845,865,885 Case Grader - Servicio Especiaizado y Reparacion Manual.

845 - 865 - 885 GRADER
Service Manual
Brz 6-46503
Table of Contents
Publication
Description Section Number
Form Number
General Tab 1
Section Index - General 6-46521
Special Tools - Cross Reference Guide 1000 6-15050
Standard Torque Specifications 1001 6-46530
Fluids and Lubricants 1002 6-46541
Metric Conversion Chart 1003 6-46550
Service Tools 1005 6-75330
Loctite Product Chart 8-98902
Engine Tab 2
Section Index - Engines 6-46561
For Engine Repair, See the Engine Service Manual
Charge Air Cooler 2002 6-75420
Fuel System Tab 3

Section Index - Fuel System 6-46591
For Fuel System Repair, See the Engine Service Manual
Electrical Tab 4
Section Index - Electrical 6-46601
Removal and Installation of Starter and Alternator 4001 6-42322
Electrical Diagram 4002 6-46621
Battery 4003 6-42331
Alternator 45 Ampere 4008 6-42361
Steering Tab 5
Section Index - Steering 6-46661
Front Wheel, Axle and Wheel Lean 5002 6-46681
Steering Control Valve (845 - 865 - 885 Grader) 5003 6-46691
Steering Priority Valve (845 - 865 - 885 Grader) 5004 6-46701
Power Train Tab 6

Section Index - Power Train 6-46731
Transmission Specifications, Pressure Checks and Troubleshooting
6002 6-46751
(845 - 865 Grader)
Copyright © 2003 Case, LLC.

CNH Latino Americana LTDA All rights reserved.
2237 General David Sarnoff Avenue Printed in Brazil
Contagem, MG Brazil Brz 6-46513 November, 2003
845 - 865 - 885 GRADER
Service Manual
Brz 6-46503
Table of Contents (Continued)
Publication
Description Section Number
Form Number
Transmission Specifications, Pressure Checks and Troubleshooting
6002 6-75350
(885 Grader)
Transmission (845 - 865 Grader) 6003 6-46761
Transmission (885 Grader) 6003 6-75360
Rear Axle With Differential Lock 6005 6-75370
Limited Slip Rear Axle 845-865 Grader 6005 6-46782
Tandem Drive Limited Slip Rear Axle 845-865 Grader 6006 6-46792
Tandem Drive Differential Hydraulic Lock 6006 6-75380
Brakes Tab 7
Section Index - Brakes 6-46810
Hydraulic Brake Troubleshooting 7002 6-46831
Brake Pedal Valve System 7003 6-46842
Hydraulics Tab 8
Section Index - Hydraulics 6-46861
Removal and Installation of Hydraulic Components 8001 6-46872
Hydraulic Schematics 8002 6-75400
Mounted Equipment Tab 9

Section Index - Mounted Equipment 6-46931
Air Conditioning Troubleshooting 9002 6-46950
Air Conditioning Troubleshooting For Systems With
9002 6-75390
HFC 134A Refrigerant
Air Conditioner System Operating Instructions 9003 6-46960
Air Conditioner System Service 9003 6-42650
Removal and Installation of Air Conditioning Components for Systems with
9004 6-46971
HFC 134A Refrigerant
Rear Ripper 9007 6-47011
Frame, Articulation Joint, Circle and Scarifier 9008 6-47001
Front Blade and Counterweight 9009 6-47021
ROPS Cab 9010 6-47031
Cab Glass Installation 9011 6-47041
NOTE: CNH Latino Americana 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.
Brz 6-46513 Revised 11-03 Printed in Brazil

SECTION INDEX
GENERAL
Section Title Section Number

Special Tools - Cross Reference Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000
Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
Fluid and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1003
Loctite Product Chart
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1005
CNH Latino Americana Ltda

2237 General David Sarnoff Avenue Printed in U.S.A.
Contagem, MG Brazil ENG 6-46521 June, 2003
1000
Section
1000
SPECIAL TOOLS
Cross Reference Guide
Case, LLC
© 2003 Case, LLC
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. 6-15050 October, 2003
1000-2
Description Old Number New Number

Axle Brake Disc Go/No Go Gauge 75301703 380000378
Axle Seal Installer 75301704 380000379
Axle Seal Installer 75301705 380000380
Transmission Input Seal Installer 75310180 380000387
Transmission Oil Seal Guide 75310181 380000388
Transmission Seal Driver 75310185 380000391
Rac 6-15050 Issued 10-03

1000-3

Hub Remover 75312684 380000394
Seal Driver 75310190 380000397
Lifting Device 75289947 380000374
Stack Nest 75289948 380000375
Lifting Device 75289949 380000376
Stack Nest 75289950 380000377
6-15050 Issued 10-03

1000-4

Plug Installer 75301709 380000381
Assembly Tools 75310177 380000382
Retaining Ring Tool 75310178 380000385
Sizing Sleeve 75310179 380000386
Sleeve Installer Adapter 75310180 380000389
Bearing Installer 75310183 380000390
Rac 6-15050 Issued 10-03

1000-5

Assembly Tools 75310186 380000392
Bearing Driver 75310187 380000393
Clutch Clearance Gauge 75310188 380000395
Aligning Sleeve 75310189 380000396
6-15050 Issued 10-03

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 Grade 8 Bolts, Nuts, and Studs
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.
Pound- Newton
Size Inches metres
Grade 5 Bolts, Nuts, and Studs 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
Pound- Newton
Size Inches metres Pound- Newton
1/4 inch 108 to 132 12 to 15 Size Feet metres
5/16 inch 204 to 252 23 to 28 7/16 inch 70 to 84 95 to 114
9/16 inch 160 to 192 217 to 260
Pound- Newton 5/8 inch 220 to 264 298 to 358
Size Feet metres 3/4 inch 380 to 456 515 to 618
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
1.0 inch 580 to 696 787 to 944 NOTE: Use thick nuts with Grade 8 bolts.
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

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 10.9
with engine oil. These values do not apply if graphite or
Molydisulfide grease or oil is used.
Pound- Newton
Size Inches metres
Grade 8.8 Bolts, Nuts, and Studs M4 36 to 48 4 to 5
M5 84 to 96 9 to 11
8.8
M6 132 to 156 15 to 18
M8 324 to 384 37 to 43
Pound- Newton
Size Inches metres
M4 24 to 36 3 to 4 Pound- Newton
Size Feet metres
M5 60 to 72 7 to 8
M10 54 to 64 73 to 87
M6 96 to 108 11 to 12
M12 93 to 112 125 to 150
M8 228 to 276 26 to 31
M14 149 to 179 200 to 245
M10 456 to 540 52 to 61
M16 230 to 280 310 to 380
M20 450 to 540 610 to 730
Pound- Newton
Size Feet metres M24 780 to 940 1050 to 1275
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 Grade 12.9 Bolts, Nuts, and Studs
M24 500 to 600 675 to 815
M30 920 to 1100 1250 to 1500 12.9
M36 1600 to 1950 2175 to 2600

Usually the torque values specified for grade 10.9 fasteners
can be used satisfactorily on grade 12.9 fasteners.

1001-5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
Tube OD Thread Pound- Newton Tube OD Thread Pound- Newton

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

Pound- Newton
Size Inches 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
Pound- Newton
Size Feet metres
1/2-13 55 to 65 74 to 88
5/8-11 140 to 150 190 to 203

1001-6
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Nom.
SAE
Dash Thread Pound- Newton Thread Pound- Newton
Size Tube OD Size Inches metres Size Inches metres
O-ring Boss End
O-ring Face Seal End Fitting or Lock Nut
-4 1/4 inch 9/16-18 120 to 144 14 to 16 7/16-20 204 to 240 23 to 27
6.4 mm
-6 3/8 inch 11/16-16 216 to 240 24 to 27 9/16-18 300 to 360 34 to 41
9.5 mm
-8 1/2 inch 13/16-16 384 to 480 43 to 54 3/4-16 540 to 600 61 to 68
12.7 mm
Thread Pound- Newton

Size Inches metres
-10 5/8 inch 1-14 552 to 672 62 to 76 7/8-14 60 to 65 81 to 88
15.9 mm
Nom. 1-1/16-12 85 to 90 115 to 122

SAE
Dash Thread Pound- Newton 1-3/16-12 95 to 100 129 to 136
Size Tube OD Size Inches metres
-12 3/4 inch 1-3/16-12 65 to 80 90 to 110 1-5/16-12 115 to 125 156 to 169
19.0 mm
-14 7/8 inch 1-3/16-12 65 to 80 90 to 110 1-5/8-12 150 to 160 203 to 217
22.2 mm
-16 1.0 inch 1-7/16-12 92 to 105 125 to 140 1-7/8-12 190 to 200 258 to 271
25.4 mm
-20 1-1/4 inch 1-11/16-12 125 to 140 170 to 190
31.8 mm
-24 1-1/2 inch 2-12 150 to 180 200 to 254
38.1 mm

1002
Section
1002
FLUIDS AND LUBRICANTS
845 - 865 - 885 Grader

2237, General David Sarnoff Avenue Printed in Brazil
Contagem, MG - Brazil ENG 46541 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 6-46541 Issued 01-03 Printed in Brazil

845 GRADER
CAPACITY CAPACITY
COMPONENTS SPECIFICATIONS
LITERS US Gal.
Fuel Tank
DIESEL Nº. 2
(Total Capacity) 341.0 90.0
Engine Oil Nº. 1 ENGINE OIL
(With Filter Change) 16.4 4.3 SAE15W-40 API CH4
(Without Filter Change) 14.2 3.7 MAT 3507 (MS 1121)
Engine Cooling System 50% WATER
(Total Capacity) 40.0 10.5 +
50%
ETHYLENE GLICOL
MS 1710
Hydraulic System
HY-TRAN ULTRA
Total Capacity 180.0 47.5 MAT 3505 (MS 1209)
Hydraulic Tank With Filter 94.6 25.0
Transmission
HY-TRAN ULTRA
Refill capacity (with filter change) 25.0 6.4 MAT 3505 (MS 1209)
Refill capacity (without filter change) 19.0 5.0
Rear Axle Graziano Model (Standard)
Center Compartment 29.0 7.7 HY-TRAN ULTRA
End / Brake compartment (each) 5.0 1.33 MAT 3505 (MS 1209)
Rear Axle Clark Model (Optional)

Planetary Hubs (Each) 6.0 1.6 MAT 3505 (MS 1209)
Tandem Drive Case
SAE 80W-90 135H EP API GL5
(For Graziano Axle)
Refill capacity (each) 29.0 7.7
Tandem Drive Case
(For Clark Axle)
Circle Turn Gear
Refill Capacity 2.8 0.75
Grease Fitting
Rear Ripper / Front Scarifier and UQN UQN CASE MOLYDISULFIDE GREASE
Dozer Blade
865 GRADER
CAPACITY CAPACITY
LITERS US Gal.
Fuel Tank
DIESEL Nº. 2
50%
ETHYLENE GLICOL
MS 1710
Hydraulic System
HY-TRAN ULTRA
Transmission
HY-TRAN ULTRA
Refill capacity (with filter change) 25.0 6.4 MAT 3505 (MS 1209)
Rear Axle Graziano Model (Standard)
End / Brake compartment (each) 5.0 1.33 MAT 3505 (MS 1209)
Rear Axle Clark Model (Optional)

Tandem Drive Case
(For Graziano Axle)
Tandem Drive Case
(For Clark Axle)
Circle Turn Gear
Grease Fitting
Dozer Blade
885 GRADER
CAPACITY CAPACITY
LITERS US Gal.
Fuel Tank
DIESEL Nº. 2
50%
ETHYLENE GLICOL
MS 1710
Hydraulic System
HY-TRAN ULTRA
Transmission
28.5 7.5 HY-TRAN ULTRA
Refill capacity (with filter change) MAT 3505 (MS 1209)
Rear Axle Clark Model
Tandem Drive Case
Refill capacity (each)
22.5 5.9
Circle Turn Gear
Grease Fitting
Dozer Blade
1002-6
ENGINE OIL RECOMMENDATIONS

Case IH No. 1 Engine oil is recommended for use
in your Case engine. Case IH 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.
NOTE: Do not put performance
additives or other oil additive
products in the engine BP99J241
crankcase. The oil change

RH99K130
intervals given in this manual
are according to tests with Case
lubricants.
BS99M162
ENG 6-46541 May, 2003 Printed in Brazi .l

1002-7
DIESEL FUEL SYSTEM

Use No. 2 diesel fuel in the engine of this machine. Fuel Storage
The use of other fuels can cause the loss of engine
power and high fuel consumption. If you keep fuel in storage for a period of time, you
can get foreign material or water in the fuel storage
In very cold temperatures, a mixture of No. 1 and No. tank. Many engine problems are caused by water in
2 diesel fuels is temporarily permitted. See the the fuel.
following Note.
Keep the fuel storage tank outside and keep the fuel
NOTE: See your fuel dealer for winter fuel as cool as possible. Remove water from the storage
requirements in your area. If the temperature of the container at regular periods of time.
fuel lowers below the cloud point (wax appearance
point), wax crystals in the fuel will restrict the fuel Fill the fuel tank at the end of the daily operating
filter and cause the engine to lose power or not start. 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 ............................................................................................................................60°C (140°F)
Cloud point (wax appearance point), maximum ...........................................................-20°C (-5°F) See Note above
Pour point, maximum ..................................................................................................-26°C (-15°F) See Note above
Distillation temperature, 90% point ................................................................................282 to 338°C (540 to 640°F)
Viscosity, at 38°C (100°F)
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 6-46541 May, 2003 Printed

. in Brazi nl
1002-8
LUBRICATION & MAINTENANCE CHART model 845
SERVICE INTERVAL (hours)
L C
H I P L
U
O T O C A E
C B A
E H D
U I H
A
R
J N
SERVICE POINTS M E I /
R N N U
C C D
6. S T G S R
K A
S E T A
T I
E N
Air cleaner (Note 1) 1 «

As
Hydraulic filter (Note 2) 2 «
needed
1. Alternator / Air conditioner belt 3 «
Engine oil level (including filters) 4 1 10
10h
7.
or Radiator (coolant level) (Note 3) 5 1 10
daily
Transmission oil level (warm, engine running) 6 1 10
8. 50h Hydraulic tank (complete system) 7 1 50
or
weekly Fuel filters / separator filter (drain water) 8 2 50
Blade lift cylinder pivots 9 2 100
Side shift cylinder pivots 10 2 100
100h Drawbar pivot and socket 11 1 100

or Front axle pivot 2 250
12
each
15 days Articulation pivots 13 2 100
Articulation cylinders pivots 14 4 100

