7 - BRAKES

8 - HYDRAULICS
9 - MOUNTED EQUIPMENT

845B / 845B DHP

865B / 865B VHP / 865B AWD
885B / 885B DHP / 885B AWD
Grader

SERVICE MANUAL

Printed in U.S.A. Part number 84559576

English
Copyright © 2011 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC. October 2011
Racine Wisconsin 53404 U.S.A.
 SECTION INDEX
Brakes
Section Title Section Number

Hydraulic Brake Troubleshooting ........................................................................................................................................... 7002

Brake Pedal Valve and System .............................................................................................................................................. 7003

Copyright © 2011 CNH America LLC.

CNH Latin America LTDA All Rights Reserved
2237, General David Sarnoff Avenue Printed in Brazil
Contagem - MG - Brazil 6-46810 ENG Issued July, 2011
 Section
7002

7002
HYDRAULIC BRAKE TROUBLESHOOTING

Copyright © 2011 CNH America LLC.

CNH Latin America LTDA All Rights Reserved
2237, General David Sarnoff Avenue Printed in Brazil
Contagem - MG - Brazil 6-46830 ENG Issued July, 2011
7002-2

TABLE OF CONTENTS
DEFECTS.......................................................................................................................................................................................3

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DEFECTS
TROUBLESHOOTING CAUSE REMEDIES
The braking action does not stop Brake pedal seized. Repair or replace brake pedal valve.
after releasing the brake pedal. Brake pedal not completely released. Check that no hardened mud or foreign material
are located under the pedal. Check that with the
pedal is totally released and there is no output
pressure from the brake valve.
Hard pedal travel. Brake pedal valve pistons seized Repair brake pedal valve
Hard braking operation. Wrong pressure setting. Checkpressure.
Weak braking effect. Low brake pressure. Check pressure.
Brake discs (axle) need to be replaced. Replace discs.
Air in the system. Bleed system.
Oil leaks in system. Inspect and eliminate leaks.
Recharge pressure of accumulators below Check pressure.
nominal value or brake accumulators inefficient.
The accumulators do not recharge. Contamination seized the priority valve (in brake Repair or replace brake pedal valve.
pedal valve).
Braking pressure fluctuating. Recharge pressure of accumulators lower than Check recharge pressure.
nominal value.
(If recharge pressure of accumulators is low, the
brake low pressure indicator on panel should be
ON).
The pressure switch is set at 65 ± 5 bar ( 942 ±
72 psi). Check the precharging pressure of the
accumulators.
The brake charge pump overheats. The recharge pressure of the accumulators is Check recharge pressure.
lower than nominal value (refer to description
above).
Oil leaks from brake pedal valve. Repair or replace brake pedal valve.
Brakes low pressure indicator on Accumulators recharge pressure lower than the Repair or replace pressure valve.
panel stays ON. nominal value.
Oil leakages from brake pedal valve.
Delayed braking and / or pedal Brake valve pressure / flow insufficient. Check that the brakes system tubes are not
return damaged.
High viscosity of the hydraulic fluid.
Braking pressure not constant. Pressure in accumulators not correct. Check for correct accumulator charge pressure;
if necessary, adjust the nitrogen charge presion
Continuous recharge of the Accumulators with too low or too high nitrogen Check nitrogen pressure in accumulators.
accumulators precharge. Worn pump.
Brake pump always under Worn pump. Repair or replace pump.
pressure Dirt in the valve. Careful check of the valve (correct sliding of the
cad seats.
Accumulators don’t charge. Contamination in the priority valve. Check the sliding of all spools, mainly of the inlet
valve.
Check the hydraulic connection.
Brakes remain applied Restricted discharge port. Check that the pedal stop adjuster allows
backlash between return and operating piston.
Non return of the pedal. Eliminate possible contamination in the valve.
Dashboard indicator always off or The pressure switch fails to operate. Replace pressure switch
always on
Brake pedal pulsate Sudden pressure changes on the outlet. Check that there are no obstructions along
discharge line.

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NOTES

6-46830 ENG Issued 07-11 Printed in Brazil

 Section
7003

7003
BRAKE PEDAL VALVE AND SYSTEM

Copyright © 2011 CNH America LLC.

CNH Latin America LTDA All Rights Reserved
2237, General David Sarnoff Avenue Printed in Brazil
Contagem - MG - Brazil 6-46840 ENG Issued July, 2011
7003-2

TABLE OF CONTENTS
BRAKE PEDAL VALVE...................................................................................................................................................................3
Description...............................................................................................................................................................................3
Operation.................................................................................................................................................................................5
SPECIFICATIONS..........................................................................................................................................................................6
MAINTENANCE.............................................................................................................................................................................7
Maintenance Standard............................................................................................................................................................7
Setting.....................................................................................................................................................................................7
Adjustment Of Service Brake Pressure...................................................................................................................................7
BRAKE PEDAL DISASSEMBLY / ASSEMBLY...............................................................................................................................8
Disassembly / Assembly........................................................................................................................................................10
CHECK OF BRAKE CONTROL PRESSURES............................................................................................................................14
SETTING OF MIN. AND MAX. ACCUMULATOR.........................................................................................................................15
Recharge Pressure................................................................................................................................................................15
SPECIAL TOOL............................................................................................................................................................................16
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR.......................................................................................16
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR.............................................................................................16
CHARGING THE ACCUMULATOR WITH DRY NITROGEN.......................................................................................................17
TEST OF ACCUMULATOR PRECHARGE..................................................................................................................................18
INSTRUCTIONS FOR THE RESETTING OF ACCUMULATOR PRECHARGE..........................................................................19
BLEEDING OF BRAKES SYSTEM..............................................................................................................................................20

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 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.

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.

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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.

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 7003-5

Operation
The brake pedal valve controls the charge of the accumu- DIFFERENTIAL LOCK
lators 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 stea-
dy 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 P Pressure, from steering priority valve "EF"
(set at 41-102 psi) monitors the pressure on the rearaxle B Discharge to hydraulic oil tank
brake circuit and energises the stop lights. T Discharge to hydraulic oil tank
S1 Stop lights pressure switch
LIMITED SLIP T1 Delivery to right side axle
T2 Delivery to left side axle
R1 Service accumulator
R2 Service accumulator
S2 Brakes system low pressure switch

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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

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 7003-7

MAINTENANCE
Maintenance Standard
•• The precautions to be strictly observed during the as-
sembly operations are listed below.
•• Ensure that connections and lines are clean; foreign
materials and dust in the system will cause malfunc-
tions 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 acti-
vete 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 ac-
cumulator charge valve.
The pressure of max. charge of the accumulators is 120
bar (1740psi), and minimum 81bar (1175psi).

Adjustment Of Service Brake

Pressure
Connect a gauge (scale 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 pis-
tons is 68 bar (985psi) .

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7003-8

BRAKE PEDAL DISASSEMBLY / ASSEMBLY

SECTION A - A

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 7003-9
Description of brake valve disassembly - assembly
1. Blind nut M10 33. O-ring
2. Nut M4 34. O-ring
3. Flat washer 35. Spring for priority valve
4. Adjustment nut 36. Charge valve cover
5. Dowel M4x50 37. Pin for single direction valve opening
6. Spring seat 38. Spring for single direction valve opening
7. Screw for spring compression 39. Brake control spring
8. Needle valve seat 40. Screw for double adjustment
9. O-ring 41. Lock washer
10. Piston for single direction valve holder 43. Nut M8x1,25 (not used)
11. Seal needle 44. Dowel M8x40 (not used)
12. O-ring 45. Protection
13. O-ring 46. Support
14. Valve spring 49. Plug
15. O-ring 50. Washer
16. Bushing for single direction valve holder 51. Link rod
17. O-ring 52. Piston for brake control
18. O-ring 53. Upper spring guide
19. O-ring 54. Approach spring
20. Pressure switch plug 55. Pressure spring
21. O-ring 56. Seal
22. Plug for single direction valve 57. Return spring
23. Spring for single direction valve 58. Lower spring guide
24. Poppet valve body 59. Snap ring
25. Poppet seat for single direction valve 60. Control valve piston
26. Accumulator charge valve body 61. O-ring
27. Snap ring 62. Control valve body
28. Snap ring 63. O-ring
29. Adjusting washer 64. Control valve body
30. Piston for priority valve 65. Centering bushing
31. Cone-shaped filter 67. Spring for control valve piston
32. Spring for filter retaining 68. Screw TC M8x1,25x150

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7003-10

Disassembly / Assembly
Turn the machine off.

WARNING: Relieve pressure from

brake accumulators pressing on brake
pedal repeatedly.

The brake pedal valve is located under the floor

on the left side, with pedal.

Proceed as follows:
• drain the oil from the hydraulic reservoir;
• discharge the brakes pressure actuating the
pedal repeatedly, with engine off;
• Lift the cab floor mat and remove the cover;
• disconnect electrical connections;
• before disassembly, tag the positions of the
fittings and or tubes for assembly.
• disconnect the hydraulic tubes and fittings;
• remove the cover (1) with brake valve;
• disassemble pedal;

Disassembly of brake pedal valve

• Mark the position of the pedal valves

• Remove screws (C2) holding control valve
section assy to the bottom of the pressure
charge section.
• For assembly tighten the screws to a torque
of 30Nm (22 lb ft.)

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 7003-11
Separate the 4 sections making sure the inner
details stay intact.

IMPORTANT: The two braking modules are Loading valve

not the same; the module in contact with pedal Braking module no. 1
support is the one with Ø 6 mm holes, supply
Braking module no. 2
and drain, not passing.
Braking modules are fitted with the select fit
pistons. Do not reverse them.

Accumulator charging valve

Remove screws (C1) securing the cover, and Support for pedal and working brake sleeve
remove internal components.
Inspect the sealing surfaces of the valve blocks.
Cleaning and inspection of components Check the sliding surfaces of the plungers and
Wash all components with a nonflammable, the condition of the relevant springs.
non-toxic detergent solution, and dry them with
compressed air. Reassembly
Any dirt entering the system can cause serious Lubricate all the components to be
operational problems. 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 Tightening torque
5. Locknut
6. Accumulator charge valve spring C1 Cover retaining screws torque 30Nm (22.2
7. Pilot plunger lb.ft)
8. Accumulator charge valve sealing needle C2 Valve body retaining screws torque 30Nm
poppet (22.2 lb.ft)
9. Seal
10. Delivery regulator valve
11. Gasket
12. Filter
13. Check valve

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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

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 7003-13
Support for pedal and working brake linkage

Disassembly of pedal support and working brake linkage

16. Lower cup

16a. Upper cup
18. Springs
18a. Springs
19. Springs
21. Control plunger
25. Gasket

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7003-14

CHECK OF BRAKE CONTROL PRESSURES

Connect two pressure gauges G1 and G2 (100
bar 1450 psi capacity) to the pressure pick-up
point indicated in figure.
Engage the parking brake.
Start the engine and at idle speed, actuate
the brake pedal and check that the pressure
indicated by the pressure gauges is 62 ÷ 68 bar
(900 ÷ 985 psi).
Loosen locknut (E) and turn screw in or out the to
adjust the pressures in case they are not within
specifications.
Tighten nut after any resetting.

WARNING: Disconnect and reconnect

all connections with engine off and
system discharged. The accumulators
maintain some branches of the circuit
pressurized with engine not running.
Pressurized fluid escaping from loose
connections can cause personal
injuries. Always wear glasses with side
shields.

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 7003-15

SETTING OF MIN. AND MAX. ACCUMULATOR

Recharge Pressure If the minimum recharge pressure is different
Connect two pressure gauges M1 and M2 (200 from the nominal value, remove cap (1), loosen
bar 2900 PSI capacity) to the quick release nut (5) and adjust screw (4) slowly, until the
pressure pick-up points (7 and 8, fig. ), located correct value is obtained.
left side of the machine. Check the pressure again before tightening
Start the engine and operate the hydraulic levers locknut (3).
to warm-up the oil to 40o ÷ 50 o C (105 o ÷ 120
o F) Parking brake ON.
Recharge maximum value
Minimum recharge value With engine at low idle read the maximum
With engine idling and machine standing still, ap- charging pressure on pressure gauges M1 and
ply brake 8 to 10 times slowly. Read on gauges M2.
M1 and M2 the values of minimum on pressure, This pressure must be 120 ÷ 126bar (1740 ÷
prior to the start of the recharge cycle. 1827 PSI).
The pressure gauges must read momentary If the maximum recharge pressure is different
81÷87bar (1175 ÷ 1262 PSI). from the nominal value, remove plug (1), loosen
locknut (3) and adjust screw (2), until this value
is obtained.

M1 PRESSURE GAUGES 4. MIN. PRESSURE SETTING SCREW

M2 PRESSURE GAUGES 5. NUT
1. CAP 6. ACCUMULATORS
2. MAX. PRESSURE SETTING SCREW 7. PRESSURE PICK-UP POINTS THD M16 X 2.
3. LOCKNUT 8. PRESSURE PICK-UP POINTS THD M16 X 2.

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7003-16

SPECIAL TOOL

CAS-10899 NITROGEN CHARGING KIT

DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

1. Use the CAS-10899 nitrogen charging kit to 6. Connect valve F to the valve stem on the
discharge the accumulator, refer to illustration accumulator.
above. The tool must be disconnected from 7. Turn the T-handle inward on valve F to
the nitrogen tank. engage the pin in the valve stem.
2. Close valves B, C and D. 8. Open valve D and check the charge pressure
3. Adjust the regulator A to the minimum on gauge E.
pressure setting by turning the knob 9. To discharge the accumulator, partially open
counterclockwise. valve B. The accumulator charge will bleed
4. Turn the T-handle on valve F fully out. down through the regulator.
5. Remove the guard and valve assembly cap 10. Once the accumulator is fully discharged,
from the accumulator. disconnect valve F from the valve stem.

CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR

1. Make sure that the oil side of the accumulator 6. Remove the cap from the accumulator valve
is completely discharged by doing the stem.
following: 7. Connect valve F to the accumulator valve
A. Stop the engine. stem.
B. Push down and release the brake pedal 8. Make sure that valve D is open.
many times to release the pressure. 9. Turn the stem into valve F and read the
2. Connect a drain hose to the test connector in pressure gauge E.
each brake circuit to release any pressure in
the brake circuit. NOTE: See chart below for pressure readings.
3. Close valves B and C on the nitrogen
charging kit, refer to the illustration. 10. If the pressure is too low, charge the
4. Turn the stem out of valve F until the stem accumulator with dry nitrogen.
stops.
5. Remove the cap screws and guard from the
accumulator.

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 7003-17

CHARGING THE ACCUMULATOR WITH DRY NITROGEN

NOTE: Check the pressure in the accumulator 6. Connect valve F to the accumulator valve
according to the instructions in Checking the stem. Turn the stem into valve F until the
Nitrogen Charge in the Accumulator. Keep stem stops moving and open valve D to
the nitrogen charging kit connected to the charge the accumulator.
accumulator. 7. After the accumulator stops charging, turn
the stem out of valve F until the stem stops
1. Close (turn counterclockwise) valve A and moving.
open valve B. Close valves C and D. 8. Close valve B and disconnect the nitrogen
2. Turn the stem out of valve F until the stem charging kit from the accumulator valve
stops moving. Disconnect val ve F f rom the stem.
accumulator valve stem. 9. Install the cap on the accumulator valve
3. Connect the nitrogen charging kit to a dry stem. Install the guard and cap screws on
nitrogen tank. the accumulator.
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.

