Руководство по ремонту dressta

Dressta Dozer operator’s, electrical wiring diagrams, workshop, service and repair manuals, spare parts catalogs, error codes in PDF download 

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Dressta 515C-520C Operator’s and Maintenance Manual [PDF]

5Mb

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Dressta 534E Operator’s and Maintenance Manual [PDF]

9.4Mb

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Dressta 560C Wheel Loader Service Manual [PDF]

13Mb

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Dressta 560E Operator’s and Maintenance Manual [PDF]

9.6Mb

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Dressta 9.50M Operator’s and Maintenance Manual [PDF]

13.3Mb

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Dressta TD-14M Dozer Service Manual [PDF]

15.7Mb

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Dressta TD-15M EXTRA STD Technical Specifications [PDF]

575.3kb

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Dressta TD-20M Dozer Service Manual [PDF]

22.6Mb

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Dressta TD-25M Dozer Service Manual [PDF]

14.6Mb

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Dressta TD-25M Operator’s and Maintenance Manual [PDF]

14.6Mb

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Dressta TD-40E Extra Transmission Service Manual [PDF]

13.2Mb

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Dressta TD-40E Extra Walk Around Technical Specifications
[PDF]

1.1Mb

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Dressta TD15H Operator’s Manual [PDF]

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Dressta Co Ltd (TM: Dresta, Dressster, HSW) — is currently a 100% subsidiary of the Huta Stalowa Wola S.A. The company provides the sale of cars, spare parts for them and
conducts advertising-information work on equipment with clients in the interests of the founding company. The company occupies an area of  605700 m2 and more than 8,000 people work on it.

Dressta CO LTD sells and supply of construction and mining equipment produced for more than 30 years at the Huta Stalowa Wola S.A. (Poland) under the license of American firms:

  • Tractor bulldozers-pouring with engines with a capacity of 70 to 520 hp.
  • Front loaders on a pneumatic coat with a bucket with a capacity of 1.1 to 6.5 m3
  • Pipe layers with a carrying capacity of 33 to 100 tons.
Dressta dozer operator's and service manuals PDF
Dressta TD40

The company has a network of regional trading representatives around the world from Miami to Moscow and Singapore, using the shopping network and client base of the Huta Stalowa Wola S.A. and her
American cooperation partners and licensed agreements: International Harvester, Dresser and Komatsu-Dresser. Regional representative offices provide wide contacts of the Polish headquarters of
the company with distributors and customers, as well as support distributors and, if necessary, conduct technical consultations.

The main sales markets with the branded sign of Stalowa Wola or Dressta — the USA, the countries of South America, Southeast Asia, Central and Western Europe, the CIS and the
Middle East.

Dressta Bulldozers: owner’s, service and maintenance manuals, error codes list, DTC, spare parts manuals & catalogues, wiring diagrams, schematics free download PDF

Title File Size Download Links
Dressta 515C-520C Operator’s and Maintenance Manual [PDF] 4.9Mb Download
Dressta 534E Operator’s and Maintenance Manual [PDF] 9.4Mb Download
Dressta 560C Wheel Loader Service Manual [PDF] 12.7Mb Download
Dressta 560E Operator’s and Maintenance Manual [PDF] 8.6Mb Download
Dressta 9.50M Operator’s and Maintenance Manual [PDF] 13.1Mb Download
Dressta TD-14M Dozer Service Manual [PDF] 14.7Mb Download
Dressta TD-15M EXTRA STD Technical Specifications [PDF] 568.5kb Download
Dressta TD-20M Dozer Service Manual [PDF] 22.4Mb Download
Dressta TD-25M Dozer Service Manual [PDF] 14.4Mb Download
Dressta TD-25M Operator’s and Maintenance Manual [PDF] 14.4Mb Download
Dressta TD-40E Extra Transmission Service Manual [PDF] 13.1Mb Download
Dressta TD-40E Extra Walk Around Technical Specifications [PDF] 1.1Mb Download
Dressta TD15H Operator’s Manual [PDF] 908.7kb Download

Dressta Bulldozer Manuals PDF

Dressta construction machinery is made in the Huta Stalowa Wola factory in Poland.

The Huta Stalowa Wola equipment business started aggressively seeking a partner to commence the manufacturing of crawler bulldozers on its grounds in the early 1970s. Production of tracked bulldozers, front loaders, and wheel loaders began in 1973 when a licensing deal was reached with the American firm International Harvester.

Dresser, Inc. purchases the construction machines section of International Harvester in the early 1980s (USA). Since then, Dresser has been the brand name for Huta Stalowa Wola’s crawler bulldozers and loaders. The partnership between Dresser and Stolowa Wola was officially established in 1995.

Simultaneously, Dresser and Komatsu established a partnership called Komatsu Dresser. Dresser plans to sell its share of the association to Komatsu by 1996. After that, Komatsu America International got to work. As a result, Komatsu America International and Huta Stalowa Wola have formed a partnership to operate Dressta.

A 1999 rebranding from Dresser to Dressta kept the machines’ functionality and their components’ originality and quality the same. There have been no modifications to the sales policy or car-selling firm. Dressta has been distributing branded goods reliably for over a decade. Stalowa Wola is home to the company’s main offices and administrative hub.

More than 20,000 L-34 wheel loaders and 13,000 crawler bulldozers were manufactured at Huta Stalowa Wola between 1973 and 2003. In addition, over 1,800 International Harvester-Dressers were manufactured under license between 1992 and 2003. (1,300 units sold in the USA).

Not able to avoid the economic downturn of 2008-2009, the Polish firm was acquired by the Chinese conglomerate LiuGong.

There are currently nine main models of crawler bulldozers offered by Dressta Co. Ltd., each with a power output ranging from 74 to 520 horsepower; seven models of wheel loaders, each with a power output ranging from 103 to 415 horsepower; one model of a crawler loader; three models of pipelayers, each with a lifting capacity ranging from 33.3 to 100 tons; two compactors; and three models of crawler bulldozers.

Dressta offers a wide range of options regarding their dozers, including different types of crawler tractors and those with longer tracks (suitable for work on soft and waterlogged soils).

Dressta bulldozers have either Cummins or Komatsu power plants, depending on the model. The machines use a modular driving system, which allows for the replacement of individual units as needed without requiring the removal of any other components or assemblies. The alignment and precision of installing spline connectors between transmission units are not critical.

A six-position blade is standard on the smallest Dressta-class dozers, while subsequent sizes have a straight, swivel, spherical, or semi-spherical edges. Additionally, loosening equipment may be added to bulldozers, with the most powerful machines having as little as one loosening tooth and the lightest vehicles having as many as five. The most incredible depth of loosening is 1.7 m.

Dressta Bulldozers manuals PDF

Dressta TD-15R

The cabs of Dressta bulldozers are shaped like 4- or 6-sided pyramids. The interior design and the standard and additional features and safety features meet or exceed all applicable international standards.

The United States, South America, Southeast Asia, Central, and Western Europe, the Commonwealth of Independent States, and the Middle East are the primary sales areas for equipment with the STALOWA WOLA or DRESSTA brand names.

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  • Руководства по ремонту

По ссылкам ниже Вы можете найти и открыть руководство по ремонту (Service manual) для погрузчиков и бульдозеров Stalowa Wola, DRESSTA.

  1. «Шарнирный погрузчик Stalowa Wola L-34», инструкция по ремонту
  2. «Погрузчик DRESSTA 534», руководство по ремонту
  3. «Погрузчик DRESSTA 534E», руководство по ремонту
  4. «Погрузчики DRESSTA 515G-520G», руководство по ремонту
  5. «Бульдозер DRESSTA TD-15M EXTRA», руководство по ремонту
  6. «Бульдозер DRESSTA TD-20M EXTRA», руководство по ремонту
  7. «Бульдозеры DRESTA TD-7M, TD-8M, TD-9M, TD-10M», руководство по ремонту

Dressta logo

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Dressta 560C Operator’s Manual

Dressta 560C Operator’s Manual

Dressta 560C Operator’s Manual.pdf

Adobe Acrobat Document
2.8 MB

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Dressta 534e Operator Manual

Dressta 534e Operator Manual

Dressta 534e Operator Manual.pdf

Adobe Acrobat Document
6.7 MB

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Dressta 515C 520C Operator’s Manual

Dressta 515C 520C Operator’s Manual

Dressta 515C 520C Operator’s Manual.pdf

Adobe Acrobat Document
1.6 MB

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Dressta TD-25H Operator’s Manual

Dressta TD-25H Operator’s Manual

Dressta TD-25H Operator’s Manual.pdf

Adobe Acrobat Document
1.0 MB

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Dressta TD-40C Operator’s Manual

Dressta TD-40C Operator’s Manual

Dressta TD-40C Operator’s Manual.pdf

Adobe Acrobat Document
834.9 KB

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Dressta TD15h Operator’s Manual

Dressta TD15h Operator’s Manual

Dressta TD15h Operator’s Manual.pdf

Adobe Acrobat Document
939.6 KB

Some DRESSTA Dozer & Loader Operator’s Manuals PDF are above this page — 534a, 560c, TD-25H, 515C, 520C, TD-15H, TD-40C.

DRESSTA Co Ltd — currently a wholly-owned subsidiary of the Huta Stalowa Wola S.A. The company provides the sale of machines, spare parts for them and conducts
advertising and information work on technology with customers in the interests of the parent company.

The enterprise covers an area of 605,700 m² and employs more than 8,000 people.

DRESSTA Co Ltd sells and delivers construction and mining equipment manufactured for more than 30 years at the Huta Stalowa Wola S.A. (Poland) under the license
of American firms: tractor bulldozers-rippers with engines from 70 to 520 hp, front loaders on a pneumatic bucket with a bucket capacity from 1.1 to 6.5 m3, pipelayers with a lifting capacity
from 33 to 100 tons.

The company has a network of regional sales offices around the world from Miami to Singapore, using the trading network and the customer base of the Bureau of Foreign Trade Huta Stalowa Wola S.A. and its American partners in cooperation and licensing agreements: INTERNATIONAL HARVESTERDRESSER and KOMATSU-DRESSER.

The regional offices provide extensive contacts of the company’s Polish headquarters with distributors and buyers, and also support employees of distributors and, if necessary, conduct technical
consultations.

The main markets for machinery with the STALOWA WOLA or DRESSTA brand are
the USA, the countries of South America, Southeast Asia, Central and Western Europe, the CIS and the Middle East.

Now is a part of LiuGong.

  1. Manuals
  2. Brands
  3. DRESSTA Manuals
  4. Industrial Equipment
  5. TD-25M EXTRA
  6. Service manual
  • Contents

  • Table of Contents

  • Troubleshooting

  • Bookmarks

Summary of Contents for DRESSTA TD-25M EXTRA

  • Page 1
    SMTD25MEX07/1E SERVICE MANUAL TD-25M SERIAL NUMBERS 75001 AND UP DRESSTA…
  • Page 3
    THIS MATERIAL IS PROPRIETARY TO DRESSTA CO. LTD. AND NOT TO BE REPRODUCED, USED, OR DISCLOSED EXCERPT IN ACCORDANCE WITH WRITTEN AUTHORIZATION FROM DRESSTA CO. LTD. IT IS OUR POLICY TO IMPROVE OUR PRODUCTS WHENEVER IT IS POSSIBLE AND PRACTICAL TO DO SO.
  • Page 5
    SECTION 1 INTRODUCTION…
  • Page 7: Table Of Contents

    15. TORQUE VALUES FOR AIR CONDITIONING TUBES AND FITTINGS ….16 16. TORQUE VALUES FOR AIR CONDITIONING O-RING CONNECTIONS ….16 DRESSTA TD-25M EXTRA…

  • Page 9: Safety Precautions

    Throughout this manual the use of the terms “Left”, “Right”, “Front” and “Rear” must be understood to avoid confusion when following instructions. “Left» and “Right» indicate the left and right sides of the machine when facing forward in the operator’s seat, refer to Fig. 1.1. DRESSTA TD-25M EXTRA…

  • Page 10
    Most operating injuries occur because of excessive speed, loss of control, failure to observe warning signs, slipping or falling while entering for dismounting, a lack piles on roadways, lack of a ROPS or seat belt, or not watching in the direction of travel. TD-25M EXTRA DRESSTA…
  • Page 11
    The extinguisher is provided with a label containing the instructions of its use and application. The operator should be familiar with these instructions. Fig. 1.2. Fire Extinguisher Location in Machine DRESSTA TD-25M EXTRA…
  • Page 12: Before Starting The Engine

    Be sure the area of the operator’s compartment, all mounting steps and grab handles are free of oil, grease, loose objects, ice and mud to lessen the possibility of slipping. Remove or secure all maintenance and personal items so they will not interfere with the operator or jam the controls. TD-25M EXTRA DRESSTA…

  • Page 13: Operation

    During the brake lock test, be sure that there are no people in the immediate area of the machine, and that the same is free from obstacles. As the brakes do not brake the machine, stop the machine operation immediately and remove the cause of the defect. DRESSTA TD-25M EXTRA…

  • Page 14
    Before operating the machine read and know the Operator’s Manual and ALL SAFETY GRAPHICS. The roll-over protective structure (ROPS) provides the operator’s protection in the event of machine rollover or upset. This structure is designed to bend during rollover to protect the operator from sudden impact loads. TD-25M EXTRA DRESSTA…
  • Page 15: Maintenance

    Servicemen and their helpers only are allowed to remain at operator’ s post while maintaining or repairing the machine. Authorized personnel only is allowed to control, maintain or repair a machine. Do not hurry. Haste could result in accident. Load things into the machine from the ground level before mounting the machine. DRESSTA TD-25M EXTRA…

  • Page 16
    One trained person must be in the operator’s seat to safeguard the second person making the checks or adjustment. As an added precaution, when making checks or adjustments with the engine operating, apply the parking brake. TD-25M EXTRA DRESSTA…
  • Page 17
    Do not pile up oily or greasy rags. They are a fire hazard. Store them in an approved, closed metal container. Use a soft iron or nonferrous hammer to install or remove ripper point. It is dangerous to hammer on the point. Wear safety glasses with side shields or goggles to reduce the chances of injury. DRESSTA TD-25M EXTRA…
  • Page 18: When Parking

    Do not jump off the machine. When operating in bad weather and storm lightening is nearby, dismount and seek shelter away from the machine. Lightening will be attracted to the machine and can cause serious injury or death. TD-25M EXTRA DRESSTA…

  • Page 19: Service Information

    DO NOT roll an O-ring during installation. To correctly install, position at one point and using a blunt tool, stretch into position. DO NOT stretch any more than is required for proper installation. DRESSTA TD-25M EXTRA…

  • Page 20: Electronic Circuits Protection During Welding At The Machine

    Type and application places of LOCTITE are showed in specific procedures of Service Manual. For surface preparation, application, setting time before placing in operation, removal and application in low temperature refer to directions for use of LOCTITE. TD-25M EXTRA DRESSTA…

  • Page 21: Standard Torques

    (nuts with distorted threads or plastic inserts); phosphate coated bolts used with copper plated weld nuts. Markings on bolt heads or nuts indicate material grade ONLY and are NOT to be used to determine required torque. DRESSTA TD-25M EXTRA…

  • Page 22
    (nuts with distorted threads or plastic inserts), phosphate coated bolts used with copper plated weld nuts. Markings on bolt heads or nuts indicate material grade ONLY and are NOT to be used to determine required torque. GENERAL APPLICATION TORQUES Nominal Thread [mm] Standard Torque [Nm] 1330 1790 2325 3010 TD-25M EXTRA DRESSTA…
  • Page 23: Split Flange Connections

    12–16 8–14 5/16 1/2 –20 16–20 14–20 9/16–18 29–33 20–27 3/4 –16 47–54 34–42 7/8–14 72–79 47–54 1-1/16–12 104–111 81–95 1-3/16–12 122–138 95–109 1-5/16–12 149–163 108–122 1–1/4 1-5/8–12 190–204 129–156 1–1/2 1-7/8–12 217–237 163–190 2-1/2–12 305–325 339–407 DRESSTA TD-25M EXTRA…

  • Page 24
    16. TORQUE VALUES FOR AIR CONDITIONING O-RING CONNECTIONS SIZE THREAD SIZE TORQUE VALUES FOR MATERIALS [Nm] [in] STEEL-STEEL 7/16–20 15 – 25 5/8–18 27 – 33 3/4–16 40 – 48 7/8–14 47 – 54 1-1/16–12 54 – 61 1-1/16–14 54 – 61 TD-25M EXTRA DRESSTA…
  • Page 25
    SECTION 5 STEERING…
  • Page 27
    STEERING SECTION 5 CONTENTS GENERAL 1. DESCRIPTION ……………………..1 DRESSTA TD-25M EXTRA…
  • Page 29
    For further detailed information on the hydraulically controlled steering system refer to SECTION 7, DRIVE TRAIN; SECTION 7C TRANSMISSION and SECTION 7E, STEERING DRIVE. DRESSTA TD-25M EXTRA…
  • Page 31
    SECTION 6 COOLING SYSTEM…
  • Page 33
    1. DESCRIPTION …………………….. 1 2. OPERATION ……………………..1 3. SPECIFICATIONS ……………………4 4. SERVICE DIAGNOSIS ………………….5 5. REMOVAL ……………………..6 6. DISASSEMBLY ……………………11 7. INSPECTION AND REPAIR ………………..12 8. REASSEMBLE ……………………12 9. INSTALLATION ……………………13 DRESSTA TD-25M EXTRA…
  • Page 35: General

    (1) and flows down through tubes. Heat is dissipated to the air being forced past the outside of the core tubes by the hydraulic motor driven fan. CAC system is designed to achieve 60 [°C] intake manifold temperatures at a 25 [°C] ambient temp. DRESSTA TD-25M EXTRA…

  • Page 36
    The oil is then directed to the hydraulic oil tank thru the hose (8). Hydraulic motor speed is controlled by the three sensors located in the engine intake air system, engine cooling system and drive train system. TD-25M EXTRA DRESSTA…
  • Page 37
    21. Turbocharger 5. Radiator Core 14. Cooling System Fill Hose 22. Engine Intake Connection 6. Coolant Inlet Tube 15. Coolant Outlet Tube 23. Overflow Hose 7. Hydraulic Motor Oil Cooler 16. Oil Outlet Hose 8. Oil Outlet Hose DRESSTA TD-25M EXTRA…
  • Page 38: Specifications

    (Torques given are for bolts and nuts lubricated with SAE-30 engine oil.) NOTE: Except for the special torque shown, all bolts and nuts are to be given a standard torque. Refer to “STANDARD TORQUES “ in Section 1, «INTRODUCTION.» TD-25M EXTRA DRESSTA…

  • Page 39
    Replace cylinder head and gasket. Torque head bolts 1. Warped cylinder head. as specified in the Troubleshooting and Repair Manual QSX15 Engines. Remove oil cooler, perform pressure test. Refer to 2. Engine oil cooler cracked. Troubleshooting and Repair Manual QSX15 Engines. DRESSTA TD-25M EXTRA…
  • Page 40
    OFF, keys are removed and the controls are tagged to prevent inadvertent engine starting. 2. Turn electrical master switch to «OFF» position. 3. Loosen the clamp and remove the air precleaner (4, Fig. 6.2). Disassemble the aspirator tube between the air precleaner and muffler. TD-25M EXTRA DRESSTA…
  • Page 41
    13. Tag and remove hose (7) from fan drive hydraulic motor oil cooler. Secure hose in an upright position to frame. 14. Loosen the clamps and remove coolant tube (4) between the radiator and engine outlet. DRESSTA TD-25M EXTRA…
  • Page 42
    18. Tag and remove fuel hose (2, Fig. 6.4) from the fuel cooler. Secure hose in an upright position to frame. Fig. 6.4. Fan Drive Hydraulic Motor Oil Cooler and Fuel Cooler Connections 1. Hydraulic Hose (inlet) 2. Fuel Hose (outlet) TD-25M EXTRA DRESSTA…
  • Page 43
    1. Air Outlet Tube (CAC outlet) 3. Coolant Tube (outlet) 2. Hydraulic Hose (inlet) 4. Fuel Hose (inlet) Fig. 6.6. Fan Drive Hydraulic Motor Disassembly Points 1. Hydraulic Hose (inlet) 3. Hydraulic Hose (drain) 2. Air Baffles 4. Hydraulic Hose (outlet) DRESSTA TD-25M EXTRA…
  • Page 44
    Fig. 6.7. Radiator Assy Disassembly Points LH and RH (upper brackets) 1. Bolts 3. Coolant Level Switch 2. Plate (link) Fig. 6.8. Radiator Assy Disassembly Points (bottom view) 1. Radiator Assy Channel (bracket) 2. Mounting Bolts TD-25M EXTRA DRESSTA…
  • Page 45
    Fig. 6.9. Radiators Assy Exploded View 1. Bolts 5. Bottom Plate 9. Fan Shroud 2. Auxiliary Tank 6. Bolts 10. Fan Guard 3. Charge Air Cooler (core) 7. Bolts 11. Bolt 4. Bolts 8. Fan Drive Hydraulic Motor Bracket DRESSTA TD-25M EXTRA…
  • Page 46
    4. Position auxiliary tank (2), install bolts (1). Reinstall vent line (4, Fig. 6.1) between auxiliary tank and radiator. 5. Tighten all bolts with care. Apply standard torques values for aluminum. 6. Reinstall fan guard (10) with bolt (11) and bracket (8) if removed. TD-25M EXTRA DRESSTA…
  • Page 47
    13. Reinstall hydraulic hose (2) to the drive train oil cooler. 14. Reinstall coolant fill hose (3) to the auxiliary tank. Tighten the clamp. 15. Reconnect wire harness connector to the coolant level switches (6, Fig. 6.3) and (3, Fig. 6.7). DRESSTA TD-25M EXTRA…
  • Page 48
    21. Position the hood (1, Fig. 6.2), install the bolts and tighten. 22. Reassemble side enclosure (2). 23. Reassemble the exhaust tube assy (3). 24. Reassemble the aspirator tube between the air precleaner and muffler. Install air precleaner (4). TD-25M EXTRA DRESSTA…
  • Page 49
    SECTION 7 DRIVE TRAIN…
  • Page 51: Service Diagnosis

