Service Manual Grader 845B

1 - GENERAL
2 - ENGINE
3 - FUEL SYSTEM
4 - ELECTRICAL
5 - STEERING
845B / 845B DHP

865B / 865B VHP / 865B AWD
885B / 885B DHP / 885B AWD
Grader
SERVICE MANUAL
Printed in U.S.A. Part number 84559573

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
GENERAL
Section Title Section Number
Standard Torque Especifications ............................................................................................................................................ 1001
Fluids and Lubricants ............................................................................................................................................................. 1002
Metric Conversion Chart . ....................................................................................................................................................... 1003
Service Tools .......................................................................................................................................................................... 1005
Copyright © 2011 CNH America LLC.

CNH Latin America LTDA All Rights Reserved
2237, General David Sarnoff Avenue Printed in Brazil
Contagem - MG - Brazil 6-46520 ENG Issued July, 2011
1001
Section
1001
STANDARD TORQUE ESPECIFICATIONS

1001-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS.........................................................................................................................................................3
Decimal....................................................................................................................................................................................3
Métric.......................................................................................................................................................................................4
Steel Hydraulic Fittings............................................................................................................................................................5
Steel Hydraulic Fittings............................................................................................................................................................6
NOTE: CASE reserves the right to make improvements in design or changes in specifications at any time
without incurring any obligation to install them on units previously sold.
6-46530 ENG Issued 07-11 Printed in Brazil

1001-3
TORQUE SPECIFICATIONS
Decimal
Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and UNF thre-
ads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphities, Molydisulfide greases,
or other extreme pressure lubricants are used.
Grade 5 Bolts, Nuts and Studs Grade 8 Bolts, Nuts and Studs
Size (inch) Pound-Inches N.m Size (inch) Pound-Inches N.m
1/4 9 - 11 12 - 15 1/4 12 - 15 16 - 20
5/16 17 - 21 23 - 28 5/16 24 - 29 33 - 39
3/8 35 - 42 48 - 57 3/8 45 - 54 61 - 73
7/16 54 - 64 73 - 87 7/16 70 - 84 95 - 114
1/2 80 - 96 109 - 130 1/2 110 - 132 149 - 179
9/16 110 - 132 149 - 179 9/16 160 - 192 217 - 260
5/8 150 - 180 203 - 244 5/8 220 - 264 298 - 358
3/4 270 - 324 366 - 439 3/4 380 - 456 515 - 618
7/8 400 - 480 542 - 651 7/8 600 - 720 814 - 976
1.0 580 - 696 787 - 944 1.0 900 - 1080 1220 - 1465
1-1/8 800 - 880 1085 - 1193 1-1/8 1280 - 1440 1736 - 1953
1-1/4 1120 - 1240 1519 - 1681 1-1/4 1820 - 2000 2468 - 2712
1-3/8 1460 - 1680 1980 - 2278 1-3/8 2380 - 2720 3227 - 3688
1-1/2 1940 - 2200 2631 - 2983 1-1/2 3160 - 3560 4285 - 4827
NOTE: Use thick nuts with Grade 8 bolts.

1001-4
Métric
Use the following torques when specifications are not given. These values apply to fasteners with coarse threads as received
from supplier, plated or unplated, or when lubricated with engine oil. These values do not apply if graphite or Molydisulfide gre-
ase or oil is used.
Grade 8.8 Bolts, Nuts and Studs Grade 10.9 Bolts, Nuts and Studs
8.8 10.9
Size (inch) Pound-Inches N.m Size (inch) Pound-Inches N.m

M4 2-3 3-4 M4 3-4 4-5
M5 5-6 6.5 - 8 M5 7-8 9.5 - 11
M6 8-9 10.5 - 12 M6 11 - 13 15 - 17.5
M8 19 - 23 26 - 31 M8 27 - 32 37 - 43
M10 38 - 45 52 - 61 M10 54 - 64 73 - 87
M12 66 - 79 90 - 107 M12 93 - 112 125 - 152
M14 106 - 127 144 - 172 M14 149 - 179 300 - 245
M16 160 - 200 217 - 271 M16 230 - 280 310 - 380
M20 320 - 380 434 - 515 M20 450 - 540 610 - 730
M24 500 - 600 675 - 815 M24 780 - 940 1050 - 1275
M30 920 - 1100 1250 - 1500 M30 1470 - 1770 2000 - 2400
M36 1600 - 1950 2175 - 2600 M36 2580 - 3090 3500 - 4200
Grade 12.9 Bolts, Nuts and Studs
12.9
Usually the torque values specified for grade 10.9 faste-

ners. can be used satisfactorily on grade 12.9 fasteners.

1001-5
Steel Hydraulic Fittings

Tube OD Thread Pound- Tube OD Thread Pound-
N.m N.m
Hose ID Size Inches Hose ID Size Inches
37 Degree Flare Fitting Straight Threads with O-ring

1/4" 1/4"
7/16 - 20 6 - 12 8 - 16 7/16 - 20 12 - 19 16 - 25
(6.4 mm) (6.4 mm)
5/16" 5/16"
1/2 - 20 8 - 16 11 - 22 1/2 - 20 16 - 25 22 - 34
(7.9 mm) (7.9 mm)
3/8" 3/8"
9/16 - 18 10 - 20 14 - 34 9/16 - 18 25 - 40 34 - 54
(9.5 mm) (9.5 mm)
1/2" 1/2"
3/4 - 16 15 - 42 20 - 56 3/4 - 16 42 - 67 57 - 90
(12.7 mm) (12.7 mm)
5/8" 5/8"
7/8 - 14 25 - 58 34 - 78 7/8 - 14 58 - 92 79 - 124
(15.9 mm) (15.9 mm)
3/4" 3/4"
1-1/16 - 12 40 - 80 54 - 108 1-1/16 - 12 80 - 128 108 - 174
(19.0 mm) (19.0 mm)
7/8" 7/8"
1-3/16 - 12 60 - 100 81 - 135 1-3/16 - 12 100 - 160 136 - 216
(22.2 mm) (22.2 mm)
1.0" 1.0"
1-5/16 - 12 75 - 117 102 - 158 1-5/16 - 12 117 - 187 159 - 253
(25.4 mm) (25.4 mm)
1-1/4" 1-1/4"
1-5/8 - 12 125 - 165 169 - 223 1-5/8 - 12 165 - 264 224 - 357
(31.8 mm) (31.8 mm)
1-1/2" 1-1/2"
1-7/8 - 12 210 - 250 285 - 338 1-7/8 - 12 250 - 400 339 - 542
(38.1 mm) (38.1 mm)
Split Flange Mounting Bolts

Size (inch) Pound-Inches N.m
5/16 - 18 15 - 20 20 - 27
3/8 - 16 20 - 25 27 - 34
7/16 - 14 35 - 45 47 - 61
1/2 - 13 55 - 65 74 - 88
5/8 - 11 140 - 150 190 - 203

1001-6
Steel Hydraulic Fittings

Nom. SAE Tube OD
Thread Pound- Thread Pound-
Dash INCH N.m N.m
Size Inches Size Inches
Size (mm)
O-ring Boss End

O-ring Face Seal End
Fitting or Lock Nut
1/4
-4 9/16-18 10 - 12 14 - 16 7/16-20 17 - 20 23 - 27
(6.4)
3/8
-6 11/16-16 18 - 20 24 - 27 9/16-18 25 - 30 34 - 41
(9.5)
1/2
-8 13/16-16 32 - 40 43 - 54 3/4-16 45 - 50 61 - 68
(12.7)
5/8
-10 1 - 14 46 - 56 62 - 75 7/8-14 60 - 65 81 - 88
(15.9)
3/4
-12 1-3/16-12 65 - 80 90 - 110 1-1/16-12 85 - 90 115 - 122
(19.0)
7/8
-14 1-3/16-12 65 - 80 90 - 110 1-3/16-12 95 - 100 129 - 136
(22.2)
1.0
-16 1-7/16-12 92 - 105 125 - 140 1-5/16-12 115 - 125 156 - 169
(25.4)
1-1/4
-20 1-11/ 16-12 125 - 140 170 - 190 1-5/8-12 150 - 160 203 - 217
(31.8)
1-1/2
-24 2-12 150 - 180 200 - 254 1-7/8-12 190 - 200 258 - 271
(38.1)

Section
1002
1002
FLUIDS AND LUBRICANTS

1002-2
TABLE OF CONTENTS
FLUIDS AND LUBRICANTS..........................................................................................................................................................3
845B / 865B / 885B Models Equipped with Tier 0, 1 and 2 Engines.......................................................................................3
845B DHP / 865B VHP / 885B DHP Models Equipped with Tier 3 Engines............................................................................4
865B AWD / 885B AWD Models Equipped with Tier 3 Engines...............................................................................................5
Recomendações de Viscosidade do Óleo e Fluidos.................................................................................................6
Oil Viscosity and Temperature Ranges....................................................................................................................................6
Hydraulic / Brake / Transmission System – Temperature Ranges...........................................................................................6
FUEL..............................................................................................................................................................................................7
Diesel Fuel...............................................................................................................................................................................7
Fuel Storage............................................................................................................................................................................7
Specifications for Acceptable No. 2 Diesel Fuel......................................................................................................................7
Lubrication & Maintenance Chart....................................................................................................................................8
845B / 865B / 885B Models Equipped with Tier 0, 1 and 2 Engines.......................................................................................8
845B DHP / 865B VHP / 885B DHP Models Equipped with Tier 3 Engines..........................................................................10
865B AWD / 885B AWD Models Equipped with Tier 3 Engines.............................................................................................12

1002-3
FLUIDS AND LUBRICANTS

845B / 865B / 885B Models Equipped with Tier 0, 1 and 2 Engines
CAPACITY
COMPONENTS SPECIFICATIONS
Liters US Gal.
Fuel tank
Total capacity 341,0 90,0 Nº 2 DIESEL
Engine oil
Engine Tier 1 (845B Models)
With filter change 16,4 4,3
Nº1 ENGINE OIL (1030190)
Without filter change 14,2 3,7
Engine Tier 0 and Tier 2 (865B / 885B Models)
Engine Cooling System
50% Water + 50% AKCELA PREMIUM
Total capacity 40,0 10,5
ANTI FREEZE (1060077)
Hydraulic System
AKCELA HY-TRAN ULTRA
Hydrauic tank with filter 90,0 23,8
Transmission
845B / 865B Models with ZF transmission
Refill capacity (with filter change) 26,0 6,9
Refill capacity (without filter change) 25,0 6,6
885B Models with FUNK transmission
Refill capacity (with filter change) 28,5 7,5 AKCELA HY-TRAN ULTRA (1040184)
Refill capacity (without filter change) 26,0 6,9 MAT 3505 (MS 1209)
Rear Axle
845B Models
AKCELA AXLEPOWER
Center compartment 40,0 10,5
SAE 80W-90 API GL5 Limited Slip
865B / 885B Models
AKCELA AXLEPOWER
Tandem and Brakes
AKCELA TRANSAXLE FLUID
Refill capacity (each) 60,0 15,8
SAE 20W-40
Circle Turn Gear Reducer
AKCELA GEAR 135HEP
Refill capacity 2,80 0,75
SAE 80W90 (1050135)
Grease Fittings
AKCELA MOLYGREASE (1070173)
Rear Ripper, Scarifier or Dozer Blade – –
CASE molydisulfide grease
Front Axle Wheel Hub and Bearings – –

1002-4
845B DHP / 865B VHP / 885B DHP Models Equipped with Tier 3 Engines
CAPACITY
Liters US Gal.
Fuel tank
Engine oil
Engine Tier 3 (845B DHP/ 865B VHP/ 885B DHP Models)
Hydraulic System
AKCELA HY-TRAN ULTRA
Hydrauic tank with filter 90,0 23,8
Transmission
845B DHP / 865B VHP Models with ZF transmission
Refill capacity (with filter change) 26,0 6,9
Refill capacity (without filter change) 25,0 6,6
845B DHP / 865B VHP Models with FUNK transmission
885B DHP Models with FUNK transmission
Rear Axle
845B DHP Models
AKCELA AXLEPOWER
865B VHP / 885B DHP Models
AKCELA AXLEPOWER
Tandem and Brakes
SAE 20W-40
AKCELA GEAR 135HEP
SAE 80W90 (1050135)
Grease Fittings

1002-5
865B AWD / 885B AWD Models Equipped with Tier 3 Engines

CAPACITY
Liters US Gal.
Fuel tank
Engine oil
Hydraulic System
Total capacity 200,0 47,5 AKCELA AW HYDRAULIC FLUID
Hydrauic tank with filter 90,0 23,8 68 HV (MS 1216)
Transmission
865B AWD Models
885B AWD Models
Rear Axle
AKCELA AXLEPOWER
Tandem and Brakes
SAE 20W-40
AKCELA GEAR 135HEP
SAE 80W90 (1050135)
Front Wheel Reducer
AKCELA AXLEPOWER
Grease Fittings

1002-6
Recomendações de Viscosidade do Óleo e Fluidos

Oil Viscosity and Temperature Ranges
Case No. 1 Engine Oil is recommended for use in your Case Engine. Case Engine Oil will lubricate your engine correctly under
all operating conditions.
If Case Multi-Viscosity Engine Oil is not available, use only oil meeting API engine oil service category CH-4 (preferred) or CG-
4.
See the chart on following page for recommended viscosity at ambient air temperature ranges.
NOTE: Do not put Performance Additives or other oil additive products in the engine crankcase. The oil change intervals given
in this manual are according to tests with CASE lubricants.
TEMPERATURE FAHRENHEIT
-40º -22º -4º 14º 32º 50º 68º 86º 104º 122º
SAE 20W-50 TROPIC
SAE 15W-40 ALL SEASONS

CASE AKCELA Nº 1 15W-40 ALL SEASONS
SAE 10W-30 WINTER

CASE AKCELA Nº 1 10W-30 WINTER
SAE 5W-30 ARCTIC
SAE 0W-30 ARCTIC
-40º -30º -20º -10º 0º 10º 20º 30º 40º 50º

TEMPERATURE CELSIUS
NOTE: Use of an engine oil pan heater or an engine coolant heater may be required when operating temperatures are in Winter or Artic conditions
Hydraulic / Brake / Transmission System – Temperature Ranges
TEMPERATURE FAHRENHEIT
-40º -22º -4º 14º 32º 50º 68º 86º 104º 122º
AKCELA AW HYDRAULIC FLUID 68 HV
CASE AKCELA Hy-Tran Ultra
CASE AKCELA Hy-Tran Ultra SSL
-40º -30º -20º -10º 0º 10º 20º 30º 40º 50º

TEMPERATURE CELSIUS

1002-7
FUEL
Diesel Fuel
Use No. 2 Diesel fuel in the engine of this machine. The use of other fuels can cause the loss of engine power and high fuel
consumption.
In very cold temperatures, a mixture of No. 1 and No. 2 Diesel fuels is temporarily permitted. See the following note.
NOTE: See your fuel dealer for winter fuel requirements in your area. If the temperature of the fuel lowers below the cloud point
(wax appearance point), wax crystals in the fuel will cause the engine to lose power or not to start.
The Diesel fuel used in this machine must meet the specifications in the chart below or Specification D975-81 of the American
Society for Testing and Materials.
Fuel Storage
If you keep fuel in storage for a period of time, you can get foreign material or water in the fuel storage tank. Many engine pro-
blems are caused by water in the fuel.
Keep the fuel storage tank outside and keep the fuel as cool as possible. Remove water from the storage container at regular
periods of time.
Fill the fuel tank at the end of the daily operating period to prevent condensation in the fuel tank.
Specifications for Acceptable No. 2 Diesel Fuel

API gravity, minimum . ................................................................................................................................................................ 34
Flash point, minimum ................................................................................................................................................ 60°C (140°F)
Cloud point (wax appearance point), maximum .................................................................................................... -20°C (-5°F) (*)
Pour point, maximum .......................................................................................................................................... -26°C (-15°F) (*)
Distillation temperature, 90% point . .................................................................................................. 282 to 338°C (540 to 640°F)
Viscosity, at 38° C (100° F)
Centistokes . .................................................................................................................................................................... 2,0 to 4,3
Saybolt Seconds Universal ............................................................................................................................................... 32 to 40
Cetane number, minimum ............................................................................................... 43 (45 to 55 for winter or high altitudes)
Water and sediment, by volume, maximum ....................................................................................................................... 0,05 %
* see note “Diesel Fuel” on this page.

1002-8
Lubrication & Maintenance Chart

845B / 865B / 885B Models Equipped with Tier 0, 1 and 2 Engines
CLEAN - DRAIN
LUBRICATE
SERVICE POINTS
REPLACE
ADJUST
POINTS
VERIFY
Air cleaner (Note 1) 1 *
Hydraulic filter (Note 2) 1 *
As needed
Cab Air Filter (if equipped) 1 *
Batteries (See Electrical System) 2 *
Engine oil level (including filters) 1 10
Radiator (coolant level) (Note 3) 1 10
10 hours or
daily Transmission oil level (warm, engine running)
1 10
(ZF and FUNK Transmission)
Differential Lock Oil Filter (if equipped) 1 10
Fuel Reservoir Filter (wash screen) 1 50
50 hours or
Fuel Water Separator (drain water) 2 50
weekly
Hydraulic tank (complete system) 1 50
Moldboard Lift Cylinder Pivots 4 100
Moldboard Lift Cylinders Balls 2 100
Moldboard Side Shift Cylinders Balls 2 100
100 hours Articulation of Tilt Cylinders 2 100
or each 15
days Moldboard Tilt Pivots 2 100
Articulation Cylinders Pivots 4 100
Articulation Bearings 2 100
Drawbar Ball and Socket 1 100
Alternator and Air Conditioner Belt 2 250
Universal Joints and Drive Shaft 2 250
Circle Turn Gearbox Oil Level 1 250
Front Axle Pivot 2 250
Front Wheel Lean Bar Pivots 2 250
Front Wheel Lean Cylinder Pivots 2 250
Front Wheel Knuckle Lean Pivots 4 250
250 hours
Knucle King Pin Bearings 4 250
or monthly
Moldboard Lift Cylinder Articulation Bearings 2 250
Tandem Swing Bearing 2 250
Tires Condition and Pressure 6 250
Cab Air Filter (if equipped) 1 250
Steering Bar Ball Joints 4 250
Moldboard Articulation Pivots 4 250
Moldboard Side Shift Pivots 2 250
Engine Oil and Oil Filter 2 250

1002-9
CLEAN - DRAIN
LUBRICATE
SERVICE POINTS
REPLACE
ADJUST
POINTS
VERIFY
Fuel Filters and Water Separator 2 500
Fuel Tank Drain Plug (drain sediment) 1 500
Hydraulic System Oil Filter 1 500
Transmission Oil and Oil Filter (Note 4)
1 500
(ZF Transmission – 845B / 865B models)
500 hours Transmission Oil and Oil Filter

2 500
or each 3 (FUNK Transmission – 885B models)
months Front Wheel Bearing Grease 2 500
Tandem Wheel Shafts Bearings (Graziano) 8 500
Tandem Case Oil Level 2 500
Rear Axle Differential and Planetary Gear Oil Level (Graziano) 1 500
ROPS Fixing Bolts Torque 16 500
Seat Belts Fixing Bolts Torque 2 500
Transmission Screen (FUNK Transmission – 885B models) 1 1000
Transmission Oil (Note 4) (ZF Transmission – 845B / 865B models) 1 1000
Transmission Oil (FUNK Transmission – 885B models) 1 1000
1000 hours Engine Valves Clearance 12 1000
or each 6
Circle Turn Gear Housing Oil 1 1000
months
Alternator and Ar Conditioning Belts 2 1000
Air Cleaner Elements (See Air Cleaner System) 2 1000
Tandem Case Oil 2 1000
Rear Axle Differential and Planetary Gear Oil (Graziano) 1 2000
2000 hours Hydraulic System Oil (Note 5) 1 2000
or yearly Engine Coolant 2 2000
Turbocharger Fixing Bolts Torque 4 2000
NOTE: See “FLUIDS AND LUBRICANTS” table on previous pages

for lubricants and fluids detailed specifications and capacities.
NOTE 1: Service the air filter elements if air filter restriction indicator (Non - Critical Warnings - YELLOW) show “air filter”.
NOTE 2: Service the hydraulic filters if hydraulic filter indicator lamp (Non - Critical Warnings - YELLOW) show “hydraulic filter”.
NOTE 3: Check the radiator coolant level if the coolant level warning lamp (Critical Warnings - RED) show “coolant level”.
NOTE 4: Change the transmission fluid and replace the filter after the first 100 hours of operation
NOTE 5: Change every 2.000 hours or once a year, whichever comes first.
*: As needed.

1002-10
845B DHP / 865B VHP / 885B DHP Models Equipped with Tier 3 Engines
CLEAN - DRAIN
LUBRICATE
SERVICE POINTS
REPLACE
ADJUST
POINTS
VERIFY
As needed
Radiator (coolant level) (Note 3) 1 10
10 hours or
daily Transmission oil level (warm, engine running)
1 10
(ZF and FUNK Transmission)
50 hours or
weekly
or each 15
250 hours Front Wheel Knuckle Lean Pivots 4 250
or monthly Knucle King Pin Bearings 4 250

1002-11
CLEAN - DRAIN
LUBRICATE
SERVICE POINTS
REPLACE
ADJUST
POINTS
VERIFY
Transmission Oil and Oil Filter (Note 4)
1 500
(ZF Transmission – 845B / 865B models)
500 hours Transmission Oil and Oil Filter
or each 3 1 500
(FUNK Transmission – 845B / 865B / 885B models)
months
Front Wheel Bearing Grease 2 500
Transmission Screen (FUNK Transmission – 845B / 865B / 885B models) 1 1000
Transmission Oil (Note 4) (ZF Transmission – 845B / 865B models) 1 1000
Transmission Oil (FUNK Transmission – 845B / 865B / 885B models) 1 1000
1000 hours Engine Valves Clearance 12 1000
or each 6
months Circle Turn Gear Housing Oil 1 1000
Alternator and Ar Conditioning Belts 2 1000
NOTE: See “FLUIDS AND LUBRICANTS” table on previous pages for lubricants and fluids detailed specifications and capacities.
NOTE 1: Service the air filter elements if air filter restriction indicator (Non-Critical Warnings – YELLOW) show “air filter”.
NOTE 2: Service the hydraulic filters if hydraulic filter indicator lamp (Non-Critical Warnings – YELLOW) show “hydraulic filter”.
NOTE 3: Check the radiator coolant level if the coolant level warning lamp (Critical Warnings – RED) show “coolant level”.
NOTE 5: Change every 2.000 hours or once a year, whichever comes first.
*: As needed.

