SEBM02380303 SOW IM TAN INTO ANIL KOMATSU GD600-3 SERIES MACHINE MODEL SERIAL No, GD6O0OR-3 14001 and up GD650R-3 24001 and up GD605R-3 34001 and up GD655R-3 44001 and up GD605A-3 54001 and up GD655A-3 64001 and up Printed in Japan % 06-86(01)00904 00-1CONTENTS No. of page 00 GENERAL 01-1 10 ENGINE 11 STRUCTURE AND FUNCTION .......... fev iceeeee ees W-4 12 TESTING AND ADJUSTING .... 1 13 DISASSEMBLY AND ASSEMBLY 1 20 POWER TRAIN 21 STRUCTURE AND FUNCTION .... 21-1 22 TESTING AND ADJUSTING .. 22-1 23 DISASSEMBLY AND ASSEMBLY . 23-1 24 MAINTENANCE STANDARD ...... 24-1 40 STEERING SYSTEM 41 STRUCTURE AND FUNCTION .......... ceveceeeeces ADT 42 TESTING AND ADJUSTING ... 42-4 43 DISASSEMBLY AND ASSEMBLY 43-1 44 MAINTENANCE STANDARD .... 44-1 50 BRAKE SYSTEM 51 STRUCTURE AND FUNCTION 51-1 52 TESTING AND ADJUSTING 52-1 53 DISASSEMBLY AND ASSEMBI - 53-1 54 MAINTENANCE STANDARD - 541 60 HYDRAULIC SYSTEM 61 STRUCTURE AND FUNCTION 61-1 62 TESTING AND ADJUSTING .. 62-1 63 DISASSEMBLY AND ASSEMBLY 63-1 64 MAINTENANCE STANDARD .. - 64-1 70 WORK EQUIPMENT 71 STRUCTURE AND FUNCTION . 1-4 72 TESTING AND ADJUSTING 72-4 73 DISASSEMBLY AND ASSEMBI 73-1 74 MAINTENANCE STANDARD 74-1 80 ELECTRICAL SYSTEM . 81-1 90 OTHERS 02 INSPECTION TABLE eens ees ee 92-1 00-2 GD600-3 SERIES oOLIST OF REVISED PAGES ‘The affected pages are indicated by the use of the following marks. Its requested that necessary actions be Mark Indication ‘Action required taken to these pages according to the table below. | Page to be newly added Add @ | Page to be replaced Replace (| Page to be deleted Discard Pages having no marks are those previously revised or made additions, LIST OF REVISED PAGES mark Page TECH | marke Page Time-f} mark Pose Timeot | mark Page MEST | mark Page sion. 201 @ 00.28 n3 wit @ 1339 «@ 0-2 © 00-26 a4 a2 @ 1340 © © 021 @ 00.27 ws @ 13 @ 1341 @ © 022 @ 00-28 ne =6©@ 14 @ 1342 @ 2° 023 © 00-29 315 @ 1343 @ 2 0-24 @ 00-30 16 @ a @ 00- 3 00-31 21 O wi @ 1s @ 00. 4 22 «© 318 @ 148 @ 00. § 23 O 19 @ 247 @ 00. 6 ont 24° © 1320 @ 1348 © 00-7 o-2 @ 2z5 @ 321 @ 1349 «© 00. 8 a3 @ 26 322 ® 13.50 00-9 a4 @ 27 @ 1323 @ 151 @ 00-10 os @ 28 =@ 1324 @ 152 @ 00-11 os @ 29 @ 1325 @ ws @ 00-12 1-7 @ 13.26 oO 13:54 @ 00-13 O18 @ 13:27 @ 1386 @ 00-14 a9 8 @ a1 @ 2 «© @ 1388 @ 00.15 oso =—@ a2 @ 1322 «@ 1357 @ 00-16 on = @ oo |) 1330 «@ 1368 00.17 oraz a4 331 @ 88 @ 00-18 ors a5 @ 32 «= 160 «6 00-19 ona a6 = @ 333 @ 61 @ 00.20 ors. a7 @ 38 @ 00.21 we = @ 138 | @ 00.22 01 @ 1338 O a4 00-23 Wet 13.9 @ 13-37 oO 212 00.24 nea 10 O 0 «=O 23 GD6003 SERIES 0-2-1LIST OF REVISED PAGES Mark Pose [eytaon | Mark Pam Tnion | Mark Pose ion | Mart Pome Fevtion | Mk F408 puton a6 21.45 nw @ nos © 2107 © as @ nse @ 22 «6 «O nos O asia a6 247 no nos O z.09 a7 nae @ na ® nso © z110 O ae ® na @ a2 na 0 nan @ a9 22 «@ an © waz © at 2200 «@ an O zis O 2112 a1 @ na na © nau @ 213 22 @ aaa nm © zis O 216 22 O aa na © ane @ 2145 24 @ 205 @ nm © ant O 21416 25 @ 2a an © ze @ ana? 26 @ nar -@ nr O zar9 ® 21-18 27 ® ae no O 220 @ 21-19 2s @ no O neo O zai @ 21-20 29 =O nao O ner ©} za ® 2121 nw na © me O| mim @ a2 @ na 0 203 O| 1m @ 21.23 243 ne 2125 @ 2126 ® zeta @ 205 O 23128 @ 21.28 22 O 2285 2.06 22 @ 21.28 ean) 2aas nar zaa20 a7 24 @ rar © noe © 2120 22 6 @ a5 O 248 ne © 2201 © 21.29 26 «=O nus O 290 © 23.123.2 @ 220 @ 2.7 @ so @ nar 2.123. @ nar @ a) o| «am © rare @ 2132 aio = @ nz O no O ra O 21.33 an =O 2s as4 @ nan © 21.94 a O 284 O 23.95 @ ain O 21-98, 2313 O 2358 © 23.96 @ 2133 @ 21-38 au O ss 0 207 @ aia @ 2197 21s O aasr O 208 «@ 212.2 @ no = @ ni O nse © 299 O ais 21.09 air @ nso O 2100 © 21% ® 21-40 aie O noo © aio 2138 21 2320 O ae O 2a102 © nasr ery nar O ae =O za10s 2138 213 na O nes O zara @ 2139 @ 24a @ no O nee O zs O zs 00-2-2 o GD6003 SERIESLIST OF REVISED PAGES ark Page TIPO! | ark Page Tet] atark Page TESH| mark Page TiMESTT mark Page Tor 2sia1 OD | © 23164 @ ant 4310 @ 51-28 «@ ata O 22.165 @ an2 an @ 5129 @ aera 23.166 @ 413 a2 @ 5130 @ aise «© | © 23187 @ ante 23.145 @ ans 23.1451 @ a1t6 aa 1 @ 23.1452 @ 2h ana7 a2 @ a2 © 23.1453 @ 242 ane aa 3 3 O 2ar4s-4 @ 243 ante aad 4 @ 231455 @ mad 41-20 us @ 25 @ 2a145-6 @ m8 121 46 26 @ zars7 @ 24. 6 anz2 2s1456 28 ain 23.1459 ® 29 ane 5-1 @ 31 O 2a.145.10 @ 24.10 41.25 51-2 32 © zaras11 @ 241 4125 @ B13 3 @ 2arasi2 ® 2at2 aa @ Bi 4 s4 @ 2a14s.13 ® 24-13 41-28 51-6 5 @ zane O ma @ 41-29 s6 @ 5-6 @ asaa7 248 41-30 7 @ zara O mate @ ana 8 are O 247 ana2 B19 544 zaiso O 24.18 4123 o sito @ 54. 2 zaisi O 2419 Bit eno) zais2 O 24-20 si12 4 @ zaisa O m2 @ a1 @ 51-13 5 @ 29.1831 @ 2422 a2 © pita 2a1sa2 ® mana ® aa © 51-15 o-1 @ 23.1833 ® a4 @ site er 2 23.1534 @ 51-17 er. 3 23164 an site 61-4 zaiss @ a2 a1 @ si-19 615 zaiss | @ aa a2 © siz @ 616 zais7 O aa a2 @ siz ®@ 67 zaise as ae O 522 @ oe 2189 O 46 4-5 @ 51-23 1-9 ato © a7 a6 © 51-28 sr o4 @ 2161 @ ane a7 O 51-25 o.92 @ zatez O a9 aa @ 51.26 s193 @ 23.163 4110 ao O 81.27 s1-94 @ GD600-3 SERIES 00-2-3 3LIST OF REVISED PAGES LIST OF REVISED PAGES mark Page Time nterk page THESE) mark Pane Tie Ot] ark Page TECK] mark Poe Talon 61-10 61-82 64.5 @ 74.1 @ erin 61-83 4-6 ® 74-2 61-12 614d 64-7 @ 4.3 @ 61-13 61-45 4-8 @ 744 @ o1131 @ o1-45-1 @ mar @ e132 ® 6142 ® mu 42 @ ora oss @ ed <<) m4 ® 61-15 616 ne mu 44 ® e168 61.87 nz ® m5 617 61.48 na @ m6 s171 @ aa @ ns ® orz2 @ oso | @ ns oars @ n-51 @ tn) ee) e174 @ n-62 © 81-2 e175 @ 1 = @ m6 @ 8-3 61176 @ 2 n7 @ ei one 6 @ a3 @ ne ® a5 61-19 n9 ® ast @ 61-20 710 a52 @ e121 1 @ na asa @ e122 a2 @ naz asa @ 61-23 63.3 @ nas 81.6 61.28 as nasi @ 61.25 as @ naz ® 61.26 e511 @ m8 921 127 @ e52 @ 92.2 61-28 @ 63-6 @ 92.3 e228 «| -@ 7 @ Q 24 @ 61-30 @ 63-8 @ 72-2 @ 92.5 @ oan @ oo O ns ® 28 a2 10 O as = @ on = as @ oi =O mi Oo 61-35 63.13 @ 73-2 ® 61-36 m3 @ 61.37 ma 61-98 o1 @ 35 @ 61-39 64-2 @ 13 6 ® 61-40 64-3 @ 13-7 ® 6-41 4 6 @ me =O G06003 SERIES 0-2-4 3A IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbols /\\ and ws are used to mark safety pre- cautions in this manuel. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation A\ SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. ‘¢ Always wear safety glasses when hitting parts with a hammer. « Always wear safety glasses when grinding parts with a grinder, ete. 3.1f welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work, 4.When carrying out any operation with two ‘or more workers, always agree on the op- erating procedure before starting. Always inform your fellow workers before starting any step of the operation, Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6.Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working, PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving 8.Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them, 9.When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing 00-3PRECAUTIONS DURING WORK 11, When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out Before disconnecting or removing compo- nents of the oil, water ot air circuits, first remove the pressure completely from the circuit 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before car- rying out any work on the oil or water circuits, 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (—) terminal first. 14.When raising heavy components, use a hoist or crane, Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- temal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires, 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As 2 general rule, do not use gasoline to wash parts. In particular, use only the mini mum of gasoline when washing electrical parts. 00-4 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. ‘« When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed, 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24, Take care when removing oF installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track,FOREWORD. This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting, TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or ‘assembling each component, as well as precautions to be taken for these operations, MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your KOMATSU distributor for the latest information. 00-5HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carrying ut repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one volume to cover all models Electrical volume —: Attachments volume ‘These various volumes are designed to avoid du- plicating the same information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment volumes are ready. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributers. Get the most up- to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page ‘number. Example 1 (Chassis volume): 21-3 Unit number (2. Power train) Ch em number (1, Structure and Function) |____ Consecutive page number for each item, Example 2 (Engine volume): 12-410 Unit number (1. Engine) Item number (2. Testing and Adjusting) Group No. (4. Fuel system) [consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page umber. File as in the example. 00-6 REVISED EDITION MARK (O@® ‘When @ manual is revised, an edition mark is recorded on the bottom outside comer of the pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbot | ern Remarks Special safety precautions are a nocessary when performing the work Safety Extra special safety precautions j ‘are necessary when performing ‘the work because itis under internal pressure. Special technical precautions or other precautions for He | Caution | preserving standards are necessary when performing the work. [Weight of pars or systems Caution necessary when (Cie) | Weight |setecting hoisting wire, or when working posture important, te ighten. | Places that require special = | Tighten: | otention for the tightening ing torque | torque during assembly. Places to be coated with Coat | adhesives and lubricants etc. Places where oil, water or fuel Tap | oll, wator| must be added, and the capacity Places where ol or water must ts, | drain |be drained, and quantity to be drained,HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS AN Heavy parts (25 kg or more) must be lifted with @ hoist etc. In the Disassembly and As- sembly section, every part weighing 25 kg,or more is indicated clearly with the symbol (5 If 8 part cannot be smoothly removed from the machine by hoisting, the following checks should be made: © Check for removal of all bolts fastening the part to the relative parts. © Check for existence of another part causing interference with the part to be removed, . Wire ropes. 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: ‘Wire ropes (Standard “2” or "S” twist ropes without galvanizing) Rope diameter (mn) | Allowable oad (tons) 10 10 12 14 125 16 14 22 16 28 18 36 20 4a 22.4 56 30 100 40 180 50 280 60 40.0 The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, ‘and @ serious accident can result. Hooks have maximum strength at the middle portion. | i Z 100% 8B 7%] THM a Fs006a 3) Do not sling a heavy load with one rope alono, but sling with two or more ropes symmetrically ‘wound o0 tothe load AN Singing with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can esultin @ dangerous accident. 4) Do not sling a heavy load with ropes forming 2 wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. ‘When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make @ 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling 8 2000 kg load ata lifting angle of 150°. Litting angleSTANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE 1, STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of “Disassembly and Assembly” ‘Thread diameter Width of bolt across flat (mim) (earn) kom Nm 6 10 1.354015 13.2214 8 13 3.2203 31.4429 10 7 67407 65.7468 12 19 115410 112298 14 22 18.0420 17719 16 24 28543 27929 18 27 394 383439 20 30 56+6 549458 22 32 76+8 748278 24 36 945410 927+98 27 a 13815, 1320140 30 46 17820 1720190 33 50 22525 22104240 36 585 28030 2780290 39 60 335435 3280+340 This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be used, or which require tightening to otherwise specified torque. + Nm (newton meter): 1Nm & 0.1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread diameter wiath Tightening torque of bolt across flats = (am) (om) kgm Nm 10 14 6.7207 65.7468 12 7 11541 112498 16 22 28523 27929 00-8STANDARD TIGHTENING TORQUE sean sues (Sac Riles 3. TIGHTENING TORQUE FOR NUTS OF FLARED Use these torques for nut part of flared. 1 == Thread diameter | Width across flats Tightening torque ‘of nut part ‘ofnutpart |} — (oom) (om) kgm Nm 14 19 26+08 245449 18 24 542 492196 22 27 B42 7854196 24 32 1423 1373294 30 36 1843 1765+294 33 a 20+5 196.1449 36 46 2545 245.2449 42 85 3025 294.249 COATING MATERIALS ae ‘The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. hone Bae ee aca ees \r-3 Used for aluminum surfaces. ° oe (Thickness after tightening: 0.07 — 0.08 mm) (G5 fittings in hydraulic circuits of less than 50 mm in diameter. (Lithium grease) eu prevention and facilitation of assembling work “LT-2ie aloo called LOCTITE in the shop manuals 00-9ELECTRIC WIRE CODE aeae th In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. ELECTRIC WIRE CODE This wire code table will help you understand WIRING DIAGRAMS. Example: O5WB indicates a cable having a nominal number 05 and white coating with black stripe, CLASSIFICATION BY THICKNESS Copper wire Nominal - | cobieo.0. | Curent cating Apolicabe ctcut ‘umber Number | Dia.ofstrands | Cross section | (rm) a ‘rand (co Cn) o n 032 088 24 12 ‘Starting Hghting signal ete oz 26 032 209 34 20 Lighting. signal ete, 05, 65 oa | 528 46 a Charging nd signat 15 24 ous 1336 70 59 Staring (Glow plug) 40 85 080 4273 114 138 Starting 60 127 0.20 eae4 138 178 Starting 100 27 080 109.1 176 230 ‘Starting CLASSIFICATION BY COLOR AND CODE creuite Priority staring | charging | Lighting signa! | strument otner Classitieaton code 5 w ® 6 Y t 1 | Primary Color ‘lock white ed ‘Green Yellow tue Code ew ‘wa RW ow YR ww 2 : Color | Biacka write | White eed | Red&winite [Greene white | Velow Red | Blues white ‘code BY we Fe cr Ye LR 3 Coior | Black & Yotow | white & Black | Red& Black | Grean&red |Yolowa Bleck | Bue & Red ‘uviory code oR we RY cy ve Ww 4 Coir | BisckaRed | White Bive | Red& Yellow [Green Velow [Yellow & Green | Bive & Yelow ‘code 5 wr AG. a ve ry 5 Color = |wnite &vetow| Rade Green | Green&stock | vetlowa Bive | Bive & Black Code we RL Cy yw 6 Color — | white e-Green | Red& Be | Groen Blue |votow & white 00-10ot GENERAL Motor grader numbering code... or 3 General view er or 4 Specifications 5 teveseesss OF 6 if Weight table cevteee ness ONO Serial number locations . . 