Manual 865 Motoniveladora PDF

r----------------------1 r----------------------1
SERVICE MANUAL SERVICE MANUAL

Grader Grader
845 845
865 865
885 885
6-46503 6-46503
--------------------~ --------------------~
1. Trim along dashed line. b 1. Trim along dashed line. b

2. Slide into pocket on Binder Spine. 2. Slide into pocket on Binder Spine.
TYPE 1·4 TYPE 1·4
r----------------------1 r----------------------1
SERVICE MANUAL SERVICE MANUAL
Grader Grader
845 845
865 865
885 885
6-46503 6-46503
--------------------~ --------------------~
1. Trim along dashed line. b 1. Trim along dashed line. b

2. Slide into pocket on Binder Spine. 2. Slide into pocket on Binder Spine.
TYPE 1·4 TYPE 1·4
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

Section
1003
METRIC CONVERSION CHART
Copyright© 2004 CNH America LLC.

CNH America LLC. All rights reserved.
245 E NORTH AVENUE Printed in U.S.A.
CAROL STREAM, IL 60188 U.S.A. Bur 6-46550 Issued January, 2004
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
4002
ELECTRICAL DIAGRAM
845- 865- 885 Grader

Contagem, MG- Brazil ENG 6-46621 May,2003
4002
DESCRIPTION .................................................................................................................. PAGE
BATTERY 12V ................................................................................................................................................ 01-01

BATTERY 12V ................................................................................................................................................ 01-01
ALTERNATOR24 VOLTS 70AMP ................................................................................................................ 01-02
INSTRUMENT ELETRONIC PANEL ................................................................................................................... 06
ELECTRONIC DATA MONITOR ......................................................................................................................... 07
ANALOGIC HOURMETER ................................................................................................................................. 08
DISPLAY GEAR/DIAGNOSTIC ....................................................................................................................... 18-01
MASTERSWITCH ......................................................................................................................................... 01-01
IGNITION SWITCH ........................................................................................................................................ 02-01
WORK LIGHT SWITCH .................................................................................................................................. 02-04
FLOOD/HEAD LIGHTS, HORN AND TURN SIGNAL SWITCH ....................................................................... 09-05
WARNING FLASHER SWITCH ...................................................................................................................... 10-01
REAR FLOOD LIGHTS SWITCH .................................................................................................................... 10-02
CAB HEAD LIGHTS SWITCH ...................................................................................................................... 10-04
FRONT BLADE BOARD ................................................................................................................................ 10-05
BRAKE LIGHT SWITCH ................................................................................................................................ 05-04
ENGINE OIL PRESSURE SENSOR AND SWITCH ......................................................................................... 06-02
ENGINE COOLANT TEMPERATURE SENSOR .............................................................................................. 06-04
TRANSMISSION OIL PRESSURE SENSOR .................................................................................................. 06-04
TRANSMISSION OIL TEMPERATURE SENSOR ........................................................................................... 06-05
FUEL SENSOR LEVEL ................................................................................................................................... 06-05
ENGINE COOLANT TEMPERATURE SWITCH .............................................................................................. 07-01
AIRCLEANERSWITCH ................................................................................................................................ 07-01
TRANSMISSION OIL FILTER RESTRICTION SWITCH .................................................................................. 07-02
TRANSMISSION OIL PRESSURE SWITCH ................................................................................................... 07-02
TRANSMISSION OIL TEMPERATURE SWITCH ............................................................................................ 07-03
HYDRAULIC OIL TEMPERATURE SWITCH .................................................................................................. 07-04
BRAKE PRESSURE SWITCH ........................................................................................................................ 07-04
MACHINE SPEED SENSOR .......................................................................................................................... 07-05
HYDRAULIC OIL FILTER RESTRICTION SWITCH ........................................................................................ 07-06
DIFFERENTIAL LOCK SWITCH OPTIONAL .................................................................................................. 08-02
STARTING AID SWITCH OPTIONAL ............................................................................................................. 08-02
SADDLE LOCK PIN SWITCH ......................................................................................................................... 08-06
RIPPER OR SCARIFIER SWITCH OPTIONAL ............................................................................................... 09-03
MOLDBOARD FLOAT L.H. SWITCH OPTIONAL ......................................................................................... 10-03
MOLDBOARD FLOAT R.H. SWITCH- OPTIONAL ........................................................................................ 10-04
LIFT SHOCK DAMPENER SWITCH- OPTIONAL .......................................................................................... 11-03
FRONT BLADE BOARD FLOAT SWITCH- OPTIONAL ................................................................................. 12-02
LEFT CAB DOME LIGHT ............................................................................................................................... 12-03
RIGHT CAB DOME LIGHT ..............................................................................................................................12-04
STROBE LIGHT SWITCH OPTIONAL ............................................................................................................ 12-04
FRONT WIPER SWITCH .............................................................................................................................. 13-02
FRONT WASHER PUMP SWITCH ................................................................................................................. 13-04
REAR WIPER SWITCH ................................................................................................................................. 13-05
REAR WASHER PUMP SWITCH ................................................................................................................... 14-01
FRONT LOWERWIPERANDWASHERSWITCH ......................................................................................... 14-04
FANS SWITCH- OPTIONAL ........................................................................................................................... 14-06
ENG 6-46621 May,2003 Printed in Brazil

4002
HIGH PRESSURE SWT. TO AIR CONDITIONER ........................................................................................... 15-03

3 SPEED SWITCH TO FANS AIR CONDITIONER SYSTEM- OPTIONAL ...................................................... 15-03
AIR CONDITIONER SWITCH- OPTIONAL .................................................................................................... 15-03
MOTOR DAMPER SWT. TO AIR CONDITIONER SYSTEM- OPTIONAL ...................................................... 15-06

FRONT WHEEL DRIVE SWITCH ................................................................................................................... 17-03
TRACTION CONTROL SWITCH .................................................................................................................... 17-05
BUMP GEAR SELECTOR .............................................................................................................................. 18-03
PARKING BRAKE SWITCH .......................................................................................................................... 18-07
LIMP HOME SWITCH ................................................................................................................................... 18-10
ENGINE SPEED MAGNETIC PICKUP SENSOR ............................................................................................. 18-11
OUTPUT SPEED MAGNETIC PICKUP SENSOR ............................................................................................ 18-11
CYLINDER SPEED MAGNETIC PICKUP SENSOR ........................................................................................ 18-12
TEMPERATURE SENSOR- TRANSMISSION FUNK ...................................................................................... 18-12
MAXI FUSE 80 AMP TO PROTECTION ALTERNATOR ................................................................................. 01-02

MAXI FUSE 80 AMP TO MASTER PROTECTIONCIRCUITS OF THE MACHINE .......................................... 01-03
AUXILIARY FUSE 7,5 AMP TO POSITION LIGHTS R.F.B.L.R. AND INSTRUMENTS LIGHT.. ....................... 03-02
AUXILIARY FUSE 5,0 AMP TO POSITION LIGHTS LEFT FRONT 8 RIGHT REAR ........................................ 03-03
SOLENOID TO ELECTRICAL ENGINE SHUT OFF ......................................................................................... 01-06

DIFFERENTIAL LOCK SOLENOID VALVE- OPTIONAL ................................................................................ 08-02
STARTING AID SOLENOID VALVE- OPTIONAL ........................................................................................... 08-04
SADDLE LOCK PIN SOLENOID VALVE ......................................................................................................... 08-06
RIPPER OR SCARIFIER SOLENOID VALVE LEFT OPTIONAL ...................................................................... 09-02
RIPPER OR SCARIFIER SOLENOID VALVE LEFT- OPTIONAL ................................................................... 09-03
RIPPER OR SCARIFIER SOLENOID VALVE RIGHT- OPTIONAL ................................................................. 09-05
RIPPER OR SCARIFIER SOLENOID VALVE RIGHT- OPTIONAL ................................................................ 09-06
MOLDBOARD FLOAT SOLENOID VALVE LEFT- OPTIONAL ....................................................................... 10-01
MOLDBOARD FLOAT SOLENOID VALVE LEFT- OPTIONAL ....................................................................... 10-01
MOLDBOARD FLOAT SOLENOID VALVE RIGHT- OPTIONAL ..................................................................... 10-04
MOLDBOARD FLOAT SOLENOID VALVE RIGHT- OPTIONAL ..................................................................... 10-01
CENTER LIFT CYLINDER ANTI-SHOCK SOLENOID VALVE-OPTIONAL ....................................................... 11-01
CENTER LIFT CYLINDER ANTI-SHOCK SOLENOID VALVE-OPTIONAL ....................................................... 11-02
LEFT LIFT CYLINDER ANTI-SHOCK SOLENOID VALVE-OPTIONAL ............................................................. 11-03
LEFT LIFT CYLINDER ANTI-SHOCK SOLENOID VALVE-OPTIONAL ............................................................. 11-04
RIGHT LIFT CYLINDER ANTI-SHOCK SOLENOID VALVE-OPTIONAL ........................................................... 11-05
RIGHT LIFT CYLINDER ANTI-SHOCK SOLENOID VALVE-OPTIONAL ........................................................... 11-05
FRONT BLADE BOARD FLOAT SOLENOID VALVE- OPT ............................................................................ 12-02
FRONT BLADE BOARD FLOAT SOLENOID VALVE- OPT ............................................................................ 12-02
DUAL POWER SOLENOID VALVE P-OPTIONAL ......................................................................................... 16-02
SOLENOID FRONT WHEEL DRIVE ON/OFF- OPTIONAL ............................................................................ 17-08
SOLENOID FRONT WHEEL DRIVE HALF VOLUME-OPTIONAL ................................................................... 17-09
SOLENOID FRONT WHEEL DRIVE REVERSE- OPTIONAL .......................................................................... 17-11
SOLENOID FRONT WHEEL DRIVE FRONT- OPTIONAL .............................................................................. 17-12
PROPORT. AND DIRECTIONAL SOLENOID VALVE 1 ................................................................................... 18-09

4002
PROPORT. AND SPEED SOLENOID VALVE A .............................................................................................. 18-09

PROPORT. AND SPEED SOLENOID VALVE B .............................................................................................. 18-10
PROPORT. AND SPEED SOLENOID VALVE C .............................................................................................. 18-10
PROPORT. AND SPEED SOLENOID VALVED .............................................................................................. 18-11
VARISTOR TO FLASHER AND TURN SIGNAL RELAY .................................................................................. 03-06

VARISTOR TO DIFFERENTIAL LOCK SONELOID VALVE- OPT ......................................................................... 08-02
VARISTOR TO STARTING AID SOLENOID VALVE- OPT ............................................................................... 08-03
VARISTOR TO SADDLE LOCK PIN SOLENOID VALVE ................................................................................. 08-05
VARISTOR TO RIPPER OR SCARIFIER SOLENOID VALVE LEFT- OPT ........................................................ 09-01
VARISTOR TO TO RIPPER OR SCARIFIER SOLENOID VALVE LEFT-OPT ................................................... 09-02
VARISTOR TO TO RIPPER OR SCARIFIER SOLENOID VALVE RIGHT ........................................................ 09-04
VARISTOR TO TO RIPPER OR SCARIFIER SOLENOID VALVE RIGHT ........................................................ 09-05
VARISTOR TO TO MOLDBOARD FLOAT SOLENOID VALVE LH-OPT .......................................................... 10-01
VARISTOR TO TO MOLDBOARD FLOAT SOLENOID VALVE RH-OPT .......................................................... 10-02
VARISTOR TO TO MOLDBOARD FLOAT SOLENOID VALVE RH-OPT ........................................................ 10-04
VARISTOR TO TO MOLDBOARD FLOAT SOLENOID VALVE RH-OPT .......................................................... 10-05
VARISTOR TO CENTER LIFT CYLINDER ANTI-SHOCK SOLENOID VALV.................................................... 11-01
VARISTOR TO CENTER LIFT CYLINDER ANTI-SHOCK SOLENOID VALV.................................................... 11-02
VARISTOR TO LEFT LIFT CYLINDER ANTI-SHOCK SOLENOID VALVE ........................................................ 11-03
VARISTOR TO LEFT LIFT CYLINDER ANTI-SHOCK SOLENOID VALVE ........................................................ 11-04
VARISTOR TO RIGTH LIFT CYLINDER ANTI-SHOCK SOLENOID VALVE ..................................................... 11-05
VARISTOR TO RIGTH LIFT CYLINDER ANTI-SHOCK SOLENOID VALVE ..................................................... 11-06
VARISTOR TO FRONT BLADE BOARD FLOAT SOLENOID VALVE .............................................................. 12-01
VARISTOR TO FRONT BLADE BOARD FLOAT SOLENOID VALVE .............................................................. 12-02
VARISTOR TO MAGNETIC GLUTH/COMPRESSOR- OPT............................................................................ 15-01
VARISTOR TO DUAL POWER SOLENOID VALVE- OPT.............................................................................. 16-02
VARISTOR TO SOLENOID FWD HALF VOLUME- OPT................................................................................ 11-05
VARISTOR TO SOLENOID FWD FRONT- OPT ............................................................................................. 11-06
DIODE TO COIL PROTECTION OF THE AUXILIARY MAGNETIC ENGINE START .......................................01-03

DIODE TO COIL PROTECTION OF THE SOLENOID ENGINE SHUT-OFF(PULL) ........................................... 01-05
DIODE TO COIL PROTECTION OF THE SOLENOID ENGINE SHUT-OFF(PULL) ........................................... 01-06
DIODE TO PROTECT ENGINE SHUT-OFF .....................................................................................................06-06
DIODE TO NEUTRAL POSITION TO START .................................................................................................. 18-06
DIODE TO PARKING BRAKE APPLIED ......................................................................................................... 18-07
DIODE BOX- LATERAL CONSOLE ................................................................................................................... 16
HORN ............................................................................................................................................................ 03-01
BUZZER ......................................................................................................................................................... 07-05
BACK-UP ALARM- OPTIONAL .................................................................................................................... 05-05
BACK-UP ALARM- STRADALE -OPTIONAL ................................................................................................ 05-06
RIGHT WORK LIGHT BEFORE MOLDBOARD .............................................................................................. 02-05
LEFT WORK LIGHT BEFORE MOLDBOARD ................................................................................................ 02-05
RIGHT WORK LIGHT AFTER MOLDBOARD ................................................................................................. 02-06
LEFT WORK LIGHT AFTER MOLDBOARD ................................................................................................... 02-06
FRONT POSITION LIGHT L.H ........................................................................................................................ 02-02

4002
REAR POSITION LIGHT R.H ......................................................................................................................... 02-02

REAR POSITION LIGHT R.H.- OPTIONAL .....................................................................................................02-03
REAR TURN SIGNAL LIGHT- OPTIONAL ......................................................................................................03-03
FRONT TURN SIGNAL R.H.CAB ................................................................................................................... 03-03
REAR TURN SIGNAL LIGHT R.H .................................................................................................................. 03-03
FRONT TURN SIGNAL R.H ........................................................................................................................... 03-04
FRONT TURN SIGNAL L.H ............................................................................................................................ 03-04
REAR TURN SIGNAL LIGHT L.H ................................................................................................................... 03-04
FRONT TURN SIGN LA R.H.CAB ................................................................................................................... 03-05
REAR TURN SIGNAL LIGHT L.H. STRADALE ............................................................................................... 03-05
LEFT HEAD LIGHT (HIGH BEAM) ................................................................................................................ 04-01
RIGHT HEAD(HIGH BEAM) ........................................................................................................................... 04-02
LEFT HEAD LIGHT (LOW BEAM) .................................................................................................................. 04-01
RIGHT HEAD(LOW BEAM) ........................................................................................................................... 04-02
FRONT POSITION LIGHT R.H ....................................................................................................................... 04-03
REAR POSITION LIGHT L.H .......................................................................................................................... 04-04
LICENSE PLATE LIGHT- OPTIONAL ............................................................................................................. 04-04
REAR POSITION LIGHT L.H.- OPTIONAL STRADALE ................................................................................. 04-04
LICENSE PLATE LIGHT- OPTIONAL STRADALE ....................................................................................... 04-05
REAR FLOOD LIGHT L.H.OPTIONAL STRADALE ......................................................................................... 04-05
REAR FLOOD LIGHT R.H. OPTIONAL STRADALE ....................................................................................... 04-05
REAR FLOOD LIGHT L.H. (CAB) ................................................................................................................... 04-06
REAR FLOOD LIGHT R.H. (CAB) .................................................................................................................. 04-06
FRONT BLADE BOARD LIGHT L.H. OPTIONAL ........................................................................................... 05-01
FRONT BLADE BOARD LIGHT R.H. OPTIONAL ........................................................................................... 05-01
BRAKE LIGHT L.H ......................................................................................................................................... 05-04
BRAKE LIGHT R.H ........................................................................................................................................ 05-04
BRAKE LIGHT L.H .. OPTIONAL STRADALE .................................................................................................. 05-04
BRAKE LIGHT L.H .. OPTIONAL STRADALE .................................................................................................. 05-04
DASH LIGHT- LATERAL PANEL ................................................................................................................... 06-01
DASH LIGHT LATERAL PANEL ...................................................................................................................... 06-02
REAR LEFT STROBE LIGHT PANEL .............................................................................................................. 12-04
FRONT RIGHT STROBE LIGHT- OPTIONAL ................................................................................................. 12-06
RESISTOR 910 OHMS 1/2 WATT .................................................................................................................. 06-04
RESISTOR 5 OHMS 100 WATTTS TO EXCITE ALTERNATOR .............................................................. 06~06
CIGARETTE LIGHTER 12 VOLTS .................................................................................................................. 19-02
ENGINE START .............................................................................................................................................. 01-03

FRONT WIPER .............................................................................................................................................. 13-02
FRONT WASHER PUMP ............................................................................................................................... 13-04
REAR WIPER ................................................................................................................................................ 13-05
REAR WASHER PUMP ................................................................................................................................. 14-01
FRONT LOWER WASHER PUMP- OPTIONAL ............................................................................................. 14-02
FRONT LOWER WIPER- OPTIONAL ........................................................................................................... 14-04
AIR SUSPENSION SEAT-OPTIONAL ............................................................................................................. 14-05
FAN L.H. ONLY OPEN CAB- OPTIONAL ...................................................................................................... 14-06
FAN R.H. ONLY OPEN CAB- OPTIONAL ..................................................................................................... 14-06
MOTOR DAMPER TO AIR CONDITIONER ................................................................................................... 15-05

4002
EVAPORATOR UNIT OPTIONAL AIR CONDITIONER ................................................................................... 15-03

ELECTRIC MAGNETIC GLUTH I COMPRESSOR OPTIONAL AIR CONDITIONER ....................................... 15-02
ELECTRONIC UNIT TRANSMISSION FUNK ...................................................................................................... 18
INCH PEDAL FUNK TRANSMISSION ............................................................................................................ 18-02
TRANSIENT VOLTAGE PROTECTION .............................................................................................................18-01

AUXILIARY MAGNETIC SWITCH TO START ENGINE ....................................................................................01-04
AUXILIARY MAGNETIC SW.TO ENGINE SHUT OFF ..................................................................................... 01-04
ELECTRONIC UNIT FRONT WHEEL DRIVE .................................................................................................. 17-05
FLASHER AND TURN SIGNAL RELAY ......................................................................................................... 03-06
ELECTRONIC STROBE LIGHT-OPTIONAL .................................................................................................... 12-05
CONVERTER VOLTAGE TO RADIO AND CIGARETTE LIGHTER 24/12 VOLTS MAX 10,0 AMP .................... 19-02
RADIO ........................................................................................................................................................... 19-04
SPEAKER L.H ................................................................................................................................................ 19-04
SPEAKER R.H ............................................................................................................................................... 19-04
ANTENNA RADIO ..........................................................................................................................................19-03
DERIVATION BOX (NEAR ENGINE)

01-03
DERIVATION BOX(IN THE LATERAL CONSOLE)
02-03
POWER PLUG 24 VOLTS MAX 10.0 AMP
16-01
DIAGNOSE CONNECTOR FRONT WHEEL DRIVE
17-03
WIRE COLORS TABLE
A ........................................................................ BLUE
B ...................................................................... WHITE
C ..................................................................... ORANGE
V ...................................................................... GREEN
G ..................................................................... YELLOW
H ....................................................................... GRAY
L. ................................................................. DARK BLUE
M .................................................................... BROWN
N ...................................................................... BLACK
R ........................................................................ RED
S ........................................................................ PINK
Z ..................................................................... PURPLE

4002-01
PAGE 01
DERIVATION BOX
(NEAR ENGINE)
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POWER SUPPLY MAGNETIC SWITCH MAGNETIC SWITCH
1 2 3 4 5 6
ENG 6-46621 May, 2003 Printed in Brazil

4002-02
CASE PAGE 02
IGNITION SWITCH DERIVATION BOX WORK LIGHT SWITCH

(IN THE LATERAL CONSOLE)
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1 I 2 3 4 5 I 6

4002-03
~.A PAGE 03
FLOOD/HEAD LIGHTS, HORN

BAT AND TURN SIGNAL SWITCH
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WARNING FLASHER SW. VARISTOR
1 I 2 I 3 I 4 5 6

4002-04
PAGE 04
HEAD LIGHT INSTRUMENTS AND SWITCH

RELAYS LIGHTS - CIRCUIT 49
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LOW BEAM PLATE LIGHTS
1 2 3 4 5 6

4002-05
CASE PAGE 05
CAB HEAD FRONT BLADE BRAKE LIGHT BACK-UP ALARM

BAT IFB SWITCH BOARD SWITCH SWITCH RELAY IFB
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31
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--_l_ NB
FRONT BLADE BRAKE LIGHT BACK-UP ALARM
CAB HEAD BOARD LIGHTS
LIGHTS
1 2 3 4 5 6

4002-06
PAGE 06
BAT IF"B IF"B

F"L 7.1
ACC 12 F"L 7.1
IGN 13 F"L 7.1

ST 21 F"L 7.1
49 49 F"L 7.1
C!
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OL
NB
ENGINE OIL PRESSURE TRASMISSION OIL FUEL SENSOR RESISTOR
SENSOR/SWITCH PRESSURE SENSOR LEVEL
DASH LIGHT ENGINE COOLANT TRANSMISSION OIL
TEMP. SENSOR TEMPERATURE SENSOR
1 2 3 4 5 6

4002-07
CASE PAGE 07
BAT ~IF~B______________E_L_EC_T_R_O_NI_C_D_A_T_A_M_O_N_IT_O_R______________________~~
ACC 12 ------------------------------------------------------~~
~
~------------------------------------------------------~~
IGN 13
ST ~2~~------------------------------------------------------~~
49
.,g
30 ... N 40H
FL 3-31J1o
RNI.O A BCI.O
a
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FL 6-2 IJio 31 p
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OL
NB TRANSM. OIL FILTER HYDRAULIC OIL MACHINE SPEED HYDRAULIC OIL F.
RESTRICTION SW. TEMP. SWITCH SENSOR RESTRICTION SW.
ENGINE -
COOLANT AIR CLEANER TRANSM. OIL TRANSM. OIL BRAKE PRESS. BUZZER
TEMP. SW. SWITCH PRESS. SW. TEMP. SW. SWITCH
1 2 3 4 5 6

4002-08
CASE PAGE 08
DIFFERENTIAL
LOCK RELAY -OPC. STARDING AID SADDLE LOCK
BAT~IF~e~----------------e---------------------~S~W~IT~C~H~-~O~P~C·~---P~I~N~S~W~I~T~CH~--~~
ACC~I~2------------------~--------------------------------------~----------=-·
IGN~1~3------------------~---------------------------------------r----------~·
ST~2~~------------------~------------------~-------------------r----------~·
49~-----------------+----------.-----~-----------.------+---------~~
0 "!
...- a:C!-
al
N ffi "'- u>
FL 7-2
FLIS-5
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~ '!: 3
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OL
NB
DIFFERENTIAL VARISTOR VARISTOR
VARISTOR LOCK SOL.VALVE STARTING AID SADDLE LOCK PIN
ANALOGIC SOLENOID VALVE SOLENOID VALVE
HOUR METER
2 3 4 5 6

4002-09
PAGE 09
RIPPER OR SCARIFIER SWITCH - OPC.

BAT~lr~B------------------------------------------------------------------------~~
ACC~I2~------------------------------------------------------------------------~~
IGN~I~~----------------------------------~------------------------------------~~
ST~2~•------------------------------------------------------------------------~~
~--------------------------------------------------------------------------~~
80 OPC.
FL 8.6
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---_ . r-e~~~~~~---------------------------------------------------------------
__L RIPPER OR SCARIFIER RIPPER OR SCARIFIER
SOLENOIDS VALVES-LEFT SOLENOIDS VALVES-RIGHT
VARISTOR VARISTOR VARISTOR VARISTOR
2 3 4 5 6

4002-10
PAGE10
RIPPER OR SCARIFIER SWITCH - OPC.

BAT_,_IF,_,B,___ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _"""'-... FL ll.l
ACC 12 FL ll.l
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ST ...J2!;!.1_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _..§L.. . FL 11.1
49 FL 11.1
80 OPC. 80 OPC.
FL 9.6 r-------..:..::::~;.;__· FL II. I
ZI.O ZI.O ZI.O
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__B_OA_R_D_F_L_OA_T______________
SOLENOIDS VALVES-LEFT SOLENOIDS VALVES-RIGHT
VARISTOR VARISTOR VARISTOR VARISTOR
2 3 4 5 6

4002-11
CASE PAGE11
LIFT SHOCK DAMPENER SWITCH - OPC.

BAT~I~>B~--------------------------------------------------------------~~
ACC-=12________________________________________________________________-=_.
IGN~13----------------------------------------------------------------~-.
FT
~-----------------------------------------------------------------=-.
49 49
f'L IO.& .____::.;BO:._O:::..P..:;C·:..___________;________________,
ZI.O
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LIFT SHOCK DAMPENER SOLENOIDS VALVES AND VARISTORS
2 3 4 5 6

4002-12
PAGE12
FRONT BLADE BOARD

BAT IFB FLOAT SWITCH-OPC. DOME LIGHT
~~--------------~------------------------------------~------~·
ACC~,~----------------------------------------------------4-----~~
IGN~I3______________________________________________________~------~·
ST~z•------------------------------------------------------4-------~•
49~4~9~----------------------------------------------------4---~._~.
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FRONT BLADE BOARD REAR LEFT FRONT RIGHT

FLOAT SOLENOIDS VALVES STROBE LIGHT STROBE LIGHT
ELECTRONIC
VARISTOR VARISTOR BEACON LIGHT
1 2 3 4 5 6

4002-13
PAGE13
FRONT WIPER FRONT WASHER REAR WIPER

BAT~~F~s ___________s_w_IT_c_H_________________P_u_MP__s_w_IT_c_H_____________s_w_IT_c_H____~1 F~a4 FL 1~.1
ACC~IZ~------------------------------------------~--------------------~12~~ FL 1~.
IGN~I~l+---------------------------------------------~--------------------~13_.: FL 1~.
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FRONT WIPER FRONT WASHER PUMP REAR WIPER
1 2 3 4 5 6

4002-14
PAGE14
REAR WASHER FRONT LOWER

IFB PUMP SWITCH WIPERS SWITCH FANS SWITCH IFB
--"'-"-------------------------------"~ FL 15.1
--'12::..,__ _ _ _ _ _f - - - - - - - - - - - - - - - - - - - - - - - - - - - - - = 1 2 - + . , . FL 15.1
_:,ll"--------t-------------------+-------!.:!
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4 .:L
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FRONT LOWER FRONT LOWER AIR SUSPENSION SEAT FANS ONLY
REAR WASHER WASHER PUMP WIPERS OPEN CAB
PUMP
2 3

4002-15
PAGE15
ELEC.MAGNETIC FANS SWITCH

BAT ~~F~a_____ c_L_u_Tc_H__R_EL_A_Y____
3_s_P_EE_o________________________________________~~
ACC ~IL2--------------------------------------------------------------~-.
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ELECTRIC MAGNETIC EVAPORATOR UNIT MOTOR DAMPER/SWITCH

VARISTOR CLUTCH/COMPRESSOR
2 3 4 5 6

4002-16
PAGE16
DUAL POWER
BAT IFB
RELAY-OPC. DIODE BOX LATERAL CONSOLE
IF'B .. F'L 171
ACC 12 12
...: F'L 17.1
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DUAL POWER
SOLEN. VALVE
CURRENT PLUG VARISTOR
2 3 4 5 6

4002-17
CASE FRONT WHEEL DRIVE • OPT PAGE 17
F'RONT WHEEL ELECTRONIC UNIT

DRIVE~ .... ~ ... FRONT
BAT IF8 Ul'tiYt. ;:)'1'111\on rnV111 WHEEL
wrn~:.LI... DRIVE
un1•1...
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FRONT WHEEL DRIVE
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PAGE19
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1 2 3 4 5 6

4002-20
CASE PAGE 20
Connector J6
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3 - c
3 - B
3 - D
LUTCI-IESISOlENOYOS
COME-HOfv£
Forwarcll Reverse
"
2' 2 • A I
3 - •
JS Connector
Jl Con~~eclor J2 Connector
1 5 12

4002-23
CASE PAGE 23
NAME DESCRIPTION PAGE BASIC SCHEMATIC

----,
I
Ml ENGINE START 1-3
M2
M~
FRONT WIPER
FRONT WASHER PUMP

13-2
13-4 J
/
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-- I
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M4 REAR WIPER 13-~ FROM PAGE 16 __/"" '- " I
COORDINATE 3 _.
M5 REAR WASHER PUMP 14-1 I
M6 FRONT LOWER WASHER PUMP - OPriONAL 14-2 I
M7 FRONT LOWER WIPER - OPTIONAL 14-4
POSITION # ON\ I
MS AIR SUSPENSION SEAT - OPTIONAL 14-5 CONNECTOR
I
M9 FAN L.H. ONLY OPEN CAB -OPTIONAL 14-S
CONNECTOR • \~ :-
MIO FAN R.H. ONLY OPEN CAB - OPTIONAL 14-S I
Mil MOTOR DAMPER TO AIR CONDITIONER 15-5
"'X I
M.T. EVAPORATOR UNIT - OPTIONAL AIR CONDiriONER 15-3 I
ELECTRIC MAGNETIC CLUTCH/COMPRESSOR
E.M. OP rl ONAL AIR CONDITIONER 15-2 CIRCUIT • ~ I
41A
COLOR /mm"_..
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POSITION • ON I
K ECU
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INCH PEDAL FUNK TRANSMISSION
'I'RANSIENT VOLTAGE PROTECTION

18
18-2
18-1 H21
'+A H22
'\/CONNECTOR I
K TVP
K Gl AUXILIARY MAGNETIC SWITCH TO START ENGINE 1-4
K G2
K FWD
KIS
AUXILIARY MAGNETIC SW. TO ENGINE SHUTT-OFF
ELECTRONIC UNIT FRONT WHEEL DRIVE
FLASHER AND TURN SIGNAL RELAY

1-4
17-~
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CO.PONENT
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CONVERTER VOLTAGE TO RADIO AND CIGARRETH
LIGHTER 24/12 VOLTS MAX. 10,0 AMP
RADIO
19-2
19-4
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SPI SPEAKER L.H. 19-4
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SP2 SPEAKER R.H. 19-4 LIGHTS , I
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l<D2 DERIVATION BOX (IN THE LATERAL CONSOLE) 2-3 L - - - - -
XC CURRENTE PLUG 24 VOLTS MAX 10.0 AMP 16-1
X CAN DIAGNOSE CONNECTOR FRONT WHELL DRIVE 17-3 WIRE COLORS TABLE
A
B
AZUL
BRANCO
BLUE
WHITE
--
c LARANJA ORANGE -
v VERDE - GREEN
G AMARELO - YELLOW
H CINZA - GRAY
L ZUL ESCURO-DARK BLUE
MAR ROM - BROWN
N PRETO - BLACK
R VERMELHO RED -
s ROSA PINK -
z VIOLETA PURPLE -
1 I 2 I 3 I 4 5 I 6

4002-24
CASE PAGE 24
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AMP. ANP. AMP. AMP. AMP. AMP. AMP. AMP. AMP. AMP. AMP. AMP.
F31
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AMP.
no~ 10.0
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K8 K9 K 10 K 11 K 12 K 13 K 14
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K7 K6 K5 K4 K3 K2 K1
NAME DESCRIPTION PAGE NAME DESCRIPTION PAGE

Fl T~~~ ~·I~N~( LTM~ASHER RELAY AND a-s F24
FUSE 3.0 AMP TO ELECTRICAL ENGINE SHUT-OFF
1-6
HOLD SOLENOID
F2 ~iC ~~O~E~M~/r~o~~~RENT PLUG AND 16-1 F25 FUSE 3.0 AMP TO BRAKE LIGHT 5-4
FUSE 7.5 AMP TO STROBE LIGHT AND FUSE 15.0 AMP TO FRONT LOWER WIPERS/WASHER
F3 tAB DOME LIGHT 12-5 F26 14-2
liND AIR SUSPENSION SEAT - OPTIONALS
F4 FUSE 7.5 AMP TO HEAD LIGHT (LOW BEAM) 4-2 F27 FUSE 7.5 AMP TO CAB HEAD LIGHT - OPTIONAL 5-I
F5 FUSE 15.0 At/P TO HORN a-1 F2B ~~t5 ~;crA~~p- TJ>p¥':~~~LLIGH t!t.•O"t. 2-3
FUSE 3.0 AMP TO E.D.M.. INSTRUMENT ELECTRON]( ~USE 7.5 AMP TO WORK LIGHT AF"TER
F6 PANEL AND BUZZER 6-6 F29 2-5
OLD BOARD
F7 FUSE 10.0 AMP TO TRANSMISSION FUNK SYSTEM 18-2 F30 FUSE 10.0 AMP TO RADIO AND GIGARETH LIGHTER 19-2
FB FUSE 10.0 AMP TO TRANSMISSION FUNK SYSTEM 18-2 F31 DON'T USED
F9 FUSE 10.0 AMP TO TRANSMISSION FUNK SYSTEM 18-2 F32 FUSE 7.5 AMP TO FRONT BLADE BOARD LIGHTS-OPT. ~-3
FlO FUSE 7.5 AMP TO FANS ONLY OPEN CAB - OPT. 14-5 Kl DON'T USED
Fll FUSE 10.0 AMP TO FRONT WIPER AND WASHER PUMP 13-1 K2 DON'T USED
F12 ~~~BL1{·~o~~PP r~ sHfDD~~~Lb~~~~l~~y~L~1';.VES 8-5 K3 AUXILIARY STARTER RELAY 16-5
Fl3 FUSE 7.5 AMP TO REAR FLOOD LIGHTS 4-5 K4 LOW BEAM RELAY 4-2
Fl4 FUSE 7.~ AMP TO HIGHT BEAM 4-1 K5 HIGH BEAM RELAY 4-1
FIS FUSE 10.0 AMP TO STARTING AID - OPTIONAL 8-4 K6 REAR FLOOD Ll GH TS RELAY 4-5
Fl6 FUSE 10.0 AMP TO REAR WIPER AND WASHER PUMI 13-4 K7 HORN RELAY 3-1
Fl7 FUSE 20.0 AMP AIR CONDITIONER SYSTEM - OPT 15-2 K8 BACK-UP ALARM RELAY - OPTIONAL 5-5
FIB DON'T USED K9 STARTING AID RELAY - OPTIONAL e-4
Fl9 DON'T USED KIO DIFFERENTIAL LOCK RELAY - OPTIONAL 8-2
FUSE 3.0 AMP TO MOTOR DAMPER AIR
F20 tONDITIONER SYSTEM - OPTIONAL 15-6 Kll DUAL POWER RELAY - OPTIONAL 16-2
F21 FUSE 10.0 AMP TO FRONT WHEEL DRIVE SYSTEM 17-1 ELECTRIC MAGNETIC CLUTCH/COMPRESSOR RELAY
Kl2 OPTIONAL AIR CONDITIONER SYSTEM 10-2
F22 FUSE 3.0 AMP TO DIFFERENTIAL LOCK - OPTIONA 8-2 Kl3 DON'T USED
F23 FUSE 3.0 AMP TO BACK-UP ALARM - OPTIONAL e-s Kl4 WORK LIGHT BEFORE BLADE RELAY - OPTIONAL 2-5
1 I 2 I 3 I 4 5 I 6

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
Section
5002
FRONT WHEEL, AXLE & WHEEL LEAN

Contagem, MG - Brazil ENG 6-46681 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

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
6002
TRANSMISSION SPECIFICATIONS, PRESSURE

CHECKS, AND TROUBLESHOOTING
845 - 865 Grader

6002-2
TABLE OF CONTENTS 845 I 865

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS ......................................................................... 6
TEST AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Theory of Operation Clutch Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Theory of Operation Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clutch Solenoid Voltage Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Test Solenoids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Solenoid Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Suction Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8-4 Power Flow Forward Speeds . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8-4 Power Flow Reverse Speeds . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshoot Transmission System Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Powershift Troubleshooting - internal disconnect models only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TRANSMISSION CONTROL UNIT . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Troubleshooting Introduction .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Transmission Control Unit (TCU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Engine Speed Magnetic Pickup Sensor (input speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cylinder Magnetic Pickup Sensor (MPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Output Speed Magnetic Pickup Sensor (MPU) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electronic Gear Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Gear I Diagnostic Indicator or "CCD display". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inching Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Transmission Analog Inching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TVP (Transient Voltage Protection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . 33
J1 Connector, Transmission Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
J4 Connector Bump Shifter Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
J6 Connector Pinout . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Transmission Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 39
Function of Proportional Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 43
Proportional Valves, Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 44
SYSTEM ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 45
ANALOG TCU DIAGNOSTIC CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 46
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 55
ABBREVIATIONS AND ACRONYMS USED IN TCU GROUP .. .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . 56

6002-3
SPECIAL TOOLS
CAS-1953A Transmission supplemental fitting kit. CAS-1808 Flowmeter kit
Includes: CAS-2324 special 90 degree adapter and
CAS-2702 Flowmeter adapter
CAS-2325 plug and cap set.
CAS-2278 Flow test kit
CAS-1804 Master pressure test kit
75289947 - Clutch Stack Lifting device. 75310180 - 75310185 - 75310190 Input seal driver.
75289948 - Stack nest for assembly. 75310182 - 75310189 Sleeve inst. adapter.
75301709 - Installation tool. 75310183 - 75310187 - Bearing inst. tool
75310177 - 75310186 - Assembly tools. 753101888 - Clutch stk clearance gage.
IMPORTANT: The special tools listed are required to properly service the transmission.
JL
A-4X 17/32 Drill Through 5/8-11 UNC-28 Tap 1-13.875 in. (98.425mm)
through J--4.31 in. (1 09.47mm)
B-9.968 in. (253.187mm) K-3.52 in. (89.40mm)
C-4x 1/2 x 45· L-4.528 in. (115.011 mm)
D-2.31 in. (58.67mm) M-.75 in. (19.05mm)
E-5.984 in. (151.993mm) N--4.625 in. (117.475mm)
F-2.362 in. (59.994mm) 0-7x 11/16 Drill Through
G-8.79 in. (223.26mm) P-.69 in. (17.52mm)
H-4.625 in. (117.475mm) Q-3. 77 in. (95. 75mm)
R- 2.992 in. (75.996mm)

6002-4
ASSEMBLY STAND PLATE
A-1.75 in. (44.45mm)

J-13.875 in. (352.425mm)
B-9.96 in. (252.98mm)
K-4.528 in. (115.011 mm)
C-8X 11/16 Drill Through
L-5.84 in. (148.33mm)
D-5.984 in. (151.993mm)
M-.5 in. (12. 7mm)
E-.5 in. (12. 7mm)
N-.25 (6.35) radius in corner
F-1.500-1.505 in. (38.1-38.227mm)
0-17/64 Drill Through as Shown
G-2.362 in. (59.994mm)
P-1.46 in. (37.08mm)
H-6.48 in. (164.59mm)
0-2.992 in. (75.996mm)
1-2.25 in. (57.15mm)
R- 3.00 in. (76.2mm)
ENG 6-46751
May, 2003 Printed in Brazil
6002-5
FRONT HOUSING LIFTING TOOL
14------l K l----t.-t
~---{ L>-----t~
A-1.42 in. (36.05mm) K-3.70 in. (94.01 mm)

B-4X .38 in. (9.52mm) L-4.83 in. (122.78mm)
C-17/32 Drill Through 5/8-11 UNC M-3.29 in. (83.6mm)
D-.75 in. maximum (19.05mm) N-5.43 in. (138mm)
E-4.99 in. (126.7mm) 0-.50 in. minimum (12.7mm)
F-3.29 in. (83.6mm) P-1.46 in. (37.08mm)
G-1.44 in. (36.5mm) Q-2.992 in. (75.996mm)
H-.47 in. (12mm) R- 3.00 in. (76.2mm)
1-.71 in. (18.11 mm)
J-2.88 in. (73.17mm) NOTE: Used for lifting main case front housing.

6002-6
SPECIFICATIONS
Item Measurement Specification
o DF-150 (Transmission model) Weight (Application Dependent) 567 Kg (1250 lbs)
o DF-150 Input-to-Output 500 mm (19.69 in)
o DF-150 Rating (Depending on Input power(maximum) - 142 kW (190

application) SAE hp)
Input no load speed (maximum) - 3000

rpm
Turbine torque (maximum) - 1288 N·m

(950 lb-ft)
o DF-150 Mountings Available Engine
Midship
Remote
o DF-150 Clutches Fully modulated, oil cooled, multidisc,

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

ratio ground gears. Up to eight speeds
forward and four speeds reverse.
o DF-150 Oil Hydraulic Transmission Fluid.
o DF-150 Filter Remote mounted spin-on type filter.
Transmission Operating Conditions Maximum Input Speed 3000 rpm
Test Input Speed 2000 rpm
Maximum Continuous Operating 93·c (200.F)

Temperature
Maximum Intermittent Operating 115·c (230.F)

Temperature
Maximum Temperature 121·c (250.F)
Normal Operating Temperature 65-93·c (150-200.F)
Check Oil Level Temperature 3TC (1 oo·F)
Pressures and Flows at Control Pump Pressure (test input 17.58-19.65 Bar (255-285 psi)
Valve speed)
Pump Flow (test input speed) 87-102 Umin (23-27 gpm)
Clutch Pressure (test input 16.55-19.31 Bar (240-280 psi)

speed)
Lube, In Pressure (test input 1.38-4.14 Bar (20-60 psi)

speed)
Test and Troubleshooting 6002-7
THEORY OF OPERATION CLUTCH ACTUATION
Hydraulic oil pressure is directed from the proportional piston area causing it to move toward the clutch
valve, through passages in the valve body, to a pack, compressing the bellville piston return springs
drilled passage in the main case that directs the oil and removing the free clearance in the clutch. The
pressure to the seal rings on the end of the clutch piston also moves the lube shut-off washer, trapped
shaft. The oil pressure is transferred from the between the piston and the bellville springs, causing
stationary housing to the rotating shaft in the area it to uncover the lube holes that provide cooling oil
between the shaft seal rings. The oil pressure then flow to the clutch. Once the free clearance in the
travels down a hole in the shaft until it enters the clutch is eliminated the piston applies pressure to the
area enclosed by clutch shaft weldment, the clutch clutch plates causing the clutch to transmit torque in
apply piston and the piston seals. Here it acts on the proportion to the oil pressure applied.
GEAR SELECTION
Two clutches must be engaged in order to transmit referred to as speed clutches. The speed clutches
torque from the transmission input to the transmission connect the cylinder gear train to the output shaft of
output shaft. In Neutral all clutches are in the the transmission at various ratios. Working in
released condition. conjunction with the directional clutches up to 8
speed ranges in forward and 4 ranges reverse
The clutches numbered "1" through "4" are referred to directions are possible. The speed clutches are
as directional clutches. Clutches "1" and "2" engage located in the lower part of the transmission.
forward gears and clutches "3" and "4" engage
reverse gears. These clutches have two passages NOTE: The following table shows which clutches are
through the shaft in order to maximize the "lube flow" engaged for each ratio in a eight speed
to cool the clutches. These clutches have more forward and four speed reverse.
friction surface area and a higher thermal capacity
than the speed clutches. The directional clutches are FORWARD REVERSE
Range Directional Speed Directional Speed
used for modulation during shifting and when using
the clutch pedal. The directional clutches connect the
"1" "A" "3" "A"
input shaft of the transmission through various ratios 2 "2" "A" "4" "C"
to the cylinder gear train and are located in the upper 3 "1" "C" "3" "8"
part of the transmission. 4 "2" "C" "4" "D"
5 "1" "8"
6 "2" "8"
The clutches lettered "A", "B", "C" and "D" are
7 "1" "D"
8 "2" "D"

6002-8
THEORY OF OPERATION HYDRAULIC SYSTEM
Oil is picked up by the transmission charge pump main regulator valve to the charge circuit controlled
from the transmission sump through a suction screen. by the flow restrictions in the heat exchanger and the
It travels through an external suction tube to the inlet lube circuits.
side of the charge pump. The charge pump is an The cooled oil returning to the valve body from the
external gear pump with fixed clearance end plates heat exchanger is directed to the lube circuit. An
and the gear shafts supported by bushings. The internal manifold in the transmission main case
pump is driven by a gear train directly coupled to the directs the lube oil to the ends of each of the clutch
engine and has a displacement such that it pumps 25 shafts. This oil flow passes through the lube shut-off
to 27 gpm at engine high idle speed. washers on the engaged clutches and provides the
cooling for the clutches. There is also leakage flow to
From the pump the oil is directed to a filter assembly. the disengaged clutches to lubricate and cool them
The filter head has an internal bypass valve that and many orifices provide flow to lubricate the
bypasses oil to a dedicated port when the pressure bearings on these shafts. After exiting the clutch and
drop across the filter element exceeds 60 psi. bearings on these shafts the oil returns to the
Bypassed oil is directed to the lube system and back transmission sump where it is again picked up by the
to the transmission sump, not to the proportional charge pump. If the pressure in the lube circuit
control valves. The filter head also contains a exceeds 45 psi, the lube relief valve opens and
pressure switch that can be used to alert the operator dumps the excess flow to the transmission sump.
of nearing bypass conditions. This switch actuates at This condition is normal when the transmission is in
a pressure drop across the filter element of 50 psi. neutral with all lube shut-off washers closed and the
engine is at high idle.
Filtered oil from the filter assembly is directed to the
valve body located on the transmission. The flow of
oil is available for the proportional control valves and
clutch transmission. The flow of oil is available for the
proportional control valves and clutch engagement.
The pressure in the system is controlled by the main
regulator valve and is regulated to 270 psi at a flow
of 27 gpm. A small amount of this flow leaks through
the pilot orifices in the proportional control valves and
past the seal rings in the shafts when a clutch is
engaged. The balance of the flow is dumped by the

6002-9
CLUTCH SOLENOID VOLTAGE REQUIREMENTS
NOMINAL 24V
VOLTAGE
ALLOWABLE 20-28V
VOLTAGE
CURRENT .6 AMP
DRAW NOMINAL
CURRENT .7 AMPS
DRAW MAX.
RESISTANCE 53 OHMS
±3%
All checks must be made at the valve.
TEST SOLENOIDS
IMPORTANT: If a solenoid is removed from the 1. Select solenoids 1 and A.

valve, it must be installed in the
same location. If low pressure exists, then solenoid or clutch 1 or A
is defective.
NOTE: To determine the defective clutch is simply a
matter of elimination. For example, if the gear 2. Select solenoids 2 and A.
selected uses solenoids 1 and A, and low
pressure is indicated, select another clutch If pressure is OK, then solenoid or clutch 1 is
that uses one of those solenoids. If pressure defective.
is good, then the solenoid or clutch not
selected is the one that is bad. 3. Select solenoids 1 and B.
To confirm that this is the faulty circuit, select If low pressure exists, then this confirms solenoid or
another clutch that uses this solenoid, to clutch 1 is defective.
assure that the discrepancy is actually in this
solenoid or clutch.