TEMPERATURE CHARGE PRESSURE TEMPERATURE CHARGE PRESSURE

0° C 32° F 89.4 BAR 1297 PSI 0° C 32° F 51.2 BAR 743 PSI
5° C 41° F 91.1 BAR 1321 PSI 5° C 41° F 52.2 BAR 757 PSI
10° C 50° F 92.7 BAR 1345 PSI 10° C 50° F 53.1 BAR 770 PSI
15° C 59° F 94.4 BAR 1369 PSI 15° C 59° F 54.1 BAR 784 PSI
20° C 68° F 96.0 BAR 1392 PSI 20° C 68° F 55.0 BAR 798 PSI
25° C 77° F 97.6 BAR 1416 PSI 25° C 77° F 55.9 BAR 811 PSI
30° C 86° F 99.3 BAR 1440 PSI 30° C 86° F 56.9 BAR 825 PSI
35° C 95° F 100.9 BAR 1464 PSI 35° C 95° F 57.8 BAR 839 PSI
40° C 104° F 102.6 BAR 1487 PSI 40° C 104° F 58.8 BAR 852 PSI

TEMPERATURE/CHARGE PRESSURE TEMPERATURE/CHARGE PRESSURE

PARKING BRAKE ACCUMULATOR BRAKE ACCUMULATOR

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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;
• tighten screw (2)to a torque of 11 Nm (8.1
Fig. 4.10 - Test of accumulators precharge
lb.ft);
• check for accumulator leaks with soapy
D. Accumulator precharge test tool
water.
D1. Handle, plug 2 control
• reinstall cap (1).
D2. Discharge cock
M. Pressure gauge
If the pressure is below the nominal value,
1. Protection cap
recharge the accumulator proceeding as 2. Threaded plug
indicated in page 7003-17 C1. Tightening of plug = 11 N.m ( 8.1 lb . ft)

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 7003-19

INSTRUCTIONS FOR THE RESETTING OF ACCUMULATOR PRECHARGE

With tool 75298472 (D, figure) applied to the • shut the valve of the nitrogen reservoir;
accumulator connection (refer to chapter 7003- • wait 5 minutes;
16) proceed as follows: • check the pressure gauge (M) the pressure
• remove the plug and connect the hose of should be 60 bar.
the nitrogen tank, equipped with safety valve • if lower, repeat the operation.
(V);
If the pressure is higher, proceed as follows:
WARNING:To recharge accumulators • rotate slowly valve (D2) to let nitrogen
use nitrogen only. Never use oxygen or escape, thEn close it;
other gases,since there is a risk of an • Oserve the on pressure gauge (M) that the
explosion. pressure is as desired. If not, repeat the
operation;
• turn handle (Dl) to tighten screw (2) on the
• open slowly the nitrogen tank cock and accumulator;
check the filling pressure on the pressure • remove tool (D);
gauge (M); • tighten screw (2) to a torque of 11 Nm (8.1
lb.ft);
IMPORTANT - The filling pressure must be • check the SEALING of the accumulator with
at least 10% higher than the nominal value, soapy water;
considering that the pressure in the accumulator
decreases when the compressed gas cools. 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)

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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

WARNING: The brakes are inoperative plugs.
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 Differential lock axle brake system bleeding 4
air is expelled from the system plugs.
(the fluid must flow without air
bubbles);
• repeat the same operation on the
other axle.

6-46840 ENG Issued 07-11 Printed in Brazil

 SECTION INDEX
Hydraulics
Section Title Section Number

Removal and Installation of Hydraulic Components . ............................................................................................................. 8001

Front Wheel Drive Hydraulic Pump and Motor – 865B AWD / 885B AWD Models ................................................................ 8003

Hydraulic Schematics – 865B AWD / 885B AWD Models ...................................................................................................... 8004

Copyright © 2011 CNH America LLC.

CNH Latin America LTDA All Rights Reserved
2237, General David Sarnoff Avenue Printed in Brazil
Contagem - MG - Brazil 6-46812 ENG Issued July, 2011
 8001
Section
8001

REMOVAL AND INSTALLATION OF HYDRAULIC COMPONENTS

Copyright © 2011 CNH America LLC.

CNH Latin America LTDA All Rights Reserved
2237, General David Sarnoff Avenue Printed in Brazil
Contagem - MG - Brazil 6-46870 ENG Issued July, 2011
8001-2

TABLE OF CONTENTS
SERVICE POSITION......................................................................................................................................................................3
PUMP REMOVAL...........................................................................................................................................................................4
PUMP REPAIR INSTRUCTIONS...................................................................................................................................................5
DISASSEMBLING AND ASSEMBLY OF THE PUMP....................................................................................................................9
Inspection of the Parts for Wear............................................................................................................................................12
DISASSEMBLE THE PILOT VALVE.............................................................................................................................................18
REPLACEMENT OF THE INPUT SEAL.......................................................................................................................................28
RETAINERS AND COMPONENTS KIT.......................................................................................................................................30
PILOT VALVE...............................................................................................................................................................................31
HYDRAULIC CONTROL VALVE..................................................................................................................................................38
Valve Section Disassembly....................................................................................................................................................42
Cleaning and Inspection........................................................................................................................................................43
Valve Section Housing...........................................................................................................................................................43
Valve Section – Assembly......................................................................................................................................................44
Main Hydraulic Manifold Valve.......................................................................................................................................45
Assembly...............................................................................................................................................................................45
Installation.............................................................................................................................................................................47
DUAL OVER CENTER (COUNTERBALANCE) VALVE...............................................................................................................48
SOLENOID / PRESSURE REGULATING VALVE........................................................................................................................51
DUAL CHECK VALVE..................................................................................................................................................................52
HYDRAULIC CYLINDERS...........................................................................................................................................................53
Removal................................................................................................................................................................................53
Installation.............................................................................................................................................................................54
RIPPER CYLINDER.....................................................................................................................................................................55
Disassembly..........................................................................................................................................................................55
Assembly...............................................................................................................................................................................56
SPECIFICATIONS........................................................................................................................................................................57
Moldboard Lateral Shift Cylinder...........................................................................................................................................57
Moldboard Pitch Cylinder......................................................................................................................................................57
Wheel Lean Cylinder.............................................................................................................................................................58
Moldboard Lift Cylinder..........................................................................................................................................................58
Saddle Pin Lock Cylinder (5 Point Saddle)............................................................................................................................59
Steering Cylinder...................................................................................................................................................................60
Articulation Cylinder...............................................................................................................................................................61
Scarifier Cylinder...................................................................................................................................................................61
Ripper Cylinder......................................................................................................................................................................62

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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.

12. 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.

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PUMP REMOVAL
Disassembly of the hydraulic pump.

Open the hood.

845B Models – Hydraulic Pump

Type: Gear pump, fixed displacement, unloader

valve load sensing, variable discharge.

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

865B and 885B Models – Hydraulic Pump

Type: Piston pump, variable displacement,

pressure and flow compensated, load sensing.

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

To start disassembly of the pump, drain the

hydraulic tank, disconnect the hoses and tube
from the hydraulic pump.

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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.

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8001-6
DIAGRAM OF THE PUMP

1. Main Hydraulic Pump 13. Wear Plate

2. Plug 14. Plug
3. Seal Gland 15. Rear Cover
4. Seal Retainer 16. Nut- LoadSenseModule
5. Packing Ring 17. Spring
6. Front Cover 18. O-Ring
7. Bushing 19. Cap
8. Lockwasher 20. O-Ring - Relief Valve Cartridge Setscrew
9. Bolt 21. O-Ring- Relief Valve Cartridge Seat
10. Driveshaft/Gear- Driving 22. O-Ring- Relief Valve Cartridge
11. Seal- Shaft 23. Back - up Ring
12. Driveshaft/Gear- Driven 24. O-Ring - Relief Valve Cartridge Housing

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 8001-7
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

1. Load sense module housing 6. Bypass port to the tank

2. Low unload spring 7. Flow control Spool
3. Load sense port 8. Discharge port
4. Unload spool 9. Adjustable Bias spring
5. Fixed Bias Spring 10. Bias pressure adjusting screw

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8001-8
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.

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 8001-9

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.

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8001-10
Remove the central section of the pump.

Remove the eight tap bolts of the rear cover.

Remove the seal retainer of the rear cover and

discard it. Remove er ar cover and discard it.

Remove the seal gasket of the rear cover and

replace it with wwa new part.

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 8001-11
Remove the square section o-ring and discard it.
Replace it with a new part.

Remove the wear plate of the front cover.

Remove the rubber plug of the drain seal.

Remove the retainer seal of the front cover and

discard it. Replace it with a new part.

Remove the gasket of the front cover and discard

it. Replace it with a new part.

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8001-12
Remove the square section o-ring of the front
cover and discard it. Replace it with a new part.

Remove the retainer if there is one installed on

the front cover and use a screwdriver or another
tool to remove the retainer from the front cover
shaft.

Inspection of the Parts for Wear

Clean all parts before inspecting them. It is not
necessary to inspect the retainers that must be
replaced from the front cover shaft.

Inspect the surface of the gears of both shafts

for excessive wear or scratches.

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 8001-13
Inspect the bushings on the front cover for
excessive wear, flacking, or movement of the
bushings.

Inspect the bushings on the rear cover for

excessive wear, flacking, or movement of the
bushings.

Inspect the central section of the gear casing.

It must not show excessive wear or deep
scratches.

Inspect the bronze side from both plates for

erosion and scratches. Replace them if they
are damaged.The left model is used on the G30
barnes pump.

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8001-14
Typical content of the repairs of the pump G30.

Install a new retainer on the front cover. Mount

the retainer with a stop spring for the internal part
of the pump. Press the retainer on the diameter
of the pump housing. You must apply a uniform
pressure to prevent the retainer from getting out-
of-true or damaged. Lubricate the retainer with
graphite grease after installing it.

Put the rear cover on a work bench with the

retainer cavity up. Lubricate the retainer cavity
with graphite grease.

Put the rear cover on a work bench with the

retainaer cavity up. Lubricate the retainer cavity
with graphite grease.

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 8001-15
Install the assembly on the rear cover cavity. Be
very careful when you press the assembly into
place: it must seat firmly in its housing. This is
important for the installation of the bronze wear
plate.

Lubricate the bronze surface of the wear plate

and install the retainer over it. This picture shows
the wear plate of the G20, the wear plate of the
G30 is different.

Apply a thin coat of graphite grease on the

housing of the square section o-ring and carefully
install it in the housing. Take care that the o-ring
dos not spin in the housing: it must be correctly
positioned inside the housing or the pump will
leak on this spot.

Install the eight top bolts on the rear cover.

Tightening torque of the top bolts: 33.9 - 47.5
Nm.(25 - 35ft.lb)

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8001-16
Install the central section on the top bolts. Check
the alignment of the top bolts on the central
section.

Lubricate the drive gear and install the gears on

the appropriate bushings. Align the teeth marks
of the gear.

Place the front cover on a clean work bench with

the retainers cavity up. Lubricate the retainers
cavity with graphite grease.

Lubricate both the gasket and the plastic retainer

with graphite grease. Carefully install the gasket
in the internal part of the plastic retainer, checking
whether the gasket is well set into the retainer.

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 8001-17
Install the assembly on the front cover cavity.
Carefully press the assembly into place; checking
whether it is firmly seating in place. This is very
important for the installation of the wear plate.

Apply graphite grease to the square section

housing of the o-ring, and carefully install it on
the front cover housing. Be very careful: the
o-ring must not spin within the housing or the
pump will leak at this spot.

Lubricate the steel side of the bronze wear plate

with graphite grease and install it on top of the
retainer.

Install the washers and nuts on the top bolts.

Torque of the top bolts: 196 - 210 Nm. (145-155
ft.lbs).

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8001-18

DISASSEMBLE THE PILOT VALVE

Mark the position of the cover in relation to the

casing when it is in place, and remove the allen
head screws.

Remove the cover together with the control

components.

Remove the cone roller bearing and the

wedges.

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 8001-19
Remove the rotor entirely.

Remove the O-ring.

Remove the bearings of the roller bearings.

Using a roller bearing extractor, remove the roller

bearings from the casing.

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8001-20
Remove the distributor plate.

Use the roller bearing extractor to remove the

rear part of the casing.

Remove the O-ring.

Loosen the lock nut of the adjustment bolt.

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 8001-21
Disassemble the adjustment bolt.

Disassemble the command piston guide.

Disassemble the guide opposite the piston.

Pull the input shaft out.

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8001-22
Remove the pistons and the retention plate.

Remove the concave washer.

Compress the central spring to dissasemble the

retainer ring.

Disassemble the retainer ring.

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 8001-23
Components of the rotor: bolts, cylinders, wedge,
spring, and wedge.

Remount the pump following the reverse order

of the disassembling.

The roller bearing on the cover of the pump must

have a initial preload between 0...0.05 mm.

Put the distributor plate in place. Lubricate it with

grease before assembling it.

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8001-24
Position the O-ring on this place.

Maintain the tension of the spring with screws

(they must not be tightened into place).

Correct position of the bearing (lubrication hole

and highpressure
side).

Before putting the cover back on its correct

position (see mark), remove the screw that
retains the spring.

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 8001-25
Install the plug.

It is possible to reuse the cradle where the piston

shoe works.

NOTE: It is possible to reuse the cradle where

the piston shoe works.

Check the coupling between the rotor and the

distribution plate.

Check the surface conditions of the control

piston.

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8001-26
Check the condition of the bolt opposite the
piston.

Distributor plate, inclination piston of the plate,

and return spring.

Complete rotor.

Casing of the pump and bearings of the roller

bearings.

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 8001-27
Input shaft and cone roller bearings.

Adapter with hole for pilot valve.

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8001-28

REPLACEMENT OF THE INPUT SEAL

Remove the retainer ring of the seal.
Remove the seal.

Change the seal and check the work area of

the seal.
Apply grease to the retainer.

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 8001-29
Monte novamente o retentor utilizando uma
ferramenta adequada.

Put the retainer ring back on its place.

With a tubular tool, place the lock correctly in its

housing.

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8001-30

RETAINERS AND COMPONENTS KIT

Seal of the entrance shaft.

Full seal kit.

The kits are based on the type of the pump.
The picture shows the kit used on the
HA10VO100DFR pump.

Pilot valve. Pressure and flow control.

Distributor plate, inclination piston of the place

and Command spool.

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 8001-31

PILOT VALVE
Remove the allen screws of the pilot valves.

Remove the O-rings.

Remove the hexagonal nuts.

First, remove the pressure command, and then
the flow command.

Remove the lock nut and the adjusting screws.

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8001-32
Remove the plug.

Remove the adjusting disc.

Remove the spring (two for the flow control

valve).

Remove the cover of the spring.