01-12 Motor grader description «2... + O13 01-1 D600 SERIESMOTOR GRADER NUMBERING CODE GDGOOR-3 i Basic mode A: Articulated Rigid > L__briving system ° Direct drive 5: Power shift drive machine size 20, 30, 40, 60, 60, 70 in ascending order |__ Indicates motor grader Example: GD600R, 650R-3 Direct drive, GD6E05R, 655R-3 Hydroshift drive, rigid type GD605A, 655-3 Hydroshift drive, articulated type Basic mode A: Articulated R: Rigid HYDROSHIFT transmission or TOROF LOW transmission GD600-3 SERIESGENERAL GENERAL VIEW GENERAL VIEW GD600R-3, GD6SOR-3 GD605R-3, GDE55R-3 Leaning cylinder Head lamp Blade lft eytindor Drawbar side shift cylinder Rear tire Blade Front tire (}: Gbss0R2, aDes5R-s srio4o10) 23803001 @D6003 SERIES 01-3 QGENERAL GENERAL VIEW GD605A3 GD655A-3 Head famp Blade lift cylinder Drawbar side shift cylinder Articulate oylinder Rear tire Blade Front tire ( @pessas 1370 | Ee sis 23603002 01-4 GD600-3 SERIES aGENERAL GENERAL VIEW GD605A-3 (Serial No. 57001 and up) GDE55A-3 (Serial No. 67001 and up) Head lamp Blade tft cylinder Drawbar side shift eylinder Articulate cylinder Rear tire Blade Front tire Rope Cab 3280 Fo Height Rops Cab 3400 ou exp 22909036 GD600-3 SERIES. orGENERAL GENERAL Eee SPECIFICATIONS GD600R-3, GD605R-3 GDE50R-3, GDG5R-3 MODEL Gbeoons | GDs50RS | GDS0ERs | GDSEERS SERIAL NUMBERS 14001 and up | 24007 and up | 34001 end up _| 44001 and up 1 | Operating weight a) 77190 12370 12490 12670 & On front axle (ka) 3635 3735 3665 3765 2 | onrearaxte tea) 8555 2635 2825 2905 Overaength (mm) 2420 2420 2420 8420 Overall width (om) 2395 2375 2375 2375 8 | ratae et exhaust pipe tom) a0 ae Eo a B | wheel base (mm) 6000 6000 6000 6000 B | trese, front (om) 1970 1970 1970 1970 ° ‘Tread, rear (mm) 2000 2000 2000 2000 Ground clearance (ov) 240 240 330 330 Le Atk ie 38kmih Land 63 km and 63km/h Lad 120mm Sed 105k Lah 201mm 4th 145k FORWARD Sth 26.1 km/h Hot 92kmm oh 43.6 kmh a Hand 14-1 kein g\s H 3rd 26.9km/m s|2 Hath 44.8km/h a 1 4Bkmm ix Akin g and 7.4 kev and 74 ken ord 14.1 km/h ad 12.4 km/h REVERSE 4th 23.6 km/h 4th 17.2 km/h Sth 30.9km/h eth 51.8km/h Max, drawbar pull tka) 6840 6900 7060 7120 Turning radius (om) 104 104 104 104 01.6 206003 SERIES ®GENERAL SPECIFICATIONS, MODEL ‘Deon | GdSsORS | GososRS | GDSSERS SERIAL NUMBERS 1400" and up [ 24008 and up | 24001 and up| 44001 and up z Tire 13.00 — 24 — 10PR 5 [im 80076 x 24 SDC [Control vale FH. Spool, LH. spool with safety valve 1 §[Wox otpeaure T5taen? Bs] 011 pump discharge 2x 398/min. 2-5 i motor aecnarge 7at/min. ie BAO mmx | AW mix | a7IOmmx | ADI MMx 3 | Blade length x height x thickness 655 mm x 655 mm x 655 mm x 655 mm x 19.0 19mm 19mm 19 mm Model 601254 No, of elindrs — bore xstoke (mm) 125% 150 Piston deplacement (ce) 11040 Fiywheel horsepower (HP hpm) | 48/1800 | es/te00 | v4s/ie00 | 165/160 [Maximum ror tkamfomy | 73/00 | 7700 | 7anvoo | 77/1100 2 | Fos oi Diese fuel ASTM 97S No. 2or No. 1 Fuel pump Bosch PE-NB type Governor Bosch RSV Centrifugal al-sped type ‘Alternator 2av_26A Starting motor 2aV_75KW Battery a 12V, 150Ah x 2 D603 SERIESSPECIFICATIONS GENERAL SPECIFICATIONS — cpe05a-3, D6554-3 MODEL GO605AS GD6SEAS SERIAL NUMBERS 54001 and up | 67001 and up | 64001 and up | 67001 and up i | Operating woah rr) 12870 | 14840(14800) | 13040 | 14890 (14860) & | onsront axle ko) 3705 4086 (4048) 3805 4081 (4070) 2 | onvearaxte (eo) e165 | ro7e4 10755) | 9205 | 10900 10780) ‘Overall length (oom) 8420 e040 8420 2440 Overall width (onm) 2375 2400 2375 2400 2 J overait height (emmy 3240 | 3480 (9280) a24o | 3480 (3280) B | wheel base (rom) ‘6000 6000 6000 6000 3 | read, front (mmm) 1970 1970 1970 1970 OT ead, rer (oo) 2000 2000 2000 2000 Ground clearance (um) 330 360 330 360 tt 35 36 35 36 and 63 65 63 65 | corwaro 3rd 108 108 105 108 = ath 145 15.0 145 15.0 = 5th 26.1 27a 26.1 274 : aun «6 4a a6 asa wld tat 4a 43 44 43 2\z and 74 1 74 1 Z\F 3rd 124 128 124 128 2 REVERSE ath 172 178 172 178 s 5th 309 319 309 319 ath 516 528 516 528 ‘Max drawbar pull tks) 7328 18630 (8600) 7384 "8650 (8630) Turning radius with articulated om) 69 67 69 67 without articulated im) 104 104 104 10.4 ): Low Profile Rops Cab GD6003 SERIESGENERAL SPECIFICATIONS MODEL GD605A3 GDesEAS. ‘SERIAL NUMBERS. ‘54001 and up | 67001 and up | 64001 and up | 67001 and up ¥ pe 13.00-24-10PR | 14.00-24-10R | 13.00-24-10PR | 14.00-24-10PR = [Rim 8.00TG x 24 SDC Control valve 5 sp001, 3 spo0!, 1 spool control valve Max. oil pressure (kg/em?) 175 it pump discharge (@/min) 2x39 2x49 2x39 2x49 Oil motor discharge (@imin) 78 98, 78 98 Work equipment and| hydraulic control Blade length x height x thickness 3710 mm x 655 mm x 19 mm 4010 mm x 655 mm x 19 mm Wo Koma D125 Te. of onde —tonrx aoe lem = 1254150 snail IR 1000 Fipuhee oneponer (HPht ‘aaron resr00 «, [Maximum tore tegnrpmi | _7anvoa | 7aanioo | 777m | _7ear00 7 Fuel pump Bosch PE-NB type ae Beth RV Cen al apd wpe terse ava | _20v.00a_| _20v.260 | 20608 Sing motor fav. 75] Bev, new _| Bev. Tew | Bev, Tew covery Tay, 1s0an x2 |2v, an x2 [av. 160ah 2 fav, 200An x? GD6003 SERIES 01-9 ®GENERAL WEIGHT TABLE WEIGHT TABLE AS, This weight tabie is a guide for use when transporting or handling components. Unit: kg MODEL Gos00Ra | GDssORS | GDSOSRS | GDSsERS SERIAL NUMBERS 14007 and up | 24001 and up | 24007 and up | 44001 and up Engine sssembly (ary) 1700 700 7120 1720 Engine with elutch assembly (dry 1290 1200 : = Engine, damper, HYDROSHIFT transmission, Parking and piping assembly (cy) - : 1907 1907 Chute assembly (ary) 190 190 . = Damper ssemby = = 25 6 “Transmission assembly (dry 400 400 208 805 Radiator asembly 85 85 85 5 Fuel tan (inc, bracket) (dry 185 185 185 185 Devestete (ieee) 16 | ower) 16 2 2 Final rive, tandm drive, rea axle and rake sembly (ary) 024 3028 2028 024 Final aie assembly 89 895 895 295 Tandem drive assembly ysox2 | 750x2 | 750x2 | 760x2 Front axle asembly (ne, leaing cylinder) 522 592 52 5x2 Wht assembly wsaxe | t59x6 | 153x6 | 153x6 Parking brake asembly ” ” ” ” Frame asiembly 2004 2004 2008 2004 Operator's compartment assembly 330 320 426 496 Blade tit eyinder %8 98 °8 oe Blade sit cylinder 56 55 55 56 Leaning cylinder 20 20 20 20 Steering cylinder 20 20 20 20 Scarifier linger (HF ecvinped) 8 8 28 22 Drawber, crcl, circle reverse and bade duster bracket 1290 1490 1290 1490 Circa reverse astemily 100 100 100 100 Dawber with circle assembly 1120 1120 1120 1120 Blade sesemby 762 903 762 808 Searifirasembly (If equipped 700 700 700 700 Hydraulic tank (ary) c 0 «0 © Hydraulic pump os 95 9s 9s Steering pump 96 96 45 45 Transmission pump : - 59 59 it motor 10 10 10 10 01-10 a GD600-3 SERIESGENERAL WEIGHT TABLE Unit: tg MODEL GDGD5AS GOSBSAS SERIAL NUMBERS 4001 and up [67001 and up | 64001 and up [67001 nd up Engine asombly (rv) 1120 1120 1120 7120 Foveiingand pioingssembiy ayy” | 1967 tu vs ty Damper assembly 25 25 25 25 ‘Transmission assembly (dry) 805, 805 805 805 Radiator assembly (dry) 85 2 35 85 Fuel tank in. bracket (ry) 185, 105, 105 185 Drive shaft (Lower) 2 12 12 12 Fina te and irr x aed 024 024 024 024 Final drive assembly (dry) 895 930 895 930 Tandem drive assembly each) (dry) 750 840 750 240 Front axle asembly inl aingeylinder 522 522 592 592 Whee! aesmbly (each 189 105 182 185 Parking brake assembly ” ” 7 ” Frame asembly (Front and Rear) 2307 2072 2207 ara Front frame asembly 1453 53 1459 1469 Roar rae assrbly 854 1020 054 1020 Operator's compartment assembly 480 320 496 320 ROPS canopy asembly E 18 a 78 Blade it eyindr 98 98 98 98 Blade shit cylinder 55 55 5 55 Drawbar chit ylinder 23 23 2 2 Leaning evinder 20 20 20 20 Steering eylinder 20 20 20 20 ‘Scarifier cylinder (If equipped) 28 28 28 28 Power it cylinder (If equipped) 21 a 2 a Articulation cylinder 60 60 0 60 raw, hcl even an ae a a a a Cite rotation assembly 100 100 100 100 Drawoar with ce asembly 1120 1120 1120 1120 Blade assembly 762 m7 803 754 Sear aeembly (equiped 700 700 700 700 Hydrate tank (dy) 60 60 60 60 Hydreule pump 95 95 9s 95 Steering pump 4s 45 45 4s Transmission pump 59 sa 59 59 i motor 10 10 10 10 600-3 SERIES 01-11 2GENERAL SERIAL NUMBER LOCATIONS SERIAL NUMBER LOCATIONS © Leaning cylinder No. Steering cylinder No. i © Blade lift cylinder No, | © Circle rotation motor No. Ge ; : 22000004 © Blade side shift cylinder No. 29803005 305A) © _Arteulatoytinder No. {EB895A) mp i ‘sand 2388001 © Hydromaster No. © Air tank No. (op) ee 01-12 606003 SERIESGENERAL MOTOR GRADER DESCRIPTION FUNCTION ‘The major functions of a motor grader are to level road surfaces and dig ditches of fixed shape. In terms of function, a grader can be likened to a gigantic carpenter's plane. ee = gear L = gear M~ output shaft (No. 4 shaft) -> output coupl- ing, in that order. 4D600-3 SERIESSTRUCTURE AND FUNCTION REVERSE Ist SPEED 606003 SERIES 2iFo1s Gear A, which is fixed by the spline on the input shaft (No. 1 shaft), is constantly meshing with gear B, which is revolving on No. 2 shaft. When power from the input coupling revolves the input shaft, it revolves constantly gear B which is on No. 2 shaft When the gear shift lever in the operator’s compartment is moved, the coupling (dog) gear (1) on No. 2 shaft is slid towards 1 speed by the shifter fork and meshes the external gear of the boss section of gear B and the internal teeth of the coupling gear. ‘The internal teath of coupling gear (2) are fixed by the spline on No. 2 shaft and the revolutions of the input shaft are transmitted to No. 2 shaft. ‘At the same time, the revolutions of the input shaft are ‘transmitted to gear | > gear J > No, 3 shaft > gear N ~ gear P~ output shaft (No. 4 shaft) ~ output coupling, in that order. 21-15STRUCTURE AND FUNCTION TRANSMISSION TRANSMISSION CONTROL LEVER F2a803008 21-16 GD6003 SERIESDAMPER, STRUCTURE AND FUNCTION, GD605R, GDE55R, GDGOSA, GDE5SA-3 DAMPER 21F008 Sectton A-A 21-17 GD6003 SERIESSTRUCTURE AND FUNCTION. HYDROSHIFT TRANSMISSION HYDROSHIFT TRANSMISSION _ cpsos5r, GD655R, GD605A, GD655A-3 SueelO alee d 10 11 12 18 14 15 Ny \ \ \ \\ i an \ 2IFOITA 21-18 GD600-3 SERIESSTRUCTURE AND FUNCTION Model GD605A, 655A, 605R, 655R are equipped with planetary type transmission (F6, R6) and is a combina tion of planetary gear system and disc clutch. For each revolution direction and rpm, three of 7 dise clutchs of the planetary gear system are hydraulically locked by acutating the control valve. R clutch is for Reverse, F clutch is for Forward, No. 3 ‘and H for 6th speed, No. 2 and H for Sth speed, No. 1 ‘and H for 4th speed, No. 3 and L for 3rd speed, No. 2 and L for 2nd speed, No. 1 and L for 1st speed. 1. cate Gove R. planetary pinion heft . nouing 3rd piston 2nd housing 8. sieve 10. 2ndearrer 2 8 5. F. 3rd, planetary pinion shaft 6. 8 11. 2nd planetary pinion shaft 12, tet ring 13. tstpiston 14. st housing 15. Cage 16. Cone 17, Teonster ease 18. Cone 19. Shaft 20. Case 21. Cage 22. tstsoring 23. Isthousing 24. 2nd piston 25. 3rd, F, carrier 26. F. piston 27, B carior 28, Input shat GD600-3 SERIES 29. L. planetary pinion shaft 20, Cape 31. spring 22, Housing Shaft cove cove Sleeve sleeve ‘Shaft Hi dram cape 42. Histon 43, Leearier 44, piston 45, Coupling 46, Shaft SERRBSRREB Reduction ratio ach speed ratio ara2a| Te | He [Toe eguetion Fi me] iam | (jt) aoe | tae s.n67 1.657 F2 | 1.000 2967 1.389 Fa | 2.000 a | 2008 te] seer] | 8) tne | 1880 F6 | 1.000 7 068 0.698 ar | -2506 | | -7.290 L ne | 1408} |, | 4039 “ ra | oes | |*"°7) 2009 1.389 ra | ~2596 er aa ns | 1.409 og) ~2.989 ae a6 | -oess 00) ose HYDROSHIFT TRANSMISSION zroe™mpope>, KoA eerozzrne R. sun gear (28 ween) A. planetary pinion (21 seeth) ring gear (71 woth ving ese (71 wan) F. sun geae (38 weet) F. planetary pinion 117 woth! Fring gear (78 worn) re sun gear {38 woth) 3rd planetaly pinion (19-tweth) 3rd ing gar (76 worn) 2nd sun 99s (98 teeth) 2nd planetaly pinion (19 wath) 2nd ring ger (78 woth) ‘st gear (75 eth) Gear (32 teetn) Gear (31 e02h) oar (30 toedhh Gear (22 wethd H. ocar sun gear LL planetary pinion ering gear 21-19STRUCTURE AND FUNCTION, PLANETARY GEAR SYSTEM Planetary gear system (structure) ‘The planetary gear mechanism consists of sun gear A, planetary pinion B, ring gear C and carrier D. ‘The planetary pinion is supported by the carrier and meshes with the sun gear and the ring gear. When the ring gear is fixed, The sun gear A revolutions ere transmitted to the planetary pinions B. ‘The planetary pinions are meshed with the ring gear C. Since the ring gear is fixed, it cannot revolve as it is ‘Therefore, the planetary pinions revolve on their axes while revolving around the sun gear along the ring gear. ‘At this time the torque of the sun gear becomes carrier D torque and is transmitted. The direction of rotation of the carrier isthe same as that of the sun gear. When the carrer is Fixed, The sun gear A revolutions are transmitted to the planetary pinions 8. Because carrier D is fixed, the planetary pinions meshed ‘with the sun gear revolve on their own axes at their posi- tions. The ring gear C which is meshed with planetary pinions revolves in the opposite direction to the sun ‘ear, and the sun gear torque becomes the torque of the ring gear and is transmitted Combination such as -> Sun gear ~ Planetary pinion ~ Ring gear or carrier, is the structure of B.F. 3rd, 2nd, L clutches. However, for R clutch, the sun gear becomes the power source and transmits power to the ring gear, and for F, L clutch, the sun gear is the power source ‘and transmits power to the carrier, and for 3rd and 2nd clutches the cartier is the power source and transmits ower to 3rd and 2nd sun gears. 21-20 HYDROSHIFT TRANSMISSION ‘A. Sun gear 8. Planetary pinion ing gear . Ptonetery carrer 2iFo18 2iroie 606003 SERIES.STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION Revolving clutch ‘A revolving eluteh is used for tst clutch of GDEOSA, Because of friction force of disk (47) and plate (48) which are pressed together with ‘st piston (13), the power from 2nd carrier (10) is transmitted to the output shaft through ‘st gear N fixed to the output shat (19) {A volving clutch ie als ued for H cute. Because of friction force of disk (8) and plete (50) which are pressed with H piston (42), the power from the input y Shafts. transmited 10 the output shaft through the H ao ib. gear fed tothe Input shaft in the following order SHE 3 ise ~ Plate H drum (40} > L carer (43) > Output shaft = fo 2iroz2 GD600-3 SERIES 21-21STRUCTURE AND FUNCTION FOR FIXING FORWARD RING GEAR In order to fix the ring gear a disk clutch made up of piston (26), plate (50), disk (51), pin (52), piston return spring (53), washer spring (54), etc, is installed. The internal teeth of the disk mesh with the external teeth of the ring gear. ‘The plate is fixed in the direction of rotation by the meshing of the notched protrusions of the outer diameter and pins (52) fixed into the housing (6). The piston is also fixed in the direction of rotation in the same way. Clutch “ENGAGED” (Fixed) Hydraulic oil from the control valve passes through the ort of the housing (6) and transmits pressure to the bback of the piston (26). The piston presses disk (51) and plate (50) and the friction stops the disk rotation, resulting in fixing ring gear G which is meshing with the interior teeth of the disk Clutch “DISENGAGED™ (Released) When the hydraulic oll from the control valve is inter rupted, the piston return spring (53) acts to return the piston (26) to its original position, the plate (50) and disk (51) friction is released and the ring gear G becomes neutral The washer spring (54) installed between the pin (52) plate and the plate acts to return the piston more quick: ly when the clutch is disengaged, improve plate and disk separation and prevent the disk drag rotation. 