Documente Academic
Documente Profesional
Documente Cultură
845 845
865 865
885 885
6-46503 6-46503
--------------------~ --------------------~
r----------------------1 r----------------------1
SERVICE MANUAL SERVICE MANUAL
Grader Grader
845 845
865 865
885 885
6-46503 6-46503
--------------------~ --------------------~
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
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
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
GENERAL
SPECIAL TOOLS
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
TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE ......................................................................................... 3
Pound- Newton
Size Feet metres
1/2-13 55 to 65 74 to 88
5/8-11 140 to 150 190 to 203
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
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)
Grease Fitting
Rear Ripper / Front Scarifier and UQN UQN CASE MOLYDISULFIDE GREASE
Dozer Blade
865 GRADER
FLUIDS AND LUBRICANTS
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) 21.1 5.5 SAE15W-40 API CH4
(Without Filter Change) 18.9 4.8 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)
Grease Fitting
Rear Ripper / Front Scarifier and UQN UQN CASE MOLYDISULFIDE GREASE
Dozer Blade
885 GRADER
FLUIDS AND LUBRICANTS
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) 21.1 5.5 SAE15W-40 API CH4
(Without Filter Change) 18.9 4.8 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
28.5 7.5 HY-TRAN ULTRA
Refill capacity (with filter change) MAT 3505 (MS 1209)
Refill capacity (without filter change) 22.0 5.8
Rear Axle Clark Model
Center Compartment 12.0 3.2 HY-TRAN ULTRA
Planetary Hubs (Each) 6.0 1.6 MAT 3505 (MS 1209)
Tandem Drive Case
SAE 80W-90 135H EP API GL5
Refill capacity (each)
22.5 5.9
Circle Turn Gear
Refill Capacity 2.8 0.75
SAE 80W-90 135H EP API GL5
Grease Fitting
Rear Ripper / Front Scarifier and UQN UQN CASE MOLYDISULFIDE GREASE
Dozer Blade
1002-6
BS99M162
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
NOTE: See “FLUIDS AND LUBRICANTS” table on previous pages for lubricants and fluids detailed
specifications and capacities.
NOTE 1: Service the air filter elements if air filter restriction indicator is in the red area.
NOTE 2: Service the hydraulic filters if hydraulic filter indicator lamp iluminates.
NOTE 3: Check the radiator coolant level if the coolant level warning lamp iluminates.
NOTE 4: Change the rear axle oil after the first100 hours of operation.
NOTE 5: Change the transmission oil and replace the filter after the first100 hours of operation.
NOTE 6: Contact your dealer and see the service manual.
NOTE 7: Change every 2.000 hours or once a year, whichever comes first.
«: As needed
ENG 6-46541 Issued 01-03 Printed in Brazil
1002-10
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
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
NOTES
TABLE OF CONTENTS
CONVERSION FACTORS ............................................................................................................................................. 3
Metric to U.S. .......................................................................................................................................................... 3
U.S. to Metric ......................................................................................................................................................... 4
CONVERSION FACTORS
Metric to U.S.
MULTIPLY BY TO OBTAIN
U.S. to Metric
MULTIPLY BY TO OBTAIN
* = exact
1005
1005
SERVICE TOOLS
TABLE OF CONTENTS
Service tools ........................................................................................................................ 3
ENG 6-75330
Service Tools
380000512
Ordering Info: 38040085 Pressure Test Fitting Kit and Hose Assembly
Dealer Standard: Code A (required at all servicing locations)
ENG 6-75330
Service Tools
ENG 6-75330
Service Tools
ENGINES
845
P.I.N. HBZ020101 AND AFTER
865
P.I.N. HBZ022101 AND AFTER
885
P.I.N. HBZ024101 AND AFTER
TABLE OF CONTENTS
Specifications.................................................................................3
Specifications
MAKE/MODEL: DENSO
CORE SIZE 27.6 High x 8.3 wide x 5.7 (700 x 211.2 x 144 )
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.
2 - Fit hose (4) to tube (5). Then fit clamps (3) in place
and fit tube (7).
Adjust clamps until the clamp springs are fully
compressed.
4 - Fit clamp (d) in place and torque bolts (C) to 2,8 kgf.
FUEL SYSTEM
ELECTRICAL
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
ALTERNATOR 45A
Removal Installation
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
Removal Installation
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
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
PAGE 01
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LIGHTS
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DASH LIGHT ENGINE COOLANT TRANSMISSION OIL
TEMP. SENSOR TEMPERATURE SENSOR
1 2 3 4 5 6
CASE PAGE 07
BAT ~IF~B______________E_L_EC_T_R_O_NI_C_D_A_T_A_M_O_N_IT_O_R______________________~~
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CASE PAGE 08
DIFFERENTIAL
LOCK RELAY -OPC. STARDING AID SADDLE LOCK
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HOUR METER
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2 3 4 5 6
PAGE10
ACC 12 FL ll.l
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CASE PAGE11
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CASE
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CASE PAGE 20
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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"_..