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 8001-33
Remove the plug

Be careful when you disassemble the piston.

Disassemble the restrictor(it is on the spring

area of the pressure controller).

Disassemble the plug or restrictor that is on the

spring area of the flow controller.

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8001-34
Nut Torque 12Nm (108 lb.in).

Nut Torque 12Nm (108 lb.in).

Remount the pilot valve following the reverse

order of the disassembling.

Check the opening of the restrictor hole; if

necessary, use compressed air to clean it.

Be careful when you clean the hole.

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 8001-35

Check the movement of the pilot valve spool. It

must not be mounted if it is damaged.

Adjust the pilot valve (see instructions on the

pages below).

When the pressure line is closed, it is possible to

regulate the pressure controller (190 bar = 2.800
psi).

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8001-36

Adjust the outflow regulator to 200 bar; this will

allow the pump to reach its maximum outflow of
210 l/min. (55 gpm)

Mechanical flow limiter: Used to adjust the

minimum flow.

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 8001-37

Section drawing of the pilot valve.

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8001-38

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.

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.

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.

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 8001-39
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.

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8001-40

1. Remove the special nuts and compression 4. Remove the O-ring, bias spring and
washers from the tie rods on the outlet compensator piston. Discard the O-ring.
endcap. Keep the tie rods in the manifold valve Store the bias spring and compensator piston
assembly. The outlet endcap Is identified by in a safe, clean place and identified by the
a load sense signal port. Discard the nuts. valve section from which they originated.

2. Carefully place the manifold valve assembly NOTE: The valve section next to the outlet endcap
on its end, resting on the three tie rod ends does not have a load sense shuttle disc. You
of the inlet endcap. may need to use small straight nosed external
snap ring pliers or similar small expanding tool
3. Remove the outlet endcap. to remove the compensator piston.

1. Compensator Spring 10. Load Sense Signal Passage

2. Workport "A" 11. Load Sense Signal Transfer Passage
3. Bridge 12. Pressure Passage
4. Workport "B" 13. Tank Passage
5. Spool Centering Spring 14. Compensator Load Sense Signal Passage
6. Spring Cap 15. Compensator
7. Spool 16. Load Sense Shuttle
8. Load Sense Drain to Tank 17. O-Ring
9. Valve Body
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 8001-41
5. Remove the remaining valve sections,
together with the load sense shuttle discs,
installed between the eight valve sections.

Removing Compensator Piston from Valve Section

Housing

Removing Load Sense Shuttle Disc

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8001-42

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.

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

Removing Spring Seats. Spring and Spool Stop

Ring.

Removing Valve Spring from Valve Section Housing

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 8001-43
7. Remove the O-ring from the spring retaining
screw.
8. Remove and discard the wiper seals and
O-rings.

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.
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.
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.

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8001-44

Valve Section – Assembly

1. Lightly clamp the valve section housing in a
vise with soft jaws.

NOTE: Excessive clamping force may distort the

valve spool bore and compensator piston bore.

2. Lubricate new valve spool 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.

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)

Torque-tightening Spool End Assembly.

NOTE: To prevent the valve spool from rotating,

insert a thin rod or similar tool in the linkage pin
hole.

4. Install the spring cap. Make sure the mating

face notches are clean.

5. Secure the spring cap with the socket head

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

6. Secure the seal plate with the machine

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

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 8001-45

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.

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.

Installing Compensator Piston into Valve Section

Housing

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8001-46
7. Insert the bias spring into the hollow end of
the compensator piston.

8. Install the load sense shuttle disc into the

recess of the load sense passage.

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.

12. 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.

16. Torque the lower tie rod nuts to 19N.m (14

lbf.ft ). This is the final torque value.

17. Torque the upper tie rod nuts to 45 N.m (33

lbf.ft). This is the final torque value.

18. Torque Tie Rods Nuts

19. Check for proper spool movement.

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 8001-47

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.

3. Connect the control rods to the valve spools.

Install the shoulder socket head bolts and
new locknuts.

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8001-48

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)
HEX DIMENSION
ACROSS FLATS : 1 1/8 (28,6)

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 8001-49
Dual over center valve, moldboard lift and right
cylinder.

Dual over center valve, circle side shift cylinder.

Dual over center valve, rear ripper cylinder.

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8001-50
Dual over center valve, frame articulation
cylinders.

Dual over center valve, molboard pitch cylinder.

Dual over center valve, front scarifier and dozer

blade cylinder.

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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.

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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.

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HYDRAULIC CYLINDERS
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 MOLDBOARD LATERAL CYLINDER

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.

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.

MOLDBOARD PITCH CYLINDER

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.

Remove the cylinder to a work bench for

disassembly.

WHEEL LEAN CYLINDER

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Installation

This is the reverse procedure of removal.

MOLDBOARD LIFT CYLINDERS WHEEL LEAN CYLINDER

CIRCLE SHIFT CYLINDER ARTICULATION CYLINDER

SADDLE PIN LOCK CYLINDER SCARIFIER OR DOZER BLADE CYLINDER

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RIPPER CYLINDER
Disassembly

Drain any oil remaining in the cylinder in an Remove the piston assembly.
appropriate container.

Unscrew (or unbolt) the cylinder head from the Remove the seals from the piston.
cylinder tube using wrench tool.
Pull the cylinder rod assembly from the tube.

Remove the head assembly.

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.

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Remove the O - rings. Remove the seals.

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.

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SPECIFICATIONS
Moldboard Lateral Shift Cylinder

A. Lubricate and torque cylinder head ................................................................................. 1400 – 1600 Nm (1032 – 1180 lb.ft)
B. Piston rod O.D. ........................................................................................................... 49.960 – 50.000 mm (1.967 – 1.968 in)
C. Lubricate and torque piston rod locknut to ............................................................................ 900 – 1000 Nm (664 – 738 lb.ft)
D. Stroke of the piston rod ...................................................................................................................................1219 mm (48 in)

Moldboard Pitch Cylinder

A. Lubricate and torque cylinder head ................................................................................. 1400 – 1600 Nm (1032 – 1180 lb.ft)
B. Piston rod O.D. ........................................................................................................... 48.960 – 50.000 mm (1.967 – 1.968 in)
C. Lubricate and torque piston rod locknut to ............................................................................ 900 – 1000 Nm (664 – 738 lb.ft)
D. Stroke of the piston rod ................................................................................................................................... 187 mm (7.4 in)

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Wheel Lean Cylinder

A. Lubricate and torque cylinder head ................................................................................. 1400 – 1600 Nm (1032 – 1180 lb.ft)
B. Piston rod O.D. ........................................................................................................... 49.960 – 50.000 mm (1.967 – 1.968 in)
C. Cylinder I.D. ................................................................................................................. 90.000 - 90.054 mm (3.543 - 3.545 in)
D. Lubricate and torque piston rod locknut to ............................................................................ 900 – 1000 Nm (664 – 738 lb.ft)
E. Stroke of the piston rod ................................................................................................................................... 187 mm (7.4 in)

Moldboard Lift Cylinder

A. Lubricate and torque cylinder head ................................................................................. 1400 – 1600 Nm (1032 – 1180 lb.ft)
B. Cylinder head rod bore I.D .......................................................................................... 56.120 - 56.160 mm (2.209 - 2.211 in)
C. Piston rod O.D. ........................................................................................................... 55.960 – 56.000 mm (2.209 – 2.211 in)
D. Cylinder I.D. ................................................................................................................. 90.000 - 90.054 mm (3.543 - 3.545 in)
E. Lubricate and torque piston rod locknut to ............................................................................ 900 – 1000 Nm (664 – 738 lb.ft)
F. Stroke of the piston rod .................................................................................................................................. 1143 mm (45 in)

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A. Lubricate and torque cylinder head ................................................................................. 1400 – 1600 Nm (1032 – 1180 lb.ft)
B. Piston rod O.D. ........................................................................................................... 49.960 – 50.000 mm (1.967 – 1.968 in)
C. Cylinder I.D. ................................................................................................................ 90.000 – 90.054 mm (3.543 - 3.545 in)
D. Lubricate and torque piston rod locknut to ............................................................................ 900 – 1000 Nm (664 – 738 lb.ft)
E. Stroke of the piston rod ............................................................................................................................... 578 mm (22.75 in)

Saddle Pin Lock Cylinder (5 Point Saddle)

A. Lubricate and torque cylinder head ......................................................................................... 576 – 712 Nm (425 – 525 lb.ft)
B. Cylinder head rod bore I.D. ......................................................................................... 31.801 - 31.852 mm (1.252 - 1.254 in)
Piston rod O.D. ............................................................................................................ 31.674 - 31.750 mm (1.247 - 1.250 in)
C. Cylinder I.D. ................................................................................................................. 63.627 - 63.754 mm (2.505 - 2.510 in)
Piston O.D. .................................................................................................................. 63.195 - 63.297 mm (2.488 - 2.492 in)
D. Lubricate and torque piston rod locknut to ................................................................................ 271 - 339 Nm (200 - 250 lb.ft)
E. Stroke of the piston rod .............................................................................................................................. 57.15 mm (2.25 in)

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A. Lubricate and torque cylinder head ......................................................................................... 140 – 160 Nm (103 – 118 lb.ft)
B. Piston rod O.D. ........................................................................................................... 49.960 - 50.000 mm (1.967 – 1.968 in)
C. Lubricate and torque piston rod locknut to .............................................................................. 90 – 100 Nm (66.4 – 73.8 lb.ft)
D. Stroke of the piston rod .................................................................................................................................. 1219 mm (48 in)

Steering Cylinder

A. Lubricate and torque cylinder head ......................................................................................... 440 – 542 Nm (325 – 400 lb.ft)
B. Cylinder head rod bore I.D. ......................................................................................... 38.151 - 38.202 mm (1.502 - 1.504 in)
C. *Cylinder head rod bushing bore I.D. .................................................................. 44.4373 – 44.4500mm (1.7495 – 1.7500 in)
Bushing O.D. ....................................................................................................... 44.4881 - 44.5389 mm (1.7515 - 1.7535 in)
D. Bushing I.D. ......................................................................................................... 38.2016 - 38.3032 mm (1.5040 - 1.5080 in)
Piston rod O.D. ............................................................................................................ 38.024 - 38.100 mm (1.497 - 1.500 in)
E. Cylinder I.D. ................................................................................................................. 63.627 - 63.754 mm (2.505 - 2.510 in)
Piston O.D. .................................................................................................................. 63.246 - 63.348 mm (2.490 - 2.494 in)
F. Lubricate and torque the piston rod locknut to .......................................................................... 339 - 407 Nm (250 - 300 lb.ft)
G. Stroke of the piston rod .............................................................................................................................. 266.7 mm (10.5 in)
*SERVICE NOTE: Press bushing into head flush with face of head.

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Articulation Cylinder

A. Lubricate and torque cylinder head ........................................................................................... 784 - 863 Nm (578 - 636 lb.ft)
B. Cylinder head rod bore I.D. ......................................................................................... 45.120 - 45.160 mm (1.776 - 1.778 in)
C. Piston rod O.D. ........................................................................................................... 44.960 – 45.000 mm (1.770 – 1.771 in)
D. Cylinder I.D. ................................................................................................................. 80.000 - 80.064 mm (3.149 - 3.152 in)
E. Lubricate and torque piston rod locknut to ................................................................................ 794 - 873 Nm (585 - 644 lb.ft)
F. Stroke of the piston rod .................................................................................................................................. 377 mm (14.8in)

Scarifier Cylinder

A. Lubricate and torque cylinder head ................................................................................... 1898 - 2034 Nm (1400 - 1500 lb.ft)
B. Cylinder head rod bore I.D. ......................................................................................... 50.851 - 50.902 mm (2.002 - 2.004 in)
Piston rod O.D. ............................................................................................................ 50.724 - 50.800 mm (1.997 - 2.000 in)
C. Cylinder I.D. ............................................................................................................. 101.727 - 101.854 mm (4.005 - 4.010 in)
Piston O.D. .............................................................................................................. 101.295 - 101.397 mm (3.988 - 3.992 in)
D. Lubricate and torque piston rod locknut to ............................................................................ 1152 - 1288 Nm (850 - 950 lb.ft)
E. Stroke of the piston rod ............................................................................................................................... 311 mm (12.25 in)

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Ripper Cylinder

A. Torque cylinder head capscrews to ...................................................................................... 216 -235 Nm (159.3 - 173.3 lb.ft)
B. Cylinder head rod bore I.D. ......................................................................................... 60.800 - 61.000 mm (2.394 - 2.402 in)
C. Piston rod O.D. .................................................................................................................. 59.960 – 60.000 (2.361 - 2.362 in)
D. Cylinder I.D. ............................................................................................................. 120.120 - 120.260 mm (4.729 - 4.735 in)
E. Piston O.D. ............................................................................................................... 117.950 - 118.090 mm (4.644 - 4.649 in)
F. Lubricate and torque piston rod locknut to ........................................................................ 2196 - 2393 Nm (1620 - 1765 lb.ft)
G. Stroke of the piston rod ................................................................................................................................. 478 mm (18.8 in)

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 Section
8003

8003
Front WHEEL DRIVE HYDRAULIC PUMP AND MOTOR
865B AWD / 885B AWD
Models

Copyright © 2011 CNH America LLC.

CNH Latin America LTDA All Rights Reserved
2237, General David Sarnoff Avenue Printed in Brazil
Contagem - MG - Brazil 6-46890 ENG Issued July, 2011
8003-2

TABLE OF CONTENTS
PRODUCT SPECIFICATIONS.......................................................................................................................................................3
Wheel Drive Hydraulic Pump...................................................................................................................................................3
Wheel Drive Hydraulic Motor...................................................................................................................................................3
MODELS IDENTIFICATION...........................................................................................................................................................4
SERVICE SPECIFICATIONS (MAINTENANCE)...........................................................................................................................5
GENERAL INFORMATION (MANUFACTURER)...........................................................................................................................6
Variable Pump HPV-02............................................................................................................................................................6
Hydraulic Motor HMV- 02........................................................................................................................................................6
Mechanical Linkage.................................................................................................................................................................6
Input and Output Shafts...........................................................................................................................................................6
High and Low Pressure Lines, Maximum Pressures...............................................................................................................6
Venting Port, Leakage Lines and Case Pressure....................................................................................................................6
Hydraulic Fluids, Temperature and Filtration...........................................................................................................................7
Hydrostatic Transmission in Closed Loop...............................................................................................................................7
Circuit Diagram (Manufacturer Example)................................................................................................................................8
INITIAL START UP.........................................................................................................................................................................9
Cleanliness..............................................................................................................................................................................9
Drive Rotation..........................................................................................................................................................................9
Initial Filling of the Hydrostatic Transmission...........................................................................................................................9
Test Instruments......................................................................................................................................................................9
Filling Device...........................................................................................................................................................................9
Initial Filling of HST With a Filling Device..............................................................................................................................10
Filling and Venting of the Entire System................................................................................................................................11
Information.............................................................................................................................................................................11
Filling Procedure....................................................................................................................................................................11
Environmental Concerns.......................................................................................................................................................11
Start Drive Engine for First Time and Leave it Running for a Few Seconds.........................................................................12
Starting the Engine Again......................................................................................................................................................12
Start Drive Engine Again.......................................................................................................................................................12
Hint........................................................................................................................................................................................12
Initial Filling of the HST Without a Filling Device...................................................................................................................12
HYDRAULIC PUMP HPV-02........................................................................................................................................................13
HYDRAULIC MOTOR HMV-02....................................................................................................................................................14
HYDRAULIC SCHEMATIC...........................................................................................................................................................15
HYDRAULIC PUMP.....................................................................................................................................................................16
Mounting................................................................................................................................................................................16
Components Identification.....................................................................................................................................................17
HYDRAULIC MOTOR..................................................................................................................................................................22
Mounting................................................................................................................................................................................22
Components Identification.....................................................................................................................................................23

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PRODUCT SPECIFICATIONS
Wheel Drive Hydraulic Pump
MODEL: HPV 55-02 L E2 24 X 420 e A

TYPE: Piston, variable displacemen with high pressure swash plate pump for
closed loop circuit.

