Galion Grader Service Manual - Jensales Tractor … GRADER~ PLANER 0 ROLLER 0 CRANED Shop Manual A-9 R1/C2 VERTICAL STEERING SHAFT ASSEMBLY APPLICABLE MODELS 104B & C SERIAL NUMBERS

GA-S-T500A+

GGaall iioonnService Manual

T500A & T500BVolume 1 of 2

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF GALION OR IT’S SUCCESSORS. GALION AND IT’S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

Serv

ice

Man

ual

http://www.jensales.com/products/galion-grader-service-manual-ga-s-t500a.html

Shop Manual

MOTOR GRADER

SERIAL NUMBERS ALL .

SMG-TSOOA

GALION


GRADER [if PLANER 0 ROLLER 1!1 CRANE~

Shop Manual A-1.20

ROSS POWER STEERING GEAR

CONTENTS

APPLICABLE GRADER MODELS 118A 118B 118C 104A 104B 104C 104HA 104HB 160B 160C 160L T500A T500L T600B APPLICABLE ROLLER MODELS PTR 9-Wheel Roller APPLICABLE CRANE MODELS .. 80 90 thru 125 90A thru 125A 125F 125FA 140F 150A 150FA 200FA

Torque Sheet . . . . . . . . . . . . . . Di sassembly . . . . . . . . . . . . . . Service to Cam and Actuator Assembly .. Service to Lever Shaft and Stud Assembly Service to Valve Assembly ...... .

:. SERIAL NUMBERS-. 07245 thru 07600 07601 thru 10750 10751 thru 12013 07245 thru 07600 07601 thru 10750 10751 thru 12013 07245 thru 07619 07620 thru 10693 02155 thru 02714 02715 thru 03029 02121 thru 03083 02601 thru 07994 02944 thru 07994 01501 thru 02535

: SERIAL NUMBERS 00101 thru 05678 SERIAL NUMBERS. 01001 thru 03131 01150 thru 08774 02006 thru 08774 07247 thru 08774 07990 thru 08774 07571 thru 08774 02832 and Up 07305 and Up 09401 and Up

Page Back of Cover

1 9

10 11 14 Reassembly ............... .

Installation and Adjustment of Valve Assembly Lubricant Specifications

22 25 25 Troubleshooting .............. .

0783

Dresser Industries, Inc .• Construction Equipment Division. P.O. Box 647 • Galion, OH 44833 U.S.A. (419) 468·4321 • Telex: 987430 • Cable: Galiron

C6

C6


SHOP MANUAL

45

Install shims and qaskets (use a gasket on each end of shim assembiy). Gaskets are .010" thick but each become only .006" when compressed. Shims are available in .002", .003", and .010" thickness. Torque cap screws to 25 foot-pounds.

46

Cam should turn freely in housing by finqer pressure. If it does not turn freely, add shims to end cover. Cam should have no end movement by finger nressure. If it does have end movement, remove shims from end cover.

Proceed to Step 50 on paqe 17.

47

If steering gear is equipped with two-piece actuator housing, assemble cam in housinq. Be certain that cam rotates and oscillates freely in housing.

16

FILE A

SECTION 1.20


\ i

GRADER~ PLANER 0 ROLLER 0 CRANED

Shop Manual A-9 R1/C2

VERTICAL STEERING SHAFT ASSEMBLY

APPLICABLE MODELS

104B & C

SERIAL NUMBERS

07601 thru 11214 07619 thru 10692 07601 thru 12013 02155 thru 03029 02101 thru 03083 02601 thru 07994 01501 thru 02535

104H, B & C 118B & C 160B & C 160L T-500A & L T-600B

-----CAUTION----.. ALL COMPONENTS MUST BE PROPERLY SUPPORTED DURING

DISASSEMBL.:Y AND ASSEMBLY.

ALL JACKING, HOISTING, AND GENERAL WORKSHOP EQUIPMENT REQUIRED FOR THIS OPERATION MUST BE IN GOOD WORKING ORDER.

EXTREME CAUTION TO BE OBSERVED AT ALL TIMES TO PREVENT INJURY.

SAFE WORKSHOP PRACTICES ARE A MUST.

CONTENTS Torque Sheet Disassembly Reassembly

Page Back of Cover

1 4

Dresser Industries. Inc .• Galion Division • South Street • P.O. Box 647 • Galion. OH 44833 U.S.A. (419) 468-4321 • Telex: 987430 • Cable: Galiron

C2 0281


GRADER lil PLANER 0 ROLLER lil CRANE 0

B-6 C2

CONVERTER OUTPUT SHAFT GOVERNOR

APPLICABLE MODELS

5-8/8-10 1/2 ROM 8-12/10-14 ROM 13-20 Three Axle ROM 3-Whee1 ROM T-400A T-500A & L T-600B

SERIAL NUMBERS.

39831 thru 57161 39844 thru 57034 39844 thru 54441 42607 thru 44196 01001 & Up 01001 thru 07994 01001 thru 02535

-----CAUTION ----.. ALL COMPONENTS MUST BE PROPERLY SUPPORTED DURING

DISASSEMBLY AND ASSEMBLY.

ALL JACKING. HOISTING. AND GENERAL WORKSHOP EQUIPMENT REQUIRED FOR THIS OPERATION MUST BE IN GOOD WORKING ORDER.



CONTENTS

Torque Sheet Disassembly Reassembly .