Moldboard lift cylinders balls 15 2 100
Engine oil and oil filter 16 1 250
Universal joints and drive shaft 17 2 250
Differential and planetary drives oil level (Note 4) 18 3 250
Circle turn gear housing 19 1 250

250h
or Alternator and ar conditioning belts 20 2 250
monthly
Moldboard adjusting link ends 21 4 250
Moldboard side shift link ends 22 2 250

Front wheel lean link and knuckle pivot 23 8 250
Front axle spindle pivot 24 2 250

Front wheel lean cylinder 25 2 250
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 6-46541
«: As needed Issued 01-03 Printed in Brazil
1002-9
LUBRICATION/FILTERS/FLUIDS
L C
H I P U
L
O O C A E
T C
H
B
D A
U E I H R N
SERVICE POINTS A
I
J
R N E
N U
/
M C C D
S T G S R
S K A
E T A
T I
E N
26 1
Cab air filter (if equipded) 27 250
250h
or Tandem case 28 250
monthly
Steering arm pivot 29 4 250
Tire condition and pressure 30 4 250
Fuel filters 31 1 500
Front wheel bearing grease 32 2 500
Tandem drive case oil level 33 2 500
500h Tandem wheel shaft bearings 34 8 500

or Transmission oil filter (Note 5) 1 500
35
each
3 months Rear axle cooling system filter 36 1 500
Fuel tank drain plug (drain sediment) 37 1 500

Rops and seat belts bolts torque 38 500
Transmission oil (Note 5) 39 1 1000
1000h Transmission screen 40 1000

or Fuel pump and injectors (Note 6) 41 6 1000
each
6 Engine valves clearance (Note 6) 42 12 1000
months Air cleaner elements 43 « 1000
Circle turn gearbox oil 44 1000
Hydraulic oil (Note 7) 45 1 2000
Differential and planetary drives oil (Note 4) 46 1 2000
2000h
or Front wheel bearing (repack) 46 2 2000
each Tandem drive case oil 48 2 2000
year
Engine coolant 49 10 2000
Turbocharger bolts torque 50 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
1002-10
LUBRICATION & MAINTENANCE

I CHART model 865
L C
H P U
L
C A E
O O C B A
H D
U I H
A
R
J N
SERVICE POINTS E I /
R N N U
C C D
S T G S R
K A
S E T A
T I
E N
Air cleaner (Note 1) «

As
Hydraulic filter (Note 2) «
needed
Alternator / Air conditioner belt «
Engine oil level (including filters) 1 10
10h
or Radiator (coolant level) (Note 3) 1 10
daily
Transmission oil level (warm, engine running) 1 10
50h Hydraulic tank (complete system) 1 50
or
weekly Fuel filters / separator filter (drain water) 2 50
Blade lift cylinder pivots 2 100
Side shift cylinder pivots 2 100
100h Drawbar pivot and socket 1 100

each
15 days Articulation pivots 2 100
Articulation cylinders pivots 4 100

Moldboard lift cylinders balls 2 100
Engine oil and oil filter 1 250
Universal joints and drive shaft 2 250
Differential and planetary drives oil level (Note 4) 3 250
Circle turn gear housing 1 250

250h
or Alternator and ar conditioning belts 2 250
monthly
Moldboard adjusting link ends 4 250
Moldboard side shift link ends 2 250

Front wheel lean link and knuckle pivot 8 250
Front axle spindle pivot 2 250

Front wheel lean cylinder 2 250

1002-11
L C
H P U
L
C A E
O O C B A
H D
U I H R N
SERVICE POINTS A J
R N E
N
I
U
/
C C D
S T G S R
S K A
E T A
T I
E N
Fuel sediment bowl (wash filter screen) 1 250

Cab air filter (if equipded) 250
250h
or Tandem case 250
monthly
Steering arm pivot 4 250
Tire condition and pressure 4 250
Fuel filters 2 500
Front wheel bearing grease 2 500
Tandem drive case oil level 2 500
500h Tandem wheel shaft bearings 8 500

each
3 months Rear axle cooling system filter 1 500
Engine cooling system filter 1 500
Fuel tank drain plug (drain sediment) 1 500

Rops and seat belts bolts torque 500
Transmission oil (Note 5) 1 1000
1000h Transmission screen 1000

or Fuel pump and injectors (Note 6) 6 1000
each
6 Engine valves clearance (Note 6) 1/2 1000
months Air cleaner elements « 1000
Circle turn gearbox oil 1000
Hydraulic oil and filter (Note 7) 1 2000
Differential and planetary drives oil (Note 4) 1 2000
2000h
or Front wheel bearing (repack) 2 2000
each Tandem drive case oil 2 2000
year
Engine coolant 10 2000
Turbocharger bolts torque 2000

1002-12
LUBRICATION & MAINTENANCE CHART model 885

L C
H P U
L
C A E
O O C B A
H D
U I H
A
R
J N
SERVICE POINTS E I /
R N N U
C C D
S T G S R
K A
S E T A
T I
E N
Air cleaner (Note 1) «

As
Hydraulic filter (Note 2) «
needed
Alternator / Air conditioner belt «
Engine oil level (including filters) 1 10
10h
or Radiator (coolant level) (Note 3) 1 10
daily
Transmission oil level (warm, engine running) 1 10
50h Hydraulic tank (complete system) 1 50
or
weekly Fuel filters / separator filter (drain water) 2 50
Blade lift cylinder pivots 2 100
Side shift cylinder pivots 2 100
100h Drawbar pivot and socket 1 100

each
15 days Articulation pivots 2 100
Articulation cylinders pivots 4 100

Moldboard lift cylinders balls 2 100
Engine oil and oil filter 1 250
Universal joints and drive shaft 2 250
Differential and planetary drives oil level (Note 4) 3 250
Circle turn gear housing 1 250

250h
or Alternator and ar conditioning belts 2 250
monthly
Moldboard adjusting link ends 4 250
Moldboard side shift link ends 2 250

Front wheel lean link and knuckle pivot 8 250
Front axle spindle pivot 2 250

Front wheel lean cylinder 2 250

1002-13
LUBRICATION/FILTERS/FLUIDS
L C
H P U
L
C A E
O O C B A
H D
U I H R N
SERVICE POINTS A J
R N E
N
I
U
/
C C D
S T G S R
S K A
E T A
T I
E N
Cab air filter (if equipded) 7 250

250h
or Tandem case 250
monthly
Steering arm pivot 4 250
Tire condition and pressure 4 250
Fuel filters 2 500
Front wheel bearing grease 2 500
Tandem drive case oil level 2 500
500h Tandem wheel shaft bearings 8 500

each
3 months Rear axle cooling system filter 1 500
Engine cooling system filter 1 500
Fuel tank drain plug (drain sediment) 1 500

Rops and seat belts bolts torque 500
Transmission oil (Note 5) 1 1000
1000h Transmission screen 1000

or Fuel pump and injectors (Note 6) 6 1000
each
6 Engine valves clearance (Note 6) 12 1000
months Air cleaner elements « 1000
Circle turn gearbox oil 1000
Hydraulic oil and filter (Note 7) 1 2000
Differential and planetary drives oil (Note 4) 1 2000
2000h
or Front wheel bearing (repack) 2 2000
each Tandem drive case oil 2 2000
year
Engine coolant 10 2000
Turbocharger bolts torque 2000

Template Name: SM_2_col Alt= to hide template information
Template Date: 1997_01_13 Alt+ to display template information
1002-14
NOTES
ENG 6-46541 Revised 1-03 Printed in Brazil

1003-2
TABLE OF CONTENTS
CONVERSION FACTORS ............................................................................................................................................. 3
Metric to U.S. .......................................................................................................................................................... 3
U.S. to Metric ......................................................................................................................................................... 4

1003-3
CONVERSION FACTORS
Metric to U.S.
MULTIPLY BY TO OBTAIN
Area: sq. meter 10.763 91 square foot

hectare 2.471 05 acre
Force: newton 3.596 942 ounce force

newton 0.224 809 pound force
Length: millimeter 0.039 370 inch

meter 3.280 840 foot
kilometer 0.621 371 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 0.145 038 lb/sq. inch

bar 14.50385 lb/sq. inch
Temperature: degree C 1.8 x C +32 degree F
Torque: newton meter 8.850 748 lb/inch

newton meter 0.737 562 lb/foot
Velocity: kilometer/hr. 0.621 371 miles/hr.
Volume: cubic centimeter 0.061 024 cubic inch

cubic meter 35.314 66 cubic foot
cubic meter 1.307 950 cubic yd.
milliliter 0.033 814 ounce (US fluid)
litre 1.056 814 quart (US liquid)
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid)
litre 0.219 969 gallon (Imperial)
Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)

litre/min. 0.219 969 gallon/min. (Imperial)

1003-4
U.S. to Metric
MULTIPLY BY TO OBTAIN
Area: square foot 0.092 903 square meter

acre 0.404 686 hectare
Force: ounce force 0.278 014 newton

pound force 4.448 222 newton
Length: inch 25.4 * millimeter

foot 0.304 8 * meter
mile 1.609 344 * kilometer
Mass: pound 0.453 592 kilogram

ounce 28.35 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. 6.894 757 kilopascal

lbs/sq. in. 0.069 bar
lbs/sq. in. 0.070 303 kg/sq. cm
Temperature: degree F 1.8 F - 32 degree C
Torque: pound/inch 0.112 985 newton meter

pound/foot 1.355 818 newton meter
Velocity: miles/hr. 1.609 344 * kilometer/hr.
Volume: cubic inch 16.387 06 cubic centimeter

cubic foot 0.028 317 cubic meter
cubic yard 0.764.555 cubic meter
ounce (US fluid) 29.573 53 milliliter
quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallons (Imperial) 4.546 092 litre
Volume/Time: gallon/min. 3.785 412 litre/min.
* = exact

Section
1005
1005
SERVICE TOOLS

2237, General David Sarnoff Avenue
Contagem,MG-Brazil ENG 6-75330 June, 2003
1005-2
TABLE OF CONTENTS
Service tools ........................................................................................................................ 3

Service Tools
Required Service Tools for Case Motor Graders

380050007 Transmission Seal and Tandem Kit 380050007 is required to properly service the
Axle Special Tools transmission input shaft seal, lock up brake, and
tandem axles of Case Motor Grader models 845,
380000378 865 and 885.
380050007 Kit Contents:
380000379 380000380 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
380000387 380000388 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,
380000391
Models 845 and 865.
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 6-75330
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
380000510 380000511 380000513 380000514 down pressure, turn table right, turn table left and
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.
fittings. CAS1884-2 — External M14 x 1.5 O-ring boss
adapter with 90° elbow and external PD style quick
380040085 Kit Contents: 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 6-75330
Service Tools
Required Service Tools for Selected Case Construction Equipment

Option 2 — 380040112
380040112 Digital Pressure Analyzer Kit • Displays readings in PSI and bar for checking
European specifications.
380040112 • 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.
Option 2 offers the 380040112 Digital Pressure and • 20 foot pick up cable.
Temperature Analyzer kit. Purchasing this kit allows This kit also includes the following fittings from kit
the technician to easily read and analyze pressure 380040085:
information up to 10,000 PSI during diagnostic
• 380000510 • 380000511 • 380000513
procedures, eliminating the need for analog gauges.
• 380000514 • 380000515 • 380000516
The 380040112 Digital Pressure and Temperature
Analyzer offers the following: • CAS1884-2 • CAS2336
Application:Case Construction Equipment

Ordering Info: 380040112 Digital Pressure Tester and Fitting Kit
ENG 6-75330
Service Tools
Required Service Tools for Case Motor Graders

380050009 Transmission Tools 380050009 Kit Contents:
380000374 380000375
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
380000376 380000377 from the transmission housing, Models 845 and 865.
Lifting Device 380000376 - Used to lift the
transmission clutch stage assemblies during repair
procedures, Model 885.
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
380000381 380000382 transmission clutch stage assemblies while removed
from the transmission housing, Model 885.
380000752 Plug Installer 380000381 - Used to install plugs in
transmission shafts, Models 845, 865, and 885.
Ass embly Tools 380 000 382 - Used to han dle
380000755
individual clutch stage assemblies and in clutch
380000754 assembly, Models 845, 865, and 885.
380000753
Installation Tools 380000385 - Used to install
380000385 380000386
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 380000390 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,
380000392 380000393 865, and 885.
Bearing Driver 380000393 - Used to properly install
and position bearings, Models 845 and 865.
380000748
380000747 Clutch Stack Clearance Gauge Set 380000395 -
Used to measure clutch plate clearance, Models 845,
380000749
865, and 885.
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 6-75330
Loctite Product Chart
SECTION INDEX
ENGINES
Charge Air Cooler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................2002
FOR ENGINE REPAIR, SEE THE ENGINE SERVICE MANUAL

Contagem, MG Brazil ENG 6-46561 June,2003
2002
Section
2002
CHARGE AIR COOLER SYSTEM
845
P.I.N. HBZ020101 AND AFTER
865
885
CNH Latino Americana LTDA

Contagem, MG Brazil ENG 6-75420 June, 2003
2002-2
TABLE OF CONTENTS
Specifications.................................................................................3
Charge Air Cooler Removal...........................................................4

Charge Air Cooler Installation.......................................................7
CNH LATINO AMERICANA LTDA

Contagem, MG Brazil 6-75420 June 2003
2002- 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

2002- 4
Charge Air Cooler Removal
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).

2002- 5

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)

2002- 6

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.

2002- 7
Charge Air Cooler Installation
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.

2002- 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.

SECTION INDEX
FUEL SYSTEM
FOR FUEL SYSTEM REPAIR, SEE THE ENGINE SERVICE MANUAL

2237, General David Sarnoff, Avenue
Contagem , MG - Brazil ENG 6-46591 May 2003
SECTION INDEX
ELECTRICAL
Removal and Installation and Alternator. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001

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

2237,General David Sarnoff Avenue Printed in Brazil
4001
Section
4001
REMOVAL AND INSTALLATION OF STARTER AND

ALTERNATOR
CNH Latino Americana Ltda.