DISPLACEMENT: Maximum 54,8cc/rev

FLOW AT FULL STROKE: 37.9 gpm (143,5 LPM) @ 2200 engine rpm

MAXIMUM PRESSURE: Maximum operational pressure 420 bar and

maximum continuous pressure 500 bar.

DRIVE RATIO: 1:1.19 (Transmission R.H. side drive)

DRIVE TYPE: SAE “C” spline shaft 1.25in – 14 teeth 12/24 D.P.

MOUNTING: SAE “C” 2 bolts

ELECTRIC SYSTEM: Electro-hydraulic proportional control type E2 with 2 proportionals

solenoids and 1 additional switching solenoid, all 24 V, characteristic
4-16 bar, connector type: AMP-JT, 2-pin male

HYDRAULIC SYSTEM: Integrated combined boost and high pressure relief valves setting 420
bar + 15 bar
Integrated low pressure relief valves for boost pressure relief valve
(setting 24 bar) and cold start relief valve (setting 32 bar)
External suction of the boost pump 22,5 cc/rev

PUMP FILTER: Integrated micro oil filter 10 μm

Wheel Drive Hydraulic Motor

MODEL: HMV 75-02 E6

TYPE: High pressure swash plate motor for closed loop circuit.

DISPLACEMENT: Maximum 75.9 cc/rev.

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MODELS IDENTIFICATION

VARIABLE DISPLACEMENT
HYDRAULIC PUMP HPV- 02

VARIABLE DISPLACEMENT
HYDRAULIC MOTOR HMV- 02

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SERVICE SPECIFICATIONS (MAINTENANCE)

VARIABLE DISPLACEMENT HYDRAULIC PUMP AND MOTOR ASSEMBLY

Maintenance of the hydrostatic transmission is confined to exchanging the filter of the HPV-02
pump and exchanging the hydraulic fluid of machine.

1. Checking and maintenance points

1.1 Test points
• High pressure (HP)
• Low pressure (LP)
1.2 Checking points
• Oil level
• Measuring sticks
1.3 Maintenance points
• Filters
• Filler and drain plugs
• Magnetic plugs

2. Exchange of filters

The filter supplied with the HPV pump has to be replaced 100 hours after final commissioning.
Further exchanges must be made after every 500 hours.

IMPORTANT: Only original filters may be utilized.

3. Exchange of hydraulic fluid

4.
Attention! Use proper handling and storage and material.
The hydraulic fluid is to be exchanged after every 2000 hours (according to hydraulic system service
specifications).
High working temperatures in combination with frequent phases of cooling down at lower temperatures
result in water condensation and shorten the exchange intervals of hydraulic fluid.
Proper oil exchange is done by draining all the oil from tank, cooler, pump and motor housing. The
quantity of oil remaining in the high pressure circuit need not be replaced (do not bother to open the high
pressure lines).
Procedures stated for initial filling are similarly applicable to the exchange of hydraulic fluid.

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GENERAL INFORMATION (MANUFACTURER)

Installation of the hydraulic system must be completed ac- Input and Output Shafts
cording to the circuit and piping diagram and the installa-
tion requirements of machine. In axial piston units of series 02, the shaft ends of the pri-
mary input or output are released as edge centered splines
For the hydraulic piping seamless drawn precision steel pi- with involute type splines as per ANSI B92.1.
pes according to DIN 2391/ C or hoses of suitable pressure
rating must be chosen. The prescribed counter fit of coupling; pinion or pulley must
be strictly adhered to. In principle, both during assembly
Pipes have to be deburred, washed out and blown through. and disassembly input and output elements must not be
Pipes which have a accumulated scale or rust must be ste- treated with knocking or beating forces (e.g.hammer blo-
eped and then neutralized; hose lines when contaminated ws) on shaft ends of axial piston units, since this will inevi-
need brushing out and flushing through. tably lead to damage of drive assembly, particularly of the
Cleanliness is an important point. shaft bearings.

The connection ports of hydraulic equipment are, as a rule,

closed by the manufacturer with plastic plugs or tape after High and Low Pressure Lines,
thoroughly flushing all passages. Cleanliness must be the Maximum Pressures
supreme concern while assembling a hydraulic system.
Be sure that hose, pipes and fitting are sufficiently strong
Never plug finished pipes with rags; use plastic foil, tape
with regards to bursting. In regards to operational reliability,
or plugs instead.
it is important to keep in mind the maximum permissible
Under no circumstances use cloth. pressures at the connection point of working and auxiliary
ports of units.
Variable Pump HPV-02
If mounting position is horizontal, servo device on top is
Venting Port, Leakage Lines and
preferred for better venting. Case Pressure
Case drains lines must be installed in such a way that the
Hydraulic Motor HMV- 02 housings of the hydraulic components are always filled with
fluid.
Any position is okay, except when the drive shaft points
vertically upwards. This requires special measures becau- The case pressure (build-up) should not rise and stay hi-
se of the risk of shaft bearing and shaft seal running dry. A gher than 2.5 bar (absolute)during operation.
modified version which tolerates this position is available
upon inquiry.

Mechanical Linkage
The mechanical connection of a unit to the drive system is
made by housing flange and the shaft end of its primary or
output.
Axial piston units are conceived as plug-on units for coaxial
connection to a drive system, i. e. for coupling without ra-
dial or angular off-set between driving and driven shaft.

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Hydraulic Fluids, Temperature and Filtration

Acceptable fluids, recommended per manufacturer:
• Mineral oil HLP according to DIN 51524
• Biodegradable oils upon inquiry
• Fluids hydraulic

Technical data
working viscosity range (mm2 / S) = (cSt) 10 to 80
Optimum working viscosity (mm2 / S) = (cSt) 15 to 30
Max viscosity (short time start up) (mm2 / S) = (cSt) 1000

Viscosity recommendations
working temperature (ºC) Viscosity class (mm2 /s) = (cSt) at 40 ºC
30 to 40 22
60 to 80 46 to 68

Knowledge of operating temperature in the circuit is a precondition for the right choice of fluid.

CAUTION: Mixing different mineral hydraulic fluids is only possible after consulting us for
release. Mixing mineral oils with bio-type oils is always forbidden.

Filtration
In order to ensure functionality of the hydraulic components and their high efficiency, cleanliness of the
working fluid should at least correspond to class 18/13 as per ISO 4406 at all time.
With today’s filtration technology, however, far better values can be achieved, which contributes essentially
to prolonging the working life of hydraulic pumps and motors and the whole system.

Hydrostatic Transmission in Closed Loop

The mains connection ports of the hydraulic pump are connected to the main connection ports of the
hydraulic motor by means of hydraulic hoses, pipes or tubes. The circulation of fluid always goes from the
hydraulic pump to the hydraulic motor and from there directly back to the hydraulic pump.

Leakage is replaced by an auxiliary pump (boost pump). Since leakage is extremely small in such
systems, it is necessary to continuously exchange the oil by means of a purging system on the hydraulic
motor to provide cooling. So the boost pump also works as a purging pump and as a pressure source for
the servo control.

The direction and speed of flow and therefore rpm and direction of rotation at the output shaft of the
hydraulic motor depends on:

• The pump direction of rotation

• The over center direction of the swash plate
•
Pump rotation is always defined by looking at the drive shaft and noted on the name plate.
Changing of drive rotation requires conversion of both HPV pump and auxiliary pump. System pressure
is determined by the load on the motor shaft.

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Circuit Diagram (Manufacturer Example)

1. Hydraulic pump HPV- 02 2. Hydraulic motor HMF-02
• With electro-hydraulic control E1 • with purging device *
• Drive direction clockwise pressure in at A: clockwise rotation
• Boost pump with internal suction pressure in at B: counter clockwise rotation
• Oil cooler (by costumer) in boost pressure
* Purging arrangement, see functional description of
loop
hydraulics motors

EXPLANATIONS EXPLANATIONS
1. Hydraulic Pump HPV-02 2. Hydraulic Motor HMF 02 (Example)
P, S High pressure port A, B High pressure ports
B Suction port boost pump L, U Oil leakage ports
A Pressure port boost pump Connection enabling case to the
F Control and boost pressure supply filled with oil
T Tank and vent port
X Boost pressure gage port
Y,Z Control pressure gage port
MY, MZ Proportional solenoid 24v
Ms , Mp High pressure gage port
L Oil filling, tank and vent port
U Drain, flushing return from hydraulic
motor

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INITIAL START UP
Professional and careful start up is the prerequisite for trou- Filling Device
ble-free operation and optimum life expectancy!
The manufacturer recommend performing the initial filling
by means of a filling device. The filling device consists of a
Cleanliness gear pump with a capacity of about 5 l/min and a pressure
Oil reservoir and installation have to be checked again for relief valve at 23 bar (pressure setting of boost pressure
cleanliness before the hydraulic medium is added. This act relief valve e.g. 19 bar + 4 bar) , plus a fine mesh filter of
has to be performed immediately before pouring in. It may 10 microns or better.
even be expedient to rinse the entire installation!!
Make sure that only absolutely clean and filtered hydraulic
is filled in.

Drive Rotation
Before starting the engine make sure that the HPV-02
pump will be driven with the correct direction of rotation.
With electric motors, it must be checked that the electrical
connections are correct. The electric symbol is normally
found in the cover of the connector box.

CAUTION: Under no circumstances start the en-

gine to check the rotation! Filling device
If the HPV-02 pump is driven against its specified ro-
tation, the boost pump (auxiliary pump) is unable to Filling device consisting of :
build up base pressure. For lack of lubrication the dri- 1. Shut off valve
ve group will instantly be damage (initial damage) whi- 2. Low pressure gauge 0 - 40 bar
ch may result in total break down. 3. Gear pump Q = 5 l/min
4. Pressure relief valve p = 23 bar
Initial Filling of the Hydrostatic 5. Fine strainer 10 microns or
Transmission better
Before starting the prime mover, it must be assured that
the housings of the hydraulic components are filled with oil.
Before the hydraulic components may be loaded, the entire
circuit must be filled up and vented.

Test Instruments
During commissioning it is necessary to monitor the base
pressure (boost pressure of the auxiliary pump). Remove
the plug from gauge port “X” in the filter flange and connect
a gauge 0-40bar.

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Initial Filling of HST With a Filling Device

Preparation
•• Connect gauge to port “X”
•• Connect filling device to port “F” (boosting)
•• Loosen vent plug on cooler
•• Loosen fittings on gauge ports ‘Ms” and “MP” of the HPV pump and remove them. Connect two small lines for venting and
lead both into a reservoir
•• Loosen plug on port “L” or “U” (the one which is not occupied)
•• If the housing of hydraulic motor is not easily accessible, ot must be filled with clean oil beforehand.

EXPLANATIONS
Hydraulic Pump HPV-02
P, S High pressure port
B Suction port boost pump
A Pressure port boost pump
F Control and boost pressure supply
T Tank and vent port
X Boost pressure gage port
Y,Z Controls pressure gage port
MY, MZ Proportional solenoid 24v
Ms , Mp High pressure gage port
L Oil filling, tank and vent port
U Drain, flushing return from hydr
motor

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Filling and Venting of the Entire Environmental Concerns

System
ATTENTION: Dump the collected waste fluid
When using the filling device, depending on the installation,
according to the prevailing regulations, do not use
the entire system is filled with hydraulic fluid.
it again! Now the hydraulic system is nearly full of
hydraulic fluid and vented.
Information
The pressure of the filling device opens the boost pressure DANGER : Before starting the engine, remember
relief valve in the pump; as a result, the pump housing, the following points!
hydraulic tank, cooler and hydraulic motor housing are fil- a. Make sure the pilot lines for the pump’s control are
led. Make up valves for the closed loop open and both lines disconnected!
are filled. Take care that the relief valve of the filling device b. In the starting phase the HPV-02 pump must not
is set at least 4 bar higher than the corresponding boost be actuated! Disengage the machine and secure it
pressure setting. While filling, monitor the reservoir for over against rolling away or jack it up. Safeguard machi-
filling. nes according to their nature. Safeguard surroun-
dings of the machine. Uninvolved personnel are to
Filling Procedure be keep at a safe distance at the moment of star-
ting.
•• Switch the filling device on.
•• Keep an eye on the venting plugs on hydraulic motor
and cooler and close as soon as no more bubbles show
in the hydraulic fluid.
•• The hydraulic tank is to be filled as high as to the middle
of the upper level indicator.
•• Monitor for leak.
•• Next disconnect the micro hoses on the high pressure
gauge connections “Mp” and ”Ms” and plug the connec-
tion ports.
•• Remove the filling device.
•• Collect any hydraulic fluid that may have come out and
wipe clean.

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Start Drive Engine for First Time Start Drive Engine Again
and Leave it Running for a Few •• Drive engine runs at low idle
•• HPV-02 pump runs at no load. Boost pressure is stable
Seconds and shows the required value
•• Engine is running at low idle. The HPV-02 pump runs
•• Operate engine at working speed
at no load
•• Have HPV-02 pump gradually actuate in both directions
•• Electric motors: switch on and after 5 seconds switch
up to max angle (for some 30 seconds in each direc-
off
tion). Full load should not be reached
•• After initial oscillation boost pressure rises immediately
•• By now the purging device of the motor is also activa-
to set pressure of the safety valve.
ted. With a pressure differential A-B of some 20 bar a
•• This can be read on the gauge (port “X”) measured quantity of hydraulic fluid is discharged and
•• Switch engine off and check fluid level in the tank. Top thereby taking the remaining air with it.
off if necessary •• Switch engine off. Remove gauge from “X”. Install plug
•• If the pressure setting could not be reached in the star- and tighten. Check the system again for leaks and ti-
ting phase switch engine off at once. ghten if necessary
•• Find the reason before you start again. •• Check fluid level again and top off if required.
•• Wait for approx.5 minutes before you start once more
and search the installation for possible leakage! Atta-
ch micro-hose lines to the high pressure gauge ports
Hint
“”MP” and ”MS” and lead them both into a reservoir. If Leave the machine for about 30 min. Residual air can es-
micro-hose are not available then bleed main lines by cape to the hydraulic tank only when the drive engine is at
cracking open the fittings on “MP” & “MS” for a couple stand still.
of turns. The hydrostatic transmission is now ready to use!
•• Connect / activate control of the HPV-02 pump
Initial Filling of the HST Without a
Starting the Engine Again Filling Device
•• Engine is running at low idle •• Before you ignite the engine make sure that the housin-
•• HPV-02 pump runs at no load. Boost pressure is stable gs of the hydraulic units are filled with hydraulic fluid
and shows the required value •• Fill hydraulic reservoir with hydraulic fluid
•• Set engine speed at approx. 1500 rpm and switch off •• Vent the HPV housing at port “T” or “L (U) ” and the
after 5-10 seconds motor housing at port “L (U)”
•• Disconnect the micro hoses from the high pressure •• Connect a pressure gauge at port “X“
gauge ports “MP” and “MS” ; install plugs and secure •• Loosen cooler vent plug
with the corresponding torque •• Loosen the fittings at gauge ports “MS” and “MP” of the
•• Check oil level in the hydraulic tank and top off as re- HPV pump and take them away.
quired •• Connect micro hoses as vent lines and lead them both
into a reservoir.