Page

Back of Cover 1 7

'1i~~~~ Dresser Industries, Inc. • Galion Division • South Street • P.O. Box 647 • Gallon. OH 44833 U.S.A. t.! ~ (419) 468-4321 • Telex: 987430 • cable: Galiron

0282

C2


DRESSER MATERIAL LIFT 0 GRADER It PLANER 0 ROLLER 0

La':,$I,I:31:': ,t:,~ Iml,t·umm·l, ,:S"!

CRANE 0

SHOP MANUAL 8-6.10 R2/C2

TAILSHAFT GOVERNOR [used with I.H. enginesJ

APPLICABLE MODELIS

T-400A T-500A T-500C T-500l T-500M T-600B T-600C

SERIAL NUMBERIS


..-------CAUTI ON ------.

ALL COMPONENTS MUST BE PROPERLY SUPPORTED DURING DISASSEMBLY AND REASSEMBLY.

ALL JACKING. HOISTING AND GENERAL WORKSHOP EQUIPMENT REQUIRED FOR THIS OPERATION MUST BE IN GOOD WORKING ORDER.



CONTENTS PAGE

Torque Sheet Engine Speeds

01001 thru 07994 07995 & Up . . .

Speed Check 01001 thru 07994 07995 & Up . . .

Governor Adjustment 01001 thru 07994 . 07995 & Up . . . .

Back of Cover

1 9

12 12

2 13

DRESSER INDUSTRIES, INC. EAST SUNNYSIDE AVE. LIBERTYVIllE, Il 60048 . 0485 C2


GALION I@RESSE"ifJ

TECHNICAL SERVICES

MATERIAL LIFT 0 GRADER I!f PLANER 0 ROLLER 0 CRANE 0

SHOP MANUAL 8-8.10 R2/C1

OUTPUT SHAFT GOVERNOR ADJUSTMENT

CUMMINS ENGINE APPLICABLE MODEL/S

T-500A T-500C T-500L T-500M T-600B T-600C

SERIAL NUMBERIS

02601 thru 07994 07995 thru 10739 03286 thru 07994 07995 thru 10487 01501 thru 02535 02536 thru 03099

r------CAUTION---~


ALL JACKING. HOISTING AND GENERAL WORKSHOP EQUIPMENT REQUIRED FOR THIS OPERATION MUST BE IN GOOD WORKING ORDER.



CONTENTS Page

Torque Sheet Back of Cover Engine Speeds

02601 thru 07994 1 07995 & Up . 6

Speed Check 02601 thru 07994 2 07995 & Up . . 9

Governor Adjustment 02601 thru 07994 3 07995 & Up 10 C1

GALION MANUFACTURING DIVISION. DRESSER INDUSTRIES. INC .• P.O. BOX 647, GALION, OHIO 44838. PHONE: 419/468-4321

0584


GRADER u1 PLANER 0 ROLLER 0 CRANE 0

Shop Manual B-10.10

TAILSHAFT GOVERNOR SETTING & GOVERNOR ADJUSTMENT

. USED WITH DETROIT DIESEL

APPLICABLE MODELS

T-400A T-500A T-500C T-500l T-500M T-600B T-600C

SERIAL NUMBERS







CONTENTS Engine Speed Settings .... Tai1shaft Governor Adjustment Shut-down Solenoid Adjustment

Page 1

. 2

. 10

C2

C2

Dresser Industries, Inc .• Construction Equipment Division. P.O. Box 647 • Galion. OH 44833 U.S.A. (419) 468·4321 • Telex: 987430 • Cable: Galiron

0984


MATERIAL LIFT 0 GRADER [!1 PLANER 0 ROLLER 0 CRANE B

SHOP MANUAL C-07.00 R3/C4

TRANSMISSION (MODEL 2420)

APPLICABLE MODELS'

GRADERS SERIAL NUMBERS

T-400A T-500A & L T-6008 (IH engine only)

CRANES gOA thru 125A 125FA 150A 150FA

CAUTION

01001 thru 02110 02602 thru 07994 03855 thru 03866

02006 thru 08769 07990 thru 08769 02832 thru 08623 07305 thru 08623


ALL JACKING, HOISTING AND GENERAL WORKSHOP EQUIPMENT REQUIRED FOR THIS OPERATION MUST BE IN GOOD WORKING ORDER.



CONTENTS Torque Sheet . . . . . . Special Tools ..... Transmission Disassembly Clutch Disassembly ... Clutch Reassembly . . . . . . . . ... . . . Control Valve & Oil Circuit Plate Disassembly & Assembly Transmission Reassembly Pressure Checks . . . . . . . . . . . . . . .

Pafe Back 0 Cover

i 1

13 18 24 26 40

KOMATSU DRESSER COMPANY EAST SUNNYSIDE AVE. LIBERTYVILLE, IL 60048

12-85 .- ., :.. .......


GRADER (If PLANER 0 ROLLER 0 CRANE 0

Shop Manual E-2.10 HYDRAULIC CONTROL

VALVE ASSEMBLY

APPLICABLE MODELS SERIAL NUMBERS

503l T-400A T-500A T-500l T-600B

02611 & Up 01001 & Up 02601 thru 07994 03286 thru 07994 01501 thru 02535

R1/C1


DISASSEMBLY AND ASSEMBL Y.




CONTENTS Torque Sheet . . . . . . . . . . . Removal of Control Valve Assembly Removal of Individual Valves .. Disassembly of Valve Components Cleaning and Inspection .... Reassembly of Valve Components . Installation of Individual Valves .. Installation of Control Valve Assembly Testing and Troubleshooting .....

