION 14 GENERAL ........2 SERVICE .
  • Page 543 UNDERCARRIAGE GENERAL EXPLODED VIEW OF UNDERCARRIAGE 7. Mounting Pin 13. Wear Bar Shim 19. Counterweight 1. Track Frame 8. Front Crossbar 14. Thrust Plate 20. Roller Shield 2. Retaining Ring 9. Track Roller 15. Thrust Plate Shim 21. Track Adjuster Cover 3.
  • Page 544 DESCRIPTION D32E-1 track frame has five track rollers attached to it. The remaining models have six track rollers attached to it. The track spring housing is a permanent welded part of the track frame, with the heavy coil spring being trapped within it.
  • Page 545 UNDERCARRIAGE SERVICE DIAGNOSIS GENERAL COMPLAINT PROBABLE CAUSE REMARKS Track Chain Comes Off During Operation Track chain loose. Adjust tension. Refer to OPERATION & MAINTE- NANCE MANUAL. Front idler worn. Inspect front idler for wear. Repair or replace as necessary. Front idler misaligned. Inspect idler for excessive wear or distortion.
  • Page 546 SERVICE DIAGNOSIS UNDERCARRIAGE Track Rollers Do Not Rotate Insufficient lubrication. Lubricate per the OPERATION & MAINTENANCE MANUAL. Dirt or mud packed tight against rollers. Remove dirt or mud. Internal seizure. Remove rollers and inspect parts. Thoroughly clean and replace parts as necessary. Front Idler Does Not Rotate Insufficient lubrication.
  • Page 547 UNDERCARRIAGE WEAR LIMIT CHECKS SPECIFICATIONS - D32E-1, D32P-1, D38E-1 OR D38P-1 STANDARD GROUSER HEIGHT 100% REMAINING 53.6 mm (2.11 in) 25% REMAINING 30.2 mm (1.19 in) 75% REMAINING 46.0 mm (1.81 in) 0% REMAINING 22.4 mm (0.88 in) 50% REMAINING 38.1 mm (1.50 in)
  • Page 548 WEAR LIMIT CHECKS UNDERCARRIAGE SPECIFICATIONS - D39E-1 OR D39P-1 STANDARD GROUSER HEIGHT 100% REMAINING 53.6 mm (2.11 in) 25% REMAINING 30.2 mm (1.19 in) 75% REMAINING 46.0 mm (1.81 in) 0% REMAINING 22.4 mm (0.88 in) 50% REMAINING 38.1 mm (1.50 in) WEAR FACTOR 31.2 mm (1.23 in) LINK HEIGHT...
  • Page 549 UNDERCARRIAGE WEAR LIMIT CHECKS GENERAL Track components have a certain dimension when new. As wear occurs dimensions will decrease (or increase in case of track pitch and front idler flange height) until a decision must be made whether to rebuild or recondition components, replace them or run them to destruction.
  • Page 550 WEAR LIMIT CHECKS UNDERCARRIAGE INTERNAL PIN AND BUSHING WEAR (PITCH) REMARK To measure track pitch, chain must be tight. Place end of 3 m (10 ft) tape (1) on front of one track pin and measure length of four links to front of fifth track pin. Refer to SPECIFICATIONS. FRONT IDLER FLANGE HEIGHT Insert 305 mm (12 in) scale (1) in squeeze bar (2).
  • Page 551 UNDERCARRIAGE FRONT IDLER EXPLODED VIEW OF FRONT IDLER LEGEND FOR EXPLODED AND CROSS SECTION VIEWS 1. Front Idler 4. Port Plug 7. O-Ring 2. Bushing 5. Thrust Washer 8. Mounting Support 3. Idler Shaft 6. Seal Kit 9. Roll Pin 14 - 10...
  • Page 552 D32E-1, D32P-1 ........
  • Page 553 UNDERCARRIAGE FRONT IDLER REMOVAL 1. Remove track chain per SECTION 15. It is only necessary to lift chain free from front idler. Disconnect fork (1) from both sides of front idler (2). Remove thrust plates (3) and shims both sides of front idler. 2.
  • Page 554 FRONT IDLER 3. Remove bottom wear bar and shims. Drive roll pin (9) from mounting support (8). h eye bolts and hoist to mounting support (8). Pry up on suppor while carefully applying hoist. This is necessary to overcome dra caused by o-ring inside support.
