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DRESSTA TD-25M EXTRA, Service Manual

The DRESSTA TD-25M EXTRA is a powerful and reliable construction bulldozer designed to deliver exceptional performance. Enhance your experience with the comprehensive Service Manual, available for free download on our website. Maximize efficiency and keep your machine running smoothly with this essential manual — all just a click away at manualshive.com.

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Summary of Contents for TD-25M EXTRA

Page 1: ...SMTD25MEX07 1E SERVICE MANUAL TD 25M EXTRA SERIAL NUMBERS 75001 AND UP DRESSTA ...

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Page 3: ...H 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 LATEST REVISION CONTENTS 1 INTRODUCTION 5 STEERING 6 COOLING SYSTEM 7 DRIVE TRAIN 7B HYDRAULIC TORQUE CONVERTER 7C TRANSMISSION 7E STEERING DRIVE 7F FINAL DRIVE 8 ELECTRICAL ...

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Page 5: ...SECTION 1 INTRODUCTION ...

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Page 7: ...TION AND REPAIR 11 8 ELECTRONIC CIRCUITS PROTECTION DURING WELDING AT THE MACHINE 12 LOCTITE USAGE 9 LOCTITE USAGE 12 STANDARD TORQUES 10 BOLT IDENTIFICATION CHART 13 11 TORQUE VALVES FOR STANDARD FASTENERS 13 12 SPLIT FLANGE CONNECTIONS 15 13 HYDRAULIC TUBES AND FITTINGS 15 14 HOSE CLAMPS 16 15 TORQUE VALUES FOR AIR CONDITIONING TUBES AND FITTINGS 16 16 TORQUE VALUES FOR AIR CONDITIONING O RING C...

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Page 9: ...r add improvements at any time without incurring any obligation to install such changes on products sold previously Fig 1 1 TD 25 Series M EXTRA Crawler Tractor 1 Right Hand Side of the Machine 2 Left Hand Side of the Machine 3 Front of the Machine 4 Rear of the Machine Throughout this manual there will be two types of cross references One type is to a heading in another section The other is to a ...

Page 10: ... call your attention to important function having influence on the right functioning of the machine or for informational purposes WORK SAFETY FOLLOW THESE RULES This symbol and text with bold letters is used throughout this manual to call your attention to instructions concerning your personal safety Observe and follow these instructions Be certain anyone operating and servicing this machine is aw...

Page 11: ... safety requirements Carefully evaluate your particular application and machine for equipment such as heater and defroster all windshield wipers warning lights side view and rearview mirrors back up alarms fire extinguisher rotating beacons and additional lights If in doubt contact your distributor It is recommended that the machine be equipped with a fully charged fire extinguisher and the first ...

Page 12: ...the engine is operating move the machine outdoors as soon as possible Exhaust gases are dangerous and can cause unconscious ness and death Always place the drive train neutral lock lever in locked position and apply the parking brake before starting the engine The operator must be alert physically fit and free from the influences of alcohol drugs or medications that might affect his eyesight heari...

Page 13: ...d windows and mirrors if equipped clean Before starting the engine be sure you understand all control functions Check all controls including the brakes decelerator steering and transmission Check all gauges warning lights and safety devices Correct any malfunctions Only one person the operator should be permitted to ride on the machine when it is in operation Perform an operational check of the ma...

Page 14: ...ck the engine exhaust system for leaks Exhaust gases are dangerous to the operator Do not operate the machine in a condition of extreme fatigue or illness Be sure chains or cables and their anchor points are strong enough to handle the expected load Inspect carefully chains and cables for flaws before using them Always wear gloves when handling cables and chains Avoid looping or knotting a cable o...

Page 15: ...xcavations If it is not possible to avoid turn the machine front towards the bank edge or excavation Travel slowly in congested areas or on rough ground slopes or near drop offs or on snow ice or slippery surfaces Maintain a safe distance between your machine and other vehicles according to the condition of the road and load Never hold the hydraulic controls in their extreme position after the equ...

Page 16: ... repairs and maintenance Failure to do so could compromise your personal safety and machine performance and reliability Use only approved parts for repairs and maintenance show in your parts catalog Failure to do so could compromise your personal safety and machine performance and reliability Never align holes with fingers or hands Use a proper aligning tool Be sure all used tools are in good cond...

Page 17: ...for suspected leaks Do not use hands If injured by escaping fluid see a doctor at once Serious infection or reaction can occur if proper medical treatment is not administered immediately When welding wear proper protective equipment such as a helmet dark safety glasses protective glasses near welding DO NOT look at the arc without proper eye protection Wear proper protective equipment such as gogg...

Page 18: ...tainer 8 Do not store fluid containers in the operator s compartment Never mix gasoline gasohol or alcohol with diesel fuel This creates an extreme fire or explosion hazard which could result in personal injury or death Do not use bleach color dye or solvents on the seat belt webbing This may cause a severe loss of tensile strength This could cause the webbing to break resulting in personal injury...

Page 19: ...mber and the engine serial number refer to SECTION 1 INTRODUCTION in OPERATOR S MANUAL All other components having serial numbers are each equipped with a separate stamped serial number plate Use machine serial numbers when requesting information or ordering parts and proper numbers from PARTS CATALOGUE 7 INSPECTION AND REPAIR Bearings Inspect for evidence of overheating cracks scores pitting and ...

Page 20: ... or excessive wear on initial operation Failure to provide starting lube may result in serious damage 8 ELECTRONIC CIRCUITS PROTECTION DURING WELDING AT THE MACHINE Welding on a Vehicle With an Electronic Controlled Fuel System and CMCV One Lever Controlled Drive System The welding at the engine or engine installed components is not recommended However if a welding within the machine is unavoidabl...

Page 21: ...VALUES FOR STANDARD FASTENERS The following charts provide tightening torque for general purpose applications using original equipment standard hardware as listed in the PARTS CATALOGUE for the machine involved DO NOT SUBSTITUTE Special torques and applications which are nonstandard are listed separately on a SPECIAL NUT AND BOLT TORQUE charts in further Sections of the manual A torque value to a ...

Page 22: ...t supplemental lubrication as received condition The torques shown below apply to phosphate coated bolts designed for 60 yield strength The torques shown below also apply to the following phosphate coated bolts used in tapped holes in steel or gray iron phosphate coated bolts used with phosphate coated prevailing torque nuts nuts with distorted threads or plastic inserts phosphate coated bolts use...

Page 23: ...9 180 Inside diameter of hydraulic tube or hose fitting 13 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 These torques are not recommended for tube with wall thickness of 0 89 mm or less Size Tubing O D in Thread size in Torque values for 37 flared fittings Nm Torque values for ...

Page 24: ... 6 Worm Drive All Ultra Title 10 7 to 11 8 4 5 to 5 6 15 TORQUE VALUES FOR AIR CONDITIONING TUBES AND FITTINGS SWAGED 45 CONNECTIONS SIZE THREAD SIZE in TORQUE VALUES FOR MATERIALS Nm STEEL STEEL BRONZE STEEL COPPER STEEL ALUMINUM STEEL 1 4 7 16 20 16 23 15 20 15 20 12 18 3 8 5 8 18 27 33 23 38 23 38 20 25 1 2 3 4 16 47 54 38 46 38 46 28 36 5 8 7 8 14 61 68 45 53 45 53 34 42 3 4 1 1 16 12 72 80 49...

Page 25: ...SECTION 5 STEERING ...

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Page 27: ...STEERING SECTION 5 DRESSTA TD 25M EXTRA CONTENTS GENERAL 1 DESCRIPTION 1 ...

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Page 29: ...ed on the rear main frame cover Brake pedal cable mechanically and drive train control valve hydraulically operate the steering valve Oil pressure from the drive train control valve is directed to the steering valve to operate the steering drive unit For further detailed information on the hydraulically controlled steering system refer to SECTION 7 DRIVE TRAIN SECTION 7C TRANSMISSION and SECTION 7...

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Page 31: ...SECTION 6 COOLING SYSTEM ...

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Page 33: ...M SECTION 6 DRESSTA TD 25M EXTRA CONTENTS Page GENERAL 1 DESCRIPTION 1 2 OPERATION 1 3 SPECIFICATIONS 4 4 SERVICE DIAGNOSIS 5 5 REMOVAL 6 6 DISASSEMBLY 11 7 INSPECTION AND REPAIR 12 8 REASSEMBLE 12 9 INSTALLATION 13 ...

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Page 35: ... side bottom of the modular radiator For detailed information on the engine cooling system components refer to the Engine Operation and Maintenance Manual QSX15 Engines Bulletin No 3666423 Troubleshooting and Repair Manual QSX15 Engines Bulletin 3666239 and Troubleshooting Repair Manual Electronic Control System QSX15 Engines Bulletin No 3666259 Drive Train Oil Cooling System The drive train cooli...

Page 36: ...motive type radiator cap with a built in pressure vacuum relief valve The relief valve of the cap is incorporated to maintain a minimum and maximum pressure in the cooling system The valve allows excess air and vapor to escape through an overflow tube 23 at a pressure of 45 55 kPa Drive Train Oil Cooling System The oil used in drive train system is directed to the inlet hose 17 of the oil cooler 2...

Page 37: ...se 5 Radiator Core 6 Coolant Inlet Tube 7 Hydraulic Motor Oil Cooler 8 Oil Outlet Hose 9 Oil Inlet Hose 10 Fuel Cooler 11 Fuel Outlet Hose 12 Fuel Inlet Hose 13 Engine Vent Hose 14 Cooling System Fill Hose 15 Coolant Outlet Tube 16 Oil Outlet Hose 17 Oil Inlet Hose 18 Air Inlet Tube 19 Hump Hose with Clamps 20 Air Outlet Tube 21 Turbocharger 22 Engine Intake Connection 23 Overflow Hose ...

Page 38: ...Core Replaceable Test pressure 300 kPa Maximum allowable pressure drop across CAC and piping 101 kPa Drive Train Oil Cooler Type Fins and flat tubes Core Replaceable Test pressure 1500 kPa Fuel Cooler Type Fins and flat tubes Core Replaceable Test pressure 750 kPa Fan Drive Hydraulic Motor Oil Cooler Type Fins and flat tubes Core Replaceable Test pressure 750 kPa Special Nut and Bolt Torque Data R...

Page 39: ...n 1 Low coolant level Fill cooling system to proper level 2 Tank cap not securely tightened to seal the pressure system Remove radiator cap and inspect Replace cap if gasket is worn Tighten radiator cap to maintain pressure in system 3 Pressure relief valve on tank cap is faulty Coolant pressure escaping Replace cap Do not repair or replace any relief valve parts 4 Faulty thermostat s Check thermo...

Page 40: ...Refer to Troubleshooting and Repair Manual QSX15 Engines Drive Train Cooling System COMPLAINT PROBABLE CAUSE REMARKS Drive Train Oil Overheating 1 Operating too long in low efficiency ranges Review operating instructions in the Operator s Manual 2 Clogged radiator Flush with steam for external clogging 3 Temperature gauge or sensor faulty Replace sensor or temperature gauge 4 Torque converter prob...

Page 41: ... Operator s Manual 9 Loosen the clamp and remove vent hose 5 Fig 6 3 from the auxiliary tank and attach it to engine IMPORTANT Disconnected lines must be capped with the correct size plastic caps or clean corks Openings must never be plugged with rags This practice could easily introduce dirt or lint in to critical components of the system 10 Disconnect wire harness connector from the coolant leve...

Page 42: ... Hose 4 Coolant Inlet Tube 5 From Engine Vent Hose 6 Coolant Level Switch 7 Hose Outlet 17 Tag and remove hydraulic hose 1 Fig 6 4 from fan drive hydraulic motor oil cooler Secure hose in an upright position to frame NOTE Small quantity of oil from oil cooler should be drained to the suitable container 18 Tag and remove fuel hose 2 Fig 6 4 from the fuel cooler Secure hose in an upright position to...

Page 43: ... Loosen the clamps and remove coolant outlet tube 2 Fig 6 5 from the radiator and engine inlet 22 Tag and remove fuel hose 4 from the fuel cooler Secure hose in an upright position to frame NOTE Small quantity of fuel from fuel cooler should be drained to the suitable container Fig 6 5 Radiators Assy Connections lower 1 Air Outlet Tube CAC outlet 2 Hydraulic Hose inlet 3 Coolant Tube outlet 4 Fuel...

Page 44: ... plate and tighten IMPORTANT Do not use the hydraulic motor bracket for radiator assy hoisting 26 Unscrew bolts 1 Fig 6 7 securing radiator to plate 2 27 Unscrew bolts 2 Fig 6 8 securing radiator assy to channel 1 at the bottom 28 Carefully hoist the radiator assy up and over frame Position assy horizontally hydraulic motor up using suitable height wooden pads Fig 6 7 Radiator Assy Disassembly Poi...

Page 45: ...core of the radiator assy it is possible to remove a single core required repairing without disassembly of all elements Charge air cooler removing Fig 6 9 Radiators Assy Exploded View 1 Bolts 2 Auxiliary Tank 3 Charge Air Cooler core 4 Bolts 5 Bottom Plate 6 Bolts 7 Bolts 8 Fan Drive Hydraulic Motor Bracket 9 Fan Shroud 10 Fan Guard 11 Bolt ...

Page 46: ...the cleaning procedure 2 Inspect top and bottom particular radiator for cracks 3 Inspect all hoses for cracks or rupture and install new when in doubt 4 Inspect the radiator cap 5 Inspect shock absorber and rubber pads for wear 6 Perform pressure test particular cooler if necessary 7 Check and repair fan shroud and fan guard for cracks 8 Check fan for cracks and other damage Do not repair Replace ...

Page 47: ...radiator assy to the bottom channel Remove lifting slings 3 Reinstall hydraulic hoses 1 3 and 4 Fig 6 6 to the fan drive hydraulic motor 4 Reinstall fuel hose 4 Fig 6 5 to the fuel cooler 5 Reinstall coolant tube 3 to the radiator and engine inlet Tighten the clamps 6 Reinstall hydraulic hose 2 to the drive train oil cooler 7 Reinstall tube 1 to the air cooler CAC and engine intake manifold Tighte...

Page 48: ...rator s Manual WARNING Before working on the machine be sure to turn OFF master switch and take key out to prevent accidental starting 19 Attach a suitable lifting device to the crankcase guard Lift the guard and install the bolts WARNING This procedure requires extreme caution Use suitable blocking equipment while under confines of machine 20 Install air baffles 2 Fig 6 6 Close front radiator doo...

Page 49: ...SECTION 7 DRIVE TRAIN ...

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Page 51: ...ND LUBRICATION OIL FLOW 11 7 STEERING SYSTEM OIL FLOW 11 SERVICE DIAGNOSIS 8 TROUBLE SHOOTING 17 9 SPECIFICATIONS 18 10 TRANSMISSION AND TORQUE CONVERTER OIL PRESSURE TEST 19 11 TORQUE CONVERTER STALL SPEED CHECK 22 12 DRIVE TRAIN CLUTCH TEST 23 13 STEERING SYSTEM OIL PRESSURE CHECK 24 14 STEERING SYSTEM FUNCTIONAL CHECK 26 15 TRANSMISSION FIVE PENNY DIAGNOSTIC TEST 27 16 STEERING SYSTEM SUPPLY PR...

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Page 53: ...ig 7 1 Drive Line 1 O Ring 2 Torque Converter 3 Drive Shaft 4 Transmission Input Yoke 5 Transmission 6 O Ring 7 O Ring 8 Steering Drive 9 Drive Pinion Sleeve 10 Steering Drive Output Shaft 11 Bolt 12 Retaining Ring 13 Final Drive 14 Sprocket Drive Segment 15 Sprocket Drive Segment 16 Charge and Scavenge Pump 17 O Ring 18 O Ring 19 Equipment Pump 20 Fan Drive Pump 21 Gasket 22 Connector Plate 23 Co...

Page 54: ...o speed steering drive contains one low range clutch pack one high range clutch pack one brake clutch pack and a planetary on each side of the machine The low and high range clutch packs are hydraulically applied and spring released whereas the brake clutch packs are spring applied and hydraulically released An inner planetary provides the reduction in speed for the low range If a hydraulic failur...

Page 55: ...e right the following occurs The initial lever movement lowers signal pressure causing a sequence valve to automatically shift the right track from HI to LO With further lever travel to the right the right LO track will go to the neutral condition as indicated by the feel point as discussed earlier Further lever movement will result in a pivot turn As the lever is moved back to the upright positio...

Page 56: ...When the right speed range switch of the drive train control lever is in its upper position HI and the left rocker switch in its lower LO position Fig 7 5 the drive train electronic controller EC chooses the correct solenoid selections to result in the gradual left turn The EC controller upshifts or downshifts the appropriate track to complete the turn When the control lever is moved to the right ...

Page 57: ...of Rise Valve and the Range Selector Valve are described in a separate section For a complete description and operation refer to SECTION 7C HYDRAULIC OIL FLOW 5 TRANSMISSION SYSTEM OIL FLOW Refer to Fig s 7 2 and 7 3 The rear part of main frame 9 is the common oil reservoir for torque converter transmission and steering drive When the engine is running oil is drawn out from the bottom of the main ...

Page 58: ...he drive train control valve refer to SECTION 7C Legend for Fig s 7 2 and 7 3 1 Transmission 2 Suction Strainer 3 Drive Train Charge Pump 4 Drive Train Scavenge Pump 5 Pressure Filters 5A Drive Train Oil Pressure Filters Warning Light 6 Torque Converter 6A Drive Train System Oil Temperature Gauge 7 Oil Cooler 8 Suction Strainer 9 Main Frame 10 Switching Valve 10A Low Transmission Main Pressure and...

Page 59: ...DRIVE TRAIN SECTION 7 Page 7 DRESSTA TD 25M EXTRA HYDRAULIC OIL FLOW Fig 7 2 Drive Train Hydraulic Oil Flow with Trans First Forward TWO SPEED STEERING DRIVE ...

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Page 61: ...DRIVE TRAIN SECTION 7 Page 9 DRESSTA TD 25M EXTRA HYDRAULIC OIL FLOW Fig 7 3 Drive Train Hydraulic Oil Flow with Trans Third Reverse TWO SPEED STEERING DRIVE ...

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Page 63: ...tch packs in steering drive This steering drive M oil pressure functions on a range 1790 1930 kPa The drive clutch packs are actuated on a range of 690 1930 kPa and the brake clutch packs are released on a range 620 1930 kPa When the pressure is dissipated below 690 kPa the drive clutch packs release and then the brake clutch packs begin to engage when the pressure is dropping as hitherto When the...

Page 64: ...RADUAL TURN LEFT Fig 7 5 When the drive train control lever is in drive position with the left speed range switch in its lower LO position and the right speed range switch in its upper HI position the left side steering drive is working as described above but on the right side high low range solenoid SOL is energized The solenoid direct pilot oil pressure to right side of HI LO spool causing the H...

Page 65: ... LC RC HI LO SOL SEQ FB EC 23 J SD Main Pressure Brake Clutch Right Pilot Pressure Brake Clutch Left Pilot Pressure Left Clutch Section Right Clutch Section High Low Range Section HI LO Range Solenoid Sequence Valve Cartridge Foot Brake Section Drive Train Electronic Controller Steering Manifold Steering Drive ...

Page 66: ...SECTION 7 DRIVE TRAIN Page 14 TD 25M EXTRA DRESSTA HYDRAULIC OIL FLOW Fig 7 4 Starting and LO Range Straight Travel TWO SPEED STEERING DRIVE ...

Page 67: ...DRIVE TRAIN SECTION 7 Page 15 DRESSTA TD 25M EXTRA HYDRAULIC OIL FLOW Fig 7 5 Gradual Left Turn TWO SPEED STEERING DRIVE ...

Page 68: ...SECTION 7 DRIVE TRAIN Page 16 TD 25M EXTRA DRESSTA HYDRAULIC OIL FLOW Fig 7 6 Pivot Turn Right TWO SPEED STEERING DRIVE ...

Page 69: ... ranges Review operating instructions in OPERATOR S MANUAL 4 Clogged oil cooler Clean according to OPERATOR S MANUAL 5 Clogged drive train suction filter Remove and clean 6 Leakage on suction line Check suction line for tightness 7 Transmission problem Check transmission temperature and clutches oil pressure Refer to DIAGNOSTIC CHART in Par 10 below 8 Torque converter oil leakage excessive Refer t...

Page 70: ...ECTION 8 ELECTRICAL 9 SPECIFICATIONS Charge and Scavenge Pump Type gear dual element Capacities 2094 engine rpm Front scavenge section 275 l min Rear charge section 206 l min Transmission Test Oil Pressures Main oil pressure M 1790 1930 kPa Torque converter inlet oil pressure C In neutral 790 930 kPa In gear 790 930 kPa Lubrication oil pressure L In neutral 280 450 kPa In gear 240 350 kPa Transmis...

Page 71: ...ever to NEUTRAL Fig 7 7 Pressure Gauge Connect Points 1 Right Brake RB 2 Left Brake LB 3 Range Clutch PC 4 Main M 5 Converter C 6 Lubrication L 7 Directional Clutch FR 8 Two Speed Steering Valve 9 Pressure Regulator Valve 10 Range Selector Valve 1 Open the door at the left hand side of the platform Remove the protective covers from quick disconnect fittings and connect the Test Pressure Gauges Kit...

Page 72: ...e chart However C and L pressure readings are much lower than those shown in the above chart with the same conditions IMPORTANT Additionally measure the L pressure with the engine running at low idle Never operate the machine if the L pressure reading is 0 0 kPa WARNING Be sure the area around the machine is clear of personnel and obstructions as the vehicle may move during these tests If the mach...

Page 73: ...erform STEERING SYSTEM SUPPLY PRESSURE TEST described in this Section h Defective rear section of pump 2 High main oil pressure a Main regulator spool stuck b Incorrect priority valve adjustment after repairing or replacement 3 Low torque converter oil pressure a Low main oil pressure Refer to problem 1 above b Clogged suction oil filter Refer to OPERATOR S MANUAL c Leaking pump inlet lines d Stuc...

Page 74: ...e selector valve directional spool damaged c Leaking one of manifold outside seal gear F R on input shaft Perform Five Penny Test described in this Section d Leaking one of directional clutch pack Perform Five Penny Test described in this Section 10 Low or zero one of 1st 2nd or 3rd clutch pressure a Faulty solenoid valve on gear shifting valve 2nd or 3rd b Range selector valve range spool damaged...

Page 75: ... reverse third gear range Gradually release the decelerator pedal and again check for drive shaft and final drive sprocket rotation 5 Fully depress the decelerator pedal and shift transmission into neutral Move the drive train neutral lock lever to the ON position Place the engine speed control lever in the low idle position and release the decelerator pedal Stop the engine 6 If the drive shaft an...

Page 76: ...scription to avoid confusion when performing these checks Fig 7 8 Pressure Gauge Connect Points 1 Right Clutch RC 2 Right Brake RB 3 Left Clutch LC 4 Left Brake LB NOTE The following pressure checks should be performed with the engine running at full throttle and oil at operating temperature To obtain operating temperature shift to third forward with the foot brake applied until the temperature ga...

Page 77: ... both LO HI range switches in their lower position Initial movement of the control lever to the right 1790 1930 Main minus 0 35 Main minus 0 35 590 760 590 760 5 Left track in pivot or brake and right track in low range clutch engagement both LO HI range switches in their lower position Control lever fully shifted to the left 1790 1930 0 0 Main minus 0 35 Main minus 0 35 6 Left track at feel point...

Page 78: ...valve pressures must be checked Refer to Paragraph 13 STEERING SYSTEM OIL PRESSURE CHECK With machine on level and hard ground and with the Test Pressure Gauges Kit refer to SERVICE SPECIAL TOOLS in this Section still connected to right and left brake quick disconnect fittings on the diagnostic center and to the RC and LC test ports on the steering valve Refer to Step 2 in Paragraph 13 of this Sec...

Page 79: ...es of all circuits must be recorded for future comparisons refer to TRANSMISSION AND TORQUE CONVERTER OIL PRESSURE TEST in this Section If the pressure test shows that there is low pressure in one or more circuits then Five Penny Test may be done Five Penny Test Procedure 1 Remove the range selector valve refer to RANGE SELECTOR VALVE in TRANSMISSION SECTION 7C Fig 7 9 Pennies Disks Placing on the...

Page 80: ...ke all drive train pressures again The pressures should be taken in all ranges and in both directions refer to TRANSMISSION AND TORQUE CONVERTER OIL PRESSURE TEST in this Section Shut off the engine 4 If the pressures which were low on the first test are NOW correct the problem is internal to the transmission and it will have to be removed and repaired for more details refer to Transmission and To...

Page 81: ...orrect with the steering valve connected then the steering system needs to be further checked Refer to STEERING SYSTEM OIL PRESSURE CHECK in this Section 4 Remove plug from the tee 2 and reconnect supply hose 3 to the pressure regulator valve 17 PRIORITY VALVE PRESSURE CHECK AND ADJUSTMENT PROCEDURE The priority valve is located at the machine L H side under the drive train system filters behind t...

Page 82: ...ty valve pressure regulator 3 calls for adjustment Refer to Priority Valve Pressure Adjustment Procedure below 5 Disconnect the pressure gauge and restore the protective cap Priority Valve Pressure Adjustment Procedure The check is to be carried out at the engine maximum RPM 1 Connect the pressure gauge and check priority valve pressure as described in Priority Valve Pressure Check above 2 To adju...

Page 83: ...SECTION 7B HYDRAULIC TORQUE CONVERTER ...

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Page 85: ...ERVICE SPECIAL TOOLS 1 SERVICE SPECIAL TOOLS 1 GENERAL 2 DESCRIPTION AND OPERATION 2 3 SPECIFICATIONS 5 4 SERVICE DIAGNOSIS 5 5 TORQUE CONVERTER INTERNAL LEAKAGE TEST 6 TORQUE CONVERTER 6 REMOVAL 7 7 DISASSEMBLY 10 8 INSPECTION AND REPAIR 16 9 REASSEMBLY 17 10 INSTALLATION 26 ...

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Page 87: ...AL TOOLS 1 SERVICE SPECIAL TOOLS TOOL FOR DRIVEN GEAR MOUNTING C Bolt M24 x 130 8 8 B Fe Zn5 601 02 2629 6 02 D Nut M24 5 B Fe Zn5 603 01 2262 0 02 E Round Washer A 25 8 612 48 1170 0 02 F Special Washer per Drawing SPECIAL WASHER F TOOL FOR HOUSING COVER BEARING SEATING WASHER G ...

Page 88: ...SECTION 7B HYDRAULIC TORQUE CONVERTER Page 2 TD 25M EXTRA DRESSTA GENERAL 2 DESCRIPTION AND OPERATION Refer to Fig s 7B 1 and 7B 2 Fig 7B 1 Cross Section View of Torque Converter ...

Page 89: ...HYDRAULIC TORQUE CONVERTER SECTION 7B Page 3 DRESSTA TD 25M EXTRA GENERAL Fig 7B 2 Exploded View of Tor ...