    13. STEERING SYSTEM OIL PRESSURE CHECK …………..24 14. STEERING SYSTEM FUNCTIONAL CHECK …………….26 15. TRANSMISSION “FIVE PENNY” DIAGNOSTIC TEST …………27 16. STEERING SYSTEM SUPPLY PRESSURE TEST …………..28 17. PRIORITY VALVE PRESSURE CHECK AND ADJUSTMENT PROCEDURE ……29 DRESSTA TD-25M EXTRA…

  • Page 53: Service /Special Tools

    15. Sprocket Drive Segment 21. Gasket 4. Transmission Input 10. Steering Drive Output 16. Charge and Scavenge 22. Connector Plate Yoke Shaft Pump 23. Connector 5. Transmission 11. Bolt 17. O-Ring 24. O-Ring 6. O-Ring 12. Retaining Ring 18. O-Ring DRESSTA TD-25M EXTRA…

  • Page 54: Drive Train Main Components

    “M” port and is distributed to the direction and steering spools. When the control lever is in the centered “neutral” position, oil is active at the selected steering ports but is blocked at the direction spools. TD-25M EXTRA DRESSTA…

  • Page 55
    The LC and RC clutch sections control the flow of oil to the clutch packs to drive each track individually. Both of the sections contain a metering spools which are each held in the rear drive position by pilot pressure CL and CR respectively from the drive train control valve. DRESSTA TD-25M EXTRA…
  • Page 56
    When the up-shift control button is pressed once the second gear solenoid is energized and the second gear is selected. With pressed up-shift button once again the third gear is selected (the third gear solenoid is energized). TD-25M EXTRA DRESSTA…
  • Page 57: Hydraulic Oil Flow

    When this shift occurs, the main pressurized oil is directed to rate of rise valve (14) by P, P1 ports of range selector valve (13) and is passed onto the FR and PC ports of range selector valve (13). DRESSTA TD-25M EXTRA…

  • Page 58
    20. To Steering Drive Lubricating 21. To Lower Steering Valve 22. Hydraulic Dampers 23. Drive Train Electronic Controller 24. Engine RPM Sensor 25. Transmission Input Shaft RPM Sensor 26. FWD&RWD Travel Pressure Switch 27. Ripper Shank Pin Control System Connection TD-25M EXTRA DRESSTA…
  • Page 59
    DRIVE TRAIN SECTION 7 Page 7 HYDRAULIC OIL FLOW Fig. 7.2. Drive Train Hydraulic Oil Flow with Trans First Forward — TWO SPEED STEERING DRIVE DRESSTA TD-25M EXTRA…
  • Page 61
    DRIVE TRAIN SECTION 7 Page 9 HYDRAULIC OIL FLOW Fig. 7.3. Drive Train Hydraulic Oil Flow with Trans Third Reverse — TWO SPEED STEERING DRIVE DRESSTA TD-25M EXTRA…
  • Page 63: Torque Converter And Lubrication Oil Flow

    To make a left gradual turn, shift the right speed range switch to its upper (HI) position and shift the left speed range switch in its lower (LO) position during machine is moving forward or rearward. The electronic controller will select the left track to low range and the right track to high range. DRESSTA TD-25M EXTRA…

  • Page 64
    Machine is in a right brake condition. The machine pivots turn right. For a more complete description and operation of the steering valve and the steering drive, refer to SECTION 7E. TD-25M EXTRA DRESSTA…
  • Page 65
    — Left Clutch Section — Right Clutch Section HI-LO — High-Low Range Section — HI-LO Range Solenoid — Sequence Valve Cartridge — Foot Brake Section EC (23) — Drive Train Electronic Controller — Steering Manifold — Steering Drive DRESSTA TD-25M EXTRA…
  • Page 66
    DRIVE TRAIN SECTION 7 Page 14 HYDRAULIC OIL FLOW Fig. 7.4. Starting and LO Range Straight Travel TWO SPEED STEERING DRIVE TD-25M EXTRA DRESSTA…
  • Page 67
    DRIVE TRAIN SECTION 7 Page 15 HYDRAULIC OIL FLOW Fig. 7.5. Gradual Left Turn TWO SPEED STEERING DRIVE DRESSTA TD-25M EXTRA…
  • Page 68
    DRIVE TRAIN SECTION 7 Page 16 HYDRAULIC OIL FLOW Fig. 7.6. Pivot Turn Right TWO SPEED STEERING DRIVE TD-25M EXTRA DRESSTA…
  • Page 69: Trouble Shooting

    4. Transmission oil level too high Check operation and condition of scavenge circuit. 5. Slipping clutch packs in transmission Refer to Par. 12, DRIVE TRAIN CLUTCH TEST. and/or steering drive 6. Excessive torque converter oil leakage Refer to SECTION 7B, TORQUE CONVERTER. DRESSTA TD-25M EXTRA…

  • Page 70
    Converter and hydraulic ……..1520 – 1680 [RPM] TD-25M EXTRA…
  • Page 71
    Test Pressure Gauges Kit (refer to SERVICE /SPECIAL TOOLS) to the pressure regulator valve (quick disc. fittings 4, 5 and 6) and range selector valve (quick disc. fittings 3 and 7) ports shown in Fig. 7.7. DRESSTA TD-25M EXTRA…
  • Page 72
    Oil pressures should increase and decrease rapidly when engaging and disengaging clutch packs. Fully depress the decelerator pedal and shift the transmission in neutral. Repeat this step for each transmission reverse gear range. TD-25M EXTRA DRESSTA…
  • Page 73
    Stuck lubrication spool in pressure regulator valve. d. Incorrect number of shims at lube spool in pressure regulator valve. Each shim changes the pressure by approximately 7 [kPa]. DO NOT use more than a total three shims. DRESSTA TD-25M EXTRA…
  • Page 74: Torque Converter Stall Speed Check

    Engine injection pump defective or improperly adjusted. 1. Stall speed too high b. Refer to Par. 12, DRIVE TRAIN CLUTCH TEST. 2. Stall speed too low a. Too low engine power. Refer to ENGINE REPAIR MANUAL. TD-25M EXTRA DRESSTA…

  • Page 75: Drive Train Clutch Test

    5. Final drive sprocket stationary and drive shaft turns Slipping reverse directional clutch in in reverse third gear range but not in forward third transmission. 6. Final drive sprocket rotates Slipping brake clutch in steering drive. DRESSTA TD-25M EXTRA…

  • Page 76: Steering System Oil Pressure Check

    Repeat this procedure until the midpoint will be in green range. 3. Run the engine at full throttle and check the gauge readings with those in the following chart. TD-25M EXTRA DRESSTA…

  • Page 77
    0 – 35 Control lever in neutral and foot brake pedal at feel point. (%) — Oil pressure drop should be gradual with control lever movement. (#) — Oil pressure drop should be gradual with brake pedal movement. DRESSTA TD-25M EXTRA…
  • Page 78: Steering System Functional Check

    RH brake position and record the LB brake clutch pressure (gauge connected to LB on the diagnostic center). 6. The pressures obtained should be between 550 – 690 [kPa]. TD-25M EXTRA DRESSTA…

  • Page 79: Transmission «Five Penny» Diagnostic Test

    3. Orifice Strainer 8. Rate of Rise Valve 4. Manifold Gasket 9. Rate of Rise Valve Gasket 5. Pressure Regulator Valve 10. Range Selector Valve Penny Coins (or Small Disks φ 21.3 [mm] dia. and 2 [mm] thick) DRESSTA TD-25M EXTRA…

  • Page 80: Steering System Supply Pressure Test

    RANGE SELECTOR VALVE in TRANSMISSION, SECTION 7C. 16. STEERING SYSTEM SUPPLY PRESSURE TEST Fig. 7.10. Steering System Supply Pressure Test 1. Transmission 4. Steering Valve 2. Hydraulic Tee 5. Rear Main Frame 3. Steering Valve Supply Hose TD-25M EXTRA DRESSTA…

  • Page 81: Priority Valve Pressure Check And Adjustment Procedure

    The valve is not under normal diagnostic procedure. In case of valve repair or replacement check the pressure and adjust it if needed. Refer to procedures described below. Fig. 7.11. Pressure Gauge Connect Point 1. Priority Valve 2. Quick Disconnect Fitting 3. Priority Valve Pressure Regulator DRESSTA TD-25M EXTRA…

  • Page 82
    3. Tighten the counter nut (4) to the pressure regulator (2) after adjustment. Recheck the priority valve pressure and disconnect the pressure gauge. Fig. 7.12. Pressure Gauge Connect Point 1. Priority Valve 3. Adjusting Screw 2. Priority Valve Pressure Regulator 4. Counter Nut TD-25M EXTRA DRESSTA…
  • Page 83
    SECTION 7B HYDRAULIC TORQUE CONVERTER…
  • Page 85
    4. SERVICE DIAGNOSIS ………………….5 5. TORQUE CONVERTER INTERNAL LEAKAGE TEST …………6 TORQUE CONVERTER 6. REMOVAL ……………………..7 7. DISASSEMBLY ……………………10 8. INSPECTION AND REPAIR ………………..16 9. REASSEMBLY ……………………17 10. INSTALLATION ……………………26 DRESSTA TD-25M EXTRA…
  • Page 87: Service /Special Tools

    C – Bolt M24 x 130 – 8.8-B-Fe/Zn5 601-02-2629-6-02 D – Nut M24-5-B-Fe/Zn5 603-01-2262-0-02 E – Round Washer A-25.8 612-48-1170-0-02 F – Special Washer (per Drawing) SPECIAL WASHER (F) TOOL FOR HOUSING COVER BEARING SEATING (WASHER G) DRESSTA TD-25M EXTRA…

  • Page 88: General

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

  • Page 89
    HYDRAULIC TORQUE CONVERTER SECTION 7B Page 3 GENERAL Fig. 7B.2. Exploded View of Tor DRESSTA TD-25M EXTRA…
  • Page 90
    Seal rings (3) and (15) at oil inlet and outlet, respectively separate oil high pressure chamber from the other torque converter work volume. These seal rings and their condition are crucial to torque converter leakage rate and consequently, torque converter loss rate and its efficiency. TD-25M EXTRA DRESSTA…
  • Page 91: Specifications

    Replace bearings, turbine, impeller and stator as impeller blades to strike the fixed stator necessary. High Torque Converter Oil Temperature (Gauge on Instrument Panel) See SERVICE DIAGNOSIS in SECTION 7 Loss of Power See SERVICE DIAGNOSIS in SECTION 7 DRESSTA TD-25M EXTRA…

  • Page 92: Torque Converter Internal Leakage Test

    Turn the electric master switch ON and start the engine with the drive train control lever in NEUTRAL position and drive train control lock lever in locked (ON) position. TD-25M EXTRA DRESSTA…

  • Page 93: Removal

    (2) from the torque converter (7). 7. Remove the charge and scavenge pump (8). Refer to SECTION 7C for this procedure. 8. Remove the fan drive pump (3). Refer to SECTION 10A for this procedure. DRESSTA TD-25M EXTRA…

  • Page 94
    12. Remove the universal joint (4) between the torque converter and transmission: a. Unscrew four bolts connecting the joint to the torque converter flange. b. Unscrew four bolts connecting the joint to the transmission flange. TD-25M EXTRA DRESSTA…
  • Page 95
    Take up the torque converter. NOTE: Cover the opening at the flywheel housing to prevent dirt and dust from entering. 14. Remove the O-ring from the converter housing flange. Fig. 7B.6. Removing Torque Converter DRESSTA TD-25M EXTRA…
  • Page 96: Disassembly

    Screw two bolts (30A) into two threaded holes facing each other in the housing flange. Screw the bolts in a regular way until the housing (30) clears the impeller flange. Remove the housing (30) with bearing (31) and turbine assy (29). TD-25M EXTRA DRESSTA…

  • Page 97
    (30) using 122 to 127 [mm] dia. driver supporting it against the bearing (31) outer race. 6. Remove the retaining ring (28) from the output shaft (14) and retaining ring (27) from ground sleeve hub (2). Remove stator (26) from ground sleeve hub (2). DRESSTA TD-25M EXTRA…
  • Page 98
    (4) out of the impeller (12). Press bearing (4) out of drive gear (5) using 114 [mm] dia. driver supporting it against the bearing (4) outer race. 9. Remove seal ring (3) from ground sleeve hub (2). TD-25M EXTRA DRESSTA…
  • Page 99
    35 [mm] to 49 [mm] dia. driver. Keep bearing (8) in housing (1) bore. Repeat for remaining driven gears (11). NOTE: Take care not to intermix the spacer washers (7) and retain them with suitable gears (11) for further reuse. DRESSTA TD-25M EXTRA…
  • Page 100
    (18) is free. 15. Remove seal ring (15), retaining ring (16) and spacer washer (17) from output shaft (14). Tap the shaft (14) out of ball bearing (18) with a hammer and soft metal driver. TD-25M EXTRA DRESSTA…
  • Page 101
    (2) from converter housing (1) using 120 to 130 [mm] dia. driver. If bearing (4) replacement is necessary, remove bearing inner race from ground sleeve hub (2). 18. If converter housing (1) needs to be replaced or repaired, unscrew eyebolt (U). DRESSTA TD-25M EXTRA…
  • Page 102: Inspection And Repair

    (14), the hub must be replaced. 12. Output flange (23) shall not be grooved by seal ring (21) while contact surface smoothing and darkening are admissible. 13. Replace the converter housing (1) if cracks, thread stripping or bearing bores damages occurs. TD-25M EXTRA DRESSTA…

  • Page 103: Reassembly

    –30 [ºC] for 30 [min] prior to assembly. To ensure the correct hub installation insert two M12 bolts (B) 50 [mm] length into ground sleeve hub to eliminate the existing clearance. DRESSTA TD-25M EXTRA…

  • Page 104
    10) and housing (1) have not been replaced use previously removed spacer washers (7) suitable for each gear. Install spacer washer (7) on the driven gear (11) hub, then install retaining ring (6). Repeat for remaining gears. TD-25M EXTRA DRESSTA…
  • Page 105
    9. Insert shaft (14) into ground sleeve hub (2) from the output end of housing (1). Seat the bearing (18) inside the housing using a suitable driver until the outer race of bearing (18) bottoms the hub (2). DRESSTA TD-25M EXTRA…
  • Page 106
    Step 11. Install O-ring (20) in the cover groove. Install cover (22) and secure it with bolts (22A) and washers (22B). Apply LOCTITE #243 to the bolts (22A) and torque to 72 ÷ 88 [Nm]. TD-25M EXTRA DRESSTA…
  • Page 107
    15. Press roller bearing (4) into drive gear (5). Install impeller (12) on bearing (4) and then thrust washer (13). Secure impeller (12) to drive gear (5) with the bolts (13A). Apply LOCTITE #243 to the bolts and torque to 48 ÷ 58 [Nm]. DRESSTA TD-25M EXTRA…
  • Page 108
    (3). 17. Install stator (26) on the ground sleeve hub (2), secure with retaining ring (27). Install retaining ring (28) into output shaft (14) groove. 18. Install turbine assy (29) on the output shaft (14) end. TD-25M EXTRA DRESSTA…
  • Page 109
    (32) thickness, so the (L) gap between the thrust washer (33) and shaft (14) will get 0,09 ÷ 0,18[mm]. Using virgin lead measure appropriate distance is acceptable L (0.09 ÷ 0.18) = P1 — P2 — X [mm] DRESSTA TD-25M EXTRA…
  • Page 110
    (31) and cover (35) gets the dimension of 0.0 to 0.1 [mm]. Using virgin lead measure distance acceptable too. L (0.0 ÷ 0.1) = P3 + X2 – P4 NOTE: Be sure bearing outer race (31) bottoms bore chamber drive housing (30). TD-25M EXTRA DRESSTA…
  • Page 111
    NOTE: Remove eyebolt (U) prior to torque converter machine installation. 26. If gear ring (36) was replaced, install new gear ring (36) to flywheel and secure with bolts. Apply LOCTITE #243 to the bolts and torque to 83 ÷ 101 [Nm]. DRESSTA TD-25M EXTRA…
  • Page 112: Installation

    Secure the torque converter to the flywheel housing. Torque the bolts (1, Fig. 7B.7) with washers to 110 [Nm]. IMPORTANT: As the converter housing enters the flywheel housing, be sure the O-ring is properly seated in the groove of the converter housing. TD-25M EXTRA DRESSTA…

