Manual de Servicio 865 DHP

SECTION INDEX
GENERAL
Section Title
Section Number
Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003
Loctite Product Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1005
CNH Latino Americana Ltda

2237, General David Sarnoff Avenue
Contagem, MG Brazil
ENG 6-46521
Printed in Brazil
June, 2003
1001
Section
1001
STANDARD TORQUE SPECIFICATIONS

2237, General David Sanoff Avenue
Contagem, MG Brazil
ENG 6-46530
May, 2003
1001-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE ......................................................................................... 3
TORQUE SPECIFICATIONS - METRIC HARDWARE ........................................................................................... 4
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS ............................................................................ 5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS ............................................................................ 6
NOTE: Case Corporation reserves the right to make improvements in design or
changes in specifications at any time without incurring any obligation to install
them on units previously sold.
ENG 6-46530
ISSUE 01-03
Printed in Brazil
1001-3
TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special torques are not
given. These torques apply to fasteners with both UNC and
UNF threads as received from suppliers dr y, or when
lubricated with engine oil. Not applicable if special graphities,
Molydisulfide greases, or other extreme pressure lubricants
are used.
Grade 8 Bolts, Nuts, and Studs
PoundInches
Newton
metres
1/4 inch
144 to 180
16 to 20
5/16 inch
288 to 348
33 to 39
3/8 inch
540 to 648
61 to 73
PoundFeet
Newton
metres
Size
Grade 5 Bolts, Nuts, and Studs
Size
PoundInches
Newton
metres
1/4 inch
108 to 132
12 to 15
Size
5/16 inch
204 to 252
23 to 28
7/16 inch
70 to 84
95 to 114
3/8 inch
420 to 504
48 to 57
1/2 inch
110 to 132
149 to 179
9/16 inch
160 to 192
217 to 260
Newton
metres
5/8 inch
220 to 264
298 to 358
Size
PoundFeet
3/4 inch
380 to 456
515 to 618
7/16 inch
54 to 64
73 to 87
7/8 inch
600 to 720
814 to 976
1/2 inch
80 to 96
109 to 130
1.0 inch
900 to 1080
1220 to 1465
9/16 inch
110 to 132
149 to 179
1-1/8 inch
1280 to 1440
1736 to 1953
5/8 inch
150 to 180
203 to 244
1-1/4 inch
1820 to 2000
2468 to 2712
3/4 inch
270 to 324
366 to 439
1-3/8 inch
2380 to 2720
3227 to 3688
7/8 inch
400 to 480
542 to 651
1-1/2 inch
3160 to 3560
4285 to 4827
1.0 inch
580 to 696
787 to 944
1-1/8 inch
800 to 880
1085 to 1193
1-1/4 inch
1120 to 1240
1519 to 1681
1-3/8 inch
1460 to 1680
1980 to 2278
1-1/2 inch
1940 to 2200
2631 to 2983
ENG 6-46530
NOTE: Use thick nuts with Grade 8 bolts.
ISSUE 01-03
Printed in Brazil
1001-4
TORQUE SPECIFICATIONS - METRIC HARDWARE

Use the following torques when specifications are not given.
Grade 10.9 Bolts, Nuts, and Studs

These values apply to fasteners with coarse threads as
received from supplier, plated or unplated, or when lubricated
with engine oil. These values do not apply if graphite or
Molydisulfide grease or oil is used.

8.8
10.9
Size
PoundInches
Newton
metres
M4
36 to 48
4 to 5
M5
84 to 96
9 to 11
M6
132 to 156
15 to 18
M8
324 to 384
37 to 43
Size
PoundFeet
Newton
metres
M10
54 to 64
73 to 87
M12
93 to 112
125 to 150
M14
149 to 179
200 to 245
M16
230 to 280
310 to 380
M20
450 to 540
610 to 730
M24
780 to 940
1050 to 1275
Size
PoundInches
Newton
metres
M4
24 to 36
3 to 4
M5
60 to 72
7 to 8
M6
96 to 108
11 to 12
M8
228 to 276
26 to 31
M10
456 to 540
52 to 61
Size
PoundFeet
Newton
metres
M12
66 to 79
90 to 107
M30
1470 to 1770
2000 to 2400
M14
106 to 127
144 to 172
M36
2580 to 3090
3500 to 4200
M16
160 to 200
217 to 271
M20
320 to 380
434 to 515
M24
500 to 600
675 to 815
M30
920 to 1100
1250 to 1500
M36
1600 to 1950
2175 to 2600

12.9
Usually the torque values specified for grade 10.9 fasteners

can be used satisfactorily on grade 12.9 fasteners.
ENG 6-46530
ISSUE 01-03
Printed in Brazil
1001-5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Tube OD
Hose ID
Thread
Size
PoundInches
Newton
metres
Tube OD
Hose ID
37 Degree Flare Fitting
Thread
Size
PoundInches
Newton
metres
Straight Threads with O-ring
1/4 inch
6.4 mm
7/16-20
72 to 144
8 to 16
1/4 inch
6.4 mm
7/16-20
144 to 228
16 to 26
5/16 inch
7.9 mm
1/2-20
96 to 192
11 to 22
5/16 inch
7.9 mm
1/2-20
192 to 300
22 to 34
3/8 inch
9.5 mm
9/16-18
120 to 300
14 to 34
3/8 inch
9.5 mm
9/16-18
300 to 480
34 to 54
1/2 inch
12.7 mm
3/4-16
180 to 504
20 to 57
1/2 inch
12.7 mm
3/4-16
540 to 804
57 to 91
5/8 inch
15.9 mm
7/8-14
300 to 696
34 to 79
Tube OD
Hose ID
Thread
Size
PoundInches
Newton
metres
Tube OD
Hose ID
Thread
Size
PoundInches
Newton
metres
5/8 inch
15.9 mm
7/8-14
58 to 92
79 to 124
3/4 inch
19.0 mm
1-1/16-12
40 to 80
54 to 108
3/4 inch
19.0 mm
1-1/16-12
80 to 128
108 to 174
7/8 inch
22.2 mm
1-3/16-12
60 to 100
81 to 135
7/8 inch
22.2 mm
1-3/16-12
100 to 160
136 to 216
1.0 inch
25.4 mm
1-5/16-12
75 to 117
102 to 158
1.0 inch
25.4 mm
1-5/16-12
117 to 187
159 to 253
1-1/4 inch
31.8 mm
1-5/8-12
125 to 165
169 to 223
1-1/4 inch
31.8 mm
1-5/8-12
165 to 264
224 to 357
1-1/2 inch
38.1 mm
1-7/8-12
210 to 250
285 to 338
1-1/2 inch
38.1 mm
1-7/8-12
250 to 400
339 to 542
Split Flange Mounting Bolts

PoundInches
Newton
metres
5/16-18
180 to 240
20 to 27
3/8-16
240 to 300
27 to 34
7/16-14
420 to 540
47 to 61
Size
PoundFeet
Newton
metres
1/2-13
55 to 65
74 to 88
5/8-11
140 to 150
190 to 203
Size
ENG 6-46530
ISSUE 01-03
Printed in Brazil
1001-6
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Nom.
SAE
Dash
Size
Tube OD
Thread
Size
PoundInches
Newton
metres
Thread
Size
PoundInches
Newton
metres
O-ring Boss End

Fitting or Lock Nut
O-ring Face Seal End

-4
1/4 inch
6.4 mm
9/16-18
120 to 144
14 to 16
7/16-20
204 to 240
23 to 27
-6
3/8 inch
9.5 mm
11/16-16
216 to 240
24 to 27
9/16-18
300 to 360
34 to 41
-8
1/2 inch
12.7 mm
13/16-16
384 to 480
43 to 54
3/4-16
540 to 600
61 to 68
Thread
Size
PoundInches
Newton
metres
7/8-14
60 to 65
81 to 88
1-1/16-12
85 to 90
115 to 122
-10
Nom.
SAE
Dash
Size
5/8 inch
15.9 mm
Tube OD
1-14
552 to 672
62 to 76
Thread
Size
PoundInches
Newton
metres
1-3/16-12
95 to 100
129 to 136
-12
3/4 inch
19.0 mm
1-3/16-12
65 to 80
90 to 110
1-5/16-12
115 to 125
156 to 169
-14
7/8 inch
22.2 mm
1-3/16-12
65 to 80
90 to 110
1-5/8-12
150 to 160
203 to 217
-16
1.0 inch
25.4 mm
1-7/16-12
92 to 105
125 to 140
1-7/8-12
190 to 200
258 to 271
-20
1-1/4 inch
31.8 mm
1-11/16-12
125 to 140
170 to 190
-24
1-1/2 inch
38.1 mm
2-12
150 to 180
200 to 254
ENG 6-46530
ISSUE 01-03
Printed in Brazil
Yellow
Clear
Blue
Purple
Purple
Brown
Blue
Red
Green
Red
Red
Green
Red
Green
Clear
Clear
Clear
Clear
Clear
Clear
Clear
Clear
Clear
White/Black
Clear
Clear
Clear
Brt Orange
Light Blue
Red
Purple
80
123
220
221
222
225
242
262
270
271
272
275
277
290
*404
*406
*409
*414
*415
*416
*420
*422
*430
*445
*454
*495
*496
504
509
510
515
515
454
454
454
454
495
271
271
262
620
277
222
290
222
0.004
0.005
0.030
0.020
0.020
0.010
0.010
0.010
0.005
0.005
0.007
0.007
0.007
0.010
0.010
0.003
0.006
0.004
0.008
0.006
0.010
0.010
0.002
0.020
0.005
0.250
0.005
0.003
0.005
2500 psi
2500 psi
750 psi
750 psi
1000 psi
750 psi
3200 psi
45/25 in lbs
80/50 in lbs
160/190 in lbs
160/320 in lbs
160/320 in lbs
180/220 in lbs
210/300 in lbs
225/300 in lbs
85/350 in lbs
3200 psi
3200 psi
2500 psi
2500 psi
2500 psi
2500 psi
2500 psi
2800 psi
2500 psi
2000 psi
53/30 in lbs
57/143 in lbs
75/44 in lbs
Strength
(Steel/Steel)
Printed_in_Brazil
Working
Fixture/Full Cure
Temperature
(Steel/Steel) Time
Range-Farenheit
Primer
Description
N/A Form a Gasket (works with oil, fuel or
24 hr
grease) Pliable
Fast
N/A Weatherstrip Adhesive
N/A
N/A Parts Cleaner Fluid
-65 to +250
6 min/24 hrs
747 Wicking Threadlocker
-65 to +300
2 min/24 hrs
747 Low Strength Threadlocker
Low Strength Threadlocker
-65 to +300
20 min/24 hrs
764 (Small Screws)
-65 to +300
7 min/24 hrs
747 Low Strength Threadlocker
-65 to +300
10 min/24 hrs
764 Medium Strength Threadlocker
-65 to +300
5 min/24 hrs
747 High Strength Threadlocker
-65 to +300
3 min/24 hrs
-65 to +300
10 min/24 hrs
-65 to +450
30 min/24 hrs
764 High Temperature, High Strength
-65 to +300
3 min/24 hrs
-65 to +300
60 min/24 hrs
-65 to +300
6 min/24 hrs
764 Wicking Threadlocker
-65 to +180
30 sec/24 hrs
NA
Instant Adhesive
-65 to +180
15 sec/24 hrs
N/A Surface Insensitive Adhesive
-65 to +180
50 sec/24 hrs
N/A Gel Instant Adhesive
-65 to +180
30 sec/24 hr
N/A Instant Adhesive
-65 to +180
50 sec/24 hrs
N/A Gap Filling Instant Adhesive (Metals)
-65 to +180
50 sec/24 hrs
N/A Gap Filling Instant Adhesive (Plastics)
-65 to +180
15 sec/24 hrs
N/A Wicking Instant Adhesive
-65 to +180
60 sec/24 hrs
N/A Gap Filling Instant Adhesive
-65 to +180
20 sec/24 hrs
N/A Metal Bonding Adhesive
-65 to +180
5 min/24 hrs
N/A Fast Setting 2 Part Epoxy
Surface Insensitive Gen
-65 to +180
15 sec/24 hrs
N/A Instant Adhesive
-65 to +180
20 sec/24 hrs
N/A General Purpose Instant Adhesive
-65 to +180
20 sec/24 hrs
N/A Metal Bonding Adhesive
-65 to +300
90 min/24 hrs
None Rigid Gasket Eliminator
-65 to +320
6 hr/72 hrs
764 Flange Sealant
-65 to +400
30 min/24 hrs
764 High Temperature, GAsket Eliminator
-65 to +300
1 hr/24 hrs
764 Gasket Eliminator 515
* Products 404-496 (except for #445) are all instant adhesives (super glues) they differ mostly in viscosity
Dark Brown
#3
Rac 8-98902
Color
Product
Similar
Gap
Products (In Inches)
LOCTITE PRODUCT CHART
Color
Red
Brown
Purple
Orange
Red
White
Orange
Brown
Brown
Brown
White
White
Black
Green
Green
Green
Green
Green
Green
Silver
Green
Green
Clear
Amber
Amber
Amber
Yellow
Clear
Clear
Green
Silver
Product
518
542
545
549
554
567
568
569
570
571
572
592
593
601
609
620
635
638
640
660
675
680
706
707
736
738
747
751
755
764
767
N/A
609
635
755
680
680
620
640
609
504
277
592
277
545
592
592
578.575
0.010
0.015
0.007
0.020
0.005
0.015
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
0.015
0.020
0.015
N/A
0.015
0.010
N/A
0.015
N/A
0.020
0.250
0.005
0.005
N/A
Similar
Gap
Products (In Inches)
515
0.030
569
N/A
Strength
(Steel/Steel)
500psi
132/92 in lbs
Printed in Brazil
Working
Fixture/Full Cure
Temperature
(Steel/Steel) Time
Range-Farenheit
Primer
Description
-65 to +300
1hr/24 hrs
764 Gasket Eliminator 518 for Aluminum
-65 to +300
2 hr/24 hrs
747 Hydraulic Sealant
Low Strength Pneumatic/Hydraulic
25/20 in lbs
-65 to +300
4 hr/24 hrs
747
Sealant
2500 psi
-65 to +300
2 hr/24 hrs
747 Instant Seal Plastic Gasket
240/240 in lbs
-65 to +300
2 to 4 hrs/24 hrs
764 Refrigerant Sealant
500 psi
-65 to +400
4 hrs/24 hrs
764 Pipe Sealant for Stainless Steel
2500 psi
-65 to +300
12 hrs/24 hrs
764 Plastic Gasket
40/25 in lbs
-65 to +300
1 hr/24 hrs
764 Hydraulic Sealant
25/40 in lbs
-65 to +300
6 hrs/72 hrs
764 Steam Sealant
40/20 in lbs
-65 to +300
2 to 4 hrs/24 hrs
764 Pipe Sealant
80/27 in lbs
-65 to +300
24 hrs/72 hrs
None Gasketing
500 psi
-65 to +400
4 hrs/72 hrs
736 Pipe Sealant with Teflon
400 psi
-95 to +400
30 min/24 hrs
N/A RTV Silicone
3000 psi
-65 to +300
10 min/24 hrs
764 Current PIN #609
3000 psi
-65 to +300
10 min/24 hrs
764 General Purpose Retaining Compound
High Temperature Retaining
3000 psi
-65 to +450
30 min/24 hrs
747
Compound
4000 psi
-65 to +300
1 hr/24 hrs
747 High Strength Retaining Compound
4100 psi
-65 to +300
10 min/24 hrs
3000 psi
-65 to +400
1 hr/24 hrs
747 High Temperature Retaining Compound
3000 psi
-65 to +300
20 min/24 hrs
764 Quick Metal
3000 psi
-65 to +300
20 min/24 hrs
747 General Purpose Retaining Compound
4000 psi
-65 to +300
10 min/24 hrs
N/A
N/A
N/A
N/A Cleaning Solvent
N/A
N/A
N/A
N/A Activaltor for Structural Adhesives
N/A
N/A
N/A
N/A Primer NF
N/A
N/A
N/A
N/A Depend Activator
N/A
N/A
N/A
N/A Primer T
N/A
N/A
N/A
N/A Activator for Structural Adhesives
N/A
N/A
N/A
N/A Cleaning Solvent
N/A
N/A
N/A
N/A Primer N
N/A
-65 to +1600
N/A
N/A Anti-Seize Lubricant
LOCTITE PRODUCT CHART
1002
Section
1002
FLUIDS AND LUBRICANTS
845 - 865 - 885 Grader

Contagem, MG - Brazil
ENG 46540
Printed in Brazil
May, 2003
1002-2
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS 845 MODEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CONVERSION FORMULAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CAPACITIES AND LUBRICANTS 865 MODEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CONVERSION FORMULAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CAPACITIES AND LUBRICANTS 885 MODEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CONVERSION FORMULAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE OIL RECOMMENDATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LUBRICATION & MAINTENANCE CHART model 845 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LUBRICATION & MAINTENANCE CHART model 865 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENG 6-46540
Issued 01-03
Printed in Brazil
845 GRADER
COMPONENTS
Fuel Tank
(Total Capacity)
Engine Oil
(With Filter Change)
(Without Filter Change)
Engine Cooling System
(Total Capacity)
Hydraulic System
Total Capacity
Hydraulic Tank With Filter
Transmission
Refill capacity (with filter change)
Refill capacity (without filter change)
Rear Axle Graziano Model
Center Compartment
End / Brake compartment (each)
Rear Axle Clark Model
Center Compartment
Planetary Hubs (Each)
Tandem Drive Case
(For Graziano Axle)
Refill capacity (each)
Tandem Drive Case
(For Clark Axle)
Circle Turn Gear
Refill Capacity
CAPACITY CAPACITY
LITERS
US Gal.
SPECIFICATIONS
DIESEL N. 2
341.0
90.0
16.4
14.2
4.3
3.7
40.0
10.5
180.0
94.6
47.5
25.0
25.0
19.0
6.4
5.0
29.0
5.0
7.7
1.33
HY-TRAN ULTRA
MAT 3505 (MS 1209)
12.0
6.0
3.2
1.6
HY-TRAN ULTRA
MAT 3505 (MS 1209)
N. 1 ENGINE OIL
SAE15W-40 API CH4
MAT 3507 (MS 1121)
50% WATER
+
50%
ETHYLENE GLICOL
MS 1710
HY-TRAN ULTRA
MAT 3505 (MS 1209)
HY-TRAN ULTRA
MAT 3505 (MS 1209)
SAE 80W-90 135H EP API GL5
29.0
7.7
22.5
5.9
2.8
0.75
Grease Fitting
Rear Ripper / Front Scarifier and As required
Dozer Blade
As required CASE MOLYDISULFIDE GREASE
865 DHP - GRADER

CAPACITY
COMPONENTS
Fuel tank
(total capacity)
Engine oil
(with filter change)
(without filter change)
(50%)
(total capacity)
Hydraulic System
Liters
341.0
Total capacity
US Gal.
90.0
SPECIFICATIONS
Diesel N2
21.1
18.9
5.5
4.8
N1 Engine Oil
SAE15W-40 API CH-4
MAT 3507 (MS 1121)
WATER (50%) + ETHYLENE GLICOL
40.0
10.5
MS 1710
180.00
47.5
HY-TRAN ULTRA
Hydrauic tank with filter

Transmission
Rear Axle Graziano Model - STD
- Center compartment
- End/Brake compartment (each)
Rear Axle Clark Model - OPTIONAL
- Center compartment
- Planetary hubs (each)
Tandem Drive Case (Graziano Axle)
Tandem Drive Case (Clark Axle)
Circle Turn Gear Reducer
94,6
25.0
MAT 3505 (MS 1209)
25.0
19.0
6.4
5.0
HY-TRAN ULTRA
MAT 3505 (MS 1209)
29.0
5.0
7.7
1.33
HY-TRAN ULTRA
MAT 3505 (MS 1209)
12.0
6.0
3.2
1.6
HY-TRAN ULTRA
MAT 3505 (MS 1209)
29.0
7.7
SAE 80W-90 135H EPAPI GL5
22.5
5.9
Refill capacity
Grease fittings , Rear Ripper
Rear Ripper , Front Scarifier or
Dozer Blade
2,8
0.75
--
--
CASE molydisulfide grease
885 GRADER
COMPONENTS
Fuel Tank
(Total Capacity)
Engine Oil
(With Filter Change)
(Without Filter Change)
(Total Capacity)
Hydraulic System
Total Capacity
Hydraulic Tank With Filter
Transmission
Rear Axle Clark Model
Center Compartment
Planetary Hubs (Each)
Tandem Drive Case
Circle Turn Gear
Refill Capacity
CAPACITY CAPACITY
LITERS
US Gal.
SPECIFICATIONS
DIESEL N. 2
341.0
90.0
21.1
18.9
5.5
4.8
40.0
10.5
180.0
94.6
47.5
25.0
28.5
22.0
7.5
5.8
HY-TRAN ULTRA
MAT 3505 (MS 1209)
12.0
6.0
3.2
1.6
HY-TRAN ULTRA
MAT 3505 (MS 1209)
N. 1 ENGINE OIL
SAE15W-40 API CH4
MAT 3507 (MS 1121)
50% WATER
+
50%
ETHYLENE GLICOL
MS 1710
HY-TRAN ULTRA
MAT 3505 (MS 1209)
22.5
5.9
2.8
0.75
Grease Fitting
Rear Ripper / Front Scarifier and As required
Dozer Blade
As required CASE MOLYDISULFIDE GREASE
1002-6
ENGINE OIL RECOMMENDATIONS

Case
No. 1 Engine oil is recommended for use
in your Case engine. Case
No. 1 Engine Oil will
lubricate your engine correctly under all operating
conditions.
If C ase No. 1 Multi-Viscosity or Single Grad e
Engine Oil is not available, use only oil meeting
API engine oil service category CH .
See the chart below for
r e c o m m e n d e d v i s c o s it y a t
ambient air temperature
ranges.
RH99K130
NOTE: Do not put performance

additives or other oil additive
products
in
the
engine
crankcase. The oil change
intervals given in this manual
are according to tests with Case
lubricants.
BP99J241
BS99M162
ENG 6-46540
May, 2003
Printed in Brazi
.l
1002-7
DIESEL FUEL SYSTEM

Use No. 2 diesel fuel in the engine of this machine.
The use of other fuels can cause the loss of engine
power and high fuel consumption.
In very cold temperatures, a mixture of No. 1 and No.
2 diesel fuels is temporarily permitted. See the
following Note.
NOTE: See your fuel dealer for winter fuel
requirements in your area. If the temperature of the
fuel lowers below the cloud point (wax appearance
point), wax crystals in the fuel will restrict the fuel
filter and cause the engine to lose power or not start.
Fuel Storage
If you keep fuel in storage for a period of time, you
can get foreign material or water in the fuel storage
tank. Many engine problems are caused by water in
the fuel.
Keep the fuel storage tank outside and keep the fuel
as cool as possible. Remove water from the storage
container at regular periods of time.
Fill the fuel tank at the end of the daily operating
period to prevent condensation in the fuel tank.
The diesel fuel used in this machine must meet the

specifications as shown below in, Specifications for
Acceptable No. 2 Diesel Fuel, or Specification
D975-81 of the American Society for Testing and
Materials.
Specifications for Acceptable No. 2 Diesel Fuel

API gravity, minimum ............................................................................................................................................. 34
Flash point, minimum ............................................................................................................................60C (140F)
Cloud point (wax appearance point), maximum ...........................................................-20C (-5F) See Note above
Pour point, maximum ..................................................................................................-26C (-15F) See Note above
Distillation temperature, 90% point ................................................................................282 to 338C (540 to 640F)
Viscosity, at 38C (100F)
Centistokes ......................................................................................................................................... 2.0 to 4.3
Cetane number, minimum .......................................................................... 43 (45 to 55 for winter or high altitudes)
Water and sediment, by volume, maximum ..................................................................................................... 0.05%
ENG 6-46540
May, 2003
Printed
. in Brazi
nl
1002-8
LUBRICATION & MAINTENANCE CHART model 845

SERVICE INTERVAL (hours)
H
O
U
R
S
6.
SERVICE POINTS
As
needed
1.
10h
or
daily
7.
50h
or
weekly
8.
I
T
E
M
C
H
E
C
K
C
H
A
N
G
E
L
U
B
R
I
C
A
T
E
Air cleaner (Note 1)
Hydraulic filter (Note 2)
Alternator / Air conditioner belt
Engine oil level (including filters)
10
Radiator (coolant level) (Note 3)
10
Transmission oil level (warm, engine running)
10
Hydraulic tank (complete system)
50
Fuel filters / separator filter (drain water)
50
Blade lift cylinder pivots
100
Side shift cylinder pivots
10
100
11
100
12
250
13
100
Articulation cylinders pivots
14
100
Moldboard lift cylinders balls
15
100
Engine oil and oil filter
16
Universal joints and drive shaft
17
250
Differential and planetary drives oil level (Note 4) 18
250
Circle turn gear housing
19
250
Alternator and ar conditioning belts
20
250
Moldboard adjusting link ends
21
250
Moldboard side shift link ends
22
250
Front wheel lean link and knuckle pivot
23
250
Front axle spindle pivot
24
250
Front wheel lean cylinder
25
250
Drawbar pivot and socket

100h
or
Front axle pivot
each
15 days Articulation pivots
250h
or
monthly
P
O
I
N
T
S
A
D
J
U
S
T
C
L
E
A
N
/
D
R
A
I
N
250
NOTE: See FLUIDS AND LUBRICANTS table on previous pages for lubricants and fluids detailed
specifications and capacities.
NOTE 1: Service the air filter elements if air filter restriction indicator is in the red area.
NOTE 2: Service the hydraulic filters if hydraulic filter indicator lamp iluminates.
NOTE 3: Check the radiator coolant level if the coolant level warning lamp iluminates.
NOTE 4: Change the rear axle oil after the first100 hours of operation.
NOTE 5: Change the transmission oil and replace the filter after the first100 hours of operation.
NOTE 6: Contact your dealer and see the service manual.
NOTE 7: Change every 2.000 hours or once a year, whichever comes first.
ENG 6-46540
: As needed
Issued 01-03
Printed in Brazil
1002-9
LUBRICATION/FILTERS/FLUIDS
H
O
U
R
S
SERVICE POINTS
250h
or
monthly
2000h
or
each
year
P
O
I
N
T
S
26
Cab air filter (if equipped)
27
Tandem case
28
Steering arm pivot
29
C
H
A
N
G
E
C
H
E
C
K
L
U
B
R
I
C
A
T
E
250
250
250
Tire condition and pressure
30
31
Front wheel bearing grease
32
Tandem drive case oil level
33
34
35
500
36
500
Fuel tank drain plug (drain sediment)
37
Rops and seat belts bolts torque
38
Transmission oil (Note 5)
39
Transmission screen
40
Fuel pump and injectors (Note 6)
41
1000
Engine valves clearance (Note 6)
42
12
1000
Air cleaner elements
43
Circle turn gearbox oil
44
Hydraulic oil (Note 7)

Differential and planetary drives oil (Note 4)
C
L
E
A
N
/
D
R
A
I
N
A
D
J
U
S
T
Fuel filters
Tandem wheel shaft bearings

500h
or
Transmission oil filter (Note 5)
each
3 months Rear axle cooling system filter
1000h
or
each
6
months
I
T
E
M
250
500
500
500
500
500
500
1000
1000
1000
1000
45
2000
46
2000
Front wheel bearing (repack)
46
2000
Tandem drive case oil
48
2000
Engine coolant
49
Turbocharger bolts torque
50
10
2000
2000
NOTE: See FLUIDS AND LUBRICANTS table on previous pages for lubricants and fluids detailed
specifications and capacities.
NOTE 1: Service the air filter elements if air filter restriction indicator is in the red area.
NOTE 2: Service the hydraulic filters if hydraulic filter indicator lamp iluminates.
NOTE 3: Check the radiator coolant level if the coolant level warning lamp iluminates.
NOTE 4: Change the rear axle oil after the first100 hours of operation.
NOTE 5: Change the transmission oil and replace the filter after the first100 hours of operation.
NOTE 6: Contact your dealer and see the service manual.
NOTE 7: Change every 2.000 hours or once a year, whichever comes first.
: As needed
ENG 6-46540
Issued 01-03
Printed in Brazil
1002-10
LUBRICATION & MAINTENANCE

CHART model 865
I
H
O
U
R
S
L
U
B
R
I
C
A
T
E
P
O
I
N
T
S
C
H
E
C
K
10
10
10
50
50
100
100
100
250
100
100
100
Differential and planetary drives oil level (Note 4)
250
250
250
250
250
250
250
250
SERVICE POINTS
C
H
A
N
G
E
A
D
J
U
S
T
C
L
E
A
N
/
D
R
A
I
N

As
needed

10h
or
daily
50h
or
weekly

100h
or
Front axle pivot
each
250h
or
monthly
ENG 6-46540
250
250
Issued 01-03
Printed in Brazil
1002-11

H
O
U
R
S
SERVICE POINTS
Fuel sediment bowl (wash filter screen)

250h
or
monthly
P
O
I
N
T
S
C
H
E
C
K
C
H
A
N
G
E
250
Tandem case
250
Steering arm pivot
Fuel filters
250
250
500
500
500
500
500
500
Engine cooling system filter
500
500
1000
1000
1000
1/2
1000
1000
1000
Hydraulic oil and filter (Note 7)
2000
2000
2000
2000
ENG 6-46540
500
Transmission screen
Engine coolant
C
L
E
A
N
/
D
R
A
I
N
250
2000h
or
each
year
A
D
J
U
S
T

500h
or
each
1000h
or
each
6
months
L
U
B
R
I
C
A
T
E
10
2000
2000
Issued 01-03
Printed in Brazil
1002-12
LUBRICATION & MAINTENANCE CHART model 885

H
O
U
R
S
L
U
B
R
I
C
A
T
E
P
O
I
N
T
S
C
H
E
C
K
10
10
10
50
50
100
100
100
250
100
100
100
Differential and planetary drives oil level (Note 4)
250
250
250
250
250
250
250
250
SERVICE POINTS
C
H
A
N
G
E
A
D
J
U
S
T
C
L
E
A
N
/
D
R
A
I
N

As
needed

10h
or
daily
50h
or
weekly

100h
or
Front axle pivot
each
250h
or
monthly
ENG 6-46540
250
250
Issued 01-03
Printed in Brazil
1002-13
LUBRICATION/FILTERS/FLUIDS

H
O
U
R
S
250h
or
monthly
SERVICE POINTS
P
O
I
N
T
S
C
H
E
C
K
C
H
A
N
G
E
L
U
B
R
I
C
A
T
E
A
D
J
U
S
T
250
Tandem case
250
Steering arm pivot
Fuel filters

500h
or
each
250
250
500
500
500
500
500
500
Engine cooling system filter
500
500

1000h
or
each
6
months
2000h
or
each
year
500
1
1000
Transmission screen
1000
1000
12
1000
1000
1000
Hydraulic oil and filter (Note 7)
2000
2000
2000
2000
Engine coolant
10
2000
ENG 6-46540
C
L
E
A
N
/
D
R
A
I
N
2000
Issued 01-03
Printed in Brazil
1003
Section
1003
METRIC CONVERSION CHART

Contagem,MG-Brazil
ENG 6-46550
May, 2003
1003-2
TABLE OF CONTENTS
CONVERSION FACTORS ............................................................................................................................................. 3
Metric to U.S. .......................................................................................................................................................... 3
U.S. to Metric ......................................................................................................................................................... 4
ENG 6-46550
Issued 1-03
Printed in Brazil
Template Name: SM_1_col

Template Date: 1994_04_05
Alt= to hide template information

Alt+ to display template information
1003-3
CONVERSION FACTORS
Metric to U.S.
MULTIPLY
BY
TO OBTAIN
Area:
sq. meter
hectare
10.763 91
2.471 05
square foot
acre
Force:
newton
newton
3.596 942
0.224 809
ounce force
pound force
Length:
millimeter
meter
kilometer
0.039 370
3.280 840
0.621 371
inch
foot
mile
Mass:
kilogram
2.204 622
pound
Mass/Area:
kilogram/hectare
0.000 466
ton/acre
Mass/Energy:
gr/kW/hr.
0.001 644
lbs/hp/hr.
Mass/Volume:
kg/cubic meter
1.685 555
lb/cubic yd.
Power:
kilowatt
1.341 02
horsepower
Pressure:
kilopascal
bar
0.145 038
14.50385
lb/sq. inch
lb/sq. inch
Temperature:
degree C
1.8 x C +32
degree F
Torque:
newton meter
newton meter
8.850 748
0.737 562
lb/inch
lb/foot
Velocity:
kilometer/hr.
0.621 371
miles/hr.
Volume:
cubic centimeter
cubic meter
cubic meter
milliliter
litre
litre
litre
litre
0.061 024
35.314 66
1.307 950
0.033 814
1.056 814
0.879 877
0.264 172
0.219 969
cubic inch
cubic foot
cubic yd.
ounce (US fluid)
quart (US liquid)
quart (Imperial)
gallon (US liquid)
gallon (Imperial)
Volume/Time:
litre/min.
litre/min.
0.264 172
0.219 969
gallon/min. (US liquid)

gallon/min. (Imperial)
ENG 6-46550
Issued 1-03
Printed in Brazil
Template Name: SM_1_col

Template Date: 1994_04_05
Alt= to hide template information

Alt+ to display template information
1003-4
U.S. to Metric
MULTIPLY
BY
TO OBTAIN
Area:
square foot
acre
0.092 903
0.404 686
square meter
hectare
Force:
ounce force
pound force
0.278 014
4.448 222
newton
newton
Length:
inch
foot
mile
25.4 *
0.304 8 *
1.609 344 *
millimeter
meter
kilometer
Mass:
pound
ounce
0.453 592
28.35
kilogram
gram
Mass/Area:
ton/acre
2241 702
kilogram/hectare
Mass/Energy:
lb/hp/hr
608.277 4
gr/kW/hr
Mass/Volume:
lb/cubic yd.
0.593 276
kg/cubic meter
Power:
horsepower
0.745 700
kilowatt
Pressure:
lbs/sq. in.
lbs/sq. in.
lbs/sq. in.
6.894 757
0.069
0.070 303
kilopascal
bar
kg/sq. cm
Temperature:
degree F
1.8 F - 32
degree C
Torque:
pound/inch
pound/foot
0.112 985
1.355 818
newton meter
newton meter
Velocity:
miles/hr.
1.609 344 *
kilometer/hr.
Volume:
cubic inch
cubic foot
cubic yard
ounce (US fluid)
quart (US liquid)
quart (Imperial)
gallon (US)
gallons (Imperial)
16.387 06
0.028 317
0.764.555
29.573 53
0.946 353
1.136 523
3.785 412
4.546 092
cubic centimeter
cubic meter
cubic meter
milliliter
litre
litre
litre
litre
Volume/Time:
gallon/min.
3.785 412
litre/min.
* = exact
ENG 6-46550
Issued 1-03
Printed in Brazil
1005
Section
1005
SERVICE TOOLS

Contagem,MG-Brazil
ENG 6-46552
June, 2003
1005-2
TABLE OF CONTENTS
Service tools ........................................................................................................................ 3
ENG 6-46550
Issued 1-03
Printed in Brazil
Service Tools
Required Service Tools for Case Motor Graders

380050007 Transmission Seal and Tandem
Axle Special Tools
380000378
Kit 380050007 is required to properly service the

transmission input shaft seal, lock up brake, and
tandem axles of Case Motor Grader models 845,
865 and 885.
380050007 Kit Contents:

380000379
380000380
380000387
380000388
Axle Brake Test Tool 380000378 - Go/No Go

gauge used to check manual lock up brake disc
wear, Model 885.
Axle Seal Tool 380000379 - Used with handle
from 38000091 to assemble the axle seals on a
manual lock up axle, Model 885.
Axle Seal Tool 380000380 - Used with handle
from 38000091 to assemble the axle seals on a
manual lock up axle, Model 885.
Transmission Input Seal Installer 380000387 Used to install the transmission input shaft seals,
Models 845 and 865.
380000391
Transmission Oil Seal Guide 380000388 - Used to

install the transmission oil seals, Model 885.
Transmission Seal Installer 380000391 - Used to
install the transmission seals, Models 845 and
865.
380000394
380000397
Tandem Wheel Hub Removal Tool 380000394 Used to remove tandem wheel hubs, Models 845
and 865.
Seal Installation Tool 380000397 - Used to install
transmission seals, Models 845 and 865.
Application:Case Motor Grader Models 845, 865, 885.

Ordering Information:380050007 Transmission Seal and Tandem Axle Tools Kit
Dealer Standard:Code A (required at all servicing locations)
ENG 6-45552
Service Tools
Required Service Tools for Selected Case Construction Equipment

Option 1 38040085
380040085 Pressure Test Adapter Kit
Used for pilot pressure, blade up pressure, blade
down pressure, turn table right, turn table left and
380000510 380000511 380000513 380000514
articulation tests on motor grader model 845.
380000513 Internal 7/16-20 JIC adapter with
external PD style quick coupler.
Used for lube pressure tests on crawler models
1650K and 1850K on 1st speed clutch, 2nd speed
380000515 380000516 CAS1884-2
CAS2336
clutch, 3rd speed clutch, forward clutch, and
reverse clutch.
380000514 Internal 9/16-18 JIC adapter with
external PD style quick coupler.
380000515 Tee Fitting, Internal 7/16-20 JIC with
Kit 380040085 is required to properly pressure test external PD style quick coupler.
the hydraulic circuits of selected Case Construction 380000516 Internal 1/8 NPTF adapter with
Equipment. The kit contains SAE and metric adapter external PD style quick coupler.
CAS1884-2 External M14 x 1.5 O-ring boss
fittings.
adapter with 90 elbow and external PD style quick
coupler.
380000510 Internal M16 x 2 adapter with 90
elbow and external PD style quick coupler.
CAS2336 Tee Fitting, Internal 1/4 BSPP x
external 1/4 BSPP adapter with external PD style
380000511 Internal M16 x 2 adapter with external quick coupler.
PD style quick coupler.
380000512 Pressure Test Adapter Hoses

380000512
The pressure hose is 6-1/2 feet in length, equipped

with internal PD style quick couplers at both ends,
and is rated at 6000 PSI. Two hoses are included.
Application: Motor Grader Model 845
Ordering Info: 38040085 Pressure Test Fitting Kit and Hose Assembly
Dealer Standard: Code A (required at all servicing locations)
ENG 6-45552
Service Tools
Required Service Tools for Selected Case Construction Equipment

Option 2 380040112
380040112 Digital Pressure Analyzer Kit
380040112
Option 2 offers the 380040112 Digital Pressure and

Temperature Analyzer kit. Purchasing this kit allows
the technician to easily read and analyze pressure
information up to 10,000 PSI during diagnostic
procedures, eliminating the need for analog gauges.
The 380040112 Digital Pressure and Temperature
Analyzer offers the following:
Displays readings in PSI and bar for checking

European specifications.
10,000 PSI capacity allows testing of hydrostatic
drive systems and other high pressure hydraulic
systems.
No need to have fuel or transmission hoses inside
the vehicle during road testing.
No makeshift taping of gauges to the windshield.
Pinpoints worn power steering pumps or racks.
"Min/Max" pinpoints fuel restrictions, plugged
filters, weak fuel pumps, and transmission
pressure spikes.
"Delta Zero" monitors fuel pressure drops caused
by faulty check valves.
20 foot pick up cable.
This kit also includes the following fittings from kit
380040085:
380000510
380000511
380000513
380000514
380000515
380000516
CAS1884-2
CAS2336
Application:Case Construction Equipment

Ordering Info: 380040112 Digital Pressure Tester and Fitting Kit
ENG 6-45552
Service Tools
Required Service Tools for Case Motor Graders

380050009 Transmission Tools
380000374
380000376
380000375
380000377
Lifting Device 380000374 - Used to lift the

transmission clutch stage assemblies during repair
procedures, Models 845 and 865.
Sta c k N e s t 3 8 0 0 0 0 3 7 5 - U s e d t o p o s i t i o n t h e
transmission clutch stage assemblies while removed
from the transmission housing, Models 845 and 865.
Lifting Device 380000376 - Used to lift the
transmission clutch stage assemblies during repair
procedures, Model 885.
380000381
380000382
Plug Installer 380000381 - Used to install plugs in

transmission shafts, Models 845, 865, and 885.
380000752
380000755
380000754
380000753
380000385
Sta c k N e s t 3 8 0 0 0 0 3 7 7 - U s e d t o p o s i t i o n t h e
transmission clutch stage assemblies while removed
from the transmission housing, Model 885.
380000386
Assembly Tools 380000382 - Used to handle

individual clutch stage assemblies and in clutch
assembly, Models 845, 865, and 885.
Installation Tools 380000385 - Used to install
transmission oil seals and retaining rings, Model 885.
Sizing Sleeve 380000386 - Used to size sealing ring
on 1st stage assembly, Model 885.
Input Seal Installer 380000389 - Used to protect input
shaft seal during installation, Model 885.
380000389
380000392
380000390
380000393
Bearing Installer 380000390 - Used to properly install

and position roller bearing on end of 4th stage
assembly, Models 845 and 865.
Assembly Tools 380000392 - Used to assemble and
align the idler shaft in the input housing, Models 845,
865, and 885.
Bearing Driver 380000393 - Used to properly install
and position bearings, Models 845 and 865.
380000748
Clutch Stack Clearance Gauge Set 380000395 Used to measure clutch plate clearance, Models 845,
865, and 885.
380000747
380000749
380000395
380000396
Aligning Sleeve 380000396 - Used to maintain

alignment of the input shaft during input housing
installation, Models 845 and 865.
Application:Case Motor Grader Models 845, 865, 885.

Ordering Information:380050009 Transmission Tools Kit
Dealer Standard: Code A (required at all servicing locations)
ENG 6-45552
SECTION INDEX
ENGINES
Section Title
Section Number
Engine and Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2001
FOR ENGINE REPAIR, SEE THE ENGINE SERVICE MANUAL

Contagem, MG Brazil
ENG 6-46502
June,2003
Section 2001
CHARGE AIR COOLER SYSTEM
845
P.I.N. HBZ020101 and After
865
885
CNH LATINO AMERICANA LTDA

Contagem, MG Brazil
6-73780
Printed in Brazil
June 2003
2001-2
TABLE OF CONTENTS
Specifications.................................................................................3
Charge Air Cooler Removal...........................................................3

Charge Air Cooler Installation.......................................................4

Contagem, MG Brazil
6-73780
Printed in Brazil
June 2003
2001- 3
CHARGE AIR COOLER SYSTEM

Specifications
MAKE/MODEL:
DENSO
TYPE:
Air to air; aluminum herringbone tube and fin; cast

aluminum tanks
CORE SIZE
27.6 High x 8.3 wide x 5.7 (700 x 211.2 x 144 )
CORE DESCRIPTION:
Rows: 2
Tube spacing: 10 per row
Fin spacing: 13 fins per inch

Contagem, MG Brazil
6-73780
Printed in Brazil
June 2003
2001- 4
Charge Air Cooler

Removal of the air cooler to turbocharger
outlet piping
1 - Remove clamps (A)
2 - Remove hose (B)
3 - Remove bolt (C) and remove clamp (D)
4 - Remove clamps (F) then remove tube (E) and hose

(G).

Contagem, MG Brazil
6-73780
Printed in Brazil
June 2003
2001- 5
Charge Air Cooler

Air inlet to cooler pipe removal
1 - Remove clamps (1)
2 - Remove hose (2)
3 - Remove clamps (3)

4 - Remove hose (4)
5 - Remove tube (5)
6 - Remove bolts (6)

7 - Remove tube (7)
8 - Remove gasket (8)

Contagem, MG Brazil
6-73780
Printed in Brazil
June 2003
2001- 6
Charge Air Cooler

Air cooler removal
1 - Remove top bolts (9)
2 - Remove bottom bolts (10)
Air cooler assembly.

1 - Place air cooler in the correct position.
2 - Fit top bolts (9) and torque to 2,8 kfg.
3 - Fit bottom bolts (10) and torque to 2,8 kfg.

Contagem, MG Brazil
6-73780
Printed in Brazil
June 2003
2001- 7
Charge Air Cooler

Assembly of air cooler outlet to turbocharger
pipe
1 - Fit hose (B) to the cooler outlet opening. Then fit
clamps (A) in place and fit tube (E) to hose (B).
Adjust clamps until the clamp springs are fully
compressed.
2 - Fit hose (A) to tube (E). Then fit hoses (F) in place
and fit hose (G) to the turbocharger inlet tube.
Ajust clamps until the clamp springs are fully
compressed.
Cooler air inlet pipe assembly.

1 - Fit hose (2) to the cooler inlet opening. Then fit
clamps (1) in place and fit tube (5).
compressed.
2 - Fit hose (4) to tube (5). Then fit clamps (3) in place
and fit tube (7).
compressed.

Contagem, MG Brazil
6-73780
Printed in Brazil
June 2003
2001- 8
3 - Fit gasket (4) between tube (7) and engine cover.

Then fit bolts (6) in place and torque to 2,8 kgf.
4 - Fit clamp (d) in place and torque bolts (C) to 2,8 kgf.

Contagem, MG Brazil
6-73780
Printed in Brazil
June 2003
2002
Section
2002
ELECTRONIC ENGINE
LOGIC AND ERROR CODES
865 DHP Grader
CNH Latin America Ltda

Av. General David Sarnoff, 2237
Printed in Brazil
Jan, 2005
2002-2
2002-3
865DHP GRADER
ELECTRONIC ENGINE - LOGIC
Engine Protection System
The engine protection system monitors temperatures and pressures and registers diagnostic
failures whenever a abnormal operation condition occurs.
In this case, the engine power starts to decrease and the operator is warned by the stop
indicator or warning indicator.
When this condition happens, the operator must stop and park the machine in order to prevent
damage to the engine.
Stop by protection
The engines stops automatically when one of the temperature, level or pressure sensors
detect that the engine is operating in a below or above the normal operation conditions.
The stop indicator will flash for 30 seconds to warn the operator.
Inlet air heating

The engine admission inlet air is heated when the engine is started in cold wheather conditions,
resulting in better starting and reduction of white smoke.
The indicator light at the instrument panel indicate when starting of the engine is possible.
The ECM (Engine Control Module) determines the heating total time based on the inlet manifold
temperature (pre-heating).
Once the engine is started, the air heater will be on until the inlet air temperature and cooling
fluid temperature reach the required values.
The heater is switched off whenever one of the following situations occur:
- Heating time exceeds 11 seconds;
- The inlet manifold temperature is greater than 19C.
Water in fuel detector sensor

When there is water in the filter housing, the indicator light will flash, indicating that the water
should be drained.
Troubleshooting codes
Operation failures are identified by failure codes, that are registred and shown by the control
system.
These failure codes are shown using the indication lights at the maintenance panel.
NOTE: The failure codes do not cover all failures that an engine may have. There are 2
kinds of failure codes: The failures codes from the electronic fuel system and the engine
protection failure codes.
2002-4
Maintenance panel
The maintenance panel indicates the operator when a maintenance operation is necessary
(like engine oil change interval).
NOTE: Probelms with the VSS (Vehicle Speed Sensor) or with the batteries may influence
the data shown by the maintenance panel.
Indication lights
[A] - Warning light: (yellow) Indicates a problem that may be verified by the operator. Does
not require imediate stop of the machine.
[B] - Stop light: (red) Indicates a serious problem with the engine. Requires imediate stop of
the machine.
[C] - Maintenance light: Indicates that an engine maintenance operation must be performed.
The system monitors the distance and time that the machine has been used.
[D] - Start light: The operator must wait until this light turns off to start the machine.
[E] - Water in fuel light: This light indicates that water must be drained from the fuel filter.
[F] - Low pressure light: This light indicates that the pressure of the diesel is low. Water must
be drained from the fuel filter.
2002-5
Work/Diagnosis switch
Work position
Security lock
Diagnosis position
Increase/Decrease switch
Increase speed /
next code
Decrease speed /
previous code
[G] - Work/Diagnosis switch: The work position is used when the engine is running OK, without
any problems. The diagnosis position is used to read the error codes when a problem
with the engine occurs.
[H] - Increase/Decrease switch: This switch has 2 functions, depending on the position of
the work/diagnosis switch.
When the work/diagnosis switch is on the work position, this switch is used to increase
or decrease the engine speed by 20 rpm.
When the work/diagnosis switch is on the diagnosis position, this switch is used to read
the next error code that is registred by the system.
2002-6
Indicator lights illumination logic and error codes

When the master key of the machine is ON, and the ignition switch is either on position OFF
or ACC, no indicator light must flash, and the buzzer mut not emit any sound, regardless of
the position ot the work/diagnosis switch.
When the master key of the machine is ON, and the ignition switch is on position IGN, the
indication lights A, B, C, D and E will lit, the buzzer will sound (2 to 4 times) and then the
checup procedure will start. Each of the indication lights will go out with a sound from the
buzzer, beggining with light A, the B, C, D , E. Light F is kept lit and the buzzer continues to
sound. (the work/diagnosis switch must be on the work position)
When the master key of the machine is ON, and the ignition switch is on position ST (start),
the chekup procedure is finished and all lights are off. The engine will be ready to start. (the
work/diagnosis switch must be on the work position)
NOTE: If the indication lights A or B goes on (lit), the engine must be shut off immediately.
These lights indicate a problem with the engine and the error codes must be verified.
Error codes interpretation
Turn off the ignition switch and turn on again, without starting the engine.
Unlock the security lock and place the Work/Diagnosis switch on position Diagnosis (down).
The indication lights A and B start to indicate the error codes through a flashing pattern as
described below. When there are more than one error code, the codes can be read using the
Increase/Decrease switch.
Seriousness
Error code example:

Yellow indication: Not serious error
1 flash
Pause
1st Digit
1st digit reading:
(3 flashes)
3 flashes
2002-7
Pause
2nd Digit
2nd digit reading:
(6 flashes)
3rd digit reading:

(3 flashes)
6 flashes
Pause
3rd Digit
3 flashes
Repeat seriousness
When the seriusness light flashes again,

the indication of the error code is
finished.
For this example, the error code is 363.
1 flash
2002-8
Code /
Lamp
Reason
Effect (when fault code is active)
115
yellow
No engine speed or position signal detectedt at pin

number 17 of the engine harness
122
Yellow
Higth voltage detected at boost pressure sensor signal pin Engine will derate to no-boost fueling
123
Yellow
Low voltage detected at boost pressure sensor signal pin

131
Yellow
High voltage detected a throttle position signal pin number Engine idles validation switch indicates idlea and ramps up
to a default set speed when the idle validation switch
30 of the OEM harness
indicates off-idle
132
Yellow
En
Low voltage detected at throttle position signal pin number ramgpinse uidpletos awhdeenfaiudlltesveat lsidpaeteiodn wshweitnchidilnedvicaalitdeastiiodnlesawnitdch
indicates off-idle
135
Yellow
High voltage detected at oil presure signal pin number 33

of the engine harness
141
Yellow
Low voltage detected at oil pressure signal pin number 33 Default value used for oil pressure no engine protection for
oil pressure
143
Yellow
Oil pressure signal indicates oil pressure below the low

minimum engine protection limit
Power derate and possible engine shutdown if engine

protection shutdown feature enabled
144
Yellow
High voltage detected at coolant temperature signal pin

Default value used coolant temperature. No engine

protection for coolant temperature.
145
Yellow
Low voltage detected at coolant temperature signal pin

Default value used for coolant temperature. No engine

protection for coolant
146
Yellow
Coolant Temperatue signal indicates

coolant temperature has exceeded the minimum engine
protection limit

protection shutdown feature is enabled
147
Yellow
A frequency below a calibrated value has been detectedat

Engine will not respond to changes in frequency trhottle.
the frequency thrttle signal pin number 4 of the engine
Engine will go to low idle
harness
148
Yellow
A frequency a bove a calibrated value has been detected

ah the frequency value
Engine will not responde to chenges in frequency thtotle.

Engine will go to idle
151
Red
Coolant temperature signal indicates coolant temperature

has exceed the maximum engine protection limit
Speed derate and possible engine shutdown if engine

protection shutdown feature is enabled
153
Yellow
High voltage detected at intake manifold temperature

signal pin number 34 of the engine harness
Default value used for intake manifold temperature .No

engine protection for intake manifold temperature.
154
Yellow
Low voltage detected at intake manifold temperature

signal pin number 34 at the engine harness
Default value used for intake manifold temperatute .

No engine protection for intake manifold temperature
155
Yellow
Intake manifold temperature signal indicates intake

manifold temperature is above the maximum engine
protection limit

protection shutdown feature
184
Yellow
Error detected in multi Unit

Syncronization
Engines will default to idle speed
234
Red
Engine speed signal indicates engine speed has

exceeded the overspeed limit.
Fuel to injectors disabled until engine speed falls below the

overs
235
Red
Coolant level signal at pin number 37 of the engine

harness indicates coolant level is low

shutdown feature is enabled
241
yellow
Vehicle speed signal on pin numbers 8 and 18 of the

OEM harness has been lost
Engine spped limited to max Engine speed without VSS

Cruise control, gear down protection and the road speed
governor will not work . Trip information data that is based
on milsage wiil be oincorrect.
Engine power derate. Possible white smoke
Engine will derate to no-boost fueling
Default value used for oil pressure. No engine protection for

oil pressure
2002-9
242
Yellow
Engine speed limited to MAX . Engine spped without VSS.

