Cebdg65194 561 700

SHOP MANUAL SECTION E-34.
OOK
TABLE OF CONTENTS
CONTENTS PAGE
INTRODUCTION ....................................................... 2
SERVICING ........................................................... 4
REMOVAL ......................................................... 4
DISASSEMBLY ..................................................... 6
CLEANING AND INSPECTION ........................................ 8
REASSEMBLY .................................................... 10
lNSTALLATlON....................................................l 2
TESTS AND ADJUSTMENTS ............................................ 13
LOCK/UNLOCK DIFFERENTIAL RELIEF VALVE ADJUSTMENT ........... 13
REAR AXLE COOLING SYSTEM ..................................... 13
1
SHOP MANUAL SECTION E-34.OOK
INTRODUCTION
the front engine mount. The pump is belt
The rear axle cooling and lock/unlock deferential pump is located under
driven by a pulley that is added to the engine crankshaft.
GlOAVO
Figure 1 EXPLODED VIEW OF LOCK/UNLOCK DIFFERENTIAL PUMP
2
LEGEND FOR LOCK/UNLOCK DIFFERENTIAL PUMP
The exploded view shown on the previous page and legend shown here are to help identity parts and their
orientation to each other while servicing the lock/unlock differential pump. Some components mentioned during
service procedure may only be shown in this illustration.
1 HOUSING, REAR 8 KEY, WOODRUFF

2 BOLT 9 PIN, SHEAR
3 PLUG 10 GASKET
4 BEARING, NEEDLE 11 HOUSING, FRONT
5 GEAR, DRIVE 12 RING, RETAINING
6 SHAFT ASSEMBLY, IDLER 13 BEARING, BALL
SHAFT, IDLER 14 SPACER
GEAR, DRIVE 15 SEAL, OIL
PIN, DRIVE 16 RING, RETAINING
RING, RETAINING 17 KEY
7 SHAFT, DRIVE
SERVICING
The following is only one method of obtaining a removal, disassembly, cleaning and inspection, reassembly, and
installation of the lock/unlock differential components.
Thoroughly clean the component to be serviced and the surrounding area. This will help prevent contamination
from entering the component or system being serviced.
REMOVAL
1. Tag and disconnect all hoses from pump and control and
relief valve.
2. Disconnect electrical connection to solenoid.
3. Remove adjustment bolt and hardware (1, Figure 2).
4. Loosen pivot mounting bolt (not shown) and remove

drive belt (2, Figure 2) from pulley (3).
5. Remove pivot mounting bolt and hardware, and pump

mounting bracket (4, Figure 2) from engine support (5).
Figure 2
6. Using a suitable puller, remove pulley assembly (1,

Figure 3) from pump drive shaft (2). Remove key (not
shown) from shaft.
7. Remove two bolts (3, Figure 3) that hold pulley bushing

(4) to pulley.
Figure 3
4
8. Remove three elbows (7, Figure 4) and tee (2).
9. Remove four bolts and flat washers (3, Figure 4), and
pump (4) from mounting bracket (5).
10. Remove two bolts and flat washers (6, Figure 4), and
control and relief valve (7) from mounting bracket (5).
Figure 4
5
DISASSEMBLY
GlOAVOl’
Figure 5
6
SHOP MANUAL SECTION E-WOOK
1. Match mark rear housing (1, Figure 5) to front housing (11).
2. Remove eight bolts (2, Figure 5), rear housing (l), and gasket (10) from front housing (11).
NOTE: Record co/or of gasket removed. A gasket of the same color must be used during assembly.
3. Remove two needle bearings (4, Figure 5) from rear housing (l), if replacement is necessary.
4. Remove shaft assembly (6, Figure 5) from front housing (11). Shaft assembly is comprised of a drive gear, idler
shaft, drive pin and retaining ring. Replace parts as needed.
5. Remove drive gear (5, Figure 5) and woodruff key (8) from drive shaft (7).
6. Remove retaining ring (16, Figure 5) from front housing (11).
7. Using and arbor press, press on rear housing end of drive shaft. Remove oil seal (15, Figure 5), spacer (14)
and drive shaft assembly from front housing. Remove two retaining rings (12) and ball bearing (13) from drive
shaft (7), if replacement of parts is necessary.
6. Remove two needle bearings (4, Figure 5) from front housing (1 l), if replacement is necessary.
SHOP MANUAL SECTION E-34.00K
CLEANING AND INSPECTION
All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or foreign
material enters unit being assembled. Even minute particles can cause malfunction of close fitting parts such as
thrust bearing, matched parts, etc.
9. Clean all metal parts thoroughly using a suitable cleaning fluid. It is recommended that parts be immersed in
cleaning fluid and moved up and down slowly until all oils, lubricants, and/or foreign materials are dissolved
and parts are thoroughly clean.
A WARNING! Care should be exercised to avoid inhalation of vapors, exposure to skin and
creating fire hazards when using solvent type cleaners.
10. For bearings that can be removed, soak them in a suitable cleaning fluid for a minute or two, then remove
bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant.
Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are thoroughly
clean. To dry bearings, use moisture-free compressed air. Be careful to direct air stream across bearing to
avoid spinning bearings that are not lubricated. DO NOT SPIN BEARINGS WHEN DRYING; bearings may be
rotated slowly by hand to facilitate drying process.
11 Carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks to determine condition. Do not
replace a bearing cone or cup individually without replacing mating cup or cone at the same time. After
inspection, dip bearings in light weight oil and wrap in clean lintless cloth or paper to protect them until
installation.
For those bearings that are to be inspected in place; inspect bearings for roughness of rotation, scoring, pitting,
cracked or chipped races. If any of these defects are found, replace bearings. Also inspect defective bearing
housing and/or shaft for grooved, galled or burred conditions that indicate bearing has been turning in its
housing or on its shaft.
12. It is more economical to replace oil seals, O-rings, sealing rings, gaskets and snap rings when unit is
disassembled than waiting for premature failures; refer to latest Micro Fiche and/or Parts Book for replacement
items. Be extremely careful when installing sealing members, to avoid cutting or scratching. Curling under of
any seal lip will seriously impair its efficiency. Apply a thin coat of Loctite #120 to outer diameter, of metal
casing, on oil seals to assure an oil tight fit into retainer. Use extreme care not to get Loctite on lips of oil seals.
If this happens, that portion of the seal will become brittle and allow leakage.
When replacing lip type seals, make sure spring loaded side is towards oil to be sealed.
8
13. If available, use magna-flux or similar process for checking for cracks that are not visible to the eye. Examine
teeth on all gears carefully for wear, pitting, chipping, nicks, cracks or scores. Replace all gears showing cracks
or spots where case hardening has worn through. Small nicks may be removed with suitable hone. Inspect
shafts and quills to make certain they have not been sprung, bent, or splines twisted, and that shafts are true.
NOTE: Spline wear is not considered detrimental except where it affects tightness of splined parts.
Inspect thrust washers for distortion, scores, burs, and wear. Replace thrust washer if defective or worn.
14. Inspect bores and bearing surfaces of cast parts and machined surfaces for scratches, wear, grooves and dirt.
Remove any scratches and burrs with crocus cloth. Remove foreign matter. Replace any parts that are deeply
grooved or scratched which would affect their operation.
9
REASSEMBLY
Figure 6
10
1. Install two needle bearing (4, Figure 6) in front housing (11).
2. Install ball bearing (13, Figure 6) on drive shaft (7). Hold bearing in place with two retaining rings (12).
3. Press bearing (13, Figure 6) with shaft (7) into front housing (11).
4. Install spacer (14, Figure 6), oil seal (15) and retaining ring (16) in front housing (11).
5. Install woodruff key (8, Figure 6) and drive gear (5) on drive shaft (7).
6. Assemble idler gear drive shaft (6, Figure 6). Shaft assembly is comprised of a drive gear, idler shaft, drive pin
and retaining ring.
7. Install two needle bearings (4, Figure 6) in rear housing (1).
8. Aligning match marks, position proper colored gasket (10, Figure 6) and rear housing (1) on front housing (11).
Install eight bolts (2). Tighten bolts from 9.5 - 12.5 Ibf ft (1.3 - 1.7 kgmm).
NOTE: New gasket must be same color as one removed during disassembly.
11
INSTALLATION
1. Attach control and relief valve (7, Figure 7) to mounting

bracket (5) with two flat washers and bolts (6).
2. Attach pump (4, Figure 7) to mounting bracket (5) with

four flat washers and bolts (3).
NOTE: 77ghtenbolts to 25 Ibf ft (3.5 kgm).
3. Install three elbows (1, Figure 7) and tee (2). Orient

elbows and tee as shown.
Figure 7
4. Attach pulley bushing (4, Figure 8) to pulley (1) with two

bolts (3).
NOTE: ~ghfen bolts to 8 Ibf ff (7. I kg@
5. Press pulley assembly (1, Figure 8) with key (not shown)

on pump drive shaft (2).
Figure 8
6. Loosen pivot mounting bolt (not shown) and remove

drive belt (2, Figure 9) from pulley (3).
7. Attach pump mounting bracket (4, Figure 9) to engine

support (5) with pivot mounting bolt (not shown) and
adjustment bolt (1, Figure 9) and hardware. Only finger
tighten bolts at this time.
8. Position drive belt (2, Figure 9) on pulley (3). Pivot

mounting bracket to apply tension on drive belt. Tighten
bolts to 110 Ibf ft (15.2 kgam).
NOTE: Belt deflection should be from 0.25 - 0.375 In.

(6.35 - 9.52 mm).
Figure 9
9. Tag and Connect all hoses from pump and control and
relief valve as tagged during removal procedure.
10. Connect electrical connection to solenoid.
12
TESTS AND ADJUSTMENTS
LOCK/UNLOCK DIFFERENTIAL RELIEF VALVE ADJUSTMENT
Connect a calibrated 3000 PSI (210.9kg/cm’) gauge to

test port (Figure 10). Test port is located on top of rear
axle.
Start engine and set engine speed control lever to 1000

RPM.
Figure 10 LOCK/UNLOCK DIFFERENTIAL TEST

PORT
3. Adjust relief valve (Figure 11) until gauge reads 625 PSI
(43.9 kg/cm*).
4. Set engine speed control lever to 2500 RPM, gauge

should read 625 k20 PSI (43.9 il.4 kg/cm*)
5. Adjust relief valve if necessary.
I
Figure 11 RELIEF VALVE
REAR AXLE COOLING SYSTEM
There is no pressure adjustment for the rear axle cooling system.

14
F-01.20K
RI
CIRCLE REVERSE SLIP CLUTCH
APPLICABLE MODELS SERIAL NUMBERS
GD530 SERIES 200840 & Up

GD530AW SERIES 200840 & Up
GD650A SERIES 200840 & Up
CAUTION
ALL COMPONENTS MUST BE PROPERLY SUPPORTED DURING
DISASSEMBLY AND REASSEMBLY.
ALL JACKING, HOISTING AND GENERAL WORKSHOP EQUIPMENT

REQUIRED FOR THIS OPERATION MUST BE IN GOOD
WORKING ORDER.
EXTREME CAUTION TO BE OBSERVED AT ALL TIMES TO PREVENT

INJURY.
SAFE WORKSHOP PRACTICES ARE A MUST.
FOR TABLE OF CONTENTS SEE PAGE 1
ILLUSTRATIONS SHOWN IN THIS MANUAL WERE TAKEN WHILE THE

SLIP CLUTCH WAS BEING ASSEMBLER AT THE FACTORY, AND DO
NUT REFLECT THE POSITION THAT THEY ARE ON A UNIT IN THE
FIELD.
KOMATSU DRESSER COMPANY 850 SOUTH STREET GALION, OH 44833
0995
GENERAL TORQUE VALUES
Refer to “General Torque Values” shop manual section when SPECIFIC TORQUES are not given in this shop
manual section. All values listed throughout this manual are lubricated (WET) unless stated otherwise.
METRIC CONVERSIONS
Refer to “Metric Conversions” shop manual section for metric conversion of U.S. Measurements.
SHOP MANUAL SECTION F-01.20K
TABLE OF CONTENTS
CONTENTS PAGE
INTRODUCTION ............................................... 2
SPECIALTOOLS .............................................. 4
SERVICING .................................................. 5
REMOVAL ................................................ 5
DISASSEMBLY ............................................. 6
CLEANING AND INSPECTION ................................. 9
REASSEMBLY ............................................ 11
INSTALLATION ............................................ 17
RETROFITTING A STANDARD CIRCLE GEAR CASE WITH A SLIP CLUTCH
FOR CIRCLE P/N 1430 851 H92 ............................... 19
CIRCLE IDENTIFICATION .................................... 19
RETROFITTING INSTRUCTIONS .............................. 19
TESTS AND ADJUSTMENTS .................................... 22
CIRCLE ADJUSTMENT ...................................... 22
SLIP CLUTCH ADJUSTMENT TEST ............................ 24
Spring Scale Test ....................................... 24
Engine and Transmission Gear Range Test .................... 25
1 Rl
INTRODUCTION
16
20
I7
18
21 *I9
G17GVOOi
Ggure 1 EXPLODED VIEW OF CIRCLE REVERSE SLIP CLUTCH
RI 2
LEGEND FOR CIRCLE REVERSE SLIP CLUTCH
The exploded view shown on the previous page and legend shown here are to help identify parts and their
orientation to each other while repairing the circle reverse slip clutch. Some components mentioned during
service procedure may only be shown in this illustration
1 PINION SHAFT 15 O-RING

2 O-RING 16 SHIM - 0.005
3 V-RING SHIM - 0.007
4 BEARING SHIM - 0.020
5 OIL LEVEL PLUG SHIM - 0.060
6 CLUTCH HOUSING 17 CLUTCH HOUSING COVER
7 BACK-UP RING 18 FLAT WASHER
8 SEPARATOR PLATE 19 BOLT
9 FRICTION PLATE 20 OIL DRAIN/FILL PLUG
10 BACKING PLATE 21 O-RING
11 CLUTCH HUB 22 PLUG
12 PINION SHAFT WASHER 23 REDUCER
13 LOCK NUT 24 CHECK VALVE
14 BELLEVILLE SPRING
3 Rl
SPECIAL TOOLS
2.40” (60.9 MM)

f;;y;%J
. -:02 MM
MATERIAL: MILD STEEL

5.91” (150.1 MM)
17014
FiCJUre 2 C;IHC;Lt SLIP C;LU I GH tiAUtit I WWL
The circle slip clutch gauge tool (Figure 3) is used in

place of the belleville springs, when the slip clutch shim
pack is being determined at assembly. The qauqe must
be removed after the shim pack thickness is determined.
Circle Slip Clutch Gauge Tool (Part Number DRl l-901).