Page 90: ...peller and turbine assy splined to the stationary ground sleeve hub 2 There is no direct mechanical connection between the impeller and turbine or stator Operating engine turns bladed impeller 12 bolted to drive housing 30 At the same time external gear pump is powered from the engine and supplies oil to impeller blades The impeller draws fluid from the opening surrounding the hub and ejects it fr...

Page 91: ... joint mounting bolts 136 Nm Torque converter mounting bolts 110 Nm 4 SERVICE DIAGNOSIS COMPLAINT PROBABLE CAUSE REMEDY Loss of Oil from Torque Converter Leaking connections Operate the engine at part throttle and inspect all lines and connections for leaks Tighten or replace parts as necessary Leaking converter a Converter rear b Converter front or through cranking motor Check all the bolts and n...

Page 92: ...ental starting WARNING Before working at the machine be sure that the blade and ripper have been lowered to the ground engine is OFF the drive train control lock lever is in locked ON position and parking brake is set The starting switch and the electrical system master switch are turned OFF keys are removed and the controls are tagged to prevent inadvertent engine starting 2 Remove the transmissi...

Page 93: ...ion and parking brake is set The starting switch and the electrical system master switch are turned OFF keys are removed and the controls are tagged to prevent inadvertent engine starting IMPORTANT Disconnected hydraulic lines must be capped with the correct size plastic caps If these caps are not available tape or clean rubber corks may be used Hydraulic openings must never be plugged with rags T...

Page 94: ...onverter supply hose 7 Fig 7B 5 from the torque converter 2 10 Disconnect torque converter drain hose 8 from the flywheel housing 11 Disconnect the scavenge suction tube 5 and transmission lube inlet hose 3 from transmission NOTE Before removing the universal joint wire the bearing cap to prevent bearings from falling off the spider trunnion 12 Remove the universal joint 4 between the torque conve...

Page 95: ...heel housing at 2 and 10 o clock positions and replace with aligning studs 1 2 13 of 100 to 130 mm in length Remove remaining bolts Fasten the hoist to lift the torque converter Fig 7B 6 While lifting the torque converter pry it and displace backwards by about 130 mm so that its weight 170 kG be transferred to the hoist and let the torque converter clear of the flywheel housing and aligning studs ...

Page 96: ...over 35 for further reuse 2 Remove bolt 33A then remove thrust washer 33 and shims 32 Keep shims 32 with washer 33 for further reuse 3 Mark the impeller 12 position in relation to drive housing 30 to keep the position of rotational parts after reassembly Remove bolts 30A with washers 30B securing housing 30 to impeller 12 Screw two bolts 30A into two threaded holes facing each other in the housing...

Page 97: ...t the bearing 31 using 60 to 79 mm dia driver 5 Press bearing 31 out of drive housing 30 using 122 to 127 mm dia driver supporting it against the bearing 31 outer race 6 Remove the retaining ring 28 from the output shaft 14 and retaining ring 27 from ground sleeve hub 2 Remove stator 26 from ground sleeve hub 2 ...

Page 98: ... drive gear 5 using two levers 8 Remove bolts 13A securing impeller 12 to the drive gear 5 Remove thrust washer 13 Tap the drive gear 5 and bearing 4 out of the impeller 12 Press bearing 4 out of drive gear 5 using 114 mm dia driver supporting it against the bearing 4 outer race 9 Remove seal ring 3 from ground sleeve hub 2 ...

Page 99: ...ther in the cover 22 Screw the bolts in a regular way to remove the rear cover 22 Remove O ring 20 Press seal ring 21 out of rear cover 22 using suitable driver Remove shims 19 and keep with cover 22 for further reuse 12 Remove retaining ring 6 and spacer washer 7 from driven gear 11 Drive the gear 11 out of ball bearing 8 using 35 mm to 49 mm dia driver Keep bearing 8 in housing 1 bore Repeat for...

Page 100: ...suitable puller 14 Turn the converter housing 1 over with its output or rear side down Working from inside housing 1 tap on the end of output shaft 14 with a hammer and a block of wood until bearing 18 is free 15 Remove seal ring 15 retaining ring 16 and spacer washer 17 from output shaft 14 Tap the shaft 14 out of ball bearing 18 with a hammer and soft metal driver ...

Page 101: ...upporting it against the bearing 8 outer race Repeat for remaining housing bores 17 Turn the torque converter housing 1 with its output or rear side up Remove ground sleeve hub 2 from converter housing 1 using 120 to 130 mm dia driver If bearing 4 replacement is necessary remove bearing inner race from ground sleeve hub 2 18 If converter housing 1 needs to be replaced or repaired unscrew eyebolt U...

Page 102: ...aces may show increased smoothness but any gear spalling is not allowable 6 Check thoroughly all bearings shaft journals and bores where bearings are seated to ensure that there are no worn out spots due to rotation of inner bearing race on its shaft or bearing outer race in its bore If the check reveals that either the bearing rotates on its shaft journals or it rotates in its bore it is seated i...

Page 103: ... the remaining bearings 3 Turn converter housing 1 over Clean and degrease surfaces both ground sleeve hub 2 flange and hub seat in converter housing 1 Apply LOCTITE 510 to ground sleeve hub 2 and install it in a way that the hub flange openings line up with their counterparts in converter housing 1 The inner race of bearing 4 must be seated on ground sleeve hub 2 before sleeve assembly NOTE If th...

Page 104: ...s operation use a driven gear pusher set see Service Special Tools in this Section which consists of bolt C nut D washer E and special thrust washer F The special washer F shall support against ball bearing s 8 inner race Repeat for remaining gears NOTE Inspect bearings preload Bearings should rotate freely 6 If one of driven gears 11 bearings 8 and 10 and housing 1 have not been replaced use prev...

Page 105: ... 7 with thickness X so the L gap between the bearing 8 and retaining ring 6 obtains the dimension of 0 0 0 3 mm Use the following formula L 0 0 0 3 P1 P2 P3 X Install spacer washer 7 on the driven gear 11 hub then install retaining ring 6 Repeat for remaining gears 8 Install retaining ring 16 and spacer washer 17 on output shaft 14 Press the output end of shaft 14 into bearing 18 until the bearing...

Page 106: ... chamber at rear cover 22 Select shims pack thickness 19 so the X1 gap between the housing and rear cover obtains the dimension of 0 0 0 1 mm L 0 0 0 1 P1 X1 P2 Using virgin lead to measure the appropriate distance is acceptable too 12 Press seal ring 21 into rear cover 22 until it is 1 2 mm out of cover outer flange The seal lip should face toward the converter when the rear cover 22 is installed...

Page 107: ...TITE 243 to the bolt 25A and torque to 83 101 Nm 14 Turn converter housing 1 over with the gear up Install seal ring 3 in the groove of ground sleeve hub 2 Coat lightly the ring with oil 15 Press roller bearing 4 into drive gear 5 Install impeller 12 on bearing 4 and then thrust washer 13 Secure impeller 12 to drive gear 5 with the bolts 13A Apply LOCTITE 243 to the bolts and torque to 48 58 Nm ...

Page 108: ...o housing 1 drive gear 5 meshes with driven gears 11 IMPORTANT If at any point when contact is made the resistance is felt rotate the assembly holding up the impeller lightly Take care when the assembly passes over the seal ring 3 17 Install stator 26 on the ground sleeve hub 2 secure with retaining ring 27 Install retaining ring 28 into output shaft 14 groove 18 Install turbine assy 29 on the out...

Page 109: ...o shaft 14 withbolt 33A using finger pressure Then loosen bolt 33A and retighten with torgue of 15 to 20 Nm NOTE Be sure bearing inner race 31 bottoms turbine 29 hub After bolt 33A retightening 21 If bearing 31 and washer 33 have not been replaced use previously removed shim pack 32 If bearing 31 or washer 33 have been replaced proceed as follows Take the P1 distance of shaft 14 face to thrust was...

Page 110: ...Place washer G see Service Special Tools in this Section of minimum thickness of 2 mm onto ball bearing 31 Install housing cover 35 on ball bearing 31 and torque the cover to drive housing 30 with bolts 35A and washers 35B to be sure bearing 31 is properly seated in drive housing 30 bore 24 Remove cover 35 and washer G Measure the P4 distance within housing cover 35 and the P3 distance between bal...

Page 111: ...243 to the bolts and torque to 48 58 Nm NOTE Make sure the shims forming the pack are centrally placed on the bearing outer race so none of them will get clamped between the housing cover and the drive housing NOTE Remove eyebolt U prior to torque converter machine installation 26 If gear ring 36 was replaced install new gear ring 36 to flywheel and secure with bolts Apply LOCTITE 243 to the bolts...

Page 112: ... 36 Fig 7B 1 or Fig 7B 2 was replaced install new gear ring and secure with bolts applying LOCTITE 243 Torque bolts to 83 101 Nm 2 Thoroughly clean the mating surfaces of the torque converter housing and the engine flywheel housing Install a new O ring on the converter housing flange 3 Install of 100 to 130 mm two aligning studs at 10 and 2 o clock positions in flywheel housing Fasten the hoist an...

Page 113: ...ipment Pump 2 Torque Converter Oil Temperature Sensors 3 Fan Drive Pump 4 Electrical Harness 5 Torque Converter Breather Hose 6 Oil Cooler Hose 7 Torque Converter 8 Charge and Scavenge Pump 5 Install transmission lube inlet hose 3 and the scavenge suction tube 5 to the transmission 6 Connect torque converter drain hose 8 to the flywheel housing 7 Connect the torque converter supply hose 7 to the t...

Page 114: ... procedure 14 Fill the equipment hydraulic reservoir as described in the OPERATOR S MANUAL 15 Place the drive train control lock lever in the locked ON position Start the engine and visually check hoses and connections for leakage NOTE It is recommended that the transmission oil filter be serviced after the first 50 hours of operation Refer to the OPERATOR S MANUAL for procedure Thereafter service...

Page 115: ...SECTION 7C TRANSMISSION ...

Page 116: ......

Page 117: ...E 12 REMOVAL AND DISASSEMBLY 39 13 INSPECTION AND REPAIR 41 14 REASSEMBLY AND INSTALLATION 41 RATE OF RISE VALVE 15 REMOVAL AND DISASSEMBLY 41 16 INSPECTION AND REPAIR 42 17 REASSEMBLY AND INSTALLATION 44 DRIVE TRAIN CONTROL VALVE 18 REMOVAL 44 19 DISASSEMBLY 47 20 INSPECTION AND REPAIR 56 21 REASSEMBLY 56 22 PRESSURE TEST 65 23 INSTALLATION 66 CHARGE AND SCAVENGE PUMP 24 REMOVAL 67 25 DISASSEMBLY...

Page 118: ...DRESSTA PRIORITY VALVE 34 REMOVAL AND DISASSEMBLY 84 35 INSPECTION AND REPAIR 85 36 REASSEMBLY AND INSTALLATION 85 DRIVE TRAIN LOCK SOLENOID VALVE 37 REMOVAL AND DISASSEMBLY 86 38 INSPECTION AND REPAIR 88 39 REASSEMBLY AND INSTALLATION 89 ...

Page 119: ... 5 8 13UNC Countershaft pusher pulling bolt 1 2 13UNC Countershaft pusher pulling bolt washer 1 2 Countershaft eyebolt 1 2 13UNC Ball bearing 5 8 Directional clutch shaft input shaft seating bearing puller 1 547 0220 Range clutch shaft output shaft seating bearing puller 1 547 0220 Countershaft seating bearing puller 1 547 0221 Charge and scavenge pump seal retainer installation sleeve Fabricate a...

Page 120: ...consists of a reverse idler gear which rides on two tapered roller bearings and is in constant mesh with the reverse driver gear and the reverse driven gear Range Clutch Shaft Output Shaft The range output shaft rotates on two tapered roller bearings The shaft consists of first second and third speed driven gears which ride on caged roller bearings The first speed driven gear is welded to the sing...

Page 121: ... 4 Manifold Gasket 5 Pressure Regulator Valve 6 O Ring 7 O Ring 8 Rate of Rise Valve 9 Rate of Rise Valve Gasket 10 Range Selector Valve Rate of Rise Valve Rate of rise valve 8 Fig 7C 1 sequences the flow and regulates the pressure of the oil to the directional and range clutch packs during shifting When a directional shift occurs oil from the range selector valve 10 enters the rate of rise valve ...

Page 122: ...tes externally splined clutch plates 13 Thickness of friction disc 2 76 2 92 mm Thickness of separator plate 2 23 2 33 mm Second speed clutch pack Number of friction discs internally splined clutch plates 13 Number of separator plates externally splined clutch plates 12 Thickness of friction disc 2 76 2 92 mm Thickness of separator plate 2 23 2 33 mm Third speed clutch pack Number of friction disc...

Page 123: ...nd or manifold failure it is possible to replace damaged parts without removing the transmission For replacement of damaged parts fist remove transmission case guard from bottom of machine Replace respective seal rings and or manifold Refer to relative Paragraphs in this Section NOTE There is possibility removing the transmission without removing the range selector valve and pressure regulator val...

Page 124: ...nt while under confines the machine 3 Remove the ROPS cab and platform Refer to SECTION 13 SUPERSTRUCTURE 4 Disconnect the breather hose 15 Fig 7C 2 from the transmission 5 5 Disconnect fan motor drain hose 8 from the cross located on the rear ROPS bracket 6 Remove the equipment pump 1 Refer to SECTION 10A for removing procedure 7 Disconnect the electrical harness 13 from the pressure switches 12 ...

Page 125: ... 1 14 Unscrew bolts securing suction strainer 3 Fig 7C 5 to the main frame 4 and move suction strainer out of the way 15 Disconnect the electrical harness from input shaft RPM sensor 5 Remove the sensor 5 from the transmission housing NOTE Before removing the universal joint wire or tape the bearing caps to prevent them from falling off the spider trunnions 16 Remove the bolts securing the univers...

Page 126: ... Move the transmission forward to free the output shaft from the steering drive Lift the transmission up of the machine NOTE Cover the opening in the main frame to prevent dirt and dust from entering Fig 7C 6 Removing Transmission Manifold 1 Transmission Manifold 2 Rate of Rise Valve 3 Rate of Rise Valve Gasket 4 Manifold Gasket 5 Transmission 20 Position the transmission assembly on a stand so th...

Page 127: ...sion 1 Housing 2 Tube 3 Reverse Idler Gear 4 Cover 5 Directional Clutch Shaft 6 Manifold 7 Shim 8 O Ring 9 Oil Seal 11 Tapered Roller Bearing 12 Countershaft 13 Tapered Roller Bearing 14 Shaft Cover 15 Shim 16 Retaining Ring 17 O Ring 18 Seal Sleeve 19 Range Clutch Shaft 20 Manifold 21 Shim 22 O Ring 23 Sump Pipe 24 Gasket 25 O Ring 26 Baffle 27 O Ring 28 O Ring ...

Page 128: ...ings 3 Manifold Seal Ring 4 Manifold Seal Ring 5 Manifold Seal Ring 6 Manifold Seal Ring 7 Lube Sleeve Seal Ring 8 2nd Piston Seal Rings 9 Shaft Seal Rings 10 3rd Piston Seal Rings 11 Lube Sleeve Seal Ring 12 Lube Sleeve Seal Ring 13 1st Piston Seal Rings 14 Shaft Seal Rings 15 Manifold Seal Ring 16 Manifold Seal Ring 17 Manifold Seal Ring 18 Manifold Seal Ring ...

Page 129: ...and shims 7 Refer NOTE above Keep shims 7 with the manifold for proper installation 5 Remove O ring 8 and oil seal 9 from manifold 6 6 Remove the two plugs from cover 14 Remove retaining ring 16 and shims 15 Thread a bolt into the center hole of cover 14 and remove the cover as shown in Fig 7C 9 Remove O ring 17 from the cover 14 Keep shims 15 with the cover for proper installation Fig 7C 8 Manifo...

Page 130: ... housing as shown in Fig 7C 11 10 Remove the five bolts with washers securing baffle 26 to cover 4 Remove the baffle as shown in Fig 7C 12 11 Install an eyebolt 5 8 13 UNC in the end of range clutch shaft 19 and hoist it up far enough to allow removal of shafts 5 and 12 as shown in Fig 7C 13 Fig 7C 12 Baffle to Cover Bolt Fig 7C 13 Removing the Shafts Reverse Idler Shaft Refer to Fig 7C 15 Fig 7C ...

Page 131: ... is necessary remove the bearing cups from both ends of the gear Fig 7C 15 Reverse Idler Shaft 1 Reverse Idler Gear Shaft 2 Reverse Idler Gear 3 Tapered Roller Bearing 4 Bearing Cone Spacer 5 Retaining Ring 6 Plate 7 Bolt 8 O Ring NOTE An internal retaining ring 5 separates the two cups inside gear 2 16 If bearing or shaft replacement is necessary press bearing cone 3 off shaft 1 Countershaft Refe...

Page 132: ...rom its groove and slide the retaining ring and gear 3 down onto gear 4 as shown in Fig 7C 18 Fig 7C 17 Removing Bearing Cone Fig 7C 18 Lowering Reverse Driven Gear 19 Remove bearing cone 11 Fig 7C 7 as shown in Fig 7C 19 Disassemble component parts in the order 2 3 2 2 4 5 and 2 using a press 20 If bearings 11 and 13 Fig 7C 7 were replaced remove bearing cup 11 from cover 4 and remove bearing cup...

Page 133: ... 6 Thrust Bearing 7 Roller Bearing 8 Reverse Driver Gear 9 Retaining Ring 10 Piston Spring 11 Spring Plate 12 Lube Sleeve Assy 13 Spring Retainer Plate 14 Clutch Support Plate 15 Retaining Ring 16 Friction Disc 17 Separator Plate 18 Friction Disc 19 Separator Plate 20 Clutch Piston 21 Clutch Hub 22 Seal Ring 23 O Ring 24 Seal Ring 25 O Ring 26 Clutch Drum 27 Forward Driver Gear 28 Tapered Roller B...

Page 134: ...earing replacement is necessary remove bearing cup from the cover Fig 7C 21 Removing Bearing Cone Fig 7C 22 Removing Retaining Ring 22 Disassemble component parts 5 6 5 8 7 5 6 and 5 in sequence indicated 23 Remove retaining ring 15 as shown in Fig 7C 22 24 Lift parts 14 16 and 17 out of drum 26 25 Compress springs 10 by pressing down on plate 11 with C clamp as shown in Fig 7C 23 and remove retai...

Page 135: ...equence indicated 33 Compress springs 10 by pressing down on plate 11 with C clamps as shown in Fig 7C 25A and remove retaining ring 9 34 Disassemble component parts 11 10 12 13 and 9 in sequence indicated Fig 7C 25 Removing Retaining Ring Fig 7C 25A Compressing Piston Springs 35 Lay the shaft on its side and apply compressed air in the shaft hole closest to the clutch pack to remove piston 20 Rem...

Page 136: ...Clutch Piston 18 Seal Ring 19 O Ring 20 Second and Third Hub 21 Seal Ring 22 Third Clutch Piston 22A Dowel Pin 23 Seal Ring 24 O Ring 25 Third Clutch Gear 26 Spacer 27 Retaining Ring 28 Retaining Ring 29 Friction Disc 30 Separator Plate 31 Friction Disc 32 Separator Plate 33 Friction Disc 34 Separator Plate 35 Clutch Support Plate 36 Second and Third Drum 37 Retainer Plate 38 First Clutch Gear 39 ...

Page 137: ...ssing down on piston 41 with C clamps as shown in Fig 7C 28 and remove retaining ring 2 Fig 7C 27 Removing Hub with Bearing Cone Fig 7C 28 Compressing Return Springs 45 Remove parts 41 14 13 16 33 34 28 35 and 46 as an assembly by lifting drum 46 off the output shaft 1 Set the assembly on a bench and disassemble component parts 41 14 13 16 33 34 28 35 and 46 in the sequence indicated 46 Disassembl...

Page 138: ...15 from the piston 22 and remove O ring 16 from the sleeve 53 Place the shaft in the stand so that second clutch gear 6 is up and remove retaining ring 2 54 Remove the bearing cone 48 with a bearing puller as shown in Fig 7C 32 NOTE Bearing cup 48 was removed with cover 4 Fig 7C 7 If bearing replacement is necessary remove bearing cup from cover Fig 7C 31 Removing Dowel Pins Fig 7C 32 Removing Bea...

Page 139: ...ing ring 2 and disassemble component parts 18 19 20 23 24 and 21 in sequence indicated If necessary remove parts 51 52 and 1 6 INSPECTION AND REPAIR 1 It is recommended that new O rings be installed whenever the transmission is disassembled for service 2 Wash all parts thoroughly in a suitable solvent Dry thoroughly with compressed air or a clean cloth NOTE Do not spin dry bearings with compressed...

Page 140: ...grooves of drum 36 NOTE When reassembling carefully place the second and third hub 20 over the shaft insuring the hub clutch oil supply holes are aligned with the shaft oil supply holes 5 Install shaft 1 manifold end first in drum 36 and secure with second retaining ring 28 6 Install sleeve 13 with new O ring 16 on the shaft 1 7 Position retainer plates 14 on piston 17 Apply LOCTITE 262 to the bol...

Page 141: ...he shaft 1 Be sure all the internally splined discs 31 are aligned in drum 36 and that the gear meshes with all the discs Install retaining ring 28 22 Install bearing 5 in the bore of gear 25 23 Install thrust bearing 4 with thrust races 3 bearing 5 and first clutch gear 38 on the shaft 1 Install following thrust bearing 4 with races 3 bushing 39 spacer ring 40 retaining ring 8 and spring retainer...

Page 142: ...ig 7C 7 with depth not less than 0 04 mm Directional Clutch Shaft Input Shaft Refer to Fig 7C 20 34 If removed install pins 30 and 31 into the shaft 1 Install metering plug 4 NOTE Press in spring pins 31 to shaft holes down to depth of 1 3 mm from shaft surface Do not damage the shaft surface during this process 35 Press in dowel pins 30 to shaft holes down to shaft surface Press in metering plug ...

Page 143: ...ission oil If facilities are not available for soaking a heavy oiling on both surfaces may be sufficient 45 Install clutch support plate 14 with retaining ring 15 Install retaining ring 9 and thrust bearing 6 with thrust races 5 46 Position forward driver gear 27 over the end of the shaft 1 Be sure all the internally splined discs 18 are aligned in drum 26 and that the gear meshes with all the dis...

Page 144: ... ring 2 NOTE Gears 3 4 and 5 preheating up to to 120 C max is allowed 64 Heat bearing cones 11 and 13 Fig 7C 7 to 135 C for 45 minutes and install on the shaft 1 until bottom To assure cones are seated keep pressure against the cones until they cool down a few seconds 65 If bearings 11 and 13 Fig 7C 7 were replaced press new bearing cup 11 in cover 4 and press new bearing cup 13 in housing 1 with ...

Page 145: ... be inserted in the baffle opening as shown in Fig 7C 40 Fig 7C 39 Shafts Installation Fig 7C 40 Baffle to Cover Bolt 75 Insert tubes 2 through the openings in housing 1 76 Apply LOCTITE 515 to the mating surfaces of cover 4 and housing 1 according to the instructions on the container Hoist the housing 1 as shown in Fig 7C 41 and lower it over the shafts guiding the ends of shafts into their prope...

Page 146: ...htly grease the directional clutch shaft manifold and range clutch shaft manifold outside diameter and leave O rings off cover and manifold To give an excessive initial end play condition for input shaft when installing the input shaft manifold use an oversize shim pack of 3 05 mm For the range clutch shaft manifold use an oversize shim pack of 4 06 mm With directional clutch shaft manifold and ra...

Page 147: ... B Input Pull Seating Front Cone on Directional Clutch Input Shaft Refer to Fig 7C 45 2 Assemble an oversize shim pack of 3 05 mm from shims 7 Fig 7C 7 and position on manifold 6 This will give an excess end float condition Install directional shaft manifold 6 with oversize shim pack Do not install O ring 8 at this time 3 Install the puller bridge 2 and pulling bolt 1 1 2 13 UNC with washer 1 2 in...

Page 148: ...up shoulders on the directional clutch shaft manifold If it is determined that end play adjustment falls below the specification and extra shims need to be added the shaft must be pulled up again with an oversize shim pack as shown in Fig 7C 45 to shoulder the bearing cup on the input shaft manifold Use caution here not to damaged the input shaft manifold seal rings with repositioning the input sh...

Page 149: ...ing Seating Pull on Countershaft Refer to Fig 7C 48 2 Assemble an oversize shim pack of 0 76 mm from shims 15 Fig 7C 7 and position on the countershaft cover 14 Fig 7C 7 against the front bearing cup This will give an excess end float condition Install countershaft cover 14 Fig 7C 7 into its bore in transmission housing without O ring 17 Fig 7C 7 3 Install the puller 1 and thread a pulling bolt 1 ...

Page 150: ... cover toward the bearing cone when shims are removed to adjust end play After the correct end play has been established install the O ring 17 Fig 7C 7 on the cover 14 Fig 7C 7 Recheck end play after shims 15 Fig 7C 7 and retaining ring 16 Fig 7C 7 are installed Reinstall two plugs in shaft cover 14 Fig 7C 7 Fig 7C 49 Transmission Countershaft Checking Shaft End Play 1 Eyebolt 2 Lever 3 Dial Indic...

Page 151: ... clutch shaft manifold 20 Fig 7C 7 with oversize shim pack being sure to align manifold over shaft without damaging previously installed seal rings Do not install O ring 22 Fig 7C 7 at this time Fig 7C 50 Transmission Range Clutch Shaft Push Operation 1 Puller 2 Pusher Bolt 3 Install the puller and pulling bolt 5 8 13 UNC with washer 5 8 as shown in Fig 7C 51 Torque the pulling bolt to 217 Nm Remo...

Page 152: ...ay adjustment falls below the specification and extra shims need to be added the shaft must be pulled up again with an oversize shim pack as shown in Fig 7C 50 to shoulder the bearing cup on the manifold Use caution here not to damaged the manifold seal rings with repositioning the manifold 6 After the correct end play has been established install O ring 22 Fig 7C 7 on manifold 20 Fig 7C 7 Install...

Page 153: ...running 8 Install input shaft RPM sensor 5 Fig 7C 5 into transmission 2 Carefully screw the sensor 5 in as far as it will go and until it just touches directional shaft drum Undo the sensor 1 3 4 turns and lock it with a lock nut Reconnect the electrical harness to the RPM sensor 5 9 Install suction strainer 3 to the main frame 4 10 Reconnect the lube hose 4 Fig 7C 3 to the transmission 11 Install...

Page 154: ...7C 54 Fig 7C 53 Exploded View of Pressure Regulator Valve 1 End Cover 2 O Ring 3 Lube Spool Spring 4 Torque Converter Spool Spring 5 Main Spool Outer Spring 6 Lube or Torque Converter Spool 7 Main Spool Inner Spring 8 Spring Guide Pin 9 Shim 10 Ball Spring 11 Check Ball 12 Spring Pin 13 Main Spool 14 Valve Housing 15 Port Plug ...