6-46890 ENG Issued 07-11 Printed in Brazil

 8003-13

HYDRAULIC PUMP HPV-02

• Mechanic-hydraulic control M1
• Drive direction CW
• Boost pump with internal suction

EXPLANATIONS
Hydraulic Pump HPV-02
P, S High pressure port
A Pressure port boost pump
B Suction port boost pump
F Control pressure supply, boost
X Control pressure gage port
Ms, Mp High pressure gage port
L Oil filling, tank and vent port
U Drain, flushing return from hydraulic motor
L1, L2 Vents ports

6-46890 ENG Issued 07-11 Printed in Brazil

8003-14

HYDRAULIC MOTOR HMV-02

• Electric control E1
• With purging device

Pressure in A: CCW rotation

Pressure in B: CW rotation

EXPLANATIONS
Hydraulic Motor HMV- 02
A,B High pressure port
E Control pressure PE 20-40 bar
MA, MB Gage port high pressure
U, I Oil filling, drain, tank and vent port, purge oil
L1 Oil filling, drain, tank and vent port

6-46890 ENG Issued 07-11 Printed in Brazil

 8003-15

HYDRAULIC SCHEMATIC

6-46890 ENG Issued 07-11 Printed in Brazil

8003-16

HYDRAULIC PUMP
Mounting

1. GASKET 7. WASHERLOCK 11. SEAL RING

2. SPACER 8. BOLT (Tighten the bolt item 8 at 12. BOLT
3. BOLT xxx to xxx Nm / xxx to xxx pound- 13. WASHERLOCK
4. GASKET feet torque) 14. FLANGE
5. HPV-02 - PUMP ASSEMBLY 9. KIT REPAIR 15. FILTER (NOTE)
6. WASHER 10. PLUG

NOTE: The filter supplied with the HPV pump has to be replaced 100 hours after final commissioning.
Further exchanges must be made after every 500 hours.
6-46890 ENG Issued 07-11 Printed in Brazil
 8003-17

Components Identification

1. BEARING 11. SPRING 21. SPACER

2. PAD 12. WASHER 22. PLATE
3. O’RING 13. WASHER 23. PLUNGER
4. HOUSING 14. SHIM 24. DRUM
5. SEAL RING 15. SNAP RING 25. PLATE
6. SNAP RING 16. WASHER 26. SPACER
7. PLUG 17. PIN 27. PIN
8. HALF BUSHING 18. BRACKET 28. PLATE
9. PIN 19. BOLT 29. SHIM
10. SHAFT 20. PLATE 30. BEARING

6-46890 ENG Issued 07-11 Printed in Brazil

8003-18

1. PLUG 10. PLUNGER 19. O’RING

2. PLUG 11. WASHER 20. SPRING
3. O’RING 12. SPRING 21. SHIM
4. VALVE 13. CUP 22. PLUG
5. RING 14. RING 23. PLUG
6. O’RING 15. O’RING 24. VALVE
7. TUBE 16. WASHER 25. KIT Seal
8. O’RING 17. HOUSING
9. WASHER 18. BOLT

6-46890 ENG Issued 07-11 Printed in Brazil

 8003-19

1. SNAP RING 9. COVER 17. O’RING

2. BUSHING 10. WOODRUFF KEY 18. BOLT
3. SPRING 11. SHAFT 19. O’RING
4. SHIM 12. O’RING 20. PUMP
5. PLUG 13. SEAL RING 21. KIT parts / case
6. O’RING 14. BOLT 22. VALVE
7. SLEEVE 15. BOLT
8. O’RING 16. COVER

6-46890 ENG Issued 07-11 Printed in Brazil

8003-20

1. PLUG 9. STUD 17. PLUG

2. LEVER 10. NUT 18. PLUG
3. PLUNGER 11. PLUG 19. PLUG
4. CUP 12. O’RING 20. BOLT
5. SPRING 13. SHIM 21. HOUSING
6. CUP 14. SPACER 22. O’RING
7. SNAP RING 15. PIN 23. PIN
8. NUT 16. PLUG 24. O’RING

6-46890 ENG Issued 07-11 Printed in Brazil

 8003-21

1. SPRING 8. BOLT 15. O’RING

2. PLUNGER 9. O’RING 16. COIL
3. BUSHING 10. SPRING 17. BOLT
4. PLUNGER 11. PLUNGER 18. COIL
5. SPRING 12. CUP 19. BOLT
6. PLUG 13. SPRING 20. BALL
7. NUT 14. PLUNGER 21. CONNECTOR

6-46890 ENG Issued 07-11 Printed in Brazil

8003-22

HYDRAULIC MOTOR
Mounting

1. HMV-02 - HYDRAULIC MOTOR ASSEMBLY

2. WASHERLOCK
3. BOLT (Tighten the bolt (3) at xxx to xxx Nm / xxx to xxx pound-feet torque)
4. O’RING

6-46890 ENG Issued 07-11 Printed in Brazil

 8003-23

Components Identification

1. PIN 11. PIN 21. PLATE

2. BEARING 12. SHAFT 22. SHIM
3. SPACER 13. PLUNGER 23. BEARING
4. PAD 14. PLATE 24. WASHER
5. PLUG 15. SPACER 25. SNAP RING
6. HOUSING 16. PLATE 26. SHIM
7. SEAL RING 17. BOLT 27. WASHER
8. SNAP RING 18. PLATE 28. SPRING
9. BRACKET 19. DRUM 29. WASHER
10. HALF BUSHING 20. PIN 30. KIT Seal

6-46890 ENG Issued 07-11 Printed in Brazil

8003-24

1. NUT 9. NUT 17. O’RING

2. STUD 10. VALVE 18. WASHER
3. BOLT 11. SLEEVE 19. BUSHING
4. O’RING 12. PLUNGER 20. PLUNGER
5. O’RING 13. SPRING 21. BOLT
6. VALVE 14. HOUSING 22. O’RING
7. COIL 15. SPRING 23. PAD
8. O’RING 16. CUP 24. SPRING

6-46890 ENG Issued 07-11 Printed in Brazil

 8003-25

1. HOUSING 10. PLUG 19. SPRING

2. PLUG 11. STUD 20. SHIM
3. KIT Repair - Include items2 and 4 12. NUT 21. PLUG
4. WASHER 13. STUD 22. VALVE
5. O’RING 14. BOLT 23. SPRING
6. RING 15. BOLT 24. WASHER
7. TUBE 16. DIAPHRAGM 25. O’RING
8. PLUNGER 17. O’RING 26. PLUG
9. PLUNGER 18. BALL 27. VALVE

6-46890 ENG Issued 07-11 Printed in Brazil

8003-26

1. BOLT 5. VALVE 9. SENSOR

2. COVER 6. BOLT 10. O’RING
3. O’RING 7. BRACKET
4. BOLT 8. BOLT

6-46890 ENG Issued 07-11 Printed in Brazil

 Section
8004

HYDRAULIC SCHEMATICS
865B AWD / 885B AWD

8004
Models

Copyright © 2011 CNH America LLC.

CNH Latin America LTDA All Rights Reserved
2237, General David Sarnoff Avenue Printed in Brazil
Contagem - MG - Brazil 6-46891 ENG Issued July, 2011
8004-2

TABLE OF CONTENTS
HYDRAULIC DIAGNOSTIC PANEL CHECK.................................................................................................................................3
HYDRAULIC SCHEMATIC TO AWD..............................................................................................................................................4
BASIC STRUCTURE TO AWD.......................................................................................................................................................5

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 8004-3

HYDRAULIC DIAGNOSTIC PANEL CHECK

When hydraulic system pressure failures occurs, pressure
specifications are as follow:

1. Hydraulic System
(193±3,4 bar; 2800±50 PSI) *1

2. Steering Hydraulic System

(151 bar; 2200PSI) *2

3. Brake Accumulators LH
(81-87 bar; 1175-1262 PSI) *1,3
Diagnostic test panel
(120-126 bar; 1740-1827 PSI) *1,4

2 3 4
1 4. Brake Accumulators RH
(81-87 bar; 1175-1262 PSI) *1,3
(120-126 bar; 1740-1827 PSI) *1,4

5. Brake System LH
40-45 bar (580-653 PSI) *1

7 8 6. Brake System RH
5 6 40-45 bar (580-653 PSI) *1

Centralized pressure takeoffs

7. Blade Lift Cylinder RH

(98-113 bar; 1420-1640 PSI) *1

8. Blade Lift Cylinder LH

(98-113 bar; 1420-1640 PSI) *1

NotE: *1 Engine speed 2200 rpm

*2 Engine speed 900 rpm
*3 Minimum accumulator pressure
*4 Maximum accumulator pressure

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8004-4

HYDRAULIC SCHEMATIC TO AWD

6-46891 ENG Issued 07-11 Printed in Brazil

 8004-5

BASIC STRUCTURE TO AWD

6-46891 ENG Issued 07-11 Printed in Brazil

8004-6

NOTES

6-46891 ENG Issued 07-11 Printed in Brazil

 SECTION INDEX
Mounted Equipment
Section Title Section Number

Air Conditioning Troubleshooting and System Checks for Systems With HFC-134A Refrigerant . ........................................ 9002

Removal and Installation of Air Conditioning Components for Systems With HFC-134A Refrigerant . .................................. 9004

Rear Ripper ............................................................................................................................................................................ 9007

Frame, Articulation Joint Circle and Scarifier ......................................................................................................................... 9008

Front Blade and Counterweight . ............................................................................................................................................ 9009

Copyright © 2011 CNH America LLC.

CNH Latin America LTDA All Rights Reserved
2237, General David Sarnoff Avenue Printed in Brazil
Contagem - MG - Brazil 6-46940 ENG Issued July, 2011
 Section
9002

9002
AIR CONDITIONING TROUBLESHOOTING
AND SYSTEM CHECKS
FOR SYSTEMS WITH HFC-134A REFRIGERANT

Copyright © 2011 CNH America LLC.

CNH Latin America LTDA All Rights Reserved
2237, General David Sarnoff Avenue Printed in Brazil
Contagem - MG - Brazil 6-46950 ENG Issued July, 2011
9002-2

TABLE OF CONTENTS
SAFETY PROCEDURES...............................................................................................................................................................3
SPECIAL TOOLS...........................................................................................................................................................................4
OPERATION...................................................................................................................................................................................5
TROUBLESHOOTING...................................................................................................................................................................6
SYSTEM CHECKS.........................................................................................................................................................................8
Mechanical Compressor Check...............................................................................................................................................8
Blower and Compressor Clutch Check....................................................................................................................................9
Cab Temperature Check........................................................................................................................................................10
Visual and Leak Check..........................................................................................................................................................11
Evaporator/Heater Core Check.............................................................................................................................................12
PRESSURE TESTING.................................................................................................................................................................13
Manifold Gauge Set...............................................................................................................................................................13
Pressure Test Connection......................................................................................................................................................13
NORMAL OPERATING AIR CONDITIONING CONDITIONS......................................................................................................14
A/C RECOVERY AND CHARGING STATION CONNECTIONS..................................................................................................15
PROBLEM – NO COOLING.........................................................................................................................................................16
Indication of No Refrigerant or Low Refrigerant Charge:......................................................................................................16
Indication of Large Quantity of Air in System:........................................................................................................................17
Condenser Malfunctioning - Indications:...............................................................................................................................17
Expansion Valve Malfunctioning - Indications:.......................................................................................................................18
Refrigerant Contamination:....................................................................................................................................................18
HFC-134a Stable Saturation Pressure/ Temperature Chart..................................................................................................18
PROBLEM – NOT ENOUGH COOLING......................................................................................................................................19
Air in the System - Indications...............................................................................................................................................19
Not Enough Refrigerant - Indications:...................................................................................................................................20
Condenser Malfunctioning - Indications:...............................................................................................................................21
Expansion Valve Not Operating - Indications:.......................................................................................................................21
PROBLEM – INTERMITTENT COOLING....................................................................................................................................24
PROBLEM – NOISE IN SYSTEM................................................................................................................................................25
SCREWS AND TUBE CONNECTIONS TORQUE CHART..........................................................................................................26

6-46950 ENG Issued 07-11 Printed in Brazil

 9002-3

SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU
SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILI-
TY OF PERSONAL INJURY OR DEATH.
M171B

ATTENTION: Only authorized technicians 3. Keep refrigerant containers in the correct

certified by an approved training and certification upright position. Always keep refrigerant
organization may service or repair motor vehicle containers away from heat and sunlight. The
or mobile air conditioning systems. It is mandatory pressure in a container will increase with
that all refrigerant must be RECOVERED and heat.
RECYCLED when removed from a system
during servicing. 4. Always reclaim refrigerant from the system,
if you are going to weld or steam clean near
Refrigerant HFC-134a is the most stable, and the air conditioner system.
easiest to work with of the refrigerants now used
in air conditioner systems. Refrigerant HFC- 5. Always check the temperature and pressure
134a does not contain any chlorofluorocarbons of the air conditioner system before reclaiming
(CFC’s) which are harmful to the earth’s ozone refrigerant and when you test the system.
layer.
Safety procedures must be followed when 6. Dangerous gas can form when refrigerant
working with Refrigerant HFC-134a to prevent comes in contact with an open flame. Never
possible personal injury. permit fumes to be inhaled.

1. Always wear safety goggles when doing any 7. Never leak test with compressed air or
service work near an air conditioner system. flame testers. Tests have indicated that
Liquid refrigerant getting into the eyes can compressed mixtures of HFC-134a and air
cause serious injury. Do the following if you can form a combustible gas.
get refrigerant near or in your eyes:
8. Always reclaim refrigerant from the system
A. Flush your eyes with water for 15 before removing any air conditioning
minutes. component.

B. See a physician immediately.

2. A drop of liquid refrigerant on your skin may

cause frostbite. Open the fittings carefully
and slowly when it is necessary to service
the air conditioner system. Your skin must be
treated for frostbite or a physician must be
seen if you get refrigerant on your skin.