1002-12
865B AWD / 885B AWD Models Equipped with Tier 3 Engines
CLEAN - DRAIN
LUBRICATE
SERVICE POINTS
REPLACE
ADJUST
POINTS
VERIFY
As needed
10 hours or Radiator (coolant level) (Note 3) 1 10
daily Transmission oil level (warm, engine running) 1 10
50 hours or
weekly
or each 15
250 hours Front Wheel Knuckle Lean Pivots 4 250
or monthly Knucle King Pin Bearings 4 250

1002-13
CLEAN - DRAIN
LUBRICATE
SERVICE POINTS
REPLACE
ADJUST
POINTS
VERIFY
Front Wheel Drive (AWD) Pump Filter (Note 6) 1 500
500 hours Transmission Oil and Oil Filter 1 500
or each 3
months Front Wheel Bearing Grease 2 500
Transmission Screen 1 1000
Transmission Oil 1 1000
Engine Valves Clearance 12 1000
1000 hours Circle Turn Gear Housing Oil 1 1000
or each 6
months Alternator and Ar Conditioning Belts 2 1000
Front Wheel Drive (AWD) Gear Housing Oil (Note 5) 2 1000
NOTE: See “FLUIDS AND LUBRICANTS” table on previous pages for lubricants and fluids detailed specifications and capacities.
NOTE 1: Service the air filter elements if air filter restriction indicator (Non-Critical Warnings – YELLOW) show “air filter”.
NOTE 2: Service the hydraulic filters if hydraulic filter indicator lamp (Non-Critical Warnings – YELLOW) show “hydraulic filter”.
NOTE 3: Check the radiator coolant level if the coolant level warning lamp (Critical Warnings – RED) show “coolant level”.
NOTE 5: Change every 2000 hours or once a year, whichever comes first.
NOTE 6: Change the front wheel drive gear housing oil after the first 100 hours of operation
NOTE 7: Change the front wheel drive pump hydraulic filter after the first 100 hours of operation.
*: As needed.

1002-14
NOTES

Section
1003
1003
METRIC CONVERSION CHART

1003-2
TABLE OF CONTENTS
CONVERSION FACTORS.............................................................................................................................................................3
Metric to U.S............................................................................................................................................................................3
U.S. to Metric...........................................................................................................................................................................4

1003-3
CONVERSION FACTORS
Metric to U.S.
MULTIPLY BY TO OBTAIN
sq. meter 10.76391 square foot

Area
hectare 2.47105 acre
newton 3.596942 ounce force

Force
newton 0.224809 pound force
millimeter 0.039370 inch

Length meter 3.280840 foot
kilometer 0.621371 mile
Mass kilogram 2.204622 pound
Mass / Area kilogram/hectare 0.000446 ton / acre
Mass / Energy gr/kW/hr. 0.001644 bs/hp/hr.

kg/cubic meter
Massa / Volume 1.685555 llb/cubic yd.
Power kilowatt 1.685555 horsepower
kilopascal 0.145038 lb/sq. inch

Pressure
bar 14.50385 lb/sq. inch
Temperature degree C 1.8 x ºC + 32 degree F
newton meter 8.850748 lb/inch

Torque
newton meter 0.737562 lb/foot
Velocity kilometer/hr. 0.621371 miles/hr.
cubic centimeter 0.061024 cubic inch

cubic meter 35.31466 cubic foot
cubic meter 1.307950 cubic yd.
milliliter 0.033814 ounce (US fluid)
Volume
litre 1.056814 quart (US liquid)
litre 0.879877 quart (Imperial)
litre 0.264172 gallon (US liquid)
litre 0.219969 gallon (Imperial)
litre/min. 0.264172 gallon/min. (US liquid)

Volume / Time
litre/min. 0.219969 gallon/min. (Imperial)

1003-4
U.S. to Metric
MULTIPLY BY TO OBTAIN
square foot 0.0092903 sq. meter

Area
acre 0.404686 hectare
ounce force 0.278014 newton

Force
pound force 4.448222 newton
inch 25.4 millimeter

Length foot 0.3048 meter
mile 1.609344 kilometer
pound 2.204622 kilogram

Mass
ounce 28.35 gram
Mass / Area ton / acre 2241.702 kilogram/hectare
Mass / Energy bs/hp/hr. 608.2774 gr/kW/hr.
Massa / Volume llb/cubic yd. 0.593276 kg/cubic meter
Power horsepower 0.745700 kilowatt
lbs/sq. in. 6.894757 kilopascal

Pressure lbs/sq. in. 0.069 bar
lbs/sq. in. 0.070303 kg/sq. cm
Temperature degree F 1.8 x °F - 32 degree C
pound/inch 0.112985 newton meter

Torque
pound/foot 1.355818 newton meter
Velocity miles/hr. 1.609344 kilometer/hr.
cubic inch 16.38706 cubic centimeter

cubic foot 0.028317 cubic meter
cubic yard 0.764555 cubic meter
ounce (US fluid) 29.57353 milliliter
Volume
quart (US liquid) 0.946353 litre
quart (Imperial) 1.136523 litre
gallon (US) 3.785412 litre
gallons (Imperial) 4.546092 litre
Volume / Time gallon/min. 3.785412 litre/min.

Seção
1005
SERVICE TOOLS
1005

1005-2
TABLE OF CONTENTS
Required Service Tools for Motor Graders.............................................................................................................3
Required Service Tools for Selected Equipment....................................................................................................5
LOCTITE PRODUCT CHART........................................................................................................................................................7

1005-3
Required Service Tools for Motor Graders

Transmission Seal and Tandem Axle Special Tools (380050007)
Kit 380050007 is required to properly service the transmis-
sion input shaft seal, lock up brake, and tandem axles of
Motor Grader 845B / 845B DHP models.
380050007 Kit Contents:
•• Axle Brake Test Tool 380000378 - Go/No Go gauge used to
check manual lock up brake disc wear, 885B / 885B DHP /
885B AWD models.
•• Axle Seal Tool 380000379 - Used with handle from
38000091 to assemble the axle seals on a manual lock
up axle, 885B / 885B DHP / 885B AWD models.
•• Axle Seal Tool 380000380 - Used with handle from
38000091 to assemble the axle seals on a manual lock
up axle, 885B / 885B DHP / 885B AWD models.
•• Transmission Input Seal Installer 380000387 - Used to
install the transmission input shaft seals, 845B / 845B
DHP / 865B / 865B VHP / 865B AWD models.
•• Transmission Oil Seal Guide 380000388 - Used to ins-
tall the transmission oil seals, 885B / 885B DHP / 885B
AWD models.
•• Transmission Seal Installer 380000391 - Used to install
the transmission seals, 845B / 845B DHP / 865B / 865B
VHP / 865B AWD models.
•• Tandem Wheel Hub Removal Tool 380000394 - Used to
remove tandem wheel hubs, 845B / 845B DHP / 865B /
865B VHP / 865B AWD models.
•• Seal Installation Tool 380000397 - Used to install trans-
mission seals, 845B / 845B DHP / 865B / 865B VHP /
865B AWD models.
Application: Motor Grader All Models
Ordering Information: 380050007 Transmission Seal and
Tandem Axle Tools Kit
Dealer Standard:Code A (required at all servicing loca-
tions)

1005-4
Transmission Tools (380050009)

•• Lifting Device 380000374 - Used to lift the transmis-
sion clutch stage assemblies during repair procedures,
Models G140VP- G170VP.
•• Stack Nest 380000375 - Used to position the transmis-
sion clutch stage assemblies while removed from the
transmission housing, Models G140VP- G170VP.
•• Lifting Device 380000376 - Used to lift the transmis-
sion clutch stage assemblies during repair procedures,
885B / 885B DHP / 885B AWD models.
•• Stack Nest 380000377 - Used to position the transmis-
sion clutch stage assemblies while removed from the
transmission housing, 885B / 885B DHP / 885B AWD
models.
•• Plug Installer 380000381 - Used to install plugs in
transmission shafts, Models G140VP- G170VP.
•• Assembly Tools 380000382 - Used to handle indivi-
dual clutch stage assemblies and in clutch assembly,
Models G140VP-G170VP- G200
•• Installation Tools 380000385 - Used to install trans-
mission oil seals and retaining rings, 885B / 885B DHP
/ 885B AWD models.
•• Sizing Sleeve 380000386 - Used to size sealing ring
on 1st stage assembly, 885B / 885B DHP / 885B AWD
models.
•• Input Seal Installer 380000389 - Used to protect input
shaft seal0 during installation, 885B / 885B DHP / 885B
AWD models.
•• Bearing Installer 380000390 - Used to properly install
and position roller h stage bearing on end of 4t assem-
bly, Models G140VP - G170VP.
•• Assembly Tools 380000392 - Used to assemble
and align the idler shaft in the input housing, Models
G140VP- G170VP - G200.
•• Bearing Driver 380000393 - Used to properly install
and position bearings, Models G140VP and G170VP.
•• Clutch Stack Clearance Gauge Set 380000395 - Used
to measure clutch plate clearance, Models G140VP-
G170VP - G200.
•• Aligning Sleeve 380000396 - Used to maintain align-
ment of the input shaft during input housing installation,
Models G140VP - G170VP.
Application: Motor Grader All models.
Ordering Information: 380050009 Transmission Tools Kit
Dealer Standard:Code A (required at all servicing loca-
tions)

1005-5
Required Service Tools for Selected Equipment

Option 1 – Pressure Test Adapter Kit (380040085)
Kit 380040085 is required to properly pressure test the
hydraulic circuits of selected. Equipment. The kit contains
SAE and metric adapter fittings.
•• 380000510 - Internal M16 x 2 adapter with 90° elbow
and external PD style quick coupler.
•• 380000511 - Internal M16 x 2 adapter with external PD
style quick coupler. Used for pilot pressure, blade up
pressure, blade down pressure, turn table right, turn
table left and articulation tests on motor grader 845B /
845B DHP models.
•• 380000513 - Internal 7/16-20 JIC adapter with external
PD style quick coupler. Used for lube pressure tests on
crawler models 1650K and 1850K on 1st speed clutch,
2nd speed clutch, 3rd speed clutch, forward clutch, and
reverse clutch.
•• 380000514 - Internal 9/16-18 JIC adapter with external
PD style quick coupler.
•• 380000515 - Tee Fitting, Internal 7/16-20 JIC with ex-
ternal PD style quick coupler.
•• 380000516 - Internal 1/8 NPTF adapter with external
PD style quick coupler.
•• CAS1884-2 - External M14 x 1.5 O-ring boss adapter
with 90° elbow and external PD style quick coupler.
•• CAS2336 - Tee Fitting, Internal 1/4 BSPP x external 1/4
BSPP adapter with external PD style quick coupler.
Application: Motor Grader 845B / 845B DHP models.
Ordering Info: 38040085 Pressure Test Fitting Kit and
Hose Assembly.
Dealer Standard: Code A (required at all servicing loca-
tions).
Pressure Test Adapter Hoses (380000512)

1005-6
Option 2 – Digital Pressure Analyzer Kit (380040112)

•• Displays readings in PSI and bar for checking Europe-
an specifications.
•• 10,000 PSI capacity allows testing of hydrostatic drive
systems and other high pressure hydraulic systems.
•• No need to have fuel or transmission hoses inside the
vehicle during road testing.
•• No makeshift taping of gauges to the windshield.
•• Pinpoints worn power steering pumps or racks.
•• "Min/Max" pinpoints fuel restrictions, plugged filters,
weak fuel pumps, and transmission pressure spikes.
Kit 380040112 Digital Pressure and Temperature Analyzer
•• "Delta Zero" monitors fuel pressure drops caused by
kit. Purchasing this kit allows the technician to easily read
faulty check valves.
and analyze pressure information up to 10,000 PSI during
diagnostic procedures, eliminating the need for analog •• 20 foot pick up cable.
gauges.
The 380040112 Digital Pressure and Temperature.
This kit also includes the following fittings from kit
Analyzer offers the following: 380040085:
Application: Equipment •• 380000510
Ordering Info: 380040112 Digital Pressure Tester and Fit- •• 380000511
ting Kit
•• 380000513
•• 380000514
•• 380000515
•• 380000516
•• CAS1884-2
•• CAS2336

1005-7
LOCTITE PRODUCT CHART

Working Fixture /
Similar Gap Strength Temperature Full Cure
Product Color Primer Description
Products (Inches) (Steel/Steel) Range- (Steel / Steel)
Farenheit Time
Dark Form a Gasket (works with oil, fuel or
#3 24 hr N/A
Brown grease) Pliable
80 Yellow Fast N/A Weatherstrip Adhesive
123 Clear N/A N/A Parts Cleaner Fluid
220 Blue 290 0.003 57/143 in lbs -65 to +250 6 min/24 hrs 747 Wicking Threadlocker
221 Purple 222 0.005 75/44 in lbs -65 to +300 2 min/24 hrs 747 Low Strength Threadlocker
Low Strength Threadlocker (Small
222 Purple 0.005 53/30 in lbs -65 to +300 20 min/24 hrs 764
Screws)
225 Brown 222 0.010 45/25 in lbs -65 to +300 7 min/24 hrs 747 Low Strength Threadlocker
242 Blue 0.005 80/50 in lbs -65 to +300 10 min/24 hrs 764 Medium Strength Threadlocker
262 Red 271 0.005 160/190 in lbs -65 to +300 5 min/24 hrs 747 High Strength Threadlocker
270 Green 271 0.007 160/320 in lbs -65 to +300 3 min/24 hrs 747 High Strength Threadlocker
271 Red 262 0.007 160/320 in lbs -65 to +300 10 min/24 hrs 764 High Strength Threadlocker
272 Red 620 0.007 180/220 in lbs -65 to +450 30 min/24 hrs 764 High Temperature, High Strength
275 Green 277 0.010 210/300 in lbs -65 to +300 3 min/24 hrs 747 High Strength Threadlocker
277 Red 0.010 225/300 in lbs -65 to +300 60 min/24 hrs 764 High Strength Threadlocker
290 Green 0.003 85/350 in lbs -65 to +300 6 min/24 hrs 764 Wicking Threadlocker
*404 Clear 495 0.006 3200 psi -65 to +180 30 sec/24 hrs N/A Instant Adhesive
*406 Clear 0.004 3200 psi -65 to +180 15 sec/24 hrs N/A Surface Insensitive Adhesive
*409 Clear 454 0.008 2500 psi -65 to +180 50 sec/24 hrs N/A Gel Instant Adhesive
*414 Clear 0.006 2500 psi -65 to +180 30 sec/24 hr N/A Instant Adhesive
*415 Clear 454 0.010 2500 psi -65 to +180 50 sec/24 hrs N/A Gap Filling Instant Adhesive (Metals)
*416 Clear 454 0.010 2500 psi -65 to +180 50 sec/24 hrs N/A Gap Filling Instant Adhesive (Plastics)
*420 Clear 0.002 2500 psi -65 to +180 15 sec/24 hrs N/A Wicking Instant Adhesive
*422 Clear 454 0.020 2800 psi -65 to +180 60 sec/24 hrs N/A Gap Filling Instant Adhesive
*430 Clear 0.005 2500 psi -65 to +180 20 sec/24 hrs N/A Metal Bonding Adhesive
White /
*445 0.250 2000 psi -65 to +180 5 min/24 hrs N/A Fast Setting 2 Part Epoxy
Black
Surface Insensitive Gen / Instant
*454 Clear 0.010 3200 psi -65 to +180 15 sec/24 hrs N/A
Adhesive
*495 Clear 0.004 2500 psi -65 to +180 20 sec/24 hrs N/A General Purpose Instant Adhesive
*496 Clear 0.005 2500 psi -65 to +180 20 sec/24 hrs N/A Metal Bonding Adhesive
Brt
504 515 0.030 750 psi -65 to +300 90 min/24 hrs None Rigid Gasket Eliminator
Orange
Light
509 0.020 750 psi -65 to +320 6 hr/72 hrs 764 Flange Sealant
Blue
510 Red 0.020 1000 psi -65 to +400 30 min/24 hrs 764 High Temperature, GAsket Eliminator
515 Purple 0.010 750 psi -65 to +300 1 hr/24 hrs 764 Gasket Eliminator 515
Gasket Eliminator 518 for
518 Red 515 0.030 500 psi -65 to +300 1hr/24 hrs 764
Aluminum
542 Brown 569 N/A 132/92 in lbs -65 to +300 2hr/24 hrs 747 Hydraulic Sealant
Low Strength Pneumatic/Hydraulic
545 Purple N/A 25/20 in lbs -65 to +300 4hr/24 hrs 747
Sealant
549 Orange 504 0.020 2500 psi -65 to +300 2hr/24 hrs 747 Instant Seal Plastic Gasket
* Products 404-496 (except for #445) are all instant adhesives (super glues) they differ mostly in viscosity

1005-8
Working Fixture /
Similar Gap Strength Temperature Full Cure
Product Color Primer Description
Products (Inches) (Steel/Steel) Range- (Steel / Steel)
Farenheit Time
240/240 in 2 to 4 hrs/24
554 Red 277 0.015 -65 to +300 764 Refrigerant Sealant
lbs hrs
567 White 592 N/A 500 psi -65 to +300 4hr/24 hrs 764 Pipe Sealant for Stainless Steel
568 Orange 277 0.015 2500 psi -65 to +300 12 hrs/24 hrs 764 Plastic Gasket
569 Brown 545 0.010 40/25 in lbs -65 to +300 1 hr/24 hrs 764 Hydraulic Sealant
570 Brown 592 N/A 25/40 in lbs -65 to +300 6 hr/24 hrs 764 Steam Sealant
2 to 4 hrs/24
571 Brown 592 0.015 40/20 in lbs -65 to +300 764 Pipe Sealant
hrs
572 White 578.575 N/A 80/27 in lbs -65 to +300 24 hrs/72 hrs None Gasketing
592 White 0.020 500 psi -65 to +400 4 hrs/72 hrs 736 Pipe Sealant with Teflon
30 min/24
593 Black 0.250 400 psi -65 to +400 N/A RTV Silicone
hrs
10 min/24
601 Green 609 0.005 3000 psi -65 to +300 764 Current PIN #609
hrs
10 min/24 General Purpose Retaining
609 Green 0.005 3000 psi -65 to +300 764
hrs Compound
30 min/24 High Temperature Retaining
620 Green 640 0.015 3000 psi -65 to +450 747
hrs Compound
High Strength Retaining
635 Green 680 0.010 4000 psi -65 to +300 1 hr/24 hrs 747
Compound
10 min/24 High Strength Retaining
638 Green 680 0.015 4100 psi -65 to +300 747
hrs Compound
High Temperature Retaining
640 Green 620 0.007 3000 psi -65 to +400 1 hr/24 hrs 747
Compound
20 min/24
660 Silver 0.020 3000 psi -65 to +300 764 Quick Metal
hrs
20 min/24 General Purpose Retaining
675 Green 609 0.005 3000 psi -65 to +300 747
hrs Compound
10 min/24 High Strength Retaining
680 Green 635 0.015 4000 psi -65 to +300 747
hrs Compound
706 Clear 755 N/A N/A N/A N/A N/A Cleaning Solvent
707 Amber N/A N/A N/A N/A N/A Activaltor for Structural Adhesives
736 Amber N/A N/A N/A N/A N/A Primer NF
738 Amber N/A N/A N/A N/A N/A Depend Activator
747 Yellow N/A N/A N/A N/A N/A N/A Primer T
751 Clear N/A N/A N/A N/A N/A Activator for Structural Adhesives
755 Clear N/A N/A N/A N/A N/A Cleaning Solvent
764 Green N/A N/A N/A N/A N/A Primer N
767 Silver N/A N/A -65 to +1600 N/A N/A Anti-Seize Lubricant

SECTION INDEX
Engine
Engine – Tier 3 ....................................................................................................................................................................... 2002
Charge Air Cooler System . .................................................................................................................................................... 2003

Section
2002
2002
ENGINE – TIER 3
845B DHP / 865B VHP / 885B DHP /
865B AWD / 885B AWD
Models

2002-2
TABLE OF CONTENTS
ENGINE DIAGNOSTIC TOOL........................................................................................................................................................6
FAILS DIAGNOSTICS....................................................................................................................................................................7
Engine Fails to Start................................................................................................................................................................7
Engine Overheating.................................................................................................................................................................8
Engine Lacks Power and Operates Irregularly........................................................................................................................9
Engine Smokes Black or Dark Grey......................................................................................................................................10
Engine Smokes (Tending to White).......................................................................................................................................10
Engine Smokes Light Blue....................................................................................................................................................10
Engine Knocks Abnormally....................................................................................................................................................11
The Engine Dies....................................................................................................................................................................12
Excessive or Insufficient Oil Pressure...................................................................................................................................12
Excessive Fuel Consumption................................................................................................................................................12
ENGINE........................................................................................................................................................................................13
Identification Code.................................................................................................................................................................14
Properties..............................................................................................................................................................................14
General Specifications......................................................................................................................................................15
CRANKSHAFT MECHANISM COMPONENTS AND CYLINDERS SET.....................................................................................17
VALVE MECHANISM – CYLINDER SET.....................................................................................................................................20
SPECIAL TOOLS.........................................................................................................................................................................22
TIGHTENNING TORQUES..........................................................................................................................................................23
667TA ENGINES..........................................................................................................................................................................25
DESCRIPTION OF ENGINE MAIN COMPONENTS...................................................................................................................26
Engine Block..........................................................................................................................................................................26
Crankshaft.............................................................................................................................................................................27
Connecting Rod.....................................................................................................................................................................28
Piston.....................................................................................................................................................................................29
Camshaft...............................................................................................................................................................................30
Exhaust Gas Recirculation - EGR.........................................................................................................................................30
Valve Control.........................................................................................................................................................................31
Cylinder Head of Engines – 667TA/EBF – 667TA/EBD – 667TA/EED..................................................................................32
Cylinder Head of Engines – 667TA/EEG – 667TA/EEC........................................................................................................33
Cylinder Head of Engines – 667TA/EDJ................................................................................................................................34
Valves and Valves Seats.......................................................................................................................................................35
Valves Bridge.........................................................................................................................................................................35
Cylinder Head Machining......................................................................................................................................................36
Engine Flywheel....................................................................................................................................................................36
AUXILIARY DEVICES DRIVING..................................................................................................................................................37
ENGINE LUBRICATION...............................................................................................................................................................38
Oil Coller................................................................................................................................................................................39
Oil Pressure Control Valve.....................................................................................................................................................39
Deviation Valve......................................................................................................................................................................39
Oil Pump................................................................................................................................................................................40
Oil Sump of Engines – 667TA/EEG – 667TA/EEC – 667TA/EBF – 667TA/EED – 667TA/EDJ.............................................41
Oil Sump of Engines – 667TA/EED – 667TA/EBD................................................................................................................41
Blow-By.................................................................................................................................................................................42
ENGINE COOLER.......................................................................................................................................................................43
Water Pump...........................................................................................................................................................................44
COMMON RAIL – HIGH PRESSURE ELECTRONIC INJECTION SYSTEM..............................................................................45

2002-3
EDC7UC31 – ELECTRONIC CONTROL UNIT OPERATION......................................................................................................46