Page 155: ...the controls are tagged to prevent inadvertent engine starting IMPORTANT When disconnecting hydraulic lines for any reason they should be properly capped with the correct size plastic cap If these caps are not available tape or clean rubber corks may be used Hydraulic openings must never be plugged with rags This practice could easily introduce dirt or lint into critical hydraulic components of th...

Page 156: ...bricate the spools and valve bores with transmission oil upon reassembly 1 Apply LOCTITE Pipe Sealant 569 to plug 15 and install in the valve housing 14 if removed 2 Reassemble component parts 11 10 and 12 of spool 13 in reverse numerical order 3 Reassemble component parts 13 6 8 9 7 5 4 3 2 and 1 in sequence indicated Tighten the bolts securing covers 1 to a torque 26 28 Nm NOTE Be sure springs a...

Page 157: ...ntrols are tagged to prevent inadvertent engine starting IMPORTANT When disconnecting hydraulic lines for any reason they should be properly capped with the correct size plastic cap If these caps are not available tape or clean rubber corks may be used Hydraulic openings must never be plugged with rags This practice could easily introduce dirt or lint into critical hydraulic components of the mach...

Page 158: ...ses at the range selector valve and tag them 3 Remove the bolts and washers securing the valve assembly to the top of the transmission manifold Remove the valve assembly and mounting O rings 4 Disassemble component parts 1 5 6 2 4 8 and 3 in sequence indicated Fig 7C 56 Exploded View of Range Selector Valve 1 End Cover 2 Range Selector Spool 3 Directional Spool 4 Return Spring 5 O Ring 6 O Ring 7 ...

Page 159: ... S MANUAL IMPORTANT As soon as the engine starts observe the transmission main and range clutch oil pressure lamp on the instrument panel If lights immediately turnoff the engine 5 Start the engine Checks for leaks Check the oil pressures as described in Paragraph 10 TRANSMISSION AND TORQUE CONVERTER OIL PRESSURE TEST in SECTION 7 6 Install the center floor plate between seat and instrument panel ...

Page 160: ...do not fall within the specifications shown in Paragraph 3 SPECIFICATIONS they must be replaced NOTE Springs 3 and 8 appear to be identical however they are different Intermixing will result in loss of range clutch pressure and loss of directional pressure Fig 7C 57 Cross Section of Rate of Rise Valve 1 End Cover 2 Gasket 3 Outer Piston Spring 4 Spring Retainer 5 Inner Piston Spring 6 Modulating P...

Page 161: ... Rate of Rise Valve 1 End Cover 2 Gasket 3 Outer Piston Spring 4 Spring Retainer 5 Inner Piston Spring 6 Modulating Piston 7 Valve Housing 8 Reducing Spring 9 Reducing Spool 10 Sequence Valve Spool 11 Dowel Pin 12 Sequence Valve Spacer 13 Sequence Valve Disc 14 Sequence Spool Spring 15 Spring Spacer ...

Page 162: ...loor mat if cab equipped DRIVE TRAIN CONTROL VALVE 18 REMOVAL WARNING Before working at the machine be sure that the blade and ripper have been lowered to the ground engine is OFF the drive train control lock lever is in locked ON position and parking brake is set The starting switch and the electrical system master switch are turned OFF keys are removed and the controls are tagged to prevent inad...

Page 163: ...re 4 Bolts 1 Access Cover 2 Filter Bracket 3 Bracket Mounting Bolts 4 Filters 4 Disconnect drive train control lever harness 3 Fig 7C 62 5 Remove the screws 2 Fig 7C 61 and remove cover 1 Fig 7C 61 Disassembly Console to Access Drive Train Control Valve Fig 7C 62 Drive Train Control Valve Disconnecting Points 1 Cover 2 Screws 3 Valve Console 4 Bolts 5 Control Lever 1 Hoses 2 Drive Train Control Va...

Page 164: ... bolts 4 Fig 7C 61 securing valve console 3 to the platform and remove console 3 out of the platform 10 Unscrew four mounting bolts 1 Fig 7C 63 securing valve bracket 2 to the platform and remove the valve with bracket from the platform Unscrew three mounting bolts 3 securing drive train control valve 4 to valve bracket 2 and remove the bracket 2 out of the valve 4 Fig 7C 63 Drive Train Control Va...

Page 165: ...TRANSMISSION SECTION 7C Page 47 DRESSTA TD 25M EXTRA DRIVE TRAIN CONTROL VALVE 19 DISASSEMBLY Refer to Fig s 7C 64 and 7C 65 Fig 7C 64 Exploded View of Drive Train Control Valve ...

Page 166: ...ng Spool 5 Guide Sleeve 6 Inner Spring 7 Outer Spring 8 Directional Spool 9 Thrust Washer 10 Directional Spool Spring 11 Stop Nut 12 Rocker End 13 Jam Nut 14 Seal Ring 15 Seal Ring 16 O Ring 17 Dowel Pin 18 O Ring 19 O Ring 20 Plug 21 Bottom Cover 22 Port Plug 23 Lever 24 Dowel Pin 25 Joint Housing 26 Pivot Ring 27 Universal Joint 28 Dowel Pin 29 Universal Joint Boot 30 Strip 31 Joint Base 32 Dowe...

Page 167: ...e dowel pin 28 in the lever 23 Apply the press and drive the pin out clearing the housing with lever 2 Remove the lever 23 with the joint housing 25 from the valve 3 Position the assembly in a vise Remove the hardware and separate the housing 25 from the pivot ring 26 4 Drive the dowel pin 24 out from the housing 25 Remove the lever 23 from the joint housing 25 ...

Page 168: ...5 Cut and remove the tie straps 30 from the joint boot 29 6 Remove the boot 29 from the universal joint 7 Remove the spool rocker end 12 and jam nut 13 from each spool 8 Position the assembly in a vise Remove the dowel pin 28 connecting the universal joint 27 to the joint base 31 ...

Page 169: ...move the universal joint 27 10 Unscrew four bolts and remove the joint base 31 If required remove two dowels pins 32 from the base 31 11 Turn the valve over and remove the two opposite side mounting bolts 12 Install two threaded rods with washers and nuts to the vacated mounting holes ...

Page 170: ...f each nut until all spring tension is relieved WARNING Spring loaded assembly Cover must be held to relieve spring pressure Use extreme care when disassembling 15 Remove the threaded rods and the bottom cover 21 from the valve 16 Remove and discard the O rings 16 and 18 from the bottom cover 21 If necessary remove dowel pin 17 ...

Page 171: ...NTROL VALVE 17 Remove and discard O ring 16 from the valve housing Remove the outer springs 7 18 Remove the inner springs 6 19 Remove the guide sleeve 5 from each steering spool 4 20 Remove the directional spool springs 10 at each directional spool in the valve housing ...

Page 172: ... valve housing push the directional spool 8 up and out of the valve body Repeat for remaining spool If necessary remove dowel pin 17 23 Install two 3 8 NC nuts on the directional spool 8 and position in a vise Remove the loctited stop nut 11 from the spool Repeat for remaining spool 24 Remove the thrust washer 9 from the spool 8 Repeat for remaining spool ...

Page 173: ...age 55 DRESSTA TD 25M EXTRA DRIVE TRAIN CONTROL VALVE 25 Remove and discard seal rings 14 and 15 from the valve housing 26 Remove the orifice plugs 33 from the bottom cover 21 27 Remove two plugs 20 with O rings 19 if necessary ...

Page 174: ...eplaced 4 Clean threads with a stiff brush and solvent Check for damage 5 Inspect the condition of the springs If they are wore or damaged they must be replaced 6 Inspect the pivot ring and spool rocker ends for excessive wear or scratches and replace if necessary 21 REASSEMBLY Refer to Fig s 7C 64 and 7C 65 IMPORTANT Sealing rings should be lubricated with petroleum jelly for ease of assembly The...

Page 175: ...h the directional spool nutted in a vise install the thrust washer 9 5 Apply LOCTITE 242 to the nut threads and install the stop nut s 11 Torque the nuts to 22 Nm Repeat Step 4 through 5 for remaining spool 6 Install the directional spool 8 into the valve housing using a slight turning motion to aid the spool pass through the seal ring Repeat for remaining spool If removed install dowel pin 17 ...

Page 176: ...t turning motion to aid the spool pass through the seal ring Repeat for remaining spool 8 Install the directional spool springs 10 in the recessed bores 9 Install the guide sleeves 5 over the steering spools with the recessed area towards the valve housing 10 Install O ring 16 into valve housing Install the inner springs 6 to the steering spools ...

Page 177: ...ll two threaded rods to valve housing 13 Install new O rings 16 and 18 to the bottom cover 21 If removed install dowel pin 17 14 Position the bottom cover 21 over the threaded rods with the offset dowel pin holes to the dowel pins 17 Draw down equally on the nuts until the cover is flush NOTE Be careful not to bind the cover to the dowel pin ...

Page 178: ...emove the threaded rods and install the remaining bolts 16 Torque the mounting bolts to 38 Nm 17 If removed install two dowel pins 32 Install joint base 31 to the valve housing aligning the base dowel pins with the offset recess in the valve housing Torque the bolts to 11 Nm 18 Slide the universal joint 27 over the joint base 31 ...

Page 179: ...el pin 28 in making sure it is countersunk at each end 20 Apply a generous amount of grease refer to OPERATOR S MANUAL to the universal joint 21 Install the boot 29 over the universal joint 27 and secure with the tie straps 30 22 Install the jam nuts 13 and the spool rocker ends 12 to each spool ...

Page 180: ...nto the housing 25 and align with the dowel pin 24 Drive the pin into the housing so that it completely clears the housing 25 Attach the joint housing 25 to the pivot ring 26 and torque the bolts to 11 Nm 26 Install the joint housing 25 over the universal joint 27 and align the dowel pin opening in the universal joint with the opening in the joint housing ...

Page 181: ...universal joint 27 so that it completely clears the housing 25 Drive Train Control Valve Adjustment 28 Apply a generous amount of grease refer to OPERATOR S MANUAL to the pivot ring 26 surface 29 Run all four spool rocker ends 12 up against the pivot ring until the lever 23 is vertical with no free play between the pivot ring surface and rocker ends ...

Page 182: ...ALVE 30 Move the lever fully in all directions to seat the steering and directional spools against their springs Recheck for free play between the pivot ring and rocker ends and correct as necessary 31 Tighten the jam nuts to the spool rocker ends Torque the nuts to 32 37 Nm ...

Page 183: ... be the same respectively c The pressures in test points F and R must be 0 0 MPa for control lever in neutral N position 5 Left and right steering pressure test starting from neutral N position a The pressures in test points CR and CL must be M 0 07 MPa for drive train control lever in neutral N position b Gradually shift the lever from neutral N position to the right RH direction with the lever b...

Page 184: ... control valve 2 7 Install bracket 2 Fig 7C 60 with filters 4 to the ROPS bracket and secure with bolts 3 Reconnect the electrical harness to the filter base WARNING Be sure the area around the machine is clear of personnel and obstructions as the vehicle may move during these test If the machine starts to move fully depress the decelerator pedal and shift the drive train control lever to NEUTRAL ...

Page 185: ...ings must never be plugged with rags This practice could easily introduce dirt or lint into critical hydraulic components of the machine Tag all disconnected oil lines to facilitate easier installation 1 Remove floor mat cab equipped machines and center floor plate from between operator s seat and instrument panel 2 Remove the transmission case guard from the bottom of the machine WARNING This pro...

Page 186: ...ve and discard the pump mounting O ring Fig 7C 67 Charge and Scavenge Pump Disconnect Points Bottom View 1 Pump Mounting Bolt 2 Main Suction Tube 3 Charge and Scavenge Pump 4 Scavenge Suction Pump Hose 25 DISASSEMBLY Refer to Fig 7C 68 IMPORTANT If prying off sections becomes necessary take extreme care not to mar or damage machined surfaces Excessive force while prying can result in misalignment ...

Page 187: ...aft Oil Seal 2 Seal Retainer 3 O Ring 4 Retaining Ring 5 Housing Seal 6 Channel Seal 7 Wear Plate 8 Stud 9 Washer 10 Nut 11 Shaft Coupling 12 Port Plug 13 Needle Bearing 14 Rear Housing 15 Seal Ring 16 Driven Gear Housing 17 Driven Gear Set 18 Bearing Housing 19 Drive Gear Housing 20 Drive Gear Set 21 Front Housing 22 Retainer Spacer ...

Page 188: ...d surfaces during assembly or disassembly 2 Remove the 8 hex nuts 10 and washers 9 with a socket wrench 3 Lift off the rear housing 14 If necessary to pry loose be careful not to damage the machined surfaces If the wear plate 7 remains in the gear housing 16 it can be tapped out later with a wooden hammer handle Be careful not to distort the wear plate 7 4 Lift the gear housing 16 from the gears 1...

Page 189: ... are a matched set Examine and replace if necessary See Paragraph 26 INSPECTION AND REPAIR in this SECTION 6 Lift or pry off the bearing housing 18 Take care not to damage the machined surfaces 7 Remove the coupling shaft 11 8 Lift or pry off the first section gear housing 19 Be careful not to damage machined surfaces Remove wear plate 7 as described in Step 3 ...

Page 190: ...er or similar tool Avoid distorting the wear plates 7 Remove and discard all rubber channel seals 6 and housing seals 5 11 Examine all needle bearings 13 for wear and discoloration If replacement is necessary pull the bearings 13 with a bearing puller Any sign wear or discoloration calls for replacement 12 It is generally advisable to replace seal rings 15 when rebuilding unit To replace remove th...

Page 191: ...h retaining ring pliers 14 Remove the retainer spacer 22 15 Remove the seal retainer 2 and seal with a light duty bearing puller Remove and discard O ring 3 16 Tap the shaft seal 1 from the seal retainer 2 and discard Clean seal bore with solvent to remove old sealant If bore is scored smooth with fine grade emery paper It is generally advisable to replace the seal retainer 2 ...

Page 192: ...nd main frame for dirt Where cut out is moderate 0 13 mm or less gear housing is in good condition and both ports are of the same size housing may be flopped over and reused B Gears Any wear on gear hubs detectable by touch or in excess of 0 05 mm necessitates replacement Nicking grooving fretting of teeth surfaces or head discoloration also necessitates replacement Scoring grooving or burring of ...

Page 193: ...t is required Wear or damage to splines keys or keyways necessitates replacement E Bearings If gears are replaced bearings must be replaced Bearings should fit into bore with a light press fit A neat hand fit is allowable If bearings can fall out bore may be oversize F Seals and gaskets Replace all rubber and polymer seals whenever disassembling pump Include all O rings channel seals behind wear p...

Page 194: ...e vise with the mounting face down Examine the plug 12 to be sure it is tightly in place Replace only if parts is damaged or missing ASSEMBLY STEPS 3 4 5 AND 6 APPLY TO FRONT HOUSING BEARING HOUSING AND REAR HOUSING 3 If seal rings 15 are being replaced insert into bottom of drive gear bearing bore flat side down The notch in the seal ring MUST BE VISIBLE This is a check to be certain the notched ...

Page 195: ...6 and insert into the middle slots in the wear plate 7 With the channel seals 6 down place the wear plate 7 over the bearings 13 Tap the wear plate 7 down firmly against the machined surface with a soft hammer Tap wear plate 7 with a soft hammer to about 0 8 mm from the machined surface 7 Insert the integral shaft and gear 20 Push down until the gear is tight against the wear plate 7 Insert the ma...

Page 196: ...ation when pump is started 10 Position the bearing housing 18 with wear plates 7 on the gear housing 19 so that the needle bearings 13 receive the journals of the drive and driven gears 20 Make sure that the index marks See Step 1 Disassembly are properly aligned Tap the bearing housing 18 tight with a soft hammer 11 Insert the coupling shaft 11 in the spline of the drive gear 20 12 Insert the dri...

Page 197: ...14 Place the rear housing 14 over the gear journals and tap tightly against the gear housing 16 Be careful not to pinch the housing seal 5 15 Thread the 8 studs 8 and nuts 10 with washers 9 into the front housing 21 and snug up alternately or cross corner Rotate the drive shaft with a 6 wrench to make sure there is no binding in the pump After the nuts 10 are tight and it is sure there is no inter...

Page 198: ... 22 The spacer may need to be lightly tapped into the spacer bore 19 Install the retaining ring 4 in the groove 28 INSTALLATION 1 Position the charge and scavenge pump 3 Fig 7C 66 with new mounting O ring on the torque converter flange Using bolts 1 Fig 7C 67 and 1 Fig 7C 66 previously removed secure the pump to torque converter IMPORTANT Before connecting any lines to the pump fill all ports with...

Page 199: ...er have been lowered to the ground engine is OFF the drive train control lock lever is in locked ON position and parking brake is set The starting switch and the electrical system master switch are turned OFF keys are removed and the controls are tagged to prevent inadvertent engine starting IMPORTANT Disconnected hydraulic lines must be properly capped with the correct size plastic cap If caps ar...

Page 200: ...crew two bolts 6 and separate gear shifting valve 4 from the bracket 5 6 Disconnect drain hose 1 and pressure supply hose 7 and remove the valve out of machine 30 DISASSEMBLY 1 Unscrew the solenoid coils from the solenoid valves 1 and 2 Fig 7C 70 Remove the solenoid valve 1 and 2 bodies from the valve housing 3 Remove and discard the valve seal kit and replace with new 2 Remove plug 4 if necessary...

Page 201: ...install it if removed 2 Install a new seal kit to the solenoid valve 1 and 2 bodies Install the solenoid valves bodies to the valve housing 3 Torque the solenoid valve 1 and 2 bodies to 20 5 22 5 Nm Install the solenoid coils on valve bodies and torque them to 4 3 4 8 Nm 33 INSTALLATION 1 Temporarily secure the gear shifting valve 4 Fig 7C 69 to the valve bracket 5 Reconnect the pressure supply ho...

Page 202: ...tice could introduce dirt or lint into critical hydraulic components Remove all dirt accumulation from the main frame cover Tag disconnected lines to facilitate faster and correct installation Fig 7C 71 Priority Valve Disconnect Points 1 Drain Hose 2 Priority Valve 3 Mounting Bolt 4 Priority Valve to Transmission Hose 5 Pressure Supply Hose 6 Bracket 1 Turn electrical master switch to OFF position...

Page 203: ...Check for damage 36 REASSEMBLY AND INSTALLATION 1 Install a new seal kit to the pressure regulator body 1 Fig 7C 72 2 Install the pressure regulator into the valve housing 2 Torque the regulator body 1 to 465 500 Nm 3 Secure the gear shifting valve 4 Fig 7C 71 to the LH fender bracket 6 with two mounting bolts 3 4 Reconnect the priority valve to transmission hose 6 pressure supply hose 5 and drain...

Page 204: ...plugged with rags This practice could introduce dirt or lint into critical hydraulic components Remove all dirt accumulation from the main frame cover Tag disconnected lines to facilitate faster and correct installation 1 Unscrew bolts 4 Fig 7C 73 and remove L H enclosure 3 with L H door 2 Disconnect the electrical harness from the filter base Unscrew bolts 3 Fig 7C 74 fastening filters bracket 2 ...

Page 205: ...id valve harness 1 Fig 7C 75 5 Disconnect drain hose 5 supply hose 6 and lock solenoid valve to drive train control valve hose 4 at the lock solenoid valve 2 6 Unscrew two bolts 3 and separate solenoid lock valve 2 from LH fender 7 Lift the valve from the machine and remove attached hydraulic connectors if necessary 8 Unscrew the solenoid coil from the lock solenoid valve 2 Remove the solenoid val...

Page 206: ...ECTION AND REPAIR 1 It is recommended that all new seal rings be installed upon reassembly of the valve 2 Clean all parts in a suitable solvent and blow dry with compressed air Be sure all oil passages in the valve manifold and valve cartridge are free of obstructions 3 Inspect parts for excessive wear and replace if necessary 4 Clean threads with a stiff brush and solvent Check for damage ...

Page 207: ...pply hose 6 and drain hose 5 to the lock solenoid valve 2 5 Reconnect lock solenoid valve harness 1 to the valve 2 WARNING Be sure the area around the machine is clear of personnel and obstructions as the vehicle may move during these test If the machine starts to move fully depress the decelerator pedal and shift the drive train control lever to NEUTRAL 6 Start the engine and operate with drive t...

Page 208: ......

Page 209: ...SECTION 7E STEERING DRIVE ...

Page 210: ......

Page 211: ...AL 3 5 DISASSEMBLY 8 6 INSPECTION AND REPAIR 13 7 REASSEMBLY 14 8 INSTALLATION 25 TWO SPEED STEERING VALVE 9 REMOVAL 27 10 DISASSEMBLY 28 11 INSPECTION AND REPAIR 33 12 REASSEMBLY 34 13 INSTALLATION 35 14 STEERING VALVE BRAKE SECTION TEST AND ADJUSTMENT 36 STEERING MANIFOLD 15 REMOVAL 37 16 DISASSEMBLY 37 17 INSPECTION AND REPAIR 38 18 REASSEMBLY 38 19 INSTALLATION 38 ...

Page 212: ......

Page 213: ...TION The steering system on this machine consists of a two speed steering drive located in the main frame and a two speed steering valve mounted on the rear main frame cover The oil pressure from drive train control valve operates hydraulically and brake pedal cable operates mechanically the steering valve Electronic controller operates electrically the steering valve through drive train control v...

Page 214: ...4 2 34 mm Special Nut and Bolt Torques Torques given are for bolts and nuts lubricated with SAE 30 engine oil Oil slinger to clutch plate retainer mounting bolts LOCTITE 262 applied 11 Nm Clutch plate retainer to bevel gear hub mounting bolts 108 Nm Bevel gear to bevel gear hub mounting bolt 255 Nm Pinion gear housing to main housing mounting bolts 108 Nm Nut lock ring to main housing mounting bol...

Page 215: ...made before removing the steering drive In this manner hydraulic malfunctions can be pinpointed and corrected at time of teardown WARNING Before working at the machine be sure that the blade and ripper have been lowered to the ground engine is OFF the drive train control lever is in NEUTRAL position drive train neutral lock lever is in ON position and parking brake is set The starting switch and t...

Page 216: ...the fuel drain valve 6 Fig 7E 2 and drain the fuel tank 5 Close the drain valve 6 8 Disconnect fuel supply hose 7 and fuel return hose 8 from the fuel tank 5 9 Replace two plugs located in the top of the fuel tank 3 Fig 1E 1 with two threaded eye bolts 1 NCx1 1 2 Attach a suitable hoist to the eye bolts remove fuel tank mounting bolts 13 Fig 7E 2 from bottom of fuel tank and lift off the tank usin...

Page 217: ...ck and Filler Tube 12 Hydraulic Damper 13 Fuel Tank Mounting Bolts 14 Drain Hoses 15 Main Frame Cover Bolts 16 Install two lifting eye bolts 1 2 13UNC 2B 2 Fig 7E 3 and remove the main frame cover 1 17 Remove the lube tube 3 Fig 7E 4 from the steering drive 2 and from the front surface of main frame 1 Temporarily secure the steering manifold 2 Fig 7E 9 to the bracket 17 Fig 7E 3 Main Frame Cover R...

Page 218: ...and pull it free of the steering drive as shown in Fig 7E 6 20 Repeat steps 18 and 19 on the opposite side of the machine Fig 7E 5 Removing Output Shaft Retainer Fig 7E 6 Removing Output Shaft from Steering Drive 1 Retaining Ring 2 Shaft Retainer 21 Attach a hoist with an adjusting sling to the four steering drive lifting eyes as shown in Fig 7E 7 and take up the slack NOTE An adjusting sling must...

Page 219: ...r bolt 21 Fig 7E 9 26 Move the steering drive back as far as possible being sure the spline sleeve Fig 7E 7 stays with the steering drive pinion shaft Lift the steering drive out of the rear frame 27 Remove retaining rings 20 Fig 7E 9 securing lower bolts 21 to the steering drive 1 and remove bolts 21 28 Disconnect the manifold hoses connectors and elbows from steering drive and remove the manifol...

Page 220: ...Port 2 Right Low Piston Seal Rings 3 Right Low Clutch Piston 4 Right Low Piston Return Springs 5 Right Brake Port 6 Right Brake Applying Springs 7 Right Brake Piston Seal Rings 8 Right Brake Piston 9 Right High Piston Return Springs 10 Right High Clutch Piston 11 Right High Piston Seal Rings 12 Right High Clutch Port 13 Lube Port 14 Left High Clutch Port 15 Manifold Seal Rings ...

Page 221: ...STEERING DRIVE SECTION 7E Page 9 DRESSTA TD 25M EXTRA STEERING DRIVE Fig 7E 11 Exploded View of Two Speed Steering Drive ...

Page 222: ...ng 70 Piston Retainer Hub 71 Dowel Pin 72 Retaining Ring 73 Thrust Washer 74 Spacer 75 Tapered Bearing 76 Pinion Gear Housing 77 Support Housing Shim 78 Tapered Bearing 79 Pinion Shaft Gear 80 Piston Return Spring Shim 81 Friction Disc 82 Clutch Plate 83 Bearing Spacer 84 Return Spring Retaining Ring Shims NOTE For steering drive disassembly use rotational stand 1 851 0027 1 Set the assembly on en...

Page 223: ...o lose chrome steel ball 34 Slide planet gear 39 to the outside placing one hand under the gear as the thrust washers 37 and planet gear bearing 38 are free to drop out Remove planet gear bearing 38 from planet gear 39 16 Remove the two remaining planet gears 39 from the planet carrier 33 in the same manner as described in Step 15 17 Remove clutch hub roller bearings 40 and bearing spacer 84 from ...

Page 224: ...ch plate retainer 56 Remove seal rings 50 and 52 and O rings 51 and 53 from piston retainer hub 70 27 Remove the bolts securing nut lock ring 69 to housing 67 and remove the nut lock ring and adjusting nut 68 Fig 7E 16 Removing Bevel Gear Hub Fig 7E 17 Removing Bearing Carrier 28 Turn housing 67 over Remove two of the bolts that secure gear 58 to bevel gear hub 55 and install eyebolts 5 8 11x1 1 4...

Page 225: ...acement is necessary remove bearing cups of bearings 75 and 78 from housing 76 36 If pin replacement is necessary remove pin 71 from housing 67 6 INSPECTION AND REPAIR 1 It is recommended that new O rings and seal rings be installed whenever the steering drive is disassembled for service 2 Clean all parts thoroughly in a suitable solvent Dry thoroughly with compressed air or a clean cloth NOTE Do ...

Page 226: ...s a few seconds 7 If cups of tapered bearing 59 and 62 were removed press the cups in bearing carrier 61 8 Install gear hub sealing rings 60 in the grooves of bevel gear hub 55 Before installing the sealing rings 60 coat with grease Install bearing carrier 61 on the bevel gear hub 55 9 Install cone of tapered bearing 62 on bevel gear hub 55 until it contacts cup of tapered bearing 62 Install tongu...