6-46950 ENG Issued 07-11 Printed in Brazil

9002-4

SPECIAL TOOLS
Tool No. Specification Tool Illustration Tool

CAS-10808 Belt tension tool

OEM-1437 Electronic leak detector

OEM-1415 Refrigerant recovery, recycling and charging Station

CAS-10073-3 Safety goggles

6-46950 ENG Issued 07-11 Printed in Brazil

 9002-5

OPERATION
The refrigerant circuit of the air conditioning The refrigerant, still in a high pressure liquid
system contains five major components: com- form, then flows from the receiver-drier to the
pressor, condenser, receiver-drier, expansion expansion valve. The expansion valve then
valve and evaporator. These components are causes a restriction in flow of refrigerant to
connected by tubes and hoses and operate as the evaporator core. The evaporator meters
a closed system. The air conditioner system is refrigerant f low based on evaporator heat load.
charged with HFC-134a refrigerant.
As the refrigerant flows through the evaporator
The compressor receives the refrigerant as a low core, the refrigerant is heated by the air around
pressure gas. The compressor then compresses and flowing through the evaporator fins. The
the refrigerant and sends it in the form of a high combination of increased heat and decreased
pressure gas to the condenser. The air flow pressure causes the air flow through the
through the condense r then removes the heat evaporator fins to become very cool and the
from the refrigerant. As the heat is removed the liquid refrigerant to become a low pressure gas.
refrigerant changes to a high pressure liquid. The cooled air then passes from the evaporator
to the cab for the operator’s comfort.
The high pressure refrigerant liquid then flows
from the condenser to the receiver-d r ier. The The electrical circuit of the air conditioning system
receiver-drier is a container filled with moisture consists of a fan speed control,one (1) relay, a
removing material, which removes any moisture blower motor, blower resistor, A.C.compressor
that may have entered the air conditioner system clutch, A.C. low pressure switch, A.C. high
in order to prevent corrosion of the internal pressure switch.
components of the air conditioner system.

1. EXPANSION VALVE 3. COMPRESSOR 5. RECEIVER-DRIER

2. EVAPORATOR 4. CONDENSER

6-46950 ENG Issued 07-11 Printed in Brazil

9002-6

TROUBLESHOOTING
Perform a visual inspection of the machine. 5. Are there heavy accumulations of oil, or oily
Check the following and correct as necessary: dust around the fittings, indicating refrigerant
leakage?
1. Obtain service history if possible.
6. Are air ducts undamaged, sealed properly
2. Is compressor drive belt in place and and in position?
tensioned?
7. Condensate drain hoses and check valves
3. Are grille screens, fan blades, condenser, air present and unobstructed?
filter, and evaporator unobstructed?

4. Are there any sharp bends or kinks in the

hoses?

Problem: No Cooling

Mechanical - See Mechanical Compressor

No Check Page 8
Compressor Runs
Electrical - See Blower and Compressor
Clutch Check Page 9

Yes

Internal System Problem

See Pressure Testing, Page 13

6-46950 ENG Issued 07-11 Printed in Brazil

 9002-7
Problem: Problem:
Not Enough Cooling Erratic Cooling

HEATER MECHANICAL
Make sure the heater control is OFF and that there See Mechanical Compressor Check Page 8.
is no coolant flow through the heater core.

ELECTRICAL
See Blower and Compressor Clutch Check -
SEAL Blower Motor Check, Blower Switch Check and
Make sure the sealing material is correctly in Compressor Clutch Check on Page 9.
place.

MECHANICAL INTERNAL SYSTEM PROBLEMS

See Mechanical Compressor Check page 8. See See Pressure Testing, Page 13.
Evaporator Heater Core Check Page 12.

ELECTRICAL Problem:
See Blower and Compressor Clutch Check on
System Makes Noise
Page 9.

REFRIGERANT MECHANICAL
See Cab Temperature Check Page 10. See Mechanical Compressor Check Page 8.
See Blower Motor Check Page 9.

INTERNAL SYSTEM PROBLEM

See Pressure Testing, Page 13. ELECTRICAL
See Compressor Clutch Check Page 9.

INTERNAL SYSTEM PROBLEM

See Pressure Testing, Page 13.

6-46950 ENG Issued 07-11 Printed in Brazil

9002-8

SYSTEM CHECKS
Mechanical Compressor Check

1. Too much belt wear - replace a worn belt,

Compressor and Fan Belts because a worn belt will cause too much
slippage.

1. Loose bracket mounting bolts - tighten

the bolts to the correct torque.
Compressor Mounting Brackets
2. Bracket has cracks or breaks - replace
the bracket.

1. The compressor belt will slip on the

compressor pulley if there is compressor
seizure. Remove the compressor for
service or replacement.
2. The gap between the front plate and pulley
Compressor Clutch
assembly must be 0.41 to 0.79mm.
3. Use a socket wrench to slowly rotate
the compressor clockwise. Compressor
rotation should be smooth and not require
much effort.

1. The compressor pulley and the compressor

drive pulley must be aligned within 1.6
mm (1/16 inch) of each other. Use a
Pulley and Belt Alignment
straight edge to check pulley alignment.
Adjust the compressor mounting bracket
if needed.

6-46950 ENG Issued 07-11 Printed in Brazil

 9002-9

Blower and Compressor Clutch Check

NOTE: Check supply voltage with compressor

lead plugged in and engaged. Voltage drops
will not be apparent without current flow.
Compressor Clutch 1. If there is electrical system voltage to the
clutch, check for excessive voltage drop
in the ground circuit, then see Section
9004 and replace the compressor.

1. See Section 4002 and check the high and

Low and High Pressure Switches
low pressure switches.

Blower Fuse (20 amp) 1. Check for damaged blower fuse.

1. Check switch operation. Switch must give

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

1. Check the wiring to the blower motor.

Blower Motor Make re pai rs or rep lace i tems as
necessary.

6-46950 ENG Issued 07-11 Printed in Brazil

9002-10

Cab Temperature Check

1. Make sure louvers and recirculation

vents are fully open for most efficient air
Air Louvers conditioning operation. Defrost louvers
must be closed.
2. Check blower; blower must be running.

ATTENTION: Use caution when feeling

hoses. Hoses become very hot. Check
temperature by slowly reaching for hose and
touching briefly several times with finger tips,
increasing the duration with each touch.
1. Feel the air conditioning hoses. The
Air Conditioning
high pressure hoses (small line) must be
warmer than the low pressure hose (large
line).
2. If no temperature difference, the system
is low on refrigerant, or compressor is not
working correctly.

1. Put a thermometer in the air duct behind

the seat and run the compressor for f
ive minutes to make temperature stable.
Refer to page 12.
2. Duct temperature must be below 25°
C (72° F) if the system is operating at
maximum efficiency.
Duct Temperature
NOTE: Ambient temperature must be 27 to
43° C (80 to 110° F).

3. If temperature is above 25° C (72° F),

system is low on refrigerant, there is a
rest riction in the system, compressor is
not working correctly, or air ducts are not
sealed correctly.

6-46950 ENG Issued 07-11 Printed in Brazil

 9002-11
Visual and Leak Check

1. Make sure that all hose connections are

tight.
Compressor Hoses
2. Check hoses for bends or cracks. Replace
all hoses that have damage.

1. Shut off the engine.

WARNING: When refrigerant comes in contact

with an open flame, it can form dangerous
Leak Finding Check gas. Never breathe these fumes.

2. Use electronic leak detector OEM -1437 to

inspect all connect ions. Use instructions
from manufacturer of leak finding tool.

1. Make sure the condenser is clean and the

Condenser
seals are in place.

6-46950 ENG Issued 07-11 Printed in Brazil

9002-12
Evaporator/Heater Core

Make sure heater valve is closed

Evaporator/Heater Core Check

1. See Section 9004 for access to the
evaporator/heater core.
2. Inspect the fins on the evaporator/heater
core. All the fins that have bends or
damage must be made straight.
3. Inspect the evaporator/heater core
for restrictions. If the core is dry, use
compressed air or a brush and vacuum
cleaner. If the core is wet or filled with
Evaporator/Heater Core mud, flush the core with water using a
hose without pressure. Make sure the
water drains freely from the evaporator/
heater core. DO NOT USE STEAM.

WARNING: Do not steam clean any air

conditioning systems parts while the system
is charged. The heat will cause the refrigerant
to rise to a pressure that could cause the
system to explode.

1. See Section 9004 for access to the

evaporator/heater core.
2. Make sure seals are in place so blower
Evaporator/Heater Core Sealing
wil l pul l air only through the evaporator/
heater core and not around the evaporator/
heater core.

Filters 1. Make sure the filters are clean.

6-46950 ENG Issued 07-11 Printed in Brazil

 9002-13

PRESSURE TESTING
Manifold Gauge Set Pressure Test Connection
NOTE: The gauge set is not accurate enough to optimize Connect the manifold gauge set into the air conditioning
an existing charge of HFC-134a. The best use of the gau- system as shown. Make sure that both valves in the mani-
ge set is to determine whether undercharge or overcharge fold gauge set are closed.
exists, and then evacuate, reclaim and recharge system
with the recommended quantity (charge) of HFC-134a.
The manifold gauge set is the most important tool used to
service the air conditioning system. The manifold gauge set
is used to measure the high and low pressures of the sys-
tem, as a tool to troubleshoot for correct refrigerant charge
quantity, system diagnosis, and operating efficiency. The
manifold gauge set can read both the high (discharge) and
low (suction) sides at the same time, since pressure must
be compared in order to make a diagnosis of system ope-
ration.
LOW PRESSURE GAUGE - The low pressure gauge is a
compound gauge. It is best used to judge evacuation effect
iveness. A vacuum reading indicates a system malfunction.
For this reason, it is necessary to use a compound gauge
that will indicate both pressure and vacuum.
During normal operation the low pressure gauge must
always indicate from 10 to 35 psi (0.7 to 2.4 bar) after the
system has run 10 to 15 minutes.
HIGH PRESSURE GAUGE - The high pressure gauge is
used to indicate pressures in the high side of the system.
The gauge must indicate from 0 to 400 psi (0 to 27.6 bar)
minimum.
During normal operation, the high pressure gauge will nor-
mally indicate from 120 to 310 psi (8.3 to 21.4 bar). See
pressure-temperature chart on page 14.

6-46950 ENG Issued 07-11 Printed in Brazil

9002-14

NORMAL OPERATING AIR CONDITIONING CONDITIONS

AMBIENT NORMAL LOW NORMAL HIGH AIR LOUVER (BEHIND SEAT)
TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION MAXIMUM TEMP.
°F (°C) psi (bar) psi (bar) °F (°C)
80 (27) 9 to 12 145 to 165 55 (14)
(0.62 to 0.83) (10 to 11.53)
90 (32) 11 to 15 190 to 210 61 (18)
(0.76 to 1.04) (13.10 to 14.48)
95 (35) 16 to 18 210 to 230 63 (20)
(1.10 to 1.24) (14.48 to 15.86)
100 (38) 17 to 19 235 to 255 66 (22)
(1.17 to 1.31) (16.2 to 17.58)
105 (41) 20 to 21 260 to 280 68 (23)
(1.38 to 1.45) (17.93 to 19.31)
110 (43) 22 to 24 290 to 310 72 (25)
(1.93 to 2.14) (20 to 21.37)

AMBIENT TEMPERATURE -25°C

RELATIVE HUMITY 50%
MACHINE MOTOR SPEED 2000 rpm
SUCTION PRESSURE 15+-5 psi
DISCHARGE PRESSURE 175+-15 psi

• Measurements taken 15 minutes after startup

• All panels and access doors installed and closed
• Fresh air filter and cab air filter clean and installed.
• Condenser fins clean and unobstructed and straight.
These data have great increase or decrease depending on environmental conditions

QUICK REFERENCE TROUBLESHOOTING CHART

PROBLEM LOW PRESSURE GAUGE HIGH PRESSURE GAUGE SEE PAGE

NO COOLING VERY LOW VERY LOW 16

NO COOLING HIGH HIGH 17
NOT ENOUGH COOLING NORMAL TO HIGH NORMAL 19
NOT ENOUGH COOLING LOW LOW 20
NOT ENOUGH COOLING HIGH LOW 22
NOT ENOUGH COOLING HIGH HIGH 23
INTERMITTENT COOLING NORMAL NORMAL 24
NOISE IN SYSTEM NORMAL TO HIGH HIGH 25

6-46950 ENG Issued 07-11 Printed in Brazil

 9002-15

A/C RECOVERY AND CHARGING STATION CONNECTIONS

STEP 1
WARNING: Always wear safety
goggles when working with liquid
refrigerant. Liquid refrigerant in
your eyes could cause blindness.
SM105A

Make sure the charging station manifold gauge

valves are in the closed position.

STEP 3

Clean the external surfaces of the compressor

and hoses. Remove the caps from the service
ports on the suction and pressure hoses.

WARNING: Do not steam clean

any air conditioning system parts
while the system is charged. The
heat will cause the refrigerant to
rise to a pressure that could cause BD00N030
the system to explode. 1. BLOWER FAN SWITCH
SM104A 2. A/C TEMPERATURE CONTROL

Start the engine and run at 1500 RPM maximum

speed. Operate the air conditioner system at
STEP 2 maximum cooling setting and blower speed for
15 minutes with the cab door open. Observe
Connect the hose from the test gauges to the the test gauges and check the chart on page 13
service ports by turning the knurled knobs on against the gauge readings.
the depressors.

Connect the hose from the low pressure gauge

to the port on the suction hose.

Connect the hose from the high pressure gauge

to the port on the discharge hose.

Connect the hose from the low pressure gauge

to the port on the suction hose.

6-46950 ENG Issued 07-11 Printed in Brazil

9002-16

PROBLEM – NO COOLING

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

Indication of No Refrigerant or Low Refrigerant Charge:

1. Leak test the system, see Page 11. It may

be necessary to add refrigerant. See Section
9003.

2. Evacuate and reclaim remaining refrigerant

from system. See Section 9003.

3. Repair system leaks as needed. Follow the

given repair procedure.
A. Discharge air from evaporator warm. Yes
4. Check level of oil in compressor - possible
B. Compressor does not run, or cycles off
for compressor to have an oil loss.
rapidly after start-up.
5. Remove air and moisture from the system.
Replace Receiver-Drier. See Section 9004.

6. Charge system with new refrigerant. See

Section 9003.

7. Continue performance test for other

possible problems.

6-46950 ENG Issued 07-11 Printed in Brazil

 9002-17

PROBLEM – NO COOLING

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

Indication of Large Quantity of Air in System:

1. Evacuate and reclaim refrigerant from

system. See Section 9003.
Yes 2. Replace receiver-drier.
Discharge air from evaporator warm 3. Remove air and moisture from the system.
See Section 9003.
4. Charge system with new refrigerant. See
Section 9003.

Condenser Malfunctioning - Indications:

1. Check for loose or worn compressor.

2. Check to see that condenser is clean
and unobstructed and that the fins are
Discharge air from evaporator warm straight.
3. Check system for too much refrigerant.
Evacuate, reclaim and recharge
refrigerant until gauge pressure is normal.
See Section 9003.
4. Remove and check condenser for
restrictions caused by oil or reduced heat
transfer.
A. Remove refrigerant from the system.
See Section 9003.
B. Use compressed air to remove oil
from condenser.
C. Replace receiver-drier.
D. Remove moisture and charge the
system. See section 9003.
5. Continue the performance test for other
possible problems.

