D39E-1 Shop Manual

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

PRODUCT PUBLICATIONS INFORMATION
VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION
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MANUALS.
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DESCRIPTION FORM NUMBER
PARTS BOOK - PAPER:
ENGINE AND CHASSIS - D32E-1 & D32P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB004300

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SECTION INDEX
This shop manual includes information for locations, INTRODUCTION — SECTION 1

specifications, service/special tools, tolerances, pressures,
lubricants and sealants, special torques, tests and adjust- MISCELLANEOUS — SECTION 2
ments, assembly tips and service bulletin references for
various components of the machine. This shop manual is
— SECTION 4
divided into major sections. These sections are indexed by
title and divided by individual section index tab. To use this
shop manual, locate the section required and turn to that — SECTION 5
section index tab.
COOLING — SECTION 6
DRIVE TRAIN — SECTION 7
TORQUE CONVERTER — SECTION 7B
TRANSMISSION — SECTION 7C
STEERING DRIVE — SECTION 7E
SPROCKET DRIVE — SECTION 7F
ELECTRICAL — SECTION 8
— SECTION 9
HYDRAULICS — SECTION 10
PUMPS AND MOTORS — SECTION 10A
CONTROL VALVE — SECTION 10B
CYLINDERS — SECTION 10C
— SECTION 11
POWER — SECTION 12
— SECTION 13
UNDERCARRIAGE — SECTION 14
TRACK CHAIN — SECTION 15
MOUNTED EQUIPMENT — SECTION 17

INDEX TO SECTIONS
SECTION 1 - INTRODUCTION SECTION 7F - FINAL DRIVE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LOCTITE USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 2 - MISCELLANEOUS REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
METAL TYPE FACE SEALS . . . . . . . . . . . . . . . . . . . . . . 24
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CAPACITIES AND LUBES . . . . . . . . . . . . . . . . . . . . . . . 11 SECTION 8 - ELECTRICAL
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . 15 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 4 - BRAKES SECTION 10 - HYDRAULICS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SECTION 10A - PUMP AND MOTORS
BRAKE SUPPORT BRACKET . . . . . . . . . . . . . . . . . . . . 13 CHARGE AND SCAVENGE PUMP . . . . . . . . . . . . . . . . 2
BRAKE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 6 - COOLING SECTION 10B - CONTROL VALVE
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SERVICE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 10
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SYSTEM RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 7 - DRIVE TRAIN BLADE LIFT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 20
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 BLADE TILT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BLADE ANGLE OR RIPPER SECTION . . . . . . . . . . . . . 34
SECTION 7B - TORQUE CONVERTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SECTION 10C - CYLINDERS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 RIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 SECTION 12 - ENGINE
SECTION 7C - TRANSMISSION STANDARD VALUE TABLE . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 22 SECTION 14 - SUSPENSION
DIRECTIONAL (INPUT) SHAFT . . . . . . . . . . . . . . . . . . . 38 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 SERVICE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RANGE (OUTPUT) SHAFT . . . . . . . . . . . . . . . . . . . . . . 57 WEAR LIMIT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REVERSE IDLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 80 FRONT IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
MAIN REGULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . 83 TRACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
RANGE SELECTOR VALVE . . . . . . . . . . . . . . . . . . . . . 92 TOP IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
RATE OF RISE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 99 TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 METAL TYPE FACE SEALS . . . . . . . . . . . . . . . . . . . . . . 53
TRANS/STEERING VALVE . . . . . . . . . . . . . . . . . . . . 129 TRACK FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 TRACK SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SECTION 7E - STEERING DRIVE FRONT CROSSBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REAR RIGID BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TRACK FRAME ALIGNMENT . . . . . . . . . . . . . . . . . . . . 72
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SECTION 15 - TRACK CHAIN
BRAKE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 SPLIT LINK TYPE CHAINS . . . . . . . . . . . . . . . . . . . . . . . 2
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 30
MOUNTING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 SECTION 17 - MOUNTED EQUIPMENT
BRAKE/STEERING SHOES . . . . . . . . . . . . . . . . . . . . . . 38 C FRAME PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 C FRAME RUB BARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PLANET GEAR CARRIER . . . . . . . . . . . . . . . . . . . . . . . 46 ANGLING FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 C FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 BLADE BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 78
BRAKE CYLINDER VALVE . . . . . . . . . . . . . . . . . . . . . . 81
INTRODUCTION
SECTION 1
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SAFETY PRODUCT GRAPHICS AND LOCATION . . . . . . . . . 8
SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PIN AND SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE TOOLS AND PARTS . . . . . . . . . . . . . . . . . . . . . . . 11
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LOCTITE USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SURFACE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SETTING TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
APPLICATIONS AT LOW TEMPERATURES . . . . . . . . . . . . 13
WARNING
Refer to, read and follow all safety precautions in this SECTION. Failure to do so
may result in serious injury or death.
1-1
INTRODUCTION SAFETY PRECAUTIONS
AVOID ACCIDENTS
WORK SAFETY -- FOLLOW THESE RULES
A CAREFUL MECHANIC IS THE BEST INSURANCE AGAINST AN ACCIDENT
THIS SYMBOL IS USED THROUGHOUT THIS SHOP MANUAL TO CALL YOUR ATTENTION TO
INSTRUCTIONS CONCERNING PERSONAL SAFETY. OBSERVE AND FOLLOW THESE
INSTRUCTIONS. BE CERTAIN ANYONE OPERATING OR SERVICING THIS MACHINE IS AWARE
OF THESE RULES. FAILURE TO FOLLOW THESE RULES MAY RESULT IN INJURY OR DEATH.
GENERAL
Human error is a contributing factor in most equipment related injuries. Haste, carelessness and lack of training are the
primary causes of injuries. Most operating injuries occur because of excessive speed, loss of control, failure to observe
warning signs, slipping or falling while entering or dismounting, a lack of berms on roadways or piles, lack of a ROPS
or seat belt, or not watching in the direction of travel. Most maintenance injuries occur during welding or when using
hammers or wrenches. The most common faults are improper work position, a slipped tool, missed aim, a broken tool,
flying chips and/or no welding hood. Think before you act. A careful operator or maintenance person is the best
insurance against an accident.
Always wear proper safety equipment. Avoid wearing jewelry and loose fitting clothing; they could catch on moving parts
which could result in serious injury or death. Hard hat, sturdy rough soled work shoes or safety shoes, ear protectors,
reflective clothing, safety glasses and heavy gloves may be required. Consult your employer for specific safety
equipment requirements.
Each job site and application may have personal safety requirements. Carefully evaluate your particular application and
machine for equipment such as warning lights, side view and rear view mirrors, back up alarms, fire extinguisher,
rotating beacons and additional lights. If in doubt, contact your distributor.
The machine should be equipped with a fully charged fire extinguisher. All personnel should be instructed in proper
usage. Recharge immediately after use.
The machine should not be serviced with anyone in the operator's compartment unless said person is qualified to
operate the machine and is assisting in the servicing. No unauthorized personnel should be allowed to operate, maintain
or service this machine. Do not rush. Hurrying can lead to accidents. Do not jump on or off the machine. Keep two
hands and one foot or two feet and one hand in contact with steps and grab handles and rails at all times. Place objects
on machine from ground level before mounting machine.
Electrical system is 12 volt negative ground. When using jumper cables, precautions must be taken to minimize chances
of injury or damage to electrical parts.
1. Attach one end of jumper cable to positive terminal of booster battery and other end to positive terminal of machine
battery.
2. Attach one end of second cable to negative terminal of booster battery and other end to machine's frame away from
the battery.
3. To remove cables, reverse above sequence exactly to avoid sparks near the battery. A frozen battery can explode
when the booster cables are attached.
NEVER check battery charge by placing a metal object across the battery posts. The sparks could cause an explosion.
Use a voltmeter for checking battery state of charge.
BEFORE STARTING THE ENGINE
Always place the transmission/steering lever in neutral and apply the neutral safety lock and lock the parking brake
before starting. The operator must be alert, physically fit and free from the influences of alcohol, drugs or medications
that might affect his eyesight, hearing, reactions or judgement. Observe and know the use of alternate exits from the
operator compartment. Safety must always be the operator's most important concern. He must refuse to operate when
he knows it is unsafe and consult his supervisor when safety is in doubt. The best safety device is a safe operator. Do
not use controls or hoses as hand holds when climbing on or off the machine. Hoses and controls can move and do
not provide solid support. Movement of the controls may cause inadvertent and unexpected movement of the machine
1-2
SAFETY PRECAUTIONS INTRODUCTION
or its equipment. Follow all machine mounted safety signs before starting, operating, maintaining or servicing the
machine. Be sure the area of the operator's compartment, all mounting steps and grab handles are free of oil, grease,
loose objects, ice and mud to lessen the possibility of slipping. Remove or secure all maintenance and personal items
so they will not interfere with the operator or jam the controls.
Perform a visual check of the machine before starting the engine. Look for such things as improper fluid levels, oil leaks,
and loose, damaged or missing parts. Do not start the engine until any unsafe conditions are corrected. Secure all caps
and filler plugs.
Know and understand the traffic flow patterns of your job and obey flagman, signs and signals. Check work area for
hazardous conditions. Be alert for soft ground conditions, especially when working on slopes, near drop offs or
excavations or fill material, which could lead to sudden tipping of the machine. At night and times of poor visibility,
carefully check the work area before moving in with the machine. Use all lights provided.
Before entering the operator's compartment, clear the immediate area surrounding the machine of personnel and
obstructions. Walk completely around the machine. After entering the operator's compartment, sound the horn to clear
the immediate area of the machine.
Due to the danger of fire and explosion, never check or fill fuel tank or batteries near lighted smoking materials or open
flame or sparks.
OPERATION
Before starting the engine, be sure you understand all control functions. Only one person, the operator, should be
permitted to ride on the machine when it is in operation. Never haul passengers. Perform an operational check of the
machine in a safe area before putting it to work. Check all controls, including the brake pedal, steering pedals and
transmission selector. Check all gauges, warning lights and safety devices. Correct any malfunctions. Always sit in the
operator's seat before operating any controls. Keep operating controls, hands and shoes free of grease, water and mud
to insure positive control functions.
The machine is ROPS equipped, for your personal protection, wear your seat belt. In the event of a rollover, stay with
the machine. Experience has shown this will reduce the seriousness or chance of injury. Before driving the machine,
adjust the seat and fasten the seat belt. Adjust the seat belt to fit snugly and flow around the hips to lessen the chance
and severity of injury in the event of an accident. Never wear the seat belt across the abdomen.
Check overhead clearance carefully before operating the machine in areas with low overhead clearance, such as guy
wires, power lines, bridges, low hanging tree branches and building entrances or exits. These overhead obstructions
could cause an accident.
Never start the engine indoors unless proper exhaust ventilation is provided to remove deadly exhaust gases. Once the
engine is operating, move the machine outdoors as soon as possible. Exhaust gases are dangerous and cause
unconsciousness and death. Never operate the engine at more than the regular governed speed shown in the
OPERATION & MAINTENANCE MANUAL. Excessive speeds are harmful and dangerous.
After starting the engine, but before moving the machine, warn nearby personnel by giving a couple of short horn blasts.
When operating the machine, look in the intended direction of travel to be sure personnel or allied equipment does not
interfere with the machine work pattern. Never try to get on or off the machine while it is moving. A serious injury or death
could result.
Never mix gasoline, gasohol and/or alcohol with diesel fuel. This practice creates an extreme fire hazard and under
certain conditions an explosion which could result in personal injury or death. Never remove the fuel tank filler caps or
refill the fuel tanks while the engine is running or hot or when the machine is indoors. Fumes are dangerous, a spark
or flame could result in a fire or explosion.
Avoid sidehill travel whenever possible. Drive straight up and down the slope. If the machine starts slipping sideways
on a grade, turn downhill immediately. Be careful and alert when operating sideways on a steep slope as a rollover and
serious injuries could result. There is no substitute for good judgement when working the machine on a slope.
If possible avoid crossing obstacles such as ridges, rocks or logs. If you can't avoid them, reduce speed and ease over
the obstacle at an angle.
1-3
A machine's weight and the vibration it creates can cause the edge of a high wall to collapse. Keep your machine back
from the edges of banks and excavations.
Operating in rough virgin terrain with such hazards as trees, logs, large rocks and brush is called pioneering. Be sure
you know the operating techniques required. Danger from falling branches and upturning roots is acute in pioneering.
When pushing over trees, the machine must be equipped with proper overhead guards. Never allow the machine to
climb up the root structure, especially when the tree is being felled. Use extreme care when pushing over any tree with
dead branches.
If engine has a tendency to stall for any reason under load or at idle, report this condition immediately. Do not operate
the machine until the condition has been corrected. Periodically check the engine exhaust system for leaks. Exhaust
gases are dangerous to the operator.
Use common sense, care and good judgement to avoid accidents. Operate at speeds slow enough to insure complete
control of the machine. Travel slowly in congested areas or on rough ground, slopes or near drop offs or on snow, ice
or slippery surfaces. Maintain a safe distance between your machine and other vehicles according to the condition of
the road and load. Keep the machine as close to the side of the road as is possible to provide for oncoming or passing
vehicles.
Observe instruments and warning lights frequently. Report any defects or unusual noises in machine during operation.
Be alert to the location of other personnel. Do not operate if exposed personnel enter the immediate work area. Warn
all ground persons to leave the area of the machine.
Do not operate the machine in a condition of extreme fatigue or illness. Be especially careful at the end of a work shift.
Keep your work area as smooth as possible and free of obstructions.
When pulling or towing with a chain or cable, take up the slack carefully. A sudden jerk could snap the chain or cable
causing it to whip dangerously. Do not pull or tow unless the operator compartment is guarded for a whipping chain or
cable. Clear personnel from the area. Be sure chains or cables and their anchor points are strong enough to handle
the expected load. Inspect carefully for flaws before using. Always wear gloves when handling chains or cables. Avoid
kinking the chain or cable. Do not pull with a kinked chain or cable as the high stress could cause a failure in the kinked
area. Use only designated towing or pulling attachment points. Be sure pins are attached securely before pulling. Stand
clear of chains or cables under load.
Where noise exposure exceeds 90 dBA for 8 hours, wear authorized ear protective equipment.
Keep engine exhaust system and exhaust manifold clear of combustible material for your personal protection.
Know the locations of underground cables, water mains, gas lines, etc. A ruptured gas line or cut electrical cable could
result in personal injury or death.
Never use the mounted equipment as a brake except in an emergency. Do not adjust the seat position while the
machine is in motion. A loss of control may result. Completely stop the machine, apply and lock the parking brake and
then adjust the seat. During operation always carry ripper in full raised position when not in use and lower to ground
when parked. Keep head, body, feet, hands and fingers away from the blade and ripper when they are in a raised
position. Carry the blade low for maximum stability and visibility.
Never leave the machine unattended while the engine is operating. When parking the machine, be sure all mounted
equipment is lowered completely to minimize damage or injury possibilities. Do not allow the hydraulic system to support
the mounted equipment when leaving the machine unattended. When leaving the machine unattended for any length
of time, make sure the transmission/steering lever is positioned and locked in neutral (N), the blade and rear mounted
equipment are completely lowered, the engine is stopped and the electrical master switch is locked in the OFF position.
Never hold the hydraulic controls in their extreme position after the equipment has reached its maximum travel. This
could cause overheating of the hydraulic system.
MAINTENANCE
Lower the blade to the ground or hold up with blocking, safety bar or hoist. Lower all equipment to the ground. Shift all
controls to NEUTRAL position. Lock the transmission selector in NEUTRAL to neutralize the transmission and apply
1-4
the parking brake. Turn off the electrical system master switch. Remove the key.
Read and know your OPERATION & MAINTENANCE MANUAL and SHOP MANUAL before performing any work on
the machine. Read ALL product graphics and safety precautions. Never work beneath the blade without proper blocking
and/or a safety bar properly installed. Improper blocking could result in serious injuries.
Do not attempt to make repairs that you do not understand. Consult your distributor. Use only approved parts for repairs
and maintenance. Failure to do so could compromise your personal safety and machine performance and reliability.
The rollover protective structure (ROPS) provides operator protection in the event of machine rollover or upset. This
structure is designed to bend during a rollover to protect the operator from sudden impact loads. Do not attempt to
repair a protective structure after an accident.
Repaired structures do not provide the original strength and protection. Contact your distributor for information on
structure replacement. Do not operate the machine again until the ROPS has been replaced. Use only replacement
parts shown in your PARTS BOOK.
Do not cut, grind, weld, drill or tap holes in the ROPS. This could weaken the structure, or affect the overall energy
absorption capabilities.
Do not smoke when refueling or servicing the machine. A fire could result. Never place gasoline or diesel fuel in an open
pan. Never remove the fuel tank filler cap or refill the fuel tank while the engine is operating or hot or when the machine
is indoors. The fumes are dangerous and a spark or flame could result in a fire or explosion.
Loosen the radiator cap slowly to relieve all pressure in the system and use caution when removing the caps. Loosen
the filler cap slowly to relieve reservoir pressure to prevent possible injury. Always vent the hydraulic system before
working on any hydraulic component. Have all equipment resting on the ground or blocked before removing any
component.
When service or maintenance requires access to areas that cannot be reached from the ground, use a ladder or
platform. If such ladders or platforms are not available, use the machine hand holds and steps provided. Perform all
service or maintenance carefully.
Never align holes with fingers or hands. Use a proper aligning tool. Be sure all tools are in good condition. Do not use
tools which are worn, bent or have mushroomed heads. Use the proper tool for the job. Remove sharp edges and burrs
from reworked parts.
Before working on the machine, tag and lock the electrical system master switch so no one will start it unexpectedly.
For field service, move machine to level ground if possible and block the tracks. If work is absolutely necessary on an
incline, block the machine and its attachments securely. Move the machine to level ground as soon as possible.
Do not carry loose objects in pockets that might catch on the machine or fall unnoticed into open compartments.
Before working on any part of the engine or electrical system, disconnect the battery ground cable. Tag the cable and
all controls to alert personnel that work is in progress.
When it is necessary to make any checks or adjustments with the engine operating, always use two people. One trained
person must be in the operator's seat to safeguard the second person making the checks or adjustment. As an added
precaution, when making checks or adjustments with the engine operating, make sure the transmission shift lever is
locked in neutral (N).
Never stand on the tracks or near the blade while engine is operating. If the engine is running and the side doors are
open or removed be careful of rotating parts such as the fan and belts that can cause serious injury. Never run the
engine when cleaning or lubricating the machine. Serious injury could result from contacting moving parts.
Use a non toxic, nonflammable commercial solvent for cleaning parts, unless otherwise specified. Never use gasoline,
diesel fuel, kerosene or other flammable solvents for cleaning parts. Excessive or repeated skin contact with sealants
or solvents may cause skin irritation. In case of skin contact, remove sealant or solvent promptly by washing with soap
and water. Follow the manufacturer's advise whenever cleaning agents or other chemicals are used.
1-5
Lower the blade before making hydraulic adjustments. To prevent personal injury, be sure personnel are not standing
in the way of the blade when it is being lowered. Never allow anyone to walk under or be near unblocked raised
equipment. Provide proper ventilation when operating in a closed building to avoid danger of exhaust gases. Exhaust
gases are dangerous and can cause unconsciousness and death. Hydraulic fluid escaping under pressure from a very
small hole can be almost invisible, yet have sufficient force to penetrate the skin. Use a piece of cardboard or wood to
search for suspected leaks. Do not use hands. If injured by escaping fluid, see a doctor at once. Serious infection or
reaction can occur if proper medical treatment is not administered immediately.
When welding, wear proper protective equipment such as a helmet, dark safety glasses, protective glasses near
welding. Do not look at arc without proper eye protection.
Wear proper protective equipment such as goggles or safety glasses with side shields, hard hat, safety shoes and heavy
gloves when metal or other particles are apt to fly or fall. Many of the machine's parts are hardened and can chip.
Lift and handle all heavy parts with a lifting device of proper capacity. Be sure parts are secured by proper slings and
hooks. Use lifting eyes if provided. Warn people in the area to stand clear.
When using compressed air for cleaning parts, wear goggles or safety glasses with side shields. Use a nozzle which
limits the pressure to 207 kPa (30 psi).
Do not use an open flame to check for leaks or fluid levels anywhere around the machine. Keep work area clean and
dry. Remove oil and water spills immediately. Do not pile up oily or greasy rags. They are a fire hazard. Store them in
an approved, closed metal container.
Use a soft iron or nonferrous hammer to install or remove ripper teeth. It is dangerous to hammer on the teeth. Wear
safety glasses with side shields or goggles to reduce the chances of injury.
Batteries give off a highly flammable gas. Never allow sparks or open flame near the batteries. A fire or explosion could
occur. Do not charge batteries in a closed area. Provide proper ventilation to guard against accidental explosive gas
given off in the charging process. When installing batteries, be sure the electrical master switch is locked in the OFF
position. Be sure to connect the positive cable to the positive terminal and the negative (ground) cable to the negative
terminal.
Ether fluid is flammable. Follow the precautions printed on the container. An explosion can result if sparks or flame
contact the ether in the container or if the container is stored in an area in which the temperature exceeds 120EF (49EC).
Observe the following precautions:
1. Follow correct method for starting the engine. Refer to the OPERATION & MAINTENANCE MANUAL.
2. Do not use the ether injector when the ambient temperature is above freezing.
3. For your own personal safety, always remove the ether container when welding, grinding or using a torch on the
machine.
4. Do not let ether come in contact with your skin, as it can cause localized freezing.
5. Do not breathe the hazardous ether vapor.
6. Keep the fluid container out of the reach of children.
7. Never puncture the fluid container or put it into a fire. Dispose of empty container properly.
8. Do not store fluid containers in the operator's compartment.
Never mix gasoline, gasohol or alcohol with diesel fuel. This creates an extreme fire or explosion hazard which could
result in personal injury or death.
Do not use bleach, color dye or solvents on the seat belt webbing. This may cause a severe loss of tensile strength. This
could cause the webbing to break resulting in personal injury. It is recommended that the seat belt be cleaned only with
warm water and a mild detergent.
SHUTDOWN
If parking on or near traffic lanes cannot be avoided, provide appropriate flags, barriers, flares and warning signals. Also
provide advance warning signals in the traffic lane for approaching traffic. Park the machine in a non operating and non
1-6
traffic area. Park machine on level ground whenever possible. If you must park on a slope, park at right angles to the
slope. Lock the transmission selector in neutral. Never leave the machine unattended with the engine running. When
leaving the machine unattended, slowly lower all hydraulic equipment to the ground, shift the transmission selector into
neutral and apply the neutral lock lever and shut off the engine. Relieve trapped pressure in the hydraulic system by
moving the control in both directions. Turn off the electrical system master switch. Remove the key. Always lock up
machine when leaving it unattended, including any anti vandalism attachments. Do not jump off the machine.
When operating in bad weather and storm lightning is nearby, dismount and seek shelter away from the machine.
Lightning will be attracted to the machine and cause serious injury or death.
When the machine is to be loaded onto a transport truck and trailer do so carefully. Load only when the trailer is level.
The steel track shoes will slide easily on the trailer. When the machine is properly positioned chain it securely so it can
not move on the trailer.
1-7
SAFETY PRODUCT GRAPHICS AND LOCATION
SAFETY PRODUCT GRAPHIC LOCATION
1-8
1. General Caution 4. Track Adjuster Caution

(737 994 C3) (655 434 C2)
5. Pressurized Reservoir
(2754 473 R3)
2. Door Caution
(667 460 C2)
6. Safety Caution
(1120 363 C2)
3. Instructional Caution
(628 135 C4)
7. ROPS Caution
(737 993 C3)
1-9
INTRODUCTION SERVICE INFORMATION
This illustration shows the D32E-1
GENERAL
Instructions contained in this shop manual are for information and guidance of
the service personal who are responsible for the overhaul and repair of this
machine. In this shop manual, the use of the terms left, right, front and rear
must be understood to avoid confusion when following the instructions. These
terms indicate the sides of the machine when facing forward in the operators
seat. Due to a continuous program of research and development, some proce-
dures, specifications and parts may be altered in a constant effort to improve
this machine. Some illustrations are of a general application and may not show
the component parts accurately in all details.
PIN AND SERIAL NUMBERS
The PIN (product identification number) is stamped on a plate attached to the
right hand side of the dash support on the engine side. It is also stamped on the
right rear face of the rear main frame in the upper corner. The engine serial
number is on a plate on the left side of the engine front gear cover above the
fuel pump.
1 - 10
SERVICE INFORMATION INTRODUCTION
Designation of the blade if present is stamped on the back or side of blade,

near the top right hand corner. All other components having one are each
equipped with a separate plate. Use the serial numbers when requesting or
ordering parts.
SERVICE TOOLS AND PARTS
Information regarding service tools are listed is the individual sections.
Always use genuine Komatsu service parts. Service parts are available through
your local distributor.
INSPECTION AND REPAIR
Gasket and Seals
Always use new gaskets and seals during assembly and installation. Use
extreme caution to avoid damage to seals or gaskets during these operations.
Use sleeves or tape when seals have to be passed over threads or splines.
Pack lip type seals with fresh grease prior to installation. Felt dust seals must
be soaked in light clean oil before assembly.
DO NOT roll an O-Ring during installation. To correctly install, position at one
point and using a blunt tool, stretch into position. DO NOT stretch any more
than is required for proper installation.
Bearings
Inspect for evidence of overheating, cracks, scores, pitting and general wear
and replace if necessary. Serviceable bearings must be cleaned, soaked in
fresh lube and wrapped in grease proof material.
Gears and Splines and Welds or Castings
Check splines with their mating parts for wear. Check gears and splines for
pitting, burrs, broken or missing teeth. Burrs can be removed with a fine stone,
but care must be taken so that only burr is removed and gear or spline profile
is not changed. Check all welds for cracks, twisting and misalignment. Check
castings for cracks and distortion.
Piping and Hoses
Check all fittings for leaks and thread damage. Check steel piping for cracks
and chafing. Check hoses for chafing, twisting or perishing, etc.
Relief Valves
Before commencing work on hydraulic system, check that relief valves are
opening at their correct pressures. Pressures are listed and information on how
to check and adjust pressures is in the hydraulic section.
Lubrication
During assembly, running or wear surfaces must be coated with specified
lubricant. Refer to OPERATION & MAINTENANCE MANUAL. Use sufficient
lubricant to prevent seizing, scoring or excessive wear on initial operation.
Failure to provide starting lubricant may result in serious damage.
1 - 11
INTRODUCTION LOCTITE USAGE
SURFACE PREPARATION
Plain and Phosphate Coated Parts
Clean surfaces where compounds are to be applied to remove heavy coating
of oil, grease and dirt (rust or light oil film are not detrimental). Normal shop
practice of cleaning or degreasing is adequate. Phosphate and oiled hardware
is used in as received condition provided it is dry to touch.
Zinc or Cadmium Plated Parts or For Rapid Curing of Compound
At least one mating surface should be degreased with a cleaning solution to
which concentrated primer has been added, (1 part primer concentrate to 30
parts trichlorethylene). Allow surfaces to dry for 3 to 5 minutes before applying
compound.
Drawbar Studs or Special Stud Applications
Degrease parts with a cleaning solution to which concentrated primer has been
added, (1 part primer concentrate to 30 parts trichlorethylene). Allow surfaces
to dry for 3 to 5 minutes before applying compound. In blind holes, be sure to
remove all chips and oil.
Face Sealant
Mating parts must be cleaned as for plain and phosphate coated parts.
APPLICATION
Bolt and Pipe Threads
Fill first 2 to 3 leading threads in area of engagement with compound. For larger
quantities of bolts, compound may be applied by thumbing method.
Studs
Fill full length of thread with one strip on diameters up to 25.4 mm (1 in), two
strips 180E apart on diameters up to 50.8 mm (2 in), and three strips 120E apart
on diameters over 50.8 mm (2 in).
In all cases, only apply one strip into tapped hole. On blind hole applications,
apply enough compound to fill bottom 2 to 3 threads of engagement, then insert
stud. If engagement length exceeds one diameter, use proportionally more
compound. For non-seated studs turn stud one turn deeper than required. After
bubbling stops, apply compound around stud at top of hole, then turn back to
required height.
Primers
Apply primer to surface where sealant is to be applied. Allow primer solvent to
evaporate 3 to 5 minutes before applying sealant. When sealant is applied to
a primed surface, parts should be assembled within 3 minutes.
Face Sealant
For liquid sealants, spread an even coat on one of mating surfaces. Assemble
and tighten bolts. For gel sealant, apply as continuous bead to surface of one
mating face.
REMARK
When compound is used as a gasket, bolts which attach parts should be
coated with mpl (gear lube) to prevent compound from sticking to bolts.
1 - 12
LOCTITE USAGE INTRODUCTION
SETTING TIME (BEFORE PLACING IN OPERATION)

Normal time for compound grades without use of any primer - 6 to 24 hours at
room temperature with machined carbon steel parts. Higher temperatures will
accelerate cure and lower temperatures will retard cure. Other base metals will
provide more or less catalytic effect on cure.
Primed surfaces 2 to 6 hours. This may be speeded by pretreating mating
surfaces with special primers. Some metals (such as zinc and cadmium plate,
anodized aluminum and passivated stainless steel) are inactive and require
heat or primer to cure primer. A fast curing type primer will fix parts for normal
handling in 10 to 15 minutes and will achieve 75% of ultimate strength in 1 hour
and full cure in 2 to 4 hours.
REMOVAL
Parts difficult to remove can be preheated to 204 to 260EC (400 to 500EF) prior
to removal.
APPLICATIONS AT LOW TEMPERATURES
Without special precautions, these compounds can be applied and will cure at
temperatures down to 10EC (50EF) and at that temperature full strength will be
obtained within 72 hours. At temperatures ranging from 10 to -18EC (50 to 0EF)
use of primer is recommended. If necessary, compounds can be applied at
temperatures below -18EC (0EF), only if heat is used to accelerate cure as
follows:
66EC (150EF) for 60 minutes, 93EC ( 200EF) for 45 minutes, 121EC
(250EF) for 30 minutes
1 - 13
MISCELLANEOUS
SECTION 2
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D32E-1 DIMENSIONS . . . . . . . . . . . . . . . . . . 2
D32P-1 DIMENSIONS . . . . . . . . . . . . . . . . . . 3
D38E-1 DIMENSIONS . . . . . . . . . . . . . . . . . . 4
D38P-1 DIMENSIONS . . . . . . . . . . . . . . . . . . 5
D39E-1 DIMENSIONS . . . . . . . . . . . . . . . . . . 6
D39P-1 DIMENSIONS . . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 8
D32E-1, D32P-1 SPECIFICATIONS . . . . . . . 8
D38E-1, D38P-1 SPECIFICATIONS . . . . . . . 9
D39E-1, D39P-1 SPECIFICATIONS . . . . . . 10
CAPACITIES AND LUBRICANTS . . . . . . . . . 11
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . 13
STANDARD TORQUES . . . . . . . . . . . . . . . . . 15
INTRODUCTION OF TOOLS . . . . . . . . . . . 15
BOLT IDENTIFICATION CHART . . . . . . . . 16
GRADE 5 OR 8 NON-PHOSPHATE
HARDWARE . . . . . . . . . . . . . . . . . . . . . . . 17
GRADE 8 PHOSPHATE HARDWARE . . . . 18
STANDARD METRIC FASTENERS . . . . . . 18
HOSE CLAMPS . . . . . . . . . . . . . . . . . . . . . . 19
SPLIT FLANGE CONNECTIONS . . . . . . . . 19
WARNING
Refer to, read and follow all safety precautions in SECTION 1. Failure to do so may
result in serious injury or death.
2-1
MISCELLANEOUS DIMENSIONS
D32E-1 DIMENSIONS
2-2
DIMENSIONS MISCELLANEOUS
D32P-1 DIMENSIONS
2-3
D38E-1 DIMENSIONS
2-4
D38P-1 DIMENSIONS
2-5
D39E-1 DIMENSIONS
2-6
D39P-1 DIMENSIONS
2-7
MISCELLANEOUS SPECIFICATIONS
D32E-1, D32P-1 SPECIFICATIONS
D32E-1 D32P-1
WEIGHT
! Operating weight w/o operator 7133 kg (15725 lbs) 7782 kg (17155 lbs)
BLADE
! Equipment weight (including cylinders) 1173 kg (2586 lbs) 1245 kg (2744 lbs)
! Blade capacity 1.2 m³ (1.6 yd³) 1.45 m³ (1.9 yd³)
PERFORMANCE
! Travel speeds Forward 1st 3.6 km/h (2.2 mph)
2nd 6.0 km/h (3.7 mph)
3rd 9.3 km/h (5.8 mph)
Reverse 1st 4.3 km/h (2.7 mph)
2nd 6.5 km/h (4.1 mph)
3rd 11.2 km/h (7.0 mph)
! Maximum drawbar pull 11681 kg (25751 lbs)
! Ground pressure 0.51 kg/cm² (7.3 psi) 0.31 kg/cm² (4.4 psi)
ENGINE
! Model Komatsu 4D102E-1 Diesel Engine
! Flywheel horsepower 52 kW (70 hp) @ 2500 RPM
! Maximum torque 268 NCm (198 lbf ft) @ 1200 RPM
! Starting motor 2.7 kW (12V)
! Alternator 2.7 kW (12V) @ 65A
! Battery 2.7 kW (12V) @ 700 CCA
2-8
SPECIFICATIONS MISCELLANEOUS
D38E-1 D38P-1
WEIGHT
BLADE
PERFORMANCE
2nd 5.6 km/h (3.5 mph)
3rd 9.3 km/h (5.8 mph)
2nd 6.7 km/h (4.1 mph)
3rd 11.2 km/h (6.9 mph)
ENGINE
! Model Komatsu S4D102E-1 Diesel Engine
2-9
MISCELLANEOUS SPECIFICATIONS
D39E-1 D39P-1
WEIGHT
BLADE
PERFORMANCE
2nd 5.6 km/h (3.5 mph)
3rd 9.5 km/h (5.9 mph)
2nd 6.8 km/h (4.3 mph)
3rd 11.3 km/h (7.0 mph)
ENGINE
! Model Komatsu S4D102E-1 Diesel Engine
2 - 10
CAPACITIES AND LUBRICANTS MISCELLANEOUS
CAPACITIES AND LUBRICANTS
It is not our policy to approve lubricants or to guarantee oil performance in service. The responsibility of quality of the
lubricant must remain with the supplier of the lubricant. When in doubt consult your Komatsu distributor. The lubricants
specified for this machine are shown below.
AMBIENT TEMPERATURE
RESERVOIR TYPE E C -34 -29 -23 -18 -12 -7 -1 4 10 16 21 27 32 38 43 49 E C CAPACITY
E F -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 E F
SAE 15W-40 -
Crankcase with
EO1 SAE 15W-40 9.5 R (2.5 gal)
filter change
¶ SAE 5W-20*
D32E-1
D32P-1
0.35 R (12 oz)
Front idler HDTF
D38E-1
(rebuilt) D38P-1
or ¶ SAE 30 - 0.35 R (12 oz)
EO2
D39E-1
D39P-1
0.4 R (13.5 oz)
D32E-1
D32P-1
0.35 R (12 oz)
HDTF
Track roller D38E-1
D38P-1
or ¶ SAE 30 - 0.35 R (12 oz)
(rebuilt)
EO2
D39E-1
D39P-1
0.47 R (16 oz)
D32E-1
D32P-1
0.1 R (4 oz)
HDTF
Top idler D38E-1
D38P-1
or ¶ SAE 30 - 0.1 R (4 oz)
(rebuilt)
EO2
D39E-1
D39P-1
0.1 R (4 oz)
D32E-1
D32P-1 SAE 85W-140 - 9.5 R (2.5 gal)
D38E-1
Final drive D38P-1
MPL SAE 85W-140 or 80W-90 9.5 R (2.5 gal)
D39E-1 ¶ SAE 80W-90 15.2 R (4 gal)

D39P-1
Drive train % HDTF ¶ SAE 10W - 79.5 R (21 gal)

Hydraulic system, HDTF,
EO2 or ¶ SAE 10W - 51.1 R (13.5 gal)
equipment # HTF
D975 No. 2 -
Fuel tank DF 140 R (37 gal)
¶ D975 No.1
Cooling system Refer to OPERATION & MAINTENANCE MANUAL 26.5 R (7 gal)
* SAE 5W-30 may be substituted.

% Drive train consists of the rear main frame, steering drive, transmission, torque converter, oil cooler and all
appropriate lines.
# Capacity may very depending on hydraulic equipment mounted on machine.
2 - 11
MISCELLANEOUS CAPACITIES AND LUBRICANTS
HDTF Komatsu heavy duty transmission fluid or equivalent fluid meeting C-4 or TO-4 and must NOT contain viscosity
index improver.
EO1 Komatsu engine oil or multigrade diesel engine oil or engine oil API CF/CC or MIL-L-2104 with sulphated ash
of 1.65%.
EO2 (For service only) Komatsu hydraulic fluid or engine oil API CD/CC, CD or MIL-L-2104 and passing TO-2 and
C-3 test with 0.10% minimum zinc.
MPL Komatsu gear lube or multi-purpose gear lube API GL-5 or MIL-L-2105.
MPG Komatsu super grease or multi-purpose grease 251 HEPM or NLGI grade #2 multi-purpose lithium grease with
3% MoS2 (molybdenum disulfide).
HTF (For service only) Komatsu hydraulic transmission fluid.
DF Diesel fuel per ASTM D975, Grade 1 or 2 depending on ambient temperature.
SAE: Society of Automotive Engineers

API: American Petroleum Institute
NLGI: National Lubricating Grease Institute
ASTM: American Society of Testing and Materials
2 - 12
SPECIAL TORQUES MISCELLANEOUS
POSITION SIZE TORQUE
Start, Horn and Ether Switch Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32 . . . . . . . . . . . . . . 1.8 NCm (16 lbf in)
Cranking Motor Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M5 . . . . . . . . . . . . . . . 2.6 NCm (23 lbf in)
Magnetic Switch Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32 . . . . . . . . . . . . . 2.2 NCm (20 lbf in)
Circuit Breaker Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32 . . . . . . . . . . . . . 2.0 NCm (18 lbf in)
Electrical Senders and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32 . . . . . . . . . . . . . 2.0 NCm (18 lbf in)
Alternator Terminal (+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6 . . . . . . . . . . . . . . . 3.6 NCm (32 lbf in)
Alternator Terminal (-) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 . . . . . . . . . . . . . . . . 6.8 NCm (5 lbf ft)
Alternator Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 . . . . . . . . . . . . . . . . 24 NCm (18 lbf ft)
Air Cleaner Mounting Band Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/16 . . . . . 16 to 20. NCm (12 to 15 lbf ft)
Magnetic Switch Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/16 . . . . . . . . . . . . . . . 6.8 NCm (5 lbf ft)
Universal Joint Bolt - D32E-1, D32P-1, D38E-1 or D38P-1 . . . . . . . . . . . . 5/16 . . . . . . . . . . . . . . . 32 NCm (24 lbf ft)
Alternator Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10 . . . . . . . . . . . . . . . 43 NCm (32 lbf ft)
Cranking Motor Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10 . . . . . . . . . . . . . . . 43 NCm (32 lbf ft)
Torque Converter to Flywheel Housing Bolts . . . . . . . . . . . . . . . . . . . . . . . M10 . . . . . . . . . . . . . . . 43 NCm (32 lbf ft)
Cranking Motor Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10 . . . . . . . . . . . . . 16.3 NCm (12 lbf ft)
Fan Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10 . . . . . . . . . . . . . . . 43 NCm (32 lbf ft)
Battery Hold Down Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 . . . . . . . . . . . . . . . 1.1 NCm (10 lbf in)
Battery Cable Terminal Nuts (On Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 . . . . . . . . . . . . . . . . 31 NCm (23 lbf ft)
Master Switch Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 . . . . . . . . . . . . . . . 12.2 NCm (9 lbf ft)
Steering Cylinder Fitting Flange Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 . . . . . . 16 to 20 NCm (12 to 15 lbf ft)
Rear Main Frame Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 . . . . . . . . . . . . . . 55.5 NCm (41 lbf ft)
Equipment Tube Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 . . . . . . 14 to 20 NCm (10 to 15 lbf ft)
Track Roller and Idler Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 . . . . . . . . . . . . . . . . 34 NCm (25 lbf ft)
Universal Joint Bolts - D39E-1 or D39P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 . . . . . . . . . . . . . . . . 56 NCm (42 lbf ft)
Bevel Gear Bearing Cage Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/16 . . . . . . . . . . . . . . . 75 NCm (55 lbf ft)
Bevel Gear to Gear Carrier Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/16 . . . . . . . . . . . . . . . 75 NCm (55 lbf ft)
Front Idler Wear Bar Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/16 . . . . . . . . . . . . . . . 87 NCm (64 lbf ft)
Light Switch Mounting Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/16 . . . . . . . . . . . . . . . 18 NCm (13 lbf ft)
Muffler Mounting Clamp Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/16 . . . . . . . . . . . . . . . 68 NCm (50 lbf ft)
Engine Front Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 . . . . . . . . . . . . . . . 77 NCm (57 lbf ft)
Rear Lifting Bracket Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 . . . . . . . . . . . . . . . 77 NCm (57 lbf ft)
Engine Front Mount Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 . . . . . . . . . . . . . . . . 95 NCm (70 lbf ft)
Steering Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 . . . . . . . . . . . . . . . 129 NCm (95 lbf ft)
Front Idler Fork Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 . . . . . . . . . . . . . . . 134 NCm (98 lbf ft)
Track Roller Bracket Bolts - D32E-1, D32P-1, D38E-1 or D38P-1 . . . . . . 1/2 . . . . . . . . . . . . . . . 134 NCm (98 lbf ft)
Torque Converter Drive Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 . . . . . . . . . . . . . . . 110 NCm (80 lbf ft)
Steering Cylinder Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 . . . . . . . . . . . . . . . 127 NCm (94 lbf ft)
Track Shoe Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9/16 . . . 90 ±20 NCm (65 ±15 lbf) + 120E
2 - 13
MISCELLANEOUS SPECIAL TORQUES
POSITION SIZE TORQUE
Rear Engine Mount Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/8 . . . . . . . . . . . . . . 267 NCm (195 lbf ft)
Front Idler Thrust Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/8 . . . . . . . . . . . . . . 190 NCm (140 lbf ft)
Rear Rigid Bar Lockplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/8 . . . . . . . . . . . . . . 267 NCm (195 lbf ft)
Sprocket Rock Deflector Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/8 . . . . . . . . . . . . . . 267 NCm (195 lbf ft)
Switch Mounting Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/8 . . . . . . . . . . . . . . . 4.5 NCm (40 lbf in)
Track Adjuster Check and Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/8 . . . . . . . . . . . . . . . . 68 NCm (50 lbf ft)
Track Roller Bracket Bolts - D39E-1 or D39P-1 . . . . . . . . . . . . . . . . . . . . . 5/8 . . . . . . . . . . . . . . 267 NCm (195 lbf ft)
Track Roller Shield Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/8 . . . . . . . . . . . . . . 267 NCm (195 lbf ft)
Sprocket Drive Housing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/8 . . . . . . . . . . . . . . 190 NCm (140 lbf ft)
Alternator Pulley Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/8 . . . . . . . . . . . . . . . . 80 NCm (59 lbf ft)
Master Switch Mounting Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 . . . . . . . . . . . . . . . . 51 NCm (38 lbf ft)
Pinion Gear Retainer Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 . . . . . . . . . . . . . . 434 NCm (320 lbf ft)
Neutral Starting Switch Mounting Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 . . . . . . . . . . . . . . . . 24 NCm (18 lbf ft)
Sprocket Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 . . . . . . . . . . . . . . 455 NCm (335 lbf ft)
Sprocket Shaft Retainer Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 . . . . . . . . . . . . . . 434 NCm (320 lbf ft)
Track Frame Crossbar Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 . . . . . . . . . . . . . . 455 NCm (335 lbf ft)
Track Roller Shield Spacer Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 . . . . . . . . . . . . . . 455 NCm (335 lbf ft)
Cutting Edge and End Plow Bolt Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 . . . . . . . . . . . . . . 455 NCm (335 lbf ft)
Blade to Angling Frame Retainer Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 . . . . . . . . . . . . . . 455 NCm (335 lbf ft)
Fender Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 . . . . . . . . . . . . . . 455 NCm (335 lbf ft)
Front Frame Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/8 . . . . . . . . . . . . . . 730 NCm (540 lbf ft)
Front Frame Safety Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/8 . . . . . . . . . . . . . . . . 13 NCm (10 lbf ft)
Safety Bolt Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/8 . . . . . . . . . . . . . . . . 68 NCm (50 lbf ft)
Trunnion Bracket C Frame Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . 920 NCm (680 lbf ft)
Brake Back Up Shoe Adjusting Jam Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . 170 NCm (125 lbf ft)
ROPS Mounting Bolt Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 822 ±47 NCm (605 ±35 lbf ft)
Equipment Tie Bar with Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1/8 . . . . . . . . . . . . 1220 NCm (900 lbf ft)
Equipment Tie Bar All Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1/8 . . . . . . . . . . . . . 650 NCm (480 lbf ft)
Transmission Reverse Idler Gear Shaft Nut . . . . . . . . . . . . . . . . . . . . . . . . 1-1/8 . . . . . . . . . . . . . 359 NCm (265 lbf ft)
Pinion Shaft Front Bearing Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3/4 . . . . . . . . . . . . . 440 NCm (325 lbf ft)
2 - 14
STANDARD TORQUES MISCELLANEOUS
INTRODUCTION OF NECESSARY TOOLS
The following tools are needed when carrying out maintenance.
No. Name of tool Part No. Remarks
Width across flats S1, S2

End wrench - 8x10 mm
1. Wrench Set 09000-30006 End wrench - 13x17 mm
End wrench - 7/16X1/2

End wrench - 9/16x5/8
End wrench - 15/16x1
Screwdriver - 1/4 shank
Screwdriver - 3/8 shank
Ball peen hammer
2. Tool Kit 276 820 R91 Pry bar - 9/16x16
Adjustable wrench
Punch - 5/16x10
Chisel - 7/8x10
Punch - 3/16x10
Vise grip wrench
Slip joint plier
Diagonal (side) cutter
Tool box
3. Filter Wrench DR02-535 Removal of filter cartridges.
4. Grease Pump 999 677 R91 For lubrication of machine.
For details of the fluid to use, see CAPACITIES AND LUBRI-

5. Grease Cartridge
CANTS.
If any of the above tools are broken, please order them from your Komatsu distributor.
When not using the tools, always put them in the appropriate tool box.
2 - 15
MISCELLANEOUS STANDARD TORQUES
BOLT IDENTIFICATION CHART
TYPE/CLASS DESCRIPTION HEAD MARKING
Type 5 Three radial lines on top and none on side of head. Medium carbon steel
Inch Thread quenched and tempered.
Type 5.2 Three radial lines on top and none on side of head. Low carbon boron
Inch Thread steel quenched and tempered.
Type 8 Six radial lines on top and none on side of head. Medium carbon or
Inch Thread carbon alloy steel quenched and tempered.
Type 8.2 Six radial lines on top and none on side of head. Low carbon boron steel
Inch Thread quenched and tempered.
Class 5.8
Marked on top or side of head. Low or medium carbon steel.
Metric Thread
Class 8.8 Marked on top or side of head. Medium carbon or carbon alloy or low
Metric Thread carbon boron steel quenched and tempered.
Type 8R Six radial lines on head with type designation, none on sides. Medium
Inch Thread carbon or medium carbon alloy steel quenched and tempered.
Type 8R Six radial lines on head with type designation, none on sides. Low carbon
Inch Thread boron steel quenched and tempered.
Type 9 Six radial lines on head with type designation, none on sides. Medium
Type 9R Six radial lines on head with type designation, none on sides. Medium
Class 10.9R Marked on top or side of head. Medium carbon or carbon alloy steel
Metric Thread quenched and tempered.
Class 10.9R Marked on top or side of head and underlined. Low carbon boron steel
Metric Thread quenched and tempered.
Class 12.9 Marked on top or side of head. Medium carbon alloy steel quenched and
Metric Thread tempered.
Class 12.9R Marked on top or side of head. Medium carbon alloy steel quenched and
Metric Thread tempered.
2 - 16
GRADE 5 AND 8 NON-PHOSPHATE COATED HARDWARE
Recommended torque for all Standard Application Nuts and Bolts, provided; all thread surfaces are clean and lubricated
with SAE-30 engine oil or joints are rigid, that is, no gaskets or compressible materials are used. When reusing nuts or
bolts, use minimum torque values.
GRADE 5 GRADE 8
THREAD NCCm lbf ft THREAD NCCm lbf ft
1/4NC 8 6 1/4NC 12 9
1/4NF 9 7 1/4NF 15 11
5/16NC 18 13 5/16NC 24 18
5/16NF 20 15 5/16NF 28 21
3/8NC 33 24 3/8NC 46 34
3/8NF 37 27 3/8NF 52 38
7/16NC 52 38 7/16NC 73 54
7/16NF 57 42 7/16NF 81 60
1/2NC 79 58 1/2NC 111 82
1/2NF 88 65 1/2NF 122 90
9/16NC 114 84 9/16NC 163 120
9/16NF 126 93 9/16NF 179 132
5/8NC 156 115 5/8NC 224 165
5/8NF 175 130 5/8NF 251 185
3/4NC 278 205 3/4NC 393 290
3/4NF 312 240 3/4NF 434 320
7/8NC 414 305 7/8NC 617 455
7/8NF 454 334 7/8NF 698 515
1NC 617 455 1NC 942 695
1NF 691 510 1NF 1064 785
1-1/8NC 827 610 1-1/8NC 1342 990
1-1/8NF 929 685 1-1/8NF 1505 1110
1-1/4NC 1166 860 1-1/4NC 1898 1400
1-1/4NF 1295 955 1-1/4NF 2102 1550
1-3/8NC 1532 1130 1-3/8NC 2481 1830
1-3/8NF 1749 1290 1-3/8NF 2827 2085
1-1/2NC 2034 1400 1-1/2NC 3295 2430
1-1/2NF 2291 1690 1-1/2NF 3701 2730
1-3/4NC 3213 2370 1-3/4NC 5166 3810
2NC 4813 3550 2NC 7810 5760
Multiply the standard torque by 0.65 when finished jam nuts are used, 0.7 when Molykote, white lead or similar mixture
are used as lubricants, 0.75 when parkerized bolts or nuts are used, 0.85 when cadmium plated bolts or nuts and zinc
bolts w/waxed zinc nuts are used or 0.9 when hardened surfaces are used under the nut or bolt head. The General
Torque must be used in all cases where SPECIAL TORQUES are not given. Values listed in this manual are lubricated
(wet) threads; values should be increased 1/3 for non-lubricated (dry) threads.
2 - 17
MISCELLANEOUS STANDARD TORQUES
GRADE 8 PHOSPHATE COATED HARDWARE STANDARD METRIC FASTENERS
NOMINAL STANDARD TORQUE ± 10% NOMINAL STANDARD TORQUE

THREAD NCCm lbf ft THREAD ± 10%
1/4 10 8 MILLIMETERS NCCm lbf ft
5/16 21 16 M6 10 7
3/8 38 28 M7 16 12
7/16 60 45 M8 23 17
1/2 92 70 M10 46 34
9/16 130 100 M12 80 60
5/8 180 140 M14 125 90
3/4 325 240 M16 200 150
7/8 520 390 M18 275 200
1 780 580 M20 385 290
1-1/8 1110 820 M22 530 390
1-1/4 1565 1160 M24 670 500
1-3/8 2050 1520 M27 980 730
1-1/2 2720 2020 M30 1330 990
1-3/4 3380 2510 M33 1790 1330
2 5080 3780 M36 2325 1730
M39 3010 2240
This chart provides tightening torque for general purpose
applications using original equipment standard hardware This chart provides tightening torque for general purpose
as listed in the Parts Books for the machine involved. applications using original standard hardware as listed in
the Parts Book for the machine involved.
DO NOT SUBSTITUTE.
DO NOT SUBSTITUTE.
Original equipment standard hardware is defined as
Grade 8, coarse thread bolts and nuts and thru hardened Original standard hardware is defined as metric class
flat washers (Rockwell "C" 38-45), all phosphate coated 10.9 bolts and class 10.0 nuts and thru flat washers
and assembled without supplemental lubrication (as (Rockwell "C" 38-45), all phosphate coated and assem-
received) condition. bled without supplemental lubrication.
The torques shown also apply to the following; The torques shown also apply to the following;
Phosphate coated bolts used in tapped holes in steel or Phosphate bolts used in tapped holes in steel or gray
gray iron. Phosphate coated bolts used with phosphate iron, with phosphate coated prevailing torque nuts or
coated prevailing torque nuts (nuts with distorted with copper plated weld nuts.
threads or plastic inserts). Phosphate coated bolts used
with copper plated weld nuts. Markings on bolt heads or nuts indicate material class
ONLY and are NOT to be used to determine required
Markings on bolt heads or nuts indicate material grade torque.
ONLY and are NOT to be used to determine required
torque.
2 - 18
HYDRAULIC TUBES AND FITTINGS
The torque figures are recommended for plain, cadmium or zinc plated fittings, dry or wet installations. Swivel nuts either
swaged or brazed. Figures are for tube nuts used with 37E flared fittings and JIC - 37E seat O-Ring boss plugs and
swivel nuts.
O - RING BOSS PLUGS

