WABCO 777B Service Manual Download Page 1

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Summary of Contents for 777B

Page 1: ...greater portion of the manual and adjustments Each J mi 9 1a ll lcl tr example The QH a1 l j ei JIlIJ1Y __ seussed as a unit cerau of the acqine w ft O one used ul this manual ne r UY t rto...

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Page 3: ...TABLE OF CONTENTS S UBJECT GENERAL INFORMATION SECTION A POWER TRAI N B WHEEL PARKING BRAKE MOLDBOARD CONTROLS AXL E ASSEMBLY LIC SYSTEM SYSTEM II SCARIFIE S ARIFIER I J...

Page 4: ...SECTION A GENERAL INF ORMATION PRE OPERATING CHECKS A 2 INSTRUMENTS AND CONTROLS A 4 OPERATING INSTRUCTIONS A TORQUE CHART A 9 _ SPECIFICATIONS A IO STORING AND SHIPPING A 12 i i 0 Jfl...

Page 5: ...n system to protect engine 2 Check tightness of radiator hose connections and clamps ELECTRICAL SYSTEM 1 Visually check generator belt for alignment Check belt for proper tension Check to make certain...

Page 6: ...w models 5 Check all hydraulic lines for tight ness and crimping 6 Check torque converter oil level with bayonet gauge under seat Power Flow models 7 Check hydraulic reservoir oil level at sight gauge...

Page 7: ...F only 9 Moldboard Power Shift 18 Clutch Pedal PF shown 26 Ammeter 10 Moldboard Tilt 19 Transmission Gear 27 Power Shift Clutch Oil Brake PF only Pressure PF only Figure 1 shows view of operating con...

Page 8: ...throttle by pressing down on forward pad to increase engine RPM Or use to decelerate engine RPM when working with ground speed selector lever in a set posttton By pressing down on the rear pad engine...

Page 9: ...edal in neu tral posttion press down ongear brake pedal Item 17 Figure 1 This will prevent upper shaft of lower transmission from rotating until proper gears can be engaged Shift the shifter lever Ite...

Page 10: ...er lo cated under R H side of seat Hold lever out until engine has stopped Return lever to IIrun II position Turn off key switch IJ oi PORTANT Do not use the emergency engine shut down for normal engi...

Page 11: ...ed working speed has been obtained Use the accelerator de celerator pedals as explained previously to reduce or increase the engine RPM without changing the pre set position of the governor control le...

Page 12: ...NSMISSION AND FINAL DRIVE Upper Shaft Locknut 722073 Stake Lower Shaft Locknut 722115 Stake Bull Gear Bolts 722169 Bull Pinion Shaft Bearing Cage Capscrews 920135 Transmission Housing to Final Drive H...

Page 13: ...nd 3rd 4th Creeper 1st 2nd 3rd 2 2 3 2 4 4 6 3 10 0 14 1 16 2 23 0 1 8 3 6 8 1 1 3 2 28 55 1 27 2 2 3 2 4 4 6 2 9 9 14 0 16 0 22 8 1 8 3 6 8 1 13 1 26 51 1 2 SERVICE CAPACITIES U S Standard Measuremen...

Page 14: ...i t Crankcase Without Filter Cummins Engine Torque Converter and Power Shift Transmis Wri t f i f Torque Converter Lower Transmission aP dFifuii t Hve Lower Transmission and Final Drive t TIRE INFLAT...

Page 15: ...is to be in transit for a long per iod of time or will not be used immediately A 12 upon its arrival the same precautions should be taken for shipping as outlined previously for storing The only exce...

Page 16: ...E TAILSHAFT GOVERNOR POWER SHIFT TRANSMISSION CONTROL VALVE B 2 B 6 B 8 B 14 B 15 B 16 B 19 B 24 ENGINE CLUTCH OIL B 25 UPPER TRANSMISSION STANDARD MODELS B 37 LOWER TRANSMISSION STANDARD MODELS B 43...

Page 17: ...lies will be treated as separate items Remove four capscrews and lockwashers attaching hood to top of radiator Remove two capscrews and lockwashers attaching sides of hood to sides of radiator Remove...

Page 18: ...yte Battery box may be removed by J emoval of capscrews securing it to mounting brackets Disconnect cable at starter solenoid terminals 3 ELECTRICAL Refer to Figure 4 Disconnect the three leads at vol...

Page 19: ...e into a coil and lay to one side of frame If radiator was not removed disconnect tail light and stop B 4 light wires Disconnect fuel return line If grader is equipped with a cab heater dis connect ho...

Page 20: ...eaching through L H opening of fuel tank support use a small s rewdriver to raise locking clips 1 on coupling collar 2 of PTO shaft 3 Slide collar forward away from coupling Figure 10 Refer to Figure...

Page 21: ...ey are centered with main frame Remove locking pin from lateral shift adjustable link Using both blade lift control levers lower the moldboard until front wheels have be p raised above floor for a dis...

Page 22: ...Bolt 2 Drilled Pin Refer to Figure 16 Remove connecting bolt 1 from power shift clutch control valve linkage Remove cotter pin from drilled pin 2 and remove drilled pin from gear brake lever Power Fl...

Page 23: ...ine when their speeds are approximately the same If turbine speed drops below that of pump speed oil pressure on reactor blades causes the reactor to lag and become stationary In this position the rea...