  • Page 113
    10. Install the tee connector with the oil temperature sensors (2) to the torque converter (7). Connect oil cooler hose (6) to the tee connector. Connect the electrical harness (4) to the torque converter oil temperature sensors (2). DRESSTA TD-25M EXTRA…
  • Page 114
    NOTE: It is recommended that the transmission oil filter be serviced after the first 50 hours of operation. Refer to the OPERATOR’S MANUAL for procedure. Thereafter, service the filter at the normal scheduled interval. 16. Install the center floor plate and transmission case guard. TD-25M EXTRA DRESSTA…
  • Page 115
    SECTION 7C TRANSMISSION…
  • Page 117
    33. INSTALLATION …………83 DRESSTA TD-25M EXTRA…
  • Page 118
    39. REASSEMBLY AND INSTALLATION ……… . . 89 TD-25M EXTRA…
  • Page 119
    PUMP SEAL RETAINER INSTALLATION SLEEVE All external surfaces must be free of scratches and burrs. Installation sleeve dimensions Dia. Dim. Dim. Radius Dia. Dia. Chamfer F° Drill Through Hole +0.000 +0.051 [mm] 117.5 35.027 31.979 30[º] 6.35 -0.051 -0.000 DRESSTA TD-25M EXTRA…
  • Page 120
    In «forward», oil pressure is exerted between the switch spool and directional selector spool, causing the short switch spool to compress the spring and the long directional selector spool to remain in place. TD-25M EXTRA DRESSTA…
  • Page 121
    This deleted engagement time is created by modulating piston and allows a smooth shift without shock. DRESSTA TD-25M EXTRA…
  • Page 122
    Countershaft pusher /pulling bolt ……… . 108 [Nm] NOTE: Except for the special torques shown, all bolts and nuts are to be given a standard torque. Refer to SECTION 1. TD-25M EXTRA DRESSTA…
  • Page 123
    If these caps are not available, tape or clean rubber corks may be used. Hydraulic openings must never be plugged with rags. This practice could easily introduce dirt or lint into critical hydraulic components of the machine. Tag all disconnected oil lines to facilitate easier installation. DRESSTA TD-25M EXTRA…
  • Page 124
    10. Remove the hardware securing the range selector valve (14) and pressure regulator valve (4) to the manifold (2) located on top of the transmission (5). Tie the valves (with hoses still attached) up out of the way. TD-25M EXTRA DRESSTA…
  • Page 125
    Remove the universal joint (3). 17. Install eyebolts in the threaded hole (7, Fig. 7C.2) 1/2”-13UNC-2B located in the top of the transmission (5). Fig. 7C.4. Scavenge Pump Strainer 1. Transmission 2. Strainer DRESSTA TD-25M EXTRA…
  • Page 126
    Fig. 7C.6. Remove the rate of rise valve (2, Fig. 7C.6) with gasket (3). 21. Remove the orifice strainer (3, Fig. 7C.1). 22. Remove the manifold (1, Fig. 7C.6) and manifold gasket (4) from the transmission (5). TD-25M EXTRA DRESSTA…
  • Page 127
    14. Shaft Cover 23. Sump Pipe Directional Clutch Shaft 15. Shim 24. Gasket Manifold 16. Retaining Ring 25. O-Ring Shim 17. O-Ring 26. Baffle O-Ring 18. Seal Sleeve 27. O-Ring Oil Seal 19. Range Clutch Shaft 28. O-Ring DRESSTA TD-25M EXTRA…
  • Page 128
    Manifold Seal Ring Shaft Seal Rings Manifold Seal Ring Manifold Seal Ring 3rd Piston Seal Rings Manifold Seal Ring Manifold Seal Ring Lube Sleeve Seal Ring Manifold Seal Ring Manifold Seal Ring Lube Sleeve Seal Ring Manifold Seal Ring TD-25M EXTRA DRESSTA…
  • Page 129
    Fig. 7C.8. Manifold Removing Fig. 7C.9. Countershaft Cover Removing 7. Remove the bolts securing sump pipe (23) and remove the pipe with gasket (24) and O-ring (25). Fig. 7C.10. Baffle to Housing Bolt Fig. 7C.11. Transmission Housing Removing DRESSTA TD-25M EXTRA…
  • Page 130
    Reverse Idler Shaft (Refer to Fig. 7C.15) Fig. 7C.14. Removing Reverse Idler Shaft 12. Remove the bolt (7) securing plate (6) as shown in Fig. 7C.14. Remove plate (6) and O-ring (8). Tap the reverse idler shaft (1) from the cover. TD-25M EXTRA DRESSTA…
  • Page 131
    16. If bearing or shaft replacement is necessary, press bearing cone (3) off shaft (1). Countershaft (Refer to Fig. 7C.16) Fig. 7C.16. Exploded View of Countershaft Countershaft Reverse Idler Gear First Drive Gear Retaining Ring Forward Driven Gear DRESSTA TD-25M EXTRA…
  • Page 132
    (2, 3, 2, 2, 4, 5 and 2) using a press. 20. If bearings (11 and 13, Fig. 7C.7) were replaced, remove bearing cup (11) from cover (4) and remove bearing cup (13) from housing (1). Fig. 7C.19. Removing Bearing Cone TD-25M EXTRA DRESSTA…
  • Page 133
    18. Friction Disc 29. Shaft Seal Ring 8. Reverse Driver Gear 19. Separator Plate 30. Dowel Pin 9. Retaining Ring 20. Clutch Piston 31. Spring Pin 10. Piston Spring 21. Clutch Hub 11. Spring Plate 22. Seal Ring DRESSTA TD-25M EXTRA…
  • Page 134
    24. Lift parts (14, 16 and 17) out of drum (26). 25. Compress springs (10) by pressing down on plate (11) with C clamp as shown in Fig. 7C.23 and remove retaining ring (9). Fig. 7C.23. Compressing Piston Springs Fig. 7C.24. Removing Bearing Cone TD-25M EXTRA DRESSTA…
  • Page 135
    Disassemble component parts (2, 3, 30, 4 and 31) in sequence indicated. 39. If bearings (28) were replaced, remove bearing cup (28) from cover (4, Fig. 7C.7) and remove second bearing cup (28) from housing (1, Fig. 7C.7). DRESSTA TD-25M EXTRA…
  • Page 136
    38. First Clutch Gear 50. Seal Ring 12. Return Spring 25. Third Clutch Gear 39. Bushing Spacer 51. Dowel Pin 13. Sleeve 26. Spacer 40. Spacer Ring 52. Spring Pin 14. Retainer Plate 27. Retaining Ring 41. First Clutch Piston TD-25M EXTRA DRESSTA…
  • Page 137
    49. Compress springs (11) by pressing down on plate (37) with C clamps as shown in Fig. 7C.30 and remove retaining ring (27). 50. Remove plate (37) and springs (11) from the output shaft (1). 51. Lay the shaft on its side and remove piston (22) from the output shaft assembly. DRESSTA TD-25M EXTRA…
  • Page 138
    54. Remove the bearing cone (48) with a bearing puller as shown in Fig. 7C.32. NOTE: Bearing cup (48) was removed with cover (4, Fig. 7C.7). If bearing replacement is necessary, remove bearing cup from cover. Fig. 7C.31. Removing Dowel Pins Fig. 7C.32. Removing Bearing Cone TD-25M EXTRA DRESSTA…
  • Page 139: Inspection And Repair

    4. Inspect the gears for worn, chipped or broken teeth. Replace if wear is excessive or teeth are damaged. 5. Inspect the splines on the shafts and on the gears and drums for wear. Replace shafts if wear is excessive. Slight burrs can be smoothed down with a stone. DRESSTA TD-25M EXTRA…

  • Page 140: Reassemble

    14. Heat bearing cone (48) to 135 [°C] for 45 minutes and install on the shaft (1) until it bottoms. To assure cone is seated, keep pressure against the cone until it cools down a few seconds. TD-25M EXTRA DRESSTA…

  • Page 141
    (14) on piston (41). Apply LOCTITE 262 to the bolts and secure the plates. Torque the bolts to 37 [Nm]. 28. Coat springs (12) with grease and inserts them in first clutch piston (41). Position the piston assy (41) over the shaft (1) so the springs (12) rest inside plate (9). DRESSTA TD-25M EXTRA…
  • Page 142
    38. If removed, install retaining ring (15) in the narrower of the two center grooves of drum (26). 39. Install the hub (21) with shaft (1), end with adapter (3) first, in drum (26) and secure with second retaining ring (15). TD-25M EXTRA DRESSTA…
  • Page 143
    53. Reassemble component parts (9, 13, 12A, 12, 10 and 11) in sequence indicated. 54. Compress springs (10) by pressing down on plate (11) with C clamps as shown in Fig. 7C.38 and install retaining ring (9). Fig. 7C.37. Compressing Return Springs Fig. 7C.38. Compressing Return Springs DRESSTA TD-25M EXTRA…
  • Page 144
    70. Insert the shaft assembly (1) into the transmission cover (4, Fig. 7C.7). 71. Install O-ring (8) and plate (6) on the outside of the transmission cover (4, Fig. 7C.7) and secure with bolt (7). Torque the bolt to 325 [Nm]. TD-25M EXTRA DRESSTA…
  • Page 145
    77. Secure baffle (26) to housing (1) with four bolts and washers previously removed as shown in Fig. 7C.42. Torque the bolts with washer to 38 [Nm]. 78. Install sump pipe (23) with gasket (24) and O-ring (25). Secure with two bolts. Fig. 7C.41. Transmission Housing Installation Fig. 7C.42. Baffle to Housing Bolt DRESSTA TD-25M EXTRA…
  • Page 146
    A. Input (Push) Seating Cups in Cover and Housing and Rear Cone on Directional Clutch (Input) Shaft (Refer to Fig. 7C.44) NOTE: Directional shaft assembly must have its bearing cones pressed solidly against its respective shoulder before end play (float) is adjusted. TD-25M EXTRA DRESSTA…
  • Page 147
    Fig. 7C.45. Torque the pulling bolt (1) with washer to 108 [Nm]. Remove pulling bolt, washer and puller bridge. Fig. 7C.45. Transmission Directional Clutch Shaft “Pull” Operation 1. Pulling Bolt with Washer 2. Puller Bridge 3. Input Shaft DRESSTA TD-25M EXTRA…
  • Page 148
    4. Eyebolt COUNTERSHAFT D. Countershaft (Push) Seating Rear Bearing Cups and Cones in Cover (Refer to Fig. 7C.47) NOTE: Countershaft assembly must have its bearing cones pressed solidly against its respective shoulder before end play (float) is adjusted. TD-25M EXTRA DRESSTA…
  • Page 149
    Fig. 7C.48. Torque the bolt to 108 [Nm] to seat the bearing cone on the countershaft. Remove the pulling bolt with washer and puller. Fig. 7C.48. Transmission Countershaft “Pull” Operation 1. Puller 2. Pulling Bolt with Washer DRESSTA TD-25M EXTRA…
  • Page 150
    1. Place the 5/8” ball bearing in the machining pilot center on the output shaft. Install the puller (1) and pusher bolt (2) 5/8”-13 UNC as shown in Fig. 7C.50. Torque the pusher bolt to 217 [Nm]. Remove pusher bolt, puller and 5/8” ball bearing. TD-25M EXTRA DRESSTA…
  • Page 151
    3. Install the puller and pulling bolt 5/8”-13 UNC with washer 5/8” as shown in Fig. 7C.51. Torque the pulling bolt to 217 [Nm]. Remove the pulling bolt (2) with washer and puller. Fig. 7C.51. Transmission Range Clutch Shaft “Pull” Operation 1. Puller 2. Pulling Bolt DRESSTA TD-25M EXTRA…
  • Page 152
    2. Be sure the mating surfaces of the rate of rise valve (8) and transmission manifold (2) are clean and free of any old gasket material. Install the rate of rise valve (8) with new gasket (9). 3. Remove the covering from the rear main frame opening. TD-25M EXTRA DRESSTA…
  • Page 153
    TRANSMISSION AND TORQUE CONVERTER OIL PRESSURE TEST. 21. Install the front center floor plate and the transmission case guard. 22. Check the rear frame oil level and add if necessary. 23. After first 50 hours of operation change the pressure filters. DRESSTA TD-25M EXTRA…
  • Page 154
    7. Main Spool Inner Spring 12. Spring Pin 3. Lube Spool Spring 8. Spring Guide Pin 13. Main Spool 4. Torque Converter Spool Spring 9. Shim 14. Valve Housing 5. Main Spool Outer Spring 10. Ball Spring 15. Port Plug TD-25M EXTRA DRESSTA…
  • Page 155
    3. Remove the bolts and washers securing the valve to top of the transmission manifold. Remove the valve assembly and mounting O-rings. 4. Disassemble component parts (1, 2, 3, 4, 5, 7, 9, 8, 6 and 13) in sequence indicated. DRESSTA TD-25M EXTRA…
  • Page 156
    7. Start the engine. Check for leaks. Check the oil pressures as described in SECTION 7, Paragraph 10, TRANSMISSION AND TORQUE CONVERTER OIL PRESSURE TEST. 8. Install the center floor plate between seat and instrument panel. Install the floor mat, if cab equipped. TD-25M EXTRA DRESSTA…
  • Page 157
    Tag all disconnected oil lines to facilitate easier installation. Fig. 7C.55. Cross Section of Range Selector Valve 1. End Cover 2. Range Selector Spool 3. Directional Spool 4. Return Spring 5. O-Ring 6. O-Ring 7. Valve Housing 8. Switch Spool DRESSTA TD-25M EXTRA…
  • Page 158
    4. Disassemble component parts (1, 5, 6, 2, 4, 8 and 3) in sequence indicated. Fig. 7C.56. Exploded View of Range Selector Valve 1. End Cover 4. Return Spring 7. Valve Housing 2. Range Selector Spool 5. O-Ring 8. Switch Spool 3. Directional Spool 6. O-Ring 9. Port Plug TD-25M EXTRA DRESSTA…
  • Page 159
    2. Remove the bolts and washers securing the valve assembly to the top of the transmission housing. Remove the valve assembly and gasket. Discard the gasket. 3. Disassemble component parts in the sequence indicated by the reference numbers in the illustration. Discard gaskets (2). DRESSTA TD-25M EXTRA…
  • Page 160
    7. Valve Housing 12. Sequence Valve Spacer 3. Outer Piston Spring 8. Reducing Spring 13. Sequence Valve Disc 4. Spring Retainer 9. Reducing Spool 14. Sequence Spool Spring 5. Inner Piston Spring 10. Sequence Valve Spool 15. Spring Spacer TD-25M EXTRA DRESSTA…
  • Page 161
    7. Valve Housing 12. Sequence Valve Spacer 3. Outer Piston Spring 8. Reducing Spring 13. Sequence Valve Disc 4. Spring Retainer 9. Reducing Spool 14. Sequence Spool Spring 5. Inner Piston Spring 10. Sequence Valve Spool 15. Spring Spacer DRESSTA TD-25M EXTRA…
  • Page 162
    (2) to the ROPS bracket and allow the bracket (2) with filters (4) to be supported by the hoses. 3. Unscrew bolts (2, Fig. 7C.59) and remove access cover (1) in order to obtain access to mounting points of the drive train control valve. TD-25M EXTRA DRESSTA…
  • Page 163
    Fig. 7C.62. Drive Train Control Valve to Access Drive Train Control Valve Disconnecting Points 1. Cover 4. Bolts 1. Hoses 2. Screws 5. Control Lever 2. Drive Train Control Valve 3. Valve Console 3. Control Lever Harness DRESSTA TD-25M EXTRA…
  • Page 164
    (4) to valve bracket (2) and remove the bracket (2) out of the valve (4). Fig. 7C.63. Drive Train Control Valve Disconnecting Points 1. Mounting Bolts 3. Mounting Bolts 2. Valve Bracket 4. Drive Train Control Valve TD-25M EXTRA DRESSTA…
  • Page 165
    TRANSMISSION SECTION 7C Page 47 DRIVE TRAIN CONTROL VALVE 19. DISASSEMBLY (Refer to Fig.’s 7C.64 and 7C.65) Fig. 7C.64. Exploded View of Drive Train Control Valve DRESSTA TD-25M EXTRA…
  • Page 166
    6. Inner Spring 15. Seal Ring 23. Lever 31. Joint Base 7. Outer Spring 16. O-Ring 24. Dowel Pin 32. Dowel Pin 8. Directional Spool 17. Dowel Pin 25. Joint Housing 33. Orifice Plug 9. Thrust Washer TD-25M EXTRA DRESSTA…
  • Page 167
    3. Position the assembly in a vise. Remove the hardware and separate the housing (25) from the pivot ring (26). 4. Drive the dowel pin (24) out from the housing (25). Remove the lever (23) from the joint housing (25). DRESSTA TD-25M EXTRA…
  • Page 168
    6. Remove the boot (29) from the universal joint. 7. Remove the spool rocker end (12) and jam nut (13) from each spool. 8. Position the assembly in a vise. Remove the dowel pin (28) connecting the universal joint (27) to the joint base (31). TD-25M EXTRA DRESSTA…
  • Page 169
    If required, remove two dowels pins (32) from the base (31). 11. Turn the valve over and remove the two opposite side mounting bolts. 12. Install two threaded rods with washers and nuts to the vacated mounting holes. DRESSTA TD-25M EXTRA…
  • Page 170
    15. Remove the threaded rods and the bottom cover (21) from the valve. 16. Remove and discard the O-rings (16 and 18) from the bottom cover (21). If necessary, remove dowel pin (17). TD-25M EXTRA DRESSTA…
  • Page 171
    Remove the outer springs (7). 18. Remove the inner springs (6). 19. Remove the guide sleeve (5) from each steering spool (4). 20. Remove the directional spool springs (10) at each directional spool in the valve housing. DRESSTA TD-25M EXTRA…
  • Page 172
    23. Install two 3/8”NC nuts on the directional spool (8) and position in a vise. Remove the loctited stop nut (11) from the spool. Repeat for remaining spool. 24. Remove the thrust washer (9) from the spool (8). Repeat for remaining spool. TD-25M EXTRA DRESSTA…
  • Page 173
    DRIVE TRAIN CONTROL VALVE 25. Remove and discard seal rings (14 and 15) from the valve housing. 26. Remove the orifice plugs (33) from the bottom cover (21). 27. Remove two plugs (20) with O-rings (19), if necessary. DRESSTA TD-25M EXTRA…
  • Page 174
    1. Install two plugs (20) with O-rings (19), if removed. 2. Install the orifice plugs (33) into the bottom cover (21). Torque the plugs to 2.7 [Nm]. TD-25M EXTRA DRESSTA…
  • Page 175
    Repeat Step 4 through 5 for remaining spool. 6. Install the directional spool (8) into the valve housing using a slight turning motion to aid the spool pass through the seal ring. Repeat for remaining spool. If removed, install dowel pin (17). DRESSTA TD-25M EXTRA…
  • Page 176
    8. Install the directional spool springs (10) in the recessed bores. 9. Install the guide sleeves (5) over the steering spools with the recessed area towards the valve housing. 10. Install O-ring (16) into valve housing. Install the inner springs (6) to the steering spools. TD-25M EXTRA DRESSTA…
  • Page 177
    14. Position the bottom cover (21) over the threaded rods, with the offset dowel pin holes to the dowel pins (17). Draw down equally on the nuts until the cover is flush. NOTE: Be careful not to bind the cover to the dowel pin. DRESSTA TD-25M EXTRA…
  • Page 178
    17. If removed, install two dowel pins (32). Install joint base (31) to the valve housing, aligning the base dowel pins with the offset recess in the valve housing. Torque the bolts to 11 [Nm]. 18. Slide the universal joint (27) over the joint base (31). TD-25M EXTRA DRESSTA…
  • Page 179
    OPERATOR’S MANUAL) to the universal joint. 21. Install the boot (29) over the universal joint (27) and secure with the tie straps (30). 22. Install the jam nuts (13) and the spool rocker ends (12) to each spool. DRESSTA TD-25M EXTRA…
  • Page 180
    25. Attach the joint housing (25) to the pivot ring (26) and torque the bolts to 11 [Nm]. 26. Install the joint housing (25) over the universal joint (27) and align the dowel pin opening in the universal joint with the opening in the joint housing. TD-25M EXTRA DRESSTA…
  • Page 181
    OPERATOR’S MANUAL) to the pivot ring (26) surface. 29. Run all four spool rocker ends (12) up against the pivot ring until the lever (23) is vertical with no free play between the pivot ring surface and rocker ends. DRESSTA TD-25M EXTRA…
  • Page 182
    Recheck for free play between the pivot ring and rocker ends and correct as necessary. 31. Tighten the jam nuts to the spool rocker ends. Torque the nuts to 32 – 37 [Nm]. TD-25M EXTRA DRESSTA…
  • Page 183
    6. If the pressures are outside specified above, control valve should be repaired or replaced. 7. Shut off the engine and, in case of successful test pressure results, continue installation as described in Paragraph 23, INSTALLATION in this Section. DRESSTA TD-25M EXTRA…
  • Page 184
    10. Install access cover (1, Fig. 7C.59) and secure with bolts (2). 11. Reinstall L.H. enclosure (3) on the left hand side and secure with bolts (4). 12. Check the oil level in the rear main frame as described in the OPERATOR”S MANUAL, add oil if required. TD-25M EXTRA DRESSTA…
  • Page 185
    5. Disconnect the lube steering drive hose (2, Fig. 7C. 66) and main pressure filters hose (4) from the top of pump (3). Fig. 7C.66. Charge and Scavenge Pump Disconnect Points (Top View) 1. Pump Mounting Bolt 3. Charge and Scavenge Pump 2. Lube Steering Drive Hose 4. Main Pressure Filters Hose DRESSTA TD-25M EXTRA…
  • Page 186
    Excessive force while prying can result in misalignment and seriously damage parts. NOTE: Gears are closely matched, therefore they must be kept together as sets when removed from a unit. Handle with care avoid damage to the journals or teeth. TD-25M EXTRA DRESSTA…
  • Page 187
    12. Port Plug 20. Drive Gear Set 5. Housing Seal 13. Needle Bearing 21. Front Housing 6. Channel Seal 14. Rear Housing 22. Retainer Spacer 7. Wear Plate 15. Seal Ring 8. Stud 16. Driven Gear Housing DRESSTA TD-25M EXTRA…
  • Page 188
    Be careful not to distort the wear plate (7). 4. Lift the gear housing (16) from the gears (17). If necessary to pry loose, take care not to damage machined surfaces. TD-25M EXTRA DRESSTA…
  • Page 189
    7. Remove the coupling shaft (11). 8. Lift or pry off the first section gear housing (19). Be careful not to damage machined surfaces. Remove wear plate (7) as described in Step 3. DRESSTA TD-25M EXTRA…
  • Page 190
    To replace, remove the drive gear bearing with a bearing puller and remove seal ring from bottom of bearing bore. Check all seal ring bores in unit for abnormal wear. If worn, replace those sections. TD-25M EXTRA DRESSTA…
  • Page 191
    16. Tap the shaft seal (1) from the seal retainer (2) and discard. Clean seal bore with solvent to remove old sealant. If bore is scored, smooth with fine grade emery paper. It is generally advisable to replace the seal retainer (2). DRESSTA TD-25M EXTRA…
  • Page 192
    Replace wear plates if they are scored, eroded, pitted or discolored. Check center of wear plates where the gears mesh. Erosion here indicates oil contamination. Pitted wear plates indicate cavitation or oil aeration. Discolored wear plates indicate overheating, probably insufficient oil. TD-25M EXTRA DRESSTA…
  • Page 193
    F. Seals and gaskets Replace rubber polymer seals whenever disassembling pump. Include all O-rings, channel seals behind wear plates, shaft seal and gasket seals. G. Plug Make sure the pressure side of the front housing is plugged. DRESSTA TD-25M EXTRA…
  • Page 194
    4. If any bearings (13) have been removed from the front housing (21), rear housing (14) or bearing housing (18), replace the bearings (13) by pressing them into the bearing bore with an arbor press. TD-25M EXTRA DRESSTA…
  • Page 195
    (7). Insert the matched driver gear (20). 8. Grease the new housing seals (5) and insert them into the grooves in both sides of gear housings (16 and 19). DRESSTA TD-25M EXTRA…
  • Page 196
    11. Insert the coupling shaft (11) in the spline of the drive gear (20). 12. Insert the drive and driven gears (17) of the second section in their respective bearings (13). Push down tightly against the wear plate (7). TD-25M EXTRA DRESSTA…
  • Page 197
    Form-A-Gasket 3D or equivalent. With the metal side of the seal down, press it into the seal retainer (2) with a 70 [mm] diameter bar and an arbor press. Be careful not to damage the lip of the seal (1). DRESSTA TD-25M EXTRA…
  • Page 198
    IMPORTANT: Before connecting any lines to the pump, fill all ports with clean oil to provide initial lubrication and avoid the unit damage. 2. Reconnect scavenge suction pump hose (4, Fig. 7C.67) and main suction tube (2) to the bottom of pump (3). TD-25M EXTRA DRESSTA…
  • Page 199
    Tag disconnected lines to facilitate faster and correct installation. Fig. 7C.69. Gear Shifting Valve Disconnect Points 1. Drain Hose 5. Bracket 2. Control Hoses 6. Bolts 3. Wiring Harnesses (Removed) 7. Pressure Supply Hose 4. Gear Shifting Valve DRESSTA TD-25M EXTRA…
  • Page 200
    (1 and 2) bodies from the valve housing (3). Remove and discard the valve seal kit and replace with new. 2. Remove plug (4), if necessary. Fig. 7C.70. Exploded View of Gear Shifting Valve 1. Solenoid Valve 3 Gear 3. Valve Housing 2. Solenoid Valve 2 Gear 4. Plug TD-25M EXTRA DRESSTA…
  • Page 201
    2. Reconnect two control hoses (2) to the valve housing. 3. Reconnect two wiring harnesses (3) to the solenoids. 4. Start the engine and operate with drive train control lever. Check for leaks and functioning. 5. Reinstall the rear plate (3, Fig. 7E.1). DRESSTA TD-25M EXTRA…
  • Page 202
    5. Lift the valve from the machine and remove attached hydraulic connectors, if necessary. 6. Remove the pressure regulator (1 Fig. 7C.72) from the valve housing (2). Remove and discard the valve seal kit and replace with new. TD-25M EXTRA DRESSTA…
  • Page 203
    5. Start the engine and operate with drive train control lever. Check for leaks and functioning. 6. Check the priority valve pressure and adjust, if necessary. Refer to PRIORITY VALVE PRESSURE CHECK AND ADJUSTMENT PROCEDURE in SECTION 7, DRIVE TRAIN. 7. Shut off the engine and close LH filter compartment door. DRESSTA TD-25M EXTRA…
  • Page 204
    Fig. 7C.73. Disassembly Access Cover Fig. 7C.74. Drive Train Pressure Filters to Drive Train Control Valve Removal 1. Access Cover 3. L.H. Enclosure 1. Access Cover 3. Bracket Mounting Bolts 2. Bolts 4. Bolts 2. Filter Bracket 4. Filters TD-25M EXTRA DRESSTA…
  • Page 205
    8. Unscrew the solenoid coil from the lock solenoid valve (2). Remove the solenoid valve cartridge from the valve manifold (1, Fig.7C.76). Remove and discard the valve seal kit and replace with new. 9. Remove plug (3), if necessary. DRESSTA TD-25M EXTRA…
  • Page 206
    2. Clean all parts in a suitable solvent and blow dry with compressed air. Be sure all oil passages in the valve manifold and valve cartridge are free of obstructions. 3. Inspect parts for excessive wear and replace if necessary. 4. Clean threads with a stiff brush and solvent. Check for damage. TD-25M EXTRA DRESSTA…
  • Page 207
    8. Install bracket (2, Fig. 7C.74) with filters (4) to the ROPS bracket and secure with bolts (3). Reconnect the electrical harness to the filter base. 9. Reinstall L.H. enclosure (3) on the left hand side and secure with bolts (4). DRESSTA TD-25M EXTRA…
  • Page 209
    SECTION 7E STEERING DRIVE…
  • Page 211
    19. INSTALLATION …………38 DRESSTA TD-25M EXTRA…
  • Page 213: Service/Special Tools

