CEBD004802

CEBM004802
Shop
Manual
D87E-2
D87P-2
CRAWLER TRACTOR
SERIAL NUMBERS
D87E-2 - P090001 and UP
D87P-2 - P092001
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except
in accordance with written authorization from Komatsu America International Company
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recom-
mended that customers contact their distributor for information on the latest revision.
D87E-2 D87P-2
September 2002 Copyright 2000 Komatsu

2 DataKom Publishing Corporation
12
CONTENTS 00
00 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . 10-1
20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-1
90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
22 D87E-2 D87P-2
PRODUCT PUBLICATIONS INFORMATION
Various product Parts and Service Publications are available to all KOMATSU construction equipment
owners, including operation and maintenance manuals, parts books and service manuals.
Special publications, such as service tool, air conditioning and turbocharger service manuals are also
available as well as selected Operation and Service manuals in foreign languages.
The Publications listed below are available for this particular machine(s).
DESCRIPTION FORM NUMBER
PARTS BOOK - PAPER:
Chassis and Engine - D87E-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB008300

Chassis and Engine - D87P-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB008700
OPERATION AND MAINTENANCE MANUAL:
Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM007302
SHOP MANUAL
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM004802
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEBM006409
SAFETY MANUAL
Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLT80-1
Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the Ko-
matsu America International Company Parts Inventory Processing System (PIPS).
If the PIPS system is not available at the distributor location, then the following Requisition for Technical
Service Publications and Service Forms can be used. Form KDC91E is shown on the reverse side of this
page.
PUBINFO.fm 9/24/02
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM
AND RETURN TO ö DataKom Publishing Division
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME
PURCHASE ORDER NO.
SHIP TO ö
ATTN.
STREET ADDRESS ORDER DATE

TYPE or PRINT CITY, STATE, ZIP CODE
ONLY ö
COUNTRY
PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE
SERIAL NUMBER MUST BE SHOWN.
PARTS BOOK
PUBLICATION
QTY. PUBLICATION FORM NO. P-Paper MODEL NUMBER SERIAL NUMBER
DESCRIPTION
M-Microfiche
KDC91E 072199 CURRENT PRICES WILL BE CHARGED

LIST OF ORIGINAL, NEW OR REVISED PAGES
12
The affected pages are indicated by using the following marks. It is Mark Indication Action
requested that necessary actions be taken to these pages according
to the table below. ❍ New page to be added Add
Pages w/o marks are previous additions or revised pages. ● Page to be replaced Replace
( ) Page to be deleted Discard

LIST OF ORIGINAL, NEW OR REVISED PAGES CEBM004802
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
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● 00-9 2 ● 10-14 2 ● 10-58 2 ● 10-102 2
● 00-10 2 ● 10-15 2 ● 10-59 2 ❍ 10-103 2
● 00-11 2 ● 10-16 2 ● 10-60 2 ❍ 10-104 2
● 00-12 2 ● 10-17 2 ● 10-61 2 ❍ 10-105 2
● 00-13 2 ● 10-18 2 ● 10-62 2 ❍ 10-106 2
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● 10-27 2 ● 10-71 2 ❍ 10-115 2
● 01-1 2 ● 10-28 2 ● 10-72 2 ❍ 10-116 2
● 01-2 2 ● 10-29 2 ● 10-73 2 ❍ 10-117 2
● 01-3 2 ● 10-30 2 ● 10-74 2 ❍ 10-118 2
● 01-4 2 ● 10-31 2 ● 10-75 2 ❍ 10-119 2
● 01-5 2 ● 10-32 2 ● 10-76 2 ❍ 10-120 2
● 01-6 2 ● 10-33 2 ● 10-77 2 ❍ 10-121 2
● 01-7 2 ● 10-34 2 ● 10-78 2 ❍ 10-122 2
● 01-8 2 ● 10-35 2 ● 10-79 2 ❍ 10-123 2
● 01-9 2 ● 10-36 2 ● 10-80 2 ❍ 10-124 2
● 01-10 2 ● 10-37 2 ● 10-81 2 ❍ 10-125 2
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❍ 01-13 2 ● 10-40 2 ● 10-84 2 ❍ 10-128 2
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D87E-2 D87P-2 3 2
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❍ 10-139 2 ● 20-16 2 ● 30-23 2 ● 30-75 2
❍ 10-140 2 ● 20-17 2 ● 30-24 2 ● 30-76 2
❍ 10-141 2 ● 20-18 2 ● 30-25 2 ● 30-77 2
❍ 10-142 2 ● 20-19 2 ● 30-26 2 ● 30-78 2
❍ 10-143 2 ● 20-20 2 ● 30-27 2 ● 30-79 2
❍ 10-144 2 ● 20-21 2 ● 30-28 2 ● 30-80 2
❍ 10-145 2 ● 20-22 2 ● 30-29 2 ● 30-81 2
❍ 10-146 2 ● 20-23 2 ● 30-30 2 ● 30-82 2
❍ 10-147 2 ● 20-24 2 ● 30-31 2 ● 30-83 2
❍ 10-148 2 ● 20-25 2 ● 30-32 2 ● 30-84 2
❍ 10-149 2 ● 20-26 2 ● 30-33 2 ● 30-85 2
❍ 10-150 2 ● 20-27 2 ● 30-34 2 ● 30-86 2
❍ 10-151 2 ● 20-28 2 ● 30-35 2 ● 30-87 2
❍ 10-152 2 ● 20-29 2 ● 30-36 2 ● 30-88 2
❍ 10-153 2 ● 20-30 2 ● 30-37 2 ● 30-89 2
❍ 10-154 2 ● 20-31 2 ● 30-38 2 ● 30-90 2
❍ 10-155 2 ● 20-32 2 ● 30-39 2 ● 30-91 2
❍ 10-156 2 ● 20-33 2 ● 30-40 2 ● 30-92 2
❍ 10-157 2 ● 20-34 2 ● 30-41 2 ● 30-93 2
❍ 10-158 2 ● 20-35 2 ● 30-42 2 ● 30-94 2
❍ 10-159 2 ● 20-36 2 ● 30-43 2 ● 30-95 2
❍ 10-160 2 ● 20-37 2 ● 30-44 2 ● 30-96 2
❍ 10-161 2 ● 20-38 2 ● 30-45 2 ● 30-97 2
❍ 10-162 2 ● 20-39 2 ● 30-46 2 ● 30-98 2
❍ 10-163 2 ● 20-40 2 ● 30-47 2 ● 30-99 2
❍ 10-164 2 ● 20-41 2 ● 30-48 2 ● 30-100 2
❍ 10-165 2 ● 20-42 2 ● 30-49 2 ● 30-101 2
❍ 10-166 2 ❍ 20-43 2 ● 30-50 2 ● 30-102 2
❍ 10-167 2 ❍ 20-44 2 ● 30-51 2 ● 30-103 2
❍ 10-168 2 ● 30-52 2 ● 30-104 2
❍ 10-169 2 ● 30-1 2 ● 30-53 2 ● 30-105 2
❍ 10-170 2 ● 30-2 2 ● 30-54 2 ● 30-106 2
❍ 10-171 2 ● 30-3 2 ● 30-55 2 ● 30-107 2
❍ 10-172 2 ● 30-4 2 ● 30-56 2 ● 30-108 2
❍ 10-173 2 ● 30-5 2 ● 30-57 2 ● 30-109 2
❍ 10-174 2 ● 30-6 2 ● 30-58 2 ● 30-110 2
● 30-7 2 ● 30-59 2 ● 30-111 2
● 20-1 2 ● 30-8 2 ● 30-60 2 ● 30-112 2
● 20-2 2 ● 30-9 2 ● 30-61 2 ● 30-113 2
● 20-3 2 ● 30-10 2 ● 30-62 2 ● 30-114 2
● 20-4 2 ● 30-11 2 ● 30-63 2 ● 30-115 2
● 20-5 2 ● 30-12 2 ● 30-64 2 ● 30-116 2
● 20-6 2 ● 30-13 2 ● 30-65 2 ● 30-117 2
42 D87E-2 D87P-2
● 30-118 2 ● 30-170 2 ● 30-222 2 ● 30-274 2
● 30-119 2 ● 30-171 2 ● 30-223 2 ● 30-275 2
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● 30-140 2 ● 30-192 2 ● 30-244 2 ● 30-296 2
● 30-141 2 ● 30-193 2 ● 30-245 2 ● 30-297 2
● 30-142 2 ● 30-194 2 ● 30-246 2 ● 30-298 2
● 30-143 2 ● 30-195 2 ● 30-247 2 ● 30-299 2
● 30-144 2 ● 30-196 2 ● 30-248 2 ● 30-300 2
● 30-145 2 ● 30-197 2 ● 30-249 2 ● 30-301 2
● 30-146 2 ● 30-198 2 ● 30-250 2 ● 30-302 2
● 30-147 2 ● 30-199 2 ● 30-251 2 ● 30-303 2
● 30-148 2 ● 30-200 2 ● 30-252 2 ● 30-304 2
● 30-149 2 ● 30-201 2 ● 30-253 2 ● 30-305 2
● 30-150 2 ● 30-202 2 ● 30-254 2 ● 30-306 2
● 30-151 2 ● 30-203 2 ● 30-255 2 ● 30-307 2
● 30-152 2 ● 30-204 2 ● 30-256 2 ● 30-308 2
● 30-153 2 ● 30-205 2 ● 30-257 2 ❍ 30-309 2
● 30-154 2 ● 30-206 2 ● 30-258 2 ❍ 30-310 2
● 30-155 2 ● 30-207 2 ● 30-259 2 ❍ 30-311 2
● 30-156 2 ● 30-208 2 ● 30-260 2 ❍ 30-312 2
● 30-157 2 ● 30-209 2 ● 30-261 2 ❍ 30-313 2
● 30-158 2 ● 30-210 2 ● 30-262 2 ❍ 30-314 2
● 30-159 2 ● 30-211 2 ● 30-263 2 ❍ 30-315 2
● 30-160 2 ● 30-212 2 ● 30-264 2 ❍ 30-316 2
● 30-161 2 ● 30-213 2 ● 30-265 2 ❍ 30-317 2
● 30-162 2 ● 30-214 2 ● 30-266 2 ❍ 30-318 2
● 30-163 2 ● 30-215 2 ● 30-267 2 ❍ 30-319 2
● 30-164 2 ● 30-216 2 ● 30-268 2 ❍ 30-320 2
● 30-165 2 ● 30-217 2 ● 30-269 2 ❍ 30-321 2
● 30-166 2 ● 30-218 2 ● 30-270 2 ❍ 30-322 2
● 30-167 2 ● 30-219 2 ● 30-271 2 ❍ 30-323 2
● 30-168 2 ● 30-220 2 ● 30-272 2 ❍ 30-324 2
● 30-169 2 ● 30-221 2 ● 30-273 2 ❍ 30-325 2
D87E-2 D87P-2 5 2
Mark Page Rev Mark Page Rev

❍ 30-326 2 ( ) 40-31 2
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❍ 30-328 2 ( ) 40-33 2
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❍ 30-345 2 ( ) 40-50 2
❍ 30-346 2 ( ) 40-51 2
( ) 40-52 2
( ) 40-1 2 ( ) 40-53 2
( ) 40-2 2 ( ) 40-54 2
( ) 40-3 2 ( ) 40-55 2
( ) 40-4 2 ( ) 40-56 2
( ) 40-5 2 ( ) 40-57 2
( ) 40-6 2 ( ) 40-58 2
( ) 40-7 2 ( ) 40-59 2
( ) 40-8 2 ( ) 40-60 2
( ) 40-9 2 ( ) 40-61 2
( ) 40-10 2 ( ) 40-62 2
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( ) 40-12 2 ( ) 40-64 2
( ) 40-13 2 ( ) 40-65 2
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( ) 40-17 2 ( ) 40-69 2
( ) 40-18 2 ( ) 40-70 2
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( ) 40-20 2 ( ) 40-72 2
( ) 40-21 2 ( ) 40-73 2
( ) 40-22 2 ( ) 40-74 2
( ) 40-23 2 ( ) 40-75 2
( ) 40-24 2 ( ) 40-76 2
( ) 40-25 2
( ) 40-26 2 ● 90-1 2
( ) 40-27 2 90-2
( ) 40-28 2
( ) 40-29 2
( ) 40-30 2
62 D87E-2 D87P-2
00 FOREWORD
12
SAFETY NOTICE .................................................................................................................................................................. 00-2
GENERAL PRECAUTIONS .............................................................................................................................................. 00-2
PREPARATIONS FOR WORK.......................................................................................................................................... 00-2
PRECAUTIONS DURING WORK ................................................................................................................................ 00-2
IMPORTANT SAFETY NOTICE................................................................................................................................... 00-2
GENERAL .............................................................................................................................................................................. 00-4
GENERAL........................................................................................................................................................................... 00-4
STRUCTURE, FUNCTION & MAINTENANCE STANDARD....................................................................................... 00-4
TESTING AND ADJUSTING ............................................................................................................................................ 00-4
DISASSEMBLY AND ASSEMBLY .................................................................................................................................. 00-4
HOW TO READ THE SHOP MANUAL............................................................................................................................... 00-5
VOLUMES .......................................................................................................................................................................... 00-5
DISTRIBUTION AND UPDATING .................................................................................................................................. 00-5
FILING METHOD .............................................................................................................................................................. 00-5
REVISED EDITION MARK .............................................................................................................................................. 00-5
REVISIONS ........................................................................................................................................................................ 00-5
SYMBOLS .......................................................................................................................................................................... 00-6
HOISTING INSTRUCTIONS ................................................................................................................................................ 00-7
HOISTING .......................................................................................................................................................................... 00-7
WIRE ROPES...................................................................................................................................................................... 00-7
COATING MATERIALS ....................................................................................................................................................... 00-8
STANDARD TIGHTENING TORQUE ................................................................................................................................ 00-9
METRIC FASTENERS....................................................................................................................................................... 00-9
NUTS AND BOLTS ........................................................................................................................................................ 00-9
HOSE NUTS.................................................................................................................................................................. 00-10
SPLIT FLANGE BOLTS............................................................................................................................................... 00-10
FLARED NUTS............................................................................................................................................................. 00-10
ALTERNATIVE FASTENERS ........................................................................................................................................ 00-11
BOLT IDENTIFICATION CHART.............................................................................................................................. 00-11
GRADE 5 AND 8 NON-PHOSPHATE COATED HARDWARE............................................................................... 00-12
GRADE 8 PHOSPHATE COATED HARDWARE ..................................................................................................... 00-13
STANDARD METRIC FASTENERS .......................................................................................................................... 00-13
HYDRAULIC TUBES AND FITTINGS ...................................................................................................................... 00-14
HOSE CLAMPS ............................................................................................................................................................ 00-14
SPLIT FLANGE CONNECTIONS ............................................................................................................................... 00-14
ELECTRIC WIRE CODE..................................................................................................................................................... 00-15
CLASSIFICATION BY THICKNESS ............................................................................................................................. 00-15
CLASSIFICATION BY COLOR AND CODE ................................................................................................................ 00-15
CONVERSION TABLES ..................................................................................................................................................... 00-16
METHOD OF USING THE CONVERSION TABLE ..................................................................................................... 00-16
D87E-2 D87P-2 00-1 2

FOREWORD SAFETY NOTICE
12SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations re-
quire the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions ac-
companying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first
consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully before op-
erating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with
buttons missing. Always wear safety glasses when hitting parts with a hammer. or grinding parts with a grinder, etc. If
welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding
work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
2. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Al-
ways inform your fellow workers before starting any step of the operation. Before starting work, hang under repair signs
on the controls in the operator's compartment. Keep all tools in good condition and learn the correct way to use them. De-
cide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct plac-
es. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK

1. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the
machine from moving. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If
this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to
lock all the control levers and hang warning signs on them.
2. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. Remove all
mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps
when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
PRECAUTIONS DURING WORK
1. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil
from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure
completely from the circuit. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get
burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. Before starting work,
remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
2. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
00-2 2 D87E-2 D87P-2

FOREWORD SAFETY NOTICE
12
3. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in posi-
tion on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. When removing components,
be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
4. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires. As a general rule, do not use gasoline to wash parts. In
particular, use only the minimum of gasoline when washing electrical parts. Be sure to assemble all parts again in their
original places. Replace any damaged part with new parts. When installing hoses and wires, be sure that they will not be
damaged by contact with other parts when the machine is being operated.
5. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. When as-
sembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards,
or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.
6. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When mea-
suring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. Take
care when removing or installing the tracks. When removing the track, the track separates suddenly, so never let anyone
stand at either end of the track.
D87E-2 D87P-2 00-3 2

FOREWORD GENERAL
12
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate under-
standing of the product and by showing him the correct way to perform repairs and make judgements. Make sure you under-
stand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
● This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE, FUNCTION & MAINTENANCE STANDARD

● This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting. This section also gives the judgement standards when
inspecting disassembled parts.
TESTING AND ADJUSTING

● This section explains checks to be made before and after performing repairs, as well as adjustments to be made at comple-
tion of the checks and repairs. Troubleshooting charts correlating problems to causes are also included in this section.
DISASSEMBLY AND ASSEMBLY

● This section explains the order to follow when removing, installing, disassembling or assembling each component, as well
as precautions to be taken for these operations.
REMARK
The specifications contained in this shop manual are subject to change at any time and without any advance
notice. Contact your distributor for the latest information.
00-4 2 D87E-2 D87P-2

FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL
VOLUMES
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series
Electrical volume: Each issued as one to cover all models
Attachment volume: Each issued as one to cover all models
These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is
necessary that chassis, engine, electrical and attachment be available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you
start any work.
FILING METHOD
1. See the page number on the bottom of the page. File the pages in correct order.
2. Following examples show how to read the page number:
Example:
10 - 3
Section number (10 Structure and Function)
Consecutive page number for each item
3. Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the exam-
ple following.
Example:
10-4
10-4-1
Added pages
10-4-2
10-5
REVISED EDITION MARK

When a manual is revised, an edition mark (123…) is recorded after the page number.
REVISIONS
Revised pages are shown at the LIST OF REVISED PAGES after the title page.
D87E-2 D87P-2 00-5 2

FOREWORD HOW TO READ THE SHOP MANUAL
12
SYMBOLS
So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following
symbols.
Symbol Item Remarks
Safety Special safety precautions are necessary when performing the work.
★ Caution
Special technical precautions or other precautions for preserving standards are necessary when perform-
ing the work.
Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is
Weight
important, etc.
Torque Places that require special attention for tightening torque during assembly.
Coat Places to be coated with adhesives and lubricants etc.
Liquid Places where oil, water or fuel must be added, and the capacity.
Drain Places where oil or water must be drained, and quantity to be drained.
00-6 2 D87E-2 D87P-2

FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS
HOISTING
WARNING! Heavy parts, 25 kg or more, must be lifted with a hoist. In Section 30, every part
weighing that or more is indicated clearly with this symbol.
● If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made:
1. Check for removal of all bolts fastening the part to the relative parts. Check for existence of another part causing interface
with the part to be removed.
WIRE ROPES
1. Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below
Wire ropes (Standard “Z” or “S” twist ropes without galvanizing)

Rope diameter Allowable load Rope diameter Allowable load
mm kN tons mm kN tons
10 9.8 1 20 43.1 4.4
11.2 13.7 1.4 22.4 54.9 5.6
12.5 15.7 1.6 30 98.1 10
14 21.6 2.2 40 176.5 18
16 27.5 2.8 50 274.6 28
18 35.3 3.6 60 392.2 40
★ The allowable load value is estimated to be 1/6 or 1/7 of the break-

ing strength of the rope used.
2. Sling wire ropes from the middle portion of the hook. Slinging near
the edge of the hook may cause the rope to slip off the hook during
hoisting, and a serious accident can result. Hooks have maximum
strength at the middle portion. Do not sling a heavy load with one
rope alone, but sling with two or more ropes symmetrically wound
on to the load.
WARNING! Slinging with one rope may cause turn-

ing of the load during hoisting, untwisting of the
rope, or slipping of the rope from its original winding
position on the load, which can result in a dangerous
accident.
3. Do not sling a heavy load with ropes forming a wide hanging angle
from the hook. When hoisting a load with two or more ropes, the
force subjected to each rope will increase with the hanging angles.
The table below shows the variation of allowable load (kg) when
hoisting is made with two ropes, each of which is allowed to sling
up to 1000 kg vertically, at various hanging angles. When two
ropes sling a load vertically, up to 2000 kg of total weight can be
suspended. This weight becomes 1000 kg when two ropes make a
120° hanging angle. On the other hand, two ropes are subject to an
excessive force as large as 4000 kg if they sling a 2000 kg load at a
lifting angle of 150°.
D87E-2 D87P-2 00-7 2

FOREWORD COATING MATERIALS
12
COATING MATERIALS
★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
LT-1A 790-129-9030 150 g Tube

● Used to prevent rubber gaskets, rubber cushions and cork plugs
from coming out
● Used in places requiring an immediately effective, strong adhe-
20 g
sive
LT-1B 790-129-9050 Polyethylene container
(2 pes.) ● Used for plastics (except polyethylene, polypropylene, tetraflu-
oroethylene, and vinyl chloride), rubber, metal and non-metal
● Features: Resistance to heat, chemicals
LT-2 09940-00030 50 g Polyethylene container ● Used for anti-loosening and sealant purposes for bolts and
plugs
Adh.: 1 kg Agent:
LT-3 790-129-9060
500 g
Can ● Used as adhesive or sealant for metal, glass or plastic
Adhesives
LT-4 790-129-9040 250 g Polyethylene container 1. Used as sealant for machined holes
Holtz MH 705 790-126-9120 75 g Tube 2. Used as heat resistant sealant for engine repair
3. Quick hardening type adhesive
Three bond 4. Cure time: within 5 sec. to 3 min.
179-129-9140 2g Polyethylene container
1735 5. Used mainly for adhesion of metals, rubbers, plastics and
woods
6. Quick hardening type adhesive
Aron alpha
790-129-9130 50 g Polyethylene container 7. Quick cure type (max. strength after 30 min.)
201
8. Used mainly for adhesion of rubbers, plastics and metals
9. Features: Resistance to heat, chemicals
Loctite 648-50 79A-129-9110 50 cc Polyethylene container
10. Used at joint portions subject to high temps
LG-1 790-129-9010 200 g Tube

● Used as adhesive or sealant for gaskets and packing of power
train case, etc.
● Features: Resistance to heat
● Used as sealant for flange surfaces and bolts at high tempera-
LG-3 790-129-9070 1 kg Can ture locations; used to prevent seizure
● Used as sealant for heat resistant gasket for at high temperature
locations such as engine pre-combustion chamber, exhaust pipe
● Features: Resistance to water, oil
● Used as sealant for flange surface, thread
LG-4 790-129-9020 200 g Tube ● Also possible to use as sealant for flanges with large clearance
● Used as sealant for mating surfaces of final drive case, trans-
mission case
Gasket sealant
● Used as sealant for various threads, pipe joints, flanges
LG-5 790-129-9080 1 kg Polyethylene container ● Used as sealant for tapered plugs, elbows, nipples of hydraulic
piping
● Features: Silicon based, resistant to heat, cold
LG-6 09940-00011 250 g Tube ● Used as sealant for flange surface, thread
● Used as sealant for oil pan, final drive case, etc.
● Features: Silicon based, quick hardening type
LG-7 09920-00150 150 g Tube ● Used as sealant for flywheel housing, intake manifold, oil pan,
thermostat housing, etc.
Three bond
1211
790-129-9090 100 g Tube ● Used as heat-resisting sealant for repairing engines
LM-G 09940-00051 60 g Can ● Used as lubricant for sliding parts (to prevent squeaking)
Molybdenum
disulfide ● Used to prevent seizure or scuffing of the thread when press fit-
lubricant LM-P 09940-00040 200 g Tube ting or shrink fitting
● Used as lubricant for linkage, bearings, etc.
SYG2-400LI SYG2-
350LI SYG2-400LI-A
G2-LI
SYG2-160LI
Various Various ● General purpose type
SYGA160CNLI
SYG2-400CA SYG2-
Grease
G2-CA
350CA SYG2-400CA-A
Various Various
● Used for normal temperature, light load bearing at places in
SYG2-160CA SYG2- contact with water or steam
160CNCA
Molybdenum
400 g
disulfide SYG2-400M
(10 per case)
Belows type ● Used for places with heavy load
lubricant
00-8 2 D87E-2 D87P-2

FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE
METRIC FASTENERS
NUTS AND BOLTS
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
Thread diameter Width across flats
mm mm N•m lbf ft
6 10 13.2 ± 1.4 9.7 ± 1
8 13 31.4 ± 2.9 23 ± 2
10 17 65.7 ± 6.8 48 ± 5
12 19 112 ± 9.8 83 ± 7
14 22 177 ± 19 131 ± 14
16 24 279 ± 29 206 ± 21
18 27 383 ± 39 282 ± 29
20 30 549 ± 58 405 ± 43
22 32 745 ± 78 550 ± 58
24 36 927 ± 98 684 ± 72
27 41 1320 ± 140 974 ± 103
30 46 1720 ± 190 1269 ± 140
33 50 2210 ± 240 1630 ± 177
36 55 2750 ± 290 2028 ± 214
39 60 3280 ± 340 2419 ± 251
Thread diameter Width across flats
mm mm N•m lbf ft
6 10 7.9 ± 1.95 6 ± 1.4
8 13 18.6 ± 4.9 14 ± 3.6
10 14 40.2 ± 5.9 30 ± 4.3
12 27 82.4 ± 7.85 61 ± 5.7
D87E-2 D87P-2 00-9 2

12
HOSE NUTS
Thread diameter Across flats Tightening torque

Nominal No.
mm mm N•m lbf ft
02 14 19 24.5 ± 4.9 18 ± 3.6
03 18 24 49 ± 19.6 36 ± 14
04 22 27 78.5 ± 19.6 58 ± 14
05 24 32 137.3 ± 29.4 101 ± 22
06 30 36 176.5 ± 29.4 130 ± 22
10 33 41 196.1 ± 49 145 ± 36
12 36 46 245.2 ± 49 181 ± 36
14 42 55 294.2 ± 49 217 ± 36
SPLIT FLANGE BOLTS

mm mm N•m lbf ft
10 14 65.7 ± 6.8 48 ± 5
12 17 112 ± 9.8 83 ± 7
16 22 279 ± 29 206 ± 21
FLARED NUTS

mm mm N•m lbf ft
14 19 24.5 ± 4.9 18 ± 3.6
18 24 49 ± 19.6 36 ± 14
22 27 78.5 ± 19.6 58 ± 14
24 32 137.3 ± 29.4 101 ± 22
30 36 176.5 ± 29.4 130 ± 22
33 41 196.1 ± 49 145 ± 36
36 46 245.2 ± 49 181 ± 36
42 55 294.2 ± 49 217 ± 36
00-10 2 D87E-2 D87P-2

12
ALTERNATIVE FASTENERS
BOLT IDENTIFICATION CHART
TYPE/CLASS DESCRIPTION HEAD MARK

Type 5 Three radial lines on top and none on side of head. Medium carbon steel quenched
Inch Thread and tempered.
Type 5.2 Three radial lines on top and none on side of head. Low carbon boron steel
Inch Thread quenched and tempered.
Type 8 Six radial lines on top and none on side of head. Medium carbon or carbon alloy
Inch Thread steel quenched and tempered.
Type 8.2 Six radial lines on top and none on side of head. Low carbon boron steel quenched
Inch Thread and tempered.
Class 5.8
Marked on top or side of head. Low or medium carbon steel.
Metric Thread
Class 8.8 Marked on top or side of head. Medium carbon or carbon alloy or low carbon bo-
Metric Thread ron steel quenched and tempered.
Type 8R Six radial lines on head with type designation, none on sides. Medium carbon or
Inch Thread medium carbon alloy steel quenched and tempered.
Type 8R Six radial lines on head with type designation, none on sides. Low carbon boron
Type 9 Six radial lines on head with type designation, none on sides. Medium carbon alloy
Type 9R Six radial lines on head with type designation, none on sides. Medium carbon alloy
Class 10.9R Marked on top or side of head. Medium carbon or carbon alloy steel quenched and
Metric Thread tempered.
Class 10.9R Marked on top or side of head and underlined. Low carbon boron steel quenched
Metric Thread and tempered.
Class 12.9
Marked on top or side of head. Medium carbon alloy steel quenched and tempered.
Metric Thread
Class 12.9R
Marked on top or side of head. Medium carbon alloy steel quenched and tempered.
Metric Thread
D87E-2 D87P-2 00-11 2

GRADE 5 AND 8 NON-PHOSPHATE COATED HARDWARE
Recommended torque for all standard application nuts and bolts, provided; all thread surfaces are clean and lubricated with
SAE-30 engine oil or joints are rigid, that is, no gaskets or compressible materials are used. When reusing nuts or bolts, use
minimum torque values.
GRADE 5 GRADE 8
THREAD THREAD
N•m lbf ft N• m lbf ft
1/4NC 8 6 1/4NC 12 9
1/4NF 9 7 1/4NF 15 11
5/16NC 18 13 5/16NC 24 18
5/16NF 20 15 5/16NF 28 21
3/8NC 33 24 3/8NC 46 34
3/8NF 37 27 3/8NF 52 38
7/16NC 52 38 7/16NC 73 54
7/16NF 57 42 7/16NF 81 60
1/2NC 79 58 1/2NC 111 82
1/2NF 88 65 1/2NF 122 90
9/16NC 114 84 9/16NC 163 120
9/16NF 126 93 9/16NF 179 132
5/8NC 156 115 5/8NC 224 165
5/8NF 175 130 5/8NF 251 185
3/4NC 278 205 3/4NC 393 290
3/4NF 312 240 3/4NF 434 320
7/8NC 414 305 7/8NC 617 455
7/8NF 454 334 7/8NF 698 515
1NC 617 455 1NC 942 695
1NF 691 510 1NF 1064 785
1-1/8NC 827 610 1-1/8NC 1342 990
1-1/8NF 929 685 1-1/8NF 1505 1110
1-1/4NC 1166 860 1-1/4NC 1898 1400
1-1/4NF 1295 955 1-1/4NF 2102 1550
1-3/8NC 1532 1130 1-3/8NC 2481 1830
1-3/8NF 1749 1290 1-3/8NF 2827 2085
1-1/2NC 2034 1400 1-1/2NC 3295 2430
1-1/2NF 2291 1690 1-1/2NF 3701 2730
1-3/4NC 3213 2370 1-3/4NC 5166 3810
2NC 4813 3550 2NC 7810 5760
Multiply the standard torque by 0.65 when finished jam nuts are used, 0.7 when molykote, white lead or similar mixture are
used as lubricants, 0.75 when parkerized bolts or nuts are used, 0.85 when cadmium plated bolts or nuts and zinc bolts with
waxed zinc nuts are used or 0.9 when hardened surfaces are used under the nut or bolt head. The general torque must be used
in all cases where special torques are not given. Values listed in this manual are lubricated (wet) threads; values should be
increased 1/3 for non lubricated (dry) threads.
00-12 2 D87E-2 D87P-2

GRADE 8 PHOSPHATE COATED HARDWARE
NOMINAL STANDARD TORQUE ± 10% This chart provides tightening torque for general purpose
THREAD N•m lbf ft applications using original equipment standard hardware as
1/4 10 8 listed in the Parts Books for the machine involved.
5/16 21 16 DO NOT SUBSTITUTE.
3/8 38 28
7/16 60 45 Original equipment standard hardware is defined as Grade 8,
1/2 92 70 coarse thread bolts and nuts and thru hardened flat washers
(Rockwell C 38-45), all phosphate coated and assembled
9/16 130 100
without supplemental lubrication (as received) condition.
5/8 180 140
3/4 325 240 The torques shown also apply to the following;
7/8 520 590
Phosphate coated bolts used in tapped holes in steel or
1 780 580
gray iron. Phosphate coated bolts used with phosphate
1-1/8 1110 820 coated prevailing torque nuts (nuts with distorted threads
1-1/4 1565 1160 or plastic inserts). Phosphate coated bolts used with cop-
1-3/8 2050 1520 per plated weld nuts.
1-1/2 2720 2020
Markings on bolt heads or nuts indicate material grade only
1-3/4 3380 2510
and are not to be used to determine required torque.
2 5080 3780
STANDARD METRIC FASTENERS
NOMINAL STANDARD TORQUE ± 10% This chart provides tightening torque for general purpose
THREAD N•m lbf ft applications using original standard hardware as listed in the
6 10 7 Parts Book for the machine involved.
7 16 12 DO NOT SUBSTITUTE.
8 23 17
10 46 34 Original standard hardware is defined as metric class 10.9
12 80 60 bolts and class 10.0 nuts and thru flat washers (Rockwell C
38-45), all phosphate coated and assembled without supple-
14 125 90
mental lubrication.
16 200 150
18 275 200 The torques shown also apply to the following;
20 385 290
Phosphate bolts used in tapped holes in steel or gray iron,
22 530 390
with phosphate coated prevailing torque nuts or with cop-
24 670 500 per plated weld nuts.
27 980 730
30 1330 990 Markings on bolt heads or nuts indicate material class only
33 1790 1330 and are not to be used to determine required torque.
36 2325 1730
39 3010 2240
D87E-2 D87P-2 00-13 2

HYDRAULIC TUBES AND FITTINGS
The torque figures are recommended for plain, cadmium or zinc plated fittings, dry or wet installations. Swivel nuts either
swaged or brazed. Figures are for tube nuts used with 37° flared fittings and JIC - 37° seat o-ring boss plugs and swivel nuts.
Tube Nuts O-ring Boss Plugs And Swivel Nuts

For 37° Flared Fitting JIC 37° Seat
Size Tubing OD Thread N•m lbf ft
4 1/4 7/16-20 12 to 16 9 to 12
5 5/16 1/2-20 16 to 20 12 to 15
6 3/8 9/16-18 33 to 21 21 to 24
8 1/2 3/4-16 47 to 54 35 to 40
10 5/8 7/8-14 72 to 79 53 to 58
12 3/4 1-1/16-12 104 to 111 77 to 82
14 7/8 1-3/16-12 122 to 136 90 to 100
16 1 1-5/16-12 149 to 163 110 to 120
20 1-1/4 1-5/8-12 190 to 204 140 to 150
24 1-1/2 2-1/2-12 217 to 237 162 to 175
32 2 2-1/2-12 305 to 325 225 to 240
HOSE CLAMPS Torque ± 0.6 N•m (5 lbf in)

Clamp Type Hydraulic System All Others
and Size lbf in
N•m lbf in N•m
T Bolt --- --- 6.2 to 7.3 55 to 65

Worm drive
under 1-3/4
This chart provides the tightening torques for hose clamps 4.5 to 5.6 40 to 50 2.2 to 3.3 20 to 30
in open
used in all rubber applications (radiator, air cleaner, operat- diameter
ing lever boots, hydraulic system, fuel systems etc.). Worm drive
over 1-3/4 in
--- --- 4.5 to 5.6 40 to 50
open diame-
ter
Worm drive
4.5 to 5.6 40 to 50 10.7 to 11.8 95 to 105
all Ultra-Tite
SPLIT FLANGE CONNECTIONS Bolt Torque

Flange Size Bolt Size
The following chart provides the tightening torques for split N• m lbf ft
flange connections used in hydraulic systems. Flanges and 1/2 5/16 20 to 24 15 to 18
fitting shoulders should fit squarely. Install all bolts, finger 3/4 3/8 30 to 37 22 to 27
tight, then torque evenly. Over torquing bolts will damage
the flanges and/or bolts, which may cause leakage. 1 3/8 37 to 47 27 to 35
1-1/4 7/16 47 to 61 35 to 45
1-1/2 1/2 62 to 79 46 to 58
2 1/2 75 to 88 55 to 65
2-1/2 1/2 107 to 123 79 to 91
3 5/8 187 to 203 138 to 150
3-1/2 5/8 159 to 180 117 to 133
00-14 2 D87E-2 D87P-2

FOREWORD ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example:05WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Unit: mm
Copper wire Current
Nominal
Number Cable O.D. rating Applicable circuit
number Dia. Of strand Cross section
of strands (Amps)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7 59 Starting (Glow plug)
40 85 0.8 42.73 11.4 135 Starting
60 127 0.8 63.84 13.6 178 Starting
100 217 0.8 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuit
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Code W B B R Y G L
Primary
1
Color White Black Black Red Yellow Green Blue
Code WR --- BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color ---
Red White White Red White White
Code WB --- BY RB YB GR LR
Color ---
Black Yellow Black Black Red Red
Code WL --- BR RY YG GY LY
Auxiliary
Color ---
Blue Red Yellow Green Yellow Yellow
Code WG --- --- RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color --- ---
Green Green Blue Black Black
Code --- --- --- RL YW GL ---
6 Red & Yellow & Green &
Color --- --- --- ---
Blue White Blue
D87E-2 D87P-2 00-15 2

FOREWORD CONVERSION TABLES
12
CONVERSION TABLES
METHOD OF USING THE CONVERSION TABLE
The Conversion Tables in this section are provided to enable simple conversion of figures. For details of the method of using
the Conversion Table, see the example given below.
EXAMPLE
● Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as 1, then draw a horizontal line from 1.
B. Locate the number 5 in the row across the top, take this as 2, then draw a perpendicular line down from 2.
C. Take the point where the two lines cross as 3. This point 3 gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.
A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to
55 mm.
B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches 2 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.26 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.85 1.89 1.929
3
1 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.48 2.52 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.11
80 3.15 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.74 3.78 3.819 3.858 3.898
00-16 2 D87E-2 D87P-2

12
Millimeters to Inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.63 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.22 1.26 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.85 1.89 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.48 2.52 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.11
80 3.15 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.74 3.78 3.819 3.858 3.898
Kilogram to Pound 1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.2 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.3 48.5 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.8 97 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.1 143.3 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.6 191.8 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
D87E-2 D87P-2 00-17 2

12
Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.17 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.34 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.51 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.68 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.85 16.115 16.379 16.643 16.907 17.171 17.435 17.7 17.964 18.228
70 18.492 18.756 19.02 19.285 19.549 19.813 20.077 20.341 20.605 20.87
80 21.134 21.398 21.662 21.926 22.19 22.455 22.719 22.983 23.247 23.511
90 23.775 24.04 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon 1 L = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.22 0.44 0.66 0.88 1.10 1.32 1.54 1.76 1.98
10 2.2 2.42 2.64 2.86 3.08 3.3 3.52 3.74 3.95 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18 2 D87E-2 D87P-2

12
N•m to lbf ft 1 N•m = 0.737562 lbf ft
0 1 2 3 4 5 6 7 8 9
0 0 0.737 1.475 2.212 2.95 3.687 4.425 5.162 5.9 6.638

10 7.375 8.113 8.85 9.588 10.325 11.063 11.801 12.538 13.276 14.013
20 14.751 15.488 16.226 16.963 17.701 18.439 19.176 19.914 20.651 21.389
30 22.126 22.864 23.601 24.339 25.077 25.814 26.552 27.289 28.027 28.764
40 29.502 30.24 30.977 31.715 32.452 33.19 33.927 34.665 35.402 36.14
50 36.878 37.615 38.353 39.09 39.828 40.565 41.303 42.041 42.778 43.516
60 44.253 44.991 45.728 46.466 47.203 47.941 48.679 49.416 50.154 50.891
70 51.629 52.366 53.104 53.842 54.579 55.317 56.054 56.792 57.529 58.674
80 59.004 59.742 60.48 61.217 61.955 62.692 63.43 64.167 64.905 65.643
90 66.38 67.118 67.855 68.593 69.33 70.068 70.805 71.543 72.281 73.018
100 73.756 74.493 75.231 75.968 76.706 77.444 78.181 78.919 79.656 80.394
110 81.131 81.869 82.606 83.344 84.082 84.819 85.557 86.294 87.032 87.769
120 88.507 89.245 89.982 90.72 91.457 92.195 92.932 93.67 94.407 95.145
130 95.883 96.62 97.358 98.095 98.883 99.57 100.3 101.046 101.783 102.521
140 103.258 103.996 104.733 105.471 106.209 106.946 107.684 108.421 109.159 109.896
150 110.634 111.371 112.109 112.847 113.584 114.322 115.059 115.797 116.534 117.272
160 118.01 118.747 119.485 120.222 120.96 121.697 122.435 123.172 123.91 124.648
170 125.385 126.123 126.86 127.598 128.335 129.073 129.811 130.548 131.286 132.023
180 132.761 133.498 134.236 134.973 135.711 136.449 137.186 137.924 138.661 139.399
190 140.136 140.874 141.612 142.349 143.087 143.824 144.562 144.562 146.037 146.774
D87E-2 D87P-2 00-19 2

12
kg/cm² to lb/in² (psi) 1 kg/cm² = 14.2233 lb/in² (psi)
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1932 1949 1963 1977
140 1991 2005 2019 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20 2 D87E-2 D87P-2

12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, con-
sider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column
at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
D87E-2 D87P-2 00-21 2

01 GENERAL
VIEW OF MACHINE............................................................................................................................................................. 01-2

D87E-2................................................................................................................................................................................. 01-2
D87P-2................................................................................................................................................................................. 01-3
DIMENSIONAL DRAWINGS............................................................................................................................................... 01-4
D87E-2................................................................................................................................................................................. 01-4
SEMI U DOZER .............................................................................................................................................................. 01-4
STRAIGHT ANGLE DOZER ......................................................................................................................................... 01-6
D87P-2................................................................................................................................................................................. 01-8
STRAIGHT DOZER........................................................................................................................................................ 01-8
SPECIFICATIONS ............................................................................................................................................................... 01-10
WEIGHT TABLE ................................................................................................................................................................. 01-13
USE OF FUEL, COOLANT AND LUBRICANTS ............................................................................................................. 01-14
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ........................................................................... 01-14
ABBREVIATIONS ....................................................................................................................................................... 01-15
ENGINE OIL SPECIFICATIONS .................................................................................................................................... 01-15
NORMAL OPERATION............................................................................................................................................... 01-15
ARCTIC OPERATION ................................................................................................................................................. 01-15
DRIVE TRAIN OIL SPECIFICATIONS ......................................................................................................................... 01-15
TRACK FRONT IDLER, TRACK ROLLER, TOP IDLER OIL SPECIFICATIONS .................................................... 01-15
EQUIPMENT SYSTEM OIL SPECIFICATIONS ........................................................................................................... 01-16
FINAL DRIVE OIL OR PIVOT SHAFT HOUSING SPECIFICATIONS...................................................................... 01-16
COOLING SYSTEM......................................................................................................................................................... 01-16
FUEL SYSTEM................................................................................................................................................................. 01-16
D87E-2 D87P-2 01-1 2

GENERAL VIEW OF MACHINE
12
VIEW OF MACHINE
D87E-2
01-2 2 D87E-2 D87P-2

GENERAL VIEW OF MACHINE
12
D87P-2
D87E-2 D87P-2 01-3 2

GENERAL DIMENSIONAL DRAWINGS
12
DIMENSIONAL DRAWINGS
D87E-2
SEMI U DOZER
On machine height dimensions, 66.55 mm has been added. This represents the track shoe grouser height.
Ref Description mm
A Height, ground to top of ROPS 3569
B Height, top of cab to top of ROPS 98
C Height, fuel tank refill 2322
D Height, exhaust stack 3378
E Length, center of final drive to center of front idler 3079
F Length, nose of mask to rear track chain 4513
G Length, blade to drawbar 6069
H Length, blade to ripper 7208
I Width, track gauge 1981
J Width, across track shoes 560 mm shoe 2541
610 mm shoe 2591
660 mm shoe 2641
K Width, including trunnions 2896
L Width, blade 3480
M Height, top of blade 1600
N Height, full blade raise 1187
O Height, full blade lower 440
P Angle, blade tilt 10.9°
Q Angle, forward pitch 4.5°
R Angle, rearward pitch 4.5°
S Height, ripper lower 599
T Height, ripper raised 686
01-4 2 D87E-2 D87P-2

D87E-2 D87P-2 01-5 2

12
STRAIGHT ANGLE DOZER
Ref Description mm
H Length, blade to ripper 7271
I Width, track gauge 1981
J Width, across track shoes 560 mm shoe 2541
610 mm shoe 2591
660 mm shoe 2641
K Width, including trunnions 2896
L Width, blade 4420
M Height, top of blade 1092
N Height, full blade raise Blade straight 1219
Blade angled 1542
O Height, full blade lower 550
P Angle, blade tilt 6.7°
Q Angle, left or right blade 25°
R Height, ripper lower 599
S Height, ripper raised 686
T Width over C frame 3175
01-6 2 D87E-2 D87P-2

D87E-2 D87P-2 01-7 2

12
D87P-2
STRAIGHT DOZER
Ref Description mm
G Length, blade to recovery hitch 5707
H Width, track gauge 2230
I Width, across track shoes 864 mm (34 in) swamp shoe 3099
914 mm (36 in) shoe 3144
J Width, including trunnions 3328
K Width, blade 4370
L Height, top of blade 1350
M Height, full blade raise 1260
N Height, full blade lower 662
O Angle, blade tilt 8.6°
P Angle, forward pitch 4.5°
Q Angle, rearward pitch 4.5°
01-8 2 D87E-2 D87P-2

12
D87E-2 D87P-2 01-9 2

GENERAL SPECIFICATIONS
12
SPECIFICATIONS
D87E-2 D87P-2
Model Unit
Semi U Blade Angle Blade Straight Blade
Serial Number P090001 P090001 P092001
Operating weight w/o operator #
kg 23998 24326 25909
# Includes blade equipment, ROPS, cab, standard equip-
Weights
ment and full capacity of lubricants, coolant and fuel.

Blade equipment kg 2902 3230 2756
Ripper equipment with 1 shank kg 2900 2900 ---
Each additional shank kg 190 190 ---
Minimum turning radius mm 991 991 1115
Grade ability degrees 36° 36° 36°
F: 54.4° Re: 56.5° F: 54.4° Re: 56.5° F: 61.4° Re: 55.1°
Stability (front, rear, left, right) degrees L: 46.2° Ri: 46.6° L: 46.2° Ri: 46.6° L: 50.6° Ri: 51.0°
Travel speeds Lo km/h 2.7 2.7 2.7
1st
Hi km/h 3.7 3.7 3.7
Forward
Lo km/h 5.0 5.0 5.0

2nd
Hi km/h 6.6 6.6 6.6
Lo km/h 8.1 8.1 8.1
3rd
Hi km/h 10.3 10.3 10.3
Performance
Lo km/h 3.4 3.4 3.4

1st
Hi km/h 4.4 4.4 4.4
Reverse
Lo km/h 6.0 6.0 6.0

2nd
Hi km/h 7.7 7.7 7.7
Lo km/h 9.5 9.5 9.5
3rd
Hi km/h 12.1 12.1 12.1
Drawbar pull kg 60000 60000 60000
Ground pressure * 560 mm shoe kg/cm² 0.69 0.701 ---
610 mm shoe kg/cm² 0.64 0.65 ---
* Includes blade equipment, ROPS,
cab, standard equipment, shoes and 660 mm shoe kg/cm² 0.59 0.60 ---
full capacity of lubricants, coolant Swamp shoes kg/cm² --- --- 0.44
and fuel.
914 mm shoe kg/cm² --- --- 0.41
Dimensions See Dimensional Drawings
Model Komatsu S6D125E-2 Diesel Engine
Four stroke cycle, water cooled, emisionized turbo-
General
Type
charged diesel engine
No. of cylinders, bore x stroke mm 6 = 125 x 150
Displacement L 11.04
Engine
Rated power kW 172 @ 2100 RPM

Performance
Maximum torque N•m 999 @ 1400 RPM

High idle speed 2100 RPM
Low idle speed 845 RPM
Fuel consumption ratio L/kW•h 0.158
01-10 2 D87E-2 D87P-2

12
D87E-2 D87P-2
Model Unit
Starting motor 24V
Electrical
Alternator 24V @ 50A

Standard 12V x 2 @ 625 CCA
Batteries
Optional 12V x 2 @ 950 CCA
Torque converter mm 356 single stage with a 2.6 to 1 stall ratio
Modular countershaft type power shift, hydrauli-
Transmission cally controlled and actuated with 3 speeds in each
Power Train
direction
Two speed gear steering with drive clutches hydrau-
Steering drive lically actuated - spring released and brake clutch
spring actuated - hydraulically released
Double reduction outboard planetary with splash
Final drives
type lubrication
Suspension Oscillation type with equalizer bar
Carrier roller 2 each side 2 each side 2 each side
Undercarriage
Track roller 7 each side 7 each side 7 each side

Front idler 1 each side 1 each side 1 each side
Track adjuster Fully hydraulic, adjusted with grease gun
Track chain Split link lubricated and sealed type
Track shoes per side 42 42 45
Charge circuits L/min 129 @ 19 kg/cm²
Drive train
Scavenge circuits L/min 163 @ 4.5 kg/cm²
Pumps
Blade lift @ 2330 RPM L/min 142 @ 70 kg/cm²

Equipment Blade tilt @ 2330 RPM L/min 62.5 @ 70 kg/cm²
Pilot system @ 2330 RPM L/min 35.6 @ 21 kg/cm²
Cylinder bore mm 114 114 114
Blade lift
Piston stroke mm 1067 1067 976

OD of rod mm 63 63 63
Rod extended mm 2088 2088 2198
Rod retracted mm 1022 1022 1222
Cylinder bore mm 165 165 165
Hydraulics
Piston stroke mm 147 147 147

Blade tilt
OD of rod mm 70 70 70
Rod extended mm 1455 1326 1455
Cylinders
Rod retracted mm 1309 1171 1309

Cylinder bore mm 152 152 ---
Ripper lift
Piston stroke mm 475 475 ---

OD of rod mm 63 63 ---
Rod extended mm 1395 1395 ---
Rod retracted mm 914 914 ---
Cylinder bore mm 140 140 ---
Ripper lift
Piston stroke mm 343 343 ---

OD of rod mm 63 63 ---
Rod extended mm 1260 1260 ---
Rod retracted mm 917 917 ---
D87E-2 D87P-2 01-11 2

12
D87E-2 D87P-2
Model Unit
Pressurized box type with sight gauge and external
Hydraulic reservoir
control valve
Blade lift w/o ripper One spool pilot operated - blade lift only
Three spool pilot operated - blade
Hydraulics
Blade lift with ripper ---

lift, ripper lift and ripper pitch
Control valve
Blade tilt One spool pilot operated - blade tilt only

Four spool valve manually operated controlling all
Blade pilot system
blade functions
Four spool valve manually operated controlling all
Ripper pilot system
ripper functions
Type of blade Semi U dozer Angle dozer Straight dozer
Capacity of blade m³ 7.04 3.88 6.03
Weight kg 2902 3230 3080
Cylinders and Cylinders and C Cylinders and
Support method
Dozer equipment
push arms frame push arms

Blade width mm 3480 4420 4370
Mounted Equipment
Blade height mm 1600 1092 1350

Blade cutting angle (pitch) degrees 18° --- 18°
Blade straight mm 1187 1219 1260
Height at full raise
Blade angled mm --- 1542 ---
Height at full lower mm 440 550 662
Blade tilt degrees 10.9° 6.7° 8.6°
Type Multi shank parallelogram type ---
Ripper equipment
With cylinders and 1 shank kg 2900 ---

Weight
Each additional shank - max of 3 kg 190 ---
Digging depth mm 599 ---
Height
Lifting height mm 686 ---
01-12 2 D87E-2 D87P-2

GENERAL WEIGHT TABLE
12
WEIGHT TABLE
Unit kg
D87E-2 D87P-2
Model
Engine, full dressed 1428 1428 1428
Radiator with internal oil cooler 235 235 235

Fuel tank 223 223 223
Drive shaft 10 10 10
Torque converter 110 110 110
Transmission with valves 450 450 450
Steering drive 550 550 550
Final drive w/o sprocket 770 770 770
Track frame 860 860 1051
Front idler 239 239 239
Top idler 38 38 38
Track roller - single flange 73 73 73
Track roller - double flange 81 81 81
Track chain with shoes 1790 1790 2304
Hydraulic reservoir 114 114 114
Control valve - 3 spool 37 37 37
Control valve - 1 spool 37 37 37

Operators seat 37 37 37
Blade lift cylinder 132 132 126
Blade tilt cylinder 123 123 123
Drive train pump 38 38 38
Equipment pump 55 55 55
ROPS with cab 855 855 855

ROPS with canopy 477 477 477
Operator’s cab 480 480 480
Ripper lift cylinder 104 104 ---

Ripper pitch cylinder 88 88 ---
D87E-2 D87P-2 01-13 2

AMBIENT TEMPERATURES 12
POINT TYPE CAPACITY
40 to -7°C 21 to -23°C -12 to -34°C -12 to -54°C
USE
lines.
01-14 2
Crankcase
GENERAL
SAE 5W-20 or Multi-purpose

with filter EO SAE 15W-40 SAE 10W-30 27 L
SAE 5W-30 ARTIC oil
change
Front idler Multi-purpose

HDTF SAE 30 0.6 L
machine are shown below.
rebuilt ARTIC oil
Track roller Multi-purpose

HDTF SAE 30 0.4 L
rebuilt ARTIC oil
Top idler Multi-purpose

HDTF SAE 30 0.3 L
rebuilt ARTIC oil
Final drive MPL SAE 85W-140 SAE 80W-90 ARTIC grade 75 38 L
Pivot shaft
MPL SAE 85W-140 SAE 80W-90 ARTIC grade 75 2.4 L
housing
OF FUEL, COOLANT AND LUBRICANTS
SAE 5W-30 or SAE 5W-30 or

Drive train% HDTF SAE 10W 173 L
SAE 5W-20 SAE 5W-20
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
Equipment Multi-purpose
HDTF SAE 10W 126 L
system ARTIC oil
Equipment
Multi-purpose
system with HDTF SAE 10W 134 L
ARTIC oil
ripper
Fuel tank DF D975 No.2D D975 No.1D VV-F-800DF-A 490 L
Cooling
For details, see COOLING SYSTEM. 58.7 L
system
USE OF FUEL, COOLANT AND LUBRICANTS
It is not our policy to approve lubricants or to guarantee oil performance in service. The responsibility of quality of the lubri-
% Drive train consists of the rear main frame, steering drive, transmission, torque converter, oil cooler and all appropriate
D87E-2 D87P-2
cant must remain with the supplier of the lubricant. When in doubt consult your distributor. The lubricants specified for this
GENERAL USE OF FUEL, COOLANT AND LUBRICANTS
ABBREVIATIONS
HDTF Komatsu heavy duty transmission fluid or equivalent.
EO1 Komatsu engine oil or multigrade diesel engine oil.
EO2 (For service only) Komatsu hydraulic fluid or engine oil API CD/CC, CD or MIL-L-2104 and passing TO-2 and C-3
test with 0.10% minimum zinc.
MPL Komatsu gear lube or multi purpose gear lube
MPG Komatsu super grease or multi purpose grease 251 HEPM or NLGI grade #2 multi purpose lithium grease with 3 to
5% MoS2 (molybdenum disulfide).
HTF (For service only) Komatsu hydraulic transmission fluid.
DF Diesel fuel Grade 1 or 2 depending on ambient temperature.
SAE: Society of Automotive Engineers NLGI: National Lubricating Grease Institute

API: American Petroleum Institute ASTM: American Society of Testing and Materials
ENGINE OIL SPECIFICATIONS

NORMAL OPERATION
Oil performance recommendations are as follows:
● The use of a quality engine lubricating oil combined with appropriate oil and filter change intervals are critical factors in
maintaining engine performance and durability. Komatsu Engine Oil or multi viscosity engine oil meeting API perfor-
mance classification CF-4, CG-4, CF-4/SG or CG-4/SH or MIL-L-2104D or E is recommended.
REMARK
Classification CD, CE, CD/SF or CE/SF oils may be used in areas where CF-4, CG-4, CF-4/SG or CG-4/SH oil
is not yet available. If API classification CC or CC/CD is used, reduce the engine oil change interval by half.
ARCTIC OPERATION
If an engine is operated in ambient temperatures consistently below -23°C (-10°F) and there are no provisions to keep the en-
gine warm when it is not in operation, use a synthetic engine oil API performance classification CF-4, CG-4, CF-4/SG or CG-
4/SH with adequate low temperature properties such as SAE 5W-20 or 5W-30.
The oil supplier must be responsible for meeting the performance service specifications.
REMARK
The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change intervals
can decrease engine life due to factors such as; corrosion, deposits and wear.
DRIVE TRAIN OIL SPECIFICATIONS

Komatsu Heavy Duty Transmission Fluid or an equivalent fluid meeting C-4 and TO-4 and not containing a viscosity index
improver is recommended. For service only of the drive train, optionally use Komatsu Hydraulic Fluid or engine oil with an
API classification of CD/CC, CD or MIL-L-2104D or E and meeting C-3 and TO-2 and containing 0.10% zinc minimum.
TRACK FRONT IDLER, TRACK ROLLER, TOP IDLER OIL SPECIFICATIONS

Komatsu Heavy Duty Transmission Fluid or an equivalent fluid meeting C-4 and TO-4 and NOT containing a viscosity index
improver is recommended. For service only of the track front idlers, track rollers and top idlers, optionally use Komatsu Hy-
draulic Fluid or engine oil with an API classification of CD/CC, CD or MIL-L-2104D or E and meeting C-3 and TO-2 and
containing 0.10% zinc minimum.
D87E-2 D87P-2 01-15 2

GENERAL USE OF FUEL, COOLANT AND LUBRICANTS
12
EQUIPMENT SYSTEM OIL SPECIFICATIONS
Komatsu Heavy Duty Transmission Fluid or an equivalent fluid meeting C-4 and TO-4 and NOT containing a viscosity index
improver is recommended. For service only of the equipment hydraulic system, optionally use Komatsu Hydraulic Fluid or en-
gine oil with an API classification of CD/CC, CD or MIL-L-2104D or E and meeting C-3 and TO-2 and containing 0.10% zinc
minimum.
FINAL DRIVE OIL OR PIVOT SHAFT HOUSING SPECIFICATIONS

Komatsu Gear Lubricant or an equivalent multi purpose gear lubricant meeting API GL-5 or MIL-L-2105C is recommended.
COOLING SYSTEM
The cooling system operates under pressure which is controlled by the pressure relief valve in the radiator cap. The belt driven
water pump circulates the coolant through the engine block, cylinder heads, radiator, and engine oil cooler. Circulation is con-
trolled by the thermostat which by passes coolant flow around the radiator until the engine reaches operating temperature.
Proper cooling is possible only when the system is sealed, the radiator cap gasket is in good condition, the pressure relief valve
and thermostat are operating properly. The system is free of coolant and air flow restrictions and filled to the proper level. Se-
lection and maintenance of the engine coolant is important to long engine life. The following information provides recommen-
dations for selecting the engine coolant, maintaining the coolant inhibitors and servicing the cooling system. The system
operates successfully with a water/antifreeze mixture or inhibited/conditioned water as the coolant. Water alone allows rust,
scale deposits, and corrosion to occur within this system. After 2000 hours or one year of operation, whichever comes first, the
cooling system should be drained, flushed and refilled.
FUEL SYSTEM
Cleanliness of diesel fuel determines the service life of the fuel injection components. Water and contaminants, allowed to
reach precision injection components, cause rapid wear and poor performance. Clean fuel and regular servicing of the fuel tank
and fuel filtering components are necessary for long service life. Always clean the area around the fuel tank filler cap before
refueling. ASTM refers to American Society for Testing and Materials. The D-396 fuels must also meet the cetane number and
sulfur requirements of the D-975 specifications.
01-16 2 D87E-2 D87P-2

10 STRUCTURE, FUNCTION & MAINTENANCE
STANDARDS
ENGINE MOUNT .......................................................... 10-3 STEERING VALVE MANIFOLD........................... 10-67

ENGINE CONTROL ...................................................... 10-5 FINAL DRIVE ............................................................. 10-68
3 LEVER CONTROL DRIVE .................................... 10-5 UNDERCARRIAGE .................................................... 10-72
1 LEVER DRIVE CONTROL .................................... 10-6 FRONT IDLER ......................................................... 10-74
FUEL LINES................................................................... 10-7 TOP IDLER .............................................................. 10-76
RADIATOR, OIL COOLER........................................... 10-8 TRACK ROLLER..................................................... 10-77
DRIVE TRAIN ............................................................... 10-9 TRACK ADJUSTER ................................................ 10-79
DRIVE SHAFT ............................................................. 10-10 TRACK SPRING ...................................................... 10-80
DRIVE TRAIN SCHEMATIC ..................................... 10-10 PIVOT SHAFT ......................................................... 10-82
3 LEVER CONTROL DRIVE .................................. 10-10 EQUALIZER BAR ................................................... 10-83
1 LEVER CONTROL DRIVE .................................. 10-12 TRACK FRAME GUIDES....................................... 10-84
DRIVE TRAIN PIPING DIAGRAM ........................... 10-14 TRACK CHAIN........................................................ 10-85
3 LEVER CONTROL DRIVE .................................. 10-14 LUBRICATED STYLE ........................................ 10-85
1 LEVER CONTROL DRIVE .................................. 10-16 DRY SEALED STYLE ......................................... 10-86
TORQUE CONVERTER MOUNTING ....................... 10-18 MAIN FRAME ............................................................. 10-88
TORQUE CONVERTER.............................................. 10-20 EQUIPMENT HYDRAULICS..................................... 10-90
TRANSMISSION ......................................................... 10-23 EQUIPMENT HYDRAULIC SCHEMATIC ........... 10-90
CONTROLS .............................................................. 10-23 EQUIPMENT HYDRAULIC DIAGRAM ............... 10-91
3 LEVER DRIVE CONTROL............................... 10-23 RESERVOIR............................................................. 10-92
1 LEVER DRIVE CONTROL............................... 10-23 PUMP ........................................................................ 10-94
MOUNTING.............................................................. 10-24 BLADE LIFT AND RIPPER VALVE BANK ......... 10-96
CROSS SECTION..................................................... 10-25 MAIN RELIEF VALVE ....................................... 10-97
GEAR SHIFT OPERATION..................................... 10-27 ANTI CAVITATION VALVE ............................. 10-97
DIRECTIONAL (INPUT) SHAFT ........................... 10-30 BLADE LIFT SECTION VALVE ........................ 10-98
COUNTERSHAFT.................................................... 10-32 RIPPER LIFT SECTION VALVE........................ 10-99
RANGE (OUTPUT) SHAFT .................................... 10-34 RIPPER PITCH SECTION VALVE................... 10-100
REVERSE IDLER SHAFT ....................................... 10-36 BLADE LIFT VALVE BANK ............................... 10-101
PRESSURE REGULATOR VALVE........................ 10-37 MAIN RELIEF VALVE ..................................... 10-102
RANGE SELECTOR VALVE.................................. 10-39 ANTI CAVITATION VALVE ........................... 10-102
RATE OF RISE VALVE........................................... 10-41 BLADE LIFT SECTION VALVE ...................... 10-103
PILOT CONTROL VALVE...................................... 10-44 BLADE TILT VALVE BANK ............................... 10-104
3 LEVER DRIVE CONTROL............................... 10-44 BLADE TILT SECTION VALVE...................... 10-105
PILOT MANIFOLD.................................................. 10-45 MAIN RELIEF VALVE ..................................... 10-105
3 LEVER DRIVE CONTROL............................... 10-45 BLADE PILOT CONTROL VALVE..................... 10-106
TASC VALVE........................................................... 10-46 DESCRIPTION ................................................... 10-106
1 LEVER DRIVE CONTROL............................... 10-46 RIPPER PILOT CONTROL VALVE .................... 10-108
NEUTRAL START VALVE .................................... 10-49 DESCRIPTION ................................................... 10-109
1 LEVER DRIVE CONTROL............................... 10-49 PILOT SUPPLY VALVE ....................................... 10-110
PRESSURE REGULATOR VALVE........................ 10-51 QUICK DROP VALVE .......................................... 10-112
1 LEVER DRIVE CONTROL............................... 10-51 GIMBAL TUBE AND YOKE................................ 10-113
CHARGE AND SCAVENGE PUMP ....................... 10-52 BLADE LIFT CYLINDER..................................... 10-114
TWO SPEED STEERING ............................................ 10-54 BLADE TILT CYLINDER..................................... 10-116
DRIVE UNIT............................................................. 10-55 DOZER MODELS .............................................. 10-116
3 LEVER DRIVE CONTROL............................... 10-56 ANGLE MODELS .............................................. 10-116
1 LEVER DRIVE CONTROL............................... 10-57 RIPPER LIFT CYLINDER..................................... 10-117
STEERING VALVE ................................................. 10-58 RIPPER PITCH CYLINDER ................................. 10-118
3 LEVER DRIVE CONTROL............................... 10-58 CAB ............................................................................ 10-119
1 LEVER DRIVE CONTROL............................... 10-62 ELECTRICAL SYSTEM ........................................... 10-120
D87E-2 D87P-2 10-1 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS TABLE OF CONTENTS
SCHEMATIC .......................................................... 10-120 WARNING HORN.............................................. 10-146

3 LEVER DRIVE CONTROL............................. 10-120 WARNING HORN SWITCH ............................. 10-146
1 LEVER DRIVE CONTROL............................. 10-122 WIPER MOTOR ................................................. 10-147
WIRING .................................................................. 10-123 WIPER AND WASHER SWITCH..................... 10-147
1 LEVER DRIVE CONTROL............................. 10-123 WASHER PUMP ................................................ 10-148
ELECTRICAL COMPONENTS............................. 10-125 DOME LIGHT .................................................... 10-148
DESCRIPTION.................................................... 10-125 CAB SWITCH PANEL....................................... 10-149
STARTING AND CHARGING GROUP............ 10-125 BLOWER MOTOR SWITCH............................. 10-149
LIGHTING GROUP ............................................ 10-125 BLADE FLOAT SOLENOID ............................. 10-150
INDICATOR GROUP ......................................... 10-125 A/C MAGNETIC CLUTCH ............................... 10-150
ACCESSORY GROUP........................................ 10-125 STEERING CONTROLLER .............................. 10-151
CRANKING MOTOR ......................................... 10-126 GRIP BUTTON MICRO SWITCHES................ 10-151
ALTERNATOR ................................................... 10-126 GEAR SPEED INDICATOR .............................. 10-152
MASTER DISCONNECT SWITCH................... 10-127 NEUTRAL SOLENOID...................................... 10-152
MAGNETIC SWITCH ........................................ 10-127 LEFT OR RIGHT SOLENOID........................... 10-153
RECTIFIER BOARD .......................................... 10-128 WIRING HARNESSES .......................................... 10-155
IN LINE DIODE .................................................. 10-128 FRONT HARNESS............................................. 10-155
LEFT AND RIGHT SOLENOID DIODE........... 10-128 ENGINE HARNESS ........................................... 10-156
KEY START SWITCH ....................................... 10-129 POD HARNESS .................................................. 10-158
BRAKE PEDAL SWITCH .................................. 10-129 CONTROL TOWER HARNESS ........................ 10-159
NEUTRAL START SWITCH ............................. 10-129 REAR HARNESS ............................................... 10-160
NEUTRAL SOLENOID SWITCH...................... 10-129 RIGHT REAR HARNESS .................................. 10-161
PREHEATER RELAY SWITCH ........................ 10-130 INSTRUMENT PANEL HARNESS .................. 10-162
ENGINE AIR PREHEATER............................... 10-130 CAB HARNESS.................................................. 10-164
PREHEAT SELECT SWITCH............................ 10-131 CAB PANEL HARNESS .................................... 10-166
BIMETAL SWITCH............................................ 10-131 CONTROLLER HARNESS................................ 10-167
PREHEAT INDICATOR..................................... 10-132 INSTRUMENT HARNESS ................................ 10-168
SOUND ALARM ................................................ 10-132 COMPARTMENT HARNESS ........................... 10-169
LIGHT SWITCH ................................................. 10-133 COMPARTMENT HARNESS ........................... 10-170
WORK LIGHTS .................................................. 10-133 A/C HEATER ............................................................. 10-171
GAUGE CLUSTER ............................................. 10-134 A/C HEATER LINES ............................................. 10-171
HOURMETER..................................................... 10-135 COMPRESSOR MOUNTING................................ 10-172
ENGINE OIL PRESSURE SWITCH .................. 10-135 CAB A/C UNIT ...................................................... 10-173
FUEL GAUGE..................................................... 10-136 CAB HEATER UNIT ............................................. 10-174
FUEL SENDER ................................................... 10-136 SPECIAL TORQUE CHART .................................... 10-175
AIR FILTER SWITCH ........................................ 10-137
TRANS OR HYDRAULIC FILTER SWITCH... 10-137
PILOT FILTER SWITCH ................................... 10-138
ENGINE OIL PRESSURE SENDER.................. 10-138
ENGINE COOLANT TEMP SENDER .............. 10-139
CONVERTER OIL TEMP SENDER.................. 10-139
ENGINE COOLANT TEMP SWITCH............... 10-139
TRANS OIL TEMP SENDER............................. 10-140
CLUTCH PRESSURE SWITCH......................... 10-140
WARNING/CAUTION LAMP ........................... 10-141
COOLANT LEVEL RELAY............................... 10-141
BULB CHECK RELAY ...................................... 10-141
COOLANT LEVEL SWITCH............................. 10-142
GEAR INDICATOR SENSOR ........................... 10-142
MAIN CIRCUIT BREAKER .............................. 10-143
INDIVIDUAL CIRCUIT BREAKERS ............... 10-143
TIME DELAY MODULE ................................... 10-144
INSTRUMENT PANEL DIODE BOARD.......... 10-144
BACK UP ALARM ............................................. 10-145
BACK UP ALARM SWITCH............................. 10-145
10-2 2 D87E-2 D87P-2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS ENGINE MOUNT
12
ENGINE MOUNT
D87E-2 D87P-2 10-3 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS ENGINE MOUNT
12
1. Front Engine Mount 5. Torque Converter
2. Front Engine Bushing 6. Air Cleaner
3. Rear Engine Bushing and Mount 7. Exhaust Muffler
4. Flywheel Housing
Unit: mm
No. Check Item Criteria Remedy
Standard Tolerance Standard Clearance