21-22 @ HYDROSHIET TRANSMISSION 2 54 50 St 6 6 21F023 a 50 2B 6 2iF024 5352 5) 50 5428 21F025 GD600-3 SERIESSTRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION 4st CLUTCH ‘A revolving clutch is used for tst clutch, Clutch “ENGAGED” (Fixed) Hydraulic oil from the control valve goes to the back of the piston (13) through the port of the cage (20). The piston force-presses disk (55) and plate (56) ‘The clutch is engaged by meshing the internal teeth of the disk and the external teeth of the gear Nand the extemal teeth of the plate and the internal teeth of the drum (2nd carrier, (10) “The gear and drum become one unit and revolve. Clutch “DISENGAGED” (Released) When the hydraulic oil from the control valve is inter- rupted the piston is returned by the disk spring (12). (On the other hand, when the piston is returned to its original position, and the clutch is disengaged, the wave spring (67) between plates (56) separates plate and disk (55) completely, and prevents drag rotation. 608003 SERIES eo 21F026 2iF027 21-23STRUCTURE AND FUNCTION FORWARD tst GEAR (F, 1st, L) Power is transmitted from F sun gear E to F planetary pinion F. Because F ring gear G is fixed, F planetary pinion Fevolves around F sun gear while revolving on its axis. F carrier (25) (one with 3rd carrier) to revolve it in the same direction as F sun gear. Furthermore, because Ist clutch has been engaged 1st ‘gear N, 2nd carrier (10) and 3rd ring gear J become one unit 21-24 21ro28 In this condition, F carrier (one with 3rd carrier) is revolving and 3rd sun gear H, 2nd sun gear K, Ist clutch, 2nd carrier and 3rd ring gear revolve as one unit, power is transmitted to revolve output shaft (19) in the same direction as F sun gear. Furthermore, power is transmitted through gears O, P, Q, R, to HL transmission, and because L clutch is f ower is transmitted to the output shaft through L. planetary pinion U and L carrier (43). GD600-3 SERIESSTRUCTURE AND FUNCTION FORWARD 4th GEAR (F, 1st, H) P 25. 1 ‘Transmission of power to the input shaft of H-L clutch is exactly the same as for Forward Ist gear, so see previous page. Power from the input shaft of H-L clutches is transmit- ted so that the output shaft revolves in the seme direc: tion and at the same speed as the input shaft, because when H clutch is engaged, L carrier, L ring gear and H clutch become one unit. GD6003 SERIES HYDROSHIFT TRANSMISSION i — 21F029 21-25STRUCTURE AND FUNCTION REVERSE 1st GEAR (R, tst, L) Power is transmitted from R sun gear A to R planetary pinion B. Because R ring gear C is fixed by R clutch, R cartier (20) is aso fixed. Because of this R planetary pinion revolves on its axis. R ring gear D revolver in the opposite direction to R sun gear. At this time power is transmitted to revolve F cartier (26) in the opposite direction to the input shaft revolution because itis one with R ring gear. ‘Transmission of power after this is the seme as with Forward 1st gear 21-26 HYDROSHIFT TRANSMISSION 43 21F030 606003 SERIESSTRUCTURE'AND FUNCTION HYDROSHIFT TRANSMISSION REVERSE 4th GEAR (R, 1st, H) 10 h 1 a 25 "| ie 3 J ; 2 a 2irost Power to the transfer input shaft is exactly the same as reverse 1st gear. Furthermore, it is transmitted through the transfer to the H-L clutches. Power from the H-L clutches Is ‘transmitted to the output shaft to revolve it in the same direction and at the same speed as for forward 4th gear. GD6003 SERIES. 21-27STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE HYDROSHIFT TRANSMISSION CONTROL VALVE GDEOSR, GDEESR, GDGISA, GDESSA-S 1 234567 8 Cover vave Spring Vatve 1 2 3 5. Priocty vave 6. Spring 7. Stopper 8 Valve 9. Modulating valve 10. Cover 11. Spring 12 Spring 13, Valve body 14. Sleeve 18, Quek owen vave 16, Stopper 17, Pug 18. Spring 19, Valve body 20, Lubricating valve 21. Spring 22. Cooler bypass waive 2 Sleeve Steines Sleeve rd site valve Stopper cover ‘sit valve ‘Stopper F.R spool Yoke Inching vave $9001 Spring Inching valve Wather ‘Sleeve Seat 9. Stopper HL shit valve = Spring - Stopper . Cover utott valve 5. Ist shite valve SRESHRSSESRSSRRAESES BRB Vavie body 21-28 GD600-3 SERIES @STRUCTURE AND FUNCTION PRIORITY VALVE 1. When neutral The priority valve (1) isa relief valve with a set pres- sure of 14kg/em? When there is no gear changing, the pilot circuit hydraulic pressure (shift valve hydraulic oil pres sure) is the same as the main circuit hydraulic pressure: 25kg/em?. The priority valve is in contact with the stopper. 2. During gear changing When the main circuit oil pressure goes down below 14kg/em?, the pilot circuit oil pressure is maintain- ed at 14kgiem? by the priority valve and the shift valve can reliably function, GD600-3 SERIES HYDROSHIFT TRANSMISSION CONTROL VALVE Topilotcitcuit Frompump J 2 / To pilot circuit From pump, ca Te shite valve 21F034 21-29STRUCTURE AND FUNCTION. MODULATING VALVE AND QUICK RETURN VALVE ‘Tha modulating valve and the quick return valve smooth: ly aise the main oll pressure when gear changing. By ‘operating the clutch, shock at driving gear changing is eliminated and the production of peak torque in the ower line is prevented. 1) Immediately after gear changing (X point) Immediately after changing gears the main circuit (from the pump) oil flows into the piston of the operating clutch Due to the flow of oil at this time, a difference in pressure is produced in the A-chamber and the B-chamber of the quick return valve (3), and the quick return valve moves to the left, At this time, the C-chamber of the modulating valve load piston port is connected to the drain circuit. By the force Of the spring (4) the modulating load piston (8), while draining the oil which has filled the C-chamber of the load piston port, returns to stroke lend (right edge). 2). While raising pressure (Y point) When the clutch piston fills with oil, the flow of oil ‘almost completely stops. The pressure of the A- chamber and B-chamber of the quick return valve (3) is almost the same. Due to this, the pressure difference (a > b) on the surface and b surface of the quick return valve causes the quick return valve to retum the right, The circuit to the drain port D- chamber of the modulating valve load piston closes. ‘At the same time the oil passed through the orifice (c} of the quick return valve pushes the modulating valve load piston (5) to the left, Then, due to the movement of the load piston, the spring (4) contracts and the relief pressure of the modulating valve gradually rises. 21:30 2 HYDROSHIFT TRANSMISSION CONTROL VALVE Gove shitting ¥ O02 04 06 0.8 1.0% Time 21F038 —~ To shit valve 21098 c 21F037 GD6003 SERIESSTRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION CONTROL VALVE. 3) Atset pressure (25ky/em*) (Z point) When the modulating valve load piston touches the stopper, the increase in the oll pressure ceases. At this time the relief pressure is the set pressure {25kg/em?) of the modulating valve. 2iFo38 GD600-3 SERIES 21-31 2ON CONTROL VALVE STRUCTURE AND FUNCTION HYDROSHIFT TRANSM ‘SPEED STAGE CHANGING VALVE 1. At neutral ‘The pilot pressure applies on the A-chamber of the cutoff valve and because the C-chamber connects ‘with the drain circuit, the spool moves to the left due to the difference in pressre between the A- ‘chamber and the C-chamber. The oil from the pump doos not operate each clutch, but lubricates the ‘transmission and PTO, and is drained into the trans: mission case. SERS oc mo, ory oe rein 21F039 2. At forward 1st speed ‘The B-chamber and_D-chamber of the back pressure side of the shift valve (1st (H.L) are each connected to the drain circuit and so a difference in pressure arises in the A-chamber and B-chamber, and the ‘Acchamber and D-chamber. The Ist spool and the H.L spool are each pushed to the left and since the F.R spool is set in the F position, the oil from the pump is led to the Ist, L, F clutch, 3, Forward 6th speed Since the E-chamber of the back pressure side of the shift valve (3rd) is connected to the drain circuit, 3 pressure difference arises between A:chamber and E-chamber and the spool is pushed to the right Since the F. R spool is set on the F position, the oil 3 from the pump flows into the 3rd, H, F clutch ers To H elute 2iFoat 21-32 GD6003 SERIESSTRUCTURE AND FUNCTION. 4, At reverse 2nd speed Because the back pressure side of the shift valve (2nd), (H.L) is connected to the drain circuit, 3 difference in pressure arises between the A-chamber and O-chamber, and the A-chamber and F-chamber. ‘The H.L spool is pushed to the left and the 2nd spool is pushed to the right. Since the F.R spool is set in the P position, the oil from the pump is led to the 2nd, L, R clutch. At other forward 2nd speed — Sth speed and reverse 1st speed and 3rd speed — 6th speed occur according to ‘combinations in the above items 2 — 4. The combina- tions are as follows: Forward 2nd speed: 2nd, L, F Forward 3rd speed: 3rd, L. F Forward 4th speed: Ist, H, F Forward Sth speed: 2nd, H, F Forward 6th speed: 3rd, H, F Reverse Ist speed: Ist, L, R Reverse 3rd speed: rd, L, R Reverse 4th speed: Ist, H, R Reverse Sth speed: 2nd, H, R Reverse 6th speed: rd, H, R INCHING VALVE When the inching pedal is depressed, the inching valve moves in the direction ~ (right). At first because oil pressure force of chamber A is larger than spring force (2), the valve moves right. ‘Then port of “F” or “R begins to close, because oil pressure is released spool (1) moves left by spring force, “This state keeps until the washer (3} reaches the stopper (4) (Oil pressure of chamber A continues releasing.) When the washer reaches the stopper, the spool moves right with the washer, Oil port of “F" or ““R" clutch ‘opens to drain circuit. 206002 SERIES HYDROSHIFT TRANSMISSION CONTROL VALVE ToR clutch LONE To 2nd etuten “ee ory Serio) Toleuen — aaroae ATR tena vave 2iFoaa 21-33STRUCTURE AND FUNCTION. HYDROSHIFT TRANSMISSION CONTROL HYDROSHIFT TRANSMISSION CONTROL GDGOSR, GDEEER, GDGOSA, GDESSA-3 Rectutch — Feturen Srd-cluich —Sndelvieh tat clutch Lotutch Hetuten 4 “Teanemission case 3 4 17] 5 16 6 15 2 ain) PTO Tranemigson tbrication it Teanemission ease 2IFOaS, 21-34 GD600-3 SERIESSTRUCTURE AND FUNCTION HYDROSHIET TRANSMISSION CIRCUIT HYDROSHIFT TRANSMISSION CIRCUIT GDGOSR, GDE55R, GDGI5A, GDG5SA-3 Reich 2nd clutch Cracking pressure Heluteh “ r ’ H 1 peo — He H HM | ' ad et) WA a ] EN Ist 2nd 3rd ath oth th a 4. Strainer 9, FA clutch vave 2, HYDROSHIFT transmission pump (SAL O45) 10. tse clutch vave 2. Oil iter 11, nd ett valve 4, Priority valve 12, drdeluteh valve 5, Modulating valve 19, H.Lelutch valve 6. Quick turn valve 14, Speed selector valve 7. Curott voive 15, Oil cooler 8. Inching waive 16. Cooler by-pas valve 17. Lubricating oie valve GD600-3 SERIES 21-35STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION LUBRICATING CIRCUIT ' HYDROSHIFT TRANSMISSION LUBRICATING CIRCUIT GD605R, GDE55R, GDGOSA, GDES5A-3 AO {Dy HY le x TK) & So a 2iroa7 206003 seRIES 21-36STRUCTURE AND FUNCTION LUBRICATING RELIEF VALVE LUBRICATING RELIEF VALVE GD6OSR, GDE55R, GD6OSA, GDESEA-3 2iroas, Plug 1 2. Spring 3. Body 4, Poppet GD600-3 SERIES 21-37STRUCTURE AND FUNCTION. HYDROSHIFT TRANSMISSION CONTROL LINKAGE HYDROSHIFT TRANSMISSION CONTROL LINKAGE GD6OSR, GDGI5A-3 GDGS5R, GDES5A-3 F23809008-4 ‘GD605A-3 (Serial No. 57001 and up} ‘GD655A-3 (Serial No. 67001 and up} o 1, tnching peas 2, Transmission control love. ra 3, Inching eonteol wie nching aie 4. FAR. contol wire soeedsencorave ——gogn0s0a8 21-38 GD600-3 SERIES @STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION PIPING HYDROSHIFT TRANSMISSION PIPING GD605, 655R-3 GD605, 6554-3 aaeri09 Hydroshitt transmission control valve Hydroshit transmission ‘otter 1. Mission pump (SAL O45) Engine en eeye Oil cooler GD6003 SERIES 21-39STRUCTURE AND FUNCTION MAIN CLUTCH PUMP MAIN CLUTCH PUMP saro25+saro20 GD600R-3 GD650R-3 1 2 3 4 1 | ain clutch pump part Steoring pump pot 29803016 Bracket Gaar cate Drive gear cover Drive gear Bushing 21-40 GD600-3 SERIESSTRUCTURE AND FUNCTION TRANSMISSION PUMP, TRANSMISSION PUMP saLoas GD6O5R-3 GD655R-3 GD605A3 GD655A-3 F2s8012 Section AA Drive gear racket rar cate cover rive gear Busing it seal ep ring GD600-3 SERIES 21-41STRUCTURE AND FUNCTION FINAL DRIVE FINAL DRIVE 7 6 case cone ‘ove pinion (13 teeth) coupling ut hie Sprocket (13 teeth) Gear (44 teeth) 21-42 10. nh 12, 13, 14 18, 16, Gear (17 teeth) Bevel gear (38 teeth) shat Gear (17 teeth) Shien Goor (a4 recth) Shatt Bearing ”. 18, 19. a 2, 2a2F 110 Flange Housing ereather it filler tube it eve eauge Hanger it drain plug GD6003 SERIESSTRUCTURE AND FUNCTION Power transmitted from the engine to the damper and to the transmission is transmitted at right angles by mesh ing of the bevel pinion (3) and bevel gears {10}. Then it is reduced by gear (8), (9) and transmitted to the sprocket (7). Also, the weight of the machine is transmitted by the final drive cases (1), (18) to the tandem cases. Because this weight is directly transmitted to the tandem case by flange (17), the shaft (15) transmits the torque only. (The shaft (15) is full floating.) Adjustment of the preload of the bevel pinion is done with nut (6) and washer. Also, adjustment of the pre: load of bevel gear, backlash, adjusting tooth contact of pinion is done with shim (13). ‘This is a device that reduces power from the transmis: sion and transmits it to the left and right tandem drive gears, When a motor grader is operated with the blade at 2 propulsion angle, or the machine on a slope, it receives fon its front section a side reaction force that tends to turn it sideways, either to left or right. Because it is ‘necessary to resist this and continue to advance straight ahead, it is generally structured without a differential installed. D600 SERIES FINAL DRIVE Mf an) 3 aoeriit 21-43STRUCTURE AND FUNCTION FINAL DRIVE (with DIFFERENTIAL) GD605A-3 (Serial No. 57001 and up) GD655A-3 (Serial No. 67001 and up) — a 20 19 18 cate cage Bevel pinion (13 teeth) coupling Nut ‘Shim ‘Sprocket Gear (44 teeth) Goar (17 oath) 21-44 @ 10 Ah 1 10. 1 2, 13, 14, 18. 16. 