Page 24: ...te Remove cover plate and gasket Working through opening in the top of converter housing remove the thirty two capscrews and shakeproof washers retain ing pump cover to pump Remove pump cov er Figure...

Page 25: ...e converter pump as illustrated in Figure 24 FIGURE24 PUMPREMOVAL 1 Pump 3 OutputShaft 2 Reactor Sleeve B 10 5 Snap Ring 6 Bearing 7 Special Washer 8 Reactor Removethe twelve capscrews and shake proof...

Page 26: ...lief valve and fittings 4 REACTOR SLEEVE Refer to Figure 27 nfill stake from sleeve retaining locknut Remove locknut with special wrench If special wrench is not available use a spanner wrench Re move...

Page 27: ...Figure 31 Remove four cap screws and lockwashers and remove cover plate 1 Remove spacer 2 Remove re tainer ring 3 Remove spacer 4 Remove bearing cup 5 and bearing cone 6 Drive or press shaft 7 from g...

Page 28: ...sequence of dis assembly as shown in Figures 25 and 26 and the following information 1 Install oil seal in bearing retainer with lip of seal towards inner side of retainer 0 2 Press bearing into reta...

Page 29: ...torque reading of 60 ft lbs Bend corner of locks over flat side of capscrews When installing the thirty two capscrews and shakeproof washers retaining cover to pump use a spring loaded clothes pin to...

Page 30: ...onverter housing Con nect hydraulic hose to the inlet and outlet ports TORQUE CONVERTER RELIEF VALVE Disassembly Refer to Figure 33 and follow the nu merical sequence as shown for disassembly Remove v...

Page 31: ...ckwashers re taining governor flange 1 to governor hous ing Remove flange and gasket 2 Lift spi der assembly 3 from housing Remove snap ring 4 from spider shaft Remove thrust bearing 5 Remove sleeve 6...

Page 32: ...stop bolt 1 and adjust stop bolt until 1 16 of threaded end of bolt extends through bracket Tighten locknut Loosen locknut on stop bolt 2 Run stop bolt against stop 3 until there is a clear ance of 1...

Page 33: ...utral until a steady flow of oil flows into container There should be a flow of 2 1 2 gallons per minute or 1 gallon in 24 seconds B 18 POWER SHIFT CLUTCH RELIEF VALVE Loosen locknut on relief valve a...

Page 34: ...assembly Disconnect all oil hose from oil cap Remove two capscrews and lockwashers and remove control valve from left side of upper transmission housing Remove nuts and washers from bolts supporting c...

Page 35: ...wo dowel pins 2 Tighten nuts until dowel pins are removed Tap out on cover 3 until cover is loose then re move NOTE Force upper and lower shafts back as cover is removed Remove gasket 4 Refer to Figur...

Page 36: ...ner Ring 2 Bearing 3 Seal Retainer Refer to Figure 48 Remove retainer ring 1 Remove outboard bearing 2 from bore in housing Item 3 is seal retainer lock LOWER SHAFT REASSEMBLY Reassembly will be the r...

Page 37: ...9 Remove the three capscrews and lockplates 1 Remove re taining ring 2 Remove backing disc 3 FIGURE 49 UPPER SHAFT DISASSEMBLY 1 Capscrews 3 Backing Disc Lockplate 4 Clutch Gear 2 Retaining Ring Remov...

Page 38: ...using Re move ball check from piston FIGURE 52 CLUTCH PISTON DISASSEMBLY 1 Piston 2 Ring 3 Seal Ring CLUTCH REASSEMBLY The reassembly of the power shift clutch will be the reverse of the disassembly p...

Page 39: ...54 Remove slotted capscrews and flatwash ers Remove the two brush holder assem blies FIGURE 54 CONTROLVALVE DISASSEMBLY 1 From Relief Valve 2 From Oil Cooler 3 To Clutch Release 4 To Pressure Gauge 5...

Page 40: ...nction of the WABCO Motor Grader oil clutch is basically the same as the rugged and dependable dry disc clutch The oil clutch incorporates either two or three Raybestos discs depending on the size and...

Page 41: ...screws enough to compress pressure springs Fig ure 57 Remove twelve capscrews and lockwash ers retaining clutch assembly to the flywheel adaptor 13 NOTE There will be shims 2 between the backing plate...

Page 42: ...lever pin and remove lever pin Remove lever assembly from pressure plate 4 Remove pivot pin from lever Remove eye bolt CLUTCHHOUSING ASSEMBLY Figure 59 shows an exploded view of clutch housing assemb...

Page 43: ...and Raise the piston rings 12 in their grooves until they can be unlocked and re moved from shaft Using a spanner wrench remove lock nut 10 Remove clutch brake drum 11 from shaft Bump end of clutch sh...

Page 44: ...These marks will aid in reassembling these parts in their same positions in relation to each other Figure 61 shows an exploded view of the pump assembly Remove four capscrews and lockwash ers retaini...

Page 45: ...Switch 3 Retaining Setscrew 4 Retaining Nut 5 Spring 6 Ball 7 0 Ring Reassembly RELIEF VALVE Reverse the disassembly procedure In stall 0 ring on valve body Put white lead on the 0 ring and install th...

Page 46: ...using If Welch plug was removed from R H bore install a new Welch plug Align roll pin hole in shaft with pin hole in bell crank Install roll pin Install second roll pin in shaft just in side L H side...