Size ID OD Clearance Limit
59.7 60.046
A Shaft and bushing 60 -0.346 to -0.1 0.4
59.9 60.000
94.9 95.02
B Bushing and bracket 95 -0.12 to 0.215
95.2 94.985
Standard Size Repair Limit
Replace
C Free height of mount 90 88
Standard Tolerance Standard Clearance

Size ID OD Clearance Limit
206.7 207.046
D Bushing and mount 207 0.346 to 0
207 207
10-4 2 D87E-2 D87P-2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS ENGINE CONTROL
12
ENGINE CONTROL
3 LEVER CONTROL DRIVE
1. Decelerator Pedal 4. Throttle Cable

2. Pedal Cable 5. Fuel Injection Pump Arm Rod
3. Fuel Control Lever 6. Overtravel Rod
The engine speed is controlled by the fuel control lever (3) or the decel-
erator pedal (1).
D87E-2 D87P-2 10-5 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS ENGINE CONTROL
12
1 LEVER DRIVE CONTROL
1. Decelerator Pedal 4. Throttle Cable

2. Pedal Cable 5. Fuel Injection Pump Arm Rod
3. Fuel Control Lever 6. Overtravel Rod
The engine speed is controlled by the fuel control lever (3) or the decel-
erator pedal (1).
10-6 2 D87E-2 D87P-2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS FUEL LINES
12
FUEL LINES
1. Fuel Tank 6. Fuel Injector Return Hose

2. Locking Fuel Cap 7. Drain Valve
3. Fuel Shut Off Valve 8. Drain Hose
4. Fuel Supply Hose 9. Fuel Filter
5. Fuel Return Hose 10. Fuel Injection Pump
D87E-2 D87P-2 10-7 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS RADIATOR, OIL COOLER
12
RADIATOR, OIL COOLER
1. Radiator Cap Specifications:

2. Drain Valve and Hose Core type: ............................................................................5-15/16 A3X5
Coolant capacity ................................................................................. 53 L
3. Fan Guard
Pressure relief valve in cap......................................... 0.46 to 0.56 kg/cm²
4. Upper Tank
5. Radiator Core
6. Lower Tank - Drive Train Oil Cooler
7. Mounting Cushion
8. Engine Outlet Line
9. Engine Inlet Lines
10-8 2 D87E-2 D87P-2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS DRIVE TRAIN
12
DRIVE TRAIN
1. S6D125E-2 Engine 5. Two Speed Steering Drive

2. Torque Converter 6. Final Drive
3. Drive Shaft 7. Drive Sprockets
4. Transmission
Power from the engine (1) is transmitted through the ring gear to the
torque converter (2). A drive shaft (3) couples the converter flange with
the transmission (4) flange. The converter delivers torque according to
the variation in load on the oil used as the medium, and transmits the
power to the transmission (4). Then, the engine power is transmitted to
the charge pump (front section), through the accessory drive gear driv-
ing the pump. The transmission is designed to provide high speed shift-
ing by use of hydraulic clutches. It has three forward and reverse speeds.
Gears are mounted on four shafts; directional (input) shaft, range (out-
put) shaft, countershaft and reverse idler shaft. The output shaft and pin-
ion gear transmits power to the bevel gear carrier in the rear main frame.
In the steering drive (5), power transfer is from the bevel gear and carri-
er assembly through the clutch and brake packs out to the final drive (6)
pinion shaft to the sprocket (7) and tracks.
D87E-2 D87P-2 10-9 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS DRIVE SHAFT
12
DRIVE SHAFT
1. Drive Shaft 2. Spider and Bearing 3. Mounting Bolts
DRIVE TRAIN SCHEMATIC

1. Rear Main Frame 10. Pilot Control Valve

2. Suction Tube Strainer 11. Pilot Control Valve Manifold
3. In Line Suction Strainer 12. Test Port Manifold
4. Charge Pump 13. Transmission
5. Torque Converter 14. Oil Cooler in Bottom of Radiator
6. Pressure Filter 15. In Hose Suction Strainer
7. Pressure Regulator Valve 16. Transmission Scavenge Pump
8. Rate of Rise Valve 17. Flywheel Housing Scavenge Pump
9. Range Selector Valve 18. Steering Control Valve
10-10 2 D87E-2 D87P-2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS DRIVE TRAIN SCHEMATIC
12
REPLACE THIS PAGE WITH FOLDED PAGE 10-11 FROM THE REAR OF BOOK.
D87E-2 D87P-2 10-11 2

12
1. Rear Main Frame 11. Pilot Control Valve Manifold

2. Suction Tube Strainer 12. Test Port Manifold
3. In Line Suction Strainer 13. Transmission
4. Charge Pump 14. Oil Cooler in Bottom of Radiator
5. Torque Converter 15. In Hose Suction Strainer
6. Pressure Filter 16. Transmission Scavenge Pump
7. Pressure Regulator Valve 17. Flywheel Housing Scavenge Pump
8. Rate of Rise Valve 18. Steering Control Valve
9. Range Selector Valve 19. Pressure Regulator Valve
10. TASC Valve 20. Neutral Start Solenoid Valve
10-12 2 D87E-2 D87P-2

12
D87E-2 D87P-2 10-13 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS DRIVE TRAIN PIPING DIAGRAM
12
DRIVE TRAIN PIPING DIAGRAM
10-14 2 D87E-2 D87P-2

12
A. Suction Circuit 6. Torque Converter
B. Charge and Cooling Circuit 7. One or Two Speed Steering Valve
C. Transmission Circuit 8. Radiator with Lower Oil Cooler
D. Scavenge Circuit 9. Transmission with Valves
E. Test Circuit 10. Pilot Control Valve Manifold
1. Suction Pipe at Rear Main Frame 11. Flywheel Housing Scavenge Pump
2. Suction Strainer 12. In Line Strainer Screen
3. Charge and Scavenge Pump 13. Range Selector Valve
4. Pressure Filter 14. Test Port Manifold
5. Pressure Regulator Valve
D87E-2 D87P-2 10-15 2

12
10-16 2 D87E-2 D87P-2

12
A. Suction Circuit 7. One or Two Speed Steering Valve
B. Charge and Cooling Circuit 8. Radiator with Lower Oil Cooler
C. Transmission Circuit 9. Transmission with Valves
D. Scavenge Circuit 10. TASC Valve
E. Test Circuit 11. Flywheel Housing Scavenge Pump
1. Suction Pipe at Rear Main Frame 12. In Line Strainer Screen
2. Suction Strainer 13. Range Selector Valve
3. Charge and Scavenge Pump 14. Test Port Manifold
4. Pressure Filter 15. Pressure Regulator Valve
5. Pressure Regulator Valve 16. Neutral Start Solenoid Valve
6. Torque Converter
D87E-2 D87P-2 10-17 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS TORQUE CONVERTER MOUNTING
12
TORQUE CONVERTER MOUNTING
1. Engine Flywheel Housing 5. Torque Converter Spacer
2. Engine Flywheel 6. Drive Shaft
3. Converter Gear Ring 7. Flywheel Housing Scavenge Pump
4. Torque Converter 8. Flywheel Housing Scavenge Pump Hose
10-18 2 D87E-2 D87P-2

12
D87E-2 D87P-2 10-19 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS TORQUE CONVERTER
12
TORQUE CONVERTER
10-20 2 D87E-2 D87P-2

12
1. Drive Housing 6. Stationary Stator 11. Output Shaft
2. Impeller 7. Thrust Washer 12. Main Converter Housing
3. Ground Sleeve Hub 8. Thrust Washer 13. Ball Bearing
4. Ball Bearing 9. Thrust Bearing 14. Ball Bearing
5. Pump Drive Gear 10. Turbine 15. Pump Driven Gear
Unit: mm
Check Item Criteria Remedy
Standard Size Clearance Limit
Output shaft bearing to
A 0 to 0.10 0 to 0.10
retainer cap
Replace
Turbine bearing to re-
B 0.127 to 0.38 0.127 to 0.38
tainer cover
Tolerance Standard Clearance
Shaft OD Clearance Limit
Seal OD Housing ID
92.2 91.98 -0.22 to
C Oil seal and housing 66.7
92.1 92.06 -0.04
The torque converter contains a single stage, single phase, three element
converter assembly and a rear gear housing to drive the drive train
charge and scavenge pump, the flywheel housing scavenge pump and
the equipment pump. The torque converter performs two functions: it
couples the engine to the transmission and multiplies engine torque. The
drive housing (1) is engine driven by a ring gear bolted to the engine
flywheel. The impeller (2) is bolted to the drive housing and is support-
ed on the ground sleeve hub (3) by a ball bearing (4). The pump drive
gear (5), bolted to the impeller hub, drives the pump driven gears (15)
whenever the engine is running. The stationary stator (6) is splined to
the hub and locked in place. Thrust washers (7 and 8), pinned to the sta-
tor, and thrust bearings (9) are located on each side of the stator to ab-
sorb the side thrusts of the impeller and turbine. The turbine (10) is
splined to the output shaft (11) and supported in the drive housing and
main housing (12) by ball bearings (13 and 14).
The impeller (2), which rotates at engine rpm, receives fluid from the
transmission pump via the main regulator valve through the main hous-
ing (12) and outside of the ground sleeve hub (3). Fluid enters the center
of the impeller and is expelled from its outside diameter blades at a high
velocity. The turbine (10) is positioned opposite the impeller and re-
ceives the full impact of the impeller discharge. A small amount of fluid
exits over the outside of the turbine to lubricate the turbine hub bearing
(13). The fluid enters the turbine at its outside diameter blades and is
discharged at its center in the opposite direction of rotation from that of
the fluid entering the impeller. The curved blades of the stator (6) redi-
rect a part of the flow of fluid back to the impeller in the same direction
that the impeller is moving to increase the torque output. The remaining
fluid flows out between the ground sleeve hub (3) and output shaft (11)
to the oil cooler.
D87E-2 D87P-2 10-21 2

12
Because the turbine blades are curved, not all the force of the oil from
the impeller is absorbed by the turbine. For example, suppose the oil
leaving the impeller carries a force of 45 kg, assume in this instance that
the turbine absorbs only 36 kg of this force. Oil leaving the turbine car-
rying a force of 9 kg is directed to the stator. The curved stator blades
will absorb only 4.5 kg of the 9 kg of force. The oil from the stator that
is redirected to the impeller carries a force of 4.5 kg. This 4.5 kg of
force is added to the original 45 kg of force. The converter will there-
fore continue to increase (multiply) the input torque up to the limits of
the converter design ratio. When the machine load is light, the turbine
speed is approximately the same as the impeller speed, thereby applying
little or no force on the blades. As the machine load increases, the tur-
bine speed decreases. Since the impeller is still turning at engine speed,
fluid is thrown from the impeller and into the turbine with great force.
Engine torque to the sprockets increases with a resulting decrease of
machine speed.
10-22 2 D87E-2 D87P-2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS TRANSMISSION
12
TRANSMISSION
CONTROLS
The transmission is pilot operated by the pilot control valve, manifold

and hosing to the transmission control valves.
The transmission is pilot operated by the TASC valve and hosing to the
transmission control valves.
D87E-2 D87P-2 10-23 2

12
MOUNTING
1. Valve Manifold 4. Range Selector Valve

2. Main Regulator Valve 5. Transmission Case
3. Rate Of Rise Valve 6. Mounting Bolts (qty. 3)
10-24 2 D87E-2 D87P-2

12
CROSS SECTION
D87E-2 D87P-2 10-25 2

12
1. Transmission Case 6. Range (Output) Shaft 11. Input Shaft Manifold Supply Tubes
2. Transmission Rear Cover 7. Reverse Idler Shaft 12. Output Shaft Manifold
3. Input from Torque Converter 8. Output to Steering Drive 13. Output Shaft Manifold Supply Tubes
4. Directional (Input) Shaft 9. Output to Rear Equipment 14. Strainer and Baffle
5. Countershaft 10. Input Shaft Manifold
Unit - mm
Bearing Adjustment End Play
A Input shaft, output shaft and countershaft 0.127 to 0.254 mm
B Reverse idler shaft 0.00 mm
Std Size
OD ID Clearance Limit
82.753 82.537 -0.216 to

C Oil seal and housing 82
82.651 82.613 -0.038
The transmission is designed to provide high speed shifting by use of

hydraulically actuated clutch packs. It has three forward and three re-
verse speeds. Gears are mounted on four shafts; directional (input) shaft
(4), range (output) shaft (6), countershaft (5) and reverse idler shaft (7).
DIRECTIONAL SHAFT: The directional (input) shaft (4) rotates on

two tapered roller bearings. It consists of a forward drive gear and a re-
verse drive gear.
COUNTERSHAFT: The countershaft (5) rotates on two tapered roller

bearings. It consists of the 3rd speed drive gear, 2nd speed drive gear
and 1st speed drive gear.
RANGE SHAFT: The range (output) shaft (6) rotates on two tapered
roller bearings. It consists of the 3rd speed driven gear, 2nd speed driv-
en gear and 1st speed driven gear. It also contains dual hydraulic clutch
pack for 1st and 3rd speeds and a single clutch pack for 2nd speed.
REVERSE IDLER SHAFT: The reverse idler shaft (7) is bolted to the
rear cover (2). It consists of a reverse idler gear which rides on a double
tapered roller bearing and is in constant mesh with reverse drive gear
and 2nd speed drive gear.
10-26 2 D87E-2 D87P-2

12
GEAR SHIFT OPERATION
Main pressure oil is detected from the range selector valve through
tubes to the manifolds and on through the shafts to engage the desired
clutch pack. Lubrication oil is always directed through tubes to lubricate
the bearings, clutches and shafts.
NEUTRAL: Engine power and torque are delivered through the con-
verter and drive shaft to the transmission directional (input) shaft (A).
As the forward and reverse clutch packs are not engaged, the shaft turns
freely inside the gears. No power is transmitted to the countershaft (B)
or to the range (output) shaft (C).
1ST SPEED FORWARD: Engine power and torque are delivered

through the converter and drive shaft to the directional (input) shaft (A).
As the forward clutch pack is activated, it engages the forward gear and
rotates it in the same direction as the shaft. The countershaft (B),
through the 3rd speed drive gear, is rotated in the opposite direction. As
the 1st speed clutch pack is activated, it engages the 1st speed driven
gear to the range (output) shaft (C). Power from the countershaft is
transferred, through the 1st speed drive gear, to the range (output) shaft
in the opposite direction of rotation. Power is delivered from the range
(output) shaft to the steering and sprocket drives and on to the tracks.
2ND SPEED FORWARD: Engine power and torque are delivered

through the 3rd speed drive gear, is rotated in the opposite direction. As
the 2nd speed clutch pack is activated, it engages the 2nd speed driven
gear to the range (output) shaft (C). Power from the countershaft is
transferred, through the 2nd speed drive gear, to the range (output) shaft
in the opposite direction of rotation. Power is delivered from the range
(output) shaft to the steering and sprocket drives and on out to the
tracks.
D87E-2 D87P-2 10-27 2

12
3RD SPEED FORWARD: Engine power and torque are delivered
through the 3rd speed clutch pack, is activated and engages the 3rd
speed driven gear to the range (output) shaft (C). Power from the 3rd
speed drive gear is transferred to the range (output) shaft in the opposite
direction of rotation. Power is delivered from the range (output) shaft to
the steering and sprocket drive and on out to the tracks.
1ST SPEED REVERSE: Engine power and torque are delivered

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

gear and rotates it in the same direction as the shaft. The 2nd speed
drive gear through the reverse idler gear (D), is rotated in the same di-
rection as the directional (input) shaft. As the 2nd speed clutch pack is
activated, it engages the 2nd speed driven gear to the range (output)
shaft (C). Power is transferred from the 2nd speed drive gear to the
range (output) shaft through the driven gear and clutch pack in the op-
posite direction of rotation from the directional (input) shaft. Power is
10-28 2 D87E-2 D87P-2

3RD SPEED REVERSE: Engine power and torque are delivered

gear and rotates it in the same direction as the shaft. The countershaft
(B), through the reverse idler gear (D) and 2nd speed drive gear, is ro-
tated in the same direction as the directional (input) shaft. As the 3rd
speed clutch pack is activated, it engages the 3rd speed driven gear to
the range (output) shaft (C). Power from the countershaft is transferred
to the range (output) shaft through the 3rd speed drive gear and driven
gear and the clutch pack in the opposite direction of rotation. Power is
D87E-2 D87P-2 10-29 2

12
DIRECTIONAL (INPUT) SHAFT
1. Tapered Roller Bearing 6. Gear Needle Bearing 11. Drum, Hub and Shaft
2. Thrust Bearing Assembly 7. Forward Clutch Pack 12. Reverse Piston
3. Fluid Manifold 8. Backing Plate 13. Reverse Clutch Pack
4. Manifold Needle Bearing 9. Piston Return Spring Assembly 14. Reverse Drive Gear
5. Forward Drive Gear 10. Forward Piston 15. Manifold Seals
Unit - mm
Item Std Size
105.001 104.919 -0.082 to
A Housing end bearing cup in retainer 105
104.98 104.957 -0.023
65.062 64.986 0.067 to
B Housing end bearing cone on shaft 65
65.026 65.001 0.025
105.001 104.919 -0.082 to
C Cover end bearing cup in cover 105
104.98 104.958 -0.022
65.062 64.986 0.067 to
D Cover end bearing cone on shaft 65
65.026 65.001 0.025
Free Length Test Length Work Length Test Load Working Coils
E Piston return spring x28 40 32 24 to 32 83 to 92 N 7.5
Standard Size Max Allowable Wear Size
F Clutch friction disc 2.46 to 2.62 2.36
The directional (input) shaft rotates on two tapered roller bearings. It

consists of a forward drive gear, reverse drive gear and dual hydraulic
clutch packs. The clutch is used to transfer power to the gear hub. It con-
sists of the pistons, friction discs and separator plates and return springs
(9). The disc teeth mesh with the outer teeth of the hub and gear. The
separator plate teeth mesh with the inner teeth of the drum housing.
CLUTCH ENGAGED: The oil from the range selector valve passes
through the port of the shaft and fills the cavity behind the piston. The
piston pushes the friction discs against the separator plates and starts the
discs rotating. The piston also holds in position the gear hub with which
the discs mesh allowing power to pass to the gear.
CLUTCH DISENGAGED: When the oil from the valve is stopped,

the piston is returned to its original position by the piston return springs.
The friction between the separator plates and the friction discs is re-
leased and the power released from the gear.
10-30 2 D87E-2 D87P-2

12
D87E-2 D87P-2 10-31 2

12
COUNTERSHAFT
1. Tapered Roller Bearing 3. Countershaft 5. 3rd Speed Gear

2. Retaining Ring 4. 2nd Speed Gear 6. 1st Speed Gear
Unit - mm
Item Std Size
105.001 104.919 -0.082 to
104.98 104.957 -0.023
65.062 64.986 0.067 to
65.026 65.001 0.025
105.001 104.919 -0.082 to
104.98 104.958 -0.022
65.062 64.986 0.067 to
65.026 65.001 0.025
The countershaft (3) rotates on two tapered roller bearings (1). It con-
sists of 3rd speed drive gear (5), 2nd speed drive gear (4) and 1st speed
drive gear (6).
10-32 2 D87E-2 D87P-2

12
D87E-2 D87P-2 10-33 2

12
RANGE (OUTPUT) SHAFT
1. Tapered Roller Bearing 9. 3rd Speed Drive Gear 17. Piston Return Spring (qty. 6)
2. Tapered Roller Bearing 10. Gear Needle Bearing 18. 3rd Speed Piston
3. Thrust Bearing Assembly 11. 1st Speed Clutch Pack 19. 2nd Speed Clutch Pack
4. Half Thrust Bearing Assembly 12. Backing Plate 20. 2nd Speed Piston
5. Fluid Manifold 13. Piston Return Spring (qty. 8) 21. 2nd Speed Drum and Hub
6. Manifold Needle Bearing 14. 1st Speed Piston 22. Retaining Ring
7. 1st Speed Drive Gear 15. 1st and 3rd Drum, Hub and Shaft 23. Manifold Seals
8. 2nd Speed Drive Gear 16. 3rd Speed Clutch Pack 24. Piston Seal
Unit - mm
Item Std Size
105.001 104.919 -0.082 to
104.98 104.958 -0.022
65.062 64.986 0.067 to
65.026 65.001 0.025
149.999 149.918 -0.081 to
149.974 149.944 -0.030
95.036 94.98 0.056 to
95.013 95.001 0.012
E Piston return spring x22 53 42 38 to 42 200 to 218 N 9.5
Standard Size Max Allowable Wear Size
F Clutch friction disc 2.77 to 2.92 2.67
The range (output) shaft rotates on two tapered roller bearings. It con-
sists of the 3rd speed driven gear, the 2nd speed driven gear and the 1st
speed driven gear. It also contains dual hydraulic clutch pack for 1st and
3rd speeds and a single clutch pack assembly for 2nd speed. The clutch
is used to transfer power to the gear hub. It consists of the pistons, fric-
tion discs and separator plates and return springs. The disc teeth mesh
with the outer teeth of the hub and gear. The separator plate teeth mesh
with the inner teeth of the drum housing.
CLUTCH ENGAGED: The oil from the range selector valve passes
through the port of the shaft and fills the cavity behind the piston. The
piston pushes the friction discs against the separator plates and starts the
discs rotating. The piston also holds in position the gear hub with which
the discs mesh allowing power to pass to the gear.
CLUTCH DISENGAGED: When the oil from the valve is stopped,

the piston is returned to its original position by the piston return springs.
The friction between the separator plates and discs is released and the
power released from the gear.
10-34 2 D87E-2 D87P-2

12
D87E-2 D87P-2 10-35 2

12
REVERSE IDLER SHAFT
1. Mounting Bolt 4. Reverse Idler Gear

2. Mounting Plate 5. Double Tapered Roller Bearing
3. Seal Ring 6. Reverse Idler Shaft
The reverse idler shaft is bolted to the housing. It consists of a reverse

idler gear which rides on two tapered roller bearings and is in constant
mesh with reverse drive gear and 2nd speed drive gear.
Unit - mm
Item Std Size
81.998 81.932 -0.066 to
A Bearing cup in gear 82
81.978 81.958 -0.020
49.987 49.959 0.028 to
B Bearing cone on shaft 50
49.999 49.984 0.015
10-36 2 D87E-2 D87P-2

12
PRESSURE REGULATOR VALVE
1. Main Spool 5. Main Spool Inner Return Spring 9. Lube Spool Return Spring
2. Main Spool Outer Return Spring 6. Converter Spool 10. Return Spring Shims
3. Cold Oil Check Ball 7. Converter Spool Return Spring
4. Check Ball Return Spring 8. Lube Spool
Unit: mm
Item Free Length Test Length Work Length Test Load Working Coils
A Check ball spring 21 15 13 to 15 75 to 84 N 7
B Main spool outer spring 77 53 47 to 54 380 to 398 N 11
C Main spool inner spring 50 35 30 to 37 193 to 207 N 10
D Converter spool spring 72 51 46 to 54 278 to 300 N 12
E Lube spool spring 81 50.80 46 to 54 95 to 109 N 16
F Main spool spring shim 0.80 (One shim will change the pressure by 0.35 kg/cm²) ..................................... max of 3
G Converter spool spring shim 0.80 (One shim will change the pressure by 0.25 kg/cm²) ..................................... max of 2
H Lube Spool Spring shim 0.80 (One shim will change the pressure by 0.07 kg/cm²) ..................................... max of 3
D87E-2 D87P-2 10-37 2

This valve is a cascade type, pressure control valve consisting of three

individual valves encased in one housing. The first valve is used to con-
trol pressure for the engagement of the clutches in the trans and steering
drive. The second valve is used to control pressure in the converter. The
third valve is used to control lube pressure in the trans. A cold oil relief
valve is included in the first valve.
Oil from the pump enters the valve at cavity M. This oil is then directed
to the other control valves and on to the trans and steering drive to oper-
ate the clutch packs. As pump flow continues, pressure builds and oil is
forced through the center of the spool, causing it to move against the
outer and inner springs. When the pressure reaches its max, the first
valve opens and allows oil to enter cavity C.
The main spool also contains a cold oil relief valve. When the oil is
cold, the check ball is forced against the spring and excessive pressure is
relieved and valve chatter is prevented.
Excessive oil from cavity M enters cavity C and is directed on to the

converter. When flow is met, pressure builds and oil is forced through
the center of the spool causing the spool to move against the spring.
When pressure reaches its max, the second valve opens and allows oil to
enter cavity L. Return oil from the oil cooler and excessive oil from cav-
ity C enters cavity L and is then directed to the transmission for lube.
Whenever this oil reaches its max, the third valve opens and dumps the
oil to drain.
10-38 2 D87E-2 D87P-2

12
RANGE SELECTOR VALVE
1. Speed Spool 3. Directional Spool - Long 5. Directional Spool Return Spring

2. Speed Spool Return Spring 4. Directional Spool - Short
Unit: mm
A Spool return spring 48 35 35 to 43 249 N 11
The range selector valve is a hydraulic controlled, directional valve con-

sisting of two speed spools and two directional spools. The speed spools
are separated in the housing by a centering spring. The directional
spools are held together at one side by their return spring. The range se-
lector valve is used to provide main pressure oil to and return oil from
the rate of rise valve to the desired clutch packs. The valve is controlled
by the pilot control valve. The short directional spool controls the flow
of oil to the rate of rise valve.
NEUTRAL: The return spring holds the short directional spool against
the long one, thereby cutting off the flow of oil.
FORWARD: Main pressure oil from the pilot control valve enters port
F and shifts spool against the return spring. Once short directional spool
is shifted over, port P1 is open to port P, directing oil to the rate of rise
valve. The long direction spool controls the flow of oil to the forward
and reverse clutch packs. Main pressure oil from pilot control valve en-
ters port F, holding long directional spool against end cover, oil from the
rate of rise valve enters port FR, and is directed out port Fc to engage
the forward clutch.
D87E-2 D87P-2 10-39 2

12
REVERSE: Main pressure oil from the pilot control valve enters port R
and shifts both spools against the return spring. Main pressure oil enters
port R, shifts spool and port FR is opened to port Rc to engage the re-
verse clutch.
1ST: The two speed spools control oil flow to range clutch packs. Main
pressure oil from the pilot control valve enters port 1, shifting the spool
against the return spring. Oil from the rate of rise valve enters port Pc
and is directed out port 1c to engage the 1st speed clutch.
2ND: Oil enters port 2 and shifts the spool. Port Pc is opened to port 2c
to engage the 2nd speed clutch.
3RD: The return spring holds both of the speed spools in place and port
Pc is opened to port 3c to engage the 3rd speed clutch.
10-40 2 D87E-2 D87P-2

12
RATE OF RISE VALVE
1. End Cover 6. Sequence Spool Spacer 11. Reducing Spool Spring
2. End Cover Gasket 7. Dowel Pin 12. Modulating Piston
3. Sequence Spool Spring 8. Valve Housing 13. Inner Piston Spring
4. Tube Spacer 9. Sequence Spool 14. Piston Spring Retainer
5. Sequence Spool Disc 10. Reducing Spool 15. Outer Piston Spring
Unit: mm
A Mod piston outer spring 46 32 22 to 36 160 to 178 N 4
B Mod piston inner spring 88 71 56 to 73 160 to 178 N 14
C Reducing spool spring 45 19 19 to 24 245 to 263 N 3.5
D Sequence spool spring 71 25 15 to 29 0.8 N 6
The rate of rise valve is a sequencing, pressure regulating valve used to

provide a smooth shift without shock. This valve controls the length of
time that it takes to fully pressurize a clutch and also allows the direc-
tional clutch to engage before range clutch. The rate of rise valve has six
ports (A to F) and two passages which are located on the bottom of the
valve but which are shown in cross section on the sides of the valve, for
clarity. Pressure oil from the main regulator valve enters the left hand
upper cavity through port A and keeps this cavity at main pressure
whenever the engine is running. Pressure oil from the main regulator
valve enters the left hand lower cavity through port B. This port con-
tains an orifice that limits the flow of oil into this cavity. This lower cav-
ity is open to drain port C. The modulating piston (12) acts as a variable
orifice for this drain to control pressure in this cavity. Pressure oil from
the range selector valve enters the right side of the lower cavity through
port D only when the short directional spool in the range selector valve
is shifted. This oil is directed out of the valve through ports E and F.
Port E directs oil to the directional spool of the range selector valve.
Port F directs oil to the range spools of the range selector valve but its
flow is controlled by the sequence spool (9).
NEUTRAL: In neutral, the range selector valve cuts off all oil flow to
port D and opens it to drain. Without any oil pressure in the right cavity
of the valve, both spools (9 and 10) will shift right. Tension from
springs (14 and 15) holds the modulating piston (12) to the right, leav-
ing drain port C open. Oil entering the left cavity through port B will
flow freely to the drain port C and no pressure will build in this cavity.
Oil pressure from port A, along with the tension from spring (3), holds
the sequence spool (9) to the right, allowing oil from port F to pass
through the spool and out drain port C.
D87E-2 D87P-2 10-41 2

12
SHIFTING: When shifting, the range selector valve directs oil to port
D. This oil flows through the holes in the reducing spool (10) and exits
through port E to fill the directional clutch. Some oil can also pass
through the orifice in the end of the spool, but because the passage G is
still open to drain, the modulation piston (12) will not shift. When the
directional clutch is full, pressure builds in the clutch and in the cavity
on the right side of the valve. The sequence spool (9) begins to move
against the tension of the spring (3) and pressure from port A. As the
spool moves to the left, the metering holes index with port F and the
drain holes in the left side of the spool are cut. Oil from port D can now
pass through the metering holes to port F to fill the range clutch. Be-
cause oil must pass through the metering holes, pressure in the right
hand cavity and to the directional clutch will remain higher than the
pressure at port F. Oil passing through the end of the reducing spool
(10) begins to build pressure against the modulating piston (12), push-
ing it slowly to the left against the springs (14 and 15). The piston has a
series of orifices which decrease in size from left to right. As the piston
moves to the left, decreasing size holes index with drain port C causing
a restriction to flow of oil from port B. This causes pressure to build
against the back side of the piston which slows its movement, which in
turn allows the build up of pressure in the clutches.
10-42 2 D87E-2 D87P-2

12
D87E-2 D87P-2 10-43 2

12
PILOT CONTROL VALVE
1. Pilot Control Valve Spool 3. Spool Detent Mechanism

2. Spool Detent Cam 4. Valve Spool Return Spring
Unit: mm
A Spool return spring 56 36 36 to 38 65 N 5
The pilot control valve is a manual controlled, directional control valve

used to direct main pressure oil to the range selector valve to shift those
spools. The pilot control valve spool incorporates a detent mechanism to
keep the shift lever in the desired position.
Main pressure oil from the main regulator valve enters the pilot control
valve at port M and flows around and through the spool. When the shift
lever is in the neutral position, oil is blocked from the directional and
speed ports. When the shift lever is moved, the spool is rotated and
moved back and forth in the valve housing. Rotation of the spool will
align oil at the front of valve with either the F or R ports. When the
spool moves back, oil flowing through the spool will be aligned with ei-
ther ports 1 or 2 or will be blocked off for 3rd speed. Main oil pressure
directed out the F or R ports and 1 or 2 ports is directed to the range se-
lector valve to shift the directional spools. Some oil is allowed to leak
past the spool for lubrication purposes and then is directed through the
D port back to the transmission.
10-44 2 D87E-2 D87P-2

12
PILOT MANIFOLD
1. Spring Retainer Plug 4. Dowel Pin 7. Check Ball Spring

2. Pin Guide Spring 5. Port Plug 8. Restrictor Fitting
3. Pin Guide 6. Check Ball 9. Manifold Housing
Unit: mm
A Pin guide spring 40 27 27 to 30 96 N 18
B Check ball spring 14 11 10 to 11 0.7 N 5
The pilot manifold serves two purposes, it directs oil from the pilot con-
trol valve to the pilot hoses and provides a pressure connection for the
transmission pressure switch. Two ball checks and a dowel pin and
spring are part of the pressure switch circuit. The ball checks work as a
shuttle valve system, allowing either Pc - clutch pressure, to the switch
when the transmission is in gear or main pressure when in neutral. With-
out this system, the switch would close when in neutral and give a false
indication. The dowel pin and spring work as a hydraulic time delay.
This delay maintains oil pressure at the switch during a shift. Without
the time delay the switch would close during clutch engagement and
cause the indicator light to blink.
D87E-2 D87P-2 10-45 2

12
TASC VALVE
10-46 2 D87E-2 D87P-2

12
1. Valve Body 18. ½NC Hex Nut 35. Detent Ball
2. Expander Plug 19. Dowel Pin 36. Range Detent Spring
3. Port Plug 20. Dowel Pin 37. Detent Guide
4. Steering Spool 21. Range Cam 38. Detent Guide Plug
5. Pickup Spacer 22. Bottom Cover 39. Seal Ring
6. Inner Spring 23. Cover Plug 40. Switch Arm
7. Outer Spring 24. Orifice Plug 41. Detent Guide Plug
8. Directional Spool 25. Dowel Pin 42. Brass Screw
9. Spring Retainer Washer 26. Motion Lever 43. Locking Bolt
10. Forward Reverse Spring 27. Bearing Housing 44. Wiper Seal
11. Retainer Nut 28. Cam Ring 45. Wiper Seal
12. Spool Rocker End 29. Ball Bearing 46. Wiper Seal
13. NC Jam Nut 30. Retaining Ring 47. Seal Ring
14. Range Spool 31. Universal Joint 48. Seal Ring
15. Thrust Bearing 32. Joint Boot 49. Seal Ring
16. Thrust Washer 33. Tie Strap
17. Dowel Pin 34. Dowel Pin
Unit: mm
Spring Criteria
A Inner Spring 67.6 38.6 25.4 to 38.6 51.2 ± 4.5 N 15.5

B Outer Spring 65.5 32.9 23.1 to 32.9 31.2 ± 3.4 N 10
C FR Spool Spring 40.4 23.6 17.3 to 23.6 120.6 ± 6.7 N 5.5
D Detent Spring 26.4 19.9 19.0 to 19.9 111.2 ± 6.7 N 6
Description
The transmission/steering valve is a manually controlled direction,

range and steering control valve. The valve is used to direct main oil
pressure to the transmission range selector valve for transmission con-
trol and to the steering drive clutches for steering control. A detent
mechanism holds the control lever in the desired transmission selection.
THEORY OF OPERATION
Main pressure from the main regulator valve enters the motion control
valve at the “P” port and is distributed along and through the range
spool and around the range spool to the direction and steering spools.
When the control lever is in the centered “neutral” position, oil is active
at the selected range port and steering ports but is blocked at the direc-
tion spools.
D87E-2 D87P-2 10-47 2

12
DIRECTION
● When the control lever is moved forward, the cam plate depresses
the forward direction spool directing oil to the “F” port at the bottom
of the valve. The “F” pressure is also directed internally to the base
of the Reverse spool which pushes the reverse spool up to the cam
plate, this action creates a hydraulic detent holding the lever for-
ward. When pulling the control lever to neutral or reverse, the cam
plate pushes down on the reverse spool which displaces the hydrau-
lic detent oil. At the same time the forward spool follows the cam
plate up and mid way through its stoke the forward pressure is cut
off as well as the reverse hydraulic detent, allowing the valve to go
into neutral. If the lever is pulled all the way to reverse the same se-
quence of events happens for the reverse hydraulic detent.
RANGE
● A transmission range gear is selected by rotating the control lever. If

rotated counterclockwise to the left most position 1st gear is se-
lected, pressure is sent to the 1st gear pilot port of the range selector
valve. Rotating the control lever clockwise one detent position will
select 2nd gear, pressure is sent to the 2nd gear pilot port of the range
selector. Rotating one more position clockwise will select 3rd gear,
no pressure is sent in 3rd gear since the range selector is normally in
3rd gear without pressure. The range detent positions are provided
by a steel ball, spring and 4 steel pins located in the cover of the
valve.
STEERING
Steering is accomplished in two ways; By moving the control lever to

the left or right or by pushing the steering control buttons.
The two steering methods can be used together and in any combination.
When the machine is started the steering begins in the default condition
of both tracks in LO-LO. With the lever pushed to forward the machine
travels in FWD, LO-LO (both tracks in LO). Initial movement of the le-
ver to the right drops right LO clutch steering pressure causing the right
steering clutch to be in a neutral condition. The neutral condition is indi-
cated by a "feel point" or effort increase in the control lever movement.
Further movement of the lever further decreases pressure at the right
brake, which if moved to the end of the lever stroke will result in a pivot
turn to the right. By pushing the HI button both tracks shift up to HI-HI
(both tracks in HI). If traveling in HI-HI and the lever is pulled to the
right the following occurs. The initial lever movement lowers signal
pressure causing a sequence valve to automatically shift the right track
from HI to LO. With further lever travel to the right the right LO track
will go to the neutral condition as indicated by the "feel point" as dis-
cussed earlier. Further lever movement will result in a pivot turn. As the
lever is moved back to the upright position the LO clutch engages and
then up into HI. Button steering results in full power turns. It does not
matter what the current machine selection is, such as LO-LO or HI-HI.
By pressing the right button the controller automatically makes the
proper clutch selection to make a right turn. When the button is released
the machine returns to the previous LO-LO or HI-HI selection.
10-48 2 D87E-2 D87P-2

12
NEUTRAL START VALVE
1. Valve Housing 2. Solenoid Valve 3. Sequence Valve
D87E-2 D87P-2 10-49 2

12
The neutral start valve provides two functions; Blocks flow to the trans-
mission and steering valve when the safety lever is in the lock position.
and allows flow to pass to the transmission and steering valve when the
safety lever is in the unlock position. It also provides a pressure location
for the transmission pressure sensing switch.
The Neutral Start Valve contains a normally closed solenoid valve and a
sequence valve. The valve is located inside the left hand pod compart-
ment. When starting the machine the safety lever is in the lock position
and the solenoid is deenergized. Transmission pressure enters the neu-
tral start valve. The normally closed solenoid valve blocks the flow. In
this condition the transmission and steering control valve is not opera-
tional. When the safety lock lever is moved to the unlocked position, an
electric switch is closed sending power to the solenoid valve. The ener-
gized solenoid valve opens and directs flow to the transmission and
steering control valve. The transmission and steering control valve is
now operational.
The second function of the valve is to provide a transmission pressure

signal to the transmission pressure switch. Transmission pressure is di-
rected to the pressure switch from the small pilot hose. The pressure sig-
nal enters the sequence valve. When the transmission is in neutral the
sequence valve shifts directing main pressure to the switch, in this con-
dition there is no pressure in the pilot line, so the main pressure signal
prevents the warning light from lighting. When a transmission shift is
made, the sequence valve shifts directing the actual transmission pres-
sure to the pressure switch.
10-50 2 D87E-2 D87P-2

12
PRESSURE REGULATOR VALVE
1. Valve Body 2. Sequence Valve Cartridge
General
The purpose of the regulator valve is to maintain a steady pressure to

the transmission and steering valve.
Transmission pump flow enters the regulator valve. The regulated pres-
sure branches off and is connected to the neutral start valve. When the
regulator pressure setting is met, the valve opens and flow continues on
to the transmission regulator valve mounted on the transmission.
There are three connections on the valve body, IN, OUT and DRAIN.
The valve is nonadjustable.
D87E-2 D87P-2 10-51 2

12
CHARGE AND SCAVENGE PUMP
1. Input Shaft 2. Charge Pump Section 3. Scavenge Pump Section
The transmission charge and scavenge pump is a dual element fixed de- Specifications
livery gear type pump located on the right hand side of the torque con-
Charge Section.............................. 121 L/min
verter. The rear section of the pump supplies the oil flow for the
transmission control valves, steering control valve and the torque con- Scavenge Section .......................... 155 L/min
verter. This section draws oil from rear main frame through the suction Delivery Mode:
strainer. The oil from the outlet side of the pump is directed through the
pressure filter and on to the valves. The front section of the pump scav- Temperature ...........................................49°C
enges the excess oil from the transmission through a screen fitting and Engine rpm ............................................2100
directs it back to the rear main frame.
Pressure..........................................21 kg/cm²
10-52 2 D87E-2 D87P-2

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MEMORANDA
D87E-2 D87P-2 10-53 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS TWO SPEED STEERING
12
TWO SPEED STEERING
10-54 2 D87E-2 D87P-2

12
DRIVE UNIT
1. Pinion Housing 4. High Speed Clutch/Lube Manifold 7. Low Speed Clutch

2. Pinion Shaft and Gear 5. High Speed Clutch 8. In Board Low Speed Planetary
3. Bevel Gear 6. Brake Clutch 9. Output (Dog Bone) Shaft
Unit - mm
Item Std Size
79.9998 79.9998 0.0 to

A Pinion outer bearing cone on shaft 80
80.0252 79.9846 -0.0406
129.9820 129.9566 -0.0254 to
B Pinion outer bearing cup in housing 130
129.9997 129.9312 -0.0685
100.0252 99.9998 -0.0254 to
C Pinion inner bearing cone on shaft 100
100.0557 99.9795 -0.0762
159.9743 159.9489 -0.0254 to
D Pinion inner bearing cup in housing 160
159.9997 159.9235 0.0762
92.0953 92.1004 0.0051 to
E Left bearing cone on hub 92
92.1207 92.075 -0.0457
152.4000 152.3746 -0.0254 to
F Left bearing cup in carrier 152
152.4254 152.3238 -0.1016
95.2881 95.2754 -0.0127 to
G Right bearing cone on hub 95
95.3135 95.2500 -0.0635
152.5778 152.3746 -0.2032 to
H Right bearing cup in carrier 152
152.6286 152.3238 -0.3048
J High clutch inner spring x40 35.052 25.4 25.4 to 30.5 400 N 5
K High clutch outer spring x40 37.363 25.4 25.4 to 30.5 587 N 3
L Brake clutch spring x32 87.249 77.5 71.2 to 77.5 1157 N 7
M Low clutch spring 59.106 38.1 38.1 to 45.7 383 N 8
Clutch Friction Discs Standard Size Max Allowable Wear Size
N High clutch 4.1656 to 4.3688 4.0640 to 4.2672
P Brake clutch 4.1656 to 4.3688 4.0640 to 4.2672
Q Low clutch 4.1910 to 4.3434 4.0894 to 4.2418
Bevel gear backlash ...........................................................................................................................................0.254 to 0.33
Pinion gear bearing preload............................................................................................................................ 1.4 to 1.8 N•m
Bevel gear bearing preload ............................................................................................................................. 1.6 to 2.3 N•m
D87E-2 D87P-2 10-55 2

12
This steering system consists of a steering drive located in the rear main
frame and a control valve mounted on the rear main frame cover. Steer-
ing levers and a brake pedal cable operate the control valve. Oil pressure
from the control valve is directed to the steering drive to operate the
clutch packs. The steering drive consists of an individual circuit for each
side of the machine.
This unit is constructed into a housing similar to a transmission. This

design affords ease of assembly and service. It contains one low range
clutch pack, one high range clutch pack, one brake clutch pack and one
planetary on each side of the machine. The low and high range clutch
packs are hydraulically applied and spring released, where as the brake
clutch packs are spring applied and hydraulically released. An inner
planetary provides reduction in speed for the low range. If a hydraulic
failure occurs or the engine is stopped, the steering drive will automati-
cally apply the brakes, after a steering lever is pulled or the foot brake is
applied.
When both steering levers are in the high range position, hydraulic pres-
sure is directed to both the high range clutch packs and the brake clutch
packs. When the high range clutch packs are engaged, the sun gear,
planets and ring gear of the inner planetary are locked together and ro-
tate as an assembly. Power to the tracks is transmitted from the pinion
shaft to the bevel gear, through the engaged drive clutch packs, to the
output shaft and on to the sprocket drive.
When both steering levers are in the low range position, hydraulic pres-
sure is directed to both the low range clutch packs and the brake clutch
packs. When the low range clutch packs are engaged, it locks the sun
gear of the inner planetary to the stationary steering drive housing forc-
ing the planet gears to walk around the locked sun gear thereby turning
the carrier. Power to the tracks is transmitted from the pinion shaft to the
bevel gear, through the inner planetary, to the output shaft and out to the
sprocket drive.
To make a left gradual turn, the left steering lever is in the low range po-
sition and the right steering lever is in the high range position. Each le-
ver engages its side clutch pack and power to the tracks is transmitted
from the pinion shaft to the bevel gear, through the inner planetary, to
the output shaft and out to the sprocket drive. A right gradual turn is the
opposite.
To make a left pivot turn, the left steering lever is in the brake position
and the right steering lever is in the high range position. Each lever en-
gages its side clutch pack and power to the right track is transmitted
from the pinion shaft to the bevel gear, through the inner planetary, to
the output shaft and out to the sprocket drive. A right pivot turn is the
opposite.
10-56 2 D87E-2 D87P-2

12
This steering system consists of a steering drive located in the rear main
frame and a control valve mounted on the rear main frame cover. Steer-
ing lever and a brake pedal cable operate the control valve. Oil pressure
from the control valve is directed to the steering drive to operate the
clutch packs. The steering drive consists of an individual circuit for each
side of the machine.
This unit is constructed into a housing similar to a transmission. This

design affords ease of assembly and service. It contains one low range
clutch pack, one high range clutch pack, one brake clutch pack and one
planetary on each side of the machine. The low and high range clutch
packs are hydraulically applied and spring released, where as the brake
clutch packs are spring applied and hydraulically released. An inner
planetary provides reduction in speed for the low range. If a hydraulic
failure occurs or the engine is stopped, the steering drive will automati-
cally apply the brakes, after the foot brake is applied.
When the high range button is pushed, hydraulic pressure is directed to

both the high range clutch packs and the brake clutch packs. When the
high range clutch packs are engaged, the sun gear, planets and ring gear
of the inner planetary are locked together and rotate as an assembly.
Power to the tracks is transmitted from the pinion shaft to the bevel gear,
through the engaged drive clutch packs, to the output shaft and on to the
sprocket drive.
When the low range button is pushed, hydraulic pressure is directed to

both the low range clutch packs and the brake clutch packs. When the
low range clutch packs are engaged, it locks the sun gear of the inner
planetary to the stationary steering drive housing forcing the planet
gears to walk around the locked sun gear thereby turning the carrier.
Power to the tracks is transmitted from the pinion shaft to the bevel gear,
through the inner planetary, to the output shaft and out to the sprocket
drive.
To make a left gradual turn, push the left button. The circuit logic will
select the left track to low range and the right track to high range. Power
to the tracks is transmitted from the pinion shaft to the bevel gear, thru
the inner planetary, to the output shaft and out to the sprocket drive. A
right gradual turn is the opposite.
To make a left pivot turn, the steering lever is in the full left posiotion.
Power to the right track is transmitted from the pinion shaft to the bevel
gear, through the inner planetary, to the output shaft and out to the
sprocket drive. A right pivot turn is the opposite.
D87E-2 D87P-2 10-57 2

12
STEERING VALVE
1. Upper Steering Valve 6. Metering Spool Return Springs 11. High Low Spools
2. Drive Clutch Signal Spools 7. Brake Spool Return Springs 12. High Low Spool Return Springs
3. Brake Spool 8. Brake Spool Poppet 13. High Low Spool Check Balls
4. Drive Clutch Metering Spools 9. Spool Poppet Return Spring 14. Check Ball Return Springs
5. Signal Spool Return Springs 10. Lower Steering Valve
Unit - mm
A Brake spool poppet spring 41.7 27.4 24.6 to 36.0 77 ± 4.4 N 11
B Brake spool inner spring 56.9 34.3 26.7 to 34.3 200 N 7.5
C Spool outer return spring 55.5 38.5 29.9 to 38.5 529 N 5
D Spool inner return spool 60.0 33.5 28.9 to 33.5 334 N 7.25
E Metering spool inner spring 26.0 22.5 22.5 to 26.0 38 ± 2.2 N 7.5
F Metering spool outer spring 41.7 27.4 24.6 to 36.0 77 ± 4.4 N 11
G Hi Lo spool return spring 88.4 63.7 63.7 to 69.3 222.5 ± 4.4 N 6.5
H Check ball return spring 42.3 21.3 21.3 to 24.6 27 N 14
Operation
The steering valve is contained in two housings. The upper housing con-
sists of three basic sections; the left side clutch, the right side clutch and
the foot brake. The left and right clutch sections control the flow of oil
to the clutch packs to drive each track individually. Both of the sections
contain a metering spool and a signal spool which are each held in the
drive position by two return springs. When the steering levers are
moved to the brake position, the signal spool is pulled against the return
spring. This movement causes a hydraulic signal that activates the me-
tering spool, moving it forward. The brake section, in the top housing,
contains one spool which is held in the drive position by a return spring.
When in this position, oil pressure from the clutch sections enter the
brake section and is evenly split into two separate circuits, one for the
left brake clutch and one for the right brake clutch. When the brake is
applied, the spool moves forward and begins to dissipate the oil pressure
to both brake clutches simultaneously.
The bottom housing contains two high/low spools, one for each side of
the machine. These spools are also controlled by the steering levers.
When the steering levers are in low position, the return springs hold the
spools in position. Oil pressure from the clutch sections enters the spool
bores and are directed out the low range port. When the levers are
moved to the high position, oil flows through the ball check in the
spools and hydraulically detentes the spools in this position. Oil pres-
sure from the clutch sections enters the spool bores and is directed out
the high range ports. When the steering levers are moved from the high
to low positions, the clutch section signal spools are momentarily
moved forward to release the hydraulic detent behind high low spools
and then both of the spools are moved back by the return springs.
10-58 2 D87E-2 D87P-2

12
D87E-2 D87P-2 10-59 2

12
10-60 2 D87E-2 D87P-2

12
Hydraulic Flow
This steering drive functions on a range of 0 to 19 kg/cm². The drive

clutches are actuated on a range of 7 to 19 kg/cm². When the pressure is
dissipated below 7 kg/cm², the drive clutches release and the brake
clutches begin to engage. The steering drive consists of two circuits for
each side of the machine. The following describes the operation of one
side only, with the other side being the same.
When the steering lever is in a drive position, main pressure from the
transmission main regulating valve enters the clutch section inlet port,
around the metering spool and on to the high low section. Here the oil is
divided into two circuits, one to the brake and one to the high low spool.
At the brake, oil enters the inlet port, around the brake spool and out to
disengage the brake clutch. At the high low spool, oil enters the inlet
port and is directed to that drive clutch. When the steering lever is slow-
ly moved to the brake position, the metering spool in the clutch section
of the valve begins to meter main pressure to the drain annulus, thereby
reducing pressure at the clutch annulus, which is connected to both the
drive and brake clutches. As pressure is reduced, the drive clutch releas-
es and the brake clutch begins to engage.
When all pressure is completely dissipated to the drain annulus, that

side of the machine is in a brake condition. When the foot brake is ap-
plied, the brake spool begins to meter main pressure to the right and left
brake clutches at the same rate. As pressure is reduced, the brake clutch-
es begin to engage. However, main pressure is still being supplied to
hold the drive clutches engaged.
Main pressure from the steering valve is also directed to the steering
valve manifold located below the main frame cover.
D87E-2 D87P-2 10-61 2

12
1. Upper Steering Valve 5. High Low Solenoid Valve 9. Spool Poppet Return Spring
2. Drive Clutch Signal Spools 6. High Low Sequence Valve 10. Lower Steering Valve
3. Brake Spool 7. Brake Spool Return Springs 11. High Low Spools
4. Drive Clutch Metering Spools 8. Brake Spool Poppet 12. High Low Spool Return Springs
Unit - mm
A Brake spool poppet spring 41.7 27.4 24.6 to 36.0 77 ± 4.4 N 11
B Brake spool upper spring 56.9 34.3 26.7 to 34.3 200 N 7.5
C Brake spool lower spring 55.5 38.5 29.9 to 38.5 529 N 5
D Hi Lo spool return spring 88.4 63.7 63.7 to 69.3 222.5 ± 4.4 N 6.5
Operation
The steering valve is contained in two housings and a rear mounted

valve. The upper housing consists of three basic sections; the left side
clutch, the right side clutch and the foot brake. The left and right clutch
sections control the flow of oil to the clutch packs to drive each track in-
dividually. Both of the sections contain a metering spool and a signal
spool which are each held in the drive position by two return springs.
When the steering lever is moved to the pivot position, the pilot pressure
TASC valve decreases. This pilot pressure activates the metering spool,
moving it forward. The brake section, in the top housing, contains one
spool which is held in the drive position by a return spring. When in this
position, oil pressure from the clutch sections enter the brake section
and is evenly split into two separate circuits, one for the left brake clutch
and one for the right brake clutch. When the brake is applied, the spool
moves forward and begins to dissipate the oil pressure to both brake
clutches simultaneously.
The bottom housing contains two high low spools, one for each side of
the machine. These spools are controlled by the high low solenoids.
When the low steering button is pressed both solenoids are de-ener-
gized. The solenoids allow oil behind the high low spool to vent, caus-
ing the high low spools to be in the low position. Oil pressures from the
clutch sections enter the spool bores and are directed out the low range
ports.
When the high steering button is pressed, both solenoids are energized.
Both solenoids direct pilot oil to both high low spools causing the high
low spools to shift to high. Oil pressure from the clutch sections enters
the spool bores and is directed out the high range ports.
When a left or right button is pressed a circuit controller logic chooses

the correct solenoid selections to result in the desired turn independent
of the present high or low selection. The controller upshifts or down-
shifts the appropriate track to complete the turn.
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D87E-2 D87P-2 10-63 2

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10-64 2 D87E-2 D87P-2

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Button and Solenoid Logic Table
Low High Left Right Left Right Left Right Lever

Result
Button Button Button Button Solenoid Solenoid Track Track Position
Straight Low ✩ Low Low Centered
Straight High ✩ ✩ ✩ High High Centered

Power Left Turn ✩ ✩ Low High Centered
Power Right Turn ✩ ✩ High Low Centered

Pivot Left Turn from Hi ✩ ✩ ✩ Pivot High Left
Pivot Right Turn from Hi ✩ ✩ ✩ High Pivot Right
Pivot Left Turn from Lo ✩ Pivot Low Left

Pivot Right Turn from Lo ✩ Low Pivot Right
✩ On
Blank Off
High Low Valve
The high low valve performs two functions; Shifts the high low steering
spool when the solenoid valve is actuated and shifts the high low steer-
ing spool from high to low when making a modulated turn.
The high low valve contains a pair of solenoid valves and a pair of se-
quence valves. The valve is bolted to the back of the lower steering
valve housing.
Left and right steering signal pressures from the transmission and steer-
ing valve are directed to the high low valve through two pilot hoses. The
Left pilot hose connects to the left section of the steering valve, and the
right pilot hose to the right section of the steering valve. A jumper pilot
hose then connects the rear of the steering valve to the front of the steer-
ing valve, left rear connects to left front, right rear to right front.
The left and right steering pilot pressures enter the high low valve and
remains unique to their individual left or right side. The steering pilot
pressure first enters the sequence valve. The purpose of the sequence
valve is to automatically shift from the high low spool from High to
Low when the steering pilot pressure decays from the full pressure of 19
kg/cm² to below 14 kg/cm². When the sequence valve shifts, the pilot
pressure behind the high low spool is connected to drain so that the high
low spool moves to the Low position.
When the steering pilot pressure is above 14 kg/cm², the pilot pressure
connects to the solenoid valve. With pilot pressure to the solenoid, the
solenoid may send pilot pressure to the high low spool when the sole-
noid is energized. When the solenoid is energized, the high low spool
shifts to the high position. A solenoid is energized when a left or right
steering button is pushed. Both solenoids are energized with the high
button is pushed.
D87E-2 D87P-2 10-65 2

12
10-66 2 D87E-2 D87P-2

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STEERING VALVE MANIFOLD
1. Cut Off Spool 2. Spool Return Spring 3. Steering Valve Manifold Housing
Unit - mm
A Spool return spring 49.8 30.9 30.9 to 40.5 334 N 9
Main pressure enters the steering valve manifold and pushes the cut off
spool back against the return spring. This opens the inlet ports to the
outlet ports, opening the flow of pressure to the drive clutches. If main
pressure to the junction manifold drops, or the engine is stopped, the
springs will return the spool to the cut off position.
D87E-2 D87P-2 10-67 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS FINAL DRIVE
12
FINAL DRIVE
The final drive consists of a set of spur gears and a planetary on each
side at the rear of the machine. Power is transmitted from the steering
drive, through the output shaft to the pinion gear.
The pinion gear is mounted in the pinion gear housing on two tapered
roller bearings and is bolted to the drive cover. The output shaft is
splined to the output sleeve at one end and to the pinion gear at the other
end. The pinion gear is meshed with the bull gear, which provides the
first gear reduction.
The bull gear is splined to the sun gear shaft, which is supported on the
drive cover by a double row spherical roller bearing. Three planet gears
are meshed with the sun gear shaft and are also meshed with the planet
ring gear.
The planet ring gear is attached to the drive cover via the planet ring
gear hub keeping the planet ring gear stationary during operation.
The planet gears provide the second gear reduction. Two roller bearings
support each planet gear on its shaft. The shafts are housed in the planet
carrier housing. The planet carrier housing and the track chain are both
attached to the sprocket hub which is supported on the drive housing by
two tapered roller bearings.
Power output from the steering drive is delivered to the final drive at the
pinion gear in the same direction of rotation. The bull gear, splined to
the pinion gear, and the sun shaft, splined to the bull gear, rotate in the
opposite direction to the pinion gear. The three planet gears, splined to
the sun gear shaft, rotate in the opposite direction to the sun gear shaft.
The three planet gears, an integral part of the planet carrier housing,
which is bolted to the sprocket hub, are forced to walk around the sta-
tionary planet ring gear rotating both the carrier housing and sprocket
hub to the sprocket and track chain in the opposite direction. The final
drive has its own lubrication and is sealed against leakage and dirt.
10-68 2 D87E-2 D87P-2

12
1. Output Shaft (Dog Bone) 5. Bull Gear 9. Planet Ring Gear Hub
2. Pinion Gear 6. Sun Gear Shaft 10. Planet Carrier Housing
3. Pinion Gear Housing 7. Planet Gear 11. Sprocket Hub
4. Final Drive Cover 8. Planet Ring Gear 12. Drive Housing
Unit - mm
Item Std Size
209.575 209.524 -0.051 to
A Pinion gear housing in drive cover 210
209.524 209.601 0.076
184.099 184.1754 0.0764 to
B Pinion gear housing in main frame 184
183.947 184.3024 0.3554
158.775 158.699 -0.076 to
C Bearing cup in pinion gear housing x2 159
158.75 158.724 -0.026
108.026 107.95 -0.076 to
D Bearing cone on pinion gear x2 108
108.001 107.975 -0.0026
179.9996 179.9996 0.0 to
E Double bearing in drive cover 180
179.9742 180.0403 0.0661
130.08 129.9743 -0.1057 to
F Double bearing on bull gear 130
130.07 129.9997 -0.0703
174.7114 174.6250 -0.0864
G Inboard bearing cup on drive housing 175
174.6631 174.6275 -0.0356
247.6754 247.5992 -0.0762 to
H Bearing cone in drive carrier x2 248
247.65 247.6246 -0.0254
174.6377 174.6250 -0.0127 to
J Outboard bearing cup on drive housing 175
174.5869 174.6275 0.0406
65.1764 65.1612 -0.0152 to
K Planet gear bearing on shaft 65
65.1612 65.1764 0.0152
94.4702 94.4549 -0.0153 to
L Planet gear bearing in planet gear 94
94.4549 94.4702 0.0153
Pinion gear end play ......................................................................................................................................0.2286 to 0.381
Pinion gear bearing preload.................................................................................................................................... 3.39 N•m
Reused bolts............................................................................................................................................................... 81 N•m
* New bolts................................................................................................................................................................... 98 N•m
Reused bolts............................................................................................................................................................. 108 N•m
** New bolts................................................................................................................................................................. 125 N•m
D87E-2 D87P-2 10-69 2

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10-70 2 D87E-2 D87P-2

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D87E-2 D87P-2 10-71 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS UNDERCARRIAGE
12
UNDERCARRIAGE
1. Track Frame 5. Guide Plates 9. Track Roller

2. Pivot Shaft 6. Front Idler 10. Track Chain
3. Equalizer Bar 7. Track Adjuster
4. Top Idler 8. Track Spring, Internal
10-72 2 D87E-2 D87P-2

12
The undercarriage consists of two sturdy one piece track frames of
heavy steel construction. Each E series track frame has seven track roll-
er attached to it. Each P series track frame has seven track rollers at-
tached to it. The track top idlers on both sides are mounted in brackets
and bolted to the track frame. A track spring is provided in each track
frame for tensioning the track. This type of track spring permits the
front idlers to recoil under shock loads and exert no tension on the track
during normal operation. The track frames are mounted on each side of
the machine, and they support the weight of the machine on the track
rollers.
The track frames are mounted at the main frame at both sides of the ma-
chine. A guide bracket is welded to the frame to provide proper spacing
between the two tracks. The track frames are attached at the rear of the
dozer to the pivot shafts. Each track is free to oscillate vertically inde-
pendently of the other track. The equalizer bar contacts both sides of the
track frame.
The sprockets pull the track chain around the track rollers, up and over
the top idlers and the front idlers. The front idlers are attached to the
front idler forks located between the two channels of the track frames.
The front idlers slide back and forth on the track frame to take up shock
loads. The front idlers are also adjustable backward and forward for the
purpose of adjusting the track chain tension.
D87E-2 D87P-2 10-73 2

12
FRONT IDLER
10-74 2 D87E-2 D87P-2

12
1. Idler Housing 3. Bushing Sleeve 5. Seal Retainer
2. Idler Shaft 4. Metal Face Seal
Unit - mm
Item Std Size
140.03 140.025 -0.005 to

A Sleeve in idler housing 140
140.05 140.000 -0.05
111.354 111.24 -0.114 to
B Bushing in sleeve 111
111.404 111.19 -0.214
Bushing End Clearance Clearance

C Distance between seal retainers ..............................................................................................................178.828 to 179.148
D Width of idler shaft bushing surface...........................................................................................................172.06 to 172.22
E Washer thickness ............................................................................................................................................3.099 to 3.251
Bushing end clearance - C minus D plus 2E....................................................................................................0.106 to 0.89
Diametral Oil Clearance Clearance
F Assembled bushing ID............................................................................................................................105.207 to 105.359
G Idler shaft diameter .................................................................................................................................104.905 to 104.955
Diametral oil clearance - F minus G ..............................................................................................................0.252 to 0.454
The front idler provides a freely rotating, guiding support for the track
chain. The front idler is supported on replaceable wear bars which slide
on the track frame channels. This sliding feature helps protect the track
frame components by allowing the track spring to absorb shock loads.
The front idlers are heat treated steel castings and rotate around bush-
ings mounted in replaceable sleeves. The front idlers are equipped with
metal type face seals which maintain a leak and dirt proof seal.
D87E-2 D87P-2 10-75 2

12
TOP IDLER
1. Top Idler Housing 3. Metal Face Seal 5. Outer Tapered Roller Bearing
2. Top Idler Shaft 4. Inner Tapered Roller Bearing
Unit - mm
Item Std Size
50.0125 49.9872 -0.0253 to
A Outer bearing cup on shaft 50
49.9935 49.9999 0.0064
81.9988 81.923 -0.0758 to
B Outer bearing cone in housing 82
81.9836 81.953 -0.0306
55.0011 55.017 -0.0159 to
C Inner bearing cup on shaft 55
54.9859 55.036 0.0501
89.9998 89.919 -0.0808 to
D Inner bearing cone in housing 90
89.9795 89.949 -0.0305
The upper section of track chain between the sprocket and the front idler
is supported by the two top idlers. The idlers are mounted in brackets
which are welded to the track frame. The top idlers revolve around ta-
pered roller bearings which ride on heat treated replaceable steel shafts.
The idlers are sealed against leakage and dirt by a metal type face seal.
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TRACK ROLLER
D87E-2 D87P-2 10-77 2

12
1. Roller Housing 3. Metal Face Seal 5. Outer Seal Retainer
2. Roller Shaft 4. Inner Seal Retainer
Unit - mm
Item Std Size
111.404 111.175 -0.229 to

A Bushing in roller housing 111
111.354 111.225 -0.129
Bushing press force............................................................................................................................................... 6350.3 kg
Roller Shaft End Clearance Clearance
B Distance between seal retainers ................................................................................................................. 201.52 to 201.68
C Width of idler shaft surface ......................................................................................................................... 194.7 to 194.86
D Thrust washer thickness................................................................................................................................. 3.099 to 3.175
Shaft end clearance - B minus C plus 2D ....................................................................................................... 0.31 to 0.782
Diametral Oil Clearance Clearance
E Assembled bushing ID........................................................................................................................... 105.207 to 105.359
F Idler shaft diameter ................................................................................................................................ 104.902 to 104.953
Diametral oil clearance - E minus F.............................................................................................................. 0.254 to 0.457
The track rollers are attached to the underside of the track frame and
carry the weight of the machine. The rollers are heat treated steel forg-
ings and rotate around bushings. The rollers are equipped with metal
type face seals which maintain a leak and dirt proof seal. The rollers are
single and double flange types.
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TRACK ADJUSTER
1. Inlet Check Valve 3. Track Adjuster Housing 5. Track Adjuster Rod

2. Relief Valve 4. Track Adjuster Piston
The hydraulic track adjuster is supported between the track spring front
seat and the rear of the front idler fork. Lubricant is introduced into the
cylinder by the use of a inlet check valve on top of the adjuster housing.
This lubricant acting upon the piston and adjusting rod forces the idler
fork and front idler forward for track chain adjustment.
D87E-2 D87P-2 10-79 2

12
TRACK SPRING
1. Track Spring 2. Track Spring Seat 3. Threaded Track Spring Seat

ITEM CRITERIA
A Assembly Length in Track Frame............................................................................................................................. 761 mm
B Spring Solid Length ............................................................................................................................................ 641.35 mm
Installed Length Load ............................................................................................................................................ 22700 kg
Solid Length Load.................................................................................................................................................. 38950 kg
C Tool Head to Bulkhead Clearance........................................................................................................................... 12.7 mm
D Spring Free Length with Seats .............................................................................................................................. 880.4 mm
E Assembled Length in Machine ........................................................................................................................... 773.45 mm
F Spring Bolt Washer ............................................................................................................................................. 338 158 R1
G Spring Bolt ........................................................................................................................................................... CZG 1365
Weight of Spring, Seats, Spring Bolt and Face Washer ............................................................................................. 193 kg
TRACK SPRING
Free Length ..................................................................................................................................................................... 823 mm
Test Length ....................................................................................................................................................... 717.55 ± 1.25 mm
Work Length.................................................................................................................................... 641.35 to 717.55 ± 1.25 mm
Test Load ............................................................................................................................................................ 22700 kg ± 10%
Number of Working Coils ..................................................................................................................................................... 10.5
Weight Of Spring................................................................................................................................................................ 157 kg
10-80 2 D87E-2 D87P-2