    The planetary provides the gear reduction in speed for low range. If a hydraulic failure occurs or the engine is stopped, the brake clutches in the steering drive will automatically apply. DRESSTA TD-25M EXTRA…

  • Page 214: Specifications

    Drawbar mounting bolts ……… . . 3100 ± 5 [%] [Nm] NOTE: Except for the special torques shown, all bolts and nuts are to be given a standard torque. Refer to SECTION 1. TD-25M EXTRA DRESSTA…

  • Page 215: Steering Drive

    Tag disconnected lines to facilitate faster and correct installation. 1. Turn the electrical master switch to OFF position and take the key out. 2. Remove transmission case guard from bottom of machine. DRESSTA TD-25M EXTRA…

  • Page 216
    13. Remove the gear shifting valve (2) as described in Paragraph 29, REMOVAL in SECTION 7C. 14. Disconnect two hoses and unscrew three mounting bolts to remove hydraulic damper (12). 15. Unscrew two cover bolts (15) to remove gear shifting valve bracket (1). Unscrew remaining cover bolts (15). TD-25M EXTRA DRESSTA…
  • Page 217
    (1). Temporarily secure the steering manifold (2, Fig. 7E.9) to the bracket (17). Fig. 7E.3. Main Frame Cover Removing Fig. 7E.4. Removing Steering Drive Lube Tube 1. Cover 2. Lifting Eye Bolts 1. Main Frame 2. Steering Drive 3. Lube Tube DRESSTA TD-25M EXTRA…
  • Page 218
    Fig. 7E.7 and take up the slack. NOTE: An adjusting sling must be used so that the steering drive can be tilted and leveled. Fig. 7E.7. Removing Steering Fig. 7E.8. Steering Drive Disconnecting Drive Points 1. Main Frame 2. Drawbar 3. Plugs TD-25M EXTRA DRESSTA…
  • Page 219
    18. Elbow 5. Hose, Manifold to HI Range Clutch 12. Hose, Manifold to LOW Range Clutch 19. Upper Bolt 6. Connector 13. Hose, Manifold to LOW Range Clutch 20. Retaining Ring 7. O-Ring 14. Connector 21. Lower Bolt DRESSTA TD-25M EXTRA…
  • Page 220: Disassembly

    4. Right Low Piston Return Springs 12. Right High Clutch Port 5. Right Brake Port 13. Lube Port 6. Right Brake Applying Springs 14. Left High Clutch Port 7. Right Brake Piston Seal Rings 15. Manifold Seal Rings 8. Right Brake Piston TD-25M EXTRA DRESSTA…

  • Page 221
    STEERING DRIVE SECTION 7E Page 9 STEERING DRIVE Fig. 7E.11. Exploded View of Two Speed Steering Drive DRESSTA TD-25M EXTRA…
  • Page 222
    9. Remove seal rings (17 and 19) and O-rings (16 and 18) from brake piston (15). 10. Lift brake plate retainer (22) with brake friction discs (81) and brake clutch plates (82) from the assembly. Remove the discs (81) and plates (82) from the retainer (22). TD-25M EXTRA DRESSTA…
  • Page 223
    22. Thread two eye bolts 3/8”-16UNC into the tapped holes in high range clutch piston (49) as shown in Fig. 7E.14 and remove the piston. 23. Turn the assembly over and repeat Steps 1 through 22 on the left side. DRESSTA TD-25M EXTRA…
  • Page 224
    Fig. 7E.16. 29. Remove piston retainer ring (66) from bevel gear hub (55). Bend up the tabs of lock washer (64) and remove lock nut (65), lock washer (64) and tongued washer (63). TD-25M EXTRA DRESSTA…
  • Page 225: Inspection And Repair

    9. The rear main frame cover mounting surfaces must be cleaned with proper solvent and inspected for scratches, irregularities, and flatness. (Maximum out of flat between any two consecutive mounting holes to be 0.25 [mm]). If the cover does not meet this requirement, the cover should be replaced. DRESSTA TD-25M EXTRA…

  • Page 226: Reassembly

    Tighten lock nut (65) until a reading of 1.5 ± 0.5 [Nm] is obtained. NOTE: The initial pull needed to start the carrier rolling will be greater. Do not use this reading for adjustment. TD-25M EXTRA DRESSTA…

  • Page 227
    13. If tapered bearings (75 and 78) were replaced, press new cups of tapered bearings in housing (76) until they bottom. Fig. 7E.20. Checking Pinion Shaft Fig. 7E.20A. Checking Pinion Shaft Bearing Preload (I Method) Bearing Preload (II Method) DRESSTA TD-25M EXTRA…
  • Page 228
    (79) rolling torque with a 1.249.0017 tool equipped with a 1.264.0024 socket. The rolling torque should range between 0.5 to 6 [Nm]. If the initial rolling torque reading falls outside this range, press the bearing (75) in until the correct reading is achieved. TD-25M EXTRA DRESSTA…
  • Page 229
    6.6 [mm]. In that case 0.1 [mm] was removed. NOTE: Due to thrust race (73) and retaining ring (72) thickness tolerance pay a particular attention while selecting these elements to account for their actual thickness. DRESSTA TD-25M EXTRA…
  • Page 230
    (68) and housing (67). Adjust the gear backlash to suit “Bl” reading etched at front of pinion shaft and bevel gear face. Reinstall nut lock ring (69) and torque the bolts to 54 [Nm]. Recheck gear backlash. TD-25M EXTRA DRESSTA…
  • Page 231
    60 [º] in relation to the proceeding plate so that tabs of two successive externally splined plates form an entire circumference. Install ring gear adapter (48) and ring gear (47) on clutch plate retainer (56) and torque the bolts to 54 [Nm]. DRESSTA TD-25M EXTRA…
  • Page 232
    Then remove the return spring retainer (44) and measure the retainer thickness D with a micrometer in two places. Subtract the retainer thickness D from the total distance. C – D = A TD-25M EXTRA DRESSTA…
  • Page 233
    (45 and 46) as shown in Fig. 7E.26 and install spring retaining ring (43) and shims (84) (if required). Remove the three bolts. Springs must rest in counterbores of spring retainer (44). Fig. 7E.26. Spring Retaining Ring Installation DRESSTA TD-25M EXTRA…
  • Page 234
    B…………..2.54 ± 0.25 [mm] TD-25M EXTRA…
  • Page 235
    (A, Fig. 7E.29) to measure the distance C from the outer edge of the piston to the retainer in two places. Then remove the piston (9) and measure the piston thickness D with a micrometer in two places. Subtract the piston thickness D from the total distance. C – D = B DRESSTA TD-25M EXTRA…
  • Page 236
    Thrust race should be 0.13 — 0.25 [mm] below shims. Add or subtract shims to obtain 0.13 — 0.25 [mm] gap. 50. Add the correct amount of shims determined in Step 49. Install bearing retainer (2) and torque the bolts to 54 [Nm]. 51. Turn the assembly over. TD-25M EXTRA DRESSTA…
  • Page 237
    6. Secure the steering drive (1, Fig. 7E.9) to the front surface of main frame with the upper bolts (19) with washers. Torque the upper bolts to 920 [Nm]. DRESSTA TD-25M EXTRA…
  • Page 238
    23. Reconnect wires of rear lamp (1, Fig. 7E.1), backup alarm (2) and fuel level sensor (8). 24. If equipped, connect hydraulic ripper hoses. 25. Fill the rear frame as described in the OPERATOR’S MANUAL. TD-25M EXTRA DRESSTA…
  • Page 239
    11. HI-LO Valve 2. Pilot Hoses (Short) 7. Bolts 12. Pilot Hoses (Disconnected) 3. Solenoids Wiring Harnesses 8. Bolts 13. Supply Hose 4. Brake Lever 9. Stud Nuts 14. Main Frame Cover 5. Pressure Check Hoses 10. Drain Hose DRESSTA TD-25M EXTRA…
  • Page 240: Installation

    4. Remove the six bolts securing upper steering valve (1) to lower steering valve (5) and separate it. Remove and discard the valve gasket (2). 5. Remove large ball (3) and two small balls (4) from the lower steering valve (5). TD-25M EXTRA DRESSTA…

  • Page 241
    7. Steering Manifold 12. Lever to Valve Link 3. Ball (Large) 8. Stud with Washer and Nut 13. Lever Pins 4. Ball (Small) 9. Lever Bracket 14. Roller Bearings 5. Lower Steering Valve 10. Lever Shaft 15. Lube Fitting DRESSTA TD-25M EXTRA…
  • Page 242
    6. Check Ball Body 14. Spring Washer 22. Outer O-Ring 30. Metering Spool Sleeve 7. Check Ball 15. Inner Spool Spring 23. Inner O-Ring 31. O-Ring 8. Port Plug 16. Inner Spring Stop 24. Outer Spool Spring TD-25M EXTRA DRESSTA…
  • Page 243
    Discard the O-rings. 21. Remove items (4 thru 7) as an assembly by pulling spools (4) out front of valve housing (1). 22. Remove the spool springs (7). 23. Remove the spring spacer (6) and spring seats (5). DRESSTA TD-25M EXTRA…
  • Page 244
    25. Unscrew the solenoid coil from the solenoid valve (2). Remove the solenoid valve (2) bodies from the valve housing (1). Remove and discard the valve seal kit. 26. Remove nozzles (5) from the valve housing (1). Remove plugs (4) and clip (6), if necessary. TD-25M EXTRA DRESSTA…
  • Page 245: Inspection And Repair

    4. Inspect the condition of the springs. If they are damaged or do not fall within the specification shown in Paragraph 3, SPECIFICATIONS, they must be replaced. 5. Clean threads with a stiff brush and solvent. Check for damage. DRESSTA TD-25M EXTRA…

  • Page 246: Reassembly

    Install the spool spring (10) toward the rear of the housing (1). 21. Prior to installation of rear cover (2), verify metering spools (26) move freely in spool sleeves (30). Use a new gasket (3) and secure rear cover (2) to housing (1). TD-25M EXTRA DRESSTA…

  • Page 247: Installation

    3. Reconnect two pilot hoses (12) and two short pilot hoses (2) to the steering valve (6) and drain hose (10) to the Hi-Lo valve (11). 4. Reconnect clevis with brake control cable to the brake lever (4). 5. Reconnect wiring harnesses (3) to the two solenoids. DRESSTA TD-25M EXTRA…

  • Page 248: Steering Valve Brake Section Test And Adjustment

    (2) and gasket (3). Remove poppet (12), and add or deduct shims (11). Each shim will raise FEEL POINT pressure 35 [kPa]. Reinstall valve rear cover (2), with a new gasket (3). Recheck feel point pressure. TD-25M EXTRA DRESSTA…

  • Page 249
    1. Remove plug (5) with O-ring (4) from housing (1). Remove O-ring from plug. 2. Pull spool (3) and spring (2) from housing (1). Fig. 7E.37. Exploded View of Steering Manifold 1. Manifold Housing 4. O-Ring 2. Spool Spring 5. Spool Plug 3. Manifold Spool DRESSTA TD-25M EXTRA…
  • Page 250
    NOTE: The manifold bracket is only used to correctly position and hold the manifold in place during hose installation. 3. Perform Steps 13 to 19 as described in Paragraph 8, INSTALLATION in this SECTION. 4. Install the steering valve as described in Paragraph 13, INSTALLATION in this SECTION. TD-25M EXTRA DRESSTA…
  • Page 251
    SECTION 7F FINAL DRIVE…
  • Page 253
    21. INSTALLATION …………17 DRESSTA TD-25M EXTRA…
  • Page 255
    (3), sprocket hub and sprocket drive segments (4) to rotate in direction A driving the machine in direction B (Fig. 7F.2). The final drive assembly has its own lubrication and is sealed against leakage and dirt. DRESSTA TD-25M EXTRA…
  • Page 256
    Lower deflector ……….. . . 845 [Nm] NOTE: Except for special torques shown, all bolts and nuts are to be given a standard torque. Refer to the STANDARD TORQUES in SECTION 1, INTRODUCTION. TD-25M EXTRA DRESSTA…
  • Page 257
    Repair or install new track frame. Final Drive Lubricant Level to High 1. Oil seal damaged between rear frame and Change oil seal. final drive 2. Oil seal output shaft surface damaged Change the shaft and oil seal. DRESSTA TD-25M EXTRA…
  • Page 258
    3. Install the outer sprocket deflector (3, Fig. 7F.3) and secure with hardware. Torque the bolts to 845 [Nm]. 4. Install the upper sprocket guards (2, Fig. 7F.3) and secure with hardware. Torque the bolts to 520 [Nm]. TD-25M EXTRA DRESSTA…
  • Page 259
    O-ring (4) in pinion gear (5). Remove the bolt and install retaining ring (2). 5. Reinstall cover (11) with shims (10). Use the LOCTITE #120 under and above shims (10). Torque bolts with washer to 125 [Nm]. DRESSTA TD-25M EXTRA…
  • Page 260
    Insert a pry bar as shown in Fig. 7F.6 to hold the cover up as it clears the drift. Pull the final drive assembly away from the main frame. Remove the pry bar and let cover (17) swing down slowly. TD-25M EXTRA DRESSTA…
  • Page 261
    FINAL DRIVE SECTION 7F Page 7 FINAL DRIVE ASSEMBLY 8. DISASSEMBLY (Refer to Fig.’s 7F.7 and 7F.8) Fig. 7F.7. Cross Section View of Final Drive DRESSTA TD-25M EXTRA…
  • Page 262
    41. Bearing Spacer 12. Retaining Ring 27. Tapered Roller Bearing 42. Planetary Gear 13. Bull Gear 28. Retainer Plate 43. Port Plug 14. Retaining Ring 29. Ring Gear Hub 44. Sprocket Drive Segment 15. Bull Gear Bearing 30. Shim TD-25M EXTRA DRESSTA…
  • Page 263
    (22). Remove protective corks (26) from three puller holes and install puller bolts 5/8”-11UNC-2B. Loose housing from hub and remove puller bolts. Install lifting eyebolts 5/8”-11UNC-2B (Fig. 7F.10) in puller holes, attach a hoist and remove housing. Fig. 7F.10. Planetary Carrier Housing DRESSTA TD-25M EXTRA…
  • Page 264
    Fig. 7F.12. Sprocket Hub 9. Lift spacer (20) from cover (17). Bearing cone (19) should not be removed from cover (17) unless replacement is necessary. Shield (21) need not be removed unless replacement or cleaning is necessary. TD-25M EXTRA DRESSTA…
  • Page 265
    NOTE: Before installing oil seal assembly, be sure seal contacting surfaces of drive cover and sprocket hub are clean, also that rubber rings of seal assembly are correctly positioned on metal rings. Refer to instructions furnished with oil seal. DRESSTA TD-25M EXTRA…
  • Page 266
    °] level plug is placed 90[ left from drain plug. Secure housing (35) to hub (22) and torque bolts to 730 [Nm]. Install protective corks (26) in puller holes. Remove the technological bolt and install plug (43). TD-25M EXTRA DRESSTA…
  • Page 267
    Fig. 7F.15. Remove the remaining planet carrier housing mounting bolts and free the housing (35) from the hub (22). Remove planet carrier housing (35) from final drive. Remove thrust button (34) from housing (35). DRESSTA TD-25M EXTRA…
  • Page 268
    4. Thoroughly scrape the final drive mating surfaces clean. Be careful not to scratch these finished surfaces or sealing may become ineffective. 5. Inspect the planet gear shaft and planet gear bore for wear and replace if necessary. TD-25M EXTRA DRESSTA…
  • Page 269
    (1) and right bearing cone (1) out of housing (7). Bearing cones and cups (1) need not be removed unless replacement is necessary. Remove oil seal (9) and O-rings (6 and 8) from housing (7). DRESSTA TD-25M EXTRA…
  • Page 270
    1. If bearings (1) were replaced, install bearing cones (1) on gear (5) until they are solid against shoulder. Fig. 7F.16. Gap Measuring Fig. 7F.17. Shims Installation 11. Cover 11A. Mounting Bolt 7. Pinion Gear Housing 10. Shim TD-25M EXTRA DRESSTA…
  • Page 271
    180 [Nm]. 2. Install retaining ring (14) into groove of final drive cover (17) through holes in gear. 3. Install the final drive as described in Paragraph 11, INSTALLATION, under FINAL DRIVE, in this SECTION. DRESSTA TD-25M EXTRA…
  • Page 273
    SECTION 8 ELECTRICAL…
  • Page 275
    25. SPECIFICATION …………52 DRESSTA TD-25M EXTRA…
  • Page 277: Description

    (40) 10 [A] to start-up lock switch (13). If the drive train lock lever is in “ON” (locked) position, current flows by start-up lock switch (13) closed contacts to solenoid of starting magnetic switch (60). DRESSTA TD-25M EXTRA…