Page 47: ...of seal toward outside Lay shifter fork in housing with angle of fork toward front of housing B 32 Install keys into keyways of cross shaft Install cross shaft assembly into housing from L H side Use...

Page 48: ...e onto springs square holes in backing plate to be aligned with eye bolts Put assembly into an arbor press Press down on backing plate to compress the pres sure springs As the backing plate is press e...

Page 49: ...sure plate assembly onto guides Install shims in the six locations from which they were removed Install capscrews retaining pressure plate assembly to flywheel housing and tight en securely Remove the...

Page 50: ...A If adjustment is required loosen locknut on connector link and rotate piston nut until free play of 1 8 is obtained Tighten lock nut Adjustment must be made when free play is 1 16 or less CLUTCH BRA...

Page 51: ...he PTO shaft will be a ball bearing retainer on shaft with two retainer rings a spacer and a grease seal The spacer will be between the grease seal and the bearing B 36 If necessary to replace bearing...

Page 52: ...gear on upper shaft One gear the reverse is in mesh with an idler gear which in turn is in mesh with the reverse gear on upper shaft If the transmission is equipped with optional creeper gears there...

Page 53: ...ing to upper transmis sion housing cover Remove shifter housing Refer to hydraulic section for instruc tions on removal of the hydraulic pumps and PTO shaft Remove pumps and PTO shaft from upper shaft...

Page 54: ...ver to transmission housing Tap outward on the four cover lugs and at same time tap the shafts back into case Bearings on upper and lower shafts will come off with cover After cover has been removed p...

Page 55: ...When reinstalling the assembly make certain this marked side is away from the threaded end of lower shaft Remove the 47 tooth reverse gear Re move the two roller bearings on which the B 40 FIGURE 82 U...

Page 56: ...VIEW OF UPPER CREEPER GEAR ASSEMBLY 1 16 Tooth Gear 4 Retaining Ring 2 38 Tooth Gear 5 Spacer 3 Bearing 6 Upper Shaft Creeper FIGURE 85 EXPLODED VIEW OF LOWER CR EPER GEAR ASSEMBLY 1 Locknut 6 38 Toot...

Page 57: ...o not tighten UPPER TRANSMISSIONLOWER SHAFT Refer to Figure 83 and reverse the nu B 42 merical sequence as shown and the following information 1 Install oil seal into seal retainer 9 with lip of oil s...

Page 58: ...rque of 550 to 575 ft lbs Stake nuts Shifter Housing Refer to Shifter Housing Removal re verse the procedure outlined and the follow ing information 1 Install the front and rear shifter forks over shi...

Page 59: ...spring 8 and poppet ball 9 from front shifter fork Remove 0 rings 10 from upper end lower shifter rails FIGURE 88 LOWER SHAFT ADAPTER REMOVAL 1 Lower Shaft 5 Bearing 2 Puller 6 Shims 3 Collar 7 Interm...

Page 60: ...n order to clear 50 tooth gear onupper shaft Move front end of upper shaft side FIGURE 90 REMOVE 15 TOOTH GEAR 1 Retainer Ring 4 Spacer 2 Bearing Inner Race 5 Upper Shaft 3 15 Tooth Gear 14 FIGURE 91...

Page 61: ...y and the following information 1 Replace all oil seals gaskets and 0 rings 2 Heat all bearings except needle bearings for floating gears and bearing inner races in hot oil Tem perature 2750 to 3000 b...

Page 62: ...cover for final drive case Place blocks under final drive case for support FIGURE94 ENGINE SUPPORT REMOVAL 1 Support 2 Gasket Refer to Figure 95 Remove seven cap screws and lockwashers 1 from both R...

Page 63: ...ng cage and shims 3 from final drive housing Remove 0 ring from bearing cage Keep shims with bearing cage Remove four capscrews and lockwashers from L H bearing cage 2 Remove bearing cage and shims fr...

Page 64: ...olling torque 5 Heat bull gear bearing cones in hot oil 3500 and press cones onto bull gear hubs Hold under pressure un til bearings have cooled 6 Install axle carrier capscrews and lockwashers Tighte...

Page 65: ...at above procedure for the other wheel Remove twelve capscrews and Iockwash ers and remove side cover and gasket from tandem housing Remove top hand hole plates and side inspection plates Refer to Fig...

Page 66: ...2 Remove tandem hous ing Figure 107 Remove brake assemblies from eccentric housing hubs See Section C for brake removal and repair FIGURE 107 TANDEM HOUSING REMOVAL 1 Tandem Housing 2 Inner Axle Carr...

Page 67: ...ough these openings to drive against bearIng cup Refer to Figure 111 Remove six cap screws and lockwashers retaining hub cap 1 to inner eccentric housing 3 Remove hub cap and shims 2 Remove twelve cap...

Page 68: ...link Chain can be pulled tight for instal lation of connector link with two bars A special tool is also avail able for this purpose Install cou pler link on outside chain so that retainer pins are tow...

Page 69: ...ket Inspect thrust rings for cracks or excessive wear Replace if dam aged 21 24 12 B 54 FIGURE 115 DRIVE AXLE AND CARRIERS 13 Capscrew Hex Head 25 Lubrication Fitting 14 Lockwasher 26 Capscrew Hex Hea...