KOMATSU DRESSER COMPANY EAST SUNNYSIDE AVE. 0284

Page Back of Cover

1 4 6 9

10 12 14 17

Cl

LIBERTYVILLE, Il 6004H


It. DRESSER

GRADER 00 PLANER 0 ROLLER 00 CRANE 0

SHOP MANUAL E-3 R1/C3

HYDRAULIC CYLINDERS

APPLICABLE MODELS.

ROLLERS SERIAL NUMBERS

3-5 and 4-6 ROM 36430 thru 56001 39861 thru 53741 39844 thru 54869 41767 thru 44140 03000 thru 05473 450001 thru 450365

5-8 and 8-10-1/2 ROM 8-12 and 10-14 ROM 3-Wheel Chief PTR VOS 84

GRADERS 104 118 160 303 T-400A T-500 T-600 503

01001 thru 11214 01001 thru 1201j 01001 thru 03083 25001 thru 26950 01001 thru 01620 01001 thru 06701 01001 thru 02241 05101 thru 06111

-----CAUTION------ALL COMPONENTS MUST BE PROPERLY SUPPORTED DURING

DISASSEMB L Y AND ASSEMB L Y.



SA.FE WORKSHOP PRACTICES ARE A MUST.

CONTENTS Torque Sheet . . . . . . . . . . . . . . . . . . . . . . . . Back of Cover Staybolt Type Cyl inder .................. . Removable Single Cast Head Type Cylinder with Screw Type Piston Removable Single Cast Head Type Cylinder with Nut Retained Piston Welded Type Cylinder .... Screw Head Type Cylinder .. Externa 1 Screw Head Cyl i nder . . . . . . . . .

1 3 5 7 9

11 C3

DRESSER MARKETING DIVISION EAST SUNNYSIDE AVE. LIBERTYVILLE, IL 60048


GRADER III PLAIIER 0 ROLLER 0 CRAIIE 0

Shop Nanual E-4 R2/CI

HYDRAULIC ItO,.OR

FOR SIDE SHIFT AIID CIRCLE REVERSE

104 104A 104B 104HA 104HB 118A 118B

160A 160B

14400-07245 07245-07601 07601-08912 07245-07619 07619-08912 07245-07601 07601-08912, EXCEPT 8756, 8757, 8876 & 8877 02019-02155 02155-02358

-----CAUTION ----..

.5"79

ALL COMPONENTS MUST BE PROPERLY SUPPORTED DURING DISASSEMBL Y AND ASSEMB L Y.



SAFE WORKSHOP PRAC:-ICES ARE A MUST.

Dresser Industries. Inc. • Construction Equipment Division. P.O. Box 647 • Galion, OH 44833 U.S.A. (419) 468·4321 • Telex: 987430 • Cable: Galiron C1


GRADER (if PLANER 0 ROLLER 0 CRANED

Shop Manual E-4.10 R2/C1

:APPJ1~~BJ~).'()t)_El.S~

104B & C 104HB 118B & C 160B & C 160L T-400A T-500A & L T-500C & M T-600B T-600C

;§_~I{11U~:_NOJYflf~~~

08912 thru 11214 08912 thru 10692 08912 thru 12013 02358 thru 03029 02358 thru 03083 01001 & Up 03034 thru 07994 07995 & Up 01656 thru 02535 02536 & Up

-----CAUTION -----ALL COMPONENTS MUST BE PROPERLY SUPPORTED DURING

DISASSEMBL Y AND ASSEMBL Y.




CONTENTS Page

Torque Sheet Special Tool

Back of Cover 1

Removal ... Disassembly . Cleaning & Inspection Reassembly . Installation ....

2 3 6 7

10

Dresser Industries, Inc .• Construction EQuipment Division. P.O. Box 647 • Galion, OH 44833 U.S.A. (419) 468-4321

Cl


DRESSER

MATERIAL UFT 0 GRADER 0' PLANER 0 ROLLER 0 [a·: ,H! li:ai :.: ,t:, ~ 1m I ,t· g; l!lJ.:, ,t;:, IJ CRANE 0

SHOP MANUAL E-06.03 R4/C1

0286

STEERING FLOW REGULATOR & RELIEF VALVE ASSEMBLY

APPLICABLE MODELJS SERIAL NUMBERIS

104 B 104-H B 118B 118C 160 C 160 B 160 L T-400 A T-500 A T-500 L T-600 B

OLD STYLE NEW STYLE

07601 thru 09938, 09939 thru 10749 07619 thru 09954, 09955 thru 11214 07601 thru 09938, 09939 thru 10749 ---------------- 10750 thru 12013 ---------------- 02706 thru 03029 02101 thru 02514, 02515 thru 03083 02101 thru 02514, 02515 thru 03083 ---------------- 01001 thru 02110 02601 thru 03314, 03315 thru 07994 02601 thru 03314, 03315 thru 07994 01505 thru 01744, 01745 thru 02535

CAUTION





CONTENTS PAGE

General Torque Values •••••••••••••••••••••••••••• Back of Cover Flow Regulator & Relief Valve Assembly ••••••••••••••••• 1 Disassembly •••••••••••••••••••••••••••••••••••••••••••• 3 Reassemb 1 y ••••••••••••••••••••••••••••••••••••••••••••• 3