Engine Pre-Post Heater Control............................................................................................................................................46
Phase Recognition................................................................................................................................................................46
Injection Control.....................................................................................................................................................................46
Closed Mesh Injection Pressure Control System..................................................................................................................46
Main Control and Main Injection Advance Control.................................................................................................................46
Idle Control............................................................................................................................................................................46
Overheating Protection..........................................................................................................................................................46
Engine Maximum Rotation Limit............................................................................................................................................46
Cut-Off...................................................................................................................................................................................46
Smoke Control Under Acceleration.......................................................................................................................................46
After Engine Cut-Off..............................................................................................................................................................46
Work Rotation Control in Normal Operation Conditions........................................................................................................46
Recovery Strategy.................................................................................................................................................................47
FUEL SUPPLY SISTEM...............................................................................................................................................................48
Fuel Supply System Diagram................................................................................................................................................49
Fuel Filter...............................................................................................................................................................................50
Mechanical Supply Pump – Normal Operation Condition.....................................................................................................51
Mechanical Supply Pump – Unit Exit Overpressure Condition..............................................................................................51
Bleeding Condition of the Fuel System.................................................................................................................................52
High Pressure Pump CP3.3 TYPE........................................................................................................................................53
High Pressure Pump Exploded View.....................................................................................................................................54
High Pressure Pump Internal View........................................................................................................................................55
Operation...............................................................................................................................................................................56
Operation Theory...................................................................................................................................................................58
Common Rail............................................................................................................................................................................59
Common Rail Pressure Relief Valve......................................................................................................................................60
ELECTROINJECTOR...................................................................................................................................................................61
Injector in Rest Position.........................................................................................................................................................61
Injection Starts.......................................................................................................................................................................61
Injection End..........................................................................................................................................................................61
Injector Nozzler......................................................................................................................................................................62
Fuel Return Pressure Limiter.................................................................................................................................................62
LOCATION OF MAIN ELECTRICAL COMPONENTS..................................................................................................................63
EDC7UC31 – Electronic Control Unit....................................................................................................................................64
Engine Pin-Out......................................................................................................................................................................65
Injectors Connector A Pin-Out Diagram.................................................................................................................................66
Injectors Connector C Pin-Out Diagram................................................................................................................................66
Cranckshaft Sensor...............................................................................................................................................................67
Camshaft Sensor...................................................................................................................................................................67
Pressure and Temperature Sensor........................................................................................................................................68
Engine Oil Pressure and Temperature Sensor......................................................................................................................68
Common Rail – Fuel Pressure Sensor..................................................................................................................................69
Electroinjector........................................................................................................................................................................70
Intake Air Resistance Heater and Rele..................................................................................................................................71
Fuel Temperature Sensor......................................................................................................................................................72
Filter Heater Rele..................................................................................................................................................................72
High Pressure Pump – Pressure Regulator..........................................................................................................................73

2002-4
FUEL SYSTEM CHECK...............................................................................................................................................................74

High Pressure Supply Test....................................................................................................................................................74
Low Pressure Pump..............................................................................................................................................................75
Common Rail Pressure Relief Valve Test..............................................................................................................................76
Fuel Counter-Flow Test from the Return................................................................................................................................77
ENGINE OVERHAULING IN BENCH..........................................................................................................................................79
Engine Disassembly..............................................................................................................................................................79
ENGINE BLOCK CHECKS AND SPECIFICATIONS...................................................................................................................91
Checks And Measurement....................................................................................................................................................91
Camshaft Lobe And Journal Surface Check..........................................................................................................................91
Bearigns................................................................................................................................................................................92
Checking The Contact Surface Between Cylinder Head And Cylinder Block........................................................................93
Camshaft Syncronism...........................................................................................................................................................93
Lobe Bearing Replacement...................................................................................................................................................94
Tappets..................................................................................................................................................................................94
Camshaft Tappets Installation................................................................................................................................................95
CRANCKSHAFT...........................................................................................................................................................................97
Cranckshaft Journal Measurement........................................................................................................................................97
Cranckshaft Journals Marking Data......................................................................................................................................97
Cranckshaft Main Tolerances................................................................................................................................................98
Oil Pump Gears Replacement...............................................................................................................................................99
Main Bearings Installation.....................................................................................................................................................99
Journals Assembly Clearance Measurement......................................................................................................................100
Cranckshaft Recess Clearance Measurement....................................................................................................................101
Connecting Rod – Piston Set..............................................................................................................................................101
Piston, Pin and Piston Ring Data........................................................................................................................................102
Piston Pin Diameter Measurement......................................................................................................................................103
Piston Pin............................................................................................................................................................................103
Pin-Piston Correct Mating Condition...................................................................................................................................103
Piston Rings........................................................................................................................................................................104
Connecting Rod...................................................................................................................................................................105
Bearings..............................................................................................................................................................................106
Connecting Rod Check........................................................................................................................................................106
Torsion Check......................................................................................................................................................................107
Flexibility Check...................................................................................................................................................................107
Connecting Rod – Piston Set Coupling Installation.............................................................................................................108
Piston Rings Installation......................................................................................................................................................109
Connecting Rods-Piston Sets – Installation in Cylinder Block.............................................................................................109
Journal Clearance Measurement in Cranckshaft Set..........................................................................................................110
Piston Outgrowth Check......................................................................................................................................................112
Timing Gear Housing...........................................................................................................................................................112
Valve Syncronism................................................................................................................................................................113
Engine Flywell Housing.......................................................................................................................................................114
ENGINE FLYWHEEL..................................................................................................................................................................115
Replacement of the Engine Flywheel Annular Gear............................................................................................................115
CYLINDER HEAD......................................................................................................................................................................121
Valve Remotion....................................................................................................................................................................121
Cylinder Head Water Sealing Check...................................................................................................................................122
Cylinder Head Contact Surface Sealing..............................................................................................................................122

2002-5
VALVES......................................................................................................................................................................................123
Cleaning, Checking and Valve Rectification........................................................................................................................123
Assembling Clearance Checking and Valve Centralization.................................................................................................123
VALVE GUIDES..........................................................................................................................................................................124
VALVE SEATS............................................................................................................................................................................125
Cylinder Head Valve Seat Main Data..................................................................................................................................125
Cylinder Head Valve Seat Main Data..................................................................................................................................126
VALVE SPRINGS.......................................................................................................................................................................127
Main Data Check of Intake and Exhaust Valve Springs......................................................................................................127
CYLINDER HEAD......................................................................................................................................................................128
Cylinder Head Installation....................................................................................................................................................129
Injectors Installation.............................................................................................................................................................130
Pushrods and Tappets.........................................................................................................................................................131
Rocker Set...........................................................................................................................................................................132
Locating the Top Dead Center (TDC)..................................................................................................................................133
Valve Clearance Adjust........................................................................................................................................................134
Wiring Harness Connection to Engine.................................................................................................................................139
STARTER...................................................................................................................................................................................141
Quick Diagnosys..................................................................................................................................................................141
Starter Bosch 24 Volts – 4KW.............................................................................................................................................142
Starter Iskra 24 Volts – 4KW...............................................................................................................................................143
Starter Denso 24 Volts – 7,8KW..........................................................................................................................................143
ALTERNATOR............................................................................................................................................................................144
Quick Diagnosys..................................................................................................................................................................144
Bosch: NCBI 28 Volt 35-70 AMP.........................................................................................................................................145
Starter Remotion.................................................................................................................................................................146
Starter Installation................................................................................................................................................................147
Alternator Remotion.............................................................................................................................................................148
Alternator Installation...........................................................................................................................................................150
Belt Installation....................................................................................................................................................................152

2002-6
ENGINE DIAGNOSTIC TOOL
The EST - Electronic Service Tool allows diagnostic services in the engine by electronical parts check-up (ECUs,
sensors, etc), flows, pressure and temperatures. The system is also capable to make fails codes reading and assist
the engine fails diagnostic modes.

2002-7
FAILS DIAGNOSTICS
Engine Fails to Start
Perform inspections described in the electrical
Battery discharged No
workshop manual
Yes
Clean, check, tighten terminal nuts or replace

Battery terminal connections inefficient No
them.
Yes
Perform inspections described in the electrical

Starter motor efficient No
workshop manual
Yes
Cold starter efficient No Verify using a multimeter, replace or repair
Yes
Fuel filter blocked No Replace
No
Fuel supply circuit or injection pump show

Yes Check and repair the air leaking
signs of air leakages
No
Check and clean supply system, including

The fuel system shows water traces Yes
tank.
No
Verify using the EST-Eletronic Service Tool

High pressure pump work properly No
and repair or replace if necessary
Yes
Verify using the EST-Eletronic Service Tool.

Injectors works properly No
Verify seal ring.Replace the injectors if
defective.
Yes
Verify compression of each cylinder, overhaul

Compression in each cylinders is as precribed. No
the engine or repair each defective part
(valves, piston rings, etc.)

2002-8
Engine Overheating
Coolant level correct No Check for possible leakages and top-up level.
Yes
Fan works properly No Replace
Yes
Check if fan drive belt works properly No Replace
Yes
Water pump works properly No Overhaul or replace group
Yes
Thermostat efficient No Replace
Yes
Oil in coolant Yes Replace iol cooler
No
Air cleaner and circuit pipes efficient Yes Clear or replace items involved
No
Coolant passages in cylinder head efficient Yes Clear entirely
No
Valves clearance is efficient No Check and adjust the valves clearance
Yes
Cylinder head gasket efficient Yes Replace

2002-9
Engine Lacks Power and Operates Irregularly

Air filter blocked No Clean or replace filter
Yes
Fuel filter blocked No Replace
Yes
Fuel system efficient No Check and repair if necessary
Yes
Yes Disconnect pipes, injection pump and clean

Fuel system shows dirty and/or traces of water
accurately and, if required, clean and dry the
fuel tank.
No
Thermostat efficient No Replace
Yes
High pressure pump works properly No Check using EST- Eletronic Service Tool
Yes
Injectors works properly No Check using EST- Eletronic Service Tool

Yes
Fuel high pressure side leakage Yes Check the o’rings and gaskets leakages
No
Turbocharger works properly No Repair or replace the unit
Yes
Valves clearance is correct No Adjust the valves clearance
Yes
Compression ratio cylindres efficient No Check the compression ratio in each cylinder
overhaul engine or repair the defective parts
( valves, pistons rings, etc. )

2002-10
Engine Smokes Black or Dark Grey

Air filter blocked No Clean or replace filter as required
Yes
Check using EST- Eletronic Service Tool

Fuel electronic system efficient No
and repair or replace as required
Yes
Diesel fuel new and clean in tank No Clean tank and replace fuel filter
Yes
No Check the compression ratio in each cylinder

Compression ration in all cylinders efficient
overhaul engine or repair the defective parts
( valves, pistons rings, etc. )
Engine Smokes (Tending to White)

Injectors efficient No Check using EST-Electronic Service Tool
and repair or replace as required
Yes
Possible passage of coolant into engine

Coolant level is correct No
cylinder; replace cylinder head gasket or
overhaul engine.
Yes
Cold start efficient No Check using a multimeter, replace or repair.
Yes
Diesel fuel new and clean in tank No Clean tank and replace fuel filter
Engine Smokes Light Blue

Excessive consuption of oil Yes Check: oil fume breather;
cylinders compression. Leakages in or out
turbocharger. Leakage in valve guides. If
No required, overhaul cylinder head or engine.
Oil contaminated with fuel (diesel) Yes Check high pressure fuel pump o’ring,
injectors o’ring or cylinder head porosity

2002-11
Engine Knocks Abnormally

Knocking found in the chankshaft Yes Check tolerances and out-of-round of
crankshaft main journals, tightening of main
No journal cap screws and flywheel; oil pressure.
Replace parts or overhaul the engine.
Knocking found in the connecting rods Yes Check tolerances and out-of-round of
crankshaft connecting rod journals, tightening
of connecting rod journal cap screws, square
No of connecting rods. Replace parts or overhaul
the engine.
Knocking found in the pistons Yes Check tolerances between cylinder sleeves
and pistons; integrity of piston rings; clearance
No between piston and pin. Replace parts or
overhaul the engine.
Knocking found in the cylinder head Yes Check valve clearance; injection pump timing;
timing. Adjustment.
No
Yes Check and replace gears as required and

Knocking in timing that there are no broken springs, there is
no excessive clearance between stems and
No guides, tappets and guides; adjust valve
clearance.
Knocking in injectors Yes Check using EST-Electronic Service Tool and

repair or replace as required
No
Knocking found in the engine flywheel Yes Replace loosen screws and replace all screws
at the prescribed torque + angle.

2002-12
The Engine Dies

Fuel tank filled No Refuel and bleed as required
Yes
Fuel filters blocked Yes Replace
No
No Check the circuit and adjust or repair as

Fuel system works properly
required
Yes
Correct valve clearance No Adjust valve clearance
Excessive or Insufficient Oil Pressure

Oil pressure control valve operates regularly No Check and replace as required
Yes
No Replace engine oil with another one of correct

Engine oil SAE viscosity is as prescribed
viscosity
Yes
Oil pump delivering correct pressure No Check and replace as required
Yes
Cranckshaft and connecting rods bearing No Replace bearings and grind crankshaft as
efficient required
Excessive Fuel Consumption

Yes Eliminate leakages as required and replace
Fuel tank and pipes efficient
deteriorated items.
No
Intake air heater leakage Yes Replace
No
No Check using EST-Electronic Service Tool and

The electronic fuel system works properly
repair or replace as required

2002-13
ENGINE

2002-14
Identification Code
Detailed description of engine model
6 6 7 T A E D J
Engine Calibration ( Power)
(D) J=97 kW (130 H.P.)
(E) G=137 kW (183.7 H.P.)
(E) D=145 kW (194.4 H.P.)
(E) C=148 kW (198.5 H.P.)
(B) F=157 kW (210.5 H.P.)
(B) D=169 kW (226.6 H.P.)
Compression ratio
B= 16.5:1> 130 kW (174 H.P.)
D= 17.5:1< 130 kW (174 H.P.)
E= 17.5:1> 130 kW (174 H.P.)
E= Electronic injection ( Common Rail)
A= With intake air cooler
T= Turbocharged
67= Total displacement 6.7 liters (409 in3)
6= Number of cylinders
Properties
A 667TA 667TA 667TA 667TA 667TA 667TA
B EEG EEC EBF EED EBD EDJ
C 6 cylinders
D 6728 cm3 (410.6 c.i.)
E 137 kW 148 kW 157 kW 145 kW 169 kW 97 kW
( 183.7 h.p.) ( 198.5 h.p.) ( 210.5 h.p.) ( 194.4 h.p.) ( 226.6h.p.) ( 130.1 h.p.)
2100 rpm 2100 rpm 2000 rpm 2000 rpm 2000 rpm 2200 rpm
F Direct Electronic injection
G “Common Rail”
H T.A.A - (Turbocharged with intake air cooler)
A. Engine type
B. Engine Model
C. Number of cylinders
D. Total displacement
E. Maximun power available
F. Injection type
G. Intake air system

2002-15
General Specifications
REF. 667TA
ENGINE TYPE
NO. EEG EEC EBF EED EBD EDJ
Cycle Diesel - 4 strokes
1 Air T.A.A - (Turbocharged with intake air cooler)
Injection Direct
2 Number of cylinders 6 in-line
3 Bore 104 mm (4.1 in.)
4 Stroke 132 mm (5.2 in.)
5 Total displacement 6728 cm3 (410.6 cu.in)
6 Compression ratio
137 kW 148 kW 157kW 145 kW 169 kW 97 kW
7 Maximun power
184 hp 198 hp 211 hp 194 hp 227 hp 130 hp
710 Nm 810 Nm 952 Nm 860 Nm 1002 Nm 607 Nm
8 Maximun torque
524 lb.-ft. 597 lb.-ft. 702 lb.-ft. 634 lb.-ft. 739 lb.-ft. 607 lb.-ft.
9 Engine speed at low idle (no load) 700 rpm
10 Engine max speed (no load)
11 Turbocharger type with intake air cooler HOLSET HX35

2002-16
REF. 667TA
ENGINE TYPE
Lubrication Forced by gear pump, pressure relief valve, oil filter
Oil pressure, engine warm, at low
1.2 bar (17.4 psi)
12 idle
Oil pressure, engine warm, at
3.8 bar (55.1 psi)
maximun speed
Cooling Liquid
Water pump drive Belt driven
13 83 a 98º
Thermostat starts opening 79 a 83º C (174 a 181º F) C (181 a
208º F)
No information No information
Oil capacity first filling
available available
No information No information
14 Oil capacity - engine oil sump
available available
Oil capacity- engine oil sump +
17 litres (18 qt.) 19 litres (20 qt.)
filter
15 Bosh high pressure supply pump High pressure Common rail system
16 Pump setting No information available
17 Delivery start No information available
18 Injection type CRIN 1 CRIN 2 CRIN 2
19 Firing order 1 -5 -3 -6 -2 -4
250-1600 250-1400 250-1600
-- --
bar bar bar
20 Injection pressure
3626- 3626- 3626-
-- --
23206 psi 20305 psi 23206 psi

2002-17
CRANKSHAFT MECHANISM COMPONENTS AND CYLINDERS SET
REF. 667TA
ENGINE TYPE
1 Cylinder block diameter 104.000 a 104.024 mm (4.0945 a 4.0954 in.)
Pistons Provided as spare part
Measure dimension X= 49.5 mm (1.948813 in.)
2
External diameter ø1= 103.759 a 103.777 mm (4.0850 to 4.0857 in)
Pin housing ø2= 38.010 a 38.016 mm (1.4965 to 1.4967 in)
3 Piston - cylinder liner 0.235 a 0.273 mm (0.0093 to 0.0107 in)
4 Piston diameter ø = 0.4 mm (0.0157 in)
5 Block outgrouth of piston No information available
6 Piston pin ø3= 37.994 a 38.000 mm (1.4958 to 1.4961 in)
7 Piston pin - Piston housing 0.01 a 0.022 mm (0.0004 to 0.0009 in)
X1= 2.705 a 2.735 mm (0.1065 to 0.1077 in)
Piston ring grooves (measured in
X2= 2.420 a 2.440 mm (0.0953 to 0.0961 in)
101 mm (3.976366 in) diameter)
X3= 4.03 a 4.05 mm (0.1587 to 0.1594 in)
8
Piston rings (measured 1,5 mm S1= 2.560 a 2.605 mm (0.1008 to 0.1026 in)
(0.05905494 in) away external S2= 2.350 a 2.380 mm (0.0925 to 0.0937 in)
diameter) S3= 3.977 a 3.990 mm (0.1566 to 0.1571 in)
1= 0.100 a 0.175 mm (0.0039 to 0.0069 in)
9 Piston rings - grooves 2= 0.04 a 0.09 mm (0.0016 to 0.0035 in)
3= 0.04 a 0.083 mm (0.0016 to 0.0033 in)
10 Piston rings 0.4 mm (0.0157 in)

2002-18
REF. 667TA
ENGINE TYPE
X1= 0.30 to 0.40 mm (0.0118 to 0.0157 in)
11 Piston ring clearance in cylinder liner X2= 0.60 to 0.80 mm (0.0236 to 0.0315 in)
X3= 0.30 to 0.55 mm (0.0118 to 0.0217 in)
Connecting rod top end bushing housing ø1 = 40.987 to 41.553 mm (1.6137 to 1.6147 in)
12
Connecting rod big end bearing housing ø2= 72.987 to 73.013 mm (2.8735 to 2.8745 in)
Connecting rod big end bearing housing
13 External ø4= 41.279 to 41.553 mm (1.6252 to 1.6359 in)
Inner ø3= 38.019 to 38.033 mm (1.4968 to 1.4974 in)
14 Connecting rod top end bushing housing 0.266 to 0.566 mm (0.0105 to 0.0223 in)
15 Piston pin - connecting rod top end bushing 0.019 to 0.039 mm (0.0007 to 0.0015 in)
Measure dimension No information available
Connecting rod axle paralelism max. error No information available
Main journal bearing ø1 = 82.990 to 83.010 mm (3.2673 to 3.2681 in)
16
Crankpin journals ø2 = 68.987 to 69.013 mm (2.7160 to 2.7170 in)
Main bearings (provided as spare parts) S1= 2.456 to 2.464 mm (0.0967 to 0.0970 in)
Connecting rod bearings S2= 1.955 to 1.968 mm (0.0770 to 0.0775 in)
17 Main and crankpin journals
Numbers 1,7 ø3= 87.982 to 88.008 mm (3.4638 to 3.4649 in)
Numbers 2,3,4,5,6 ø3= 87.977 to 88.013 mm (3.4637 to 3.4651 in)

2002-19
REF. 667TA
ENGINE TYPE
Bearings - Main journals
Number 1,7 0.044 to 0.106 mm (0.0017 to 0.0042 in)
18
Numbers 2,3,4,5,6 0.041 to 0.103 mm (0.0016 to 0.0041 in)
Bearings - Crankpin journals 0.039 to 0.111 mm (0.0015 to 0.0044 in)
Main bearings +0.250 mm (0.0098 in)
19
Connecting rod bearing +0.500 mm (0.0197 in)
20 Main bearings journal X1= 37.475 to 37.545 mm (1.4754 to 1.4781 in)
21 Main bearings journal housing X2= 25.980 to 26.480 mm (1.0228 to 1.0425 in)
22 Shoulder bearing X3= 37.280 to 37.380 mm (1.4677 to 1.4716 in)
23 Crankshaft shoulder 0.095 to 0.265 mm (0.0037 to 0.0104 in)

2002-20
VALVE MECHANISM – CYLINDER SET
REF. 667TA
ENGINE TYPE
1 Valves guides housing in cylinder head ø1= 7.042 to 7.062 mm (0.2772 to 0.2780 in)
ø4= 6.970 to 6.999 mm (0.2744 to 0.2756 in)
Valves - Intake
Angle = 60º ± 0.25º
2
ø4= 6.670 to 6.999 mm (0.2744 to 0.2756 in)
Valves - Exhaust
Angle = 45º ± 0.25º
3 Valves steam and guide 0.043 to 0.092 mm (0.0017 to 0.0036 in)
Cylinder head housing for intake valve seat 34.837 to 34.863 mm (1.3715 to 1.3725 in)
4
Cylinder head housing for exhaust valve seat 34.837 to 34.863 mm (1.3715 to 1.372 in)
Valve housing external diameter; valver seat
angle in cylinder head
ø2= 34.917 to 34.931 mm (1.3747 to 1.3752 in)
5 Intake
Angle = 60º
ø2= 34.917 to 34.931 mm (1.374681 to 1.375232 in)
Exhaust
Angle = 45º
Intake valve backcut 0.590 to 1.110 mm (0.0232 to 0.0437 in)
6
Exhaust valve backcut 0.960 to 1.480 mm (0.0.378 to 0.0583 in)
Between intake valve housing and cylinder
0.054 to 0.094 mm (0.0021 to 0.0037 in)
head
7
Between exhaust valve housing and cylinder
0.054 to 0.094 mm (0.0021 to 0.0037 in)
head
8 Valve housing No information available

2002-21
REF. 667TA
ENGINE TYPE
Valve spring height: spring free H= 47.750 mm (1.8799 in)
Under load of: 339.8 N ± 19 N (79.4 lbf ± 4.3 lbf) H1= 35 330 mm (1.3909 in)
9
Under load of: 741.0 N ± 39 N (166.6 lbf ± 8.8 lbf) H2= 25.200 mm (0.9921 in)
Injector outgrouth X= No adjustable
Camshaft bearing housing - number 7 ø7= 59.222 to 59.248 mm (2.3316 to 2.3326 in)
10
Camshaft bearing housing - number 1,2,3,4,5,6 ø1-6= 54.089 to 54.139 mm (2.1295 to 2.1315 in)
ø1,2,3,4,5,6,7= 53.995 to 54.045 mm
11 Camshaft journals: 1 to 7
(2.1258 to 2.1277 in)
Camshaft bushing external diameter - load of 3.3
12 ø= 59.222 to 59.248 mm (2.3316 to 2.3326 in)
kNm (741.8695 lbf)
13 Camshaft bushing inner diameter ø= 54.083 to 54.147 mm (2.1292 to 2.1318 in)
14 Engine bloxk journals and seat 0.113 to 0.165 mm (0.0044 to 0.0065 in)
15 Main journals 0.038 to 0.162 mm ( 0.0015 to 0.0064 in)
Lobe intake lift 6.045 mm (0.2380 in)
16
Lobe exhaust lift 7.239 mm (0.2850 in)
Engine block tappet plate housing ø1= 16.000 to 16.030 mm (0.6299 to 0.6311 in)
17 ø2= 15.924 to 15.954 mm (0.6269 to 0.6281 in)
Tappet plate external diameter
ø3= 15.960 to 15.970 mm (0.6283 to 0.6287 in)
18 Between tappet and housing 0.030 to 0.070 mm ( 0.0012 to 0.0028 in)
19 Tappets No information available
20 Rocker axle ø1= 21.965 to 21.977 mm (0.8648 to 0.8652 in)
21 Rockers ø2= 22.001 to 22.0027 mm (0.86618 to 0.86625 in)
22 Between rockers and axle 0.024 to 0.0377 mm (0.0009 to 0.0015 in)