6002-10
SOLENOID VALVE OPERATION
Before troubleshooting the electric circuit of the valve,

the chart shows what solenoids are charged when that
gear is selected.
OF SERIES EIGHT SPEEDS FORWARD AND FOUR REVERSE
OF 8/4
Gear Engage Solenoid Charged
F 8th . . . . . . . . . . . . . . . . . 2 and D
F 7th . . . . . . . . . . . . . . . . . 1 and D
F 6th . . . . . . . . . . . . . . . . . 2 and B
F 5th . . . . . . . . . . . . . . . . . 1 and B
F 4th . . . . . . . . . . . . . . . . . 2 and C
F 3rd . . . . . . . . . . . . . . . . . 1 and C
F 2nd . . . . . . . . . . . . . . . . . 2 and A
F 1st . . . . . . . . . . . . . . . . . 1 and A
Neutral
R 1st . . . . . . . . . . . . . . . . . 3 and A
R 2nd . . . . . . . . . . . . . . . . . 3 and C
R 3rd . . . . . . . . . . . . . . . . . 3 and B
R 4th . . . . . . . . . . . . . . . . . 3 and D

6002-11
SUCTION LEAK TEST
Some indications of a suction leak include: 3. Start the engine.

• Erratic oil pressure. Look for rapid fluctuation of
gauges. 4. Check for erratic oil pressure.
• Pump and filter hoses jumping.
• Excessive air entrainment in the transmission oil. 5. If any of the above conditions are corrected by this
• A long prime time (time elapsed from engine start to procedure, a suction leak exists.
an indication of pump pressure).
NOTE: Check suction tube fitting.
1. Fill to normal level with transmission fluid.
IMPORTANT: Drain the transmission to the correct
NOTE: See PRESSURE AND TEMPERATURE level after the test. Failure to do so
CHECK PORTS (6003-44) for port location. will result in poor performance and
over heating.
2. Install a 21 bar (300psi) pressure
gauge in the pressure port. 6. Verify the level of transmission fluid and correct if
is necessary.

6002-12
8-4 POWER FLOW FORWARD SPEEDS
1st Gear - 1A, 2nd Gear - 2A 3rd Gear - 1C, 4th Gear - 2C

6002-13

(CONTINUED)
5th Gear - 18, 6th Gear - 28 7th Gear - 1D, 8th Gear - 20

6002-14
8-4 POWER FLOW REVERSE SPEEDS
R1 Gear- 3A R2 Gear- 3C

6002-15

(CONTINUED)
R3 Gear- 38 R4 Gear- 3D

6002-16
TROUBLESHOOT TRANSMISSION SYSTEM

MALFUNCTIONS
Symptom Problem Solution
Erratic oil pressure. Low oil level. Add oil to proper level.
Suction tube fitting Replace 0-ring fitting.
Suction manifold 0-ring not sealing. Replace 0-ring.
Foreign object in suction port. Remove object and check for other
contamination.
Excessive oil pressure. Sticking main regulator valve. Replace main regulator valve.
Faulty spring. Replace main regulator valve.
Low oil pressure in all gears. Sticking main regulator valve. Replace main regulator valve.
Control valve body gasket leaking. Replace gaskets.
Charge pump defective. Replace pump.
Internal disconnect seal damage or Replace seal and install correctly.

installed incorrectly.
Faulty main regulator valve. Replace regulator assembly.
Control valve body cracked. Replace control valve body.
Low pressure in one gear but all Contaminated proportional solenoid. Replace proportional solenoid.
right in other gears. *Check suction screen for
contamination.
Broken wire to one solenoid, or Repair wire.

dirty connection.
Broken seal ring on input end of Replace seal ring.

clutch assembly.
Bore sleeve worn. Replace bore sleeves.
Outer or inner piston seal leaking. Replace seals.
Transmission System Pressure is Failed transmission control valve Inspect transmission control valve
Low (One or Two Gears) for external leakage, Remove
control valve. Inspect or replace
gasket.
Leakage in clutch piston or seal Air check to confirm leak.

ring.
Continued on next page

6002-17
Solenoid valve malfunction Check for a transmission fault code

on monitor, then check solenoids
using monitor diagnostics.
Filter or filter oil lines blow out. Hose bends too sharp. Reroute hoses.
Defective hose. Replace hose.
Main regulator valve faulty. Change valve and change filter and
oil.
System plumbing incorrect. Correct plumbing.
Filter 0-ring faulty. Replace filter
Foaming Oil Incorrect type of oil Change oil
High oil level Transmission overfilled or hydraulic

pump seal leaking.
Low oil level Add oil
Air leak on suction side of pump Check oil pickup tube on inside of
transmission.
Blows oil out of breather or Transmission over filled with oil. Establish proper oil level. Check
dipstick tube. front seal on auxiliary driven
hydraulic pump if equipped.
Vehicle will not move Fault code problem Check fault codes to define
problem.
Voltage to wrong solenoids on Check wiring and connecters.

control valve. (See schematic.)

6002-18
No voltage to all solenoids. Check wiring, controller and

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

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

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

transmission screen. Inspect for metal particles.
Machine "Creeps" In Neutral Warped disks and plates in clutch Check transmission
pack of transmission.
Control valve leakage Do transmission leakage test
Plugged screen on solenoid valve Remove solenoid valve and clean.
Transmission Clutch Slippage Low oil level Add oil.
Wrong oil grade Change oil.
Restricted transmission pump Remove and clean screen.

suction screen.
Leak in transmission control valve Remove valve and inspect gaskets.

or gasket

6002-19
Low transmission pump flow due to Do transmission pump flow test.

worn pump
Stuck solenoid valve Check wiring to solenoid valve.
Remove and inspect solenoid valve.
Transmission overheating. Oil level too high. Establish proper oil level. Check
front seal on auxiliary driven
Engine overheating. Check engine coolant.
Water lines defective on heat Replace lines.

exchanger.
Heat exchanger dirty. Clean heat exchanger.
Clutch slipping. Check clutch pressure.

6002-20
POWERSHIFT
TROUBLESHOOTING-INTERNAL
DISCONNECT MODELS ONLY
865 All wheel drive will not engage. Solenoid stuck open. Voltage Repair or replace solenoid. Check
applied all the time. wiring diagram and connecters.
Damaged or missing disconnect Replace or install disconnect

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

gasket and solenoid cap or
contamination.
865 All wheel drive will not No power to solenoid, solenoid Check for electric power to solenoid
disengage. inoperative. - check wiring and connecters if
O.K., replace solenoid.
Check valve installed backwards. Install check valve properly.

Transmission Control Unit 6002-21
SPECIFICATIONS
J1 connector-to-TCU Torque 0.8-1.5 N·m (7.1-13.3 lb-in)
Diagnostic indicator Mounting dimensions 50.8 mm (2 in) diameter hole with

88.9 mm (3.5 in) clearance behind
front face of indicator.
TROUBLESHOOTING INTRODUCTION
This introduction is written to initiate an understanding The best strategy in a troubleshooting plan is to
of a strategy which can be used toward solving reduce the random exchange of components by
problems in the driveline system. The preferred carefully analyzing the symptoms and then conducting
technique used in solving problems is to exchange tests which will help determine which component in
components. However, a very important element the system is likely to be the problem. The technician
necessary to the timely and successful conclusion of should use the above component list as a guide in
this activity is the selection of the malfunctioning locating the problem.
component. An understanding of the total system and
an elimination process leading to the component is Because the TCU is a relatively complex and
absolutely necessary before starting the exchange unfamiliar component, it is often the first component
activity. The transmission system as installed consists targeted for exchange. However, TCU malfunctions
of the following components linked together to form a are relatively rare. In addition, the TCU has internal
functioning system. diagnostics capabilities which are usually helpful in
isolating an operational problem. If the TCU responds
• Electronic gear selector to commands and does not provide a diagnostic code
• Wiring harness indicating an internal TCU error, the problem being
• Transmission control unit (TCU) internal to the TCU is unlikely.
• Magnetic pickups (Speed sensors)
• Temperature sensor
• Inching pedal
• Gear/Diagnostic indicator or CCD display
• Transmission control valve
• Transmission hydraulic system {pump, relief
valves, lines, etc.)
• Transmission mechanical system (clutches,
gears, shafts, seals, etc.)

6002-22
THEORY OF OPERATION
The purpose of the Transmission Control Unit (TCU) If no error conditions are detected, based upon a
is to control the functions of the transmission. combination of inputs from the shift lever and other
Upshifting, downshifting, control of the proportional applicable inputs, the TCU will select the proper
solenoids and capability to communicate with a panel transmission gear and command the transmission to
mounted gear/diagnostic indicator are the main shift to this gear. The gear/diagnostic indicator will
functions. The transmission's performance is now show the actual transmission gear.
determined by the various inputs to the TCU. Based
upon these inputs, the TCU commands the The TCU Module uses electrohydraulic proportional
transmission so that maximum performance can be valves to control the operation of the transmission.
achieved under the present operating conditions. All The solenoids controlling the transmission clutches
functions of the TCU are under software control. Park (solenoids A through D & 1 through 4) are driven by
Brake Solenoid function is connected to the TCU, a signal that produces proportional pressure/flow
however it is not controlled by the TCU or software. changes. During modulation, the solenoids are started
out with a low duty cycle and ramped up to full on.
Operation begins when the vehicle's ignition is The initial duty cycle is dependent upon several
switched to the on position, supplying electrical power factors and is not a preset value. The process of
to the TCU and related system components from the modulating these clutches greatly enhances shift
vehicle's power source. The TCU now begins quality.
monitoring all inputs and outputs. If a known conflict
in inputs or a fault condition is detected, the TCU will
command the transmission to stay in neutral
regardless of the shift lever position. A flashing error
code will be displayed on the gear/diagnostic
indicator, and will remain displayed until the error has
been resolved and the shift lever cycled back through
the neutral or park position.

6002-23
CALIBRATION
Reasons to Calibrate
• Matches Transmission Control Unit (TCU) to

Transmission. Default clutch fill and hold values are
placed in the TCU at the factory. Calibration changes
these values to match a particular transmission.
• Reduces Impact Of Manufacturing Tolerances. Since

the clutch fill and hold values are for a particular
transmission, adjustments for differences in parts due to
manufacturing tolerances are automatic.
• Provides For Consistency Between Machines. The

calibration routine makes sure each transmission clutch
starts from the same spot just prior to clutch
engagement.
• When to Calibrate:
1. If solenoid valve assemblies are changed.
2. After repairs involving transmission clutches.
3. If TCU is replaced.
4. If shift quality deteriorates.

6002-24
CLUTCH CALIBRATION: EIGHT FORWARD SPEEDS AND FOUR REVERSE
5. Start and hold the engine speed at 1600 RPM.

Transmissions Eight Forward Speeds and Four The engine governor must hold the engine speed ±
Reverse. 50 RPM.
IMPORTANT: Attempting to calibrate with sump 6. Move the shift handle to the Forward position.
temperature below minimum
calibration temperature (90.F) 7. During the first few seconds of the calibration
will trigger the "warm-up" mode. process, the display will show "---" while testing the
This mode will show "---" on the cylinder speed and response.
display as the transmission warms
to the minimum calibration 8. At this time the Clutch calibration process starts.
temperature at which time the
calibration process will a. Directional and Speed Clutch Holds. The display
automatically begin. Temperatures will show C1 H, C2H, C3H, CAH, CBH, CCH and
below so·F will result in "sump CDH while acquiring the respective "hold" time of
temperature too cold" error 100. each clutch.
b. Directional and Speed Clutch Fills. The display will

1. Bring the transmission oil temperature up to 140· show C1 F, C2F, C3F, CAF, CBF, CCF and CDF
to 16o·F (60. to 71.C) for optimum calibration. while acquiring the respective "fill" time of each
clutch.
2. With the vehicle ignition off, apply the park brake.
9. The display will show END when the routine is
3. Plug a jumper plug (which connects pin A to pin B) finished. At that time move the shift handle back to
in the calibration plug (s16) on the vehicle harness. the Neutral position.
IMPORTANT: Any errors that appear during 10. Shut the vehicle's ignition OFF, which will power
calibration will cause the procedure down the TCU.
to terminate, and you will have to
start the calibration over from the 11. Remove the jumper plug from the calibration plug
beginning. (S16).
4. Power up the TCU by turning on the vehicle The calibration is complete.

ignition. The display should show "CAL".

6002-25
SYSTEM COMPONENTS
1. Transmission control unit (TCU)

2. Engine speed magnetic pickup sensor (input
speed)
3. Cylinder magnetic pickup sensor (MPU)
4. Output speed magnetic pickup sensor (MPU)
5. Electronic gear selector
6. Temperature Sensor
7. Gear/Diagnostic Indicator
8. Inching Pedal
9. Proportional Valves

6002-26
COMPONENT FUNCTIONS
Basic Components
1. Transmission Control Unit (TCU)
FUNCTION
The TCU is the "brain" of the system. It is responsible

for the logic, computation, and decision making
processes of the transmission based on calculations.
How the TCU performs is determined by software
programmed into the TCU's memory. This software is
developed to meet the requirements of the vehicle
manufacturer, and is based on a vehicle performance
analysis. It is application specific, therefore TCUs from
different vehicles are not interchangeable. TCUs can only
be interchanged on vehicles which are identical in all
ways (same engine/drivetrain combination, same wiring,
same shift lever, same vehicle voltage, etc.)
MOUNTING
The TCU must be mounted inside the vehicle cab or

other enclosed area which will not exceed ambient
temperature range (-4o·c to +85.C). It must be mounted
to ensure good electrical grounding between the TCU
and the vehicle chassis, although a ground wire from
battery negative to the TCU is required. It must not be
mounted by any method which would isolate the TCU
from the vehicle chassis. If rubber mounted for shock
protection, a grounding strap must be utilized to ensure
proper grounding.
IMPORTANT: Do not weld on vehicle with battery and

TCU connected or the WARRANTY
WILL BE VOID.
IMPORTANT: The only way to adequately protect the

TCU from damage caused by high
voltage and amperage is to completely
remove all three wiring harness
connectors (J1, J2 and J3) and any
ground strap from the TCU prior to
welding. Disconnecting the battery
supply alone is not sufficient to protect
the TCU from ground voltage feeding
back through the wiring harness.

6002-27
2. Engine Speed Magnetic Pickup Sensor (input speed).
The engine speed magnetic pickup (A) reads engine

RPM by measuring the number of pulses per minute
generated from the teeth of the charge pump idler gear,
which is in mesh with the input gear.
Input RPM is calculated by pulses per minute divided by

the number of teeth on the input gear.
CONNECTOR PINOUT
SIGNAL DESCRIPTION SENSOR PIN TRANS CONNECTOR PIN TCU PIN
ENGINE MPU A J6-29 J1-B1
ENGINE MPU GND B J6-28 J1-C2
3. Cylinder Magnetic Pickup Sensor (MPU)
The cylinder speed magnetic pickup (C) reads cylinder

generated from the teeth of the cylinder gear.
Cylinder RPM is calculated by pulses per minute divided

by the number of teeth on the cylinder gear.
CONNECTOR PINOUT
CYLINDER MPU A J6-9 J1-B2
CYLINDER MPU GND B J6-16 J1-C2

6002-28
4. Output Speed Magnetic Pickup Sensor (MPU)
The output speed magnetic pickup (E) reads output RPM

by measuring the number of pulses per minute
generated from the teeth of the sixth stage gear. The
sixth stage gear is on the same shaft as the sixth stage
pinion which drives the output gear.
CONNECTOR PINOUT
OUTPUT MPU A J6-18 J1-A3
OUTPUT MPU GND B J6-30 J1-C2

6002-29
5. Electronic Gear Selector
The electronic gear selector handle is a "Bump" The handle can be moved forward to request a
handle which operates in an "I" pattern with a forward gear or moved back to request a reverse
horizontal bar in the middle. Neutral position is in the gear. The release ring under the handle knob must
middle of the pattern along the horizontal bar. While be pulled up to release the neutral lock.
in neutral, the handle can be moved right to request
a higher pre-selected gear or left to request a lower The handle can be moved back to the neutral
pre-selected gear. position at any time without moving the release ring
under the handle knob.
FORWARD
DOWN UP
DOWN UP
DOWN UP
REVERSE
When in the forward or reverse position the handle

can be "bumped" to the right to request an upshift or
to the left to request a downshift.

6002-30
6. Temperature sensor
The temperature sensor (A) is used to determine

transmission fluid temperature.
TEMPERATURE SENSOR A J6-25 J1-C3
TEMPERATURE SENSOR GND B J6-24 J1-D1
7. Gear/diagnostic indicator or "CCD display"
The TCU and gear/diagnostic indicator can be used on

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

88.9 mm (3.5 in) clearance behind the front face.

6002-31
8. Inching Pedal
The inching pedal provides the operator with a device for

controlling modulation of the transmission clutches when
desired. With the pedal fully depressed, the transmission
remains in neutral regardless of shift lever position.
Releasing the inching pedal engages the transmission.
The more the pedal is released, the more the clutches
engage causing the vehicle to 'inch'. When the pedal is
fully released, the transmission clutches are fully
engaged.
CONNECTOR PINOUT
SIGNAL DESCRIPTION CONNECTOR/PIN TCU PIN
VAGND T11-B J1-G1

(ANALOG GROUND)
VAREF T11-C J1-F2

(ANALOG VOLTAGE
REFERENCE)
PEDAL POSITION T11-A J1-F3
TOC INPUT J1-K3

(TOP OF CLUTCH)
NOT BOC INPUT T11-E J1-K2

(BOTTOM OF CLUTCH)
+ 24V T11-F J2-F2

6002-32
TRANSMISSION ANALOG INCHING
The pedal position output, or "inching" signal, comes pin T11-B) signal and a 5V DC reference (VAREF,
from the 2.5K-ohm potentiometer attached to the pin T11-C), both provided by the TCU. The pedal's
pedal. The potentiometer's angle changes output signal to the TCU {pin T11-A) varies between
proportionally with the degree of pedal depression. the ground and reference levels. The output signal
The potentiometer has an analog ground (VAGND, increases as the pedal is depressed.
lnclllng 'I011lll)lll!;lll. I!!Cf~l!;itlt$

Pe1:!1111 Pot l!;IS !11:11:1~1 Is ~l)rlli!CS!Id,
--~~·(......._:_..;_.:....::______ £11111 I!Uilll!lll1!{)!1
2£0~ $l b~i~lWIIIIII!I A and C
(+l• ::tv!\} C;)CfiiiU!Ili.
I
I
I
I
I lnel!ln
i! "''Cll
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'llh!!W of
P'ednl Cl:lnn!l'elnr
A normally closed switch mechanically linked to the There is no connection to inching pedal pin D (pin
pedal provides the "NOT BOTTOM OF CLUTCH" T11-D).
signal (pin T11-E) to the TCU. The switch contacts
open when the pedal is fully depressed, and are
closed for all other pedal positions. The TCU sees an
active (+24V) signal on J1-K2 whenever the
pedal is "NOT" at the bottom of its travel range.

6002-33
The TVP (Transient Voltage Protection) Module is

available in 24V version.
It has two important functions:
• Supply electrical power to the system.
• Protect the electrical system against electrical

conditions that might otherwise be potentially
damaging, such as load dump and reverse battery
protection.
Protection is provided only when the ignition switch is

on, thus energizing an internal relay which provides an
electrical connection between the vehicle battery and the
protective device inside the TVP.

6002-34
J1 CONNECTOR
NOTE: Connector pinouts reference wiring harness F1-Load sense LO (voltage reference output)
diagram in this group always reference the vehicle F2-lnching pedal HI (voltage reference output)
manufacturers wiring harness diagram for your F3-lnching pedal position (analog voltage input)
application. G1-lnching pedal LO (voltage reference output)
G2-Spare ground
CONNECTOR PINOUT G3-Spare ground
H1-Spare ground
A1-Main battery 1 (TCU Power, +24V) H2-UPSHIFT (Shift code E), (digital input)
A2-Ground 1 H3-DOWNSHIFT (Shift code D), (digital input)
A3-0utput magnetic pickup sensor input (frequency J1-FORWARD (digital input)
input) J2-REVERSE (digital input)
81-Engine magnetic pickup sensor input (frequency J3-Spare input (digital input)
input) K1-NOT PARK (digital input)
82-Cylinder magnetic pickup sensor input (frequency K2-NOT BOTTOM OF CLUTCH (digital input)
input) K3-TOP OF CLUTCH (digital input)
83-Spare magnetic pickup sensor input (frequency
input) Mating connector for J1 is:
C1-F Flow (input)
C2-Magnetic pickup sensor ground • Metri-Pack 150 series 30 way sealed P2S connector
C3-Temperature sensor (analog voltage input)
D1-Temperature sensor ground • Delphi/Packard part number: 12034398
D2-Rear-steer HI (voltage reference output)
D3-Rear-steer position (analog voltage input) • Mating terminals for J1 are Delphi/Packard
E1-Rear-steer LO (voltage reference output) terminals: 12103881
E2-Load sense HI (voltage reference output)
E3-Load sense (analog voltage input) • Tighten connector to TCU 0.8-1.5 N·m (7.1-13.3
lb-in)
"Input" and "Output" are defined relative to the TCU.

6002-35
J2 CONNECTOR
NOTE: Connector pinouts reference wiring harness E3-CCD Bus- (gear I diagnostic indicator)
diagram in this group always reference the vehicle (communication input/output)
manufacturers wiring harness diagram for your F1-Bus ground for communication lines
application. F2- +24 supply voltage output (supply voltage
output)
CONNECTOR PINOUT F3- +24 supply voltage output (supply voltage
output)
A1-Neutral (digital input)
A2-Not neutral (Shift code B), (digital input) Mating connector for J2 is:
A3-Brake cutoff (Shift code C), (digital input)
B1-Program (Shift code A), (digital input) • Delphi/Packard Metri-Pack 150 series 18 way
B2-Start (digital input) sealed P2S connector
B3-Park or park brake pressure (digital input)
C1-Auto I manual mode select (digital input) • Delphi/Packard part number: 12040921
C2-Calibrate (digital input)
C3-Disconnect (digital input) • Mating terminals for J2 are Delphi/Packard
D1-CAN HI (communication input/output) terminals: 12103881
D2-CAN LO (communication input/output)
D3-RS232 TxD (serial communication output) • Tighten connector to TCU 0.8-1.5 N·m (7.1-13.3
E1-RS232 RxD (serial communication input) lb-in)
E2-CCD Bus+ (gear I diagnostic indicator)
(communication input/output)

6002-36
J3 CONNECTOR
NOTE: Connector pinouts reference wiring harness G1- Not Used

diagram in this group, reference the vehicle G2-Not Used
manufacturers wiring harness diagram for your G3-Not Used
application. H1-Not Used
CONNECTOR PINOUT (APPLICATION H2-Disconnect solenoid (PWM output)

DEPENDENT) H3-Disconnect solenoid return (current sense input)
J1-Rear PTO solenoid (PWM output)
A1-Main battery 2 (TCU power +24V) J2-Rear PTO solenoid return (current sense input)
A2-Ground 2 J3-Front PTO solenoid (PWM output)
AS-Solenoid 1 (PWM output) K1-Front PTO solenoid return (current sense input)
81-Solenoid 1 return (current sense input) K2-Ground
82-Solenoid 2 (PWM output) K3-Ground
83-Solenoid 2 return (current sense input)
C1-Solenoid 3 (PWM output) Mating connector for J3 is:
C2-Solenoid 3 return (current sense input)
C3-Solenoid 4 (PWM output) • Delphi/Metri-Pack 150 series 30 way sealed P2S
D1-Solenoid 4 return (current sense input) connector
D2-Solenoid A (PWM output)
D3-Solenoid A return (current sense input) • Delphi/Packard part number: 12048455
E1-Solenoid 8 (PWM output)
E2-Solenoid 8 return (current sense input) • Mating terminals for J3 are Delphi/Packard
E3-Solenoid C (PWM output) terminals: 12103881
F1-Solenoid C return (current sense input)
F2-Solenoid D (PWM output) • Tighten connector to TCU 0.8-1.5 N·m (7.1-13.3
F3-Solenoid D return (current sense input) lb-in)

6002-37
J4 CONNECTOR
BUMP SHIFTER PINOUT B-J2-A2-NOT NEUTRAL (shift code B)

C-J2-A1-NEUTRAL
NOTE: Letters A through J are J6 Pinouts. D-J1-H3-DOWNSHIFT (shift code D)
Number,letter-number,letter callouts (example E-J1-H2-UPSHIFT (shift code (E)
J3-A 1) are TCU callouts. F-J1-J2-REVERSE
G-J1-J1-FORWARD
A-J3-A 1- +24 out H-J1-A2-Ground
J-S 1-A-Neutral start

6002-38
J6 CONNECTOR
CONNECTOR PINOUT 14-J3-G3- Not Used

15-J3-B3-Solenoid 2 return
NOTE: Numbers 1 through 31 are J6 Pinouts. 16-J1-C2-Magnetic pickup sensor ground
Number,letter-number,letter callouts (example 17-J3-D3-Solenoid A return
J3-B1) are TCU callouts. 18-J1-A3-0utput magnetic pickup sensor
19-J3-C2-Solenoid 3 return
1-J3-B1-Solenoid 1 return 20-J 1-A1-Park brake pressure switch supply
2-J3-A3-Solenoid 1 output (+24V)
3-J3-B2-Solenoid 2 output 21-J2-B3-Park brake pressure switch
4-J3-C1-Solenoid 3 output 22-J3-F1-Solenoid C return
5-J3-C3-Solenoid 4 output 23-J3-E3-Solenoid C return
6-J3-D1-Solenoid 4 return 24-J1-D1-Temperature sensor ground
7-J3-F3-Solenoid D return 25-J 1-C3-Temperature sensor
8-J3-F2-Solenoid D output 26-J3-H3-Disconnect solenoid return
9-J1-B2-Cylinder magnetic pickup sensor 27-J3-H1- Not Used
1O-J3-D2-Solenoid A output 28-J1-C2-Magnetic pickup sensor ground
11-J3-E2-Solenoid B return 29-J1-B1-Engine speed magnetic pickup sensor
12-J3-E1-Solenoid B output 30-J1-C2-Magnetic pickup sensor ground
13-J3-H2-Disconnect solenoid output 31-J1-A2-Magnetic pickup sensor ground

6002-39
TRANSMISSION WIRING HARNESS 1 OF 4
TCU
Jl-AZ
n-B:!
13-Al
JI-AI
NOTE: Letters A,B,C,D,E,F are labels to link to the

next page.
Wiring harness is + 24Volts grader 845 I 865

6002-40
AB 0 DE F
H-Fl
JHll
12-m
TCU
J2-A2
12·AI
Jl¥3 .!J
nm Gl!ARJ>!iU'A~
1!-H
JPI
G 0 E
NOTE: The letters G,C,E link to the next page.


6002-41
G C E
TCU
J3-A3 2
B-Bl
J3-B2 3
B-BJ 15
13-Ct 4
B.C2 19
B-CJ j
B-DI 6
B-D2 10
-
13-DJ li
B-El
12~
J3-E2 H> 0\
J3-E3 23 z
- Vol
13-F! 22 as
J3-F2 8 Vol
Vol
N
J3-F3
UsedB,.GJ
7
14
az
No UsedB-Ht 27
B·-H2 !3
J3-H3 26
J2-B3 21
20
Jl-Bl 29
Jl-C2 28
.IJ-A3 1.8
Jl,.(i2 30
JJ . . sz 9
Jl,.(i3 1.6
J!-H! 31
J!-CJ 25
TEMP SENSOR GND
J!-DI 24
c
NOTE: The letter C links to the next page.

6002-42
TCU
No Usedn-m
No UsedlHn ~=::§:
==~~
13-H S!9
H-Kl Ot.f'll'VTS
13-Jl ----3E
13-J:!: ~----~~~~~~---------------3F
A
J2-AJ E
JZ-!H c r:ro
J!-13 D INPUTS
E
f'
Til Sl7
MPU MPll
NOTE: Letters C is a label to link the previous page.


6002-43
FUNCTION OF PROPORTIONAL VALVES

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

6002-44
PROPORTIONAL VALVES
CONNECTOR PINOUT Transmission Eight Speeds Forward and
Four Reverse
SIGNAL TRANSMISSION TCU
GEAR ENGAGED ACTIVE SOLENOIDS
DESCRIPTION CONNECTOR PIN
PIN
F 8th .......... . 2 and D
J6-2 J3-A3 F 7th .......... . 1 and D
SOLENOID 1
F 6th .......... . 2 and B
F 5th .......... . 1 and B
SOLENOID 1 RETURN J6-1 J3-B1
F 4th .......... . 2 and C
F 3rd .......... . 1 and C
SOLENOID 2 J6-3 J3-B2
F 2nd .......... . 2 and A
F 1st. ......... . 1 and A
Neutral
SOLENOID 3 J6-4 J3-C1
R 1st. ......... . 3 and A
R 2nd .......... . 3 and C
J6-19 J3-C2 R 3rd .......... . 3 and B
SOLENOID 3 RETURN
R 4th .......... . 3 and D
SOLENOID 4 RETURN J6-6 J3-D1
SOLENOID A J6-10 J3-D2
SOLENOID A RETURN J6-17 J3-D3
SOLENOID B J6-12 J3-E1
SOLENOID B RETURN J6-11 J3-E2
SOLENOID C J6-23 J3-E3
SOLENOID C RETURN J6-22 J3-F1
SOLENOID D J6-8 J3-F2
SOLENOID D RETURN J6-7 J3-F3

6002-45
SYSTEM ERRORS
The TCU has the ability to detect various reverse position. If the condition causing the error still
discrepancies. exists, the error will again be detected and displayed.
Possible errors are: A CAUTION: How the TCU handles errors

depends upon what type and which error
• Pinched or broken wiring has occurred. The TCU can immediately
• Shorted or open coils shift the transmission to neutral in the
• Bad connections event of an error. The transmission will
• Shorted wiring (to either ground or vehicle voltage.) remain in neutral until the error has been
• Illogical input from the handle resolved and the shift lever cycled to
• Magnetic pickup sensor failures neutral and back to the desired position.
All errors are neutral recoverable, unless the condition The TCU retains the last eight non-repeating error
causing the error prevents the TCU from detecting a codes in nonvolatile memory in the order in which
legal neutral condition. After a neutral recovery, the they have occurred. These codes are available for
shift lever may be placed back into a legal forward or future retrieval.

6002-46
ANALOG TCU DIAGNOSTIC CODES
NOTE: The following is a list of the diagnostic codes Diagnostic Code: 25

that may be generated by the TCU.
Description: Solenoid B cannot get up to requested
Diagnostic Code: 20 current.
Description: Solenoid 1 cannot get up to requested Probable Cause: Open or short to ground in
current. Solenoid B circuit from output pin J3-E1 to return pin
J3-E2.
Probable Cause: Open or short to ground in
Solenoid 1 circuit from output pin J3-A3 to return pin Diagnostic Code: 26
J3-B1.
Description: Solenoid C cannot get up to requested
current. Solenoid C circuit from output pin J3-E3 to return pin
J3-F1.
Solenoid 2 circuit from output pin J3-B2 to return pin Diagnostic Code: 27
J3-B3.
Description: Solenoid D cannot get up to requested
current. Solenoid D circuit from output pin J3-F2 to return pin
J3-F3.
Solenoid 3 circuit from output pin J3-C1 to return pin Diagnostic Code: 28
J3-C2.
Description: Solenoid E cannot get up to requested
Description: Solenoid 4 cannot get up to requested Probable Cause: Open or short to ground in circuit
current. from output pin J3-G1 to return pin J3-G2.
Probable Cause: Open or short to ground in Diagnostic Code: 29 Not Used

Solenoid 4 circuit from output pin J3-C3 to return pin
J3-D1.
Diagnostic Code: 24
Description: Solenoid A cannot get up to requested

current.

Solenoid A circuit from output pin J3-D2 to return pin
J3-D3.

6002-47
Diagnostic Code: 30 Diagnostic Code: 35
Description: Solenoid 1 cannot drop to requested Description: Solenoid B cannot drop to requested
current. current.
Probable Cause: Short to positive in Solenoid 1 Probable Cause: Short to positive in Solenoid B
circuit from output pin J3-A3 to return pin J3-B1. circuit from output pin J3-E1 to return pin J3-E2.
Description: Solenoid 2 cannot drop to requested Description: Solenoid C cannot drop to requested
current. current.
Probable Cause: Short to positive in Solenoid 2 Probable Cause: Short to positive in Solenoid C
circuit from output pin J3-B2 to return pin J3-B3. circuit from output pin J3-E3 to return pin J3-F1.
Description: Solenoid 3 cannot drop to requested Description: Solenoid D cannot drop to requested
current. current.
Probable Cause: Short to positive in Solenoid 3 Probable Cause: Short to positive in Solenoid D
circuit from output pin J3-C1 to return pin J3-C2. circuit from output pin J3-F2 to return pin J3-F3.
Diagnostic Code: 33 Diagnostic Code: 38 Not Used
Description: Solenoid 4 cannot drop to requested

current.
Probable Cause: Short to positive in Solenoid 4

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

current.
Probable Cause: Short to positive in Solenoid A

circuit from output pin J3-D2 to return pin J3-D3.

6002-48
Diagnostic Code: 40 Legal conditions are:
Probable Cause: Request for an undefined shift 1. NOT PARK active and NEUTRAL passive.
being made.
2. NOT PARK passive and NEUTRAL active.
Diagnostic Code: 41
Diagnostic Code: 45
Probable Cause: TCU has not seen a legal neutral
signal (input pin J2-A 1) since initial power-up of Probable Cause: PARK (input pin J2-B3) is active
system. but NEUTRAL (input pin J2-A1) is passive at TCU.
Description: Bottom of Clutch input on J1-K2 is Probable Cause: NOT PARK (input pin J1-K1) and
passive. PARK (input pin J2-B3) are simultaneously active at
TCU.
Probable Cause: Input at J1-K2 must be connected
to system voltage on applications which do not utilize Legal conditions are:
inching.
1. NOT PARK active and PARK passive.
Diagnostic Code: 43
2. NOT PARK passive and PARK active.
Probable Cause: NOT PARK (input pin J1-K1) and
PARK (input pin J2-B3) are both passive at TCU. Diagnostic Code: 49
Legal conditions are: Probable Cause: Handle signal is park but PARK
PRESSURE (input pin J2-B3) is passive at TCU.
Legal conditions are:
1. PARK PRESSURE signal active while shift handle
Diagnostic Code: 44 is in park position.
Probable Cause: NOT PARK (input pin J1-K1) and 2. PARK PRESSURE signal passive while shift
NEUTRAL (input pin J2-A 1) are simultaneously handle is in gear.
passive at TCU.

6002-49
Probable Cause: UPSHIFT (input pin J1-H2) and Description: Invalid 5 bit selector code.
DOWNSHIFT (input pin J1-H3) are simultaneously
active at TCU. Probable Cause: Faulty gear selector/shift handle or
faulty wiring between selector and TCU.
Diagnostic Code: 51
Diagnostic Code: 60
Probable Cause: FORWARD (input pin J1-J1) and
REVERSE (input pin J1-J2) are simultaneously active Description: Valve driver supply voltage (TCU pin
at TCU. J3-A1) too low.
Diagnostic Code: 52 Probable Cause: Must be above 17 volts on

24 volt system.
NEUTRAL (input pin J2-A 1) and REVERSE (input pin Diagnostic Code: 80
J1-J2) are simultaneously passive at TCU.
Probable Cause: Engine MPU signal (input pin
Diagnostic Code: 54 J1-B1) missing or frequency is too low.
Probable Cause: Invalid requested gear calculation. Diagnostic Code: 82
Diagnostic Code: 56 Probable Cause: Output MPU signal (input pin

J1-A3) missing or frequency is too low.
Probable Cause: NEUTRAL (input pin J2-A 1) and
FORWARD (input pin J1-J1) are simultaneously Diagnostic Code: 84
active at TCU.
Probable Cause: Illegal or undefined vehicle mode
Legal conditions are: code.
1. NEUTRAL active and FORWARD passive. Diagnostic Code: 85

2. NEUTRAL passive and FORWARD active.
Probable Cause: PARK (input pin J2-B3) is active
Diagnostic Code: 57 but NEUTRAL (input pin J2-A1) is passive at TCU.
Probable Cause: NEUTRAL (input pin J2-A 1) and Diagnostic Code: 86

REVERSE (input pin J1-J2) are simultaneously active
at TCU. Probable Cause: Inching pedal TOP OF CLUTCH
signal (input pin J1-K3) is active but BOTTOM OF
Legal conditions are: CLUTCH (input pin J1-K2) is open.
1. NEUTRAL active and REVERSE passive. Diagnostic Code: 87

2. NEUTRAL passive and REVERSE active.
Probable Cause: PARK (input pin J2-B3) and
Diagnostic Code: 58 FORWARD (input pin J1-J1) are simultaneously
active at TCU.
Probable Cause: START (input pin J2-B2) went
active at TCU disabling internal solenoid power.
START should be active only when ignition is in
"START" position and starter is cranking.

6002-50
Probable Cause: PARK (input pin J2-B3) and Probable Cause: WHEELS-UP (input pin J1-H1) and
REVERSE (input pin J1-J2) are simultaneously active WHEELS-DOWN (input pin J1-H2) are both active.
at TCU.
Diagnostic Code: 99
Diagnostic Code: 89
Probable Cause: Attempt to change wheels-up
Probable Cause: PARK (input pin J2-B3) and NOT wheels-down mode while in an out-of-neutral
PARK (input pin J1-K1) are simultaneously passive at condition.
TCU.
Diagnostic Code: 100
Diagnostic Code: 90
Probable Cause: Sump temperature (input on J1-C3)
Probable Cause: PARK (input pin J2-B3) and NOT is too low for calibration.
PARK (input pin J1-K1) are simultaneously active at
TCU. Diagnostic Code: 101
Diagnostic Code: 91 Probable Cause: Engine speed is too high for

calibration.
Probable Cause: Seat switch (input pin J2-C3) and
NEUTRAL (input pin J2-A 1) are simultaneously Diagnostic Code: 102
passive at TCU.
Probable Cause: Engine speed is too low for
Diagnostic Code: 92 calibration.
Probable Cause: Engine speed is at or near Diagnostic Code: 103

manufacturer's warranty void level.
Probable Cause: Output speed detected during
Probable Cause: CARRIER CAB and UPPER CAB Diagnostic Code: 104
inputs are simultaneously active at TCU.
Probable Cause: No cylinder speed detected during
inputs are simultaneously passive at TCU.
Probable Cause: Incorrect forward cylinder speed
Diagnostic Code: 95 ratio during calibration.
Probable Cause: NEUTRAL (input pin J2-A 1) is Diagnostic Code: 106

passive while switching cab modes.
Probable Cause: Incorrect reverse cylinder speed
Probable Cause: Upper cab mode selected but Diagnostic Code: 107
transmission gear is not a legal gear range for upper
cab mode. Probable Cause: Cylinder speed will not drop below
the start count speed.
Diagnostic Code: 97
Probable Cause: Upper cab mode selected but

FORWARD NEUTRAL and REVERSE inputs are all
passive at TCU.

6002-51
Diagnostic Code: 108 Error: Clutch B fast fill time exceeds 300 ms.
Error: Holding clutch pressure exceeds 90 psi. Diagnostic Code: 115
Diagnostic Code: 109 Error: Clutch C fast fill time exceeds 300 ms.
Error: Clutch 1 fast fill time exceeds 300 ms. Diagnostic Code: 116
Diagnostic Code: 11 0 Error: Clutch D fast fill time exceeds 300 ms.
Diagnostic Code: 111 Error: Clutch hold pressure is above 90 psi.
Diagnostic Code: 112 Error: Clutch R fast fill time exceeds 300 ms.
Diagnostic Code: 113 Error: Clutch L fast fill time exceeds 300 ms.
Error: Clutch A fast fill time exceeds 300 ms. Diagnostic Code: 120
Diagnostic Code: 114 Error: Clutch M fast fill time exceeds 300 ms.

6002-52
Diagnostic Code: 121 Probable Cause: Transmission temperature (J1-C3)

is too high.
Probable Cause: Clutch H fast fill time exceeds 300
ms. Diagnostic Code: 154
Diagnostic Code: 127 Probable Cause: Engine MPU circuit (J1-B1) open.
Probable Cause: Attempt to calibrate with PARK Diagnostic Code: 155

(input pin J2-B3) input passive at TCU. Park brake
must be set during calibration. Probable Cause: Output MPU circuit (J1-A3) open.
Probable Cause: Low air pressure. Probable Cause: Cannot get shift constants from
EEPROM.
Probable Cause: Analog inching voltage is too low.
Probable Cause: Group one enable low should be
Diagnostic Code: 146 high.
Probable Cause: Temperature sensor circuit SENSE Diagnostic Code: 162

(J1-C3) or GROUND (J1-D1) shorted or open.
Probable Cause: Group two enable low should be
Probable Cause: Analog input (J1-D3) shorted or Diagnostic Code: 163

open.
Probable Cause: Group three enable low should be
Probable Cause: Analog inching voltage (J1-F3) is Diagnostic Code: 164

too high.
Probable Cause: Pointer in capcom20 gets too big.
Probable Cause: Vehicle system voltage (J3-A 1) is
too high. Probable Cause:Safety FET A failed OFF.

6002-53
Probable Cause: Safety FET A failed ON. Probable Cause: EEPROM checksum error.
Probable Cause: Safety FET B failed OFF. Probable Cause Code: Solenoid 11 cannot get up to
requested current.
Probable Cause: Open or short to ground in circuit
Probable Cause: Safety FET B failed ON. from output pin J3-H2 to return pin J3-H3.
Probable Cause: Safety FET C failed OFF. Probable Cause Code: Solenoid 12 cannot get up to
requested current.
Probable Cause: Safety FET C failed ON. from output pin J3-J1 to return pin J3-J2.
Probable Cause: Group one enable high should be Probable Cause Code: Solenoid 13 cannot get up to
low. requested current.
Diagnostic Code: 172 Probable Cause: Open or short to ground in circuit

from output pin J3-J3 to return pin J3-K1.
Probable Cause: Group two enable high should be
low. Diagnostic Code: 178
Diagnostic Code: 173 Probable Cause Code: Solenoid 11 cannot drop to

requested current.
Probable Cause: Group three enable high should be
low. Probable Cause: Short to positive in circuit from
output pin J3-H2 to return pin J3-H3.

6002-54
Probable Cause Code: Solenoid 12 cannot drop to Probable Cause: CCO communications link failure
requested current. between master TCU and slave TCU (CCO BUS-
(J2-E3) and ceo BUS+ (J2-B2)).
Probable Cause: Short to positive in circuit from
output pin J3-J1 to return pin J3-J2. Diagnostic Code: 199
Diagnostic Code: 180 Probable Cause: This is a non-functional base TCU.

No application specific software has been
Probable Cause Code: Solenoid 13 cannot drop to programmed into it.
requested current.

output pin J3-J3 to return pin J3-K1.

6002-55
GLOSSARY
Analog: A signal which has a continuous range of lntershift Pause Time: The minimum time delay
possible voltages. between shifts. A value preprogrammed into the TCU.
Digital: A signal which consists of only two voltage Neutral Recoverable: The process where a detected
levels-usually 0 volts and +5 volts. On/Off type fault is maintained and displayed by the TCU until the
signals are also considered to be digital. shift lever is cycled to neutral (park on some
systems) and the TCU detects the proper combination
Active: The high voltage (+12V I +24V) state of a of inputs for a legal neutral (park) condition, at which
digital input. Dependent upon vehicle system voltage. time the displayed fault will be cleared. The fault
code will still be maintained in TCU memory for future
Actual Gear: The actual physical gear of the recall.
transmission, regardless of shift lever position or
controller operation. Next Gear: The next gear the controller plans to
enter. The next gear will become the current gear if
Bus: Serial communications link which interconnects no faults are detected and all conditions for entering
intelligent electronic modules. the next gear are met.
Limp-Home: A hardware function which allows Nonvolatile Memory: Memory that retains its data
limited vehicle motion in the event of failure of certain even though power to the system has been removed.
components.
Passive: The low voltage (OV) state of a digital input.
Commanded Gear: The gear selected by the
combination of the shift lever position and the state of Previous Direction: The direction of vehicle motion
the Forward, Reverse, Neutral, and Not Neutral before a shuttle shift is initiated.
inputs. The 'destination' gear.
Previous Gear: The previous current gear.
Current Gear: The gear the controller is currently
attempting to drive the transmission into by the Sequence Shift: The type of shift which consists of
application of commands to the valves. shifting from a gear to an adjacent gear.
Downshift Inhibit: The prohibiting of downshifting, by Sequential Shifting: Multiple sequence shifts with no
the TCU, to prevent harsh and abrupt shifts or delay between shifts other than the programmed
possible overspeed conditions of the engine. The intershift pause time.
downshift will be inhibited until the current speed ratio
will permit the shift to take place. Shuttle Shift: A shift to a gear in the opposite
direction of vehicle travel made by moving the shift
Fault: An abnormal condition which results in a lever between the Forward and Reverse positions.
perceived performance change or in a loss of function
which may result in performance loss or system
damage.