Refer to “Service Tools Catalog” 1128166R2, Section 11.
Orders for these tools should be placed with;

Kent-Moore Heavy Duty Group
SPX Corporation
29784 Little Mack
Roseville, MI 48066-2298
Telephone; l-800-328-6657 USA and Canada

Figure 3
Fax; l-800-578-7375 USA and Canada
RI 4
SERVICING
The following is only one method of obtaining a removal, disassembly, cleaning and inspection, reassembly,
and installation of the circle reverse slip clutch.
Thoroughly clean the component to be repaired and the surrounding area. This will help prevent contamination
from entering the component or system being repaired.
REMOVAL
1. Before removal of circle slip clutch from grader, the circle shoes must be loosened and the circle moved
away from the pinion gear. There is a small lip by the root of the pinion gear that will prevent it from being
removed unless the circle is moved.
2. Position a floor jack under circle slip clutch assembly

to prevent it from falling.
3. Remove six bolts and lock washers (1, Figure 4),

bearing retainer (2) and shims from circle reverse
gear case cover (3).
NOTE: Keep shim pack together for reassembly.
Figure 4
4. Remove lock nut and washer (1, Figure 5) from pinion

shaft (2).
5. Slowly lower floor jack and remove circle slip clutch

assembly out of circle reverse gear case.
Figure 5
5 Rl
DISASSEMBLY
1. Remove plug (1, Figure 6) from clutch housing cover

(2).
2. Remove O-ring (not shown) from plug (1, Figure 6).
3. Remove eight bolts and flat washers (3, Figure 6),

clutch housing cover (2) and split shims (not shown)
from clutch housing (4).
NOTE: Keep each split shim pack half together.
4. Remove O-ring (1, Figure 7) from clutch housing

cover (2).
Figure 7
5. Remove two belleville springs (1, Figure 8) and

backing plate (2) from slip clutch.
Figure 6
RI 6
6. Remove eight separator plates (1, Figure 9) and

seven friction plates from clutch housing (2).
Figure 9
7. Remove back-up ring (1, Figure IO) from clutch

housing (2).
Figure 10
7 Rl
8. Remove V-ring (10, Figure 11) from

clutch housing (2).
9. Remove check valve (9, Figure 11)

and reducer (8) from end of pinion
shaft (4), if replacement is necessary.
10. Remove lock nut (7, Figure 1 l), pinion

shaft washer (6), and clutch hub (5)
from pinion shaft (4).
11. Remove pinion shaft (4, Figure 11)

from clutch housing (2).
12. Remove O-ring (3, Figure 11) from

clutch housing (2).
13. Press self-lubricated bearing (1,

Figure 11) out of clutch housing (2).
Figure 11
RI 8
Some of the following

information may not apply to the particular
component that you are servicing.
All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or
foreign material enters unit being assembled. Even minute particles can cause malfunction of close fitting parts
such as thrust bearing, matched parts, etc.
1. Clean all metal parts thoroughly using a suitable cleaning fluid. It is recommended that parts be immersed
in cleaning fluid and moved up and down slowly until all oils, lubricants, and/or foreign materials are
dissolved and parts are thoroughly clean.
A WARNING! Care should be exercised to avoid inhalation of vapors, exposure to skin and
bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubri-
cant. Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are
thoroughly clean. To dry bearings, use moisture-free compressed air. Be careful to direct air stream across
bearing to avoid spinning bearings that are not lubricated. DO NOT SPIN BEARINGS WHEN DRYING;
bearings may be rotated slowly by hand to facilitate drying process.
3. Carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks to determine condition. Do
not replace a bearing cone or cup individually without replacing mating cup or cone at the same time. After
installation.
For those bearings that are to be inspected in place; inspect bearings for roughness of rotation, scoring,
pitting, cracked or chipped races. If any of these defects are found, replace bearings. Also inspect defective
bearing housing and/or shaft for grooved, galled or burred conditions that indicate bearing has been turning
in its housing or on its shaft.
disassembled than waiting for premature failures; refer to latest Micro Fiche and/or Parts Book for replace-
ment items. Be extremely careful when installing sealing members, to avoid cutting or scratching. Curling
under of any seal lip will seriously impair its efficiency. Apply a thin coat of Loctite #120 to outer diameter,
of metal casing, on oil seals to assure an oil tight fit into retainer. Use extreme care not to get Loctite on
lips of oil seals. If this happens, that portion of the seal will become brittle and allow leakage.
9 Rl
5. If available, use magna-flux or similar process for checking for cracks that are not visible. Examine teeth
on all gears carefully for wear, pitting, chipping, nicks, cracks or scores. Replace all gears showing cracks
shafts and quills to make certain they have not been sprung, bent, or splines twisted, and that shafts are
true.
Inspect belleville springs for distortion, scores, burs, and wear. Replace thrust washer if defective or worn.
6. Inspect bores and bearing surfaces of cast parts and machined surfaces for scratches, wear, grooves and
dirt. Remove any scratches and burrs with crocus cloth. Remove foreign matter. Replace any parts that
are deeply grooved or scratched which would affect their operation.
RI IO
REASSEMBLY
1. Press self-lubricated bearing (1,

Figure 12) into bore of clutch housing
(2) until even with chamfer at point
“A.”
NOTE: Press bearing into bore from

chamfered end.
2. Install new O-ring (3, Figure 12) into

groove of clutch housing (2).
NOTE: Coat O-ring and self-

lubricated bearing with oil to
help aid installation of pinion
shaft.
3. Install pinion shaft (4, Figure 12) into

clutch housing (2).
4. Install clutch hub (5, Figure 12), pinion

shaft washer (6) and lock nut (7) on
pinion shaft (4). Tighten lock nut to
155 +20 Ibf ft (210.1 +27.1 N.m).
5. Install reducer (8, Figure 12) and

check valve (9) in end of pinion shaft
(4).
6. Install new V-ring (10, Figure 12) on

clutch housing (2).
NOTE: Lip on V-ring must point away

from housing.
Figure 12
11 Rl
7. Position new back-up ring (1, Figure 13) in clutch

housing (2).
Figure 13
8. Before build up of circle reverse slip clutch, soak

the friction plates (1, Figure 14) in hydraulic-
transmission fluid for a minimum of 30 minutes.
This will allow any expansion of plates to occur
before assembly, thus ensuring proper shimming of
slip clutch assembly.
Figure 14
9. Install a separator plate (1, Figure 15) into clutch

housing (2).
NOTE: Separator plates have external teeth that

engage clutch housing. A total of eight are
used.
Figure 15
Rl 12
10. Install a friction plate (1, Figure 16) on clutch hub

(2).
NOTE: Friction plates have internal teeth that

engage clutch hub. A total of seven are
used.
Figure 16
11. Continue to alternate the installation of separator

and friction plates. When all plates are installed, the
last one must be a separator plate (1, Figure 17)
with external teeth.
Figure 17
12. Install backing plate (1, Figure 18) on top of

separator plate (2).
NOTE: Make sure that backing plate is centered in

clutch housing.
Figure 18
13 Rl
13. Position “Circle Slip Clutch Gauge Tool” (1, Figure

19) on top of backing plate.
NOTE: Refer to “Special Tools” section of this

manual for manufacturing details of Circle
Slip Clutch Gauge Tool. This tool must be
used to obtain proper shimming of clutch
housing. The tool is ground to the
compressed thickness of the two be//evil/e
springs when installed.
Figure 19
14. Set clutch housing cover (1, Figure 20) on clutch

housing (2). Align drain plug (3) and level check
plug (4) 30” apart from each other as shown.
NOTE: Do not install O-ring on clutch housing

cover at this time.
Figure 20
15. Install four bolts (1, Figure 21) equally spaced apart
from each other. Tighten bolts to 100 Ibf in
(11.3 kgmm).
Figure 21
RI 14
16. Using a feeler gauge (1, Figure 22), measure gap

between cover (2) and housing (3) beside each bolt
(4).
17. Average the four readings together.
18. Make a shim pack that is within k.002 In.

(0.051 mm) of the average reading.
19. Remove four bolts (4, Figure 22) and clutch housing
cover (2) from clutch housing (3).
20. Remove “Circle Slip Clutch Gauge Tool” (1, Figure

19) from clutch housing (3, Figure 22).
A
WARNING! Do not leave “Circle Slip Figure 22
Clutch Gauge Tool” in clutch pack
assembly.
21. Coat new O-ring (1, Figure 23) with clean oil, and
position it in O-ring groove of clutch housing cover
(2).
Figure 23
22. With “Circle Slip Clutch Gauge Tool” (1, Figure 19)
removed, install two belleville springs (1, Figure 24)
on backing plate (2).
NOTE: Coat be//evil/e springs and mating surface

of backing plate with 3% molybdenum
disulficie grease.
A
WARNING! O.D. of belleville springs
must be in contact with backing
plate.
Figure 24
15 Rl
23. The shims used under the clutch housing cover are
a split shim design (I, Figure 25). Keep thickest
shims to the outside of the pack.
A
WARNING! Make sure that both
halves of shim pack are; 1) the same
thickness, and 2) have the same
number of half shims.
Figure 25
24. Install clutch housing cover (1, Figure 26) with new
O-ring, on clutch housing (2) with eight bolts and
flat washers (3). DO NOT TIGHTEN BOLTS.
25. Slide split shim pack (4, Figure 26) into position.
Figure 26
26. Tighten bolts (1, Figure 27) from 40 - 46 Ibf ft (5.5 -

6.4 kgmm).
27. Use a feeler gauge and check for a 0.010 In.

(0.254 mm) gap at point “A,” Figure 27. If there is
not 0.010 In. (0.254 mm) gap add separator plate
P/N 1208675Hl under backing plate.
NOTE: If 0.070 In. (0.254 mm) gap con still not be

obtained, the friction and separator plates
must be replaced with new ones. Be sure
to remove separator plate P/N 1208675Hl
from under backing plate.
Figure 27
RI 16
28. Fill circle slip clutch assembly with hydraulic-

transmission fluid.
29. Install plug (1, Figure 28) with new O-ring, on clutch
housing cover (2).
Figure 28
INSTALLATION
NOTE: The illustrations shown were taken during factory assembly. A floor jack can be used to raise
assembled circle slip clutch up into position from bottom side of circle.
1. There is a lip (“A”, Figure 29) on the pinion gear

portion of the slip clutch housing (1). Due to this lip,
all four circle shoes (2) must be loosened, so the
circle (3) can be moved away from pinion gear (4).
A WARNING! Do not remove

shoe mounting hardware.
circle
2. Position clutch housing subassembly (1, Figure 29)

into circle gear case.
Figure 29
17 Rl
3. Install washer and lock nut (1, Figure 30) on pinion

shaft (2). Tighten lock nut from 950 - 1050 Ibf ft
(1,288.O - 1,423.6 N.m).
Figure 30
4. Fill bearing retainer (1, Figure 31) with molybdenum

disulfide grease. When retainer is installed, the
grease will ensure that top bearing in circle reverse
gear case is lubricated.
Figure 31
5. Secure shims and bearing retainer (2, Figure 32) to

circle reverse gear case (3) with six lock washers
and bolts (1). Tighten bolts to 32 Ibf ft (43.4 N.m).
NOTE: Use the same amount of shims as removed

during disassembly. If necessary refer to
“Circle Reverse Gear Case” shop manual
for shimming procedure.
Figure 32
RI 18
RETROFITTING A STANDARD CIRCLE GEAR CASE WITH A SLIP CLUTCH

FOR CIRCLE P/N 1430 851 H92
CIRCLE IDENTIFICATION
Not all circles can be retrofitted with a circle slip clutch. The knee brace of the circle must provide clearance
for the slip clutch housing. A modification was made to circles to allow for slip clutch housing clearance by
moving the knee braces back. Figure 33, shows an old style configuration (1) and the new style circle (2). Note
that the knee braces (3) on circle (2) protrude out pass the circumference of the circle at point “A.” IF YOUR
KNEE BRACES DO NOT PROTRUDE, THE CIRCLE CAN NOT BE USED WITH A SLIP CLUTCH.
‘ROFITTING INSTRUCTIONS
1. Remove six bolts and lock washers (1, Figure 34),

bearing retainer (2) and shims (not shown) from
circle reverse gear case cover (3).
Figure 34
19 Rl
2. Remove lock nut and washer (1, Figure 35) from

pinion shaft/gear (2).
Figure 35
3. Using a pry bar, remove pinion shaft/gear (1, Figure

36) and oil slinger seal (not shown) from circle gear
case.
NOTE: Oil seal should remain in bore of gear

case.
4. Now proceed with the “Reassembly” and

“Installation” portions of this manual.
Figure 36
RI 20
21 Rl
CIRCLE ADJUSTMENT
Due to the lip that is located on the pinion gear, the pinion gear can not be adjusted in the same manner as
a normal pinion gear. The lip prevents measurement of the root and side gear tooth clearances. For this reason
a dial indicator must be used to determine when the circle gear teeth are bottomed into the pinion gear and
then moved back out an appropriate distance.
Use the following procedure to adjust pinion gear clearance.
1. Measure the inside diameter of circle gear teeth to determine where the smallest inside diameter is. The
smallest diameter must be known so that as the circle is rotated the tips of the circle gear teeth do not
come into contact with the roots of the pinion gear.
2. Rotate circle so that smallest inside diameter is inline with pinion gear. A circle gear tooth must be on the
centerline of the pinion gear as shown in Figure 38.
3. Loosen circle shoe vertical mounting bolts (Figure 38).
4. Loosen jam nuts on all circle shoe jacking bolts (Figure 38).
5. Using jacking bolts on circle shoes (3 and 4, Figure