12
A heavy coil spring is provided in each track frame. They permit the
front idlers to recoil under shock loads and exert tension on the track in
normal operation. Each track spring is contained in a welded housing,
which is a permanent part of the track frame. The track spring is com-
pressed and trapped in the ends of the housing between a front and rear
seat. The rear of the track adjusting rod bears against the track spring
front seat.
D87E-2 D87P-2 10-81 2

12
PIVOT SHAFT
1. Pivot Shaft 3. Pivot Shaft Seal 5. Outer Bushing

2. Lock Pin and Retainer 4. Inner Bushing 6. Clamp and Shims
Unit - mm
Item Std Size
139.65 139.598 -0.052 to
A In board bushing in track frame 140
139.75 139.548 -0.202
120.4853 120.902 0.4347 to
B In board bushing (after press) on shaft 121
120.5353 120.702 0.1667
120.6 120.7 0.1 to
C Out board bushing in track frame 121
120.7 120.6 -0.1
101.435 101.852 0.417 to
D Out board bushing (after press) on shaft 102
101.485 101.652 0.167
123.8 123.774 -0.026 to
E Out board pivot shaft in rear frame 124
123.825 123.723 -0.102
88.773 88.9 0.127 to
F In board pivot shaft in rear frame 89
88.823 88.849 0.026
The pivot shaft supports the rear of the track frame. One end of the shaft
is mounted in the rear frame and held in place with a lock pin. The other
end of the shaft mounts to the track frame and is clamped and shimmed
in place to allow proper track frame alignment.
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12
EQUALIZER BAR
1. Equalizer Bar 3. Bar Wear Pad 5. Main Frame Tunnel Bushing

2. Equalizer Bar Rebound Bracket 4. Pivot Shaft 6. Equalizer Bar Bushing
Unit - mm
Item Std Size
76.098 76.759 0.661 to
A Mounting pin in all bushings 77
76.2 76.581 0.381
88.773 88.722 -0.051 to
B All bushings in bar and holders 89
88.798 88.671 -0.127
The equalizer bar is fitted with a bushing to take the wear as the track
frames oscillate. The ends of the equalizer bar ride on hardened pads in-
serted into the track frames and corralled by the rebound bars. The
equalizer bar pivot shaft is free to rotate on bushings mounted in the
main frame tunnel support. The pivot shaft is held in the support with
retaining plates.
D87E-2 D87P-2 10-83 2

12
TRACK FRAME GUIDES
1. Guide Plates 3. Retainer Plates 5. Lower Guide Spacer

2. Wear Plates 4. Upper Guide Spacer 6. Top Idler Mounting Bracket
Item New Part Maximum Wear

A Guide Plate Wear Plate 6.35 mm 3.175 mm
At each side of the machine, the guide plates are secured to the main
frame by four bolts. The wear plates, guide spacers and retainer plates
are secured to the track frame and front top idler bracket by four bolts.
10-84 2 D87E-2 D87P-2

12
TRACK CHAIN
LUBRICATED STYLE
1. Track Chain Link 4. Split Master Link 7. Heat Treated Nuts And Bolts
2. Link Bushing 5. Track Chain Seal
3. Link Pin 6. Track Chain Shoes
Unit - mm
Item Std Size
47.62 47.19 -0.43 to
A Link pin in track link 48
47.52 47.29 -0.23
72.83 72.35 -0.48 to
B Link bushing in track link 73
72.67 72.45 -0.22
47.62 47.96 0.34 to
C Link pin in link bushing - oil 48
47.52 48.26 0.74
The track is composed of a track chain and the track shoes. The track
chain consists of drop forged, heat treated steel links which are held to-
gether by bushings and pins to form a continuous chain. The bushings
and pins are a press fit in the links, with the pins pivoting inside of the
bushings. The left and right track chains are interchangeable. Each track
has a split master link. Seals and rings are used to seal counterbore por-
tion of the link. The track shoes are attached to the track links, and they
are held in place with special heat treated bolts and nuts.
D87E-2 D87P-2 10-85 2

12
DRY SEALED STYLE
1. Track Chain Link 4. Split Master Link 7. Heat Treated Nuts And Bolts
2. Link Bushing 5. Belleville Washers
3. Link Pin 6. Track Chain Shoes
Unit - mm
Item Std Size
47.62 47.19 -0.43 to
A Link pin in track link 48
47.52 47.29 -0.23
72.83 72.35 -0.48 to
B Link bushing in track link 73
72.67 72.45 -0.22
47.62 47.96 0.34 to
C Link pin in link bushing 48
47.52 48.26 0.74
The track is composed of a track chain and the track shoes. The track
chain consists of drop forged, heat treated steel links which are held to-
gether by bushings and pins to form a continuous chain. The bushings
and pins are a press fit in the links, with the pins pivoting inside of the
bushings. The left and right track chains are interchangeable. Each track
has a split master link. Belleville washers are used in the counterbore
portion of the link to seal against the entrance of abrasives. The track
shoes are attached to the track links, and they are held in place with spe-
cial heat treated bolts and nuts.
10-86 2 D87E-2 D87P-2

12
MEMORANDNDA
D87E-2 D87P-2 10-87 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS MAIN FRAME
12
MAIN FRAME
1. Radiator Mount 5. Steering Drive Mount 9. Track Frame Guide Plate Mount
2. Front Engine Mount 6. Final Drive Mount 10. Pivot Shaft Mount
3. Rear Engine Mount 7. ROPS Sub Frame Mount 11. Front Mask Mount
4. Transmission Mount 8. Equalizer Bar Mount 12. Ripper or Drawbar Mount
The main frame is a hull type structure that mounts the above compo-
nents and basically the remaining machine.
10-88 2 D87E-2 D87P-2

12
D87E-2 D87P-2 10-89 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS EQUIPMENT HYDRAULICS
12
EQUIPMENT HYDRAULICS
EQUIPMENT HYDRAULIC SCHEMATIC
10-90 2 D87E-2 D87P-2

12
EQUIPMENT HYDRAULIC DIAGRAM
D87E-2 D87P-2 10-91 2

12
RESERVOIR
10-92 2 D87E-2 D87P-2

1. Hydraulic Reservoir 3. Filler Screen Strainer 5. Drain Plug

2. Locking Filler Cap 4. Suction Strainer 6. Pressure Vacuum Relief Valve
The reservoir is bolted to the right fender next to the fuel tank. It is a one Specifications
piece welded assembly with a strainer, reservoir, pressure relief valve,
magnetic plug, a sight gauge and various ports for the suction and return Capacity
lines. Complete.............................................. 115 L
The reservoir acts as a storage tank for the dozer equipped hydraulic Air ....................................................... 76.5 L
system oil. The remainder of oil fills the lines and system components. Oil ....................................................... 38.5 L
The vacuum relief valve will protect the pumps from cavitation as well
as maintaining pressure in the reservoir. Pressure...................................... 1.75 kg/cm²
D87E-2 D87P-2 10-93 2

12
PUMP
Specifications
First pump
Engine rpm ............................................2330
Output ........................................... 145 L/min
Pressure......................................... 70 kg/cm²
Middle pump
Engine rpm ............................................2330

Output ............................................. 62 L/min
Pressure......................................... 70 kg/cm²
End pump
Engine rpm ............................................2330

Output ............................................. 35 L/min
Pressure......................................... 21 kg/cm²
10-94 2 D87E-2 D87P-2

12
D87E-2 D87P-2 10-95 2

12
BLADE LIFT AND RIPPER VALVE BANK
1. Inlet Cover 3. Ripper Pitch Section Valve 5. Blade Lift Section Valve
2. Main Pressure Relief Valve 4. Ripper Lift Section Valve 6. Outlet Cover
The blade lift and ripper valve bank is mounted to a bracket at the right
side in front of the reservoir. This system utilizes a three spool valve.
The valve is controlled by pilot lines from the pilot valves.The valve in-
let cover contains an adjustable pilot operated main pressure relief valve
which is used to by pass oil from the pump back to the reservoir when
oil pressure exceeds the relief valve setting.
10-96 2 D87E-2 D87P-2

12
MAIN RELIEF VALVE ANTI CAVITATION VALVE
NOTE: Due to the close tolerances of the working parts, NOTE: Due to the close tolerances of the working parts,
the main relief valve internal parts are not ser- the anti cavitation valve internal parts are not ser-
viced. If service other than the seals is required, viced. If service other than the seals is required,
replace the complete relief valve. replace the complete anti cavitation valve.
1. Tamper Proof Cover

2. Adjusting Screw Jam Nut
3. Pressure Adjusting Screw
D87E-2 D87P-2 10-97 2

12
BLADE LIFT SECTION VALVE
1. Blade Raise Positioner
2. Blade Lower/float Postioner
3. Port Plug
4. Spring Loaded Check Valve
5. Anti Cavitation Valve
The blade lift section valve is a spring centered, four position

type with the FLOAT position being magnetically detented
at the blade pilot valve. Incorporated in each valve section is
a spring loaded check valve which assures smooth operation
when the spool is moved from hold to an operating position.
An anti cavitation valve is located in the blade lower circuit.
10-98 2 D87E-2 D87P-2

RIPPER LIFT SECTION VALVE

1. Ripper Raise Positioner
2. Ripper Lower Postioner
3. Port Plug
The ripper lift section valve is used for raising or lower the
ripper. The section valve is a spring centered spool, three po-
sition type. Incorporated in the valve section is a spring load-
ed check valve which assures smooth operation when the
spool is moved from hold to an operating position. An anti-
cavitation valve is located in the ripper lower circuit.
D87E-2 D87P-2 10-99 2

RIPPER PITCH SECTION VALVE

1. Ripper Raise Positioner
2. Ripper Lower Postioner
3. Port Plug
The ripper pitch section valve is used for pitching the ripper
forward or rearward. The section valve is a spring centered
spool, three position type. Incorporated in the valve section
is a spring loaded check valve which assures smooth opera-
tion when the spool is moved from hold to an operating posi-
tion.
10-100 2 D87E-2 D87P-2

12
BLADE LIFT VALVE BANK
1. Inlet Cover 3. Blade Lift Section Valve 4. Outlet Cover

2. Main Pressure Relief Valve
The blade lift valve bank is mounted to a bracket at the right side in
front of the reservoir. This system utilizes a one spool valve. The valve
is controlled by pilot lines from the blade pilot valve. The valve inlet
cover contains an adjustable pilot operated main pressure relief valve
D87E-2 D87P-2 10-101 2

12
MAIN RELIEF VALVE ANTI CAVITATION VALVE
NOTE: Due to the close tolerances of the working parts, NOTE: Due to the close tolerances of the working parts,
the main relief valve internal parts are not ser- the anti cavitation valve internal parts are not ser-
viced. If service other than the seals is required, viced. If service other than the seals is required,
replace the complete relief valve. replace the complete anti cavitation valve.
1. Tamper Proof Cover

2. Adjusting Screw Jam Nut
3. Pressure Adjusting Screw
10-102 2 D87E-2 D87P-2

12
BLADE LIFT SECTION VALVE
1. Blade Raise Positioner
2. Blade Lower/float Postioner
3. Port Plug
The blade lift section valve is a spring centered, four position

type with the FLOAT position being magnetically detented
at the blade pilot valve. Incorporated in each valve section is
a spring loaded check valve which assures smooth operation
when the spool is moved from hold to an operating position.
An anti cavitation valve is located in the blade lower circuit.
D87E-2 D87P-2 10-103 2

12
BLADE TILT VALVE BANK
1. Inlet Cover Section 3. Blade Tilt Section Valve 5. Power Beyond Port
2. Tilt Main Relief Valve 4. Outlet Cover Section
The blade tilt valve bank is mounted to a bracket at the right side in
front of the reservoir. This system utilizes a one spool valve. The valve
is controlled by pilot lines from the blade pilot valve. The valve inlet
cover contains an adjustable pilot operated main pressure relief valve
10-104 2 D87E-2 D87P-2

12
BLADE TILT SECTION VALVE
1. Blade Tilt Right Positioner

2. Blade Tilt Left Postioner
The blade tilt section valve is used for tilting the

blade forward or rearward. The section valve is a
spring centered spool, three position type. Incor-
porated in the valve section is a spring loaded
check valve which assures smooth operation
when the spool is moved from hold to an operat-
ing position.
MAIN RELIEF VALVE
D87E-2 D87P-2 10-105 2

12
BLADE PILOT CONTROL VALVE
A Lift Circuit 1. Control Lever Mounting 5. Magnetic Plunger Sleeve

B Tilt Left Circuit 2. Cam Plate 6. Plunger Feel Capsule
C Lower/Float Circuit 3. Plunger 7. Plunger Capsule
D Tilt Right Circuit 4. Plunger Sleeve 8. Metering Spools
Unit: mm
E Ports A and C spring 50 36 27 to 30 20 to 24 N 5.6
F Ports B and D spring 57.5 15 10 to 11 80 to 98 N 6.4
DESCRIPTION
The blade pilot control valve is a manually controlled for the blade lift,
lower and tilt. The valve is used to direct pilot oil pressure to the blade
lift and tilt valve banks for blade control. When the lever is released, it
will return to neutral. A magnetic detent mechanism holds the control
lever in the float position. Pilot pressure enters the control valve at the P
port and is distributed through the passages to the metering capsules.
When the lever is in the centered (neutral) position, oil is active in the
passages, but is blocked at the metering spools.
LIFT: When the lever is moved rearward, the cam plate depresses the
plunger below it which depresses the plunger capsule which
opens the metering spool directing pilot pressure oil to the blade
lift valve bank. When the lever is released it will return to neutral.
LOWER: When the lever is moved forward, the cam plate depresses
the plunger below it which depresses the plunger feel cap-
sule which opens the metering spool directing pilot pressure
oil to the blade lift valve bank. When the lever is released it
will return to neutral.
FLOAT: When the lever is moved all the way forward, the cam plate
depresses the plunger below it which depresses the plunger
feel capsule which opens the metering spool directing pilot
pressure oil to the blade lift valve bank. When released it will
remain in the float position held by the magnet located in the
opposite side plunger sleeve. The lever has to be manually re-
leased from the float position.
TILT RIGHT: When the lever is moved to the right, the cam plate de-
presses the plunger below it which depresses the plung-
er capsule which opens the metering spool directing
pilot pressure oil to the blade tilt valve bank. When the
lever is released it will return to neutral.
TILT LEFT: When the lever is moved to the left, the cam plate de-
presses the plunger below it which depresses the plunger
capsule which opens the metering spool directing pilot
pressure oil to the blade tilt valve bank. When the lever is
released it will return to neutral.
10-106 2 D87E-2 D87P-2

12
D87E-2 D87P-2 10-107 2

12
RIPPER PILOT CONTROL VALVE
10-108 2 D87E-2 D87P-2

12
A Pitch Forward Circuit D Lower Circuit 3. Plunger Capsule
B Lift Circuit 1. Control Lever Mounting 4. Metering Spools
C Pitch Rear Circuit 2. Cam Plate
DESCRIPTION
The ripper pilot control valve is a manually controlled for ripper lift,
lower and pitch. The valve is used to direct pilot oil pressure to the blade
and ripper valve bank for ripper control. When the lever is released, it
will return to neutral. Pilot pressure enters the control valve at the P port
and is distributed through the passages to the metering capsules. When
the lever is in the centered (neutral) position, oil is active in the passag-
es, but is blocked at the metering spools.
PITCH FORWARD: When the lever is moved forward, the cam plate
depresses the plunger capsule which opens the
metering spool directing pilot pressure oil to the
blade lift and ripper valve bank. When the lever
is released it will return to neutral.
LIFT: When the lever is moved to the left, the cam plate depresses the
the plunger capsule which opens the metering spool directing
pilot pressure oil to the blade lift and ripper valve bank. When
the lever is released it will return to neutral.
PITCH REAR: When the lever is moved rearward, the cam plate de-
presses the plunger capsule which opens the metering
spool directing pilot pressure oil to the blade lift and
ripper valve bank. When the lever is released it will re-
turn to neutral.
LOWER: When the lever is moved to the right, the cam plate depresses
the plunger capsule which opens the metering spool direct-
ing pilot pressure oil to the blade lift and ripper valve bank.
When the lever is released it will return to neutral.
D87E-2 D87P-2 10-109 2

12
PILOT SUPPLY VALVE
10-110 2 D87E-2 D87P-2

12
1. Pressure Regulator Spool 3. Cold Oil Relief Ball 4. Test Gauge Quick Disconnect
2. Selector Spool
Unit: mm
A Directional Spool Spring 54 29 24 to 33 62 to 71 N 12
B Regulator Spool Spring 57 33 30 to 35 338 to 374 N 7
C Check Ball Spring 22 15 14 to 15 62 to 71 N 8
The pilot supply valve provides two functions: 1) regulate supply pres-
sure to the blade and ripper pilot valves, 2) supply pilot pressure, when
the engine is off, to the blade and ripper valves so that the blade and rip-
per can be lowered.
When the engine is running, pilot pump flow enters port P. Spool 1 is a
pressure regulator spool set to regulate P pressure. P pressure enters the
PP1 right end of the spool through the pilot orifice. PP1 moves the
spool to the left into the regulating spring. When sufficient pressure is
reached the spool moves to the left and allows oil to flow to tank
through the T port. In the event of cold oil, a cold oil relief ball is pro-
vided located in the center left end of the spool. The cold oil relief limits
pressure spikes at start up.
As P pressure builds it also pushes against the right end of the selector
spool at PP2, the right hand spool diameter is less than the spool bore
allowing pilot oil to flow past this clearance and push the spool to the
left. The selector spool shifts to the left against its spring. P pressure is
now open to PP. PP supplies pressure to the pilot valves for blade and
ripper controls.
When the engine is off, both spools shift to the right. In this condition
the selector spool directs oil from port AI to PP. AI is connected to the
shuttle network from the blade and ripper cylinders. If a blade or ripper
cylinder is off of the ground or the equipment is powered into the
ground then the trapped cylinder pressure is used through the shuttle
network as pilot supply pressure. The stored pressure from the cylinders
enters port AI and passes out PP to the pilot valves.
D87E-2 D87P-2 10-111 2

12
QUICK DROP VALVE
1. Spool 2. Inner Spring 3. Outer Spring
Unit: mm
A Inner Spool Spring 93 37 37 to 47 304 N 9
B Outer Spool Spring 91 41 41 to 51 440 N 6
The quick drop valve is used for accelerated power when lowering of the
blade is required. The valve is bolted to the frame at the right side of the en-
gine. This hydraulically operated valve allow the blade to drop at a faster
rate by diverting return oil through a spool to supplement the blade cylin-
der input oil from the piston side being used to lower the blade. The valve
diverts the return oil when the control valve is in the lower position.
10-112 2 D87E-2 D87P-2

12
GIMBAL TUBE AND YOKE
1. Lift Cylinder Gimbal Tube 2. Lift Cylinder Yoke 3. Blade Lift Cylinder
Unit - mm
Item Std Size
127.102 127.025 -0.077 to

A Outer bushing in gimbal tube 127
127.152 126.975 -0.177
120.752 120.675 -0.077 to
B Inner bushing in gimbal tube 121
120.802 120.625 -0.177
112.775 112.725 -0.05 to
C Grease plug in gimbal tube 113
112.827 112.675 -0.152
114.275 114.651 0.376 to
D Yoke in gimbal tube outer bushing 114
114.325 114.596 0.271
107.925 108.302 0.377 to
E Yoke in gimbal tube inner bushing 108
107.975 108.246 0.271
88.621 89.027 0.406 to
F Cylinder bushings in yoke bushings 89
88.671 88.925 0.254
D87E-2 D87P-2 10-113 2

12
BLADE LIFT CYLINDER
1. Spherical Bearing 3. Rod Gland 5. Cylinder Piston

2. Piston Rod 4. Cylinder Mount 6. Piston Retaining Lock Nut
Unit - mm
Item Std Size
99.997 100 0.003 to

A Spherical bearing in rod end 100
100.012 99.94 -0.072
73.105 73.05 -0.055 to
B Bushing on cylinder mounts 73
73.13 73 -0.13
The blade lift cylinders are a single stage double acting type. Hydraulic Specifications Unit - mm
pressure is introduced through ports at either end of the cylinder to actu-
Stroke of rod .......................................1066.8
ate the piston and rod.
Housing ID ......................................... 114.24
Rod OD.................................................63.42
10-114 2 D87E-2 D87P-2

12
D87E-2 D87P-2 10-115 2

12
BLADE TILT CYLINDER
1. Piston Rod 3. Cylinder Piston 4. Piston Retaining Lock Nut

2. Rod Gland
Unit - mm
Item Std Size
69.951 69.85 -0.112 to

A Bushing in head end rod 70
69.962 69.78 0.171
69.951 69.85 -0.112 to
B Bushing in rod end - Angle model only 70
69.962 69.78 0.171
DOZER MODELS Specifications Unit - mm

Stroke of rod
The blade tilt cylinder is a single stage, double acting type. Hydraulic
pressure is introduced through ports at either end of the cylinder to actu- Dozer model ..................................146.5
ate the piston. Angle model .....................................155
ANGLE MODELS Housing ID ...........................................165.1
Rod D..................................................69.774
The blade tilt cylinders are a single stage, double acting type. Hydraulic
pressure is introduced through ports at either end of the cylinder to actu-
ate the piston.
10-116 2 D87E-2 D87P-2

12
RIPPER LIFT CYLINDER

2. Rod Gland
Unit - mm
Item Std Size
76.276 76.2 -0.076 to

A Bushing in rod end 76
76.302 76.124 0.178
76.276 76.2 -0.076 to
B Bushing in head end 76
76.302 76.124 0.178
The ripper lift cylinders are a single stage double acting type. Hydraulic Specifications Unit - mm
pressure is introduced through ports at either end of the cylinder to actu- Stroke of rod ........................................... 475
ate the piston.
Housing ID ...........................................152.4
Rod OD.................................................63.45
D87E-2 D87P-2 10-117 2

12
RIPPER PITCH CYLINDER

2. Rod Gland
Unit - mm
Item Std Size
82.626 82.55 -0.076 to

A Bushing in rod end 82
82.652 82.47 0.182
82.626 82.55 -0.076 to
B Bushing in head end 82
82.652 82.47 0.182
The ripper pitch cylinders are a single stage double acting type. Hydrau- Specifications Unit - mm
lic pressure is introduced through ports at either end of the cylinder to
actuate the piston. Stroke of rod ........................................... 343
Housing ID ...........................................139.7
Rod OD.................................................63.42
10-118 2 D87E-2 D87P-2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS CAB
12
CAB
D87E-2 D87P-2 10-119 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS ELECTRICAL SYSTEM
12
ELECTRICAL SYSTEM
SCHEMATIC
1. FRONT HARNESS 31. Trans Clutch Pressure Switch 62. Hourmeter

2. Left Front Light on Mask 32. Time Delay Module 63. Bulb Check Relay
3. Right Front Light on Mask 33. Back Up Alarm Switch 64. Cluster Diode Board
4. Warning Horn 34. Neutral Start Switch 65. Instrument Cluster
5. Diode 35. REAR HARNESS 66. CAB HARNESS
6. Left Coolant Level Sensor 36. Fuel Level Sender 67. Left Front Cab Light
7. Right Coolant Level Sensor 37. Back Up Alarm 68. Right Front Cab Light
8. Coolant Level Relay 38. Left Rear Work Light 69. Left Rear Cab Light
9. Converter Temperature Switch 39. RIGHT REAR HARNESS 70. Right Rear Cab Light
10. ENGINE HARNESS 40. Pilot Filter Switch 71. Rear Wiper Motor
11. Alternator 41. Equipment Filter Switch 72. Front Center Wiper Motor
12. Starter Motor 42. Warning Horn Switch 73. Front Left Door Wiper Motor
13. Engine Ground 43. Blade Float Solenoid 74. Front Right Door Wiper Motor
14. 80 Amp Main Circuit Breaker 44. INSTRUMENT PANEL HARNESS 75. Dome Light
15. 6 Amp Circuit Breaker 45. BRAKE PEDAL HARNESS 76. Cab Ground
16. Coolant Temperature Sender 46. Brake Pedal Switch 77. CAB SWITCH PANEL HARNESS
17. Coolant Temperature Switch 47. 15 Amp Circuit Breaker 78. Left & Right Wiper/Washer Switch
18a. Magnetic Switch 48. 6 Amp Circuit Breaker 79. Front & Rear Wiper/Washer Switch
18b. Rectifier 49. 15 Amp Circuit Breaker 80. AC/Heater Blower Motor Switch
19. Heater Relay 50. 15 Amp Circuit Breaker 81. 25 Amp Circuit Breaker
20. Preheater 51. 10 Amp Circuit Breaker 82. 10 Amp Circuit Breaker
21. Air Filter Restriction Switch 52. Key Start Switch 83. 10 Amp Circuit Breaker
22. Engine Oil Pressure Switch 53. Upper Work Light Switch 84. 10 Amp Circuit Breaker
23. Engine Oil Pressure Sender 54. Lower Work Light Switch 85. 10 Amp Circuit Breaker
24. AC Clutch 55. Preheat Select Switch 86. AC/Heater Assembly
25. POD HARNESS 56. Bimetal Timer 87. Batteries
26. Converter Temperature Sender 57. Preheat Indicator 88. Master Disconnect Switch
27. Left & Right Door Washer Motor 58. Instrument Panel Ground 89. Frame Ground
28. Front & Rear Door Washer Motor 59. Fuel Gauge 90. Engine Ground
29. Transmission Filter Switch 60. Warning Alarm
30. CONTROL TOWER HARNESS 61. Warning Light
10-120 2 D87E-2 D87P-2

12
D87E-2 D87P-2 10-121 2

12
10-122 2 D87E-2 D87P-2

12
WIRING
D87E-2 D87P-2 10-123 2

12
LEGEND FOR 1 LEVER CONTROL SCHEMATIC AND WIRING
1. FRONT HARNESS 37. Back Up Alarm 74. Front Right Door Wiper Motor
2. Left Front Light on Mask 38. Left Rear Work Light 75. Dome Light
3. Right Front Light on Mask 39. RIGHT REAR HARNESS 76. Cab Ground
4. Warning Horn 40. Pilot Filter Switch 77. CAB SWITCH PANEL HARNESS
5. Diode 41. Equipment Filter Switch 78. Left & Right Wiper/Washer Switch
6. Left Coolant Level Sensor 42. Warning Horn Switch 79. Front & Rear Wiper/Washer Switch
7. Right Coolant Level Sensor 43. Blade Float Solenoid 80. AC/Heater Blower Motor Switch
8. Coolant Level Relay 44. INSTRUMENT PANEL HARNESS 81. 25 Amp Circuit Breaker
9. Converter Temperature Switch 45. BRAKE PEDAL HARNESS 82. 10 Amp Circuit Breaker
10. ENGINE HARNESS 46. Brake Pedal Switch 83. 10 Amp Circuit Breaker
11. Alternator 47. 15 Amp Circuit Breaker 84. 10 Amp Circuit Breaker
12. Starter Motor 48. 6 Amp Circuit Breaker 85. 10 Amp Circuit Breaker
13. Engine Ground 49. 15 Amp Circuit Breaker 86. AC/Heater Assembly
14. 80 Amp Main Circuit Breaker 50. 15 Amp Circuit Breaker 87. Batteries
15. 6 Amp Circuit Breaker 51. 10 Amp Circuit Breaker 88. Master Disconnect Switch
16. Coolant Temperature Sender 52. Key Start Switch 89. Frame Ground
17. Coolant Temperature Switch 53. Upper Work Light Switch 90. Engine Ground
18a. Magnetic Switch 54. Lower Work Light Switch 91. 1st Speed Reed Switch
18b. Rectifier 55. Preheat Select Switch 92. 2nd Speed Reed Switch
19. Heater Relay 56. Bimetal Timer 93. 3rd Speed Reed Switch
20. Preheater 57. Preheat Indicator 94. Grip Button Switches
21. Air Filter Restriction Switch 58. Instrument Panel Ground 95. Steering Controller
22. Engine Oil Pressure Switch 59. Fuel Gauge 96. CONTROLLER HARNESS
23. Engine Oil Pressure Sender 60. Warning Alarm 97. Neutral Solenoid Switch
24. AC Clutch 61. Warning Light 98. Neutral Solenoid
25. POD HARNESS 62. Hourmeter 99. Left Solenoid
26. Converter Temperature Sender 63. Bulb Check Relay 100. Right Solenoid
27. Left & Right Door Washer Motor 64. Cluster Diode Board 101. INSTRUMENT HARNESS
28. Front & Rear Door Washer Motor 65. Instrument Cluster 102. Speed Indicator
29. Transmission Filter Switch 66. CAB HARNESS 103. TASC Valve Power Feed
30. CONTROL TOWER HARNESS 67. Left Front Cab Light 104. Left Solenoid Diode
31. Trans Clutch Pressure Switch 68. Right Front Cab Light 105. Right Solenoid Diode
32. Time Delay Module 69. Left Rear Cab Light 106. COMPARTMENT HARNESS
33. Back Up Alarm Switch 70. Right Rear Cab Light 107. CONTROL TOWER HARNESS
34. Neutral Start Switch 71. Rear Wiper Motor 108. TASC Valve Ground
35. REAR HARNESS 72. Front Center Wiper Motor
36. Fuel Level Sender 73. Front Left Door Wiper Motor
10-124 2 D87E-2 D87P-2

12
ELECTRICAL COMPONENTS
DESCRIPTION
The electrical system used on this machine is a 24 volt negative ground

system. All the electrical service is controlled by a master disconnect
switch located in a recess in the operator’s seat front support panel. The
electrical system is basically divided into four groups; starting and
charging, lighting, indicators and accessories.
STARTING AND CHARGING GROUP
The starting and charging circuits consist of the battery, cranking motor-
and solenoid, magnetic switch, neutral safety switch, keyed starting
switch, engine shutdown solenoid, cranking motor solenoid, neutral
start switch, master disconnect switch, pre heater and relay, and alterna-
tor with integral voltage regulator.
LIGHTING GROUP
The lighting circuit includes the light switches, circuit breakers, front
and rear lights.
INDICATOR GROUP
The indicator group consists of the voltmeter, hour meter and switch,
transmission filter warning lamp and switch, hydraulic oil pressure filter
warning lamp and switch, air filter warning lamp and switch, engine oil
pressure gauge and sender, engine oil pressure warning lamp, engine
coolant temperature gauge and sender, engine coolant temperature
warning lamp, clutch pressure warning lamp, converter temperature
gauge and sender, caution lamp, caution buzzer, fuel gauge, transmis-
sion range clutch LED'S, bulb check, and bulb check relay.
ACCESSORY GROUP
3 Lever Drive Control
The accessory group includes back up alarm and switch, warning horn
and switch, wiper motors and switch, A/C - heat fan and clutch, and cir-
cuit breakers.
The accessory group includes back up alarm and switch, warning horn
and switch, steering controller, wiper motors and switch, A/C - heat fan
and clutch, and circuit breakers.
The steering controller and transmission range clutch LED's recieves

power from the 6 amp breaker located in the instrument panel. Left and
right steering valve solenoid switched power through the controller. The
joystick buttons switch ground to signal the controller. These compo-
nents are grounded in the control tower. A high low signal is provided
by the controller and is sent to the transmission range clutch LED'S.
There are three replaceable mini automotive style fuses inside the steer-
ing controller.
D87E-2 D87P-2 10-125 2

12
CRANKING MOTOR
This motor is a negative ground reduction type motor, sealed against oil Specifications
and water contamination. Nominal output power .............................. 7.5 kW
Nominal voltage............................................24 V
Rating................................................. 30 Seconds
Instantaneous current ......... 260 to 340 A @ 24 V
Solenoid hold current............................ 35 A max
ALTERNATOR
This alternator is negative ground brushless type with a internal regula- Specifications
tor and is sealed against oil and water contamination. Nominal voltage..................................... DC 28 V
Indication output current............................... 50 A
Rotation range.......................... 1000 to 7000 rpm
10-126 2 D87E-2 D87P-2

12
MASTER DISCONNECT SWITCH
This keyed two position on/off switch is used to connect the supply Specifications
power from the batteries to the starting motor. The switch is sealed Nominal voltage..................................... DC 24 V
against oil and water contamination.
Continuous rating................... 175 A @ 6 to 36 V
Intermittent range................. 1000 A @ 6 to 36 V
MAGNETIC SWITCH
This continuous duty normally open switch is used to connect the sup- Specifications
ply power from the batteries to the starting motor. When actuated, the Nominal voltage............................................24 V
outer coil of the switch draws the spring tensioned spool down connect- Coil resistance......................................57 to 59 Ω
ing the battery to the starter solenoid. When released, power is disen-
gaged. Coil inductance ........................................ 11.75 H
D87E-2 D87P-2 10-127 2

12
RECTIFIER BOARD
Specifications
Nominal voltage..................................... DC 24 V
Capacity ........................................ 25 A @ 600 V
Surge Capability ......................................... 400 A
IN LINE DIODE
LEFT AND RIGHT SOLENOID DIODE
An abundance of in line diodes are used to prevent against electrical Specifications

back feed through the various circuits. The diodes are directly connect- Voltage drop
ed to each harness were used. Forward direction .......................................<1.2
Reverse direction...................................... Open
10-128 2 D87E-2 D87P-2

12
KEY START SWITCH
Conection B BR R1 R2 C ACC Specifications

OFF ✧ Nominal voltage............................................24 V
HEAT ✧ ✧ ✧ ✧ BR circuit............................................... 10 Amps
RUN ✧ ✧ ✧ ACC circuit ............................................ 15 Amps
START ✧ ✧ ✧ ✧ ✧ R1 or R2 circuit...................................... 40 Amps
C circuit:
Instant ................................................. 75 Amps
Holding............................................... 22 Amps
BRAKE PEDAL SWITCH
NEUTRAL START SWITCH
NEUTRAL SOLENOID SWITCH
This manually activated ball switch is used to connect the supply power Specifications
within the key start switch. The switch is sealed against oil and water Nominal voltage..................................... DC 24 V
contamination.
Current rating................................................ 30 A
A. Ball free height................. 15.26 to 15.79 mm
B. Switch contact point............. 13.7 to 14.5 mm
D87E-2 D87P-2 10-129 2

12
PREHEATER RELAY SWITCH
Specifications
ENGINE AIR PREHEATER
Specifications
Rated current............................................... 111 A
10-130 2 D87E-2 D87P-2

12
PREHEAT SELECT SWITCH
Conection L E H M Specifications
I ✧ ✧ Nominal voltage............................................24 V
OFF ✧ ✧ Resistance ................................................... 1 MΩ
ON ✧ ✧ Control force ........................... 0.29 to 0.127 N•m
II ✧ ✧ ✧ Pull in, out force............................................98 N
Rotation force ....................................... 1.96 N•m
BIMETAL SWITCH
Specifications
Temperature range .............................. 30 to 50°C
Resistance between 1 and 2 .......................60 mΩ
Switch point nominal ......................................0°C
D87E-2 D87P-2 10-131 2

12
PREHEAT INDICATOR
Specifications
Light with built in resistor ........ 5 mm 1-3/4 LED
SOUND ALARM
Specifications
Chime tone................................................ Warble
Frequency................................... 1900 to 2900 Hz
Sound pressure @ 610 mm .............. 75 to 95 dBa
Current ..................................................3 to 8 mA
10-132 2 D87E-2 D87P-2

12
LIGHT SWITCH
A pair of these two position switches are mounted in the dash board. Specifications
The left switch controls the upper mounted lights and the right switch Nominal voltage............................................24 V
controls the lower mounted lights.
Maintained load @ 24 V:
Lamp load.................................................. 15 A
Resistive load ............................................20 A
Inductive load............................................15 A
Momentary load @ 24 V:
Lamp load.................................................. 15 A
Resistive load ............................................20 A
Inductive load............................................15 A
WORK LIGHTS
There are seven (four front, three rear) halogen work lights mounted on Specifications
the machine and are controlled by two switches (above). Rating..................................................24 V, 60 W
D87E-2 D87P-2 10-133 2

12
GAUGE CLUSTER
The gauge cluster includes various gauges and warning lights for the Specifications
machine. Nominal voltage............................................24 V
Cluster Gauges
Specifications Engine oil pressure gauge:

Nominal voltage ............................................................. 24 V Run zone......................................................0.8 to 7 kg/cm²
Coolant temperature gauge: Checkpoint @ 0 kg/cm²:
Run zone .......................................................... 71 to 100°C Pointer tolerance .............................................. ± 0.8 mm
Checkpoint @ 71°C: Pointer direction ........................................... Descending
Pointer tolerance .............................................. ± 2.3 mm Resistance ..............................................................240 Ω
Pointer direction ............................................. Ascending Checkpoint @ 3 kg/cm²:
Resistance.............................................................. 210 Ω Pointer tolerance .............................................. ± 2.3 mm
Checkpoint @ 100°C: Pointer direction .............................................Ascending
Pointer tolerance .............................................. ± 0.8 mm Resistance ..............................................................120 Ω
Pointer direction ............................................. Ascending Voltmeter:
Resistance................................................................ 86 Ω Run zone.............................................................22 to 30 V
Transmission temperature gauge: Checkpoint @ 24 V:
Run zone .......................................................... 66 to 121°C Pointer tolerance .............................................. ± 0.8 mm
Checkpoint @ 66°C: Pointer direction ........................................... Descending
Pointer tolerance .............................................. ± 2.3 mm Checkpoint @ 30 V:
Pointer direction ............................................. Ascending Pointer tolerance .............................................. ± 0.8 mm
Resistance.............................................................. 285 Ω Pointer direction .............................................Ascending
Checkpoint @ 121°C:
Pointer tolerance .............................................. ± 0.8 mm
Pointer direction ............................................. Ascending
Resistance................................................................ 51 Ω
10-134 2 D87E-2 D87P-2

HOURMETER
The hourmeter electronically records the actual hours of the engine op- Specifications
eration. The hourmeter is supplied from the engine oil pressure switch. Nominal voltage............................................24 V
ENGINE OIL PRESSURE SWITCH
This switch feeds the hourmeter and the engine oil pressure warning Specifications
light. Nominal voltage............................................24 V
Operating pressure ........................1 to 10. kg/cm²
Contact rating.................................................. 4 A
D87E-2 D87P-2 10-135 2

12
FUEL GAUGE
The fuel gauge electronically records the fuel level in the tank. Specifications
G terminal .................................................Ground
S terminal ...................................................Signal
I terminal...................................................... Input
FUEL SENDER
The sender feeds the fuel gauge electronically from the tank. Specifications
Tank level 1/10 1/5 3/10 2/5 1/2 3/5 7/10 4/5 9/10 Full
Resistance Ω 210Ω
240Ω Ω 180Ω
Ω 150Ω
Ω 125Ω
Ω 99Ω
Ω 80Ω
Ω 66Ω
Ω 45Ω
Ω 33Ω
Ω
10-136 2 D87E-2 D87P-2

12
AIR FILTER SWITCH
The normally closed air filter switch senses the restriction within the air Specifications
cleaner. Nominal voltage............................................24 V
TRANSMISSION OR HYDRAULIC FILTER SWITCH
The normally open oil filter switch senses the restriction within the Specifications
transmisson oil filter. Nominal voltage............................................24 V
D87E-2 D87P-2 10-137 2

12
PILOT FILTER SWITCH
The normally open switch senses the restriction within the equipment Specifications
pilot system oil filter. Nominal voltage............................................24 V
ENGINE OIL PRESSURE GAUGE SENDER
Specifications
Nominal voltage ............................................24 V
Resistance at Specified Pressure

0 kg/cm² 1 kg/cm² 7 kg/cm²
Nom Limits Nom Limits Nom Limits
240 Ω 229 to 242 Ω 167 Ω 164 to 208 Ω 33 Ω 26 to 44 Ω
10-138 2 D87E-2 D87P-2

12
ENGINE COOLANT TEMPERATURE SENDER
TORQUE CONVERTER OIL TEMPERATURE SENDER
The switch montors the engine oil pressure. Specifications

Resistance @ 93°C ..........................110 to 134 Ω
Max operating pressure........................3.5 kg/cm²
ENGINE COOLANT TEMPERATURE SWITCH
The normally open temperature switch montors the engine coolant. Specifications
Contact close................................... 100 to 103°C
D87E-2 D87P-2 10-139 2

12
TRANSMISSION OIL TEMPERATURE SENDER
The normally open temperature switch montors the torque converter. Specifications
Contact close................................... 116 to 123°C
CLUTCH PRESSURE SWITCH
The diaphragm type pressure switch montors the drive train pressure. Specifications
Resistive load.................................................. 3 A
Contact resistance ...................................0.02 mΩ
10-140 2 D87E-2 D87P-2

12
WARNING/CAUTION LAMP
Specifications
COOLANT LEVEL RELAY
BULB CHECK RELAY
Specifications
Release voltage ........................................2 to 6 V
Lower contact closing voltage .............16 to 22 V
Winding resistance...........................200 to 250 Ω
Contact rating.................................. 30 A @ 24 V
D87E-2 D87P-2 10-141 2

12
COOLANT LEVEL SWITCH
Specifications
Operating temperature ..................... -40 to 150°C
Pressure rating.........................................7 kg/cm²
GEAR INDICATOR SENSOR
Specifications
10-142 2 D87E-2 D87P-2

12
MAIN CIRCUIT BREAKER
The automatic reset type breaker is used to protect the main cicuit. Specifications
Capacity ........................................................ 80 A
INDIVIDUAL CIRCUIT BREAKERS
The automatic reset type breakers are used to protect individual circuits. Specifications
Capacity .....................................6, 10 15, or 25 A
D87E-2 D87P-2 10-143 2

12
TIME DELAY MODULE
Specifications
Time delay ............................................ 2 seconds
INSTRUMENT PANEL DIODE BOARD
Specifications
10-144 2 D87E-2 D87P-2

12
BACK UP ALARM
The back up alarm sounds when the machine is shifted into reverse. Specifications
Frequency;
Style A.................................................. 1250 hz
Style B.................................................. 1110 hz
Sound level ............................................... 112 dB
Duty cycle ..................................... 1 pulse/second
50% on 50% off
BACK UP ALARM SWITCH
The normally open pressure switch sends a signal to the back up alarm Specifications
when the machine is placed in reverse. Nominal voltage............................................24 V
Contact close................................13 to 15 kg/cm²
Contact open ................................11 to 12 kg/cm²
D87E-2 D87P-2 10-145 2

12
WARNING HORN
The warning horn will sounds when the switch is depressed. Specifications
Frequency................................................... 420 hz
Sound level ............................................... 110 dB
WARNING HORN SWITCH
The push button switch, when depressed, sends a signal to the warning Specifications
horn to sound. Nominal voltage............................................24 V
A. Off travel ..............................................1.5 mm
B. On travel...............................................2.3 mm
10-146 2 D87E-2 D87P-2

12
WIPER MOTOR
Specifications
Front wipers angle .......................................... 45°
Rear wiper angle ............................................. 85°
WIPER AND WASHER SWITCH
The three position push in type switch is to operate the wiper and wash- Specifications
er systems. Nominal voltage...........................................24 V
D87E-2 D87P-2 10-147 2

12
WASHER PUMP
When the wiper and washer switch is depressed, the pump supplies a Specifications
flow of washer fluid to the ascribed window until the switch is let off. Nominal voltage............................................24 V
Delivery pressure .................................1.6 kg/cm²
Delivery rate ......................................... 0.7 L/min
DOME LIGHT
Specifications
Current draw ................................................ 15 W
10-148 2 D87E-2 D87P-2

12
CAB SWITCH PANEL
Specifications
BLOWER MOTOR SWITCH
The seven position switch is used to control the fan speed of the heating Specifications
and air conditioning system. Nominal voltage............................................24 V
D87E-2 D87P-2 10-149 2

12
BLADE FLOAT SOLENOID
Specifications
Coil resistance................. 1025 to 1135 Ω @ 20°C
A/C MAGNETIC CLUTCH
Specifications
Nominal current ...........................................1.2 A
10-150 2 D87E-2 D87P-2

12
STEERING CONTROLLER
Pin Wire Color Connection Specifications

1 Brown TASC valve button high Nominal voltage............................................24 V
2 Blue TASC valve button low
3 Gray/White Left or right solenoid
4 Green TASC valve button right
5 White TASC valve button left
6 Black Ground
7 Black Ground
8 Gray Left or right solenoid
9 N/C ---
10 N/C ---
11 Violet Signal high-low
12 Red Power
GRIP BUTTON MICRO SWITCHES

\
Specifications
D87E-2 D87P-2 10-151 2

12
GEAR SPEED INDICATOR
Specifications
NEUTRAL SOLENOID
Specifications
10-152 2 D87E-2 D87P-2

LEFT OR RIGHT SOLENOID
Specifications
D87E-2 D87P-2 10-153 2

12
MEMORANDA
10-154 2 D87E-2 D87P-2

12
WIRING HARNESSES
FRONT HARNESS
D87E-2 D87P-2 10-155 2

12
ENGINE HARNESS
Connector Gauge/ Color Connector Gauge/ Color

Circuit End Circuit End
Position Length (mm) Tag Position Length (mm) Tag
1 CNP1-A 16/1060 Orange 24 CNM7 6/1215 Red
1 24
1A CNM5-D 19S 24A 1
2 CNP1-B 16/1060 Orange 25 CNM6 6/1090
2 25 Black
2A CNM5-H 19S 25A
3 CNP1-F 16/1060 White 26 CNM5-N 16/1400
3
3A CNM5-P 20S 26 26A 16/1700 Black
4 CNP1-G 16/1060 Purple 26B CNE3-H
4
4A CNM5-M 36C 27 CNP1-X 16/1860 Yellow
27
5 CNP1-H 16/1060 Purple 27A 31P
5
5A CNM5-R 361C 28 CNP1-D 16/1860 Purple
28
6 CNP1-M 16/1060 Dark Blue 28A 37
6
6A CNM5-F 42R 29 CNP1-K 16/1860 Purple
29
7 CNP1-N 16/1060 Yellow 29A 36P
7
7A CNM5-L 32F 30 CNM5-Q 16/1165
White
8 CNP1-P 16/1060 Red 30 30A CND7 16/175
8 21C
8A CNM5-E 30F 30B CNE1
9 CNP1-R 16/1060 Orange 31 CND7 16/815
9 31 Black
9A CNM5-C 41R 31A
10 CNP1-S 16/1060 Orange 32 CNE1-2 16/1050
10 White
10A CNM5-B 41F 32 32A 16/1430
70
11 CNP1-W 16/1060 Yellow 32B CND14-C
11
11A CNM5-C 35F 33 6/1560 Red
33
12 CNP1-Q 16/1060 Orange 33A 11A
12
12A CNM5-K 53 34 6/990
34 Red
13 CNP1-T 16/2250 Dark Blue 34A
13
13A CNF2 42F 35 6/1340
35 Red
14 CNP1-J 16/2250 Yellow 35A
14
14A CNF2 30C 36 CNP1-L 16/900 Purple
36
15 CNP1-U 16/2250 Orange 36A 36T
15
15A CNF2 53B 37 CNP1-V 16/900 Gray White
37
16 CNM5-J 16/2330 Orange 37A 63
16
16A CNF2 64 38 CNP1-C 16/2250 Gray Yellow
38
17 CNM5-S 16/2330 38A CNF2 61
17 17A CNF2 16/100 Black 39 CNP20 14/1260 Orange
39
17B CNF2 39A 19S
18 CNP1-O 16/1360 Yellow 40 CNP20 16/1110 Orange
18 40
18A CNE3-J 33F 40A CND14-A 12
19 CNM5-A 16/1625 41 16/775
Orange
19 19A CND9 16/175 41 41A CND13 16/175 Black
66C
19B CNE2 41B
20 CNM5-T 16/675 42 6/230 Red
42
20 20A CND8 16/1700 Black 42A 3
20B CND9 43 14/280
43 Orange
21 CNP1-E 16/1135 43A
Light Blue
21 21A CND8 16/175 44 CNM5-U 14/1230 Orange
28 44
21B 44A 65F
22 CNP2 6/1125 Red 45 CND14-B 16/275
22
22A 2 45 45A CND13 16/175 Orange
23 CNP3 14/1110 45B
23 Black
23A
10-156 2 D87E-2 D87P-2

12
D87E-2 D87P-2 10-157 2

12
POD HARNESS
10-158 2 D87E-2 D87P-2

12
CONTROL TOWER HARNESS
D87E-2 D87P-2 10-159 2

12
REAR HARNESS
10-160 2 D87E-2 D87P-2

12
RIGHT REAR HARNESS
D87E-2 D87P-2 10-161 2

12
INSTRUMENT PANEL HARNESS
Connector Gauge/ Color Connector Gauge/ Color

1 CNP1-B 16/830 23 CNP1-C 18/575
Orange
1A 16/330 23A CNP9 18/400 Gray Yellow
1 19S 23
1B 16/800 23B CND12 18/300 61
1C CNP1-A 23C CNP5-B
2 CNP1-D 16/840 Purple
2
2A CNP13 37 24 CNP2 8/800 Red
24
3 CNP1-E 18/975 24A 2
Light Blue
3 3A CNP16 18/325 25 CNP3 14/850
28
3B CNP15-B 25A 18/375
4 CNP1-F 16/780 White 25 25B CNP18-B 18/300 Black
4
4A CNP19 20S 25C CNP17-B 18/375
5 CNP19 16/380 White 25D CNP15-A
5
5A 20 26 CNP6-2 18/375
6 CNP1-G 16/675 26A CNP14 18/415
6A CND4 18/250 Purple 26 26B 18/390 Black
6
6B CNP9 18/550 36C 26C 18/100
6C CNP5-A 26D
7 CNP1-H 16/1000 Purple 27 CND3 18/150
7
7A CNP6-6 36TC 27A CND2 18/250
8 CNP1-J 16/575 27B CND4 18/300
27 Black
8A CND3 18/150 Purple 27C CND12 18/200
8
8B CNP9 18/550 30C 27D CND11 18/275
8C CNP7-B 27E
9 CNP1-K 16/100 Purple 28 CNP12 16/890 Black
9 28
9A CNP6-1 36P 28A CNP10 10
10 CNP1-L 16/100 Purple 29 14/365
10 Orange
10A CNP6-5 36T 29 29A CNP17-5 14/100
19WL
11 CNP1-M 16/925 Dark Blue 42 29B CNP17-2
11 11A CNP18-6 18/325 Gray 30 14/365
Orange
11B 49 30 30A CNP18-5 14/100
19
12 CNP1-N 16/575 30B CNP18-2
Yellow
12 12A CNP9 18/550 31 CNP13 18/290 Orange
32F
12B CNP4-B 31A 16/400 19H
13 CNP1-O 16/575 31B
Yellow 31
13 13A CNP9 18/550 31C Light Green
33F 18/350
13B CNP7-A 31D 15
14 CNP1-P 16/950 Red 31E CNP6-4
14
14A 30F 32
Light Green
15 CNP1-Q 16/810 32 32A 18/125
15
15A 18/485 32B CNP5-C
Orange
15 15B CNP16 18/375 33 Light Green
53 33 18/115
15C 18/375 33A CNP4-C 15
15D CNP14 34
Light Green
16 CNP1-R 16/925 Orange 34 34A 18/115
16 15
16A CNP17-6 41R 34B CNP7-C
17 CNP1-S 16/925 Orange 35 Light Green
17
41F
35 18/115
17A CNP17-3 35A CNP8-C 15
18 CNP1-T 16/925 Dark Blue 42 36 CNP14 18/300 Light Blue
36
18A CNP18-3 18/100 36A CNP16 28
18 18B CNP18-A 18/350 Gray 37 16/325
18C CNP17-A 18/425 49 37A CND1 16/290 Black
37
18D CNP6-3 37B CNP10 18/340 2
19 CNP1-U 16/840 Orange 37C CNP11
19
19A 53B 38 18/285
White
20 CNP1-V 18/575 38 38A CND1 18/300
24
20A CNP9 18/350 Gray White 38B CNP11
20
20B CND11 18/350 63 39 18/350 Orange
39
20C CNP8-B 39A 19G
21 CNP1-W 16/575 40 CNP20 14/840 Orange
Yellow 40
21 21A CNP9 18/550 35F
40A 19S
21B CNP4-A 41 CNP20 16/800
22 CNP1-X 16/575 Orange
41
22A CND2 18/750 Yellow 12
22
22B CNP9 18/550 31P 41A
22C CNP8-A
10-162 2 D87E-2 D87P-2

12
D87E-2 D87P-2 10-163 2

12
CAB HARNESS
Connector Wire Gauge/ Color Connector Wire Gauge/ Color

1 CNLC3 16/2910 Orange 14 CNLC2 16/1185 Orange

1 14
1A CNC4 63RP 14A CNC6 19LL

2 15
2A CNC4 63RH 15A CNC7 63P

3 16
3A CNC4 63RL 16A CNC7 63H

4 17
4A CNC4 19R 17A CNC7 63L
5 CNCL3 16/575 Orange 18 CNLC1 16/4245 Orange

5 18
5A CNC2-E 63RW 18A CNC7 19LR
6 CNLC3 16/2440 Orange 19 CNC8 14/2520 Orange

6 19
6A CNC5 FP 19A CNC9 65F
7 CNLC3 16/2440 Orange 20 CNC1 8/275 Red

7 20
7A CNC5 63FH 20A CNLC9 1
8 CNLC3 16/2440 Orange 21 CNC3 8/375

8 21 Black
8A CNC5 63FL 21A
9 CNLC2 16/2490 Orange 22 14/200
9 22 Black
9A CNC5 19F 22A CNLC10
10 CNLC2 16/625 Orange 23 CNC2-C 16/2385
10 Orange
10A CNC2-D 63LW 23 23A CNC14 16/1085
41R
11 CNLC2 16/1185 Orange 23B CNC17
11
11A CNC6 63LP 24 CNC2-B 16/2890
Orange
12 CNLC2 16/1185 Orange 24 24A CNC13 16/450
12 41F
12A CNC6 63LH 24B CNC10
13 CNLC2 16/1185 Orange 25 CNC2-A 16/625 Orange
13 25
13A CNC6 63LL 25A CNLC1 66C
10-164 2 D87E-2 D87P-2

12
D87E-2 D87P-2 10-165 2

12
CAB PANEL HARNESS
10-166 2 D87E-2 D87P-2

12
CONTROLLER HARNESS
D87E-2 D87P-2 10-167 2

12
INSTRUMENT HARNESS
10-168 2 D87E-2 D87P-2

12
COMPARTMENT HARNESS
D87E-2 D87P-2 10-169 2

12
COMPARTMENT HARNESS
10-170 2 D87E-2 D87P-2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS A/C HEATER
12
A/C HEATER
A/C HEATER LINES
D87E-2 D87P-2 10-171 2

12
COMPRESSOR MOUNTING
10-172 2 D87E-2 D87P-2

12
CAB A/C UNIT
Specifications
Blower velocity.............................14 to 20 sm³/m
Heater output............................ 42202 kJ @ 27°C
A/C output................................ 26376 kJ @ 27°C
D87E-2 D87P-2 10-173 2

12
CAB HEATER UNIT
Specifications
Blower velocity.............................14 to 20 sm³/m
Heater output............................ 42202 kJ @ 27°C
10-174 2 D87E-2 D87P-2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS SPECIAL TORQUE CHART
12
SPECIAL TORQUE CHART
Description Size N•m Description Size N•m
Pod harness to pod M3 0.7 Compressor bracket to engine bolt M10 66 ±8
Brake pedal terminal switch 8-32 2 Top idler cover bolt M10 62
Horn switch terminal 8-32 2.6 ±0.8 Terminal B on starter motor M10 3.1 ±0.4
Neutral switch terminal 8-32 2 Preheat select nut M10 3.9 ±0.5
Back up alarm terminal 8-32 2 V-belt cover to compressor bracket M10 66 ±8
Back up alarm switch terminal 8-32 1.4 V-belt tensioner bolt lock nut M10 66 ±8
Hourmeter switch terminal 8-32 2 Converter to flywheel housing bolt M12 111 ±13
Relay mount screw 8-32 2 Converter to flywheel housing stud nut M12 111 ±13
Washer tank bolt 10-24 2 Ring gear to flywheel M12 111 ±13
Dome lamp mount screw 10-24 2 Quick drop valve mounting bolts M12 65 ±3
Transmission filter switch terminal 10-24 1.6 ±0.2 Output shaft sleeve bolt 1/2 110
Hydraulic filter switch terminal 10-24 1.6 ±0.2 Front idler & track roller seal retainer bolt 1/2 134
Pilot filter switch terminal 10-32 2 Universal joint bolt 1/2 110
Cooler temp sender switch terminal 10-32 2 Pinion access cover bolts 1/2 98 *
Main circuit breaker bolt 10-32 2 Sprocket hub retaining bolts 1/2 125 **
Bimetal timer bolt 10-32 2 Ring gear retainer bolt 1/2 125 **
Trans oil temp sender terminal 10-32 2 End cover bolt - 2 speed steering 1/2 81
Circuit breaker terminal 10-32 2 Filter door hinge bolts 1/2 98
Fuel level sender mount screw 10-32 2 Front idler seal housing bolt 1/2 134
Fuel gauge terminal 10-32 2 Front mask bolts 1/2 125
Fuel gauge mount bolt 10-32 1.2 ±0.2 Fenders to main frame bolts 5/8 220
Alternator terminal R M5 2.2 ±0.3 Pivot shaft retainer plate bolts 5/8 265
Key switch terminal M5 2.2 ±0.2 Rear main frame cover bolts 5/8 265
Alternator terminal R M6 2.2 ±0.3 Sprocket hub plate bolts 5/8 244
Cab trim screw M6 5.4 Track adjuster relief valve 5/8 68
Turnbuckle locking nut LH M6 8.3 ±1.4 Track adjuster grease valve 5/8 68
Main circuit breaker terminal 1/4 6.2 Pinion gear housing bolt 5/8 220
Decelerator pedal lever bolt M8 31 ±3 Planet gear shaft bolt 5/8 220
Foam mounting bolt M8 13.5 Upper guide bar bolts 5/8 220
Locking nuts M8 31 ±3 Dirt shield bolts 5/8 220
AC compressor bolt M8 31 ±3 Horn switch mounting nut 5/8 4.5
Stud nut by governor M8 31 ±3 Rear engine retainer plate bolts M16 260 ±25
Master switch terminal 3/8 12 Rear engine to flywheel housing bolts M16 260 ±25
Trans baffle bolt 3/8 62 Equalizer bar rebound bracket bolts 3/4 455
Battery terminal nut 3/8 31 Master switch mounting nut 3/4 51
Battery mounting bolt 3/8 9 Neutral switch mount nut 3/4 51
Compressor V-belt cover bolt M10 66 ±8 Brake pedal switch mount nut 3/4 51
Compressor V-belt tensioner bolt M10 66 ±8 Pivot shaft thrust plate bolt 3/4 455
* Initial installation of bolts - reused bolts revert torque to 92 N•m

** Initial installation of bolts - reused bolts revert torque to 108 N•m
D87E-2 D87P-2 10-175 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS SPECIAL TORQUE CHART
12
Description Size N•m Description Size N•m
Front idler fork and support bolt 3/4 455
Sprocket mounting nut 3/4 435
Track roller mounting bolts 3/4 455
Track shoe bolts 3/4 698***
Pivot shaft cover bolts 3/4 455
Track roller shield mounting bolt 3/4 455
Track roller shield spacer bolt 3/4 455
Sprocket rock deflector bolts 3/4 455
Equalizer bar cushion bolt 3/4 455
Diagonal strut eye lock nut - dozer 3/4 450
Lower strut eye lock nut - grader 3/4 450
Lift cylinder yoke bearing cap bolts 3/4 450
Switch key mounting nut M20 12 ±2.5
Operator compartment bolt M22 650
Front idler shaft support bolt 7/8 730
Final drive to main frame bolts 7/8 735
Final drive planet carrier bolts 7/8 610
Top idle block bolt 7/8 735
Rear main frame drain plug 7/8 55 ±7
Engine front mount to frame bolts 7/8 688 ±78
Engine rear mount to frame bolts 7/8 688 ±78
Blade cutting edge nut 7/8 725
Blade end bit nut 7/8 725
Transmission mounting bolts 1 920
Counterweight clevis bolt 1 1110
Track frame guide bolt 1 1110
Track frame guide retainer bolt 1 1110
ROPS to ROPS support bolts 1 920
Diagonal strut end cap bolts - dozer 1 1050
Upper strut end cap bolts - dozer 1 1050
Trunnion mounting bolts 1 1050
Pusharm bearing cap bolts 1 1050
C frame bearing cap bolts 1 1050
Gimbal tube to main frame 1-1/8 1300
ROPS support to main frame 1-1/8 1300
Rigid drawbar bolts 1-1/4 2188
Ripper mounting frame bolts 1-1/4 1800
Counterweight drawbar bolts 1-1/4 2188
Pivot shaft lock pin retainer 1-3/4 275
*** Lubricate threads and washer face with clean engine oil then torque to 400 ±74 N•m plus 120° turn (two flat of the bolt head)
10-176 2 D87E-2 D87P-2

20 TESTING, ADJUSTING AND TROUBLESHOOTING
STANDARD
12 VALUE TABLES ........................................................................................................... 20-2
TOOLS FOR TESTING AND ADJUSTING ..................................................................................... 20-11
ENGINE............................................................................................................................................... 20-12
EXHAUST COLOR ............................................................................................................................ 20-13
BELT TENSION ................................................................................................................................. 20-14
TORQUE CONVERTER STALL SPEEDS ....................................................................................... 20-15
FUEL CONTROL LINKAGE............................................................................................................. 20-16
FUEL CONTROL LINKAGE............................................................................................................. 20-18
DRIVE TRAIN LEVERS .................................................................................................................... 20-20
TASC VALVE..................................................................................................................................... 20-21
BRAKE PEDAL .................................................................................................................................. 20-22
DECELERATOR PEDAL................................................................................................................... 20-23
SAFETY LOCK LEVER..................................................................................................................... 20-24
BLADE EQUIPMENT LEVER .......................................................................................................... 20-25
REAR EQUIPMENT LEVER............................................................................................................. 20-26
DRIVE TRAIN PRESSURES ............................................................................................................. 20-27
WORK EQUIPMENT ......................................................................................................................... 20-28
SERVICE DIAGNOSIS ...................................................................................................................... 20-34
★ The following precautions are necessary when using the standard value tables for testing and adjusting or for trouble-
shooting.
1. The values in the tables are for new machines and are obtained from reference to values when the machine is shipped from
the factory. These values should be used only as a target guide for judging the progress of wear or when repairing the ma-
chine.
2. The standard values for judging failures are based on the results of various tests when shipping the machine from the fac-
tory. These values should be used as reference together with the repair condition and operating record of the machine to
make judgement on failures.
3. These standard values do not form a basis for judging claims.
WARNING! When carrying out testing, adjusting or troubleshooting, position the machine on level ground and
use blocks to prevent the machine from moving.
WARNING! When carrying out work together with other workers, use agreed signals and do not allow unau-
thorized people near the machine.
WARNING! Wait for the engine coolant to cool before checking the coolant level. If the radiator cap is removed
while the coolant is still hot, the coolant will spurt out and cause burns. Be careful to stay away from the fan,
fan belt and other moving parts
D87E-2 D87P-2 20-1 2

TESTING, ADJUSTING AND TROUBLESHOOTING STANDARD VALUE TABLES
STANDARD
12 VALUE TABLES
ENGINE IN CHASSIS
Machine Model D87E-2 D87P-2
Engine Model S6D125E-2
Item Measurement conditions Unit Standard Value Service limit value
● High idle 2200 to 2320 2200 to 2320
● Low idle 620 to 740 620 to 740

Engine speeds RPM
● Decelerator slow 800 to 900 800 to 900
● Rated speed 2100 2100
Intake manifold pres- ● At converter stall and full throt-

mm Hg 600 NA
sure tle - minimum
● At converter stall and full throt-

Intake air restriction mm H2O 300 762
tle - maximum
Valve clearance with ● Intake valve 0.33 0.33

mm
engine cold ● Exhaust valve 0.71 0.71
● Maximum at converter stall and

Exhaust back pressure mm Hg 115 NA
full throttle
Coolant temperature in operating

range
Blow by pressure mm H2O 50 Maximum 100 Maximum
● Service Tool, 799-203-2002
● Full load at rated speed
Lubricating oil pressure ● Minimum at low idle 1 0.7

with SAE 15W-40 oil
kg/cm²
and coolant tempera-
ture in operating range ● Minimum at high idle 3.5 NA
Fuel inlet restriction ● Max restriction at high idle mm Hg --- 200
● Maximum coolant operating

Coolant temperature °C --- 100
temperature
● Deflection when pressed with

13 13
finger force of ≈ 98 N
Belt tension mm
● Deflection when pressed with
18 to 22 18 to 22
finger force of ≈ 60 N
20-2 2 D87E-2 D87P-2

CHASSIS
12
● Refer to the individual test for the complete list of measurement conditions for the test procedure.
STALL SPEEDS
Machine Model D87E-2 D87P-2
Engine Model S6D125E-2
Measurement conditions Unit Standard value Permissible value
● Engine at full throttle Converter 1770 to 1910 1770 to 1910

● Engine coolant temperature in operating range
rpm
Blade tilt stall 2170 to 2290 2170 to 2290
● Drive train oil in operating range
● Brake pedal applied Full, converter and hydraulics 1540 to 1660 1540 to 1660
LEVER MOVEMENT
Item Measurement conditions Unit Standard value Permissible value
Low idle ⇒ Full throttle 51 51

Tip of knob
mm
Fuel control lever
Shutdown ⇒ Low idle 22.4 22.4
Neutral ⇒ Forward 30 ± 0.5 28 to 32

Neutral ⇒ Reverse
Engine stopped
Center of knob
° degrees
Gear shift lever Forward: Between 30 ± 0.5 28 to 32

each speed
Reverse: Between 30 ± 0.5 28 to 32

each speed
Low ⇒ high 41.5 ± 4.5 41.5 ± 4.5
Left Lever
Center of knob
° degrees
High ⇒
Engine slow
241.5 ± 8.5 241.5 ± 8.5

Steering lever
Low ⇒ high 41.5 ± 4.5 41.5 ± 4.5
Right Lever
High ⇒ 241.5 ± 8.5 241.5 ± 8.5
brake
Center of lever knob
Initial Step Stroke Distance 45 to 55 24 to 55

Engine stopped
mm
Brake pedal
Full Stroke Distance 90 to 110 78 to 118
Engine stopped
Center of pedal
mm
Decelerator pedal Pedal travel 50 to 75 45 to 75
D87E-2 D87P-2 20-3 2

12
A. Locked (start) position 0 - Vertical
Engine stopped
Center of knob
° degrees
Safety lock lever ±5
B. Unlocked (run) position 90 - Horizontal
Hold ⇒ Raise 45 to 65 40 to 65
Hold ⇒ Lower 45 to 65 40 to 65
Engine stopped
Center of lever
mm
Blade equipment lever Hold ⇒ Float 45 to 65 45 to 65
Hold ⇒ Left Tilt 45 to 65 45 to 65
Hold ⇒ Right Tilt 45 to 65 45 to 65
Engine stopped
Center of lever
mm
Rear equipment lever
Tilt In 80 to 100 73 to 100
Tilt Out 80 to 100 73 to 100
Low idle ⇒ Full throttle 51 51

Tip of knob
mm
Fuel control lever
Shutdown ⇒ Low idle 22.4 22.4
1st ⇒ 2nd 15 to 17 14 to 18
Twist angle
Engine off
2nd ⇒ 3rd 15 to 17 14 to 18
Neutral ⇒ Forward
° degrees
Knob center
7 to 9 6 to 10
Engine off
TASC valve lever

Neutral ⇒ Reverse 7 to 9 6 to 10
Neutral ⇒ Left
Engine slow
Knob center
17 to 19 16 to 20
Neutral ⇒ Right 17 to 19 16 to 20
Initial Step Stroke Distance 45 to 55 24 to 55

Engine stopped
mm
Brake pedal
Full Stroke Distance 90 to 110 78 to 118
Center of pedal
Engine off
mm
Decelerator pedal Pedal travel 50 to 75 45 to 75
20-4 2 D87E-2 D87P-2

