Case 845 865 865DHP 885 Grader Repair Manual 6-46521 - PDF DOWNLOAD

2001- 3

CHARGE AIR COOLER SYSTEM Specifications MAKE/MODEL:

DENSO

TYPE:

Air to air; aluminum herringbone tube and fin; cast aluminum tanks

CORE SIZE

27.6 High x 8.3 wide x 5.7 (700 x 211.2 x 144 )

CORE DESCRIPTION:

Rows: 2 Tube spacing: 10 per row Fin spacing: 13 fins per inch

CNH LATINO AMERICANA LTDA 2234, General David Sarnoff Avenue Contagem, MG Brazil

6-73780

Printed in Brazil June 2003

2001- 4

Charge Air Cooler Removal of the air cooler to turbocharger outlet piping 1 - Remove clamps (A) 2 - Remove hose (B)

3 - Remove bolt (C) and remove clamp (D)

4 - Remove clamps (F) then remove tube (E) and hose (G).

CNH LATINO AMERICANA LTDA 2234, General David Sarnoff Avenue Contagem, MG Brazil

6-73780

Printed in Brazil June 2003

2001- 5

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

3 - Remove clamps (3) 4 - Remove hose (4) 5 - Remove tube (5)

6 - Remove bolts (6) 7 - Remove tube (7) 8 - Remove gasket (8)

CNH LATINO AMERICANA LTDA 2234, General David Sarnoff Avenue Contagem, MG Brazil

6-73780

Printed in Brazil June 2003

2001- 6

Charge Air Cooler Air cooler removal 1 - Remove top bolts (9)

]

2 - Remove bottom bolts (10)

Air cooler assembly.

1 - Place air cooler in the correct position.

2 - Fit top bolts (9) and torque to 2,8 kfg.

3 - Fit bottom bolts (10) and torque to 2,8 kfg.

CNH LATINO AMERICANA LTDA 2234, General David Sarnoff Avenue Contagem, MG Brazil

6-73780

Printed in Brazil June 2003

2001- 7

Charge Air Cooler Assembly of air cooler outlet to turbocharger pipe 1 - Fit hose (B) to the cooler outlet opening. Then fit clamps (A) in place and fit tube (E) to hose (B).

Adjust clamps until the clamp springs are fully compressed.

2 - Fit hose (A) to tube (E). Then fit hoses (F) in place and fit hose (G) to the turbocharger inlet tube.

Ajust clamps until the clamp springs are fully compressed.

Cooler air inlet pipe assembly.

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

Adjust 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.

CNH LATINO AMERICANA LTDA 2234, General David Sarnoff Avenue Contagem, MG Brazil

6-73780

Printed in Brazil June 2003

2001- 8

3 - Fit gasket (4) between tube (7) and engine cover.

Then fit bolts (6) in place and torque to 2,8 kgf.

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

CNH LATINO AMERICANA LTDA 2234, General David Sarnoff Avenue Contagem, MG Brazil

6-73780

Printed in Brazil June 2003

5003-5

12. Remove spool and sleeve assembly from 14 hole end of housing, see Fig. 5.

Figure 3 9. Remove quad ring seal from seal gland bushing.

Attention: Do not bind spool and sleeve in housing.

Rotate spool and sleeve assembly slowly when removing from housing.

13. Push pin from spool and sleeve assembly.

10. Use a thin bladed screwdriver to pry dust seal from seal gland bushing. Do not damage bushing.

Figure 6

Figure 4 11. Remove 2 bearing races and the needle thrust bearing from spool and sleeve assembly.

14. Push spool partially from control end of sleeve, then remove 6 centering springs from spool carefully by hand, see Fig. 6 15. Push spool back through and out of sleeve, see Fig. 6 Rotate spool slowly when removing from sleeve.

16. Remove o-ring from housing, see Fig. 7 and two cylinder port shock valves (set screw, o-ring, spring, and check ball).

Figure 5 Figure 7 ENG 6-46690

May,2003

Printed in Brazil

5003-6

Section Drawing and Integral Valves NOTE: The steering control valve housing (7) Fig. 2 has internally two anti-cavitation valves (EE) and one check valve (CC). Before removing these valves, verify their positions.

17. To disassemble these valves, insert soda straws (3) in each end of the threaded holes, refer to Figure 3. Remove the steering control valve housing from the vise and tilt it until the port face (4) is upward. Continue turning until the roll pins (2) and ball checks (1) slide through the straws (3).

ENG 6-46690

May,2003

Printed in Brazil

6006 - 5

1. Tandem Case 2. Capscrew 3. Bearing Retainer Flange 4. Bearing 5. Shaft 6. Lip Seal and snap ring 7. Nut 8. Grease Retainer 9. Sprocket

ENG 6-46790

10. Chain 11. Capscrew 12. Capscrew 13. Shim 14. Capscrew 15. Shim Cap 16. Inner Cap 17. Retainer plate (holding) 18. Snap ring

Issued 1-03 Printed in Brazil

6006 - 6

18 - Hub 19 - Shim 20 - Washer 21 - Capscrew 22 - Tandem pivot seal 23 - Thrust washer 363x440mm (14.29x17.32)in

ENG 6-46790

24 - Thrust washer 380x440mm (14.96x17.32)in 25 - Tandem retaining plate 26 - Washer 27 - Capscrew 28 - Bushing

Issued 1-03 Printed in Brazil

6006 - 7

DISASSEMBLY OF THE TANDEM AND REAR AXLE REMOVAL AND INSTALLATION DISASSEMBLY OF THE TANDEM - Install the grader articulation lock pins into their frame locations. .

TANDEM TEARDOWN

- Park the grader on a level surface.

- Place the transmission in neutral and apply the handbrake. Ensure the handbrake is correctly adjusted and in good working order.

- Lower the moldboard and all attachments to the ground. Do not apply down-pressure.

- Overall view of tractor. Tag machine to note that machine is being serviced.

- Shut down the engine.

- Lift grader by extending the blade to the side being worked upon. Apply blade down pressure on the side to be lifted.

- Install the service pin in the LOCKED position (see the Operators Manual).

- Install chocks at the front and rear tandem wheels. Wedge the chocks in place.

WARNING Scissors points in area of service. Stay clear during operation. Block securely for service.

WARNING Lift and handle all heavy parts with a lifting device of proper slings and hooks. Use lifting eyes if provided. Watch out for people in the vicinity.

WARNING Observe all start up and shut down procedure an WARNING listed in the operation and maintenance instruction manual.

Keep people clear of attachments and tools while in raised position, to prevent possible injury.

Remove the tires

- Support the grader with approved supports.

WARNING When supporting machine component must be removed or installed and jacks are used, be sure the support of the jack at the machine and on the ground are appropriate to the load to be applied. Transfer the load to authorized blocking or jack stands immediately. Do not work on or under the machine or its components while supported only on a jack or other lifting device, according to local or national requirements.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 8

Remove the cover screws.

Remove the drain plug and drain the oil.

1- Filler Plug 2- Level Plug 3- Drain Plug, inside wall of tandem case.

Remove the two access covers on the top of the tandem case. Remove the four covers from the sides of tandem case.

Put the filler plug back in the place.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 9

Remove the bolts from the center cover to access the chain drive gears.

Remove the cover and gasket.

Flatten lockplate for capscrew removal.

Remove retaining plate capscrews.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 10

Remove the sprockets retaining plate.

Remove the adjustment shim.

Position the chain master link at access window on side of tandem case. Remove the cotter pins.

Remove master link.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 11

Remove chain from drive gear.

Use a hook to help removing the chain.

Prop the chain on tandem case and remove it from the tandem.

Remove the drive gears from the drive shaft.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 12

Remove the cotter pin from the hub nut.

Remove the nut and washer from the hub shaft.

Remove the hubs and key using tool 75312684 and the from hub shaft.

Remove capscrews and shaft bearing retainer.

Remove the bearing retainer. Leave the shaft in the tandem. The shaft will cock when the retainer is removed.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 13

Lift the shaft and sprocket assembly with a sling.

Remove capscrews from inside bearing retainer.

Remove bearing retainer from tandem by using rubber hammer from inside and support bearing retainer with opposite hand.

Remove sprocket to shaft lock plate capscrews.

Use puller set to remove both bearings from the shaft.

Pull the bearing by placing the bearing puller behind seal.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 14

Install the splined sprocket onto the shaft. Torque the capscrews to 61 ~ 68 Nm (45 ~ 50 ft lb.).

Install bearing seal and bearing onto the shaft. Heat the bearing to 121oC (250oF). Be sure the bearing is seated onto the shaft.

Remove the bearing race from the retainer using master bearing and seal driver kit P/N 75300850.

WARNING It is unsafe to strike hardened steel parts with anything other than a soft iron or nonferrous hammer.

When installing or removing such parts wear safety glasses with side shields and heavy gloves, etc., to reduce the possibility of injury.

Install bearing with tool P/N 75300850.

Remove bearing race from the wheel shaft bearing retainer with puller set.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 15

Install bearing cup in the wheel shaft bearing retainer using tool P/N 75300850.

Remove the lip seal (6) and snap ring (10) from the bearing retainer flange (3).

Install the snap ring (10).

Remove the hub located between the rear axle and the tandem case.

Using a proper wrench, remove the capscrews from the rear axle flange to separate tandem from axle.

Separate tandem case and rear axle using adequate hoist.

Save shims for reassembly.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 16

Remove phenolic thrust washer .