38) move circle so that circle gear tooth is bottomed
into pinion gear. Use a dial indicator (Figure 37) to
determine when circle can not be moved any farther
with jacking bolts.
NOTE: Make sure that there is clearance between

circle jacking bolts on and circle shoes 1 and
2. If there is no clearance the circle may not
be bottomed into the pinion gear.
6. Once circle is bottomed (can not be moved any

farther) loosen jacking bolts on circle shoes 3 and 4
until there is 0.250 In. (6.350 mm) clearance.
Figure 37
7. Set dial indicator to zero.
8. Using jacking bolts on circle shoes 1 and 2, move circle away from pinion until 0.125 In. (3.175 mm) is
registered on the dial indicator.
9. Do not remove dial indicator once 0.125 In. (3.175 mm) reading is obtained. Keep the dial indicator set at
its current reading so that as the circle shoes are adjusted you can maintain the circle position.
IO. Make all final adjustments to circle shoes using appropriate shop manual section “Circle Adjustment (Four
Shoe.”
11. Circle must rotate freely after all final adjustments are made.
RI 22
.125” (3.175 mm)
PINION GEAR
(3.175 mm)
CIRCLE GEAR-
*SHOE 1 PINION GEAR
CIRCLE GEAR
SHOE 4-
VERTICAL MOUNTING BOLTS
MEASURE
DIAMETER
(3 PLACES)
NOTE: ARROWS INDICATE DIRECTION

OF CIRCLE MOVEMENT WHEN SHOES
ARE ADJUSTED OUTWARD.
15371A
Figure 38
23 Rl
SLIP CLUTCH ADJUSTMENT TEST
Spring Scale Test
A WARNING! Use extreme caution when performing this test.
A WARNING! Make sure that all equipment being used to conduct test is in good condition.
A WARNING! All equipment must be capable of handling a load of at least 25,000 Lbs.
(11,337.5 kg).
After the slip clutch is installed on the grader, the following test can be made to check operation.
1. Position circle (1, Figure 39) so that

the centerline of the circle is on the
centerline of the frame (2).
2. Rotate blade (3, Figure 39) so that it

is at 90” to the centerline of circle (1)
and frame (2).
3. Sideshift the blade (3, Figure 39) so

that the end of it is more than 8 Ft.
(2.44 m) from the centerline of the
circle (1) and frame (2).
4. Attach a spring scale (4, Figure 39) to

blade (3) at 8 Ft. (2.44 m) (“xl’). [Scale
r
must be large enough to handle a
25,000 Lbs. (11,337.5 kg) load.]
Attach other end to a solid object (5)
capable of holding this load. Spring
scale must be 90” to blade. Unit must
also be on a surface capable of
obtaining traction in third and forth Figure 39
gears without slipping the wheels.
5. Circle slip clutch should slip with grader moving in a forward direction, at a force of 11,325 Lbs.
(5,135.g kg) on the spring scale (4, Figure 39). Two things may occur.
A. If the clutch slips before the 11,325 Lbs. (5135.9 kg) reading is obtained, reduce the thickness of the
slip clutch shim pack by removing 0.001 In. (0.025 mm).
B. If the clutch continues to hold after the 11,325 Lbs. (5,135.g kg) reading is obtained, increase the
thickness of the slip clutch shim pack by adding 0.001 In. (0.025 mm).
NOTE: Reducing shim pack thickness (removing shims) increases spring pressure.
Increasing shim pack thickness (adding shims) reduces spring pressure.
Repeat test until slip clutch operates properly.
RI 24
Engine and Transmission Gear Range Test
A WARNING! Use extreme caution when performing this test.
A WARNING! Make sure that all equipment being used to conduct test is in good condition.
A WARNING! All equipment must be capable of handling a load of at least 25,000 Lbs.
AA (11,337.5 kg).
After the slip clutch is installed on the grader, the following test can be made to check operation.
1. Position circle (1, Figure 40) so that

the centerline of the circle is on the
centerline of the frame (2).
2. Rotate blade (3, Figure 40) so that it

is at 90” to the centerline of the circle
(1) and frame (2).
3. Sideshift the blade (3, Figure 40) so

that the end of it is more than 8 Ft.
(2.44 m) from the centerline of the
circle (1) and frame (2).
4. At 8 Ft. (2.44 m) (“X”), position the

blade against a solid object that can
withstand a load of 25,000 Lbs.
(11,337.5 kg), and a surface capable
of obtaining traction in third and forth
gears without slipping the wheels.
5. Use a calibrated tachometer to obtain 7048

proper engine speed (RPM). Figure 40
25 Rl
6. Use the following table to determine the engine RPM at which the circle slip clutch should be tested.
MACHINE TIRE SIZE TRANSMISSIO DESIRED ENGINE RPM

MODEL N GEAR
RANGE
830 13:OO X 24 THIRD 1370 +75

(FORWARD)
850 14:00 X 24 or FORTH 1730 +75

1750 X 25 (FORWARD)
850 14:00 X 24 or THIRD 1400 +75

17:50 X 25 (FORWARD)
870 14:00 X 24 or FORTH 1730 +75

870 14:00 X 24 or THIRD 1400 +75

0 RPM . . , , r r x x x x < < . . . . . . . . . , , r r x x x x < < . . . . . . . . . , , DESIRED RPM DESIRED RPM FULL THROTTLE
CIRCLE SLIP CLUTCH SHOULD HOLD CIRCLE SLIP CLUTCH
SHOULD SLIP
7. Circle slip clutch should slip with grader moving in a forward direction when appropriate RPM reading is
obtained on the tachometer. Two things may occur.
A. If the clutch slips before proper engine RPM reading is obtained, reduce the thickness of the slip clutch
shim pack by removing 0.001 In. (0.025 mm).
B. If the clutch continues to hold after proper engine RPM reading is obtained, increase the thickness of
the slip clutch shim pack by adding 0.001 In. (0.025 mm).
NOTE: Reducing shim pack thickness (removing shims) increases spring pressure.
Increasing shim pack thickness (adding shims) reduces spring pressure.
Repeat test until slip clutch operates properly.
RI 26
F-01.30K
CIRCLE REVERSE GEAR CASE

GD530A-1 200417 & Up

GD530AW-1 200417 & Up
GD650A-1 200417 & Up
GD650AW-1 200417 & Up
GD670A-1 200417 & Up
GD670AW-1 200417 & Up
CAUTION
ALL JACKING, HOISTING AND GENERAL WORKSHOP

EQUIPMENT REQUIRED FOR THIS OPERATION MUST BE
IN GOOD WORKING ORDER.

INJURY.
0494
METRIC CONVERSIONS
TABLE OF CONTENTS
CONTENTS PAGE
INTRODUCTION ................................................. 2
SERVICING .................................................... 6
DISASSEMBLY ............................................... 6
CLEANING AND INSPECTION ................................... 13
REASSEMBLY ............................................... 15
1
INTRODUCTION
6085.0
Figure 1 EXPLODED VIEW OF CIRCLE REVERSE GEAR CASE MOTOR INSTALLATION
2
LEGEND FOR CIRCLE REVERSE GEAR CASE MOTOR
orientation to each other while servicing the circle reverse gear case motor. Some components mentioned during
service procedure may only be shown in this illustration.
1 HYDRAULIC MOTOR 7 MOUNTING PLATE

2 BOLT 8 GASKET
3 FLAT WASHER 9 COUPLING
4 GASKET 10 CIRCLE REVERSE GEAR CASE ASSEMBLY
5 BOLT
6 WASHER
0066
Figure 2 EXPLODED VIEW OF CIRCLE REVERSE GEAR CASE
4
LEGEND FOR CIRCLE REVERSE GEAR CASE
orientation to each other while servicing the circle reverse gear case. Some components mentioned during service
procedure may only be shown in this illustration.
1 RETAINER, BEARING 11 CONE, BEARING

BOLT 12 CUP, BEARING
WASHER, LOCK 13 SEAL, OIL
2 SHIM - 0.003 In. (0.076 mm) 14 SHAFT, PINION
SHIM - 0.005 In. (0.127 mm) 15 CASE, CIRCLE REVERSE
SHIM - 0.020 In. (0.508 mm) 16 CUP, BEARING
3 NUT, LOCK 17 CONE, BEARING
4 PIPE PLUG, FLUSH 18 WORM, CIRCLE REVERSE
BREATHER 19 SHIM - 0.003 In. (0.076 mm)
5 COVER, CIRCLE REVERSE CASE SHIM - 0.005 In. (0.127 mm)
BOLT SHIM - 0.020 In. (0.508 mm)
WASHER, LOCK 20 CAP, END
6 GASKET BOLT
7 WASHER WASHER, LOCK
8 CUP, BEARING 21 SEAL, OIL SLINGER
9 CONE, BEARING
10 GEAR, CIRCLE REVERSE
SERVICING
The following is only one method of obtaining a disassembly, cleaning and inspection, and reassembly of the circle
reverse gear case.
Thoroughly clean the component to be serviced and the surrounding area. This will help prevent contamination from
entering the component or system being serviced.
DISASSEMBLY
1. This circle reverse gear case is shown in this procedure, removed from the grader, to facilitate photographic
purposes. For the complete tear down and replacement of bottom seal, the gear case housing need not be
removed from grader. Should the gear case housing, have to be removed for some reason, it will be necessary
to remove the grader circle before attempting gear case removal, since three (3) bolts that are covered by the
circle.
2. Remove two bolts and flat washers (I, Figure 3), circle
reverse motor (2) and motor gasket (not shown) from
mounting plate (3). Discard gasket.
NOTE: Move motor out of the way. Wire or strap motor

to grader drawbar.
3. Remove six bolts and washers (4, Figure 3), mounting

plate (3) and mounting plate gasket (not shown) from
circle reverse gear case (5). Discard gasket.
Figure 3
4. The circle reverse worm (1, Figure 4) is coupled to the

hydraulic motor shaft with a splined coupling (2). Remove
this coupling.
Figure 4
6
5. Remove fill plug (1, Figure 5) on top of gear case (2).
Figure 5
6. Remove check level plug (1, Figure 6) at side of gear

case (2).
Figure 6
7. To aid in the reassembly of gear case, center punch

caps, cover and gear case to mark their locations, as
shown in Figure 7.
Figure 7
8. Remove six bolts and washers (1, Figure 8) from bearing

retainer (2).
Figure 8
9. Remove bearing retainer (1, Figure 9) and shims (2). Use

extreme care not to damage shims. These shims will be
used in reassembly to preload bearings.
Figure 9
10. Remove six bolts and washers (1, Figure 10) from circle
reverse case cover (2).
Figure 10
8
11. Remove circle reverse case cover (1, Figure 11) and
cover gasket (2) from circle reverse case (3). Use care
not to damage cover gasket. Bearing cup will also be
removed with cover. Discard gasket.
12. Inspect bearing cup (4, Figure 11). Remove and replace
cup if necessary.
Figure 11
13. Remove pinion shaft lock nut (1, Figure 12) and flat
washer (2) from pinion shaft (3).
NOTE: On some gear cases the pinion gear may be part

of a circle slip clutch. Refer to “Circle Reverse
Slip Clutch” shop manual section for servicing.
Figure 12
14. Using a soft face hammer, remove pinion shaft (I,

Figure 13) from circle reverse case (2).
A
WARNING! If circle reverse case is
attached to grader, support pinion shaft
from underside as shaft is driven out.
NOTE: Oil slinger seal removes with shaft. Oil will drain
from case at this time.
Figure 13
15. Inspect pinion shaft (1, Figure 14). Inspect;
A. Splines
B. Teeth
C. Oil seal sealing surface
D. Oil slinger seal
If any portion of pinion is damaged or unserviceable,

replace the pinion shaft.
16. Remove oil slinger seal (2, Figure 14) from pinion shaft
(1).
Figure 14
17. Remove circle reverse gear (1, Figure 15) from circle
reverse case (2).
Figure 15
18. Inspect circle reverse gear (1, Figure 16) and bearings (2
and 3). If gear or bearings are damaged, replace them.
Use care in replacing bearings.
A WARNING! Use suitable

bearings and cups.
puller to remove
NOTE: If a cup or bearing is damaged and replaced, the

companion cup or bearing must be replaced also.
Bearings must be sea ted tightly against shoulders
on gear.
Figure 16
10
19. Remove six bolts and washers (1, Figure 17), end cap
(2), and shim pack from circle reverse case (3).
NOTE: Use care not to damage shims.
Figure 17
20. With suitable press (or puller), press from motor flange
end, the circle reverse worm (1, Figure 18) from circle
reverse case (2).
Figure 18
21. Remove bearing cup (1 Figure 19) from cap end (2) and
inspect for damage.
Fiaure 19
11
22. Remove circle reverse worm (1, Figure 20) with two
bearing cones (2 and 3).
23. Using a suitable puller, remove two bearing cones (2 and

3, Figure 20) from circle reverse worm (l), if replacement
is necessary.
NOTE: Make certain circle reverse worm is not worn and

that circle reverse gear is in a serviceable
condition.
Figure 20
24. Using a suitable puller, remove bearing cup (1, Figure 21)
from flange end of case (2), if replacement is necessary.
NOTE: If bearing cones on circle reverse worm were

replaced (Figure 20) this cup must also be
replaced.
Figure 21
25. Using a suitable puller, remove lower bearing cup (1,

Figure 22) from circle reverse case (2), if replacement is
necessary.
NOTE: If bearings were replaced in (Figure 16) this cup

must also be replaced.
26. Remove pinion shaft seal (3, Figure 22) from circle
reverse case (2).
Figure 22
12
Some of the following information may not apply to the particular component
that you are servicing.
A WARNING! Care should be exercised to avoid inhalation

of vapors, exposure to skin and
3. Carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks to determine condition. Do not
installation.
13
14
REASSEMBLY
Clean and inspect case thoroughly prior to assembly.
1. Using an arbor press and suitable adaptor, press bearing

cup (1, Figure 23) into circle reverse case (2).
2. Install new pinion shaft seal (3) into circle reverse case
NOTE: Apply a light coating of non-hardening sealant on

the outer diameter. Be certain that pinion shaft
seal is installed with lip of seal facing toward the
inside of the case.
Figure 23

cup (I, Figure 24) into flange end of circle reverse case
(2).
Figure 24
4. Using an arbor press and suitable adaptor, install two

bearing cones (1 and 2, Figure 25) on circle reverse
worm (3).
NOTE: Make sure that bearing cones are properly

sea ted.
5. Install circle reverse worm assembly in circle reverse case

(4, Figure 25). Be certain that bearing cup in flange end
of case was installed and fully seated prior to installation
of circle reverse worm (See Figure 24). Circle reverse
worm should be installed in case with splined end of
worm toward flange of case.
Figure 25
15
6. Install bearing cup (1, Figure 26) in cap end of circle

reverse worm housing (2).
Figure 26
7. Adjust circle reverse worm preload using the following

procedure;
A. Install end cap (1, Figure 27) on circle reverse case

(2) with two bolts (3) without flat washers and without
shims, 180” apart.
B. Cross-tighten bolts (3, Figure 27) from 40 - 50 Ibf ft