Invalid or inapropriate vehicle spped signal indicated on
Cruise control, gear -down protectionand the road speed
pins number 8 and 18 of the OEM harness indicating an
governor will not work. Trip information data that is based
intermitent connection or possible tampering
on mileage will be incorrect
261
Yellow
VP44 Fuel pump Control Module indicates the fuel

temperatute has exceeded the pump protection limit
Power derate
264
Yellow
High or low voltage detected at the fuel temperature

sensor signal circuit inside the VP44 pump controller
Default value used for fuel temperature . Possible low

power
278
Yellow
Error detected in lift pump circuit at pin number 11 of the

engine harness
Possible low power, engine may die, run rougth or be

difficult to start
283
Yellow
Higth voltage detected at main engine speed / position ECM will use VP44 fuel pump speed or the engine position
sensor voltage supply pin number 8 of the engine harness signal as a backup. Possible white smoke and power loss
284
Yellow
ECM will use the VP44 fuel pump speed or the engine
Low voltage detected at main engine speed/position
sensor voltage supply pin number 8 of the engine harness position signal as a back up. Possible white smoke a
and power loss.
319
Maint
Power to the real time clock has been interrupted and its
setting is no longer valid.
349
Yellow
The auxiliary speed frequency on pin number 8 and 18 of Engine will go to idle and lose ability to control the speed
of the ayxiliary device
the OEM harness is above a calibrated threshold.
361
Red
High current detected at the VP44 fuel pump control valve Fduoewlnling to the injectors is disabled and engine is shut
362
Yellow
Low or no voltage detected at the VP44 fuel pump control Engine will lose power and may shut down
valve
363
Yellow
No fuel control valve moviment detected by the VP44 fuel

pump controller
364
Yellow
No communications or invalid data transfer rate detected

on data link between ECM and VP44 fuel pump controller Engine will run at a backup mode set speed when throttle
is off-idle
at pins 4 and 13 of the engine harness
365
yellow
Low voltage detect at the VP44 fuel pump controller

supply voltage circuit
366
yellow
VP44 fuel pump conbtroller battery voltag e measurement Engine will lose power and may shut down
is outside the range between 6 and 24 volts
367
Yellow
VP44 fuel pump spedd/ possition sensor signal lost.
Fueling to the injectors is disabled and engine will

shutdown
368
Yellow
The VP44 fuel pump controller cannot achleve the timing

value being commanded by the engine ECM
Significant engine power loss.
369
Yellow
VP44 fuel pump controller does not detect engine position Significant engine power loss. Possible white smoke
pulse at pin 7 of engine harness
372
Yellow
VP44 fuel pump controller detecs continous voltage at idle If communication is lost between the ECM and the VP44
select pin 16 of the engine harnness...OR... fuel pump
fuel pump controller, engine will only operate at a speed
controller detects an open circuit or short circuit to ground
slightly higher than idle, regardness of throtle position
at idle select pin 16 of the engine harness
373
Red
Higth voltage detect at the VP 44 fuel shut off signal pin 6 Fuelling to injectors is disabled and engine will shut down
374
Yellow
VP44 fuel pump controller has detects an internal eroor
Response wll vary from some power loss to the engine

shutting down
375
Yellow
Engine ECM is comma nding a fuelling or timming value

that the VP44 fuel pump cannot achieve
Possible no effect or engine may exhibit some power loss
376
Red
No calibration in the VP44 fuel pump
Fuelling to the injectors is disabled and engine will shut

down
377
Yellow
VP44 fuel pump controller is not powering down when key Equipment batteries may be drained low during long shut
switch power is remover from the engine control module
down periods
Time stamp in ECM powerdown data will be incorrected
Engine power loss
Engine may lose power and may shut down
2002-10
381
Yellow
Error detected in cold start aid relay 2 enable circuit at

pin number 31 of the OEM harness
Intake air cannot be fully energized by the ECM. Possible

white smoke and/or hard starting
382
Yellow
Error detected in cold start aird relay 2 enable circuit at

Intake air heater cannot be fully energized by the ECM

Possible white smoke and/ or hard starting
387
Yellow
High voltage detected at throttle position sensor +5 VDC

supply pin number 29 of the OEM harness
Engine idles when idle validation switch indicates idle and

ramps up to default set speed when idle validation switch
indicates off idle
391
yellow
Error detected in VP44 power suplly relay enable circuit

at pin 43 of engine harness
Possible no effects on performance or engine may not run
415
Yellow
Oil pressure signal indicates oil pressure below the very

low engine protection limit.

protection shutdown feature enable
418
Yellow
Water in fuel signal indicates the water in the fuel filter

needs to be drained
Excessive water in the fuel can lead to severate fuel

system damage
422
yellow
Voltage detected simultaneously on both the coolant level

high and low signal pin numbers 27 and 37 of the engine No engine protection for coolant level
harness....OR....no voltage detected on either pin(F ault is
active for switch type coolant level sensors only)
429
Yellow
Low voltage delected at water -in-fuel signal pin number

431
Idle validation signals on pin number 25 and 26 of the

OEM harness indicate voltage detected simultaneously on No effect on performance, but loss of idle validation
both pins (Open Circuit)
432
Yellow
Idle validation signla at pin 26 of the OEM harness

indicates the throttle is at the idle position when the
throttle position signal at pin 30 of the OEM harness
indicates the throttle is not at the idle validation signal at
pin number 26 of the OEM harness indicates the throtlle
position signal at pin number 30 of the OEM harness
indicates the throtlle is at the idle position.
Engine will only idle
433
Yellow
Boost presure signal indicates boost pressure is high

when other engine parameters (i.e. speed and load)
indicate boost pressure should
Possible overfuelling during acceleration. Increase in black

smoke
434
Yellow
Supply voltage to the ECM fell bellow 6.0 volts for a

fracttion of a second ....OR....the ECM was not allowed to
power down correctly ( retain battery voltagde for 30
seconds after key OFF)
Possible no noticeable performance effects....or....engine

dying or hard starting.Fault information, trip information,
maintenance monitor data,trending data, and user activated
datalogger data may be inaccurate.
441
Yellow
Voltage detected at ECM power supply pin numbers

38,39 and 40 of the engine harness indicates ECM supply Engine will die or run rough
voltage is above the maximum system voltage level
442
Yellow
Voltage deleted at ECM power supply pin numbers 38,39

and 40 of the engine harness indicates ECM supply
voltage is above the maximum system voltage level.
none on perforamnce
443
Yellow
Low voltage detected at throttle position sensor +5 VDC

supply pin number 29 of the OEM harness
Engine idles when idle validation switch indicates idle

ramps up to a default set speed when idle validation switch
indicates off-idle
488
Yellow
Intake manifold temperature signal indicates intake

manifold temperature is above the minimum engine
protection threshold

protection shutdown feature is inabled.
489
Yellow
The auxiliary speed signal frequency on pin number 8 and

18 of the OEM harness indicates the frequency is bellow a Engine will go to idle and lose ability to control the speed
of the auxiliary device
calibrated threshold value.
515
Yellow
High voltagedetected at the coolant level +5VDC Sensor

supply voltage pin number 49 of the engine harness
No engine protection for coolant level
516
Yellow
Low voltage detected at the coolant level + 5VDC sensor

suply voltage pin number 49 of the engine harness
No engine protection for coolant level
No water -in-fuel detection
2002-11
517
Yellow
A mechanically stuck fuel control valve has been detected

Engine may be shutdown
by the vp 44 fuel pump controller
528
Yellow
Error detected on the Torque curve selection switch input

Operator cannot select alternate torque curves

Normal torque curve is used
551
Yellow
Idle validation signals on pin number 25 and 26 of the

OEM harness indicate no voltage detected on either pin
Engine will only idle
599
Red
611
The dual output feature is a customer specialized

calibration and it has initiated an engine shutdown based
on the customers specified operating conditions, engine
engine will shutdown
sensor value and or OEM inputs value and or oem inputs
to the ECM
ECM detected the engine has initiated a protection
shutdown or has been keyed -off while above a specified No effect
load limit
2002-12
SECTION INDEX
ELECTRICAL
Section Title
Section Number
Removal and Installation and Alternator. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001

Electrical Diagram . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4002
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003
Alternator - 45 Ampere . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4008

2237,General David Sarnoff Avenue
Contagem, MG Brazil
ENG 6-46600
Printed in Brazil
May, 2003
4001
Section
4001
REMOVAL AND INSTALLATION OF STARTER AND
ALTERNATOR
CNH Latino Americana Ltda.

2237, General David Sarnoff
ENG 6-42320
Printed in Brazil
May,2003
TABLE OF CONTENTS
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALTERNATOR 45 A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01
01
01
02
02
02
ALTERNATOR 70 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04
ALTERNATOR 45 A .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07
ALTERNATOR 70 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
ENG 6-42320
Issued 1-03
Printed in Brazil
4001-01
STARTER
Installation
Removal
NOTE: The starter is located on the left side of the
engine, mounted to the engine flywheel housing.
1. Turn the master disconnect switch to the OFF
position.
1. Install the starter (1),and bolts (2) to

the machine. Torque the bolt (2) to 41 to 74 Nm
(30 to 54 pound-feet).
2. Install the positive cables.
2. Remove the air cleaner and the air cleaner

bracket.
3. Move the cover to gain access to the bolt (2).
Refer to the illustration below.
1. STARTER
2. BOLT
STARTER REMOVAL AND INSTALLATION
ENG 6-42320
Issued 1-03
Printed in Brazil
4001-04
ALTERNATOR 45A
Removal
position.
2. Use a wrench to move the belt tensioner (15) and
loosen the tension on the belt (17). Refer to the
illustration on the following page.
3. Remove the belt (17).
4. Remove the boots (4 and 5).
Tag and disconnect wires (12 and 13) from
from the alternator (6).
5. Remove the bolt (8),and washer (9)
from the support bracket (7) and the alternator
(6).
6. Remove the alternator (6) and shield (3) from the.
machine.
.
.
Installation
1. Install the alternator (4),on the machine.
Torque the bolt
(0) to 60 to 104 Nm (42.5 to 76 pound-feet).
Refer to the illustration on the following page.
2. Install the washer (9), and bolt (8).
Torque the bolt (8) to 60 to 104 Nm (42.5 to 76
pound-feet).
3. Use a wrench to move the belt tensioner (2) until
the belt (1) can be installed.
4. Install the belt (17).
5. Install the wire (12), lockwasher and nut to
the alternators D+ terminal. Torque the nut to
3.5 to 3.9 Nm (2.6 to 2.9 pound-feet).
6. Install the boot.
7. Install the wire (13), lockwasher and nut
to the alternators B+ terminal. Torque the nut
to 15 to 27 Nm (11 to 20 pound-feet).
9. Turn the master disconnect switch to the ON
position.
ENG 6-42320
Issued 1-03
Printed in BRAZIL
4001-03
1.
2.
3.
4.
5.
6.
7.
BOLT
BOLT
SUPPORT
BOLT
ARM
BOLT
BOLT
8. ALTERNADOR 45 A
9. PULLEY
10. BELT
ALTERNATOR 45 A TO MODEL 845 ENGINE CUMMINS SERIES B REMOVAL AND INSTALLATION ILLUSTRATION
ENG 6-42320
Issued 1-03
Printed inBrazil
4001-04
ALTERNATOR 70A
Removal
position.
2. Use a wrench to move the belt tensioner (15) and
loosen the tension on the belt (17). Refer to the
illustration on the following page.
3. Remove the belt (17).
4. Remove the boots (4 and 5).
Tag and disconnect wires (12 and 13) from
from the alternator (6).
5. Remove the bolt (8),and washer (9)
from the support bracket (7) and the alternator
(6).
6. Remove the alternator (6) and shield (3) from the.
machine.
.
.
Installation
1. Install the alternator (4),on the machine.
Torque the bolt
(0) to 60 to 104 Nm (42.5 to 76 pound-feet).
Refer to the illustration on the following page.
2. Install the washer (9), and bolt (8).
Torque the bolt (8) to 60 to 104 Nm (42.5 to 76
pound-feet).
3. Use a wrench to move the belt tensioner (2) until
the belt (1) can be installed.
4. Install the belt (17).
5. Install the wire (12), lockwasher and nut to
the alternators D+ terminal. Torque the nut to
3.5 to 3.9 Nm (2.6 to 2.9 pound-feet).
7. Install the wire (13), lockwasher and nut
to the alternators B+ terminal. Torque the nut
to 15 to 27 Nm (11 to 20 pound-feet).
9. Turn the master disconnect switch to the ON
position.
ENG 6-42320
Issued 1-03
Printed in BRAZIL
4001-05
1.
2.
3.
4.
5.
6.
7.
BOLT
BRACKET
BOLT
BOLT
BELT
PULLEY
WASHER
8. ALTERNATOR 70 A
9. BRACKET
10. BOLT
11. BOLT
12. and 13. WIRES
ALTERNATOR 70 A TO MODELS 845 ENGINE CUMMINS SERIES B REMOVAL AND INSTALLATION ILLUSTRATION
ENG 6-42320
Issued 1-03
Printed inBrazil
4002
Section
4002
ELECTRICAL DIAGRAM
845 - 865 - 885 Grader

ENG 6-46621
Printed in Brazil
May,2003
DESCRIPTIN ............................................................................................... COORDINATE

BATTERY 12V ................................................................................................................................... 01-01
BATTERY 12V ................................................................................................................................... 01-01
ALTERNATOR 24 VOLTS 70 AMP ...................................................................................................... 01-02
ELECTRONIC INSTRUMENT CLUSTER .................................................................................................. 06
ELECTRONIC MONITOR ....................................................................................................................... 07
ANALOG HOURMETER ......................................................................................................................... 08
DIAGNOSIS / GEAR DISPLAY ........................................................................................................... 18-01
MASTER BATTERY SWITCH ............................................................................................................. 01-01
IGNITION SWITCH ........................................................................................................................... 02-01
SWITCH - WORK LAMPS ................................................................................................................. 02-04
SWITCH - HORN, TURN LIGHTS ....................................................................................................... 03-03
SWITCH ........................................................................................................................................... 03-05
SWITCH - REAR WORK LAMPS ....................................................................................................... 04-05
SWITCH - CAB LIGHTS ................................................................................................................... 05-01
SWITCH - FRONT BLADE ................................................................................................................. 05-03
SWITCH - BRAKE LIGHTS ................................................................................................................ 05-04
SWITCH AND SENSOR - ENGINE OIL PRESSURE
06-02
SWITCH - ENGINE COOLANT TEMPERATURE .................................................................................. 06-03
SENSOR - TRANSMISSION OIL PRESSURE ..................................................................................... 06-04
SENSOR - TRANSMISSION OIL TEMPERATURE
06-05
SENSOR - FUEL LEVEL .................................................................................................................... 06-05
SWITCH - ENGINE COOLANT TEMPERATURE .................................................................................. 07-01
SWITCH 07-01
ISWITCH - TRANSMISSION OIL FILTER RESTRICTION
07-02
SWITCH - TRANSMISSION OIL PRESSURE ...................................................................................... 07-02
SWITCH - TRANSMISSION OIL TEMPERATURE
07-03
SWITCH - HYDRAULIC OIL TEMPERATURE ..................................................................................... 07-04
SWITCH - BRAKE PRESSURE .......................................................................................................... 07-04
SENSOR - MACHINE SPEED CONTROL ........................................................................................... 07-05
SWITCH - HYDRAULIC OIL FILTER RESTRICTION
07-06
SWITCH - OPTION, DIFFERENTIAL LOCK ......................................................................................... 08-02
SWITCH - OPTION, COLD START ..................................................................................................... 08-02
SWITCH - SADDLE LOCK PIN........................................................................................................... 08-06
SWITCH - OPTION, FOR RIPPER OR SCARIFIER
09-03
SWITCH - OPTION, BLADE LH FLOTATION ...................................................................................... 10-03
SWITCH - OPTION, BLADE RH FLOTATION ...................................................................................... 10-04
SWITCH - OPTION ........................................................................................................................... 11-03
SWITCH - FRONT BLADE FLOTATION .............................................................................................. 12-02
LEFT HAND CAB ROOF LAMP ......................................................................................................... 12-03
RIGHT HAND CAB ROOF LAMP ....................................................................................................... 12-03
RIGHT HAND ROTARY CAB BEACON .............................................................................................. 12-04
SWITCH - OPTION, ROTARY BEACON ............................................................................................. 12-04
SWITCH - FRONT WINDSCREEN WIPER .......................................................................................... 13-02
SWITCH - FRONT WINDSCREEN WIPER PUMP
13-04
SWITCH - REAR WIPER ................................................................................................................... 13-02
SWITCH - FRONT WINDSCREEN WASHER PUMP
13-04
SWITCH - REAR WIPER ................................................................................................................... 13-05
SWITCH - REAR WASHER PUMP ..................................................................................................... 14-01
SWITCH - FRONT WINDSCREEN WASHER, LOWER
14-03
Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees
91
LIST OF INSTRUMENTS
DESCRIPTION ............................................................................................... COORDINATE

SWITCH - FAN, OPTION ...................................................................................................................
SWITCH - AIR CONDITIONING SYSTEM, HIGH PRESSURE ..............................................................
SWITCH - 3-SPEED, AIR CONDITIONING SYSTEM ...........................................................................
SWITCH - OPTION, THE AIR CONDITIONER ....................................................................................
SWITCH - 6 TH DRIVE WHEEL ............................................................................................................
SWITCH - TRACTION CONTROL ......................................................................................................
GEAR SELECTOR .............................................................................................................................
SWITCH - PARKING BRAKE .............................................................................................................
SWITCH - COME HOME FEATURE ...................................................................................................
SENSOR - MAGNETIC, SPEED CONTROL ........................................................................................
SENSOR - MAGNETIC, CYLINDER SPEED CONTROL .......................................................................
SENSOR - FUNK TRANSMISSION OIL PRESSURE ............................................................................
14-06
15-03
15-03
15-05
17-03
17-05
18-03
18-07
18-10
18-11
18-11
18-12
PROTECTION FUSE (MAXI) 80 AMP FOR PROTECTION OF ALTERNATOR .......................................

PROTECTION FUSE (MAXI) 80 AMP FOR PROTECTION OF MACHINE GENERAL SYSTEM
FUSE - AUX., 7,5 AMP FOR MARKER LIGHTS AND INSTRUMENT CLUSTER LIGHTS. .....................
FUSE - AUX., 5,0 AMP FOR LEFT FRONT AND RIGHT REAR MARKER LIGHTS ................................
01-02
01-03
03-02
03-03
ENGINE FUEL SHUT OFF SOLENOID VALVE .....................................................................................

DIFFERENTIAL LOCK SOLENOID VALVE (OPTIONAL) .......................................................................
STARTER MOTOR SOLENOID VALVE ...............................................................................................
SADDLE LOCK SOLENOID VALVE ....................................................................................................
LH SOLENOID VALVE OPT FOR RIPPER OR SCARIFIER ..................................................................
01-06
08-02
08-04
08-06
09-02
09-03
09-04
09-05
09-06
LH SOLENOID VALVE FOR BLADE FLOTATION ................................................................................

LH SOLENOID VALVE FOR BLADE FLOTATION ................................................................................
RH SOLENOID VALVE FOR BLADE FLOTATION ................................................................................
RH SOLENOID VALVE FOR BLADE FLOTATION ................................................................................
CYLINDER ANTI-SHOCK VALVE ........................................................................................................
FRONT BLADE FLOTATION SOLENOID VALVE..................................................................................
FRONT BLADE FLOTATION SOLENOID VALVE..................................................................................
SOLENOID VALVE FOR DUAL POWER OPTION ...............................................................................
ON / OFF SOLENOID 6 th DRIVE WHEEL ...........................................................................................
HIGH HYDRAULIC VOLUME SOLENOID 6 th DRIVE WHEEL...............................................................
HYDRAULIC REVERSION SOLENOID 6 th DRIVE WHEEL ...................................................................
HYDRAULIC FORWARD DRIVE SOLENOID 6 th DRIVE WHEEL ..........................................................
DIRECTIONAL AND PROPORTIONAL SOLENOID VALVE1 ................................................................
SPEED AND PROPORTIONAL SOLENOID VALVE3............................................................................
10-01
10-03
10-04
10-06
11-01
11-02
11-03
11-04
11-05
11-06
12-02
12-02
16-02
17-08
17-09
17-09
17-09
18-09
18-08
18-09
18-09
18-10
18-10
18-11
92
LIST OF INSTRUMENTS
VARISTOR FOR ................................................................................................................................

VARISTOR FOR DIFFERENTIAL LOCK VALVE ..................................................................................
VARISTOR FOR COLD START SOLENOID VALVE, OPTION ...............................................................
VARISTOR FOR SOLENOID VALVE FOR SADDLE LOCK PIN .............................................................
VARISTOR FOR SOLENOID VALVE FOR RIPPER OR SCARIFIER OPTION ........................................
VARISTOR FOR LH SOLENOID VALVE RIPPER OR SCARIFIER ........................................................
VARISTOR FOR LH SOLENOID VALVE RIPPER OR SCARIFIER ........................................................
VARISTOR FOR RH SOLENOID VALVE RIPPER OR SCARIFIER ........................................................
VARISTOR FOR RH SOLENOID VALVE FOR BLADE FLOTATION .......................................................
VARISTOR FOR SOLENOID VALVE A ................................................................................................
VARISTOR FOR SOLENOID VALVE FOR FRONT BLADE ..................................................................
VARISTOR FOR ................................................................................................................................
VARISTOR FOR ................................................................................................................................
VARISTOR FOR ................................................................................................................................
VARISTOR FOR ................................................................................................................................
VARISTOR FOR ................................................................................................................................
VARISTOR FOR ................................................................................................................................
03-06
08-02
08-03
08-05
09-01
09-02
09-03
09-04
09-05
10-01
10-02
10-03
10-04
10-05
11-01
11-02
11-03
11-04
11-05
11-06
12-01
12-02
15-01
16-02
17-07
17-09
17-10
17-11
93
LIST OF INSTRUMENTS

DIODE FOR ...................................................................................................................................... 01-03
DIODE FOR ...................................................................................................................................... 01-05
DIODE FOR ...................................................................................................................................... 01-06
DIODE FOR ...................................................................................................................................... 06-06
DIODE FOR NEUTRAL START POSITION .......................................................................................... 18-06
DIODE FOR PARKING BRAKE ENGAGED ......................................................................................... 18-07
DIODE BOX - SIDE CONSOLE ............................................................................................................... 16
HORN ..............................................................................................................................................
AUDIBLE ALARM .............................................................................................................................
REVERSING ALARM - OPTION .........................................................................................................
REVERSING ALARM - OPTION STRADALE ......................................................................................
03-01
07-05
05-05
05-06
RIGHT HAND WORK LAMP AFTER THE BLADE ...............................................................................

LFEFT HAND WORK LAMP AFTER THE BLADE ................................................................................
RIGHT HAND WORK LAMP BEFORE THE BLADE ............................................................................
LFEFT HAND WORK LAMP BEFORE OF THE BLADE .......................................................................
02-05
02-05
02-06
02-06
LEFT HAND LAMP ............................................................................................................................

RIGHT HAND LAMP .........................................................................................................................
RIGHT HAND LAMP .........................................................................................................................
RIGHT HAND LAMP .........................................................................................................................
RIGHT HAND LAMP .........................................................................................................................
RIGHT HAND LAMP .........................................................................................................................
02-02
02-02
02-03
03-03
03-03
03-03
RIGHT HAND LAMP .........................................................................................................................

LEFT HAND LAMP ............................................................................................................................
LEFT HAND LAMP ............................................................................................................................
LEFT HAND LAMP ............................................................................................................................
LEFT HAND LAMP ............................................................................................................................
03-04
03-04
03-04
03-05
03-05
LEFT HAND LAMP (HIGH BEAM) ......................................................................................................

LEFT HAND LAMP (HIGH BEAM) ......................................................................................................
LEFT HAND LAMP (LOW BEAM) ......................................................................................................
LEFT HAND LAMP (LOW BEAM) ......................................................................................................
RIGHT HAND LAMP .........................................................................................................................
RIGHT HAND LAMP .........................................................................................................................
LICENSE PLATE LAMP .....................................................................................................................
LEFT HAND LAMP ............................................................................................................................
REAR MARKER LIGHT, OPTION, STRADALE ....................................................................................
LICENCE PLATE LAMP, OPTION, STRADALE ...................................................................................
LEFT HAND REAR CAB WORK LAMP ..............................................................................................
RIGHT HAND REAR CAB WORK LAMP ............................................................................................
LEFT HAND CAB LAMP ....................................................................................................................
RIGHT HAND CAB LAMP .................................................................................................................
LEFT HAND LAMP - FRONT BLADE ..................................................................................................
RIGHT HAND LAMP - FRONT BLADE ...............................................................................................
LEFT HAND BRAKE LIGHT ...............................................................................................................
RIGH HAND BRAKE LIGHT ...............................................................................................................
LEFT HAND BRAKE LIGHT, OPTION, STRADALE ..............................................................................
RIGH HAND BRAKE LIGHT, OPTION, STRADALE .............................................................................
PANEL LIGHT - SIDE CONSOLE ........................................................................................................
PANEL LIGHT - SIDE CONSOLE ........................................................................................................
04-01
04-02
04-02
04-02
04-03
04-04
04-04
04-04
04-05
04-05
04-06
04-06
05-01
05-01
05-02
05-02
05-04
05-04
05-04
05-04
06-01
06-02
94
LIST OF INSTRUMENTS
LEFT HAND ROTARY BEACON, REAR .............................................................................................. 12-04

RIGHT HAND ROTARY BEACON, FRONT ......................................................................................... 12-04
RESISTOR 910 OHMS 1/2 WATT ...................................................................................................... 06-04
RESISTOR 5 OHMS 100 WATTTS FOR ALTERNATOR ....................................................................... 06-06
CIGARETTE LIGHTER 12 VOLTS ....................................................................................................... 19-02
STARTER MOTOR ............................................................................................................................
WIPER, FRONT ................................................................................................................................
WATER PUMP, FRONT .....................................................................................................................
WIPER, REAR ..................................................................................................................................
WATER PUMP, REAR .......................................................................................................................
WATER PUMP OPTION, LOWER FRONT SCREEN ............................................................................
WIPER, LOWER FRONT ...................................................................................................................
AIR SUSPENSION SEAT ...................................................................................................................
FAN - LH, OPEN CAB ONLY ..............................................................................................................
FAN - RH - OPEN CAB ONLY ............................................................................................................
MOTOR - AIR CONDITIONING ..........................................................................................................
EVAPORATOR - AIR CONDITIONING ................................................................................................
COMPRESSOR - AIR CONDITIONER - OPTION ................................................................................
01-03
13-02
13-04
13-05
14-01
14-02
14-04
14-05
14-06
14-06
15-05
15-03
15-02
ELECTRONIC UNIT - FUNK TRANSMISSION .......................................................................................... 18

CLUTCH PEDAL - FUNK TRANSMISSION ......................................................................................... 18-02
VOLTAGE PROTECTION ................................................................................................................... 18-01
SWITCH - MAGNETIC AUX. FOR STARTER MOTOR ......................................................................... 01-04
SWITCH - MAGNETIC AUX. FOR ENGINE STOP FUEL SHUT-OFF ..................................................... 01-04
ELECTRONIC UNIT 6 TH DRIVE WHEEL ............................................................................................. 17-05
RELAY .............................................................................................................................................. 03-06
ROTARY BEACON - ELECTRONIC, OPTION ..................................................................................... 12-05
VOLTAGE CONVERTER FOR RADIO AND CIGARETTE LIGHTER .......................................................
RADIO .............................................................................................................................................
SOUND BOX - LH .............................................................................................................................
SOUND BOX - RH .............................................................................................................................
RADIO ANTENNA .............................................................................................................................
19-02
19-04
19-04
19-04
19-03
BY-PASS BOX (ENGINE) ...................................................................................................................

BY-PASS BOX (SIDE CONSOLE ) ......................................................................................................
24 VOLTS MAX 10.0 AMP .................................................................................................................
DIAGNOSIS CONNECTOR FOR 6 TH DRIVE WHEEL ...........................................................................
01-03
02-03
16-01
17-03
CODES ...................................................................................................... CABLE COLORS

A. ..................................................................................................................................................... BLUE
B .................................................................................................................................................... WHITE
C ................................................................................................................................................. ORANGE
V ................................................................................................................................................... GREEN
G ................................................................................................................................................. YELLOW
H ...................................................................................................................................................... GRAY
L. ........................................................................................................................................... DARK BLUE
M ................................................................................................................................................. BROWN
95
LIST OF INSTRUMENTS
N .................................................................................................................................................... BLACK
R ........................................................................................................................................................ RED
S ....................................................................................................................................................... PINK
Z ................................................................................................................................................... VIOLET
CONNECTORS ........................................................................................................ CODES
40-way connector - side console to cable ............................................................................................... X1
01-way connector - transmission to cable .............................................................................................. X3
40-way connector - front console to cable .............................................................................................. X6
01-way connector - transmission to cable ............................................................................................ X10
40-way connector - front console to cable ............................................................................................ X13
40-way connector - side console to cable ............................................................................................. X15
40-way connector - front console to cable ................................................................................... X26-X26A
02-way connector - calibration to transmission cable
X36
02-way connector - calibration to transmission cable
X37
01-way connector - transmission filter restriction to transmission sensor cable ..................................... X39
03-way connector - parking brake to transmission cable ....................................................................... X40
02-way connector - front wheels to transmission cable ......................................................................... X41
02-way connector - option, air suspension seat to side console cable ................................................... X42
09-way connector - gear selector ........................................................................................................... J4
31-way connector - transmission ........................................................................................................... J6
96
LIST OF INSTRUMENTS
CODE ............... FUSES ................................................................................. COORDINATE

F1
F2
F3
F4
F5
F6
........................ Fuse - 7,5 AMP for .............................................................................................. 03-06

........................ Fuse - ................................................................................................................. 16-01
........................ Fuse - 7,5 Amp for rotary beacon and cab roof lamp ............................................ 12-05
........................ Fuse - 7,5 Amp ................................................................................................... 04-02
........................ Fuse - 15,0 Amp for horn .................................................................................... 03-01
........................ Fuse - 3,0 Amp para o E.D.M., electronic instrument
cluster and audible alarm ..................................................................................... 06-06
F7 ........................ Fuse - 10,0 Amp for Funk transmission ............................................................... 18-02
F10 ....................... Fuse - 10,0 Amp for Funk transmission ............................................................... 18-02
F11 ....................... Fuse - 10,0 Amp for windscreen wiper/washer .................................................... 13-01
F12 ....................... Fuse - 15,0 Amp for solenoid valve of standard saddle lock pin and
flotation options ................................................................................................... 08-05
F13 ....................... Fuse - 7,5 Amp for rear work lamps .................................................................... 04-05
F14 ....................... Fuse - 7,5 Amp for rear work lamps .................................................................... 04-01
F15 ....................... Fuse - 10,0 Amp for cold start ............................................................................. 04-01
F16 ....................... Fuse - 10,0 Amp for windscreen wiper/washer .................................................... 13-04
F17 ....................... Fuse - 20,0 Amp for air conditioning ..................................................................... 15-02
F18 ....................... Not used ......................................................................................................................
F19 ....................... Not used ......................................................................................................................
F20 ....................... Fuse - 3,0 Amp for air conditioning system motor, option ..................................... 15-06
F21 ....................... Fuse - 10,0 Amp for 6th drive wheel .................................................................... 17-02
F22 ....................... Fuse - 3,0 Amp for differential lock ...................................................................... 08-02
F23 ....................... Fuse - 3,0 Amp for reversing buzzer ..................................................................... 05-05
F24 ....................... Fuse - 3,0 Amp for electronic fuel shut-off........................................................... 04-05
F25 ....................... Fuse - 3,0 Amp for brake light ........................................................................... 05-04
F31 ....................... Not used ............................................................................................................. 05-04
F32 ....................... Fuse - 7,5 Amp for front blade work lamps .......................................................... 05-03
K1 ........................ Not used ......................................................................................................................
K2 ........................ Not used ......................................................................................................................
K3 ........................ Relay - aux., starting ........................................................................................... 18-05
K4 ........................ Relay - low beam ................................................................................................ 04-02
K5 ........................ Relay - high beam ............................................................................................... 04-01
K6 ........................ Relay - rear work lamps ...................................................................................... 04-05
K7 ........................ Relay - horn ....................................................................................................... 03-01
K8 ........................ Relay - cold starting aid ....................................................................................... 05-05
K9 ........................ Relay - starter motor ........................................................................................... 08-04
K10 ...................... Relay - differential lock ........................................................................................ 08-02
K11 ...................... Relay .................................................................................................................. 16-02
K12 ...................... Relay .................................................................................................................. 15-02
K13 ...................... Not used ......................................................................................................................
K14 ...................... Relay - work lamp before the blade ..................................................................... 02-05
97
DERIVATION BOX (NEAR ENGINE)
ALTERNATOR
POWER
SUPPLY
STARTER
MOTOR
PAGE 01
START
AUXILIAR
MAGNETIC
SWITCH
DIODE
98
PAGE 02
IGNITION SWITCH
DERIVATION BOX
(in the lateral console)
SWITCH WORK LAMPS
WORK LIGTH BEFORE AND

AFTER MOLD BOARD
99
PAGE 03
FLOOD/HEAD LIGTHS, HORN AND TURN SIGNAL SWITCH
HORN
POSITIONS
LIGTHS
TURN SIGNAL
LIGTH R.H.
TURN SIGNAL
LIGTH R.L.
WARNING
TURN SIGNAL AND FLASHER
FLASHER S.W.
VARISTOR
100
PAGE 04
HEAD LIGHT
RELAYS
HIGH
BEAM
INSTRUMENTS AND SWITCH

LIGHTS CIRCUIT 49
LOW
BEAM
POSITION AND LICENSE

PLATE LIGHTS
REAR FLOOD SW. RELAY
REAR FLOOD LIGHTS
101
PAGE 05
FRONT
BLADE
BOARD
SWITCH
CAB
HEAD
SWITCH
HAND
CAB
LAMP
HAND
LAMP FRONT
BLADE
BRAKE
LIGHT
SWITCH
BRAKE
LIGTH
BACKUP
ALARM
RELAY
BACK UP
ALARM
102
PAGE 06
SWITCH AND SENSOR
SENSOR TRANSMISSION
ENGINE OIL PRESSURE
OIL TEMPERATURE
SWITCH -ENGINE COOLANT
FUEL SENSOR LEVEL
TEMPERATURE
103
PAGE 06
ELETRONIC
MONITOR
SWITCH SWITCH ENGINE

AIR FILTER
COOLANT
TEMPERATURE
SWITCH TRANSMISSION
OIL FILTER
RESTRICTION
SWITCH TRANSMISSION
OIL PRESSURE
SWITCH TRANSMISSION
OIL
TEMPERATURE
SWITCH BRAKE
PRESSURE
SENSOR MACHINE
SPEED
CONTROL
AUDIBLE
ALARM
SWITCH HYDRAULIC
OIL FILTER
RESTRICCION
104
DIFERENTIAL
LOCK RELAY
OPC
VARISTOR
ANALOG
HOURMETER
DIFFERENTIAL VARISTOR
LOCK
SOLENOID
VALVE
FAN DRIVE
INVERTER
SWITCH OPC
STARTER
MOTOR
SOLENOID
VALVE
SWITCH SADDLE
LOCK PIN
VARISTOR
PAGE 08
SADDLE
LOCK
SOLENOID
VALVE
105
PAGE 09
SWITCH RIPPER OR
SCARIFIER
VARISTOR
LH SOLENOIDVALVE
OPT FOR RIPPER OR
SCARIFIER
VARISTOR
VARISTOR
RH SOLENOIDVALVE
OPT FOR RIPPER OR
SCARIFIER
VARISTOR
106
PAGE 10
RIPPER OR SCARIFIER SWITCH - OPC-
VARISTOR
VARISTOR
VARISTOR
MOLDBOARD FLOAT
SOLENOIDS VALVES LEFT
MOLDBOARD FLOAT
SOLENOID VALVES
RIGTH
VARISTOR
107
PAGE 11
LIFT SHOCK DAMPENER SWITCHOPC
LIFT SHOCK DAMPENER SOLENOIDS VALVES AND VARISTORS
108
PAGE 12
FRONT BLADE BOARD FLOAT

SWITCH OPC
VARISTOR
FRONT BLADE
FLOTATION
SOLENOID
VALVE
DOME LIGTH
REAR LEFT
STROBE LIGTH
STROBE LIGTH
SWITCH OPC
ELECTRONIC
BEACOM LIGHT
FRONT RIGHT
STROBE LIGHT
109
DUAL POWER
RELAY - OPC
DIODE BOX LATERAL CONSOLE
PAGE 16
CURRENT
PLUG
113
114
115
FRONT WHEEL DRIVE
DIAGNOSIS CONECTOR
SWITCH TO 6HT DRIVE
TRACTION CONTROL
SWITCH
SOLENOID FWD ON/OFF

AND VARISTOR
ELECTRONIC UNIT TO 6HT
SOLENOID FRONT WHEEL

DRIVE
HALF VOLUME AND
VASRISTOR
6TH DRIVE WHEEL
SOLENOID FRONT AND

VARISTOR
SOLENOID AND REVERSE

VARISTOR
PAGE 17
PAGE 18
ELECTRICAL SYSTEM TRANSMISSION FUNK
116
PAGE 19
VOLTAGE CONVERTER
OPTION 1
RADIO IN - BAT
RADIO IN - IGN
OPTION 2
CIGARETTE LIGHTER RADIO AND SPEAKERS
COMPRESSOR TO TIRES
INFLATOR - OPT
117
PAGE 21
119
120
4003
Section
4003
BATTERIES

Contagem, MG Brazil
ENG 6-42330
May,2003
4003-2
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING GUIDE FOR BATTERIES OTHER THAN
MAINTENANCE FREE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENG6-42330
Issued 1-3
3
3
4
4
4
5
5
5
6
7
7
8
8
Printed in Brazil
4003-3
SAFETY RULES
warning
Never try to charge the battery if the electrolyte in the

battery is frozen.
Battery acid causes severe burns. Batteries contain

sulfuric acid. Avoid contact with skin, eyes, or clothing.
Antidote: EXTERNAL-Flush with water. INTERNALDrink large quantities of water or milk. Follow with milk
of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention.
47-83A
warning
Never cause sparks to occur or smoke near batteries

that are charging or have been recently charged.
13-8A
warning
Disconnect the ground cable first when the battery
cables are disconnected from the battery.
Connect the ground cable last when the battery cables

are connected to the battery.
47-55A
warning
Batteries produce explosive gases. Keep sparks,

flame, and cigarettes away. Ventilate when charging or
using in enclosed area. Always shield eyes when working near batteries.
Keep out of reach of children.
D-47-53A
SPECIAL TOOLS
B795328M
The CAS-10147 tester is used to do the Capacity

(Load) Test. This tool is first used on page 4003-7.
ENG 6-42330
Issued 1-3
Printed in Brazi
4003-4
MAINTENANCE
Electrolyte Level
NOTE: Add water only. DO NOT add electrolyte.
If the battery is a maintenance free battery, check

the level of the electrolyte every 1000 hours of
operation or six months, whichever occurs first. For
all other batteries, check the level of the electrolyte
every 250 hours of operation.
Inspecting and Cleaning a Battery
NOTE: Before checking the electrolyte level in the

battery, the battery must have been idle for at least
16 hours. During charging the level of the liquid may
raise.
Check the level of the electrolyte more often
during hot weather. The use of a large amount of
water by the battery can be caused by high battery
temperature or a voltage regulator setting that is too
high. Keep the electrolyte level above the top of the
plates in the battery at all times to prevent damage to
the battery.
If the level of the electrolyte is low, add distilled
water or other clean water until the electrolyte is just
below the cell well bottom, approximztely 5 mm (3/16
inch).Do not add more water than is needed. Too
much water can cause bad performance, a short
service life, and corrosion around the battery.
ENG 6-42330
If damage causes an electrolyte leak, replace the

battery.
Inspect the battery at regular intervals for dirt,
corrosion, and damage. Electrolyte and dirt on the
top of the battery can cause the battery to discharge
by making a passage for the current to flow.
If the battery must be cleaned, remove the battery
from the battery carrier and clean the battery, cable
terminals, and the battery carrier. When available,
use Case Battery Saver and Cleaner according to
the instructions on the container. Case Battery Saver
and Cleaner also helps prevent corrosion. If Case
Battery Saver and Cleaner is not available, use
baking soda and water as a cleaner. DO NOT permit
any type of cleaner to enter the cells of the battery.
Install the battery in the machine and make sure
the fasteners are tight. Apply Case Battery Saver and
Cleaner or Urethane Seal Coat to the cable terminals
to prevent corrosion. See the Parts Counter Catalog.
DO NOT apply grease.
Issued 1-3
Printed in Brazil
4003-5
BATTERY TEST
NOTE: To correctly test a battery, do each part of the
battery test until you know the condition of the
battery.
Visual Checks
1. Make sure the cable connections are clean and
tight. Clean foreign material from the top of the
battery.
2. Inspect the battery case, battery posts, and
cables for damage.
3. Check the electrolyte level. See page 4003-4.
4. If you added water to the battery, the battery
must be charged for 15 minutes at 15 to 25
amperes to mix the water with the electrolyte.
Specific Gravity Check

A hydrometer is used to check the specific gravity
(weight) of the electrolyte. The specific gravity is an
indication of the level of charge for each cell.
Hydrometers are made to show the co rrect
sp e c ific g r a vi ty w h e n t he te m p e ra t ur e of t h e
electrolyte is 26.7C (80F).
When you check the specific gravity, you must
know the temperature of the electrolyte. If your
hydrometer does not have a thermometer, get a
the rmo me ter to c he ck the tem pe ra tur e o f th e
electrolyte. The thermometer must indicate a high
temperature of at least 52C (120F).
1. Remove enough electrolyte from a cell so that
the float is free in the tube.
NOTE:
If the specific gravity cannot be checked
without first adding water to the cell, the battery must
be tilted to the left and right to about a 30 angle to
mix the water and acid. Next the battery must be
charged for 15 minutes at 15 to 25 amperes to
further mix the water with the electrolyte. Then check
the specific gravity.
2. Read the float.
3. Read the thermometer. If the reading is above
26.7C (80F) add specific gravity points to the
reading for specific gravity. If the reading is below
26.7C (80F) subtract specific gravity points from
the reading for specific gravity. See the following
illustration and add or subtract specific gravity
points as needed.
ENG 6-42330
B790863J
1. TEMPERATURE IN F
2. TEMPERATURE IN C
4. Make a record of the corrected specific gravity

reading for each cell.
5. If the difference between the high reading and
the low reading is 0.050 or more, charge the
battery and check the specific gravity again. If
after charging, the difference is still 0.050 or
more, install a new battery.
6. The corrected specific gravity reading shows the
level of charge for the cell. The level of charge
must be at least 75% in each of the cells. In
maintenance free batteries the level of charge is
at least 75% if the corrected specific gravity
reading is 1.240 or higher. In all other batteries
the level of charge is at least 75% if the corrected
specific gravity reading is 1.230 or higher.
the low reading is less than 0.050, and the level
of charge is at least 75% in all of the cells, do the
Capacity (Load) Test.
the low reading is less than 0.050, but the level of
charge is less than 75% in any of the cells,
charge the battery and check the specific gravity
again. If after charging:
A. The level of charge is less than 75% in any of
the cells, discard the battery.
B. The level of charge is at least 75% in all of the
cells, do the Capacity (Load) Test.
Issued 1-3
Printed in Brazil
4003-6
Capacity (Load) Test

This test can be done using a variable load tester
s u c h a s th e S u n E le c tr ic VAT- 3 3 . O th e r te s t
equipment can be used. Connect the test equipment
according to the instructions of the manufacturer of
the equipment.
1. The level of charge of the battery must be at
least 75%. Do the Specific Gravity Check in this
section.
2. Prepare the tester (Sun Electric VAT-33 shown)
for the test.
4. Apply a 15 ampere load to the battery for 15

seconds. Wait at least three minutes before
applying the load again.
5. Check and make a record of the temperature of
the electrolyte.
6. Find the correct load for this test in Specifications
in Section 4002.
NOTE: The correct load is half of the cold cranking amperes at
-17C (0F).
A. Select the voltmeter range that will measure 1

to 18 volts.
7. Turn the load control knob until the ammeter

indicates the specified load. Keep the load for 15
seconds and read the voltmeter. Turn the load
control knob to OFF.
B. Make sure the load control knob is in the OFF

position.
8. Compare the test reading and the temperature of

the electrolyte to the chart below.
C. Select the ammeter range that will measure 0

to 1000 amperes.
D. Move the volt lead switch to the INT. position.
3. Connect the tester to the battery as shown.
TEMPERATURE OF
ELECTROLYTE
MINIMUM
VOLTAGE
21C (70F) and above . . . . . . . . . . . . . . . . . . . . . 9.6

16C (60F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
10C (50F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
4C (40F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
-1C (30F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
-7C (20F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
-12C (10F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.7
-18C (0F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
A. If the test result is equal to or more than the
voltage shown, the battery is in good
condition.
B. If the test result is less than the voltage

shown, discard the battery.
B790499J
1. LOAD CONTROL KNOB

2. AMMETER CLAMP (TIP OF ARROW
AWAY FROM BATTERY)
NOTE: Never apply a load for longer than 15

seconds. After each 15 seconds, turn the load control
knob to OFF for at least one minute.
ENG 6-42330
Issued 1-3
Printed in Brazil
4003-7
CHARGING A BATTERY
Before you charge the battery, check the level of
the electrolyte.
1. Too much gas causes the electrolyte to flow from

the cells.
It is difficult to give an e xa ct cha rgin g rate

because of the following variable conditions: (1)
temperature of the electrolyte, (2) level of charge,
and (3) condition of the battery. Use the charging
guide for the correct charging rate and time.
2. The temperature of the electrolyte rises above

52C (125 F).
Se e Sp ecifica tio ns in Se ctio n 4 002 for th e

reserve capacity of the battery in this machine.
The charging rate must be decreased if:
NOTE: For the best charge, use the slow charging

rates.
The battery is fully charged when, over a three
hour period at a low charging rate, no cell is giving
too much gas, and the specific gravity does not
change.
CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES

Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See Reserve
Capacity under Specifications
Slow Charge
Fast Charge
10 Hours at 5 Amperes
2.5 Hours at 20 Amperes

Above 80 to 125 Minutes


80 Minutes or Less
*Initial rate for standard taper charger

NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If
the center part of the decal has been removed to get access to the battery caps, it is possible the words
Maintenance Free will have been removed from the decal.
ENG 6-42330
Issued 1-3
Printed in Brazil
4003-8
CHARGING GUIDE FOR BATTERIES OTHER THAN

MAINTENANCE FREE BATTERIES
Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See Reserve
Capacity under Specifications
Slow Charge
Fast Charge



Above 250 Minutes
80 Minutes or Less
*Initial rate for standard taper charger
PREPARING A DRY CHARGED BATTERY FOR USE

1. Remove the caps from the battery.
4. Connect a battery charger to the battery.
2. Fill each cell to the top of the separators with

ele ctro ly te . Th is will p er mit the vo lu me of
electrolyte to increase when heated by charging
the battery.
5. Charge the battery at 30 amperes until the

s p e cif ic g ra v it y is 1 .2 5 0 o r m o r e a n d t h e
temperature of the electrolyte is at least 15.5C
(60 F).
3. Install the caps on the battery. If the battery in

your machine must have nonspill caps, install the
nonspill caps. See Specifications in Section 4002
to find if the battery in your machine must have
nonspill caps.
6. If necessary, fill each cell with electrolyte until the

electrolyte is just below split ring at the bottom of
the cell opening.
ENG 6-42330
Issued 1-3
Printed in Brazil
Section
4008
4008
ALTERNATOR - 45 AMPERE

2237, Geeral David Sarnoff Avenue
Contagem, MG Brazil
ENG6-42360
Printed in Brazil
January, 2003
4008-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 Ampere Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of the Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Testing of the Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Testing of the Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the Rectifier Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Replacement of the Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENG 6-42360
Issued 01-03
3
3
4
4
8
9
10
10
11
11
14
Printed in Brazil
4008-3
SPECIFICATIONS
45 Ampere Alternator
Rated output ........................................................................................................................... 28 volts at 45 amperes
Resistance of rotor ............................................................................................................................. 8.1 to 9.9 ohms
Maximum runout for slip rings ....................................................................................................0.05mm (0.002 inch)
Minimum diameter of slip rings.................................................................................................. 26.8 mm (1.055 inch)
Resistance of stator........................................................................................................................ 0.20 to 0.24 ohms
Minimum length of brushes ...............................................................................................................7mm (0.27 inch)
Torque nut for pulley ..............................................................................................60 to 73 Nm (45 to 54 pound-feet)
ENG 6-42360
Issued 8-01
Printed in Brazil
4008-4
ALTERNATOR
STEP 3
Disassembly
STEP 1
B523411M
Remove the retainer and the pulley from the shaft.

B518007M
Fasten the pulley of the alternator in a vise that has

soft jaws. Loosen and remove the nut and washer.
STEP 4
STEP 2
B523413M
Remove the fan from the shaft.

B523405M
STEP 5
Hit the face of the pulley softly with a hammer to

loosen the retainer in the pulley.
B8971201M
Loosen and remove the screws and flat washers that

fasten the voltage regulator and brush holder to the
housing.
ENG 6-42360
Issued 8-01
Printed in Brazil
4008-5
STEP 6
STEP 9
B8971204M
Remove the voltage regulator and brush holder.
B8971213M
Loosen and remove the nut, flat washer, and fiber

washers from the D+ terminal.
STEP 7
STEP 10
B8971207M
Disconnect the lead for the capacitor.
B8971216M
Loosen and remove the nut, flat washer, and fiber

washers from the B+ terminal.
STEP 8
STEP 11
B8971210M
Loosen and remove the screw and remove the

capacitor.
B8971219M
Make an alignment mark on the cover, the stator, and

the housing.
ENG 6-42360
Issued 8-01
Printed in Brazil
4008-6
STEP 12
STEP 15
B8971222M
Loosen and remove the screws that fasten the cover,

stator, and housing together.
B8971301M
Remove the rotor from the cover.
STEP 16
STEP 13
B8971304M
B8971231M
Remove the cover and rotor from the stator and

housing. The cover can be difficult to remove. Use a
soft hammer as required to remove the cover.
1. SCREWS
Loosen and remove the screws that fasten the

rectifier bridge to the housing.
STEP 17
STEP 14
B8971307M
B8971508M
Loosen and remove the screws that fasten the

bearing retainer to the cover. The rotor now can be
removed.
ENG 6-42360
Remove the housing.
Issued 8-01
Printed in Brazil
4008-7
STEP 18
STEP 20
B8971310M
Remove the insulator from the B+ terminal.
B8971319M
Remove the shield from the housing.
STEP 19
B8971313M
Remove the insulator from the D+ terminal.
ENG 6-42360
Issued 8-01
Printed in Brazil
4008-8
STEP 23
Inspection of the Brushes

STEP 21
B9064418M
B9064411M
Use an ohmmeter and check the continuity from

each terminal and brush. If the reading is not zero,
replace the brush or voltage regulator and brush
holder.
Measure the length of each brush. If one brush is

less than 7 mm (0.27 inch) long replace both brushes
or the voltage regulator and brush holder.
STEP 24
STEP 22
B9064421M
B9064414M
Remove the shield.
To replace the brushes, use a soldering iron to

remove the original brushes. Install the springs and
new brushes and use rosin core solder to solder the
leads to the terminals. Before soldering the terminal
shown, open the sleeve for the brush lead and then
crimp the sleeve.
STEP 25
B9064414M
Install the shield.

ENG 6-42360
Issued 8-01
Printed in Brazil
4008-9
Inspection and Testing of the Rotor
STEP 28
STEP 26
B9064433M
B9064405M
Touch the leads of the ohmmeter to the slip rings.

The reading must be as specified, see below. If the
reading is not as specified, a new rotor must be
installed.
45 Ampere Alternator . . . . . . . . . . . . 8.1to 9.9ohms
Use a dial indicator and measure the runout of each

slip ring. If the runout is more than 0.05 mm (0.002
inch) a new rotor must be used or use a lathe to
remove enough material until the runout is less than
specified.
STEP 29
STEP 27
B9064436M
Measure the diameter of the slip ring. The diameter

must not be less than 26.8 mm (1.055 inch).
B9064407M
Touch the leads to each slip ring and the shaft. If a

reading shows continuity, a new rotor must be
installed.
ENG 6-42360
Issued 8-01
Printed in Brazil
4008-10
STEP 33
Inspection and Testing of the

Stator
STEP 30
Look for burned insulation on the coils of the stator.
This is an indication of a short circuit. Install a new
stator.
STEP 31
B9064502M
Use a high watt soldering iron and rosin core solder

to solder the leads of the stator to the rectifier bridge.
Testing the Capacitor

STEP 34
B9064319M
Touch the leads of the ohmmeter to each lead from

the stator and the common connection. The readings
must be as specified, see below. If the readings are
not as specified, a new stator must be installed.
45 Ampere Alternator . . . . . . . . . 0.20 to 0.24 ohms
STEP 32
B9064424M
Touch the leads of the ohmmeter to the capacitor as

shown. The reading will initially approach zero ohms,
then gradually increase to an open circuit as the
capacitor is charged. If there is no indication of
resistance, a new capacitor must be installed. The
capacitor is used to reduce radio noise.
STEP 35
B9064322M
Touch the leads of the ohmmeter to each lead from

th e s ta t o r a n d t he fr a me . If a re a d in g sh o w s
continuity, a new stator must be installed.
ENG 6-42360
Touch the terminal to the bracket to discharge the

condenser.
Issued 8-01
Printed in Brazil
4008-11
Testing the Rectifier Bridge
Inspection and Replacement of the

Bearings
STEP 36
STEP 38
B9064402M
Touch the leads of the ohmmeter to a positive diode

and the heat sink as shown. Then reverse the leads.
There must be a high reading and a low or zero
reading. Then test the other two positive diodes. If a
positive diode did not have readings as specified, the
positive diode is bad and a new rectifier bridge must
be installed.
B8971402M
Inspect the bearings on the rotor. If the bearings are

damaged, use the following procedure to replace the
bearings.
STEP 37
B8971426M
B9064332M
1. Use a suitable support between the front bearing

and the bearing retainer on the rotor shaft and
press the rotor shaft out of the front bearing and
the spacer.
Touch the leads of the ohmmeter to a negative diode

and the heat sink as shown. Then reverse the leads.
There must be a high reading and a low or zero
reading. Then test the other two negative diodes. If a
negative diode did not have readings as specified,
the negative diode is bad and a new rectifier bridge
must be installed.
NOTE: If the tester you are using has a diode test
function, use the tester according to the instructions
of the manufacturer to check the positive and
negative diodes.
B8971429M
2. Remove the bearing retainer.
ENG 6-42360
Issued 8-01
Printed in Brazil
4008-12
B8971432M
B8971504M
3. Use a suitable support between the rear bearing

and the slip ring on the other end of the rotor
shaft and press the rotor shaft out of the rear
bearing.
6. Press the spacer onto the rotor shaft until the

spacer stops moving.
B8971505M
B8971429M
7. Press the new rear bearing onto the other end of

the rotor shaft.
4. Install the bearing retainer on the rotor shaft.
B8971435M
5. Press the new front bearing onto the rotor shaft

until the front bearing stops moving.
ENG 6-42360
Issued 8-01
Printed in Brazil
4008-13
18
23 22
24
20
21
22
23
16
24
22
23
17
19
10
21
11
23
26
27
7
15
12
13
14
3
5
6
7
8
4
BS01B125
1.
2.
3.
4.
5.
6.
7.
NUT
WASHER
RETAINER
SCREW
PULLEY
FAN
SCREW
8.
9.
10.
11.
12.
13.
14.
COVER
SPACER
FRONT BEARING
BEARING RETAINER
KEY
ROTOR
REAR BEARING
15.
16.
17.
18.
19.
20.
21.
STATOR
SCREW
RECTIFIER BRIDGE
INSULATOR
SHIELD
HOUSING
FIBER WASHER
22.
23.
24.
25.
26.
FLAT WASHER
NUT
LOCK WASHER
BRUSH
VOLTAGE REGULATOR
AND BRUSH HOLDER
27. CAPACITOR
45 AMPERE ALTERNATOR
ENG 6-42360
Issued 8-01
Printed in Brazil
4008-14
STEP 42
Assembly
STEP 39
B8971601M
Install the housing on the rectifier bridge.