Remove lockwire and capscrews.

Remove the tandem retaining plate.

Remove the phenolic thrust washer.

Remove external tandem pivot seal.

Remove hub.

Remove internal tandem pivot seal.

Remove phenolic bushing

REAR AXLE REMOVAL Disconnect the drive shaft at differential input flange (1).

Remove nuts retainer plate, housing nuts and capscrews(2).

Disconnect the brake supply lines and brake cooler lines.

Remove the rear axle assy.

NOTE: For rear axle disassembly and assembly see section 6005.

REAR AXLE ASSEMBLY Position the rear axle under the grader.

Install retainer plate nuts, housing nuts and capscrews(2) torque to 830 ~ 850 Nm (614 ~629 ft lb.).

Connect the brake supply lines and brake cooler lines.

Connect the drive shaft at differential input flange (1), capscrews torque to 135 ~165 Nm (100 ~ 122 ft lb.) use Loctite 271.

ASSEMBLY OF THE TANDEM

Install bushing and tandem pivot seal.

Apply light coat of graphite grease on the outside diameter of phenolic bushing.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 17

TANDEM CASE OSCILLATION ADJUSTMENT PROCEDURES DETERMINATION OF THE SHIM PACK (SP) - Clean all the parts, hub, thrust washer 363 x 440 mm (14.29 x 17.32 in), tandem retaining plate & thrust washer 380 x 440mm (14.96 x 17.32 in) and and assemble them per the sketch in the vertical position.

- Measure the clearence "X"in six (6) equally spaced points.

- Use the largest dimension found = X. - Establish the shim pack(19) "SP"(mm) = X + (0.15 ~0.20mm).

"SP"(in) = X + (.006 ~.008 in).

Assemble the hub (18) and external seal (22).

Install thrust washer (23) with a thin coating of graphite grease.

Assemble tandem retaining plate (25), washer (26) and capscrews (27). Torque the capscrews to 450 ~ 480 Nm (333 ~ 355 lb ft.) .

Apply lock wire to retaining capscrews, see figure.

Assemble the tandem case on the axle using the parts and the shims, covering the cleaned part surfaces with a thin coating of graphite grease.

After assembly, torque all the hub capscrews (21) to 280 ~ 320 Nm (207 ~ 236 lb ft.) .

The tandem case should pivot on the axle with a force (P) of 70 to 150 kg (150 ~ 330 lb), applied at the center of one of the wheels.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 18

- Install drive sprockets (29), adjusting shim (30), sprockets retaining washer (31), capscrews (32) to 115 ~125 Nm (85 ~ 93 lb.ft.) .

Lock the capscrews.

Place chain in case tandem.

Apply Permatex or Loctite 1114 to inner cap and tandem case. Place rear bearing cap on case.

Tighten capscrews to torque 122 ~ 136 Nm (45 ~50 ft lb.).

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 19

Pack the rear bearing with grease prior to installing the sprocket and shaft in the tandem case. Install the gear and shaft in the tandem case.

Pack front bearing with grease.

Do not engage chain in sprocket.

Leave the outboard seal off the wheel end. Temporarily install the wheel end onto the tandem case.

Tighten the capscrews to torque.

Place cap without shims onto bearing cap. Tighten four screws evenly and rotate shaft at the same time.

Check the shaft bearing for the correct rolling torque.

Rolling torque is adjusted by shims on the opposite side of the case. When the rolling torque is observed to be within specification, measure the gap between the two caps. Install gap with shims.

Tighten shim cap capscrew to torque 122 ~136 Nm (90 ~ 100 ft lb.) use loctite 277 and check rolling torque to 6.8 ~7.4 Nm (60 ~70 in lb.).

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 20

Remove the bearing retainer flange and position the chain around the sprocket.

Do not let the chain bunch in one position.

Reinstall the bearing retainer flange after applying Loctite 1114 or Permatex and tighten the retaining capscrews torque to 122 ~136 Nm (90 ~100 ft lb.).

Wheel end shaft bearing shim with greased packed bearings and prior to installing seal.

Install the seal. Using a tube (3 15/16" x 10") press the seal onto the shaft and wheel end.

Loop the chain over the drive gear. Connect the two ends of the chain with the master link.

Install master link.

Install cotter pin (always install new cotter pin).

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 21

Install the gasket and gear cover onto the tandem case.

Apply Loctite 1114 capscrews thread and torque to 28 ~35 Nm (21 ~26 ft lb).

Install tandem chain access covers.

Apply Loctite 1114 on the both sides of the gasket and capscrews thread.

Install gaskets, cover and capscrews torque to 28 ~35 Nm (21 ~26 ft lb).

Add specified oil through the filler holes until oil runs out of the oil level hole, see operators manual.

Tighten the filler plug.

Install the key on the hub shaft.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 22

Install the washer and the nut on the wheel hub shaft.

Torque the nut 540 ~560 Nm (400 ~ 415 Ft lb.).

Install tires to the tandem case.

Torque the nuts to 407 ~476 Nm (300 ~350 Ft lb.).

Wheel nuts tightening sequence.

ENG 6-46790

Issued 1-03 Printed in Brazil

Section 6006

6006

TANDEM DRIVE DIFFERENTIAL HYDRAULIC LOCK

CNH Latino Americana Ltda 2237, General David Sarnoff Avenue Contagem, MG - Brazil

ENG 6-46791

May,2003

6006 - 2

DESCRIPTION.............................................. ........................................................................ PAGE

GENERAL DESCRIPTION..................................................................................................... 3 DISASSEMBLY OF THE TANDEM AND REAR AXLE REMOVAL AND INSTALLATION ....... .... 5 DISASSEMBLY OF THE TANDEM ....... ...................................................................................... 8 REAR AXLE REMOVAL AND INSTALLATION .............................................................................. 10 ASSEMBLY OF THE TANDEM ............................................................................................ 11 TANDEM CASE OSCILLATION ADJUSTMENT PROCEDURES .............................................. 12 DETERMINATION OF THE SHIM PACK ..................................................................................... 12

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 3

GENERAL DESCRIPTION TANDEMS Driving sprockets, which are splined to the rear axle shafts, transfer power through heavy roller driving chains to the wheel shaft sprockets which are attached to the wheel reduction (four planetary assemblies bolted to tandem case).

Each tandem assembly oscillates and pivots on a tandem hub bushing, located in the hub.

Differential hydraulic lock is operator controlled.

Outboard wet disc brakes.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 4

18 - Hub 19 - Shim 20 - Washer 21 - Capscrew 22 - Tandem pivot seal 23 - Thrust washer 380x440mm (14.96x17.32)in

ENG 6-46790

24 - Tandem retaining plate 25 - Washer 26 - Capscrew 27 - Bushing

Issued 1-03 Printed in Brazil

6006 - 5

DISASSEMBLY OF THE TANDEM AND REAR AXLE REMOVAL AND INSTALLATION DISASSEMBLY OF THE TANDEM - Install the grader frame lock pins into their frame locations if working on an articulated grader.

TANDEM TEARDOWN

- Park the grader on a level surface.

- Place the transmission in neutral and apply the handbrake. Ensure the handbrake is correctly adjusted and in good working order.

- Lower the moldboard and all attachments to the ground. Do not apply down-pressure.

- Overall view of tractor. Tag machine to note that machine is being serviced.

- Shut down the engine.

- Lift grader by extending the blade to the side being worked upon. Apply blade down pressure on the side to be lifted.

- Install the service pin in the LOCKED position (see the Operators Manual).

- Install chocks at the front and rear tandem wheels. Wedge the chocks in place.

WARNING Scissors points in area of service. Stay clear during operation. Block securely for service.

WARNING Lift and handle all heavy parts with a lifting device of proper slings and hooks. Use lifting eyes if provided. Watch out for people in the vicinity.

WARNING Observe all start up and shut down procedure and WARNINGS listed in the operation and maintenance instruction manual.

Keep people clear of attachments and tools while in raised position, to prevent possible injury.

Remove the tires

- Support the grader with approved supports.

WARNING When supporting machine component must be removed or installed and jacks are used, be sure the support of the jack at the machine and on the ground are appropriate to the load to be applied. Transfer the load to authorized blocking or jack stands immediately. Do not work on or under the machine or its components while supported only on a jack or other lifting device, according to local or national requirements.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 6

Remove the cover screws.

Remove the drain plug and drain the oil.

Remove the chain access cover.

Put the filler plug back in the place.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 7

Remove the bolts from the center cover to accessthe chain drive sprockets.

Remove the cover and gasket.

Position the chain master link at access window on side of tandem case.

Remove the cotter pins.

Remove the master link .

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 8

Remove the chains.

Remove the drive sprocket.

Remove the half shaft.

Remove the hub located between the rear axle and the tandem case.

Using a proper wrench, remove the capscrews from the rear axle flange to separate tandem from axle.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 9

Separate tandem case and rear axle using adequate hoist.

Save shims for reassembly.

Remove phenolic thrust washer .

Remove lockwire and capscrews.

Remove the tandem retaining plate.

Remove the phenolic thrust washer.

Remove tandem pivot seal.

Remove hub.

Remove phenolic bushing.

Remove lip seal tandem case.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 10

Remove lip seal (from the) axle case.

REAR AXLE REMOVAL Disconnect the drive shaft at differential input flange (2).

Remove nuts retainer plate, housing nuts and capscrews(3).

Disconnect the brake supply lines and differential lock lines and guard.