6002-56
ABBREVIATIONS AND ACRONYMS USED IN TCU GROUP
TCU: Transmission Control Unit V: Volt
PWM: Pulse Width Modulation CYL: Cylinder
MPU: Magnetic Pickup Sensor ENG: Engine
GND: Ground TEMP: Temperature
RPM: Revolutions Per Minute CAN: Controller Area Network
P: Park SOL: Solenoid
DC: Direct Current POT: Potentiometer
TOC: Top of Clutch CCD: Chrysler Collision Detection
BOC: Bottom of Clutch

Section
6002
TRANSMISSION SPECIFICATIONS, PRESSURE

CHECKS, AND TROUBLESHOOTING
885 Grader

6002-2
TABLE OF CONTENTS 885

SPECIAL TOOLS ................................................................................ 3
SPECIFICATIONS ................................................................................ 6
TEST AND TROUBLESHOOTING ................................................................... 7
Theory of Operation Clutch Actuation .............................................................. 7
Gear Selection ................................................................................. 7
Theory of Operation Hydraulic System .............................................................. 8
Clutch Solenoid Voltage Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Test Solenoids. . . . . . . . . . . ..................................................................... 9
Solenoid Valve Operation ...................................................................... 10
Suction Leak Test ............................................................................ 11
8-4 Power Flow Forward Speeds . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................... 12
8-4 Power Flow Reverse Speeds . . . . . . . .. . . . . . . ....................................................14
Troubleshoot Transmission System Malfunctions .................................................... 16
Powershift Troubleshooting - internal disconnect models only ............................................ 20
TRANSMISSION CONTROL UNIT ...................................................................21
Specifications .................................................................................21
Troubleshooting Introduction .......................................................................21
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................... 22
Calibration .................................................................................. 23
Clutch Calibration . . . . . . . . . . . . . . . . ............................................................ 24
SYSTEM COMPONENTS ........................................................................ 25
Transmission Control Unit (TCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 26
Engine Speed Magnetic Pickup Sensor (input speed) ..................................................27
Cylinder Magnetic Pickup Sensor (MPU) ............................................................27
Output Speed Magnetic Pickup Sensor (MPU) ........................................................28
Electronic Gear Selector ........................................................................29
Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............................................30
Gear I Diagnostic Indicator or "CCD display" ......................................................... 30
Inching Pedal . . . . . . . . . . . . . . . . . . ..............................................................31
Transmission Analog Inching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 32
TVP (Transient Voltage Protection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . ...... 33
J1 Connector, Transmission Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
J4 Connector Bump Shifter Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
J6 Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Transmission Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Function of Proportional Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Proportional Valves, Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SYSTEM ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ANALOG TCU DIAGNOSTIC CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
ABBREVIATIONS AND ACRONYMS USED IN TCU GROUP .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

6002-3
SPECIAL TOOLS
CAS-1953A Transmission supplemental fitting kit. CAS-1808 Flowmeter kit
Includes: CAS-2324 special 90 degree adapter and
CAS-2702 Flowmeter adapter
CAS-2325 plug and cap set.
CAS-2278 Flow test kit
CAS-1804 Master pressure test kit
75289949 - Clutch Stage Lifting tool. 7531 0179 - Sizzing sleeve
75289950 - Stack nest for assembly. 75310181 - Oil seal guide
75301709 - 75310178 Installation tools. 7531 0182 - Sleeve inst. adapter.
75310177- 75310186- Assembly tools. 7531 01888 - Clutch stk clearance gage.
IMPORTANT: The special tools listed are required to properly service the transmission.
JL
A-4X 17/32 Drill Through 5/8-11 UNC-28 Tap 1-13.875 in. (98.425mm)
through J-4.31 in. (1 09.47mm)
B-9.968 in. (253.187mm) K-3.52 in. (89.40mm)
C-4x 1/2 x 45· L-4.528 in. (115.011 mm)
D-2.31 in. (58.67mm) M-.75 in. (19.05mm)
E-5.984 in. (151.993mm) N-4.625 in. (117.475mm)
F-2.362 in. (59.994mm) 0-7x 11/16 Drill Through
G-8.79 in. (223.26mm) P-.69 in. (17.52mm)
H-4.625 in. (117.475mm) Q-3.77 in. (95.75mm)
R- 2.992 in. (75.996mm)

6002-4
ASSEMBLY STAND PLATE
A-1.75 in. (44.45mm)

J-13.875 in. (352.425mm)
B-9.96 in. (252.98mm)
K-4.528 in. (115.011 mm)
C-8X 11/16 Drill Through
L-5.84 in. (148.33mm)
D-5.984 in. (151.993mm)
M-.5 in. (12. 7mm)
E-.5 in. (12. 7mm)
N-.25 (6.35) radius in corner
F-1.500-1.505 in. (38.1-38.227mm)
0-17/64 Drill Through as Shown
G-2.362 in. (59.994mm)
P-1.46 in. (37.08mm)
H-6.48 in. (164.59mm)
Q-2.992 in. (75.996mm)
1-2.25 in. (57.15mm)
R- 3.00 in. (76.2mm)
ENG 6-75350
May, 2003 Printed in Brazil
6002-5
FRONT HOUSING LIFTING TOOL
II
E I
I
; M
F
Iu I
~
14-----{ L }-------1~
A-1.42 in. (36.05mm) K-3.70 in. (94.01 mm)

B-4X .38 in. (9.52mm) L-4.83 in. (122.78mm)
C-17/32 Drill Through 5/8-11 UNC M-3.29 in. (83.6mm)
D-.75 in. maximum (19.05mm) N-5.43 in. (138mm)
E-4.99 in. (126.7mm) 0-.50 in. minimum (12.7mm)
F-3.29 in. (83.6mm) P-1.46 in. (37.08mm)
G-1.44 in. (36.5mm) Q-2.992 in. (75.996mm)
H-.47 in. (12mm) R- 3.00 in. (76.2mm)
1-.71 in. (18.11 mm)
J-2.88 in. (73.17mm) NOTE: Used for lifting main case front housing.

6002-6
SPECIFICATIONS
o DF-250 (Transmission model) Weight (Application Dependent) 703 Kg (1550 lbs)
o DF-250 Input-to-Output 550 mm (21.65 in)
o DF-250 Rating (Depending on Input power(maximum) - 224 kW (300

application) SAE hp)
Input no load speed (maximum) - 3000

rpm
Turbine torque (maximum) - 1898 N·m

(1400 lb-ft)
o DF-250 Mountings Available Engine
Midship
Remote
o DF-250 Clutches Fully modulated, oil cooled, multidisc,

hydraulic actuated and self-adjusting.
o DF-250 Gearing Constant mesh, in line, high contact

ratio ground gears. Up to eight speeds
forward and four speeds reverse.
o DF-250 Oil Hydraulic Transmission Fluid.
o DF-250 Filter Remote mounted spin-on type filter.
Transmission Operating Conditions Maximum Input Speed 3000 rpm
Test Input Speed 2000 rpm
Maximum Continuous Operating 93·c (200.F)

Temperature
Maximum Intermittent Operating 11 o·c (230.F)

Temperature
Maximum Temperature 121·c (250.F)
Normal Operating Temperature 65-93·c (150-200.F)
Check Oil Level Temperature 3TC (1 oo·F)
Pressures and Flows at Control Pump Pressure (test input 17.58-19.65 Bar (255-285 psi)
Valve speed)
Pump Flow (test input speed) 87-102 Umin (23-27 gpm)
Clutch Pressure (test input 16.55-19.31 Bar (240-280 psi)

speed)
Lube, In Pressure (test input 1.38-4.14 Bar (20-60 psi)

speed)
Test and Troubleshooting 6002-7
THEORY OF OPERATION CLUTCH ACTUATION
Hydraulic oil pressure is directed from the proportional piston area causing it to move toward the clutch
valve, through passages in the valve body, to a pack, compressing the bellville piston return springs
drilled passage in the main case that directs the oil and removing the free clearance in the clutch. The
pressure to the seal rings on the end of the clutch piston also moves the lube shut-off washer, trapped
shaft. The oil pressure is transferred from the between the piston and the bellville springs, causing
stationary housing to the rotating shaft in the area it to uncover the lube holes that provide cooling oil
between the shaft seal rings. The oil pressure then flow to the clutch. Once the free clearance in the
travels down a hole in the shaft until it enters the clutch is eliminated the piston applies pressure to the
area enclosed by clutch shaft weldment, the clutch clutch plates causing the clutch to transmit torque in
apply piston and the piston seals. Here it acts on the proportion to the oil pressure applied.
GEAR SELECTION
Two clutches must be engaged in order to transmit referred to as speed clutches. The speed clutches
torque from the transmission input to the transmission connect the cylinder gear train to the output shaft of
output shaft. In Neutral all clutches are in the the transmission at various ratios. Working in
released condition. conjunction with the directional clutches up to 8
speed ranges in forward and 4 ranges reverse
The clutches numbered "1" through "4" are referred to directions are possible. The speed clutches are
as directional clutches. Clutches "1" and "2" engage located in the lower part of the transmission.
forward gears and clutches "3" and "4" engage
reverse gears. These clutches have two passages NOTE: The following table shows which clutches are
through the shaft in order to maximize the "lube flow" engaged for each ratio in a eight speed
to cool the clutches. These clutches have more forward and four speed reverse.
friction surface area and a higher thermal capacity
than the speed clutches. The directional clutches are FORWARD REVERSE
Range Directional Speed Directional Speed
used for modulation during shifting and when using
the clutch pedal. The directional clutches connect the
"1" "A" "3" "A"
input shaft of the transmission through various ratios 2 "2" "A" "3" "C"
to the cylinder gear train and are located in the upper 3 "1" "C" "3" "B"
part of the transmission. 4 "2" "C" "3" "D"
5 "1" "B"
6 "2" "B"
The clutches lettered "A", "B", "C" and "D" are
7 "1" "D"
8 "2" "D"

6002-8
THEORY OF OPERATION HYDRAULIC SYSTEM
Oil is picked up by the transmission charge pump main regulator valve to the charge circuit controlled
from the transmission sump through a suction screen. by the flow restrictions in the heat exchanger and the
It travels through an external suction tube to the inlet lube circuits.
side of the charge pump. The charge pump is an The cooled oil returning to the valve body from the
external gear pump with fixed clearance end plates heat exchanger is directed to the lube circuit. An
and the gear shafts supported by bushings. The internal manifold in the transmission main case
pump is driven by a gear train directly coupled to the directs the lube oil to the ends of each of the clutch
engine and has a displacement such that it pumps 25 shafts. This oil flow passes through the lube shut-off
to 27 gpm at engine high idle speed. washers on the engaged clutches and provides the
cooling for the clutches. There is also leakage flow to
From the pump the oil is directed to a filter assembly. the disengaged clutches to lubricate and cool them
The filter head has an internal bypass valve that and many orifices provide flow to lubricate the
bypasses oil to a dedicated port when the pressure bearings on these shafts. After exiting the clutch and
drop across the filter element exceeds 60 psi. bearings on these shafts the oil returns to the
Bypassed oil is directed to the lube system and back transmission sump where it is again picked up by the
to the transmission sump, not to the proportional charge pump. If the pressure in the lube circuit
control valves. The filter head also contains a exceeds 45 psi, the lube relief valve opens and
pressure switch that can be used to alert the operator dumps the excess flow to the transmission sump.
of nearing bypass conditions. This switch actuates at This condition is normal when the transmission is in
a pressure drop across the filter element of 50 psi. neutral with all lube shut-off washers closed and the
engine is at high idle.
Filtered oil from the filter assembly is directed to the
valve body located on the transmission. The flow of
oil is available for the proportional control valves and
clutch transmission. The flow of oil is available for the
proportional control valves and clutch engagement.
The pressure in the system is controlled by the main
regulator valve and is regulated to 270 psi at a flow
of 27 gpm. A small amount of this flow leaks through
the pilot orifices in the proportional control valves and
past the seal rings in the shafts when a clutch is
engaged. The balance of the flow is dumped by the

6002-9
CLUTCH SOLENOID VOLTAGE REQUIREMENTS
NOMINAL 24V
VOLTAGE
ALLOWABLE 20-28V
VOLTAGE
CURRENT .6 AMP
DRAW NOMINAL
CURRENT .7 AMPS
DRAW MAX.
RESISTANCE 53 OHMS
±3%
All checks must be made at the valve.
TEST SOLENOIDS
IMPORTANT: If a solenoid is removed from the 1. Select solenoids 1 and A.

valve, it must be installed in the
same location. If low pressure exists, then solenoid or clutch 1 or A
is defective.
NOTE: To determine the defective clutch is simply a
matter of elimination. For example, if the gear 2. Select solenoids 2 and A.
selected uses solenoids 1 and A, and low
pressure is indicated, select another clutch If pressure is OK, then solenoid or clutch 1 is
that uses one of those solenoids. If pressure defective.
is good, then the solenoid or clutch not
selected is the one that is bad. 3. Select solenoids 1 and B.
To confirm that this is the faulty circuit, select If low pressure exists, then this confirms solenoid or
another clutch that uses this solenoid, to clutch 1 is defective.
assure that the discrepancy is actually in this
solenoid or clutch.
ENG 6·75350 May, 2003 Printed in Brazil

6002-10
SOLENOID VALVE OPERATION
Before troubleshooting the electric circuit of the valve,

the chart shows what solenoids are charged when that
gear is selected.
OF SERIES EIGHT SPEEDS FORWARD AND FOUR REVERSE
OF 8/4
Gear Engage Solenoid Charged
F 8th ................. 2 and D
F 7th ................. 1 and D
F 6th ................. 2 and B
F 5th ................. 1 and B
F 4th ................. 2 and C
F 3rd ................. 1 and C
F 2nd ................. 2 and A
F 1st ................. 1 and A
Neutral
R 1st ................. 3 and A
R 2nd ................. 3 and C
R 3rd ................. 3 and B
R 4th ................. 3 and D

6002-11
SUCTION LEAK TEST
Some indications of a suction leak include: 3. Start the engine.

• Erratic oil pressure. Look for rapid fluctuation of
gauges. 4. Check for erratic oil pressure.
• Pump and filter hoses jumping.
• Excessive air entrainment in the transmission oil. 5. If any of the above conditions are corrected by this
• A long prime time (time elapsed from engine start to procedure, a suction leak exists.
an indication of pump pressure).
NOTE: Check suction tube fitting.
1. Fill to normal level with transmission fluid.
IMPORTANT: Drain the transmission to the correct
NOTE: See PRESSURE AND TEMPERATURE level after the test. Failure to do so
CHECK PORTS (6003-44) for port location. will result in poor performance and
over heating.
2. Install a 21 bar (300psi) pressure
gauge in the pressure port. 6. Verify the level of transmission fluid and correct if
is necessary.

6002-12
1st Gear - 1A, 2nd Gear - 2A 3rd Gear - 1C, 4th Gear - 2C

6002-13

(CONTINUED)
5th Gear - 18, 6th Gear - 28 7th Gear - 1D, 8th Gear - 20

6002-14
R1 Gear- 3A R2 Gear- 3C

6002-15

(CONTINUED)
R3 Gear- 38 R4 Gear- 3D

6002-16
TROUBLESHOOT TRANSMISSION SYSTEM

MALFUNCTIONS
Erratic oil pressure. Low oil level. Add oil to proper level.
Suction tube fitting Replace 0-ring fitting.
Suction manifold 0-ring not sealing. Replace 0-ring.
Foreign object in suction port. Remove object and check for other
contamination.
Excessive oil pressure. Sticking main regulator valve. Replace main regulator valve.
Faulty spring. Replace main regulator valve.
Low oil pressure in all gears. Sticking main regulator valve. Replace main regulator valve.
Control valve body gasket leaking. Replace gaskets.
Charge pump defective. Replace pump.
Internal disconnect seal damage or Replace seal and install correctly.

installed incorrectly.
Faulty main regulator valve. Replace regulator assembly.
Control valve body cracked. Replace control valve body.
Low pressure in one gear but all Contaminated proportional solenoid. Replace proportional solenoid.
right in other gears. *Check suction screen for
contamination.
Broken wire to one solenoid, or Repair wire.

dirty connection.
Broken seal ring on input end of Replace seal ring.

clutch assembly.
Bore sleeve worn. Replace bore sleeves.
Outer or inner piston seal leaking. Replace seals.
Transmission System Pressure is Failed transmission control valve Inspect transmission control valve
Low (One or Two Gears) for external leakage, Remove
control valve. Inspect or replace
gasket.
Leakage in clutch piston or seal Air check to confirm leak.

ring.

6002-17
Solenoid valve malfunction Check for a transmission fault code

on monitor, then check solenoids
using monitor diagnostics.
Filter or filter oil lines blow out. Hose bends too sharp. Reroute hoses.
Defective hose. Replace hose.
Main regulator valve faulty. Change valve and change filter and
oil.
System plumbing incorrect. Correct plumbing.
Filter 0-ring faulty. Replace filter
Foaming Oil Incorrect type of oil Change oil
High oil level Transmission overfilled or hydraulic

pump seal leaking.
Low oil level Add oil
Air leak on suction side of pump Check oil pickup tube on inside of
transmission.
Blows oil out of breather or Transmission over filled with oil. Establish proper oil level. Check
dipstick tube. front seal on auxiliary driven
Vehicle will not move Fault code problem Check fault codes to define
problem.
Voltage to wrong solenoids on Check wiring and connecters.

control valve. (See schematic.)

6002-18
No voltage to all solenoids. Check wiring, controller and

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

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

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

transmission screen. Inspect for metal particles.
Machine "Creeps" In Neutral Warped disks and plates in clutch Check transmission
pack of transmission.
Control valve leakage Do transmission leakage test
Plugged screen on solenoid valve Remove solenoid valve and clean.
Transmission Clutch Slippage Low oil level Add oil.
Wrong oil grade Change oil.
Restricted transmission pump Remove and clean screen.

suction screen.
Leak in transmission control valve Remove valve and inspect gaskets.

or gasket

6002-19
Low transmission pump flow due to Do transmission pump flow test.

worn pump
Stuck solenoid valve Check wiring to solenoid valve.
Remove and inspect solenoid valve.
Transmission overheating. Oil level too high. Establish proper oil level. Check
front seal on auxiliary driven
Engine overheating. Check engine coolant.
Water lines defective on heat Replace lines.

exchanger.
Heat exchanger dirty. Clean heat exchanger.
Clutch slipping. Check clutch pressure.

6002-20
POWERSHIFT
TROUBLESHOOTING-INTERNAL
DISCONNECT MODELS ONLY
885 All wheel drive will not engage. Solenoid stuck open. Voltage Repair or replace solenoid. Check
applied all the time. wiring diagram and connecters.
Damaged or missing disconnect Replace or install disconnect

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

gasket and solenoid cap or
contamination.
885 All wheel drive will not No power to solenoid, solenoid Check for electric power to solenoid
disengage. inoperative. - check wiring and connecters if
O.K., replace solenoid.
Check valve installed backwards. Install check valve properly.

Transmission Control Unit 6002-21
SPECIFICATIONS
Diagnostic indicator Mounting dimensions 50.8 mm (2 in) diameter hole with

88.9 mm (3.5 in) clearance behind
front face of indicator.
TROUBLESHOOTING INTRODUCTION
This introduction is written to initiate an understanding The best strategy in a troubleshooting plan is to
of a strategy which can be used toward solving reduce the random exchange of components by
problems in the driveline system. The preferred carefully analyzing the symptoms and then conducting
technique used in solving problems is to exchange tests which will help determine which component in
components. However, a very important element the system is likely to be the problem. The technician
necessary to the timely and successful conclusion of should use the above component list as a guide in
this activity is the selection of the malfunctioning locating the problem.
component. An understanding of the total system and
an elimination process leading to the component is Because the TCU is a relatively complex and
absolutely necessary before starting the exchange unfamiliar component, it is often the first component
activity. The transmission system as installed consists targeted for exchange. However, TCU malfunctions
of the following components linked together to form a are relatively rare. In addition, the TCU has internal
functioning system. diagnostics capabilities which are usually helpful in
isolating an operational problem. If the TCU responds
• Electronic gear selector to commands and does not provide a diagnostic code
• Wiring harness indicating an internal TCU error, the problem being
• Transmission control unit (TCU) internal to the TCU is unlikely.
• Magnetic pickups (Speed sensors)
• Temperature sensor
• Inching pedal
• Gear/Diagnostic indicator or CCD display
• Transmission control valve
• Transmission hydraulic system {pump, relief
valves, lines, etc.)
• Transmission mechanical system (clutches,
gears, shafts, seals, etc.)

6002-22
THEORY OF OPERATION
The purpose of the Transmission Control Unit (TCU) If no error conditions are detected, based upon a
is to control the functions of the transmission. combination of inputs from the shift lever and other
Upshifting, downshifting, control of the proportional applicable inputs, the TCU will select the proper
solenoids and capability to communicate with a panel transmission gear and command the transmission to
mounted gear/diagnostic indicator are the main shift to this gear. The gear/diagnostic indicator will
functions. The transmission's performance is now show the actual transmission gear.
determined by the various inputs to the TCU. Based
upon these inputs, the TCU commands the The TCU Module uses electrohydraulic proportional
transmission so that maximum performance can be valves to control the operation of the transmission.
achieved under the present operating conditions. All The solenoids controlling the transmission clutches
functions of the TCU are under software control. Park (solenoids A through D & 1 through 4) are driven by
Brake Solenoid function is connected to the TCU, a signal that produces proportional pressure/flow
however it is not controlled by the TCU or software. changes. During modulation, the solenoids are started
out with a low duty cycle and ramped up to full on.
Operation begins when the vehicle's ignition is The initial duty cycle is dependent upon several
switched to the on position, supplying electrical power factors and is not a preset value. The process of
to the TCU and related system components from the modulating these clutches greatly enhances shift
vehicle's power source. The TCU now begins quality.
monitoring all inputs and outputs. If a known conflict
in inputs or a fault condition is detected, the TCU will
command the transmission to stay in neutral
regardless of the shift lever position. A flashing error
code will be displayed on the gear/diagnostic
indicator, and will remain displayed until the error has
been resolved and the shift lever cycled back through
the neutral or park position.

6002-23
CALIBRATION
Reasons to Calibrate
• Matches Transmission Control Unit (TCU) to

Transmission. Default clutch fill and hold values are
placed in the TCU at the factory. Calibration changes
these values to match a particular transmission.
• Reduces Impact Of Manufacturing Tolerances. Since

the clutch fill and hold values are for a particular
transmission, adjustments for differences in parts due to
manufacturing tolerances are automatic.
• Provides For Consistency Between Machines. The

calibration routine makes sure each transmission clutch
starts from the same spot just prior to clutch
engagement.
• When to Calibrate:
1. If solenoid valve assemblies are changed.
2. After repairs involving transmission clutches.
3. If TCU is replaced.
4. If shift quality deteriorates.

6002-24
CLUTCH CALIBRATION: EIGHT FORWARD SPEEDS AND FOUR REVERSE
5. Start and hold the engine speed at 1600 RPM.

Transmissions Eight Forward Speeds and Four The engine governor must hold the engine speed ±
Reverse. 50 RPM.
IMPORTANT: Attempting to calibrate with sump 6. Move the shift handle to the Forward position.
temperature below minimum
calibration temperature (90.F) 7. During the first few seconds of the calibration
will trigger the "warm-up" mode. process, the display will show "---" while testing the
This mode will show "---" on the cylinder speed and response.
display as the transmission warms
to the minimum calibration 8. At this time the Clutch calibration process starts.
temperature at which time the
calibration process will a. Directional and Speed Clutch Holds. The display
automatically begin. Temperatures will show C1 H, C2H, C3H, CAH, CBH, CCH and
below so·F will result in "sump CDH while acquiring the respective "hold" time of
temperature too cold" error 100. each clutch.
b. Directional and Speed Clutch Fills. The display will

1. Bring the transmission oil temperature up to 140· show C1 F, C2F, C3F, CAF, CBF, CCF and CDF
to 16o·F (60. to 71.C) for optimum calibration. while acquiring the respective "fill" time of each
clutch.
2. With the vehicle ignition off, apply the park brake.
9. The display will show END when the routine is
3. Plug a jumper plug (which connects pin A to pin B) finished. At that time move the shift handle back to
in the calibration plug (s16) on the vehicle harness. the Neutral position.
IMPORTANT: Any errors that appear during 10. Shut the vehicle's ignition OFF, which will power
calibration will cause the procedure down the TCU.
to terminate, and you will have to
start the calibration over from the 11. Remove the jumper plug from the calibration plug
beginning. (S16).
4. Power up the TCU by turning on the vehicle The calibration is complete.

ignition. The display should show "CAL".

6002-25
SYSTEM COMPONENTS
1. Transmission control unit (TCU)

2. Engine speed magnetic pickup sensor (input
speed)
3. Cylinder magnetic pickup sensor (MPU)
4. Output speed magnetic pickup sensor (MPU)
5. Electronic gear selector
6. Temperature Sensor
7. Gear/Diagnostic Indicator
8. Inching Pedal
9. Proportional Valves

6002-26
COMPONENT FUNCTIONS
Basic Components
1. Transmission Control Unit (TCU)
FUNCTION
The TCU is the "brain" of the system. It is responsible

for the logic, computation, and decision making
processes of the transmission based on calculations.
How the TCU performs is determined by software
programmed into the TCU's memory. This software is
developed to meet the requirements of the vehicle
manufacturer, and is based on a vehicle performance
analysis. It is application specific, therefore TCUs from
different vehicles are not interchangeable. TCUs can only
be interchanged on vehicles which are identical in all
ways (same engine/drivetrain combination, same wiring,
same shift lever, same vehicle voltage, etc.)
MOUNTING
The TCU must be mounted inside the vehicle cab or

other enclosed area which will not exceed ambient
temperature range (-4o·c to +85.C). It must be mounted
to ensure good electrical grounding between the TCU
and the vehicle chassis, although a ground wire from
battery negative to the TCU is required. It must not be
mounted by any method which would isolate the TCU
from the vehicle chassis. If rubber mounted for shock
protection, a grounding strap must be utilized to ensure
proper grounding.
IMPORTANT: Do not weld on vehicle with battery and

TCU connected or the WARRANTY
WILL BE VOID.
IMPORTANT: The only way to adequately protect the

TCU from damage caused by high
voltage and amperage is to completely
remove all three wiring harness
connectors (J1, J2 and J3) and any
ground strap from the TCU prior to
welding. Disconnecting the battery
supply alone is not sufficient to protect
the TCU from ground voltage feeding
back through the wiring harness.

6002-27
2. Engine Speed Magnetic Pickup Sensor (input speed).
The engine speed magnetic pickup (A) reads engine

generated from the teeth of the charge pump idler gear,
which is in mesh with the input gear.
Input RPM is calculated by pulses per minute divided by

the number of teeth on the input gear.
CONNECTOR PINOUT
ENGINE MPU A J6-29 J1-B1
ENGINE MPU GND B J6-28 J1-C2
3. Cylinder Magnetic Pickup Sensor (MPU)

Cylinder RPM is calculated by pulses per minute divided

by the number of teeth on the cylinder gear.
CONNECTOR PINOUT
CYLINDER MPU A J6-9 J1-B2
CYLINDER MPU GND B J6-16 J1-C2

6002-28
4. Output Speed Magnetic Pickup Sensor (MPU)
The output speed magnetic pickup (E) reads output RPM

by measuring the number of pulses per minute
generated from the teeth of the sixth stage gear. The
sixth stage gear is on the same shaft as the sixth stage
pinion which drives the output gear.
CONNECTOR PINOUT
OUTPUT MPU A J6-18 J1-A3
OUTPUT MPU GND B J6-30 J1-C2

6002-29
5. Electronic Gear Selector
The electronic gear selector handle is a "Bump" The handle can be moved forward to request a
handle which operates in an "I" pattern with a forward gear or moved back to request a reverse
horizontal bar in the middle. Neutral position is in the gear. The release ring under the handle knob must
middle of the pattern along the horizontal bar. While be pulled up to release the neutral lock.
in neutral, the handle can be moved right to request
a higher pre-selected gear or left to request a lower The handle can be moved back to the neutral
pre-selected gear. position at any time without moving the release ring
under the handle knob.
FORWARD
DOWN UP
DOWN UP
DOWN UP
REVERSE
When in the forward or reverse position the handle

can be "bumped" to the right to request an upshift or
to the left to request a downshift.

6002-30
6. Temperature sensor
The temperature sensor (A) is used to determine

transmission fluid temperature.
TEMPERATURE SENSOR A J6-25 J1-C3
TEMPERATURE SENSOR GND B J6-24 J1-D1
7. Gear/diagnostic indicator or "CCD display"
The TCU and gear/diagnostic indicator can be used on

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

88.9 mm (3.5 in) clearance behind the front face.

6002-31
8. Inching Pedal
The inching pedal provides the operator with a device for

controlling modulation of the transmission clutches when
desired. With the pedal fully depressed, the transmission
remains in neutral regardless of shift lever position.
Releasing the inching pedal engages the transmission.
The more the pedal is released, the more the clutches
engage causing the vehicle to 'inch'. When the pedal is
fully released, the transmission clutches are fully
engaged.
CONNECTOR PINOUT
SIGNAL DESCRIPTION CONNECTOR/PIN TCU PIN
VAGND T11-B J1-G1

(ANALOG GROUND)
VAREF T11-C J1-F2

(ANALOG VOLTAGE
REFERENCE)
PEDAL POSITION T11-A J1-F3
TOC INPUT J1-K3

(TOP OF CLUTCH)
NOT BOC INPUT T11-E J1-K2

(BOTTOM OF CLUTCH)
+24V T11-F J2-F2

6002-32
TRANSMISSION ANALOG INCHING
The pedal position output, or "inching" signal, comes pin T11-B) signal and a 5V DC reference (VAREF,
from the 2.5K-ohm potentiometer attached to the pin T11-C), both provided by the TCU. The pedal's
pedal. The potentiometer's angle changes output signal to the TCU {pin T11-A) varies between
proportionally with the degree of pedal depression. the ground and reference levels. The output signal
The potentiometer has an analog ground (VAGND, increases as the pedal is depressed.
lnclllng 'I011lll)lll!;lll. I!!Cf~l!;itlt$

Pe1:!1111 Pot # -~~----- l!;IS p!M:I~IIs ~l)rlli!CS!Id,
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A normally closed switch mechanically linked to the There is no connection to inching pedal pin D (pin
pedal provides the "NOT BOTTOM OF CLUTCH" T11-D).
signal (pin T11-E) to the TCU. The switch contacts
open when the pedal is fully depressed, and are
closed for all other pedal positions. The TCU sees an
active (+24V) signal on J1-K2 whenever the
pedal is "NOT" at the bottom of its travel range.

6002-33
The TVP (Transient Voltage Protection) Module is

available in 24V version.
It has two important functions:
• Supply electrical power to the system.
• Protect the electrical system against electrical

conditions that might otherwise be potentially
damaging, such as load dump and reverse battery
protection.
Protection is provided only when the ignition switch is

on, thus energizing an internal relay which provides an
electrical connection between the vehicle battery and the
protective device inside the TVP.

6002-34
J1 CONNECTOR
NOTE: Connector pinouts reference wiring harness F1-Load sense LO (voltage reference output)
diagram in this group always reference the vehicle F2-lnching pedal HI (voltage reference output)
manufacturers wiring harness diagram for your F3-lnching pedal position (analog voltage input)
application. G1-lnching pedal LO (voltage reference output)
G2-Spare ground
CONNECTOR PINOUT G3-Spare ground
H1-Spare ground
A1-Main battery 1 (TCU Power, +24V) H2-UPSHIFT (Shift code E), (digital input)
A2-Ground 1 H3-DOWNSHIFT (Shift code D), (digital input)
A3-0utput magnetic pickup sensor input (frequency J1-FORWARD (digital input)
input) J2-REVERSE (digital input)
81-Engine magnetic pickup sensor input (frequency J3-Spare input (digital input)
input) K1-NOT PARK (digital input)
82-Cylinder magnetic pickup sensor input (frequency K2-NOT BOTTOM OF CLUTCH (digital input)
input) K3-TOP OF CLUTCH (digital input)
83-Spare magnetic pickup sensor input (frequency
input) Mating connector for J1 is:
C1-F Flow (input)
C2-Magnetic pickup sensor ground • Metri-Pack 150 series 30 way sealed P2S connector
C3-Temperature sensor (analog voltage input)
D1-Temperature sensor ground • Delphi/Packard part number: 12034398
D2-Rear-steer HI (voltage reference output)
D3-Rear-steer position (analog voltage input) • Mating terminals for J1 are Delphi/Packard
E1-Rear-steer LO (voltage reference output) terminals: 12103881
E2-Load sense HI (voltage reference output)
E3-Load sense (analog voltage input) • Tighten connector to TCU 0.8-1.5 N·m (7.1-13.3
lb-in)

6002-35
J2 CONNECTOR
NOTE: Connector pinouts reference wiring harness E3-CCD Bus- (gear I diagnostic indicator)
diagram in this group always reference the vehicle (communication input/output)
manufacturers wiring harness diagram for your F1-Bus ground for communication lines
application. F2-+24 supply voltage output (supply voltage
output)
CONNECTOR PINOUT F3-+24 supply voltage output (supply voltage
output)
A1-Neutral (digital input)
A2-Not neutral (Shift code B), (digital input) Mating connector for J2 is:
A3-Brake cutoff (Shift code C), (digital input)
B1-Program (Shift code A), (digital input) • Delphi/Packard Metri-Pack 150 series 18 way
B2-Start (digital input) sealed P2S connector
B3-Park or park brake pressure (digital input)
C1-Auto I manual mode select (digital input) • Delphi/Packard part number: 12040921
C2-Calibrate (digital input)
C3-Disconnect (digital input) • Mating terminals for J2 are Delphi/Packard
D1-CAN HI (communication input/output) terminals: 12103881
D2-CAN LO (communication input/output)
D3-RS232 TxD (serial communication output) • Tighten connector to TCU 0.8-1.5 N·m (7.1-13.3
E1-RS232 RxD (serial communication input) lb-in)
E2-CCD Bus+ (gear I diagnostic indicator)
(communication input/output)

6002-36
J3 CONNECTOR
NOTE: Connector pinouts reference wiring harness G1- Not Used

diagram in this group, reference the vehicle G2-Not Used
manufacturers wiring harness diagram for your G3-Not Used
application. H1-Not Used
CONNECTOR PINOUT (APPLICATION H2-Disconnect solenoid (PWM output)

DEPENDENT) H3-Disconnect solenoid return (current sense input)
J1-Rear PTO solenoid (PWM output)
A1-Main battery 2 (TCU power +24V) J2-Rear PTO solenoid return (current sense input)
A2-Ground 2 J3-Front PTO solenoid (PWM output)
A3-Solenoid 1 (PWM output) K1-Front PTO solenoid return (current sense input)
81-Solenoid 1 return (current sense input) K2-Ground
82-Solenoid 2 (PWM output) K3-Ground
83-Solenoid 2 return (current sense input)
C1-Solenoid 3 (PWM output) Mating connector for J3 is:
C2-Solenoid 3 return (current sense input)
C3-Solenoid 4 (PWM output) • Delphi/Metri-Pack 150 series 30 way sealed P2S
D1-Solenoid 4 return (current sense input) connector
D2-Solenoid A (PWM output)
D3-Solenoid A return (current sense input) • Delphi/Packard part number: 12048455
E1-Solenoid 8 (PWM output)
E2-Solenoid 8 return (current sense input) • Mating terminals for J3 are Delphi/Packard
E3-Solenoid C (PWM output) terminals: 12103881
F1-Solenoid C return (current sense input)
F2-Solenoid D (PWM output) • Tighten connector to TCU 0.8-1.5 N·m (7.1-13.3
F3-Solenoid D return (current sense input) lb-in)

6002-37
J4 CONNECTOR
BUMP SHIFTER PINOUT B-J2-A2-NOT NEUTRAL (shift code B)

C-J2-A1-NEUTRAL
NOTE: Letters A through J are J6 Pinouts. D-J1-H3-DOWNSHIFT (shift code D)
Number,letter-number,letter callouts (example E-J1-H2-UPSHIFT (shift code (E)
J3-A 1) are TCU callouts. F-J1-J2-REVERSE
G-J1-J1-FORWARD
A-J3-A 1- +24 out H-J1-A2-Ground
J-S 1-A-Neutral start

6002-38
J6 CONNECTOR
CONNECTOR PINOUT 14-J3-G3- Not Used

15-J3-B3-Solenoid 2 return
NOTE: Numbers 1 through 31 are J6 Pinouts. 16-J 1-C2-Magnetic pickup sensor ground
Number,letter-number,letter callouts (example 17-J3-D3-Solenoid A return
J3-B1) are TCU callouts. 18-J1-A3-0utput magnetic pickup sensor
19-J3-C2-Solenoid 3 return
1-J3-B1-Solenoid 1 return 20-J 1-A1-Park brake pressure switch supply
2-J3-A3-Solenoid 1 output (+24V)
3-J3-B2-Solenoid 2 output 21-J2-B3-Park brake pressure switch
4-J3-C1-Solenoid 3 output 22-J3-F1-Solenoid C return
5-J3-C3-Solenoid 4 output 23-J3-E3-Solenoid C return
6-J3-D1-Solenoid 4 return 24-J1-D1-Temperature sensor ground
7-J3-F3-Solenoid D return 25-J1-C3-Temperature sensor
8-J3-F2-Solenoid D output 26-J3-H3-Disconnect solenoid return
9-J1-B2-Cylinder magnetic pickup sensor 27-J3-H1- Not Used
1O-J3-D2-Solenoid A output 28-J1-C2-Magnetic pickup sensor ground
11-J3-E2-Solenoid B return 29-J 1-B 1-Engine speed magnetic pickup sensor
12-J3-E1-Solenoid B output 30-J1-C2-Magnetic pickup sensor ground
13-J3-H2-Disconnect solenoid output 31-J1-A2-Magnetic pickup sensor ground

6002-39
TCU
Jl-AZ
n-B:!
13-Al : - - - - - - - ' ! TVJ> MODULE
NOTE: Letters A,B,C,D,E,F are labels to link to the

next page.
Wiring harness is + 24Volts grader 885

6002-40
AB 0 DE F
H-Fl
JHll
12-m
TCU
J2-A2
12·AI
Jl¥3 .!J
nm Gl!ARJ>!iU'A~
1!-H
JPI
G 0 E
NOTE: The letters G,C,E link to the next page.


6002-41
G C E
TCU
J3-A3 2
B-Bl
J3-B2 3
B-BJ 15
13-Ct 4
B.C2 19
B-CJ j
B-DI 6
B-D2 10
-
13-DJ li
B-El
12~
J3-E2 H> 0\
J3-E3 23 z
- Vol
13-F! 22 as
J3-F2 8 Vol
Vol
J3-F3
N UsedB,.GJ
7
14
az
No UsedB-Ht 27
B·-H2 !3
J3-H3 26
J2-B3 21
20
Jl-Bl 29
Jl-C2 28
.IJ-A3 1.8
Jl,.(i2 30
JJ . . sz 9
Jl,.(i3 1.6
J!-H! 31
J!-CJ 25
TEMP SENSOR GND
J!-DI 24
c
NOTE: The letter C links to the next page.

6002-42
TCU
No UsedB·m
No UsedJHJ<l
13-13 519
J;M;J OliTI'!JfS
JJ,JJ
.J3,J];
A
n-A~ B
JUH c uo
jj,JJ n INP!JJS
E
.1!-Cl F
~-····~-.
::J~ a::::~:::=:
Tl! Sl7
MI"U MPV
~-~ .."'-·
NOTE: Letters C is a label to link the previous page.


6002-43
FUNCTION OF PROPORTIONAL VALVES

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

6002-44
PROPORTIONAL VALVES
CONNECTOR PINOUT Transmission Eight Speeds Forward and
Four Reverse
SIGNAL TRANSMISSION TCU
GEAR ENGAGED ACTIVE SOLENOIDS
DESCRIPTION CONNECTOR PIN
PIN
F 8th .......... . 2 and D
J6-2 J3-A3 F 7th .......... . 1 and D
SOLENOID 1
F 6th .......... . 2 and B
F 5th .......... . 1 and B
F 4th .......... . 2 and C
F 3rd .......... . 1 and C
SOLENOID 2 J6-3 J3-B2
F 2nd .......... . 2 and A
F 1st. ......... . 1 and A
Neutral
R 1st. ......... . 3 and A
R 2nd .......... . 3 and C
J6-19 J3-C2 R 3rd .......... . 3 and B
SOLENOID 3 RETURN
R 4th .......... . 3 and D
SOLENOID 4 RETURN J6-6 J3-D1
SOLENOID A J6-10 J3-D2
SOLENOID A RETURN J6-17 J3-D3
SOLENOID B J6-12 J3-E1
SOLENOID B RETURN J6-11 J3-E2
SOLENOID C J6-23 J3-E3
SOLENOID C RETURN J6-22 J3-F1
SOLENOID D J6-8 J3-F2
SOLENOID D RETURN J6-7 J3-F3

6002-45
SYSTEM ERRORS
The TCU has the ability to detect various reverse position. If the condition causing the error still
discrepancies. exists, the error will again be detected and displayed.
Possible errors are: A CAUTION: How the TCU handles errors

depends upon what type and which error
• Pinched or broken wiring has occurred. The TCU can immediately
• Shorted or open coils shift the transmission to neutral in the
• Bad connections event of an error. The transmission will
• Shorted wiring (to either ground or vehicle voltage.) remain in neutral until the error has been
• Illogical input from the handle resolved and the shift lever cycled to
• Magnetic pickup sensor failures neutral and back to the desired position.
All errors are neutral recoverable, unless the condition The TCU retains the last eight non-repeating error
causing the error prevents the TCU from detecting a codes in nonvolatile memory in the order in which
legal neutral condition. After a neutral recovery, the they have occurred. These codes are available for
shift lever may be placed back into a legal forward or future retrieval.

6002-46
ANALOG TCU DIAGNOSTIC CODES
NOTE: The following is a list of the diagnostic codes Diagnostic Code: 25

that may be generated by the TCU.
Description: Solenoid B cannot get up to requested
current. Solenoid B circuit from output pin J3-E1 to return pin
J3-E2.
Solenoid 1 circuit from output pin J3-A3 to return pin Diagnostic Code: 26
J3-B1.
Description: Solenoid C cannot get up to requested
current. Solenoid C circuit from output pin J3-E3 to return pin
J3-F1.
Solenoid 2 circuit from output pin J3-B2 to return pin Diagnostic Code: 27
J3-B3.
Description: Solenoid D cannot get up to requested
current. Solenoid D circuit from output pin J3-F2 to return pin
J3-F3.
Solenoid 3 circuit from output pin J3-C1 to return pin Diagnostic Code: 28
J3-C2.
Description: Solenoid E cannot get up to requested
Description: Solenoid 4 cannot get up to requested Probable Cause: Open or short to ground in circuit
current. from output pin J3-G1 to return pin J3-G2.
Probable Cause: Open or short to ground in Diagnostic Code: 29 Not Used

Solenoid 4 circuit from output pin J3-C3 to return pin
J3-D1.
Diagnostic Code: 24
Description: Solenoid A cannot get up to requested

current.

Solenoid A circuit from output pin J3-D2 to return pin
J3-D3.

6002-47
Description: Solenoid 1 cannot drop to requested Description: Solenoid B cannot drop to requested
current. current.
Probable Cause: Short to positive in Solenoid 1 Probable Cause: Short to positive in Solenoid B
circuit from output pin J3-A3 to return pin J3-B1. circuit from output pin J3-E1 to return pin J3-E2.
Description: Solenoid 2 cannot drop to requested Description: Solenoid C cannot drop to requested
current. current.
Probable Cause: Short to positive in Solenoid 2 Probable Cause: Short to positive in Solenoid C
circuit from output pin J3-B2 to return pin J3-B3. circuit from output pin J3-E3 to return pin J3-F1.
Description: Solenoid 3 cannot drop to requested Description: Solenoid D cannot drop to requested
current. current.
Probable Cause: Short to positive in Solenoid 3 Probable Cause: Short to positive in Solenoid D
circuit from output pin J3-C1 to return pin J3-C2. circuit from output pin J3-F2 to return pin J3-F3.
Description: Solenoid 4 cannot drop to requested

current.
Probable Cause: Short to positive in Solenoid 4

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

current.
Probable Cause: Short to positive in Solenoid A

circuit from output pin J3-D2 to return pin J3-D3.

6002-48
Diagnostic Code: 40 Legal conditions are:
Probable Cause: Request for an undefined shift 1. NOT PARK active and NEUTRAL passive.
being made.
2. NOT PARK passive and NEUTRAL active.
Diagnostic Code: 41
Diagnostic Code: 45
Probable Cause: TCU has not seen a legal neutral
signal (input pin J2-A 1) since initial power-up of Probable Cause: PARK (input pin J2-B3) is active
system. but NEUTRAL (input pin J2-A1) is passive at TCU.
Description: Bottom of Clutch input on J1-K2 is Probable Cause: NOT PARK (input pin J1-K1) and
passive. PARK (input pin J2-B3) are simultaneously active at
TCU.
Probable Cause: Input at J1-K2 must be connected
to system voltage on applications which do not utilize Legal conditions are:
inching.
Diagnostic Code: 43
Probable Cause: NOT PARK (input pin J1-K1) and
PARK (input pin J2-B3) are both passive at TCU. Diagnostic Code: 49
Legal conditions are: Probable Cause: Handle signal is park but PARK
PRESSURE (input pin J2-B3) is passive at TCU.
Legal conditions are:
1. PARK PRESSURE signal active while shift handle
Diagnostic Code: 44 is in park position.
Probable Cause: NOT PARK (input pin J1-K1) and 2. PARK PRESSURE signal passive while shift
NEUTRAL (input pin J2-A 1) are simultaneously handle is in gear.
passive at TCU.

6002-49
Probable Cause: UPSHIFT (input pin J1-H2) and Description: Invalid 5 bit selector code.
DOWNSHIFT (input pin J1-H3) are simultaneously
active at TCU. Probable Cause: Faulty gear selector/shift handle or
faulty wiring between selector and TCU.
Diagnostic Code: 51
Diagnostic Code: 60
REVERSE (input pin J1-J2) are simultaneously active Description: Valve driver supply voltage (TCU pin
at TCU. J3-A1) too low.
Diagnostic Code: 52 Probable Cause: Must be above 17 volts on

24 volt system.
NEUTRAL (input pin J2-A 1) and REVERSE (input pin Diagnostic Code: 80
J1-J2) are simultaneously passive at TCU.
Probable Cause: Engine MPU signal (input pin
Diagnostic Code: 54 J1-B1) missing or frequency is too low.
Probable Cause: Invalid requested gear calculation. Diagnostic Code: 82
Diagnostic Code: 56 Probable Cause: Output MPU signal (input pin

J1-A3) missing or frequency is too low.
Probable Cause: NEUTRAL (input pin J2-A 1) and
FORWARD (input pin J1-J1) are simultaneously Diagnostic Code: 84
active at TCU.
Probable Cause: Illegal or undefined vehicle mode
Legal conditions are: code.
1. NEUTRAL active and FORWARD passive. Diagnostic Code: 85

2. NEUTRAL passive and FORWARD active.
Probable Cause: PARK (input pin J2-B3) is active
Diagnostic Code: 57 but NEUTRAL (input pin J2-A1) is passive at TCU.
Probable Cause: NEUTRAL (input pin J2-A 1) and Diagnostic Code: 86

REVERSE (input pin J1-J2) are simultaneously active
at TCU. Probable Cause: Inching pedal TOP OF CLUTCH
signal (input pin J1-K3) is active but BOTTOM OF
Legal conditions are: CLUTCH (input pin J1-K2) is open.
1. NEUTRAL active and REVERSE passive. Diagnostic Code: 87

2. NEUTRAL passive and REVERSE active.
Probable Cause: PARK (input pin J2-B3) and
Diagnostic Code: 58 FORWARD (input pin J1-J1) are simultaneously
active at TCU.
Probable Cause: START (input pin J2-B2) went
active at TCU disabling internal solenoid power.
START should be active only when ignition is in
"START" position and starter is cranking.