(5.5 - 6.9 kg*m).
NOTE: Rotate circle reverse worm occasionally to

assure proper seating of bearings.
C. Completely loosen two bolts (3, Figure 27).
Figure 27
D. Cross-tighten bolts (3, Figure 27) to 30 Ibf ft
(4.1 kg*m).
NOTE: Rotate circle reverse worm occasionally to assure proper seating of bearings.
E. With a suitable feeler gauge, measure gap between end cap (1, Figure 27) and circle reverse case (2) next
to both torqued bolts (3) and average the two readings.
F. Add 0.013” (0.330 mm) to average gap reading to obtain shim pack thickness.
NOTE: That will establish a 0.000” to 0.002” (0.000 to 0.057 mm) preload.
First gap reading
+ Second gap reading

= Total gap reading t 2 = Average reading
+ 0.013” Constant
= Shim pack thickness
16
G. Remove two bolts (3, Figure 27) and end cap (1,
Figure 28) from circle reverse case (2).
H. Place shim pack in position.
I. Install end cap (1, Figure 28) and six bolts with
washers (2). Tighten bolts to 32 Ibf ft (4.4 kg*m).
Figure 28

cones (2 and 3, Figure 29) on circle reverse gear (1).
NOTE: Make sure that bearing cones are fully seated.
Figure 29
9. Insert circle reverse gear (I, Figure 30) in circle reverse

case (2) with longer shoulder to the bottom of case.
(Bearing cone (3, Figure 29) is mounted on long
shoulder.)
NOTE: Circle reverse gear should be engaged with circle

reverse worm as it is inserted in circle reverse
case.
Figure 30
17
10. Install oil slinger seal (2, Figure 31) on pinion shaft (l),
making certain it is properly seated on shaft. Flat side of
slinger installs toward oil seal.
11 Insert pinion shaft (1, Figure 32) into bottom of circle

reverse case (2) through circle reverse gear (3). A light
coat of grease should be applied to lower seal prior to
installation of pinion shaft. Be certain that during this
installation the lower seal and oil slinger are not
damaged.
12. Install flat washer (2, Figure 33) on pinion shaft (3).
13. Install pinion shaft lock nut (1, Figure 33) on pinion shaft
(2). Tighten pinion shaft lock nut from 950 - 1050 Ibf ft
(131.4 - 145.2 kg*m).
Figure 33
18

cup (1, Figure 34) into circle reverse case cover (2).
15. Apply a light coat of non-hardening sealant to circle

reverse case cover (2, Figure 34) and install new gasket
(3).
Figure 34
16. Install circle reverse case cover (1, Figure 35) on circle
reverse case (2) with six washers and bolts (3). Cross-
tighten bolts to 70 Ibf ft (9.7 kgam).
NOTE: Install cover so that fill plug hole (4, Figure 35) is
directly across from worm side of case, or if parts
were center punched (Figure 7) this will also aid
in correct alignment.
Figure 35
19
17. Adjust circle reverse gear preload using the following

procedure;
A. Install bearing retainer (2, Figure 36) on circle reverse

case cover (3) with two bolts (1) without flat washers
and without shims, 180” apart.
B. Cross-tighten bolts (1, Figure 36) from 40 - 50 Ibf ft

(5.5 - 6.9 kg*m).
NOTE: Rotate circle reverse worm occasionally to

assure proper seating of circle reverse gear
bearings.
C. Completely loosen two bolts (1, Figure 36).

Figure 36
D. Cross-tighten bolts (I, Figure 36) to 30 Ibf ft

(4.1 kg*m).
NOTE: Rotate circle reverse worm occasionally to assure proper seating of circle reverse gear bearings.
E. With a suitable feeler gauge, measure gap between bearing retainer (1, Figure 36) and circle reverse case
cover (2) next to both torqued bolts (1) and average the two readings.
F. Add 0.007” (0.178 mm) to average gap reading to obtain shim pack thickness.
NOTE: That will establish a 0.006” to 0.008” (0.752 to 0.203 mm) preload.
First gap reading
+ Second gap reading

= Total gap reading t 2 = Average reading
+ 0.007” Constant
= Shim pack thickness
18. Remove two bolts (1, Figure 36) and bearing retainer (2) from circle reverse case cover (3)
19. Fill bearing retainer (1, Figure 37) with multi-purpose

grease prior to installation on circle reverse case cover.
NOTE: This grease will ensure that the top bearing is

sufficiently lubricated during operation.
20. Place determined shim pack (2, Figure 37) on bearing

retainer (1).
Figure 37
20
21. Install bearing retainer (1, Figure 38) and shims to circle
reverse case cover (2) with six washers and bolts (3).
Tighten bolts to 32 Ibf ft (4.4 kgam).
Figure 38
22. Install circle reverse worm to motor coupling (1,

Figure 39) on worm.
Figure 39
23. Secure new mounting plate gasket (not shown) and

mounting plate (3, Figure 40) to circle reverse case (5)
with six washers and bolts (4).
24. Secure new motor gasket (not shown) and circle reverse
motor (2, Figure 40) to mounting plate (3) with two flat
washers and bolts (1). Tighten bolts to 110 Ibf ft
(15.2 kgam).
NOTE: Apply Loctite #518 to bolts threads to prevent oil

leaks.
Figure 40
21
25. Add proper gear oil to circle reverse case until oil comes
out of oil level check hole on side of circle reverse case.
Add oil through fill plug hole on top of circle reverse case.
(1, Figure 41) Level check plug hole; (2) fill plug hole;
install level check after proper oil level is reached.
NOTE: Refer to Operation and Maintenance Manual for

proper oil specification.
26. Breather installs in case where plug (3, Figure 41) is

shown. Breather must always be clean and in serviceable
condition prior to installation.
Figure 41
27. Install fill plug (1, Figure 42) in top of circle reverse case
(2).
Figure 42
22
SHOP MANUAL F-l 1.80K
RI
TANDEM CASE
(SINGLE AND DOUBLE STRAND CHAINS)
GD530A-1 200417 & Up

GD530AW-1 200417 & Up
GD650A-1 200417 & Up
GD650AW-1 200417 & Up
GD670A-1 200417 & Up
GD670AW-1 200417 & Up
CAUTION

ALL JACKING, HOISTING AND GENERAL WORKSHOP


INJURY.
FOR TABLE OF CONTENTS SEE BACK OF COVER.
0594
METRIC CONVERSIONS
TABLE OF CONTENTS
CONTENTS PAGE
LOCATION ON MACHINE ........................................ . 2

DESCRIPTION ................................................ . 2
FINAL DRIVE PLANETARY/NON-PLANETARY IDENTIFICATION ........ . 5
Part Number Tag ........................................ . 6
Physical Measurement of Tandem Case ........................ . 6
SPECIFICATIONS ............................................. . 7
SERVICE DIAGNOSIS .......................................... . 7
SERVICE/SPECIAL TOOLS ...................................... . 8
WHEEL KNOCKER TOOL ..................................... . 9
AXLE LIFTING TOOL ........................................ . 10
AXLE ROLLING TORQUE TOOL ................................ . 11
SPREADER BAR AND CHAINS ................................. . 12
TOLERANCES ................................................ . 13
LUBRICANTS AND SEALANTS .................................... . 13
SPECIAL TORQUES ............................................ . 13
TESTSANDADJUSTMENTS ..................................... . 13
ROADTESTING ............................................ . 13
SERVICING .................................................. . 14
REMOVAL ................................................ . 14
DISASSEMBLY ............................................. . 17
CLEANING AND INSPECTION ................................. . 18
REASSEMBLY ............................................. . 20
INSTALLATION ............................................. . 22
1
LOCATION ON MACHINE
The tandem cases are located on each end of the rear axle assembly.
DESCRIPTION
The service of the tandem case is the same whether the grader is equipped with a planetary or non-planetary
reduction axle. Planetary or non-planetary reduction only means the tandem case will have a single or double
strand chain.
‘,4 13
r-
‘\\“\, 16
\
I \ \ 127
‘r
i. 11
\ .
5648
FYgure 1 EXPLODED VIEW OF TANDEM DRIVE CASE WITHOUT PLANETARY FINAL DRI
2
LEGEND FOR TANDEM DRIVE CASE WITHOUT PLANETARY FINAL DRIVE
orientation to each other while servicing the tandem drive case. Some components mentioned during service
1. NUT, AXLE 18. SHAFT WELDMENT - FRONT

2. WASHER, LOCKING 19. CHAIN - DOUBLE STRAND
3. WASHER 20. .LINK, CONNECTING
4. WHEEL .LINK, ROLLER
5. KEY 21. COVER, ACCESS
6. BOLT 22. WASHER, FLAT
7. WASHER, FLAT 23. BOLT
8. RETAINER, BEARING 24. BOLT
9. SHIM - 0.030 In. (0.762 mm) - CORAL 25. WASHER, FLAT
SHIM - 0.015 In. (0.381 mm) - PINK 26. COVER, ACCESS
SHIM - 0.005 In. (0.127 mm) - BLUE 27. BREATHER VALVE ASSEMBLY
SHIM - 0.003 In. (0.076 mm) - GREEN 28. BUSHING, REDUCER
SHIM - 0.002 In. (0.051 mm) - RED 29. ADAPTER, PIPE
10 SEAL, OIL 30. PLUG, MAGNETIC
11. BOLT 31. CASE, TANDEM - L.H.
12. WASHER, FLAT CASE, TANDEM - R.H.
13. HOUSING, TANDEM 32. .STEP - R.H. ONLY
14. GASKET, LIQUID - 300ML CARTRIDGE 33. .STEP - R.H. ONLY
15. CUP, BEARING
16. CONE, BEARING
17. SHAFT WELDMENT - REAR
Figure 2 EXPLUutU VIEW OF TANDEM DRIVE CASE WITH PLANETARY FINAL DRIVE
4
LEGEND FOR TANDEM DRIVE CASE WITH PLANETARY FINAL DRIVE
orientation to each other while servicing the tandem drive case. Some components mentioned during service
1. NUT, AXLE 17. SHAFT WELDMENT - REAR

2. WASHER, LOCKING 18. SHAFT WELDMENT - FRONT
3. WASHER 19. CHAIN - SINGLE STRAND
4. WHEEL 20. .LINK, CONNECTING
5. KEY 21. COVER, ACCESS
6. BOLT 22. WASHER, FLAT
7. WASHER, FLAT 23. BOLT
8. RETAINER, BEARING 24. BOLT
9. SHIM - 0.030 In. (0.762 mm) - CORAL 25. WASHER, FLAT
SHIM - 0.015 In. (0.381 mm) - PINK 26. COVER, ACCESS
SHIM - 0.005 In. (0.127 mm) - BLUE 27. BREATHER VALVE ASSEMBLY
SHIM - 0.003 In. (0.076 mm) - GREEN 28. BUSHING, REDUCER
SHIM - 0.002 In. (0.051 mm) - RED 29. ADAPTER, PIPE
10. SEAL, OIL 30. PLUG, MAGNETIC
11. BOLT 31. CASE, TANDEM - L.H.
12. WASHER, FLAT CASE, TANDEM - R.H.
13. HOUSING, TANDEM 32. .STEP - R.H. ONLY
14. GASKET, LIQUID - 300ML CARTRIDGE 33. .STEP - R.H. ONLY
15. CUP, BEARING
16. CONE, BEARING
The tandem case is the final drive line reduction point. By means of double or single strand chains the tandem case
transmits power from the rear axle assembly output shafts to the tandem case axle and sprocket assemblies.
The tandem cases are allowed to pivot independently of each other on the rear axle. This allows the tires to remain
in contact with the ground on uneven train. Stop blocks are welded to the tandem case weldment to limit the total
oscillation (pivoting) action of each case.
FINAL DRIVE PLANETARY/NON-PLANETARY IDENTIFICATION
A final drive with or without planetary reduction, can be easily identified without removing any access covers or
other components by using one of two methods.
Part Number Tag
A part number tag (Figure 3) is located on the front side of

the R.H. axle mounting pad. The pat-t number stamped into
this tag indicates the version of axle that is installed.
P/N 1277 411 H91 = Non-Planetary Axle

P/N 1277 412 H91 = Planetary Axle
Physical Measurement of Tandem Case
Measure the distance from the outside of the axle bearing housing to the end of the tandem case.
Planetary Reduction Axle = 1.500 In. (38.100 mm) (Figure 4)
Non-Planetary Axle = 2.000 In. (50.800 mm) (Figure 5)
The difference in chain pitch from a planetary reduction final drive to a non-planetary, causes the axles to be closer
together or farther apart. For that reason the distance from the outside of the axle bearing housing to the end of
the tandem case will be different.
NOTE: The tandem case has the same overall length for both a planetary or non-planetary final drive.
A planetary reduction axle uses a single strand chain. A non-planetary axle uses a double strand chain.
1639! i 16396
igure 4 PLANETARY REDUCTION FINAL DRIVE :igure 5 NON-PLANETARY FINAL DRIVE
6
SPECIFICATIONS
Non-Planetary Reduction Tandem Case;

Spiral Bevel Ratio ......................................................... 4.364 : 1
Tandem Case Ratio ........................................................ 4.091 : 1
Total Final Drive and Tandem Ratio ........................................... 17.853 : 1
Centerline to Centerline of Axle and Sprockets ........................ 60.964 In. (1548.486 mm)
Planetary Reduction Tandem Case;

Spiral Bevel Ratio ......................................................... 4.364 : 1
Planetary Ratio ........................................................... 3.714 : 1
Total Final Drive Ratio ..................................................... 16.208 : 1
Tandem Case Ratio ........................................................ 1.100 : 1
Total Final Drive and Tandem Ratio ........................................... 17.829 : 1
Centerline to Centerline of Axles and Sprockets ....................... 61.956 In. (1573.682 mm)
Another item to note is that the tandem case axles for units with S/N 100477 thru 199999, have a different number
of teeth cut in them, then units S/N 200000 & Up.
Planetary Reduction Tandem Case Axle

S/N 100477 thru 199999 = 21 Teeth
S/N 200000 & Up = 22 Teeth
Non-Planetary Tandem Case Axle