2237, General David Sarnoff Printed in Brazil
Contagem, MG - Brazil ENG 6-42322 November,2003
TABLE OF CONTENTS
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01
ALTERNATOR 45 A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02
ALTERNATOR 70 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04

4001-01
STARTER
Removal Installation
NOTE: The starter is located on the left side of the 1. Install the starter (1),and bolts (2) to
engine, mounted to the engine flywheel housing. the machine. Torque the bolt (2) to 41 to 74 Nm
(30 to 54 pound-feet).
1. Turn the master disconnect switch to the OFF
position. 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

4001-02
ALTERNATOR 45A
1. Turn the master disconnect switch to the OFF 1. Install the alternator (4),on the machine.
position. Torque the bolt
(0) to 60 to 104 Nm (42.5 to 76 pound-feet).
2. Use a wrench to move the belt tensioner (15) and
Refer to the illustration on the following page.
loosen the tension on the belt (17). 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
3. Remove the belt (17).
pound-feet).
4. Remove the boots (4 and 5).
3. Use a wrench to move the belt tensioner (2) until
Tag and disconnect wires (12 and 13) from
the belt (1) can be installed.
from the alternator (6).
4. Install the belt (17).
5. Remove the bolt (8),and washer (9)
from the support bracket (7) and the alternator 5. Install the wire (12), lockwasher and nut to
(6). the alternator’s D+ terminal. Torque the nut to
3.5 to 3.9 Nm (2.6 to 2.9 pound-feet).
6. Remove the alternator (6) and shield (3) from the.
machine. 6. Install the boot.
. 7. Install the wire (13), lockwasher and nut
. to the alternator’s B+ terminal. Torque the nut
to 15 to 27 Nm (11 to 20 pound-feet).
8. Install the boot.
9. Turn the master disconnect switch to the ON
position.
4001-03
1. BOLT 8. ALTERNADOR 45 A
2. BOLT 9. PULLEY
3. SUPPORT 10. BELT
4. BOLT
5. ARM
6. BOLT
7. BOLT
ALTERNATOR 45 A TO MODEL 845 ENGINE CUMMINS SERIES B REMOVAL AND INSTALLATION ILLUSTRATION
4001-04
ALTERNATOR 70A
1. Turn the master disconnect switch to the OFF 1. Install the alternator (4),on the machine.
position. Torque the bolt
(0) to 60 to 104 Nm (42.5 to 76 pound-feet).
2. Use a wrench to move the belt tensioner (15) and
Refer to the illustration on the following page.
loosen the tension on the belt (17). 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
3. Remove the belt (17).
pound-feet).
4. Remove the boots (4 and 5).
3. Use a wrench to move the belt tensioner (2) until
Tag and disconnect wires (12 and 13) from
the belt (1) can be installed.
from the alternator (6).
4. Install the belt (17).
5. Remove the bolt (8),and washer (9)
from the support bracket (7) and the alternator 5. Install the wire (12), lockwasher and nut to
(6). the alternator’s D+ terminal. Torque the nut to
3.5 to 3.9 Nm (2.6 to 2.9 pound-feet).
6. Remove the alternator (6) and shield (3) from the.
machine. 6. Install the boot.
. 7. Install the wire (13), lockwasher and nut
. to the alternator’s B+ terminal. Torque the nut
to 15 to 27 Nm (11 to 20 pound-feet).
8. Install the boot.
9. Turn the master disconnect switch to the ON
position.
4001-05
1. BOLT 8. ALTERNATOR 70 A
2. BRACKET 9. BRACKET
3. BOLT 10. BOLT
4. BOLT 11. BOLT 12. and 13. WIRES
5. BELT
6. PULLEY
7. WASHER
ALTERNATOR 70 A TO MODELS 845 ENGINE CUMMINS SERIES B REMOVAL AND INSTALLATION ILLUSTRATION
NOTES
Section
4003
4003
BATTERIES

Contagem, MG Brazil ENG 6-42331 May,2003
4003-2
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHARGING GUIDE FOR BATTERIES OTHER THAN
MAINTENANCE FREE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ENG6-42331 Issued 1-3 Printed in Brazil

4003-3
SAFETY RULES
Never try to charge the battery if the electrolyte in the Battery acid causes severe burns. Batteries contain
! battery is frozen. sulfuric acid. Avoid contact with skin, eyes, or clothing.
47-83A Antidote: EXTERNAL-Flush with water. INTERNAL-
Drink large quantities of water or milk. Follow with milk
of magnesia, beaten egg, or vegetable oil. Call physi-
Never cause sparks to occur or smoke near batteries
cian immediately. Eyes: Flush with water for 15 min-
! that are charging or have been recently charged.
13-8A
utes and get prompt medical attention.
! Batteries produce explosive gases. Keep sparks,
Disconnect the ground cable first when the battery flame, and cigarettes away. Ventilate when charging or
cables are disconnected from the battery. using in enclosed area. Always shield eyes when work-
ing near batteries.
! Connect the ground cable last when the battery cables
are connected to the battery. Keep out of reach of children.
47-55A
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 6-42331 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 Inspecting and Cleaning a Battery
the level of the electrolyte every 1000 hours of
operation or six months, whichever occurs first. For If damage causes an electrolyte leak, replace the
all other batteries, check the level of the electrolyte battery.
every 250 hours of operation.
Inspect the battery at regular intervals for dirt,
NOTE: Before checking the electrolyte level in the corrosion, and damage. Electrolyte and dirt on the
battery, the battery must have been idle for at least top of the battery can cause the battery to discharge
16 hours. During charging the level of the liquid may by making a passage for the current to flow.
raise.
If the battery must be cleaned, remove the battery
Check the level of the electrolyte more often from the battery carrier and clean the battery, cable
during hot weather. The use of a large amount of terminals, and the battery carrier. When available,
water by the battery can be caused by high battery use Case Battery Saver and Cleaner according to
temperature or a voltage regulator setting that is too the instructions on the container. Case Battery Saver
high. Keep the electrolyte level above the top of the and Cleaner also helps prevent corrosion. If Case
plates in the battery at all times to prevent damage to Battery Saver and Cleaner is not available, use
the battery. baking soda and water as a cleaner. DO NOT permit
any type of cleaner to enter the cells of the battery.
If the level of the electrolyte is low, add distilled
water or other clean water until the electrolyte is just Install the battery in the machine and make sure
below the cell well bottom, approximztely 5 mm (3/16 the fasteners are tight. Apply Case Battery Saver and
inch).Do not add more water than is needed. Too Cleaner or Urethane Seal Coat to the cable terminals
much water can cause bad performance, a short to prevent corrosion. See the Parts Counter Catalog.
service life, and corrosion around the battery. DO NOT apply grease.

4003-5
BATTERY TEST
NOTE: To correctly test a battery, do each part of the
battery test until you know the condition of the 1 2
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 B790863J
A hydrometer is used to check the specific gravity 1. TEMPERATURE IN F° 2. TEMPERATURE IN C°

(weight) of the electrolyte. The specific gravity is an 4. Make a record of the corrected specific gravity
indication of the level of charge for each cell. reading for each cell.
Hydrometers are made to show the co rrect 5. If the difference between the high reading and
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 the low reading is 0.050 or more, charge the
electrolyte is 26.7°C (80°F). battery and check the specific gravity again. If
When you check the specific gravity, you must after charging, the difference is still 0.050 or
know the temperature of the electrolyte. If your more, install a new battery.
hydrometer does not have a thermometer, get a 6. The corrected specific gravity reading shows the
the rmo me ter to c he ck the tem pe ra tur e o f th e level of charge for the cell. The level of charge
electrolyte. The thermometer must indicate a high must be at least 75% in each of the cells. In
temperature of at least 52°C (120°F). maintenance free batteries the level of charge is
1. Remove enough electrolyte from a cell so that at least 75% if the corrected specific gravity
the float is free in the tube. reading is 1.240 or higher. In all other batteries
the level of charge is at least 75% if the corrected
NOTE: If the specific gravity cannot be checked specific gravity reading is 1.230 or higher.
without first adding water to the cell, the battery must
be tilted to the left and right to about a 30° angle to 7. If the difference between the high reading and
mix the water and acid. Next the battery must be the low reading is less than 0.050, and the level
charged for 15 minutes at 15 to 25 amperes to of charge is at least 75% in all of the cells, do the
further mix the water with the electrolyte. Then check Capacity (Load) Test.
the specific gravity. 8. If the difference between the high reading and
2. Read the float. the low reading is less than 0.050, but the level of
charge is less than 75% in any of the cells,
3. Read the thermometer. If the reading is above charge the battery and check the specific gravity
26.7°C (80°F) add specific gravity points to the again. If after charging:
reading for specific gravity. If the reading is below
26.7°C (80°F) subtract specific gravity points from A. The level of charge is less than 75% in any of
the reading for specific gravity. See the following the cells, discard the battery.
illustration and add or subtract specific gravity B. The level of charge is at least 75% in all of the
points as needed. cells, do the Capacity (Load) Test.

4003-6
Capacity (Load) Test 4. Apply a 15 ampere load to the battery for 15

seconds. Wait at least three minutes before
This test can be done using a variable load tester applying the load again.
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 5. Check and make a record of the temperature of
according to the instructions of the manufacturer of the electrolyte.
the equipment. 6. Find the correct load for this test in Specifications
1. The level of charge of the battery must be at in Section 4002.
least 75%. Do the Specific Gravity Check in this NOTE: The correct load is half of the cold cranking amperes at
section. -17°C (0°F).
2. Prepare the tester (Sun Electric VAT-33 shown) 7. Turn the load control knob until the ammeter
for the test. indicates the specified load. Keep the load for 15
A. Select the voltmeter range that will measure 1 seconds and read the voltmeter. Turn the load
to 18 volts. control knob to OFF.
B. Make sure the load control knob is in the OFF 8. Compare the test reading and the temperature of
position. the electrolyte to the chart below.
TEMPERATURE OF MINIMUM
C. Select the ammeter range that will measure 0
ELECTROLYTE VOLTAGE
to 1000 amperes.
21°C (70°F) and above . . . . . . . . . . . . . . . . . . . . . 9.6
D. Move the volt lead switch to the INT. position. 16°C (60°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
3. Connect the tester to the battery as shown. 10°C (50°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
4°C (40°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
-1°C (30°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
2 -7°C (20°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
-12°C (10°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.7
-18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
A. If the test result is equal to or more than the
voltage shown, the battery is in good
condition.
1 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.

4003-7
CHARGING A BATTERY
Before you charge the battery, check the level of 1. Too much gas causes the electrolyte to flow from
the electrolyte. the cells.
It is difficult to give an e xa ct cha rgin g rate 2. The temperature of the electrolyte rises above
because of the following variable conditions: (1) 52°C (125° F).
temperature of the electrolyte, (2) level of charge,
NOTE: For the best charge, use the slow charging
and (3) condition of the battery. Use the charging
rates.
guide for the correct charging rate and time.
The battery is fully charged when, over a three
Se e Sp ecifica tio ns in Se ctio n 4 002 for th e
hour period at a low charging rate, no cell is giving
reserve capacity of the battery in this machine.
too much gas, and the specific gravity does not
The charging rate must be decreased if: 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

80 Minutes or Less

Above 80 to 125 Minutes
7.5 Hours at 10 Amperes 1.5 Hours at 50 Amperes
20 Hours at 5 Amperes 5 Hours at 20 Amperes

Above 125 to 170 Minutes 10 Hours at 10 Amperes 2 Hours at 50 Amperes

*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.

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

80 Minutes or Less

7.5 Hours at 10 Amperes 1.5 Hours at 50 Amperes

Above 125 to 170 Minutes 10 Hours at 10 Amperes 2 Hours at 50 Amperes

6 Hours at 40 Amperes
Above 250 Minutes 24 Hours at 10 Amperes
4 Hours at 60 Amperes
*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 5. Charge the battery at 30 amperes until the
ele ctro ly te . Th is will p er mit the vo lu me of 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
electrolyte to increase when heated by charging temperature of the electrolyte is at least 15.5°C
the battery. (60° F).
3. Install the caps on the battery. If the battery in 6. If necessary, fill each cell with electrolyte until the
your machine must have nonspill caps, install the electrolyte is just below split ring at the bottom of
nonspill caps. See Specifications in Section 4002 the cell opening.
to find if the battery in your machine must have
nonspill caps.

Section
4008
ALTERNATOR - 45 AMPERE
4008

2237, Geeral David Sarnoff Avenue Printed in Brazil
Contagem, MG Brazil ENG 6-42361 January, 2003
4008-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
45 Ampere Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection of the Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection and Testing of the Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection and Testing of the Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Testing the Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Testing the Rectifier Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspection and Replacement of the Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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)

4008-4
ALTERNATOR
Disassembly STEP 3
STEP 1
B523411M
Remove the retainer and the pulley from the shaft.

B518007M
Fasten the pulley of the alternator in a vise that has STEP 4

soft jaws. Loosen and remove the nut and washer.
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.

4008-5
STEP 6 STEP 9
B8971204M B8971213M
Remove the voltage regulator and brush holder. 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

STEP 8 washers from the B+ terminal.
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.

4008-6
STEP 12 STEP 15
B8971222M B8971301M
Loosen and remove the screws that fasten the cover, Remove the rotor from the cover.
stator, and housing together.
STEP 16
STEP 13
B8971304M
B8971231M 1. SCREWS
Remove the cover and rotor from the stator and
Loosen and remove the screws that fasten the
housing. The cover can be difficult to remove. Use a
rectifier bridge to the housing.
soft hammer as required to remove the cover.
STEP 17
STEP 14
B8971307M
B8971508M
Remove the housing.
Loosen and remove the screws that fasten the
bearing retainer to the cover. The rotor now can be
removed.

4008-7
STEP 18 STEP 20
B8971310M B8971319M
Remove the insulator from the B+ terminal. Remove the shield from the housing.
STEP 19
B8971313M
Remove the insulator from the D+ terminal.

4008-8
Inspection of the Brushes STEP 23
STEP 21
B9064418M
Measure the length of each brush. If one brush is

B9064411M
less than 7 mm (0.27 inch) long replace both brushes
Use an ohmmeter and check the continuity from or the voltage regulator and brush holder.
each terminal and brush. If the reading is not zero,
replace the brush or voltage regulator and brush STEP 24
holder.
STEP 22
B9064421M
To replace the brushes, use a soldering iron to

remove the original brushes. Install the springs and
B9064414M
new brushes and use rosin core solder to solder the
Remove the shield. 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.