B8971316M
STEP 43
Install a new shield in the housing.
STEP 40
1
B8971304M
1. SCREWS
B8971313M
Install the insulator on the D+ terminal.
STEP 41
Install and tighten the screws that fasten the rectifier

bridge to the housing.
STEP 44
B8971310M
Install the insulator on the B+ terminal.
ENG 6-42360
B8971604M
Install the fiber washers, flat washer, and nut on the

B+ terminal.
Issued 8-01
Printed in Brazil
4008-15
STEP 45
STEP 48
B8971607M
Check for a short circuit between the terminal and

the housing. If there is continuity, the insulator is bad.
B8971301M
Install the rotor in the cover.
STEP 49
STEP 46
B8971508M
B8971610M
Install the fiber washers, flat washer, and nut on the

D+ terminal.
Install and tighten the screws that fasten the bearing

retainer and rotor to the cover.
STEP 50
STEP 47
B8971231M
B8971613M
Check for a short circuit between the terminal and

the housing. If there is continuity, the insulator is bad.
ENG 6-42360
Make sure the marks are in alignment and install the

cover and rotor in the stator and housing.
Issued 8-01
Printed in Brazil
4008-16
STEP 51
STEP 54
B8971222M
B8971622M
Install and tighten the screws evenly that fasten the

housing, stator, and cover.
Install the voltage regulator and the brush holder. Be

careful not to damage the brushes.
STEP 52
STEP 55
B8971616M
Install the capacitor and tighten the screw.
B8971625M
Install the screws and flat washers and tighten the

screws.
STEP 53
STEP 56
B8971619M
Connect the lead to the terminal.
B523413M
Install the fan.
ENG 6-42360
Issued 8-01
Printed in Brazil
4008-17
STEP 57
STEP 59
B523418M
Install the pulley and the retainer.
B518009M
Fasten the pulley in a vise with soft jaws. Tighten the

nut to a torque of 60 to 73 Nm (45 to 54 pound-feet).
STEP 58
B523407M
Install the washer and start the nut onto the shaft.
ENG 6-42360
Issued 8-01
Printed in Brazil
4008-18
NOTES
ENG 6-42360
Issued 8-01
Printed in Brazil
SECTION INDEX
STEERING
Section Title
Section Number
Front Wheel, axle & Wheel Lean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5002

Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5004
Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5005

Contagem, MG Brazil
ENG 6-46660
Printed in Brazil
June,2003
5002
Section
5002
FRONT WHEEL, AXLE & WHEEL LEAN

ENG 6-46781
Printed in Brazil
June, 2003
5002
TABLE OF CONTENTS
General Description ...............................................................................................................................
Troubleshooting .....................................................................................................................................
Removal & Installation ...........................................................................................................................
SPECIFICATIONS
Front wheel and Spindle ........................................................................................................................
Front Axle and Steering.........................................................................................................................
Front Wheel Lean ..................................................................................................................................
ENG 6-46780
June, 2003
01
02
03
11
13
15
Printed in Brazil
5002-01
GENERAL DESCRIPTION
FRONT WHEEL, AXLE & WHEEL LEAN
It is important that the front wheels, front axle and the wheel lean be kept in proper
adjustment, alignment and repair. Steering of the front wheels is accomplished by the
use of two hydraulic cylinders.
The wheel lean is actuated by a hydraulic cylinder attached to a wheel lean link. The
wheel lean link is connected to the knuckle assemblies and spindles. The axle
assembly pivots in the frame, allowing the axle to oscillate.
1. Wheel bearing adjustment nut

2. Wheel hub
3. Spindle assembly
4. Axle
5. Wheel lean link
ENG 6-46680
6. Steering cylinder
7. Wheel lean lock
8. Axle pivot pin
9. Toe-in adjustment rod
10. Steering arm
June, 2003
Printed in Brazil
ENG 6-46680
Replace bearing and / or adjust shims

Adjust bearings
Straighten link or replace
Replace
Inflate to specified pressure
Correct alignment
Observation
Low air pressure in front tires

Steering links
Improper toe-in
Malfunction in power assist hydraulic
system
Damaged wheel lean link
Axle pivot pin and bushing worn
Worn drag link socket or swivel joints
Loose wheel or spindle bearing
Damaged or worn power steering
Loose steering arm
Worn or loose spindle bearing
Wheel bearings loose
Bent wheel lean link
Knuckle bushing or pin worn
Tires over or under inflated
Misalignment of tires
Hard to steer in either direction
Excessive free play in steering

wheel
Improper caster in front wheels
Uneven or abnormal tire wear
Conduct pressure
test
Observation
Observation
Observation
Observation
Observation
Observation
Improper toe-in
Rims improperly installed on wheel
Wheel bearing loose
Steering arm loose
Spindle bearing loose
Drag link damage
Front wheels wobble
Repair or replace
Adjusting bearings
Repair or replace
Adjusting bearings
Repair or replace
Replace
Inflate to proper pressure

Repair
Adjust toe-in
Insure pressure is correct
Correct toe in
Straighten rim or wheel
Adjust wheel bearings
Tighten nut
Adjust bearing
Repair
Conduct pressure test Repair valve if pressure incorrect

Observation
Repair hydraulic cylinder
Repair or replace
Leaking control valve

Leaking hydraulic cylinder
Hydraulic lines or joints leaking
Front wheels will not remain in

desired position
Remove bolt
Repair valve if pressure incorrect
Free link joint
Replace
Replace
SOLUTION
Observation
Conduct pressure test
Observation
Conduct pressure test
Observation
TEST
Wheel lean safety bolt installed

Control valve malfunction
Wheel lean link frozen or seized
Damaged hydraulic cylinder
Damaged hydraulic hose
PROBABLE CAUSE
Wheel lean fails to function
SYMPTOM
5002-02
TROUBLESHOOTING
June, 2003
Printed in Brazil
5002-03
REPAIR PROCEDURE
REMOVAL & INSTALLATION
WARNING
Lift and handle all heavy parts with a lifting device

of proper capacity. Be sure parts are supported
by proper slings and hooks. Use lifting eyes if
provided. Watch out for people in the vicinity.
STEP 1
Using a suitable hoist and sling or blade down
pressure raise front end of machine. Raise the
machine until the tires clear the floor then block
and support.
STEP 2
Remove wheel nuts and tires.
STEP 3
Remove wheel and cover,
STEP 4
Remove cotter pin, nut, and washer from
spindle shaft.
ENG 6-46780
June, 2003
Printed in Brazil
5002-4
!
STEP 5
Remove outboard bearing.
STEP 6
Use a suitable hoist and sling to remove bearing
housing from spindle shaft.
WARNING
It is unsafe to strike hardened steel parts with
anything other than a soft iron or non-ferrous
hammer. When installing or removing such parts,
wear safety glasses with side shields and heavy
gloves, etc., to reduce the possibility of injury.
STEP 7
Block and support bearing housing on a sturdy
bench and tap inboard bearing race, bearing and
seal from housing
STEP 8
Rotate housing and tap outboard bearing race out
of housing.
ENG 6-46781 June, 2003
Printed in Brazil
5002-05
STEP 9
Remove cotter keys and castle nuts, tap steering
cylinder and toe in adjustment rod from steering
arm.
STEP 10
Remove top and bottom bearing retaining covers.
NOTE: Shims are only located under the top
retaining cover.
STEP 11
Install slide hammer to remove pin, bearing and
race from spindle.
STEP 12
Support spindle when removing top pin and remove
spindle.
ENG 6-46781 June, 2003
Printed in Brazil
5002-6
STEP 13
Remove set screw from wheel lean knuckle.
STEP 14
Remove cotter key, castle nut, and pin from wheel
lean arm.
STEP 15
Remove one seal cap from wheel lean knuckle.
STEP 16
Support wheel lean knuckle and tap pin from
knuckle.
NOTE: Other seal cap is removed with the pin.
ENG 6-46781 June, 2003
Printed in Brazil
5002-07
STEP17
Remove wheel lean knuckle.
STEP 18
Remove seals from wheel lean knuckle.
STEP 19
Remove seals and needle roller bearing from the
front axle
STEP 20
Remove bearing from wheel lean arm.
ENG 6-46781 June, 2003
Printed in Brazil
5002-08
STEP 21
Remove steering cylinder hoses.
STEP 22
Remove steering cylinder retaining washer with
puller screw.
STEP 23
Remove snap ring and cylinder from front frame.
STEP 24
Remove hoses from wheel lean cylinder and right
steering cylinder.
ENG 6-46781 June, 2003
Printed in Brazil
5002-09
WARNING
Scissors points in area of service.

Block securely for service.
STEP 25
Support wheel end from hinging down with suitable
hoist. Remove cotter key, castle nut, and pin from
wheel lean cylinder.
STEP 26
Remove locking capscrews and pry pin from wheel
lean cylinder. Remove cylinder.
STEP 27
Tap bearing from wheel lean cylinder boss.
STEP 28
Tap wear sleeve from wheel lean knuckle boss.
ENG 6-46781 June, 2003
Printed in Brazil
5002-10
STEP 29
Using a suitable hoist and sling, support front axle.
STEP 30
Remove capscrews.
STEP 31
Tap center pin from front axle and remove front axle
from frame.
STEP 32
INSTALLATION
Assembly axle in reverse order of removal. For
adjustments see specification section of this
manual.
ENG 6-46781 June, 2003
Printed in Brazil
5002-11
ENG 6-46781 June, 2003
Printed in Brazil
5002-12
SPECIFICATION
Front Wheel and Spindle
ITEM
STEP#
A
K
L
M
N
NAME
Wheel lug nuts
Spindle to knuckle cap capscrews
Hub cap capscrews
Spindle to knuckle cap capscrews
Link nut
TORQUE
Nm
446 -480
40 - 54
40 - 54
40 - 54
122 -149
Ft Ibs
325 - 350
30 - 40
30 - 40
30 - 40
90 -110
DIMENSIONS
ITEM
NAME
mm
in
Hub bore I.D.

Bearing Cup O. D.
122.121-122.212
122.237 - 122.263
4.8095 - 4.8115
4.8125 - 4.8135
Spindle O. D.
Bearing Cone I. D.
66.644 - 66.670
66.675 - 66.688
2.6238 - 2.6248
2.6250 - 2.6255
Hub bore l. D.
Bearing cup O .D.
146.924 -146.975
147.000
5.7844 - 5.7864
5.7874
Spindle O. D.
Bearing cone I.D.
89.944 - 89.995
90.000
3.5411 - 3.5431
3.5433
Spindle I. D.
Pin O. D.
44.399 - 44.425
44.437 - 44.450
1.7480 - 1.7490
1.7495-1.7500
Knuckle I. D.
Bearing Cup O. D.
72.24 -72.29
72.2325
2.844 - 2.846
2.8438
Pin O. D.
Bearing Cone I.D.
34.938 - 34.963
34.9250
1.3755 -1.3765
1.3750
PROCEDURES
F
Tighten nut to 34 - 41 Nm (25 - 30 ft Ibs) to seat bearings. Revolve hub when tightening. Back nut off and
relieve bearing preload. Re-tighten nut until rolling torque reaches 1.7 - 2.8 Nm (15 - 25 in lbs). Back nut
off to nearest hole and insert cotter pin.
Spindle to knuckle bearing adjustment is obtained by installing lower retainer and then adding or
removing shims to the top retainer. Install the top retainer without shims and tighten capscrews evenly
until bearing preload is first noticed while oscillating the spindle. Measure shim gap, remove retainer and
unset the bearing cup from the cone. Install shim pack equal to the gap minus 0.03 - 0.05 mm (0.001 0.002 in). Bearing must have a preload of 2.3 - 6.2 Nm (20 - 55 in Ibs). oscillating torque. Adjust shim
pack as required. When changing shims1 always unseat bearing cup before each adjustment.
Hand pack bearing C & E with wheel bearing grease and fill hub cavity half full. Use wheel bearing
grease only.
ENG 6-46781 June, 2003
Printed in Brazil
5002-13
ENG 6-46781 June, 2003
Printed in Brazil
5002-14
FRONT AXLE AND STEERING

ITEM
NAME
H
I
TORQUE
Nm
40 -54
122 149
Pin set screw

Steering cylinder retaining nut
ft Ib
35-40
90 - 100
DIMENSION
ITEM
NAME
mm
in
Front axle I. D.
Bearing O. D.
60.312 60.338
60.32
2.3745 2.3755
2.375
Pin O. D.
Bearing I. D.
50.785 - 50.800
50.800
1.9994 - 2.0000
2.0000
Front axle center pivot I. D.

Bearing O. D.
60.30 - 60.32
60.363 - 60.414
2.374 - 2.375
2.3765 - 2.3785
Shaft O. D.
Bearing I.D.
50.749 - 50.762
50.902 - 51.003
1.9980 - 19885
2.0040 - 2.0080
Cylinder pivot I. D.
Bearing O. D.
Cylinder pivot mounting pin O. D.
50.762 - 50.787
50.787 - 50.800
31.73 - 31.78
1.9985 - 1.9995
1.9995 - 2.0000
1.249 - 1.251
PROCEDURES
STEERING CYLINDER ADJUSTMENT Remove Iink (G). Retract left steering cylinder until piston bottoms
Adjust socket until left spindle stop contacts the axle. Extend the cylinder. Adjust socket into steering
cylinder two full turns. Lock socket with jam nut. Repeat procedure for right steering cylinder. Install link
(G).
TOE-IN ADJUSTMENT Lock wheel lean with capscrew. Lift front wheels off the ground. Adjust link until
distance across front of the tires is 8.00 - 11.05 mm (0.315 - 0.435 in) less than across the rear of the
tires. Measure from the center of the tread. Tires must inflated to specified pressure.
ENG 6-46781 June, 2003
Printed in Brazil
5002-15
ENG 6-46781 June, 2003
Printed in Brazil
5002-16
FRONT WHEEL LEAN

ITEM
NAME
mm
in
Cylinder pivot bearing I.D.

Bearing O. D.
Pivot Pin O. D.
Bearing I.D.
Cylinder rod I.D.
Bearing O. D.
50.762 50.787
50.787 50.800
31.763 31.788
31.737 31.750
50.762 - 50.787
50.787 50.800
1.9885 1.9995
1.9995 2.0000
1.2505 1.2515
1.2495 1.2500
1.9985 - 1.9995
1.9995 - 2.0000
Front wheel lean link bearing bore I. D.

Bearing O. D.
50.762 - 50.787
50.787 - 50.800
1.9985 1.9995
1.9995 - 2.0000
PROCEDURE
D
Tighten nut to 542 670 Nm (400 500 ft lbs), then increase torque to align holes for the cotter pin.
NOTE: Lock wheel lean with capscrew and nut attached on front axle structure.
Lift front wheels off floor. Adjust wheels link until distance across front of tires is .375+/- 0.060 inches less than
across rear of tires. Measure from center of tread.
Tires must be properly inflated.
ENG 6-46781 June, 2003
Printed in Brazil
5003
Section
5003
STEERING CONTROL VALVE
845 - 865 - 885 Grader

ENG 6-46690
Printed in Brazil
May, 2003
5003-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
3
3
5
6
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ENG 6-46690
May,2003
Printed in Brazil
5003-3
SPECIFICATIONS
Manufacturer ..................................................................................................................................................... Eaton
Special Torques
Cap screws for end cap ............................................................................................... 31 NM (275 pound-inches)
SPECIAL TOOLS
Spring installation............................................................................................................. Eaton part number 600057
Order Special Tools from:

Eaton Corporation, Hydraulics Division, 15151 Highway 5, Eden Prairie, MN 55344
STEERING CONTROL VALVE

Disassembly
1. Clean the port area of the steering control valve
housing before disconnecting the hydraulic lines.
2. Drain the oil, and plug the ports. Clean the
exterior of the steering control valve housing.
Protect the machines surfaces during repair.
3. Put the steering control valve in a vise so that the
end cap (2) is up, refer to Figure 1.
Figure 1-A
7. Remove housing from vise. Place housing on a
clean soft cloth to protect surface finish. Use a thin
bladed screwdriver to pry retaining ring from
housing, as shown in Fig. 1- A .
1
GS98K501
1. VISE
2. END CAP
3. ANTI-CAVITATION VALVES
4. CHECK VALVE
FIGURE 1. STEERING CONTROL VALVE-END CAP UP
4. Remove the seven cap screws (1), end cap (2),

O-ring (3), gerotor (4), O-ring (3), spacer plate
(5), and O-ring (3), refer to Figure 2.
5. Remove the gerotor star from gerotor (4), Figure 2.
6. Remove drive shaft (6), Figure 2.
ENG 6-46690
May,2003
Figure 1 - B
8. Rotate spool and sleeve until pin is horizontal.
Push spool and sleeve assembly forward with your
thumbs just far enough to free gland bushing from
housing, see Fig. 1 - B. Remove bushing
Printed in Brazill
5003-4
1.
2.
3.
4.
5.
6.
7.
CAP SCREW
END CAP
O-RING
GEROTOR
SPACER PLATE
DRIVE SHAFT
STEERING CONTROL HOUSING
8.
9.
10.
11.
12.
13.
14.
SLEEVE
SPOOL
SPACER
PIN
CENTERING SPRING
NEEDLE THRUST BEARING
BEARING RACE
15. O-RING
16. O-RING
17. SEAL GLAND BUSHING
18. RETAINING RING
19. DUST SEAL
20. 23. BALL CHECK
21. 22. ROLL PIN
FIGURE 2. STEERING CONTROL VALVE - EXPLODED VIEW

ENG 6-46690
May,2003
Printed in Brazil
5003-5
12. Remove spool and sleeve assembly from 14 hole

end of housing, see Fig. 5.
Figure 3
9. Remove quad ring seal from seal gland bushing.
Attention: Do not bind spool and sleeve in housing.

Rotate spool and sleeve assembly slowly when
removing from housing.
13. Push pin from spool and sleeve assembly.
10. Use a thin bladed screwdriver to pry dust seal from

seal gland bushing. Do not damage bushing.
Figure 6
Figure 4
11. Remove 2 bearing races and the needle thrust
bearing from spool and sleeve assembly.
14. Push spool partially from control end of sleeve, then

remove 6 centering springs from spool carefully by
hand, see Fig. 6
15. Push spool back through and out of sleeve, see Fig. 6
Rotate spool slowly when removing from sleeve.
16. Remove o-ring from housing, see Fig. 7 and two
cylinder port shock valves (set screw, o-ring, spring,
and check ball).
Figure 5
Figure 7
ENG 6-46690
May,2003
Printed in Brazil
5003-6
Section Drawing and Integral Valves

NOTE: The steering control valve housing (7) Fig. 2 has internally two anti-cavitation valves (EE) and one check
valve (CC). Before removing these valves, verify their positions.
17. To disassemble these valves, insert soda straws (3) in each end of the threaded holes, refer to Figure 3. Remove
the steering control valve housing from the vise and tilt it until the port face (4) is upward. Continue turning until the
roll pins (2) and ball checks (1) slide through the straws (3).
ENG 6-46690
May,2003
Printed in Brazil
5003-7
3
4
2
3
GS98K530
1. BALL CHECK
2. ROLL PIN
3. SODA STRAW
4. PORT FACE
6. CHECK VALVE
FIGURE 8. ANTI-CAVITATION VALVE - DISASSEMBLY
Inspection
1. Clean all parts in cleaning solvent and air dry on
paper towels. Do not use cloths to wipe parts dry,
as it may leave lint on the parts.
2. Check all machined surfaces for wear or
damage. If there are rough places on the ends of
the gerotor star or gerotor (4), steering control
valve housing (7), end cap (2), or spacer plate
(5), use 600 grit emery cloth to smooth the
surfaces, refer to Figure 2. Place the emery cloth
on a flat surface. If the emery cloth is new, rub a
piece of steel across the emery cloth six times to
remove the sharp pieces of grit. Make sure that
the part is held flat on the emery cloth. Rub each
part across the cloth six times. Check to see if
the rough places are removed. Use this method
until all rough places are removed. Clean the
parts in cleaning solvent to remove any grit.
ENG 6-46690
May,2003
3. If the spool (9) and sleeve (8) or the bore in the

housing of the steering control valve (7) is
damaged or worn, use a new steering control
valve.
4. Inspect the cap screws (1), pin (11), backup
washer (15), seal ring (16), O-ring (17),
needle thrust bearing (13) and bearing race
(14). Use new parts as required.
5. If your steering control valve has anti-cavitation
and check valves, inspect the balls checks (20),
(23) and roll pins(21), (22) for damage or wear.
Use new parts as required.
Printed in Brazil
5003-8
Assembly
NOTE: Use new seals (3), (16), and (19) when
reassembling the steering control valve.
IMPORTANT: Lubricate all new seals (with exception
of new quad seal) with clean petroleum jelly such as
Vaseline.
Do not use excessive lubricant on seals for meter section.
Refer to parts listings covering your steering control unit
when ordering replacement parts. A good service policy
is to replace all old seals with new seals.
1. Use a soda straw (3) as a guide tool, refer to
Figure 9. Drop the straw (3) into the anti-cavitation
valves (5) and check valve (6) to the bottom of the bore.
Drop the ball check (2) through the straw (3). Pull
the straw (3) out and use the same procedure in
the others ball seat.
FIGURE 10
3. Assemble spool and sleeve carefully so that the

spring slots line up at the same end. Rotate spool
while sliding parts together. Some spool and
sleeve sets have identification marks, align these
marks as shown in Fig.10. Test for free rotation.
Spool should rotate smoothly in sleeve with finger
tip force applied at splined end.
2
3
4
FIGURE 11
6
GS98K504
5
1. ROLL PIN
2. BALL CHECK
3. SODA STRAW
4. PORT FACE
6. CHECK VALVE
FIGURE 9. CHECK AND ANTI-CAVITATION VALVES ASSEMBLY
2. Use a small light and check each bore to make

sure each ball check (2) is in the correct place.
Add the roll pin (1) in each.
ENG 6-46690
May,2003
4. Bring spring slots of both parts in line and stand

parts on end of bench. Insert spring installation tool
through spring slots of both parts. Tool is available
as part no. 600057. Position 3 pairs of centering
springs (or 2 sets of 3 each) on bench so that
extended edge is down and arched center section
is together. In this position, insert one end of entire
spring set into springinstallation tool, see Fig. 11.
5. Compress extended end of centering spring set
and push into spool sleeve assembly with drawing
installation tool at the same time.
6. Center the spring set in the parts so that they push
down evenly and flush with the upper surface of the
spool and sleeve.
Printed in Brazil
5003-9
FIGURE 12
7. Install pin through spool and sleeve

assembly until pin becomes flush at both sides
of sleeve.
Figure 14
10. Install 2 bearing races and the needle thrust
bearing in the order shown in Fig. 14.
11. Install dust seal in seal gland bushing, flat or
smooth side of dust seal must face down toward
bushing, see Fig.16.
FIGURE 13
12. Install dry quad ring seal in seal gland bushing,

Smooth seal in place with your finger. Do not use
any seal that falls freely into pocket of bushing , see
Fig. 19.
8. Position the spool and sleeve assembly so

that the splined end of the spool enters the 14
hole end of housing first, see Fig. 13.
Attention: Be extremely careful that the parts do
not tilt out of position while inserting. Push parts
gently into place with slight rotating action, keep
pin nearly horizontal. Bring the spool assembly
entirely within the housing bore until the parts
are flush at the meter end or 14 hole end of
housing. Do not pull the spool assembly beyond
this point to prevent the cross pin from dropping
into the discharge groove of the housing. With
the spool assembly in this flush position, check
for free rotation within the housing by turning
with light finger tip force at the splined end.
FIGURE 15
9. Place housing on clean, lint free cloth. Install

seal in housing, see Fig. 14.
ENG 6-46690
May,2003
Printed in Brazil
5003-10
13. Install seal gland bushing over the spool end

with a twisting motion. Tap the bushing in place with
a rubber hammer. Make sure the bushing is flush
against the bearing race.
15 Clamp housing in vise, as shown in Fig. 17.

Clamp lightly on edges of mounting area. Do not
over tighten jaws.
Note: Check to insure that the spool and sleeve are
flush or slightly below the 14 hole surface of the
housing.
Attention: Clean the upper surface of the housing

by wiping with the palm of clean hand. Clean each
of the flat surfaces of the meter section parts in a
similar way when ready for reassembly. Do not use
cloth or paper to clean surfaces.
FIGURE 16
14. Install retaining ring (see Fig. 15-16) in housing.

After installing ring, tap on ring end to pry with
screwdriver around entire circumference of
ring to property seat ring in groove.
FIGURE 18
16. Install seal in housing, see Fig. 18.
17. Install spacer plate. AIign bolts holes in spacer

plate with tapped holes in housing.
FIGURE 17
FIGURE 19
ENG 6-46690
May,2003
Printed in Brazil
5003-11
18. Rotate spool and sleeve assembly until pin is

parallel with port face, see Fig. 19. Install drive,
make sure you engage drive with pin, To
assure proper alignment, mark drive as shown
in Fig. 21 (ref. B). Note relationship between
slotted end of drive to splined end of drive
when marking.
FIGURE 22
FIGURE 20
21. Install drive spacer when used, in meter

see Fig. 22
19. Install seal in meter.
22. Install seal in end cap.
23. Install end cap on gerotor, align holes.
FIGURE 23
24. Install 7 dry cap screws in end cap. Pretighten

screws to 17 N.m (150 lb.in), then torque screws
to 31 N.m (275 lb.in) in the sequence show in
Fig. 23.
FIGURE 21
20. With seat side of meter toward spacer plate,

align star valleys (ref. A) on drive (ref. B). Note the
parallel relationship of reference lines A, B, , and
D - Fig. 21. Align bolt holes without disengaging
meter from drive.
ENG 6-46690
May,2003
Printed in Brazil
5003-12
TROUBLE SHOOTING
Must steering problems can be corrected if the problem is properly defined. The entire steering system should be
evaluated before removing any components. The steering control unit is generally not the cause of most steering
problems. The following is a list of steering problems along with possible causes and suggested corrections.
Problem
1. Slow steering, hard steering, or loss
of power assist.
2. Wander Vehicle will not stay in a

straight line.
3. Drift Vehicle veers slowly in one

direction.
4. Slip A slow movement of steering

wheel fails to cause any movement of
steered wheels.
Possible Cause
Worn or malfunctioning pump.
Correction
Replace pump.
Stuck flow divider piston.
Replace flow divider.
Worn pump compensator allowing the

system pressure to be less than
specified.
Replace pump and compensator.
Malfunctioning relief valve allowing the

system pressure to be less than
specified.
Replace the relief valve.
Overloaded steer axle.
Reduce Load.
If load sensing system

1. Leaking or kinked load sensing
signal line.
2. Malfunctioning priority valve.
Correct
Air in the system due to low level of oil, Correct.

cavitating pump, leaky fitting, pinched
hose, etc.
Worn mechanical linkage.
Repair or replace.
Bending of linkage or cylinder rod.
Repair or replace.
Loose cylinder piston.
Repair or replace.
Leaky crossover relief or anticavitation

valve in cylinder lines.
Repair or replace the accessory valve.
Severe wear in steering control unit.
Replace the steering control unit.
Single rod end cylinder slowly extends

without turning the steering wheel.
A small rate of extension may be

normal on a closed center system.
Worn or damaged steering linkage.
Replace linkage and align front end.
Leakage of cylinder piston seals or

Replace seals or accessory valve.
accessory valve between cylinder lines
or ports.
Worn steering control unit meter.
ENG 6-46690
Check spring and sticking piston.

Check damping orifices in both ends of
main bore.
Check system pressure at SCU inlet
for proper system pressure. If not
correct replace priority valve relief
cartridge.
Replace steering control unit.

May,2003
Printed in Brazil
5003-13
Problem
5. Temporary hard steering or
hang-up.
Possible Cause
Thermal Shock*
6. Erratic steering.
Air in system due to low level of Correct condition and add fluid.
oil, cavitating pump, leaky fitting,
pinched hose, etc.
7. Spongy or soft steering.
Correction
Check unit for proper operation
and cause of thermal shock.
Loose cylinder piston.
Replace cylinder.
*Thermal shock damage.
Replace steering control unit.
Sticking flow control spool.
Replace flow control valve.
Air in hydraulic system. Most

likely air trapped in cylinders or
lines.
Bleed air out of system. Placing

ports on top of the cylinder will
help prevent air trapping.
Low fluid level.
Add fluid and check for leaks.
Tighten steering wheel nut.

8. Free Wheeling-Steering wheel Steering column upper shaft is
turns freely with no feeling of
loose or damaged.
pressure and no action on
steered wheels.
Lower splines of column may be Repair or replace column.
disengaged or broken.
Steering control unit meter has a Usually starting engine will cure
problem.
lack of oil. This can happen on
start-up. after repair, or long periods of non use.
No flow to steering unit can be
caused by:
1. Low fluid level.
2. Ruptured hose.
3. Internal steering control unit
damage due to thermal shock *.
9. Free Wheeling-Steering wheel Leaking crossover relief or antiturns with slight resistance but
cavitation valve in cylinder lines.
results in little or no steered
wheel action.
Piston seal blown out.
Add fluid and check for leaks.

Replace hose.
Replace the unit.
Repair or replace the accessory

valve.
Determine cause. Correct and

replace seal.
Thermal shock - A condition caused when the hydraulic system is operated for some time without
turning the steering wheel so that fluid in the reservoir and system is hot and the steering control unit
o
is relatively cool (more than 50 F temperature differential). When the steering wheel is turned quickly
the result is temporary seizure and possible damage to internal parts of the steering control unit. The
temporary seizure may be followed by total free wheeling.
ENG 6-46690
May,2003
Printed in Brazil
5003-14
Problem
10. Excessive free play at
steering wheel.
Possible Cause
Loose steering wheel nut.
Steering column shaft worn or
damaged. There should be very
little free play in the unit itself.
11. Excessive free play at

steered wheels.
Broken or worn Iinkage between Check for loose fitting bearings

cylinder and steered wheels.
and anchor points in steering
Iinkage between cylinder and
steered wheels.
Leaky cylinder seals.
12. Binding or poor centering of

steering wheel.
13.Steering unit locks up.
14. Steering wheel oscillates or

turns by itself.
15.Steered wheels turn in wrong

direction when operator
activates steering wheel
16. Steering wheel kicks at start
of steering.
ENG 6-46690
Correction
Repair or replace steering wheel
connection or column.
Replace cylinder seals.
Binding or misalignment in steer- AIign column pilot and spline to

ing column or splined input con- steering control unit.
nection.
High back pressure in tank line
can cause slow return to center.
Should not exceed 300 psi.
Revise circuit return line.
Large particles can cause

binding between the spool and
sleeve.
Clean the unit and filter the oil. If

another component has failed
generating contaminants, flush
the system while bypassing the
steering control unit.
Large particles in meter section.
Clean the unit.
Insufficient hydraulic power

3
(units over 15 in ).
Check hydraulic power supply.
Severe wear and/or broken pin.
Replace the unit.
*Thermal shock.
Replace the unit.
Parts assembled wrong.

Steering unit improperly timed.
Correct timing.
Lines connected to wrong ports.
Reconnect lines correctly.
Lines connected to wrong

cylinder ports.
Reconnect lines correctly.
No inlet check valve on steering

control unit.
Install a check valve.
May,2003
Printed in Brazil
5004
Section
5004
STEERING PRIORITY VALVE
845 - 865 - 885 Grader

ENG 6-46700
May, 2003
5004-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
3
3
4
4
SPECIAL TORQUES
Spool Orifice Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 to 9.6 Nm (65 to 85 lb-inch).
Plugs and Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.9 to 54.2 Nm (25 to 40 lb-ft).
Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 to 9.5 Nm (72 to 84 lb-inch).
Eng 6-46700
Issued 1-03
Printed in Brazil.
5004-3
STEERING PRIORITY VALVE

STEP 4
Disassembly
Remove spring (5).
STEP 1
Put the steering priority valve in a soft jawed vise.
STEP 5
STEP 2
Remove spool (6).
Remove relief valve (1). Remove and discard O-ring

(2) from relief valve.
STEP 6
STEP 3
Remove plug (7). Remove and discard O-ring (8)

from plug.
Remove plug (3). Remove and discard O-ring (4)

from plug.
1. RELIEF VALVE
2. O-RING
3. PLUG
4. O-RING
5. SPRING
ENG 6-46700
6. SPOOL
7. PLUG
8. O-RING
9. HOUSING
Issued 1-03
Printed in Brazil
5004-4
Cleaning and Inspection
Assembly
STEP 7
STEP 11
Clean all parts in cleaning solvent. Immerse housing

(9) in cleaning solvent and agitate cleaning solvent.
WEAR EYE PROTECTION WHEN USING
COMPRESSED AIR. Use compressed air to remove
foreign matter from interior of valve housing and to
ensure that all orifices and bores are clear.
Install new O-ring (10) on plug (9). Install plug and

O-ring. Tighten plug to a torque of 33.9 to 54.2 Nm
(25 to 40 lb-ft).
STEP 8
STEP 13
Insp ect spo ol (6) a nd ho using b ore s for d ee p

scratches, gouges, and other damage. Replace
steering priority valve if any of these conditions are
seen.
Install new O-ring (4) on plug (3). Install plug and

O-ring. Tighten plug to a torque of 33.9 to 54.2 Nm
(25 to 40 lb-ft).
STEP 12
Install spool (8) and spring (7),
STEP 14
STEP 9
Check that orifice screws in each end of spool (6) are
fr e e a n d c le a r o f fo r e ig n m a tt e r. W E AR EY E
PROTECTION WHEN USING COMPRESSED AIR.
If n e c e ss a r y, r e m o ve o ri fic e s c re w s a n d u s e
compressed air to remove foreign matter from interior
of spool (6) and orifice screws. Install orifice screws
in spool (6) ends. Tighten screws to a torque of 7.3 to
9.6 Nm (65 to 85 lb-inch).
Install new O-ring (2) on relief valve (1). Install relief

valve and O-ring. Tighten relief valve to a torque of
33.9 to 54.2 Nm (25 to 40 lb-ft).
STEP 10
Check spring (5) for cracks, breaks, or signs of
permanent set. Replace if any of these conditions are
seen.
10
1. RELIEF VALVE
2. O-RING
3. RELIEF VALVE
ENG 6-46700
4. O-RING
5. SPRING
6. SPOOL
7. PLUG
8. O-RING
9. HOUSING
Issued 1-03
Printed in Brazil
SECTION INDEX
POWER TRAIN
Section Title
Section Number
Transmission specifications, pressure checks, and troubleshooting 845 . . . . . . . . . . . . . . . . . . . . . . . . 6002

Transmission specifications, pressure checks, and troubleshooting 865 - 885. . . . . . . . . . . . . . . . . . . . . 6002
Transmission 885 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6003
Transmission 845 - 865. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6003
Rear axle with differential lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6005
Limited slip Rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6005
Tandem drive limited slip rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6006
Tandem drive differential hydraulic lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6006

Contagem, MG Brazil
ENG 6-46730
Printed in Brazil
May,2003
6002
Section
6002
TRANSMISSION SPECIFICATIONS, PRESSURE
CHECKS, AND TROUBLESHOOTING
845 - 865 Grader

ENG 6-46750
Printed in Brazil
May, 2003
6002-2
TABLE OF CONTENTS 845 / 865

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TEST AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Theory of Operation Clutch Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Theory of Operation Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clutch Solenoid Voltage Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Test Solenoids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Solenoid Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Suction Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8-4 Power Flow Forward Speeds . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8-4 Power Flow Reverse Speeds . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshoot Transmission System Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Powershift Troubleshooting - internal disconnect models only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TRANSMISSION CONTROL UNIT . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Troubleshooting Introduction .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Transmission Control Unit (TCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Engine Speed Magnetic Pickup Sensor (input speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cylinder Magnetic Pickup Sensor (MPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Output Speed Magnetic Pickup Sensor (MPU) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electronic Gear Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Gear / Diagnostic Indicator or "CCD display" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inching Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Transmission Analog Inching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TVP (Transient Voltage Protection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . 33
J1 Connector, Transmission Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

J4 Connector Bump Shifter Pinout
.............................................
J6 Connector Pinout
. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Function of Proportional Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Proportional Valves, Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
SYSTEM ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
ANALOG TCU DIAGNOSTIC CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
ABBREVIATIONS AND ACRONYMS USED IN TCU GROUP .. .. . . . . . . . . . . . . . . . . . . . . . . . . . .. .
ENG 6-46750
May, 2003
Printed in Brazil
34
35
36
37
38
39
43
44
45
46
55
56
6002-2
TABLE OF CONTENTS 885

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
TEST AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Theory of Operation Clutch Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Theory of Operation Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Clutch Solenoid Voltage Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Test Solenoids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Solenoid Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Suction Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8-4 Power Flow Forward Speeds . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
8-4 Power Flow Reverse Speeds . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Troubleshoot Transmission System Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Powershift Troubleshooting - internal disconnect models only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
TRANSMISSION CONTROL UNIT . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Troubleshooting Introduction .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Transmission Control Unit (TCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Engine Speed Magnetic Pickup Sensor (input speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Cylinder Magnetic Pickup Sensor (MPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Output Speed Magnetic Pickup Sensor (MPU) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Electronic Gear Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Gear / Diagnostic Indicator or "CCD display" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Inching Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Transmission Analog Inching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
TVP (Transient Voltage Protection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 87
J1 Connector, Transmission Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

J4 Connector Bump Shifter Pinout
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
J6 Connector Pinout
. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Transmission Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Function of Proportional Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Proportional Valves, Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
SYSTEM ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
ANALOG TCU DIAGNOSTIC CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
ABBREVIATIONS AND ACRONYMS USED IN TCU GROUP .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
ENG 6-46750
May, 2003
Printed in Brazil
6002-3
SPECIAL TOOLS
CAS-1953A Transmission supplemental fitting kit.
Includes: CAS-2324 special 90 degree adapter and
CAS-2325 plug and cap set.
CAS-1804 Master pressure test kit
75289947
75289948
75301709
75310177
Clutch Stack Lifting device.

Stack nest for assembly.
Installation tool.
75310186 - Assembly tools.
CAS-1808 Flowmeter kit

CAS-2702 Flowmeter adapter
CAS-2278 Flow test kit
75310180 - 75310185 - 75310190 Input seal driver.

75310182 - 75310189 Sleeve inst. adapter.
75310183 - 75310187 - Bearing inst. tool
753101888 - Clutch stk clearance gage.
IMPORTANT: The special tools listed are required to properly service the transmission.
A4X 17/32 Drill Through 5/8-11 UNC-2B Tap

through
B9.968 in. (253.187mm)
C4x 1/2 x 45
D2.31 in. (58.67mm)
E5.984 in. (151.993mm)
F2.362 in. (59.994mm)
G8.79 in. (223.26mm)
H4.625 in. (117.475mm)
ENG 6-46750
I13.875 in. (98.425mm)

J4.31 in. (109.47mm)
K3.52 in. (89.40mm)
L4.528 in. (115.011mm)
M.75 in. (19.05mm)
N4.625 in. (117.475mm)
O7x 11/16 Drill Through
P.69 in. (17.52mm)
Q3.77 in. (95.75mm)
R 2.992 in. (75.996mm)
May, 2003
Printed in Brazil
6002-4
ASSEMBLY STAND PLATE
A1.75 in. (44.45mm)

B9.96 in. (252.98mm)
C8X 11/16 Drill Through
D5.984 in. (151.993mm)
E.5 in. (12.7mm)
F1.5001.505 in. (38.138.227mm)
G2.362 in. (59.994mm)
H6.48 in. (164.59mm)
I2.25 in. (57.15mm)
ENG 6-46750
J13.875 in. (352.425mm)

K4.528 in. (115.011mm)
L5.84 in. (148.33mm)
M.5 in. (12.7mm)
N.25 (6.35) radius in corner
O17/64 Drill Through as Shown
P1.46 in. (37.08mm)
Q2.992 in. (75.996mm)
R 3.00 in. (76.2mm)
May, 2003
Printed in Brazil
6002-5
FRONT HOUSING LIFTING TOOL
A1.42 in. (36.05mm)

B4X .38 in. (9.52mm)
C17/32 Drill Through 5/8-11 UNC
D.75 in. maximum (19.05mm)
E4.99 in. (126.7mm)
F3.29 in. (83.6mm)
G1.44 in. (36.5mm)
H.47 in. (12mm)
I.71 in. (18.11mm)
J2.88 in. (73.17mm)
ENG 6-46750
K3.70 in. (94.01mm)

L4.83 in. (122.78mm)
M3.29 in. (83.6mm)
N5.43 in. (138mm)
O.50 in. minimum (12.7mm)
P1.46 in. (37.08mm)
Q2.992 in. (75.996mm)
R 3.00 in. (76.2mm)
NOTE: Used for lifting main case front housing.
May, 2003
Printed in Brazil
6002-6
Item
SPECIFICATIONS
Measurement
Specification
DF-150 (Transmission model)
Weight (Application Dependent)
567 Kg (1250 lbs)
DF-150
Input-to-Output
500 mm (19.69 in)
DF-150
Rating (Depending on
application)
Input power(maximum) - 142 kW (190

SAE hp)
Input no load speed (maximum) - 3000
rpm
Turbine torque (maximum) - 1288 Nm
(950 lb-ft)
DF-150
Mountings Available
Engine
Midship
Remote
DF-150
Clutches
Fully modulated, oil cooled, multidisc,

hydraulic actuated and self-adjusting.
DF-150
Gearing
Constant mesh, in line, high contact

ratio ground gears. Up to eight speeds
forward and four speeds reverse.
DF-150
Oil
Hydraulic Transmission Fluid.
DF-150
Filter
Remote mounted spin-on type filter.
Maximum Input Speed
3000 rpm
Test Input Speed
2000 rpm
Maximum Continuous Operating

Temperature
93C (200F)
Maximum Intermittent Operating

Temperature
115C (230F)
Maximum Temperature
121C (250F)
Normal Operating Temperature
6593C (150200F)
Check Oil Level Temperature
37C (100F)
Pump Pressure (test input

speed)
17.5819.65 Bar (255285 psi)
Pump Flow (test input speed)
87102 L/min (2327 gpm)
Clutch Pressure (test input

speed)
16.5519.31 Bar (240280 psi)
Lube, In Pressure (test input

speed)
1.384.14 Bar (2060 psi)
Transmission Operating Conditions
Pressures and Flows at Control

Valve
ENG 6-46750
May, 2003
Printed in Brazil
Test and Troubleshooting
6002-7
THEORY OF OPERATION CLUTCH ACTUATION

Hydraulic oil pressure is directed from the proportional
valve, through passages in the valve body, to a
drilled passage in the main case that directs the oil
pressure to the seal rings on the end of the clutch
shaft. The oil pressure is transferred from the
stationary housing to the rotating shaft in the area
between the shaft seal rings. The oil pressure then
travels down a hole in the shaft until it enters the
area enclosed by clutch shaft weldment, the clutch
apply piston and the piston seals. Here it acts on the
piston area causing it to move toward the clutch

pack, compressing the bellville piston return springs
and removing the free clearance in the clutch. The
piston also moves the lube shut-off washer, trapped
between the piston and the bellville springs, causing
it to uncover the lube holes that provide cooling oil
flow to the clutch. Once the free clearance in the
clutch is eliminated the piston applies pressure to the
clutch plates causing the clutch to transmit torque in
proportion to the oil pressure applied.
GEAR SELECTION
Two clutches must be engaged in order to transmit
torque from the transmission input to the transmission
output shaft. In Neutral all clutches are in the
released condition.
The clutches numbered 1 through 4 are referred to
as directional clutches. Clutches 1 and 2 engage
forward gears and clutches 3 and 4 engage
reverse gears. These clutches have two passages
through the shaft in order to maximize the lube flow
to cool the clutches. These clutches have more
friction surface area and a higher thermal capacity
than the speed clutches. The directional clutches are
used for modulation during shifting and when using
the clutch pedal. The directional clutches connect the
input shaft of the transmission through various ratios
to the cylinder gear train and are located in the upper
part of the transmission.
The clutches lettered A, B, C and D are
ENG 6-46750
referred to as speed clutches. The speed clutches

connect the cylinder gear train to the output shaft of
the transmission at various ratios. Working in
conjunction with the directional clutches up to 8
speed ranges in forward and 4 ranges reverse
directions are possible. The speed clutches are
located in the lower part of the transmission.
NOTE: The following table shows which clutches are

engaged for each ratio in a eight speed
forward and four speed reverse.
Range
1
2
3
4
5
6
7
8
FORWARD
Directional Speed
1
2
1
2
1
2
1
2
A
A
C
C
B
B
D
D
May, 2003
REVERSE
Directional Speed
3
4
3
4
A
C
B
D
Printed in Brazil
6002-8
THEORY OF OPERATION HYDRAULIC SYSTEM

Oil is picked up by the transmission charge pump
from the transmission sump through a suction screen.
It travels through an external suction tube to the inlet
side of the charge pump. The charge pump is an
external gear pump with fixed clearance end plates
and the gear shafts supported by bushings. The
pump is driven by a gear train directly coupled to the
engine and has a displacement such that it pumps 25
to 27 gpm at engine high idle speed.
From the pump the oil is directed to a filter assembly.
The filter head has an internal bypass valve that
bypasses oil to a dedicated port when the pressure
drop across the filter element exceeds 60 psi.
Bypassed oil is directed to the lube system and back
to the transmission sump, not to the proportional
control valves. The filter head also contains a
pressure switch that can be used to alert the operator
of nearing bypass conditions. This switch actuates at
a pressure drop across the filter element of 50 psi.
main regulator valve to the charge circuit controlled

by the flow restrictions in the heat exchanger and the
lube circuits.
The cooled oil returning to the valve body from the
heat exchanger is directed to the lube circuit. An
internal manifold in the transmission main case
directs the lube oil to the ends of each of the clutch
shafts. This oil flow passes through the lube shut-off
washers on the engaged clutches and provides the
cooling for the clutches. There is also leakage flow to
the disengaged clutches to lubricate and cool them
and many orifices provide flow to lubricate the
bearings on these shafts. After exiting the clutch and
bearings on these shafts the oil returns to the
transmission sump where it is again picked up by the
charge pump. If the pressure in the lube circuit
exceeds 45 psi, the lube relief valve opens and
dumps the excess flow to the transmission sump.
This condition is normal when the transmission is in
neutral with all lube shut-off washers closed and the
engine is at high idle.
Filtered oil from the filter assembly is directed to the

valve body located on the transmission. The flow of
oil is available for the proportional control valves and
clutch transmission. The flow of oil is available for the
proportional control valves and clutch engagement.
The pressure in the system is controlled by the main
regulator valve and is regulated to 270 psi at a flow
of 27 gpm. A small amount of this flow leaks through
the pilot orifices in the proportional control valves and
past the seal rings in the shafts when a clutch is
engaged. The balance of the flow is dumped by the
ENG 6-46750
May, 2003
Printed in Brazil
6002-9
CLUTCH SOLENOID VOLTAGE REQUIREMENTS
NOMINAL
24V
VOLTAGE
ALLOWABLE
VOLTAGE
2028V
CURRENT
DRAW NOMINAL
.6 AMP
CURRENT
DRAW MAX.
.7 AMPS
RESISTANCE
53 OHMS
3%
All checks must be made at the valve.
TEST SOLENOIDS
IMPORTANT: If a solenoid is removed from the
valve, it must be installed in the
same location.
NOTE: To determine the defective clutch is simply a

matter of elimination. For example, if the gear
selected uses solenoids 1 and A, and low
pressure is indicated, select another clutch
that uses one of those solenoids. If pressure
is good, then the solenoid or clutch not
selected is the one that is bad.
To confirm that this is the faulty circuit, select
another clutch that uses this solenoid, to
assure that the discrepancy is actually in this
solenoid or clutch.
ENG 6-46750
1. Select solenoids 1 and A.

If low pressure exists, then solenoid or clutch 1 or A
is defective.
2. Select solenoids 2 and A.
If pressure is OK, then solenoid or clutch 1 is
defective.
3. Select solenoids 1 and B.
If low pressure exists, then this confirms solenoid or
clutch 1 is defective.
May, 2003
Printed in Brazil
6002-10
SOLENOID VALVE OPERATION

Before troubleshooting the electric circuit of the valve,
the chart shows what solenoids are charged when that
gear is selected.
DF SERIES EIGHT SPEEDS FORWARD AND FOUR REVERSE
DF 8/4
Gear Engage
F 8th . . . . .
F 7th . . . . .
F 6th . . . . .
F 5th . . . . .
F 4th . . . . .
F 3rd . . . . .
F 2nd . . . . .
F 1st . . . . .
Neutral
R 1st . . . . .
R 2nd . . . . .
R 3rd . . . . .
R 4th . . . . .
ENG 6-46750
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Solenoid Charged
2 and D
1 and D
2 and B
1 and B
2 and C
1 and C
2 and A
1 and A
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3
3
3
3
and
and
and
and
A
C
B
D
May, 2003
Printed in Brazil
6002-11
SUCTION LEAK TEST

Some indications of a suction leak include:
Erratic oil pressure. Look for rapid fluctuation of
gauges.
Pump and filter hoses jumping.
Excessive air entrainment in the transmission oil.
A long prime time (time elapsed from engine start to
an indication of pump pressure).
3. Start the engine.

4. Check for erratic oil pressure.
5. If any of the above conditions are corrected by this
procedure, a suction leak exists.
NOTE: Check suction tube fitting.

1. Fill to normal level with transmission fluid.
NOTE: See PRESSURE AND TEMPERATURE

CHECK PORTS (6003-44) for port location.
2. Install a 21 bar (300psi) pressure
gauge in the pressure port.
ENG 6-46750
IMPORTANT: Drain the transmission to the correct

level after the test. Failure to do so
will result in poor performance and
over heating.
6. Verify the level of transmission fluid and correct if
is necessary.
May, 2003
Printed in Brazil
6002-12
YZ738
-UN-10DEC93
8-4 POWER FLOW FORWARD SPEEDS
1st Gear - 1A, 2nd Gear - 2A
ENG 6-46750
3rd Gear - 1C, 4th Gear - 2C
May, 2003
Printed in Brazil
6002-13
YZ740
-UN-10DEC93
8-4 POWER FLOW FORWARD SPEEDS

(CONTINUED)
5th Gear - 1B, 6th Gear - 2B
ENG 6-46750
7th Gear - 1D, 8th Gear - 2D
May, 2003
Printed in Brazil
6002-14
YZ742
-UN-10DEC93
8-4 POWER FLOW REVERSE SPEEDS
R1 Gear - 3A
ENG 6-46750
R2 Gear - 3C
May, 2003
Printed in Brazil
6002-15
YZ744
-UN-10DEC93
8-4 POWER FLOW REVERSE SPEEDS

(CONTINUED)
R3 Gear - 3B
ENG 6-46750
R4 Gear - 3D
May, 2003
Printed in Brazil
6002-16
TROUBLESHOOT TRANSMISSION SYSTEM

MALFUNCTIONS
Symptom
Problem
Solution
Erratic oil pressure.
Low oil level.
Add oil to proper level.
Suction tube fitting
Replace O-ring fitting.
Suction manifold O-ring not sealing.
Replace O-ring.
Foreign object in suction port.
Remove object and check for other

contamination.
Sticking main regulator valve.
Replace main regulator valve.
Faulty spring.
Sticking main regulator valve.
Control valve body gasket leaking.
Replace gaskets.
Charge pump defective.
Replace pump.
Internal disconnect seal damage or

installed incorrectly.
Replace seal and install correctly.
Faulty main regulator valve.
Replace regulator assembly.
Control valve body cracked.
Replace control valve body.
Contaminated proportional solenoid.
Replace proportional solenoid.

*Check suction screen for
contamination.
Broken wire to one solenoid, or

dirty connection.
Repair wire.
Broken seal ring on input end of

clutch assembly.
Replace seal ring.
Bore sleeve worn.
Replace bore sleeves.
Outer or inner piston seal leaking.
Replace seals.
Failed transmission control valve
Inspect transmission control valve

for external leakage, Remove
control valve. Inspect or replace
gasket.
Leakage in clutch piston or seal

ring.
Air check to confirm leak.
Excessive oil pressure.
Low oil pressure in all gears.
Low pressure in one gear but all

right in other gears.
Transmission System Pressure is

Low (One or Two Gears)
Continued on next page
ENG 6-46750
May, 2003
Printed in Brazil
6002-17
Symptom
Problem
Solution
Solenoid valve malfunction
Check for a transmission fault code

on monitor, then check solenoids
using monitor diagnostics.
Hose bends too sharp.
Reroute hoses.
Defective hose.
Replace hose.
Main regulator valve faulty.
Change valve and change filter and

oil.
System plumbing incorrect.
Correct plumbing.
Filter O-ring faulty.
Replace filter
Incorrect type of oil
Change oil
High oil level
Transmission overfilled or hydraulic

pump seal leaking.
Low oil level
Add oil
Air leak on suction side of pump
Check oil pickup tube on inside of

transmission.
Blows oil out of breather or

dipstick tube.
Transmission over filled with oil.
Establish proper oil level. Check

front seal on auxiliary driven
hydraulic pump if equipped.
Vehicle will not move
Fault code problem
Check fault codes to define

problem.
Voltage to wrong solenoids on

control valve. (See schematic.)
Check wiring and connecters.
Filter or filter oil lines blow out.
Foaming Oil
ENG 6-46750
May, 2003
Printed in Brazil
6002-18
Symptom
Excessive noise.
Machine Creeps In Neutral
Transmission Clutch Slippage
Problem
Solution
No voltage to all solenoids.
Check wiring, controller and

connecters.
Voltage to more than two solenoids.
Check wiring and controller.
Proportional solenoid stuck.
Replace solenoid.
Failed shift switch
Check that basic display window

shows correct gear when shift
switch is moved.
Check Inching Pedal.
Replace Switch or wiring.
Charge pump defective.
Replace pump.
Excessive backlash in gear train.
Replace bearings and inspect for

defective gears.
Auxiliary driven pump bad.
Remove pump and check for noise.
Worn parts or damage in

transmission
Remove transmission suction

screen. Inspect for metal particles.
Warped disks and plates in clutch

pack of transmission.
Check transmission
Control valve leakage
Do transmission leakage test
Plugged screen on solenoid valve
Remove solenoid valve and clean.
Low oil level
Add oil.
Wrong oil grade
Change oil.
Restricted transmission pump

suction screen.
Remove and clean screen.
Leak in transmission control valve

or gasket
Remove valve and inspect gaskets.
ENG 6-46750
May, 2003
Printed in Brazil
6002-19
Symptom
Problem
Solution
Low transmission pump flow due to

worn pump
Do transmission pump flow test.
Stuck solenoid valve
Check wiring to solenoid valve.