S/N 100477 thru 199999 = 43 Teeth
S/N 200000 & Up = 45 Teeth
SERVICE DIAGNOSIS
PROBLEM POSSIBLE CAUSE CORRECTION
Excessive noise. Misalignment of sprockets. Since misalignment introduces

abnormal loading and wear,
alignment must be checked to
maintain normal drive conditions.
Inadequate lubrication. Improve or correct lubrication

system to insure that a proper
amount of lubrication is available
at the pin/bushing contact areas.
Worn or incorrectly installed Correct as soon as possible as

bearings. worn bearings will misalign the
entire drive system.
Worn chain or sprockets. Replace chain and if necessary

the sprocket.
Obstruction in chain travel. Remove obstruction in chain path.
Tight chain joints. Remove or repair stiff links.
Heavy and pulsating load. Reduce load.
Chain drive running hot. Volume of lubricant not sufficient. Increase volume of oil to be
consistent with good maintenance
practices.
Chain continually contacting an Remove obstruction and protect

obstruction. chain from unnecessary
vibrations.
Chain climbing or jumping Worn chain or sprockets. Replace chain and sprockets if
sprocket teeth. necessary.
Material build up in sprocket tooth Remove material build- up so that

pockets. chain engages properly with
sprocket teeth.
Chain stiffens, starts to whip. Worn chain or sprockets. Replace chain and sprockets if
necessary.
One or more stiff chain joints. Remove or repair stiff links.
8
PROBLEM POSSIBLE CAUSE

I CORRECTION
Link plate fails. Pulsating drive conditions can If possible, eliminate cause of
also initiate link plate failure. pulsations. Check for excessive
slack indicating worn chain
sprockets: replace if necessary.
Roller link plates are worn. See Wear pattern (A) is usually Sprocket and shaft alignment
(Figure 6). caused by drive misalignment. should be checked and corrected.
Wear pattern (B) is usually Replace chain.

caused by the chain rubbing
against the casting or some
obstruction.
16392
Figure 6
SERVICE/SPECIAL TOOLS
The following is a comprehensive listing of service/special tools use to perform the overhaul of this component. For
manufacturing details see Section 2, “Special Tools.”
Wheel Knocker Tool

Axle Lifting Tool
Axle Rolling Torque Tool
Spreader Bar and Chains
WHEEL KNOCKER TOOL
The wheel knocker (Figure 7) is used to remove the tire and wheel assemblies from the tandem case axles.
WELD ALL AROUND WITH

MILD STEEL ROD. \
NUT
3” DIA. x 6” LG. MILD STEEL BAR

15166
The wheel knocker tool is used to free the taper axle shaft
from the wheel. Using tire tongs, sling tire (1, Figure 8).
Install wheel knocker tool (2) on axle (4). Strike wheel
knocker tool with sledge hammer to free wheel (3) from
taper of axle.
Figure 8
10
AXLE LIFTING TOOL
The axle lifter tool (Figure 9) is used to remove the axles from the tandem case.
D-60539 NUT
l/4” x l/2” x 16” MILD STEEL

WELD BAR TO NUT USING BAR. BEND BAR TO FIT
MILD STEEL ROD NUT AS SHOWN.
rlgure Y ~n~t LIP I II~ I UUL
The axle lifting tool (1, Figure 10) is installed on the end of
the axle (2). Then using a suitable lifting device, the axle
can then be lifted out of the tandem case (3).
I 1 1637:
Figure 10 AXLE LIFTING TOOL INSTALLED 01

AXLE
11
AXLE ROLLING TORQUE TOOL
The axle rolling torque tool (Figure 11) is used to obtain the proper preload on the tandem case axle bearings.
D-60539 NUT
WELD SOCKET, BAR

AND NUT TOGETHER,
USING MILD STEEL
ROD.
3/8” DRIVE
SOCKET
l/4” x l/2” MILD STEEL

BAR CUT TO FLAT TO
FLAT ON NUT.
Figure ii nn~t HULLII~ I uncut I UUL
The axle rolling torque tool (1, Figure 12) is installed on the
end of the axle (2). Then using a 0 - 100 Ibf ft (0 -
13.8 kgam) dial indicator and/or bending bar torque wrench
measure the rolling torque.
NOTE: Do not use a clicker type torque wrench.
Figure 12 AXLE ROLLING TORQUE TOOI

INSTALLED ON AXLE TO OBTAIN ROLLING
TORQUE
12
SPREADERBARANDCHAINS
Shown here are manufacturing details for the spreader used to hold chains apart while removing and installing axle
assembly.
r (4) 0.125” HOLES

2.000” (TYP.1
e r1.500” (REF.)
..
l-l/Z x 1 l/2
“11:
x 3/16” ANGLE
4f
0.7’50” (TYP.1
0.500” (TYP.1
15853
Figure 13 MANUFACTURING DETAILS FOR SPREADER BAR
Figure 14, shows how the spreader bar should be attached

between chains.
Two chains 17 Ft. (5.18 m) long with 0.375 In. (9.525 mm)
links are required.
NOTE: Spreader bar should be notched to receive

0.375 In. (9.525 mm) chain link. Both ends of
spreader must be moused (locked) to chain, 6 Ft.
(1.83 m) from lifting eye(s). Chains must have a
lifting capacity of not less than 2 Tons (1.81 Mg).
A piece of wire passed through the two drilled holes and

twisted will hold chain in position in spreader bar.
15854
!gure 14 SPREADER BAR AND CHAIP
ARRANGEMENT
13
TOLERANCES
The following is a comprehensive listing of tolerances allowed during overhaul of this component.
LUBRICANTS AND SEALANTS
The following is a comprehensive listing of lubricants and sealants used during overhaul of this component.
Loctite Grade 518

Loctite Grade 592
Permatex #2 or equivalent
SPECIAL TORQUES
The following is a comprehensive listing of special torques used during overhaul of this component.
Tandem Housing to Tandem Case Weldment ................................. 70 Ibf ft (9.7 kgam)

Wheel Bearing Retainer to Tandem Housing .................................. 70 Ibf ft (9.7 kgam)
Tandem case to Final Drive ....................................... 150 Ibf ft dry (20.7 kgam dry)
Axle Nuts to Axle and Sprocket Weldment ................................ 1950 Ibf ft (269.7 kgam)
Tandem Case Axle Rolling Torque ................................. 20 - 40 Ibf ft (2.8 - 5.5 kgam)
ROAD TESTING
After the tandems and final drive are reinstalled, the grader must be road tested to ensure that the tandems, final
drive and brakes are functioning properly, before returning unit to service.
Drive the unit forward and backward approximately 20 Ft. (6.10 m), applying the brakes to bring the unit to a hard
stop. Do this ten times and recheck 1950 Ibf ft (269.7 kgam) torque on axle nuts. Repeat this procedure until axle
nut does not tighten any more. This procedure ensures that the tapered axle and wheel assembly are seated to
each other prior to bending tab on lock washer.
A WARNING! Lock washer tabs: The axle nuts must be retorqued

operation and lock washer tabs bent to secure them in position.
after several minutes of
Recheck all oil levels.
14
SERVICING
installation of the tandem cases.
REMOVAL
1. Park grader where both tandems and all four rear tires are within reach of a 2 Ton lifting device. Position
moldboard crossways under grader resting solidly on ground. Shutdown engine. Disconnect (-) negative battery
cables from batteries to prevent accidental starting of unit.
2. Place a IO Ton jack (1, Figure 15) under the rear of

each tandem case (2). Place adequate blocking or
support stand (3) under the rear of the frame (4) to
support unit when jacks are removed. Remove jacks.
NOTE: With heel of moldboard positioned in front of

rear tires, extending one lit? cylinder at a time
will a/so tend to raise the rear of the frame, to
place blocking under it. DO NOT support grader
with moldboard.
Figure 15
3. Bend tab on axle shaft nut lock washer (1, Figure 16)
back.
4. Remove axle nut (2) lock washer and washer (3) from
axle (4).
NOTE: If the grader is equipped with wheel weights,

they should be removed to help gain access to
lock washer and axle nut.
NOTE: On units with Serial Number 200925 & Up the

ax/e nut was changed to a self-locking nylon
insert nut. The lock washer was eliminated at
this time. The “f/at” on the axle shaft was also
removed with the introduction of the self-locking
I
nut. The self-locking nuts CAN NOT used on Figure 18
ax/es with the “f/at. ”
15
5. Using tire tongs, sling tire (1, Figure 17). Install wheel
knocker tool (2) on axle (4). Strike wheel knocker tool
with sledge hammer to free wheel (3) from taper of
axle.
NOTE: Make sure that wheel knocker tool is tight

against end of axle while hitting it with hammer.
If the knocker is not tight, the axle threads will
absorb the impact causing possible damage to
them. Placing a small washer between the end
of the axle and wheel knocker tool will help
ensure that the knocker is against the axle. See
Section 2, Special Tools for manufacturing
details of wheel knocker tool.
L-1 16375
Tire must have solid contact with the ground. ‘igure 17

This can be accomplished by pivoting the
tandem case with a jack.
6. After wheel is free from the tapered portion of the axle, carefully remove the wheel knocker tool, key and tire
from axle.
7. Repeat this procedure for remaining wheel and tire assemblies. Mark all locations of tires for reassembly.
8. Place jack(s) and blocking (1, Figure 18) under tandem

case (2). Remove drain plug (3) from side of case.
Drain and discard old oil. Reinstall drain plug.
NOTE: Tandem case holds approximately 8.7 U.S.

Gallons (32.9 0).
9. Remove four side access hole covers (4) and two top
access covers (5) from tandem case.
1637;
‘igure 18
16
10. Position two washers (1, Figure 19) (previously

removed during Step 4) on axle (2).
11. Install two axle shaft nuts (3) and rotate axle assembly
until master link (4) is accessible through side access
hole.
NOTE: Rotation of final drive input shaft will also move

master link into position.
16378P
Figure 19
12. Remove master link (1, Figure 20) from chain (2).
NOTE: There are two different types of chains used in

the tandem case. A double strand chain is used
with a non-planetary axle. Single strand chain
is used with a planetary reduction axle. The
master links and components for these chains
are shown in Figure 21 and Figure 22.
13. Remove axle shaft nuts (3, Figure 19) and washers (1)
from axle.
Figure 20
16381
‘igure 21 DOUBLE STRAND CHAIN MASY Figure 22 SINGLE STRAND CHAIN MASTER LINI
_INK (NON-PLANETARY AXLE) (PLANETARY REDUCTION AXLE)
17
14. Position two jacks under tandem case (1, Figure 23) so
that it will remain level.
15. Using a 2 ton (1,814 kg) lifting device, sling tandem

case as shown.
16. Remove twenty-four bolts and hardened washers that

secure tandem to final drive.
NOTE: Seven bolts at top of final drive can not be

removed until the tandem case is separated
from the final drive.
17. Repeat preceding removal steps for the remaining

tandem case.
‘igure 23
18
DISASSEMBLY
lgure 24
1. Remove six bolts (6, Figure 24) and hardened washers (7), bearing retainer (8) and shims (9) from tandem
housing (13). Remove oil seal (10) from retainer if necessary.
2. Remove twelve prevailing-torque bolts (11) and hardened washers (12) and tandem housing (13) from tandem
case weldment (31). Remove outer bearing cup (15) from tandem housing if necessary.
3. Using axle lifting tool, remove axle and sprocket weldment (17 and/or 18) from tandem case weldment (31).
Remove two bearing cones (16) from axle if necessary.
NOTE: See Section 2, Special Tools for manufacturing details of axle lifting tool.
4. Remove inner bearing cup (15) from tandem case weldment (31) if necessary.
5. Repeat all disassembly steps for remaining axles.
6. Remove breather (27), reducer bushing (28) and pipe adapter (29) from each tandem case weldment (31).
19
Some of the following information may not apply to the particular component
that you are servicing.
A. Clean all metal parts thoroughly using a suitable cleaning fluid. It is recommended that parts be immersed in

B. For bearings that can be removed, soak them in a suitable cleaning fluid for a minute or two, then remove
C. Carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks to determine condition. Do not
installation.
D. It is more economical to replace oil seals, O-rings, sealing rings, gaskets and snap rings when unit is
20
E. If available, use magna-flux or similar process for checking for cracks that are not visible to the eye. Examine
F. Inspect bores and bearing surfaces of cast parts and machined surfaces for scratches, wear, grooves and dirt.
G. Sprockets should be checked for evidence of chain climbing on the teeth. If an excessive amount of climbing
is noticeable, sprockets should be replaced.
21
REASSEMBLY
1. Install inner bearing cup (15, Figure 25) in tandem case weldment (31), if removed at disassembly.
2. Heat two bearing cones (16) in hot oil. After bearings are thoroughly heated, install them on axle and sprocket
weldment (17 and/or 18). When bearing cones have cooled, use a suitable driver to ensure that they are
properly seated.
3. Using axle lifting tool, position axle and sprocket weldment (17 and/or 18) in tandem case weldment (31).
NOTE: See Section 2, Special Tools for manufacturing details of axle lifting.
22
4. Prime and coat mating surfaces of tandem housing (13) and tandem case weldment (31) with Loctite Grade
518. Secure housing to case with twelve hardened washers (12) and prevailing-torque bolts (11). Torque to
70 Ibf ft (9.7 kg*m).
NOTE: Thoroughly clean surface to be sealed with degreasing solvent. Apply primer “At” (spray can-
accelerator) liberally to one surface to shorten curing time. Apply gasket-sealant as required to other
surface. Assemble without excessive lateral movement.
5. Install outer bearing cup (15) in tandem housing (13), if removed at disassembly.
6. To obtain proper preload of bearings, position a 0.060 In. (1.524 mm) thick shim pack, and wheel bearing
retainer (8) (without oil seal), on tandem housing (13). Install three hardened washers (7) and bolts (6) 120”
apart and torque evenly to 70 Ibf ft (9.7 kg*m), while turning axle and sprocket in both directions to be sure
bearings are seated properly.
NOTE: Shims come in 0.030 In. (0.762 mm) (CORAL), 0.015 In. (0.381 mm) (PINK), 0.005 In. (0.127 mm)
(BLUE), 0.003 In. (0.076 mm) (GREEN), and 0.002 In. (0.051 mm) (RED) sizes. If combination of these
shims do not match the desired thickness, go to the closest, higher combination.
7. Install axle rolling torque tool on end of axle shaft. Then using a dial indicator torque wrench measure the rolling
torque. Rolling torque must be 20 - 40 Ibf ft (2.8 - 5.5 kgam).
NOTE: Do not use a clicker type torque wrench.
NOTE: See “Special Tools” for manufacturing details of axle sprocket rolling torque tool.
8. If rolling torque is not with in limits, add or subtract shims to shim pack to obtain proper rolling torque.
9. Remove two bolts (6) hardened washers (7) and retainer (8) from housing (13) after shim pack value is
determined.
10. Coat O.D. of oil seal (10) with Permatex #2 or equivalent. Press oil seal into bearing retainer (8).
11. Position shim pack (9) (Determined in Step ?) and wheel bearing retainer (8) on tandem housing (13). Install
six hardened washers (7) and bolts (6). Torque bolts to 70 Ibf ft (9.7 kgam).
12. Install pipe adapter (29), reducer bushing (28) and breather (29) in each tandem case weldment (31). Coat
threads of pipe adapter engaging tandem case weldment with Loctite Grade 592.
23
INSTALLATION
1. Prepare mating surfaces of tandem case (1, Figure 26)