  • Page 555 UNDERCARRIAGE FRONT IDLER 7. Remove seal half (6) and discard. 8. Using hoist and eye bolts, lift idler (1) from shaft. Remove and discard remaining seal half. 9. Remove seal half (5) from mounting support. 10. Remove thrust washer (5). 11.
  • Page 556 FRONT IDLER UNDERCARRIAGE 12. Remove lower wear bar and shims. Drive roll pin (9) from mounting support. is necessary to overcome internal o-ring drag. Remove and discard o-ring (7) from each mounting support. REMARK enever inspection or a new seal used. Refer to metal type face seals in this...
  • Page 557 UNDERCARRIAGE FRONT IDLER CLEARANCES FRONT IDLER BUSHING CLEARANCES Remove the bushings in idler body and replace with new. Coat 19 to 25 mm (0.75 to 1 in) of outer idler hub bores with Loctite #609. Coat 19 to 25 mm (0.75 to 1 in) of leading edge of bushing (edge which engages bore first) with Loctite #609, Position in press and install bushings 0.762 mm (0.030 in) below washer face surface.
  • Page 558 FRONT IDLER UNDERCARRIAGE D32E-1, D32P-1, D38E-1 or D38P-1 END CLEARANCE A. Pin to Pin Holes in Shaft 8.806 to 8.797 in. 223.672 to 223.444 mm MINUS (!) MINUS (!) B. Pin Hole to Washer Face of Support 2.916 to 2.928 in.
  • Page 559 UNDERCARRIAGE FRONT IDLER REASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 1. Install new o-ring (7) into mounting support and coat with amber grease. Apply a thin coat of "Never Seez" to shaft bore. 2.
  • Page 560 FRONT IDLER UNDERCARRIAGE 6. Install mounting support (8) with shaft (3) into front idler (1). Install SEALS in this section. Coat thrust washer (5) with a light film of clean oil and install on shaft up 9. Install new o-ring (7) into mounting supp Apply a thin coat of "Never Seez"...
  • Page 561 UNDERCARRIAGE FRONT IDLER 11. Install support (8) onto shaft. 12. Reposition support to shaft and temporarily secure with aligning dowel. 13. Reposition idler as shown. Remove aligning dowel. Press down on support (8) while driving in roll pin (9). This will energize each seal. 14.
  • Page 562 FRONT IDLER UNDERCARRIAGE 16. Fill idler with recommended oil, refer to OPERATION & MAINTENANCE MANUAL. 17. Rotate mounting support five to ten revolutions to distribute oil. Check level and add as required. Proper level is when fill hole at vertical, oil level should be at base of fill plug hole.
  • Page 563 UNDERCARRIAGE FRONT IDLER INSTALLATION FRONT IDLER INSTALLATION A. Roller Equalized Within Track Frame B. Thrust Plate to Track Frame gap ......... . 0.152 to 0.762 mm (0.006 to 0.030 in) C.
  • Page 564 FRONT IDLER UNDERCARRIAGE 3. Measure distance between top of wear bar mounting surface (1) and bottom of mounting block (2) at three places. Read, average and record measurements. Repeat for remaining side. REMARK Fill port plug side is determined as outer side of front idler. 4.
  • Page 565 UNDERCARRIAGE FRONT IDLER 8. Torque bolts to 87 NCm (64 lbf ft). 9. Using large outside calipers (1) from undercarriage tool kit, measure distance between outside of mounting blocks (2) at front and rear. 10. Read, average and record measurements. 11.
  • Page 566 FRONT IDLER UNDERCARRIAGE 13. Measure shims (1) for thickness. 14. Install thrust plate (1) and shims (2) and secure with hardware. Repeat for remaining side. 15. Apply thin coat of clean oil to each sliding surface (1) of track frame. 16.
  • Page 567 UNDERCARRIAGE FRONT IDLER 18. Install track adjuster (1) to front idler (2) and secure with hardware. Torque bolts to 134 NCm (98 lbf ft). 19. Install track frame covers and secure with hardware. Torque bolts to 92 NCm (70 lbf ft) ±10%. 20.
  • Page 568 TRACK ADJUSTER UNDERCARRIAGE EXPLODED AND CROSS SECTION VIEWS OF TRACK ADJUSTER 14 - 27...