Remove and inspect solenoid valve.
Transmission overheating.
ENG 6-46750
Oil level too high.
Establish proper oil level. Check

front seal on auxiliary driven
hydraulic pump if equipped.
Engine overheating.
Check engine coolant.
Water lines defective on heat

exchanger.
Replace lines.
Heat exchanger dirty.
Clean heat exchanger.
Clutch slipping.
Check clutch pressure.
May, 2003
Printed in Brazil
6002-20
POWERSHIFT
TROUBLESHOOTING-INTERNAL
DISCONNECT MODELS ONLY
Symptom
Problem
865 All wheel drive will not engage. Solenoid stuck open. Voltage
applied all the time.
865 All wheel drive will not

disengage.
Repair or replace solenoid. Check

wiring diagram and connecters.
Damaged or missing disconnect

retainer spring.
Replace or install disconnect

retainer spring.
Bleed port blocked.
Check for proper installation of

gasket and solenoid cap or
contamination.
No power to solenoid, solenoid

inoperative.
Check valve installed backwards.
ENG 6-46750
Solution
Check for electric power to solenoid

- check wiring and connecters if
O.K., replace solenoid.
Install check valve properly.
May, 2003
Printed in Brazil
Transmission Control Unit
6002-21
SPECIFICATIONS
Item
Measurement
Specification
J1 connector-to-TCU
Torque
0.81.5 Nm (7.113.3 lb-in)
J2 connector-to-TCU
Torque
0.81.5 Nm (7.113.3 lb-in)
J3 connector-to-TCU
Torque
0.81.5 Nm (7.113.3 lb-in)
Diagnostic indicator
Mounting dimensions
50.8 mm (2 in) diameter hole with

88.9 mm (3.5 in) clearance behind
front face of indicator.
TROUBLESHOOTING INTRODUCTION
This introduction is written to initiate an understanding
of a strategy which can be used toward solving
problems in the driveline system. The preferred
technique used in solving problems is to exchange
components. However, a very important element
necessary to the timely and successful conclusion of
this activity is the selection of the malfunctioning
component. An understanding of the total system and
an elimination process leading to the component is
absolutely necessary before starting the exchange
activity. The transmission system as installed consists
of the following components linked together to form a
functioning system.
Electronic gear selector

Wiring harness
Transmission control unit (TCU)
Magnetic pickups (Speed sensors)
Temperature sensor
Inching pedal
Gear/Diagnostic indicator or CCD display
Transmission control valve
Transmission hydraulic system (pump, relief
valves, lines, etc.)
Transmission mechanical system (clutches,
gears, shafts, seals, etc.)
ENG 6-46750
The best strategy in a troubleshooting plan is to

reduce the random exchange of components by
carefully analyzing the symptoms and then conducting
tests which will help determine which component in
the system is likely to be the problem. The technician
should use the above component list as a guide in
locating the problem.
Because the TCU is a relatively complex and
unfamiliar component, it is often the first component
targeted for exchange. However, TCU malfunctions
are relatively rare. In addition, the TCU has internal
diagnostics capabilities which are usually helpful in
isolating an operational problem. If the TCU responds
to commands and does not provide a diagnostic code
indicating an internal TCU error, the problem being
internal to the TCU is unlikely.
May, 2003
Printed in Brazil
6002-22
THEORY OF OPERATION
The purpose of the Transmission Control Unit (TCU)

is to control the functions of the transmission.
Upshifting, downshifting, control of the proportional
solenoids and capability to communicate with a panel
mounted gear/diagnostic indicator are the main
functions. The transmissions performance is
determined by the various inputs to the TCU. Based
upon these inputs, the TCU commands the
transmission so that maximum performance can be
achieved under the present operating conditions. All
functions of the TCU are under software control. Park
Brake Solenoid function is connected to the TCU,
however it is not controlled by the TCU or software.
Operation begins when the vehicles ignition is
switched to the on position, supplying electrical power
to the TCU and related system components from the
vehicles power source. The TCU now begins
monitoring all inputs and outputs. If a known conflict
in inputs or a fault condition is detected, the TCU will
command the transmission to stay in neutral
regardless of the shift lever position. A flashing error
code will be displayed on the gear/diagnostic
indicator, and will remain displayed until the error has
been resolved and the shift lever cycled back through
the neutral or park position.
ENG 6-46750
If no error conditions are detected, based upon a

combination of inputs from the shift lever and other
applicable inputs, the TCU will select the proper
transmission gear and command the transmission to
shift to this gear. The gear/diagnostic indicator will
now show the actual transmission gear.
The TCU Module uses electrohydraulic proportional
valves to control the operation of the transmission.
The solenoids controlling the transmission clutches
(solenoids A through D & 1 through 4) are driven by
a signal that produces proportional pressure/flow
changes. During modulation, the solenoids are started
out with a low duty cycle and ramped up to full on.
The initial duty cycle is dependent upon several
factors and is not a preset value. The process of
modulating these clutches greatly enhances shift
quality.
May, 2003
Printed in Brazil
6002-23
CALIBRATION
Reasons to Calibrate
Matches Transmission Control Unit (TCU) to
Transmission. Default clutch fill and hold values are
placed in the TCU at the factory. Calibration changes
these values to match a particular transmission.
Reduces Impact Of Manufacturing Tolerances. Since
the clutch fill and hold values are for a particular
transmission, adjustments for differences in parts due to
manufacturing tolerances are automatic.
Provides For Consistency Between Machines. The
calibration routine makes sure each transmission clutch
starts from the same spot just prior to clutch
engagement.
When to Calibrate:
1. If solenoid valve assemblies are changed.
2. After repairs involving transmission clutches.
3. If TCU is replaced.
4. If shift quality deteriorates.
ENG 6-46750
May, 2003
Printed in Brazil
6002-24
CLUTCH CALIBRATION: EIGHT FORWARD SPEEDS AND FOUR REVERSE

Transmissions Eight Forward Speeds and Four
Reverse.
IMPORTANT: Attempting to calibrate with sump
temperature below minimum
calibration temperature (90F)
will trigger the warm-up mode.
This mode will show --- on the
display as the transmission warms
to the minimum calibration
temperature at which time the
calibration process
will
automatically begin. Temperatures
below 50F will result in sump
temperature too cold error 100.
1. Bring the transmission oil temperature up to 140
to 160F (60 to 71C) for optimum calibration.
5. Start and hold the engine speed at 1600 RPM.

The engine governor must hold the engine speed
50 RPM.
6. Move the shift handle to the Forward position.
7. During the first few seconds of the calibration
process, the display will show --- while testing the
cylinder speed and response.
8. At this time the Clutch calibration process starts.
a. Directional and Speed Clutch Holds. The display
will show C1H, C2H, C3H, CAH, CBH, CCH and
CDH while acquiring the respective hold time of
each clutch.
b. Directional and Speed Clutch Fills. The display will
show C1F, C2F, C3F, CAF, CBF, CCF and CDF
while acquiring the respective fill time of each
clutch.
2. With the vehicle ignition off, apply the park brake.

3. Plug a jumper plug (which connects pin A to pin B)
in the calibration plug (s16) on the vehicle harness.
9. The display will show END when the routine is

finished. At that time move the shift handle back to
the Neutral position.
IMPORTANT: Any errors that appear during

calibration will cause the procedure
to terminate, and you will have to
start the calibration over from the
beginning.
10. Shut the vehicles ignition OFF, which will power

down the TCU.
4. Power up the TCU by turning on the vehicle

ignition. The display should show CAL.
The calibration is complete.
ENG 6-46750
11. Remove the jumper plug from the calibration plug

(S16).
May, 2003
Printed in Brazil
6002-25
SYSTEM COMPONENTS
1. Transmission control unit (TCU)

2. Engine speed magnetic pickup sensor (input
speed)
3. Cylinder magnetic pickup sensor (MPU)
4. Output speed magnetic pickup sensor (MPU)
5. Electronic gear selector
6. Temperature Sensor
7. Gear/Diagnostic Indicator
8. Inching Pedal
9. Proportional Valves
ENG 6-46750
May, 2003
Printed in Brazil
6002-26
COMPONENT FUNCTIONS
Basic Components
1. Transmission Control Unit (TCU)
FUNCTION
The TCU is the brain of the system. It is responsible
for the logic, computation, and decision making
processes of the transmission based on calculations.
How the TCU performs is determined by software
programmed into the TCUs memory. This software is
developed to meet the requirements of the vehicle
manufacturer, and is based on a vehicle performance
analysis. It is application specific, therefore TCUs from
different vehicles are not interchangeable. TCUs can only
be interchanged on vehicles which are identical in all
ways (same engine/drivetrain combination, same wiring,
same shift lever, same vehicle voltage, etc.)
MOUNTING
The TCU must be mounted inside the vehicle cab or
other enclosed area which will not exceed ambient
temperature range (-40C to +85C). It must be mounted
to ensure good electrical grounding between the TCU
and the vehicle chassis, although a ground wire from
battery negative to the TCU is required. It must not be
mounted by any method which would isolate the TCU
from the vehicle chassis. If rubber mounted for shock
protection, a grounding strap must be utilized to ensure
proper grounding.
IMPORTANT: Do not weld on vehicle with battery and
TCU connected or the WARRANTY
WILL BE VOID.
IMPORTANT: The only way to adequately protect the
TCU from damage caused by high
voltage and amperage is to completely
remove all three wiring harness
connectors (J1, J2 and J3) and any
ground strap from the TCU prior to
welding. Disconnecting the battery
supply alone is not sufficient to protect
the TCU from ground voltage feeding
back through the wiring harness.
ENG 6-46750
May, 2003
Printed in Brazil
6002-27
2. Engine Speed Magnetic Pickup Sensor (input speed).

The engine speed magnetic pickup (A) reads engine
RPM by measuring the number of pulses per minute
generated from the teeth of the charge pump idler gear,
which is in mesh with the input gear.
Input RPM is calculated by pulses per minute divided by
the number of teeth on the input gear.
CONNECTOR PINOUT
SIGNAL DESCRIPTION
SENSOR PIN
TRANS CONNECTOR PIN
TCU PIN
ENGINE MPU
J6-29
J1-B1
ENGINE MPU GND
J6-28
J1-C2
3. Cylinder Magnetic Pickup Sensor (MPU)

The cylinder speed magnetic pickup (C) reads cylinder
RPM by measuring the number of pulses per minute
generated from the teeth of the cylinder gear.
Cylinder RPM is calculated by pulses per minute divided
by the number of teeth on the cylinder gear.
CONNECTOR PINOUT
ENG 6-46750
SIGNAL DESCRIPTION
SENSOR PIN
TRANS CONNECTOR PIN
TCU PIN
CYLINDER MPU
J6-9
J1-B2
CYLINDER MPU GND
J6-16
J1-C2
May, 2003
Printed in Brazil
6002-28
4. Output Speed Magnetic Pickup Sensor (MPU)

The output speed magnetic pickup (E) reads output RPM
by measuring the number of pulses per minute
generated from the teeth of the sixth stage gear. The
sixth stage gear is on the same shaft as the sixth stage
pinion which drives the output gear.
CONNECTOR PINOUT
ENG 6-46750
SIGNAL DESCRIPTION
SENSOR PIN
TRANS CONNECTOR PIN
TCU PIN
OUTPUT MPU
J6-18
J1-A3
OUTPUT MPU GND
J6-30
J1-C2
May, 2003
Printed in Brazil
6002-29
5. Electronic Gear Selector
The electronic gear selector handle is a Bump

handle which operates in an I pattern with a
horizontal bar in the middle. Neutral position is in the
middle of the pattern along the horizontal bar. While
in neutral, the handle can be moved right to request
a higher pre-selected gear or left to request a lower
pre-selected gear.
The handle can be moved forward to request a

forward gear or moved back to request a reverse
gear. The release ring under the handle knob must
be pulled up to release the neutral lock.
The handle can be moved back to the neutral
position at any time without moving the release ring
under the handle knob.
When in the forward or reverse position the handle

can be bumped to the right to request an upshift or
to the left to request a downshift.
ENG 6-46750
May, 2003
Printed in Brazil
6002-30
6. Temperature sensor
The temperature sensor (A) is used to determine
transmission fluid temperature.
SIGNAL DESCRIPTION
SENSOR PIN
TRANS CONNECTOR PIN
TCU PIN
TEMPERATURE SENSOR
J6-25
J1-C3
TEMPERATURE SENSOR GND
J6-24
J1-D1
7. Gear/diagnostic indicator or CCD display

The TCU and gear/diagnostic indicator can be used on
both 12 and 24 volt applications.
CONNECTOR PINOUT
SIGNAL DESCRIPTION
CONNECTOR AND PIN
TCU PIN
+12V/+24V
S5-A
J3-A1
GROUND
S5-B
J2-F1
CCD BUS+
S5-C
J2-E2
CCD BUS-
S5-D
J2-E3
NOTE: Mounting requires a 2 inch diameter hole with

88.9 mm (3.5 in) clearance behind the front face.
ENG 6-46750
May, 2003
Printed in Brazil
6002-31
8. Inching Pedal
The inching pedal provides the operator with a device for
controlling modulation of the transmission clutches when
desired. With the pedal fully depressed, the transmission
remains in neutral regardless of shift lever position.
Releasing the inching pedal engages the transmission.
The more the pedal is released, the more the clutches
engage causing the vehicle to inch. When the pedal is
fully released, the transmission clutches are fully
engaged.
CONNECTOR PINOUT
SIGNAL DESCRIPTION CONNECTOR/PIN
TCU PIN
VAGND
(ANALOG GROUND)
T11-B
J1-G1
VAREF
(ANALOG VOLTAGE
REFERENCE)
T11-C
J1-F2
PEDAL POSITION
T11-A
J1-F3
TOC INPUT
(TOP OF CLUTCH)
NOT BOC INPUT
(BOTTOM OF CLUTCH)
+ 24V
ENG 6-46750
J1-K3
T11-E
J1-K2
T11-F
J2-F2
May, 2003
Printed in Brazil
6002-32
TRANSMISSION ANALOG INCHING

The pedal position output, or inching signal, comes
from the 2.5K-ohm potentiometer attached to the
pedal. The potentiometers angle changes
proportionally with the degree of pedal depression.
The potentiometer has an analog ground (VAGND,
pin T11-B) signal and a 5V DC reference (VAREF,

pin T11-C), both provided by the TCU. The pedals
output signal to the TCU (pin T11-A) varies between
the ground and reference levels. The output signal
increases as the pedal is depressed.
A normally closed switch mechanically linked to the

pedal provides the NOT BOTTOM OF CLUTCH
signal (pin T11-E) to the TCU. The switch contacts
open when the pedal is fully depressed, and are
closed for all other pedal positions. The TCU sees an
active (+24V) signal on J1-K2 whenever the
pedal is NOT at the bottom of its travel range.
There is no connection to inching pedal pin D (pin

T11-D).
ENG 6-46750
May, 2003
Printed in Brazil
6002-33
The TVP (Transient Voltage Protection) Module is

available in 24V version.
It has two important functions:
Supply electrical power to the system.
Protect the electrical system against electrical
conditions that might otherwise be potentially
damaging, such as load dump and reverse battery
protection.
Protection is provided only when the ignition switch is
on, thus energizing an internal relay which provides an
electrical connection between the vehicle battery and the
protective device inside the TVP.
ENG 6-46750
May, 2003
Printed in Brazil
6002-34
J1 CONNECTOR
NOTE: Connector pinouts reference wiring harness

diagram in this group always reference the vehicle
manufacturers wiring harness diagram for your
application.
CONNECTOR PINOUT
A1Main battery 1 (TCU Power, +24V)
A2Ground 1
A3Output magnetic pickup sensor input (frequency
input)
B1Engine magnetic pickup sensor input (frequency
input)
B2Cylinder magnetic pickup sensor input (frequency
input)
B3Spare magnetic pickup sensor input (frequency
input)
C1F Flow (input)
C2Magnetic pickup sensor ground
C3Temperature sensor (analog voltage input)
D1Temperature sensor ground
D2Rear-steer HI (voltage reference output)
D3Rear-steer position (analog voltage input)
E1Rear-steer LO (voltage reference output)
E2Load sense HI (voltage reference output)
E3Load sense (analog voltage input)
Input and Output are defined relative to the TCU.
ENG 6-46750
F1Load sense LO (voltage reference output)

F2Inching pedal HI (voltage reference output)
F3Inching pedal position (analog voltage input)
G1Inching pedal LO (voltage reference output)
G2Spare ground
G3Spare ground
H1Spare ground
H2UPSHIFT (Shift code E), (digital input)
H3DOWNSHIFT (Shift code D), (digital input)
J1FORWARD (digital input)
J2REVERSE (digital input)
J3Spare input (digital input)
K1NOT PARK (digital input)
K2NOT BOTTOM OF CLUTCH (digital input)
K3TOP OF CLUTCH (digital input)
Mating connector for J1 is:
Metri-Pack 150 series 30 way sealed P2S connector
Delphi/Packard part number: 12034398
Mating terminals for J1 are Delphi/Packard
terminals: 12103881
Tighten connector to TCU 0.81.5 Nm (7.113.3
lb-in)
May, 2003
Printed in Brazil
6002-35
J2 CONNECTOR

diagram in this group always reference the vehicle
application.
CONNECTOR PINOUT
A1Neutral (digital input)
A2Not neutral (Shift code B), (digital input)
A3Brake cutoff (Shift code C), (digital input)
B1Program (Shift code A), (digital input)
B2Start (digital input)
B3Park or park brake pressure (digital input)
C1Auto / manual mode select (digital input)
C2Calibrate (digital input)
C3Disconnect (digital input)
D1CAN HI (communication input/output)
D2CAN LO (communication input/output)
D3RS232 TxD (serial communication output)
E1RS232 RxD (serial communication input)
E2CCD Bus+ (gear / diagnostic indicator)
(communication input/output)
E3CCD Bus- (gear / diagnostic indicator)

(communication input/output)
F1Bus ground for communication lines
F2 +24 supply voltage output (supply voltage
output)
F3 +24 supply voltage output (supply voltage
output)
Delphi/Packard Metri-Pack 150 series 18 way
sealed P2S connector
terminals: 12103881
lb-in)

ENG 6-46750
May, 2003
Printed in Brazil
6002-36
J3 CONNECTOR

diagram in this group, reference the vehicle
application.
G1 Not Used
G2 Not Used
G3 Not Used
H1 Not Used
CONNECTOR PINOUT (APPLICATION

DEPENDENT)
H2Disconnect solenoid (PWM output)

H3Disconnect solenoid return (current sense input)
J1Rear PTO solenoid (PWM output)
J2Rear PTO solenoid return (current sense input)
J3Front PTO solenoid (PWM output)
K1Front PTO solenoid return (current sense input)
K2Ground
K3Ground
A1Main battery 2 (TCU power +24V)

A2Ground 2
A3Solenoid 1 (PWM output)
B1Solenoid 1 return (current sense input)
B2Solenoid 2 (PWM output)
B3Solenoid 2 return (current sense input)
C1Solenoid 3 (PWM output)
C2Solenoid 3 return (current sense input)
C3Solenoid 4 (PWM output)
D1Solenoid 4 return (current sense input)
D2Solenoid A (PWM output)
D3Solenoid A return (current sense input)
E1Solenoid B (PWM output)
E2Solenoid B return (current sense input)
E3Solenoid C (PWM output)
F1Solenoid C return (current sense input)
F2Solenoid D (PWM output)
F3Solenoid D return (current sense input)

Delphi/Metri-Pack 150 series 30 way sealed P2S
connector
terminals: 12103881
lb-in)

ENG 6-46750
May, 2003
Printed in Brazil
6002-37
J4 CONNECTOR
BUMP SHIFTER PINOUT
NOTE: Letters A through J are J6 Pinouts.

Number,letter-number,letter callouts (example
J3-A1) are TCU callouts.
AJ3-A1 +24 out
ENG 6-46750
BJ2-A2NOT NEUTRAL (shift code B)

CJ2-A1NEUTRAL
DJ1-H3DOWNSHIFT (shift code D)
EJ1-H2UPSHIFT (shift code (E)
FJ1-J2REVERSE
GJ1-J1FORWARD
HJ1-A2Ground
JS1-ANeutral start
May, 2003
Printed in Brazil
6002-38
J6 CONNECTOR
CONNECTOR PINOUT
NOTE: Numbers 1 through 31 are J6 Pinouts.

Number,letter-number,letter callouts (example
J3-B1) are TCU callouts.
1J3-B1Solenoid 1 return
2J3-A3Solenoid 1 output
3J3-B2Solenoid 2 output
4J3-C1Solenoid 3 output
5J3-C3Solenoid 4 output
6J3-D1Solenoid 4 return
7J3-F3Solenoid D return
8J3-F2Solenoid D output
9J1-B2Cylinder magnetic pickup sensor
10J3-D2Solenoid A output
11J3-E2Solenoid B return
12J3-E1Solenoid B output
13J3-H2Disconnect solenoid output
ENG 6-46750
14J3-G3 Not Used

15J3-B3Solenoid 2 return
16J1-C2Magnetic pickup sensor ground
17J3-D3Solenoid A return
18J1-A3Output magnetic pickup sensor
19J3-C2Solenoid 3 return
20J1-A1Park brake pressure switch supply
(+24V)
21J2-B3Park brake pressure switch
22J3-F1Solenoid C return
23J3-E3Solenoid C return
24J1-D1Temperature sensor ground
25J1-C3Temperature sensor
26J3-H3Disconnect solenoid return
27J3-H1 Not Used
29J1-B1Engine speed magnetic pickup sensor
31J1-A2Magnetic pickup sensor ground
May, 2003
Printed in Brazil
6002-39
TRANSMISSION WIRING HARNESS 1 OF 4
NOTE: Letters A,B,C,D,E,F are labels to link to the

next page.
Wiring harness is + 24Volts grader 845 / 865
ENG 6-46750
May, 2003
Printed in Brazil
6002-40
NOTE: The letters G,C,E link to the next page.

ENG 6-46750
May, 2003
Printed in Brazil
6002-41
Not Used
Not Used
Not Used
Not Used
NOTE: The letter C links to the next page.

ENG 6-46750
May, 2003
Printed in Brazil
6002-42
Not Used
Not Used
Not Used
Not Used
NOTE: Letters C is a label to link the previous page.

ENG 6-46750
May, 2003
Printed in Brazil
6002-43
FUNCTION OF PROPORTIONAL VALVES

The proportional valve is pilot operated. It has a main spool that is forced in one direction by a spring and clutch
pressure. In this position the valve is off, meaning that system pressure is shut off from the clutch actuation line and the
clutch actuation line is open to sump to insure that there is 0 PSI in the clutch.
To apply pressure to the clutch, the spool must be moved against the spring and clutch pressure. This shuts off the opening
from the clutch to the sump and opens the system pressure to the clutch. The pressure then forces the clutch piston against
the friction plates and applies the clutch.
In a proportional valve the main spool is able to be forced part way open to provide a partial pressure to the clutch. In this
position the system pressure is partially open to the clutch while the clutch is also partially open to sump. As the system
pressure is open more, the opening to sump is shut off more, increasing pressure in the clutch.
The pilot section is the part of the valve that forces the spool open against the spring. It is a sealed chamber into which
the main spool slides in and out of like a hydraulic cylinder. There are two openings into this chamber. One is a small hole
which allows oil into the chamber from system pressure. The other hole allows the oil to flow out of the chamber. At this
point the pressure in the pilot section is near 0 PSI and is not enough force to move the spool against the spring.
The large hole is able to be shut off by a small poppet that is normally held away from the hole by the oil exiting the
cavity. It is forced shut against the outlet hole when the electric solenoid is turned on. This allows pressure to build up in
the pilot section. As the pressure builds up it forces the main spool against the spring and clutch pressure on the other end
and brings the valve on.
In a proportional valve the poppet in the pilot section can be controlled to any position between open and closed. The poppet
is controlled to an intermediate position by a variable magnetic force from the solenoid coil. In this position it is equally
opposed by the pressure in the cavity acting on the ball.
A variable force from the coil is created with a Pulse Width Modulated (PWM) signal. The PWM signal is a voltage that cycles
in the form of a square wave. The duty cycle is the percentage of the signal period that the voltage is on. For example, a
duty cycle of 25% at a frequency of 50 cycles per second, (a 20 millisecond period) would be full voltage for 5 milliseconds
and 0 volts for 15 milliseconds. In an analog valve the frequency used is high enough that the coil then averages out the
current to some intermediate value. This average varies with the duty cycle of the PWM signal, and controls the position of
the poppet. If the poppet is partially closed, the pressure in the pilot section is at an intermediate pressure between 0 PSI
and system pressure. This moves the main spool to a position where the spring force and clutch pressure increases to match it,
holding the main spool in a partially displaced position that provides a proportional pressure to the clutch.
ENG 6-46750
May, 2003
Printed in Brazil
6002-44
PROPORTIONAL VALVES
CONNECTOR PINOUT
SIGNAL
DESCRIPTION
Transmission Eight Speeds Forward and

Four Reverse
TRANSMISSION
CONNECTOR
PIN
TCU
PIN
SOLENOID 1
J6-2
J3-A3
SOLENOID 1 RETURN
J6-1
J3-B1
SOLENOID 2
J6-3
J3-B2
SOLENOID 2 RETURN
J6-15
J3-B3
SOLENOID 3
J6-4
J3-C1
SOLENOID 3 RETURN
J6-19
J3-C2
SOLENOID 4
J6-5
J3-C3
SOLENOID 4 RETURN
J6-6
J3-D1
SOLENOID A
J6-10
J3-D2
SOLENOID A RETURN
J6-17
J3-D3
SOLENOID B
J6-12
J3-E1
SOLENOID B RETURN
J6-11
J3-E2
SOLENOID C
J6-23
J3-E3
SOLENOID C RETURN
J6-22
J3-F1
SOLENOID D
J6-8
J3-F2
SOLENOID D RETURN
J6-7
J3-F3
ENG 6-46750
GEAR ENGAGED
F 8th .
F 7th .
F 6th .
F 5th .
F 4th .
F 3rd .
F 2nd.
F 1st .
Neutral
R 1st .
R 2nd.
R 3rd .
R 4th .
ACTIVE SOLENOIDS
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2
1
2
1
2
1
2
1
and
and
and
and
and
and
and
and
D
D
B
B
C
C
A
A
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3
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and
and
and
and
A
C
B
D
May, 2003
Printed in Brazil
6002-45
SYSTEM ERRORS
The TCU has the ability to detect various
discrepancies.
Possible errors are:
Pinched or broken wiring

Shorted or open coils
Bad connections
Shorted wiring (to either ground or vehicle voltage.)
Illogical input from the handle
Magnetic pickup sensor failures
All errors are neutral recoverable, unless the condition

causing the error prevents the TCU from detecting a
legal neutral condition. After a neutral recovery, the
shift lever may be placed back into a legal forward or
ENG 6-46750
reverse position. If the condition causing the error still

exists, the error will again be detected and displayed.
CAUTION: How the TCU handles errors

depends upon what type and which error
has occurred. The TCU can immediately
shift the transmission to neutral in the
event of an error. The transmission will
remain in neutral until the error has been
resolved and the shift lever cycled to
neutral and back to the desired position.
The TCU retains the last eight non-repeating error

codes in nonvolatile memory in the order in which
they have occurred. These codes are available for
future retrieval.
May, 2003
Printed in Brazil
6002-46
ANALOG TCU DIAGNOSTIC CODES

NOTE: The following is a list of the diagnostic codes
that may be generated by the TCU.
Diagnostic Code: 20
Description: Solenoid 1 cannot get up to requested
current.
Probable Cause: Open or short to ground in
Solenoid 1 circuit from output pin J3-A3 to return pin
J3-B1.
Diagnostic Code: 21
current.
Solenoid 2 circuit from output pin J3-B2 to return pin
J3-B3.
Diagnostic Code: 22
current.
Solenoid 3 circuit from output pin J3-C1 to return pin
J3-C2.
Diagnostic Code: 25
Description: Solenoid B cannot get up to requested
current.
Solenoid B circuit from output pin J3-E1 to return pin
J3-E2.
Diagnostic Code: 26
Description: Solenoid C cannot get up to requested
current.
Solenoid C circuit from output pin J3-E3 to return pin
J3-F1.
Diagnostic Code: 27
Description: Solenoid D cannot get up to requested
current.
Solenoid D circuit from output pin J3-F2 to return pin
J3-F3.
Diagnostic Code: 28
Diagnostic Code: 23
Description: Solenoid E cannot get up to requested

current.

current.
Probable Cause: Open or short to ground in circuit

from output pin J3-G1 to return pin J3-G2.

Solenoid 4 circuit from output pin J3-C3 to return pin
J3-D1.
Diagnostic Code: 29 Not Used
Diagnostic Code: 24
Description: Solenoid A cannot get up to requested
current.
Solenoid A circuit from output pin J3-D2 to return pin
J3-D3.
ENG 6-46750
May, 2003
Printed in Brazil
6002-47
Diagnostic Code: 30
Diagnostic Code: 35
Description: Solenoid 1 cannot drop to requested

current.
Description: Solenoid B cannot drop to requested

current.
Probable Cause: Short to positive in Solenoid 1

circuit from output pin J3-A3 to return pin J3-B1.
Probable Cause: Short to positive in Solenoid B

circuit from output pin J3-E1 to return pin J3-E2.
Diagnostic Code: 31
Diagnostic Code: 36

current.
Description: Solenoid C cannot drop to requested

current.

circuit from output pin J3-B2 to return pin J3-B3.
Probable Cause: Short to positive in Solenoid C

circuit from output pin J3-E3 to return pin J3-F1.
Diagnostic Code: 32
Diagnostic Code: 37

current.
Description: Solenoid D cannot drop to requested

current.

circuit from output pin J3-C1 to return pin J3-C2.
Probable Cause: Short to positive in Solenoid D

circuit from output pin J3-F2 to return pin J3-F3.
Diagnostic Code: 33

current.
circuit from output pin J3-C3 to return pin J3-D1.
Diagnostic Code: 34
Description: Solenoid A cannot drop to requested

current.
Probable Cause: Short to positive in Solenoid A
circuit from output pin J3-D2 to return pin J3-D3.
ENG 6-46750
May, 2003
Printed in Brazil
6002-48
Diagnostic Code: 40
Legal conditions are:
Probable Cause: Request for an undefined shift

being made.
1. NOT PARK active and NEUTRAL passive.

2. NOT PARK passive and NEUTRAL active.
Diagnostic Code: 41
Diagnostic Code: 45
Probable Cause: TCU has not seen a legal neutral
signal (input pin J2-A1) since initial power-up of
system.
Probable Cause: PARK (input pin J2-B3) is active

but NEUTRAL (input pin J2-A1) is passive at TCU.
Diagnostic Code: 42
Diagnostic Code: 48
Description: Bottom of Clutch input on J1-K2 is

passive.
Probable Cause: NOT PARK (input pin J1-K1) and

PARK (input pin J2-B3) are simultaneously active at
TCU.
Probable Cause: Input at J1-K2 must be connected

to system voltage on applications which do not utilize
inching.

1. NOT PARK active and PARK passive.
Diagnostic Code: 43
2. NOT PARK passive and PARK active.
PARK (input pin J2-B3) are both passive at TCU.
Diagnostic Code: 49
Probable Cause: Handle signal is park but PARK
PRESSURE (input pin J2-B3) is passive at TCU.
1. NOT PARK active and PARK passive.

2. NOT PARK passive and PARK active.
Diagnostic Code: 44
NEUTRAL (input pin J2-A1) are simultaneously
passive at TCU.
ENG 6-46750
1. PARK PRESSURE signal active while shift handle

is in park position.
2. PARK PRESSURE signal passive while shift
handle is in gear.
May, 2003
Printed in Brazil
6002-49
Diagnostic Code: 50
Diagnostic Code: 59
Probable Cause: UPSHIFT (input pin J1-H2) and

DOWNSHIFT (input pin J1-H3) are simultaneously
active at TCU.
Description: Invalid 5 bit selector code.

Probable Cause: Faulty gear selector/shift handle or
faulty wiring between selector and TCU.
Diagnostic Code: 51
Diagnostic Code: 60
Probable Cause: FORWARD (input pin J1-J1) and
REVERSE (input pin J1-J2) are simultaneously active
at TCU.
Diagnostic Code: 52
Probable Cause: FORWARD (input pin J1-J1) and
NEUTRAL (input pin J2-A1) and REVERSE (input pin
J1-J2) are simultaneously passive at TCU.
Description: Valve driver supply voltage (TCU pin

J3-A1) too low.
Probable Cause: Must be above 17 volts on
24 volt system.
Diagnostic Code: 80
Diagnostic Code: 54
Probable Cause: Engine MPU signal (input pin

J1-B1) missing or frequency is too low.
Probable Cause: Invalid requested gear calculation.
Diagnostic Code: 82
Diagnostic Code: 56
Probable Cause: Output MPU signal (input pin

J1-A3) missing or frequency is too low.
Probable Cause: NEUTRAL (input pin J2-A1) and

FORWARD (input pin J1-J1) are simultaneously
active at TCU.
1. NEUTRAL active and FORWARD passive.
2. NEUTRAL passive and FORWARD active.
Diagnostic Code: 57
Probable Cause: NEUTRAL (input pin J2-A1) and
at TCU.
1. NEUTRAL active and REVERSE passive.
2. NEUTRAL passive and REVERSE active.
Diagnostic Code: 58
Diagnostic Code: 84
Probable Cause: Illegal or undefined vehicle mode
code.
Diagnostic Code: 85
Probable Cause: PARK (input pin J2-B3) is active
but NEUTRAL (input pin J2-A1) is passive at TCU.
Diagnostic Code: 86
Probable Cause: Inching pedal TOP OF CLUTCH
signal (input pin J1-K3) is active but BOTTOM OF
CLUTCH (input pin J1-K2) is open.
Diagnostic Code: 87
Probable Cause: PARK (input pin J2-B3) and
FORWARD (input pin J1-J1) are simultaneously
active at TCU.
Probable Cause: START (input pin J2-B2) went

active at TCU disabling internal solenoid power.
START should be active only when ignition is in
START position and starter is cranking.
ENG 6-46750
May, 2003
Printed in Brazil
6002-50
Diagnostic Code: 88
Diagnostic Code: 98
Probable Cause: PARK (input pin J2-B3) and

at TCU.
Probable Cause: WHEELS-UP (input pin J1-H1) and

WHEELS-DOWN (input pin J1-H2) are both active.
Diagnostic Code: 99
Diagnostic Code: 89
Probable Cause: PARK (input pin J2-B3) and NOT
PARK (input pin J1-K1) are simultaneously passive at
TCU.
Probable Cause: Attempt to change wheels-up

wheels-down mode while in an out-of-neutral
condition.
Diagnostic Code: 100
Diagnostic Code: 90
Probable Cause: PARK (input pin J2-B3) and NOT
PARK (input pin J1-K1) are simultaneously active at
TCU.
Diagnostic Code: 91
Probable Cause: Seat switch (input pin J2-C3) and
NEUTRAL (input pin J2-A1) are simultaneously
passive at TCU.
Diagnostic Code: 92
Probable Cause: Engine speed is at or near
manufacturers warranty void level.
Diagnostic Code: 93
Probable Cause: CARRIER CAB and UPPER CAB
inputs are simultaneously active at TCU.
Diagnostic Code: 94
Probable Cause: CARRIER CAB and UPPER CAB
inputs are simultaneously passive at TCU.
Diagnostic Code: 95
Probable Cause: NEUTRAL (input pin J2-A1) is
passive while switching cab modes.
Diagnostic Code: 96
Probable Cause: Upper cab mode selected but
transmission gear is not a legal gear range for upper
cab mode.
Probable Cause: Sump temperature (input on J1-C3)

is too low for calibration.
Probable Cause: Engine speed is too high for
calibration.
Probable Cause: Engine speed is too low for
calibration.
Probable Cause: Output speed detected during
calibration.
Probable Cause: No cylinder speed detected during
calibration.
Probable Cause: Incorrect forward cylinder speed
ratio during calibration.
Probable Cause: Incorrect reverse cylinder speed
ratio during calibration.
Probable Cause: Cylinder speed will not drop below
the start count speed.
Diagnostic Code: 97
Probable Cause: Upper cab mode selected but
FORWARD NEUTRAL and REVERSE inputs are all
passive at TCU.
ENG 6-46750
May, 2003
Printed in Brazil
6002-51
Error: Clutch B fast fill time exceeds 300 ms.
Error: Holding clutch pressure exceeds 90 psi.
Error: Clutch C fast fill time exceeds 300 ms.
Error: Clutch 1 fast fill time exceeds 300 ms.
Error: Clutch D fast fill time exceeds 300 ms.
Error: Clutch hold pressure is above 90 psi.
Error: Clutch R fast fill time exceeds 300 ms.
Error: Clutch L fast fill time exceeds 300 ms.
Error: Clutch A fast fill time exceeds 300 ms.
Error: Clutch M fast fill time exceeds 300 ms.
ENG 6-46750
May, 2003
Printed in Brazil
6002-52
Probable Cause: Transmission temperature (J1-C3)

is too high.
Probable Cause: Clutch H fast fill time exceeds 300

ms.
Probable Cause: Engine MPU circuit (J1-B1) open.
Probable Cause: Attempt to calibrate with PARK

(input pin J2-B3) input passive at TCU. Park brake
must be set during calibration.
Probable Cause: Low air pressure.
Probable Cause: Cannot get shift constants from

EEPROM.
Probable Cause: Output MPU circuit (J1-A3) open.

Probable Cause: Analog inching voltage is too low.
Probable Cause: Temperature sensor circuit SENSE
(J1-C3) or GROUND (J1-D1) shorted or open.
Probable Cause: Analog input (J1-D3) shorted or
open.
Probable Cause: Analog inching voltage (J1-F3) is
too high.
Probable Cause: Group one enable low should be

high.
Probable Cause: Group two enable low should be
high.
Probable Cause: Group three enable low should be
high.
Probable Cause: Pointer in capcom20 gets too big.

Probable Cause: Vehicle system voltage (J3-A1) is
too high.
Probable Cause:Safety FET A failed OFF.
ENG 6-46750
May, 2003
Printed in Brazil
6002-53
Probable Cause: Safety FET A failed ON.
Probable Cause: EEPROM checksum error.
Probable Cause: Safety FET B failed OFF.
Probable Cause Code: Solenoid 11 cannot get up to

requested current.

Probable Cause: Safety FET B failed ON.

from output pin J3-H2 to return pin J3-H3.
Probable Cause: Safety FET C failed OFF.

requested current.

Probable Cause: Safety FET C failed ON.

from output pin J3-J1 to return pin J3-J2.
Probable Cause: Group one enable high should be

low.

requested current.

from output pin J3-J3 to return pin J3-K1.
Probable Cause: Group two enable high should be

low.
Probable Cause: Group three enable high should be
low.
ENG 6-46750

Probable Cause Code: Solenoid 11 cannot drop to
requested current.
Probable Cause: Short to positive in circuit from
output pin J3-H2 to return pin J3-H3.
May, 2003
Printed in Brazil
6002-54

requested current.
Probable Cause: CCD communications link failure

between master TCU and slave TCU (CCD BUS(J2-E3) and CCD BUS+ (J2-B2)).

output pin J3-J1 to return pin J3-J2.
requested current.

Probable Cause: This is a non-functional base TCU.
No application specific software has been
programmed into it.

output pin J3-J3 to return pin J3-K1.
ENG 6-46750
May, 2003
Printed in Brazil
6002-55
GLOSSARY
Analog: A signal which has a continuous range of
possible voltages.
Intershift Pause Time: The minimum time delay

between shifts. A value preprogrammed into the TCU.
Digital: A signal which consists of only two voltage

levelsusually 0 volts and +5 volts. On/Off type
signals are also considered to be digital.
Neutral Recoverable: The process where a detected

fault is maintained and displayed by the TCU until the
shift lever is cycled to neutral (park on some
systems) and the TCU detects the proper combination
of inputs for a legal neutral (park) condition, at which
time the displayed fault will be cleared. The fault
code will still be maintained in TCU memory for future
recall.
Active: The high voltage (+12V / +24V) state of a

digital input. Dependent upon vehicle system voltage.
Actual Gear: The actual physical gear of the
transmission, regardless of shift lever position or
controller operation.
Bus: Serial communications link which interconnects
intelligent electronic modules.
Limp-Home: A hardware function which allows
limited vehicle motion in the event of failure of certain
components.
Next Gear: The next gear the controller plans to

enter. The next gear will become the current gear if
no faults are detected and all conditions for entering
the next gear are met.
Nonvolatile Memory: Memory that retains its data
even though power to the system has been removed.
Passive: The low voltage (0V) state of a digital input.
Commanded Gear: The gear selected by the

combination of the shift lever position and the state of
the Forward, Reverse, Neutral, and Not Neutral
inputs. The destination gear.
Previous Direction: The direction of vehicle motion

before a shuttle shift is initiated.
Previous Gear: The previous current gear.
Current Gear: The gear the controller is currently

attempting to drive the transmission into by the
application of commands to the valves.
Downshift Inhibit: The prohibiting of downshifting, by
the TCU, to prevent harsh and abrupt shifts or
possible overspeed conditions of the engine. The
downshift will be inhibited until the current speed ratio
will permit the shift to take place.
Fault: An abnormal condition which results in a
perceived performance change or in a loss of function
which may result in performance loss or system
damage.
ENG 6-46750
Sequence Shift: The type of shift which consists of

shifting from a gear to an adjacent gear.
Sequential Shifting: Multiple sequence shifts with no
delay between shifts other than the programmed
intershift pause time.
Shuttle Shift: A shift to a gear in the opposite
direction of vehicle travel made by moving the shift
lever between the Forward and Reverse positions.
May, 2003
Printed in Brazil
6002-56
ABBREVIATIONS AND ACRONYMS USED IN TCU GROUP

TCU: Transmission Control Unit
V: Volt
PWM: Pulse Width Modulation
CYL: Cylinder
MPU: Magnetic Pickup Sensor
ENG: Engine
GND: Ground
TEMP: Temperature
RPM: Revolutions Per Minute
CAN: Controller Area Network
P: Park
SOL: Solenoid
DC: Direct Current
POT: Potentiometer
TOC: Top of Clutch
CCD: Chrysler Collision Detection
BOC: Bottom of Clutch
ENG 6-46750
May, 2003
Printed in Brazil
6003
Section
6003
TRANSMISSION
845 - 865 - 885 Grader

ENG 6-46760
Printed in Brazil
May, 2003
6003-2
TABLE OF CONTENTS 845 - 865

TRANSMISSION COMPONENT IDENTIFICATION . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION MOUNTING / SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHARGE PUMP . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIRECT DRIVE INPUT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
MAIN CASE FRONT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
GEAR RATIO GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
MAIN CASE REAR HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
BRAKE GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
REPLACE CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
ENG 6-46760
May, 2003
Printed in Brazil
6003-2
TABLE OF CONTENTS 885

TRANSMISSION COMPONENT IDENTIFICATION . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
TRANSMISSION MOUNTING / SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
CHARGE PUMP . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
DIRECT DRIVE INPUT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
MAIN CASE FRONT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
GEAR RATIO GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
MAIN CASE REAR HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
BRAKE GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
REPLACE CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
ENG 6-46760
January, 2003
Printed in Brazil
6003-3
DIRECT DRIVE TRANSMISSION COMPONENT IDENTIFICATION
ADirect drive input shaft

BFront cover assembly
CCharge pump group
DMain case front housing
EMain case rear housing
FDipstick gauge
GDipstick tube assembly
HDisk brake caliper assembly
IYoke Flange
ENG 6-46760
JBrake disk
KMagnetic pickup sensor
LSuction screen assembly
MOutput yoke fitting
NControl valve group
OAuxiliary pump drive
PFirst stage output shaft
QSuction Tube
RGround drive pump (Application dependent)
SMagnetic pickup sensor
May, 2003 Printed in Brazil
6003-4
TRANSMISSION LIFTING PROCEDURE

Use a lift sling similar to (A). It should hold the
transmission level without bending the lift hangers (B).
TRANSMISSION REPAIR STAND

NOTE: The repair stand (A) used in this manual is OTC
DIVISION part number 1735, capacity is 907 Kg
(2000)lbs.
OTC Division
Sealed Power Corporation
655 Eisenhower Drive
Owatonna, Mn 55060
When any other stand is used, consult the
Manufacturers instructions for mounting.
Approximate dry weights:
Model 845 - 865 = 545 Kg (1250 lbs).
Actual weights depend on the options included.
ENG 6-46760
May, 2003 Printed in Brazill
6003-5
MOUNTING DF SERIES TRANSMISSION TO

REPAIR STAND
NOTE: See Section No. 6002, Special Tools for Assembly
Stand Plate drawings.
REMOVE AND INSTALL INPUT HOUSING

MAGNETIC PICKUP SENSOR
1. Remove two cap screws (A), two lock washers (B),
two flat washers (C), cover (D), sensor (E) and O-ring
(F).
2. Clean and inspect for wear and damage.
INSTALL:
3. Lubricate new o-ring and install in reverse order.
REMOVE AND INSTALL CYLINDER

MAGNETIC PICKUP SENSOR
CAUTION: Wear eye protection when removing

or installing snap rings.
1. Remove snap ring (A).

2. Remove washer (B).
3. Remove magnetic sensor (C).
INSTALL
1. Lubricate new o-ring (D).
2. Install component items in reverse order.
ENG 6-46760
6003-6
REMOVE AND INSTALL OUTPUT MAGNETIC

PICKUP SENSOR
1. Remove two cap screws (A), two lock washers (B),
two flat washers (C), cover (D), sensor (E) and O-ring
(F).
2. Clean and inspect for wear and damage.
INSTALL:
3. Lubricate new o-ring and install in reverse order.
ENG 6-46760
6003-7
OTHER MATERIAL
Number
Name
Use
Transmission fluid
All moving parts and o-rings.
SPECIFICATIONS
Item
Measurement
Specification
Charge pump-to-input housing cap

screws.
Torque
100 Nm (74 lb-ft)
Suction manifold-to-input housing

cap screws.
Torque
25 Nm (18 lb-ft)
Suction tube-to-charge pump.
Torque
190 Nm (140 lb-ft)
Suction tube-to-suction manifold.
Torque
190 Nm (140 lb-ft)
Wiring harness bracket-to-rear

housing cap screw.
Torque
87 Nm (64 lb-ft)
Wiring harness connector-to-wiring

harness bracket
Torque
1827 Nm (1320 lb-ft)
ENG 6-46760
6003-8
REMOVE WIRING HARNESS

1. Loosen nut (A).
NOTE: Tag all wiring connectors for identification

before removing wiring harness.
2. Unfasten all weather pack connectors (B).

3. Remove wiring harness (C).
4. Inspect for wear and damage.
ENG 6-46760
January, 2003 Printed in Brazil
6003-9
DISASSEMBLE SUCTION TUBE GROUP
AO-ring fitting (2 used)

BSuction tube
ENG 6-46760
CSuction screen assembly

DCap screw (2 used)
EGasket
FSuction manifold
GO-ring
6003-10
REMOVE SUCTION TUBE AND OIL

MANIFOLD ASSEMBLY
IMPORTANT: All oil should be drained from
transmission before beginning
disassembly.
NOTE: Refer to INTERVALS FOR CHANGING

TRANSMISSION OIL AND FILTERS in section
1002 for draining oil.
1. Loosen cap screws (A).
2. Move bracket (B).
3. Completely loosen upper O-ring fitting nut (C).
ENG 6-46760
6003-11
4. Completely loosen lower O-ring fitting nut (D).
5. Remove suction screen assembly (E) and gasket (F)

from suction manifold (G).
6. Remove two cap screws (H).
7. Remove and discard O-ring (I)
ENG 6-46760
6003-12
8.Remove suction tube (J) with O-ring fitting parts.

9. Clean and inspect all parts for damage.
ENG 6-46760
6003-13
CHARGE PUMP GROUP
AOil pump
BCup plug
CSet screw
DCap screw M16x65 8.8 (3 used)
ESleeve (SAE C)
ENG 6-46760
FSnap ring
GO-ring
THE CHARGE PUMP IS NOT REPAIRABLE. THE
PUMP MUST BE REPLACED IF FOUND
DEFECTIVE.
6003-14
REMOVE CHARGE PUMP GROUP

NOTE: Transmission is shown with the input housing
engine side down.
1. Remove three cap screws (A).
CAUTION: The driven gear and support

bearings may come out of the input housing
when the charge pump is removed. These
assemblies are a slip fit. Do not allow gear and
bearing assembly to fall. Personal injury or
damage could result.
IMPORTANT: The driven gear and bearing assembly

stays in the input housing and
additional disassembly of the
transmission is expected, remove the
driven gear and bearing assembly to
prevent it from falling out when the
transmission is turned over.
NOTE: Refer to section (Direct Drive Input Assembly)

for information on disassembling and assembling
driven gear assembly (A).
2. Remove charge pump (B) and bearing assembly (D)
from input housing.
3. Remove o-ring (C).
4. Discard o-ring (C).
ENG 6-46760
6003-15
INSTALL CHARGE PUMP TO DIRECT DRIVE

INPUT ASSEMBLY
NOTE: The driven gear on the charge pump must mesh
with the idler gear. Refer to section, Direct
Drive input assembly (install driven gear
assemblies). The idler gear assembly can be
installed immediately before the charge pump
or as part of the charge pump.
CAUTION: Never install idler gear assembly

without installing the charge pump. The idler
gear assembly is a slip fit and can fall out
causing personal injury.
1. Lubricate new o-ring (C) install onto charge pump (B).
NOTE: OPTIMOLY PASTE WHITE T is used for

long-term separating and lubricating effect,
prevention of fretting corrosion and avoidance of
squeaking noises.
IMPORTANT: OPTIMOL OPTIMOLY PASTE WHITE T
is only suitable for paste-specific
applications and cannot replace oil or
grease lubrication. Do not mix with
other greases, pastes or oils.
2. Apply OPTIMOLY PASTE WHITE T to charge pump
spline.
3. Install charge pump (B) into front cover.

4. Install three cap screws (A) through charge pump into
front cover.
5. Tighten cap screws to 115 Nm (85 lb-ft).
OPTIMOL is a regestered trademark. OPTIMOLY PASTE WHITE T

can be purchased from Castrol Industrial North America Inc.
ENG 6-46760
6003-16
ASSEMBLE SUCTION TUBE GROUP
AO-ring fitting (2 used)

BSuction tube
ENG 6-46760
CSuction screen assembly

DCap screw (2 used)
EGasket
FSuction manifold
GO-ring
6003-17
INSTALL SUCTION TUBE, SUCTION

SCREEN ASSEMBLY AND SUCTION
MANIFOLD
1. Insert the upper end of the suction tube (A) into the
o-ring fitting half (B) in the charge pump and lightly
tighten, by hand, nut (C).
2. Lubricate and install a new O-ring (D) in the groove in

the suction manifold (E).
3. Place the suction manifold in its working position. Be

sure the O-ring stays in place.
4. Insert the lower end of the suction tube in the O-ring
fitting half (F) and lightly tighten, by hand, nut (G).
5. Install two cap screws (H) and tighten to 25 Nm (18
lb-ft).
6. Lubricate gasket (I).

7. Install the suction screen assembly (J) and gasket.
8. Tighten 3/4 to one turn after the gasket contacts
the face of suction manifold.
9. Check for leaks after operating transmission.
ENG 6-46760
6003-18
10. Tighten nut (K) to 190 Nm (140 lb-ft).
11. Tighten nut (L) to 190 Nm (140 lb-ft).
12. Move wiring harness bracket (M) back in place and

tighten two cap screws (N) 87 Nm (64 lb-ft).
13. Install wiring harness (O). Be sure to route the
harness away from moving parts, Make connections as
they were before disassembly.
ENG 6-46760
6003-19
14. Place main wiring harness connector (O) in bracket.

15. Tighten nut to 1827 Nm (1320 lb-ft).
ENG 6-46760
Direct Drive Input Assembly
6003-20
OTHER MATERIAL
Number
Name
Use
....
LOCTITE #620
Oil seal
Grease
O-ring
Transmission fluid
All moving parts and o-rings
SPECIFICATIONS
Item
Measurement
Specification
Magnetic pickup-to-input housing

cap screws.
Torque
10 Nm (8 lb-ft)
Input housing assembly-to-front

housing cap screws.
Torque
87 Nm (64 lb-ft)
Socket head hex plug-to-input

housing.
Torque
102 Nm (75 lb-ft)
Lift bracket-to-input housing
Torque
87 Nm (64 lb-ft)
Bearing retainer cap screw-to-front

housing.
Torque
37 Nm (27 lb-ft)
Direct drive input housing assembly
Weight
50 Kg (110 lbs)
ENG 6-46760
6003-21
REMOVE INPUT HOUSING ASSEMBLY GROUP
AHex cap screw, 12x280mm (4 used)

BOil seal
CInput housing (SAE 3)
ENG 6-46760
DTransmission Assembly
EDowel pin
FHex cap screw, 12x110mm (3 used)
6003-22
REMOVE AND DISASSEMBLE INPUT

HOUSING ASSEMBLY
1. Remove wiring harness.
2. Remove charge pump.
3. Position transmission with input housing assembly up.
4. Remove seven cap screws (A).
CAUTION: Be sure the lifting device will lift the

entire input housing assembly. This
component weight approximately 50 kg (110
lbs.)
IMPORTANT: The lifting device must be arranged so

that it lifts the input housing assembly
straight up without binding or tipping.
5. Install lifting device (A).
ENG 6-46760
6003-23
CAUTION: Be sure the input shaft assembly

(B) does not move up with the input housing
assembly (A). It might fall causing damage or
personal injury. Input bearing (C) will some
times come up with the input housing be
careful that it does not drop out.
NOTE: If the input bearing (C) stays with the input

housing (A), be sure it does not fall out. It can be
removed later.
6. Carefully lift input housing assembly (A) from the
transmission (E). The input shaft assembly (B), input
bearing (C) and O-ring (D) should stay with the
transmission (see caution and note).
ENG 6-46760
6003-24
INPUT ASSEMBLY
AInput housing
BHex socket plug
CLift hanger
DCap screw M12x20mm 8.8 (2 used)
EBearing (3 used)
FDriven gear 36T
GBearing (with snap ring)
ENG 6-46760
HBearing spacer
ISnap ring
JCap screw M6x20mm 8.8 (2 used)
KLock washer (2 used)
LWasher (2 used)
MMagnetic pickup cover
NMagnetic pickup sensor
OO-ring
6003-25
REMOVE IDLER GEAR SHAFTS

1. Position input housing assembly (A) engine side up.
2. Install a bolt (A) into threaded hole in idler shaft (B).

Use this bolt to pull idler shafts out of input housing. The
shafts are a slip fit.
3. Remove O-ring (C) from groove in each idler shaft.
4. Remove two O-rings from bottom of each idler shaft
bores.
5. Discard O-rings and inspect idler shaft for wear or
damage.
REMOVE INPUT OIL SEAL AND BALL

BEARING
NOTE: If the input ball bearing (B) stayed in the input
housing, remove it with the oil seal.
1. Drive the oil seal (A) down on top of the input ball
bearing below. Continue driving to remove both the oil
seal and the input ball bearing.
2. Remove oil seal (A) and input ball bearing (B).
ENG 6-46760
6003-26
REMOVE AND DISASSEMBLE AUXILIARY

PUMP DRIVE GEAR ASSEMBLY
1. Install two cap screws (A) in threaded holes in the
bearing spacer (B).
CAUTION: The bearing spacer (B) is not a tight

fit on the bearing, do not allow the auxiliary
pump drive driven gear and bearing assembly
(C) to fall, causing damage or personal injury.
2. Remove the bearing spacer with the auxiliary pump

drive driven gear and bearing assembly (C).
3. Remove bearing spacer (B).
4. Note the position of the snap ring on bearing

(A) for reassembly purposes. Use a puller to remove
bearings (A) and (B) from driven gear (C).
ENG 6-46760
6003-27
ASSEMBLE AUXILIARY PUMP DRIVE

DRIVEN GEAR ASSEMBLY
IMPORTANT: Press only on inner race of bearing.
1. Use a press bearing installation tool to install new
bottom bearing (A) on auxiliary pump drive driven gear
(B).
2. Turn driven gear (B) over and press the new top
bearing with snap ring (D) onto gear.
NOTE: Install new bearing with snap ring down next to

gear.
3. Set assembly aside.
ENG 6-46760
6003-28
REMOVE AND DISASSEMBLE IDLER GEARS

AND BEARING ASSEMBLY
1. Remove charge pump idler gear assembly (A) though
charge pump ports.
2. Remove auxiliary pump drive idler gear and bearing

assembly (A) through the auxiliary pump drive port.
NOTE: Both right and left idler gear and bearing

assemblies are disassembled in the same way.
CAUTION: Wear safety glasses when removing

3. Remove snap ring (A).
ENG 6-46760
6003-29
4. Push both bearings (A) out from the side the snap
ring was removed.
ABearing (2 used)
BGear
CSnap ring (2 used)
ENG 6-46760
6003-30
ASSEMBLE IDLER GEAR ASSEMBLY

NOTE: Both idler gears assemble the same. Install
bearing into the idler gear correctly. Snap ring
side of bearing to the outside of the gear.
1. Install new bearing (A) snap ring side of bearing to
the outside of gear.
2. Turn idler gear over and install the second bearing.

3. Set both assemblies aside.
ENG 6-46760
6003-31
REMOVE AND INSTALL LIFT BRACKET

1. Remove two cap screws (A).
2. Remove lift bracket (B).
INSTALL LIFT BRACKET

IMPORTANT: Using new cap screws, replace with the
same length and grade as original
equipment.
1. Install two cap screws (A).
REMOVE AND INSTALL SOCKET HEAD HEX

PLUG
1. Remove socket head hex plug (A) and O-ring (B).
2. Discard O-ring.
3. Inspect socket head plug for damage.
INSTALL SOCKET HEAD HEX PLUG

1. Lubricate new O-ring (A) and install on Plug (B).
2. Install plug assembly.
3. Tighten to 102 Nm (75 lb-ft).
ENG 6-46760
6003-32
ASSEMBLE INPUT ASSEMBLY
AInput housing
BHex socket plug
CLift hanger
DCap screw M12x20mm 8.8 (2 used)
EBearing (3 used)
FDriven gear 36T
GBearing (with snap ring)
ENG 6-46760
HBearing spacer
ISnap ring
JCap screw M6x20mm 8.8 (2 used)
KLock washer (2 used)
LWasher (2 used)
MMagnetic pickup cover
NMagnetic pickup sensor
OO-ring
6003-33
INSTALL OIL SEAL

1. Position input housing (A) with engine side up.
IMPORTANT: If the new oil seal is not coated on the
outside diameter with a sealer, apply
LOCTITE #620.
2. Install new oil seal (B) flush with machined surface on
input housing.
LOCTITE is a registered trademark of LOCTITE Corporation.
ENG 6-46760
6003-34
INSTALL IDLER GEAR AND BEARING

ASSEMBLIES
1. Lubricate all bearings with clean transmission fluid.
2. Place idler gear assembly (A) into auxiliary pump
drive port of the input housing.
3. Slide the idler gear assembly (A) into its position

between the auxiliary pump port and the input shaft
bore.
4. Place the other idler gear assembly (B) into its

position between the charge pump port and the input
shaft bore.
ENG 6-46760
6003-35
INSTALL IDLER SHAFTS

NOTE: The through hole in the idler shafts (D) must line
up with the through hole in the input housing (B).
Use one of the long input housing cap screws (F)
to guide alignment of the shaft.
1. Align the bearing bore in the idler gear assembly (A)
with the idler shaft bore in the input housing (B).
2. Lubricate the O-ring (C) with grease and install in the
groove on the idler shaft (D).
3. Use grease to hold O-ring (E) to the bottom of the
idler shaft during installation (also see the alternate
installation procedure 4.)
ALTERNATE O-RING INSTALLATION PROCEDURE
4. Lubricate O-ring (E) with grease and place in position
at the bottom of the idler shaft bore in the input housing.
5. Align the through hole in the idler shaft with through
hole in the input housing by inserting one of the long
input housing attaching cap screws (F) through both
parts.
6. Push the idler shaft through the idler gear assembly
and into the input housing. Be sure both O-ring stay in
place.
7. Install the other idler shaft (G) in the same way.