and final drive with Loctite Grade 518, following
manufacturer’s directions.
NOTE: Thoroughly clean surface to be sealed with

degreasing solvent. Apply primer “N” (spray
can-accelerator) liberally to one surface to
shorten curing time. Apply gasket-sealant as
required to other surface. Assemble without
excessive lateral movement.
2. Apply Loctite Grade 518 to all bolt threads.
3. Install seven of the hardened washers and bolts that

secure the final drive and tandem case together, into
the tandem mounting sleeve. With the seven bolts in a Figure 28
row, rotate the sleeve until they are located at the top
of the sleeve under the frame.
4. Using a 2 Ton lifting device, sling tandem case as showt I.
5. Position the tandem case against the final drive assembly, aligning the sleeve with the case. Install the
remaining seventeen hardened washers and bolts to secure tandem to final drive.
NOTE: Torque all twenty-four bolts to 150 Ibf fi (20.7 kgom).
6.
A WARNING! Position jacks under tandem case to prevent rocking.
Install chains into tandem case by lowering them over

the axle sprockets and bringing them up over final drive
sprockets (Figure 27).
a:
I
1516
Figure 27
24
7. Position two washers (1, Figure 28) on axle (2).
8. Install two axle nuts (3) and rotate axle assembly until
master link can be installed through side access hole.
9. Draw both ends of chain together using chain puller.
NOTE: Rotating the final drive input shaft will position

chain so that master link may be installed
through side access hole.
‘igure 28
10. Install master link (1, Figure 29) in chain (2) with cotter
pin side towards center of tandem case.
NOTE: There are two different types of chains used in

the tandem case. A double strand chain is used
with a non-planetary ax/e. Single strand chain
is used with a planetary reduction axle. The
master links and components for these chains
are shown in Figure 30 and Figure 31.
11. Remove axle nuts (3, Figure 28) and washers (1) from
axle (2).
1637s
‘igure 29
16361
‘igure 30 DOUBLE STRAND CHAIN MASY ‘igure 31 SINGLE STRAND CHAIN MASTER LINI
_INK (NON-PLANETARY AXLE) PLANETARY AXLE)
25
12. Install four side access hole covers (4, Figure 32) and
two top access hole covers (5) on tandem case.
NOTE: Seal access covers with Loctite Grade 518,

following manufacturer’s instructions.
13. Be sure drain plug (3) is securely in place and fill

tandem case (2) with 8.7 U.S. Gallons (32.9 a) of oil.
Refer to “Operator’s Manual” for proper lubricant and
specification.
NOTE: Apply Loctite Grade 592, to drain plug and oil

level plug.
14. Leave jack and blocking (1) under tandem case.

‘igure 32
15. Using tire tongs, sling tire. Position wheel (1, Figure 33)
on axle (2). Align keyways and install key. Install
washer (3), lock washer (4) and axle nut (5) on axle.
NOTE: Torque axle nuts to 1950 Ibf ft (269.7 kgam).
NOTE: On units with Serial Number 200925 & Up the

axle nut was changed to a self-locking nylon
insert nut. The lock washer was eliminated at
this time. The “flat” on the axle shaft was also
removed with the introduction of the self-locking
nut. The self-locking nuts CAN NOT used on
axles with the “flat. ”
16. Do not bend lock tabs at this time. The unit must be
roaded then the nuts must be torqued again to ensure Figure 33
proper seating of tapers.
17. After roading and retorquing, bend up tab on lock washer (4) to secure nut (5) in place.
18. Remove blocking from under unit once the remaining tandem and tires are installed.
19. Perform “Road Testing” at this time.
26
SHOP MANUAL G-01 .I 3K
GEARBOX ASSEMBLY ADVANCED TO “R3”
(ALL WHEEL DRIVE)


CAUTION
ALL JACKING HOISTING AND GENERAL WORKSHOP


INJURY.
0695
METRIC CONVERSIONS
SHOP MANUAL SECTION G-01.13K
TABLE OF CONTENTS
CONTENTS PAGE
DESCRIPTION ........................................... . 1
SERVICE/SPECIAL TOOLS ................................. . 4
INSTALLATION OF TWO PIECE SEAL ...................... . 4
TESTSANDADJUSTMENTS ................................ . 10
FRONT WHEEL ALIGNMENT & TURNING RADIUS ADJUSTMENT . . 10
SERVICING ............................................. . 13
REMOVAL ........................................... . 13
DISASSEMBLY ........................................ . 17
CLEANING AND INSPECTION ............................ . 27
REASSEMBLY ........................................ . 29
INSTALLATION ........................................ . 40
DESCRIPTION
The concept of All Wheel Drive (AWD) graders was introduced in 1983.
This machine uses a hydraulic system and tandem drive system that has been field proven in the DRESSER
Graders. With front wheel assist, tractive effort of the machine is increased which means improved job production.
An electronic network samples rear wheel speed and controls a variable displacement piston pump. Flow from this
pump drives a piston motor in each front wheel gearbox assembly.
This gearbox assembly is a compact, low profile unit with double reduction gearing, a one way clutch for
overrunning in the forward direction, a hydraulic clutch pack for reverse drive and a hydraulic check valve motor
circuit for reverse overrun.
This assembly has many critical areas such as bearing adjustments, bolt torques, machining tolerances and maybe
the most important . . . CLEANLINESS!
Castings must be thoroughly washed before reassembling. See “Cleaning and Inspection” section of this manual
for complete instructions.
Bolts and mating threads must be degreased and dried where thread lock compound is used.
The gearbox oil must be filtered to 10 microns.
The purpose of this Shop Manual Section is intended to aid service personnel on DRESSER products. It includes
maintenance procedures for removal, disassembly, cleaning, inspection, reassembly and installation of the All
Wheel Drive Gearbox Assembly used on the models listed on the front cover of this manual.
Procedures presented here represent only one method or means available to service personnel for performing such
procedures.
Directives contained herein are not intended as substitutes for technical training, applicable experience, safety
codes and/or Local, State or Federal requirements.
NOTE: Check latest issue of applicable parts microfiche before ordering any replacement parts.
1 R3
15467
?gure 1 EXPLODED VIEW OF AWD GEAR BOX
2
The exploded view shown on the previous page and legend show here are to help identify parts and their
orientation to each other while servicing the AWD gear box. Some components mentioned during service procedure
may only be shown in this illustration.
1. BOLT 41. THRUST WASHER

2. LOCK WASHER 42. CLUTCH SPRING
3. SHIM 43. CLUTCH SLEEVE
4. BOLT 44. SEPARATOR PLATE
5. BEARING RETAINER PLATE 45. FRICTION PLATE
6. BEARING CUP 46. REVERSE CLUTCH HOUSING
7. BEARING CONE 47. PLAIN WASHER
8. BEARING SUPPORT 48. BALL BEARING
9. O-RING 49. BEARING SPACER
10. PISTON SEAL I.D. 50. RETAINING RING
11. PISTON SEAL O.D. 51. SPECIAL WASHER
12. PISTON 52. BULL GEAR
13. THRUST BEARING 53. ONE-WAY CLUTCH
14. BOLT 54. RETAINING RING
15. LOCK WASHER 55. SUN GEAR DRIVE SHAFT
16. PLAIN WASHER 56. GASKET
17. WELDMENT GUARD 57. BOLT
18. SPACER 58. OIL SEAL
19. PIPE PLUG R.H. ONLY 59. SHIM
20. PIPE PLUG L.H. ONLY 60. BEARING CONE
21. BOLT AND WASHER 61. BEARING CUP
22. AWD MOTOR 62. FRONT DRIVE WHEEL
23. O-RING 63. RING GEAR
24. SPRING DISC 64. ROLL PIN
25. RETAINING RING 65. PLANET PIN
26. BALL BEARING 66. O-RING
27. SENSOR R.H. ONLY 67. THRUST WASHER
28. BOLT L.H. ONLY 68. THRUST WASHER
29. JAM NUT L.H. ONLY 69. AWD PLANETARY HOUSING
30. FASTENER SEAL 70. NEEDLE BEARING
31. MOTOR PINION 71. SPACER
32. BEARING ROLLER 72. AWD PLANETARY HOUSING
33. DOWEL PIN 73. O-RING
34. GEAR CASE HOUSING 74. LOCK WASHER
35. WHEEL RETAINER 75. BOLT
36. STEERING ARM WELDMENT 76. MAGNETIC PLUG
37. BOLT 77. O-RING
38. BOLT 78. SELF-LOCKING SCREW
39. BOLT 79. BOLT
40. BOLT 80. LOCK WASHER
R3
SERVICE/SPECIAL TOOLS
The SEAL INSTALLATION TOOL P/N DR08-106 is used to install the two piece seal assembly. Refer to ‘Service
Tools Catalog” 1128-I 66-Rl , Section 8.
15277
igure 2
INSTALLATION OF TWO PIECE SEAL
Incorrect assembly of two piece seal assembly can result in toric ring to slip at one location, but not all around
causing the ring to twist resulting in uneven pressure which will cause galling, scoring and leakage. Other results
of improper installation may be cocked seals which results in a wobbling motion of the seal allowing dirt to enter.
R3 4
Remove any oil film, dust or other foreign matter from the toric rubber rings (2, Figure 3), and from the tramps (4
and 7) and lips (3 and 8) of both the rings (1) and housings (6). Use tri-chloroethane, and clean cloth or paper
towels for wiping.
IMPORTANT: Never permit oil to get on the toric rings or ramps before both sea/ rings are put together in their
final assembled position.
A
WARNING! Contains tri-chloroethane. Avoid prolonged skin contact. Avoid breathing vapors in
enclosed areas without adequate ventilation. Do not use open flame, welding operations or
other heated surfaces exceeding 900°F (482.2”(Z).
15267
Ygure 3
Put toric ring (2 Figure 4) on seal ring (l), at the bottom of seal ring ramp (7) and against lip (8).
NOTE: Make sure that toric ring (2) is straight on seal ring (I) and is not twisted. Be careful when you work on the
rubber toric ring. Nicks, cuts and scratches can cause leaks.
15268
Figure 4
R3
Put seal installation tool (9, Figure 5) ‘Special Tool Number DR08-106” onto seal ring (1) with toric ring (2). Lower
the rings into a container with tri-chloroethane until all surfaces of toric ring (2) are wet.
NOTE: Do not use stanosol, or any other liquid that leaves an oil film, or does not evaporate quickly.
15269
igure 5
With all surfaces of the toric rings (2, Figure 6) still wet, use the installation tool (9) to position the seal ring (1) and
the toric ring (2) squarely against the housing (5) as shown. Use sudden and even pressure to pop (push) the toric
ring (2) under the retaining lip (3) of the housing (5).
15270
I
Figure 6
R3 6
Check assembled height (A) (See Figure 7) in at least four places, 90” apart. The differences in height around the
ring must not be more than 0.039 In. (0.9906 mm).
15271
Figure 7
If small adjustments are necessary, do not push directly on seal ring (1, Figure 8) ; use installation tool (9).
15272
Figure 8
7 R3
Toric ring (2, Figure 9) can twist if it is not wet all around during installation, of if there are burrs or fins on the
retaining lip (3) of the housing (5).
NOTE: Misalignments, twists and bulges of the toric ring will cause seal failures. If correct installation is not
obvious, remove seal from housing and repeat installation steps.
IMPORTANT: Toric rings (2, Figure 9) must never&on the ramps of either sea/ rings (I) or sea/ ring housings
(5). To prevent slippage, wait a minimum of two minutes to let the tri-chloroethane evaporate
before further assembly. Once correctly in place, the toric ring must &I on the ramps only.
15273
Figure 9
Wipe the seal faces (6, Figure 10) of the seal rings (1) clean. Use a lintless cloth or paper towel. No particles of
any kind are permissible on the sealing surfaces. Even a small piece from a paper towel can hold the seal faces
apart and cause leakage.
Put a thin film of clean oil on the seal faces (6). Be careful not to get any oil on the rubber toric rings.
15274
Figure 10
R3 8
Make sure both housings (5, Figure 11) are in correct alignment and are concentric. Move the parts slowly and
carefully toward each other.
NOTE: Do not slam seals together. High impact can scratch or brake the seal components. Once in place, fasten
all parts tightly.
Figure 11
9 R3
FRONT WHEEL ALIGNMENT & TURNING RADIUS ADJUSTMENT
START POINT
The steering cylinders control how far the spindle assemblies are allowed to move. This movement in turn controls
the turning radius of the grader. The steering cylinders must be adjusted this way to obtain a proper turning radius
in both directions.
1. Steering cylinders to be equal length.
A. Factory production set at 24” overall retracted

All Wheel Drive, print # 158206
Non-All Wheel Drive, print # 157537
B. Field check - measurement from hex end of

steering cylinder piston rod behind lock nut to
center of grease fitting on ball socket assembly
must be 3 g/16”.
1) Loosen jam nut (1, Figure 12) on ball socket

assembly (2).
2) The steering cylinder ball socket assembly (with

jam nut installed) must be adjusted in the end Figure 12
of the piston rod (3) until 3.562 In. (90.475 mm)
can be measured from end of piston rod to center of grease fitting on ball socket assembly, as shown
in, Figure 12. This can be done by turning the piston rod.
3) Once the 3.562 In. (90.475 mm) adjustment is made, tighten the jam nut.
4) Repeat Steps 1 .B.l) thru 1 .B.3), for other steering cylinder.
PROCEDURE
1. Park grader on a “LEVEL” concrete surface. Make sure 1 F .