  • Page 569 UNDERCARRIAGE TRACK ADJUSTER 1. Adjuster Shield 5. Adjuster Check Valve 9. Rod Wiper 2. Scraper Plate 6. Front Idler Fork 10. Track Adjuster Rod 3. Adjuster Bleeder Plug 7. Piston Ring 4. Lube Fitting 8. Adjuster Piston SPECIFICATIONS Type of Adjuster ..............Single Acting Weight of Adjuster .
  • Page 570 TRACK ADJUSTER UNDERCARRIAGE 5. Remove check valve (5) with lube fitting (4) and bleeder plug (3). 6. Remove wiper seal (9) from fork. 7. Install a ½NC threaded rod into piston and remove from fork. 8. Remove piston ring (7) from piston (8). 9.
  • Page 571 UNDERCARRIAGE TRACK ADJUSTER 10. Coat piston ring and bore of fork with clean grease. Install a ½NC threaded rod into piston and insert into fork being careful not to cut or slice piston ring on wiper ring groove. 11. Install wiper seal (9) into groove in fork (6) with lips facing out. 12.
  • Page 572 TRACK ADJUSTER UNDERCARRIAGE 15. Install track frame cover and secure with hardware. Torque mounting bolts to 92 NCm (70 lbf ft) ±10%. 16. Install front idler, refer to FRONT IDLER. 14 - 31...
  • Page 573 UNDERCARRIAGE TOP IDLER EXPLODED AND CROSS SECTION VIEWS OF TOP IDLER 14 - 32...
  • Page 574 TOP IDLER UNDERCARRIAGE 1. Idler Housing 5. O-Ring 9. Roll Pin 2. Idler Shaft 6. Idler Cover 10. Port Plug 3. Inner Bearing 7. O-Ring 11. Bearing Spacer 4. Retaining Ring 8. Seal Retainer 12. Metal Type Face Seal SPECIFICATIONS Weight of Top Idler .
  • Page 575 UNDERCARRIAGE TOP IDLER 5. Using a chisel, spread idler support for removal of idler. 6. Remove idler from support. DISASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 1. Position idler in vise. Remove plug (10) from cover and allow idler to drain.
  • Page 576 TOP IDLER UNDERCARRIAGE 4. Remove bearing spacer (11) from shaft. 5. Turn assembly around in vise. Drive out roll pin (9) from seal retainer. 6. Remove seal retainer (8) from shaft. REMARK Metal portion of seal half will usually stay with shaft. 7.
  • Page 577 UNDERCARRIAGE TOP IDLER 9. Remove metal portion of seal half (12) from shaft. 10. Remove metal portion of seal half (12) from idler body. 11. Remove rubber portion of seal half (12) from idler body. 12. Position assembly in press, cover side up. Apply press and remove shaft (2) from idler body.
  • Page 578 TOP IDLER UNDERCARRIAGE 14. Using a suitable puller remove rear bearing cup from idler body. 15. Turn roller body over in press and remove remaining bearing cup. 16. Install puller arrangement and press bearing (3) off shaft. REMARK Whenever a top idler is disassembled, used seals must pass an inspection or a new seal used.
  • Page 579 UNDERCARRIAGE TOP IDLER 3. Install idler body (1) over shaft (2). Heat bearing cone (3) to 135EC (275EF) for 45 minutes. Install on shaft and bottom. To insure cone is seated, keep pressure against cone until it cools. 4. Install bearing spacer (11) on shaft. 5.
  • Page 580 TOP IDLER UNDERCARRIAGE 8. Install seal half (12) into idler body. Refer to METAL TYPE FACE SEALS 9. Coat o-ring in seal retainer (8) with #2 MPG and install on shaft. 10. Using a dowel pin to load seal retainer, install roll pin (9). 11.
  • Page 581 UNDERCARRIAGE TOP IDLER 13. Fabricate an air pressure tester and connect to top idler at fill plug hole. Slowly apply 21 to 34 kPa (3 to 5 psi) of air pressure to idler. Assembly must maintain this pressure for 10 to 20 seconds with no drop in pressure.