4008-9
Inspection and Testing of the Rotor STEP 28
STEP 26
B9064433M
Use a dial indicator and measure the runout of each

B9064405M
slip ring. If the runout is more than 0.05 mm (0.002
Touch the leads of the ohmmeter to the slip rings. inch) a new rotor must be used or use a lathe to
The reading must be as specified, see below. If the remove enough material until the runout is less than
reading is not as specified, a new rotor must be specified.
installed.
45 Ampere Alternator . . . . . . . . . . . . 8.1to 9.9ohms 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.

4008-10
Inspection and Testing of the STEP 33

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 terminal to the bracket to discharge the
Touch the leads of the ohmmeter to each lead from condenser.
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.

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 B8971402M

and the heat sink as shown. Then reverse the leads. Inspect the bearings on the rotor. If the bearings are
There must be a high reading and a low or zero damaged, use the following procedure to replace the
reading. Then test the other two positive diodes. If a bearings.
positive diode did not have readings as specified, the
positive diode is bad and a new rectifier bridge must
be installed.
STEP 37
B8971426M
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.
B9064332M
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.

4008-12
B8971432M B8971504M
3. Use a suitable support between the rear bearing 6. Press the spacer onto the rotor shaft until the
and the slip ring on the other end of the rotor spacer stops moving.
shaft and press the rotor shaft out of the rear
bearing.
B8971505M
7. Press the new rear bearing onto the other end of

B8971429M 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.

4008-13
18
20
21
23 22
24 22
23
16
24 22
17
23 19
9
21 10
11
23
26 12
27 13
7
7 15 14
1
2
3
5
6
8
4
BS01B125
1. NUT 8. COVER 15. STATOR 22. FLAT WASHER

2. WASHER 9. SPACER 16. SCREW 23. NUT
3. RETAINER 10. FRONT BEARING 17. RECTIFIER BRIDGE 24. LOCK WASHER
4. SCREW 11. BEARING RETAINER 18. INSULATOR 25. BRUSH
5. PULLEY 12. KEY 19. SHIELD 26. VOLTAGE REGULATOR
6. FAN 13. ROTOR 20. HOUSING AND BRUSH HOLDER
7. SCREW 14. REAR BEARING 21. FIBER WASHER 27. CAPACITOR
45 AMPERE ALTERNATOR

4008-14
Assembly STEP 42
STEP 39
B8971601M
Install the housing on the rectifier bridge.

B8971316M
Install a new shield in the housing. STEP 43
STEP 40
B8971304M
1. SCREWS
B8971313M
Install and tighten the screws that fasten the rectifier
Install the insulator on the D+ terminal.
bridge to the housing.
STEP 41 STEP 44
B8971310M
B8971604M
Install the insulator on the B+ terminal.
Install the fiber washers, flat washer, and nut on the
B+ terminal.

4008-15
STEP 45 STEP 48
B8971607M B8971301M
Check for a short circuit between the terminal and Install the rotor in the cover.
the housing. If there is continuity, the insulator is bad.
STEP 49
STEP 46
B8971508M
B8971610M Install and tighten the screws that fasten the bearing
Install the fiber washers, flat washer, and nut on the retainer and rotor to the cover.
D+ terminal.
STEP 50
STEP 47
B8971231M
B8971613M Make sure the marks are in alignment and install the
Check for a short circuit between the terminal and cover and rotor in the stator and housing.
the housing. If there is continuity, the insulator is bad.

4008-16
STEP 51 STEP 54
B8971222M B8971622M
Install and tighten the screws evenly that fasten the Install the voltage regulator and the brush holder. Be
housing, stator, and cover. careful not to damage the brushes.
STEP 52 STEP 55
B8971616M B8971625M
Install the capacitor and tighten the screw. 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.

4008-17
STEP 57 STEP 59
B523418M B518009M
Install the pulley and the retainer. 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.

4008-18
NOTES

SECTION INDEX
STEERING
Front Wheel, Axle & Wheel Lean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5002

Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5003
Steering Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5004

Contagem, MG Brazil ENG 6-46661 June,2003
5002-2
NOTES
Bur 6-46681 (Brz) Revised 6-03 Printed in Brazil

5002-3
TABLE OF CONTENTS
General Description ............................................................................................................................... 01
Troubleshooting ..................................................................................................................................... 02
Removal & Installation ........................................................................................................................... 03
SPECIFICATIONS
Front wheel and Spindle ........................................................................................................................ 11
Front Axle and Steering......................................................................................................................... 13
Front Wheel Lean .................................................................................................................................. 15
ENG 6-46681 June, 2003 Printed in Brazil

5002-4
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 6. Steering cylinder

2. Wheel hub 7. Wheel lean lock
3. Spindle assembly 8. Axle pivot pin
4. Axle 9. Toe-in adjustment rod
5. Wheel lean link 10. Steering arm

SYMPTOM PROBABLE CAUSE TEST SOLUTION
ENG 6-46681
Wheel lean fails to function Wheel lean safety bolt installed Observation Remove bolt
Control valve malfunction Conduct pressure test Repair valve if pressure incorrect
Wheel lean link frozen or seized Observation Free link joint
Damaged hydraulic cylinder Conduct pressure test Replace
Damaged hydraulic hose Observation Replace
Front wheels will not remain in Leaking control valve Conduct pressure test Repair valve if pressure incorrect
desired position Leaking hydraulic cylinder Observation Repair hydraulic cylinder
Hydraulic lines or joints leaking Repair or replace
Front wheels wobble Improper toe-in Observation Correct toe – in
Rims improperly installed on wheel Observation Straighten rim or wheel
Wheel bearing loose Observation Adjust wheel bearings
Steering arm loose Observation Tighten nut
Spindle bearing loose Observation Adjust bearing
Drag link damage Observation Repair
Hard to steer in either direction Low air pressure in front tires Observation Inflate to proper pressure
Steering links Repair
Improper toe-in Adjust toe-in
Malfunction in power assist hydraulic Conduct pressure Insure pressure is correct
system test
Damaged wheel lean link Repair or replace
Axle pivot pin and bushing worn Replace
TROUBLESHOOTING
Excessive free play in steering Worn drag link socket or swivel joints Repair or replace
wheel Loose wheel or spindle bearing Adjusting bearings
Damaged or worn power steering Repair or replace
Loose steering arm Adjusting bearings
June, 2003
Improper caster in front wheels Worn or loose spindle bearing Replace bearing and / or adjust shims
Wheel bearings loose Adjust bearings
Bent wheel lean link Straighten link or replace
Knuckle bushing or pin worn Replace
Uneven or abnormal tire wear Tires over or under inflated Inflate to specified pressure
Misalignment of tires Correct alignment
Printed in Brazil
5002-5
5002-6
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 6-46681 June , 2003 Printed in Brazil

5002-7
!
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.

5002-8
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.

5002-9
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.

5002-10
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.

5002-11
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.

5002-12
! 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.

5002-13
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.

5002-14

5002-15
SPECIFICATION
Front Wheel and Spindle
ITEM STEP# NAME TORQUE

Nm Ft Ibs
A Wheel lug nuts 446 -480 325 - 350
K Spindle to knuckle cap capscrews 40 - 54 30 - 40
L Hub cap capscrews 40 - 54 30 - 40
M Spindle to knuckle cap capscrews 40 - 54 30 - 40
N Link nut 122 -149 90 -110
DIMENSIONS
ITEM NAME mm in
B Hub bore I.D. 122.121-122.212 4.8095 - 4.8115

Bearing Cup O. D. 122.237 - 122.263 4.8125 - 4.8135
C Spindle O. D. 66.644 - 66.670 2.6238 - 2.6248

Bearing Cone I. D. 66.675 - 66.688 2.6250 - 2.6255
D Hub bore l. D. 146.924 -146.975 5.7844 - 5.7864

Bearing cup O .D. 147.000 5.7874
E Spindle O. D. 89.944 - 89.995 3.5411 - 3.5431

Bearing cone I.D. 90.000 3.5433
G Spindle I. D. 44.399 - 44.425 1.7480 - 1.7490

Pin O. D. 44.437 - 44.450 1.7495-1.7500
H Knuckle I. D. 72.24 -72.29 2.844 - 2.846

Bearing Cup O. D. 72.2325 2.8438
I Pin O. D. 34.938 - 34.963 1.3755 -1.3765

Bearing Cone I.D. 34.9250 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.
J 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.
O Hand pack bearing C & E with wheel bearing grease and fill hub cavity half full. Use wheel bearing
grease only.

5002-16

5002-17
FRONT AXLE AND STEERING
ITEM NAME TORQUE

Nm ft Ib
H Pin set screw 40 -54 35-40
I Steering cylinder retaining nut 122 – 149 90 - 100
DIMENSION
ITEM NAME mm in
A Front axle I. D. 60.312 – 60.338 2.3745 – 2.3755

Bearing O. D. 60.32 2.375
B Pin O. D. 50.785 - 50.800 1.9994 - 2.0000

Bearing I. D. 50.800 2.0000
C Front axle center pivot I. D. 60.30 - 60.32 2.374 - 2.375

Bearing O. D. 60.363 - 60.414 2.3765 - 2.3785
D Shaft O. D. 50.749 - 50.762 1.9980 - 19885

Bearing I.D. 50.902 - 51.003 2.0040 - 2.0080
E Cylinder pivot I. D. 50.762 - 50.787 1.9985 - 1.9995

Bearing O. D. 50.787 - 50.800 1.9995 - 2.0000
Cylinder pivot mounting pin O. D. 31.73 - 31.78 1.249 - 1.251
PROCEDURES
F 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).
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.

5002-18

5002-19
FRONT WHEEL LEAN
ITEM NAME mm in
A Cylinder pivot bearing I.D. 50.762 – 50.787 1.9885 – 1.9995

Bearing O. D. 50.787 – 50.800 1.9995 – 2.0000
Pivot Pin O. D. 31.763 – 31.788 1.2505 – 1.2515
Bearing I.D. 31.737 – 31.750 1.2495 – 1.2500
B Cylinder rod I.D. 50.762 - 50.787 1.9985 - 1.9995
Bearing O. D. 50.787 – 50.800 1.9995 - 2.0000
C Front wheel lean link bearing bore I. D. 50.762 - 50.787 1.9985 – 1.9995
Bearing O. D. 50.787 - 50.800 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 rera of tires. Measure from center of tread.
Tires must be properly inflated.

5002-20
NOTES
Bur 6-46681 (Brz) Revised 6-03 Printed in Brazil

Section
5003
5003
STEERING CONTROL VALVE
845 - 865 - 885 Grader

Contagem, MG - Brazil ENG 6-46691 May, 2003
5003-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ENG 6-46691 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.
3 Figure 1-A
4
2 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 3. ANTI-CAVITATION VALVES

2. END CAP 4. CHECK VALVE
FIGURE 1. STEERING CONTROL VALVE-END CAP UP
4. Remove the seven cap screws (1), end cap (2), Figure 1 - B
O-ring (3), gerotor (4), O-ring (3), spacer plate
(5), and O-ring (3), refer to Figure 2. 8. Rotate spool and sleeve until pin is horizontal.
5. Remove the gerotor star from gerotor (4), Figure 2. Push spool and sleeve assembly forward with your
thumbs just far enough to free gland bushing from
6. Remove drive shaft (6), Figure 2. housing, see Fig. 1 - B. Remove bushing
ENG 6-46691 May,2003 Printed in Brazill

5003-4
1. CAP SCREW 8. SLEEVE 15. O-RING

2. END CAP 9. SPOOL 16. O-RING
3. O-RING 10. SPACER 17. SEAL GLAND BUSHING
4. GEROTOR 11. PIN 18. RETAINING RING
5. SPACER PLATE 12. CENTERING SPRING 19. DUST SEAL
6. DRIVE SHAFT 13. NEEDLE THRUST BEARING 20. 23. BALL CHECK
7. STEERING CONTROL HOUSING 14. BEARING RACE 21. 22. ROLL PIN
FIGURE 2. STEERING CONTROL VALVE - EXPLODED VIEW

5003-5
12. Remove spool and sleeve assembly from 14 hole

end of housing, see Fig. 5.
Attention: Do not bind spool and sleeve in housing.

Rotate spool and sleeve assembly slowly when
Figure 3 removing from housing.
9. Remove quad ring seal from seal gland bushing.
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 4 Figure 6
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

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).

5003-7
3
4
6
1
5
2
3
GS98K530
1. BALL CHECK 4. PORT FACE

2. ROLL PIN 5. ANTI-CAVITATION VALVES
3. SODA STRAW 6. CHECK VALVE
FIGURE 8. ANTI-CAVITATION VALVE - DISASSEMBLY
Inspection 3. If the spool (9) and sleeve (8) or the bore in the
housing of the steering control valve (7) is
1. Clean all parts in cleaning solvent and air dry on damaged or worn, use a new steering control
paper towels. Do not use cloths to wipe parts dry, valve.
as it may leave lint on the parts.
4. Inspect the cap screws (1), pin (11), backup
2. Check all machined surfaces for wear or washer (15), seal ring (16), O-ring (17),
damage. If there are rough places on the ends of needle thrust bearing (13) and bearing race
the gerotor star or gerotor (4), steering control (14). Use new parts as required.
valve housing (7), end cap (2), or spacer plate
(5), use 600 grit emery cloth to smooth the 5. If your steering control valve has anti-cavitation
surfaces, refer to Figure 2. Place the emery cloth and check valves, inspect the balls checks (20),
on a flat surface. If the emery cloth is new, rub a (23) and roll pins(21), (22) for damage or wear.
piece of steel across the emery cloth six times to Use new parts as required.
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.