that the front tires are properly inflated to the same PSI.
Tires must be the same brand and size.
2. Using steering wheel and leaning wheel cylinder control

lever, position front wheels to that they are in the
straight ahead position and that the camber angle “X”
(Figure 13) is the same on both sides.
I
Figure 13
R3 10
3. Check and adjust front wheel “Toe In,” if necessary.
All Wheel Drive - 0.0 In. (0.000 mm)

Non-All Wheel Drive - 0.125 In. (3.175 mm)
A. Measure the distance between the wheels of the

grader on the same horizontal centerline as the
spindle axle. These measurements must be taken
at both the front and rear of the wheels (Figure 14).
NOTE: Do not measure on tires or tire rims. Due to

variances in tires, inaccurate measure-
ments can result.
B. NON-ALL WHEEL DRIVE AXLE ONLY: The 15359

measurement at the rear of the wheels should be ‘igure 14
approximately l/8” (0.12” f0.03”) more than the
front. If not, the tie rod will have to be adjusted to obtain proper toe-in.
C. ALL WHEEL DRIVE AXLE ONLY: On All Wheel Drive (AWD) front axles, there MUST BE ZERO TOE-IN.
Front and rear measurements MUST EQUAL.
D. If front wheels need alignment, loosen jam nut (1,

Figure 15) on both ends of the tie rod (2), at the
ball socket assembly (3).
E. The tie rod has R.H. threads on the R.H. end, and
L.H. threads on the L.H. end. This thread
combination allows the wheel alignment to be
adjusted by turning the tie rod.
F. Once the proper alignment is obtained, tighten the

jam nuts (1).
15729
Figure 15
11 R3
4. Synchronize steering cylinders:
A. Disconnect L.H. steering

cylinder ball stud assembly
r MATCH MARK
7
from L.H. steering arm.
B. Steer machine right so rod

end of disconnected L.H.
steering cylinder is extended
and both steering cylinders
are being bottomed by
hydraulic pressure.
C. Match mark rod end of L.H. EXAMPLE:

steering cylinder and ball stud
assembly, so that the number L.H. CYLINDER R.H. CYLINDER
of adjustment turns can be
3 TURNS TO SEAT. 1 - l/2 TURNS FOR
counted.
FINAL ADJUSTMENT.
D. With steering pressure holding
both cylinders bottomed,
adjust L.H. steering cylinder
ball stud, “IN” or “OUT” to
seat it fully in steering arm. DIVIDE BY TWO.
NOTE: Very carefully count

the number of full and 1 - l/2 TURNS FOR
partial turns. FINAL ADJUSTMENT.
NOTE: Record the direction

(,,,’ or “OLJY) of
ball stud turns.
E. Divide number of turns above

15935
by 2.
FigWe 16
NOTE: The result is the

amount of turns both steering cylinders must be adjusted from their “ORIGINAL POSITION.”
Direction of turns (“IN” or “‘OLJrl) from “ORIGINAL POSITION” for each cylinder is the same, as
required to seat ball stud in steering arm in Step 4.0 above.
F. Reset L.H. ball stud at l/2 amount of turns moved in Step 4.D, and re-assemble in steering arm.
G. Match mark rod end of R.H. steering cylinder and ball stud assembly, so that the number of adjustment
turns can be counted.
H. On R.H. steering cylinder, loosen ball stud to steering cylinder rod lock nut and adjust ball stud position by
turning cylinder rod the number of turns calculated in Step 4.E above.
NOTE: Make sure that direction piston rod is turned results in correct direction of ball stud movement
noted at Step 4.0.
5. Re-tighten all lock nuts.
R3 12
6. Measure from grease fitting to piston rod end on both cylinders to ensure measurements are equal. This
measurement may vary from the initial 3 g/16” setting.
7. Secure the R.H. and L.H. ball stud assemblies into position. Install plain washer and slotted nut to 170 Ibf ft
(23.5 kgam). If necessary, increase torque on nut to install cotter pin.
SERVICING
installation of the All Wheel Drive Gearbox.
REMOVAL
1. With the parking brake set, moldboard centered

crosswise under the machine and transmission in
neutral, raise front end of machine with the blade lift
cylinders.
2. Place suitable blocking/cribbing (1, Figure 17)

underneath the axle assembly (2) and lower machine
onto blocking.
A
WARNING! Use extreme caution when
positioning blocking under axle
assembly.
Figure 17
3. Using tire tongs and suitable lifting device, remove six

lug nuts (1, Figure 18) and rim clamps (2). Remove tire
and rim assembly (3) from axle.
Figure 18
13 R3
4. Tag, remove and plug hoses (1, Figure 19) to wheel

motor (2) and hose (3) from elbow.
Figure 19
5. Remove plastic tie straps (1, Figure 20) and quick

disconnect fitting to sensor assembly (2).
6. Remove and plug hose (3, Figure 20).
NOTE: On 830/850/870 mode/ units, the disconnect

fitting is located farther away from the sensor
than shown here.
Figure 20
7. Tag, remove and plug hose (1, Figure 21).
Figure 21
R3 14
8. Remove cotter pins (1, Figure 22), slotted nuts (2) and
flat washers from tie rod (3) and steering cylinder rod
end (4).
NOTE: On some ax/e assemblies, there may not be a

f/at washer under the slotted nuts.
Figure 22
9. Remove retaining ring (1, Figure 23) and cover plate

(2), from top and bottom of spindle assembly.
NOTE: Remove grease fitting from cover plate, if

necessary.
Figure 23
10. Drive roll pin (1, Figure 24) into center pin (2) until pin
can be felt bottoming against arm (3).
Figure 24
15 R3
11. Support gearbox assembly with suitable lifting device

and sling (3, Figure 25).
12. Drive spindle pin (1, Figure 25) through steering yoke
(2) and gearbox assembly (4).
13. Remove gearbox assembly from spindle yoke and

prepare it for disassembly.
NOTE: A thrust washer is located between gearbox

assembly arms and steering yoke at top and
bottom.
14. Once pin (1, Figure 25) is driven out remove roll pin (1,
Figure 24) from it.
Figure 25
15. Remove bushing (not shown) from steering yoke, if
replacement is necessary.
NOTE: When removing bushing pay attention to which side of the bushing is worn, so that when new bushing
is installed the split can be properly located.
16. Remove four bolts (1, Figure 26) and plain washers,
and steering arm weldment (2).
Figure 26
R3 16
17. Remove four bolts, lock washers and plain washers (1,
Figure 27) and motor guard weldment (2) including four
spacers (3) after weldment is removed.
Figure 27
18. Remove two bolts, hardened plain washers (1,

Figure 28) and motor (2) (including motor O-ring and
disc spring underneath).
NOTE: See appropriate Shop Manual Section for All

Wheel Drive Motor servicing.
Figure 28
DISASSEMBLY
1. Remove plug (I, Figure 29) with O-ring (2) from

planetary carrier and drain approximately 1 U.S. Gallon
(3.78 liters) of oil from assembly. Remove eight bolts
and lock washers (3), and planetary housing (4).
Figure 29
17 R3
2. Remove O-ring (1, Figure 30) from planetary housing

(2).
‘igure 30
3. To remove the planet gear (1, Figure 31), the roll pin (2)
must be driven into the planet pin (3) past the flange.
Remove pin with O-ring (4), planetary gear (l), two
thrust washers (5) and two special shaped thrust
washers (6).
NOTE: Be careful care when handling gear. There

are two rows of twenty-two needle bearings
(7) and a spacer (8) in each gear. Do not
lose them.
Figure 31
NOTE: If this is a R.H. wheel assembly, loosen lock nut and remove sensor assembly (Figure 32). If this is a
L.H. wheel assembly, remove bolt, seal and jam nut (Figure 33).
Figure 32 SENSOR ASSEMBLY (R.H. SIDE ONLY) Figure 33 PLUG ASSEMBLY (L.H. SIDE ONLY)
R3 18
4. Remove four bolts and lock washers (1, Figure 34) from - I
bearing cap (2).
I‘igure 34
5. Remove four bolts and lock washers (1, Figure 35) from
bearing support (2).
r
Figure 35
6. Insert two screwdrivers into slots in cap (1, Figure 36)

and pry off cap. Remove shims and O-ring from inside
cap.
Figure 36
19 R3
7. Remove three socket head bolts (1, Figure 37) and cap n
(2) with shims (3).
?gure 37
8. Using appropriate puller, remove bearing support

assembly (1, Figure 38).
NOTE: Care should be taken that bearing is not

dropped, damaged or lost.
Figure 38
9. Remove two bearing cups (1, Figure 39) and cones (2)
and O-ring (3) from bearing support (4).
NOTE: These are slip-fit bearings and should not

require a puller.
Figure 39
R3 20
10. Through hole “A” in bearing support (1, Figure 40) use
a drift punch to drive piston (2) out of it. Remove I.D.
seal (3) and O.D. seal (4) from piston.
Figure 40
11. Remove thrust bearing (1, Figure 41) from inside

housing (2)
Figure 41
12. Remove two bolts and lock washers (1 and 2,

Figure 42) from gear housing.
Figure 42
21 R3
13. Remove two remaining bolts (1, Figure 43). Remove

lock washers and reinstall at 180” apart., Engage
enough threads to prevent damage [approximately
0.375 In. (9.52 mm)]. Sling housing and raise housing
approximately 1.500 In. to 2 In. (38.1 mm to 50.8 mm)
above work surface. Strike bolt heads alternately until
gear housing is freed. Remove gear housing (3) from
wheel retainer (4).
NOTE: Be careful not to damage threads in gear

housing.
Figure 43
14. Remove gasket (1, Figure 44).
Figure 44
15. Remove motor pinion (1, Figure 45), ball bearing (2)
and retaining ring (3) from gear housing (4).
Figure 45
R3 22
16. Remove retaining ring (1, Figure 46) from pinion (2).
Press pinion from bearing (3).
Figure 46
17. CLUTCH PACK AND BULL GEAR
A. Remove three socket head bolts (1 Figure 47), and

thrust washer (2).
A
WARNING! Thrust washer is under
spring load.
I
Figure 47
B. Remove twelve clutch springs (1, Figure 48) from

reverse clutch housing.
Figure 46
23 R3
C. Remove clutch 1 sleeve (1, Figure 49) from inside

‘igure 49
D. Remove twelve separator plates and eleven friction

plates (1, Figure 50).
NOTE: There are two missing teeth in each friction

plate, not necessarily 180” apart. These
must be in line throughout installation.
Figure 50
E. Remove bull gear assembly (1, Figure 51) from

housing.
Figure 51
R3 24
F. Remove six socket head bolts (1, Figure 52)

securing bull gear (2) to clutch housing.
?gure 52
G. Remove reverse clutch housing (1, Figure 53) from

bull gear (2).
NOTE: It may be necessary to leave two bolts (1,

Figure 52) in housing 180” apart and tap
off reverse clutch housing.
Figure 53
H. Invert assembly and remove retaining ring. Press

sun gear shaft (1, Figure 54) from bull gear (2).
NOTE: Arrowpoints in direction that sun gear shaft

must be pressed from bull gear.
j~~~-,”.,j
Figure 54
25 R3
I. Remove one way clutch (1, Figure 55), from bull

gear (2).
NOTE: Remove outer ball bearing (3) as procedure

progresses. Do not damage bearing.
J. Slide bearing spacer (4, Figure 55) to one side of

gear hub. Press against spacer and remove bearing
(5). Retaining ring (6) is now accessible; remove
retaining ring (6). Press bearing (3) and special
washer (7) from bull gear.
Figure 55
18. RING GEAR AND WHEEL BEARING GROUP
A. Remove roller bearing (I, Figure 56) from retainer

housing (3). Remove eight bolts (2) and retainer
housing from front drive wheel (4).
Figure 56
B. Remove seal (I, Figure 57) from retainer housing.
NOTE: If unit is equipped with a two piece face

seal, second seal member must be
removed from front drive wheel. (See
“Installation of Two Piece Seal” in this
manual for proper installation).
Figure 57
R3 26
C. Remove shims (1, Figure 58), bearing cups (2)

cones (3) and ring gear (4) from wheel.
Figure 58
Some d the following information may not apply to the paffiedaf component that you afe sewieing.