2 l.-r'ZI.O I
POSITION • ON I
K ECU
K IP
ELECTRONIC UNIT TRANSMISSION FUNK
18-2
18-1 H21
'+A H22
'\/CONNECTOR I
K TVP
K G2
K FWD
KIS
AUXILIARY MAGNETIC SW. TO ENGINE SHUTT-OFF
17-~
a-s
CO.PONENT
CONNECTOR
Pr /
IEB
NBI.O
. /UNION
~o:.::.L_____,.,./
2
TO PAGE 16 1
/ -...~COORDINATE 3l
K Cl
KR
CONVERTER VOLTAGE TO RADIO AND CIGARRETH
LIGHTER 24/12 VOLTS MAX. 10,0 AMP
RADIO
19-2
19-4
,
( FL16-3) __ I
SPI SPEAKER L.H. 19-4
I POSITION I I
SP2 SPEAKER R.H. 19-4 LIGHTS , I
ANTENNA RADIO 19-~
AT
I I' I
l<DI DERIVAriON BOX (NEAR ENGINE) 1-3
'
I I 5 I
_ _j
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
CASE PAGE 24
Fll Fll FlO Fl n
it F~
F9 F7 Fl F4 Fl Fl
......
n ~p
BOX l
t:J ~ [iJ 0 0 0 ¢.:>
f E.O.M -,y;-
<D &
15..~
,en AM AMP
7.5 AMP.
10.0 AMP
10.0
AMP.
10.0 AMP.
10.0 AMP.
FU{¢)
10.0 AMP.
t
3.0 15.0 7.5 7.5 15.0 7.5
AMP. AMP. AMP. AMP.
10.0
AMP.
AMP.
Fl4
7.5
AMP.
§0 m~
75AMP.
,,. FH Fll
eUN ~ '~ir:J ¢ ¢ ¢
F2& F24 F23 F22 F20 Fl9 Fl8 Fl7
f!!J ~
7.5 7,5 15.0 3,0 3.0 3,0 3.0 10.0 3.0 10.0 10.0 20,0
AMP. ANP. AMP. AMP. AMP. AMP. AMP. AMP. AMP. AMP. AMP. AMP.
F31
}J\_ 7.5 AMP, F3~ 7.5
AMP.
no~ 10.0
AMP.
Fll 0)
At,,
J5
AMP.
12V 12V
/
:Qj))) @~ @ (l (l (£) R
K8 K9 K 10 K 11 K 12 K 13 K 14
~ ([J= =o v @ ® ® ~
K7 K6 K5 K4 K3 K2 K1
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
4003
BATTERIES
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
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
MAINTENANCE
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.
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.
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
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.
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.
6 Hours at 40 Amperes
Above 250 Minutes 24 Hours at 10 Amperes
4 Hours at 60 Amperes
ALTERNATOR - 45 AMPERE
4008
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
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)
ALTERNATOR
Disassembly STEP 3
STEP 1
B523411M
STEP 2
B523413M
B523405M STEP 5
Hit the face of the pulley softly with a hammer to
loosen the retainer in the pulley.
B8971201M
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
STEP 11
B8971210M
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.
B8971310M B8971319M
Remove the insulator from the B+ terminal. Remove the shield from the housing.
STEP 19
B8971313M
STEP 21
B9064418M
STEP 22
B9064421M
STEP 25
B9064414M
STEP 26
B9064433M
STEP 27
B9064436M
STEP 31
B9064502M
B9064319M
STEP 32
B9064424M
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.
B9064402M
STEP 37
B8971426M
B8971429M
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
B8971435M
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
Assembly STEP 42
STEP 39
B8971601M
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.
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.
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
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.
STEERING
NOTES
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
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
! WARNING
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.
!
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.
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.
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
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.
STEP 21
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.
! WARNING
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.
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.
DIMENSIONS
ITEM NAME mm in
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.
DIMENSION
ITEM NAME mm in
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.
ITEM NAME mm in
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.
NOTES
5003
STEERING CONTROL VALVE
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIFICATIONS
Manufacturer ..................................................................................................................................................... Eaton
Special Torques
Cap screws for end cap ............................................................................................... 31 NM (275 pound-inches)
SPECIAL TOOLS
Spring installation............................................................................................................. Eaton part number 600057
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
1
GS98K501
Figure 4 Figure 6
15. Push spool back through and out of sleeve, see Fig. 6
Rotate spool slowly when removing from sleeve.
Figure 5
Figure 7
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).
3
4
6
1
5
2
3
GS98K530
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.
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
FIGURE 12
Figure 14
FIGURE 15
9. Place housing on clean, lint free cloth. Install
seal in housing, see Fig. 14.
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.
FIGURE 16
FIGURE 17
FIGURE 19
FIGURE 22
FIGURE 20
21. Install drive spacer when used, in meter
19. Install seal in meter. see Fig. 22
FIGURE 23
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.
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.
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.
6. Erratic steering. Air in system due to low level of Correct condition and add fluid.
oil, cavitating pump, leaky fitting,
pinched hose, etc.
7. “Spongy ”or soft steering. 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.
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.
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.
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.
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.
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.
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.
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).
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.
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
POWER TRAIN
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)
ENG 6-46751
May, 2003 Printed in Brazil
6002-5
14------l K l----t.-t
~---{ L>-----t~
Midship
Remote
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)
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"
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
NOMINAL 24V
VOLTAGE
ALLOWABLE 20-28V
VOLTAGE
CURRENT .6 AMP
DRAW NOMINAL
CURRENT .7 AMPS
DRAW MAX.
