SERVICE MANUAL Motor Grader 836C 836C AWD 856C 856C AWD Part number 47829048 English January 2015 © 2015 CNH Industrial Italia S.p.A. All Rights Reserved.
SER VICE MANUAL 836C A 836C 856C A 856C 47829048 22/01/2015
Link Product / Engine
Product Market Product Engine 836C Europe F4HFE613Y*B003 836C A Europe F4HFE613Y*B003 856C Europe F4HFE613Y*B003 856C A Europe F4HFE613Y*B003 47829048 22/01/2015
Engine and crankcase
Selective Catalytic Reduction (SCR) exhaust treatment
Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment
cooling system
lubrication system
13]
transmission
Powershift transmission external controls
Powershift transmission lubrication system
Powershift transmission internal components
Final drive hub, steering knuckles, and shafts
Rear bevel gear set and dif ferential
and final drives T andem axle Chain drive system
Contents INTRODUCTION Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [10.001]
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.500]
. . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
Engine
Engine
T ransmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust
Powershift
Front axle system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [25.100] Powered
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 [25.108]
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [29.204] Reservoir , cooler , and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1 [29.218] Pump and motor components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.2 Brakes and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic service brakes 47829048 22/01/2015
T orque converter
front axle
Rear axle system
Planetary
Hydrostatic drive
10] Parking brake parking lock Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [35.000] Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.300] Reservoir , cooler , and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.102] Pump control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.105] Charge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 Hydraulic central joint [35.739] Swing arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8 [35.741] Dozer blade cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9 [35.742] Ripper hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10 [35.310] Distributor and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 1 Frames and ballasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic control components Pump Cylinders Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [44.51 Front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2 Cab climate control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heating Electrical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 47829048 22/01/2015
Battery
Selective Catalytic Reduction (SCR) electrical system
Exhaust Gas Recirculation (EGR) electrical system
Electronic modules
Cab controls Camera W
arning
blade and arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [86.1 10] Dozer blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.1 [86.1 12] Moldboard blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.2 T ools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ripper assembly Platform, cab, bodywork, and decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.120] Mechanically-adjusted operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 47829048 22/01/2015
and instruments Dozer
INTRODUCTION 47829048 22/01/2015 1
Foreword - Important notice regarding equipment servicing
All repair and maintenance work listed this manual must carried out only qualified dealership strictly complying with the instructions and whenever the special
Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall responsible for any subsequent
The manufacturer and all the organizations its distribution chain, including - without limitationnational, regional, local reject any responsibility for damages caused parts and / components not approved the facturer , including those used for the servicing repair the product manufactured marketed the manufacturer any case, warranty given attributed the product manufactured marketed the manufacturer case damages caused parts and / components not approved the manufacturer
The manufacturer reserves the right make improvements design and changes specifications any time without notice and without incurring any obligation install them units previously and illustrative material herein are accurate known time publication but are subject change without notice.
case refer your CASE
CONSTRUCTION Sales and Service
INTRODUCTION
47829048 22/01/2015 3
F
Safety rules
Personal safety
This the safety alert used alert you potential personal injury Obey all safety messages that follow this symbol avoid possible death injury .
Throughout this manual you will find the signal words W and CAUTION followed special These precautions are intended for the personal safety you and those working with
Read and understand all the safety messages this manual before you operate service the
DANGER indicates a hazardous situation not will result death serious injury
W
ARNING indicates a hazardous situation not could result death serious injury
CAUTION indicates a hazardous situation that, not avoided, could result minor moderate injury .
AILURE T O FOLLOW DANGER, W ARNING, AND CAUTION MESSAGES COULD RESUL T DEA SERIOUS INJUR Y .
Machine safety
NOTICE: Notice indicates a situation not could result machine property
Throughout this manual you will find the signal word Notice followed special instructions prevent machine property The word Notice used address practices not related personal safety
Information
NOTE: Note indicates additional information that clarifies other information this
Throughout this manual you will find the word Note followed additional information about a other information the The word Note not intended address personal safety property
INTRODUCTION
800C
47829048 22/01/2015 4
Personal safety
Carefully read this Manual before proceeding with refuelling other machine
Repairs have carried out only authorized and structed staf specific precautions have taken when welding when using mallets heavy mers.
Not authorized persons are not allowed repair carry out maintenance this machine. not carry out any work the equipment without prior
Ask your employer about the safety instructions force and safety
Nobody should allowed the cab during machine maintenance unless a qualified operator helping with the maintenance
necessary move the equipment carry out pairs not lift lower the equipment from any other position than the operator ’ s seat.