  • Page 278
    (98) to get reenergized. The drive train electronic controller (10) is in charge of solenoid valves being reenergized or deenergized. The time duration the control button is depressed has no bearing on gear shifting. TD-25M EXTRA DRESSTA…
  • Page 279
    Troubleshooting and Repair Manual QSK Fuel System. h. Accessories Circuit This circuit supplies power to the lights, fuel solenoid valve, ether solenoid valve, instruments and any accessory items on the machine. Automatic reset circuit breakers are used to protect them. DRESSTA TD-25M EXTRA…
  • Page 280
    46. Fan Drive System Filter Clogging Warning Light 47. Low Engine Oil Pressure Warning Light 48. Alarm (Low Engine Oil Pressure or Coolant Level) 49. Drive Train Oil Temperature Gauge Sensor 50. Drive System Oil Temperature Sensor that Controls Fan RPM TD-25M EXTRA DRESSTA…
  • Page 281
    87. Cab Automatic Circuit Breakers 88. Condenser Fans 89. Heater/ Air Conditioner Valve Control Potentiometer 90. Condenser Fans Power Supply Relay 91. Air Conditioner/ Heater 92. Operator’s Seat Suspension System Pump (option) 93. Backup Alarm 94. RH Rear Lamp DRESSTA TD-25M EXTRA…
  • Page 282
    R – Engine Warning Light “FLUID” Wire color code Code Color Amber White Yellow Black Brown Gray Orange Pink Violet Dark Blue Light Blue Dark Green Light Green Green Wire cable marking: W/LG – 38D wire color code/ cable designation TD-25M EXTRA DRESSTA…
  • Page 283
    SECTION 8 ELECTRICAL Page 7 Fig. 8.1. Wiring Diagram (earlier version) DRESSTA TD-25M EXTRA…
  • Page 286
    SECTION 8 ELECTRICAL Page 10 Fig. 8.1A. Wiring Diagram (later version) TD-25M EXTRA DRESSTA…
  • Page 287
    41. Portable Lamp Receptacle 42. Engine ECM Memory Activation Momentary Switch 43. Engine ECM Failure Code Display Momentary Switch 44. Fuel Level Gauge 45. Hourmeter 46. Fan Drive System Filter Clogging Warning Light 47. Low Engine Oil Pressure Warning Light DRESSTA TD-25M EXTRA…
  • Page 288
    87. Cab Automatic Circuit Breakers 88. Condenser Fans 89. Heater/ Air Conditioner Valve Control Potentiometer 90. Condenser Fans Power Supply Relay 91. Air Conditioner/ Heater 92. Operator’s Seat Suspension System Pump (option) 93. Backup Alarm 94. RH Rear Lamp TD-25M EXTRA DRESSTA…
  • Page 289
    R – Engine Warning Light “FLUID” Wire color code Code Color Amber White Yellow Black Brown Gray Orange Pink Violet Dark Blue Light Blue Dark Green Light Green Green Wire cable marking: W/LG – 38D wire color code/ cable designation DRESSTA TD-25M EXTRA…
  • Page 290: Drive Train Control System

    The microprocessor controller is responsible for the following: gear change, speed range change, gradual turns (different ranges being used for both tracks), auto downshift and gear presetting. b. Description to signal diodes incorporated in the drive train electronic controller Fig. 8.1A. LEDs arrangement on the electronic controller TD-25M EXTRA DRESSTA…

  • Page 291
    L17 – ON, when the 2nd gear was engaged, L16 and L18 must not be ON; • L18 – ON, when the 1st gear was engaged, L16 and L17 must not be ON; • L19, L20, L21 – are used to learn the machine type code (different wiring). Refer to Table 8.1. DRESSTA TD-25M EXTRA…
  • Page 292
    LED ON providing power to controller [V] TD-15M EXTRA TD-20M EXTRA TD-25M EXTRA TD-40E EXTRA • L22 – ON, when the controller is fed with a pulse train coming from the torque converter output CIW magnetic sensor; this pulse train is a must for correct operation of auto downshift;…
  • Page 293
    A, H, V (refer to Table 8.1) got corrupted. 4. If a single solenoid valve is at fault, take a voltage check at the solenoid valve coil’s terminals. DO NOT take a voltage to the machine ground. DRESSTA TD-25M EXTRA…
  • Page 294
    – the display will change from “2” to “3”, diode L17 will come off and L16 will come on, the third gear solenoid valve EZ3 will energize, while that for third gear EZ2 will de-energize; TD-25M EXTRA DRESSTA…
  • Page 295
    WO – Auto Downshift Mode Switch CIW – Torque Converter Output RPM Magnetic Switch CS – Engine RPM Magnetic Switch ST – Electronic Controller D – Display EZ2 – 2nd Gear Solenoid Valve EZ3 – 3rd Gear Solenoid Valve DRESSTA TD-25M EXTRA…
  • Page 296
    L9 to come on. When the machine is stopped both sensors will not provide any signal to the controller and diodes L8 and L9 will be off. Fig. 8.1D. provides a control system schematic in this operation mode. TD-25M EXTRA DRESSTA…
  • Page 297
    L16 and L18 will come off. Fig. 8.1E. provides a drive control system schematic in this operation mode. Fig. 8.1E. Control System Schematic for 2/2 Presetting Mode WB – Gear Presetting Mode Switch ST – Electronic Controller D – Display EZ2 – 2nd Gear Solenoid Valve DRESSTA TD-25M EXTRA…
  • Page 298
    EZR solenoid valve – a diode L12 will come on. The EZL solenoid valve will remain deactivated – the L13 diode will come off. The result will be machine left gradual turn. TD-25M EXTRA DRESSTA…
  • Page 299: Service Diagnosis

    1. Electrical problem in fan control circuit Refer to Fan Circuit in Paragraph 3 in this Section 2. Problem in fan drive system Refer to “SERVICE DIAGNOSIS” in SECTION 10 “HYDRAULIC” NOTE: For electrical switches location on the machine refer to their system. DRESSTA TD-25M EXTRA…

  • Page 300: Introduction

    M10x1.5 SAE Grade 8 ……….72 [Nm] 6. INTRODUCTION Fig. 8.3. View of Alternator 1. Pos. or Output Terminal 2. Relay Terminal 3. Ground Screw TD-25M EXTRA DRESSTA…

  • Page 301: Operation Principles

    1. Heavy — Duty Roller Bearing with Lip Seal 2. Grease Reservoir 3. Stationary Field Coil (Brushless Construction) 4. Steel Thread Insert 5. Double Sealed Heavy — Duty Ball Bearing 6. Labyrinth Seal 7. Felt Seals 8. Adjustable Steel Bushing DRESSTA TD-25M EXTRA…

  • Page 302
    If the connection between POS. and (R2) should become open-circuit (TR3) and (TR1) will turn off, thus preventing high system voltage. Capacitor (C1) smoothes out the voltage across (R3), resistor (R4) prevents excessive current through (TR1) at high temperatures, and diode (D2) prevents high-induced-voltages in the field windings when (TR1) turns off. TD-25M EXTRA DRESSTA…
  • Page 303: Troubleshooting Procedures

    6. With all accessories turned off, increase engine speed as required to obtain maximum voltage reading. 7. If voltage exceeds 30 Volts on a 24-Volt system remove Integral Charging System for repair as covered below under heading of INTEGRAL CHARGING SYSTEM REPAIR. DRESSTA TD-25M EXTRA…

  • Page 304: Integral Charging System Repair

    If ampere output is not within 10 Amperes of rated output as stamped on Integral Charging System frame, remove the Integral Charging System for repair as covered in section entitled INTEGRAL CHARGING SYSTEM REPAIR. Fig. 8.6. Basic Wiring Diagram 1. Integral Charging System 2. Vehicle Loads 3. Battery TD-25M EXTRA DRESSTA…

  • Page 305
    Insulated 12. Rectifier Bridge Washer a. Regulator Check The regulator cannot be checked with an ohmmeter. Use an approved regulator tester available from various test equipment manufacturers. b. Diode Trio Check Fig. 8.8. Checking Trio 1. Ohmmeter DRESSTA TD-25M EXTRA…
  • Page 306
    (Step 2, Fig. 8.9). If ohmmeter reading is low, the field coil is grounded. To check for opens, connect an ohmmeter to the two field coil leads as shown in (Step 3, Fig. 8.9). If ohmmeter reading is high (infinite), the field coil is open. TD-25M EXTRA DRESSTA…
  • Page 307
    However, if all other electrical checks are normal and the generator fails to supply rated output, shorted stator windings are indicated. f. Disassembly and Repairing (Fig. 8.10) Fig. 8.10. Exploded View of Alternator DRESSTA TD-25M EXTRA…
  • Page 308
    8. To replace rectifier housing bearing (38): a. Push out bearing (38) from either end. b. Use a thin wall tube in space between grease cup and housing to push bearing (38) in to dimension as shown in Fig. 8.11. TD-25M EXTRA DRESSTA…
  • Page 309: Safety Precautions

    3. Do not break live circuits at the terminals of batteries. 4. Make certain the battery cable clamps are making good connections. 5. Be careful that tools or metallic objects do not fall across the battery terminal. DRESSTA TD-25M EXTRA…

  • Page 310: Electrolyte State Of Charge

    Batteries used in temperature climates have a fully charged specific gravity in the 1.250 to 1.280 range. A fully charged electrolyte specific gravity of 1.210 to 1.230 is used in tropical climates. This increases the service life of the battery. TD-25M EXTRA DRESSTA…

  • Page 311: Testing And Maintenance The Battery

    If electrolyte levels are found to be low or a battery is in a deep state of discharge, check for charging system malfunction and/or loose battery trays and hold-down clamps. Add water before proceeding further. The state-of-charge of low water loss batteries can be determined with an accurate voltmeter. DRESSTA TD-25M EXTRA…

  • Page 312
    10 [°C] 4 [°C] -1 [°C] -7 [°C] -12 [°C] -18 [°C] If the voltage is less than the minimum specified, replace the battery. If the voltage meets or exceeds the specified minimum, return it to service. TD-25M EXTRA DRESSTA…
  • Page 313: Battery Charging Guide

    Storage above 27 [°C] increases self-discharge. If batteries are discharged, the electrolyte may freeze when stored below -7 [°C]. Battery stock must be rotated on a strict «first-in, first-out» basis. DRESSTA TD-25M EXTRA…

  • Page 314: Battery Primary Ratings

    It is recommended wait for 3 hours after filling of battery. 5. Charge battery no more than 7 [A] for 30 minutes. Battery is ready if specific gravity is 1.250 or more at temperature 15.5 [°C]. 6. Check electrolyte level and add distillated water if need. TD-25M EXTRA DRESSTA…

  • Page 315: Visual Inspection Of Battery

    If the container and/or cover is cracked it could be due to abuse (an impact blow), freezing or the battery exploded. High temperatures may permit the container to bulge. DRESSTA TD-25M EXTRA…

  • Page 316
    Noise housing bolts torque ……….190 — 250 [Nm] TD-25M EXTRA…
  • Page 317: Introduction

    Lubrication is provided to the sintered bronze bushings by an oil saturated wick (3, 9 and 14, Fig. 8.13). Oil can be added to each wick by removing an oil reservoir cup which is accessible on the outside of the motor. DRESSTA TD-25M EXTRA…

  • Page 318: Operating

    19. O-Ring 9. Oil Wick 20. One — Piece Brush 10. Sealing Boot 21. O-Ring 11. Totally Enclosed Shift Mechanism NOTE: The starting circuit was explained in WIRING DIAGRAM Paragraph. 3, Machine Electrical System in this Section. TD-25M EXTRA DRESSTA…

  • Page 319: Troubleshooting The Cranking Circuit

    If the armature does not turn freely the motor should be disassembled immediately. However, if the armature does rotate freely, the motor should be given a no-load test before disassembly. DRESSTA TD-25M EXTRA…

  • Page 320
    Grounded armature or fields. Check further after disassembly. 3. Failure to operate with high current draw indicates: a. A direct ground in the terminal or fields. b. «Frozen» bearings (this should have been determined by turning the armature by hand). TD-25M EXTRA DRESSTA…
  • Page 321
    The full brush surface should ride on the commutator to give proper performance. Check by hand to insure that the brush springs are giving firm contact between the brushes and commutator. If the springs are distorted or discolored, they should be replaced. DRESSTA TD-25M EXTRA…
  • Page 322
    This check cannot be made if the ground connection cannot be disconnected. Opens — Connect test lamp leads to ends of field coils. If lamp does not light, the field coils are open. TD-25M EXTRA DRESSTA…
  • Page 323
    Where the pole shoe has a long lip on one side and a short lip on the other, the long lip should be assembled in the direction of armature rotation so becomes the trailing (not leading) edge of the pole shoe. DRESSTA TD-25M EXTRA…
  • Page 324
    M terminal as shown. If the carbon pile is not needed, connect a jumper directly from the battery to the M terminal. Fig. 8.16. Solenoid Circuit with Ground Return Terminals 1. Hold — In Winding 3. Start Switch 5. To Motor Windings 2. Pull — In Winding 4. Battery TD-25M EXTRA DRESSTA…
  • Page 325
    Delco Remy No. 1960954 on the washer located on the shaft between the armature and shift lever housing. Sintered bronze bearings used in these motors have a dull finish, as compared to the early type machined, cast bronze bearings which had a shiny finish. DRESSTA TD-25M EXTRA…
  • Page 326
    3. Push the pinion or drive back towards the commutator end to eliminate slack movement. 4. Measure the distance between drive and housing (Fig. 8.20). 5. Adjust clearance by removing plug and turning shaft nut (Fig. 8.20). Fig. 8.19. Checking Pinion Clearance Circuit 1. Battery TD-25M EXTRA DRESSTA…
  • Page 327
    A …………… . 8.3 – 9.9 [mm] DRESSTA TD-25M EXTRA…
  • Page 328: Cranking Motor 39 Mt

    Control Circuit Voltage Drop at 20 [°C] Max. 2 [V] Max. 2 [V] Engagement Positive Soft Start Ventilation Orientation Not Applicable +/- 30 [°] Solenoid barrier Normal or High High Seal Wet or Dry * — in-rush / steady-state current TD-25M EXTRA DRESSTA…

  • Page 329
    The Delco Remy electrical «Soft Start» system slowly rotates the pinion until it is properly engaged to the ring gear before cranking. This feature provides an additional measure of protection from the inputs that can cause pinion chipping and milling which can result in cranking motor failure. DRESSTA TD-25M EXTRA…
  • Page 330
    In addition to the new mounting hardware, a lower torque value is required as compared to the 42MT cranking motor. Fig. 8.23. View of 39MT Cranking Motor with Integral Magnetic Switch IMS- Integral Magnetic Switch TD-25M EXTRA DRESSTA…
  • Page 331
    SECTION 9 FRAME…
  • Page 333
    SECTION 9 CONTENTS SERVICE /SPECIAL TOOLS 1. SERVICE /SPECIAL TOOLS …………………. 1 GENERAL 2. DESCRIPTION ……………………..1 3. WELDING ………………………. 3 FRAME 4. MAINTENANCE …………………….. 3 5. SPECIFICATIONS ……………………4 6. REMOVAL ……………………… 4 7. INSTALLATION ……………………… 4 DRESSTA TD-25M EXTRA…
  • Page 335: Description

    Hence, working loads applied to the rear frame by rear mounted attachments or to the crosstube by the blade, are distributed through the frame side members to the undercarriage not affecting the drive train components. DRESSTA TD-25M EXTRA…

  • Page 336
    FRAME SECTION 9 Page 2 GENERAL Fig. 9.2. View of Frame TD-25M EXTRA DRESSTA…
  • Page 337: Welding

    A periodic inspection of the frame sections should be made to detect weld cracks, broken welds or damaged brackets. Special attention should be given to the seals bushings, guard and covers are in good condition. To keep rust and corrosion to a minimum, periodic painting of abrasions and bare metal is recommended. DRESSTA TD-25M EXTRA…

  • Page 338: Installation

    6. Liberally coat bushing bores and lift yoke bushing surfaces with fresh grease. 7. Install the lift cylinder yoke (refer to SECTION 17). 8. Install blade lift cylinder (refer to SECTION 10C). 9. Lubricate crosstube bushings; refer to OPERATOR’S MANUAL. TD-25M EXTRA DRESSTA…

  • Page 339
    SECTION 10 HYDRAULICS…
  • Page 341
    11. FAN DRIVE SYSTEM PERFORMANCE TEST ……..20 DRESSTA TD-25M EXTRA…
  • Page 343: Description

    Hydraulic Cylinders The blade and ripper cylinders are the single stage double acting type. Hydraulic pressure is introduced through ports at either end to actuate the piston. DRESSTA TD-25M EXTRA…

  • Page 344
    The purpose of this valve is to direct the oil to the main control valve when the tilt cylinder does not act and to unload the engine in the movement described above in Directional Valve description, switching the tilt pump over to the sink. TD-25M EXTRA DRESSTA…
  • Page 345
    When the lever is moved to any direction, the pivot plate actions the plunger actuator which engages the metering spool. In that way the metering spool opens the pilot pressure oil to the ripper lift or pitch valve section. When the lever is released it will return to neutral. DRESSTA TD-25M EXTRA…
  • Page 346
    11. Blade Tilt Cylinder 17. Pilot Pressure Filter 5. Three Spool Control Valve 12. Blade Tilt Control Valve 18. Pilot Pressure Valve 6. Blade Pilot Control Valve 13. Hydraulic Three Section Vane Pump 7. Ripper Pilot Valve 14. Hydraulic Reservoir TD-25M EXTRA DRESSTA…
  • Page 347
    19. Double Tilt/Pitch Solenoid Valve 6. Blade Pilot Control Valve Vane Pump 19A. Pitch Solenoid Valve 7. Ripper Pilot Control Valve 14. Hydraulic Reservoir 19B. Double Tilt Solenoid Valve 8. Directional Valve 14A. Suction Strainer 20. Blade Double Tilt/Pitch Cylinder DRESSTA TD-25M EXTRA…
  • Page 348
    (3), check valve (7) and hydraulic oil cooler (4) with bypass valve (5). The fan drive axial piston variable pump (12) is controlled by electro — hydraulic pressure control module (8) mounted on the pump (12). TD-25M EXTRA DRESSTA…
  • Page 349
    (failsafe in case ECM failure). Overriding the current signal is an adjustable hydromechanical setting of maximum pressure. For detailed description of the fan electrical control refer to Paragraph 3, MACHINE ELECTRICAL SYSTEM in SECTION 8, ELECTRICAL. DRESSTA TD-25M EXTRA…
  • Page 350
    Drive train system oil ……….115 [°C] TD-25M EXTRA…
  • Page 351
    All Cylinders No or Slow Movement 1. Insufficient oil supply Refer to Noisy Operation Oil Foaming. 2. Pilot supply valve out of order Refer to SECTION 10B, PILOT PRESSURE VALVE. 3. Rear pilot pump worn out Refer to SECTION 10A, PUMPS. DRESSTA TD-25M EXTRA…
  • Page 352
    Clean or wash filter. clogged Blade and Ripper Cannot Be Lowered after Engine Shutdown 1. Stuck spool or fatigued spring in pilot Repair or replace parts as necessary. Refer to pressure valve SECTION 10B, PILOT PRESSURE VALVE TD-25M EXTRA DRESSTA…
  • Page 353: Test And Adjustment

    1. One or Three Spool Control Valve 2. Main Pressure Quick Disconnect Fitting 3. Blade Tilt (Tilt/Pitch) Pressure Quick Disconnect Fitting 4. Blade Tilt (Tilt/Pitch) Control Valve 5. Pilot Pressure Quick Disconnect Fitting 6. Pilot Pressure Valve DRESSTA TD-25M EXTRA…

  • Page 354
    9. Jam Nut 13. Pilot Popper Seat 2. End Cap 6. O-Ring 10. Adjusting Screw 14. Main Poppet 3. Seal Washer 7. Main Poppet Spring 11. End Cap 15. Main Poppet Seat 4. O-Ring 8. O-Ring 12. Pilot Poppet TD-25M EXTRA DRESSTA…
  • Page 355
    5. End Cap 9. Pilot Relief Seat 12. End Cap 2. Jam Nut 6. Poppet Spring 10. Check Valve Spring 13. O-Ring 3. Adjusting Screw 7. Relief Poppet 11. Check Valve 14. Washer 4. O-Ring 8. O-Ring DRESSTA TD-25M EXTRA…
  • Page 356: Blade Lift Cylinder Drift Test (Machine Without Ripper)

    3. Fully raise blade and move lever to LOWER position releasing it to HOLD before blade drops to ground. 4. Perform blade lift cylinders drift test. Check cylinders for drift, rods should travel out of cylinders no more than 18 [mm] per minute. TD-25M EXTRA DRESSTA…

  • Page 357: Blade Lift Cylinders And Ripper Lift Cylinders Drift Test (Machine With Ripper) /Blade And Ripper Lift Cylinders Are Dropping

    6. Fully raise the blade and move the blade lift lever to LOWER position releasing it to HOLD before the blade drops to the ground 7. Perform blade lift cylinders drift test. Check cylinders for drift, rods should travel out of cylinders no more then 18 [mm] per minute. DRESSTA TD-25M EXTRA…