Dresser Industries, Inc .• Galion Division • South Street • P.O. Box 647 • Galion, OH 44833 U.S.A. (419) 468-4321 • Telex: 987430 • Cable: Galiron


GRADER IiJ PLANERD ROLLER D CRANED

Shop Manual E-B.10 C3

GRADER HYDRAULIC SYSTEM

APPLICABLE MODEUS

104, A, B, C, H, HA & HB 118, A, B & C 160 , A, B, C & L 303A 503A 503L T-400A T-500, A & L T-600 & B

SERIAL NUMBERIS

02600 thru 10693 02601 thru 12013 01375 thru 03029 26888 thru 26950 05101 thru 06111 06112 & Up 01001 thru 02110 01684 thru 07994 01266 thru 02535

-----CAUTION -----ALL COMPONENTS MUST BE PROPERL Y SUPPORTED DURING




SAFE WORKSHOP PRAC"!"ICES ARE A MUST.

I DRESSER e JjJ Dresser Industries. Inc. • Construction Eouipment Division • P.O. Box 647 • Galion. OH 44833 U.S.A. INDUSTRIES .. NUn:. (419) 468-4321

0184

C3


INDEX

STANDARD GRAPHICAL SYMBOLS ------------------------------------------------- 1

MANIFOLD CONTROLS ---------------------------------------------------------- 2

CURRENT GALION GRADER HYDRAULIC SYSTEM ------------------------------------- 5

HYDRAULIC TANK AND FILTER -------------------------------------------------- 5

Dipstick -------------------------------------------------------------- 7

Filter ---------------------------------------------------------------- 9

Hydraulic Tank Breather ----------------------------------------------- 11

Hydraulic System Lubricant -------------------------------------------- 11

HYDRAULIC PUMP ------------------------------------------------------------- 12

Function of the Hydraulic Pump ---------------------------------------- 13

Tolerance of the Pump ------------------------------------------------- 14

FLOW REGULATOR ------------------------------------------------------------- 15

STEERING CIRCUIT ----------------------------------------------------------- 22

Mechanical Power Boosted Steering ------------------------------------- 22

Hydrostatic Power Steering -------------------------------------------- 29

MANIFOLD CIRCUIT ----------------------------------------------------------- 33

Series Flow ----------------------------------------------------------- 33

Galion Control Valves ------------------------------------------------- 35

Flow within a Control Valve ------------------------------------------- 36

PAST GRADER HYDRAULIC SYSTEMS ---------------------------------------------- 40

Flow Regulators ------------------------------------------------------- 40

Past Hydraulic Systems ------------------------------------------------ 41

HYDRAULIC SYSTEM PRESSURES ------------------------------------------------- 48

Manifold Pressure Check ----------------------------------------------- 48

Steering Pressure Check ----------------------------------------------- 49

TROUBLESHOOTING --- File E, Section 17 of the Galion Grader Shop Manual

i


Shop Manual

GR_AQE_R HYDRAI.J_LIC TROUBLESHOOTING

'APPLicABLE -MODELS 104B, HB & 118B 160B 160L 503A 503L T-400A T-500A & L T-600B

SERIAL NUMBERS 07601 thru 10749 02101 thru 02713 02101 thru 03083 05101 thru 06111 06112 & Up 01001 thru 02110 02601 thru 07994 01501 thru 02535

GRADER [!J PLANER D ROLLER D CRANED

E-17 R4/C1





SAFE WORKSHOP PRAC-:ICES ARE A MUST.

CONTENTS Page Grader Hydraulic System .................... -1-Hydraulic Circuit Diagram Index & Control Valve System Pressures 2 Control Valve System Pressure Check Procedure 3 Steering System Pressure Check 3 Hydraulic Tank Oil Level Check 3 Troubleshooting . . . . . . 6 Hydraulic Circuit Diagrams 10

I~DNI@RESSEif)1 ~~s~~d~~~~~!!!~o~DN 0684

Cl


DRESSER

MATERIAL LIFT 0 GRADER [!J PLANER [!J ROLLER 0 CRANE 0

SHOP MANUAL E-20 C1

HYDRAULIC CYLINDERS Although this shop manual section has primarily been prepared for the RP-30 road planer, it can also be used for old style mainline graders and the T-400A.

Illustrated removal and installation procedures are typical sequential steps and mayor may not apply to these graders.

Serial numbers of machines using these cylinders are as follows:

APPLICABLE GRADER MODELS APPLICABLE CYLINDER SERIAL NUMBERS

T-400A Steeri ng 01001 thru 02110 T-400A Leaning Wheel 01001 thru 02110 T-500A & L 06702 thru 07994 T-600B 02242 thru 02535

APPLICABLE PLANER MODELS APPLICABLE CYLINDER SERIAL NUMBERS

RP-30/42 RP-30/42 RP-30/42 RP-30/42

Steering 01001 Leani ng Wheel 01001 Drum Lift 01001 Drum Shift 01001

CAUTION





thru thru thru thru

CONTENTS PAGE

General Torque Values . Steering Cylinder ... Leaning Wheel Cylinder Drum Lift Cylinder Drum Shift Cyl inder ..