IMPORTANT: Both idler gears must turn.
8. Remove the cap screws that were used as alignment
guides.
ENG 6-46760
6003-36
INSTALL AUXILIARY PUMP DRIVE GEAR

1. Lubricate both bearings with clean transmission fluid.
2. Install auxiliary pump drive gear assembly (A) snap
ring up in pump drive port.
3. Align gear teeth (B) and (C).

4. Push auxiliary pump drive gear assembly (D) into bore
in front cover.
5. Install bearing spacer (E).
CAUTION: Wear eye protection when removing

or installing snap rings. Personal injury to self
or bystanders could result.
6. Install snap ring (F) in groove.
ENG 6-46760
6003-37
INPUT SHAFT ASSEMBLY
AInput shaft assembly

BTransmission assembly
ENG 6-46760
6003-38
REMOVE AND DISASSEMBLE INPUT SHAFT

ASSEMBLY
N
N
CAUTION: Be sure the input shaft assembly

(B) does not come up with the input housing
assembly (A). It could fall and cause damage
or personal injury.
CAUTION: The input bearing will usually come
up with the input housing assembly. Do not let
it fall out before it can be safely removed.
1. Remove the input housing assembly (A).

CAUTION: Do not allow the coupling shaft (D)
to fall if it comes up with the input shaft
assembly.
2. Lift input shaft assembly (B) from bearing retainer (C).
3. Place input assembly (E) with snap ring up.
ENG 6-46760
6003-39
4. Remove and discard seal ring (F).

or installing snap ring.
5. Remove snap ring (G).

6. Remove thrust race (H).
7. Mark input shaft (I) and gear (J) for reassembly.
8. Remove gear from input shaft.

9. Inspect all parts for wear and damage.
ENG 6-46760
6003-40
ASSEMBLE INPUT SHAFT

1. Align marks made on input shaft (A) and gear (B).
2. Install gear on input shaft.
3. Install thrust race (C).

4. Install snap ring (D).
IMPORTANT: Always use new seal rings. The seal

rings must be sized to fit the shaft
groove tightly to prevent damage
during installation. Check that seal ring
is in place and sized immediately
before assembly.
5. Size the seal ring (E) by twisting in a tight circle,
approximately 25 mm (1 in) in diameter.
6. Apply grease to the seal ring and seal surfaces.
7. Install seal ring (E).
ENG 6-46760
6003-41
REMOVE COUPLING SHAFT AND RETAINER

1. Remove coupling shaft (A).
2. Remove O-ring (B).
IMPORTANT: Note the placement of the oil deflector

(E). This part must be installed
correctly for the transmission to
function and lubricate properly.
3. Remove seven cap screws (C) and oil deflector from
bearing retainer assembly (D).
IMPORTANT: Do not scratch or damage the inside

diameter of the bearing retainer. The
input shaft seal ring surface will be
damaged.
4. Remove bearing retainer (D).
ENG 6-46760
May, 2003, 2003 Printed in Brazil
6003-42
5. Use a soft drift to remove bearing (A). Do not damage

retainer (B).
ASSEMBLE AND INSTALL BEARING

RETAINER
IMPORTANT: This bearing installs below flush. Firmly
seated on the bottom of the bearing
bore.
1. Install new bearing (A).
2. Install retainer with bearing (C). Use one of the

attaching cap screws (D) to help align through holes in
retainer with threaded holes in transmission front housing
(E).
ENG 6-46760
6003-43
NOTE: There are two holes (H) in the retainer that are
oil passages, not attaching holes.
3. Install seven cap screws (F) and deflector (G).
IMPORTANT: Pay attention to the placement of the

oil deflector (G).
4. Install the oil deflector (G) as shown in the
photograph.
5. Lubricate bearing with clean transmission fluid.
6. Tighten cap screws (F) to 37 Nm (27 lb-ft). Besure

the oil deflector stays in its proper position.
ENG 6-46760
6003-44
7. Lubricate the O-ring (J) with grease.
NOTE: O-ring must sit flat against front housing.

8. Install O-ring on bearing retainer.
INSTALL COUPLING SHAFT

1. Lubricate coupling shaft (A) with clean transmission
fluid.
2. Install coupling shaft into transmission first stage shaft.
NOTE: Both ends of the shaft are the same.
ENG 6-46760
6003-45
INSTALL INPUT SHAFT ASSEMBLY AND

INPUT BALL BEARING
IMPORTANT: Immediately before installing the input
shaft assembly, check that the seal ring
(A) is in place, sized and lubricated.
NOTE: Refer to ASSEMBLE INPUT SHAFT in this group

for more information about sizing seal rings.
1. Check that the seal ring (A) is in place, sized and
lubricated with grease.
2. Lubricate with grease the seal area (B) and the shaft
splines (C).
3. Install the input shaft assembly (D).
4. Lubricate input ball bearing (E) with clean

transmission fluid.
5. Install new ball bearing (B).
ENG 6-46760
6003-46
INSTALL INPUT HOUSING ASSEMBLY

IMPORTANT: Dowel pin (A) must be installed. If left
out, transmission will be damaged.
1. Check for dowel pin (A), if not in place, install dowel
pin.
IMPORTANT: The input housing assembly and the
transmission must be level to avoid
damage to the oil seal as it moves over
the input shaft spline.
2. Slowly lower the input housing assembly (B) onto front
housing, input bearing and dowel pin.
ENG 6-46760
6003-47
NOTE: Front housing (D) must mount flush with input

housing assembly (C).
3. Check input housing (C).
4. Remove lifting tooling (E).
5. Install seven cap screws (F).
6. Tighten cap screws (F) to 87 Nm (64 lb-ft).
ENG 6-46760
Control Valve
6003-48
OTHER MATERIAL
Number
Name
Use
Transmission Fluid
SPECIFICATIONS
Item
Measurement
Specification
Control valve-to-front housing cap

screw (27).
Torque
40 Nm (30 lb-ft)
Proportional valve nut-to-proportional

solenoid assembly (8).
Torque
1.72.8 Nm (1525 lb-in)
7/16-20 plug-to-valve housing (12).
Torque
12 Nm (9 lb-ft)
9/16-18 plug-to-valve housing (2).
Torque
25 Nm (18 lb-ft)
Temperature sensor-to-valve
housing.
Torque
16 Nm (12 lb-ft)
Proportional valve-to-valve housing

(8).
Torque
1620 Nm (1215 lb-ft)
Main regulator assembly-to-valve

housing.
Torque
142 Nm (105 lb-ft)
Relief valve assembly-to-valve

housing.
Torque
102 Nm (75 lb-ft)
Valve assembly
Weight
25 Kg (55 lbs)
ENG 6-46760
6003-49
CONTROL VALVE GROUP
A-Gasket
B-Plate
C-Gasket
D-Valve Assembly
E-Flat Washer (27 used)
ENG 6-46760
F-Cap screw M8x45 10.9 (5 used)

G-Cap screw M8x75 10.9 (13 used)
H-Temperature Sender
I-O-ring
J-Cap screw M8x90 10.9 (9 used)
6003-50
REMOVE CONTROL VALVE GROUP

1. Tag all electrical connections.
2. Remove wiring harness.
3. Remove charge pump group.
4. Remove input housing group.
REMOVE TEMPERATURE SENSOR

Remove temperature sensor.
INSTALL TEMPERATURE SENSOR
Install temperature sensor and tighten to 2427 Nm
(1820 lb-ft).
IMPORTANT: Do not allow any of the flat washers

(B) to fall into control valve assembly
or transmission openings. The
transmission may not operate properly
or damage may result.
5. Remove 27 cap screws (A) and flat washers (B).
CAUTION: Approximate weight of valve

assembly is 25 Kg (55 lbs).
6. Remove valve assembly (C).
ENG 6-46760
6003-51
7. Remove and discard gasket (D).

IMPORTANT: Do not bend plate (E).
8. Remove plate (E).
9. Remove and discard gasket (F).
10. Clean and inspect all gasket surfaces.
ENG 6-46760
6003-52
DISASSEMBLE AND ASSEMBLE CONTROL VALVE

O-rings. Use only new O-rings.
Install new O-rings onto cartridge
type valve.
THE CARTRIDGE TYPE VALVES USED IN THIS

ASSEMBLY ARE NOT USER REPAIRABLE. ANY
VALVE FOUND TO BE DEFECTIVE MUST BE
REPLACED AS A UNIT.
IMPORTANT: Cartridge valves require a O-rings.
When assembling valves grease all
AValve Housing
BHex Socket Plug 7/16-20
(12 used)
CProportional 12 or 24 Volt
Valve (7 used)
ENG 6-46760
D90 Relief Valve

EMain Regulator Assembly
FSteel Ball 9/32 (4 used)
GHex Socket Plug 9/16-18
(2 used)
USE THE DRAWINGS PROVIDED AS GUIDES FOR

FURTHER DISASSEMBLY AND ASSEMBLY OF THE
CONTROL VALVE.
HPlug
IO-ring
JO-ring
KO-ring
LProportional Solenoid
Plug
6003-53
DISASSEMBLE VALVE ASSEMBLY

PROPORTIONAL SOLENOID
1. Remove nut (A), washer (B) and coil (C) from
proportional solenoid.
2. Remove proportional valve (D).

3. Inspect for contamination.
REMOVE 90 RELIEF VALVE

1. Remove 90 relief valve (A).
2. Inspect for wear and contamination.
REMOVE MAIN REGULATOR ASSEMBLY

1. Remove main regulator assembly (A).
ENG 6-46760
6003-54
REMOVE PROPORTIONAL PLUG

1. Remove solenoid assemblies.
2. Remove proportional plug (A).

REMOVE PLUG
1. Remove plug (A).
INSTALL PLUG
1. Lubricate new o-ring.
2. Install new o-ring onto plug.
3. Install plug (A).
4. Tighten plug to 12 Nm (9 lb-ft).
ENG 6-46760
6003-55
INSTALL PROPORTIONAL PLUG

1. Lubricate new o-rings (3).
2. Install new o-rings onto proportional plug.
3. Install proportional plug (A).
4. Tighten proportional plug.
INSTALL MAIN REGULATOR ASSEMBLY

2. Install new o-rings.
3. Install main regulator assembly (A).
4. Tighten main regulator assembly 142 Nm (105 lb-ft).
INSTALL RELIEF VALVE

2. Install new o-rings (A).
3. Install relief valve.
4. Tighten relief valve 102 Nm (75 lb-ft).
ENG 6-46760
6003-56
INSTALL PROPORTIONAL SOLENOID

ASSEMBLY
1. Install new o-rings (A), (B) and (C) onto proportional
valve.
2. Install proportional valve (D) into valve housing.

3. Tighten proportional valve 1620 Nm (1215 lb-ft).
4. Install coil (E), washer (F) and nut (G) onto

proportional valve.
5. Tighten nut 1.72.8 Nm (1525 lb-in).
ENG 6-46760
6003-57
INSTALL CONTROL VALVE GROUP
AGasket
BPlate
CGasket
DValve Assembly
EFlat Washer (27 used)

FCap screw M8x45 10.9 (5
used)
IMPORTANT: The gaskets and metal plate must

be installed correctly. The first
gasket is cut out to the shape of the
casting on the front housing. The
second gasket is cut out to the
shape of the metal plate and has a
boot-like shape cut out of it.
1. Install gasket (A).
ENG 6-46760
GCap screw M8x75 10.9

(13 used)
HTemperature Sender
IO-ring
JCap screw M8x90 10.9 (9
used)
2. Install plate (B).

3. Install gasket (C).
4. Install valve assembly (D).
5. Install cap screws (F), (G) and (J) and washers
(E). Observe tightening sequence and torque
specifications given in this section.
6003-58
INSTALL GASKETS AND PLATE TO FRONT

HOUSING TO FRONT HOUSING VALVE
SURFACE
IMPORTANT:There are two (2) gaskets and a plate
that go between the valve assembly
and front housing. The first gasket is
cut out to the shape of the casting on
the front housing. The second gasket
is cut out to the shape of the metal
plate and has a boot-like shape cut out
of it.
NOTE: Guide pins used are bolts with heads removed.

Guide pins length will need to be long enough for
removal after placing valve housing assembly
onto front housing.
1. Install two guide pins (A).
IMPORTANT: Gasket must match opening in front

housing.
2. Place and fit new gasket (B) onto front housing using
guide pins (A) as holders.
IMPORTANT: Opening in plate must match opening
in gasket.
3. Place plate (C) over the guide pins and onto gasket
(B).
IMPORTANT: Cut out opening in gasket must match

opening in plate.
4. Place new gasket (D) over guide pins onto plate (C).
ENG 6-46760
6003-59
INSTALL CONTROL VALVE ASSEMBLY
CAUTION: The valve assembly weighs

approximately 25 Kg (55 lbs).
NOTE: Guide pins (B) must be long enough to remove

after installing valve assembly.
1. Install valve assembly (A).
2. Remove guide pins (B).
IMPORTANT: The 27 cap screws (C) that attach the

control valve are three different
lengths. Use proper length cap screws
for each cap screw hole.
IMPORTANT: Do not allow washers to fall into any
opening in valve assembly or
transmission openings.
3. Install 27 cap screws (C) and flat washers.
IMPORTANT: Tighten cap screws (E) evenly in

sequence as directed by instructions
in, CAP SCREW TIGHTENING
SEQUENCE AND TORQUE
SPECIFICATIONS found in this
section.
4. Tighten cap screws to torque specifications and
tightening sequence in this section.
5. Tighten cap screws (E) to 40 Nm (30 lb-ft).
ENG 6-46760
6003-60
CAP SCREW TIGHTENING SEQUENCE AND TORQUE SPECIFICATIONS
Tighten cap screws in rotational sequence

represented by call outs.
1. First rotational sequence tighten all cap screws to
40 Nm (30 lb-ft).
ENG 6-46760
2. Repeat step 1.
CONTROL VALVE CAP SCREW TORQUE
SPECIFICATIONS.....40 Nm (30 lb-ft)
6003-61
PRESSURE AND TEMPERATURE CHECK PORTS (WITHOUT WET BRAKE)
AValve Housing
BConverter Out Pressure
Check Port
CConverter In Pressure
Check Port
DClutch 1 Pressure Check
Port
EClutch 2 Pressure Check
Port
FLube Pressure Check Port

GConverter Relief
HPressure Regulator
IPump In Port
JClutch B Check Port
KClutch A Check Port
LAuxiliary Pressure Source
MConvert out temperature

NSystem Pressure Check
Port
OLube In Port
POil Out To Heat
Exchanger
QAuxiliary Pressure Source
RClutch D Check Port

SClutch C Check Port
TSolenoid Assembly
UTemperature Sensor
VClutch 4 Check Port
WClutch 3 Check Port
OPERATING CONDITIONS:
PORT PRESSURES:
Engine speed at 2000 rpm
In neutral
Transmission temperature range at 6593C

(150200F).
Converter in 4.1 - 7.9 Bar (60 - 115 psi) (see footnote)

Converter out 2.7 - 6.2 Bar (4090 psi)
Pump flow 87102 L/min (2327 gpm) at

16.5519.31 Bar (255280 psi).
Lube 2.7 - 4.1 Bar (4060 psi)

In gear
Lube 1.4 - 2.7 Bar (2040 psi)
In neutral, Converter In pressure should always be higher than Lube

pressure.
ENG 6-46760
6003-62
PRESSURE AND TEMPERATURE CHECK PORTS
Following is identification of ports as they are marked on

the valve body casting.
Ports marked 1, 2, 3 and 4 are Direction Clutch Ports.
1 and 2 are forward clutches.
3 and 4 are reverse clutches.
Ports marked A, B, C and D are Speed Clutch Ports.
NOTE: All check ports are 7/16-20 UNF SAE O-ring,

unless otherwise specified.
ENG 6-46760
Main Case Front Housing
6003-63
OTHER MATERIAL
Number
Name
Use
Transmission fluid
LOCTITE #242
Oil Seal
SPECIFICATIONS
Item
Measurement
Specification
Front housing-to-rear housing cap

screws.
Torque
87 Nm (64 lb-ft)
Front housing.
Weight
120 Kg (265 lbs.)
1 5/8 Plug
Torque
190 Nm (140 lb-ft)
OUTPUT YOKE
AV-ring seal
BYoke
CO-ring
DYoke washer
ECap screw
ENG 6-46760
6003-64
REMOVE OUTPUT YOKE

NOTE: Output yoke will turn when removing cap screw.
Place block of wood or similar object between
yoke and housing to aid in removing output yoke
assembly.
1. Loosen cap screw (C).
2. Remove cap screw (C) washer (D) and O-ring (E).
3. Remove output yoke (A).
ENG 6-46760
6003-65
DISASSEMBLE AND ASSEMBLE FRONT HOUSING
AHex cap screws

12x120mm (18 used)
BFront Housing (DF250)
ENG 6-46760
CBore Sleeve (4 used)

DInput Bushing
EDowel Pin (2 used)
FBearing Cup
GPlug with O-ring (2 used)
HLube Relief Valve
Assembly
IBracket
6003-66
REMOVE CAP SCREWS AND WIRING

CONNECTOR BRACKET FROM FRONT
HOUSING
1. Loosen cap screw (A).
2. Remove cap screw (B).
3. Remove wiring connector bracket (C).
4. Remove remaining cap screws (D).
5. Remove dowel pin (E) if loose.
ENG 6-46760
6003-67
INSTALL FRONT HOUSING LIFTING TOOL

1. Use four threaded holes (A) in the front housing to
attach lifting tool.
CAUTION: Use four high grade fasteners (C) of

the correct length to attach the lifting tool to
the front housing.
2. Position lifting tool (B).
3. Install four cap screws (C).
CAUTION: The front housing assembly weighs

NOTE: Use a hoist with a safety hook (D) when

removing the front housing.
ENG 6-46760
6003-68
REMOVE FRONT HOUSING

IMPORTANT: Pry on the housings to loosen the
gasket seal, use lugs provided on the
front and rear housings.
CAUTION: The front housing assembly weighs

approximately 120 Kg (265 lbs.) Do not allow
any part of the body under the front housing
assembly.
1. Remove front housing.
2. Remove and discard gasket (C).
3. Check for two dowel pins (D).
ENG 6-46760
6003-69
DISASSEMBLE THE FRONT HOUSING ASSEMBLY
ALube relief valve

BBore sleeve (4 used)
CBearing cup
DInput bushing
EPlug with O-ring (2 used)
REMOVE PLUG WITH O-RING
1. Remove two plugs (A) with O-rings.
2. Remove O-rings (B) and discard.
INSTALL PLUG WITH O-RING
1. Lubricate new O-rings.
2. Install new O-rings.
3. Install plugs with O-rings.
4. Tighten to 190 Nm (140 lb-ft).
ENG 6-46760
6003-70
REMOVE BORE SLEEVES

1. Inspect bore sleeves (A) for wear or damage.
NOTE: See Section 6002, special tools.

2. Remove bore sleeves from front side of front housing.
ENG 6-46760
6003-71
INSTALL BORE SLEEVES

1. Position front housing with bearing bore side up.
IMPORTANT: Install bore sleeves with the internal
chamfer up.
2. Place bore sleeve (A) onto driving tool (B) with

outside diameter chamfer of bore sleeve to end of tool.
3. Install bore sleeve flush with shoulder.
ENG 6-46760
6003-72
REMOVE LUBE RELIEF VALVE

1. Position front housing with bearing bore side up.
2. Remove lube relief valve (A).
INSTALL LUBE RELIEF VALVE

1. Position front housing with bearing bore side down.
2. Install new lube relief valve (A).
REMOVE BEARING CUP

Remove bearing cup.
ENG 6-46760
6003-73
INSTALL BEARING CUP

Install new bearing cup (A).
REMOVE OIL SEAL

Remove oil seal (A).
INSTALL OIL SEAL

NOTE: Apply LOCTITE #242 or equivalent to outside
diameter of oil seal before installation.
Install new oil seal flush with shoulder.
ENG 6-46760
6003-74
PREPARE REAR HOUSING AND GEAR

GROUP FOR ASSEMBLY WITH FRONT
HOUSING
1. Clean gasket surfaces on front and rear housings.
IMPORTANT: Check for both dowel pins (D). If not in
place they must be installed before
jointing front and rear housing.
2. Install dowel pins (D).
3. Install new gasket (C).
IMPORTANT: Use guide pins (D) to align the front

and rear housings. Failure to install
guide pins will cause damage to seal
rings.
NOTE: Guide pins (D) must be long enough to reach

through the front housing and be removed after
front housing is in place.
4. Install two guide pins (D).
ENG 6-46760
6003-75
INSTALL SEAL RINGS AND LUBRICATE

IMPORTANT: The seal ring ends overlap and must fit
together.
IMPORTANT: Use new seal rings.
NOTE: For shaft assemblies twist seal rings 19 mm (3/4

inch). For first stage shaft twist seal ring 25 mm
(1 inch).
1. Twist seal ring into tight circle, approximately 25 mm
(1 inch).
2. Install seal ring (A) on first stage shaft (B).
ENG 6-46760
6003-76
3. Install as required either two or three seal rings (C) on

clutch shaft assemblies.
4. Lubricate all seal rings.

5. Check seal rings for proper fit in the grooves, in clutch
shaft assemblies.
6. Rotate seal rings so that the end gaps are
approximately 120 degrees apart.
7. Lubricate all bearings with clean transmission fluid.
8. Apply grease to the yoke spline (E) on the output

stage shaft.
ENG 6-46760
6003-77
INSTALL FRONT HOUSING
N
N
CAUTION: Front housing weight is

approximately 120 kg (265 lbs).
CAUTION: Use four high grade fasteners of the
correct length to attach the lifting tool to the
front cover.
1. Attach lifting tool (B).
CAUTION: Do not allow any part of the body

under the front housing assembly. Personal
injury is possible.
IMPORTANT: Use guide pins to prevent damage to

seal rings.
2. Install guide pins (C).
3. Check for dowel pins (D), gasket (E) is flat on rear
housing surface.
4. Lower front housing assembly (F) onto clutch shaft
assemblies and onto rear housing.
IMPORTANT: Do not attempt to mate front and rear
housing together using cap screw
fasteners. If the housings do not close
up completely without force there is a
problem condition that must be
corrected.
5. Check front housing is level with rear housing (H).
ENG 6-46760
6003-78
6. Install cap screws (J) and wiring harness bracket (K).
8. Remove lifting tool (L).
ENG 6-46760
6003-79
INSTALL OUTPUT YOKE

1. Lubricate the seal and seal surfaces on the output
yoke (A).
2. Install output yoke (A).
3. Lubricate new O-ring (E).

4. Install new O-ring (E).
5. Install washer (D).
6. Install cap screw (C).
7. Use a block of wood (F) to keep output yoke from

turning.
8. Tighten cap screw (C) to 215 Nm (159 lb-ft).
ENG 6-46760
Gear Ratio Group
6003-80
OTHER MATERIAL
Number
Name
Use
Transmission fluid
SPECIFICATIONS
Item
Measurement
Specification
Output group
Weight
30 Kg (65 lbs.)
Clutch stages less output stage.
Weight
272 Kg (600 lbs.)
Oil trough-to-rear housing cap

screws.
Torque
25 Nm (18 lb-ft)
Clutch assemblies
Clutch plate-to-clutch plate

retainer clearance
2.79 mm5.59mm (.110.220 in)
Clutch gear
End play
.25 mm (.010 in)
ENG 6-46760
6003-81
REMOVE OUTPUT GROUP

1. Remove two cap screws (A) holding oil trough
assembly (B).
N
N
CAUTION: The output group weighs

CAUTION: The oil trough has sharp edges.
Personal injury could occur.
2. Remove output group (C) and oil trough (B).
NOTE: Oil trough must be removed with the output

group.
ENG 6-46760
Section
6005
LIMITED SLIP
6005
REAR AXLE
845 - 865 Grader
CNH Latino Americano Ltda

ENG 6-46780
Printed in Brazil
May, 2003
6005-2
TABLE OF CONTENTS
SPECIAL TOOLS ........................................................................................................................................... 2
TROUBLES HOOTING .................................................................................... ........................................................ 8
AXLE SECTION ...................................................................................................................... .................................. 9
OIL CHANGE PROCEDURE .................................................................................................................................. 10
GENERAL INSTRUCTIONS ........................................................................................................................... 11
DISASSEMBLY AND ASSEMBLING .............................................................................................................. 12
DISASSEMBLY AXLE SUPPORT WITH PLANETARY SPIDER .................................................................... 13
DISASSEMBLE BRAKES ................................................................................................................................ 19
COMPUTING OF BRAKE DISC PACK OF FINAL DRIVE ............................................................................. 21
DETERMINE PRESSURE PLATE SHIMS ...................................................................................................... 22
DETERMINATION OF SHIMS BETWEEN HALF SHAFT AND REDUCTION HUB .............................................. 25
DIFFERENTIAL ASSEMBLY AND DISASSEMBLY ............................................................................................ 27
DISASSEMBLY AND ASSEMBLY LIMITED SLIP DIFFERENTIAL ................................................................ 31
ENG 6-46760
May, 2003
6005-3
Material: Nut M8 steel classe 8
Material: Steel classe 8
ENG 6-46760
May, 2003
Material: Spring Steel
6005-4
ENG 6-46760
May, 2003
6005-5
TOOLS FOR MOUNTING OF RING RETAINING CUP
HAND GRIP O.D.- 50mm (2") - M16
ENG 6-46760
6005-6
Material: Tool steel SAE1080 /1085

quench and temper (HRC 52 ~60)
ENG 6-46760
May, 2003
6005-7
Material: Tool steel SAE1080 /1085

quench and temper (HRC 52 ~60)
ENG 6-46760
May, 2003
6005-8
TROUBLESHOOTING
SYMPTOM
PROBABLE CAUSE
SOLUTION
Oil
leakage from final drive carrier
Incorrect screw torque

O-Ring damaged
Oil
leakage from seals
Incorrect installation
Seals damaged
Replace seals
Replace seals
Oil
leakage from breather
High oil level
Check oil level
Incorrect lubricant
Replace the oil.
Incorrect lubricant
Replace the oil
Low oil level
Check oil level
Incorrect bearing adjustment
Verify and adjust the bearing

setting
Bearing damaged
Verify and change the bearing
Gears damaged
Verify and replace the gears.
Incorrect lubricant
Replace the oil
Incorrect backlash
Verify and adjust
Incorrect bearing preload
Verify and adjust
Incorrect bevel pinion position
Verify the pinion position
Side gears thrust washer

damaged
Verify and replace.
Lubricant
Final
with excessive foam
drive noise
Differential
assy noise
ENG 6-46760
Check the torque

Replace O-Ring
May, 2003
AXLE SECTION
6005-9
10
11
12
13
21
20
19
18
17
16
15
14
22
26
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
ENG 6-46760
25
Differential support
Limited slip differential assembly
Filter
Central housing
Pressure plate
Steel disk
Friction disk
Brake disk drum
Planetary gear
Half-shaft thrust washer
Shim
Reduction support assembly
Sprocket retaining washer
24
23
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Adjusting shim
Sprocket z = 20
Axle support
Half-shaft
Pin
Ring gear
Gear
Brake disks retaining pin
Piston
Retaining spring cup
Pressure plate return spring
Pin
Shim
May, 2003
6005-10
Oil change procedure

Keep adeguate containers corresponding to
drain plugs.
- Remove oil filling and level plug (a).
- Remove drain plug (b) and drain the oil.
- Remove the two screws and strainer oil (c).
- Wash and clean by compressed air, replace
the O-Ring.
- Fill until oil flows from level hole (a).
- Install the level and filling plug (a), start
the engine to circulte the oil.
- After three minutes shutoff the engine and
recheck oil level and, if necessary, add oil.
- Install the oil plug (a).
IMPORTANT: Dispose of used oil in accordance with specific local regulation.
ENG 6-46760
May, 2003
6005-11
GENERAL INSTRUCTIONS
SHIMS
All adjustments shall be carried out after all shims have been selected measuring
them one by one with a micrometer gauge and, then, summing up all values measured; do not
trust incorrect measurement of pack as a unit or sum of nominal value printed on each shim.
SEALS FOR REVOLVING SHAFTS
Proceed as follows for proper fitting of oil seals:
prior assembly, seals should be soaked, for at least half an hour, in the same oil
to be sealed;
clean thoroughly shaft and make sure that working surface is not damaged;
position sealing lip against the fluid to be sealed; in case of hydrodynamic lip lines should be
oriented so that, considering direction of revolving shaft, they lead fluid inside of sealing
means;
smear sealing lip with a film of lubricant (oil is better than grease) and fill up with grease the
space between sealing lip and dust shield lip, if using double sealing lip type seals;
press seal in relevant position or use a proper fitter with flat contact surface; never use hammer or mallet to mount seal;
when press fitting seal make sure that it is correctly driven in relevant position, i.e., square
with respect to its position, as fitting is completed make sure, if required, that seal itself be in
contact with relevant shoulder;
to prevent damage of seal lip when inserting shaft, protect component during assembly.
O-RING SEALS
Lubricate O-RING seals at assembly to prevent twisting that would impair correct sealing.
SEALING COMPOUNDS
For matching surfaces use compound LOCTITE 510 or similar one.
Clean matching surface as follows prior, smearing compound:
remove old deposits using a metal brush;
degrease surfaces by one the following cleaners: trichloroethylene, kerosene or a warm
water and soda solution.
BEARINGS
When assembling them it is advisable to proceed as follows:
heat them at 80 to 90 C (176 to 194 F) before fitting on relevant shafts;
cool them before inserting in relevant external position.
SPRING PINS
When using spring pins be sure that lengthwise slot be positioned toward stress on pin.
Coil pins don't require specific position.
IMPORTANT: Dispose of worn and replaced materials has to follow local regulation.
ENG 6-46760
May, 2003
6005-12
DISASSEMBLY AND ASSEMBLING
! WARNING: Lift and handle each part by a lifting tool with proper capacity.
Make sure that groups or part are lifted by proper hooks.
Position the axle on proper support.
STEP 1
Before dissassembly mark position of each
housing, both sides.
Remove the eighteen nuts.
STEP 2
Remove the axle support.
Position axle assy vertically, with adequate
support to avoid accidents.
Suggested support
ENG 6-46760
May, 2003
6005-13
Disassembly axle support with planetary spider
STEP 3
Remove reduction hub with
proper lifting device.
STEP 4
Remove the bearing cone from the hub.
STEP 5
Remove the ring gear.
If necessary, replace the inner bearing with
universal puller.
Reassemble heating the bearing (80 90 C)
(176 194 F).
6005-14
STEP 6
Remove the elastic pin.
STEP 7
Remove the gear pin.
STEP 8
Remove the planetary gear.
STEP 9
Check needle bearings, pins, side gears
and if worn replace.
ENG 6-46760
May, 2003
6005-15
STEP 10
Apply grease to needle bearings (total 62).
IMPORTANT
In case of replacement , use

the same class of bearing.
- Place the pin on a flat surface;
- insert a thrust washer and apply grease
to the pin;
- mount the first needle rollers;
- mount the spacer;
- Mount needle bearing rollers.
- position the side gear and the second thrust
washer, hold the two thrust washers and
install the pin.
STEP 11
Install the side gear ass'y.
ENG 6-46760
May, 2003
6005-16
STEP 12
- Position the pin with hole align with
the hole of the planetary spider hub.
- Install elastic pin in notch.
~ 40 mm
IMPORTANT
Elastic pin
The elastic pin must be new

- Make sure of free pin rotation.
- Make the same procedure for the other two
side gears.
fig. 15a
STEP 13
If the removal of the hub from the support is
necessary, remove the six screws.
At reassembly tighten screws with a torque
of 470 Nm.
STEP 14
Position and remount the ring gear.
ENG 6-46760
May, 2003
6005-17
STEP 15
Inspect bearing for wear and if necessary
remove and replace.
STEP 16
Assemble the oil seal at 5 - 6 mm (0.2 - 0.24)"
cup bearing seat (see fig).
Use a suitable sleeve having a diameter that will
fit inside the cage I.D. and press in seal.
Install the cup bearings
Oil seal
5-6 mm
STEP 17
Position the reduction hub on a base of ~ 150 mm
(5.9"), the studs must not touch the surface.
Mount the reduction unit on axle support, the
oil seal spring must not extend from seat.
ENG 6-46760
May, 2003
6005-18
STEP 18
Install bearing cone after heating to
90 to 100C (176 to 194F)
STEP 19
Install the two sprockets, positioning
them as in figure.
STEP 20
Install sprocket retainer washer with
two bolts without adjusting shim.
Tighten two bolts to obtain bearing rolling
resistance of 115 to 125 Nm (85 to 92 lb.ft).
STEP 21
Remove sprocket retainer washer and
measure distance from sprocket to end
of reduction support assembly to determine
adjusting shim thickness.
ENG 6-46760
May, 2003
6005-19
STEP 22
Install sprocket retaining washer and adjust
shim, torque the four bolts to 115 to 125 Nm
( 85 to 93 lb.ft ) and recheck rolling torque
which should be 10 to 30 Nm (7.4 to 22lb.ft)
after rotating sprocket ten revolutions.
DISASSEMBLE BRAKES
Before disassembly of the brakes, remove axle supports assembly, as described previously.
STEP 23
Remove the friction disks and the steel discs.
STEP 24
Remove half-shaft with brake drum.
ENG 6-46760
May, 2003
6005-20
STEP 25
Inspect components of half-shaft assembly for wear
and if necessary replace.
STEP 26
Use special tool (page 3) to push the
retaining spring cup and remove the lock ring.
Use the same procedure on remaining ones.
STEP 27
Remove the pressure plate.
Use compressed air to remove the piston.
STEP 28
Replace the two piston O-Rings.
Install the two O-Rings in piston groove
and lubricate with hydraulic fluid.
Install the piston, using a plastic hammer.
ENG 6-46760
May, 2003
6005-21
Computing of Brake Disc Pack of Final Drive

To assemble steel discs pack,
to use a standard pack.
Friction disc
The total pack of standard steel discs

is 17.50 mm (0.689"). Then its possible to use:
2 steel disks of 4.25 mm (0.167")
2 steel disks of 4.50 mm (0.177")
Steel disc
! Important : In case of brake components overhaul measure
to determine shims between pressure plate and central housing.
Pressure plate
Central housing
Shims S
ENG 6-46760
May, 2003
6005-22
Determine pressure plate shims

STEP 29
Position the pressure plate in its seat, measure
the distance between the central housing surface
and the pressure plate in three points making
the average: measurement "A".
STEP 30
Measure distance from planetary spider hub
to surface of axle support housing at three points and
average,measurement "B".
STEP 31
Measure thickness of five brake friction discs,
measurement "C".
STEP 32
Measure thickness of four brake steel discs,
measurement "D".
ENG 6-46760
May, 2003
6005-23
Determination of shim S:
Subtract measurement (A - B) and subtract
from (C + D) and subtract 4.25 mm (0.167"),
stroke value of brake disc pack:
S(mm) = (A - B) - (C + D) - 4.25 mm (stroke)
S" = (A - B) - (C + D) - 0.167" (stroke)
example:
A = 82.50 mm (3.248")
B = 36.45 mm (1.435")
C = 23.80 mm (5 brake discs total value)
C = 0.937" (5 brake discs total value)
D = 17.50 mm (4 lug brake discs total value)
D = 0.689" (4 lug brake discs total value)
then, well have:
S(mm) = (82.50 - 36.45) - (23.80 + 17.50) - 4.25
S = 0.50 mm
S" = (3.248 - 1.435) - (0.937+ 0.689) - 0.167
S = 0.02"
B
C+D
4.25 0.25 Stroke
The results will be the thickness of shim

pack "S ".
STEP 33
Install shims pack "S " between pressure

plate and central housing for each pin.
STEP 34
Position the pressure plate in its seat;
Position the lock ring on tools page 5.
Position the retaining cup and spring on
the pin.
ENG 6-46760
May, 2003
6005-24
STEP 35
Compress return spring and install retainer.
Use the same procedure on the others
Reassemble the half-shaft assy: insert

first a friction disk (inner teeth), a steel
disc and alternate friction discs and steel
discs.
Friction disc
ENG 6-46760
Steel disc
May, 2003
6005-25
Determination of shims between half-shaft and reduction hub

STEP 36
Remove the half shaft thrust washer.
STEP 37
Make a plate with same dimension of the
thrust washer differing only thickness which
should be 13 mm (0.512").
Install this plate stop which will be
dimension "E".
Install axle support assy with half- shaft and
measure GAP with feeler gauge at three
points and average, dimension "F".
E-F=G
i.e.: 13 - 0.5 = 12.5mm ( 0.512 - 0.0197 = 0.492")
Subtract dimension of plate stop 13mm
(0.512") "E" from dimension "F" (GAP) to obtain
dimension "G".
Determine shim pack thickness "X" by
subtracting 11mm (0.433"), original thurst washer
thickness 10.5 mm (0.413") add 0.5mm ( 0.020")
shaft end play, from dimension "G".
X = 12.5 - 11 = 1.5 mm ( 0.492 - 0.433) = 0.059"
this is the shim requested between thrust plate
and reduction support assembly, see page 9.
ENG 6-46760
May, 2003
6005-26
STEP 38
Install shims X already calculated, apply
Loctite 270 to original thurst washer and
Install in reduction support assembly.
See page 9.
STEP 39
Apply LOCTITE 510 sealant or similar
to mating surface of central housing.
Check the position of bevel gear because the retaining
pins must stay into their seats.
STEP 40
Install axle support housing on studs, observe correct
position in relation to imput shaft. Apply loctite 242 on
nuts and torque to 240 Nm (177lb.ft).
ENG 6-46760
May, 2003
6005-27
Differential assembly and disassembly
Before removal of the differential assy. remove the axle supports and the two shafts as
described.
STEP 41
Remove differential assy, mounting screws
Remove unit from axle casing.
Place differential on stand or work bench.
STEP 42
Mark trunion caps position before disassembly
Loosen the screws of the bevel gear.
STEP 43
Remove the elastic pins.
ENG 6-46760
May, 2003
6005-28
STEP 44
Loosen screws and remove trunion
caps and ring nuts.
STEP 45
Loosen jan nut and remove thrust screw.
STEP 46
Remove differential assembly from support.
STEP 47
Remove the four screws and pinion nose
support bracket, use the extraction holes.
ENG 6-46760
May, 2003
6005-29
STEP 48
Straighten lock ring notches on pinion nut collar, then position reaction tool on drive flange
to unlock nut, remove pinion nut.
STEP 49
Remove drive flange from pinion shank.
Remove bevel pinion from differential
support, hammer pinion shank by a
proper punch, taking care not to damage
threads.
STEP 50
Pry off oil seal from differential support.
STEP 51
Remove outer races of outer and inner pinion
bearings.
ENG 6-46760
May, 2003
6005-30
STEP 52
Pick up shims for pinion axial position and
pre-load.
STEP 53
Remove the underhead
pinion bearing, and the inner ring of the
pinion bearing on the pinion nose support bracket .
STEP 54
Remove the retaining pin and then replace
the pinion bearing on the connecting frame.
ENG 6-46760
May, 2003
6005-31
Disassembly and assembly limited slip Differential

STEP 55
Should bevel gear set be replaced, undo
bevel gear fixing screws and remove.
Replace, if required, the bearings, by removing them with a puller and assemble them
Heat to 120C (248F).
STEP 56
Mark the two half cases, remove
the screws and open them.
STEP 57
Remove the planetary gear with steel
disc, clutch discs and inner clutch disc.
STEP 58
Remove spider with the four side gears and
bevel thrust washers.
ENG 6-46760
May, 2003
6005-32
STEP 59
Before reassembling, all smooth faces have
to be lubricated with oil.
- Insert a first steel disc in housing, then a friction
clutch disc (both surfaces are made of
sintered material); alternate the other discs.
- Insert the outer cluth disc with the smooth
surface turned to the planetary gear .
- Apply oil and insert the bevel planetary
gear.
STEP 60
Assemble the side gears with relevant thrust
washers on the spider and position them on
the half-casing.
Apply oil and position the planetary gear.
Insert an outer clutch disc with the smooth
surface turned to planetary gear.
Insert first steel disc, then a friction clutch
disc and the others alternately.
STEP 61
Align the steel discs tanges.
ENG 6-46760
May, 2003
6005-33
STEP 62
Mount the half-casing aligned against the
intermediate and shim discs, close the two
half-casings, taking care to align the reference marked.
STEP 63
- Torque the four screws, check the revolving
torque of 90 120 Nm (67 89 lb.ft) .
- Remove or add intermediate discs of adequate shims.
- Lock the union screws and fix with
110 120 Nm (81 89 lb.ft).
STEP 64
Mount the bevel gear and lock the screws
with a torque of 315 345Nm (233 255 lb.ft).
ENG 6-46760
May, 2003
6005-34
STEP 65
Reassembly of bevel pinion and adjustment
Prior to the installation of the bevel pinion in the
differential support, it is necessary to measure
the dimensions to define the thickness of the
shim to be placed between the head bearing and
the shoulder in the relevant seal in the differential.
Measure the dimension of the crown wheel center
line at the shoulder of the head bearing, designated as
A, positioning a cylinder on the caps, then feel in an
accurate manner the gap to which it is necessary to add
the radius 62.5 mm (2.461 in) of the differential bearing.
Example: A = dimension measured + 62.5 mm or (2.46
in)
in this case:
A = 162.60 + 62.50 = 225.10 mm
A = 6.402 + 2.461 = 8.863 in
NOTE: Use tube O.D. ~ 60 mm (2.4") x 280mm (11")
STEP 66
On the front of the head of the each bevel pinion,
and number with mark (+ - ) is stamped or marked.
This number, in tenth of millimeter, indicates the
deviation from the theoretical dimension (184 mm)
(7.244 in) under the head of the pinion from the
center line of the crown gear.
Example: -1 = 0,10 mm (0.004 in)
in this case
B = theoretical 184.00 mm - 0.10 = 183.90 mm
B = theoretical 7.244 in - 0.004 = 7.240 in
ENG 6-46760
May, 2003
6005-35
STEP 67
Measurethe pinion head height from
bearing seating face to outer edge
and marked as H.
i.e.:
H = 82.00 mm (3.228")
STEP 68
Measure the width of pinion underhead
bearing as D.
i.e.:
D = 37.00 mm (1.457")
STEP 69
Shim S thickness should be determined for
correct axial position of bevel pinion:
i.e.: S = A - (B + D)
in our case:
S = 225.10 - (183.90 + 37.00) = 4.20 mm
S = 8.863 - (7.240 + 1.457) = 0.166"
Reduce by 0.05 mm (0.002") the theoretical
computed thickness to compensate the
different dimension of bearing after
press-fitting.
Round up or down to the nearest tenth of
millimeter the computed thickness.
ENG 6-46760
May, 2003
6005-36
STEP 70
Fit the bearing inner ring on the bevel pinion
nose.
.
STEP 71
Install the cone bearing heat at 80 ~ 90C
176 ~ 194F
STEP 72
Insert adjusting shim for axial position of

pinion. Its value was computed previously;
also, fit outer races of pinion underhead and
shank bearings.
ENG 6-46760
May, 2003
6005-37
STEP 73
To assure the correct assembly of the
differential, it is necessary to position the
pinion in its seat and the cylinder
on the caps and measure distance E.
E = B - (62.50 + H) mm
E = B - (2.461 + H) in
in our case:
E = 183.90 - (62.50 + 82.00) mm = 39.40 mm
E = 7.240 - (2.461 + 3.228) in = 1.551 in
In this phase the quota E ,
must be lower than 0 0.05 mm,
(0 0.002") than theoretical calculation.
STEP 74
Position the bevel pinion in its seat, on the
differential support, fit on the spacer
and the adjusting shims of bearing preload,
then fit the inner race of the outer pinion
bearing.
To simplify the determination of the correct preload, it is advisable to insert as many adjusting shims as required to assure a pinion
end play and not a pre-load on bearings.
STEP 75
Mount drive flange on pinion;
Nut with a torque of 570 630 Nm
(422 466 lb.ft).
Check by a dial gauge end play of pinion;
Disassemble again and change adjusting
shims in order to get the play till the pre-load.
ENG 6-46760
May, 2003
6005-38
STEP 76
- Remount and check the correct bearing pre-load
corresponding to a revolving torque (without
seal) of 2 4 Nm (1.5 3 lb.ft).
- As bearing pre-load has been determined,
remove drive flange and fit lip seal in relevant seat.
- Remount flange and lock up.
STEP 77
Mount the connecting frame locking the four
screws with 315 345 Nm (230 254 lb.ft) .
STEP 78
Position the differential unit on the support;
- mount the caps, being careful not to reverse positions;
- lock the fixing screws to 315 345 Nm
(230 254 lb.ft) .
STEP 79
- Check by a dial gauge the end play of differential
unit
- Turn in a ring nut so as to have a notch aligned against the hole of lock spring pin and
actuate the opposite one up to eliminate end
play.
Then adjust bearing pre-load by turning
in ring nut one more notch.
ENG 6-46760
May, 2003
6005-39
STEP 80
Position a dial gauge perpendicular to the ring
gear tooth and check that, with the pinion
steady, backlash of 0.18 0.23 mm.
(0.007 0.009 in).
In opposite cases, rotate both ring nuts,
displacing them the same number of notches
and nearing ring gear to pinion if backlash is
excessive .
STEP 81
Brush red lead on ring gear teeth, rotate to mesh pinion and ring gear repeatedly,
to make evident tooth contact.
Proper and correct tooth contact marks are
visible on a new bevel gear set as a result of
an optimal contact approached on the tester,
a proper axial position of pinion against ring
gear will emphasize remarking of previous
tester contact markings.
STEP 82
Press fit spring pins locking rings.
.
STEP 83
- Apply sealing compound on deflection pin of
bevel gear, screw in till bevel crown contact;
- Loosen with ~ 60 to create the play requested
and tighten the lock nut with screw in position.
ENG 6-46760
May, 2003
6005-40
STEP 84
- Perform two securing notches on pinion nut.
- Clean with care contact surfaces, apply Loctite
510 or similar compound and then mount
the differential unit on axle body.
- Lock the connecting screws with a torque of
105 115 Nm ( 77 85 lb.ft) .
- Mount the two half-shafts and axle supports
as described before.
ENG 6-46760
May, 2003
Section
6005
REAR AXLE
6005
WITH
DIFFERENTIAL LOCK
CNH Latino Americano Ltda

Brz ENG 6-46780
Printed in Brazil
January, 2003
6005-2
TABLE OF CONTENTS
SPECIAL TOOLS ............................................................................................................................ 2
DIFFERENTIAL AND CARRIER ASSEMBLY INSTRUCTION ILLUSTRATION ............................. 3
CHECKING AND DRAINING OIL HYDRAULIC PRESSURE TEST-SPECIAL OPERATION ...... 4
SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART .......................................... 5
DIFFERENTIAL ASSEMBLY ........................................................................................................... 7
DIFFERENTIAL REMOVAL ............................................................................................................. 9
DIFFERENTIAL DISASSEMBLY ..................................................................................................... 12
DIFFERENTIAL REASSEMBLY ...................................................................................................... 14
PINION AND CAGE REASSEMBLY ............................................................................................... 17
DIFFERENTIAL INSTALLING ..........................................................................................................19
RING GEAR TO PINION MOUNTING DISTANCE PROCEDURE ................................................. 20
DIFFERENTIALINSTALLATIONINAXLEHOUSING ........................................................................ 23
WHEEL REDUCTOR AXLEASSEMBLY ........................................................................................ 24
SCREW-LOCKING,SEALING AND LUBRICATING MATERIALS .................................................. 25
SPECIALTOOLS ............................................................................................................................. 25
DISASSEMBLY OF REDUCTION GEAR ........................................................................................ 26
CHECKING WEAR BRAKING DISC ............................................................................................... 26
DISASSEMBLY OF THE INPUT UNIT ............................................................................................ 26
DISASSEMBLY OF THE PLANETARY REDUCTION .................................................................... 30
ASSEMBLY OF PLANETARY REDUCTION .................................................................................. 34
SPECIALTOOLS
75301703 CHECK WEAR BRAKING DISCS - T1
75301704 ASSEMBLY OF SEAL - T2
75301705 ASSEMBLY OF SEAL - T3
ENG 6-46780
Issued 01-03
Printed in Brazil
6005-3
DIFFERENTIAL AND CARRIER - ASSEMBLY INSTRUCTION ILLUSTRATION
Brz ENG 6-46780
Issued 02-02
Printed in Brazil
6005-4
CHECKING AND DRAINING OIL - HYDRAULIC PRESSURE TEST - SPECIAL OPERATION
When the inner pinion bearing or the pinion shaft and ring gear are being replaced staking of the pinion end to the
inner pinion bearing is required.
If a staking is in the pinion shaft use procedure shown in Figure "A" and a square end staking tool.
fIf pinion has no staking groove use procedure in Figure "B" and a standard prick punch to up-set the metal over the
bearing inner race.
(3,175 mm)
ENG 6-46780
Issued 01-03
Printed in Brazil
6005-5
SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART
ENG 6-46780
Issued 01-03 Printed in Brazil
6005-6
SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART
ENG 6-46780
6005-7
DIFFERENTIAL ASSEMBLY
2
18
15
13
16
12
17
11
9
23
12
25
34
33
32
31
30
24
29
73 22
28
27
21
20
26
45
48
54
44
58
59
56
55
57
40 41
42
35
49
44
43
18
51
37
39
17
14
16 15
53
38
4
5
19
52
36
10
59
60
62
63
50
44
43
44
68
47
69
61
67
64
65
66
59
71
46
35
72
70
D1240102
ENG 6-46780
6005-8
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
DIFFERENTIAL ASSEMBLY
Q.TY.
DESCRIPTION
1
1
1
2
1
1
1
1
4
4
1
30
24
1
2
2
2
2
1
1
1
1
AR
1
6
1
1
1
1
1
1
1
1
1
1
20
CENTRAL BODY
VENT PLUG
FILL PLUG
PLUG O-RING
MAGNET DRAIN PLUG
DIFFERENTIAL CARRIER AND CAP ASSY.
CARRIER CAP
DIFFERENTIAL CARRIER
CARRIER CAP WASHER
CARRIER CAP CAPSCREW
DOWEL PIN
LOCKWASHER
CAPSCREW
O-RING
ADJUSTING NUT CAPSCREW
NUT LOCK
TAPERED BEARING
ADJUSTING NUT
BEARING
CENTER PINION BEARING
SPACER
O-RING
SHIM
BEARING RETAINER
BEARING RETAINER CAPSCREW
GREASE FITTING
OUTER PINION BEARING CUP
OIL SEAL
GREASE SEAL
THRUST WASHER
V-RING SEAL
BUSHING
O-RING
NUT
CARRIER ASSEMBLY
CARRIER CAPSCREW
ENG 6-46780
ITEM
Q.TY.
DESCRIPTION
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
20
1
1
1
1
1
4
4
1
1
12
1
1
12
1
1
1
1
1
6
4
1
3
1
1
1
2
CARRIER WASHER
THRUST WASHER
DIFFERENTIAL SIDE GEAR (LEFT)
DIFFERENTIAL SIDE GEAR (RIGHT)
THRUST WASHER
CROSS
DIFFERENTIAL PINION GEAR
THRUST WASHER
DIFFERENTIAL CASE SEAL
RING & PINION SET
CAPSCREW
PISTON HOUSING
PLUG
NUT
PISTON
OUTER SEALING RING
INNER SEALING RING
BUSHING
SEAL RETAINER
PLUG
SEALING RING
PISTON
PISTON SEAL
ADAPTOR
O-RING
FILTER
PLUG
68
69
70
71
72
73
1
1
6
6
1
AR
CLUTCH DRIVER
SNAP-RING
INNER DISC.
OUTER DISC.
FLANGE
PINION BEARING SHIM
6005-9
DIFFERENTIAL REMOVAL
STEP 1 1
STEP 2
Remove differential to axle housing capscrews (13)

and spring (12) washer.
Install four (4) capscrews "A" in the threaded holes in

the differential carrier flange (7). Attach a chain hoist.
7
A
13
12
F1240852
STEP 3
STEP 4
Tighten capscrews "A" evenly and lift differential

straight up and off of alignment dowel (11) and axle
Loosen companion flange nut (34).
housing (1).
Mount differential on differential overhaul stand. Check and record

ring gear backlash with a dial indicator.
This information is necessary for reassembly unless a new gear set
is installed.
34
A
7
11
STEP 5
STEP 6
Remove flange nut (34).
34
Remove companion flange (72).
72
F1240855
ENG 6-46780
6005-10
STEP 8
STEP 7
Remove tank port and pressure port nipples (60).
Remove adjusting nut lock capscrew (15).
60
15
STEP 10
STEP 9
GB
Remove adjusting nut lock (16).
GB
Remove seal retainer (55).
16
STEP 11
Mark differential caps (8) for reassembly. Remove cap
GB
(8), capscrews (10) and washers (9).
STEP 12
GB
Remove differential caps (8).
8
10
9
8
F1240861
ENG 6-46780
6005-11
STEP 14
STEP 13
Remove adjusting nuts (18).
Remove ring gear to flange half case capscrew nuts

(50).
18
50
STEP 16
STEP 15
Drive ring gear capscrews (47) from ring gear (46).
Remove differential assembly from carrier (6).
GB
6
47
46
STEP 17
GB
STEP 18
Remove seal retainer capscrews (25) and washer (12).
GB
Remove pinion (46) and bearing cage (24).
46
25
24
12
ENG 6-46780
6005-12
DIFFERENTIAL DISASSEMBLY
STEP 19
Pinion (46), cage assembly (24) and shims (23)

removed.
STEP 20
Remove flanged half case (48).
GB
46
48
24
23
STEP 21
GB
46
Install a seal retainer "B" as shown. Carefully and

slowly apply air to hole in seal retainer and remove
clutch piston (51).
STEP 22
GB
Remove piston inner (53) and outer (52) square cut

seals.
51
51
53
52
STEP 23
GB
STEP 24
GB
Remove ring gear (46).
Remove clutch driver snap ring (69).
8
46
69
ENG 6-46780
6005-13
STEP 25
Remove friction (70) and reaction (71) plates.
STEP 26
Remove clutch driver (68).
68
71
70
STEP 27
STEP 28
Remove differential case seal (45).
Remove cap half case to clutch housing capscrews

(36) and washers (37).
45
36 37
STEP 29
STEP 30
Separate case halves (35).
Remove standard side gear (39) and washer (38) from

cap half case (35).
35
38
35
ENG 6-46780
39
6005-14
STEP 31
Remove differential cross (42) and pinions (43) from

clutch housing (35).
STEP 32
Remove clutch side gear (40).
40
43
42
35
35
DIFFERENTIAL REASSEMBLY
STEP 33
STEP 34
Remove clutch side gear washer (41).
NOTE: All parts must be lubricated with CASE

MAT - 3505 recommended axle lubricant at reassembly.
No part should be reassembled dry.
41
35
STEP 35
Position tanged side gear washer (41) in clutch

housing (35).
STEP 36
Install clutch side gear (40).
40
41
35
35
ENG 6-46780
6005-15
STEP 37
Install cross (42), pinions (43) and thrust washers (44)

as an assembly.
STEP 38
Position standard side gear (39) on pinion and cross

assembly.
39
43
42
35
STEP 39
Place side gear washer (38) on side gear.
STEP 40
Position cap half case (35) and bearing (17) on clutch

housing (35) being sure to align match marks.
17
38
35
STEP 41
Apply Loctite #262 and install case capscrews and

washers.
Tighten to specified torque.
STEP 42
Position clutch driver (68) on splines of clutch side

gear (40).
40
36 37
68
ENG 6-46780
Issued 01-03 Printed in Brazill
6005-16
STEP 43
STEP 44
Install driver to gear snap ring (69).
Position 1st friction plate (70) in half case (35). Note

notch in splines.
70
69
35
STEP 45
STEP 46
Install 1st reaction plate (71).
Install next friction plate (70) aligning notch in friction

plate with notch in preceding friction plate. Alternate
reaction and friction plates (70) until six (6) friction
plates and six (6) reaction plates (71) are installed, and always align
the notch with the preceding friction plate notch.
71
70
35
STEP 47
Position new square cut inner (53) and outer (52) seal
rings on piston (51).
STEP 48
Carefully tap piston (51) into position in flange half

case (48) using caution as not to damage seal rings
(52), (53).
51
52
54
51
48
ENG 6-46780
6005-17
STEP 49
Align capscrew holes and match marks of flanged half

case (48) with clutch housing (35).
STEP 50
Place flanged half case (48) in position.
48
48
35
STEP 51
Turn differential body assembly (35) over and align

ring gear capscrew holes with body holes.
35
STEP 52
Tap ring gear (46) into position. Temporarily install two

(2) ring gear to flange half case capscrews (47) and
nuts (50) to hold differential assembly together.
47 50
46
46
PINION AND CAGE REASSEMBLY
STEP 53
Press inner bearing (19) on pinion (46).
STEP 54
Stake pinion (46) to bearing inner race four (4) places

equally spaced around diameter. (Refer to SPECIAL
OPERATION) page 2.
46
19
19
ENG 6-46780
46
6005-18
STEP 55
Press center bearing (20) on pinion shaft (46) with

large diameter of bearing down.
NOTE:
A pinion bearing spacer (21) and shim kit
(73) is provided for repair of carrier assemblies. This kit consists of
a spacer and a quantity of shims. If pinion (46), pinion bearings
(20), (27), or bearing cage (24) was not changed, use original
bearing spacer (21) for reassembly.
STEP 56
Position pinion bearing spacer (21) and shim (73) on

pinion shaft (46).
If pinion and shim kit is used also add one (1) shim.
73
46
46
21
20
20
STEP 57
Install center taper bearing cup (20) in bearing cage

(24).
STEP 58
Install outer bearing cup (27).
24
20
STEP 59
ENG 6-46780
Place outer taper bearing (27) in bearing cup.
STEP 60
Position cage (24), cup (20), (27) and bearing on pinion

(46). Press outer taper bearing (27) in place.
6005-19
Install input flange (72) and flange nut (34) on pinion
(46). Tighten nut to 600 lbf.ft. [813 Nm] minimum (dry
threads). Locate pinion cage in vise to allow pinion to
rotate. Use an "inch pound" torque wrench "D" to check rolling
pinion bearing resistance torque.
Rolling torque to be 13 to 23 lbf.in. [1.5 2.6 Nm] if rolling torque is
not within specifications, add shims (73) to decrease torque or
remove shims (73) o increase torque.
STEP 61
72
34
STEP 62
NOTE:
This rolling torque check must be made
again after pinion and cage assembly (24) is installed
in carrier housing (6).
Install bearing cage and pinion shaft assembly (24) in differential
carrier assembly (6) with original bearing cage shims (73). Use four
(4) oil pinion seal retainer capscrews (25) with washers (12) to pull
pinion shaft assembly (46) fully into carrier assembly. Make sure oil
passages are aligned.
Use "inch pound" torque wrench to check bearing preload. If
bearing preload is not between 13 and 23 lbf.in. [1.5 2.6 Nm],
disassemble parts and add shims (73) to decrease preload or
remove shim (73) to increase preload.
NOTE:
Flange (24) will be removed after ring gear to pinion
tooth contact and backlash has been set.
STEP 64
STEP 63
DIFFERENTIAL INSTALLING
Insert bar through differential to facilitate hoisting.
Position differential (35) into carrier (6), tilting it so that
ring gear (46) will clear inner bearing boss in carrier (6).
Position differential taper bearing cups on each side

over taper bearings (17).
46
17
35
17
STEP 66
STEP 65
Install adjusting nuts (18) on each side against bearing
cup.
NOTE:
Turn adjusting nuts (18) by hand to be
sure of proper thread alignment.
18
Position bearing caps (8) on bearings and adjusting

nuts (18), making sure match marks made during
disassembly are properly aligned.
Install cap bolts (10) and washer (9) and tighten lightly. Do not
torque this time.
18
9
8
10
18
8
ENG 6-46780
6005-20
RING GEAR TO PINION MOUNTING DISTANCE PROCEDURE
STEP 67
Use a dial indicator "E" as shown. Move ring gear (46)

by loosening one adjusting nut (18) and tightening
opposite adjusting nut. Adjust position until gear
backlash is to backlash specifications of .009" (0.23 mm) to .013"
(0.33 mm) for new ring gear set, or adjust to backlash noted at
disassembly for used gears.
When proper backlash is achieved, tighten opposite adjusting nut
(18) to set preload on taper bearings. Using only thumb and
forefinger, move ring gear. When ring gear becomes difficult to
move, preload on bearing is set.
STEP
GB69
46
Remove differential assembly (35) from carrier (6).
STEP 68
IF MOUNTING DISTANCE PINION SETTING GAUGE

"E" IS USED, FOLLOW INSTRUCTIONS SUPPLIED
WITH GAUGE.
USE THE FOLLOWING PROCEDURE WHEN A PINION SETTING
GAUGE "E" IS NOT AVAILABLE.
Check ring and pinion gear (46) for proper tooth contact. Paint ring
gear with a gear tooth marking compound. When ring and pinion
gears are rotated, the compound is squeezed away by the contact
of the teeth, leaving bare areas the exact size, shape and location
of the contacts. As a rule, painting about 10 or 12 teeth is sufficient
for checking purposes.
Sharper impressions may be obtained by applying a small amount
of resistance to the ring gear with a flat steel bar and using a
wrench to rotate the pinion. Gears should be rotated, under slight
load, until ring gear has turned at least one revolution in both
directions.
Check tooth contact pattern on drive side (convex side) of ring gear
teeth. Coast side will automatically correct when drive side pattern
is correct. Refer to gear tooth contact chart. If proper tooth contact
pattern is not as shown, readjust backlash or, add to or subtract
from shim pack (73) between bearing cage flange and differential
housing.
Addition of or subtraction of shims should be made in small
increments until proper contact is established.
After optimum tooth contact is made, the differential and pinion
must be removed from the carrier, this will allow for proper sealing
measures at reassembly.
STEP 70
Remove pinion and cage assembly (24) from carrier.