RESISTANCE 53 OHMS
±3%
TEST SOLENOIDS
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.
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
1st Gear - 1A, 2nd Gear - 2A 3rd Gear - 1C, 4th Gear - 2C
5th Gear - 18, 6th Gear - 28 7th Gear - 1D, 8th Gear - 20
R1 Gear- 3A R2 Gear- 3C
R3 Gear- 38 R4 Gear- 3D
Erratic oil pressure. Low oil level. Add oil to proper level.
Foreign object in suction port. Remove object and check for other
contamination.
Excessive oil pressure. Sticking main regulator valve. Replace main regulator valve.
Low oil pressure in all gears. Sticking main regulator valve. Replace main regulator valve.
Low pressure in one gear but all Contaminated proportional solenoid. Replace proportional solenoid.
right in other gears. *Check suction screen for
contamination.
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.
Filter or filter oil lines blow out. Hose bends too sharp. Reroute hoses.
Main regulator valve faulty. Change valve and change filter and
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.
Auxiliary driven pump bad. Remove pump and check for noise.
Machine "Creeps" In Neutral Warped disks and plates in clutch Check transmission
pack of transmission.
Transmission overheating. Oil level too high. Establish proper oil level. Check
front seal on auxiliary driven
hydraulic pump if equipped.
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.
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.
SPECIFICATIONS
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.)
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.
CALIBRATION
Reasons to Calibrate
• 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.
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.
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).
SYSTEM COMPONENTS
COMPONENT FUNCTIONS
Basic Components
FUNCTION
MOUNTING
CONNECTOR PINOUT
CONNECTOR PINOUT
CONNECTOR PINOUT
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
6. Temperature sensor
CONNECTOR PINOUT
8. Inching Pedal
CONNECTOR PINOUT
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.
I
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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.
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.
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)
J3 CONNECTOR
J4 CONNECTOR
J6 CONNECTOR
TCU
Jl-AZ
n-B:!
13-Al
JI-AI
AB 0 DE F
H-Fl
JHll
12-m
TCU
J2-A2
12·AI
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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
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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.
Wiring harness is + 24Volts grader 845 I 865
TCU
No Usedn-m
No UsedlHn ~=::§:
==~~
13-H S!9
H-Kl Ot.f'll'VTS
13-Jl ----3E
13-J:!: ~----~~~~~~---------------3F
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J2-AJ E
JZ-!H c r:ro
J!-13 D INPUTS
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MPU MPll
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.
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
SOLENOID 2 RETURN J6-15 J3-B3
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 J6-5 J3-C3
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.
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.
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
Diagnostic Code: 21 current.
Description: Solenoid 2 cannot get up to requested Probable Cause: Open or short to ground in
current. Solenoid C circuit from output pin J3-E3 to return pin
J3-F1.
Probable Cause: Open or short to ground in
Solenoid 2 circuit from output pin J3-B2 to return pin Diagnostic Code: 27
J3-B3.
Description: Solenoid D cannot get up to requested
Diagnostic Code: 22 current.
Description: Solenoid 3 cannot get up to requested Probable Cause: Open or short to ground in
current. Solenoid D circuit from output pin J3-F2 to return pin
J3-F3.
Probable Cause: Open or short to ground in
Solenoid 3 circuit from output pin J3-C1 to return pin Diagnostic Code: 28
J3-C2.
Description: Solenoid E cannot get up to requested
Diagnostic Code: 23 current.
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.
Diagnostic Code: 24
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.
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.
1. NOT PARK active and PARK passive.
Legal conditions are:
2. NOT PARK passive and PARK active.
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.
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.
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
Probable Cause: CARRIER CAB and UPPER CAB Diagnostic Code: 104
inputs are simultaneously active at TCU.
Probable Cause: No cylinder speed detected during
Diagnostic Code: 94 calibration.
Probable Cause: CARRIER CAB and UPPER CAB Diagnostic Code: 105
inputs are simultaneously passive at TCU.
Probable Cause: Incorrect forward cylinder speed
Diagnostic Code: 95 ratio during calibration.
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
Diagnostic Code: 108 Error: Clutch B fast fill time exceeds 300 ms.
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.
Error: Clutch 2 fast fill time exceeds 300 ms. Diagnostic Code: 117
Error: Clutch 3 fast fill time exceeds 300 ms. Diagnostic Code: 118
Diagnostic Code: 112 Error: Clutch R fast fill time exceeds 300 ms.
Error: Clutch 4 fast fill time exceeds 300 ms. Diagnostic Code: 119
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.
Diagnostic Code: 127 Probable Cause: Engine MPU circuit (J1-B1) open.
Probable Cause: Low air pressure. Probable Cause: Cannot get shift constants from
EEPROM.
Diagnostic Code: 145
Diagnostic Code: 161
Probable Cause: Analog inching voltage is too low.
Probable Cause: Group one enable low should be
Diagnostic Code: 146 high.
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.
Diagnostic Code: 168
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.
Diagnostic Code: 170
Probable Cause: Open or short to ground in circuit
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.
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
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.
885 Grader
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)
ENG 6-75350
May, 2003 Printed in Brazil
6002-5
II
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Midship
Remote
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)
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"
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
NOMINAL 24V
VOLTAGE
ALLOWABLE 20-28V
VOLTAGE
CURRENT .6 AMP
DRAW NOMINAL
CURRENT .7 AMPS
DRAW MAX.