  • Page 358
    HYDRAULICS SECTION 10 Page 16 TEST AND ADJUSTMENT Fig. 10.10. Hydraulic Chart, Blade Tilt/Pitch Attachment TD-25M EXTRA DRESSTA…
  • Page 359: Ripper Lift Cylinders Drift Test /Blade Lift Cylinders

    7. If ripper cylinders drift is more than 16 [mm] per minute control valve spool is leaking. Proceed to CONTROL VALVE in SECTION 10B. 8. When proceeding tests are completed, vent hydraulic system and add oil as necessary. Refer to the OPERATOR’S MANUAL. Visually check for oil leakage. DRESSTA TD-25M EXTRA…

  • Page 360: Cylinder Time Cycle

    3. Lift cycle should take not more than 3.5 seconds. If average cycle time is more than 3.5 seconds, front pump should be repaired or replaced as necessary. NOTE: This check should be made only in blade raising cycle. TD-25M EXTRA DRESSTA…

  • Page 361: Piston Packing Test

    Stop the engine. Tie the end of rod to the head of cylinder. Remove rod end hose. WARNING! During next step, pressurized oil may be expelled from cylinder. 2. Hydraulically extend cylinder(s) again and check rod end port of cylinder(s) for oil flow. DRESSTA TD-25M EXTRA…

  • Page 362: Pressure Diagnostic Chart

    3. If any recorded fan velocities is out of specifications or the fan fails to operate steplessly between minimum and maximum speed range, refer to “Fan drive system diagnosis” in Paragraph 4, SERVICE DIAGNOSIS in this Section. TD-25M EXTRA DRESSTA…

  • Page 363
    SECTION 10A PUMPS…
  • Page 365
    10. INSTALLATION …………18 DRESSTA TD-25M EXTRA…
  • Page 367
    E……..Material — Clean Wood With Smooth Finish Surface DRESSTA TD-25M EXTRA…
  • Page 368
    The inlet and outlet support plates hold the flex side plates in position and contain passages which allow fluid pass from the inlet to the pumping cartridge and from the cartridge to the outlet port. TD-25M EXTRA DRESSTA…
  • Page 369
    B’s outlet support plate (7) through the center of the rear cover and past the wear plate and is discharged through the pressure plate into the end cover outlet port. DRESSTA TD-25M EXTRA…
  • Page 370
    Fluid outside the inlet is at atmospheric pressure or higher. Fig. 10A.5. Cutaway of Pumping Chamber 1. Pressure Plate 5. Rotor Ring 8. Shaft 2. Cover 6. Vane 9. Spring 3. Back Pressure in System Effective Here 7. Rotor 10. Pressure in Cartridge 4. Discharge TD-25M EXTRA DRESSTA…
  • Page 371
    Tighten loose connections. Check the fluid in reservoir. 5. Vane(s) stuck in rotor slots Disassemble pump. Check for dirt or metal chips. Clean parts thoroughly and replace any damaged pieces. Flush system and refill with clean fluid. DRESSTA TD-25M EXTRA…
  • Page 372
    SECTION 12, POWER. 4. Disconnect two hoses (2 and 6) from the hydraulic block (4). 5. Disconnect: suction tube (7), blade tilt control valve hose (8) and pilot control system hose (9) from the top of the pump (1). TD-25M EXTRA DRESSTA…
  • Page 373
    7. Remove the O-ring from the equipment pump housing flange. Unscrew the four bolts and remove the hydraulic block (4) from the pump. NOTE: Cover the opening at the torque converter housing to prevent dirt and dust from entering. DRESSTA TD-25M EXTRA…
  • Page 374
    PUMPS SECTION 10A Page 8 EQUIPMENT PUMP 6. DISASSEMBLY (Refer to Fig. 10A.7) Fig. 10A.7. Exploded View of Equipment Pump TD-25M EXTRA DRESSTA…
  • Page 375
    (45) then remove bolts. Remove end cover (39) with O-ring (40). Lift wear plate (48) with rotor ring (43), rotor (41) and pressure plate (46) off of pump and separate parts (Fig. 10A.9). Remove dowel pins (47) from rear cover (2). Discard three O-rings (40, 44 and 49). DRESSTA TD-25M EXTRA…
  • Page 376
    Fig. 10A.10. Rear Cover Fig. 10A.11. Cartridge B D. Match Marks 2. Rear Cover B. Cartridge Kit B 16. Mounting Bolt 1. Mounting Bolt 40. O-Ring D. Match Marks 17. Inlet Housing F. Pry with Screwdriver 37. Outlet Housing TD-25M EXTRA DRESSTA…
  • Page 377
    (37). If necessary, remove retaining ring (32) and press bearing (33) off of shaft. Remove washer spacer (35, Fig.10A.14) from outlet housing and drive shaft seal (36) out being careful not to damage seal mounting bore area. Fig. 10A.14. Spacer Washer Fig. 10A.15. Seal Removal 35. Washer DRESSTA TD-25M EXTRA…
  • Page 378
    (8 or 21) off of outlet flex side plate (9 or 22). DO NOT allow outlet flex side plate to move across rotor ring or rotor. Move outlet flex side plate off center (Fig. 10A.24) just enough to lift up and away without sliding. TD-25M EXTRA DRESSTA…
  • Page 379
    PUMPS SECTION 10A Page 13 EQUIPMENT PUMP Fig. 10A.18. Inlet Flex Side Plate Fig. 10A.19. Reverse Cartridge Fig. 10A.20. Outlet Support Plate Fig. 10A.21. Outlet Flex Side Plate H. Seal Packs DRESSTA TD-25M EXTRA…
  • Page 380
    Align scribe marks to insure correct flex plate is used with support plate. Bronze wear surface must face rotor when assembled. NOTE: Flex side plates develop a wear pattern with rotor and vanes and should not be interchanged. TD-25M EXTRA DRESSTA…
  • Page 381
    Hold cartridge kit in a horizontal shaft position and lift rotor with finger. Rotor should move freely back and forth within cartridge. If rotor binds, open kit, clean and stone all possible areas of bind and reassemble using aforementioned procedures. Rotor must move freely within cartridge when assembled. DRESSTA TD-25M EXTRA…
  • Page 382
    6. Rotate ball bearing (33) while applying pressure to check for wear, looseness and pitted or cracked races. 7. Inspect seal and bushing mating surfaces on drive shaft (34) for scoring or wear. Replace the shaft if marks cannot be removed by light polishing. TD-25M EXTRA DRESSTA…
  • Page 383
    Turn cover slightly until scribe marks and bolt holes are in line. Oil and torque mounting bolts (16) 205 ± 10 [Nm]. Turn pump shaft by hand to verify freedom of cartridge. DRESSTA TD-25M EXTRA…
  • Page 384
    1. Remove the covering from the torque converter housing. Thoroughly clean the mating surfaces of the torque converter housing and the equipment pump housing. 2. Install the hydraulic block (4) to the pump and secure with four bolts. 3. Install a new O-ring on the equipment pump housing flange. TD-25M EXTRA DRESSTA…
  • Page 385
    5. Reconnect pilot control system hose (9), tilt control valve hose (8) and: suction tube (7) to the equipment pump (1). 6. Reconnect two hoses (2 and 6) to the hydraulic block (4). 7. Install decelerator pedal assy to the platform. Reconnect decelerator pedal control cable. Refer to SECTION 12, POWER DRESSTA TD-25M EXTRA…
  • Page 386
    Check for external leaks in the hydraulic system. 11. Check the oil level in hydraulic reservoir and add oil if necessary. 12. Stop the engine. Install the center floor plate and floor mat (if equipped). TD-25M EXTRA DRESSTA…
  • Page 387
    SECTION 10B VALVES…
  • Page 389
    22. SERVICE …………. . . 20 DRESSTA TD-25M EXTRA…
  • Page 391
    NEUTRAL position, drive train lock lever is in ON position and parking brake is set. The starting switch and the electrical system master switch are turned OFF, keys are removed and the controls are tagged to prevent inadvertent engine starting. DRESSTA TD-25M EXTRA…
  • Page 392
    3. Remove return filters (2, Fig. 10B.2) to gain access to control valve (1). Fig. 10B.2. Hydraulic Return Filters Removal 1. One Spool or Three Spool Control Valve 3. Mounting Bolt with Washer 2. Hydraulic Return Filters TD-25M EXTRA DRESSTA…
  • Page 393
    3. Quick Disconnect Fitting Hose 3. One or Three Spool Control Valve 4. Bracket 4. Platform R.H. Console 5. Inlet Hose 6. Reservoir Return Tube 7. Pilot Hoses (Lower) 8. Outlet Hoses 9. One or Three Spool Control Valve DRESSTA TD-25M EXTRA…
  • Page 394
    1. Mounting Stud 4. Plug 7. Ripper Pitch section 10. Outlet Cover Plate Assy 2. Nut 5. O-Ring 8. Ripper Lift Section 11. O-Ring 3. Inlet Cover Plate Assy 6. Relief Valve 9. Blade Lift Section 12. Plug TD-25M EXTRA DRESSTA…
  • Page 395
    9. Check the operation of the control valve by shifting the control levers into all operating positions. Check and correct possible leakage. 10. Adjust the main pressure relief valve as described in SECTION 10, RELIEF VALVES PRESSURE TESTS,. Close the door (1). DRESSTA TD-25M EXTRA…
  • Page 396
    3. Inspect all parts for scoring, damage or excessive wear. If float spool (2) or section housing bore (1) are worn out too much, the whole section must be replaced as these parts are not available separately. 4. Lubricate with engine oil SAE10W all clean parts that can be reinstalled. TD-25M EXTRA DRESSTA…
  • Page 397
    2. If needed, remove the float spool positioners (6 and 7) bolts and then remove float spool (2). Fig. 10B.7. Cross Section View of Ripper Lift Section 1. Section Housing 5. Anticavitation Valve 2. Float Spool 6. Hydraulic Remote Positioner 3. Check Load Valve 7. Hydraulic Remote Positioner 4. Port Plug DRESSTA TD-25M EXTRA…
  • Page 398
    Fig. 10B.8. Cross Section View of Ripper Pitch Section 1. Section Housing 4. Port Plug 2. Float Spool 5. Hydraulic Remote Positioner 3. Check Load Valve 6. Hydraulic Remote Positioner TD-25M EXTRA DRESSTA…
  • Page 399
    8. Remove the seal ring (10) and the backup ring (11) from the main poppet (8) and discard. 9. Remove the seal ring (12) from the pilot poppet housing (6) and discard. 10. Remove the seal ring (13) from the adjusting screw (1) and discard. DRESSTA TD-25M EXTRA…
  • Page 400
    3. Due to the close tolerances of the working parts, the main relief valve internal parts are not serviced. If service other than the seals is required, replace the complete relief valve. 4. Lubricate with engine oil SAE 10W all clean parts that can be reinstalled. TD-25M EXTRA DRESSTA…
  • Page 401
    Refer to EQUIPMENT SYSTEM RELIEF VALVES PRESSURE TESTS, Paragraph 5 in SECTION 10. 14. Tighten the jam nut (1) to 11 — 16 [Nm]. 15. Reinstall tamper proof cover after adjusting procedure. DRESSTA TD-25M EXTRA…
  • Page 402
    3. Pilot Supply Spool Spring 10. Pressure Regulating Spool 17. Shim(s) 4. Body 11. Pin 18. Regulating Spool Spring 5. Pilot Supply Spool 12. Ball 19. O-Ring 6. O-Ring 13. Relief Valve Spring 20. Plug 7. Plug 14. Plug TD-25M EXTRA DRESSTA…
  • Page 403
    VALVES SECTION 10B Page 13 PILOT PRESSURE VALVE Fig. 10B.10. Exploded View of Pilot Pressure Valve DRESSTA TD-25M EXTRA…
  • Page 404
    OFF, the drive train control lock lever is in locked (ON) and parking brake is set. The starting switch and the electrical system master switch are turned OFF, keys are removed and the controls are tagged to prevent inadvertent engine starting. TD-25M EXTRA DRESSTA…
  • Page 405
    Check free movement of spools and their surfaces for wear, scores or scratches and replace if necessary. 6. Replace all O-rings. Lubricate parts with clean oil. Reassembly parts in reverse order of disassembly steps 1, 2, 3 and 4. DRESSTA TD-25M EXTRA…
  • Page 406
    5. Unscrew four bolts (5) with washers securing plate (6) to frame (2). Remove valve (1) together with plate (6). 6. Unscrew three bolts with washer securing quick drop valve (1) to plate (6) and remove valve from plate. 7. Installation is reverse of removal. TD-25M EXTRA DRESSTA…
  • Page 407
    2. Reassemble parts in opposite sequence indicated in Step 1. Lubricate all parts with clean oil. 3. Attach the valve with all external hydraulic connectors if previously disconnected, using new O-rings. Fig. 10B.14. Exploded View of Quick Drop Valve DRESSTA TD-25M EXTRA…
  • Page 408
    QUICK DROP VALVE Fig. 10B.15. Cross Section View of Quick Drop Valve Legend for Fig. 10B.14 and 10B.15 1. Plug 4. Spool 7. Spring 2. O-Ring 5. Retainer 8. O-Ring 3. Body 6. Spring 9. Cover, Bolts, Washers TD-25M EXTRA DRESSTA…
  • Page 409
    4. Unscrew all connectors from valve (8). Remove and discard old O-rings. 5. Unscrew three bolts with washer securing unloading valve (8) to plate (6) and remove valve from plate. 6. Installation is reverse order of removal. DRESSTA TD-25M EXTRA…
  • Page 410
    16. Spring Retainer 3. O-Ring 10. Spring Retainer 17. Spring 4. Plug 11. Spool Bumper 18. Sleeve 5. O-Ring 12. Spring 19. Pin 6. Main Spool 13. Sleeve 20. Gasket 7. Spring Retainer 14. Controlling Spool 21. Cover TD-25M EXTRA DRESSTA…
  • Page 411
    VALVES SECTION 10B Page 21 UNLOADING VALVE Fig. 10B.17. Exploded View of Unloading Valve Fig. 10B.18. Cross Section View of Unloading Valves DRESSTA TD-25M EXTRA…
  • Page 413
    SECTION 10C CYLINDERS…
  • Page 415
    30. REMOVAL, INSTALLATION AND SERVICE ……..32 DRESSTA TD-25M EXTRA…
  • Page 417
    3. Disconnect hoses (5) at the cylinder manifold (9). Fig. 10C.1. Blade Lift Cylinder Removal 1. Cylinder Rod Pin 4. Tube 7. Blade Lift Cylinder 2. Blade 5. Hoses 8. Yoke Cap 3. Lift Yoke 6. Cylinder Rod 9. Cylinder Manifold DRESSTA TD-25M EXTRA…
  • Page 418
    (7) from machine. Fig. 10C.2. Yoke and Cap Stamp Marks 1. Yoke Caps 2. Lift Yoke 2. DISASSEMBLY (Refer to Fig.’s 10C.3 and 10C.4) Fig. 10C.3. Cross Section View of Blade Lift Cylinder TD-25M EXTRA DRESSTA…
  • Page 419
    3. Attach a hoist to the cylinder rod eye as shown in Fig. 10C.5, using a strap to protect the bearing in the rod eye. Raise the cylinder up and secure it to the hoist frame. Using the hoist, pull the cylinder rod out to approximately 1/2 stroke. DRESSTA TD-25M EXTRA…
  • Page 420
    A suggested method is to clamp the eye end of the piston rod in a hydraulic press and use a torque multiplier as shown in Fig. 10C.7, or an impact tool. Fig. 10C.7. Removing Piston Rod Nut TD-25M EXTRA DRESSTA…
  • Page 421
    Tighten nuts to draw gland up against lock ring. Remove puller arrangement. Coat inner cylinder housing surface over the gland with high temperature type 230 HHT grease 1 [mm] in thickness. Secure cover (20) to gland (13) and torque bolts with washer to 46 [Nm]. DRESSTA TD-25M EXTRA…
  • Page 422
    Secure the pins (1) with the locking hardware. 9. Vent the hydraulic system and add oil as necessary, refer to the OPERATOR’S MANUAL. Visually check for oil leakage. 10. Cycle cylinder a few times. Recheck cylinder and cover bolt torque. TD-25M EXTRA DRESSTA…
  • Page 423: Removal

    5. Remove bolts with washers securing socket cap (2) and move socket cap of blade (3). Keep shims with blade (3). 6. Remove mounting hardware securing pin (7) to the bracket on push arm and remove pin (7). Remove tilt cylinder (1) from machine. DRESSTA TD-25M EXTRA…

  • Page 424
    CYLINDERS SECTION 10C Page 8 BLADE TILT CYLINDER 7. DISASSEMBLY (Refer to Fig.’s 10C.12 and 10C.13) Fig. 10C.12. Cross Section View of Blade Tilt Cylinder Fig. 10C.13. Exploded View of Blade Tilt Cylinder TD-25M EXTRA DRESSTA…
  • Page 425
    (13) and buffer ring (12) with O-ring (19) from gland (10). 10. Slide cover (16) and socket cap (17) off of cylinder rod (18). 11. If necessary, remove the cylinder bushing (2) from cylinder housing (1). DRESSTA TD-25M EXTRA…
  • Page 426: Inspection And Repair

    4. Install piston seal (8) onto piston (7). Install O-rings (6) and wear rings (5) on each end of piston (7). Install and slide piston onto rod (18). Secure with washer (4) and nut (3). Clamp ball rod into press as shown in Fig. 10C.16. Using a multiplier torque piston nut (3) to 3250 [Nm]. TD-25M EXTRA DRESSTA…

  • Page 427: Installation

    Visually check for oil leakage. 6. Cycle cylinder a few times and recheck cylinder and cover bolts torque. 7. Install center guard (4, Fig. 10C.10), lower guard (2) and upper guard (3) to the blade tilt cylinder (1). DRESSTA TD-25M EXTRA…

  • Page 428: Removal

    5. Remove bolts with washer securing socket cap (2) and move socket cap of blade (3). Keep shims with blade (3). 6. Remove mounting hardware securing pin (7) to the bracket on push arm and remove pin. Remove tilt/pitch cylinder (1) from machine. TD-25M EXTRA DRESSTA…

  • Page 429
    CYLINDERS SECTION 10C Page 13 BLADE TILT AND PITCH CYLINDER 12. DISASSEMBLY (Refer to Fig.’s 10C.20 and 10C.21) Fig. 10C.20. Cross Section View of Blade Tilt/Pitch Cylinder Fig. 10C.21. Exploded View of Blade Tilt/Pitch Cylinder DRESSTA TD-25M EXTRA…
  • Page 430
    (14), seal ring (13) and buffer ring (12) with O-ring (19) from gland (10). 10. Slide cover (16) and socket cap (17) off of cylinder rod (18). 11. If necessary, remove the cylinder bushing (2) from cylinder housing (1). TD-25M EXTRA DRESSTA…
  • Page 431
    4. Install piston seal (8) onto piston (7). Install O-rings (6) and wear rings (5) on each end of piston (7). Install and slide piston onto rod (18). Secure with washer (4) and nut (3). Clamp ball rod into press as shown in Fig. 10C.24. Using a multiplier torque piston nut (3) to 3250 [Nm]. DRESSTA TD-25M EXTRA…
  • Page 432
    Visually check for oil leakage. 6. Cycle cylinder a few times and recheck cylinder and cover bolts torque. 7. Install center guard (4, Fig. 10C.18), lower guard (2) and upper guard (3) to the blade tilt/pitch cylinder (1). TD-25M EXTRA DRESSTA…
  • Page 433
    5. Remove bolts with washers securing socket cap (2) and move socket cap of blade (3). Keep shims with blade (3). 6. Remove mounting hardware securing pin (7) to the bracket on push arm and remove pin. Remove double tilt and pitch cylinder (1) from machine. DRESSTA TD-25M EXTRA…
  • Page 434
    12. Buffer Ring 17. Socket Cap 3. Nut 8. Piston Seal 13. Seal Ring 18. Cylinder Rod 4. Washer 9. O-Ring Backup Ring 14. Wiper Ring 19. O-Ring 5. Wear Ring 10. Cylinder Gland 15. Lock Ring TD-25M EXTRA DRESSTA…
  • Page 435
    Fig. 10C.31, to provide working clearance. 5. Using a brass drift as shown in Fig. 10C.31, drive gland into cylinder housing (1) until the tension of the lock ring (15) is off. Fig. 10C.31. Relieving Tension on Lock Ring DRESSTA TD-25M EXTRA…
  • Page 436: Inspection And Repair

    5. Inspect all sealing ring grooves for scratches, burrs or other damage. «Dress-up» grooves or replace as necessary. 6. Inspect tapped holes for damaged threads. 7. If the housing eye bushings were removed, remove all rust, scale or paint from the bushing bore. TD-25M EXTRA DRESSTA…