2002-22
SPECIAL TOOLS
380000158 Torque screwdriver from 1 to 6 Nm of torque for injetor solenoid valve connector locknut
calibration (Common Rail).
380000665 Tool for crankshaft front seal remotion
380000663 Tool for crankshaft rear seal remotion
380000671 Injector remotion tool
380000666 Crankshaft front seal installation coupler
380000664 Crankshaft rear seal installation coupler (except engines: 667TA/EBF - 667TA/EED)
380000988 Engine flywheel turning tool (except engines: 667TA/EBF - 667TA/EED).
380001099 Injetors remotion tool

2002-23
TIGHTENNING TORQUES
PART TORQUE - Nm(lb.-ft.)
Securing screws - cylinder head
1st Phase
Screws M12X1.75X70 45 to 55 Nm (33.2 to 40.6 lb.-ft.)
Screws M12x1.75x140 35 to 45 Nm (25.8 to 33.2 lb.-ft.)
Screws M12x1.75x180 (lubricate with oil) 65 to 75 Nm (47.9 to 55.3 lb.-ft.)
2ndt Phase (aditional tightenning) 90 degrees
3rd Phase (aditional torque screws 140 and 180 mm) 90 degrees
Crankshaft main journals
1st Phase (lubricate with oil) 44 to 56 Nm (32.5 to 41.3 lb.-ft.)
2ndt Phase 74 to 86 Nm (54.6 to 63.4 lb.-ft.)
3rd Phase (aditional tightenning) 90 ± 5 degrees
Connecting rod cap screws
1st Phase (lubricate with oil) 55 to 65 Nm (40.6 to 47.9 lb.-ft.)
2ndt Phase (aditional tightenning) 60 ± 5 degrees
Engine flywheel screws
1st Phase 26 to 34 Nm (19.2 to 25.1 lb.-ft.)
Injector supply connector nut 45 to 50 Nm (33.2 to 36.9 lb.-ft.)
Oil sump 20 to 28Nm (14.8 to 20.7lb.-ft.)
Fuel filter Contact + 3/4 turn
Injection pump cover screws 20 to 30 Nm (14.8 to 22.1 lb.-ft.)
Timing housing and cover screws 20 to 28Nm (14.8 to 20.7 lb.-ft.)
Intake manifold screws 20 to 28 Nm (14.8 to 20.7 lb.-ft.)
Fuel pump screws 20 to 30 Nm (14.8 to 22.1 lb.-ft.)
Exhaust manifold screws 48 to 58 Nm (35.4 to 42.8 lb.-ft.)
Valve cover nuts 20 to 28 Nm (14.8 to 20.7 lb.-ft.)
Rocker supports screws 31 to 41Nm (22.9 to 30.2 lb.-ft.)
Rocker adjustment screws 20 to 28 Nm (14.8 to 20.7 lb.-ft.)
Camshaft pulley screws
1st Phase 45 to 55 Nm (33.2 to 40.6 lb.-ft.)
Camshaft shoulder plate screws 20 to 28 Nm (14.8 to 20.7 lb.-ft.)
Fan support screws 20 to 30 Nm (14.8 to 22.1 lb.-ft.)
Injection pump screws 7 to 17 Nm (5.2 to 12.5 lb.-ft.)
Fan pulley screws 37 to 49 Nm (27.3 to 36.1 lb.-ft.)
Turbocharger screws 20 to 30 Nm (14.8 to 22.1 lb.-ft.)
Starter screws 37 to 49 Nm (27.3 to 36.1 lb.-ft.)
Alternator screws 37 to 49 Nm (27.3 to 36.1 lb.-ft.)
Water pump screws 20 to 28 Nm (14.8 to 20.7 lb.-ft.)
Oil filter screws Contact + 3/4 turn
Tension belt screw 37 to 49 Nm (27.3 to 36.1 lb.-ft.)
Control unity EDC7UC31 exchanger heater oil-water
M6 Screw 8 to 12 Nm (5.9 to 8.9 lb.-ft.)

2002-24
PART TORQUE - Nm(lb.-ft.)

Front cover and oil pump screws
1st Stage 7 to 9 Nm (5.2 toa 6.6 lb.-ft.)
2ndt Stage 20 to 28 Nm (14.8 to 20.7 lb.-ft.)
Oil nozzle screw 12 to 18 Nm (8.9 to 13.3 lb.-ft.)
Common Rail screws 20 to 28 Nm (14.8 to 20.7 lb.-ft.)
Intake air temperature and pressure sensor screw 5 to 7 Nm (3.7 to 5.2 lb.-ft.)
Olil level sensor screw 10 to 14 Nm (7.3 to 10.3 lb.-ft.)
Turbocharger to exhaust manifold screws 37 to 49 Nm (27.3 to 36.1 lb.-ft.)
Electrical cable tube M6 scrëws 8 to 12 Nm (5.9 to 8.9 lb.-ft.)
Injector electrical cable support screw 20 to 28 Nm (14.8 to 20.7 lb.-ft.)
Fuel filer support
Engine flywheel housing
M12 Screw 44 to 55Nm (32.5 to 40.6 lb.-ft.)
Camshaft sensor screw 6 to 10 Nm (4.4 to 7.4 lb.-ft.)
Crankshaft sensor screw 6 to 10 Nm (4.4 to 7.4 lb.-ft.)
Cooler temperature sensor screw 17 to 23 Nm (12.5 to 17.0 lb.-ft.)
Oil temperature and pressure sensor screw 5 to 7 Nm 3.7 to 5.2 lb.-ft.)
Fuel pressure sensor screw 30 to 40 Nm (22.1 to 29.5 lb.-ft.)
Fuel temperature sensor screw 17 to 23 Nm (12.5 to 17.0 lb.-ft.)

2002-25
667TA ENGINES
BS06K020 Figura 3000-12
1. Turbocharger 7. Oil sump

2. Automatic tension belt 8. Electronic Control Unit - E.C.U.
3. Alternator 9. Fuel filter
4. Fix guide pulley 10. High pressure pump
5. Water pump 11. Common Rail
6. Engine flywheel counterweight

2002-26
DESCRIPTION OF ENGINE MAIN COMPONENTS

Engine Block
1. Cylinder bore 5. Main journals

2. Mounting for water pump 6. Stiffening plate
3. Mounting for Camshaft bearing 7. Mounting for water-oil exchange heater
4. Mounting for oil pump
The cylinder block is a cast iron structure with cylinders bores (1), main journals (5) e moun-tings for camshaft bearing
(3) and valves, water-oil exchanger heater (7), water pump (2) and oil pump (4). The block also has coolant and oil
passages. The lubrication circuit provides oil for the moving parts. The stiffening plate (6) is applied in the engine
block botton to increase the resistance to mechanical fatigue.

2002-27
Crankshaft
BS06K022 Figura 3000-14
1. Oil pump gear 3. Timing gear

2. Crankshaft 4. Mounting for engine flywheel
The crankshaft is steel made and rests in seven journals tempered by induction.
There is a series of drilled passages for the lubricating oil.
The follow items are pressed in front: oil pump gear (1), position sensor sprocket, counterweight,
and the auxiliary devices pulley.
The follow items are pressed in rear: timing gear (3), and the mounting for engine flywheel (4).
The main journals bearings are steel made and coated by a anti-friction alloy. One of them is equipped with shoulders
to limit the cranckshaft axial clearance.
The timing gear (3) and the engine flywheel mounting (4) are forced positioned in the cranckshaft
rear and can not be replaced.
CRANCKSHAFT OIL SEALS

The front and rear seals are box type with radial sealing. To remove them use the special tools 380000665 e
380000663. For installation se special tools 380000666 e 380000664.

2002-28
Connecting Rod
BS06K023 Figura 3000-15
Connecting rods are forged steel. The big ends are made with an oblique angle. Caps and rods are separeted by a
fracture splitting method that produces a strong and unique fit cap.
The connecting rod big end bearings are coated by anti-friction alloy.
They are marked two ways:

• Body-cap: have a number that indicates match and cylinder which they are assembled.
• Rod shank: marked with a letter indicating weight class.

2002-29
Piston
BS06K024 Figura 3000-16
A coroa na cabeça do pistão apresenta uma câmara de combustão de alta turbulência. A parte inferior da coroa
na cabeça do pistão é arrefecida pelo óleo do motor distribuído por um bico pulverizador instalado no bloco do
motor.
Existem três canaletas para anéis do pistão com diferentes funções e diferente geometria:
The piston crown features a high turbulence combustion chamber. The piston crown is cooled from underneath by
a spray nozzle installed in the cranckcase.
There is three groves for piston rings with different functions and different geometry:
• 1st pinston ring with trapezoidal section (keystone) and coated by chome ceramic.
• 2ndt piston ring with torsional conical rectangular section.
• 3rd piston ring with double oil scraper and inner spring.
In the piston crown are marked the reference data:

1. Number of spare part and number of design modification.
2. Mark (looking from the frontal engine block) indicating the direction of assembly of the piston in the cylinder
3. Date of manufacture.
4. Mark indicating the first test of the recess insert.

2002-30
Camshaft
BS06K025 Figura 3000-17
BS06K026 Figura 3000-18
A. Intake valve lobe

B. Exhaust valve lobe
C. Lobe EGR
Camshaft is supported by seven journals in the engine block.

The front and rear journals seats are equipped with steel bushings coated with anti-friction material forced
positioned.
There is two lobes for each cylinder
A. Intake lobe
B. Exhaust lobe
Camshaft is directly controlled by rear gears moved by the crankshaft.
Exhaust Gas Recirculation - EGR

The exhaust gas can return partially to the cylinder and reduce the maximum temperature res-ponsible caused by
the nitrogen oxide (NOx) generation.
The ECR reduces the combustion temperature, decreasing the oxigen concentration in the combustion chamber,
creating a efficient system to control the NOx emissions. The EGR lobe is not equipped with any electronic control,
and the system is always enabled. Its configuration do not requires aditional elements such as retaining valve, pipes
or heat dissipation.
There is an aditional lobe (C). When a cylinder is intaking, this lobe allow a brief opening of the exhaust valve. The
recirculation occurs in that cylinder due the great exhaust pressure compared to the intake gases.

2002-31
Valve Control
BS06K027 Figura 3000-19
1. Rocker 6. Spring
2. Valve clearance adjusting screw 7. Camshaft
3. Pushrod 8. Tappet
4. Valve cone 9. Bridge
5. Valve seat 10. Rocker axle

2002-32
Cylinder Head of Engines – 667TA/EBF – 667TA/EBD – 667TA/EED
1. Exhaust manifold 4. Valve seat

2. Injector 5. Intake air heater
3. Thermostat 6. Intake manifold
The cast iron cylinder head is machined to allow mounting the following parts:
• Valve seats (4).
• Injectors (2).
• Thermostat (3).
It is designed also to accommodate the following components:

• Exhaust manifold (1).
• Intake manifold (6) with intake air heater mounting (5).

2002-33
Cylinder Head of Engines – 667TA/EEG – 667TA/EEC
1. Exhaust manifold 5. Injectors electrical cable support

4. Valve seat
• Valve seats (4)
• Injectors (2)
• Thermostat (3)

• Exhaust manifold (1)
• Intake manifold (7) with intake air heater mounting (6)

2002-34
Cylinder Head of Engines – 667TA/EDJ
1. Exhaust manifold 5. Injectors with electrical cable support

4. Valve seat
• Valve seats (4)
• Injectors (2)
• Thermostat (3)

• Exhaust manifold (1)
• Intake manifold (7) with intake air heater mounting (6)

2002-35
Valves and Valves Seats

The valve seats has the following angles:
Exhaust valve - 45°
Intake valve - 60°
NOTE: The exhaust valves (2) has a identification
cavity in its center.
1. Intake valve
2. Exhaust valve
3. Intake side
4. 4. Exhaust side
Oil seals (1) installed in the valves steams.
The cylinder head do not has guides inserts. The

guides are machined directly in cylinder head.
1. 7.042 A 7.062mm (0.277 A 0.278 IN)
2. Intake valves
3. Exhaust valves
Valves Bridge
NOTE: During the cylinder head installation, the rocker
bridge direction must be positioned with the marks (1)
turned to the exhaust ma-nifold.
1. Bridge
2. Pushrods

2002-36
Cylinder Head Machining
The cylinder head nominal thickness (A) is 105 ±

0.25mm (4.134 ± 0.0098 in) and the maximum material
remotion (B) MUST BE less than 0.13mm (0.0051
in).
Engine Flywheel
The engine flywheel (1) is not synchronized to the
crankshaft and do not have any marks, slots or
reference holes for sensors or sychronism. The fixation
screws holes equidistance (2) allows the installation
in any position.
FLYWHEEL OF ENGINES: 667TA/EEG - 667TA/EEC
FLYWHEEL OF ENGINES: 667TA/EED - 667TA/EBD
FLYWHEEL OF ENGINES: 667TA/EBF - 667TAEED FLYWHEEL OF ENGINES: 667TA/EDJ

2002-37
AUXILIARY DEVICES DRIVING
1. Automatic belt tensioning 4. Water pump

2. Alternator 5. Crankshaft
3. Poli-V belt
A Poly-V belt (3) transmits the crankshaft (5) rotation to the water pump (4) and alternator (2). The belt tensioning
is controlled by a automatic belt tensor (1).

2002-38
ENGINE LUBRICATION
1. Turbocharger oil pressure control valve A. Oil sump: 667TA\EDB

2. Deviation valve B. Oil sump: 667TA\EEG-667TA\EEC-667TA\EBT-667TA\
3. Oil filter cartridge type EED-667TA\EDJ
4. Oil and water cooler C. Pressurized oil path
D. Oil returning by gravity path
The pressurized lubrication is held by the following components: water pump (5), located in the engine block front
side, drived by the crankshaft gear; water and oil coller (4) located in the engine block, under the oil filter support;
deviation valve (2) to eliminate the oil filter obstruction and oil filter cartridge type (3).

2002-39
Oil Coller
1. Heat dissipation housing 5. Oil to filter return*

2. Inner gasket 6. Oil to filter inlet*
3. Water and oil cooler 7. Oil filter
4. Gasket between cooler and engine block * Only engines 667TA/EEG - 667TA/EEC
Oil Pressure Control Valve

Oil temperature calibration of 100°C (212°F).
-- Minimum pressure 1.2 bar (17.4 psi).
-- Maximum pressure 3.8 bar (55.1 psi).
1. 66 mm (2.589 in)
2. 41.25 mm (1.624 in)
3. 136.9 ± 10.5 N (30.8 ± 2.36 lbf)
Deviation Valve
“Blow-by” (oil sump vapours) máx:
20cm3/min (.68oz/min) with 0.83 bar (12 psi) pressure
and 26.7° C (80° F) of oil temperature
A. Flow direction

2002-40
Oil Pump
Cranckshaft with oil pump driving gear.

2002-41
Oil Sump of Engines –

667TA/EEG – 667TA/EEC – 667TA/EBF – 667TA/EED – 667TA/EDJ
OIL SUMP GASKET INSTALLATION
OIL SUMP GASKET END VIEW

The oil sump (1) is set to the engine block by a flexible
mode through a aluminum plate and a rubber gasket
(2).
The “C” section rubber gasket (2) , mounted in the
oil sump fixation contour, increase the oil sealing and
reduce the noise level.
Oil Sump of Engines – 667TA/EED – 667TA/EBD

CAST IRON OIL SUMP
The cast iron oil sump is fixed in the engine block by
screws and washers, and a thin gasket.

2002-42
Blow-By
1. Pre-separator A. Condensed oil

2. Intake recirculation B. Oil steam
3. Blow-by filter
4. Engine return
The rocker cover has a blow-by pre-separator (1), designed to increase the oil steam exit velocity while it is partially
condensed. The condensed oil returns to oil sump and the residual steam are collected and directed through blow-
by filter (3).
In the blow-by filter (3), one portion of steam condenses parttialy and return to oil sump through line (4), and the rest
is directed to engine intake through line (2).

2002-43
ENGINE COOLER
1. Oil radiator A. Water flowing outside thermostat

2. Water pump B. Water recirculating in engine
3. Thermostat C. Water flowing inside water pump
The engine cooling system is closed circuit type, forced circulation and incorporate the folowing components:
• Oil cooler used to cool the lubricating oil. See oil cooler in page 38.
• Centrifuge water pump located in he engine block frontal side.
• Thermostat to control the engine coolant circulation.

2002-44
Water Pump
WATER PUMP
WATER PUMP END VIEW

The water pump is located in a engine block fronta side
cavity, and is driven by the Poly-V belt. It is sealed in
the engine block by a o’ring.
The engine temperature is controlled by a
thermostat.
THERMOSTAT
Thermostat opening:
Engines 667TA/EEG, EEC, EBF, EED, EBD= 79 a 83°
C (174 a 181° F).
Engines 667TA/EDJ= 83 a 98° C (181 a 208° F).
A. The opening starts at 96° C (204° F) ≥ 7.5mm

(.30 inches).

2002-45
COMMON RAIL – HIGH PRESSURE ELECTRONIC INJECTION SYSTEM
1. Injectors electric cable 7. Pressure regulator

2. Electronic injector 8. Fuel heater and temperature sensor
3. Coolant temperature sensor 9. Camshaft sensor
4. Engine oil and pressure sensor 10. Fuel pressure sensor
5. Cranckshaft sensor 11. Turbocharger supply and pressure sensor
6. Electronic Control Unit - EDC7UC31
Extremely high pressures are required to reduce CERTAIN emissions.

The common rail system makes 1450 to 1600 bar (21030 to 23206 psi) fuel injection pressure possible, while the
precision of the injection obtained by the electronic controle EDC7UC31 optimize the engine operation, limiting its
emissions and the fuel consumption.
For powerfull engines more than 152 kW(203 hp), the CRIN2 injectors has DLLA nozzles that works with pressures
up to 1600 bar (23206 psi), while less powerfull engines (< 152 kW (203 hp)) are equipped with DSLA nozzles,
working with pressures up to 1450 bar (21030 psi).

2002-46
EDC7UC31 – ELECTRONIC CONTROL UNIT OPERATION

Engine Pre-Post Heater Control Engine Maximum Rotation Limit
The pre-post heater are enabled even if only one sensor Depending the application, the control unit memory can
(water, air or fuel temperature) detect a temperature lower contain appropriate engine rotation limits. When the engine
than 5°C (41°F). rotation overcome those limits, the ontrol unit set the power
reduction, controlling the injectors electrical signal time. In
Phase Recognition some applications, the response to the maximum limit is
cut the engine off.
The signals transmitted by cranckshaft and camshaft sen-
sors controls in wich cylinder the fuel must be injected.
Cut-Off
Injection Control The fuel cut-off release is managed by the control unit with
the flowing logical interventions:
Through informations transmitted by sensors, the control
unit determine and regulate the pressure, and changes the •• Electroinjectors deactivation.
pre-injection and the main injection mode. •• Electroinjectors reactivation immediately before it rea-
ches idle rotation.
Closed Mesh Injection Pressure •• Fuel pressure regulator control.
Control System
The engine load is determined by the data processing Smoke Control Under Acceleration
transmitted by the several sensors, and by the control unit. Under intense load demand, through signals received from
It commands the regulator to maintain the injection pressu- crankshaft and pressure temperature sensors, the control
re in constant and satisfactory values. unit manage the pressure regulator and modulates the
electroinjector to avoid exhaust smoke emission.
Main Control and Main Injection
Advance Control After Engine Cut-Off
The signals transmitted by several sensors to the control After the engine cut-off, the control unit microprocessor
unit, determine the best injection time in inner mapping ba- save many parameters to EEPROM memory, including the
sis. mode fails register that can be available when the engine
restarts.
Idle Control
Work Rotation Control in Normal
The control unit process the signals transmitted by several
sensors and adjust the fuel quantity to be injected. Operation Conditions
Controls also the pressure regulator and modulates the in- Every time that the work load varies, the control unit ad-
jection duration. Within specific li-mits, the control unit con- just the torque to maintain the engine in maximum power
trols also the battery tension. conditions. If the load causes a power reduction, the con-
trol unit increase the torque, and this way increasing the
injected fuel quantity to put the engine in maximum power
Overheating Protection conditions.
If the water temperature reaches 110°C (230°F) the control
unity reduce the engine performance.
When the temperature returns to a value lower than 100°C
(212°F) the engine restarts the normal operation.
In some applications, the intake manifold temperature is
the reference.

2002-47
Recovery Strategy
•• Fuel leak control
In case of problems in fuel supply, the system controls
the engine with constant power appropriated values
with low rotation and high torque, to inject the maximum
quantity of fuel.
•• Rail pressure control (Delivery pipe).
When the rail pressure overcomes the safety values,
the engine reduces power.
•• Syncronism issue
In case of syncronism issue, defective rotation sensors,
the systems controls the engine increasing the rotation
to optimize the signals reading.
•• Power restrictions as the operation temperature incre-
ases.
When the air temperature of turbocharger raises above
88°C (190°F), a power reduction starts. When the tem-
perature of 120°C (248°F) is reached, the performance
is more reduced, and in this case is compared to the
performance of the same engine if it was aspira-ted
type.
•• Power reduction as the reference temperature chan-
ges
In normal operation conditions, the system recognizes
the turbocharger air, oil and water temperatures. If the
engine water temperature is not available, gthe system
uses as refe-rence the oil temperature, and when it re-
aches near 103°C (217°F), starts to redue the available
power. Reaching 113°C (235°F), the power is reduced
to 50%.

