Service Manual. 555 Motor Grader
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1 Wabco Service Manual 555 Motor Grader Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF WABCO OR IT S SUCCESSORS. WABCO 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. WAB-S-555M/GDR
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3 TABLE OF CONTENTS SUBJECT GENERAL INFORMATION POWER TRAIN.. BRAKES AND TIRES MOLDBOARD, CIRCLE GEAR AND DRAWBAR GEAR HOUSINGS.. HYDRAULIC SYSTEM FRONT AXLE ASSEMBLY ELECTRICAL SYSTEM SECTION A B c D E F G H CAB AND ENCLOSURE RIPPER - SCARIFIER J lubrication AND SERVICE K
4 SECTION A GENERAL INFORMATION PRE-OPERATING CHECKS. INSTRUMENTS AND CONTROLS OPERATING INSTRUCTIONS SPECI F ICATIONS TORQUE CHART A-2 A-4 A-6 A-8 A-9 A-1
5 ) Moldboard Assembly Length and Width Lift for Ground Clearance Pitch Positions..... Bank Cutting Angle... Shoulder Reach (outside tires). Tires, Front and Rear (tubeless) Optional.... GRADE5 TORQUE CHART STANDARD HEX HEAD CAPSCREWS AND NUTS (Lubricated and Cadmium Plated Threads) Tolerance± 10% Capscrew Torque Torque Capscrew Torque or NutSize Grade 5 Grade 8 or Nut Size Grade 5 Ft. Lbs. Kg/M Ft. Lbs. Kg/M Ft. Lbs. Kg/M 1/ , ,38 3/ ,43 1/ ,1 11 1,52 7/ ,26 5/ , ,9 7/ ,42 5/ , ,38 3/ , , ,22 3/ , , ,61 7/ , ,02 1-1/ ,9 7/ , ,57 1-1/ ,81 1/ , ,45 1-1/ ,84 1/ , ,14 1-1/ ,83 9/ , ,29 1-3/ ,96 9/ , ,67 1-3/ ,17 5/ , ,2 1-1/ ,51 5/ , ,28 1-1/ ,11 3/ , ,97 12' x 28" 22-3/4" " RH 92" LH 14:00 x PR 16:00 x PR o GRADE8 Torque Grade 8 Ft. Lbs. Kg/M , , , , , , , , , , , , , ,1 i ) '-' A-9
6 SECTION B POWER TRAIN POWER TRAIN B-2 ENGINE 0 0 B-5 CLUTCH (OIL) UPPER TRANSMISSION LOWER TRANSMISSION FINAL DRIVE TANDEMS.. B B-23 B-26 B-29 B-1
7 FIGURE 14. CLUTCH REMOVAL 1. Hold-down 3. Pressure Plate Capscrews 4. Clutch to Flywheel 2. Backing Plate Capscrews FIGURE 16. FLYWHEEL 1. PTO Adaptor 3. Flywheel Adaptor 2. Bearing FIGURE 15. CLUTCH DISCS 1. Lined Disc 2. Steel Disc 3. Driven Hub Remove lined clutch disc from driven hub (Figure 15). Remove outer disc (steel) from flywheel adaptor. FIGURE 17. DISASSEMBLED CLUTCH 1. Pressure Springs 4. Pivot Pin 2. Anti-rattle Springs 5. Eye Bolt 3. Lever Pin Remove six capscrews (GM) retaining PTO adaptor to flywheel and remove PTO adaptor and bearing. Remove flywheel adaptor. Refer to Figure 16. Disassembly Place clutch backing plate and pressure plate proof washers from eye bolts. assembly in an arbor press and force backing plate down until hold-down bolts can be removed. Re- Remove clutch assembly from press. move hold-down bolts. Remove nuts and shake- B-8
8 Keep shims with bearing cage. Remove "0" ring from bearing cage. Remove bearing cups from both bearing cages. Remove bearing cones (4) from shaft. Press spiral bevel ring gear from shaft. NOTE: It will require a force of approximately 75 tons to remove ring gear. Remove square key and spacer from bull pinion shaft (6). Reassembly Reassembly of the final drive will be the reverse of disassembly procedure and the following information. 1. Install spacer on bull pinion shaft with chamfered side of bore toward bull pinion. 2. Heat spiral bevel gea. in hot oil (3500 ). Press gear onto bull pinion shaft until gear is tight against spacer. Hold under pressure until gear cools. 3. Heat bearing cones in hot oil and press onto shaft. Hold under pressure until bearings have cooled. 4. Install bearing cages with all the shims from both cages on the R.H. bearing cage. Tighten bearing cage capscrews to 190 ft. Ibs. of torque. Refer to Figure 61. Wrap sash cord around spacer (1) and pull with a fish scale (2). Rolling torque must be 12 to 15 Ibs. pull. Add or remove shims to obtain this rolling torque. FIGURE 62. BULL GEAR ROLLING TORQUE 1. Gear Hub 2. Scale 3. Adjusting Nut 5. Heat bull gear bearing cones in hot oil (350 0 ) and press cones onto bull gear hubs. Hold under pressure until bearings have cooled, FIGURE 61. CHECKING ROLLING TORQUE 1. Spacer 2. Scale FIGURE 63. PINION AND GEAR BACKLASH 1. Dial Indicator 2. Output Pinion 3. Bevel Gear 6. I nstall axle carrier capscrews and lock washers. Tighten to 275 ft. Ibs. of torque. Refer to Figure 62. Wrap sash cord around bull gear hub (1) and pull on fish scale (2). Tighten or loosen adjusting nut (3) until a rolling torque of 18 to 25 Ibs. pull is obtained. NOTE: Loosen bull pinion shaft_bearing cage capscrews before adjusting bull gear bearing preload. B-28