6002-50
Probable Cause: PARK (input pin J2-B3) and Probable Cause: WHEELS-UP (input pin J1-H1) and
REVERSE (input pin J1-J2) are simultaneously active WHEELS-DOWN (input pin J1-H2) are both active.
at TCU.
Diagnostic Code: 99
Diagnostic Code: 89
Probable Cause: Attempt to change wheels-up
Probable Cause: PARK (input pin J2-B3) and NOT wheels-down mode while in an out-of-neutral
PARK (input pin J1-K1) are simultaneously passive at condition.
TCU.
Diagnostic Code: 90
Probable Cause: Sump temperature (input on J1-C3)
Probable Cause: PARK (input pin J2-B3) and NOT is too low for calibration.
PARK (input pin J1-K1) are simultaneously active at
TCU. Diagnostic Code: 101
Diagnostic Code: 91 Probable Cause: Engine speed is too high for

calibration.
Probable Cause: Seat switch (input pin J2-C3) and
NEUTRAL (input pin J2-A 1) are simultaneously Diagnostic Code: 102
passive at TCU.
Probable Cause: Engine speed is too low for
Probable Cause: Engine speed is at or near Diagnostic Code: 103

manufacturer's warranty void level.
Probable Cause: Output speed detected during
inputs are simultaneously active at TCU.
Probable Cause: No cylinder speed detected during
inputs are simultaneously passive at TCU.
Probable Cause: Incorrect forward cylinder speed
Probable Cause: NEUTRAL (input pin J2-A 1) is Diagnostic Code: 106

passive while switching cab modes.
Probable Cause: Incorrect reverse cylinder speed
Probable Cause: Upper cab mode selected but Diagnostic Code: 107
transmission gear is not a legal gear range for upper
cab mode. Probable Cause: Cylinder speed will not drop below
the start count speed.
Diagnostic Code: 97
Probable Cause: Upper cab mode selected but

FORWARD NEUTRAL and REVERSE inputs are all
passive at TCU.

6002-51
Diagnostic Code: 108 Error: Clutch B fast fill time exceeds 300 ms.
Error: Holding clutch pressure exceeds 90 psi. Diagnostic Code: 115
Diagnostic Code: 109 Error: Clutch C fast fill time exceeds 300 ms.
Diagnostic Code: 11 0 Error: Clutch D fast fill time exceeds 300 ms.
Diagnostic Code: 111 Error: Clutch hold pressure is above 90 psi.
Diagnostic Code: 112 Error: Clutch R fast fill time exceeds 300 ms.
Diagnostic Code: 113 Error: Clutch L fast fill time exceeds 300 ms.
Error: Clutch A fast fill time exceeds 300 ms. Diagnostic Code: 120
Diagnostic Code: 114 Error: Clutch M fast fill time exceeds 300 ms.

6002-52
Diagnostic Code: 121 Probable Cause: Transmission temperature (J1-C3)

is too high.
Probable Cause: Clutch H fast fill time exceeds 300
ms. Diagnostic Code: 154
Diagnostic Code: 127 Probable Cause: Engine MPU circuit (J1-B1) open.
Probable Cause: Attempt to calibrate with PARK Diagnostic Code: 155

(input pin J2-B3) input passive at TCU. Park brake
must be set during calibration. Probable Cause: Output MPU circuit (J1-A3) open.
Probable Cause: Low air pressure. Probable Cause: Cannot get shift constants from
EEPROM.
Probable Cause: Analog inching voltage is too low.
Probable Cause: Group one enable low should be
Probable Cause: Temperature sensor circuit SENSE Diagnostic Code: 162

(J1-C3) or GROUND (J1-D1) shorted or open.
Probable Cause: Group two enable low should be
Probable Cause: Analog input (J1-D3) shorted or Diagnostic Code: 163

open.
Probable Cause: Group three enable low should be
Probable Cause: Analog inching voltage (J1-F3) is Diagnostic Code: 164

too high.
Probable Cause: Pointer in capcom20 gets too big.
Probable Cause: Vehicle system voltage (J3-A 1) is
too high. Probable Cause:Safety FET A failed OFF.

6002-53
Probable Cause: Safety FET A failed ON. Probable Cause: EEPROM checksum error.
Probable Cause: Safety FET B failed OFF. Probable Cause Code: Solenoid 11 cannot get up to
requested current.
Probable Cause: Safety FET B failed ON. from output pin J3-H2 to return pin J3-H3.
Probable Cause: Safety FET C failed OFF. Probable Cause Code: Solenoid 12 cannot get up to
requested current.
Probable Cause: Safety FET C failed ON. from output pin J3-J1 to return pin J3-J2.
Probable Cause: Group one enable high should be Probable Cause Code: Solenoid 13 cannot get up to
low. requested current.
Diagnostic Code: 172 Probable Cause: Open or short to ground in circuit

from output pin J3-J3 to return pin J3-K1.
Probable Cause: Group two enable high should be
low. Diagnostic Code: 178
Diagnostic Code: 173 Probable Cause Code: Solenoid 11 cannot drop to

requested current.
Probable Cause: Group three enable high should be
low. Probable Cause: Short to positive in circuit from
output pin J3-H2 to return pin J3-H3.

6002-54
Probable Cause Code: Solenoid 12 cannot drop to Probable Cause: CCO communications link failure
requested current. between master TCU and slave TCU (CCO BUS-
(J2-E3) and ceo BUS+ (J2-B2)).
output pin J3-J1 to return pin J3-J2. Diagnostic Code: 199
Diagnostic Code: 180 Probable Cause: This is a non-functional base TCU.

No application specific software has been
Probable Cause Code: Solenoid 13 cannot drop to programmed into it.
requested current.

output pin J3-J3 to return pin J3-K1.

6002-55
GLOSSARY
Analog: A signal which has a continuous range of lntershift Pause Time: The minimum time delay
possible voltages. between shifts. A value preprogrammed into the TCU.
Digital: A signal which consists of only two voltage Neutral Recoverable: The process where a detected
levels-usually 0 volts and +5 volts. On/Off type fault is maintained and displayed by the TCU until the
signals are also considered to be digital. shift lever is cycled to neutral (park on some
systems) and the TCU detects the proper combination
Active: The high voltage (+12V I +24V) state of a of inputs for a legal neutral (park) condition, at which
digital input. Dependent upon vehicle system voltage. time the displayed fault will be cleared. The fault
code will still be maintained in TCU memory for future
Actual Gear: The actual physical gear of the recall.
transmission, regardless of shift lever position or
controller operation. Next Gear: The next gear the controller plans to
enter. The next gear will become the current gear if
Bus: Serial communications link which interconnects no faults are detected and all conditions for entering
intelligent electronic modules. the next gear are met.
Limp-Home: A hardware function which allows Nonvolatile Memory: Memory that retains its data
limited vehicle motion in the event of failure of certain even though power to the system has been removed.
components.
Passive: The low voltage (OV) state of a digital input.
Commanded Gear: The gear selected by the
combination of the shift lever position and the state of Previous Direction: The direction of vehicle motion
the Forward, Reverse, Neutral, and Not Neutral before a shuttle shift is initiated.
inputs. The 'destination' gear.
Previous Gear: The previous current gear.
Current Gear: The gear the controller is currently
attempting to drive the transmission into by the Sequence Shift: The type of shift which consists of
application of commands to the valves. shifting from a gear to an adjacent gear.
Downshift Inhibit: The prohibiting of downshifting, by Sequential Shifting: Multiple sequence shifts with no
the TCU, to prevent harsh and abrupt shifts or delay between shifts other than the programmed
possible overspeed conditions of the engine. The intershift pause time.
downshift will be inhibited until the current speed ratio
will permit the shift to take place. Shuttle Shift: A shift to a gear in the opposite
direction of vehicle travel made by moving the shift
Fault: An abnormal condition which results in a lever between the Forward and Reverse positions.
perceived performance change or in a loss of function
which may result in performance loss or system
damage.

6002-56
ABBREVIATIONS AND ACRONYMS USED IN TCU GROUP
TCU: Transmission Control Unit V: Volt
PWM: Pulse Width Modulation CYL: Cylinder
MPU: Magnetic Pickup Sensor ENG: Engine
GND: Ground TEMP: Temperature
RPM: Revolutions Per Minute CAN: Controller Area Network
P: Park SOL: Solenoid
DC: Direct Current POT: Potentiometer
TOC: Top of Clutch CCD: Chrysler Collision Detection
BOC: Bottom of Clutch

Section
6003
TRANSMISSION
845 - 865 Grader

6003-2
TABLE OF CONTENTS 845 - 865

TRANSMISSION COMPONENT IDENTIFICATION ................................................ 3
TRANSMISSION MOUNTING I SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHARGE PUMP . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIRECT DRIVE INPUT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
MAIN CASE FRONT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
GEAR RATIO GROUP ..................................................................... 80
MAIN CASE REAR HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
BRAKE GROUP.......................................................................... 129
REPLACE CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

6003-3
DIRECT DRIVE TRANSMISSION COMPONENT IDENTIFICATION
A-Direct drive input shaft J-Brake disk

B-Front cover assembly K-Magnetic pickup sensor
C-Charge pump group L-Suction screen assembly
D-Main case front housing M-Output yoke fitting
E-Main case rear housing N-Control valve group
F-Dipstick gauge 0--Auxiliary pump drive
G-Dipstick tube assembly P-First stage output shaft
H-Disk brake caliper assembly Q-Suction Tube
1-Yoke Flange R-Ground drive pump (Application dependent)
S-Magnetic pickup sensor

6003-4
TRANSMISSION LIFTING PROCEDURE
Use a lift sling similar to (A). It should hold the

transmission level without bending the lift hangers (B).
TRANSMISSION REPAIR STAND
NOTE: The repair stand (A) used in this manual is OTC

DIVISION part number 1735, capacity is 907 Kg
(2000)Ibs.
OTC Division
Sealed Power Corporation
655 Eisenhower Drive
Owatonna, Mn 55060
When any other stand is used, consult the

Manufacturer's instructions for mounting.
Approximate dry weights:

Model 845 - 865 = 545 Kg (1250 lbs).
Actual weights depend on the options included.
ENG 6-46761 May, 2003 Prin1ed in Brazill

6003-5
MOUNTING OF SERIES TRANSMISSION TO

REPAIR STAND
NOTE: See Section No. 6002, "Special Tools" for Assembly

Stand Plate drawings.
REMOVE AND INSTALL INPUT HOUSING

MAGNETIC PICKUP SENSOR
1. Remove two cap screws (A), two lock washers (B),

two flat washers (C), cover (D), sensor (E) and 0-ring
(F).
2. Clean and inspect for wear and damage.
INSTALL:
3. Lubricate new o-ring and install in reverse order.
REMOVE AND INSTALL CYLINDER

MAGNETIC PICKUP SENSOR
A CAUTION: Wear eye protection when removing

or installing snap rings.
1. Remove snap ring (A).
2. Remove washer (B).
3. Remove magnetic sensor (C).
INSTALL
1. Lubricate new o-ring (D).
2. Install component items in reverse order.

6003-6
REMOVE AND INSTALL OUTPUT MAGNETIC

PICKUP SENSOR
1. Remove two cap screws (A), two lock washers (B),

two flat washers (C), cover (D), sensor (E) and 0-ring
(F).
2. Clean and inspect for wear and damage.
INSTALL:
3. Lubricate new o-ring and install in reverse order.

6003-7
OTHER MATERIAL
Number Name Use
Transmission fluid All moving parts and o-rings.
SPECIFICATIONS
Charge pump-to-input housing cap Torque 100 N·m (74 lb-ft)

screws.
Suction manifold-to-input housing Torque 25 N·m (18 lb-ft)

cap screws.
Suction tube-to-charge pump. Torque 190 N·m (140 lb-ft)
Suction tube-to-suction manifold. Torque 190 N·m (140 lb-ft)
Wiring harness bracket-to-rear Torque 87 N·m (64 lb-ft)

housing cap screw.
Wiring harness connector-to-wiring Torque 18-27 N·m (13-20 lb-ft)

harness bracket

6003-8
REMOVE WIRING HARNESS
1. Loosen nut (A).
NOTE: Tag all wiring connectors for identification

before removing wiring harness.
2. Unfasten all weather pack connectors (B).
3. Remove wiring harness (C).
4. Inspect for wear and damage.
ENG 6-46761 January, 2003 Printed in Brazil

6003-9
DISASSEMBLE SUCTION TUBE GROUP
A-0-ring fitting (2 used) C-Suction screen assembly E-Gasket G-O-ring

8-Suction tube D-Cap screw (2 used) F-Suction manifold

6003-10
REMOVE SUCTION TUBE AND OIL

MANIFOLD ASSEMBLY
IMPORTANT: All oil should be drained from

transmission before beginning
disassembly.
NOTE: Refer to INTERVALS FOR CHANGING

TRANSMISSION OIL AND FILTERS in section
1002 for draining oil.
1. Loosen cap screws (A).
2. Move bracket (B).
3. Completely loosen upper 0-ring fitting nut (C).

6003-11
4. Completely loosen lower 0-ring fitting nut (D).
5. Remove suction screen assembly (E) and gasket (F)

from suction manifold (G).
6. Remove two cap screws (H).
7. Remove and discard 0-ring (I)
ENG 6-46761 May, 2003 Printed in Brazill

6003-12
8.Remove suction tube (J) with 0-ring fitting parts.
9. Clean and inspect all parts for damage.

6003-13
CHARGE PUMP GROUP
A-Oil pump F-Snap ring

B-Cup plug G-O-ring
C-Set screw
D-Cap screw M16x65 8.8 (3 used) THE CHARGE PUMP IS NOT REPAIRABLE. THE
E-Sieeve (SAE C) PUMP MUST BE REPLACED IF FOUND
DEFECTIVE.

6003-14
REMOVE CHARGE PUMP GROUP
NOTE: Transmission is shown with the input housing

engine side down.
1. Remove three cap screws (A).
A CAUTION: The driven gear and support

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

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

for information on disassembling and assembling
driven gear assembly (A).
2. Remove charge pump (B) and bearing assembly (D)

from input housing.
3. Remove o-ring (C).
4. Discard o-ring (C).

6003-15
INSTALL CHARGE PUMP TO DIRECT DRIVE

INPUT ASSEMBL V
NOTE: The driven gear on the charge pump must mesh

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

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

long-term separating and lubricating effect,
prevention of fretting corrosion and avoidance of
squeaking noises.
IMPORTANT: OPTIMOL® OPTIMOLY PASTE WHITE T

is only suitable for paste-specific
applications and cannot replace oil or
grease lubrication. Do not mix with
other greases, pastes or oils.
2. Apply OPTIMOLY PASTE WHITE T to charge pump

spline.
3. Install charge pump (B) into front cover.
4. Install three cap screws (A) through charge pump into

front cover.
5. Tighten cap screws to 115 N·m (85 lb-ft).
OPT/MOL® is a regestered trademark. OPT/MOLY PASTE WHITE T

can be purchased from Castro/ Industrial North America Inc.

6003-16
ASSEMBLE SUCTION TUBE GROUP


6003-17
INSTALL SUCTION TUBE, SUCTION

SCREEN ASSEMBLY AND SUCTION
MANIFOLD
1. Insert the upper end of the suction tube (A) into the
o-ring fitting half (B) in the charge pump and lightly
tighten, by hand, nut (C).
2. Lubricate and install a new 0-ring (D) in the groove in

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

sure the 0-ring stays in place.
4. Insert the lower end of the suction tube in the 0-ring

fitting half (F) and lightly tighten, by hand, nut (G).
5. Install two cap screws (H) and tighten to 25 N·m (18

lb-ft).
6. Lubricate gasket (1).
7. Install the suction screen assembly (J) and gasket.
8. Tighten 3/4 to one turn after the gasket contacts

the face of suction manifold.
9. Check for leaks after operating transmission.

6003-18
10. Tighten nut (K) to 190 N·m (140 lb-ft).
11. Tighten nut (L) to 190 N·m (140 lb-ft).
12. Move wiring harness bracket (M) back in place and

tighten two cap screws (N) 87 N·m (64 lb-ft).
13. Install wiring harness (0). Be sure to route the

harness away from moving parts, Make connections as
they were before disassembly.

6003-19
14. Place main wiring harness connector (0) in bracket.
15. Tighten nut to 18-27 N·m (13-20 lb-ft).

6003-20 Direct Drive Input Assembly
OTHER MATERIAL
Number Name Use
LOCTITE® #620 Oil seal
Grease 0-ring
Transmission fluid All moving parts and o-rings
SPECIFICATIONS
Magnetic pickup-to-input housing Torque 10 N·m (8 lb-ft)

cap screws.
Input housing assembly-to-front Torque 87 N·m (64 lb-ft)

housing cap screws.
Socket head hex plug-to-input Torque 102 N·m (75 lb-ft)

housing.
Lift bracket-to-input housing Torque 87 N·m (64 lb-ft)
Bearing retainer cap screw-to-front Torque 37 N·m (27 lb-ft)

housing.
Direct drive input housing assembly Weight 50 Kg (11 0 lbs)

6003-21
REMOVE INPUT HOUSING ASSEMBLY GROUP
A-Hex cap screw, 12x280mm (4 used) D-Transmission Assembly

B-Oil seal E-Dowel pin
C-lnput housing (SAE 3) F-Hex cap screw, 12x11 Omm (3 used)

6003-22
REMOVE AND DISASSEMBLE INPUT

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

entire input housing assembly. This
component weight approximately 50 kg (11 0
lbs.)
IMPORTANT: The lifting device must be arranged so

that it lifts the input housing assembly
straight up without binding or tipping.
5. Install lifting device (A).

6003-23
A (B)
CAUTION: Be sure the input shaft assembly
does not move up with the input housing
assembly (A). It might fall causing damage or
personal injury. Input bearing (C) will some
times come up with the input housing be
careful that it does not drop out.
NOTE: If the input bearing (C) stays with the input

housing (A), be sure it does not fall out. It can be
removed later.
6. Carefully lift input housing assembly (A) from the

transmission (E). The input shaft assembly (B), input
bearing (C) and 0-ring (D) should stay with the
transmission (see caution and note).
ENG 6-46761 January, 2003 Prin1ed in Brazil

6003-24
- - - -
INPUT~A~S~S:E::MB~LY__________
A-lnp
B- ut housing H-Bea n~g
1-S · spacer
Hex socket nap nng
C-Lift h plug
anger J-Cap
K screw M6x20
0 L-Lock washer (2 mm 8.8 (2 used)
-Cap ·screw M12x20mm 8
E-Be
F-D .anng (3 used) .8 (2 used) -VVasher (2 used)
M-M . used)
G- nve.n gear 36T N agnetlc picku
Beanng (with snap nng)
. -Magnetic . P cover
. p1ckup sensor
0--0-nng
ENG 6-46761 May, 2003 Printed.In Brazil

6003-25
REMOVE IDLER GEAR SHAFTS
1. Position input housing assembly (A) engine side up.
2. Install a bolt (A) into threaded hole in idler shaft (B).

Use this bolt to pull idler shafts out of input housing. The
shafts are a slip fit.
3. Remove 0-ring (C) from groove in each idler shaft.
4. Remove two 0-rings from bottom of each idler shaft

bores.
5. Discard 0-rings and inspect idler shaft for wear or

damage.
REMOVE INPUT OIL SEAL AND BALL

BEARING
NOTE: If the input ball bearing (B) stayed in the input

housing, remove it with the oil seal.
1. Drive the oil seal (A) down on top of the input ball
bearing below. Continue driving to remove both the oil
seal and the input ball bearing.
2. Remove oil seal (A) and input ball bearing (B).

6003-26
REMOVE AND DISASSEMBLE AUXILIARY

PUMP DRIVE GEAR ASSEMBLY
1. Install two cap screws (A) in threaded holes in the

bearing spacer (B).
A fitCAUTION: The bearing spacer (B) is not a tight

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

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

(A) for reassembly purposes. Use a puller to remove
bearings (A) and (B) from driven gear (C).

6003-27
ASSEMBLE AUXILIARY PUMP DRIVE

DRIVEN GEAR ASSEMBLY
IMPORTANT: Press only on inner race of bearing.
1. Use a press bearing installation tool to install new

bottom bearing (A) on auxiliary pump drive driven gear
(B).
2. Turn driven gear (B) over and press the new top
bearing with snap ring (D) onto gear.
NOTE: Install new bearing with snap ring down next to

gear.
3. Set assembly aside.

6003-28
REMOVE AND DISASSEMBLE IDLER GEARS

AND BEARING ASSEMBL V
1. Remove charge pump idler gear assembly (A) though

charge pump ports.
2. Remove auxiliary pump drive idler gear and bearing

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

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


6003-29
4. Push both bearings (A) out from the side the snap
ring was removed.
A-Bearing (2 used)
B-Gear
C-Snap ring (2 used)

6003-30
ASSEMBLE IDLER GEAR ASSEMBLY
NOTE: Both idler gears assemble the same. Install

bearing into the idler gear correctly. Snap ring
side of bearing to the outside of the gear.
1. Install new bearing (A) snap ring side of bearing to

the outside of gear.
2. Turn idler gear over and install the second bearing.
3. Set both assemblies aside.

6003-31
REMOVE AND INSTALL LIFT BRACKET
1. Remove two cap screws (A).
2. Remove lift bracket (B).
INSTALL LIFT BRACKET
IMPORTANT: Using new cap screws, replace with the

same length and grade as original
equipment.
1. Install two cap screws (A).
REMOVE AND INSTALL SOCKET HEAD HEX

PLUG
1. Remove socket head hex plug (A) and 0-ring (B).
2. Discard 0-ring.
3. Inspect socket head plug for damage.
INSTALL SOCKET HEAD HEX PLUG
1. Lubricate new 0-ring (A) and install on Plug (B).
2. Install plug assembly.
3. Tighten to 102 N·m (75 lb-ft).

6003-32
ASSEMBLE INPUT ASSEMBLY
A-lnp
B- ut housing H-Bea n~g
1-S · spacer
Hex socket nap nng
C-Lift h plug
anger J-Cap
K screw M6x20
0 L-Lock washer (2 mm 8.8 (2 used)
-Cap ·screw M12x20mm 8
E-Be
F-D .anng (3 used) .8 (2 used) -VVasher (2 used)
M-M . used)
G- nve.n gear 36T N agnetlc picku
Beanng (with snap nng)
. -Magnetic . P cover
. p1ckup sensor
0--0-nng

6003-33
INSTALL OIL SEAL
1. Position input housing (A) with engine side up.
IMPORTANT: If the new oil seal is not coated on the

outside diameter with a sealer, apply
LOCTITE® #620.
2. Install new oil seal (B) flush with machined surface on

input housing.
LOCTITE.® is a registered trademark of LOCTITE Corporation.

6003-34
INSTALL IDLER GEAR AND BEARING

ASSEMBLIES
1. Lubricate all bearings with clean transmission fluid.
2. Place idler gear assembly (A) into auxiliary pump

drive port of the input housing.
3. Slide the idler gear assembly (A) into its position

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

position between the charge pump port and the input
shaft bore.

6003-35
INSTALL IDLER SHAFTS
NOTE: The through hole in the idler shafts (D) must line
up with the through hole in the input housing (B).
Use one of the long input housing cap screws (F)
to guide alignment of the shaft.
1. Align the bearing bore in the idler gear assembly (A)

with the idler shaft bore in the input housing (B).
2. Lubricate the 0-ring (C) with grease and install in the

groove on the idler shaft (D).
3. Use grease to hold 0-ring (E) to the bottom of the

idler shaft during installation (also see the alternate
installation procedure 4.)
ALTERNATE 0-RING INSTALLATION PROCEDURE
4. Lubricate 0-ring (E) with grease and place in position

at the bottom of the idler shaft bore in the input housing.
5. Align the through hole in the idler shaft with through

hole in the input housing by inserting one of the long
input housing attaching cap screws (F) through both
parts.
6. Push the idler shaft through the idler gear assembly

and into the input housing. Be sure both 0-ring stay in
place.
7. Install the other idler shaft (G) in the same way.
IMPORTANT: Both idler gears must turn.
8. Remove the cap screws that were used as alignment

guides.
ENG 6-46761 May, 2003 Prin1ed in Brazil

6003-36
INSTALL AUXILIARY PUMP DRIVE GEAR
1. Lubricate both bearings with clean transmission fluid.
2. Install auxiliary pump drive gear assembly (A) snap

ring up in pump drive port.
3. Align gear teeth (B) and (C).
4. Push auxiliary pump drive gear assembly (D) into bore

in front cover.
5. Install bearing spacer (E).

or installing snap rings. Personal injury to self
or bystanders could result.
6. Install snap ring (F) in groove.

6003-37
INPUT SHAFT ASSEMBLY
'
------
A-Input shaft assembly

B-Transmission assembly

6003-38
REMOVE AND DISASSEMBLE INPUT SHAFT

ASSEMBLY
A (B)
CAUTION: Be sure the input shaft assembly
does not come up with the input housing
assembly (A). It could fall and cause damage
or personal injury.
A CAUTION: The input bearing will usually come

up with the input housing assembly. Do not let
it fall out before it can be safely removed.
1. Remove the input housing assembly (A).

A CAUTION: Do not allow the coupling shaft (D)
to fall if it comes up with the input shaft
assembly.
2. Lift input shaft assembly (B) from bearing retainer (C).
3. Place input assembly (E) with snap ring up.

6003-39
4. Remove and discard seal ring (F).

or installing snap ring.
5. Remove snap ring (G).
6. Remove thrust race (H).
7. Mark input shaft (I) and gear (J) for reassembly.
8. Remove gear from input shaft.
9. Inspect all parts for wear and damage.

6003-40
ASSEMBLE INPUT SHAFT
1. Align marks made on input shaft (A) and gear (B).
2. Install gear on input shaft.
3. Install thrust race (C).

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

rings must be sized to fit the shaft
groove tightly to prevent damage
during installation. Check that seal ring
is in place and sized immediately
before assembly.
5. Size the seal ring (E) by twisting in a tight circle,

approximately 25 mm (1 in) in diameter.
6. Apply grease to the seal ring and seal surfaces.
7. Install seal ring (E).

6003-41
REMOVE COUPLING SHAFT AND RETAINER
1. Remove coupling shaft (A).
2. Remove 0-ring (B).
IMPORTANT: Note the placement of the oil deflector

(E). This part must be installed
correctly for the transmission to
function and lubricate properly.
3. Remove seven cap screws (C) and oil deflector from

bearing retainer assembly (D).
IMPORTANT: Do not scratch or damage the inside

diameter of the bearing retainer. The
input shaft seal ring surface will be
damaged.
4. Remove bearing retainer (D).
ENG 6-46761 May, 2003, 2003 Printed in Brazil

6003-42
5. Use a soft drift to remove bearing (A). Do not damage

retainer (B).
ASSEMBLE AND INSTALL BEARING

RETAINER
IMPORTANT: This bearing installs below flush. Firmly

seated on the bottom of the bearing
bore.
1. Install new bearing (A).
2. Install retainer with bearing (C). Use one of the

attaching cap screws (D) to help align through holes in
retainer with threaded holes in transmission front housing
(E).

6003-43
NOTE: There are two holes (H) in the retainer that are
oil passages, not attaching holes.
3. Install seven cap screws (F) and deflector (G).
IMPORTANT: Pay attention to the placement of the

oil deflector (G).
4. Install the oil deflector (G) as shown in the

photograph.
5. Lubricate bearing with clean transmission fluid.
6. Tighten cap screws (F) to 37 N·m (27 lb-ft). Besure

the oil deflector stays in its proper position.

6003-44
7. Lubricate the 0-ring (J) with grease.
NOTE: 0-ring must sit flat against front housing.
8. Install 0-ring on bearing retainer.
INSTALL COUPLING SHAFT
1. Lubricate coupling shaft (A) with clean transmission

fluid.
2. Install coupling shaft into transmission first stage shaft.
NOTE: Both ends of the shaft are the same.

6003-45
INSTALL INPUT SHAFT ASSEMBLY AND

INPUT BALL BEARING
IMPORTANT: Immediately before installing the input

shaft assembly, check that the seal ring
(A) is in place, sized and lubricated.
NOTE: Refer to ASSEMBLE INPUT SHAFT in this group

for more information about sizing seal rings.
1. Check that the seal ring (A) is in place, sized and

lubricated with grease.
2. Lubricate with grease the seal area (B) and the shaft
splines (C).
3. Install the input shaft assembly (D).
4. Lubricate input ball bearing (E) with clean

transmission fluid.
5. Install new ball bearing (B).

6003-46
INSTALL INPUT HOUSING ASSEMBLY

IMPORTANT: Dowel pin (A) must be installed. If left
out, transmission will be damaged.
1. Check for dowel pin (A), if not in place, install dowel

pin.
IMPORTANT: The input housing assembly and the

transmission must be level to avoid
damage to the oil seal as it moves over
the input shaft spline.
2. Slowly lower the input housing assembly (B) onto front

housing, input bearing and dowel pin.

6003-47
NOTE: Front housing (OJ must mount flush with input

housing assembly (C).
3. Check input housing (C).
4. Remove lifting tooling (E).
5. Install seven cap screws (F).
6. Tighten cap screws (F) to 87 N·m (64 lb-ft).

6003-48 Control Valve
OTHER MATERIAL
Number Name Use
Transmission Fluid All moving parts and o-rings.
SPECIFICATIONS
Control valve-to-front housing cap Torque 40 N·m (30 lb-ft)

screw (27).
Proportional valve nut-to-proportional Torque 1. 7-2.8 N·m (15-25 Ib-in)

solenoid assembly (8).
7/16-20 plug-to-valve housing (12). Torque 12 N·m (9 lb-ft)
Temperature sensor-to-valve Torque 16 N·m (12 lb-ft)

housing.
Proportional valve-to-valve housing Torque 16-20 N·m (12-15 lb-ft)

(8).
Main regulator assembly-to-valve Torque 142 N·m (1 05 lb-ft)

housing.
Relief valve assembly-to-valve Torque 102 N·m (75 lb-ft)

housing.
Valve assembly Weight 25 Kg (55 lbs)

6003-49
CONTROL VALVE GROUP
~ 0
0
() 0
Oo
0 ,,
~
J
0
0
0 0 ~ 0
A-Gasket F-Cap screw M8x45 10.9 (5 used)

B-PI ate G-Cap screw M8x75 10.9 (13 used)
C-Gasket H-Temperature Sender
D-Valve Assembly l-O-ring
E-Fiat Washer (27 used) J-Cap screw M8x90 10.9 (9 used)

6003-50
REMOVE CONTROL VALVE GROUP
1. Tag all electrical connections.
2. Remove wiring harness.
3. Remove charge pump group.
4. Remove input housing group.
REMOVE TEMPERATURE SENSOR
• Remove temperature sensor.
INSTALL TEMPERATURE SENSOR
• Install temperature sensor and tighten to 24-27 N·m

(18-20 lb-ft).
IMPORTANT: Do not allow any of the flat washers

(B) to fall into control valve assembly
or transmission openings. The
transmission may not operate properly
or damage may result.
5. Remove 27 cap screws (A) and flat washers (B).
A assembly
CAUTION: Approximate weight of valve
is 25 Kg (55 lbs).
6. Remove valve assembly (C).

6003-51
7. Remove and discard gasket (D).
IMPORTANT: Do not bend plate (E).
8. Remove plate (E).
9. Remove and discard gasket (F).
10. Clean and inspect all gasket surfaces.

6003-52
DISASSEMBLE AND ASSEMBLE CONTROL VALVE

THE CARTRIDGE TYPE VALVES USED IN THIS 0-rings. Use only new 0-rings.
ASSEMBLY ARE NOT USER REPAIRABLE. ANY Install new 0-rings onto cartridge
VALVE FOUND TO BE DEFECTIVE MUST BE type valve.
REPLACED AS A UNIT.
USE THE DRAWINGS PROVIDED AS GUIDES FOR
IMPORTANT: Cartridge valves require a 0-rings. FURTHER DISASSEMBLY AND ASSEMBLY OF THE
When assembling valves grease all CONTROL VALVE.
A-Valve Housing D-90 Relief Valve H-Piug K-0-ring

8-Hex Socket Plug 7/16-20 E-Main Regulator Assembly l-O-ring L-Proportional Solenoid
(12 used) F-Steel Ball 9/32 (4 used) J-0-ring Plug
C-Proportional 12 or 24 Volt G-Hex Socket Plug 9/16-18
Valve (7 used) (2 used)

6003-53
DISASSEMBLE VALVE ASSEMBLY
PROPORTIONAL SOLENOID
1. Remove nut (A), washer (B) and coil (C) from

proportional solenoid.
2. Remove proportional valve (D).
3. Inspect for contamination.
REMOVE 90 RELIEF VALVE
1. Remove 90 relief valve (A).
2. Inspect for wear and contamination.
REMOVE MAIN REGULATOR ASSEMBLY
1. Remove main regulator assembly (A).

6003-54
REMOVE PROPORTIONAL PLUG
1. Remove solenoid assemblies.
2. Remove proportional plug (A).
REMOVE PLUG
1. Remove plug (A).
INSTALL PLUG
1. Lubricate new o-ring.
2. Install new o-ring onto plug.
3. Install plug (A).
4. Tighten plug to 12 N·m (9 lb-ft).

6003-55
INSTALL PROPORTIONAL PLUG
1. Lubricate new o-rings (3).
2. Install new o-rings onto proportional plug.
3. Install proportional plug (A).
4. Tighten proportional plug.
INSTALL MAIN REGULATOR ASSEMBLY
2. Install new o-rings.
3. Install main regulator assembly (A).
4. Tighten main regulator assembly 142 N·m (1 05 lb-ft).
INSTALL RELIEF VALVE
2. Install new o-rings (A).
3. Install relief valve.
4. Tighten relief valve 102 N·m (75 lb-ft).

6003-56
INSTALL PROPORTIONAL SOLENOID

ASSEMBLY
1. Install new a-ring's (A), (B) and (C) onto proportional

valve.
2. Install proportional valve (D) into valve housing.
3. Tighten proportional valve 16-20 N·m (12-15 lb-ft).
4. Install coil (E), washer (F) and nut (G) onto

proportional valve.
5. Tighten nut 1.7-2.8 N·m (15-25 lb-in).

6003-57
INSTALL CONTROL VALVE GROUP
~ 0
0
() 0
Oo
0 ,,
~
J
0
0
0 0 ~ 0
A-Gasket E-Fiat Washer (27 used) G-Cap screw M8x75 10.9 l-O-ring
B-PI ate F-Cap screw M8x45 10.9 (5 (13 used) J-Cap screw M8x90 10.9 (9
C-Gasket used) H-Temperature Sender used)
D-Valve Assembly
IMPORTANT: The gaskets and metal plate must 2. Install plate (B).
be installed correctly. The first
gasket is cut out to the shape of the 3. Install gasket (C).
casting on the front housing. The
second gasket is cut out to the 4. Install valve assembly (D).
shape of the metal plate and has a
boot-like shape cut out of it. 5. Install cap screws (F), (G) and (J) and washers
(E). Observe tightening sequence and torque
1. Install gasket (A). specifications given in this section.

6003-58
INSTALL GASKETS AND PLATE TO FRONT

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

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

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

in gasket.
3. Place plate (C) over the guide pins and onto gasket
(B).
IMPORTANT: Cut out opening in gasket must match

opening in plate.
4. Place new gasket (D) over guide pins onto plate (C).

6003-59
INSTALL CONTROL VALVE ASSEMBLY
A approximately
CAUTION: The valve assembly weighs
25 Kg (55 lbs).
NOTE: Guide pins (B) must be long enough to remove

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

control valve are three different
lengths. Use proper length cap screws
for each cap screw hole.
IMPORTANT: Do not allow washers to fall into any

opening in valve assembly or
transmission openings.
3. Install 27 cap screws (C) and flat washers.
IMPORTANT: Tighten cap screws (E) evenly in

sequence as directed by instructions
in, "CAP SCREW TIGHTENING
SEQUENCE AND TORQUE
SPECIFICATIONS" found in this
section.
4. Tighten cap screws to torque specifications and

tightening sequence in this section.
5. Tighten cap screws (E) to 40 N·m (30 lb-ft).

6003-60
CAP SCREW TIGHTENING SEQUENCE AND TORQUE SPECIFICATIONS
Tighten cap screws in rotational sequence 2. Repeat step 1.

represented by call outs.
CONTROL VALVE CAP SCREW TORQUE
1. First rotational sequence tighten all cap screws to SPECIFICATIONS .... .40 N·m (30 lb-ft)
40 N·m (30 lb-ft).

6003-61
PRESSURE AND TEMPERATURE CHECK PORTS (WITHOUT WET BRAKE)
A-Valve Housing F-Lube Pressure Check Port M-Convert out temperature R-Ciutch D Check Port
8-Converter Out Pressure G-Converter Relief N-System Pressure Check S-Ciutch C Check Port
Check Port H-Pressure Regulator Port T-Solenoid Assembly
C-Converter In Pressure 1-Pump In Port 0-Lube In Port U-Temperature Sensor
Check Port J-Ciutch 8 Check Port P-Oil Out To Heat
D-Ciutch 1 Pressure Check K-Ciutch A Check Port Exchanger V-Ciutch 4 Check Port
Port L-Auxiliary Pressure Source Q-Auxiliary Pressure Source W-Ciutch 3 Check Port
E-Ciutch 2 Pressure Check
Port
OPERATING CONDITIONS: PORT PRESSURES:
• Engine speed at 2000 rpm In neutral
• Transmission temperature range at 65-93·c • Converter in 4.1 - 7.9 Bar (60- 115 psi) (see footnote)
(15o·-2oo·F).
• Converter out 2.7 - 6.2 Bar (40-90 psi)
• Pump flow 87-102 Umin (23-27 gpm) at
16.55-19.31 Bar (255-280 psi). • Lube 2.7 - 4.1 Bar (40-60 psi)
In gear
• Lube 1 .4 - 2. 7 Bar (20-40 psi)
In neutral, "Converter In" pressure should always be higher than Lube

pressure.

6003-62
PRESSURE AND TEMPERATURE CHECK PORTS
Following is identification of ports as they are marked on

the valve body casting.
Ports marked 1, 2, 3 and 4 are Direction Clutch Ports.
• 1 and 2 are forward clutches.
• 3 and 4 are reverse clutches.
Ports marked A, B, C and D are Speed Clutch Ports.
NOTE: All check ports are 7/16-20 UNF SAE 0-ring,

unless otherwise specified.

Main Case Front Housing 6003-63
OTHER MATERIAL
Number Name Use
LOCTITE® #242 Oil Seal
SPECIFICATIONS
Front housing-to-rear housing cap Torque 87 N·m (64 lb-ft)

screws.
Front housing. Weight 120 Kg (265 lbs.)
1 5/8 Plug Torque 190 N·m (140 lb-ft)
OUTPUT YOKE
A-V-ring seal
B-Yoke
C-O-ring
D-Yoke washer
E-Cap screw

6003-64
REMOVE OUTPUT YOKE
NOTE: Output yoke will turn when removing cap screw.

Place block of wood or similar object between
yoke and housing to aid in removing output yoke
assembly.
1. Loosen cap screw (C).
2. Remove cap screw (C) washer (D) and 0-ring (E).
3. Remove output yoke (A).

6003-65
DISASSEMBLE AND ASSEMBLE FRONT HOUSING
o t!,DE
0~"®
or;:o
((;
A-Hex cap screws C-Bore Sleeve (4 used) F-Bearing Cup 1-Bracket

12x120mm (18 used) D-lnput Bushing G-Piug with 0-ring (2 used)
8-Front Housing (DF250) E-Dowel Pin (2 used) H-Lube Relief Valve
Assembly

6003-66
REMOVE CAP SCREWS AND WIRING

CONNECTOR BRACKET FROM FRONT
HOUSING
1. Loosen cap screw (A).
2. Remove cap screw (B).
3. Remove wiring connector bracket (C).
4. Remove remaining cap screws (D).
5. Remove dowel pin (E) if loose.

6003-67
INSTALL FRONT HOUSING LIFTING TOOL

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

the correct length to attach the lifting tool to
the front housing.
2. Position lifting tool (B).
3. Install four cap screws (C).
A approximately
CAUTION: The front housing assembly weighs
120 Kg (265 lbs).
NOTE: Use a hoist with a safety hook (D) when

removing the front housing.

6003-68
REMOVE FRONT HOUSING
IMPORTANT: Pry on the housings to loosen the

gasket seal, use lugs provided on the
front and rear housings.
A CAUTION: The front housing assembly weighs

approximately 120 Kg (265 lbs.) Do not allow
any part of the body under the front housing
assembly.
1. Remove front housing.
2. Remove and discard gasket (C).
3. Check for two dowel pins (D).

6003-69
DISASSEMBLE THE FRONT HOUSING ASSEMBLY
A-Lube relief valve

B-Bore sleeve (4 used)
C-Bearing cup
D-lnput bushing
E-Piug with 0-ring (2 used)
REMOVE PLUG WITH 0-RING
1. Remove two plugs (A) with 0-rings.
2. Remove 0-rings (B) and discard.
INSTALL PLUG WITH 0-RING
1. Lubricate new 0-rings.
2. Install new 0-rings.
3. Install plugs with 0-rings.

6003-70
REMOVE BORE SLEEVES
1. Inspect bore sleeves (A) for wear or damage.
NOTE: See Section 6002, special tools.
2. Remove bore sleeves from front side of front housing.

6003-71
INSTALL BORE SLEEVES
1. Position front housing with bearing bore side up.
IMPORTANT: Install bore sleeves with the internal

chamfer up.
2. Place bore sleeve (A) onto driving tool (B) with

outside diameter chamfer of bore sleeve to end of tool.
3. Install bore sleeve flush with shoulder.

6003-72
REMOVE LUBE RELIEF VALVE
2. Remove lube relief valve (A).
INSTALL LUBE RELIEF VALVE
1. Position front housing with bearing bore side down.
2. Install new lube relief valve (A).
REMOVE BEARING CUP
• Remove bearing cup.

6003-73
INSTALL BEARING CUP
• Install new bearing cup (A).
REMOVE OIL SEAL
• Remove oil seal (A).
INSTALL OIL SEAL
NOTE: Apply LOCTITE #242 or equivalent to outside

diameter of oil seal before installation.
• Install new oil seal flush with shoulder.

6003-74
PREPARE REAR HOUSING AND GEAR

GROUP FOR ASSEMBLY WITH FRONT
HOUSING
1. Clean gasket surfaces on front and rear housings.
IMPORTANT: Check for both dowel pins (D). If not in

place they must be installed before
jointing front and rear housing.
2. Install dowel pins (D).
3. Install new gasket (C).
IMPORTANT: Use guide pins (D) to align the front

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

through the front housing and be removed after
front housing is in place.
4. Install two guide pins (D).

6003-75
INSTALL SEAL RINGS AND LUBRICATE
IMPORTANT: The seal ring ends overlap and must fit

together.
IMPORTANT: Use new seal rings.
NOTE: For shaft assemblies twist seal rings 19 mm (3/4

inch). For first stage shaft twist seal ring 25 mm
(1 inch).
1. Twist seal ring into tight circle, approximately 25 mm

(1 inch).
2. Install seal ring (A) on first stage shaft (B).

6003-76
3. Install as required either two or three seal rings (C) on

clutch shaft assemblies.
4. Lubricate all seal rings.
5. Check seal rings for proper fit in the grooves, in clutch

shaft assemblies.
6. Rotate seal rings so that the end gaps are

approximately 120 degrees apart.
8. Apply grease to the yoke spline (E) on the output

stage shaft.

6003-77
INSTALL FRONT HOUSING
A approximately
CAUTION: Front housing weight is
120 kg (265 lbs).
A CAUTION: Use four high grade fasteners of the

correct length to attach the lifting tool to the
front cover.
1. Attach lifting tool (B).
A CAUTION: Do not allow any part of the body

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

seal rings.
2. Install guide pins (C).
3. Check for dowel pins (D), gasket (E) is flat on rear

housing surface.
4. Lower front housing assembly (F) onto clutch shaft

assemblies and onto rear housing.
IMPORTANT: Do not attempt to mate front and rear

housing together using cap screw
fasteners. If the housings do not close
up completely without force there is a
problem condition that must be
corrected.
5. Check front housing is level with rear housing (H).

6003-78
6. Install cap screws (J) and wiring harness bracket (K).
8. Remove lifting tool (L).

6003-79
INSTALL OUTPUT YOKE
1. Lubricate the seal and seal surfaces on the output

yoke (A).
2. Install output yoke (A).
3. Lubricate new 0-ring (E).
4. Install new 0-ring (E).
5. Install washer (D).
6. Install cap screw (C).
7. Use a block of wood (F) to keep output yoke from

turning.
8. Tighten cap screw (C) to 215 N·m (159 lb-ft).

6003-80 Gear Ratio Group
OTHER MATERIAL
Number Name Use
SPECIFICATIONS
Output group Weight 30 Kg (65 lbs.)
Clutch stages less output stage. Weight 272 Kg (600 lbs.)
Oil trough-to-rear housing cap Torque 25 N·m (18 lb-ft)

screws.
Clutch assemblies Clutch plate-to-clutch plate 2. 79 mm-5.59mm (.11 0-.220 in)

retainer clearance
Clutch gear End play .25 mm (.01 0 in)

6003-81
REMOVE OUTPUT GROUP
1. Remove two cap screws (A) holding oil trough

assembly (B).
A CAUTION: The output group weighs

approximately 30 Kg (65 lbs).
A CAUTION: The oil trough has sharp edges.

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

group.