TUBE NUTS
AND SWIVEL NUTS
E FLARED FITTINGS
FOR 37E E SEAT
JIC - 37E
SIZE TUBING THREAD MINIMUM MAXIMUM MINIMUM MAXIMUM
O.D. SIZE NCCm NCCm lbf ft lbf ft
4 1/4 7/16-20 12 16 9 12
5 5/16 1/2-20 16 20 12 15
6 3/8 9/16-18 29 33 21 24
8 1/2 3/4-16 47 54 35 40
10 5/8 7/8-14 72 79 53 58
12 3/4 1-1/16-12 104 111 77 82
14 7/8 1-3/16-12 122 136 90 100
16 1 1-5/16-12 149 163 110 120
20 1-1/4 1-5/8-12 190 204 140 150
24 1-1/2 2-1/2-12 217 237 162 175
32 2 2-1/2-12 305 325 225 240
HOSE CLAMPS SPLIT FLANGE CONNECTIONS
The following chart provides the tightening torques for The following chart provides the tightening torques for
hose clamps used in all rubber applications (radiator, air split flange connections used in hydraulic systems.
cleaner, operating lever boots, hydraulic system, fuel Flanges and fitting shoulders should fit squarely. Install all
systems etc.). bolts, finger tight, then torque evenly. Over torquing bolts
will damage the flanges and/or bolts, which may cause
TORQUE ± 0.6 NCCm (5 lbf in) leakage.
CLAMP RADIATOR, AIR HYDRAULIC

CLEANER, BOOTS, SYSTEM
FLANGE BOLT BOLT TORQUE
TYPE AND SIZE SIZE
SIZE ETC. NCCm lbf ft
NCCm lbf in NCCm lbf in 1/2 5/16 20 to 24 15 to 18
T Bolt 6.2 to 7.3 55 to 65 ----- ----- 3/4 3/8 30 to 37 22 to 27
Worm Drive - 1 3/8 37 to 47 27 to 35
1-¾ in Open
2.2 to 3.3 20 to 30 4.5 to 5.6 40 to 50 1-1/4 7/16 47 to 61 35 to 45
Diameter and
Under 1-1/2 1/2 62 to 79 46 to 58
Worm Drive
- Over 1-¾ in
2 1/2 75 to 88 55 to 65
4.5 to 5.6 40 to 50 ------ ------
Open Diame- 2-1/2 1/2 107 to 123 79 to 91
ter
3 5/8 187 to 203 138 to 150
Worm Drive -
10.7 to 11.8 95 to 105 4.5 to 5.6 40 to 50
All Ultra-Tite 3-1/2 5/8 159 to 180 117 to 133
2 - 19
BRAKES
SECTION 4
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 4
BRAKE AND DECELERATOR PEDAL . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 10
BRAKE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 18
BRAKE SUPPORT BRACKET . . . . . . . . . . . . 21
WARNING
4-1
BRAKES GENERAL
EXTERNAL BRAKE CONTROLS

1. Shoes and Levers 6. Main Brake Rod 11. Control Rod Boot 16. Clevis Pin
2. Brake Pad 7. Brake and Decel. Pedal 12. Boot Clamp 17. Equalizer Support
3. Final Brake Rod 8. Turnbuckle Rod 13. Return Spring 18. Secondary Brake Pedal
4. Rod End Clevis 9. LH Thread Yoke 14. Actuator Support 19. Brake Cylinder
5. Support Bracket 10. Brake Rod Clevis 15. Pivot Pin 20. Connector
4-2
GENERAL BRAKES
DESCRIPTION
These machines are equipped with a disc and pad type brake system which can be applied manually or hydraulically.
The brake and decelerator pedal manually actuates the brakes and the secondary brake pedal control the hydraulic
system. This section covers the external portion of the pedal systems only with the hydraulic and internal portions
covered in Section 7E. Complete brake system adjustment is also covered in Section 7E.
SPECIFICATIONS
Brake Pad Tension Spring:

Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.243 in (82.610 mm)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 in (50.8 mm)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 to 2.125 in (45.72 to 53.98 mm)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5 to 24.5 lbf (95.3 to 108.7 N)
Number of Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Brake Pad Return Spring:
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 in (127 mm)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.85 in (224.79 mm)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.85 to 9.89 in (224.79 to 251.21 mm)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.1 lbf (116.1 N)
Number of Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Brake and Decelerator Pedal Effort:
To Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34 lbf (14.85 N)
Finish (At Dash) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.38 lbf (19.48 N)
4-3
BRAKES BRAKE AND DECELERATOR PEDAL
BRAKE PEDAL AND BRACKET

1. Brake Pedal 4. Lube Fitting 7. Roll Pin
2. Needle Bearing 5. Cross Shaft
3. Bearing Seal 6. Pedal Bracket
4-4
BRAKE AND DECELERATOR PEDAL BRAKES
REMOVAL
WARNING
Be sure blade and any rear mounted equipment has been lowered
to the ground or on suitable blocking. Turn the master switch to the
off position and remove key or remove one of the cables from the
master switch to prevent accidental starting.
WARNING!
1. Remove engine right side door.
2. Remove cotter and clevis pins (1) from brake rod (2) and release from
pedal. Remove cotter and clevis pins (3) from decelerator over travel rod
(4) and release from pedal.
3. Remove hardware securing pedal and bracket to dashboard.
4. Rotate pedal and bracket 90E sideways and remove from dashboard.
SERVICE
REMARK
Callouts from exploded view correspond with callouts in following steps.
1. Position assembly in vise. Drive roll pin (7) from mounting bracket and
shaft.
4-5
2. Remove cross shaft (5) from bracket.
3. Remove pedal (1) from bracket.
4. Remove wiper seals (3) from each side of pedal and replace with new.
5. Drive out needle bearings (2) from each side of pedal.
REMARK
Needle bearing will be destroyed when removed from pedal. Replace with
new.
6. Position pedal (1) in press. Position needle bearing (2) in pedal. Using a
driver with a slightly smaller diameter than wiper seal, press bearing
flush with rear seal surface. Repeat for remaining needle bearing. Coat
bearings with fresh grease.
4-6
BRAKE PEDAL
4-7
7. Position new wiper seal (3) in pedal (1).
8. Using a driver with a slightly larger diameter than wiper seal, press seal
flush with outer surface of pedal. Repeat for remaining wiper seal.
9. Insert brake pedal (1) into bracket (6).
10. Align pedal with bracket and secure with cross shaft (5).
11. Mount cross shaft to bracket and secure with roll pin (7).
4-8
INSTALLATION
1. Insert brake pedal to dashboard.
2. Mount pedal and bracket to dashboard with hardware. Torque bolts to

92 NCm (70 lbf ft) ±10%.
3. Connect decelerator over travel rod (4) to brake pedal tang with clevis
and new cotter pin (3). Connect brake rod (2) to brake pedal with clevis
and new cotter pin (1).
4. Install right engine side door and secure with hardware. Torque bolts to
38 NCm (28 lbf ft) ±10%.
4-9
BRAKESPAD
BRAKE BRAKE AND DECELERATOR
BRAKES
PEDAL
EXPLODED VIEW OF BRAKE PAD
1. Final Bellcrank 5. Brake Pawl 9. Retaining Ring 13. Tension Spring

2. Needle Bearing 6. Flat Washer 10. Release Rod
3. Lube Fitting 7. Retaining Ring 11. Spring Spacer
4. Mounting Bracket 8. Flat Washer 12. Roll Pin
4 - 10
BRAKE PAD BRAKES
FLAT VIEW OF BRAKE PAD
4 - 11
BRAKE PAD BRAKES
REMOVAL
WARNING
Be sure blade and any rear mounted equipment has been
lowered to the ground or on suitable blocking. Turn the
master switch to the off position and remove key or remove
one of the cables from the master switch to prevent
accidental starting.
1. Remove operator’s compartment floor plate.
2. Disconnect final brake rod from brake pad.
3. Unhook return spring from brake pad.
4. Disconnect turnbuckle rod from brake rod.
4 - 12
BRAKE PAD BRAKES
5. Remove brake pad mounting hardware.
6. Remove brake pad from machine.
7. If brake release rod assembly warrants repair, proceed as

follows:
Compress return spring (13) and drive out roll pin (12). Pull out
release rod (10) and remove remaining parts (11 and 13).
WARNING
Spring loaded assembly. Assembly must be held to remove
spring. Use extreme care when disassembling.
SERVICE
REMARK
Callouts from exploded and flat views correspond with callouts in
following steps.
1. Position assembly in vise.
2. Remove large retaining ring (7).
4 - 13
BRAKE PAD BRAKES
3. Remove spacer washer (6).
4. Slide final bellcrank (1) off mounting bracket shaft.
5. Remove small retaining ring (9).
6. Remove spacer washer (8).
4 - 14
BRAKE PAD BRAKES
7. Slide brake pawl (5) off mounting bracket shaft.
8. Remove inner retaining ring (9).
9. Position final bellcrank (1) in press. Using a drive of same or

slightly smaller diameter, press both bearings out on same
press.
10. Position new needle bearing, seal edge outward, to final

bellcrank (1). Using a driver of a larger diameter than needle
bearing, press flush with edge. Repeat for remaining side. Coat
new needle bearing with fresh grease.
4 - 15
BRAKE PAD BRAKES
FINAL BELLCRANK
4 - 16
BRAKE PAD BRAKES
11. Install inner retaining ring (9) to mounting bracket shaft.
12. Coat mounting bracket shaft with Never-Seez. Install brake pawl
(5) on shaft.
13. Install spacer washer (8) on shaft.
14. Install outer retaining ring (9) to shaft.
4 - 17
BRAKE PAD BRAKES
15. Install final bellcrank (1) to mounting bracket shaft.
16. Install spacer washer (6) to mounting bracket shaft.
17. Install retaining ring (7) to mounting bracket shaft.
INSTALLATION
1. Check mounting surface of brake pad at frame and remove all

dirt and foreign debris.
4 - 18
BRAKE PAD BRAKES
2. Install brake pad to machine.
3. Secure brake pad to main frame with mounting hardware.

Torque bolts to 98 NCm (70 lbf ft) ±10%.
4. Secure turnbuckle rod to brake pad with clevis and new cotter
pins.
5. Attach return spring to brake pad.
4 - 19
BRAKE PAD BRAKES
6. Secure final brake rod to brake pad with clevis and new cotter
pins.
7. Install operator’s compartment floor plate and secure with

hardware. Torque bolts to 38 NCm (28 lbf ft) ±10%.
4 - 20
BRAKES BRAKE SUPPORT BRACKET
BRAKE SUPPORT BRACKET
1. Support Bracket 4. Lube Fitting 7. Brake Shaft 10. Throttle Control Bell-
2. Sealed Bearing 5. Grease Seal 8. Throttle Shaft crank
3. Main Bellcrank 6. Roll Pin 9. Decel Bellcrank
4 - 21
BRAKE SUPPORT BRACKET BRAKES
BRAKE SUPPORT BRACKET
4 - 22
COOLING
SECTION 6
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 2
SERVICE DIAGNOSIS . . . . . . . . . . . . . . . . . . . 3
RADIATOR - D32E-1 & D32P-1 . . . . . . . . . . . . 4
RADIATOR - D38E/P-1 & D39E/P-1 . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 12
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 20
WARNING
6-1
COOLING GENERAL
DESCRIPTION
The cooling system used is a closed type system that permits operation at extreme angles without loss of coolant
through the overflow pipe and also permits operation at higher engine temperatures without boiling. Extra care must
be taken that all connections are tight.
A centrifugal water pump circulates the coolant from the radiator lower tank through the cylinder head and crankcase
water jackets, past the thermostat into the radiator upper tank and down through the tubes of the radiator core to the
lower water tank where the cycle is repeated. Hoses and tubes provide the connections between the radiator inlet and
outlet headers and the engine.
The radiator uses an automotive type radiator cap with a built in pressure/vacuum valve to maintain a minimum pressure
of 0 to 3.45 kPa (0 to 0.5 psi) and a maximum of 45 to 55 kPa (6.5 to 8 psi) in the cooling system. For service of the
relief valve or radiator cap, refer to the OPERATION & MAINTENANCE MANUAL.
OPERATION
When the engine is started cold, the by pass type thermostat is closed, preventing circulation of low temperature coolant
through the radiator core. The coolant circulates only through the water pump and engine water passages. This
circulation during warm up period prevents formation of steam pockets. When the engine reaches operating
temperature, which is determined by thermostat specifications, the coil of the thermostat expands and opens the
passage for the coolant to flow from the engine water passages through the radiator and back to the water pump. The
temperature of the coolant controls the extent of the thermostat opening which, in turn, controls the amount of coolant
circulation.
SPECIFICATIONS
Cooling System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.5 R (7 gal)

Water Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal
Standard Thermostat Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 to 95EC (176 to 203EF)
Radiator Cap
Minimum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 3.45 kPa (0 to 0.5 psi)
Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 to 55 kPa (6.5 to 8 psi)
Coolant Temperature:
Minimum Top Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71EC (160EF)
Maximum Top Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95EC (203EF)
Engine Fan and Spacer Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 NCm (32 lbf ft)
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to the OPERATION & MAINTENANCE MANUAL
6-2
COOLING SERVICE DIAGNOSIS
GENERAL COMPLAINT
PROBABLE CAUSE REMARKS
Engine Overheating
Add coolant to radiator and check cooling system for

1. Not enough coolant. leaks. Refer to the OPERATION & MAINTENANCE
MANUAL.
Review operating instructions per OPERATION &

2. Engine overloaded.
MAINTENANCE MANUAL.
Remove obstruction. If exterior requires cleaning, apply

3. Radiator obstructed preventing free air passage.
air or water pressure to radiator from engine side.
Check tension; replace belt if greasy or worn. Refer to

4. Fan belt slipping.
the OPERATION & MAINTENANCE MANUAL.
5. Damaged fan shrouds or no fan shrouds. Repair or install and adjust new fan shrouds.
Remove radiator cap and inspect. Replace cap if gas-

6. Radiator cap not securely tightened to seal
ket is worn. Tighten radiator cap to maintain pressure
pressure system.
in system.
Replace cap. DO NOT repair or replace any regulating

7. Pressure relief valve on radiator cap faulty.
valve parts.
8. Collapsed lines or loose connections on suction Inspect lines for internal collapse. Replace where
side. necessary.
9. Coolant temperature gauge or sending unit

Test and/or replace parts as necessary.
faulty.
Flush with steam for external and internal clogs. Rod

10. Clogged radiator.
out core tubes.
Reverse flush cooling system to remove scale. Check

11. Scale deposits in crankcase or heads.
soluble oil content.
12. Incorrect range thermostat. Remove and replace with correct thermostat.
13. Thermostat inoperative. Replace.
14. Worn water pump. Replace pump.
15. Drive system overheating. Refer to SECTION 7.
Engine Runs Cold
1. Extremely cold weather. Cover radiator.
2. Incorrect range or inoperative thermostat. Remove and replace with correct thermostat.
3. Temperature gauge or sending unit faulty. Test and/or replace as necessary.
6-3
COOLING RADIATOR
RADIATOR AND CONNECTIONS - D32E-1 & D32P-1
1. Radiator 5. Hose Clamp 9. Drain Cock 13. Hose Fitting

2. Mounting Bracket 6. Inlet Hose 10. Top/Bottom Seal 14. Hose Clamp
3. Rubber Insulator 7. Hose Clamp 11. Side Seal 15. Stabilizer Link
4. Outlet Hose 8. Hose Clamp 12. Vent Hose 16. Vent Fitting
6-4
COOLING RADIATOR
RADIATOR AND CONNECTIONS - D38E-1, D38P-1, D39E-1, D39P-1

1. Radiator 6. Inlet Hose 11. Side Seal 16. Vent Fitting
2. Mounting Bracket 7. Hose Clamp 12. Vent Hose 17. Hose
3. Rubber Insulator 8. Hose Clamp 13. Hose Fitting 18. Hose
4. Outlet Tube 9. Drain Cock 14. Hose Clamp
5. Hose Clamp 10. Top/Bottom Seal 15. Stabilizer Link
6-5
COOLING RADIATOR
1. Reversible Fan
2. Front Cover
3. Mounting Bolt
4. Flat Washer
5. Fan Spacer
6. Blower Fan
7. Fan Spacer
FANS
1. Upper Fan Shroud
2. Lower Fan Shroud
3. Right Fan Guard
4. Left Fan Guard
FAN SHROUD AND GUARDS
6-6
RADIATOR COOLING
REMOVAL
WARNING
master switch to the off position and remove key.
WARNING
Hot scalding coolant can spray out if the radiator cap is
removed suddenly. Relieve system pressure by slowly
lifting the safety lever. Remove the cap ONLY after the
pressure is relieved.
WARNING
This procedure requires extreme caution. Use suitable
blocking equipment while under confines of machine.
1. Remove engine left side door.
3. From inside of engine compartment relieve tension off of tie

down rod (1) and compression ball (2). Disconnect mounting
bracket (3) hardware and remove bracket, rod and ball. Repeat
for opposite side.
4. Remove air inlet cap (1) from inlet pipe. Remove hood rear
mounting hardware (2). If equipped with forestry sweeps,
remove.
5. Install dNC eye bolts to hood and attach hoist.
6. Remove hood from machine.
6-7
COOLING RADIATOR
7. Install sling through pull hook on crankcase guard and position

around lift cylinders. Attach hoist to sling.
8. From under machine, carefully remove hardware and slowly

lower guard to ground. Pull guard out front of machine, attach
hoist and remove.
9. Remove radiator guard.
10. Carefully remove radiator cap to assist drainage of radiator.

Drain radiator into a suitable container.
11. Remove tube (1), connector hoses, and vent hose (2) from
radiator and engine.
12. Remove left and right fan guards.
6-8
RADIATOR COOLING
13. Remove upper fan shroud.
14. Reversible Fan: Remove front cover. In side housing remove

two bolts 180E apart and install M10 aligning studs. This will
keep fan pulley in place on fan hub. Remove remaining bolts
and lift fan with spacer from engine.
15. Blower Fan: Remove two bolts 180E apart and install M10
aligning studs. This will keep fan pulley in place on fan hub.
Remove remaining bolts and lift fan with spacer from engine.
16. Remove horn harness from two clips on radiator.
17. Through access hole in frame disconnect, cap and plug drive
train cooler hoses (1). Remove radiator lower hose (2).
REMARK
Lower radiator shroud removed for clarity.
18. Disconnect and remove stabilizing link from main frame and top
of radiator.
6-9
COOLING RADIATOR
19. Install two dNC eye bolts to holes in top tank. Connect hoist to
eye bolts.
20. Remove hardware from mounting brackets.
21. Using hooked pry bar, carefully work mounting brackets from
main frame.
22. Install dNF eye bolt to rubber insulator. Using a block of wood
and pry bar, carefully remove insulator being cautious not to
damage cylinder rod.
REMARK
When removing rubber insulators, do not allow eye bolt to enter
below nut as it may contact and damage radiator core fins. The
rubber insulators will be destroyed if not removed prior to radiator
removal.
23. Using hoist remove radiator from machine. Remove lower fan
shroud from radiator. Remove and replace foam strips from top
and bottom tanks.
6 - 10
RADIATOR COOLING
EXPLODED VIEW OF RADIATOR

1. Core and Header 5. Left Side Bracket 9. Gasket Strip 13. Hose Clip
2. Top Tank 6. Bolting Bar 10. Core Support 14. Radiator Cap
3. Bottom Tank 7. Bolting Bar 11. Core Side 15. Sight Glass
4. Right Side Bracket 8. End Gasket 12. Overflow Hose
DISASSEMBLY REMARK
6 - 11
COOLING RADIATOR
Callouts from exploded view correspond with callouts in

following steps.
1. Position radiator on blocking as shown. Remove overflow hose

(12), clips (13) and cap (14).
2. Remove sight glass (15) from top tank (2).
3. Remove hardware securing top tank (2) to left and right side
brackets (4 and 5).
4. Remove top front and rear bolting bars (7).
5. Using mechanics fingers to hold nut, remove hardware and top

side bolting bar (6) from each side of radiator.
6 - 12
RADIATOR COOLING
6. Remove top tank (2).
7. Remove top strip gaskets (9) and end gaskets (8) from core and
header.
8. Mark left side bracket (5) as shown.
9. Using mechanics fingers to hold nut, remove inner hardware

from bottom side bolting bar (6).
10. Remove outer hardware, clip and bottom side bolting bar (6).
11. Remove left side bracket (5) front and rear mounting hardware.
6 - 13
COOLING RADIATOR
12. Carefully slide left side bracket (5) out from core and header
(1).
13. Check condition of core support (10) and core side (11) and
replace as necessary.
14. Mark right side bracket (4) as shown.
15. Using mechanics fingers to hold nut, remove inner hardware

from bottom side bolting bar (6).
16. Remove outer hardware and bottom side bolting bar (6).
17. Remove right side bracket (4) front and rear mounting hard-
ware.
6 - 14
RADIATOR COOLING
18. Carefully slide left side bracket (5) out from core and header
(1).
19. Check condition of core support (10) and core side (11) and
20. Remove lower front and rear bolting bars (7).
21. Lift core and header (1) from bottom tank (3).
6 - 15
COOLING RADIATOR
22. Remove bottom strip gaskets (9) and end gaskets (8) from
bottom tank (3).
23. Flush out the upper and lower tanks with water. Flush out the
core with water under pressure, both inside and out. If the core
is greasy, clean it with steam cleaning equipment. Clean all
remaining radiator parts. Be sure all the old gasket material is
removed. Inspect the radiator water tanks for cracks. Examine
the fins and tubes of the core for damage. Rod out the tubes to
be sure they are not restricted. Straighten bent fins if possible to
avoid air flow restrictions. Examine all hoses for cracks or
rupture and install new when in doubt. Inspect the radiator cap.
REASSEMBLY
REMARK
Callouts from exploded view correspond with callouts in
following steps.
1. Position new bottom strip gaskets (9) and end gaskets (8) to
bottom tank (3).
2. Set core and header (1) on bottom tank (3) and align with pins.
3. Install lower front and rear bolting bars (7), bolts facing down.
6 - 16
RADIATOR COOLING
4. Start right side bracket (4) into core and header (1) using a soft
face mallet.
5. Insert aligning dowels and secure to bottom tank, bolts facing

down.
6. Position side bolting bar (6) and secure with hardware, three
inner bolts facing upward and two outer bolts facing down.
7. Start left side bracket (5) into core and header (1) using a soft
face mallet.
8. Insert aligning dowels and secure to bottom tank, bolts facing

down.
9. Position side bolting bar (6) and secure with hardware, three
inner bolts facing upward and two outer bolts facing down.
Install clip.
10. Position new top strip gaskets (9) and end gaskets (8) to core
and header (1).
6 - 17
COOLING RADIATOR
11. Position top tank (2) on core and header (1) and align to side
brackets with pins.
12. Install left side bolting bar (6) and clip and mount with outer
hardware, bolts facing up. Remove aligning pins and secure left
side bracket (5) to top tank (2) with bolts facing up.
13. Install three inner bolts facing down.
14. Install right side bolting bar (6) and mount with outer hardware,
bolts facing up. Remove aligning pins and secure right side
bracket (4) to top tank (2) with bolts facing up.
15. Install three inner bolts facing down.
16. Install front and rear bolting bars (7), bolts facing down.
6 - 18
RADIATOR COOLING
17. Torque all original mounting bolts to 18 NCm (13 lbf ft) ±10% or
replacement mounting bolts to 21 NCm (16 lbf ft) ±10%.
18. Coat sight glass (15) with Loctite pipe sealant and install to top
tank.
19. Install hose clips (13) to front of left side bracket (5).
20. Install overflow hose (12) to filler neck and connect to clips.
Install radiator cap (14). Install eye bolts to top tank and attach
hoist.
21. Install lower fan shroud loosely to radiator.
6 - 19
COOLING RADIATOR
INSTALLATION
1. Remove and discard radiator side foam strips from each side.
2. Tape horn harness to side of frame. This will assist in installing

radiator.
3. Install new bottom foam strip, flush with front edge of bottom
tank evenly spaced between both ends.
4. From left edge of foam strip (1), cut a small hole (2) (for
overflow hose) . 63 mm (2.5 in.). Install top foam strip, flush
with front edge of top tank evenly spaced between both ends.
Position overflow hose (3) through hole and secure to clips (4).
5. Check condition of bushings in stabilizing link. To replace,

position in press and remove.
6. If removed, press bushing into link and bottom.
6 - 20
RADIATOR COOLING
7. Install stabilizing link (1) to radiator (2) over foam strip (3). Mark
(4) foam at bottom of link. Remove link and cut slit in foam.
8. Install link and check it for fit up. Adjust as necessary. Remove
link.
9. Using hoist, lower radiator into frame being careful not to

damage bottom strip and horn harness.
10. Install stabilizing link and connect to radiator. Torque bolt to 38

NCm (28 lbf ft) ±10%.
11. Connect stabilizing link to front frame. Torque bolt to 38 NCm

(28 lbf ft) ±10%.
6 - 21
COOLING RADIATOR
12. Install rubber insulator (1) to mounting bracket (2).
13. Install left mounting bracket with rubber insulator to frame and
radiator using longer bolts.
14. Install right mounting bracket with rubber insulator to frame and
radiator and carefully draw in using longer bolts.
15. Remove long bolts from right side and install correct hardware.
16. Remove long bolts from left side and install correct hardware.
17. Through access hole in frame connect drive train cooler hoses
(1). Install radiator lower hose (2).
6 - 22
RADIATOR COOLING
18. Install right radiator side foam strip to side main frame with back
edge even with radiator.
19. Using small screwdriver tuck rear edge into radiator.
20. Install left radiator side foam strip (1) to side main frame with
back edge even with radiator. Using small screwdriver tuck rear
edge into radiator. Untape horn harness (2) and install to clips
(3) at top and bottom radiator tanks.
21. Blower Fan; Install fan (1) with spacer (2) over studs (3) and
install two bolts. Remove studs and install remaining bolts.
22. Torque mounting bolts to 43 NCm (32 lbf ft).
23. Reversible Fan: Install fan spacer (1) over studs (2).
24. Install fan and secure with two bolts. Remove studs and install
remaining bolts. Torque mounting bolts to 43 NCm (32 lbf ft).
25. Install fan cover.
6 - 23
COOLING RADIATOR
26. Install top fan shroud. Measure fan to shroud clearance and
equalize gap around fan and secure shrouding. Torque bolts to
38 NCm (28 lbf ft) ±10%.
27. Install left and right fan guard. Torque bolts to 21 NCm (16 lbf ft)
±10%.
28. Install tube (1), connector hoses, and vent hose (2) from
radiator to engine.
29. Install radiator guard. Torque bolts to 92 NCm (70 lbf ft) ±10%.
30. Position crankcase guard under machine.
31. Install sling (1) through pull hook on crankcase guard and
position around lift cylinders. Attach hoist to sling and lift guard
in place and secure. Torque bolts to 38 NCm (28 lbf ft) ±10%.
32. Install hood to machine. Remove eye bolts from hood.
6 - 24
RADIATOR COOLING
33. Install air inlet cap (1) to inlet pipe. Install hood rear mounting
hardware (2) loosely.
34. From inside of engine compartment, install hood tie down

brackets (3). Torque bolts to 10 NCm (8 lbf ft) ±10%. Install hook
rod (1) and ball (2) to hood and bracket and tighten nut until ball
compresses. Repeat for other side. Torque hood rear mounting
hardware to 92 NCm (70 lbf ft) ±10%.
35. Install engine left side door. Torque bolts to 38 NCm (28 lbf ft)
±10%.
36. Install engine right side door. Torque bolts to 38 NCm (28 lbf ft)
±10%.
37. Fill the cooling system per the OPERATION & MAINTENANCE
MANUAL.
6 - 25
DRIVE TRAIN
SECTION 7
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 2
DRIVE TRAIN SCHEMATIC . . . . . . . . . . . . . 3
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 5
PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . 7
BRAKE CYLINDER RELEASE . . . . . . . . . . . 8
TRANSMISSION CLUTCH . . . . . . . . . . . . . . 8
STALL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . 9
WARNING
7-1
DRIVE TRAIN GENERAL
SPECIFICATIONS
Tools:
Digital Optical Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 799-203-8001

Pressure Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR04-309
0 to 4137 kPa (0 to 600 psi) Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially Available
Pressures:
In Neutral:
Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 to 241 kPa (20 to 35 psi)
Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483 to 655 kPa (70 to 95 psi)
Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1792 to 1930 kPa (260 to 280 psi)
Converter Stalled:
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main minus 34 to 105 kPa (5 to 15 psi)
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main minus 34 to 105 kPa (5 to 15 psi)
First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction minus 0 to 69 kPa (0 to 10 psi)
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction minus 0 to 69 kPa (0 to 10 psi)
Third . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction minus 0 to 69 kPa (0 to 10 psi)
Stall Speeds:
Converter Stall:
D32E-1 or D32P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2050 to 2350 rpm
D38E-1 or D38P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1970 to 2280 rpm
D39E-1 or D39P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1850 to 2080 rpm
Full ( Converter and Hydraulic) Stall:
D32E-1 or D32P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1650 to 1990 rpm
D38E-1 or D38P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1650 to 2010 rpm
D39E-1 or D39P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1610 to 1860 rpm
7-2
GENERAL DRIVE TRAIN SCEMATIC
I, REGULATOR VALVE
RANGE SELECTOR VALVE TRklNS/STEERING
VClLVE
n
A
I I
RATE OF RISE VALVE
CHECK
LEFT BRhKE PEDFlLVClLVE PP VCILVE
l-4
TOW PORT
I I -
I I
CLI BR 1
I
CHARGE
SCAV
LEFT STEERING CYLINDER RIGHT STEERING CYLINDER

TRANSMISSION
Ill/
BRAKE CYLINDER
REAR MAIN FRAME
KCRW1816
7-3
DRIVE TRAIN GENERAL
7-4
GENERAL DRIVE TRAIN
DRIVE TRAIN COMPONENTS
1. Engine 7. Transmission 13. Left Brake Disc

2. Flex Plate 8. Output Shaft and Pinion 14. Right Brake Disc
3. Torque Converter 9. Bevel Gear Carrier 15. Right Sprocket Drive
4. Drive Shaft 10. Rear Main Frame 16. Left Sprocket Drive
5. Output Flange 11. Left Clutch Disc 17. Left Track
6. Transmission Input Flange 12. Right Clutch Disc 18. Right Track
DESCRIPTION
Power from the engine (1) is transmitted through a flex plate (2) to the torque converter (3). A drive shaft (4) couples
the output flange (5) of the torque converter with the input flange (6) of the transmission.
When the transmission is engaged, power is transmitted from the output shaft and pinion gear (8) to the bevel gear
carrier (9) in the rear frame (10).
OPERATION
The rear main frame is the common oil reservoir for the torque converter, transmission and steering drive. When the
engine is running, oil is drawn from bottom of the rear main frame, through suction strainer and on to the charge pump
(front section). The charge pump delivers oil flow through the pressure filter to the M port of the main pressure regulator
valve. For a more complete description and operation of the main pressure regulator valve, refer to Section 7C. The
charge pump flow is also teed off the line to the main pressure regulator valve to feed the neutral start valve and
transmission/steering valve. For a complete description of components, refer to Section 7C.
7-5
DRIVE TRAIN GENERAL
Again, the charge pump flow is teed off the outlet elbow of the pressure filter and directed to the left brake pedal valve
which releases the brake cylinder in the rear main frame. For a complete description of components, refer to Section
7E.
Main pressure oil is directed out the F or R port and also out the 1 or 2 port of the transmission/steering valve. When
directed out these ports, main pressure oil is routed by hoses to the range selector valve to shift the spools. For a
complete description of these valves, refer to Section 7C. Main pressurized oil from the main pressure regulator valve
is directed to the rate of rise valve and the range selector valve. For a complete description of the rate of rise valve, refer
to Section 7C.
Converter pressurized oil from the C port of the main pressure regulator valve is directed by hose to the inlet port of the
torque converter. After pressurized oil is used for torque multiplication, it exits the torque converter at the outlet port and
is directed by hose to the inlet port of the oil cooler, which is located in the radiator bottom tank. For a more complete
description and operation of the torque converter, refer to Section 7B.
Cooled oil from the outlet port of the oil cooler is regulated by the lubrication spool in the main pressure regulator valve
and directed to the transmission for lubrication purposes. Oil from the transmission housing is scavenged by hose
through an in-line oil strainer and through the rear element of double pump. From the pump outlet, oil is delivered back
to the rear main frame.
7-6
GENERAL DRIVE TRAIN
PRESSURES
i Measurement Conditions
‚ Engine at full throttle
‚ Engine coolant temperature in operating range
‚ Drive train oil in operating range
‚ Hydraulic oil at operating range
‚ Safety lock lever in the unlocked (up) position
‚ Secondary brake pedal applied
‚ Mounted equipment raised 76 to 101 mm (3 to 4 in.) off the
ground
1. Remove operator's foot platform and connect Drive Train

Pressure Test Kit to regulating valve and selector valve ports as
shown. Connect hose to elbow at inlet of converter.
2. With secondary brake pedal fully applied, run engine at full

throttle in neutral, 1st 2nd 3rd forward and 1st reverse. Read
and record readings.
WARNING
At full throttle, the brake will NOT hold the machine in either
1st or 2nd gear.
7-7
DRIVE TRAIN GENERAL
BRAKE CYLINDER RELEASE

‚ Safety lock lever in the locked (down) position
‚ Mounted equipment lowered to the ground
1. Open battery box door. Connect pressure gauge to quick

disconnect fitting.
2. With the above conditions met, read and record pressure with
the secondary brake pedal in the upright position. Fully depress
pedal and read and record pressure on gauge.
TRANSMISSION CLUTCH
‚ Safety lock lever in the unlocked (up) position
Remove the operator's foot platform. Start the engine and set at
full throttle and fully apply the secondary brake pedal. With the
transmission\steering lever in 3rd forward and then in 3rd reverse
check for sprocket or drive shaft rotation.
7-8
GENERAL DRIVE TRAIN
STALL SPEEDS

Converter Stall
Connect digital optical tachometer. With engine speed at full

throttle and secondary brake pedal applied, shift transmission into
3rd forward and register stall speed RPM.
i Do not keep the stall condition for more than 20 seconds.

Make sure that the converter oil temperature does not
exceed 120EC (248EF).
Full Stall (Converter and Hydraulic)
Connect digital optical tachometer. With engine speed at full

throttle and secondary brake pedal applied, shift transmission into
3rd forward. Raise the blade fully and hold to activate the equip-
ment relief valve. Register full stall speed RPM.
i Do not keep the stall condition for more than 20 seconds.
7-9
TORQUE CONVERTER
SECTION 7B
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 4
SERVICE DIAGNOSIS . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 13
COMPLETE ASSEMBLY . . . . . . . . . . . . . . . 13
CONVERTER ASSEMBLY . . . . . . . . . . . . . 17
REAR HOUSING . . . . . . . . . . . . . . . . . . . . . 21
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 24
REAR HOUSING . . . . . . . . . . . . . . . . . . . . . 24
CONVERTER ASSEMBLY . . . . . . . . . . . . . 28
COMPLETE ASSEMBLY . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 39
WARNING
7B - 1
TORQUE CONVERTER GENERAL
DESCRIPTION
The torque converter contains a single stage, single phase, three element converter assembly and a rear gear housing
to drive the drive train charge and scavenge pump and the equipment pump. The torque converter performs two
functions: it couples the engine to the transmission and multiplies engine torque. The converter assembly (1) is engine
driven by a flexible drive plate (2) bolted to the engine flywheel. The impeller (3) is bolted to the drive housing and is
supported on the ground sleeve hub (4) by a caged roller bearing (5). The pump drive gear (6), splined to the impeller
hub, drives the equipment and transmission pump gears (7) whenever the engine is running.
The stationary stator (8) is splined to the sleeve hub (4) and locked in place. Thrust washers (9 and 10) and bearings
(11) are located on each side of the stator to absorb the side thrusts of the impeller and turbine. The turbine (12) is
splined to the output shaft (13) and supported in the drive housing by a ball bearing (14). The output shaft is supported
at the rear by a ball bearing (15) in the rear gear housing (16) and the retainer cover (17).
OPERATION
The impeller (3), which rotates at engine rpm, receives fluid from the transmission pump via the main regulator valve
through the rear housing (16) and outside of the ground sleeve hub (4). Fluid enters the center of the impeller and is
expelled from its outside diameter blades at a high velocity. The turbine (12) is positioned opposite the impeller and
receives the full impact of the impeller discharge.
A small amount of fluid exits over the outside of the turbine to lubricate the turbine hub bearing (14). The fluid enters
the turbine at its outside diameter blades and is discharged at its center in the opposite direction of rotation from that
of the fluid entering the impeller. The curved blades of the stator (8) redirect a part of the flow of fluid back to the
impeller in the same direction that the impeller is moving to increase the torque output. The remaining fluid flows out
between the ground sleeve hub (4) and output shaft (13) to the oil cooler.
Because the turbine blades are curved, not all the force of the oil from the impeller is absorbed by the turbine. For
example, suppose the oil leaving the impeller carries a force of 45 kg (100 lbs), assume in this instance that the turbine
absorbs only 36 kg (80 lbs) of this force. Oil leaving the turbine carrying a force of 9 kg (20 lbs) is directed to the stator.
The curved stator blades will absorb only 4.5 kg (10 lbs) of the 9 kg (20 lbs) of force. The oil from the stator that is
redirected to the impeller carries a force of 4.5 kg (10 lbs). This 4.5 kg (10 lbs) of force is added to the original 45 kg
(100 lbs) of force. The converter will therefore continue to increase (multiply) the input torque up to the limits of the
converter design ratio.
When the machine load is light, the turbine speed is approximately the same as the impeller speed, thereby applying
little or no force on the blades. As the machine load increases, the turbine speed decreases. Since the impeller is still
turning at engine speed, fluid is thrown from the impeller and into the turbine with great force. Engine torque to the
sprockets increases with a resulting decrease of machine speed.
SPECIAL TOOLS
Engine Barring Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J 38686

Converter Lifting Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR04-718
Retainer Hub Aligning Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR04-717
Pump Spur Gear Bearing Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR04-719
Rear Housing Aligning Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR04-720
7B - 2
GENERAL TORQUE CONVERTER
TORQUE CONVERTER OPERATION

1. Converter Assembly 7. Pump Gears 13. Output Shaft
2. Drive Plate 8. Stator 14. Ball Bearing
3. Impeller 9. Thrust Washers 15. Ball Bearing
4. Ground Sleeve Hub 10. Thrust Washers 16. Rear Gear Housing
5. Caged Roller Bearing 11. Thrust Bearings 17. Retainer Cover
6. Pump Drive Gear 12. Turbine
7B - 3
TORQUE CONVERTER GENERAL
SPECIFICATIONS
Universal Joint Mounting Bolts - D32E-1, D32P-1, D38E-1 or D38P-1 . . . . . . . . . . . . . . . . . . . . . . . 33 NCm (24 lbf ft)
Universal Joint Mounting Bolts - D39E-1 or D39P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 NCm (42 lbf ft)
Converter Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 NCm (32 lbf ft)
Housing Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 to 58 NCm (36 to 43 lbf ft)
Flex Plate Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 to 58 NCm (36 to 43 lbf ft)
Yoke Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 to 88 NCm (54 to 65 lbf ft)
Drive Plate Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 NCm (80 lbf ft)
Bearing Retainer Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 to 58 NCm (36 to 43 lbf ft)
Impeller to Drive Housing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 to 58 NCm (36 to 43 lbf ft)
Stall Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 to 1
Type - D32E-1 or D32P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 mm (10 in) Single Stage Fixed Stator
Type - D38E-1 or D38P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 mm (10.6 in) Single Stage Fixed Stator
Type - D39E-1 or D39P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287 mm (11.3 in) Single Stage Fixed Stator
Fluid Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . 82E to 92EC (180E to 200EF) With a Maximum of 121EC (250EF)
Weight:
D32E-1 or D32P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394.6 kg (179 lbs)
D38E-1 or D38P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401.2 kg (182 lbs)
D39E-1 or D39P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445.3 kg (202 lbs)
SERVICE DIAGNOSIS
PROBABLE CAUSE REMEDY

Loss of Fluid from Torque Converter
1. Leaking connections. Run engine at part throttle and inspect lines for leaks.
Tighten or replace parts as necessary.
2. Leaking converter. Check all hardware and gasket joints while system is
under pressure. Replace parts as necessary. Check
sleeve and shaft seal ring. Replace as necessary.
Torque Converter Overheating
1. Operating too long in low efficiency ranges. Review operating instructions in OPERATION & MAIN-
TENANCE MANUAL
2. Low basic pressure. Check for broken lines or loose connections on pressure
side of system. Check for excessive fluid leaking.
3. Low oil level. Check level in rear main frame.
4. Converter by-pass valve sticking. Remove valve and clean. Inspect bore and spring.
5. Excessive converter oil leakage into flywheel hous- Check ground sleeve and turbine shaft sealing ring wear.
ing. Replace as necessary.
Loss of Power
1. Low oil level. Check level in rear main frame.
2. Low basic pressure. Refer to Item 2 under Torque Converter Overheating.
3. Engine not up to rated performance. Refer to ENGINE SHOP MANUAL.
4. Excessive converter oil leakage. Check ground sleeve and turbine shaft sealing ring wear.
Replace.
Grinding or Scraping Noise Inside Converter Housing
1. Bearing failure allowing turbine or impeller blades to
strike fixed stator. Replace bearings, turbine or impeller as necessary.
7B - 4
REMOVAL TORQUE CONVERTER
WARNING
1. Drain hydraulic reservoir. Refer to the OPERATION & MAINTE-

NANCE MANUAL.
2. Drain transmission system. Refer to the OPERATION &

MAINTENANCE MANUAL.
7B - 5
TORQUE CONVERTER REMOVAL

for opposite side.
mounting hardware (2).
7. Install eye bolts to hood and attach hoist.
9. Remove front (1) and side (2) floor mat retainer angles from
each side of machine.
10. Remove floor mat.
11. Remove floor plate.
7B - 6
12. Remove rear cover.
13. Disconnect front and rear light harness (1) from main harness
(2). Cut tie strap (3) and remove from clip.
14. Attach four leg chain and hoist to ROPS lifting brackets.
Remove mounting hardware and lift ROPS from machine.
REMARK
For a machine equipped with a cab, see Section 13 for cab
removal.
15. Using a rolling floor jack, remove transmission guard from

under machine.
7B - 7
16. Disconnect final brake rod (1) from bellcrank (2).
17. Remove dash brace bar from right side of machine.
18. Cut cable tie holding hoses. Remove fuel filter mounting block
from dashboard and roll forward. Remove dash brace bar from
left side of machine.
19. Disconnect pump control rod (1) and over travel decelerator (2)
from throttle control assembly (3).
20. Disconnect instrument panel harness at bracket at rear of

engine.
21. Disconnect dual harness lead.
22. Disconnect and remove engine shutoff solenoid.
23. D32E-1 or D32P-1: Disconnect wiring lead from switch at air

cleaner outlet pipe.
7B - 8
24. D38E-1, D38P-1, D39E-1 or D39P-1: Disconnect wiring lead

from switch at air cleaner outlet pipe.
25. D32E-1 or D32P-1: Disconnect elbow at air intake manifold.

Cover inlet to engine manifold.
26. D38E-1, D38P-1, D39E-1 or D39P-1: Loosen hose clamp (1) at

inlet of turbocharger (2) and remove hose (3) from turbo-
charger. Cover turbocharger inlet.
REMARK
Tag, cap and plug all disconnected hoses, tubing and fittings.
27. At left side, disconnect two hoses (1 and 2) at foot brake valve
(3).
28. At right side, disconnect remaining hose (1) at foot brake valve
(2).
7B - 9
29. Install two ½NC eye bolts to dashboard and attach chain and
hoist.
30. Remove three mounting bolts from each side and lift dashboard
from machine.
REMARK
On some models there will be shims between dashboard and
main frame. Keep shims with sides they were removed from.
On machines with cabs, the dashboard will come off with the cab.
See Section 13 for cab removal.
31. Disconnect, cap and plug converter inlet hose at torque con-
verter.
32. Disconnect, cap and plug converter drain hose at torque

converter.
33. Disconnect, cap and plug pump to filter hose at front port of
charge and scavenge pump.
34. Disconnect, cap and plug pump to rear main frame hose at rear
port of charge and scavenge pump.
35. Disconnect, cap and plug front half of reservoir to pump hose at
top port of equipment pump.
36. Remove mounting hardware and drive shaft.
7B - 10
37. Disconnect, cap and plug pump to equipment valve hose at

bottom port of equipment pump.
38. Disconnect drive train temperature lead at switch. Disconnect,

cap and plug converter outlet switch tube adapter from elbow at
bottom of torque converter.
39. Disconnect, cap and plug both hoses at bottom ports of charge
and scavenge pump.
40. Remove mounting hardware from equipment pump, slide out of

converter and remove. Remove mounting hardware from
charge and scavenge pump, slide out of converter and remove.
41. Cut harness loose from battery cable. Unclip harness and cable
from converter and release from mounting bracket. Position
wiring out of the way.
42. Remove fuel strainer and cap lines.
7B - 11
43. Remove or reposition throttle linkage out of the way.
44. Remove access cover and barring tool cover.
45. Using barring tool, J38686 rotate engine so that all eight
flywheel to flex plate bolts can be removed.
46. Remove two top converter mounting bolts. Install lifting tool,
DR04-718 between top pump mounting holes and removed bolt
holes. Attach hoist. Remove remaining bolts. Install two M10
mounting studs and slide converter out. Adjust balancing slide
of bracket so converter hangs evenly.
47. Lift converter out of machine.
48. Check condition of flywheel and housing, refer to ENGINE

SHOP MANUAL. Flywheel housing is a dry type and should not
contain any oil.
7B - 12
DISASSEMBLY TORQUE CONVERTER
COMPLETE ASSEMBLY
EXPLODED VIEW OF COMPLETE ASSEMBLY
7B - 13
TORQUE CONVERTER DISASSEMBLY
CROSS SECTION VIEW OF COMPLETE ASSEMBLY
Legend for Exploded and Cross Section Views

1. Converter Housing 7. Retainer Gasket 13. Retaining Ring
2. Pump Drive Gear 8. Output Shaft 14. Converter Assembly
3. Output Yoke 9. Ball Bearing 15. Rear Housing
4. Flat Washer 10. Seal Ring 16. Port Plug
5. Oil Seal 11. Cover Gasket 17. Port Plug
6. Bearing Retainer 12. Oil Seal 18. Retainer Shim
7B - 14
1. While retaining output yoke, remove hardware, lock plate and

flex plate.
REMARK
Callouts from exploded and cross section views correspond with
callouts in following steps.
2. Remove one bearing retainer plate (6) bolt and install longer
one that will allow output yoke (3) to be retained while removing
yoke bolt. Remove bolt.
3. Remove washer (4) and output yoke (3).
4. Remove bearing retainer (6) mounting hardware.
5. Remove bearing retainer (6).
6. Separate gasket (7) from bearing retainer (6) and discard.
7. Press oil seal (5) from bearing retainer (6).
8. Remove bearing shims (18).
7B - 15
9. Pull output shaft (8) with bearing (9) out from assembly.
10. Remove seal ring (10) from output shaft (8).
11. Check condition of bearing (9) and if replacement is necessary,

position in press and remove.
12. Insert two ½NC eye bolts to pump mounting holes and connect
hoist. Remove rear housing (15) mounting hardware.
13. Lift rear housing (15) off from converter housing (1).
14. Remove rear retaining ring (13).
7B - 16
15. Carefully pry pump drive gear (2) from converter assembly.
16. Remove front retaining ring (13).
17. Lift housing (1) off from converter assembly.
18. Drive oil seal (12) from housing (1) and discard.
CONVERTER ASSEMBLY
1. Remove mounting hardware and impeller (3) from assembly.
2. Check condition of oil seal sleeve (4). If replacement is neces-

sary remove as follows: Using a low heat source, break Loctite
bond between oil seal sleeve and impeller hub. Cold chisel at
four spots on sleeve, inset of splines, and remove from hub.
REMARK
Oil seal sleeve is press fit on impeller hub and retained with Loctite
#609.
7B - 17
EXPLODED VIEW OF CONVERTER ASSEMBLY
7B - 18

1. Drive Housing
2. Ball Bearing
3. Impeller
4. Oil Seal Sleeve
5. Needle Bearing
6. Turbine
7. Stator
8. Thrust Washer
9. Thrust Bearing
10. Thrust Washer
11. O-Ring
12. Flex Plate
13. Lock Plate
REMARK
3. Check condition of needle bearing inside of impeller hub. If

replacement is necessary, using a drift, remove and discard.
4. Remove housing O-Ring (11).
5. Remove outer thrust washer (10), thrust bearing (9) and inner
thrust washer (8).
6. Remove stator (7).
7B - 19
7. Remove inner thrust washer (8), thrust bearing (9) and outer
thrust washer (10).
8. Install four bolts of sufficient length to drive housing (1).
9. Position a block of wood on bench. Turn drive housing (1) over

and carefully bump on bench until turbine with bearing come
free of housing.
10. If bearing (2) replacement is necessary, install three legged

puller and remove.
7B - 20
REAR HOUSING
EXPLODED VIEW OF REAR HOUSING
7B - 21

1. Hub Gasket
2. Ground Sleeve Hub
3. Ball Bearing
4. Pump Gear
5. Seal Ring
6. Retaining Ring
7. Retaining Ring
8. Rear Housing
9. Retainer Hub
10. Hub Gasket
REMARK
1. Position rear housing (8) on suitable blocking. Remove bearing

retaining ring (7) from one pump mounting side.
2. Drive gear with bearing from housing.
3. Turn housing over and drive other bearing (3) out of housing.
4. Install puller arrangement to bearing (3) and remove from gear

(4).
7B - 22
5. Remove retaining ring (6) from drive housing.
6. Remove bearing retaining ring (7) from other pump mounting

side.
7. Drive gear (4) with bearing from housing.
8. Turn housing over and drive other bearing (3) out of housing.
9. Install puller arrangement to bearing (3) and remove from gear

(4).
10. Remove retaining ring (6) from drive housing.
11. Position drive housing in press. Using suitable driver, remove

ground sleeve hub (2), retainer hub (9) and gaskets (1 and 10).
Discard gaskets.
12. Remove seal ring (5) from retainer hub.
7B - 23
TORQUE CONVERTER REASSEMBLY
REAR HOUSING
EXPLODED VIEW OF REAR HOUSING
7B - 24
REASSEMBLY TORQUE CONVERTER

1. Hub Gasket
2. Ground Sleeve Hub
3. Ball Bearing
4. Pump Gear
5. Seal Ring
6. Retaining Ring
7. Retaining Ring
8. Rear Housing
9. Retainer Hub
10. Hub Gasket
REMARK
1. Install aligning studs, DR04-717 into retainer hub. Position

gasket (10) over studs aligning holes.
2. Install ground sleeve hub (2) over studs against retainer hub (9).
Position assembly in controlled freezer at -40EC (-40EF) for 4
hours or pack in dry ice for 4 hours.
3. Position rear housing (8) in press. Position hub gasket (1) in

housing aligning holes.
4. Remove assembly from freezer and aligning studs with holes,

press and bottom in rear housing.
7B - 25
5. After hubs have reached room temperature, install hooked seal

ring (5) to retainer hub.
6. Install retaining ring (6) into housing at one pump mounting

area.
7. Finger press outer bearing (3) into housing up against retaining

ring.
8. Position pump gear (4) in press. Press inner bearing (3) onto
gear until it bottoms.
9. From under side of housing position pump gear (4) with bolt and
washer from DR04-719 through bearing.
REMARK
Rear housing rotated 180E for clarity.
10. Position driver DR04-719 on bearing inner race and secure with
washer and nut.
11. Tighten installing tool until inner bearing bottoms against large
retaining ring.
12. Install retaining ring (7) to pump gear (4).
7B - 26
13. Install retaining ring (6) into housing at other pump mounting
area.
14. Finger press outer bearing (3) into housing up against retaining
ring.
15. Position pump gear (4) in press. Press inner bearing (3) onto
gear until it bottoms.
16. From under side of housing position pump gear (4) with bolt and
washer from, DR04-719 through bearing.
REMARK
Rear housing rotated 180E for clarity.
17. Position driver DR04-719 on bearing inner race and secure with
washer and nut.
18. Tighten installing tool until inner bearing bottoms against large
retaining ring.
19. Install retaining ring (7) to pump gear (4).
7B - 27
CONVERTER ASSEMBLY
EXPLODED VIEW OF CONVERTER ASSEMBLY
7B - 28

1. Drive Housing
2. Ball Bearing
3. Impeller
4. Oil Seal Sleeve
5. Needle Bearing
6. Turbine
7. Stator
8. Thrust Washer
9. Thrust Bearing
10. Thrust Washer
11. O-Ring
12. Flex Plate
13. Lock Plate
REMARK
1. Place impeller (3) in press. Position needle bearing (5) in hub

and bottom with press.
2. Heat oil seal sleeve (4).
3. Install oil seal sleeve (4) on impeller hub until gear splines clear.
7B - 29
4. Place impeller (3) in press. Start spur gear on splines and shore
up press.
5. Coat oil seal sleeve mounting area with Loctite #609 and bottom
sleeve with gear and press. Remove gear.
6. Locate heavy mark on drive housing (1) and mark line to side.
7. Using press, bottom ball bearing (2) on turbine hub.
8. Install turbine (6) into drive housing until bearing bottoms.