Page 70: ...s until front side of mounts are pulled together tight Any gap be tween the mounts must be at rear side of mounts FIGURE 117 ENGINE INSTALLATION t 1 Capscrew 4 EngmeiBracket 2 Rubber Biscuit 5 Locknut...

Page 71: ...02 to 030 B 56 LIMITWG SPEED GOVERNOR J t i the engine limiting speed governor has been reconditioned or replaced it will be necessary to make adjustment for maxi mum no load engine speed and the idle...

Page 72: ...arge con tainer Start engine and run at 600 RPM Oil should flow at the rate of 2 1 2 gals per minute or 1 gal in 24 sec onds If oil does not flow at this rate check for A Plugged oil line or oil scree...

Page 73: ...functioning properly further along in Trouble Shooting TRANSMISSION TROUBLE Clutches fail to release CAUSE Broken seal rings REMEDY Replace seal rings Oil return line to valve re stricted REMEDY Free...

Page 74: ...ate easily by hand REMEDY Replace damaged or broken parts TROUBLE Hard shifting of lower trans mission CAUSE Power shift clutch assem bly clutches dragging REMEDy Remedy dragging of clutch es CAUSE Im...

Page 75: ...e place with new hose CAUSE Faulty pump REMEDY Repair or replace pump CAUSE Faulty relief valve REMEDY Repair or replace relief valve CAUSE Loose impeller in water pump REMEDY Repair water pump CAUSE...

Page 76: ...MEDY Remove and replace broken or stuck piston rings EXHAUST SMOKE ANALYSIS Black or Gray Smoke Probable causes A Insufficient air B Improper grade of fuel C Lugging engine Blue Smoke Probable Cause F...

Page 77: ...ND PARKING BRAKES INDEX WHEEL BRAKES WHEEL CYLINDER Bleeding Brakes Adjusting Brakes BRAKE MASTER CYLINDER POWER BRAKES OPTIONAL PARKING BRAKE TROUBLE SHOOTING WHEELS AND TIRES C 2 C 4 C 5 C 5 C 5 C 6...

Page 78: ...der 2 Capscrews Lockwashers Disassembly Refer to Figure 3 and disassemble brake assembly by following the numerical se quence Remove the two shoe return springs 1 Remove automatic adjusting cable 2 Re...

Page 79: ...ed on brake shoes there are several precautions necessary a Snug fit between liners and shoes b Selection of proper rivets c Removal of high spots on lining Snug fit is absolutely necessary be tween l...

Page 80: ...er ical sequence for disassembly Remove con necting links 1 Remove boots 2 Remove pistons 3 piston cups 4 and piston spring 5 Remove hydraulic line fitting 6 and bleeder valve 7 from the valve body 8...

Page 81: ...t bleeding procedure on the rest of brakes As the parking brake is equipped with a wheel cylinder it will be necessary to bleed parking brake also Adjusting Brakes After bleeding brakes shift transmis...

Page 82: ...ticularly in the creases Extend and retract boot by hand to check flexibility Replace boot if not in serviceable condition 3 Inspect piston and cylinder bore for scoring scratches and wear Re place al...

Page 83: ...ly is removed as a complete unit Disassembly EXPLODED VIEW OF MASTER CYLINDER POWER BRAKES 6 Reaction Piston 10 Retaining Ring 14 Valve Seat Assembly 11 U Cup 15 Cylinder 7 Check Valve 12 U Cup Retain...

Page 84: ...e shown for disassembly also the following information 1 Clean all parts in a good solvent and dry with compressed air Never use waste or soft cloths to clean in ternal parts Lint from these will clog...

Page 85: ...on 5 Insert reaction piston assembly into piston 3 and insert the assembly into housing Secure with retaining ring 1 Installation Install master cylinder onto power cyl inder by reversing the removal...

Page 86: ...g Plate 8 Socket Adjusting Screw 3 Remove two capscrews and washers re taining wheel cylinder 4 to backing plate and remove wheel cylinder Refer to Page C 4 of this section for disassembly of wheel cy...

Page 87: ...to be removed to in stall the two top backing plate capscrews Adjustment Loosen locknut on anchor bolt Remove cover plate from slot in backing plate In sert adjusting tool through slot and contact too...

Page 88: ...kely to be in pump or flow control valve Partial contact between lin ings and drum REMEDY Requires grinding of linings or turning of drums on lathe CAUSE CAUSE Oil or hydraulic fluid on lin ings REMED...

Page 89: ...erly to form part of the basic air chamber Never lift the rim by using the valve hole FIG 12 LOCKING RING TIRES Never drop tumble or roll rim parts If rim parts are to be stored outside ex posed to th...

Page 90: ...d previously for flange ring After bead is completely broken loose remove tire from rim base Remove valve from rim base TIRE MOUNTING Clean rim base thoroughly of all dirt and rust Wire brush the 0 ri...

Page 91: ...evice of some type be used when in flating the tire in case locking ring should blow off due to improper seating Never stand in front of or over tire and wheel when inflating Figure 16 TIRE INFLATION...

Page 92: ...ASSEMBLIES CIRCLE REVERSE GEAR HOUSING ASSEMBLY MOLDBOARD CIRCLE AND DRAWBAR Moldboard Cylinders Slide Shift Cylinder Tilt Plate MOLDBOARD ROTARY VALVE CIRCLE DRAWBAR LATERAL SHIFT RACK TROUBLE SHOOT...