7, 18 Role Pig ea case Nut ‘Bove ger (38 teeth) Lock Gear (40 teeth) Geer (40 teeth) Geer (17 teeth) hate Flange 19. 21 2, 24, 25. 2. FINAL DRIVE 23803010 Besring Shoft Housing eather it ove gauge it file tude Lever (or differentia tock) shim Hanger GD600-3 SERIESSTRUCTURE AND FUNCTION “The final drive isa speed reduction gearing system which ‘transmits drive power from the transmission to the right and left tandem drive gears When @ motor grader is operated with its blade set to an angled position or with the machine body tilted, the reaction of the surface being graded will cause a lateral force to turn the front end of the machine right or left, To keep the machine traveling straight forward by resisting this turning foree, ordinary motor graders are equipped with a differential. However, since the GD605A3is an articulated machine, in which the rear wheels are likely to slip sideways when articulation is in effect, a differential is used to prevent ‘early wear of the rear tires, The differential can be locked when necessary by remote control from the operator's seat. ‘The rotation of the engine is transmitted through the damper to the transmission along the machine center line. The rotation of the transmission output shaft is ‘then transmitted through bevel gear (12), which is in mesh with transmission output shaft bevel pinion (3), to the bevel gear shaft which is at a right angle to the machine center line. The rotation of the bevel gear shaft is in turn transmitted to sprockets (7) after it speed of rotation is decreased by gear trains (8) — (9) and (8) ~ (16), respectively The full-floating shaft (20) transmits only torque. ‘The weight of the machine is directly delivered to the tandem case from final drive case (1) and housing (21) by bearing (19) and flange (18). The bevel pinion preload can be adjusted with nut (6). Shim (6) and nut (11) are used to adjust the tooth contact between the bevel gear and pinion, the backlash ‘and the bevel gear preload. ‘Shim (26) is used to correct the step between the right and left mounting surfaces to which hanger (27) is fitted when mounting the ease on the main frame. ving FINAL DRIVE Fea80g011 GD6003 SERIES 21F0s3 21-45STRUCTURE AND FUNCTION DIFFERENTIAL LOCK AND UNLOCK PIPING DIFFERENTIAL LOCK AND UNLOCK PIPING GD605A-3 (Serial No. 57001 and up) GD655A-3 (Serial No. 67001 and up) Section AA 298106 Lever (Ditferentiat control), Lever (Lifter lock release) Hydromaster 1 Air tube ene Air cogulator valve 21-46 GD6003 SERIES @STRUCTURE AND FUNCTION TANDEM DRIVE D603 SERIES Cover Breather hein Hub shate Sprocket cage ‘Broke drum 1 fall! | | Ite 10. nh 12, 13. TANDEM DRIVE F290015 Bearing “Tondem cate cover CO} level gage Cover i drain lug 21-47STRUCTURE AND FUNCTION TANDEM DRIVE TANDEM DRIVE (witn pisc BRAKE) GDE05A-3 (Serial No. 57001 and up) GDES5A-3 (Serial No. 67001 and up) F298015-1 4. Chain 10. Bearing 2. Breather 11, Geer (105 teeth 3. Cover 12, Plate (138 eth) 4. shat 13, Dike 5. Bearing 14, Tandem case 6. Sprocket 15. i tovet gouge 7. Cage 16. Cover 8 Piston 17. Drain plug 8. Spring 21-48 GD600-3 SERIES ®STRUCTURE AND FUNCTION Power from the final drive is transmitted to the front and back rear wheels by chain, ‘The tandem eases (14) can swing up and down 13° each. All four rear wheels are in contact with the ground even when ‘the ground is rough restricting the up-and-down movernent Of the blade to 2 minimum, ‘The movement of the blade of a motor grader when its rear wheels ride over an obstacle is as follows: 1. When both left and right wheels ride over on object (height: H) at the same time, the center of the rear axle rise H/2 as right figure shows, and because the blade is situated about halfway between the front and rear axles, its movement further becomes H/4, When only one left rear wheel rides over an object (height: Hy), the rise at the conter of rear axle is H/2 at its left end as right figure shows and H/4 at the center line of machine and on the real axle. ‘The movement of the center part of the blade is half of that, which is H/8, D603 SERIES TANDEM DRIVE wie 2iFOs6POWER TRAIN \ 22 TESTING AND ADJUSTING GD6003 SERIESTESTING AND ADJUSTING MAIN CLUTCH S0e008'3 ‘TESTING HEIGHT OF CLUTCH PEDAL Using a convex rule, measure the distance from the floor to the center of the mounting bolt of pedal (1). ADJUSTING HEIGHT OF CLUTCH PEDAL Using pedal stopper bolt (2), adjust the height of clutch pedal (1). TESTING PLAY OF CLUTCH PEDAL Using a convex rule, measure the distance of the pedal in the operating direction, + Measure with the engine stopped, ADJUSTING PLAY OF CLUTCH PEDAL 1. Remove cover (3). 2. Screw in adjustment bolt (4) until piston (5) and valve (6) contact. Then unscrew it 4 turns and tighten lock put, 3. Install cover (3) 4, Install rod (7) so that it becomes standard play (40 * 10mm). % Bend cotter pin securely. 22-2 MAIN CLUTCH 292F203 22F002 22F003 GD600-3 SERIESMAIN CLUTCH TESTING AND ADJUSTING ‘TESTING CLUTCH PEDAL STROKE QS Confirm that gearshift lover is in neutral and park- ing brake lever is pulled on. Start the engine and use convex rule @) to measure dis- ‘ance traveled from up to down of pedal (1). ADJUSTING CLUTCH PEDAL STROKE Remove cover (8). femove clutch inspection cover (9) Loosen two lock nuts (10) and remove lock plate (11). ‘Adjust nut (12) so that it bocomes standard measure- 42 ment (a= 54 “5 mm) + Engage clutch when adjusting. 5. After adjusting, see section “CLUTCH PEDAL STROKE CHECK" and confirm that stroke is within the standard ‘measurement (1565 mm). pene dé 202208 ‘TESTING CLUTCH PEDAL OPERATING FORCE ‘Start the engine, use the push-pull scale () to measure ‘maximum value just short of the pedal stroke end. ‘Measurement is done both with engine low idling and. at full rpm. le Pe3b03020! 6D600-3 SERIES 22:3TESTING AND ADJUSTING MAIN CLUTCH ‘TESTING CLUTCH INERTIA BRAKE Start the engine, depress clutch pedal fully and use 2 stop watch, etc., to measure the time for the main clutch shaft to stop. 4 Measurement is done with engine at full rpm. ADJUSTING CLUTCH INERTIA BRAKE AY Adjustment must be done with engine stopped when the clutch is already mounted on the chassis. 1, Set length of rod (13) between pin holes at 80mm. 2. Keep clutch engaged, and bring brake drum (15) and bbrake band (16) into close contact by turning adjust- ment bolt (14) until clearance is 0. 3. Turn adjustment bolt back 4 tums and adjust until ‘clearance between brake and drum becomes 2mm. Then Jock with two nuts (17) 4. Adjust installation height of spring (18) to 58mm and, lock with two nuts (19). 5, After adjustment see section, “CLUTCH INERTIA BRAKE CHECK" and confirm that stopping time is the a standard value (within 3 seconds.) TESTING CLUTCH BOOSTER PRESSURE Special tool Part number Partname | Q'ty A | 790-301-1103 | Hydraulic tester 1 1, Remove plug (1) for measurement, 2. Attach hydraulic tester A (78 kg/cm”), RN 3. Start the engine. When oi temperature is between 35 to 45°C, depress the main clutch pedal and measure relief pressure. Ppeseoso22 cr GD600-3 SERIESTESTING AND ADJUSTING MAIN CLUTCH, INCHING PEDAL ADJUSTING CLUTCH BOOSTER PRESSURE 4+ Af nya prese is avi standrd vl (at egine full rpm: 45 + 3 kg/em?}, adjust according to following procere A Acumen done wit nine topped 1. Remove side cover (2). 2. Loosen nut (3), turn adjustment sorew (4) and adjust ‘tension of internal spring (61. % Hydraulic pressure rises when screw is turned to right. Hydraulic pressure falls when screw is turned to left. 3, After adjustment, confirm that hydraulic pressure is within standard value with the procedure of “TESTING CLUTCH BOOSTER PRESSURE”. INCHING PEDAL STROKE AND OPERATING FORCE GD605R, GDG5ER, GDGOSA, GDES5A-3 ‘TESTING TRAVEL Using a scale (1), measure the length of the movement from up to down from the beginning to the end of depressing the inching pedal (1). TESTING OPERATING FORCE Using push-pull scale (2), measure the maximum value in the stroke to just before the inching pedal stroke ond. GD600-3 SERIES 22-5TESTING AND ADJUSITNG HYDROSHIFT TRANSMISSION GD605R, GDESSR, GDE0SA, GDES5A-3 Special tool Part number Partname | 'ty A | 790-301-1103 | Hydraulic tester 1 Unit: kg/om? No. | Measurement check item | Standard Plug (2) _| Pilot oil pressure 14.5405 Plug (3) | Modulating oil pressure 25.5215 Plug (4) | Lubrication oil pressure 26418 TESTING TRANSMISSION OIL PRESSURE (PILOT PRESSURE) 1, Remove side cover (1). 2. Remove measuring plug (2) and attach hydraulic tester A (25 kglem?), 3. Run engine, measure transmission pilot pressure. ‘TESTING TRANSMISSION OIL PRESSURE (MODU- LATING PRESSURE) 1, Remove side cover (1) 2, Remove measuring plug (3), and attach hydraulic gauge A(70 kg/em*). 3. Run engine, measure transmission lating pressure). To confirm the modulating set pressure only, it is necessary to fun the engine. 4 To confirm clutch oil pressure for each gear shift (except F and R), run the engine and measure with ‘the inching pedal depressed. i pressure (modu HYDROSHIFT TRANSMISSION D603 SERIESTESTING AND ADJUSTING ‘TESTING TRANSMISSION OIL PRESSURE (LUBRICANT PRESSURE) 1. Remove measuring plug (4) and attach hydraulic tester (25 kg/em*). 2. Run engine, measure transmission lubricating oil pres: ADJUSTING TRANSMISSION OIL PRESSURE (MODULATING PRESSURE) % — IFil pressure is outside standard value, adjust according +o following procedure. 1. Remove transmission control valve assembly (4). + For procedure of removing from chassis, see section, “TRANSMISSION CONTROL VALVE ASSEM- BLY REMOVAL”. 2. Remove cover (5) and valve (6) 3. Increase and decrease shims (7) and adjust spring (8) tension. 4 Increase shims and oil pressure rises. Decrease shims and oil pressure falls % Standard shim thickness: 1.0 mm 4 Kind of shim: 0.8 mm, 0.6 mm 4. After adjustment confirm that transmission oil pressure (modulating pressure) is within standard value (25 kg/em*), following procedure of section, “TRANS- MISSION OIL PRESSURE (MODULATING PRES- SURE) CHECK’ 606003 SERIES HYDROSHIFT TRANSMISSION 22015, 22-7 ®TESTING AND ADJUSTING HYDROSHIET TRANSMISSION GD605A.3 (Serial No. 57001 and up) GD655A-3 (Serial No. 67001 and up) ‘Special too! Part number Partname [Q'ty A | 790-301-1103 | Hydraulic tester | 1 Unit: keglem* No. Measurement check item | Standard Plug (1) | Modulating oil pressure [25.5 £ 1.5 Plug (2) | Pilot oil pressure 145 £05 Plug (3) | Lubrication oil pressure [25215 ‘TESTING TRANSMISSION MODULATING PRESSURE CHECK 1 Remove measuring plug (1) and attach hydraulic gouge (70 kg/om* ). 2. Run the engine, measure transmission oil pressure (modulating pressure). * To confirm the modulating set pressure only, it is necessary to run the engine. # To confirm clutch oil pressure for each gear shift (except F and R), run the engine and measure with the inching pedal pressed, TESTING TRANSMISSION PILOT PRESSURE CHECK 11 Remove measuring plug (2) and attach hydraulic gauge A. (25 kg/em). 2. Run the engine, measure transmi pressure, jon lubricating oil ‘TESTING TRANSMISSION LUBRICANT PRESSURE CHECK 1 Remove measuring plug (3) and attach hydraulic gauge A (25 kg/om® ). 2 Run the engine and measure transmission lubricating pressure. p2anga073 ADJUSTING TRANSMISSION OIL PRESSURE (MODULATING PRESSURE) For details, soe Page 22-7. 22-8 GD600-3 SERIES @TESTING AND ADJUSTING TRANSMISSION CONTROL LEVER STROKE AND OPERATING FORCE TRANSMISSION CONTROL LEVER STROKE AND OPERATING GD60OR, GDE50R-3 TESTING AND ADJUSTING STROKE Use a convex rule to measure the stroke of the gear shift levers at the tip of each lever between each gear shift. (1to4=N) (He N= L). ‘* Measure with engine stopped. The stroke of the gear shift lever is determined by the working distance of the shifter case fork section on the transmission side, but in order that the gear shift lever will not interfere with other parts when itis being used, ‘the neutral position is adjusted with rods (2), (3) ‘TESTING AND ADJUSTING OPERATING FORCE Use the push-pull scale (P) to measure maximum value in the stroke to just before the stroke end of each gear shift at the ‘gear shift lever (1) tip. + Measure with engine stopped. ‘The operating force of the gear shift lever is determined. jon side. However, when the operating force is above standard value, check for rod twisting, If ‘there is no abnormality, disassemble the transmission side and check the operating condition of the shifter ‘case notch section and gear movement within the trans- fon the transmis mission, GD600-3 SERIES 29803029 229TESTING AND ADJUSTING TRANSMISSION CONTROL LEVER STROKE AND OPERATING FORCE Theo CONTROL LEVER STROKE AND OPERATING FORC! GD605R, GDESSR, GDE0SA, GDESEA-3 ‘TESTING AND ADJUSTING STROKE Use a convex rule to measure the stroke of the gear shift levers at the tip of each lever between each gear shift. ‘% Measure with engine stopped. ‘The stroke of the goar shift lever is determined by the working distance of the lever notch on the transmission side. However, the neutral position of the gear shift lever is determined by adjusting rod (2) and cable (3) without removing the gear shift lever guide. ‘TESTING AND ADJUSTING OPERATING FORCE Use the push-pull scale (@) to measure maximum value in the stroke to just before the stroke end of each gear at the gear shift lever (1) tip. % Measure with engine stopped. ‘The operating force af the gear lever is determined on the transmission side, However when the operating force is above standard value, check the movement of the connecting rod. If it is normal, disassemble the trans: mission side and check the operating condition of the notched part and the movement of the spool. 2241 0 GD600-3 SERIESPOWER TRAIN 23 DISASSEMBLY AND ASSEMBLY @) MAIN CLUTCH . STEERING PUMP AND MAIN CLUTCH PUMP Removal... eos Removal and installation vo 23118 lostallation so. 23.5 HYDROSHIFT TRANSMISSION PUMP MAIN CLUTCH CASE Removal and instalation ............ 23419 Disassembly 23:10 BEVEL PINION Assombly Doiceeeeees BBH2 Removal fete eeeees 23420 MAIN CLUTCH Installation 23.122 Disassembly ooo veeeee eee e es 2814 Disassembly... 23-124 ASSOMBIY occ ceeceser eee 2316 Assembly... 23-125 DAMPER BEVEL GEAR AND SHAFT Removal and installation... 2322 Disassembly 23-126 Disassembly and assembly... eves + 23-28 Assembly... ceeee ees BBN27 TRANSMISSION BEVEL GEAR Removal ceceeees 2824 Disassembly. 23-128 Installation sete: 2327 Assembly... feces 231282 Disassembly. 2332 ‘TANDEM AND FINAL DRIVE Assembly. oe 23.40 Removal 23-130 HYDROSHIFT TRANSMISSION Installation... 23-192 Dissmiby reenter tre 2362 Disassembly... - 23-134 ‘Assembly Dene. 2368 Assembly 23-139 CAGE AND REVERSE CARRIER TANDEM CASE AND SPROCKET Disassembly Leseeee 2388 Removal ..... veces 28146 ‘Assembly er aa0y Installation 23-180 1ST SPEED ROTARY CLUTCH WHEEL BRAKE AND SPROCKET Disassembly veeee 2398 Removal and installation... 