Liberally coat turbine with clean oil.
7B - 30
9. Install outer thrust washer (10), smaller OD, into turbine.
10. Install thrust bearing (9) onto thrust washer.
11. Install inner thrust washer (8), larger OD, onto thrust bearing.
12. Install stator (7), indented end, in turbine onto thrust and
bearing. Liberally coat with clean oil.
13. Install inner thrust washer (8), larger OD, into stator.
14. Install thrust bearing (9) onto thrust washer.
15. Install outer thrust washer (10), smaller OD, onto thrust bearing.
Liberally coat with clean oil.
16. Locate heavy mark on impeller (3) and mark line to side. Install
O-ring (11) on impeller.
7B - 31
17. Aligning marks on impeller (3) to drive housing (1), install

impeller and secure with hardware. Torque to 49 to 58 NCm (36
to 43 lbf ft).
COMPLETE ASSEMBLY
REMARK
1. Clean out oil seal mounting area in converter housing (1).
2. Position oil seal (12) with spring garter lip facing rear housing.
3. Using suitable driver, install oil seal (12) flush with outer edge of
converter housing.
4. Liberally coat oil seal sleeve with clean oil.
7B - 32
7B - 33
CROSS SECTION VIEW OF COMPLETE ASSEMBLY

Legend for Exploded and cross Section views
1. Converter Housing 6. Bearing Retainer 11. Cover Gasket 16. Port Plug
2. Pump Drive Gear 7. Retainer Gasket 12. Oil Seal 17. Port Plug
3. Output Yoke 8. Output Shaft 13. Retaining Ring 18. Retainer shim
4. Flat Washer 9. Ball Bearing 14. Converter
5. Oil Seal 10. Seal Ring Assembly
15. Rear Housing
7B - 34
5. Attach eye bolts and hoist to converter housing (1) and lower
over converter assembly (14) being careful not to damage oil
seal.
6. Install retaining ring (13) in lower groove on impeller hub.
7. Install pump drive spur gear (2) to impeller hub.
8. Install retaining ring (13) in upper groove on impeller hub.
9. Install new gasket (11) on converter housing.
7B - 35
10. Install four aligning studs DR04-720, to converter housing.
11. Install ½NC eye bolts to pump mounting flanges and lower
rear housing (15) over studs to converter housing (1).
12. Reposition eye bolts as shown and install mounting hardware.

Torque bolts to 49 to 58 NCm (36 to 43 lbf ft).
13. Press bearing (9) onto output shaft (8) and bottom. Install
hooked ring seal (10) to groove on output shaft.
14. Using eye bolt, lower output shaft (8) aligning splines with
stator and turbine and bottoming against ground sleeve hub.
Remove aligning studs from ground sleeve retainer.
7B - 36
15. Install gasket (7) to housing. Position solder at three equidis-

tant spots on bearing (9) outer race.
16. Install bearing retainer (6) being careful not to dislodge solder
from bearing race. Torque bolts to 49 to 58 NCm (36 to 43 lbf
ft). Remove bolts and bearing retainer.
17. Measure each solder thickness, average readings. Elect a

shim pack equal to averaged readings. Shims are available in
thickness increments of 0.127, 0.254 and 0.508 mm (0.005,
0.010 and 0.020 in).
18. Install required shim pack (18) on outer race of bearing.
19. Position bearing retainer (6) in press and install oil seal (5)
flush with edge.
20. Install bearing retainer (6) with hardware and torque to 49 to

58 NCm (36 to 43 lbf ft).
7B - 37
21. Install output yoke (3), flat washer (4) and hardware. Install
eye bolts and bolt and secure with pry bars. Torque bolt to 73
to 88 NCm (54 to 65 lbf ft).
22. Install fittings with new o-rings to rear housing at marked

positions. Install lifting device DR04-718 to torque converter.
23. Install flex plate and lock plate and secure with hardware.
Torque bolts to 49 to 58 NCm (36 to 43 lbf ft).
7B - 38
INSTALLATION TORQUE CONVERTER
1. Position converter in frame. Slide up on dowels aligning con-

verter nose with flywheel pilot bore. Secure with half of the
metric bolts. Remove lifting tool and dowels. Install remaining
mounting bolts and torque all to 43 NCm (32 lbf ft).
2. Using barring tool, J 38686 rotate engine so that one flywheel

to flex plate bolts can be installed. Coat bolt with clean oil and
torque to 49 to 58 NCm (36 to 43 lbf ft). Repeat for remaining
seven bolts.
3. Install access cover and barring tool cover with new o-ring.
4. Reposition throttle linkage.
5. Install breather hose to engine.
6. Install in line fuel strainer.
7. Reclip harness and battery cable to damper. Apply electrical

sealing grease, Grafo 112-X to bottom terminal connector
and install to mounting bracket. Tie strap harness to battery
cable.
7B - 39
TORQUE CONVERTER INSTALLATION
8. Install new o-ring to equipment pump and slide in converter

housing and secure with hardware. Install new o-ring to
charge and scavenge pump and slide in converter housing
and secure with hardware. Torque bolts to 92 NCm (70 lbf ft)
±10%.
9. Install both hoses at bottom ports of charge and scavenge

pump.
10. Connect converter outlet switch tube adapter to elbow at

bottom of torque converter. Apply electrical sealing grease,
Grafo 112-X to drive train temperature lead and connect at
switch.
11. Connect pump to equipment valve hose to bottom port of

equipment pump.
12. Install drive shaft with mounting hardware. Torque D32E-1,

D32P-1, D38E-1 or D38P-1 bolts to 33 NCm (24 lbf ft). Torque
D39E-1 or D39P-1 bolts to 57 NCm (42 lbf ft).
13. Connect front half of reservoir to pump hose to top port of

equipment pump.
14. Connect pump to rear main frame hose to rear port of charge
and scavenge pump.
15. Connect pump to filter hose at front port of charge and

scavenge pump.
7B - 40
16. Connect converter drain hose at torque converter.
17. Connect converter inlet hose at torque converter.
18. Position dashboard in place. Coat hardware (3 each side) with

Loctite #262 and secure with shims. Torque bolts to 92 NCm
(70 lbf ft) ±10%.
REMARK
On machines with cabs, the dashboard will reinstall with the
cab. See Section 13 for cab reassembly.
19. At right side, connect hose (1) to foot brake valve (2).
20. At left side, connect two hoses (1 and 2) to foot brake valve
(3).
21. D32E-1 or D32P-1; Remove cover from inlet manifold and

connect elbow.
7B - 41
22. D38E-1, D38P-1, D39E-1 or D39P-1; Remove cover from

turbocharger (2) and connect hose (3) and secure with hose
clamp (1).
23. D32E-1 or D32P-1; Apply electrical sealing grease, Grafo

112-X to wiring lead and connect to switch at air cleaner
outlet pipe.
24. D38E-1, D38P-1, D39E-1 or D39P-1; Apply electrical sealing

grease, Grafo 112-X to wiring lead and connect to switch at
air cleaner outlet pipe.
25. Reinstall and connect fuel shutoff solenoid.
25. Connect dual harness lead.
26. Connect instrument panel harness to bracket at rear of en-

gine.
7B - 42
27. Connect pump control rod (1) and over travel decelerator (2)
to throttle control (3). Torque bolt to 10 NCm (8 lbf ft) ±10%.
28. Install dash brace bar to left side of machine. Torque bolts to
92 NCm (70 bf ft) ±10%.
29. Install dash brace bar to right side of machine. Torque bolts to
92 NCm (70 bf ft) ±10%.
30. Install final brake rod (1) to bellcrank (2).
31. Using a rolling floor jack, install transmission guard to ma-

chine and secure with hardware. Torque bolts to 92 NCm (70
lbf ft) ±10%.
32. Using hoist, install ROPS on machine securing with hardware

(nuts inward) and torque to 822 ±47 NCm (605 ±35 lbf ft).
REMARK
reassembly.
7B - 43
33. Connect front and rear light harness (1) to main harness (2).
Tie strap (3) and insert in clip.
34. Position rear cover in place and secure with hardware.

35. Install operators compartment floor plate. Torque bolts to 38

NCm (28 lbf ft) ±10%.
36. Install floor mat.
37. Install front (1) and side (2) floor mat retainer angles at each
side of machine. Torque bolts to 38 NCm (28 lbf ft) ±10%.
7B - 44

brackets (3). Torque bolts to 10 NCm (8 lbf ft) ±10%. Install
hook rod (1) and ball (2) to hood and bracket and tighten nut
until ball compresses. Repeat for other side. Torque hood
rear mounting hardware to 92 NCm (70 lbf ft) ±10%.
±10%.
42. Install engine right side door. Torque bolts to 38 NCm (28 lbf
ft) ±10%.
43. Refill hydraulic and drive train systems with proper fluid, refer
to the OPERATION & MAINTENANCE MANUAL.
7B - 45
TRANSMISSION
SECTION 7C
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . 84
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 85
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 5 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 RANGE SELECTOR VALVE . . . . . . . . . . . . . . . . . . 92
COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 22 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . 93
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 94
DIRECTIONAL (INPUT) SHAFT . . . . . . . . . . . . . . . . 38 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
SPRING CRITERION . . . . . . . . . . . . . . . . . . . . . . 40 RATE OF RISE VALVE . . . . . . . . . . . . . . . . . . . . . . . 99
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 104
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 105
COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 TRANSMISSION/STEERING VALVE . . . . . . . . . . . 129
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
RANGE (OUTPUT) SHAFT . . . . . . . . . . . . . . . . . . . 57 THEORY OF OPERATION . . . . . . . . . . . . . . . . . 131
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 132
SPRING CRITERION . . . . . . . . . . . . . . . . . . . . . . 59 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 135
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
REVERSE IDLER SHAFT . . . . . . . . . . . . . . . . . . . . . 80 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 152
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 155
MAIN REGULATOR VALVE . . . . . . . . . . . . . . . . . . . 83 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
WARNING
7C - 1
TRANSMISSION GENERAL
CROSS SECTION VIEW OF TRANSMISSION
1. Transmission Case 8. Output Shaft 15. 2nd Speed Gear

2. Transmission Cover 9. Directional Clutch Manifold 16. 3rd Speed Gear
3. Mounting O-Ring 10. Reverse Gear 17. Countershaft
4. Output Shaft Manifold 11. Forward Gear 18. Idler Shaft
5. 1st Speed Driven Gear 12. Input Shaft 19. Reverse Idler Gear
6. 2nd Speed Driven Gear 13. Countershaft Cover
7. 3rd Speed Driven Gear 14. 1st Speed Gear
REMARK
Unless otherwise notated, all reference callouts refer to cross section view of transmission.
7C - 2
GENERAL TRANSMISSION
DESCRIPTION
The transmission is designed to provide high speed shifting by use of hydraulically actuated clutch packs. It has three
forward and three reverse speeds. Gears are mounted on four shafts; directional (input) shaft (12), range (output) shaft
(8), countershaft (17) and reverse idler shaft (18).
Directional (Input) Shaft
The directional (input) shaft (12) rotates on two tapered roller bearings. It consists of a forward drive gear (11), reverse
drive gear (10) and dual hydraulic clutch packs.
Reverse Idler Shaft
The reverse idler shaft (18) is bolted to the housing (1). It consists of a reverse idler gear (19) which rides on two
tapered roller bearings and is in constant mesh with reverse drive gear (10) and 2nd speed drive gear (15).
Countershaft
The countershaft (17) rotates on two tapered roller bearings. It consists of 3rd speed drive gear (16), 2nd speed drive
gear (15) and 1st speed drive gear (14).
Range (Output) Shaft
The range (output) shaft (8) rotates on two tapered roller bearings. It consists of the 3rd speed driven gear (7), the 2nd
speed driven gear (6) and the 1st speed driven gear (5). It also contains dual hydraulic clutch pack for 2nd and 3rd
speeds and a single clutch pack assembly for 1st speed.
OPERATION
Main pressure oil is detected from the range selector valve through passages
in the trans case to the manifolds and on through the shafts to engage the
desired clutch pack. Lubrication oil is always directed through passages to
lubricate the bearings, clutches and shafts.
Neutral
Engine power and torque are delivered through the converter and drive shaft
to the transmission directional (input) shaft (A). As the forward and reverse
clutch packs are not engaged, the shaft turns freely inside the gears. No
power is transmitted to the countershaft (C) or to the range (output) shaft (B).
1st Speed Forward

to the directional (input) shaft (A). As the forward clutch pack is activated, it
engages the forward gear (B) and rotates it in the same direction as the shaft.
The countershaft (C), through the 3rd speed drive gear (D), is rotated in the
opposite direction. As the 1st speed clutch pack is activated, it engages the
1st speed driven gear (E) to the range (output) shaft (F). Power from the
countershaft is transferred, through the 1st speed drive gear (G), to the range
(output) shaft in the opposite direction of rotation. Power is delivered from the
range (output) shaft to the steering and sprocket drives and on to the tracks.
7C - 3
TRANSMISSION GENERAL
2nd Speed Forward

The countershaft (C), through the 3rd speed drive gear (D), is rotated in the
opposite direction. As the 2nd speed clutch pack is activated, it engages the
2nd speed driven gear (E) to the range (output) shaft (F). Power from the
countershaft is transferred, through the 2nd speed drive gear (G), to the
range (output) shaft in the opposite direction of rotation. Power is delivered
from the range (output) shaft to the steering and sprocket drives and on out
to the tracks.
3rd Speed Forward

The countershaft (C), through the 3rd speed clutch pack, is activated and
engages the 3rd speed driven gear (D) to the range (output) shaft (E). Power
from the 3rd speed drive gear (F) is transferred to the range (output) shaft in
the opposite direction of rotation. Power is delivered from the range (output)
shaft to the steering and sprocket drive and on out to the tracks.
1st Speed Reverse

Engine power and torque are delivered through the torque converter and
drive shaft to the directional (input) shaft (A). As the reverse clutch pack is
activated, it engages the reverse gear (B) and rotates it in the same direction
as the shaft. The countershaft (C), through the reverse idler gear (D) and the
2nd speed drive gear (E), is rotated in the same direction as the directional
(input) shaft. As the 1st speed clutch pack is activated it engages the 1st
speed driven gear (F) to the range (output) shaft (G). Power from the
countershaft is transferred, through the 2nd and 1st speed drive gear (H) and
1st speed driven gear, to the range (output) shaft in the opposite direction of
rotation. Power is delivered from the range (output) shaft to the steering and
sprocket drives and on out to the tracks.
2nd Speed Reverse

as the shaft. The 2nd speed drive gear (C), through the reverse idler gear
(D), is rotated in the same direction as the directional (input) shaft. As the 2nd
speed clutch pack is activated, it engages the 2nd speed driven gear (E) to
the range (output) shaft (F). Power is transferred from the 2nd speed drive
gear to the range (output) shaft through the driven gear and clutch pack in
the opposite direction of rotation from the directional (input) shaft. Power is
delivered from the range (output) shaft to the steering and sprocket drives
and on out to the tracks.
7C - 4
GENERAL TRANSMISSION
3rd Speed Reverse

as the shaft. The countershaft (C), through the reverse idler gear (D) and the
2nd speed drive gear (E), is rotated in the same direction as the directional
(input) shaft. As the 3rd speed clutch pack is activated, it engages the 3rd
speed driven gear (F) to the range (output) shaft (G). Power from the
countershaft is transferred to the range (output) shaft through the 3rd speed
drive gear (H) and driven gear and the clutch pack in the opposite direction
of rotation. Power is delivered from the range (output) shaft to the steering
and sprocket drives and on out to the tracks.
SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power shift

Number of Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Forward - 3 Reverse
Shaft End Play - All Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 to 0.31 mm (0.007 to 0.012 in)
Forward or Reverse Clutch Pack:
Friction Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Separator Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
!st Speed Clutch Pack:
Friction Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2nd or 3rd Speed Clutch Pack
Friction Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Special Tools:
Transmission Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR04-721
Directional Shaft Manifold Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR04-721-1
Dowel Pin Installing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR04-721-2
Bearing Adjuster Bridge Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR04-721-3
Transmission Valve Aligning Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR04-721-4
Range (Output) Shaft Holder Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR04-721-5
Clutch Pack Spring Compressor Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR04-721-6
Range (Output) Shaft 1st Pack Compacting Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR04-721-7
Transmission Aligning Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR04-721-8
Transmission Manifold Aligning Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR04-720
Sealant:
Transmission Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #515
Countershaft Cover Pipe Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #592
Transmission Valve Manifold Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #262
Transmission Valve Manifold Orifice Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #592
Transmission Valve Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #262
Range (Output) Shaft Splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Molykote "G"
Rear Main Frame Gasket Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300139H1
Electrical Sealing Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grafo 112-X
Transmission Shifter Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #242
Weights:
Transmission with Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 kg (448 lbs)
Transmission w/o Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 kg (370 lbs)
Torques:
Battery Hold Down Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9 NCm (10 lbf in)
Battery Terminal Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 NCm (23 lbf ft)
Transmission Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 to 406 NCm (260 to 300 lbf ft)
Pinion Gear Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434 NCm (320 lbf ft)
7C - 5
TRANSMISSION REMOVAL
WARNING

NANCE MANUAL.

MAINTENANCE MANUAL.
7C - 6
REMOVAL TRANSMISSION

for opposite side.
9. Remove front (1) and side (2) floormat retainer angles from
7C - 7
REMARK
removal.

under machine
7C - 8
18. Remove dash brace bar from left side of machine.

engine.
22. Disconnect and remove fuel shutoff solenoid.
23. D32E-1 or D32P-1; Disconnect wiring lead from switch at air

7C - 9
24. D38E-1, D38P-1, D39E-1 or D39P-1; Disconnect wiring lead



REMARK
(3).
(2).
7C - 10
hoist.
from machine.
REMARK
On machines with cabs, the dashboard will come off with the cab.
See Section 13 for cab removal.
30. Remove armrest and brackets from each side of machine.
31. Connect sling and hoist to seat. Remove front and rear hard-
ware and lift seat from machine.
32. Remove seat platform.
33. Remove cover of fuel level switch at top of fuel tank.
34. Disconnect wire leads at switch.
7C - 11
35. Replace cover and unclip harness from fuel tank.
36. Remove back up alarm mounting hardware.
37. Flip over alarm and remove wire leads.
38. Close fuel shut off valve (1). Disconnect and cap hose (2).
Disconnect and cap fuel return hose (3).
7C - 12
39. Install lifting bracket to front of fuel tank and attach hoist..
40. Remove mounting hardware and spacers, then remove fuel

tank from machine.
41. Disconnect battery cable (1) and ground cable (2) from discon-
nect switch (3). Remove battery cable from machine.
42. Release tube brackets from front seat support.
7C - 13
43. Disconnect throttle cable (1) from overtravel rod (2).
44. At lower left side of seat support disconnect throttle cable from
support.
45. Remove hardware and seat support from machine.
46. Disconnect right side brake and clutch hoses (1) at fittings on
rear main frame cover. Remove brake cylinder hose (2).
7C - 14
47. Disconnect left side brake and clutch hoses (1) at fittings on rear
main frame cover. Disconnect pressure hose at (2) top inlet
screen fitting (3) at neutral start valve. Remove return hose (4)
from bottom fitting at neutral start valve.
48. From inside battery box, disconnect and remove positive battery
cable and position outside of box.
49. Remove brake valve return hose (1). Unclamp (2) pressure filter
hoses (3) at steering cylinder fitting clamp.
50. Disconnect forward (1) and 2nd speed (2) hoses from fittings at
bottom of trans/steer valve and position outside of box.
51. Disconnect reverse (1) and 1st speed (2) hoses from fittings at
bottom and side of trans/steer valve and position outside of box.
7C - 15
52. Disconnect drive train pressure filter hoses and position outside
of box.
53. Disconnect wire lead at pressure filter. Remove from clamp on

box wall.
54. Mark reed valve switches, squeeze housing and disconnect.
55. Unclip transmission pressure switch.
56. Disconnect wire leads at back up alarm switch.
57. Disconnect wire leads at neutral start switch. Feed harness out
of battery box.
58. Install lifting bracket to battery box.
7C - 16
59. Attach chain and hoist to lifting bracket. Remove mounting

hardware and remove from machine. Keep shims in positions
they were removed.
60. Remove two hoses at inlet tee on main regulator valve.
61. Remove hose from outlet port of charge and scavenge pump.
62. Disconnect wire leads (1) at horn switch and wire lead (2) at
equipment filter. Unclip from box wall.
7C - 17
63. Feed hydraulic box harness out. Unclip remaining harness from
rear main frame cover and reservoir box and position out of the
way.
64. Remove drive train dipstick.
65. Remove dipstick and filler tube.
66. Remove lower filler tube.
7C - 18
67. Plug port.
68. Remove two crossover tubes.
69. Disconnect and cap four hoses from tubes.
70. Remove upper and lower rear tubes from valve bank.
71. Disconnect rear equipment suction tube from fitting.
72. Disconnect suction tube assembly from pump and remove.
7C - 19
73. Disconnect and remove brake rod.
74. Disconnect valve bank inlet hose from tube.
75. Remove drive shaft.
76. Disconnect and remove pump to rear mainframe hose.
77. Disconnect cooler outlet hose from front of transmission.

Position out of the way.
78. Remove drain hose between converter and transmission.
79. Remove large scavenge hose from bottom rear section of pump
and transmission.
7C - 20
80. Disconnect hoses at suction strainer and position out of the way.
Cap ports on strainer. Remove strainer and mounting bracket
from machine.
81. Install a ½NC eye bolt (1) at top of transmission (2) and attach
hoist. Remove mounting hardware. Work transmission away
from rear main frame face and remove from machine.
REMARK
Transmission sealing o-ring on case will cause a drag when
removing.
7C - 21
TRANSMISSION COMPLETE ASSEMBLY
7C - 22
COMPLETE ASSEMBLY TRANSMISSION
1. Transmission Case 12. Countershaft Cover 23. Scavenge Tube Baffle

2. Rear Cover 13. Port Plug 24. Main Regulator Valve
3. Directional (Input) Shaft 14. Reverse Idler Gear 25. Range Selector Valve
4. Tapered Roller Bearing 15. Range (Output) Shaft 26. Rate of Rise Valve
5. Directional Shaft Manifold 16. Tapered Roller Bearing 27. Valve Gasket
6. Dowel Pin 17. Tapered Roller Bearing 28. Orifice Strainer
7. Seal Ring 18. Range Shaft Manifold 29. Valve Manifold
8. Shim 19. Seal Ring 30. Manifold Gasket
9. Retaining Ring 20. Shim 31. Scavenge Tube
10. Oil Seal 21. Retaining Ring 32. Scavenge Tube Gasket
11. Countershaft 22. Adapter Fitting
DISASSEMBLY
REMARK
Callouts from exploded view correspond with callouts in the
following steps.
1. D32E-1, D32P-1, D38E-1 or D38P-1: Remove mounting bolt

and spacer securing pinion gear to output shaft.
1. D39E-1 or D39P-1: Remove mounting bolt and spacer securing

pinion gear to output shaft.
2. Remove pinion gear from output shaft. A puller arrangement

may be necessary to remove gear.
3. Remove four hoses at range selector valve (25).
4. Remove main regulator valve (24). Discard two large and two
small mounting o-rings. Refer to MAIN REGULATOR VALVE for
service.
5. Remove range selector valve (25). Remove and discard ten

mounting o-rings. Refer to RANGE SELECTOR VALVE for
service.
7C - 23
6. Remove rate of rise valve (27). Discard mounting gasket. Refer

to RATE OF RISE VALVE for service.
7. If necessary, remove orifice strainer (28) from manifold plate.
8. Remove valve manifold (29) from transmission housing. Discard

manifold gasket.
REMARK
Eleven bolts secure valve manifold to transmission housing. Three
are 2 in" long and eight are 1-½ in" long.
9. Remove scavenge tube (32). Discard mounting gasket.
10. Break loose, do not remove, rear cover (2) mounting bolts.
11. Rotate assembly and rest on mounting flanges. Remove rear

cover mounting bolts.
12. Attach four legged chain to mounting flange holes and remove
transmission housing (1).
7C - 24
13. Attach eye bolt to range (output) shaft (15) and remove. Refer
to RANGE (OUTPUT) SHAFT for service.
14. Attach eye bolt to directional (input) shaft (3) and remove. Refer
to DIRECTIONAL (INPUT) SHAFT for service.
15. Attach eye bolt to countershaft (11) and remove. Refer to

COUNTERSHAFT for service.
16. Remove scavenge tube baffle (23).
17. If bearing cup(s) require replacement, weld a bead around cup

to shrivel, then remove.
REMARK
When one or two cups are removed, make sure remaining cup(s)
are completely covered.
7C - 25
18. Remove drive shaft yoke.
19. Pry oil seal (10) from housing.
20. Carefully tap down on directional shaft manifold (5) to free up

retaining ring (9). Remove ring.
21. Remove shims (8).
22. Install manifold tool, DR04-721-1, to directional shaft manifold

(5). Equally pull up on tool and remove manifold.
23. Tap down on countershaft cover (12) to free up retaining ring

(9), then remove.
25. From inside housing, drive countershaft cover (12) out. This is
necessary to overcome drag caused by o-ring. Remove and
discard o-ring.
7C - 26
26. Tap on range clutch manifold (18) to free up retaining ring (21),
then remove ring.
28. Install port plug in range shaft manifold (18). Using a long drift
on port plug from inside housing, remove manifold.
29. Remove reverse idler gear mounting bolt and spacer.
30. Install a long bolt to reverse idler gear (14) shaft and drive from
housing. This is necessary to overcome drag of shaft o-ring.
Refer to REVERSE IDLER GEAR for service.
31. Drive dowel pin from housing.
32. Using a suitable drive, remove bearing cup from housing.
33. Drive dowel pin from input shaft bore.
7C - 27
34. Using a suitable driver, remove bearing cup from input shaft
bore. Using same driver, remove bearing cup from countershaft
bore.
REASSEMBLY
REMARK
Callouts from exploded view correspond with callouts in following
steps.
1. If removed, install new bearing cups in rear cover. Bottom new

cups in their bores.
2. Install bearing cups in housing flush with edges.
3. Insert dowel pin into input shaft bore. Using installing tool,
DR04-721-2, position to predetermined depth.
4. Insert dowel pin into output shaft bore. Using installing tool,
DR04-721-2, position to predetermined depth.
5. Coat leading edge of reverse idler gear (14) shaft with amber
grease and install into transmission housing. Be careful not to
cut or distort shaft seal ring while installing.
7C - 28
6. Install shaft retainer and bolt and torque to 325 NCm (240 lbf ft)
±10%.
7. Using a dial indicator, check reverse idler gear (14) for end play.
These bearings are non adjustable. The idle gear should turn
freely with 0 to 0.25 mm (0 to 0.010 in) end play.
8. Install countershaft (11) into bearing cup in rear cover.
9. Install directional (input) shaft (3) into bearing cup in rear cover.
10. Install range (output) shaft (15) into bearing cup in rear cover.
11. Install scavenge tube baffle (23) and secure with hardware.
Torque to 38 NCm (28 lbf ft) ±10%.
12. Install new seal rings (19) to range (output) shaft.
13. Install new seal rings (7) to directional (input) shaft.
7C - 29
14. Apply Loctite #515 to mating surface of rear cover (2). Loop
around bolt holes.
15. Using four legged chain lower transmission housing (1), over
shafts, aligning dowel pins with holes. Install hardware finger
tight.
16. Turn assembly over on its side. Torque mounting bolts to 92

NCm (70 lbf ft) ±10%.
17. Install countershaft cover (12) with new o-ring into transmission
housing. For ease of assembly cover o-ring with a coat of amber
grease.
18. Install retaining ring (9) WITHOUT shims.
19. Install bridge tool, DR04-721-3, as follows;
Thread rod through countershaft cover center hole into counter-

shaft lifting threads. Lock nut against cover. Install bridge and
secure with clamp, washer and nut.
20. Pull up on countershaft with a torque of 108 NCm (80 lbf ft) to
seat components. Reduce torque to zero.
21. Remove tool. Lightly tap down on countershaft cover to attempt

to achieve zero end play.
7C - 30
22. Refit bridge tool to countershaft. Install extension adapter to

torque wrench. Position dial indicator on threaded rod of tool
and set to zero. Pull up on countershaft with 58 NCm (43 lbf ft)
and read and record indicator movement.
R = T X L ÷ (L + C)
T- Torque Required 58 NCm (43 lbf ft)
MULTIPLIED BY (x)
L - Wrench Length mm ( in)
DIVIDED BY (÷)
PLUS (+)
C- Extension Length mm ( in)
EQUALS (=)
R - Reading on Scale NCm ( lbf ft)
23. Determine shim pack (8) as follows;

Subtract 0.178 to 0.508 mm (0.007 to 0.012 in) from indicator
reading recorded in Step 22. This thickness is countershaft
shim pack. Shim pack must include at least one 0.762 mm
(0.030 in) shim to be placed against retaining ring. Remove
retaining ring and install shim pack.
24. Install retaining ring (9) up against 0.762 mm (0.030 in) shim
into groove in housing.
25. Coat pipe plugs (13) threads with Loctite #592 and install into
countershaft cover (12).
26. Using tool DR04-721-1, install directional (input) shaft manifold

(5), indexing manifold slot with dowel pin, into transmission
housing. Be careful not to cut, twist or distort seal rings on shaft.
27. Install retaining ring (9) WITHOUT shims, into groove in trans-
mission housing.
28. Install bridge tool DR04-721-3, as follows;
Thread rod into directional (input) shaft (3) lifting threads.

Lock nut against shaft. Install bridge with extension legs and
secure with clamp, washer and nut. Pull up on directional
(input) shaft with a torque of 108 NCm (80 lbf ft) to seat
components. Reduce torque to zero.
7C - 31
29. Remove bridge tool. Lightly tap down on directional (input) shaft
to attempt to achieve zero end play.
30. Refit bridge tool to directional (input) shaft. Install extension

adapter on torque wrench. Position dial indicator on threaded
rod of tool and set to zero. Pull up on directional (input) shaft
with 58 NCm (43 lbf ft) and read and record indicator movement.
R = T X L ÷ (L + C)
MULTIPLIED BY (x)
DIVIDED BY (÷)
PLUS (+)
EQUALS (=)

Subtract 0.178 to 0.508 mm (0.007 to 0.012 in) from indicator
reading recorded in Step 30. This thickness is directional
(input) shaft shim pack. Shim pack must include at least one
0.762 mm (0.030 in) shim to be placed against retaining ring.
Remove retaining ring and install shim pack.
33. Install new o-ring to range (output) shaft manifold (18). Install
manifold, indexing slot with dowel pin, into trans housing. Be
careful not to cut, twist or distort seal rings on shaft.
34. Remove lifting eye and adapter fitting (22).
7C - 32
35. Install long bolt to range (output) shaft and tap down on shaft
while rotating.
36. Install retaining ring (21) WITHOUT shims, into groove in

transmission housing.
37. Install bridge tool DR04-721-3, as follows;
Thread rod into range (output) shaft lifting threads. Lock nut
against shaft. Install bridge and secure with clamp, washer
and nut. Pull up on range (output) shaft with a torque of 108
NCm (80 lbf ft) to seat components. Reduce torque to zero.
38. Remove bridge tool. Lightly tap down on range (output) shaft
manifold (18) to attempt to achieve zero end play.
39. Refit bridge tool to range (output) shaft. Install extension

adapter. Position dial indicator on rod and set to zero. Pull up on
range (output) shaft with 58 NCm (43 lbf ft) and read and record
indicator movement.
R = T X L ÷ (L + C)
MULTIPLIED BY (x)
DIVIDED BY (÷)
PLUS (+)
EQUALS (=)

Subtract 0.178 to 0.508 mm (0.007 to 0.012 in) from reading
recorded in Step 39. This thickness is range (output) shaft
shim pack. Shim pack must include at least one 0.762 mm
(0.030 in) shim to be placed against retaining ring. Remove
retaining ring and install shim pack.
7C - 33
42. Install new oil seal (10) flush with transmission housing.
43. Install two aligning studs DR04-720, to transmission housing.

Position gasket (30) over studs.
44. Install valve manifold (29) over studs. Apply Loctite #262 to two
mounting bolts and install.
45. Apply Loctite #262 to remaining mounting bolts and install.

Remove studs and install remaining bolts with Loctite #262.
Torque to 38 NCm (28 lbf ft) ±10%.
46. Coat orifice fitting (28) threads with Loctite #592 and install to
port in rate of rise valve land.
47. Install aligning dowels DR04-721-4, to top rate of rise valve

mounting bolt holes. Position gasket (27) over studs.
48. Install rate of rise valve (26) over studs Apply Loctite #262 to
bottom bolts and install. Remove studs and install two top bolts
with Loctite #262. Torque bolts to 38 NCm (28 lbf ft) ±10%.
49. Install aligning dowels DR04-721-4, to bottom range selector

valve mounting bolt holes. Position o-rings (qty. 10), to ports.
7C - 34
50. Install range selector valve (25) over studs. Apply Loctite #262
to top bolts and install. Remove studs and install two bottom
bolts with Loctite #262. Torque bolts to 38 NCm (28 lbf ft) ±10%.
51. Install aligning dowels DR04-721-4, to bottom main regulator

valve mounting bolt holes. Position o-rings, two large, two small
to ports.
52. Install main regulator valve (24) over studs. Apply Loctite #262
to top bolt and install. Remove studs and install two bottom bolts
with Loctite #262. Torque bolts to 38 NCm (28 lbf ft) ±10%.
53. Install scavenge tube (31) and gasket (32) and secure with one
bolt.
REMARK
Scavenge tube and gasket are secured with hose, split flanges
and bolts mounted at installation.
54. Install transmission input flange.
55. Install holder tool DR04-721-5, in range (output) shaft manifold

(18). From rear, slowly rotate range (output) shaft until lock bolt
can be installed.
56. Coat range (output) shaft (15) splines with Molykote "G".
7C - 35
57. Install pinion gear on splines.
58. Coat mounting bolt threads with clean oil.
59. D32E-1, D32P-1, D38E-1 or D38P-1: Secure pinion gear to

range (output) shaft with bolt and spacer.
60. D39E-1 or D39P-1: Secure pinion gear to range (output) shaft

with bolt and spacer.
7C - 36
61. Secure range (output) shaft on tool with large wrench. Torque
pinion gear mounting bolt to 434 NCm (320 lbf ft).
62. Remove tool from range (output) shaft manifold (18).
63. Install adapter fitting (22) with new o-ring to range (output) shaft
manifold.
64. Install new o-ring to rear cover (2).
65. Install hoses to fittings at range selector valve.
7C - 37
TRANSMISSION DIRECTIONAL (INPUT) SHAFT
GENERAL
CROSS SECTION VIEW OF DIRECTIONAL (INPUT) SHAFT
7C - 38
DIRECTIONAL (INPUT) SHAFT TRANSMISSION
EXPLODED VIEW OF DIRECTIONAL (INPUT) SHAFT
7C - 39
1. Input Shaft 8. Return Spring 15. Seal Ring

2. Thrust Race 9. Hub and Drum Kit 16. Friction Disc
3. Thrust Bearing 10. Retaining Ring 17. Separator Plate
4. Needle Bearing 11. Clutch Piston 18. Support Plate
5. Forward Gear and Hub 12. Inner Piston Seal 19. Captured Retaining Ring
6. Retaining Ring 13. Seal Ring 20. Reverse Gear and Hub
7. Spring Retainer 14. Outer Piston Seal 21. Bearing Spacer
PISTON RETURN SPRING CRITERION
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.98 mm (2.204 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.32 mm (1.430 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.59 to 36.32 mm(1.165 to 1.430 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1493 ±149 N (336 ±34 lbf)
Number of Working Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
DISASSEMBLY
REMARK
1. Position directional (input) shaft in stand supported by bars.

Remove four seal rings from shaft.
2. Install bearing puller arrangement on reverse gear and hub.

Activate ram to unseat bearing press fit. Remove arrangement
after press fit is unseated.
3. Remove bearing cone from directional (input) shaft.
4. Remove bearing spacer (21) from directional (input) shaft.
5. Remove outer thrust race (2).
6. Remove thrust bearing (3).
7C - 40
7. Remove inner thrust race (2).
8. Remove reverse gear and hub (20) from directional (input)

shaft.
9. Remove needle bearing (4).
13. Using retaining ring pliers, retract captured retaining ring (19)
and remove with support plate (18).
14. Remove friction discs (16) and separator plates (17).
7C - 41
15. Turn assembly over in stand and support with metal bars. Install
bearing puller arrangement on forward gear and hub. Activate
ram to unseat bearing press fit. Remove puller arrangement
after press fit is unseated.
16. Remove bearing cone from directional (input) shaft.
17. Remove bearing spacer (21) from directional (input) shaft.
21. Remove forward gear and hub (5) from directional (input) shaft.
7C - 42
28. Position assembly in press and install spring compressor tool

DR04-721-6 on spring retainer (7). Activate press to move
retainer below retaining ring (6). Move ring out of groove and up
on shaft. Slowly let off press until spring (8) fully decompresses.
Turn assembly over in press and repeat for remaining side.
WARNING
Spring loaded assembly. Assembly must be held to relieve
spring pressure. Use extreme care when disassembling.
29. Position assembly back in stand seal ring groove side down
(reverse). Remove retaining ring (6) from shaft.
30. Remove outer spring retainer (7).
7C - 43
31. Remove spring (8).
REMARK
Check spring(s) for damage and fatigue against those values
shown in spring criterion.
32. Remove inner spring retainer (7).
33. Turn assembly over in stand seal ring groove side up (reverse).
Remove retaining ring (6) from shaft.
34. Remove outer spring retainer (7).
35. Remove spring (8).
REMARK
Check spring(s) for damage and fatigue against those values
shown in spring criterion.
36. Remove inner spring retainer (7).
37. Using compressed air in center (reverse) groove port, unseat

piston from clutch hub and drum.
REMARK
Wear eye protection when using air under pressure. Limit air
pressure to 206 kPa (30 psi).
38. Remove piston (11) from hub and drum.
7C - 44
39. Using compressed air in lower (forward) groove port, unseat

piston from clutch hub and drum.
REMARK
40. Raise assembly and remove piston (11).
41. Remove retaining ring (10) from each side of hub and drum.
42. Position assembly in press and separate shaft (1) from hub and
drum (9).
43. Remove piston seal (12) and seal ring (13) from each side of
hub and drum.
44. Remove piston seal (14) and seal ring (15 ) from each piston.
REASSEMBLY
REMARK
1. Install new ring seal (13) in groove at each side of hub and
drum.
2. Install new piston seal (12) over ring seal in groove at each side
of hub and drum.
7C - 45
3. Install one retaining ring (10) in groove in hub and drum.
4. Position hub and drum in press. Align dowel pin in shaft with
notched spline of hub and drum.
5. Press shaft into hub and drum bottoming against retaining ring.
6. Install remaining retaining ring (10).
7. Install seal ring (15) in groove on piston.
8. Install piston ring (14) over seal ring in groove on piston. Repeat
previous and this step for other piston.
9. Coat lead in chamfers of hub and drum with clean oil. Spline
piston (11) in hub and press in place being careful not to
damage piston rings.
10. Using wooden dowels, carefully bottom piston into hub and
drum.
7C - 46
11. Turn assembly over in stand and support with bars. Coat lead in
chamfers of hub and drum with clean oil. Spline piston in hub
and press in place being careful not to damage piston rings.
Using wooden dowels, carefully bottom piston into hub and
drum.
12. Install inner spring retainer (7).
13. Install piston return spring (8).
14. Install outer spring retainer (7).
15. Position retaining ring (6) on shaft.
16. Turn assembly over in stand and support with bars. Install inner
spring retainer (7).
18. Install outer spring retainer (7).
7C - 47
19. Position retaining ring (6) on shaft.

retainer below retaining ring (6). Install ring in groove on shaft.
Slowly let off press until spring (8) is held by retainer. Turn
assembly over in press and repeat for remaining side.
WARNING
Spring loaded assembly. Assembly must be held to install
spring. Use extreme care when assembling.
21. Position assembly in stand and support with bars. Coat friction
disc (16) lightly with clean oil and install into assembly.
22. Install separator plate (17).
23. Alternately install friction disc and separator plates ending with
friction disc (16). A total of six friction discs and five separator
plates are to be used.
24. Position captured retaining ring (19) into support plate (18).
Install two #6-32 screws at opposite side of retaining ring
opening.
7C - 48
25. Retract retaining ring (19) and install two #6-32 screws in
support plate (18).
26. Install support plate (18) into assembly.
27. Retract retaining ring (19) and remove four screws. Carefully let
off retaining ring until it seats in groove in drum.
28. Install inner thrust race (2).
29. Install thrust bearing (3) to race. Coat bearing needles with
clean oil.
30. Install outer thrust race (2).
31. Install gear needle bearing (4). Coat bearing needles with clean
oil.
7C - 49
32. Install forward gear and hub (5) aligning all six friction disc.
clean oil.
36. Install bearing spacer (21).
37. Heat bearing cone to 135EC (275EF) for 45 minutes. Install on

shaft and bottom. To insure cone is seated, keep pressure
against cone until it cools.
38. Turn assembly over in stand and support with bars. Coat friction
7C - 50
friction disc (16). A total of six friction discs and five separator
opening.
support plate (18).
7C - 51
clean oil.
48. Install reverse gear and hub (20) aligning all six friction discs.
49. Install gear needle bearing (4). Coat bearing needles with clean
oil.
51. Install thrust bearing (3). Coat bearing needles with clean oil.
7C - 52
53. Install bearing spacer (21).

55. Install four new manifold seal rings to shaft.
7C - 53
TRANSMISSION COUNTERSHAFT
GENERAL
EXPLODED AND CROSS SECTION VIEWS OF COUNTERSHAFT

1. Countershaft 3. 2nd Speed Gear 5. Retaining Ring
2. 3rd Speed Gear 4. 1st Speed Gear
7C - 54
COUNTERSHAFT TRANSMISSION
DISASSEMBLY
REMARK
1. Install bearing puller arrangement to 2nd speed gear (3).
Activate ram to unseat bearing press fit. Remove puller arrange-
ment and bearing after press fit is unseated.
2. Remove 1st speed gear (4).
3. Remove 2nd speed gear (3).
4. Remove retaining rings (5) from shaft (1).
5. Slide 3rd speed gear (2) inboard on shaft (1) as far as possible.
Working behind bearing with pliers and screwdriver, unseat
retaining ring and remove.
6. Position assembly in press. Supporting countershaft (1), press

from 3rd speed gear (2) and bearing.
REASSEMBLY
1. Position countershaft (1) with 3rd speed gear end up, side with
two retaining ring grooves. Install retaining ring (5) to lower
groove.
7C - 55
TRANSMISSION COUNTERSHAFT
2. Install 3rd speed gear (2).
3. Install retaining ring (5) to top groove in countershaft.

5. Turn countershaft over. Install retaining ring (5).
6. Install 2nd speed gear (3) on countershaft against retaining ring.
7. Install 1st speed gear (4) on countershaft against 2nd speed

gear.

7C - 56
RANGE (OUTPUT) SHAFT TRANSMISSION
GENERAL
EXPLODED VIEW OF RANGE (OUTPUT) SHAFT
7C - 57
TRANSMISSION RANGE (OUTPUT) SHAFT
CROSS SECTION VIEW OF RANGE (OUTPUT) SHAFT
7C - 58
1. Output Shaft 10. Lube Sleeve 19. Separator Plate 28. Retaining Ring
2. Bearing Spacer 11. Hub and Drum Kit 20. Support Plate 29. Seal Ring
3. Retaining Ring 12. Retaining Ring 21. Captured Retaining Ring 30. 1st Piston Housing
4. Thrust Race 13. 3rd Speed Piston 22. 1st or 2nd Speed Piston 31. Ring Spacer
5. Thrust Bearing 14. Piston Seal 23. Piston Seal 32. Retaining Ring
6. Needle Bearing 15. Seal Ring 24. Seal Ring 33. 1st Speed Drum
7. 3rd Gear and Hub 16. Piston Seal 25. 2nd Gear and Hub
8. Spring Retainer 17. Seal Ring 26. Needle Bearing
9. Return Spring 18. Friction Disc 27. 1st Gear and Hub
PISTON RETURN SPRING CRITERION

Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.98 mm (2.204 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.32 mm (1.430 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.59 to 36.32 mm (1.165 to 1.430 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1493 ±149 N (336 ±34 lbf)
DISASSEMBLY
REMARK
1. Position range shaft in stand, 3rd speed clutch up, supported by

bars. Install a puller arrangement to 3rd speed gear and hub
(7). Apply ram to puller arrangement and unseat bearing.
2. Remove bearing from assembly.
3. Remove bearing spacer (2).
4. Remove retaining ring (3).
5. Remove thrust races (4) and bearing (5) together.
6. Remove 3rd speed gear and hub (7).
7C - 59
8. Remove thrust races (4) and bearing (5).

11. Turn assembly over in stand and support with metal bars.
Remove four seal rings from shaft.
12. Install 1st pack compressing tool DR04-721-7, to shaft. Draw

down on center bolt until retaining ring (32) clears housing.
Move retaining ring out of groove and up shaft.
7C - 60
13. Remove 1st pack compressing tool.
14. Remove retaining ring (32) from shaft.
15. Remove ring spacer (31).
16. Remove seal ring (29) from under 1st speed piston housing
(30).
17. Position blocking under 1st speed drum (32). Using retaining
ring pliers, retract captured retaining ring (21) and remove.
18. Remove 1st piston housing (30) with bearing.
19. Remove eight friction discs (18) and seven separator plates
(19).
20. Remove 1st speed drum (32) with support plate (20) and
captured retaining ring (21).
7C - 61
21. Remove seal ring (29) from groove in shaft.

DR04-721-6 on lube sleeve (10). Activate press to move
retainer below retaining ring (28). Move ring out of groove and
up on shaft. Slowly let off press until spring fully decompresses.
Remove tool and retaining ring from shaft.
WARNING
Remove lube sleeve (10), spring (9), spring retainer (8) and
retaining ring (3) from assembly.
23. Remove 1st speed gear and hub (27).
24. Remove thrust races (4) and bearing (5) from inside 1st speed
gear and hub (27).
27. Remove 2nd speed gear and hub (25).
7C - 62
30. Using retaining ring pliers, compact captured retaining ring (21)
31. Remove seven friction discs (18) and six separator plates (19).