2002-48
FUEL SUPPLY SISTEM
1. Electroinjector A. High pressure

2. Common Rail B. Low pressure
3. Fuel filter C. Fuel return
4. Pre-filter D. Pump terminal high pressure
5. Common Rail pressure relief valve
6. Counter pressure regulator for fuel return
7. Supply pump low pressure gear type
The common rail system has a high pressure pump that keeps the fuel supply constantly under very high pressure,
regardless what cylinder phase will receive the injection. The high pressure fuel is kept in a pipe (the common rail)
wich is shared by all electroinjectors. This means that allways there is fuel supply available in the electroinjectors
entrance, determined by the electronic EDC7UC31 control unit.
When a injector solenoid valve is energized by the ECU, the fuel that comes from the common rail is injected in the
corresponding cylinder. this fuel system is formed by a low pressure circuit and a high pressure circuit.
The high pressure circuit is formed by the lines:
• Line connecting the path from high pressure pump to common rail.
• Lines supplying the electroinjectors from common rail.
The low pressure circuit is formed by the lines:
• Fuel line from tank to pre-filter.
• Lines supplying the mechanical supply pump through control unit exchange heat, the manual priming pump
and pre-filter.
The fuel system is completed by the common rail fuel return, the injectors and the high pressure pump cooler
circuit.
2002-49
Fuel Supply System Diagram
1. High pressure pump 12. Fuel tank

2. Low pressure regulator valve in high pressure 13. Gear supply pump
pump 14. Fuel filter
3. Common rail safety relief valve 15. High pressure pump deviation retaining valve
4. Counter-pressure valve in the injector fuel 16. High pressure pump return line
return line 17. Impeller pump deviation retaining valve
5. Common Rail 18. Impeller pump pressure safety deviation
6. Common rail pressure sensor
7. Electroinjector A. Drain
8. Injector and high pressure pump return line B. Suction
9. Control Unit EDC7UC31 exchange heat C. Low pressute
10. Manual priming pump D. High pressure
11. Pre-filter
The supply pressure regulator controls the required fuel flow in the low pressure system. The high pressure pump
supplies the common rail. This fuel pressurization improves the energy efficiency and limits the fuel heat in the
system.
The low pressure regulator valve (2), installed in the high pressure pump, maintain the pressure
in a constant level of 5 bars (72 psi.).
The low pressure regulator valve (2) operates to increase the fuel flow in the high pressure pump cooler circuit
through the line (16), taking the fluid in and out line (8).
The common rail safety relief valve (3) is installed in the cylinder head. It controls the fuel flow coming from the
injectors under a pressure of 1.3 a 2 bars (19 a 29 psi.).
Parallel to the mechanical supply pump there is two deviation valves.
The impeller pump pressure safety deviation valve (18) makes possible the fuel flow return from the mechanical
pump exit to its entrance, when the pressure in the fuel filter entrance overcomes the permissible limits. The impeller
pump deviation valve (17) makes possible the supply of the fuel system through the priming pump (10).

2002-50
Fuel Filter
1. Fuel filter support A. High pressure pump exit connection

2. Fuel temperature connector B. Common Rail, inlet connection of injector
3. Fuel electrical heater exhaust line in cylinder head
4. Fuel filter C. Connection for high pressure pump exhaust line
5. Fuel temperature sensor D. Inlet connection of supply pump
E. Exit connection for fuel tank
The fuel filter is installed in the engine block, in the circuit between the supply pump and high pressure pump
(CP3).
The heater is activated when the fuel temperature becomes lower than 0°C (32°F) and it is heated until reaches 5°C
(41°F). The fuel temperature is controlled by the EDC7UC31 control unit.

2002-51
Mechanical Supply Pump – Normal Operation Condition
1. Pressure safety valve A. Fuel entrance (from tank)

2. Priming deviation valve in closed position B. Fuel exit to the filter
The supply gear pump, installed in the high pressure pump rear side pulls fuel from the tank through the pre-filter
and send it to the high pressure pump through the main fuel filter.
The supply pump is driven by the high pressure pump axle.
In normal condition of operation the supply pump flow enters in the hole (A), flow around the gear external side and
get out through the hole (B).
Mechanical Supply Pump – Unit Exit Overpressure Condition

2. Deviation hole B. Fuel exit to the filter
The pressure safety valve (1) opens when the pump (B) exit pressure becomes excessive due the filter restriction,
or malfuncion of the supply pressure regulator. The fuel pressure will them overcome the force exerced by the spring
(1) allowing the fuel flow to the pump entrance through the passage (2).

2002-52
Bleeding Condition of the Fuel System

2. deviation valve in closed position B. Fuel exit to filter
The deviation valve(2) opens when the engine is cut-off. The fuel system must be supplied by the manual priming
pump.
When operating the manual pump, the deviation valve (2) is opened due the entrance pressure, allowing fuel flow
to the exit (B).

2002-53
High Pressure Pump CP3.3 TYPE
1. Fuel exit connection for Common Rail 6. Control unit exchanger heat fuel entrance
2. High pressure pump connection
3. High pressure regulator 7. Fuel exit connection from mechanical pump to
4. Fuel entrance connection from filter filter
5. Fuel drain return connection in the filter 8. Supply gear mechanical pump
support
The high pressure pump has three radial pistons activated by a lob axle moved by a gear. It do not needs to be
syncronized.
In the high pressure pump rear side is located the mechanical supply gear pump wich is operated by the high
pressure pump axle.
IMPORTANT: The high pressure pump unit can not be reconditioned and do not exists adjustings.

2002-54
High Pressure Pump Exploded View
1. Gear supply mechanical pump 6. Pump axle

2. Gears kit 7. High pressure pump fuel entrance (from filter)
3. Common Rail high pressure fuel delivery valve 8. 5 bar (72psi) high pressure fuel regulator valve
4. Individual piston from high pressure pump (1 of 3) 9. High pressure regulator solenoid valve
5. Supply pump deviation valves

2002-55
High Pressure Pump Internal View

The pumping unit is formed of:
• Three pistons (5) operated by a three lobes
element (2) in the pump axle (6). When the axle
(6) turns the three lobes element (2) moves the
piston (5), pumping high pressure fuel that goes
through the delivering sphere valve (4), going to
the common rail.
7. High pressure fuel entrance
8. Fuel supply lines of the pumping elements
1. Cylinder
2. Three lobes element
3. Housing entrance valve
4. Delivering sphere valve
5. Piston
6. Pump axle

2002-56
Operation
1. Common Rail delivery line exit 5. Piston supply passage

2. Common rail delivery valve 6. Pressure regulator supply passage
3. High pressure piston 7. High pressure regulator
4. Pump axle
The high pressure piston (3) runs over the lobe

installed in the pump axle (4).
In the piston entrance phase it is supplied by fuel
through the supply passage (5). The fuel amount to
be provided to the piston is determined
by the pressure regulator (7). The pressure regulator
controls the high pressure pump exit flow, based in
the PWM command (pulse width modulated)received
from the EDC7UC31 control unit.
During the piston compression phase the fuel reaches
enough pressure to open the common rail delivery
valve (2) and is forced through the exit (1) to the
common rail.

2002-57
The picture in the left shows
A figura ao lado mostra as passagenthe hogh pressure
fuel passages inside the pump. It shows the main
piston supply passage (4), the individual piston supply
passages (1, 3, 6), the passages used to lubricate
the pump (2), the hogh pressure regulator (5), the 5
bar (72 psi) pressure regulator valve (8), and the fuel
exhaust passage (7).
The high pressure regulator (5) define the fuel amount
delivered by the the high pressure pistons to the
common rail. The fuel excess goes out through the
passage (9).
The regulator valve (8) was designed to keep a 5
bar (72 psi) constant pressure in the high pressure
regulator entrance.
1. High pressure pistons entrance

2. Pump lubrication passages
4. Main piston supply passage
5. High pressure regulator valve
7. Drain passage of supply pressure regulator
8. Regulator valve 5 bar (72 psi) supply pressure
9. Fuel exhaust of high pressure regulator valve
entrance
The picture in the left shows the fuel flow under high
pressure flowing through the exhaust galleries of
pumping elements.
1. Fuel exhaust pipe
2. Fuel exhaust flowing from pump with connector
for common rail high pressure line
3. Fuel exhaust gallerie

2002-58
Operation Theory
The cylinders are supplied through the housing entrance valve, only if the supply pressure is enough to open the
pumping elements delivering valve kit, about 2 bars (29 psi.).
The fuel amount that supply the high pressure pump is dosed by the high pressure regulator. The high pressure
regulator is controlled by the EDC7UC31 control unit through the PWM signal (Pulse width modulated).
When the fuel is sent to a pumping element, the corresponding piston is displaced down (suction course). When
this course is inverted, the intake valve closes and the fuel in the pumping element chamber is compressed in the
common rail.
The generated pressure open the exit valve and the coressed fuel reaches the high pressure circuit.
The pumping element compress the fuel until reaches the TDC (Top dead center).
Then, the pressure decreases until the exit valve closes.
The pumping element piston returns to the BDC (Botton dead center) and the remaining fuel is uncompressed.
When the pressure in the pumping element chamber stays lower than the supply pressure, the intake valve opens
again and the cycle repeats.
The common rail delivering pressure is modulated between 250 and 1600 bars (3625 and 23206 psi.) by the
EDC7UC31 control unit, through the pressure regulator solenoid valve.
The pump is lubricaed and cooled by the fuel.
The time spent to replace the pump in the engine is reduced compared to traditional injection pumps because do
not requires syncronism.
IMPORTANT: If the line between the fuel filter and high pressure pump is removed or replaced, verify the cleaness
of the components.

2002-59
Common Rail
1. Fuel pressure sensor
The common rail volume is a high pressure fuel storare device. It has a small storage to allow a quick pressurization
during start, in idle, and in case of high flow ratio.
It has enough volume capable to minimize the system pulses peak caused by the injectors opening and closing and
by the high pressure pump operation. This function is optimized through a calibrated hole between the high pressure
pump and the common rail system.
A fuel pressure sensor (1) is installed in common rail. Its signal is sent to the EDC7UC31 control unit, that send it
back to the common rail pressure sensor correcting what is required.

2002-60
Common Rail Pressure Relief Valve
1. Tank direct exhaust 4. Spring

2. Stop 5. Small piston
3. Body 6. Rail seat
A. Normally, the piston conical end (5) remains closed and the exhaust is diverted to the tank
B. If the 1750 bar fuel pressure is exceeded in rail, the small piston moves and the excess of pressure is
discharged in the fuel tank
The common rail pressure relief valve is installed in a common rail end, and was designed to protect the systems
components in case of excess of pressure.
The valve can be of one step (as shown above), or two steps with two limits of operation for 1750 bar and 800 bar
(25381 psi and 11603 psi) pressure relief.
In second case, when the pressure in the high pressure system reaches 1750 bar (25381 psi), the valve is activated
as a one step to discharge the fuel and therefore reduce the pressure until reaches the correct pressure. Then reduce
the pressure in common rail to near 800 bar (11603 psi)
The relief valve makes possible the engine operation in a limited performance, avoiding the fuel overheating and
protecting the system.
If the opening pressure of the two steps relief valve is reached, the EDC7UC31 control unit stops the pressure
regulator operation. The high pressure pump will operate then in maximum delivery to common rail, and a fail code
wil be stored.

2002-61
ELECTROINJECTOR
INJECTOR IN REST POSITION INJECTION STARTS

1. Pressure steam 9. Control volume
2. Plunger 10. Control duct
3. Nozzle 11. Supply duct
4. Coil 12. Conrol fuel exit
5. Main valve 13. Electrical connection
6. Sphereical shutter 14. Spring
7. Control area 15. High pressure fuel entrance
8. Pressure chamber
Injector in Rest Position Injection Starts

The injector is the same of the conventional injectors, ex- When coil (4) is energized, displace up the spherical shut-
cept by the plunger return spring. ter (6). The control volume fuel flows to the control fuel exit
(12) causing a pressure drop in control volume (9).
The injector has two basics parts:
Simultaneously the fuel pressure in the fuel chamber (8) lift
•• Pressure steam (1) with composite spray nozzle, the
the plunger (2), injecting fuel in the cylinder.
plunger (2) and the nozzle (3).
•• Control solenoid valve formed by coil (4) and main val- Injection End
ve (5). When coil (4) is deenergized, the spherical shutter (6) re-
The solenoid valve controls the nozzle plunger lift. turns to its closed position in order to recover the balance
of forces and returns the plunger (2) to its closed position
and concludes the injection cycle.
IMPORTANT: The injector inner parts can not be replaced,
and the injetor is not repairable.

2002-62
Injector Nozzler
The injectors are CRIN 1 and CRIN 2 Bosch type. The
spray nozzles used are specified according to engine
developed power.
1. Injector nozzler
Pressures
Injectors Injector nozzle Engines
Minimum Nominal
CRIN 1 Not available 667TA/EEG – 667TA/EEC Not available Not available
CRIN 2 DLLA 137 PV 3 667TA/EBF – 667TA/EBD 250 bar (3626 psi.) 1600 bar (23206 psi.)
CRIN 2 DSLA 143 PV 3 667TA/EED 250 bar (3626 psi.) 1400 bar (20305 psi.)
CRIN 2 Not available 667TA/EDJ 250 bar (3626 psi.) 1400 bar (20305 psi.)
Fuel Return Pressure Limiter

The fuel return pressure limiter is located in the cylinder
head rear side. This limiter adjust the fuel pressure that
returns from the injectors with a pressure of 1.3 to 2.0
bar (18.9 to 29 psi.).
Keeping this pressure in the return fuel, avoid the
steam formation inside the injectors, optimizing the
spray and the fuel pressure.
A. To fuel tank
B. From injectors

2002-63
LOCATION OF MAIN ELECTRICAL COMPONENTS
1. Coolant temperature sensor 7. Pressure regulator solenoid valve

2. Electroinjector 8. Fuel temperature sensor
3. Rail fuel pressure sensor 9. EDC7UC31- Electronic control unit
4. Pressure and temperature 10. Cranckshaft sensor
5. Starter 11. Engine oil pressure and temperature sensor
6. Camshaft sensor 12. Heater
The engine is controlled by EDC7UC31 - electronic control unit. It is installed over flexible supports in order to reduce
vibrations transmited by engine.
The fuel exchange heater removes the heat from the control unit due the high tensions required to injectors ignition. It
removes the heat and transfers to fuel cooler. Colect also some heat from the engine through the cylinder head. The
unit is equipped with a 20 A fuse. The main rele, used to supply energy to the system, is located inside the unit.
Through the engine control module, is possible verify the engine operations and also help in the diagnosis of fails,
through the fail codes generated by the EDC7UC31 control unit.

2002-64
EDC7UC31 – Electronic Control Unit
A. Injectors connector
B. Energy entrance and applications functions connector
C. Sensors connector

2002-65
Engine Pin-Out
A. A Connector (injectors) ECU EDC7UC31 (Energy) 5. Camshaft sensor

B. B Connector nor shown (see note below) 6. Oil temperature and pressure sensor
C. C Connector (sensors) ECU EDC7UC31 (signal) 7. Fuel temperature
8. Coolant temperature sensor
1. Cylinder injectors 1-2 9. Air pressure and temperature sensor
2. Cylinder injectors 3-4 10. Common rail temperature sensor
3. Cylinder injectors 5-6 11. Fuel high pressure regulator sensor
4. Crankshaft sensor
NOTE: The B connector is not shown because it is specific to the applications.

2002-66
Injectors Connector A Injectors Connector C

Pin-Out Diagram Pin-Out Diagram
ECU EDC7UC31 PIN DA ECU EDC7UC31 PIN
1 Cylinder injector 5 1 not used
7 not used 7 not used
8 not used 8 not used
9 High pressure regulator with fuel feeder 9 Camshaft sensor - signall
10 High pressure regulator with fuel feeder 10 Camshaft sensor - Earth
12 Cylinder injector 3 12 Common rail pressure and temperature
13 Cylinder injector 1 sensor - Earth
14 Cylinder injector 4 13 Common rail pressure and temperature
sensor - positive
15 Cylinder injector 6
14 Common rail pressure and temperature
16 Cylinder injector 5
sensor - signal
NOTE: The B connector is not shown because it is 15 Coolant temperature sensor - signal
specific to the applications.
16 Not used
17 Not used
18 Fuel temperature sensor - signal
19 Cranckshaft sensor - Earth
20 Not used
21 Not used
22 Not used
23 Cranckshaft sensor - Signal
24 Engine oil temperature and pressure -
Earth
25 Intake pressure sensor - Earth
26 Coolant temperature sensor - Earth
27 Oil pressure sensor - signal
28 Oil temperature sensor - signal
29 Not used
30 Not used
31 Not used
32 Engine oil temperature and pressure-
Signal
33 Intake pressure sensor - Positive
34 Intake pressure sensor - Signal
35 Fuel temperature sensor - Signal
36 Intake temperature sensor - Signal

2002-67
Cranckshaft Sensor
The cranckshaft sensor is a inductive sensor located in the engine front left side. The cranckshaft sensor produces
signals obtained from the magnetic intensity field through the sonant wheel openings embedded over the
cranckshaft.
The cranckshaft sensor is connected to the EDC-7 control unit in 19C - 23C pins. The sensor impedance is near
900 ohms.
Camshaft Sensor
A. Camshaft sensor
B. Connector
C. Wiring diagram
ECU EDC7UC31
Reference Description
Camshaft sensor Syncronism sensor
1 Signal 19C 10C
2 Signal 23C 9C
3 Protector

2002-68
Pressure and Temperature Sensor

This component incorporates a pressurre and
temperature sensor in only one unity.
Installed in the intake manifold, the sensor measures
temperature and pressure to exact calculate the fuel
amount to be injected in each cycle.
The sensor is connect to pins 25C - 36C - 33C - 34C
of EDC7UC31 control unit.
It is provided with a 5 volts electrical current.
The sensor exit tension is proportional to the pressure
or detected temperature.
• Temperature: Pins 25C - 36C
• Pressure: Pins 33C - 34C
Engine Oil Pressure and Temperature Sensor

This component incorporates a pressurre and
temperature sensor in only one unity.
The sensor is installed in the engine oil filter support
in a vertical position. Measures the temperature and
pressure of engine oil.
It is connected to pins 24C - 28C - 32C - 27C of
EDC7UC31 control unit.
The sensor is supplied with 5 volts. The pressure
signal is transmitted to the EDC7UC31 control unit,
wich send signal to dash panel display and to low
pressure indicating light.
The oil temperature is not shown in any display.
This value is used only by the control unit.
• Temperature: Pins 24C - 28C
• Pressure: Pins 32C - 27C
Número do pino da unidade de

Reference Description Controle EDC7UC31
Óleo Ar
1 Terra 24C 25C
2 Unidade de controle EDC7UC31 - Sinal (temperatura) 28C 36C
3 Energia de +5 volts fornecida ao sensor 32C 33C
4 Sinal (pressão) 27C 34C

2002-69
Common Rail – Fuel Pressure Sensor
Reference Description EDC7UC31 Control unit pin

1 Earth 12C
2 Signal 14C
3 Energy supply 13C
The common rail fuel pressure sensor is installed in a common rail end. It measures the inside fuel pressure and
returns this information to the EDC7UC31 Control unit.
The injection pressure value is used as a pressure control return signal, and to define the electric pulse duration for
the injection command.
This sensor is connected to 12C - 14C - 13C pins of EDC7UC31 Control unit. The energy provided to the sensor
is 5 volts.

2002-70
Electroinjector
INJECTION WIRING HARNESS LAYOUT
INJECTION WIRING HARNESS
The electroinjectors are a solenoid valve normally closed (N.C.)

Each injector is connected to A connector from EDC7UC31 control unit
The coil impedance of each injector is 0.56 - 0.57 ohms.
Reference Description EDC7UC31 Control unit pin

1 Cylinder injector 2 11A
CONNECTOR 1
CONNECTOR 2
CONNECTOR 3

2002-71
Intake Air Resistance Heater and Rele

INTAKE AIR RESISTANCE HEATER
The intake air heater is located over the intake
manifold.
Its objective is to heat the air in heating operations. Is
supplied by a rele located in chassis.
The intake air heater impedance is near 0.5 ohms.
INTAKE AIR HEATER CONTROL RELE

The control rele is connected to the EDC7UC31 B
connector.
It is activated when the water and/or fuel temperature
is lower than 5° C (41° F).
The rele impedance is near 15 ohms.
WARNING:Fluids or starter helpers such as

eter must not be used, to avoid serious
engine damages, or personal injuries.
COOLANT TEMPERATURE SENSOR

The coolant temperature sensor has variable
resistance and is capable to read the coolant
temperature and provide to the control unit a indication
of the engine temperature condition.
The same signal is used by gthe control unit to activate
a dash panel display, if it exists.
This sensor is connected to pins 15C - 26C of
EDC7UC31 control unit.
Its impedance in 20°C (68°F) is near 2.5 k (2500)
ohms

2002-72
Fuel Temperature Sensor

This sensor detects the fuel temperature in order
to permit the EDC7UC31 control unit injects with
precision the required amount of fuel.
The fuel temperature sensor is connected to pins 35C
- 18C of EDC7UC31.
Its impedance in 20°C (68°F) is near 2.5 k (2500)
ohms.
1. Fuel temperature sensor

2. Filter heater rele
Filter Heater Rele
The EDC7UC31 activates the filter heater rele when the fuel temperature is below 5°C (41°F).
EDC7UC31 pin
Reference Description
Coolant Fuel
1 Terra 15C 35C
2 Sinal de temperatura 26C 18C

2002-73
High Pressure Pump – Pressure Regulator
A. Pressure regulator
The fuel amount provided to high pressure pump is controlled by the solenoid valve of the supply pressure regulator.
The high pressure regulator is controlled by the EDC7UC31.
The delivering pressure to common rail is modulated between 250 and 1600 bars (3625 and 23206 psi.) by EDC7UC31,
that controls the solenoid valve of the high pressure regulator.
• This component is a solenoid valve normally opened..
• The solenoid is connected to pins 9A - 10A of EDC7UC31.
• The solenoid valve impedance is near 3.2 ohms.

2002-74
FUEL SYSTEM CHECK

High Pressure Supply Test
COMPONENTS INSTALLATION DIAGRAM FOR SPECIFIC TEST
1. Fuel tank 8. Common Rail

2. Pre-filter 9. Fuel recirculation
3. Low pressure pump 10. Injectors
4. Fuel delivery circuit 11. M1-0-15 bar manometer in fuel filter entrance
5. Fuel filter 12. M2-Manometer in fuel filter exit
6. High pressure pump 13. External container positioned 1m (39 in) beneath
7. High pressure circuit engine

2002-75
Low Pressure Pump
The gear pump function is supply the high pressure pump. Is driven by high pressure axle and is installed in its rear
side.
Under normal operations conditions, the fuel flow inside pump is as shown above.
Whith a pressurized fuel system, a fully loaded battery and a external fuel supply source positioned 1 meter (39 in)
beneath the engine, the engine must be operated within 20 seconds after the starter be activated. If the pump can
not pull the fuel up to engine, probably the low pressure pump is defective.
After start the engine, check the pressure at 1500 rpm.
The M1 manometer (11) must indicates between 6 e 9 bar (87 e 130 psi.).
• If lower 6 bar (87 psi.) replace the pump.
• If higher 9 bar (130 psi.) replace the fuel filter.
The M2 manometer (12) must indicates a pressure higher than 5 bar (72.5 psi.).
• If lower, replace the fuel filter.
• If the issue persists, check the fuel filter support engagements seals and high pressure pump entrance.

2002-76
Common Rail Pressure Relief Valve Test
The pressure relief valve is installed in a common rail end. Its function is protect the system components in case
that a malfunction occurs and also excessive pressure increase in the high pressure system.
Disconnect the recirculation line (1) from pressure relief valve and cover its hole with the test kit VOOS
connection.
Must be no diesel leak from the valve in any engine rotation. If diagnosys system indicates a fail code type “Engine-
backfill valve control, it means that the EDC7UC31 recognized that the valve opened after a significant changing
in the rail pressure higher than 1700 bar (24656 psi.). Once its opening must be considered a anormal increase of
pressure consequence, the valve IS NOT defective, even if a great amount of oil is leaking.
If the valve lets the diesel leaks without a fail code, replace the valve.
With the common rail pressure sensor disconnected and a fail code generated, and the rail pressure in 710 bar
(10298 psi.) measured by the diagnosys tool, the issue must be in the wiring and not in the component.
IMPORTANT: Informations obtained currently indicates that the sensor is rarely defective.