23-153 Assembly... cecesees 2399 cuain HIGH SPEED ROTARY CLUTCH Rao oe 23-184 Dien ao Installation... 23-156 Assembly setsssses sess 20110 WHEEL BRAKE AND SPROCKET ELANETARY.GEAR Disessembly ee... 23-188 Disassembly and assembly... 2. 23113 ean 23161 HYDROSHIFT TRANSMISSION CONTROL VALVE Removal. .eceeececeeee evens) 2BME lostallation ooo. eee cece cece 2B GD6003 SERIES 23-1DISASSEMBLY AND ASSEMBLY REMOVAL OF MAIN CLUTCH ae Draining nyarautc it Clutch shore uieh | ca contol rod 0 MAIN CLUTCH ~Dise ing hydraulic oi! YS Loosen oi iter cap to remove residual pressure from tank. Logsen drain plug (1) to drain oll, 3 Hydraulic tank: Approx. 278 Refer to “23 REMOVAL OF TRANSMISSION” section. 3, Fuel tank assembly Refer to “13 REMOVAL OF FUEL TANK ASSEMBLY section, Pate 23F00! GD600-3 SERIES.DISASSEMBLY AND ASSEMBLY MAIN CLUTCH 4, Clutch control rod. Disconnect clutch control lever (2) from lever at booster side. 5. Spring Remove spring (3). 6. Hydraulic pump outlet hose Disconnect hydraulic pump outlet hose (4) from tube (5). 7. Clutch piping 1) Remove lubricating valve to booster tube (6). 2). Disconnect lubricating valve (7) from main clutch case. 3) Disconnect booster to transmission lubricating hose (8) from booster. 4) Disconnect clutch case to transmission case tube (9) from clutch case. & Clutch shaft Remove clutch shaft (10). 6D6003 SERIES 23-3DISASSEMBLY AND ASSEMBLY &% Clutch case 1) Remove inspection cover (11). 2) Temporarily sling main clutch case (12). Main clutch case: 90kg jove mounting bolts. Sling up and remove main clutch case. 3) 10. Clutch 1) Temporarily sling clutch (13). Clutch: 60kg 2) Remove mounting bolts. Sling up and remove main clutch. % Put match marks to pressure plate and tlywhee! bbefore removal. 11. Dise, Plate Remove dises (14) and plates (15). Disc: Specs, Plate: 2pes. 12, Hub Remove mounting bolts (16) and remove hub (17) 23-4 D MAIN CLUTCH ‘GD600-3 SERIESDISASSEMBLY AND ASSEMBLY MAIN CLUTCH INSTALLATION OF MAIN CLUTCH GD600R-3 GD650R-3 6 Aang oak 1 wen on ’ aa 2 3 ol ia ctucen Bee, uteh| teh cae 9 son iain ch cages 4 Fer ay “ 2002 Fed * erate i 1. up Install hub (17) 0 flywheel and tighten mounting bolts 6). 2. ise, Pate Install discs (14) and plates (15) in order. 4 True up notches of plates and align them with oll vent on flywheel. 4% True up notches of dise in the same position, ‘% Coat dises and plates with engine oil. 3 Clutch Align match marks put at the time of dismounting. Sling ‘and install eluteh (13). GD600-3 SERIES 23-5DISASSEMBLY AND ASSEMBLY MAIN CLUTCH Installing position of main clutch when pressure plate Standard for aligning is replaced is as follows: 1) Bring match mark on flywheel right below. 2) Install pressure plate aligning its widest notch ‘with A portion as shown in the Figure right. Position of match mark 29F003, 1 on tyme 4, Clutch case Install clutch case (12) fitting lever (18) in cage (19). # Charge grease (G2-L!) to ol seal lip groove as much as to fill up 40 to 60%. 5. Clutch shaft Install clutch shaft (10), + Care should be taken not to damage seal and bearing ‘when installing shaft, }. Adjusting clutch 1 Loowen fock nut and disconnect lock (20) fom nut sroove. 2) Tum and adust nuts thatthe distance“ between nut (21) end face and flange end face becomes the Specitied distance. 3 The spectedditance: a= 54 "Zn * If protuded portion of nut travis 75 to 8 pitches, the dstanceinereses or dereass Ir. 3) Fit lock in nut groove and tighten lock nut. 23-6 GD600-3 SERIES.DISASSEMBLY AND ASSEMBLY 4) Attach gasket and install inspection cover (11). Too Gasket: Gasket sealant (LG-1) 5) Adjusting clutch play i) Remove cover (22). ii) Loosen lock nut (23) and fully loosen adjust- ment bolt (24). Screw in bolt four turns and lock itwith lock nut. * At that time valve to piston clearance in booster should be 6mm. i) Attach gasket and install cover (2). Ow Gasket: Gasket sealant (LG-1), 7. Cluteh piping 1) Fit O-ring and connect main clutch case to transmis: sion case tube (9) to main clutch, 2) Connect booster to transmission lubricating hose (8) ‘to booster. 3) Fit O-ring and install lubricating valve (7) on main clutch case. 4) Install lubricating valve to booster tube (6) 8. Hydraulic pump outlet hose Connect hydraulic pump outlet hose (4) to tube (6). # Install hose with care to avoid twisting and inter- ference. GD600-3 SERIES. MAIN CLUTCHDISASSEMBLY AND ASSEMBLY MAIN CLUTCH 2. Spring Install spring (3). 10. Main clutch control rod Connect control rod (2} to lever at booster side. Bend down cotter pin firmly. _23R002 11, Fuel tank assembly Refer to "13. INSTALLATION OF FUEL TANK ASSEMBLY" section. 12, Transmission Rafer to “23 INSTALLATION OF TRANSMISSION” section. 13, Feeding hydrate o Trahan dain plu and feed engine il upto the speed leg trough o filing ore (2 “Ee Braselton. Aporox. 278 ‘* Start engine to circulate oil in piping and recheck oil level. 23-8 GD600-3 SERIES @ISASSEMBLY AND ASSEMBLY MAIN CLUTCH CASE DISASSEMBLY OF MAIN CLUTCH CASE eben vate brake band Bearing it seat 23F004 1 Valve Rornove valve (1). 2. Inertia brake band 1). Disconnect rod (2) from lever at booster side, remove lock nut (3), remove inertia brake band (4). 2) Remove bracket (5). 3. Clutch booster Remove mounting bolts, remove booster (6). 29P016 23-10 GD600-3 SERIES aDISASSEMBLY AND ASSEMBLY MAIN CLUTCH CASE 4, Shaft 1) Remove bolt (7), remove lever (8) 2) Remove screw (9}, pull out shaft (10), remove lever an, 8. Cap Remove cap (12). 6 Bearing Pull out bearing (13) 7. Oil seal Remove oil seal (14) GD600-3 SERIES 23-11 oSASSEMBLY AND ASSEMBLY MAIN CLUTCH CASE ASSEMBLY OF MAIN CLUTCH CASE 660083 lurch cate ain clutch booster Terie brake bond Voive 23F00s 1. Oil seal Press-ft oil seal (14) using push tool (#110). # Charge grease (G2:LI) to oil seal lip groove as much as, to fill up 40 to 60%, 2. Bearing Using push tool (9125) press-fit bearing (13). 3. Cap Install cap (12). * Bend down lock plate firmly, 4, Shaft 1) Install shaft (10) while inserting lever (11) into shaft 4% Charge grease (G2-LI) to bearing, 2). Tighten screw (9), install lever, lock screw with wire. 3) Install lever (8) and lock it with bolt (7) 23-12 GD600-3 SERIES oDISASSEMBLY AND ASSEMBLY MAIN CLUTCH CASE 5. Main clutch booster ‘Attach gasket and install booster (6). he Gasket: Gasket sealant (LG-1) 23016 6. Inertia brake band 1) Install bracket (5). X= Bracket sliding portion: Abrassive (LM-P) 2) Install inertia brake band (4) on bracket, tighten lock ‘out (3), connect rod (2) to lever at booster side. 7. Valve Fit O-ring and install valve (1), GD600-3 SERIES ooh 3DISASSEMBLY AND ASSEMBLY MAIN CLUTCH DISASSEMBLY OF MAIN CLUTCH sD600R-3 GDE5OR-3 ' 2 2 ‘ 5 ouch come ee oe Ring corer TOA ond eo Special tools Part number Partname [arty 791-216-1000 _ | Compressor 1 A | 790-101-1101__| Pump 1 790-101-2101 _| Puller (30%) 1 29020 1. Cage 1) Remove snap ring (1), ” 2) Install gear puller (1) and remove cage (2). 23P021 2. Spring YAS Be careful since tang is anid 325ky sring tension, 1) Install too! A and remove mounting bolt from flange (3). 2) Remove tool, remove flange and spring (4) 23-14 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY MAIN CLUTCH 3. Guide Remove guide (5). 4, Ring 1) Remove nut, remove lock (6). 2) Remove adjustment nut (7) 3) Put match mark to ring (8) and cover before rermov- ing ther, ‘Match mark is for bringing lock position right below when lock is installed. 5. Cover 1) Put match mark to cover (9) and pressure plate (10). YAS Be caret since ide is applied 29.5k9 spring tension. 2) Compress spring and remove collar (11), quide (12) and spring (13). 3} Remove cover (9). 6 Rod, Lover Remove rod (14) and lever (18). 7. Guide Remove guide (16) 8 Seat Remove seat (17) GD6003 SERIES 23-15 ODISASSEMBLY AND ASSEMBLY ASSEMBLY OF MAIN CLUTCH 9289983 MAIN CLUTCH Prox pt sot Guide 4 veh come | Rea eg Guide Floor cae 20F007 Special tools Part number Part name arty 791-2161000 _| Compressor 1 8 [790-101-1701 | Pump 1 790-101-2101 Puller (30t) 1 1. Seat Install seat (17) on pressure plate (10), % Bend down lock plate firmly. 2. Guide Install quide (16) on pressure plate. 4 Bend down lock plate firmly. 3. Rod, Lever Install rod (14) and lever (18) on cover (9). 23P029 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY cLuTCH 4. Pressure plate 1). Align match marks put whon disassembled and install pressure plate (10) on cover (9). 2aP034 2), Install spring (13), guide (12) and collar (11) on pres- sure plate and install pressure plate on cover. * Confirm whether collar is installed firmly, 5. Ring 1) Align match marks put at the time of disassembling and install ring (8) 2) Screw adjustment nut (7). * Screw in adjustment nut to the approx. same amount as before disassembling, 3) Install lock (6). * Bend down cotter pin firmly. 6 Guide Install guide (5). Gp600-3 SERIES 231 7DISASSEMBLY AND ASSEMBLY 7. Flange 1) Install spring (4), 2) Using too! A compress spring and install flange (3) 4 Bend down lock plate firmly. 8. Cage 1) Press-fit bearing into cage and install cage (2) using push toot 2) (668). 2). install snap ring (1). 23-18 o MAIN CLUTCH 23P020 (GD600-3 SERIESDISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CLUTCH HUB = GD600R-3 GDE50R-3 1. Remove snap ring (1) Remove retainer (2) from hub (3). 3. Remove lock (4). 4, Remove snap ring (5) and pull out bearing (6) from ‘retainer using pross-fitting tool (678). ASSEMBLY OF CLUTCH HUB. GD600R-3 GDE5OR-3 1. Using pressitting tool (6116) press-fit bearing into retainer and install snap ring (6). %* Coat bearing with engine oil, 2. Install lock (4) on hub. ‘% Install lock with its slightly bent side faced down. 3. Using press-fiting tool (675) install retainer (2) on hub @). 4. Install snap ring (1). 23-20 MAIN CLUTCH 23r03a 2ar03s 2ar036 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CLUTCH BOOSTER GD600R-3 GDE5OR-3 1, Remove cover (1) and cover at the other side. 2, Remove bolt (2), pull out lever and shaft assembly (3), remove lever (4). 3. Remove piston (5), spacer (6) and valve (7) from body (a). 4, Remove ring (9) and disassemble valve into guide (10), spring (11), guide (12) and valve (13). ASSEMBLY OF CLUTCH BOOSTER — GD600R-3. GDES5OR-3 ‘* Coat sliding portion of each part with engine oil before assembling, 1, Fit O-ring to valve (13) and install guide (12), spring (11) and guide (10) in that order and fix them with ring (9). ADs Oring: Grease (G2-LI) Ds Valve: Grease (G2-LI) Dx Spring: Grease (G2-L1) 2, Fit O-ring and install valve (7}, spacer (6) and piston (5) con body (8). 3. While installing lever (4) on lever and shaft assembly (3), install assembly on body and tighten bolt (2. 7Tix Contact face of valve and lover: Abrassive (LM-P) 4. Attach gasket and install cover (1) and cover at the other side. T= Gasket: Gasket sealant (LG-1) GD6003 SERIES MAIN CLUTCH 23037 29P041 23-21 ®DISASSEMBLY AND ASSEMBLY DAMPER, REMOVAL OF DAMPER GD6O5R, GDES5R, GD6O5A, GDES5AS 1. Remove HYDROSHIFT transmission, Refer to “REMOVAL OF HYDROSHIFT TRANSMIS: SION” section. 2. ‘Temporarily sting damper (1), 3. Remove stopper (2). Sling up and remove damper (1), [is] Damper: Approx. 36 ka INSTALLATION OF DAMPER GD605R, GDE55R, GDG0SA, GDES5A-3 1. Sling damper (1) into flywheel 2, Install stopper (2). Bend down lock plate firmly, 3. _ Install HYDROSHIFT transmission. Refer to “INSTALLATION OF HYDROSHIFT TRANS- MISSION" section. 23-22 606008 SERIES ®DISASSEMBLY AND ASSEMBLY DAMPER DISASSEMBLY OF DAMPER GD605R, GDE55R, GD6OSA, GDESSA-3 1. Remove flange (1). 2. Turn over damper and romove flange (2. 3. Pull out body (4) and rubber (5) from body (3) 4, Remove gear (6} from body (3). 20P083 ASSEMBLY OF DAMPER GDG05R, GDE55R, GDGO5A, GD655A-3 1. Install gear (6) on body (3). ‘# Bend down lock plate firmly. 2, Install flange (1). # Bend down lock plate firmly, * Charge grease (G2-LI) to flange pilot as much as one fifth of its eapacity. Charge grease (G2:LI) 2aPoaa ‘as much as one fifth of its capacity, Flange 29F008 2ap0as 3. Install body (4) and rubber (5) on body (3). oie Rubber: Grease (G2-LI) 4, Install flange (2) + Bend down lock plate firmly. 20p0s6 GD600-3 SERIES 23-23 oODISASSEMBLY AND ASSEMBLY TRANSMISSION REMOVAL OF TRANSMISSION GD6OOR, GDESOR-3 23803080 1. Draining oil from transmission case Remove drain plug (1) to drain oil from transmission case, : boy Transm : ApPFOK. ‘wxtay Transmission case: Approx. 33° J A 2. Operator's seat Sling and remove operator's seat (2) (Cig) Operator's seat: 43 kg e92F250 23:24 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY 3. Transmission control rod Remove control rods (3) and (4) together with bracket ‘a an assembly. 4. Piping 1) Remove oil filling port (6) and oil level gauge tube ch 2). Disconnect transmission lubrication hose (7) from tube. 3) Disconnect hoses (8), (9), (10). 5. Parking brake cable Disconnect parking brake cable (11) GD600-3 SERIES TRANSMISSION T. . &TRANSMISSION DISASSEMBLY AND ASSEMBLY 6. Speedometer cable Disconnect speedometer cable (12). 7. Universal joint 1) Remove upper universal joint (13). 2) Remove lower universal joint (14). & Transmission 1) Temporarily sling transmission. CE] Transmisson: 650 ko 2) Remove mounting bolts (15) (both front and rear). 3) Sling up and remove transmission from the lower side of body. % Koop shims of mounting portion as sets, ‘22P250) 23-26 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY. TRANSMISSION INSTALLATION OF TRANSMISSION — 6D600R, Gbé50R-3 2 ‘Univeral joint Spscaorecor exble Parking brake eable 1 5 Piping storor radar} Transmission FFransmission| contrat red esaing oT fe wens Hon ease 29803001 Special tool Part number Partname | arty ‘A | 792-271-1000 [Centering tool 1. Transmission 1) Place removed shims at mounting portion and sliding transmission into mounting portion. 2) Tighten mounting bolts (15) (both front and rear), SRE] Mounting bolt: 28.5 +3 kam 4 Tightly fasten the mounting bolt after aligning the transmission. 232258) 606003 SERIES. 23-27 @DISASSEMBLY AND ASSEMBLY 3) Carry out centering as follows. j) Install tool A on couplings of main clutch and ion. clutch in RELEASED state. Measure axial runout and radial runout when rotating couplings of main clutch and transmission simultaneously and confirm whether they are within the standard. * Stendard Axial runout: 1.0 mm Max, (Runout in the Y direc: tion) iiy Radial runout: 1.5 mm Max. (Runout in the X direc- tion) If runout is out of the standard, adjust for proper runout by inereasing or decreasing shims at mounting portion 2. Universal joint 1) Install tower universal joint (14), G3) Mounting bolt: 11.541 kgm 4 After installing, apply grease (G2-L1) 2). Install upper universal joint (13). FZ] Mounting bolt: 7£0.5 kon ‘* After installing, apply grease (G2-L1) 23-28 oO TRANSMISSION 2ar012 D603 SERIESDISASSEMBLY AND ASSEMBLY. 