  • Page 582 TOP IDLER UNDERCARRIAGE 2. Center top idler along string. Remove chisel. 3. Install crimp mounting bolt and torque to 180 NCm (140 lbf ft) ±10%. Lower chain on top idler. Install track shoes and adjust chain, refer to SECTION 15. 14 - 41...
  • Page 583 UNDERCARRIAGE TRACK ROLLER EXPLODED VIEW OF TRACK ROLLER 1. Track Roller Body 4. Port Plug 7. O-Ring 2. Roller Body Bushing 5. Thrust Washer 8. Mounting Bracket 3. Track Roller Shaft 6. Metal Face Seal 9. Roll Pin 14 - 42...
  • Page 584 D32E-1, D32P-1, D38E-1 or D38P-1 ........
  • Page 585 UNDERCARRIAGE TRACK ROLLER 3. If there is not enough track chain slack to remove roller, position jack between chain and frame. Jack up until enough clearance is obtained to remove track roller. 4. Remove roller from track frame. DISASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps.
  • Page 586 TRACK ROLLER UNDERCARRIAGE 4. Remove outer half of metal type face seals (6) from assembly. Refer to METAL TYPE FACE SEALS in this section. REMARK Keep original mated metal rings as a set. Do not mix a metal ring from one side of roller with other side.
  • Page 587 UNDERCARRIAGE TRACK ROLLER 9. Remove outer half of metal type face seals (6) from mounting bracket. Refer to METAL TYPE FACE SEALS in this section. REMARK Keep original mated metal rings as a set. Do not mix a metal ring from one side of roller with other side.
  • Page 588 TRACK ROLLER UNDERCARRIAGE CLEARANCES 1. Remove the bushings in idler body and replace with new. Coat 19 to 25 mm (0.75 to 1 in) of outer idler hub bores with Loctite #609. 2. Coat 19 to 25 mm (0.75 to 1 in) of leading edge of bushing (2) (edge which engages bore first) with Loctite #609.
  • Page 589 UNDERCARRIAGE TRACK ROLLER TRACK ROLLER CLEARANCES D32E-1, D32P-1, D38E-1 or D38P-1 END CLEARANCE A. Pin to Pin Holes in Shaft 8.406 to 8397 in. 213.512 to 213.284 mm MINUS (!) MINUS (!) B. Pin Hole to Washer Face of Support 1.484 to 1.504 in.
  • Page 590 TRACK ROLLER UNDERCARRIAGE REASSEMBLY REMARK Callouts from exploded and cross section views correspond with callouts in following steps. 1. Position mounting bracket (8) in vise. Install new o-ring (7) into bracket. Apply a thin coat of #2 MPG to o-ring to aid in installation. 2.
  • Page 591 UNDERCARRIAGE TRACK ROLLER 6. Install roller (1) over shaft. 7. Install one half of metal type face seal (6) into roller body. Refer to METAL TYPE FACE SEAL . 8. Install thrust washer (5) against idler body. 9. Install new o-ring (7) into bracket. Apply a thin coat of #2 MPG to o-ring to aid in installation.
  • Page 592 TRACK ROLLER UNDERCARRIAGE 11. Position assembly in press. Install remaining mounting bracket (8) on shaft. Apply press and align pin holes with dowel. Install roll pin (9). 12. Fabricate an air pressure tester and connect to track roller at fill plug hole.
  • Page 593 Secure roller to track frame by first installing forward bolts to bring bracket in contact with track frame, then install rear bolts. 2. Torque bolts to 134 NCm (98 lbf ft) for D32E-1, D32P-1, D38E-1 or D38P-1 and 267 NCm (195 lbf ft) for D39E-1 or D39P-1. Remove any jacks between track chain and track frame.
  • Page 594 METAL TYPE FACE SEALS UNDERCARRIAGE SEAL INSPECTION 1. Check condition of rubber seal rings. If any sign of wear, scratches, nicks, cuts, etc. replace complete seal. Inspect condition of metal ring seal surfaces as follows. Highly polished surfaces of rings must be free of chips, pocks and deep scratches.
  • Page 595 UNDERCARRIAGE METAL TYPE FACE SEALS SEAL INSTALLATION REMARK Cleanliness is critical when handling seals. Never handle seal with greasy, oily or dirty hands. Do not drop, bump or roughly handle seals. 1. Remove any corrosion or hardened material that may exist on surface (1) that contact rubber rings.