Page 227: ...aring Preload II Method 12 Bend back the tabs of lock washer 64 Install piston retainer ring 66 in the groove of bevel gear hub 55 13 If tapered bearings 75 and 78 were replaced press new cups of tapered bearings in housing 76 until they bottom Fig 7E 20 Checking Pinion Shaft Bearing Preload I Method Fig 7E 20A Checking Pinion Shaft Bearing Preload II Method ...

Page 228: ... Take a reading of the drag newtons pull needed to start the housing rolling A reading 0 29 5 N should be obtained If the reading is higher a smaller retaining ring 72 must be installed If the reading is lower a larger retaining ring 72 must be installed 17 II Method Pinion gear shaft adjustment procedure Fig 7E 20B Pinion Gear Shaft Adjustment 72 Retaining Ring 73 Thrust Race 74 Spacer 75 Tapered...

Page 229: ... a 3 05 mm retaining ring 72 to get a total thickness equal to 6 23 mm In that case 0 07 mm was removed c Apply a force of 25000 N to a cone bearing inner ring 75 to get a 0 13 mm bearing shift towards the assy inner side to facilitate selected retaining ring 72 and thrust race 73 installation Make use of a 2 5 T hydraulic press to get a required force d Place the pinion gear shaft 79 on pinion ge...

Page 230: ...ing Pinion Shaft End Gap 23 Adjust the bevel gear and pinion shaft gear backlash as follows a Tighten adjusting nut 68 until the bolt holes in the nut line up with the bolt holes in housing 67 and there is little or no gear backlash It is necessary to tap on opposite end of bevel gear hub 55 while tightening adjusting nut 68 Install nut lock ring 69 and torque the bolts to 54 Nm b Position a dial ...

Page 231: ...aller in thickness and the plates bigger in thickness to serve the brake clutches and high range clutches respectively NOTE Thoroughly oil all of the internally splined friction discs with same oil as used in the main frame prior to assembling in the retainer 26 Install spacers A Fig 7E 24 in holes of clutch plates 21 Alternately install one internally splined friction disc 20 and one externally s...

Page 232: ...r springs b Compress the springs and install the spring retaining ring 43 c Screw into four topped holes four bolts 3 8 16UNCx6 with a minimum of 32 mm thread A Fig 7E 25 90 apart until they bottom Torque the bolts to 13 6 Nm This will cause the piston to make contact with the clutch pack d Determine the average distance A Fig 7E 25A between the high range clutch piston 49 and the return spring re...

Page 233: ...ig 7E 25A is below 25 4 mm shimming is not required If the distance is more than this figure add shims 84 as necessary to bring distance as close to a figure of 25 4 mm as possible Each shim 84 is 0 5 mm No more than three shims 84 should be required 28 Position clutch return springs 45 and 46 on high range clutch piston 49 and place spring retainer 44 on top of the springs Using three bolts 3 8 1...

Page 234: ...sun gear 31 and install the gear in sun gear hub 32 Press ball bearing 29 in sun gear hub 32 until it bottoms on sun gear 31 Install bearing retainer ring 28 in groove of sun gear hub 32 34 Press hub assembly on planet carrier 33 until ball bearing 29 bottoms Be sure sun gear 31 meshes with planet gears 39 35 Check that sleeve retaining ring 26 is properly seated in output shaft sleeve 27 Install ...

Page 235: ...on top of brake plate retainer 22 Secure both retainers to housing 67 and torque bolts with washer to 108 Nm 42 Oil friction discs 10 refer to NOTE above Install spacers A Fig 7E 24 in holes of clutch plates 11 Alternately install one externally splined clutch plate 11 and one internally splined friction disc 10 in low range clutch plate retainer 13 Start from externally splined clutch plate 11 Wh...

Page 236: ...er 13 Make sure that the springs nest in counterbores Position the low range clutch piston 9 on top of piston return springs 12 46 Position thrust race 23 thrust bearing 24 and second washer race 23 on output shaft sleeve 27 47 Install O rings 5 and 7 and piston seal rings 6 and 8 on retainer cover 4 as shown in Fig 7E 18 Install retainer cover 4 on low range clutch plate retainer 13 and torque th...

Page 237: ... elbows and manifold hoses to the steering drive refer to Fig 7E 9 Temporarily secure steering manifold 2 Fig 7E 9 to the bracket 17 Reconnect all hoses to steering drive 2 Be sure the steering drive output shafts are pulled out of steering drive and spline sleeve is on pinion shaft NOTE The output shafts can not be installed once the steering drive is in place 3 Thoroughly clean the mating surfac...

Page 238: ...1 2 13UNC 2B 2 Fig 7E 3 to the cover 1 14 Thoroughly clean the mating surfaces of the main frame and cover Apply LOCTITE 504 to the cover surfaces only Using a hoist and position the cover on the main frame being careful not to get excessive amounts of LOCTITE inside the rear main frame Install the hardware previously removed Install bracket 1 Fig 7E 2 of gear shifting valve 2 and secure with bolt...

Page 239: ...extreme caution Use suitable blocking equipment while under confines the machine 29 Check the oil pressures in the steering drive as described in SECTION 7 TWO SPEED STEERING VALVE 9 REMOVAL Refer to Fig 7E 31 Fig 7E 31 Two Speed Steering Valve Disconnect Points 1 Gear Shifting Valve 2 Pilot Hoses Short 3 Solenoids Wiring Harnesses 4 Brake Lever 5 Pressure Check Hoses 6 Two Speed Steering Valve 7 ...

Page 240: ...tion 2 Perform Steps 5 to 9 as described in Paragraph 4 REMOVAL in this SECTION 3 Disconnect wiring harnesses 3 at two solenoids of Hi Lo valve 11 4 Disconnect clevis from the brake lever 4 5 Disconnect two pilot hoses 12 at the steering valve 6 drain hose 10 at the HI LO valve 11 and two short pilot hoses 2 6 Disconnect pressure supply hose 13 and two pressure check hoses 5 7 Unscrew the three st...

Page 241: ...iew of Two Speed Steering Valve 1 Upper Steering Valve 2 Valve Gasket 3 Ball Large 4 Ball Small 5 Lower Steering Valve 6 Manifold Gasket 7 Steering Manifold 8 Stud with Washer and Nut 9 Lever Bracket 10 Lever Shaft 11 Brake Lever 12 Lever to Valve Link 13 Lever Pins 14 Roller Bearings 15 Lube Fitting ...

Page 242: ... 5 Front Cover 6 Check Ball Body 7 Check Ball 8 Port Plug 9 Port Plug 10 Spool Spring 11 Shim 12 Spool Poppet 13 Brake Spool 14 Spring Washer 15 Inner Spool Spring 16 Inner Spring Stop 17 Spring Spacer 18 Outer Spring Stop 19 End Cap 20 Wiper Seal 21 Pilot Tube 22 Outer O Ring 23 Inner O Ring 24 Outer Spool Spring 25 O Ring 26 Metering Spool 27 Dowel Pin 28 Nozzle 29 Connector 30 Metering Spool Sl...

Page 243: ... the left and right pilot tubes 21 out of the valve housing 1 Remove and discard O rings 22 and 25 from pilot tubes 21 15 Remove plugs or fittings 4 from top of housing 1 Remove the check ball body 6 and check ball 7 from the valve housing 1 if necessary 16 Inspect parts for excessive wear and replace if necessary Metering spools 26 should slide freely inside spool sleeves 30 Closely inspect the i...

Page 244: ...er 7 Spool Spring 8 Plug 9 Outer O Ring 10 Rear Cover Gasket Hi Lo Valve Fig 7E 35 24 Remove the sequence valves 3 from the valve housing 1 Remove and discard the valve seal kit 25 Unscrew the solenoid coil from the solenoid valve 2 Remove the solenoid valve 2 bodies from the valve housing 1 Remove and discard the valve seal kit 26 Remove nozzles 5 from the valve housing 1 Remove plugs 4 and clip ...

Page 245: ...e all oil passages in the valve bodies and spools are free of obstructions 3 Inspect parts for excessive wear and replace if necessary refer to NOTE NOTE The oil inlet port of the lower valve housing may show signs of wear caused from the ball PEENING the valve section each time pressure re enters the valve Do not replace the valve section when this appearance is observed 4 Inspect the condition o...

Page 246: ... port plugs 4 and the hose fittings if removed and install the plugs and fittings in the top of housing 1 10 Install the check balls 7 into the housing 1 bores Coat the check ball body 6 threads with LOCTITE 262 and install into the housing 1 Torque the check ball bodies 6 to 32 Nm 11 Install new O rings 22 and 25 to left and right pilot tubes 21 Install the pilot tubes into the valve housing 1 12...

Page 247: ...the steering valve opening in the main frame and install steering valve as follows A Install a new gasket 6 Fig 7E 32 over studs 8 B Thoroughly clean the mating surfaces of the main frame cover and steering valve Apply LOCTITE 504 to rear main frame cover in a continuous bead on centerline of valve mounting holes refer to Fig 7E 36 C Lower steering valve 6 Fig 7E 31 onto studs Secure valve 6 with ...

Page 248: ...s can have the following figures steering valve inactive maximum total leak 2 5 l min with one gear shifting range change operation or master brake application the leaks can total 17 l min 14 STEERING VALVE BRAKE SECTION TEST AND ADJUSTMENT 1 Install a 3000 kPa pressure gauge in right or left brake port of diagnostic center Gauge should have a hose of sufficient length to reach operators compartme...

Page 249: ...his practice could introduce dirt or lint into critical hydraulic components Remove all dirt accumulation from the main frame cover Tag disconnected lines to facilitate faster and correct installation 1 Remove the steering valve as described in Paragraph 9 REMOVAL in this Section 2 Double nut and remove the three studs from manifold 3 Remove the main frame cover as described in Step 10 to 16 Parag...

Page 250: ...imum out of flat between any two consecutive mounting holes to be 0 25 mm If the cover does not meet this requirement the cover should be replaced 18 REASSEMBLY Refer to Fig 7E 37 1 Insert spring 2 into the end of spool 3 2 Slide spool 3 into the housing 1 spring end first 3 Assemble new O ring 4 onto plug 5 Secure into housing 1 19 INSTALLATION 1 Temporarily secure the steering manifold to the ma...

Page 251: ...SECTION 7F FINAL DRIVE ...

Page 252: ......

Page 253: ...AND INSTALLATION 4 OUTPUT SHAFT 6 REMOVAL AND INSTALLATION 5 FINAL DRIVE ASSEMBLY 7 REMOVAL 6 8 DISASSEMBLY 7 9 INSPECTION AND REPAIR 11 10 REASSEMBLY 11 11 INSTALLATION 13 PLANETARY CARRIER HOUSING 12 REMOVAL 13 13 DISASSEMBLY 14 14 INSPECTION AND REPAIR 14 15 REASSEMBLY 15 16 INSTALLATION 15 PINION GEAR 17 REMOVAL 15 18 DISASSEMBLY 15 19 INSPECTION AND REPAIR 16 20 REASSEMBLY 16 21 INSTALLATION ...

Page 254: ......

Page 255: ...n the drive cover 17 by a double row spherical roller bearing 15 is splined to the sun gear shaft 33 Three planet gears 42 are meshed with the sun gear shaft 33 which is splined to the bull gear 13 and are also meshed with the planetary ring gear 32 The ring gear hub 29 is splined to the drive cover 17 and is fixed with the planetary ring gear 32 keeping the ring gear stationary during operation T...

Page 256: ... Bearing retainer plate to ring gear hub mounting bolts 350 Nm Planetary carrier housing to sprocket hub mounting bolts 730 Nm Pinion gear housing to drive cover mounting bolts 180 Nm Final drive to rear main frame mounting bolts 920 Nm Pinion gear access cover to pinion gear housing mounting bolts 125 Nm Track roller shield mounting bolts 845 Nm Sprocket guard and deflector mounting bolts Upper g...

Page 257: ...nt Leakage 1 Lubricant leaks at drain plugs or level plug Tighten plug or replace sealing ring as necessary 2 Lubricant leaks between final drive cover and rear main frame or between planetary carrier housing and sprocket hub Clean sealing surfaces and apply liquid gasket 3 Lubricant leaks between sprocket hub and final drive cover Replace oil seal Excessive Wear on Sprockets 1 Tracks run too loos...

Page 258: ...r 4 2 Change the sprocket drive segments proceed as follows a Remove the bolts and nuts with washers 2 Fig 7F 4 securing sprocket drive segment 1 to sprocket hub Remove sprocket drive segment b In place of the dismounted segment install a new segment and secure it with nuts and washers Torque the nuts to 900 Nm c Drive the dozer to position another sprocket drive segment in place as shown in Fig 7...

Page 259: ...ring drive output shaft and pull it free of final drive as shown in Fig 7F 5 Installation 3 With a bolt 5 8 11UNC 2B installed in the end of the steering drive output shaft slide the shaft in so it splines first with the final drive pinion gear and then with the steering drive Remove the bolt NOTE If the shaft will not spline with the steering drive slightly rotate the sprocket 4 With a bolt 1 2 1...

Page 260: ...ocket to clear track chain Block under main frame Fig 7F 6 Removing Final Drive 5 Loosen the top final drive mounting bolt and the top sprocket drive segment mounting bolt Attach a hoist at these two bolts as shown in Fig 7F 6 Remove one of the final drive cover mounting bolts and insert a brass drift in the hole as shown in Fig 7F 6 The drift will support the cover when it is first freed from the...

Page 261: ...FINAL DRIVE SECTION 7F Page 7 DRESSTA TD 25M EXTRA FINAL DRIVE ASSEMBLY 8 DISASSEMBLY Refer to Fig s 7F 7 and 7F 8 Fig 7F 7 Cross Section View of Final Drive ...

Page 262: ...Bearing 16 Retaining Ring 17 Drive Cover 18 Oil Seal Kit 19 Tapered Roller Bearing 20 Bearing Spacer 21 Oil Seal Shield 22 Sprocket Hub 23 Bar Magnet 24 Plug Gasket 25 Drain or Filler Plug 26 Cork Plug 27 Tapered Roller Bearing 28 Retainer Plate 29 Ring Gear Hub 30 Shim 31 Bearing Retainer Plate 32 Planetary Ring Gear 33 Sun Gear Shaft 34 Thrust Button 35 Planetary Carrier Housing 36 Retaining Rin...

Page 263: ...using from cover 17 Remove housing 7 NOTE If disassembly of pinion gear assembly is necessary refer to PINION GEAR in this Section Fig 7F 9 Pinion Gear Assembly 4 Lift drive gear assembly 13 14 16 12 and 15 from shaft 33 Remove retaining rings 12 and 16 bearing 15 and retaining ring 14 from gear 13 It is impossible to remove bearing 15 without damaging it 5 Turn assembly over and support it on cov...

Page 264: ... C with a torch if necessary Separate ring gear 32 from hub 29 by removing retainer plates 28 8 Install four eyebolts 7 8 9x2 3 4 90 apart in hub 22 as shown in Fig 7F 12 and attach a hoist to two opposite eyebolts Install a bar in two remaining eyebolts and position a hydraulic ram under bar Use ram to free bearing cone 27 from shaft of cover 17 and lift hub 22 off with hoist If replacement is ne...

Page 265: ...amage or wear Inspect the ring gear hub and sun gear splines for excessive wear or damage Slight burrs can be smoothed down with a stone 8 It is recommended that new oil seal kit 18 be installed whenever the final drive is disassembled Refer to SEAL INSPECTION under METAL TYPE FACE SEALS in SECTION 14 SUSPENSION 10 REASSEMBLY Refer to Fig s 7F 7 and 7F 8 1 Support cover 17 flange down If sprocket ...

Page 266: ...s bearings Release torque and remove retainer plate after all parts have cooled down 4 For proper shimming do as follows Put symmetrical 5 pcs of virgin leads on the drive cover 17 Install retainer plate 31 Fig 7F 13 and retorque five old bolts 31A Fig 7F 13 equally spaced to 120 Nm Remove the retainer plate 31 and determine the average thickness of virgin leads Subtract 0 076 to 0 1 mm from this ...

Page 267: ...as shown in Fig 7F 6 Remove the pry bar and push the final drive in all the way If the shaft will not spline with the final drive slightly rotate the sprocket Install the final mounting bolts and remove the drift Torque the bolts to 920 Nm 3 Remove the hoist and install the bolts removed for attaching the hoist 4 Remove the blocking from under the rear frame and slowly lower the unit until the spr...

Page 268: ... AND REPAIR 1 Make a preliminary inspection of all parts before cleaning to detect discrepancies which may not show up once the parts are cleaned Examine the oil for metal particles dirt and other foreign material Check for foreign material in the bearings which will cause excessive wear 2 Wash all parts thoroughly in a suitable solvent Dry thoroughly with compressed air or a clean cloth NOTE Do n...

Page 269: ... housing 35 to hub 22 with hardware previously removed Torque bolts to 730 Nm Remove the technological bolt and install plug 43 3 Fill the final drive as described in the OPERATOR S MANUAL PINION GEAR 17 REMOVAL Refer to Fig s 7F 7 and 7F 8 1 Remove final drive as described in Paragraph 7 REMOVAL under FINAL DRIVE in this Section Set final drive down on housing 35 so that gear 13 is up 2 Rotate bu...

Page 270: ...dry with compressed air 4 Inspect bearings for excessive wear or damage and replace if necessary Reusable bearings should be soaked in clean oil and wrapped with clean paper until ready for reassembly 5 Inspect the pinion splines and gear teeth for damage Slight burrs can be smoothed down with a stone If the pinion gear teeth are worn the pinion and possibly the drive gear will have to be replaced...

Page 271: ...to 40 N rolling pull 5 If it is found that the rolling gear pull with spring scale exceeds maximum an assembly error cocking of bearing cones and or cups may have been made The complete assembly should then be inspected for any misassembly of parts Unscrew bolts 6 Apply LOCTITE 120 under and above shims 10 Torque eight bolts with washer to 125 Nm 7 Install oil seal 9 and O rings 6 and 8 on housing...

Page 272: ......

Page 273: ...SECTION 8 ELECTRICAL ...

Page 274: ......

Page 275: ...NG SYSTEM REPAIR 29 BATTERY 10 SAFETY PRECAUTIONS 33 11 ELECTROLYTE STATE OF CHARGE 34 12 ELECTROLYTE IN TROPICAL AND ARCTIC CLIMATES 34 13 TESTING AND MAINTENANCE THE BATTERY 35 14 BATTERY CHARGING GUIDE 37 15 BATTERY STORAGE 37 16 BATTERY PRIMARY RATINGS 38 17 COLD ENGINE CRANKING PERFORMANCE 38 18 DRY CHARGE ACTIVATION 38 19 TYPICAL OF CAUSE BATTERY FAILURE 39 20 VISUAL INSPECTION OF BATTERY 39...

Page 276: ......

Page 277: ...ernator master switch or batteries while the alternator is in operation Surfaces under all terminals must be clean and good electrical connections must be established after assembly All clips must grip cables tightly to prevent vibration and rapid cable wear CAUTION When installing batteries be sure to connect the ground cable to the negative terminal Before working on any part of the electrical s...

Page 278: ...M is dropping The fan starts to work at higher speed Engine air inlet temperature sensor and engine cooling temperature sensor refer to Electrical Diagram at Troubleshooting and Repair Manual QSK Engine Fuel System are connected to ECM 8 too When air inlet temperature or cooling temperature rises the fan starts to work at higher speed too The fan will work at max speed 1560 RPM when drive train oi...

Page 279: ...th a signal being passed to the backup alarm 93 The display 56 powered from the controller 10 will indicate both the gear and range engaged e Equipment Circuit The machine is always equipped with blade floating position electromagnetic latch 31 located at the blade control valve The electromagnetic latch is energized by the starting switch 39 in position ON from accessory supply magnetic switch 59...

Page 280: ...e Temperature Switch 4 ºC 22 Ether Solenoid Valve 23 Air Conditioner Compressor Electromagnetic Clutch 24 Alternator 25 Cranking Motor 26 Receptacle 24V 27 Blade Pitch Solenoid Valve Coil 28 Blade Dual Tilt Solenoid Valve Coil 29 Blade Pitch Solenoid Valve Button 30 Blade Dual Tilt Solenoid Valve Button 31 Float Position Latch Electromagnet 32 Horn Pushbutton 33 Hydraulic System Return Filters War...

Page 281: ...Filter s Clogging Warning Light Switch 67 Over current Protection 68 ROPS side Lamps option 69 Fuse 15 A Voltage Converter Circuit 70 Fuse 10 A Operator s Seat Suspension System Power Supply 71 Electric System Master Switch 72 24 V 12 V Voltage Converter 73 Radio option 74 Radio Antenna option 75 RH Door Wiper 76 Radio Speakers option 77 Cab Rear Lamps 78 Rear Wiper 79 Defroster Fans option 80 Cab...

Page 282: ...rning Light C Low Transmission Main Pressure and Range Clutches Pressure Warning Light D Drive Train Oil Filter Warning Light E Air Cleaner Vacuum Warning Light F Low Coolant Level Warning Light H Coolant Temperature Gauge J Drive Train Oil Temperature Gauge K Engine Oil Pressure Gauge L Gauges Illumination Lights M Voltmeter N Engine Warning Light STOP P Engine Warning Light WARNING R Engine Warn...

Page 283: ...ELECTRICAL SECTION 8 Page 7 DRESSTA TD 25M EXTRA Fig 8 1 Wiring Diagram earlier version ...

Page 284: ......

Page 285: ......

Page 286: ...SECTION 8 Page 10 ELECTRICAL TD 25M EXTRA DRESSTA Fig 8 1A Wiring Diagram later version ...

Page 287: ... 20 Coolant Temperature Sensor 21 Engine Intake Air Preheater Magnetic Switch 22 Engine Intake Air Preheater Circuit Breaker 23 Air Conditioner Compressor Electromagnetic Clutch 24 Alternator 25 Cranking Motor 26 Receptacle 24V 27 Blade Pitch Solenoid Valve Coil 28 Blade Dual Tilt Solenoid Valve Coil 29 Blade Pitch Solenoid Valve Button 30 Blade Dual Tilt Solenoid Valve Button 31 Float Position La...

Page 288: ...ure Filters Clogging Warning Light Switch 66 Fan Drive System Filter s Clogging Warning Light Switch 67 Over current Protection 68 ROPS side Lamps option 69 Fuse 15 A Voltage Converter Circuit 70 Fuse 10 A Operator s Seat Suspension System Power Supply 71 Electric System Master Switch 72 24 V 12 V Voltage Converter 73 Radio option 74 Radio Antenna option 75 RH Door Wiper 76 Radio Speakers option 7...

Page 289: ...rning Light C Low Transmission Main Pressure and Range Clutches Pressure Warning Light D Drive Train Oil Filter Warning Light E Air Cleaner Vacuum Warning Light F Low Coolant Level Warning Light H Coolant Temperature Gauge J Drive Train Oil Temperature Gauge K Engine Oil Pressure Gauge L Gauges Illumination Lights M Voltmeter N Engine Warning Light STOP P Engine Warning Light WARNING R Engine Warn...

Page 290: ...rotection module EPD 3A 2 DRIVE TRAIN CONTROL SYSTEM OPERATION PRINCIPLE a General The drive control is done in two different ways First hydraulically with a valve control lever of the drive control system that actuates suitable valves the other being a combination of electrical and electronics with control lever imbedded buttons rocker switches assisted with a microprocessor controller sensors an...

Page 291: ...le both L15 and L7 are still ON and if the drive train neutral lock lever is in unlocked position L3 LED is OFF or the machine has been operated at the low range straight on L15 was ON and with the RT right switch changed from the low to high range that is a gradual turn to the left L7 ON and if the if the drive train neutral lock lever is in unlocked position L3 LED is OFF L13 ON when the solenoi...

Page 292: ... connector is corrupted L19 dim diode means that lead connection to pin V of controller Deutsch connector is corrupted L25 ON when the auto downshift mode was activated WO switch contacts shorted L26 L27 not used L28 ON when 2 2 presetting mode II was activated L29 ON when 1 2 presetting mode I was activated 3A 3 ELECTRONIC CONTROLLER OPERATION AFTER POWER UP a Power up with the control system ope...

Page 293: ...f the Deutsch connector providing power to the controller for voltage presence a If U 18 V the controller processor operation has been held up by power supply watchdog Turn the control system off check the cause for voltage down clear the fault and restart the power supply b If the voltage is OK and the green diode L18 will not come on then EPD has tripped as a result of system over voltage short ...

Page 294: ...p button to up shift and a Dn button to downshift Depress this button once for a gear to be changed however if you keep depressing the button this will not change the controller status if the operator wants a gear change that involves two gears he is to depress the suitable button twice Only one button can be depressed at a time the controller will ignore any attempt to depress more buttons than o...

Page 295: ...come on the second and third gear solenoid valves EZ2 and EZ3 respectively will de energize when the actual gear was the first gear the controller will do nothing the display will continue to show 1 the second and third gear solenoid valves EZ2 and EZ3 respectively will de energize the L18 diode will come on and L17 and L16 will come off b Auto downshift mode Auto downshift mode is provided with a...

Page 296: ...c Presetting mode Presetting mode is provided with the highest priority in a gear change system Generally presetting allows the machine motion at well predefined gears gear can be defined regardless the machine motion forward or reverse The controller ignores Up and Dn buttons in this gear change mode The auto downshift mode is not operational either regardless the WO switch position Machines are ...

Page 297: ...B switch is set to 2 2 position which in turn will cause a yellow diode L28 to come on Machine will move forward and reverse in the second gear The actual gear is displayed The second gear solenoid valve EZ2 is activated while EZ3 is deactivated diode L17 will come on while L16 and L18 will come off Fig 8 1E provides a drive control system schematic in this operation mode Fig 8 1E Control System S...

Page 298: ...5 will come on while L14 will come off When the rocker switches are in different positions machine will make a gradual turn the description of which will follow later in the text 3A 6 DRIVE TRAIN CONTROL SYSTEM OPERATION WHILE MAKING GRADUAL TURNS The following description refers to Fig 8 1F The machine will turn if one of the rocker switches is set to high speed range and the other in low speed r...

Page 299: ...ections Clean all connections and tighten 3 Defective starting switch 10 A circuit breaker start up lock switch cranking motor solenoid switch cranking motor master switch By process of elimination check for voltage using a voltmeter or check lamp beginning at the power source and step by step until problem is found Refer to Starting Circuit in Paragraph 3 in this Section Transmission Control Malf...

Page 300: ...d 2000 RPM 27 4 0 4 V Permissible voltage change at 5000 RPM and load 5 95 max of current 0 8 V Current A at RPM 12 2000 A RPM 26 3000 A RPM 35 4000 A RPM 41 5000 A RPM 50 6000 A RPM Voltage setting at 10 A and 5000 RPM 27 4 0 6 V Bolts torgues values M8x1 25 SAE Grade 5 29 Nm M8x1 25 SAE Grade 8 37 Nm M10x1 5 SAE Grade 5 57 Nm M10x1 5 SAE Grade 8 72 Nm 6 INTRODUCTION Fig 8 3 View of Alternator 1 ...