Remove the rear axle assy.

NOTE: For rear axle disassembly and assembly see section 6005.

REAR AXLE ASSEMBLY Position the rear axle under the grader.

Install retainer plate nuts, housing nuts and capscrews(2) torque to 830 ~ 850 Nm (614 ~629 ft lb.).

Connect the brake supply lines and differential lock lines and guard.

Connect the drive shaft at differential input flange (1), capscrews torque to 135 ~165 Nm (100 ~ 122 ft lb.) use Loctite 271.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 11

ASSEMBLY OF THE TANDEM

Install bushing and tandem pivot seal (see figure).

Apply light coat of graphite grease on the outside diameter of phenolic bushing.

Install new lip seal (see figure).

Mark covers to identify the tandem stop angle.

Remove the cover,bearing and sprocket.

Remove the wheel reduction axle assembly.

NOTE: For rear axle disassembly and assembly see section 6005.

Install the wheel reduction axle assembly, apply Loctite 1114 on the surface and studs thread.

Nuts torque to 267 ~ 273 Nm (198 ~202 lb ft.).

Install sprocket,bearing.

Apply Loctite 1114 on the cover and capscrews thread.

Install cover and capscrews torque to 122 ~ 136 Nm (90 ~100 ft lb.).

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 12

TANDEM CASE OSCILLATION ADJUSTMENT PROCEDURES DETERMINATION OF THE SHIM PACK (SP) - Clean all the parts, hub, thrust washer 363 x 440 mm (14.29 x 17.32in), tandem retaining plate & thrust washer 380 x 440mm (14.96 x 17.32in) and and assemble them per the sketch in the vertical position.

- Measure the clearence "X"in six (6) equally spaced points.

Use the largest dimension found = X. - Establish the shim pack(19) "SP"(mm) = X + (0.15 ~0.20mm).

"SP"(in) = X + (.006 ~.008 in).

Assemble the external seal (22) and hub (18).

Install thrust washer (23) with a thin coating of graphite grease.

Assemble tandem retaining plate (24), washer (25) and capscrews (26). Torque the capscrews to 450 ~ 480 Nm (333 ~ 355 lb ft.) .

Apply lock wire to retaining capscrews, see figure.

Assemble the tandem case on the axle using the parts and the shims, covering the cleaned part surfaces with a thin coating of graphite grease.

After assembly, torque all the hub capscrews (21) to 280 ~ 320 Nm (207 ~ 236 lb ft.) .

The tandem case should pivot on the axle with a force (P) of 70 to 150 kg (150 ~ 330 lb), applied at the center of one of the wheels.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 13

Install new lip seal (see figure for assembly position ).

Install the half shaft,carefully, to avoid damage to seals.

Install the drive sprocket.

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 14

Loop the chain over the drive gear. Connect the two ends of the chain with the master link.

Install master link.

Install cotter pin (always install new cotter pin).

Install the gasket and sprocket cover onto the tandem case.

Apply Loctite 1114 to capscrews thread and torque to 28 ~35 Nm (21 ~26 ft lb).

Install tandem chain access covers

Apply Loctite 1114 on the both sides of the gasket and capscrews thread.

Install gaskets, cover and capscrews torque to 28 ~35 Nm (21 ~26 ft lb).

ENG 6-46790

Issued 1-03 Printed in Brazil

6006 - 15

Add specified oil through the filler holes until oil runs out of the oil level hole, see operators manual.

Tighten the plugs.

Install tires to the tandem case.

Torque the nuts to 407 ~476 Nm (300 ~350 ft lb.).

Wheel nuts tightening sequence.

ENG 6-46790

Issued 1-03 Printed in Brazil

7003

Section 7003 BRAKE PEDAL VALVE AND SYSTEM

845 - 865 - 885 Grader

CNH Latino Americana Ltda 2237, General David Sarnoff Avenue Contagem, MG - Brazil

Eng 6-46841

Printed in Brazil May,2003

7003-2

TABLE OF CONTENTS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION .............................................................................................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS ..................... . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BRAKE PEDAL DISASSEMBLY - ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECK OF BRAKE CONTROL PRESSURES .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . .. .

SETTING OF MIN. AND MAX. ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TEST OF ACCUMULATORS PRECHARGE .......................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTRUCTIONS FOR THE RESETTING OF ACCUMULATORS PRECHARGE . . . . . . . . .. . . . . . . . . . . . . . .

BLEEDING OF BRAKES SYSTEM .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .

ENG 6-46840

issued 1- 03

3 5 6 7 8 14 15 16 17 18

Printed in Brazil

7003-3

BRAKE PEDAL VALVE

DESCRIPTION The brake pedal valve assembly is a compact ajustable valve with a modular configuration.

These modules are assembled into an assembly to provide the braking pressure for the machine.

4

2 3

5

1

6

1 Pedal/support group - 2 First braking module - 3 Second braking module - 4 Accumulator charge valve 5 Adjustment screw, brake pressure - 6 Minimum and maximum accumulator recharge pressure

The brake pedal valve is made of elements assembled in a modular mode.

These elements are: • Pedal/support group.

• First braking module.

• Second braking module.

• Accumulator charge valve.

ENG 6-46840

issued 1- 03

Printed in Brazil

7003-4

Support/pedal group The brake pedal is secured with support group to the floor plate of the machine.

This group regulates: • the maximum braking pressure which is obtained through the pedal stroke against stop screw;

Braking modules The braking modules are the elements controlling the braking pressure. Each braking module is connected to a valve and an accumulator. The accumulators are high pressure type containers with a special membrane nitrogen charge, on one side, and to the oil pressure on the other. Three threaded outlets connect the module to the brakes, the accumulator and the pressure switch controlling the stop lights.

The modules have longitudinal ducts allowing a hydraulic connection with the discharge and the charging circuit of the accumulators.

Accumulator charge valve The valve maintains the value of the pressure of the accumulators at a determined range (1175-1825 psi). This pressure is set by turning the screw (6) located on the cylindrical end and is protected by a cap nut.

ENG 6-46840

issued 1- 03

Printed in Brazil

7003-5

OPERATION

The brake pedal valve controls the charge of the accumulators that are fed by the hydraulic power control system. During the charge phase, the charge valve acts, charging the accumulators, ensuring the hydraulic supply to other functions of the power control systems. .

Once the charge pressure of the accumulator is reached, the charge valve directs the entire flow from the pressure line "P" to hydraulic tank.

The pressure in the accumulator circuit is maintained steady within the tolerance range of the charge valve.

The two service braking circuits are mutually protected through the check valves so that, in case of failures one of the two circuits, operates normally.

The charge condition of the accumulator is monitored by the pressure switch so that the operator has a visual and audio signal in case of insufficient hydraulic pressure in the accumulators.

Operation of the service braking system When the service brake pedal is actuated, the two circuit braking valve regulates the pressure to the brake pistons according to the actuating force. The machine is slowed down by the action of the both brakes right and left.

At the release of the braking pedal, the oil returns to the tank.

In case of failure of one brake circuit, the second remains in operating condition through the mechanical contact of the two braking valve plungers, ensuring the functionality of one accumulator. The actuating force remains unchanged.

Every time the service brake is actuated, a pressure switch (set at 41-102 psi) monitors the pressure on the rearaxle brake circuit and energises the stop lights.

LIMITED SLIP

DIFFERENTIAL LOCK P Pressure, from steering priority valve "EF" - B Discharge to hydraulic oil tank - T Discharge to hydraulic oil tank S1 Stop lights pressure switch - T1 Delivery to right side axle - T2 Delivery to left side axle - R1 Service accumulator R2 Service accumulator - S2 Brakes system low pressure switch

ENG 6-46840

issued 1- 03

Printed in Brazil

7003-6

SPECIFICATIONS Brake pedal ....................................................................................................................................... type S6 Installation ...................................................................................................................................... horizontal Diameter of brake valve modules ....................................................................................................... 14 mm Braking circuits ............................................................................................................................................. 2 Braking pressure ......................................................................................................................... 65 +/- 3 bar Accumulator recharge pressure................................................................................................... 81 ~ 87 Bar Maximum accumulator pressure................................................................................................ 120 ~126 Bar Accumulator flow rate ...................................................................................................................... 5.5 LPM

ENG 6-46840

issued 1- 03

Printed in Brazil

7003-7

MAINTENANCE MAINTENANCE STANDARD The precautions to be strictly observed during the assembly operations are listed below.

• Ensure that connections and lines are clean; foreign materials and dust in the system will cause malfunctions and wear.

• To bleed the air from the system, (see page no.7003-18).

SETTING Adjustment and check of accumulator pressure (see page no. 7003-15) When the accumulators are discharged, connect a gauge (scale 200 bar/2900psi) to the.

Start the engine and press the pedal several times to activete the automatic charge; read the pressure.

The max./min. pressure is adjustable through the adjusting screw (6) (protected by the cap nut) on the body of the accumulator charge valve.

The pressure of max. charge of the accumulators is 120 bar (1740psi), and minimum 81bar (1175psi).

6

Adjustment of service brake pressure Connect a gauge (scale 100 bar/1500psi) to brake circuits, see page no. 7003-14.

The pressure depends on the pedal stroke.

The braking pressure is adjustable by the adjusting screw (5) under the pedal. The max. pressure for the brake pistons is 68 bar (985psi) .