  • Page 596 METAL TYPE FACE SEALS UNDERCARRIAGE 5. Final installation assembly will energize seal as shown, so that rubber rings load seal and drive mating metal rings together. 14 - 55...
  • Page 597 UNDERCARRIAGE TRACK FRAME REMOVAL 1. Raise machine and position on stands: Machine Rear: Install mounting blocks DR11-714 (1) to rear frame and position on stands. Machine Front: Install stands under front crossbar. 2. Remove track chain per SECTION 15. Remove front idler, track adjuster and covers per this section.
  • Page 598 TRACK FRAME UNDERCARRIAGE 6. Remove rear rigid bar lock plate and shims. 7. Remove front crossbar mounting hardware. 8. Using hoist and pry bar, remove track frame from machine. INSTALLATION Refer to TRACK FRAME ALIGNMENT in this section. 14 - 57...
  • Page 599 UNDERCARRIAGE TRACK SPRING EXPLODED AND CROSS SECTION VIEWS OF SPRING IN TRACK FRAME 1. Front Spring Seat 2. Rear Spring Seat 3. Track Spring 14 - 58...
  • Page 600 SPECIFICATIONS D32E-1, D32P-1, D38E-1 or D38P-1 A. Assembly Installation Length ..........550.5 mm (21.673 in) B.
  • Page 601 Consult SECTION 1 and your Komatsu distributor on any and all questions regarding safety. 1. Remove track frame from machine as described in this section. Position frame (1) on suitable blocking as shown.
  • Page 602 TRACK SPRING UNDERCARRIAGE 6. Install ram push support, DR11-713-4, (1) to frame. Install ram (2) and connect push rod, DR11-713-5, (3) to spring bolt (4). 7. Activate ram to compress spring. 8. Install nut, DR11-713-3, to spring bolt. 9. Remove containment plate from track frame. Position sling hoist to frame.
  • Page 603 UNDERCARRIAGE TRACK SPRING 11. Insert captured spring into coffin with nut end toward access hole. 12. Install bolt collar, DR11-713-6, to spring bolt head. 13. Position ram (1) in coffin and fully extend. Measure distance from stroked ram to pusher plate (2). Add blocking (3) 6.3 mm (1/4 in) longer than measured distance.
  • Page 604 TRACK SPRING UNDERCARRIAGE 16. Let off ram until spacer bars, DR11-700-5, (1) retain spring. Remove blocking against ram. Engage ram and remove spacer bars. 17. Slowly let off ram until spring decompresses. Install sling and remove from coffin. 18. Install spring (1) with retainers (2), spring bolt (3) and bolt collar (4) into coffin.
  • Page 605 UNDERCARRIAGE TRACK SPRING 21. Install long spacer bars (1) and let off ram. Install blocking (2) and apply ram. Remove long spacer bars. 22. Apply ram directing spring bolt through access hole. 23. Install retainer nut. Compress spring until assembly installation length is attained.
  • Page 606 29. Remove containment plate (1) and lifting strap (2). 30. Install removed track rollers and secure with hardware. Torque bolts to 134 NCm (98 lbf ft) for D32E-1, D32P-1, D38E-1 or D38P-1 or 267 NCm (195 lbf ft) for D39E-1 or D39P-1.
  • Page 607 UNDERCARRIAGE TRACK SPRING 31. Install track roller shields and secure with hardware. Torque shield to frame bolts to 267 NCm (195 lbf ft). 32. Torque shield spacer bolts to 455 NCm (335 lbf ft). 33. Install track frame, refer to TRACK FRAME in this section. 14 - 66...
  • Page 608 5. On each side of machine, tie strap two top hoses (1) to lift cylinder tube. Disconnect and cap lower hose (2) and position out of way in C frame. 6. D32E-1 or D32P-1; Position equipment lever in blade float (full forward). On each side of machine, attach lifting sling at C frame towers and connect to hoist.
  • Page 609 UNDERCARRIAGE FRONT CROSSBAR 7. On each side of machine, attach lifting sling and hoist to front crossbar. 8. On each side of machine, remove retaining ring (1) and ring retainer (2) from mounting pin. 9. On each side of machine, drive out mounting pin. 10.