Page 301: ...gulator circuit components A fan located on the drive end provides airflow for cooling The bearings are sealed so no periodic lubrication is required Only one wire is needed to connect the Integral Charging System to the battery along with an adequate ground return An R terminal is provided for use in some circuits to operate auxiliary equipment 7 OPERATING PRINCIPLES Fig 8 4 Cross Sectional View ...

Page 302: ... and the POS terminal As speed increases current is provided for charging the battery and operating electrical accessories The stator also supplies D C field current through the diode trio the field TR1 and then through the diodes in the rectifier bridge back to the stator As the speed and voltage increase the voltage between R2 and R3 increases to the value where zener diode D1 conducts Transisto...

Page 303: ...in the OPERATING RANGE c Magnetizing the Rotor The rotor normally retains magnetism to provide voltage buildup when the engine is started After disassembly or servicing however it may be necessary to reestablish the magnetism To magnetize the rotor connect the Integral Charging System to the battery in a normal manner then momentarily connect a jumper lead from the battery positive post to the Int...

Page 304: ...r RPM or more and adjust carbon pile as required to obtain maximum current output IMPORTANT Initial voltage buildup is by residual magnetism in the rotor Increase the speed as required to obtain maximum current output f If ampere output is within 10 Amperes of rated output as stamped on alternator frame Integral Charging System is not defective g If ampere output is not within 10 Amperes of rated ...

Page 305: ...inal Connector 5 Capacitor 6 Output Terminal Nut Lock Washer Washer Nut Lock Washer Washer Insulated Washer 7 Relay Terminal Bushing Washer Bushing Washer Connector Washer Nut 8 Regulator 9 Two Field Leads Two Insulated Screw 10 Connector 11 Diode Trio 12 Rectifier Bridge a Regulator Check The regulator cannot be checked with an ohmmeter Use an approved regulator tester available from various test...

Page 306: ...r 4 Ohmmeter 5 Ohmmeter 6 Ohmmeter Omit for overcharged battery To check the rectifier bridge connect the ohmmeter to a heat sink and one of the three terminals Step 1 Fig 8 9 Then reverse the lead connections to the same heat sink and same terminal If both readings are the same replace the rectifier bridge by detaching the necessary screws and nuts A good rectifier bridge will give one high and o...

Page 307: ...field coil see the Par below entitled Disassembly and Repairing e Stator Checks Omit for overcharged battery The stator windings may be checked with a 110 Volt test lamp or an ohmmeter If the lamp light or if the meter reading is low when connected from any stator lead to the frame the windings are grounded Step 4 Fig 8 9 If the lamp fails to light or if the meter reading is high when successively...

Page 308: ...28 and end cover 8 2 Remove fan 22 and pulley 3 Remove 4 thru bolts 39 4 Separate drive end frame 4 and rotor 2 from rectifier end frame 1 and stator 3 5 Press rotor 2 from end frame 4 6 Remove inside collar 20 from rotor 2 7 To replace drive end frame bearing 19 a Remove four retaining plate 17 attaching bolts 26 b Remove retainer plate 17 and felt washer 34 c Push on race to remove bearing 19 d ...

Page 309: ...pen and flood it with cool clean water for approximately fifteen minutes and doctor should be called immediately 6 Do not place a battery or acid within the reach of children If acid is taken internally drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil 7 To prepare electrolyte always pour the concentrated acid slowly into the water not the water into ...

Page 310: ... 26 7 C contains an electrolyte with approximately 36 sulfuric acid by weight or 25 by volume Pure sulfuric acid has a specific gravity of 1 835 The specific gravity can be measured directly with a hydrometer or determined by the stabilized voltage The state of charge battery shows the chart below Charge Level Specific Gravity Voltage 100 1 265 12 68 75 1 225 12 45 50 1 190 12 24 25 1 155 12 06 Di...

Page 311: ...ed or broken case or cover which would allow electrolyte loss If top of a battery is dirty secure vent plugs clean it with a brush dipped in ammonia or soda solution After foaming stops flush of battery with clean water Check for terminal damage Brighten terminal contact surfaces with steel wool or a stiff brush Check the condition of the battery cables b Electrolyte Levels and State of Charge In ...

Page 312: ...tabilized voltage of the battery was 12 4 V or above when it was first examined proceed to Load Procedure c Load Procedure NOTE This procedure is valid only if the battery is at or above the state of charge specified in Electrolyte Levels and State of Charge The load test procedure is conducted to determine if the battery has adequate electrical performance or must be replaced 1 Connect the voltme...

Page 313: ... a three hour period When any battery is being charged periodically measure the temperature of the electrolyte if the temperature exceeds 52 C or if violent gassing or spewing of electrolyte occurs the charging rate must be reduced or temporarily halted The battery generally cannot be fully charged the fast charge method But it will receive sufficient charge 70 to 90 for practical service To compl...

Page 314: ...at 25 A until its voltage drops below 10 5 V 17 COLD ENGINE CRANKING PERFORMANCE Effect of temperature and oil viscosity on ENGINE CRANKING PERFORMANCE 1 Battery capacity is greatly reduced by cold The reduction in cranking power when the temperature drops from 26 7 C to 0 C is 65 or 18 C is 40 2 Stiff engine oil adds to the load of starting With the use of single viscosity winter grade SAE 20W oi...

Page 315: ...minated with foreign material Cloudy electrolyte can indicate active material shedding due to overcharge or vibration Electrolyte contamination can cause high self discharge rates and poor performance 5 Are alternate plates dark and light colored In a charged cell the positive plates should be dark in color and the negative plates light If all plates are very light severe undercharging could be in...

Page 316: ...the positive grids and reduces the cross section of the wires If the plate is hard when scratched or has areas of white sulfate on it the battery has stood in a discharged condition 2 NEGATIVE PLATES The sponge lead of the negative plate is normally a slate gray color If you rub the back of your thumbnail or a spatula across a good negative plate this will create a path of metallic sheen If a meta...

Page 317: ...ousing 4 Field Frame 5 End Cap Heavy duty cranking motors have a shift lever in lever housing 2 Fig 8 12 and plunger in solenoid 1 that are totally enclosed to protect them from exposure to dirt icing conditions and splash The nose housing 3 can be rotated to obtain a number of different solenoid 1 positions with respect to the mounting flange Lubrication is provided to the sintered bronze bushing...

Page 318: ...ide of the housing To relocate the housing it is only necessary to remove the bolts rotate the housing to the desired position and reinstall the bolts In this type of assembly the lever housing and the commutator end cap are attached to the field frame independently by bolts entering threaded holes in the field frame 23 OPERATING Fig s 8 12 and 8 13 Fig 8 13 Cross Sectional View of Cranking Motor ...

Page 319: ...e Inspect all connections to the cranking motor solenoid magnetic switch any other control switch and battery including all ground connections Clean and tighten all connections as required The cranking system cannot operate properly with excessive resistance in the circuit c Magnetic Switch Solenoid and Control Switches Inspect all switches to determine their condition From the Electrical Dozer Sy...

Page 320: ...th the current remaining essentially unchanged However if the exact voltage is desired a carbon pile connected across the battery can be used to reduce the voltage to the specified value Connect the carbon pile to only one of the 12 Volt batteries If the specified current draw does not include the solenoid deduct from the ammeter reading the specified current draw of the solenoid hold in winding M...

Page 321: ...olenoid motor terminal and ground return lead from solenoid if present 3 On motors which have brush inspection plates remove the plates and then remove the brush lead screws This will disconnect the field leads from the brush holders 4 Remove the attaching bolts and separate the commutator end frame from the field frame 5 Separate the nose housing and field frame from lever housing by removing att...

Page 322: ...ate above the of the armature core in which the short circuit is located Shorts between bars are sometimes produced by brush dust or copper between the bars These shorts can be eliminated by cleaning out the slots 3 Grounds Grounds in the armature can be detected by the use of a 110 Volt test lamp and test points If the lamp lights when one test point is placed on the commutator with the other poi...

Page 323: ...s can be removed from the field frame assembly by using a pole shoe screwdriver A pole shoe spreader should also be used to prevent distortion of the field frame Careful installation of the field coils is necessary to prevent shorting or grounding of the field coils as the pole shoes are tightened into place Where the pole shoe has a long lip on one side and a short lip on the other the long lip s...

Page 324: ...oid motor terminal Fig 8 18 Compare with the pull in winding specification A high reading indicates a shorted pull in winding and a low reading indicates excessive resistance To avoid excessive heating leave the pull in winding connected no more than 10 seconds at a time The current will decrease as the heating increases To check for grounds move battery lead from M terminal Fig 8 18 to a clean me...

Page 325: ...onnecting across its winding o Brushes Reassembly To reassemble the brush plate assembly with brushes onto the field frame with armature in place lift the brushes up so the spring contacts the side of the brush Assemble to the field frame with the attaching screw Lift up springs and position brushes onto cummutator p Lubrication All bearings wicks and oil reservoirs should be saturated with SAE 20...

Page 326: ...leed through and lubricate the shaft Middle bearings are support bearings and prevent armature deflection during cranking As compared to end frame bearings the clearance between middle bearing and shaft is large and the clearance provides a loose fit when assembled r Pinion Clearance To check pinion or drive clearance follow the steps listed below 1 Make connections as shown in Fig 8 19 2 Momentar...

Page 327: ...SECTION 8 Page 51 DRESSTA TD 25M EXTRA CRANKING MOTOR 42 MT Fig 8 20 Measuring Pinion Clearance 1 Plug Remove 2 Shaft Nut Turn to Adjust Pinion Clearance 3 Press on Drive to Take Up Movement 4 Pinion A 8 3 9 9 mm ...

Page 328: ...tic switch reduces the control side current draw for these type of applications The IMS option provides the opportunity to use a shorter wiring run and reduces the number of attachment points This should result in a higher quality installation The 39MT HD cranking motor has the similar power as the 42MT with the same battery configuration but is a smaller lighter package size as summarized in Tabl...

Page 329: ...round Terminal The 39MT HD cranking motor is more efficient than the earlier 42MT model providing more output torque for stronger starts with a new planetary gear reduction design This reduction also reduces heat build up in the cranking motor The open construction of the new 39MT HD allows for the release of any condensation that has formed or contamination that has penetrated the device increasi...

Page 330: ...22 to interface with the engine flywheel housing while the 42MT utilizes a cast iron nose housing The lower compressive yield of the aluminum nose housing requires the use of a mounting washer to prevent brinnelling In addition to the new mounting hardware a lower torque value is required as compared to the 42MT cranking motor Fig 8 23 View of 39MT Cranking Motor with Integral Magnetic Switch IMS ...

Page 331: ...SECTION 9 FRAME ...

Page 332: ......

Page 333: ...FRAME SECTION 9 DRESSTA TD 25M EXTRA CONTENTS SERVICE SPECIAL TOOLS 1 SERVICE SPECIAL TOOLS 1 GENERAL 2 DESCRIPTION 1 3 WELDING 3 FRAME 4 MAINTENANCE 3 5 SPECIFICATIONS 4 6 REMOVAL 4 7 INSTALLATION 4 ...

Page 334: ......

Page 335: ...radiator guard The front section supports the engine and torque converter and includes an equalizer bar cross tunnel for attaching and housing the equalizer bar and an integral radiator guard for mounting the radiator The rear section consists the double wall side steel castings and supports the transmission the steering drive and final drives Cross members including equalizer bar tunnel join the ...

Page 336: ...SECTION 9 FRAME Page 2 TD 25M EXTRA DRESSTA GENERAL Fig 9 2 View of Frame ...

Page 337: ...e protection Successful welding repairs require some knowledge of the materials being worked use of the correct type and size of welding electrode and preparation of material to be welded The alloy steels used in the construction of this machine have a low carbon content but have been heat treated to obtain maximum strength hardness and wear resistance To retain their strength the steel members mu...

Page 338: ...ug 24 Fig 9 2 in the crosstube using press and aligning pin refer to SERVICE SPECIAL TOOLS Paragraph 1 in this SECTION 3 Slide new inner tube bushing 23 Fig 9 2 into crosstube inner bushing bore Properly align bushing with bore and apply press to push bushing 189 1 5 mm deep 4 Slide new outer bushing 22 into crosstube outer bushing bore Properly align bushing with bore and apply press to push bush...

Page 339: ...SECTION 10 HYDRAULICS ...

Page 340: ......

Page 341: ...ESSURE TESTS 11 6 BLADE LIFT CYLINDER DRIFT TEST MACHINE WITHOUT RIPPER 14 7A BLADE LIFT CYLINDERS AND RIPPER LIFT CYLINDERS DRIFT TEST MACHINE WITH RIPPER BLADE AND RIPPER LIFT CYLINDERS ARE DROPPING 15 7B RIPPER LIFT CYLINDERS DRIFT TEST BLADE LIFT CYLINDERS ARE NOT DROPPING 17 8 CYLINDER TIME CYCLE 18 9 PISTON PACKING TEST 19 10 PRESSURE DIAGNOSTIC CHART 20 11 FAN DRIVE SYSTEM PERFORMANCE TEST ...

Page 342: ......

Page 343: ...the pumps from cavitation as well as maintaining pressure in the reservoir Refer to the OPERATOR S MANUAL for service of this valve The reservoir acts as a storage tank for the dozer equipped hydraulic system oil The remainder of oil fills the lines and system components Hydraulic Equipment Pump The positive displacement three element pumping cartridges are of the rotary vane type with shaft side ...

Page 344: ...h Control Valve This single spool valve consists of an inlet and outlet portion The inlet portion spool is a three position type spring centered A load check valve is located within the valve A main relief valve is located in the port adjacent to the spool cover An adjustable pilot operated main pressure relief valve is used to by pass oil from the pump back to reservoir when oil pressure exceeds ...

Page 345: ... valve is used to direct pilot oil pressure to the blade lift and tilt valve sections for blade control When the lever is released it will return to neutral A magnetic detent mechanism holds the control lever in the FLOAT position Pilot pressure enters the control valve at the P port and is distributed through the passages to the metering spools When the lever is in the centered NEUTRAL position o...

Page 346: ...inder 4 Quick Drop Valve 5 Three Spool Control Valve 6 Blade Pilot Control Valve 7 Ripper Pilot Valve 8 Directional Valve 9 Shuttle Valves 10 Unloading Valve 11 Blade Tilt Cylinder 12 Blade Tilt Control Valve 13 Hydraulic Three Section Vane Pump 14 Hydraulic Reservoir 14A Suction Strainer 15 Breather Valve 16 Return Filters 17 Pilot Pressure Filter 18 Pilot Pressure Valve ...

Page 347: ...rol Valve 7 Ripper Pilot Control Valve 8 Directional Valve 9 Shuttle Valves 10 Unloading Valve 11 Blade Tilt Pitch Cylinder 12 Blade Tilt Pitch Control Valve 13 Hydraulic Three Section Vane Pump 14 Hydraulic Reservoir 14A Suction Strainer 15 Breather Valve 16 Return Filters 17 Pilot Pressure Filter 18 Pilot Pressure Valve 19 Double Tilt Pitch Solenoid Valve 19A Pitch Solenoid Valve 19B Double Tilt...

Page 348: ...ontrol Cylinder Piston 12 Axial Piston Variable Pump Generally the fan drive system consists of mechanical and hydraulic portions Mechanical portion of the fan drive system is detailed in SECTION 6 COOLING SYSTEM The hydraulic portion of the fan drive system consists of the common hydraulic reservoir 1 the fan drive pump with control module 2 mounted on the torque converter accessory drive 13 the ...

Page 349: ...id 9 The control module solenoid 9 controls the variable pressure valve 10 The pressure valve 10 actuates pump cylinder piston 11 Pump 12 varies oil flow rate passing to the hydraulic motor 3 which drives the fan 14 from minimum to maximum speed range refer to SPECIFICATION in this Section The fan drive pump output pressure depends on the current intensity to the control module solenoid 9 If pump ...

Page 350: ...n Pilot Rear Section 2145 RPM 33 l min Pressure Settings Main Pressure Relief Valve 16900 17600 kPa Tilt Pressure Relief Valve 18350 19100 kPa Pilot Control Pressure Relief Valve 2400 2560 kPa Fan Drive System Pressure Relief Valve 25000 kPa Fan Drive System Standby Pressure 1400 kPa Fan Drive Performance Minimum speed below 400 RPM At temperatures Engine coolant 85 C Engine charge air 45 C Drive ...

Page 351: ...R S MANUAL 3 Dirty oil strainer in reservoir Clean 4 Dirty reservoir pressure vacuum relief valve Clean 5 Air leakage into hydraulic suction lines Apply shave cream to all suction connections and tighten where cream disappears Blade Lift Cylinder Drops 1 Faulty one of blade lift circuit assembly Refer to Paragraph 6 BLADE LIFT CYLINDER DRIFT TEST Ripper Lift Cylinders Drops 1 Faulty one of ripper ...

Page 352: ... Pitch or Double Tilt Pitch Cylinders Drop 1 Problem in one of system Refer to Paragraph 8 PISTON PACKING TEST Momentary Drop when Actuated from Hold 1 Scored or worn load check valve or seat Replace 2 Load check held of its seat Clean system Check for foreign matter Oil Overheating 1 Oil level too low Fill to proper level 2 Very light oil in a hot climate Used recommended oil per the OPERATOR S M...

Page 353: ...ECTION 8 ELECTRICAL 2 Solenoid valve coil faulty or one of control module valves faulty Replace control module 3 Axial piston pump faulty Replace pump TEST AND ADJUSTMENT 5 EQUIPMENT SYSTEM RELIEF VALVES PRESSURE TESTS Fig 10 7 Pressure Check Connect Port 1 One or Three Spool Control Valve 2 Main Pressure Quick Disconnect Fitting 3 Blade Tilt Tilt Pitch Pressure Quick Disconnect Fitting 4 Blade Ti...

Page 354: ...e tilt lever into a power position until cylinder is in an extreme position Read and record pressure on test gauge at which relief valve unloads Repeat with engine at low idle Obtained pressures should range from 18350 tro 19100 kPa if not proceed as follows If both low and high idle readings are similar but not as specified system is operating correctly but relief valve must be adjusted Refer to ...

Page 355: ...nnected hose 1 ONE SPOOL VALVE Once operating temperature is reached run engine at full throttle and slowly move blade lift control lever to raise position Read and record pressure on gauge at which relief valve unloads 2 THREE SPOOL VALVE Once operating temperature is reached run engine at full throttle and slowly move ripper lift control level into a power position until cylinders are in extreme...

Page 356: ... 2400 2560 kPa if not proceed as follows If both low and high idle pressure readings are similar but not as specified system is operating correctly but pilot pressure valve must be repaired Proceed to SECTION 10B VALVES If relief valve pressure is within 2400 2560 kPa at high idle but cannot be reached at low idle refer to SECTION 10A PUMPS 5 Remove test gauge from the quick disconnect fitting and...

Page 357: ...e blade Stop the machine and check for drift If cylinders drift is much less than checked in point 4 control valve is faulty Repair or replace the valve Refer to ONE SPOOL CONTROL VALVE in SECTION 10B If cylinders drift is still the same the quick drop valve is faulty Repair or replace the valve Refer to QUICK DROP VALVE in SECTION 10B 10 When proceeding tests are completed vent hydraulic system a...

Page 358: ...SECTION 10 HYDRAULICS Page 16 TD 25M EXTRA DRESSTA TEST AND ADJUSTMENT Fig 10 10 Hydraulic Chart Blade Tilt Pitch Attachment ...

Page 359: ...t control valve is faulty Repair or replace the valve Refer to RIPPER PILOT CONTROL VALVE in SECTION 10B If cylinders drift is still the same pilot pressure valve is faulty Repair or replace the valve Refer to PILOT PRESSURE VALVE in SECTION 10B 11 When proceeding tests are completed vent hydraulic system and add oil as necessary Refer to the OPERATOR S MANUAL Visually check for oil leakage 7B RIP...

Page 360: ...readings 3 If average cycle times are more than above mentioned middle pump should be repaired or replaced as necessary NOTE In case of fully retracted blade tilt cylinders maximum cylinder time cycle can reach 16 0 seconds Blade Lift NOTE Before performing cylinder time cycle test perform cylinder blade tilt test to insure that middle pump is correct NOTE Before performing cylinder time cycle tes...

Page 361: ...nd record time it takes ripper to reach full raised position Repeat this procedure several times and average time readings 3 Lift cycle should take not more than 1 8 seconds If average cycle time is more than 1 8 seconds front pump should be repaired or replaced as necessary NOTE This check should be made only in ripper raising cycle 9 PISTON PACKING TEST Blade Tilt or Blade Tilt Pitch and Ripper ...

Page 362: ...ismantle valve for inspection and repair Refer to SECTION 10B VALVES 11 FAN DRIVE SYSTEM PERFORMANCE TEST WARNING Be sure the area in front and behind the machine is clear of personnel and obstructions DO NOT allow anyone near the trucks or on the access steps during this test NOTE Performing test will require two people one person to operate the machine the second person to time the machine s per...

Page 363: ...SECTION 10A PUMPS ...

Page 364: ......

Page 365: ...TS SERVICE SPECIAL TOOLS 1 SERVICE SPECIAL TOOLS 1 EQUIPMENT PUMP 2 DESCRIPTION AND OPERATION 2 3 SPECIFICATIONS 5 4 SERVICE DIAGNOSIS 5 5 REMOVAL 6 6 DISASSEMBLY 8 7 CARTRIDGE KITS 12 8 INSPECTION AND REPAIR 16 9 REASSEMBLY 17 10 INSTALLATION 18 ...

Page 366: ......

Page 367: ...IPTION TOOL NUMBER Shaft Seal Driver Fabricate Fig 10A 1 Cartridge V Block Fabricate Fig 10A 2 Fig 10A 1 Shaft Seal Driver A 90 mm B 8 4 mm C 45 mm D 41 2 mm E Material Tubular Stock Fig 10A 2 Cartridge V Block A 19 mm B 95 mm C 305 mm D Wood Screw E Material Clean Wood With Smooth Finish Surface ...

Page 368: ...tem System pressure is fed under the vanes assuring their sealing contact against the rotor ring during normal operation In the intra vane cartridge full system pressure is continuously applied only to the area between the vane and insert This area is small and thrust is correspondingly light During vane travel through pressure areas full system pressure is applied against the bottom area of the o...

Page 369: ...ump consists of a ported end cover 39 and a pumping cartridge Components of the pumping cartridge are an elliptical rotor ring 43 a slotted rotor 41 splined to fit the drive shaft twelve vanes 42 to fit the rotor slots a wear plate 48 and a pressure plate 46 with spring 45 The pumping cartridge is sandwiched between the end cover 39 and the rear cover 2 A bushing pressed in the pressure plate supp...

Page 370: ...e causes the vanes to follow the elliptical inner surface of the rotor ring Radial movement of the vanes and turning of the rotor cause the chamber volume between the vanes to increase as the vanes pass the inlet section of the rotor ring This results in a low pressure condition which allows atmospheric pressure to force fluid into the chambers Fluid outside the inlet is at atmospheric pressure or...

Page 371: ...rotation as viewed from the shaft end 3 SPECIFICATIONS Special Bolt Torque Data End cover to rear cover mounting bolts 55 5 Nm Rear cover to inlet cover mounting bolts 95 5 Nm Center cartridge kit retaining bolts 5 0 5 Nm Inlet cover to outlet housing mounting bolts 205 10 Nm Front cartridge kit retaining bolts 15 0 5 Nm NOTE Except for the special torques shown all bolts and nuts are to be given ...

Page 372: ...ough understanding of the complete hydraulic system 5 REMOVAL Refer to Fig 10A 6 WARNING Before working at the machine be sure that the blade and ripper have been lowered to the ground engine is OFF the drive train control lock lever is in locked ON position and parking brake is set The starting switch and the electrical system master switch are turned OFF keys are removed and the controls are tag...

Page 373: ...equires two people for appropriate handling of sling with pump during pump lift out of machine 6 Attach a suitable sling to equipment pump 1 The sling must be installed to give the best possible balance Place tension on the hoist Unscrew two mounting flange bolts with washers 3 Handle the pump 1 with care to pull the pump clear of torque converter 5 and lift out of machine 7 Remove the O ring from...

Page 374: ...SECTION 10A PUMPS Page 8 TD 25M EXTRA DRESSTA EQUIPMENT PUMP 6 DISASSEMBLY Refer to Fig 10A 7 Fig 10A 7 Exploded View of Equipment Pump ...

Page 375: ...sharp edges from splins drill points key ways and end of shaft Match mark sections to ensure correct reassembly To aid you in disassembly and reassembly pump should be retained in some manner We recommend use of a steel plate bolted to and extending over edge of a work bench Plate should have a hole large enough for adapter flange pilot to drop through and two holes matching location of mounting h...

Page 376: ...B Fig 10A 11 out of pump and put off to side for later disassembly Pry with a screwdriver if necessary but be sure to stone off any burrs raised with screwdriver Remove mounting bolts 16 and lift inlet housing 17 off of outlet housing 37 Lift cartridge kit A Fig 10A 12 out of pump and put off to side for later disassembly Refer to CARTRIDGE KITS for service Fig 10A 10 Rear Cover Fig 10A 11 Cartrid...

Page 377: ... Shaft 4 Remove spiral lock ring 31 Fig 10A 13 Slide shaft 34 with bearing 33 out of outlet housing 37 If necessary remove retaining ring 32 and press bearing 33 off of shaft Remove washer spacer 35 Fig 10A 14 from outlet housing and drive shaft seal 36 out being careful not to damage seal mounting bore area Fig 10A 14 Spacer Washer Fig 10A 15 Seal Removal 35 Washer A ...

Page 378: ...ts 15 or 18 NOTE Do not slide outlet flex side plates 9 or 22 across rotor ring 12 or 25 and rotor 10 or 23 Burrs on ring or rotor can cause deep scratches in soft bronze surface 3 Slide inlet support plate 13 or 20 and seal packs 8 or 21 off of cartridge DO NOT allow inlet flex side plates 9 or 22 to slide with support plate Refer to Fig 10A 17 Raise inlet flex side plate Fig 10A 18 just enough t...

Page 379: ...PUMPS SECTION 10A Page 13 DRESSTA TD 25M EXTRA EQUIPMENT PUMP Fig 10A 18 Inlet Flex Side Plate Fig 10A 19 Reverse Cartridge Fig 10A 20 Outlet Support Plate Fig 10A 21 Outlet Flex Side Plate H Seal Packs ...

Page 380: ...scoring is evident All cartridge kit parts must be free of burrs Stone mating surfaces of each part with an oiled Arkansas stone prior to assembly NOTE Direction of rotation is viewed from shaft end right hand rotation is clockwise left hand rotation coounterclockwise This pump is assembled for counterclockwise rotation Assemble cartridge kit A in direction of rotation notated Assemble cartridge B...