6-46950 ENG Issued 07-11 Printed in Brazil

9002-18

PROBLEM – NO COOLING
Expansion Valve Malfunctioning - Indications:

A. Discharge air from heater/evaporator

warm.
See Section 9004 and replace the expansion
B. Much condensation on suction hose at
valve.
compressor.
C. Much condensation on evaporator outlet.

Refrigerant Contamination:

1. See table below and check stable

Refrigerant Contamination saturation pressures at given temperature
to determine if contamination exists.
A. Measure pressure from gauge on
reclamation unit.
B. Measure temperature from refrigerant
in reclamation tank. If refrigerant has
HFC-134a Stable Saturation been in reclamation unit for some
time, use ambient temperature. The
Pressure/ Temperature Chart numbers in the table represent the
Temperature °F (° C) Pressure PSIG (Bar) boiling point for HFC-134a.
C. Pressure readings below range
50 (10) 45 (3.1)
given in chart indicate contaminated
55 (13) 51 (3.5) refrigerant.
60 (16) 57 (3.9)
65 (18) 64 (4.4) IMPORTANT: Do not use contaminated
70 (21) 71 (4.9) refrigerant or mix with uncontaminated
refrigerant. Dispose of in accordance with all
75 (24) 78 (5.4)
applicable laws and local procedure.
80 (27) 88 (6.1)
85 (29) 95 (6.6)
90 (32) 104 (7.2)
95 (35) 114 (7.9)
100 (38) 124 (8.6)
102 (39) 129 (8.9)
104 (40) 133 (9.2)
106 (41) 138 (9.5)
108 (42) 142 (9.8)
110 (43) 147 (10.1)
112 (44) 152 (10.5)
114 (46) 157 (10.8)
116 (47) 162 (11.2)
118 (48) 167 (11.5)
120 (49) 172 (11.9)

6-46950 ENG Issued 07-11 Printed in Brazil

 9002-19

PROBLEM – NOT ENOUGH COOLING

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

Air in the System - Indications

1. Test system for leaks. See page 11.

Possible leak has let air enter; check
compressor seal carefully.

2. Discharge system of refrigerant. See

Section 9003.

A. Suction line warm to your hand. 3. Repair system leak as necessary.

B. Discharge air from heater/evaporator only 4. Replace receiver-drier.

a little cool.
5. Check compressor oil level.

6. Remove air and moisture from the system.

See Section 9003.

7. Charge system with new refrigerant. See

Section 9003.

6-46950 ENG Issued 07-11 Printed in Brazil

9002-20

PROBLEM – NOT ENOUGH COOLING

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

Not Enough Refrigerant - Indications:

1. Leak test system - system has a loss of
refrigerant.

NOTE: Normally, the system will lose 1/2 to

1 ounce (14.7 to 29.5 grams) of refrigerant
between seasons.

A. If leak is found, go to Step 2.

B. If no leak is found, go to Step 6.

2. Discharge refrigerant from system. See

Discharge air from evaporator cool or warm Section 9003.
- not cold.
3. Repair system leaks as needed.

4. Check oil level in compressor - It is

possible for compressor to lose oil.

5. Remove air and moisture from the system.

Replace Receiver-Drier. See Section
9004.

6. Charge system with new refrigerant. See

Section 9003.

6-46950 ENG Issued 07-11 Printed in Brazil

 9002-21

PROBLEM – NOT ENOUGH COOLING

Condenser Malfunctioning - Indications:

A. Discharge air from heater/evaporator only 1. Discharge refrigerant from system-

a little cool. restriction in receiver-drier or liquid line must
B. Condensation or frost on receiver-drier. be removed.
C. Liquid line to receiver-drier cool, with frost 2. Remove and replace part with restriction.
or condensation. 3. Remove air and moisture from the system.
See Section 9003.
NOTE: The frost will form downstream from 4. Charge system with new refrigerant. See
or at the point of the restriction Section 9003.

Expansion Valve Not Operating - Indications:

1. Expansion valve outlet with condensation

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

6-46950 ENG Issued 07-11 Printed in Brazil

9002-22

PROBLEM – NOT ENOUGH COOLING

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

Compressor Turning But Not Pumping Properly - Indications:

1. Discharge refrigerant from system. See

Section 9003.

2. Remove the compressor from the

machine. See Section 9004.

3. Remove and replace compressor

because there is indication of internal
leak in compressor.
A. System is fully charged.
4. Replace compressor.
B. Cool discharge air from evaporator.
5. Replace receiver-drier if:

A. System has been opened before.

B. Receiver-drier has been used two

or more years. See Section 9004 for
receiver-drier replacement.

6. Charge the system with refrigerant. See

Section 9003.

Expansion Valve Stuck Open

1. Replace expansion valve. See Section
Expansion Valve Stuck Open
9004.

6-46950 ENG Issued 07-11 Printed in Brazil

 9002-23

PROBLEM – NOT ENOUGH COOLING

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

Condenser Not Operating - Indications:

1. Check for loose or worn compressor belt.

2. Check to see that condenser is clean and

that the fins are straight.

3. Check system for too much system.

See section 9003.
A. Remove all refrigerantfrom system.
See 9003.
B. Add specified refrigerant charge
A. Liquid line very hot.
(1450+- 50g).
C. If there is still a problem, do step4.
B. Discharge air from evaporator warm.
4. Remove and inspect condenser for
restrictions caused by oil or reduced heat
transfer.
A. Discharge refrigerant from system.
See Section 9003.
B. Use compressed air to remove oil
from condenser.
C. Replace receiver-drier. See Section
9004.

Air in the System - Indications:

1. Discharge refrigerant from system. See

Section 9003.
2. Replace receiver-drier.
Warm discharge air from evaporator. 3. Remove air and moisture from the system.
See Section 9003.
4. Charge system with new refrigerant. See
Section 9003.

6-46950 ENG Issued 07-11 Printed in Brazil

9002-24

PROBLEM – INTERMITTENT COOLING

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

Moisture in the System - Indications:

1. Discharge system of refrigerant. If too

much moisture enters the orifice of the
expansion valve, the freezing of this
moisture can stop refrigerant flow. See
Section 9003.

2. Replace receiver-drier. The moisture

removing material could be full to capacity
with moisture. See Section 9004.
Cooling is acceptable during cool part of day
but not acceptable during hot part of day.
3. Remove air and moisture from the system.
See Section 9003.

NOTE: The time needed to remove a large

amount of moisture will be two to three hours
minimum.

4. Charge system with new refrigerant. See

Section 9003.

6-46950 ENG Issued 07-11 Printed in Brazil

 9002-25

PROBLEM – NOISE IN SYSTEM

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

Too Much Refrigerant in System - Indications:

1. Remove all refrigerant from system.

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

6-46950 ENG Issued 07-11 Printed in Brazil

9002-26

SCREWS AND TUBE CONNECTIONS TORQUE CHART

TUBING SIZE 3/8 inch 1/2 inch 5/8 inch
THREAD SIZE M10 -1.25 5/8-18 3/4-18 7/8-18 1-14
OR OR
3/4-16 7/8-14
STEEL TO STEEL 31-36 Nm 31-36 Nm 40-46 Nm 45-52 Nm 45-52 Nm
ALUMINUM TO BRASS 10-14 Nm 10-14 Nm 24-30 Nm 30-37 Nm 45-52 Nm

NOTE: When tightening air conditioning hose or pipe fittings, a second wrench serving as support must
be used.

IMPORTANT: Special care is required when tightening the fittings on the compressor, condenser and
evaporator since these connections are easily distorted.

6-46950 ENG Issued 07-11 Printed in Brazil

 Section
9004

REMOVAL AND INSTALLATION

OF AIR CONDITIONING COMPONENTS
FOR SYSTEMS WITH HFC 134A REFRIGERANT

9004

Copyright © 2011 CNH America LLC.

CNH Latin America LTDA All Rights Reserved
2237, General David Sarnoff Avenue Printed in Brazil
Contagem - MG - Brazil 6-46971 ENG Issued July, 2011
9004-2

TABLE OF CONTENTS
CLEAN / REPLACE FRESH AIR FILTER.......................................................................................................................................3
CLEAN / REPLACE RECIRCULATED AIR FILTER.......................................................................................................................4
TO REPLACE RESISTOR AND EVAPORATOR FAN....................................................................................................................5
REPLACE HEATER AND EVAPORATOR......................................................................................................................................8
REPLACE THERMOSTATIC SWITCH AND EXPANSION VALVE................................................................................................9
REPLACE COMPRESSOR AND BELT........................................................................................................................................10
REPLACE CONDENSER, RECEIVER DRIER AND PRESSURE SWITCH................................................................................12
REPLACE AIR CONDITONING HOSE ASSY..............................................................................................................................14
AIR CONDITIONING CONTROL SWITCH..................................................................................................................................17

6-46971 ENG Issued 07-11 Printed in Brazil

 9004-3

CLEAN / REPLACE FRESH AIR FILTER

Open the cover (external side cab) and remove nuts with
10mm wrench. Remove support and clean / replace fresh
air filter.

6-46971 ENG Issued 07-11 Printed in Brazil

9004-4

CLEAN / REPLACE RECIRCULATED AIR FILTER

1. Find 04 (four) nuts of evaporator housing support that
is located at the bottom side of seat plate and remove
the filter

2. Use a Philips screw driver to remove 02 (two) bolts and

replace the filter.

6-46971 ENG Issued 07-11 Printed in Brazil

 9004-5
TO REPLACE RESISTOR AND EVAPORATOR FAN
1. Remove charge with proper equipment. Never let refri-
gerant charge flows to air.
2. Turn off two hot water valves located the machine en-
gine compartment

3. Remove seat.
4. Remove seat plate.

6-46971 ENG Issued 07-11 Printed in Brazil

9004-6
5. Disconnect 02 (two) air conditioning hose assemblies.
Use 16 and 22 mm wrench.

6. Disconnect 02 (two) hot water hoses removing clips

with pliers

6-46971 ENG Issued 07-11 Printed in Brazil

 9004-7
7. Remove 03(three) bolts from evaporator housing. Use
13 mm wrench. Disconnect electrical cables and remo-
ve evaporator housing.

8. Put evaporator housing on a workbench. Disconnect

electrical cable from resistor. Use a Philips screw driver
to remove 02 (two) screws and replace resistor.

9. Remove 03 (three) bolts on each fan. Use a 8 mm

wrench. Remove and replace fans.

6-46971 ENG Issued 07-11 Printed in Brazil

9004-8

REPLACE HEATER AND EVAPORATOR

1. Follow steps 3.1 to 3.5, disconnect electrical cables, re-
move evaporator housing and put it on a workbench.
2. Remove 09 (nine) screws. Use a Philips screw driver.
Remove cover.
3. Remove 02 ( two) screws. Use a Philips screw driver.
Make sure that expansion valve support is free.

4. Remove 06 (six) screws from evaporator and heater

plate located at each side of evaporator housing. Use a
Philips screw driver.
5. Remove evaporator first. Then, remove heater.
6. Replace evaporator and/or heater. In order to reassem-
ble these parts, follow these steps backwards.

6-46971 ENG Issued 07-11 Printed in Brazil

 9004-9
REPLACE THERMOSTATIC SWITCH AND EXPANSION VALVE
1. Follow steps 4.1 to 4.5, without removing heater plate
bolts (03). Remove evaporator and put it over workben-
ch.
2. Remove 02 (two) screws from thermostatic switch su-
pport. Use a Philips screw driver. Remove and replace
thermostatic switch. Make sure that its sensor (bulb) is
correctly mounted at evaporator fins hole.

3. Remove expansion valve. Use 19 and 25mm wrench.

Replace it and replace o-ring seal.

4. In order to reassemble evaporator, follow these steps

in reverse order

6-46971 ENG Issued 07-11 Printed in Brazil

9004-10
REPLACE COMPRESSOR AND BELT
1. Remove charge with proper equipment. Never let refri-
gerant charge flow to air.
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 com-
pressor to make belt free. Use 17 mm wrench. Remove
compressor.

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.

6-46971 ENG Issued 07-11 Printed in Brazil

 9004-11
4. Loosen free but do not remove the 03 (three) bolts from
compressor. Replace belt with proper tension.

6-46971 ENG Issued 07-11 Printed in Brazil

9004-12

REPLACE CONDENSER, RECEIVER DRIER AND PRESSURE SWITCH

1. Remove charge with proper equipment. Never let refri-
gerant charge flow to air. If is necessary, replace only
switch pressure, do not remove charge.
2. Remove condenser hose fitting. Use 19 and 22mm
wrench. Remove receiver drier hose fitting. Use 16 and
19mm wrench.

3. Remove 04 (four) bolts from condenser supports. Use

a 17mm wrench. Put it on a workbench.

6-46971 ENG Issued 07-11 Printed in Brazil

 9004-13
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 moun-
ted.
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.

6-46971 ENG Issued 07-11 Printed in Brazil

9004-14

REPLACE AIR CONDITONING HOSE ASSY

1. Hose assy assembly chart.

POSITION P/N DESCRIPTION QTD

1 75254533 EVAPORATOR BOX 01
2 75257962 CONDENSER 01
3 75251988 COMPRESOR 01
4 75257955 HOSE COMPRESOR TO CONDENSER 01
5 75257956 HOSE CONDENSER TO EVAPORATOR 01
6 75257954 HOSE EVAPORATOR TO COMPRESOR 01
7 75255522 CASE 01
8 MOTOR 01
9 CASE 01
10 BELT GX G140 01
10 BELTG170VP /G200 01
11 75310261 O-RING SEAL #6 02
12 75310923 O-RING SEAL #8 02
13 75310260 O-RING SEAL #10 02
14 SCREW 03
15 WASHER 03
16 NUT 03

6-46971 ENG Issued 07-11 Printed in Brazil

 9004-15
2. Remove charge with proper equipment. Never let refri-
gerant charge flow to air.
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.

4. Replace hose assy – receiver drier to evaporator: re-

move 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.

6-46971 ENG Issued 07-11 Printed in Brazil

9004-16
5. Replace hose assy – evaporator to compressor: remo-
ve expansion valve hose fitting. Use a 22 mm wrench.
Remove compressor hose fitting. Use a 30 mm wren-
ch. Do not remove the grommet (cab floor). Replace
the hose assy. Be careful when mounting it through the
grommet. Replace the o-ring seals.

6-46971 ENG Issued 07-11 Printed in Brazil

 9004-17

AIR CONDITIONING CONTROL SWITCH

1. The air conditioning switch controls are located at right
side of cab.
2. Function of each one – refer to Operator's Manual.
3. Replace / maintenance of air conditioning switch con-
trol: remove panel cover. Be careful with electrical ca-
bles and heater valve cable.
4. Replace / maintenance of heating system.

5. Turn off two hot water valves located at machine engine

compartment.

6. Disconnect 02 (two) hot water hoses removing clips

with a pliers.
7. Remove heater control valve cable.
8. 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 du-
ring this procedure).