ENG 6-46840

5

issued 1- 03

Printed in Brazil

7003-8

BRAKE PEDAL DISASSEMBLY - ASSEMBLY

1 2

SECTION A - A

3

39

5

38

6

37

7 8

4

36

9

35

10

34

11

33

12

32

13

31

14

30

15

29

16

28

17

27

18 26

ENG 6-46840

41 40

21 25 24 23 22 21 20 19 issued 1- 03

Printed in Brazil

7003-9

Description of brake valve disassembly - assembly 1 - Blind nut M10 2 - Nut M4 3 - Flat washer 4 - Adjustment nut 5 - Dowel M4x50 6 - Spring seat 7 - Screw for spring compression 8 - Needle valve seat 9 - O-ring 10 - Piston for single direction valve holder 11 - Seal needle 12 - O-ring 13 - O-ring 14 - Valve spring 15 - O-ring 16 - Bushing for single direction valve holder 17 - O-ring 18 - O-ring 19 - O-ring 20 - Pressure switch plug 21 - O-ring 22 - Plug for single direction valve 23 - Spring for single direction valve 24 - Poppet valve body 25 - Poppet seat for single direction valve 26 - Accumulator charge valve body 27 - Snap ring 28 - Snap ring 29 - Adjusting washer 30 - Piston for priority valve 31 - Cone-shaped filter 32 - Spring for filter retaining 33 - O-ring 34 - O-ring

ENG 6-46840

35 - Spring for priority valve 36 - Charge valve cover 37 - Pin for single direction valve opening 38 - Spring for single direction valve opening 39 - Brake control spring 40 - Screw for double adjustment 41 - Lock washer 43 - Nut M8x1,25 (not used) 44 - Dowel M8x40 (not used) 45 - Protection 46 - Support 49 - Plug 50 - Washer 51 - Link rod 52 - Piston for brake control 53 - Upper spring guide 54 - Approach spring 55 - Pressure spring 56 - Seal 57 - Return spring 58 - Lower spring guide 59 - Snap ring 60 - Control valve piston 61 - O-ring 62 - Control valve body 63 - O-ring 64 - Control valve body 65 - Centering bushing 67 - Spring for control valve piston 68 - Screw TC M8x1,25x150

issued 1- 03

Printed in Brazil

7003-10 DISASSEMBLY - ASSEMBLY

Turn the machine off.

WARNING Relieve pressure from brake accumulators pressing on brake pedal repeatedly.

The brake pedal valve is located under the floor on the left side, with pedal.

Proceed as follows: - drain the oil from the hydraulic reservoir; - discharge the brakes pressure actuating the pedal repeatedly, with engine off; -

Lift the cab floor mat and remove the cover; disconnect electrical connections; before disassembly, tag the positions of the fittings and or tubes for assembly. disconnect the hydraulic tubes and fittings;

-

remove the cover (1) with brake valve; disassemble pedal;

1

Disassembly of brake pedal valve - Mark the position of the pedal valves - Remove screws (C2) holding control valve section assy to the bottom of the pressure charge section.

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

(C2)

ENG 6-46840

issued 1- 03

Printed in Brazil

7003-11

Separate the 4 sections making sure the inner details stay intact.

IMPORTANT The two braking modules are not the same; the module in contact with pedal support is the one with Ø 6 mm holes, supply and drain, not passing.

Braking modules are fitted with the select fit pistons. Do not reverse them.

Loading valve Braking module no. 1 Braking module no. 2

Support for pedal and working brake sleeve Accumulator charging valve Remove screws (C1) securing the cover, and remove internal components.

Cleaning and inspection of components Wash all components with a nonflammable, non-toxic detergent solution, and dry them with compressed air.

Any dirt entering the system can cause serious operational problems.

Inspect the sealing surfaces of the valve blocks. Check the sliding surfaces of the plungers and the condition of the relevant springs.

Reassembly Lubricate all the components to be reassembled.

Reassemble the components of the valve in the same order of the disassembly sequence and referring to the figure below.

Disassembly of loading valve 1. Cap nut M10 – 2. Accumulator recharge pressure max. Setting adjustment screw – 3. Locknut for screw (2) – 4. Accumulator recharge pressure min. Setting adjustment screw – 5. Locknut – 6. Accumulator charge valve spring – 7. Pilot plunger – 8. Accumulator charge valve sealing needle poppet – 9. Seal – 10. Delivery regulator valve – 11. Gasket – 12. Filter – 13. Check valve.

Tightening torque C1. Cover retaining screws torque 30Nm (22.2 lb.ft) C2. Valve body retaining screws torque 30Nm (22.2 lb.ft).

ENG 6-46840

issued 1- 03

Printed in Brazil

7003-12

Braking module (block) no. 1 and 2 Remove the braking proportional valve spool (15) and spring (26) from block no. 1 identifying it with the relevant block.

Braking module (block) no. 1

Remove the second block of the valve and recover the braking proportional valve (17) and balancing valve (14).

Disassembly of brake pedal valve blocks 14. Balance valve 15. Braking proportional valve 17. Braking proportional valve 26. Spring

Braking module (blocks) no. 2

ENG 6-46840

issued 1- 03

Printed in Brazil

7003-13

Support for pedal and working brake linkage Disassembly of pedal support and working brake linkage 16. Lower cup – 16 a. Upper cup – 18, 18 a, 19. Springs – 21. Control plunger – 25.Gasket.

ENG 6-46840

issued 1- 03

Printed in Brazil

7003-14

CHECK OF BRAKE CONTROL PRESSURES Check the accumulator charge pressure before cheking the brake application pressure Connect two pressure gauges G1 and G2 (100 bar 1450 psi capacity) to the pressure pick-up point indicated in figure.

Engage the parking brake.

Start the engine and at idle speed, actuate the brake pedal and check that the pressure indicated by the pressure gauges is 62 ÷ 68 bar (900 ÷ 985 psi).

Loosen locknut (E) and turn screw in or out the to adjust the pressures in case they are not within specifications.

Tighten nut after any resetting.

WARNING – Disconnect and reconnect all connections with engine off and system discharged.

The accumulators maintain some branches of the circuit pressurized with engine not running.

Pressurized fluid escaping from loose connections can cause personal injuries.

Always wear glasses with side shields.

ENG 6-46840

issued 1- 03

Printed in Brazil

7003-15

SETTING OF MIN. AND MAX. ACCUMULATOR RECHARGE PRESSURE Connect two pressure gauges M1 and M2 (200 bar 2900 PSI capacity) to the quick release pressure pick-up points (7 and 8, fig. ), located left side of the machine.

Start the engine and operate the hydraulic levers to warm-up the oil to 40o ÷ 50 o C (105 o ÷ 120 o F) Parking brake ON.

Minimum recharge value With engine idling and machine standing still, apply brake 8 to 10 times slowly. Read on gauges M1 and M2 the values of minimum on pressure, prior to the start of the recharge cycle The pressure gauges must read momentary 81÷87bar (1175 ÷ 1262 PSI).

If the minimum recharge pressure is different from the nominal value, remove cap (1), loosen nut (5) and adjust screw (4) slowly, until the correct value is obtained.

Check the pressure again before tightening locknut (3).

Recharge maximum value With engine at low idle read the maximum charging pressure on pressure gauges M1 and M2.

This pressure must be 120 ÷ 126bar (1740 ÷ 1827 PSI).

If the maximum recharge pressure is different from the nominal value, remove plug (1), loosen locknut (3) and adjust screw (2), until this value is obtained.

M1 and M2 Pressure gauges – 1. Cap – 2. Max. Pressure setting screw – 3. Locknut – 4. Min. pressure setting screw – 5. Nut – 6. Accumulators – 7. And 8. Pressure pick-up points thd M16 x 2.

ENG 6-46840

issued 1- 03

Printed in Brazil

7003-16

SPECIAL TOOL E

C F

D

B

A 94L95

CAS-10899 NITROGEN CHARGING KIT

DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR 1. Use the CAS-10899 nitrogen charging kit to discharge the accumulator, refer to illustration above. The tool must be disconnected from the nitrogen tank.

2. Close valves B, C and D. 3. Adjust the regulator A to the minimum pressure setting by turning the knob counterclockwise.

4. Turn the T-handle on valve F fully out.

5. Remove the guard and valve assembly cap from the accumulator.

6. Connect valve F to the valve stem on the accumulator.

7. Turn the T-handle inward on valve F to engage the pin in the valve stem.

8. Open valve D and check the charge pressure on gauge E. 9. To discharge the accumulator, partially open valve B. The accumulator charge will bleed down through the regulator.

10. Once the accumulator is fully discharged, disconnect valve F from the valve stem.

CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR 1. Make sure that the oil side of the accumulator is completely discharged by doing the following: A. Stop the engine.

B. Push down and release the brake pedal many times to release the pressure.

2. Connect a drain hose to the test connector in each brake circuit to release any pressure in the brake circuit.

5. Remove the cap screws and guard from the accumulator.

6. Remove the cap from the accumulator valve stem.

7. Connect valve F to the accumulator valve stem.

8. Make sure that valve D is open.

9. Turn the stem into valve F and read the pressure gauge E.

3. Close valves B and C on the nitrogen charging kit, refer to the illustration.

NOTE: See chart below for pressure readings.

4. Turn the stem out of valve F until the stem stops.

10. If the pressure is too low, charge the accumulator with dry nitrogen.

ENG 6-47760

Issued 1-03

Printed in Brazil

7003-17

CHARGING THE ACCUMULATOR WITH DRY NITROGEN NOTE: Check the pressure in the accumulator according to the instructions in Checking the Nitrogen Charge in the Accumulator. Keep the nitrogen charging kit connected to the accumulator.