RESISTANCE 53 OHMS
±3%
TEST SOLENOIDS
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.
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
1st Gear - 1A, 2nd Gear - 2A 3rd Gear - 1C, 4th Gear - 2C
5th Gear - 18, 6th Gear - 28 7th Gear - 1D, 8th Gear - 20
R1 Gear- 3A R2 Gear- 3C
R3 Gear- 38 R4 Gear- 3D
Erratic oil pressure. Low oil level. Add oil to proper level.
Foreign object in suction port. Remove object and check for other
contamination.
Excessive oil pressure. Sticking main regulator valve. Replace main regulator valve.
Low oil pressure in all gears. Sticking main regulator valve. Replace main regulator valve.
Low pressure in one gear but all Contaminated proportional solenoid. Replace proportional solenoid.
right in other gears. *Check suction screen for
contamination.
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.
Filter or filter oil lines blow out. Hose bends too sharp. Reroute hoses.
Main regulator valve faulty. Change valve and change filter and
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.
Auxiliary driven pump bad. Remove pump and check for noise.
Machine "Creeps" In Neutral Warped disks and plates in clutch Check transmission
pack of transmission.
Transmission overheating. Oil level too high. Establish proper oil level. Check
front seal on auxiliary driven
hydraulic pump if equipped.
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.
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.
SPECIFICATIONS
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.)
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.
CALIBRATION
Reasons to Calibrate
• 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.
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.
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).
SYSTEM COMPONENTS
COMPONENT FUNCTIONS
Basic Components
FUNCTION
MOUNTING
CONNECTOR PINOUT
CONNECTOR PINOUT
CONNECTOR PINOUT
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
6. Temperature sensor
CONNECTOR PINOUT
8. Inching Pedal
CONNECTOR PINOUT
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.
I
I
I
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: 111111111111
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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.
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.
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)
J3 CONNECTOR
J4 CONNECTOR
J6 CONNECTOR
TCU
Jl-AZ
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B-BJ 15
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B.C2 19
B-CJ j
B-DI 6
B-D2 10
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J3-F2 8 Vol
Vol
J3-F3
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J2-B3 21
20
Jl-Bl 29
Jl-C2 28
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Jl,.(i3 1.6
J!-H! 31
J!-CJ 25
TEMP SENSOR GND
J!-DI 24
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NOTE: The letter C links to the next page.
Wiring harness is + 24Volts grader 885
TCU
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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.
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
SOLENOID 2 RETURN J6-15 J3-B3
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 J6-5 J3-C3
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.
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.
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
Diagnostic Code: 21 current.
Description: Solenoid 2 cannot get up to requested Probable Cause: Open or short to ground in
current. Solenoid C circuit from output pin J3-E3 to return pin
J3-F1.
Probable Cause: Open or short to ground in
Solenoid 2 circuit from output pin J3-B2 to return pin Diagnostic Code: 27
J3-B3.
Description: Solenoid D cannot get up to requested
Diagnostic Code: 22 current.
Description: Solenoid 3 cannot get up to requested Probable Cause: Open or short to ground in
current. Solenoid D circuit from output pin J3-F2 to return pin
J3-F3.
Probable Cause: Open or short to ground in
Solenoid 3 circuit from output pin J3-C1 to return pin Diagnostic Code: 28
J3-C2.
Description: Solenoid E cannot get up to requested
Diagnostic Code: 23 current.
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.
Diagnostic Code: 24
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.
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.
1. NOT PARK active and PARK passive.
Legal conditions are:
2. NOT PARK passive and PARK active.
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.
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.
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
Probable Cause: CARRIER CAB and UPPER CAB Diagnostic Code: 104
inputs are simultaneously active at TCU.
Probable Cause: No cylinder speed detected during
Diagnostic Code: 94 calibration.
Probable Cause: CARRIER CAB and UPPER CAB Diagnostic Code: 105
inputs are simultaneously passive at TCU.
Probable Cause: Incorrect forward cylinder speed
Diagnostic Code: 95 ratio during calibration.
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
Diagnostic Code: 108 Error: Clutch B fast fill time exceeds 300 ms.
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.
Error: Clutch 2 fast fill time exceeds 300 ms. Diagnostic Code: 117
Error: Clutch 3 fast fill time exceeds 300 ms. Diagnostic Code: 118
Diagnostic Code: 112 Error: Clutch R fast fill time exceeds 300 ms.
Error: Clutch 4 fast fill time exceeds 300 ms. Diagnostic Code: 119
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.
Diagnostic Code: 127 Probable Cause: Engine MPU circuit (J1-B1) open.
Probable Cause: Low air pressure. Probable Cause: Cannot get shift constants from
EEPROM.
Diagnostic Code: 145
Diagnostic Code: 161
Probable Cause: Analog inching voltage is too low.
Probable Cause: Group one enable low should be
Diagnostic Code: 146 high.
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.
Diagnostic Code: 168
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.
Diagnostic Code: 170
Probable Cause: Open or short to ground in circuit
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.
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
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.