27 R3
3. Carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks to determine condition. Do not
installation.
R3 28
REASSEMBLY
- IMPORTANT -
Prior to staring reassembly of gearbox, immerse clutch pack plates for the clutch pack in CLEAN
gearbox oil. Plates must soak for at least 30 minutes prior to installation.
NOTE: Thoroughly clean wheel, ring gear, and gearbox housing with solvent and blow dry before beginning the
assembly. It is extremely important that no contaminants be allowed to enter this unit.
Install seal (1, Figure 59) in retainer housing.
NOTE: See “Installation of Two Piece Seal” section of

this manual for installation instructions.
Figure 59
2. Install two ring gear bearing cups (1 and 2 Figure 60) in

wheel (3) with proper driver.
NOTE: The bearing cups must be fully seated in order

to properly adjust the preload on the bearings
when gear case half is installed.
Figure 60
29 R3
3. Install one outer bearing cone on shoulder of the ring

gear (1, Figure 61). With ring rear setting on table,
lower front drive wheel (2) into piston on bearing cone
and ring gear. Position inner bearing cone (3) on ring
gear. Make sure that the bearings are well lubricated
with clean oil so that they will adjust accurately.
4. The purpose of the following procedure is to achieve a

preload of 0.002 In. to 0.004 In. (0.0508 mm to 0.1016
mm) on the wheel bearings that were just installed.
This preload is controlled by a shim pack between the

ring gear and the retainer housing.
To determine the correct size of this shim pack you

must first determine the size of the gap between the ?gure 61
ring gear and the retainer housing as follows.
A. Install retainer housing (1, Figure 62) without seal

or shims. Install two bolts (2) in holes adjacent to
the depth micrometer measurement holes. Rotate
wheel to distribute torque while tightening bolts
evenly to 60 Ibf ft (8.3 kg*m).
B. Measure the depth from the retainer housing to the

face of the ring gear with a depth micrometer
through the two holes provided in the retainer
housing. Determine the average of these two
measurements. Record this average as
measurement “A.”
C. Remove the retainer housing and measure the

thickness of the housing next to the two depth
measurement holes (See Figure 63). Determine the Figure 62
average of these two measurements. Record this
average as measurement “B.”
D. Subtract measurement “B” from measurement “A.” Record this figure as measurement “C.”
E. Add 0.014 In. (0.3556 mm) to measurement “C.” This is the size of the shim pack required to achieve the
desired preload on the wheel bearings.
Measurement “A”
Measurement “B”
= Measurement “C”
+ 0.014” Constant
= Shim Pack Thickness
R3 30
F. Assemble the shim pack using 0.020 In., 0.007 In., and 0.005 In. (0.508 mm, 0.1778 mm, and 0.127 mm)
shims as necessary.
5. Install two piece seal on gear case inner half (See “Installation of Two Piece Seal” for proper installation).
6. Install retainer housing with shim pack.
7. Apply one drop of Loctite #242 to threads of each bolt. Install bolts and torque to 95 Ibf ft (13.1 kgam) while
rotating assembly to distribute torque.
Figure 63
31 R3
8. Place new gasket (1, Figure 64) on retainer housing (2)

over alignment dowel pins.
Figure 64
9. CLUTCH PACK AND BULL GEAR GROUP
A. After pressing one roller bearing (1, Figure 65) onto

the shaft, install special washer (2). Then install
shaft (3) into bull gear. Install retaining ring (4)
spacer (5), and press on second bearing (6).
Figure 65
B. Install one way clutch (1, Figure 66).
NOTE: There is one lip on the outside of the

clutch, and depending on which gear case
is being reworked, the lip will be installed
a way from the planetary gears for the R. H.
side and toward the planetary gears for the
L.H. side.
A simple way to tell if the one way clutch is

installed properly, is to turn the sun shaft in
the direction it is allowed to turn. On a R.H.
Gearbox it will turn in a clockwise direction.
On a L.H. Gearbox it will turn in a
counterclockwise direction.
Figure 66
R3 32
C. Install retaining ring (1, Figure 67)
Figure 67
D. Position reverse clutch housing (1, Figure 68) I

against bull gear (2).
Figure 66
NOTE: Coat threads of bolts with Loctite #242

compound before installation. Make sure
threads are clean and free of previous
compound and oil before applying new.
E. Invert assembly and attach reverse clutch housing

to bull gear (1, Figure 69) with six socket head bolts
(2). Tighten bolts to 31 Ibf ft (4.3 kg*m).
Figure 69
33 R3
F. Install motor pinion (1, Figure 70) in retainer

housing (2).
NOTE: Make sure pinion is seated in retainer

housing.
Figure 70
G. Install bull gear assembly (I, Figure 71) into

planetary assembly in wheel. Install clutch sleeve
(2).
IMPORTANT: Friction plates must be immersed
in gearbox oil for 30 minutes prior
to installation.
H. Install clutch sleeve. Install twelve separator plates

(3, Figure 71) and eleven friction plates (4) into the
NOTE: Install separator plate (3) first, then friction

plate (4). Then alternate between the two
until all are installed. If done properly there
will be a separator plate in first and last. Figure 71
There are two missing teeth in each friction
plate, not necessarily 180” apart. These gaps should be installed in line throughout installation.
Putting additional gearbox oil on plates when they are being installed, will also help prevent them
being damaged.

I. Install twelve clutch springs (1, Figure 72), thrust

plate (2) and three socket head bolts (3). Tighten
bolts to 9 Ibf ft (1.2 kgam).
Figure 72
R3 34
J. Install gear case housing (1, Figure 73) over

gasket, using alignment dowel pins for proper
alignment. Install four bolts and lock washers (2).
K. Tighten bolts to 115 Ibf ft (15.9 kg*m).
Figure 73
L. Press bearing (1, Figure 74) on pinion (2) and into

gear housing (3) at same time.
M. Install retaining ring (4).
Figure 74
N. Install disc spring (1, Figure 75) over pinion

assembly (2).
Figure 75
35 R3
0. Install I.D. piston seal (1, Figure 76) and O.D.

piston seal (2) on reverse clutch piston (3).
Figure 76
P. Lubricate piston seals and push piston (1,

Figure 77) into bearing support (2) until the outer
seal clears the lip. Install O-ring seal (3) on bearing
support outer lip O.D.
Figure 77
Q. Install two bearing cups (1, Figure 78) in bearing

support (2).
Figure 76
R3 36
R. Apply a light coat of petroleum jelly (or equivalent),

to the bottom side of reverse clutch piston (1,
Figure 79) and install thrust bearing (2).
‘igure 79
S. Carefully place bearing support (1, Figure 80) on

assembly, making sure thrust bearing stays in place
and orient housing so that hydraulic port (2) is
opposite the motor mount (3).
Figure 80

T. Install cap (I, Figure 81) with three socket head

bolts (2)
U. Alternately tighten socket head bolts to 35 Ibf ft

(4.8 kg*m).
NOTE: These bolts will seat bearings as they are

being torqued to proper value.
Figure 81
37 R3
v. Install four bearing retainer bolts and lock washers

(1, Figure 82).
W. Tighten bolts (1) to 24 Ibf ft (3.3 kgam) .
Figure 82
X. Install bearing cap (1, Figure 83) with O-ring, but

WITHOUT shims and WITHOUT bolts.
Y. Measure gap between cap and bearing support.

Add 0.002 In. (0.0508 mm) worth of shims to value
obtained. This will result in a 0.000 In. to 0.003 In.
(0.000 mm to 0.0762 mm) end play for bearings.
NOTE: Shims range in sizes of 0.005 In., 0.007 In.

and 0.020 In. (0.127 mm, 0.1778 mm, and
0.508 mm).
Z. After shim pack is established, insert shims and cap

with four bolts and lock washers. Tighten bolts to
13 Ibf ft (1.8 kg*m).
Figure 83
AA. In L.H. assemblies, install bolt seal, and jam nut

(Figure 84).
NOTE: Bolt should not protrude past inside

surface of housing.
\ 15275
Figure 84
R3 38
AB. In R.H. wheel assemblies reinstall sensor

assembly (Figure 85). With feeler gauge obtain
a 0.040 In. to 0.050 In. (1.016 mm to
1.270 mm) gap between the gear teeth and the
sensor pickup. DO NOT tighten the lock nut
more than 35 Ibf ft (4.8 kg*m).
NOTE: Refer to “Troubleshooting and

Adjustment Manual” for your unit for
proper final adjustment.
‘igure 85
10. PLANETARY GEAR ASSEMBLY
A. Using a liberal amount of grease to hold the needle

bearings in place, install two rows of twenty-two
needle bearings, (7, Figure 86) and a spacer (8) in
each planet gear (1).
B. Pick up in order, special washer (6), wave thrust

washer (5), planet gear (I), wave thrust washer (5)
and special washer (6). Position components in
carrier (See Figure 87)
C. Place O-ring (4, Figure 86) on planet gear pin (3)

and insert from the face of the carrier.
‘igure 86
NOTE: Orientation of special shaped washer (1,

Figure 87).
D. Turn the planet gear pin using screwdriver slot until

hole lines up with hole in carrier flange and insert
roll pin.
Figure 87
39 R3
E. Install O-ring (1, Figure 88) on planet carrier (2) and

install carrier assembly in to gear box. Install eight
bolts and lock washers (3).
F. Tighten bolts to 115 Ibf ft (15.9 kg*m).
Figure 88
INSTALLATION
1. Make sure motor disc spring is over the pinion bearing.

Install the pinion bearing and motor (2, Figure 89) with
O-ring using two bolts (1) and lock washers.
2. Tighten bolts to 58 Ibf ft (8.0 kgam).
NOTE: Make sure that motors are properly oriented.

Install “Port A” to the top side for R. H. gearbox.
Install “Port B” to the top side for L. H. gearbox.
Figure 89
3. Install the motor guard weldment (2, Figure VW, . . . ..I
spacers (3) using four bolts and lock washers

(1). Tighten bolts to 115 Ibf ft (15.9 kg*m).
4. Position gearbox assembly in place in spindle yoke.
Figure 90
R3 40
5. Install the steering arm weldment (2, Figure 91) for a

R.H. assembly or L.H. assembly using three 5/8”-11 x
4-l/2” Grade 8 bolts and one 5/8”-11 x l-1/2” Grade 8
bolt (1) and hardened plain washers. Tighten bolts to
165 Ibf ft (22.8 kg*m).
NOTE: Apply Loctite #242 to bolt threads. Use only

one drop per bolt.
6. Using a suitable lifting device and sling (3), position

gearbox assembly (4) into position.
NOTE: Place a thrust washer between gearbox

assembly arms and steering yoke at top and
bottom.
7. Align holes between thrust washers, gearbox assembly

and steering yoke. Drive center pin (1, Figure 92) in,
until roll pin hole in center pin aligns with roll pin hole in
gearbox assembly arm.
NOTE: Once center pin is installed, remove sling (3).
8. Drive roll pin (1, Figure 93) into center pin (2) until flush
with gearbox assembly arm (3).
Figure 93
41 R3
9. Install cover plate (2, Figure 94) and retaining ring (1)
in top and bottom of spindle assembly.
NOTE: Install new grease fitting in cover if removed at

disassembly.
Figure 94
10. Install tie rod (3, Figure 95), steering cylinder rod end
(4), with flat washers, slotted nuts (2) and cotter pin (1).
Tighten slotted nut to 170 Ibf ft (23.5 kg*m). If
necessary, increase torque on nut to install cotter pin.
NOTE: A f/at washer must be used under the slotted

nut. Install a f/at washer if one was not present
at disassembly.
Figure 95
11. Remove plugs and install hose (1, Figure 96) to position
tagged during removal.
Figure 96
R3 42
12. Remove plugs and install hose (3, Figure 97) in position
tagged during removal.
13. Install quick disconnect fitting to sensor assembly (2)

and fasten with two plastic tie straps (1).
NOTE: On 830/850/870 mode/ units, the disconnect

fitting is located farther away from the sensor
than shown here.
Figure 97
14. Remove plugs and install hoses (1 and 3, Figure 98) to

wheel motor (2) in positions tagged during removal.
Figure 98
15. Using tire tongs and suitable lifting device, install tire
and rim assembly (3, Figure 99) six rim clamps (2) and
lug nuts (1). Tighten lug nuts to 115 Ibf ft (15.9 kg*m).
Figure 99
43 R3
16. With the parking brake set, moldboard centered

crosswise under the machine, transmission in neutral,
raise front end of the machine with the blade lift
cylinders.
17. Remove blocking/cribbing (1, Figure 100) underneath

the axle assembly (2) and lower the machine to the
ground. Recheck torque of lug nuts.
A
NOTE:
WARNING! Use extreme care when
removing blocking from under axle.
Fill gearbox with approximately I U.S. Gallon

(3.78 liters) of oil. Refer to Operator’s manual
for proper oil specification.
Figure 100
R3 44

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SHOP MANUAL SECTION E-34.

LEGEND FOR LOCK/UNLOCK DIFFERENTIAL PUMP

1 HOUSING, REAR 8 KEY, WOODRUFF

2. Disconnect electrical connection to solenoid.

3. Remove adjustment bolt and hardware (1, Figure 2).

4. Loosen pivot mounting bolt (not shown) and remove

5. Remove pivot mounting bolt and hardware, and pump

6. Using a suitable puller, remove pulley assembly (1,

7. Remove two bolts (3, Figure 3) that hold pulley bushing

8. Remove three elbows (7, Figure 4) and tee (2).

1. Match mark rear housing (1, Figure 5) to front housing (11).

6. Remove retaining ring (16, Figure 5) from front housing (11).

CLEANING AND INSPECTION

1. Install two needle bearing (4, Figure 6) in front housing (11).

7. Install two needle bearings (4, Figure 6) in rear housing (1).

1. Attach control and relief valve (7, Figure 7) to mounting

2. Attach pump (4, Figure 7) to mounting bracket (5) with

NOTE: 77ghtenbolts to 25 Ibf ft (3.5 kgm).

3. Install three elbows (1, Figure 7) and tee (2). Orient

4. Attach pulley bushing (4, Figure 8) to pulley (1) with two

NOTE: ~ghfen bolts to 8 Ibf ff (7. I kg@

5. Press pulley assembly (1, Figure 8) with key (not shown)

6. Loosen pivot mounting bolt (not shown) and remove

7. Attach pump mounting bracket (4, Figure 9) to engine

8. Position drive belt (2, Figure 9) on pulley (3). Pivot

NOTE: Belt deflection should be from 0.25 - 0.375 In.

10. Connect electrical connection to solenoid.

TESTS AND ADJUSTMENTS

LOCK/UNLOCK DIFFERENTIAL RELIEF VALVE ADJUSTMENT

Connect a calibrated 3000 PSI (210.9kg/cm’) gauge to

Start engine and set engine speed control lever to 1000

Figure 10 LOCK/UNLOCK DIFFERENTIAL TEST

4. Set engine speed control lever to 2500 RPM, gauge

5. Adjust relief valve if necessary.

REAR AXLE COOLING SYSTEM

There is no pressure adjustment for the rear axle cooling system.

GD530 SERIES 200840 & Up

ALL JACKING, HOISTING AND GENERAL WORKSHOP EQUIPMENT

EXTREME CAUTION TO BE OBSERVED AT ALL TIMES TO PREVENT

SAFE WORKSHOP PRACTICES ARE A MUST.

FOR TABLE OF CONTENTS SEE PAGE 1

ILLUSTRATIONS SHOWN IN THIS MANUAL WERE TAKEN WHILE THE

KOMATSU DRESSER COMPANY 850 SOUTH STREET GALION, OH 44833

LEGEND FOR CIRCLE REVERSE SLIP CLUTCH

1 PINION SHAFT 15 O-RING

2.40” (60.9 MM)

MATERIAL: MILD STEEL

FiCJUre 2 C;IHC;Lt SLIP C;LU I GH tiAUtit I WWL

The circle slip clutch gauge tool (Figure 3) is used in

Circle Slip Clutch Gauge Tool (Part Number DRl l-901).

Orders for these tools should be placed with;

Telephone; l-800-328-6657 USA and Canada

2. Position a floor jack under circle slip clutch assembly

3. Remove six bolts and lock washers (1, Figure 4),

NOTE: Keep shim pack together for reassembly.

4. Remove lock nut and washer (1, Figure 5) from pinion

5. Slowly lower floor jack and remove circle slip clutch

1. Remove plug (1, Figure 6) from clutch housing cover

2. Remove O-ring (not shown) from plug (1, Figure 6).