  • Page 610 4. Each side of machine, apply Loctite Plastic Gasket or #568 to mounting surfaces of C frame trunnions. 5. D32E-1 or D32P-1: Using hoist and slings lift C frame and connect trunnion with hardware on each side of machine. D38E-1, D38P-1, D39E-1 or D39P-1: On each side of machine, rotate trunnion (1) in position and secure with hardware.
  • Page 611 UNDERCARRIAGE FRONT CROSSBAR 7. On each side of machine, reconnect bottom hose (1) to manifold. Cut loose upper hoses (2). 8. If equipped, on each side of machine, install hose bracket and secure with hardware. Torque bolts to 92 NCm (70 lbf ft) ±10%. 9.
  • Page 612 REAR RIGID BAR UNDERCARRIAGE REPLACEMENT 1. Remove track frames from each side of machine. Refer to TRACK FRAME in this section. 2. On each side of machine, attach lifting slings and hoist to rear rigid bar (1). Match mark half block (2) to welded block and remove hardware. 3.
  • Page 613 UNDERCARRIAGE TRACK FRAME ALIGNMENT TRACK FRAME ALIGNMENT 1. Centerline of Sprocket 5. Front Centerline of Machine 2. Centerline of Rear Roller to Sprocket 6. Centerline of Front Idler 3. Required Shims and Lock Bar 7. Centerline of Machine to Front Idler 4.
  • Page 614 TRACK FRAME ALIGNMENT UNDERCARRIAGE 3. Determine center line of sprocket along five or six teeth. Average readings and record. 4. Center rear track roller (1) with sprocket (2) by moving track frame (3) in or out on rear rigid bar. 5.
  • Page 615 UNDERCARRIAGE TRACK FRAME ALIGNMENT 8. Install track adjuster (1) in track frame. 9. Install front idler (1) with keeper tabs, DR11-715 (2), to track frame. 10. Determine front centerline (1) of machine and position large scale (2) through C frame out over front idler. 11.
  • Page 616 TRACK FRAME ALIGNMENT UNDERCARRIAGE 13. Using a magnetic base pointer (1) at centerline of front idler, move track frame in or out and snug up crossbar bolt when achieved. 14. Torque bolts to 455 NCm (335 lbf ft). Remove tooling from front idler. Attach track adjuster to front idler and install track fame covers, refer to FRONT IDLER in this section.
  • Page 617 TRACK CHAIN SECTION 15 SPLIT LINK TYPE CHAINS ....2 SPECIFICATIONS ......4 DESCRIPTION .
  • Page 618 TRACK CHAIN SPLIT LINK TYPE CHAINS EXPLODED VIEW OF TRACK CHAIN (SINGLE NOTCH SPLIT LINK) 1. Right Split Link - Pin 4. Link Pin 7. Left Chain Link 10. Pin Plug 2. Left Split Link - Pin 5. Thrust Ring 8.
  • Page 619 SPLIT LINK TYPE CHAINS TRACK CHAIN EXPLODED VIEW OF TRACK CHAIN (MULTIPLE NOTCH SPLIT LINK) 15 - 3...
  • Page 620 Press Generated Force ............82000 lbs (365 kN) Weight - D32E-1 - One Complete Chain: With 381 mm (15 in) Shoes .
  • Page 621 SPLIT LINK TYPE CHAINS TRACK CHAIN DESCRIPTION The interlocking type track chain consists of drop forged heat treated steel links (6 and 7) and drop forged heat treated split links (1, 2, 8 and 9) which are held together by bushings (3) and pins (4) to form a continuous chain. The bushings and pins are press fitted to the links, with the pins pivoting inside of the bushings.
  • Page 622 TRACK CHAIN SPLIT LINK TYPE CHAINS REMOVAL 1. Move machine forward until split link is on front lower half of front idler. Relieve track tension per OPERATION & MAINTENANCE MANUAL. Block up under shoe and remove split link bolts and shoe. WARNING When split link bolts and track shoes are removed, chain is free to separate.
  • Page 623 SPLIT LINK TYPE CHAINS TRACK CHAIN Reassembly 1. On new or reused pins, index a mark (1) on hole end (2) of pins on opposite side of lube hole (3). 2. Adjust press to above specified force. Install assembly adapters on ram heads.