2002-77
Fuel Counter-Flow Test from the Return

The fuel counter-flow tests from the return establish
the injectors operation conditions. The rotation and
engine power are controlled through the injectors. he
power required by the user through the accelerator, is
conver-ted in fuel amount injected by cycle. This, on
the other hand, is converted in injector microseconds
of opening according with the rail pressure.
NOTE: The injectors may have mechanical or electrical

problems. Therefore, before continue with the following
analysis, check the water presence in the tank and in
the fuel pre-filter.
When the EDC7UC31 warning light indicate problems

during the acceleration and/or cold start, remember to
do the follow:
• Check if the cylinder head injector duct locknut
torque (1) is 45 - 55 Nm (33.2 - 40.6 lb-ft).
1. Injector duct locknut

2002-78
Continue with the injector fuel counter-flow tests as follows:

• Remove the duct (1) from cylinder head.
• Cover its connection (2)
• Install a transparent hose (3)
Check if engine idle is correct. Check the fuel recirculation amount in cylinder head.
The process to measure the injector return fuel amount is:
• Engine idle and compressor or airconditioning off.
• Engine temperature higher than 50°C (122°F).
The fuel amount draining must not be higher than 80ml (2.7 oz.) of diesel per minute. The excessive recirculation,
higher than 80ml (2.7 oz.) of diesel per minute can be caused by:
• Incorrect coupling between one or more injectors and needles.
• Leaking inside the injector.

To identify the defective injector, proceed as follows:
Measure the fuel amount draining during one minute by the cylinder head coupling. If the recirculation exceeds 80
ml. (2.7 oz.) per minute, cover the rail exit of one injector (1)at a time, using the test kit rail plugs.
The defective injector is that wich causes a significant reduction in the recirculation fuel when covered.
NOTE: When replace a injector, replace the duct also.
After the identification of the injectors/ducts with high recirculation of fuel, check the torque of ducts. If required, tight
it with 45 - 55 Nm (33.2 - 40.6 lb-ft) torque. Then check again the recirculation values.
If the torque is correct, remove the line and check if the spherical end in direction of the injector is oval shaped.
Replace if required. Check again the new recirculation value. If the duct is not deformed, replace the injector. Check
the recirculation value again.

2002-79
ENGINE OVERHAULING IN BENCH

Engine Disassembly
STAGE 1
Drain engine oil removing the oil sump plug.
STAGE 2
Use the supports to hold the engine in the stand as
follows (working in the engine left side):
• Use a appropriated tool to remove the fuel filter
(5) from its support (1).
• Disconnect the low pressure lines (2, 3, 4) from
fuel filter support (1)
• Remove the fuel filter support (1) from the engine
block.
STAGE 3
IMPORTANT: Push bracker (1) as shown in picture
B to disconnect the low pressure fuel lines (2, 3, 4)
from corresponding connections. Then replace the
loop (1) in the position shown in picture A avoiding
any deformation.
STAGE 4
Disconnect the fuel line (1) from common rail and from
high pressure pump (5), remove it taking the screws
(2) off.
IMPORTANT: When loose the connection (3) from
the fuel line (1), is necessary use a appropriate tool
to avoid the turning of the high pressure pump (5)
connection (4)
STAGE 5
From the right side:
• Remove the screws (2) and the oil lines (3) from
Engine block Turbocharger (1)
• Remove the starter (5) from the engine flywheel
housing (4).
• Hold the engine in a appropriate support.

2002-80
STAGE 6
1. Injectors connection 7. Pressure and temperature sensor

2. Engine coolant temperature sensor 8. Camshaft sensor
3. Common rail fuel pressure sensor 9. Fuel heater temperature sensor
4. Oil pressure and temperature sensor 10. High pressure regulator
5. Cranckshaft sensor 11. EDC7UC31 Control Unit
6. Injector
Disconnect the battery cable, releasing the following

connectors:
• Injectors wiring (6) connectors (1)
• Engine coolant sensor in thermostat (2)
• Common rail fuel pressure sensor (3)
• Cranckshaft sensor (5)
• Pressure and temperature sensor (7)
• Camshaft sensor (8)
• High pressure regulator (10)
• EDC7UC31 Control Unit (11)

2002-81
STAGE 7
Disconnect the “common rail” (2):
• Fuel line (4) according stage 3 procedure, page 80
• Fuel lines (5)
• Injectors connectors (3)
• Remove the screws (1) and disconnect common
rail (2)
STAGE 8
Disconnect line (2) from fuel return pressure limiter (1)
as shown in stage 3, page 80.
Remove nut, loose the retaining collar and disconnect
the oil vapours line (5). Remove screws (3) and take
the blow-by filter (4) off.
STAGE 9
Remove valve tappets cover and nuts including
the gasket.
Remove screws (1) and disconnect the injectors wiring
spacing bar (2) with gasket.
Remove screws (5) and disconnect the pressure and
temperature sensor (6)
Remove nuts (3) and the fuel entrance connectors
(4).
IMPORTANT: The fuel connectors (4) disassembled
must not be used again. It must be replaced by new
ones.
STAGE 10
Loose valve tappets adjusting nuts (1) and unscrew
the adjusters.
Remove screws (2), the rocker set (3) consisting of
support (6), rockers (4), axles (5), and remove the
valve bridges (7).
Remove pushrods (8).

2002-82
STAGE 11
Remove the injectors screws.
Use the special tool l380001099 (1) to remove the
injectors (2) from cylinder head.
STAGE 12
Remove the deflector 5) (if exists) from turbocharger
(1).
Disconnect the oil line (3) from the exchange heat oil
filter support.
Remove the nuts (2) and separate the turbocharger
(1) from the exhaust manifold (4).
STAGE 13
Remove the screws (1) and remove the exhaust
manifold in two sections (2 and 3) with gaskets.
STAGE 14
Remove the screws (1) and disconnect the intake
manifold and heater air deflector (2).
Remove screws (4) and take the thermostat housing
(3) off. Them take the thermostat off.
Remove the screws (5) from cylinder head (6).

2002-83
STAGE 15
Install supports (1) to cylinder head and remove it from
the cylinder block using a pulley.
STAGE 16
Remove the cylinder head gasket (1).
STEP 17
Release the belt tensor (2) and remove belt (2) from
pulleys. Then remove the tensor (2). Remove the
alternator screws, then the alternator (1)
STEP 18
Remove the screws and the oil pressure and
temperature sensor (2).
Remove the screws and then remove the oil filter
exchange heat (1), the imtermediate plate (4) and
gaskets.
Remove the oil level sensor (3).

2002-84
STEP 19
Remove the screws and disconnect the EDC7UC31
Control Unit (1), including the exchange heat.
STEP 20
Remove nut and disconnect the syncronism sensor
(1). remove nuts and disconnect the high pressure
pump (3), including the supply pump (2).
STEP 21
Loose the engine flywheel screws (1) without removing
the flywheel.
STEP 22
Remove the screws (3), the engine flywheel vibration
damper (2) and the cranckshaft pulley (1).

2002-85
STEP 23
Remove the screws and disconnect the water pump
(1). Remove the screw and disconnect the cranckshaft
sensor (2).
STEP 24
Install the 380000665 tool (4) to the cranckshaft (2).
Working through the guide holes of the 380000665
special tool (4), drill the inner seal ring with a 3.5mm
(9/64 in.) drill bit (A) 5mm (3/16 in.) deep B).
Hold the 3800000665 special tool (4) to the ring (1),
screwing the six screws provided with the tool to the
cranckshaft front cover.
Then extract the seal ring (1) pressing the screw (3).
STAGE 25
Using a crowbar (3) and a lever (4), remove the
external seal ring (2) from the front cover.
STEP 26
Remove the screws and the front cover (1).
IMPORTANT: Note the installation position of the
screws because it has different lenghts.

2002-86
STEP 27
Remove the screws and the gear oil pump (1).
IMPORTANT: The oil pump can not be repaired.
STEP 28
Remove the tool (1) and the engine flywheel screws
(3).
STEP 29
Screws two pins of suitable lenght in the cranckshaft
holes (3).
Remove the engine flywheel (1) with a pulley.
STAGE 30
Remove the screws and the rear cover (1).
IMPORTANT: Note the installation position of the
screws because it has different lenghts.

2002-87
STEP 31
Turn engine up side down.
NOTE: Only for engines: 667TA/EEG- /EEC- / EBF- /
EED- /EDJ.
Remove the screws, the plate (2) and oil sump (1).
STEP 32
NOTE: Only for engines: 667TA/EEG- /EEC- / EBF- /
EED- /EDJ.
Remove screws (1 and 4) and the suction strainer
(5). Remove the screws (2) and the strenghtening
plate (3).
STEP 33
NOTE: Only for engines: 667TA/EED-/EBD.
Remove the screws and oil sump (1)
STEP 34
NOTA: Only for engines: 667TA/EED-/EBD.
Remove the screws (1 and 4) and suction strainer
(5). Remove the screws (2) and the strenghtening
plate (3).

2002-88
ETAPA 35
Remova os parafusos e a engrenagens (2) da árvore
de comando das válvulas (1).
STEP 36
Remove the screws and the timing gear
housing (1).
IMPORTANT: Note the screw installation position
because it has different lenghts.
STEP 37
Remove the screws (1), then take the connecting
rod caps (2) off.
Remove the pistons (completes with the connecting
rods) from the engine block.
IMPORTANT: The bearings must be kept in its own
housing. In case of be used again, install it in the same
position before the remotion.
STEP 38
Remove the screws (1) and main journals caps (2).

2002-89
STEP 39
The main journals caps (1) and its bearings (2) has a
rebound to control the cranckshaft axial clearance.
IMPORTANT: Note the assembly position of main
journals and bearings. In case of be used again, install
it in the same position before the remotion.
STEP 40
Remove the cranckshaft (2) from engine block usig a
appropriate tool (1) and a pulley.
STEP 41
Remove the main bearings (1).
Remove the screws (2) and the oil nozzles (3).
IMPORTANT: Note the main journals and bearings
position assembly. In case of be used again, install it
in the same position before the remotion.
STEP 42
Remove the screws and camshaft (2), and the
retaining plate (1).
IMPORTANT: Note the plate assembly position (1).

2002-90
STEP 43
Remove carefully the camshaft (1) from the engine
block.
STEP 44
Remove tappets (1) from engine block.

2002-91
ENGINE BLOCK CHECKS AND SPECIFICATIONS

Checks And Measurement
STEP 45
After the engine disassembly, clean the block
carefully.
Verify the block structure agains cracks and the
plug conditions. Replace then in case of rust or seal
capacity doubtful. Check the cylinder holes surfaces if
there is deformations, ovalization, scratches, conicity
or excessive wear.
Check the cylinder hole inner diameter (to measure
the ovalization, the conicity and wear), using a hole
diameter measurer (1) equipped with a display
IMPORTANT: If a measurer is not available, use a
micrometer to perform test.
STEP 46
The measurements must be performed in each
cylinder, in three differents hole heights (1, 2, 3)
and in two planes perpendicular to each other. One
parallel to the longitudinal engine axle (A), and other
perpendicular to the transversal axle (B). The bigger
wear normally is found in plane (B), and during the
first measurement. If a ovalization,conicity or wear in
the cylinder holesis detected , it must be rectified and
reconditioned. The reconditioning must observe the
piston and rings oversizes patterns.
Camshaft Lobe And Journal Surface Check

STEP 47
Using a micrometer (1) check the camshaft.The journal
surface wear must be lower then 0.04 mm (0.0016 in.).
If not, replace the camshaft. Check also the lobe (3). It
must be 7.582 mm (0.2985 in.) for exhaust and 6.045
mm (0.2380 in.) for intake. If different values are found
replace the camshaft. Check the camshaft journal
using a micrometer (1) in two axles in a perpendicular
way each other.

2002-92
Bearigns
STEP 48
The camshaft bearings (2) must be pressed in its
housings.
The inner surfaces must not shown deformations or
wear.
Use a hole measurer (3) to measure the front and rear
bearing diameters (2) and the intermediate housings
of the camshaft (1)
The measures must be performed in two axles in a
perpendicular way each other.
MAIN FEATURES OF CAMSHAFT BEARINGS AND ITS HOUSINGS DIMENSIONS-B AFTER BEARING
INSTALLATION
STEP 49
CYLINDER HOLE DIMENSIONS AND
SPECIFICATIONS
IMPORTANT: In case of reconditioning, all cylinder
holes must be machined observing the 0.5mm (0.02in.)
oversizing patterns.
Check the main bearings housings as follows:
• Install the caps over the supports without
bearings.
• Screw with the specified torque.
• With a inner comparator, check if the housing
diameter is the specified.
If the value is out of the specified tolerance, replace
the engine block.

2002-93
Checking The Contact Surface Between Cylinder Head And Cylinder Block
STEP 50
Check if the the contact surface between cylinder head
and engine block shown any deformation. This check
can be performed removing the guide pins (4), using
a ruller (2), and a thickness calibrator (3). In case of
existence of a deformed area, rectify the engine block
surface. The deformation must be lower than 0.075mm
(0.0030 in).
IMPORTANT: After the repair conclusion, check if the
cylinder overgrouth in the engine block is not bigger
than the specified.
Then restore the hole cylinder bevel as shown in the
picture of step 49.
Camshaft Syncronism
CAMSHAFT MAIN FEATURES
STEP 51
The camshaft journals and the lobe surfaces must be perfectly smooth. In case of deformation or scratches, replace
the camshaft and bearings.

2002-94
Lobe Bearing Replacement

STEP 52
During the bearing (1) replacement use a hammer (2)
and a appropriate guide for installation.
IMPORTANT: During installation, the bearing (1) must
be aligned in order to align the lubrication holes with
the housing holes in the engine block.
Tappets
TAPPETS AND ENGINE BLOCK SEATS MAIN
FEATURES

2002-95
Camshaft Tappets Installation

STEP 53
Lubricate tappets (1) and intall in the engine block
seats.
STEP 54
Lubricate the camshaft journal bearings and install the
camshaft (1), taking care to not damage the bearings
or seats.
STEP 55
Place the camshaft (1), the retaining plate (2) in the
notched hole turned to engine block upside, and the
stamp turned to operator. Then, tight the screws with
20 to 30 Nm (14.8 to 22.1 lb.-ft) specified torque.

2002-96
STEP 56
Check the camshaft axial play, that must be between
0.13 - 0.23 mm (0.005 - 0.009 in.).
STEP 57
Install the oil nozzles (2) and tight the screws (1) with
the specified torque.

2002-97
CRANCKSHAFT
Cranckshaft Journal Measurement
STEP 58
If any deformaion, scretches or ovalization in journals
is found, the journals must be rectified.
Before rectify the journals (2), use a micro-meter (1) to
define the size that the journals should be reduced.
IMPORTANT: We recommend that the measurement
valus be noted in the picture below.
The reduction classes are 0.250 and 0.50 mm (0.0100
and 0.0200 in).
IMPORTANT: The journals must be allways rectifieds
in the same reduction class. The reduction must
be marked with a special stamp in the cranckshaft
shoulder side. For the reduced journals pins use “M”,
and for journals use “MB”
Cranckshaft Journals Marking Data

2002-98
Cranckshaft Main Tolerances
TOLERANCES ABOUT
TOLERANCES ABOUT GRAPHIC SYMBOL
FEATURES
Rounding 1
FORMAT
Cylindrical 2
Parallelism 3
ORIENTATION Perpendiculars 4
Straightening 5
POSITION Concentricity or Coaxially 6
Circular oscillation 7
OSCILLANTION Total oscillation 8
Conicity 9
1. Syncronism side bearings

2. Syncronism side bearings
3. First bearing in the upper side

2002-99
Oil Pump Gears Replacement

STEP 59
Make sure that the gear tooths (1) are not damage or
worn. In case positive remove the gear using a extrator
(3) pressed over the drive axle (2)
When installing a new gear, this must be heated
for 10 minutes in a small oven at a temperature of
160°C ± 10% (320°F ± 10%), and then forced over
the cranckshaft.
WARNING:Use allways protection gloves

agaisnt heat to avoid hands burn.
Main Bearings Installation

STEP 60
IMPORTANT: If the main bearings do not need be
replaced, install in the same position it was before
the remotion.
IMPORTANT: The main bearings (1) are provided as
spare parts, with the inner diameter 0.25 - 0.50 mm
(0.0098 - 0.0197 in) reduced.
Clean the main bearings (1) and its lubrication holes
before the installation.

2002-100
Journals Assembly Clearance Measurement

STEP 61
Install the cranckshaft (1) in the engine block.
Check the play between the journals and bearings
as follows:
STEP 62
Clean the parts to eliminate dirt, dust and oil.
Place a bit of calibration strip (3) in parallel position to
the cranckshaft journal pin (4).
Intall the caps (1) with the bearings (2) over the
supports.
STEP 63
Install the pre-lubricated screws (1), tightenning in
three steps:
• 1st step, using a torquemeter with 44 - 56 Nm
(32.5 - 41.3 lbf ft) of torque.
• 2ndt step, using a torquemeter with 74 -86 Nm
(54.6 - 63.4 lbf ft) of torque.
STEP 64
• 3rd step, using a apprpriated tool (1), installed
as shown, and tight the screws (2) with a angular
torque of 90° ± 5°.

2002-101
STEP 65
Remove the supports caps.
The clearance between the main journals and the
journals pins can be stablished, comparing the
calibrator strip widht (2) with the more narrow point in
the calibrator package scale (1).
The scale numbers indicating the clarance in
milimeters (inches).
Replace the bearings and repeat the check about
different clearances values. Once obtained the
specified clearance, lubricate the main journals
and install the supports, tight the screws according
previously described.
Cranckshaft Recess Clearance Measurement

STEP 66
The recess clearance is checked installing a magnetic
bases comparator (2) over de drive axle (3), as shown
in picture: the normal assembly clearance is 0.068 a
0.410 mm (0.0027 a 0.0161 in).
If the comparator pointer drop down from scale, replace
the main bearings from the second rear support (1)
and repeat the check between the journal pins and
the main bearings.
Connecting Rod – Piston Set

PARTS THAT FORM QUE CONNECTING ROD – PISTON SET
1. Retention piston rings 5. Connecting rod cap screws

2. Piston pin 6. Bearings
3. Piston 7. Connecting rod
4. Piston ring 8. Busch

2002-102
Piston, Pin and Piston Ring Data

DIMENSION TAKED OVER 101 mm DIAMETER
IMPORTANT: The pistons are provided as spare parts, classifieds in 0.4mm (0.016 in) size.
STEP 67
Piston ring(1) of piston (2) remotion using a pliers
(3).
STEP 68
The piston pins (1) retaining rings (2) are removed
using a tracer (3)

2002-103
Piston Pin Diameter Measurement

STEP 69
Measure the piston (1) diameter using a micrometer
(2) to define the assembly clearance.
STEP 70
The clearance between the piston and cylinder can be
measured through a feeler gauge set (1).
Piston Pin
STEP 71
Measure the piston pin (1) diameter using a micrometer
(2).
Pin-Piston Correct Mating Condition

STEP 72
Lubricate the pin (1) and its piston seat with engine
oil. Insert the pin in the piston slightly, pressing with
the fingers.

2002-104
Piston Rings
STEP 73
Check the piswton rings (2) thickness using a
micrometer (1).
STEP 74
Use a feeler gauge (2) to check the clea-rance
between the piston rings (3) and the second and third
piston grove (1)
Utilize um calibrador de lâminas (2) para ve-rificar a
folga entre os anéis do pistão (3) da 2ª e 3ª canaleta
e os respectivo alojamentos no pistão (1).
STEP 75
Due the peculiar format of the two trapezoidal
rings, of transversal section sealing, the clearance
between the grove and the ring must be measured
as follows:
• Allow the piston (1) lift in the engine block in order
that half part of the ring (2) appears in the engine
block (3)
• In this position, and using a thickness measurer,
check the clearance (X) between the ring and
the grove. The value must correspond to the
specified.
End view for trapezoidal ring (X) clearance
measuring.
STEP 76
Measure the clearance between the ring ends (2),
inserting in the cylinder hole a feeler gauge (1).

2002-105
Connecting Rod
* Inner diameter value to be obtained after introduction
in the small connecting rod end and refaced by a
extender.
** This dimension can not be measured in free
condition.
IMPORTANT: The connecting rod - cap mating surface

are knurled to assure better mating.
We recommend do not remove the knurl.
Connecting rod, piston pin bush and bearing main

data.
IMPORTANT: Each connecting rod is marked as

follows:
• By number (over body and cap) wich indicates
the connecting rod and cylinder mating where
it is installed. In case of replacement, the new
connecting rod must be marked with the same
number of the replaced.
• By letter (over the connecting rod body) wich
indicates the connecting rod weight class
assembled in factory.
V- 1560 to 1600 (yellow mark)
W- 1601 to 1640 (green mark)
X- 1641 a 1680 (blue mark)
The replacing connecting rods are provided in classe

W and marked in green.
Is not allowed remove material.

2002-106
Bearings
STEP 77
Make shure that the bush in the small connecting
rod end is not loose and do not show scretches and
deformation. If shows, it must be replaced.
The remotion and reassembly are performed with the
same appropriated tool.
During the bush introduction, make shure that the
lubrication holes are unobstructed,
to allow the oil flow over the bushs and the small
connecting rod end. Use an extender to reface the
buch and tehn get the desired diameter.
Connecting Rod Check

STEP 78
Check if the connecting rod center lines (1) are
parallels, using a correct device (5) as follows:
• Install the connecting rod (1) over the tool axle (5),
and hold with the screw (4).
• Place the axle over V-blocks, placing the connecting
rod (1) over the backbar(2).

2002-107
Torsion Check
STEP 79
Check the connecting rod (5) torsion comparing the
two points (A and B) of the pin (3) in the horizontal
plane area of the connecting rod axle.
Place the support (1) of the comparator (2) in order
that the comparator be pre-loaded near 0.5mm (.02 in)
over the pin (3) in point A. Then set the comparator (2)
to zero. Move the axle (4) with the connecting rod (5),
then compare the deviation (if exists) over the opposite
side (B) of the pin (3). The difference between A and
B must be lower than 0.08mm (0.003 in.).
Flexibility Check
STEP 80
Check the connecting rod (5) flexibility comparing the
two points (C and D) of pin (5) in the vertical plane
area of the connecting rod axle.
Place the vertical support (1) of the comparator (2)
in order that the comparator rests over the pin (3) in
point (C).
Oscillate the connecting rod to front and rear, looking
the highest position in pin. Under such condition, adjust
the comparator (2) to zero.
Move the axle with the connecting rod (5) and repeat
the check from the highest point in the opposite (D) of
pin (3). The difference between (C) and (D) must be
lower than 0.08 mm (0.003 in.).