TRANSMISSION
OTC Division
Sealed Power Corporation
655 Eisenhower Drive
Owatonna, Mn 55060
INSTALL:
INSTALL
INSTALL:
OTHER MATERIAL
SPECIFICATIONS
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).
OTHER MATERIAL
Grease 0-ring
SPECIFICATIONS
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.
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
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. Turn driven gear (B) over and press the new top
bearing with snap ring (D) onto gear.
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)
2. Discard 0-ring.
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
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.
'
------
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.
NOTE: There are two holes (H) in the retainer that are
oil passages, not attaching holes.
2. Lubricate with grease the seal area (B) and the shaft
splines (C).
OTHER MATERIAL
SPECIFICATIONS
~ 0
0
() 0
Oo
0 ,,
~
J
0
0
0 0 ~ 0
A assembly
CAUTION: Approximate weight of valve
is 25 Kg (55 lbs).
PROPORTIONAL SOLENOID
REMOVE PLUG
INSTALL PLUG
~ 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.
2. Place and fit new gasket (B) onto front housing using
guide pins (A) as holders.
3. Place plate (C) over the guide pins and onto gasket
(B).
4. Place new gasket (D) over guide pins onto plate (C).
A approximately
CAUTION: The valve assembly weighs
25 Kg (55 lbs).
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
• 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
OTHER MATERIAL
SPECIFICATIONS
OUTPUT YOKE
A-V-ring seal
B-Yoke
C-O-ring
D-Yoke washer
E-Cap screw
o t!,DE
0~"®
or;:o
((;
A approximately
CAUTION: The front housing assembly weighs
120 Kg (265 lbs).
A approximately
CAUTION: Front housing weight is
120 kg (265 lbs).
OTHER MATERIAL
SPECIFICATIONS
l
I
• Application dependent
A CAUTI~N:
snap rmg.
Wear eye protection when removing
• Application dependent
19. Lift out snap ring, retaining ring, and clutch return
springs.
A snap
CAUTI~N: Wear eye protection when installing
rmg.
• Application dependent
20. Place new bearing (B) on shaft, start bearing into the
clutch gear assembly.
• Application dependent
24. Press only on snap ring. Press until snap ring slips
into snap ring groove.
A approximately
CAUTION: Weight of stage assemblies
272 Kg (600 lbs).
1. Install output group (D) and oil trough (E) into main
case rear housing.
SPECIFICATIONS
REAR HOUSING
,,
10. Align bearing retainer bolt holes with bolt hole circle
in the rear housing.
SPECIFICATIONS
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).
15. Remove the brake disc (B) and yoke flange (C) as a
group.
16. Remove six hex nuts (A), six lock washers (B). and
six cap screws (C).
2. Install six cap screws (C), six lock washers (D), and
six Hex nuts (E).
NOTES
TRANSMISSION
885 Grader
OTC Division
Sealed Power Corporation
655 Eisenhower Drive
Owatonna, Mn 55060
A-Snap ring
B-Fiat washer
C-Magnetic pickup sensor
D-O-ring
OTHER MATERIAL
Name Use
SPECIFICATIONS
OTHER MATERIAL
Name Use
Grease 0-ring
SPECIFICATIONS
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.
YZ,CTM149,30,2 -19-04NOV98
A-Input housing
B-Ball bearing
A CAUTI~N:
snap rmgs.
Wear eye protection when installing
1. Lubricate 0-ring.
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.
OTHER MATERIAL
Name Use
SPECIFICATIONS
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
0
0
() 0
Oo
0
0
CJ
D
,,
~
~ 0
0
J
0 0
0 0 ~
0
0
00
A assembly
CAUTION: Approximate weight of valve
is 25 Kg (55 lbs).
PROPORTIONAL SOLENOID
REMOVE PLUG
INSTALL PLUG
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).
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.
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
• 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
OTHER MATERIAL
SPECIFICATIONS
A-V-ring seal
B-Yoke
C-O-ring
D-Yoke washer
E-Cap screw
YZ,CTM149,40,3 ·19·15JUN98
OTHER MATERIAL
Name Use
SPECIFICATIONS
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).
injury.
DISASSEMBLE FIRST STAGE ASSEMBLY NOTE: Press only on inner race of bearing.
1. Remove and discard Seal Ring (A). 1. Install new bearing (B).
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).
l
I
A snap
CAUTI~N: Wear eye protection when removing
rmg.
19. Lift out snap ring, retaining ring, and clutch return
springs.
23. Remove outer piston seal (A) and 0-ring (B) from
piston.
A snap
CAUTI~N: Wear eye protection when installing
rmg.
20. Place new bearing (B) on shaft, start bearing into the
gear and hub assembly.
24. Press only on snap ring. Press until snap ring slips
into snap ring groove.
A-Bearing cone (2 used) 8-Seventh stage output C-Oil Trough Assembly D-Cap Screw M8x12 8.8 (2
shaft gear assembly used)
1. Install output group (D) and oil trough (E) into main
case rear housing.
SPECIFICATIONS
~---
A-1/4 I.D. Hose C-Dipstick tube assembly D-Cap screw (2 used) E-Dipstick gasket
B-Dipstick
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).
,,
2. Install new bearing cup into rear housing 1/4 inch past
flush.
10. Align bearing retainer bolt holes with bolt hole circle
in the rear housing.
SPECIFICATIONS
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).