WARNING
33. Let off press and remove compression tool. Remove retaining
ring (3) from shaft.
34. Remove spring retainer (8).
35. Remove piston return spring (9).
REMARK
Check spring for damage and fatigue against those values shown
in spring criterion.
36. Remove lube sleeve (10).
7C - 63
37. Turn assembly over in press and install spring compressor tool
WARNING
38. Let off press and remove compression tool. Remove retaining
ring (3) from shaft.
39. Remove spring retainer (8).
40. Remove piston return spring (9).
REMARK
in spring criterion.
41. Remove lube sleeve (10).
42. Position assembly back in stand seal ring groove side up. Using
compressed air in bottom (2nd) groove port, unseat 2nd speed
piston (22) from hub and drum.
REMARK
43. Using compressed air in top (3nd) groove port, unseat 3rd
speed piston (13) from hub and drum.
REMARK
44. Remove 2nd (22) and 3rd speed pistons from hub and drum.
7C - 64
45. If hub and drum (11) is to be remove from output shaft (1),
remove retaining rings (12) from each side.
46. Position assembly in press and separate shaft (1) from hub and
drum (11).
47. Remove piston seal (14) and seal ring (15) from each side of
hub and drum.
48. Remove piston seal (16) and seal ring (17 ) from 3rd speed
piston (13).
49. Remove piston seal (23) and seal ring (24 ) from 2rd speed
piston (22).
50. Using compressed air through port in 1st piston housing (30),
remove 1st speed piston (22).
REMARK
7C - 65
51. Remove piston seal (14) and seal ring (15) from 1st piston
housing (30).
52. Remove piston seal (23) and seal ring (24 ) from 1st speed
piston (22).
53. Install puller arrangement to bearing and remove.
REASSEMBLY
REMARK
1. Install one retaining ring (12) in groove in hub and drum (11).
Take note of half notched spline in hub and drum.
7C - 66
2. Position hub and drum (11) in press. Align dowel pin in shaft (1)
with notched spline of hub and drum.
3. Press shaft (1) into hub and drum (11) bottoming against
retaining ring.
4. Using compressed air through port of bottom groove, ascertain

that piston apply ports align.
REMARK
5. Work remaining retaining ring (12) into groove in hub and drum.
6. Install new seal ring (17) in groove on 3nd speed piston (13).
7. Install new piston seal (16) over seal ring into groove on 3nd
speed piston (13).
8. Install new seal ring (15) into groove at hub and drum (11).
9. Install new piston seal (14) over seal ring into groove at hub and
drum (11).
7C - 67
11. Install lube sleeve (10).
13. Install spring retainer (8) over spring.
14. Install retaining ring (3) as far down shaft as possible.
15. Install new seal ring (24) in groove on 2nd speed piston (22).
16. Install new piston seal (23) over seal ring into groove on 2nd
speed piston (22).
17. Install new seal ring (15) into groove at hub and drum (11).
7C - 68
18. Install new piston seal (14) over seal ring into groove at hub and
drum (11).
20. Install lube sleeve (10).
22. Install spring retainer (8) over spring.
23. Install retaining ring (3) as far down shaft as possible.

retainer below ring groove.
WARNING
25. Install retaining ring (3) into groove on shaft.
7C - 69
26. Slowly let off press until spring (9) is held by retainer (8).
Turn assembly over in press and repeat steps 24 through 26 for

remaining side.
WARNING
27. Position assembly in stand and support with bars. Coat friction
friction disc (18). A total of seven friction discs and six separator
opening.
support plate (20).
7C - 70
clean oil.
37. Install 3rd speed gear and hub (7) aligning all seven friction
discs.
38. Install needle bearing (6) inside 3rd speed gear and hub. Coat
bearing needles with clean oil.
7C - 71
clean oil.
42. Install retaining ring (3) up against step on output shaft.
43. Seat bearing spacer (2) on outer thrust race against retaining
ring.

against cone until it cools. After bearing has cooled turn
assembly over in clutch stand.
45. Coat friction disc (18) lightly with clean oil and install into
assembly.
friction disc (18). A total of seven friction discs and six separator
7C - 72
opening.
support plate (20).
clean oil.
7C - 73
55. Install 2nd speed gear and hub (25) aligning all seven friction
discs.
56. Install needle bearing (6) inside 2nd speed gear and hub. Coat
bearing needles with clean oil.
clean oil.
60. Install gear needle bearing (26). Coat bearing needles with
clean oil.
61. Install 1st speed gear and hub (27) over needle bearing onto
outer thrust race.
7C - 74
clean oil.
65. Install retaining ring (3) into groove against outer thrust race.
66. Install spring retainer (8) against retaining ring.
67. Install piston return spring (9) to retainer.
68. Install lube sleeve (10) to spring.
69. Position retaining ring (28) as far down on shaft as possible.
7C - 75

DR04-721-6 on lube sleeve (10). Activate press to move
retainer below retaining ring groove. Install retaining ring (28) in
groove on shaft. Slowly let off press until spring is held by lube
sleeve.
WARNING

1st piston housing (30) and bottom. To insure cone is seated,
keep pressure against cone until it cools.
72. Install new seal ring (24) in groove on 1st speed piston (22).
73. Install new piston seal (23) over seal ring into groove on 1st
speed piston (22).
74. Install new seal ring (15) to groove in 1st speed piston housing
(30).
75. Install new piston seal (14) over seal ring into groove on 1st
speed piston housing (30).
76. Install retaining ring (21) into groove at one side of 1st speed
drum (33).
7C - 76
77. Position 1st speed drum (33), installed retaining ring side down,
on clutch stand. Insert 1st speed housing (30), bearing end
down, up against retaining ring.
piston (22) in housing and press in place being careful not to
79. Coat friction disc (18) lightly with clean oil and install into
assembly.
friction disc (18). A total of eight friction discs and seven separa-
tor plates are to be used.
opening.
7C - 77
support plate (20).
86. Install seal ring (29) to groove in shaft.
87. Install 1st clutch assembly on shaft aligning eight friction discs
with 1st speed gear and hub (27) and 1st piston housing with
shaft. Be careful not to cut inner seal ring.
88. Install seal ring (29) under 1st piston housing up against step on
shaft.
89. Install ring spacer (31) against seal ring.
7C - 78
90. Start retaining ring (32) on shaft and position next to ring spacer
(31). Install compression tool, DR04-721-7, and move clutch
assembly down until retaining ring can be inserted into groove
on shaft. Insert. Remove tool.
7C - 79
TRANSMISSION REVERSE IDLER SHAFT
GENERAL
EXPLODED AND CROSS SECTION VIEWS OF REVERSE IDLER SHAFT

1. Reverse Idler Shaft 3. Cone Spacer 5. Reverse Idler Gear 7. Mounting Bolt
2. Double Bearing 4. Bearing Cup Spacer 6. Shaft Retainer 8. Seal Ring
7C - 80
REVERSE IDLER SHAFT TRANSMISSION
DISASSEMBLY
REMARK
1. Remove seal ring (8) from reverse idler shaft (1).
2. Remove reverse idler gear (5) with outer tapered roller bearing
(2) cone. Remove cone from gear.
3. Remove bearing cone spacer (3).
4. Remove inner tapered roller bearing (2) cone from reverse idler
shaft (1).
5. Drive tapered roller bearing (2) cups from reverse idler gear (5).
Remove bearing cup spacer (4).
REASSEMBLY
1. Install bearing cup spacer (4) into groove in reverse idler gear
(5). Press each tapered roller bearing (2) cup into gear and
bottom against spacer.
7C - 81
TRANSMISSION REVERSE IDLER SHAFT
2. Install inner tapered roller bearing (2) on reverse idler shaft (1)
and bottom against step.
3. Install bearing cone spacer (3).
4. Install reverse idler gear (5) on inner tapered roller bearing

cone.
5. Install outer tapered roller bearing (2) cone.
6. Install new seal ring (8) to groove on reverse idler shaft (1).
7C - 82
MAIN REGULATOR VALVE TRANSMISSION
EXPLODED VIEW OF MAIN REGULATOR VALVE
7C - 83
TRANSMISSION MAIN REGULATOR VALVE
CROSS SECTION VIEW OF MAIN REGULATOR VALVE

1. Valve Housing 6. Check Ball Spring 11. Main Spool Shim 16. O-Ring
2. Main Spool Assy 7. Spring Guide Pin 12. Lube Spool 17. End Cover
3. Check Ball 8. Main Outer Spring 13. TC Spool 18. Port Plug
4. Spring Pin 9. Main Inner Spring 14. TC Spool Spring
5. Main Spool 10. Spool Shim 15. Lube Spool Spring
DESCRIPTION
This valve is a cascade type, pressure control valve consisting of three individual valves encased in one housing. The
first valve is used to control pressure for engagement of the clutches in the transmission and the steering drive. The
second valve is used to control pressure in the torque converter. The third valve is used to control lube pressure in the
transmission. A cold oil relief valve is included in the first valve.
THEORY OF OPERATION
Oil from the pump enters the valve at cavity M. This oil is then directed through the other control valves and on to the
transmission and steering drive to operate the clutch packs. As pump flow continues, pressure builds and oil is forced
through the center of spool (5), causing the spool to move against the outer and inner springs (8 and 9). When the
pressure reaches 1792 to 1930 kPa (260 to 280 psi) the first valve opens and allows oil to enter cavity C. The main
spool also contains a cold oil relief valve. When the oil is cold pressure can exceed 1930 kPa (280 psi). When this hap-
pens, the check ball (3) is forced against the spring (6) and excessive pressure is relieved and valve chatter is prevented.
Excessive oil from cavity M enters cavity C and is directed on to the converter. When flow requirements for the converter
is met, pressure builds and oil is forced through the center of the spool (13) causing the spool to move against the spring
(14). When pressure reaches 483 to 655 kPa (70 to 95 psi) in neutral or in gear, the second valve opens and allows
oil to enter cavity L. Return oil from the oil cooler and excessive oil from cavity C enters cavity L and is then directed to
the transmission for lube. Whenever this lube oil reaches 172 to 241 kPa (25 to 35 psi) in neutral or 138 to 206 kPa (20
to 30 psi) in gear, the third valve opens and dumps the oil to drain.
7C - 84
SPECIFICATIONS
Spring Criteria:
Main Spool Valve Check Ball Spring (4):
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.13 mm (0.832 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.42 mm (0.607 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.52 to 15.42 mm (0.375 to 0.607 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.72 to 83.62 N (16.8 to 18.8 lbf)
Number of Working Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Main Spool Outer Spring (7):
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.45 mm (3.01 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.45 mm (2.065 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.24 to 53.85 mm (1.86 to 2.12 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380.3 to 398.1 N (85.5 to 89.5 lbf)
Number of Working Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-½
Main Spool Inner Spring:
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.8 mm (1.96 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 mm (1.38 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.0 to 36.6 mm (1.18 to 1.44 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 to 207 N (43.5 to 46.5 lbf)
Converter Valve Spring (14):
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.77 mm (2.55 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.8 mm (2 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 to 195 N (38 to 44 lbf)
Number of Working Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lube Valve Spring (15):
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.06 mm (2.64 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.8 mm (2 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 to 78.4 N (14.5 to 17.5 lbf)
Number of Working Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
End Cover Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 NCm (16 lbf ft) ±10%
DISASSEMBLY
REMARK
1. Position valve assembly into vise, supporting valve as neces-

sary.
7C - 85
2. Remove bolts and lock washers from end cover (17). Slowly
back off vise allowing springs to decompress.
WARNING
spring pressure. Use extreme caution when disassembling.
3. Remove lube spool spring (15). Identify spring for ease of

testing and reassembly.
REMARK
in specifications.
4. Remove lube spool (12) with spring shims (10). Keep removed
amount of shims with spool.
REMARK
A total quantity of 3 shims can used under spool spring. Each shim
added or deleted will raise or lower lube pressure by 6.9 kPa (1
psi).
REMARK
Lube spool (12) and converter spool (13) are interchangeable. Do
not switch spools in each others housing bore.
5. Remove converter spool spring (14). Identify spring for ease of

REMARK
in specifications.
7C - 86
6. Remove converter spool (13) with spring shims (10). Keep

removed amount of shims with spool.
REMARK
added or deleted will raise or lower converter pressure by 24 kPa
(3.5 psi).
REMARK
Lube spool (12) and converter spool (13) are interchangeable. Do
not switch spools in each others housing bore.
7. Remove main spool outer spring (8). Identify spring for ease of
REMARK
in specifications.
8. Remove main spool inner spring (9). Identify spring for ease of
REMARK
in specifications.
9. Remove spring guide pin (7).
7C - 87
10. Remove main spool assembly (2) with spring shims (11). Keep
removed amount of shims with spool.
REMARK
added or deleted will raise or lower main pressure by 34 kPa (5
psi).
11. Remove and discard o-rings (16) from housing (1). Remove
remaining end cover and discard o-rings.
12. If necessary, disassemble main spool (2) as follows;

Rest assembly (2) on block of wood. Using pin drift drive spring
pin (4) from spool (5) allowing pin drift to retain spring (6).
Carefully remove pin drift allowing check ball spring to decom-
press. Remove spring and check ball.
WARNING
Spring loaded assembly. Assembly must be contained to
relieve spring pressure. Use extreme caution when disas-
sembling.
REMARK
in specifications.
REASSEMBLY
REMARK
1. Reassemble main spool (2) as follows;
Install check ball (3) and check ball spring (6) into spool (5).
Compress spring and secure with spring pin (4).
WARNING
7C - 88
2. Install new o-rings (16) into bottom of housing and bolt bottom
end cover (17) in place. Torque bolts to 21 NCm (16 lbf ft) ±10%.
Install new o-rings (16) into top of housing (1).
3. Install main spool assembly (2) with same amount of shims (11)
that were removed.
REMARK
added or deleted will raise or lower main pressure by 34 kPa (5
psi).
4. Install spring guide pin (7) in housing bore.
5. Install main inner spring (9).
7C - 89
6. Install main outer spring (8).
7. Install converter spool (13) with spring shims (10) that were
removed with spool.
REMARK
added or deleted will raise or lower converter or pressure by 24
kPa (3.5 psi).
REMARK
Spool (12) and spool (13) are interchangeable. Do not switch
spools in each others housing bore.
8. Install converter spool spring (14).
9. Install lube spool (12) with spring shims (10) that were removed
with spool.
REMARK
added or deleted will raise or lower lube pressure by 6.9 kPa (1
psi).
REMARK
Spool (12) and spool (13) are interchangeable. Do not switch
spools in each others housing bore.
7C - 90
10. Install lube spool spring (15).
11. Position valve and end cover (17) in vise.
12. Slowly compress vise and install mounting hardware. Torque

bolts to 21 NCm (16 lbf ft) ±10%.
WARNING
7C - 91
TRANSMISSION RANGE SELECTOR VALVE
EXPLODED VIEW OF RANGE SELECTOR VALVE
7C - 92
RANGE SELECTOR VALVE TRANSMISSION
CROSS SECTION VIEW OF RANGE SELECTOR VALVE

1. Valve Housing 4. Directional Spool - Long 7. Small O-ring
2. Speed Spool Return Spring 5. Directional Spool - Short 8. End Cover
3. Speed Spool 6. Large O-Ring 9. Port Plug
DESCRIPTION
Range selector valve is a hydraulically controlled, directional control valve consisting of two speed spools and two
directional spools. Speed spools are separated in valve housing by a centering spring. Directional spools are held
together at one side by their return spring.
THEORY OF OPERATION
Function of range selector valve is to provide main pressure oil to rate of rise valve and return oil from rate of rise valve
to desired clutch packs. Valve is hydraulically controlled by pilot control valve. Short directional spool (5) controls flow
of oil to rate of rise valve. When in neutral, return spring (2) holds this spool (5) against long direction spool (4), thereby
cutting off flow of oil. When shift lever is placed in forward, main pressure oil from pilot control valve enters port F and
shifts spool (5) against return spring (2). When shift lever is placed in reverse, main pressure oil from pilot control valve
enters port R and shifts both spools (4 and 5) against return spring (2). Once short directional spool (5) is shifted over,
port P1 is open to port P, directing oil to rate of rise valve. Long direction spool (4) controls flow of oil to forward and
reverse clutch packs. When shift lever is in forward, main pressure oil from pilot control valve enters port F, holding long
directional spool (5) against end cover (8). When in this position, oil from rate of rise valve enters port FR, and is directed
out port FC to engage forward clutch shaft. When shift lever is placed in reverse, main pressure oil enters port R, shifts
spool (4) and port FR is opened to port RC to engage reverse clutch pack. Two speed spools (3) control flow of oil to
speed clutch packs. When shift lever is placed in first, main pressure oil from pilot control valve enters port 1, shifting
spool (3) against return spring (2). When in this position, oil from rate of rise valve enters port PC and is directed out port
1C to engage first speed clutch pack. When shift lever is placed in second, oil enters port 2 to shift spool (3) and port
PC is opened to port 2C to engage second speed clutch pack. When shift lever is in third, return spring (2) holds spools
(3) in place and port PC is opened to port 3C to engage third speed clutch pack.
7C - 93
SPECIFICATIONS
Spring Criteria:
Speed or Directional Selector Spool Spring (2);
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.01 mm (1.933 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.56 mm (1.4 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.56 to 43.48 mm (1.40 to 1.712 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232.2 N (52.2 lbf)
End Cover Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 NCm (16 lbf ft) ±10%
DISASSEMBLY
REMARK
1. Slowly loosen end cover (8) bolts until all spring tension is
relieved. Remove end cover.

relieve spring pressure. Use extreme caution when disassem-
bling.
2. Remove speed spool (3) from housing.
REMARK
Spool is to be kept with housing bore side that it was removed
from.
3. Remove speed spool return spring (2) from housing bore.
REMARK
in specifications.
7C - 94
4. Remove directional spool return spring (2) from housing bore.
REMARK
in specifications.
5. Remove short directional spool (5) from housing bore.
REMARK
from.
6. Remove remaining end cover (8).
7. Remove long directional spool (4) from housing bore.
REMARK
from.
7C - 95
8. Remove remaining speed spool (3) from housing bore.
REMARK
from.
9. Remove large (6) and small (7) o-rings from each end of
housing. Discard o-rings and replace with new.
REASSEMBLY
REMARK
1. Coat new large (6) and small (7) o-rings with amber grease and
install in counter bores in each end of housing.
2. Install speed spool (3) into its housing bore.
3. Install long directional spool (4) into its housing bore.
7C - 96
4. Install end cover and secure with hardware. Torque bolts to 21

NCm (16 lbf ft) ±10%.
5. Install short directional spool (5) into its housing bore.
6. Install directional spool return spring (2) into spool.
7. Install speed spool return spring (2) into spool.
7C - 97
8. Install remaining speed spool (3) into its housing bore.
9. Install end cover (8) and secure with hardware. Torque bolts to
21 NCm (16 lbf ft) ±10%.
WARNING
7C - 98
RATE OF RISE VALVE TRANSMISSION
CROSS SECTION VIEW OF RATE OF RISE VALVE
A. Main Pressure Oil E. Main Oil Pressure to Directional Spool

B. Orificed Main Pressure Oil F. Main Oil Pressure to Range Spools
C. Drain Port G. Internal Passage
D. Main Pressure Oil from Short Directional Spool H. Internal Passage
1. Valve Housing 6. Reducing Spool 11. Sequence Spool Disc

2. Modulating Piston 7. Reducing Spool Spring 12. Sequence Spool Spring
3. Piston Spring Retainer 8. Sequence Spool 13. Tube Spacer
4. Outer Piston Spring 9. Dowel Pin 14. End Cover Gasket
5. Inner Piston Spring 10. Sequence Spool Spacer 15/16. End Cover
Description
The rate of rise valve is a sequencing, pressure regulating valve use to provide a smooth shift without shock. This valve
controls the length of time that it takes to fully pressurize a clutch pack and also allows the directional clutch pack to
engage before range pack clutch.
The rate of rise valve has six ports (A to F) and two passages (G and H) which are located on the bottom of the valve
but which are shown in cross section on the sides of the valve, for clarity. Main pressure oil from the main regulator valve
enters the left hand upper cavity through port A and keeps this cavity at main pressure whenever the engine is running.
Main pressure oil from the main regulator valve enters the left hand lower cavity through port B. This port contains an
orifice that limits the flow of oil into this cavity. This lower cavity is open to drain port C. The modulating piston (2) acts
as a variable orifice for this drain to control pressure in this cavity. Main pressure oil from the range selector valve enters
the right side of the lower cavity through port D only when the short directional spool in the range selector valve is
shifted. This oil is directed out of the rate of rise valve through ports E and F. Port E directs oil to the directional spool
of the range selector valve. Port F directs oil to the speed spools of the range selector valve but its flow is controlled by
the sequence spool (8).
7C - 99
TRANSMISSION RATE OF RISE VALVE
Theory of Operation
RATE OF RISE VALVE IN NEUTRAL POSITION


IN NEUTRAL
When the shift lever is in NEUTRAL, the range selector valve cuts off all oil flow to port D and it opens port D to drain.
Without any oil pressure in the right hand cavity of the rate of rise valve, both spools (6 and 8) will shift right. Tension
from the springs (4 and 5) holds the modulating piston (2) to the right, leaving drain port C wide open. Oil entering the
lower left cavity through port B will flow freely to the drain port C and no pressure will build in this cavity. Main oil
pressure from port A, along with the tension from spring (12), holds the sequence spool (8) to the right, allowing oil from
port F and passage G to pass through the sequence spool (8), through passage H and out drain port C.
7C - 100
DURING A SHIFT
SEQUENCE SPOOL SHIFTED, MODULATING PISTON STILL IN NEUTRAL POSITION


When a shift occurs, the range selector valve directs oil to port D. This oil flows through the holes in the reducing spool
(6) and exits through port E to fill the directional clutch pack. Some oil can also pass through the orifice in the end of
the reducing spool (6), but because the passage G is still open to drain, the modulation piston (2) will not shift. When
the directional clutch pack is full, pressure begins to build in the clutch pack and in the cavity on the right side of the rate
of rise valve. As pressure builds, the sequence spool (8) begins to move against the tension of the spring (12) and main
pressure from port A. As this spool moves to the left, the metering holes in the sequence spool (8) index with port F
and the drain holes in the left side of the spool are cut off from passage H. Oil from port D can now pass through the
metering holes in the sequence spool (8) to port F to fill the range clutch pack. Because oil must pass through the
metering holes, pressure in the right hand cavity of the valve and pressure to the directional clutch pack will remain
higher than the pressure at port F going to the range clutch pack. During the range clutch pack fill sequence, the
sequence spool (8) also blocked off passage G. Oil passing through the orifice in the end of the reducing spool (6)
begins to build pressure against the modulating piston (2), pushing it slowly to the left against the springs (4 and 5). The
modulating piston (2) has a series of orifices which decrease in size from left to right. As the piston (2) moves to the left,
decreasing size holes index with drain port C causing a restriction to flow of oil from port B. This causes pressure to build
against the back side of the piston (2) which slows its left hand movement, which in turn allows the build up of pressure
in the clutch packs.
7C - 101
SEQUENCE SPOOL SHIFTED, MODULATING PISTON SHIFTED TO LEFT


7C - 102
EXPLODED VIEW OF RATE OF RISE VALVE
7C - 103
CROSS SECTION VIEW OF RATE OF RISE VALVE
1. Valve Housing 5. Inner Piston Spring 9. Dowel Pin 13. Tube Spacer
2. Modulating Piston 6. Reducing Spool 10. Sequence Spool Spacer 14. End Cover Gasket
3. Piston Spring Retainer 7. Reducing Spool Spring 11. Sequence Spool Disc 15. End Cover
4. Outer Piston Spring 8. Sequence Spool 12. Sequence Spool Spring 16. End Cover
SPECIFICATIONS
Modulating Piston Outer Spring (4);
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.23 mm (1.82 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.75 mm (1.25 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.59 to 36.06 mm (0.85 to 1.42 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160.1 to 177.9 N (36 to 40 lbf)
Number of Working Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Modulating Piston Inner Spring (5);
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.63 mm (3.45 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.12 mm (2.8 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.88 to 73.15 mm (2.20 to 2.88 in)
Number of Working Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4
Reducing Spool Spring (7);
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.52 mm (1.477 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.05 mm (0.75 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.05 to 23.49 mm (0.75 to 0.925 in)
Sequence Spool Spring (12);
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.4 mm (1.787 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4 mm (1 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.14 to 29.36 mm (0.597 to 1.156 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.8 N (4 lbf)
Number of Working Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
End Cover Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 NCm (28 lbf ft) ±10%
7C - 104
DISASSEMBLY
REMARK
1. While holding down on end cover (16), slowly let off mounting
bolts until all spring tension is released. Then remove cover.
WARNING
sembling.
2. Remove and discard end cover gasket (14).
3. Remove sequence spool spring (12) from housing bore.
REMARK
in specifications.
4. Remove tube spacer (13) from housing bore.
5. Remove sequence spool disc (11) from housing bore.
7C - 105
6. Remove dowel pin (9) from housing bore.
7. Remove outer piston spring (4) from housing bore.
REMARK
in specifications.
8. Remove piston spring retainer (3) from housing bore.
9. Remove inner piston spring (5) from housing bore.
REMARK
in specifications.
10. Remove modulating piston (2) from housing bore.
11. Slowly remove end cover (15) hardware until all spring tension
is released. Remove cover.
WARNING
sembling.
7C - 106
12. Remove and discard end cover gasket (14).
13. Remove reducing spool (6) from housing bore.
14. Remove reducing spool spring (7) from housing bore.
REMARK
in specifications.
15. Remove sequence spool (8) from housing bore.
16. Using a wooden dowel pin, insert into housing bore up against
sequence spool spacer. Gently tap on dowel to dislodge spacer
from housing.
17. Remove sequence spool spacer (10) from housing.
REASSEMBLY
REMARK
1. Squarely seat sequence spool spacer (10) into housing bore.
7C - 107
2. Install sequence spool (8) into housing bore.
3. Install reducing spool spring (7) into housing bore.
4. Seat reducing spool (6) in housing bore.
5. Insert aligning studs DR04-720, to housing. Install new end

cover gasket (14) to housing.
6. Install end cover (15) over aligning studs and secure with four
bolts. Remove aligning studs and install remaining bolts. Torque
WARNING
7C - 108
7. Install modulating piston (2) into housing bore.
8. Install inner piston spring (5) into modulating piston in housing

bore.
9. Install piston spring retainer (3) over spring.
10. Install outer piston spring (4) over retainer.
11. Install dowel pin (9) in housing bore into sequence spool spacer.
12. Install sequence spool disc (11) on dowel pin.
13. Install tube spacer (13).
7C - 109
14. Install sequence spool spring (12) inside tube spacer.
15. Insert aligning studs DR04-720, to housing. Install new end

cover gasket (14) to housing.
16. Install end cover (16) over aligning studs and secure with four
bolts. Remove aligning studs and install remaining bolts. Torque
WARNING
7C - 110
INSTALLATION TRANSMISSION
1. Remove caps from fittings. Using lock ring pliers, remove

retaining ring.
2. Remove hardware and seal flange.
3. Remove connector boot.
4. Remove long connector from cylinder. Repeat Steps 1 through

4 for remaining four fittings.
5. Remove hardware and side, front and back stiffeners.
6. Remove rear frame cover.
7. Remove and discard rear frame cover gasket. Replace gasket

with new.
8. Remove arm return springs (1). Connect a 2070 kPa (300 psi)
power source to connector (2) to retract actuator rods. Loosen
lock nuts (3) and turn in adjusting bolts (4). Remove hardware,
then remove brake cylinder (5) from base plates.
REMARK
For cylinder service, refer to Section 7E.
7C - 111
TRANSMISSION INSTALLATION
9. Install aligning studs (1), DR04-721-8, to top transmission

mounting bolt holes. Position five 0.5 mm (0.020 in) mounting
shims (2) on each stud. On pinion gear notate and record
dimension etched on face of gear. Coat new mounting o-ring
with liberal amount of amber grease. Using hoist position
transmission in place and work into rear main frame engaging
pinion gear with ring gear. Install mounting bolts and torque to
130 NCm (100 lbf ft).
10. Measure and record distance (A) between face of pinion gear to
ring gear carrier machined groove. Add or subtract mounting
shims to bring pinion gear within dimension etched on face,
recorded in Step 9, within 0.025 mm (0.001 in). Torque trans-
mission mounting bolts to 352 to 406 NCm (260 to 300 lbf ft).
11. D32E-1, D32P-1, D38E-1 or D38P-1
12. D39E-1 or D39P-1
7C - 112
13. With pressure source in place, install brake cylinder (5)to base
plates and torque mounting bolts to 92 NCm (70 lbf ft) ±10%.
Screw both adjustment bolts (4) out until they just make contact
with equalizer bar. Secure with locknuts (3) and torque to 92
NCm (70 lbf ft). Install return springs (1).
14. Thoroughly clean all mounting surfaces of cover, rear frame

and new gasket with methyl ethyl ketone (MEK). Install eight
aligning studs, DR04-720, to rear frame. Position gasket over
studs with one odd square corner located at right rear corner.
Apply gasket cement, 1300139H1, to top surface of gasket.
15. Apply gasket cement, 1300139H1, to mounting surface of rear

frame cover.
16. Position rear frame cover on gasket centering gasket metal

spacers within holes of cover.
17. Install front, back and side stiffeners and secure with hardware.
Remove aligning studs and install remaining hardware. Torque
bolts to 55 NCm (41 lbf ft).
18. Install long connector, with new o-ring, to cylinder port.
19. Install boot down over connector against cover.
20. Install seal flange and secure with hardware. Torque lock nut to
16 to 20 NCm (12 to 15 lbf ft).
7C - 113
21. Using lock ring pliers, install ring over boot and under lip.
22. Install lower filler tube.
23. Install upper filler tube.
24. Install suction strainer and bracket and secure with hardware.
Torque bolts to 38 NCm (28 lbf ft) ±10%. Connect and tighten
hoses at strainer fittings.
25. Install large suction hose between bottom rear section of pump
and transmission.
7C - 114
26. Install drain hose between torque converter and transmission.
27. Install cooler outlet hose to front of transmission.
28. Install pump to rear mainframe hose.
29. Install drive shaft and secure with bolts.
D32E-1, D32P-1, D38E-1 or D38P-1; Torque bolts to 33 NCm

(24 lbf ft).
D39E-1 or D39P-1; Torque bolts to 57 NCm (42 lbf ft).
30. Connect valve bank inlet hose (1) to tube (2).
31. Install brake rod (1).
7C - 115
32. Install rear suction tube to fitting at reservoir.
33. Connect front suction tube to equipment pump. Connect front

suction tube to rear suction tube with rubber hose and clamps.
34. Install upper and lower rear tubes at valve bank.
35. Connect four hoses to tubes.
36. Install two crossover tubes (1).
37. Insert drive train dipstick
7C - 116
38. Feed harness into hydraulic reservoir box. Reclip harness to

reservoir box and rear main frame cover.
39. Apply electrical sealing grease, Grafo 112-X to wire leads and
connect to horn (1) switch and equipment (2) filter switch. Reclip
to box wall.
40. Install hose to outlet port of charge and scavenge pump
41. Install two hoses at inlet tee on main regulator valve.
7C - 117
42. Position battery box in place on fender with shims that were
removed with it and secure with hardware finger tight.
REMARK
When installing battery box, make sure crossover tubes at left
front of rear frame clear bottom floor plate of box. Tubes go inside
box.
43. Remove lifting bracket from battery box.
44. Feed harness into battery box. Apply electrical sealing grease,
Grafo 112-X to wire leads and connect to neutral start switch.
connect to back up alarm switch.
46. Install harness connector to transmission pressure switch.
47. Match marked reed switches and connect.
7C - 118
48. Apply electrical sealing grease, Grafo 112-X to wire lead and
connect to drive train pressure filter. Reclamp to box wall.
Reclamp wiring harness to inside of battery box.
49. Connect hoses drive train pressure filter.
50. Connect reverse (1) and 1st speed (2) hoses to fittings at bottom
and side of trans/steer valve.
51. Connect forward (1) and 2nd speed (2) hoses to fittings at
bottom of trans/steer valve.
52. Install brake valve return hose (1). Clamp (2) pressure filter
hoses (3) at steering cylinder fitting clamp. Torque lock nut to 12
to 15 lbf ft (16 to 20 NCm).
53. Apply electrical sealing grease, Grafo 112-X to positive battery

cable and torque nut to 31 NCm (23 lbf ft).
7C - 119
54. Install return hose (4) to bottom fitting at neutral start valve.
Connect pressure hose to (2) top inlet screen fitting (3) at
neutral start valve. Connect left side brake and clutch hoses (1)
to fittings on rear main frame cover.
55. Connect right side brake and clutch hoses (1) to fittings on rear
main frame cover. Install brake cylinder hose (2).
56. Position front seat support in place with hardware finger tight.
57. At lower left of seat support connect throttle cable to support.
7C - 120
58. Connect throttle cable (1) to overtravel rod (2).
59. Install tube brackets to front seat support. Torque center dNC
bolt to 38 NCm (28 lbf ft) ±10% and right ½NC bolts to 92 NCm
(70 lbf ft) ±10%. Torque front seat support hardware to 38 NCm
(28 lbf ft) ±10%.
60. Apply electrical sealing grease, Grafo 112-X to battery (1) and
ground (2) cables and connect to master disconnect switch (2).
Torque nuts to 12 NCm (9 lbf ft).
61. Position fuel tank in place and secure with mounting hardware
and spacers. Torque ¾NC bolts to 325 NCm (240 lbf ft) ±10%.
7C - 121
62. Remove lifting bracket from front of fuel tank.
63. Connect fuel return hose (3) to fitting at tank. Connect fuel
supply hose (2) to shut off valve (1). Open valve.
connect at back of alarm. Torque nuts to 1.8 NCm (16 lbf in)
±10%.
65. Position back up alarm and secure with hardware. Torque bolts
to 38 NCm (28 lbf ft) ±10%.
7C - 122
66. Remove cover and feed harness through grommet to fuel level
sender switch. Reclip harness to tank.
connect to switch.
68. Install cover with new gasket and secure with hardware. Torque
to 21 NCm (16 lbf ft) ±10%.
69. Position seat platform in place and secure with side and front
hardware. Align battery box to platform and fuel tank. Torque
bolts to 38 NCm (28 lbf ft) ±10%. Install rear seat platform to fuel
tank hardware and torque ½NC bolts to 92 NCm (70 lbf ft)
±10%. Torque battery box bolts to 180 NCm (140 lbf ft) ±10%.
70. Install seat and secure with hardware. Torque bolts to 38 NCm
(28 lbf ft) ±10%.
71. Install armrests and bracket. Torque bolts to 38 NCm (28 lbf ft)
±10%.
7C - 123

Loctite #262 and secure with shims. Torque bolts to 92 NCm (70
lbf ft) ±10%.
REMARK
On machines with cabs, the dashboard will reinstall with the cab.
See Section 13 for cab reassembly.
74. At left side, connect two hoses (1 and 2) to foot brake valve (3).

connect elbow.

clamp (1).
7C - 124
77. D32E-1 or D32P-1; Apply electrical sealing grease, Grafo 112-X

to wiring lead and connect to switch at air cleaner outlet pipe.

grease, Grafo 112-X to wiring lead and connect to switch at air
79. Assemble fuel shutoff solenoid and connect harness.
80. Connect instrument panel harness to bracket at rear of engine.
81. Connect pump control rod (1) and over travel decelerator (2) to
throttle control (3). Torque bolt to 10 NCm (8 lbf ft) ±10%.
82. Install dash brace bar to left side of machine. Torque bolts to 92
NCm (70 bf ft) ±10%.
7C - 125
92 NCm (70 bf ft) ±10%.
85. Using a rolling floor jack, install transmission guard to machine

±10%.

REMARK
reassembly.
87. Connect front and rear light harness (1) to main harness (2). Tie
strap (3) and insert in clip.
7C - 126
88. Position rear cover in place and secure with hardware. Torque

NCm (28 lbf ft) ±10%.
7C - 127

±10%.
±10%.
97. Refill hydraulic and drive train systems with proper fluid, refer to
the OPERATION & MAINTENANCE MANUAL. Test transmis-
sion per Section 7.
7C - 128
TRANSMISSION/STEERING VALVE TRANSMISSION
EXPLODED VIEW OF TRANSMISSION/STEERING VALVE
7C - 129
TRANSMISSION TRANSMISSION/STEERING VALVE
CROSS SECTION VIEW OF TRANSMISSION/STEERING VALVE
7C - 130
1. Valve Body 18. ½NC Hex Nut 35. Detent Ball

2. Expander Plug 19. Dowel Pin 36. Range Detent Spring
3. Port Plug 20. Dowel Pin 37. Detent Guide
4. Steering Spool 21. Range Cam 38. Detent Guide Plug
5. Pickup Spacer 22. Bottom Cover 39. O-ring
6. Inner Spring 23. Cover Plug 40. Switch Arm
7. Outer Spring 24. Orifice Plug 41. Ceramic Ring Magnet
8. Directional Spool 25. Dowel Pin 42. Brass Screw
9. Spring Retainer Washer 26. Motion Lever 43. Locking Bolt
10. Forward Reverse Spring 27. Bearing Housing 44. Wiper Seal
11. Retainer Nut 28. Cam Ring 45. Wiper Seal
12. Spool Rocker End 29. Ball Bearing 46. Wiper Seal
13. dNC Jam Nut 30. Retaining Ring 47. O-ring
14. Range Spool 31. Universal Joint 48. O-ring
15. Thrust Bearing 32. Joint Boot 49. O-ring
16. Thrust Washer 33. Tie Strap
17. Dowel Pin 34. Dowel Pin
DESCRIPTION
The transmission/steering valve is a manually controlled direction, range and steering control valve. The valve is used
to direct main oil pressure to the transmission range selector valve for transmission control and to the steering drive
clutches for steering control. A detent mechanism holds the control lever in the desired transmission selection.
THEORY OF OPERATION
Main pressure from the main regulator valve enters the motion control valve at the “P” port and is distributed along and
through the range spool and around the range spool to the direction and steering spools. When the control lever is in
the centered “neutral” position, oil is active at the selected range port and steering ports but is blocked at the direction
spools.
When the control lever is moved forward, the cam plate depresses the forward direction spool directing oil to the “F”
port at the bottom of the valve. The “F” pressure is also directed internally to the base of the Reverse spool which
pushes the reverse spool up to the cam plate, this action creates a hydraulic detent holding the lever forward. When
pulling the control lever to neutral or reverse, the cam plate pushes down on the reverse spool which displaces the
hydraulic detent oil. At the same time the forward spool follows the cam plate up and mid way through its stoke the
forward pressure is cut off as well as the reverse hydraulic detent, allowing the valve to go into neutral. If the lever is
pulled all the way to reverse the same sequence of events happens for the reverse hydraulic detent.
A transmission range gear is selected by rotating the control lever. If rotated counterclockwise to the left most position
1st gear is selected, pressure is sent to the 1st gear pilot port of the range selector valve. Rotating the control lever
clockwise one detent position will select 2nd gear, pressure is sent to the 2nd gear pilot port of the range selector.
Rotating one more position clockwise will select 3d gear, no pressure is sent in 3rd gear since the range selector is
normally in 3rd gear without pressure. The range detent positions are provided by a steel ball, spring and 4 steel pins
located in the cover of the valve.
Steering is accomplished by moving the control lever to the left or right. With the control lever in the upright position both
tracks are driven equally and the tractor travels straight ahead. Pulling the control lever to the right will begin a right hand
turn. The initial movement of the lever drops the right steering clutch pressure causing the right steering clutch to be
in a neutral condition. The neutral condition is indicated by a “feel point” or effort increase in the control lever movement.
Further movement of the control lever to the right increases pressure in the right brake clutch which if pulled to the end
of the lever stoke will result in a pivot turn. A left hand turn is accomplished by pushing the lever to the left. The same
“feel point” feature and series of events takes place as with the right hand turn.
7C - 131
SPECIFICATIONS
Steering Spool Inner Spring (6)

Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.6 mm (2.66 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.6 mm (1.52 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4 to 38.6 mm (1 to 1.52 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.2 ±4.45 N (11.5 ±1 lbf)
Number of Working Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5
Steering Spool Outer Spring (7)
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.5 mm (2.58 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.9 mm (1.29 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 to 32.9 mm (0.91 to 1.29 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 ±3.34 N (7 ±0.75 lbf)
Forward Reverse Spool Spring (10)
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.4 mm (1.59 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.6 mm (0.93 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3 to 23.6 mm (0.68 to 0.93 in )
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120.6 ±6.67 N (27 ±1.5 lbf)
Number of Working Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Range Detent Spring (36)
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.4 mm (0.96 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.9 mm (0.78 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.0 to 19.9 mm (0.75 to 0.785 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.4 ±6.67 N (16.5 ±1.5 lbf)
Number of Working Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Torques:
Directional Spool Retainer Nut (11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 NCm (16 lbf ft)
Rocker End Jam Nut (13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 NCm (28 lbf ft)
Range Cam Retainer Nut (18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 NCm (40 lbf ft)
Bottom Cover (22) Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 NCm (28 lbf ft)
Orifice Plug (24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 NCm (2 lbf ft)
Bearing Housing (27) Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 NCm (8 lbf ft)
Detent Guide Plug (38) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 NCm (15 lbf ft)
Sealant:
Directional Spool Retainer Nut (11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite # 242
Range Cam Retainer Nut (18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite # 242
Cam Ring (28) Working System (Generous Amount) . . . . . . . . . . . . . . . KOMATSU Super Grease - 1400120H91
Universal Joint (31) (Liberal Amount in Joint Area) . . . . . . . . . . . . . . . . . KOMATSU Super Grease - 1400120H91
Magnet Brass Screw (42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #242
Switch Arm (40) Locking Bolt (43) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #242
7C - 132
REMOVAL
WARNING
1. Open battery door. Remove inner pin and remove door from
battery box.
2. Remove battery hold down clamp and hardware.
3. Remove battery and position on wooden blocks.
4. Remove battery mounting pad.
7C - 133
5. Remove trans/steer valve inlet (1) and outlet (2) hoses.
REMARK
6. Disconnect 1st speed hose from fitting at side of trans/steer

valve.
7. Disconnect wires at back up alarm switch.
8. Disconnect reverse (1), forward (2) and 2nd speed (3) hoses
from fittings at bottom of trans/steer valve.
9. Disconnect steering right brake (1) and clutch (2) hoses from
fittings at side of trans/steer valve.
10. Remove ball knob from safety lock lever. Remove hardware
and slide front cover off lever.
11. Disconnect left brake (1) and clutch (2) tubes from hoses (3 and
4) at bottom of battery box. Unclamp (5) tubes. Remove clutch
tube first, then brake tube from fittings at side of transmis-
sion/steering valve.
REMARK
Left brake and clutch tubes have a M23 hex nut at valve fittings.
12. Remove feathering handle.
7C - 134
13. Move control lever inward and loosen jam nut. Unthread control
handle and remove nut.
14. Remove boot and clamp.
15. Install a small ID, large OD washer (1) to valve shaft and secure
with jam nut (2).
REMARK
When valve is removed, it has to be tilted forward so that ceramic
magnet on switch arm clears reed (1,2,3) switch housing.
16. While supporting valve, remove mounting hardware. Slowly tilt

forward and remove from battery box.
DISASSEMBLY
REMARK
1. Position valve in press with hole in bearing housing (27) aligned

with dowel pin in motion lever (26). Apply press and drive pin
into housing clearing lever.
2. Remove motion lever (26) with bearing housing (27) from valve.
3. Position assembly in vise. Remove hardware and separate

bearing housing (27) from cam ring (28).
7C - 135
4. Remove motion lever (26) from bearing housing.
5. Drive outer bearing (29) from housing
6. Remove two internal retaining rings (30) from bearing housing.

Drive remaining inner bearing (29) from housing.
7. Cut and remove tie straps (33) from joint boot (32).
8. Remove boot (32) from universal joint.
9. Loosen bolt (43) on switch arm (40).
7C - 136
10. Remove spool rocker end (12) and jam nut (13) from each
spool.
11. With switch arm (40) position out of the way, remove dowel pin
(34) connecting universal joint (31) to range spool.
12. Remove universal joint (31).
13. Remove switch arm (40) and position in vise.
14. Break Loctite bond of brass screw (42).
7C - 137
15. Remove brass screw (42) and ceramic magnet (41) from switch
arm (40).
16. Remove detent guide plug (38)and discard o-ring (39).
WARNING
Spring loaded assembly. Use extreme caution when disas-
sembling.
17. Remove spring (36), detent guide (37) and detent ball (35).
18. Remove two opposite side mounting bolts.
19. Install two dNC thread rods with washers and nuts to vacated
mounting holes.
7C - 138
20. Remove remaining two mounting bolts.
21. Let off each nut until all spring tension is relieved.
WARNING
sembling.
22. Remove threaded rods and bottom cover (22) from valve.
23. Remove and discard o-rings (47, 48 and 49) from bottom cover
(22).
24. Remove outer spring (7).
7C - 139
25. Remove inner spring (6).
26. Remove pick up spacer (5) from each steering spool (4).
27. Remove forward reverse spring (10) at each directional spool in

valve body.
28. Remove two steering spools (4) from valve body.
7C - 140
29. From under valve body, push directional spool (8) up and out of
valve body. Repeat for remaining spool.
30. Install two nuts on directional spool (8) and position in vise.
Remove Loctited nut from spool.
31. Remove spring retaining washer (9) from spool.
32. From under valve body, push range selector spool (14) up and
out of valve body.
33. Position range selector spool (14) in vise. Remove retaining nut
(18) from spool.
REMARK
Nut is retained with Loctite.
34. Remove range cam (21) from spool
7C - 141
35. If necessary, remove dowel pin(s) (19 and/or 20).
36. Remove top thrust washer (16).
38. Remove bottom thrust washer (16).
39. Remove and discard range selector wiper seal (46) from valve
body.
7C - 142
40. Remove and discard steering spool wiper seal (44) and direc-
tional spool wiper seal (45) from valve body.
41. Remove orifice plugs (24) from bottom cover (22).
42. Discard all software and replace with new.
REASSEMBLY
REMARK
1. Install orifice plugs (24) and torque to 2.7 NCm (2 lbf ft).
2. Install new wiper seals (44 and 45), with U cup portion facing
down, to spool bores in valve body.
7C - 143
3. Install new wiper seal (46), with U cup portion facing down, to
center spool bore in valve body.
4. Install bottom thrust washer (16) to range selector spool.
5. Lightly coat thrust bearing (15) with clean oil and install on thrust
washer.
6. Install outer thrust washer (16) on thrust bearing (15).
7. If removed, press dowel pins (19 and/or 20) flush with stepped
surface of range cam (21). Install range cam aligning dowel pin
(17) with hole to range selector spool (14).
8. Apply Loctite #242 to threads of nut (18).
9. Install nut and torque to 54 NCm (40 lbf ft).
7C - 144
10. Position valve body (1) bottom side facing up in vise. Install
range selector spool (14) into body using a slight turning motion
to aid spool to pass through wiper seal.
11. With directional spool nutted in vise, install spring retainer

washer (9).
12. Apply Loctite #242 to nut threads, install nut (11) and torque to
22 NCm (16 lbf ft).
13. Install directional spool (8) into body using a slight turning
motion to aid spool pass through wiper seal.
14. Install steering spool (4) into body using a slight turning motion
to aid spool pass through wiper seal.
7C - 145
15. Install forward reverse springs (10) in recessed bores.
16. Install pick up spacers (5) over steering spools (4) with recessed
area towards valve body.
17. Install inner springs (6) to steering spools.
18. Install outer springs (7) to steering spools.
7C - 146
19. Check alignment of range selector spool as follows:
Position bottom cover (22) with offset dowel pin hole to dowel
pin (25). Align spool range cam dowel pins with offset recess
in bottom cover.
20. Install two dNC threaded rods to valve body.
21. Install new o-rings (47, 48 and 49) to bottom cover (22).
22. With bottom cover (22) aligned per Step 19, install over
threaded rods. Draw down equally on nuts until cover is flush.
REMARK
Be careful not to bind cover to dowel pins.
23. Install mounting hardware at open holes. Remove threaded

rods and install remaining hardware.
7C - 147
24. Torque mounting hardware to 38 NCm (28 lbf ft).
25. Apply clean grease to detent ball (35) to hold it in guide (37).
Install guide with ball, spring (36) and cap with plug (38) with
new o-ring (39). Torque plug to 20 NCm (15 lbf ft).
26. Coat brass screw (42) with Loctite #242.
27. Install ceramic ring magnet (41) to switch arm (40) with brass
screw (42) and tighten.
7C - 148
28. Slide switch arm (40) over universal joint, making sure that
magnet (41) is on top side of arm and locking bolt (43) is
aligned with counter sunk hole in universal joint.
29. Slide universal joint over range spool making sure that switch
arm points to cast indentation in valve body.
30. Drive dowel pin (34) in making sure it is countersunk at each

end.
31. Apply Loctite #242 to bolt (43) threads. Align the switch arm (40)
over the locking hole on universal joint (31) and lock bolt in.
7C - 149
32. Apply Komatsu Super Grease to universal joint.
33. Install boot (32) over universal joint (31) and secure with tie
straps (33).
34. Install jam nuts (13) and spool rocker ends (12) to each spool.
35. Start dowel pin (34) into universal joint.
7C - 150
36. Install two retaining rings (30) inside bearing housing (27).
37. Press bearings (29) into housing against retaining rings.
38. Attach bearing housing to cam ring and torque bolts to 11 NCm
(8 lbf ft).
39. Install bearing housing (27) over universal joint (31), placing
dowel pin through opening in bearing housing.
40. Install motion lever (26) and align with dowel pin (34). Drive pin
into universal joint so that it completely clears bearing housing.
ADJUSTMENT
1. Apply a generous amount of Komatsu Super Grease to cam

ring surface.
2. Run all four spool rocker ends (12) up against cam plate until
motion lever (26) is vertical with no free play between cam ring
and rocker ends.
7C - 151
3. Move motion lever fully in all directions to seat range selector

spool against needle bearing. Recheck for free play between
cam ring and rocker ends and correct as necessary.
4. Tighten jam nuts to spool rocker ends.
INSTALLATION
1. Apply Loctite #515 to valve mounting surface. Using large flat

washer on valve lever, lift valve, tilting forward to clear reed
switch magnet, into position and secure with mounting hard-
ware.
2. Apply clear RTV sealant to underside boot all around to fashion

a water tight joint.
3. Apply corrosion inhibiter to inside of valve mounting cavity.
4. Install boot with clamp and plate and secure with hardware.
REMARK
Lever portion of boot incorporates an o-ring, be careful not to cut
or damage during installation.
5. Install handle to desired position and secure with jam nut.
6. Install feathering handle and secure with hardware.
7C - 152
7. Install left steering brake (1) and clutch (2) tubes to fittings at
front of trans/steer valve. Connect hoses (3 and 4) to tubes and
secure with clamp (5).
REMARK
Left brake and clutch tubes have a M23 hex nut at valve fittings.
8. Slide front cover (2) over lever and secure in place with hard-
ware. Install ball knob (1) to lever.
9. Connect right steering brake (1) and clutch (2) hoses to fittings
at side of trans/steer valve.
10. Connect reverse (1), forward (2) and 2nd speed (3) hoses to
fittings at bottom of trans/steer valve.
11. Connect wires at back up alarm switch.
12. Connect 1st speed hose to fitting at side of trans/steer valve.
13. Install trans/steer valve inlet (1) and outlet (2) hoses.
7C - 153
14. Install battery mounting pad.
15. Install battery with negative terminal forward.
16. Install battery hold down clamp with hardware.
17. Position battery door in place and secure with hardware.

Connect door link.
7C - 154
DRIVE SHAFT TRANSMISSION
EXPLODED VIEW OF DRIVE SHAFT

1. Mounting Bolts 2. Transmission Yoke 3. Spider and Bearing 4. Drive Shaft
SPECIFICATIONS
D32E-1, D32P-1, D38E-1 or D38P-1:
Yoke Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C
Bolt Torque - 5/16NF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 NCm (24 lbf ft)
D39E-1 or D39P-1:
Yoke Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C
Bolt Torque - 3/8NF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 NCm (42 lbf ft)
7C - 155
TRANSMISSION DRIVE SHAFT
SERVICE
WARNING
4. Disconnect spider at torque converter. Slide shaft back into

transmission, pull up to clear converter yoke and remove from
machine. Check condition of shaft parts and replace as neces-
sary. Check oil seal at transmission input shaft and replace if
necessary. If seal is replaced install new seal flush with housing.
5. Position drive shaft yoke to transmission input shaft and slide in

being careful not to damage oil seal. Align front spider to
converter yoke and secure with bolts. Torque bolts, D32E-1,
D32P-1, D38E-1 or D38P-1 to 33 NCm (24 lbf ft) or D39E-1 or
D39P-1 to 57 NCm (42 lbf ft).

NCm (28 lbf ft) ±10%.
7C - 156
DRIVE SHAFT TRANSMISSION
7C - 157
STEERING DRIVE
SECTION 7E
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 14
BRAKE CYLINDER . . . . . . . . . . . . . . . . . . . . . 24
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 26
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 26
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 28
STEERING CYLINDER . . . . . . . . . . . . . . . . . . 30
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 31
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 31
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 33
MOUNTING PLATE . . . . . . . . . . . . . . . . . . . . 35
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
BRAKE/STEERING SHOES . . . . . . . . . . . . . . 38
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 40
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
BEARING CARRIER . . . . . . . . . . . . . . . . . . . . 43
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
PLANET GEAR CARRIER . . . . . . . . . . . . . . . 46
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 67
BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . 78
BRAKE CYLINDER VALVE . . . . . . . . . . . . . . 81
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . 81
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 82
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 82
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 83
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 85
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 86
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 87
WARNING
7E - 1
STEERING DRIVE GENERAL
DESCRIPTION
This steering system combines a planetary gear type drive, hydraulically applied clutch and brake discs and a spring applied
hydraulic released brake cylinder - that doubles as a parking brake - all located in the rear main frame. Steering is operated
by the transmission/steering valve. The right brake pedal is used to apply both brake discs simultaneously for stopping or
holding the machine. The planetary gear type drive consists of a bevel gear, bevel gear carrier, to which the bevel gear
mounts, and two planet gear carriers (located within the bevel gear carrier) which supports the planet gear assemblies. A
clutch disc and sun gear assembly is located on each side of the bevel gear carrier. The clutch disc is splined to the sun gear
and held with retainer rings. The sun gear is supported on bushings in the bevel gear carrier bearing cage and meshes with
the planet gears. The brake discs (disc next to each clutch disc) are splined to the sprocket drive pinion shaft.
OPERATION
During normal operation (machine moving in a straight line) power transfer is from the bevel gear and gear carrier assembly
through the planet gears to the planet gear carriers out the sprocket drive pinion shaft to the sprocket drive and tracks.
During this time, the clutch discs are held stationary by the clutch shoes allowing the planet gear to walk around the clutch
disc sun gear carrying the planet gear carriers with them as they rotate on their respective shafts. In a turn, the clutch disc
on the side to which the turn is made is released from the clutch shoe. When the clutch disc is released, the planet gears
rather than turning the planet gear carrier, rotate freely on their respective shafts and transfer motion to the free clutch disc.
At this time, the track on this side of the machine is just being carried along the ground. When the track is held stationary
(as in a pivot turn), the clutch disc is still free and the transfer of motion is to the free clutch disc as before only now the brake
disc is held by the brake shoe preventing the sprocket drive pinion shaft from turning.
Steering Operation
Fluid for the steering system is supplied by the transmission hydraulic system. With the transmission/steering valve in the
centered position, oil enters the valve and is directed to the steering cylinders to apply pressure against the clutch side of
the pistons. The pistons push against the clutch levers which cause the eccentric shafts (13) to rotate, clamping the clutch
discs between the clutch shoes. As the clutch levers rotate, the attached return springs (17) hold the brake levers (6) against
the brake end of the pistons (18) to assure the full release of the brake disc. When either the transmission/steering valve
is moved left or right slightly, the valve spool begins metering pressurized oil to the brake application side of the steering
cylinder while simultaneously metering the oil from the clutch apply side of the cylinder to the return side of the system. This
action releases the clutch disc and “centers” the cylinder so neither the clutch or the brake disc is held. Further movement
of the transmission/steering valve causes the spool to direct full system pressure to the brake side of the cylinder, rotating
the eccentric and clamping the brake disc. At this time the oil from the clutch side of the cylinder is directed to the return
side of the system.
Brake Pedal Linkage
The brake pedal rod (5) enters the frame (4) at the top right hand side and connects to the brake actuator bar (3) under the
frame cover. This bar pivots on a pin in the left side of the frame and connects at the center to the brake equalizer bar (1).
Above both bars is a plate (welded to the frame cover) which acts as a guide. Below both bars on the right side is a guide
plate (welded to the steering cylinder base plate). A plate welded to the steering cylinder base plate on the left side acts
as a guide below the equalizer bar only. The equalizer bar contacts the lower pad on each brake lever (6) located at the front
corners of the frame.
Steering Cylinders
A steering cylinder base plate (7) is bolted and doweled to a pad on each side of the frame. Each base plate has bearings
to support the top of clutch and brake eccentric shafts (13). Each base plate also supports the steering cylinder housing for
the clutch and brake pistons. The clutch end of the piston (16) contacts the clutch lever (15) at the rear of the frame. The
brake end of the piston (18) contacts the upper pad on the brake lever (6) at the front of the frame.
Clutch and Brake Shoe Actuating Linkage
The clutch and brake eccentric shafts (13) are supported in bearings at the bottom of the frame and at the top in the steering
cylinder base plates (7). The clutch and brake shoes (8 and 12) are supported on bearings located on the eccentric shafts.
The shaft bearing surfaces supporting shoes are off center from the shaft bearing surfaces in the frame and the cylinder
base plate which results in eccentricity between the shafts and shoes. The clutch and brake levers (6 and 15) are splined
and indexed to the top of the eccentric shafts. The return spring (17) connected between the clutch and brake levers is used
to assure full release of one disc as the other is held. The brake shoes (8) contact their discs (9) at the front of the frame
while the clutch shoes (12) contact their discs (19) at the rear of the frame. The clutch and brake back-up shoes (10 and
14) are mounted (loose fit) on dowels in the main frame. The clutch adjusting screw is threaded into the frame and secured
with a lock plate. This screw can only be reached when the frame cover is removed or, without rear mounted equipment,
through the power take off opening in the rear of the frame. The brake adjusting screw passes through the side of the frame
and sprocket housing and can be reached externally. Each adjusting screw is used to correctly position its respective backup
shoe in the frame.
7E - 2
GENERAL STEERING DRIVE
STEERING DRIVE
1. Brake Equalizer Bar 6. Brake Lever 11. Sprocket Pinion Shaft 16. Clutch End of Piston
2. Bar Pivot Pin 7. Cylinder Base Plate 12. Clutch Shoe 17. Return Spring
3. Brake Actuator Bar 8. Brake Shoe 13. Eccentric Shaft 18. Brake End of Piston
4. Rear Main Frame 9. Brake Disc 14. Clutch Back-Up Shoe 19. Clutch Disc
5. Brake Pedal Rod 10. Brake Back-Up Shoe 15. Clutch Lever 20. Sun Gear
SPECIFICATIONS
Bevel Pinion Gear Set Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.177 to 0.3048 mm(0.007 to 0.012 in)
Bevel Gear Carrier Preload (Rolling Torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.56 NCm (120 lb in)
Pinion Shaft End Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stamped on End of Pinion Shaft ± 0.0254 mm (±0.001 in)
Bevel Gear to Carrier Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 NCm (55 lb ft)
Transmission Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 to 407 NCm (260 to 300 lb ft)
Loading Fixture Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 NCm (25 lb ft)
Bearing Carrier Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.5 to 102 NCm (55 to 75 lb ft)
Base Plate Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 NCm (95 lb ft)
Steering Cylinder Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 NCm (94 lb ft)
Brake Adjusting Screw Jam Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 NCm (125 lb ft)
Steering Cylinder Fitting Flange Mounting Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 to 20 NCm (12 to 15 lb ft)
Rear Main Frame Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 NCm (41 lb ft)
Steering Brake Disc to Hub Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 to 196 NCm (36 to 44 lb ft)
Pinion Gear Retaining Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434 NCm (320 lb ft)
Steering Cylinder End Cap Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR06-580
Transmission Range (Output) Shaft Manifold Holder Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR04-721-5
Bearing Carrier Loading Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR06-581
Steering Cylinder Arm Adjustment Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR06-582
Brake Adjusting Screw Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR06-583
Aligning Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR04-720
7E - 3
STEERING DRIVE REMOVAL
WARNING

NANCE MANUAL.