  • Page 624 TRACK CHAIN SPLIT LINK TYPE CHAINS 5. Check seal by inserting nozzle of lubricator through plug. Pull a vacuum of 67.53 kPa (20 in Hg (mercury)) and hold for 10 seconds. In event that vacuum cannot by held, either seal to bushing face or chain pin to link bore mating surfaces are leaking.
  • Page 625 SPLIT LINK TYPE CHAINS TRACK CHAIN 8. Turn link over and reposition press over remaining side link. Using bushing pusher, press link off bushing. Inspect parts for wear, damage or improper assembly. Discard any parts which would adversely affect rebuild. Reassembly 1.
  • Page 626 TRACK CHAIN SPLIT LINK TYPE CHAINS 4. Using small hydraulic ram spread link about 6.35 mm (0.25 in) and position link over next link being careful not to damage seals. Line up links and slip in forcing pin. Remove ram. Secure aligning adapter in end of press C frame and thread short pin on ram.
  • Page 627 SPLIT LINK TYPE CHAINS TRACK CHAIN 8. Apply Loctite #640 on O.D. of pin. Push completely in. Repeat this step on next joint. Place a rubber stopper in end of pin so that it is flush with or slightly below bottom of chamfer in hole and insert nozzle of lubricator into plug.
  • Page 628 MOUNTED EQUIPMENT SECTION 17 C FRAME RUB BARS ....2 MOUNTING ......2 ANGLING FRAME .
  • Page 629 MOUNTED EQUIPMENT C FRAME RUB BARS MOUNTING D32E-1 OR D38E-1 1. C Frame 2. Rub Bar 3. Spacer Plate 4. Nominal Gap 5. Shims 6.35 ±1.5 mm (0.25 ±0.06 in) Center C frame (1) on machine. Bolt rub bar (2) and spacer plate (3) without shims. Measure gap (4) between rub bar and C frame plate along length.
  • Page 630 C FRAME RUB BARS MOUNTED EQUIPMENT REMARK D39E-1 does not require rub bar and shimming. D39P-1 1. C Frame 2. Rub Bar 3. Nominal Gap 4. Shims 6.35 ±1.5 mm (0.25 ±0.06 in) Center C frame (1) on machine. Bolt rub bar (2) without shims. Measure gap (3) between rub bar and C frame plate along length.
  • Page 631 MOUNTED EQUIPMENT ANGLING FRAME BUSHING REPLACEMENT ANGLING FRAME 17 - 4...
  • Page 632 ANGLING FRAME MOUNTED EQUIPMENT 1. Angling Frame 3. Angling Bushing 5. Pin Seal 7. Pin Seal 2. Wear Plate 4. Blade Pin Bushing 6. Cylinder Bushing 8. Lube Fitting SPECIFICATIONS Wear Plate New Thickness ............6.35 mm (0.25 in) Wear Plate Maximum Wear Replacement .
  • Page 633 MOUNTED EQUIPMENT C FRAME PIN PIN SHIMS 1. Shim gap between angling frame and C frame as required to minimize gap to permit free movement without any binding. A minimum of one shim to a maximum of two shims allowed. 2.
  • Page 634 C FRAME MOUNTED EQUIPMENT BUSHING REPLACEMENT C FRAME 1. C Frame 2. Trunnion Pin Bushing 3. Cylinder Pin Bushing 4.Pin Seal 1. Remove old bushing from frame. Press in new bushing (2) flush with outside edge of C frame. 2. Remove and discard pin seals (4), replace with new. Drive old bushing out. Position new bushing (3) in place and press in to dimension shown.
  • Page 635 MOUNTED EQUIPMENT BLADE BUSHINGS BUSHING REPLACEMENT BLADE BUSHINGS 1. Blade 2. Trunnion Pin Bushing 3. Cylinder Pin Bushing 4.Pin Seal 1. Remove old bushing from blade. Press in new bushing (2) flush with inner edge of tube in blade. 2. Remove and discard pin seals (4), replace with new. Drive old bushing out. Position new bushing (3) in place and press in to dimension shown.
  • Page 636 Komatsu America International Company 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. PROPOSAL FOR MANUAL REVISION Attn: Technical Publications Fax No. (847) 970-4186 FOR INTERNAL USE ONLY -- No. PMR P NAME OF COMPANY: LOCATION: PHONE NO: DEPARTMENT: DATE:...

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