15. Remove the brake disc (B) and yoke flange (C) as a
group.
16. Remove six hex nuts (A), six lock washers (B). and
six cap screws (C).
2. Install six cap screws (C), six lock washers (D), and
six Hex nuts (E).
19. Install cap screw (C). Tighten cap screw to 215 N·m
(159 lb-ft).
REAR AXLE
WITH
DIFFERENTIAL LOCK
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
f'>.,_TIGHTEN TO
!)-"'z2-26 tt~f·ft
[30-35 H·m)
ENLARGED VIEW
SCALE 2 ' I
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
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.
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.
JJ7
15/", 12
16 13
4
5
12
14~~
~ 18
?r
16 15
51
01240102
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).
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).
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).
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).
STEP 26
STEP 25 Remove friction (70) and reaction (71) plates. Remove clutch driver (68).
STEP 29 Separate case halves (35). STEP 30 Remove standard side gear (39) and washer (38) from
cap half case (35).
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).
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.
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).
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.
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 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.
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.
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).
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).
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).
01240108
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
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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.
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.
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 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
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 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).
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.
STEP 147
Install plug (25) and screw it with a dynamometric
wrench set to 35-4 0 Nm (26- 30 lb. II).
LIMITED SLIP
REAR AXLE
6005
845 - 865 Grader
TABLE OF CONTENTS
M8
~
0
C)
~ I
I
I
15
TROUBLESHOOTING
▲ Oil leakage from final drive carrier ● Incorrect screw torque ■ Check the torque
O-Ring damaged Replace O-Ring
▲ Oil leakage from breather ● High oil level ■ Check oil level
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
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.
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.
,&. WARNING: Lift and handle each part by a lifting tool with proper capacity.
Make sure that groups or part are lifted by proper hooks.
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.
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
STEP 7
STEP 8
Remove the planetary gear.
STEP 9
Check needle bearings, pins, side gears
and if worn replace.
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.
~ 40 mm IMPORTANT
Elastic pin The elastic pin must be new
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.
STEP 15
Inspect bearing for wear and if necessary
remove and replace.
STEP 17
Position the reduction hub on a base of ~ 150 mm
(5.9"), the studs must not touch the surface.
STEP 18
STEP 19
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
STEP 22
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.
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.
Steel disc
Pressure plate
Central housing
Shims S
STEP 29
STEP 30
STEP 31
STEP 32
Measure thickness of four brake steel discs,
measurement "D".
STEP 33
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.
STEP 35
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".
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).
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.
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.
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.
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.
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.
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.
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).
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
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
STEP 70
STEP 71
Install the cone bearing heat at 80 ~ 90°C
176 ~ 194°F
STEP 72
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.
STEP 76
STEP 77
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.
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
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.
STEP 84
TANDEM DRIVE
LIMITED SLIP REAR AXLE
SPECIAL TOOLS ......... ........ ... ........ ... .. ... ... ... ... ... ... ... .. ... ... ... ... ... ... ... ... ... ... ... .. ... ... ... ... ... ... ... .. 3
DISASSEMBLY OF THE TANDEM AND REAR AXLE REMOVAL AND INSTALLATION ........... 7
TANDEMCASEOSCILLATIONADJUSTMENTPROCEDURES ................................................ 17
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
18 19
-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).
& 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.
1- Filler Plug
2- Level Plug
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.
Remove the lip seal (6) and snap ring (1 0) from the
bearing retainer flange (3).
Remove the hub located between the rear axle and the
tandem case.
Remove hub.
TANDEMCASEOSCILLATIONADJUSTMENT
PROCEDURES
Loop the chain over the drive gear. Connect the two
ends of the chain with the master link.
Add specified oil through the filler holes until oil runs
out of the oil level hole, see operators manual.
1
10 @
Wheel nuts tightening sequence.
@ o•
10 011
•0 @a
'It@ o,
·~
@
7 @
2
TANDEM DRIVE
DIFFERENTIAL HYDRAULIC LOCK
DISASSEMBLY OF THE TANDEM AND REAR AXLE REMOVAL AND INSTALLATION ........... 5
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.
18 19
-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).
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.
Remove the hub located between the rear axle and the
tandem case.
Remove hub.
Remove phenolicbushing.
Loop the chain over the drive gear. Connect the two
ends of the chain with the master link.
Add specified oil through the filler holes until oil runs
out of the oil level hole, see operators manual.
1
10 @
@ fll
1110 0)11
Wheel nuts tightening sequence.
•0 @:.
'ft@ o.
@
7 @
2 ••
NOTES
BRAKES
7002
HYDRAULIC BRAKE TROUBLESHOOTING
TABLE OF CONTENTS
HYDRAULIC BRAKE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DEFECTS
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.
The accumulators do not recharge. Contamination seized the priority Repair or replace brake pedal valve.
valve (in brake pedal valve).
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.
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.
Continuous recharge Accumulators with too low or too Check nitrogen pressure in
of the accumulators high nitrogen precharge. accumulators.
Accumulators Contamination in the priority Check the sliding of all sports, mainly of
don't charge valve. the inlet valve.
Non return of the pedal. Check that the pedal stop adjuster
allows backlash between return and
operating piston.
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.
NOTES
7003
BRAKE PEDAL VALVE AND SYSTEM
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
.
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 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.