6003-82
OUTPUT GROUP AND OIL TROUGH
A-Bearing cone (2 used) C-Oil trough assembly

B-Seventh stage output shaft gear assembly D-Cap screw M8x12 8.8 (2 used)

6003-83
DISASSEMBLE OUTPUT GROUP
IMPORTANT: Do not attempt to remove gear from

shaft. This is a permanent assembly.
Damage to parts will result.
1. Remove bearing cones (A).
Assemble Output Group
1. Install new bearing cones (A).
2. Lubricate two new bearings with clean transmission

fluid.

6003-84
REMOVE ALL CLUTCH STAGE ASSEMBLIES
A CAUTION: Approximate weight of all clutch

stage assemblies is 272 Kg (600 lbs).
IMPORTANT: Lift all clutch stage assemblies at one

time using lift tool.
NOTE: See Section 6002 for special tools.
1. Install lift tool (A).
2. Lock holders (B) into place.
3. Install bolt (C) into sixth stage assembly.
4. Lift all clutch stage assemblies from rear housing.

6003-85
IMPORTANT: If more that one threaded hole is

provided in the lifting tool. Use the hole
designed for the model of transmission
being repaired.
5. Install lifting eye (D).
6. Use hoist with safety latch (E).
NOTE: It may be necessary to shake the stages loose.

Grasp the chain between the hoist and the lifting
tool and forcefully move it back and forth.
7. Lift shaft stage assemblies.

6003-86
A CAUTION: Weight is approximately 272 Kg (600

lbs). Do not allow any part of the body under
stage assemblies.
8. Place stages on work table.
A CAUTION: Place shaft stage assemblies in

center of work table to prevent personal injury.
IMPORTANT: Do not remove lifting tool until a strap

has been placed around the group of
assemblies.
9. Remove cap screw (H).
10. Move four retainers (I) out of grooves in clutch

shafts.

6003-87
11. Place a strap (J) around the gear ratio group to

prevent any of the stages from falling.
12. Remove the lifting tool (K).
A CAUTION: Do not allow the stages to fall or to

roll off the work surface.
13. Block stages (L) as they are removed to prevent

them from rolling.

6003-88
DISASSEMBLE FIRST STAGE ASSEMBLY
1. Remove and discard Seal Ring (A).
2. Remove Bearing (B).
3. Remove Bearing (C).
4. Inspect first stage shaft assembly (C).
ASSEMBLE FIRST STAGE ASSEMBLY
NOTE: Press only on inner race of bearing.
1. Install new bearing (B).
2. Install new bearing (C).
NOTE: Refer to Sizing Seal Rings in this group.
3. Install new seal ring (A).
4. Lubricate ball bearings.
DISASSEMBLE SIXTH STAGE ASSEMBLY
1. Remove ball bearing (A).
2. Remove bearing inner race (B).
ASSEMBLE SIXTH STAGE ASSEMBLY
1. Install new ball bearing (A).
2. Install new bearing inner race (B).

6003-89
SECOND STAGE CLUTCH ASSEMBLY
A-Seal Ring (3 used) K-Ciutch Separator Plate (20 used)

B-Ball Bearing (2 used) L-Retainer Ring (2 used)
C-Retaining Ring (2 used) M-Snap Ring Retainer (2 used)
D-Bearing (2 used) N-Ciutch Return Spring (12 used)
E-2nd Clutch 54T Gear 0-Lube Shutoff Washer (2 used)
F-Bearing (2 used) P-Ciutch Piston (2 used)
G-O-ring (2 used) Q-Piston Outer Seal (2 used)
H-Snap ring (internal),(2 used) R-0-ring (2 used)
1-Ciutch Plate Retainer (2 used) S-2nd Stage Shaft Assembly
J-Ciutch Plate (20 used) T-61T Clutch Gear (2nd and 3rd stage)

6003-90
THIRD STAGE CLUTCH ASSEMBLY
A-Seal Ring (2 used) J-Retaining Ring

B-Ball Bearing (2 used) K-Ciutch Separator Plate (1 0 used)
C-3rd Stage Shaft Assembly L-Ciutch Plate (1 0 used)
D-O-ring M-Ciutch Plate Retainer
E-Piston Outer Seal N-Snap Ring
F-Ciutch Piston 0--0-ring
G-Lube Shutoff Washer P-Bearing
H-Ciutch Return Spring (6 used) Q-61T Clutch Gear (2nd and 3rd stage)
1-Snap Ring Retainer R-Bearing
S-Retaining Ring

6003-91
FOURTH STAGE CLUTCH ASSEMBLY
A-Seal ring (3 used) K-Retaining ring (2 used)

B-Bearing (2 used) L-Snap ring retainer (2 used)
C-Snap ring (2 used) M-Ciutch retainer spring (12 used)
D-Bearing N-Lube shutoff piston (2 used)
E-4th clutch assembly gear 0-Ciutch piston (2 used)
F-Bearing (2 used) P-Piston outer seal (2 used)
G-Snap ring (2 used) Q-0-ring (2 used)
H-Ciutch plate retainer (2 used) R-4th and 5th stage shaft assembly
1-Ciutch plate (20 used) S-Ball bearing w/Bronze cage (2 used)*
J-Ciutch separator plates (20 used) T-38th clutch gear
* Application Dependent U-Bearin

6003-92
FIFTH STAGE CLUTCH ASSEMBLY
A-Seal ring (3 used) J-Ciutch separator plate (20 used)

B-Bearing (2 used) K-Retaining ring (2 used)
C-Snap ring (2 used) L-Snap ring retainer (2 used)
D-Bearing (2 used) M-Ciutch retainer spring (12 used)
E-86T clutch gear (2 used) N-Lube shutoff washer (2 used)
F-Bearing (2 used) 0--Ciutch piston (2 used)
G-Snap ring (2 used) P-Outer piston seal (2 used)
H-Ciutch plate retainer (2 used) Q-0-ring (2 used)
1-Ciutch plate (20 used) R---4th and 5th stage shaft assembly

6003-93
DISASSEMBLE CLUTCH STAGE ASSEMBLY

All clutch stage assemblies in the
transmission assemble and disassemble in the same
manner. In this manual we show the disassembly
and assembly of the second stage clutch.
1. Remove three teflon seal rings.

6003-94
2. Install bearing removal tool (A).
3. Install gear puller (B) onto bearing removal tool.
4. Remove bearing (C) from shaft assembly.

6003-95
5. Remove snap ring (D) from shaft assembly.
6. Install gear puller.
7. Remove clutch gear (E).
l
I

6003-96
8. Remove bearing (A).
IMPORTANT: * Fourth stage clutch gear (clutch A)

must use special bearings. Use only
approved bronze caged bearings.
• Application dependent

6003-97
NOTE: 0-ring (A) is directional clutch only. Speed clutch

will not have an a-ring.
9. Remove o-ring (A).

6003-98
A CAUTI~N:
snap rmg.
Wear eye protection when removing


6003-99
12. Turn shaft assembly over. Remove all clutch and

separator plates.
13. Turn shaft assembly over.
14. Install puller.
15. Remove ball bearing and discard bearing.

6003-100
16. Place shaft assembly on press.
17. Use press tool (B) to compress clutch return springs.
18. Remove snap ring (C).

6003-101
IMPORTANT: Pay attention to the assembly of the

clutch return springs. They must be
reassembled in the same way.
19. Lift out snap ring, retaining ring, and clutch return
springs.
20. Remove lube shutoff washer.

6003-102

piston from cylinder. If cylinder is damaged DO
NOT place hand on top of piston.
21. Apply air pressure through oil passage to force

piston from shaft assembly.
22. Remove piston from cylinder.
23. Remove 0-ring and piston outer seal from piston.
24. Inspect all parts.

6003-103
ASSEMBLE CLUTCH STAGE ASSEMBLY
1. Install new 0-ring (A).
2. Install new piston outer seal (B).
3. Install clutch piston (C).
4. Install lube shutoff washer (D).

6003-104
IMPORTANT: Install clutch return springs (A)

correctly. Use the photograph as a
guide.
5. Install clutch return springs (A).
6. Place press tool (B) over shaft.
7. Place snap ring retainer (C) and retaining ring (D)

over shaft.

6003-105
8. Compress clutch return springs.
9. Install retaining ring (E).
10. Release pressure on clutch return springs slowly, be

sure snap ring retainer is properly positioned.
NOTE: Clutch separator plates are all steel with external

spline teeth. Clutch plates have a lining material
on the face and internal spline teeth. Lubricate
and install one plate at a time. First install a
clutch separator plate then a clutch plate.
Continue until all plates are installed.
11. Install clutch separator plate (A).
12. Install clutch plate (B).
Repeat steps 11 and 12 until all plates are installed.

6003-106
13. Install clutch plate retainer (A).
A snap
CAUTI~N: Wear eye protection when installing
rmg.
14. Install snap ring (B).
NOTE: Check that clutch and separator plates are not in

a bind. Clearance between clutch plate and
clutch plate retainer must be 2. 79-5.59 mm
(. 110-.220 in).

6003-107
IMPORTANT: Clutch plate splines must be aligned

before installing bearings on shaft
assembly to avoid clutch plate damage.
15. Use clutch gear assembly to align clutch plates and

separator plates.
16. After aligning clutch plates remove clutch gear

assembly.
IMPORTANT: Seal side of bearing goes toward the

clutch plates.
IMPORTANT: *Fourth stage clutch gear (clutch A)

17. Install new bearing with seal side of bearing toward

clutch plates.

6003-108
18. Press new bearing, seal side down, until bearing

contacts shoulder of shaft.
19. Install clutch gear assembly (A).
IMPORTANT: Place steel ruler or sight across gear

face (A) to check if clutch gear is
install properly. Sighting or steel ruler
will be below snap ring groove in
cylinder shaft.

20. Place new bearing (B) on shaft, start bearing into the
clutch gear assembly.
IMPORTANT: Start bearing into clutch gear. DO NOT

press bearing below snap ring groove
in shaft. Pressing bearing too far into
gear will preload bearing. This will
cause the bearing to fail.
21. PARTIALLY install bearing into clutch gear hub

assembly.

6003-109
22. Position snap ring (C) on top of bearing.
23. Place press tool on top of snap ring.
24. Press only on snap ring. Press until snap ring slips
into snap ring groove.

6003-110
25. Install new outer bearing (D).
IMPORTANT: Check clutch gear for end play. It must

have at least .25 mm (.010 in) end play.

6003-111
SIZING SEAL RINGS

groove tightly to avoid damage during
installation of front housing. Check and
size seal rings before installation of
front housing.
1. Twist seal ring into a tight circle, approximately 3/4

inch in diameter.
2. Install three seal rings in the ring grooves in the shaft

assembly.

6003-112
ARRANGE STAGES TO ACCEPT LIFTING TOOL
NOTE: The output group is installed separately.
• Arrange stage assemblies.
First stage assembly (A) Fourth stage assembly (D)

Second stage assembly (B) Fifth stage assembly (E)
Third stage assembly (C) Sixth stage assembly (F)

6003-113
INSTALL LIFTING TOOL

IMPORTANT: Keep stage assemblies secured with
strap until all are fitted into the lifting
tool.
A approximately
CAUTION: Weight of stage assemblies
272 Kg (600 lbs).
IMPORTANT: Use the special lifting tool to move all

stages at one time.
1. Install lifting tool (A).
2. Lock four retainers (B) in place in the grooves in the

clutch shafts.
3. Install cap screw (C) in threaded hole in end of the

sixth stage shaft.
4. Remove the security strap (D).

6003-114
IMPORTANT: Lubricate all bearings on the bottom of

the stages, also races and bearing
cups in the rear housing before
lowering the stage assemblies into the
rear housing.
A CAUTION: Do not put your hands inside the

rear housing while installing the stage
assemblies.
5. Lower stage assemblies (A) into the rear housing.
IMPORTANT: All stages must be completely down in

their bores or bearings.
6. Check stages; must be in bottom of rear housing

bores.
7. Move the four retainers (B) out of the grooves in the

clutch shafts.
8. Remove cap screw (C).
9. Remove lifting tool (D).
IMPORTANT: Size and install seal rings immediately

before installing the front housing.
Refer to "SIZING SEAL RINGS" this
group for instructions.

6003-115
INSTALL OUTPUT GROUP AND OIL TROUGH
A-Bearing cone (2 used) C-Oil Trough Assembly

B-Seventh stage output shaft gear assembly D-Cap Screw M8x12 8.8 (2 used)

6003-116
INSTALL OUTPUT GROUP AND OIL

TROUGH
NOTE: Be sure new bearing cup has been installed in

main case rear housing. Oil bearing cup before
installing output group. See group 50 (remove
bearing cup}.
NOTE: Output group can be installed upside down.

Install as shown in illustration.
1. Install output group (D) and oil trough (E) into main
case rear housing.
3. Tighten cap screws (A) to 25 N·m (18 lb-ft).
NOTE: Ref to "INSTALL FRONT HOUSING TO

REAR HOUSING" for installation of housing.

Main Case Rear Housing 6oo3-117
SPECIFICATIONS
Lift hanger and cover-to-rear Torque 87 N·m (64 lb-ft)

housing cap screw.
Bearing retainer-to-rear housing cap Torque 25 N·m (18 lb-ft)

screws.
Dipstick tube assembly-to-front Torque 25 N·m (18 lb-ft)

housing cap screws.
Yoke-to-output shaft cap screw. Torque 215 N·m (159 lb-ft)
Output shaft. End play 0± .051 mm (0± .002 inch)

6003-118
REAR HOUSING COMPONENT IDENTIFICATION (DF150)
A-Gasket F-Bearing Cup J-Washer (2 used) M-Snap Ring

8-Rear Housing (OF 150) G-O-ring (2 used) K-Lock Washer (2 used) N-Fiat Washer
C-Eibow H-Magnetic Pickup Sensor L-Cap Screw M6x20 8.8 (2 0-Piug (If Magnetic Pickup
D-ldentification Plate 1-Cover used) Sensor Not Used)
E-Drive Screw (2 used)

6003-119
REAR HOUSING
NOTE: Refer to earlier groups in manual for removal of

input housing, valve assembly, front housing and
gear ratio group.
• Rotate rear housing (A).
REMOVE LIFT BRACKET (REAR)
1. Remove three cap screws (A) and lift bracket(B).
2. Inspect lift bracket for damage.
INSTALL LIFT BRACKET (REAR)
1. Install three cap screws (A).

6003-120
REMOVE BEARINGS (ROLLER)

IMPORTANT: If bearings (A) and (B) are removed
from the rear housing they must be
replaced with new bearings.
IMPORTANT: Use new inner races for these bearings

on the fourth stage clutch assembly
and the sixth stage shaft assembly.
1. Remove fourth stage bearing (A).
2. Remove sixth stage bearing (B).
INSTALL BEARINGS (ROLLER)

IMPORTANT: Use bearing installation tooling that
applies force only to the outer race of
the bearing.
IMPORTANT: Seat bearings (A) firmly against the

bottom of the bearing bores. Do not
damage the bearing cages and races
during installation.
1. Lubricate bearings with clean transmission fluid.
2. Install two new bearings (A).
3. Seat bearings against the bottom of the bearings

bores.

6003-121
REMOVE BEARING RETAINER ASSEMBLY AND SHIMS
,,
A-0-ring C-.18 shim (as required) E-Bearing retainer G-Oil seal

B-.51 shim (as required) D-.13 shim (as required) F-Cap screw M8x60 8.8 (6
used)

6003-122
1. Position rear housing with bearing retainer up.
2. Remove two cap screws (A).
3. Install two guide pins (B).
4. Remove the remaining four cap screws.
5. Remove bearing retainer assembly (C) and the shims

(D).
NOTE: Save the shims and keep them together they

may be reused if in good condition.
REMOVE OIL SEAL FROM BEARING

RETAINER
1. Remove and discard oil seal (A).
2. Clean and inspect bearing retainer.

6003-123
INSTALL OIL SEAL IN BEARING RETAINER
IMPORTANT: If the new oil seal does not have the

outside diameter coated with a sealer,
apply LOCTITE® #620 sealer.
1. Apply LOCTITE® #620 to outside diameter of oil seal,

if not pre-coated.
2. Install new oil seal (A).
3. Seat oil seal on the bottom of the bore in bearing

retainer.
REMOVE 0-RING FROM BEARING

RETAINER
• Remove and discard 0-ring (B).
INSTALL 0-RING ON BEARING RETAINER
1. Lubricate new 0-ring with transmission fluid.
2. Install new 0-ring (B).

6003-124
REMOVE BEARING CUP FROM REAR

HOUSING
1. Remove bearing cup (A).
2. Clean and inspect bearing bore in housing.
INSTALL BEARING CUP IN REAR HOUSING
1. Lubricate the new bearing cup with clean transmission

fluid.
2. Install new bearing cup (B) 6 mm (1/4 inch) deeper

than flush.
ENG 6-46761 January, 2003 Prin1ed in Brazil

6003-125
IMPORTANT: Set the bearing cup not more than

Gmm (1/4 inch) deeper than flush with
the face of the bearing bore.
NOTE: The bearing retainer and shim arrangement will

set the exact depth for the bearing cup during
the end play adjustment procedure.
INSTALL BEARING RETAINER

(PRELIMINARY INSTALLATION, PRIOR TO
SETTING BEARING END PLAY OUTPUT
SHAFT)
1. Install two guide pins (A).
NOTE: Use all original shims and one additional .254mm

(.010 inch) shim for setting end play of the output
stage assembly. The additional shim is to help
prevent damage to the output shaft assembly
tapered roller bearing during the initial assembly,
before the proper shim thickness has been
established.
2. Place shims (B) on guide pins.

6003-126
SETTING END PLAY OF OUTPUT GROUP
INSTALL OUTPUT YOKE
1. Install yoke (B) with V-ring seal (A) onto splined

output shaft.
2. Install 0-ring (C), washer (D) and cap screw (E).
3. Tighten cap screw 215 N·m (159 lb-ft).
IMPORTANT: Check and reset output shaft end play

whenever new parts are installed. Set
End play at a 0 ± .051 mm (0 ± .002 in).
Check end play
IMPORTANT: Check end play with dial indicator on

cap screw.
4. Place dial indicator on cap screw.
5. Use pry bars under yoke to check end play.

A-V-ring seal
B-Yoke
C-O-ring
D-Yoke washer
E-Cap screw

6003-127
6. Remove cap screw, washer and yoke from output

shaft.
7. Remove bolts from bearing retainer.
8. Remove bearing retainer from rear housing.
NOTE: Use guide pins for installation of shims and

retainer. Shims can be .003 thickness and roll
onto retainers outside diameter causing possible
leak or damage to a-ring.
9. Remove or install correct amount of shims to reach a

0 ± .051 mm (0 ± .002 in) amount of end play.

6003-128
10. Align bearing retainer bolt holes with bolt hole circle
in the rear housing.
11. Install cap screws.
13. Install yoke, 0-ring, washer and cap screw.
14. Tighten cap screw to 215 N·m (159 lb-ft).
NOTE: Refer to group 55 for installation of brake

calipers.

Brake Group 6003-129
SPECIFICATIONS
Disk brake-to-yoke cap screw. Torque 48 N·m (36 lb-ft)
Yoke flange-to-output shaft cap Torque 215 N·m (159 lb-ft)

screw.
Caliper assembly-to-brake bracket Torque 87 N·m (64 lb-ft)

cap screw.
DISC BRAKE GROUP
A-Yoke flange E-O-ring 1-Lock washer (6 used) L-Brake bracket

B-Yoke washer F-Brake disc J-Cap screw (6 used) M-Mount pin (2 used)
C-Cap screw G-Cap screw (6 used) K-Caliper assembly N-Cotter pin (4 used)
D-V-ring seal H-Hex nut (6 used)

6003-130
DISASSEMBLE DISC BRAKE
1. Loosen cap screw (A) to keep output shaft from

turning.
2. Remove four cap screws (A).
3. Remove caliper assembly and brake bracket (B) as a

group.
4. Remove two cotter pins (A).
5. Remove two mount pins (B).
6. Remove caliper assembly (C) from brake bracket (D).

6003-131
7. Remove cotter pin (A).
8. Unscrew adjusting nut (B).
9. Remove operating lever (C). Pay attention to the

position of the operating lever for reassembly purposes.
10. Remove cam (D).
11. Remove two actuating pins (E).
12. Remove two brake pad and spring groups (F) from
caliper assembly (G).
13. Remove cap screw (A), yoke washer (B), and 0-ring
(C).
14. Loosen six hex nuts (A).
15. Remove the brake disc (B) and yoke flange (C) as a
group.

6003-132
16. Remove six hex nuts (A), six lock washers (B). and
six cap screws (C).
17. Remove brake disc (A) from yoke flange (B).
18. Inspect all parts for wear. Replace as necessary.
ASSEMBLE DISC BRAKE
1. Assemble yoke flange (A) and brake disc (B).
2. Install six cap screws (C), six lock washers (D), and
six Hex nuts (E).
3. Install brake disk and yoke flange group on output

shaft of transmission.
4. Tighten six cap screws (A) to 87 N·m (64 lb-ft).

6003-133
5. Install two brake pads and spring groups (F) to caliper

assembly (G).
IMPORTANT: Make sure end of actuating pin with the

shoulder is installed into the caliper
assembly first.
6. Install two actuating pins (E).
7. Install cam (D).
8. Install operating lever (C) in same position as when

removed.
9. Install adjusting nut (B). Do not tighten. Allow enough

clearance between pads and disc to prevent dragging.
10. Install new cotter pin (A).
11. Install caliper assembly (C) on brake bracket (D).
12. Install two mount pins (B).
13. Install two new cotter pins (A).
14. Install caliper and brake bracket group (A).
15. Install four cap screws (B).

6003-134
IMPORTANT: 0-ring is positioned flat against the

face of the output shaft.
17. Lubricate and install new 0-ring (A).
IMPORTANT: The machined face of the washer must

be installed next to the 0-ring.
18. Install yoke washer (B).
19. Install cap screw (C).
NOTE: Use brake caliper (B) to keep output shaft from

turning.

6003-135
REMOVE BRAKE PADS
1. Remove Cotter pin (A).
2. Remove Adjusting nut (B).
3. Remove operating lever (C).

6003-136
4. Remove cap screws (D).
5. Lift spring (F) over bolt in brake assembly.
6. Remove cap screw (E).

6003-137
7. Swing brake assembly (G) away from brake disk.
8. Remove actuating pins (H).
9. Remove brake pad (1).
10. Move spring (J) in front of brake assembly.
11. Lift brake pad (K) up and out to remove.

6003-138
INSTALL BRAKE PADS
NOTE: There are two pins located in the lower brake

pad area (A) of the brake assembly. Brake pads
have two holes that locate on pins.
1. Install brake pad (B) spring behind brake assembly.
2. Install brake Pad (C) with spring behind threaded

shaft of brake assembly.
3. Install actuating pins (D) to locate top brake pad.
4. Swing brake assembly onto disk brake.

6003-139
7. Install cam and lever (C).
8. Install adjusting nut (B).
9. Install cotter pin (A).

6003-140
REPLACE DEUTSCH™ CONNECTORS
1. Select correct size extractor tool for size of wire to be

removed:
a. Extractor Tool for 12 to 14 gauge wire.

b. Extractor Tool for 16 to 18 gauge wire.
c. Extractor Tool for 20 gauge wire.
2. Start correct size extractor tool over wire at handle

(A).
3. Slide extractor tool rearward along wire until tool tip

snaps onto wire.
IMPORTANT: Do NOT twist tool when inserting in

connector.
4. Slide extractor tool along wire into connector body

until it is positioned over terminal contact.
5. Pull wire out of connector body, using extractor tool.
DEUTSCH is a trademark of the DEUTSCH CO.
IMPORTANT: Install contact in proper location using

correct size grommet.
6. Push contact straight into connector body until positive

stop is felt.
7. Pull on wire slightly to be certain contact is locked in

place.
8. Transfer remaining wires to correct terminal in new

connector.

6003-144
REPLACE WEATHER PACK™ CONNECTOR
IMPORTANT: Identify wire color locations with

connector terminal letters.
1. Open connector body.
2. Insert Extraction Tool over terminal contact in

connector body.
3. Hold extractor tool fully seated and pull wire from

connector body.
NOTE: If terminal cannot be removed, insert wire or nail

through extractor tool handle and push terminal
contact from connector.
WEATHER PACK is a trademark of PACKARD ELECTRIC
IMPORTANT: Carefully spread contact lances to

assure good seating on connector
body.
NOTE: Connector bodies are "keyed" for proper contact

mating. Be sure contacts are in proper alignment.
4. Push contact into new connector body until fully

seated.

place.

connector.
7. Close connector body.
REPLACE SURE-SEAL TM CONNECTOR WITH

WEATHER PACK CONNECTOR
1. Pull wire to remove contact from SURE-SEAL

connector.

6003-142
2. Remove wire as close as possible to contact, using

Universal Electrical Plier.
IMPORTANT: SURE-SEAL and WEATHER PACK

connector bodies are "keyed" for
proper contact mating. Be sure
contacts are in proper alignment.
SURE-SEAL connectors are keyed 1, 2,
3. WEATHER PACK connectors are
keyed A, B, C. "A" matches 1, "B"
matches 2 and "C" matches 3. See
component replacement stories for any
exceptions on connector codes.
3. Install WEATHER PACK contact on wire. (See install

WEATHER PACK Contact in this section.)
4. Push contact into WEATHER PACK connector body

until fully seated.

place.

6003-143
REMOVE CONNECTOR BODY FROM BLADE

TERMINALS
1. Depress locking tang (A) on terminal, using a small

screw driver. Slide connector body off.
2. Be sure to bend locking tang back to its original

position (B) before installing connector body.
$
INSTALL DEUTSCH CONTACT
1. Strip 6 mm (1/4 in.) insulation from wire.
2. Adjust selector (A) on Crimper for correct

wire size.
3. Loosen lock nut (B) and turn adjusting screw (C) in

until it stops.
IMPORTANT: Select proper size contact "sleeve" or

"pin" to fit connector body.
4. Insert contact (A) and turn adjusting screw (D) until

contact is flush with cover (B).
5. Tighten lock nut (C).
IMPORTANT: Contact must remain centered between

indentors while crimping.
6. Insert wire in contact and crimp until handle touches

stop.
7. Release handle and remove contact.

6002-2
IMPORTANT: If all wire strands are not crimped into

contact, cut off wire at contact and
repeat contact installation procedures.
NOTE: Readjust crimping tool for each crimping

procedure.
8. Inspect contact to be certain all wires are in crimped

barrel.
INSTALL WEATHER PACK CONTACT
NOTE: Cable seals are color coded for three sizes of

wire:
a) Green - 18 to 20 gauge wire
b) Gray- 14 to 16 gauge wire
c) Blue - 10 to 12 gauge wire
1. Slip correct size cable seal on wire.
2. Strip insulation from wire to expose 6 mm (1/4 in.)

and align cable seal with edge of insulation.
NOTE: Contacts have numbered identification for two

sizes of wire:
a) #15 for 14 to 16 gauge wire
b) #19 for 18 to 20 gauge wire
3. Put proper size contact on wire and crimp in place

with a "W" type crimp, using Terminal Applicator.
4. Secure cable seal to contact as shown, using

Terminal Applicator.

6003-145

IMPORTANT: Proper contact installation for "sleeve"

(A) and "pin" (B) is shown.
Brz ENG 6-46761 May, 2002 Printed in Brazil

6003-146
NOTES
Brz ENG 6-46761 Revised 5-03 Printed in Brazil

Section
6003
TRANSMISSION
885 Grader

6003-2
TABLE OF CONTENTS 885

TRANSMISSION COMPONENT IDENTIFICATION .................................................. 3
TRANSMISSION MOUNTING I SENSOR ......................................................... 5
CHARGE PUMP ............................................................................ 16
DIRECT DRIVE INPUT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CONTROL VALVE .......................................................................... 44
MAIN CASE FRONT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
GEAR RATIO GROUP ...................................................................... 70
MAIN CASE REAR HOUSING . . . . . . . . ....................................................... 106
BRAKE GROUP ........................................................................... 116
REPLACE CONNECTORS . . . . . . . . . . . . . . . . . . . . . . ........................................... 127

6003-3
DF250 DIRECT DRIVE TRANSMISSION COMPONENT IDENTIFICATION
A-Direct drive input shaft K-Magnetic pickup sensor

B-Front cover assembly L-Suction screen assembly
C-Charge pump group M-Output yoke fitting
D-Main case front housing N-Control valve group
E-Main case rear housing 0-Magnetic pickup sensor
F-Dipstick gauge P-First stage output shaft
G-Dipstick tube assembly Q-Auxiliary pump drive
H-Disk brake caliper assembly R-Suction Tube
1-Yoke Flange
J-Brake disk T-Magnetic pickup sensor

6003-4
TRANSMISSION LIFTING PROCEDURE
Use a lift sling similar to (A). It should hold the

transmission level without bending the lift hangers (B).
TRANSMISSION REPAIR STAND
NOTE: The repair stand (A) used in this manual is OTC

DIVISION part number 1735, capacity is 907 Kg
(2000)1bs.
OTC Division
Sealed Power Corporation
655 Eisenhower Drive
Owatonna, Mn 55060
When any other stand is used, consult the

Manufacturer's instructions for mounting.
Approximate dry weights:

Model 885 = 703 Kg (1550 lbs).

6003-5
MOUNTING OF SERIES TRANSMISSION TO

REPAIR STAND
NOTE: See Section No. 6002, "Special Tools" for Assembly

Stand Plate drawings.

6003-6
REMOVE UPPER MAGNETIC PICKUP

SENSOR
1. Remove cap screw (2), washer and lockwasher.
2. Remove cover (A).
3. Remove magnetic pickup sensor (B).
4. Remove and discard o-ring.
INSTALL UPPER MAGNETIC PICKUP SENSOR
7. Install new o-ring.
8. Install magnetic pickup sensor (B).
10. Install Cover (A).
11. Install cap screws (2) with lockwashers and washers.

6003-7
REMOVE CYLINDER MAGNETIC PICKUP

SENSOR (MPU)
A-Snap ring
B-Fiat washer
C-Magnetic pickup sensor
D-O-ring

REMOVE CYLINDER MAGNETIC PICKUP SENSOR
2. Remove flat washer (B).
3. Remove magnetic pickup sensor (C).
4. Remove a-ring (D).
5. Inspect for wear or damage.
6. Discard a-ring (D).
INSTALL CYLINDER MAGNETIC PICKUP SENSOR
1. Lubricate new a-ring with transmission fluid.
2. Install new a-ring (D) onto magnetic pickup sensor

(C).
3. Install magnetic pickup sensor (C).
4. Install flat washer (B).
5. Install snap ring (A).

6003-8
REMOVE LOWER MAGNETIC PICKUP

SENSOR
1. Remove cap screw (2), washer and lockwasher.
2. Remove cover (A).
3. Remove magnetic pickup sensor (B).
4. Remove and discard o-ring.
INSTALL LOWER MAGNETIC PICKUP SENSOR
7. Install new o-ring.
9. Install Cover (A).
10. Install cap screws (2) with lockwashers and washers.

6003-9
OTHER MATERIAL
Name Use
SPECIFICATIONS
Charge pump-to-Input Housing cap Torque 115 N·m (85 lb-ft)

screws.
Suction Manifold-to-Input Housing Torque 25 N·m (18 lb-ft)

cap screws.
Suction Tube-to-Charge Pump. Torque 190 N·m (140 lb-ft)
Suction Tube-to-Suction Manifold. Torque 190 N·m (140 lb-ft)
Wiring Harness Bracket-to-Rear Torque 87 N·m (64 lb-ft)

Housing cap screw.
Wiring Harness Connector-to-wiring Torque 18-27 N·m (13-20 lb-ft)

harness bracket.

6003-10
REMOVE WIRING HARNESS
1. Loosen nut (A).
NOTE: Tag all wiring connectors before disconnecting

wiring harness.
2. Unfasten all weather pack connectors (B).
INSTALL WIRING HARNESS
1. Fasten all weather pack connectors.
2. Place main wiring harness connector (A) in bracket.
3. Tighten nut to 18-27 N·m (13-20 lb-ft).

6003-11
3. Loosen cap screws (A).
4. Move bracket (B).

6003-12
DISASSEMBLE SUCTION TUBE GROUP


6003-13
REMOVE SUCTION TUBE ASSEMBLY
NOTE: Refer to INTERVALS FOR CHANGING

TRANSMISSION OIL AND FILTER in Section 1002
for draining oil.
IMPORTANT: All oil should be drained from

transmission before beginning
disassembly.
1. Loosen wiring harness connector bracket and move

wiring harness connector bracket out of the way.
2. Loosen nut (A) on suction tube.
3. Remove suction screen assembly (B). Clean and

inspect.
4. Loosen nut (C) connecting suction tube (D) to suction

manifold.
5. Remove two cap screws (E) from suction manifold.
6. Remove suction manifold and 0-ring in groove on

back of manifold.
7. Remove suction tube (D).

6003-14
ASSEMBLE SUCTION TUBE GROUP


6003-15
INSTALL SUCTION TUBE
IMPORTANT: There must not be any suction leaks.

Use care assembling and installing the
suction tube. A leak may cause the
transmission to not operate properly or
the charge pump to fail. Refer to
CHECK OIL LINES AND FITTINGS in
general information section 6002 for
recommended tightening of tube
fittings.
1. Place suction tube (D) into fitting on charge pump.
2. Install 0-ring on back side of suction manifold.
3. Start one cap screw (E) into suction manifold.
4. Position suction tube (D) into suction manifold.
5. Install and tighten cap screws (E) to 25 N·m (18 lb-ft).
6. Tighten nuts (A) and (C) at both ends of suction tube

(D) to 190 N·m (140 lb-ft).
7. Install suction screen assembly (B).
8. Reposition wiring harness bracket (F).
9. Tighten wiring harness bracket cap screws to 87 N·m

(67 lb-ft).

6003-16
CHARGE PUMP GROUP
A-Oil pump F-Snap ring

B-Cup plug G-O-ring
C-Set screw
D-Cap screw M16x65 8.8 (3 used) THE CHARGE PUMP IS NOT REPAIRABLE. THE
E-Sieeve (SAE C) PUMP MUST BE REPLACED IF FOUND
DEFECTIVE.

6003-17
REMOVE CHARGE PUMP GROUP
NOTE: Transmission is shown with the input housing

engine side down.
1. Remove three cap screws (A).
A CAUTION: The driven gear and support

bearings will usually stay with the charge
pump when removed from input housing. Do
not allow these parts to fall from the charge
pump, personal injury or damage could result.
NOTE: The driven gear and support bearings are

considered part of the Input Housing Group, but
they will usually come out with the charge pump
when it is removed. For information concerning
these parts see section (Direct Drive Input
Assembly) in this manual.
2. Remove charge pump (B) from input housing.
3. Remove o-ring (C).
4. Discard o-ring (C).
REMOVE DRIVEN GEAR AND BEARING

ASSEMBLY
1. Remove driven gear and bearing assembly (A) from

charge pump.

6003-18
INSTALL CHARGE PUMP TO DIRECT DRIVE

INPUT ASSEMBL V
NOTE: The driven gear on the charge pump must mesh

with the idler gear. Refer to section, Direct
Drive input assembly (install driven gear
assemblies). The idler gear assembly can be
installed immediately before the charge pump
or aspart of the charge pump.
A CAUTION: Never install idler gear assembly

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

long-term separating and lubricating effect,
prevention of fretting corrosion and avoidance of
squeaking noises.
IMPORTANT: OPTIMOL® OPTIMOLY PASTE WHITE T

is only suitable for paste-specific
applications and cannot replace oil or
grease lubrication. Do not mix with
other greases, pastes or oils.
2. Apply OPTIMOLY PASTE WHITE T to charge pump

spline.
3. Install charge pump (B) into front cover.
4. Install three cap screws (A) through charge pump into

front cover.
OPT/MOL® is a regestered trademark. OPT/MOLY PASTE WHITE T

can be purchased from Castro/ Industrial North America Inc.

6003-19
OTHER MATERIAL
Name Use
LOCTITE® #620 Oil seal
Grease 0-ring
Transmission fluid All moving parts and o-rings
SPECIFICATIONS
Magnetic Pickup-to-Input Housing Torque 10 N·m (8 lb-ft)

Cap Screws.
Input Housing Assembly-to-Main Torque 87 N·m (64 lb-ft)

Case Front Housing Cap Screws.
THEORY OF OPERATION DIRECT DRIVE TRANSMISSION
The engine is directly connected to the input shaft of output shaft by depressing the clutch pedal or by
the transmission. When the transmission is engaged shifting the transmission to the neutral or park
into gear the engine power is connected to the output position.
shaft of the transmission at different speed ratios
depending on which directional and speed clutches The transmission charge pump and vehicle pumps
are engaged. Each clutch is engaged hydraulically are always connected to the engine power via a
and controlled by an individual proportional valve. The constant mesh gear train.
rate of the pressure rise behind each clutch piston is
determined by the Transmission Control Unit (TCU) A torsional damper may be installed between the
providing the current to each valve. The engine engine and transmission input shaft to detune the
power may be disconnected from the transmission system from harmful resonant frequencies.

6003-20
REMOVE INPUT HOUSING ASSEMBLY GROUP

REMOVE INPUT HOUSING AND INPUT

ASSEMBLY
1. Position transmission with input housing up.
2. Remove seven bolts (A).

6003-21
A CAUTION: Weight of input housing assembly is

50 Kg (11 0 lbs).
3. Install lifting device.
REMOVE INPUT ASSEMBL V A-Input shaft assembly

B-Transmission assembly
A-Input shaft
B-43T pulse gear
C-Thrust race
D-Snap ring
E-Bearing
F-Seal ring
1. Remove Seal ring (F).
2. Remove Bearing (E) inspect and discard.
3. Remove Snap ring (D)
4. Remove thrust race (C).
5. Remove 43T pulse gear (B).

ASSEMBLE INPUT SHAFT ASSEMBLY
1. Place 43T pulse gear (B) onto Input shaft (A).
2. Place thrust race (C) onto pulse gear.
3. Install snap ring (D) onto input shaft.
4. Press new bearing (E) onto input shaft.
5. Lubricate bearing (E) with transmission fluid.
6. Install seal ring (F).

6003-22
1. Lift input housing carefully from transmission. The

direct drive input assembly should stay with transmission.
2. Remove input assembly (A).

6003-23
REMOVE COUPLING SHAFT AND INPUT BEARING RETAINER
A-Cap screw M8x50mm 10.9 (7 used) D-Coupling shaft

B-Direct Drive input bearing retainer E-Transmission assembly
C-O-ring F-Deflector
G-lnset drawing
1. Remove coupling shaft (B).
2. Remove cap screws (C).
3. Remove cap screw and deflector (D).
4. Remove o-ring (E).
5. Remove direct drive input bearing retainer (F).

6003-24
DISASSEMBLE INPUT ASSEMBLY
A-Input housing H-Bearing spacer

B-Hex socket plug 1-Snap ring
C-Lift hanger J-Cap screw M6x20mm 8.8 (2 used)
D-Cap screw M12x20mm 8.8 (2 used) K-Lock washer (2 used)
E-Bearing (3 used) L-VVasher (2 used)
F-Driven gear 36T M-Magnetic pickup cover
G-Bearing (with snap ring) N-Magnetic pickup sensor
0--0-ring

6003-25
DISASSEMBLE INPUT HOUSING
1. Position input housing assembly (A) engine side up.
2. Install a bolt (C) into threaded hole in idler shaft (B).

Use this bolt to pull idler shafts, the shafts are a slip fit
in their bores
3. Remove two idler shafts (B).
NOTE: 0-rings on bottom of idler shafts can remain in

bottom of idler shaft bores.
4. Remove two o-rings from idler shafts and two o-rings

from bottom of idler shaft bores. Discard o-rings.
5. Inspect idler shaft for wear or damage.
YZ,CTM149,30,2 -19-04NOV98
6. Use a driving tool to remove oil seal and bearing from

input housing.

6003-26
REMOVE AND DISASSEMBLE DRIVEN

GEARS
1. Position input housing to have pump ports and driven

gear assemblies up.
2. Remove driven gear assembly (A) from charge pump

side.
3. Remove snap ring (B) from groove in auxiliary pump

side bore .
4. Remove spacer and driven gear assembly (C).
5. Use puller to remove bearings (A) from gear (B).
6. Inspect bearings and gears.

6003-27
ASSEMBLE DRIVEN GEARS AND BEARINGS

(CHARGE PUMP SIDE)
IMPORTANT: Use press tool that bears on the inner

race of the bearing.
1. Press bearing (A) onto driven gear (B).
2. Turn gear over and press bearing (C) onto gear.
NOTE: Auxiliary pump port driven gear assembly will

have one bearing with a snap ring. Install this
bearing with snap ring closest to gear.
REMOVE IDLER GEARS AND DISASSEMBLE
1. Remove idler gears through input housing pump ports.
2. Remove snap ring (A) from top bearing.
3. Support gear so that the bottom bearing is free to

come out when the top bearing is pressed through.
4. Press top bearing through idler gear, removing both

bearings.
5. Inspect bearings and gears for wear or damage.

6003-28
ASSEMBLE IDLER GEARS
NOTE: Both idler gears assemble the same. Install

bearing into the idler gear correctly. Snap ring
side of bearing to the outside of the gear.
1. Use a press and bearing installation tool to install

bearings into idler gear.
REMOVE MAGNETIC PICKUP
1. Remove two cap screws, two lock washers and two

flat washers (A).
2. Remove magnetic pickup cover (B).
3. Remove magnetic pickup sensor with 0-ring (C).
NOTE: Install magnetic pickup after installing driven

gears.

6003-29
ASSEMBLE INPUT ASSEMBLY
A-Input housing H-Bearing spacer

B-Hex socket plug 1-Snap ring
C-Lift hanger J-Cap screw M6x20mm 8.8 (2 used)
D-Cap screw M12x20mm 8.8 (2 used) K-Lock washer (2 used)
E-Bearing (3 used) L-VVasher (2 used)
F-Driven gear 36T M-Magnetic pickup cover
G-Bearing (with snap ring) N-Magnetic pickup sensor
0--0-ring

6003-30
REMOVE DIRECT DRIVE INPUT HOUSING AND BEARING
A-Input housing
B-Ball bearing

6003-31
INSTALL OIL SEAL AND BALL BEARING
1. Position input housing with engine side up.
2. Install new oil seal.
NOTE: If outside diameter of oil seal is not already

coated with a sealer, apply LOCTITE® #620.
Oil seal guide, special tool 75310178 (QRM 803092).
Oil seal drive, special tool 75310178 (QRM 803094).
3. Position input housing with engine side down.
4. Install dowel pin (D).
5. Install new ball bearing (E) into front cover.

6003-32
A-Idler shaft (2 used) D-37T Idler gear (2 used)

B-O-ring (2 used) E-Bearing (2 used)
C-Bearing (2 used) F-0-ring (2 used)
G-lnput housing

6003-33
INSTALL IDLER GEARS AND BEARING

ASSEMBLIES
1. Place idler gear assembly (A) into auxiliary pump port

of the input housing.
2. Position idler gear assembly into its cavity beside

auxiliary pump port.
3. Install idler gear assembly (B) into charge pump port

and place into cavity.

6003-34
INSTALL IDLER SHAFTS
NOTE: Through hole in idler shaft must line up with bolt

hole in input housing. Use a bolt to guide the
alignment while installing.
1. Align bearing bore of idler gear assemblies (A) with

input housing shaft bore.
2. Lubricate 0-ring (B) with grease and install in groove

on shaft.
3. Use grease to hold 0-ring (C) to the bottom of the

idler shaft during installation.
ALTERNATE 0-RING INSTALLATION PROCEDURE
3a. Position 0-ring (C) at the bottom of the shaft bore in

the input housing.

6003-35
4. Use bolt to align thru hole in idler shaft with threaded

hole in the input cover.
5. Push idler shaft (D) through idler gear assembly into

input housing.
6. Install the other idler shaft in this same manner.

6003-36
INSTALL DRIVEN GEAR ASSEMBLY

(AUXILIARY PUMP PORT SIDE)
1. Install driven gear assembly with the snap ring up.
2. Rotate idler gear (A) to align teeth with driven gear

(B).
3. Push idler gear bearing into bore in input housing.

6003-37
4. Install bearing spacer (C).
A CAUTI~N:
snap rmgs.
Wear eye protection when installing
5. Install snap ring into groove.

6003-38
INSTALL MAGNETIC PICKUP
1. Lubricate 0-ring.
2. Install new 0-ring in groove on magnetic pickup

sensor (A).
3. Push magnetic pickup sensor into input housing.
4. Install magnetic pickup cover (B).
5. Install cap screws and lock washers (C).

6003-39
ASSEMBLE DIRECT DRIVE INPUT

ASSEMBLY
1. Align the oil passage and bolt holes in the direct drive
input bearing retainer with oil passage and bolt holes in
the front housing.
IMPORTANT: Deflector (B) must be in place and

installed correctly to properly direct oil
flow. It also must not interfere with
installing the input housing.
2. Install cap screws (A) and deflector (B).
3. Lubricate and install new o-ring (C).
5. Install coupling shaft (D).
6. Install input assembly (E).

6003-40
ASSEMBLE INPUT HOUSING GROUP


6003-41
INSTALL INPUT HOUSING ASSEMBLY TO

MAIN CASE FRONT HOUSING
1. Install lifting device, make sure the input housing

assembly hangs level.
IMPORTANT: Be sure main case front housing is

level before attempting to install input
housing assembly. Special attention is
required when lowering input housing
onto front housing. Avoid damage to
input seal during installation.
2. Lower input housing assembly carefully over direct

drive input bearing retainer onto front housing.
NOTE: Be sure the input housing goes down completely

and sits flat on the front housing.
3. Install seven cap screws (A).
4. Tighten cap screws to 87 N·m (64 lb-ft)

6003-42
OTHER MATERIAL
Name Use
SPECIFICATIONS
Control valve-to-front housing cap Torque 40 N·m (30 lb-ft)

screw (27).
Proportional valve nut-to-proportional Torque 1. 7-2.8 N·m (15-25 Ib-in)

solenoid assembly (8).
Temperature sensor-to-valve Torque 16 N·m (12 lb-ft)

housing.
Proportional valve-to-valve housing Torque 16-20 N·m (10-15 lb-ft)

(8).
Main regulator assembly-to-valve Torque 142 N·m (1 05 lb-ft)

housing.
Relief valve assembly-to-valve Torque 102 N·m (75 lb-ft)

housing.