12
A. Locked (start) position 0 - Vertical
Engine stopped
Center of knob
° degrees
Safety lock lever ±5
B. Unlocked (run) position 90 - Horizontal
Engine stopped
Center of lever
mm
Engine stopped
Center of lever
mm
Tilt In 80 to 100 73 to 100
Tilt Out 80 to 100 73 to 100
OPERATING EFFORT
Side Effort at Low Idle 20 to 40 13 to 40

Engine stopped
Center of knob
Fuel control lever Low Idle ⇒ Full Throttle 30 to 50 23 to 50

N
Low Idle ⇒ Stop 15 to 25 13 to 29
Neutral ⇒ 1st 30 to 50 30 to 60
1st ⇒ 2nd 30 to 50 30 to 60
2nd ⇒ 3rd 30 to 50 30 to 60
Forward
3rd ⇒ 2nd 40 to 60 40 to 70
2nd ⇒ 1st 40 to 60 40 to 70
Engine stopped
Center of knob
1st ⇒ Neutral 40 to 60 40 to 70
Gear shift lever
N
Neutral ⇒ 1st 30 to 50 30 to 60
1st ⇒ 2nd 30 to 50 30 to 60
2nd ⇒ 3rd 30 to 50 30 to 60
Reverse
3rd ⇒ 2nd 40 to 60 40 to 70
2nd ⇒ 1st 40 to 60 40 to 70
1st ⇒ Neutral 40 to 60 40 to 70
D87E-2 D87P-2 20-5 2

12
Initial Step 85 to 115 79 to 115
Engine stopped
Center of pedal
Brake pedal
N
Full stroke 160 to 200 160 to 212
Engine stopped
Center of pedal
Decelerator pedal Full stroke 65 to 85 60 to 85
N
Locked (start) position 22 13 to 31
Engine stopped
Center of knob
Safety lever lock
N
Unlocked (run) position 22 13 to 31
High to low 25 to 45 25 to 45
Left lever Low to high 25 to 45 25 to 45
Center of knob
Engine slow
Low to brake 75 70 to 120

Steering levers
N
High to low 25 to 45 25 to 45
Right lever Low to high 25 to 45 25 to 45
Low to brake 75 70 to 120
Engine stopped
Center of lever

N

Raise ⇒ Lower 10 to 20 10 to 26
Engine stopped
Center of lever

N
Tilt In ⇒ Tilt Out 10 to 20 10 to 20
Side Effort at Low Idle 20 to 40 13 to 40

Engine stopped
Center of knob
Fuel control lever Low Idle ⇒ Full Throttle 30 to 50 23 to 50

N
Low Idle ⇒ Stop 15 to 25 13 to 29
20-6 2 D87E-2 D87P-2

12
1st ⇒ 2nd 2.7 to 3.2 2.5 to 3.4
Twist angle
Engine off
2nd ⇒ 3rd 3.2 to 3.7 3.0 to 4.0
Neutral ⇒ Forward
Knob center
31 to 40 26 to 44
Engine off
TASC valve lever
Neutral ⇒ Reverse 31 to 40 26 to 44
Engine slow Neutral ⇒ Left

Knob center
17 to 49 17 to 49
Neutral ⇒ Right 17 to 49 17 to 49
N
Initial Step 85 to 115 79 to 115
Engine stopped
Brake pedal
Full Stroke 160 to 200 160 to 212
Center of pedal
Engine off
Decelerator pedal Full Stroke 65 to 85 60 to 85
Locked (start) position 22 13 to 31

Engine stopped
Center of knob
Safety lever lock

N
Unlocked (run) position 22 13 to 31
Engine stopped
Center of lever

N

Raise ⇒ Lower 10 to 20 10 to 26
Engine stopped
Center of lever

N
Tilt In ⇒ Tilt Out 10 to 20 10 to 20
D87E-2 D87P-2 20-7 2

DRIVE TRAIN
12
Pressures and Speed
Item Measurement Conditions Unit Standard Value Permissible Value
Main (1) 18.3 to 19.7 18.3 to 19.7
Converter inlet (2) 6.7 to 8.8 6.7 to 8.8

neutral, oil at operating temperature
Engine at high idle, transmission in
Lubrication (3) 3.2 to 4.6 3.2 to 4.6

Transmission pres-
In neutral 0 0
sures Forward or re-
verse clutch
In gear 0 to 7 0 to 7
In neutral 0 0
1st, 2nd or 3rd (4)
kg/cm²
In gear 1 to 1.76 1 to 1.76
Engine at low idle, trans
in neutral, oil at operat-
ing temperature
Drive train pilot reg-

In neutral 18.6 to 19.6 18.6 to 19.6
ulated pressure
Main 18.3 to 19.7 18.3 to 19.7

Engine at high
idle, transmis-
Steering pressures sion in neutral, Right or left clutch 0 to 0.35 0 to 0.35
oil at operating
temperature
Right or left brake 0 to 0.35 0 to 0.35
Low 2.7 2.7

Forward 1st
High 3.7 3.7
Low 5.0 5.0

Forward 2nd
High 6.6 6.6
Coolant temperature within operating range
Low 8.1 8.1

Measurement distance - 20 m
Run up distance - 10 to 30 m
Forward 3rd
Engine at full throttle
Level road surface
High 10.3 10.3

km/h
Travel speed
Low 3.4 3.4
Reverse 1st
High 4.4 4.4
Low 6.0 6.0

Reverse 2nd
High 7.7 7.7
Low 9.5 9.5

Reverse 3rd
High 12.1 12.1
20-8 2 D87E-2 D87P-2

WORK EQUIPMENT
12
Hydraulic Drift
D87E-2
Engine: stopped
Hydraulic oil temperature: 82 to 88°C
Blade lift Downward movement at center of blade 225 Max 225 Max
cutting edge when fully raised
Control valve lift in hold position
mm per 15 minutes
Left tilt
Engine: low idle 200 Max 200 Max
Blade tilt Hydraulic oil temperature: 82 to 88°C
Downward movement at cutting edge
corner when fully raised
Right tilt
Control valve lift in hold position 200 Max 200 Max
Engine: stopped
Ripper lift Hydraulic oil temperature: 82 to 88°C 120 Max 120 Max
Ripper point: 500 mm above ground
D87P-2
Engine: stopped
Blade lift Downward movement at center of blade 225 Max 225 Max
cutting edge when fully raised
mm per 15 minutes
Control valve lift in hold position

Left tilt
Engine: low idle 200 Max 200 Max

Blade tilt Hydraulic oil temperature: 82 to 88°C
Downward movement at cutting edge
corner when fully raised
Right tilt
Control valve lift in hold position 200 Max 200 Max
D87E-2 D87P-2 20-9 2

Equipment Speed
12
D87E-2
Lower Raise
2.5 to 3.5 2.4 to 3.5
Engine: full throttle
Hydraulic oil temperature: 82 to 88°C 1.5 to 2.5 1.0 to 2.5
Blade lift
Blade: No load
Float
0.8 to 1.3 0.7 to 1.3
Ground to maximum height
1.5 Maximum 1.7 Maximum
time
Lag
Engine: full throttle 2.5 to 3.5 2.5 to 3.5
Left
Seconds
Blade tilt
Blade: No load
Right
Left tilt ÷ Right tilt 2.5 to 3.5 2.3 to 4.0
Raise
Engine: full throttle 2.5 to 3.5 2.5 to 3.5
Lower
Ripper lift 1.5 to 2.5 1.5 to 2.9
Shank set at bottom hole
time
Lag
D87P-2

Lower Raise
2.5 to 3.5 2.4 to 3.5

Hydraulic oil temperature: 82 to 88°C 1.5 to 2.5 1.0 to 2.5
Blade lift
Blade: No load
Float
0.8 to 1.3 0.7 to 1.3

Seconds

time
Lag
Left

Blade tilt 2.5 to 3.5 2.5 to 3.5
Blade: No load
Right
Left tilt ÷ Right tilt
Equipment Pressures
Measurement Conditions Unit Standard Value Permissible Value
Blade Lift (1) 173 ± 3 173 ± 3

Engine at high idle, transmission
kg/cm²
in neutral, oil at operating tem- Blade Tilt (2) 183 ± 3 183 ± 3

perature
Pilot Control (3) 23 ± 2 23 ± 3
20-10 2 D87E-2 D87P-2

TESTING, ADJUSTING AND TROUBLESHOOTING TOOLS FOR TESTING AND ADJUSTING
TOOLS
12 FOR TESTING AND ADJUSTING
Check or Measurement Symbol Part No. Part Name Remarks
Engine speed A1 799-203-9000 Digital optical tach Follow instructions with tool
Engine stall speeds A1 799-203-9000 Digital optical tach Follow instructions with tool
Engine Engine tools See ENGINE SHOP MANUAL
B1 799-201-9000 Handy smoker Discoloration 0 to 70% (with stan-
Exhaust color dard color) (Discoloration%x1/10
B2 Commercially available Smoke meter = Bosch index)
Lever travel C1 Commercially available Scale
79A-264-0020 0 to 294 N
Operating effort D1 Push pull scale
79A-264-0090 0 to 490 N
Drive train pressures E1 DR04-309 Pressure test kit Multiple gauges
Work equipment F1 Commercially available Pressure gauge and hose 0 to 352 kg/cm²
Work equipment or drive
G1 Commercially available Pressure gauge and hose 0 to 35 kg/cm²
train pilot system
D87E-2 D87P-2 20-11 2

TESTING, ADJUSTING AND TROUBLESHOOTING ENGINE
ENGINE
12
WARNING! When removing or installing any measuring

equipment, be careful not to touch any high temperature
parts
ENGINE SPEED
★ Measure the engine speed under the following conditions.
Coolant temperature ..................................... Within operating range
Hydraulic oil temperature ................................................45 to 55°C
Drive train oil temperature ...............................................70 to 90°C
1. Install digital optical tachometer A1, using the instructions sup-

plied with it. Start the engine, and measure the engine speed.
★ For the remaining engine tests, refer to the Engine Shop Manual.
20-12 2 D87E-2 D87P-2

TESTING, ADJUSTING AND TROUBLESHOOTING EXHAUST COLOR
EXHAUST
12 COLOR
★ When measuring in the field when there is no air or power supply,
use the handy smoker checker B1; when recording official data use
the smoke meter B2. Raise the coolant temperature to the operating
range before measuring.
WARNING! When removing or installing the measuring

equipment, be careful not to touch any high temperature
parts
MEASURING WITH HANDY SMOKER CHECKER B1
1. Fit the filter paper in the tool. Insert the exhaust gas intake port into
the exhaust pipe, accelerate the engine suddenly and at the same
time operate the handle of tool to catch the exhaust gas on the filter
paper.
2. Remove the filter paper and compare it with the scale provided to
judge the condition.
MEASURING WITH SMOKE METER B2
1. Insert the probe of tool into the outlet port of exhaust pipe (1), then
tighten the clip to secure it to the exhaust pipe.
2. Connect the probe hose, accelerator switch plug and air hose to
tool. The pressure of the air supply should be less than 15 kg/cm².
3. Connect the power cord to the AC power source socket. When con-
necting the port, check first that the power switch of tool is OFF.
4. Loosen the cap nut of the suction pump, then fit the filter paper. Fit
the filter paper securely so that the exhaust gas does not leak. Turn
the power switch of tool ON.
5. Accelerate the engine suddenly and at the same time, depress the
accelerator pedal of tool and catch the exhaust gas color on the fil-
ter paper.
6. Lay the filter paper used to catch the exhaust gas color on top of un-
used filter paper, 10 sheets or more, inside the filter paper holder
and read the indicated value.
D87E-2 D87P-2 20-13 2

TESTING, ADJUSTING AND TROUBLESHOOTING BELT TENSION
BELT
12 TENSION
★ Refer to the Operation & Maintenance Manual for tools and
proper procedure.
20-14 2 D87E-2 D87P-2

TESTING, ADJUSTING AND TROUBLESHOOTING TORQUE CONVERTER STALL SPEEDS
TORQUE
12 CONVERTER STALL SPEEDS
★ Measurement Conditions
● Engine at full throttle
● Engine coolant temperature in operating range
● Drive train oil in operating range
● Hydraulic oil at operating range
● Secondary brake pedal applied
CONVERTER STALL
Connect the digital optical tachometer A1. With the engine speed at full
throttle and the brake pedal applied, shift the transmission into 3rd for-
ward and register the engine stall speed rpm.
★ Do not keep the stall condition for more than 20 seconds. Make
sure that the converter oil temperature does not exceed 120°C.
FULL STALL (CONVERTER AND HYDRAULIC)

Connect the digital optical tachometer A1.With the engine speed at full
throttle and the brake pedal applied, shift the transmission into 3rd for-
ward. Raise the blade fully and hold to activate the equipment relief
valve. Register the full engine stall speed rpm.
★ Do not keep the stall condition for more than 20 seconds. Make
sure that the converter oil temperature does not exceed 120°C.
D87E-2 D87P-2 20-15 2

TESTING, ADJUSTING AND TROUBLESHOOTING FUEL CONTROL LINKAGE
FUEL
12 CONTROL LINKAGE
● Engine stopped
● Safety lock lever in the locked (down) position
● Mounted equipment lowered to the ground
LEVER TRAVEL
Measure travel distance with scale C1 from low idle to high idle at the
center tip of the lever knob.
LEVER EFFORT
Side Effort At Low Idle
Using the push pull scale D1, measure the maximum effort required
when moving the lever out and away from the ratchet gate.
Low Idle To Full Throttle
when moving the lever out and away from the ratchet gate at low idle
then back to the full throttle position.
Low Idle To Stop
when moving the lever out and away from the ratchet gate at low idle to
the stop position.
THROTTLE ADJUSTMENT
1. Set the throttle lever (1) to maintain 680 ± 60 RPM with the engine
control lever (3) in the Lo position by adjusting the control rod (2).
2. With the low idle set, move the engine control lever (3) to the Hi
position and check that the engine RPM reaches 2260 ± 60. Lock
the throttle lever in position with the locknuts on the control rod.
3. With the engine control lever in the Hi position, adjust the deceler-
ator pedal cable clevis (4) and the pin (5) to reduce dimension A to
zero. Lock in position with the locknut.
20-16 2 D87E-2 D87P-2

12
D87E-2 D87P-2 20-17 2

FUEL
12 CONTROL LINKAGE
● Engine stopped
LEVER TRAVEL
Measure travel distance with scale C1 from low idle to high idle at the
center tip of the lever knob.
LEVER EFFORT
Side Effort At Low Idle
when moving the lever out and away from the ratchet gate.
Low Idle To Full Throttle
when moving the lever out and away from the ratchet gate at low idle
then back to the full throttle position.
Low Idle To Stop
when moving the lever out and away from the ratchet gate at low idle to
the stop position.
THROTTLE ADJUSTMENT
1. Set the throttle lever (1) to maintain 680 ± 60 RPM with the engine
control lever (3) in the Lo position by adjusting the control rod (2).
2. With the low idle set, move the engine control lever (3) to the Hi
position and check that the engine RPM reaches 2260 ± 60. Lock
the throttle lever in position with the locknuts on the control rod.
3. With the engine control lever in the Hi position, adjust the deceler-
ator pedal cable clevis (4) and the pin (5) to reduce dimension A to
zero. Lock in position with the locknut.
20-18 2 D87E-2 D87P-2

12
D87E-2 D87P-2 20-19 2

TESTING, ADJUSTING AND TROUBLESHOOTING DRIVE TRAIN LEVERS
DRIVE
12 TRAIN LEVERS
GEAR SHIFT LEVER
● Engine stopped
Lever Travel
Measure the travel distance with scale C1 from neutral to forward or re-
verse, and between each speed range.
Lever Effort
when moving the lever between each gear range.
STEERING LEVERS
● Engine stopped
Lever Travel
Measure the lever travel distance with scale C1 from the low to high
range and the high range to brake.
Lever Effort
when moving the lever between low and high range (lever forward) and
low range and brake (lever rearward).
20-20 2 D87E-2 D87P-2

TESTING, ADJUSTING AND TROUBLESHOOTING TASC VALVE
TASC
12 VALVE
● Engine stopped
GEAR TWIST TRAVEL
Measure the lever movement with scale C1 from 1st to 2nd and from
2nd to 3rd.
GEAR TWIST EFFORT
when moving the lever between 1st to 2nd and from 2nd to 3rd.
FRONT TO REAR LEVER TRAVEL
Measure the lever movement with scale C1 from centered forward and
centered rearward.
FRONT TO REAR LEVER EFFORT
when moving the lever between centered forward and centered rear-
ward.
LEFT TO RIGHT LEVER TRAVEL
Measure the lever movement with scale C1 from centered left and cen-
tered right.
LEFT TO RIGHT LEVER EFFORT
when moving the lever between centered left and centered right.
D87E-2 D87P-2 20-21 2

TESTING, ADJUSTING AND TROUBLESHOOTING BRAKE PEDAL
BRAKE
12 PEDAL
PEDAL TRAVEL
● Engine stopped with the safety lock lever in the locked (down)
position and the mounted equipment lowered to the ground
Using scale C1, measure the pedal initial step stroke distance and its
full stroke distance.
PEDAL OPERATING FORCE

● Engine stopped with the safety lock lever in the locked (down)
position and the mounted equipment lowered to the ground
Set push pull scale D1, at center of the pedal, and measure the pedal ini-
tial step stroke distance and its full stroke distance.
ADJUSTMENT
1. With brake pedal fully depressed and foot brake spool of steering
valve fully extracted, adjust the pedal arm to obtain dimension A,
(5.5 to 6.5 mm) from the fire wall (5) to the radius of the pedal.
Tighten the clevis locknut.
20-22 2 D87E-2 D87P-2

TESTING, ADJUSTING AND TROUBLESHOOTING DECELERATOR PEDAL
DECELERATOR
12 PEDAL
PEDAL TRAVEL
Using scale C1, measure the pedal travel.
PEDAL OPERATING FORCE

Set push pull scale D1, at center of the pedal, and measure the pedal ef-
fort.
D87E-2 D87P-2 20-23 2

TESTING, ADJUSTING AND TROUBLESHOOTING SAFETY LOCK LEVER
SAFETY
12 LOCK LEVER
● Engine stopped with the mounted equipment lowered to the

ground

Using push pull scale D1, measure the maximum effort required when
moving the lever from locked (start) position to unlocked (run) position.
● After ≈ 45° the lever effort will fall off due to the over center-
ing design of the linkage.

Using push pull scale D1, measure the maximum effort required when
moving the lever from locked (start) position to unlocked (run) position.
20-24 2 D87E-2 D87P-2

TESTING, ADJUSTING AND TROUBLESHOOTING BLADE EQUIPMENT LEVER
BLADE
12 EQUIPMENT LEVER

ground
RAISE, LOWER AND FLOAT TRAVEL

Using the scale C1, measure the travel distances from; hold to raise,
hold to lower and hold to float at the center top of the lever knob.
TILT TRAVEL
Using the scale C1, measure the travel distances from; hold to right tilt
and hold to left tilt at the center top of the lever knob.
RAISE, LOWER AND FLOAT EFFORT

Using the push pull scale D1 at the base of the knob, measure the maxi-
mum effort required when moving the lever from hold to raise, hold to
lower and hold to float.
TILT EFFORT
Using the push pull scale D1 at the base of the knob, measure the maxi-
mum effort required when moving the lever from hold to right tilt and
hold to left tilt.
D87E-2 D87P-2 20-25 2

TESTING, ADJUSTING AND TROUBLESHOOTING REAR EQUIPMENT LEVER
REAR
12 EQUIPMENT LEVER
ground.
RAISE AND LOWER TRAVEL

Using scale C1, measure travel distances from hold to raise and hold to
lower at the center of the lever knob.
TILT IN AND OUT TRAVEL

Using scale C1, measure travel distances from hold to tilt in and hold to
tilt out at the center of the lever knob.
RAISE AND LOWER EFFORT

Using push pull scale D1 at the base of the knob, measure the maximum
effort required when moving the lever from hold to raise and hold to
lower.
TILT IN AND OUT EFFORT

Using push pull scale D1 at the base of the knob, measure the maximum
effort required when moving the lever from hold to tilt in and hold to tilt
out.
20-26 2 D87E-2 D87P-2

TESTING, ADJUSTING AND TROUBLESHOOTING DRIVE TRAIN PRESSURES
DRIVE
12 TRAIN PRESSURES
● Engine at full throttle with the engine coolant, drive train oil
and hydraulic oil temperature in the operating range.
● Safety lock lever in the unlocked (up) position.
● Mounted equipment raised to 76 to 101 mm off the ground.
1. Open the left side door and connect tool E1, to the test ports.
2. With the brake pedal fully applied, run the engine at full throttle in
neutral, 1st, 2nd, 3rd forward and 1st reverse. Read and record the
pressures.
WARNING! At full throttle, the brake will NOT hold the ma-
chine in either 1st or 2nd gear.
TRANSMISSION CLUTCH
● Engine at full throttle with the engine coolant temperature,

drive train oil and hydraulic oil in operating range
● Safety lock lever in the unlocked (up) position with the mount-
ed equipment lowered to the ground
Remove the operator’s foot platform. Start the engine and set at full
throttle and fully apply the brake pedal. With the transmission lever in
3rd forward and then in 3rd reverse check for sprocket or drive shaft ro-
tation.
PILOT REGULATED PRESSURE

● Engine at low idle with the engine coolant, drive train oil and
hydraulic oil temperature in the operating range.
● Safety lock lever in the locked (down) position.
1. With the engine off, open the left side door. At the drive train filter
outlet elbow, remove the plug (1) and install a qd fitting (2) with
cap (3). Connect the test gauge and hose, G1 (4) to the quick dis-
connect fitting.
2. With the brake pedal fully applied, run the engine at low idle in
neutral. Read and record the pressure.
D87E-2 D87P-2 20-27 2

TESTING, ADJUSTING AND TROUBLESHOOTING WORK EQUIPMENT
WORK
12 EQUIPMENT
● Engine at full throttle with the engine coolant, drive train oil
and hydraulic oil temperature in the operating range.
● Safety lock lever in the locked (up) position. and the brake
pedal locked.
★ Bottoming a cylinder for a short period of time will not damage the
hydraulic system, but for an extended period will produce exces-
sive heat and result in an inaccurate gauge reading.
SYSTEM RELIEF VALVE TEST

BLADE LIFT SYSTEM (1)
1. Open the right side door and connect gauge and hose, F1, to the
quick disconnect fitting (1) on the block.
★ ONE SPOOL CONTROL VALVE; Because of the relief poppets

in the blade lift cylinders, the blade raise supply line must be
capped (Q) at the valve bank. Lower the blade to the ground. Dis-
connect the rod end supply hose and fitting from the control valve.
Install a plug with seal ring and secure at the control valve. Cap the
disconnected hose fitting.
2. ONE SPOOL CONTROL VALVE; Once operating temperature

is reached, run the engine at full throttle and move the blade control
lever rearward. Read and record the pressure on the test gauge at
which the relief valve unloads. Repeat this step with the engine
running at low idle.
THREE SPOOL CONTROL VALVE; Once operating tempera-
ture is reached, run the engine at full throttle and slowly move the
ripper lift control level into a power position until the cylinders are
in the extreme position. Read and record the pressure on the test
gauge at which the relief valve unloads. Repeat this step with the
engine running at low idle.
3. The pressure obtained should be as specified in the Standard Value

Table.
If both low and high idle pressure readings are alike but not as
specified, system is operating correctly but relief valve must be ad-
justed.
If relief pressure is within specifications at high idle but cannot be
reached at low idle, refer to EQUIPMENT PRESSURES.
★ ONE SPOOL CONTROL VALVE; Remove the plug from the

raise supply port and reconnect the supply hose and fitting to the
valve port.
20-28 2 D87E-2 D87P-2

BLADE TILT SYSTEM (2)

12
1. Open the right side door and connect gauge and hose, F1, to the
quick disconnect fitting (2) at the inlet connector of the tilt valve.
2. Once operating temperature is reached, run the engine at full throt-

tle and slowly move the blade tilt lever into a power position until
the cylinder is in an extreme position. Read and record the pressure
on the test gauge at which the relief valve unloads. Repeat this step
with the engine running at low idle.

Table.
If both the low and high idle readings are the same but not as speci-
fied, the system is operating correctly but the relief valve must be
adjusted.
If relief pressure is within specifications at high idle but cannot be
BLADE PILOT SYSTEM (3)
1. Open the right side door and connect gauge and hose, G1, to the
quick disconnect fitting (3) on top of the valve.
2. Once operating temperature is reached, run the engine at full throt-

tle and read and record the pressure on the test gauge at which the
relief valve unloads. Repeat this step with the engine running at
low idle.

Table.
If both the low and high idle pressure readings are alike but not as
specified, system is operating correctly but pilot supply valve must
be repaired.
If relief valve is within specifications at high idle but cannot be
D87E-2 D87P-2 20-29 2

ADJUSTING
12 RELIEF VALVE
★ The blade tilt system relief valve must be set prior to the blade lift
system relief valve.
BLADE TILT SYSTEM
Loosen the jam nut (1) and turn the adjusting body (2) clockwise to in-
crease the pressure or counterclockwise to decrease the pressure. After
the correct pressure on the gauge is obtained, lock down the jam nut.
BLADE LIFT SYSTEM
Loosen the jam nut (1) and turn the adjusting screw (2), using a screw-
driver, clockwise to increase the pressure or counterclockwise to de-
crease the pressure. After the correct pressure on the gauge is obtained,
lock down the jam nut.
PILOT SYSTEM
The pilot supply valve incorporates an internal relief system adjusted by

0.38 mm shims. Each shim that is removed or installed will change the
pilot system pressure by 0.35 kg/cm².
20-30 2 D87E-2 D87P-2

CYLINDER
12 DRIFT TEST
The problem of cylinder drift can be traced to two main causes, internal
or external leakage. External leakage is not detailed here, since it can be
visually located. Internal leakage is not always readily pinpointed to its
source and may require a series of tests to isolate the problem.
There are five places that might be a source of leakage; one of the hy-
draulic cylinders might be leaking past the piston packing or piston pop-
pet(s), the control valve could leak at the spool and/or the quick drop
valve spool could be stuck, the shuttle valve(s) or the pilot supply valve
could leak
Following is a series of tests developed to trace the source of internal

leakage. Oil must be at operating temperature.
1. Fully raise the blade, move the blade lift lever to the lower position
releasing it to hold before the blade drops to the ground. Check for
cylinder drift. The piston rod should not travel out of the cylinder at
more than 16 mm per minute.
● The 16 mm per minute figure represents the accumulative allow-

able loss of the control valve and cylinders combined.
2. If the cylinder drift is less than the 16 mm per minute proceed to

CYLINDER CYCLE TIME.
3. If the machine does not pass the cylinder drift test above, follow the
pressure diagnostic chart.
4. Disconnect and the plug pilot line between the shuttle valve and the
cylinder raise port. If the cylinder drift does not exceed 13 mm per
minute, the shuttle valve or pilot supply valve are at fault. If the
cylinder drift exceed 13 mm proceed to Step 4.
5. Reconnect the pilot line in Step 2. Disconnect and plug the pilot
line between the shuttle valve and the pilot supply valve. If the cyl-
inder drift does not exceed 13 mm, the pilot supply valve should be
replaced. The shuttle valve must be replaced if the cylinder drift ex-
ceeds 13 mm.
6. With the shuttle pilot to the pilot supply line still plugged, install
two shutoff valves at each cylinder raise port. Raise to the maxi-
mum lift position and place the valve in the hold position. Close the
shut off valves and check for drift. If the cylinder drift does not ex-
ceed 6 mm per minute, the control valve or quick drop valve are at
fault. The cylinders must be replaced if the cylinder drift exceed 6
mm per minute.
7. Remove the shut off valves and install a shut off valve in the raise
line between the control valve and the quick drop valve and check
for drift. If the cylinder drift does not exceed 11 mm per minute, the
control valve is at fault and must be replaced. The quick drop valve
must be replaced if the cylinder drift exceed 11 mm per minute.
8. After all the repairs are made, purge the hydraulic system of air, re-
connect the shuttle valve pilot line and repeat the drift test.
D87E-2 D87P-2 20-31 2

CYLINDER
12 TIME CYCLE
BLADE LIFT
★ Before performing the cylinder time cycle test, perform the cylin-
der drift test to insure that the control valve, cylinders and valves
are performing satisfactory.
If there is no excessive drift when the blade lift control is in the HOLD
position, but slow load speed, slow response or low power is present in
the raise position, the problem could be either the hydraulic pump or the
pressure relief valve. Loss of flow can be caused by the pressure relief
valve not sealing, allowing oil to flow into the reservoir passage. To
check the pump, the following time cycles should be observed when
raising the blade.
1. Position the machine so that the blade will not touch the
ground in its fully lowered position. Run the engine at full
throttle.
2. Starting with the blade in its fully lowered position, put the
control lever in the raise position and record the time it takes
the blade to reach the full raised position. Repeat this proce-
dure several times and average the time readings.
3. The lift cycle should take not more than 3.4 seconds. If the av-
erage cycle time is more than 4.5 seconds, the pump should be
repaired or replaced as necessary.
★ This check should made only in the blade raise cycle.
BLADE TILT
Before performing the cylinder time cycle, perform the PISTON PACK-
ING TEST to insure that the cylinder is satisfactory. If the cylinder is
satisfactory, but the tilt circuit is weak or slow, the problem could be ei-
ther hydraulic pump or the tilt relief valve. Loss of flow can be caused
by the tilt relief valve not sealing, allowing the oil to flow into the reser-
voir passage. To check pump following time cycles should be observed
when tilting blade to left and to right.
1. Lift the blade off the ground and run the engine at full throttle.
2. Starting with the blade in its extreme left position, put the con-
trol lever into the right tilt and read and record the time it takes
the blade to reach its extreme position. The tilt cycle should
take not more then 3 seconds.
3. Starting with the blade in its extreme right position, put the
control lever in the left tilt position and read and record the
time it takes the blade to reach its extreme left position. The tilt
cycle should take not more than 4.6 seconds. Repeat left to
right and right to left several times and take an average of read-
ings.
4. If average cycle times are more than above mentioned, the

pump should be repaired or replaced as necessary.
20-32 2 D87E-2 D87P-2

PISTON
12 PACKING TEST
BLADE TILT AND RIPPER CYLINDERS
1. Position the machine so that the cylinder(s) to be tested can be

completely extended. Start the engine, completely extend the cylin-
der(s) and place the control lever in hold. Stop the engine. Remove
the rod end hose.
WARNING! During next step, pressurized oil maybe expelled

from cylinder.
2. Hydraulically extend the cylinder(s) again and check the rod end
port of the cylinder(s) for oil flow. If oil flows, remove and repair
the cylinder.
CYLINDER RATE OF TRAVEL

1. With the machine in a test fixture, the engine at full throttle, the cyl-
inder rod shall travel from the lowered position to the maximum
raise position at a rate not less the 240 mm per second.
2. If the machine does not pass the cylinder rate of travel test, but
passed the cylinder drift test, the pump is at fault and must be re-
placed.
DEAD ENGINE LOWER TEST

1. With the machine in a test fixture or the blade attached, retract the
lift cylinders to the full raise position. Turn off the engine and move
the lever to the lower position.
2. If the blade does not lower, reject the pilot supply valve for sticki-
ness.
D87E-2 D87P-2 20-33 2

TESTING, ADJUSTING AND TROUBLESHOOTING SERVICE DIAGNOSIS
SERVICE
12 DIAGNOSIS
ENGINE COOLING SYSTEM
COMPLAINT
PROBABLE CAUSE REMARKS
ENGINE OVERHEATING DUE TO RESTRICTED AIR FLOW
1. Clogged radiator. Flush with steam for external and internal clogs.
2. Fan belt slipping. Check tension; replace belt if greasy or worn. Refer to the Op-
eration & Maintenance Manual.
3. Bent or damaged fan blades. Replace fan.
4. Damaged fan shrouds or no fan shrouds. Repair or install and adjust new fan shrouds.
5. Engine overloaded. Review operating instructions per the Operation & Mainte-
nance Manual.
ENGINE OVERHEATING DUE TO POOR CIRCULATION
1. Not enough coolant. Add coolant to radiator and check cooling system for leaks.
Refer to the Operation & Maintenance Manual.
2. Radiator cap not securely tightened to seal pressure sys- Remove radiator cap and inspect. Replace cap if gasket is
tem. worn. Tighten radiator cap to maintain pressure in system.
3. Pressure relief valve on radiator cap faulty. Replace cap. Do not repair or replace any regulating valve
parts.
4. Thermostat inoperative. Check thermostat for operation. Replace if faulty
5. Radiator obstructed preventing free air passage. Remove obstruction. If exterior requires cleaning, apply air or
water pressure to radiator from engine side.
6. Coolant temperature gauge or sending unit faulty. Test and/or replace parts as necessary.
7. Worn water pump. Replace pump.
8. Collapsed lines or loose connections on suction side. Inspect lines for internal collapse. Replace where necessary.
9. Scale deposits in crankcase or heads. Reverse flush cooling system to remove scale. Check soluble
oil content.
10. Incorrect range thermostat. Remove and replace with correct thermostat.
11. Drive system overheating. Refer to Transmission.
INTERNAL LEAKAGE
1. Warped cylinder head. Replace cylinder head and gasket. Torque head bolts as speci-
fied in the Engine Shop Manual.
2. Incorrect range or inoperative thermostat. Remove and replace with correct thermostat.
ENGINE RUNS COLD
1. Extremely cold weather. Cover radiator.

2. Incorrect range or inoperative thermostat. Remove and replace with correct thermostat.
3. Temperature gauge or sending unit faulty. Test and/or replace as necessary.
20-34 2 D87E-2 D87P-2

12
COMPLAINT
EXTERNAL LEAKAGE
1. Defective hoses or connections. Replace defected hoses. Check clamps for fatigue and replace
if necessary.
2. Radiator leaks. Remove the radiator. Repair or replace as necessary.
3. Radiator cores seams split or broken. Remove radiator. Tests for leaks and solder. Replace if neces-
sary.
4. Damaged gaskets. Checks for leaks around coolant pump, outlet header or elbow
and cylinder head. Replace defective gaskets.
5. Worn coolant pump. Remove pump and inspect sealing parts, Replace if necessary.
6. Cracked or warped cylinder head. Replace cylinder head and gasket. Torque head bolts as speci-
fied in the Engine Shop Manual.
7. Cracked crankcase. Replace crankcase, refer to Engine Shop Manual.
DRIVE TRAIN COOLANT SYSTEM
COMPLAINT
DRIVE TRAIN OIL OVER HEATING
1. Operating too long in low efficiency ranges. Review operating instructions in the Operation and Mainte-
nance Manual.
2. Clogged oil cooler. Clean oil cooler.
3. Temperature gauge or sensors faulty. Replace sensors or temperature gauge.
4. Torque converter problem. See Torque Converter following.
5. Transmission system problem. See Transmission following.
6. Steering problem. See Steering following.
D87E-2 D87P-2 20-35 2

DRIVE
12 TRAIN
COMPLAINT
CLUTCH PRESSURE LAMP GLOWS RED

(Shift Lever in Neutral, Engine Running, Oil Warm)
1. Low main pressure. Refer to LOW MAIN PRESSURE, following.

2. Pressure sensor malfunction. Check and replace sensor.
3. Pilot valve manifold malfunction. Check conditions of valves in manifold.
CLUTCH PRESSURE LAMP GLOWS RED
(Shift Lever in Gear, Engine Running, Oil Warm)
1. Low main pressure. Refer to DRIVE TRAIN PRESSURES, following.

2. Low pressure at gear and/or range. Refer to DRIVE TRAIN PRESSURES, following.
HIGH TORQUE CONVERTER OIL TEMPERATURE
(Gauge on Dash)
1. Operating too long in low efficiency ranges. Review operating instructions in the Operation and Mainte-
nance Manual.
2. Clogged oil cooler. Clean oil cooler.
3. Transmission problem. Check transmission temperature and clutch oil pressure. Refer
to DRIVE TRAIN PRESSURES, following.
4. Clogged transmission suction screen. Remove and clean.
5. Clogged and/or restricted torque converter oil line. Clean and check for correct routing.
6. Steering drive brake clutch dragging. Refer to DRIVE TRAIN CLUTCHES, following.
7. Temperature gauge or sending unit malfunction. Replace sending unit or temperature gauge.
8. Torque converter oil pressure abnormal. Refer to DRIVE TRAIN PRESSURES, following.
9. Torque converter oil leakage excessive. Refer to TORQUE CONVERTER, following.
LOSS OF POWER UNDER LOAD
1. Low oil level. Check level in rear main frame.

2. Low basic pressure. Refer to TORQUE CONVERTER, following.
3. Engine not up to rated performance. Refer to Engine Shop Manual.
4. Transmission oil level too high. Check operation of scavenge circuit.
5. Excessive converter oil leakage. Check ground sleeve and turbine shaft sealing ring wear. Re-
place.
SLOW OR ERRATIC TRANSMISSION CLUTCH ENGAGEMENT
1. Low transmission oil pressures. Refer to DRIVE TRAIN PRESSURES, following.

2. Rate of rise valve malfunction. Check valve and orifice screen. Install new gasket.
TRANSMISSION SHAFT LEVER JUMPS OUT OF GEAR
1. Restricted oil drain line from pilot valve manifold. Correct and check for proper routing.
2. Excessive internal leakage in pilot valve. Replace pilot valve.
20-36 2 D87E-2 D87P-2

DRIVE
12 TRAIN PRESSURES
PROBLEM PROBABLE CAUSE
1. Low main oil pressure A. Low oil level in rear frame. Refer to Operation and Main-
tenance Manual.
B. Clogged suction oil filter. Refer to Operation and Mainte-
nance Manual.
C. Leaking pump inlet lines.
D. Fatigued main spool springs in regulator valve. Broken
main spring pin.
E. Incorrect number of shims at main spool in pressure regu-
lator valve. Each shim changes the pressure by approxi-
mately 0.34 kg/cm². DO NOT use more than a total three
shims.
F. Relief check ball in pressure regulator valve malfunction.
G. Defective rear section of pump.
2. High main oil pressure A. Incorrect number of shims at main spool in pressure regu-
shims.
B. Main regulator spool stuck.
3. Low converter oil pressure A. Low main oil pressure. Refer to problem 1.
B. Clogged suction oil filter. Refer to Operation and Mainte-
nance Manual.
C. Leaking pump inlet lines.
D. Stuck converter spool in pressure regulator valve.
E. Fatigued converter spool spring in pressure regulator
valve.
F. Incorrect number of shims at main spool in pressure regu-
shims.
G. Internal leak in converter. Check ground sleeve and tur-
bine shaft seal rings
H. Defective rear section of pump. Leaking mounting o-ring
for pressure regulator valve.
4. High converter oil pressure. A. Restricted or blocked oil passage or line.
B. Restricted oil cooler.
C. Stuck converter spool in pressure regulator valve.
D. Incorrect number of shims at main spool in pressure regu-
mately 0.34 kg/cm². DO NOT use more than a total two
shims.
D87E-2 D87P-2 20-37 2

12
5. Low transmission lubrication oil pressure. A. Low converter oil pressure. Refer to problem 3.
B. Fatigued lubrication spool spring in pressure regulator
valve.
C. Incorrect number of shims at main spool in pressure regu-
shims.
D. Leaking clutch manifold seal rings on input shaft.
E. Leaking clutch shaft seal rings on output shaft.
6. High transmission lubrication oil pressure. A. Restricted or blocked oil passage.
B. Stuck lubrication spool in pressure regulator valve.
C. Incorrect number of shims at main spool in pressure regu-
shims.
7. Low or zero, each (FR) directional and (PC) range clutch A. Low main oil pressure. Refer to problem 1.
oil pressure.
B. No signal oil pressure from transmission pilot control
valve. Tee in a 30 kg/cm² test pressure gauge at the F and/
or R port on the range selector valve and check for oil
pressure.
C. Binding switch spool in range selector valve.
D. Rate of rise valve damaged.
E. Leaking manifold seal rings on input shaft.
F. Leaking piston seal rings on input shaft.
G. Screen filter under rate of rise valve clogged.
8. Low or zero pressure at both forward and reverse clutch. A. Leaking input shaft manifold seal (between R and F).
9. Low or zero pressure at both 2nd and 1st or lst and 3rd A. Leaking shaft manifold seal (between 2 and 1 or 1 and 3).
10.Low or zero pressure at F, R, 1st, 2nd or 3rd. A. No signal pressure from pilot control valve.
B. Range selector valve spool or spring damaged.
C. Leaking one of manifold seal (F, R, 2, 3).
D. Leaking one of clutch pack seals.
TORQUE CONVERTER STALL SPEED
1. Stall speed too high. A. Engine injection pump defective or improperly adjusted.
2. Stall speed too low. A. Too low engine power. See Engine Shop Manual.
20-38 2 D87E-2 D87P-2

TRANSMISSION
12 CLUTCH RESULTS
1. Sprocket stationary but drive shaft turns in all transmis-

sion ranges. Slippage in steering drive.
2. Sprocket stationary but drive shaft turns in 2nd F only. 2nd range pack slipping in transmission.
3. Sprocket stationary but drive shaft turns in 3rd F and R. 3rd range pack slipping in transmission.
4. Sprocket stationary but drive shaft turns in 3rd F but not
in 3rd R. F directional clutch pack slipping in transmission.
5. Sprocket stationary but drive shaft turns in 3rd R but not
in 3rd F. R directional clutch pack slipping in transmission.
6. Sprocket rotates with brakes applied. Slippage in steering drive.
TORQUE CONVERTER
COMPLAINT
LOSS OF FLUID FROM TORQUE CONVERTER
1. Leaking connections. Run engine at part throttle and inspect lines for leaks. Tighten
or replace parts as necessary.
2. Leaking converter. Check all hardware and gasket joints while system is under
pressure. Replace parts as necessary. Check sleeve and shaft
seal ring. Replace as necessary.
TORQUE CONVERTER OVERHEATING
1. Operating too long in low efficiency ranges. Review operating instructions in the Operation & Mainte-
nance Manual.
Check for broken lines or loose connections on pressure side
2. Low basic pressure. of system. Check for excessive fluid leaking.
4. Excessive converter oil leakage into flywheel housing. Check ground sleeve and turbine shaft sealing ring wear. Re-
place as necessary.
LOSS OF POWER

2. Low basic pressure. Refer to DRIVE TRAIN PRESSURES, previously.
3. Engine not up to rated performance. Refer to Engine Shop Manual.
4. Excessive converter oil leakage. Check ground sleeve and turbine shaft sealing ring wear. Re-
place.
GRINDING OR SCRAPING NOISE INSIDE CONVERTER HOUSING
1. Bearing failure allowing turbine or impeller blades to

Replace bearings, turbine or impeller as necessary.
strike fixed stator.
D87E-2 D87P-2 20-39 2

FINAL
12 DRIVE
COMPLAINT
FINAL DRIVE OVERHEATING
1. Improper or insufficient lubricant. Use proper grade and amount of lubricant. Refer to the Oper-
ation & Maintenance Manual.
2. Bearing seizure or damaged bearings. Remove final drive and inspect.
NOISE
1. Improper, dirty or insufficient lubricant. Use proper grade and amount of lubricant. Refer to the Oper-
2. Bearings scored or damaged. Replace bearings.
3. Worn or damaged gears. Inspect all gears and replace as necessary.
LUBRICANT LEAKING
1. Leakage at drain or level plugs. Tighten plugs as necessary.

2. Leakage between the final drive housing and rear main
frame. Clean sealing surfaces and apply new Loctite.
3. Leakage between the sprocket carrier and final drive
Replace carrier oil seal.
housing.
FINAL DRIVE LUBRICANT LEVEL TO HIGH
1. Oil seal damaged between rear frame and final drive. Change oil seal.
2. Oil seal out put shaft surface damaged. Change the shaft and oil seal.
EXCESSIVE WEAR ON SPROCKETS
1. Tracks run too loosely. Adjust tracks.

2. Tracks worn excessively. Install new tracks.
3. Track frame out of alignment or damaged. Repair or install new track frame.
20-40 2 D87E-2 D87P-2

EQUIPMENT
12 HYDRAULIC SYSTEM
COMPLAINT
NOISY OPERATION, OIL FOAMING
1. Low oil level. Check level at sight gauge and fill as necessary. Check for ex-
ternal leaks and tighten or replace parts as necessary.
2. Oil viscosity too heavy. Use oil per the Operation & Maintenance Manual.
3. Dirty oil strainer in reservoir. Clean.
4. Dirty reservoir pressure/vacuum relief valve. Clean per the Operation & Maintenance Manual.
5. Air leakage into suction lines. Apply shaving cream to all suction connections and tighten
where cream disappears.
BLADE LIFT CIRCUIT WEAK AND/OR SLOW
(Cylinder Droop)
1. Faulty blade circuit. Refer to CYLINDER DRIFT TEST.

BLADE TILT CIRCUIT WEAK AND/OR SLOW
1. Internal leak in tilt control valve relief valve. Refer to SYSTEM RELIEF VALVE TEST.
2. Internal leak in the tilt cylinder. Refer to PISTON PACKING TEST.
3. Rear pump section worn out. Repair or replace the pump.
BLADE LIFT RIPPER CIRCUITS WEAK AND/OR SLOW
1. Internal leak in main control valve relief valve. Refer to SYSTEM RELIEF VALVE TEST.
2. Front pump section worn out. Repair or replace the pump.
ALL CIRCUITS WEAK AND/OR SLOW
1. Insufficient oil supply. Refer to Noisy Operation - Oil Foaming.

2. Low main relief valve pressure. Refer to SYSTEM RELIEF VALVE TEST.
3. Pump worn out. Refer to CYLINDER TIME CYCLE.
ONE BLADE LIFT OR TILT OR RIPPER CIRCUIT SLOW AND/OR NO MOVEMENT
1. Pilot control valve spool out of order. Repair or replace pilot control valve.
2. Main control valve spool section out of order. Repair or replace the main control valve.
RIPPER PITCH OR LIFT CYLINDERS DROP
1. System problem. Refer to PISTON PACKING TEST.

MOMENTARY DROP WHEN ACTUATED FROM HOLD
1. Scored or worn load check and/or seat. Replace.

2. Load check held off its seat. Clean system. Check for foreign matter.
3. Broken or spent load check spring. Replace.
D87E-2 D87P-2 20-41 2

12
COMPLAINT
OIL OVER HEATING
1. Excessive feathering of controls. Review instructions in the Operation & Maintenance Man-
ual.
2. Using very light oil in a hot climate. Use oil per the Operation & Maintenance Manual.
3. Dirty return filter in reservoir. Replace.
4. Oil level too low. Fill per the Operation & Maintenance Manual.
5. Improper main relief valve pressure. Refer to SYSTEM RELIEF VALVE TEST.
SHORT LIFE OF PUMP
1. Aeration or cavitation. Refer to Noisy Operation, Oil Foaming.

2. Main relief valve pressure too high. Refer to SYSTEM RELIEF VALVE TEST.
3. Reservoir pressure vacuum valve filter clogged. Clean or replace filter.
EQUIPMENT SYSTEM RESULTS
1. Low relief pressure at low idle when using both ripper A. Ripper cylinder leaking. Refer to PISTON PACKING
lift and pitch control lever. TEST.
B. Relief valve not seating. Repair or replace relief valve.
C. Worn pump. Refer to CYLINDER TIME CYCLE.
2. Low relief pressure at low idle when using blade tilt con- A. Blade tilt cylinder leaking. Refer to PISTON PACKING
trol lever. TEST.
C. Worn pump. Refer to CYLINDER TIME CYCLE TEST.
3. Low relief pressure at low idle when using blade lift con- A. Blade tilt cylinder leaking. Refer to PISTON PACKING
trol lever (one spool valve). TEST.
C. Worn pump. Refer to CYLINDER TIME CYCLE.
4. Low relief pressure at low idle when using ripper lift, A. Ripper lift cylinder leaking. Refer to PISTON PACKING
correct pressure when using the ripper pitch. TEST.
5. Low relief pressure at low idle when using ripper pitch, A. Ripper tilt cylinder leaking. Refer to PISTON PACKING
correct pressure when using ripper lift. TEST.
20-42 2 D87E-2 D87P-2

UNDERCARRIAGE
12
COMPLAINT
TRACK CHAIN COMES OFF DURING OPERATION
1. Track chain loose. Adjust tension per the Operation & Maintenance Manual.
2. Front idler worn. Inspect front idler for wear. Repair or replace as necessary.
3. Front idler misaligned. Inspect idler for excessive wear or distortion. Repair or re-
place as necessary.
4. Rocks or debris in track assembly. Clean out all rocks and packed dirt from the undercarriage.
5. Worn sprocket teeth. Replace sprocket.
MACHINE CREEPS TO ONE SIDE
1. One track loose. Adjust tension per the Operation & Maintenance Manual.
2. Track spring weak or broken. Remove/check tension or replace.
TRACK CHAIN LOOSE
1. Track not properly adjusted. Adjust tension per the Operation & Maintenance Manual.
2. Sprocket worn. Inspect the sprocket for worn teeth or damage. If wear is ex-
cessive, replace the sprocket.
3. Track link or bushings worn. Inspect the track links and bushing for wear or damage. Re-
place any damaged parts if necessary.
EXCESSIVE OR UNEVEN WEAR OF TRACK AND COMPONENTS
1. Damaged sprocket. Replace the sprocket.

2. Front idler misaligned. Inspect idler for excessive wear and for distortion. Repair or
replace as necessary.
3. Track tension incorrect. Adjust tension per the Operation & Maintenance Manual.
4. Track frame misaligned. Check for bent track frame, front or rear crossbar. Replace
parts as necessary.
5. Track idler does not turn. Internal seizure. Repair or replace defective parts.
LUBRICANT LEAKAGE
1. Leakage at track roller, top idler and/or front idler. Remove faulty part. Inspect and repair or replace parts as nec-
essary.
FRONT IDLER DOES NOT ROTATE
1. Insufficient lubrication. Lubricate per the Operation & Maintenance Manual.

2. Dirt or mud packed tight against front idlers. Remove dirt or mud.
3. Internal seizure. Remove idler and inspect parts. Thoroughly clean and replace
parts as necessary.
D87E-2 D87P-2 20-43 2

12
COMPLAINT
TOP IDLERS DO NOT ROTATE

2. Dirt or mud packed tight against idler Remove dirt or mud.
3. Internal seizure. Remove idler and inspect parts. Thoroughly clean and replace
parts as necessary.
TRACK IDLERS DO NOT ROTATE

2. Dirt or mud packed tight against rollers. Remove dirt or mud.
3. Internal seizure. Remove rollers and inspect parts. Thoroughly clean and re-
place parts as necessary.
MACHINE LOSES POWER
1. Track chain too tight Adjust tension per the Operation & Maintenance Manual.
TRACK SHOES BOLTS BREAK
1. Bolts not properly tightened. Tighten bolts to proper torque.

2. Bolt heads snap off. Track shoes out of flat. Replace track shoe.
20-44 2 D87E-2 D87P-2

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL .......................................... 30-3 INPUT (DIRECTIONAL) CLUTCH SHAFT .................. 30-54
PRECAUTIONS, OPERATION ......................................... 30-7 DISASSEMBLY............................................................ 30-55
SPECIAL TOOL LIST .......................................................... 30-10 ASSEMBLY .................................................................. 30-57
CRANKCASE GUARD ........................................................ 30-19 COUNTERSHAFT............................................................ 30-61
REMOVAL........................................................................ 30-19 DISASSEMBLY............................................................ 30-61
INSTALLATION .............................................................. 30-19 ASSEMBLY .................................................................. 30-62
TRANSMISSION GUARD................................................... 30-20 OUTPUT (RANGE) SHAFT ............................................ 30-63
REMOVAL........................................................................ 30-20 DISASSEMBLY............................................................ 30-64
INSTALLATION .............................................................. 30-20 ASSEMBLY .................................................................. 30-69
ENGINE HOOD ....................................................................30-21 REVERSE IDLER SHAFT ............................................... 30-75
REMOVAL........................................................................ 30-21 SERVICE....................................................................... 30-75
INSTALLATION .............................................................. 30-21 MAIN REGULATOR VALVE......................................... 30-76
ROPS ..................................................................................... 30-22 DISASSEMBLY............................................................ 30-77
REMOVAL........................................................................ 30-22 ASSEMBLY .................................................................. 30-80
INSTALLATION .............................................................. 30-22 RANGE SELECTOR VALVE.......................................... 30-84
CAB ....................................................................................... 30-23 DISASSEMBLY............................................................ 30-84
INSTALLATION .............................................................. 30-23 RATE OF RISE VALVE................................................... 30-90
OPERATOR’S SEAT............................................................ 30-24 DISASSEMBLY............................................................ 30-91
INSTALLATION .............................................................. 30-24 PILOT CONTROL VALVE AND MANIFOLD.............. 30-97
OPERATOR’S COMPARTMENT .......................................30-25 3 LEVER DRIVE CONTROL ...................................... 30-97
REMOVAL........................................................................ 30-25 TASC VALVE................................................................. 30-103
INSTALLATION .............................................................. 30-25 1 LEVER DRIVE CONTROL .................................... 30-103
FUEL TANK ......................................................................... 30-26 NEUTRAL START VALVE .............................................. 30-122
REMOVAL........................................................................ 30-26 1 LEVER DRIVE CONTROL ........................................ 30-122
INSTALLATION .............................................................. 30-26 REMOVAL.................................................................. 30-122
RADIATOR...........................................................................30-27 INSTALLATION ........................................................ 30-122
REMOVAL........................................................................ 30-27 DISASSEMBLY.......................................................... 30-122
INSTALLATION .............................................................. 30-28 STEERING CONTROLLER............................................... 30-124
DISASSEMBLY................................................................ 30-29 1 LEVER DRIVE CONTROL ........................................ 30-124
ASSEMBLY ...................................................................... 30-30 REMOVAL.................................................................. 30-124
ENGINE................................................................................. 30-31 INSTALLATION ........................................................ 30-124
REMOVAL........................................................................ 30-31 SERVICE..................................................................... 30-124
INSTALLATION .............................................................. 30-31 REGULATOR VALVE....................................................... 30-125
TORQUE CONVERTER ...................................................... 30-32 1 LEVER DRIVE CONTROL ........................................ 30-125
REMOVAL........................................................................ 30-32 REMOVAL.................................................................. 30-125
INSTALLATION .............................................................. 30-32 INSTALLATION ........................................................ 30-125
DISASSEMBLY................................................................ 30-34 SERVICE..................................................................... 30-126
ASSEMBLY ...................................................................... 30-36 STEERING DRIVE............................................................. 30-127
CHARGE AND SCAVENGE PUMP ................................... 30-39 REMOVAL...................................................................... 30-127
REMOVAL........................................................................ 30-39 INSTALLATION ............................................................ 30-128
INSTALLATION .............................................................. 30-39 STEERING UNIT ........................................................... 30-129
DISASSEMBLY................................................................ 30-41 DISASSEMBLY.......................................................... 30-129
ASSEMBLY ...................................................................... 30-41 ASSEMBLY ................................................................ 30-145
SCAVENGE PUMP AND DRIVE .......................................30-43 STEERING VALVE ....................................................... 30-164
REMOVAL........................................................................ 30-43 3 LEVER DRIVE CONTROL .................................... 30-164
INSTALLATION .............................................................. 30-43 1 LEVER DRIVE CONTROL .................................... 30-188
DRIVE SHAFT...................................................................... 30-44 STEERING MANIFOLD................................................ 30-203
SERVICE...........................................................................30-44 FINAL DRIVE AND SPROCKET ..................................... 30-205
TRANSMISSION .................................................................. 30-45 SPROCKET..................................................................... 30-205
REMOVAL........................................................................ 30-45 REMOVAL.................................................................. 30-205
INSTALLATION .............................................................. 30-45 INSTALLATION ........................................................ 30-205
COMPLETE ASSEMBLY ................................................ 30-46 FINAL DRIVE ................................................................ 30-206
DISASSEMBLY............................................................ 30-47 REMOVAL.................................................................. 30-206
ASSEMBLY .................................................................. 30-50 INSTALLATION ........................................................ 30-206
D87E-2 D87P-2 30-1 2

DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
DISASSEMBLY.......................................................... 30-208 ASSEMBLY ................................................................ 30-287

ASSEMBLY ................................................................ 30-213 UNDERCARRIAGE ........................................................... 30-289
EQUIPMENT PUMP .......................................................... 30-218 WEAR LIMITS ............................................................... 30-290
REMOVAL...................................................................... 30-218 SPECIFICATIONS...................................................... 30-290
INSTALLATION ............................................................ 30-218 GENERAL................................................................... 30-291
EQUIPMENT VALVES...................................................... 30-219 TRACK SHOE GROUSER HEIGHT......................... 30-291
BLADE LIFT VALVE BANK........................................ 30-219 LINK HEIGHT............................................................ 30-291
REMOVAL..................................................................30-219 BUSHING OUTSIDE DIAMETER............................ 30-291
INSTALLATION ........................................................ 30-219 INTERNAL PIN AND BUSHING WEAR................. 30-292
DISASSEMBLY.......................................................... 30-220 FRONT IDLER FLANGE HEIGHT........................... 30-292
ASSEMBLY ................................................................ 30-220 TRACK ROLLER ROLLING DIAMETER ............... 30-292
BLADE LIFT AND RIPPER VALVE BANK................ 30-229 TOP IDLER ROLLING DIAMETER......................... 30-292
REMOVAL..................................................................30-229 FRONT IDLER ............................................................... 30-293
INSTALLATION ........................................................ 30-229 REMOVAL.................................................................. 30-293
DISASSEMBLY.............................................................. 30-230 INSTALLATION ........................................................ 30-293
ASSEMBLY ................................................................ 30-230 DISASSEMBLY.......................................................... 30-295
BLADE TILT VALVE BANK........................................ 30-240 ASSEMBLY ................................................................ 30-296
REMOVAL..................................................................30-240 CLEARANCE LIMITS ............................................... 30-298
INSTALLATION ........................................................ 30-240 TRACK ADJUSTER....................................................... 30-300
BLADE PILOT VALVE ................................................. 30-241 REMOVAL.................................................................. 30-300
REMOVAL..................................................................30-241 INSTALLATION ........................................................ 30-300
INSTALLATION ........................................................ 30-241 DISASSEMBLY.......................................................... 30-301
DISASSEMBLY.......................................................... 30-243 ASSEMBLY ................................................................ 30-301
ASSEMBLY ................................................................ 30-244 TRACK ROLLER ........................................................... 30-302
PLUNGER CAPSULE ................................................30-245 REMOVAL.................................................................. 30-302
METERING CAPSULE .............................................. 30-248 INSTALLATION ........................................................ 30-302
RIPPER PILOT VALVE ................................................. 30-249 DISASSEMBLY.......................................................... 30-304
REMOVAL..................................................................30-249 ASSEMBLY ................................................................ 30-305
INSTALLATION ........................................................ 30-249 ROLLER CLEARANCES........................................... 30-307
DISASSEMBLY.......................................................... 30-251 TOP IDLER ..................................................................... 30-308
ASSEMBLY ................................................................ 30-252 REMOVAL.................................................................. 30-308
PLUNGER CAPSULE ................................................30-253 INSTALLATION ........................................................ 30-308
METERING CAPSULE .............................................. 30-254 DISASSEMBLY.......................................................... 30-310
PILOT SUPPLY VALVE................................................30-255 ASSEMBLY ................................................................ 30-314
REMOVAL..................................................................30-255 TRACK FRAME ............................................................. 30-319
INSTALLATION ........................................................ 30-255 REMOVAL.................................................................. 30-319
DISASSEMBLY.......................................................... 30-257 INSTALLATION ........................................................ 30-321
ASSEMBLY ................................................................ 30-258 TRACK FAME GUIDE .................................................. 30-323
QUICK DROP VALVE................................................... 30-260 SERVICE..................................................................... 30-324
REMOVAL..................................................................30-260 EQUALIZER BAR.......................................................... 30-325
INSTALLATION ........................................................ 30-260 SERVICE..................................................................... 30-326
DISASSEMBLY.......................................................... 30-262 PIVOT SHAFT................................................................ 30-328
EQUIPMENT CYLINDERS............................................... 30-264 INSTALLATION ........................................................ 30-329
BLADE LIFT................................................................... 30-264 RECOIL SPRING............................................................ 30-330
REMOVAL..................................................................30-264 REMOVAL.................................................................. 30-330
INSTALLATION ........................................................ 30-264 INSTALLATION ........................................................ 30-331
DISASSEMBLY.......................................................... 30-266 TRACK FRAME ALIGNMENT .................................... 30-333
ASSEMBLY ................................................................ 30-267 METAL TYPE FACE SEALS ........................................ 30-335
DOZER TILT ..................................................................30-269 SEAL INSPECTION ................................................... 30-335
REMOVAL..................................................................30-269 SEAL INSTALLATION ................................................. 30-336
INSTALLATION ........................................................ 30-269 TRACK CHAIN .............................................................. 30-338
DISASSEMBLY.......................................................... 30-271 MAINTENANCE ........................................................ 30-339
ANGLE TILT ..................................................................30-274 INSTALLATION ........................................................ 30-340
REMOVAL..................................................................30-274 COMPLETE CHAIN REBUILD ................................ 30-340
INSTALLATION ........................................................ 30-274 SINGLE JOINT REBUILD......................................... 30-343
DISASSEMBLY.......................................................... 30-276
ASSEMBLY ................................................................ 30-277
RIPPER LIFT ..................................................................30-279
REMOVAL..................................................................30-279
INSTALLATION ........................................................ 30-279
DISASSEMBLY.......................................................... 30-281
ASSEMBLY ................................................................ 30-282
RIPPER PITCH ............................................................... 30-284
REMOVAL..................................................................30-284
INSTALLATION ........................................................ 30-284
DISASSEMBLY.......................................................... 30-286
D87E-2 D87P-2 30-2 2

DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD
12 OF USING MANUAL
1. When removing or installing unit assemblies
① When removing or installing a unit, the order of work and techniques used are given for the removal operation; the
order of work for the installation operation is not given.
② Any special techniques applying only to the installation procedures are marked , and the same mark is placed af-
ter the relevant step in the removal procedure to indicate which step in the installation procedure it applies to.
[Example]
● ● ● ● ASSEMBLY .................................................................. Component.
REMOVAL................................................................................. Operation to be performed.
............................................................................................. Precaution related to safety when carrying out the operation.
1.XXXX (1)................................................................................ Step in operation.
★................................................................................................. Technique or important point to remember when removing

XXX (1).
2. ▲ ▲ ▲ ▲ (2)...................................................................... Indicates that a technique is listed for use during installation.
3. ■ ■ ■ ■ assembly (3)
............................................................................................. See Lubricant and Coolant Table.
INSTALLATION........................................................................ Operation to be perform
● .................................................................................................. Carry out installation in the reverse order of removal.
............................................................................................. Technique used during installation.
★................................................................................................. Technique or important point to remember when installing.
● Adding water, oil ..................................................................... Step in operation.
★................................................................................................. Point to remember when adding water or oil.
............................................................................................. Quantity when filling with oil or water.
2. General precautions when carrying out installation or removal, disassembly or assembly of units are given togeth-
er as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when car-
rying out the operation.
3. Listing of special tools
① For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure,
see the SPECIAL TOOLS LIST given in this manual.
➁ Special tools marked ★ in the table cannot be supplied.
➂ Special tools with part number 79●T-●●●●-●●●● in the table are prohibited for supply.
➃ Special tools marked ● in the sketch column are tools introduced in this manual in sketches for special tools.
However, note that Komatsu cannot accept any responsibility for special tools manufactured according to the sketch.
D87E-2 D87P-2 30-3 2

12
4. General tightening torque table
★ In the case of metric nut and bolts for which there is no special instructions, tighten to the torque giv-
en in the table below.
ZINC PLATED HARDWARE - METRIC
Thread diameter (A) Width across flats (B) N•m lbf ft
6 10 13 ± 1 10 ± 1
8 13 31 ± 3 23 ± 2
10 17 66 ± 7 49 ± 5
12 19 112 ± 10 82 ± 7
14 22 177 ± 19 130 ± 14
16 24 279 ± 29 206 ± 21
18 27 383 ± 39 282 ± 29
20 30 549 ± 58 405 ± 43
22 32 745 ± 78 549 ± 57
24 36 927 ± 98 683 ± 72
27 41 1320 ± 140 973 ± 103
30 46 1720 ± 190 1268 ± 140
33 50 2210 ± 240 1629 ± 177
36 55 2750 ± 290 2027 ± 214
39 60 3280 ± 340 2417 ± 251
PHOSPHATE COATED HARDWARE - METRIC
6 10 10 ± 10% 7 ± 10%
8 13 23 ± 10% 17 ± 10%
10 16 46 ± 10% 34 ± 10%
12 18 80 ± 10% 60 ± 10%
14 21 125 ± 10% 90 ± 10%
16 24 200 ± 10% 150 ± 10%
18 27 275 ± 10% 200 ± 10%
20 30 385 ± 10% 290 ± 10%
22 32 530 ± 10% 390 ± 10%
24 36 670 ± 10% 500 ± 10%
27 41 980 ± 10% 730 ± 10%
30 46 1330 ± 10% 990 ± 10%
33 50 1790 ± 10% 1330 ± 10%
36 55 2325 ± 10% 1730 ± 10%
39 60 3010 ± 10% 2240 ± 10%
PHOSPHATE COATED HARDWARE - INCH

1/4 NC 7/16 10 ± 10% 8 ± 10%
5/16 NC 1/2 21 ± 10% 16 ± 10%
3/8 NC 9/16 38 ± 10% 28 ± 10%
7/16 NC 5/8 60 ± 10% 45 ± 10%
1/2 NC 3/4 92 ± 10% 70 ± 10%
9/16 NC 13/16 130 ± 10% 100 ± 10%
5/8 NC 15/16 180 ± 10% 140 ± 10%
3/4 NC 1-1/8 325 ± 10% 240 ± 10%
7/8 NC 1-5/16 520 ± 10% 390 ± 10%
1 NC 1-1/2 780 ± 10% 580 ± 10%
1-1/8 NC 1-11/16 1110 ± 10% 820 ± 10%
1-1/4 NC 1-7/8 1565 ± 10% 1160 ± 10%
1-3/8 NC 2-1/6 2050 ± 10% 1520 ± 10%
1-1/2 NC 2-1/4 2720 ± 10% 2020 ± 10%
30-4 2 D87E-2 D87P-2

12
NON PHOSPHATE COATED HARDWARE - INCH
Grade 5 Grade 8
Thread diameter (A) Width across flats (B)
N•m lbf ft N•m lbf ft
1/4 NC 7/16 8 6 12 9
1/4 NF 7/16 9 7 15 11
5/16 NC 1/2 18 13 24 18
5/16 NF 1/2 20 15 28 21
3/8 NC 9/16 33 24 46 34
3/8 NF 9/16 37 27 52 38
7/16 NC 5/8 52 38 73 54
7/16 NF 5/8 57 42 81 60
1/2 NC 3/4 79 58 111 82
1/2 NF 3/4 88 65 122 90
9/16 NC 13/16 114 84 163 120
9/16 NF 13/16 126 93 179 132
5/8 NC 15/16 156 115 224 165
5/8 NF 15/16 175 130 251 185
3/4 NC 1-1/8 278 205 393 290
3/4 NF 1-1/8 312 240 434 320
7/8 NC 1-5/16 414 305 617 455
7/8 NF 1-5/16 454 334 698 515
1 NC 1-1/2 617 455 942 695
1 NF 1-1/2 691 510 1064 785
1-1/8 NC 1-11/16 827 610 1342 990
1-1/8 NF 1-11/16 929 685 1505 1110
1-1/4 NC 1-7/8 1166 860 1898 1400
1-1/4 NF 1-7/8 1295 955 2102 1550
1-3/8 NC 2-1/6 1532 1130 2481 1830
1-3/8 NF 2-1/6 1749 1290 2827 2085
1-1/2 NC 2-1/4 2034 1400 3295 2430
1-1/2 NF 2-1/4 2291 1690 3701 2730
5. Table of tightening torques for flared nuts
★ In the case of metric flared nuts for which there is no special instructions, tighten to the torque giv-
en in the table below.
METRIC THREAD
Thread diameter Width across flats N•m lbf ft
14 19 25 ± 5 18 ± 4
18 24 49 ± 20 36 ± 15
22 27 78 ± 20 57 ± 15
24 32 137 ± 30 101 ± 22
30 36 176 ± 30 130 ± 22
33 41 196 ± 49 144 ± 36
36 46 245 ± 49 181 ± 36
42 55 294 ± 49 217 ± 36
D87E-2 D87P-2 30-5 2

★ The torque figures are recommended for plain, cadmium or zinc plated fittings, dry or wet installations. Swivel nuts either
12
swaged or brazed. Figures are for tube nuts used with 37° flared fittings and JIC 37° seat seal ring boss plugs and swivel
nuts.
INCH THREAD
Tube Nuts Seal Ring Boss Plugs And Swivel Nuts
For 37° Flared Fitting JIC 37° Seat

Size Tubing OD Thread N•m lbf ft
4 1/4 7/16-20 12 to 16 9 to 12
5 5/16 1/2-20 16 to 20 12 to 15
6 3/8 9/16-18 33 to 21 21 to 24
8 1/2 3/4-16 47 to 54 35 to 40
10 5/8 7/8-14 72 to 79 53 to 58
12 3/4 1-1/16-12 104 to 111 77 to 82

14 7/8 1-3/16-12 122 to 136 90 to 100
16 1 1-5/16-12 149 to 163 110 to 120
20 1-1/4 1-5/8-12 190 to 204 140 to 150

24 1-1/2 2-1/2-12 217 to 237 162 to 175
32 2 2-1/2-12 305 to 325 225 to 240
6. Table of tightening torques for split flange bolts
★ In the case of split flange bolts for which there is no special instructions, tighten to the torque given in the table below.
METRIC THREAD
Thread diameter Width across flats N•m lbf ft
10 14 66 ± 7 49 ± 5
12 17 112 ± 10 83 ± 7
16 22 279 ± 29 206 ± 21
INCH THREAD
Flange size Bolt size N•m lbf ft
1/2 5/16 NC 20 to 24 15 to 18
3/4 3/8 NC 30 to 37 22 to 27
1 3/8 NC 37 to 47 27 to 35
1-1/4 7/16 NC 47 to 61 35 to 45
1-1/2 1/2 NC 62 to 79 45 to 58
2 1/2 NC 75 to 88 55 to 65
2-1/2 1/2 NC 107 to 123 79 to 91
3 5/8 NC 159 to 180 117 to 133
3-1/2 5/8 NC 187 to 203 138 to 150
30-6 2 D87E-2 D87P-2

7. Table of tightening torques for hose clamps Torque ± 0.6 N•m

Clamp
This chart provides the tightening torques for hose clamps Type and Hydraulic System All Others
used in all rubber applications (radiator, air cleaner, operat- Size
ing lever boots, hydraulic system, fuel systems etc.). N• m lbf in N• m lbf in
T Bolt --- --- 6.2 to 7.3 55 to 65
Worm drive under

1-3/4 in open
diameter
4.5 to 5.6 40 to 50 2.2 to 3.3 20 to 30
Worm drive over

1-3/4 in open
diameter
--- --- 4.5 to 5.6 40 to 50
Worm drive all

Ultra-Tite 4.5 to 5.6 40 to 50 10.7 to 11.8 95 to 105
PRECAUTIONS WHEN CARRYING OUT OPERATION

★ When carrying out removal or installation, disassembly or assembly of units, be sure to follow the general precautions
given below when carrying out the operation.
1. Precautions when carrying out removal work
● If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind
plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil.
● Confirm the match marks showing the installation position and make match marks in the necessary places before
removal to prevent any mistake when assembling.
● To prevent excessive force from being applied to the wiring, always hold the connectors when disconnecting the con-
nectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake
when installing.
● Check the number and thickness of the shims and keep in a safe place. When raising components, be sure to use lift-
ing equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws
uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dirt or dust
from entering after removal.
2. Precautions when handling metric piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1. Hoses and tubes using sleeve nuts
Nominal number Plug (nut end) Sleeve nut (elbow end) - Use two below as set
02 07376-50210 07221-20210 nut, 07222-00210 plug
03 07376-50315 07221-20315 nut, 07222-00312 plug
04 07376-50422 07221-20422 nut, 07222-00414 plug
05 07376-50522 07221-20522 nut, 07222-00515 plug
06 07376-50628 07221-20628 nut, 07222-00616 plug
10 07376-51034 07221-20034 nut, 07222-01018 plug
12 07376-51234 07221-21234 nut, 07222-01219 plug
D87E-2 D87P-2 30-7 2

12 2. Split flange type hoses and tubes

Nominal number Flange (hose end) Sleeve (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3. If the part is not under hydraulic pressure, the following corks can be used
Nominal number Part number Dimensions (mm)
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
30-8 2 D87E-2 D87P-2

12
3. Precautions when carrying out installation work
● Tighten all hardware to the specified KES torque.