Remove flange (24) from pinion. Remove pinion (46)
from pinion bearing cage (24).
46
24
35
STEP 71
seal in.
Apply Loctite #515 to outer diameter of the pinion oil

seal (28).
Press seal (28) in pinion bearing cage (24) with lip of
STEP 72
Install grease seal (29) with lip of seal up.
29
28
24
ENG 6-46780
6005-21
STEP 73
Press V-ring washer (30) against grease seal (29).
STEP 74
Apply Loctite #515 to bearing cage shims (23) and

joining surfaces in a continuous bead and spread over
entire surface to provide a thin and even coat.
23
30
24
STEP 76
STEP 75
Press pinion into bearing cage and seal assembly.
Position pinion and cage assembly (24) in carrier
housing (6).
151 lb.ft).
Install cage (24) to carrier housing, capscrews (25) and

washers (12).
Apply Loctite #262 and tighten to 185 205 Nm (136
24
24
25 12
STEP 77
Position a new V-ring seal (31) on companion flange

(72). Apply RTV-Q3-7069 to the flange splines. Install
flange (72) on pinion (46).
Some models will have an "O" ring (33).
72
31
STEP 78
Apply RTV-Q3-7069 to pinion threads and between

flange and flange nut (34). Install flange nut (34) and
tighten to 600 lbf.ft [813 Nm].
34
33
46
ENG 6-46780
6005-22
STEP 79
INSTALL DIFFERENTIAL ASSEMBLY IN CARRIER

HOUSING AS EXPLAINED IN FIGURES PAGE 1,
AGAIN MAKE RING GEAR BACKLASH CHECK AND
BEARING PRELOAD CHECK.
MAKE A RING AND PINION TOOTH CONTACT CHECK AS
EXPLAINED AFTER FIGURE PAGE 3 AND 4.
IF OPTIMUM TOOTH CONTACT PATTERN IS MADE, PROCEED
WITH FIGURE
STEP 80
Install new rotary seals (57) on piston housing (55).

Place seal retainer and seals in position as shown.
STEP 82
STEP 81
Install ring gear to flange half case capscrews (36).

Apply Loctite #262 to capscrew threads and install nuts
(50). Tighten nuts to 185 205 Nm (136 151 lb.ft).
Install new square cut seal (59) on piston retainer (58),

place piston retainer in seal retainer (55). Install
adjusting nut lock.
Apply Loctite #262 to lock capscrew (10). Install capscrew (10) and
washer (9) and tighten to 560 615 Nm (413 454 lb.ft).
36 50
58 59
55
9 10
F1240928
STEP 83
lb.ft).
Install new square cut seals (61) to "O" ring (59)

nipples (60). Turn carrier over and install nipples
in carrier housing (7). Tighten to 40 50 Nm (30 36
60
STEP 84
59
61
ENG 6-46780
6005-23
DIFFERENTIAL INSTALLATION IN AXLE HOUSING

STEP 85 Position a new carrier to axle housing seal (14) on
carrier (6).
STEP 86
Apply a light coat of grease to flange of carrier (6);

lower assembly carefully into axle housing. Align
cowel pin (11) in housing (1) with hole in carrier. Tap
at dowel pin location and lower assembly into position.
6
6
14
11
1
F1240933
STEP 87
STEP 88
Install carrier (6) to housing capscrews (13) and spring
washers (12) .
Tighten carrier capscrews (13) to 180 210 Nm (132

206 lb. ft).
13
13
12
GB
ENG 6-46780
WHEEL REDUCTOR AXLE ASSEMBLY
6005-24
22
20
21
19
11
18
10
14
17
15
12
16
24
13
6
23
4
4
33
34
32
35
29
38 36
37
39
30
40
23
36
26
37
31
28
27
25
D1240108
1 - Top cap
2 - Screw
3 - Cover
4 - Stub axle
5 - Coupling
6 - Braking unit, assy.
7 - Intermediate disc
8 - Brake disc
9 - Spacer
10 - Adjusting bolt
11 - Spring
12 - Piston
13 - O-ring
14 - O-ring
ENG 6-46780
15
16
17
18
19
20
21
22
23
24
25
26
27
28
- Anti-extrusion ring
- Anti-extrusion ring
- Snap ring
- Input shaft
- Sealing ring
- Snap ring
- Spacer
- Bearing
- Half shaft
- O-ring
- Plug
- Screw
- Planetary gear carrier
- Screw
29
30
31
32
33
34
35
36
37
38
39
40
- Crown
- Safety plate
- Bushing
- Hub
- Sealing ring
- Inner bearing
- Outer bearing
- Snap ring
- Planetary gear
- Shim
- Snap ring
- O-ring
6005-25
SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS
1 - Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor.
2 - The table below gives an account of the typical applications of each single material, in order to facilitate replacement with similar
products marketed by different brand names with different trade marks.
DENOMINATION
APPLICATION
LOCTITE 242
Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength locking.
Before using it, completely remove any lubricant by using the specific activator.
LOCTITE 243
The oleocompatible alternative to 242. Does not require the activation of lubricated surfaces.
LOCTITE 270
Anaerobic product for very-high strength locking of screws and nuts. Before using it, completely remove any
lubricant by using the specific activator. To remove parts, it may be necessary to heat them at 80C approx.
(AREXONS)
Repositionable jointing
compound for seals
Solvent-based sealing compound for elastic seals, drying through evaporation. Used for sealing the outer diameter of sealing rings for rotating shafts with outer metal reinforcement.
SPECIAL TOOLS
T1 - 75301703 CHECK WEAR BRAKING DISCS
T2 - 75301704 ASSEMBLY OF SEAL
ENG 6-46780
T3 - 75301705 ASSEMBLY OF SEAL
6005-26
DISASSEMBLY OF REDUCTION GEAR
CHECKING WEAR BRAKING DISC

STEP 89
CAUTION! Execute all operations on both reduction

gear units.
Remove upper oil fill cap (1).
Brake once and, while brake is pressed, use tool T1 to

check thickness "S" between the discs.
Minimum admissible "S" value: 5 mm.
CAUTION! If necessary, replace braking and intermediate discs on
both sides.
STEP 90
T1
1
S
D1240103
DISASSEMBLY OF THE INPUT UNIT

STEP 91 Loosen and remove check screws (2) of cover (3).
STEP 92 With
the help of two levers inserted in the provided

slots, detach the complete cover (3) from the stub axle
(4).
3
3
2
2
STEP 93
Connect the complete cover (3) to a hoist and remove

it.
STEP 94
Lift the driving coupling (5) of braking discs.

To lift the coupling, use two screw-drivers inserted in
two opposing lubrication holes.
5
3
ENG 6-46780
6005-27
STEP 95
STEP 96
Remove driving coupling (5).
Remove the braking unit (6) to be replaced.
STEP 97
Remove spacer (9) and clean any deposits that may

have formed due to brake disc wear.
CAUTION! Prevent any deposits from falling in the
planetary reduction.
STEP 98
Loosen up the adjusting bolt (10).

NOTE. Loosen adjusting bolts (10) in an alternate and
criss-cross manner.
10
9
F1240987
STEP 99
Remove adjusting bolts (10) and springs (11) of piston

(12) reversal.
10
ENG 6-46780
STEP 100
Slowly introduce low-pressure compressed air through

the connection point of service brake in order to
extract the piston (12).
CAUTION! Hold piston (12) as it may be rapidly ejected and
therefore damaged.
12
11
12
6005-28
STEP 101 Remove O-rings (13) and (14) and anti-extrusion rings
STEP 102
(15) and (16) from piston (12).

NOTE. O-rings (13) and (14) and anti-extrusion rings
(15) and (16) must be replaced every time the unit is disassembled.
13
Remove the snap ring (17) that checks the input shaft
(18).
14
12
18
11
17
12
STEP 104
STEP 103
Extract the complete input shaft unit (18).

Extract sealing ring (19).
NOTA. Note down assembly direction of sealing ring (19).
18
Remove snap ring (20) and spacer (21).

NOTA. Note down orientation of spacer (21).
Place the input shaf under a press and extract the bearing (22).
19
20
18
22
21
ENG 6-46780
6005-29
STEP 105 With the help of a press, fit bearing (22) on the input
STEP 106
shaft (18).
Install spacer (21) and snap ring (20).

NOTE. Check the orientation of the sealing ring.
18
21
22
20
21
STEP 107 Install the sealing ring (19) in the cover (3).
STEP 108
CAUTION! 1 - Pay attention to ring (19) orientation.

2 - Lubricate the outer surface and the sealing lip.
19
Install the complete input shaft (18) in the cover (3) by

using a plastic hammer.
18
19
STEP 109 Fit the snap ring (17) that checks the complete input
STEP 110
shaft (18) into the cover.
rings.
Fit O-rings (13) and (14), and anti-extrusion rings (15)

and (16) on piston (12).
NOTA. Pay attention to the position of anti-extrusion
13
14
12
17
11
12
ENG 6-46780
6005-30
STEP 111 Lubricate
the O-rings and install the complete piston

(12). Orient piston and drive it to its end of stroke with a
plastic hammer.
STEP 112
Position springs (11), apply Loctite 242 to screw thread

(10) and tighten adjusting bolts.
NOTE. Tighten adjusting bolts (10) with a standard
wrench, using the alternate and criss-cross methods.
12
10
STEP 113
11
STEP 114
Lock adjusting bolts (10) with a dynamometric wrench
set to 10 15 Nm (7.4 - 11 lb.ft).
Fit the spacer (9) in the stub axle (4).
10
4
STEP 115
Fit the driving coupling (5) on the half shaft (23).
STEP 116
Lubricate the brake discs (8) and fit them into the stub
axle (4) starting with a steel disc (7) and a brake disc
(8).
NOTA. The sequence starts and ends with a steel disc (7).
8
7
4
23
ENG 6-46780
6005-31
STEP 118
STEP 117
Check that O-ring (24) of cover (3) is in good condition
and correctly positioned; lubricate the seal and install
the complete cover.
Lock cover (3) with screws (2) by using a dynamometric wrench set to a torque of 82 91 Nm (60-67 lb.tft).
3
2
24
DISASSEMBLY OF THE PLANETARY REDUCTION

STEP
GB 67 Remove the plug (25).
NOTA. The cap hole must be used for removing the
planetary gear unit.
STEP 68
Remove the screws (26) fixing the planetary gear

carrier (27).
27
25
26
STEP 118 Connect the complete planetary gear carrier (27) to a
hoist.
NOTES. 1 - Use a fixed bracket "A", using a spacer
and the plug (25) hole.
2 - To detach planetary gear carrier (27), use two levers inserted in
the slots provided.
STEP 119 Remove the complete planetary gear carrier (27).
27
A
27
ENG 6-46780
6005-32
STEP 120
STEP 121
Extract the half shaft (23).
Extract and remove the locking screws (28) of crown

(29).
23
STEP 121
28
29
STEP 122
Remove the safety plate (30).
Partly and equally tighten three screws (28) arranged

in a triangular way.
With the help of an extractor, disengage crown (29)
from centring bushing (31).
30
29
28
STEP 123
Remove the three screws (28) which you have applied

in the previous phase and remove the crown (29).
STEP 124
Remove the outer bearing (35).

Hook the complete hub (32) to a hoist and remove it.
To ease hub extraction, use a plastic hammer.
29
30
35
ENG 6-46780
32
6005-33
STEP 125
STEP 126
Remove sealing ring (33) from hub (32).
Extract sealing ring (33) and inner bearing (34).
33
33
34
32
STEP 127
Remove the external thrust blocks of bearings (34) and

(35).
STEP 128
Remove the snap rings (36) that check the planetary

gear (37).
36
34
37
35
STEP 129
Extract the planetary gear (37).

NOTE. Note down assembly direction of gears.
37
ENG 6-46780
STEP 130
ONLY IF NECESSARY
Using an extractor for inner parts, remove shim (38).
38
6005- 34
ASSEMBLY OF PLANETARY REDUCTION

STEP 131 ONLY IF PREVIOUSLY REMOVED
With the help of a push rod and a plastic hammer,

install the shim washer (38).
STEP 132
Fit planetary gear (37) into planetary gear carrier (27).

CAUTION! Pay attention to gears direction of assembly.
37
27
38
STEP 134
STEP 133
Fit the snap rings (36).
Place the hub (32) under a press and, using tool T2,
position the ring of the outer bearing (35).
T2
36
35
37
32
STEP 135
Turn the hub (32) upside down and fit the ring of the
inner bearing (34) by using tool T2.
STEP 136
Install the inner bearing (34).

Apply replaceable seal putty to the outer surface of
sealing ring (33).
T2
34
33
32
ENG 6-46780
34
6005-35
STEP 137
Position the sealing ring (33) on the hub and, with the
help of tool T3, press ring down into its seat.
NOTE. Pay attention to ring orientation.
STEP 138
Connect the hub to a hoist and fit the complete hub

(32) to the stub axle (4).
NOTE. If necessary, give some light hammer blows
around the circular edge with a plastic hammer.
T3
32
33
STEP 139
Make sure that hub (32) is well seated by giving it

alternate rotating motions.
Install the outer bearing (35).
STEP 140
Position crown (29) by centring the holes onto the

centring bushing (31).
29
31
32
35
STEP 141
Fit crown (29) onto the bushing (31) by using a push

rod and a plastic hammer.
NOTE. Check that crown (29) is properly engaged
onto the outer bearing (35).
STEP 142
Fit the safety plate (30).
30
29
ENG 6-46780
6005- 36
STEP 144
STEP 143
Apply Loctite 270 to the thread of screws (28) and

screw tightly; tighten screws in an alternate and crisscross manner by means of a dynamometric wrench set
to 220 222 Nm (163 - 164 lb.ft).
Insert and engage half shaft (23), complete with snap

ring (39), into the input shaft.
23
28
STEP 146
STEP 145
Check that O-ring (40) of planetary gear carrier (27) is

in good condition and correctly positioned.
Lubricate the O-ring (40) and install the complete
planetary gear carrier (27).
Fix planetary gear carrier (27) to hub (32) with screws

(26) and tighten in a criss-cross manner with the help
of a dynamometric wrench set to 82 91 Nm (66 - 67 lb.ft).
27
27
26
32
40
STEP 147
Install plug (25) and screw it with a dynamometric

wrench set to 35 - 4 0 Nm (26 - 30 lb.ft).
25
ENG 6-46780
GB
Section
6006
TANDEM DRIVE
LIMITED SLIP REAR AXLE
6006
845 - 865 Grader

ENG 6-46791
January, 2003
6006 - 2
DESCRIPTION.............................................. ........................................................................ PAGE
SPECIAL TOOLS ............................... ................................................................................... 3

GENERAL DESCRIPTION..................................................................................................... 4
DISASSEMBLY OF THE TANDEM AND REAR AXLE REMOVAL AND INSTALLATION ....... .... 7
DISASSEMBLY OF THE TANDEM ....... ...................................................................................... 7
REAR AXLE REMOVAL AND INSTALLATION ............................................................................ 16
ASSEMBLY OF THE TANDEM ............................................................................................ 16
TANDEM CASE OSCILLATION ADJUSTMENT PROCEDURES ................................................ 17
DETERMINATION OF THE SHIM PACK ..................................................................................... 17
ENG 6-46790
6006 - 3
Special Tool 75312684
Special tool 75300850
ENG 6-46790
6006 - 4
GENERAL DESCRIPTION
TANDEMS
Driving sprockets, which are splined to the rear axle shafts, transfer power through heavy roller driving
chains to the wheel shaft sprockets which are attached to the wheel shafts. Wheel shafts are supported by
inner and outer bearing retainers.
Each tandem assembly oscillates and pivots on a tandem hub bushing, located in the hub.
29. Drive sprockets

30. Adjusting shim
31. Sprockets retaining washer
32. Capscrews
33. Lock plate
ENG 6-46790
6006 - 5
1. Tandem Case
2. Capscrew
3. Bearing Retainer Flange
4. Bearing
5. Shaft
6. Lip Seal and snap ring
7. Nut
8. Grease Retainer
9. Sprocket
ENG 6-46790
10. Chain
11. Capscrew
12. Capscrew
13. Shim
14. Capscrew
15. Shim Cap
16. Inner Cap
17. Retainer plate (holding)
18. Snap ring
6006 - 6
18 - Hub
19 - Shim
20 - Washer
21 - Capscrew
22 - Tandem pivot seal
23 - Thrust washer 363x440mm (14.29x17.32)in
ENG 6-46790
24 - Thrust washer 380x440mm

(14.96x17.32)in
25 - Tandem retaining plate
26 - Washer
27 - Capscrew
28 - Bushing
6006 - 7
DISASSEMBLY OF THE TANDEM AND

REAR AXLE REMOVAL AND
INSTALLATION
DISASSEMBLY OF THE TANDEM
- Install the grader articulation lock pins into their
frame locations.
.
TANDEM TEARDOWN
- Park the grader on a level surface.

- Place the transmission in neutral and apply the
handbrake. Ensure the handbrake is correctly
adjusted and in good working order.
- Lower the moldboard and all attachments to the

ground. Do not apply down-pressure.
- Overall view of tractor. Tag machine to note

that machine is being serviced.
- Shut down the engine.
- Lift grader by extending the blade to the side

being worked upon. Apply blade down pressure
on the side to be lifted.
- Install the service pin in the LOCKED position

(see the Operators Manual).
- Install chocks at the front and rear tandem
wheels. Wedge the chocks in place.
WARNING
Scissors points in area of service. Stay clear
during operation. Block securely for service.
WARNING
Lift and handle all heavy parts with a lifting
device of proper slings and hooks. Use lifting
eyes if provided. Watch out for people in the
vicinity.
WARNING
Observe all start up and shut down procedure an
WARNING listed in the operation and maintenance instruction manual.
Keep people clear of attachments and tools
while in raised position, to prevent possible
injury.
Remove the tires
- Support the grader with approved supports.
WARNING
When supporting machine component must be
removed or installed and jacks are used, be sure
the support of the jack at the machine and on
the ground are appropriate to the load to be
applied. Transfer the load to authorized blocking
or jack stands immediately. Do not work on or
under the machine or its components while
supported only on a jack or other lifting device,
according to local or national requirements.
ENG 6-46790
6006 - 8
Remove the cover screws.
Remove the drain plug and drain the oil.

1- Filler Plug
2- Level Plug
3- Drain Plug, inside wall of tandem case.
Remove the two access covers on the top of the

tandem case. Remove the four covers from the sides
of tandem case.
Put the filler plug back in the place.
ENG 6-46790
6006 - 9
Remove the bolts from the center cover to access

the chain drive gears.
Remove the cover and gasket.
Flatten lockplate for capscrew removal.
Remove retaining plate capscrews.
ENG 6-46790
6006 - 10
Remove the sprockets retaining plate.
Remove the adjustment shim.
Position the chain master link at access window on

side of tandem case. Remove the cotter pins.
Remove master link.
ENG 6-46790
6006 - 11
Remove chain from drive gear.
Use a hook to help removing the chain.
Prop the chain on tandem case and remove it from the

tandem.
Remove the drive gears from the drive shaft.
ENG 6-46790
6006 - 12
Remove the cotter pin from the hub nut.
Remove the nut and washer from the hub shaft.
Remove the hubs and key using tool 75312684 and the
from hub shaft.
Remove capscrews and shaft bearing retainer.

Remove the bearing retainer. Leave the shaft in the
tandem. The shaft will cock when the retainer is
removed.
ENG 6-46790
6006 - 13
Lift the shaft and sprocket assembly with a sling.
Remove capscrews from inside bearing retainer.

Remove bearing retainer from tandem by using rubber
hammer from inside and support bearing retainer with
opposite hand.
Remove sprocket to shaft lock plate capscrews.
Use puller set to remove both bearings from the shaft.

Pull the bearing by placing the bearing puller behind
seal.
ENG 6-46790
6006 - 14
Install the splined sprocket onto the shaft. Torque the

capscrews to 61 ~ 68 Nm (45 ~ 50 ft lb.).
Install bearing seal and bearing onto the shaft. Heat
the bearing to 121oC (250oF). Be sure the bearing is
seated onto the shaft.
Remove the bearing race from the retainer using

master bearing and seal driver kit P/N 75300850.
WARNING
It is unsafe to strike hardened steel parts with anything
other than a soft iron or nonferrous hammer.
When installing or removing such parts wear safety
glasses with side shields and heavy gloves, etc., to
reduce the possibility of injury.
Install bearing with tool P/N 75300850.
Remove bearing race from the wheel shaft bearing

retainer with puller set.
ENG 6-46790
6006 - 15
Install bearing cup in the wheel shaft bearing retainer

using tool P/N 75300850.
Remove the lip seal (6) and snap ring (10) from the
bearing retainer flange (3).
Install the snap ring (10).
Remove the hub located between the rear axle and the
tandem case.
Using a proper wrench, remove the capscrews from

the rear axle flange to separate tandem from axle.
Separate tandem case and rear axle using adequate

hoist.
Save shims for reassembly.
ENG 6-46790
6006 - 16
Remove phenolic thrust washer .

Remove lockwire and capscrews.
Remove the tandem retaining plate.
Remove the phenolic thrust washer.
Remove external tandem pivot seal.
Remove hub.
Remove internal tandem pivot seal.
Remove phenolic bushing
REAR AXLE REMOVAL

Disconnect the drive shaft at differential input flange
(1).
Remove nuts retainer plate, housing nuts and
capscrews(2).
Disconnect the brake supply lines and brake cooler
lines.
Remove the rear axle assy.
NOTE: For rear axle disassembly and assembly see
section 6005.
REAR AXLE ASSEMBLY
Position the rear axle under the grader.
Install retainer plate nuts, housing nuts and
capscrews(2) torque to 830 ~ 850 Nm (614 ~629 ft lb.).
Connect the brake supply lines and brake cooler lines.
Connect the drive shaft at differential input flange (1),
capscrews torque to 135 ~165 Nm (100 ~ 122 ft lb.) use
Loctite 271.
ASSEMBLY OF THE TANDEM
Install bushing and tandem pivot seal.

Apply light coat of graphite grease on the outside
diameter of phenolic bushing.
ENG 6-46790
6006 - 17
TANDEM CASE OSCILLATION ADJUSTMENT

PROCEDURES
DETERMINATION OF THE SHIM PACK (SP)
- Clean all the parts, hub, thrust washer 363 x 440
mm (14.29 x 17.32 in), tandem retaining plate &
thrust washer 380 x 440mm (14.96 x 17.32 in) and
and assemble them per the sketch in the vertical
position.
- Measure the clearence "X"in six (6) equally
spaced points.
- Use the largest dimension found = X.
- Establish the shim pack(19) "SP"(mm) = X + (0.15
~0.20mm).
"SP"(in) = X + (.006 ~.008 in).
Assemble the hub (18) and external seal (22).
Install thrust washer (23) with a thin coating of

graphite grease.
Assemble tandem retaining plate (25), washer (26)

and capscrews (27). Torque the capscrews to
450 ~ 480 Nm (333 ~ 355 lb ft.) .
Apply lock wire to retaining capscrews, see figure.
Assemble the tandem case on the axle using the
parts and the shims, covering the cleaned part
surfaces with a thin coating of graphite grease.
After assembly, torque all the hub capscrews (21)
to 280 ~ 320 Nm (207 ~ 236 lb ft.) .
The tandem case should pivot on the axle with a

force (P) of 70 to 150 kg (150 ~ 330 lb), applied at
the center of one of the wheels.
ENG 6-46790
6006 - 18
- Install drive sprockets (29), adjusting shim (30),

sprockets retaining washer (31), capscrews (32) to
115 ~125 Nm (85 ~ 93 lb.ft.) .
Lock the capscrews.
Place chain in case tandem.
Apply Permatex or Loctite 1114 to inner cap and

tandem case. Place rear bearing cap on case.
Tighten capscrews to torque 122 ~ 136 Nm
(45 ~50 ft lb.).
ENG 6-46790
6006 - 19
Pack the rear bearing with grease prior to installing

the sprocket and shaft in the tandem case. Install
the gear and shaft in the tandem case.
Pack front bearing with grease.

Do not engage chain in sprocket.
Leave the outboard seal off the wheel end. Temporarily install the wheel end onto the tandem case.
Tighten the capscrews to torque.
Place cap without shims onto bearing cap. Tighten

four screws evenly and rotate shaft at the same
time.
Check the shaft bearing for the correct rolling

torque.
Rolling torque is adjusted by shims on the opposite
side of the case. When the rolling torque is observed to be within specification, measure the gap
between the two caps. Install gap with shims.
Tighten shim cap capscrew to torque 122 ~136 Nm
(90 ~ 100 ft lb.) use loctite 277 and check rolling
torque to 6.8 ~7.4 Nm (60 ~70 in lb.).
ENG 6-46790
6006 - 20
Remove the bearing retainer flange and position the

chain around the sprocket.
Do not let the chain bunch in one position.
Reinstall the bearing retainer flange after applying
Loctite 1114 or Permatex and tighten the retaining
capscrews torque to 122 ~136 Nm (90 ~100 ft lb.).
Wheel end shaft bearing shim with greased packed

bearings and prior to installing seal.
Install the seal. Using a tube (3 15/16" x 10") press

the seal onto the shaft and wheel end.
Loop the chain over the drive gear. Connect the two
ends of the chain with the master link.
Install master link.

Install cotter pin (always install new cotter pin).
ENG 6-46790
6006 - 21
Install the gasket and gear cover onto the tandem

case.
Apply Loctite 1114 capscrews thread and torque to
28 ~35 Nm (21 ~26 ft lb).
Install tandem chain access covers.
Apply Loctite 1114 on the both sides of the gasket

and capscrews thread.
Install gaskets, cover and capscrews torque to
28 ~35 Nm (21 ~26 ft lb).
Add specified oil through the filler holes until oil runs
out of the oil level hole, see operators manual.
Tighten the filler plug.
Install the key on the hub shaft.
ENG 6-46790
6006 - 22
Install the washer and the nut on the wheel hub

shaft.
Torque the nut 540 ~560 Nm (400 ~ 415 Ft lb.).
Install tires to the tandem case.

Torque the nuts to 407 ~476 Nm (300 ~350 Ft lb.).
Wheel nuts tightening sequence.
ENG 6-46790
Section
6006
6006
TANDEM DRIVE
DIFFERENTIAL HYDRAULIC LOCK

ENG 6-46791
May,2003
6006 - 2
DESCRIPTION.............................................. ........................................................................ PAGE
GENERAL DESCRIPTION..................................................................................................... 3
DISASSEMBLY OF THE TANDEM AND REAR AXLE REMOVAL AND INSTALLATION ....... .... 5
DISASSEMBLY OF THE TANDEM ....... ...................................................................................... 8
REAR AXLE REMOVAL AND INSTALLATION .............................................................................. 10
ASSEMBLY OF THE TANDEM ............................................................................................ 11
TANDEM CASE OSCILLATION ADJUSTMENT PROCEDURES .............................................. 12
DETERMINATION OF THE SHIM PACK ..................................................................................... 12
ENG 6-46790
6006 - 3
GENERAL DESCRIPTION
TANDEMS
Driving sprockets, which are splined to the rear axle shafts, transfer power through heavy roller driving
chains to the wheel shaft sprockets which are attached to the wheel reduction (four planetary assemblies
bolted to tandem case).
Each tandem assembly oscillates and pivots on a tandem hub bushing, located in the hub.
Differential hydraulic lock is operator controlled.
Outboard wet disc brakes.
ENG 6-46790
6006 - 4
18 - Hub
19 - Shim
20 - Washer
21 - Capscrew
22 - Tandem pivot seal
23 - Thrust washer 380x440mm (14.96x17.32)in
ENG 6-46790
24 - Tandem retaining plate

25 - Washer
26 - Capscrew
27 - Bushing
6006 - 5
DISASSEMBLY OF THE TANDEM AND

REAR AXLE REMOVAL AND
INSTALLATION
DISASSEMBLY OF THE TANDEM
- Install the grader frame lock pins into their
frame locations if working on an articulated
grader.
TANDEM TEARDOWN
- Park the grader on a level surface.
- Place the transmission in neutral and apply the

handbrake. Ensure the handbrake is correctly
- Lower the moldboard and all attachments to the
ground. Do not apply down-pressure.
- Overall view of tractor. Tag machine to note

that machine is being serviced.
- Shut down the engine.
- Lift grader by extending the blade to the side

being worked upon. Apply blade down pressure
on the side to be lifted.
- Install the service pin in the LOCKED position

(see the Operators Manual).
- Install chocks at the front and rear tandem
wheels. Wedge the chocks in place.
WARNING
Scissors points in area of service. Stay clear
during operation. Block securely for service.
WARNING
Lift and handle all heavy parts with a lifting
device of proper slings and hooks. Use lifting
eyes if provided. Watch out for people in the
vicinity.
WARNING
Observe all start up and shut down procedure and
WARNINGS listed in the operation and maintenance instruction manual.
Keep people clear of attachments and tools
while in raised position, to prevent possible
injury.
Remove the tires
- Support the grader with approved supports.
WARNING
When supporting machine component must be
removed or installed and jacks are used, be sure
the support of the jack at the machine and on
the ground are appropriate to the load to be
applied. Transfer the load to authorized blocking
or jack stands immediately. Do not work on or
under the machine or its components while
supported only on a jack or other lifting device,
according to local or national requirements.
ENG 6-46790
6006 - 6
Remove the cover screws.
Remove the drain plug and drain the oil.
Remove the chain access cover.
Put the filler plug back in the place.
ENG 6-46790
6006 - 7
Remove the bolts from the center cover to accessthe chain drive sprockets.
Remove the cover and gasket.
Position the chain master link at access window on

side of tandem case.
Remove the cotter pins.
Remove the master link .
ENG 6-46790
6006 - 8
Remove the chains.
Remove the drive sprocket.
Remove the half shaft.
Remove the hub located between the rear axle and the
tandem case.
Using a proper wrench, remove the capscrews from

the rear axle flange to separate tandem from axle.
ENG 6-46790
6006 - 9
Separate tandem case and rear axle using adequate

hoist.
Save shims for reassembly.
Remove phenolic thrust washer .

Remove lockwire and capscrews.
Remove the tandem retaining plate.
Remove the phenolic thrust washer.
Remove tandem pivot seal.
Remove hub.
Remove phenolic bushing.
Remove lip seal tandem case.
ENG 6-46790
6006 - 10
Remove lip seal (from the) axle case.

REAR AXLE REMOVAL
Disconnect the drive shaft at differential input flange
(2).
Remove nuts retainer plate, housing nuts and
capscrews(3).
Disconnect the brake supply lines and differential lock
lines and guard.
Remove the rear axle assy.
section 6005.
REAR AXLE ASSEMBLY
Position the rear axle under the grader.
Install retainer plate nuts, housing nuts and
capscrews(2) torque to 830 ~ 850 Nm (614 ~629 ft lb.).
Connect the brake supply lines and differential lock
lines and guard.
Connect the drive shaft at differential input flange (1),
capscrews torque to 135 ~165 Nm (100 ~ 122 ft lb.) use
Loctite 271.
ENG 6-46790
6006 - 11
ASSEMBLY OF THE TANDEM
Install bushing and tandem pivot seal (see figure).
Apply light coat of graphite grease on the outside

diameter of phenolic bushing.
Install new lip seal (see figure).
Mark covers to identify the tandem stop angle.

Remove the cover,bearing and sprocket.
Remove the wheel reduction axle assembly.
section 6005.
Install the wheel reduction axle assembly, apply Loctite
1114 on the surface and studs thread.
Nuts torque to 267 ~ 273 Nm (198 ~202 lb ft.).
Install sprocket,bearing.
Apply Loctite 1114 on the cover and capscrews
thread.
Install cover and capscrews torque to 122 ~ 136 Nm
(90 ~100 ft lb.).
ENG 6-46790
6006 - 12
TANDEM CASE OSCILLATION ADJUSTMENT

PROCEDURES
DETERMINATION OF THE SHIM PACK (SP)
- Clean all the parts, hub, thrust washer 363 x 440
mm (14.29 x 17.32in), tandem retaining plate &
thrust washer 380 x 440mm (14.96 x 17.32in) and
and assemble them per the sketch in the vertical
position.
- Measure the clearence "X"in six (6) equally
spaced points.
Use the largest dimension found = X.
- Establish the shim pack(19) "SP"(mm) = X + (0.15
~0.20mm).
"SP"(in) = X + (.006 ~.008 in).
Assemble the external seal (22) and hub (18).
Install thrust washer (23) with a thin coating of

graphite grease.
Assemble tandem retaining plate (24), washer (25)

and capscrews (26). Torque the capscrews to
450 ~ 480 Nm (333 ~ 355 lb ft.) .
Apply lock wire to retaining capscrews, see figure.
Assemble the tandem case on the axle using the
parts and the shims, covering the cleaned part
surfaces with a thin coating of graphite grease.
After assembly, torque all the hub capscrews (21)
to 280 ~ 320 Nm (207 ~ 236 lb ft.) .
The tandem case should pivot on the axle with a

force (P) of 70 to 150 kg (150 ~ 330 lb), applied at
the center of one of the wheels.
ENG 6-46790
6006 - 13
Install new lip seal (see figure for assembly

position ).
Install the half shaft,carefully, to avoid damage to

seals.
Install the drive sprocket.
ENG 6-46790
6006 - 14
Loop the chain over the drive gear. Connect the two
ends of the chain with the master link.
Install master link.

Install cotter pin (always install new cotter pin).
Install the gasket and sprocket cover onto the

tandem case.
Apply Loctite 1114 to capscrews thread and torque to
28 ~35 Nm (21 ~26 ft lb).
Install tandem chain access covers
Apply Loctite 1114 on the both sides of the gasket

and capscrews thread.
Install gaskets, cover and capscrews torque to
28 ~35 Nm (21 ~26 ft lb).
ENG 6-46790
6006 - 15
Add specified oil through the filler holes until oil runs
out of the oil level hole, see operators manual.
Tighten the plugs.
Install tires to the tandem case.

Torque the nuts to 407 ~476 Nm (300 ~350 ft lb.).
Wheel nuts tightening sequence.
ENG 6-46790
SECTION INDEX
BRAKES
Section Title
Section Number
Brake pedal valve and system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7002

Hydraulic brake Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7003

2237,General David Sarnoff Avenue
Contagem, MG Brazil
ENG 6-46810
Printed in Brazil
May, 2003
HYDRAULIC BRAKE TROUBLESHOOTING
845 - 865 - 885 Grader

ENG 6-46830
Printed in Brazil
May,2003
7002
Section
7002
7002
TABLE OF CONTENTS
HYDRAULIC BRAKE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ENG 6-46830
issued 1- 03
Printed in Brazil
7002-01
DEFECTS
TROUBLE
PROBABLE CAUSE
REMEDIES
The braking action does not stop

after releasing the brake pedal.
Brake pedal seized.
Repair or replace brake pedal valve.
Brake pedal not completely

released.
Check that no hardened mud or

foreign material are located under
the pedal. Check that with the pedal
is totally released and there is no
output pressure from the brake valve.
Hard pedal travel.
Brake pedal valve pistons seized.
Repair brake pedal valve.
Hard braking operation.
Wrong pressure setting.
Checkpressure.
Weak braking effect.
Low brake pressure.
Check pressure.
Brake discs (axle) need to be

replaced.
Replace discs.
Air in the system.
Bleed system.
Oil leaks in system.
Inspect and eliminate leaks.
Recharge pressure of accumulators Check pressure.

below nominal value or brake
accumulators inefficient.
The accumulators do not recharge.
Contamination seized the priority Repair or replace brake pedal valve.

valve (in brake pedal valve).
Braking pressure fluctuating.
Recharge pressure of accumulators Check recharge pressure.

lower than nominal value. ( If
recharge pressure of accumulators
is low, the brake low pressure
indicator on panel should be ON.
The pressure switch is set at 65 5
bar ( 942 72 psi). Check the
precharging pressure of the
accumulators.
The brake charge pump overheats.
The recharge pressure of the Check recharge pressure.

accumulators is lower than nominal
value (refer to description above).
Oil leaks from brake pedal valve.
ENG 6-46830
issued 1- 03
Repair or replace brake pedal valve.
Printed in Brazil
7002-02
TROUBLE
PROBABLE CAUSE
REMEDIES
Brakes low pressure

indicator on panel stays ON.
Accumulators recharge pressure

lower than the nominal value.
Oil leakages from brake pedal valve.
Repair or replace pressure valve.
Delayed braking and / or

pedal return
Brake valve pressure / flow

insufficient.
Check that the brakes system tubes are

not damaged.
High viscosity of the hydraulic fluid.
Braking pressure not

constant
Pressure in accumulators not

correct.
Check for correct accumulator charge

pressure; if necessary,
adjust the nitrogen
charge presion
Continuous recharge
of the accumulators
Accumulators with too low or too

high nitrogen precharge. Worn pump
Check nitrogen pressure in

accumulators.
Brake pump always

under pressure
Worn pump.
Repair or replace pump.
Dirt in the valve.
Careful check of the valve (correct

sliding of the cad seats.
Contamination in the priority

valve.
Check the sliding of all spools, mainly of

the inlet valve.
Accumulators
don't charge
Check the hydraulic connection.
Brakes remain applied
Restricted discharge port.
Non return of the pedal.
Check that the pedal stop adjuster

allows backlash between return and
operating piston.
Eliminate possible contamination
in the valve.
ENG 6-46830
issued 1- 03
Printed in Brazil
7003-03
TROUBLE
PROBABLE CAUSE
REMEDIES
Dashboard indicator always

off or always on
The pressure switch fails to

operate.
Replace pressure switch
Brake pedal pulsate
Sudden pressure changes on the

outlet.
Check that there are no obstructions

along discharge line.
ENG 6-46830
issued 1- 03
Printed in Brazil
7003
Section
7003
BRAKE PEDAL VALVE AND SYSTEM
845 - 865 - 885 Grader

Eng 6-46841
Printed in Brazil
May,2003
7003-2
TABLE OF CONTENTS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION .............................................................................................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS ..................... . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PEDAL DISASSEMBLY - ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK OF BRAKE CONTROL PRESSURES .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . .. .
SETTING OF MIN. AND MAX. ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEST OF ACCUMULATORS PRECHARGE .......................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS FOR THE RESETTING OF ACCUMULATORS PRECHARGE . . . . . . . . .. . . . . . . . . . . . . . .
BLEEDING OF BRAKES SYSTEM .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
.
ENG 6-46840
issued 1- 03
3
5
6
7
8
14
15
16
17
18
Printed in Brazil
7003-3
BRAKE PEDAL VALVE
DESCRIPTION
The brake pedal valve assembly is a compact ajustable valve with a modular configuration.
These modules are assembled into an assembly to provide the braking pressure for the machine.
1 Pedal/support group - 2 First braking module - 3 Second braking module - 4 Accumulator charge valve
5 Adjustment screw, brake pressure - 6 Minimum and maximum accumulator recharge pressure
The brake pedal valve is made of elements assembled in a modular mode.

These elements are:
Pedal/support group.
First braking module.
Second braking module.
Accumulator charge valve.
ENG 6-46840
issued 1- 03
Printed in Brazil
7003-4
Support/pedal group
The brake pedal is secured with support group to the floor plate of the machine.
This group regulates:
the maximum braking pressure which is obtained through the pedal stroke against stop screw;
Braking modules
The braking modules are the elements controlling the braking pressure. Each braking module is connected
to a valve and an accumulator. The accumulators are high pressure type containers with a special membrane
nitrogen charge, on one side, and to the oil pressure on the other. Three threaded outlets connect the module
to the brakes, the accumulator and the pressure switch controlling the stop lights.
The modules have longitudinal ducts allowing a hydraulic connection with the discharge and the charging
circuit of the accumulators.
Accumulator charge valve

The valve maintains the value of the pressure of the accumulators at a determined range (1175-1825 psi). This
pressure is set by turning the screw (6) located on the cylindrical end and is protected by a cap nut.
ENG 6-46840
issued 1- 03
Printed in Brazil
7003-5
OPERATION
The brake pedal valve controls the charge of the accumulators that are fed by the hydraulic power control
system. During the charge phase, the charge valve acts, charging the accumulators, ensuring the hydraulic
supply to other functions of the power control systems.
.
Once the charge pressure of the accumulator is reached, the charge valve directs the entire flow from the
pressure line "P" to hydraulic tank.
The pressure in the accumulator circuit is maintained steady within the tolerance range of the charge valve.
The two service braking circuits are mutually protected through the check valves so that, in case of failures
one of the two circuits, operates normally.
The charge condition of the accumulator is monitored by the pressure switch so that the operator has a visual
and audio signal in case of insufficient hydraulic pressure in the accumulators.
Operation of the service braking system

When the service brake pedal is actuated, the two circuit braking valve regulates the pressure to the brake
pistons according to the actuating force. The machine is slowed down by the action of the both brakes right
and left.
At the release of the braking pedal, the oil returns to the tank.
In case of failure of one brake circuit, the second remains in operating condition through the mechanical
contact of the two braking valve plungers, ensuring the functionality of one accumulator. The
actuating force remains unchanged.
Every time the service brake is actuated, a pressure switch (set at 41-102 psi) monitors the pressure on
the rearaxle brake circuit and energises the stop lights.
LIMITED SLIP
DIFFERENTIAL LOCK
P Pressure, from steering priority valve "EF" - B Discharge to hydraulic oil tank - T Discharge to hydraulic oil tank
S1 Stop lights pressure switch - T1 Delivery to right side axle - T2 Delivery to left side axle - R1 Service accumulator
R2 Service accumulator - S2 Brakes system low pressure switch
ENG 6-46840
issued 1- 03
Printed in Brazil
7003-6
SPECIFICATIONS
Brake pedal ....................................................................................................................................... type S6
Installation ...................................................................................................................................... horizontal
Diameter of brake valve modules ....................................................................................................... 14 mm
Braking circuits ............................................................................................................................................. 2
Braking pressure ......................................................................................................................... 65 +/- 3 bar
Accumulator recharge pressure................................................................................................... 81 ~ 87 Bar
Maximum accumulator pressure................................................................................................ 120 ~126 Bar
Accumulator flow rate ...................................................................................................................... 5.5 LPM
ENG 6-46840
issued 1- 03
Printed in Brazil
7003-7
MAINTENANCE
MAINTENANCE STANDARD
The precautions to be strictly observed during the assembly operations are listed below.
Ensure that connections and lines are clean; foreign materials and dust in the system will cause
malfunctions and wear.
To bleed the air from the system,
(see page no.7003-18).
SETTING
Adjustment and check of accumulator pressure (see page no. 7003-15)
When the accumulators are discharged, connect a gauge (scale 200 bar/2900psi) to the.
Start the engine and press the pedal several times to activete the automatic charge; read the pressure.
The max./min. pressure is adjustable through the adjusting screw (6) (protected by the cap nut)
on the body of the accumulator charge valve.
The pressure of max. charge of the accumulators is 120 bar (1740psi),
and minimum 81bar (1175psi).
Adjustment of service brake pressure

Connect a gauge (scale 100 bar/1500psi) to brake
circuits, see page no. 7003-14.
The pressure depends on the pedal stroke.
The braking pressure is adjustable by the
adjusting screw (5) under the pedal. The max.
pressure for the brake pistons is 68 bar (985psi) .
ENG 6-46840
issued 1- 03
Printed in Brazil
7003-8
BRAKE PEDAL DISASSEMBLY - ASSEMBLY
1
2
SECTION A - A
39
38
37
7
8
36
35
10
34
11
33
12
32
13
31
14
30
15
29
16
28
17
27
18
26
ENG 6-46840
41
40
21 25 24 23 22 21 20 19
issued 1- 03
Printed in Brazil
7003-9
Description of brake valve disassembly - assembly

1 - Blind nut M10
2 - Nut M4
3 - Flat washer
4 - Adjustment nut
5 - Dowel M4x50
6 - Spring seat
7 - Screw for spring compression
8 - Needle valve seat
9 - O-ring
10 - Piston for single direction valve holder
11 - Seal needle
12 - O-ring
13 - O-ring
14 - Valve spring
15 - O-ring
16 - Bushing for single direction valve holder
17 - O-ring
18 - O-ring
19 - O-ring
20 - Pressure switch plug
21 - O-ring
22 - Plug for single direction valve
23 - Spring for single direction valve
24 - Poppet valve body
25 - Poppet seat for single direction
valve
26 - Accumulator charge valve body
27 - Snap ring
28 - Snap ring
29 - Adjusting washer
30 - Piston for priority valve
31 - Cone-shaped filter
32 - Spring for filter retaining
33 - O-ring
34 - O-ring
ENG 6-46840
35 - Spring for priority valve

36 - Charge valve cover
37 - Pin for single direction valve opening
38 - Spring for single direction valve opening
39 - Brake control spring
40 - Screw for double adjustment
41 - Lock washer
43 - Nut M8x1,25 (not used)
44 - Dowel M8x40 (not used)
45 - Protection
46 - Support
49 - Plug
50 - Washer
51 - Link rod
52 - Piston for brake control
53 - Upper spring guide
54 - Approach spring
55 - Pressure spring
56 - Seal
57 - Return spring
58 - Lower spring guide
59 - Snap ring
60 - Control valve piston
61 - O-ring
62 - Control valve body
63 - O-ring
64 - Control valve body
65 - Centering bushing
67 - Spring for control valve piston
68 - Screw TC M8x1,25x150
issued 1- 03
Printed in Brazil
7003-10
DISASSEMBLY - ASSEMBLY
Turn the machine off.