6-46971 ENG Issued 07-11 Printed in Brazil

9004-18

NOTES

6-46971 ENG Issued 07-11 Printed in Brazil

 Section
9007

REAR RIPPER

9007

Copyright © 2011 CNH America LLC.

CNH Latin America LTDA All Rights Reserved
2237, General David Sarnoff Avenue Printed in Brazil
Contagem - MG - Brazil 6-47011 ENG Issued July, 2011
9007-2

TABLE OF CONTENTS
MAIN DIMENSIONS.......................................................................................................................................................................3
Rear Ripper 845B / 845B DHP Models...................................................................................................................................3
Rear Ripper 865B / 865B VHP / 865B AWD / 885B / 885B DHP / 885B AWD Models...........................................................5

6-47011 ENG Issued 07-11 Printed in Brazil

 9007-3

MAIN DIMENSIONS
Rear Ripper 845B / 845B DHP Models
• 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 mm in.
A. Internal diameter of the support 70.100 – 70.174 2.7598 – 2.7627
B. Internal diameter of the arm 60.000 – 60.046 2.3622 – 2.3640
C. Internal diameter of the frame 50.080 – 50.180 1.9716 – 1.9756
D. External diameter of the bushing 60.07 – 60.10 2.365 – 2.366
Internal diameter of the bushing 50.195 – 50.265 1.9761 – 1.9789
E. External diameter of the bolt 49.961 - 50.000 1.9669 - 1.9685
6-47011 ENG Issued 07-11 Printed in Brazil
9007-4
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 p.in.
Try to notice the mounting angle to avoid
breaking the claws.

6-47011 ENG Issued 07-11 Printed in Brazil

 9007-5

Rear Ripper 865B / 865B VHP / 865B AWD /

885B / 885B DHP / 885B AWD Models
The mounting process is similar to the one for
the G140VP.
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.

6-47011 ENG Issued 07-11 Printed in Brazil

9007-6

Notes

6-47011 ENG Issued 07-11 Printed in Brazil

 Section
9008

FRAME,
ARTICULATION JOINT CIRCLE
AND SCARIFIER

9008

Copyright © 2011 CNH America LLC.

CNH Latin America LTDA All Rights Reserved
2237, General David Sarnoff Avenue Printed in Brazil
Contagem - MG - Brazil 6-47001 ENG Issued July, 2011
9008-2

TABLE OF CONTENTS
ARTICULATION JOINT..................................................................................................................................................................3
CIRCLE REMOVAL........................................................................................................................................................................6
DRAWBAR & CIRCLE....................................................................................................................................................................9
MOLDBOARD CONTROL............................................................................................................................................................12
DISASSEMBLY OF CIRCLE TURN GEARBOX..........................................................................................................................14
CIRCLE TURN ASSEMBLY.........................................................................................................................................................18
FRAME.........................................................................................................................................................................................19

6-47001 ENG Issued 07-11 Printed in Brazil

 9008-3

ARTICULATION JOINT
The articulation joint consists of tapered roller
bearings. The joint allows a total of 50 degrees
articulation.

Support the two main frames on jack stands

during rebuild.

WARNING : Do not work under or near

unblocked or unsupported linkage, parts or
machine.

Clean bearing bores.

WARNING : Never use gasoline solvent or

other flammable fluids to clean. Use authorized
comercial non-flamable, non-toxic solvents.
Watch out for people in the vicinity.

Measure the bearing height of the outer races

plus the height of the spacer. Record these
dimmensions. Keep the bearing pieces matched.
Repeat the measurement for the other bearing.

6-47001 ENG Issued 07-11 Printed in Brazil

9008-4
Measure the thickness of frame boss at the
bore.
Record these dimensions and repeat the
measuring process at the other frame boss.
Select shims to build the provided.

Use driver P/N 75300850 to install the bearing

cup into the frame bore. Install the bearing
retainer in place.

WARNING: It is unsafe to strike hardened

steel parts with anything other than a soft iron
or non-ferrous hammer. When installing or
removing such parts wear safety glasses with
side shields and heavy gloves, etc, to reduce the
possibility of injury.

Install the bearing into the bore. Prior to installing

the bearing retainers onto the frame, install the
seal into the retainer. Clean the joining surfaces
of the seal and retainer with P/N 75000782.
Apply sealant P/N 75000778 on the retainer.
Press seal into retainer. Do not get sealant on
sealing surface.

Position rear frame around the front frame.

Level the two frames prior to installation. Install
pins. Install bushing and inner on bottom joint
pin.
Install plates and tighten capscrews to
specification.

WARNING: Lift and handle all heavy parts

with a lifting device or proper capacity. Be sure
parts are supported by proper slings and hooks.
Use lifting eyes if provided. Watch out for people
in the vicinity.

6-47001 ENG Issued 07-11 Printed in Brazil

 9008-5

A. Pin O.D. .....................................................................................................................66.7133 – 66.725 mm (2.626 – 2.627 in)

Bearing cone I.D. ........................................................................................................ 66.675 – 66.888 mm (2.625 – 2.626 in)
B. Articulation support I.D. ............................................................................................ 66.7133 – 66.725 mm (2.626 – 2.627 in)
Bearing cup O.D. ........................................................................................................ 66.675 – 66.888 mm (2.625 – 2.626 in)
C. Torque capscrews . ................................................................................................................ 135 – 157 Nm (100 – 116 ft.lbs)
D. Torque capscrews . .................................................................................................................. 123 – 135 Nm (90 – 100 ft.lbs)
E. Pin O.D ..................................................................................................................... 66.7133 – 66.725 mm (2.626 – 2.627 in)
Bushing I.D. ....................................................................................................................... 66.890 – 67.160 (2.633 – 2.644 in)
F. Pin O.D. ...................................................................................................................... 66.713 – 66.725 mm (2.626 – 2.627 in)
Bearing cone I.D. ...................................................................................................... 66.6753 – 66.725 mm (2.626 – 2.627 in)
G. Pin O.D. .................................................................................................................... 66.7133 – 66.725 mm (2.626 – 2.627 in)
Bearing cone I.D. ...................................................................................................... 66.7133 – 66.725 mm (2.626 – 2.627 in)
H. Pin O.D. .................................................................................................................... 66.7133 – 66.725 mm (2.626 – 2.627 in)
Bushing I.D. ..................................................................................................................... 66.8909 – 67.160 (2.633 – 2.644 in)
I. Torque capscrews. . .................................................................................................. 66.7133 – 66.725 mm (2.626 – 2.627 in)
J. Torque capscrews. . .................................................................................................. 66.7133 – 66.725 mm (2.626 – 2.627 in)
K. Pin O.D. .................................................................................................................... 66.7133 – 66.725 mm (2.626 – 2.627 in)

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9008-6

CIRCLE REMOVAL
Lower moldboard so that the blade is on the
ground. Turn off the electrical master switch.

WARNING: Always turn the master switch

to the off position before cleaning, repairing,
servicing or parking the machine to prevent
injury.

Disconnect the right and left moldboard lift

cylinders at the lower trunnion ball joint. Keep
shims in position.

Disconnect the moldboard shift cylinder at

the trunnion ball on the circle. Keep shims in
position.

Disconnect hoses at front of circle frame.

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 9008-7
Remove capscrews connecting ball housing to
the tractor frame.

Installation is the reverse of removal with the

exception of measuring shim pack gap on the
cylinders.
Measure the gap between the ball and socket
with the capscrews tightened to final torque.
Add the specified dimension.

If the circle guides or wear plates have to be

replaced place the moldboard upon the ground.
Turn off electrical master switch.

WARNING: Always turn the master switch

to the off position before cleaning, repairing,
servicing or parking the machine to prevent
injury.

Remove bolts holding guides in position.

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9008-8
Install new wear surfaces

Install shims; guide and bolts.

Measure gap between wear plate and frame.

Make a shim pack equal to the gap plus the
specified dimension.

The guides must be adjusted see section for

procedure and specifications.

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 9008-9

DRAWBAR & CIRCLE

DRAWBAR AND CIRCLE TURN

• Adjust shims (A) to provide 1.5 mm (0.06 in.) vertical clearance between wear plates and circle
guide.
• With circle against front circle guide adjust capscrews(B) to provide 8-15 mm (0.03 – 0.06 in) clearance
between the circle and each circle guide. Torque capscrews (B) to 1080 Nm (800 ft.lbs)
• Adjust rear guides (C) to provide 0.7mm (0.03 in) maximum horizontal clearance the circle and each
rear guide.
• Torque capscrews (D) to 1080 Nm (800 ft.lbs)..

NOTE: Rotate circle 3600 to check free clearance.

• Torque capscrews (E) to 122 – 136 Nm (90 – 100 ft.lbs)

• Torque capscrews (F) to 570 – 585 Nm (420 – 430 ft.lbs)
• Adjust shims (G) to provide 0.00 – 0.25 mm 0.000 – 0.010 in) end play between ball and socket.
• Torque nut (H) to 810 Nm (600 ft.lbs).

NOTE: Do not apply lubricant to circle guide shoe liners or wear surface of circle.

• Torque capscrews (I) to 245 – 325 Nm (180 – 240 ft.lbs)

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9008-10
Remove the lower saddle plate capscrews and
the plate.

Disconnect light wires.

Disconnect the moldboard lift cylinders at the

yoke.

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 9008-11
Disconnect the moldboard shift cylinder where
it connects to the saddle as well as the hose
bracket.

Disconnect saddle lock cylinder hydraulic

tubing.

Support the saddle and remove the capscrews

securing the back plate to the saddle. Lift saddle
from the grader frame.

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.

Remove capscrews holding saddle support to

the frame. Keep shims in position.

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.

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9008-12

MOLDBOARD CONTROL

A. Shim to provide . ............................................................................................ 0.000 – 1.207 mm (0.000 – 0.005 in) loose ball
B. Torques ................................................................................................................................ 400 – 450 Nm (300 – 333 Ft.lbs.)
C. Torques ................................................................................................................................ 230 – 255 Nm (170 – 187 Ft.lbs.)
D. Torques ................................................................................................................................ 310 – 340 Nm (230 – 250 Ft.lbs.)
E. Apply a ligth coat of Molykote “G” lubricant paste to surfaces indicated.
F. Dimensions
Pin O.D. ................................................................................................................. 47.752 – 47.803 mm (1.880 – 1.882 inch.)
Trunnion bushing O.D. . ......................................................................................... 47.904 – 47.995 mm (1.886 – 1.888 inch.)
G. Dimensions
Trunnion bushing O.D. . ......................................................................................... 37.993 – 38.040 mm (1.496 – 1.498 inch.)
Trunnion bushing O.D. . ......................................................................................... 37.846 – 37.871 mm (1.490 – 1.491 inch.)
H. Torques ........................................................................................................................................ 47 – 53 Nm (35 – 39 Ft.lbs.)
I. With the grader on flat ground, measure the vertical distance from the ground to the center of the left and right lift cylinder
trunion yoke. For every 13 mm (0,5 inch) Difference betwwen the two dimensions, add two shims to the side with the lowest
pivot. Do not add more than fours shims.

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 9008-13

A. A. *Journal bore I.D. .................................................................................................. 82.559 – 82.575 mm (3.250 – 3.251 in)l

Journal bore O.D. ....................................................................................................... 82.559 – 82.575 mm (3.250 – 3.251 in)
Journal bore I.D. ......................................................................................................... 76.302 – 76.752 mm (3.004 – 3.006 in)
Journal bore O.D. ....................................................................................................... 76.175 – 76.200 mm (2.999 – 3.000 in)
B. Lubricate seals with molydisufide grease
C. Install shims to obtain ......................................................................................... 0.025 – 0.076 mm (0.001 – 0.003) end play.
D. Torque capscrews to . .............................................................................................................. 120 – 136 Nm (90 – 100 ft.lbs)
E. Torque capscrews to . .......................................................................................................... 940 – 1040 Nm (700 – 770 ft.lbs)
F. Use shims to provide ........... 0.000 – 0.127mm (0.0000 – 0.005 in) clearance between saddle support and sadle assembly.

* SERVICE NOTE:
1. Install inside bearing flush to 0.77 mm (0.03 in) below face of counterbore.
2. Install outside bearing to 10.2 mm (0.40 in) inside journal bore.

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DISASSEMBLY OF CIRCLE TURN GEARBOX

Remove the cover.

Drain the assembly.

Remove washer(2) and shims(A).Keep in

relative position.

Remove the outer cover.

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 9008-15
Remove circle turn motor.

Remove circle turn cover. Keep shims (B) in

position.

Remove worm gear assembly (3)

Remove snap ring

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Force shaft assembly from the housing.

Press the bushing from the cover.

Remove worm and bearing.

Inspect the roller bearings; if necessary,

replace.

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 9008-17
Check worm rolling torque.

The shaft assembly must have an end play.

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9008-18

CIRCLE TURN ASSEMBLY

A. Install shims as needed to obtain 0.0 – 3.3 mm (0.00 – 0.13 in) end shake. Do not preload.
B. With worm gear tremoved , install shims to obtain 9.3 – 9.7 Nm (6.9 – 7 ft.lbs) of rolling torque upon the
bearings.

1. Torques
One Place .............................................................................................................................. 120 – 137 Nm (90 – 100 Ft.lbs.)
Five Places .......................................................................................................................... 155 – 176 Nm (115 – 130 Ft.lbs.)
2. Torques ........................................................................................................................................ 47 – 54 Nm (35 – 40 Ft.lbs.)
3. Torques ................................................................................................................................ 474 – 508 Nm (350 – 375 Ft.lbs.)

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FRAME

A. Torques ........................................................................................................................................ 88 – 96 Nm (65 – 71 Ft.lbs.)

B. Torques ........................................................................................................................................ 88 – 96 Nm (65 – 71 Ft.lbs.)
C. Torques ........................................................................................................................................ 38 – 42 Nm (28 – 31 Ft.lbs.)
D. Torques ........................................................................................................................................ 38 – 42 Nm (28 – 31 Ft.lbs.)
E. Torques ................................................................................................................................ 304 – 332 Nm (224 – 245 Ft.lbs.)
F. Torques ........................................................................................................................................ 88 – 96 Nm (65 – 71 Ft.lbs.)

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NOTES

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 Section
9009

FRONT BLADE and COUNTERWEIGHT

9009

Copyright © 2011 CNH America LLC.

CNH Latin America LTDA All Rights Reserved
2237, General David Sarnoff Avenue Printed in Brazil
Contagem - MG - Brazil 6-47021 ENG Issued July, 2011
9009-2

TABLE OF CONTENTS
FRONT BLADE..............................................................................................................................................................................3
COUNTERWEIGHTG.....................................................................................................................................................................4

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 9009-3

FRONT BLADE
The mounting process of the front blade is similar to that of
the front scarifier. To mount the replaceable and reversible-
cutting edgesknifes, tighten the nuts with a 290 to 310 Nm
torque (215 – 230 ft.lbs.)

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9009-4

COUNTERWEIGHTG
To mount the front counterweight, put the front plate into
place and tighten the nuts.

6-47021 ENG Issued 07-11 Printed in Brazil