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 FIGURE 10
is to replace all old seals with new seals.
3. Assemble spool and sleeve carefully so that the
spring slots line up at the same end. Rotate spool
1. Use a soda straw (3) as a guide tool, refer to while sliding parts together. Some spool and
Figure 9. Drop the straw (3) into the anti-cavitation sleeve sets have identification marks, align these
valves (5) and check valve (6) to the bottom of the bore. marks as shown in Fig.10. Test for free rotation.
Drop the ball check (2) through the straw (3). Pull Spool should rotate smoothly in sleeve with finger
the straw (3) out and use the same procedure in tip force applied at splined end.
the others ball seat.
3 1
FIGURE 11
4. Bring spring slots of both parts in line and stand

parts on end of bench. Insert spring installation tool
6 through spring slots of both parts. Tool is available
as part no. 600057. Position 3 pairs of centering
GS98K504 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
5 spring set into springinstallation tool, see Fig. 11.
5. Compress extended end of centering spring set

1. ROLL PIN 4. PORT FACE and push into spool sleeve assembly with drawing
2. BALL CHECK 5. ANTI-CAVITATION VALVES installation tool at the same time.
3. SODA STRAW 6. CHECK VALVE
FIGURE 9. CHECK AND ANTI-CAVITATION VALVES ASSEMBLY 6. Center the spring set in the parts so that they push
2. Use a small light and check each bore to make down evenly and flush with the upper surface of the
sure each ball check (2) is in the correct place. spool and sleeve.
Add the roll pin (1) in each.

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.
12. Install dry quad ring seal in seal gland bushing,

Smooth seal in place with your finger. Do not use
FIGURE 13 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.

5003-10
13. Install seal gland bushing over the spool end 15 Clamp housing in vise, as shown in Fig. 17.
with a twisting motion. Tap the bushing in place with Clamp lightly on edges of mounting area. Do not
a rubber hammer. Make sure the bushing is flush over tighten jaws.
against the bearing race.
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

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
19. Install seal in meter. see Fig. 22
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, Ç, and
D - Fig. 21. Align bolt holes without disengaging
meter from drive.

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 Possible Cause Correction

1. Slow steering, hard steering, or loss Worn or malfunctioning pump. Replace pump.
of power assist.
Stuck flow divider piston. Replace flow divider.
Worn pump compensator allowing the Replace pump and compensator.

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

system pressure to be less than
specified.
Overloaded steer axle. Reduce Load.
If load sensing system Correct

1. Leaking or kinked load sensing
signal line.
2. Malfunctioning priority valve. 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.
2. Wander – Vehicle will not stay in a Air in the system due to low level of oil, Correct.
straight line. 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 Repair or replace the accessory valve.

valve in cylinder lines.
Severe wear in steering control unit. Replace the steering control unit.
3. Drift – Vehicle veers slowly in one Single rod end cylinder slowly extends A small rate of extension may be
direction. without turning the steering wheel. normal on a closed center system.
Worn or damaged steering linkage. Replace linkage and align front end.
4. Slip – A slow movement of steering Leakage of cylinder piston seals or Replace seals or accessory valve.
wheel fails to cause any movement of accessory valve between cylinder lines
steered wheels. or ports.
Worn steering control unit meter. Replace steering control unit.

5003-13

5. Temporary hard steering or Thermal Shock* Check unit for proper operation
hang-up. and cause of 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.
Loose cylinder piston. Replace cylinder.
*Thermal shock damage. Replace steering control unit.
Sticking flow control spool. Replace flow control valve.
7. “Spongy ”or soft steering. Air in hydraulic system. Most Bleed air out of system. Placing
likely air trapped in cylinders or ports on top of the cylinder will
lines. help prevent air trapping.
Low fluid level. Add fluid and check for leaks.
8. Free Wheeling-Steering wheel Steering column upper shaft is Tighten steering wheel nut.
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
lack of oil. This can happen on problem.
start-up. after repair, or long per-
iods of non use.
No flow to steering unit can be

caused by:
1. Low fluid level. Add fluid and check for leaks.
2. Ruptured hose. Replace hose.
3. Internal steering control unit Replace the unit.
damage due to thermal shock *.
9. Free Wheeling-Steering wheel Leaking crossover relief or anti- Repair or replace the accessory
turns with slight resistance but cavitation valve in cylinder lines. valve.
results in little or no steered
wheel action.
Piston seal blown out. Determine cause. Correct and
replace seal.
4
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
is relatively cool (more than 50oF 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.

5003-14

10. Excessive free play at Loose steering wheel nut. Repair or replace steering wheel
steering wheel. Steering column shaft worn or connection or column.
damaged. There should be very
little free play in the unit itself.
11. Excessive free play at Broken or worn Iinkage between Check for loose fitting bearings
steered wheels. cylinder and steered wheels. and anchor points in steering
Iinkage between cylinder and
steered wheels.
Leaky cylinder seals. Replace cylinder seals.
12. Binding or poor centering of Binding or misalignment in steer- AIign column pilot and spline to
steering wheel. ing column or splined input con- steering control unit.
nection.
High back pressure in tank line Revise circuit return line.

can cause slow return to center.
Should not exceed 300 psi.
Large particles can cause Clean the unit and filter the oil. If
binding between the spool and another component has failed
sleeve. generating contaminants, flush
the system while bypassing the
steering control unit.
13.Steering unit locks up. Large particles in meter section. Clean the unit.
Insufficient hydraulic power Check hydraulic power supply.

3
(units over 15 in ).
Severe wear and/or broken pin. Replace the unit.
*Thermal shock. Replace the unit.
14. Steering wheel oscillates or Parts assembled wrong. Correct timing.

turns by itself. Steering unit improperly timed.
Lines connected to wrong ports. Reconnect lines correctly.
15.Steered wheels turn in wrong Lines connected to wrong Reconnect lines correctly.
direction when operator cylinder ports.
activates steering wheel
16. Steering wheel kicks at start No inlet check valve on steering Install a check valve.
of steering. control unit.

5004
Section
5004
STEERING PRIORITY VALVE
845 - 865 - 885 Grader

5004-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 6-46701 Issued 1-03 Printed in Brazil.

5004-3
STEERING PRIORITY VALVE
Disassembly STEP 4
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
Remove plug (7). Remove and discard O-ring (8)
STEP 3 from plug.
Remove plug (3). Remove and discard O-ring (4)
from plug.
1. RELIEF VALVE 6. SPOOL

2. O-RING 7. PLUG
3. PLUG 8. O-RING
4. O-RING 9. HOUSING
5. SPRING

5004-4
Cleaning and Inspection Assembly

STEP 7 STEP 11
Clean all parts in cleaning solvent. Immerse housing Install new O-ring (10) on plug (9). Install plug and
(9) in cleaning solvent and agitate cleaning solvent. O-ring. Tighten plug to a torque of 33.9 to 54.2 Nm
WEAR EYE PROTECTION WHEN USING (25 to 40 lb-ft).
COMPRESSED AIR. Use compressed air to remove
foreign matter from interior of valve housing and to STEP 12
ensure that all orifices and bores are clear. Install spool (8) and spring (7),
STEP 8 STEP 13
Insp ect spo ol (6) a nd ho using b ore s for d ee p Install new O-ring (4) on plug (3). Install plug and
scratches, gouges, and other damage. Replace O-ring. Tighten plug to a torque of 33.9 to 54.2 Nm
steering priority valve if any of these conditions are (25 to 40 lb-ft).
seen.
STEP 14
STEP 9
Install new O-ring (2) on relief valve (1). Install relief
Check that orifice screws in each end of spool (6) are valve and O-ring. Tighten relief valve to a torque of
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 33.9 to 54.2 Nm (25 to 40 lb-ft).
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).
STEP 10
Check spring (5) for cracks, breaks, or signs of
permanent set. Replace if any of these conditions are
seen.
10 9
1. RELIEF VALVE 4. O-RING 7. PLUG

2. O-RING 5. SPRING 8. O-RING
3. RELIEF VALVE 6. SPOOL 9. HOUSING

SECTION INDEX
POWER TRAIN
Transmission Specifications, Pressure Checks, and Troubleshooting 845-865 Grader . . . . . . . . . . . . . .6002

Transmission Specifications, Pressure Checks, and Troubleshooting 885 Grader. . . . . . . . . . . . . . . . . .6002
Transmission 885 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6003
Transmission 845 - 865. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6003
Rear axle with differential lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6005
Limited Slip Rear Axle 845-865 Grader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6005
Tandem Drive Limited Slip Rear Axle 845-865 Grader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6006
Tandem Drive Differential Hydraulic Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6006

Contagem, MG Brazil ENG 6-46731 May,2003
Section
6005
LIMITED SLIP
REAR AXLE
6005
845 - 865 Grader
CNH Latino Americano Ltda

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 6-46782 May, 2003

6005-4
Material: Spring Steel
ENG 6-46782 l May, 2003

6005-5
TOOLS FOR MOUNTING OF RING RETAINING CUP
HAND GRIP O.D.- 50mm (2") - M16
ENG 6-46782 January, 2003 Printed in Brazil

6005-6
Material: Tool steel SAE1080 /1085

quench and temper (HRC 52 ~60)
ENG 6-46782 May, 2003

6005-7
Material: Tool steel SAE1080 /1085

quench and temper (HRC 52 ~60)
ENG 6-46782 May, 2003

6005-8
TROUBLESHOOTING
SYMPTOM PROBABLE CAUSE SOLUTION
▲ Oil leakage from final drive carrier ● Incorrect screw torque ■ Check the torque
O-Ring damaged Replace O-Ring
▲ Oil leakage from seals ● Incorrect installation ■ Replace seals

Seals damaged Replace seals
▲ Oil leakage from breather ● High oil level ■ Check oil level
▲ Lubricant with excessive foam ● Incorrect lubricant ■ Replace the oil.
▲ Final drive noise ● 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.
▲ Differential assy noise ● 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 ■ Verify and replace.

damaged
ENG 6-46782 May, 2003

AXLE SECTION
6005-9
3 4 5 6 7 8 9 10 11 12 13
22
21 20 19 18 17 16 15 14
1
26 25 24 23
1. Differential support 14. Adjusting shim

2. Limited slip differential assembly 15. Sprocket z = 20
3. Filter 16. Axle support
4. Central housing 17. Half-shaft
5. Pressure plate 18. Pin
6. Steel disk 19. Ring gear
7. Friction disk 20. Gear
8. Brake disk drum 21. Brake disks retaining pin
9. Planetary gear 22. Piston
10. Half-shaft thrust washer 23. Retaining spring cup
11. Shim 24. Pressure plate return spring
12. Reduction support assembly 25. Pin
13. Sprocket retaining washer 26. Shim
ENG 6-46782 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 6-46782 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 ham-
mer 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 6-46782 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 6-46782 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 6-46782 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 6-46782 May, 2003

6005-17
STEP 15
Inspect bearing for wear and if necessary
remove and replace.
STEP 16 Oil seal

Assemble the oil seal at 5 - 6 mm (0.2 - 0.24)" 5-6 mm
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
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 6-46782 May, 2003

6005-18
STEP 18
Install bearing cone after heating to

90 to 100°C (176 to 194°F)
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 6-46782 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 6-46782 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 6-46782 May, 2003

6005-21
Computing of Brake Disc Pack of Final Drive
To assemble steel discs pack, Friction disc

to use a standard pack.
The total pack of standard steel discs

is 17.50 mm (0.689"). Then it’s 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 6-46782 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 6-46782 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) B
D = 17.50 mm (4 lug brake discs total value) C+D
D = 0.689" (4 lug brake discs total value) 4.25 ± 0.25 Stroke
then, we’ll have:

S(mm) = (82.50 - 36.45) - (23.80 + 17.50) - 4.25
S = 0.50 mm
A
S" = (3.248 - 1.435) - (0.937+ 0.689) - 0.167
S = 0.02"
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 6-46782 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 Steel disc
ENG 6-46782 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 6-46782 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
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 6-46782 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 6-46782 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 6-46782 May, 2003

6005-29
STEP 48
Straighten lock ring notches on pinion nut col-
lar, 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 6-46782 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 6-46782 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 remo-
ving them with a puller and assemble them
Heat to 120°C (248°F).
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 6-46782 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 6-46782 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 referen-
ce 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 ade-
quate 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 6-46782 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 6-46782 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 6-46782 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 ~ 90°C
176 ~ 194°F
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 6-46782 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 pre-
load, it is advisable to insert as many adju-
sting 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 6-46782 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 rele-
vant 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 ali-
gned 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 6-46782 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, rota-

te 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 6-46782 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 6-46782 l May, 2003

SECTION INDEX
BRAKES
Brake pedal valve and system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7002

Hydraulic brake Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7003

2237,General David Sarnoff Avenue Printed in Brazil
Contagem, MG Brazil ENG 6-46810 January, 2003
Section
7002
7002
HYDRAULIC BRAKE TROUBLESHOOTING
845 - 865 - 885 Grader

Contagem, MG - Brazil ENG 6-46831 May,2003
7002-2
TABLE OF CONTENTS
HYDRAULIC BRAKE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENG 6-46831 Issued 1- 03 Printed in Brazil

7002-6
NOTES
ENG 6-46831 Issued 1- 03 Printed in Brazi

Section
7003
7003
BRAKE PEDAL VALVE AND SYSTEM
845 - 865 - 885 Grader

Contagem, MG - Brazil Eng 6-46842 November,2003
7003-2
TABLE OF CONTENTS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION .............................................................................................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIFICATIONS ..................... . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BRAKE PEDAL DISASSEMBLY - ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHECK OF BRAKE CONTROL PRESSURES .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . .. . 14
SETTING OF MIN. AND MAX. ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TEST OF ACCUMULATORS PRECHARGE .......................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTRUCTIONS FOR THE RESETTING OF ACCUMULATORS PRECHARGE . . . . . . . . .. . . . . . . . . . . . . . . 17
BLEEDING OF BRAKES SYSTEM .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 18
.
ENG 6-46842 issued 11- 03 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.
4
2
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.

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 (81+-126 bar). This
pressure is set by turning the screw (6) located on the cylindrical end and is protected by a cap nut.

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 2.8 ~ 7 bar) 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

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

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 pag no.7003-18).
SETTING
Adjustment and check of accumulator pressure (see page no. 7003-15)
When the accumulators are discharged, connect a gauge (scale 250 bar/3600psi) to the special plug.
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 250 bar/3600psi) to brake

circuits, see page no. 7003-14.
The pressure depends on the pedal stroke.
The braking pressure is adjustable by the 5
adjusting screw (5) under the pedal. The max.
pressure for the brake pistons is 68 bar (985psi) .