Page 93: ...1 and gasket 2 by pulling straight forward on mo tor until splines on motor shaft have cleared FIGUHE 1 BLADE LIFT HYDRAULIC MOTOR 1 R H Blade Lift Motor 2 Gasket 3 Coupling 4 L H Blade Lift Motor D 2...

Page 94: ...e bronze bearing 2 to a horizontal position and re move from housing Disassembly FIGURE 5 REMOVEMOTORADAPTER 1 Adapter 2 Bearing Cup 3 0 Ring 4 Capscrews 5 Housing Refer to Figure 5 Remove four cap sc...

Page 95: ...retainer 3 and remove 0 ring from retainer Remove four stud nuts and lockwashers from worm thrust cap 4 Remove thrust cap and remove 0 ring from thrust cap Place a block of wood be tween spiral gear...

Page 96: ...th torque bolt torque bolt and 6 u 1 will be necessary bolt in order to tighten Adjustments THRUSTBEARING Loosen locknut on adjustment screw in first reduction bearing adjusting cap With Allen wrench...

Page 97: ...ve is same manner as outlined above CIRCLE REVERSE GEAR HOUSING ASSEMBLY Removal Disconnect all hydraulic lines to hydrau lie motor Plug all hydraulic fittings to pre vent foreign matter from entering...

Page 98: ...ear 5 Remove four setscrews and lockwashers from thrust bearing adjusting cap 6 Re move cap Remove adjusting capscrew and jam nut from cap Remove worm thrust bearing 7 from bore in housing Remove 0 ri...

Page 99: ...om one end of hub until bushing is flush with face of hub From opposite end of hub install spacer and press the other new bushing into hub until flush with face of hub 3 Press worm shaft into worm unt...

Page 100: ...n Rod 6 0 Rings Disassembly Refer to Figure 17 Unscrew packing gland 1 from cylinder 2 Pull piston rod assembly from cylinder Remove nut 3 from piston rod Remove piston 4 from piston rod and remove pi...

Page 101: ...f shims until all free play is elimi nated Do not peel off more shims than required Removal inder out from between circle legs and mold board FIGURE 18 TILT PLATE REMOVAL 1 Hex Nut 5 Slotted Nut 2 Til...

Page 102: ...ston rod separately until piston rod and piston have been installed in cylinder The packing set con sists of cup shaped rings The lip of the cups must be away from the packing gland when installed 3 W...

Page 103: ...moval instructions ROTARY VALVE Removal Refer to Figure 21 Remove four cap screws and lockwashers from bottom of sup port 1 and remove support Disconnect hydraulic hose 2 3 and 4 2 Slide shift cylinde...

Page 104: ...n be attached to circle Refer to moldboard removal and remove moldboard Refer to rotary valve removal and re move rotary valve Lower drawbar and circle until circle legs rest on floor Refer to Figure...

Page 105: ...ntil outside of circle is approximately aligned with outside of drawbar at rear L H and R H corners Adjust the two center circle pushers un til pushers are against circle All pushers should now be aga...

Page 106: ...all the four drilled head capscrews and tighten until drawbar ball will re main in any position without drop ping of its own weight but can still be moved by hand Measure clear ance between ball cap a...

Page 107: ...turning Rotate splined worm shaft clock wise to force worm shaft assembly out of gear housing through bearing bore Remove roller bearing cup 5 tapered roller bear ing 6 and spacer 7 Place shaft assem...

Page 108: ...rt bracket in such a position that the contact point of dial indicator rests on end 4 Press one of reduction housing bush ings into hub until flush with face of hub From opposite end of hub in stall s...

Page 109: ...l be four sets of shims one set at each end of rack one set at each bore for plug and stud ball Attach these shims to the rack at the location where they were to prevent their loss They will be requir...

Page 110: ...t hand column the thickness of shims to be removed will be found directly opposite in the right hand column Measured Clearance 0 to 010 011 to 014 015 to 022 023 to 029 030 to 036 037 to 043 044 to 05...

Page 111: ...ge D 14 TROUBLE Moldboard coasting CAUSE Wear in gear box worm REMEDY Adjust gear housing thrust bearing as instructed on page D 17 CAUSE Worn ball and sockets on lift links and lateral shift link REM...

Page 112: ...SECTION E FRONT AXLE ASSEMBLY INDEX AXLE ASSEMBLY Wheel Spindle Fork E 2 E 2 E 3 LEANING WHEEL CYLINDER E 4 STEERING LINKAGE E 6 AXLE E 8 TROUBLE SHOOTING E 9 E l...

Page 113: ...cup 2 and outer bearing cup 3 from hub ITre quired remove outer bearing retainer snap ring from hub SPINDLE Refer to Figure 3 Using a bearing pull er remove inner bearing cone 1 Remove cotter pin from...

Page 114: ...re move pivot pin 1 Remove fork 2 Re move bushing 3 from fork Remove bush ing 4 from fork Remove hearing cup 5 from inside top bore of fork FIGURE 5 SPINDLE REMOVAL 1 Spindle Bearing 5 Capscrew FIGUR...

Page 115: ...tight against shoulder in hub 5 Press felt seal retainer into wheel hub until retainer is flush with face of hub Use extreme care not to damage retainer FIGURE 7 SPINDLE ADJUSTMENT 1 Spindle Bearing...