MAINTENANCE MANUAL.
3. Remove front (1) and side (2) floormat retainer angles from
7E - 4
REMOVAL STEERING DRIVE

REMARK
removal.

under machine
7E - 5
14. Remove cover of fuel level switch at top of fuel tank.
15. Disconnect wire leads at switch.
7E - 6
16. Replace cover and unclip harness from fuel tank.
17 Remove back up alarm mounting hardware.
18. Flip over alarm and remove wire leads.
19. Close fuel shut off valve (1). Disconnect and cap hose (2).
Disconnect and cap fuel return hose (3).
7E - 7
20. Install lifting bracket to front of fuel tank and attach hoist..
21. Remove mounting hardware and spacers, then remove fuel

tank from machine.
7E - 8
support.
27. Disconnect right side brake and clutch hoses (1) at fittings on
rear main frame cover. Remove brake cylinder hose (2).
7E - 9
28. Disconnect left side brake and clutch hoses (1) at fittings on rear
main frame cover. Disconnect pressure hose at (2) top inlet
screen fitting (3) at neutral start valve. Remove return hose (4)
from bottom fitting at neutral start valve.
29. From inside battery box, disconnect and remove positive battery
cable and position outside of box.
30. Remove brake valve return hose (1). Unclamp (2) pressure filter
hoses (3) at steering cylinder fitting clamp.
31. Disconnect forward (1) and 2nd speed (2) hoses from fittings at
bottom of trans/steer valve and position outside of box.
32. Disconnect reverse (1) and 1st speed (2) hoses from fittings at
bottom and side of trans/steer valve and position outside of box.
7E - 10
33. Disconnect drive train pressure filter hoses and position outside
of box.
34. Disconnect wire lead at pressure filter. Remove from clamp on

box wall.
35. Mark reed valve switches, squeeze housing and disconnect.
36. Unclip transmission pressure switch.
37. Disconnect wire leads at back up alarm switch.
38. Disconnect wire leads at neutral start switch. Feed harness out
of battery box.
39. Install lifting bracket to battery box.
7E - 11
40. Attach chain and hoist to lifting bracket. Remove mounting

hardware and remove from machine. Keep shims in positions
they were removed.
41. Remove two hoses at inlet tee on main regulator valve.
42. Remove hose from outlet port of charge and scavenge pump.
43. Disconnect wire leads (1) at horn switch and wire lead (2) at
equipment filter. Unclip from box wall.
7E - 12
44. Feed hydraulic box harness out. Unclip remaining harness from
rear main frame cover and reservoir box and position out of the
way.
46. Remove dipstick and filler tube.
47. Remove lower filler tube and plug port.
7E - 13
STEERING DRIVE DISASSEMBLY
EXPLODED VIEW OF STEERING DRIVE
7E - 14
DISASSEMBLY STEERING DRIVE
EXPLODED VIEW OF STEERING DRIVE SHOES AND LEVERS
7E - 15
CROSS SECTION VIEW OF STEERING DRIVE
7E - 16
1. Planet Gear Carrier 14. Carrier Shim 27. Back Up Shoe 40. Long Connector
2. Retaining Ring 15. Sun Gear 28. Arm Return Spring 41. Seal Flange
3. Planet Gear 16. Retaining Ring 29. Adjustment Screw 42. Connector Boot
4. Needle Bearing Kit 17. Clutch Disc 30. Screw Lock Plate 43. Boot Clamp
5. Needle Bearing Spacer 18. Brake Disc 31. Adjustment Screw 44. Steering Cylinder
6. Planet Gear Shaft 19. Apply Shoe 32. Left Mounting Plate 45. Brake Rod Clevis
7. Thrust Washer 20. Eccentric Shaft 33. Dowel Pin 46. Brake Actuator Bar
8. Ring and Pinion Set 21. Thrust Washer 34. Needle Bearing 47. Brake Equalizer Bar
9. Retainer Plate 22. Left Steering Arm 35. Right Mounting Plate 48. Clevis Pin
10. Ring Gear Carrier 23. Right Steering Arm 36. Dowel Pin 49. Pivot Pin
11. Tapered Roller Bearing 24. Left Brake Arm 37. Needle Bearing 50. Frame Bearings
12. Bearing Carrier 25. Right Brake Arm 38. Plate Mounting Spacer 51. Brake Cylinder
13. Carrier Bushing 26. Retaining Ring 39. Spring Pin 52. Cylinder Fitting
REMARK
1. Using lock ring pliers, remove boot clamp (43).
2. Remove seal flange (41) mounting hardware.
3. Remove seal flange (41). Remove boot (42) from long connec-
tor (40).
4. Using deep well socket, remove long connector.
Repeat steps for remaining four connectors.
5. Remove front, rear and side stiffeners from rear main frame
cover. Remove rear main frame cover and gasket. Discard
gasket and replace with new. Reinstall long connectors with
caps to cylinders.
6. Remove arm return springs (1). Connect a 2070 kPa (300 psi)
power source to connector (2) to retract actuator rods. Loosen
lock nuts (3) and turn in adjusting bolts (4). Remove hardware,
then remove brake cylinder (5) from base plates.
Refer to BRAKE CYLINDER in this section for service.
7E - 17
10. Remove retaining ring (28) from left steering arm (22) and left
brake arm (24). Repeat for remaining side (items 23 and 25).
11. Remove left steering arm (22) and left brake arm (24). Repeat
for remaining side (items 23 and 25).
12. Remove cotter pin from clevis pin (48). Remove pin.
13. Detach brake equalizer bar (47) from brake actuator bar and
remove.
14. Remove pivot pin (49).
15. Rotate brake actuator bar (46) up and remove cotter pin from
clevis pin.
7E - 18
16. Remove clevis pin and brake actuator bar (46).
17. Detach steering cylinder (44) mounting hardware.
18. Remove steering cylinder (44) from mounting plate. As a rule,

spring pin (39) will stay with mounting plate. Repeat for remain-
ing side.
Refer to STEERING CYLINDER in this section for service.
19. Remove left mounting plate (32) hardware. Install two dNC
jacking bolts (A) to plate.
20. Remove bolt spacers (38) from outer mounting holes.
21. Using jacking bolts equally break loose mounting plate.
22. Remove left mounting plate (32). Repeat steps for remaining
side.
Refer to MOUNTING PLATE in this section for service.
7E - 19
23. Remove thrust washers (21).
24. Remove left front eccentric shaft (20).
25. Remove left front apply shoe (19). Remove left rear eccentric
shaft and apply shoe.
Refer to BRAKE/STEERING SHOES in this section for

service.
26. Remove thrust washers (21) from bottom front and rear of
frame.
27. Slide brake disk (18) inboard and remove left front back up shoe
(27). Repeat steps 22 to 26 for remaining (right) side.
Refer to BRAKE/STEERING SHOES in this section for

service.
28. Remove final drives from each side, refer to SECTION 7F.
29. Remove brake disc (18) from both sides.
7E - 20
30. Remove outer retaining ring (16) from sun gear at both side.
31. Remove clutch disc (17) from each side.
32. Remove rear apply shoe (27) from each side.
33. Remove sun gear (15) from each side.
34. Attach hoist and sling to ring gear carrier (10).
35. Loosen bearing carrier (12) hardware at each side.
36. Remove shim halves (14) from each side.
37. Remove hardware and bearing carriers (12) from each side
allowing sling and hoist to support ring gear carrier.
Refer to BEARING CARRIER in this section for service.
7E - 21
38. Remove ring gear carrier (10) from rear main frame.
39. Position gear carrier (10) in press. Using properly sized plates,
press down on planet gear carrier to unseat bearing cup.
40. Remove assembly from press. Remove planet gear carrier (1

through 7).
Refer to PLANET GEAR CARRIER in this section for service.
41. Remove remaining planet gear carrier (1 through 7).
Refer to PLANET GEAR CARRIER in this section for service.
42. Remove ring gear (8) from carrier.
7E - 22
43. Remove pinion gear (8) mounting hardware.
44. Remove pinion gear (8) from transmission output (range) shaft.
7E - 23
STEERING DRIVE BRAKE CYLINDER
EXPLODED VIEW OF BRAKE CYLINDER
7E - 24
BRAKE CYLINDER STEERING DRIVE
CROSS SECTION VIEW OF BRAKE CYLINDER
7E - 25
1. Cylinder Body 5. Cylinder Piston 9. Spring Retainer 13. Wear Ring

2. Cylinder Support 6. ½NC Connector Nut 10. ½NC Retainer Bolt 14. Piston Seal
3. Piston Rod 7. Inner Spring 11. Rod Seal 15. O-ring
4. Stop Bolt 8. Outer Spring 12. Backup Ring 16. Wear Ring
SPECIFICATIONS
Inner Return Spring (7);

Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138.4 mm (5.45 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.6 mm (3.53 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 986 49± N (224 ±11 lbf)
Outer Return Spring (8);

Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 mm (5.75 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.3 mm (3.75 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1740 134 ± N (391 ±30 lbf)
DISASSEMBLY
REMARK
For removal of brake cylinder, refer to DISASSEMBLY and follow
steps to brake cylinder removal.
REMARK
1. Position steering cylinder in vise.
2. Remove end support (2) with hardware. With port unplugged,

remove internal assemblies from body.
3. Remove rod seal (11), back up ring (12) and wear ring (13) from
body bore. Discard and replace with seal kit. Remove body from
vise.
4. Position assembly in vise. Remove stop bolt (4) and lock nut.
7E - 26
5. Turn assembly over in vise and clamp along flats of piston rod
(3). Start to loosen retainer bolt (10) until all tension is relieved
off of inner an outer springs.
WARNING
sembling.
6. After all tension is relieved, remove retainer bolt (10) and spring
retainer (9).
7. Remove outer spring (8).
REMARK
Check spring for damage and fatigue against those values listed
in SPECIFICATIONS.
8. Remove inner spring (7).
REMARK
in SPECIFICATIONS.
9. Remove connector nut (6) from piston rod.
10. Remove piston (5) from rod.
11. Remove wear ring (16) from piston. Discard and replace with
seal kit.
12. Remove piston seal (14) and o-ring (15) from piston. Discard
and replace with seal kit.
13. If not already done, discard all o-rings and seals and replace
with new seal kit. Clean all parts in solvent and dry thoroughly
with compressed air. Inspect cylinder housing wall, end cap and
piston/rod for wear, scoring, scratches or grooves that may
cause seal kit failure. Very slight scratches can be polished out
with a fine emery cloth and oil so a smooth surface is presented
to seal kit. Inspect all parts for cracks and breakage and replace
as necessary.
7E - 27
REASSEMBLY
REMARK
1. Install o-ring (15) in piston. For ease of assembly, soak piston

seal ring (14) in water heated to 82 to 93EC (180 to 200EF) until
it is pliable. Install heated seal ring into piston groove over inner
o-ring.
2. Install wear ring (16) to piston.
3. Install piston (5) to rod.
4. Install connecting nut (6) tight to piston rod.
5. Install inner spring (7).
6. Install outer spring (8).
7. Install retainer plate (9) and bolt (10).
8. Compress springs with retainer bolt (10). Insert bolt down until
contact with piston rod is felt.
7E - 28
9. Install stop bolt (4) and lock nut to piston rod.
10. Install rod seal (11), back up ring (12) and wear ring (13) to
body bore.
11. Coat all seals with a liberal layer of clean oil. Install assembly to
cylinder body being careful not to cut or clip seals in cylinder
body.
12. Install end support with hardware. Torque bolts to 38 NCm (28
lbf ft) ±10%
13. Fabricate a test tool. Apply 2070 kPa (300 psi) at port. Assembly
must maintain this pressure for 10 to 20 seconds with no drop
in pressure.
REMARK
For installation of brake cylinder, refer to REASSEMBLY and
follow steps from brake cylinder installation to end.
7E - 29
STEERING DRIVE STEERING CYLINDER
EXPLODED AND CROSS SECTION VIEWS OF STEERING CYLINDER
7E - 30
STEERING CYLINDER STEERING DRIVE
1. Cylinder Housing 4. Piston Seal 7. O-Ring

2. Cylinder Piston and Rods 5. O-Ring 8. Quad Ring
3. End Cap 6. Quad Ring 9. Retaining Ring
DESCRIPTION
Steering cylinders are a double acting, double rod type that control engaging and disengaging of the brake or clutch
plates. The cylinders are operated by the steering control valve through hoses. Fluid from the control valve enters the
designated port extending the cylinder rod on the opposite side. Return flow from the other side of the piston flows to
drain through the control valve.
DISASSEMBLY
REMARK
For removal of cylinder, refer to DISASSEMBLY and follow steps
to cylinder removal.
REMARK
1. Position steering cylinder in vise. Using end cap tool DR06-580,
rotate cap (3) until end of retaining ring (9) is visible. Using
screwdriver and tool start retaining ring out of cylinder housing.
2. Remove retaining ring (9) from cylinder.
3. Pull out on piston/rod (2) to unseat end cap (3) from cylinder
housing.
4. Remove end cap (3) from piston/rod.
7E - 31
5. Remove piston/rod (2) from housing.
6. Remove quad ring (6) from cylinder housing.
7. Remove piston seal (4) and o-ring (5) from piston/rod.
8. Remove o-ring (7) from end cap.
9. Remove quad ring (8) from inside of end cap.
10. If not already done, discard all o-rings, seals and quad rings and
replace with new seal kit. Clean all remaining parts in solvent
and dry thoroughly with compressed air. Inspect cylinder
housing wall, end cap and piston/rod for wear, scoring,
scratches or grooves that may cause seal kit failure. Very slight
scratches can be polished out with a fine emery cloth and oil so
a smooth surface is presented to seal kit. Inspect all parts for
cracks and breakage and replace as necessary.
7E - 32
STEERING CYLINDER STEERING DRIVE
REASSEMBLY
REMARK
1. Install new quad ring (8) into end cap. Make sure ring sits
squarely in groove.
2. Install new o-ring (7) at outer groove on end cap.
3. Install new o-ring (5) to groove on piston/rod.
4. For ease of assembly, soak piston seal ring (4) in water heated
to 82 to 93EC (180 to 200EF) until it is pliable. Install heated seal
ring into piston groove over inner o-ring.
5. Install new quad ring (6) into cylinder housing. Make sure ring
sits squarely in groove.
6. Place mounting hardware in position on cylinder.
7E - 33
7. Coat piston seal on piston/rod with a liberal layer of clean oil.

Install piston/rod to cylinder housing being careful not to cut or
clip piston seal or quad ring in cylinder housing.
8. Coat internal quad ring in end cap (3) with a liberal layer of
clean oil. Install end cap to piston/rod being careful not to cut or
clip piston or quad ring.
9. Coat o-ring on end cap (3) with a liberal layer of clean oil.
Aligning notch in end cap side with slot (A) in cylinder housing,
install end cap to cylinder housing being careful not to cut or clip
o-ring.
10. Through slot in cylinder housing, connect hooked end of

retaining ring (9) to end cap. Using end cap tool, (DR06-580)
rotate retaining ring into housing.
REMARK
For installation of cylinder, refer to REASSEMBLY and follow
steps from cylinder installation to end.
7E - 34
MOUNTING PLATE STEERING DRIVE
SECTION VIEW OF CYLINDER PLATE
32. Left Mounting Plate 35. Right Mounting Plate
33. Dowel Pin 36. Dowel Pin
34. Needle Bearing 37. Needle Bearing
7E - 35
STEERING DRIVE MOUNTING PLATE
SERVICE
REMARK
For removal of mounting plate, refer to DISASSEMBLY and follow
steps to mounting plate removal.
1. Position mounting plate in press with bearing over open area.

Apply press and remove bearing.
2. Position mounting plate in press with bearing over closed area.

Apply press and install bearing flush with both edges of plate.
3. Using press and pusher rod, remove dowel pins (33 or 36) from
mounting plate.
4. Press new dowel pin (33 or 36) in place in plate to plate at a

15.7 mm (0.625 in) protrusion.
7E - 36
MOUNTING PLATE STEERING DRIVE
5. Measure pin height and correct as necessary.
REMARK
For installation of mounting plate, refer to REASSEMBLY and
follow steps from mounting plate installation to end.
7E - 37
STEERING DRIVE BRAKE/STEERING SHOES
EXPLODED VIEW OF BRAKE OR STEERING SHOES
7E - 38
BRAKE/STEERING SHOES STEERING DRIVE
SECTION VIEW OF BRAKE OR STEERING SHOES
7E - 39
Apply Shoe Assembly 3. Mounting Screw 5. Back Up Shoe

1. Apply Shoe 4. Needle Bearing 6. Shoe Lining
2. Shoe Lining Back Up Shoe Assembly 7. Mounting Screw
SPECIFICATIONS
Mating Surfaces Degreaser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Solvent

Mating Surfaces Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite Primer "T"
Mating Surfaces Adherent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #568 or Loctite Plastic Gasket
Mounting Screw Adherent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #262
Mounting Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 to 12 NCm (7 to 9 lbf ft)
Bearing Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flush or 0.254 mm (0.010 in) Below Finished Surface
SERVICE
REMARK
For removal of brake or steering shoes, refer to DISASSEMBLY
and follow steps to shoe removal. Callouts from exploded and
section views correspond with callouts in following steps.
Apply Shoes
Using a long drift, drive bearings out of each end of shoe housing.
Press new bearing in flush or 0.254 mm (0.010 in) below finished
surface at both ends.
3. Remove lining (2) from shoe and discard.
4. Using a ¼NC tap, remove all Loctite from threaded holes in

shoe.
7E - 40
BRAKE/STEERING SHOES STEERING DRIVE
5. Degrease mating surfaces of lining and shoe with cleaning

solvent. Apply Loctite Primer "T" and Plastic Gasket or #568 per
Section 1 or instructions that come with material. Allow an
adequate period for fixture time.
Apply Loctite #262 to threads of screws (3) and install.
6. Torque screws to 9.5 to 12 NCm (7 to 9 lbf ft).
Back Up Shoes
7. Remove lining from shoe and discard. Using a ¼NC tap,

remove all Loctite from threaded holes in shoe.
8. Degrease mating surfaces of lining and shoe with cleaning

solvent. Apply Loctite Primer "T" and Plastic Gasket or #568 per
Section 1 or instructions that come with material. Allow an
adequate period for fixture time.
Apply Loctite #262 to threads of screws (7) and install.
9. Torque screws to 9.5 to 12 NCm (7 to 9 lbf

ft).
7E - 41
REMARK
For installation of brake or steering shoes, refer to REASSEMBLY
and follow steps from brake or steering shoes installation to end.
7E - 42
BEARING CARRIER STEERING DRIVE
SERVICE
REMARK
For removal of brake carrier, refer to DISASSEMBLY and follow
steps to brake carrier removal.
11. Tapered Roller Bearing
12. Bearing Carrier
13. Carrier Bushing
1. Install puller arrangement to bearing cone (11). Apply ram to

puller arrangement and unseat bearing cone.
2. Position bearing carrier (12) in press with opening under carrier

large enough so pressed out bushings will clear when removed.
Apply press and remove both bushing at same time.
A. 0.76 to 2.03 mm (0.03 to 0.08 in)
12. Bearing Carrier
13. Bearing Carrier Bushings
3. Install bushings (13) into bearing carrier (12) as follows.
7E - 43
STEERING DRIVE BEARING CARRIER
4. Apply coat of Loctite #609 to outside diameter of bushing (13).
5. Position bearing carrier (12) in press, bearing surface facing up.

Start chamfered edge of bushing (13) into carrier and secure
with press. Apply press and install bushing 0.76 to 2.03 mm
(0.03 to 0.08 in) below edge of carrier.
6. Turn carrier over in press. Apply coat of Loctite #609 to outside

diameter of bushing (13).
7. Start chamfered edge of bushing (13) into carrier and secure

with press. Apply press and install bushing 0.76 to 2.03 mm
(0.03 to 0.08 in) below edge of carrier.
7E - 44
BEARING CARRIER STEERING DRIVE
8. Heat bearing cone (11) to 135EC (275EF) for 45 minutes. Install

on bearing carrier (12) and bottom. To insure cone is seated,
keep pressure against cone until it cools.
REMARK
For installation of brake carrier, refer to REASSEMBLY and follow
steps from brake carrier installation to end.
7E - 45
STEERING DRIVE PLANET GEAR CARRIER
SERVICE
REMARK
For removal of planet gear carrier, refer to DISASSEMBLY and
follow steps to planet gear carrier removal.
1. Planet Gear Carrier 5. Needle Bearing Spacer
2. Retaining Ring 6. Planet Gear Shaft
3. Planet Gear 7. Thrust Washer
4. Needle Bearing Kit
1. Remove retaining ring (2) from inside planet gear carrier (1).
2. Drive roll pin into shaft (6).
3. Push planet gear shaft (6) out of carrier.
4. Drive roll pin from planet gear shaft (6).
5. While supporting gear (3) assembly from inside of planet gear

carrier, remove shaft and gear. Disassemble gear and keep
shaft, gear, bearing needles, bearing spacer and thrust washers
together.
Repeat procedure for remaining five planet gears.
7E - 46
PLANET GEAR CARRIER STEERING DRIVE
6. Liberally coat planet gear (3) bore with amber grease. Position
shaft (6) in gear. Install bottom row of bearing needles (4)
around shaft (qty. 20).
7. Install bearing needle spacer (5) and press bottom row of

needle bearings down into gear.
8. Fill gear bore with a second row of needle bearing (4) (qty. 20)
and bottom against bearing spacer. Place a thrust washer on
each side of planet gear to retain bearing needles. Slowly pull
shaft out (6) being careful not to disturb needle bearings.
Repeat for remaining five gears.
9. Align pin hole in shaft with hole in carrier (1). While holding gear
(3) assembly in place, install shaft (6) into carrier and gear being
careful not to disturb needle bearings.
10. Using pin driver, completely align holes in carrier and shaft.
11. Secure planet gear shaft to carrier with roll pin. Install retaining
ring into carrier.
REMARK
For installation of planet gear carrier, refer to REASSEMBLY and
follow steps from planet gear carrier installation to end.
7E - 47
STEERING DRIVE REASSEMBLY
EXPLODED VIEW OF STEERING DRIVE
7E - 48
REASSEMBLY STEERING DRIVE
EXPLODED VIEW OF STEERING DRIVE SHOES AND LEVERS
7E - 49
CROSS SECTION VIEW OF STEERING DRIVE
7E - 50
1. Planet Gear Carrier 14. Carrier Shim 27. Back Up Shoe 40. Long Connector
2. Retaining Ring 15. Sun Gear 28. Arm Return Spring 41. Seal Flange
3. Planet Gear 16. Retaining Ring 29. Adjustment Screw 42. Connector Boot
4. Needle Bearing Kit 17. Clutch Disc 30. Screw Lock Plate 43. Boot Clamp
5. Needle Bearing Spacer 18. Brake Disc 31. Adjustment Screw 44. Steering Cylinder
6. Planet Gear Shaft 19. Apply Shoe 32. Left Mounting Plate 45. Brake Rod Clevis
7. Thrust Washer 20. Eccentric Shaft 33. Dowel Pin 46. Brake Actuator Bar
8. Ring and Pinion Set 21. Thrust Washer 34. Needle Bearing 47. Brake Equalizer Bar
9. Retainer Plate 22. Left Steering Arm 35. Right Mounting Plate 48. Clevis Pin
10. Ring Gear Carrier 23. Right Steering Arm 36. Dowel Pin 49. Pivot Pin
11. Tapered Roller Bearing 24. Left Brake Arm 37. Needle Bearing 50. Frame Bearings
12. Bearing Carrier 25. Right Brake Arm 38. Plate Mounting Spacer 51. Brake Cylinder
13. Carrier Bushing 26. Retaining Ring 39. Spring Pin 52. Cylinder Fitting
REMARK
REMARK
Thoroughly coat all moving surfaces with clean oil. Refer to
OPERATION & MAINTENANCE MANUAL for proper type and
grade.
1. Secure bevel gear (8) to gear carrier (10) with two bolts.
Lubricate remaining bolts with clean engine oil and install.
Remove two securing bolts and lubricate and reinstall. Torque
2. Position carrier assembly in press with bevel gear end down.

Place bearing cup (11) in carrier. Using suitable pusher plate,
apply press and install cup flush with edge of carrier.
3. Remove assembly from press and position with bevel gear end
up. Install one planet carrier assembly with retaining ring end up.
7E - 51
4. Install remaining planet gear carrier assembly with retaining ring

end down.
5. Reposition assembly in press, bevel gear end up. Place bearing

cup (11) in carrier. Using suitable push plate, apply press and
install cup flush with edge of carrier.
6. Install holder tool DR04-721-5, in transmission range (output)

shaft manifold. From rear, slowly rotate range (output) shaft until
lock bolt can be installed.
7. Coat range (output) shaft splines with Molykote "G".
7E - 52
8. Install pinion gear on splines.
9. Coat mounting bolt threads with clean oil.
10. D32E-1, D32P-1 D38E-1 or D38P-1: Secure pinion gear to

range (output) shaft with bolt and spacer.
10. D39E-1 or D39P-1: Secure pinion gear to range (output) shaft

with bolt and spacer.
7E - 53
11. Secure tool with socket and breaker bar.
12. Torque pinion gear mounting bolt to 434 NCm(320 lbf ft).
13. Remove tool from range (output) shaft manifold. Install adapter
fitting with new o-ring to range (output) shaft manifold. Install
hose fitting with new o-ring and attach hose.
14. Loosen transmission mounting bolts and remove shims. Install

2.54 mm (0.100 in) shim pack on each side. Torque bolts to 135
NCm (100 lbf ft). Read and record gauge distance dimension
and backlash etched on face of pinion gear.
15. Using a hoist position bevel gear, to right side, and carrier
assembly in rear main frame.
16. Install right bearing carrier assembly with lube hole facing up.
17. Partially assemble loading fixture DR06-581, bridge (¹), center

rod (²), lock washers and nuts (³). Hold in place with loading
fixture and secure with two bolts. Snug up bolts.
18. Install left bearing carrier assembly with lube hole facing up.
Secure with remaining parts of loading fixture. Snug up bolts.
7E - 54
19. From left side, preload carrier bearings by torquing mounting

fixture to 34 NCm (25 lbf ft). Let off loading fixture mounting bolts
(two each side). Remove hoist and sling.
20. Position dial indicator on machined bevel gear carrier surface

and determine distance between extremes of eccentricity.
Maximum permissible 0.254 mm (0.010 in) TIR (total indicator
run out).
21. Measure and record distance between face of pinion gear to

ring gear carrier machined groove. Add or subtract mounting
shims to bring pinion gear within dimension etched on face,
recorded in Step 14, within 0.025 mm (0.001 in). Torque trans
mounting bolts to 352 to 406 NCm (260 to 300 lbf ft).
D32E-1, D32P-1, D38E-1 or D38P-1
7E - 55
D39E-1 or D39P-1
22. Back out both left side bridge bolts ¼ in. Position dial indicator
on heel of ring gear. Check backlash with dimension recorded
from Step 14. To decrease backlash, turn right bridge bolts in.
To increase backlash, turn left bridge bolts in.
23. On one side and using depth micrometer, measure depths at

open holes in bearing carrier. Record and average readings.
Repeat for remaining side.
Or. On one side and using set of feeler gauges, measure gap
between bearing carrier and main frame wall at three places.
Record and average readings for that side. Repeat for remain-
ing side.
24. Install averaged shim pack at right side and secure with four
bolts. Torque bolts to 61 NCm (45 lbf ft). Install averaged shim
pack at left side and secure with four bolts finger tight. Remove
loading fixture.
7E - 56
25. Apply a thorough coat of clean oil to carrier bearings. Rotate

ring gear carrier five or six revolutions for proper seating. Using
a torque wrench (lbf in scale), read and record ring gear carrier
rolling torque. Reading not to exceed 13.5 NCm (120 lbf in).
‚ If above value, check transmission for binding.
‚ If within value, torque two opposite left side bearing carrier
bolts to 61 NCm (45 lbf ft). Recheck rolling torque, an increase
of 2.3 to 7.3 NCm (20 to 65 lbf in) from previous pull.
‚ If value is exceeded, add shims to left side.
‚ If value is too low, remove shims from left side.
Recheck until value is correct. Install all remaining bearing
carrier hardware and torque to 74 NCm (55 lbf ft).
26. Recheck backlash at 3 places around ring gear, must be with

0.18 to 0.30 mm (0.007 to 0.012 in).
‚ If value is too high, move shims from right side to left side.
‚ If value is too low, move shims from left side to right side.
27. Recheck rolling torque. Value should not exceed one obtained
in second pull of Step 25 by more than 2.3 NCm (20 lbf in).
28. Required backlash, gauge distance and bearing setting should

now be correctly set. To check, coat ring gear teeth (about 8 to
10) with white pattern paste. Rotate ring gear against pinion gear
to obtain patterns.
29. Compare tooth patterns with those shown. If patterns are not
closely approximated, recheck all settings.
A. Ring Gear
B. Pinion Gear
C. Coast Side
D. Drive Side
7E - 57
30. Install drive shoe adjustment screw (29) (both sides) partially
into rear main frame.
31. Install clutch back up shoe (27) onto dowels in rear main frame.
32. Install sun gear (15) with inner retaining ring (16) into bearing
carrier (12) meshing with three planet gears.
33. Install clutch (drive) disc (17) on sun gear and secure with outer
retaining ring (16).
34. Install back up (brake) shoe (27) on dowel pins in rear main
frame.
Repeat Steps 31 through 34 for remaining side.
35. Coat bottom thrust washer (21) with clean oil and place in
position over lower bearing (37).
36. Position apply (drive) shoe (19) in rear main frame.
37. Install eccentric shaft (20) through apply shoe engaging bearing
in rear main frame.
7E - 58
38. Install top thrust washer (21) to eccentric shaft.
39. Position brake disc (18) in rear main frame on both sides.
40. Install final drive to both sides. Refer to SECTION 7F.
position over lower bearing.
42. Position apply (brake) shoe (19) in rear main frame.
in rear main frame. Install top thrust washer to eccentric shaft.
position over lower bearing.
45. Install apply (brake) shoe (19) on thrust washer.
7E - 59
in rear main frame.
47. Install top thrust washer (21).
48. Install left mounting plate (32) over eccentric shafts engaging
dowel pins in rear main frame.
49. Install plate mounting spacers (38) at each outside corner.
50. Secure mounting plate with hardware. Torque bolts to 129 NCm
(95 lbf ft).
REMARK
Drawing down on hardware may be necessary to seat mounting
plate to rear main frame on dowel pins.
51. Install steering cylinder (44), blunt end nose rear ward, over
spring pin (39) and secure to mounting plate with hardware.
52. Torque bolts to 127 NCm (94 lbf ft).

R = T X L ÷ (L + C)
MULTIPLIED BY (x)
L - Wrench Length in ( mm)
DIVIDED BY (÷)
PLUS (+)
C- Extension Length in ( mm)
EQUALS (=)
R - Reading on Scale lbf ft ( NCm)
Repeat Steps 48 through 52 for right side of machine.
7E - 60
53. Position brake actuator bar (46) in brake rod clevis (45) and
secure with clevis and new cotter pins.
54. Position brake actuator bar (46) in place in rear main frame and
secure with pivot pin (49).
55. Install brake equalizer bar (47) and secure to brake actuator bar
with clevis pin (48) and new cotter pin.
56. Install left (24) and right (25) brake arms indexing marks on
arms with marks on eccentric shafts.
57. Install left (22) and right (23) steering arms indexing marks on
arms with marks on eccentric shafts.
7E - 61
58. Install retaining ring (26) at all four arms.
59. Install adjustment tool (DR06-582) on rear main frame.
60. Set combination square at 195.6 ±0.76 mm (7.70 ±0.03 in).

Clean off mounting area on face of rear main frame. Position
square at rear nose of steering cylinder. Back out tool bolt until
rear nose contacts square. Lock tool bolt with nut.
61. From inside rear main frame, turn in adjusting screw (29) until
left steering arm (22) bottoms against nose end of steering
cylinder.
7E - 62
STEERING DRIVE
Secure ad d
hardware. Torque bolts to 38 N m (28 lbf ft) ±10%.
Repeat Steps 59 through 62 for right side of machine.
Adjustment tool is reversible by moving adjusting bolt block to
63. Turn adjusting

from left brake arm (24) and cylinder rod. Repeat for right side.
Avoid over tightening, which will cause erroneous adjustment.
64. final bellcrank against its stop, turn brake rod turnbuckl
and rem m
nuts.
7E - 63
65. Rotate brake shoe adjustment screw (31) ¼ turn counterclock-

wise. Check that there is a 3 mm (0.12 in) gap between brake
arm (24) and piston end.
66. Install tool DR06-583, to adjusting screw lock nut (B).
67. Torque lock nut to 170 NCm (125 lbf ft).

R = T X L ÷ (L + C)
MULTIPLIED BY (x)
DIVIDED BY (÷)
PLUS (+)
EQUALS (=)
68. With pressure source in place, install brake cylinder (5)to base
plates and torque mounting bolts to 92 NCm (70 lbf ft) ±10%.
Screw both adjustment bolts (4) out until they just make contact
with equalizer bar. Secure with locknuts (3) and torque to 92
NCm (70 lbf ft). Install return springs (1).
69. Thoroughly clean all mounting surfaces of cover, rear frame

and new gasket with methyl ethyl ketone (MEK). Install eight
aligning studs, DR04-720, to rear frame. Position gasket over
studs with one odd square corner located at right rear corner.
Apply gasket cement, 1300139H1, to top surface of gasket.
70. Apply gasket cement, 1300139H1, to mounting surface of rear

frame cover.
71. Position rear frame cover on gasket centering gasket metal

spacers within holes of cover.
7E - 64
72. Install front, back and side stiffeners and secure with hardware.
Remove aligning studs and install remaining hardware. Torque
73. Install long connector, with new o-ring, to cylinder port.
74. Install boot down over connector against cover.
75. Install seal flange and secure with hardware. Torque lock nut to
16 to 20 NCm (12 to 15 lbf ft).
76. Using lock ring pliers, install ring over boot and under lip.
Repeat at four remaining spots.
77. Install lower filler tube.
7E - 65
78. Install upper filler tube.
7E - 66
INSTALLATION STEERING DRIVE
1. Install inner rock deflector and secure with hardware. Torque

2. Attach sling and hoist to sprocket install sprocket to carrier

securing with hardware.
3. Torque bolts to 455 NCm (335 lbf ft). Remove sling and hoist.
4. Install outer rock deflector and secure with hardware. Torque

5. Install track chain, refer to SECTION 15.
6. If removed, install fender and secure with hardware. Torque

7. Insert drive train dipstick
7E - 67
STEERING DRIVE INSTALLATION
8. Feed harness into hydraulic reservoir box. Reclip harness to

reservoir box and rear main frame cover.

connect to horn (1) switch and equipment (2) filter switch. Reclip
to box wall.
10. Install hose to outlet port of charge and scavenge pump
11. Install two hoses at inlet tee on main regulator valve.
7E - 68
12. Position battery box in place on fender with shims that were
removed with it and secure with hardware finger tight.
REMARK
When installing battery box, make sure crossover tubes at left
front of rear frame clear bottom floor plate of box. Tubes go inside
box.
13. Remove lifting bracket from battery box.
14. Feed harness into battery box. Apply electrical sealing grease,
Grafo 112-X to wire leads and connect to neutral start switch.
connect to back up alarm switch.
16. Install harness connector to transmission pressure switch.
17. Match marked reed switches and connect.
7E - 69
18. Apply electrical sealing grease, Grafo 112-X to wire lead and
connect to drive train pressure filter. Reclamp to box wall.
Reclamp wiring harness to inside of battery box.
19. Connect hoses drive train pressure filter.
20. Connect reverse (1) and 1st speed (2) hoses to fittings at bottom
and side of trans/steer valve.
21. Connect forward (1) and 2nd speed (2) hoses to fittings at
bottom of trans/steer valve.
22. Install brake valve return hose (1). Clamp (2) pressure filter
hoses (3) at steering cylinder fitting clamp. Torque lock nut to 12
to 15 lbf ft (16 to 20 NCm).
23. Apply electrical sealing grease, Grafo 112-X to positive battery

cable and torque nut to 31 NCm (23 lbf ft).
7E - 70
24. Install return hose (4) to bottom fitting at neutral start valve.
Connect pressure hose to (2) top inlet screen fitting (3) at
neutral start valve. Connect left side brake and clutch hoses (1)
to fittings on rear main frame cover.
25. Connect right side brake and clutch hoses (1) to fittings on rear
main frame cover. Install brake cylinder hose (2).
7E - 71
(28 lbf ft) ±10%.
31. Position fuel tank in place and secure with mounting hardware
and spacers. Torque ¾NC bolts to 325 NCm (240 lbf ft) ±10%.
7E - 72
32. Remove lifting bracket from front of fuel tank.
33. Connect fuel return hose (3) to fitting at tank. Connect fuel
supply hose (2) to shut off valve (1). Open valve.
connect at back of alarm. Torque nuts to 1.8 NCm (16 lbf in)
±10%.
35. Position back up alarm and secure with hardware. Torque bolts
to 38 NCm (28 lbf ft) ±10%.
7E - 73
36. Remove cover and feed harness through grommet to fuel level
sender switch. Reclip harness to tank.
connect to switch.
38. Install cover with new gasket and secure with hardware. Torque
to 21 NCm (16 lbf ft) ±10%.
(28 lbf ft) ±10%.
±10%.
7E - 74

±10%.

REMARK
reassembly.
7E - 75
46. Adjust length of final brake rod (1) so that stop (2) on bellcrank
is in contact with mounting bracket (3). Adjust length of main
brake link (4) so that top of brake decelerator or brake pedal (5)
is 137 mm (5.4 in) (6) from floor (7) as shown.
Complete remaining installation procedure then refer to Step 50.

NCm (28 lbf ft) ±10%.
7E - 76
50. Verify brake adjustment as follows:
Connect a portable pump to quick-disconnect fitting in battery

box and apply 260 PSI to brake cylinder to release brakes.
With throttle lever in high idle position, brake pedal depressed

and transmission in first gear. Release brake pedal and start
machine rolling. Depress foot brake pedal (A), it must stall
tracks at . 71 (B) to 94 (C) mm (2.8 to 3.7 in) (engine deceler-
ated) from floor plate.
If pedal falls out of this range, loosen jam nut (1) and turn
adjusting screw (2) on side of unstalled track 1/12 of a turn (½
flat). Clockwise (in) for less pedal travel, counterclockwise
(out) for more pedal travel. Repeat until pedal stalls both
tracks within range given above.
7E - 77
STEERING DRIVE BRAKE ADJUSTMENT
REMARK
Following procedures are to be performed with brake pedal in up,
released position unless noted otherwise.
1. Remove front (1) and rear (2) floor mat retainer angles from
3. Remove operators compartment floor plate.
4. Loosen jam nuts (1) and rotate (lengthen) brake rod (2),
increasing pedal free play. Increase brake pedal free play until
pedal can be pushed easily to floor.
5. Loosen jam nut (1) on both sides of machine. Turn adjusting

screw (2) clockwise until all clearance has been eliminated and
resistance to turning is felt.
REMARK
Brake adjusting screws should only be tightened enough to
remove internal brake component clearance. Over tightening will
cause erroneous adjustment.
REMARK
If it is obvious that rust or other foreign matter in threaded area of
adjusting screw or rear frame housing is causing screw to be
"hard to turn", screw should be removed and problem corrected.
7E - 78
BRAKE ADJUSTMENT STEERING DRIVE
6. Rotate (shorten) brake rod (2) until brake pedal free play is
eliminated. Lock jam nuts (1).
7. Connect a portable pump to quick-disconnect fitting in battery

box and apply 260 PSI to brake cylinder to release brakes.
7. Scribe or otherwise mark hex head of brake adjusting screws.

Mark should run from center of hex outward either vertically or
horizontally (1). Turn out (counterclockwise) both adjusting
screws exactly 1/4 turn each.
8. Apply and lock brake pedal. Using tool, DR06-583, torque

adjusting screw jam nut to 170 NCm (125 lbf ft). Recheck
position of scribe mark. Repeat for opposite side.
R = T X L ÷ (L + C)
MULTIPLIED BY (x)
DIVIDED BY (÷)
PLUS (+)
EQUALS (=)
7E - 79
STEERING DRIVE BRAKE ADJUSTMENT
9. With transmission in first gear and engine at full throttle, foot

brake (A) must stall tracks and at . 71 (B) to 94 (C) mm (2.8 to
3.7 in) from floor plate. If dimension is not obtained, repeat
Steps 2 through 6 until it is.

NCm (28 lbf ft) ±10%.
7E - 80
BRAKE CYLINDER VALVE STEERING DRIVE
GENERAL
BRAKE CYLINDER VALVE
7E - 81
STEERING DRIVE BRAKE CYLINDER VALVE
1. Spool Wiper 7. Outer Metering Spring 13. O-ring

2. Valve Housing 8. End Cover 14. Port Plug
3. Input Spool 9. Spool Return Spring 15. Inner Metering Spring
4. Metering Spool 10. Seal Retainer 16. Spring Guide
5. Spool Stop 11. Mounting Bolt 17. O-ring
6. Spring Retainer Washer 12. Flat Washer
SPECIFICATIONS
Outer Metering Spring (7);
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.5 mm (1.478 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3 mm (1.075 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3 mm to 38.5 mm (1.075 to 1.515)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 N (28 lbf)
Number of Working Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Spool Return Spring (9);
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.8 mm (2.513 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.5 mm (1.830 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2 mm to 46.5 mm (1.306 to 1.830 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 N (70 lbf)
Inner Metering Spring (15);
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.7 mm (1.365 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.5 mm (0.965 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.5 mm to 35.7 mm (0.965 to 1.405 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 N (8 lbf)
OPERATION
The left brake pedal valve performs two functions in the drive train hydraulic system.
The first function, pedal upright, is to allow full disengagement of the brake cylinder. The second function, pedal fully
depressed, is to allow full engagement of the brake cylinder.
When the pedal is fully upright (no depression), the input spool is positioned down against its stop. Pressurized fluid from
the main regulator valve enters through a one way check valve to the P port past the metering spool and out the C port.
The metering spool is unable to move because of mechanical stack up of its internal components. From the C port fluid
enters the brake cylinder releasing the brakes.
When the pedal is fully depressed, the input spool is pulled up off its mechanical stop. Pressurized fluid from the main
regulator valve enters through a one way check valve to the P port around the metering spool. Oil enters the drilled
passage moving the metering spool upwards. As the metering spool shifts, the D (drain) port is fully open, dropping the
pressure in the C port, brake cylinder, allowing full engagement of the brake cylinder. The D port has a drilled passage
to the spring side of the metering spool for lubrication of the valve components.
7E - 82
REMOVAL
WARNING
3. Cut and remove cable ties from left dash brace. Remove dash
brace from left side of machine. Remove mounting hardware
and fuel filter mounting bracket from dashboard. Roll bracket
with filter forward.
Remove dash brace from right side of machine.
4. Remove link from left brake pedal.
7E - 83
5. Remove return spring.
6. Remove linkage from valve spool.
REMARK

(3).

(2).
9. Remove mounting hardware and valve from machine.
7E - 84
DISASSEMBLY
REMARK
1. Remove two end cover bolts (11) and washers (12) across from
each other. Install longer bolts in place. Remove remaining two
end cover bolts. Slowly loosen two longer bolts until all spring
tension is relieved. Remove end cover (8).
WARNING
sembling.
2. Remove seal retainer (10) from spool.
3. Remove spool wiper (1) and o-ring (17) from retainer (10) and
discard.
4. Remove return spring (9) and spool (3) from valve body.
REMARK
in SPECIFICATIONS.
5. Remove spool stop (5) and retainer washer (6) from spool.
6. Remove end plug (14) and o-ring (15) from valve body.
7. Remove metering spool (4) from valve housing.
8. Remove inner (15), outer (7) metering springs and spring guide
(16) from valve housing.
REMARK
in SPECIFICATIONS.
9. If not already done, discard all o-rings and seal and replace with
new. Clean all parts in solvent and dry thoroughly with com-
pressed air. Inspect valve body wall, and spool for wear, scoring,
scratches or grooves that may cause seal kit failure. Very slight
scratches can be polished out with a fine emery cloth and oil so
a smooth surface is presented to new seals. Inspect all parts for
cracks and breakage and replace as necessary.
7E - 85
REASSEMBLY
REMARK
1. Install retainer washer (6) and spool stop (5) to spool.
2. Install spool (3) and return spring (9) into valve housing.
3. Install new spool wiper (1) and o-ring (17) to seal retainer.
4. Install seal retainer (10) over spool being careful not to cut or
slice wiper.
5. Install end cover (8) to retainer and secure with two longer bolts.
Install hardware (11 and 12) and draw retainer and spring into
housing. Be careful not to cut or slice o-ring. Remove longer
bolts and install remaining hardware. Torque bolts to 21 NCm
(16 lbf ft) ±10%
6. Install spring guide (16), inner (15) and outer (7) metering
springs into valve body.
7. Install metering spool (4), ported end up, into valve body.
8. Install end plug (14) with new o-ring (15) to valve body.
7E - 86
INSTALLATION
1. Install valve to dashboard and secure with hardware. Torque

4. Connect linkage to valve.
5. Install return spring.
6. Connect link to left pedal.
7E - 87
7. Install fuel filter mounting bracket with filter to dashboard.

Torque bolts to 21 NCm (16 lbf ft) ±10%. Install dashbrace on
left side of machine. Torque bolts to 92 NCm (70 lbf ft) ±10%.
Install (2) cable ties for fuel filter hoses and harness. Install
dashbrace on right side of machine. Torque bolts to 92 NCm (70
lbf ft) ±10%.
±10%.
±10%.
7E - 88
FINAL DRIVE
SECTION 7F
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE DIAGNOSIS . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 7
D32E-1, D32P-1, D38E-1 OR D38P-1 . . . . . 8
D39E-1 OR D39P-1 . . . . . . . . . . . . . . . . . . . 11
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 16
D32E-1, D32P-1, D38E-1 OR D38P-1 . . . . 17
D39E-1 OR D39P-1 . . . . . . . . . . . . . . . . . . . 20
METAL TYPE FACE SEALS . . . . . . . . . . . . . . 24
SEAL INSPECTION . . . . . . . . . . . . . . . . . . . 24
SEAL INSTALLATION . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 26
WARNING
7F - 1
FINAL DRIVE GENERAL
CROSS SECTION VIEW OF FINAL DRIVE
7F - 2
GENERAL FINAL DRIVE
1. Housing O-Ring 9. Mounting Bolt 17. Tapered Roller Bearing

2. Sprocket Carrier Shaft 10. Cover Gasket 18. Retaining Ring
3. Metal Type Face Seal 11. Carrier Shaft Cover 19. Oil Seal
4. Tapered Roller Bearing 12. Final Drive Housing 20. Drain Plug
5. Tapered Roller Bearing 13. Sprocket Drive Gear 21. Housing Bottom Cover
6. Bearing Spacer 14. Retaining Screw 22. Drive Sprocket
7. Carrier Shim 15. Drive Pinion
8. Carrier Washer 16. Tapered Roller Bearing
DESCRIPTION AND OPERATION

The final drive is a single reduction gear type mounted to each side of the machine. The reduction is provided by the
sprocket drive gear (13) and the drive pinion (15). The final drive housing (12) along with the bottom housing cover (21)
serve as a reservoir for the lubricating oil.
The drive pinion (15) is splined to the planet gear carrier at the inner end and is supported at the outer end by two
tapered roller bearings (16 and 17). Power from the planet gear carrier is transmitted through the drive pinion to the
sprocket drive gear (13). The drive gear is splined on the carrier shaft (2) and transfers power through the carrier shaft
to the sprocket (22). The sprocket is mounted to the carrier shaft on the outside of the housing (12). The carrier shaft
is supported in the final drive housing on tapered roller bearings (4 and 5) and is secured to the drive gear by a set screw
(9). The final drive is splash lubricated by its own supply of lubricant and is sealed against leakage and dirt.
SPECIFICATION
Pinion Gear End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 0.229 mm (0 to 0.009 in)
Rock Deflector Bolts - 5/8NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 NCm (195 lbf ft)
Sprocket Bolts - 3/4NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445 NCm (335 lbf ft)
Sprocket Carrier Shaft Retainer Bolt - 3/4NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475 NCm (350 lbf ft)
Final Drive Mounting Bolts - 5/8NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 NCm (140 lbf ft)
Main Frame to Final Drive Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730 NCm (540 lbf ft)
Gear Retainer Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 NCm (150 lbf in)
Retainer Screw Jam Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 NCm (60 lbf ft)
Weights:
D32E-1 or D38E-1:
Final Drive with Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 kg (548 lb)
Final Drive w/o Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 kg (470 lb)
Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 kg (78 lb)
D32P-1 or D38P-1:
Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 kg (78 lb)
D39E-1 or D39P-1:
Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 kg (111 lb)
Final Drive to Rear Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #568 or Plastic Gasket
Bottom Housing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #568 or Plastic Gasket
Housing Mounting Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #568 or Plastic Gasket
Final Drive Fill and Drain Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #592
Service Tools:
Mounting Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR11-714
Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR10-817
Puller Screws:
D32EP-1, D38P-1, D39E-1 or D39P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR10-818
D32E-1 or D38E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR10-819
Drive Gear Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR10-820
Alignment Rod and Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR10-821
Drive Gear Shims - D39E-1 or D39P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR10-822
7F - 3
FINAL DRIVE GENERAL
SERVICE DIAGNOSIS
PROBABLE CAUSE REMEDY
Final Drive Overheating
Improper or insufficient lubricant. Use proper grade and amount of lubricant. Refer to
OPERATION & MAINTENANCE MANUAL.
Bearing seizure or damaged bearings. Remove final drive and inspect.
Noise
Improper, dirty or insufficient lubricant. Use proper grade and amount of lubricant. Refer to
OPERATION & MAINTENANCE MANUAL
Bearings scored or damaged. Replace bearings.
Worn or damaged gears. Inspect all gears and replace as necessary.
Lubricant Leakage
Leakage at drain or level plugs. Tighten plugs as necessary.
Leakage between final drive housing and rear main Clean sealing surfaces and apply new Loctite.
frame.
Leakage between sprocket carrier and final drive hous- Replace carrier seal.
ing.
Excessive Wear on Sprockets
Tracks run too loosely. Adjust tracks.
Tracks worn excessively. Install new tracks.
Track frame out of alignment or damaged. Repair or install new track frame.
7F - 4
REMOVAL FINAL DRIVE
REMARK
Following procedure is for removal of final drive on one side of
machine. Procedure is identical for opposite side.
WARNING
This procedure requires extreme caution. Use suitable
blocking equipment while under confines of machine.
WARNING
1. Drain rear main frame and final drive to be removed per the
OPERATION & MAINTENANCE MANUAL. Install mounting
blocks DR11-714 to rear frame and position on jack stands.
Position split link at top left position on sprocket.
2. Remove track adjuster shield (1) and scraper plate (2).
3. Loosen bleeder valve (1) and allow track chain to fully release.
4. Attach hoist (1) to track shoe (2) at rear of chain and tension
chain. Remove bolts (3) and track shoe over split link. Separate
split link and lower track chain to floor with hoist. Attach hoist to
remaining section of track chain and move forward to contact
blade.
5. Remove bolts (1) and outer rock deflector (2).
6. Attach eye bolt (1) to top hole in sprocket, attach hoist (2) and
tension chain. Remove sprocket mounting bolts (3).
7. Position pry bar (1) between rear of sprocket (2) and final drive
housing (3) and remove.
8. Remove bolts (1) and inner rock deflector (2).
7F - 5
FINAL DRIVE REMOVAL
9. Remove bolts (1) and rear rigid crossbar cap (2).
10. D32E-1, D32P-1, D38E-1 or D38P-1; Reinstall top front cap bolt
(1) as a safety measure. Remove four final drive to main frame
bolts (2) spacer plate (3).
10. D39E-1 or D39P-1; Reinstall top front cap bolt (1) as a safety
measure. Remove four final drive to main frame bolts (2).
11. Remove two bolts and install removal tool rods, DR10-817, (1).
Assemble and position removal tool (2). Adjust vertical mem-
bers to support weight of final drive when removed from rear
main frame.
12. Remove lock nut and brake adjuster (1), threaded into rear
main frame housing. Remove final drive housing top bolts (2)
and inner lower hardware.
13. Remove corks from two puller screw holes. Install two eNCx3
puller bolts (1) and draw final drive (2) away from rear main
frame. Slide final drive out to clear side of machine.
14. Install two eye bolts (1) and nuts in top most holes in final drive
housing. Attach hoist and tension. Remove support tool (2) and
remove final drive (3).
7F - 6
FINAL DRIVE DISASSEMBLY
EXPLODED VIEW OF FINAL DRIVE

1. O-Ring 6. Spacer 11. Cover 15. Pinion 20. Drain Plug
2. Carrier Shaft 7. Shim 12. Housing 16. Outer Bearing 21. Bottom Cover
3. Seal 8. Washer 12a Filler Plug 17. Inner Bearing 22. Sprocket
4. Outer Bearing 9. Bolt 13. Drive Gear 18. Retaining Ring 23. Spacer Plate
5. Inner Bearing 10. Gasket 14. Screw 19. Oil Seal D32E&P D38E&P
7F - 7
D32E-1, D32P-1, D38E-1 OR D38P-1
REMARK
steps
1. Rest final drive on bench with main frame mounting face down.
Assemble safety restraint.
2. Replace two top corner bolts of bottom cover with ½NCx7 bolts.
Remove corks from puller screw holes in bottom cover (21).
Remove remaining cover mounting hardware. Install ½NC
puller screws. Remove bottom cover by running in puller bolts.
3. Slide bottom cover (21) out on two bolts, install eye bolt and nut.
Attach hoist to eye bolt and remove bolts then cover.
4. Rotate sprocket drive gear (13) to position jam nut and retainer
screw (14) for removal. Remove sprocket carrier retaining screw
and jam nut.
Discard retainer screw and replace with new.
5. Remove carrier shaft cover (11) and gasket.
6. Rotate sprocket drive gear (13) to position a relief hole to

assemble support bridge. Install retainer tool DR10-820 and
torque bolts to 95 NCm (70 lbf ft).
7F - 8
DISASSEMBLY FINAL DRIVE
7. Remove sprocket carrier bolt (9), and washer (8) and shim pack
(7).
REMARK
Heat may have to be applied to bolt for removal.
8. Install alignment rod DR10-821 in end of sprocket carrier shaft

and bridge over rod and secure to housing.
9. Apply amber grease to puller screws DR10-819, E series or

DR10-818, P series, threads and forcing face. Thread puller
screws through holes in sprocket carrier shaft (2) and aligned
with cast bosses on outside of housing. Thread in puller screws
to pull out shaft.
10. With space between shaft and housing of approximately 32 mm

(1.25 in), install lifting strap around shaft and behind bearing.
Connect to hoist.
11. Continue to draw out shaft (2) and remove from housing.
Remove alignment rod from shaft. Remove alignment bridge
and bearing from housing.
12. Thread lifting strap through top relief hole in sprocket drive gear
(13) and support gear with hoist. Remove support bridge and
gear retainer. Remove gear from housing.
13. Remove sprocket shaft seal half (3) from housing.
14. Remove O-ring (1) from drive pinion face of housing.
7F - 9
15. Remove oil seal (19) from housing by driving a screwdriver

through flange of seal and prying out of housing.
16. Remove retaining ring (18) from housing.
17. Install puller arrangement and draw out pinion shaft (15) with
bearing cones and inner cup.
18. Remove puller. Remove pinion shaft (15) and inner cone (17).
Inspect and remove outer bearing cone if necessary.
19. Install puller arrangement and remove inner bearing (17) from
pinion shaft (15).
20. Install puller arrangement and remove outer bearing (16) from
pinion shaft (15).
21. Remove seal half (3) from sprocket carrier shaft (2).
7F - 10
22. Install puller arrangement and remove bearing (4) from

sprocket carrier shaft.
23. If necessary to replace bearing spacer (6), heat and remove.