Back of Cover 1 6

12 17

01123 01123 01123 01123

Dresser Industries. Inc .• Construction Equipment Division. P.O. Box 647 • Galion, OH 44833 USA. (419) 468·4321

0485 C1


• DRESSER

MATERIAL LIFT [ ] GRADER [X] PLANER [ ] ROLLER [ ]

CRANE [ ]

SHOP MANUAL E-30.00 R1

HYDRAULIC OIL SWIVEL BLOCK (TWO-WAY & FOUR-WAY)


SEE PAGE NUMBER 1 FOR APPLICABLE MODELS AND SERIAL NUMBER RANGES

CAUTION


ALL JACKING HOISTING AND GENERAL WORKSHOP EQUIPMENT REQUIRED FOR THIS OPERATION MUST BE IN GOOD WORKING ORDER.



CONTENTS PAGE

GENERAL TORQUE VALUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back of Cover SPECIAL TOOLS ...•.............................................. 2 INTRODUCTION ................................................... 3 SERVICING ...........................•.......................... 4

TWO-WAY SWIVEL BLOCK SERVICING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4 TWO-WAY BLOCK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4 TWO-WAY BLOCK DISASSEMBLY ............................... 5 CLEANING AND INSPECTION .................................. 6 TWO-WAY BLOCK REASSEMBLY ................................ 7 TWO-WAY BLOCK INSTALLATION ............................... 8

FOUR-WAY SWIVEL BLOCK SERVICING ............... " ............. 9 FOUR-WAY BLOCK REMOVAL .................................. 9 FOUR-WAY BLOCK DISASSEMBLY. . ...... . . . . . . . . . . . . . . . . . . . . .. 10 CLEANING AND INSPECTION ................................. 11 FOUR-WAY BLOCK REASSEMBLY. . . .... . . . . . . . . . . . . . . . . . . . . . .. 12 FOUR-WAY BLOCK INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13

TESTING AND ADJUSTMENTS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14


0989


-~'!'-~.~~--~

\'~Jt

It DRESSER

Shop Manual

DRAWBAR SHIFT CYLINDER

APPLICABLE MODELS

118C 160C 160L T-400A T-500A T-500L T-600S

SERIAL NUMBERS

11088 & Up 02799 & Up 02796 & Up 01242 & Up 04570 & Up 04570 & Up 01961 & Up

GRADER ~ PLANER 0 ROLLER 0 CRANE 0

E-31 C1

-----CAUTION -----ALL COMPONENTS MUST BE PROPERLY SUPPORTED DURING





CONTENTS Torque Sheet . . . . . . Remova 1 . . . . . . Disassembly ..... . Cleaning and Inspection Reassembly • . . . . . . Installation ..... .

DRESSER MARKETING DIVISION

0981

EAST SUNNYSIDE AVE.

Page Back of Cover

1 2 4 5 6

LIBERTYVILLE, IL 60048


i ~ j.

• DRESSER

SHOP MANUAL

HYDRAULIC GEAR PUMP

APPUCABLE MODELS GRADERS 303A 160 503 T-400A T-500A T-500L T-600B ROLLERS 3 Wheel R.O.M. Chief/Warrior

SERIAL NUMBERS


40623 thru 41485

GRADER fit PLANER D ROLLER [!f CRANED

E-X C1

-----CAUTION-----ALL COMPONENTS MUST BE PROPERLY SlJPPORTED DURING

DISASSEMB L Y AND ASSEMB L Y.


EXTREME CAUTION TO BE OBSERVED AT ALL TIMES TO PREVENT - INJURY.


CONTENTS Page Torque Sheet . . . General Instructions . Assembly ..... . Testing ..... .

DRESSER MARKETING DIVISION

0381

EAST SUNNYSIDE AVE.

Back of Cover 1 2

13

UBERTYVILLE, IL 60048

C1


GRADER £if PLANERD ROLLER D CRANED

Shop Manual F-1 lR1/~2

CIRCLE REVERSE CASE

Applicable Models

1 04, A, B, & HB 118A & B 160B 160L T-500A & L T-600B 503A 503L

Serial Numbers

07271 thru 09618 07271 thru 09618 02155 thru 02163 02101 thru 02261 02601 thru 03229 01501 thru 01582 01501 thru 06111 06112 and Up

-----CAUTION ----..

0280

ALL COMPONENTS MUST BE PROPER L Y SUPPORTED DURING DISASSEMBLY AND ASSEMBLY.




CONTENTS

Torque Sheet General Disassembly Assembly . .

Page

Back of Cover 1

. 1 ... 5

C2 Dresser Industries, Inc .• Galion Division • South Street. P.O. Box 647 • Galion, OH 44833 U.S.A. (419) 468-4321 • Telex: 987430 • Cable: Galiron


It. DRESSER

MATERIAL LIFT [ ] GRADER [X] PLANER [ ] ROLLER [ ]

CRANE [ ]

SHOP MANUAL F-01.10 C8

CIRCLE REVERSE GEAR CASE APPLICABLE MODELS SERIAL NUMBERS

SEE BACK OF COVER FOR APPLICABLE MODELS AND SERIAL NUMBER RANGES

CAUTION



EXTREME .CAUTION TO BE OBSERVED AT ALL TIMES TO PREVENT INJURY.


CONTENTS PAGE

SERIAL NUMBER RANGES ......................... Back of Cover DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3 REASSEMBLY .................................................... 8


C8 0989


__ DRESSER

CRADER 00 PLANER 0 ROLLER 0 CRANE 0

SHOP MANUAL F-2 R2/CI

SIDE SHIF,. CASE


05466 thru 10693 05466 thru 10750 01739 thru 03083 02601 thru 06938 01001 thru 02298

104 118 160 T-500A & L T-600B



ALL JACKING HOISTING AND GENERAL WORKSHOP EQUIPMENT REQUIRED FOR THIS OPERA TION MUST BE IN GOOD WORKING ORDER.