● Install the hoses without twisting or interference.
● Replace all gaskets, seal rings, cotter pins and lock plates with new parts.
● Bend the cotter pins and lock plates securely.
● When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two to three
drops of adhesive.
● Clean all parts and correct any damage, dents, burrs or rust.
● Coat rotating parts and sliding parts with engine oil.
● When press fitting parts, coat the surface with anti-friction compound [LM-P].
● After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
● When connecting wiring connectors, clean the connector to remove all oil, dirt or water, then connect securely.
● When using eye bolts, check that there is no deformation or deterioration, screw them in fully and align the direction of
the hook.
● When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equip-
ment removed for repair, always bleed the air as follows:
A. Start the engine and run at low idle.
B. Operate the work equipment control lever to operate the hydraulic cylinder four to five times, stopping the cylinder
100 mm from the end of its stroke.
C. Next, operate the hydraulic cylinder three to four times to the end of its stroke.
D. After doing this, run the engine at normal speed.
E. When using the machine for the first time after repair or long storage, follow the same procedure.
4. Precautions when completing the operation
● If the coolant has been drained, tighten the drain valve and add water to the specified level. Run the engine to circulate the
water through the system. Then check the water level again.
● If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to
circulate the oil through the system. Then check the oil level again.
● If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the
parts. For details, see TESTING AND ADJUSTING.
● Add the specified amount of grease [molybdenum disulfide grease] to the work equipment parts.
D87E-2 D87P-2 30-9 2

DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL
12 TOOL LIST
★ Tools with part number N-A cannot be supplied [they are items to be made or bought locally].
★ Necessity
★ ■ Cannot be substituted for, should always be used.
★ ▲ Extremely useful if available, can be substituted with commercially available part.
★ N/R New/remodel
★ N Tools with new part numbers, newly developed for this model.
★ R Tools with upgraded part numbers, remodeled for items already available for other models.
★ Blank - Tools already available for other models, used without any modification.
★ Tools marked ✔ in the sketch column are tools introduced in special sketches.
Necessity
Sketch
Action
Nature of work Tool Part number Part name Remarks
N/R
Qty
Engine R/I See Engine Shop Manual
A1 637 985 C91 Track measuring tool ▲ 1 I/R Measuring undercarriage
B1 N-A Seal driver ■ 1 ✔ R/I Install torsion seal
C1 N-A Puller tool ■ 1 N ✔ R/I Pull pivot shaft lock pin
D1 N-A Adapter plate ■ 1 ✔ R/I Pull pivot shaft
D2 N-A Ram screw ■ 1 ✔ R/I Pull pivot shaft
D3 N-A Ram tube ■ 1 ✔ R/I Pull pivot shaft
D4 N-A Speed nut ■ 1 ✔ R/I Pull pivot shaft
E1 N-A Pivot shaft aligner ■ 1 ✔ R/I Align shaft to lock pin
Undercarriage
F1 N-A Ram pusher plate ■ 2 ✔ R/I Service recoil spring
F2 N-A Ram pusher tube ■ 1 ✔ R/I Service recoil spring
F3 N-A Spacer fixture ■ 1 ✔ R/I Service recoil spring
F4 N-A Spring bolt ■ 1 ✔ R/I Service recoil spring
791-600-2001 Spring compressor ▲ 1 R/I Service recoil spring
790-101-1102 Pump ▲ 1 R/I Service recoil spring
G1
790-101-1600 63 Mg cylinder ▲ 1 R/I Service recoil spring
791-635-3160 Extension ▲ 1 R/I Service recoil spring
H1 DR11-808 Seal tester/lubricator ▲ 1 D/A Leakage and lube
Track chain J1 DR11-802-2 Track portable press ▲ 1 D/A 91 Mg
K1 N-A Track table press ▲ 1 D/A Purchase locally
30-10 2 D87E-2 D87P-2

B1 - Pivot Shaft Seal Tool

12
Material - SAE 4140 Steel
1. 51 mm 4. 123.9 + 0.05 mm 7. Maximum Radius 1 mm 10. 122.3 + 0.05 mm

2. 31.75 ± 0.1 mm 5. 127.25 ± 0.1 mm 8. 0.75 mm x 45° 11. 30° Chamfer
3. 26.05 mm 6. 0.25 mm x 45° 9. 151.15 ± 01. mm
C1 - Pivot Shaft Lock Pin Puller Tool
1. 89 mm 3. 25 mm 5. Flat Washer - 25 557 R1

2. 19 mm 4. Bolt - 3/4NCx6 - 25 698 R1
D87E-2 D87P-2 30-11 2

D1 - Pivot Shaft Puller Tool - Adapter Plate

1289
1. 114 x 51 mm Round Stock 3. 70 mm Bolt Center 4. 19 mm Holes on Center, 120° Apart

2. 1-5/8-5-1/2 Thread
D2 - Pivot Shaft Puller Tool - Ram Screw
Material - Cold Rolled Steel
1. 41 x 695 mm Round Stock 4. 51 mm 7. 51 mm

2. 1-5/8-5-1/2 Thread 5. 126 mm 8. 25 mm Square
3. 695 mm 6. 467 mm
30-12 2 D87E-2 D87P-2

D3 - Pivot Shaft Puller Tool - Ram Tube

12
1. 83 x 19 mm Round Stock 3. 159 x 140 x 673 mm Tube 4. Weld

2. 51 mm Hole on Center
D4 - Pivot Shaft Puller Tool - Speed Nut
1. 76 x 50 mm Round Stock 3. 1-5/8-5-1/2 Thread 4. Weld

2. 13 x 101 mm Round Stock
D87E-2 D87P-2 30-13 2

E1 (1 of 2) - Pivot Shaft Installer Tool - Shaft to Lock Pin Aligner

12
1. 127 x 127 x 13 mm Side Plate 3. 432 x 76 x 13 mm Top Plate 5. 19 mm Holes - 120° Apart
2. 16 x 508 mm Round Stock 4. 70 mm Bolt Center
30-14 2 D87E-2 D87P-2

E1 (2 of 2) - Pivot Shaft Installer Tool - Shaft to Lock Pin Aligner

12
1. Pivot Shaft Aligning Tool 2. Center all Parts 3. Weld
D87E-2 D87P-2 30-15 2

F1 - Recoil Spring Tool - Ram Pusher Plate (Qty. 2)

12

1. 152 x 229 x 25 mm Plate 3. 114.5 mm 5. 200 mm
2. 225 mm 4. 127 mm Radius 6. 225 mm
F2 - Recoil Spring Tool - Ram Pusher Tube

1. 82.5 x 82.5 x 16 mm Base Plate 3. 65 mm 5. 25 mm Weld, 4 Places
2. 82.5 x 53 x 194 mm Seamless Tube 4. 73 mm
30-16 2 D87E-2 D87P-2

F3 - Recoil Spring Tool - Spacer Fixture
1. 343 x 57 x 19 mm Leg - Qty. 2 4. 28.5 mm 7. 3 mm Weld

2. 105 x 38 x 8 mm Brace 5. 159 mm 8. 3 mm Weld 8 Places
3. 19 mm Round Stock Handle 6. 16 mm
D87E-2 D87P-2 30-17 2

F4 - Recoil Spring Tool - Spring Bolt

12
1. Spring Bolt 6. 75.5 mm Diameter 11. 0.5 mm Radius

2. Flat Washer - 338 258 R1 7. 50.5 mm Diameter 12. 26.9 mm Diameter
3. 754 mm 8. 4NA-2G Acme Thread 13. 28 mm Deep
4. 711.7 mm 9. 114.5 mm 14. 25.6 mm Square
5. 42.3 mm 10. 7.6 mm x 45° 15. 22.5 mm Deep
30-18 2 D87E-2 D87P-2

DISASSEMBLY AND ASSEMBLY CRANKCASE GUARD
CRANKCASE
12 GUARD
REMOVAL
WARNING! Be sure that the blade and any rear mounted
equipment have been lowered to the ground or onto suitable
blocking. This procedure requires extreme caution. Use
suitable blocking equipment while under the confines of the
machine.
Turn the ignition switch to the OFF position and remove the
key. Disconnect the negative $ terminal at the battery.
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE
D87E-2 D87P-2 30-19 2

DISASSEMBLY AND ASSEMBLY TRANSMISSION GUARD
TRANSMISSION
12 GUARD
REMOVAL
machine.
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE
30-20 2 D87E-2 D87P-2

DISASSEMBLY AND ASSEMBLY ENGINE HOOD
ENGINE
12 HOOD
REMOVAL
blocking. Turn the ignition switch to the OFF position and
remove the key. Disconnect the negative $ terminal at the
battery.
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE
D87E-2 D87P-2 30-21 2

DISASSEMBLY AND ASSEMBLY ROPS
ROPS
12
REMOVAL
battery.
1. Position the machine in place which makes it possible to use an
overhead crane for lifting of the removed assembles.
2. Turn the ignition electrical switch to the OFF position.
3. Unscrew the bolts securing the ROPS structure to the crossbeam

(five bolt on each side). Use a suitable lifting device to remove the
ROPS.
INSTALLATION
● Carry out installation in the reverse order of removal.
ROPS bolts................................................................... 920 N•m
30-22 2 D87E-2 D87P-2

DISASSEMBLY AND ASSEMBLY CAB
CAB
REMOVAL
battery.
1. Remove the following;
ROPS.............................................................................Refer to ROPS.
2. Remove the armrests and console covers in the cab.
3. Disconnect from under the platform, the cab harness electric plug
and the air conditioner control panel harness plug.
★ Disconnected electrical harness (plugs) must be protected against

to dirt oil, grease and water. Also tag disconnected harness (plugs)
for easier installation.
4. Remove the floor plate in order to obtain access to the linkage con-
nections and the windshield washer tanks.
5. Disconnect the hoses from the windshield washer tanks.
6. Unscrew bolts securing cab to the platform, the remove the cab.
INSTALLATION
Connectors ............................................112X Electrical Sealant

(1270464H1)
D87E-2 D87P-2 30-23 2

DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT
OPERATOR’S
12 SEAT
REMOVAL
battery.
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE
30-24 2 D87E-2 D87P-2

DISASSEMBLY AND ASSEMBLY OPERATOR’S COMPARTMENT
OPERATOR’S
12 COMPARTMENT
REMOVAL
blocking. Turn the ignition switch to the off position and re-
move the key. Disconnect the negative $ terminal at the bat-
tery.

Cab .................................................................................. Refer to CAB.
Operator’s seat.....................................Refer to OPERATOR’S SEAT.
★ When disconnecting hydraulic lines for any reason, they should be
property capped with correct size plastic cap. If these caps are not
available, tape or clean rubber corks may be used. Hydraulic open-
ings must never be plugged with rags. This practice could easily in-
troduce dirt or lint into critical hydraulic components of machine.
Tag all disconnect oil lines to facilitate installation.
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE
Mounting bolts ............................................................. 650 N•m
D87E-2 D87P-2 30-25 2

DISASSEMBLY AND ASSEMBLY FUEL TANK
FUEL
12 TANK
REMOVAL
machine.
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE
30-26 2 D87E-2 D87P-2

DISASSEMBLY AND ASSEMBLY RADIATOR
RADIATOR
12
REMOVAL
battery.
Hot scalding coolant can spray out if the radiator cap is re-
moved suddenly. Relieve the system pressure by slowly
turning the cap. Remove the cap ONLY after the pressure is
relieved.
This procedure requires extreme caution. Use suitable
blocking equipment while under the confines of the ma-
chine.
Engine hood................................................. Refer to ENGINE HOOD.
Engine crankcase guard...................Refer to CRANKCASE GUARD.
2. Position the machine in place which makes it possible to use an

overhead crane for lifting of the removed assembles. Remove the
bolts securing the front hood over the radiator and remove it. Re-
move the bolts securing the front radiator doors, and swing them
open. Remove the upper (1), right (2) and left (3) air baffles from
the front of the grill area. Remove the two clips securing the top to
bottom tank hose (4) to the frame.
3. Open the drain valve (5) and drain coolant from the cooling system
as described in the Operator's and Maintenance Manual. After the
radiator has been drained loosen the clamp and disconnect the out-
let (6) and by pass (7) hoses from the bottom radiator tank (8). Dis-
connect and tag the two oil cooler hoses (9) from the bottom tank.
Secure the hoses in an upright position to the frame.
★ Disconnected hydraulic and cooling lines must be capped with the

correct size plastic caps or clean corks. Openings must never be
plugged with rags. This practice could easy introduce dirt or lint in-
to critical components of the machine.
4. At the top radiator tank (10), loosen the clamps, disconnect the inlet
hose (11) and position out of the way. Disconnect the vent hose
(12).
5. Attach the hoist to the radiator lifting eye and take up slack. On
each side of the frame, remove the covers (13) and mounting flang-
es (14) (two flanges on each side of the frame). If necessary remove
the rubber insulators (15) from the radiator using a slide hammer
with 3/8" thread.
★ When removing the rubber insulators from an assembled radiator,

do not allow the threaded rod of the slide hammer to enter below
the nut as it may contact and damage the radiator core fins (6).
D87E-2 D87P-2 30-27 2

12
1. Upper Radiator Baffle 6. Bottom Tank Outlet Hose 11. Top Tank Inlet Hose
2. Right Radiator Baffle 7. By Pass Hose 12. Vent Hose
3. Left Radiator Baffle 8. Radiator Bottom Tank 13. Frame Side Covers
4. Top To Bottom Tank Hose 9. Drive Train Cooler Hoses 14. Mounting Flanges
5. Drain Valve 10. Radiator Top Tank 15. Rubber Mounting Insulators
INSTALLATION
● Refill the cooling system, refer to the Operation and Maintenan-
ace Manual.
30-28 2 D87E-2 D87P-2

DISASSEMBLY
12
1. Hose Clip 4. Radiator Core 7. Side Support Members

2. Over Flow Hose 5. Side Gasket Strip 8. Bottom Tank And Oil Cooler
3. Top Tank 6. End Gasket Strip 9. Radiator Cap
D87E-2 D87P-2 30-29 2

12
1. Support the radiator in an upright position. Disassemble the clips
(1) and the overrun hose (2). Loosen the clamps and remove the top
to bottom tank hose.
2. Remove the mounting hardware from the top tank (3) and radiator
core (4). Remove the top tank and discard the gaskets strips (5 and
6).
3. Remove the hardware securing the side channels (7) to the bottom
tank (8). Slide the right and left channels from of the core.
4. Turn the radiator over and support it on the top flange of core (4).
Remove the mounting hardware from the bottom tank and core. Re-
move the bottom tank and discard the gasket (5 and 6).
5. Remove the rubber insulators from the side channels using a slide
hammer with 3/8NC thread (if not removed previously).
★ The torque converter oil cooler is an integral part of the radiator

bottom tank and in case of damage, replace with a new one.
Flush out the upper and lower tanks with water. Flush out the core
with water under pressure, both inside and outside. If the core is
greasy, clean with steam cleaning equipment. Clean all remaining
INSPECTION
parts. Be sure all the old gasket material is removed.

Examine the fins and tubes of the core for damage. Rod out the tubes
to be sure they are not restricted. Straighten all bent fins if possible to
avoid air flow restrictions.
Inspect the top and bottom tanks for cracks. Inspect all hoses for
cracks or rupture and install new when in doubt. Inspect the radiator
cap. Inspect the rubber insulators for wear and replace. Perform a
pressure test after assembly.
ASSEMBLY
1. Be sure the gasket surfaces of the core (4) and tanks (3 or 8) are
clean. Set the bottom tank (8) in a flat position. Position new gas-
kets (5 and 6) on tank.
2. Set the core on the bottom tank and secure loosely with the mount-
ing hardware.
3. Position new gaskets (5 and 6) and the top tank (3) on the core and
secure loosely with the mounting hardware.
4. Slide in the side channels (7) and install the mounting hardware.
Tighten all the mounting hardware securely, top and bottom tanks
to core and side channels.
5. Install the top to bottom tank hose and clamps. Reassemble the
clips (1) and the overflow hose (2).
6. Install rubber insulators (10) to the radiator side channels (7).
30-30 2 D87E-2 D87P-2

DISASSEMBLY AND ASSEMBLY ENGINE
ENGINE
12
REMOVAL
machine.

Transmission guard ................... Refer to TRANSMISSION GUARD.
Cab .................................................................................. Refer to CAB.
Compartment..................Refer to OPERATOR’S COMPARTMENT.
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE
Front mount bolt to frame .................................610 to 765 N•m
Rear mount to flywheel.....................................235 to 285 N•m
Rear mount to frame .........................................610 to 765 N•m
Rear mount bolt ................................................235 to 285 N•m
D87E-2 D87P-2 30-31 2

DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
TORQUE CONVERTER
REMOVAL
machine.

Drain hydraulic reservoir ............. Refer to OPERATORS MANUAL.
Cab .................................................................................. Refer to CAB.
Compartment..................Refer to OPERATOR’S COMPARTMENT.
Drive train pumps............................ Refer to DRIVE TRAIN PUMPS.
Equipment pump ...............................Refer to EQUIPMENT PUMPS.
Drive shaft ......................................................Refer to DRIVE SHAFT.
★ Before removing the torque converter perform diagnostics of fail-
ures and check for oil leaks, so as to be sure that the disassembly of
the torque converter is advisable.
★ Disconnected hydraulic lines must be capped with the correct size

plastic cap. 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 introduce dirt or lint into critical hydraulic
components of the machine. Also tag all disconnected lines to facil-
itate correct and easier installation.
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE
Housing bolts ......................................................98 to 123 N•m
Housing studs (qty 5) ............................................. Loctite #277
Housing studs nuts ..............................................98 to 123 N•m
Ring gear to flywheel bolts .................................98 to 123 N•m
Ring gear to flywheel bolts .................................... Loctite #277
● Refill the drive train system, refer to the Operation and Mainte-
nanace Manual.
30-32 2 D87E-2 D87P-2

12
D87E-2 D87P-2 30-33 2

12
1. Drive Housing 12. Thrust Washer 23. Housing Cover Gasket 34. Retaining Ring
2. Converter Housing 13. Stator 24. Flange Retaining Plate 35. Pump Drive Gear
3. Output Flange 14. Stator Aligning Pins 25. Retaining Plate Washer 36. Drive Gear Front Bearing
4. Drive Housing Cover 15. Stator Ring 26. Output Shaft 37. Drive Gear Rear Bearing
5. Cover Shims 16. Thrust Washer 27. Shim Retainer Cover 38. Retaining Ring
6. Retaining Plate 17. Thrust Bearing 28. Shaft Oil Seal 39. Splined Sleeve
7. Retaining Plate Washer 18. Turbine 29. Shim Retainer Gasket 40. Retaining Ring
8. Impeller 19. Drive Housing Bearing 30. Retainer Shims 41. Shaft Seal Ring
9. Thrust Bearing Spacer 20. Pump Gear Drive Gear 31. Outboard Bearing 42. Ground Sleeve Hub
10. Aligning Pins 21. Impeller Bearing 32. Retaining Ring 43. Hub Gasket
11. Thrust Bearing 22. Top Cover 33. Shaft Seal Ring
DISASSEMBLY
★ Before disassembling the torque converter, thoroughly clean the
outside of the housing. Select a clean, dust free location. Cleanli-
ness is very important when repairing the converter.
★ Callouts from the exploded view correspond with the callouts in the
following steps.
1. Place the converter on a bench so that the drive housing (1) is fac-
ing up. Block under the converter housing (2) to clear the output
flange (3). Unscrew the bolts and remove the housing cover (4) and
shims (5). Keep the shims with the cover. Bend back the tabs on the
retaining plate (6) and remove the bolts, retaining plate and washer
(7).
2. Use two eyebolts and lift the drive housing assembly from the con-
verter housing. Place the assembly on the bench, remove the hoist
and turn over so that the drive housing is facing down.
3. Remove the bolts securing the impeller (8) to the housing and lift
the impeller with attached parts from housing.
30-34 2 D87E-2 D87P-2

12
4. Lift the bearing spacer (9) with pins (10), bearing (11) and thrust
washer (12) off the stator. Remove the stator (13) with pins (14)
and stator ring (15) from turbine (16). The pins (14) and ring (15)
need not be removed unless replacement is necessary. Lift the
thrust washer (16) and thrust bearing (17) out of turbine (18).
5. Carefully pry the turbine (18) from the drive housing bearing (19).
Drive the bearing (5) out from the gear side of the drive housing (1)
using a suitable driver. Place the impeller (8) on wood blocks with
the gear (20) down. Remove the bolts securing the gear to the im-
peller. Tap the bearing and gear out of the impeller. Press the bear-
ing (21) out of the gear.
6. Remove the bolts and remove the cover (22) and gasket (23) from
the main converter housing (2). Place the housing down with the
output flange (3) facing up. Bend back the tabs on the retaining
plate (24) and remove bolts, retaining plate and washer (25). Slide
the output flange from the output shaft (26). Remove the bolts and
remove the retainer (27) with seal (28). Remove the seal from the
retainer. Discard the gasket (29) and seal. Remove the shims (30)
and keep with the retainer to facilitate proper installation.
7. Place the converter housing on its side and working from inside of
the housing, tap on the end of the output shaft (26) with a hammer
and a block of wood until the bearing (31) is free. Remove the shaft
with bearing, retaining ring (32) and seal ring (33). Remove seal
ring and discard. If the bearing or shaft replacement is necessary,
remove the retaining ring (32) and press the bearing from the shaft.
8. Place the converter housing down with the output flange side fac-
ing up. Remove the retaining ring (34) from hub of gear (35). Tap
the gear with the front bearing (36) from housing. If the front bear-
ing replacement is necessary, remove the bearing from the gear. If
the rear bearing (37) replacement is necessary, remove the retainer
ring (38) and drive the bearing out the rear of the housing. Repeat
step for the remaining pump drive gear. Remove the splined sleeve
(39) and retaining ring (40) if necessary.
9. Remove and discard the seal ring (41) from the ground sleeve hub
(42). If the ground sleeve hub needs to be replaced, place the con-
verter housing in a press with the splined end of ground sleeve hub
facing down. Block up on the inside of the housing as close to the
outside diameter of the hub as possible without contacting the hub.
Insert a steel plug on the rear of the hub and press out. Remove the
gasket (43) and discard.
It is recommended that new seal rings, gaskets and oil seals be in-
stalled whenever the torque converter is disassembled for service. Re-
place with the available seal kit. Wash all parts thoroughly in a
suitable solvent. Dry thoroughly with compressed air or a clean cloth.
Do not spin dry bearings with compressed air. Inspect and clean all
INSPECTION
hoses and piping removed when removing the torque converter. In-
spect sealing surfaces for wear or damage.
Inspect all splines and gear teeth for excessive wear, burrs or damage
and replace if necessary. Slight burrs can be removed with a fine oil
stone. Replace all bearings that do not rotate freely. Inspect the impel-
ler, stator and turbine for signs of rubbing. If this condition exists, it is
an indication that one or more of the bearings in the converter need
replacement. If the blades are excessively worn or damaged, the en-
tire assembly must be replaced.
D87E-2 D87P-2 30-35 2

ASSEMBLY
★ If the ground sleeve hub (42) was removed pack it in dry ice or
freezer to -300°C for 30 minutes prior to assembly.
following steps.
1. If the ground sleeve hub (19) was removed, proceed as follows;
A. Place the converter housing (2) in a press with its output side
down. Position the gasket (43) in the housing. Insert the two
guide bolts (3/8NCx2-1/2 with the heads cut off) into the fro-
zen ground sleeve hub. Using the shoulder of the ground
sleeve hub, press the hub into the housing. Remove the guide
bolts when the ground sleeve hub is properly seated in the
housing. Install the seal ring (41) on the hub. Be sure to hook
the seal ring and coat with oil.
2. Seat the retaining ring (38) in the housing bore. Using a bearing
driver tap the rear bearing (37) into the bore from the output end of
the housing until it bottoms on the retaining ring. Start the pump
drive gear (35) with front bearing (36) into bore from the other end
of the housing using a soft hammer. Insert a standard threaded pull-
er rod through gear and position a piece of bar stock over behind
gear. Secure with nut. Place a 45 mm socket on the leg and against
the rear bearing. Install a nut and draw gear into rear bearing until
ring groove in gear hub appears. Install retaining ring (34). Repeat
for the remaining drive gear. Install splines sleeve (41) and retain-
ing ring (40).
3. Install the retaining ring (32) to the shaft (26). Press the output end
of the shaft into the bearing (31) until the bearing seats against the
retaining ring. The bearing must be held in the press so that both of
the bearing races are supported. Install the seal ring (33) in the
groove of the shaft. Coat the ring lightly with hydraulic oil. Insert
the shaft into the ground sleeve hub (42) from the output end of the
housing. Using a suitable driver against the outer race bearing, seat
the bearing against the hub.
4. Press the oil seal (28) in so that it is flush (A) with the outer edge of
the retainer (27). The seal lip (garter spring end) is to face (B) into
the converter when the retainer is installed.
30-36 2 D87E-2 D87P-2

12
5. An output shaft end gap (A) of 0 to 0.1 mm must be maintained in
the converter assembly. Be sure the bearing (31) is bottomed in the
ground sleeve hub (42). Install virgin lead (≈ 2 mm thick) on the
outer bearing race. Install the retainer (27) and gasket (29). DO
NOT install the shims at this time. Tighten the mounting bolts to 49
to 58 N•m.
6. Remove the retainer and compressed lead. Carefully measure the

thickness of the compressed lead with a micrometer. This measure-
ment, less 0 to 0.1 mm, is the amount of shims (30) to be installed
between output shaft bearing and retainer. The shim pack should
never be the same or greater than thickness of the gap measurement
(compressed lead).
Shim pack ................................. Measurement less 0 to 0.1 mm
7. Install the shims (30) in the bore of the bearing retainer (27) with
gasket (29) and secure with hardware.
Retainer bolts ........................................................49 to 58 N•m
D87E-2 D87P-2 30-37 2

8. Install the output flange (3). Install washer (25), retaining plate (24)
and secure with bolts. After torquing the bolts, bend up the tabs of
the retaining plate.
Retainer plate bolts ...............................................23 to 27 N•m
9. Install the cover (22) with a new gasket (23) to the housing (2) and
secure with the hardware.
Cover bolts ........................................................ 110 to 132 N•m

10. Place the drive housing (1) on work bench with the gear end up.
Position the bearing (19) in the bore of the housing. Turn the hous-
ing over and position the turbine (18) inside housing so that the hub
of the turbine enters the bearing. Tap the turbine into the bearing
being careful not to drive the bearing out of the housing. Install the
bearing (21) into the drive gear (20) and secure the impeller (8) to
the drive gear with hardware.
Drive gear bolts.....................................................23 to 27 N•m
11. Position the thrust bearing (17) and washer (16) in the turbine (18).
Be sure the ring (15) and pins (14) are in position in the stator (13).
Position the stator in the turbine so that the pin engages in the thrust
washer. Position the thrust washer (12) in stator engaging pin. Place
the thrust bearing (11) and spacer (9) on the thrust washer. Position
the impeller (8) over turbine being sure pin (10) engages spacer. Se-
cure the impeller to the drive housing (1) with hardware.
Impeller bolts ........................................................23 to 27 N•m
12. Place the converter housing (2) on a bench so that the output flange
(3) is facing down. Block under the converter housing to clear the
output flange. Secure a hoist and lower assembly into housing. As
the assembly is being lowered into the housing, the splines of the
stator (13) will engage with the splines of the ground sleeve hub
(42); then the splines of the turbine (18) will engage the splines of
the output shaft (26) and finally, the drive gear (20) will mesh with
the pump drive gears (35). If at any point when contact is made, the
hoist sling becomes slack, place a slight strain on the sling and ro-
tate the housing to engage properly, then continue to lower the as-
sembly into the housing. Install the washer (7) and retaining plate
(6) and secure with bolts. After torquing the bolts, bend up the tabs
of the retaining plate.

13. Install more shims (5) than were removed and cover (4) and tighten
the mounting bolts to 49 to 58 N•m to assure the bottoming of the
bearing (19). Loosen the mounting bolts remove all shims and re-
tighten cover hardware finger tight. Check the clearance (A) be-
tween the cover and the housing with a feeler gauge. There must be
a clearance of 0.127 to 0.381 mm. If necessary, add shims (2) until
the clearance is obtained without having the cover bolts tightened.
When the correct gap is obtained, tighten the bolts.
30-38 2 D87E-2 D87P-2

DISASSEMBLY AND ASSEMBLY CHARGE AND SCAVENGE PUMP
CHARGE
12 AND SCAVENGE PUMP
REMOVAL
machine.
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE
nanace Manual.
D87E-2 D87P-2 30-39 2

12
1. Mounting Nut 11. Drive Gear Housing 21. Seal Plate

2. Flat Washer 12. Seal Plate 22. Seal Ring
3. Spacer Sleeve 13. Seal Ring 23. Driven Gear
4. Stud Bolt 14. Dowel Pin 24. Driven Gear Housing
5. Mounting Flange 15. Center Section 25. Plate Seal
6. Plate Seal 16. Seal Plate 26. Plate Seal
7. Plate Seal 17. Seal Ring 27. Seal Plate
8. Seal Plate 18. Plate Seal 28. Seal Ring
9. Seal Ring 19. Plate Seal 29. Rear Section
10. Drive Gear 20. Dowel Pin
30-40 2 D87E-2 D87P-2

DISASSEMBLY
12
following steps. Clean the exterior of the pump before disassembly.
★ Position the pump on a work bench so that the drive shaft is up. In-
dex mark the five sections to retain relationship during assembly,
1. Remove the nuts (1), washers (2) and sleeves (3) from the studs (4).
2. Remove the mounting flange (5). Remove the plate seals (6 and 7)
from flange.
3. Remove the seal plate (8) and the seal ring (9).
4. Carefully index mark the teeth of the drive gears (10) to obtain the
original mesh so that the same wear pattern will be re-established.
Remove the drive gears from the gear housing (11).
5. Remove the drive gear housing, seal ring (12) and seal plate (13). If
necessary, remove dowel pin (14).
6. Lift off the center section (15). Remove the plate seals (16 and 17)
from one side and the plate seal (18 and 19) from the other side of
the center section. If necessary, remove dowel pin (20).
7. Remove the seal plate (21) and seal ring (22).
8. Carefully index mark the teeth of the driven gears (23) to obtain the
original mesh so that the same wear pattern will be re-established.
Remove the gears from the driven gear housing (24),
9. Remove the driven gear housing, seal ring (25) and seal plate (26).
10. Remove the plate seals (27 and 28) from the rear section (29). Re-
move the studs from the rear section.
Discard all seals and seal plates and replace with new ones during as-
sembly.
Wash all parts thoroughly in a suitable solvent. Dry thoroughly with
compressed air.
INSPECTION
Inspect the edges of gear teeth and faces for scoring or roughness. If
possible, remove roughness or scoring with an oil stone. Also inspect
the gear hubs for excessive wear at the bearing surfaces.
Remove any roughness from the machined surfaces of flange, hous-
ings and section with an oil stone. If roughness is excessive, the com-
ponents should be replaced.
Rewash all parts that were smoothed with an oil stone and dry thor-
oughly.
ASSEMBLY
following steps. Clean the exterior of the pump before disassembly.
1. Install half of the studs (4), course threads first, into the rear section
(29). Install the seals (27 and 28) in the groove of the rear section.
D87E-2 D87P-2 30-41 2

12
2. Place the seal ring (25) around the seal plate (26) and install on the
rear section. The seal plate must be installed so that the bronze side
with the slots will face toward the driven gears and that the port
holes are aligned.
3. Install the gear housing (24) on the rear section so that the index
marks line up. Install the driven gears (23) aligning the index marks
on the gear teeth.
4. Install the plate seals (18 and 19) in the grooves in the center sec-
tion (15). Place the seal ring (22) around the seal plate (21) and in-
stall on the center section. The seal plate must be installed so that
the bronze side with the slots will face toward the driven gears and
that the port holes are aligned.
★ The seal plate (21) may require grease on its underside to keep it in
place during assembly.
5. Install the center section (15) on the driven gear housing (24) so
that the index marks line up.
★ Check that the dowel pins (20) are installed in the in the center sec-
tion and are flush with the surface of the section.
6. Insert the remaining studs (4), course threads 1st, through the holes
and turn them into section (20).
7. Install the plate seals (16 and 17) in the grooves in the center sec-
tion (15). Place the seal ring (12) around plate (13) and install on
the center section. The seal plate must be installed so that the
bronze side with the slots will face toward the drive gears and that
the port holes are aligned.
8. Install the drive gear housing (11) on the center section so that the
index marks line up. Install the upper drive gear (10) in the housing
being sure it splines with the driven gear (23). Insert the lower
drive gear aligning the index mark on it with the index mark on the
other gear.
9. Install seals (6 and 7) in the groove in the mounting flange (5).

Place the seal ring (9) around plate (8) and install on the mounting
flange. The seal plate must be installed so that the bronze side with
the slots will face toward the drive gears and that the port holes are
aligned. The seal plate may require grease on its underside to keep
it in place during assembly.
10. Install the mounting flange on the drive gear housing so that the in-
dex marks line up. Install the washers (2) and secure with nuts (5).
Stud nuts ...............................................................30 to 35 N•m
30-42 2 D87E-2 D87P-2

DISASSEMBLY AND ASSEMBLY SCAVENGE PUMP AND DRIVE
SCAVENGE
12 PUMP AND DRIVE
REMOVAL
machine.
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE
Pump drive gear nut ..............................................63 to 77 N•m
Converter top cover bolts.................................. 110 to 132 N•m
nanace Manual.
D87E-2 D87P-2 30-43 2

DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
DRIVE
12 SHAFT
1. Universal Joint 2. Mounting Bolt 3. Drive Shaft
SERVICE
battery.
chine.
Mounting bolt .............................................................. 110 N•m
30-44 2 D87E-2 D87P-2

DISASSEMBLY AND ASSEMBLY TRANSMISSION
TRANSMISSION
12
REMOVAL
battery.
chine.
1. Drain hydraulic reservoir and drive train system. Refer to the Oper-
★ Before removing the transmission, perform diagnostics of failures

and check for oil leaks, so as to be sure that the disassembly of the
transmission is advisable.

Operator’s CAB.................................... Refer to OPERATOR’S CAB.
Operator’s area ...............Refer to OPERATOR’S COMPARTMENT.
Drive shaft ......................................................Refer to DRIVE SHAFT.
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE
Transmission mounting bolts ....................................... 920 N•m

nanace Manual.
● Refill the hydraulic system, refer to the Operation and Mainte-
nanace Manual.
D87E-2 D87P-2 30-45 2

COMPLETE
12 ASSEMBLY
30-46 2 D87E-2 D87P-2

12
1. Pressure Regulator Valve 14. Input (Directional) Clutch Shaft 27. Output Shaft Cover
2. Mounting Seal Ring 15. Input Flange Oil Seal 28. Output (Range) Clutch Shaft
3. Mounting Seal Ring 16. Cover Seal Ring 29. Output Clutch Shaft Cover Shims
4. Mounting Seal Ring 17. Input Shaft Cover Shims 30. Cover Seal Ring
5. Range Selector Valve 18. Short Supply Tubes (Qty. 3) 31. Sump Pipe Flange
6. Mounting Seal Ring 19. Long Supply Tubes (Qty. 4) 32. Seal Rings
7. Rate Of Rise Valve 20. Supply Tube Seals 33. Seal Ring
8. Valve Gasket 21. Manifold Short Support Stud 34. Transmission Housing Rear Cover
9. Manifold Orifice Strainer 22. Manifold Long Support Tube 35. Transmission Housing Strainer
10. Valve Manifold 23. Countershaft Cover 36. Reverse Idler Gear
11. Manifold Gasket 24. Countershaft 37. Mounting Bolt
12. Transmission Housing 25. Countershaft Cover Shims 38. Retaining Plate
13. Input Shaft Cover 26. Cover Seal Rings 39. Seal Ring
DISASSEMBLY
following steps.
★ Before disassembling the transmission, thoroughly clean the out-

side of the housing. Select a clean, dust free location. Cleanliness is
very important when repairing the transmission.
1. Remove the hoses, the pressure regulator valve (1) and seal rings
(2, 3 and 4), the range selector valve (5) and seal rings (6) and the
rate of rise valve (7) and its gasket (8) if not removed earlier. Re-
move the orifice strainer (9).
★ Refer to PRESSURE REGULATOR VALVE for service.
★ Refer to RANGE SELECTOR VALVE for service.
★ Refer to RATE OF RISE VALVE for service.
2. Position the transmission assembly on a stand so that transmission

case is upright. Remove the valves manifold (10) and manifold gas-
ket (11) from the transmission case (12).
D87E-2 D87P-2 30-47 2

12
3. Remove the input cover (13) from the directional clutch shaft (14).
Remove and discard the oil seal (15) and seal ring (16) from the
cover. Keep the shims (17) with the cover.
★ There are three 3/8NC puller holes provided in the input cover to
aid in removal.
4. Remove the short tubes (18) from the transmission case by insert-
ing an eyebolt (threaded shaft smaller than tube ID) into the end of
the tube, cock it to the side and pull. Repeat for the long tubes (19).
Remove and discard tube seals (20).
★ The tubes do not need to be pulled completely out of the case, thus
avoiding damage to inner seal rings on tube.
5. Unthread and remove the manifold-short support stud (21).
6. Remove the manifold-long support tube (22).
30-48 2 D87E-2 D87P-2

12
7. Remove and tag the countershaft cover (23) from the countershaft
(24) opening. Remove the shims (25) and keep with the cover for
proper installation. Remove and discard seal ring (26) from cover.
★ There are three 3/8NC puller holes provided in the countershaft

cover to aid in removal.
8. Remove and tag the output cover (27) from the output shaft (28)
opening. Remove the shims (29) and keep with the cover for proper
installation. Remove and discard seal ring (30) from cover.
★ The cover and shims are the same type as used on the countershaft
and output shaft openings and can easily become intermixed.
9. Remove the sump pipe flange (31) from housing. Remove a seal
rings (32 and 33) from the flange and discard.
10. Remove the hardware securing cover (34) to housing. Attach a

hoist to the housing and lift straight up and off.
★ If the transmission housing and cover will not separate easily, tap
along the seam with a soft mallet until the cover is free of the hous-
ing dowel pins.
11. Remove the two nuts and washers securing the transmission strain-
er (35) to cover and remove.
12. Install an eyebolt in the end of the range clutch shaft (28) and hoist
it up far enough to allow the removal of the countershaft (24) and
the output shaft (14).
★ Refer to COUNTERSHAFT for service.
★ Refer to OUTPUT SHAFT for service.
★ Refer to RANGE CLUTCH SHAFT for service.
13. Remove the bolt (37) securing plate (38). Remove plate and seal
ring (39). Tap the reverse idler gear (36) from the cover.
★ Refer to REVERSE IDLER GEAR for service.
D87E-2 D87P-2 30-49 2

12
It is recommended that new seal rings be installed whenever the
transmission is disassembled for service. Wash all parts thoroughly in
a suitable solvent. Dry thoroughly with compressed air or a clean
cloth. Do not spin dry bearings with compressed air. Inspect bearings
for excessive wear or damage and replace if necessary. Reusable
bearings should be soaked in clean oil and wrapped with clean paper
until ready for assembly.
INSPECTION
Inspect the gears for worn, chipped or broken teeth. Replace if wear is
excessive or teeth are damaged. Inspect the splines on the shafts for
wear. Replace shafts if wear is excessive. Slight burrs can be
smoothed down with a stone. Flush all oil passages of the input and
output shafts. Be sure all lube holes are clean and free of obstruction.
Inspect the clutch plates for excessive wear or warpage and replace if
necessary. Using an oil stone, remove any burrs that might damage
sealing surfaces or increase wear to close tolerance parts. Check the
compression springs for damage and fatigue. If they do not fall within
the tolerances, they must be replaced.
Flush and clean all oil lines and the oil cooler to assure a clean hy-
draulic system.
ASSEMBLY
★ Callouts from exploded view correspond with callouts in following

steps.
1. Install the reverse idle gear (36) through the rear cover (34). Install
seal ring (39) and retainer plate (38) and secure with prevailing
torque bolt (37).
30-50 2 D87E-2 D87P-2

12
2. Position the rear cover (34) on the work stand. Attach a hoist to the
output (range) clutch shaft (28) and lower the shaft into the bearing
cup in the rear cover. Do not set the shaft all the way down.
3. Install the input (directional) clutch shaft (14) and the countershaft
(24) into the bearing cups in the rear cover (34). Lower the (range)
clutch shaft (28) all the way down enmeshing all gearing. Remove
the hoist and eyebolt.
4. Turn the input and output shaft manifolds so that the tube ports are
aimed between the counter shaft and the input shaft. Install the
transmission strainer (35) and secure with the hardware.
5. Apply Loctite #515 to the mating surfaces of the cover (34) and
housing (12) according to the instructions on the container. Hoist
the housing and lower over the shafts until the dowel pins enter the
cover and secure with hardware.
Rear cover .............................................................. Loctite #515
6. Insert the manifold short support stud (21) through the opening in
housing and thread it into the manifold of the input (directional)
clutch shaft (14).
★ The input (directional) clutch shaft can be rotated to enhance posi-

tive thread engagement into the clutch shaft manifold.
D87E-2 D87P-2 30-51 2

12
7. Insert the manifold long support tube (22) through the opening in
housing and into the manifold of the output (range) clutch shaft
(28).
8. Install new seal rings (20) on the tubes (18 and 19). Install the seal
rings over the seal rings. Insert the tubes through the openings in
housing. Using an eyebolt in the end of the tubes, insert them until
they seat in the manifolds.
★ Do not pull the tubes all the way out once the first set of seal rings
have passed through the housing (16). The inside edge of the holes
will damage the seal rings.
9. Install new seal rings (32 and 33) on flange (33) and secure to the
housing with hardware.
10. Install new seal rings (26 or 30) on the shaft covers (23 or 27). To
check the countershaft (shown) or output (range) clutch shaft end
play, secure the cover (23 or 27) with the original shim packs (25 or
29) to the housing using standard torque. Remove the pipe plugs
from the shaft covers.
Install a hoist, by threading the bolt into the shaft. Mount a dial in-
dicator on the housing, place the indicator pointer on the end of the
shaft and set at zero.
Raise the hoist until the transmission begins to raise and take a
reading. Add or subtract shims to obtain the proper shaft end play
of 0.127 to 0.254 mm.
To regulate end play, shims (25 or 29) must be used. The thickness
of the shims available are: 0.5 mm, 0.18 mm, 0.12 mm.
Shaft end play .............................................. 0.127 to 0.254 mm

Install the proper amount of shims (25 or 29) and secure the covers
(23 or 27) to the housing. Install the pipe plugs in the shaft covers.
30-52 2 D87E-2 D87P-2

12
11. Install new seal ring (16) on the shaft covers (13). To check the in-
put (directional) clutch shaft end play, secure the cover (13) with
the original shim packs (17) to the housing using standard torque.
Install a hoist, by threading the bolt into the shaft. Mount a dial in-
dicator on the housing, place the indicator pointer on the end of the
shaft and set at zero.
Raise the hoist until the transmission begins to raise and take a
reading. Add or subtract shims to obtain the proper shaft end play
of 0.127 to 0.254 mm.
To regulate end play, shims (25 or 29) must be used. The thickness
of the shims available are: 0.5 mm, 0.18 mm, 0.12 mm.
Shaft end play .............................................. 0.127 to 0.254 mm

Install the proper amount of shims (17) and secure the covers (23 or
27) to the housing.
Install oil seal (15) in input cover flush with the edge of the cover.
12. Install the drive yoke on the splines of the input (directional) clutch
shaft.
D87E-2 D87P-2 30-53 2

INPUT
12 (DIRECTIONAL) CLUTCH SHAFT
30-54 2 D87E-2 D87P-2

12
1. Oil Distribution Manifold 19. Spring Retaining Plate 37. Separator Plate
2. Tapered Roller Bearing Cone 20. Plate Retaining Ring 38. Piston Return Spring
3. Thrust Washer 21. Spring Lube Sleeve 39. Spring Retaining Plate
4. Side Thrust Bearing 22. Dowel Pin 40. Plate Retaining Ring
5. Input (Directional) Shaft 23. Spring Backing Plate 41. Spring Lube Sleeve
6. Oil Manifold Needle Bearing 24. Forward Piston 42. Dowel Pin
7. Shaft Seal Ring 25. Piston Seal Ring 43. Spring Backing Plate
8. Thrust Washer 26. Piston Seal Ring 44. Reverse Piston
9. Side Thrust Bearing 27. Reverse Drive Gear 45. Piston Seal Ring
10. Forward Drive Gear 28. Tapered Roller Bearing Cone 46. Piston Seal Ring
11. Thrust Washer 29. Thrust Washer 47. Hub Seal Ring
12. Side Thrust Bearing 30. Side Thrust Bearing 48. Hub Seal Ring
13. Gear Needle Bearing 31. Gear Needle Bearing 49. Clutch Hub
14. Captured Retaining Ring 32. Thrust Washer 50. Drum Retaining Ring
15. End Support Plate 33. Side Thrust Bearing 51. Hub Drum
16. Friction Disc 34. Captured Retaining Ring 52. Hub To Shaft Retaining Valve
17. Separator Plate 35. End Support Plate
18. Piston Return Spring 36. Friction Disc
DISASSEMBLY
★ Callouts from the exploded view correspond with callouts in the

following steps.
1. Place the input (directional) clutch shaft in a suitable stand so that

the oil manifold (1) is up. Install a gear puller to manifold. Remove
the manifold (1), bearing cone (2) and thrust bearing parts (3 and 4)
from the shaft (5). If necessary, remove the bearings (6) from the
manifold (1).
★ The bearing cup was removed with the transmission housing. If

bearing replacement is necessary, remove the cup from the housing.
2. Remove and discard seal rings (7) from clutch shaft. Remove the
thrust bearing parts (8 and 9) from the clutch shaft.
3. Install two bolts in the forward drive gear (10) and remove from the
clutch shaft. Remove the thrust bearing parts (11 and 12) and nee-
dle bearing (13) from the clutch shaft.
4. Using retaining ring pliers, retract the captured retaining ring (14)
and remove with the support plate (15).
5. Remove friction discs (16) and separator plates (17). Compress the
piston return springs (18) by pressing down on the retaining plate
(19) with C clamps and remove retaining ring (20). Remove parts
(18 through 23) from the clutch shaft.
WARNING! SPRING LOADED ASSEMBLY. Assembly must

be held to relieve the spring pressure. Use extreme care
when disassembling.
D87E-2 D87P-2 30-55 2

12
6. Lay the shaft on its side and apply compressed air in port closest to
the clutch pack to remove the piston (24). Remove the seal ring
(25) and seal ring (26) from the piston.
★ Wear eye protection when using air under pressure. Limit the air
pressure to 2.1 kg/cm².
7. Place the shaft in the stand so that reverse drive gear (27) is up. Re-
move the bearing cone (28) and gear using the gear as the puller.
Remove the thrust bearing parts (29 and 30) and needle bearing
(31) from the clutch shaft.
★ The bearing cup was removed with the rear housing cover. If bear-
ing replacement is necessary, remove the cup from the housing cov-
er.
8. Using retaining ring pliers, retract the captured retaining ring (34)
and remove with the support plate (35).
9. Remove friction discs (36) and separator plates (37). Compress the
piston return springs (38) by pressing down on the retaining plate
(39) with C clamps and remove retaining ring (40). Remove parts
(38 through 43) from the clutch shaft.

when disassembling.
10. Lay the shaft on its side and apply compressed air in the center port
to remove the piston (44). Remove seal ring (45) and seal ring (46)
from piston.
★ Wear eye protection when using air under pressure. Limit the air
pressure to 2.1 kg/cm².
30-56 2 D87E-2 D87P-2

12
11. Remove seal ring (47) and seal ring (48) from each side of the hub
(49). Remove one of the retaining rings (50) and remove the shaft
(5) with hub from the drum (51). The second retaining ring (47)
need not be removed unless replacement is necessary.
12. Remove one of the retaining rings (52) and press hub off the shaft.
The second retaining ring (52) on the shaft need not be removed
unless replacement is necessary.
It is recommended that new seal and seal rings be installed whenever

the clutch shaft is disassembled for service. Wash all parts thoroughly
in a suitable solvent. Dry thoroughly with compressed air or a clean
INSPECTION

Inspect the friction disc and separator plates for excessive wear or
warpage and replace if necessary. Using an oil stone, remove any
burrs that might damage sealing surfaces or increase wear to close
tolerance parts. Check the compression springs for damage and fa-
tigue. If they do not fall within the tolerances, they must be replaced.
ASSEMBLY

following steps.
★ When assembling the hub to the shaft, the porting between the two
parts is critical. Align the porting accordingly.
1. Install one retaining ring (52) to the clutch shaft (5). Heat the hub
(49) to 200°C and press it on the clutch shaft until it bottoms on the
retaining ring. After the hub has cooled, install the seal ring (48)
and piston seal (47) on each side of the hub. Reinstall the second
retaining ring (52). Install one retaining ring (50) inside of the drum
(51). Mount the drum on the hub and clutch shaft and secure with
the remaining retaining ring.
D87E-2 D87P-2 30-57 2

12
2. Place the shaft in a suitable stand so that the splined end is down.
Install a new seal ring (45) and seal ring (46) on the reverse piston
(44) and install the piston in the drum being careful not to damage
the piston rings.
3. Assemble parts (38 through 43) on the shaft. Compress the springs
and secure with the retaining ring (40).

when assembling.
4. Alternately install one internally splined friction disc (36) and one
externally splined separator plate (37), ending with an internally
splined friction disc, into the drum.
★ The internally splined friction disc must be thoroughly oiled (with

same oil as used in the transmission) prior to assembling in the
drum. Because the facing is porous and absorbs oil, a light oiling
may not be sufficient. Whenever possible, the plates must be
soaked, for at least two minutes, in a container of clean transmis-
sion oil. If facilities are not available for soaking, a heavy oiling on
both surfaces may be sufficient.
5. Position the captured retaining ring (34) into the support plate (35).
Install two #6-32 screws at opposite sides of the retaining ring
opening.
6. Retract the retaining ring (34) and install two #6-32 screws in the
support plate (35).
7. Install support plate (35) into assembly.
8. Retract retaining ring (34) and remove four screws. Carefully let
off retaining ring until it seats in groove in drum.
9. Install the thrust bearing parts (32 and 33) and needle bearing (31)
to the clutch shaft. Position the reverse drive gear (27) over the end
of the shaft. Be sure all the internally splined discs are aligned in
drum and that the gear meshes with all the discs and sits squarely
on the needle bearing. Install the thrust bearing parts (29 and 30).
Heat the bearing cone (28) to 130°C for 45 minutes and install on
the shaft until it bottoms. To assure that the cone is seated, keep
pressure against the cone until it cools down.
30-58 2 D87E-2 D87P-2

12
10. Turn the shaft assembly over in the stand so that the splined end is
up. Install a new seal ring (25) and seal ring (26) on the forward
piston (24) and install the piston into the drum being careful not to
damage the seals.
11. Assemble parts (18 through 23) on the shaft. Compress the springs
and secure with the retaining ring (20).

when assembling.

opening.
support plate (15).
D87E-2 D87P-2 30-59 2

12
15. Install the thrust bearing parts (11 and 12) and needle bearing (13)
to the clutch shaft. Position the forward drive gear (10) over the end
of the shaft. Be sure all the internally splined discs are aligned in
drum and that the gear meshes with all the discs and sits squarely
on the needle bearing. Install the thrust bearing parts (8 and 9).
16. Install new shaft seals (7) to the grooves on the shaft. Install the oil
manifold (1) onto the shaft being careful not to damage the seals.
Install the thrust bearing parts (3 and 4).
17. Heat the bearing cone (2) to 130°C for 45 minutes and install on the
shaft until it bottoms. To assure that the cone is seated, keep pres-
sure against the cone until it cools down.
30-60 2 D87E-2 D87P-2

COUNTERSHAFT
12
1. Tapered Roller Bearing 4. 3rd Speed and Forward Drive Gear 7. Tapered Roller Bearing
2. 1st Speed Drive Gear 5. Countershaft
3. Retaining Ring 6. 2nd Speed and Reverse Drive Gear
DISASSEMBLY
following steps.
★ The cup for bearing (1) was removed with the countershaft cover
during the complete transmission tear down. If bearing replacement
is necessary, remove the cup from the cover.
1. Support the countershaft in a press under the 1st speed drive gear
(2) and press the shaft from the gear and bearing cone (1).
2. Disassemble the component parts (3 through 6) in the order shown.
3. Support the countershaft in a press under the rear bearing cone (7)
and press the shaft from the bearing cone.
★ The cup for bearing (7) was removed with the rear housing cover
during the complete transmission tear down. If bearing replacement
is necessary, remove the cup from the cover.
D87E-2 D87P-2 30-61 2

12
It is recommended that new retaining rings be installed whenever the
countershaft is disassembled for service. Wash all parts thoroughly in
a suitable solvent. Dry thoroughly with compressed air or a clean
INSPECTION
wear. Replace the shaft if wear is excessive. Slight burrs can be
smoothed down with a stone.
ASSEMBLY
following steps.
1. Reassemble component parts (2 through 6) in reverse sequence.
2. Heat bearing cone (1) to 130°C for 45 minutes and install on the
sure against the cone until it cools down a few seconds.
3. Heat bearing cone (7) to 130°C for 45 minutes and install on the
sure against the cone until it cools down a few seconds.
4. If the bearings were replaced, press new bearing cups in the rear
cover and shaft covers.
30-62 2 D87E-2 D87P-2

OUTPUT
12 (RANGE) SHAFT
D87E-2 D87P-2 30-63 2

12
1. Tapered Roller Bearing 19. Captured Retaining Ring 37. Support Plate 55. Friction Discs
2. Retaining Ring 20. Support Plate 38. Friction Discs 56. Separator Plates
3. 2nd Speed Hub 21. Spring Retainer Cup 39. Separator Plates 57. Spring Retainer Cup
4. Range (Output) Shaft 22. Retaining Ring 40. Spring Retainer Cup 58. Piston Return Springs
5. Retaining Ring 23. Thrust Bearing Washer 41. Piston Return Springs 59. Retaining Ring
6. 2nd Speed Hub Drum 24. Side Thrust Bearing 42. Retaining Ring 60. 1st Speed Piston
7. Internal Retaining Ring 25. 2nd Speed Driven Gear 43. 3rd Speed Piston 61. Lube Oil Sleeve
8. Piston Seal 26. Needle Bearing 44. Lube Oil Sleeve 62. Sleeve Seal Ring
9. Backer Seal Ring 27. Side Thrust Bearing 45. Sleeve Seal Ring 63. Captured Retaining Ring
10. Seal Ring 28. Thrust Bearing Washer 46. 1st Speed Driven Gear 64. 1st & 3rd Speed Hub
11. Captured Retaining Ring 29. Oil Input Manifold 47. Tapered Roller Bearing 65. 1st & 3rd Speed Drum
12. Piston Return Springs 30. Roller Bearings 48. Thrust Bearing Washer 66. Captured Retaining Ring
13. 2nd Speed Piston 31. Shaft Oil Seal 49. Side Thrust Bearing 67. Retaining Ring
14. Retaining Ring 32. 3rd Speed Driven Gear 50. Needle Bearing 68. Piston Seal
15. Lube Oil Sleeve 33. Needle Bearing 51. Thrust Bearing Washer 69. Backer Seal Ring
16. Sleeve Seal Ring 34. Thrust Bearing Washer 52. Side Thrust Bearing 70. Piston Seal
17. Friction Discs 35. Side Thrust Bearing 53. Captured Retaining Ring 71. Backer Seal Ring
18. Separator Plates 36. Captured Retaining Ring 54. Support Plate 72. Seal Ring
DISASSEMBLY
following steps.
1. Place the range (output) shaft in a suitable stand so that the 2nd
speed clutch pack is facing up. Remove the retaining ring (2) secur-
ing the 2nd speed hub (3) to the shaft (4). Remove the retaining
ring (5) securing the 2nd speed hub to the drum (6).
★ There is an internal retaining ring (7) mounted in the hub that is

used for hub placement. As the hub is being pulled from the shaft,
the retaining ring will ride down the hubs beveled surface (A) and
remain with the shaft.
2. Install a puller arrangement to the hub and remove with bearing

cone (1). Remove and discard piston seal (8) and backer seal ring
(9) from hub.
★ The cup for the tapered roller bearing cone (1) was removed with
the rear housing cover during the complete transmission tear down.
If bearing replacement is necessary, remove the cup from the cover
and the cone from the hub.
30-64 2 D87E-2 D87P-2

12
3. Remove the retaining ring (7) and seal ring (10) from the shaft. Re-
move the retaining ring (11) from the drum (6).
4. Compress the piston return springs (12) by pressing down on the

piston (13) with C clamps and remove the retaining ring (14).
Slowly release the C clamps.

when disassembling.
5. Remove the 2nd speed piston (13) with lube sleeve (15). Separate
the parts and discard seal ring (16).
6. Remove the drum (6) with the seven friction discs (17) and the six
separator plates (18). Separate the retaining ring (19), support plate
(20), friction discs and separator plates from the drum.
7. Remove the eight piston return springs (12) and the spring retaining
cup (21) from the drum.
8. Remove the retaining ring (22), thrust bearing washer (23) and the
side thrust bearing (24).
9. Remove the 2nd speed driven gear (25) and needle bearing (26).
D87E-2 D87P-2 30-65 2

12
10. Remove the top side trust bearing (27) and thrust washer (28) from
the input manifold (29).
11. Remove the input manifold with the roller bearings (30).
12. Remove the bottom side thrust bearing (27) and thrust washer (28)
from the input manifold (29).
13. Remove and discard the shaft to manifold seals (31).
14. Remove the 3rd speed driven gear (32) and roller bearing (33).
15. Remove the thrust washers (34) and side thrust bearing (35). Re-
move the retaining ring (36) and support plate (37) from the drum.
Remove the friction discs (38) and the separator plates (39).
30-66 2 D87E-2 D87P-2

12
16. Position two C clamps to the piston return spring retainer (40).
Compress the return springs (41), then remove the retaining ring
(42).

when disassembling.
17. Slowly let off the C clamps to release the return spring tension. Re-
move the spring retainer and six springs.
18. Remove the 3rd clutch piston (43) and the lube sleeve (44) from the
shaft. Remove and discard the seal ring (45) from the lube sleeve.
19. Install a puller to the 1st speed driven gear (46). Draw up on puller
until the tapered roller bearing (47) is free from the shaft. Remove
the bearing and puller.
★ The cup for the tapered roller bearing cone (47) was removed with
the output (range) shaft cover during the complete transmission tear
down. If bearing replacement is necessary, remove the cup from the
cover and the cone from the hub.
20. Remove the thrust washers (48) and side thrust bearing (49) from
the gear. Remove the 1st speed driven gear (46) and roller bearing
(50).
D87E-2 D87P-2 30-67 2

12
21. Remove the thrust washers (51) and side thrust bearing (52). Re-
move the retaining ring (53) and support plate (54) from the drum.
Remove the friction discs (55) and the separator plates (56).
22. Position two C clamps to the piston return spring retainer (57).
Compress the return springs (58), then remove the retaining ring
(59).

when disassembling.
23. Slowly let off the C clamps to release the return spring tension. Re-
move the spring retainer and six springs.
24. Remove the 3rd clutch piston (60) and the lube sleeve (61) from the
shaft. Remove and discard the seal ring (62) from the lube sleeve.
25. Remove one of the retaining rings (63) and remove the shaft (4)
with hub (64) from the drum (65). The second retaining ring (66)
need not be removed unless replacement is necessary.
26. Remove the piston seal rings (68 and 70) and the backer seal rings
(69 and 71) from each side of the hub (64). Remove the retaining
rings (67) and press the hub off the shaft. Remove the seal ring (72)
from the shaft.
30-68 2 D87E-2 D87P-2

It is recommended that new seal and seal rings be installed whenever

the clutch shaft is disassembled for service. Wash all parts thoroughly
in a suitable solvent. Dry thoroughly with compressed air or a clean
INSPECTION

Inspect the friction disc and separator plates for excessive wear or
tolerance parts. Check the compression springs for damage and fa-
tigue. If they do not fall within the tolerances, they must be replaced.
ASSEMBLY

following steps.
★ When assembling the hub to the shaft, the porting between the two
parts is critical. Align the porting accordingly.
1. Heat the hub (64) to 200°C. Install seal ring (72) to the clutch shaft
(4). Press the clutch shaft into the hub until it bottoms against its
stop. After the hub has cooled, install the seal ring (71 & 69) and
piston seal (68 &70) on each side of the hub. Install the retaining
ring (67).
2. Install one retaining ring (66) inside of the drum (65). Mount the
drum on the hub and clutch shaft and secure with the remaining re-
taining ring (63).
3. Install a new seal ring (62) to the lube sleeve (61) and insert on the
clutch shaft up against the hub. Install the 1st speed piston (60) into
hub being careful not damage the hub and sleeve seals.
4. Install the eight piston return springs (58) into the pockets of the
piston and cap with the spring retainer (57). Using two C clamps,
compress the return spring retainer and secure with the retaining
ring (57).

when assembling.
D87E-2 D87P-2 30-69 2

12

opening.
support plate (54). Install the support plate into the assembly. Re-
tract the retaining ring and remove the four screws. Carefully let off
the retaining ring until it seats in the groove in the drum. Install the
side thrust bearing parts (51 and 52) to the clutch shaft.
8. Install the roller bearing (50) onto the clutch shaft. Position the 1st
speed driven gear (46) over the end of the shaft. Be sure all the in-
ternally splined discs are aligned in drum and that the gear meshes
with all the discs and sits squarely on the needle bearing. Install the
thrust bearing parts (48 and 49).
30-70 2 D87E-2 D87P-2

12
9. Heat the bearing cone (47) to 130°C for 45 minutes and install on
the shaft until it bottoms. To assure that the cone is seated, keep
pressure against the cone until it cools down.
10. Install a new seal ring (45) to the lube sleeve (44) and insert on the
clutch shaft up against the hub. Install the 3rd speed piston (43) into
hub being careful not damage the hub and sleeve seals.
11. Install the six piston return springs (41) into the pockets of the pis-
ton and cap with the spring retainer (40). Using two C clamps,
compress the return spring retainer and secure with the retaining
ring (42).

when assembling.