Never carry out any operation the machine when the engine running, except when specifically indicated.
Stop the engine and ensure that all pressure relieved from hydraulic circuits before removing caps, covers,
All repair and maintenance operations should carried out with the greatest care and
Service stairs and platforms used a workshop the field should built compliance with the safety rules
Any functional especially those fecting the safety the should therefore rectified immediately .
DANGER
Unexpected movement!
Make sure parking brake applied. Secure machine with wheel chocks. Failure comply will result death serious injury .
D0013A
Before performing any work the attach a maintenance progress This tag can applied the the cab door , any other well visible place.
TULI12WEX2004AA 1
INTRODUCTION
47829048 22/01/2015 5
Product identification
Record the machine and part identification numbers. When ordering parts, obtaining information assistance, always supply your dealer with the type and serial number your machine Keep a record these numbers and your Manufacturer ’ s Statement Origin a safe the machine report the numbers your local law enforcement agency
INTRODUCTION
SS14C1 1 Pos. Designation Pos. Designation 1 Model plate the machine 3 Model plate the cab 2 Model plate the engine 47829048 22/01/2015
SER VICE MANUAL Engine 836C A 836C 856C A 856C 47829048 22/01/2015
Engine - Engine and crankcase
Engine - Remove W ARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity . Always support units parts with suitable slings hooks. Make sure the work area clear all bystanders. Failure comply could result death serious injury
W0398A
Prior operation:
Rear wheels - Remove (44.520)
Hood - Remove (90.100) .
Selective Catalytic Reduction (SCR) muffler and catalyst - Remove (10.500)
Battery - Remove (55.302)
Radiator - Remove
Engine support and mounts - Remove (10.001)
Engine hood panel rear support - Remove (90.100) .
NOTE: the optional air conditioning system drain off the refrigerant a filling / draining system this not available, the air conditioning compressor should detached from the engine, the condenser from the combination cooler and the filter - drier from the bracket without cutting off the refrigerant
NOTE: Emissions sensors mounted the exhaust stream are sensitive extreme Use tools that generate extreme such impact wrenches and will result damage emission A void using these tools during any service procedure close proximity emission the use these tools cannot remove the sensors using extreme caution prior performing any service
Remove the screws (2)
Remove the two rear wheel cover (1) from the rear
Remove the screws (2)
Remove the four wheel cover brackets (1) from the rear axle.
1
SS14J050
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SS14K001
1
Detach the ground cables for the engine, cab and tery from the grounding point the right inside the
Remove the hoses from the Organic Acid T echnology (OA coolant tank (1) .
Remove the Organic Acid T echnology (OA coolant tank (1)
Remove the
Remove the hoses (3) from the fuel pump (1)
Remove the screws (2)
Remove the fuel pump (1)
- Engine and crankcase
Engine
INA 3
SS14K002 4
SS14K037 5
SS14K006 6 47829048 22/01/2015 10.1 [10.001] / 5
13. Remove the hose (3) .
14. Loosen the clamp (4) .
Loosen the clamps (2) from the air intake system (1)
Remove the air intake system (1)
17. Remove the hoses.
Detach all hydraulic lines from the hydraulic fluid
Screw two M12 eye bolts (1) into the hydraulic fluid tank and secure with lifting gear
Remove the three mounting bolts (2)
Remove the mounting bolt (3) from the
Engine - Engine and crankcase
the SS14K007 7
Remove
SS14K008 8
SS14K009 9
SS14K010 47829048 22/01/2015 10.1 [10.001] / 6
Engine - Engine and crankcase
22. Detach all hydraulic lines from the pump unit (1) . Remove the screws (2) Remove the pump unit (1) from the
25. Unscrew the 4 cap bolts (2) .
26. Remove the power transmission shaft (1) the mission
27. Remove the hydraulic components and hoses.
Secure the engine - transmission pump unit with lifting gear
29. Loosen the assembly mounting bolts (1) .
30. Carefully raise the engine out the grader frame.
SS14K01 1 1 1
SS14K012
SS14K013
47829048 22/01/2015 10.1 [10.001] / 7
SS14K014
31. Set the engine - transmission - pump unit down a suitable assembly and secure
Secure the transmission using lifting gear
Remove the cover from the flywheel housing gain access the four bolts (1) that connect the flywheel the torque converter
After loosening the first bolt (1) , turn the engine hand until the second bolt located the hole and can
Remove the other two bolts the same way
Next operation:
Powershift transmission - Remove (21.1 13)
Engine - Engine and crankcase
INA
SS14K015
47829048 22/01/2015 10.1 [10.001] / 8
Engine - Engine and crankcase
Engine - Install W ARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity . Always support units parts with suitable slings hooks. Make sure the work area clear all bystanders. Failure comply could result death serious injury
Prior operation:
Powershift transmission - Install (21.1 13)
Insert the first the four bolts (10) into the hole the flywheel housing and tighten temporarily .