Torque Sheet Disassembly Reassembly ..

CONTENTS Page

Back of Cover 1 6

DRESSER MARKETING DIVISION EAST SUNNYSIDE AVE.

Cl

UBERTYVILLE. IL 60048

876


MATERIAL LIFT [ 1 GRADER [xl PLANER [ 1 ROLLER [ 1

CRANE [ 1

SHOP MANUAL F-07.00 R31Cl

TANDEM CASE DOUBLE REDUCTION TANDEM

DRIVE WITH 6 SPLINE AXLES APPLICABLE MODELS

T-500L T-500A T-600B

160L

SERIAL NUMBERS

02601 - 02810 02601 - 02810 01501 - 01823 with Cummins 01501 - 01735 D. D. Only

02101 - 02601 with Cummins 02101 - 02474 D. D. Only

CAUTION





CONTENTS PAGE

Torque Sheet ..................................... Back of Cover Di sassembly ......................................... 1 - 25 Reassembly .......................................... 26 - 51 Lubrication.......................................... 18

KOMATSU DRESSER COMPANY EAST SUNNYSIDE AVE. LIBERTYVILLE, IL 60048

CI 0187


GRADER (!j PLANER 0 ROLLER 0 CRANE 0

Shop Manual F- •• I. Ri/c!

-rAIiDEM CASE SIIiGLE REDUC71011-

DOUBLE S7liAliD CHAIII WITH TAPERED AXLES AND KEY

Applicable Models Serial Numbers Applicable Models Serial Numbers

104B & C 09857 thru 11214 160B & C 02404 thru 03029 104HB 09857 thru 10693 T-400A 01001 & Up 118B & C 09857 thru 12013 T-500A & L 03290 thru 07994 160L 02601 thru 03083 T-600B 01823 thru 02535 (Cummins only) (Cummins & IH)

NOTE: Tandem housings need not be removed from machine for procedures shown. However~ we have removed the final drive and tandems from the grader for photographic purposes only.






CONTENTS Page

Torque Sheet . . . . . . Back of Cover Disassembly ..... . Reassembly . . . . . . . Di.agram & Procedure for use of wheel Lubrication . . . . . . . . . . . .

"knocker"

1 17 29 30

Dresser Industries, Inc. • Galion Division. South Street. P.O. Box 647 • Galion, OH 44833 U.S.A. C2 (419) 468-4321 • Telex: 987430 • Cable: Galiron

279


SHOP MANUAL

31

Remove wheel.

32

Remove key from axle.

33

Remove two brake shoe return springs and one (1) self-adjusting cable from shoe return spring pins. (arrows)

11

FILE F SECTION 9.10


It. DRESSER

GRADER iii PLANER 0 ROLLER 0 CRANED

SHOP MANUAL G-1.10 R2/C2

FRO.NT AXLE SPINDLE A'ND YOKE 'ASSEMBLY

APPUCABLE MODELS

104, A, B & C 160, A, B & C 160L T-400A T-500A & L T-600B

SERIAL NUMBERS

05790 thru 11213 01860 thru 03029 02101 thru 02307 01001 & Up 02054 thru 07994 01350 thru 02535

--.... --CAUTION-----ALL COMPONENTS MUST BE PROPERLY SUPPORTED DURING

DISASSEMB L Y AND ASSEMB L Y •




CONTENTS Page

Torque Sheet ..•. Disassembly ..... Inspection & Cleaning . Assembly . . . . • . .

. Back of Cover 1 3 4

DRESSER' MARKETING DIVISION EAST SUNNYSIDE AVE. UBERTYVILlE, IL 60048

C2 1181


DRESSER

MATERIAL LIFT q GRADER III PLANER ~ ROLLER 0 CRANE 0

SHOP MANUAL G-04.00 R4/C4

DRIVE AXLE (INDEPENDENT TYPE)

APPLICABLE MODELIS 104 B & C 104 HB 118 B & C 160 B & C 160 L T-500-A T-500-L T-600-B T-500-C T-500-M T-600-C RP-30/42 CAUTION

SERIAL NUMBERIS 07601 thru 11214 07619 thru 10692 07601 thru 12013 02155 thru 03029 02101 thru 03083 02601 thru 07994 03286 thru 07994 01501 thru 02535 07995 thru 10739 07995 thru 10487 02536 thru 03099 01001 thru 01123

All COMPONENTS MUST BE PROPERLY SUPPORTED DURING DISASSEMBLY AND REASSEMBLY.

All JACKING, HOISTING AND GENERAL WORKSHOP EQUIPMENT REQUIRED FOR THIS OPERATION MUST BE IN GOOD WORKING ORDER.



CONTENTS eAGE.

Torque Sheet • • • • • Removal Disassembly Cl eani n9 • •

. . . Inspection •••

. .

Reassembly • •• • Wear Pattern Procedure • Installation •••••

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . .

• Back of Cover • •• 1

• • •• 5 12

• •• 13 • •• 14

22 26 C4

I Dresser Industries. Inc. • Construction EQuipment Division • P.O. Box 647 • Galion. OH 44833 U.S.A. I~~J:':-:':s W·?Wf!I (419) 468-4321

078S


{!':-\~i

~~""',;J

Shop Manual FRONT AXLE ASSEMBLY

SERIAL NUMBERS

GRADER It PLANER lit ROLLER 0 CRANE 0

G-10 C1

APPLICABLE MODELS

104B & HB 104C

08758 thru 10749 except 08775 & 08776 10750 thru 11214

118B

118C 160B 160C 160L T-400A T-500A & L T-600B RP-30

08668 thru 08710 & 08723 thru 10749 except 08775 & 08776

10750 thru 12013 02308 thru 02714 02715 thru 03029 02308 thru 03083 01001 & Up 02990 thru 02996 & 03003 01501 thru 02535 01001 & Up




EXTREME CAUTION TO BE OBSERVED AT ALL TIMES TO PREVENT INJURY

SAFE WORKSHOP PRACTICES ARE A MUST

CONTENTS Torque Sheet . . . . . . . . . . . . Front Axle Assembly Removal ..... Yoke and Spindle Assembly Removal .. Yoke and Spindle Assembly Disassembly Cleaning and Inspection ...... . Yoke and Spindle Assembly Reassembly Yoke and Spindle Assembly Installation Front Axle Assembly Installation ...

. . . . . Back of Cover 1 5 9

12 13 16 23

Dresser Industries, Inc. • Construction Equipment Division • P.O. Box 647 • Galion, OH 44833 U.S.A. (419) 468·4321 • Telex: 987430 • Cable: Galiron C 1

0284

.'


.-- ..

DRESSER

MATERIAL LIFT 0 GRADER [!J PLANER 0 ROLLER 0 CRANE 0 ta·: ,fa 1; i :;! :.: ,t:, !~ I m i ,0 ~.:, ,: ~ , I J

SHOP MANUAL H-1.00 R2IC4

CIRCLE ADJUSTMENT (THREE SHOE)

APPLICABLE MODELIS

104 B, C & HB 118 B & C 160 B, C & L T-400-A T-500-A & L T-600-B

CAUTION

SERIAL NUMBERIS

09619 thru 11214 09619 thru 12013 02155 thru 03083 01001 thru 02110 03230 thru 07994 01668 thru 02535





CONTENTS EAG£

Torque Sheet • • • • • Circle Preparation •••••• Vertical Adjustment ••••• Pi n; on Adj ustment • • • • • • Lubrication •••••

. . . . . . . • · ·

. . . · ·

· Back of Cover

· · · 1

· · . . . 1

· 3

· · · 4

C4

I DRESSER E. a Dresser Industries. Inc. • Galion Division • South Street • P.O. Box 647 • Galion. OH 44833 U.S.A. INDUSTRIES .. 1'Mti, (419) 468-4321 • Telex: 987430 • Cable: Galiron

0785


__ DRESSER MATERIAL LIFT LJ

GRADER i1 PLANER It! ROLLER 0 CRANE 0 SHOP MANUAL K-1.10

R2/C5 REBUILD & ADJUSTMENT

OF SELF-ADJUSTING BRAKES APPLICABLE MODEL/S

104 118

160 T-400 A T-500 A & L T-600 B T-500 C T-500 M T-600 C A-400 E A/S 450/500 E A/S 560 E A-500 A-550 A-600 A-556/606 A-566 E

RP-30/42

SERIAL NUMBERIS

08824 thru 11214 08724 thru 08727, 08733, 08734, 08745 thru 08757 & 08824 thru 12013 02335 thru 03083 01001 thru 02110 03025 thru 07994 01653 thru 02535 07995 thru 10739 07995 thru 10487 02536 thru 03099 11501 & Up 10477 & Up 10893 & Up 09269 & Up 09251 & Up 02850 & Up 09725 & Up 11164 & Up

01001 thru 01123

r-----CAUTION----.. ALL COMPONENTS MUST BE PROPERLY SUPPORTED DURING

DISASSEMBL Y AND REASSEMBLY.




Torque Sheet . . . . . . Disassembly ...... .

Back of Cover 1

Grader Tapered Axle Wheel Reassembly . . . . . . Rim Centering Procedure . Brake Adjustment . .

Removal 1 5 8 9

DRESSER MARKETING DIVISION EAST SUNNYSIDE AVE. LIBERTYVILLE, IL 60048 0485 C5


__ DRESSER GRADER IiJ PLANER 0 ROLLER 0 CRANE I!f

SHOP MANUAL .Kic~ WAGNER POWER MASTER CYLINDER

USED WITH FOUR WHEEL SERVICE BRAKES

Two designs 0"( pow-er· "ma·s"ter-cYlinders-·"hav-e-been used on GALION equi pment; these wi 11 be referred to as the 1101 d styl ell and the II new styl ell • The disassembly of the power cylinder for both styles is the same, the difference between the two styles is in the master cylinder section. Identify the style of your power master cylinder by referring to the following list or to Figure 1, page 1.

GRADER MODELS

104C 104HB 118B 11aC 160B 160C 160L T-400A T-500A T-500L T-600 T-600B T-700 CRANE MODELS 80 90 thru 125 90A thru l25A 125F 150A 150FA 220A 25A Prime Mover

CONTENTS Power Function . . . . . . Manual Function ..... Disassembly of Power Unit

OLD STYLE

07601 thru 10181

02155 thru 02576


Reassembly of Power Unit . . . . • . Disassembly of Old Style Master Cylinder Reassembly of Old Style Master Cylinder Disassembly of New Style Master Cylinder. Reassembly of New Style Master Cylinder Special Tools ....... .