7003-8
BRAKE PEDAL DISASSEMBLY - ASSEMBLY
1
2
41 3
40 4
39 5
38 6
37 7
8
36 9
35 10
34 11
33 12
SECTION A - A
32 13
31 14
30 15
29 16
28 17
27 18
26 21 25 24 23 22 21 20 19

7003-9
Description of brake valve disassembly - assembly
1 - Blind nut M10 35 - Spring for priority valve

2 - Nut M4 36 - Charge valve cover
3 - Flat washer 37 - Pin for single direction valve opening
4 - Adjustment nut 38 - Spring for single direction valve opening
5 - Dowel M4x50 39 - Brake control spring
6 - Spring seat 40 - Screw for double adjustment
7 - Screw for spring compression 41 - Lock washer
8 - Needle valve seat 43 - Nut M8x1,25 (not used)
9 - O-ring 44 - Dowel M8x40 (not used)
10 - Piston for single direction valve holder 45 - Protection
11 - Seal needle 46 - Support
12 - O-ring 49 - Plug
13 - O-ring 50 - Washer
14 - Valve spring 51 - Link rod
15 - O-ring 52 - Piston for brake control
16 - Bushing for single direction valve holder 53 - Upper spring guide
17 - O-ring 54 - Approach spring
18 - O-ring 55 - Pressure spring
19 - O-ring 56 - Seal
20 - Pressure switch plug 57 - Return spring
21 - O-ring 58 - Lower spring guide
22 - Plug for single direction valve 59 - Snap ring
23 - Spring for single direction valve 60 - Control valve piston
24 - Poppet valve body 61 - O-ring
25 - Poppet seat for single direction 62 - Control valve body
valve 63 - O-ring
26 - Accumulator charge valve body 64 - Control valve body
27 - Snap ring 65 - Centering bushing
28 - Snap ring
67 - Spring for control valve piston
29 - Adjusting washer
68 - Screw TC M8x1,25x150
30 - Piston for priority valve
31 - Cone-shaped filter
32 - Spring for filter retaining
33 - O-ring
34 - O-ring

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
check section.
- For assembly tighten the screws to a
torque of 30Nm (22 lb ft.)
(C2)

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 Loading valve
with Ø 6 mm holes, supply and drain, not
passing. Braking module no. 1
Braking modules are coupled with the relative Braking module no. 2
pistons. Do not reverse them.
Support for pedal and working brake sleeve
Loading valve
Remove screws (C1) securing the cover, Inspect the sealing surfaces of the valve
and remove internal components. blocks. Check the sliding surfaces of the
plungers and the condition of the
relevant springs.
Cleaning and inspection of components
Wash all components with a non- Reassembly
flammable, non-toxic detergent solution, Lubricate all the components to be
and dry them with compressed air. reassembled.
Reassemble the components of the valve
Any dirt entering the system can cause in the same order of the disassembly
serious operational problems. 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).

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

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.

7003-14
CHECK OF BRAKE CONTROL PRESSURES
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.

7003-15
SETTING OF MIN. AND MAX. ACCUMULATOR If the minimum recharge pressure is different from
RECHARGE PRESSURE the nominal value, remove cap (1), loosen nut (5)
Connect two pressure gauges M1 and M2 (200 and adjust screw (4) slowly, until the correct value
bar 2900 PSI capacity) to the quick release is obtained.
pressure pick-up points (7 and 8, fig. ), located left Check the pressure again before tightening
side of the machine. locknut (3).
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. Recharge maximum value
With engine at low idle read the maximum
charging pressure on pressure gauges M1 and
Minimum recharge value M2.
With engine idling and machine standing still, This pressure must be 120 ÷ 126bar (1740 ÷ 1827
apply brake 8 to 10 times slowly. Read on PSI).
gauges M1 and M2 the values of minimum on If the maximum recharge pressure is different from
pressure, prior to the start of the recharge cycle the nominal value, remove plug (1), loosen locknut
The pressure gauges must read momentary (3) and adjust screw (2), until this value is
81÷87bar (1175 ÷ 1262 PSI). 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.
7003-16
SPECIAL TOOL
C E
D B A
94L95
CAS-10899 NITROGEN CHARGING KIT
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

1. Use the CAS-10899 nitrogen charging kit to 6. Connect valve F to the valve stem on the
discharge the accumulator, refer to illustration accumulator.
above. The tool must be disconnected from the
7. Turn the T-handle inward on valve F to engage
nitrogen tank.
the pin in the valve stem.
2. Close valves B, C and D.
8. Open valve D and check the charge pressure on
3. Adjust the regulator A to the minimum pressure gauge E.
setting by turning the knob counterclockwise.
9. To discharge the accumulator, partially open
4. Turn the T-handle on valve F fully out. valve B. The accumulator charge will bleed down
through the regulator.
5. Remove the guard and valve assembly cap from
the accumulator. 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 5. Remove the cap screws and guard from the
completely discharged by doing the following: accumulator.
A. Stop the engine. 6. Remove the cap from the accumulator valve
stem.
B. Push down and release the brake pedal many
times to release the pressure. 7. Connect valve F to the accumulator valve stem.
2. Connect a drain hose to the test connector in 8. Make sure that valve D is open.
each brake circuit to release any pressure in the
9. Turn the stem into valve F and read the pressure
brake circuit.
gauge E.
3. Close valves B and C on the nitrogen charging
NOTE: See chart below for pressure readings.
kit, refer to the illustration.
10. If the pressure is too low, charge the accumulator
4. Turn the stem out of valve F until the stem stops.
with dry nitrogen.
7003-17
CHARGING THE ACCUMULATOR WITH DRY NITROGEN

NOTE: Check the pressure in the accumulator 5. If the pressure increases above required
according to the instructions in Checking the pressure, quickly open and close valve D and
Nitrogen Charge in the Accumulator. Keep the read gauge E. If the pressure is still too high,
nitrogen charging kit connected to the accumulator. close valve A (turn counterclockwise) a small
amount and quickly open and close valve D. The
1. Close (turn counterclockwise) valve A and open
pressure shown on gauge E is the charge
valve B. Close valves C and D.
pressure.
2. Turn the stem out of valve F until the stem stops
6. Connect valve F to the accumulator valve stem.
moving. Disconnect valve F from the
Turn the stem into valve F until the stem stops
accumulator valve stem.
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
3. Connect the nitrogen charging kit to a dry accumulator.
nitrogen tank.
7. After the accumulator stops charging, turn the
4. Slowly turn valve A clockwise and read gauge E stem out of valve F until the stem stops moving.
until the pressure is equal to charge pressure
8. Close valve B and disconnect the nitrogen
required for accumulator being charged. Stop
charging kit from the accumulator valve stem.
turning valve A.
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 CHARGE PRESSURE TEMPERATURE CHARGE PRESSURE

0° C 32° F 89.4 BAR 1297 PSI 0° C 32° F 51.2 BAR 743 PSI
TEMPERATURE/CHARGE PRESSURE PARKING BRAKE TEMPERATURE/CHARGE PRESSURE BRAKE

ACCUMULATOR ACCUMULATOR
7003-18
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.
Axle limited slip brakes system

bleeding 2 plugs.
To bleed the system proceed as described below
(the operation requires two people):
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 Differential lock axle brake
bleeding plug (see figure) and the other system bleeding 4 plugs.
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.
SECTION INDEX
HYDRAULICS

Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002
CNH Latino Americana LTDA.

8002
Section
8002
HYDRAULIC SCHEMATICS
CNH Latino Americana LTDA .

2234 General David Sarnoff Avenue
Contagem, MG Brazil Printed in Brazil
ENG 6-75400 June, 2003
8002-2
TABLE OF CONTENTS
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
ENG 6-75400 Issued 6-03 Printed in U.S.A.

8002-3
BC03J073

8002-4
BC03J074

8002-5
BC03J075

8002-6
BC03J076

SECTION INDEX
MOUNTED EQUIPMENT

Air Conditioning Troubleshooting 845-865-885 Grader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9002
Air Conditioning Troubleshooting For Systems With R-134a Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9002
Air Conditioner System Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9003
Air Conditioner System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003
Removal and Installation of Air Conditioning System Components For Systems With R-134a Refrigerant
845-865-885 Grader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9004
Rear Ripper 845-865-885 Grader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9007
Frame, Articulation Joint, Circle, and Scarifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9008
Front Blade and Counterweight 845-865-885 Grader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9009
ROPS Cab 845-865-885 Grader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9010
Cab Glass Installation 845-865-885 Grader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9011
CNH Latino Americana LTDA.

9002
Section
9002
AIR CONDITIONING SYSTEM

TROUBLESHOOTING
845 - 865 - 885 Grader

Contagem, MG - Brazil ENG 6-46950 January, 2003
TABLE OF CONTENTS
TROUBLESHOOTING ............... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01
NORMAL OPERATING AIR CONDITIONING CONDITIONS..... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 03
ELECTRICAL DIAGRAM HVAC SYSTEM . . . . . . . . . ... . .. .. . . .. . ... . .. . . .. . . . . . . . . . . . . . . 04
9002-01
Trouble-shooting for Grader`s air conditioning system.
PROBLEM GAUGE READING DESCRIPTION CORRECTION

SUCTION DISCHARGE
Low suction LOW NORMAL Suction hose obstructed. Check and replace hose.
pressure
High suction HIGH NORMAL Compressor malfunction. Check and replace

Pressure. compressor.
HIGH HIGH Low condenser air flow. Clean and repair

condenser fins.
Low NORMAL LOW Low evaporator air flow. Clean and repair
discharge evaporator fins.
pressure. Low charge. Evacuate system and
apply correct charge.
High NORMAL HIGH Air in system. Evacuate system and
discharge TO apply new charge.
pressure HIGH Overcharge.
Low cooling NORMAL NORMAL Moisture in system. Evacuate system, replace
capacity. TO receiver drier, make
HIGH internal cleaning and
apply new charge.
Excessive oil amount. Evacuate system, make
internal cleaning and
apply new charge.

9002-02
Low cooling LOW LOW Insufficient charge. Check and repair leak.
Capacity. Apply new charge.
LOW TO LOW Receiver drier clogged. Evacuate system, replace
VACUUM receiver drier, make
internal cleaning and
apply new charge.
ZERO TO LOW Expansion valve obstructed. Check and replace
VACUUM Expansion valve.
LOW NORMAL Compressor cut off disable. Replace thermostatic
switch.
HIGH NORMAL TO Expansion valve being Check and replace
LOW opened. expansion valve.
NORMAL NORMAL Mixture of cold air with heated Check and replace heater
air. valve and its control.
NORMAL HIGH Compressor malfunction– low Check and repair belt
belt tension. tension.
Belt ---------- ---------- Compressor pulley not Check and repair
malfunction. aligned. compressor pulley
alignment.
NORMAL HIGH Overcharge. Evacuate system and
apply new charge.
Compressor ---------- ---------- Low charge – leak. Check and repair leak.
malfunction. Apply new charge.
Compressor coil not Check and replace fuse.
energized.
Check and replace A/C
switch.
Check and replace A/C
relay.
Check and replace
pressure switch.
Check and replace
thermostatic switch.
Check and replace coil.
Compressor clutch drive Replace compressor.
malfunction.
Low LOW NORMAL Evaporator fin obstructed Check and replace
evaporator (ice). thermostatic switch.
air flow.
---------- ---------- Evaporator fan malfunction or Check and replace fuse.
not energized.
Check and replace speed
fan switch.
Check and replace fan
resistor.
Check electrical cable
malfunction.
Air filters obstructed. Clean or replace air
filters.
Evaporator fan damaged. Check and replace
evaporator fan.
Noise. ---------- ---------- Low or high belt tension. Check and repair belt
tension.
HIGH LOW Compressor damaged. Check and replace
compressor.
HIGH HIGH Overcharge. Evacuate system and

9002-03
---------- ---------- Hose resonance. Protect hose against

other part or include a
muffler.
Pulley (motor, compressor, Align or replace pulley.

idley) not aligned.
Clutch drive malfunction. Evacuate system and

Check and replace
compressor.
Pulley bearing damaged. Check and replace
compressor.
Bolts not tightened. Retighten bolts.
NOTE: service, repair or recharging must be performed by qualified personnel only.
Normal operating air conditioning conditions (after 15 minutes use).
Environment temperature: --------------- 25°C.

Relative humidity: -------------------------- 50%.
Machine motor speed: ---------------------2000 rpm.
Suction pressure: --------------------------- 15 + - 5 psi.
Discharge pressure: ----------------------- 175 + - 15 psi.
These data have great increase or decrease depending on environmental conditions.
Advices.
Some chemical substances (which are used to clean the machine motor) may attack belt
compressor, causing damage or noise.
Must be used proper equipment and fluid to make internal cleaning (flushing). Compressor
and expansion valve should not be cleaned.
Add synthetic PAG oil quantity according to the part that was removed or replaced.
1) Compressor : when it is replaced (before removing it, turn on air conditioning system
for five minutes), drain all oil which is inside the used compressor and measure it. Drain all
oil which is inside the new compressor and charge it with the same quantity measured at
the used compressor. If the used one was damaged due to insufficient oil (no oil when it is
drained), charge new compressor with 60 ml oil.
2) In order to add oil for the other parts see this table:
PART OIL QTY ( ml )
Evaporator 40
Condenser 50
Receiver drier / accumulator 30
Hose (each one) 20
Use proper equipment in order to recover refrigerant charge. Never let

refrigerant charge flow to air.

9002-4
Electrical Diagram HVAC System
+24 VDC
20A
B2
2 3
B1
1 4
B2 P1
RL1 RL2
EM
R
M1 M2 T
EVAPORATOR HOUSE
B1 SPEED FAN SWITCH
B2 ON-OFF A/C SWITCH
EM CLUTCH COIL
RL1 CLUTCH COIL RELAY
RL2 CONDENSER FAN RELAY
P1 GAS LEAK / HIGH PRESSURE SWITCH
ON / OFF CONDENSER FAN
R EVAPORATOR HOUSE RESISTOR
T THERMOSTATIC SWICTH
M1 EVAPORATOR HOUSE FAN / M2 EVAPORATOR HOUSE FAN

9002
Section
9002
AIR CONDITIONING TROUBLESHOOTING AND SYSTEM

CHECKS FOR SYSTEMS WITH HFC-134A
REFRIGERANT
CNH Latino Ameicana Ltda.