D87E-2 D87P-2 30-71 2

12
opening.
the retaining ring until it seats in the groove in the drum. Install the
side thrust bearing parts (34 and 35) to the clutch shaft.
15. Install the roller bearing (33) onto the clutch shaft. Position the 3rd
speed driven gear (32) over the end of the shaft. Be sure all the in-
ternally splined discs are aligned in drum and that the gear meshes
with all the discs and sits squarely on the needle bearing.
16. Install new manifold seals (31) to the clutch shaft.
30-72 2 D87E-2 D87P-2

12
17. Install the side thrust bearing (27) and thrust washer (28) onto the
clutch shaft against the 3rd speed driven gear.
★ If the bearings (30) were replaced from the input manifold (29),
press in the new bearings 0 to 0.254 mm below face.
18. Install the input manifold (29) onto the clutch shaft being careful
not to damage the shaft seals.
19. Install the thrust washer (28) and side thrust bearing (27) against
the input manifold.
20. Install the needle bearing (26) onto the clutch shaft. Install the 2nd
speed driven gear (26) onto bearing.
21. Install the thrust washers (23) and side thrust bearing (24) and se-
cure with the retaining ring (22).
22. Install the spring retainer cup (21). Equally space the eight piston
return springs (12) around the cup.
23. Install the support plate (20) and retaining ring (19) as follows.
opening.
D87E-2 D87P-2 30-73 2

12
the retaining ring until it seats in the groove in the drum (6). Install
the drum and backing plate to the clutch shaft.

the same transmission oil) prior to assembling in the drum. Because
the facing is porous and absorbs oil, a light oiling is not sufficient.
Whenever possible, the discs must be soaked, for at least two min-
utes, in clean transmission oil. If facilities are not available for
soaking, a heavy oiling on both surfaces may be sufficient.
27. Install the 2nd speed piston (13) over the return springs (12) into
the drum. Install a new seal ring (16) to the lube sleeve (15) and po-
sition between the shaft and piston being careful not to damage the
seal ring.
28. Using two C clamps, compress the 2nd speed piston (13) and se-
cure with the retaining ring (14).

when assembling.
29. Install seal ring (10) and internal retaining ring (7) to the clutch
shaft.
30. Install a new seal ring (9) and piston seal (8) to the 2nd speed hub
(3). Install the hub into the drum (6) being careful not to damage
the seals. Secure with the retaining ring (2 & 5).
31. Heat the bearing cone (1) to 130°C for 45 minutes and install on the
hub until it bottoms. To assure that the cone is seated, keep pressure
against the cone until it cools down.
30-74 2 D87E-2 D87P-2

REVERSE
12 IDLER SHAFT
1. Reverse Idler Shaft 3. Tapered Roller Bearing 5. Tapered Roller Bearing

2. Reverse Idler Gear 4. Inner Bearing Spacer 6. Outer Bearing Spacer
SERVICE
★ Callouts from exploded view correspond with callouts in following

steps.
1. Place the shaft assembly in a press so the shaft (1) points up and the
gear (2) supports the assembly. Using a suitable driver, press the
shaft out of the gear. One bearing (3) will be pressed off with the
gear.
2. Remove the spacer (4) from shaft. If bearing or gear replacement is

necessary remove the bearing from the gear and shaft.
3. Reverse steps 1 & 2 to assemble.
D87E-2 D87P-2 30-75 2

MAIN
12 REGULATOR VALVE
1. Valve Housing
2. Top End Cover
3. Seal Ring
4. Lube Spool Return Spring
5. Lube Spool
6. Lube Spring Spool Shim
7. Converter Spool Return Spring
8. Converter Spool
9. Converter Spring Spool Shim
10. Main Spool Outer Return Spring
11. Main Spool Inner Return Spring
12. Spring Guide Pin
13. Main Spool
14. Inner and Outer Main Spring Shim
15. Bottom End Cover
16. Seal Ring
17. Spring Retaining Roll Pin
18. Check Ball Return Spring
19. Check Ball
20. Housing Port Plug
30-76 2 D87E-2 D87P-2

DISASSEMBLY
12
★ Callouts from the exploded view correspond with the callouts in

following steps.
1. Position the valve housing (1) into a vise, supporting the valve as
necessary.
2. Remove the bolts and lock washers from the end cover (2). Slowly
back off vise allowing springs to decompress.

when disassembling.
3. Remove the seal rings (3) from the valve housing and discard.
4. Remove the lube spool spring (4). Identify the spring for ease of
testing and assembly.
★ Check the spring for damage and fatigue against those values given
in SECTION 10.
D87E-2 D87P-2 30-77 2

12
5. Remove the lube spool (5) with the spring shims (6). Keep the re-
moved amount of shims with the spool.
★ A total quantity of 3 shims can used under the spool spring. Each
shim that is added or deleted will raise or lower the lube pressure
by 0.07 kg/cm².
★ The lube spool (5) and converter spool (8) are interchangeable. Do
not switch the spools in each others housing bore.
6. Remove the converter spool spring (7). Identify the spring for ease
of testing and assembly.
in SECTION 10.
7. Remove the converter spool (8) with spring shims (9). Keep the re-
moved amount of shims with the spool.
shim that is added or deleted will raise or lower the converter pres-
sure by 0.24 kg/cm².
★ The lube spool (5) and converter spool (8) are interchangeable. Do
not switch the spools in each others housing bore.
8. Remove the main spool outer spring (10). Identify the spring for
ease of testing and assembly.
in SECTION 10.
30-78 2 D87E-2 D87P-2

9. Remove the main spool inner spring (11). Identify the spring for
ease of testing and assembly.
in SECTION 10.
10. Remove the spring guide pin (12).
11. Remove the main spool assembly (13) with the spring shims (14).
Keep the removed amount of shims with the spool.
shim that is added or deleted will raise or lower the main pressure
by 0.35 kg/cm².
12. Remove the remaining end cover (15) and discard the seal rings
(16).
13. If necessary, disassemble the main spool as follows;
Rest the assembly on a block of wood. Using a pin drift, drive the
spring pin (17) from the spool (13) allowing the pin drift to retain
the spring (18). Carefully remove the pin drift allowing the check
ball spring to decompress. Remove the spring and check ball (19).

when disassembling.
in SECTION 10.
D87E-2 D87P-2 30-79 2

12
It is recommended that all new seal rings be installed upon assem-
bly of the valve.
Clean all the parts in a suitable solvent and blow dry with com-
INSPECTION
pressed air. Be sure all the oil passages in the valve housing are
clean and free of obstructions.
Inspect the parts for excessive wear and replace if necessary.
Inspect the condition of the springs. If they are damaged or do not
fall within the specifications given in SECTION 10, they must be
replaced.
ASSEMBLY
following steps.
1. Reassemble the main spool as follows;
A. Install the check ball (19) and the check ball spring (18) into
the spool (13). Compress the spring and secure with the spring
pin (17).

when assembling.
2. Install new seal rings (16) into the bottom of the housing and bolt
the bottom end cover (15) in place.
3. Install the main spool assembly (13) with same amount of shims
(14) that were removed.
shim added or deleted will raise or lower the main pressure by 0.35
kg/cm².
4. Install the spring guide pin (12) in the housing bore.
30-80 2 D87E-2 D87P-2

12
5. Install the main spool inner spring (11).
6. Install the main spool outer spring (7).
7. Install the converter spool (8) with the spring shims (9) that were
removed with the spool.
shim added or deleted will raise or lower the converter pressure by
0.24 kg/cm².
★ The lube spool (5) and the converter spool (8) are interchangeable.
Do not switch the spools in each others housing bore.
8. Install the converter spool spring (7).
D87E-2 D87P-2 30-81 2

12
9. Install the lube spool (5) with the spring shims (6) that were re-
moved with the spool.
shim added or deleted will raise or lower the lube pressure by 0.07
kg/cm².
★ The lube spool (5) and the converter spool (8) are interchangeable.
Do not switch the spools in each others housing bore.
10. Install the lube spool spring (4).
11. Install new seal rings (3) into the housing grooves.
12. Position the valve housing and the top end cover (2) in the vise.
30-82 2 D87E-2 D87P-2

12
13. Slowly close the vise and install the mounting hardware to the cov-
er.

when assembling.
D87E-2 D87P-2 30-83 2

RANGE
12 SELECTOR VALVE
DISASSEMBLY
1. End Cover
2. Speed Spool
3. Return Spring
4. Return Spring
5. Short Directional Spool
6. End Cover
7. Long Directional Spool
8. Speed Spool
9. Large Seal Ring
10. Small Seal Ring
11. Port Plug
12. Valve Housing
30-84 2 D87E-2 D87P-2

12
1. Slowly loosen the end cover (1) bolts until all the spring tension is
relieved. Remove the end cover.

when disassembling.
2. Remove the speed spool (2) from the housing.
★ The spool is to be kept with the housing bore side that it was re-
moved from.
3. Remove the speed spool return spring (3) from the housing bore.
in SECTION 10.
4. Remove the directional spool return spring (4) from the housing
bore.
in SECTION 10.
D87E-2 D87P-2 30-85 2

12
5. Remove the short directional spool (5) from the housing bore.
moved from.
6. Remove the remaining end cover (6).
7. Remove the long directional spool (7) from the housing bore.
moved from.
8. Remove the remaining speed spool (8) from housing bore.
moved from.
30-86 2 D87E-2 D87P-2

12
9. Remove the large (9) and small (10) seal rings from each end of the
housing. Discard the seal rings and replace with new.

bly of the valve.
Clean all parts in a suitable solvent and blow dry with compressed
INSPECTION
air. Be sure all the oil passages in the valve housing are clean and
free of obstructions.
fall within the specifications as given in SECTION 10, they must
be replaced.
ASSEMBLY
★ Callouts from the exploded view correspond with the callouts in

following steps.
1. Coat the new large (9) and small (10) seal rings with amber grease
and install in the counter bores in each end of the housing.
2. Install the speed spool (8) into its housing bore.
3. Install the long directional spool (7) into its housing bore.
4. Install the end cover (6) and secure with the hardware.
D87E-2 D87P-2 30-87 2

12
5. Install the short directional spool (5) into its housing bore.
6. Install the directional spool return spring (4) into the spool.
7. Install the speed spool return spring (3) into the spool.
8. Install the remaining speed spool (2) into its housing bore.
30-88 2 D87E-2 D87P-2

12
9. Install end cover (8) and secure with hardware.

when assembling.
D87E-2 D87P-2 30-89 2

RATE
12 OF RISE VALVE
1. End Cover
2. End Cover Gasket
3. Sequence Spool Spring
4. Tube Spacer
5. Sequence Spool Disc
6. Dowel Pin
7. Outer Piston Return Spring
8. Piston Return Spring Retainer
9. Inner Piston Return Spring
10. Modulating Piston
11. End Cover
12. End Cover Gasket
13. Reducing Spool
14. Reducing Spool Return Spring
15. Sequence Spool
16. Spool Spacer
17. Valve Housing
30-90 2 D87E-2 D87P-2

DISASSEMBLY
12
following steps.
1. While holding down on the end cover (1), slowly let off the mount-
ing bolts until all the spring tension is released. Then remove the
cover.

when disassembling.
2. Remove and discard the end cover gasket (2).
3. Remove the sequence spool spring (3) from the housing bore.
in SECTION 10.
4. Remove the tube spacer (4) from the housing bore.
5. Remove the sequence spool disc (5) from the housing bore.
D87E-2 D87P-2 30-91 2

12
6. Remove the dowel pin (6) from the housing bore.
7. Remove the outer piston spring (7) from the housing bore.
in SECTION 10.
8. Remove the piston spring retainer (8) from the housing bore.
9. Remove the inner piston spring (9) from the housing bore.
in SECTION 10.
10. Remove the modulating piston (10) from the housing bore.
11. Slowly remove the end cover (11) hardware until all the spring ten-
sion is released. Remove the cover.

when disassembling.
30-92 2 D87E-2 D87P-2

12
12. Remove and discard the end cover gasket (12).
13. Remove the reducing spool (13) from the housing bore.
14. Remove the reducing spool spring (14) from housing bore.
in SECTION 10.
15. Remove the sequence spool (15) from the housing bore.
16. Using a wooden dowel pin, insert into the housing bore up against
the sequence spool spacer. Gently tap on dowel to dislodge the
spacer from the housing.
17. Remove the sequence spool spacer (16) from the housing (17).

bly of the valve.
Clean all parts in a suitable solvent and blow dry with compressed
INSPECTION
air. Be sure all the oil passages in the valve housing are clean and
free of obstructions.
fall within the specifications as given in SECTION 10, they must
be replaced.
D87E-2 D87P-2 30-93 2

ASSEMBLY
12
following steps.
1. Squarely seat the sequence spool spacer (16) into the housing bore.
2. Install sequence spool (15) into housing bore.
3. Install reducing spool spring (14) into housing bore.
4. Seat the reducing spool (13) in the housing bore.
5. Insert the aligning studs to the housing. Install a new end cover gas-
ket (12) to the housing.
30-94 2 D87E-2 D87P-2

12
6. Install the end cover (11) over the aligning studs and secure with
four bolts. Remove the aligning studs and install the remaining
bolts.

when assembling.
7. Install the modulating piston (10) into the housing bore.
8. Install the inner piston spring (9) into the modulating piston in the
housing bore.
9. Install the piston spring retainer (8) over the spring.
10. Install the outer piston spring (7) over the retainer.
11. Install the dowel pin (6) in the housing bore into the sequence spool
spacer.
12. Install the sequence spool disc (5) on the dowel pin.
D87E-2 D87P-2 30-95 2

13. Install the tube spacer (4).
14. Install the sequence spool spring (3) inside the tube spacer.
15. Insert the aligning studs to the housing. Install a new end cover gas-
ket (2) to the housing.
16. Install the end cover (1) over the aligning studs and secure with
four bolts. Remove the aligning studs and install the remaining
bolts.

when assembling.
30-96 2 D87E-2 D87P-2

PILOT
12 CONTROL VALVE AND MANIFOLD
Removal

blocking. Turn the ignition switch to the off position and re-
move the key. Disconnect the negative $ terminal at the bat-
tery.
1. Open the door at the left hand side of the machine and remove the
transmission suction oil filter behind the door.
2. Remove bolts and cover in order to get to the connecting bolts of

the pilot control valve and the manifold.
3. Remove the bolts securing the manifold to the bottom of the pilot
control valve and allow the manifold to lay in a drain pan at the bot-
tom of the control box. Discard the gasket.
4. Remove the control handle knob (1). Remove hardware and lift off
the housing (2).
5. Remove the pin and bolts from both sides of the pilot control valve.
Remove the valve.
Installation
Control handle knob............................................... Loctite #262
D87E-2 D87P-2 30-97 2

Disassembly
12
1. Detent Housing 5. Detent Balls 9. Detent Ball Retainer

2. Seal Ring 6. Pilot Control Valve Housing 10. Detent Cam
3. Detent Sleeve Return Spring 7. Valve Spool 11. Seal Ring
4. Detent Sleeve 8. Valve Spool Seal
30-98 2 D87E-2 D87P-2

12
following steps.
1. Position the valve in a vise, with the spool end down. Using a
wrench on the flats of the detent housing (1), slowly unthread the
housing until all spring tension is dissipated. Remove and discard
the seal ring (2) from the housing.

when disassembling.
2. Remove the detent spring (3) from the housing.
in SECTION 10.
3. Remove the detent sleeve (4).
4. Using a tool box magnet, remove the four detent balls (5).
5. Reposition housing (6) in vise and remove spool (7) in direction of

arrow.
6. Remove and discard the spool seal (8) from the housing.
7. Position the spool, on its flats, in a vise. Lift up on the ball retainer
(9) and remove detent cam (10).
D87E-2 D87P-2 30-99 2

12
8. Remove and discard the seal ring (11) from the detent cam.
It is recommended that new seal rings and spool seal be installed

upon assembly of the valve. Clean all parts in a suitable solvent
and blow dry with compressed air. Be sure all the oil passages in
INSPECTION
the valve housing are clean and free of obstructions. Inspect the
parts for excessive wear and replace if necessary.
Inspect the condition of the springs. If they are damaged or do not fall
within the specifications as given in SECTION 10, they must be re-
placed. Clean threads with a stiff brush and solvent. Check for dam-
age.
Assembly
★ Callouts from the exploded views correspond with the callouts in

the following steps.
1. Install a new seal ring (11) to the detent cam (10).
2. Install the ball retainer (5), flat bottom to threads, to the detent cam
(3). Apply Loctite #568 or Plastic Gasket to the threads of the cam.
Cam threads ........................................................... Loctite #568

or Plastic Gasket
3. Position the spool (7), on its flats, in a vise. Mount the detent cam
(3) with the ball retainer (5) to the spool.
Detent cam ..............................................................8 to 13 N•m
R = T X L ÷ (L + C)
T - Torque Required N•m
MULTIPLIED BY (x)
L - Wrench Length mm
DIVIDED BY (÷)
L - Wrench Length mm
PLUS (+)
C - Extension Length mm
EQUALS (=)
R - Reading on Scale N•m
4. Install a new seal (8) into the groove in the housing.
5. Build up a tapered incline of masking tape (A) at eye end of spool

(7). Make sure tape covers spool chamfer (B).
30-100 2 D87E-2 D87P-2

12
6. Coat taped end of spool and seal in housing with liberal coat of am-
ber grease.
7. From spring end of housing, insert spool being careful not to cut or
destroy seal lips. Remove the tape from the spool.
8. Position the housing in the vise. Install the four detent balls (6) into
the recesses in the ball retainer (5).
9. Install the detent sleeve (4).
10. Install the detent spring (3) over the sleeve.
11. Install a new seal ring (2) to the detent housing (1). Position the
housing over the spring and pushing down, thread into the valve
housing. Secure with a wrench.

when assembling.
D87E-2 D87P-2 30-101 2

Manifold
12
1. Manifold Housing 4. Check Ball 7. Seal Ring 10. Guide Spring

2. Connector 5. Check Ball Spring 8. Port Plug 11. Guide Pin
3. Seal Ring 6. Port Plug 9. Seal Ring 12. Dowel Pin
SERVICE
1. Disconnect the hoses from the manifold, tag them and remove the
two electrical sensors.
2. Remove plug (8) and check condition of parts (10, 11 and 12). Dis-
card and replace seal ring (9).
3. Remove the connector (2) and check the condition of parts (4 and
5) and seats inside the housing (1).
★ Check the springs (5 and 10) for damage and fatigue against those
values given in SECTION 10.
4. Install all parts with new seal rings and connect hoses and sensors.
30-102 2 D87E-2 D87P-2

TASC
12 VALVE
Removal

battery.

plugs and cap. If these are not available, tape or clean rubber corks
may be used. Hydraulic openings must never be plugged with rags.
This practice could introduce dirt or lint into critical hydraulic com-
ponents of the machine. Also tag all disconnected lines to facilitate
correct and easier installation.
1. Remove the left sided filter box (1) with door.
2. Remove the filter header mounting hardware (2) and allow the fil-
ter to be supported by the hoses.
3. Remove the inner access cover (3).
4. Disconnect and cap all hoses at the TASC valve (4).
5. Remove the control lever boot retaining plate (5).
6. Remove the stiffener ring (6) from the boot (7). Invert the boot up
along the control handle (8). Through the cover cutout disconnect
the control lever harness (9) from the wall.
7. Remove the mounting hardware from the TASC valve (4) and lift
from the bracket with the boot and control handle.
★ Be careful not to damage the reed switches (10) when removing the
TASC valve.
Installation
D87E-2 D87P-2 30-103 2

Disassembly
12
30-104 2 D87E-2 D87P-2

12
1. Valve Body 14. Range Spool 27. Bearing Housing 40. Switch Arm
2. Expander Plug 15. Thrust Bearing 28. Cam Ring 41. Ceramic Ring Magnet
3. Port Plug 16. Thrust Washer 29. Ball Bearing 42. Brass Screw
4. Steering Spool 17. Dowel Pin 30. Retaining Ring 43. Locking Bolt
5. Pickup Spacer 18. Hex Nut 31. Universal Joint 44. Wiper Seal
6. Inner Spring 19. Dowel Pin 32. Joint Boot 45. Wiper Seal
7. Outer Spring 20. Dowel Pin 33. Tie Strap 46. Wiper Seal
8. Directional Spool 21. Range Cam 34. Dowel Pin 47. Seal Ring
9. Spring Retainer Washer 22. Bottom Cover 35. Detent Ball 48. Seal Ring
10. Forward Reverse Spring 23. Cover Plug 36. Range Detent Spring 49. Seal Ring
11. Retainer Nut 24. Orifice Plug 37. Detent Guide
12. Spool Rocker End 25. Dowel Pin 38. Detent Guide Plug
13. Jam Nut 26. Motion Lever 39. Seal Ring
following steps.
1. Position the valve in press with the hole in the bearing housing (27)
aligned with the dowel pin in the motion lever (26). Apply the press
and drive the pin into the housing clearing the lever.
2. Remove the motion lever (26) with the bearing housing (27) from
the valve.
3. Position the assembly in a vise. Remove the hardware and separate

the bearing housing (27) from the cam ring (28).
4. Remove the motion lever (26) from the bearing housing.
5. Drive the outer bearing (29) from the housing
D87E-2 D87P-2 30-105 2

12
6. Remove the two internal retaining rings (30) from the bearing
housing. Drive the remaining inner bearing (29) from the housing.
7. Cut and remove the tie straps (33) from the joint boot (32).
8. Remove the boot (32) from the universal joint.
9. Loosen the bolt (43) on the switch arm (40).
10. Remove the spool rocker end (12) and jam nut (13) from each
spool.
30-106 2 D87E-2 D87P-2

12
11. With the switch arm (40) positioned out of the way, remove the
dowel pin (34) connecting the universal joint (31) to the range
spool.
12. Remove the universal joint (31).
13. Remove the switch arm (40) and position in a vise.
14. Break the loctite bond of the brass screw (42).
15. Remove the brass screw (42) and the ceramic magnet (41) from the
switch arm (40).
D87E-2 D87P-2 30-107 2

12
16. Remove the detent guide plug (38) and discard the seal ring (39).

when assembling.
17. Remove the spring (36), detent guide (37) and detent ball (35).
18. Remove the two opposite side mounting bolts.
19. Install two threaded rods with washers and nuts to the vacated
mounting holes.
20. Remove remaining two mounting bolts.
21. Let off each nut until all spring tension is relieved.

when assembling.
30-108 2 D87E-2 D87P-2

12
22. Remove tthe hreaded rods and the bottom cover (22) from the
valve.
23. Remove and discard the seal rings (47, 48 and 49) from the bottom
cover (22).
24. Remove the outer spring (7).
25. Remove the inner spring (6).
D87E-2 D87P-2 30-109 2

12
26. Remove the pick up spacer (5) from each steering spool (4).
27. Remove the forward reverse spring (10) at each directional spool in
the valve body.
28. Remove the two steering spools (4) from the valve body.
29. From under the valve body, push the directional spool (8) up and
out of the valve body. Repeat for the remaining spool.
30-110 2 D87E-2 D87P-2

12
30. Install two nuts on the directional spool (8) and position in a vise.
Remove the loctited nut from the spool.
31. Remove the spring retaining washer (9) from the spool.
32. From under the valve body, push the range selector spool (14) up
and out of the valve body.
33. Position the range selector spool (14) in a vise. Remove the retain-
ing nut (18) from the spool.
★ The nut is retained with Loctite.
34. Remove the range cam (21) from the spool
35. If necessary, remove the dowel pin(s) (19 and/or 20).
D87E-2 D87P-2 30-111 2

12
36. Remove the top thrust washer (16).
37. Remove the thrust bearing (15).
38. Remove the bottom thrust washer (16).
39. Remove and discard the range selector wiper seal (46) from the
valve body.
40. Remove and discard the steering spool wiper seal (44) and the di-
rectional spool wiper seal (45) from the valve body.
30-112 2 D87E-2 D87P-2

12
41. Remove the orifice plugs (24) from the bottom cover (22).
42. Discard all software and replace with new.
Reassembly

following steps.
1. Install the orifice plugs (24).
Orifice plugs ................................................................. 2.7 N•m
2. Install new wiper seals (44 and 45), with the U cup portion facing
down, to the spool bores in the valve body.
3. Install new wiper seal (46), with the U cup portion facing down, to
the center spool bore in the valve body.
4. Install the bottom thrust washer (16) to the range selector spool.
5. Lightly coat the thrust bearing (15) with clean oil and install on the
thrust washer.
D87E-2 D87P-2 30-113 2

12
6. Install the outer thrust washer (16) on the thrust bearing (15).
7. If removed, press the dowel pins (19 and/or 20) flush with the
stepped surface of the range cam (21). Install the range cam align-
ing dowel pin (17) with the hole to the range selector spool (14).
8. Apply Loctite #242 to the threads of the nut (18).
Nut ......................................................................... Loctite #242
9. Install the nut.
Nut ................................................................................. 54 N•m
10. Position the valve body (1) bottom side facing up in a vise. Install
the range selector spool (14) into the body using a slight turning
motion to aid the spool to pass through the wiper seal.
11. With the directional spool nutted in a vise, install the spring retainer
washer (9).
12. Apply Loctite #242 to the nut threads, and install the nut (11).
Nut ......................................................................... Loctite #242

Nut ................................................................................. 22 N•m
30-114 2 D87E-2 D87P-2

12
13. Install the directional spool (8) into the body using a slight turning
motion to aid the spool pass through the wiper seal.
14. Install the steering spool (4) into the body using a slight turning
motion to aid the spool pass through the wiper seal.
15. Install the forward reverse springs (10) in the recessed bores.
16. Install the pick up spacers (5) over the steering spools with the re-
cessed area towards the valve body.
D87E-2 D87P-2 30-115 2

12
17. Install the inner springs (6) to the steering spools.
18. Install the outer springs (7) to the steering spools.
19. Check the alignment of the range selector spool as follows:
A. Position the bottom cover (22) with the offset dowel pin hole
to the dowel pin (25). Align the spool range cam dowel pins
with the offset recess in the bottom cover.
20. Install two threaded rods to the valve body.
30-116 2 D87E-2 D87P-2

12
21. Install new seal rings (47, 48 and 49) to the bottom cover (22).
22. With the bottom cover (22) aligned per Step 19, install over the
threaded rods. Draw down equally on the nuts until the cover is
flush.
★ Be careful not to bind the cover to the dowel pins.
23. Install the hardware at the open holes. Remove the threaded rods
and install the remaining hardware.
24. Torque the mounting hardware.
Bolts ............................................................................... 38 N•m
25. Apply clean grease to the detent ball (35) to hold it in the guide
(37). Install the guide with the ball, spring (36) and cap with the
plug (38) with new seal ring (39). Torque the plug.
.
Plug ................................................................................ 20 N•m
D87E-2 D87P-2 30-117 2

12
26. Coat the brass screw (42) with Loctite #242.
Brass screw ............................................................ Loctite #242
27. Install the ceramic ring magnet (41) to the switch arm (40) with the
brass screw (42) and tighten.
28. Slide the switch arm (40) over the universal joint, making sure that
the magnet (41) is on the top side of the arm and the locking bolt
(43) is aligned with the counter sunk hole in the universal joint.
29. Slide the universal joint over the range spool making sure that the
switch arm points to the cast indentation in the valve body.
30-118 2 D87E-2 D87P-2

12
30. Drive the dowel pin (34) in making sure it is countersunk at each
end.
31. Apply Loctite #242 to the bolt (43) threads. Align the switch arm
(40) over the locking hole on the universal joint (31) and lock the
bolt in.
Bolt......................................................................... Loctite #242
32. Apply Komatsu Super Grease to the universal joint.
Universal joint....................................... Komatsu Super Grease
33. Install the boot (32) over the universal joint (31) and secure with
the tie straps (33).
D87E-2 D87P-2 30-119 2

12
34. Install the jam nuts (13) and the spool rocker ends (12) to each
spool.
35. Start the dowel pin (34) into the universal joint.
36. Install the two retaining rings (30) inside the bearing housing (27).
37. Press the bearings (29) into the housing against the retaining rings.
38. Attach the bearing housing to the cam ring and torque the bolts.
Bolts ............................................................................... 11 N•m
30-120 2 D87E-2 D87P-2

12
39. Install the bearing housing (27) over the universal joint (31), plac-
ing the dowel pin through the opening in the bearing housing.
40. Install the motion lever (26) and align with the dowel pin. Drive the
pin into the universal joint so that it completely clears the bearing
housing (27).
Adjustment
1. Apply a generous amount of Komatsu Super Grease to the cam ring

surface.
2. Run all four spool rocker ends (12) up against the cam plate until
the motion lever (26) is vertical with no free play between the cam
ring and rocker ends.
3. Move the motion lever fully in all directions to seat the range selec-
tor spool against the needle bearing. Recheck for free play between
the cam ring and rocker ends and correct as necessary.
4. Tighten the jam nuts to the spool rocker ends.
D87E-2 D87P-2 30-121 2

DISASSEMBLY AND ASSEMBLY NEUTRAL START VALVE
NEUTRAL
12 START VALVE
REMOVAL

battery.

4. Disconnect the harness from the clutch pressure switch (4) and so-
lenoid (5) at the neutral start valve (6).
5. Disconnect and cap the three hoses at the neutral start valve. Re-
move the mounting hardware and lift the valve from the machine.
INSTALLATION
DISASSEMBLY
following steps.
1. If neccesaary, remove the clutch pressure switch (1) from the valve
body.
30-122 2 D87E-2 D87P-2

DISASSEMBLY AND ASSEMBLY NEUTRAL START VALVE
12
2. Remove the solenoid (2) from the valve block (5). Remove and dis-
card the seal kit (4) and replace with new.
3. Install a new seal kit to the solenoid as shown in the illustration. In-
stall the solenoid to the valve block (5) and tighten.
Solenoid ......................................................................... 41 N•m
Coil nut, if neccessary........................................... 6.7 N•m max
4. Remove the sequence valve (3) from the valve block (5). Remove
and discard the seal kit (6) and replace with new.
5. Install a new seal kit to the sequence valve as shown in the illustra-
tion. Install the sequence valve to the valve block and tighten.
Sequence valve .............................................................. 27 N•m
D87E-2 D87P-2 30-123 2

DISASSEMBLY AND ASSEMBLY STEERING CONTROLLER
STEERING
12 CONTROLLER
REMOVAL

battery.

4. Disconnect the wiring harness (4) at the controller (5). Remove

mounting hardware and lift from machine.
INSTALLATION
SERVICE
★ Inside the controller, there are three automotive type fuses installed.
Using a puller remove the blown fuse and replace with new.
30-124 2 D87E-2 D87P-2

DISASSEMBLY AND ASSEMBLY REGULATOR VALVE
REGULATOR
12 VALVE
REMOVAL

battery.

1. Open the left side filter box (1) door.
2. Disconnect and cap the hoses at the regulator valve (2). Remove the
mounting hardware and lift the valve from the machine.
INSTALLATION
Carry out installation in the reverse order of removal.
D87E-2 D87P-2 30-125 2

DISASSEMBLY AND ASSEMBLY REGULATOR VALVE
SERVICE
12
following steps.
1. Remove the valve cartridge (1) from the valve block (2). Remove
2. Install a new seal kit to the valve cartridge as shown in the illustra-
tion. Install the valve cartridge to the valve block and tighten.
Valve cartridge ............................................................. 475 N•m
30-126 2 D87E-2 D87P-2

DISASSEMBLY AND ASSEMBLY STEERING DRIVE
STEERING
12 DRIVE
REMOVAL
battery.
chine.
★ Before removing the steering drive perform diagnostics of failures

and check for oil leaks, so as to be sure that the disassembly of the
steering drive is advisable.

1. Drain the hydraulic reservoir and the drive train system. Refer to
the Operation & Maintenance Manual.
2. Remove the fuel tank ...................................Refer to FUEL TANK.
3. 3 Lever Drive Control; Disconnect the pressure supply hose (1) and
the two pressure check hoses (2). Disconnect clevis (3) from the
steering valve levers. Remove the mounting hardware from both
sides securing the steering valve (4) to the main frame cover (5)
and remove the valve. Discard the gasket. Cover the steering valve
opening to prevent dirt from entering the system.
3. 1 Lever Drive Control; Disconnect the pressure supply hose (1A)

and the two pressure check hoses (2A). Disconnect clevis (3A)
from the steering valve levers. Disconnect the two pilot hoses (4B)
and the drain hose (4C) at the high low valve (4D). Disconnect wir-
ing harness (4E) at the two solenoids. Remove the mounting hard-
ware from the steering valve (4A) to the main frame cover (5A) and
remove the valve. Discard the gasket. Cover the steering valve
opening to prevent dirt from entering the system.
D87E-2 D87P-2 30-127 2

12
4. 3 Lever Drive Control; Remove the rear main frame dipstick (6).
Install lifting eyes and remove the main frame cover (5).
4. 1 Lever Drive Control; Remove the rear main frame dipstick (6).
Install lifting eyes and remove the main frame cover (5).
5. Remove the dipstick tube (7) from the rear surface of the main
frame. Remove the bolt securing the lube tube (8) to the support
bracket. Disconnect the tube from the steering drive and pull the
tube free of the main frame.
6. Remove the pinion access cover (9) with seal ring from each final
drive.
7. Remove the snap ring (10) that secures the retainer (11) in the pin-
ion gear. Thread a bolt in the retainer and pull it out of the pinion
gear. Thread a bolt in the steering drive output shaft (12) and pull it
free of the steering drive.
8. Attach a hoist with an adjusting sling to the steering drive (13) and
take up the slack. An adjusting sling must be used so that the steer-
ing drive can be tilted and leveled.
9. Remove the bolts securing the steering drive to the front surface of
the main frame. Move the steering drive back as far as possible, be-
ing sure the spline sleeve stays with the steering drive.
10. On machines equipped with a cab, it is necessary to lower the steer-

ing drive and rotate it, to clear the back of the cab, before raising
and removing the steering drive. Therefore, before removing the
steering drive, the rear frame suction tube mounting bolts should be
removed, allowing the tube to be shifted to prevent damage. Lift
the steering drive up 100 mm and then tilt it back so that the mount-
ing flanges will clear the main frame opening. Set the assembly
down, disconnect the manifold hoses from the steering drive and
remove the manifold with hoses.
INSTALLATION
Valve to rear cover ................................................. Loctite #504
Valve bolts.................................................................... 100 N•m
Rear cover to frame................................................ Loctite #504
Rear cover bolts ........................................................... 265 N•m
Steering drive to frame .......................................... Loctite #504
Steering drive to frame bolts........................................ 735 N•m

nanace Manual.
nanace Manual.
30-128 2 D87E-2 D87P-2

STEERING
12 UNIT
DISASSEMBLY
D87E-2 D87P-2 30-129 2

12
1. Bearing Retainer 37. Lock Ball 73. Separator Plate 109. High Clutch Piston
2. Bearing Retainer Shims 38. Thrust Washer 74. Brake Piston 110. Piston Seal
3. Side Thrust Bearing 39. Needle Bearing 75. Piston Seal 111. Back Up Ring
4. Thrust Washer 40. Carrier Bearing 76. Back Up Ring 112. Piston Seal
5. Retainer Cover 41. Side Thrust Bearing 77. Piston Seal 113. Back Up Ring
6. Low Clutch Piston 42. Thrust Washer 78. Back Up Ring 114. Retaining Ring
7. Piston Seal 43. Not Assigned 79. Brake Plate Retainer 115. Clutch Plate Retainer
8. Back Up Ring 44. Spring Retainer 80. Friction Disc 116. Piston Retainer Hub
9. Piston Seal 45. Retaining Ring 81. Separator Plate 117. Oil Slinger
10. Back Up Ring 46. Ring Shims 82. Sleeve Retainer Washer 118. Rear Retaining Ring
11. Piston Return Spring 47. Inner Return Spring 83. Retaining Ring 119. Nut Lock Ring
12. Spring Shim 48. Outer Return Spring 84. Output Sleeve 120. Adjusting Nut
13. Piston Actuator Spring 49. Ring Gear 85. Sun Gear Hub 121. Main Housing
14. Plate Retainer 50. Ring Gear Adapter 86. Bearing Retaining Ring 122. Spiral Ring Gear
15. Friction Disc 51. Friction Disc 87. Sun Gear 123. Ring Gear Hub
16. Separator Plate 52. Separator Plate 88. Gear Bearing 124. Tongued Washer
17. Brake Piston 53. High Clutch Piston 89. Retaining Ring 125. Adjusting Nut
18. Piston Seal 54. Piston Seal 90. Planet Gear Carrier 126. Lock Washer
19. Back Up Ring 55. Back Up Ring 91. Oil Scoop 127. Bearing Carrier
20. Piston Seal 56. Piston Seal 92. Planet Gear Shaft 128. Tapered Roller Bearing
21. Back Up Ring 57. Back Up Ring 93. Planet Gear 129. Shaft Seal Rings
22. Brake Plate Retainer 58. Bearing Retainer 94. Lock Ball 130. Plate Retainer
23. Friction Disc 59. Bearing Retainer Shims 95. Thrust Washer 131. Oil Slinger
24. Separator Plate 60. Side Thrust Bearing 96. Needle Bearing 132. Tapered Roller Bearing
25. Sleeve Retainer Washer 61. Thrust Washer 97. Carrier Bearing 133. Pinion Gear Housing
26. Retaining Ring 62. Retainer Cover 98. Side Thrust Bearing 134. Housing Shims
27. Output Sleeve 63. Low Clutch Piston 99. Thrust Washer 135. Retaining Ring
28. Sun Gear Hub 64. Piston Seal 100. Spring Retainer 136. Pinion Gear Shaft
29. Bearing Retaining Ring 65. Back Up Ring 101. Retaining Ring 137. Tongued Washer
30. Sun Gear 66. Piston Seal 102. Ring Shims 138. Lock Nut
31. Gear Bearing 67. Back Up Ring 103. Inner Return Spring 139. Lock Washer
32. Retaining Ring 68. Piston Return Spring 104. Outer Return Spring 140. Tapered Roller Bearing
33. Planet Gear Carrier 69. Spring Shim 105. Ring Gear 141. Tapered Roller Bearing
34. Oil Scoop 70. Piston Actuator Spring 106. Ring Gear Adapter 142. Housing Dowel Pin
35. Planet Gear Shaft 71. Plate Retainer 107. Friction Disc
36. Planet Gear 72. Friction Disc 108. Separator Plate
30-130 2 D87E-2 D87P-2

12
following steps.
1. Set the assembly on end so that the right hand side is up. Remove
the bearing retainer (1) and shims (2). Keep the shims with the re-
tainer for proper assembly.
2. Remove the side thrust bearing (3) and thrust washers (4).
3. Remove four bolts equispaced around the retainer cover (5). Install
threaded rod with washers and nuts and tighten. Remove the re-
maining hardware securing the cover. Slowly loosen the nuts until
all spring tension is released. Lift the cover with low range clutch
piston (6) and seals (7 through 10). To remove the piston from the
cover, apply compressed air to the port in the cover. Remove and
discard the piston seals (7 and 9) and back up rings (8 and 10) from
the cover.

when disassembling.
4. Remove the springs (11), shims (12) (if equipped) and springs (13).
D87E-2 D87P-2 30-131 2

5. Remove the bolts securing the brake plate retainer (14) and lift the
retainer with the friction discs (15) and the separator plates (16)
from the assembly. Remove the discs and plates from the retainer.
6. Remove the brake piston (17) from the brake plate retainer, using
compressed air. Remove and discard the seal rings (18 and 20) and
back up rings (19 and 21) from the brake piston.
7. Lift the brake plate retainer (22) with the friction discs (23) and
separator plates (24) from the assembly. Remove the discs and
plates from the retainer.
30-132 2 D87E-2 D87P-2

12
8. Remove the hardware securing the sleeve retaining washer (25) to
the shaft.
9. Remove the retaining ring (26) and the output sleeve (27).
10. Pull the sun gear hub (28) together with attaching parts (29 through
32) off the shaft of the planet carrier.
11. Remove the bearing retainer ring (29) from the gear hub (28). Place
the hub in a press with the sun gear (30) up and press the gear, to-
gether with the bearing (31) and the retaining ring (32), out of the
hub. Remove the retaining ring (30) from the sun gear (31).
D87E-2 D87P-2 30-133 2

12
12. Remove the planet gear carrier (33) with attached parts (34 through
39).
13. Disassemble the planet carrier as follows;
A. Remove the two bolts, securing the oil scoop (34) and remove
the scoop. Turn the planet carrier (33) over and drive the planet
gear shaft (35) from the gear (36) and the carrier. When remov-
ing the shaft, be careful not to lose the lock ball (37).
B. Slide the planet gear to the outside, placing one hand under the
gear as the washers (38) and bearing (39) are free to drop out.
Remove the bearing from the planet gear.
14. Remove the two remaining planet gears from the planet carrier in
the same manner described in Step 13.
15. Remove the bearings (40) from the planet carrier.
16. Remove the thrust washers (41) and the side thrust bearing (42)
from the ring gear hub.
17. Install three bolts with nuts and washers through the return spring
retainer (44) and thread them into the tapped holes in the clutch pis-
ton. Turn the nuts down to compress the springs and remove the
spring retaining ring (45) and shims (if equipped). Slowly back off
the nuts to completely relieve the spring tension and remove the re-
maining bolts.
30-134 2 D87E-2 D87P-2

12 WARNING! SPRING LOADED ASSEMBLY. Assembly must

when disassembling.
18. Remove the retainer, shims (46) (if equipped) and return springs
(47 and 48).
19. Remove the hardware securing the ring gear (49) and adapter (50)
to the clutch plate retainer. Remove the ring gear, adapter, separator
plates (51) and friction discs (52).
20. Thread two bolts into the tapped holes in the high range clutch pis-
ton (53) and remove. Remove and discard the piston seals (54 and
56) and back up rings (55 and 57).
D87E-2 D87P-2 30-135 2

12
21. Set the assembly on end so that the left hand side is up. Remove the
bearing retainer (58) and the shims (59) (if equipped). Keep the
shims with the retainer for proper installation.
22. Remove the side thrust bearing (60) and the thrust washers (61).
23. Remove four bolts equispaced around the retainer cover (62). In-
stall threaded rod with washers and nuts and tighten. Remove the
remaining hardware securing cover. Slowly loosen the nuts until all
spring tension is released. Lift the cover with low range clutch pis-
ton (63) and seals (64 through 67). To remove the piston from the
cover, apply compressed air to the port in the cover. Remove and
discard the piston seals (64 and 65) and back up rings (66 and 67)
from the cover.

when disassembling.
30-136 2 D87E-2 D87P-2

24. Remove the springs (68), shims (69) (if equipped) and springs (70).
25. Remove the bolts securing the plate retainer (71) and lift the retain-
er with the friction discs (72) and the separator plates (73) from the
assembly. Remove the discs and plates from the retainer.
26. Remove the brake piston (74) from the brake plate retainer, using
compressed air. Remove the seal rings (75 and 77) and back up
rings (76 and 78) from the brake piston.
D87E-2 D87P-2 30-137 2

12
27. Lift the plate retainer (79) with the friction discs (80) and the sepa-
rator plates (81) from the assembly. Remove the discs and plates
from the retainer.
28. Remove the hardware securing the sleeve retaining washer (82) to
the shaft.
29. Remove the retaining ring (83) and the output sleeve (84).
30. Pull the sun gear hub (85) together with attaching parts (86 through
89) off the shaft of the planet carrier.
30-138 2 D87E-2 D87P-2

31. Remove the bearing retainer ring (86) from the gear hub (85). Place
the hub in a press with the sun gear (87) up and press the gear, to-
gether with the bearing (88) and retaining ring (89), out of the hub.
Remove the retaining ring from the sun gear.
32. Remove the planet gear carrier (90) with attached parts (91 through
96).
33. Disassemble the planet carrier as follows;
A. Remove the two bolts, securing the oil scoop (91) and remove
the scoop. Turn the planet carrier (90) over and drive the planet
gear shaft (92) from the gear (93) and the carrier. When remov-
ing the shaft, be careful not to lose the lock ball (94).
B. Slide the planet gear to the outside, placing one hand under the
gear as the washers (95) and bearing (96) are free to drop out.
Remove the bearing from the planet gear.
34. Remove the two remaining planet gears from the planet carrier in
the same manner described in Step 33.
35. Remove the bearings (97) from the planet carrier shaft.
36. Remove the thrust washers (98) and the side thrust bearing (99)
from the ring gear hub.
D87E-2 D87P-2 30-139 2

37. Install three bolts with nuts and washers through the return spring
retainer (100) and thread them into the tapped holes in the clutch
piston. Turn the nuts down to compress the springs and remove the
spring retaining ring (101) and shims (102). Slowly back up on the
nuts to completely relieve the spring tension and remove the bolts.

when assembling.
38. Remove the retainer, shims (102) (if equipped) and the return
springs (103 and 104).
39. Remove the bolts securing the ring gear (105) and adapter (106) to
the clutch plate retainer. Remove the ring gear, adapter, separator
plates (107) and friction discs (108).
30-140 2 D87E-2 D87P-2

12
40. Thread two bolts into the tapped holes in the high range clutch pis-
ton (109) and remove. Remove and discard the piston seals (110
and 112) and back up rings (111 and 113).
41. Remove the retainer ring (114) from the ring gear hub.
42. Install two bolts into the tapped holes in clutch plate retainer (115)
and lift it out along with the piston retainer hub (116). Remove the
bolts securing the retainer to the piston retainer hub and separate.
Remove the oil slingers (117) from the retainer.
D87E-2 D87P-2 30-141 2

12
43. Position the main housing on blocking with the pinion gear housing
facing down. Remove the rear retaining ring (118). Remove the
hardware securing the nut lock ring (119) to the housing and re-
move with the adjusting nut (120).
44. Turn the housing (121) over so that the ring gear side is facing up.
Remove two of the bolts that secure the ring gear (122) to the ring
gear hub (123) and install eyebolts.
45. Attach a hoist to the eyebolts and lift out as an assembly.
46. Bend up the tabs of the tongued washer (124) and remove the nut
(125), washer, and lock washer (126).
30-142 2 D87E-2 D87P-2

12
47. Thread the adjusting nut (120) on the bearing carrier (127) and in-
stall a bearing puller.
48. Pull up on the carrier to unseat the bearing cone (128). Remove the
bearing cone and carrier. Remove the nut from the carrier.
49. Remove the seal rings (129) from the hub (123) and discard. Re-
move the ring gear (122) and the retainer (130) from the hub. Re-
move the oil slingers (131) from the retainer.
50. If bearing replacement is necessary, remove the bearing cone (132)

from the hub (123) and remove the bearing cups from the carrier
(127).
D87E-2 D87P-2 30-143 2

12
51. Remove the bolts securing the pinion gear housing (133) and shims
(134) to the main housing (121). Remove the pinion gear assembly.
52. Remove the retaining ring (135) from the pinion gear shaft (136).
53. Bend up the tabs of the tongued washer (137) and remove the lock
nut (138), lock washer (139) and the tongued washer from the pin-
ion gear shaft.
54. Press the pinion gear shaft (136) out of the housing. When the shaft
is pressed out, the bearing cone (140) can be lifted out of housing.
55. Press the bearing cone (141) off the gear shaft.
56. If bearing replacement is necessary, remove the bearing cups (140

and 141) from the housing.
30-144 2 D87E-2 D87P-2

12
57. If replacement is necessary, remove the dowel pin (142) from the
main housing (121).
New seal rings and seal rings are to be installed whenever the steering
drive is disassembled for service.
Clean all parts thoroughly in a suitable solvent. Dry thoroughly with
compressed air or a clean cloth. Do not spin bearings with the com-
pressed air. Inspect bearings for excessive wear or damage and re-
place if necessary. Reusable bearings should be soaked in clean oil
and wrapped with clean paper until ready for assembly.
Inspect the gears for wear or chipped or broken teeth. Replace if wear
is excessive or teeth are damaged. Inspect all splines for wear. Re-
place parts if wear is excessive. Slight burrs can be smoothed down
INSPECTION
with a stone.
Inspect the separator plates and friction discs for excessive wear or
tolerance parts.
Check the compression springs for damage and fatigue. If they do not
fall within the tolerances given in SECTION 10, they must be re-
placed.
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 0.254 mm. If the cover does not meet this requirement, the cover
should be replaced.
ASSEMBLY
following steps.
1. If the dowel pin (142) was removed, install a new pin in the hous-
ing (121) flush.
D87E-2 D87P-2 30-145 2

12
2. If the bearing cups (140 and 141) were replaced, press the new cups
in the housing until they bottom.
3. Heat the bearing cone (141) to 120°C for 45 minutes and press on
the pinion gear shaft (136) until it bottoms.
4. Insert the pinion gear shaft (136) in the flange end of the housing
(133). Place the assembly in a press. Heat the bearing cone (140) to
120°C for 45 minutes and press the on the cone until it clears the
threads on the shaft.
5. Install the tongued washer (137) and lock washer (139). Thread the
adjusting nut (138) on finger tight.
6. Wrap a cord around the 200 mm diameter of the pinion support

housing (133) and attach a spring scale. Take a reading of the drag
needed to keep the housing rolling at an even pace. Tighten the ad-
justing nut (138) until a reading of 13 to 18 N is obtained.
★ The initial pull needed to start the housing rolling will be greater.
Do not use this reading for the adjustment.
7. Bend back the tabs of the tongued washer (137). Install the retain-
ing ring (135) in the groove of the pinion gear shaft (80).
8. Install the pinion housing (133) to the main housing (121) with the
same amount of shims (134) previously removed and secure with
hardware.
Pinion housing bolts..................................................... 108 N•m

★ Record the etched dimension (A) located at the spline end of the
pinion gear shaft.
30-146 2 D87E-2 D87P-2

12
9. If the bearing cone (132) was removed, heat the cone to 120°C for
45 minutes and install on gear hub (123) until it bottoms. To assure
the cone is seated, keep pressure against it until it cools a few sec-
onds.
10. Position the oil slingers (131) on the clutch plate retainer (130) and
secure with hardware. Install the retainer on the ring gear hub (123)
and secure with hardware. Install the ring gear (122) on the gear
hub and secure with hardware. Install new seal rings (129) to the
shaft.
Oil slinger bolts...................................................... Loctite #262
Oil slinger bolts.............................................................. 11 N•m
Hub retainer bolts........................................................... 54 N•m
Ring gear bolts ............................................................. 258 N•m
11. If the bearing cups (128 and 132) were removed, press the cups into
the carrier (127) until they bottom.
12. Install the bearing carrier (127) on the hub. Heat the bearing cone
(128) to 120°C for 45 minutes and install on the gear hub until it
contacts the bearing cup.
D87E-2 D87P-2 30-147 2

12
13. Install the tongued washer (126) and lock washer (124). Thread the
lock nut (125) on finger tight.
14. Wrap a cord around the 180 mm diameter of the bearing carrier
(61) and attach a spring scale. Take a reading of the drag needed to
keep the carrier rolling at an even pace. Tighten the nut (65) until a
reading of 18 to 22 N is obtained. Bend back the tabs of the lock
washer.
★ The initial pull needed to start the carrier rolling will be greater. Do
not use this reading for adjustment.
15. Set the main housing (121) down so that the right hand side is up.
Attach a hoist to the ring gear hub and lower it into the main hous-
ing being sure that the dowel pin (142) engages the slot in bearing
carrier. Lower the ring gear hub enmeshing the ring and pinion
gears, then remove the hoist.
16. Working through the opening in the top of the main housing (121),
measure the gap (A) between the end of the pinion gear shaft (136)
and the raised edge of the bearing carrier (61). This gap is stamped
on the end of the pinion gear shaft, see Step 8.
30-148 2 D87E-2 D87P-2

12
17. If necessary, remove or add shims (134) to obtain the correct gap.
18. Install the adjusting nut (120) onto the bearing carrier (127) hand
tight.
19. Adjust the ring gear and pinion gear shaft backlash as follows:
A. Tighten the adjusting nut (120) until the bolt holes in the nut
line up with the bolt holes in the main housing and there is lit-
tle or no gear backlash. Install the lock ring (119) and secure
with hardware
Lock ring bolts ............................................................... 54 N•m

B. Position a dial indicator on the main housing so that the pointer
rests against the heel of a pinion gear shaft tooth.
C. Hold the ring gear stationary and turn the pinion gear to the
limit of its movement. Set the indicator to zero. Next move the
pinion gear shaft to its limit of free play while holding the ring
gear stationary and note the indicator reading.
D. Repeat Steps B and C at four equidistant points on the ring

gear and adjust for the minimum backlash at the tightest point.
Required gear backlash .................................. 0.254 to 0.33 mm
E. To change the gear backlash, remove the nut lock ring (119)
and turn the adjusting nut (120). Backlash is changed in incre-
ments of 0.08 mm by turning the nut until the next bolt pattern
lines up between the nut and the housing. Reinstall the nut lock
ring and secure with hardware. Recheck gear backlash.
Lock ring bolts ............................................................... 54 N•m
D87E-2 D87P-2 30-149 2

12
20. Install the rear retaining ring (118) to the shaft.
21. Install the piston retainer hub (116) on the gear hub bottoming it
against the rear retainer ring. Position the oil slingers (117) on the
clutch plate retainer (115) and secure with hardware. Install the re-
tainer on the ring gear hub (123) and secure with hardware. Install
retainer ring (114).
Oil slinger bolts...................................................... Loctite #262
Oil slinger bolts.............................................................. 11 N•m
Clutch plate retainer bolts .............................................. 54 N•m
22. Install new back up rings (111 and 113) and piston seals (110 and
112) to the piston (109) and the piston retainer hub (116).
30-150 2 D87E-2 D87P-2

12
23. Using two eye bolts install the high clutch piston in place being
careful not to damage the piston seals.
externally splined separator plate (108) in the clutch plate retainer.
Install the ring gear (105) and adapter (106) to the clutch plate re-
tainer and secure with hardware.
Ring gear bolts ............................................................... 54 N•m
★ The internally splined friction disc must be thoroughly oiled prior

to assembling in the hub. Because the friction disc facing is porous
and absorbs oil, a light oiling may not be sufficient. When possible,
the plates must be soaked, for at least two minutes, in a container of
clean oil. If facilities are not available for soaking, a heavy oiling
on both surfaces may be sufficient.
25. Shims (102) may be required between the spring retainer (100) and
the spring retaining ring (101). To determine if necessary and how
many are required, proceed as follows:
A. Place four outer clutch springs (104) into the four piston pock-
ets with the tapped holes in the center. Place the spring retainer
(100) over the piston with its four holes centered above the
four springs.
B. Compress the springs and install the retaining ring (101).
C. Screw in two bolts, 180° apart until they bottom. Torque the
bolts to 14 N•m. This will cause the piston to make contact
with the clutch pack.
D87E-2 D87P-2 30-151 2

12 D. Determine the average distance (A) between the clutch piston

(109) and the spring retainer (100). To obtain this figure, use a
depth gauge to measure the distance from the piston to the out-
er edge of the retainer. Measure through two holes. Then re-
move the retainer and measure the retainer thickness with a
micrometer. Subtract the retainer thickness from the total dis-
tance. Average the distance (A) from the two holes.
E. If the average distance (A) is below 25.4 mm, shimming is not

required. If the distance is more than this figure, add shims as
necessary to bring the distance as close to a figure of 25.4 mm
as possible. Each shim is 0.51 mm. No more than three shims
should be required.
F. Position the inner and outer clutch return springs (103 and 104)
on the clutch piston and place the spring retainer (100) on top
of the springs. Compress the springs and install the spring re-
taining ring (101) and shims (if required) (102). Remove the
bolts, nuts and washers. The springs must nest in the counter-
bores of the retainer.

when assembling.
26. Install the clutch hub thrust washer (99), side thrust bearing (98)
and carrier bearing (97) on the ring gear hub.
27. Position the planet gear (93) with the planet gear bearing (96) in-
stalled on the outer diameter of the planet carrier (90). Use a round
tool to center the planet gear and thrust washers (95) with the shaft
bore in the planet carrier before installing the planet gear shaft (92).
Tap the shaft with the lock ball (94) into the carrier, aligning the
ball with the slot in the carrier. Install the bearing scoop (35) and
secure with hardware.
Oil scoop bolts ............................................................... 54 N•m

28. Install the remaining two planet gears in the same manner.
30-152 2 D87E-2 D87P-2

12
29. Install the planet gear carrier (90) with attached parts. Be sure all
the internally splined discs are aligned in the carrier and that the
sun gears mesh with the ring gear and the assembly sits squarely on
the bearings.
30. Install the sun gear retaining ring (89) on the sun gear (87). Install
the gear into the sun gear hub (85). Press the ball bearing (88) into
the sun gear hub until it bottoms on the sun gear. Install the bearing
retainer ring (86) in the groove of the hub.
31. Press the sun gear hub assembly (85) on the planet carrier until the
bearing bottoms. Be sure the sun gear meshes with the planet gears.
32. Install the retaining ring (83) into the output shaft sleeve (84). In-
stall the sleeve onto the shaft of the planet carrier, taper end first,
until the retaining ring is against the shaft.
D87E-2 D87P-2 30-153 2

12
33. Install the sleeve retaining washer (82) in the shaft sleeve and se-
cure with hardware.
Sleeve retaining washer bolt .......................................... 54 N•m
34. Position the brake plate retainer (79) on the main housing (121) so
the port on the retainer is in line with the port on the housing.
35. Alternately install one externally splined separator plate (81) and
one internally splined friction disc (80) into the brake plate retainer.

36. Install the back up rings (76 and 78) and piston seals (75 and 77) on
the brake piston (74).
37. Install the piston (74) on the brake plate retainer.
30-154 2 D87E-2 D87P-2

12
38. Position the plate retainer (71) on top of the retainer. Secure both
retainers to the housing (67) with hardware.
Plate retainer bolts ......................................................... 81 N•m
one internally splined friction disc (72) into the retainer.

40. Shims (69) may be required under the springs (68). To determine if
necessary, and how many, proceed as follows:
A. Place four of the clutch springs (68) into the four pockets with
the tapped holes in the center of the retainer (71). Place the pis-
ton (63) over the springs.
B. Thread two studs (3/8NCx3-1/2) (A) into two of the pockets

180° apart. Screw the studs approximately 10 mm into the re-
tainer. Using a washer and a nut, pull the piston against the
clutch pack. Torque the nuts to 14 N•m.
C. Determine the average distance between the piston and the re-
tainer. To obtain this figure, use a depth gauge to measure the
distance from the outer edge of the piston to the retainer. Mea-
sure through two holes. Then remove the piston and measure
the piston thickness with a micrometer. Subtract the thickness
from the total depth. Then average the distance (B) from the
two holes.
D. If the average distance is below 38.1 mm, shimming is not re-

quired. If the distance is more than this figure, add shims as
as possible. Each shim is 0.510 mm thick. The shims are to be
placed on the retainer side of each spring.
E. Remove the piston and the studs from the retainer.
41. Position the brake piston return springs (70) on the brake piston and
the piston return springs (68) with shims (69) (if equipped, see Step
40) on the brake plate retainer.
D87E-2 D87P-2 30-155 2

12
42. Install the low range clutch piston (63) on top of the springs. The
springs must nest in the counterbores of the piston.
43. Install new back up rings (65 and 67) and piston seals (66 and 68)
on the retainer cover (62) and install on the brake plate retainer and
Brake plate retainer bolts ............................................... 81 N•m

when assembling.
44. Position the thrust washer (61) and the side thrust bearing (60) on
the output shaft sleeve.
45. Position the same amount of shims (59) that were previously re-
moved on the retainer cover. Using a depth gauge, measure the dif-
ference between the surface of the thrust washer and the surface of
the shims. The thrust washer should be 0.1 to 0.2 mm below the
shims. Add or subtract shims to obtain a 0.1 to 0.2 mm gap.
46. Add the correct amount of shims determined. Install the retainer
(58) and secure with hardware.
Shim retainer bolts ......................................................... 35 N•m
30-156 2 D87E-2 D87P-2

12
47. Install new back up rings (55 and 57) and piston seals (54 and 56)
to the piston (53) and the piston retainer hub.
48. Using two eye bolts install the high clutch piston in place being
careful not to damage the piston seals.
externally splined separator plate (52) in the clutch plate retainer.
Install the ring gear (49) and adapter (50) to the clutch plate retainer
and secure with hardware.
Ring gear bolts ............................................................... 54 N•m

50. Shims may be required between the spring retainer (44) and the
spring retaining ring (45). To determine if necessary and how many
are required, proceed as follows:
A. Place four outer clutch springs (48) into the four piston pockets
with the tapped holes in the center. Place the spring retainer
(44) over the piston with its four holes centered above the four
springs.
B. Compress the springs and install the retaining ring (45).
D87E-2 D87P-2 30-157 2

12 C. Screw in two bolts, 180° apart until they bottom. Torque the
bolts to 14 N•m. This will cause the piston to make contact
with the clutch pack.
D. Determine the average distance (A) between the clutch piston

(53) and the spring retainer (44). To obtain this figure, use a
depth gauge to measure the distance from the piston to the out-
er edge of the retainer. Measure through the two holes. Then
remove the retainer and measure the retainer thickness with a
micrometer. Subtract the retainer thickness from the total dis-
tance. Average the distance (A) from the two holes.
E. If the average distance (A) is below 25.4 mm, shimming is not

required. If the distance is more than this figure, add shims as
as possible. Each shim is 0.51 mm. No more than three shims
should be required.
F. Position the inner and outer clutch return springs (47 and 48)
on the clutch piston and place the spring retainer (44) on top of
the springs. Compress the springs and install the spring retain-
ing ring (45) and shims (if required) (46). Remove the bolts,
nuts and washers. The springs must nest in the counterbores of
the retainer.

when assembling.
30-158 2 D87E-2 D87P-2

12
51. Install the clutch hub thrust washer (42), side thrust bearing (41)
and carrier bearing (40) on the ring gear hub.
52. Position the planet gear (36) with the planet gear bearing (39) in-
stalled on the outer diameter of the planet carrier (33). Use a round
tool to center the planet gear and thrust washers (38) with the shaft
bore in the planet carrier before installing the planet gear shaft (35).
Tap the shaft with the lock ball (37) into the carrier, aligning the
ball with the slot in the carrier. Install the bearing scoop (35) and
Oil scoop bolts ............................................................... 54 N•m
53. Install the remaining two planet gears in the same manner.
54. Install the planet gear carrier (33) with attached parts. Be sure all
the internally splined discs are aligned in the carrier and that the
sun gears mesh with the ring gear and the assembly sits squarely on
the bearings.
55. Install the sun gear retaining ring (32) on the sun gear (30) and in-
stall the gear into the sun gear hub (28). Press the ball bearing (31)
into the sun gear hub until it bottoms on the sun gear. Install the
bearing retainer ring (29) into the groove of the hub.
D87E-2 D87P-2 30-159 2

56. Press the sun gear hub assembly (28) on the planet carrier until the
bearing bottoms. Be sure the sun gear meshes with planet gears.
57. Install the retaining ring (26) into the output shaft sleeve (27). In-
stall the sleeve onto the shaft of the planet carrier, taper end first,
until the retaining ring is against the shaft.
58. Install the sleeve retaining washer (25) in the shaft sleeve and se-
cure with hardware.
Sleeve retaining washer bolt .......................................... 54 N•m
59. Position the brake plate retainer (22) on the main housing (121) so
the port on the retainer is in line with the port on the housing.
one internally splined friction disc (23) into the brake plate retainer.

30-160 2 D87E-2 D87P-2

61. Install the back up rings (18 and 20) and piston seals (19 and 21) on
the brake piston (17).
62. Install the piston on the brake plate retainer.
63. Position the plate retainer (14) on top of the retainer. Secure both of
the retainers to the housing with hardware.
Plate retainer bolts ......................................................... 81 N•m

one internally splined friction disc (15) into the retainer.