Page 116: ...piston and packing gland assembly from cylinder Remove self locking nut from end of piston rod Remove piston assembly and packing gland assembly from piston rod Remove 0 ring from groove in threaded e...

Page 117: ...and the following information 1 Snug up the slotted nut on tilt pin then back off 1 16 of a turn or A 4 more if necessary to install cotter pin 2 The hex nut on anchor pin should be snugged up tight...

Page 118: ...URE 12 EXPLODED VIEW OF BALL SHAFT 1 Slotted Nut 5 Tie Rod Ends 2 Flatwasher 6 Spherical Bushing 3 Seal Pads 7 Double Ball Shaft 4 Retaining Rings halves and can be removed as soon as it clears the ti...

Page 119: ...the bol ster pin raise or lower front of grader E 8 Refer to Figure 13 Loosen jam nuts 1 on both tie rod ends Remove cotter pin from slotted nuts 2 and remove slotted nut from both L H and R H steeri...

Page 120: ...ster pin between bolster plate and axle flange TROUBLE SHOOTING TROUBLE Front wheels shimmy CAUSE Loose connections in link age REMEDY Tighten all connections after checking for excessive wear CAUSE W...

Page 121: ...Main Pump HYDRAULIC PUMP DRIVE HYDRAULIC MOTORS CONTROL VALVES HYDRECO CONTROL VALVES SUNDSTRAND STEERING GEAR ROSS HYDRAPOWER FLOW CONTROL VALVE HYDRAULIC RESERVOIR AIR LINE FILTER HYDRAULIC CIRCUITS...

Page 122: ...is located on draw bar The other two motors power the R H and L H blade lifts and are located under front cover plate at front of grader HYDRAULIC CYLINDERS Power Shift Moldboard Cylinder Sup plies p...

Page 123: ...their same relative po sition To separate the two pumps remove the four capscrews from the highest bosses on the steering pump cover Pry steering pump away from main pump cover until free of dowel pi...

Page 124: ...nstall oil seal after drive shaft has been installed Place thin shim stock over splines on shaft to prevent damage to seal 2 Refer to Figure 3 Press bushings 1 into adapter until bushing is against sh...

Page 125: ...RIVE Removal Refer to hydraulic pump removal in structions and remove pump assembly Remove capscrews and lockwashers re taining spider bearings to PTO universal coupling NOTE Twist a piece of wire aro...

Page 126: ...ring as sembly into bore of housing 6 Place yoke assembly into housing and guide shaft through bearing In stall lockwasher and nut Tighten locknut until a definite drag is felt when yoke assembly is r...

Page 127: ...Washers 8 Wear Plate 2 Cover 9 Seal Assembly 3 Wear Plate 10 Adapter 4 0 Rings 11 Bearings 5 Housing 12 Retaining Ring 6 Driven Gear 13 Bearing Remove roller bearings 11 from adapt er 10 Remove retain...

Page 128: ...up assembly before starting disas sembly Removal FIGURE 7 VALVE CONTROLLINKAGE 1 Control Linkage 2 Hydraulic Lines 3 Capscrews Disassembly VALVEGROUP Refer to Figure 8 and follow the numer ical sequen...

Page 129: ...taining plate 12 and wiper 13 Remove plunger assembly 14 Remove plunger eye 15 Remove 0 ring from eye Remove plunger check spring 16 plunger check 17 and 0 ring 18 Remove three 0 rings 19 from oil por...

Page 130: ...dition CONTROLVALVE Reassembly of the control valve will be the reverse of the disassembly sequence and the following information 1 Install hydraulic fittings in valve housing hand tight until in pro...

Page 131: ...ere is leaking between sections or it is desired to remove or add a valve section Disconnect all hydraulic lines at valve fittings Plug all hose ends and hydraulic fittings to prevent foreign material...

Page 132: ...section 12 and separator 13 This valve controls the R H blade lift Remove end section 14 This section F 12 contains the flow control valve RELIEF VALVE Figure 13 shows an exploded view of the Sundstr...

Page 133: ...can be tapped lightly on clevis end of stem Remove the spirolox retaining ring 5 and remove spring retainers 6 and center ing spring 7 from valve stem 8 Remove the two check valve assemblies from valv...

Page 134: ...ace if damaged Reassembly will be the reverse of the disassembly numerical sequence CONTROLVALVE Check valve stem for indications of scoring or burring Should valve stem ap pear to be tight in valve b...

Page 135: ...urn plug in to increase pressure or turn plug out to decrease pressure Care should be taken when adjusting the FIGURE 17 RELIEF VALVE ADJUSTMENT 1 Hydraulic Fitting 2 Gauge 3 Adjusting Plug relief val...

Page 136: ...e caps Swing double ball shaft and tie rods to rear until clear of pitman arm F 16 tion of oil in the cylinder however oil is circulating from the pump through the con trol valve and back to the reser...

Page 137: ...ing of steering column and push column to rear until coupling is clear of splined end of input shaft Take up on hoist and remove steering assembly from grader Refer to Figure 19 Remove four capscrews...

Page 138: ...ing Lift output shaft from housing Using a spanner wrench remove ad justing screw retainer from end of output F 18 shaft Remove adjusting screw two thrust washers and a thrust bearing VALVE AND ADAPTO...

Page 139: ...thrust bearing spacer 11 thrust bearing 12 and thick thrust bearing race 13 Refer to Figure 23 and follow the nu merical sequence outlined for disassembly of the adapter and piston rack Remove 0 ring...