1. Close (turn counterclockwise) valve A and open valve B. Close valves C and D. 2. Turn the stem out of valve F until the stem stops moving. Disconnect valve F from the accumulator valve stem.

3. Connect the nitrogen charging kit to a dry nitrogen tank.

4. Slowly turn valve A clockwise and read gauge E until the pressure is equal to charge pressure required for accumulator being charged. Stop turning valve A.

5. If the pressure increases above required pressure, quickly open and close valve D and read gauge E. If the pressure is still too high, close valve A (turn counterclockwise) a small amount and quickly open and close valve D. The pressure shown on gauge E is the charge pressure.

6. Connect valve F to the accumulator valve stem.

Turn the stem into valve F until the stem stops m ov i n g a n d o p e n va l ve D t o c h a r g e t h e accumulator.

7. After the accumulator stops charging, turn the stem out of valve F until the stem stops moving.

8. Close valve B and disconnect the nitrogen charging kit from the accumulator valve stem.

9. Install the cap on the accumulator valve stem.

I n s t a l l t h e g u a r d a n d c a p s c r ew s o n t h e accumulator.

TEMPERATURE 0° C 32° F 5° C 41° F 10° C 50° F 15° C 59° F 20° C 68° F 25° C 77° F 30° C 86° F 35° C 95° F 40° C 104° F

CHARGE PRESSURE 89.4 BAR 1297 PSI 91.1 BAR 1321 PSI 92.7 BAR 1345 PSI 94.4 BAR 1369 PSI 96.0 BAR 1392 PSI 97.6 BAR 1416 PSI 99.3 BAR 1440 PSI 100.9 BAR 1464 PSI 102.6 BAR 1487 PSI

TEMPERATURE/CHARGE PRESSURE PARKING BRAKE ACCUMULATOR

ENG 6-46840

TEMPERATURE 0° C 32° F 5° C 41° F 10° C 50° F 15° C 59° F 20° C 68° F 25° C 77° F 30° C 86° F 35° C 95° F 40° C 104° F

CHARGE PRESSURE 51.2 BAR 743 PSI 52.2 BAR 757 PSI 53.1 BAR 770 PSI 54.1 BAR 784 PSI 55.0 BAR 798 PSI 55.9 BAR 811 PSI 56.9 BAR 825 PSI 57.8 BAR 839 PSI 58.8 BAR 852 PSI

TEMPERATURE/CHARGE PRESSURE BRAKE ACCUMULATOR

Issued 1-03

Printed in Brazil

7003-18

TEST OF ACCUMULATOR PRECHARGE The accumulators installed in the brake system are of a membrane type with nitrogen precharge.

The natural porosity of the membrane and continuous operation, reduce, in time, the precharge pressure, reducing the efficiency of the accumulator.

It is recommended that a check is performed every six months, and, if required, the nitrogen precharge is reset.

The precharge pressure must never drop below 90 % of the nominal value.

The check operation must be performed with accumulators emptied of hydraulic oil.

Check brake accumulator condition , pressing pedal repetitively and slowly, with engine off, (at least 30 strokes).

Check the precharge as follows: - remove protection cover (1, figure) - loosen screw ½ turn (2) with Allen wrench; - Install tool 75298472 (D) on the accumulator connection; - check that cock (D2) is closed; - rotate handle (D1) to loosen screw (2); - when the pointer of pressure gauge (M) starts moving, loosen handle (D1) a turn further;

- At this point, the pressure gauge indicates the precharge pressure of the accumulator, that must read 60 bar.

If the pressure is within the specified value, proceed as follows: - shut handle (D1); - open cock (D2) to discharge the nitrogen pressure inside tool (D); - disconnect tool (D) from the accumulator;

Fig. 4.10 - Test of accumulators precharge D. Accumulator precharge test tool D1. Handle, plug 2 control D2. Discharge cock M. Pressure gauge 1. Protection cap 2. Threaded plug C1. Tightening of plug = 11 N.m ( 8.1 lb . ft)

- tighten screw (2)to a torque of 11 Nm (8.1 lb.ft); - check for accumulator leaks with soapy water.

- reinstall cap (1).

If the pressure is below the nominal value, recharge the accumulator proceeding as indicated in page 7003-17

Brz_ENG 6-46840

issued 1- 06

Printed in Brazil

7003-19

INSTRUCTIONS FOR THE RESETTING OF ACCUMULATOR PRECHARGE With tool 75298472 (D, figure) applied to the accumulator connection (refer to chapter 7003-16) proceed as follows: - remove the plug and connect the hose of the nitrogen tank, equipped with safety valve (V); WARNING To recharge accumulators use nitrogen only. Never use oxygen or other gases,since there is a risk of an explosion.

- open slowly the nitrogen tank cock and check the filling pressure on the pressure gauge (M);

IMPORTANT - The filling pressure must be at least 10% higher than the nominal value, considering that the pressure in the accumulator decreases when the compressed gas cools.

- shut the valve of the nitrogen reservoir; - wait 5 minutes; - check the pressure gauge (M) the pressure should be 60 bar.

- if lower, repeat the operation.

If the pressure is higher, proceed as follows: - rotate slowly valve (D2) to let nitrogen escape, thEn close it; Oserve the on pressure gauge (M) that the pressure is as desired. If not, repeat the operation; - turn handle (Dl) to tighten screw (2) on the accumulator; - remove tool (D); - tighten screw (2) to a torque of 11 Nm (8.1 lb.ft); - check the SEALING of the accumulator with soapy water; Retighten protection cap (1).

Accumulators recharge device A. Nitrogen tank - D. Accumulator precharge test tool – D1. Handle, plug 2 control - D2. Discharge cock M. Pressure gauge V. Safety valve - 1. Protection cap - 2. Threaded plug. – C1. Tightening of plug 11 Nm (8.1 lb.ft)

ENG 6-46840

issued 1- 03

Printed in Brazil

7003-20

BLEEDING OF BRAKES SYSTEM It is necessary to bleed the brakes system whenever one of following occurs: - after changing the hydraulic oil;

- after air has penetrate the system, due to leakage in the hydraulic system; - after disconnecting or replacing any component of the system.

To bleed the system proceed as described below (the operation requires two people):

Axle limited slip brakes system bleeding 2 plugs.

WARNING: The brakes are inoperative when undergoing maintenance or repair operations. place the machine on a flat surface and block the wheels.

-

place the machine on a flat surface, start the engine and park brake ON; with engine idling, one operator loosens the bleeding plug (see figure) and the other operator pushes the brake valve pedal; tighten the bleeding plug before releasing the pedal; repeat the operation until all the air is expelled from the system (the fluid must flow without air bubbles); repeat the same operation on the other axle.

ENG 6-46840

Differential lock axle brake system bleeding 4 plugs.

issued 1- 03

Printed in Brazil

8001-3

Service Position Before making any service, maintenance or inspection procedure, the grader must be placed in the Service Position.

1.

Park the grader on a level surface.

2. Place the transmission in neutral and apply the handbrake. Ensure the handbrake is correctly adjusted and in good working order.

3.

Lower the moldboard and all attachments to the ground. Do not apply down-pressure.

4.

Shut down the engine.

5.

Install the service pin in the LOCKED position (see the Operators Manual).

6.

Install chocks at the front and rear tandem wheels. Wedge the chocks in place.

7.

Relieve residual hydraulic pressure by operating all control levers.

8. Some hydraulic circuits may contain lock valves. Operating the control levers in these circuits will not relieve residual hydraulic pressure. Such pressure must be relieved by loosening a fitting or electrically activating the solenoid valve. Wear face and eye protection. Danger of spraying oil.

9.

Fasten a “DO NOT OPERATE” or similar warning tag on the steering wheel.

10. Remove and retain the ignition key.

11. Turn the battery isolation switch to the 0FF position.

1 2. Allow the engine and hydraulic system to cool before working in these areas.

13. Be aware of other service personnel in your work area.

14. If the service procedure includes welding, you must disconnect the following items: a) Negative battery cable. b) Positive battery cable. c) Power supply harness at the transmission controller. d) Transmission wiring harness at the controller (see the operators Manual). e) Alternator to battery wiring harness f)

24V-12V converter wiring harness at the fuse.

g) Float valve module (if installed) wiring harness at the module.

Connect the arc-welder ground cable as close as possible to the work area.

ENG 6-46870

May,2003

Printed in Brazil

8001-4

PUMP

REMOVAL

Disassembly of the hydraulic pump.

Open the hood.

845 hydraulic pump.

Type: Gear pump, fixed displacement, unloader valve load sensing, variable discharge.

Displacement :................ 91 Cu.cm/rev. (5.51Cu.in/rev.)

865 and 885 hydraulic pump .

Type: Piston pump, variable displacement, pressure and flow compensated, load sensing.

Displacement :............ 100 Cu.cm/rev. (6.10Cu.in/rev.)

To start disassembly of the pump, drain the hydraulic tank, disconnect the hoses and tube from the hydraulic pump.

ENG 6-46870

Issued 01-03

Printed in Brazil

8001-5

GRADER 845 PUMP REPAIR INSTRUCTIONS

The pump, with identification plate data, the inlet and the safety valve of the pump Below, is the cover of the outflow control valve.