Contagem, MG Brazil 6-75390 May,2003
9002-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cab Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Evaporator/Heater Core Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Evaporator/Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Test Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PRESSURE-TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
QUICK REFERENCE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A/C RECOVERY AND CHARGING STATION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PROBLEM: NO COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indication of No Refrigerant or Low Refrigerant Charge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indication of Large Quantity of Air in System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Condenser Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HFC-134a Stable Saturation Pressure/ Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Expansion Valve Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Refrigerant Contamination: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PROBLEM: NOT ENOUGH COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Not Enough Refrigerant - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
High Side Restriction - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Expansion Valve Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Compressor Turning But Not Pumping Properly - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Expansion Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Condenser Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PROBLEM: INTERMITTENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Moisture in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PROBLEM: NOISE IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Too Much Refrigerant in System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TUBE CONNECTIONS TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-75390 Issued 8-01 Printed in Brazil

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 3. Keep refrigerant containers in the correct upright
by an approved training and certification organization position. Always keep refrigerant containers
may service or repair motor vehicle or mobile air away from heat and sunlight. The pressure in a
conditioning systems. It is mandatory that all container will increase with heat.
refrigerant must be RECOVERED and RECYCLED
4. Always reclaim refrigerant from the system, if
when removed from a system during servicing.
you are going to weld or steam clean near the air
Refrigerant HFC-134a is the most stable, and easiest conditioner system.
to work with of the refrigerants now used in air
5. Always check the temperature and pressure of
conditioner systems. Refrigerant HFC-134a does not
the air conditioner system before reclaiming
contain any chlorofluorocarbons (CFC’s) which are
refrigerant and when you test the system.
harmful to the earth’s ozone layer.
6. Dangerous gas can form when refrigerant comes
Safety procedures must be followed when working
in contact with an open flame. Never permit
with Refrigerant HFC-134a to prevent possible
fumes to be inhaled.
personal injury.
7. Never leak test with compressed air or flame
1. Always wear safety goggles when doing any
testers. Tests have indicated that compressed
service work near an air conditioner system.
mixt ur e s o f HFC - 13 4 a a n d a ir c an fo rm a
Liquid refrigerant getting into the eyes can cause
combustible gas.
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: 8. Always reclaim refrigerant from the system
before removing any air conditioning component.
A. Flush your eyes with water for 15 minutes.
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.

9002-4
299L7C A22094
BELT TENSION TOOL CAS-10808 REFRIGERANT RECOVERY, RECYCLING AND CHARGING
STATION, OEM-1415
A22090
109L7
ELECTRONIC LEAK DETECTOR OEM-1437
SAFETY GOGGLES CAS-10073-3

9002-5
OPERATION
The refrigerant circuit of the air conditioning system The refrigerant, still in a high pressure liquid form,
con ta in s five major co mp on ents: comp ressor, then flows from the receiver-drier to the expansion
condenser, receiver-drier, expansion valve and valve. The expansion valve then causes a restriction
evaporator. These components are connected by in flow of refrigerant to the evaporator core. The
tubes and hoses and operate as a closed system. 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
The air conditioner system is charged with HFC-134a evaporator heat load.
refrigerant.
As the refrigerant flows through the evaporator core,
The compressor receives the refrigerant as a low the refrigerant is heated by the air around and
pressure gas. The compressor then compresses the flowing through the evaporator fins. The combination
refrigerant and sends it in the form of a high pressure of increased heat and decreased pressure causes
gas to the condenser. The air flow through the the air flow through the evaporator fins to become
condenser then removes t he heat from the very cool and the liquid refrigerant to become a low
refrigerant. As the heat is removed the refrigerant pressure gas. The cooled air then passes from the
changes to a high pressure liquid. evaporator to the cab for the operator’s comfort.
The high pressure refrigerant liquid then flows from The electrical circuit of the air conditioning system
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 consists of a fan speed control,one (1) relay, a blower
receiver-drier is a container filled with moisture motor, blower resistor, A.C.compressor clutch, A.C.
removing material, which removes any moisture that low pressure switch, A.C. high pressure switch.
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 3. COMPRESSOR 5. RECEIVER-DRIER

2. EVAPORATOR 4. CONDENSER

9002-6
TROUBLESHOOTING
Perform a visual inspection of the machine. Check 5. - Are there heavy accumulations of oil, or oily
the following and correct as necessary: dust around the fittings, indicating refrigerant
leakage?
1. - Obtain service history if possible.
6. - Are air ducts undamaged, sealed properly and
2. - Is compressor drive belt in place and tensioned?
in position?
3. - Are grille screens, fan blades, condenser, air filter, and
7. - Condensate drain hoses and check valves
evaporator unobstructed?
present and unobstructed?
4. - Are there any sharp bends or kinks in the
hoses?
Problem: No Cooling
Mechanical - See Mechanical Compressor
No Check Page 8
Compressor Runs
Electrical - See Blower and Compressor
Clutch Check Page 9
Yes
Internal System Problem

See Pressure Testing, Page 13

9002-7
Problem: Problem:
Not Enough Cooling Erratic Cooling
MECHANICAL
See Mechanical Compressor Check Page 8.

HEATER
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
See Pressure Testing, Page 13. INTERNAL SYSTEM PROBLEM
See Pressure Testing, Page 13.

9002-8
SYSTEM CHECKS
Mechanical Compressor Check

1. Too much belt wear - replace a worn belt,
Compressor and Fan Belts because a worn belt will cause too much
slippage.
1. Loose bracket mounting bolts - tighten the

bolts to the correct torque.
Compressor Mounting Brackets 2. Bracket has cracks or breaks - replace the
bracket.
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
Compressor Clutch 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.
1. The compressor pulley and the

compressor drive pulley must be aligned
within 1.6 mm (1/16 inch) of each other.
Pulley and Belt Alignment 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.

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.
1. See Section 4002 and check the high and

Low and High Pressure Switches low pressure switches.
Blower Fuse (20 amp) 1. Check for damaged blower fuse.
1. Check switch operation. Switch must give

four different blower speeds: OFF, Low
Medium and High.
Blower Fan Switch 2. Check for loose connections or broken
wires. Repair or replace as necessary.
3. Check resistor board.
1. Check the wiring to the blower motor.

Make repairs or replace items as
necessary.
Blower Motor

9002-10
Cab Temperature Check

1. Make sure louvers and recirculation vents are fully open
for most efficient air conditioning operation. Defrost
Air Louvers 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 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.

9002-11
Visual and Leak Check

1. Make sure that all hose connections are
tight.
Compressor Hoses 2. Check hoses for bends or cracks.
Replace all hoses that have damage.
1. Shut off the engine.

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
Leak Finding Check finding tool.
1. Make sure the condenser is clean and the

seals are in place.
Condenser

9002-12
Evaporator/Heater Core Check

Make sure heater valve is closed
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
Evaporator/Heater Core 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.
1. See Section 9004 for access to the

evaporator/heater core.
2. Make sure seals are in place so blower
Evaporator/Heater Core Sealing 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.

9002-13
PRESSURE TESTING
Manifold Gauge Set During normal operation the low pressure gauge
must always indicate from 10 to 35 psi (0.7 to 2.4
NOTE: The gauge set is not accurate enough to bar) after the system has run 10 to 15 minutes.
optimize an existing charge of HFC-134a. The best
use of the gauge set is to determine whether HIGH PRESSURE GAUGE - The high pressure
undercharge or overcharge exists, and then gauge is used to indicate pressures in the high side
evacuate, reclaim and recharge system with the of the system. The gauge must indicate from 0 to 400
recommended quantity (charge) of HFC-134a. psi (0 to 27.6 bar) minimum.
The manifold gauge set is the most important tool During normal operation, the high pressure gauge
used to service the air conditioning system. The will normally indicate from 120 to 310 psi (8.3 to 21.4
manifold gauge set is used to measure the high and bar). See pressure-temperature chart on page 14.
low pressures of the system, as a tool to troubleshoot
for correct refrigeran t charge quantity, system Pressure Test Connection
diagnosis, and operating efficiency. The manifold
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
gauge set can read both the high (discharge) and low
conditioning system as shown. Make sure that both
(suction) sides at the same time, since pressure must
valves in the manifold gauge set are closed.
be compared in order to make a diagnosis of system
operation.
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.
Bur 6-75390 Issued 8-01 Printed in Brazil

9002-14
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 12 145 to 165 55 (14)

(0.62 to 0.83) (10 to 11.53)
90 (32) 11 to 15 190 to 210 61 (18)
(0.76 to 1.04) (13.10 to 14.48)
95 (35) 16 to 18 210 to 230 63 (20)
(1.10 to 1.24) (14.48 to 15.86)
100 (38) 17 to 19 235 to 255 66 (22)
(1.17 to 1.31) (16.2 to 17.58)
105 (41) 20 to 21 260 to 280 68 (23)
(1.38 to 1.45) (17.93 to 19.31)
110 (43) 22 to 24 290 to 310 72 (25)
(1.93 to 2.14) (20 to 21.37)
The pressure-temperature chart is based on the 2. All panels and access doors installed and closed.
following conditions:
3. Cab filters clean and installed.
NOTE: High humidity will cause higher air louver
4. Heater valve at engine closed.
temperatures and dramatic increase in suction
pressure. The table shown represents readings 5. Measurements taken 15 minutes after startup.
taken in low relative humidity. Adjust the chart
according to local conditions.
1. Engine at 1500 RPM, no load, fan speed &
temperature control at max setting, A/C switch
ON, all louvers and doors open
QUICK REFERENCE TROUBLESHOOTING CHART
PROBLEM LOW PRESSURE HIGH PRESSURE SEE

GAUGE GAUGE 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

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
BD00N030
to rise to a pressure that could cause the
system to explode. SM104A 1. BLOWER FAN SWITCH
2. A/C TEMPERATURE CONTROL
Start the engine and run at 1500 RPM maximum
STEP 2
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
Connect the hose from the test gauges to the
minutes with the cab door open. Observe the test
service ports by turning the knurled knobs
gauges and check the chart on page 13 against the
on the depressors.
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.
6-75390 Issued 8-01 Printed in Brazil.

9002-16
PROBLEM: NO COOLING
VERY LOW VERY LOW
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
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 4. Check level of oil in compressor - possible
Yes
rapidly after start-up. 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 test for other

possible problems.

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.
4. Remove and check condenser for restrictions

A. Liquid line (between evaporator and
caused by oil or reduced heat transfer.
condenser) is very hot.
A. Remove refrigerant from the system. See
B. Discharge air from evaporator warm.
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier.
D. Remove moisture and charge the system. See
section 9003.
5. Continue the performance test for other possible

problems.

9002-18
Expansion Valve Malfunctioning - Indications:

A. Discharge air from heater/evaporator
warm.
B. Much condensation on suction hose at See Section 9004 and replace the expansion
compressor. valve.
C. Much condensation on evaporator
outlet.
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
Refrigerant Contamination
table represent the boiling point for HFC-134a.
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) 45 (3.1)
55 (13) 51 (3.5)
60 (16) 57 (3.9)
65 (18) 64 (4.4)
70 (21) 71 (4.9)
75 (24) 78 (5.4)
80 (27) 88 (6.1)
85 (29) 95 (6.6)
90 (32) 104 (7.2)
95 (35) 114 (7.9)
100 (38) 124 (8.6)
102 (39) 129 (8.9)
104 (40) 133 (9.2)
106 (41) 138 (9.5)
108 (42) 142 (9.8)
110 (43) 147 (10.1)
112 (44) 152 (10.5)
114 (46) 157 (10.8)
116 (47) 162 (11.2)
118 (48) 167 (11.5)
120 (49) 172 (11.9)

9002-19
PROBLEM: NOT ENOUGH COOLING
NORMAL TO NORMAL TO
SLIGHTLY HIGH 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 4. Replace receiver-drier.
only a little cool.
5. Check compressor oil level.
6. Remove air and moisture from the system.
See Section 9003.
Section 9003.

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 3. Repair system leaks as needed.

cool or warm - not cold.
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
1. Discharge refrigerant from system-restriction in
only a little cool.
receiver-drier or liquid line must be removed.
B. Condensation or frost on
2. Remove and replace part with restriction.
receiver-drier.
3. Remove air and moisture from the system. See
C. Liquid line to receiver-drier cool, with
Section 9003.
frost or condensation.
4. Charge system with new refrigerant. See Section
NOTE: The frost will form downstream
9003.
from or at the point of the restriction

9002-21
Expansion Valve Not Operating - Indications:

1. Expansion valve outlet with condensation or frost is
A. Discharge air from evaporator warm an indication of a restriction in the expansion valve.
or cool - not cold. Replace expansion valve. See Section 9004.
B. Condensation or frost on expansion 2. Inlet end of expansion valve is warm (not hot),
valve outlet. indicating expansion valve is not completely open.
C. Inlet end of expansion valve is If the valve is stuck closed, there will be little or no
warm. flow of refrigerant through the valve. Replace
expansion valve. See Section 9004.

9002-22
HIGH LOW
476L7
SEE THE PRESSURE - TEMPERATURE CHART ON PAGE 14
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 1. Replace expansion valve. See Section 9004.

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. Add specified refrigerant charge(1450+- 50g).
B. Discharge air from evaporator warm.
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.
2. Replace receiver-drier.
Warm discharge air from evaporator. 3. Remove air and moisture from the
Section 9003.

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. 3. Remove air and moisture from the
NOTE: The time needed to remove a large
amount of moisture will be two to three hours
minimum.

Section 9003.

9002-25
PROBLEM: NOISE IN SYSTEM
NORMAL
HIGH
TO HIGH
476L7
Too Much Refrigerant in System - Indications:

1. Remove all refrigerant from system.
See section 9003.
A. Cool discharge air from heater/evaporator.
2. Add specified refrigerant charge (1450+-50g).
B. Compressor makes noise.
See section 9003.
.

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 7/8-18 1-14
OR OR
3/4-16 7/8-14
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.

9003
Section
9003
AIR CONDITIONNING SYSTEM

OPERATING INSTRUCTIONS
845 - 865 - 885 Grader

Contagem, MG - Brazil ENG 6-46960 January, 2003
TABLE OF CONTENTS
OPERATING INSTRUCTIONS - AIR CONDITIONING CONTROLS LOCATION. . .. . . . . . . .. . . . . . . . . . . . . 01
AIR LOUVERS ADJUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . . . 01
EVAPORATOR FAN OPERATION. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . 01
AIR CONDITIONING SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. 02
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03
CLEAN/REPLACE AIR CONDITIONNING AIR FILTERS. . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . 04
FRESH AIR FILTERS.......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . .. . . . . . .. 04
9003-01
Air conditioning system – Graders.
Operating instructions – air conditioning controls location.