Page 381: ...f rotor and vanes with clean oil Locate scribe marks on inlet support plate 13 or 26 and flex side plate 9 or 22 Hold inlet support plate and flex side plate together and assemble over exposed rotor ring rotor and vanes Assure that scribe marks are in line NOTE Cast in arrows located next to mounting bolts 15 or 18 indicate cartridge direction of rotation The O D of all component parts of cartridg...

Page 382: ...OT use a dry stone on the bronze surface or scratches will result 3 Inspect both sides of each vane and insert in order If pickup heavy wear or scoring is found inspect the appropriate rotors 10 23 and 41 slot Replace scored parts 4 Inspect rotor rings 12 25 and 43 for vane chatter marks wear and or scratches Replace if scoring is evident NOTE Replacement rotor rings 12 25 and 43 width must be ide...

Page 383: ...to prevent damage to seal Lubricate shaft end with petroleum jelly and carefully push shaft through seal until bearing bottoms in outlet housing and secure with spiral lock ring 31 Fig 10A 13 2 Install square cut sealing ring 28 into outlet housing Install O ring 29 and back up ring 30 onto cartridge kit A Fig 10A 12 outlet support plate hub Carefully install cartridge kit A over shaft and into ou...

Page 384: ... cover Position wear plate 48 with O ring 44 groove side up and coat with clean oil Position rotor 41 with vanes 42 on plate and place rotor ring 43 over rotor aligning scribe marks Position sub assembly over dowels aligning rotor with shaft dowel pins with holes and scribe marks Apply a liberal coat of clean oil to rotor and vanes and verify rotor and vane freedom of movement Install pressure pla...

Page 385: ...dure requires two people for appropriate handling of sling with pump during pump lift off to the machine 4 Attach a suitable sling to equipment pump 1 The sling must be installed to give the best possible balance Handle the pump with care to install the pump 1 to the torque converter 5 and secure with bolts and washers 3 IMPORTANT Before connecting any lines to the pump fill all ports with clean o...

Page 386: ... described in the OPERATOR S MANUAL 10 Start the engine and carefully press the quick disconnect check points at blade valves to remove the air from hydraulic system Check for external leaks in the hydraulic system 11 Check the oil level in hydraulic reservoir and add oil if necessary 12 Stop the engine Install the center floor plate and floor mat if equipped ...

Page 387: ...SECTION 10B VALVES ...

Page 388: ......

Page 389: ...STALLATION 5 8 BLADE LIFT SECTION 6 9 RIPPER LIFT SECTION 7 10 RIPPER PITCH SECTION 8 11 MAIN PRESSURE RELIEF VALVE 9 PILOT PRESSURE VALVE 12 SPECIFICATION 12 13 DESCRIPTION 12 14 REMOVAL AND INSTALLATION 14 15 SERVICE 15 QUICK DROP VALVE 16 SPECIFICATION 16 17 DESCRIPTION 16 18 REMOVAL AND INSTALLATION 16 19 SERVICE 17 UNLOADING VALVE 20 SPECIFICATION 19 21 REMOVAL AND INSTALLATION 19 22 SERVICE ...

Page 390: ......

Page 391: ...ositions except the blade FLOAT position are not detented and all the spools of the valve are spring centered for return to the HOLD position All sections are assembled between the inlet and outlet cover All section housings are of the same design although the spools differ in their functioning A machine can be equipped with one or three spool control valve Regardless of the number of sections eac...

Page 392: ...raulic components Tag all disconnected lines to facilitate their proper installation Fig 10B 1 Disassembly R H Enclosure 1 R H Door 2 R H Enclosure 3 Bolts 1 Drain the hydraulic system of oil as described in OPERATOR S MANUAL 2 Unscrew bolts 3 Fig 10B 1 and remove R H enclosure 2 with R H door 1 3 Remove return filters 2 Fig 10B 2 to gain access to control valve 1 Fig 10B 2 Hydraulic Return Filter...

Page 393: ...8 from ripper lift and pitch sections of control valve 9 9 Disconnect upper pilot hoses 1 and lower pilot hoses 7 from control valve 9 10 Protect the control valve 9 with a wooden plank against gravitating Remove three bolts and washers 3 Fig 10B 2 and 2 Fig 10B 4 securing valve to the bracket 4 Fig 10B 3 and remove it from machine using suitable hoist Fig 10B 3 Control Valve Disconnect Points Fig...

Page 394: ...6 THREE SPOOL CONTROL VALVE Remove the ripper lift section 8 from the valve bank Remove and discard the between section seal rings Refer to RIPPER LIFT SECTION Paragraph 9 in this Section 7 THREE SPOOL CONTROL VALVE Remove the ripper pitch section 7 from the valve bank Remove and discard the between section seal rings Refer to RIPPER PITCH SECTION Paragraph 10 in this Section 8 Remove the relief v...

Page 395: ...utlet cover 3 on the studs 1 against the ripper pitch section 7 Oil the nut 2 threads and install to the mounting studs 1 Tighten the stud nuts to 68 82 Nm 7 Install all hydraulic connectors previously removed NOTE If the stud nuts are not tightened to the above specified torque value valve spools seizure or O ring displacement can occur 7 INSTALLATION NOTE Clean hydraulic system suction filter pr...

Page 396: ...e 6 Hydraulic Remote Positioner 7 Hydraulic Remote Positioner Disassembly 1 Remove the check load valve 3 Fig 10B 6 the port plug 4 and the anticavitation valve 5 The anticavitation valve 5 the plug 4 and the check valve 3 are the only replacable parts 2 If needed remove the float spool positioners 6 and 7 bolts and then remove float spool 2 Inspection and Repair 1 Wash all parts thoroughly in a s...

Page 397: ...the valve section is a spring loaded check valve which assures smooth operation when the spool is moved from hold to an operating position An anticavitation valve is located in the lower part of section Disassembly 1 Remove the check load valve 3 Fig 10B 7 the port plug 4 and the anticavitation valve 5 The anticavitation valve 5 the plug 4 and the check valve 3 are the only replacable parts 2 If n...

Page 398: ...ble the parts in the reverse order to that of their disassembly 2 Tighten the spool positioners 6 and 7 mounting bolts to 12 15 Nm 3 Tighten the anticavitation valve 5 check load valve 3 and port plug 4 to 45 53 Nm 10 RIPPER PITCH SECTION Description The ripper pitch section valve is used for pitching the ripper forward or rearword The section valve is a spring centered spool three position type I...

Page 399: ...heir disassembly 2 Tighten the spool positioners 5 and 6 mounting bolts to 12 15 Nm 3 Tighten the check load valve 3 and port plugs 4 to 45 53 Nm 11 MAIN PRESSURE RELIEF VALVE Removal and Disassembly 1 Remove main pressure relief valve 6 Fig 10B 5 from inlet cover 3 if not removed earlier 2 Position the relief valve in a vise adjusting end up Remove the tamper proof cover While holding the adjusti...

Page 400: ...et Housing 7 Main Poppet Spring 8 Main Poppet 9 Orifice Screen 10 Seal Ring 11 Backup Ring 12 Seal Ring 13 Seal Ring 14 Seal Ring 15 Backup Ring 16 Seal Ring 17 Seal Ring 18 Backup Ring 19 Valve Housing 20 Retaining Ring Inspection and Repair 1 Wash all parts thoroughly in a suitable solvent Dry thoroughly with compressed air 2 Discard all seals and replace them with new ones 3 Due to the close to...

Page 401: ...reen 9 into the valve housing 19 7 Install the main poppet spring 7 8 Install the pilot poppet housing 6 Tighten housing 6 to 11 16 Nm 9 Install the pilot poppet 4 and the return spring 5 10 Install the adjusting screw 1 half way into the pilot poppet housing 6 11 While holding the adjusting screw 1 install jam nut 2 12 Tighten valve housing 19 to 45 53 Nm 13 Final adjustment of the main pressure ...

Page 402: ...nt of cold oil a cold oil relief ball 12 is provided located in the center left end of the spool 10 The cold oil relief limits pressure spikes at start up As P pressure builds it also pushes against the right end of the pilot supply spool 5 The right hand spool diameter is less than the spool bore allowing pilot oil to flow past this clearance and push the spool 5 to the left The pilot supply spoo...

Page 403: ...VALVES SECTION 10B Page 13 DRESSTA TD 25M EXTRA PILOT PRESSURE VALVE Fig 10B 10 Exploded View of Pilot Pressure Valve ...

Page 404: ...aulic openings must never be plugged with rags This practice could easily induce dirt lint or contaminants into critical hydraulic components Tag disconnected lines to facilitate correct and faster installation WARNING Before working at the machine be sure that the blade and ripper have been lowered to the ground engine is OFF the drive train control lock lever is in locked ON and parking brake is...

Page 405: ...ig s 10B 10 and 10B 11 1 Slowly unscrew plug 1 and remove O ring 2 and spring 3 from body 4 Unscrew plug 7 and remove O ring 6 and pull out spool 5 2 Unscrew plug 20 and remove O ring 19 spring 18 shim s 17 and sleeve 16 from body 4 3 Unscrew plug 8 and remove O ring 9 and spool 10 from body Unscrew plug 14 and remove O ring 15 from body 4 Push out pin 11 from spool 10 and remove spring 13 and bal...

Page 406: ...clean rubber corks may be used Hydraulic openings must never be plugged with rags This practice could easily introduce dirt lint or contaminants into critical hydraulic components Tag disconnected lines to facilitate correct and faster installation WARNING Before working at the machine be sure that the blade and ripper have been lowered to the ground engine is OFF the drive train control lock leve...

Page 407: ...4 Fig 10B 14 and 10B 15 Check springs against specifications if springs are damaged and or do not meet said requirements replace them Clean all remaining parts If either a spool or housing bore is worn or scored allowing excessive internal leakage install a new control valve Replace O rings 2 and 8 2 Reassemble parts in opposite sequence indicated in Step 1 Lubricate all parts with clean oil 3 Att...

Page 408: ... Page 18 TD 25M EXTRA DRESSTA QUICK DROP VALVE Fig 10B 15 Cross Section View of Quick Drop Valve Legend for Fig 10B 14 and 10B 15 1 Plug 2 O Ring 3 Body 4 Spool 5 Retainer 6 Spring 7 Spring 8 O Ring 9 Cover Bolts Washers ...

Page 409: ...er be plugged with rags This practice could easily induce dirt lint or contaminants into critical hydraulic components Tag disconnected lines to facilitate correct and faster installation WARNING Before working at the machine be sure that the blade and ripper have been lowered to the ground engine is OFF the drive train control lock lever is in locked ON and parking brake is set The starting switc...

Page 410: ...metal bar push out slide sleeve 13 together with controlling spool 14 washer 15 and spring retainer 16 5 From other section push out spool 6 6 If required unscrew plug 2 7 Check all springs against specification If they don t meet specification replace Check free movement of spools and spools for scores 8 Discard all O rings and gasket and replace them for new Lubricate parts with clean oil Reasse...

Page 411: ...VALVES SECTION 10B Page 21 DRESSTA TD 25M EXTRA UNLOADING VALVE Fig 10B 17 Exploded View of Unloading Valve Fig 10B 18 Cross Section View of Unloading Valves ...

Page 412: ......

Page 413: ...SECTION 10C CYLINDERS ...

Page 414: ......

Page 415: ...VAL 12 12 DISASSEMBLY 13 13 INSPECTION AND REPAIR 15 14 REASSEMBLY 15 15 INSTALLATION 16 BLADE DOUBLE TILT AND PITCH CYLINDER 16 REMOVAL 17 17 DISASSEMBLY 18 18 INSPECTION AND REPAIR 20 19 REASSEMBLY 21 20 INSTALLATION 22 RIPPER LIFT AND PITCH CYLINDERS 21 REMOVAL 22 22 DISASSEMBLY 24 23 INSPECTION AND REPAIR 27 24 REASSEMBLY 27 25 INSTALLATION 28 RIPPER PIN PULLER CYLINDER 26 REMOVAL 29 27 DISASS...

Page 416: ......

Page 417: ...rs Openings must never be plugged with rags This practice could introduce dirt or lint into critical hydraulic components Tag all disconnected lines to facilitate proper installation 1 Disconnect the lift cylinders 7 Fig 10C 1 at the blade 2 by removing the cylinder rod pins 1 and drive out the mounting pins 1 on both side of the dozer Secure the lift cylinders 7 to the frame with the cylinders ha...

Page 418: ...t marked stamp letters A and B on the caps 1 and corresponding yoke ears 2 in the areas shown in Fig 10C 2 Identification marks to be in the same area either side or end as shown bellow 5 Remove the bolts securing the yoke caps 8 Fig 10C 1 to the mounting lift yoke 3 and remove the yoke caps with pins Keep pins with yoke caps for proper installation Remove the cylinder hangers and remove the blade...

Page 419: ... Ring 19 Wiper Ring 20 End Cover 21 Cylinder Rod 22 Cylinder Rod Assy 23 O Ring 24 Rod Bearing 25 Retainer Plate 26 Retainer Plate 1 Steam clean or wash the cylinder with solvent before disassembly Remove the wire securing the cylinder rod to the cylinder housing 2 Remove the tube 4 Fig 10C 1 and cylinder manifold 9 from cylinder 7 3 Attach a hoist to the cylinder rod eye as shown in Fig 10C 5 usi...

Page 420: ...er 4 and piston 8 from the cylinder rod 21 Remove the relief poppets 9 wear rings 6 O rings 5 and piston seal 7 from piston 8 9 Slide gland 13 from the cylinder rod 21 Remove O ring 10 backup ring 11 wear ring 14 O ring 18 seal ring 17 buffer ring 16 and O ring 15 from gland 13 Slide cover 20 off of rod 21 and remove wiper ring 19 from cover 10 Unscrew bolts securing retainer plates 25 and 26 to t...

Page 421: ...onto cylinder rod 21 IMPORTANT Outer end of gland is determined as bolts end and inside end as facing piston 2 Coat the bores and grooves of gland 13 with grease Install seal ring 17 by squeezing the side of the seal together and starting the seal into the groove Then work the remainder in with the thumbs DO NOT use a screwdriver as it will damage the seal Install O ring 18 into gland 13 3 Install...

Page 422: ...s 8 3 Slip yoke caps 1 Fig 10C 2 marked sides appropriately matched to lift yoke 2 A to A and B to B 4 Secure the yoke caps 8 Fig 10C 1 to the lift yoke 3 Check to be sure that pins are still engaged in the hole in the yoke bushings Torque the mounting bolts with washer to 450 Nm 5 Secure the lift cylinders 7 to the frame with the cylinders hangers Remove the hoist sling 6 Connect the cylinder hos...

Page 423: ...event inadvertent engine starting Fig 10C 10 Blade Tilt Cylinder Guard Fig 10C 11 Blade Tilt Cylinder Removal R H Side 1 Blade Tilt Cylinder 2 Lower Guard 3 Upper Guard 4 Center Guard 1 Blade Tilt Cylinder 2 Socket Cap 3 Blade 4 Hoses 5 Hose Clamp 6 Hoist Sling 7 Pin 1 Remove the upper guard 3 Fig 10C 10 lower guard 2 and center guard 4 from tilt cylinder 1 at R H side of the machine 2 Unscrew bol...

Page 424: ...10C CYLINDERS Page 8 TD 25M EXTRA DRESSTA BLADE TILT CYLINDER 7 DISASSEMBLY Refer to Fig s 10C 12 and 10C 13 Fig 10C 12 Cross Section View of Blade Tilt Cylinder Fig 10C 13 Exploded View of Blade Tilt Cylinder ...

Page 425: ...cover up to the socket cap as shown in Fig 10C 15 to provide working clearance 5 Using a brass drift as shown in Fig 10C 15 drive gland into cylinder housing 1 until the tension of the lock ring 15 is off 6 Remove three piece lock ring 15 from cylinder housing and pull rod assembly out of cylinder housing 1 7 Remove piston rod nut 3 NOTE It will be necessary to hold the ball end of the rod station...

Page 426: ...ct tapped holes for damaged threads 7 If the housing eye bushings were removed remove all rust scale or paint from the bushing bore 9 REASSEMBLY Refer to Fig s 10C 12 and 10C 13 1 Position socket cap 17 and cover 16 onto cylinder rod 18 IMPORTANT Outer end of gland is determined as bolt end and inside end as facing piston 2 Coat the bore and grooves of gland 10 with fresh grease Install seal ring ...

Page 427: ... 120 Nm 7 If removed install the cylinder bushing 2 to cylinder housing 1 10 INSTALLATION 1 Attach a hoist sling to the blade tilt cylinder 1 Fig 10C 11 as was done in removal procedure 2 Position the housing eye of the tilt cylinder into the bracket on the push arm at R H side of the machine Install pin 7 into push arm bracket and secure with hardware 3 Install cylinder rod ball in socket of blad...

Page 428: ...r installation Fig 10C 18 Blade Tilt Pitch Cylinder Guard Fig 10C 19 Blade Tilt Pitch Cylinder Removal L H Side 1 Blade Tilt Pitch Cylinder 2 Lower Guard 3 Upper Guard 4 Center Guard 1 Blade Tilt Pitch Cylinder 2 Socket Cap 3 Blade 4 Hoses 5 Hose Clamp 6 Hoist Sling 7 Pin 1 Remove the upper guard 3 Fig 10C 18 lower guard 2 and center guard 4 from tilt pitch cylinder 1 at L H side of the machine 2 ...

Page 429: ...C Page 13 DRESSTA TD 25M EXTRA BLADE TILT AND PITCH CYLINDER 12 DISASSEMBLY Refer to Fig s 10C 20 and 10C 21 Fig 10C 20 Cross Section View of Blade Tilt Pitch Cylinder Fig 10C 21 Exploded View of Blade Tilt Pitch Cylinder ...

Page 430: ...he cover up to the socket cap as shown in Fig 10C 23 to provide working clearance 5 Using a brass drift as shown in Fig 10C 23 drive gland into cylinder housing 1 until the tension of the lock ring 15 is off 6 Remove three piece lock ring 15 from cylinder housing and pull rod assembly out of cylinder housing 1 7 Remove piston rod nut 3 NOTE It will be necessary to hold the ball end of the rod stat...

Page 431: ... tapped holes for damaged threads 7 If the housing eye bushings were removed remove all rust scale or paint from the bushing bore 14 REASSEMBLY Refer to Fig s 10C 20 and 10C 21 1 Position socket cap 17 and cover 16 onto cylinder rod 18 IMPORTANT Outer end of gland is determined as bolt end and inside end as facing piston 2 Coat the bore and grooves of gland 10 with fresh grease Install seal ring 1...

Page 432: ...0 Nm 7 If removed install the cylinder bushing 2 to cylinder housing 1 15 INSTALLATION 1 Attach a hoist sling to the blade tilt pitch cylinder 1 Fig 10C 19 as was done in removal procedure 2 Position the housing eye of the tilt pitch cylinder into the bracket on the push arm at L H side of the machine Install pin 7 into push arm bracket and secure with hardware 3 Install cylinder rod ball in socke...

Page 433: ... and Pitch Cylinder Guard Fig 10C 27 Blade Double Tilt and Pitch Cylinder Removal R H Side 1 Blade Double Tilt and Pitch Cylinder 2 Lower Guard 3 Upper Guard 4 Center Guard 1 Blade Double Tilt and Pitch Cylinder 2 Socket Cap 3 Blade 4 Hoses 5 Hose Clamp 6 Hoist Sling 7 Pin 1 Remove the upper guard 3 Fig 10C 26 lower guard 2 and center guard 4 from double tilt and pitch cylinder 1 at R H side of th...

Page 434: ...ble Tilt and Pitch Cylinder Fig 10C 29 Exploded View of Blade Double Tilt and Pitch Cylinder Legend for Fig s 10C 28 and 10C 29 1 Cylinder Housing 2 Cylinder Bushing 3 Nut 4 Washer 5 Wear Ring 6 O Ring 7 Piston 8 Piston Seal 9 O Ring Backup Ring 10 Cylinder Gland 11 Wear Ring 12 Buffer Ring 13 Seal Ring 14 Wiper Ring 15 Lock Ring 16 Cover 17 Socket Cap 18 Cylinder Rod 19 O Ring ...

Page 435: ...to the hoist frame 3 Using the hoist pull the cylinder rod out to approximately 1 2 stroke Fig 10C 30 Securing Cylinder to Hoist 4 Remove the bolts and washer securing cylinder cover 16 to gland 10 and tie the cover up to the socket cap as shown in Fig 10C 31 to provide working clearance 5 Using a brass drift as shown in Fig 10C 31 drive gland into cylinder housing 1 until the tension of the lock ...

Page 436: ...off of cylinder rod 18 11 If necessary remove the cylinder bushing 2 from cylinder housing 1 18 INSPECTION AND REPAIR 1 It is recommended that all new O rings wear rings seals and wiper rings be installed when the cylinder is disassembled 2 Wash all parts in a solvent and air dry Lubricate machined surfaces of usable parts to protect them 3 Inspect the cylinder housing for roundness throughout its...

Page 437: ... on each end of piston 7 Install and slide piston onto rod 18 Secure with washer 4 and nut 3 Clamp ball rod into press as shown in Fig 10C 32 Using a multiplier torque piston nut 3 to 3250 Nm 5 Secure cylinder housing 1 to hoist frame Attach hoist to socket cap 17 and lower rod assembly into housing 1 using extreme care not to damage wear rings 5 and piston seal 8 Once piston 7 has entered housing...

Page 438: ...e be sure that the blade and ripper have been lowered to the ground engine is OFF the drive train control lock lever is in locked ON position and parking brake is set The starting switch and the electrical system master switch are turned OFF keys are removed and the controls are tagged to prevent inadvertent engine starting IMPORTANT Disconnected hydraulic lines must be capped with the correct siz...

Page 439: ...ift Cylinder or Pitch Cylinder Removal 1 Pin 2 Head End Tube 3 Rod End Hose 4 Frame 5 Indicator Rod 6 Pin 7 Pin 8 Toolbeam 9 Lift Cylinder 10 Rod End Hose 11 Pitch Cylinder 12 Head End Tube Fig 10C 35 Ripper Lift Cylinder Removal 1 Fuel Tank Holder 2 Ripper Pitch Cylinder 3 Ripper 4 Ripper Lift Cylinder ...

Page 440: ... and plate securing pin 7 to toolbeam 8 Using a pry bar move pin outward until rod eye is clear 5 Remove bolts and plate securing pin 1 to frame 4 Using a pry bar move pin outward until housing eye is clear 6 Remove pitch cylinder 11 from ripper 22 DISASSEMBLY Refer to Fig s 10C 36 and 10C 37 Fig 10C 36 Cross Section View of Ripper Lift and Pitch Cylinder Legend for Fig s 10C 36 and 10C 37 1 Cylin...

Page 441: ...rap to protect the bearing in eye Raise the cylinder up and secure it to the hoist frame Pull the cylinder rod out to approximately 1 2 stroke 3 Remove hardware securing cover 17 to gland 11 Tie cover up to the rod eye as shown in Fig 10C 39 to provide working clearance 4 Using a brass drift as shown in Fig 10C 39 drive gland into cylinder housing 1 until the tension is off the lock ring 16 Remove...

Page 442: ...uggested method is to clamp the eye end of the piston rod in a hydraulic press and use a torque multiplier as shown in Fig 10C 40 or an impact tool 6 Remove washer 5 and piston 9 from rod 18 Remove wear rings 6 O rings 7 and piston seal 8 from piston 9 7 Slide gland 11 from rod 18 Remove O ring with backup ring 10 wear ring 12 buffer ring with O ring 13 wiper ring 15 and seal ring 14 from gland 11...

Page 443: ... the seal together and starting the seal into the groove Then work the remainder in with the thumbs DO NOT use a screwdriver as it will damage the seal 3 Install O ring with buffer ring 13 notched edge facing in into gland 11 and follow with wear ring 12 Install O ring with backup ring 10 and wiper ring 15 into gland 11 Slide gland 11 onto rod 18 tapped holes toward rod eye 4 Install piston seal 8...

Page 444: ...nd tube 12 with tube clamp to pitch cylinder 11 6 Vent the hydraulic system and add oil as necessary refer to OPERATOR S MANUAL Visually check for oil leakage 7 Cycle cylinder a few times and recheck cylinder cover bolts torque Installation Ripper Pitch Cylinder 1 Attach a hoist to the pitch cylinder position housing eye to frame 4 Fig 10C 35 Install pin 1 and secure with plate and hardware 2 Posi...

Page 445: ...emoved and the controls are tagged to prevent inadvertent engine starting IMPORTANT Disconnected hydraulic lines must be capped with the correct size plastic cap If caps are not available use tape or rubber stoppers Openings must never be plugged with rags This practice could introduce dirt or lint into critical hydraulic components Tag all disconnected lines to facilitate proper installation Fig ...

Page 446: ...NDERS Page 30 TD 25M EXTRA DRESSTA RIPPER PIN PULLER CYLINDER 27 DISASSEMBLY Refer to Fig s 10C 43 and 10C 44 Fig 10C 43 Cross Section View of Pin Puller Cylinder Fig 10C 44 Exploded View of Ripper Pin Puller Cylinder ...

Page 447: ...f round replace Check all parts for scores nicks or scratches and replace as necessary Shallow scratches can be polished out with a fine emery cloth 28 REASSEMBLY Refer to Fig s 10C 43 and 10C 44 1 Coat bores and grooves of gland 5 with fresh grease Install seal ring 13 by squeezing sides of seal together and starting seal into the groove Then work remainder in with thumbs DO NOT use a screwdriver...

Page 448: ... 2 30 REMOVAL INSTALLATION AND SERVICE Removal installation and service of the blade tilt cylinder G 2 is similar to the blade tilt cylinder shown in this Section Details for blade tilt cylinder G 2 can be found in relevant Sections of PARTS CATALOGUE and OPERATOR S MANUAL ...

Page 449: ...SECTION 10E RESERVOIRS AND FILTERS ...

Page 450: ......

Page 451: ...RESERVOIRS AND FILTERS SECTION 10E DRESSTA TD 25M EXTRA CONTENTS 1 DESCRIPTION 1 2 REMOVAL 2 3 DISASSEMBLY 5 4 INSPECTION AND REPAIR 5 5 REASSEMBLY 5 6 INSTALLATION 6 ...

Page 452: ......

Page 453: ...of Hydraulic Reservoir 1 Hydraulic Reservoir 2 Bracket 3 Bracket 4 Breather Valve 5 Plug 6 O Ring 7 Filler Cap 8 Reservoir Cover 9 O Ring 10 Strainer Retaining Ring 11 Tube 12 Nut 13 Washer 14 Strainer 15 Sight Gauge 16 O Ring 17 Filler Strainer 18 Magnetic Plug 19 Ecology Oil Drain Valve 20 Hydraulic Connector 21 Drain Valve 22 Drain Hose ...

Page 454: ...nd ripper have been lowered to the ground engine is OFF the drive train control lever is in NEUTRAL position drive train lock lever is in ON position and parking brake is set The starting switch and the electrical system master switch are turned OFF keys are removed and the controls are tagged to prevent inadvertent engine starting IMPORTANT Disconnected hydraulic lines must be capped with the cor...