T urn the engine hand the same way , insert and temporarily tighten the other three
Progressing tighten the transmission outer mounting bolts the engine.
T ighten the bolts with N·m ( 32.5 )
T ighten the four inner mounting bolts that fasten the flywheel the torque converter .
T ighten the bolts with N·m ( )
Check the engine mounts and replace necessary
Set the engine - transmission unit the using the lifting When doing check that not catching any hydraulic hoses electrical lines.
Screw the assembly mounting bolts (1) and tighten
W0398A
1
SS14K015
2
SS12D566
3 47829048 22/01/2015 10.1 [10.001] / 9
SS14K014
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Fix the power transmission shaft (1) the transmission with the four cap bolts (2)
Install the pump unit (1) the transmission.
10. Fix the pump unit (1) with the screws (2) .
1 Attach all hydraulic lines the pump unit (1)
With the lifting lift the hydraulic fluid tank onto the frame and align the
Fix the hydraulic fluid tank the frame with screws (2) and (3)
Unscrew the two M12 eye bolts (1) and remove
15. Connect the appropriate hydraulic lines the draulic fluid
Install the air intake system (1)
Lift the Selective Catalytic Reduction muf fler (SCR) (1) into the
Fix the clamps (2)
Fix the clamp (4)
Attach the hose (3)
Install the DEF / AdBlue refer Diesel Exhaust Fluid (DEF) / AdBlue® tank - Install (10.500) .
- Engine and crankcase
Engine
SS14K012 4
SS14K01 1 5
SS14K010 6
SS14K008 7
47829048 22/01/2015 10.1 [10.001] /
22. Install the fuel pump (1) with the screws (2) .
Attach the hoses (3) the fuel pump (1)
24. Install the following attachments.
Install the Organic Acid T echnology (OA coolant tank (1)
Attach the hoses the Organic Acid T echnology (OA coolant tank (1) SS14K017
Connect the ground cables for the and battery the grounding point the right inside the
Engine - Engine and crankcase
8
SS14K006
9
SS14K037
INA 1 1 47829048 22/01/2015 10.1 [10.001] / 1 1
Engine - Engine and crankcase
Next operation:
Engine hood panel rear support - Install (90.100)
Selective Catalytic Reduction (SCR) muffler and catalyst - Install (10.500)
Engine support and mounts - Install (10.001)
Radiator - Install Battery - Install (55.302)
Hood - Install (90.100) .
Rear wheels - Install Engine - Complete (10.001)
28. Install the four wheel cover brackets (1) the rear axle with the screws (2) SS14K001 Install the two rear wheel cover (1) the rear axle with the screws (2) . SS14J05047829048 22/01/2015 10.1 [10.001] /
Engine - Engine and crankcase
Engine - Complete
Fill with hydraulic fluid and engine draining / filling equipment fill the air ditioning system with
Start the engine and carry out a function
Check all connections for necessary , top the hydraulic fluid and engine
22/01/2015 10.1 [10.001] /
47829048
Engine - Engine and crankcase
Engine support and mounts - Remove
Removing support bracket together with exhaust muffler and handrail
Remove the hoses from the fuel pre - filter (1) .
Remove the fuel pre - filter (1) .
Loosen the clamp (3) from the dryer (1) the air
Loosen the hoses the screw fitting (2)
Remove the dryer (1)
Secure the bracket (1) using lifting gear
Loosen the mounting bolts from the right
Loosen the mounting bolts from the left side.
Raise the bracket (1) , taking care detach the flexible exhaust line from the exhaust pipe the turbocharger
1
SS14K003
2
SS14K004
3 47829048 22/01/2015 10.1 [10.001] /
SS14K022
Engine - Engine and crankcase
Engine support and mounts - Install
Install the bracket (1) using lifting gear
Fix the mounting bolts from the right
Fix the mounting bolts from the left
Attach the flexible exhaust line from the exhaust pipe the turbocharger
Install the dryer (1) and fix with the clamp (3)
Fix the hoses the screw fitting (2)
Install the fuel pre - filter (1)
Attach the hoses the fuel pre filter (1)
1
SS14K022
2
SS14K004
3 47829048 22/01/2015 10.1 [10.001] /
SS14K003