The air conditioning switch controls are located at right side of the cab (Fig. 01).
Air louvers adjust.

The air louvers (07) are located at the seat bottom area (02 louvers -feet), on the cab roof –
front side (03 louvers) and on the cab roof rear side (03 louvers).
Louvers can be adjusted in several positions (360º at horizontal axle and 50º at vertical axle).
They can be closed or opened individually.
When all of them are opened a most homogeneous temperature is obtained.
In order to cool down or heat up specific areas, some louvers should be closed, e.g.: to obtain
maximum cold or heat at the feet area, roof louvers (05) should be closed.
Evaporator fan operation.

Evaporator fan has 3 (three) speeds, which are turned on rotating switch fan clockwise (Fig.
02).

9003-02
Rotate heater valve switch clockwise (Fig. 03) to increase heat capacity.When this switch is
totally turned on anticlockwise there is no heat air.Heat capacity can be adjusted turning on this
switch on intermediary positions.
Air conditioning system operation (cold air).

Turn off heater valve (rotate heater valve switch totally anticlockwise – Fig. 03).
Turn on evaporator fan (Fig. 02) on third speed (maximum velocity). Air conditioning system
will only work if evaporator fan is turned on.
Turn on A/C switch (Fig. 04).

To adjust cold air capacity:
1) Choose evaporator fan speed (first speed for low capacity and third speed for high
capacity).
2) Adjust louvers according to your preference.
3) Mixture cold air with heat air, choosing a position for heater valve switch and a/C switch
turned on.

9003-03
4) Use recirculation function to obtain maximum cold air capacity. Turn on recirculation air
switch (Fig. 05).
NOTE : the mixture of cold air with heated air is usually meaninful on cold raining days (cold
air to defrost glasses and heat air to make a warm environment). In this case, use of heated
air will not defrost glasses.
Maintenance.
1) Daily.
- Check condenser and fresh air filter cleaning, specially at heavy duty conditions.
2) Each 250 hours.
- Clean internal air filter, with some soft Knocks (never wash it or apply pressured air
flow).
- Clean fresh air filter with some soft Knocks or apply pressured air flow on right
direction (see the arrow on finter).
- Check compressor belt tension and repair if it is necessary.
3) Each 1000 hours (before if it is necessary).
- Replace internal air filter and fresh air filter.
4) Each 2000 hours (before if it is necessary).
- Replace compressor belt.

9003-04
Clean / replace air conditioning air filters.
Internal air filter.

Remove 04 (four) nuts (Fig. 06). Remove and clean or replace filter.
Fresh air filter.

Open the cover (Fig. 07).

9003-04
Remove nuts (Fig.08). Use a 10 mm wrench.

Section
9003
9003
AIR CONDITIONER SYSTEM SERVICE
CNH Latino Ameicana Ltda.

Contagem, MG Brazil 6-42650 May, 2003
9003-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

9003-3
SPECIFICATIONS
Air conditioning system refrigerant capacity ........................................................................................ 1.6 kg (3.5 lbs)
SPECIAL TOOLS
A22094 109L7
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING SAFETY GOGGLES CAS-10073-3
STATION OEM-1415

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 3. Keep refrigerant containers in the correct upright
by an approved training and certification organization position. Always keep refrigerant containers
may service or repair motor vehicle or mobile air away from heat and sunlight. The pressure in a
conditioning systems. It is mandatory that all container will increase with heat.
refrigerant must be RECOVERED and RECYCLED
4. Always reclaim refrigerant from the system, if
when removed from a system during servicing.
you are going to weld or steam clean near the air
Refrigerant HFC-134a is the most stable and easiest conditioner system.
to work with of the refrigerants now used in air
5. Always check the temperature and pressure of
conditioning systems. Refrigerant HFC-134a does
the air conditioner system before reclaiming
not contain chlorofluorocarbons (CFC’s) which are
refrigerant and when you test the system.
harmful to the Earth’s ozone layer.
6. Dangerous gas can form when refrigerant comes
Safety procedures must be followed when working
in contact with an open flame. Never permit
with refrigerant HFC-134a to prevent possible
fumes to be inhaled.
personal injury.
7. Never leak test with compressed air or flame
1. Always wear safety goggles when doing any
testers. Tests have indicated that compressed
service work near an air conditioner system.
mixt ur e s o f HFC - 13 4 a a n d a ir c an fo rm a
Liquid refrigerant getting into the eyes can cause
combustible gas.
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: 8. Always reclaim refrigerant from the system
before removing any air conditioning component.
A. Flush your eyes with water for 15 minutes.
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.

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 STEP 3
separator and a filter-drier before entering the
refrigerant tank. The moisture indicator will turn
green when dry refrigerant passes over it.
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.

9003-6
STEP 5 STEP 7
A22112 A22110
Connect the main power plug to a 115 volt AC outlet. Slowly open the oil drain valve and drain the oil into
Move the main power switch to the ON position and the reservoir. When the oil stops draining, close the
depress the recovery start switch. oil drain valve completely.
The compressor will shut OFF automatically when
recovery is complete. Wait for 5 minutes and observe STEP 8
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 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.

9003-7
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

IMPORTANT: Replace the receiver-drier if one or Air and moisture are removed from the system by a
more of the following conditions occurs before you vacuu m pum p. A vacuum pum p is the only
remove the air and moisture from the system. equipment made to lower the pressure enough to
change the moisture to vapor that can be removed
A. The system has been opened for service
from the system.
before.
NOTE: Refer to the vacuum pump manufacturer’s
B. Receiver-drier has operated two or more
user manual for additional information.
years.
C. Disassembly of compressor shows small STEP 11
particles of moisture removing material (gold
or brown particles).
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 A22115
after the system has been opened for maintenance. Press the Charge key. “Program” and “Charge” will
Air enters the system when the system is opened. Air appear on the display.
has moisture that must be removed to prevent
damage to the system components.
NOTE: The pump on the reclamation unit will not
pull a sufficient vacuum to remove air and moisture.

9003-8
STEP 13 STEP 16
A22113 A22123
Program 3.5 lbs and press the enter key. The display Press the Vacuum key. “Automatic” will appear on
will flash once indicating the programmed data has the display. Vacuum will appear on the display and
been accepted. after a slight delay, the vacuum pump will start. The
display will show the amount of time programmed
STEP 14 and begin a countdown to zero.
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
Fully open the low and high pressure valves.
STEP 15
A22113
Press the charge key to begin refrigerant charging.

“Automatic” and “Charge” will appear on the display.
A22107 The display shows the programmed amount and
Open the red (vapor) and blue (liquid) valves on the counts down to zero as charging proceeds. When
tank. charging is completed, the display shows “CPL”.

9003-9
STEP 18 STEP 20
A22114 A22117
Completely close the high and low pressure manifold Observe the pressure gauge readings to determine
valves. that the correct amount of refrigerant has entered the
system. See chart on Page 9002-9 for temperature
ATTENTION: Check the OEM equipment manual
and pressure variations.
before performing Step 19 to avoid damaging the
recovery unit. The pressure reading should be
obtainable with valves closed. Damage may occur if STEP 21
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 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 BD01D273
compressor, the air conditioner control or blower Stop the engine, close any open valves and carefully
switch must be turned to the OFF position and then remove the manifold gauge hoses.
to the ON position.
STEP 22
BD01D251
Install the caps on the service ports on the suction

and discharge hoses.

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 12 145 to 165 55 (14)
(0.62 to 0.83) (10 to 11.5)
90 (32) 11 to 15 190 to 210 61 (18)
(0.76 to 1.04) (13.1 to 14.5)
95 (35) 16 to 18 210 to 230 63 (20)
(1.10 to 1.24) (14.5 to 15.8)
100 (38) 17 to 19 235 to 255 66 (22)
(1.17 to 1.31) (16.2 to 17.6)
105 (41) 20 to 21 260 to 280 68 (23)
(1.38 to 1.45) (17.9 to 19.3)
110 (43) 22 to 24 290 to 310 72 (25)
(1.93 to 2.14) (20 to 21.4)
The pressure-temperature chart is based on the 5. Both cab doors open

following conditions:
6. All panels and access doors installed and closed.
1. Engine operating at 1500 RPM
7. Cab filters clean and installed.
2. No engine load
8. Heater valve at engine closed.
3. Fan speed control in maximum position (full
9. Measurements taken 15 minutes after start-up.
clockwise) and all louvers open.
4. Cab temperature control set to maximum cooling
(full counterclockwise).

9004
Section
9004
REMOVAL AND INSTALLATION OF AIR CONDITIONING

COMPONENTS FOR SYSTEMS WITH 134 a REFRIGERANT
845 - 865 - 885 Grader

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.
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

9004-4
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
3.5) Remove 03 (three) bolts from evaporator housing. Use 13 mm wrench. Disconnect electrical cables and remove
evaporator housing.
ENG 6-46971 May, 2003 Printed in Brazil

9004-5
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.

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 form 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
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.

9004-7
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.
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.

9004-8
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.

9004-9
POSIÇÃO P/N DESCRIÇÃO QTY

1 75254533 EVAPORATOR BOX ....01
2 75257962 CONDENSER ....01
3 75251988 COMPRESOR .....01
4 75257955 HOSE COMPRESOR TO CONDENSER ........01
5 75257956 HOSE CONDENSER TO EVAPORATOR 01
6 75257954 HOSE EVAPORATOR TO COMPRESOR 01
7 75255522 CASE 01
8 MOTOR 01
9 CASE 01
10 BELT GX 845 01
10 BELT65/885 ...............01
11 75310261 O-RING SEAL #6 02
12 75310923 O-RING SEAL #8 02
13 75310260 O-RING SEAL #10 02
14 SCREW 03
15 WASHER 03
16 NUT 03
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.

9004-10
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.
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.

9004-11
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).

9004-12
NOTES

9007
Section
9007
REAR RIPPER
845 - 865 - 885 Grader

TABLE OF CONTENTS
REAR RIPPER 845.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . . . 01
REAR RIPPER 865 / 885 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. 02
12 9007-01
REAR RIPPER 845
* Mount the articulation plates of the connecting rods and

the tray on the rear frame
* Mount the rear tray 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 m m In. 12
SECTION
A - Internal diameter of the support 70.100 - 70.174 2.7598 - 2.7627
B - Internal diameter of the arm 60.000 - 60.046 2.3622 - 2.3640
C - Internal diameter of the frame 50.080 - 50.180 1.9716 - 1.9756
D - External diameter of the bushing 60.07 - 60.10 2.365 - 2.366
Internal diameter of the bushing 50.195 - 50.265 1.9761 - 1.9789
E - External diameter of the bolt 59.954 - 60.000 2.3604 - 2.3622
F - External diameter of the bolt 49.961 - 50.000 1.9669 - 1.9685

9007-02
Install the ripper teeth on the rear tray 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
The mounting process is similar to the one for the 845

Notice that, besides the ripper teeth, there are the scarifier
teeth.
12
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.

9009
Section
9009
FRONT BLADE & COUNTERWEIGHT
845 - 865 - 885 Grader

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 revers-
iblecutting edgesknifes, tighten the nuts with a 290 to 310 Nm
torque.
COUNTERWEIGHT845/865/885
To mount the front counterweight, put the front plate into

place and tighten the nuts.
12
SECTION

9009-02
NOTES

9010
Section
9010
Rops CAB
845 - 865 - 885 Grader

Contagem, MG - Brazil ENG 6-47031 June, 2003
9010-08
NOTES
Bur 6-47031 Revised 6-03 Printed in Brazil

9011
Section
9011
CAB GLASS INSTALLATION
845 - 865 - 885 Grader


845,865,885 Case Grader - Servicio Especiaizado y Reparacion Manual.

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845 - 865 - 885 GRADER

Fuel System Tab 3

Power Train Tab 6

Copyright © 2003 Case, LLC.

Mounted Equipment Tab 9

NOTE: CNH Latino Americana reserves the right to make improvements in

Brz 6-46513 Revised 11-03 Printed in Brazil

Section Title Section Number

CNH Latino Americana Ltda

Cross Reference Guide

Description Old Number New Number

Axle Seal Installer 75301704 380000379

Axle Seal Installer 75301705 380000380

Transmission Input Seal Installer 75310180 380000387

Transmission Oil Seal Guide 75310181 380000388

Transmission Seal Driver 75310185 380000391

Rac 6-15050 Issued 10-03

Description Old Number New Number

Seal Driver 75310190 380000397

Lifting Device 75289947 380000374

Stack Nest 75289948 380000375

Lifting Device 75289949 380000376

Stack Nest 75289950 380000377

6-15050 Issued 10-03

Description Old Number New Number

Assembly Tools 75310177 380000382

Retaining Ring Tool 75310178 380000385

Sizing Sleeve 75310179 380000386

Sleeve Installer Adapter 75310180 380000389

Bearing Installer 75310183 380000390

Rac 6-15050 Issued 10-03

Description Old Number New Number

Bearing Driver 75310187 380000393

Clutch Clearance Gauge 75310188 380000395

Aligning Sleeve 75310189 380000396

6-15050 Issued 10-03

STANDARD TORQUE SPECIFICATIONS

CNH Latino Americana Ltda

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

ENG 6-46530 ISSUE 01-03 Printed in Brazil

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

ENG 6-46530 ISSUE 01-03 Printed in Brazil

TORQUE SPECIFICATIONS - METRIC HARDWARE

M12 66 to 79 90 to 107 M30 1470 to 1770 2000 to 2400

M16 160 to 200 217 to 271

M36 1600 to 1950 2175 to 2600

ENG 6-46530 ISSUE 01-03 Printed in Brazil

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Tube OD Thread Pound- Newton Tube OD Thread Pound- Newton

Split Flange Mounting Bolts

ENG 6-46530 ISSUE 01-03 Printed in Brazil

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Thread Pound- Newton

Nom. 1-1/16-12 85 to 90 115 to 122

ENG 6-46530 ISSUE 01-03 Printed in Brazil

FLUIDS AND LUBRICANTS