DIAGRAM

OF

THE

1- Main Hydraulic Pump 2- Plug 3-Seal Gland 4-Seal Retainer 5-Packing Ring 6-Front Cover 7-Bushing 8-Lockwasher 9 - Bolt ENG 6-46870

PUMP

10-Driveshaft/Gear-Driving 11-Seal-Shaft 12-Driveshaft/Gear-Driven 13 - Wear Plate 14 - Plug 15 - Rear Cover 16-Nut-LoadSenseModule 17 - Spring 18 - O-Ring

19- Cap 20 - O-Ring - Relief Valve Cartridge Setscrew 21 - O-Ring- Relief Valve Cartridge Seat 22 - O-Ring- Relief Valve Cartridge 23 - Back - up Ring 24 - O-Ring - Relief Valve Cartridge Housing

May,2003

Printed in Brazil

8001-6

The load sensor module is a component integrated to the rear part of the hydraulic pump. The module allows the pump to discharge to the low pressure tank when it is not required . Each time the oil is required to run a function, the module reacts by giving priorities to the flow.

With no active function, there is no load sign on the load sensor line. The absence of load makes the spool move up against the spring. All the flow of the pump is directed to the by-pass port. The pressure is determined by the low unload spring force, is 90 psi.

Flow Control spool should be closed 10 bias pressure adjusting screw

CAPTION 1234-

ENG 6-46870

Load sense module housing Low unload spring Load sense port Unload spool

56789-

Fixed Bias Spring Bypass port to the tank Flow control Spool Discharge port Adjustable Bias spring

10-Bias pressure adjusting screw

Issued 01-03

Printed in Brazil

8001-7

When the piston gets to the end of its stroke or finds an resistance to flow load through the valve, the result is a reduction of the pressure. The pump increases the output flow. The flow control spool opens and directs all the remaining flow to the by-pass port. The outflow pressure is limited to 2500 psi.

The surface area in the load sense of the spool on the unloading spool is greater than the area a the pump discharge port. This area difference maintains the unloading spool seated against the pump housing when there is load sense signal present. The laod sense signal comes from the maximum pressure required to actuate any of the graders funstions.

When the system is operating in the flow control mode, the flow control spool rises, alowing excess pump outlet flow to by- pass to the tank port based upon the pump flow required at the Grader valve. The flow control spool will maintain an approximately 300 psi pressure difference between the pump outlet pressure and the load sense signal returned from the grader control valve. This 300 psi pressure difference will assure that any flow required at the grader valve will be available.

When the piston gets to the end of its stroke or finds a high resistance to flow through the grader valve., the result is an increase the load sense pressure. The maximum load sense pressure is limited by the load sense relief valve in the outlet section of the grader valve. The maximum load sense pressure specification is 2600 psi. which will result in the pump outlet pressure being 2900 psi, due to the 300 psi differential across the flow control spool.

ENG 6-46870

May,2003

Printed in Brazil

8001-8 DISASSEMBLING AND ASSEMBLY OF THE PUMP

Unfasten and remove the eight nuts and washers of the tap bolts.

Remove the front cover. Label the intersection of the teeth of the driven and drive gear with a marker before removing them off the pump. Carefully remove the drive gear off the pump and put it on a work bench.

Remove the drive gear off the pump and put it on a smooth surface.

ENG 6-46870

Issued 01-03

Printed in Brazil

8001-37

HYDRAULIC CONTROL VALVE Front view of the control valve: from left to right you can see the pressure valve adjusted with 214bar, the safety valve of the cylinder of the left side, and Load sense valve with 193 bar.

A - The Load Sense Valve 193± 3,5 bar.

B - Main pressure 214 bar.

A

B

The valve assembly is mounted just below the frame, at the height of the steering valve of the machine. It is accessed from under the machine. You can also see the retainer valve of the articulation system of the machine.

Control valve assembly is made up of 9 blocks, with spools and one way valves. It is a closed center type and has a Load Sensing port that allows it to control the feed pump flow; the Load Sense pressure is 179 ± 3,5 bar.

A - The Load Sense.

A

Front view of the valve. From left to right, you can see the main relief valve adjusted to 214 bar and the lift safety valves of the moldboard regulated to 103 ± 3,5 bar.

ENG 6-46870

Issued 01-03

Printed in Brazil

8001-38

The control valve of the service pressure is mounted on an independent block; it is a piloted type and can be adjusted by means of a screw.

Pressure control valve out of the distributor.

Pressure control valve removed; here you can see the pilot piston with its respective spring and also the nut and the screw for pressure adjustment.

Safety valve of the blade lift circuit; it is adjusted to 1.500 PSI. The distributor has two valves of this type, one for each blade lift cylinder.

ENG 6-46870

May,2003

Printed in Brazil

8001-39

LEGEND 1 - Compensator Spring 2 - Workport "A" 3 - Bridge 4 - Workport "B" 5 - Spool Centering Spring 6 - Spring Cap 7 - Spool 8 - Load Sense Drain to Tank 9 - Valve Body

10 - Load Sense Signal Passage 11 - Load Sense Signal Transfer Passage 12 - Pressure Passage 13 - Tank Passage 14 - Compensator Load Sense Signal Passage 15 - Compensator 16 - Load Sense Shuttle 17 - O-Ring

1.

Remove the special nuts and compression washers from the tie rods on the outlet endcap.

Keep the tie rods in the manifold valve assembly. The outlet endcap Is identified by a load sense signal port. Discard the nuts.

2.

Carefully place the manifold valve assembly on its end, resting on the three tie rod ends of the inlet endcap.

3.

Remove the outlet endcap.

ENG 6-46870

4.

Remove the O-ring, bias spring and compensator piston. Discard the O-ring. Store the bias spring and compensator piston in a safe, clean place and identified by the valve section from which they originated.

NOTE: The valve section next to the outlet endcap does not have a load sense shuttle disc.

You may need to use small straight nosed external snap ring pliers or similar small expanding tool to remove the compensator piston.

Issued 01-03

Printed in Brazil

8001-40

3. Remove the socket head screws and the spring cap.

4. Remove the spool end.

NOTE: To prevent the valve spool from rotating, insert a thin rod or similar tool in the linkage pin hole.

5. Remove the spring seats, spring and spool stop ring.

Removing Compensator Piston from Valve Section Housing 5. Remove the remaining valve sections, together with the load sense shuttle discs, installed between the eight valve sections.

Removing Spring Seats. Spring and Spool Stop Ring.

6. Pull the valve spool out of the valve section housing.

Removing Load Sense Shuttle Disc

Valve Section Disassembly 1 - Lightly clamp the valve section housing in a vise with soft jaws.

NOTE: Excessive clamping force may distort valve spool bore and compensator piston bore.

2. Remove the machine screws and the seal plate.

Removing Valve Spring from Valve Section Housing ENG 6-46870

Issued 01-03

Printed in Brazil

8001-41 7. Remove the O-ring from the spring retaining screw.

8. Remove and discard the wiper seals and O-rings.

All ports within the O-ring mating area of the valve sections rely on the machined surface for sealing.

Inspect the machined surfaces for scratches, grooves or other damage that may cause leakage between ports.

Inspect the housing casting for cracks especially at the tank passage section. This would be the result of excessive back pressure.

Valve Section – Assembly 1. Lightly clamp the valve section housing in a vise with soft jaws.

NOTE: Excessive clamping force may distort the valve spool bore and compensator piston bore.

Removing Spool Wiper Seals and O-Rings Cleaning and Inspection Immerse parts in fresh cleaning solvent. Agitate the parts to remove all foreign matter. Parts should remain in the solvent long enough to be thoroughly cleaned. Thoroughly rinse parts to remove all traces of dirt and solvent.

2. Lubricate new valve spool O-rings and install them in the valve section housing counterbores .

Lubricate and install new wiper seals against the O-rings in the valve section housing counterbores.

3. Lubricate and install the valve spool in the valve section housing.

After rinsing, immediately dry the parts using moisture free compressed air.

Lint-free, uncontaminated wiping rags can be used ensure all oil passages are unblocked. Wrap in clean, lint-free cloth or paper and store in a cool, dry place.

A careful and thorough inspection of all parts is extremely important. If you see any evidence of damage or wear, replace all defective items with genuine CASE parts.

Retain O-rings and wiper seals only for inspection and troubleshooting purposes. You must replace all O-rings and wiper seals when overhauling the main hydraulic manifold valve.

Valve Section Housing Inspect the spool bore and compensator piston bore for excessive wear scratches and grooves that will cause excessive leakage.

ENG 6-46870

Installing Valve Spool in Valve Section Housing 4. Lubricate and install a new O-ring on the spool end. Assemble the spring seats, spring and spool stop ring on the spool end.

5. Install the spool end assembly on the end of the valve spool. Torque the spool end assembly to 9 N.m ± 1,3 (7 lbf.ft ± 1) May,2003

Printed in Brazil

8001-42

Torque-tightening Spool End Assembly NOTA: To prevent the valve spool from rotating, insert a thin rod or similar tool in the linkage pin hole.

6. Install the spring cap. Make sure the mating face notches are clean.

7. Secure the spring cap with the socket head screws.

Torque the screws to 9 N.m±1,3 (7 lbf.ft ±1).

8. Secure the seal plate with the machine screws.

Torque the screws to 5 N.m±1,3 (4 Ibf~ft ±1).

Inlet Endcap and Three Tie Rods 4. Lubricate the mating surface with system oil.