Press fit requires destroying spacer.
24. If necessary, remove studs from housing.
D39E-1 OR D39P-1
REMARK
steps
1. Rest final drive on bench with main frame mounting face down.
Install safety restraint.
2. Replace two top corner bolts of bottom cover with ½NCx7 bolts.
Remove corks from puller screw holes in bottom cover (21).
Remove remaining hardware. Install two ½NC puller bolts.
Remove cover by running in puller bolts.
3. Slide bottom cover (21) out on two bolts. Install eye bolt and nut.
Attach hoist to eye bolt and remove bolts, then cover.
4. Remove carrier shaft cover (11) and gasket (10).
7F - 11
5. Remove sprocket carrier retaining screw (14) and jam nut.

Discard retainer screw and replace with new.
REMARK
Assembly shown rotated for clarity.
6. Position a wedge between housing and sprocket drive gear (13)

to prevent gear from rotating. Loosen sprocket carrier bolt (9).
REMARK
Heat may have to be applied to bolt for removal.
7. Remove sprocket carrier bolt (9), washer, (8) and shim pack (7).
8. Install drive gear retaining tool DR10-820, thru a relief hole in

sprocket drive gear, to prevent it from falling from housing when
shaft is removed. Apply amber grease to puller screws DR10-
818 threads and forcing face. Install puller screws through holes
in sprocket carrier shaft (2) and aligned with cast bosses on
outside of housing (12).
9. Install lifting strap between lower puller screw and sprocket

carrier shaft.
10. Install alignment rod DR10-821 in end of sprocket carrier shaft

and bar in place of shaft cover.
7F - 12
11. Thread in puller screws to draw shaft from sprocket drive gear.
When shaft groove is visible between gear and housing,
reposition lifting strap as shown.
12. Remove sprocket carrier shaft from housing.
13. Install lifting strap through top relief hole in sprocket drive gear
and support gear with hoist. Remove gear retainer.
14. Remove sprocket drive gear (13) from housing.
15. Remove alignment tool and inner bearing (5) from housing.
16. Remove seal half (3) from housing.
7F - 13
17. Remove o-ring (1) from drive pinion face of housing.
18. Remove oil seal (19) from housing by tapping OD of seal toward
center and prying out of housing.
19. Remove retaining ring (18) from housing.
20. Following are two possible ways of removal:
A) Install a slide hammer in pinion shaft (15). Remove shaft with

inner bearing and cone and outer bearing. Inspect and
remove outer cone if necessary.
B) Install puller arrangement and remove pinion shaft (15) with

inner bearing and cone and outer bearing. Inspect and
remove outer cone if necessary.
21. Remove seal half (3) from sprocket carrier shaft.
7F - 14
22. Install puller arrangement and remove bearing (4) from

sprocket carrier shaft.
23. If necessary to replace bearing spacer (6), heat and remove.

Press fit requires destruction of spacer during removal.
24. Install puller arrangement and remove outer bearing (16) from
drive pinion.
25. Install puller arrangement and remove inner bearing (17).
7F - 15
REASSEMBLY FINAL DRIVE
EXPLODED VIEW OF FINAL DRIVE

1. O-Ring 6. Spacer 11. Cover 15. Pinion 20. Drain Plug
2. Carrier Shaft 7. Shim 12. Housing 16. Outer Bearing 21. Bottom Cover
3. Seal 8. Washer 12a Filler Plug 17. Inner Bearing 22. Sprocket
4. Outer Bearing 9. Bolt 13. Drive Gear 18. Retaining Ring 23. Spacer Plate
5. Inner Bearing 10. Gasket 14. Screw 19. Oil Seal D32E&P D38E&P
7F - 16
D32E-1, D32P-1, D38E-1 OR D38P-1
REMARK
steps
1. Block final drive housing in a horizontal position with rear main

frame mating face up. Check height of two mounting studs for
65 mm (2.56 in) dimension. If necessary to install new studs,
use Loctite #568 or Plastic Gasket.
2. Assemble studs to housing and set to 65 mm (2.56 in) dimen-

sion. If necessary, assemble drive pinion outer bearing cup (16)
into housing. Using a driver, tap to seat in housing.
3. Heat drive pinion inner bearing (17) to 135EC (275EF) for 45

minutes and assemble to shaft (15). Tap to seat against
shoulder of shaft.
4. Heat drive pinion outer bearing (16) to 135EC (275EF) for 45

minutes and assemble to shaft (15). Tap to seat against
shoulder of shaft.
5. Prelube drive pinion bearings and set shaft (15) into outer
bearing cone.
6. Using driver, install inner bearing cup until a slight resistance to

rotation is felt.
7. Attempt to insert 2.769 mm (0.109 in) retaining ring (18). If

possible to insert ring, bump cup back against ring with slide
hammer. If shaft rotates freely assembly is complete.
8. Position indicator against hose clamp assembled to shaft. Set to

zero. Insert pry bar between housing and shaft. Pry shaft
upward from within housing to determine end play. Observe and
record reading. Repeat two or three times and average read-
ings. Required end play is 0 to 0.229 mm (0 to 0.009 in). If end
play should exceed 0.229 mm (0.009 in) with 2.769 mm (0.109
in) retaining ring, install 2.972 mm (0.117 in) ring and bump cup
back against ring. If 2.769 mm (0.109 in) retaining ring will not
fit, or shaft will not rotate freely, install 2.565 mm (0.101 in)
retaining ring and bump cup back against retaining ring.
7F - 17
FINAL DRIVE REASSEMBLY
9. Install sprocket carrier shaft inner (5) and outer (4) bearing cups
in housing and using a driver, bottom cups. With lifting strap,
position sprocket drive gear (13) in housing with retainer screw
hole facing up. Install gear retaining tool DR10-820 to housing
and torque bolts to 95 NCm (70 lbf ft).
10. Heat locating spacer (6) to 135EC (275EF) and assemble to

sprocket carrier shaft. With drift and hammer, tap to seat against
shaft face.
11. Heat sprocket carrier outer bearing (4) to 135EC (275EF) for 45
minutes. Install on shaft against locating spacer. With a drift and
hammer, tap inner bearing race to seat.
12. Assemble alignment rod DR10-821 in end of sprocket carrier

shaft. Install shaft oil seal (3). Refer to METAL TYPE FACE
SEALS in this section.
13. Position four eye bolts in housing and install alignment bridge
DR10-821.
14. Raise housing and install oil seal half (3) in housing. Refer to
METAL TYPE FACE SEALS in this section.
15. Apply oil to outer bearing (4) and leading edge of carrier shaft
spline. Lower housing over sprocket carrier shaft (2) allowing
alignment pin to extend through hole in alignment bar. Lower
housing to align shaft groove for retainer screw and nut.
7F - 18
16. Assemble and tighten new retainer screw (14) and jam nut (20).
Torque retainer screw to 17 NCm (150 lbf in) and jam nut to 80
NCm (60 lbf ft). Continue to lower housing to seat. Remove
alignment bridge from housing and pin from shaft.
17. Heat bearing (5) to 135EC (275EF) for 45 minutes. Assemble

bearing to sprocket carrier shaft. Tap with driver to seat.
18. Install 2.667 to 2.743 mm (0.105 to 0.108 in) initial shim pack
(7). Assemble three carrier washers (8) using a 3/4NCx4-3/4
bolt, 25 964 R1 (B). Torque to 305 NCm (225 lbf ft). Remove
gear retainer tool (A).
19. Position dial indicator against washer (8) and set to zero. Pry
between bottom face of sprocket gear (13) and housing (12).
Read and record amount of movement of dial indicator. Repeat
two or three times and average readings. Add 0.25 mm (0.010
in) to reading and subtract total from initial shim pack. The result
is amount of shim pack to be installed. Replace initial shim pack
with calculated shim pack. Reinstall three carrier washers and
longer bolt loose.
REMARK
Excessive force applied to pry bar will result in a false reading due
to case deflection. Housing cover must be installed prior to
tightening carrier shaft bolt to prevent housing deflection.
20. Reposition housing onto main frame mounting face. Assemble

safety restraint. Apply a 6.35 mm (0.25 in) bead of Loctite
Plastic Gasket to cover mounting face of housing.
REMARK
Bead must completely encircle each bolt hole.
22. If necessary, install dowel pins in bottom cover mounting face of

housing. Suspend bottom cover (21) to housing (12). Position
two ½NCx7 bolts through cover into housing to slide cover on.
Remove eye bolt and seat cover to housing. Secure cover with
7F - 19
22. D32E-1 or D38E-1: Assemble two ¾NF bolts in opposite holes

of sprocket carrier shaft (2). Position pry bar to prevent shaft
rotation. Torque sprocket carrier shaft retainer bolt to 305 NCm
(225 lbf ft).
D32P-1 or D38P-1: Assemble two ¾NC bolts in opposite holes
of sprocket carrier shaft (2). Position pry bar to prevent shaft
rotation. Torque sprocket carrier shaft retainer bolt to 305 NCm
(225 lbf ft).
Now remove longer bolt and two carrier washers. Install bolt (9)
and torque to 475 NCm (350 lbf ft).
24. Assemble carrier shaft cover (11) and gasket (10). Secure with
25. Carefully work shaft oil seal (19) (spring garter facing out) down
pinion shaft (15), being careful not to cut sealing lip surface.
Using a suitable driver, press pinion shaft seal edge flush with
shoulder.
D39E-1 OR D39P-1
REMARK
steps.
1. Block final drive housing in a horizontal position with rear main

frame mating face up. Check height of two mounting studs for
65 mm (2.56 in) dimension. If necessary to install new studs,
apply Loctite #568 or Plastic Gasket before installing. If neces-
sary, assemble pinion shaft outer bearing cup (16) to housing.
Using a driver, tap to seat in housing.
2. Heat pinion shaft outer bearing (16) to 135EC (275EF) for 45

minutes and assemble to shaft. Tap to seat against shoulder of
shaft.
3. Invert shaft. Heat pinion shaft inner bearing (17) to 135EC

(275EF) for 45 minutes and assemble to shaft. Tap to seat
against shoulder of shaft.
4. Prelube pinion shaft bearings and set shaft (15) into outer
bearing cone.
5. Using driver, install inner bearing cup, while rotating shaft, until
a slight resistance to rotation is felt.
7F - 20
6. Attempt to insert 2.769 mm (0.109 in) retaining ring (18). If

possible to insert ring, bump cup back against ring with slide
hammer. If shaft rotates freely assembly is complete.
7. Position indicator against bearing cone (17). Set to zero.
8. Insert pry bar between housing and shaft (15). Pry shaft upward
from within housing to determine end play. Observe and record
reading. Repeat two or three times and average readings.
Required end play is 0 to 0.229 mm (0 to 0.009 in). If end play
should exceed 0.229 mm (0.009 in) with 2.769 mm (0.109 in)
retaining ring, install 2.972 mm (0.117 in) ring and bump cup
back against ring. If 2.769 mm (0.109 in) retaining ring will not
fit, or shaft will not rotate freely, install 2.565 mm (0.101 in)
retaining ring and bump cup back against retaining ring.
9. Assemble sprocket carrier shaft inner (5) and outer (4)

bearing cups in sprocket housing. Using a driver, bottom
bearing cups in housing. Reposition housing to rest on main
frame mounting surface. With lifting strap, position sprocket
drive gear (13) in housing and install gear retaining tool.
Torque bolts to 95 NCm (70 lbf ft). Reposition housing with
mounting face up.
10. Heat locating spacer (6) to 135EC (275EF) and assemble to

sprocket carrier shaft (2). With drift and hammer, tap to seat
against shaft face.
11. Heat sprocket carrier outer bearing (4) to 135EC (275EF) for 45
minutes. Install on shaft against locating spacer. With a drift and
hammer, tap bearing inner race to seat.
12. Assemble alignment rod in end of sprocket carrier shaft (2).

Install metal face seal (3) into housing. Refer to METAL TYPE
FACE SEALS in this section.
13. Reposition housing so drive pinion (15) is vertical and facing up.
Apply oil to inner bearing and leading edge of spline. Lower
housing over sprocket carrier shaft (2) allowing alignment pin to
extend through hole in alignment bar. Replace alignment pin
with ¾NCx5-3/4 bolt and washer. Position gear shims (DR10-
822) between housing and sprocket drive gear. Tighten bolt to
draw shaft through gear and contact alignment bridge.
7F - 21
14. Assemble and tighten new retainer screw (14) and jam nut (20).
Torque retainer screw to 17 NCm (150 lbf in) and jam nut to 80
NCm (60 lbf ft). Continue to lower housing to seat. Remove gear
shims and alignment bridge.
15. Heat bearing to 135EC (275EF) for 45 minutes. Assemble

bearing cone (5) to sprocket carrier shaft.
16. Install 2.667 to 2.743 mm (0.105 to 0.108 in) initial shim pack
(7). Assemble three carrier washers (8) using a 3/4NCx4-3/4
bolt, 25 964 R1 (A). Torque to 305 NCm (225 lbf ft). Remove
gear retainer tool.
17. Position dial indicator against washer (8) and set to zero. Raise
final drive clear of stand. Using a pry bar, pry between bottom
face of sprocket gear (13) and housing. Read and record
amount of movement of dial indicator. Repeat two or three times
and average readings. Add 0.48 mm (0.019 in) to reading and
subtract total from initial shim pack. Result is amount of shim
pack to be installed.
REMARK
Excessive force applied to pry bar will result in a false reading due
to case deflection. Housing cover must be installed prior to
tightening carrier shaft bolt to prevent housing deflection.
19. Apply a 6.35 mm (0.25 in) bead (1) of Loctite Plastic Gasket to
cover mounting face of housing. If necessary, install dowel pins
in bottom cover mounting face of housing. Bead must com-
pletely encircle each bolt hole.
20. Suspend bottom cover (21) to housing. Assemble two ½NCx7

bolts through cover above dowels. Remove eye bolt and seat
cover to housing. Secure with hardware. Torque bolts to 92 NCm
(70 lbf ft) ±10%.
21. Assemble two ¾NC bolts in opposite holes of sprocket carrier

(2) and position pry bar to prevent shaft rotation. Torque
sprocket carrier shaft retainer bolt to 304 NCm (225 lbf ft). Now
remove longer bolt and two carrier washers. Install mounting
bolt (9) and torque to 475 NCm (350 lbf ft).
7F - 22
22. Assemble carrier shaft cover (11) and gasket (10). Secure with
23. Carefully work shaft oil seal (19) (spring garter facing out) down
pinion shaft, being careful not to cut sealing lip surface. Using a
suitable driver, press pinion shaft seal flush with surface.
7F - 23
FINAL DRIVE METAL TYPE FACE SEALS
SEAL INSPECTION
1. Check condition of rubber seal rings. If any sign of wear,

scratches, nicks, cuts, etc. replace complete seal. Inspect
condition of metal ring seal surfaces as follows. Highly polished
surfaces of rings must be free of chips, pocks and deep
scratches.
2. Narrow highly polished sealing bank must be within outer half of

sealing face.
3. Narrow band must be uniform and concentric with ID and OD.

If metal rings do not conform to these specifications, discard
seal and replace with new.
4. If metal rings conform to specifications above, clean and check

rings as follows.
Remove any corrosion or hardened material that may exist on

surface A. Use a scraper and/or any stiff bristled fiber brush
to remove this material from entire surface. Wash rings with
non flammable solvent to remove all oil and wipe dry. Use a
lint free wiper to remove all traces of oil or grease from all
surfaces. Apply a thin coat of clean Grade 30 oil on sealing
face of metal rings. Do not allow oil to wet other surfaces.
Slide sealing faces of two metal rings together. Bottom ring
should cling to top ring for a minimum of two seconds when
lifted by top ring. If they fail to cling, discard seal and replace
with new.
7F - 24
SEAL INSTALLATION
REMARK
Cleanliness is critical when handling seals. Never handle seal with
greasy, oily or dirty hands. Do not drop, bump or roughly handle
seals.
1. Remove any corrosion or hardened material that may exist on

surface (1) that contact rubber rings. Use a non petroleum base
solvent and wipe dry with a lint free wrapper. Make sure outer
edge (2) is free of burrs.
2. Break plastic protector band (1) if applicable, by inserting a

sharp tool (2) at edge of band. Be careful not to scratch or
damage seal faces (3). Do not cut or damage rubber rings (4).
3. Carefully remove plastic band and gently "slide" (1) two seal
halves apart. Metal ring faces must not be damaged or contami-
nated. Check to be sure rubber rings are flush (2) against inside
shoulder of metal ring.
4. Install one seal half (1) into receptacle (2) so protruding lip just
contacts seal bore. Press with both clean hands (180E apart)
against metal ring until rubber ring is evenly seated against bore
shoulder. Make sure seal is not cocked in bore. Repeat proce-
dure for other seal half (3) and receptacle (4). Wipe both metal
ring sealing faces clean (5) with a lint free wiper. Apply a light
coat (6), just enough to wet faces, of clean lubricant to seal
faces of metal rings.
5. Final installation assembly will energize seal as shown, so that

rubber rings load seal and drive mating metal rings together.
7F - 25
FINAL DRIVE INSTALLATION
1. Apply Loctite #568 or Plastic Gasket to final drive mounting face

of rear main frame. Spread with evenly putty knife.
REMARK
Loctite must not be closer than 25.4 mm (1 in) from outside
diameter of large bore and brake adjustment screw hole.
2. Install o-ring (1) to mounting face of final drive.
3. Apply brake pedal lock to prevent brake discs from moving

when assembling final drive. Thread support tool rods DR10-
817 (1) into rear main frame. Install two eNC eye bolts (2) into
top most holes of final drive. Attach two legged chain to eye
bolts and lifting strap to sprocket carrier shaft. Adjust strap to
maintain pinion shaft perpendicular to rear main frame mounting
face.
4. Slide final drive onto support tool rods until vertical support can
be assembled. Adjust vertical members DR10-817 (1) to
contact rods and support weight of final drive. Lower final drive
to rest on rods. Remove two legged chain and eye bolts. Lifting
strap (2) remains on sprocket carrier shaft to assist alignment of
drive pinion during installation.
5. Slide final drive against rear main frame while threading drive
pinion through brake and clutch discs and into planet gear
carrier. Also, studs on inner bottom of final drive slide through
bosses of rear main frame.
6. Coat mounting bolts with engine oil or grease and install. Install
lower inside hardware. Remove two support rods and replace
with mounting bolts. Torque mounting bolts to 190 NCm (140 lbf
ft). Install brake adjustment screw (1) and locknut. Adjust
brakes, refer to Section 7E. Install and trim corks in two puller
screw holes.
7. D32E-1, D32P-1, D38E-1 or D38P-1; From under machine,

remove front cap bolt (2). Place spacer plate (3) in place and
install main frame to final drive bolts (1) (qty. four). Torque all to
730 NCm (540 lbf ft).
7. D39E-1 or D39P-1; From under machine, remove front cap bolt

(2). Install main frame to final drive bolts (1) (qty. four) and
torque all to 730 NCm (540 lbf ft).
8. Install rear rigid crossbar mounting cap (2) with bolts (1) and
torque to 780 NCm (580 lbf ft) ±10%..
7F - 26
INSTALLATION FINAL DRIVE
9. Install inner rock deflector (2) and bolts (1) and torque to 267
NCm (195 lbf ft).
10. Attach eye bolt (1) to hole in sprocket, attach hoist (2) and install
sprocket to carrier. Install bolts (3) and torque to 455 NCm (335
lbf ft). Remove eye bolt.
11. Install outer rock deflector (2) and bolts (1) and torque to 267
NCm (195 lbf ft).
12. Attach hoist (1) to front section of track chain, pull chain to rear
and position split link over sprocket. At least two links should
contact sprocket. Reattach hoist to other section of chain, raise
chain to engage and align split link. Install track shoe (2) and
bolts (3). Liberally lubricate bolts with engine oil or chassis
grease. Torque bolts to value given in SECTION 15.
13. Raise machine to clear blocking, remove, and lower machine to

ground. Fill final drive with oil and adjust track chain, refer to
7F - 27
ELECTRICAL
SECTION 8
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 2
TORQUE DATA . . . . . . . . . . . . . . . . . . . . . . . 2
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . 3
WARNING
8-1
ELECTRICAL GENERAL
DESCRIPTION
The electrical system used on this machine is a 12 volt negative ground system. Warm or Cold Start - Both of these
systems have one twelve volt battery. All electrical service is controlled by a master disconnect switch located in a
recess in the operators seat front support panel. The electrical system is basically divided into four groups; starting and
charging, lighting, indicators and accessories. The starting and charging circuits consist of the battery, cranking motor,
magnetic switch, neutral safety switch, keyed starting switch, engine shutdown solenoid, engine shutdown switch,
cranking motor solenoid, neutral start switch, master disconnect switch and an alternator with integral voltage regulator.
The lighting circuit includes light switch, circuit breaker, front and rear lights, and instrument panel light. The indicator
group consists of voltmeter, hourmeter and switch, transmission filter warning light and switch, hydraulic oil pressure
filter warning light and switch, air filter warning light and switch, engine oil pressure gauge and sender, engine coolant
temperature gauge and sender, and transmission temperature gauge and sender. The accessory group includes ether
start switch and solenoid valve, back up alarm and switch, warning horn and switch, and a circuit breaker. Using a
desired electrical tester, perform the necessary test(s) as outlined in the instructions furnished with the tool.
SPECIFICATIONS
System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
System Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative
Circuit breaker - Back-up Alarm and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Amp
Circuit Breaker - Lighting and Horn Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Amp
Circuit Breaker - Staring and Ether Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Amp
SPECIAL TOOLS
Starting and Charging System Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR05-404-3

Volt/Ohm Multi-Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR05-562
Electrical Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR05-901
TORQUE DATA
Magnetic Switch:
#10-32 Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 NCm (20 lbf in)
5/16 Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 NCm (5 lbf in)
Circuit Breaker Terminals - #10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 NCm (18 lbf in)
Electrical Senders and Switches - #10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 NCm (18 lbf in)
Master Switch Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2 NCm (9 lbf in)
Master Switch Mounting Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 NCm (38 lbf ft)
Neutral Starting Switch Mounting Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 NCm (18 lbf ft)
8-2
GENERAL ELECTRICAL
WIRING DIAGRAM
KCRW1956
8-3
HYDRAULICS
SECTION 10
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 4
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . 5
BLADE EQUIPMENT LEVER . . . . . . . . . . . . 8
REAR EQUIPMENT LEVER . . . . . . . . . . . . . 9
WARNING
10 - 1
HYDRAULICS GENERAL
HYDRAULIC SYSTEM
10 - 2
GENERAL HYDRAULICS
1. Hydraulic Reservoir 6. Blade Lift Section 11. Anti-Cav Valve 16. Blade Angle Cylinders
2. Suction Strainer 7. Blade Tilt Section 12. ¼ Orifice Check 17. Ripper Cylinders
3. Gear Pump 8. Blade Angle Section 13. c Orifice Check 18. Return Line Filter
4. Control Valve 9. Ripper Section 14. Blade Lift Cylinders 19. Vacuum/Relief Valve
5. System Relief Valve 10. Load Check Valve 15. Blade Tilt Cylinder
DESCRIPTION
The hydraulic system consists of a reservoir (1), gear pump (3), control valve (4), piping, and cylinders (14, 15 and 16).
A ripper attachment is available and consists of an additional valve section (9), cylinders (17) and piping.
OPERATION
The hydraulic reservoir (1), mounted next to the fuel tank, supplies oil through a suction strainer (2) to the gear pump
(3). The pump is flange mounted at the left side of the torque converter and is driven by the converter accessory gear
whenever the engine is running. Oil from the pump is directed to the inlet section of the main control valve (4). When
the valve is not actuated, oil will flow back to the reservoir. The reservoir is bolted to a bracket mounted to the rear main
frame. It is equipped with a 100 mesh suction strainer (2), an external mounted return oil filter (18), incorporating a cold
oil bypass valve and an external vacuum pressure relief breather (19). The breather will protect the pump from cavitating
as well as maintaining pressure in the reservoir.
A positive displacement, single element, gear type pump (2) is used to supply pressurized fluid to the main control valve
(4). The pump operates continually while the engine is running, but is under load only when the main control valve
spool(s) is/are shifted from neutral. As oil is supplied to the pump, gear rotation forces oil to the outer diameter of the
housing between the teeth. As oil exits it is directed to the main control valve.
The main control valve (4) is mounted to a bracket in the right control console in front of the reservoir located on the
right fender. This system utilizes either a three or four spool valve depending on whether or not a ripper is used. The
valve is controlled by mechanical linkage between the control levers and the valve. Mechanical linkage controls the
blade and ripper, if equipped. The valve inlet cover contains an adjustable pilot operated main pressure relief valve (5)
which is used to by pass oil from the pump back to the reservoir when oil pressure exceeds the relief valve setting. The
spools are spring centered, either three or four position type with the FLOAT position being detented. Incorporated in
the valve section is a spring loaded check valve (10) which will assure smooth operation when the spool is moved from
hold to an operating position. An anti-cavitation valve (11) is located in the blade lift (6), blade angle (8), and ripper
section (9), if equipped, sections. A three spool control valve is used on machines equipped with a six way blade. A four
spool control valve is used on machines equipped with a six way blade and a ripper.
Six Way Blade: The first spool is used for the blade lift (6) and is a spring centered, four position type with FLOAT
position being detented. The middle spool (7) is used for blade tilt. The third spool is for blade angle (8). Both of the
spools are spring centered, three position type. Incorporated in each valve section is a spring loaded check valve (10)
which assures smooth operation when the spool is moved from hold to an operating position. An anti-cavitation valve
(11) is located in the blade lift and angle valve sections only.
Six Way Blade With Ripper: The first spool is used for the blade lift (6) and is a spring centered, four position type with
FLOAT position being detented. The middle spool (7) is used for the blade tilt. The third spool (8) is for the blade angle.
Both of the spools are spring centered, three position type. Incorporated in each valve section is a spring loaded check
valve (10) which assures smooth operation when the spool is moved from hold to an operating position. An anti-
cavitation valve (11) is located in the blade lift and angle valve sections only. The fourth spool is for the ripper (9). The
spool is a spring centered, three position type. Incorporated in the valve section is a spring loaded check valve (10)
which assures smooth operation when the spool is moved from hold to an operating position. An anti-cavitation valve
(11) is located in each end of the valve section.
Located in the blade lift rod end and blade tilt rod and head end ports are check orifice (12 or 13) which restrict the flow
of oil. This gives the operator more precise control when lowering the blade and tilting the blade in either direction. As
the oil flows to the cylinder, the orifice button is forced against its seat forcing the oil to flow through the orifice only,
restricting its flow. As oil returns, the orifice button is forced against its "legs" allowing the oil to flow thru the orifice and
around the button sides to allow a greater flow preventing a void from forming.
10 - 3
HYDRAULICS GENERAL
SPECIFICATIONS
System Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15525 ±345 kPa (2250 ±50 psi)
Blade Lift Speed;
Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 to 2.6 seconds
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 to 2.4 seconds
Blade Tilt Speed;
Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.2 seconds
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.85 to 1.0 seconds
Blade Angle Speed - D32E-1, D32P-1, D38E-1 or D38P-1;
Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 to 2.3 seconds
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 to 2.3 seconds
Blade Angle Speed - D39E-1 or D39P-1;
Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 to 2.3 seconds
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 to 2.3 seconds
Cylinder Oil Leakage;
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 to 4.7 cm³/min (0.073 to 0.28 in³/min)
Blade Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 to 4.7 cm³/min (0.073 to 0.28 in³/min)
Blade Angle Cylinder;
D32E-1, D32P-1, D38E-1 or D38P-1 . . . . . . . . . . . . . . . . . . . . . 0.85 to 3.4 cm³/min (0.052 to 0.021 in³/min)
D39E-1 or D39P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 to 4.7 cm³/min (0.073 to 0.28 in³/min)
Blade Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 to 300 mm (0.6 to 11.8 in) per 15 minutes
Blade Equipment Lever Movement;
Hold to Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 ±15 mm (2.5 in ±0.6 in)
Hold to Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 ±10 mm (2.5 in ±0.4 in)
Hold to Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 ±10 mm (4.2 in ±0.4 in)
Hold to Left Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 ±10 mm (1.7 in ±0.4 in)
Hold to Right Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 ±10 mm (1.7 in ±0.4 in)
Hold to Left Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ±5E
Hold to Right Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ±5E
Blade Equipment Lever Force;
Hold to Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 ±22 N (14 ±5 lbs)
Hold to Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ±9 N (5 ±2 lbs)
Hold to Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 ±22 N (13 ±5 lbs)
Hold to Left Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ±9 N (9 ±2 lbs)
Hold to Right Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ±9 N (9 ±2 lbs)
Hold to Left Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 ±1.4 NCm (3.8 ±1 lbf ft)
Hold to Right Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 ±1.4 NCm (3.8 ±1 lbf ft)
Rear Equipment Lever Movement;
Hold to Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 ±13 mm (2.9 ±0.5 in )
Hold to Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 ±13 mm (2.8 ±0.5 in)
Rear Equipment Lever Force;
Hold to Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 ±9 N (8 ±2 lbs)
Hold to Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 ±9 N (8 ±2 lbs)
SPECIAL TOOLS
Push Pull Scale;
0 to 294 N (30 kg) (14lb) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79A-264-0020
0 to 294 N (30 kg) (14lb) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79A-264-0020
34500 kPa (5000 psi) Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially available
10 - 4
GENERAL HYDRAULICS
WORK EQUIPMENT
‚ Brake and decelerator pedal locked
System Relief Valve Test
1. Remove access panel and connect gauge to the quick discon-

nect fitting on the inlet tube.
REMARK
Pressure check should be performed with the oil at operating
temperature. To bring the temperature up, move the control
valve levers through all positions while the engine is at low idle
and bottom the cylinders for a few seconds in each position.
Repeat this procedure while gradually increasing engine speed.
Bottoming the cylinder for a short period of time will not damage
the hydraulic system, but an extended period will produce
excessive heat and result in an inaccurate gauge reading.
2. Once operating temperature is reached, run the engine at full

throttle and slowly move the tilt control lever until the cylinder is
in an extreme position. Read and record the pressure on the test
gauge at which the relief valve unloads. Then repeat this
procedure with the angle control lever. Repeat this step with the
engine running at low idle.
3. The pressure obtained should be as specified in SPECIFICA-

TIONS. If both the low and high idle readings are the same but
not as specified, the system is operating correctly but the relief
valve must be adjusted.
Adjusting Relief Valve
Loosen the jam nut and turn the adjusting screw using a screw-
driver, clockwise to increase pressure or counterclockwise to
decrease pressure. After the correct pressure on the gauge is
obtained, lock down the jam nut.
10 - 5
HYDRAULICS GENERAL
Cylinder Drift Test
The problem of cylinder drift can be traced to two main causes,

internal or external leakage. External leakage is not detailed here,
since it can be visually located. Internal leakage is not always readily
pin pointed to its source and may require a series of tests to isolate
the problem.
There are two places that might be a source of internal leakage; the
cylinders might have leakage past the piston packing and the control
valve could leak at the spool.
Following is a series of tests developed to trace the source of

internal leakage. Oil must be at operating temperature.
1. Fully raise the blade, move the blade lift lever to the lower
position releasing it to hold before the blade drops to the
ground. Check for cylinder drift. The piston rod should not travel
out of the cylinder at more than 16 mm (0.625 in) per minute.
REMARK
The 16 mm (0.625 in) per minute figure represents accumula-
tive allowable loss of control valve and cylinders combined.
2. If the cylinder drift is less than 8 mm (0.3125 in) per minute,

proceed to CYLINDER TIME CYCLE.
3. If the cylinder drift is more than 8 mm (0.3125 in) per minute,

proceed with step 4.
4. Lower the blade and install a shut off valve at the raise port of
both cylinders. Fully raise the blade, close the shut off valves
and check for drift.
A. If the cylinder drift is more than 3.2 mm (0.125 in) per minute,
the cylinder is at fault.
B. If the cylinder drift is less than 3.2 mm (0.125 in) per minute,
the control valve is at fault.
5. When the preceding tests are completed, remove the shut off
valves. Vent the hydraulic system and add oil as necessary.
Refer to the OPERATION & MAINTENANCE MANUAL. Visually
check for oil leakage.
10 - 6
GENERAL HYDRAULICS
Cylinder Time Cycle
Before performing the cylinder time cycle test, perform the CYLIN-
DER DRIFT TEST to insure that the control valve and the cylinders
are performing satisfactorily. If there is no excessive drift when the
blade lift control is in the hold position, but slow lift speed, slow
response or low power is present in the raise position, the problem
could be either the hydraulic pump or the main pressure relief valve.
Loss of flow can be caused by the main pressure relief valve not
sealing, allowing oil to flow into return to the reservoir passage. To
check the pump, the following time cycles should be observed when
raising the blade.
1. Position the machine so the blade will not touch the ground in its
fully lowered position.
2. Run the engine at full throttle.
3. Starting with the blade in its fully lowered position, put the
control lever in raise and record the time it takes to reach the
fully raised position. Repeat several times and then average the
readings.
The lift cycle should take 3 seconds. If the average cycle time is
more than 3 seconds, the pump should be inspected for replace-
ment or repair.
REMARK
This check should be made only when raising the blade.
Piston Packing Test
1. Position the machine so that the cylinder(s) to be tested can be

completely extended.
2. Start the engine, completely extend the cylinder(s) and place the
control lever in hold.
3. Stop the engine, block the rod and remove the hose.
WARNING
During next step, pressurized oil may be expelled from
cylinder.
4. Hydraulically extend the cylinder(s) again and check the rod end
port of the cylinder for oil flow. Flow should be minimal to none.
If oil flow is present, repair or replace the cylinder(s).
10 - 7
HYDRAULICS GENERAL
BLADE EQUIPMENT LEVER
‚ Engine stopped
Raise, Lower and Float Travel
Using scale, measure the travel distances from; hold to raise, hold
to lower and hold to float at the center top of the lever knob.
Raise, Lower and Float Effort
Using push pull scale at the base of the knob, measure the
maximum effort required when moving the lever from hold to
raise, hold to lower and hold to float.
Tilt Travel
Using scale, measure the travel distances from; hold to right tilt
and hold to left tilt at the center top of the lever knob.
Tilt Effort
maximum effort required when moving the lever from hold to right
tilt and hold to left tilt.
10 - 8
GENERAL HYDRAULICS
Angle Degrees
Using an angle gauge, measure travel distances in degrees from;

hold to right angle and hold to left angle at the center top of the
lever knob.
Angle Effort
Using a torque measuring device, measure the maximum effort

required when moving the lever hold to right angle and hold to left
angle.
REAR EQUIPMENT LEVER
‚ Engine stopped
Raise and Lower Travel
Using scale, measure travel distances from hold to raise and hold
to lower at the center top of the lever knob.
Raise and Lower Effort
maximum effort required when moving the lever from hold to raise
and hold to lower.
10 - 9
PUMPS
SECTION 10A
CHARGE AND SCAVENGE PUMP . . . . . . . . . 2

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 9
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 13
EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . 14
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 17
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 19
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 21
WARNING
10A - 1
PUMPS CHARGE AND SCAVENGE PUMP
EXPLODED VIEW OF CHARGE AND SCAVENGE PUMP
10A - 2
CHARGE AND SCAVENGE PUMP PUMPS
CROSS SECTION VIEW OF CHARGE AND SCAVENGE PUMP
1. Short Tie Bolt 6. Section O-Ring 11. Back Up Gasket 16. Gear Key 21. Long Dowel Pin
2. Long Tie Bolt 7. Check Ball 12. Front Diaphragm 17. Front Housing 22. Rear Gear
3. Front Plate 8. Return Spring 13. Thrust Plate 18. Drive Gear/Shaft 23. Rear Housing
4. Retaining Ring 9. Diaphragm Seal 14. Rear Diaphragm 19. Idler Gear/Shaft 24. Back Plate
5. Shaft Oil Seal 10. Protector Gasket 15. Short Dowel Pin 20. Center Housing 25. Retainer Washer
GENERAL
The transmission charge and scavenge pump is a dual element fixed delivery gear type pump located on the right hand
side of the torque converter. The front section of the pump supplies the oil flow for the transmission control valves,
steering control valve and the torque converter. This section draws oil from rear main frame through the suction strainer.
The oil from the outlet side of the pump is directed through the pressure filter and on to the valves. The rear section of
the pump scavenges the excess oil from the transmission through a screen fitting and directs it back to the rear main
frame.
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Element Gear

D32E-1, D32P-1, D38E- or D38P-1 Rated Capacity @ 1977 RPM;
Front Section Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 R/min (21 gpm)
Rear Section Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 R/min (28 gpm)
D39E-1 or D39P-1 Rated Capacity @ 1819 RPM;
Front Section Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 R/min (19 gpm)
Rear Section Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 R/min (26 gpm)
Pump Section Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 to 68 NCm (40 to 50 lbf ft)
10A - 3
REMOVAL
WARNING
master switch to the off position and remove key to prevent
accidental starting.

MAINTENANCE MANUAL.

under machine
10A - 4
6. Disconnect and cap lines at top and bottom of pump and allow
pump to drain into suitable container. Remove mounting
hardware and lift pump out of machine.
DISASSEMBLY
REMARK
1. Remove and discard mounting o-ring and replace with new.
2. Remove fittings from charge section of pump. Remove fittings

from scavenge section of pump.
4. Thoroughly clean pump before disassembly. Match mark

sections of pump as shown.
5. Remove tie bolts (1 and 2).
6. Tap on front plate (3) to loosen from dowel pins.
7. Remove front plate (3) from assembly.
10A - 5
8. Remove section o-ring (6) from front plate.
9. Remove back up gasket (11) from front plate.
10. Remove protector gasket (10) from front plate.
11. Remove diaphragm seal (9) from front plate.
12. Turn front plate over. Remove retaining ring (4) from front plate.
13. Remove seal retainer washer (25) from front plate.
14. Turn front plate over and rest on wooden blocks. Using a punch
drift, remove shaft seal (5) from front plate.
15. Remove check balls (7) and springs (8).
10A - 6
16. Remove front diaphragm (12).
17. Remove idler gear and shaft (19).
18. Tap on front housing (17) and center housing (20) to loosen
from dowel pins. Remove front housing.
19. Remove center housing (20) with drive gear and shaft (18).
Keyed rear gear will most likely stay with assembly.
20. Remove key (16) from drive gear and shaft (18).
21. Remove drive gear and shaft (18) from center housing.
22. Remove thrust plate (13) from center housing.
23. Remove section o-ring (6).
10A - 7
24. Turn center section over. Remove back up gasket (11).
25. Remove protector gasket (10).
26. Remove diaphragm seal (9).
27. Remove section o-ring (6).
28. Remove rear diaphragm (14) from pump.
29. Remove rear gears (22).
30. Tap on rear housing (23) to loosen from dowel pins and
remove.
31. Remove thrust plate (13) and section o-ring (6) from back plate
(24).
10A - 8
INSPECTION
1. Tie bolts (1 and 2), seal repair kit (4 through 14) and seal
retainer washer (25) are only serviced parts. If any other part
other than these need replacement, replace complete pump.
2. Clean all parts and dry thoroughly with compressed air. Inspect
edges and faces of gears for scoring or roughness. If possible,
remove with Carborundum stone. Inspect shaft and bushings for
excessive wear. Inspect remaining parts for wear, cracks and
breakage.
REASSEMBLY
REMARK
REMARK
When assembling pump, absolute cleanliness is a must to prevent
premature failure. Lubricate all parts liberally as they are assem-
bled with clean oil.
1. Install thrust plate (13), bronze side up, with cut out towards
suction port, large port, to back plate (24).
2. Coat section o-ring (6) with amber grease and install to groove
in back plate.
3. Aligning match marks, install rear housing (23) to back plate.
4. Install rear gears (22) into rear housing.
5. Using a dull tool, tuck the diaphragm seal (9) into grooves of
center housing (20) so the open part of "U" section is down.
10A - 9
6. Position protector gasket (10) over diaphragm seal. Using dull

tool, carefully press gasket into diaphragm seal and bottom.
Use air to blow any gasket particles which may have been
trimmed off during seating of gasket.
7. Install back up gasket (11) in same manner as protector gasket.

Installation is correct when, with diaphragm seal and both
gaskets in position, back up gasket is below top of diaphragm
seal and even with inside face of center housing.
8. Position rear diaphragm (14) on back up gasket with bronze

side facing up. Rear diaphragm must fit into raised rim of
diaphragm seal until it is flush with outer top surfaces of center
housing.
in center housing.
10. Turn housing over. Coat section o-ring (6) with amber grease
and install to remaining groove in center housing.
suction port, large port, to center housing.
12. Insert drive gear and shaft (18) through center housing. Coat
key (16) with amber grease and install in gear and shaft.
13. Aligning match marks, install center housing (20) over dowel
pins to rear housing. Make sure key in drive gear and shaft
aligns with key slot in rear gear.
10A - 10
14. Install driven gear and shaft (19).
15. Aligning match marks, install front housing (17) over gears on
dowel pins.
16. Install front diaphragm (12), bronze face down to shafts.
front plate so the open part of "U" section is down.

seal and even with inside face of front plate.
in front plate.
21. Install springs (8), large end down, with check balls (7) to front
diaphragm.
10A - 11
22. Aligning match marks, install front plate (3) over dowels to front
housing.
23. Install tie bolts (1 and 2) and torque to 54 to 68 NCm (40 to 50 lbf
ft).
24. Start oil seal (5) over shaft into front plate.
25. Using a deep well socket, bottom seal into front plate.
26. Install seal retainer washer (25).
27. Install retaining ring (4).
28. Install fittings with new o-rings to scavenge section of pump.

Install fittings with new o-rings to charge section of pump.
10A - 12
30. Install new mounting o-ring to pump.
INSTALLATION
1. Install pump to torque converter being careful not to damage o-

ring and secure with hardware. Torque bolts to 92 NCm (70 lbf
ft) ±10%. Reconnect lines at pump.
2. Using rolling floor jack, install transmission guard to machine

±10%.

NCm (28 lbf ft) ±10%.
6. Refill transmission system. Refer to the OPERATION & MAIN-

TENANCE MANUAL.
10A - 13
PUMPS EQUIPMENT PUMP
EXPLODED VIEW OF EQUIPMENT PUMP
10A - 14
EQUIPMENT PUMP PUMPS
CROSS SECTION VIEW OF EQUIPMENT PUMP
1. Check Ball Spring 7. Back Up Gasket 13. Drive Gear and Shaft
2. Check Ball 8. Diaphragm 14. Driven Gear
3. O-Ring 9. Thrust Plate 15. Dowel Pin
4. Diaphragm Seal 10. Short Tie Bolt 16. Pump Body
5. Shaft Seal Ring 11. Long Tie Bolt 17. Rear Plate
6. Protector Gasket 12. Front Plate
GENERAL
The equipment hydraulic pump is a single element fixed delivery gear type pump located on the left hand side of the
torque converter. The pump supplies oil for the equipment control valve and cylinders. Oil is gravity fed from the
reservoir through the pump and outlet flow is directed to the valve.
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Element Fixed Delivery Gear Pump

Rated Capacity;
D32E-1, D32P-1, D38E-1 or D38P-1 @ 1977 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.7 R (20 gpm)
D39E-1 or D39P-1 @ 1819 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 R (18.4 gpm)
Rated Capacity Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6900 kPa (1000 psi)
Pump Section Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 to 68 NCm (40 to 50 lbf ft)
10A - 15
REMOVAL
WARNING

NANCE MANUAL.
5. Using rolling floor jack, remove transmission guard from under

machine.
10A - 16
6. Disconnect and cap lines at top and bottom of pump and allow
pump to drain into suitable container. Remove hardware and lift
pump out of machine.
DISASSEMBLY
REMARK
1. Remove and discard mounting o-ring and replace with new.
2. Thoroughly clean pump before disassembly. Match mark

sections of pump as shown. Remove mounting bolts (10 and
11).
3. Tap on front plate (12) to loosen from dowel pins.
4. Remove front plate (12) from assembly.
5. Remove section o-ring (3) from front plate.
10A - 17
6. Remove back up gasket (7) from front plate.
7. Remove protector gasket (6) from front plate.
8. Remove diaphragm seal (4) from front plate.
9. Turn front plate over and rest on wooden blocks. Using a punch
drift, remove shaft seal (5) from front plate.
10. Remove check balls (1) and springs (2).
11. Remove diaphragm (8).
12. Remove drive (13) and driven (14) gears.
13. Tap on gear housing (16) to loosen from dowel pins and
remove.
10A - 18
14. Remove thrust plate (9) and section o-ring (3) from back plate
(17).
INSPECTION
1. Tie bolts (10 and 11) and seal repair kit (1 through 9) are only
serviced parts. If any other part other than these need replace-
ment, replace complete pump.
2. Clean all parts and dry thoroughly with compressed air. Inspect
edges and faces of gears for scoring or roughness. If possible,
remove with Carborundum stone. Inspect shaft and bushings
for excessive wear. Inspect remaining parts for wear, cracks and
breakage.
REASSEMBLY
REMARK
REMARK
When reassembling pump, absolute cleanliness is a must to
prevent premature failure. Lubricate all parts liberally as they are
assembled with clean oil.
suction port, large port, to back plate (17).
in back plate.
3. Aligning match marks, install housing (16) to back plate.
4. Install drive (13) and driven (14) gears.
5. Install diaphragm (8), bronze face down on gears.
10A - 19
front plate so the open part of "U" section is down.


seal and even with inside face of front plate.
in front plate.
10. Install springs (2), large end down, with check balls (1) to front
diaphragm.
11. Aligning match marks, install front plate (12) over dowels to
front housing.
10A - 20
12. Install mounting bolts (10 and 11) and torque to 54 to 68 NCm
(40 to 50 lbf ft).
13. Start oil seal (5) over shaft into front plate.
14. Using a deep well socket, bottom seal into front plate.
15. Install new mounting o-ring to pump.
INSTALLATION
1. Install pump to torque converter being careful not to damage o-

ring and secure with hardware. Torque bolts to 92 NCm (70 lbf
ft) ±10%. Reconnect lines (1 and 2) at pump.
10A - 21
2. Using rolling floor jack, install transmission guard to machine

±10%.