Page 140: ...Ring 19 Unloader Valve Seat 3 Spiral Lockring 11 Washer 20 Unloader Valve 4 Seal 12 Back Up Washer 21 Piston Rack 5 Back Up Washer 13 Seal Cup 22 Jam Nut 6 Adapter 14 Seal 23 Adjusting Screw 7 Cylinde...

Page 141: ...il 7 8 of threaded end is left exposed As semble the jam nut and tighten se curely 6 Install large 0 ring in face of adapter and the small 0 rings in recesses provided in face of adapt er Retain them...

Page 142: ...tall bearing retaining ring into groove in bearing NOTE The bearing must be installed so that it is press ed on the groove end After bearing is in stalled check freedom of the rollers in bearing Rotat...

Page 143: ...reading in inch pounds rotate input shaft 900 each side of center at same time adjust the adjustment screw until a torque of 15 to 20 in lbs is provided Back out the adjustment screw one turn and chec...

Page 144: ...e plug 1 and remove shims 2 from plug Remove poppet 3 and poppet spring 4 from valve 5 f u _ If i _ 2 i t FIGURE 26 VALVE DISASSEMBLY 1 Orifice Plug 4 Poppet Spring 2 Shims 5 Valve 3 Poppet Reassembly...

Page 145: ...servoir and can be changed without drain ing the reservoir A relief valve adjusted at 5 psi returns the oil directly to reservoir in case filters become clogged Removal and Disassembly Remove the twen...

Page 146: ...to remove the filter assembly from the grader to service or clean Refer to Figure 29 Unscrew clamping ring 1 to remove bowl 2 Unscrew and re move baffle 3 to remove filter element 4 from body 5 Remove...

Page 147: ...er mitted to flow through the valve ports to the hydraulic motor causing the motor to ro tate either clockwise or counter clockwise depending upon which direction control valve was moved As the motor...

Page 148: ...leaning over should the valve be opened while grader is parked It also prevents the piston from wandering or coasting while F 28 grader is operating When the control lever is activated the oil flow c...

Page 149: ...FLOW CONTROL TO CYL CONTROL VALVES CONTROL VALVES LIMIT VALVES BLADE LIFT MOTOR FIGURE 30 BLADE LIFT CIRCUIT RELIEF VALVE...

Page 150: ...FLOW CONTROL TO CYL CONTROL VALVES CONTROL VALVES MANIFOLD TO CIR REV FIGURE 31 LATERAL SHIFT AND CIRCLE REVERSE CIRCUIT RELIEF VALVE...

Page 151: ...IFOLD t CD f PRESSURE TUBE TO POWER STEERING VALVE PRESSURE TUBE FROM i HYDRAULIC PUMP FROM STEERING VALVE FLOW CONTROL VALVE CD TO STEERING VALVE 41_1 BRAKE POWER CYLINDER FROM RESERVOIR 1 Without Po...

Page 152: ...TO TANK ROM Ik FLOWCONTROL CONTROL VALVES 070 DOUBLE PILOT CHECK VALVE ___ ORFICE CHECK VALVE RELIEF VALVE 086 FIGURE 33 LEANINGWHEEL CIRCUIT...

Page 153: ...are as follows 1 Excessive heat means trouble A warmer than normal reservoir re turn line from a relief valve indi cates relief valve is set for too low a pressure Cavitation and slippage in a pump wi...

Page 154: ...ief valve setting incorrect REMEDY Install pressure gauge and adjust system relief valve F 34 CAUSE REMEDY Worn or damaged system relief valve Repair or replace valve CAUSE REMEDY Fluid dirty or low s...

Page 155: ...laced as an assembly CAUSE Input shaft bent or sprung REMEDY Replace bent parts CAUSE Output shaft adjustment too tight REMEDY Refer to adjustment section and readjust output shaft ad justment screw C...

Page 156: ...GENERATOR Removal Disassembly Reassembly REGULATOR STARTER BATTERIES SECTION G ELECTRICAL SYSTEM INDEX G 2 G 3 G S G S G 6 G 6 WIRING CIRCUITS G 7 o r...

Page 157: ...end and a roller bearing at the slip ring end See Figure 2 Each bearing is factory packed with lubri cant which eliminates the need for periodic lubrication However after periods of ex Removal Disconn...

Page 158: ...ning of vise as this could cause distortion of ro tor Remove the shaft nut pulley fan and collar Remove end frame from rotor shaft ROTORCHECK The rotor may be checked for grounded open or short circui...

Page 159: ...e as the shock may damage the other diodes G 4 SLIP RINGS If the slip rings are dirty they may be cleaned and finished with 400 grain or finer polishing cloth Spin the rotor in a lathe andt hold the p...

Page 160: ...utside of the end frame Support the inside of the end frame with a hollow cylinder to prevent breakage of the end frame Saturate the felt seal with SAE 20 oil and install the seals and metal retainer...

Page 161: ...shes should have good clean contact with the commutator and should have the proper spring tension If brushes are worn so that they will not last until the next inspection periods they should be replac...

Page 162: ...CABLE CLAMP ON CAB ENCLOSURE ONLY Y CONNECTOR GROMMET IN INSTRUMENT BOX CLAMP ON CAB ENCLOSURE ONLY CLAMP ON CANOPY TOP ONLY GROMMET ON CANOPY TOP ONLY 1 H HEAD LAMP The followingwiring diagrams showt...