Lubricate and install a new O-ring in the O-ring groove.

5. Install the valve section that is identified as being adjacent to the inlet endcap.

NOTE: Install the valve sections in their original order as identified before disassembly.

6. Insert the compensator piston into the compensator piston bore, nose end first.

Main Hydraulic Manifold Valve - Assembly 1. Install a new special nut and compression washer on each tie rod. Ensure two or three threads show at the end of each rod.

NOTE: The outside edge of the compression washer must contact the valve section housing and the center must contact the nut.

2.

Insert the tie rods into the inlet endcap.

3. Place the inlet endcap on its end, resting on the three tie rod ends.

ENG 6-46870

Installing Compensator Piston into Valve Section Housing

Issued 01-03 Printed in Brazil

8001-43

7. Insert the bias spring into the hollow end of the compensator piston.

16. Torque the lower tie rod nuts to 19N.m (14 lbf.ft ). This is the final torque value.

8. Install the load sense shuttle disc into the recess of the load sense passage.

17. Torque the upper tie rod nuts to 45 N.m (33 lbf.ft). This is the final torque value.

Torque Tie Rods Nuts Installing Load Sense Shuttle Disc

9.

Lubricate and install a new O-ring in the O-ring groove.

10. Repeat the installation steps until all the valve sections, including the outlet endcap, are installed.

11. Install the compression washers with the outside edge contacting the valve section housing.

Install new special nuts and tighten to finger tightness.

18. Check for proper spool movement.

Main Hydraulic Manifold Valve – Installation 1. Attach a safe lifting device to the manifold valve assembly. Carefully install the manifold valve assembly onto the manifold support.

2. Secure the manifold valve assembly with the four bolts, nuts, flatwashers and lockwashers.

2.

Connect the control rods to the valve spools.

Install the shoulder socket head bolts and new locknuts.

11. Place the manifold valve assembly on a precision flat surface.

NOTE: Torque-tightening the tie bolt nuts on a nonflat surface may cause spool or shuttle disc binding.

13. To align all valve sections and endcaps , press down on the endcaps before tightening the tie bolt nuts to the final torque value.

14. Torque the lower tie rod nuts to 9 N.m ± 3,4 (7 lbf.ft ± 2.5). This is a preliminary torque procedure.

15. Torque the upper tie rod nuts to 9 N.m ± 3,4 (7 lbf.ft ± 2.5 ). This is a preliminary torque procedure.

ENG 6-46870

Issued 01-03 Printed in Brazil

8001-44

DUAL

OVER

CENTER

(COUNTERBALANCE)

VALVE

Counterbalance valves with pilot assist combine two valves; a check valve and a relief valve. The check valve allows free flow from the directional valve (port 2) to the load (port 1) while a direct-acting, pilot-assisted relief valve controls flow from port 1 to port 2.

ADJUSTMENT - Pressure setting 207 bar (3000psi).

Turn screw (1) clockwise to reduce setting and counterwise to inclease setting.

Nut Torque 12Nm (108 lb.in).

See figure for position of o'rings and back up rings.

Valve Installation (2) Torque

60 - 70 Nm (45 - 50 lb.ft)

ENG 6-46870

Issued 01-03 Printed in Brazil

8001-45

ENG 6-46870

Issued 01-03 Printed in Brazil

8001-46

Dual over center valve, front scarifier and dozer blade cylinder.

ENG 6-46870

Issued 01-03 Printed in Brazil

8001-47

SOLENOID / PRESSURE REGULATING VALVE

View of the saddle pressure control valve and the command solenoid.

Disassembly of regulating valve: the pressure in the saddle circuit is 42 bar (600 psi) and can be adjusted by removing plug and rotate set screw clockwise to increase pressure.

View of pressure regulating valve cartrige.

ENG 6-46870

Issued 01-03 Printed in Brazil

8001-48

DUAL

CHECK

VALVE

This valve allows flow from the V ports to the C ports, while blocking flow from the C ports to the V ports when pressure is applied at opposite V port.

Retainer valve of wheel lean.

The retainer valve of the wheels is a simple valve, that has a safety system. It is composed of a piston and two onewayvalves.

The retainer valve of the wheel lean is located on the upper part of the frame support.

ENG 6-46870

Issued 01-03 Printed in Brazil

8001-49

HYDRAULIC CYLINDERS Hydraulic Cylinder – Removal WARNING: Place the grader in the Service Position.

Prior to removing cylinders, install any linkage or frame lock pins where applicable; especially wheel lean (see the Operators Manual).

Support the weight of the cylinders with a suitable lifting device.

!

WARNING 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.

MOLDBOARD LATERAL CYLINDER

!

WARNING Danger of spraying oil. Always wear face or eye protection when loosening hydraulic fittings. Fluid escaping under high pressure can penetrate skin causing serious injury.

Relieve all hydraulic pressure. Take care with hydraulic circuits that contain lock valves.

Disconnect the cylinder from all pivot pins, sockets or trunnions.

Disconnect the hydraulic hoses. Immediately plug the open ports and fittings to prevent contamination.

MOLDBOARD PITCH CYLINDER

Remove the cylinder to a work bench for disassembly.

Hydraulic Cylinder – Installation This is the reverse procedure of removal.

WHEEL LEAN CYLINDER

ENG 6-46870

Issued 01-03 Printed in Brazil

8001-50

MOLDBOARD LIFT CYLINDERS

CIRCLE SHIFT CYLINDER

SADDLE PIN LOCK CYLINDER

ENG 6-46870

WHEEL LEAN CYLINDER

ARTICULATION CYLINDER

SCARIFIER OR DOZER BLADE CYLINDER

Issued 01-03 Printed in Brazil

8001-51

RIPPER CYLINDER

Hydraulic Cylinder – Disassembly

Remove the piston assembly.

Drain any oil remaining in the cylinder in an appropriate container.

Unscrew (or unbolt) the cylinder head from the cylinder tube using wrench tool.

Pull the cylinder rod assembly from the tube.

Place the cylinder rod (pin end) in a vise and support the rod a suitable lifting device. Remove the piston retaining nut from the rod.

ENG 6-46870

Remove the seals from the piston.

Remove the head assembly.

Issued 01-03 Printed in Brazil

8001-52

Hydraulic Cylinder – Assembly Assembly of the cylinder is reverse procedure of disassembly with the following exceptions.

1- Check all parts for signs of excessive wear and compare dimensions with those listed in Specifications.

2- Install new bushings, seals and O-rings.

3 - Install piston assembly in same position that it was removed and tighten retaining nut to specifications.

Remove the O - rings.

Remove the seals.

ENG 6-46870

Issued 01-03 Printed in Brazil

8001-51

RIPPER CYLINDER

Hydraulic Cylinder – Disassembly

Remove the piston assembly.

Drain any oil remaining in the cylinder in an appropriate container.

Unscrew (or unbolt) the cylinder head from the cylinder tube using wrench tool.

Pull the cylinder rod assembly from the tube.

Place the cylinder rod (pin end) in a vise and support the rod a suitable lifting device. Remove the piston retaining nut from the rod.

ENG 6-46870

Remove the seals from the piston.

Remove the head assembly.

Issued 01-03 Printed in Brazil

8001-52

Hydraulic Cylinder – Assembly Assembly of the cylinder is reverse procedure of disassembly with the following exceptions.

1- Check all parts for signs of excessive wear and compare dimensions with those listed in Specifications.

2- Install new bushings, seals and O-rings.

3 - Install piston assembly in same position that it was removed and tighten retaining nut to specifications.

Remove the O - rings.

Remove the seals.

ENG 6-46870

Issued 01-03 Printed in Brazil

9004-3

1) CLEAN / REPLACE FRESH AIR FILTER. 1.1) Open the cover (external side cab) and remove nuts with 10mm wrench. Remove support and clean / replace fresh air filter.

2) CLEAN / REPLACE RECIRCULATED AIR FILTER. 2.1) Find 04 (four) nuts of evaporator housing support that is located at the bottom side of seat plate and remove the filter .

2.2) Use a Philips screw driver to remove 02 (two) bolts and replace the filter.

ENG 6-46970

Issued 01-03

Printed in Brazil

9004-4 3)TO REPLACE RESISTOR AND EVAPORATOR FAN. 3.1) Remove charge with proper equipment. Never let refrigerant charge flows to air.

3.2) Turn off two hot water valves located the machine engine compartment

3.3) Remove seat.

3.2) Remove seat plate.

3.3) Disconnect 02 (two) air conditioning hose assemblies. Use 16 and 22 mm wrench.

3.4) Disconnect 02 (two) hot water hoses removing clips with pliers

ENG 6-46970

May, 2003

Printed in Brazil

9004-5

3.5) Remove 03(three) bolts from evaporator housing. Use 13 mm wrench. Disconnect electrical cables and remove evaporator housing.

3.6) Put evaporator housing on a workbench. Disconnect electrical cable from resistor. Use a Philips screw driver to remove 02 (two) screws and replace resistor.

3.7) Remove 03 (three) bolts on each fan. Use a 8 mm wrench. Remove and replace fans.

4) REPLACE HEATER AND EVAPORATOR. 4.1) Follow steps 3.1 to 3.5, disconnect electrical cables, remove evaporator housing and put it on a workbench.

4.2) Remove 09 (nine) screws. Use a Philips screw driver. Remove cover.

4.3) Remove 02 ( two) screws. Use a Philips screw driver. Make sure that expansion valve support is free.