65. Shims (12) may be required under the springs (11). To determine if
necessary, and how many, proceed as follows:
A. Place four of the clutch springs (11) into the four pockets with
the tapped holes in the center of the retainer (14).
B. Place the low clutch piston (6) over the springs. Thread two
studs (3/8NCx3-1/2) (A) into two of the pockets 180° apart.
Screw the studs approximately 10 mm into the retainer. Using
a washer and a nut, pull the piston against the clutch pack.
Torque the nuts to 14 N•m.
D87E-2 D87P-2 30-161 2

C. Determine the average distance between the piston (31) and

the retainer (36). To obtain this figure, use a depth gauge to
measure the distance from the outer edge of the piston to the
retainer. Measure through two holes. Then remove the piston
and measure the piston thickness with a micrometer. Subtract
the thickness from the total depth. Then average the distance
(B) from the two holes.
D. If the average distance is below 38.1 mm, shimming is not re-

quired. If the distance is more than this figure, add shims as
as possible. Each shim is 0.510 mm thick. The shims are to be
placed on the retainer side of each spring.
E. Remove the piston and the studs from the retainer.
66. Position the brake piston return springs (13) on the brake piston and
the piston return springs (11) with shims (12) on the brake plate re-
tainer.
67. Install the low range clutch piston (6) on top of the springs. The
springs must nest in the counterbores of the piston.
68. Install new back up rings (8 and 10) and piston seals (7 and 9) on
the retainer cover (5) and install on the brake plate retainer and se-
cure with hardware.
Brake plate retainer bolts ............................................... 81 N•m

when assembling.
69. Position the thrust washer (4) and the side thrust bearing (3) on the
output shaft sleeve.
30-162 2 D87E-2 D87P-2

12
70. Position the same amount of shims (59) that were previously re-
moved on the retainer cover. Using a depth gauge, measure the dif-
ference between the surface of the thrust washer and the surface of
the shims. The thrust washer should be 0.1 to 0.2 mm below the
shims. Add or subtract shims to obtain a 0.1 to 0.2 mm gap.
71. Add the correct amount of shims as determined. Install the retainer
Shim retainer bolts ......................................................... 35 N•m
D87E-2 D87P-2 30-163 2

STEERING
12 VALVE
Disassembly
1. Left Steering Valve Lever 4. Lever Bracket 7. Large Check Ball

2. Right Steering Lever 5. Upper Steering Valve 8. Small Check Ball
3. Brake Lever 6. Lower Steering Valve 9. Between Valve Gasket
30-164 2 D87E-2 D87P-2

12
following steps.
1. Disconnect and remove the left steering valve lever (1) from the
valve spool.
2. Disconnect and remove the right steering valve lever (2) from the
valve spool. Disconnect and remove the brake lever (3) from the
spool.
3. Remove the lever bracket (4) from the valve.
4. Remove the hardware and separate upper steering valve (5) from
the lower steering valve (6). Refer to individual valve breakdowns
in this section.
D87E-2 D87P-2 30-165 2

12
5. Remove the large (7) and small check balls (8) from the lower
steering valve.
6. Remove and discard the gasket (9) from the upper steering valve.
Replace with new.
Assembly
● Carry out assembly in the reverse order of disassembly.
30-166 2 D87E-2 D87P-2

Upper Steering Valve

12
D87E-2 D87P-2 30-167 2

12
1. Seal Cover 14. Inner Spool Spring 27. Spring Spacer 40. Outer Spool Spring
2. Brake Spool 15. Spring Seat 28. Spring Stop 41. Spring Stop
3. Spool Poppet Spring 16. Left Clutch Spool 29. Inner Spool Spring 42. Spring Spacer
4. Brake Spool Poppet 17. Metering Outer Spring 30. Spring Seat 43. Spring Stop
5. Poppet Shims 18. Metering Inner Spool 31. Right Clutch Spool 44. Inner Spool Spring
6. Seal End Cap 19. Spring Shims 32. Metering Outer Spring 45. Spring Seat
7. Spool Seal 20. Metering Spring Guide 33. Metering Inner Spool 46. Spool Sleeve Cover
8. Inner Seal Ring 21. Seal End Cap 34. Spring Shims 47. Cover Gasket
9. Outer Seal Ring 22. Spool Seal 35. Metering Spring Guide 48. Metering Spool
10. Outer Spool Spring 23. Inner Seal Ring 36. Seal End Cap 49. Spool Sleeves
11. Outer Spring Stop 24. Outer Seal Ring 37. Spool Seal 50. Check Ball Cavity
12. Spring Spacer 25. Outer Spool Spring 38. Inner Seal Ring 51. Check Ball
13. Spring Stop 26. Spring Stop 39. Outer Seal Ring 52. Valve Housing
DISASSEMBLY
following steps.
1. Stand the valve on end. Remove the seal cover (1) outer bolts.
2. Install bolts that are about 25.4 mm longer.

when disassembling.
30-168 2 D87E-2 D87P-2

12
3. Slowly remove inner bolts allowing cover to rest on outer bolts.
4. Install bolts that are about 25.4 mm longer in the inner bolt holes.
Slowly remove the outer bolts allowing the cover up against the in-
ner bolts. Install bolts that are about 25.4 mm longer in the outer
bolt holes. Slowly back off the bolts until all tension is off the
springs. Remove the seal cover.
5. Remove the brake spool (2) from the valve.
6. At the end of the brake spool, remove the spool poppet spring (3).
7. Remove the spool poppet (4) and shims (5) from the brake spool.
D87E-2 D87P-2 30-169 2

12Remove
spool.
8. Turn the the
spoolspool poppet
over and (4)the
remove wfth
endshims
cap (6)(5) from
with the the
seals.brake
9. Remove and discard the spool seal (7) and the inner (8) and outer
(9) seal rings and replace with new.
10. Remove the outer spool spring (10).
11. Remove the outer spring stop (11).
12. Remove the spring spacer (12).
13. Remove the spring stop (13).
14. Remove inner spool spring (14).
15. Remove the spring seat (15).
30-170 2 D87E-2 D87P-2

12
16. Pull the left clutch spool (16) out of the valve body. Remove the
metering spool outer spring (17).
17. Remove the metering spool inner spring (18).
18. Remove the shims (19) and keep with the metering springs.
19. Remove the metering spring guide (20).
20. Turn the spool over and remove the end cap (21) with seals.
21. Discard the spool seal (22) and the inner (23) and outer (24) seal
rings and replace with new.
23. Remove outer spring stop (26).
D87E-2 D87P-2 30-171 2

12
26. Remove the inner spool spring (29).
28. Pull the right clutch spool (31) out of the valve body. Remove the
metering spool outer spring (32).
29. Remove the metering spool inner spring (33).
30. Remove the shims (34) and keep with the metering springs.
31. Remove the metering spring guide (35).
30-172 2 D87E-2 D87P-2

12
32. Turn the spool over and remove the end cap (36) with seals.
33. Discard the spool seal (37) and the inner (38) and outer (39) seal
rings and replace with new.
35. Remove outer spring stop (41).
38. Remove the inner spool spring (44).
D87E-2 D87P-2 30-173 2

40. Remove the spool sleeve cover (46) and discard the gasket (47).
41. Remove the metering spools (48) and spool sleeves (49).
42. Remove the check ball cavity (50) and the check ball (51) from the
valve housing.

upon assembly of the valve.
Clean all parts in a suitable solvent and blow dry with compressed air.
Be sure all the oil passages in the valve housing are clean and free of
INSPECTION
obstructions.
The oil inlet port of the valve may show signs of wear caused from the
ball peening the valve section each time pressure reenters the valve.
Do not replace the valve section when this appearance is observed. In-
spect the parts for excessive wear and replace if necessary.
placed.
Clean threads with a stiff brush and solvent. Check for damage.
30-174 2 D87E-2 D87P-2

ASSEMBLY
12
following steps.
1. Install the check ball (51) into the housing bores. Coat the check
ball cavity (50) threads with Loctite #262 and install into the hous-
ing.
Cavity threads ........................................................ Loctite #262
Check ball cavity ........................................................... 32 N•m
2. Install the metering spools (48) into the spool sleeves (49).
3. Install the spool sleeve cover (46) with a new gasket (47) to the
valve housing.
4. Install the spring seat (45) on the right clutch spool.
5. Install the inner spool spring (44).
D87E-2 D87P-2 30-175 2

12
6. Install the spring stop (43).
7. Install the spring spacer (42).
8. Install outer spring stop (41).
9. Install the outer spool spring (40).
10. Install the spool seal (37) and the inner (38) and outer (39) seal
rings to the end cap (36).
11. Install the end cap (36) with seals to the spool.
12. Install the metering spring guide (35).
13. Install the shims (34).
30-176 2 D87E-2 D87P-2

12
14. Install the metering spool inner spring (33).
15. Install the metering spool outer spring (32). Install the right clutch
spool (31) into the valve housing.
16. Install the spring seat (30) to the left clutch spool (16).
17. Install the inner spool spring (29).
20. Install outer spring stop (26).
D87E-2 D87P-2 30-177 2

12
24. Install the metering spring guide (20).
25. Install the shims (19).
26. Install the metering spool inner spring (17).
27. Install the metering spool outer spring (18). Install the left clutch
spool (16) into the valve housing.
28. Install the spring seat (15).
29. Install inner spool spring (14).
30-178 2 D87E-2 D87P-2

12
32. Install the outer spring stop (11).
34. Install the spool seal (7) and the inner (8) and outer (9) seal rings to
the end cap (6).
36. Install the spool poppet (4) with shims (5) to the brake spool.
37. At the end of the brake spool, install the spool poppet spring (3).
D87E-2 D87P-2 30-179 2

12
38. Install the brake spool (2) into the valve housing.
39. Position spool cover (1) and secure with long bolts at outer holes.
40. Install the seal cover (1) and secure with long bolts at outer holes.
Compress the spring tension and secure the seal cover with bolts in
the inner holes.
41. When the spring tension is fully compressed, secure the seal cover
with the remaining hardware.
30-180 2 D87E-2 D87P-2

Lower Steering Valve

12
D87E-2 D87P-2 30-181 2

12
1. Spool Seal Cover 9. Inner Seal Ring 17. Seal End Cap
2. Check Ball Cover 10. Outer Seal Ring 18. Spool Seal
3. Cover Gasket 11. Spool Spring 19. Inner Seal Ring
4. Right High Low Spool 12. Spring Spacer 20. Outer Seal Ring
5. Check Ball Spring 13. Spring Seat 21. Spool Spring
6. Check Ball 14. Left High Low Spool 22. Spring Spacer
7. Seal End Cap 15. Check Ball Spring 23. Spring Seat
8. Spool Seal 16. Check Ball 24. Valve Housing
DISASSEMBLY
following steps.
1. Remove the outer spool seal cover (1) bolts and replace with ones
25 mm longer. Slowly back out the center bolt until the cover rests
against the outer bolts.

when disassembling.
2. Remove the inner cover bolt and replace with one 25 mm longer.
Slowly back out outer bolts until all spring tension is released.
3. If necessary, remove check ball cover (2) and gasket (3). Discard
the gasket and replace with new.
30-182 2 D87E-2 D87P-2

4. Pull out the right high low spool (4) out of the valve housing.
5. Remove the check ball spring (5) from the spool.
6. Remove the check ball (6) from the spool.
7. Remove the seal end cap (7) with seals (8, 9 and 10). Discard the
seals and replace with new.
8. Remove the spool spring (11).
9. Remove the spring spacer (12) and spring seat (13).
D87E-2 D87P-2 30-183 2

12
10. Pull out the left high low spool (14) out of the valve housing.
11. Remove the check ball spring (15) from the spool.
12. Remove the check ball (16) from the spool.
13. Remove the seal end cap (17) with seals (18, 19 and 20). Discard
the seals and replace with new.
30-184 2 D87E-2 D87P-2


INSPECTION
obstructions. The oil inlet port of the valve may show signs of wear
caused from the ball peening the valve section each time pressure re-
enters the valve. Do not replace the valve section when this appear-
ance is observed. Inspect the parts for excessive wear and replace if
necessary.
placed.
ASSEMBLY
following steps.
1. Install the spring spacer (22) and spring seat (23).
2. Install the spool spring (21).
5. Install the check ball (16) from the spool.
6. Install the check ball spring (15) from the spool.
D87E-2 D87P-2 30-185 2

12
7. Install the left high low spool (14) into the valve housing.
10. Install the spool seal (8) and the inner (9) and outer (10) seal rings
to the end cap (7).
12. Install the check ball (6) from the spool.
13. Install the check ball spring (5) from the spool.
30-186 2 D87E-2 D87P-2

12
14. Install the right high low spool (4) into the valve housing.
15. Install check ball cover (2) and new gasket (3).
16. Install the outer spool seal cover (1) bolts with ones 25 mm longer.
Slowly turn down the bolts until the cover rests against the valve
housing. Install remaining hardware.

when assembling.
D87E-2 D87P-2 30-187 2


12
Disassembly
1. High Low Steering Valve 4. Upper Steering Valve 7. Between Valve Gasket
2. Lower Steering Valve 5. Large Check Valve
3. Between Valve Gasket 6. Small Check Ball
30-188 2 D87E-2 D87P-2

1. Remove the high low valve (1) from the rear of the lower steering
valve (2). Remove and discard the between valves gasket (3). Refer
to individual valve breakdown in this section.
2. Disconnect and remove the brake lever (A) from the spool. Remove
the lever bracket (B) from the valve.
3. Remove the hardware and separate the upper steering valve (4)
from the lower steering valve (2). Refer to individual valve break-
downs in this section.
4. Remove the large (5) and small check balls (6) from the lower
steering valve.
5. Remove and discard the gasket (7) from the upper steering valve.
Replace with new.
Assembly
● Carry out assembly in the reverse order of disassembly.
D87E-2 D87P-2 30-189 2

Upper Steering Valve

12
30-190 2 D87E-2 D87P-2

12
1. Seal Cover 8. Spool Seal Ring 15. Spring Seat 22. Pilot Tube Lower Ring
2. Spool Poppet Spring 9. End Cap Seal Ring 16. Spool Sleeve Cover 23. Metering Spool
3. Poppet Shims 10. Outer Spool Spring 17. Cover Gasket 24. Metering Spool Sleave
4. Spool Poppet 11. Outer Spring Stop 18. Left Pilot Tube 25. Check Ball Cavity
5. Brake Spool 12. Spring Spacer 19. Right Pilot Tube 26. Check Ball
6. End Cap 13. Inner Spring Stop 20. Valve Body 27. Fitting And Seal
7. Spool Seal 14. Inner Spool Spring 21. Pilot Tube Upper Ring 28. Orifice Plug
DISASSEMBLY
following steps.
1. Stand the valve on end. Remove the seal cover (1) outer bolts.
2. Install bolts that are about 25.4 mm longer.

when disassembling.
3. Slowly remove inner bolts allowing cover to rest on outer bolts. In-
stall bolts that are about 25.4 mm longer in the inner bolt holes.
Slowly remove the outer bolts allowing the cover up against the in-
ner bolts. Install bolts that are about 25.4 mm longer in the outer
bolt holes. Slowly back off the bolts until all tension is off the
springs. Remove the seal cover.
D87E-2 D87P-2 30-191 2

4. Remove the brake spool from the valve.
5. At the end of the brake spool, remove the spool poppet spring (2).
6. Remove the spool poppet (4) and shims (3) from the brake spool
(5).
7. Turn the spool over and remove the end cap (6) with the seals.
8. Remove and discard the spool seal (7) and the inner (8) and outer
(9) seal rings and replace with new.
10. Remove the outer spring stop (11).
30-192 2 D87E-2 D87P-2

13. Remove inner spool spring (14).
15. Remove the spool sleeve cover (16) and discard the gasket (17).
16. Pull the left (18) and right (19) pilot tubes out of the valve body
(20). Remove and discard seal rings (21 and 22) from pilot tubes.
D87E-2 D87P-2 30-193 2

17. Remove the metering spools (23) and spool sleeves (24).
18. Remove the check ball cavity (25) and the check ball (26) from the
valve housing.

INSPECTION
obstructions.
The oil inlet port of the valve may show signs of wear caused from the
ball peening the valve section each time pressure reenters the valve.
Do not replace the valve section when this appearance is observed. In-
spect the parts for excessive wear and replace if necessary.
placed.
ASSEMBLY
following steps.
1. Install the check ball (26) into the housing bores. Coat the check
ball cavity (25) threads with Loctite #262 and install into the hous-
ing.
Cavity threads ........................................................ Loctite #262
Check ball cavity ........................................................... 32 N•m
30-194 2 D87E-2 D87P-2

12
2. Install the metering spools (23) into the spool sleeves (24).
3. Install the spool sleeve cover (16) with a new gasket (17) to the
valve housing.
4. Install new seal rings (21 and 22) to the left (18) and right (19) pilot
tubes. Install the pilot tubes into the valve housing (20).
5. Install the spring seat (15).
6. Install inner spool spring (14).
D87E-2 D87P-2 30-195 2

12
9. Install the outer spring stop (11).
11. Install the spool seal (7) and the inner (8) and outer (9) seal rings to
the end cap (6).
13. Install the spool poppet (4) with shims (5) to the brake spool.
14. At the end of the brake spool, install the spool poppet spring (3).
30-196 2 D87E-2 D87P-2

12
15. Install the brake spool (2) into the valve housing.
16. Install the seal cover and secure with long bolts at outer holes.
17. Compress the spring tension and secure the seal cover with bolts in
the inner holes.
18. When the spring tension is fully compressed, secure the seal cover
(1) with the remaining hardware.
D87E-2 D87P-2 30-197 2

Lower Steering Valve

12
1. End Cover 4. Spool Return Spring 7. Hi Lo Spool

2. End Cap 5. Spool Stop 8. Valve Housing
3. End Cap Seal Ring 6. Spring Rest
30-198 2 D87E-2 D87P-2

DISASSEMBLY
following steps.
1. Remove the outer spool seal cover (1) bolts and replace with ones
25 mm longer. Slowly back out the center bolt until the cover rests
against the outer bolts.

when disassembling.
2. Remove the inner cover bolt and replace with one 25 mm longer.
Slowly back out outer bolts until all spring tension is released.
3. Pull out the end cap (2) with seal ring (3) out of the valve housing.
Discard the seal ring and replace with new
D87E-2 D87P-2 30-199 2


INSPECTION
necessary.
placed.
ASSEMBLY
following steps.
3. Install both of the high low spools (7) and end caps (2) into the
valve housing.
4. Install the end cover (1) bolts until the cover rests against the valve
housing. Install remaining hardware.

when assembling.
30-200 2 D87E-2 D87P-2

High Low Valve

12
1. Sequence Valve 3. Sequence Valve Seal Kit 5. Solenoid Valve Seal Kit
2. Valve Block 4. SolenoidValve 6. Orifice Inlet Plug
D87E-2 D87P-2 30-201 2

SERVICE
following steps.
1. Remove the sequence valves (1) from the valve block (2). Remove
2. Install a new seal kit to the sequence valve as shown in the illustra-
tion. Install the sequence valve to the valve block and tighten.
Sequence valve .............................................................. 27 N•m
3. Remove the solenoids (4) from the valve block. Remove and dis-
card the seal kit (5) and replace with new.
4. Install a new seal kit to the solenoid as shown in the illustration. In-
stall the solenoid to the valve block and tighten.
Solenoid ......................................................................... 27 N•m
Coil nut, if neccessary........................................... 6.7 N•m max
30-202 2 D87E-2 D87P-2

STEERING
12 MANIFOLD
1. Port Plug
2. Seal Ring
3. Manifold Spool
4. Spool Return Spring
5. Manifold Housing
Service
following steps.
1. Remove the port plug (1) with seal ring (2). Discard the seal ring
and replace with new.

when disassembling.
D87E-2 D87P-2 30-203 2

12
2. Remove the spool (3) and return spring (4) from the valve housing
(5).

INSPECTION
necessary.
placed.
3. Assemble in the reverse order of disassembly.
30-204 2 D87E-2 D87P-2

DISASSEMBLY AND ASSEMBLY FINAL DRIVE AND SPROCKET
FINAL
12 DRIVE AND SPROCKET
SPROCKET
battery.
chine.
REMOVAL
1. Remove the track chain.......................... Refer to TRACK CHAIN.
★ It is not necessary to remove the track chain from under the ma-
chines track frame.
2. Remove the sprocket outer rock shield. Jack up the rear of the ma-
chine enough to allow the sprocket to clear the track chain. Block
the rear main frame.
3. Attach a hoist to the sprocket (1) and take up the slack. Remove the
hardware securing the sprocket to the final drive carrier. Remove
the sprocket from the final drive.
Check for excessive wear on the sprocket. Refer to SECTION 20 for

INSPECTION
causes of excessive wear and how they can be corrected.
INSTALLATION
Sprocket rock shield bolts............................................ 455 N•m
Sprocket mounting nuts ............................................... 434 N•m
D87E-2 D87P-2 30-205 2

FINAL
12 DRIVE
REMOVAL

battery.
chine.
★ The following procedure is for removal of the final drive on one
side of the machine. The opposite side is identical.
1. Drain the rear main frame and the final drive that is to be removed.
Refer to the Operation & Maintenance Manual.
2. Remove the track chain.......................... Refer to TRACK CHAIN.
★ It is not necessary to remove the track chain from under the ma-
chines track frame.
3. Remove the sprocket rock shield. Jack up the rear of the unit
enough for the sprocket to clear the track chain. Block under the
main frame. Remove the cover with seal ring and retaining ring.
Thread a bolt into the shaft retainer and pull it out of the pinion
gear. Thread a bolt in the steering drive output shaft and pull it free
of the steering drive.
4. Remove the top sprocket mounting bolt and the top planetary carri-
er mounting bolt. Attach a hoist at these points. Remove one of the
final drive cover mounting bolts and insert a brass drift in the hole.
The drift will support the cover when it is first freed from the main
frame.
5. Remove the remaining final drive cover mounting bolts and free
the cover from the main frame. Insert a pry bar to hold the cover up
as it clears the drift. Pull the final drive assembly away from the
main frame. Remove pry bar and let the cover swing down slowly.
Remove the steering drive output shaft from the gear.
INSTALLATION
★ Carry out installation in the reverse order of removal.
Rock shield bolts.......................................................... 267 N•m
Cover bolts ..................................................................... 98 N•m
Final drive mounting bolts ........................................... 732 N•m
Final drive to rear frame ......................... Loctite Plastic Gasket
● Refill the final drive, refer to the Operation and Maintenanace

Manual.
30-206 2 D87E-2 D87P-2

12
D87E-2 D87P-2 30-207 2

12
1. Pinion Gear Access Cover 14. Seal Ring 27. Bearing Retainer Plate
2. Seal Ring 15. Retaining Ring 28. Plate Shims
3. Retaining Ring 16. Spherical Roller Bearing 29. Ring Gear
4. Shaft Retainer 17. Retaining Ring 30. Ring Gear Hub
5. Seal Ring 18. Planetary Gear Housing 31. Retainer Plate
6. Bearing Retainer 19. Sprocket Hub 32. Tapered Roller Bearing
7. Final Drive Cover 20. Thrust Button 33. Tapered Roller Bearing
8. Bull Gear 21. Planetary Gear Shaft 34. Outer Oil Seal Guard
9. Pinion Housing 22. Planetary Gear 35. Metal Type Face Seal
10. Pinion Gear 23. Roller Bearing 36. Roller Bearing Spacer
11. Tapered Roller Bearing 24. Thrust Washer 37. Middle Oil Seal Guard
12. Gear Oil Seal 25. Roller Bearing Spacer 38. Inner Oil Seal Guard
13. Seal Ring 26. Sun Gear Shaft
DISASSEMBLY
following steps. Items 1 thru 5 were removed when the final drive
was removed from the machine.
1. Position the final drive down on the planetary housing so that the
bull gear is facing up.
2. Remove the hardware securing the bearing retainer (6) to the final
drive cover (7). Turn the bull gear (8) as necessary, to reach all the
retainer hardware.
3. Attach a hoist to the bull gear hub and lift slowly until the bull gear
(13) contacts the housing (4).
30-208 2 D87E-2 D87P-2

4. Remove the hardware securing the pinion housing (9) to the final
drive cover. Install jack screws in the holes provided in the pinion
housing and remove the housing from the final drive cover.
5. Place the pinion gear housing in a press so that the mounting flange
is down. Place a suitable driver on the end of the pinion gear (10)
and press the gear with bearings (11) out of the housing. The bear-
ing cups need not be removed unless replacement is necessary.
6. Remove oil seal (12) and seal rings (13 and 14) from the housing
and discard.
7. Lift the bull gear (8) with attaching parts from the sun gear shaft
and housing.
8. Remove the retaining rings (15 and 17), spherical roller bearing
(16) and retainer (6) from the bull gear.
★ It is impossible to remove the spherical roller bearing (16) without

destroying it. Replacement is imminent.
D87E-2 D87P-2 30-209 2

12
9. Turn the assembly over and support it on the final drive cover. Re-
move the hardware securing the planetary gear housing (18) to the
sprocket hub (19).
10. Remove the three cork plugs from the puller holes and install puller
bolts. Break the housing loose from the hub and remove the puller
bolts. Install lifting eyes in the puller holes, attach a hoist and re-
move the housing.
11. Place the assembly on a bench with the planet gear side up. Re-
move the thrust button (20) from the carrier. Remove the hardware
securing the gear shaft (21) in the housing. Install an eye bolt in the
end of the shaft and pull it out of the housing.
12. Slide the planetary gear (22), roller bearings (23), thrust washers
(24) and spacer (25) from the carrier housing. Separate the parts af-
ter removal.
13. Disassemble the remaining two planet gear assemblies in the same
manner.
30-210 2 D87E-2 D87P-2

12
14. Install an eyebolt in the end of the sun gear shaft (26) and lift the
shaft straight up and out. Remove the bearing retainer plate (27)
and shims (28).
15. Using a puller and a driver, remove the ring gear and parts (29, 30
and 31) from the cover.
16. Heat the ring gear hub assembly to a maximum of 260°C with a
torch if necessary.
17. Separate the ring gear (29) from the hub (30) by removing the re-
tainer plates (31).
D87E-2 D87P-2 30-211 2

12
18. Install four eyebolts 90° apart in the hub (19) and attach a hoist to
two opposite eyebolts. Install a bar in two remaining eyebolts and
position a hydraulic ram under the bar.
19. Use the ram to free the bearing cone (19) from the cover shaft and
lift the hub off with hoist. If replacement is necessary, remove the
bearing cups (32 and 33) and the shield (34) from the hub.
20. Remove the oil seal assembly (35). Half of the seal may be on the
hub and the other half on the carrier. Lift the bearing spacer (36)
from the cover shaft. The bearing cone (33) should not be removed
from the cover unless replacement is necessary. The oil seal shields
(37 and 38) need not be removed unless replacement or cleaning is
necessary.
It is recommended that new seal rings and oil seals be installed when-
ever the final drive is disassembled for service.
Make a preliminary inspection of all parts before cleaning to detect
discrepancies which may not show up once the parts are cleaned. Ex-
amine the oil for metal particles, dirt and other foreign material.
Check for foreign material in the bearings which would cause exces-
sive wear.
Wash all the parts thoroughly in a suitable solvent and dry with com-
pressed air or a clean cloth. Do not spin dry the bearings with com-
pressed air. Inspect the bearings for scores, cracks and wear. Replace
INSPECTION
if necessary. Reusable bearings should be soaked in clean oil and

wrapped with clean paper until ready for assembly.
Using coarse paper, a file or a hand grinder, remove any corrosion or
hardened foreign material that may exist on the seal bore surfaces of
the hub and cover. Do this carefully to avoid changing the dimensions
of the bore.
Thoroughly scrape the final drive mating surfaces clean. Be careful
not to scratch these finished surfaces or sealing may become ineffec-
tive.
Inspect the ring gear, ring gear hub, sun gear and planetary gear teeth
for damage or wear. Inspect the ring gear hub and sun gear splines for
excessive wear or damage. Slight burrs can be smoothed down with a
stone.
30-212 2 D87E-2 D87P-2

ASSEMBLY
12
following steps. 1 thru 5 will be assembled when the final drive is
installed to the machine.
1. Support the cover, shaft end up. If the hub bearings were replaced,
heat the inner bearing cone (33) to 150°C and install on cover until
it is solid against the shoulder. To assure the cone is against shoul-
der, make a final press after the cone has reasonably cooled down.
The outer bearing cone (32) will be installed later. Install the spacer
(36) on the shaft of cover.
2. Install the oil seal shields (37 and 38) on the cover and secure with
hardware.
Oil seal shield bolts........................................................ 81 N•m
3. Press the bearing cups (32 and 33) into the hub (19). Install the oil
seal shield (34) to the hub and secure with hardware.
Oil seal shield bolts........................................................ 81 N•m
4. Install the oil seal (35), follow instructions furnished with seal or
kit.
★ Refer to METAL TYPE FACE SEALS.
5. With the aid of a hoist, position the hub assembly on the cover be-
ing sure the bearing cone (33) seats squarely in the cup.
D87E-2 D87P-2 30-213 2

12
6. Heat the outer bearing cone (32) to 150°C and install on the cover
shaft until it is solid against the bearing spacer. To assure the cone
is against the spacer, make a final press after the cone has reason-
ably cooled down.
7. Install the ring gear (29) on the hub (30) and secure with the retain-
ers (42) and hardware.
Retainer bolts - new ..................................................... 125 N•m

Retainer bolts - used .................................................... 108 N•m
8. Heat the ring gear assembly to a maximum of 260°C. Install the

ring gear assembly on the cover shaft splines until the ring gear bot-
toms against bearing cone.
9. Measure gap (A) between the retainer plate (27) and the end of the
cover shaft (7) as follows;
A. Use virgin lead placed 90° apart (4 pieces) on the cover shaft.
Install the retainer plate (27) with NO shims (28) and torque
the four bolts (every other hole) to 135 N.m. Remove the re-
tainer and measure the virgin lead, averaging the readings from
the four pieces. Subtract 0.0762 to 0.1016 mm from this gap
and assembly a shim pack of this size.
B. The shim pack should never be the same or greater than the
gap measurement (see following ★). Remove the retainer, in-
stall the shims (28) and retainer (27) and secure with hardware.
Retainer plate bolts ...................................................... 244 N•m
30-214 2 D87E-2 D87P-2

★ On the rebuild of older machines, if the ring gear hub (30) splines
12
are loose (rotational movement) on the cover shaft (7) splines, these
parts should be replaced with new parts. However, if it is decided to
use the old parts, instead of subtracting 0.0762 to 0.1016 mm to the
virgin lead measured thickness, add 0.0762 to 0.1016 mm to the
virgin lead thickness.
10. Install the sun gear shaft (26) through the cover shaft.
11. Slide the bearing spacer (25) and the roller bearings (23), one from
each side, into the planet gear (22).
12. Assemble the thrust washers (24), tab side facing away from gear,
on each side of the planet gear and slide assembly into carrier hous-
ing.
13. Align the gear assembly with the shaft hole in carrier housing and
install gear shaft (21). Remove the eye bolt. Secure the shaft with
the hardware.
Sun gear shaft bolt ....................................................... 217 N•m

14. Assemble the remaining two planet gear assemblies in the same
manner.
15. Apply a coat of grease to the thrust button (20) and install in the
housing.
D87E-2 D87P-2 30-215 2

★ The plug in the planet carrier housing must be placed at angle 90°
12
to the plug in the hub.
16. Apply Loctite #120 to mating surface of the hub (23). Attach a
hoist to the housing (30).
Hub to carrier housing ........................................... Loctite #120
17. Lower the housing on hub (23) being sure the sun gears (34) mesh
with the sun gear shaft and the ring gear. Secure the housing (30) to
hub (23) with the hardware. Install cork plugs in the puller holes.
Hub to carrier housing bolts......................................... 610 N•m
18. Heat the bearing cones (11) to 150°C and install on the pinion gear
(10) until they are solid against the shoulder. To assure the cones
are against the shoulder, keep pressure against the cones until they
reasonably cool down. Install the oil seal (12) and seal rings (13
and 14) on gear housing (9). Insert the pinion gear (10) into gear
housing, being careful not to damage the oil seal, until the bearing
cone seats in its cup. Press the remaining bearing cup into the gear
housing against the shoulder. The bearing cone must be flush with
the cover mounting face. Use the cover and three bolts as a driver.
★ The preload of the bearings can be checked by wrapping a string

around the pinion gear teeth and using a spring scale. The rolling
drag should not exceed 45 N rolling pull. The end play should not
exceed 0.03 mm. If it is found that the rolling drag with the spring
scale exceeds the maximum, an assembly error of the bearing cones
and/or cups may have been made. The complete assembly should
then be inspected for any misassembly of parts.
19. Install the retaining ring (15) into the bull gear (8). Place the bear-
ing retainer (6) over the spindle on the hub. Heat the bearing (16) to
90°C and install on the spindle of the bull gear. Install the retaining
ring (17).
30-216 2 D87E-2 D87P-2

12
20. Turn the final drive over and set it on the planetary carrier housing.
Attach a hoist to the bull gear (8) and partly lower it onto the sun
gear shaft (26). Position the pinion gear housing (9) with new a seal
ring (13) on the cover (7) and tap it down with a soft faced hammer.
Lower the bull gear and using a drift on the outer race of the bear-
ing (16), tap the bearing evenly into the bore of the cover.
21. Secure the pinion housing (4) to the cover and secure with hard-
ware.
Pinion housing bolts..................................................... 217 N•m

22. Through the holes in the bull gear (13), insert the six bolts with
washers securing the retainer (16) to the cover.
Bearing retainer bolts................................................... 125 N•m
D87E-2 D87P-2 30-217 2

DISASSEMBLY AND ASSEMBLY EQUIPMENT PUMP
EQUIPMENT
12 PUMP
REMOVAL
machine.
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE

nanace Manual.
30-218 2 D87E-2 D87P-2

DISASSEMBLY AND ASSEMBLY EQUIPMENT VALVES
EQUIPMENT
12 VALVES
battery.
chine.
BLADE LIFT VALVE BANK

REMOVAL
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE

nanace Manual.
D87E-2 D87P-2 30-219 2

DISASSEMBLY
1. Position the valve bank on a work bench with the mounting studs
facing up. Remove the nuts (1) from the tie bolts (2). Remove the
outlet cover plate (3) from the valve bank. Remove and discard the
between section seal rings (4) and replace with new.
2. Remove the blade lift section (5) from the valve bank.
3. Remove and discard the between section seal rings (4) and replace
with new.
★ Refer to BLADE LIFT SECTION.
4. Remove the main relief valve (6) from the inlet cover (7).
★ Refer to MAIN RELIEF VALVE.
5. Remove the port plugs (8 and 9) from the inlet and outlet covers.
It is recommended that new seal rings be installed whenever the blade

lift valve bank is disassembled for service.
INSPECTION

pressed air or a clean cloth.
ASSEMBLY
1. Install the port plug (9) with new seal ring to the outlet cover port.
Port plugs ..............................................................45 to 53 N•m

2. Install the main relief valve (6) and port plug (8) with new seal ring
to the inlet cover (7).
Main relief valve ...................................................45 to 53 N•m

Port plug............................................................129 to 156 N•m
3. Oil the threads of the tie bolts (2) and install into the inlet cover.
4. Install the between section seals (4), Slide the blade lift section on
the tie bolts up against the inlet cover.
5. Install the outlet cover on the tie bolts against the blade lift section.
Oil the nut threads and install to the tie bolts.
Tie bolt nuts ..........................................................68 to 82 N•m
30-220 2 D87E-2 D87P-2

Blade Lift Section

12
SERVICE
1. The anti cavitation valve (1), the load check poppet (2) and the
blank port plug (3) are the only replacable parts.
Anti cavitation valve .............................................45 to 53 N•m

Load check poppet ................................................45 to 53 N•m
Port plug................................................................45 to 53 N•m
D87E-2 D87P-2 30-221 2

System Relief Valve

12
1. Adjusting Screw 8. Main Poppet 15. Back Up Ring

2. Jam Nut 9. Filter Screen 16. Seal Ring
3. Washer 10. Seal Ring 17. Seal Ring
4. Pilot Poppet 11. Back Up Ring 18. Back Up Ring
5. Poppet Return Spring 12. Seal Ring 19. Valve Body
6. End Cap 13. Seal Ring 20. Retaining Ring
7. Main Poppet Spring 14. Seal Ring
30-222 2 D87E-2 D87P-2

DISASSEMBLY
12
following steps.
1. Position the relief valve in a vise, adjusting end up. Remove the
tamper proof cover. While holding the adjusting screw (1), remove
the jam nut (2) and washer (3).
2. Remove the adjusting screw (1).

when disassembling.
3. Remove the pilot poppet (4) and the spring (5).
4. Remove the end cap (6).

when disassembling.
D87E-2 D87P-2 30-223 2

12
5. Remove the main poppet spring (7).
6. Remove the main poppet (8) with the filter screen (9).
7. Remove the seal ring (10) and the back up ring (11) from the main
poppet and discard.
8. Remove the seal ring (12) from the end cap (5) and discard.
30-224 2 D87E-2 D87P-2

12
9. Remove the seal ring (13) from the adjusting screw (1) and discard.
10. Remove the seal ring (14) and back up ring (15) from inside the
valve body and discard.
11. Remove the seal rings (16 and 17) and back up ring (18) on the out-
side of the valve body (19) and discard.
Due to the close tolerances of the working parts, the main relief
INSPECTION
valve internal parts are not serviced. If service other than the seals
is required, replace the complete relief valve.
ASSEMBLY
following steps.
1. Install new seal rings (16 and 17) and back up ring (18) on the out-
side of the valve body (19).
2. Install a new seal ring (14) and back up ring (15) down inside the
valve body.
D87E-2 D87P-2 30-225 2

12
3. Install a new seal ring (13) to the adjusting screw (1).
4. Install a new seal ring (12) to the end cap (5).
5. Install a new seal ring (10) and back up ring (11) to the main pop-
pet.
6. Install the main poppet (8) with the filter screen (9) into the valve
body.
30-226 2 D87E-2 D87P-2

12
7. Install the main poppet spring (7)
8. Install the end cap (6).

when assembling.
End cap ................................................................. 11 to 16 N•m
9. Install the pilot poppet (4) and the return spring (5).
10. Install the adjusting screw (1) half way into the end cap.

when assembling.
★ Final adjustment of the system relief valve will have to be made
with the control valve reinstalled into the machine. Refer to SEC-
TION 20.
D87E-2 D87P-2 30-227 2

12
11. While holding the adjusting screw (1), install jam nut (2).
30-228 2 D87E-2 D87P-2

BLADE
12 LIFT AND RIPPER VALVE BANK
battery.
chine.
REMOVAL
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE

nanace Manual.
D87E-2 D87P-2 30-229 2

DISASSEMBLY
1. Position the valve bank on a work bench with the mounting studs
facing up. Remove the nuts (1) from the tie bolts (2). Remove the
outlet cover plate (3) from the valve bank. Remove and discard the
between section seal rings (4) and replace with new.
2. Remove the blade lift section (5) from the valve bank. Remove and
discard the between section seal rings (4) and replace with new.
★ Refer to BLADE LIFT SECTION.
3. Remove the ripper lift section (6) from the valve bank. Remove and
discard the between section seal rings (4) and replace with new.
★ Refer to RIPPER LIFT SECTION.
4. Remove the ripper pitch section (7) from the valve bank. Remove
and discard the between section seal rings (4) and replace with new.
★ Refer to RIPPER PITCH SECTION.
5. Remove the main relief valve (8) from the inlet cover (9).
★ Refer to MAIN RELIEF VALVE.
6. Remove the port plugs (10 and 11) from the inlet and outlet covers.
It is recommended that new seal rings be installed whenever the blade

lift valve bank is disassembled for service.
INSPECTION

pressed air or a clean cloth.
ASSEMBLY
1. Install the port plug (10) with new seal ring to the outlet cover port.
Port plugs ..............................................................45 to 53 N•m

2. Install the main relief valve (8) and port plug (11) with new seal
ring to the inlet cover (9).
Main relief valve ...................................................45 to 53 N•m

Port plug............................................................129 to 156 N•m
3. Oil the threads of the tie bolts (2) and install into the inlet cover.
4. Install the between section seals (4). Slide the blade lift section, rip-
per lift section and ripper pitch section on the tie bolts up against
the inlet cover.
5. Install the outlet cover on the tie bolts against the ripper pitch sec-
tion. Oil the nut threads and install to the tie bolts.
Tie bolt nuts ..........................................................68 to 82 N•m
30-230 2 D87E-2 D87P-2

Blade Lift Section

12
SERVICE

Port plug................................................................45 to 53 N•m
Ripper Lift Section
SERVICE
1. The blank port plug (1), the load check poppet (2) and the blank
port plug (3) are the only replacable parts.
Port plug................................................................45 to 53 N•m

Port plug................................................................45 to 53 N•m
D87E-2 D87P-2 30-231 2

Ripper Pitch Section

12
SERVICE

Port plug................................................................45 to 53 N•m
30-232 2 D87E-2 D87P-2

System Relief Valve

12
1. Adjusting Screw 8. Main Poppet 15. Back Up Ring

2. Jam Nut 9. Filter Screen 16. Seal Ring
3. Washer 10. Seal Ring 17. Seal Ring
4. Pilot Poppet 11. Back Up Ring 18. Back Up Ring
5. Poppet Return Spring 12. Seal Ring 19. Valve Body
6. End Cap 13. Seal Ring 20. Retaining Ring
7. Main Poppet Spring 14. Seal Ring
D87E-2 D87P-2 30-233 2

DISASSEMBLY
12
following steps.
1. Position the relief valve in a vise, adjusting end up. Remove the
tamper proof cover. While holding the adjusting screw (1), remove
the jam nut (2) and washer (3).
2. Remove the adjusting screw (1).

when disassembling.
3. Remove the pilot poppet (4) and the spring (5).
4. Remove the end cap (6).

when disassembling.
30-234 2 D87E-2 D87P-2

5. Remove the main poppet spring (7).
6. Remove the main poppet (8) with the filter screen (9).
7. Remove the seal ring (10) and the back up ring (11) from the main
poppet and discard.
8. Remove the seal ring (12) from the end cap (5) and discard.
D87E-2 D87P-2 30-235 2

12
9. Remove the seal ring (13) from the adjusting screw (1) and discard.
10. Remove the seal ring (14) and back up ring (15) from inside the
valve body and discard.
11. Remove the seal rings (16 and 17) and back up ring (18) on the out-
side of the valve body (19) and discard.
Due to the close tolerances of the working parts, the main relief
INSPECTION
valve internal parts are not serviced. If service other than the seals
is required, replace the complete relief valve.
ASSEMBLY
following steps.
1. Install new seal rings (16 and 17) and back up ring (18) on the out-
side of the valve body (19).
2. Install a new seal ring (14) and back up ring (15) down inside the
valve body.
30-236 2 D87E-2 D87P-2

3. Install a new seal ring (13) to the adjusting screw (1).
4. Install a new seal ring (12) to the end cap (5).
5. Install a new seal ring (10) and back up ring (11) to the main pop-
pet.
6. Install the main poppet (8) with the filter screen (9) into the valve
body.
D87E-2 D87P-2 30-237 2

12
7. Install the main poppet spring (7)
8. Install the end cap (6).

when assembling.
End cap ................................................................. 11 to 16 N•m
9. Install the pilot poppet (4) and the return spring (5).
10. Install the adjusting screw (1) half way into the end cap.

when assembling.
★ Final adjustment of the system relief valve will have to be made
with the control valve reinstalled into the machine. Refer to SEC-
TION 20.
30-238 2 D87E-2 D87P-2

12
11. While holding the adjusting screw (1), install jam nut (2).
D87E-2 D87P-2 30-239 2

BLADE
12 TILT VALVE BANK
battery.
chine.
REMOVAL
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE
★ This valve bank contains no serviceable parts, therefore replace the

complete valve bank.

nanace Manual.
30-240 2 D87E-2 D87P-2

BLADE
12 PILOT VALVE
battery.
chine.
REMOVAL
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE

nanace Manual.
D87E-2 D87P-2 30-241 2

1. Lever Boot 12. Upper Housing 23. Spring Spacer D Spool Components
2. Control Nut 13. Spring Retainer Clapper 24. Plunger Capsule 34. Plunger Actuator
3. Pivot Plate 14. Return Spring 25. Metering Capsule 35. Actuator Sleeve
4. Hardware 15. Spring Spacer C Spool Components 36. Upper Housing
5. Boot Clamp 16. Plunger Capsule 26. Plunger Actuator 37. Spring Retainer Clapper
6. Mounting Plate 17. Metering Capsule 27. Actuator Sleeve 38. Return Spring
7. Hardware B Spool Components 28. Upper Housing 39. Spring Spacer
8. Pivot Joint 18. Plunger Actuator 29. Spring Retainer Clapper 40. Plunger Capsule
9. Lower Housing 19. Actuator Sleeve 30. Return Spring 41. Metering Capsule
A Spool Components 20. Upper Housing 31. Spring Spacer
10. Plunger Actuator 21. Spring Retainer Clapper 32. Plunger Capsule
11. Magnetic Sleeve 22. Return Spring 33. Metering Capsule
30-242 2 D87E-2 D87P-2

DISASSEMBLY
12
following steps.
1. With the valve assembly mounted in a vise, remove the protective

boot (1).
2. Remove the control nut (2) and pivot plate (3).
3. Remove hardware (4) and the boot clamp (5).

when disassembling.
4. Remove the mounting plate (6) with the pivot joint (8). Remove the
hardware (7) and separate the parts.
★ Set aside four containers to house each of the spool parts, A, B, C

or D.
★ Disassemble the valve, one spool at a time and keep those parts in
their designated containers.
5. Remove the plunger actuator (10) and the magnetic sleeve (11)
6. Remove the upper housing (12) with the retainer clapper (13), re-
turn spring (14) and spacer (15).
7. Remove the plunger capsule (16) and metering capsule (17) from
the lower housing (9).
★ For service, refer to PLUNGER CAPSULE or METERING

CAPSULE in this section.
8. Disassemble the remaining three spools (B, C and D) per Steps 5

through 7.
D87E-2 D87P-2 30-243 2

ASSEMBLY
12
following steps.
★ Assemble the valve, one spool at a time.
1. Install the metering capsule (17) into the lower housing (9).
Metering capsule...................................................41 to 49 N•m

2. Install plunger capsule (16), spring end down, into the lower hous-
ing.
3. Install the spring spacer (15), return spring (14) and the spring re-
tainer clapper (13) on the plunger capsule.
4. Install the upper housing (12) over the return spring.
5. Install the magnetic sleeve (11) into the upper housing. Install the
plunger actuator through the sleeve.
★ Install the remaining three spools (B, C and D) per Steps 1 through
5.
6. Install the pivot joint (8) to the mounting plate (6) with hardware
(7).
•
Pivot joint bolt ........................................................ 8 to 11 N•m
7. Install the mounting plate and boot clamp (5) to the lower housing
and secure with hardware (4).
Clamp and plate bolt .............................................17 to 21 N•m

8. Install the pivot plate (3) on the pivot joint and secure with the con-
trol nut (2).
Control nut ............................................................58 to 72 N•m

9. Install the boot (1) to the mounting nut and clamp.
30-244 2 D87E-2 D87P-2

PLUNGER CAPSULE
12
A Spool
1. Capsule Body 2. Seal Ring 3. Shaft seal
SERVICE
1. Slide the capsule body (1) off the plunger shaft. Remove and dis-
card the seal ring (2) and shaft seal (3). Do not disassemble the
plunger capsule any further, if any of the remaining parts need re-
placement, replace the complete plunger assembly.
2. Install a new shaft seal into the capsule body, lips facing out. Using
tool DR-7-3059 install the capsule body to the plunger shaft.
D87E-2 D87P-2 30-245 2

B and D Spool
12
1. Capsule Body 2. Seal Ring 3. Shaft seal
SERVICE
1. Slide the capsule body (1) off the plunger shaft. Remove and dis-
card the seal ring (2) and shaft seal (3). Do not disassemble the
plunger capsule any further, if any of the remaining parts need re-
placement, replace the complete plunger assembly.
tool DR-7-3059 install the capsule body to the plunger shaft.
30-246 2 D87E-2 D87P-2

C Spool
12
1. Special Nut 4. Return Spring 7. Shaft Seal

2. Top Body 5. Spring Retainer
3. Retainer Washer 6. Seal Ring
SERVICE
1. Remove the nut (1) from the plunger shaft. Slide the top body (2),
washer (3) and return spring (4) off of the shaft. Remove spring re-
tainer (5). Remove seal ring (6) and shaft seal (7) and discard. Do
not disassemble the plunger capsule any further, if any of the re-
maining parts need replacement, replace the complete plunger as-
sembly.
2. Install a new shaft seal into the spring retainer, lips facing out. Us-
ing tool DR-7-3059 install the retainer to the plunger shaft.
3. Install the return spring, washer and top body to the plunger shaft
and secure with the nut.
D87E-2 D87P-2 30-247 2

METERING CAPSULE
12
1. Capsule Body 2. Large Seal Ring 3. Seal Ring 4. Back Up Ring
Service
1. Slide the capsule body (1) off the metering shaft. Remove and dis-
card the large seal ring (2) and seal ring (3) and back up ring (4).
Do not disassemble the metering capsule any further, if any of the
remaining parts need replacement, replace the complete plunger as-
sembly.
2. Install a new seal ring and back up ring into the capsule body. In-
stall a new large seal ring to the capsule. Slide the metering shaft
into the capsule.
30-248 2 D87E-2 D87P-2

RIPPER
12 PILOT VALVE
battery.
chine.
REMOVAL
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE
● Refill the hydraulic system, refer to the Operation and Mainten-

ace Manual.
D87E-2 D87P-2 30-249 2

1. Cover Boot 4. Mounting Hardware 7. Eye Bolt 10. Valve Housing

2. Control Nut 5. Boot Clamp 8. Mounting Plate Gasket 11. Metering Capsule
3. Pivot Plate 6. Mounting Plate 9. Plunger Capsule
30-250 2 D87E-2 D87P-2

DISASSEMBLY
following steps.
1. With the valve assembly mounted in a vise, remove the protective

boot (1).
2. Remove the control nut (2) and pivot plate (3).
3. Remove hardware (4) and the boot clamp (5).

when disassembling.
4. Remove the mounting plate (6) with the pivot bolt (7). Remove the
gaskets (8) and discard.
5. Remove the plunger capsule (9) and metering capsule (11) from the
lower housing (10).
★ For service, refer to PLUNGER CAPSULE or METERING CAP-

SULE in this section.
D87E-2 D87P-2 30-251 2

ASSEMBLY
12
following steps.
1. Install the metering capsule (11) into the housing (10).
Metering capsule...................................................41 to 49 N•m

2. Install plunger capsule (9), spring end down, into the lower hous-
ing.
3. Install the pivot bolt (7) to the mounting plate (6). Install gaskets
(8) to housing then the mounting plate and boot clamp (5) and se-
cure with hardware (4).
•
Mounting plate bolt...............................................17 to 21 N•m
4. Install the pivot plate (3) on the pivot bolt and secure with the con-
trol nut (2).
Control nut ............................................................58 to 72 N•m

5. Install the boot (1) to the mounting nut and clamp.
30-252 2 D87E-2 D87P-2

PLUNGER CAPSULE
12
1. Retaining Ring 2. Capsule Body 3. Seal Ring 4. Shaft Seal
Service
1. Remove the retaining ring (1) from the plunger shaft. Slide the cap-
sule body (2) off the plunger shaft. Remove and discard the seal
ring (3) and shaft seal (4). Do not disassemble the plunger capsule
any further, if any of the remaining parts need replacement, replace
the complete plunger assembly.
tool DR-7-3059 install the capsule body to the plunger shaft. Install
a new seal ring to the capsule body. Install the retaining ring to the
plunger shaft.
D87E-2 D87P-2 30-253 2

METERING CAPSULE
12
1. Capsule Body 2. Large Seal Ring 3. Seal Ring 4. Back Up Ring
Service
1. Slide the capsule body (1) off the metering shaft. Remove and dis-
card the large seal ring (2) and seal ring (3) and back up ring (4).
Do not disassemble the metering capsule any further, if any of the
remaining parts need replacement, replace the complete plunger as-
sembly.
2. Install a new seal ring and back up ring into the capsule body. In-
stall a new large seal ring to the capsule. Slide the metering shaft
into the capsule.
30-254 2 D87E-2 D87P-2

PILOT
12 SUPPLY VALVE
battery.
chine.
REMOVAL
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE

ace Manual.
D87E-2 D87P-2 30-255 2

1. End Cap 7. Spring Retainer 13. Roll Pin

2. Return Spring 8. Spring Shim 14. Check Ball Spring
3. Pilot Supply Spool 9. Seal Ring 15. Check Ball
4. Seal Ring 10. End Plug 16. Shipping Plug
5. End Plug 11. Seal Ring 17. Seal Ring
6. Return Spring 12. Pressure Regulator Spool 18. Quick Disconnect Fitting
-For Checking Pilot Pressure-
30-256 2 D87E-2 D87P-2

DISASSEMBLY
12
following steps.
1. Slowly remove each end caps (1) until the return spring (2) pres-
sure is alleviated, then remove the supply spool (3) and spring. Re-
move and discard the seal rings (4) from the end plugs.

when disassembling.
2. Slowly remove the end cap (5) until the return spring (6) pressure is
alleviated, then remove the spring retainer (7), shim (8) and spring.
Remove and discard the seal ring (9) from the end plug.

when disassembling.
3. Remove the end cap (10) and discard seal ring (11). Remove the
pressure regulator spool (12) from the valve housing (19).
4. Using a drift, remove the roll pin (13) from the pressure regulator
spool. Slowly retract the drift pin and remove the return spring (14)
and the check ball (15) from the spool.

when disassembling.
D87E-2 D87P-2 30-257 2

12
It is recommended that new seal rings be installed upon assembly
of the valve.
INSPECTION
obstructions.
placed.
ASSEMBLY
following steps.
1. Install the check ball (15) and return spring (14) into the pressure
regulator spool (12). Compress the return spring and hold with a
drift pin. Install roll pin (13), driving drift pin out below the edge of
the spool.

when assembling.
2. Coat the pressure regulator spool with clean oil and install into the
valve housing. Install end plug (10) with a new seal ring (11).
3. Install retainer (7), shims (8) -that were removed- and return spring
(6) into valve housing and secure with the end cap (5) with a new
seal ring (9).

when assembling.
★ Each 0.381 mm shim added will change the regulator pressure by
0.35 kg/cm².
30-258 2 D87E-2 D87P-2

12
4. Coat the pilot supply spool (3) with clean oil and insert into the
valve housing with the return spring (2). Install a end cap (1) with a
new seal ring (4) at one end of the housing. Compress the return
spring and install the remaining end cap (1) with a new seal ring
(4).

when assembling.
D87E-2 D87P-2 30-259 2

QUICK
12 DROP VALVE
battery.
chine.
REMOVAL
NOT AVAILABLE
INSTALLATION
NOT AVAILABLE

ace Manual.
30-260 2 D87E-2 D87P-2

12
1. Cover Plate 4. Inner Return Spring 7. End Cap

2. Seal Ring 5. Spring Retainer 8. Valve Spool
3. Outer Return Spring 6. Seal Ring 9. Quick Drop Valve Housing
D87E-2 D87P-2 30-261 2

DISASSEMBLY
12
following steps.
1. Remove two of the bolts from the cover plate (1). Install M10x100
studs (A) and secure with M10 nuts and washers. Remove the re-
maining two bolts from the cover plate. Slowly loosen the nuts un-
til all of the tension from the return springs is dissipated. Remove
and discard the cover seal ring (2).

when disassembling.
2. Remove the outer (3) and inner (4) return springs and the spring re-
tainer (5) from the valve housing (9).
3. Remove the end cap (7) and discard seal ring (6). Remove the valve
spool (8) from the housing.
It is recommended that new seal rings be installed upon assembly

of the valve.
INSPECTION
obstructions.
placed.
30-262 2 D87E-2 D87P-2

ASSEMBLY
12
following steps.
1. Install the valve spool (8) into the valve housing (9). Install end
plug (7) with new seal ring (6) to the valve housing.
2. Install the spring retainer (5) and inner (4) and outer (3) return
springs into the valve housing.
3. Install a new seal ring (2) into the valve housing. Install the studs
(A) into the valve housing. Position the cover plate (1) over the
studs onto the return springs. Using the nuts and washers, draw the
cover plate down and secure with hardware.
Cover plate bolts ...................................................41 to 51 N•m

when assembling.
D87E-2 D87P-2 30-263 2

DISASSEMBLY AND ASSEMBLY EQUIPMENT CYLINDERS
EQUIPMENT
12 CYLINDERS
BLADE LIFT
REMOVAL

battery.
chine.
1. Attach a hoist to the blade lift cylinder (1). Remove the rod pin (2)
at the blade. Connect the rod end to the cylinder housing using
strong wire.
2. Disconnect the tubes (3) from the cylinder. Remove the bearing
caps (4) with kidney plates and remove the lift cylinder.
INSTALLATION
Bearing cap bolts ......................................................... 450 N•m

ace Manual.
30-264 2 D87E-2 D87P-2

12
1. Cylinder Rod 9. Wear Ring 17. Rod Seal

2. End Cover 10. Seal Ring 18. Rod Wiper
3. End Cover Gland 11. Piston Seal 19. Rod Bearing
4. Segmented Lock Ring 12. Seal Ring 20. Bearing Retainer Plate
5. Piston Nut 13. Back Up Ring 21. Bearing Retainer Plate - Threaded
6. Nut Washer 14. Wear Ring 22. Cylinder Barrel
7. Cylinder Piston 15. Buffer Ring 23. Yoke Bearing
8. Piston Poppet 16. Seal Ring
D87E-2 D87P-2 30-265 2

DISASSEMBLY
12
following steps.
1. Steam clean or wash the cylinder with solvent before disassembly.

Attach a hoist to the cylinder rod eye, using a strap to protect the
bearing in the 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.
2. Remove bolts securing the end cover (2) to the gland (3) and tie the
cover up to the rod eye. Using a brass drift, drive the gland into the
housing until the tension is off of the lock ring (4).
3. Remove the lock ring from the housing and pull the cylinder rod as-
sembly out of the housing with the hoist.
4. Remove the piston rod nut (5).
★ It will be necessary to hold the eye end of the rod stationary when
removing the nut. A suggested method is to clamp the eye end of
the piston rod in a hydraulic press and use a torque multiplier, or an
impact tool.
5. Remove the washer (6) and piston (7) from the rod. Remove the
poppets (8), wear rings (9), seal rings (10) and piston seal (11) from
piston.
6. Slide the gland (3) from the rod. Remove the seal ring (12), back up
ring (13), wear ring (14), buffer ring (15) and seal ring (16) and rod
seal (17) from the gland. Slide the end cover (2) off of the rod and
remove the rod wiper (18) from the cover.
30-266 2 D87E-2 D87P-2

12
7. If the bearing (19) needs replacement, remove plates (20 and 21)
and press out the old bearing.
It is recommended that all new seal rings, backup rings, wear rings,
packing and seals be installed when the lift cylinder is disassembled.
Wash all parts in a suitable solvent and air dry. Lubricate machined
surfaces of usable parts to protect them. Inspect the cylinder housing
for roundness through its length. If a tight spot is noticed when re-
moving the piston, the area of binding should be given particular at-
INSPECTION
tention. A cylinder housing that is out-of-round should be replaced.

Check the cylinder housing and piston rod for scratches or grooves.
Shallow scratches can be polished out with fine emery cloth and oil
so a smooth surface is presented to the packing. Inspect all sealing
ring grooves for scratches, burrs or other damage. Dress up grooves
or replace part as necessary. Inspect tapped holes for damaged
threads.
If the piston rod bearing was removed, remove all rust, scale or paint
from the bore in the piston rod. Inspect the cylinder mounting bush-
ings for excessive wear or damage and replace if necessary. Inspect
the poppets and their seats in the piston.
ASSEMBLY
following steps.
1. If the bearing (19) was removed, press the new bearing in the rod
eye and install the plates (20 and 21) and secure with hardware.
The bearing must be installed in the bore of the piston rod with the
slots positioned as shown.
Bearing plate bolts ................................................73 to 89 N•m
2. Install the outer rod wiper (18), lip facing out, into the cover and in-
stall the cover onto the cylinder rod.
★ The outer end of the gland is determined as the bolt end and the in-
side end as facing the piston.
3. Coat the bores and grooves of the gland with fresh grease. Install
the rod seal (17) by squeezing the side of the seal together and start-
ing the seal into the groove. Then work the remainder in with the
thumbs. DO NOT use a screwdriver as it will damage the seal. In-
stall the seal ring (16) and buffer ring (15), notched edge facing in,
into the gland and follow with the wear ring (14). Install the seal
ring (12) and backup ring (13) into the gland. Slide the gland onto
the rod, tapped holes toward the rod eye.
D87E-2 D87P-2 30-267 2

4. Install the piston seal (11) onto the piston (7). Install the seal rings
(10) and wear rings (9) on each end of the piston. Install the pop-
pets (8), three each end, into the piston and the slide piston onto the
rod. Secure with washer (6) and piston nut (5). Clamp rod assembly
into press.
Piston retaining nut .......................................1017 to 1085 N•m

5. Apply a generous amount of fresh grease to the inside of the hous-
ing and secure to the hoist frame. Install a ring compressor on the
piston and compress the wear rings. Compressing the wear rings
will memory the rings back to size and greatly reduce the possibili-
ty of damage during installation. Attach a hoist to the rod and lower
the assembly into the barrel using extreme care as not to damage
the wear rings (10) and piston seal (11). Once the piston has entered
the barrel, remove the compressor. Tie the end cover (2) to rod eye
to provide working clearance. Drive the rod down to about 1/2
stroke.
6. Start the gland assembly into the housing and drive in just below
the lock ring groove. Install the lock ring (4) into the groove. Re-
lease the end cover and position in place. Install two puller bolts
and nuts and thread into the gland. Tighten the nuts to draw the
gland up against the lock rings. Remove the puller arrangement.
Secure the cover to the gland with hardware.
End cover bolts ...................................................... Loctite #262
End cover bolts .................................................481 to 550 N•m
30-268 2 D87E-2 D87P-2

12
DOZER TILT
REMOVAL

battery.
chine.
1. Remove the hoses guard (1) and disconnect the hoses (2) at the tilt
cylinder (3) and position out of the way.
2. Attach a hoist and sling (A) to the tilt cylinder. The hoist must be
installed to give the best possible balance. Place tension on the
hoist.
3. Remove the bolts securing the socket cap (4) and move the cap off
of the blade. Keep the socket cap shims (5) with the blade.
4. Remove the pin (6), then remove the cylinder from the machine.
INSTALLATION
Install the socket cap without the shims. Measure the gap between the
socket cap and the socket, then remove the bolts. Install a shims pack of
the measured gap plus an additional shim for clearance.
Socket cap bolts ........................................................... 450 N•m

ace Manual.
D87E-2 D87P-2 30-269 2

12
1. Socket Cap 8. Piston Nut 15. Back Up Ring

2. Piston Rod 9. Flat Washer 16. Wear Ring
3. End Cover 10. Cylinder Piston 17. Buffer Ring
4. Cylinder Gland 11. Wear Ring 18. Back Up Ring
5. Segmented Lock Ring 12. Seal Ring 19. Rod Seal
6. Seal Ring 13. Piston Seal 20. Rod Wiper
7. Cylinder Barrel 14. Seal Ring 21. Pin Bushing
30-270 2 D87E-2 D87P-2

DISASSEMBLY
12
following steps.
★ Steam clean or wash the cylinder with solvent before disassembly.
1. Attach a hoist and sling to the socket cap (1). Raise the cylinder up
and secure it to the hoist frame. Using the hoist, pull the cylinder
rod (2) out to approximately 1/2 stroke.
2. Remove the hardware securing the end cover (3) to the gland (4)
and tie the cover to the socket cap to provide working clearance.
3. Using a brass drift drive the gland into the housing until the tension
of the lock ring (5) is off. Remove the seal ring (6) and the three
piece lock ring from the housing. Pull the rod assembly out of the
housing (7).
★ It will be necessary to hold the ball end of the rod stationary when
removing the nut. A suggested method is to clamp the flats of the
ball end of the piston rod in a vise and use a torque multiplier, or an
impact tool.
wear rings (11), seal rings (12) and piston seal (13) from the piston.
6. Slide the gland (4) off the rod. Remove the seal ring (14), back up
ring (15), wear ring (16), buffer ring (17), seal ring (18), rod seal
(19) and rod wiper (20) from the gland. Remove the seal ring (6),
slide the end cover (3) and the socket cap off of the rod.
D87E-2 D87P-2 30-271 2

12
7. If necessary, press the bushing (21) from the housing (7). Press the
new bushing into the housing until flush (A).
INSPECTION
tention. A cylinder housing that is out of round should be replaced.

threads.
Inspect the cylinder mounting bushings for excessive wear or damage
and replace if necessary. Inspect the poppets and their seats in the pis-
ton.
ASSEMBLY
following steps.
1. Coat the bore and grooves of the gland (9) with fresh grease. Install
thumbs. Do not use a screwdriver as it will damage the seal. Install
the seal ring (17) and buffer ring (18), notched edge facing in, into
the gland and follow with the wear ring (16). Install the rod wiper
(20) into the gland. Install the seal ring (14) and backup ring (15)
onto gland (9).
2. Install the seal ring (6) onto the gland. The tapped holes in gland
must face toward the rod ball. Position the socket cap (1), end cover
(3) and gland (4) onto the cylinder rod
30-272 2 D87E-2 D87P-2

12
(12) and wear rings (11) on each end of the piston. Install and slide
the piston onto the rod. Secure with the washer (9) and nut (8).
Clamp ball rod into press.
Piston nut ......................................................1730 to 1790 N•m

will memory rings back to size and greatly reduce the possibility of
damage during installation. Tie the end cover (3) to the strut ball
cap to provide working clearance. Attach a hoist to the socket cap
and lower the rod into the housing using extreme care not to dam-
age the wear rings (11) and piston seal (13). Once the piston has en-
tered the housing, remove the ring compressor and drive the
cylinder rod to 1/2 stroke.
End cover bolts .....................................................73 to 89 N•m
D87E-2 D87P-2 30-273 2

12
ANGLE TILT
REMOVAL

battery.
chine.
1. Remove the hoses guard (1) and disconnect the hoses (2) at the tilt
cylinder (3) and position out of the way.
2. Attach a hoist and sling (A) to the tilt cylinder. The hoist must be
hoist.
3. Remove the pins (4), then remove the cylinder from the machine.
INSTALLATION

ace Manual.
30-274 2 D87E-2 D87P-2

12
1. Piston Rod 9. Flat Washer 17. Buffer Ring

2. Pin Bushing 10. Cylinder Piston 18. Back Up Ring
3. End Cover 11. Wear Ring 19. Rod Seal
4. Cylinder Gland 12. Seal Ring 20. Rod Wiper
5. Segmented Lock Ring 13. Piston Seal 21. Pin Bushing
6. Seal Ring 14. Seal Ring 22. Bleeder Line Plug
7. Cylinder Barrel 15. Back Up Ring
8. Piston Nut 16. Wear Ring
D87E-2 D87P-2 30-275 2

DISASSEMBLY
12
following steps.
1. Attach a hoist and sling to the rod eye. Raise the cylinder up and se-
cure it to the hoist frame. Using the hoist, pull the cylinder rod (1)
out to approximately 1/2 stroke.
and tie the cover to the rod eye to provide working clearance.
housing (7).
impact tool.
slide the end cover (3) off of the rod.
30-276 2 D87E-2 D87P-2

12
7. If necessary, press the bushing (21 or 2) from the housing (7) or rod
(1). Press the new bushing into the housing or rod until it is flush
(A).
INSPECTION

threads.
ton.
ASSEMBLY
following steps.
onto gland (9).
D87E-2 D87P-2 30-277 2

12
Piston nut ......................................................1730 to 1790 N•m

damage during installation. Tie the end cover (3) to the rod eye to
provide working clearance. Attach a hoist to the rod eye and lower
the rod into the housing using extreme care not to damage the wear
rings (11) and piston seal (13). Once the piston has entered the
housing, remove the ring compressor and drive the cylinder rod to
1/2 stroke.
30-278 2 D87E-2 D87P-2

RIPPER
12 LIFT
REMOVAL

battery.
chine.
1. Disconnect the hydraulic hoses (1) to the cylinder (2).
2. Attach a hoist and sling to the cylinder. The hoist and sling must be
sling.
3. Remove the pin retainer plate (3) and take out the pins (4). Remove
the ripper lift cylinder.
INSTALLATION

ace Manual.
D87E-2 D87P-2 30-279 2

12
1. Piston Rod 8. Piston Nut 15. Back Up Ring

2. Rod Bushing 9. Flat Washer 16. Wear Ring
30-280 2 D87E-2 D87P-2

DISASSEMBLY
12
following steps.
housing (7).
impact tool.
D87E-2 D87P-2 30-281 2

12
7. If necessary, press the bushing (21 or 2) from the housing (7) or rod
(1). Press the new bushing into the housing or rod until it is flush
(A).
INSPECTION

threads.
ton.
ASSEMBLY
following steps.
onto gland (9).
30-282 2 D87E-2 D87P-2

12
Piston nut ......................................................2778 to 2913 N•m

1/2 stroke.
D87E-2 D87P-2 30-283 2

RIPPER
12 PITCH
REMOVAL

battery.
chine.
1. Disconnect the hydraulic hoses (1) to the cylinder (2).
2. Attach a hoist and sling to the ripper pitch cylinder. The hoist and
sling must be installed to give the best possible balance. Place ten-
sion on the sling.
3. Remove the pin retainer plate (3) and take out the pins (4). Remove
the ripper pitch cylinder.
INSTALLATION

ace Manual.
30-284 2 D87E-2 D87P-2

12
1. Piston Rod 8. Piston Nut 15. Back Up Ring

2. Rod Bushing 9. Flat Washer 16. Wear Ring
D87E-2 D87P-2 30-285 2

DISASSEMBLY
12
following steps.
housing (7).
impact tool.
30-286 2 D87E-2 D87P-2

12
7. If necessary, press the bushing (21 or 22) from the housing (7) or
rod (2). Press the new bushing into the housing or rod until it is
flush (A).
INSPECTION

threads.
ton.
ASSEMBLY
following steps.
onto gland (9).
D87E-2 D87P-2 30-287 2

12
Piston nut ......................................................1694 to 1762 N•m

1/2 stroke.
30-288 2 D87E-2 D87P-2

DISASSEMBLY AND ASSEMBLY UNDERCARRIAGE
UNDERCARRIAGE
12
1. Front Idler 4. Front Top Idler 7. Equalizer Bar

2. Track Adjuster 5. Track Frame 8. Pivot Shaft
3. Track Roller 6. Track Guide Plates 9. Recoil Spring
D87E-2 D87P-2 30-289 2

WEAR
12 LIMITS
SPECIFICATIONS
Standard Grouser Height

100% REMAINING 66.55 mm 25% REMAINING 40.39 mm
50% REMAINING 49.02 mm WEAR FACTOR 34.79 mm
Link Height
Bushing OD - Dry Sealed Track System
Bushing OD - Lubricated Track System
Internal Pin and Bushing Wear (Pitch)
Front Idler Flange Height
Track Roller Diameter
Top Idler Diameter
50% REMAINING 184.15 WEAR FACTOR 12.7 mm
30-290 2 D87E-2 D87P-2

GENERAL
12
The track components have a certain dimension when new. As wear oc-
curs, the dimensions will decrease (or increase in case of the track pitch
and the front idler flange height) until a decision must be made whether
to rebuild or recondition the components, replace them or run them to
destruction. For each component or condition, five different dimensions
are given. 100% is the dimension of the component when new. 075%,
050% and 025% indicate % of wear remaining before a maintenance ac-
tion should be taken. 000% is the point at which either maintenance
must take place or the components are to be run to destruction. Before
inspecting, the chain tension on both sides must be tightened. To do this,
a metal bar should be placed in the sprocket tooth under the chain. The
machine should then be moved backward so the sprocket can grab the
metal bar and tighten the chain. This pulls the chain tight off the top
idler.
★ The tools used to measure the undercarriage components are in-
cluded in the Track Specialist Kit A1.
TRACK SHOE GROUSER HEIGHT
Clean off all the materials on the shoe plate and the grouser tops. Lay
the squeeze bar (2) across the grousers approximately 1/4 of the way in
from the end of the shoe. Insert the 305 mm scale (1) in the squeeze bar
so that the scale is against the top of the track shoe plate. Take a reading.
Measure two or more shoes to get an average.
LINK HEIGHT
Clean out all materials between the links. Place the squeeze bar (1)
across the center of the links. Insert the 305 mm (12 in) scale (2) in the
squeeze bar so that the scale is against the bottom of the track shoe
plate. Take a reading. Measure two or more place along the chain to get
an average.
BUSHING OUTSIDE DIAMETER
Close the 102 mm outside caliper (1) around the bushing with a mini-
mum amount of drag, making certain that one of caliper tips is posi-
tioned in the forward drive side wear area. Slide the caliper off the
bushing and measure the distance between the caliper tips using the 305
mm scale. Repeat on the reverse drive side wear area. Measure two or
more bushings to get an average.
★ Whichever wear is greater, forward or reverse, determines the per-

centage of wear remaining.
D87E-2 D87P-2 30-291 2

INTERNAL PIN AND BUSHING WEAR (PITCH)

12
★ To measure the track pitch, the track chain must be tight.
Place the end of the 3 m tape (1) on the front of one track pin and mea-
sure the length of four links to the front of the fifth track pin.
FRONT IDLER FLANGE HEIGHT
Insert the 305 mm scale (1) in the squeeze bar (2). Rest the squeeze bar
on the top of the flange and push the scale down until it makes contact
in the middle of the tread area as shown. Take a reading.
TRACK ROLLER ROLLING DIAMETER
Place the tips of the 305 mm caliper (1) against the tread area of the roll-
er. Adjust the caliper so that a slight drag is present when the caliper is
removed. Using the scale measure the distance between the caliper tips.
Repeat the steps on the remaining rollers.
TOP IDLER ROLLING DIAMETER
Place the tips of the 305 mm caliper (1) snugly around the tread area of
the top idler and remove. Using the scale, measure distance between the
caliper tips. Repeat the steps on the remaining rollers.
30-292 2 D87E-2 D87P-2