WARNING
Relieve pressure from brake accumulators
pressing on brake pedal repeatedly.
The brake pedal valve is located under
the floor on the left side, with pedal.
Proceed as follows:
- drain the oil from the hydraulic reservoir;
- discharge the brakes pressure actuating the pedal
repeatedly, with engine off;
-
Lift the cab floor mat and remove the cover;

disconnect electrical connections;
before disassembly, tag the positions of
the fittings and or tubes for assembly.
disconnect the hydraulic tubes and fittings;
remove the cover (1) with brake valve;

disassemble pedal;
Disassembly of brake pedal valve

- Mark the position of the pedal valves
- Remove screws (C2) holding control valve section
assy to the bottom of the pressure
charge section.
- For assembly tighten the screws to a
torque of 30Nm (22 lb ft.)
(C2)
ENG 6-46840
issued 1- 03
Printed in Brazil
7003-11
Separate the 4 sections making sure the inner

details stay intact.
IMPORTANT
The two braking modules are not the same;
the module in contact with pedal support is the one
with 6 mm holes, supply and drain, not
passing.
Braking modules are fitted with the select fit
pistons. Do not reverse them.
Loading valve
Braking module no. 1
Braking module no. 2
Support for pedal and working brake sleeve

Accumulator charging valve
Remove screws (C1) securing the cover,
and remove internal components.
Cleaning and inspection of components

Wash all components with a nonflammable, non-toxic detergent solution,
and dry them with compressed air.
Any dirt entering the system can cause
serious operational problems.
Inspect the sealing surfaces of the valve

blocks. Check the sliding surfaces of the
plungers and the condition of the
relevant springs.
Reassembly
Lubricate all the components to be
reassembled.
Reassemble the components of the valve
in the same order of the disassembly
sequence and referring to the figure below.
Disassembly of loading valve

1. Cap nut M10 2. Accumulator recharge pressure max. Setting adjustment screw 3. Locknut for
screw (2) 4. Accumulator recharge pressure min. Setting adjustment screw 5. Locknut
6. Accumulator charge valve spring 7. Pilot plunger 8. Accumulator charge valve sealing
needle poppet 9. Seal 10. Delivery regulator valve 11. Gasket 12. Filter 13. Check valve.
Tightening torque
C1. Cover retaining screws torque 30Nm (22.2 lb.ft) C2. Valve body retaining screws torque 30Nm (22.2 lb.ft).
ENG 6-46840
issued 1- 03
Printed in Brazil
7003-12
Braking module (block) no. 1 and 2

Remove the braking proportional valve spool (15) and spring (26)
from block no. 1 identifying it with the relevant block.
Braking module (block) no. 1
Remove the second block of the valve and

recover the braking proportional valve (17) and
balancing valve (14).
Disassembly of brake pedal valve blocks

14. Balance valve
15. Braking proportional valve
17. Braking proportional valve
26. Spring
Braking module (blocks) no. 2
ENG 6-46840
issued 1- 03
Printed in Brazil
7003-13
Support for pedal and working brake linkage

Disassembly of pedal support and working brake linkage
16. Lower cup 16 a. Upper cup 18, 18 a, 19. Springs 21. Control plunger 25.Gasket.
ENG 6-46840
issued 1- 03
Printed in Brazil
7003-14
CHECK OF BRAKE CONTROL PRESSURES

Check the accumulator charge pressure before
cheking the brake application pressure
Connect two pressure gauges G1 and G2 (100 bar
1450 psi capacity) to the pressure pick-up point
indicated in figure.
Engage the parking brake.
Start the engine and at idle speed, actuate the
brake pedal and check that the pressure
indicated by the pressure gauges is 62 68 bar
(900 985 psi).
Loosen locknut (E) and turn screw in or out the to
adjust the pressures in case they are not within
specifications.
Tighten nut after any resetting.
WARNING Disconnect and reconnect all

connections with engine off and system
discharged.
The accumulators maintain some branches of the
circuit pressurized with engine not running.
Pressurized fluid escaping from loose
connections can cause personal injuries.
Always wear glasses with side shields.
ENG 6-46840
issued 1- 03
Printed in Brazil
7003-15
SETTING OF MIN. AND MAX. ACCUMULATOR

RECHARGE PRESSURE
Connect two pressure gauges M1 and M2 (200
bar 2900 PSI capacity) to the quick release
pressure pick-up points (7 and 8, fig. ), located left
side of the machine.
Start the engine and operate the hydraulic levers
to warm-up the oil to 40o 50 o C (105 o 120 o F)
Parking brake ON.
Minimum recharge value

With engine idling and machine standing still,
apply brake 8 to 10 times slowly. Read on
gauges M1 and M2 the values of minimum on
pressure, prior to the start of the recharge cycle
The pressure gauges must read momentary
8187bar (1175 1262 PSI).
If the minimum recharge pressure is different from

the nominal value, remove cap (1), loosen nut (5)
and adjust screw (4) slowly, until the correct value
is obtained.
Check the pressure again before tightening
locknut (3).
Recharge maximum value

With engine at low idle read the maximum
charging pressure on pressure gauges M1 and
M2.
This pressure must be 120 126bar (1740 1827
PSI).
If the maximum recharge pressure is different from
the nominal value, remove plug (1), loosen locknut
(3) and adjust screw (2), until this value is
obtained.
M1 and M2 Pressure gauges 1. Cap 2. Max. Pressure setting screw 3. Locknut 4. Min. pressure
setting screw 5. Nut 6. Accumulators 7. And 8. Pressure pick-up points thd M16 x 2.
ENG 6-46840
issued 1- 03
Printed in Brazil
7003-16
SPECIAL TOOL
E
C
F
A
94L95
CAS-10899 NITROGEN CHARGING KIT
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

1. Use the CAS-10899 nitrogen charging kit to
discharge the accumulator, refer to illustration
above. The tool must be disconnected from the
nitrogen tank.
2. Close valves B, C and D.
3. Adjust the regulator A to the minimum pressure
setting by turning the knob counterclockwise.
4. Turn the T-handle on valve F fully out.
5. Remove the guard and valve assembly cap from
the accumulator.
6. Connect valve F to the valve stem on the

accumulator.
7. Turn the T-handle inward on valve F to engage
the pin in the valve stem.
8. Open valve D and check the charge pressure on
gauge E.
9. To discharge the accumulator, partially open
valve B. The accumulator charge will bleed down
through the regulator.
10. Once the accumulator is fully discharged,
disconnect valve F from the valve stem.
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR

1. Make sure that the oil side of the accumulator is
completely discharged by doing the following:
A. Stop the engine.
B. Push down and release the brake pedal many
times to release the pressure.
2. Connect a drain hose to the test connector in
each brake circuit to release any pressure in the
brake circuit.
5. Remove the cap screws and guard from the

accumulator.
6. Remove the cap from the accumulator valve
stem.
7. Connect valve F to the accumulator valve stem.
8. Make sure that valve D is open.
9. Turn the stem into valve F and read the pressure
gauge E.
3. Close valves B and C on the nitrogen charging

kit, refer to the illustration.
NOTE: See chart below for pressure readings.
4. Turn the stem out of valve F until the stem stops.
10. If the pressure is too low, charge the accumulator

with dry nitrogen.
ENG 6-47760
Issued 1-03
Printed in Brazil
7003-17
CHARGING THE ACCUMULATOR WITH DRY NITROGEN

NOTE: Check the pressure in the accumulator
according to the instructions in Checking the
Nitrogen Charge in the Accumulator. Keep the
nitrogen charging kit connected to the accumulator.
1. Close (turn counterclockwise) valve A and open
valve B. Close valves C and D.
2. Turn the stem out of valve F until the stem stops
moving. Disconnect valve F from the
accumulator valve stem.
3. Connect the nitrogen charging kit to a dry
nitrogen tank.
4. Slowly turn valve A clockwise and read gauge E
until the pressure is equal to charge pressure
required for accumulator being charged. Stop
turning valve A.
5. If the pressure increases above required

pressure, quickly open and close valve D and
read gauge E. If the pressure is still too high,
close valve A (turn counterclockwise) a small
amount and quickly open and close valve D. The
pressure shown on gauge E is the charge
pressure.
6. Connect valve F to the accumulator valve stem.
Turn the stem into valve F until the stem stops
m ov i n g a n d o p e n va l ve D t o c h a r g e t h e
accumulator.
7. After the accumulator stops charging, turn the
stem out of valve F until the stem stops moving.
8. Close valve B and disconnect the nitrogen
charging kit from the accumulator valve stem.
9. Install the cap on the accumulator valve stem.
I n s t a l l t h e g u a r d a n d c a p s c r ew s o n t h e
accumulator.
TEMPERATURE
0 C
32 F
5 C
41 F
10 C
50 F
15 C
59 F
20 C
68 F
25 C
77 F
30 C
86 F
35 C
95 F
40 C
104 F
CHARGE PRESSURE
89.4 BAR
1297 PSI
91.1 BAR
1321 PSI
92.7 BAR
1345 PSI
94.4 BAR
1369 PSI
96.0 BAR
1392 PSI
97.6 BAR
1416 PSI
99.3 BAR
1440 PSI
100.9 BAR
1464 PSI
102.6 BAR
1487 PSI
TEMPERATURE/CHARGE PRESSURE PARKING BRAKE

ACCUMULATOR
ENG 6-46840
TEMPERATURE
0 C
32 F
5 C
41 F
10 C
50 F
15 C
59 F
20 C
68 F
25 C
77 F
30 C
86 F
35 C
95 F
40 C
104 F
CHARGE PRESSURE
51.2 BAR
743 PSI
52.2 BAR
757 PSI
53.1 BAR
770 PSI
54.1 BAR
784 PSI
55.0 BAR
798 PSI
55.9 BAR
811 PSI
56.9 BAR
825 PSI
57.8 BAR
839 PSI
58.8 BAR
852 PSI
TEMPERATURE/CHARGE PRESSURE BRAKE

ACCUMULATOR
Issued 1-03
Printed in Brazil
7003-18
TEST OF ACCUMULATOR
PRECHARGE
The accumulators installed in the brake system
are of a membrane type with nitrogen precharge.
The natural porosity of the membrane and
continuous operation, reduce, in time, the precharge
pressure, reducing the efficiency of the
accumulator.
It is recommended that a check is performed every
six months, and, if required, the nitrogen precharge
is reset.
The precharge pressure must never drop below
90 % of the nominal value.
The check operation must be performed with
accumulators emptied of hydraulic oil.
Check brake accumulator condition , pressing pedal
repetitively and slowly, with engine off, (at least 30
strokes).
Check the precharge as follows:
- remove protection cover (1, figure)
- loosen screw turn (2) with Allen wrench;
- Install tool 75298472 (D) on the accumulator
connection;
- check that cock (D2) is closed;
- rotate handle (D1) to loosen screw (2);
- when the pointer of pressure gauge (M) starts
moving, loosen handle (D1) a turn further;
- At this point, the pressure gauge indicates the

precharge pressure of the accumulator, that must
read 60 bar.
If the pressure is within the specified value,

proceed as follows:
- shut handle (D1);
- open cock (D2) to discharge the nitrogen pressure
inside tool (D);
- disconnect tool (D) from the accumulator;
Fig. 4.10 - Test of accumulators precharge

D. Accumulator precharge test tool
D1. Handle, plug 2 control
D2. Discharge cock
M. Pressure gauge
1. Protection cap
2. Threaded plug
C1. Tightening of plug = 11 N.m ( 8.1 lb . ft)
- tighten screw (2)to a torque of 11 Nm (8.1 lb.ft);

- check for accumulator leaks with soapy water.
- reinstall cap (1).
If the pressure is below the nominal value, recharge
the accumulator proceeding as indicated in page
7003-17
Brz_ENG 6-46840
issued 1- 06
Printed in Brazil
7003-19
INSTRUCTIONS FOR THE RESETTING OF

ACCUMULATOR PRECHARGE
With tool 75298472 (D, figure) applied to the
accumulator connection (refer to chapter 7003-16)
proceed as follows:
- remove the plug and connect the hose of the
nitrogen tank, equipped with safety valve (V);
WARNING
To recharge accumulators use nitrogen only. Never
use oxygen or other gases,since there is a risk of
an explosion.
- open slowly the nitrogen tank cock and check the

filling pressure on the pressure gauge (M);
IMPORTANT - The filling pressure must be at least

10% higher than the nominal value, considering that
the pressure in the accumulator decreases when
the compressed gas cools.
- shut the valve of the nitrogen reservoir;

- wait 5 minutes;
- check the pressure gauge (M) the
pressure should be 60 bar.
- if lower, repeat the operation.
If the pressure is higher, proceed as follows:

- rotate slowly valve (D2) to let nitrogen
escape, thEn close it;
Oserve the on pressure gauge (M) that the pressure
is as desired. If not, repeat the operation;
- turn handle (Dl) to tighten screw (2) on the
accumulator;
- remove tool (D);
- tighten screw (2) to a torque of 11 Nm (8.1 lb.ft);
- check the SEALING of the accumulator with soapy
water;
Retighten protection cap (1).
Accumulators recharge device

A. Nitrogen tank - D. Accumulator precharge test tool D1. Handle, plug 2 control - D2. Discharge cock
M. Pressure gauge V. Safety valve - 1. Protection cap - 2. Threaded plug. C1. Tightening of plug
11 Nm (8.1 lb.ft)
ENG 6-46840
issued 1- 03
Printed in Brazil
7003-20
BLEEDING OF BRAKES SYSTEM

It is necessary to bleed the brakes system
whenever one of following occurs:
- after changing the hydraulic oil;
- after air has penetrate the system, due to

leakage in the hydraulic system;
- after disconnecting or replacing any component of
the system.
To bleed the system proceed as described below

(the operation requires two people):
Axle limited slip brakes system

bleeding 2 plugs.
WARNING:
The brakes are inoperative when undergoing
maintenance or repair operations.
place the machine on a flat surface and block the
wheels.
-
place the machine on a flat surface, start the

engine and park brake ON;
with engine idling, one operator loosens the
bleeding plug (see figure) and the other
operator pushes the brake valve pedal;
tighten the bleeding plug before releasing the
pedal;
repeat the operation until all the air is expelled
from the system (the fluid must flow without air
bubbles);
repeat the same operation on the other axle.
ENG 6-46840
Differential lock axle brake

system bleeding 4 plugs.
issued 1- 03
Printed in Brazil
SECTION INDEX
HYDRAULICS
Section Title
Section Number
Removal and Installation of Hydraulic ComponentsSteering Components . . . . . . . . . . . . . . . . . . . . . . . . . . 8001
CNH Latino Americana LTDA.

Contagem, MG Brazil
ENG 6-46860
Printed in Brazil
May, 2003
Section
8001
REMOVAL AND INSTALLATION OF
HYDRAULIC COMPONENTS
8001
845 - 865 - 885 Grader

ENG 6-46870
Printed in Brazil
May,2003
8001-2
SECTION .................................. D E S C R I P T I O N ......................................................... P A G E
SERVICE POSITION ..................................................................................................................... 3

PUMP REMOVAL ........................................................................................................................ 4
GRADER 845 PUMP REPAIR INSTRUCTIONS ............................................................................ 5
GRADER 865 - 885 PUMP REPAIR INSTRUCTIONS ................................................................... 16
HYDRAULIC DISTRIBUTOR .......................................................................................................... 36
MAIN HYDRAULIC MANIFOLD VALVE - REMOVAL ...................................................................... 36
MAIN HYDRAULIC MANIFOLD VALVE - DISASSEMBLY ............................................................... 36
MAIN HYDRAULIC MANIFOLD VALVE - INSTALLATION ................................................................ 42
DUALOVER CENTER (COUNTERBALANCE) VALVE................................................................... 43
SOLENOID / PRESSURE REGUALTING VALVE ........................................................................... 46
DUAL CHECK VALVE .................................................................................................................... 47
HYDRAULIC CYLINDERS .................................... ............................................................................. 48
HYDRAULICCYLINDERS DISASSEMBLY .................................................................................... 50
HYDRAULIC CYLINDER ............................................................................................................... 52
ENG 6-46870
Issued 01-03
Printed in Brazil
8001-3
Service Position
Before making any service, maintenance or inspection procedure, the grader must be placed in the
Service Position.
1.
Park the grader on a level surface.
2. Place the transmission in neutral and apply the handbrake. Ensure the handbrake is correctly
3.
Lower the moldboard and all attachments to the ground. Do not apply down-pressure.
4.
Shut down the engine.
5.
Install the service pin in the LOCKED position (see the Operators Manual).
6.
Install chocks at the front and rear tandem wheels. Wedge the chocks in place.
7.
Relieve residual hydraulic pressure by operating all control levers.
8. Some hydraulic circuits may contain lock valves. Operating the control levers in these circuits
will not relieve residual hydraulic pressure. Such pressure must be relieved by loosening a fitting or
electrically activating the solenoid valve. Wear face and eye protection. Danger of spraying oil.
9.
Fasten a DO NOT OPERATE or similar warning tag on the steering wheel.
10. Remove and retain the ignition key.

11. Turn the battery isolation switch to the 0FF position.
1 2. Allow the engine and hydraulic system to cool before working in these areas.
13. Be aware of other service personnel in your work area.
14. If the service procedure includes welding, you must disconnect the following items:
a) Negative battery cable.
b) Positive battery cable.
c) Power supply harness at the transmission controller.
d) Transmission wiring harness at the controller (see the operators Manual).
e) Alternator to battery wiring harness
f)
24V-12V converter wiring harness at the fuse.
g) Float valve module (if installed) wiring harness at the module.

Connect the arc-welder ground cable as close as possible to the work area.
ENG 6-46870
May,2003
Printed in Brazil
8001-4
PUMP
REMOVAL
Disassembly of the hydraulic pump.
Open the hood.
845 hydraulic pump.

Type: Gear pump, fixed displacement, unloader valve
load sensing, variable discharge.
Displacement :................ 91 Cu.cm/rev. (5.51Cu.in/rev.)
865 and 885 hydraulic pump .

Type: Piston pump, variable displacement, pressure
and flow compensated, load sensing.
Displacement :............ 100 Cu.cm/rev. (6.10Cu.in/rev.)
To start disassembly of the pump, drain the hydraulic

tank, disconnect the hoses and tube from the
hydraulic pump.
ENG 6-46870
Issued 01-03
Printed in Brazil
8001-5
GRADER 845 PUMP REPAIR INSTRUCTIONS
The pump, with identification plate data,

the inlet and the safety valve of the pump
Below, is the cover of the outflow control valve.
DIAGRAM
OF
THE
1- Main Hydraulic Pump

2- Plug
3-Seal Gland
4-Seal Retainer
5-Packing Ring
6-Front Cover
7-Bushing
8-Lockwasher
9 - Bolt
ENG 6-46870
PUMP
10-Driveshaft/Gear-Driving
11-Seal-Shaft
12-Driveshaft/Gear-Driven
13 - Wear Plate
14 - Plug
15 - Rear Cover
16-Nut-LoadSenseModule
17 - Spring
18 - O-Ring
19- Cap
20 - O-Ring - Relief Valve Cartridge Setscrew
21 - O-Ring- Relief Valve Cartridge Seat
22 - O-Ring- Relief Valve Cartridge
23 - Back - up Ring
24 - O-Ring - Relief Valve Cartridge Housing
May,2003
Printed in Brazil
8001-6
The load sensor module is a component integrated to the

rear part of the hydraulic pump. The module allows the
pump to discharge to the low pressure tank when it is not
required . Each time the oil is required to run a function,
the module reacts by giving priorities to the flow.
With no active function, there is no load sign on the load

sensor line. The absence of load makes the spool move up
against the spring. All the flow of the pump is directed to the
by-pass port. The pressure is determined by the low
unload spring force, is 90 psi.
Flow Control spool should be closed

10 bias pressure adjusting screw
CAPTION
1234-
ENG 6-46870
Load sense module housing

Low unload spring
Load sense port
Unload spool
56789-
Fixed Bias Spring

Bypass port to the tank
Flow control Spool
Discharge port
Adjustable Bias spring
10-Bias pressure adjusting screw
Issued 01-03
Printed in Brazil
8001-7
When the piston gets to the end of its stroke or finds an

resistance to flow load through the valve, the result
is a reduction of the pressure. The pump increases the
output flow. The flow control spool opens and directs
all the remaining flow to the by-pass port. The
outflow pressure is limited to 2500 psi.
The surface area in the load sense of the spool on the

unloading spool is greater than the area a the pump
discharge port. This area difference maintains the unloading
spool seated against the pump housing when there is load
sense signal present. The laod sense signal comes from the
maximum pressure required to actuate any of the graders
funstions.
When the system is operating in the flow control mode, the
flow control spool rises, alowing excess pump outlet flow to
bypass to the tank port based upon the pump flow required
at the Grader valve. The flow control spool will maintain an
approximately 300 psi pressure difference between the
pump outlet pressure and the load sense signal returned
from the grader control valve. This 300 psi pressure
difference will assure that any flow required at the grader
valve will be available.
When the piston gets to the end of its stroke or finds a high
resistance to flow through the grader valve., the result is an
increase the load sense pressure. The maximum load sense
pressure is limited by the load sense relief valve in the outlet
section of the grader valve. The maximum load sense
pressure specification is 2600 psi. which will result in the
pump outlet pressure being 2900 psi, due to the 300 psi
differential across the flow control spool.
ENG 6-46870
May,2003
Printed in Brazil
8001-8
DISASSEMBLING AND ASSEMBLY OF THE
PUMP
Unfasten and remove the eight nuts and washers of the

tap bolts.
Remove the front cover. Label the intersection of the teeth

of the driven and drive gear with a marker before removing
them off the pump. Carefully remove the drive gear off
the pump and put it on a work bench.
Remove the drive gear off the pump and put it on a smooth
surface.
ENG 6-46870
Issued 01-03
Printed in Brazil
8001-9
Remove the central section of the pump.
Remove the eight tap bolts of the rear cover.
Remove the seal retainer of the rear cover and discard it.
Remove er ar cover and discard it.
Remove the seal gasket of the rear cover and replace it with
a new part.
ENG 6-46870
Issued 01-03
Printed in Brazil
8001-10
Remove the square section o-ring and discard it. Replace

it with a new part.
Remove the wear plate of the front cover. Remove the

rubber plug of the drain seal.
Remove the retainer seal of the front cover and discard it.
Replace it with a new part.
Remove the gasket of the front cover and discard it.

Replace it with a new part.
ENG 6-46870
January, 2003
Printed in Brazil
8001-11
Remove the square section o-ring of the front cover and
discard it. Replace it with a new part.
Remove the retainer if there is one installed on the front

cover and use a screwdriver or another tool to remove the
retainer from the front cover shaft.
INSPECTION OF THE PARTS FOR WEAR

Clean all parts before inspecting them. It is not
necessary to inspect the retainers that must be
replaced from the front cover shaft.
Inspect the surface of the gears of both shafts

for excessive wear or scratches.
ENG 6-46870
Issued 01-03
Printed in Brazil
8001-12
Inspect the bushings on the front cover for excessive wear,

flacking, or movement of the bushings.
Inspect the bushings on the rear cover for excessive wear,

flacking, or movement of the bushings.
Inspect the central section of the gear casing. It must not

show excessive wear or deep scratches.
Inspect the bronze side from both plates for erosion and
scratches. Replace them if they are damaged.The left
model is used on the G30 barnes pump.
ENG 6-46870
January, 2003
Printed in Brazil
8001-13
Typical content of the repairs of the pump G30.
Install a new retainer on the front cover. Mount the

retainer with a stop spring for the internal part of the pump.
Press the retainer on the diameter of the pump housing.
You must apply a uniform pressure to prevent the retainer
from getting out-of-true or damaged. Lubricate the retainer with graphite grease after installing it.
Put the rear cover on a work bench with the retainer cavity
up. Lubricate the retainer cavity with graphite grease.
Put the rear cover on a work bench with the retainaer cavity
up. Lubricate the retainer cavity with graphite grease.
ENG 6-46870
8001-14
Install the assembly on the rear cover cavity. Be very careful

when you press the assembly into place: it must seat firmly
in its housing. This is important for the installation of the
bronze wear plate.
Lubricate the bronze surface of the wear plate and install

the retainer over it. This picture shows the wear plate of the
G20, the wear plate of the G30 is different.
Apply a thin coat of graphite grease on the housing of the

square section o-ring and carefully install it in the housing.
Take care that the o-ring dos not spin in the housing: it must
be correctly positioned inside the housing or the pump will
leak on this spot.
Install the eight top bolts on the rear cover. Tightening

torque of the top bolts: 33.9 - 47.5 Nm.(25 - 35ft.lb)
ENG 6-46870
May,2003
Printed in Brazil
8001-15
Install the central section on the top bolts. Check the
alignment of the top bolts on the central section.
Lubricate the drive gear and install the gears on the

appropriate bushings. Align the teeth marks of the gear.
Place the front cover on a clean work bench with the

retainers cavity up. Lubricate the retainers cavity with
graphite grease.
Lubricate both the gasket and the plastic retainer with

graphite grease. Carefully install the gasket in the internal
part of the plastic retainer, checking whether the gasket
is well set into the retainer.
ENG 6-46870
Issued 01-03
Printed in Brazil
8001-16
Install the assembly on the front cover cavity. Carefully

press the assembly into place; checking whether it is firmly
seating in place. This is very important for the installation of
the wear plate.
Apply graphite grease to the square section housing

of the o-ring, and carefully install it on the front cover
housing. Be very careful: the o-ring must not spin within the
housing or the pump will leak at this spot.
Lubricate the steel side of the bronze wear plate with

graphite grease and install it on top of the retainer.
Install the washers and nuts on the top bolts. Torque of the
top bolts: 196 - 210 Nm. (145-155 ft.lbs)
ENG 6-46870
May,2003
Printed in Brazil
8001-17
GRADER 865 - 885 PUMP REPAIR INSTRUCTIONS
Disassemble the pilot valve.
Mark the position of the cover in relation to the casing when

it is in place, and remove the allen head screws.
Remove the cover together with the control components.
Remove the cone roller bearing and the wedges.
ENG 6-46870
Issued 01-03
Printed in Brazil
8001-18
Remove the rotor entirely.
Remove the O-ring.
Remove the bearings of the roller bearings.
Using a roller bearing extractor, remove the roller bearings from the casing.
ENG 6-46870
May,2003
Printed in Brazil
8001-19
Remove the distributor plate.
Use the roller bearing extractor to remove the rear part

of the casing.
Remove the O-ring.
Loosen the lock nut of the adjustment bolt.
ENG 6-46870
Issued 01-03
Printed in Brazil
8001-20
Disassemble the adjustment bolt.
Disassemble the command piston guide.
Disassemble the guide opposite the piston.
Pull the input shaft out.
ENG 6-46870
January, 2003
Printed in Brazil
8001-21
Remove the pistons and the retention plate.
Remove the concave washer.
Compress the central spring to dissasemble the

retainer ring.
Disassemble the retainer ring.
ENG 6-46870
Issued 01-03
Printed in Brazil
8001-22
Components of the rotor: bolts, cylinders, wedge,

spring, and wedge.
Remount the pump following the reverse order of the

disassembling.
The roller bearing on the cover of the pump must have a

initial preload between 0...0.05 mm.
Put the distributor plate in place.

Lubricate it with grease before assembling it.
ENG 6-46870
May,2003
Printed in Brazil
8001-23
Position the O-ring on this place.
Maintain the tension of the spring with screws (they must

not be tightened into place).
Correct position of the bearing (lubrication hole and highpressure side).
Before putting the cover back on its correct position (see

mark), remove the screw that retains the spring.
ENG 6-46870
May,2003
Printed in Brazil
8001-24
Install the plug.
It is possible to reuse the cradle where the piston

shoe works.
NOTE: We do not recommend that you press onthe external

part of the piston.
Check the coupling between the rotor and the distribution

plate.
Check the surface conditions of the control piston.
ENG 6-46870
May,2003
Printed in Brazil
8001-25
Check the condition of the bolt opposite the piston.
Distributor plate, inclination piston of the plate, and

return spring.
Complete rotor.
Casing of the pump and bearings of the roller

bearings.
ENG 6-46870
Issued 01-03
Printed in Brazil
8001-26
Input shaft and cone roller bearings.
Adapter with hole for pilot valve.
ENG 6-46870
May,2003
Printed in Brazil
8001-27
REPLACEMENT OF THE INPUT SEAL
Remove the retainer ring of the seal.

Remove the seal.
Change the seal and check the work area of the

seal.
Apply grease to the retainer.
ENG 6-46870
Issued 01-03
Printed in Brazil
8001-28
Remount the seal using the proper tool.
Put the retainer ring back on its place.
With a tubular tool, place the lock correctly in its

housing.
ENG 6-46870
May,2003
Printed in Brazil
8001-29
RETAINERS AND COMPONENTS KIT

Seal of the entrance shaft.
Fullseal kit.
The kits are based on the type of the pump.
The picture shows the kit used on the
HA10VO100DFR pump.
Pilot valve. Pressure and flow control.
Distributor plate, inclination piston of the place and

Command spool.
ENG 6-46870
Issued 01-03
Printed in Brazil
8001-30
PILOT VALVE
Remove the allen screws of the pilot valves.
Remove the O-rings.
Remove the hexagonal nuts.

First, remove the pressure command, and then
the flow command.
Remove the lock nut and the adjusting screws.
ENG 6-46870
May,2003
Printed in Brazil
8001-31
Remove the plug.
Remove the adjusting disc.
Remove the spring (two for the flow control valve).
Remove the cover of the spring
ENG 6-46870
Issued 01-03
Printed in Brazil
8001-32
Remove the plug
Be careful when you disassemble the piston.
Disassemble the restrictor(it is on the spring

area of the pressure controller).
Disassemble the plug or restrictor that is on the

spring area of the flow controller.
ENG 6-46870
January, 2003
Printed in Brazil
8001-33
Nut Torque 12Nm (108 lb.in).
Remount the pilot valve following the reverse order

of the disassembling.
Check the opening of the restrictor hole; if necessary,

use compressed air to clean it.
Be careful when you clean the hole.
ENG 6-46870
Issued 01-03
Printed in Brazil
8001-34
Check the movement of the pilot valve spool. It must

not be mounted if it is damaged.
Adjust the pilot valve (see instructions on the pages below).
When the pressure line is closed, it is possible to regulate

the pressure controller (190 bar = 2.800 psi).
ENG 6-46870
May,2003
Printed in Brazil
8001-35
Adjust the outflow regulator to 200 bar; this will allow the
pump to reach its maximum outflow of 210 l/min. (55
gpm)
Mechanical flow limiter: Used to adjust the minimum flow.
ENG 6-46870
Issued 01-03
Printed in Brazil
8001-36
PILOT VALVE
Section drawing of the pilot valve.
ENG 6-46870
May,2003
Printed in Brazil
8001-37
HYDRAULIC CONTROL VALVE

Front view of the control valve: from left to right you can see
the pressure valve adjusted with 214bar, the safety valve
of the cylinder of the left side, and Load sense valve with
193 bar.
A - The Load Sense Valve 193 3,5 bar.
B - Main pressure 214 bar.
The valve assembly is mounted just below the frame, at

the height of the steering valve of the machine. It is
accessed from under the machine. You can also see
the retainer valve of the articulation system of
the machine.
Control valve assembly is made up of 9 blocks, with spools and

one way valves. It is a closed center type and has a Load
Sensing port that allows it to control the feed
pump flow; the Load Sense pressure is 179 3,5 bar.
A - The Load Sense.
Front view of the valve. From left to right, you can see
the main relief valve adjusted to 214 bar and the lift
safety valves of the moldboard regulated to 103 3,5 bar.
ENG 6-46870
Issued 01-03
Printed in Brazil
8001-38
The control valve of the service pressure is mounted

on an independent block; it is a piloted type and can
be adjusted by means of a screw.
Pressure control valve out of the distributor.
Pressure control valve removed; here you can see the

pilot piston with its respective spring and also the nut and
the screw for pressure adjustment.
Safety valve of the blade lift circuit; it is adjusted to 1.500

PSI. The distributor has two valves of this type, one for
each blade lift cylinder.
ENG 6-46870
May,2003
Printed in Brazil
8001-39
LEGEND
1 - Compensator Spring
2 - Workport "A"
3 - Bridge
4 - Workport "B"
5 - Spool Centering Spring
6 - Spring Cap
7 - Spool
8 - Load Sense Drain to Tank
9 - Valve Body
10 - Load Sense Signal Passage

11 - Load Sense Signal Transfer Passage
12 - Pressure Passage
13 - Tank Passage
14 - Compensator Load Sense Signal Passage
15 - Compensator
16 - Load Sense Shuttle
17 - O-Ring
1.
Remove the special nuts and compression

washers from the tie rods on the outlet endcap.
Keep the tie rods in the manifold valve
assembly. The outlet endcap Is identified by a
load sense signal port. Discard the nuts.
2.
Carefully place the manifold valve assembly on

its end, resting on the three tie rod ends of the
inlet endcap.
3.
Remove the outlet endcap.
ENG 6-46870
4.
Remove the O-ring, bias spring and

compensator piston. Discard the O-ring. Store
the bias spring and compensator piston in a
safe, clean place and identified by the valve
section from which they originated.
NOTE: The valve section next to the outlet

endcap does not have a load sense shuttle disc.
You may need to use small straight nosed
external snap ring pliers or similar small
expanding tool to remove the compensator
piston.
Issued 01-03
Printed in Brazil
8001-40
3. Remove the socket head screws and the spring

cap.
4. Remove the spool end.
NOTE: To prevent the valve spool from rotating,
insert a thin rod or similar tool in the linkage pin
hole.
5. Remove the spring seats, spring and spool stop
ring.
Removing Compensator Piston from Valve Section

Housing
5. Remove the remaining valve sections, together
with the load sense shuttle discs, installed between
the eight valve sections.
Removing Spring Seats. Spring and Spool Stop

Ring.
6. Pull the valve spool out of the valve section

housing.
Removing Load Sense Shuttle Disc
Valve Section Disassembly

1 - Lightly clamp the valve section housing in a vise
with soft jaws.
NOTE: Excessive clamping force may distort
valve spool bore and compensator piston bore.
2. Remove the machine screws and the seal plate.
Removing Valve Spring from Valve Section
Housing
ENG 6-46870
Issued 01-03
Printed in Brazil
8001-41
7. Remove the O-ring from the spring retaining
screw.
8. Remove and discard the wiper seals and

O-rings.
All ports within the O-ring mating area of the valve

sections rely on the machined surface for sealing.
Inspect the machined surfaces for scratches,
grooves or other damage that may cause leakage
between ports.
Inspect the housing casting for cracks especially at
the tank passage section. This would be the result
of excessive back pressure.
Valve Section Assembly
1. Lightly clamp the valve section housing in a vise
with soft jaws.
NOTE: Excessive clamping force may distort the
valve spool bore and compensator piston bore.
Removing Spool Wiper Seals and O-Rings

Cleaning and Inspection
Immerse parts in fresh cleaning solvent. Agitate the
parts to remove all foreign matter. Parts should
remain in the solvent long enough to be thoroughly
cleaned. Thoroughly rinse parts to remove all traces
of dirt and solvent.
2. Lubricate new valve spool O-rings and install

them in the valve section housing counterbores .
Lubricate and install new wiper seals against the
O-rings in the valve section housing counterbores.
3. Lubricate and install the valve spool in the valve
section housing.
After rinsing, immediately dry the parts using

moisture
free
compressed
air.
Lint-free,
uncontaminated wiping rags can be used ensure all
oil passages are unblocked. Wrap in clean, lint-free
cloth or paper and store in a cool, dry place.
A careful and thorough inspection of all parts is
extremely important. If you see any evidence of
damage or wear, replace all defective items with
genuine CASE parts.
Retain O-rings and wiper seals only for inspection
and troubleshooting purposes. You must replace all
O-rings and wiper seals when overhauling the main
hydraulic manifold valve.
Valve Section Housing

Inspect the spool bore and compensator piston bore
for excessive wear scratches and grooves that will
cause excessive leakage.
ENG 6-46870
Installing Valve Spool in Valve Section Housing

4. Lubricate and install a new O-ring on the spool
end. Assemble the spring seats, spring and spool
stop ring on the spool end.
5. Install the spool end assembly on the end of the
valve spool. Torque the spool end assembly
to 9 N.m 1,3 (7 lbf.ft 1)
May,2003
Printed in Brazil
8001-42
Torque-tightening Spool End Assembly

NOTA: To prevent the valve spool from rotating,
insert a thin rod or similar tool in the linkage pin
hole.
6. Install the spring cap. Make sure the mating
face notches are clean.
7. Secure the spring cap with the socket head
screws.
Torque the screws to 9 N.m1,3 (7 lbf.ft 1).
8. Secure the seal plate with the machine screws.
Torque the screws to 5 N.m1,3 (4 Ibf~ft
1).
Inlet Endcap and Three Tie Rods

4. Lubricate the mating surface with system oil.
Lubricate and install a new O-ring in the O-ring
groove.
5. Install the valve section that is identified as
being adjacent to the inlet endcap.
NOTE: Install the valve sections in their original
order as identified before disassembly.
6. Insert the compensator piston into the
compensator piston bore, nose end first.
Main Hydraulic Manifold Valve - Assembly

1. Install a new special nut and compression
washer on each tie rod. Ensure two or three
threads show at the end of each rod.
NOTE: The outside edge of the compression
washer must contact the valve section housing and
the center must contact the nut.
2.
Insert the tie rods into the inlet endcap.
3. Place the inlet endcap on its end, resting on the

three tie rod ends.
ENG 6-46870
Installing Compensator Piston into Valve Section

Housing
8001-43
7. Insert the bias spring into the hollow end of the

compensator piston.
16. Torque the lower tie rod nuts to 19N.m

(14 lbf.ft ). This is the final torque value.
8. Install the load sense shuttle disc into the

recess of the load sense passage.
17. Torque the upper tie rod nuts to 45 N.m

(33 lbf.ft). This is the final torque value.
Torque Tie Rods Nuts

Installing Load Sense Shuttle Disc
9.
Lubricate and install a new O-ring in the O-ring

groove.
10. Repeat the installation steps until all the valve

sections, including the outlet endcap, are
installed.
11. Install the compression washers with the
outside edge contacting the valve section housing.
Install new special nuts and tighten to finger
tightness.
18. Check for proper spool movement.

Main Hydraulic Manifold Valve Installation
1. Attach a safe lifting device to the manifold valve
assembly. Carefully install the manifold valve
assembly onto the manifold support.
2. Secure the manifold valve assembly with the four
bolts, nuts, flatwashers and lockwashers.
2.
Connect the control rods to the valve spools.

Install the shoulder socket head bolts and new
locknuts.
11. Place the manifold valve assembly on a

precision flat surface.
NOTE: Torque-tightening the tie bolt nuts on a nonflat surface may cause spool or shuttle disc binding.
13. To align all valve sections and endcaps , press
down on the endcaps before tightening the tie bolt
nuts to the final torque value.
14. Torque the lower tie rod nuts to
9 N.m 3,4 (7 lbf.ft 2.5). This is a preliminary
torque procedure.
15. Torque the upper tie rod nuts to 9 N.m
3,4 (7 lbf.ft 2.5 ). This is a preliminary torque
procedure.
ENG 6-46870
8001-44
DUAL
OVER
CENTER
(COUNTERBALANCE)
VALVE
Counterbalance valves with pilot assist combine two valves; a check valve and a
relief valve. The check valve allows free flow from the directional valve (port 2) to
the load (port 1) while a direct-acting, pilot-assisted relief valve controls flow
from port 1 to port 2.
ADJUSTMENT - Pressure setting 207 bar (3000psi).
Turn screw (1) clockwise to reduce
setting and counterwise to inclease setting.
See figure for position of o'rings and back up rings.
Valve Installation (2) Torque
60 - 70 Nm (45 - 50 lb.ft)
ENG 6-46870
8001-45
ENG 6-46870
8001-46
Dual over center valve, front scarifier

and dozer blade cylinder.
ENG 6-46870
8001-47
SOLENOID / PRESSURE REGULATING VALVE
View of the saddle pressure control valve

and the command solenoid.
Disassembly of regulating valve: the pressure in the

saddle circuit is 42 bar (600 psi) and can be adjusted
by removing plug and rotate set screw clockwise to
increase pressure.
View of pressure regulating valve cartrige.
ENG 6-46870
9002
Section
9002
AIR CONDITIONING TROUBLESHOOTING AND SYSTEM
CHECKS FOR SYSTEMS WITH HFC-134A
REFRIGERANT
CNH Latino Ameicana Ltda.

Contagem, MG Brazil
6-42650
Printed in Brazil
May,2003
8001-48
DUAL
CHECK
VALVE
This valve allows flow from the V ports to the C

ports, while blocking flow from the C ports to the
V ports when pressure is applied at opposite V
port.
Retainer valve of wheel lean.
The retainer valve of the wheels is a simple valve, that has

a safety system. It is composed of a piston and two onewayvalves.
The retainer valve of the wheel lean is located on the

upper part of the frame support.
ENG 6-46870
8001-49
HYDRAULIC CYLINDERS
Hydraulic Cylinder Removal
WARNING: Place the grader in the Service Position.
Prior to removing cylinders, install any linkage or
frame lock pins where applicable; especially wheel
lean (see the Operators Manual).
Support the weight of the cylinders with a suitable lifting
device.
WARNING
of proper capacity. Be sure parts are supported by
proper slings and hooks. Use lifting eyes if
MOLDBOARD LATERAL CYLINDER
WARNING
Danger of spraying oil. Always wear face or eye
protection when loosening hydraulic fittings. Fluid
escaping under high pressure can penetrate skin
causing serious injury.
Relieve all hydraulic pressure. Take care with hydraulic

circuits that contain lock valves.
Disconnect the cylinder from all pivot pins, sockets or
trunnions.
Disconnect the hydraulic hoses. Immediately plug the
open ports and fittings to prevent contamination.
MOLDBOARD PITCH CYLINDER
Remove the cylinder to a work bench for disassembly.

Hydraulic Cylinder Installation
This is the reverse procedure of removal.
WHEEL LEAN CYLINDER
ENG 6-46870
8001-50
MOLDBOARD LIFT CYLINDERS
CIRCLE SHIFT CYLINDER
SADDLE PIN LOCK CYLINDER
ENG 6-46870
WHEEL LEAN CYLINDER
ARTICULATION CYLINDER
SCARIFIER OR DOZER BLADE CYLINDER
8001-51
RIPPER CYLINDER
Hydraulic Cylinder Disassembly
Remove the piston assembly.
Drain any oil remaining in the cylinder in an

appropriate container.
Unscrew (or unbolt) the cylinder head from the

cylinder tube using wrench tool.
Pull the cylinder rod assembly from the tube.
Place the cylinder rod (pin end) in a vise and support

the rod a suitable lifting device. Remove the piston
retaining nut from the rod.
ENG 6-46870
Remove the seals from the piston.
Remove the head assembly.
8001-52
Hydraulic Cylinder Assembly

Assembly of the cylinder is reverse procedure of
disassembly with the following exceptions.
1- Check all parts for signs of excessive wear and

compare dimensions with those listed in Specifications.
2- Install new bushings, seals and O-rings.
3 - Install piston assembly in same position that it was
removed and tighten retaining nut to specifications.
Remove the O - rings.
Remove the seals.
ENG 6-46870
8001-53
SPECIFICATIONS
MOLDBOARD LATERAL SHIFT CYLINDER

A.
Lubricate and torque cylinder head .................................... 1400 1600 Nm (1032 1180 lb.ft)
B.
Piston rod O.D. ...................................................................... 49.960 50.000 mm (1.967 1.968 in)
D. Lubricate and torque piston rod locknut to ............................ 900 1000 Nm (664 738 lb.ft)
E.
Stroke of the piston rod ......................................................... 1219mm (48 in)
MOLDBOARD PITCH CYLINDER

A.
Lubricate and torque cylinder head ..................................... 1400 1600 Nm (1032 1180 lb.ft)
B.
Piston rod O.D. ......................................................................
48.960 50.000 mm (1.967 1.968 in)
E.
Stroke of the piston rod ......................................................... 187mm (7.4 in)

ENG 6-46870
8001-54
WHEEL LEAN CYLINDER

A.
B.
C. Cylinder I.D. ........................................................................... 90.000 - 90.054 mm (3.543 - 3.545 in)
E.
Stroke of the piston rod ......................................................... 187mm (7.4 in)
MOLDBOARD LIFT CYLINDER

A.
B.
Cylinder head rod bore I.D .................................................... 56.120 - 56.160 mm (2.209 - 2.211 in)
E.
Stroke of the piston rod ......................................................... 1143 mm (45 in)
ENG 6-46870
8001-55
CIRCLE SHIFT CYLINDER

A.
Lubricate and torque cylinder head ....................................
1400 1600 Nm (1032 1180 lb.ft)
B.
E.
Stroke of the piston rod ......................................................... 578 mm (22.75 in)
SADDLE PIN LOCK CYLINDER (5 POINT SADDLE)

A.
B.
Piston rod O.D. ...................................................................... 31.674 - 31.750 mm (1.247 - 1.250 in)

Piston O.D. ........................................................................... 63.195 - 63.297 mm (2.488 - 2.492 in)
D. Lubricate and torque piston rod locknut to ............................ 271 - 339 Nm (200 - 250 lb.ft)
E.
Stroke of the piston rod ......................................................... 57.15 mm (2.25 in)

ENG 6-46870
8001-56
SADDLE PIN LOCK CYLINDER (3 POINT SADDLE)

A.
B.
Piston rod O.D. ...................................................................... 49.960 - 50.000 mm (1.967 1.968 in)
D. Lubricate and torque piston rod locknut to ............................ 90 100 Nm (66.4 73.8 lb.ft)
E.
Stroke of the piston rod ......................................................... 1219mm (48 in)
A.
B.
STEERING CYLINDER
C.
*Cylinder head rod bushing bore I.D. .......... ..........................44.4373 44.4500mm (1.7495 1.7500 in)
Bushing O.D. .......................................................................... 44.4881 - 44.5389 mm (1.7515 - 1.7535 in)
D. Bushing I.D. ............................................................................ 38.2016 - 38.3032 mm (1.5040 - 1.5080 in)
E.
Piston rod O.D .....................................................................
38.024 - 38.100 mm (1.497 - 1.500 in)
Cylinder I.D ...........................................................................
63.627 - 63.754 mm (2.505 - 2.510 in)
Piston O.D. ........................................................................... 63.246 - 63.348 mm (2.490 - 2.494 in)

F.
Lubricate and torque the piston rod locknut to ....................... 339 - 407 Nm (250 - 300 lb.ft)
G. Stroke of the piston rod ........................................................... 266.7 mm (10.5 in)
* SERVICE NOTE: Press bushing into head flush with face of head.
ENG 6-46870
8001-57
ARTICULATION CYLINDER
A.
Lubricate and torque cylinder head .................................... 784 - 863 Nm (578 - 636 lb.ft)
B.
Cylinder head rod bore I.D .................................................... 45.120 - 45.160 mm (1.776 - 1.778 in0
E.
Stroke of the piston rod ......................................................... 377 mm (14.8in)
SCARIFIER CYLINDER
A.
Lubricate and torque cylinder head ..................................... 1898 - 2034 Nm (1400 - 1500 lb.ft)
B.
Piston rod O.D. ...................................................................... 50.724 - 50.800 mm (1.997 - 2.000 in)
C. Cylinder I.D. .......................................................................... 101.727 - 101.854 mm (4.005 - 4.010 in)

Piston O.D. ............................................................................ 101.295 - 101.397 mm (3.988 - 3.992 in)
E.
ENG 6-46870
8001-58
RIPPER CYLINDER
A.
Torque cylinder head capscrews to .................................... 216 -235 Nm (159.3 - 173.3 lb.ft)
B.
Cylinder head rod bore I.D ................................................... 60.800 - 61.000 mm (2.394 - 2.402 in)
Piston rod O.D. .................................................................... 59.960 60.000 (2.361 - 2.362 in)
C. Cylinder I.D. ......................................................................... 120.120 - 120.260 mm (4.729 - 4.735 in)

Piston O.D. .......................................................................... 117.950 - 118.090 mm (4.644 - 4.649 in)
E.
ENG 6-46870
SECTION INDEX
MOUNTED EQUIPMENT
Section Title
Section Number
Air conditioning troubleshooting and system checks for system with HFC-134a refrigerant. . . . . . . . . . . 9002
Air conditioner system service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003
Removal and installation of air conditioning components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9004
Rear ripper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9007
Frame, articulation joint circle and scarifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9008
Front blade & counterweigth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9009
Rops CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9010
CAB glass installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..9011

Contagem, MG Brazil
ENG 6-46930
Printed in Brazil
May,2003
9002-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator/Heater Core Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator/Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Test Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE-TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
QUICK REFERENCE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C RECOVERY AND CHARGING STATION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROBLEM: NO COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indication of No Refrigerant or Low Refrigerant Charge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indication of Large Quantity of Air in System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HFC-134a Stable Saturation Pressure/ Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion Valve Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Contamination: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROBLEM: NOT ENOUGH COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not Enough Refrigerant - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Side Restriction - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion Valve Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Turning But Not Pumping Properly - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROBLEM: INTERMITTENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Moisture in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROBLEM: NOISE IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Too Much Refrigerant in System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TUBE CONNECTIONS TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-42650
Issued 8-01
Printed in Brazil
3
5
6
6
8
8
9
10
11
12
12
13
13
13
14
14
15
16
16
17
17
18
18
18
19
19
20
20
21
22
22
23
23
24
24
25
25
26
9002-3
SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH.
M171B
ATTENTION: Only authorized technicians certified

by an approved training and certification organization
may service or repair motor vehicle or mobile air
conditioning systems. It is mandatory that all
refrigerant must be RECOVERED and RECYCLED
when removed from a system during servicing.
Refrigerant HFC-134a is the most stable, and easiest
to work with of the refrigerants now used in air
conditioner systems. Refrigerant HFC-134a does not
contain any chlorofluorocarbons (CFCs) which are
harmful to the earths ozone layer.
Safety procedures must be followed when working
with Refrigerant HFC-134a to prevent possible
personal injury.
1. Always wear safety goggles when doing any
service work near an air conditioner system.
Liquid refrigerant getting into the eyes can cause
se rio u s in jur y. D o th e fo llow ing if yo u g et
refrigerant near or in your eyes:
A. Flush your eyes with water for 15 minutes.
3. Keep refrigerant containers in the correct upright

position. Always keep refrigerant containers
away from heat and sunlight. The pressure in a
container will increase with heat.
4. Always reclaim refrigerant from the system, if
you are going to weld or steam clean near the air
conditioner system.
5. Always check the temperature and pressure of
the air conditioner system before reclaiming
refrigerant and when you test the system.
6. Dangerous gas can form when refrigerant comes
in contact with an open flame. Never permit
fumes to be inhaled.
7. Never leak test with compressed air or flame
testers. Tests have indicated that compressed
mixt ur e s o f HFC - 13 4 a a n d a ir c an fo rm a
combustible gas.
8. Always reclaim refrigerant from the system
before removing any air conditioning component.
B. See a physician immediately.

2. A drop of liquid refrigerant on your skin may
cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air
conditioner system. Your skin must be treated for
frostbite or a physician must be seen if you get
refrigerant on your skin.
6-42650
Issued 8-01
Printed in Brazil
9002-4
299L7C
BELT TENSION TOOL CAS-10808
A22094
REFRIGERANT RECOVERY, RECYCLING AND CHARGING

STATION, OEM-1415
A22090
109L7
ELECTRONIC LEAK DETECTOR OEM-1437

SAFETY GOGGLES CAS-10073-3
6-42650
Issued 8-01
Printed in Brazil
9002-5
OPERATION
The refrigerant, still in a high pressure liquid form,
then flows from the receiver-drier to the expansion
valve. The expansion valve then causes a restriction
in flow of refrigerant to the evaporator core. The
e va p o r a t o r me t e r s r e fr ig e ra n t f lo w b a s e d o n
evaporator heat load.
The refrigerant circuit of the air conditioning system

con ta in s five major co mp on ents: comp ressor,
condenser, receiver-drier, expansion valve and
evaporator. These components are connected by
tubes and hoses and operate as a closed system.
The air conditioner system is charged with HFC-134a
refrigerant.
As the refrigerant flows through the evaporator core,

the refrigerant is heated by the air around and
flowing through the evaporator fins. The combination
of increased heat and decreased pressure causes
the air flow through the evaporator fins to become
very cool and the liquid refrigerant to become a low
pressure gas. The cooled air then passes from the
evaporator to the cab for the operators comfort.
The compressor receives the refrigerant as a low

pressure gas. The compressor then compresses the
refrigerant and sends it in the form of a high pressure
gas to the condenser. The air flow through the
condenser then removes t he heat from the
refrigerant. As the heat is removed the refrigerant
changes to a high pressure liquid.
The electrical circuit of the air conditioning system

consists of a fan speed control,one (1) relay, a blower
motor, blower resistor, A.C.compressor clutch, A.C.
low pressure switch, A.C. high pressure switch.
.
The high pressure refrigerant liquid then flows from

t h e c o n d e n s e r t o t h e r e c e i v e r - d r i e r. T h e
receiver-drier is a container filled with moisture
removing material, which removes any moisture that
may have entered the air conditioner system in order
to prevent corrosion of the internal components of
the air conditioner system.
3
5
4
208L95
1. EXPANSION VALVE
2. EVAPORATOR
6-42650
3. COMPRESSOR
4. CONDENSER
5. RECEIVER-DRIER
Issued 8-01
Printed in Brazil
9002-6
TROUBLESHOOTING
Perform a visual inspection of the machine. Check
the following and correct as necessary:
1. - Obtain service history if possible.
5. - Are there heavy accumulations of oil, or oily

dust around the fittings, indicating refrigerant
leakage?
6. - Are air ducts undamaged, sealed properly and
in position?
2. - Is compressor drive belt in place and tensioned?

3. - Are grille screens, fan blades, condenser, air filter, and
evaporator unobstructed?
7. - Condensate drain hoses and check valves

present and unobstructed?
4. - Are there any sharp bends or kinks in the

hoses?
Problem: No Cooling
Compressor Runs
No
Mechanical - See Mechanical Compressor

Check Page 8
Electrical - See Blower and Compressor
Clutch Check Page 9
Yes
Internal System Problem
See Pressure Testing, Page 13
6-42650
Issued 8-01
Printed in Brazil
9002-7
Problem:
Not Enough Cooling
Problem:
Erratic Cooling
MECHANICAL
HEATER
See Mechanical Compressor Check Page 8.
Make sure the heater control is OFF and that there is no coolant
flow through the heater core.
ELECTRICAL
See Blower and Compressor Clutch Check - Blower Motor
Check, Blower Switch Check and Compressor Clutch Check
on Page 9.
SEAL
Make sure the sealing material is correctly in place.
INTERNAL SYSTEM PROBLEMS
See Pressure Testing, Page 13.
MECHANICAL
See Mechanical Compressor Check page 8. See Evaporator
Heater Core Check Page 12.
Problem:
System Makes Noise
ELECTRICAL
See Blower and Compressor Clutch Check on Page 9.
MECHANICAL
See Mechanical Compressor Check Page 8.
See Blower Motor Check Page 9.
REFRIGERANT
See Cab Temperature Check Page 10.
ELECTRICAL
See Compressor Clutch Check Page 9.
INTERNAL SYSTEM PROBLEM
INTERNAL SYSTEM PROBLEM

6-42650
Issued 8-01
Printed in Brazil
9002-8
SYSTEM CHECKS
Mechanical Compressor Check
Compressor and Fan Belts
1. Too much belt wear - replace a worn belt,

because a worn belt will cause too much
slippage.
Compressor Mounting Brackets
1. Loose bracket mounting bolts - tighten the

bolts to the correct torque.
2. Bracket has cracks or breaks - replace the
bracket.
Compressor Clutch
1. The compressor belt will slip on the

compressor pulley if there is compressor
seizure. Re mo ve the compresso r for
service or replacement.
2. The gap between the front plate and
pulley assembly must be 0.41 to
0.79mm.
.
3. Use a socket wrench to slowly rotate the
co m p re s so r c loc k wis e . Co m p re s so r
rotation should be smooth and not require
much effort.
Pulley and Belt Alignment
1. The
compressor
pulley
and
the
compressor drive pulley must be aligned
within 1.6 mm (1/16 inch) of each other.
Us e a str aig ht ed g e to ch ec k p u lle y
alignment. Adjust the compressor
mounting bracket if needed.
6-42650
Issued 8-01
Printed in Brazil
9002-9
Blower and Compressor Clutch Check

NOTE: Check
supply
voltage
with
compressor lead plugged in and engaged.
Voltage drops will not be apparent without
current flow.
Compressor Clutch
1. If there is electrical system voltage to the

clutch, check for excessive voltage drop in
the ground circuit, then see Section 9004
and replace the compressor.
Low and High Pressure Switches
1. See Section 4002 and check the high and

low pressure switches.
Blower Fuse (20 amp)
1. Check for damaged blower fuse.
Blower Fan Switch
1. Check switch operation. Switch must give

four different blower speeds: OFF, Low
Medium and High.
2. Check for loose connections or broken
wires. Repair or replace as necessary.
3. Check resistor board.
Blower Motor
6-42650
1. Check the wiring to the blower motor.