3. Speedometer cable ‘Connect speedometer cable (12). 4, Parking brake cable Connect parking brake cable (11), 5. Piping 1) Connect hoses (8), (9), (10). 2) Connect transmission lubricating hose (7) to tube. 3) Fit O-ring and install oil filling port (6), and oil level gouge tube (6). 606003 SERIES. TRANSMISSIONDISASSEMBLY AND ASSEMBLY TRANSMISSION 6. Transmission control rod Install control rods (3) and (4) with brackets installed. % Bend down cotter pins firmly. 7. Operator's seat Sling and install operator’s seat (2). aaePeso 8 Feeding oll to transmission case Tighten drain plug and feed engine oil up to the speci ied level through oil filling port (16), BP ansmision case: Approx. 38 ‘* Start engine to circulate oil in piping and recheck oil level 23-30 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION 60900R:3 TRANSMISSION 1 GD650R-3 inna fo 5 ; oe Dum Fiooe 1 Secosoneer ese 8 / Toa emt K 8 Node 5 Tarcare ae _ ‘No. 3 front rrnsmision 7 Wo. Fone 1 oe " To, ort Front support No, 2 rear L Sting tor 23-32 v Holder Yoke No. reer GD600-3 SERIESDISASSEMBLY AND ASSEMBLY TRANSMISSION 0 Tale tare oer % “No 4 shat “Geer a Holoer 2 a a Bearing cone ‘Outer race 0 Holoer 2 Holder Ay Hotcer = 8 Holder a 2 a No.2 ahatt |_Surer ce Ey 2 Gear ee et io, 7 sate a Outer race 29F013 % Transmission shafts are called No, 1, No. 2, No. 3 and ‘No. 4 from input slide, and front and rear when they ace mounted on machine. GD6003 SERIES 23-33DISASSEMBLY AND ASSEMBLY 1. Rear support Remove tear support (1). 2. Front support Remove front support (2) Drum Remove brake drum (3) 4, Flange Remove holder (4), remove flange (5), 5. Parking brake Remove parking brake assembly (6). 23:34 2ar0cs, GD600-3 SERIES.DISASSEMBLY AND ASSEMBLY TRANSMISSION 6. Lubricating tube 1) Fix tube with shifting fork side up. 2) Remove joint bolt, remove lubricating tube (7), ‘and oil level gauge tube (69), oil filler tube (70). r F2ap03022 sifting fork cover ing jack bolt (Thread dia, = 12 mm, Pitch = 1.75 mm) 8 remove 3rd and 4th speed shifting fork covers (8). 8. Shifting fork cover Using jack bolt (Thread dia, = 12 mm, Pitch = 1.75 mm) remove 2nd and 1st speed shifting fork covers (9). 9 Holder Remove holder (10). 10. Yoke Remove yoke (11). 11, No. 1 rear cover Remove cover (12). 12, No, 2 rear cover Remove cover (13), 12, No. 3 rear cover Remove cover (14), 14, Speedometer shaft 1) Remove speedometer shaft (15). 2) Remove bolts mounting cover (16) GD600-3 SERIES oeDISASSEMBLY AND ASSEMBLY TRANSMISSION 15. No. 4 front cover Remove cover (17). 16. No. 3 front cover Remove cover (18). 17, No, 1 front cover Remove cover (19). 18, No. 2 front cover Remove cover (20). 19, Holder Remove holder (21). 20. Holder Remove holder (22) 21. Holder Remove holder (23). 22. Bearing cage Using jack bolt (Thread dia. = 12 mm, Pitch = 1.7mm) remove bearing cage (24). 23. Holder Remove holder (26) and confirm the number of shim. 24. Holder Remove Holder (26). 25. Holder Remove holder (27). 23-36 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY TRANSMISSION 26. No. 4 shaft, Gear 1) Using push puller @) push out No. 4 shaft (28) to rear side and remove bearing (29) and spacer (30). 2) Pull out No. 4 shaft and remove gears (31) and (32), spacer (33), gears (34), (35) and (36), and spacer. 27. No. 3 shaft, Gear 1) Using push puller (1) push out No. 3 shaft (37) to front side and remove bearing (38). 2) Pull out No. 3 shaft and remove collar (39), gear (40) and coller (41), gears (42) and (43) and collar (44). GD600-3 SERIES 23-37DISASSEMBLY AND ASSEMBLY TRANSMISSION 28. No. 2shat, Gear 1)” Using push puller @_ push out No, 2 shat (45) to front side and remove bearing (0) and spacer. 23078 2), Pull out No. 2 shaft and remove gears (47), (48), (49) and (50), collar (51), gear (52), spacer (53), gear (54) and spacer. 29. No. 1 shaft, Gear 1) Using push puller @) push out No. 1 shaft (55) to front side and remove bearing (56) and spacer. 2) Remove spacer (80), pull out No. 1 shaft, remove gear (87), collar (58), gears (59), (60), (61) and (62) and spacer. 23-38 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY TRANSMISSION 20, tale shatt goat Remove tock (63). Using puller @) pull out idle shaft (64) and remove gear (65). 31, Outer race Remove outer race (66). 32. Outer race Remove outer race (67). 33, Outer race Remove outer race (68). GD600-3 SERIES.DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY OF TRANSMISSION GD600R-3 ¢ GD65OR3 Holder Q Wo. fone |___ 1 Jeon 7 Spscer nerrae [Not aare os Geer 8 0 " 2 Bearing No, eer Yoke Hor 2 8 " 8 Ouerrace Bez LL votaer | | APR. 2 rome 8 a Fraser Bearing Hoiser a Owes | = 2 u Holder eee 9 No, 3 shalt “Gear Beoring | % Tale shake No, shake gear Gear * Coat sliding portion of each part with engine oil before installing, 23-40 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY ‘sniting fork cover % Front support TRANSMISSION . Berio wotder [Lf No.3 or ean) a . NE | brake: i o 23-41DISASSEMBLY AND ASSEMBLY 1. Outer race Using push toot @) (9120) install outer race (68) 2. Outer rece Using push toot @) (9120) instal outer race (67) 3. Outer race Using push toot G) (9120) instal outer race (6) 4. dle shat gear 1) Install snap cing inside of gear (69). Using pes-iting took @ (6120) preset bearings (70). Preset bearings, one each from both end of sear. 2) Fit O-ring to idle shaft (64) and install gear (65) and fix shaft with lock (63). 23-42 oD TRANSMISSION c¥Y ss 8 5 % GD600-3 SERIESDISASSEMBLY AND ASSEMBLY TRANSMISSION, No. 1 shaft _--No. 2shatt Front <> > Rear © Backlash of each gear Unit: mm tater shatt No. | Gearmesh | Backlash a-e | 017-0. ' “0 4 23F015 c-D | 018-042 Fig.1 €-F | 017-029 G-H | 018-042 -s | o18-0.42 =k |o18—042 L-m |02 -044 N-o [019-041 o-P__|oi9-o41 606002 SERIES 23-43DISASSEMBLY AND ASSEMBLY TRANSMISSION 5. No. 4 shaft, Gear 3 1). Using pressitting toot G) (956) press-fit bearing g (71) to No. 4 shaft (55). 2). Install No. 1 shaft from the front of transmission and. install spacer, gears (62), (61), (60) and (59), collar (58), gear (57) and spacer in order. ‘* Install gears and spacers as shown in the Fig 1 3) Using push tool (6120) install bearing (71) together shaft as an assembly in case. 6 Holder Install holder (26). # Bend down lock plate firmly, 7. Spacer Install spacer (80). & No. 1 front cover Fit O-ring and install cover (19). G0600-3 SERIESDISASSEMBLY AND ASSEMBLY 9. Bearing Using push toot (956) install bearing (56). 10. No. 1 rear cover, 1) Using push toot @) (#100) instal oil seal on cover (12), Charge grease (G2-LI) to lip groove of oil seal to fill up 40 to 60%. 2) Attach gasket and install cover (12). Hon Gatket: Gasket sealant (LG-1) 11, Yoke Install yoke (11) 12, Holder Fit O-ring and install holder (10). # Bend down lock piate firmly. 13. No. 2 shaft, Gear 1} Using pressfitting tool G) ($55) press-fit bearing (72) to No. 2 shaft (45). 2). Install No, 2 shaft from the front of transmission and install spacer, gear (64), spacer (63), gear (62), collar (51), gears (50), (49), (48) and (47) and spacer in order. ‘# Install gears and spacers as shown in the Fig. 1 3) Using push tool (#120) install bearing (72) together with shaft as an assembly in case. D600 SERIES TRANSMISSIONDISASSEMBLY AND ASSEMBLY. TRANSMISSION, 14, Holder Install holder (27), 4 Bend down lock plate firmly, 15. No. 2 front cover Fit O-ring and install cover (20) ‘* Install it with lubricating tube mounting portion faced up. 16. Bearing Using push tool (#68) install bearing (46). 17, Holder Install holder (22). * Bend down lock plate firmly. 23-46 GD600-3 SERIES DDISASSEMBLY AND ASSEMBLY TRANSMISSION 19, No. 3 shaft, Gear 1) Using press-fiting tool @ (955) press-fit bearing (73) to No. 3 shaft (37). 2) While installing No. 3 shaft from the front of trans- mission, install collar (44), gears (43) and (421, collar (41), gears (40) and collar (39) in order. ‘* Install gears and collars as shown in the Fig. 1. 3) Using push tool (6120) install bearing (73) together with shaft as an assembly in case. 20. Holder Install holder (25). 4 Bend down lock plate firmly, 21. No. 3 front cover Fit O-ring and install cover (18). 606003 SERIES 23-47DISASSEMBLY AND ASSEMBLY. TRANSMISSION 22. Bearing Using push toot (986) install bearing (38), 23. Holder Install holder (21) after fitting the shims. + Confirm that clearance between holder and end of bearing is 0.1 to 0.2. mm. 4 Standard shim thickness: 3.0 mm 4% Kind of shim: 0.1 mm and 0.5 mm % Bend down lock plate firmly. 24. No. 3 rear cover Fit O-ring and install cover (14). op 29P 108 25, No, 4 shat, Gear 1)" Using push tool @ ($100) instal ot eat (74) on cover (16). Charge areas (G2-L1) 10 lip groove of ol salto fil up 40 to 60%. 2). Using pressing tool @. (6120) preset bearing (75) to cover (16). 3) Install snap ring (76). [esp 20P112 23:48 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY TRANSMISSION 4) Fit O-ring to cover (16) and press-fit No. 4 shaft (28), 55) While installing No. shaft (28) together with cover as an assembly from the rear of transmission, instal spacer, gears (36), (35) and (34), spacer, goars (32), and (31) in order. 6} Tighten botts mounting cover (16). 26. Bearing Install spacer (30). Using push tool (955) install bearing (29, 27. Holder Install holder (23) + Bend down lock plate firmly. 28. Beating cage 1) Using presscitting tool (9120) press‘it outer race (77) to bearing cage (24) and install snap ring. 2), Fit O-ring and install bearing cage (24). GD600-3 SERIES 23:49DISASSEMBLY AND ASSEMBLY ‘TRANSMISSION 29. No. 4 front cover 1) Fit O-ring and install No. 4 front cover (17). 2) After assembling each shaft and gear assembly, measure backlash of each gear and confirm that back- lash is within standard shown in the Fig. 1 (Page 23-43), 30. Shifting fork cover Attach gasket and install shifting fork cover (9). * Confirm that shifting fork is closely fitted in sliding ‘gear groove. A Gasket: Gasket sealant (LG-1) 31. Shifting fork cover, “Attach gasket and install shifting fork cover (8). % Confirm that shifting fork is closely fitted in sliding gear groove. ADm Gasket: Gasket sealant (LG-1) 32. Lubricating tube Attach gaskets to both ends and install lubricating tube (7), and oil level gauge tube (69), oil filler tube (70). GD Jointbolt: 3+0.5kam 33. Parking brake 1) Fit O-ring and install speedometer shaft (18). Km Speedometer shaft circumference: Grease (G2-L1) Lock shaft with wire firmly. GD600-3 SERIES.DISASSEMBLY AND ASSEMBLY 2) Install parking brake assembly (6). S735 Mounting bolt: 18: 2kam 4 Bend down lock plate firmly. 34. Flange 41) Install flange (5). 2) Fit O-ring and install holder (4). Bend down lock plate firmly. 35. Drum Install brake drum (3). GE] Mounting bolt: 18 2kam 36. Front support Install front support (2). X= Support mounting portion: Grease (G2-L1) 37. Rear support Install rear support (1). 6D6003 SERIES. TRANSMISSIONDISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION DISASSEMBLY OF HYDROSHIFT TRANSMISSION GD605A, GDESEA, GD6OSR, GDESER-3 ~ it 10 ‘“ Sleeve, 1 A 5 ry, eseatg |] com - i : 2 eval _ Eee —— — 23-52 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY. HYDROSHIFT TRANSMISSION ® 2 [Reverse wove Fevers wove] fina ger finggeer | TA 8 2 2 [Raven rare Sorina | piston and spring | Toe ung ay Ey 4 Bre Bucy | toc — Piste Piste s FFranemieion q 4 Sleeve © fa ‘soring |— too —oecking air 8 a Sue? Loe a] Abit Tow piston 4“ s a ae 0 case |—{ wown Spacer Leno oe Al Pn L—t06 Tow - Tos aoe Tok aoe ToL _ Tom 2aF018 GD6003 SERIES 23-53DISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION 2 song a oa Bee? = Boe 4 Fin co] riro ee x 1 /— amare snap ing |_fore Sane . ioraery |\ 2 2 ew _[ toma unger —\ ® Housing r—_/ 6 6 _ vow ——e # cae a s « 1 @ G coe tees shat oor raring “ a L coe Gear 9 " com 2aro1e 23-54 ‘ap600-2 SERIES woDISASSEMBLY AND ASSEMBLY. HYDROSHIFT TRANSMISSION a soira 2 a a 2 ® a paton ne Bee? LY eee case ‘soar cis ey) —L: Ra ea » Rad weed A fasesr Saeees BS s ' sone Special toot Partnumber Partneme [Oey | 796301-1300_| Airchecker 1 1. Drum Remove brake drum (1), 2. Flange Remove center bolt, remove flange (2), GD600-3 SERIES.DISASSEMBLY AND ASSEMBLY 3. Parking brake Remove parking brake assembly (3). 23P151 4. Transmission control valve piping Remove transmission control valve tubes (4), (5) and (6). * Care should be taken not to let strainer to come out from the tube (4). 5. Transmission control rod Disconnect transmission control rod (7) from lever and remove it together with bracket (8) as an assembly. 6 Tube Remove tubes (9), (10) and (11), 7. Lubricating tube Remove lubricating tube (12). & Transmission contral valve Remove transmission control valve (13) together with a cooler bypass valve (14) as an assembly. re 23-56 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION 9. Cover ‘Screw in jack bolt and remove cover (15). 10. Stoeve c ‘Sorew in jack bolts (Thread dia, = 16 mm, Pitch = 2.0 mm) and remove sleeves (16), (17) and (18). Since there are two kinds of sleeves, confirm their location before removal, 11. Yoke Loosen lock nut and remove F—R yoke (19) and inching ‘yoke (20) from spool 12, Sleeve Remove snap ring and move sleeve (21) to the right side to disconnect from control valve. oT 4. 290157 13. Transmission control valve Remove four mounting bolts (Thread dia. = 10 mm) and lift transmission control valve (22) to remove. GD600-3 SERIES 23-57DISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION 14, Sleeve Remove sleeves (21) and (24), 16, Transmission case 1) Set transmission in place with its transfer case faced down, % Before setting in place, remove mounting bolts tightened from transfer case side. 2) Install eye bolts @) (Thread dia. = 10 mm, Pitch = 1.75 mm) and (@) (Thread dia. = 12. mm, Pitch = 1,75 1mm). Sling and remove transmission ease (26). Slowly sling transmission case horizontally, Transmi n case: Approx. 130kg 16. Checking air Using tool A, measure piston stroke at each speed stage (F, R, 3rd, 2nd and L) as well as check their function. +” Air pressure: Bkg/em? min. Pisin stroke (Unit: mm) Speed stage | F | R | ard | 2nd | Stroke 3s | 3s | 25 | 25 | 35 2aP 162 23-58 GD600-3 SERIES DDISASSEMBLY AND ASSEMBLY ION 17. Cage and reverse travel carrier assembly 1) Remove tie bolt. 2). Install eye bolts @ (Thread dia, = 14 mm, Pitch = 2.0 mm). Sling and remove cage and reverse travel carrier assembly (26). (ia"] Cage and reverse travel carrier assembly: ‘Approx. 35k 23P163 18. Reverse travel ring gear Remove ring gear (27). 19. Spring Remove spring (28). 20. Spring, Disc, Plate 1) Remove spring (28). 