NCm (28 lbf ft) ±10%.
6. Refill hydraulic system. Refer to the OPERATION & MAINTE-

NANCE MANUAL.
10A - 22
CONTROL VALVE
SECTION 10B
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . 10
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 10
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 13
SYSTEM RELIEF VALVE . . . . . . . . . . . . . . . . 15
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 17
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 18
BLADE LIFT SECTION . . . . . . . . . . . . . . . . . . 20
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 24
BLADE TILT SECTION . . . . . . . . . . . . . . . . . . 29
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 31
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 31
BLADE ANGLE OR RIPPER SECTION . . . . . 34
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 34
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 39
WARNING
10B - 1
CONTROL VALVE REMOVAL
WARNING

NANCE MANUAL.
10B - 2
REMOVAL CONTROL VALVE

REMARK
removal.
10B - 3
support.
10B - 4
16. Remove right front access cover.
17. Open reservoir door. Disconnect door lock from inside cavity.
18. Remove door hinge inside mounting hardware and lift door from
machine.
10B - 5
20. Remove filler tube from rear cover and cap opening.
REMARK
Mark, cap and plug all disconnected lines.
21. Disconnect four hoses at tubes.
22. RIPPER: Disconnect hoses at valve and position out of the

way.
23. Disconnect top tube (1) from angle section valve and remove.
Disconnect bottom tube (2) from angle section valve and
remove.
24. Disconnect top tube (1) from tilt section valve and remove.
Disconnect bottom tube (2) from tilt section valve and remove.
25. Disconnect crossover tubes from remaining tubes from control

valve.
26. Disconnect remaining tubes at valve bank.
27. Pull lower tube rearward and disconnect right lift hose.
28. Pull upper tube rearward and disconnect right lift hose.
10B - 6
29. Through access cover disconnect inlet tube at elbow.
30. Disconnect tube inlet tube from hose and remove.
31. Loosen jam nut at outlet elbow.
32. Remove reservoir breather (1) and filler cap (2).
33. Remove filter and switch lead from header.
34. Unbolt header from bracket. Unthread elbow at reservoir inlet.
35. Rotate filter header down and remove from control valve outlet
elbow.
36. Loosen jam nut under lever handle. Remove handle and jam
nut from lever.
10B - 7
37. Remove boot and mounting.
38. Remove forward lower mounting bolt.
39. Remove remaining and carefully remove from machine.
40. Position control valve in vise
41. Disconnect lift link from spool. Discard cotter pin and replace
with new.
10B - 8
42. Disconnect tilt link from spool. Discard cotter pin and replace
with new.
43. Disconnect angle link from spool. Discard cotter pin and replace
with new.
44. Remove mounting hardware and lift linkage assembly from

control valve.
10B - 9
CONTROL VALVE COMPLETE ASSEMBLY
DISASSEMBLY
1. Position valve bank on bench. Remove nuts (7) and slide inlet
cover (1) off tie bolts.
2. Slide blade lift section (3) off tie bolts. Remove and discard
between section o-rings.
3. Slide blade tilt section (4) off tie bolts. Remove and discard
4. Slide blade angle section (5) off tie bolts. Remove and discard
10B - 10
COMPLETE ASSEMBLY CONTROL VALVE
1. Inlet Cover
2. System Relief Valve
3. Blade Lift Section
4. Blade Tilt Section

-7
5. Blade Angle Section
6. Outlet Cover
7. Mounting Hardware
6 1
8. Ripper Section
/
8 KCRW1825
IOB-11
10B - 12
COMPLETE ASSEMBLY CONTROL VALVE
5 If equipped, slide ripper section (8) off tie bolts. Remove and
discard between section o-rings.
REASSEMBLY
REMARK
1. Position outlet cover (6) with tie bolts (7) facing up. Install new
between section o-ring kit.
2. If equipped, install ripper section (8) down over bolts on top of

end cover. Install new between section o-ring kit.
3. Install blade angle section (5) down over bolts on top of end
cover. Install new between section o-ring kit.
10B - 13
4. Install blade tilt section (4) down over bolts on top of end cover.
Install new between section o-ring kit.
5. Install blade lift section (3) down over bolts on top of end cover.
Install new between section o-ring kit. Install inlet cover (1) and
secure with nuts.
10B - 14
SYSTEM RELIEF VALVE CONTROL VALVE
1. Filter Screen
2. Retaining Ring
3. Main Poppet
4. Valve Body
6 5. End Cap
6. Jam Nut
7. Adjusting Screw
8. Pilot Poppet
9. O-ring
10. Back Up Ring
11. O-ring,
12. O-ring
13. O-ring
14. Back Up Ring
15. Back Up Ring
16. O-ring
17. O-ring
18. Main Poppet Spring
19. Pilot Poppet Spring
16 20. Flat Washer
KCRW1826
10B - 15
CONTROL VALVE SYSTEM RELIEF VALVE
10B - 16
DISASSEMBLY
1. Remove system relief valve (2) from inlet cover (1).
REMARK
2. Position relief valve in vise, adjusting end up.
3. While holding adjusting screw (7), remove jam nut (6).
4. Remove adjusting screw (7).
5. Remove pilot poppet (8) and spring (19).
6. Remove end cap (5).
7. Remove main poppet spring (18).
8. Remove main poppet (3) with filter screen (1).
10B - 17
CONTROL VALVE SYSTEM RELIEF VALVE
9. Remove o-ring (15) and back up ring (16) from main poppet (3)
and discard.
10. Remove o-ring (12) from end cap (5) and discard.
11. Remove o-ring (11) from adjusting screw (7) and discard.
12. Remove o-ring (9) and back up ring (14) from inside valve body
(4) and discard. Remove o-ring (13) at outside of valve body (4)
and discard.
REASSEMBLY
REMARK
1. Install new o-ring (13) on outside of valve body (4). Install new
o-ring (9) and new back up ring (14) down inside valve body (4).
2. Install new o-ring (11) to adjusting screw (7).
3. Install new o-ring (12) to end cap (5).
4. Install new o-ring (12) and back up ring (16) to main poppet (3).
10B - 18
5. Install main poppet (3) with filter screen (1) into valve body.
6. Install main poppet spring (18).
7. Install end cap (5).
8. Install pilot poppet (8) and spring (19).
9. Install adjusting screw (7) half way into end cap.
REMARK
Final adjustment of system relief valve will have to be made with
control valve reinstalled into machine. Refer to SECTION 10.
10. While holding adjusting screw (7), install jam nut (6).
11. Install valve (2) into end cover.
10B - 19
CONTROL VALVE BLADE LIFT SECTION
CROSS SECTION VIEW OF DETENT POSITIONER
10B - 20
BLADE LIFT SECTION CONTROL VALVE
1. Detent Assembly
2. Load Check Valve
-8 3. Anti-Cav Valve
4. Back Up Washer
5. O-ring Seal
6. Seal Retainer
7. Shipping Plate
8. Section Spool
9. Valve Body
10. Detent Housing
11. Retaining Ring
12. Spring Retainer
13. Spool Spring
14. Spring Retainer
15. Detent Sleeve
16. Seal Ring
17. Seal Ring
18. Retainer Sleeve
8 19. Detent Ball Follower
20. Detent Spring
21. Detent Ball
Orifice Vent
18-
17-
KCRW1827
lOB-21
10B - 22
DISASSEMBLY
REMARK
1. Position valve section in vise. Remove hardware and detent

housing (10).
2. Install shipping/retainer plate, 1299240H1, (7) over spool spring

retainer and secure with bolts. Draw down evenly on bolts until
retaining ring (11) is exposed, then remove.
3. Install a second plate (7) with longer bolts. Remove previous

bolts. Slowly and evenly let off bolts until all tension on spring is
relieved.
4. Remove spool spring (13) with both retainers (12 and 14).
5. Remove four detent balls (21).
6. Remove detent sleeve (15).
7. Remove seal rings (16 and 17).
8. Remove retainer sleeve (18).
10B - 23
9. Remove detent ball follower (19) and detent spring (20).
10. Remove section spool (8) from valve body.
11. Remove anti-cavitation valve (3) from valve body. Disassemble

as follows:
Separate check poppet (3/7), poppet spring (3/8), check ball
retainer (3/10) and check ball (3/9) from body (3/6). Remove
and discard all software (3/1 through 3/5). Replace with new.
12. Remove load check valve (2) from valve body. Disassemble as
follows:
Separate check poppet (2/7) and poppet spring (2/8) from
body (2/6). Remove and discard all software (2/1 through 2/6).
Replace with new.
13. Remove seal retainer (6).
14. Remove back up washer (4) and o-ring seal (5).
REASSEMBLY
REMARK
1. Install load check valve (2) at spool end of spool end as follows.
Install check poppet (2/7) and poppet spring (2/8) into bore.
Install check ball body (2/6) with new o-ring seal (2/1), back
up ring (2/2), o-ring seal (2/3), back up rings (2/4) and o-ring
seal (2/5) into valve bore.
10B - 24
LOAD CHECK VALVE
2/l. O-ring Seal
212. Back Up Ring
2/3. O-ring Seal
2/4. Back Up Ring
2/5. O-ring Seal
2/6. Valve Ball Body
2/7. Check Poppet
2/8. Poppet Spring
ANTI-CAV VALVE
3/l. O-ring Seal
3/2. Back Up Ring
2/6 3/6 3/3. O-ring Seal
314. Back Up Ring
3/5. O-ring Seal
316. Check Ball Body

-2/3
3/7. Check Poppet
2/4 318. Poppet Spring
214 3/9. Check Ball
318 3/lO. Ball Retainer

216
300
3/l
KCRW1828
IOB- 25
10B - 26
2. Install anti-cavitation valve (3) at housing end as follows.
Install check poppet (3/7) and poppet spring (3/8) into valve
bore.
Install check ball retainer (3/10) with new back up rings (3/4)
and o-ring seal (3/5) into valve bore.
Install check ball (3/9) into retainer in valve bore.
up ring (3/2) and o-ring seal (3/3) into valve bore.
3. Install section spool (8) into bore.
4. Install detent ball follower (19) and detent spring (20).
5. Install retainer sleeve (18).
6. Install new seal rings (16 and 17).
10B - 27
7. Install detent sleeve (15) engaging seal ring (16) in bottom

groove.
8. Coat four detent balls (21) with grease and position in holes in
spool.
9. Position retainers (12 and 14) and spring (13) on spool.
10. Install two shipping/retainer plates, 1299240H1, (7) with long

bolts as shown. Draw down evenly on bolts until shorter bolts
can be installed in second plate. Remove top plate and bolts.
11. Draw down evenly on shorter bolts until retaining ring groove is
exposed. Instal retaining ring (11) and remove plate and bolts.
12. Install detent housing (10) and secure with hardware.
10B - 28
BLADE TILT SECTION CONTROL VALVE
1. Spool Positioner
2. Load Check Valve
3. Seal Retainer
4. Back Up Ring
5. O-ring Seal
6. Retainer Plate
7. Section Spool
8. Valve Body
9. Spool Housing
10. Spool Collar
11. Spring Retainer
12. Centering Spring
13. Orifice Vent
-11
-6
KCRW1829
IOB-29
CONTROL VALVE BLADE TILT SECTION
10B - 30
DISASSEMBLY
REMARK
1. Position blade tilt section in vise. Remove hardware and spool

positioner housing (9).

spool collar (10) is free, then remove.
3. Slowly and evenly let off bolts until all tension on spring is
relieved.
4. Remove spool retainers (11) and centering spring (12).
5. Remove seal retainer (3), back up seal (4) and o-ring seal (5) at
each end of spool bore.
6. Insert spool collar (10) to spool (7) and remove.
7. Remove load check valve (2) from valve body. Separate check
poppet (2/7) and poppet spring (2/8) from body (2/6). Remove
REASSEMBLY
REMARK
1. Install load check valve (2) at each spool end as follows.
bore.
10B - 31
CONTROL VALVE BLADE TILT SECTION
LOAD CHECK VALVE

1. O-ring Seal 4. Back Up Ring 7. Check Poppet
2. Back Up Ring 5. O-ring Seal 8. Check Poppet Spring
3. O-ring Seal 6. Valve Body
10B - 32
up ring (2/2), o-ring seal (2/3), back up rings (2/4) and o-ring
seal (2/5) into valve bore.
2. Insert spool (7) into bore and remove collar (10).
3. Install new o-ring seal (5), back up ring (4) and seal retainer (3)
into each end of spool bore.
4. Install centering spring retainers (11) and centering spring (12)

to spool.

spool collar (10) can be installed. Tighten down spool collar
then remove retaining plate and bolts.
6. Install spool positioner housing (9) and secure with hardware.
10B - 33
CONTROL VALVE BLADE ANGLE OR RIPPER SECTION
DISASSEMBLY
REMARK
1. Position blade angle or ripper section in vise. Remove hardware

and spool positioner housing (9).

spool collar (10) is free, then remove.
3. Slowly and evenly let off bolts until all tension on spring is
relieved.
4. Remove spool retainers (11) and centering spring (12).
5. Remove seal retainer (3), back up seal (4) and o-ring seal (5) at
each end of spool bore.
6. Insert spool collar (10) to spool (7) and remove.
7. Remove anti-cavitation valve (2) from each side of valve body.

Separate check poppet (2/7), poppet spring (2/8), check ball
retainer (2/10) and check ball (2/9) from body (2/6). Remove
REASSEMBLY
1. Install anti-cavitation valve (2) at each spool end as follows.
bore.
10B - 34
BLADE ANGLE OR RIPPER SECTION CONTROL VALVE
1. Spool Positioner
2. Anti- Cav Valve
3. Seal Retainer
4. Back Up Ring
5. O-ring Seal
6. Retainer Plate
7. Section Spool
8. Valve Body
9. Spool Housing
10. Spool Collar
11. Spring Retainer
12. Centering Spring
13. Orifice Vent
KCRW1830
IOB-35
10B - 36
BLADE ANGLE OR RIPPER SECTION CONTROL VALVE
ANTI-CAVITATION VALVE
1. O-ring Seal 5. O-ring Seal 9. Check Ball
2. Back Up Ring 6. Check Ball Body 10. Check Ball Retainer
3. O-ring Seal 7. Check Poppet
4. Back Up Ring 8. Poppet Spring
10B - 37
Install check ball retainer (2/10) with new back up rings (2/4)
and o-ring seal (2/5) into valve bore.
Install check ball (2/9) into retainer in valve bore.
up ring (2/2) and o-ring seal (2/3) into valve bore.
REMARK
2. Insert spool (7) into bore and remove collar (10).
3. Install new o-ring seal (5), back up ring (4) and seal retainer (3)
into each end of spool bore.
4. Install centering spring retainers (11) and centering spring (12)

to spool.

spool collar (10) can be installed. Tighten down spool collar
then remove retaining plate and bolts.
6. Install spool positioner housing (9) and secure with hardware.
10B - 38
INSTALLATION CONTROL VALVE
1. With spool seals flush in bore install linkage and secure with
2. Attach linkage links to valve spools with pin and new cotter.
3. Position assembly in reservoir box and secure with hardware.

4. Install boot with retainer over lever and secure with hardware.
5. Thread jam nut down blade lever. Install lever handle to desired
height and position and secure with jam nut.
6. With outlet elbow jam nut loosened at control valve. Install

return hose with filter header and rotate upright.
10B - 39
CONTROL VALVE INSTALLATION
7. Secure filter header to mounting bracket with hardware. Torque

bolts to 38 NCm (28 lbf ft) ±10%. Connect elbow to reservoir
inlet.
8. Install new filter to header, refer to OPERATION & MAINTE-

NANCE MANUAL. Apply electrical sealing grease, Grafo 112-X
to header lead and connect to terminal.
9. Install reservoir breather (1) and filler cap (2).
10. Tighten jam nut at control valve outlet elbow.
11. Fish inlet tube through box and connect to pump outlet hose.
12. Connect inlet tube to elbow to control valve.
13. Connect upper tube to right lift hose.
14. Connect lower tube to right lift hose.
10B - 40
15. Connect lower then upper tubes to control valve.
16. Connect crossover tubes to installed tubes.
17. Fish bottom tilt tube (2) through box and connect to control
valve. Fish top tilt tube (1) through box and connect to control
valve.
18. Fish bottom angle tube (2) through box and connect to control
valve. Fish top angle tube (1) through box and connect to
control valve.
19. RIPPER: Connect hoses to control valve.
20. Connect four hoses to tubes.
21. Install filler tube to rear main frame cover.
22. Install drive train dipstick.
10B - 41
23. Position door in place and secure hinge to reservoir. Torque

24. Connect door locking mechanism to box.
25. Install right access panel. Torque bolts to 38 NCm (28 lbf ft)
±10%.
10B - 42
(28 lbf ft) ±10%.
10B - 43
(28 lbf ft) ±10%.
±10%.

REMARK
reassembly.
10B - 44

NCm (28 lbf ft) ±10%.
50. Fill hydraulic reservoir, refer to OPERATION & MAINTENANCE

MANUAL. Adjust system relief valve per SECTION 10.
10B - 45
CYLINDERS
SECTION 10C
BLADE EQUIPMENT . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 5
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 10
RIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 14
BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 20
WARNING
10C - 1
CYLINDERS BLADE EQUIPMENT
EXPLODED AND CROSS SECTION VIEWS OF BLADE LIFT, TILT OR ANGLE CYLINDER
10C - 2
BLADE EQUIPMENT CYLINDERS
1. Gland Retainer 7. Back Up Ring q 13. Cylinder Piston

2. Cylinder Gland 8. O-Ring q 14. Lock Nut
3. Rod Wiper q 9. Wear Ring q 15. Cylinder Rod
4. Rod Seal q 10. Seal Ring q 16. Cylinder Housing
5. Buffer Ring q 11. O-Ring q q - Part of Cylinder Seal Kit
6. O-Ring q 12. Wear Ring q
SPECIFICATIONS
Bore and Stroke:

Lift Cylinder - ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.9 x 448.564 mm (3.5 x 17.66 in)
Tilt Cylinder - ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.9 x 144.272 mm (3.5 x 5.68 in)
Angle Cylinder - D32E-1, D32P-1, D38E-1, or D38P-1 . . . . . . . . . . . . . . . . . . . . . 76.2 x 352.044 mm (3 x 13.86 in)
Angle Cylinder - D39E-1 or D39P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.9 x 352.044 mm (3.5 x 13.86 in)
Weights:
Lift Cylinder - D32E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 kg (72 lbs)
Lift Cylinder - D32P-1, D38E-1 or D38P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 kg (83 lbs)
Lift Cylinder - D39E-1 or D39P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 kg (122 lbs)
Tilt Cylinder - ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 kg (64 lbs)
Angle Cylinder - D32E-1, D32P-1, D38E-1 or D38P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 kg (58 lbs)
Angle Cylinder - D39E-1 or D39P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 kg (69 lbs)
Torques:
Piston Lock Nut;
Lift Cylinder - ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597 to 651 NCm (440 to 480 lbf ft)
Tilt Cylinder - ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597 to 651 NCm (440 to 480 lbf ft)
Angle Cylinder - D32E-1, D32P-1, D38E-1 or D38P-1 . . . . . . . . . . . . . . . . . . . 448 to 502 NCm (330 to 370 lbf ft)
Angle Cylinder - D39E-1 or D39P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597 to 651 NCm (440 to 480 lbf ft)
Gland Retainer:
Lift Cylinder - ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814 to 882 NCm (600 to 650 lbf ft)
Tilt Cylinder - ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814 to 882 NCm (600 to 650 lbf ft)
Angle Cylinder - D32E-1, D32P-1, D38E-1 or D38P-1 . . . . . . . . . . . . . . . . . . . 611 to 678 NCm (450 to 500 lbf ft)
Angle Cylinder - D39E-1 or D39P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814 to 882 NCm (600 to 650 lbf ft)
Seal Test Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2750 kPa (400 psi)
Gland Retainer Tool
For Cylinders with 76.2 mm (3 in) Diameter Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR07-6064
For Cylinders with 88.9 mm(3.5 in) Diameter Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR07-6065
REMOVAL
REMARK
Removal of cylinders are similar with tilt cylinder shown.
WARNING
Park machine on level ground, and stop the engine, lower
the blade and all attachments to the ground, lock the trans-
mission shift lever in neutral, apply the brake pedal lock,
and turn off the electrical system master switch.
1. Operate equipment control lever to dissipate any pressure in

system. Disconnect and cap hoses at cylinder. Allow cylinder to
drain in a suitable container.
10C - 3
2. Using retainer tool, relieve torque on gland retainer. Refer to

SPECIFICATIONS for tool number.
3. Remove rod end anchor bolt.
4. Using ½NC eye bolt, remove rod end pin.
5. Remove piston end anchor bolt. Cylinder may have to be

jockeyed around to allow bolt clearance.
10C - 4
6. Using ½NC eye bolt, remove piston end pin.
7. Attach hoist and sling to cylinder and remove.
DISASSEMBLY
REMARK
1. Mount cylinder in vise. Remove port plug and allow to drain into
a suitable container.
2. Extend rod out to drain remaining oil.
10C - 5
3. Unthread gland retainer (1) and position out at end of rod.
4. Pull rod (15) with gland (2) and piston (13), out of cylinder
barrel.
5. Position rod in vise. Break torque on piston lock nut.
6. Remove lock nut (14).
8. Remove gland (2) and retainer (1) from rod.
10C - 6
9. Remove and discard wear rings (9) from piston.
10. Cut piston seal ring (10) and remove and discard.
11. Remove and discard o-ring (11) from piston.
12. Remove and discard back up ring (7) from gland.
13. Remove and discard o-ring (8) from gland.
14. Pop out rod wiper (3) from gland and discard.
15. Remove and discard rod seal (4) from gland.
16. Remove and discard buffer ring (5) from gland.
10C - 7
18. Remove and discard wear ring (12) from gland.
19. If not already done, discard all o-rings, seals and rings. Clean all
remaining parts in solvent and dry thoroughly with compressed
air. Inspect cylinder wall and rod for wear, scoring, scratches or
grooves that may cause seal kit failure. Very slight scratches
can be polished out with a fine emery cloth and oil so a smooth
surface is presented to seal kit. Inspect all parts for cracks and
breakage and replace as necessary.
REASSEMBLY
REMARK
1. Install new o-ring (6) into groove in gland. Work buffer ring (5),
with lip facing in, into groove under o-ring. Install wear ring (12)
into large groove in gland. Install rod seal (4) with expander (o-
ring) facing towards wear ring. Squeeze sides of seal together
and start into groove. Work remainder in with thumbs. Start rod
wiper (3), lip facing out, in gland bore and drive flush with edge
of gland. Install o-ring (8) and back up ring (7) into outer groove
on gland.
2. Install new o-ring (11) into piston.
ring into piston groove over inner o-ring, using shim stock,
wrapped around end of piston. Install wear rings (9), slits 180E
apart, onto piston.
4. Install gland retainer (1) on rod. Coat internal seals in gland (2)
with a liberal layer of clean oil. Install gland to rod being careful
not to cut or clip internal seals.
5. Install piston (13) on rod.
10C - 8
6. Install lock nut (14) to rod.
7. Reposition rod in vise and torque lock nut to value shown.
Lift - ALL . . . . . . . . . . . . . . . . . . 597 to 651 NCm (440 to 480 lbf ft)

Tilt - ALL . . . . . . . . . . . . . . . . . . 597 to 651 NCm (440 to 480 lbf ft)
Angle - D32E-1 or D32P-1 . . . 448 to 502 NCm (330 to 370 lbf ft)
8. Coat external seals on piston (13) and gland (2) with a layer of
clean oil. Install rod assembly into barrel being careful not to cut
or clip external seals.
9. Thread gland retainer (1) hand tight to barrel. Position cylinder

in holding fixture and using retainer tool, see SPECIFICATIONS,
torque gland retainer to value given in SPECIFICATIONS, using
the following formula.
R = T X L ÷ (L + C)
T- Torque Required NCm ( lbf ft)
MULTIPLIED BY (x)
DIVIDED BY (÷)
PLUS (+)
EQUALS (=)
10C - 9
INSTALLATION
REMARK
Installation of cylinders are similar with tilt cylinder shown.
1. Using hoist and sling, position cylinder in place on machine.
2. Install mounting pin using eye bolt to align anchor bolt mounting
holes.
3. Install anchor bolt and secure with nut. Torque bolt to 60 NCm
(45 lbf ft) ±10%.
4. Install mounting pin using eye bolt to align anchor bolt mounting
holes.
10C - 10
5. Install anchor bolt and secure with nut. Torque bolt to 60 NCm
(45 lbf ft) ±10%.
6. Using retainer tool, make sure gland retainer is up to torque

value given in SPECIFICATIONS, using the following formula.
R = T X L ÷ (L + C)
T- Torque Required NCm ( lbf ft)
MULTIPLIED BY (x)
DIVIDED BY (÷)
PLUS (+)
EQUALS (=)
7. Reconnect lines at cylinder. Check fluid level in reservoir and

add as required, refer to OPERATION & MAINTENANCE
MANUAL. Slowly operate cylinder ten to twelve cycles to bleed
out air. Recheck fluid level in reservoir and add as required.
10C - 11
CYLINDERS RIPPER
EXPLODED AND CROSS SECTION VIEWS OF RIPPER CYLINDER
10C - 12
RIPPER CYLINDERS
1. Retainer Ring 8. O-Ring q 15.Lock Nut

2. Cylinder Gland 9. Wear Ring q 16.Rod Bushing
3. Rod Wiper q 10. Seal Ring q 17.Cylinder Rod
4. Rod Seal q 11. O-Ring q 18.Barrel Bushing
5. Buffer Ring q 12. Wear Ring q 19.Cylinder Barrel
6. O-Ring q 13. O-Ring q q - Part of Cylinder Seal Kit
7. Back Up Ring q 14. Cylinder Piston
SPECIFICATIONS
Bore and Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.2x172.72 mm (3x6.8 in)

Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 kg (69 lbs)
Torques - Piston Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610 to 678 NCm (450 to 500 lbf ft)
Seal Test Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2750 kPa (400 psi)
Rod End Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not to Exceed 1 mm (0.039 in) Per Minute
REMOVAL
RIPPER CYLINDER REMOVAL
1. Ripper Cylinder Hoses 3. Front Mounting Pin

2. Ripper Cylinder 4. Rear Mounting Pin
WARNING
Park machine on level ground, and stop engine, lower the blade and all attachments to the ground, lock
the transmission shift lever in neutral, apply the brake pedal lock, and turn off electrical system master
switch.
1. Operate equipment control lever to relieve any pressure in system. Disconnect and cap hoses (1) at cylinder (2).
Drain into a suitable container. Attach hoist and sling to cylinder. Remove front (3) and rear (4) mounting pins from
cylinder and remove.
10C - 13
CYLINDERS RIPPER
DISASSEMBLY
REMARK
1. Position cylinder in vise. Pull out rod to drain remaining oil into
suitable container. Using a 3 in. spanner wrench, rotate gland
(2) and remove retainer ring (1).
2. Pull out rod (17) with gland (2) and piston from cylinder barrel.
3. Break torque on lock nut.
4. Remove lock nut (15) from rod.
6. Remove and discard piston o-ring (13) from rod.
10C - 14
RIPPER CYLINDERS
7. Remove gland (2) from rod.
8. Remove and discard wear rings (9) from piston.
9. Cut, remove and discard seal ring (10) from piston.
10. Remove and discard o-ring (11) from piston.
11. Remove and discard back up ring (7) from gland.
10C - 15
CYLINDERS RIPPER
13. Pop out and discard rod wiper (3) from gland.
14. Remove and discard rod seal (4) from gland.
15. Remove and discard buffer ring (5) from gland.
17. Remove and discard wear ring (12) from gland.
BUSHINGS
Cylinder Barrel
1. Position barrel in press and remove both bushings at same time.
10C - 16
RIPPER CYLINDERS
2. Position bushing in barrel and using suitable driver, press in

flush with edge of barrel. Turn over barrel and repeat for
remaining bushing.
Cylinder Rod
1. Position rod in press and remove both bushings at same time.
2. Position bushing in rod and using suitable driver, press in flush

with edge of rod. Turn over rod and repeat for remaining
bushing.
REASSEMBLY
REMARK
1. Install wear ring (12) into large groove in gland.
2. Install new o-ring (6) into groove in gland.
10C - 17
CYLINDERS RIPPER
3. Work buffer ring (5), with lip facing in, into groove under o-ring.
4. Install rod seal (4) with expander (o-ring) facing towards wear
ring. Squeeze sides of seal together and start into groove. Work
remainder in with thumbs.
5. Start rod wiper (3), lip facing out, in gland bore
6. Drive flush with edge of gland.
7. Install back up ring (7) into outer groove on gland.
8. Install o-ring (8) into outer groove on gland.
9. Install new o-ring (11) into piston.
10C - 18
RIPPER CYLINDERS
ring into piston groove over inner o-ring, using shim stock,
wrapped around end of piston.
11. Using ring tool, compress piston seal.
12. Install wear rings (9), slits 180E apart, onto piston.
13. Coat internal seals in gland with a liberal layer of clean oil.
Install gland to rod being careful not to cut or clip internal seals.
14. Install piston o-ring (13) to rod.
15. Install piston (14) to rod being careful not to clip or cut o-ring on
rod.
16. Install lock nut to rod and torque to 610 to 678 NCm (450 to 500
lbf ft).
17. Coat external seals on piston and gland with a layer of clean oil.
Install barrel onto rod assembly being careful not to cut or clip
external seals.
10C - 19
POWER
SECTION 12
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD VALUE TABLE
D32E AND D32P . . . . . . . . . . . . . . . . . . . . 2
D38E AND D38P . . . . . . . . . . . . . . . . . . . . 3
D39E AND D39P . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 17
THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 28
FUEL CONTROL LINKAGE . . . . . . . . . . . . 31
WARNING
12 - 1
POWER ENGINE
STANDARD VALUE TABLE FOR ENGINE - D32E AND D32P
Machine models D32E-1/P-1
Engine model 4D102E-1
Standard value for

Item Measurement condition Unit Service limit value
new machine
‚ High idle 2650 to 2780 2650 to 2780
RPM
Engine speeds ‚ Low idle 830 to 1030 830 to 1030
‚ Rated speed 2500 2500
New
305 (12)
mm H2O
‚ At torque converter stall and
(in H2O)
element
Intake air restriction full throttle max. 508 (12)
‚ At restriction indicator port Used
element
508 (20)
Lubricating oil pres- kPa *

(psi)
‚ Minimum at low idle 70 (10) 70 (10)
sure with SAE 15W-
40 oil & coolant tem-
kPa *
perature in operating
(psi)
‚ Minimum at high idle 207 (30) 207 (30)

range
mm Hg
(in Hg)
Fuel filter inlet ‚ Maximum restriction at high

100 (3.9) 200 (3.9)
restriction idle
‚ Coolant temperature in op-

mm H2O
erating range:
(in H2O)
Blow-by pressure ‚ Service Tool orifice size 25 (1) 50 (2)

• 5.613 mm (0.221 in)
‚ Full load at rated speed
mm Hg
(in Hg)
Exhaust back pres- ‚ Maximum at converter stall

76 (3.0) 76 (3.0)
sure and full throttle
EC (EF)
‚ Maximum coolant operating

Coolant temperature 100 (212) 100 (212)
temperature
mm (in)
‚ Intake valves 0.25 (0.010) 0.25 (0.010)

Valve clearances
with engine cold
‚ Exhaust valves 0.51 (0.020) 0.51 (0.020)
* To determine kg/cm² from kPa, divide (÷) kPa by ten.
p For further detailed information, refer to Engine Shop Manual.
12 - 2
ENGINE POWER
Engine model S4D102E-1
Standard value for

new machine
‚ High idle 2600 to 2770 2600 to 2770
RPM
mm Hg
(in Hg)
Intake manifold pres- 700 to 800 650 to 850
sure (27.6 to 31.5) (25.6 to 33.5)
New
305 (12)
mm H2O
(in H2O)
element
element
635 (25)
kPa *
Lubricating oil pres-

(psi)

sure with SAE 15W-
kPa *
(psi)

range
mm Hg
(in Hg)

100 (3.9) 100 (3.9)
restriction idle

mm H2O
erating range:
(in H2O)
Blow-by pressure ‚ Service Tool orifice size 70 (2.8) 270 (10.6)

• 5.613 mm (0.221 in)
mm Hg
(in Hg)

76 (3.0) 76 (3.0)
EC (EF)

temperature
mm (in)
‚ Intake valves 0.25 (0.010) 0.25 (0.010)

Valve clearances
with engine cold
‚ Exhaust valves 0.51 (0.020) 0.51 (0.020)
12 - 3
POWER ENGINE
Engine model S4D102E-1
Standard value for

new machine
‚ High idle 2350 to 2465 2350 to 2465
RPM
mm Hg
(in Hg)
Intake manifold pres- 1000 to 1100 950 to 1150
sure (39.4 to 43.3) (37.4 to 45.3)
New
305 (12)
mm H2O
(in H2O)
element
element
635 (25)
kPa *
Lubricating oil pres-

(psi)

sure with SAE 15W-
kPa *
(psi)

range
mm Hg
(in Hg)

100 (3.9) 200 (7.9)
restriction idle

mm H2O
erating range:
(in H2O)
Blow-by pressure ‚ Service Tool orifice size 60 (2.4) 250 (9.8)

• 5.613 mm (0.221 in)
mm Hg
(in Hg)

76 (3.0) 76 (3.0)
EC (EF)

temperature
mm (in)
‚ Intake valves 0.25 (0.010) 0.25 (0.010)

Valve clearances
with engine cold
‚ Exhaust valves 0.51 (0.020) 0.51 (0.020)
12 - 4
ENGINE POWER
REMOVAL
WARNING

NANCE MANUAL.

MAINTENANCE MANUAL.
12 - 5
POWER ENGINE
5. From inside of engine compartment relieve tension from the tie

for opposite side.
12 - 6
ENGINE POWER
position around lift cylinders. Attach hoist to sling.
13. From under machine, carefully remove hardware and slowly

lower guard to ground. Pull guard out front of machine, attach
hoist and remove.
14. Remove radiator guard.
15. Carefully remove radiator cap to assist drainage of radiator.

Drain radiator into a suitable container.
16. Remove top hose (1) and vent hose (2) from radiator and
engine.
17. Remove left and right fan guards.
12 - 7
POWER ENGINE
18. Remove upper fan shroud.
19. Through access hole in frame disconnect and remove radiator

lower hose.
REMARK
Lower radiator shroud removed for clarity.
REMARK
removal.
12 - 8
ENGINE POWER

under machine
26. Cut cable tie holding hoses to left dash brace. Remove fuel filter
mounting block from dashboard and roll forward. Remove dash
brace bar from left side of machine.

engine.
12 - 9
POWER ENGINE
30. D32E-1 or D32P-1; Disconnect wiring lead from switch at air

30. D38E-1, D38P-1, D39E-1 or D39P-1; Disconnect wiring lead



12 - 10
ENGINE POWER
REMARK
(3).
(2).
hoist.
from machine.
REMARK
36. Disconnect, cap and plug converter inlet hose at torque con-
verter.
37. Disconnect, cap and plug converter drain hose at torque

converter.
38. Disconnect, cap and plug pump to filter hose at front port of
charge and scavenge pump.
39. Disconnect, cap and plug pump to rear main frame hose at rear
port of charge and scavenge pump.
12 - 11
POWER ENGINE
40. Disconnect, cap and plug front half of reservoir to pump hose at
top port of equipment pump.
41. Remove mounting hardware and drive shaft.
42. Disconnect, cap and plug pump to equipment valve hose at

bottom port of equipment pump.
43. Disconnect drive train temperature lead at switch. Disconnect,

cap and plug converter outlet switch tube adapter from elbow at
bottom of torque converter.
44. Disconnect, cap and plug both hoses at bottom ports of charge
and scavenge pump.
45. Remove mounting hardware from equipment pump, slide out of

converter and remove. Remove mounting hardware from
charge and scavenge pump, slide out of converter and remove.
46. Disconnect and remove ground wires at frame.
12 - 12
ENGINE POWER
47. Disconnect and remove battery cable at cranking motor

terminal.
48. Unclip battery cable from converter housing and position out of
the way.
49. Disconnect rear harness from mounting block.
50. Disconnect, plug and cap fuel inlet (1) and outlet (2) lines.
12 - 13
POWER ENGINE
51. Remove horn and bracket from main frame.
52. Disconnect wiring lead at horn terminal.
53. Unclip horn harness at top and bottom corners of radiator.
Tape a feeder line of sufficient length to horn harness. From

engine side of radiator, pull horn harness through. Remove
feeder line from harness position out of the way.
54. Attach load leveler with hoist to engine lifting brackets. Rotate
muffler for additional clearance.
55. Remove rear engine mounting bolt from each side of machine.
12 - 14
ENGINE POWER
56. Remove front engine mounting bolt from each side of machine.
57. Using hoist and load leveler, slowly remove engine with torque
converter from machine carefully checking for snagging or
binding. Place engine on work stand. For further detailed
information, refer to the ENGINE SHOP MANUAL.
Remove front and rear mounts and replace with new.
12 - 15
POWER ENGINE
ENGINE MOUNTING - D32E-1 OR D32P-1
ENGINE MOUNTING - D38E-1, D38P-1, D39E-1 OR D39P-1
12 - 16
ENGINE POWER
INSTALLATION
1. Clean rear mounting surface at each side of machine. Install

aligning stud (1) to mount. Over stud position bottom portion of
new bushing (2) with spacer (3).
REMARK
Aligning stud : Make from eNCx5 bolt 24 883 R1 by removing
head and cutting a slot in its place.
2. Clean front mounting surface at each side of machine. Install

aligning stud (1) to mount. Over stud position bushing limiter (2),
lower portion of new bushing (3) and tube spacer (4).
REMARK
Aligning stud : Make from ½Ncx4 bolt 24 868 R1 by removing
head and cutting a slot in its place.
3. Using hoist and load leveler slowly lower engine with torque
converter into machine over studs being careful not to damage
the front or rear lower bushings.
REMARK
Install bushing and hardware on one side of engine at a time.
4. Install spacer washer (1) and top portion of new rear bushing (2)
over spacer. Remove aligning stud. Install outer washer (3) and
secure with hardware loosely. Repeat for remaining rear side.
On each side, equalize the gap between center of bolt and
inside rail of main frame. When done secure hardware.
12 - 17
POWER ENGINE
REMARK
Install bushing and hardware on one side of engine at a time.
5. Install top portion of new front bushing (1) over spacer. Remove
aligning stud. Secure with hardware. Repeat for remaining rear
side.
6. Torque front engine mounting bolts to 92 NCm (70 lbf ft).
7. Torque rear engine mounting bolts to 267 NCm (195 lbf ft).
8. Remove hoist and leveler from engine. Reposition muffler to

original spot and torque muffler clamp nut to 68 NCm (50 lbf ft).
12 - 18
ENGINE POWER
9. Tape feeder line to horn harness. From blade side of radiator,

pull horn harness through. Remove feeder line from harness.
Clip horn harness at top and bottom corners of radiator.
10. Apply electrical sealing grease, Grafo 112-X to terminal and

connect to horn.
11. Install horn and bracket to main frame. Torque bolts to 38 NCm
(28 lbf ft) ±10%.
12. Reconnect fuel inlet (1) and outlet (2) lines at engine.
13. Connect rear harness to mounting block.
12 - 19
POWER ENGINE
14. Connect battery cable to converter housing and toque bolts to

46 NCm (34 lbf ft) ±10%.
15. Apply electrical sealing grease, Grafo 112-X to battery cable

and connect at cranking motor terminal. Torque nut to 16 NCm
(12 lbf ft) ±10%.
16. Connect ground wires to frame with hardware. Torque bolt to 33

NCm (24 lbf ft) ±10%.
17. Install new o-ring to equipment pump and slide in converter

housing and secure with hardware. Install new o-ring to charge
and scavenge pump and slide in converter housing and secure
with hardware. Torque bolts to 92 NCm (70 lbf ft) ±10%.
18. Install both hoses at bottom ports of charge and scavenge

pump.
19. Connect converter outlet switch tube adapter to elbow at bottom

of torque converter. Apply electrical sealing grease, Grafo 112-
X to drive train temperature lead and connect at switch.
12 - 20
ENGINE POWER
20. Connect pump to equipment valve hose to bottom port of

equipment pump.
21. Install drive shaft with mounting hardware. Torque D32E-1,

D32P-1, D38E-1 or D38P-1 bolts to 33 NCm (24 lbf ft). Torque
D39E-1 or D39P-1 bolts to 57 NCm (42 lbf ft).
22. Connect front half of reservoir to pump hose to top port of

equipment pump.
23. Connect pump to rear main frame hose to rear port of charge
and scavenge pump.
24. Connect pump to filter hose at front port of charge and scav-
enge pump.
25. Connect converter drain hose at torque converter.
26. Connect converter inlet hose at torque converter.

Loctite #262 and secure with shims. Torque bolts to 92 NCm (70
lbf ft) ±10%.
12 - 21
POWER ENGINE

connect elbow.

clamp (1).
32. D32E-1 or D32P-1; Apply electrical sealing grease, Grafo 112-X

to wiring lead and connect to switch at air cleaner outlet pipe.
12 - 22
ENGINE POWER

grease, Grafo 112-X to wiring lead and connect to switch at air
35. Connect instrument panel harness to bracket at rear of engine.
26. Connect pump control rod (1) and over travel decelerator (2) to
throttle control (3). Torque bolt to 10 NCm (8 lbf ft) ±10%.
37. Install dash brace bar to left side of machine. Torque bolts to 92
NCm (70 bf ft) ±10%. Install fuel filter mounting bracket to
dashboard. Torque bolts to 21 NCm (16 bf ft) ±10%. Install cable
ties to harness and dash brace.
92 NCm (70 bf ft) ±10%.
12 - 23
POWER ENGINE

±10%.

REMARK
reassembly.
12 - 24
ENGINE POWER
44. Install radiator guard. Torque bolts to 92 NCm (70 lbf ft) ±10%.
45. Position crankcase guard under machine.
position around lift cylinders. Attach hoist to sling and lift guard
in place and secure. Torque bolts to 38 NCm (28 lbf ft) ±10%.

NCm (28 lbf ft) ±10%.
12 - 25
POWER ENGINE

±10%.
12 - 26
ENGINE POWER
±10%.
43. Refill hydraulic and drive train systems with proper fluid, refer to
the OPERATION & MAINTENANCE MANUAL.
12 - 27
POWER THROTTLE
ADJUSTMENT
Adjust brake and decelerator pedal (1) to the specified height. Adjust
bolt (2) so that threaded tab (3) of throttle control bellcrank is
vertical. Place throttle lever (4) in detented LOW IDLE position.
Adjust stop bolt (5) so that it just contacts throttle lever and lock in
place. Adjust the length of the throttle rod (6) to fit between the
center of the slot (7) of the throttle control bellcrank (8) and the
injection pump lever (9) held against its LOW IDLE stop. Tighten the
bolt (10) so that throttle rod is in the center of the slot.
Move the throttle lever (4) toward the HIGH IDLE position until the
injection pump lever (9) contacts high stop on the pump. Adjust stop
bolt (11) on throttle lever and lock in place. With throttle lever in
HIGH IDLE position, back off stop bolt (2) until contact with pickup
tab (12) is just being made. Lock bolt in place. Make sure the
transmission is in neutral. Start engine and depress brake and
decelerator pedal until decelerated speed is obtained, 800 to 900
rpm. Adjust bolt (13) to contact stop block when decelerated speed
is reached.
1. Brake and Decelerator Pedal

2. Adjustment Bolt
3. Threaded Tab
4. Throttle Lever
5. Low Idle Stop Bolt
6. Injector Rod
7. Center of Slot
8. Throttle Control Bellcrank
9. Engine Injector Lever
10. Injector Rod Bolt
11. High Idle Stop Bolt
12. Bellcrank Pickup Tab
13. Decelerator Stop Block Bolt
12 - 28
THROTTLE
POWER
KCRW1817
12-29
POWER THROTTLE
12 - 30
THROTTLE POWER
FUEL CONTROL LINKAGE
‚ Engine stopped
Lever Travel
Measure travel distance with scale from low idle to high idle at the
center tip of the lever knob.
Lever Effort
Using the push pull scale measure the maximum effort required
when moving the lever from low to high idle and high to low idle.
12 - 31
UNDERCARRIAGE
SECTION 14
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TOP IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
FRONT IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
TRACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
TRACK SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
TRACK TOP IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
FRONT CROSSBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REAR RIGID BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SERVICE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
WEAR LIMIT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
TRACK SHOE GROUSER HEIGHT . . . . . . . . . . . . . . . . . 8 METAL TYPE FACE SEALS . . . . . . . . . . . . . . . . . . . . . . . 53
LINK HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SEAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
BUSHING OUTSIDE DIAMETER . . . . . . . . . . . . . . . . . . . 8 SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INTERNAL PIN AND BUSHING WEAR (PITCH) . . . . . . 9 TRACK FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
FRONT IDLER FLANGE HEIGHT . . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
TRACK ROLLER ROLLING DIAMETER . . . . . . . . . . . . . 9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
TOP IDLER ROLLING DIAMETER . . . . . . . . . . . . . . . . . . 9 TRACK SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
FRONT IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 FRONT CROSSBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 REAR RIGID BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
TRACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 TRACK FRAME ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 72
WARNING
14 - 1
UNDERCARRIAGE GENERAL
EXPLODED VIEW OF UNDERCARRIAGE

1. Track Frame 7. Mounting Pin 13. Wear Bar Shim 19. Counterweight
2. Retaining Ring 8. Front Crossbar 14. Thrust Plate 20. Roller Shield
3. Ring Retainer 9. Track Roller 15. Thrust Plate Shim 21. Track Adjuster Cover
4. Rear Rigid Bar 10. Top Idler 16. Track Spring 22. Track Adjuster Cover
5. Lock Bar 11. Front Idler 17. Track Adjuster 23. C Frame Rub Bar
6. Lock Bar Shim 12. Wear Bar 18. Final Drive 24. Foot Step
14 - 2
GENERAL UNDERCARRIAGE
DESCRIPTION
D32E-1 track frame has five track rollers attached to it. The remaining models have six track rollers attached to it. The
track spring housing is a permanent welded part of the track frame, with the heavy coil spring being trapped within it.
The track frames are attached at the rear to the rear rigid bar and at the front by the front crossbar. The rear rigid bar
and crossbar mount in the main frame. A track adjuster and front idler are located between the two channels of the track
frame and slide back and forth to take up shock loads and for adjusting the track chain tension. The top idler on each
side is mounted in a bracket welded to the track frame.
FRONT IDLER - 11
The front idler provides a freely rotating, guiding support for the track chain. The front idler is supported on replaceable
wear bars which slide on the track frame channels. This sliding feature helps protect the track frame components by
allowing the track spring to absorb shock loads. The front idlers are heat treated steel castings and rotate around
bushings. The front idlers are equipped with metal type face seals which maintain a leak and dirt proof seal.
TRACK ADJUSTER - 17
The hydraulic track adjuster is contained in the front idler fork. Lubricant is introduced into the adjuster by the use of a
lubrication fitting on top of the fork. This lubricant acting upon the piston and fork forces the idler fork and front idler
forward for track chain adjustment.
TRACK SPRING - 16
A heavy coil spring is provided in each track frame . They permit the front idlers to recoil under shock loads and exert
tension on the track in normal operation. Each track spring is contained in a welded housing, which is a permanent part
of the track frame. The track spring is compressed and trapped in the ends of the housing between a front and rear
seat. The rear of the track adjusting rod bears against the track spring front seat.
TRACK TOP IDLER - 10
The upper section of track chain between the sprocket and the front idler is supported by a top idler. The idlers are
mounted in brackets which are welded to the track frame. The top idlers revolve around tapered roller bearings which
ride on heat treated replaceable steel shafts. The idlers are sealed against leakage and dirt by a metal type face seal.
TRACK ROLLER - 9
Track rollers are attached to the underside of the track frame and carry the weight of the machine. The rollers are heat
treated steel forgings and rotate around bushings. The rollers are equipped with metal type face seals which maintain
a leak and dirt proof seal. The rollers are single flange type.
FRONT CROSSBAR - 8
The crossbar is fitted with pins to the main frame. The ends of the crossbar are bolted to the track frames
REAR RIGID BAR - 4
The rear rigid bar is a solid rigid type bar mounted to the main frame by the half cinch type blocks. The rear of the track
frames mount to the crossbar.
MAINTENANCE
The track links have only one wearing surface which contacts the track rollers, front idler and track idlers. It usually
becomes necessary to replace the pins and bushings before the links wear out, and it is a matter of judgement then
whether the links are good enough to justify a new set of pins and bushings. Only wear on the outside of the bushings
is visible. Wear on the pins and interior of the bushings is indicated by track stretch. The amount of wear can be
determined by measuring the pitch length of the track chain under tension and comparing it with the allowable pitch
lengths, refer to WEAR LIMIT CHECKS in this section.
14 - 3
UNDERCARRIAGE SERVICE DIAGNOSIS
GENERAL COMPLAINT
PROBABLE CAUSE REMARKS
Track Chain Comes Off During Operation
Track chain loose. Adjust tension. Refer to OPERATION & MAINTE-

NANCE MANUAL.
Front idler worn. Inspect front idler for wear. Repair or replace as
necessary.
Front idler misaligned. Inspect idler for excessive wear or distortion. Repair or
Rocks or debris in track assembly. Clean out all rocks and packed dirt from the chains,
idlers, rollers and sprocket.
Worn sprocket teeth. Replace sprocket.
Machine Creeps To One Side
Malfunction in drive system. Refer to SECTION 7.
One track loose. Adjust tension. Refer to OPERATION & MAINTE-

NANCE MANUAL.
Track spring weak or broken. Remove/check with SPECIFICATIONS or replace.
Brake in steering drive hanging up. Check, refer to SECTION 4.
Excessive Or Uneven Wear Of Track and Components
Damaged sprocket. Replace sprocket.
Front idler misaligned. Inspect idler for excessive wear and for distortion.
Repair or replace as necessary.
Track tension incorrect. Adjust tension. Refer to OPERATION & MAINTE-

NANCE MANUAL.
Track frame misaligned. Check for bent track frame, front or rear crossbar.
Replace parts as necessary.
Track Idlers Do Not Rotate
Insufficient lubrication. Lubricate per the OPERATION & MAINTENANCE

MANUAL.
Dirt or mud packed tight against idler Remove dirt or mud.
Internal seizure. Remove idler and inspect parts. Thoroughly clean and
replace parts as necessary.
14 - 4
SERVICE DIAGNOSIS UNDERCARRIAGE
Track Rollers Do Not Rotate

MANUAL.
Dirt or mud packed tight against rollers. Remove dirt or mud.
Internal seizure. Remove rollers and inspect parts. Thoroughly clean

and replace parts as necessary.
Front Idler Does Not Rotate

MANUAL.
Dirt or mud packed tight against front idlers. Remove dirt or mud.
Internal seizure. Remove idler and inspect parts. Thoroughly clean and
replace parts as necessary.
Lubricant Leakage
Leakage at track roller, top idler and/or front idler. Remove faulty part. Inspect and repair or replace
parts as necessary.
Machine Loses Power
Track chain too tight. Adjust tension. Refer to the OPERATION & MAINTE-
NANCE MANUAL.
14 - 5
UNDERCARRIAGE WEAR LIMIT CHECKS
SPECIFICATIONS - D32E-1, D32P-1, D38E-1 OR D38P-1
STANDARD GROUSER HEIGHT

100% REMAINING 53.6 mm (2.11 in) 25% REMAINING 30.2 mm (1.19 in)
50% REMAINING 38.1 mm (1.50 in) WEAR FACTOR 31.2 mm (1.23 in)
LINK HEIGHT
BUSHING OD - DRY SEALED TRACK SYSTEM
BUSHING OD - LUBRICATED TRACK SYSTEM
INTERNAL PIN AND BUSHING WEAR (PITCH)
FRONT IDLER FLANGE HEIGHT
New Front Idler Flange Diameter 581.7 mm (22.9 in) New Front Idler Wear Diameter 546.1 mm (21.5 in)
TRACK ROLLER DIAMETER
TOP IDLER DIAMETER
14 - 6
WEAR LIMIT CHECKS UNDERCARRIAGE
SPECIFICATIONS - D39E-1 OR D39P-1
STANDARD GROUSER HEIGHT

LINK HEIGHT
BUSHING OD - DRY SEALED TRACK SYSTEM
BUSHING OD - LUBRICATED TRACK SYSTEM
New Front Idler Flange Diameter 581.7 mm (22.9 in) New Front Idler Wear Diameter 546.1 mm (21.5 in)
TRACK ROLLER DIAMETER
TOP IDLER DIAMETER
14 - 7
UNDERCARRIAGE WEAR LIMIT CHECKS
GENERAL
Track components have a certain dimension when new. As wear occurs

dimensions will decrease (or increase in case of track pitch and front idler
flange height) until a decision must be made whether to rebuild or recondition
components, replace them or run them to destruction. For each component
or condition, five different dimensions are given. 100% is dimension of
component when new. 075%, 050% and 025% indicate % of wear remaining
before a maintenance action should be taken. 000% is point at which either
maintenance must take place or components run to destruction. Before
inspecting, chain tension on both sides must be tightened. To do this, blocks
of wood or metal should be placed in sprocket tooth under chain. Machine
should then be moved backward so sprocket can grab block and tighten
chain. This pulls chain tight off top idler.
REMARK
Tools used to measure undercarriage components are included in Track
Specialist Kit 637985C91.
TRACK SHOE GROUSER HEIGHT
Clean off all materials on shoe plate and grouser tops. Lay squeeze bar (2)
across grousers approximately ¼ of way in from end of shoe. Insert 305 mm
(12 in) scale (1) in squeeze bar so that scale is against top of track plate and
take a reading. Measure two or more shoes to get an average. Refer to
SPECIFICATIONS.
LINK HEIGHT
Clean out all materials between links. Place squeeze bar (1) across center
of links. Insert 305 mm (12 in) scale (2) in squeeze bar so that scale is
against bottom of track shoe plate and take a reading. Measure two or more
place along chain to get an average. Refer to SPECIFICATIONS.
BUSHING OUTSIDE DIAMETER
Close 102 mm (4 in) outside caliper (1) around bushing with a minimum
amount of drag, making certain that one of caliper tips is positioned in
forward drive side wear area. Slide caliper off bushing and measure distance
between caliper tips using 305 mm (12 in) scale. Repeat on reverse drive
side wear area. Measure two or more bushings to get an average. Refer to
SPECIFICATIONS.
REMARK
Whichever wear is greater, forward or reverse, determines percentage of
wear remaining.
14 - 8
WEAR LIMIT CHECKS UNDERCARRIAGE
REMARK
To measure track pitch, chain must be tight.
Place end of 3 m (10 ft) tape (1) on front of one track pin and measure
length of four links to front of fifth track pin. Refer to SPECIFICATIONS.
Insert 305 mm (12 in) scale (1) in squeeze bar (2). Rest squeeze bar on top
of flange and push scale down until it makes contact in middle of tread area
as shown and take a reading. Refer to SPECIFICATIONS.
TRACK ROLLER ROLLING DIAMETER
Place tips of 305 mm (12 in) caliper (1) against tread area of roller. Adjust
caliper so a slight drag is present when caliper is removed. Using 305 mm
(12 in) scale measure distance between caliper tips. Refer to
SPECIFICATIONS. Repeat steps on remaining rollers.
TOP IDLER ROLLING DIAMETER
Place tips of 305 mm (12 in) caliper (1) snugly around tread area of top idler
and remove. Using 305 mm (12 in) scale, measure distance between caliper
tips. Refer to SPECIFICATIONS.
14 - 9
UNDERCARRIAGE FRONT IDLER
EXPLODED VIEW OF FRONT IDLER

LEGEND FOR EXPLODED AND CROSS SECTION VIEWS
1. Front Idler 4. Port Plug 7. O-Ring
2. Bushing 5. Thrust Washer 8. Mounting Support
3. Idler Shaft 6. Seal Kit 9. Roll Pin
14 - 10
FRONT IDLER UNDERCARRIAGE
CROSS SECTION VIEW OF FRONT IDLER
SPECIFICATIONS
Weight:
D32E-1, D32P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 kg (200 lb)
D38E-1, D38P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 kg (200 lb)
D39E-1, D39P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 kg (297 lb)
Refill Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 mR (12 fl oz)
Refill Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See OPERATION & MAINTENANCE MANUAL
Bushing Installation Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #609
Drain Plug Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #592
Fork Mounting Bolts Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 NCm (98 lb ft)
Drain Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 NCm (25 lb ft)
Thrust Plate Bolts Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 NCm (140 lb ft)
14 - 11
REMOVAL
1. Remove track chain per SECTION 15. It is only necessary to lift chain
free from front idler. Disconnect fork (1) from both sides of front idler (2).
Remove thrust plates (3) and shims both sides of front idler.
2. Remove one counterweight mounting bolt. Install a through bolt of

sufficient length with large washers and nut and connect hoist.
3. Slide front idler out from track fame and remove from machine.
4. Position front idler on ground with blocking. Remove counterweights.
REMARK
Each counterweight weighs approximately 19 kg (42 lbs).
DISASSEMBLY
REMARK
Callouts from exploded and cross section views correspond with callouts
in following steps.
1. Using eye bolts and hoist, position front idler on work table.
14 - 12
FRONT IDLER
2.
3. Remove bottom wear bar and shims.
Drive roll pin (9) from mounting support (8).
5. h eye bolts and hoist to mounting support (8). Pry up on suppor

while carefully applying hoist. This is necessary to overcome dra
caused by o-ring inside support.
6.
14 - 13
7. Remove seal half (6) and discard.
8. Using hoist and eye bolts, lift idler (1) from shaft. Remove and discard
remaining seal half.
9. Remove seal half (5) from mounting support.
10. Remove thrust washer (5).
11. Remove lower wear bar hardware.
14 - 14
12. Remove lower wear bar and shims.
Drive roll pin (9) from mounting support.
14. is necessary to overcome

internal o-ring drag.
Remove and discard o-ring (7) from each mounting support.
REMARK
enever n
inspection or a new seal used. Refer to metal type face seals in this
CLEARANCES
FRONT IDLER BUSHING CLEARANCES
Remove the bushings in idler body and replace with new. Coat 19 to 25 mm
(0.75 to 1 in) of outer idler hub bores with Loctite #609. Coat 19 to 25 mm
(0.75 to 1 in) of leading edge of bushing (edge which engages bore first) with
Loctite #609, Position in press and install bushings 0.762 mm (0.030 in)
below washer face surface. A minimum press force of 6350 kg (14,000 lbs)
is required to install bushing. Repeat for remaining bushing. Discard thrust
washers and replace with new. Inspect the condition and OD of idler shaft
and replace as necessary.
Coat bushings and thrust washers with clean film of oil. Pin shaft to one
mounting support. Install thrust washer onto shaft. Insert shaft through idler
and secure with remaining mounting support. Position idler on blocking so
that mounting supports and shaft are free to rotate. Position dial indicator on
idler body with pointer on shaft and set to zero. Pry up on mounting support
and record reading on dial indicator. Repeat a few time and average
readings. Reading must be within specification. If not check dimensions of all
parts and repeat until clearance is achieved. Disassemble assembly after
clearance has been attained.
14 - 16
D32E-1, D32P-1, D38E-1 or D38P-1
END CLEARANCE
A. Pin to Pin Holes in Shaft 8.806 to 8.797 in. 223.672 to 223.444 mm
MINUS (!) MINUS (!)
B. Pin Hole to Washer Face of Support 2.916 to 2.928 in. 74.066 to 74.371 mm
MINUS (!) MINUS (!)
C. Idler Hub Washer to Washer Face 5.681 to 5.691 in 144.297 to 144.551 mm
MINUS (!) MINUS (!)
D. Thrust Washer Thickness 0.166 to 0.174 in. 4.216 to 4.420 mm
EQUALS (4) EQUALS (4)
0.004 to 0.043 in. 0.102 to 1.092 mm
DIAMETRAL (OIL) CLEARANCE
D. Bushing Assembled Inside Diameter 1.752 to 1.755 in. 44.501 to 44.577 mm
MINUS (!) MINUS (!)
E. Idler Shaft Diameter 1.744 to 1.742 in. 44.298 to 44.247 mm
0.008 to 0.013 in. 0.203 to 0.330 mm
D39E-1 or D39P-1
END CLEARANCE
MINUS (!) MINUS (!)
MINUS (!) MINUS (!)
MINUS (!) MINUS (!)
0.004 to 0.043 in. 0.102 to 1.092 mm
D. Bushing Assembled Inside Diameter 2.252 to 2.255 in. 57.201 to 57.277 mm
MINUS (!) MINUS (!)
E. Idler Shaft Diameter 2.244 to 2.242 in. 56.998 to 56.947 mm
0.008 to 0.013 in. 0.203 to 0.330 mm
14 - 17
REASSEMBLY
REMARK
in following steps.
1. Install new o-ring (7) into mounting support and coat with amber grease.
Apply a thin coat of "Never Seez" to shaft bore.
2. Install shaft (3) into mounting support (8) aligning pin hole with dowel.
Secure shaft to support with roll pin (9).
3. Coat thrust washer (5) with a light film of clean oil and install on shaft up
against support.
4. Install new seal half (6) into support. Refer to METAL TYPE FACE
5. Position front idler (1) on work table as shown. Install new seal half (6)
into front idler. Refer to METAL TYPE FACE SEALS in this section. Apply
a light film of clean oil to each bushing.
14 - 18
6. Install mounting support (8) with shaft (3) into front idler (1).
Install E
Coat thrust washer (5) with a light film of clean oil and install on shaft up
9. Install new o-ring (7) into mounting supp