Page 163: ...A C Genera tor Engine Hour Meter Batteries Ammeter Horn Button Ignition Switch ELECTRICAL GENERAL CUMM INS ENGINE G 8 0...

Page 164: ...f L A C Generator F ressure Switch E gine Hour Meter Batteries Horn f r ECTRICA CGENERAL GM ENGINE G 9...

Page 165: ...Q I I o WIRES OF MASTER HARNESS l CltD 4 J I I L A C Generator I LlAR E 55_ c E R p _ 5of loA HIP _ _ 9 Pressure Switch o GENERA TOR AND REGULA TOR CIRCUIT...

Page 166: ...SECTION H CAB AND ENCLOSURE INDEX CAB AND ENCLOSURE Door Locks Door Latch Adjustment Glass Installation H 3 H 3 H 5 H 5 _ l__ _ _ i _J H l...

Page 167: ...FIGURE 1 CAB AND ENCLOSURE 1 Rear Panel 2 Cab Back 3 L H R H Uprights 4 Base 5 Roof 6 Filler 7 Door Bumper 9 Sill 8 Striker 10 Caps H 2 _...

Page 168: ...all weather seal and seal retainer around outside edge of rear window and se cure with capscrews and lockwashers Install weather stripping and bar across top of windshield opening inside enclosure Ins...

Page 169: ...INSTALLATION 1 Lock Pawl 3 Lock Pawl 20 Screwdriver H 4 FIGURE 5 CAM INSTALLATION 1 Roll Pins 2 Insert Screwdriver 3 Cam Compress springs with screwdriver and drive rolled pins 1 into lock pawls Figu...

Page 170: ...GLASSINSTALLATION Each piece ofglass in enclosure is pro vided with its own rubber channel made to fit one certain opening Type of channel used is shown in Figure 9 FIGURE 9 GLASS CHANNEL TYPE 1 Roun...

Page 171: ...nel is in place on cab opening Figure 12 Continue to pull each end of cord grad ually lapping channel over cap opening Fig ure 13 Use care at corners to prevent tear ing channel Installation of the lo...

Page 172: ...PPER SCARIFIER AND SCARIFIER INDEX RI PPER SCARI FI ER General Removal and Disassembly Reassembly and Installation 1 2 1 2 1 3 SCARIFIER General Removal Disassembly Reassembly and Installation 1 4 1 4...

Page 173: ...from the twelve mounting bolts six on each side and remove the bolts Start engine and move the grader for ward until rear end of frame is clear of rip The hydraulic rams can be removed servicing witho...

Page 174: ...move hydraulic fitting 1 from cylin der This fitting threads into the stuffing box Using a spanner wrench remove pack ing gland 2 Remove retainer ring 3 and back up ring 4 Piston rod assembly 5 can no...

Page 175: ...tter pins pivot pin nuts 2 and nuts from pivot pin Remove pin from ends of drawbars Start engine and move grader forward until scar ifier block 4 and drawba rs can be removed 1 4 General Before perfor...

Page 176: ...d 3 Piston Rings 8 Retaining Ring 4 Teflon Seal 9 0 Ring Small 0 Ring 10 U Cup Seal 5 0 Ring Large 11 Wiper Remove 0 ring 9 U cup seal 10 and wiper seal 11 Reassembly Reassembly of the hydraulic cylin...

Page 177: ...ave been a to pivot pin install slotted nuts tighten until drawba rs are pulled to within 1 32 of bosses Install cot ter pin 2 Assemble lift arms on cross shaft until they are against collars Aft er t...

Page 178: ...SECTION J LUBRICATION AND SERVICE INDEX LUBRICATION INSTRUCTIONS J 2 GREASE GUN LUBRICATION POINTS J 6 TABLE OF HOUSING CAPACITIES J 8 t l I r i...

Page 179: ...MRESERVOm The capacity of the hydraulic reservoir does not represent the quantity of oil requir ed to operate the hydraulic system Oil re quirements vary according to grader s hy J 2 INSTRUCTIONS drau...

Page 180: ...er every 500hours of operation thereafter At any time the con verter or power shift clutches have been dis assembled for repairs the oil should be changed For Standard Machines refer to NOTE on Page J...

Page 181: ...ry to change oil unless the hous ings have been disassembled for repairs 7 BLADE LIFT HOUSINGS Check oil level every 60 hours of operation Add oil if required It is not necessary to change oil unless...

Page 182: ...tank every 10 hours J 11 FUEL fILTER Cummins Drain sediment and water every 10 hours Change elements every 250 hours or more often un der adverse conditions Drain moisture from fuel tank every 10 hour...

Page 183: ...9 Power Shift Moldboard 2 21 Power Shift Clutch Pedal 2 10 Blade Lift Link Ball and 4 22 Steering Shaft Bearing and 2 Cap Coupling 11 Slide Bar Bearings 2 23 Moldboard Tilt cylinders 4 12 Lateral Shif...

Page 184: ...L f...

Page 185: ...pecial Lubricant 6 Circle Reverse Housing 4 1 2 Qts Special Lubricant f t _ Circle Reverse Reduction Housing 1 Qt Special Lubricant f 7 Blade Lift Housing each 5 Qts Special Lubricant _ 8 Tandems each...

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WABCO 777B, Service Manual

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