Page 455: ... Fan Drive Pump 4 Disconnect suction tube 1 Fig 10E 3 and return tube 3 from the reservoir 4 Remove and discard old O rings 5 Disconnect two return hydraulic hoses 2 and 6 return hose 5 and suction tube 7 from the reservoir 4 Remove and discard old O rings Cap the reservoir ports to prevent entry of dirt 6 Attach a suitable hoist sling to holder mounted on the reservoir 4 Remove reservoir 4 mounti...

Page 456: ...DRESSTA HYDRAULIC RESERVOIR Fig 10E 4 Exploded View of Vacuum Pressure Relief Valve 1 Retainer Ring 2 Cover 3 Ceramic Filter 4 Gasket 5 Cover 6 Spring 7 Retainer 8 Sleeve 9 O Ring 10 Ring 11 O Ring 12 Poppet 13 Poppet Spring 14 Poppet Guide 15 Valve Housing ...

Page 457: ...eservoir inspect the residue in the tank Check for deposition of foreign particles that could indicate a component failure of system 3 Clean and dry all parts thoroughly Clean the strainers 14 and 17 Fig 10E 1 in a suitable solvent and air dry 4 Inspect the reservoir and all fittings for signs of wear or damage 5 Be sure all parts move freely in the breather valve Clean or replace the breather val...

Page 458: ...ube 7 return hose 5 and two return hydraulic hoses 2 and 6 to the reservoir 4 3 Reconnect suction tube 1 Fig 10E 2 and return tube 3 to the reservoir 4 4 Reinstall R H enclosure 2 Fig 10E 2 with R H door 1 and secure it with bolts 3 5 Reconnect wire harness of rear lamp 6 Fill the hydraulic reservoir Refer to the OPERATOR S MANUAL for this procedure 7 Start the engine move the hydraulic controls i...

Page 459: ...SECTION 12 POWER ...

Page 460: ......

Page 461: ...POWER SECTION 12 DRESSTA TD 25M EXTRA CONTENTS Page 1 DESCRIPTION 1 2 SPECIFICATIONS 1 3 AIR INDUCTION SYSTEM TEST 2 4 CONTROL ADJUSTMENT 4 5 REMOVAL 8 6 ENGINE REPAIR 13 7 INSTALLATION 14 ...

Page 462: ......

Page 463: ...ulletin No 3666259 2 SPECIFICATIONS Special Bolt and Nut Torque Data Air precleaner mounting clamp 14 20 Nm Air cleaner hose clamps 10 12 Nm Air intake bumper hose clamps 7 9 Nm Alternator terminals No 10 24 ground terminal 1 7 2 8 Nm 28 positive terminal 6 8 Nm Battery terminals 34 42 Nm Cranking motor No 10 32 switch terminal 1 8 3 4 Nm 13 ground terminal 27 35 Nm 13 battery terminal 27 35 Nm En...

Page 464: ...ion System Service Points 1 Air Cleaner Warning Light Switch 2 Air Intake Connection 3 Plug M14x1 5 4 Ether Injector Nozzle 6 Using a soap solution and a paint brush coat the following places and check for leaks Fig 12 2 a Air cleaner body surfaces around the outlet tube connections b Air cleaner restriction indicator warning light switch to air cleaner c All clamped hose connections between air c...

Page 465: ... restriction flow test 1 Perform the charge air cooler system performance tests with engine running check pressure drop test internal flow air restriction ambient and intake air temperature differential efficiency of cooling system due to significant influence for the engine performance durability and emission compliance For detailed procedure refer to Engine Manual ...

Page 466: ...must be done with the engine running WARNING When removing or installing the measuring equipment or during measuring engine speed be careful not to touch any high temperature parts or rotating parts 1 Remove the center floor plate in operator s compartment 2 Disconnect wire harness connector 18 from the potentiometer 17 3 Remove bolts 11 and remove bracket 25 with control elements from under the p...

Page 467: ...olts 12 Pin 13 Clevis 14 Lock Nut 15 Control Rod 16 Plate 17 Potentiometer 18 Wire Harness Connector 19 Control Lever 20 Intermediate Lever 21 Pin 22 Clevis 23 Lock Nut 24 Spring Enclosure 25 Bracket 26 Control Cable 27 Control Cable 28 Spring 29 Bushing 30 Lock Nut 31 Link 32 Washer and Cup 33 Nut A Dimension 185 to 188 mm B Gap 6 mm C Gap 2 3 mm D Gap 0 0 mm E Dimension 19 5 mm F Dimension 10 5 ...

Page 468: ...rake spool of the steering valve Refer to SECTION 7E should be fully moved out If the brake spool is not fully moved out loosen lock nut 6 and make adjustment of rod 5 with clevis 7 Tighten lock nut 6 2 Press brake pedal 4 to the resist Check if C gap 2 to 3 mm is obtained 3 Release brake pedal 4 and check A dimension between floor and pedal center top which should be 185 to 188 mm Engine Running ...

Page 469: ...s of 50 and 31 pins connectors more than 100K Ω Fig 12 4 Engine Control Interface Connectors 1 50 Pin Connector view of harness connector 2 31 Pin Connector 3 Potentiometer Circuit 4 TC Oil Temperature Sensor 5 Pin No 48 5VDC Supply 6 Pin No 49 Signal 7 Pin No 47 Return After checking has been performed machine must be checked out in actual operation for proper functioning NOTE If potentiometer is...

Page 470: ...the engine wire harness connectors 1 Fig 12 5 Unscrew the nut and remove socket from the bracket Disconnect the engine potentiometer control wire harness connector 2 and engine speed sensor connector 6 Secure plugs and sockets against dirt and damage NOTE One of the two engine wire harness connectors is located behind the fuel filter IMPORTANT Disconnected electrical connectors must be capped with...

Page 471: ... the frame 9 MACHINES EQUIPPED WITH A C SYSTEM Disconnect the connector 1 Fig 12 6 from the magnetic clutch of the A C system compressor Remove A C compressor and alternator drive belt Remove bolts 2 securing A C compressor 3 to the bracket Remove compressor with attached hoses Do not disconnect the hoses of the compressor Disconnecting the hoses causes gas escape out of air conditioner system Sec...

Page 472: ... to the hood support 14 Disconnect the wire connector 2 of the ether solenoid valve temperature switch 15 Disconnect the wire from the coolant temperature sensor 3 16 Remove cab heater supply hose 4 from valve 17 Loosen hose clamp 5 remove air cleaner mounting bolts 6 Remove air cleaner assy out of the way IMPORTANT Tape or plug turbocharger openings to prevent from entering the dirt or rags 18 Lo...

Page 473: ...G This procedure requires extreme caution Use suitable blocking equipment while working under the machine 21 Remove hose and tube 4 Fig 12 9 from the drive train system pump Wire hose in upright position 22 Remove oil inlet hose 3 from torque converter 23 Remove torque converter drain hose 5 from the flywheel housing Fig 12 9 Torque Converter Disconnecting Points bottom side 1 Fan Drive System Hyd...

Page 474: ...aft 29 Drain the hydraulic reservoir as described in Operator s Manual 30 Remove hoses 5 from the hydraulic pump Wire hoses in upright position 31 Remove tube 7 from the hydraulic system pump 32 Remove hoses 6 from the drive train system pump Wire hoses in upright position 33 Unscrew bolts 1 Fig 12 11 securing front engine bracket 3 to frame 34 Remove bolts 5 both sides and remove bar 4 to gain ac...

Page 475: ...l disconnects required for engine removal have been made Guide the engine with torque converter forward Then lift and turn assy round vertical axis until torque converter with pumps is outside of machine frame 38 Position engine into the suitable engine support stand NOTE After engine is removed from machine it should be placed on a prepared block frame support 39 Install the hoist to the torque c...

Page 476: ...15 engine is 2000 kg The engine lifting equipment must be designed to safely lift the engine 4 Reinstall bar 4 Fig 12 11 with the bolts 5 both sides 5 Reinstall hoses 6 Fig 12 10 to the drive train system pump 6 Reinstall tube 7 to the hydraulic system pump 7 Reinstall hoses 5 to the hydraulic system pump 8 Reinstall bolts securing drive shaft 4 to the torque converter output shaft 9 Use a new gas...

Page 477: ...ect the engine potentiometer control wire harness connector 2 and engine speed sensor connector 6 31 Reassemble rear doors and shields assembly on both sides of engine compartment 32 Reassemble radiator assy as described in section 6 COOLING SYSTEM 33 Refill the equipment hydraulic reservoir as described in Operator s Manual 34 Open the fuel valve under the fuel tank 35 Turn the master switch to O...

Page 478: ......

Page 479: ...SECTION 13 SUPERSTRUCTURE ...

Page 480: ......

Page 481: ...SUPERSTRUCTURE SECTION 13 DRESSTA TD 25M EXTRA CONTENTS Page 1 DESCRIPTION 1 2 SPECIFICATION 1 3 CAB REMOVAL 1 4 POD REMOVAL 3 5 INSPECTION 6 6 POD REASSEMBLY 7 7 CAB REASSEMBLY 7 ...

Page 482: ......

Page 483: ...ssible to use a lifting device for lifting of disassembled assembles 2 Turn electrical master switch to OFF position WARNING Before working at the machine be sure that the blade and ripper have been lowered to the ground engine is OFF the drive train control lever is locked in neutral position and parking brake is set The starting switch and the electrical system master switch are turned OFF keys ...

Page 484: ... and ROPS Disconnecting Points LH side 1 Bolts 2 A C System Quick Couplings Fig 13 2 A C System Condenser Disassembly Points 1 Supply Cable 2 Ground Cable 3 Heater Control Potentiometer Plug 4 Front and Rear Lamps Plug 5 A C Heater Control Switch Plug 6 ROPS Lamps Plug 7 Control Panel ...

Page 485: ... valve 5 and ripper control pilot valve 7 to the mounting plate Pull the valves down 3 Pull the horn push button 6 down 4 Disconnect brake control cable 2 Fig 13 4 Remove brake control cable from the bracket under pod 5 Disconnect wire harness plug 3 Fig 13 4 of the engine control potentiometer 6 Remove the plate from instrument panel column and disconnect electrical connectors for two cables 4 Fi...

Page 486: ...ce dirt or lint into critical hydraulic components of machine Tag all disconnect oil lines to facilitate installation 9 Tag and remove the hoses 2 3 and 4 from the drive train control valve Remove the frame on the bottom of console Pool the hoses down from console Fig 13 4 Disassemble Points Under the Pod 1 Wiper Washer Tanks 2 Brake Control Cable 3 Engine Control Potentiometer Plug Wire Harness P...

Page 487: ...rol Pilot Valve 6 Horn Push Button 7 Ripper Control Pilot Valve 8 A C Heater Assy 9 Conditioner Mounting Hardware 10 Air Hoses Fig 13 7 LH Console and Instrument Panel Column electrical Connections 1 Wire Harness Sockets 3 Engine Data Link Connector 2 Wire Harness Plugs 4 Instrument Panel Supply and Ground Cables 10 Remove wire harness plugs from the sockets 1 Fig 13 7 ...

Page 488: ...e 1 covering the platform mounting bolts Remove platform mounting bolts 4 Fig 13 8 and plate 3 Attach the hoist and lift pod Make a visual inspection around the pod to be sure that all disconnects required for pod removal have been made 14 Raise the pod enough to separate the frame Place the platform on suitable support stand 15 Protect the air conditioner assy 8 against damage 16 Disassemble bolt...

Page 489: ... hoses 6 to pilot lock valve 5 and switching valve 7 8 Reinstall wire harness plugs to the sockets 1 Fig 13 7 9 Reinstall one wire harness socket in the platform hole torque the nuts to 0 7 Nm Reconnect wire harness plugs 2 Reconnect electrical connectors for two cables 4 of the instrument panel supply Install the plate 10 Reconnect wire harness plug 4 Fig 13 4 of the engine control potentiometer ...

Page 490: ...ire harness plug 3 and A C heater switch wire harness plug 5 7 Reconnect electrical connectors for two cables 1 and 2 supply and ground of the cab electrical system 8 Install left right and rear plastic shields in the cab Install the armrest 9 Position ROPS structure Install the bolts 1 Fig 13 1 securing ROPS to the crossbeam assembly five bolts on each side and torque them to 1500 Nm 10 Turn elec...

Page 491: ...SECTION 14 SUSPENSION ...

Page 492: ......

Page 493: ... REPAIR 12 10 REASSEMBLY 13 11 INSTALLATION 14 HYDRAULIC TRACK ADJUSTER 12 DESCRIPTION 14 13 REMOVAL 15 14 DISASSEMBLY 15 15 INSPECTION AND REPAIR 16 16 REASSEMBLY 16 17 INSTALLATION 16 TOP IDLER 18 DESCRIPTION 17 19 REMOVAL 17 20 DISASSEMBLY 18 21 INSPECTION AND REPAIR 18 22 REASSEMBLY 19 23 INSTALLATION 19 TRACK ROLLER 24 DESCRIPTION 20 25 REMOVAL 20 26 DISASSEMBLY 21 27 INSPECTION AND REPAIR 22...

Page 494: ...SPECTION AND REPAIR 30 42 INSTALLATION 31 TRACK CHAIN GUIDE BAR 43 DESCRIPTION 32 44 REMOVAL 32 45 INSPECTION AND REPAIR 32 46 INSTALLATION 33 TRACK FRAME AND PIVOT SHAFT 47 DESCRIPTION 33 48 REMOVAL AND DISASSEMBLY 33 49 INSPECTION AND REPAIR 37 50 REASSEMBLY AND INSTALLATION 37 TRACK FRAME ALIGNMENT 51 TRACK FRAME ALIGNMENT 39 TRACK SPRINGS 52 DESCRIPTION 42 53 REMOVAL AND DISASSEMBLY 42 54 REAS...

Page 495: ...Tool Sleeve 1 547 0358 Pivot Shaft Seal Tool Ring 1 547 0397 Track Spring Bolt 1 559 0221 No 96 Spring Compression Tool 1 559 0221 Tool for pivot shaft seal driving into seal shield 1 547 0359 GENERAL NOTE The following procedures covers of a suspension from right side of the machine only The procedures are the same for left side 2 DESCRIPTION Fig 14 1 Exploded View of Right Track Assembly ...

Page 496: ...he dozer and they support the weight of the dozer on the track rollers The track frames are mounted at the main frame both side of machine A guide bracket is welded to the frame to provide proper spacing between the two tracks The track frames are attached at the rear of the dozer to the pivot shafts Each track is free to oscillate vertically independently of the other track The equalizer bar cont...

Page 497: ... 0 04 mm Bushing OD 190 13 190 176 mm Track frame housing ID 190 0 025 mm Outer bushing Bushing ID before press 131 1 0 03 mm Bushing ID after press 130 785 130 999 mm Pivot shaft OD 130 517 130 557 mm Bushing OD 150 190 150 253 mm Track frame housing ID 150 0 025 mm Track Springs Outer track spring Free length 721 736 mm Test length 771 mm Test load 267 9 kN Number of working coils 10 4 Weight of...

Page 498: ... and Bolt Torque Data Torques given are for bolts and nuts lubricated with SAE 30 engine oil Front Idler Bushing retainer bolts 170 Nm Fork and mounting block bolts 730 Nm Drain plug 20 50 Nm Top Idler Front top idler mounting block bolts 845 Nm Rear top idler mounting block bolts 845 Nm Drain plug 20 50 Nm Top idler cover mounting bolts 35 Nm Track Roller Roller retainer bolts 135 Nm Roller shaft...

Page 499: ...igned Correct alignment of the front idler Machine Creeps to One Side 1 Track loose on one side Adjust the track chain tension 2 Track shoes loose Tighten bolts to proper torque Track Chain Loose 1 Track not properly adjusted Adjust the track tension 2 Sprocket worn Inspect sprocket for worn teeth or damage If wear is excessive replace the sprocket rim 3 Track links or bushings worn Inspect track ...

Page 500: ... Shoe Bolts Break 1 Bolts not properly tightened Tighten bolts to proper torque 2 Bolt head snap off Track shoes out of flat Replace track shoes 5 CHECKING UNDERCARRIAGE WEAR WARNING Before working at the machine be sure that the blade and ripper have been lowered to the ground engine is OFF the drive train neutral lock lever is in locked ON position and parking brake is set The starting switch an...

Page 501: ...track plate and take a reading Measure two or more shoes to get an average and compare with dimensions given refer to SPECIFICATIONS in SECTION 15 Link Height Fig 14 4 Clean out all materials between links Place squeeze bar 1 across center of links Insert about 300 mm scale 2 in squeeze bar 1 refer to SERVICE SPECIAL TOOLS in this Section so that scale is against bottom of track shoe plate and tak...

Page 502: ...n SECTION 15 Front Idler Flange Height Fig 14 7 Insert about 300 mm scale 1 in squeeze bar 2 refer to SERVICE SPECIAL TOOLS in this Section Rest squeeze bar 2 on top of flange and push scale down until it makes contact in middle of treat area as shown and take a reading Compare with dimensions given refer to SPECIFICATIONS in this Section Fig 14 6 Measuring Track Pitch Fig 14 7 Measuring Flange He...

Page 503: ... the blade and ripper have been lowered to the ground engine is OFF the drive train control lock lever is in locked ON position and parking brake is set The starting switch and the electrical system master switch are turned OFF keys are removed and the controls are tagged to prevent inadvertent engine starting CAUTION Lift and handle all heavy parts with a lifting of proper capacity Be sure parts ...

Page 504: ... of the area Fig 14 10 Front Idler Fig 14 11 Track Adjuster 1 Front Idler Cover 2 Track Frame 3 Track Chain 4 Front Idler 1 Relief Valve 2 Lubrication Fitting Ball Check Valve 3 Track Frame 8 DISASSEMBLY Refer to Fig s 14 13 and 14 14 Fig 14 12 Front Idler and Fork 1 Fork Assy 2 Left Front Idler Block 3 Pin 4 Front Idler 5 Right Front Idler Block ...

Page 505: ...Front Idler Bushing 9 Front Idler Housing with Bushing 10 Drain Plug 11 Front Idler Shaft Fig 14 14 Cross Section View of Front Idler 1 Front Idler Seal Retainer 2 O Ring 3 Seal Kit 4 Retaining Ring 5 Front Idler Bushing Retainer 6 O Ring 7 Thrust Washer 8 Front Idler Bushing 9 Front Idler Housing with Bushing 10 Drain Plug 11 Front Idler Shaft 12 Left Front Idler Block 13 Right Front Idler Block ...

Page 506: ...e and bushing retainer 5 with O ring 6 from each side of idler Remove washer 7 Position idler in press and remove shaft 11 Bushing 8 are a press fit in front idler housing 9 and must not be removed unless replacement is necessary 9 INSPECTION AND REPAIR 1 It is recommended that new O rings be installed whenever the front idler is disassembled for service 2 Wash all parts thoroughly in a suitable s...

Page 507: ...ft 11 in front idler housing 9 Repeat Step 2 on opposite side of front idler housing 9 Fig 14 16 Bushing Installation A 7 06 0 64 mm 4 Check that front idler end clearance is within tolerance given in Fig 14 15 From side of roller dial indicator is to be mounted push roller shaft into housing to be sure it is bottomed against washer Place indicator base on idler housing with indicator pointer rest...

Page 508: ...ting blocks 2 and 5 Fig 14 12 with grease Install the dowel pin 3 into front idler shaft Install blocks onto idler shaft and secure with fork 1 and hardware Torque fork bolts to 730 Nm 11 INSTALLATION 1 Lubricate the guides inside track frame 2 Using a hoist and sling position front idler and fork onto guide bars up against adjuster cylinder 3 Tighten the relief valve 1 Fig 14 11 to 68 Nm 4 Instal...

Page 509: ...vided Warn people in the area to stand clear 1 Remove the track chain as described in SECTION 15 2 Remove the front idler refer to Paragraph 7 REMOVAL in this Section 3 Remove hydraulic track adjuster from front of track frame by sliding it out front of track frame 14 DISASSEMBLY Refer to Fig 14 18 Fig 14 18 Exploded View of Track Adjuster 1 Hydraulic Track Adjuster 2 Retaining Ring 3 Piston Seal ...

Page 510: ...ston 2 Install retaining ring 2 in groove on piston 4 3 Place a small amount of grease in bore of track adjuster 1 Insert piston assembly seal end first into track adjuster bore until it bottoms so that all air be expelled Grease appears through valve openings in track adjuster 1 4 Thread lube fitting 10 into ball check valve 9 5 Install ball check valve 9 and relief valve 8 on track adjuster 1 an...

Page 511: ... drive train control lock lever is in locked ON position and parking brake is set The starting switch and the electrical system master switch are turned OFF keys are removed and the controls are tagged to prevent inadvertent engine starting CAUTION Lift and handle all heavy parts with a lifting of proper capacity Be sure parts are secured by proper slings and hook Use lifting eyes if provided Warn...

Page 512: ...placed press cone off shaft 6 Bearing cups 5 and 8 need not be removed from housing 7 unless replacement is necessary 4 Using coarse paper a file or a hand grinder remove any corrosion or hardened foreign material that may exist on seal bore surfaces of housing 7 and retainer 12 Do this carefully to avoid changing dimensions of bore Fig 14 21 Exploded View of Top Idler 1 Drain Plug 2 End Cover 3 O...

Page 513: ...e seal kit 11 with greasy oily or dirty hands Track idler must not be filled with lubricant until idler and track frame are in position on machine 4 Before installing seal assembly be sure seal contacting surfaces of idler housing bore and seal retainer are clean Also that rubber rings of seal assembly are correctly positioned on metal rings Install seal Refer to SEAL INSTALLATION under METAL TYPE...

Page 514: ...ng CAUTION Lift and handle all heavy parts with a lifting of proper capacity Be sure parts are secured by proper slings and hook Use lifting eyes if provided Warn people in the area to stand clear 1 Release the tension in the track chain refer to ADJUSTING TRACK TENSION in SECTION 15 2 Wedge a steel plate between the frame and equalizer bar 3 Remove the track roller rock shields and or sprocket ro...

Page 515: ...Washer 7 Track Roller Bushing 8 Track Roller Shaft 9 Track Roller Housing Double Flange 10 Track Roller Housing Single Flange 11 Drain Plug 12 Spring Pin Fig 14 24 Cross Section View of Track Roller 1 Roller Bracket 2 O Ring 3 Seal Kit 4 Roller Retainer 5 O Ring 6 Thrust Washer 7 Track Roller Bushing 8 Track Roller Shaft 9 Track Roller Housing Single Flange 10 Track Roller Housing Double Flange 11...

Page 516: ...the opposite side of the roller 4 Remove the washers 6 With parts removed from both sides of the roller housing remove the shaft 8 from the roller housing and bushings 7 5 The bushings 7 are pressed into the roller housing When replacement is necessary they can be pressed from position 27 INSPECTION AND REPAIR 1 Wash all the parts thoroughly in a solvent and dry with compressed air Wash all the bu...

Page 517: ...0 04 mm D Bushing Inside Diameter assembled 105 3 0 05 mm E Roller Shaft Diameter 104 93 0 05 mm Diametral Clearance D E 0 35 0 1 mm End Clearance A B 2C 0 6 0 3 mm 28 REASSEMBLY Refer to Fig s 14 23 and 14 24 Fig 14 27 Bushing Installation A Bushing Pressed Below Edge of Roller Bore 7 06 0 64 mm 1 If replacing bushings 7 coat 25 mm of outer end of roller bore and leading edges of bushing OD with ...

Page 518: ...e opposite side of the roller housing as was done previously 5 Check that track roller end clearance is within tolerance given in Fig 14 26 From side of roller dial indicator is to be mounted to push roller shaft into housing to be sure it is bottomed against washer 6 Place dial indicator magnetic base on roller housing with indicator pointer resting against end of shaft Set indicator at zero Fig ...

Page 519: ... between the track frame 4 Release the jacks under the front frame and rear main frame slowly until the slot in the track frame and track roller are in position 5 Secure the roller in position by installing bolts through the track roller shaft brackets and into the track frame Tighten the bolts evenly Release the jacks the rest of the way 6 Remove the steel wedge from between the equalizer bar and...

Page 520: ...ate 6 Shims 7 Guide Plate 8 Retainer Plate 9 Front Top Idler Mounting Bracket 32 REMOVAL Refer to Fig 14 33 WARNING Before working at the machine be sure that the blade and ripper have been lowered to the ground engine is OFF the drive train control lock lever is in locked ON position and parking brake is set The starting switch and the electrical system master switch are turned OFF keys are remov...

Page 521: ...ide parts that are damaged must be replaced with new parts 3 Inspect the wear plates and the guide plate for excessive wear refer to SPECIFICATIONS in this Section Replace if necessary 34 INSTALLATION Refer Fig 14 33 1 Secure plate 7 to machine frame with same thickness of shims 6 as were removed Torque bolts to 1500 Nm 2 Position plate 1 between track frame and plate 7 Insert top bolts through ho...

Page 522: ...been lowered to the ground engine is OFF the drive train control lock lever is in locked ON position and parking brake is set The starting switch and the electrical system master switch are turned OFF keys are removed and the controls are tagged to prevent inadvertent engine starting CAUTION Lift and handle all heavy parts with a lifting of proper capacity Be sure parts are secured by proper sling...

Page 523: ...er to Fig 14 34 1 If shaft bushings in tunnel were removed install new bushings in equalizer bar tunnel If bushings 24 Fig 14 1 were removed press new bushings into equalizer bar 23 until flush and install new seal rings 25 2 Be sure wear pads 2 are in place on track frame brackets 1 3 Insert equalizer bar 23 Fig 14 1 in tunnel and align shaft holes Lightly grease shaft 34 and install in tunnel Se...

Page 524: ...chain refer to SECTION 15 2 Remove front idler assembly refer to FRONT IDLER in this Section Fig 14 35 Front Idler Lower and Upper Guide Bars 1 Upper Guide Bar 2 Lower Guide Bar 3 Front Idler Block 4 Track Frame 5 Front Idler 41 INSPECTION AND REPAIR 1 Inspect the front idler guide bars for distortion or excessive wear refer to Paragraph 3 SPECIFICATIONS in this Section Any guide bars are damaged ...

Page 525: ...o positioning new guide bar to the track frame preheat guide bar to 180 230 C Position new guide bar to dimensions shown in Fig 14 36 and clamp in place Lay a 6 mm weld along the length of the bars Lay a 12 mm weld along the front and rear ends of the bars 3 Measure distance A Fig 14 36 between upper guide bar 1 and lower guide bar 2 on both sides 4 Lubricate guide bars inside track frame 5 Instal...

Page 526: ...de Bars 297 2 1 5 mm B Track Chain Guide Bar Distance from Track Frame Edge 10 1 5 mm C Track Chain Guide Bar Distance from Track Frame Edge 9 1 5 mm D Guide Bar Wear Limit 2 mm 1 Remove track chain refer to SECTION 15 2 Remove front idler assembly refer to FRONT IDLER in this Section 3 If the guide bars 1 are worn refer to Inspection and Repair below cut the welds out from the track frame Smooth ...