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.
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.
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
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.
SETTING
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).
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
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;
(C2)
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.
Remove the braking proportional valve spool (15) and spring (26)
from block no. 1 identifying it with the relevant block.
16. Lower cup – 16 a. Upper cup – 18, 18 a, 19. Springs – 21. Control plunger – 25.Gasket.
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
WARNING:
The brakes are inoperative when undergoing
maintenance or repair operations.
place the machine on a flat surface and block the
wheels.
HYDRAULICS
DUALCHECKVALVE .................................................................................................................... 47
Service Position
Before making any service, maintenance or inspection procedure, the grader must be placed in the
Service Position.
2. Place the transmission in neutral and apply the handbrake. Ensure the handbrake is correctly
adjusted and in good working order.
3. Lower the moldboard and all attachments to the ground. Do not apply down-pressure.
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.
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.
1 2. Allow the engine and hydraulic system to cool before working in these areas.
14. If the service procedure includes welding, you must disconnect the following items:
Connect the arc-welder ground cable as close as possible to the work area.
PUMP REMOVAL
3
Flow Control spool should be closed
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
Remove the drive gear off the pump and put it on a smooth
surface.
Remove the seal retainer oft he rear cover and discard it.
It must be replaced by a new part.
Remove the retainer seal ofthe front cover and discard it.
Replace it with a new part.
Put the rear cover on a work bench with the retainer cavity
up. Lubricate the retainer cavity with graphite grease.
Install the washers and nuts on the top bolts. Torque ofthe
top bolts: 196-210 Nm. (145-155 ft.lbs)
RemovetheO-ring.
RemovetheO-ring.
Complete rotor.
0 00
PILOT VALVE
Mechanicalflowlimiter:Usedtoadjusttheminimumflow.
PILOT VALVE
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.
Torque-tightening Spool End Assembly Inlet Endcap and Three Tie Rods
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 ).
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.
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.
0 0
See figure for position of o'rings and back up rings.
0
PILOT
0
OUTLET
INLET
0
ENG 6-46872 Issued 01-03 Printed in Brazil
8001-45
•
View of pressure regulating valve cartrige.
HYDRAULIC CYLINDERS
ffi 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 MOLDBOARD LATERAL CYLINDER
provided. Watch out for people in the vicinity.
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.
RIPPER CYLINDER
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.
SPECIFICATIONS
A B c D
A. Lubricate and torque cylinder head .................................... 1400- 1600 Nm (1 032- 1180 lb.ft)
D. Lubricate and torque piston rod locknut to ............................ 900- 1000 Nm (664- 738 lb.ft)
A. Lubricate and torque cylinder head ..................................... 1400- 1600 Nm (1 032- 1180 lb.ft)
D. Lubricate and torque piston rod locknut to ............................ 900- 1000 Nm (664- 738 lb.ft)
A. Lubricate and torque cylinder head .................................... 1400- 1600 Nm (1 032- 1180 lb.ft)
D. Lubricate and torque piston rod locknut to ............................ 900- 1000 Nm (664- 738 lb.ft)
A B c
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)
D. Lubricate and torque piston rod locknut to ............................ 900- 1000 Nm (664- 738 lb.ft)
A. Lubricate and torque cylinder head .................................... 1400- 1600 Nm (1 032- 1180 lb.ft)
D. Lubricate and torque piston rod locknut to ............................ 900- 1000 Nm (664- 738 lb.ft)
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)
D. Lubricate and torque piston rod locknut to ............................ 271 - 339 Nm (200- 250 lb.ft)
A. Lubricate and torque cylinder head 140- 160 Nm (1 03- 118 lb.ft)
D. Lubricate and torque piston rod locknut to ............................ 90- 100 Nm (66.4- 73.8 lb.ft)
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)
F. Lubricate and torque the piston rod locknut to ....................... 339 - 407 Nm (250 - 300 lb.ft)
*SERVICE NOTE: Press bushing into head flush with face of head.
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
Piston rod O.D. ...................................................................... 44.960- 45.000 mm (1.770- 1.771 in)
D. Lubricate and torque piston rod locknut to ............................ 794- 873 Nm (585- 644 lb.ft)
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)
Piston rod O.D. ...................................................................... 50.724- 50.800 mm (1.997- 2.000 in)
D. Lubricate and torque piston rod locknut to ............................ 1152 - 1288 Nm (850 - 950 lb.ft)
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)
D. Lubricate and torque piston rod locknut to ............................ 2196 - 2393 Nm (1620 - 1765 lb.ft)
HYDRAULIC SCHEMATICS
TABLE OF CONTENTS
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
BC03J073
BC03J074
BC03J075
BC03J076
MOUNTED EQUIPMENT
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
apply correct charge.
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
+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
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
SAFETY PROCEDURES
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.
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
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
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
Problem: Problem:
Not Enough Cooling Erratic Cooling
MECHANICAL
ELECTRICAL
See Blower and Compressor Clutch Check on Page 9.
MECHANICAL
SYSTEM CHECKS
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.
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.
PRESSURE-TEMPERATURE CHART
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
STEP 3
PROBLEM: NO COOLING
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
HIGH HIGH
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
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.