6003-43
PROPORTIONAL VALVES
The proportional valve is a pilot operated cartridge open. There is a light spring on the opposite end of
valve. The amount of electrical current going to the the main spool resisting this pressure plus the clutch
coil creates a magnetic force which opens a pilot port pressure is fed to the spring end of the main
valve allowing flow to exit the pilot cavity. The pilot spool as a feedback, causing the valve spool to close
cavity is fed a controlled amount of flow from the inlet as the clutch pressure and spring force becomes
pressure port of the valve via a fixed pilot feed equal to the pilot pressure. The output pressure from
orifice. The difference between the restrictions of the the valve is zero at zero current and increases to
pilot inlet orifice and pilot exit valve controls the oil within 15 psi of the inlet pressure as the current to
pressure in the pilot cavity. This pressure acts on the the coil is increased.
area on one end of the main spool causing it to

6003-44
CONTROL VALVE GROUP
0
0
() 0
Oo
0
0
CJ
D
,,
~
~ 0
0
J
0 0
0 0 ~
0
0
00
A-Gasket F-Cap screw M8x45 10.9 (5 used)

B-PI ate G-Cap screw M8x75 10.9 (13 used)
C-Gasket H-Temperature Sender
D-Valve Assembly l-O-ring
E-Fiat Washer (27 used) J-Cap screw M8x90 10.9 (9 used)

6003-45
REMOVE CONTROL VALVE GROUP
1. Tag all electrical connections.
2. Disconnect wiring harness.
REMOVE TEMPERATURE SENSOR
• Remove temperature sensor.
INSTALL TEMPERATURE SENSOR
• Install temperature sensor and tighten to 24-27 N·m

(18-20 lb-ft).
IMPORTANT: Do not allow any of the flat washers

(B) to fall into control valve assembly
or transmission openings. The
transmission may not operate properly
or damage may result.
3. Remove 27 cap screws (A) and flat washers (B).
A assembly
CAUTION: Approximate weight of valve
is 25 Kg (55 lbs).
4. Remove valve assembly (C).

6003-46
DISASSEMBLE AND ASSEMBLE CONTROL VALVE

THE CARTRIDGE TYPE VALVES USED IN THIS 0-rings. Use only new 0-rings.
ASSEMBLY ARE NOT SERVICEABLE. ANY Install new 0-rings onto cartridge
VALVE FOUND TO BE DEFECTIVE MUST BE valve.
REPLACED AS A UNIT.
USE THE DRAWINGS PROVIDED AS GUIDES FOR
IMPORTANT: Cartridge valves require a 0-rings. FURTHER DISASSEMBLY AND ASSEMBLY OF THE
When assembling valves grease all CONTROL VALVE.
A-Valve Housing D-90 Relief Valve H-Piug K-0-ring

8-Hex Socket Plug 7/16-20 E-Main Regulator Assembly l-O-ring L-Proportional Solenoid
(12 used) F-Steel Ball 9/32 (4 used) J-0-ring Plug
C-Proportional 24 Volt G-Hex Socket Plug 9/16-18
Valve (7 used) (2 used)

6003-47
DISASSEMBLE VALVE ASSEMBLY
PROPORTIONAL SOLENOID
1. Remove nut (A), washer (B) and coil (C) from

proportional solenoid.
2. Remove proportional valve (D).
REMOVE 90 RELIEF VALVE
1. Remove 90 relief valve (A).
2. Inspect for wear and contamination.

6003-48
REMOVE MAIN REGULATOR ASSEMBLY
IMPORTANT: The main regulator is an assembly and

is not serviceable and must be
replaced if found defective. 0-rings (3)
are serviceable items.
1. Remove main regulator assembly (A).
2. Discard o-rings (3).
REMOVE PROPORTIONAL PLUG
1. Remove solenoid assemblies.
NOTE: In some applications proportional plugs are used

in-place-of solenoids.
2. Remove proportional plug (A).

6003-49
REMOVE PLUG
1. Remove plug (A).
INSTALL PLUG
2. Install new o-ring onto plug.
3. Install plug (A).
4. Tighten plug to 12 N·m (9 lb-ft).
INSTALL PROPORTIONAL PLUG
2. Install new o-rings onto proportional plug.
3. Install proportional plug (A).
4. Tighten proportional plug.
INSTALL MAIN REGULATOR ASSEMBLY
2. Install new o-rings.
3. Install main regulator assembly (A).
4. Tighten main regulator assembly 142 N·m (1 05 lb-ft).

6003-50
INSTALL RELIEF VALVE
1. Install new o-rings (A).
2. Install relief valve.
3. Tighten relief valve 102 N·m (75 lb-ft).

6003-51
INSTALL PROPORTIONAL SOLENOID

ASSEMBLY
1. Install new a-ring's (A), (B) and (C) onto proportional

valve.
2. Install proportional valve (D) into valve housing.
3. Tighten proportional valve 16-20 N·m (12-15 lb-ft).
4. Install coil (E), washer (F) and nut (G) onto

proportional valve.
5. Tighten nut 1.7-2.8 N·m (15-25 lb-in).

6003-52
INSTALL CONTROL VALVE GROUP
0
0
() 0
Oo
0
0
CJ
D
,,
~
~ 0
0
J
0 0
0 0 ~
0
0
00
A-Gasket E-Fiat Washer (27 used) G-Cap screw M8x75 10.9 l-O-ring
B-PI ate F-Cap screw M8x45 10.9 (5 (13 used) J-Cap screw M8x90 10.9 (9
C-Gasket used) H-Temperature Sender used)
D-Valve Assembly
IMPORTANT: The gaskets and metal plate must 2. Install plate (B).
be installed correctly. The first
gasket is cut out to the shape of the 3. Install gasket (C).
casting on the front housing. The
second gasket is cut out to the 4. Install valve assembly (D).
boot-like shape cut out of it. 5. Install cap screws (F), (G) and (J) and washers
(E). Observe tightening sequence and torque
1. Install gasket (A). specifications given in this section.

6003-53
INSTALL GASKET TO FRONT HOUSING

IMPORTANT:There are two (2) gaskets and a plate
that are placed on the front housing, in
a particular order, before installing the
valve assembly to the front housing.
The first gasket is cut out to the shape
of the casting on the front housing.
The second gasket is cut out to the
boot-like shape cut out of it.
1. Install both adapter studs M8 X 90 (A) to front housing.
2. Place and fit gasket (B) onto front housing using

adapter studs (A).
INSTALL PLATE AND GASKET

1. Place and fit plate (A) on top of first gasket using
adapter studs.
2. Place and fit gasket (B) on top of plate (A).

6003-54
INSTALL VALVE ASSEMBLY
1. Using guide pins for hole alignment, place valve

assembly (A) on top of gaskets.
2. Remove guide pins (B).
3. Install cap screws (C).
4. Tighten cap screws to torque specifications and

tightening sequence in this section.

6003-55
CAP SCREW TIGHTENING SEQUENCE AND TORQUE SPECIFICATIONS
Tighten cap screws in rotational sequence 2. Repeat step 1.

represented by call outs.
CONTROL VALVE CAP SCREW TORQUE
1. First rotational sequence tighten all cap screws to SPECIFICATIONS .... .40 N·m (30 lb-ft)
40 N·m (30 lb-ft).

6003-56
A-Valve Housing F-Lube Pressure Check Port M-Temperature Sensor R-Ciutch D Check Port
B-Converter Out Pressure G-Converter Relief N-System Pressure Check S-Ciutch C Check Port
Check Port H-Pressure Regulator Port T-Solenoid Assembly
C-Converter In Pressure 1-Pump In Port 0-Lube In Port U-Converter Out
Check Port J-Ciutch B Check Port P-Oil Out To Heat Temperature
D-Ciutch 1 Pressure Check K-Ciutch A Check Port Exchanger V-Ciutch 4 Check Port
Port L-Auxiliary Pressure Source Q-Auxiliary Pressure Source W-Ciutch 3 Check Port
E-Ciutch 2 Pressure Check
Port
OPERATING CONDITIONS: PORT PRESSURES:
• Engine speed at 2000 rpm In neutral
• Transmission temperature range at 65-93·c • Converter in 4 - 8 Bar (60-115 psi) (see footnote)
(15o·-2oo·F).
• Converter out 2.8 - 6.2 Bar (40-90 psi)
• Pump flow 87-102 L/min (23-27 gpm} at
1655-1931 kPa (255-280 psi). • Lube 2.8 - 4 Bar (40-60 psi)
In gear
• Lube 1 .4 - 2.8 Bar (20-40 psi)
In neutral, "Converter In" pressure should always be higher than Lube

pressure.

6003-57

(WITHOUT WET BRAKE) continued
Following is identification of ports as they are marked on

the valve body casting.
Ports marked 1, 2, 3 and 4 are Direction Clutch Ports.
• 1 and 2 are forward clutches.
• 3 and 4 are reverse clutches.
Ports marked A, B, C and D are Speed Clutch Ports.
NOTE: All check ports are 7/16-20 UNF SAE 0-ring,

unless otherwise specified.

6003-58
OTHER MATERIAL
Number Name Use
LOCTITE® #242 Oil Seal
SPECIFICATIONS
Front Housing-to-Rear Housing Cap Torque 87 N·m (64 lb-ft)

Screws.
Main Case Front Housing. Weight 120 Kg (265 lbs.)
REMOVE OUTPUT YOKE
1. Remove cap screw (E), washer (D), 0-ring (C).
2. Remove yoke (B) and V-ring seal (A).
A-V-ring seal
B-Yoke
C-O-ring
D-Yoke washer
E-Cap screw

6003-59
DISASSEMBLE AND ASSEMBLE FRONT HOUSING
A-Hex cap screws C-Bore Sleeve (4 used) F-Bearing Cup 1-Bracket

12x120mm (18 used) D-lnput Bushing G-Piug with 0-ring (2 used)
8-Front Housing (DF250) E-Dowel Pin (2 used) H-Lube Relief Valve
Assembly
D - Input bushing driver guide, special tool 75310178 (QRM 803142).

6003-60
1. Remove cap screws from front housing.
NOTE: See 6002-5 for special tools.
1. Use four threaded holes (A) in front housing to attach

lifting tool.
NOTE: Use only high grade fasteners for holding the

lifting tool to the front cover.
2. Attach lifting tool (B) onto front housing.
YZ,CTM149,40,3 ·19·15JUN98

6003-61
3. Attach chain and hooks to lifting tool.
A CAUTION: Front housing weight is

approximately 120kg (265 lbs).
4. Lift front housing (A) from rear housing (B).

6003-62
DISASSEMBLE FRONT HOUSING
A-Lube relief valve 8-Bore sleeve (4) C-Bearing cup
REMOVE BORE SLEEVES
1. Inspect bore sleeves (A) for wear or damage.
2. Remove bore sleeves from front side of front housing.

6003-63
INSTALL BORE SLEEVES
IMPORTANT: Install bore sleeves with the internal

chamfer up.
2. Place bore sleeve (A) onto driving tool (B) with

outside diameter chamfer of bore sleeve to end of tool.
3. Install bore sleeve flush with shoulder.

6003-64
REMOVE LUBE RELIEF VALVE
2. Remove lube relief valve (A).
INSTALL LUBE RELIEF VALVE
1. Position front housing with bearing bore side down.
2. Install new lube relief valve (A).
REMOVE BEARING CUP
1. Remove bearing cup.

6003-65
INSTALL BEARING CUP
1. Install new bearing cup (A).
REMOVE OIL SEAL
1. Remove oil seal (A).
INSTALL OIL SEAL
NOTE: Apply LOCTITE #242 or equivalent to outside

diameter of oil seal before installation.
1. Install new oil seal flush with shoulder.

6003-66
INSTALL FRONT HOUSING TO REAR

HOUSING
IMPORTANT: When installing front housing to rear

housing use guide pins to help align
housings and to protect seal rings
during installation. Check for dowel
pins before installing (Refer to
DISASSEMBLE AND ASSEMBLE FRONT
HOUSING for dowel pins hole location).
1. Attach lift tool to front housing.
NOTE: Refer to remove front housing for information on

attaching lifting tool.
2. Install new gasket onto rear housing.
3. Install front housing (A) to rear housing (B).

6003-67

6003-68
OTHER MATERIAL
Name Use
SPECIFICATIONS
Output group Weight 30 Kg (65 lbs.)
Clutch stages less output stage. Weight 272 Kg (600 lbs.)
Oil trough-to-rear housing cap Torque 25 N·m (18 lb-ft)

screws.
Clutch assemblies Separator plate-to-clutch plate 2. 79 mm-5.59mm (.11 0-.220 in)

retainer clearance
Clutch gear End play .25 mm (.01 0 in)

6003-69
REMOVE OUTPUT GROUP
1. Remove two cap screws (A) from oil trough assembly

(B).
A CAUTION: Approximate weight of output group

is 30 Kg (65 lbs).
2. Remove output group (D) and oil trough (E).

6003-70
DISASSEMBLE OUTPUT GROUP AND OIL TROUGH
A-Bearing cone (2 used) 8-Seventh stage output C-Oil Trough Assembly D-Cap Screw M8x12 8.8 (2
shaft gear assembly used)
NOTE: Oil trough can only be removed or installed Disassemble Output Group
with output group.
1. Remove bearing cones (A).
IMPORTANT: Do not attempt to remove gear from
shaft. This is a permanent assembly. Assemble Output Group
Damage to parts will result.
1. Install new bearing cones (A).

6003-71
REMOVE ALL CLUTCH STAGE ASSEMBLIES
A CAUTION: Approximate weight of all clutch

stage assemblies is 272 Kg (600 lbs).
IMPORTANT: Lift all clutch stage assemblies at

one time using lift tool.
NOTE: See section 6002 for special tools.
1. Install lift tool (A) 75289949.
2. Lock holders (B) into place.
3. Install bolt (C) into sixth stage assembly.
4. Lift all clutch stage assemblies from rear housing.

6003-72
5. Place stages on work table.
A CAUTION: Place clutch stage assemblies in

center of work table to prevent personal
6. Remove lift tool from clutch stage assemblies.
injury.

6003-73
FIRST STAGE SHAFT ASSEMBLY
A-Seal ring B-Bearing C-First stage shaft D-Bearing

assembly
DISASSEMBLE FIRST STAGE ASSEMBLY NOTE: Press only on inner race of bearing.
1. Remove and discard Seal Ring (A). 1. Install new bearing (B).
2. Remove and discard Bearing (B). 2. Install new bearing (D).
3. Remove and discard Bearing (D). NOTE: Refer to Sizing Seal Rings in this group.
4. Inspect first stage shaft assembly (C). 3. Install new seal ring (A).
ASSEMBLE FIRST STAGE ASSEMBLY

6003-74
SECOND STAGE CLUTCH ASSEMBLY
A-Seal Ring (3 used) K-Ciutch Separator Plate (26 used)

B-Ball Bearing (2 used) L-Retainer Ring (2 used)
C-Retaining Ring (2 used) M-Snap Ring Retainer (2 used)
D-Bearing (2 used) N-Ciutch Return Spring (16 used)
E-2nd Clutch 54T Gear 0-Lube Shutoff Washer (2 used)
F-Bearing (2 used) P-Ciutch Piston (2 used)
G-O-ring (2 used) Q-Piston Outer Seal (2 used)
H-Snap ring (internal),(2 used) R-0-ring (2 used)
1-Ciutch Plate Retainer (2 used) S-2nd Stage Shaft Assembly
J-Ciutch Plate (22 used) T-61T Clutch Gear (2nd and 3rd stage)

6003-75
THIRD STAGE CLUTCH ASSEMBLY
A-Seal Ring (2 used) J-Retaining Ring

B-Ball Bearing (2 used) K-Ciutch Separator Plate (13 used)
C-3rd Stage Shaft Assembly L-Ciutch Plate (11 used)
D-O-ring M-Ciutch Plate Retainer
E-Piston Outer Seal N-Snap Ring
F-Ciutch Piston 0--0-ring
G-Lube Shutoff Washer P-Bearing
H-Ciutch Return Spring (8 used) Q-61T Clutch Gear (2nd and 3rd stage)
1-Snap Ring Retainer R-Bearing
S-Retaining Ring

6003-76
FOURTH STAGE CLUTCH ASSEMBLY
A-Seal ring (3 used) L-Snap ring retainer (2 used)

B-Bearing (2 used) M-Ciutch retainer spring (16 used)
C-Snap ring (2 used) N-Lube shutoff piston (2 used)
D-Bearing 0--Spring backup plate (2 used)
E-4th clutch assembly gear P-Bellville spring (2 used)
F-Bearing Q-Ciutch piston (2 used)
G-Snap ring (2 used) R-Piston outer seal (2 used)
H-Ciutch plate retainer (2 used) S-O-ring (2 used)
1-Ciutch separator plate (20 used) T-4th and 5th stage shaft assembly
J-Ciutch plate (22 used) U-Bronze cage bearing (2 used)
K-Retainin rin 2 used V-44 Tooth clutch ear

6003-77
FIFTH STAGE CLUTCH ASSEMBLY
A-Seal ring (3 used) K-Retaining ring (2 used)

B-Bearing (2 used) L-Snap ring retainer (2 used)
C-Snap ring (2 used) M-Ciutch retainer spring (16 used)
D-Bearing (2 used) N-Lube shutoff washer (2 used)
E-86T clutch gear (2 used) 0-Spring backup plate (2 used)
F-Bearing (2 used) P-Bellville spring (2 used)
G-Snap ring (2 used) Q-Ciutch piston (2 used)
H-Ciutch plate retainer (2 used) R-Piston outer seal (2 used)
1-Ciutch separator plate (20 used) S-O-ring (2 used)
J-Ciutch plate (22 used) T-4th and 5th stage shaft assembly

6003-78
DISASSEMBLE CLUTCH STAGE ASSEMBLY

All clutch stage assemblies in the
transmission assemble and disassemble in the same
manner. In this manual we show the disassembly
and assembly of the second stage clutch.
1. Remove three teflon seal rings.

6003-79
2. Install bearing removal tool (A).
3. Install gear puller (B) onto bearing removal tool.
4. Remove bearing (C) from shaft assembly.

6003-80
5. Remove snap ring (D) from shaft assembly.
6. Install gear puller.
7. Remove clutch gear (E).
l
I

6003-81
8. Remove bearing (A).
IMPORTANT: Fourth stage clutch gear (clutch A)


6003-82
NOTE: 0-ring (A) is on the directional clutched only.

Speed clutcheswill not have an o-ring.
9. Remove o-ring (A).

6003-83
A snap
CAUTI~N: Wear eye protection when removing
rmg.


6003-84
12. Turn shaft assembly over. Remove all clutch and

separator plates.
NOTE: Fourth and Fifth stage assemblies will have

special clutch assemblies. Spring backup plate
(A) and Bellville spring (B) and are not
interchangeable with the second and third stage
assemblies.

6003-85
13. Turn shaft assembly over.
14. Install puller.
15. Remove ball bearing and discard bearing.

6003-86
16. Place shaft assembly on press.
17. Use press tool (B) to compress clutch return springs.

753110177 (QRM 112482 - QRM 112517)
18. Remove snap ring (C).

6003-87
IMPORTANT: Pay attention to the assembly of the

clutch return springs. They must be
reassembled in the same way.
19. Lift out snap ring, retaining ring, and clutch return
springs.
20. Remove lube shutoff washer.

6003-88

piston from cylinder. If cylinder is damaged DO
NOT place hand on top of piston. If cylinder is
turned upside down the piston will blow all the
way out.
21. Apply air pressure through oil passage to force

piston from shaft assembly.

6003-89
NOTE: Fourth and fifth stage assemblies have special

pistons and will not interchange with second and
third stage assemblies.
22. Remove piston from cylinder.
23. Remove outer piston seal (A) and 0-ring (B) from
piston.
24. Inspect all parts.

6003-90
ASSEMBLE CLUTCH STAGE ASSEMBLY
2. Install new piston outer seal (B).
3. Install clutch piston (C).
4. Install lube shutoff washer (D).
NOTE: Fourth and fifth clutch stage assemblies use

special pistons and will not interchange with
second and third stage assemblies.

6003-91
IMPORTANT: Install clutch return springs (A)

correctly. Use the photograph as a
guide.
5. Install clutch return springs (A).
6. Place press tool (B) 75310177 (QRM 112482 -

QRM 112517) over shaft.
7. Place snap ring retainer (C) and retaining ring (D)

over shaft.

6003-92
8. Compress clutch return springs.
9. Install retaining ring (E).
10. Release pressure on clutch return springs slowly, be

sure snap ring retainer is properly positioned.

6003-93
NOTE: Bellville spring (A) installed with inside diameter

of spring contacting piston (refer to FOURTH
AND FIFTH STAGE CLUTCH ASSEMBLY).
NOTE: Spring backup plate (B) installed with flat face

up (ref to FOURTH AND FIFTH STAGE CLUTCH
ASSEMBLY).

6003-94
NOTE: Clutch separator plates are all steel with external

spline teeth. Clutch plates have a lining material
on the face and internal spline teeth. Lubricate
and install one plate at a time. First install a
clutch separator plate then a clutch plate.
Continue until all plates are installed.
11. Install clutch separator plate (A).
12. Install clutch plate (B).
Repeat steps 11 and 12 until all plates are installed.

6003-95
13. Install clutch plate retainer (A).
A snap
CAUTI~N: Wear eye protection when installing
rmg.
14. Install snap ring (B).
NOTE: Check that clutch and separator plates are not in

a bind. Clearance between clutch plate and
clutch plate retainer must be 2. 79-5.59 mm
(. 110-.220 in).

6003-96
IMPORTANT: Clutch plate splines must be aligned

before installing bearings on shaft
assembly to avoid clutch plate damage.
15. Use gear and hub assembly to align clutch plates

and separator plates.
16. After aligning clutch plates remove gear and hub

assembly.
IMPORTANT: Seal side of bearing goes toward the

clutch plates.

must use special bearing. Use only
approved bronze bearings. Bronze
caged bearing do not have sealed sides
and can be installed either side up.
17. Install new bearing with seal side of bearing toward

clutch plates.

6003-97
18. Press bearing, seal side down, until bearing contacts

shoulder of shaft.
19. Install hub and gear assembly (A).
IMPORTANT: Place steel ruler or sight across gear

face (A) to check if clutch gear is
install properly. Sighting or steel ruler
will be below snap ring groove in
cylinder shaft.

must use special bearing. Use only
approved bronze bearings.
20. Place new bearing (B) on shaft, start bearing into the
gear and hub assembly.
IMPORTANT: Start bearing into gear and hub. DO

NOT press bearing below snap ring
groove in shaft. Pressing bearing too
far into gear will preload bearing. This
will cause the bearing to fail.
21. PARTIALLY install bearing into gear and hub

assembly.

6003-98
22. Position snap ring (C) on top of bearing.
23. Place press tool on top of snap ring.
24. Press only on snap ring. Press until snap ring slips
into snap ring groove.

6003-99
25. Install new outer bearing (D).
NOTE: Check clutch gear for end play. It must have at

least .25 mm (.010 in) end play.

6003-100
SIZING SEAL RINGS

groove tightly to avoid damage during
installation of front housing. Check and
size seal rings before installation of
front housing.
1. Twist seal ring into a tight circle, approximately 3/4

inch in diameter.
2. Install three seal rings in the ring grooves in the shaft

assembly.

6003-101
1. Arrange stage assemblies.
2. Install lifting tool (75289949).
3. Secure all stage assemblies to lifting tool.

6003-102
IMPORTANT: Both stage assemblies and rear 4. Install stage assemblies.

housing must be level. If either is at
an angle binding will occur and/or 5. Move locks (B) away from shaft grooves and
damage will occur. remove bolt (C) from lifting tool (A).
6. Remove lifting tool carefully from stage assemblies

to avoid damage to seal rings.

6003-103
INSTALL OUTPUT GROUP AND OIL TROUGH
A-Bearing cone (2 used) 8-Seventh stage output C-Oil Trough Assembly D-Cap Screw M8x12 8.8 (2
shaft gear assembly used)

6003-104
INSTALL OUTPUT GROUP AND OIL

TROUGH
NOTE: Be sure new bearing cup has been installed in

main case rear housing. Oil bearing cup before
installing output group. See (remove
bearing cup}.
NOTE: Output group can be installed upside down.

Install as shown in illustration.
1. Install output group (D) and oil trough (E) into main
case rear housing.
IMPORTANT: Apply LOCTITE® #262 to the thread

diameter of cap screws before
installation.
3. Tighten cap screws (A) to 25 N·m (18 lb-ft).
NOTE: Ref to "INSTALL FRONT HOUSING TO

REAR HOUSING" for installation of housing.

6003-105
SPECIFICATIONS
Lift Hanger and Cover-to-Main Case Torque 87 N·m (64 lb-ft)

Rear Housing Cap screw.
Direct Drive Input Bearing Torque 37 N·m (27 lb-ft)

Retainer-to-Main Case Front
Housing Cap Screws.
Dipstick Tube Assembly-to-Front Torque 25 N·m (18 lb-ft)

Housing Cap Screws.
Yoke-to-Output Shaft cap screw. Torque 215 N·m (159 lb-ft)
Output Shaft. End play 0± .051 mm (0± .002 inch)

6003-106
REAR HOUSING COM PONE NT IDENTIFICATION
A-Gasket F-Bearing Cup K-Lock w N-Fiat Washer

L-Cap Scr::er (2 used)
B-Rear Ho . G-O-ring
H (2 used) used) M6x20 8.8 (2 0-Magnetic Pickup Sensor
C-Eibow usmg (OF 250)
-Magnetic Pi k
1-Cover c up Sensor
D-ldenrr·
E- . • •cation Plate M-Snap R"mg
Dnve Screw (2 used) J-Wash er (2 used)

6003-107
IMPORTANT: Front housing must be level when

removing to prevent damage to oil
seals on stage assemblies. Use guide
pins when raising front housing.
1. Remove front housing (A).
2. Remove Gasket (B).

6003-108
REMOVE AND INSTALL DIPSTICK ASSEMBLY
~---
A-1/4 I.D. Hose C-Dipstick tube assembly D-Cap screw (2 used) E-Dipstick gasket
B-Dipstick
REMOVE DIPSTICK TUBE INSTALL DIPSTICK TUBE
1. Remove 1/4 inch hose (A) from valve and dipstick 1. Install new gasket (E).
tube assembly (C).
2. Install two cap screws (D) in dipstick tube
2. Remove two cap screws (D) from dipstick tube assembly.
assembly.
3. Install 1/4 inch hose (A) from valve to dipstick tube
3. Remove dipstick tube assembly. assembly (C).
4. Remove gasket. 4. Tighten cap screws (D) to 25 N·m (18 lb-ft).

6003-109
REMOVE BEARING RETAINER
,,
A-0-ring C-.18mm (.007in) shim (as E-Bearing retainer G-Oil seal

B-.51 mm (.02in) shim (as required) F-Cap screw M8x60 8.8 (6
required) D-.13mm (.005in) shim (as used)
required)
1. Position rear housing with bearing retainer up.
2. Remove cap screws (A) from bearing retainer (B).

6003-110
IMPORTANT: Keep shims together for reassembly.
3. Remove bearing retainer and shims.
DISASSEMBLE BEARING RETAINER
1. Remove oil seal (A)
2. Remove 0-ring (B).
3. Discard oil seal and o-ring.
ASSEMBLE BEARING RETAINER
1. Install new oil seal.

6003-111
REMOVE AND INSTALL BEARING CUP

(REAR HOUSING)
1. Remove bearing cup.
NOTE: Install bearing cup 1/4 inch past rear housing

bore surface. Rear housing bore is a light fit for
setting end play of the seventh stage assembly.
2. Install new bearing cup into rear housing 1/4 inch past
flush.

6003-112
INSTALL BEARING RETAINER

(PRELIMINARY INSTALLATION, PRIOR TO
SETTING BEARING END PLAY OUTPUT
SHAFT)
NOTE: Use all original shims and one additional .25 mm

(.010 in) shim onto bearing retainer for setting
end play of the output seventh stage.
1. Place shims on bearing retainer.
2. Install bearing retainer with shims.
3. Install cap screws (A) through bearing retainer (B) into

rear housing.
4. Tighten cap screws but do not tighten to final torque.

6003-113
SETTING END PLAY OF OUTPUT GROUP
INSTALL OUTPUT YOKE
1. Install yoke (B) with V-ring seal (A) onto splined

output shaft.
2. Install 0-ring (C), washer (D) and cap screw (E).
IMPORTANT: Check and reset output shaft end play

whenever new parts are installed. Set
End play at a 0 ± .002.
Check end play
IMPORTANT: Check end play with dial indicator on

cap screw.
4. Place dial indicator on cap screw.
5. Use pry bars under yoke to check end play.

A-V-ring seal
B-Yoke
C-O-ring
D-Yoke washer
E-Cap screw

6003-114
6. Remove cap screw, washer and yoke from output

shaft.
7. Remove bolts from bearing retainer.
8. Remove bearing retainer from rear housing.
NOTE: Use guide pins for installation of shims and

retainer. Shims can be .003 thickness and roll
onto retainers outside diameter causing possible
leak or damage to a-ring.
9. Remove or install correct amount of shims to reach a

0 ± .002 amount of end play.

6003-115
10. Align bearing retainer bolt holes with bolt hole circle
in the rear housing.
13. Install yoke, 0-ring, washer and cap screw.

6003-116
SPECIFICATIONS
Disk Brake-to-Yoke Cap Screw. Torque 48 N·m (36 lb-ft)
Yoke Flange-to-Output Shaft Cap Torque 215 N·m (159 lb-ft)

Screw.
Caliper Assembly-to-Brake Bracket Torque 87 N·m (64 lb-ft)

Cap Screw.
DISC BRAKE GROUP
A-Yoke flange E-O-ring 1-Lock washer (6 used) L-Brake bracket

8-Yoke washer F-Brake disc J-Cap screw (6 used) M-Mount pin (2 used)
C-Cap screw G-Cap screw (6 used) K-Caliper assembly N-Cotter pin (4 used)
D-V-ring seal H-Hex nut (6 used)

6003-117
DISASSEMBLE DISC BRAKE
1. Loosen cap screw (A) to keep output shaft from

turning.
2.Remove four cap screws (A).
3.Remove caliper assembly and brake bracket (B) as a

group.
4. Remove two cotter pins (A).
5. Remove two mount pins (B).
6. Remove caliper assembly (C) from brake bracket (D).

6003-118
7. Remove cotter pin (A).
8. Unscrew adjusting nut (B).
9. Remove operating lever (C). Pay attention to the

position of the operating lever for reassembly purposes.
10. Remove cam (D).
11. Remove two actuating pins (E).
12. Remove two brake pad and spring groups (F) from
caliper assembly (G).
13. Remove cap screw (A), yoke washer (B), and 0-ring
(C).
14. Loosen six hex nuts (A).
15. Remove the brake disc (B) and yoke flange (C) as a
group.

6003-119
16. Remove six hex nuts (A), six lock washers (B). and
six cap screws (C).
17. Remove brake disc (A) from yoke flange (B).
18. Inspect all parts for wear. Replace as necessary.
ASSEMBLE DISC BRAKE
1. Assemble yoke flange (A) and brake disc (B).
2. Install six cap screws (C), six lock washers (D), and
six Hex nuts (E).
3. Install brake disk and yoke flange group on output

shaft of transmission.
4. Tighten six cap screws (A) to 87 N·m (64 lb-ft).

6003-120
5. Install two brake pads and spring groups (F) to caliper

assembly (G).
IMPORTANT: Make sure end of actuating pin with the

shoulder is installed into the caliper
assembly first.
6. Install two actuating pins (E).
7. Install cam (D).
8. Install operating lever (C) in same position as when

removed.
9. Install adjusting nut (B). Do not tighten. Allow enough

clearance between pads and disc to prevent dragging.
10. Install new cotter pin (A).
11. Install caliper assembly (C) on brake bracket (D).
12. Install two mount pins (B).
13. Install two new cotter pins (A).
14. Install caliper and brake bracket group (A).
15. Install four cap screws (B).

6003-121
IMPORTANT: 0-ring is positioned flat against the

face of the output shaft.
17. Lubricate and install 0-ring (A).
IMPORTANT: The machined face of the washer must

be installed next to the 0-ring.
18. Install yoke washer (B).
19. Install cap screw (C). Tighten cap screw to 215 N·m
(159 lb-ft).
NOTE: Use brake caliper (B) to keep output shaft from

turning.

6003-122
REMOVE BRAKE PADS
1. Remove Cotter pin (A).
2. Remove Adjusting nut (B).
3. Remove operating lever (C).

6003-123
4. Remove cap screws (D).
5. Lift spring (F) over bolt in brake assembly.
6. Remove cap screw (E).

6003-124
7. Swing brake assembly (G) away from brake disk.
8. Remove actuating pins (H).
9. Remove brake pad (1).
10. Move spring (J) in front of brake assembly.
11. Lift brake pad (K) up and out to remove.

6003-125
INSTALL BRAKE PADS
NOTE: There are two pins located in the lower brake

pad area (A) of the brake assembly. Brake pads
have two holes that locate on pins.
1. Install brake pad (B) spring behind brake assembly.
2. Install brake Pad (C) with spring behind threaded

shaft of brake assembly.
3. Install actuating pins (D) to locate top brake pad.
4. Swing brake assembly onto disk brake.

6003-126
7. Install cam and lever (C).
8. Install adjusting nut (B).
9. Install cotter pin (A).

6003-127
REPLACE DEUTSCH™ CONNECTORS
1. Select correct size extractor tool for size of wire to be

removed:
a. Extractor Tool for 12 to 14 gauge wire.

b. Extractor Tool for 16 to 18 gauge wire.
c. Extractor Tool for 20 gauge wire.
2. Start correct size extractor tool over wire at handle

(A).
3. Slide extractor tool rearward along wire until tool tip

snaps onto wire.
IMPORTANT: Do NOT twist tool when inserting in

connector.
4. Slide extractor tool along wire into connector body

until it is positioned over terminal contact.
5. Pull wire out of connector body, using extractor tool.
DEUTSCH is a trademark of the DEUTSCH CO.
IMPORTANT: Install contact in proper location using

correct size grommet.
6. Push contact straight into connector body until positive

stop is felt.

place.

connector.

6003-128
REPLACE WEATHER PACK™ CONNECTOR
IMPORTANT: Identify wire color locations with

connector terminal letters.
1. Open connector body.
2. Insert Extraction Tool over terminal contact in

connector body.
3. Hold extractor tool fully seated and pull wire from

connector body.
NOTE: If terminal cannot be removed, insert wire or nail

through extractor tool handle and push terminal
contact from connector.
WEATHER PACK is a trademark of PACKARD ELECTRIC
IMPORTANT: Carefully spread contact lances to

assure good seating on connector
body.
NOTE: Connector bodies are "keyed" for proper contact

mating. Be sure contacts are in proper alignment.
4. Push contact into new connector body until fully

seated.

place.

connector.
REPLACE SURE-SEAL TM CONNECTOR WITH

WEATHER PACK CONNECTOR
1. Pull wire to remove contact from SURE-SEAL

connector.

6003-129
2. Remove wire as close as possible to contact, using

Universal Electrical Plier.
IMPORTANT: SURE-SEAL and WEATHER PACK

connector bodies are "keyed" for
proper contact mating. Be sure
contacts are in proper alignment.
SURE-SEAL connectors are keyed 1, 2,
3. WEATHER PACK connectors are
keyed A, B, C. "A" matches 1, "B"
matches 2 and "C" matches 3.
3. Install WEATHER PACK contact on wire. (See install

WEATHER PACK Contact in this section.)
4. Push contact into WEATHER PACK connector body

until fully seated.

place.

6003-130
REMOVE CONNECTOR BODY FROM BLADE

TERMINALS
1. Depress locking tang (A) on terminal, using a small

screw driver. Slide connector body off.
2. Be sure to bend locking tang back to its original

position (B) before installing connector body.
$
INSTALL DEUTSCH CONTACT
1. Strip 6 mm (1/4 in.) insulation from wire.
2. Adjust selector (A) on JDG360 Crimper for correct

wire size.
3. Loosen lock nut (B) and turn adjusting screw (C) in

until it stops.
IMPORTANT: Select proper size contact "sleeve" or

"pin" to fit connector body.
4. Insert contact (A) and turn adjusting screw (D) until

contact is flush with cover (B).
5. Tighten lock nut (C).
IMPORTANT: Contact must remain centered between

indentors while crimping.
6. Insert wire in contact and crimp until handle touches

stop.
7. Release handle and remove contact.

6003-131
IMPORTANT: If all wire strands are not crimped into

contact, cut off wire at contact and
repeat contact installation procedures.
NOTE: Readjust crimping tool for each crimping

procedure.
8. Inspect contact to be certain all wires are in crimped

barrel.
INSTALL WEATHER PACK CONTACT
NOTE: Cable seals are color coded for three sizes of

wire:
a) Green - 18 to 20 gauge wire
b) Gray- 14 to 16 gauge wire
c) Blue - 10 to 12 gauge wire
1. Slip correct size cable seal on wire.
2. Strip insulation from wire to expose 6 mm (1/4 in.)

and align cable seal with edge of insulation.
NOTE: Contacts have numbered identification for two

sizes of wire:
a) #15 for 14 to 16 gauge wire
b) #19 for 18 to 20 gauge wire
3. Put proper size contact on wire and crimp in place

with a "W" type crimp, using Terminal
Applicator.


6003-132

IMPORTANT: Proper contact installation for "sleeve"

(A) and "pin" (B) are shown.

Section
6005
REAR AXLE
WITH
DIFFERENTIAL LOCK

Contagem, MG - Brazil Brz ENG 6-75370 January, 2003
6005-2
TABLE OF CONTENTS
SPECIAL TOOLS ............................................................................................................................ 2
DIFFERENTIAL AND CARRIER ASSEMBLY INSTRUCTION ILLUSTRATION ............................. 3
CHECKING AND DRAINING OIL- HYDRAULIC PRESSURE TEST-SPECIAL OPERATION ...... 4
SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART .......................................... 5
DIFFERENTIAL ASSEMBLY ........................................................................................................... 7
DIFFERENTIAL REMOVAL ............................................................................................................. 9
DIFFERENTIAL DISASSEMBLY ..................................................................................................... 12
DIFFERENTIAL REASSEMBLY ...................................................................................................... 14
PINION AND CAGE REASSEMBLY ............................................................................................... 17
DIFFERENTIAL INSTALLING .......................................................................................................... 19
RING GEAR TO PINION MOUNTING DISTANCE PROCEDURE ................................................. 20
DIFFERENTIALINSTALLATIONINAXLEHOUSING ........................................................................ 23
WHEEL REDUCTOR AXLEASSEMBL Y ........................................................................................ 24
SCREW-LOCKING,SEALING AND LUBRICATING MATERIALS .................................................. 25
SPECIAL TOOLS ............................................................................................................................. 25
DISASSEMBLY OF REDUCTION GEAR ........................................................................................ 26
CHECKING WEAR BRAKING DISC ............................................................................................... 26
DISASSEMBLY OF THE INPUT UNIT ............................................................................................ 26
DISASSEMBLY OF THE PLANETARY REDUCTION .................................................................... 30
ASSEMBLY OF PLANETARY REDUCTION .................................................................................. 34
SPECIAL TOOLS
75301703 CHECK WEAR BRAKING DISCS- T1
75301704 ASSEMBLY OF SEAL- T2
75301705 ASSEMBLY OF SEAL- T3

6005-3
DIFFERENTIAL AND CARRIER· ASSEMBLY INSTRUCTION ILLUSTRATION
f'>.,_TIGHTEN TO
!)-"'z2-26 tt~f·ft
[30-35 H·m)
ENLARGED VIEW
SCALE 2 ' I
D>APPLY LOCT!TE •262 THREAD LOCKING COMPOUND.
IJ>APPLY DOW CORNING RTV-Q3-7069 SEALANT.
~APPLY LOCTITE •515 SEALANT,
D-.._SELECT A SPACER TO OBTAIN A ROLLING PINION BEARING

~)-""RESISTANCE TOROI.JE Or 10-30 l~f·in(l.l-3.4 N·m]
WITH PINION ASSEMBLED IN CARRIER.
THIS CHECK IS TO BE MAOE BEFORE DifFERENTIAL IS ASSEMBlED
AND NOT TO INCLUDE PINION OIL SEAL DRAG,
~t-.IFF'ERENTIAL BRG NUTS TO BE AO<IUSTED
t.:YToTAl<€: UP ALL SLACK IN DIFFERENTIAL
BEARINGS. OIA ACROSS CA,p BOSSES NOT
TO EXCEED 13.563[?>44.50j AFTER FINAL
ADJUSTMENT.
~IFFERENTIAL ASSEMBLY TO BE ADJUSTED
[:;Y'TO OBTAIN A BACKLASH OF .009(0.23mm)
TO .Ot3(0.33mm)BETWEEN RING GEAR AND
P~NION
Brz ENG 6-75370 Issued 02-02 Printed in Brazil

6005-4
CHECKING AND DRAINING OIL • HYDRAULIC PRESSURE TEST· SPECIAL OPERATION
When the inner pinion bearing or the pinion shaft and ring gear are being replaced staking of the pinion end to the
inner pinion bearing is required.
If a staking is in the pinion shaft use procedure shown in Figure "A" and a square end staking tool.
flf pinion has no staking groove use procedure in Figure "B" and a standard prick punch to up-set the metal over the
bearing inner race.
~1/8"
(3,175 mm)
FIGURE A
OPTIONAL CONSTRUCTION
(NO STAKING GROOVE)
FIGURE B
ENG 6-75370 Issued 01·03 Printed in Brazil

6005-5
SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART
All contact bearings shown below are on right hand spiral ring gear -
the drive is on the convex side of the tooth.
FIG. 1
Typical preferred bearing on both sides of tooth
while under a light load
FIG. 2
Toe bearing on both sides of tooth - gear set noisy.
To move bearing toward heel increase backlash within
limits by moving gear away from pinion.
FIG. 3
Heel bearing on both sides of tooth - gearset noisy
and could result in early gear failure. To move bearing
toward toe decrease backlash within limits by movin
gear toward pinion.
FIG. 4
Low bearing on gear and high bearing on pinion.
Correct by pulling pinion away from gear
(increase mounting distance).
FIG. 5
High bearing on gear and low bearing on pinion.
Correct by moving pinion in toward gear
(decrease mounting distance).
BACKLASH
Backlash should be measured with a dial indicator rigidly mounted with the stem perpendicular
to the tooth surface at the extreme heel. See sheet no. 2 for backlash values.

6005-6 SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART
MOVf orAl AWAY Ft.OM

f'!NJOO "'~ TWiS O!UCNON
All contact bearings shown below are on right hand spiral ring gear-
the drive is on the convex side of the tooth.
FIG.1
Typical preferred bearing on both sides of tooth
while under a light load
FIG.2
Toe bearing on both sides of tooth - gear set noisy.
To move bearing toward heel increase backlash within
limits by moving gear away from pinion.
FIG.3
Heel bearing on both sides of tooth- gearset noisy
and could result in early gear failure. To move bearing
toward toe decrease backlash within limits by movin
gear toward pinion.
FIG. 4
Low bearing on gear and high bearing on pinion.
Correct by pulling pinion away from gear
(increase mounting distance).
FIG.5
High bearing on gear and low bearing on pinion.
Correct by moving pinion in toward gear
(decrease mounting distance).
BACKLASH
Backlash should be measured with a dial indicator rigidly mounted with the stem perpendicular
to the tooth surface at the extreme heel. See sheet no. 2 for backlash values.
Issued 01-03 Printed in Brazil

ENG 6-75370
6005-7
DIFFERENTIAL ASSEMBLY
JJ7
15/", 12
16 13
4
5
12
14~~
~ 18
?r
16 15
51
01240102

6005-8
DIFFERENTIAL ASSEMBLY
ITEM Q.TY. DESCRIPTION ITEM Q.TY. DESCRIPTION
1 CENTRAL BODY 37 20 CARRIER WASHER

2 VENT PLUG 38 THRUST WASHER
3 FILL PLUG 39 DIFFERENTIAL SIDE GEAR (LEFT)
4 2 PLUG 0-RING 40 DIFFERENTIAL SIDE GEAR (RIGHn
5 MAGNET DRAIN PLUG 41 THRUST WASHER
6 DIFFERENTIAL CARRIER AND CAP ASSY. 42 CROSS
7 CARRIER CAP 43 4 DIFFERENTIAL PINION GEAR
8 1 DIFFERENTIAL CARRIER 44 4 THRUST WASHER
9 4 CARRIER CAP WASHER 45 1 DIFFERENTIAL CASE SEAL
10 4 CARRIER CAP CAPSCREW 46 RING & PINION SET
11 1 DOWEL PIN 47 12 CAPSCREW
12 30 LOCKWASHER 48 PISTON HOUSING
13 24 CAP SCREW 49 PLUG
14 1 0-RING 50 12 NUT
15 2 ADJUSTING NUT CAPSCREW 51 PISTON
16 2 NUT LOCK 52 OUTER SEALING RING
17 2 TAPERED BEARING 53 INNER SEALING RING
18 2 ADJUSTING NUT 54 BUSHING
19 BEARING 55 1 SEAL RETAINER
20 CENTER PINION BEARING 56 6 PLUG
21 SPACER 57 4 SEALING RING
22 1 0-RING 58 1 PISTON
23 AR SHIM 59 3 PISTON SEAL
24 1 BEARING RETAINER 60 ADAPTOR
25 6 BEARING RETAINER CAPSCREW 61 0-RING
26 GREASE FITTING 62 FILTER
27 OUTER PINION BEARING CUP 63 2 PLUG
28 OIL SEAL
29 GREASE SEAL
30 THRUST WASHER
31 V-RING SEAL
32 BUSHING 68 CLUTCH DRIVER
33 0-RING 69 1 SNAP-RING
34 NUT 70 6 INNER DISC.
35 1 CARRIER ASSEMBLY 71 6 OUTER DISC.
36 20 CARRIER CAPSCREW 72 1 FLANGE
73 AR PINION BEARING SHIM

6005-9
DIFFERENTIAL REMOVAL
STEP 1 STEP 2
Remove differential to axle housing capscrews (13) Install four (4) capscrews "A" in the threaded holes in
and spring (12) washer. the differential carrier flange (7). Attach a chain hoist.
STEP3 STEP4
Tighten capscrews "A" evenly and lift differential Loosen companion flange nut (34).
straight up and off of alignment dowel (11) and axle
hOUSing (1 ).
Mount differential on differential overhaul stand. Check and record
ring gear backlash with a dial indicator.
This information is necessary for reassembly unless a new gear set
is installed.
STEPS Remove flange nut (34). STEPS Remove companion flange (72).

6005-10
STEP7 STEPS
Remove tank port and pressure port nipples (60). Remove adjusting nut lock capscrew (15).
STEP9 STEP10
Remove adjusting nut lock (16). Remove seal retainer (55).
STEP 11 STEP 12
Mark differential caps (8) for reassembly. Remove cap Remove differential caps (8).
(8), capscrews (1 0) and washers (9).