9 SECTION C BRAKES AND TIRES WHEEL BRAKES Operation Removal and Disassembly Installation... WHEEL CYLINDERS General Removal and Disassembly. Reassembly and Installation Bleeding Brakes... BRAKE MASTER CYLINDER Operation Removal and Disassembly Cleaning and Inspection. Reassembly and Installation Adjustment PARKING BRAKE Removal and Disassembly Inspection Reassembly and Installation Adj ustment. TIRES Inflation Chart C-2 C-2 C-4 C-4 C-4 C-4 C-5 C-5 C-6 C-7 C-7 C-7 C-7 C-9 C-9 C-10 C-10 C-12 C-1
10 SECTION 0 MOLDBOARD, CIRCLE GEAR AND DRAWBAR MANUAL SHIFT AND TILT Removal.... Disassembly..... Reassembly and Installation POWER SHIFT MOLDBOARD Removal.. Installation. Adjustment. TILT CYLINDERS (OPTIONAL) Removal. Installation CIRCLE GEAR Removal. Installation and Adjustment DRAWBAR Removal Installation D-2 D-3 D-3 D-4 D-6 D-6 D-6 D-7 D-7 D-7 D-8 D-9 D-1
11 SECTION E GEAR HOUSINGS LATERAL SHIFT GEAR ASSEMBLY Removal and Disassembly Inspection. Reassembly. Adjustment. BLADE LI FT GEAR ASSEMBLY Removal and Disassembly. Inspection and Reassembly CI RCLE REVE RSE GEAR ASSEMBLY Removal.... Disassembly.... Reassembly and Adjustment E-2 E-3 E-3 E-5 E-6 E-7 E-8 E-8 E-8 E-1
12 SECTION F HYDRAULIC SYSTEM HYDRAULIC SYSTEM Schematic... HYDRAULIC RESERVOIR HYDRAULIC PUMP. CONTROL VALVES PRESSURE RELIEF VALVE ROTARY VALVE HYDRAULIC CYLINDERS HYDRAULIC MOTORS. POWER STEERING GEAR STEERING SYSTEM Power Steering Gear F-2 F-3 F-4 F-8 F-11 F-12 F-14 F-15 F-18 F-18 F-18 F-'-1,....,.-.
13 SECTION G FRONT AXLE ASSEMBLY WHEEL, FORK AND SPINDLE Removal and Disassembly. Service and Inspection Reassembly and Installation STEERING LINKAGE Removal. Installation AXLE Removal Reassembly. Adjustment. G-2 G-4 G-4 G-5 G-5 G-6 G-7 G-8 G-1
14 SECTION H ELECTRICAL SYSTEM ELECTRICAL SYSTEM Batteries... Generator Cranking Motor ELECTRICAL SCHEMATICS Cummins Engine. GM Engine.... H-2 H-3 H-4 H-5 H-6 ) H-1
15 SECTION I CAB AND ENCLOSURE CAB AND ENCLOSURE.. Door Locks..... Door Latch Adjustment Glass Installation
16 SECTION J RIPPER - SCARIFIER RIPPER-SCARIFIER General Removal and Disassembly. Reassembly and Installation SCARIFIER General Removal HYDRAULIC CYLINDERS I nsta liation..... J-2 J-2 J-3 J-3 J-4 J-4 J-l
17 SECTION K LUBRICATION AND SERVICE LUBRICANT TYPE AND LOCATION K-2 TABLE OF HOUSING CAPACITIES. K-7 GREASE GUN LUBRICATION POINTS K-8 K-1
18 13. FUEL FLOAT TANK Clean screen at inlet fitting at same time fuel filter is changed. Do not clean screen with abrasive materials. Replace if damaged. 14. BYPASS LUBE OIL FILTER (CUMMINS) Change element every 100 homs. Fill filter before starting engine idle engine for approximately 5 minutes. Check for oil leaks. Recheck crankcase dipstick and add oil as necessary. BYPASS LUBE OIL FILTERS (GM) Change elements every 250 hours or more often under adverse conditions. 15. CORROSION RESISTOR (CUMMINS) The corrosion resistor is located in the cooling system to prevent the deteriorati'on of metals due to acid or salt. Regular servicing intervals are necessary for effective operation. Remove and change element every 200 to 300 hours if test facilities are not available to determine amount of corrosive products in coolant. When installing filter, lubricate gasket and spin filter on threaded adapter to gasket contact. Add 1/2 to 3/4 turn. Do not overtighten. Refer to engine manufacturer's operation and maintenance manual for test procedures. 16. HYDRAULIC RESERVOIR FILTER The hydraulic reservoir filter elements should be changed after the first 50 to 75 working hours have been accumulated on a new motor grader. Thereafter, the elements should be changed every 500 hours of operation. K-6
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