2) Remove dises (30), plates (31) and spring (29) in order. % Disc: Specs. Plate: 2 pos. 21, Reverse travel piston and housing assembly Install eye bolts @) (Thread dia. = 14 mm, Pitch = 2.0 mm). Sling and remove revorse travel piston and hot assembly (32). D603 SERIES. 23-59DISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION 22. Reverse travel ring gear Remove snap ring (33), remove ring gear (34) 23. Spring Remove spring (35). 24. Spring, Disc, Plate Remove spring (36), discs (37) and plates (38). Disc: Ses. Plate; 2 pes, 25. Ring gear Remove ring gear (39). * Confirm installing direction of ring gear before removal. 26. Forword travel and 3rd speed pistons and housing assembly Install eye bolts @ (Thread dia, = 14 mm, Pitch = 2.0 mmm). Sling and remove forward travel and 3rd speed pistons and housing asembly (40) ++ Hold 3rd speed piston by the hand to prevent falling (Gaz) Forward and 3rd speed pistons and housings assembly: Approx. 35k9 27. Spring Remove spring (41). GD600-3 SERIESDISASSEMBLY AND ASSEMBLY. HYDROSHIFT TRANSMISSION 28. Spring, Disc, Plate Remove spring (42), discs (43) and plate (44) in order. % Disc: 2pes. Plate: 1 pe. 29. Pin Remove pin (45). 30. Snap ring Remove snap ring (46). 31, Forward travel and 3rd sped caters sembly Using gear puller @) (9219) pul out forward and Grd ‘speed carriers assembly (47). 32. Spacer Remove spacer (48). 33. 3rd speed sun gear Remove 3rd speed sun gear (49). 3A, 3rd speed ring gear Remove snap ring (60), remove 3rd speed ring gear (51). 35. Spacer Remove spacer (52). GD600-3 SERIES 23-61DISASSEMBLY AND ASSEMBLY. HYDROSHIFT TRANSMISSION DISASSEMBLY AND ASSEMBLY eee ‘36. 2nd speed piston and housing assembly Install eye bolts @) (Thread dia. = 14 mm, Pitch = 2.0 mm}. Sling and remove 2nd speed piston and housing assembly (63). + Hold piston by the hand to prevent falling. 37. Spring Remave spring (54). 38. Spring, Dise, Plate Remove spring (55), discs ($8) and plate (57). Disc: 2pes. Plate: 1 pe. 39, 2nd speed ring gear Remove 2nd speed ring gear (58). 40, 1st speed housing Install eye bolts @) (Thread dia. = 14 mm, Pitch = 2.0 mm), Sling and remove 1st speed housing (59). 23-62 GD600-3 SERIES.DISASSEMBLY AND ASSEMBLY. HYDROSHIFT TRANSMISSION 41. Ast speed rotary clutch Install sling plate @) . Sling and remove 1st sped clutch (60). ‘st apeed clutch: Approx. 85kg Bing plate mounting bolt: “Thread dia. 14 mm, Pitch = 2.0 42, Cage Remove cage (61), 43, No. 1 gear Remove No. 1 gear (62) 44, Cage Remove cage (63). 45, Worm Remove worm (64) 46. Spacer Remove spacer (65). GD600-3 SERIES 23-63HYDROSHIFT TRANSMISSION DISASSEMBLY AND ASSEMBLY. 47. Low piston housing 1) Remove tie bot. 2) Using push puller @)_ pull out low piston housing (66) trom shat. 3) Install eye bolts @ (Thread dia. = 14 mm, Pitch = 2.0 mm), Sling and remove low piston housing. 4+ Hold piston with the hand to prevent falling. 48. Spring Remove spring (67). 49, Spring, Dise, Plate Remove spring (68), discs (69) and plates (70) in order. Disc: 3pes. Plate: 2 pes. 50. Low ring gear Remave low ring gear (71). 51. Pin Remove pin (72. 52. Housing Install eye bolts @ (Thread dia. = 14 mm, Pitch = 2.0 ‘mm), Sling and remove housing (73), 23-64 GD600-3 SERIES DDISASSEMBLY AND ASSEMBLY 183. High speed rotary clutch 1) Remove four cage mounting bolts (74). 2) Install eye bolts @ (Thread dia. = 14 mm, Pitch = 2.0 mm). Sling and remove high speed rotary clutch (78), [Cie] Hioh speed rotary clutch: Approx. 75k 84, Cage 1) Place transfer in place with its mounting face down. 2) Screw in jack bolt and remove cage (76). + Koop shims identified their location, 55. Cage Screw in jack bolt and remove cage (77) ‘+ Keep shims identified their location. 56, Cage Screw in jack bolt and remove cage (78). ‘+ Keep shims identified their location. 57. Cage ‘Screw in jack bolt and remove cage (79). + Koop shims identified their location, 58. No. 2 gear Remove gear (80), 89. Bearing Remove bearing (81) together with collar (82) as an assembly. GD600-3 SERIES. HYDROSHIFT TRANSMISSION we 23P 199 23-65 ‘aDISASSEMBLY AND ASSEMBLY. HYDROSHIFT TRANSMISSION 60. Shaft Remove shaft (83). 61. No. 3 gear Remove gear (84). ¥ eee een ies 62. Bearing 1) amove being (8) totter with caller (98) a an . = assembly. a p J 2}, Remove beoring outer races (87) and (88) from transer cate. ° ae ASS ZOPIB 68. Valve Remove plate (89), remove valve (90), spring (91) and sleeve (92) 20137 23-66 e06003 SERIES DDISASSEMBLY AND ASSEMBLY ASSEMBLY OF HYDROSHIFT TRANSMISSION GD605R, GDES5R, GD605A, GDG55AS HYDROSHIFT TRANSMISSION valve —_ 5 & 1 8 Q Bearing No, 8 gear Shae Bearing cove uv ein LL 1e 2 4 4 18/ owsna cone No. 4 gear case Housing = Hydroshite 0 u No. 2 gear cope » a ‘nd opeed iin gear Spacer 2 2 0 u 2adepeed |___ ‘No. 1 gear cope cone da] 2 Tatspeed touting uw Pin Special tools Part number Partname [arty A_|_ 799-301-1300 _ | Air checker 1 792-371-1500 _| Spline shaft 1 B | 795-630-1830 | Adaptor 1 795-6301810 _| Torque wrench 1 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION a 7 i oc s 8 Cage ee Bis S/ 2 | x x “ Saeed « 5 “ ~~ 3rd speed eee Ting gear yes \ a \ «/ . : Bee | fereres fescaate |\ “ \ —]_ serina \—————— soning \ ten 2z3F020 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION B a c ‘Snap ing ‘Seal ring . ® Ta « _ {Ee o— J minnie “ a 4 ‘Spring = overs rave Be Piste / fos, so / Feat scr” pany = a " sere cone 23-70 o 29F021 6060-3 SERIESDISASSEMBLY AND ASSEMBLY. HYDROSHIFT TRANSMISSION 4 6 abeesting ining tube oy 10 Flange rum Transmission oncrol rod s 8 ‘checking air }_[Fransmision + Apply engine oil to sliding portion of each part before instaling. 1. Valve 1) Fix transfer ease with its mounting face down. 2) Install sleeve (92), install spring (91), valve (90) and plate (89). (606003 SERIESDISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION 2. Cage 1). Using push tool (#130) press-fit bearing outer races (87) and (88), 2) Using push tool ($130) press-fit bearing outer race (93), 3) Using push tool (990) press-fit bearing (94) and install snap ring (95) to tock bearing. 4) Fix transfer case with its mounting face up. 5) Install cage (96) 3. No.4 gear 1) Using pressitting too! @_ (975) press-fit bearing (8) to ora (97) 29°20! 23-72 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY. 2) Fix transfer case with its mounting face down, 3) Install No. 4 gear (99). Number of teeth: 2= 22 A) Fit O-ring and install sleeve (100). 4. Cage 1). Using press-fitting tool (130) press-fit bearing outer race (101). 2). Using press-fitiing tool ($70) press-fit collar (102) aligning mounting position and install ball (103). + If mounting position is not aligned, ball cannot be installed. 3) Install snap ring (104) to press bal. 4) _Ingert shims (105) into mounting portion and install cage (76). %* Use removed shims, the same amount at upper and lower sides. G3 Mounting bolt: 11 1.6kam 5) Adjusting bearing pretoad % Transfer gears are No. 1, No. 2 and No. 4 from input side. a transfer case with its mounting face directed frontward. ii) Install tool & to measure starting torque of No. 4 gear alone and confirm that it is ‘within standard. Adjustment canbe accomplished by increasing or decreasing shims, # Starting torque: 1 to 10 kgem % Measure starting torque after racing gear 4 or § turns and use the minimum value, 0600-3 SERIES HYDROSHIFT TRANSMISSION 2aP208 29P208DISASSEMBLY AND ASSEMBLY 5. Bearing 41) Fix transfer ease with its mounting face down. 2) Press-fit bearing (85) into collar (86) and install it on transfer case. 6. No. 3 gear Install No. 3 gear (84). * Number of teeth: 2=30 jear has proper installing direction and install it with spot faced boss faced up. 7. Shaft Install snap ring and install shaft (83). 8. Bearing Pressit bearing (81) to collar (82) and install it on shaft. 9. Cage 1) Using press-fitting tool (130) press-fit bearing outer race (106). 2) Fit O-ring and install cage (77) with shims (107) inserted into mounting portion, % Use removed shims as they are, the same amount at right and left sides. ‘F3=) Mounting bolt: 11+ 1.5kom 23-74 HYDROSHIFT TRANSMISSION 29r211 * @ + 20n212 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY 3) ‘Adjusting bearing preload i) Fix transfer case with its mounting face direct- ed frontward. ii) Install tool B and measure starting torque with No. 4 gear (total starting torque of No. 4 and No. 3 gears) and confirm that it is within standard, Adjustment can be accomplished by increasing or decreasing shims. ‘4 Starting torque: 2 to 17 koem ‘% Measure starting torque after racing gear 4 fr § turns and use the minimum value. * Adjust preload so that starting torque increases more than 1kgem and less than 10kgem as gear is added one each. 10. No. 2 gear » Using prestting toot @) (#76) presse bearings (109) to both ends of ear (108). 2) Install gear (80). Number of teeth: Z=31 11. Cage 1). Using press-fiting tool (130) press-fit bearing outer race (110). 2). Fit O-ring, inserted shims (111) to mounting portion, install cage (78). Use removed shims as they are, the same amount at right and left sides GEE) Mounting bolt: 11 £ 1.5kam 3) Adjusting bearing preload Install too! B in the same manner described in 9:3) section, measure starting torque with No.4 gear (total starting torque of No. 4, No. 3 and No. 2 gears) ‘and confirm that it is within standard. Adjustment can be accomplished by increasing or decreasing shims. 4% Starting torque: 3 t0 24 kgem ‘* Other instructions are subject to those described in 9-3) section. GD6003 SERIES. HYDROSHIFT TRANSMISSION 23-75 ®DISASSEMBLY AND ASSEMBLY. HYDROSHIFT TRANSMISSION 12, No. 4 gear 1) in transer case with its mounting face up. 2) Using pressitting toot @) (685) preset bearings (113) to both ends of gear (112) 3) fasta No. 1 gear (62) + Number ofteeth: — 2=32 18. Cage 1) Using press-fitting tool (#130) press-fit bearing outer race (114). 2) Install cage (61), 14, Cage 1). Fix transfer case with its mounting face down, 2). Using press-itting tool (9130) press-fit bearing outer ace (115), 3) Fit O-ring, insert shims (116) to mounting portion, install cage (79). GE) Mountng bolt: 174 tkam 4) Adjusting bearing preload Install tool @ in the same manner as deseribed in @-3) section, measure starting torque with No. 4 gear (total starting torque of No. 4, No, 3, No. 2 and No. 1 gears}, confirm that it is within standard. Adjustment can be accomplished by increasing or decreasing shims, * Starting torque: 3.5 10 30.5 kgem * Other instructions are subject to those described in 9.3) section 23:76 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY. HYDROSHIFT TRANSMISSION 18. High speed rotary clutch 1) Fix transfer case with its mounting face up. 2) Install eye bolts @) (Thread dia. = 14 mm, Pitch = 2.0 mm). Sling and remove high speed rotary clutch (78). [ig] High rotary clutch: Approx. 70kg 16. Housing Install eye bolts @ (Thread dia. ‘mm). Sling and install housing (73). 14 mm, Piteh 17. Pin Install pin (72) 18, Low ring gear Install low ring gear (71). ‘* Install ring gear with its recessed inner teeth side up. 19. Spring, Dise, Plate Install spring (68), discs (69) and plates (70). + Install discs aligning their notches in the same posi tion, * Disc: 3pes. Plate: 2 pes. 20. Spring Install spring (67) GD600-3 SERIES 23-77DISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION 21. Low piston housing 1). Using press-fiting too! (9140) press-fit bearing (1171. 2) Install seal rings (120) on piston (118) and housing (119) and install piston in housing. 4% Install seal ring with care to avoid twisting, 120 ayp231 3) Fit O-ring, install eye bolts @ (Thread dia. 14 mm, Pitch = 2.0 mm). Sling and install low piston housing (66), * Hold piston by the hand to prevent falling off. 4) Using push too! @) (#80) install tow piston housing (66). + Install housing with care not to damage planetary carrier seal ring, 5) Tighten tie bolt. ZH) Tie bolt: 17+ tkam %* Confirm that spring (67) is firmly installed in housing and piston groove, 23-78 GD6003 SERIES oODISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION 22. Spacer Install seal ring (121) and install spacer (65). 23. Worm Install worm (64). 2op2aa 24. Cage 1) Using push too! (997) install oil seal (122) and install speedometer shaft (123). % Charge grease (G2-LI) to, up 40 to 60%. 2) Fit O-rings (two} and install cage (63). FE) Mounting bolt: 11 1.5kom ea groove to fill 20p295 25. Cage 1) Fix transfer case with its mounting face directed to the other side. 2). Screw in jack bolt and remove cage (76). ‘* Keep removed shims identified their location. 26. Snap ring Install snap ring (124) 27. Seal ring Install seal ring (125). 4 Install seal rings not aligning their slits 238237 406003 SERIES. 23-79DISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION 28. Cage Fit O-ring, insert shims in mounting portion and install ‘cage (76), + Install cage with care not to damage seal ring. + Install removed shims as they are. G2] Mounting bolt: 11 # 1.5kam 29. Ist speed rotary clutch 1) Fix transfer ease with its mounting face up. 2) Install sling plates ). Sling and install 1st speed rotary clutch (60), ‘1st speed rotary clutch: Approx. 85kg 30. 2nd speed sun gear Install 2nd speed sun gear (126). 31. Spacer Install spacer (52). T= Inside surface of bushing: Grease (G2-L1) 32. 1st speed housing Install eye bolts (@) (Thread dia. = 14 mm, Pitch = 2.0 mm). Sling and install 1st speed housing (59). GD600-3 SERIES.DISASSEMBLY AND ASSEMBLY 33. 2nd speed ring gear Install 2nd speed ring gear (58). ‘* Install ring gear with its recessed inner teeth side down. 34, Pin Install pin (45). 36. Spring, Dise, Plate Install spring (85), dises (56) and plate (57) in order. 4% Install discs aligning notches of inner teeth in the same position. Disc: 2pes. Plate: 1 pe. 36. Spring Install spring (54). 37, 2nd speed piston ond housing assembly 1) Install eat ring and install piston in housing. 2) Install 2nd speed piston and housing assembly (53). % Hold piston by the hand to prevent falling off * Confirm that spring (54) is firmly installed in housing and piston groove. ‘38. rd speed sun gear Install 3rd speed sun gear (49). 39. Spacer Install spacer (48). 6060-3 SERIES. HYDROSHIFT TRANSMISSION zaDISASSEMBLY AND ASSEMBLY. HYDROSHIFT TRANSMISSION 40. 3rd speed ring gear Install 3rd speed ring gear (51) and fix it with snap ring (50), * Confirm that ring gear is firmly installed on planetary 41, Forward travel and 3rd speed carriers assembly 1) Install sea ring (128) and planetary gear. 4 Refer to “INSTALLATION OF PLANETARY GEAR” section. 2). Using push toot @ (680) install forward travel and 3rd speed carriers assembly (47). 42. Snap ring Install snap ring (46). 43. Spring, Dise, Plate Install spring (421, dises (43) and plate (44) in order. + Install discs. aligning their notches in the same * Disc: 2pes. Plate: 1 pe. 44. Spring Install spring (41) 45. Forward travel and 3rd speed piston and housing assembly 41) Install seal ring and instal piston in housing. 