6005-11
STEP13 STEP14
Remove adjusting nuts (18). Remove ring gear to flange half case capscrew nuts
(50).
STEP15 STEP16
Drive ring gear capscrews (47) from ring gear (46). Remove differential assembly from carrier (6).
STEP17 STEP 18
Remove seal retainer capscrews (25) and washer (12). Remove pinion (46) and bearing cage (24).

6005-12
DIFFERENTIAL DISASSEMBLY
STEP19 STEP 20
Pinion (46), cage assembly (24) and shims (23) Remove flanged half case (48).
removed.
STEP 21 STEP 22
Install a seal retainer "B" as shown. Carefully and Remove piston inner (53) and outer (52) square cut
slowly apply air to hole in seal retainer and remove seals.
clutch piston (51).
STEP 23 Remove ring gear (46). STEP 24 Remove clutch driver snap ring (69).

6005-13
STEP 26
STEP 25 Remove friction (70) and reaction (71) plates. Remove clutch driver (68).
STEP 27 Remove differential case seal (45).

STEP 28 Remove cap half case to clutch housing capscrews
(36) and washers (37).
STEP 29 Separate case halves (35). STEP 30 Remove standard side gear (39) and washer (38) from
cap half case (35).

6005-14
STEP 31 STEP 32 .
Remove differential cross (42) and pinions (43) from Remove clutch s1de gear (40).
clutch housing (35).
DIFFERENTIAL REASSEMBLY
STEP 33 Remove clutch side gear washer (41). STEP 34 NOTE: All parts must be lubricated with CASE
MAT- 3505 recommended axle lubricant at reassembly.
No part should be reassembled dry.
STEP 35 Position tanged side gear washer (41) in clutch STEP 36 Install clutch side gear (40).
housing (35).

6005-15
STEP37 STEP38
Install cross (42), pinions (43) and thrust washers (44) Position standard side gear (39) on pinion and cross
as an assembly. assembly.
STEP 39 Place side gear washer (38) on side gear. STEP 40 Position cap half case (35) and bearing (17) on clutch
housing (35) being sure to align match marks.
STEP 41 Apply Loctite #262 and install case capscrews and STEP 42 Position clutch driver (68) on splines of clutch side
washers. gear (40).
Tighten to specified torque.
ENG 6-75370 Issued 01-03 Printed in Brazill

6005-16
STEP 44
STEP 43 Install driver to gear snap ring (69). Position 1st friction plate (70) in half case (35). Note
notch in splines.
STEP 45 Install 1"1 reaction plate (71). STEP 46 Install next friction plate (70) aligning notch in friction
plate with notch in preceding friction plate. Alternate
reaction and friction plates (70) until six (6) friction
plates and six (6) reaction plates (71) are installed, and always align
the notch with the preceding friction plate notch.
STEP 47 Position new square cut inner (53) and outer (52) seal STEP 48 Carefully tap piston (51) into position in flange half
rings on piston (51). case (48) using caution as not to damage seal rings
(52), (53).

6005-17
STEP49 Align capscrew holes and match marks of flanged half STEP 50 Place flanged half case (48) in position.
case (48) with clutch housing (35).
STEP 51 Turn differential body assembly (35) over and align STEP 52 Tap ring gear (46) into position. Temporarily install two
ring gear capscrew holes with body holes. (2) ring gear to flange half case capscrews (47) and
nuts (50) to hold differential assembly together.
PINION AND CAGE REASSEMBLY

STEP 53 Press inner bearing (19) on pinion (46). STEP 54 Stake pinion (46) to bearing inner race four (4) places
equally spaced around diameter. (Refer to •SPECIAL
OPERATION••) page 2.

6005-18
STEP 55 STEP 56
Press center beanng
. (20) on p1n1on
· · s hatt (46) w1t· h Position pinion bearing spacer (21) and shim (73) on
large diameter of bearing down. pinion shaft (46).
NOTE: A pinion bearing spacer (21) and shim kit If pinion and shim kit is used also add one (1) shim.
(73) is provided for repair of carrier assemblies. This kit consists of
a spacer and a quantity of shims. If pinion (46), pinion bearings
(20), (27), or bearing cage (24) was not changed, use original
bearing spacer (21) for reassembly.
STEP 57 STEP 58 .
Install center taper bearing cup (20) in bearing cage Install outer beanng cup (27).
(24).
STEP 59 Place outer taper bearing (27) in bearing cup.

STEP 60 Position cage (24}, cup (20}, (27) and bearing on pinion
(46). Press outer taper bearing (27) in place.

6005-19
STEP 61 Install input flange (72) and flange nut (34) on pinion STEP 62 NOTE: This rolling torque check must be made
(46). Tighten nut to 600 lbf.ft. [813 Nm[ minimum (dry again after pinion and cage assembly (24) is installed
threads). Locate pinion cage in vise to allow pinion to in carrier housing (6).
rotate. Use an "inch pound" torque wrench "D" to check rolling Install bearing cage and pinion shaft assembly (24) in differential
pinion bearing resistance torque. carrier assembly (6) with original bearing cage shims (73). Use four
Rolling torque to be 13 to 23 lbf.in. [1.5- 2.6 Nm] if rolling torque is (4) oil pinion seal retainer capscrews (25) with washers (12) to pull
not within specifications, add shims (73) to decrease torque or pinion shaft assembly (46) fully into carrier assembly. Make sure oil
remove shims (73) o increase torque. passages are aligned.
Use "inch pound" torque wrench to check bearing preload. If
bearing preload is not between 13 and 23 lbf.in. [1.5- 2.6 Nm],
disassemble parts and add shims (73) to decrease preload or
remove shim (73) to increase preload.
NOTE: Flange (24) will be removed after ring gear to pinion
tooth contact and backlash has been set.
STEP 63 STEP 64
DIFFERENTIAL INSTALLING
Insert bar through differential to facilitate hoisting. Position differential taper bearing cups on each side
Position differential (35) into carrier (6), tilting it so that over taper bearings (17).
ring gear (46) will clear inner bearing boss in carrier (6).
STEP 65 STEP66
Install adjusting nuts (18) on each side against bearing Position bearing caps (8) on bearings and adjusting
cup. nuts (18), making sure match marks made during
NOTE: Turn adjusting nuts (18) by hand to be disassembly are properly aligned.
sure of proper thread alignment. Install cap bolts (10) and washer (9) and tighten lightly. Do not
torque this time.

6005-20
RING GEAR TO PINION MOUNTING DISTANCE PROCEDURE

STEP 67 Use a dial indicator "E" as shown. Move ring gear (46) STEP 68 IF MOUNTING DISTANCE PINION SETTING GAUGE
by loosening one adjusting nut (18) and tightening "E" IS USED, FOLLOW INSTRUCTIONS SUPPLIED
opposite adjusting nut. Adjust position until gear WITH GAUGE.
backlash is to backlash specifications of .009" (0.23 mm) to .013" USE THE FOLLOWING PROCEDURE WHEN A PINION SETTING
(0.33 mm) for new ring gear set, or adjust to backlash noted at GAUGE "E" IS NOT AVAILABLE.
disassembly for used gears. Check ring and pinion gear (46) for proper tooth contact. Paint ring
When proper backlash is achieved, tighten opposite adjusting nut gear with a gear tooth marking compound. When ring and pinion
(18) to set preload on taper bearings. Using only thumb and gears are rotated, the compound is squeezed away by the contact
forefinger, move ring gear. When ring gear becomes difficult to of the teeth, leaving bare areas the exact size, shape and location
move, preload on bearing is set. of the contacts. As a rule, painting about 10 or 12 teeth is sufficient
for checking purposes.
Sharper impressions may be obtained by applying a small amount
of resistance to the ring gear with a flat steel bar and using a
wrench to rotate the pinion. Gears should be rotated, under slight
load, until ring gear has turned at least one revolution in both
directions.
Check tooth contact pattern on drive side (convex side) of ring gear
teeth. Coast side will automatically correct when drive side pattern
is correct. Refer to gear tooth contact chart. If proper tooth contact
pattern is not as shown, readjust backlash or, add to or subtract
from shim pack (73) between bearing cage flange and differential
housing.
Addition of or subtraction of shims should be made in small
increments until proper contact is established.
After optimum tooth contact is made, the differential and pinion
must be removed from the carrier, this will allow for proper sealing
measures at reassembly.
STEP 69 Remove differential assembly (35) from carrier (6). STEP 70 Remove pinion and cage assembly (24) from carrier.
Remove flange (24) from pinion. Remove pinion (46)
from pinion bearing cage (24).
STEP 71 Apply Loctite #515 to outer diameter of the pinion oil STEP 72 Install grease seal (29) with lip of seal up.
seal (28).
Press seal (28) in pinion bearing cage (24) with lip of
seal in.

6005-21
STEP 73 Press V-ring washer (30) against grease seal (29). STEP 74 Apply Loctite #515 to bearing cage shims (23) and
joining surfaces in a continuous bead and spread over
entire surface to provide a thin and even coat.
STEP75 STEP76
Press pinion into bearing cage and seal assembly. Install cage (24) to carrier housing, capscrews (25) and
Position pinion and cage assembly (24) in carrier washers (12).
housing (6). Apply Loctite #262 and tighten to 185-205 Nm (136-
151 lb.ft).
STEP 77 STEP 78
Position a new V-ring seal (31) on companion flange Apply RTV-03-7069 to pinion threads and between
(72). Apply RTV-03-7069 to the flange splines. Install flange and flange nut (34). Install flange nut (34) and
flange (72) on pinion (46). tighten to 600 lbf.ft [813 Nm].
Some models will have an "0" ring (33).

6005-22
STEP 79 INSTALL DIFFERENTIAL ASSEMBLY IN CARRIER STEP 80 Install new rotary seals (57) on piston housing (55).
HOUSING AS EXPLAINED IN FIGURES PAGE 1, Place seal retainer and seals in position as shown.
AGAIN MAKE RING GEAR BACKLASH CHECK AND
BEARING PRELOAD CHECK.
MAKE A RING AND PINION TOOTH CONTACT CHECK AS
EXPLAINED AFTER FIGURE PAGE 3 AND 4.
IF OPTIMUM TOOTH CONTACT PATIERN IS MADE, PROCEED
WITH FIGURE
STEP 81 STEP 82
Install new square cut seal (59) on piston retainer (58), Install ring gear to flange half case capscrews (36).
place piston retainer in seal retainer (55). Install Apply Loctite #262 to capscrew threads and install nuts
adjusting nut lock. (50). Tighten nuts to 185-205 Nm (136-151 lb.ft).
Apply Loctite #262 to lock capscrew (10). Install capscrew (10) and
washer (9) and tighten to 560-615 Nm (413-454 lb.ft).
STEP 83 STEP 84
Install new square cut seals (61) to "0" ring (59)
nipples (60). Turn carrier over and install nipples
in carrier housing (7). Tighten to 40-50 Nm (30-36
lb.ft).

6005-23
DIFFERENTIAL INSTALLATION IN AXLE HOUSING

STEP 85 Position a new carrier to axle housing seal (14) on STEP 86 Apply a light coat of grease to flange of carrier (6);
carrier (6). lower assembly carefully into axle housing. Align
cowel pin (11) in housing (1) with hole in carrier. Tap
at dowel pin location and lower assembly into position.
STEP 87 STEP 88
Install carrier (6) to housing capscrews (13) and spring Tighten carrier capscrews (13) to 180-210 Nm (132-
washers (12) . 206 lb. ft).

6005-24 WHEEL REDUCTOR AXLE ASSEMBLY
01240108
1 -Top cap 15 -Anti-extrusion ring 29 -Crown

2 -Screw 16 -Anti-extrusion ring 30 -Safety plate
3 -Cover 17 -Snap ring 31 -Bushing
4 -Stub axle 18 -Input shaft 32 -Hub
5 -Coupling 19 -Sealing ring 33 -Sealing ring
6- Braking unit, assy. 20 -Snap ring 34 -Inner bearing
7 -Intermediate disc 21 -Spacer 35 -Outer bearing
8 -Brake disc 22 -Bearing 36 -Snap ring
9 -Spacer 23 -Half shaft 37 -Planetary gear
10 -Adjusting bolt 24 -0-ring 38 -Shim
11 -Spring 25 -Plug 39 -Snap ring
12 -Piston 26 -Screw 40 -0-ring
13 -0-ring 27 -Planetary gear carrier
14 -0-ring 28 -Screw

6005-25
SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS
A 1 - Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor.
2- The table below gives an account of the typical applications of each single material, in order to facilitate replacement with similar
products marketed by different brand names with different trade marks.
DENOMINATION APPLICATION
Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength locking.
LOCTITE 242
Before using it, completely remove any lubricant by using the specific activator.
LOCTITE 243 The oleocompatible alternative to 242. Does not require the activation of lubricated surfaces.
Anaerobic product for very-high strength locking of screws and nuts. Before using it, completely remove any
LOCTITE 270
lubricant by using the specific activator. To remove parts, it may be necessary to heat them at ao•c approx.
(AREXONS) Solvent-based sealing compound for elastic seals, drying through evaporation. Used for sealing the outer dia-
Repositionable jointing
compound for seals meter of sealing rings for rotating shafts with outer metal reinforcement.
SPECIAL TOOLS
T1 - 75301703 CHECK WEAR BRAKING DISCS

li I I il
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T2 - 75301704 ASSEMBLY OF SEAL T3 - 75301705 ASSEMBLY OF SEAL
-
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6005-26 DISASSEMBLY OF REDUCTION GEAR
CHECKING WEAR BRAKING DISC

STEP 89 CAUTION! Execute all operations on both reduction STEP 90 Brake once and, while brake is pressed, use tool T1 to
gear units. check thickness "')" between the discs.
Remove upper oil fill cap (1). Minimum admissible "S" value: 5 mm.
CAUTION! If necessary, replace braking and intermediate discs on
both sides.
01240103
DISASSEMBLY OF THE INPUT UNIT

STEP 91 Loosen and remove check screws (2) of cover (3). STEP 92 With the help of two levers inserted in the provided
slots, detach the complete cover (3) from the stub axle
(4).
STEP 93 Connect the complete cover (3) to a hoist and remove STEP 94 L"ft
1 t he d. . coup 1·1ng (5) of bra k"1ng d"1scs.
nv1ng
it. To lift the coupling, use two screw-drivers inserted in
two opposing lubrication holes.

6005-27
STEP 95 Remove driving coupling (5). STEP 96 Remove the braking unit (6) to be replaced.
STEP97 STEP98
Remove spacer (9) and clean any deposits that may Loosen up the adjusting bolt (10).
have formed due to brake disc wear. NOTE. Loosen adjusting bolts (10) in an alternate and
CAUTION! Prevent any deposits from falling in the criss-cross manner.
planetary reduction.
STEP99 Remove adjusting bolts (10) and springs (11) of piston STEP 100 Sl ow1y .mtro d uce 1ow-pressure compresse d a1r
· t h roug h
(12) reversal. the connection point of service brake in order to
extract the piston (12).
CAUTION! Hold piston (12) as it may be rapidly ejected and
therefore damaged.

6005-28
STEP 101 Remove 0-rings (13) and (14) and anti-extrusion rings STEP 102 Remove the snap ring (17) that checks the input shaft
(15) and (16) from piston (12). (18).
NOTE. 0-rings (13) and (14) and anti-extrusion rings
(15) and (16) must be replaced every time the unit is disassembled.
STEP 103 STEP 104

Extract the complete input shaft unit (18). Remove snap ring (20) and spacer (21).
Extract sealing ring (19). NOTA. Note down orientation of spacer (21).
NOTA. Note down assembly direction of sealing ring (19). Place the input shaf under a press and extract the bearing (22).

6005-29
STEP 105 With the help of a press, fit bearing (22) on the input
STEP 106 Install spacer (21) and snap ring (20).
shaft (18). NOTE. Check the orientation of the sealing ring.
STEP 107 Install the sealing ring (19) in the cover (3). STEP 1OS Install the complete input shaft (18) in the cover (3) by
CAUTION! 1 -Pay attention to ring (19) orientation. using a plastic hammer.
2 - Lubricate the outer surface and the sealing lip.
STEP 109 Fit the snap ring (17) that checks the complete input
STEP 110
Fit 0-rings (13) and (14), and anti-extrusion rings (15)
shaft (18) into the cover. and (16) on piston (12).
NOTA. Pay attention to the position of anti-extrusion

6005-30
STEP 111 Lubricate the 0-rings and install the complete piston STEP 112 Position springs (11 ), apply Loctite 242 to screw thread
(12). Orient piston and drive it to its end of stroke with a (1 0) and tighten adjusting bolts.
plastic hammer. NOTE. Tighten adjusting bolts (10) with a standard
wrench, using the alternate and criss-cross methods.
STEP 113 STEP 114

Lock adjusting bolts (10) with a dynamometric wrench Fit the spacer (9) in the stub axle (4).
set to 10 ± 15 Nm (7.4- 11 lb.ft).
STEP 116
STEP 115 Fit the driving coupling (5) on the half shaft (23). Lubricate the brake discs (8) and fit them into the stub
axle (4) starting with a steel disc (7) and a brake disc
(8).
NOTA. The sequence starts and ends with a steel disc (7).

6005-31
STEP 117 STEP 118

Check that 0-ring (24) of cover (3) is in good condition Lock cover (3) with screws (2) by using a dynamo-
and correctly positioned; lubricate the seal and install metric wrench set to a torque of 82 ± 91 Nm (60-67 lb.tft).
the complete cover.
DISASSEMBLY OF THE PLANETARY REDUCTION

STEP 67 Remove the plug (25). STEP 68 Remove the screws (26) fixing the planetary gear
carrier (27).
NOTA. The cap hole must be used for removing the
planetary gear unit.
STEP 118 Connect the complete planetary gear carrier (27) to a STEP 11 9 Remove the complete planetary gear carrier (27).
hoist.
NOTES. 1 - Use a fixed bracket "A", using a spacer
and the plug (25) hole.
2 -To detach planetary gear carrier (27), use two levers inserted in
the slots rovided.

6005-32
STEP 120 STEP 121

Extract the half shaft (23). Extract and remove the locking screws (28) of crown
(29).
STEP 121 STEP 122

Remove the safety plate (30). Partly and equally tighten three screws (28) arranged
in a triangular way.
With the help of an extractor, disengage crown (29)
from centring bushing (31).
STEP 123 STEP 124

Remove the three screws (28) which you have applied Remove the outer bearing (35).
in the previous phase and remove the crown (29). Hook the complete hub (32) to a hoist and remove it.
To ease hub extraction, use a plastic hammer.

6005-33
STEP 125 STEP 126

Remove sealing ring (33) from hub (32). Extract sealing ring (33) and inner bearing (34).
STEP 127 STEP 128

Remove the external thrust blocks of bearings (34) and Remove the snap rings (36) that check the planetary
(35). gear (37).
STEP 129 STEP 130

Extract the planetary gear (37). ONLY IF NECESSARY
NOTE. Note down assembly direction of gears. Using an extractor for inner parts, remove shim (38).

6005-34
ASSEMBLY OF PLANETARY REDUCTION

STEP 131 ONLY IF PREVIOUSLY REMOVED STEP 132 Fit planetary gear (37) into planetary gear carrier (27).
With the help of a push rod and a plastic hammer, CAUTION! Pay attention to gears direction of assem-
install the shim washer (38). bly.
STEP 133 STEP 134

Fit the snap rings (36). Place the hub (32) under a press and, using tool T2,
position the ring of the outer bearing (35).
STEP 135 STEP 136

Turn the hub (32) upside down and fit the ring of the Install the inner bearing (34).
inner bearing (34) by using tool T2. Apply replaceable seal putty to the outer surface of
sealing ring (33).

6005-35
STEP 137 STEP 138

Position the sealing ring (33) on the hub and, with the Connect the hub to a hoist and fit the complete hub
help of tool T3, press ring down into its seat. (32) to the stub axle (4).
NOTE. Pay attention to ring orientation. NOTE. If necessary, give some light hammer blows
around the circular edge with a plastic hammer.
STEP 139 STEP 140

Make sure that hub (32) is well seated by giving it Position crown (29) by centring the holes onto the
alternate rotating motions. centring bushing (31).
Install the outer bearing (35).
STEP 141 STEP 142

Fit crown (29) onto the bushing (31) by using a push Fit the safety plate (30).
rod and a plastic hammer.
NOTE. Check that crown (29) is properly engaged
onto the outer bearing (35).

6005-36
STEP 143 STEP 144

Apply Loctite 270 to the thread of screws (28) and Insert and engage half shaft (23), complete with snap
screw tightly; tighten screws in an alternate and criss- ring (39}, into the input shaft.
cross manner by means of a dynamometric wrench set
to 220±222 Nm (163- 1641b.ft}.
STEP 145 STEP 146

Check that 0-ring (40) of planetary gear carrier (27) is Fix planetary gear carrier (27) to hub (32) with screws
in good condition and correctly positioned. (26) and tighten in a criss-cross manner with the help
Lubricate the 0-ring (40) and install the complete of a dynamometric wrench set to 82 ± 91 Nm (66- 67 lb. II).
planetary gear carrier (27).
STEP 147
Install plug (25) and screw it with a dynamometric
wrench set to 35-4 0 Nm (26- 30 lb. II).

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

6005-3
M8
~
0
C)
~ I
I
I
15
Nr. 2 - Stud Bolt

Material: Steel classe 8
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

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

6005-12
DISASSEMBLY AND ASSEMBLING
,&. WARNING: Lift and handle each part by a lifting tool with proper capacity.
Make sure that groups or part are lifted by proper hooks.
Position the axle on proper support.
STEP1
Before dissassembly mark position of each
housing, both sides.
Remove the eighteen nuts.
STEP2
Remove the axle support.
Position axle assy vertically, with adequate
support to avoid accidents.
Tube material: SAE 1 OHl -1020

1..0 370 -371 Tnk.1.2mm {Ch5"}
smm (o.2s"•1G 3o . 9.Gmm (1 .2.... 3.5'')

Suggested support
Material: Plate stear SAF1 01.0 .-Hl20"
Thk 12mm (0.5'}
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
6006
TANDEM DRIVE
LIMITED SLIP REAR AXLE
845- 865 Grader

Contagem, MG - Brazil ENG 6-46792 January, 2003
6006-2
DESCRIPTION ...................................................................................................................... PAGE
SPECIAL TOOLS ......... ........ ... ........ ... .. ... ... ... ... ... ... ... .. ... ... ... ... ... ... ... ... ... ... ... .. ... ... ... ... ... ... ... .. 3
GENERAL DESCRIPTION ..................................................................................................... 4
DISASSEMBLY OF THE TANDEM AND REAR AXLE REMOVAL AND INSTALLATION ........... 7
DISASSEMBLY OF THE TANDEM ............................................................................................. 7
REAR AXLE REMOVAL AND INSTALLATION ............................................................................ 16
ASSEMBLY OF THE TANDEM ............................................................................................ 16
TANDEMCASEOSCILLATIONADJUSTMENTPROCEDURES ................................................ 17
DETERMINATION OF THE SHIM PACK ..................................................................................... 17

6006-3
Special Tool 75312684
Special tool 75300850

6006-4
GENERAL DESCRIPTION
TANDEMS
Driving sprockets, which are splined to the rear axle shafts, transfer power through heavy roller driving
chains to the wheel shaft sprockets which are attached to the wheel shafts. Wheel shafts are supported by
inner and outer bearing retainers.
Each tandem assembly oscillates and pivots on a tandem hub bushing, located in the hub.
29
29. Drive sprockets

30. Adjusting shim
31. Sprockets retaining washer
32. Capscrews
33. Lock plate

6006-5
1. Tandem Case 10.Chain

2.Capscrew 11 . Capscrew
3. Bearing Retainer Flange 12. Capscrew
4. Bearing 13. Shim
5.Shaft 14. Capscrew
6. Lip Seal and snap ring 15. Shim Cap
7. Nut 16.1nnerCap
8. Grease Retainer 17. Retainer plate (holding)
9. Sprocket 18. Snap ring

6006-6
18 19
18- Hub 24 -Thrust washer 380x440mm

19- Shim (14.96x17 .32)in
20- Washer 25- Tandem retaining plate
21 - Capscrew 26- Washer
22- Tandem pivot seal 27 - Capscrew
23- Thrust washer 363x440mm (14.29x17 .32)in 28- Bushing

6006-7
DISASSEMBLY OF THE TANDEM AND

REARAXLEREMOVALAND
INSTALLATION
DISASSEMBLY OF THE TANDEM
- Install the grader articulation lock pins into their
TANDEMTEARDOWN
frame locations.
- Park the grader on a level surface.
- Place the transmission in neutral and apply the

hand brake. Ensure the hand brake is correctly
adjusted and in good working order.
-Lower the moldboard and all attachments to the -Overall view of tractor. Tag machine to note
ground. Do not apply down-pressure. that machine is being serviced.
-Shut down the engine. - Lift grader by extending the blade to the side
being worked upon. Apply blade down pressure
-Install the service pin in the LOCKED position
on the side to be lifted.
(see the Operators Manual).
-Install chocks at the front and rear tandem

wheels. Wedge the chocks in place.
Li:i WARNING
Observe all start up and shut down procedure an
WARNING listed in the operation and mainte-
& WARNING
nance instruction manual.
Scissors points in area of service. Stay clear Keep people clear of attachments and tools
during operation. Block securely for service. while in raised position, to prevent possible
injury.
& WARNING
Remove the tires
Lift and handle all heavy parts with a lifting
device of proper slings and hooks. Use lifting
eyes if provided. Watch out for people in the
vicinity.
-Support the grader with approved supports.
& WARNING
When supporting machine component must be
removed or installed and jacks are used, be sure
the support of the jack at the machine and on
the ground are appropriate to the load to be
applied. Transfer the load to authorized blocking
or jack stands immediately. Do not work on or
under the machine or its components while
supported only on a jack or other lifting device,
according to local or national requirements.

6006-8
Remove the cover screws.
Remove the drain plug and drain the oil.
1- Filler Plug
2- Level Plug
3- Drain Plug, inside wall of tandem case.
Remove the two access covers on the top of the

tandem case. Remove the four covers from the sides
of tandem case.
Put the filler plug back in the place.

6006-9
Remove the bolts from the center cover to access

the chain drive gears.
Remove the cover and gasket.
Flatten lockplate for capscrew removal.
Remove retaining plate capscrews.

6006-10
Remove the sprockets retaining plate.
Remove the adjustment shim.
Position the chain master link at access window on

side of tandem case. Remove the cotter pins.
Remove master link.

6006- 11
Remove chain from drive gear.
Use a hook to help removing the chain.
Prop the chain on tandem case and remove it from the

tandem.
Remove the drive gears from the drive shaft.

6006-12
Remove the cotter pin from the hub nut.
Remove the nut and washer from the hub shaft.
Remove the hubs and key using tool75312684 and the

from hub shaft.
Remove capscrews and shaft bearing retainer.
Remove the bearing retainer. Leave the shaft in the

tandem. The shaft will cock when the retainer is
removed.

6006- 13
Lift the shaft and sprocket assembly with a sling.
Remove capscrews from inside bearing retainer.
Remove bearing retainer from tandem by using rubber

hammer from inside and support bearing retainer with
opposite hand.
Remove sprocket to shaft lock plate capscrews.
Use puller set to remove both bearings from the shaft.

Pull the bearing by placing the bearing puller behind
seal.

6006-14
Install the splined sprocket onto the shaft. Torque the

capscrews to 61 - 68 Nm (45- 50ft lb.).
Install bearing seal and bearing onto the shaft. Heat

the bearing to 121°C (250°F). Be sure the bearing is
seated onto the shaft.
Remove the bearing race from the retainer using

master bearing and seal driver kit P/N 75300850.
it. WARNING
It is unsafe to strike hardened steel parts with anything
other than a soft iron or nonferrous hammer.
When installing or removing such parts wear safety
glasses with side shields and heavy gloves, etc., to
reduce the possibility of injury.
Install bearing with tool P/N 75300850.
Remove bearing race from the wheel shaft bearing

retainer with puller set.

6006- 15
Install bearing cup in the wheel shaft bearing retainer

using tool P/N 75300850.
Remove the lip seal (6) and snap ring (1 0) from the
bearing retainer flange (3).
Install the snap ring (10).
Remove the hub located between the rear axle and the
tandem case.
Using a proper wrench, remove the capscrews from

the rear axle flange to separate tandem from axle.
Separate tandem case and rear axle using adequate

hoist.
Save shims for reassembly.

6006-16
Remove phenolic thrust washer .
Remove lockwire and capscrews.
Remove the tandem retaining plate.
Remove the phenolic thrust washer.
Remove external tandem pivot seal.
Remove hub.
Remove internal tandem pivot seal.
Remove phenolic bushing
REAR AXLE REMOVAL
Disconnect the drive shaft at differential input flange

(1 ).
Remove nuts retainer plate, housing nuts and

capscrews(2).
Disconnect the brake supply lines and brake cooler

lines.
Remove the rear axle assy.
NOTE: For rear axle disassembly and assembly see

section 6005.
REAR AXLE ASSEMBLY
Position the rear axle under the grader.
Install retainer plate nuts, housing nuts and

capscrews(2)torqueto 830-850 Nm (614 -629ft lb.).
Connect the brake supply lines and brake cooler lines.
Connect the drive shaft at differential input flange ( 1),

capscrewstorqueto 135-165 Nm (1 00-122ftlb.) use
Loctite 271.
ASSEMBLY OF THE TANDEM
Install bushing and tandem pivot seal.
Apply light coat of graphite grease on the outside

diameter of phenolic bushing.

6006- 17
TANDEMCASEOSCILLATIONADJUSTMENT
PROCEDURES
DETERMINATION OF THE SHIM PACK {SP)
-Clean all the parts, hub, thrust washer 363 x 440

mm (14.29 x 17.32 in), tandem retaining plate &
thrust washer 380 x 440mm (14.96 x 17.32 in) and
and assemble them per the sketch in the vertical
position.
18 19
- Measure the clearence "X"in six (6) equally
spaced points.
- Use the largest dimension found =X.
-Establish the shim pack(19) "SP"(mm) =X+ (0.15

-0.20mm).
"SP"(in) =X+ (.006 -.008 in).
Assemble the hub (18) and external seal (22).
Install thrust washer (23) with a thin coating of

graphite grease.
Assemble tandem retaining plate (25), washer (26)

and capscrews (27). Torque the capscrews to
450 - 480 Nm (333 - 355 lb ft.) .
Apply lock wire to retaining capscrews, see figure.
Assemble the tandem case on the axle using the

parts and the shims, covering the cleaned part
surfaces with a thin coating of graphite grease.
After assembly, torque all the hub capscrews (21)

to 280- 320 Nm (207- 236 lb ft.).
The tandem case should pivot on the axle with a

force (P) of70 to 150 kg (150- 330 lb), applied at
the center of one of the wheels.

6006-18
-Install drive sprockets (29), adjusting shim (30),

sprockets retaining washer (31 ), capscrews (32) to
115 -125 Nm (85- 93 lb.ft.) .
Lock the capscrews.
Place chain in case tandem.
Apply Permatex or Loctite 1114 to inner cap and

tandem case. Place rear bearing cap on case.
Tighten capscrews to torque 122-136 Nm
(45 -50ft lb.).

6006- 19
Pack the rear bearing with grease prior to installing

the sprocket and shaft in the tandem case. Install
the gear and shaft in the tandem case.
Pack front bearing with grease.
Do not engage chain in sprocket.
Leave the outboard seal off the wheel end. Tempo-

rarily install the wheel end onto the tandem case.
Tighten the capscrews to torque.
Place cap without shims onto bearing cap. Tighten

four screws evenly and rotate shaft at the same
time.
Check the shaft bearing for the correct rolling

torque.
Rolling torque is adjusted by shims on the opposite

side of the case. When the rolling torque is ob-
served to be within specification, measure the gap
between the two caps. Install gap with shims.
Tighten shim cap capscrew to torque 122 -136 Nm
(90 - 100ft lb.) use loctite 277 and check rolling
torque to 6.8-7.4 Nm (60 -70 in lb.).

6006-20
Remove the bearing retainer flange and position the

chain around the sprocket.
Do not let the chain bunch in one position.
Reinstall the bearing retainer flange after applying

Loctite 1114 or Permatex and tighten the retaining
capscrews torque to 122 -136 Nm (90 -100ft lb.).
Wheel end shaft bearing shim with greased packed

bearings and prior to installing seal.
Install the seal. Using a tube (3 15/16" x 10") press

the seal onto the shaft and wheel end.
Loop the chain over the drive gear. Connect the two
ends of the chain with the master link.
Install master link.
Install cotter pin (always install new cotter pin).

6006-21
Install the gasket and gear cover onto the tandem

case.
Apply Loctite 1114 capscrews thread and torque to

28 -35 Nm (21 -26ft lb).
Install tandem chain access covers.
Apply Loctite 1114 on the both sides of the gasket

and caps crews thread.
Install gaskets, cover and capscrews torque to

28 -35 Nm (21 -26ft lb}.
Add specified oil through the filler holes until oil runs
out of the oil level hole, see operators manual.
Tighten the filler plug.
Install the key on the hub shaft.

6006-22
Install the washer and the nut on the wheel hub

shaft.
Torque the nut 540-560 Nm (400- 415Ft lb.).
Install tires to the tandem case.
Torque the nuts to 407-476 Nm (300 -350Ft lb.).
1
10 @
Wheel nuts tightening sequence.
@ o•
10 011
•0 @a
'It@ o,
·~
@
7 @
2

Section
6006
TANDEM DRIVE
DIFFERENTIAL HYDRAULIC LOCK

Contagem, MG -Brazil ENG 6-75380 May,2003
6006-2
DESCRIPTION ...................................................................................................................... PAGE
GENERAL DESCRIPTION ..................................................................................................... 3
DISASSEMBLY OF THE TANDEM AND REAR AXLE REMOVAL AND INSTALLATION ........... 5
DISASSEMBLY OF THE TANDEM ............................................................................................. 8
REAR AXLE REMOVAL AND INSTALLATION .............................................................................. 10
ASSEMBLY OF THE TANDEM ............................................................................................ 11
TANDEM CASE OSCILLATION ADJUSTMENT PROCEDURES .............................................. 12
DETERMINATION OF THE SHIM PACK ..................................................................................... 12

6006-3
GENERAL DESCRIPTION
TANDEMS
Driving sprockets, which are splined to the rear axle shafts, transfer power through heavy roller driving
chains to the wheel shaft sprockets which are attached to the wheel reduction (four planetary assemblies
bolted to tandem case).
Each tandem assembly oscillates and pivots on a tandem hub bushing, located in the hub.
Differential hydraulic lock is operator controlled.
Outboard wet disc brakes.

6006-4
18 19
18- Hub 24- Tandem retaining plate

19- Shim 25- Washer
20- Washer 26 - Capscrew
21 - Capscrew 27- Bushing
22- Tandem pivot seal
23- Thrust washer 380x440mm (14.96x17 .32)in

6006-5
DISASSEMBLY OF THE TANDEM AND

REARAXLEREMOVALAND
INSTALLATION
DISASSEMBLY OF THE TANDEM
- Install the grader frame lock pins into their
TANDEMTEARDOWN
frame locations if working on an articulated
grader.
- Park the grader on a level surface.
- Place the transmission in neutral and apply the

hand brake. Ensure the hand brake is correctly
-Lower the moldboard and all attachments to the -Overall view of tractor. Tag machine to note
ground. Do not apply down-pressure. that machine is being serviced.
-Shut down the engine. - Lift grader by extending the blade to the side
being worked upon. Apply blade down pressure
-Install the service pin in the LOCKED position
on the side to be lifted.
(see the Operators Manual).
-Install chocks at the front and rear tandem

wheels. Wedge the chocks in place.
it. WARNING
Observe all start up and shut down procedure an
WARNING listed in the operation and mainte-
Lb. WARNING
nance instruction manual.
Scissors points in area of service. Stay clear Keep people clear of attachments and tools
during operation. Block securely for service. while in raised position, to prevent possible
injury.
it. WARNING
Remove the tires
Lift and handle all heavy parts with a lifting
device of proper slings and hooks. Use lifting
eyes if provided. Watch out for people in the
vicinity.
-Support the grader with approved supports.
it. WARNING
When supporting machine component must be
removed or installed and jacks are used, be sure
the support of the jack at the machine and on
the ground are appropriate to the load to be
applied. Transfer the load to authorized blocking
or jack stands immediately. Do not work on or
under the machine or its components while
supported only on a jack or other lifting device,
according to local or national requirements.

6006-6
Remove the cover screws.
Remove the drain plug and drain the oil.
Remove the chain access cover.
Put the filler plug back in the place.

6006-7
Remove the bolts from the center cover to access-

ing the chain drive gears.
Remove the cover and gasket.
Position the chain master link at access window on

side of tandem case.
Remove the cotter pins.
Remove the master link .

6006-8
Remove the chains.
Remove the drive gear.
Remove the half shaft.
Remove the hub located between the rear axle and the
tandem case.
Using a proper wrench, remove the capscrews from

the rear axle flange to separate tandem from axle.

6006-9
Separate tandem case and rear axle using adequate

hoist.
Save shims for reassembly.
Remove phenolic thrust washer .
Remove lockwire and capscrews.
Remove the tandem retaining plate.
Remove the phenolic thrust washer.
Remove tandem pivot seal.
Remove hub.
Remove phenolicbushing.
Remove lip seal tandem case.

6006-10
Remove lip seal (1) axle case.
REAR AXLE REMOVAL
Disconnect the drive shaft at differential input flange

(2).
Remove nuts retainer plate, housing nuts and

capscrews(3).
Disconnect the brake supply lines and differential lock

lines and guard.
Remove the rear axle assy.

section 6005.
REAR AXLE ASSEMBLY
Position the rear axle under the grader.
Install retainer plate nuts, housing nuts and

capscrews(2)torqueto 830-850 Nm (614 -629ft lb.).
Connect the brake supply lines and differential lock

lines and guard.
Connect the drive shaft at differential input flange ( 1),

capscrewstorqueto 135-165 Nm (1 00-122ftlb.) use
Loctite 271.

6006- 11
ASSEMBLY OF THE TANDEM
Install bushing and tandem pivot seal (see figure).
Apply light coat of graphite grease on the outside

diameter of phenolic bushing.
Install new lip seal (see figure).
Mark covers to identify the tandem stop angle.
Remove the cover,bearing and sprocket.
Remove the wheel reduction axle assembly.

section 6005.
Install the wheel reduction axle assembly, apply Loctite

1114 on the surface and studs thread.
Nuts torque to 267-273 Nm (198 -2021b ft.).
Install sprocket, bearing.
Apply Loctite 1114 on the cover and capscrews

thread.
Install cover and capscrews torque to 122- 136 Nm

(90 -100ft lb.).

6006-12
TANDEM CASE OSCILLATION ADJUSTMENT

PROCEDURES
DETERMINATION OF THE SHIM PACK (SP)
-Clean all the parts, hub, thrust washer 363 x 440

mm (14.29 x 17.32in), tandem retaining plate &
thrust washer 380 x440mm (14.96 x 17.32in) and
and assemble them per the sketch in the vertical
position.
18 18
- Measure the clearence "X"in six (6) equally
spaced points.
Use the largest dimension found =X.
-Establish the shim pack(19) "SP"(mm) =X+ (0.15

-0.20mm).
"SP"(in) =X+ (.006 -.008 in).
Assemble the external seal (22) and hub (18).
Install thrust washer (23) with a thin coating of

graphite grease.
Assemble tandem retaining plate (24), washer (25)

and capscrews (26). Torque the capscrews to
450 - 480 Nm (333 - 355 lb ft.) .
Apply lock wire to retaining capscrews, see figure.
Assemble the tandem case on the axle using the

parts and the shims, covering the cleaned part
surfaces with a thin coating of graphite grease.
After assembly, torque all the hub capscrews (21)

to 280- 320 Nm (207- 236 lb ft.).
The tandem case should pivot on the axle with a

force (P) of 70 to 150 kg (150- 330 Ib), applied at
the center of one of the wheels.

6006- 13
Install new lip seal (see figure for assembly

position).
Install the half shaft,carefully, to avoid damage to

seals.
Install the drive gear.

6006-14
Loop the chain over the drive gear. Connect the two
ends of the chain with the master link.
Install master link.
Install cotter pin (always install new cotter pin).
Install the gasket and sprocket cover onto the

tandem case.
Apply Loctite 1114 to capscrews thread and torque to

28 -35 Nm (21 -26ft lb).
Install tandem chain access covers
Apply Loctite 1114 on the both sides of the gasket

and capscrews thread.
Install gaskets, cover and capscrews torque to

28 -35 Nm (21 -26ft lb).

6006- 15
Add specified oil through the filler holes until oil runs
out of the oil level hole, see operators manual.
Tighten the filler plug.
Install tires to the tandem case.
Torque the nuts to 407 -476 Nm (300 -350ft lb.}.
1
10 @
@ fll
1110 0)11
Wheel nuts tightening sequence.
•0 @:.
'ft@ o.
@
7 @
2 ••

6006-16
NOTES

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

7002-3
DEFECTS
TROUBLE PROBABLE CAUSE REMEDIES
The braking action does not stop Brake pedal seized. Repair or replace brake pedal valve.
after releasing the brake pedal.
Brake pedal not completely Check that no hardened mud or
released. foreign material are located under
the pedal. Check that with the pedal
is totally released and there is no
output pressure from the brake valve
Hard pedal travel. Brake pedal valve pistons seized. Repair brake pedal valve.
Hard braking operation. Wrong pressure setting. Checkpressure.
Weak braking effect. Low brake pressure. Check pressure.
Brake discs (axle) need to be Replace discs.

replaced.
Air in the system. Bleed system.
Oil leaks in system. Inspect and eliminate leaks.
Recharge pressure of accumulators Check pressure.

below nominal value or brake
accumulators inefficient.
The accumulators do not recharge. Contamination seized the priority Repair or replace brake pedal valve.
valve (in brake pedal valve).
Braking pressure fluctuating. Recharge pressure of accumulators Check recharge pressure.

lower than nominal value. ( If
recharge pressure of accumulators
is low, the brake low pressure
indicator on panel should be ON.
The pressure switch is set at 65 ± 5
bar ( 942 ± 72 psi). Check the
precharging pressure of the
accumulators.
The charge pump overheats. The recharge pressure of the Check recharge pressure.
accumulators is lower than nominal
value (refer to description above).
Oil leaks from brake pedal valve. Repair or replace brake pedal valve.

7002-4
Brakes low pressure Accumulators recharge pressure Repair or replace pressure valve.
indicator on panel stays ON. lower than the nominal value.
Oil leakages from brake pedal valve.
Delayed braking and I or Brake valve pressure I flow Check that the brakes system tubes are
pedal return insufficient. not clogged.
High viscosity of the hydraulic fluid.
Braking pressure not Pressure in accumulators not Check for correct

constant correct. accumulator pressure; if necessary,
operate the adjuster on the cylindrical
head of the accumulator charge valve.
Continuous recharge Accumulators with too low or too Check nitrogen pressure in
of the accumulators high nitrogen precharge. accumulators.
Feeding pump always Worn pump. Repair or replace pump.

under pressure
Dirt in the valve. Careful check of the valve (correct
sliding of the cad seats.
Accumulators Contamination in the priority Check the sliding of all sports, mainly of
don't charge valve. the inlet valve.
Check the hydraulic connection.
Brakes remain applied Uncorrectet discharge.
Non return of the pedal. Check that the pedal stop adjuster
allows backlash between return and
operating piston.
Eliminate possible contamination

in the valve.

7002-5
Dashboard indicator always The pressure switch fails to Replace pressure switch
off or always on operate.
Brake pedal pulsate Sudden pressure changes on the Check that there are no obstructions
outlet. along discharge line.
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.

Section
8001
REMOVAL AND INSTALLATION OF

HYDRAULIC COMPONENTS
845 - 865 - 885 Grader

Contagem, MG - Brazil ENG 6-46872 May,2003
8001-2
SECTION .................................. DESCRIPTION ......................................................... PAGE
SERVICE POSITION ..................................................................................................................... 3
PUMP REMOVAL ........................................................................................................................ 4
GRADER 845 PUMP REPAIR INSTRUCTIONS ............................................................................ 5
GRADER 865-885 PUMP REPAIR INSTRUCTIONS ................................................................... 16
HYDRAULIC DISTRIBUTOR .......................................................................................................... 36
MAIN HYDRAULICMANIFOLDVALVE- REMOVAL ...................................................................... 36
MAIN HYDRAULIC MANIFOLD VALVE- DISASSEMBLY ............................................................... 36
MAIN HYDRAULIC MANIFOLD VALVE -INSTALLATION ................................................................ 42
DUAL OVER CENTER (COUNTERBALANCE) VALVE ................................................................... 43
SOLENOID/PRESSURE REGUALTING VALVE ........................................................................... 46
DUALCHECKVALVE .................................................................................................................... 47
HYDRAULIC CYLINDERS ................................................................................................................. 48
HYDRAULICCYLINDERS DISASSEMBLY .................................................................................... 50

HYDRAULIC CYLINDER ............................................................................................................... 52
ENG 6·46872 Issued 01-03 Printed in Brazil

8001-3
Service Position
Before making any service, maintenance or inspection procedure, the grader must be placed in the
Service Position.
1. Park the grader on a level surface.
2. Place the transmission in neutral and apply the handbrake. Ensure the handbrake is correctly
3. Lower the moldboard and all attachments to the ground. Do not apply down-pressure.
4. Shut down the engine.
5. Install the service pin in the LOCKED position (see the Operators Manual).
6. Install chocks at the front and rear tandem wheels. Wedge the chocks in place.
7. Relieve residual hydraulic pressure by operating all control levers.
8. Some hydraulic circuits may contain lock valves. Operating the control levers in these circuits
will not relieve residual hydraulic pressure. Such pressure must be relieved by loosening a fitting or
electrically activating the solenoid valve. Wear face and eye protection. Danger of spraying oil.
9. Fasten a "DO NOT OPERATE" or similar warning tag on the steering wheel.
10. Remove and retain the ignition key.
11. Turn the battery isolation switch to the OFF position.
1 2. Allow the engine and hydraulic system to cool before working in these areas.
13. Be aware of other service personnel in your work area.
14. If the service procedure includes welding, you must disconnect the following items:
a) Negative battery cable.
b) Positive battery cable.
c) Power supply harness at the transmission controller.
d) Transmission wiring harness at the controller (see the operators Manual).
e) Alternator to battery wiring harness
f) 24V-12V converter wiring harness at the fuse.

g) Float valve module (if installed) wiring harness at the module.
Connect the arc-welder ground cable as close as possible to the work area.

8001-4
PUMP REMOVAL
Disassembly of the hydraulic pump.
Open the hood.
845 hydraulic pump.