FRONT
12 IDLER
REMOVAL

machine.
1. Remove the following.
Track chain ................................................... Refer to TRACK CHAIN.
★ It is only necessary to lift chain free from front idler.
2. Remove the front idler covers (1) from the track frame (2).
★ Be sure the track adjuster relief valve is unscrewed one full turn to
avoid entering a vacuum in the cylinder.
3. Attach a hoist to the front idler and fork (3) and remove from the
track frame.
WARNING! After the front idler and fork clears the track
frame, it will swing down. Stay clear of the area.
4. Check the on the upper (4) and lower guide (5) bars.
Front idler guide bars ..........Refer to FRONT IDLER GUIDE BARS.
INSTALLATION
Front cover bolts .......................................................... 220 N•m
D87E-2 D87P-2 30-293 2

12
1. Track Adjuster Fork 6. Seal Ring 11. Idler Bushing

2. Clamp Block 7. Metal Type Face Seal 12. Idler Shaft
3. Pipe Plug 8. Inner Seal Retainer 13. Idler Housing
4. Retaining Ring 9. Seal Ring
5. Outer Seal Retainer 10. Thrust Washer
30-294 2 D87E-2 D87P-2

DISASSEMBLY
12
following steps.
1. Remove the hardware and fork (1) from the front idler. Remove the
bolts from the clamp block (2). Using a large pry bar, relieve the
clamping tension on the front idler shaft. Remove the blocks. Re-
move the dowel pin from the idler shaft.
2. Remove the plug (3) and drain the oil from the front idler. Remove
the retaining ring (4).
3. Slide the outer seal retainer (5) with the seal ring (6) off the shaft.
Remove the metal type face seal half (7) from shaft. One half of the
metal face seal will remain in the seal retainer, remove and, along
with the other seal half and seal ring, discard and replace with new.
Metal type face seals ..............Refer to METAL TYPE FACE SEALS
4. Remove mounting hardware from the inner seal retainer (8). Using
the three 1/2NC jack screw holes in the seal retainer, remove the re-
tainer with bushing and thrust washer (10) from one side of the
front idler. Remove and discard the seal ring (9). Remove the idler
shaft (12). Remove the seal retainer from the remaining idler side.
D87E-2 D87P-2 30-295 2

12
5. The bushing (12) is a press fit in the seal retainer with the thrust
washer (10) captured, and must not be removed unless replacement
is necessary.
It is recommended that new seal rings be installed whenever the front

idler is disassembled for service.
Wash all parts thoroughly in a suitable solvent. Dry thoroughly with
compressed air.
INSPECTION
Inspect the idler shaft, bushing, washer and idler for cracks, scores or
excessive wear.
Check the clearance limits.
Inspect the blocks and guide for distortion or excessive wear. Replace
if necessary.
Whenever the front idlers is disassembled, the oil seal must be rebuilt
or replaced. Follow the instruction furnished with the seal or kit.
ASSEMBLY
following steps.
1. If replacing the bushing, install the thrust washer (10) into the seal
retainer. Thinly coat the leading 25 mm edge of the bushing (11)
OD. Press the bushing into the retainer up against the thrust washer.
Bushing OD coating............................................... Loctite #609

2. Apply a small amount of grease to seal ring (4) and install in
groove in retainer (3).
3. Install three 1/2NC aligning studs (A) into the idler housing and po-
sition in a press. Position seal retainer (8) over studs and press flush
against the idler housing being careful not to damage the seal ring
(9). Secure with the hardware.
Seal retainer bolts......................................................... 135 N•m
30-296 2 D87E-2 D87P-2

12
4. Turn the assembly over and apply a thin coat of engine oil to the in-
side of the bushing. Insert the shaft (12) into the front idler housing.
Install three 1/2NC aligning studs (A) into the idler housing and po-
sition in a press. Position seal retainer (8) over studs and press flush
against the idler housing being careful not to damage the seal ring
(9). Secure with the hardware.
Seal retainer bolts......................................................... 135 N•m
5. Check that the front idler end clearance is within the tolerance giv-
en. From the side of the roller the dial indicator is to be mounted,
push the roller shaft into the housing to be sure it is bottomed
against the thrust washer. Place the indicator base on the idler hous-
ing with the indicator pointer resting against the end of the shaft.
Set the indicator at zero. Push the shaft toward the indicator until it
bottoms and take a reading. If the reading obtained is below specifi-
cation, check the measured surfaces for squareness. If above check
is below specifications, check the parts for excessive wear.
End clearance ................................................. 0.106 to 0.89 mm
★ Do not at any time handle the metal type face seal with greasy, oily
or dirty hands. The idler must not be filled with lubricant until the
idler and the track frame are in position. Before installing the metal
type face seal, be sure the seal contacting surfaces of the housing
and retainer are clean and dry. Also that the rubber rings of the seal
assembly are correctly positioned on the metal rings.
Metal type face seals ..............Refer to METAL TYPE FACE SEALS
6. Apply a small amount of grease on the seal ring (6) and install in
the seal retainer (5).
7. Secure the seal retainer in place with the retaining rings (4).
D87E-2 D87P-2 30-297 2

CLEARANCE LIMITS
12
A. Distance between seal retainers ........................................................................................................ 178.828 to 179.148 mm

MINUS (–)
B. Width of idler shaft bushing surface ..................................................................................................... 172.06 to 172.22 mm
MINUS (–)
C. Washer thickness ....................................................................................................................................... 3.099 to 3.251 mm
EQUALS (=)
End Clearance ........................................................................................................................................... 0.106 to 0.89 mm
D. Bushing Assembled Inside Diameter ................................................................................................ 105.207 to 105.359 mm

MINUS (–)
E. Idler Shaft Diameter.......................................................................................................................... 104.905 to 104.955 mm
EQUALS (=)
Diametral (Oil) Clearance ...................................................................................................................... 0.252 to 0.454 mm
30-298 2 D87E-2 D87P-2

12
1. Apply pipe sealant to the plug threads. When reusing a pipe plug,
clean the plug before applying new pipe sealant to assure a tight
seal. Insert lubricator nozzle all way into shaft until it enters small
fill hole in center of shaft. Pump lubricant in until air is forced out
and lubricant back flows freely out plug hole in shaft. Then quickly
remove lubricator nozzle and install lubrication plug.
Pipe plug threads.................................................... Loctite #592

Pipe plug ...............................................................21 to 55 N•m
★ When reassembling the front idler to the blocks and fork, the drain
plug must be facing to the outside and the dowel pin to the inside.
2. Coat the bores of mounting blocks (2) with grease. Install the dow-
el pin into the idler shaft. Install the blocks onto the idler shaft and
secure with the fork (1) and hardware.
Fork bolts ..................................................................... 455 N•m

3. Install the mounting block clamp bolts. Install the mounting block
with the dowel pin to the inside (opposite the lube plug) of the front
idler and mounting block and secure with hardware.
Mounting block clamp bolts ........................................ 730 N•m
D87E-2 D87P-2 30-299 2

TRACK
12 ADJUSTER
REMOVAL

machine.
1. Remove the following.
Front idler ...................................................... Refer to FRONT IDLER.
★ It is only necessary to lift chain free from front idler. Be sure the
track adjuster relief valve is unscrewed one full turn to avoid enter-
ing a vacuum in the cylinder.
2. Slide the track adjuster out of the track frame and remove.
INSTALLATION
1. Adjuster Rod 5. Retaining Ring 9. Check Filler Valve

2. Adjuster Housing 6. Piston Seal 10. Relief Valve
3. Rod Wiper 7. Guide Rings
4. Adjuster Piston 8. Lube Fitting
30-300 2 D87E-2 D87P-2

DISASSEMBLY
12
following steps.
1. Pull the rod (1) out of the manifold (2). Remove the rod wiper (3).
2. Remove the piston (4) as an assembly from the manifold. A tapped

hole is provided in the piston to facilitate removal.
3. Remove the retaining ring (5), piston seal (6) and guide rings (7)
from the piston.
4. Remove the lube fitting (8), check filler valve (9) and relief valve
(10) from the manifold.
It is recommended that a new retaining ring and piston seal be in-

INSPECTION
stalled whenever the track adjuster is disassembled. Wash all parts

thoroughly in a suitable solvent. Dry completely with compressed air.
Inspect parts for excessive wear or damage and replace if necessary.
Inspect the blocks and guide for damage or excessive wear and re-
placed if necessary.
ASSEMBLY
following steps.
1. Secure the lube fitting (10) to the filler valve (9). Install the valve
with the fitting and relief valve (8) to the manifold.
Filler or relief valve ....................................................... 68 N•m

2. Install the guide rings (7) onto the piston (4). Position the guide
rings on piston with sliced cuts 180° apart. Install the piston seal (6)
on the piston with the U cup of the seal facing the retaining ring
groove. Install the retaining ring (5) in the groove on the piston.
3. Place fresh grease in the bore of the manifold. Insert the piston as-
sembly, retaining ring end first, into the manifold until it bottoms so
that the air will be expelled and grease appears through the valve
openings in the manifold. Place enough grease into the manifold to
fill the undercut area on the rod. Install the rod wiper (2), lips fac-
ing out, into the groove on the manifold. Install the rod, undercut
end first, slowly and evenly into the manifold until it bottoms. If
too much grease was installed in the manifold behind the piston,
the rod wiper may be forced out as the rod is inserted. If this hap-
pens, remove the rod and reinstall the wiper and rod.
D87E-2 D87P-2 30-301 2

TRACK
12 ROLLER
REMOVAL

machine.
WARNING! Please observe all safety and precautionary

standards as dictated by environment and work conditions
under which equipment will be inspected, reworked and re-
paired. See Safety and your distributor on any and all ques-
tions regarding safety.
1. Release chain tension.
2. Jack up the machine approximately 152 mm off the ground and in-
stall suitable stands under the mainframe. Remove the sprocket
rock shields (1).
3. Remove the track roller shields (2) from the track frame.
4. Remove the bolts securing the track roller (3) shaft brackets to the
underside of the track frame. Remove the roller. A tap with a soft
hammer will usually free the roller if it tends to stick in the frame.
If there is not enough track chain slack to remove the roller, posi-
tion two jacks between the chain and frame. Jack up the frame until
enough clearance is obtained to remove the track roller.
INSTALLATION
Rock deflector bolts ..................................................... 455 N•m
Roller shield bolts ........................................................ 455 N•m
Track roller bolts.......................................................... 455 N•m
30-302 2 D87E-2 D87P-2

12
1. Dowel Pin 5. Metal Type Face Seal 9. Roller Bushing

2. Mounting Bracket 6. Seal Retainer 10. Roller Housing
3. Roller Shaft 7. Seal Ring 11. Pipe Plug
4. Seal Ring 8. Thrust Washer
D87E-2 D87P-2 30-303 2

DISASSEMBLY
12
following steps.
1. Drain the roller into a suitable container. Drive out the dowel pin
(1) securing the mounting bracket (2) to the shaft (3) on each side
of roller.
2. Remove the brackets with the seal ring (4) from each side. Remove
the metal type face seals (5) from either the bracket or the retainer
(6) depending on how the seal separates.
3. Remove seal retainer (6) with seal rings (7) and thrust washer (8)
from each side of roller. Pull roller shaft (3) out of the roller hous-
ing (10).
4. The bushings (9) are a press fit in the roller housing and must not
be removed unless replacement is necessary. Check the clearances.
Replace parts as necessary.
30-304 2 D87E-2 D87P-2

12
Clean all parts with a solvent and dry with compressed air. Clean and
flush out bore of track roller, as well as oil passages in roller shaft.
Make a final check of end clearance with a dial indicator after com-
plete roller has been assembled. Whenever a track roller is disassem-
bled, used seals must pass an inspection or a new seal used. Refer to
METAL TYPE FACE SEALS for seal service.
Using coarse paper, a file, or a hand grinder, remove any corrosion or
hardened foreign material that may exist on seal bore surfaces of re-
tainer and bracket. Do this carefully to avoid changing dimensions of
INSPECTION
bore. It is suggested that all sealing rings be replaced with new ones.
Check thrust washers for wear and, if worn beyond limits given, re-
place with new. Check remaining clearances and replace worn parts
as required.
Wash all the parts thoroughly in a solvent and dry with compressed
air. Wash all the bushings. Clean and flush out the bore of the track
roller, as well as the oil passage in the roller shaft. Replace all seal
rings and sealing rings with new. Inspect the roller shafts, bushings
and rollers for cracks, scores or excessive wear. Determine if the
thrust washers are worn beyond the limits. If worn, replace with new.
Check the end clearance and diametral clearance. Whenever the track
roller is disassembled, the oil seal must be rebuilt or replaced with a
new seal. Follow the instructions furnished with the seal or kit.
ASSEMBLY
following steps.
1. If replacing the bushings, install new bushings as follows:
Thoroughly clean the bores of the roller body with clean solvent
and dry with compressed air. Apply Loctitte primer T or N on the
outside of the bushing and allow to dry completely. Coat the lead-
ing 25 mm of the outer edge of the roller body bore and the leading
edge of bushing. Press bushings in to 7.1 to 7.7 mm (A). Bushings
must be pressed in within 5 minutes after applying loctite.
Leading edge of bore and bushing ......................... Loctite #609
2. Place the thrust washer (8) in the roller bore so it is flat against the
bushing. Apply small amount of fresh grease to the seal ring (7)
and install in the groove in the roller body. Position the seal retainer
(6) on the roller body and secure with hardware. Turn the assembly
around and apply a thin coat of fresh oil to insides of bushings. In-
sert the roller shaft (3) into the roller body.
Retainer bolt threads .............................................. Loctite #120

Retainer bolts ................................................................. 87 N•m
D87E-2 D87P-2 30-305 2

12
3. Check that the track roller end clearance is within tolerances given.
Apply small amount of fresh grease to the seal ring and install in
the groove in the roller body. Position the seal retainer on the roller
body and secure with hardware.
Retainer bolt threads .............................................. Loctite #120

Retainer bolts ................................................................. 87 N•m
4. Place the dial indicator base on the roller body with the indicator
point resting on the end of the shaft. Set the indicator to zero. Push
up on the shaft and take a reading. Bottom the shaft and retake the
reading and average. If the reading obtained is below specification,
check measured surfaces (A, B and C).
5. Apply a small amount of fresh grease to the seal ring (4) and install
in the shaft. Install the seal, refer to METAL TYPE FACE SEALS
in this section. Install the bracket (2) on the shaft.
6. Apply hand pressure to the bracket until the pin holes are aligned.
Install the dowel pin (1) until it is slightly below the bracket surface
and peen over the bracket casting to maintain its position. Repeat
this step on opposite side.
7. Position the roller with the fill port facing up. Coat the drain plug
threads. Using a tank type lubricator, insert the lubricator tube as
far as possible into the roller shaft. Fill the roller until lubricant
back flows freely around the tube, then remove the tube and quick-
ly install the drain plug. Position the roller body in a vise. Rotate
the shaft a minimum of ten complete revolutions for the initial seal-
ing and proper seal performance.
Pipe plug treads...................................................... Loctite #592

Pipe plug ...............................................................20 to 61 N•m
30-306 2 D87E-2 D87P-2

ROLLER CLEARANCES
12
A. Distance between seal retainers ............................................................................................................ 201.52 to 201.68 mm

MINUS (–)
B. Width of idler shaft bushing surface ....................................................................................................... 194.7 to 194.86 mm
MINUS (–)
C. Washer thickness ....................................................................................................................................... 3.099 to 3.175 mm
EQUALS (=)
End Clearance ........................................................................................................................................... 0.31 to 0.782 mm
D. Bushing Assembled Inside Diameter ................................................................................................ 105.207 to 105.359 mm

MINUS (–)
E. Idler Shaft Diameter.......................................................................................................................... 104.902 to 104.953 mm
EQUALS (=)
Diametral (Oil) Clearance ...................................................................................................................... 0.254 to 0.457 mm
D87E-2 D87P-2 30-307 2

TOP
12 IDLER
REMOVAL

machine.

1. Release chain tension.
2. Position a jack between the track frame and the track chain and
raise the chain off of the top idlers.
3. Loosen the bolts (1) on top of the idler mounting bracket (2).
4. Spread the slot in the bracket with a chisel. Partially slide the top
idler (3) out of the bracket.
5. Attach a hoist and sling to the top idler, pull it free of the bracket
and remove. Check condition of mounting bracket and replace as
necessary.
INSTALLATION
Mounting bracket bolts ................................................ 735 N•m
30-308 2 D87E-2 D87P-2

12
1. Fill Pipe Plug 6. Roll Pin 11. Idler Housing

2. End Cover 7. Seal Retainer 12. Tapered Roller Bearing
3. Seal Ring 8. Metal Type Face Seal 13. Tapered Roller Bearing
4. Retaining Ring 9. Seal Ring
5. Bearing Spacer 10. Idler Shaft
D87E-2 D87P-2 30-309 2

DISASSEMBLY
12
following steps.
1. Position the idler in a vise. Remove the pipe plug (1) from the cov-
er and allow the idler to drain. When drained, remove the hardware
and the cover (2) from the idler.
2. Remove the seal ring (3) and discard.
3. Remove the retaining ring (4) from the shaft.
4. Remove the bearing spacer (5) from the shaft.
30-310 2 D87E-2 D87P-2

12
5. Turn the assembly around in the vise. Drive out the roll pin (6)
from the seal retainer.
6. Remove the seal retainer (7) from the shaft.
★ The metal portion of the seal half will usually stay with the shaft.
7. Remove the rubber portion of the seal half (8) from the seal retain-
er.
8. Remove the seal ring (9) from the seal retainer.
D87E-2 D87P-2 30-311 2

12
9. Remove the metal portion of the seal half (8) from the shaft (10).
10. Remove the metal portion of the seal half (8) from the idler body
(11).
11. Remove the rubber portion of the seal half (8) from the idler body.
12. Position the assembly in a press, cover side up. Apply the press and
remove the shaft from the idler body.
30-312 2 D87E-2 D87P-2

12
13. Remove the loose bearing cone (12) from the assembly.
14. Using a suitable puller remove the rear bearing cup (13) from the
idler body.
15. Turn the roller body over in the press and remove the remaining
bearing cup (12).
16. Install a puller arrangement and press the bearing cone (13) off of
the shaft.
★ Whenever an idler assembly is disassembled, replace seals with

new. Refer to METAL TYPE FACE SEALS.
D87E-2 D87P-2 30-313 2

ASSEMBLY
12
following steps.
1. Position the idler body in a press and bottom the bearing cup (13).
Turn the idler body over and repeat for the remaining bearing cup
(12).
2. Heat bearing cone (13) to 135°C for 45 minutes. Install on shaft

and bottom. To insure cone is seated, keep pressure against cone
until it cools.
3. Install the idler body (11) over the shaft (10). Heat the bearing cone
(12) to 135°C for 45 minutes. Install the bearing on the shaft and
bottom. To insure the cone is seated, keep pressure against the cone
until it cools.
4. Install the 2.235 mm thick bearing spacer (5) on the shaft.
30-314 2 D87E-2 D87P-2

12
5. Install the retaining ring (4) to the shaft.
6. With the assembly still supported in the press, rotate the idler body.
If it does not turn freely, tap the end of the shaft with a brass mallet
to seat the bearings. If it still does not turn freely, check for proper
running clearance of 0.076 to 0.381 mm. Install a magnetic base di-
al indicator to the idler body with the indicator on the shaft. Set the
dial to zero. Pull down on the idler body and take reading. Repeat
several times to obtain average. Two more thickness bearing spac-
ers are available. Remove the assembly from the press and place on
the bench cover end down.
7. Install a new seal ring (9) into the seal retainer.
8. Install a seal half (8) into the seal retainer. Refer to METAL TYPE
FACE SEALS.
D87E-2 D87P-2 30-315 2

9. Install the other seal half (8) into the idler body. Refer to METAL
12
TYPE FACE SEALS.
10. Coat the seal ring in the seal retainer (7) and install on the shaft.
Seal ring coatage ...........................................................#2 MPG
11. Using a dowel rod to load the seal retainer, install the roll pin (6).
12. Install the seal ring (3) into the idler body.
30-316 2 D87E-2 D87P-2

13. Install the cover (2) and secure with hardware.
14. Fabricate an air pressure tester and connect to the top idler at the fill
plug hole. Slowly apply 0.21 to 0.34 kg/cm² of air pressure to the
idler. The assembly must maintain this pressure for 10 to 20 sec-
onds with no drop in that pressure.
15. Fill the top idler with recommended type and quantity of lubricant.
16. Install the fill pipe plug (1).
Fill pipe plug .......................................................... Loctite #592

Fill pipe plug .........................................................20 to 61 N•m
D87E-2 D87P-2 30-317 2

12
17. Rotate the idler five to ten revolutions to distribute the lubricant.
30-318 2 D87E-2 D87P-2

TRACK
12 FRAME
REMOVAL

machine.

Blade and pusharms .................................... Refer to DOZER BLADE.

Track adjuster ...................................... Refer to TRACK ADJUSTER.
Top idler ..............................................................Refer to TOP IDLER.
Track frame guide .........................Refer to TRACK FRAME GUIDE.
Equalizer bar ........................................... Refer to EQUALIZER BAR.
2. Jack the front and rear of the machine up and block it securely. The
machine should be raised high enough for the track rollers and
shields to clear the chain. Attach a hoist to the track frame. Lift the
track frame load off the pivot shaft and track chain.
3. Remove the sprocket rock deflector (1) from the rear of the track
frame. Remove cover (2) and outer wear washer (3).
4. Remove the hardware securing the retainer plate (4).
D87E-2 D87P-2 30-319 2

12
5. Remove the retainer plate (4), inner wear washer (5) and shims (6)
from the end of the pivot shaft. Keep the shims with the plate to fa-
cilitate installation.
6. Perform a check to make sure all components are disconnected.
7. 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. Using a bearing puller, remove seal from bore
of track frame. If bushings need replacement, they can be removed
with aid of a portable hydraulic press.
It is recommended that new seals be installed whenever the track

frame is removed. Wash all parts thoroughly in a suitable solvent.
Dry thoroughly with compressed air. Check surface for sharp cor-
ner. If necessary, grind and polish. Inspect thrust plate, wear plates,
INSPECTION
pivot shaft and bushings for damage or excessive wear and replace
if necessary. Inspect guide bars for distortion or broken welds. If
replacement is necessary, cut bars off track frame and replace. In-
spect the track frame for damage and excessive warpage. Inspect
the equalizer wear pad for excessive wear or damage and replace if
necessary. If the equalizer wear pad need to be replaced, also
check the contacting surfaces on the equalizer bar ends.
30-320 2 D87E-2 D87P-2

INSTALLATION
12
1. If the bushings were removed, apply Loctite Primer T or N on the

outside surface of the bushings and allow to dry completely. Be
sure bore of the track frame is clean and dry. Apply a continuous 6
mm band 360° on the outer edge of the track frame bore and lead-
ing edge of bushing. Press the inner bushing (7) into the track
frame until it bottoms in its bore. Press the outer bushings (8) into
track frame until each are flush with outside edges of track frame.
Bushing and frame edge ........................................ Loctite #609
★ The bushings must be pressed in within five minutes after applying

the Loctite.
2. Using the seal tool (B1), install the torsion seal (9) on the pivot
shaft. Check the seal, it must be flush against the frame.
3. Apply a light coating of chassis lubricant to the bushings. Attach a

hoist to the track frame and keeping it horizontal, position it over
the pivot shaft.
4. Install the inner wear plate (5) into the track frame. To seat the tor-
sion seal (9) in bore of the track frame, position a 12 mm shim pack
(6) on end of pivot shaft and secure the retainer plate (4). Remove
enough shims to align the center line of the last track roller with the
center line of the sprocket and reinstall plate (5) and secure with
hardware.
Retainer plate bolts ...................................................... 455 N•m
D87E-2 D87P-2 30-321 2

12
5. Install the outer wear washer (3) in the pivot shaft cover (2). Coat
the cover and install on the track frame. Secure the cover with hard-
ware.
Pivot shaft cover .................................................... Loctite #504

Cover bolts ................................................................... 455 N•m
6. Install the sprocket rock deflectors (1) and secure with hardware.
Deflector bolts.............................................................. 455 N•m

7. Remove the hoist from the track frame. Remove the blocking from
the machine and lower the machine onto the track chain. Refill piv-
ot shaft housing as described in the Operation and Maintenance
Manual.
8. Install the following;

Equalizer bar ........................................... Refer to EQUALIZER BAR.
Track frame guide .........................Refer to TRACK FRAME GUIDE.
Track adjuster ...................................... Refer to TRACK ADJUSTER.
Blade and pusharms .................................... Refer to DOZER BLADE.
9. Whenever the track frame or wear plates are reinstalled, the track
frame alignment must be checked.
Track frame alignment ....... Refer to TRACK FRAME ALIGNMENT.
30-322 2 D87E-2 D87P-2

TRACK
12 FAME GUIDE
1. Guide Plate 4. Top Spacer 7. Bottom Spacer Shim

2. Guide Plate Shim 5. Bottom Spacer 8. Wear Plates
3. Retainer Plate 6. Top Spacer Shim 9. Top Idler Bracket
D87E-2 D87P-2 30-323 2

SERVICE
12

machine.

following steps.

★ The track frame does not have to be removed to service the track
frame guides.
2. Position suitable blocking under the front and rear of the track
frame. Remove the hardware securing the guide plate (1) to the
main frame and remove with the shims (2).
3. Remove the hardware securing the retainer plate (3) and remove
with remaining parts (4 through 8). Inspect the wear plates and
guide plate for excessive wear or damage. If either of these parts
are worn more than specified, replace with new.
4. Place the idler mounting bracket (9) flush with the track frame post
and secure with hardware. Position the bowed wear plates (8) as
shown. Assemble the top (4) and bottom (5) spacers, guide plate (1)
and retainer plate (3) and secure with hardware.
Idler bracket bolts ........................................................ 735 N•m
5. Install the top (6) and bottom (7) shims behind the spacers to obtain
a 0.5 mm clearance (A) along the length of each side of the guide
plate (1). The guide plate must be free to move up and down for the
entire length of the wear plates (8).
Top spacer plate bolts................................................. 1110 N•m

Bottom spacer plate bolts........................................... 1110 N•m
Guide plate to frame .................................................. 1110 N•m
★ The shims (2) behind the guide are used for track frame alignment.
30-324 2 D87E-2 D87P-2

EQUALIZER
12 BAR
1. Rebound Bracket 4. End Plates 7. Wear Pads

2. Bracket Shims 5. Pivot Shaft
3. Equalizer Bar 6. Bar Bushing
D87E-2 D87P-2 30-325 2

SERVICE
12

machine.
following steps.
2. Remove the rebound bracket (1) and shims (2) from both track
frames. Keep the shims with the brackets for proper installation.
Jack up the front of the machine until the weight is off the equalizer
bar (3). Install blocking or jack stands under the main frame.
3. Remove the plates (4) from each side of the equalizer bar tunnel.
Using a slide hammer with a puller, remove the shaft (5) from the
bore. Remove the equalizer bar out either side of the tunnel.
4. If replacement is necessary, press the bushing (6) out of the bar (3).
Press a new bushing into the bar until flush with the edge.
30-326 2 D87E-2 D87P-2

12
5. If replacement is necessary, remove the two pivot shaft bushings
(A) located inside the equalizer bar tunnel. Press new bushings into
the equalizer bar tunnel until flush with the outer edge.
Wash all parts thoroughly in a suitable solvent. Dry thoroughly

INSPECTION
with compressed air. Inspect equalizer bar, bushings, brackets,

pads, pin and retainer plates for excessive wear or damage and re-
place if necessary.
6. Be sure the wear pads (7) are in place on the track frames.
7. Insert the equalizer bar in the tunnel and align the pivot shaft (5)
holes. Lightly grease the shaft and install it through the rear of the
tunnel. Install the plates and secure with hardware.
Shaft plate bolts ........................................................... 264 N•m
8. Lower the front of the machine so that the equalizer bar (3) rests on
the wear pads (7) and remove blocking or jacks. Install the shims
(2) and rebound brackets (1) and secure with hardware.
Rebound bracket bolts ................................................. 264 N•m
9. Check the clearance (A) between the top of the equalizer bar and
the bottom of the rebound bracket. Add or subtract shims to obtain
a clearance of 4.8 to 6.4 mm.
D87E-2 D87P-2 30-327 2

PIVOT
12 SHAFT
WARNING! It is mandatory that the rear frame be drilled in
the location shown, as a mutter of safety, before applying
heat to the pivot shaft housing. This must be done on the
side the pivot shaft is to be removed.
It has been found that oil will seep into the cavities A of the rear main
frame and this cavity must be drained before any heat is applied. Drain-
ing of the rear frame will not empty the cavities. They must be drilled
(37/64 in.), drained, tapped and replugged. When you have completed
removal of the pivot shaft the holes can be tapped (3/8NPT) and
plugged (444 698).
Plugs................................................... Loctite pipe sealant #592

REMOVAL

machine.

Track frame .................................................Refer to TRACK FRAME.
2. The lock pins are located at the lower corners on the front wall of
the rear frame. Remove the lock pin retainer. Using puller tool
(C1), remove the lock pin (2).
★ For safety reasons and for shortening the heating time of the pivot
shaft bore, drain the oil from the rear main frame (see above).
3. Bolt the adapter (D1) to the pivot shaft (3) with three bolts (4) and
thread ram screw (D2) into the adapter. Position tube assembly
(D3) over the ram screw and pivot shaft and against the rear frame.
Place a 91mg hydraulic ram (5) on the ram screw against the tube
assembly. Lock the ram to the screw with speed nut (D4).
4. Use a steady pull on the ram while heating the pivots shaft bore un-
til the shaft is free. It is recommended that two torches with multi-
ple orifice tips (rosebuds) be used to heat the area around the hub
and at the bottom and forward wall of the main frame in the bore
area. Keep the flame away from the pivot shaft.
30-328 2 D87E-2 D87P-2

INSTALLATION
12
1. The pivot shaft can be installed easier by packing the shaft in ice or
dry ice for two to three hours before installing.
2. Prepare the pivot shaft lock pin (1) for installation by threading it
onto a 3/4NC threaded rod or a bolt (2) at least 6 in. long.
3. Expand the pivot shaft bore in the rear frame by heating to 246° C.
This will be enough heat to install the shaft by gloved hand, espe-
cially if it was packed in ice or dry ice. Two torches with multiple
orifice tips (rosebuds) are recommended. Use a soft flame, playing
it back and forth on the area being heated. The specified degree of
heat is critical and must be determined with a Tempelstik crayon
applied to an area adjacent to the bore. Do not put the flame direct-
ly on the Tempelstik, but allow the heat to spread gradually to it.
Heating time will vary according to the ambient temperature of the
rear frame.
4. Bolt the alignment tool (E1) to the pivot shaft (3) with bolts (4).
The position of the pivot shaft notch (A) in relation to the tool han-
dle must be as shown so the tool handle will clear the sprocket
drive.
★ Once started the installation of the pivot shaft must be completed

quickly or heat will transfer from the bore to the shaft causing it to
bind.
5. Guide the pivot shaft into the rear frame with the notch facing up.
When the end of the alignment tool bottoms against the hub on the
rear frame, the shaft will be installed to the correct depth. Rotate
the pivot shaft with the tool handle to align the groove in the shaft
with the lock pin hole in the rear frame. Drive in the pivot shaft
lock pin with the threaded rod or bolt. Unscrew the threaded rod
from the lock pin and install the retainer plug.
Retainer plug................................................................ 275 N•m

6. Refill the rear main frame with the correct grade and amount of lu-
bricant as specified in the Operations and Maintenance Manual.
7. Install the following;

D87E-2 D87P-2 30-329 2

RECOIL
12 SPRING
REMOVAL

machine.

2. Turn the frame upside down and securely block in position. Re-
move all track rollers. The track spring must be compressed before
it can be removed from the track frame.
★ A 50-ton hydraulic ram must be used to compress the spring for re-
moval.
3. Install the hydraulic ram pusher plate (F1) against the front idler
casting overlap inside the track frame. This overlap will act as the
backing support for the hydraulic ram pusher plate. Install the push-
er tube (F2) through the hole in the bulkhead of the track frame and
into the counterbore in the front spring retainer. Install hydraulic
ram positioning it between the pusher plate and pusher tube.
4. Compress the spring by applying pressure to the hydraulic ram.

Compress the spring to a dimension of 698 mm. This dimension in-
cludes the spring and both retainers. Install the spacer fixture (F3)
between the track frame bulkhead and spring retainer. With the
spacer fixture permanently in place, release the hydraulic ram pres-
sure. The spring load should now be held compressed by the spacer
fixture. Remove the hydraulic ram, pusher tube and pusher plate.
30-330 2 D87E-2 D87P-2

12
5. Install the track spring retainer bolt (F4). Thread the bolt into the
rear retainer until the head bottoms on the forward spring retainer.
Reinstall the pusher plate, hydraulic ram and pusher tube and apply
sufficient hydraulic pressure to release the spring load from the
spacer fixture. Remove the fixture. Release the hydraulic pressure.
Then remove the hydraulic ram and pusher tube.
6. The spring can now be lifted from the track frame.
7. To remove the spring bolt from the compressed spring, place the
compressed spring with retainers in the spring compressor (G1).
Compress the spring with retainers sufficiently to remove the
spring load from the spring retainer bolt. Remove the spring bolt,
then release the hydraulic pressure. The spring free length is 823
mm.
INSTALLATION
1. If a new spring is being installed, it first must be compressed within
the spring retainers and retained by the retainer bolt. To compress
the spring, place the spring with retainers in the spring compressor
(G1). Compress the spring with retainers to an installation dimen-
sion of 761 mm. This dimension includes the spring and retainers
and spring bolt. With the spring and retainers compressed, install
the retainer bolt. Release the hydraulic ram to allow the spring re-
tainer bolt to carry the spring load.
2. Lift the compressed spring from the spring compressor and install it
in the track frame with the head of the spring retainer bolt toward
the front idler.
D87E-2 D87P-2 30-331 2

12
3. Install the pusher plate and the pusher tube. Position the ram.
4. With the hydraulic ram, compress the spring with retainers suffi-
ciently to permit installation of the spacer fixture. Release the hy-
draulic ram. The spacer fixture should now be carrying the spring
load. Remove the hydraulic ram, pusher tube and pusher plate. Re-
move the spring retainer bolt.
5. Reinstall the pusher plate, hydraulic ram and pusher tube and apply
sufficient hydraulic pressure to release the spring load from the
spacer fixture. Remove the fixture. Release the hydraulic pressure.
Then remove the hydraulic ram and pusher tube.The spring load
should now be carried by the track frame bulkheads.
6. Complete the track frame assembly by installing the bottom track

rollers and roller guards.
Roller bolts................................................................... 455 N•m

Roller shield bolts ........................................................ 455 N•m
7. Reinstall the track frame.
30-332 2 D87E-2 D87P-2

TRACK
12 FRAME ALIGNMENT
1. Front Idler 3. Wear Guide Plates 5. Pivot Shaft

2. Front Top Idler 4. Rear Top Idler 6. Sprocket
1. Assemble the track rollers and front idler to the track frame.
2. Install the front top idler mounting bracket (1) with the guide
mounting face flush with the post on the track frame. Position the
bowed wear plates (2).
3. Assemble the spacers (3 and 4), and retainer (5) with guide plate
temporarily held in place. Use shims (6 and 7) at spacers as re-
quired to get a clearance of 1 mm maximum between the guide
plate (8) and the wear plate.
D87E-2 D87P-2 30-333 2

12
4. Keeping the track frame horizontal, assemble it on the pivot shaft.
Align the last track roller with the sprocket by equalizing the dis-
tances Y1 and Y2 within ±1.5 mm.
5. Determine the shim pack (9) at the end of the pivot shaft (10) so
that the shim outer face is flush with track frame surface. Add one 3
mm shim, 655 422 C1, to the shim pack. Assemble wear plate (11),
thrust plates (12) and cover (13) to the pivot shaft.
Wear plate bolts............................................................ 455 N•m

Pivot shaft cover .................................................... Loctite #504
Cover bolts ................................................................... 455 N•m
6. Install the shims (14) and rebound brackets (15) and secure with
hardware. Check the clearance (A) between the top of the equalizer
bar and the bottom of the rebound bracket. Add or subtract shims to
obtain a clearance of 4.8 to 6.4 mm.
Rebound bracket bolts ................................................. 264 N•m
7. Oscillate track frame up and down three times to make sure track
frame is moving freely. Add shims (16) as required to fill the gap
between the guide plate and the mounting face of the front frame
★ Do not force the track frame inward or outward.
Guide plate bolts ........................................................ 1110 N•m
8. Loosen upper spacer mounting bolt (17). Align the front and rear
top idlers so that the centerline of both top idlers lie within 1.5 mm
from the line passing through the sprocket centerline and front idler
centerline. Clamp the front top idler by tightening bolt (18), bolt
(19) and bolt (17).
30-334 2 D87E-2 D87P-2

METAL
12ping
Align the
tances AL TYPE
track
last
and y2 FACE
frame(9)
track
within SEALS
roller
(horizontal,
1.5with
mm the assemble
sprocketit by
on equalizing
the pivot shaft.
dis-
SEAL INSPECTION
1. Check the condition of the rubber seal rings. If any sign of wear,
scratches, nicks, cuts, etc. replace the complete seal. Inspect the
condition of the metal ring seal surfaces as follows. Highly pol-
ished surfaces of the rings must be free of chips, pocks and deep
scratches.
2. The narrow highly polished sealing bank must be within the outer
half of the sealing face.
3. The narrow band must be uniform and concentric with the ID and
OD. If the metal rings do not conform to these specifications, dis-
card the seal and replace with new.
4. If the metal rings conform to specifications above, clean and check

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

the surface A. Use a scraper and/or any stiff bristled fiber
brush to remove this material from the entire surface. Wash the
rings with non flammable solvent to remove all oil and wipe
dry. Use a lint free wiper to remove all traces of oil or grease
from all surfaces. Apply a thin coat of clean Grade 30 oil on
sealing face of the metal rings. Do not allow oil to wet other
surfaces. Slide the sealing faces of two metal rings together.
The bottom ring should cling to the top ring for a minimum of
two seconds when lifted by the top ring. If they fail to cling,
discard the seal and replace with new.
D87E-2 D87P-2 30-335 2

SEAL
12 INSTALLATION
★ Cleanliness is critical when handling the seals. Never handle the
seal with greasy, oily or dirty hands. Do not drop, bump or roughly
handle the seals.
1. Remove any corrosion or hardened material that may exist on the

surface (1) that contacts the rubber rings. Use a non petroleum base
solvent and wipe dry with a lint free wrapper. Make sure the outer
edge (2) is free of burrs.
2. Break the plastic protector band (3) if applicable, by inserting a

sharp tool (4) at edge of the band. Be careful not to scratch or dam-
age the seal faces (5). Do not cut or damage the rubber rings (5).
3. Carefully remove the plastic band and gently slide (1) the two seal
halves apart. The metal ring faces must not be damaged or contam-
inated. Check to be sure that the rubber rings are flush (2) against
the inside shoulder of the metal ring.
4. Install one seal half (9) into the receptacle (10) so that the protrud-
ing lip just contacts the seal bore. Press with both clean hands (180°
apart) against the metal ring until the rubber ring is evenly seated
against the bore shoulder. Make sure the seal is not cocked in the
bore. Repeat the procedure for the other seal half (11) and recepta-
cle (12). Wipe both of the metal ring sealing faces clean (13) with a
lint free wiper. Apply a light coat (14), just enough to wet the faces,
of clean lubricant to the seal faces of the metal rings.
30-336 2 D87E-2 D87P-2

12
5. Final installation assembly will energize the seal as shown, so that
the rubber rings load the seal and drive the mating metal rings to-
gether.
D87E-2 D87P-2 30-337 2

TRACK
12 CHAIN
1. Lubrication Plug 7. Link Bushing A2. Chain Seal

2. Link Pin 8. Split Link - Pin A3. Thrust Ring
3. Split Link - Bushing 9. Split Link - Pin B. Seal Assembly
4. Split Link - Bushing 10. Belleville Washer B1. Seal Ring
5. Chain Link A. Seal Assembly B2. Chain Seal
6. Chain Link A1. Seal Ring B3. Thrust Ring
30-338 2 D87E-2 D87P-2

MAINTENANCE
The track links have only one wearing surface which contacts the track
rollers, front idler and track idlers. However, it usually becomes neces-
sary to replace the pins and bushings before the links wear out, and it is
a matter of judgement then whether the links are good enough to justify
a new set of pins and bushings. Only the wear on the outside of the
bushings is visible. Wear on the pins and the interior of the bushings is
indicated by track stretch (forward adjustment of the front idler). The
amount of wear can be determined by measuring the pitch length of the
track (distance between centers of pins) under tension and comparing it
with new and maximum allowable pitch lengths. Sprocket wear must al-
so be considered in conjunction with track chain wear. Wear of the
sprocket teeth decreases the pitch length of the sprocket, while wear of
pins and bushings increases the pitch length of the track. The results are
that the pitch lengths of the sprocket and track becomes more and more
out of phase, and the bushings ride higher on the sprocket teeth. Com-
bined wear of the sprocket and the track should never be allowed to
reach this point. Whenever new or rebuilt track chains are installed, the
sprocket should also be replaced or interchanged to present the better
side of the teeth to the bushings. Never remove one link to bring a
stretched track to within the range of proper track adjustment. A track
that is worn badly enough to take up the length of one link, will be so far
out of pitch that the increased wear on the sprocket will far more than
offset the saving obtained by the removal of one link in the track chain.
★ Refer to UNDERCARRIAGE WEAR LIMITS in this section.
REMOVAL

machine.
WARNING! When the split link bolts and track shoes are re-
moved, the chain is free to separate. Before disconnecting
the chain for any reason, be sure to relieve all the track ad-
juster pressure. This must be done for safety reasons.
1. Move the machine forward until the split link is at the front lower
half of the front idler. Relieve the track tension per the Operation &
Maintenance Manual. Block up under the shoe and remove the split
link bolts and shoe.
2. Move the machine backward until the sprocket is at the end of the
chain. Place a plank flush against the rear of the chain when it is
flat on the ground. The plank should be approximately the same
thickness and width as the chain and long enough so that the entire
machine can rest on the plank. Move the machine off the chain and
onto the plank.
D87E-2 D87P-2 30-339 2

INSTALLATION
1. Position the chain in front of the plank with the split link half with
the shoe surface against the plank. If the chain is reversed from the
position shown, severe undercarriage wear will result. Block up the
front of the chain. Drive the machine forward onto the chain. As the
sprocket passes the end of the chain, pull the chain over the sprock-
et and top idler. Stop the machine when the front idler contacts the
blocked up chain.
2. Be sure the machined surfaces of the split links are clean. Interlock
the split link halves in front of the front idler. Align the link side
surfaces and install the bolts to check alignment. Remove the bolts.
Install the track shoe and bolts and torque to value given. Adjust
track tension. Refer to the Operation & Maintenance Manual.
★ Two methods for repairing a chain are available. One is to repair

the complete chain using a twin head table press K1. The other is to
rebuild only the leaking joints using a portable 91 mg track press
J1.
COMPLETE CHAIN REBUILD
Disassembly
1. Lubricated Track Chain; Using a slow speed drill and a 12 mm drill

bit, remove the rubber plugs (1) from the pins (2).
30-340 2 D87E-2 D87P-2

12
2. Position the chain on the press so that the bushing end (non thread-
ed end) of the split links (3 and 4) are toward the ram. Remove the
track shoes.
3. Install the disassembly adapters on the ram heads. Advance the

chain and lower the table so that the split link drops into the saddle.
Press the pin out of the right link (5), then press the pin out of the
left link (6). Remove the loose split links from the press.
4. Advance the track chain so that the next link drops into the saddle.
Press the pin and bushing (7) out of the right link, then press the pin
and bushing out of the left link. Remove the loose links, bushing
and pin from the press.
5. Lubricated Track Chain; Repeat Step 3 with the remaining sections

of the chain. Remove the seals (A and B) from the chain links.
Dry Sealed Track Chain; Repeat Step 3 with the remaining sections
of the chain. Remove the belleville washers (10) from the chain
links.
Assembly
1. Lubricated Track Chain; On new or reused pins, index a mark (A)

on the hole end (B) of the pins on the opposite side of the lube hole
(C).
2. Install the assembly adapters on the ram heads. Bolt the split links
together and position on the press assembly adapters. Position a
bushing in the press saddle. Press the links onto the bushing to the
projection height specified, following. Remove the bolts securing
the two halves together.
Bushing projection height;

Lubricated chain (A) ...........................................................1.65 mm
Dry sealed track chain (B) ......................................8.48 to 8.68 mm
D87E-2 D87P-2 30-341 2

12
3. Advance the chain on the press and position a pin in the assembled
bushing. Apply a coat of oil on the ends of the bushing with a tissue
(not your fingers) being careful not to get it on the pin surface. Po-
sition next the bushing in the press saddle.
4. Lubricated Track Chain; Install a new seal assembly (A or B) in the

counterbore of the next chain links.
5. Dry Sealed Track Chain; Install the belleville washers (10), inside
diameters facing, in the counterbore of the next chain links.
6. Apply sealant sparingly in the outer half of the pin bore of the links.
Link pin bore.......................................................... Loctite #680
30-342 2 D87E-2 D87P-2

12
7. Lubricated Track Chain; Position the links on the press assembly
adapters. Check that the index mark is at the bottom. All the lube
holes must face the same direction. Press the links onto the pins and
bushings being sure that the link counterbore and bushing face are
seated against the spacer. Do not exceed the force indicated as this
can damage the spacer. Do not adjust the links for bolt hole loca-
tion. After the chain is moved to the next position, place a rubber
plug in the end of the pin of the completed joint. Tap it in until it is
flush or slightly below the chamfer of the pin hole.
Check the seal by inserting the nozzle of the lubricator H1 through

the plug. Pull a vacuum of 0.69 kg/cm² and hold for 10 seconds. In
event that the vacuum cannot by held, either the seal to the bushing
face or the chain pin to the link bore mating surfaces are leaking. To
determine which side is leaking, pressurize the joint with 0.34 kg/
cm² of air pressure, apply soap solution to both seal areas and check
for bubbles. After determining which side is leaking, the joint must
be rebuilt. After vacuum holds for 10 seconds, press the lubricant
button on nozzle and fill the evacuated pin under 1.03 to 1.72 kg/
cm² with extreme pressure gear lubricant with 0.02% red dye. Re-
move the lubricator. Prepare the chains for transport back to the
machine.
Link lubricant................................... 85W140 or 80W90 EPGL
★ Once the joint is lubricated, there is no way of checking for leaks.
8. Dry Sealed Track Chain; Position the links on the press assembly
adapters. Press the links onto the pins and bushings being sure that
the link counterbore and bushing face are seated against the
belleville washers. Do not exceed force indicated as this can dam-
age the washers. Do not adjust the links for bolt hole location.
SINGLE JOINT REBUILD
Disassembly
1. Lubricated Track Chain; Using a slow speed drill and a 12 mm drill

bit, remove the rubber stopper from the leaking joint pin. Using the
press, secure the aligning adapter in the end of the press frame.
Block the chain off the ground and position the press over the chain
so that the forcing pin will be against the end of the track pin oppo-
site the lube hole. Press the pin from the joint.
Dry Sealed Track Chain; Using the press, secure the aligning adapt-
er in the end of the press frame. Block the chain off the ground and
position the press over the chain so that the forcing pin will be
against the end of the track pin. Press the pin from the joint.
D87E-2 D87P-2 30-343 2

12
2. Lubricated Track Chain; Using a small hydraulic ram, spread the
links about 6.35 mm and separate the chain being careful not to
damage seal. Remove oil seals and spacers from links.
Dry Sealed Track Chain; Using a small hydraulic ram, spread the
links about 6.35 mm and separate the chain. Remove the belleville
washers from the links.
3. Inspect for wear, damage or improper assembly. If wear, damage or

improper assembly is present, proceed to the next step. If no wear
damage or improper assembly is present, proceed to ASSEMBLY.
4. Lubricated Track Chain; Drill out the plug from the next pin to the
right of the leaking joint. Block the chain off the ground and press
the pin out. Using small hydraulic ram, spread link about 6.35 mm
(0.25 in) and remove track link being careful not to damage seal.
Remove oil seals and spacers from links.
5. Dry Sealed Track Chain; Block the chain off the ground and press
the pin out from the right of the leaking joint. Using a small hy-
draulic ram, spread the links about 6.35 mm and separate the chain.
Remove the belleville washers from the links.
6. Secure the bushing disassembly adapter in the end of the press

frame. Position the adapter in the press frame and the adapter on
the ram. Remove the aligning adapter from the press frame and in-
stall the bushing adapter. Using the press, remove the long pin from
the threads of the ram and thread the short pin on the ram. Position
the press over the one side link. Using the bushing pusher, press the
link off the bushing.
7. Turn the link over and reposition the press over the remaining side
link. Using the bushing pusher, press the link off the bushing. In-
spect the parts for wear, damage or improper assembly. Discard any
parts which would adversely affect the rebuild.
30-344 2 D87E-2 D87P-2

Assembly
1. Dress up the parts with emery cloth as required. Secure the rear
bushing plate in the press frame. Position the press over one link.
Using the bushing adapter, press the new bushing in the link until it
bottoms against the adapter.
2. Turn the link over and reposition the press over the second link. Us-
ing the bushing installer, press the bushing into the second link un-
til it bottoms against the adapter. Be sure the counterbores in the
links are clean.
3. Lubricated Track Chain; Install a new seal in the counterbores.
Dry Sealed Track Chain; Install the belleville washers, inside diam-
eters facing, in the counterbore.
4. Using a small hydraulic ram spread the link about 6.35 mm and po-
sition the link over the next link. Line up the links and slip in the
forcing pin. Remove the ram. Secure the aligning adapter in the end
of the press frame and thread the short pin on the ram.
D87E-2 D87P-2 30-345 2

12
5. Lubricated Track Chain; On new or reused pins, index a mark (A)
on the hole end (B) of the pins on the opposite side of the lube hole
(C).
Dry Sealed Track Chain; On a new or reused pin, install it in the

bore of the press frame.
6. Position the press over the track. Press the pin in, stopping before
the pin enters the last link. Relieve the pressure on press and re-
move the forcing pin.
7. Apply sealant in the outer half of the bore of the last link.
Bore link ................................................................ Loctite #680
8. Lubricated Track Chain; Apply sealant on the OD of the pin. Push

the pin completely in. Repeat this step on the next joint. Place a
rubber stopper in the end of the pin so that it is flush with or slightly
below the bottom of the hole chamfer and insert the nozzle of the
lubricator into the plug. Pull a vacuum of 0.69 kg/cm² and hold for
10 seconds to check the seals. In event vacuum cannot be held, ei-
ther the seal to the bushing face or the track pin to the link pin boss
mating surfaces are leaking. The joint must be rebuilt. Release the
lubricant into the evacuated pin and fill to 1.03 to 1.72 kg/cm² with
extreme pressure gear lubricant. Repeat this step on the remaining
pins.
Pin OD ................................................................... Loctite #680
Pin lubricant ..................................... 85W140 or 80W90 EPGL
Dry Sealed Track Chain; Apply sealant on the OD of the pin. Push
the pin completely in. Repeat this step on the next joint.
Pin OD ................................................................... Loctite #680
30-346 2 D87E-2 D87P-2

90 OTHERS

3 LEVER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
1 LEVER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
TORQUE CONVERTER MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
DIRECTIONAL (INPUT) SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
RANGE (OUTPUT) SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
RATE OF RISE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
TWO SPEED STEERING
3 LEVER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
1 LEVER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-71
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-89
EQUIPMENT HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90
EQUIPMENT HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95
BLADE PILOT CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107
RIPPER PILOT CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108
BLADE LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-119
ELECTRICAL WIRING SCHEMATIC
3 LEVER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121
1 LEVER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-122
WIRING
1 LEVER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-123
WIRING HARNESSES
FRONT HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
ENGINE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
POD HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
CONTROL TOWER HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-159
REAR HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
RIGHT REAR HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
INSTRUMENT PANEL HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-163
CAB HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-165
CAB PANEL HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
CONTROLLER HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-167
INSTRUMENT HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-168
COMPARTMENT HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
CONTROL TOWER HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170
A/C HEATER
A/C HEATER LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-171
COMPRESSOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-172
D87E-2 D87P-2 90-1 2

OTHERS MEMORANDA
12
MEMORANDA
90-2 D87E-2 D87P-2

STRUCTURE AND FUNCTION & MAINTENANCE STANDARDS DRIVE TRAIN SCHEMATIC

D87E-2 D87P-2 10-11 2

STRUCTURE AND FUNCTION & MAINTENANCE STANDARDS DRIVE TRAIN SCHEMATIC
D87E-2 D87P-2 10-13 2

TORQUE CONVERTER MOUNTING
D87E-2 D87P-2 10-19 2

DIRECTIONAL (INPUT) SHAFT
D87E-2 D87P-2 10-31 2

COUNTERSHAFT
D87E-2 D87P-2 10-33 2

STRUCTURE,FUNCTION & MAINTENANCE STANDARDS TRANSMISSION
RANGE (OUTPUT) SHAFT
D87E-2 D87P-2 10-35 2

RATE OF RISE VALVE
D87E-2 D87P-2 10-43 2

STEERING VALVE
D87E-2 D87P-2 10-59 2

TWO SPEED STEERING STRUCTURE, FUNCTION & MAINTENANCE STANDARDS
HYRAULIC FLOW
10-60 2 D87E-2 D87P-2

STEERING VALVE
D87E-2 D87P-2 10-63 2

TWO SPEED STEERING STRUCTURE, FUNCTION & MAINTENANCE STANDARDS
HYRAULIC FLOW
10-64 2 D87E-2 D87P-2

D87E-2 D87P-2 2 10-71

D87E-2 D87P-2 10-89 2

EQUIPMENT HYDRAULIC SCHEMATIC
1. Hydraulic Reservoir
2. 100 Mesh Strainer
3. Blade Lift and Ripper Pump
4. Blade Tilt Pump
5. Pilot Control Sytem Pump
6. Test Gauge Port
7. Pilot System Filter
8. Pilot Supply Valve
9. Blade Control Pilot Valve
10. Ripper Control Pilot Valve
11. Blade Lift and Ripper Control Valve
12. Blade Tilt Control Valve
13. Blade Lift Cylinders
14. Blade Quick Drop Valve
15. Blade Tilt Cylinder - E and P Model Dozer
16. Blade Tilt Cylinders - E Model Grader
17. Blade and Ripper Shuttle Valves
18. Ripper Pitch Cylinders
19. Ripper Lift Cylinders
20. Pressure Vacuum Relief Valve
21. Return Line Filter
10-90 2 D87E-2 D87P-2

EQUIPMENT HYDRAULIC DIAGRAM
D87E-2 D87P-2 10-91 2

STRUCTURE AND FUNCTION & MAINTENANCE STANDARDS EQUIPMENT HYDRAULICS
D87E-2 D87P-2 10-95 2

D87E-2 D87P-2 10-107 2

RIPPER PILOT CONTROL VALVE
10-108 2 D87E-2 D87P-2

D87E-2 D87P-2 10-115 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS CAB
CAB
D87E-2 D87P-2 10-119 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS ELECTRICAL WIRING SCEMATIC
ELECTRICAL WIRING SCEMATIC
10-120 2 D87E-2 D87P-2

D87E-2 D87P-2 10-121 2

10-122 2 D87E-2 D87P-2

WIRING
D87E-2 D87P-2 10-123 2

WIRING HARNESSES
FRONT HARNESS
Connector Gauge/Length Color

Circuit End
Position mm Tag
1 CNF4-C 16/1825
1A CNF2 16/1250
Orange
1 1B CND5 16/225
53B
1C CNF6 16/2100
1D CNF1-C
2 CNF2 16/1325 Yellow
2
2A CNF5 30C
3 CNF1-B 16/2925
3 3A CNF2 16/1825 Black
3B CNF4-B
4 CNF2 16/2125
Dark Blue
4 4A CNF8 16/1550
42F
4B CNF7
5 CNF2 16/1800
Orange
5 5A CND6 16/375
64
5B CNF3
6 CNF2 16/1800
6 6A CND6 16/375 Black
6B CNF9
7 CNF4-D 16/1000 Yellow
7
7A CNF5 30CR
8 CNF1-D 16/2100
Yellow
8 8A CNF6 16/225
30CL
8B CND5
9 CNF2 16/825 Grey
9
9A 61
D87E-2 D87P-2 10-155 2

ENGINE HARNESS
D87E-2 D87P-2 10-157 2

POD HARNESS

Circuit End
Position (mm) Tag
1 CNC2-A 16/2220 Orange
1
1A CNM5-A 66C
2 CNC2-B 16/2220 Orange
2
2A CNM5-B 41F
3 CNC2-C 16/2220 Orange
3
3A CNM5-C 41R
4 CNC2-D 16/2720 Orange
4
4A CNM2 63LW
5 CNC2-F 16/2520 Orange
5
5A CNM1 63LW
6 CNM4-A 16/2275 Orange
6
6A CNM5-D 19S
7 CNM4-B 16/2345
7 7A 16/2345 Black
7B CNM4-C
8 CNM4-D 16/2275 Red
8
8A CNM5-E 30F
9 CNM4-F 16/650 Orange
9
9A CNM3-H 64
10 CNM4-G 16/2275 Dark Blue
10
10A CNM5-F 42R
11 CNM4-J 16/2275 Yellow
11
11A CNM5-G 35F
12 CNM4-K 16/2275 Orange
12
12A CNM5-H 19S
13 CNM4-L 16/2275 Orange
13
13A CNM5-J 64
14 CNM4-M 16/2275 Orange
14
14A CNM5-K 53
15 16/2375 Yellow
15
15A CNM5-L 32F
16 CNM3-B 16/2175 Purple
16
16A CNM5-M 36C
17 CNM3-D 16/2245
17 17A 16/270 Black
17B CNM5-N
18 CNM3-E 16/2175 White
18
18A CNM5-P 20S
19 CNM3-F 16/2175 White
19
19A CNM5-Q 21C
20 CNM5-R 16/600 Purple
20
20A CNM8 36TC
21 16/270
21 Black
21A CNM5-S
22 16/970
22A CNM2 16/600
22 Black
22B CNM1 16/700
22C CNM5-T
23 CNC3 6/2260
23 Black
23A CNM6
24 CNC1 6/2260 Red
24
24A CNM7 1
25 CNM5-U 14/2300 Orange
25
25A CNC8 65F
10-158 2 D87E-2 D87P-2


Circuit End mm
Position Tag
1 CNF4-C 16/1825
1A CNF2 16/1250
Orange
1 1B CND5 16/225
53B
1C CNF6 16/2100
1D CNF1-C
2 CNF2 16/1325 Yellow
2
2A CNF5 30C
3 CNF1-B 16/2925
3 3A CNF2 16/1825 Black
3B CNF4-B
4 CNF2 16/2125
Dark Blue
4 4A CNF8 16/1550
42F
4B CNF7
5 CNF2 16/1800
Orange
5 5A CND6 16/375
64
5B CNF3
6 CNF2 16/1800
6 6A CND6 16/375 Black
6B CNF9
7 CNF4-D 16/1000 Yellow
7
7A CNF5 30CR
8 CNF1-D 16/2100
Yellow
8 8A CNF6 16/225
30CL
8B CND5
9 CNF2 16/825 Grey
9
9A 61
D87E-2 D87P-2 10-159 2

REAR HARNESS

Circuit End
Position (mm) Tag
1 CNM4-D 16/900 Purple

1
1A 36C
2 CNM4-C 16/900
2 Black
2A
3 CNM4-G 16/2080 Dark Blue
3
3A 42R
4 CNM4-B 16/1880
4 Black
4A CNR3-3
5 CNM4-F 16//1080 Orange
5
5A 64A
6 CNM4-A 16/1080 Orange

6
6A 19S
7 CNM4-J 16/1880 Yellow

7
7A CNR3-2 35F
8 CNM4-K 16/1880 Orange

8
8A CNR3-5 19S
9 CNM4-L 16/1880 Orange

9
9A CNR3-1 64
10 CNM4-M 16/1880 Orange

10
10A CNR3-6 53
10-160 2 D87E-2 D87P-2

RIGHT REAR HARNESS

Circuit End mm
Position Tag
1 CNR3-1 16/1130 Orange
1
1A 64
2 CNR3-2 16/560
Yellow
2 2A 16/1280
35F
2B
3 CNR3-3 16/905
3 3A 16/175 Black
3B CNR2-2
4 CNR3-5 16/1130 Orange
4
4A 19S
5 CNR3-6 16/905
Orange
5 5A 16/175
53
5B CNR2-1
D87E-2 D87P-2 10-161 2

INSTRUMENT PANEL HARNESS
D87E-2 D87P-2 10-163 2

CAB HARNESS
D87E-2 D87P-2 10-165 2

CAB PANEL HARNESS

Circuit End
Position (mm) Tag
1A CNLC9 6/300 Red
1
1B 1
2 16/230 Red
2
2A 61F
3 16/1775 Dark Blue
3
3A CNLC4-F 61L
4 CNLC4-E 16/1775 Light Green
4
4A 61M
5 CNLC4-D 16/1775 Orange
5
5A 61H
6 CNLC4-B 16/1875 Orange
6
6A CNLC1 66C
7 CNLC4-A 16/1775 Black
7
7A 66
8 CNLC4-C 16/1675
8 Black
8A CNLC10
9 CNLC3 16/400 Orange
9
9A CNLC7 63RP
10
10A CNLC7 63RH
11
11A CNLC7 63RL
12
12A 19R
13
13A CNLC3 63RW
14
14A CNLC8 63FP
15
15A CNLC8 63FH
16
16A CNLC8 63FL
17 CNLC2 16/330
Orange
17 17A 16/230
19F
17B CNLC8
18
18A CNLC2 63LW
19
19A CNLC2 63LP
20
20A CNLC2 63LH
21
21A CNLC2 63LL
22
22A 19LL
23
23A CNLC2 63P
24
24A CNLC6 63H
25
25A CNLC6 63L
26 CNLC6 16/280
Orange
26 26A 16/330
19LR
26B CNLC1
10-166 2 D87E-2 D87P-2

CONTROLLER HARNESS

Circuit End mm
Position Tag
1 CNJ5-A 18/450
1 Blue
1A CNJ4-2
2 CNJ5-B 18/450
2 Brown
2A CNJ4-1
3 CNJ5-C 18/450
3A CNJ4-6 18/150
3 Black
3B CNJ4-7 18/275
3C CNJ11
4 CNJ5-D 18/450
4 Gray
4A CNJ4-4
5 CNJ5-E 18/450
5 White
5A CNJ4-5
6 CNJ11 18/275
Gray White
6A CNJ4-3
7 CNJ11 18/275
7 Gray
7A CNJ4-8
8 CNJ11 18/275
8 Purple
8A CNJ4-11
9 CNJ11 18/275
9 Red
9A CNJ4-12
D87E-2 D87P-2 10-167 2

INSTRUMENT HARNESS

Circuit End
Position (mm) Tag
1 CNJ19-14 18/950
1 Purple
1A CNJ1
2 CNJ19-2 18/950 Gray
2
2A CNJ1 Blue
3 CNJ19-3 18/950 Gray
3
3A CNJ1 Yellow
4 CNJ19-4 18/950 Light
4
4A CNJ1 Green
5 CNJ19-13 18/950
5 Black
5A CNJ2
7 CNJ19-5 18/950
7 7A CNJ2 18/950 Red
7B CNJ20
10-168 2 D87E-2 D87P-2

COMPARTMENT HARNESS

Circuit End mm
Position Tag
1 CNJ7-G 18/1575
1A CNJ8-B 18/150
1B CNJ9-B 18/350
1 Black
1C CND3 18/150
1D CND2 18/4825
1E CNJ19-13
2 CNJ19-2 18/3550 Gray
2
2A CNJ7-J Blue
3 CNJ19-3 18/3550 Gray
3
3A CNJ7-K Yellow
4 CNJ19-4 18/3550 Light
4
4A CNJ7-L Green
5 CNJ8-A 18/1575 Green
5
5A CNJ7-M White
6 CNJ9-A 18/1575
6 6A CNJ7-N 18/1375 Green
6B CND2
7 CNJ19-5 18/3550
7 Red
7A CNJ7-P
8 CNJ19-14 18/3550
8 Purple
8A CNJ7-H
D87E-2 D87P-2 10-169 2


Circuit End
Position (mm) Tag
1 CNJ7-G 18/350
1A CNJ13 18/300
1B CNJ11 18/200
1 1C CNJ16 18/300 Black
1D CNJ14 18/150
1E CNJ15 18/275
1F CNJ12-A
2 CNJ13 18/350 Gray
2
2A CNJ7-J Blue
3 CNJ14 18/350 Gray
3
3A CNJ7-K Yellow
4 CNJ15 18/350 Light
4
4A CNJ7-L Green
5 CNJ11 18/200 Green
5
5A CNJ7-M White
6 CNJ11 18/200
6 Green
6A CNJ7-N
7 CNJ11 18/200
7 7A CNJ7-P 18/525 Red
7B CNJ17
8 CNJ18 18/450
8 Yellow
8A CNJ12-B
9 CNJ7-H 18/250
9 Purple
9A CNJ11
10-170 2 D87E-2 D87P-2

A/C HEATER
A/C HEATER PIPING
1. Compressor
2. Condenser
3. Reciever Dryer
4. A/C Heater Unit
4. Heater Unit
5. Evaporator
6. Compressor to Condenser Hose
7. Condenser to Reciever Dryer Hose
8. Reciever Dryer to Evaporator Hose
9. Evaporator to Compressor Hose
10. Heater Shut Off Valves
11. Heater Inlet Hose
12. Heater Outlet Hose
D87E-2 D87P-2 10-171 2

COMPRESSOR MOUNTING
1. A/C Compressor
2. Magnetic Clutch
3. Drive Belt and Pulley
4. Clutch and Pulley Cover
5. Belt Adjusting Bolt
5. Belt Adjusting Lock Nut
6. Compressor Mounting Bracket
7. Compressor to Condenser Hose
8. Evaporator to Compressor Hose
10-172 2 D87E-2 D87P-2

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CEBM004802

September 2002 Copyright 2000 Komatsu

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . 10-1

20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . 20-1

30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-1

DESCRIPTION FORM NUMBER

PARTS BOOK - PAPER:

Chassis and Engine - D87E-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB008300

OPERATION AND MAINTENANCE MANUAL:

Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM007302

Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLT80-1

STREET ADDRESS ORDER DATE

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

KDC91E 072199 CURRENT PRICES WILL BE CHARGED

( ) Page to be deleted Discard

Mark Page Rev Mark Page Rev

D87E-2 D87P-2 00-1 2

PREPARATIONS FOR WORK

PRECAUTIONS DURING WORK

00-2 2 D87E-2 D87P-2

D87E-2 D87P-2 00-3 2

STRUCTURE, FUNCTION & MAINTENANCE STANDARD

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

00-4 2 D87E-2 D87P-2

Chassis volume: Issued for every machine model

Engine volume: Issued for each engine series

Electrical volume: Each issued as one to cover all models

Attachment volume: Each issued as one to cover all models

DISTRIBUTION AND UPDATING

2. Following examples show how to read the page number:

Section number (10 Structure and Function)

Consecutive page number for each item

REVISED EDITION MARK

D87E-2 D87P-2 00-5 2

Symbol Item Remarks

Coat Places to be coated with adhesives and lubricants etc.

00-6 2 D87E-2 D87P-2

Wire ropes (Standard “Z” or “S” twist ropes without galvanizing)

★ The allowable load value is estimated to be 1/6 or 1/7 of the break-

WARNING! Slinging with one rope may cause turn-

D87E-2 D87P-2 00-7 2

Category Code Part No. Quantity Container Main applications, features

LT-1A 790-129-9030 150 g Tube

LG-1 790-129-9010 200 g Tube

00-8 2 D87E-2 D87P-2

Thread diameter Width across flats

Thread diameter Width across flats

D87E-2 D87P-2 00-9 2

Thread diameter Across flats Tightening torque

SPLIT FLANGE BOLTS

Thread diameter Across flats Tightening torque

Thread diameter Across flats Tightening torque

00-10 2 D87E-2 D87P-2

TYPE/CLASS DESCRIPTION HEAD MARK

D87E-2 D87P-2 00-11 2