2). Install eye bolts (3) (Thread dia. = 14 mm, Pitch = 2.0 mm). Sling and install forward travel and 3rd speed pistons and housing assembly (40). + Hold pistons by the hand to prevent falling off and confirm that springs are installed flrmily in housings and piston groove. Forward and 3rd speed piston and housing assembly: Approx. 35k9 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY 46, Ring gear Install ring gear (39). + Install ring gear with recessed inner teeth up. 47. Spring, Dise, Plate Install spring (36), discs (37) and plate (38) in order. ‘# Install dises aligning notches of inner teeth in the same position. * Disc: 3pes. Plato: 2 pes. 48. Spring lostall spring (25), 49. Reverse travel ring gear Install reverse travel ring gear (34) and fix it with snap ring (33). * Confirm that ring gear is firmly installed on planetary 50. Reverse travel piston and housing assembly 1) Install seal ring and install piston on housing, 2) Install eye bolts @) (Thread dia. = 14 mm, Pitch = 2.0 mm). Sling and install reverse travel piston and housing assembly (32). %* Confirm that spring (36) is firmly installed in housing and piston groove, GD600-3 SERIES HYDROSHIFT TRANSMISSIONDISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION 51. Reverse travel ring gear Install reverse travel ring gear (27) ‘+ Install ring gear with its ring gear inner teeth up. 52. Spring, Dise, Plate Install spring (29), dises (30) and plates (31) in order. + Install discs aligning notches of inner teeth in the same position. * Disc: 3pes. Plate: 2pes, 53. Spring Install spring (28). 54, Cage and reverse travel carrer assembly 1) Install eye bolts @ (Thread dia. = 14 mm, Pitch = 2.0 mm). Sling and install cage and reverse travel carrier assembly (28). 2), Tighten tie bot. GED Tiebolt: 17 tkam Confirm that spring (28) is firmly installed in housing and piston groove. 55. Checking air Using tool A check function of piston at each speed stage (F, R, 3rd, 2nd and L). Measure piston stroke and confirm that itis within standard, Air pressure: Skg/em? min, + Piston stroke (Units_mm) Speed stage | F | R | ad | and | u -| swoke | 35 | 35 [25 | 25 | a5 | 23-84 GD600-3 SERIES oODISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION ‘Attach gasket to mounting fece, install eye bolts @) (Thread dia, = 10 mm, Pitch = 1.8 mm) and @ (Thread Gia. = 12 mm, Pitch = 1.75 mm). Sling and Install tane- tission exe (25). AD = Gasket: Gasket sealant (LG) 2) Mounting bolt: 182 2kam CEE) Transmission case: Approx. 13049 56. Transmission case 4 \ j % 4 57. Sleeve 1) Reise up transmission and fix it with transmission control valve mounting face directed frontward. 2). Fit O-rings to both ends and install sleeves (21) and (24), i= Oring: Grease (G2-LI) 88, Transmission control valve Attach O-ring to mounting surface, insert transmission ‘control valve (22) into sleeve (24) and install, ‘* When inserting transmission control valve into sleeve, be careful not to damage O-ring of sleeve. S52] Mounting bolt: 3.5 0.5kgm 59. Sleeve Move sleeve (21) to the left side to connect to contro! valve, install snap ring to fix sleeve, GD600-3 SERIES 23-85DISASSEMBLY AND ASSEMBLY. HYDROSHIFT TRANSMISSION DISASHEMUEY AND ASSEMBEY __—— 60. Yoke Install F-R yoke (19) and inching yoke (20) setting distance “a” at the standard at the state where spool is pulled and tighten lock nut to fix them on spo9l ‘Distance “a’": 19mm 61. Steeve Fit O-rings to both ends and install sleeves (16), (17) and (1g) Ls Oring: Grease (G2-L1) 62. Cover 1) Attach gasket, connect speed selector lever to spool yoke, install cover (16). AZ Gaskot: Gasket sealant (LG-1) =] Mounting bolt: 7+ 0.5kgm_ 2) Remove cover (129) to confirm whether speed selector lever is firmly connected to spool and install, cover with gasket attached. Ls Gasket: Gasket sealant (LG-1) bolt: Gasket sealant (LG-1) ‘ZI Mounting bolt: 3.5 + 0.6kgm_ Fit O-ring to mounting portion and install transmission control valve (13) together with cooler bypass valve (14) {9s an assembly. FS Mounting bolt: 4.5 tkem 23-86 606003 SERIESDISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION 65. Piping 67, 69, Flange 70, Drum Attach gaskets to both ends and install lubricating tube (12) GD Joint bolt: 11,54 2.5kam Fit O-rings to both ends and install tubes (9), (10) and a, ‘Transmission control rod. Fit bracket (8) and connect the transmission control rod (7) on lever (control valve side, Zar 1s3] * Bend down cotter pin firmly. Transmission control valve piping 1) Fit Oxrings to both ends and install control valve tubes (4) and (5), Install strainer in tube (4) 2). Fit O-ring and install control valve tube (6).. RE Control valve common tightening bolt: 4.5% Tkym Parking brake Install parking brake assembly (3). GD Mounting bolt: 18+ 2kom Bend down lock plate firmly. 1) Install flange (2) on shaft. 2) Fit O-ring and install holder (130) and tighten center bolt. Zw Center bolt: Thread tightener (LT-2) ZBI Centerbolt: 23.5 2.5kgm Install brake drum (1) G3] Mounting bolt: 184 2kgm 2orisi 20p259 GD600-3 SERIES 23-87 DDISASSEMBLY AND ASSEMBLY HYDROSHIET TRANSMISSION DISASSEMBLY OF CAGE AND REVERSE CARRIER ASSEMBLY GD605R, GDES5R, GD60SA, GDES5A-3 ane ieverse sun et, LE=| fae Hee Hew} carrier ass'y " 7 , [=| : [ae] : ex ' a a ‘Stembly 0 = a 23F022 1. Forward sun gear Remove snap ring (1) and remove forward sun goar (2), 2. Snap ring Remove snap ring (3). 3. Reverse sun gear Remove snap ring (4) and remove reverse sun gear (5). 0600-3 SERIESDISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION 4, Spacer Remove spacer (6). 5, Input shaft Using preze-fting toot ©) pl out input shaft (7). 290257. 6. Revers carrer assembly 1} Remove snap ring (8). 2). Using pressfitting tool @) (9108) pull out reverse carrier (9). 7. Seal ring Remove seal ring (10) GD600-3 SERIES 23-89SASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION 8. Beating 1) Remove snap ring (11). 2). Using presiting tool @) (9130) pull out bearing (2) 1). Remove snap ring (13). 2) Using press‘itting toot @ ($79) pull out bearing (14, 2a°263 | 10. Planetary gear Refer to “DISASSEMBLY OF PLANETARY GEAR” section. 23.90 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION ASSEMBLY OF CAGE AND REVERSE CARRIER ASSEMBLY GDG0SR, GDESSR, GD6O5A, GDESSA-3 Bearing Seal cing pur shat ‘Spacer Feverse sun oer }—— toa ‘Bearing ww A=] snap riee Forware sun gear ‘Coat sliding portion of each part with engine oil before 1. Bearing 1) Using pressftting toot @) (#160) press-fit bearing 2, 2). Unstall snap ring (11). 2. Seal ring Install seal ring (10). 6D600-3 SERIES. 2ar023, 29P260DISASSEMBLY AND ASSEMBLY HYDROSHIET TRANSMISSION 3. Planetary gear Refer to “ASSEMBLY OF PLANETARY GEAR" section. ; = 4. Bearing f. 1) Using press-fitting too! 4990) press-fit bearing O} E (14), 2) Install snap ving (13). ssp266 23P263 5. Cage assembly 1) Using press-itting tool (2) press-fit cage assembly. 4 Pressefit cage using care not to damage its seal ring, 2) Install snap ring (8). 20287 pau) 2sP2d 6. Input shate Using presfting too! @ preset input shat (7). 7. Spacer Install spacer (6). 23.92 (606003 SERIESDISASSEMBLY AND ASSEMBLY. HYDROSHIFT TRANSMISSION 8 Reverse sun gear Install reverse sun gear (5) and install snap ring (4). 9. Snap ring Install snap ring (3). 10. Forward sun gear Install forward sun gear (2) and install snap ring (1) D603 SERIES. 23.93DISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION DISASSEMBLY OF 1ST SPEED ROTARY CLUTCH GD605R, GDE55R, GD60SA, GDESEAS Taine a a ‘ > Be cote ToA a Sn ing 3 Sn ros 5 ‘ 1 /— nase |e Ta oed carrier ae pect oear ec " . ——_] a of soxer 9 " of sone Eaton 8 4 u Cy case seatviog |] seains 2oroz4 Part number Part name arty 792371-1300_| Plate 7 A 790:207-3360 | Push tool 7 23-94 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY 11, Housing assembly 1) Remove plate (1). 2) Remove housing (2). 2 Snap ring Remove snap ring (3). 3. Shaft, Bearing Set shaft (4) and bearing (6) in press and pull out them, 4 Collar Pull out collar (6). ‘5. 2nd speed carrier assembly 1) Remove mounting bolts (7) leaving two bolts un- removed. GD6003 SERIES. HYDROSHIFT TRANSMISSION 23P270 zare72DISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION 2) Fix carrier faced up, 3) Remove remaining bolts and remove 2nd carrier assembly (8) 29273 6. Spring, Disc, Plate Remove spring (9), discs (10) and plates (11) in order. * Disc: Specs. Plate: 2s 23P274 1st speed gear Remove gear (12). 290278 8 Spacer Remove spacer (13). 23-96 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY 'T TRANSMISSION 9. Spring Be careful since spring is applied tension. 1)" Put match marks on piston (14) and cage (16). 2), Using too! A compress spring with press and remove snap ring (17). 3) Remove snap ring (18). 10. Piston assembly Remove piston assombly (19). 29279 11, Cage assembly 1) Remove bolts mounting cage (20), 2) Using pressfitting too! @) (690) pull out cage assembly (22) from cage (21). 20292 GD600-3 SERIES 23:97DISASSEMBLY AND ASSEMBLY 12, Cage Remove cage (23). 13. Seal ring Remove seal ring (24) 14, Bearing Remove snap rings (26) and (26) and pull out bearings (27) and (28). 23-98 i HYDROSHIFT TRANSMISSION. 20R288 D603 SERIESDISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION ASSEMBLY OF 1ST SPEED ROTARY CLUTCH GD605R, GD655R, GDGOSA, GDEESA-3 cage Bearing ‘Seal ring cage | ____— ter Top 1 a / cone : 5 ‘ TTT 8 a “ rn 0 o—|: Be" ene y Plate (23F025, Spo toot ss Cs 5 Lszareia0 | Pate 7 760-201-2360 | Push vol i % Coat sliding portion of each part with engine ail before installing, GD600-3 SERIES 23-99DISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION 1. Beating 1) Using pressfittng toot @_ (9130) preset bearing (28). 2) Using press‘itting toot @)_ (676) press-fit bearing 27. 3) Install snap rings (25) and (26), 290290 2. Seal ring Install seal rings (24). Install rings not aligning their slits 23-1 00. GD600-3 SERIESDISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION 3. Cage assembly Using pressfitting tool @) (#115) press-fit cage assembly (22) t0 cage (21), 29°291 4, Cage 8 Install cage (23) aligning its oil vent with that on cage a ' 0. = + Install cage using care not to damage seal ring Ls Mounting bolt: Thread tightener (LT-2) FZ] Mounting bolt: 1.35+ 0.18kgm 2or292 5. Piston assembly 1) Install sea rings (29) and (30) on piston. ‘* Install seal rings using care to avoid twisting, gee a ——= 23R293, 2) Install piston assembly (19) aligned with match mark ut when disassembled GD6003 SERIES. 23-101DISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION 6. Spring 1) Install spring (18). 2), Be sure to align match marks on piston and cage and install snap ring (17) compressing spring with press using too! A. Secure snap ring firmly. 29P278 7. Spacer 2 Install spacer (13). 8 Shaft Press-fit shatt (4). 9. tet speed gear Install gear (12). 23-102 GD6003 SERIESDISASSEMBLY AND ASSEMBLY. HYDROSHIFT TRANSMISSION, 10. Spring, Disc, Plate Install spring (9), dises (10) and plates (11) in order. % Disc: Specs. Plate: 2 pes, + Align plate intemal teeth with piston external teeth, 111, 2nd speed carrier assembly 11 Align mounting bolt holes and install 2nd speed ‘carrier assembly (8). 2) Fix cage faced up and tighten mounting bolts (7). Ls Mounting bolt: Thread tightener (LT-2) G2) Mounting bolt: 11+ 1.5kam 12, Collar 1) Install seal rings (31) on collar. + Install seal rings not aligning their slits, 2) Using press-fitting tool G) (976) press-fit collar (6), — Press-fit collar using care not to damage seal ring. 29901 6D6003 SERIESDISASSEMBLY AND ASSEMBLY 13, Bearing Using press-fitting tool G) (#76) press-fit bearing (5). 14, Snap «i {install snap ring (3). 15. Housing assembly 1) Install housing assembly (2). 2) Install plate (1). 72 Mounting bolt: Thread tightener (LT-2) S232] Mounting bolt: 6.5 + 1.0kgm 23-104 a HYDROSHIFT TRANSMISSION 29P270 2D600-3 SERIESDISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION DISASSEMBLY OF HIGH SPEED ROTARY CLUTCH GDG0SR, GDESSR, GDG0SA, GDE55A-3 Seta i soca rota Cate ey 2 2 ‘ 5 5 ‘ovary LY cape any rum ee High ovr L— toa 1 ‘ 3 1 u 2 nf sores | reioney |] cose sratewy |] serene | Barro zorzs ‘Special tools Part number Partname [Oey 7223711400 _ | Stove 7 1 [_ 790-201-2660 _| Push too! 1 790202760 _ | Push tol 1 1. Sea ing Remove seal ring (1), 2. Gear assembly 1) Remove snap ring (2). 2) Remove gear assembly (3). nb >». “itm 23-106 GD600-3 SERIESDISASSEMBLY AND ASSEMBLY 3. Cage assembly Remove cage assembly (4). 4, Drum Remove mounting bolts and remove drum (6). 5. Spring, Disc, Plate Remove spring (6), discs (7) and plates (8) in order. * Disc: Spes. Plate: 2pes. 6. High gear Remove gear (9). 6D6003 SERIES HYDROSHIFT TRANSMISSIONDISASSEMBLY AND ASSEMBLY. HYDROSHIFT TRANSMISSION YAS ne caeasne sro plied ten 1) Put match marks on piston (10) and carrier (11), 2). Using tool A compress spring (12) with press and remove snap ring (13). 3) Remove cage (14) and remove spring (12) 8, Piston assembly 1) Remove pin (15) and remove piston assembly (10). 9. Cage 1) Remove snap ring (16). 2) Remove cage (17). 10. Shaft assembly 1) Remove shaft (18). 2) Remove bushing (19) and seal ring (20) from shaft assembly. 23-108 @D600-3 SERIES oDDISASSEMBLY AND ASSEMBLY 11, Seart ring Remove seal ring (21). 12, Planetary gear Remove planetary gear (22). # Refer to “DISASSEMBLY OF PLANETARY GEAR” section for removal of planetary gear. 606003 SERIES HYDROSHIET TRANSMISSION, 23-109 oODISASSEMBLY AND ASSEMBLY HYDROSHIFT TRANSMISSION ASSEMBLY OF HIGH SPEED ROTARY CLUTCH GDGOSR, GDES5R, GD60SA, GDESSA-3 1 : a ‘ 5 toweanier LL Paretrr LL seating Lf shat ay coe Piston a'y P= TOA ‘ 1 : : zara? ‘Special tools farcnumber | Porname [ow 7623711400 _| Seve 1 9 [790-201-2660 | Pah rol 1 702012760 _| Pueh 00 1 * Coat sliding portion of each part with engine oil before installing. 1. Planetary gear Install planetary gear (22). * Refer to “ASSEMBLY OF PLANETARY GEAR” section for installing planetary gear. 2. Seal ing Install seal ring (21). 3. Shaft assembly 1) Press-fit bushing (19) to shaft and install seal rings (20), % Install seal rings not aligning their slits. 2) Install shaft assembly (18) on carrier assembly. 234 10 GD600-3 SERIES.DISASSEMBLY AND ASSEMBLY 4. Cage 1) Instil seal ring (23) and install cage (17). <= Mounting bolt: Thread tightener (LT-2) G3] Mounting bolt: 3 £ 0.5kgm 2) Install snap ring (16) 5. Piston assombly 1) Install seal ring (24) on piston. 2), Install piston assembly (10) aligning match marks put when disassembled and install pin (15). 6. Spring 1) Install spring (12) and cage (14). ‘D603 SERIES HYDROSHIFT TRANSMISSION 29P319