Make repairs or replace items as
necessary.
Issued 8-01
Printed in Brazil
9002-10
Cab Temperature Check

Air Louvers
1. Make sure louvers and recirculation vents are fully open

for most efficient air conditioning operation. Defrost
louvers must be closed.
2. Check blower; blower must be running.
ATTENTION: Use caution when feeling hoses. Hoses

become very hot. Check temperature by slowly reaching for
hose and touching briefly several times with finger tips,
increasing the duration with each touch.
Air Conditioning
1. Feel the air conditioning hoses. The high pressure

hoses (small line) must be warmer than the low pressure
hose (large line).
2. If no temperature difference, the system is low on
refrigerant, or compressor is not working correctly.
1. Put a thermometer in the air duct behind the seat and

run the compre ssor fo r five minutes to make
temperature stable. Refer to page 12.
2. Duct temperature must be below 25 C (72 F) if the
system is operating at maximum efficiency.
Duct Temperature
6-42650
NOTE: Ambient temperature must be 27 to 43 C (80 to

110 F).
3. If temperature is above 25 C (72 F), system is low on
re fr ig e ra n t, th e r e is a r e st ric tio n in th e s ys te m,
compressor is not working correctly, or air ducts are not
sealed correctly.
Issued 8-01
Printed in Brazil
9002-11
Visual and Leak Check

Compressor Hoses
1. Make sure that all hose connections are

tight.
2. Check hoses for bends or cracks.
Replace all hoses that have damage.
1. Shut off the engine.
Leak Finding Check
Condenser
6-42650
WARNING: When refrigerant comes in

contact with an open flame, it can form
dangerous gas. Never breathe these fumes.
2. Use electronic leak detector OEM -1437
to inspect all connections. U se
instructions from manufacturer of leak
finding tool.
1. Make sure the condenser is clean and the

seals are in place.
Issued 8-01
Printed in Brazil
9002-12
Evaporator/Heater Core Check

Make sure heater valve is closed
Evaporator/Heater Core
Evaporator/Heater Core
1. See Section 9004 for access to the

evaporator/heater core.
2. Inspect the fins on the evaporator/heater
core. All the fin s th at have b end s or
damage must be made straight.
3. Inspect the evaporator/heater core for
r e s t r i c t i o n s . I f t h e c o r e i s d r y, u s e
compressed air or a brush and vacuum
cleaner. If the core is wet or filled with
mud, flush the core with water using a
hose without pressure. Make sure the
wate r dra in s freely from th e
evaporator/heater core. DO NOT USE
STEAM.
WARNING: Do not steam clean any air
conditioning systems parts while the system is
charged. The heat will cause the refrigerant to
rise to a pressure that could cause the system
to explode.
Evaporator/Heater Core Sealing
1. See Section 9004 for access to the

evaporator/heater core.
2. Make sure seals are in place so blower
will pull a ir o nly throu gh th e
evaporator/heater core and not around
the evaporator/heater core.
Filters
1. Make sure the filters are clean.
6-42650
Issued 8-01
Printed in Brazil
9002-13
PRESSURE TESTING
Manifold Gauge Set
NOTE: The gauge set is not accurate enough to
optimize an existing charge of HFC-134a. The best
use of the gauge set is to determine whether
undercharge or overcharge exists, and then
evacuate, reclaim and recharge system with the
recommended quantity (charge) of HFC-134a.
The manifold gauge set is the most important tool
used to service the air conditioning system. The
manifold gauge set is used to measure the high and
low pressures of the system, as a tool to troubleshoot
for correct refrigeran t charge quantity, system
diagnosis, and operating efficiency. The manifold
gauge set can read both the high (discharge) and low
(suction) sides at the same time, since pressure must
be compared in order to make a diagnosis of system
operation.
During normal operation the low pressure gauge

must always indicate from 10 to 35 psi (0.7 to 2.4
bar) after the system has run 10 to 15 minutes.
HIGH PRESSURE GAUGE - The high pressure
gauge is used to indicate pressures in the high side
of the system. The gauge must indicate from 0 to 400
psi (0 to 27.6 bar) minimum.
During normal operation, the high pressure gauge
will normally indicate from 120 to 310 psi (8.3 to 21.4
bar). See pressure-temperature chart on page 14.
Pressure Test Connection

C o n n e c t th e ma n if o l d g a u g e s e t in t o t h e a ir
conditioning system as shown. Make sure that both
valves in the manifold gauge set are closed.
LOW PRESSURE GAUGE - The low pressure gauge

is a compound gauge. It is best used to judge
e va c u a tio n e ff e ct iv e ne s s . A va c u u m r e a d in g
indicates a system malfunction. For this reason, it is
nece ssary to use a compo und gau ge tha t w ill
indicate both pressure and vacuum.
6-42650
Issued 8-01
Printed in Brazil
9002-14
NORMAL OPERATING AIR CONDITIONING CONDITIONS

AIR LOUVER (BEHIND
SEAT)
MAXIMUM TEMP.
TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION
F (C)
psi (bar)
psi (bar)
F (C)
AMBIENT
80 (27)
90 (32)
95 (35)
100 (38)
105 (41)
110 (43)
AMBIENT TEMPERATURE
RELATIVE HUMITY
MACHINE MOTOR SPEED
SUCTION PRESSURE
DISCHARGE PRESSURE
NORMAL LOW
NORMAL HIGH
9 to 12
145 to 165
(0.62 to 0.83)
(10 to 11.53)
11 to 15
190 to 210
(0.76 to 1.04)
(13.10 to 14.48)
16 to 18
210 to 230
(1.10 to 1.24)
(14.48 to 15.86)
17 to 19
235 to 255
(1.17 to 1.31)
(16.2 to 17.58)
20 to 21
260 to 280
(1.38 to 1.45)
(17.93 to 19.31)
22 to 24
290 to 310
(1.93 to 2.14)
(20 to 21.37)
55 (14)
61 (18)
63 (20)
66 (22)
68 (23)
72 (25)
-25C
50%
2000 rpm
15+-5 psi
175+-15 psi
-Measurements taken 15 minutes after startup

-All panels and access doors installed and closed
-Fresh air filter and cab air filter clean and installed.
-Condenser fins clean and unobstructed and straight.
These data have great increase or decrease depending on environmental conditions
QUICK REFERENCE TROUBLESHOOTING CHART

PROBLEM
LOW PRESSURE
GAUGE
HIGH PRESSURE
GAUGE
SEE
PAGE
NO COOLING
VERY LOW
VERY LOW
16
NO COOLING
HIGH
HIGH
17
NOT ENOUGH COOLING
NORMAL TO HIGH
NORMAL
19
NOT ENOUGH COOLING
LOW
LOW
20
NOT ENOUGH COOLING
HIGH
LOW
22
NOT ENOUGH COOLING
HIGH
HIGH
23
INTERMITTENT COOLING
NORMAL
NORMAL
24
NOISE IN SYSTEM
NORMAL TO HIGH
HIGH
25
6-42650
Issued 8-01
Printed in Brazil
9002-15
A/C RECOVERY AND CHARGING STATION CONNECTIONS

STEP 1
WARNING: Always wear safety goggles

when working with liquid refrigerant. Liquid
r e f r ig e r a n t i n y o u r e y e s c o u l d c a u s e
blindness.
SM105A
Make sure the charging station manifold gauge

valves are in the closed position.
STEP 3
Clean the external surfaces of the compressor and

hoses. Remove the caps from the service ports on
the suction and pressure hoses.
WARNING: Do not steam clean any air

conditioning system parts while the system is
charged. The heat will cause the refrigerant
to rise to a pressure that could cause the
system to explode.
SM104A
STEP 2
Connect the hose from the test gauges to the
service ports by turning the knurled knobs
on the depressors.
BD00N030
1. BLOWER FAN SWITCH

2. A/C TEMPERATURE CONTROL
Start the engine and run at 1500 RPM maximum

sp ee d . O pe ra te the a ir co nd itio n er sys tem at
maximum cooling setting and blower speed for 15
minutes with the cab door open. Observe the test
gauges and check the chart on page 13 against the
gauge readings.
Connect the hose from the low pressure gauge to the

port on the suction hose.
Connect the hose from the high pressure gauge to
the port on the discharge hose.

port on the suction hose.
6-42650
Issued 8-01
Printed in Brazil.
9002-16
PROBLEM: NO COOLING
VERY LOW
VERY LOW
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
476L7
Indication of No Refrigerant or Low Refrigerant Charge:

1. Leak test the system, see Page 11. It may
be necessary to add refrigerant. See
Section 9003.
2. Evacuate
and
reclaim
remaining
refrigerant from system. See Section
9003.
3. Repair system leaks as needed. Follow
the given repair procedure.
A. Discharge air from evaporator warm.
B. Compressor does not run, or cycles off
rapidly after start-up.
Yes
4. Check level of oil in compressor - possible

for compressor to have an oil loss.
5. Remove air and moisture from the
system. Replace Receiver-Drier. See
Section 9004.
6. Charge system with new refrigerant. See
Section 9003.
7. Continue performance
possible problems.
6-42650
Issued 8-01
test for
other
Printed in Brazil
9002-17
HIGH
HIGH
476L7
Indication of Large Quantity of Air in System:

1. Evacuate and reclaim refrigerant from
system. See Section 9003.
2. Replace receiver-drier.
Discharge air from evaporator warm
Yes
3. Remove air and moisture

from the

Section 9003.
Condenser Malfunctioning - Indications:

1. Check for loose or worn compressor.
2. Check to see that condenser is clean and

unobstructed and that the fins are straight.
3. Check system for too much refrigerant. Evacuate,
recla im a nd recharge refrigera nt un til gauge
pressure is normal. See Section 9003.
A. Liquid line (between evaporator and
condenser) is very hot.
B. Discharge air from evaporator warm.
4. Remove and check condenser for restrictions

caused by oil or reduced heat transfer.
A. Remove refrigerant from the system. See
Section 9003.
B. Use compressed
condenser.
air
to
remove
oil
from
C. Replace receiver-drier.
D. Remove moisture and charge the system. See
section 9003.
5. Continue the performance test for other possible
problems.
6-42650
Issued 8-01
Printed in Brazil
9002-18
Expansion Valve Malfunctioning - Indications:

A. Discharge air from heater/evaporator
warm.
B. Much condensation on suction hose at
compressor.
C. Much condensation
outlet.
on
See Section 9004 and replace the expansion

valve.
evaporator
Refrigerant Contamination:
1. See table below and check stable saturation pressures at
given temperature to determine if contamination exists.
A. Measure pressure from gauge on reclamation unit.
B. Measure temperature from refrigerant in reclamation
tank. If refrigerant has been in reclamation unit for some
time, use ambient temperature. The numbers in the
table represent the boiling point for HFC-134a.
Refrigerant Contamination
C. Pressure readings below range given in chart indicate

contaminated refrigerant.
IMPORTANT: Do not use contaminated refrigerant or mix
with uncontaminated refrigerant. Dispose of in accordance
with all applicable laws and local procedure.
HFC-134a Stable Saturation Pressure/ Temperature Chart

Temperature F ( C)
Pressure PSIG (Bar)
50 (10)
55 (13)
60 (16)
65 (18)
70 (21)
75 (24)
80 (27)
85 (29)
90 (32)
95 (35)
100 (38)
102 (39)
104 (40)
106 (41)
108 (42)
110 (43)
112 (44)
114 (46)
116 (47)
118 (48)
120 (49)
45 (3.1)
51 (3.5)
57 (3.9)
64 (4.4)
71 (4.9)
78 (5.4)
88 (6.1)
95 (6.6)
104 (7.2)
114 (7.9)
124 (8.6)
129 (8.9)
133 (9.2)
138 (9.5)
142 (9.8)
147 (10.1)
152 (10.5)
157 (10.8)
162 (11.2)
167 (11.5)
172 (11.9)
6-42650
Issued 8-01
Printed in Brazil
9002-19
PROBLEM: NOT ENOUGH COOLING
NORMAL TO
SLIGHTLY HIGH
NORMAL TO
HIGH
476L7
Air in the System - Indications:

1. Test system for leaks. See page 11. Possible
leak has let air enter; check compressor seal
carefully.
2. Discharge system of refrigerant. See Section
9003.
A. Suction line warm to your hand.
3. Repair system leak as necessary.
B. Discharge air from heater/evaporator

only a little cool.
5. Check compressor oil level.
6. Remove air and moisture from the system.
See Section 9003.
Section 9003.
6-42650
Issued 8-01
Printed in Brazil
9002-20
LOW
LO W
476L7
Not Enough Refrigerant - Indications:

1. Leak test system - system has a loss of refrigerant.
NOTE: Normally, the system will lose 1/2 to 1 ounce (14.7
to 29.5 grams) of refrigerant between seasons.
A. If leak is found, go to Step 2.
B. If no leak is found, go to Step 6.
2. Discharge refrigerant from system. See Section 9003.
A. Discharge air from evaporator
cool or warm - not cold.
3. Repair system leaks as needed.

4. Check oil level in compressor - It is possible for
compressor to lose oil.
5. Remove air and moisture from the system. Replace
Receiver-Drier. See Section 9004.
6. Charge system with new refrigerant. See Section
9003.
High Side Restriction - Indications:

A. Discharge air from heater/evaporator
only a little cool.
B. Condensation
receiver-drier.
or
frost
on
C. Liquid line to receiver-drier cool, with

frost or condensation.
NOTE: The frost will form downstream
from or at the point of the restriction
6-42650
1. Discharge refrigerant from system-restriction in

receiver-drier or liquid line must be removed.
2. Remove and replace part with restriction.
3. Remove air and moisture from the system. See
Section 9003.
4. Charge system with new refrigerant. See Section
9003.
Issued 8-01
Printed in Brazil
9002-21
Expansion Valve Not Operating - Indications:

A. Discharge air from evaporator warm
or cool - not cold.
B. Condensation or frost on expansion
valve outlet.
C. Inlet end of expansion valve is
warm.
6-42650
1. Expansion valve outlet with condensation or frost is

an indication of a restriction in the expansion valve.
Replace expansion valve. See Section 9004.
2. Inlet end of expansion valve is warm (not hot),
indicating expansion valve is not completely open.
If the valve is stuck closed, there will be little or no
flow of refrigerant through the valve. Replace
expansion valve. See Section 9004.
Issued 8-01
Printed in Brazil
9002-22
HIGH
LOW
SEE THE PRESSURE - TEMPERATURE CHART ON PAGE 14
476L7
Compressor Turning But Not Pumping Properly - Indications:

1. Discharge refrigerant from system. See Section
9003.
2. Remove the compressor from the machine. See
Section 9004.
3. Remove and replace compressor because there is
indication of internal leak in compressor.
A. System is fully charged.
4. Replace compressor.
B. Cool discharge air from evaporator.
5. Replace receiver-drier if:

A. System has been opened before.
B. Receiver-drier has been used two or more
years. See Section 9004 for receiver-drier
replacement.
6. Charge the system with refrigerant. See Section
9003.
Expansion Valve Stuck Open

Expansion Valve Stuck Open
6-42650
1. Replace expansion valve. See Section 9004.
Issued 8-01
Printed in Brazil
9002-23
HIGH
HIGH
476L7
Condenser Not Operating - Indications:

1. Check for loose or worn compressor belt.
.
2. Check to see that condenser is clean and that
the fins are straight.
3. Check system for too much system.
See section 9003.
A. Remove all refrigerantfrom system.
See 9003.
A. Liquid line very hot.
B. Discharge air from evaporator warm.
B. Add specified refrigerant charge(1450+- 50g).

C. If there is still a problem, do step4.
4. Remove and inspect condenser for restrictions
caused by oil or reduced heat transfer.
A. Discharge refrigerant from system. See
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier. See Section 9004.
Air in the System - Indications:

1. Discharge refrigerant from system. See
Section 9003.
Warm discharge air from evaporator.

from the

Section 9003.
6-42650
Issued 8-01
Printed in Brazil
9002-24
PROBLEM: INTERMITTENT COOLING
NORMAL
NORMAL
476L7
Moisture in the System - Indications:

1. Discharge system of refrigerant. If too
much moisture enters the orifice of the
expansion valve, the fre ezing of this
moisture can stop refrigerant flow. See
Section 9003.
2. Replace receiver-drier. The moisture
removing material could be full to capacity
with moisture. See Section 9004.
Cooling is acceptable during cool part of day
but not acceptable during hot part of day.

from the
NOTE: The time needed to remove a large

amount of moisture will be two to three hours
minimum.
Section 9003.
6-42650
Issued 8-01
Printed in Brazil
9002-25
PROBLEM: NOISE IN SYSTEM
NORMAL
TO HIGH
HIGH
476L7
Too Much Refrigerant in System - Indications:

A. Cool discharge air from heater/evaporator.
B. Compressor makes noise.
6-42650
1. Remove all refrigerant from system.

See section 9003.
2. Add specified refrigerant charge (1450+-50g).
See section 9003.
.
Issued 8-01
Printed in Brazil
9002-26
SCREWS AND TUBE CONNECTIONS TORQUE CHART

TUBING SIZE
3/8 inch
1/2 inch
5/8 inch
THREAD SIZE
M10 -1.25
5/8-18
3/4-18
OR
3/4-16
7/8-18
OR
7/8-14
1-14
STEEL TO STEEL
31-36 Nm
31-36 Nm
40-46 Nm
45-52 Nm
45-52 Nm
ALUMINUM TO BRASS
10-14 Nm
10-14 Nm
24-30 Nm
30-37 Nm
45-52 Nm
NOTE: When tightening air conditioning hose or pipe fittings, a second wrench serving as support must be used.
IMPORTANT: Special care is required when tightening the fittings on the compressor, condenser and evaporator
since these connections are easily distorted.
6-42650
Issued 8-01
Printed in Brazil
9003
Section
9003
AIR CONDITIONER SYSTEM SERVICE
CNH Latino Ameicana Ltda.

Contagem, MG Brazil
6-42650
Printed in Brazil
May, 2003
9003-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42660
Issued 8-01
3
3
4
5
7
10
Printed in Brazil
9003-3
SPECIFICATIONS
Air conditioning system refrigerant capacity ........................................................................................ 1.6 kg (3.5 lbs)
SPECIAL TOOLS
A22094
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING

STATION OEM-1415
Bur 6-42660
109L7
SAFETY GOGGLES CAS-10073-3
Issued 8-01
Printed in Brazil
9003-4
SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH.
M171B
ATTENTION: Only authorized technicians certified

by an approved training and certification organization
may service or repair motor vehicle or mobile air
conditioning systems. It is mandatory that all
refrigerant must be RECOVERED and RECYCLED
when removed from a system during servicing.
Refrigerant HFC-134a is the most stable and easiest
to work with of the refrigerants now used in air
conditioning systems. Refrigerant HFC-134a does
not contain chlorofluorocarbons (CFCs) which are
harmful to the Earths ozone layer.
Safety procedures must be followed when working
with refrigerant HFC-134a to prevent possible
personal injury.
1. Always wear safety goggles when doing any
service work near an air conditioner system.
Liquid refrigerant getting into the eyes can cause
se rio u s in jur y. D o th e fo llo w ing if yo u ge t
refrigerant near or in your eyes:
A. Flush your eyes with water for 15 minutes.
3. Keep refrigerant containers in the correct upright

position. Always keep refrigerant containers
away from heat and sunlight. The pressure in a
container will increase with heat.
4. Always reclaim refrigerant from the system, if
you are going to weld or steam clean near the air
conditioner system.
5. Always check the temperature and pressure of
the air conditioner system before reclaiming
refrigerant and when you test the system.
6. Dangerous gas can form when refrigerant comes
in contact with an open flame. Never permit
fumes to be inhaled.
7. Never leak test with compressed air or flame
testers. Tests have indicated that compressed
mixt ur e s o f HFC - 13 4 a a n d a ir c an fo rm a
combustible gas.
8. Always reclaim refrigerant from the system
before removing any air conditioning component.
B. See a physician immediately.

2. A drop of liquid refrigerant on your skin may
cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air
conditioner system. Your skin must be treated for
frostbite or a physician must be seen if you get
refrigerant on your skin.
Bur 6-42660
Issued 8-01
Printed in Brazil
9003-5
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY

R e co v e re d re f rig e r a n t p a ss e s th r o u g h a n o il
separator and a filter-drier before entering the
refrigerant tank. The moisture indicator will turn
green when dry refrigerant passes over it.
STEP 3
If possible, run the air conditioning system for ten

minutes before starting the recovery process. Turn
the system off before proceeding.
STEP 1
A22114
Open the high and low valves.
STEP 4
BD01D251
Clean the external surfaces of the compressor and

hoses. Remove the caps from the service ports on
the suction and pressure hoses.
STEP 2
A22107
Make certain the refrigerant tank gas and liquid

valves are open.
BD01D273
With the charging station manifold gauge valves in

the closed position, connect the hoses from the test
gauges to the service ports.
port on the suction hose. Turn in valve depressor.
Connect the hose from the high pressure gauge to
the p ort o n the discha rge h ose . Turn in valve
depressor.
Bur 6-42660
Issued 8-01
Printed in Brazil
9003-6
STEP 5
STEP 7
A22112
A22110
Connect the main power plug to a 115 volt AC outlet.

Move the main power switch to the ON position and
depress the recovery start switch.
Slowly open the oil drain valve and drain the oil into
the reservoir. When the oil stops draining, close the
oil drain valve completely.
The compressor will shut OFF automatically when

recovery is complete. Wait for 5 minutes and observe
the manifold pressure gauges for a pressure rise. If
pressure rises above 0 psi (0 bar), depress the
hold/cont switch. Then wait for the compressor to
automatically shut OFF.
STEP 8
STEP 6
A22111
Fill the A/C compressor with fresh SP-20 PAG oil

equal to the amount in the reservoir.
STEP 9
A22108
Drain the oil separator of the A/C system oil. Open

the air purge valve long enough to let some of the
comp ress or d isch ar ge p re ssure ba ck into th e
separator.
BD01D273
Remove the hoses from the service ports and install

the caps.
Bur 6-42660
Issued 8-01
Printed in Brazil
9003-7
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

IMPORTANT: Replace the receiver-drier if one or
more of the following conditions occurs before you
remove the air and moisture from the system.
A. The system has been opened for service
before.
B. Receiver-drier has operated two or more
years.
C. Disassembly of compressor shows small
particles of moisture removing material (gold
or brown particles).
Air and moisture are removed from the system by a

vacuu m pum p. A vacuum pum p is the only
equipment made to lower the pressure enough to
change the moisture to vapor that can be removed
from the system.
NOTE: Refer to the vacuum pump manufacturers
user manual for additional information.
STEP 11
D. Large system leak (broken hose, break in

line).
E. Too much air or moisture in system.
F. Removal of compressor caused the system to
be open (uncapped) longer than 5 minutes.
STEP 10
A22113
Connect the main power plug to a 115 volt AC outlet.

Move the main power switch to the ON position. If
program and vacuum do not appear at the top of the
display press the vacuum key. Program a minimum
of 45 minutes and press the Enter key. The display
will flash once indicating the programmed data has
been accepted.
STEP 12
BD01D273
With the charging station manifold gauge valves in

the closed position, connect the hoses from the test
gauges to the service ports as follows:
1. Connect the hose from the low pressure gauge
to the port on the suction hose.
2. Connect the hose from the high pressure gauge
to the port on the discharge hose.
3. Turn in both thumbscrews to depress the service
valves.
Removal of air and moisture from the system is
necessary after the refrigerant has been removed
after the system has been opened for maintenance.
Air enters the system when the system is opened. Air
has moisture that must be removed to prevent
damage to the system components.
A22115
Press the Charge key. Program and Charge will

appear on the display.
NOTE: The pump on the reclamation unit will not

pull a sufficient vacuum to remove air and moisture.
Bur 6-42660
Issued 8-01
Printed in Brazil
9003-8
STEP 13
STEP 16
A22113
A22123
Program 3.5 lbs and press the enter key. The display
will flash once indicating the programmed data has
been accepted.
Press the Vacuum key. Automatic will appear on

the display. Vacuum will appear on the display and
after a slight delay, the vacuum pump will start. The
display will show the amount of time programmed
and begin a countdown to zero.
STEP 14
W h e n th e p ro g r a mme d tim e h a s e la p se d , a n
automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28 to
29-1/2 inches of mercury (Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 10 minutes. A previously charged,
le a k - f r e e s y s te m w il l l e a c h r e fr ig e r a n t f r o m
compressor oil and raise system pressure under
vacuum. If the system will not hold vacuum, a leak
exists that must be corrected before recharging can
begin. See Section 9002 in the manual for a leak
test.
A22114
STEP 17
A22107
Press the charge key to begin refrigerant charging.

Automatic and Charge will appear on the display.
The display shows the programmed amount and
counts down to zero as charging proceeds. When
charging is completed, the display shows CPL.
Fully open the low and high pressure valves.
STEP 15
A22113
Open the red (vapor) and blue (liquid) valves on the

tank.
Bur 6-42660
Issued 8-01
Printed in Brazil
9003-9
STEP 18
STEP 20
A22114
A22117
Completely close the high and low pressure manifold

valves.
Observe the pressure gauge readings to determine

that the correct amount of refrigerant has entered the
system. See chart on Page 9002-9 for temperature
and pressure variations.
ATTENTION: Check the OEM equipment manual

before performing Step 19 to avoid damaging the
recovery unit. The pressure reading should be
obtainable with valves closed. Damage may occur if
the machine is started with the valves accidently
open or if either or both valves are opened while the
A/C system is operating.
STEP 21
STEP 19
Start the engine and run at 1500 RPM. Operate the
air conditioner system at maximum cooling setting
and blower speed with the doors and windows open.
NOTE: The compressor will not operate if the
system pressure is too low or too high. The pressure
indicator lamp will illuminate when the relay is
actuated by a low or high pressure and the
compressor clutch will disengage. To restart the
compressor, the air conditioner control or blower
switch must be turned to the OFF position and then
to the ON position.
BD01D273
Stop the engine, close any open valves and carefully

remove the manifold gauge hoses.
STEP 22
BD01D251
Install the caps on the service ports on the suction

and discharge hoses.
Bur 6-42660
Issued 8-01
Printed in Brazil
9003-10
PRESSURE - TEMPERATURE CHART

AMBIENT
NORMAL LOW
NORMAL HIGH
AIR LOUVER (BEHIND
TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION SEAT) MAXIMUM TEMP.
F (C)
psi (bar)
psi (bar)
F (C)
80 (27)
9 to 12
(0.62 to 0.83)
145 to 165
(10 to 11.5)
55 (14)
90 (32)
11 to 15
(0.76 to 1.04)
190 to 210
(13.1 to 14.5)
61 (18)
95 (35)
16 to 18
(1.10 to 1.24)
210 to 230
(14.5 to 15.8)
63 (20)
100 (38)
17 to 19
(1.17 to 1.31)
235 to 255
(16.2 to 17.6)
66 (22)
105 (41)
20 to 21
(1.38 to 1.45)
260 to 280
(17.9 to 19.3)
68 (23)
110 (43)
22 to 24
(1.93 to 2.14)
290 to 310
(20 to 21.4)
72 (25)
The pressure-temperature chart is based on the

following conditions:
1. Engine operating at 1500 RPM
2. No engine load
3. Fan speed control in maximum position (full
clockwise) and all louvers open.
5. Both cab doors open

6. All panels and access doors installed and closed.
7. Cab filters clean and installed.
8. Heater valve at engine closed.
9. Measurements taken 15 minutes after start-up.
4. Cab temperature control set to maximum cooling

(full counterclockwise).
Bur 6-42660
Issued 8-01
Printed in Brazil
9004
Section
9004
REMOVAL AND INSTALLATION OF AIR CONDITIONING
COMPONENTS FOR SYSTEMS WITH 134 a REFRIGERANT
845 - 865 - 885 Grader

ENG 6-46970
Printed in Brazil
May, 2003
TABLE OF CONTENTS
CLEAN / REPLACE FRESH AIR FILTER . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 3
CLEAN / REPLACE RECIRCULATED AIR FILTER. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPLACE RESISTOR AND EVAPOTATOR FAN. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPLACE HEATER AND EVAPORATOR...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REPLACE THERMOSTATIC SWITCH AND EXPANSION VALVE. . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 6
REPLACE COMPRESSOR AND BELT.......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REPLACE CONDENSER , RECEIVER DRIER AND PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REPLACE AIR CONDITIONNING HOSE ASSY. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . 8
AIR CONDITIONING SWITCH CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9004-3
1) CLEAN / REPLACE FRESH AIR FILTER.

1.1) Open the cover (external side cab) and remove nuts with 10mm wrench. Remove support and clean / replace fresh
air filter.
2) CLEAN / REPLACE RECIRCULATED AIR FILTER.

2.1) Find 04 (four) nuts of evaporator housing support that is located at the bottom side of seat plate and remove the filter
.
2.2) Use a Philips screw driver to remove 02 (two) bolts and replace the filter.
ENG 6-46970
Issued 01-03
Printed in Brazil
9004-4
3)TO REPLACE RESISTOR AND EVAPORATOR FAN.
3.1) Remove charge with proper equipment. Never let refrigerant charge flows to air.
3.2) Turn off two hot water valves located the machine engine compartment
3.3) Remove seat.

3.2) Remove seat plate.
3.3) Disconnect 02 (two) air conditioning hose assemblies. Use 16 and 22 mm wrench.
3.4) Disconnect 02 (two) hot water hoses removing clips with pliers
ENG 6-46970
May, 2003
Printed in Brazil
9004-5
3.5) Remove 03(three) bolts from evaporator housing. Use 13 mm wrench. Disconnect electrical cables and remove evaporator
housing.
3.6) Put evaporator housing on a workbench. Disconnect electrical cable from resistor. Use a Philips screw driver to
remove 02 (two) screws and replace resistor.
3.7) Remove 03 (three) bolts on each fan. Use a 8 mm wrench. Remove and replace fans.
4) REPLACE HEATER AND EVAPORATOR.

4.1) Follow steps 3.1 to 3.5, disconnect electrical cables, remove evaporator housing and put it on a workbench.
4.2) Remove 09 (nine) screws. Use a Philips screw driver. Remove cover.
4.3) Remove 02 ( two) screws. Use a Philips screw driver. Make sure that expansion valve support is free.
ENG 6-46970
Issued 01-03
Printed in Brazil
9004-6
4.4) Remove 06 (six) screws from evaporator and heater plate located at each side of evaporator housing. Use a Philips
screw driver.
4.5) Remove evaporator first. Then, remove heater.
4.6) Replace evaporator and/or heater. In order to reassemble these parts, follow these steps backwards.
5) REPLACE THERMOSTATIC SWITCH AND EXPANSION VALVE.
5.1) Follow steps 4.1 to 4.5, without removing heater plate bolts (03). Remove evaporator and put it over workbench.
5.2) Remove 02 (two) screws from thermostatic switch support. Use a Philips screw driver. Remove and replace
thermostatic switch. Make sure that its sensor (bulb) is correctly mounted at evaporator fins hole.
5.3) Remove expansion valve. Use 19 and 25mm wrench. Replace it and replace o-ring seal.
In order to reassemble evaporator, follow these steps in reverse order
ENG 6-46970
May, 2003
Printed in Brazil
9004-7
6) REPLACE COMPRESSOR AND BELT.
6.1) Remove charge with proper equipment. Never let refrigerant charge flow to air.
6.2) Disconnect electrical cable. Remove hose fitting. Use a 27mm wrench for suction hose and 22mm wrench for
discharge hose. Remove 03 (three) bolts from compressor to make belt free. Use 17 mm wrench. Remove compressor.
6.3) Conduct repairs or replace compressor, mounting it at support. Check if its pulley is aligned with motor
pulley. If it is not aligned, remove the bolts from compressor support. Handling support until the pulleys are aligned (used a rule or
Tight the bolts.
6.4) Loosen free but do not remove the 03 (three) bolts from compressor. Replace belt with proper tension.
ENG 6-46970
Issued 01-03
Printed in Brazil
9004-8
L 7)REPLACE CONDENSER, RECEIVER DRIER AND PRESSURE SWITCH .
If is necessary, replace only switch pressure, do not remove charge.
7.2) Remove condenser hose fitting. Use 19 and 22mm wrench. Remove receiver drier hose fitting. Use 16 and 19mm
wrench.
7.3) Remove 04 (four) bolts from condenser supports. Use a 17mm wrench. Put it on a workbench.
7.4) Replace condenser and receiver drier (it is important to replace receiver drier in order to prevent moisture
contamination). Follow these steps in reverse order to reassembly these parts.
NOTE: be sure the correct position of inlet (IN) is mounted.
7.5) If it is necessary replace only pressure switch , do not remove charge and condenser. Remove only switch pressure
fitting. Use a 17mm wrench. Do not remove pressure switch nut.
8) REPLACE AIR CONDITONING HOSE ASSY.

8.1) Hose assy assembly chart.
ENG 6-46970
Issued 01-03
Printed in Brazil
9004-9
8) REPLACE AIR CONDITONING HOSE ASSY.
8.1) Hose assy assembly chart.
POSITION
1
2
3
4
5
6
7
8
9
10
10
11
12
13
14
15
16
P/N
75254533
75257962
75251988
75257955
75257956
75257954
75255522
75310261
75310923
75310260
DESCRIPTION
EVAPORATOR BOX
CONDENSER
COMPRESOR
HOSE COMPRESOR TO CONDENSER
HOSE CONDENSER TO EVAPORATOR
HOSE EVAPORATOR TO COMPRESOR
CASE
MOTOR
CASE
BELT GX 845
BELT65/885
O-RING SEAL #6
O-RING SEAL #8
O-RING SEAL #10
SCREW
WASHER
NUT
QTY
01
01
01
01
01
01
01
01
01
01
01
02
02
02
03
03
03
ENG 6-46970
Issued 01-03
Printed in Brazil
9004-10
8.3) Replace hose assy compressor to condenser: remove compressor hose fitting. Use a 22 mm wrench. Remove
condenser hose fitting. Use a 19 and 22 mm wrench. The two wrenches must be used. Replace the hose, mounting it the
same way. Replace the o-ring seals.
8.4) Replace hose assy receiver drier to evaporator: remove receiver drier hose fitting. Use a 19 and 16 mm wrench.
Remove expansion valve hose fitting. Use a 16 mm wrench. Do not remove the grommet (cab floor). Replace the hose assy. Be
careful when mounting it through the grommet. Replace the o-ring seals.
8.5) Replace hose assy evaporator to compressor: remove expansion valve hose fitting. Use a 22 mm wrench.
Remove compressor hose fitting. Use a 30 mm wrench. Do not remove the grommet (cab floor). Replace the hose assy. Be
careful when mounting it through the grommet. Replace the o-ring seals.
ENG 6-46970
May, 2003
Printed in Brazil
9004-11
9) AIR CONDITIONING CONTROL SWITCH.

9.1) The air conditioning switch controls are located at right side of cab.
Function of each one refer to Operator's Manual.
9.2) Replace / maintenance of air conditioning switch control: remove panel cover. Be careful with electrical cables and
heater valve cable.
9.3) Replace / maintenance of heating system.
9.3.1) Turn off two hot water valves located at machine engine compartment.
9.3.2) ) Disconnect 02 (two) hot water hoses removing clips with a pliers.
9.3.3) Remove heater control valve cable.

9.3.4) Replace valve. Follow these steps in reverse order to reassembly this part.
NOTE: refer to machine operator's manual in order to fill up radiator with water (in case some amount was lost during
this procedure).
ENG 6-46970
Issued 01-03
Printed in Brazil
9007
Section
9007
REAR RIPPER
845 - 865 - 885 Grader

ENG 6-47010
Printed in Brazil
May, 2003
TABLE OF CONTENTS
REAR RIPPER 845.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . . . 01
REAR RIPPER 865 / 885 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. 02
12
9007-01
REAR
RIPPER
845
SECTION
12
* Mount the articulation plates of the connecting rods and

the tray on the rear frame
* Mount the rear support with articulation connecting rods
and the tray on the rear plate.
* Mount the cylinder on the bearing and tighten the
screws
* Connect the tubes and hoses to the counterbalance valve
Dimensions
A - Internal diameter of the support
B - Internal diameter of the arm
C - Internal diameter of the frame
D - External diameter of the bushing
Internal diameter of the bushing
E- External diameter of the bolt
ENG 6-47010
m m
70.100 - 70.174
60.000 - 60.046
50.080 - 50.180
60.07 - 60.10
50.195 - 50.265
49.961 - 50.000
In.
2.7598 - 2.7627
2.3622 - 2.3640
1.9716 - 1.9756
2.365 2.366
1.9761 - 1.9789
1.9669 - 1.9685
May, 2003
Printed in Brazil
9007-02
Install the ripper teeth on the support with their respective

bolts and cotter pins.
The teeth of the ripper are replaceable; to replace

them, remove the elastic lock pin.
.
Try to notice the mounting angle to avoid breaking the
claws.
SECTION
REAR
RIPPER
865/885
12
The mounting process is similar to the one for the 845

Notice that, besides the ripper teeth, there are the scarifier
teeth.
The scarifier replacement process is similar to that of

the front. To replace the ripper teeth
it is necessary to remove the elastic lock pins.
ENG 6-47010
May, 2003
Printed in Brazil
9008
Section
9008
FRAME, ARTICULATION JOINT

CIRCLE AND SCARIFIER

Contagem, MG Brazil
ENG 9008-6-47000
Printed in Brazil
May, 2003
TABLE OF CONTENTS
Articulations joint .......................................................................................................................... 01
Circle removal .................................................................................... ................................................... 04
Saddle removal ...................................................................................................................... ................ 08
Disassembly of circle turn gearbox........................................................................................................ 12
Circle turn assembly ..................................................................................................................... 16
Frame specifications ..................................................................................................................... 17
ENG 6-47000
9008-01
ARTICULATION JOINT
The articulation joint consists of tapered roller bearings.
the joint allows a total of 50 degrees articulation.
Support the two main frames on jack stands during.

rebuild.
WARNING
Do not work under or near unblocked or unsupported linkage, parts or machine
Clean bearing bores.

WARNING
Never use gasoline solvent or other flammable
fluids to clean. Use authorized comercial
non-flamable, non-toxic solvents.
Watch out for people in the vicinity.
Measure the bearing height of the outer races plus the

height of the spacer. Record these dimmensions. Keep
the bearing pieces matched. Repeat the measurement
for the other bearing.
ENG 6-47000
May, 2003
Printed in Brazil
9008-02
Measure the thickness of frame boss at the bore.

Record these dimensions and repeat the measuring process at the other frame boss. Select shims to build the
provided.
Use driver P/N 75300850 to install the bearing cup into
the frame bore. Install the bearing retainer in place.

WARNING
It is unsafe to strike hardened steel parts with
anything other than a soft iron or non-ferrous
hammer. When installing or removing such parts
wear safety glasses with side shields and heavy
gloves, etc, to reduce the possibility of injury.
Install the bearing into the bore. Prior to installing the

bearing retainers onto the frame, install the seal into the
retainer. Clean the joining surfaces of the seal and
retainer with P/N 75000782. Apply sealant P/N
75000778 on the retainer. Press seal into retainer. Do
not get sealant on sealing surface.
Position rear frame around the front frame.

Level the two frames prior to installation. Install pins.
Install bushing and inner on bottom joint pin.
Install plates and tighten capscrews to specification
WARNING
or proper capacity. Be sure parts are supported
ENG 6-47000
May, 2003
Printed in Brazil
9008-03
ARTICULA TION JOINT
A Pin O.D...................................... 66.7133 - 66.725 mm (2.626-2.627 in)

Beari ng cone I.D. .................... 66.675 - 66.888 mm (2.625-2.626 in )
B Articulation support I.D............... 66.7133 - 66.725 mm (2.626-2.627 in)
Bearing cup O.D. ...................... 66.675 - 66.888 mm (2.625-2.626 in)
C Torque capscrews...................... 135 - 157 Nm (100-116 ft.lbs)
D Torque capscrews...................... 123 - 135 Nm (90-100 ft.lbs)
E Pin O.D....................................... 66.7133 - 66.725 mm (2.626-2.627 in)
Bushing I.D................................. 66.890 - 67.160 (2.633-2.644 in)
F
G
H
I
J
K
ENG-6-47000
Pin O.D...................................... 66.713 - 66.725 mm (2.626-2.627 in)

Bearing cone I.D........................ 66.6753 - 66.725 mm (2.626-2.627 in)
Pin O.D....................................... 66.7133 - 66.725 mm (2.626-2.627 in)
Bearing cone I.D........................ 66.7133 - 66.725 mm (2.626-2.627 in)
Pin O.D....................................... 66.7133 - 66.725 mm (2.626-2.627 in)
Bushing I.D................................ 66.8909 - 67.160 (2.633-2.644 in)
Torque capscrews...................... 66.7133 - 66.725 mm (2.626-2.627 in)
Torque capscrews....................... 66.7133 - 66.725 mm (2.626-2.627 in)
Pin O.D........................................ 66.7133 - 66.725 mm (2.626-2.627 in)
Issued 1-03
Printed in Brazil
9008-04
CIRCLE REMOVAL
Lower moldboard so that the blade is on the ground.
Turn off the electrical master switch.
WARNING
WARNING
WARNING
Always turn the master switch to the off position
before cleaning, repairing, servicing or parking
the machine to prevent injury.
Disconnect the right and left moldboard lift cylinders at

the lower trunnion ball joint. Keep shims in position.
Disconnect the moldboard shift cylinder at the trunnion

ball on the circle. Keep shims in position.
Disconnect hoses at front of circle frame.
ENG 6-47000
May, 2003
Printed in Brazil
9008-05
Remove capscrews connecting ball housing to the

tractor frame.
Installation is the reverse of removal with the exception

of measuring shim pack gap on the cylinders.
Measure the gap between
the ball and socket with the capscrews tightened to final
torque. Add the specified dimension.
If the circle guides or wear plates have to be replaced

place the moldboard upon the ground. Turn off electrical
master switch.
WARNING
Remove bolts holding guides in position.
ENG 6-47000
May, 2003
Printed in Brazil
9008-06
Install new wear surfaces
Install shims; guide and bolts.
Measure gap between wear plate and frame. Make a

shim pack equal to the gap plus the specified dimension
The guides must be adjusted see section for

procedure and specifications.
ENG 6-47000
May, 2003
Printed in Brazil
9008-07
DRAWBAR & CIRCLE
DRAWBAR AND CIRCLE TURN

Adjust shims (A) to provide 1.5 mm (0.06 in.) vertical clearance between wear plates and circle guide.
With circle against front circle guide adjust capscrews(B) to provide 8-15 mm (0.03 - 0.06 in) clearance
between the circle and each circle guide. Torque capscrews (B) to 1080 Nm (800 ft.lbs)
Adjust rear guides (C) to provide 0.7mm (0.03 in) maximum horizontal clearance the circle and each
rear guide.
Torque capscrews (D) to 1080 Nm (800 ft.lbs).
NOTE: Rotate circle 3600 to check free clearance.
Torque capscrews (E) to 122 - 136 Nm (90 - 100 ft.lbs)
Torque capscrews (F) to 570 - 585 Nm (420 - 430 ft.lbs)
Adjust shims (G) to provide 0.00 - 0.25 mm 0.000 - 0.010 in) end play between ball and socket.
Torque nut (H) to 810 Nm (600 ft.lbs).
NOTE: Do not apply lubricant to circle guide shoe liners or wear surface of circle.
Torque capscrews (I) to 245 - 325 Nm (180 - 240 ft.lbs)
ENG-6-47000
Issued 1-03
Printed in Brazil
9008-08
CIRCLE REMOVAL
Lower moldboard so that the blade is on the ground.
Turn off the electrical master switch.
WARNING
WARNING
WARNING
Remove the lower saddle plate capscrews and the

plate.
Disconnect light wires.
Disconnect the moldboard lift cylinders at the yoke.
ENG 6-47000
May, 2003
Printed in Brazil
9008-09
Disconnect the moldboard shift cylinder where it connects to the saddle as well as the hose bracket.
Disconnect saddle lock cylinder hydraulic tubing.
Support the saddle and remove the capscrews securing

the back plate to the saddle. Lift saddle from the grader
frame.
WARNING
Remove capscrews holding saddle support to the frame.

Keep shims in position.
WARNING
ENG 6-47000
May, 2003
Printed in Brazil
9008-10
MOLDBOARD CONTROL
A. Shim to provide 0.000 - 1.207 mm (0.000 - 0.005 in) loose ball

Torques
Nm
Ft.lbs.
B. ........................ 400 - 450 ..................... 300 - 333
C. ........................ 230 - 255 ..................... 170 - 187
D. ........................ 310 - 340 ..................... 230 - 250
H. ........................ 47 - 53 ......................... 35 - 39
E. Apply a ligth coat of Molykote "G" lubricant paste to surfaces indicated.
Dimensions
mm
inch
F. Pin O.D. ...................................... 47.752 - 47.803 ........... 1.880 - 1.882
Trunnion bushing O.D. ............... 47.904 - 47.995 ........... 1.886 - 1.888
G. Trunnion bushing O.D. ............... 37.993 - 38.040 ........... 1.496 - 1.498
Trunnion bushing O.D. ............... 37.846 - 37.871............ 1.490 - 1.491
I. With the grader on flat ground, measure the vertical distance from the ground
to the center of the left and right lift cylinder trunion yoke. For every 13 mm (0,5 inch)
Difference betwwen the two dimensions, add two shims to the side with the
lowest pivot. Do not add more than fours shims.
ENG-6-47000
Issued 1-03
Printed in Brazil
9008-11
MOLDBOARD CONTROL
A. *Journal bore I.D............................. 82.559 - 82.575 mm (3.250 - 3.251 in)

Journal bore O.D........................... 82.559 - 82.575 mm (3.250 - 3.251 in)
Journal bore I.D............................. 76.302 - 76.752 mm (3.004 - 3.006 in)
Journal bore O.D............................ 76.175 - 76.200 mm (2.999 - 3.000 in)
*SERVICE NOTE:
1. Install inside bearing flush to 0.77 mm (0.03 in) below face of counterbore.
2. Install outside bearing to 10.2 mm (0.40 in) inside journal bore.
B. Lubricate seals with Case molydisufide grease
C.
D.
E.
F.
ENG-6-47000
Install shims to obtain 0.025 - 0.076 mm (0.001 - 0.003) end play.

Torque capscrews to.......................... 120 - 136 Nm (90 - 100 ft.lbs)
Torque capscrews to.......................... 940 - 1040 Nm (700 - 770 ft.lbs)
Use shims to provide.......................... 0.000 - 0.127mm (0.0000 - 0.005 in) clearance
between saddle support and sadle assembly.
Issued 1-03
Printed in Brazil
9008-12
DISASSEMBLY OF CIRCLE TURN GEARBOX

Remove the cover.
Drain the assembly
Remove washer(2) and shims(A).Keep in relative

position.
Remove the outer cover.
ENG 6-47000
May, 2003
Printed in Brazil
9008-13
Remove circle turn motor.
Remove circle turn cover. Keep shims (B) in position.
Remove worm gear assembly (3)
Remove snap ring
ENG 6-47000
May, 2003
Printed in Brazil
9008-14
Force shaft assembly from the housing.
Press the bushing from the cover
Remove worm and bearing.
Inspect the roller bearings; if necessary, replace

.
ENG 6-47000
May, 2003
Printed in Brazil
9008-15
Check worm rolling torque.
The shaft assembly must have an end play.
ENG 6-47000
May, 2003
Printed in Brazil
9008-16
CIRCLE TURN ASSEMBLY
A. Install shims as needed to obtain 0.0 - 3.3 mm (0.00 - 0.13 in) end shake. Do not preload.
B. With worm gear tremoved , install shims to obtain 9.3 - 9.7 Nm (6.9 - 7 ft.lbs) of rolling torque
upon the bearings.
Torque
Nm
ft.lbs
1.
One place ......................................... 120 - 137

five places ......................................... 155 - 176
90 - 100
115 - 130
2.
3.
............................................................. 47 - 54
............................................................. 474 - 508
35 - 40
350 - 375
9008-17
FRAME
Torques
Nm
Ft.lbs
A ..................................................... 88 - 96 ........................ 65 - 71
B ..................................................... 88
C ..................................................... 38
D ..................................................... 38
E .....................................................304
96 ........................ 65 42 ........................ 28 42 ........................ 28 332 ........................224
71
31
31
- 245
F ..................................................... 88 - 96 ......................... 65 - 71
9009
Section
9009
FRONT BLADE & COUNTERWEIGHT
845 - 865 - 885 Grader

ENG 6-46960
Printed in Brazil
May, 2003
TABLE OF CONTENTS
REAR RIPPER 845 / 865 / 885.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . . . 01
9009-01
FRONT
BLADE
845/865/885
The mounting process of the front blade is similar to that

of the front scarifier. To mount the replaceable and reversiblecutting edgesknifes, tighten the nuts with a 290 to 310 Nm
torque(215 - 230 ft.lbs.)
COUNTERWEIGHT845/865/885
SECTION
12
To mount the front counterweight, put the front plate into

place and tighten the nuts.
ENG 6-47010
May, 2003
Printed in Brazil
9010
Section
9010
Rops CAB
845 - 865 - 885 Grader

ENG 6-47031
Printed in Brazil
June, 2003
TABLE OF CONTENTS
CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01
INSTALLATION OF THE CLOSED AND OPEN CABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03
REMOVAL OF THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08
9010-01
TYPES OF CAB
* FOPS and ROPS closed cab.
* FOPS and ROPS open cab.
CHARACTERISTICS
* The closed cab has laminated safety glass for the windshield and the other glass is tempered. The
interior is lined with vinyl, has a bottle holder, catalogue holder, lunch box, air diffusers, windshield wipers,
front and rear washer, 2 (two) general and directional lamps, floor mat, thermal and acoustical insulation, flexible
antenna for radio receiver, and loudspeakers. Mounting for: radio, air-conditioning with heater and blower fan
* The open cab has laminated safety glass for the windshield and the rear glass is tempered; 1 (one) general
and directional lamp, windshield wiper and washer.
ENG 6-47030
June, 2003
Printed in Brazil
9010-02
Side view of the open cab.
Front view of the closed cab.
Rear view of the closed cab.
Side view of the closed cab

.
ENG 6-47030
June,2003
Printed in Brazil
9010-03
INSTALLATION OF THE
AND OPEN CABS
CLOSED
Hoist the cab with the proper lifting devices.
After lifting the cab, put the rubber seats on the

contact surfaces of the cabin. Use Supercraft Threebond
glue.
ENG 6-47030
June,2003
Printed in Brazil
9010-04
Release the support plate of the tension regulator
Disconnect the analog instrument panel.
Remove the analog panel support box.
Remove the vinyl covering lining of the central colums.

IMPORTANT: You must do this during the mounting
to avoid damage to the air conditioning.
This operation is required only on closed cabs.
ENG 6-47030
June, 2003
Printed in Brazil
9010-05
Remove the plastic base of the central columns. This
operation is required for closed cabs only.
Remove the disconnect switch box.
Mount the side panels and the access cover.

This operation is required for closed cabs
only.
Tilt the pedestal fully backwards and the seat back

fully forward. This operation makes it easy to lower
the cab on the machine structure.
ENG 6-470300
June, 2003
Printed in Brazil
9010-06
Carefully lower the cab; pay attention to the electric

cables and directional tube of the air conditioning.
Remove the access ladder on both sides.
Remove the lower protections from both sides.
With the help of a lever, align the holes between the

cabin and the floor.
ATTENTION: The use of SAE Grade 8
bots is required use new self locking nuts each time
They are removed.
ENG 6-47030
June, 2003
Printed in Brazil
9010-07
INSTALLATION OF THE
AND OPEN CABS
CLOSED
Hoist the cab with the proper lifting devices.
After lifting the cab, put the rubber seats on the

contact surfaces of the cabin. Use Supercraft Threebond
glue.
Mounted cab.
Check the water level tank daily.

(390 to 485 ft.lbs)torque.
ENG 6-47030
June, 2003
Printed in Brazil
9011
Section
9011
CAB GLASS INSTALLATION
845 - 865 - 885 Grader

ENG 6-47040
Printed in Brazil
May, 2003
TABLE OF CONTENTS
WINDSHIELD MEASUREMENT'S . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . 01
. . .. .
9011-01
TOP
1448
1381
* Material: laminated safety glass, thickness: 6.73 to

7.14 mm (optional 6.35), with interpolated 0.76mm
R=88.5(x5)
MANUFACTURERS
LOGO
WINDSHIELD
* It must comply to the requirements of the:

ANSI Z 26.1 - Category AS-1, item 2, section 4 E.C.E
regulation # 43 (annex 6),
E.E.G Director Counsel 92/22/EEC, ANNEX II, section
B.
962
* The glass must have a mark according to the ANSI

Z 26.1, E.C.E regulation # 43;
E.C.E Director Counsel 92/22;
Border finishing according to SAE J673.
WINSDSHIELD - LOWER LEFT
R=43.5(x1)
191.5
737

ANSI Z 26.1 - Category AS-1, item 2, section 4;
E.C.E regulation # 43 (annex 6),
B.
R=88.5(x5)

7.14 mm (optional 6,35),with interpolated 0.76mm
plastic.
545.5
557.5
246
294.5

Z 26.1;
E.C.E regulation # 43;
E.C.E Director Counsel 92/22; FMVSS # 205;
ENG 6-47040
532
May, 2003
Printed in Brazil
WINSDSHIELD - LOWER RIGHT
9011-02
7.14 mm (optional 6.35), with interpolated 0.76mm
plastic.
737
R=43.5(x1)
191.5

Z 26.1;
E.C.E Director Counsel 92/22;
R=88.5(x5)
must comply to the requirements of the:

Z 26.1 - Category AS-1, item 2, section 4;
Director Counsel 92/22/EEC, ANNEX II, section
545.5
* It
ANSI
E.C.E
E.E.G
B.
557.5
246
294.5
532
WINSDSHIELD - CAB SIDE

1377
* It
ANSI
E.C.E
E.E.G
H.
R=88.5(x4)
* Material: tempered safety glass, thickness 5.55

(optional 6mm).

Z 26.1;
532
ENG 6-47040
May, 2003
Printed in Brazil
WINDOW - CAB SIDE
9011-03

1377
* It
ANSI
E.C.E
E.E.G
H.
R=88.5(x4)

(optional 6 mm).

Z 26.1;
532
WINDOW - CAB DOOR
88.5
738
R=88.5(x05)

(optional 6 mm).
ENG 6-47040
1495
1528
105 207
137
33

Z 26.1;
1706

E.C.E regulation # 43 (annex 5),
H.
546
103
May, 2003
Printed in Brazil
WINDOW - CAB DOOR
9011-04
(optional 6 mm).
88.5

R88.5(x5)

Z 26.1;
1528
1706
546
1495
* It
ANSI
E.C.E
E.E.G
H.
738
137
33
207 105
103
WINDOW - REAR

Z 26.1;
R=88.5(x5)
1287

MANUFACTURES
LOGO
* It
ANSI
E.C.E
E.E.G
H.
1124

(optional 6 mm).
895
ENG 6-47040
May, 2003
Printed in Brazil

Manual de Servicio 865 DHP

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Manual de Servicio 865 DHP

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SECTION INDEX

Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

CNH Latino Americana Ltda

CNH Latino Americana Ltda

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Grade 8 Bolts, Nuts, and Studs

Grade 5 Bolts, Nuts, and Studs

NOTE: Use thick nuts with Grade 8 bolts.

TORQUE SPECIFICATIONS - METRIC HARDWARE

Grade 10.9 Bolts, Nuts, and Studs

Grade 8.8 Bolts, Nuts, and Studs

Grade 12.9 Bolts, Nuts, and Studs

Usually the torque values specified for grade 10.9 fasteners

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

37 Degree Flare Fitting

Straight Threads with O-ring

Split Flange Mounting Bolts

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

O-ring Boss End

O-ring Face Seal End

LOCTITE PRODUCT CHART

LOCTITE PRODUCT CHART

845 - 865 - 885 Grader

CNH Latino Americana Ltda

SAE 80W-90 135H EP API GL5

SAE 80W-90 135H EP API GL5

As required CASE MOLYDISULFIDE GREASE

865 DHP - GRADER

Hydrauic tank with filter

MAT 3505 (MS 1209)

SAE 80W-90 135H EPAPI GL5

SAE 80W-90 135H EPAPI GL5

SAE 80W-90 135H EPAPI GL5

CASE molydisulfide grease

SAE 80W-90 135H EP API GL5

SAE 80W-90 135H EP API GL5

As required CASE MOLYDISULFIDE GREASE

ENGINE OIL RECOMMENDATIONS

NOTE: Do not put performance

DIESEL FUEL SYSTEM

The diesel fuel used in this machine must meet the

Specifications for Acceptable No. 2 Diesel Fuel

LUBRICATION & MAINTENANCE CHART model 845

Air cleaner (Note 1)

Hydraulic filter (Note 2)

Alternator / Air conditioner belt

Engine oil level (including filters)

Radiator (coolant level) (Note 3)

Transmission oil level (warm, engine running)

Hydraulic tank (complete system)

Fuel filters / separator filter (drain water)

Blade lift cylinder pivots

Side shift cylinder pivots

Articulation cylinders pivots

Moldboard lift cylinders balls

Engine oil and oil filter

Universal joints and drive shaft

Differential and planetary drives oil level (Note 4) 18

Circle turn gear housing

Alternator and ar conditioning belts

Moldboard adjusting link ends

Moldboard side shift link ends

Front wheel lean link and knuckle pivot

Front axle spindle pivot