Page 527: ...de back and forth to take up shock loads and for adjusting the track chain tension Pivot Shaft The pivot shaft supports the rear track frame and permits free track oscillation in conjunction with the guides frame It is fitted with bushings to take the wear as the frames oscillate One end of the shaft is bolted to the main frame while the other is bearing mounted to the track frame The bearing is l...

Page 528: ...rear of track frame 6 Install blocks in equalizer bar tunnel on each side of machine to prevent movement of equalizer bar Remove equalizer bar elastic suspension refer to EQUALIZER BAR in this Section NOTE Whenever possible an adjusting sling should be used to remove track frame With an adjusting sling track frame can be tilted or leveled as required reducing job time effort and hazard Fig 14 38 B...

Page 529: ...ar washer 7 retaining plate 6 inner wear washer 7 and shims 8 from end of pivot shaft 5 Keep shims if present with plate 6 to facilitate installation 11 Unscrew bolts with washers securing the snap ring 4 and seal shield 3 to the track frame 1 and move back ring 4 12 Using a pry bar between track frame and main frame move track frame out horizontally Swing track frame from pivot shaft and away fro...

Page 530: ... ring 12 and seal shield 3 with outer part of seal 11 15 Preheat the seal inner ring 11 to remove inner ring stuck to the pivot shaft 5 To do it use suitable puller 16 Remove snap ring 4 from the pivot shaft 5 17 Remove the track rollers Refer to TRACK ROLLER in this Section 18 Remove top idlers and top idler mounting brackets if required Refer to TOP IDLER in this Section 19 If bushings 9 and 10 ...

Page 531: ...a hoist sling to the pivot shaft The hoist must be installed to give the best possible balance Position the pivot shaft to the main frame b Secure the pivot shaft to the main frame Torque the bolts to 2750 Nm 2 Put the snap ring 4 on pivot shaft 5 3 Install the pivot shaft seal 11 on pivot shaft 5 as follows Fig 14 42 NOTE Take care at seal 11 installation not to damage the rubber parts of seal a ...

Page 532: ... 4 with seal shield 14 to the track frame 1 Torque bolts with washers to 108 Nm 11 Install inner wear washer 7 to the track frame Position shim pack 8 on end of pivot shaft 5 and secure the retaining plate 6 Remove or add enough shims 8 to align the center line of the last track roller with the center line of the sprocket refer to TRACK FRAME ALIGNMENT in this Section Install plate 6 and torque bo...

Page 533: ...his practice could introduce dirt or lint into critical hydraulic components Remove all dirt accumulation from the main frame cover Tag disconnected lines to facilitate faster and correct installation Fig 14 43 Track Frame Alignment 1 Sprocket 2 Pivot Shaft 3 Rear Top Idler 4 Front Top Idler 5 Guide Plate 6 Front Idler S1 Pivot Shaft Shims S2 Guide Plate Shims W W1 Gauge W W1 2140 mm CHECKING ALIG...

Page 534: ...efer to TOP IDLER in this Section 6 Position the wear plates 1 and 5 Fig 14 33 Assemble the spacer blocks 4 and retainer plate 8 with the guide plate 7 temporarily held in place Use shims 3 at spacer blocks 4 as required to get a clearance of 1 mm maximum between the guide plate 7 and one of the wear plates 1 or 5 Refer to TRACK FRAME GUIDE in this Section 7 Keeping the track frame horizontal alig...

Page 535: ...GUIDE in this Section NOTE Do not force track frame inward or outward 10 Loosen upper spacer block 4 Fig 14 33 mounting bolt Attach a piece of strong cord 1 Fig 14 45 between centerline of sprocket 2 and centerline of front idler 3 Align the front and rear top idlers 4 so that the centerline of both top idlers 4 lie exact to 0 8 mm from the line passing through the sprocket centerline and front id...

Page 536: ...FF the drive train control lock lever is in locked ON position and parking brake is set The starting switch and the electrical system master switch are turned OFF keys are removed and the controls are tagged to prevent inadvertent engine starting CAUTION Lift and handle all heavy parts with a lifting of proper capacity Be sure parts are secured by proper slings and hook Use lifting eyes if provide...

Page 537: ...fer to TRACK FRAME AND PIVOT SHAFT in this Section 4 Position track frame on 300x300 mm blocks as shown in Fig 14 47 and remove all track rollers refer to TRACK ROLLER in this Section 5 If springs are broken use a torch and cut in pieces for removal Fig 14 47 Track Frame Position 6 Install springs bolt 4 Fig 14 46 1 559 0221 No 96 through front of track frame Through hole in bottom plate thread bo...

Page 538: ...nto 1 559 0221 spring compression tool 2 Install the spring bolt 4 into the spring compression tool and thread the bolt in until the bolt contacts rear spring seat 5 Thread the bolt in until an installation dimension equal to 836 mm B has been reached 3 Attach the sling to the spring s assembly and install them into track frame Slowly thread the spring bolt out 4 until the track springs have been ...

Page 539: ...uts 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 1B The narrow highly polished sealing band must be within outer half of the sealing face see Figs 14 49 and 14 50 Fig 14 49 Metal Ring Acceptable for Rebuild Fig 14 50 Metal Ring Acceptable for Rebuild Arrow shows narrow highly poli...

Page 540: ...of metal rings Do not allow oil to wet other surfaces Slide sealing faces of two metal rings together 2D If the rings have been properly cleaned and oiled the bottom ring should cling to the top ring for a minimum of two seconds when the top ring is picked up and held an 30 mm above a table surface Failure to meet this requirements indicates that the metal rings are unusable or dirty Repeat Steps ...

Page 541: ...sh against inside shoulder 2 of metal ring Fig 14 53 Metal Ring Surfaces Checking Fig 14 54 Metal Ring Faces Checking 3 Install one seal half 1 Fig 14 55 into receptacle 2 so protruding lip just contacts seal bore Press with both clean hands 180 apart against metal ring until rubber ring is evenly seated against bore shoulder Make sure seal is not cocked in bore Repeat procedure for other seal hal...

Page 542: ......

Page 543: ...SECTION 15 TRACK OR WHEELS ...

Page 544: ......

Page 545: ...ION 15 DRESSTA TD 25M EXTRA CONTENTS SERVICE SPECIAL TOOLS 1 SERVICE SPECIAL TOOLS 1 TRACK CHAIN 2 DESCRIPTION 1 3 SPECIFICATIONS 1 4 SERVICE DIAGNOSIS 2 5 MAINTENANCE 2 6 REMOVAL 5 7 TRACK CHAIN REPAIR 6 8 INSTALLATION 18 ...

Page 546: ......

Page 547: ... bushings and pins are a press fit in the links with the pins pivoting inside of the bushings The left and right track chains are interchangeable Each track has a split master link Spring seal washers dry sealed tracks are used in the counterbored portion of the link to seal against the entrance of abrasives Seals and O rings lubricated tracks are used to seal counterbored portion of the link The ...

Page 548: ...CATIONS in this Section Sprocket wear must also be considered in conjunction with track chain wear Wear of the sprocket teeth decreases the pitch length of the sprocket while wear of pins and bushings increases the pitch length of the track The results are that the pitch lengths of the sprocket and track become more and more out of phase and the bushings ride higher on the sprocket teeth Combined ...

Page 549: ...ck chains are adjusted by hydraulic pressure Lubricant is introduced into the hydraulic cylinder which is attached to the front end of the track spring housing by the use of a lubrication fitting 2 This lubricant acting upon the piston within the hydraulic cylinder forces the front idler fork and front idler forward for track adjustment The relief valve port 1 is used to relieve the hydraulic pres...

Page 550: ...r the pressurized lubricant If lubricant does not escape through the relief passage loosen the ball check 2 one half to one full turn to allow the pressurized lubricant to escape from the second relief passage DANGER Use extreme care when relieving pressure with the following emergency method If loosened excessively the cylinder pressure can eject the ball check or relief valve NEVER loosen the re...

Page 551: ... of turn CAUTION As a safety measure use goggles to protect your eyes while striking bolts IMPORTANT Do not use common bolts in the track shoes 6 REMOVAL 1 Move the machine forward until split link is located on front lower half of front idler as shown in Fig 15 3 and block up under track Fig 15 3 Removing Split Link CAUTION Before disconnecting track chain be sure to first relieve pressure on hyd...

Page 552: ...or each track press will vary so specific disassembly instructions will be found with the manufacturer s operational instructions Sprocket wear must also be considered in conjunction with track chain wear Wear of sprocket teeth decreases pitch length of track Results are that pitch lengths of sprocket and track become more and more out of phase and bushings ride higher on sprocket teeth Combined w...

Page 553: ...t links together and position them on press assembly adapters Position a bushing in press saddle Press links onto bushing until bushing is seated against assembly adapter Remove bolts securing two halves together Advance track on press and position a pin in assembled bushing Apply a coat of oil on ends of bushing with tissue not your fingers as shown in Fig 15 8 being careful not to get it on pin ...

Page 554: ...he pin hole around its chamfer edge using header refer to SERVICE SPECIAL TOOLS to prevent plug from escaping NOTE Once joint is lubricated there is no way of checking for leaks 6 Install track shoes on chain Prepare chains for transport back to machine Fig 15 5 Exploded View of Lubricated Track System 1 Master Split Link Pin R H Down 2 Master Split Link Pin L H Down 3 Link Bushing 4 Link Pin 5 Th...

Page 555: ...5 Track Link 6 Pin 7 Thrust Ring Fig 15 8 Coat of Oil to Bushing Fig 15 9 LOCTITE 680 to Pin Bore SINGLE CHAIN JOINT REBUILD Disassembly NOTE Track must be on floor and be blocked up on each side of pin to be removed Assemble Ram Fig 15 10 as follows Install hoses from pump to ram Thread connecting rods 3 into cylinder 1 Install bolster 2 on connecting rods 3 Thread nuts 6 on connecting rods 3 ...

Page 556: ... rod 2 Install pin receiver 9 to bolster 2 Align forcing pin on track pin and press track pin out Remove oil seals and spacers from track links Inspect parts for wear or damage NOTE If bushing removal is not required proceed with Step 1 under pin installation If bushing removal is required refer to bushing removal Fig 15 10 150 Ton Ram DR11 809 1 Cylinder Assembly 2 Bolster 3 Connecting Rods 4 Gui...

Page 557: ...al 2 Bolster 8 Forcing Pin 10 Bushing Adapter 11 Pin Adapter Bushing Removal Fig s 15 12 and 15 13 1 Using a slow speed drill and a 12 mm drill bit remove rubber stopper from pin next to previously removed pin Align forcing pin 8 on track pin and press track pin out Remove pin receiver 9 from bolster 2 Install bushing adapter 10 in bolster 2 Install pin adapter 11 on forcing pin 8 Press bushing of...

Page 558: ...in 11 Pin Adapter 12 Bushing Receiver Fig 15 15 Seal Installation 1 Track Seal 2 O Ring 3 Bushing 4 Track Link 5 Track Link 6 Pin 7 Thrust Ring Pin Installation Fig 15 16 1 On new or reused pin make an index mark 1 Fig 15 6 on lube hole end of pin opposite cross drilled hole 3 Fig 15 6 Remove nuts 6 and bolster 2 from connecting rods Install guide plate 4 with hitch pin 7 Reinstall bolster 2 and c...

Page 559: ...CE SPECIAL TOOLS Tap it in until it is flush or slightly below chamber of pin hole 7 For final check of the seal use seal tester or vacuum pump refer to SERVICE SPECIAL TOOLS Insert lubricator nozzle of tool through plug Pull a vacuum of 70 5 kPa and hold for 10 sec In event that vacuum cannot by held either seal to bushing face or chain pin to link bore mating surfaces are leaking To determine wh...

Page 560: ...ose split links from press Advance track chain so next link drops into saddle Press pin and bushing out of right link then press pin and bushing out of left link Remove loose links bushing and pin from press Repeat this step with remaining sections of chain Remove spring seal washers from chain links Fig 15 17 Exploded View of Dry Sealed Track System 1 Master Split Link Pin R H Down 2 Master Split...

Page 561: ...IMPORTANT Be careful not to damage the inner faces of the links when cutting the bushings and pins Fig 15 18 Removal of Damaged Links 3 Bushing 4 Pin A Broken Link or Links to be Replaced B Torch Cut and Weld Pins and Bushings at Each End of Broken Links 4 The pieces of the pins and bushings remaining in the links must now be securely welded together at the cuts Fig 15 18 It is important that the ...

Page 562: ... track parts such as pins bushings links etc Since wear occurs on one side of the link pins and bushing Fig 15 20 the track pins and bushings can be reversed to obtain additional service from the track To do this press out all the track pins and bushings Rebuild the track chain pressing the pins and bushings in so that they are turned 180 degrees 1 2 turn Follow the instructions furnished with the...

Page 563: ...mount of Track Length Increase per Link A New Link Assembly Joint B Worn Link Assembly Joint C Turn Pins and Bushings D Track Shortens E Track Stretches Reconditioning Track Shoe Grousers by Manual Arc Welding When the wear of the track shoe grousers reaches a point called the permissible wear limit it should then be decided whether a set of new shoes is to be installed or whether the old ones are...

Page 564: ... tapped holes Remove master link bolts and install track shoe Coat split link bolt threads with engine oil and torque to 650 70 Nm 120 of turn Refer to MAINTENANCE in this Section 4 Adjust track tension refer to SPECIFICATIONS in this Section and OPERATOR S MANUAL Installing Chain when Not Removed from Under Machine 1 Position split link half with wearing surface and next link just past front idle...

Page 565: ...SECTION 17 MOUNTED EQUIPMENT ...

Page 566: ......

Page 567: ...REMOVAL AND DISASSEMBLY 11 9 REASSEMBLY AND INSTALLATION 12 BULLGRADER BLADE 10 REMOVAL 13 11 INSTALLATION 16 BULLGRADER C FRAME 12 REMOVAL 18 13 INSTALLATION 19 BULLGRADER STRUTS 14 REMOVAL AND DISASSEMBLY 19 15 REASSEMBLY AND INSTALLATION 21 TRUNNIONS 16 TRUNNION REPLACEMENT 21 LIFT CYLINDER YOKE 17 LIFT CYLINDER YOKE REPLACEMENT 22 SINGLE SHANK RIPPER 18 REMOVAL 23 19 DRAFT FRAME 24 20 TOOL BEA...

Page 568: ......

Page 569: ...d nuts 3100 5 Nm Drawbar mounting bolts 3100 5 Nm Weights Blade U 2 3900 kg Blade D 2 3450 kg Blade G 2 2480 kg Coal Blade 4850 kg Bulldozer blade tilt cylinder without blade pitch 200 kg Bulldozer blade tilt cylinder with blade pitch 200 kg Bulldozer blade pitch cylinder 178 kg Bullgrader blade tilt cylinder 180 kg Bulldozer diagonal strut 85 kg Bulldozer upper strut 103 kg Bullgrader lower strut...

Page 570: ...ylinder Brackets 10 Diagonal Strut Socket 11 Diagonal Strut Shim 12 Lube Fitting 13 Right Cutting Edge End Bit 14 Right Cutting Edge 15 Center Cutting Edges 16 Left Cutting Edge 17 Left Cutting Edge End Bit 18 Side Cutter Plate 19 Lower Wear Plate 20 Pusher Plate 21 Upper Strut 21A Blade Tilt pitch Cylinder with Blade Pitch 22 Pin 23 Left Push Arm Assy 24 Trunnion Assy 25 Pin 26 Diagonal Strut 27 ...

Page 571: ...uard with the cylinder hangers 3 Install blocks under diagonal struts 26 Fig 17 1 and remove the bolts securing the strut cap to blade socket Remove shims 11 from blade socket 10 Keep shims 11 with diagonal strut 26 for proper installation 4 Machine with Blade Tilt Attach a hoist to the tilt cylinder 1 Fig 17 2 on the right side Place tension on the hoist Remove the bolts securing tilt cylinder ca...

Page 572: ...3 Shims 4 Blade Socket 5 Tilt Cylinder Cap 6 Cylinder Rod Ball 7 Blade 8 Pin 9 Push Arm Bracket 10 Lift Cylinder Brackets 11 Push Arm Fig 17 3 Blade Disconnecting Point with Blade Pitch 1 Blade Tilt Pitch Cylinder 2 Cap Bolts 3 Shims 4 Blade Socket 5 Tilt Pitch Cylinder Cap 6 Cylinder Rod Ball 7 Blade 8 Pin 9 Push Arm Bracket 10 Lift Cylinder Bracket 11 Push Arm ...

Page 573: ...ackets 10 Hydraulically retract the rods and secure the cylinders to the radiator guard with the cylinder hangers 3 Unscrew bolts 2 Fig 17 4 and remove blade hoses connection cover 1 from push arm 3 Repeat this step on the opposite side of the machine 4 Machine with Blade Tilt Disconnect hoses 4 and 5 Fig 17 5 from right trunnion 1 5 Machine with Blade Tilt Pitch Disconnect hoses 4 and 5 Fig 17 5 ...

Page 574: ... the bolts 2 with washers add the amount of shims 3 required and install and torque the bolts with washers to 845 Nm Remove the block from under tilt cylinder Repeat this procedure for the upper strut on the left side 4 Machine with Blade Tilt Pitch Attach a hoist to the tilt pitch cylinder 1 Fig 17 3 on the left side Place tension on the hoist Slowly raise the cylinder 1 and insert the piston rod...

Page 575: ... the bolts add the number of shims 7 required and install and torque the bolts to 2100 Nm Repeat this procedure on the opposite side of machine It may be necessary to adjust the diagonal struts to move the push arms either in or out before attaching them to the trunnions 3 Machine with Blade Tilt Connect the hoses 4 and 5 Fig 17 5 to right trunnion 1 4 Machine with Blade Tilt pitch Connect hoses 4...

Page 576: ... cap 2 with shims 7 from push arm 6 7 Disconnect the push arm 28 Fig 17 1 from the blade 1 by removing the pin retainer 7 and drive out pin 6 Remove the push arm 28 from the machine 8 If necessary remove two hoses 4 and 5 Fig 17 5 from the push arm 6 Left Push Arm 1 Lower the blade 1 Fig 17 1 to the ground and install blocks under the front and rear push arm 23 being removed 2 Machine with Blade T...

Page 577: ...TION 10C Paragraph 20 INSTALLATION 10 Remove the blocks from under push arm 28 Left Push Arm 1 Position the push arm 23 Fig 17 1 so that the bracket 8 and the rear of the push arm is up against the trunnion 24 2 Position trunnion cap 2 Fig 17 5 over the trunnion and connect it to push arm 6 with the two bolts and nuts Be sure to tighten the bolts evenly Determine the number of shims 7 needed to fi...

Page 578: ...ght and bulk of each bulldozer component a suitable hoist or lifting device MUST be used Remove each component separately using suitable blocking on the remaining components 1 Attach a hoist to the upper strut Place tension on the hoist 2 Disconnect upper strut 21 Fig 17 1 from the push arm 23 by removing the pin locking hardware and drive out pin 22 3 Remove the bolts securing upper strut cap to ...

Page 579: ...gned Insert pin 22 through the bracket aligning the lock holes Secure the pin 22 with the locking hardware BULLDOZER DIAGONAL STRUTS 8 REMOVAL AND DISASSEMBLY WARNING Before working at the machine be sure that the blade and ripper have been lowered to the ground engine is OFF the drive train neutral lock lever is in locked ON position and parking brake is set The starting switch and the electrical...

Page 580: ...rm 23 or 28 and the strut ball in blade socket 10 Connect the strut socket cap to the blade socket 10 with the four bolts 6 and washers Be sure to tighten the bolts evenly Determine the number of shims 11 needed to fill the gap between strut socket cap and socket 10 then add one additional shim 11 to provide clearance Each shim 11 is 0 75 mm thick Remove the bolts add the amount of shims 11 requir...

Page 581: ... Bullgrader Blade 1 7 Center Cutting Edges 1 8 L H Cutting Edge End Bit 1 9 R H Cutting Edge End Bit 1 10 Cutting Edges 1 11 L H Side Plate 1 12 R H Side Plate 1 13 L H Upper Strut Bracket 1 14 R H Upper Strut Bracket 1 15 L H Lower Strut Bracket 1 16 R H Lower Strut Bracket 1 17 C Frame Bracket 1 18 Guard C Frame Assy 2 Upper Strut 2A Blade Tilt Cylinder 3 Lower Left Right Strut Assy 4 C Frame As...

Page 582: ...4 Attach a hoist to the blade lifting eye and take up the slack 2 Machine without hydraulic tilt Disconnect upper strut 2 from the swivel bar 1 1 by removing the pin 1 3 locking hardware and drive out pin 1 3 Flip the upper strut 2 back away from the blade 1 Repeat this procedure on the opposite side of the machine 3 Machine with hydraulic tilt Remove the hose guard 17 Fig 17 10 and disconnect fra...

Page 583: ... 6 Tube Assy 7 Frame to Blade Hose 8 Split Flange 9 O Rings 10 Flange Guard 11 Plate 12 Trunnion to Frame Hoses 13 Valve to Trunnion Hose 14 Valve to Trunnion Hose 15 G 2 Blade Assy 16 Hose Guards 17 Hose Center Guard 18 Tube Assy 19 Hose Guard on Cylinder 20 Hose Guard on C Frame 21 Hose Guard 22 Tube Assy 23 Frame to Blade Hose 24 Plugs 25 Hose Guard 26 R H Trunnion ...

Page 584: ...t hoses 12 Fig 17 10 from right trunnion 26 5 Unscrew two trunnion cap bolts 5 Fig 17 11 and remove cap 4 with shims 6 from C frame 1 Repeat this step on the opposite side of the machine 6 Back the machine out from between the C frame 7 Reassemble shims 6 and caps 4 to the C frame 1 and secure with bolts 5 to prevent their damage or being lost 11 INSTALLATION WARNING Before working at the machine ...

Page 585: ...oses 4 and 5 to the tubes 6 and 22 at the left side of the machine and reconnect hoses 4 and 5 to the tubes 6 and 18 at the right side of the machine Reconnect frame to blade hoses 7 and 23 to the tubes 6 at the rear of the blade 15 Install the hose guard 17 to the rear of the blade 15 Adjust and vent the blade tilt hydraulic system with C frame according to OPERATOR S MANUAL 7 Remove the blocks f...

Page 586: ...e out the mounting pins Hydraulically retract the rods and secure the cylinders to the main frame radiator guard with the cylinder hanger and wire 3 Disconnect left lower strut 3 from the C frame bracket by removing the lock pin and free the strut trunnion from the C frame bracket Flip the lower left strut 3 back away from the C frame 4 and install blocks under the lower left strut 3 Repeat this p...

Page 587: ...ing pin 1 5 and cotter pin 5 Position the lower strut 3 in the C frame bracket Insert the strut trunnion in the brackets on the top of C frame and secure with the trunnion locking pin Repeat this procedure on the opposite side of the machine Remove the blocks from the both lower struts 3 6 Machine with hydraulic tilt Reconnect the hoses 12 Fig 17 10 to the right trunnion 26 Reconnect frame to blad...

Page 588: ...el bar 1 1 by removing the pin locking hardware and drive out pin 1 3 Remove the upper strut 2 from the machine 3 Remove the eyebolt 1 Fig 17 12 from the strut body 2 Remove bushing 3 from the eyebolt 1 if necessary Repeat this step on the opposite side of the strut Lower Strut Fig 17 13 Lower Strut Adjustment 1 Lower Strut Body 2 Eyebolt 3 Bushing A Nominal Strut Mounting Length 1694 mm 1 Disconn...

Page 589: ...per strut 2 as described in the OPERATOR S MANUAL Lower Strut 1 If removed install strut trunnion and trunnion pin If removed install new bushing 3 Fig 17 13 in the eyebolt 2 Install the eyebolt 2 on lower strut body 1 2 Adjust the lower strut to nominal mounting length 1694 mm 3 Position the eye of the lower strut 3 Fig 17 9 in the blade swivel bar 1 1 so that the pin holes are aligned Insert pin...

Page 590: ...ape or rubber stoppers Openings must never be plugged with rags This practice could introduce dirt or lint into critical hydraulic components Tag all disconnected lines to facilitate proper installation Fig 17 14 Lift Cylinder Yoke 1 Lift Yoke Assembly 2 Lube Fitting 3 Yoke Cap 4 Spring Pin 5 Yoke Bushing 6 Lift Cylinder Yoke 7 Wiper Ring 1 Remove the hydraulic lift cylinder Refer to SECTION 10C f...

Page 591: ... Mounting Frame 2 Cylinder Pin 3 Stop Plate 4 Right Mounting Frame 5 Draft Frame Pin 6 Ripper Pitch Cylinder 7 Ripper Lift Cylinder 8 Bushing 9 Draft Frame 10 Stop Plate 11 Cylinder Pin 12 Lube Fitting 13 Cylinder Pin 14 Stop Plate 15 Ripper Shank Pin Bushing 16 Draft Frame Pin 17 Tool Beam 18 Ripper Shank Assy STD 19 Ripper Shank Assy DEEP DIG ...

Page 592: ...2 and 11 in mounting frame 1 and 4 and draft frame 9 3 Attach hoist to cylinder mounting pins 13 at tool beam 17 and take out slack in hoist Remove draft frame pins 16 and lift tool beam 17 from ripper If necessary remove shank 18 or 19 from tool beam 17 4 Attach hoist to draft frame 9 and take out slack in hoist Remove draft frame pins 5 and lift draft frame 9 from ripper 5 Attach hoist to cylind...

Page 593: ...e that the blade and ripper have been lowered to the ground engine is OFF the drive train neutral lock lever is in locked ON position and parking brake is set The starting switch and the electrical system master switch are turned OFF keys are removed and the controls are tagged to prevent inadvertent engine starting WARNING Due to the considerable weight and bulk of each bulldozer component a suit...

Page 594: ...k Ripper 1 Left Mounting Frame 2 Cylinder Pin 3 Stop Plate 4 Right Mounting Frame 5 Draft Frame Pin 6 Ripper Pitch Cylinder 7 Ripper Lift Cylinder 8 Bushing 9 Draft Frame 10 Stop Plate 11 Cylinder Pin 12 Lube Fitting 13 Cylinder Pin 14 Stop Plate 15 Draft Frame Pin 16 Tool Beam 17 Ripper Shank Assy ...

Page 595: ... fresh grease Remove draft frame 9 from the stand 24 INSTALLATION Refer to Fig 17 16 1 Clean mating surfaces of mounting frames 1 and 4 to rear main frame 2 Using hoist on cylinder pin 2 place mounting frame 1 into position Install hardware and torque the bolts to 3100 5 Nm Remove pin 2 from mounting frame 1 3 Using hoist on cylinder pin 2 place mounting frame 4 into position Install hardware and ...

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