ENG 6-46970

Issued 01-03

Printed in Brazil

9004-6

4.4) Remove 06 (six) screws from evaporator and heater plate located at each side of evaporator housing. Use a Philips screw driver.

4.5) Remove evaporator first. Then, remove heater.

4.6) Replace evaporator and/or heater. In order to reassemble these parts, follow these steps backwards.

5) REPLACE THERMOSTATIC SWITCH AND EXPANSION VALVE. 5.1) Follow steps 4.1 to 4.5, without removing heater plate bolts (03). Remove evaporator and put it over workbench.

5.2) Remove 02 (two) screws from thermostatic switch support. Use a Philips screw driver. Remove and replace thermostatic switch. Make sure that its sensor (bulb) is correctly mounted at evaporator fins hole.

5.3) Remove expansion valve. Use 19 and 25mm wrench. Replace it and replace o-ring seal.

In order to reassemble evaporator, follow these steps in reverse order

ENG 6-46970

May, 2003

Printed in Brazil

9004-7 6) REPLACE COMPRESSOR AND BELT. 6.1) Remove charge with proper equipment. Never let refrigerant charge flow to air.

6.2) Disconnect electrical cable. Remove hose fitting. Use a 27mm wrench for suction hose and 22mm wrench for discharge hose. Remove 03 (three) bolts from compressor to make belt free. Use 17 mm wrench. Remove compressor.

6.3) Conduct repairs or replace compressor, mounting it at support. Check if its pulley is aligned with motor pulley. If it is not aligned, remove the bolts from compressor support. Handling support until the pulleys are aligned (used a rule or Tight the bolts.

6.4) Loosen free but do not remove the 03 (three) bolts from compressor. Replace belt with proper tension.

ENG 6-46970

Issued 01-03

Printed in Brazil

9004-8 L 7)REPLACE CONDENSER, RECEIVER DRIER AND PRESSURE SWITCH .

7.1) Remove charge with proper equipment. Never let refrigerant charge flow to air.

If is necessary, replace only switch pressure, do not remove charge.

7.2) Remove condenser hose fitting. Use 19 and 22mm wrench. Remove receiver drier hose fitting. Use 16 and 19mm wrench.

7.3) Remove 04 (four) bolts from condenser supports. Use a 17mm wrench. Put it on a workbench.

7.4) Replace condenser and receiver drier (it is important to replace receiver drier in order to prevent moisture contamination). Follow these steps in reverse order to reassembly these parts.

NOTE: be sure the correct position of inlet (IN) is mounted.

7.5) If it is necessary replace only pressure switch , do not remove charge and condenser. Remove only switch pressure fitting. Use a 17mm wrench. Do not remove pressure switch nut.

8) REPLACE AIR CONDITONING HOSE ASSY. 8.1) Hose assy assembly chart.

ENG 6-46970

Issued 01-03

Printed in Brazil

9004-9 8) REPLACE AIR CONDITONING HOSE ASSY. 8.1) Hose assy assembly chart.

POSITION 1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 16

P/N 75254533 75257962 75251988 75257955 75257956 75257954 75255522

75310261 75310923 75310260

DESCRIPTION EVAPORATOR BOX CONDENSER COMPRESOR HOSE COMPRESOR TO CONDENSER HOSE CONDENSER TO EVAPORATOR HOSE EVAPORATOR TO COMPRESOR CASE MOTOR CASE BELT GX 845 BELT65/885 O-RING SEAL #6 O-RING SEAL #8 O-RING SEAL #10 SCREW WASHER NUT

QTY 01 01 01 01 01 01 01 01 01 01 01 02 02 02 03 03 03

8.2) Remove charge with proper equipment. Never let refrigerant charge flow to air.

ENG 6-46970

Issued 01-03

Printed in Brazil

9004-10

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.

ENG 6-46970

May, 2003

Printed in Brazil

9004-11

9) AIR CONDITIONING CONTROL SWITCH. 9.1) The air conditioning switch controls are located at right side of cab.

Function of each one – refer to Operator's Manual.

9.2) Replace / maintenance of air conditioning switch control: remove panel cover. Be careful with electrical cables and heater valve cable.

9.3) Replace / maintenance of heating system.

9.3.1) Turn off two hot water valves located at machine engine compartment.

9.3.2) ) Disconnect 02 (two) hot water hoses removing clips with a pliers.

9.3.3) Remove heater control valve cable.

9.3.4) Replace valve. Follow these steps in reverse order to reassembly this part.

NOTE: refer to machine operator's manual in order to fill up radiator with water (in case some amount was lost during this procedure).

ENG 6-46970

Issued 01-03

Printed in Brazil

9007

Section 9007 REAR RIPPER

845 - 865 - 885 Grader

CNH Latino Americana Ltda.

2237, General David Sarnoff Avenue Contagem, MG - Brazil

ENG 6-47010

Printed in Brazil May, 2003

TABLE OF CONTENTS REAR RIPPER 845.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . . . 01 REAR RIPPER 865 / 885 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. 02

12 9007-01

REAR

RIPPER

845

SECTION

12

* Mount the articulation plates of the connecting rods and the tray on the rear frame * Mount the rear support with articulation connecting rods and the tray on the rear plate. * Mount the cylinder on the bearing and tighten the screws * Connect the tubes and hoses to the counterbalance valve

Dimensions A - Internal diameter of the support B - Internal diameter of the arm C - Internal diameter of the frame D - External diameter of the bushing Internal diameter of the bushing E- External diameter of the bolt

ENG 6-47010

m m 70.100 - 70.174 60.000 - 60.046 50.080 - 50.180 60.07 - 60.10 50.195 - 50.265 49.961 - 50.000

In. 2.7598 - 2.7627 2.3622 - 2.3640 1.9716 - 1.9756 2.365 2.366 1.9761 - 1.9789 1.9669 - 1.9685

May, 2003

Printed in Brazil

9007-02

Install the ripper teeth on the support with their respective bolts and cotter pins.

The teeth of the ripper are replaceable; to replace them, remove the elastic lock pin. .

Try to notice the mounting angle to avoid breaking the claws.

SECTION

REAR

RIPPER

865/885

12

The mounting process is similar to the one for the 845 Notice that, besides the ripper teeth, there are the scarifier teeth.

The scarifier replacement process is similar to that of the front. To replace the ripper teeth it is necessary to remove the elastic lock pins.

ENG 6-47010

May, 2003

Printed in Brazil

9010

Section 9010 Rops CAB

845 - 865 - 885 Grader

CNH Latino Americana Ltda.

2237, General David Sarnoff Avenue Contagem, MG - Brazil

ENG 6-47031

Printed in Brazil June, 2003

TABLE OF CONTENTS CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 INSTALLATION OF THE CLOSED AND OPEN CABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03 REMOVAL OF THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08

9010-01

TYPES OF CAB * FOPS and ROPS closed cab. * FOPS and ROPS open cab.

CHARACTERISTICS

* The closed cab has laminated safety glass for the windshield and the other glass is tempered. The interior is lined with vinyl, has a bottle holder, catalogue holder, lunch box, air diffusers, windshield wipers, front and rear washer, 2 (two) general and directional lamps, floor mat, thermal and acoustical insulation, flexible antenna for radio receiver, and loudspeakers. Mounting for: radio, air-conditioning with heater and blower fan

* The open cab has laminated safety glass for the windshield and the rear glass is tempered; 1 (one) general and directional lamp, windshield wiper and washer.

ENG 6-47030

June, 2003

Printed in Brazil

9010-02

Side view of the open cab.

Front view of the closed cab.

Rear view of the closed cab.

Side view of the closed cab .

ENG 6-47030

June,2003

Printed in Brazil

9010-03 INSTALLATION OF THE AND OPEN CABS

CLOSED

Hoist the cab with the proper lifting devices.

After lifting the cab, put the rubber seats on the contact surfaces of the cabin. Use Supercraft Threebond glue.

ENG 6-47030

June,2003

Printed in Brazil

9010-04

Release the support plate of the tension regulator

Disconnect the analog instrument panel.

Remove the analog panel support box.

Remove the vinyl covering lining of the central colums.

IMPORTANT: You must do this during the mounting to avoid damage to the air conditioning.

This operation is required only on closed cabs.

ENG 6-47030

June, 2003

Printed in Brazil

9010-05

Remove the plastic base of the central columns. This operation is required for closed cabs only.

Remove the disconnect switch box.

Mount the side panels and the access cover.

This operation is required for closed cabs only.

Tilt the pedestal fully backwards and the seat back fully forward. This operation makes it easy to lower the cab on the machine structure.

ENG 6-470300

June, 2003

Printed in Brazil

9010-06

Carefully lower the cab; pay attention to the electric cables and directional tube of the air conditioning.

Remove the access ladder on both sides.

Remove the lower protections from both sides.

With the help of a lever, align the holes between the cabin and the floor.

ATTENTION: The use of SAE Grade 8 bots is required use new self locking nuts each time They are removed.

ENG 6-47030

June, 2003

Printed in Brazil

9010-07 INSTALLATION OF THE AND OPEN CABS

CLOSED

Hoist the cab with the proper lifting devices.

After lifting the cab, put the rubber seats on the contact surfaces of the cabin. Use Supercraft Threebond glue.

Mounted cab.

Check the water level tank daily.

(390 to 485 ft.lbs)torque.

ENG 6-47030

June, 2003

Printed in Brazil