  • Page 437
    (16). Coat inner cylinder housing surface over the gland with high temperature type 230 HHT grease 1 [mm] in thickness. Secure cover (16) to gland (10) and torque bolts with washer to 110 — 120 [Nm]. 7. If removed, install the cylinder bushing (2) to cylinder housing (1). DRESSTA TD-25M EXTRA…
  • Page 438: Installation

    6. Remove bolts and plate securing pin (6) to toolbeam (8). Using a pry bar move pin outward until rod eye is clear. 7. Remove bolts and plate securing pin to frame (4). Using a pry bar move pin outward until housing eye is clear. 8. Remove lift cylinder (9) from ripper. TD-25M EXTRA DRESSTA…

  • Page 439
    8. Toolbeam 11. Pitch Cylinder 3. Rod End Hose 6. Pin 9. Lift Cylinder 12. Head End Tube Fig. 10C.35. Ripper Lift Cylinder Removal 1. Fuel Tank Holder 3. Ripper 2. Ripper Pitch Cylinder 4. Ripper Lift Cylinder DRESSTA TD-25M EXTRA…
  • Page 440
    3. Lube Fitting 10. O-Ring and Backup Ring 16. Lock Ring 4. Nut 11. Cylinder Gland 17. Cover 5. Washer 12. Wear Ring 18. Cylinder Rod 6. Wear Ring 13. O-Ring and Buffer Ring 19. Rod Bushing 7. O-Ring TD-25M EXTRA DRESSTA…
  • Page 441
    4. Using a brass drift as shown in Fig. 10C.39, drive gland into cylinder housing (1) until the tension is off the lock ring (16). Remove lock ring (16) from cylinder housing and pull rod assembly out of housing. DRESSTA TD-25M EXTRA…
  • Page 442
    O-ring (13), wiper ring (15) and seal ring (14) from gland (11). Slide cover (17) off of rod (18). 8. If bushings (2 and 19) needs replacement, press out the old bushings from cylinder housing (1) and cylinder rod eye. TD-25M EXTRA DRESSTA…
  • Page 443: Inspection And Repair

    230 HHT grease 1 [mm] in thickness. Secure cover (17) to gland (11) and torque the bolts with washer to 75 — 90 [Nm]. 7. If removed, press new bushings (2 and 19) to cylinder housing (1) and to cylinder rod (18). DRESSTA TD-25M EXTRA…

  • Page 444: Installation

    4. RIGHT PITCH CYLINDER ONLY: Install indicator rod (5) to the rod eye and cylinder housing. 5. Vent the hydraulic system and add oil as necessary, refer to OPERATOR’S MANUAL. Visually check for oil leakage. 6. Cycle cylinder a few times and recheck cylinder cover bolts torque. TD-25M EXTRA DRESSTA…

  • Page 445
    Fig. 10C.42. Pin Puller Cylinder Removal 1. Cylinder Hoses 2. Pin Puller Cylinder 3. Mounting Bolts 1. Disconnect cylinder hoses (1) from cylinder (2). 2. Remove bolts (3) and remove pin puller cylinder (2) from ripper. DRESSTA TD-25M EXTRA…
  • Page 446
    CYLINDERS SECTION 10C Page 30 RIPPER PIN PULLER CYLINDER 27. DISASSEMBLY (Refer to Fig.’s 10C.43 and 10C.44) Fig. 10C.43. Cross Section View of Pin Puller Cylinder Fig. 10C.44. Exploded View of Ripper Pin Puller Cylinder TD-25M EXTRA DRESSTA…
  • Page 447
    2. Connect hoses (1) to cylinder (2). 3. Vent the hydraulic system and add oil as necessary, refer to the OPERATOR’S MANUAL. Visually check for oil leakage. 4. Cycle cylinder a few times and recheck nut torque. DRESSTA TD-25M EXTRA…
  • Page 448
    Removal, installation and service of the blade tilt cylinder (G-2) is similar to the blade tilt cylinder shown in this Section. Details for blade tilt cylinder (G-2) can be found in relevant Sections of PARTS CATALOGUE and OPERATOR’S MANUAL. TD-25M EXTRA DRESSTA…
  • Page 449
    SECTION 10E RESERVOIRS AND FILTERS…
  • Page 451
    6. INSTALLATION …………. 6 DRESSTA TD-25M EXTRA…
  • Page 453
    20. Hydraulic Connector 3. Bracket 9. O-Ring 15. Sight Gauge 21. Drain Valve 4. Breather Valve 10. Strainer Retaining Ring 16. O-Ring 22. Drain Hose 5. Plug 11. Tube 17. Filler Strainer 6. O-Ring 12. Nut 18. Magnetic Plug DRESSTA TD-25M EXTRA…
  • Page 454
    2. R.H. Enclosure 3. Bolts 1. Drain the hydraulic reservoir. Refer to the OPERATOR’S MANUAL for this procedure. 2. Disconnect wire harness of rear lamp. 3. Unscrew bolts (3, Fig.10E.2) and remove R.H. enclosure (2) with R.H. door (1). TD-25M EXTRA DRESSTA…
  • Page 455
    6. Attach a suitable hoist sling to holder mounted on the reservoir (4). Remove reservoir (4) mounting bolts from the bottom of reservoir and lift the reservoir up using the hoist. Remove the reservoir from the machine. DRESSTA TD-25M EXTRA…
  • Page 456
    Fig. 10E.4. Exploded View of Vacuum Pressure Relief Valve 1. Retainer Ring 6. Spring 11. O-Ring 2. Cover 7. Retainer 12. Poppet 3. Ceramic Filter 8. Sleeve 13. Poppet Spring 4. Gasket 9. O-Ring 14. Poppet Guide 5. Cover 10. Ring 15. Valve Housing TD-25M EXTRA DRESSTA…
  • Page 457
    5. Install the cover (8) with O-ring (9) and lower snap ring (10) to the reservoir (1). Secure the cover (8) with three bolts. 6. Install the filler strainer (17) and upper strainer snap ring (10) to the cover (8). 7. Install the breather valve (4). DRESSTA TD-25M EXTRA…
  • Page 458
    6. Fill the hydraulic reservoir. Refer to the OPERATOR’S MANUAL for this procedure. 7. Start the engine, move the hydraulic controls in all directions and visually check hoses and connections for leakage, check oil level and add oil if needed. TD-25M EXTRA DRESSTA…
  • Page 459
    SECTION 12 POWER…
  • Page 461
    POWER SECTION 12 CONTENTS Page 1. DESCRIPTION ……………………..1 2. SPECIFICATIONS ……………………1 3. AIR INDUCTION SYSTEM TEST………………..2 4. CONTROL ADJUSTMENT ………………….4 5. REMOVAL ……………………… 8 6. ENGINE REPAIR ……………………13 7. INSTALLATION ……………………14 DRESSTA TD-25M EXTRA…
  • Page 463: Specifications

    (Torques given are for bolts and nuts lubricated with SAE-30 engine oil.) NOTE: Except for the special torques shown, all bolts and nuts are to be given a standard torque. Refer to the „STANDARD TORQUE DATA CHART” in Section 1, „GENERAL.” DRESSTA TD-25M EXTRA…

  • Page 464: Air Induction System Test

    If leakage still persists, remove the parts to determine cause. Inspect and replace worn parts as necessary and retest. 8. Remove the filter element and remove the duct tape. Inspect the seals for damage. Reinstall both elements and the end cover. TD-25M EXTRA DRESSTA…

  • Page 465
    (internal flow air restriction) ambient and intake air temperature differential (efficiency of cooling system) due to significant influence for the engine performance, durability and emission compliance. For detailed procedure, refer to Engine Manual. DRESSTA TD-25M EXTRA…
  • Page 466
    9. Install pin (21), position control lever (1) in rear position (HI). 10. Loosen lock nuts (9). Check and adjust the cable (26) with link (8) to 0.0 [mm] gap at point “D”. Tighten the lock nut (9). TD-25M EXTRA DRESSTA…
  • Page 467
    27. Control Cable D. Gap 0.0 [mm] 8. Link 18. Wire Harness Connector 28. Spring E. Dimension 19.5 [mm] 9. Lock Nut 19. Control Lever 29. Bushing F. Dimension 10.5 [mm] 10. Nuts 20. Intermediate Lever 30. Lock Nut DRESSTA TD-25M EXTRA…
  • Page 468
    (refer to Troubleshooting Fault Codes in Troubleshooting and Repair Manual Electronic Control System QSX15 Engines, Bulletin No.3666259. Inspect visually wire harness and connectors for damaged pin(s). Dry connector by using electrical contact cleaner P/N 3824510. TD-25M EXTRA DRESSTA…
  • Page 469
    NOTE: If potentiometer is changed or after calibration downloaded move the control lever (1, Fig. 12.3) (key switch ON) thought its complete travel 3 times. This procedure calibrates the new potentiometer with the ECM. NOTE: If designated engine speeds are not achieved contact with Authorized Cummins Service. DRESSTA TD-25M EXTRA…
  • Page 470: Removal

    Fig. 12.5. Electrical and Fuel System Disconnecting Points (LH side). 1. Wire Harness Connectors 4. Lifting Bracket 2. Engine Potentiometer Control Wire 5. Fuel Return Hose Harness Connector 6. Engine Speed Sensor Wire Harness 3. Fuel Supply Hose Connector TD-25M EXTRA DRESSTA…

  • Page 471
    10. Remove cables (4) from the alternator (5). Secure wire harness out of the way. 11. Remove bolts securing coolant filter bracket (6) to frame. Wire bracket to engine. 12. Remove cab heater return hose (7) from valve. DRESSTA TD-25M EXTRA…
  • Page 472
    IMPORTANT: Tape or plug turbocharger openings to prevent from entering the dirt or rags. 18. Loosen tube clamp (9, Fig. 12.7), remove muffler mounting bolts (8). Remove muffler assy (7). 19. Remove the cranking motor cables positive (+), ground (-) (1 and 2 Fig. 12.8), and wire harness (3). TD-25M EXTRA DRESSTA…
  • Page 473
    23. Remove torque converter drain hose (5) from the flywheel housing. Fig. 12.9. Torque Converter Disconnecting Points (bottom side) 1. Fan Drive System Hydraulic Pump 3. Hose (inlet) 5. Drain Hose (leakage) 2. Bolt 4. Hose and Tube (inlet) DRESSTA TD-25M EXTRA…
  • Page 474
    36. Install an engine lifting attachment to engine lifting brackets (4, Fig. 12.5) and (10, Fig.12.7). NOTE: Engine flywheel housing is critically close to the equalizer bar tunnel. For this reason it is hard to dismount torque converter off engine. We recommend dismounting the engine complete with the torque converter. TD-25M EXTRA DRESSTA…
  • Page 475: Engine Repair

    For detailed information pertaining to maintenance or engine repair, refer to the Engine Operation and Maintenance Manual QSX15 Engines, Bulletin No 3666423, Troubleshooting and Repair Manual QSX15 Engines, Bulletin 3666239 and Troubleshooting Repair Manual Electronic Control System QSX15 Engines, Bulletin No.3666259. DRESSTA TD-25M EXTRA…

  • Page 476: Installation

    19. Install cab heater supply hose (4) to valve. 20. Reconnect the wire to the coolant temperature sensor (3). 21. Reconnect the wires connector (2) of the ether solenoid valve temperature switch. 22. Reconnect the wire connector to air cleaner warning light switch (1). TD-25M EXTRA DRESSTA…

  • Page 477
    37. If necessary perform engine control system adjustments as described in Par. 4, ENGINE CONTROL ADJUSTMENTS. 38. Working under machine, install transmission case guard and crankcase guard. Use lifting device for lifting heavy guards. WARNING! This procedure requires extreme caution. Use suitable blocking equipment while under confines of machine. DRESSTA TD-25M EXTRA…
  • Page 479
    SECTION 13 SUPERSTRUCTURE…
  • Page 481
    7. CAB REASSEMBLY …………7 DRESSTA TD-25M EXTRA…
  • Page 483: Specification

    GENERAL 1. DESCRIPTION The TD-25M Extra dozer is equipped with 6-sided, 2-door cab symmetrically located on the machine. The cab is installed to the shock absorber mounted platform, separated from the engine compartment to reduce noise. The platform is supported in four points to the crossbeam assembly and front bar mounted to the main frame.

  • Page 484
    Fig. 13.2. A/C System Condenser Disassembly Points 1. Supply Cable (+) 5. A/C Heater Control Switch Plug 2. Ground Cable (-) 6. ROPS Lamps Plug 3. Heater Control Potentiometer Plug 7. Control Panel 4. Front and Rear Lamps Plug TD-25M EXTRA DRESSTA…
  • Page 485: Pod Removal

    (1, Fig. 13.5) pilot lock valve (5) and switching valve (7). NOTE: Remove the transmission filters bracket bolts and swing filters assy out to the to gain easier access to the hydraulic and electrical connections in L.H. console. DRESSTA TD-25M EXTRA…

  • Page 486
    Fig. 13.5. Lock Valve and Control Valve Disconnecting Points (LH console) 1. Drive Train Control Valve 5. Pilot Lock Valve 2. Hoses (steering control) 6. Hydraulic Hoses 3. Hoses (forward – rear) 7. Switching Valve 4. Hose (Drain) TD-25M EXTRA DRESSTA…
  • Page 487
    Fig. 13.7. LH Console and Instrument Panel Column electrical Connections 1.Wire Harness Sockets 3. Engine Data Link Connector 2. Wire Harness Plugs 4. Instrument Panel Supply and Ground Cables 10. Remove wire harness plugs from the sockets (1, Fig. 13.7). DRESSTA TD-25M EXTRA…
  • Page 488: Inspection

    16. Disassemble bolt and nut (7, Fig. 13.8), rubber shock absorber (1) and plate (2) if necessary. 5. INSPECTION Fig. 13.8. Front and Rear Support of Platform 1. Rubber Shock Absorber 4. Bolts 7. Bolt and Nut 2. Plate 5. Cover Plate 8. Front Bracket 3. Plate 6. Bolt 9. Rear Bracket TD-25M EXTRA DRESSTA…

  • Page 489: Pod Reassembly

    2. Screw in threaded sleeve (6) until it comes to contact with the pod surface. Install the bolts with washers (3) and torque to 80 [Nm]. Check the seal gasket (5) between the cab (4) and pod (7) for defects in spots where dust could penetrate inside the cab. DRESSTA TD-25M EXTRA…