Type: Gear pump, fixed displacement, unloadervalve
load sensing, variable discharge.
Displacement: ................ 91 Cu.cm/rev. (5.51 Cu.in/rev.)
865 and 885 hydraulic pump.
Type: Piston pump, variable displacement, pressure

and flow compensated, load sensing.
Displacement: ............ 1OOCu.cm/rev. (6.1 OCu.in/rev.)
To start disassembly of the pump, drain the hydraulic

tank, disconnect the hoses and tube from the
hydraulic pump.

8001-5
GRADER 845 PUMP REPAIR INSTRUCTIONS
The pump, with identification plate data,

the inlet and the safety valve of the pump
Below, is the cover oft he outflow control valve.
DIAGRAM OF THE PUMP
1- Main Hydraulic Pump 10-Driveshaft/Gear- Driving

2- Plug 11-Seai-Shaft 19-Cap
3-Seal Gland 12-Driveshaft/Gear- Driven 20 - 0-Ring -Relief Valve Cartridge Setscrew
4-Seal Retainer 13- Wear Plate 21 - 0-Ring- Relief Valve Cartridge Seat
5-Packing Ring 14 -Plug 22- 0-Ring- Relief Valve Cartridge
6-Front Cover 15- Rear Cover 23- Back- up Ring
24 - 0-Ring - Relief Valve Cartridge Housing
?-Bushing 16-Nut-Load Sense Module
8-Lockwasher 17- Spring
9- Bolt 18- 0-Ring
8001-6
The load sensor module is a component integrated to the
rear part ofthe hydraulic pump. The module allows the
pumptodischargetothe low pressure tank when it is not
required. Eachtimetheoil is required to run a function,
the module reacts by giving priorities to the flow.
With no active function, there is no load sign on the load

sensor line. The absence of load makes the spool move up
againstthespring.AIItheflowofthepumpisdirectedtothe
by-pass port. The pressure is determined by the low
unload spring force, is 90 psi.
3
Flow Control spool should be closed
ure adjusting screw
CAPTION
1- Load sense module housing 5- Fixed Bias Spring 10-Bias pressure adjusting screw
2- Low unload spring 6- Bypassporttothetank
3- Load sense port 7- Flow control Spool
4- Unload spool 8- Discharge port
9- Adjustable Bias spring

8001-7
When the piston gets to the end of its stroke or finds an

resistance to flow load through the valve, the result
is a reduction of the pressure. The pump increases the
output flow. The flow control spool opens and directs
all the remaining flow to the by-pass port. The
outflow pressure is limited to 2500 psi.
The surface area in the load sense of the spool on the

unloading spool is greater than the area a the pump
discharge port. This area difference maintains the unloading
spool seated against the pump housing when there is load
sense signal present. The laod sense signal comes from the
maximum pressure required to actuate any of the graders
funstions.
When the system is operating in the flow control mode, the
flow control spool rises, alowing excess pump outlet flow to
bypass to the tank port based upon the pump flow required
at the Grader valve. The flow control spool will maintain an
approximately 300 psi pressure difference between the
pump outlet pressure and the load sense signal returned
from the grader control valve. This 300 psi pressure
difference will assure that any flow required at the grader
valve will be available.
When the piston gets to the end of its stroke or finds a high
resistance to flow through the grader valve., the result is an
increase the load sense pressure. The maximum load sense
pressure is limited by the load sense relief valve in the outlet
section of the grader valve. The maximum load sense
pressure specification is 2600 psi. which will result in the
pump outlet pressure being 2900 psi, due to the 300 psi
differential across the flow control spool.

8001-8
DISASSEMBLING AND ASSEMBLY OF THE
PUMP
Unfasten and remove the eight nuts and washers of the

tap bolts.
Remove the front cover. Label the intersection ofthe teeth

of the driven and drive gear with a marker before removing
them off the pump. Carefully remove the drive gear off
the pump and put it on a work bench.
Remove the drive gear off the pump and put it on a smooth
surface.

8001-9
Remove the central section ofthe pump.
Remove the eight tap bolts ofthe rear cover.
Remove the wearing plate ofthefrontcover.
Remove the seal retainer oft he rear cover and discard it.
It must be replaced by a new part.

8001-10
Remove the seal gasket of the rear cover and replace it with
anew part.
Remove the square section o-ring and discard it. Replace

it with a new part.
Remove the wear plate of the front cover. Remove the

rubber plug ofthe drain seal.
Remove the retainer seal ofthe front cover and discard it.
Replace it with a new part.

8001-11
Remove the gasket of the front cover and discard it.
Replace it with a new part.
Remove the square section a-ring of the front cover and

discard it. Replace it with a new part.
Remove the retainer ifthere is one installed on the front

cover and use a screwdriver or another tool to remove the
retainerfrom the front cover shaft.
INSPECTION OF THE PARTS FOR WEAR
Clean all parts before inspecting them. It is not

necessary to inspect the retainers that must be
replaced by new parts.

8001-12
Inspect the surface ofthe gears of both shafts for excessive
wear or scratches.
lnspectthe bushings on the front coverfor excessive wear,

flacking, or movementofthe bushings.
lnspectthe bushings on the rearcoverforexcessivewear,

flacking, or movementofthe bushings.
lnspectthe central section oft he gear casing. It must not

show excessive wear or deep scratches.

8001-13
lnspectthe bronze side from both plates for erosion and
scratches. Replace them if they are damaged. The left
model is used on the G30 barnes pump.
Typical content of the repairs ofthe pump G30.
Install a new retainer on the front cover. Mount the

retainer with a stop spring for the internal part ofthe pump.
Press the retainer on the diameter oft he pump housing.
You must apply a uniform pressure to prevent the retainer
from getting out-of-true or damaged. Lubricate there-
tainer with graphite grease after installing it.
Put the rear cover on a work bench with the retainer cavity
up. Lubricate the retainer cavity with graphite grease.

8001-14
Lubricate both retainers using a brush, and lubricate the
gasket and the retainer with grease. Carefully install the
gasket on the inner part ofthe retainer; check whether the
gasket is perfectly assembled in the retainer.
Install the assembly on the rear cover cavity. Be very careful

when you press the assembly into place: it mustseatfirmly
in its housing. This is important for the installation ofthe
bronze wear plate.
Lubricate the bronze surface oft he wear plate and install

the retainer over it. This picture shows the wear plate ofthe
G20, the wear plate of the G30 is different.
Apply a thin coat of graphite grease on the housing ofthe

square section o-ri ng and carefully install it in the housing.
Takecarethattheo-ringdosnotspininthehousing:itmust
be correctly positioned inside the housing or the pump will
leak on this spot.
Install the eighttop bolts on the rear cover. Tightening

torque of the top bolts: 33.9-47.5 Nm.(25- 35ft. Ib)

8001-15
Install the central section on the top bolts. Check the
alignment of the top bolts on the central section.
Lubricate the drive gear and install the gears on the

appropriate bushings. Align the teeth marks ofthe gear.
Place the front cover on a clean work bench with the

retainers cavity up. Lubricate the retainers cavity with
graphite grease.
Lubricate both the gasket and the plastic retainer with

graphite grease. Carefully install the gasket in the internal
part of the plastic retainer, checking whether the gasket
is well set into the retainer.

8001-16
Install the assembly on the front cover cavity. Carefully
press the assembly into place; checking whether it is firmly
seating in place. This is very importantforthe installation of
the wear plate.
Apply graphite grease to the square section housing

of the o-ring, and carefully install it on the front cover
housing. Beverycareful:theo-ring mustnotspinwithinthe
housing or the pumpwillleakatthis spot.
Lubricate the steel side of the bronze wear plate with

graphite grease and install ito n top oft he retainer.
Install the washers and nuts on the top bolts. Torque ofthe
top bolts: 196-210 Nm. (145-155 ft.lbs)

8001-17
GRADER 865 - 885 PUMP REPAIR INSTRUCTIONS
Disassemble the pilot valve.
Mark the position ofthe cover in relation to the casing when

it is in place, and remove the allen head screws.
Remove the cover together with the control components.
Remove the cone roller bearing and the wedges.

8001-18
Remove the rotor entirely.
RemovetheO-ring.
Remove the bearings of the roller bearings.
Using a roller bearing extractor, remove the roller bear-

ings from the casing.

8001-19
Remove the distributor plate.
Use the roller bearing extractor to remove the rear part

ofthecasing.
RemovetheO-ring.
Loosen the lock nut of the adjustment bolt.

8001-20
Disassemble the adjustment bolt.
Disassemble the command piston guide.
Disassemble the guide opposite the piston.
Pull the input shaft out.

8001-21
Remove the pistons and the retention plate.
Remove the concave washer.
Compress the central spring to dissasemble the

retainer ring.
Disassemble the retainer ring.

8001-22
Components of the rotor: bolts, cylinders, wedge,

spring, and wedge.
Remount the pump following the reverse order of the

disassembling.
The roller bearing on the cover ofthe pump must have a

initial preload between 0... 0.05 mm.
Putthe distributor plate in place.

Lubricate it with grease before assembling it.

8001-23
Position the 0-ring on this place.
Maintain the tension ofthe spring with screws (they must

not be tightened into place).
Correct position ofthe bearing (lubrication hole and high-

pressure side).
Before putting the cover back on its correct position (see

mark), remove the screw that retains the spring.

8001-24
Install the plug.
It is possible to reuse the cradle where the piston

shoe works.
NOTE:Wedo not recommend that you press on the external

part ofthe piston.
Check the coupling between the rotor and the distribution

plate.
Check the surface conditions of the control piston.

8001-25
Check the condition of the bolt opposite the pis-

ton.
Distributor plate, inclination piston of the plate, and

return spring.
Complete rotor.
Casing of the pump and bearings of the roller

bearings.

8001-26
Input shaft and cone roller bearings.
Adapter with hole for pilot valve.

8001-27
REPLACEMENT OF THE INPUT SEAL
Remove the retainer ring of the seal.

Remove the seal.
Change the seal and check the work area of the

seal.
Apply grease to the retainer.

8001-28
Remount the seal using the proper tool.
Put the retainer ring back on its place.
With a tubular tool, place the lock correctly in its

housing.

8001-29
RETAINERS AND COMPONENTS KIT
Seal ofthe entrance shaft.
Full seal kit.

The kits are based on the type of the pump.
The picture shows the kit used on the
HA 1OV01 OODFR pump.
Pilot valve. Pressure and flow control.
0 00
Distributor plate, inclination piston of the place and

Command spool.

8001-30
PILOT VALVE
Remove the allen screws of the pilot valves.
Remove the 0-rings.
Remove the hexagonal nuts.

First, remove the pressure command, and then
the flow command.
Remove the lock nut and the adjusting screws.

8001-31
Remove the plug.
Remove the adjusting disc.
Remove the spring (two for the flow control valve).
Remove the cover of the spring
Remove the plug.

8001-32
Be careful when you disassemble the piston.
Disassemble the restrictor(it is on the spring

area of the pressure controller).
Disassemble the plug or restrictor that is on the

spring area of the flow controller.
Clean the casing and the components with cleaning

fluid, and carefully dry them with compressed air.

8001-33
Remount the pilot valve following the reverse order

of the disassembling.
Check the opening of the restrictor hole; if necessary,

use compressed air to clean it.
Be careful when you clean the hole.

8001-34
Check the movement of the pilot valve spool. It must

not be mounted if it is damaged.
Adjustthepilotvalve (see instructions on the pages below).
When the pressure line is closed, it is possible to regulate

the pressure controller (190 bar= 2.800 psi).

8001-35
Adjustthe outflow regulator to 200 bar; this will allow the

pump to reach its maximum outflow of 210 1/min. (55
gpm)
Mechanicalflowlimiter:Usedtoadjusttheminimumflow.

8001-36
PILOT VALVE
Section drawing of the pilot valve.

8001-37
HYDRAULIC CONTROL VALVE
Frontviewofthe control valve: from left to right you can see

the pressure valve adjusted with 214bar, the safety valve
of the cylinder of the left side, and Load sense valve with
193 bar.
A- The Load Sense Valve 193± 3,5 bar.
B- Main pressure 214 bar.
The valve assembly is mounted just below the frame, at

the height of the steering valve of the machine. It is
accessed from under the machine. You can also see
the retainer valve of the articulation system of
the machine.
Control valve assembly is made upof9 blocks, with spools

way valves. It is a closed center type and has a Load
Sensing port that allows it to control the feed
pump flow; the Load Sense pressure is 179 ± 3,5 bar.
A- The Load Sense.
Frontviewofthevalve. From left to right, you can see

the main relief valve adjusted to 214 bar and the lift
safety valves of the moldboard regulated to 103 ± 3,5 bar.
Main Hydraulic Manifold Valve- Removal

1. Remove the shoulder socket head bolts
connecting the control rods to the valve spools.
Discard the locknuts.
2. Identify all hoses to prevent confusion during

assembly. Disconnect the hoses from the valve
section fittings. Immediately plug the open
fittings to prevent contamination.
3. Attach a safe lifting device to the manifold valve

assembly. Remove the three bolts, nuts,
flatwashers and lockwashers securing the mani-
fold valve assembly to the manifold
support.
Main Hydraulic Manifold Valve- Disassembly
Note: Use a scriber or oil-proof method

to mark the sequence of valve sections
in the manifold valve assembly. Each
valve section is designed specifically
for the function it controls and cannot
be interchanged.
ENG 6·46872 Issued 01·03 Printed in Brazil
8001-38
The control valve of the service pressure is mounted
on an independent block; it is a piloted type and can
be adjusted by means of a screw.
Pressure control valve out of the distributor.
Pressure control valve removed; here you can see the

pilot piston with its respective spring and also the nut and
the screw for pressure adjustment.
Safety valve oft he blade lift circuit; it is adjusted to 1.500

PSI. The distributor has two valves of this type, one for
each blade lift cylinder.

8001-39
2 1
17 11 16
3 14
12 9 8
LEGEND
1 -Compensator Spring 10 - Load Sense Signal Passage
2 - Workport "A" 11 - Load Sense Signal Transfer Passage
3- Bridge 12 - Pressure Passage
4 - Workport "B" 13- Tank Passage
5 - Spool Centering Spring 14 - Compensator Load Sense Signal Passage
6 - Spring Cap 15 - Compensator
7- Spool 16 - Load Sense Shuttle
8 - Load Sense Drain to Tank 17- 0-Ring
9 - Valve Body
1. Remove the special nuts and compression 4. Remove the 0-ring, bias spring and
washers from the tie rods on the outlet endcap. compensator piston. Discard the 0-ring. Store
Keep the tie rods in the manifold valve the bias spring and compensator piston in a
assembly. The outlet endcap Is identified by a safe, clean place and identified by the valve
load sense signal port. Discard the nuts. section from which they originated.
NOTE: The valve section next to the outlet

2. Carefully place the manifold valve assembly on
endcap does not have a load sense shuttle disc.
its end, resting on the three tie rod ends of the You may need to use small straight nosed
inlet endcap. external snap ring pliers or similar small
expanding tool to remove the compensator
3. Remove the outlet endcap. piston.

8001-40
3. Remove the socket head screws and the spring

cap.
4. Remove the spool end.
NOTE: To prevent the valve spool from rotating,

insert a thin rod or similar tool in the linkage pin
hole.
5. Remove the spring seats, spring and spool stop

ring.
Removing Compensator Piston from Valve Section

Housing
5. Remove the remaining valve sections, together

with the load sense shuttle discs, installed between
the eight valve sections.
Removing Spring Seats. Spring and Spool Stop

Ring.
6. Pull the valve spool out of the valve section

housing.
Removing Load Sense Shuttle Disc
Valve Section Disassembly
1 - Lightly clamp the valve section housing in a vise

with soft jaws.
NOTE: Excessive clamping force may distort

valve spool bore and compensator piston bore.
2. Remove the machine screws and the seal plate.

Removing Valve Spring from Valve Section
Housing

8001-41
7. Remove the 0-ring from the spring retaining All ports within the 0-ring mating area of the valve
screw. sections rely on the machined surface for sealing.
Inspect the machined surfaces for scratches,
8. Remove and discard the wiper seals and
grooves or other damage that may cause leakage
0-rings.
between ports.
Inspect the housing casting for cracks especially at

the tank passage section. This would be the result
of excessive back pressure.
Valve Section - Assembly
1. Lightly clamp the valve section housing in a vise

with soft jaws.
NOTE: Excessive clamping force may distort the

valve spool bore and compensator piston bore.
2. Lubricate new valve spool 0-rings and install

Removing Spool Wiper Seals and 0-Rings
them in the valve section housing counterbores .
Cleaning and Inspection Lubricate and install new wiper seals against the
0-rings in the valve section housing counterbores.
Immerse parts in fresh cleaning solvent. Agitate the
parts to remove all foreign matter. Parts should 3. Lubricate and install the valve spool in the valve
remain in the solvent long enough to be thoroughly section housing.
cleaned. Thoroughly rinse parts to remove all traces
of dirt and solvent.
After rinsing, immediately dry the parts using

moisture free compressed air. Lint-free,
uncontaminated wiping rags can be used ensure all
oil passages are unblocked. Wrap in clean, lint-free
cloth or paper and store in a cool, dry place.
A careful and thorough inspection of all parts is

extremely important. If you see any evidence of
damage or wear, replace all defective items with
genuine CASE parts.
Retain 0-rings and wiper seals only for inspection
and troubleshooting purposes. You must replace all
0-rings and wiper seals when overhauling the main Installing Valve Spool in Valve Section Housing
hydraulic manifold valve.
4. Lubricate and install a new 0-ring on the spool
end. Assemble the spring seats, spring and spool
Valve Section Housing stop ring on the spool end.
Inspect the spool bore and compensator piston bore
for excessive wear scratches and grooves that will 5. Install the spool end assembly on the end of the
cause excessive leakage. valve spool. Torque the spool end assembly
to 9 N.m ± 1,3 (71bf.ft ± 1)

8001-42
Torque-tightening Spool End Assembly Inlet Endcap and Three Tie Rods
NOTA: To prevent the valve spool from rotating,

insert a thin rod or similar tool in the linkage pin 4. Lubricate the mating surface with system oil.
hole. Lubricate and install a new 0-ring in the 0-ring
groove.
6. Install the spring cap. Make sure the mating
face notches are clean. 5. Install the valve section that is identified as
being adjacent to the inlet endcap.
7. Secure the spring cap with the socket head
screws. NOTE: Install the valve sections in their original
Torque the screws to 9 N.m±1 ,3 (7 lbf.ft ±1 ). order as identified before disassembly.
8. Secure the seal plate with the machine screws. 6. Insert the compensator piston into the
Torque the screws to 5 N.m±1 ,3 (4 lbHt compensator piston bore, nose end first.
±1 ).
Main Hydraulic Manifold Valve - Assembly

1. Install a new special nut and compression
washer on each tie rod. Ensure two or three
threads show at the end of each rod.
NOTE: The outside edge of the compression

washer must contact the valve section housing and
the center must contact the nut.
2. Insert the tie rods into the inlet endcap.
3. Place the inlet endcap on its end, resting on the

three tie rod ends.
Installing Compensator Piston into Valve Section
Housing

8001-43
7. Insert the bias spring into the hollow end of the 16. Torque the lower tie rod nuts to 19N.m
compensator piston. (14 lbf.ft ). This is the final torque value.
8. Install the load sense shuttle disc into the 17. Torque the upper tie rod nuts to 45 N.m
recess of the load sense passage. (33 lbf.ft). This is the final torque value.
Preliminary Value 9::!: 3.4 N.m (7:! 2.5 lb.ft)

Final Value 45N.m (33 lb.ft)
Preliminary Value 9± 3.4 N.m (7:!: 2.5 lb.ft)

Final Vab! 45N.m (33 lb.ft)
Torque Tie Rods Nuts
Installing Load Sense Shuttle Disc

18. Check for proper spool movement.
9. Lubricate and install a new 0-ring in the 0-ring Main Hydraulic Manifold Valve - Installation
groove.
1. Attach a safe lifting device to the manifold valve
assembly. Carefully install the manifold valve
10. Repeat the installation steps until all the valve assembly onto the manifold support.
sections, including the outlet endcap, are
installed. 2. Secure the manifold valve assembly with the four
bolts, nuts, flatwashers and lockwashers.
11. Install the compression washers with the 2. Connect the control rods to the valve spools.
outside edge contacting the valve section housing. Install the shoulder socket head bolts and new
Install new special nuts and tighten to finger locknuts.
tightness.
11. Place the manifold valve assembly on a

precision flat surface.
NOTE: Torque-tightening the tie bolt nuts on a non-

flat surface may cause spool or shuttle disc binding.
13. To align all valve sections and endcaps , press

down on the endcaps before tightening the tie bolt
nuts to the final torque value.
14. Torque the lower tie rod nuts to

9 N.m ± 3,4 (7 lbf.ft ± 2.5). This is a preliminary
torque procedure.
15. Torque the upper tie rod nuts to 9 N.m ±

3,4 (7 lbf.ft ± 2.5 ). This is a preliminary torque
procedure.

8001-44
DUAL OVER CENTER (COUNTERBALANCE) VALVE
Counterbalance valves with pilot assist combine two valves; a check valve and a
relief valve. The check valve allows free flow from the directional valve (port 2) to
the load (port 1) while a direct-acting, pilot-assisted relief valve controls flow
from port 1 to port 2.
ADJUSTMENT - Pressure setting 207 bar (3000psi).

Turnscrew(1) clockwisetoreduce
setting and counterwise to inclease setting.
Nut Torque 12Nm (1 08 lb.in).
0 0
See figure for position of o'rings and back up rings.
Valve Installation (2) Torque

60 - 70 Nm (45 -50 lb.ft)
HEX DIMENSION
ACROSS FLA. TS: 1 118 (28,6)
0
PILOT
0
OUTLET
INLET
0
8001-45
Dual over center valve,

moldboard lift and right cylinder

circle side shift cylinder.
Dual over center valve, rear

ripper cylinder.

8001-46

frame artie ulatio n
cylinders.
Dual over center

valve, molboard pitch
cylinder.
Dual over center valve, front scarifier

and dozer blade cylinder.
ENG 6-46872 Issued 01-03 Prin1ed in Brazil

8001-47
SOLENOID I PRESSURE REGULATING VALVE
View of the saddle pressure control valve

and the command solenoid.
Disassembly of regulating valve: the pressure in the

saddle circuit is 42 bar (600 psi) and can be adjusted
by removing plug and rotate set screw clockwise to
increase pressure.
•
View of pressure regulating valve cartrige.

8001-48
DUAL CHECK VALVE
This valve allows flow from the V ports to the C

ports, while blocking flow from the C ports to the
V ports when pressure is applied at opposite V
port.
Retainer valve of wheel lean.
The retainervalveofthewheels isasimplevalve, that has

a safety system. It is composed of a piston and two one-
wayvalves.
The retai nervalve ofthe wheel lean is located on the

upper part of the frame support.

8001-49
HYDRAULIC CYLINDERS
Hydraulic Cylinder- Removal
WARNING: Place the grader in the Service Position.

Prior to removing cylinders, install any linkage or
frame lock pins where applicable; especially wheel
lean (see the Operators Manual).
Support the weight of the cylinders with a suitable lifting

device.
ffi WARNING
of proper capacity. Be sure parts are supported by
proper slings and hooks. Use lifting eyes if MOLDBOARD LATERAL CYLINDER
ffi WARNING
Danger of spraying oil. Always wear face or eye
protection when loosening hydraulic fittings. Fluid
escaping under high pressure can penetrate skin
causing serious injury.
Relieve all hydraulic pressure. Take care with hydraulic

circuits that contain lock valves.
Disconnect the cylinder from all pivot pins, sockets or

trunnions.
Disconnect the hydraulic hoses. Immediately plug the

open ports and fittings to prevent contamination. LDBOARD PITCH CYLINDER
Remove the cylinder to a work bench for disassembly.
Hydraulic Cylinder -Installation

This is the reverse procedure of removal.
WHEEL LEAN CYLINDER

8001-50
MOLDBOARD LIFT CYLINDERS

WHEEL LEAN CYLINDER
CIRCLE SHIFT CYLINDER ARTICULATION CYLINDER
SCARIFIER OR DOZER BLADE CYLINDER

SADDLE PIN LOCK CYLINDER

8001-51
RIPPER CYLINDER
Hydraulic Cylinder - Disassembly Remove the piston assembly.

Drain any oil remaining in the cylinder in an
appropriate container.
Unscrew (or unbolt) the cylinder head from the Remove the seals from the piston.
cylinder tube using wrench tool.
Pull the cylinder rod assembly from the tube.
Place the cylinder rod (pin end) in a vise and support

the rod a suitable lifting device. Remove the piston Remove the head assembly.
retaining nut from the rod.

8001-52
Hydraulic Cylinder - Assembly

Assembly of the cylinder is reverse procedure of
disassembly with the following exceptions.
1- Check all parts for signs of excessive wear and

compare dimensions with those listed in Specifications.
2- Install new bushings, seals and 0-rings.
3- Install piston assembly in same position that it was

removed and tighten retaining nut to specifications.
Remove the 0 - rings.
Remove the seals.

8001-53
SPECIFICATIONS
A B c D
MOLDBOARD LATERAL SHIFT CYLINDER
A. Lubricate and torque cylinder head .................................... 1400- 1600 Nm (1 032- 1180 lb.ft)
B. Piston rod O.D. ...................................................................... 49.960- 50.000 mm (1.967- 1.968 in)
D. Lubricate and torque piston rod locknut to ............................ 900- 1000 Nm (664- 738 lb.ft)
E. Stroke of the piston rod ......................................................... 1219mm (48 in)
MOLDBOARD PITCH CYLINDER
A. Lubricate and torque cylinder head ..................................... 1400- 1600 Nm (1 032- 1180 lb.ft)
E. Stroke of the piston rod ......................................................... 187mm (7.4 in)

8001-54
A B C
WHEEL LEAN CYLINDER
C. Cylinder I.D. ........................................................................... 90.000- 90.054 mm (3.543- 3.545 in)
E. Stroke of the piston rod ......................................................... 187mm (7.4 in)
A B c
MOLDBOARD LIFT CYLINDER
A. Lubricate and torque cylinder head ..................................... 1400- 1600 Nm (1 032- 1180 lb.ft)
B. Cylinder head rod bore I.D .................................................... 56.120 - 56.160 mm (2.209 - 2.211 in)
Piston rod O.D. ...................................................................... 55.960- 56.000 mm (2.209- 2.211 in)
E. Stroke of the piston rod ......................................................... 1143 mm (45 in)

8001-55
CIRCLE SHIFT CYLINDER
E. Stroke of the piston rod ......................................................... 578 mm (22.75 in)
SADDLE PIN LOCK CYLINDER (5 POINT SADDLE)
A. Lubricate and torque cylinder head ..................................... 576- 712 Nm (425- 525 lb.ft)
B. Cylinder head rod bore I.D .................................................... 31.801 - 31.852 mm (1.252 - 1.254 in)
Piston rod O.D ....................................................................... 31.674- 31.750 mm (1.247- 1.250 in)
C. Cylinder I. D............................................................................ 63.627- 63.754 mm (2.505- 2.510 in)

Piston O.D. ........................................................................... 63.195 - 63.297 mm (2.488 - 2.492 in)
D. Lubricate and torque piston rod locknut to ............................ 271 - 339 Nm (200- 250 lb.ft)
E. Stroke of the piston rod ......................................................... 57.15 mm (2.25 in)

8001-56
A. Lubricate and torque cylinder head 140- 160 Nm (1 03- 118 lb.ft)
B. Piston rod O.D. ...................................................................... 49.960 - 50.000 mm (1.967- 1.968 in)
D. Lubricate and torque piston rod locknut to ............................ 90- 100 Nm (66.4- 73.8 lb.ft)
E. Stroke of the piston rod ......................................................... 1219mm (48 in)
STEERING CYLINDER
A. Lubricate and torque cylinder head ..................................... 440- 542 Nm (325- 400 lb.ft)
B. Cylinder head rod bore I.D .................................................... 38.151 - 38.202 mm (1.502- 1.504 in)
C. *Cylinder head rod bushing bore I.D .................................... .44.4373- 44.4500mm (1.7495- 1.7500 in)
Bushing O.D ........................................................................... 44.4881-44.5389 mm (1.7515 -1.7535 in)
D. Bushing I.D ............................................................................. 38.2016 - 38.3032 mm (1.5040 - 1.5080 in)
Piston rod O.D ..................................................................... 38.024 - 38.100 mm (1.497 - 1.500 in)
E. Cylinder I.D ........................................................................... 63.627- 63.754 mm (2.505- 2.510 in)

Piston O.D. ........................................................................... 63.246 - 63.348 mm (2.490 - 2.494 in)
F. Lubricate and torque the piston rod locknut to ....................... 339 - 407 Nm (250 - 300 lb.ft)
G. Stroke of the piston rod ........................................................... 266.7 mm (1 0.5 in)
*SERVICE NOTE: Press bushing into head flush with face of head.

8001-57
0 c B A
ARTICULATION CYLINDER
A. Lubricate and torque cylinder head .................................... 784 - 863 Nm (578 - 636 lb.ft)
B. Cylinder head rod bore I.D .................................................... 45.120-45.160 mm (1.776- 1.778 inO
C. Cylinder I.D ............................................................................ 80.000-80.064 mm (3.149- 3.152 in)
E. Stroke of the piston rod ......................................................... 377 mm (14.8in)
A B c
D
SCARIFIER CYLINDER
A. Lubricate and torque cylinder head ..................................... 1898 - 2034 Nm (1400 - 1500 lb.ft)
B. Cylinder head rod bore I.D .................................................... 50.851 - 50.902 mm (2.002- 2.004 in)
C. Cylinder I. D. .......................................................................... 101.727- 101.854 mm (4.005- 4.010 in)

Piston O.D. ............................................................................ 101.295 - 101.397 mm (3.988 - 3.992 in)
D. Lubricate and torque piston rod locknut to ............................ 1152 - 1288 Nm (850 - 950 lb.ft)

8001-58
B c D
RIPPER CYLINDER
A. Torque cylinder head capscrews to .................................... 216 -235 Nm (159.3- 173.3 lb.ft)
B. Cylinder head rod bore I.D ................................................... 60.800 - 61.000 mm (2.394 - 2.402 in)
Piston rod O.D. .................................................................... 59.960- 60.000 (2.361 - 2.362 in)
C. Cylinder I.D .......................................................................... 120.120- 120.260 mm (4.729- 4.735 in)

Piston O.D. .......................................................................... 117.950 - 118.090 mm (4.644 - 4.649 in)
D. Lubricate and torque piston rod locknut to ............................ 2196 - 2393 Nm (1620 - 1765 lb.ft)

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

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

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.

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.

Section
9008
FRAME, ARTICULATION JOINT

CIRCLE AND SCARIFIER

TABLE OF CONTENTS
Articulations joint .......................................................................................................................... 01

Circle removal ....................................................................................................................................... 03
Saddle removal ...................................................................................................................... ................ 06
Frame specifications .............................................................................................................................. 12
Articulation joint specifications ...................................................................................................... 13
Drawbar and circle turn specifications .......................................................................................... 14
Moldboard control ........................................................................................................................... 15

9008-01
ARTICULATION JOINT
The hitch used consists of tapered roller bearings. The
hitch allows a total of 50 degrees articulation.
Support the two main frames on jack stands during.

rebuild.
A WARNING
Do not work under or near unblocked or un-

supported linkage, parts or machine
Clean bearing bores.
A wARNING
Never use gasoline solvent or other flammable
fluids to clean element. Use authorized com-
mercial, non-flamable, non-toxic solvents.
Measure the bearing height of the outer races plus the

height of the spacer. Record these dimmensions. Keep
the bearing pieces matched. Repeat the measurement
for the other bearing.

9008-02
Measure the thickness of frame boss at the bore.

Record these dimensions and repeat the measuring pro-
cess at the other frame boss. Select shims to build the
provided.
Use driver P/N 75300850 to install the bearing cup into

the frame bore. Install the bearing retainer in place.
A WARNING
It is unsafe to strike hardened steel parts with
anything other than a soft iron or non-ferrous
hammer. When installing or removing such parts
wear safety glasses with side shields and heavy
gloves, etc, to reduce the possibility of injury.
Install the bearing into the bore. Prior to installing the

bearing retainers onto the frame, install the seal into the
retainer. Clean the joining surfaces of the seal and
retainer with P/N 75000782. Apply sealant P/N
75000778 on the retainer. Press seal into retainer. Do
not get sealant on sealing surface.
Position rear frame around the front frame.

Level the two frames prior to installation. Install pins.
Install bushing and inner on bottom hitch pin.
Install plates and tighten capscrews to specification
A wARNING
or proper capacity. Be sure parts are supported

9008-03
CIRCLE REMOVAL
Lower moldboard so that the blade is on the ground.
Turn off the electrical master switch.
WARNING
Always turn the master switch to the off position

before cleaning, repairing, servicing or parking
the machine to prevent injury.
Disconnect the right and left moldboard lift cylinders at

the lower trunnion ball joint. Keep shims in position.
Disconnect the moldboard shift cylinder at the trunnion

ball on the circle. Keep shims in position.
Disconnect hoses at front of circle frame.

9008-04
Remove capscrews connecting ball housing to the

tractor frame.
Installation is the reverse of removal with the exception

of measuring shim pack gap on the cylinders.
Measure the gap between
the ball and socket with the capscrews tightened to final
torque. Add the specified dimension.
If the circle guides or wear plates have to be replaced

place the moldboard upon the ground. Turn off electrical
master switch.
A WARNING

Remove bolts holding guides in position.

9008-05
Install new wear surfaces
Install shims; guide and bolts.
Measure gap between wear plate and frame. Make a

shim pack equal to the gap plus the specified dimension
The guides must be adjusted see section for

procedure and specifications.

9008-06
CIRCLE REMOVAL
Lower moldboard so that the blade is on the ground.
Turn off the electrical master switch.
A WARNING
.. W~No.JG
Remove the lower saddle plate capscrews and the

plate.
Disconnect light wires.
Disconnect the moldboard lift cylinders at the yoke.

9008-07
Disconnect the moldboard shift cylinder where it con-

nects to the saddle as well as the hose bracket.
Disconnect saddle lock cylinder hydraulic tubing.
Support the saddle and remove the capscrews securing

the back plate to the saddle. Lift saddle from the grader
frame.
A WARNING
Remove capscrews holding saddle support to the frame.

Keep shims in position.
A WARNING

9008-08
DISASSEMBLY OF CIRCLE TURN GEARBOX

Remove the cover.
Drain the assembly
Remove washer(2) and shims(A).Keep in relative

position.
Remove the outer cover.

9008-09
Remove circle turn motor.
Remove circle turn cover. Keep shims (B) in position.
Remove worm gear assembly (3)
Remove snap ring

9008-10
Force shaft assembly from the housing.
Press the bushing from the cover
Remove worm and bearing.
Inspect the roller bearings; if necessary, replace

9008-11
Check worm rolling torque.
The shaft assembly must have an end play.

9008-12
FRAME
A 8 c
Torques Nm Ft.lbs
A ..................................................... 88 - 96 ........................ 65 - 71
B ..................................................... 88 - 96 ........................ 65 - 71
c ... .................................................. 38 - 42 ........................ 28 - 31
D ... ... .... .... ..... .... .... ..... .... .... .... ..... .... 38 - 42 . ..... .... .... .... ..... . 28 - 31
E ..................................................... 304 - 332 ........................ 224 - 245
F ..................................................... 88 - 96 ......................... 65 - 71
9008-13
ARTICULATION JOINT
A Pin 0.0 ...................................... 66.7133- 66.725 mm (2.626-2.627 in)

Bearing cone I. D..................... 66.675 - 66.888 mm (2.625-2.626 in)
B Articulation support I. D............... 66.7133 - 66.725 mm (2.626-2.627 in)
Bearing cup 0.0 ....................... 66.675 - 66.888 mm (2.625-2.626 in)
C Torque capscrews ...................... 135- 157 Nm (100-116 ft.lbs)
D Torque capscrews ...................... 123 - 135 Nm (90-1 00 ft.lbs)
E Pin 0.0 ....................................... 66.7133- 66.725 mm (2.626-2.627 in)
Bushing 1.0 ................................. 66.890 - 67.160 (2.633-2.644 in)
F Pin 0.0 ...................................... 66.713 - 66.725 mm (2.626-2.627 in)
Bearing cone 1.0 ........................ 66.6753 - 66.725 mm (2.626-2.627 in)
G Pin 0.0 ....................................... 66.7133 - 66.725 mm (2.626-2.627 in)
Bearing cone 1.0 ........................ 66.7133 - 66.725 mm (2.626-2.627 in)
H Pin 0.0 ....................................... 66.7133- 66.725 mm (2.626-2.627 in)
Bushing 1.0 ................................ 66.8909 - 67.160 (2.633-2.644 in)
I Torque capscrews ...................... 66.7133 - 66.725 mm (2.626-2.627 in)
J Torque capscrews ....................... 66.7133- 66.725 mm (2.626-2.627 in)
K Pin 0.0 ........................................ 66.7133 - 66.725 mm (2.626-2.627 in)
ENG-6-47001 Issued 1-03 Printed in Brazil

9008-14
DRAWBAR & CIRCLE
H G
DRAWBAR AND CIRCLE TURN

Adjust shims (A) to provide 1.5 mm (0.06 in.) vertical clearance between wear plates and circle guide.
With circle against front circle guide adjust capscrews(B) to provide 8-15 mm (0.03 - 0.06 in) clearance
between the circle and each circle guide. Torque capscrews (B) to 1080 Nm (800 ft.lbs)
Adjust rear guides (C) to provide 0.7mm (0.03 in) maximum horizontal clearance the circle and each
rear guide.
Torque capscrews (D) to 1080 Nm (800 ft.lbs).
NOTE: Rotate circle 360° to check free clearance.
Torque capscrews (E) to 122 - 136 Nm (90 - 100 ft.lbs)

Torque capscrews (F) to 570 - 585 Nm (420 - 430 ft.lbs)
Adjust shims (G) to provide 0.00 - 0.25 mm 0.000 - 0.010 in) end play between ball and socket.
Torque nut (H) to 810 Nm (600 ft.lbs).
NOTE: Do not apply lubricant to circle guide shoe liners or wear surface of circle.
Torque capscrews (I) to 245 - 325 Nm (180 - 240 ft.lbs)

9008-15
MOLDBOARD CONTROL
A. Shim to provide 0.000 - 1.207 mm (0.000 - 0.005 in) loose ball

Torques Nm Ft.lbs.
B......................... 400 - 450 ..................... 300 - 333
c......................... 230- 255 ..................... 170- 187
D......................... 310- 340 ..................... 230- 250
H......................... 47 - 53 ......................... 35 - 39
E. Apply a ligth coat of Molykote "G" lubricant paste to surfaces indicated.
Dimensions mm inch
F. Pin O.D ....................................... 47.752 - 47.803 ........... 1.880 - 1.882
Trunnion bushing O.D ................ 47.904 - 47.995 ........... 1.886 - 1.888
G. Trunnion bushing O.D ................ 37.993 - 38.040 ........... 1.496 - 1.498
Trunnion bushing O.D ................ 37.846 - 37.871 ............ 1.490 - 1.491
I. With the grader on flat ground, measure the vertical distance from the ground
to the center of the left and right lift cylinder trunion yoke. For every 13 mm (0,5 inch)
Difference betwwen the two dimensions, add two shims to the side with the
lowest pivot. Do not add more than fours shims.
9008-16
MOLDBOARD CONTROL
A. *Journal bore I.D ............................. 82.559- 82.575 mm (3.250- 3.251 in)

Journal bore O.D ........................... 82.559 - 82.575 mm (3.250 - 3.251 in)
Journal bore I.D ............................. 76.302 - 76.752 mm (3.004 - 3.006 in)
Journal bore O.D ............................ 76.175 - 76.200 mm (2.999 - 3.000 in)
*SERVICE NOTE:
1. Install inside bearing flush to 0.77 mm (0.03 in) below face of counterbore.
2. Install outside bearing to 10.2 mm (0.40 in) inside journal bore.
B. Lubricate seals with Case molydisufide grease
C. Install shims to obtain 0.025 - 0.076 mm (0.001 - 0.003) end play.
D. Torque capscrews to .......................... 120 - 136 Nm (90 - 100 ft.lbs)
E. Torque capscrews to .......................... 940 - 1040 Nm (700 - 770 ft.lbs)
F. Use shims to provide .......................... 0.000 - 0.127mm (0.0000 - 0.005 in) clearance
between saddle support and sadie assembly.

9008-17
CIRCLE TURN ASSEMBLY
A. Install shims as needed to obtain 0.0 - 3.3 mm (0.00 - 0.13 in) end shake. Do not preload.
B. With worm gear tremoved , install shims to obtain 9.3 - 9.7 Nm (6.9 - 7 ft.lbs) of rolling torque
upon the bearings.
Torque Nm ft.lbs
1. One place ......................................... 120 - 137 90 - 100

five places ...................................... .. . 155 - 176 115 - 130
2. ............................................................. 47- 54 35- 40
3. ............................................................. 474 - 508 350 - 375
e
9008-18
NOTES
Bur 6-47001 Revised 5-03 Printed in Brazil

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
TABLE OF CONTENTS
CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01
INSTALLATION OF THE CLOSED AND OPEN CABS .................................................... 03
REMOVAL OF THE CAB .................................................................... 08
9010-01
TYPES OF CAB
* FOPS and ROPS closed cab.

* FOPS and ROPS open cab.
CHARACTERISTICS
* The closed cab has laminated safety glass for the windshield and the other glass is tempered. The
interior is lined with vinyl, has a bottle holder, catalogue holder, lunch box, air diffusers, windshield wipers,
front and rear washer, 2 (two) general and directional lamps, floor mat, thermal and acoustical insulation, flexible
antenna for radio receiver, and loudspeakers. Mounting for: radio, air-conditioning with heater and blower fan
*The open cab has laminated safety glass for the windshield and the rear glass is tempered; 1 (one) general
and directional lamp, windshield wiper and washer.

9010-02
Side view of the open cab.
Front view of the closed cab.
Rear view of the closed cab.
Side view of the closed cab
ENG 6-47031 June,2003 Printed in Brazil

9010-03
INSTALLATION OF THE CLOSED

AND OPEN CABS
Hoist the cab with the proper lifting devices.
After lifting the cab, put the rubber seats on the

contact surfaces of the cabin. Use Supercraft Threebond
glue.

9010-04
Release the support plate of the tension regulator
Disconnect the analogical instrument panel.
Remove the analogic support box.
Remove the vinyl covering lining of the central colums.
IMPORTANT: You must do this during the mounting

to avoid damage to the air conditioning.
This operation is required only on closed cabs.

9010-05
Remove the plastic base of the central columns. This
operation is required for closed cabs only.
Remove the disconnect switch box.
Mount the lateral panels and the access cover of the

tie beams. This operation is required for closed cabs
only.
Tilt the pedestal fully backwards and the seat back

fully forward. This operation makes it easy to lower
the cab on the machine structure.

9010-06
Carefully lower the cab; pay attention to the electric
cables and directional tube of the air conditioning.
Remove the access ladder on both sides.
Remove the lower protections from both sides.
With the help of a lever, align the holes between the

cabin and the floor.
ATTENTION: The use of SAE Grade 8

bats is required use new selft- locking nuts each time
They are removed.

9010-07
INSTALLATION OF THE CLOSED
AND OPEN CABS
Hoist the cab with the proper lifting devices.
After lifting the cab, put the rubber seats on the

contact surfaces of the cabin. Use Supercraft Threebond
glue.
Mounted cab.
Check the water level tank daily.

(390 to 485 ft.lbs)torque.

9010-08
NOTES
Bur 6-47031 Revised 6-03 Printed in Brazil

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

TABLE OF CONTENTS
DISMOUNTING OF THE CAB .......................................................................... 01
9011-01
WINDSHIELD TOP
(/)
0:::
L.LJ
~?
Ll)
-5
0:: Ll)
::J cxi
t; co
II
* Material: laminated safety glass, thickness: 6.73 to 0::
I)
7.14 mm (optional 6.35), with interpolated 0.76mm 0
..... (.!) co
co
M
..... g ""'""'
.....
* It must comply to the requirements of the:

ANSI Z 26.1 - Category AS-1, item 2, section 4 E.C.E
regulation # 43 (annex 6),
E.E.G Director Counsel 92/22/EEC, ANNEX II, section
B. '
962
* The glass must have a mark according to the ANSI
Z 26.1, E.C.E regulation # 43;
E.C.E Director Counsel 92/22;
Border finishing according to SAE J673.
WINSDSHIELD- LOWER LEFT

557 5
~~(~
* Material: laminated safety glass, thickness: 6.73 to
7.14 mm (optional 6,35),with interpolated 0.76mm
plastic. 1.0
Lri
-.:1'
~!
1.0

ANSI Z 26.1 - Category AS-1, item 2, section 4;
E.C.E regulation # 43 (annex 6),
\. /
B. ~~ / 246
1 294.5
z 26.1; . 532
•
E.C.E regulation # 43;
E.C.E Director Counsel 92/22; FMVSS # 205;

WINSDSHIELD- LOWER RIGHT
9011-02
* Material: laminated safety glass, thickness: 6.73 to
557 5
7.14 mm (optional 6.35), with interpolated 0.76mm
plastic.
~
~,,
* It
ANSI
must comply to the requirements of the:
Z 26.1 - Category AS-1. item 2, section 4;
~
L~
t1: I"
E.E.G Director Counsel 92/22/EEC, ANNEX II, section M
I"
B.
* The glass must have a mark according to the ANSI ~ /
z 26.1;
E.C.E Director Counsel 92/22;
246 \ ~~
294.5 1

. 532
•
WINSDSHIELD- CAB SIDE
* Material: tempered safety glass, thickness 5.55

(optional 6mm). /
H.
z 26.1;
532

WINDOW- CAB SIDE
9011-03
~
(optional 6 mm).

ANSI
E.C.E
Z 26.1 - Category AS-2, item 2, section 4;
regulation # 43 (annex 5),
& ~
~
H. ....
~
z 26.1;
532
WINDOW- CAB DOOR

(optional 6 mm).

H.
z 26.1;

WINDOW- CAB DOOR
9011-04
(optional 6 mm).

H.
z 26.1;
WINDOW- REAR

(optional 6 mm).
~?
I!
"'
.c.
ANSI Z 26.1 - Category AS-2, item 2, section 4; "'
00
00
II
0::
E.E.G Director Counsel 92/22/EEC, ANNEX II, section r--
H. ""'
N
~
co
,....
N
~0
z'-'
"'o
::;;_,
z 26.1;
895
-

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r----------------------1 r----------------------1

SERVICE MANUAL SERVICE MANUAL

1. Trim along dashed line. b 1. Trim along dashed line. b

1. Trim along dashed line. b 1. Trim along dashed line. b

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

845 - 865 - 885 Grader