NEW STYLE

10750 thru 11214 10182 thru 10693 10182 thru 10750 10750 thru 12013 02577 thru 02705 02706 thru 03029 02581 thru 03083 01 007 thru 01745 03460 thru 07994 03460 thru 07994 01501 thru 02496 01779 thru 02535

04001 thru 07323 01254 thru 07323 02006 thru 07323 07247 thru 07323 02832 thru 07323 07305 thru 07323 07107 thru 07112 04331 thru 07323

. . - --- -_.

Page 3 3 4 8

11 13 16 17 19

DRESSER MARKETING DIVISION EAST SUNNYSIDE AVE. LIBERTYVILLE, IL 60048 Co

0183


CONTENTS PAGE

General Torque Values ................................. i Removal from Machine .................................. 1 Disassembly of Reservoir .............................. 2 Reassembly of Reservoir Section ....................... 3 Disassembly of Power Assist Section ................... 4 Reassembly of Power Assist Section.................... 5 Installation of Brake Valve on Machine ................ 8 Brake Bleeding Procedure .............................. 10

C2


It DRESSER

MATERIAL LIFT [if GRADER li1 PLANER [!J ROLLER Li1 CRANE 1!1

Shop Manual L-10

TROUBLESHOOTING & REMOVAL OF CRANKING MOTORS

APPLICABLE MODELS Although the style of mechanical linkage may vary from unit to unit (Bendix drive, exposed shift lever, enclosed shift lever, etc.), the basic components (solenoid, brushes, commutator, armature, etc.) and functions of cranking motor remain the same. Therefore, this Shop Manual covers basic service information for two specific motors of similar structure and/or ratings. Standard torque specifications apply unless otherwise stated.


DISASSEMBL Y AND ASSEMBL Y.

ALL JACKING. HOISTING, AND GENERAL WORKSHOP EQUIPMENT REQUIRED FOR THIS OPERATION MUST BE IN GOOD WORKING ORDER.



CONTENTS Torque Sheet Preliminary Checks Removal .... Bench Test; ng I nsta 11 ation . Lubrication .

DRESSER MARKETING DIVISION EAST SUNNYSIDE AVE.

Page Back of Cover

1 5 6 9

10

LIBERTYVILLE, IL 60048

C3

C3


MATERIAL LIFT I!f GRADER [if PLANER I!f ROLLER l!f CRANE I1f

·Shop Manual L-11

TROUBLESHOOTING & REMOVAL OF ALTERNATORS

APPLICABLE MODELS

Units with De1co-Remy alternators (10-SI Series & 27-SI Series, 100 Type)

-----CAUTION ----... ALL COMPONENTS MUST BE PROPERLY SUPPORTED DURING

DISASSEMBL Y AND ASSEMBLY.


EXTREME CAUTION TO BE OBSERVED AT ALL TIMES TO PREVENT INJURY


CONTENTS . Torque Sheet

Preliminary Checks Removal Installation Lubrication

Page Back~Cover

1 6 7 8

rJ~~~-'m~1 Dresser Industries. Inc. • Construction Eauipment Division. P.O. Box 647 • Galion. OH 44833 U.S.A. (419) 468·4321

0182

C1

C1


[ t.

Shop Manual

iCA"B-"liEATE-R-""'2S""OOOBTUJ"

~JHU"pP CORP.J

[!~PI!C"AB_lE MO.DEL): T-400-A T-500-A T-500-C T-500-L T-500-M T-600-8 T-600-C

RP-30/42

~SERIAL NUMBER~


01001 thru 01123

GRADER iii PLANER iii ROLLER 0 CRANED






CONTENTS Page Torque Sheet . . . . . . . . . . . . . Typical Cab Heater (26000 BTU) Removal

Back of Cover 1

Heater Disassembly ......... . Cleaning & Inspection ........ . Heater Reassembly . . . . . . . . . . . . . Typical Cab Heater (26000 BTU) Installation

3 5 6 8

Dresser Industries. Inc" • Construction Equipment Division. P"O. Box 647 • Galion. OH 44833 U.S.A. (419) 468·4321 • Telex: 987430 • Cable: Galiron

0786


(~-": ......

It DRESSER

MATERIAL LIFT [X] GRADER [X] PLANER [X] ROLLER [X]

CRANE [X]

SHOP MANUAL Y-01.00

GENERAL TORQUE VALUES APPLICABLE MODELS

ALL MODELS

CAUTION

SERIAL NUMBERS

ALL SERIAL NUMBERS





CONTENTS PAGE

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 TORQUES ....................................................... 2

TORQUE VALUES FOR STANDARD ENGLISH FASTENERS ................ 2 BOLT IDENTIFICATION CHART .................................. 2 TYPE 1,5 AND 8 NON-PHOSPHATE COATED HARDWARE ............. 2 TYPE 8 PHOSPHATE COATED HARDWARE ........................ 4

TORQUE VALUES FOR STANDARD METRIC FASTENERS ......... . . . . . . .. 5 TORQUE VALUES FOR HOSE CLAMPS .............................. 6 TORQUE VALUES FOR SPLIT FLANGE CONNECTIONS .................. 7 TORQUE VALUES FOR HYDRAULIC TUBES AND FITTINGS ............... 8


0989


Galion Grader Service Manual - Jensales Tractor … GRADER~ PLANER 0 ROLLER 0 CRANED Shop Manual A-9 R1/C2 VERTICAL STEERING SHAFT ASSEMBLY APPLICABLE MODELS 104B & C SERIAL NUMBERS

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