2002-108
Connecting Rod – Piston Set Coupling Installation

The reference data that follows are spiked in the
piston crown:
1. Part number and Changing Design number.
2. The arrow showing the piston set direction in the
cylinder, turned to the engine block front brace.
3. Date of manufacture
4. Mark showing the insert test of the first grove.
STEP 81
Connect the piston (2) in the connecting rod (4)
insertind the pin (3) in order that the reference
registration (1) to piston installation (2) in the cylinder,
and the stamped numbers over the connecting rod (4)
must be seen as the side picture shows.
STEP 82
Insert pin (1) and install the retaining rings (2).

2002-109
Piston Rings Installation

STEP 83
Use a pliers (3) to install the rings (1) over the piston
(2). The rings must be installed with the word “TOP”
up and the openings displaced 120° each other.
IMPORTANT: The piston spare rings are provided in
the following dimensions:
• Pathern, marked in yellow
• Oversized 0.4mm (0.016 in), marked yellow-
green.
STEP 84
Intall the connecting rod bearings (1) and the
connecting rod cap.
IMPORTANT: If the bearings do not need to be
replaced, must be installed in the same order and
position that was before removed.
No mating operation must be performed to the
bearings.
Connecting Rods-Piston Sets – Installation in Cylinder Block

STEP 85
Lubricate the pistons fully, including the piston rings
and the inner cylinder holes.
Use the piston girdle tool (2) to install the connecting
rod-piston sets (1) in the cylinder block checking if:
• The number of each connecting rod correponds
to the mating number of the cap.
STEP 86
• The piston rings openings are displaced 120°
each other
• Every connecting rod-piston sets has the same
weight.
• (1) is turned to the front of engine block, and
the slot in the piston skirt corresponds to the oil
nozzles.
Connecting rod - piston set installation scheme in the
respective cylinder

2002-110
Journal Clearance Measurement in Cranckshaft Set

STEP 87
The clearance can be measured following the
procedure below:
• Fully clean the parts and eliminate any oil trace.
• Place a bit of calibrator strip (2) in the cranckshaft
journals(1)
• Install the connecting rod caps (3) with the
respective bearings (4)
STEP 88
Tight the screws (1), previouslly lubricated with engine
oil with the specified torque using a torquemeter (2)
STEP 89
Install a appropriated tool (1) over the protractor, and
then tight the screws (2) with a aditional tightenning
in a cruzade sequence.
Consult the torque specifications in page 22.
STEP 90
Remove the connecting rod caps and calculate the
existing measure, comparing the calibrator strip width
(1) with the scale in the calibrator strip package (2).

2002-111
STEP 91
If the clearance value measured is different from the
specified, replace the bearings and repeat the check.
Once obtained the specified clearance value, lubricate
the conne-cting rod bearings and install it tighting the
connecting rods caps screws with the specified torque
in page 22.
IMPORTANT: Before install the connecting rod caps
screws, make shure that the dia-meter measure in the
thread middle lenght is not lower than 0.1mm (0.004
in.) of the diameter measured near 10mm (0.39 in.)
from the screw end.
Check manually if the connecting rods (1) slide freely
over the journals, and if the axial clearance measure
with a feeler gauge (2) is 0.10 to 0.33mm (0.004 to
0.013 in.)

2002-112
Piston Outgrowth Check

STEP 92
After the connecting rod-piston installation, check with
a indicator gauge (1) equipped with base (2), the piston
outgrowth (3) in the TDC relactive to the engine block
upper plane surface. The outgrowth must be 0.28 -
0.52 mm (0.011 - 0.0205 in).
Timing Gear Housing

STEP 93
Fully clean the timing gear housing (1) and the engine
block. To obtain a satisfactory sealing, the surfaces
must be clean. Apply a fillet of few milimeters of
diameter of LOCTITE 5205 to the timing gear housing.
Must have uniform size, without air bubbles, thin
areas or gaps. Any imperfection must be corrected
immediately. Avoid use excess of seal. It can drain
by the gasket sides and obstruct the lubrication
passages. Install gasket within 10-20 minutes after
the seal application.
Seal application area.
STEP 94
Install agin the timing gear cover (1) in the engine
block.
Install the screws in the same position it was when
removed, and tight with the follow torque values, in
the sequence shown below.
• Screws M12: 65 to 89 Nm (48 to 66 lbf. -ft.)
• Screws M8: 20 to 28 Nm (15 to 21 lbf.- ft.)
• Screws M10: 42 to 52 Nm (31 to 38 lbf.- ft.)
Timing gear cover screws diagram

2002-113
Valve Syncronism
STEP 95
Mark with a felt tip pencil the drive gear tooth (3)
installed in the crackshaft (2) with (→) indicating the
side syncronism.
STEP 96
Turn the cranckshaft (4) and the camshaft (1) in order
that installing the driven gear (2) over the camshaft the
marks of the gears (2 and 3) be aligned.
STEP 97
Install the screws (1) of gear (2) to the camshaft (3)
and tight using the torque specifications.

2002-114
Engine Flywell Housing

STEP 98
Fully clean the mating surfaces of the engine flywheel
housing and the timing gear cover. A satisfactorily
sealing is obtained only through a clean surface. Apply
a fillet of few milimeter of diameter LOCTITE 5205 to
the timing gear cover. Must be of uniform size, without
air bubbles, gaps or thin areas. Any imperfection must
be corrected immediately. Avoid the use of excessive
seal that can drain through the gasket and clog the
lubrication passages. Install the gasket within 10-20
minutes after the application.
Seal application area in the engine flywheel housing
STEP 99
Install again the housing in the engine block, install the
screws the same position of remotion. Tight with the
torque values indicated below, and in the numerical
sequence indicated in the side picture.
• Screws M2: 75 to 95 Nm (55 to 70 lbf ft.)

• Screws M10: 32 to 53 Nm (32 to 39 lbf ft.)
Tighteness sequence to the engine flywheel housing
screws.
STEP 100
Install the 380000664 special tool piece (5) over the
cranckshaft rear axle (6), hold with the screws (4) and
press the new seal ring (3).
Place the piece (1) over the piece (5), then tight nut (2)
to fully mount the seal ring (3) in the engine flywheel
housing (7).

2002-115
ENGINE FLYWHEEL
Replacement of the Engine Flywheel Annular Gear
STEP 101
Check the annular gear tooth conditions.
If there is broken or too worn tooths, remove the
annular gear using a appropriated knocker. Install a
new annular gear heated at 150° C (302° F) for 15 to
20 minutes. The annular gear bevel must be turned
to the flywheel.
A. Engines: 667TA/EEG - 667TA/EEC

B. Engines: 667TA/EBF - 667TA/EED -667TA/EDJ
C. Engines: 667TA/EED - 667TA/EBD
STEP 102
Tight two pins (2) with appropriated size in the axle
holes (3), then remove the engine flywheel (1) using
appropriated cables and a pulley
STEP 103
Install the tool (2) (except for engines 667TA/EEG -
667TA/EEC), to the engine flywheel housing (1) avoind
the turning of the flywheel (3).
Tight the flywheel (3) screws (4) to the cranckshaft.
STEP 104
Tight the flywheel (2) screws (1) in two steps:
• 1st step - Tight with a torque of 26 to 34 Nm (19
a 25 lbf ft)
• 2ndt step - Tight with more 60° ± 5°

2002-116
STEP 105
Install the oil pump (1).
Install the screws (2) and tight with the specified torque
of 20 to 30 Nm (14.8 to 22.1 lb.-ft).
STEP 106
Install a new seal ring (2) to the water pump (1).
STEP 107
Install the water pump (1).
of 20 to 30 Nm (14.8 to 22.1 lb.-ft).
STEP 108
Remove the seal ring (2) from the front cover (1), fully
clean the surfaces and apply Loctite 5205.

2002-117
STEP 109
Fully clean the front cover (2) and install it with the
screws (1). Tight with the specified torque of 20 to 30
Nm (14.8 to 22.1 lb.-ft).
STEP 110
Install the special tool 80000666 (5) over the
cranckshaft front axle (6), hold with the screws (4) and
press the new seal ring (3). Place the piece (1) over
the piece (5), then tight the nut (2) to fully mount the
seal ring (3) in the front cover (7).
STEP 111
Only for engines 667TA/EED-/EBD-/EDJ.
Install the plate (3) and the suction strainer (5), then
install the screws (1, 2, 4), and tight with the specified
torque.
STEP 112
Install the gasket in the cast iron oil sump (1). Install
the screws and tight with the specified torque in the
page 22.

2002-118
STEP 113
Only for engines 667TA/EEG- /EEC- /EBF- /EED.
Install the plate (3), the suction strainer (1) and tight
the screws (2).
STEP 114
Place the gasket (1) in the cast iron oil sump (2).
STEP 115
Intall the oil sump (1) and place the aluminun plate (3)
to it. Install the screws (2) and tight with the specified
torque.
STEP 116
Install the phonic wheel (1) and the cube (2)in the
cranckshaft.
Tight the screws in two steps:
• 1st step - using a torquemeter tight with a torque
of 45 to 55Nm (33 to 40 lbf ft)
• 2ndt step - using a goniometer (4) tight more 90°.
Install the engine flywheel damper (5) and the pulley
(6). Install the screws (7) and tight with a torque of 61
to 75 Nm (45 to 55 lbf ft).

2002-119
STEP 117
Install a new seal ring over the cranckshaft sensor
(3).
Install the cranckshaft sensor (3) over the front cover
(1) and tight the screws (2) with the specified torque.
STEP 118
Install the followin items over the engine block: a new
gasket (1), the heat exchanger (2), a new gasket (3),
and the oil filter support (4).
of 20 to 30 Nm (14.8 to 22.1 lb.-ft).
STEP 119
Lubricate the seal ring (2) with engine oil and place it
over the oil filter (3).
Install the oil filter (3) over its support (1) until the
gasket lean the support, then turn it more 3/4 turn
(except for engines 667TA/EEG e 667TAEEC).
Install a new seal ring over the oil pressure and
temperature sensor (4) and install it over the oil filter
support (1).
Tight the screws (5) with the specified torque of 20
Nm (14.8 lb.-ft). Install a new seal ring (6) in its engine
block housing.
STEP 120
Place the alternator support (1) in order that its pins
(3) lean agaist the engine block.
Tight the screws (2) with the specified torque of 40 to
50 Nm (29.5 to 36.9 lb.-ft).

2002-120
STEP 121
Connecte again the alternator (1) and tight the screws
with the specified torque of 40 to 50 Nm (29.5 to 36.9
lb.-ft).
Connecte again the automatic belt tensor (4) and tight
the screws (3) with the specified torque of 40 to 50
Nm (29.5 to 36.9lb.-ft).
Turn the automatic belt tensor (4) in order to install the
belt (2) over the pulleys and guide rollers.
STEP 122
Install the high pressure pump (4) including the
supply pump (5) and tight the nuts with the specified
torque. Install the support (3) with a new seal ring, the
syncronism sensor (2) with a new seal ring, tight the
nuts (1) with the specified torque in page 22.
STEP 123
Instale a unidade de controle eletrônico EDC7UC31
(3), inclusive o trocador de calor, ao bloco do motor
e aperte os parafusos (2), ao torque especificado na
página 22.
IMPORTANTE: Substitua os elementos do amortecedor
de vibrações (1).

2002-121
CYLINDER HEAD
Valve Remotion
STEP 124
The intake valve heads (1) and exhaust (2) has the
same diameter.
The central slot (→) in the exhaust valve head makes
it different compared with the intake valve.
IMPORTANT: If is not necessary replace the cylynder
head valves, number it before the remotion in order to
be installed in the same position.
A = Intake side
S = exhaust side
STEP 125
The valves can be removed using a valve string
compressor (1), pressing slightly the collar (3) in order
that the cones (2) can be removed as the strings (4)
are compressed repeat the operation for all valves.
Turn the cylinder head upside down and remove the
valves (5).
STEP 126
Remove the seal rings (1 and 2) from the valves
guides.
IMPORTANT: The intake valves seal rings (1) are
yellow.
The exhaust valve seal rings (2) are green.

2002-122
Cylinder Head Water Sealing Check

STEP 127
Check the water seal using a appropriated equipment.
Use a pump to supply 90° C (194° F) heated water in
a pressure of 2 to 3 bar (29 to 43 psi.).
If plugs leaks are detected, replace the plugs using
a appropriated knocker for installation and remotion
operations.
IMPORTANT: Before intalling the plugs, apply a water
repellent seal in.
If are detected cylinder head leaks, it must be
replaced.
Cylinder Head Contact Surface Sealing

STEP 128
The cylinder head plane area (1) wich contacts the
engine block is checked using a ruller (2) and a feeler
gauge (3).
The twist found in the entire cylinder head lenght must
be lower than 0.20mm (.0.008 in).
If bigger value are found, rectify the cylinder head
accordin with the values provided in the next step.
STEP 129
The nominal cylinder head thickness “A” is 105 ±
0.25mm (4.134 ± 0.0099 in). The maximum material
remotion must not exceed the thickness “B” by 49,100
kg (108,020 lb).
IMPORTANT: After the rectification, check the valve
sinking. If necessary rectifies again the valve seats to
obtain the specified value.

2002-123
VALVES
Intake and exhaust valve main data.
Cleaning, Checking and Valve Rectification

STEP 130
Remove the valve carbon deposits using a special
metal brush.
Check if the valves shows deformation traces,
scretches or crackings.
Rectify if necessary the valve seats, removing the
minimum possible material.
STEP 131
Use a micrometer (2) to measure the valve steam
(1), wich must be 6.97 to 6.99 mm (0.2744 to 0.2751
in.).
Assembling Clearance Checking and Valve Centralization

STEP 132
Use a comparator with magnetic bases (1), placed
as shown. The assembly clearance must be 0.039 to
0.079 mm (0.0015 to 0.0031 in.).
Turn the valve (2) and check if the centralization error
do not exceeds 0.03 mm (0.0011 in).

2002-124
VALVE GUIDES
STEP 133
Use a cylinder hole calibration to measure the valve
guide inner diameter, that must be 7.042 to 7.062 mm
(0.2772 to 0.2780 in.).

2002-125
VALVE SEATS
Cylinder Head Valve Seat Main Data
STEP 134
Check the valve seats (2). If light scretches or burrs
are found, rectify the seats with the tool (1), according
with the angle values shown in the picture above.

2002-126
Cylinder Head Valve Seat Main Data
STEP 135
If the valve seats can not be recovered by rectification,
replace it by spare parts. Use the tool (1, in step 134,
previous page) to remove as mutch possible material
from the seats (taking care to not make damages in
the cylinder head), and then taking the old seat out
using a punch.
Heat the cylinder head 80° to 100° C (176° to 212°
F), and using an appropriate knocker install the new
seats (also previouslly cooled) in the heated cylinder
head.
Refurbish the valve seats with the tool (1 in the 134
previous step), according with the values in the picture
above.
STEP 136
After reconditioning operatios check with a display
gauge (1) with base (2) if the seat depth (3)
corresponds to the specified value.

2002-127
VALVE SPRINGS
Main Data Check of Intake and Exhaust Valve Springs
Height (mm) Under a load of: (Nm)

H 47.75 Free
H1 35.33 P 339.8 ± 9 N
H2 25.20 P2 741 ± 39 N

2002-128
CYLINDER HEAD
STEP 139
Place the spring (4) and the upper collar (3) in cylinder
head. Use the tool (1) to compress the spring (4) and
lock the pieces to the valves using the cones (2).
STEP 138
Lubricate valve steam (1) and insert it in the respective
guide according with the position marked during the
disassembly.
Install the seal rings (2 and 3) in the valve guides.
IMPORTANT: The intake valve seal rings (2) are
yellow. The exhaust valve seal rings (3) are green.

2002-129
Cylinder Head Installation

STEP 140
Make shure that the mating surfaces between engine
block and cylinder head are clean.
Take care to not damage the cylinder head gasket.
Place the cylinder head gasket (1) with the word “TOP”
turned to cylinder head.
The arrow indicates the point where the gasket
thicknes is located.
IMPORTANT: Before reuse the cylinder head
screws, make shure that it do not shows wear traces,
deformation or corrosion. In positive case replace it.
STEP 141
Install the cylinder head (1), and the screws (2), and
tight the screws in three successive steps, according
with the procedure shown in next picure (step 142).
STEP 142
Cylinder head screws tightness sequence:
• 1st step: Pre-tight using a torqueme ter
- Screw 12 x 1.75 x 130 mm (1): 30 - 40 Nm (22 - 30 lbf ft.)
- Screw 12 x 1.75 x 150 mm (2): 50 - 60 Nm (37 - 44 lbf ft.)
• 2ndt step: Angular tight: 90° ± 5°- with tool (3)
• 3rd step: Angular tight: 90° ± 5°- with tool (3)
1. Not shaded screws: 12X1.75X130 mm

2. Shaded screws: 12X1.75X150 mm
A. Front

2002-130
Injectors Installation
STEP 143
Install a new seal ring (2) lubricated with vaseline and
a new seal washer (3) in the injector (1).
STEP 144
Install the injectors (1) in the cylinder head seats,
directed in order that the fuel entrance hole (2) be
turned to the fuel collector seat side (3).
STEP 145
Use the 380001099 speial tool (1) to install the injector
(2) in its seat.
Screw the injectors screws without tight it.
STEP 146
Install a new seal ring (3) lubricated with vaseline in
the fuel collector (2) and install the fuel collector in the
cylinder head seat in order that the positioning sphere
(5) be aligned with the housing slot (4).
IMPORTANT: The disassembled fuel collectors (2)
must not be reused, and need to be replaced by a
new ones.
IMPORTANT: During this operation, the injector
(1) must be moved in order that the collector (2) be
correctly inserted in the fuel entrance hole.

2002-131
STEP 147
Use a torquemeter to gradually and alternatively tight
the injector screws with a torque of 7.7 - 9.3 Nm (5.7
- 6.9 lbf ft).
Screw the nuts (2) over the fuel collector (3) without
lock it.
Tight the fuel collector nuts (2) with a torque of 50 Nm
(36.9 lbf ft).
Pushrods and Tappets

STEP 148
The rocker control pushrods must not be warped. The
spheres seats in contact with the rocker adjusting
screw and tappets (arrows) must not present binding
or wear traces. In positive case replace it. The control
pushrods of intake and exhaust valve are identical and
therefore interchangeable.

2002-132
Rocker Set
Parts that form the rocker set:
1. Screws
2. Support
3. Axle
4. Rocker
STEP 149
Make shure that the coupling surfaces between axle
and rocker do not shows excessive wear or any other
damage.
Axle-rocker main data
STEP 150
Install the pushrods (2).
Place the bridges (1) over the valves with the marks
(→) turned to the exhaust manifold.
STEP 151
Make shure that the tappets adjusters (1) are not
loosen to avoid this interference over the pushrods
(2) during the rocker set installation.
Then install the rocker set formed by: support (5),
rockers (3), axles (4), and lock it to the cylinder head,
tight the screws (2) with the specified torque of 36 Nm
(26.5 lbf ft).

2002-133
Locating the Top Dead Center (TDC)

IMPORTANT: Due the EGR aditional lobe, each
cylinder must be adjusted leading it to the TDC, and
adjusting both valves of each cylinder.
STEP 152
• Remove the cylinder one injector.
• Turn the engine using the 380000988 special
tool to lead the cylinder one to a highest point,
using a indicator gauge. Check if the pushrods
are loosen. If not turn the engine 360º. Now the
pushrods must be loosen.
• Make a reference mark over the phonic wheel (1)
and engine block (2).
1. Cylinder block
2. Phonic wheel
STEP 153
Measure the phonic wheel circunference and divide
it by 3. Starting by the phonic wheel reference mark
made in step 152, make the others two calculated
marks.

2002-134
Valve Clearance Adjust

STEP 154
Adjust the clearance between the rockers and valves
using a Allen tools kit (1), a wrench tool (3) and a
feeler gauge (2).
The operation clearance will be the following:
• Intake valves: 0.20 - 0.30 mm (0.008 - 0.012 in.)
• Exhaust valves: 0.46 - 0.56 mm (0.18 - 0.022 in.)
NOTE: Firing order (1- 5- 3- 6- 2- 4)
• Adjust the cylinder 1 valves.
• Turn to the next reference mark and adjust the
valve clearrance of cylinder 5.
valve clearrance of cylinder 3. Now you made a
whole turn in phonic wheel
valve clearrance of cylinder 4. Shoul have been
made two complete turns in the phonic wheel and
all valves been adjusted.
• Install the injector number 1 again.
STEP 155
Apply LOCTITE 5999 to the intake manifold (1) contact
surfaces and install the manifold and heater to the
cylinder head.
of 20 to 30 Nm (14.8 to 22.1 lb.-ft).
Install the air intake (4) with a new gasket (5) and tight
the screws (3) with the specified torque in page 22.
The picture on the left shows the air intake for engines
667TA/EEG - 667TA/EEC.

2002-135
STEP 156
Install the rail (2) and tight the screws (1) with the
specified torque. Connect the earth cable (3) to the
intake manifold (4) and tight the nut (5) with the
specified torque of 20 to 30 Nm (14.8 to 22.1 lb.- ft).
STEP 157
Connect new fuel lines (1) to rail (3) and injectors
collectors (2).
IMPORTANT: Every time that the fuel lines (1) is
removed, it must be replaced by new ones
STEP 158
Connect the fuel line (4) to rail (2) following the
procedure shown in the next step (157).
IMPORTANT: The fuel line connections (4) must be
tighted with a torque of 20 Nm (14.8 lb.-ft), using a
correct wrench tool and torquemeter 380000158 (3).
STEP 159
Press the loop (1) in the arrow direction (B) and
connect the line to rail (2) (picture of step 158). Adjust
again the loop to the initial lock position (A).
IMPORTANT: Check if the ful line connection is
correct.

2002-136
STEP 160
Check the efficiency of the wiring harness (5) and
replace it if damage, cutting off the supports loop (2)
and removing the screws (4) that makes it locked
in the connectors (3). Install a new gasket (1) in the
support (2).
STEP 161
Install the wiring support (2) and tight the screws (1)
with the specified torque.
STEP 162
Connect the electrical cables (1) to injectors (3) using
the 380000158 special tool and torquemeter (4), then
tight the nuts with the specified torque.
STEP 163
Install a new gasket (2) in the tappet cover (1).

2002-137
STEP 164
Install the tappet cover (1) and tight the nuts (2) with
the specified torque of 20 to 30 Nm (14.8 to 22.1 lb.-
ft).
STEP 165
Install the exhaust manifold (6) again with a new
gasket. Install the screws (5) and tight with the
specified torque of 48 to 58 Nm (35,4 to 42.8 lb.-ft).
Install the turbocharger (1) to the exhaust manifold
(6) with a new gasket and tight the nuts (7) with the
specified torque of 20 to 30 Nm (14.8 to 22.1 lb.-ft).
Connect the line (2) to the turbocharger (1)support
(3).
Connect the oil line (4) to the exchanger heat
support.
STEP 166
Connect the air duct (2) to the turbocharger (3) and
lock it with the loop (1).
STEP 167
Insert the blow-by filter (4) tighting the screws.
Connect the line (6) and install the oil vapour recover
line with the loop (5).
Connect the line (2) to the pressure limiter device (1)
as shown in picture below (step 166).

2002-138
STEP 168
Press the loop (1) in direction to the arrow (B) and
onnect the line. Adjust the loop again to the inicial
lock position (A).
I M P O R TA N T : C h e c k t h e c o r r e c t f u e l l i n e
connection.