  • Page 490
    Check for leaks disconnected previously hydraulic lines of drive train control valve (1, Fig. 13.5) pilot lock valve (4) and switching valve (7). Stop the engine. 11. Install console cover plate and transmission pressure filters cover. 12. Install floor plate (2, Fig. 13.6) in the cab. TD-25M EXTRA DRESSTA…
  • Page 491
    SECTION 14 SUSPENSION…
  • Page 493
    30. ARRANGEMENT OF TRACK ROLLERS ……..25 DRESSTA TD-25M EXTRA…
  • Page 494
    56. SEAL INSTALLATION …………46 TD-25M EXTRA…
  • Page 495
    Tool for pivot shaft seal driving into seal shield …………..1.547.0359 GENERAL NOTE: The following procedures covers of a suspension from right side of the machine only. The procedures are the same for left side. 2. DESCRIPTION Fig. 14.1. Exploded View of Right Track Assembly DRESSTA TD-25M EXTRA…
  • Page 496
    (rolling diameter is diameter at point of contact with track chain) ….241 ± 0.7 [mm] Maximum permissible wear of track roller rolling diameter ….. . . 25.1 [mm] TD-25M EXTRA DRESSTA…
  • Page 497
    Weight of spring ……….. . 32 [kg] DRESSTA TD-25M EXTRA…
  • Page 498
    Equalizer bar end cover bolts ……….520 [Nm] TD-25M EXTRA…
  • Page 499
    3. Front idler misaligned Correct alignment of front idler. 4. Track rollers do not turn Internal seizure. Remove and replace defective parts. 5. Track idler does not turn Internal seizure. Remove and replace defective parts. DRESSTA TD-25M EXTRA…
  • Page 500
    To do this, blocks of wood or metal should be placed in the sprocket tooth under the track chain as shown in Fig. 14.2. The machine should then be moved backward so the sprocket can grab the block and tighten the chain. This pulls the chain tight and up off the top idler. TD-25M EXTRA DRESSTA…
  • Page 501
    Measure two or more place along chain to get an average and compare with dimensions given, refer to SPECIFICATIONS in SECTION 15. Fig. 14.4. Measuring Link Height Fig. 14.5. Measuring Bushing OD 1. Squeeze Bar 2. Scale 1. Outside Caliper DRESSTA TD-25M EXTRA…
  • Page 502
    Place tips of 300 [mm] caliper (1) (refer to SERVICE/SPECIAL TOOLS in this Section) snugly around tread area of top idler and remove. Using about 300 [mm] scale, measure distance between caliper tips. Compare with dimensions given, refer to SPECIFICATIONS in this Section. TD-25M EXTRA DRESSTA…
  • Page 503
    2. Be sure the relief valve (1, Fig. 14.11) is unscrewed one full turn to avoid entering a vacuum in the cylinder. 3. Move the front idler and attach a hoist to front idler (4, Fig. 14.10) and fork. Remove front idler with fork from track frame. DRESSTA TD-25M EXTRA…
  • Page 504
    2. Lubrication Fitting (Ball Check Valve) 3. Track Frame 8. DISASSEMBLY (Refer to Fig.’s 14.13 and 14.14) Fig. 14.12. Front Idler and Fork 1. Fork Assy 3. Pin 5. Right Front Idler Block 2. Left Front Idler Block 4. Front Idler TD-25M EXTRA DRESSTA…
  • Page 505
    12. Left Front Idler Block 3. Seal Kit 8. Front Idler Bushing 13. Right Front Idler Block 4. Retaining Ring 9. Front Idler Housing with Bushing 14. Pin 5. Front Idler Bushing Retainer 10. Drain Plug 15. Bolt with Washer DRESSTA TD-25M EXTRA…
  • Page 506
    End clearance A — (B + 2C) ……….. . 0.6 ± 0.3 [mm] TD-25M EXTRA…
  • Page 507
    Also that rubber rings of seal assembly are correctly positioned on metal rings. Refer to SEAL INSTALLATION under METAL TYPE FACE SEALS in this Section. Install seal retainer (1) and secure with retaining ring (4). Repeat Step 5 on opposite side of idler. DRESSTA TD-25M EXTRA…
  • Page 508
    Lubricant is introduced into the cylinder by the use of a lubrication fitting on top of the cylinder. This lubricant acting upon the piston and adjusting rod forces the idler fork and idler forward for track chain adjustment. TD-25M EXTRA DRESSTA…
  • Page 509
    2. Remove piston (4) from track adjuster (1). 3. Remove retaining ring (2) and piston seal (3) wear rings (5) from piston (4). 4. Remove lube fitting (10), ball check valve (9) and relief valve (8) from track adjuster (1). DRESSTA TD-25M EXTRA…
  • Page 510
    1. Slide track adjuster (rod end toward front idler) into front of track frame. 2. Install front idler, refer to INSTALLATION, Paragraph 11, in this Section. 3. Install the track chain as described in SECTION 15. 4. Adjust the track chain tension as described in SECTION 15. TD-25M EXTRA DRESSTA…
  • Page 511
    (2) until it is clear of the top idlers. 3. Loosen four bolts (1, Fig. 14.20) securing block (2) and spread block with a chisel. Pull the top idler from the block. DRESSTA TD-25M EXTRA…
  • Page 512
    NOTE: Clean all parts thoroughly in a dry cleaning solvent, especially the inside of the idler. Blow all parts dry with compressed air. 1. Inspect the bearings for cracks, scores and wear. Replace if necessary. Soak in oil, wrap and cover all re-usable bearings until ready for assembly. TD-25M EXTRA DRESSTA…
  • Page 513
    (two bolts for each top idler mounting block) and then torque the others. Torque bolts to 845 [Nm]. 2. Lower track chain onto idlers and remove jack. Adjust track chain tension, refer to SECTION 15. DRESSTA TD-25M EXTRA…
  • Page 514
    6. If there is not enough track chain slack to remove the roller, position two small jacks (3) between the track and track frame. Jack up until sufficient clearance exists to remove the track roller. Fig. 14.22. Removing Roller 1. Bolt 2. Roller Bracket 3. Small Jacks TD-25M EXTRA DRESSTA…
  • Page 515
    9. Track Roller Housing (Single Flange) 2. O-Ring 6. Thrust Washer 10. Track Roller Housing (Double Flange) 3. Seal Kit 7. Track Roller Bushing 11. Drain Plug 4. Roller Retainer 8. Track Roller Shaft 12. Spring Pin DRESSTA TD-25M EXTRA…
  • Page 516
    5. Check the end clearance and diametral clearance given in Fig. 14.26. 6. It is recommended that new seal kits (3) be installed whenever the track roller is disassembled. Refer to SEAL INSPECTION under METAL TYPE FACE SEALS in this Section. TD-25M EXTRA DRESSTA…
  • Page 517
    A. Bushing Pressed Below Edge of Roller Bore ……7.06 ± 0.64 [mm] 1. If replacing bushings (7), coat 25 [mm] of outer end of roller bore and leading edges of bushing OD with LOCTITE #601. Press bushing in as indicated in Fig. 14.27. DRESSTA TD-25M EXTRA…
  • Page 518
    9. Fill track roller with recommended lubricant. Refer to OPERATOR’S MANUAL for recommended lubricant. Clean threads of plug (11) and apply LOCTITE Pipe Sealant with Teflon #592. Install plug in track roller shaft (8) and torque to 20 — 50 [Nm]. TD-25M EXTRA DRESSTA…
  • Page 519
    Track rollers 2, 4 and 6 on each side of dozer have single flanges (SF) and 1, 3, 5 and 7 have double flanges (DF). Fig. 14.32. Track Roller Arrangement SF — Single Flanged DF – Double Flanged A. Front of Machine DRESSTA TD-25M EXTRA…
  • Page 520
    CAUTION! Lift and handle all heavy parts with a lifting of proper capacity. Be sure parts are secured by proper slings and hook. Use lifting eyes if provided. Warn people in the area to stand clear. TD-25M EXTRA DRESSTA…
  • Page 521
    Apply grease into clearance A and B. 5. Install front top idler, refer to Paragraph 23, INSTALLATION, in this Section. Remove blocking under front and rear track frame. Install the track chain as described in SECTION 15. DRESSTA TD-25M EXTRA…
  • Page 522
    Warn people in the area to stand clear. Fig. 14.34. Equalizer Bar 1. Track Frame Bracket 6. Bolts with Washer 2. Wear Pad 7. Equalizer Bar End Cover 3. Equalizer Bar 8. Insert 4. Equalizer Bar Plate 9. Wear Pad 5. Shims TD-25M EXTRA DRESSTA…
  • Page 523
    15 x 2 pcs. for one side 1.5 [mm] — thickness of one shim c. Install shims (5) and torque the bolts (6) with washer to 520 [Nm]. 7. Follow the same steps for the other end of the equalizer bar (3). DRESSTA TD-25M EXTRA…
  • Page 524
    1. Inspect the front idler guide bars for distortion or excessive wear, refer to Paragraph 3, SPECIFICATIONS in this Section. Any guide bars are damaged or worn must be replaced with new parts. NOTE: Do not replace only one bar. Replace as a set. TD-25M EXTRA DRESSTA…
  • Page 525
    4. Lubricate guide bars inside track frame. 5. Install the front idler assemble, refer to FRONT IDLER in this Section. 6. Install the track chain, refer to SECTION 15. 7. Adjust the track tension, refer to the ADJUSTING TRACK TENSION in SECTION 15. DRESSTA TD-25M EXTRA…
  • Page 526
    1. Inspect the track chain guide bars for distortion or excessive wear, refer to Paragraph 3, SPECIFICATIONS in this Section. Any guide bars are damaged or worn must be replaced with new parts. NOTE: Do not replace only one bar. Replace as a set. TD-25M EXTRA DRESSTA…
  • Page 527
    If caps are not available, use tape or rubber stoppers. Openings must never be plugged with rags. This practice could introduce dirt or lint into critical hydraulic components. Remove all dirt accumulation from the main frame cover. Tag disconnected lines to facilitate faster and correct installation. DRESSTA TD-25M EXTRA…
  • Page 528
    8. Jack front and rear of machine up and block it securely. Machine should be raised high enough for track rollers and shields to clear chain. Attach a hoist to two track idlers as shown in Fig. 14.39. Lift track frame load off pivot shaft and track chain. TD-25M EXTRA DRESSTA…
  • Page 529
    12. Using a pry bar between track frame and main frame, move track frame out horizontally. Swing track frame from pivot shaft and away from machine. Fig. 14.40. Cross Section View of Track Frame and Pivot Shaft DRESSTA TD-25M EXTRA…
  • Page 530
    Attach a hoist sling to the pivot shaft. The hoist must be installed to give the best possible balance. Place tension on the hoist. b. Unscrew bolts securing the pivot shaft to the machine. Remove the pivot shaft from machine. TD-25M EXTRA DRESSTA…
  • Page 531
    C …………..488.5 ± 0.8 [mm] DRESSTA TD-25M EXTRA…
  • Page 532
    Using flanges (3, Fig. 14.38) and O-rings (2) reconnect hoses (4) to the trunnion (1). Install trunnion (1) to track frame (1, Fig. 14.41) and torque the bolts to 845 [Nm]. Install cover (14) and secure it. 21. Install blade with push arm, refer to SECTION 17. TD-25M EXTRA DRESSTA…
  • Page 533
    3. Measure distances at Y1 and Y2 inside edge of track roller (6, Fig. 14.44) outside flange to outside edge of sprocket (7) on both sides of machine. Measure (W, Fig. 14.43) distance between center line of sprockets and W1 distance between front idlers. These should both check out to 2140 [mm]. DRESSTA TD-25M EXTRA…
  • Page 534
    At final alignment must be Y1 = Y2 ± 0.8 [mm]. Refer to TRACK FRAME AND PIVOT SHAFT in this Section. Torque all the bolts. Fig. 14.44. Rear Track Frame Alignment 1. Track Frame 5. Retaining Plate 2. Pivot Shaft 6. Track Roller 3. Shims 7. Sprocket 4. Wear Washer 8. Shaft Cover TD-25M EXTRA DRESSTA…
  • Page 535
    11. If necessary, refill the track frame pivot shaft housing as described in the OPERATOR’S MANUAL. 12. Install blade with push arm, refer to SECTION 17. Fig. 14.45. Track Frame Alignment 1. Cord 4. Top Idler 2. Sprocket 5. Inside Edge 3. Front Idler DRESSTA TD-25M EXTRA…
  • Page 536
    Tag disconnected lines to facilitate faster and correct installation. Fig. 14.46. Track Springs 1. Track Spring Front Seat 4. Spring Bolt 2. Track Outer Spring 5. Track Spring Rear Seat 3. Track Inner Spring TD-25M EXTRA DRESSTA…
  • Page 537
    (5). Tread the bolt in until an installation dimension equal to 836 [mm] has been reached (B, Fig. 14.46). 7. Position lifting sling (1, Fig. 14.48), centering around track spring (2) and attach to hoist (4). Remove springs (2) from track frame (3). DRESSTA TD-25M EXTRA…
  • Page 538
    5. Install track frame to machine, refer to TRACK FRAME AND PIVOT SHAFT in this Section. 6. Install the front idler, refer to FRONT IDLER in this Section. 7. Install the track chain, refer to SECTION 15 for this procedure. TD-25M EXTRA DRESSTA…
  • Page 539
    C – Center of Sealing Face O.H. – Outer Half of Sealing Face I.H. – Inner Half of Sealing Face 1C. The narrow band must be uniform and be concentric with the I.D. and O.D. (see Figs. 14.50 and 14.51). DRESSTA TD-25M EXTRA…
  • Page 540
    Keep the seals in their original packages until ready for assembly. Do not do not drop, bump or roughly handle the metal sealing rings as the mating surfaces of these ring shave a highly polished finish that could be damaged by careless handling. TD-25M EXTRA DRESSTA…
  • Page 541
    4. Final installation assembly will energize seal as shown in Fig. 14.56, so that rubber rings load seal and drive mating metal rings together. Fig. 14.55. Seal Kit Preparing for Installation Fig. 14.56. Seal Kit Final Installation DRESSTA TD-25M EXTRA…
  • Page 543
    SECTION 15 TRACK OR WHEELS…
  • Page 545
    8. INSTALLATION …………18 DRESSTA TD-25M EXTRA…
  • Page 547: Description

    OD lubricated tracks ……….6.1 [mm] DRESSTA TD-25M EXTRA…

  • Page 548: Service Diagnosis

    (Fig. 15.2). Inspect the tension of the track chain, and tighten if necessary (Fig. 15.1). When new tracks or track shoes are installed, the track tension and track shoe bolts must be checked after first 10 hours of operation and adjusted if necessary. TD-25M EXTRA DRESSTA…

  • Page 549
    When relieving track tension, never loosen these valves more than 2 – 2 ½ turns. If adjustment becomes necessary, remove the bolts securing the track adjuster cover to the track frame and proceed as follows: DRESSTA TD-25M EXTRA…
  • Page 550
    4. When the proper tension has been obtained, tighten the ball check and/or relief valve to 61 — 75 [Nm] torque. 5. After all adjustments are completed, secure the track adjuster cover to the track frame. Track Shoe Bolts Fig. 15.2. Checking Track Shoe Bolts Torque TD-25M EXTRA DRESSTA…
  • Page 551: Removal

    This must be done for safety reasons even if there is the slack in chain. To insure that there is no pressure against the idler, pry the front idler and fork back away from the front idler stops. 2. Remove the master link track shoe bolts. DRESSTA TD-25M EXTRA…

  • Page 552
    A cross-drilled passage permits oil to enter bushings for lubrication of pins, bushings and oil seals. If seals become dry, dirt can enter and cause sealing surface of bushing to wear. Track chains are factory lubricated; no oil level checks are necessary. Leaking joints can be detected by any of following methods: TD-25M EXTRA DRESSTA…
  • Page 553
    If vacuum holds for 10 [sec], fill evacuated pin with oil under 100 to 170 [kPa] to obtain required oil level 54 to 74 [mm] below the end face of the pin. DRESSTA TD-25M EXTRA…
  • Page 554
    2. Master-Split Link — Pin L.H. Down 8. Master-Split Link — Bushing L.H. Upper 3. Link Bushing 9. Master-Split Link — Bushing R.H. Upper 4. Link Pin 10. Pin Plug 5. Thrust Ring 11. Chain Seal 6. Right Chain Link TD-25M EXTRA DRESSTA…
  • Page 555
    NOTE: Track must be on floor and be blocked up on each side of pin to be removed. Assemble Ram (Fig. 15.10) as follows: Install hoses from pump to ram. Thread connecting rods (3) into cylinder (1). Install bolster (2) on connecting rods (3). Thread nuts (6) on connecting rods (3). DRESSTA TD-25M EXTRA…
  • Page 556
    14. Adapter Plug 3. Connecting Rods 9. Pin Receiver 15. Cap Screw 4. Guide Plate 10. Bushing Adapter 16. Electric Pump 5. Cylinder Rod 11. Pin Adapter 17. Hand Pump 6. Connecting Rod Nut 12. Bushing Receiver TD-25M EXTRA DRESSTA…
  • Page 557
    Align forcing pin (8) on track pin and press track pin out. Remove pin receiver (9) from bolster (2). Install bushing adapter (10) in bolster (2). Install pin adapter (11) on forcing pin (8). Press bushing off link. Reposition ram and press bushing off other link. DRESSTA TD-25M EXTRA…
  • Page 558
    2. Remove forcing pin and pin adapter (11, Fig. 15.14) from ram. Install ram cap (13) on ram. Install adapter plug (14). NOTE: Be sure ram cap is fully threaded on ram. Be sure ram cap bolt is fully threaded into ram cap. TD-25M EXTRA DRESSTA…
  • Page 559
    SERVICE /SPECIAL TOOLS). Tap it in until it is 3 [mm] below chamfer edge of pin hole. After installing plug punch the pin hole around its chamfer edge using header (refer to SERVICE /SPECIAL TOOLS) to prevent plug from escaping. NOTE: Once joint is lubricated, there is no way of checking for leaks. DRESSTA TD-25M EXTRA…
  • Page 560
    7. Left Track Link 2. Master Split Link — Pin L.H. Down 5. Spring Seal Washer 8. Master-Split Link — Bushing L.H. Upper 3. Track Link Bushing 6. Right Track Link 9. Master-Split Link — Bushing R.H. Upper TD-25M EXTRA DRESSTA…
  • Page 561
    (Fig. 15.19). Place the bushing and links assembly onto the track and insert the aligning pin to hold the track link alignment while the new pin is pressed in position (Fig. 15.19). Use the aligning pin again when joining the two sections of track. DRESSTA TD-25M EXTRA…
  • Page 562
    The unworn surface of each pin is operating against the unworn surface in its bushing and the unworn outside surface of the bushing which contacts the sprocket. Fig. 15.19. Assembly of New Links 1. Master Bushing 4. Spacer 2. Standard Pin 5. New Link or Links 3. Spring Seal Washers 6. Aligning Pin TD-25M EXTRA DRESSTA…
  • Page 563
    DRESSTA TD-25M EXTRA…
  • Page 564: Installation

    650 ± 70 [Nm] + 120 [°] of turn. If only leaking joints were rebuilt, install track shoes on both sides of repaired joints. 3. Adjust track tension, refer to SPECIFICATIONS in this Section and OPERATOR’S MANUAL. TD-25M EXTRA DRESSTA…

  • Page 565
    SECTION 17 MOUNTED EQUIPMENT…
  • Page 567
    24. INSTALLATION …………27 DRESSTA TD-25M EXTRA…
  • Page 569
    Ripper shank STD (multi shank ripper) ……..340 [kg] DRESSTA TD-25M EXTRA…
  • Page 570: Removal

    12. Lube Fitting 26. Diagonal Strut 13. Right Cutting Edge End Bit 27. Blade Tilt Cylinder (without Blade Pitch) 14. Right Cutting Edge 27A. Blade Tilt Cylinder (with Blade Pitch) 15. Center Cutting Edges 28. Right Push Arm Assy TD-25M EXTRA DRESSTA…

  • Page 571
    6. Disconnect the push arm (11, Fig. 17.2) from the push arm bracket (9) by removing the pin retainer and drive out pin (8). Repeat this step on the opposite side of the machine. 7. Remove the blade (7). DRESSTA TD-25M EXTRA…
  • Page 572
    Fig. 17.3. Blade Disconnecting Point (with Blade Pitch) 1. Blade Tilt/Pitch Cylinder 5. Tilt/Pitch Cylinder Cap 9. Push Arm Bracket 2. Cap Bolts 6. Cylinder Rod Ball 10. Lift Cylinder Bracket 3. Shims 7. Blade 11. Push Arm 4. Blade Socket 8. Pin TD-25M EXTRA DRESSTA…
  • Page 573
    (6). Repeat this step on the opposite side of the machine. 7. Back the machine out from between the push arms. 8. Reassemble shims (7, Fig. 17.5) and caps (2) to the push arms (6) and secure with bolts (3) to prevent their damage or being lost. DRESSTA TD-25M EXTRA…
  • Page 574: Installation

    845 [Nm]. Remove the block from under tilt/pitch cylinder. Repeat this procedure for the tilt cylinder on the right side as described above. Fig. 17.6. Installing Diagonal Strut to Blade Socket 1. Diagonal Strut 3. Strut Ball 5. Shims 2. Strut Cap 4. Blade Socket 6. Bolts TD-25M EXTRA DRESSTA…

  • Page 575: Removal

    WARNING! Due to the considerable weight and bulk of each bulldozer component, a suitable hoist or lifting device MUST be used. Remove each component separately using suitable blocking on the remaining components. DRESSTA TD-25M EXTRA…

  • Page 576
    8. Disconnect the push arm (23, Fig. 17.1) from the blade by removing the pin retainer (7) and drive out pin (6). Remove the push arm (23) from the machine. 9. If necessary, remove two hoses (4 and 5, Fig. 17.5) from the push arm (6). TD-25M EXTRA DRESSTA…
  • Page 577: Installation

    Secure the pin (22) with locking hardware. 8. Machine with Blade Tilt/pitch: Install the blade tilt/pitch cylinder (21A, Fig. 17.1) to the machine as described in SECTION 10C, Paragraph 15, INSTALLATION. 9. Remove the blocks from under push arm (23). DRESSTA TD-25M EXTRA…

  • Page 578
    A. Nominal Strut Mounting Length ……… 1356 [mm] TD-25M EXTRA…
  • Page 579
    (25). 3. Remove the bolts (6, Fig. 17.6) securing cap (2) to socket (4) and remove the strut (1) and shims (5). 4. If necessary, remove the eyebolt (7, Fig. 17.8) from diagonal strut housing (4). DRESSTA TD-25M EXTRA…
  • Page 580
    4. Position the eye of the diagonal strut (26) in the bracket on the side of the push arm (23 and 28) so that the pin holes are aligned. Insert the mounting pin (25) through the bracket, aligning the lock holes. Secure the pin (25) with the locking hardware. TD-25M EXTRA DRESSTA…
  • Page 581: Removal

    1.6. Bullgrader Blade 1.12. R.H. Side Plate 1.18. Guard “C” Frame Assy 2. Upper Strut 2A. Blade Tilt Cylinder 3. Lower Left & Right Strut Assy 4. “C” Frame Assy 5. Frame Trunnion Assys 6. Lower Strut Pin DRESSTA TD-25M EXTRA…

  • Page 582
    (1). Repeat this procedure at the opposite side of the machine. 6. Disconnect the blade (1) from the “C” frame (4) by removing the cotter pin, mounting pin (1.5) and drive out blade center pin (1.4). 7. Lift off the blade. TD-25M EXTRA DRESSTA…
  • Page 583
    23. Frame to Blade Hose 6. Tube Assy 15. G-2 Blade Assy 24. Plugs 7. Frame to Blade Hose 16. Hose Guards 25. Hose Guard 8. Split Flange 17. Hose Center Guard 26. R.H. Trunnion 9. O-Rings 18. Tube Assy DRESSTA TD-25M EXTRA…
  • Page 584: Installation

    CAUTION! Due to the considerable weight and bulk of each bullgrader component, a suitable hoist or lifting device MUST be used. Remove each component separately using suitable blocking on the remaining components. TD-25M EXTRA DRESSTA…

  • Page 585
    “C” frame according to OPERATOR’S MANUAL. Operate the tilt cylinders and check for leaks. 5. Install blade hoses connection cover (2, Fig.17.11) to the “C” frame (1) and secure with bolts (3). Repeat this step on the opposite side of the machine. DRESSTA TD-25M EXTRA…
  • Page 586: Removal

    8. Back the machine out from between the “C” frame (1). 9. Reassemble shims (6, Fig.17.11) and caps (4) to the “C” frame (1) and secure with bolts (5) to prevent their damage or being lost. TD-25M EXTRA DRESSTA…

  • Page 587: Installation

    CAUTION! Due to the considerable weight and bulk of each bullgrader component, a suitable hoist or lifting device MUST be used. Remove each component separately using suitable blocking on the remaining components. DRESSTA TD-25M EXTRA…

  • Page 588
    1. Disconnect upper strut (2, Fig. 17.9) or tilt cylinder (2A) from lower strut (3) by removing the lock pin and drive out pin (6). Tie upper strut (2) or tilt cylinder (2A) up out of the way. TD-25M EXTRA DRESSTA…
  • Page 589: Trunnion Replacement

    4. Mount the trunnion to the track frame. Secure the trunnion with eight bolts. Tighten the bolts to 845 [Nm]. 5. Install the blade with push arm (3, Fig. 17.4) or “C” frame (1, Fig. 17.11) as described in this Section. DRESSTA TD-25M EXTRA…

  • Page 590
    Align the tang of the eccentric yoke (6) with the slot in the crosstube. Insert and turn the yoke 90 degrees to the rear of the machine. The turning action will lock the yoke into position. 4. Install the hydraulic lift cylinder. Refer to SECTION 10C for installation procedure. TD-25M EXTRA DRESSTA…
  • Page 591: Draft Frame

    15. Ripper Shank Pin Bushing 6. Ripper Pitch Cylinder 16. Draft Frame Pin 7. Ripper Lift Cylinder 17. Tool Beam 8. Bushing 18. Ripper Shank Assy (STD) 9. Draft Frame 19. Ripper Shank Assy (DEEP DIG) 10. Stop Plate DRESSTA TD-25M EXTRA…

  • Page 592
    2. Place new bushing (15) in tool beam (9). Using the hydraulic press, press bushing (15) into tool beam (17). Repeat for other bushing (15). Coat inner surfaces of bushings (15) with fresh grease. Remove tool beam (17) from the stand. TD-25M EXTRA DRESSTA…
  • Page 593
    3. Attach hoist to cylinder mounting pins (13) at tool beam (16) and take out slack in hoist. Remove draft frame pins (15) and lift tool beam (16) from ripper. If necessary, remove shanks (17) from tool beam (16) DRESSTA TD-25M EXTRA…
  • Page 594
    4. Right Mounting Frame 13. Cylinder Pin 5. Draft Frame Pin 14. Stop Plate 6. Ripper Pitch Cylinder 15. Draft Frame Pin 7. Ripper Lift Cylinder 16. Tool Beam 8. Bushing 17. Ripper Shank Assy 9. Draft Frame TD-25M EXTRA DRESSTA…
  • Page 595
    (16) to draft frame (9) with pins (15), plates and hardware. Position suitable blocking under tool beam (16). 6. Install ripper lift cylinders (7), refer to SECTION 10C. 7. Install ripper pitch cylinders (6), refer to SECTION 10C. 8. If removed, install shanks (17) to toll beam (16). DRESSTA TD-25M EXTRA…

This manual is also suitable for:

Extra td-20m

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