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)
NORMAL TO NORMAL TO
SLIGHTLY HIGH HIGH
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
LOW LO W
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
HIGH LOW
476L7
SEE THE PRESSURE - TEMPERATURE CHART ON PAGE 14
HIGH HIGH
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
NORMAL NORMAL
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
NORMAL
HIGH
TO HIGH
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
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.
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.
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
AIR CONDITIONER SYSTEM SERVICE
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
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
SAFETY PROCEDURES
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.
STEP 1
A22114
STEP 4
BD01D251
STEP 2
A22107
BD01D273
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
STEP 9
A22108
BD01D273
STEP 10
A22113
STEP 12
BD01D273
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
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
2.2) Use a Philips screw driver to remove 02 (two) bolts and replace the filter.
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.
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.
4.2) 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.
4.4) Remove 06 (six) screws from evaporator and heater plate located at each side of evaporator housing. Use a Philips
screw driver.
4.6) Replace evaporator and/or heater. In order to reassemble these parts, follow these steps backwards.
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.
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.
7.2) Remove condenser hose fitting. Use 19 and 22mm wrench. Remove receiver drier hose fitting. Use 16 and 19mm
wrench.
7.3) Remove 04 (four) bolts from condenser supports. Use a 17mm wrench. Put it on a workbench.
7.4) Replace condenser and receiver drier (it is important to replace receiver drier in order to prevent moisture
contamination). Follow these steps in reverse order to reassembly these parts.
NOTE: be sure the correct position of inlet (IN) is mounted.
7.5) If it is necessary replace only pressure switch , do not remove charge and condenser. Remove only switch pressure
fitting. Use a 17mm wrench. Do not remove pressure switch nut.
8.2) Remove charge with proper equipment. Never let refrigerant charge flow to air.
8.3) Replace hose assy – compressor to condenser: remove compressor hose fitting. Use a 22 mm wrench. Remove
condenser hose fitting. Use a 19 and 22 mm wrench. The two wrenches must be used. Replace the hose, mounting it the
same way. Replace the o-ring seals.
8.4) Replace hose assy – receiver drier to evaporator: remove receiver drier hose fitting. Use a 19 and 16 mm wrench.
Remove expansion valve hose fitting. Use a 16 mm wrench. Do not remove the grommet (cab floor). Replace the hose assy. Be
careful when mounting it through the grommet. Replace the o-ring seals.
8.5) Replace hose assy – evaporator to compressor: remove expansion valve hose fitting. Use a 22 mm wrench.
Remove compressor hose fitting. Use a 30 mm wrench. Do not remove the grommet (cab floor). Replace the hose assy. Be
careful when mounting it through the grommet. Replace the o-ring seals.
9.2) Replace / maintenance of air conditioning switch control: remove panel cover. Be careful with electrical cables and
heater valve cable.
9.3.2) ) Disconnect 02 (two) hot water hoses removing clips with a pliers.
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).
NOTES
REAR RIPPER
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
Install the ripper teeth on the rear tray with their respective
bolts and cotter pins.
ARTICULATION JOINT
The hitch used consists of tapered roller bearings. The
hitch allows a total of 50 degrees articulation.
A WARNING
A wARNING
Never use gasoline solvent or other flammable
fluids to clean element. Use authorized com-
mercial, non-flamable, non-toxic solvents.
provided. Watch out for people in the vicinity.
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.
A wARNING
Lift and handle all heavy parts with a lifting device
or proper capacity. Be sure parts are supported
by proper slings and hooks. Use lifting eyes if
provided. Watch out for people in the vicinity.
CIRCLE REMOVAL
Lower moldboard so that the blade is on the ground.
Turn off the electrical master switch.
WARNING
A WARNING
CIRCLE REMOVAL
Lower moldboard so that the blade is on the ground.
Turn off the electrical master switch.
A WARNING
.. W~No.JG
Always turn the master switch to the off position
before cleaning, repairing, servicing or parking
the machine to prevent injury.
A 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.
A 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.
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
H G
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.
MOLDBOARD CONTROL
MOLDBOARD CONTROL
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
e
9008-18
NOTES
COUNTERWEIGHT845/865/885
12
SECTION
NOTES
Rops CAB
TYPES OF 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.
Mounted cab.
NOTES
(/)
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Ll)
-5
0:: Ll)
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t; co
II
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I)
7.14 mm (optional 6.35), with interpolated 0.76mm 0
..... (.!) co
co
M
..... g ""'""'
.....
~~(~
* 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
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;
~
E.C.E regulation # 43 (annex 6),
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 regulation # 43;
E.C.E Director Counsel 92/22;
246 \ ~~
294.5 1
532
9011-03
* Material: tempered safety glass, thickness 5.55
~
(optional 6 mm).
~
H. ....
~
* 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; FMVSS # 205;
Border finishing according to SAE J673.
532
9011-04
* Material: tempered safety glass, thickness 5.55
(optional 6 mm).
WINDOW- REAR
I!
"'
.c.
* It must comply to the requirements of the:
ANSI Z 26.1 - Category AS-2, item 2, section 4; "'
00
00
II
0::
E.C.E regulation # 43 (annex 5),
E.E.G Director Counsel 92/22/EEC, ANNEX II, section r--
H. ""'
N
~
co
,....
N
~0
z'-'
"'o
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* 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; FMVSS # 205;
Border finishing according to SAE J673.
895
-