Apply a thin coat of "Never Seez" to shaft bore.
10. new seal half (6) into support. Refer to METAL TYPE FACE
11. Install support (8) onto shaft.
12. Reposition support to shaft and temporarily secure with aligning dowel.
13. Reposition idler as shown. Remove aligning dowel. Press down on

support (8) while driving in roll pin (9). This will energize each seal.
14. Remove filler plug (4).
15. Fabricate an air pressure tester and connect to idler at fill plug hole.
Slowly apply 21 to 34 kPa (3 to 5 psi) of air pressure to idler. Assembly

must maintain this pressure for 10 to 20 seconds with no drop in
pressure.
14 - 20
16. Fill idler with recommended oil, refer to OPERATION & MAINTENANCE
MANUAL.
17. Rotate mounting support five to ten revolutions to distribute oil. Check
level and add as required. Proper level is when fill hole at vertical, oil
level should be at base of fill plug hole.
18. Coat fill plug with Loctite #592.
19. Torque fill plug to 34 NCm (25 lbf ft).
20. Install counterweights, at furthest outer point, and secure with hardware.
14 - 21
INSTALLATION
FRONT IDLER INSTALLATION

A. Roller Equalized Within Track Frame
B. Thrust Plate to Track Frame gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.152 to 0.762 mm (0.006 to 0.030 in)
C. Distance Between Mounting Support and Track Frame Wear Bar
D. Distance Between Track Frame and Wear Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.152 to 1.016 mm (0.006 to 0.040 in)
1. Measure distance between top outside edges (1) of track frame (2) at
three places. Read, average and record measurements.
2. Measure distance between top slide rail (1) and bottom of welded wear
bar (2) at each end and center. Read, average and record
measurements. Repeat for remaining side.
14 - 22
3. Measure distance between top of wear bar mounting surface (1)

and bottom of mounting block (2) at three places. Read,
average and record measurements. Repeat for remaining side.
REMARK
Fill port plug side is determined as outer side of front idler.
4. Measure thickness of wear bar (1) at three places. Read,

average and record measurements. Repeat for remaining wear
bar.
REMARK
Keep readings from each side separate from each other.
5. Determine each wear bar shim thickness as follows;

A. Subtract averaged readings of Steps 2 and 4 from Step
3 and record.
B. Subtract 0.152 to 1.016 mm (0.006 to 0.040 in) from A to
obtain shim thickness.
6. Measure shims (1) for thickness.
7. Install wear bar (1) and shims (2) and secure with hardware.
14 - 23
9. Using large outside calipers (1) from undercarriage tool kit,

measure distance between outside of mounting blocks (2) at
front and rear.
10. Read, average and record measurements.
11. Measure distance of stepped area of thrust plate (1) at three

places. Read, average and record measurements.
12. Determine thrust plate shim thickness as follows;

A. Add averaged readings of Steps 10 and 11(X2). Subtract this
from averaged readings in Step 1.
B. Add 0.305 to 1.524 mm (0.012 to 0.060 in) to A to obtain shim
thickness. Split shims evenly per side.
14 - 24
13. Measure shims (1) for thickness.
14. Install thrust plate (1) and shims (2) and secure with hardware.
15. Apply thin coat of clean oil to each sliding surface (1) of track
frame.
16. Install front idler (1) into track frame.
17. Torque thrust plate bolts to 190 NCm (140 lbf ft) on each side.
14 - 25
18. Install track adjuster (1) to front idler (2) and secure with
hardware. Torque bolts to 134 NCm (98 lbf ft).
19. Install track frame covers and secure with hardware. Torque
20. Install track chain, refer to SECTION 15.
14 - 26
TRACK ADJUSTER UNDERCARRIAGE
EXPLODED AND CROSS SECTION VIEWS OF TRACK ADJUSTER
14 - 27
UNDERCARRIAGE TRACK ADJUSTER
1. Adjuster Shield 5. Adjuster Check Valve 9. Rod Wiper

2. Scraper Plate 6. Front Idler Fork 10. Track Adjuster Rod
3. Adjuster Bleeder Plug 7. Piston Ring
4. Lube Fitting 8. Adjuster Piston
SPECIFICATIONS
Type of Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Acting
Weight of Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 kg (22 lbs)
Refill Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to OPERATION & MAINTENANCE MANUAL
Check Valve Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 NCm (50 lbf ft)
Safety Relief Valve Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 NCm (50 lbf ft)
Fork Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 NCm (98 lbf ft)
SERVICE
REMARK
in following steps.
1. Remove front idler, refer to FRONT IDLER. Remove front frame cover.
2. Separate fork (6) from rod (10).
3. Remove fork from track frame.
4. Release rod (10) from spring retainer and remove.
14 - 28
5. Remove check valve (5) with lube fitting (4) and bleeder plug (3).
6. Remove wiper seal (9) from fork.
7. Install a ½NC threaded rod into piston and remove from fork.
8. Remove piston ring (7) from piston (8).
9. Install piston ring (7) to piston (8) with "U" portion of ring facing away
from piston.
14 - 29
UNDERCARRIAGE TRACK ADJUSTER
10. Coat piston ring and bore of fork with clean grease. Install a ½NC
threaded rod into piston and insert into fork being careful not to cut or
slice piston ring on wiper ring groove.
11. Install wiper seal (9) into groove in fork (6) with lips facing out.
12. Install bleeder plug (3) and check valve (5) with lube fitting (4) to fork.
Torque each to 68 NCm (50 lbf ft).
13. Position rod (10) in spring retainer and rest on track frame.
14. Position fork (6) and slide down on adjuster rod being careful not to cut
or slice wiper ring.
14 - 30
15. Install track frame cover and secure with hardware. Torque mounting
16. Install front idler, refer to FRONT IDLER.
14 - 31
UNDERCARRIAGE TOP IDLER
EXPLODED AND CROSS SECTION VIEWS OF TOP IDLER
14 - 32
TOP IDLER UNDERCARRIAGE
1. Idler Housing 5. O-Ring 9. Roll Pin

2. Idler Shaft 6. Idler Cover 10. Port Plug
3. Inner Bearing 7. O-Ring 11. Bearing Spacer
4. Retaining Ring 8. Seal Retainer 12. Metal Type Face Seal
SPECIFICATIONS
Weight of Top Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 kg (34 lbs)

Refill Capacity and Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to OPERATION & MAINTENANCE MANUAL
O-Ring Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #2 MPG
Drain Plug Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #592
Drain Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 61 NCm (15 to 45 lbf ft)
REMOVAL
1. Relieve track tension, refer to SECTION 15. Remove track shoe to rear
of top idler.
REMARK
Make sure split link chain is not in the vicinity of top idler.
2. Remove track shoe to front of top idler.
3. Attach hoist to chain and lift off of top idler.
4. Between chain and frame, remove cinch mounting bolt from idler
support.
14 - 33
5. Using a chisel, spread idler support for removal of idler.
6. Remove idler from support.
DISASSEMBLY
REMARK
in following steps.
1. Position idler in vise. Remove plug (10) from cover and allow idler to
drain. When drained, remove hardware and cover (6) from idler.
2. Remove o-ring (5) and discard.
3. Remove retaining ring (4) from shaft.
14 - 34
4. Remove bearing spacer (11) from shaft.
5. Turn assembly around in vise. Drive out roll pin (9) from seal retainer.
6. Remove seal retainer (8) from shaft.
REMARK
Metal portion of seal half will usually stay with shaft.
7. Remove rubber portion of seal half (12) from seal retainer.
8. Remove o-ring (7) from seal retainer.
14 - 35
9. Remove metal portion of seal half (12) from shaft.
10. Remove metal portion of seal half (12) from idler body.
11. Remove rubber portion of seal half (12) from idler body.
12. Position assembly in press, cover side up. Apply press and remove shaft
(2) from idler body.
13. Remove loose bearing cone (3) from assembly.
14 - 36
14. Using a suitable puller remove rear bearing cup from idler body.
15. Turn roller body over in press and remove remaining bearing cup.
16. Install puller arrangement and press bearing (3) off shaft.
REMARK
Whenever a top idler is disassembled, used seals must pass an inspection
or a new seal used. Refer to METAL TYPE FACE SEALS in this section.
REASSEMBLY
REMARK
in following steps.
1. Position idler body in press and bottom bearing cup. Turn idler body over
and repeat for remaining bearing cup.
2. Heat bearing cone (3) to 135EC (275EF) for 45 minutes. Install on shaft
and bottom. To insure cone is seated, keep pressure against cone until
it cools.
14 - 37
3. Install idler body (1) over shaft (2). Heat bearing cone (3) to 135EC
(275EF) for 45 minutes. Install on shaft and bottom. To insure cone is
seated, keep pressure against cone until it cools.
4. Install bearing spacer (11) on shaft.
5. Install retaining ring (4) to shaft.
6. Install new o-ring (7) into seal retainer.
7. Install seal half (12) into seal retainer. Refer to METAL TYPE FACE
SEALS.
14 - 38
8. Install seal half (12) into idler body. Refer to METAL TYPE FACE SEALS
9. Coat o-ring in seal retainer (8) with #2 MPG and install on shaft.
10. Using a dowel pin to load seal retainer, install roll pin (9).
11. Install o-ring (5) into idler body.
12. Install cover (6) and secure with hardware. Torque bolts to 38 NCm (28
lbf ft) ±10%.
14 - 39
13. Fabricate an air pressure tester and connect to top idler at fill plug hole.

pressure.
14. Fill top idler with recommended type and quantity of lubricant. Refer to
15. Apply Loctite #592 to fill plug (10) and install. Torque plug to 20 to 61
NCm (15 to 45 lbf ft).
16. Rotate idler 5 to 10 revolutions to distribute lubricant.
INSTALLATION
1. Install top idler into support. Run a string between center of front idler
and center of sprocket.
14 - 40
2. Center top idler along string. Remove chisel.
3. Install crimp mounting bolt and torque to 180 NCm (140 lbf ft) ±10%.
Lower chain on top idler. Install track shoes and adjust chain, refer to
SECTION 15.
14 - 41
UNDERCARRIAGE TRACK ROLLER
EXPLODED VIEW OF TRACK ROLLER

1. Track Roller Body 4. Port Plug 7. O-Ring
2. Roller Body Bushing 5. Thrust Washer 8. Mounting Bracket
3. Track Roller Shaft 6. Metal Face Seal 9. Roll Pin
14 - 42
TRACK ROLLER UNDERCARRIAGE
CROSS SECTION VIEW OF TRACK ROLLER

SPECIFICATIONS
Weight of Roller;
D32E-1, D32P-1, D38E-1 or D38P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1 kg (42 lbs)
D39E-1 or D39P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.8 kg (48 lbs)
Refill Lubricant and Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to OPERATION & MAINTENANCE MANUAL
Drain Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 61 NCm (15 to 45 lbf ft)
Track Roller and Shield Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 NCm (195 lbf ft)
REMOVAL
1. Release chain tension, refer to SECTION 15. Jack up machine

approximately 153 mm (6 in) off ground and install suitable stands under
mainframe. Remove sprocket rock shields (1) and/or track roller shields
(if necessary) (2) from track frame.
2. Remove bolts securing track roller shaft brackets to underside of track

frame and remove roller. A tap with a soft hammer will usually free roller
if it tends to stick in frame.
14 - 43
3. If there is not enough track chain slack to remove roller, position jack
between chain and frame. Jack up until enough clearance is obtained to
remove track roller.
4. Remove roller from track frame.
DISASSEMBLY
REMARK
in following steps.
1. Remove drain plug (4) from roller shaft and drain into a suitable
container.
2. Drive out dowel pin (9) securing mounting bracket to shaft.
3. Remove mounting bracket (8) from shaft.
14 - 44
4. Remove outer half of metal type face seals (6) from assembly. Refer to
REMARK
Keep original mated metal rings as a set. Do not mix a metal ring from one
side of roller with other side.
5. Remove thrust washer (5).
6. Remove inner half of metal type face seals (6) from assembly. Refer to
REMARK
7. Remove shaft (3) with remaining mounting bracket (8).
8. Remove inner half of metal type face seals (6) from roller body. Refer
to METAL TYPE FACE SEALS in this section.
REMARK
14 - 45
9. Remove outer half of metal type face seals (6) from mounting bracket.
Refer to METAL TYPE FACE SEALS in this section.
REMARK
10. Remove thrust washer (5) from shaft.
11. Drive roll pin (9) from mounting bracket.
12. Position shaft (3) and mounting bracket (8) in press and separate. This
is required to overcome drag generated by internal o-ring.
13. Remove and discard o-ring (7) from each mounting bracket (8).
REMARK
Whenever a roller is disassembled, used seals must pass an inspection or
a new seal used. Refer to METAL TYPE FACE SEALS in this section.
14 - 46
CLEARANCES
1. Remove the bushings in idler body and replace with new. Coat 19 to 25
mm (0.75 to 1 in) of outer idler hub bores with Loctite #609.
2. Coat 19 to 25 mm (0.75 to 1 in) of leading edge of bushing (2) (edge

which engages bore first) with Loctite #609.
3. Position in press and install bushings 0.762 mm (0.030 in) below washer
face surface. A minimum press force of 6350 kg (14,000 lbs) is required
to install bushing. Repeat for remaining bushing.
4. Discard thrust washers and replace with new. Inspect the condition and
OD of roller shaft and replace as necessary. Coat bushings and thrust
washers with clean film of oil. Pin shaft to one mounting support. Install
thrust washer onto shaft. Insert shaft through roller and secure with
remaining mounting support. Position roller on blocking so that mounting
supports and shaft are free to rotate.
5. Position dial indicator on roller body with pointer on shaft and set to zero.
Pry up on mounting support and record reading on dial indicator. Repeat
a few time and average readings. Reading must be within specification.
If not check dimensions of all parts and repeat until clearance is
achieved. Disassemble assembly after clearance has been attained.
14 - 47
TRACK ROLLER CLEARANCES

D32E-1, D32P-1, D38E-1 or D38P-1 END CLEARANCE
A. Pin to Pin Holes in Shaft 8.406 to 8397 in. 213.512 to 213.284 mm
MINUS (!) MINUS (!)
MINUS (!) MINUS (!)
C. Roller Hub Washer to Washer Face 6.703 to 6.713 in 170.256 to 170.510 mm
MINUS (!) MINUS (!)
0.006 to 0.053 in. 0.152 to 1.346 mm

E. Bushing Assembled Inside Diameter 1.752 to 1.757 in. 44.501 to 44.628 mm
MINUS (!) MINUS (!)
F. Idler Shaft Diameter 1.744 to 1.742 in. 44.298 to 44.247 mm
0.008 to 0.015 in. 0.203 to 0.381 mm
D39E-1 or D39P-1 END CLEARANCE

MINUS (!) MINUS (!)
MINUS (!) MINUS (!)
MINUS (!) MINUS (!)
0.006 to 0.053 in. 0.152 to 1.346 mm

E. Bushing Assembled Inside Diameter 2.007 to 2.002 in. 50.978 to 50.851 mm
MINUS (!) MINUS (!)
F. Idler Shaft Diameter 1.992 to 1.994 in. 50.597 to 50.648 mm
0.008 to 0.015 in. 0.203 to 0.381 mm
14 - 48
REASSEMBLY
REMARK
in following steps.
1. Position mounting bracket (8) in vise. Install new o-ring (7) into bracket.
Apply a thin coat of #2 MPG to o-ring to aid in installation.
2. Install shaft (3) in bracket (8) and secure with roll pin. Be careful not to
damage internal o-ring.
3. Install thrust washer (5) over shaft in bracket.
4. Install one half of metal type face seal (6) into bracket. Refer to METAL
TYPE FACE SEAL .
5. Install one half of metal type face seal (6) into roller body. Refer to
METAL TYPE FACE SEAL .
14 - 49
6. Install roller (1) over shaft.
7. Install one half of metal type face seal (6) into roller body. Refer to
METAL TYPE FACE SEAL .
8. Install thrust washer (5) against idler body.
9. Install new o-ring (7) into bracket. Apply a thin coat of #2 MPG to o-ring
to aid in installation.
10. Install one half of metal type face seal (6) into mounting bracket. Refer
to METAL TYPE FACE SEAL .
14 - 50
11. Position assembly in press. Install remaining mounting bracket (8) on

shaft. Apply press and align pin holes with dowel. Install roll pin (9).
12. Fabricate an air pressure tester and connect to track roller at fill plug
hole.

pressure.
13. Fill top idler with recommended type and quantity of lubricant. Refer to
14. Apply Loctite #592 to fill plug (4) and install. Hold mounting bracket (8)
with utility bar and torque plug to 20 to 61 NCm (15 to 45 lbf ft).
15. Using utility bar, rotate assembly ten to fifteen revolutions to insure initial
sealing.
14 - 51
INSTALLATION
1. Place roller assembly in position under track frame with lube plug facing
out. Secure roller to track frame by first installing forward bolts to bring
bracket in contact with track frame, then install rear bolts.
2. Torque bolts to 134 NCm (98 lbf ft) for D32E-1, D32P-1, D38E-1 or
D38P-1 and 267 NCm (195 lbf ft) for D39E-1 or D39P-1. Remove any
jacks between track chain and track frame.
3. Install track roller shields to track frame and torque to 267 NCm (195 lbf
ft). Install sprocket rock shields and torque bolts to 267 NCm (195 lbf ft).
Remove stands from machine and lower to ground. Adjust track tension
per SECTION 15.
14 - 52
METAL TYPE FACE SEALS UNDERCARRIAGE
SEAL INSPECTION
1. Check condition of rubber seal rings. If any sign of wear, scratches,

nicks, cuts, etc. replace complete seal. Inspect condition of metal ring
seal surfaces as follows. Highly polished surfaces of rings must be free
of chips, pocks and deep scratches.
2. Narrow highly polished sealing bank must be within outer half of sealing
face.
3. Narrow band must be uniform and concentric with ID and OD. If metal
rings do not conform to these specifications, discard seal and replace
with new.
4. If metal rings conform to specifications above, clean and check rings as

follows.
Remove any corrosion or hardened material that may exist on surface
A. Use a scraper and/or any stiff bristled fiber brush to remove this
material from entire surface. Wash rings with non flammable solvent
to remove all oil and wipe dry. Use a lint free wiper to remove all traces
of oil or grease from all surfaces. Apply a thin coat of clean Grade 30
oil on sealing face of metal rings. Do not allow oil to wet other
surfaces. Slide sealing faces of two metal rings together. Bottom ring
should cling to top ring for a minimum of two seconds when lifted by
top ring. If they fail to cling, discard seal and replace with new.
14 - 53
UNDERCARRIAGE METAL TYPE FACE SEALS
SEAL INSTALLATION
REMARK
Cleanliness is critical when handling seals. Never handle seal with greasy,
oily or dirty hands. Do not drop, bump or roughly handle seals.
1. Remove any corrosion or hardened material that may exist on surface

(1) that contact rubber rings. Use a non petroleum base solvent and wipe
dry with a lint free wrapper. Make sure outer edge (2) is free of burrs.
2. Break plastic protector band (1) if applicable, by inserting a sharp tool (2)
at edge of band. Be careful not to scratch or damage seal faces (3). Do
not cut or damage rubber rings (4).
3. Carefully remove plastic band and gently "slide" (1) two seal halves
apart. Metal ring faces must not be damaged or contaminated. Check to
be sure rubber rings are flush (2) against inside shoulder of metal ring.
4. Install one seal half (1) into receptacle (2) so protruding lip just contacts
seal bore. Press with both clean hands (180E apart) against metal ring
until rubber ring is evenly seated against bore shoulder. Make sure seal
is not cocked in bore. Repeat procedure for other seal half (3) and
receptacle (4). Wipe both metal ring sealing faces clean (5) with a lint
free wiper. Apply a light coat (6), just enough to wet faces, of clean
lubricant to seal faces of metal rings.
14 - 54
METAL TYPE FACE SEALS UNDERCARRIAGE
5. Final installation assembly will energize seal as shown, so that rubber

rings load seal and drive mating metal rings together.
14 - 55
UNDERCARRIAGE TRACK FRAME
REMOVAL
1. Raise machine and position on stands:
Machine Rear: Install mounting blocks DR11-714 (1) to rear frame and
position on stands.
Machine Front: Install stands under front crossbar.
2. Remove track chain per SECTION 15. Remove front idler, track adjuster
and covers per this section.
3. Remove top idler.
4. Install large eye bolt to idler mounting bracket and attach hoist.
5. Remove inner and outer sprocket rock deflectors from rear of track
frame.
14 - 56
TRACK FRAME UNDERCARRIAGE
6. Remove rear rigid bar lock plate and shims.
7. Remove front crossbar mounting hardware.
8. Using hoist and pry bar, remove track frame from machine.
INSTALLATION
Refer to TRACK FRAME ALIGNMENT in this section.
14 - 57
UNDERCARRIAGE TRACK SPRING
EXPLODED AND CROSS SECTION VIEWS OF SPRING IN TRACK FRAME

1. Front Spring Seat 2. Rear Spring Seat 3. Track Spring
14 - 58
TRACK SPRING UNDERCARRIAGE
SPECIFICATIONS
D32E-1, D32P-1, D38E-1 or D38P-1
A. Assembly Installation Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550.5 mm (21.673 in)

B. Spring Solid Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406.4 mm (16 in)
Solid Length Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112.32 kn (25,250 lbs)
C. Tool Head to Bulkhead Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.58 mm (0.85 in)
D. Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535.4 mm (21.08 in)
E. Assembled Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439.42 mm (17.3 in)
F. Assembled Length in Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496.5 mm (19.54 in)
Track Spring:
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535.94 mm (21.1 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463.55 mm (18.25 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406.40 to 463.55 mm (16 to 18.25 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.28 kn ± 10% (14000 lbs ± 10%)
Number of Working Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44
Weight of Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.31 kg (71.22 lbs)
D39E-1 or D39P-1
A. Assembly Installation Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550.5 mm (21.673 in)

B. Spring Solid Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388.62 mm (15.3 in)
Solid Length Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.33 kn (27,501 lbs)
C. Tool Head to Bulkhead Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.84 mm (0.702 in)
D. Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553.72 mm (21.8 in)
E. Assembled Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426.72 mm (16.8 in)
F. Assembled Length in Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480.06 mm (18.9 in)
Track Spring:
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553.7 mm (21.8 in)
Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441.96 mm (17.4 in)
Work Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388.62 to 441.96 mm (15.3 to 17.4 in)
Test Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.74 kn ± 10% (18600 lbs ± 10%)
Weight of Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.824 kg (90 lbs)
SPECIAL TOOLS
Track Spring Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR11-713

Containment Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR11-713-1
Track Spring Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR11-713-2
Track Spring Bolt Nut (26 009 R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR11-713-3
Ram Push Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR11-713-4
Push Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR11-713-5
Bolt Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR11-713-6
Track Spring Coffin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR11-700-1
Pusher Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR11-700-2
Spacer Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR11-700-4
Spacer Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR11-700-5
14 - 59
REPLACEMENT
WARNING
Please observe all safety and precautionary standards as dictated
by environment and work conditions under which equipment will be
inspected, reworked and repaired. Consult SECTION 1 and your
Komatsu distributor on any and all questions regarding safety.
1. Remove track frame from machine as described in this section. Position

frame (1) on suitable blocking as shown. Remove track roller shields (2).
2. Remove hardware from 2nd and 3rd rear track roller.
3. Attach hoist and sling to rollers and remove.
4. Install containment plate, DR11-713-1, between track roller mounting

surfaces.
5. Insert spring bolt, DR11-713-2, through housing and spring.
14 - 60
6. Install ram push support, DR11-713-4, (1) to frame. Install ram (2) and
connect push rod, DR11-713-5, (3) to spring bolt (4).
7. Activate ram to compress spring.
8. Install nut, DR11-713-3, to spring bolt.
9. Remove containment plate from track frame. Position sling hoist to

frame. Let off ram allowing sling to support track spring. Remove spring
from frame.
10. Position spring coffin, DR11-700-1, (1) with pusher plate, DR11-700-2,
(2) on work table. Position blocking (3) so that spring bolt retainer nut will
center through access hole.
14 - 61
11. Insert captured spring into coffin with nut end toward access hole.
12. Install bolt collar, DR11-713-6, to spring bolt head.
13. Position ram (1) in coffin and fully extend. Measure distance from stroked
ram to pusher plate (2). Add blocking (3) 6.3 mm (1/4 in) longer than
measured distance. Destroke ram and add blocking. Stroke ram until
spring bolt retainer nut is free of load.
14. Remove spring bolt retainer nut.
15. Let off ram until spacer bars, DR11-700-4, (1) retain spring. Insert
smaller blocking against ram. Engage ram and remove spacer bars.
14 - 62
16. Let off ram until spacer bars, DR11-700-5, (1) retain spring. Remove
blocking against ram. Engage ram and remove spacer bars.
17. Slowly let off ram until spring decompresses. Install sling and remove
from coffin.
18. Install spring (1) with retainers (2), spring bolt (3) and bolt collar (4) into
coffin. Center spring bolt with wire.
19. While supporting spring bolt, fully apply ram.
20. Install short spacer bars (1) and let off ram. Install blocking (2) and apply
ram. Remove short spacer bars.
14 - 63
21. Install long spacer bars (1) and let off ram. Install blocking (2) and apply
ram. Remove long spacer bars.
22. Apply ram directing spring bolt through access hole.
23. Install retainer nut. Compress spring until assembly installation length is
attained. Refer to SPECIFICATIONS.
24. Remove captured spring from coffin.
25. Install captured spring (1) into track fame with retainer nut (2) towards
rear.
14 - 64
26. Apply ram to connect push rod (1) to spring bolt (2).
27. Install containment plate.
28. Apply ram and remove retainer nut from spring bolt. Slowly let off ram
allowing spring to seat in track frame.
29. Remove containment plate (1) and lifting strap (2).
30. Install removed track rollers and secure with hardware. Torque bolts to
134 NCm (98 lbf ft) for D32E-1, D32P-1, D38E-1 or D38P-1 or 267 NCm
(195 lbf ft) for D39E-1 or D39P-1.
14 - 65
31. Install track roller shields and secure with hardware. Torque shield to
frame bolts to 267 NCm (195 lbf ft).
32. Torque shield spacer bolts to 455 NCm (335 lbf ft).
33. Install track frame, refer to TRACK FRAME in this section.
14 - 66
FRONT CROSSBAR UNDERCARRIAGE
REMOVAL
1. Remove track frames from each side of machine. Refer to TRACK

FRAME in this section.
2. Block at rear of machine as shown using DR11-714.
3. Position blocking (1) at front of machine under radiator guard portion of

front frame.
D32E-1 or D32P-1; DO NOT block under C frame.
D38E-1, D38P-1, D39E-1 or D39P-1; Position blocking (2) under C

frame on each side.
4. If equipped, remove hose clamps at each side of frame.
5. On each side of machine, tie strap two top hoses (1) to lift cylinder tube.
Disconnect and cap lower hose (2) and position out of way in C frame.
6. D32E-1 or D32P-1; Position equipment lever in blade float (full forward).

On each side of machine, attach lifting sling at C frame towers and
connect to hoist. Remove hardware from C frame trunnions. Lower C
frame using hoist.
D38E-1, D38P-1, D39E-1 or D39P-1; On each side of machine, remove

hardware (1) from C frame trunnions (2). Allow each trunnion to swing
forward.
14 - 67
UNDERCARRIAGE FRONT CROSSBAR
7. On each side of machine, attach lifting sling and hoist to front crossbar.
8. On each side of machine, remove retaining ring (1) and ring retainer (2)
from mounting pin.
9. On each side of machine, drive out mounting pin.
10. Lower crossbar and remove from machine.
INSTALLATION
1. Position crossbar (1) into machine. Coat mounting pins (2) with "Never
Seez" and install with rear ring retainer and retaining ring on each side
of machine.
14 - 68
FRONT CROSSBAR UNDERCARRIAGE
2. On each side of machine, install ring retainer (1) to mounting pin (2).
3. On each side of machine, install retaining ring (1) to mounting pin (2).
4. Each side of machine, apply Loctite Plastic Gasket or #568 to mounting

surfaces of C frame trunnions.
5. D32E-1 or D32P-1: Using hoist and slings lift C frame and connect
trunnion with hardware on each side of machine.
D38E-1, D38P-1, D39E-1 or D39P-1: On each side of machine, rotate

trunnion (1) in position and secure with hardware.
14 - 69
UNDERCARRIAGE FRONT CROSSBAR
7. On each side of machine, reconnect bottom hose (1) to manifold. Cut

loose upper hoses (2).
8. If equipped, on each side of machine, install hose bracket and secure

with hardware. Torque bolts to 92 NCm (70 lbf ft) ±10%.
9. On each side of machine, install track frame. Refer to TRACK FRAME

in this section.
14 - 70
REAR RIGID BAR UNDERCARRIAGE
REPLACEMENT
1. Remove track frames from each side of machine. Refer to TRACK

FRAME in this section.
2. On each side of machine, attach lifting slings and hoist to rear rigid bar
(1). Match mark half block (2) to welded block and remove hardware.
3. Remove rear rigid bar from machine.
4. Position rear rigid bar in place and loosely secure with half block and
hardware.
5. On each side of machine, position rear rigid bar at equally spaced

positions and secure with hardware. Torque bolts to 780 NCm (580 lbf ft)
±10%
REMARK
When positioning rear rigid bar, keep retaining slot in bar horizontal.
6. On each side of machine, install track frame. Refer to TRACK FRAME

in this section.
14 - 71
UNDERCARRIAGE TRACK FRAME ALIGNMENT
TRACK FRAME ALIGNMENT
1. Centerline of Sprocket 5. Front Centerline of Machine

2. Centerline of Rear Roller to Sprocket 6. Centerline of Front Idler
3. Required Shims and Lock Bar 7. Centerline of Machine to Front Idler
4. Centerline of Machine to Sprocket 8. Center of Top Idler To Sprocket and Front Idler
1. Position track frame (1) on rear rigid bar (2) and move into place under
front cross bar (3).
2. Attach track frame to front crossbar (1) with hardware in a loose

condition.
14 - 72
TRACK FRAME ALIGNMENT UNDERCARRIAGE
3. Determine center line of sprocket along five or six teeth. Average

readings and record.
4. Center rear track roller (1) with sprocket (2) by moving track frame (3)
in or out on rear rigid bar.
5. Install required shims (1) and lock bar (2) and secure with hardware.
7. Measure and record dimension from centerline of machine to center line

of sprocket.
14 - 73
UNDERCARRIAGE TRACK FRAME ALIGNMENT
8. Install track adjuster (1) in track frame.
9. Install front idler (1) with keeper tabs, DR11-715 (2), to track frame.
10. Determine front centerline (1) of machine and position large scale (2)
through C frame out over front idler.
11. Determine centerline of front idler (1).
12. Determine amount of in or out movement of track frame from dimension

attained in Step 7.
14 - 74
TRACK FRAME ALIGNMENT UNDERCARRIAGE
13. Using a magnetic base pointer (1) at centerline of front idler, move track
frame in or out and snug up crossbar bolt when achieved.
Remove tooling from front idler. Attach track adjuster to front idler and
install track fame covers, refer to FRONT IDLER in this section.
15. Run a line between center of sprocket and front idler and center top idler
(1).
16. Torque bolt to 180 NCm (140 lbf ft) ±10%. Repeat entire procedure for
remaining side.
17. Install track chain and adjust. Refer to SECTION 15.
14 - 75
TRACK CHAIN
SECTION 15
SPLIT LINK TYPE CHAINS . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COMPLETE CHAIN REBUILD . . . . . . . . . . . . . . . 6
SINGLE TRACK CHAIN JOINT REBUILD . . . . . . 8
WARNING
15 - 1
TRACK CHAIN SPLIT LINK TYPE CHAINS
EXPLODED VIEW OF TRACK CHAIN

(SINGLE NOTCH SPLIT LINK)
1. Right Split Link - Pin 4. Link Pin 7. Left Chain Link 10. Pin Plug
2. Left Split Link - Pin 5. Thrust Ring 8. Left Split Link - Bushing 11. Chain Seal
3. Link Bushing 6. Right Chain Link 9. Right Split Link - Bushing
15 - 2
SPLIT LINK TYPE CHAINS TRACK CHAIN
EXPLODED VIEW OF TRACK CHAIN

(MULTIPLE NOTCH SPLIT LINK)
15 - 3
CROSS SECTION VIEW OF TRACK CHAIN

SPECIFICATIONS
Number of Links (Including Split Master Link) - One Chain:

D32E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
D32P-1, D38E-1 or D38P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
D39E-1 or D39P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See SECTION 14
Press Generated Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82000 lbs (365 kN)
Weight - D32E-1 - One Complete Chain:
With 381 mm (15 in) Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517 kg (1140 lbs)
With 381 mm (15 in) Mud Relief Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502 kg (1107 lbs)
Weight - D32P-1 or D38P-1 - One Complete Chain:
Weight - D39P-1 - One Complete Chain:
Seal Tester and Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR11-808
91 Mg (100 Ton) Portable Track Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DR11-802-2
Twin Head Hydraulic Track Table Press and Small Hydraulic Ram . . . . . . . . . . . . . . . . . . . . . . . . . Purchase Locally
Bushing Projection Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45 mm (0.057 in)
Pin Projection Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Outer Half of Pin Bore of Link Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite #680
Pin Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85W140 EPGL or 80W90 EPGL
Track Shoe Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 ±20 NCm (65 ±15 lbf ft) Plus 120E
15 - 4
DESCRIPTION
The interlocking type track chain consists of drop forged heat treated steel
links (6 and 7) and drop forged heat treated split links (1, 2, 8 and 9) which
are held together by bushings (3) and pins (4) to form a continuous chain.
The bushings and pins are press fitted to the links, with the pins pivoting
inside of the bushings. The pin has a hollow center which is used as a
hydraulic reservoir. A cross drilled passage permits the oil to enter the
bushings for lubrication of the pins, bushings and oil seals. The plug (10)
retains the oil in the pin. Oil seal (11) seals against lubricant loss and
prevents the entrance of contaminants.
The track shoes are mounted to the track links, and are held in place with
heat treated dome head bolts with integral washers. The split links are bolted
together with longer track shoe bolts to form a continuous chain.
MAINTENANCE
The track links have only one wearing surface which contacts the track
rollers, front idler and track idlers. However, it usually becomes necessary to
replace pins and bushings before the links wear out, and it is a matter of
judgement then whether the links are good enough to justify a new set of pins
and bushings. Only the wear on the outside of the bushings is visible. Wear
on the pins and interior of the bushings is indicated by track stretch (forward
adjustment of the front idler). The amount of wear can be determined by
measuring the pitch length of the track (distance between centers of pins)
under tension and comparing it with new and maximum allowable pitch
lengths listed in SECTION 14. Sprocket wear must also be considered in
conjunction with track chain wear.
Wear of the sprocket teeth decreases the pitch length of the sprocket, while
wear of pins and bushings increases the pitch length of the track. The results
are that the pitch lengths of the sprocket and track becomes more and more
out of phase, and the bushings ride higher on the sprocket teeth. Combined
wear of sprocket and track should never be allowed to reach this point.
Whenever new or rebuilt track chains are installed, the sprocket should also
be replaced or interchanged to present the better side of teeth to the
bushings. Never remove one link to bring a stretched track to within the range
of proper track adjustment. A track that is worn badly enough to take up the
length of one link, will be so far out of pitch that the increased wear on the
sprocket will far more than offset the saving obtained by the removal of one
link in the track chain.
15 - 5
REMOVAL
1. Move machine forward until split link is on front lower half of front idler.
Relieve track tension per OPERATION & MAINTENANCE MANUAL.
Block up under shoe and remove split link bolts and shoe.
WARNING
When split link bolts and track shoes are removed, chain is free to
separate. Before disconnecting chain for any reason, be sure to re-
lieve all track adjuster pressure. This must be done for safety rea-
sons.
2. Move machine backward until sprocket is at end of chain. Place a plank
flush against rear of chain when it is flat on ground. Plank should be
approximately same thickness and width as chain and long enough so
that entire machine can rest on plank. Move machine off chain and onto
plank.
INSTALLATION
1. Position chain in front of plank with split link half with shoe surface
against plank. If chain is reversed from position shown above, severe
undercarriage wear will result. Block up front of chain. Drive machine
forward onto chain. As sprocket passes end of chain, pull chain over
sprocket and top idler. Stop machine when front idler contacts blocked
up chain.
2. Be sure machined surfaces of split links are clean. Interlock split link
halves in front of front idler. Align link side surfaces and install bolts to
check alignment. Remove bolts. Install track shoe and bolts and torque
to value given. Adjust track tension. Refer to OPERATION & MAINTE-
NANCE MANUAL
REMARK
Two methods for repairing a chain are available. One method is to repair
complete chain using a twin head table press. The other is to rebuild only
leaking joints using portable 91 mg (100 ton) track press.
COMPLETE CHAIN REBUILD
Disassembly
1. Using a slow speed drill and a 0.50 in or 12 mm drill bit, remove rubber
plugs (10) from pins (4). Position chain on press so that bushing end
(non threaded end) of split link (9 and 10) is toward rams. Remove track
shoes.
2. Install disassembly adapters on ram heads. Advance chain and lower

table so split link drops into saddle. Press pin out of right link (8), then
press pin out of left link (9). Remove loose split links from press.
3. Advance track chain so next link drops into saddle. Press pin (4) and
bushing (5) out of right link (7), then press pin and bushing out of left link
(6). Remove loose links, bushing and pin from press.
4. Repeat Step 3 with remaining sections of chain. Remove seals (11) from
chain links.
15 - 6
Reassembly
1. On new or reused pins, index a mark (1) on hole end (2) of pins on
opposite side of lube hole (3).
2. Adjust press to above specified force. Install assembly adapters on ram

heads. Bolt split links together and position on press assembly adapters.
Position a bushing in press saddle. Press links onto bushing to projection
height (1) specified. Remove bolts securing two halves together.
3. Advance chain on press and position a pin in assembled bushing. Apply

a coat of oil on ends of bushing with tissue (not your fingers) being
careful not to get it on pin surface. Position next bushing in press saddle.
4. Install o-rings (2), seals (1) and spacers (6) in counterbore of next chain
links. Apply Loctite #680 sparingly in outer half of pin bore of links.
Position links on press assembly adapters. Check that index mark is at
bottom. All lube holes must face same direction. Press links onto pins
and bushings being sure that link counterbore and bushing face are
seated against spacer. Do not exceed force indicated as this can
damage spacer. Do not adjust links for bolt hole location. After chain is
moved to next position, place a rubber plug in end of pin of completed
joint. Tap it in until it is flush or slightly below chamfer of pin hole.
15 - 7
5. Check seal by inserting nozzle of lubricator through plug. Pull a vacuum

of 67.53 kPa (20 in Hg (mercury)) and hold for 10 seconds. In event that
vacuum cannot by held, either seal to bushing face or chain pin to link
bore mating surfaces are leaking. To determine which side is leaking,
pressurize joint with 34 kPa (5 psi) of air pressure, apply soap solution
to both seal areas and check for bubbles. After determining which side
is leaking, joint must be rebuilt. After vacuum holds for 10 seconds,
press lubricant button on nozzle and fill evacuated pin under 103 to
172 kPa (15 to 25 psi). Use 85W140 or 80W90 EPGL with 0.02% red
dye. Remove lubricator. Prepare chains for transport back to machine.
REMARK
Once joint is lubricated, there is no way of checking for leaks.
SINGLE TRACK CHAIN JOINT REBUILD

Disassembly
1. Using a slow speed drill and a ½ in or 12 mm drill bit, remove rubber
stopper from leaking joint pin.
2. Using press, secure aligning adapter in end of press C frame. Block
chain off ground and position press over chain so that forcing pin will be
against end of track pin opposite lube hole. Press pin from joint.
3. Using a small hydraulic ram, spread links about 6.35 mm (0.25 in) and
separate chain being careful not to damage seal. Remove oil seals and
spacers from links.
4. Inspect for wear, damage or improper assembly. If wear, damage or

improper assembly is present, proceed with Step 5. If no wear damage
or improper assembly is present, proceed to REASSEMBLY.
5. Drill out plug from next pin to right of leaking joint as described in Step
1. Block chain off ground and press pin out as described in Step 2.
6. Using small hydraulic ram, spread link about 6.35 mm (0.25 in) and
remove track link being careful not to damage seal. Remove oil seals
and spacers from links.
7. Secure bushing disassembly adapter in end of press C frame. Position
adapter in press C frame and adapter on ram. Remove aligning adapter
from press C frame and install bushing adapter. Using press, remove
long pin from threads of ram and thread short pin on ram. Position press
over one side link. Using bushing pusher, press link off bushing.
15 - 8
8. Turn link over and reposition press over remaining side link. Using
bushing pusher, press link off bushing. Inspect parts for wear, damage
or improper assembly. Discard any parts which would adversely affect
rebuild.
Reassembly
1. Dress up parts with emery cloth as required. Secure rear bushing

assembly plate in press C frame. Position press over one link. Using
bushing adapter, press new bushing in link until it bottoms against
adapter.
2. Turn link over and reposition press over second link. Using bushing
installer, press bushing into second link until it bottoms against adapter.
Be sure counterbores in links are clean.
3. Install o-rings, seals and spacers in counterbores.
15 - 9
4. Using small hydraulic ram spread link about 6.35 mm (0.25 in) and
position link over next link being careful not to damage seals. Line up
links and slip in forcing pin. Remove ram. Secure aligning adapter in end
of press C frame and thread short pin on ram.
5. On new or REUSED pin, mark an index mark (1) on lube hole end of pin
so that it is opposite from cross drilled hole (3). Position track pin in bore
of press C frame so that lube hole (2) is facing out and index mark is
opposite track shoes when installed.
6. Position press over track. Press pin in, stopping before pin enters last
link. Relieve pressure on press and remove forcing pin.
7. Apply Loctite #640 in outer half of bore of last link.
15 - 10
8. Apply Loctite #640 on O.D. of pin. Push completely in. Repeat this step
on next joint. Place a rubber stopper in end of pin so that it is flush with
or slightly below bottom of chamfer in hole and insert nozzle of lubricator
into plug. Pull a vacuum of 67.53 kPa (20 in Hg (mercury)) and hold for
10 seconds to check seals. In event vacuum cannot be held, either seal
to bushing face or track pin to link pin boss mating surfaces are leaking.
Joint must be rebuilt. Release lubricant into evacuated pin and fill to 103
to 172 kPa (15 to 25 psi). Use 85W140 or 80W90 extreme pressure gear
lubricant. Repeat this step on remaining pins.
15 - 11
MOUNTED EQUIPMENT
SECTION 17
C FRAME RUB BARS . . . . . . . . . . . . . . . . . . . . 2

MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ANGLING FRAME . . . . . . . . . . . . . . . . . . . . . . . 4
BUSHING REPLACEMENT . . . . . . . . . . . . . 4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 5
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . 5
C FRAME PIN . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PIN SHIMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BLADE BUSHINGS . . . . . . . . . . . . . . . . . . . . . . 8
WARNING
17 - 1
MOUNTED EQUIPMENT C FRAME RUB BARS
MOUNTING
D32E-1 OR D38E-1
1. C Frame 2. Rub Bar 3. Spacer Plate 4. Nominal Gap 5. Shims
6.35 ±1.5 mm
(0.25 ±0.06 in)
Center C frame (1) on machine. Bolt rub bar (2) and spacer plate (3) without shims. Measure gap (4) between rub bar
and C frame plate along length. Install shims (5) between spacer plate and track frame mounting block to establish a
nominal gap. Torque bolts to 180 NCm (140 lbf ft) ±10%.
D32P-1 OR D38P-1
1. C Frame
2. Rub Bar 3. Spacer Plate 4. Nominal Gap 5. Shims
6.35 ±1.5 mm
(0.25 ±0.06 in)
Center C frame (1) on machine. Bolt rub bar (2) and spacer plate (3) without shims. Measure gap (4) between rub bar
and C frame plate along length. Install shims (5) between spacer plate and track frame mounting block to establish a
nominal gap. Torque bolts to 180 NCm (140 lbf ft) ±10%.
17 - 2
C FRAME RUB BARS MOUNTED EQUIPMENT
REMARK
D39E-1 does not require rub bar and shimming.
D39P-1
1. C Frame 2. Rub Bar 3. Nominal Gap 4. Shims
6.35 ±1.5 mm
(0.25 ±0.06 in)
Center C frame (1) on machine. Bolt rub bar (2) without shims. Measure gap (3) between rub bar and C frame plate
along length. Install shims (4) between spacer plate and track frame mounting block to establish a nominal gap. Torque
17 - 3
MOUNTED EQUIPMENT ANGLING FRAME
BUSHING REPLACEMENT
ANGLING FRAME
17 - 4
ANGLING FRAME MOUNTED EQUIPMENT
1. Angling Frame 3. Angling Bushing 5. Pin Seal 7. Pin Seal

2. Wear Plate 4. Blade Pin Bushing 6. Cylinder Bushing 8. Lube Fitting
SPECIFICATIONS
Wear Plate New Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.35 mm (0.25 in)

Wear Plate Maximum Wear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When no Shims Can Be Used
Wear Plate Overhang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.35 mm (0.25 in)
Wear Plate Weld Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.35 mm (0.25 in)
Angling Bushing Press Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flush with Mounting Surface
Blade Pin Bushing Press Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.87 mm (0.31 in)
Cylinder Bushing Press Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.35 mm (0.25 in)
REMARK
Before performing any service on angling frame, preview general
welding manual SM-WELD-2.
1. Using a cutting torch, remove plate weld. After cool down period
grind off any remaining weld or excessive metal to provide a
smooth surface for new wear plate.
2. Position new wear plate (2) to angling frame (1) at dimensions

shown. Secure on place with c clamps. Weld a bead along front
outside edge and rear inside edge.
3. Remove old bushing from frame. Press in new bushing (3) flush
with edges of frame.
4. Remove and discard pin seals (5), replace with new. Drive old
bushing out. Position new bushing (4) in place and press in to
dimension shown. Install new pin seals flush with surface face
by only driving in on outer steel shells.
5. Remove and discard pin seals (7), replace with new. Drive old
bushing out. Position new bushing (6) in place and press in to
dimension shown. Install new pin seals flush with surface face
by only driving in on outer steel shells.
ADJUSTING
Periodically or as required the lower (1) and upper (2) shims (both
sides) may have to be removed to take up wear between the angling
frame (3) and the blade (4). The gap between the angling frame and
blade should not exceed 3 mm (0.12 in) minimum gap.
The lower shim pack is to consist of no less than 1 shim and no

more than 6 shims. The upper shim pack is to consist of no less than
2 shim and no more than 7 shims. The gap should permit free
movement between the angling frame and blade without any
binding.
17 - 5
MOUNTED EQUIPMENT C FRAME PIN
PIN SHIMS
1. Shim gap between angling frame and C frame as required to

minimize gap to permit free movement without any binding. A
minimum of one shim to a maximum of two shims allowed.
2. Install one shim at this location.
3. Shim gap between angling frame and C frame as required to

minimize gap to permit free movement without any binding. A
minimum of four shims to a maximum of six shims allowed.
17 - 6
C FRAME MOUNTED EQUIPMENT
BUSHING REPLACEMENT
C FRAME
1. C Frame 2. Trunnion Pin Bushing 3. Cylinder Pin Bushing 4.Pin Seal
1. Remove old bushing from frame. Press in new bushing (2) flush with outside edge of C frame.
2. Remove and discard pin seals (4), replace with new. Drive old bushing out. Position new bushing (3) in place and
press in to dimension shown. Install new pin seals flush with surface face by only driving in on outer steel shells.
17 - 7
MOUNTED EQUIPMENT BLADE BUSHINGS
BUSHING REPLACEMENT
BLADE BUSHINGS
1. Blade 2. Trunnion Pin Bushing 3. Cylinder Pin Bushing 4.Pin Seal
1. Remove old bushing from blade. Press in new bushing (2) flush with inner edge of tube in blade.
2. Remove and discard pin seals (4), replace with new. Drive old bushing out. Position new bushing (3) in place and
press in to dimension shown. Install new pin seals flush with surface face by only driving in on outer steel shells.
17 - 8
Komatsu America International Company
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Technical Publications
PROPOSAL FOR MANUAL REVISION
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
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If more space is needed, use another sheet.
FOR INTERNAL USE ONLY

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D39E-1 Shop Manual

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CEBM003100

NOV 98 COPYRIGHT 1998 KOMATSU AMERICA INTERNATIONAL COMPANY

DESCRIPTION FORM NUMBER

PARTS BOOK - PAPER:

ENGINE AND CHASSIS - D32E-1 & D32P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB004300

PARTS BOOK - MICROFICHE:

ENGINE AND CHASSIS - D32E-1 & D32P-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPM004300

OPERATION AND MAINTENANCE MANUAL:

SAFETY MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLT80-1

STREET ADDRESS ORDER DATE

PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE

KDC91D 081696 CURRENT PRICES WILL BE CHARGED

This shop manual includes information for locations, INTRODUCTION — SECTION 1

DRIVE TRAIN — SECTION 7

TORQUE CONVERTER — SECTION 7B

STEERING DRIVE — SECTION 7E

SPROCKET DRIVE — SECTION 7F

PUMPS AND MOTORS — SECTION 10A

CONTROL VALVE — SECTION 10B

CYLINDERS — SECTION 10C

TRACK CHAIN — SECTION 15

MOUNTED EQUIPMENT — SECTION 17

SECTION 1 - INTRODUCTION SECTION 7F - FINAL DRIVE

WORK SAFETY -- FOLLOW THESE RULES

A CAREFUL MECHANIC IS THE BEST INSURANCE AGAINST AN ACCIDENT

BEFORE STARTING THE ENGINE

Keep your work area as smooth as possible and free of obstructions.

SAFETY PRODUCT GRAPHICS AND LOCATION

SAFETY PRODUCT GRAPHIC LOCATION

1. General Caution 4. Track Adjuster Caution

This illustration shows the D32E-1

Designation of the blade if present is stamped on the back or side of blade,

SETTING TIME (BEFORE PLACING IN OPERATION)

D32E-1, D32P-1 SPECIFICATIONS

! Blade capacity 1.2 m³ (1.6 yd³) 1.45 m³ (1.9 yd³)

! Travel speeds Forward 1st 3.6 km/h (2.2 mph)

2nd 6.0 km/h (3.7 mph)

3rd 9.3 km/h (5.8 mph)

Reverse 1st 4.3 km/h (2.7 mph)

2nd 6.5 km/h (4.1 mph)

3rd 11.2 km/h (7.0 mph)

! Maximum drawbar pull 11681 kg (25751 lbs)

! Model Komatsu 4D102E-1 Diesel Engine

! Flywheel horsepower 52 kW (70 hp) @ 2500 RPM

! Maximum torque 268 NCm (198 lbf ft) @ 1200 RPM

! Starting motor 2.7 kW (12V)

! Alternator 2.7 kW (12V) @ 65A

! Battery 2.7 kW (12V) @ 700 CCA

D38E-1, D38P-1 SPECIFICATIONS

! Blade capacity 1.45 m³ (1.9 yd³) 1.45 m³ (1.9 yd³)

! Travel speeds Forward 1st 3.3 km/h (2.1 mph)

2nd 5.6 km/h (3.5 mph)

3rd 9.3 km/h (5.8 mph)

Reverse 1st 4.0 km/h (2.5 mph)

2nd 6.7 km/h (4.1 mph)

3rd 11.2 km/h (6.9 mph)

! Maximum drawbar pull 14217 kg (31343 lbs)

! Model Komatsu S4D102E-1 Diesel Engine

! Flywheel horsepower 60 kW (80 hp) @ 2500 RPM

! Maximum torque 324 NCm (239 lbf ft) @ 1500 RPM

! Starting motor 2.7 kW (12V)

! Alternator 2.7 kW (12V) @ 65A

! Battery 2.7 kW (12V) @ 700 CCA

D39E-1, D39P-1 SPECIFICATIONS