2002-139
Wiring Harness Connection to Engine

STEP 169
1. Electroinjectors connection 7. Pressure and temperature sensor

2. Coolant temperature sensor 8. Camshaft sensor
3. Common rail fuel pressure sensor 9. Heater temperature sensor
4. Oil pressure and temperature sensor 10. High pressure regulator
5. Cranckshaft sensor 11. EDC7UC31 Control Unit
6. Electroinjector
Install again the engine harness connecting the electroinjectors (6) wiring connectors (1), the air pressure and
temperature sensor (7), the common rail pressure sensor (3), the EDC7UC31 Control Unit (11), the high pressure
pump sensor (10), the camshaft sensor (8), the coolant temperature sensor in thermostat (2) and the crackshaft
sensor (5).
Install the lifting hooks, hook the engine in a pulley and separate it from the support. Remove the support.

2002-140
STEP 170
Complete the engine installation as follows:
From the rigth side:
• Install the starter (5) to the engine flywheel housing
(4) and tight the nuts with the specification torque
of 50 to 60 Nm (36.9 to 44.3 lb.-ft).
• Install the oil line (3) with a new seal ring in the engine
block and mount it in the turbocharger (1) with the
screws (2), and tight the screws with the specified
torque of 20 to 30 Nm (14.8 to 22.1 lb.-ft).
STEP 171
Install the support (2) including the fuel filter support
(1) to the engine block, and tight the screws (3) with
the specified torque in page 22.
STEP 172
Screw by hand the fuel filter to the support (1). Tight
the fuel filter until the gasket lean in support, then tight
it more 3/4 turn. Connecte the fuel lines (2, 3, 4) to the
connections of the appropriate support (1) as shown
in the next picture (step 171).
STEP 173
Press the loop (1) as shown in picture B.
After connect the lines readjust the loop (1) to the initial
lock position (A), to avoid deformations.
NOTE: After complete the installation, fill up the engine
with the correct lubricant oil.

2002-141
STARTER
Manufacturer - BOSCH - 24 Volt - 4kW
For engines: 667TA/EEG-667TA/EEC
Manufacturer - ISKRA - 24 Volt - 4kW

For engines: 667TA/EBF - 667TA/EED
Manufacturer - Denso - 24 Volt - 7.8kW

For engines: 667TA/EDJ
Quick Diagnosys
FAIL POSSIBLE CAUSES SOLUTION
1. Discharged batteries Charge or replace the batteries
2. Circuit connectios loose or oxidized Replace the component
3. Damaged or worn brushes Replace the component
Insufficient start torque
4. Fiel coil with short circuit Replace the component
5. Armor with open circuit or short circuit Replace the component
6. Oval bushings Replace the component
Start torque sufficient but Starter turns free or fail in the coupling
Replace the component
engine does not run solenoid
Pinion do not gear Conicity in the flywheel gear Restore the flywheel gear

2002-142
Starter Bosch 24 Volts – 4KW

6 poles with excitation series and gear through fork
controlled by electromagnet.
• Counterwise sense
• Nominal tension - 24 Volts
• Power - 4 kW
Wiring diagram
Curves
3/4 View
Pinion adjustment

2002-143
Starter Iskra 24 Volts – 4KW

Gear fork activated by electromagnet
• Clockwise sense.
• Nominal tension - 24 volts
• Power - 4kW
Wiring diagram
3/4 View
Starter Denso 24 Volts – 7,8KW

There is no information about this starter so far.
Used in 667TA/EDJ engine.

2002-144
ALTERNATOR
Manufacturer - BOSCH
Part number - NCBI 28 V 35-70 A
For engines:
• 667TA/EEG
• 667TA/EEC
• 667TA/EDJ
Quick Diagnosys
FAIL POSSIBLE CAUSES SOLUTION
1. Recharge circuit opened (warning light, Check the recharge connections circuit.
fuse, connector, etc) Clean and tight the alternator and battery
cables terminal
Do not charge 2. Tension regulator do not work Replace the component
3. Rotor winding opened Replace the component
4. Worn brushes Replace the component
1. Belt loose Inspect the automatic belt tensioner
2. Defective tension regulator Replace the component
3. Excessive worn of the collector rings or Replace the component
Insufficient charge
brushes
4. Diodes with short circuit Replace the component
5. Rotor windings with short circuit Replace the component
1. Circuit connections looses Check the starter and alternator terminals
connections, and battery cable terminals
Excessive recharge
2. Tension regulator do not work
3. Defective earth Check earth connections

2002-145
Bosch: NCBI 28 Volt 35-70 AMP

Three phases, rotor claws type, 11 rectified diodes and electronic tension regulator.
Clockwise sense (seen by controlator side)

Provided current 6.000 min-1 >= 55 amps
Nominal tension- 28.5 volts
WIRING DIAGRAM 3/4 VIEW
TENSION REGULATOR CURVES

2002-146
Starter Remotion
STEP 1
Place identification labels in the positive cables and
remove it from the starter.
STEP 2
Remove the earth cable from the starter, the screws
and the starter.

2002-147
Starter Installation
STEP 3
Apply Loctite 747 in the studs and nuts.
Apply two drops of Loctite 271 in each hole and each
stud. Install the studs immediately, with torque of 19
to 29 Nm (14 to 21 lbs-ft).
Before install the starter, let the adhesive cure during
20 minutes.
1. Studs
2. Nuts
STEP 4
Place the engine. Hold the cable in the lower stud (2)
and install the nut. Hold the earth cable and wire in
the upper stud (1) and install the nut.
In the three nuts apply a torque of 40 to 50 Nm (29
to 37 lbs-ft).
STEP 5
Install the wirings in the starter solenoid an tight it.
Remove the labels.

2002-148
Alternator Remotion
STEP 1
Disconnect the alternator wiring.
STEP 2
Remove the four screws of the belt protection. Remove
the protection.
STEP 3
Use a tool to move the belt tensor and ease the belt
tension. Remove the belt.

2002-149
STEP 4
Remove the alternator screws and the alternator.

2002-150
Alternator Installation
STEP 5
Place the alternator over the engine, instal the
alternator screws and tight it.
STEP 6
Use a tool to ease the belt tensor. Install the belt.
NOTE: The instrutions to place the belt are in the belt
protection.
STEP 7
Install the belt protection tighting the four protection
screws.

2002-151
STEP 8
Plug the alternator wiring and place therubber cap
over the positive pole.

2002-152
Belt Installation
WITHOUT AIRCONDITIONING
WITH AIRCONDITIONING

Section
2003
2003
CHARGE AIR COOLER SYSTEM

2003-2
TABLE OF CONTENTS
CHARGE AIR COOLER SYSTEM.................................................................................................................................................3
Specifications..........................................................................................................................................................................3
Removal of the Air Cooler to Turbocharger Outlet Piping........................................................................................................4
Air Inlet to Cooler Pipe Removal.............................................................................................................................................5
Air Cooler Removal.................................................................................................................................................................6
Air Cooler Assembly................................................................................................................................................................7
Assembly of Air Cooler Outlet to Turbocharger Pipe...............................................................................................................7
Cooler Air Inlet Pipe Assembly................................................................................................................................................8

2003-3
CHARGE AIR COOLER SYSTEM

Specifications
Make / Model . ................................................................................................................................................................... DENSO
Type . .................................................................................... Air to air; aluminum herringbone tube and fin; cast aluminum tanks
Core Size . ............................................................................................................ 27.6 High x 8.3 wide x 5.7 (700 x 211.2 x 144 )
Core Description
Rows . ..................................................................................................................................................................................... 2
Tube spacing ........................................................................................................................................................... 10 per row
Fin spacing ...................................................................................................................................................... 13 fins per inch

2003-4
Removal of the Air Cooler to Turbocharger Outlet Piping

1. Remove clamps (A)
2. Remove hose (B)
3. Remove bolt (C) and remove clamp (D)
4. Remove clamps (F) then remove tube (E) and hose

(G).

2003-5
Air Inlet to Cooler Pipe Removal

1. Remove clamps (1)
2. Remove hose (2)
3. Remove clamps (3)

4. Remove hose (4)
5. Remove tube (5)
6. Remove bolts (6)

7. Remove tube (7)
8. Remove gasket (8)

2003-6
Air Cooler Removal

1. Remove top bolts (9)
2. Remove bottom bolts (10)

2003-7
Air Cooler Assembly

1. Place air cooler in the correct position.
2. Fit top bolts (9) and torque to 2,8 kfg.
3. Fit bottom bolts (10) and torque to 2,8 kfg.
Assembly of Air Cooler Outlet to Turbocharger Pipe

1. Fit hose (B) to the cooler outlet opening. Then fit clamps
(A) in place and fit tube (E) to hose (B).
Adjust clamps until the clamp springs are fully compres-
sed.
2. Fit hose (A) to tube (E). Then fit hoses (F) in place and
fit hose (G) to the turbocharger inlet tube.
Ajust clamps until the clamp springs are fully compres-
sed.

2003-8
Cooler Air Inlet Pipe Assembly

1. Fit hose (2) to the cooler inlet opening. Then fit clamps
(1) in place and fit tube (5).
sed.
2. Fit hose (4) to tube (5). Then fit clamps (3) in place and
fit tube (7).
sed.
3. Fit gasket (4) between tube (7) and engine cover. Then
fit bolts (6) in place and torque to 2,8 kgf.
4. Fit clamp (d) in place and torque bolts (C) to 2,8 kgf.

SECTION INDEX
Fuel System
Fuel System ........................................................................................................................................................................... 3001

3001
Section
3001
FUEL SYSTEM

3001-2
TABLE OF CONTENTS
FUEL SYSTEM...............................................................................................................................................................................3

3001-3
FUEL SYSTEM
For Fuel System Repair, See the Engine Service Manual

3001-4
NOTES

SECTION INDEX
Electrical
Removal and Installation of Starter and Alternator . ............................................................................................................... 4001
Electrical Diagram – Without All Wheel Drive System . .......................................................................................................... 4002
Electrical Diagram– With All Wheel Drive System . ................................................................................................................ 4003
Battery .................................................................................................................................................................................... 4004

4001
Section
4001
REMOVAL AND INSTALLATION

OF STARTER AND ALTERNATOR

4001-2
TABLE OF CONTENTS
STARTER.......................................................................................................................................................................................3
Removal..................................................................................................................................................................................3
Installation...............................................................................................................................................................................3

4001-3
STARTER
Removal Installation
NOTE: The starter is located on the left side of the engine, 1. Install the starter (1),and bolts (2) to the machine. Tor-
mounted to the engine flywheel housing. que the bolt (2) to 41 to 74 Nm (30 to 54 pound-feet).
1. Turn the master disconnect switch to the OFF position. 2. Install the positive cables.
2. Remove the air cleaner and the air cleaner bracket.
3. Move the cover to gain access to the bolt (2). Refer to
the illustration below.
FIGURE 1 GR4001001A
STARTER REMOVAL AND INSTALLATION
1. Starter
2. Bolt

4001-4
ALTERNATOR 80 A
Removal Installation
1. Turn the master disconnect switch to the OFF position. 1. Install the alternator(10),on the machine. Torque the
bolt (2) to 60 to 104 Nm (2) to 60 to 104 Nm (42.5 to
2. Use a wrench to move the belt tensioner and loosen
76 pound-feet). Refer to the illustration on the following
the tension on the belt . Refer to the illustration on the
page.
following page.
2. Install the washer (12), And (13) and bolt (2). Torque the
3. Remove the belt.
bolt to 60 to 104 Nm (42.5 to 76) pound-feet).
4. Remove the boots.
3. Use a wrench to move the belt tensioner until the belt
5. Tag and disconnect wires (14) and (15) from from the can be installed.
alternator.
4. Install the belt .
6. Remove the bolt (2),and washer (12) and (13) from the
5. Install the wire, lockwasher and nut to the alternator’s
support bracket (1) and the alternator (10).
D+ terminal. Torque the nut to 3.5 to 3.9 Nm (2.6 to 2.9
7. Remove the alternator (10) and shield from the. ma- pound-feet).
chine.
6. Install the boot.
7. Install the wire, lockwasher and nut to the alternator’s
B+ terminal. Torque the nut to 15 to 27 Nm (11 to 20
pound-feet).
8. Install the boot.
9. Turn the master disconnect switch to the ON position..

4001-5
FIGURE 2 GR4001002A
ALTERNATOR 80 A REMOVAL AND INSTALLATION
1. Support 6. Washer 11. Washer

2. Screw 7. Screw 12. Washer
3. Screw 8. Bushing 13. Lockwasher
4. Plate 9. Nut 14. Wire
5. Screw 10. Alternator 15. Wire

4001-6
NOTES

Section
4002
4002
ELECTRICAL DIAGRAM
845B / 845B DHP /
865B / 865B VHP /
885B / 885B DHP
Models
Without ALL WHEEL DRIVE SYSTEM

4002-2
TABLE OF CONTENTS
COMPONENTS LIST.....................................................................................................................................................................3
ELECTRIC DIAGRAMS..................................................................................................................................................................9
Diagram 2 – Sheet 3 (Models with Tier 3 Engines)...............................................................................................................10
Diagram 3 – Sheet 4..............................................................................................................................................................11
Diagram 4 – Sheet 5..............................................................................................................................................................12
Diagram 5 – Sheet 6..............................................................................................................................................................13
Diagram 6 – Sheet 7..............................................................................................................................................................14
Diagram 7 – Sheet 8..............................................................................................................................................................15
Diagram 8 – Sheet 9 (Models with ZF Transmission)............................................................................................................16
Diagram 9 – Sheet 9a (Models with FUNK Transmission)....................................................................................................17
Diagram 10 – Sheet 10..........................................................................................................................................................18
Diagram 11 – Sheet 11..........................................................................................................................................................19
Diagram 12 – Sheet 12..........................................................................................................................................................20
Diagram 13 – Sheet 13..........................................................................................................................................................21
Diagram 14 – Sheet 14..........................................................................................................................................................22
Diagram 15 – Sheet 15..........................................................................................................................................................23
Diagram 16 – Sheet 16..........................................................................................................................................................24
Diagram 17 – Sheet 17..........................................................................................................................................................25
Diagram 18 – Sheet 18..........................................................................................................................................................26
Diagram 19 – Sheet 19..........................................................................................................................................................27
Diagram 20 – Sheet 20..........................................................................................................................................................28
Diagram 21 – Sheet 21 (Models with ZF Transmission)........................................................................................................29
Diagram 22 – Sheet 22..........................................................................................................................................................30
Diagram 23 – Sheet 23 (Models with Tier 3 Engines)...........................................................................................................31
Diagram 24 – Sheet 24 (Models with Tier 3 Engines)...........................................................................................................32
Diagram 25 – Sheet 25 (Models with FUNK Transmission)..................................................................................................33
Diagram 26 – Sheet 26..........................................................................................................................................................34
Diagram 27 – Sheet 31..........................................................................................................................................................35

4002-3
COMPONENTS LIST
NAME DESCRIPTION SHEET
AE ELECTRIC ACCELERATOR 23-6
AEB TRANSMISSION ZF TOOL CONNECTOR 21-2
AIC ADV. INSTRUMENT CLUSTER 9-6 / 9a-6
AT AERIAL, ANTENNA FOR RADIO 22-3
CB1 CIRCUIT BREAKER 105 AMP 2-3 / 3-4
CI1 CYLINDER INJECTOR 1 (ELECTROVALVE) 24-6
D1 DIODE TO ENGINE SHUT–OFF SOLENOID VALVE (PULL) 2-5
D2 DIODE TO ENGINE SHUT–OFF SOLENOID VALVE (HOLD) 2-6
D6 DIODE, PARKING BRAKE SIGNAL TO START RELAY (ZF) 21-7
D8 DIODE TO ON–OFF FAN DRIVE SYSTEM – OPT. 14-4
D12 DIODE TO ELECTRIC MASTER SWITCH (ACC) 2-5 / 3-5
D13 DIODE TO ELECTRIC MASTER SWITCH (IGN) 2-5 / 3-5
DB1 DIODE BOX FOR TURN SIGNAL 6-3
DB2 DIODE BOX FOR WIPERS AND DEFROSTER FANS 17-4
DR DIODE AND RESISTOR BOX FOR PARKING BRAKE SIGNAL AND COME–HOME (FUNK) 25-7 / 25-8
ECA FUSE BOX ON LATERAL CONSOLE 32 e 33
ECB FUSE AND RELAY BOX ON LATERAL CONSOLE 32 e 33
ECC FUSE AND RELAY BOX ON LATERAL CONSOLE 32 e 33
ECD FUSE AND RELAY BOX ON LATERAL CONSOLE 32 e 33
ECE FUSE AND RELAY BOX ON FRONT CONSOLE 34
EDC7 ENGINE DATA CONTROL ON LATERAL CONSOLE 23 e 24
EM ELECTRIC MAGNETIC CLUTCH FOR A/C 19-1
EV1 SOLENOID TO ELECTRICAL ENGINE SHUT–OFF 2-6
EV2 DIFFERENTIAL LOCK SOLENOID VALVE (OPT.) 11-1
EV3 STARTING AID SOLENOID VALVE (ETHER) – MECHANICAL ENGINE ONLY (OPT.) 16-2
EV4 SADDLE LOCK PIN SOLENOID VALVE 11-5
EV5 RIPPER OR SCARIFIER SOLENOID VALVE LEFT (OPT.) 15-2
EV7 RIPPER OR SCARIFIER SOLENOID VALVE RIGHT (OPT.)
EV8 RIPPER OR SCARIFIER SOLENOID VALVE RIGHT (OPT.) 15-6
EV9 MOLD BOARD FLOAT SOLENOID VALVE LEFT (OPT.) 12-2
EV11 MOLD BOARD FLOAT SOLENOID VALVE RIGHT (OPT.) 12-5
EV13 LEFT LIFT CYLINDER ANTI–SHOCK SOLENOID VALVE (OPT.) 13-2
EV17 RIGHT LIFT CYLINDER ANTI–SHOCK SOLENOID VALVE (OPT.) 13-5
EV19 FRONT BLADE BOARD FLOAT SOLENOID VALVE (OPT.) 14-1
EV27 FAN DRIVE INVERTER SOLENOID VALVE (OPT.) 11-4
EV28 SOLENOID ON–OFF FAN DRIVE (OPT.) 14-6
EV–LOCK–UP LOCK–UP SOLENOID 21-10
EV–P. BRAKE PARKING BRAKE SOLENOID (ZF ONLY TRANSMISSION) 9-6
EVT1 PROPORTIONAL SOLENOID VALVE 1 – DIRECTIONAL 25-9
EVTA PROPORTIONAL SOLENOID VALVE A – SPEED 25-9
EVTB PROPORTIONAL SOLENOID VALVE B – SPEED 25-10
EVTC PROPORTIONAL SOLENOID VALVE C – SPEED 25-10
EVTD PROPORTIONAL SOLENOID VALVE D – SPEED 25-11
EV–Y1 PROPORTIONAL SOLENOID CLUTCH K4 – ZF 21-10
EV–Y2 PROPORTIONAL SOLENOID CLUTCH KR – ZF 21-11

4002-4
EV–Y5 PROPORTIONAL SOLENOID CLUTCH KV – ZF 21-11
FGH MEGA FUSE 125.0 AMP – GRID HEATER 23-4
FH FUEL FILTER HEATER 3-6
G1 BATTERY 12V – 1010 CCA 2-1 / 3-1
G2 BATTERY 12V – 1010 CCA 2-1 / 3-1
G3 ALTERNATOR 28 VOLTS 90 AMP 2-2 / 3-2
GH GRID HEATER 23-3
H1 RIGHT WORK LIGHT BEFORE MOLD BOARD 5-2
H2 LEFT WORK LIGHT BEFORE MOLD BOARD 5-3
H3 RIGHT WORK LIGHT AFTER MOLD BOARD 5-3
H4 LEFT WORK LIGHT AFTER MOLD BOARD 5-4
H5 FRONT POSITION LIGHT L.H. 6-2
H6 REAR POSITION LIGHT R.H. 6-2
H7 RIGHT SNOW WORK LIGHT 5-5
H8 LEFT SNOW WORK LIGHT 5-6
H9 FRONT TURN SIGNAL LIGHT R.H. CAB. – RESERVE 6-5
H10 REAR TURN SIGNAL LIGHT R.H. 6-5
H11 FRONT TURN SIGNAL LIGHT R.H. 6-5
H12 FRONT TURN SIGNAL LIGHT L.H. 6-4
H13 REAR TURN SIGNAL LIGHT L.H. 6-4
H14 FRONT TURN SIGNAL LIGHT L.H. CAB. – RESERVE 6-4
H16 LEFT HEAD LIGHT (HIGH BEAM) 7-1
H17 RIGHT HEAD LIGHT (HIGH BEAM) 7-2
H18 LEFT HEAD LIGHT (LOW BEAM) 7-2
H19 RIGHT HEAD LIGHT (LOW BEAM) 7-3
H20 FRONT POSITION LIGHT R.H. 7-3
H21 REAR POSITION LIGHT L.H. 7-3
H22 LICENSE PLATE LIGHT (OPT.) 7-4
H27 REAR FLOOD LIGHT R.H. (CAB) 7-6
H28 REAR FLOOD LIGHT L.H. (CAB) 7-6
H29 CAB HEAD LIGHT L.H. (OPT.) 8-1
H30 CAB HEAD LIGHT R.H. (OPT.) 8-2
H31 FRONT BLADE BOARD LIGHT L.H. (OPT.) 8-2
H32 FRONT BLADE BOARD LIGHT R.H. (OPT.) 8-3
H33 BRAKE LIGHT L.H. 8-4
H34 BRAKE LIGHT R.H. 8-4
H40 FRONT RIGHT STROBE LIGHT (OPT.) 16-6
HA1 HORN 6-1
HA2 BUZZER (AIC) 9-3 / 9a-3
HA3 BACK–UP ALARM (OPT.) 8-5
J1–J2–J3 FUNK ECU CONNECTORS 25
J4 FUNK BUMP GEAR SELECTOR 25-3
J6 TRANSMISSION FUNK CONNECTOR 25-8
K15 FLASHER RELAY 6-3
K C1 CONVERTER VOLTAGE 24 TO 12 VOLTS FOR RADIO AND CIGARETTE LIGHTER 22-1
K ECU ELECTRONIC CONTROL UNIT – FUNK TRANSMISSION 25
KFH FUEL FILTER & WATER SEPARATOR HEATER RELAY 3-5
KG2 PULL SOLENOID RELAY – SHUT–OFF 2-4
K IP INCH PEDAL – FUNK TRANSMISSION 25-1
K PT AUXILIARY MAGNETIC SWITCH TO TIRES INFLATOR 22-6
KR RADIO 22-4
KRD REAR WINDOW & SIDE MIRRORS DEFROSTER RELAY 20-2
KRV1 A/C FAN – 1º SPEED RELAY 19-2
KSR STARTER RELAY 3-4
K TCU TRANSMISSION CONTROL UNIT – ZF TRANSMISSION 21
K TVP TRANSIENT VOLTAGE PROTECTION – FUNK TRANSMISSION 25-1
M1 ENGINE START 2-3 / 3-3

4002-5
M2 FRONT WIPER 17-3
M3 FRONT WASHER PUMP 17-4
M4 REAR WIPER 17-6
M5 REAR WASHER PUMP 18-1
M6 FRONT LOWER WASHER PUMP (OPT.) 18-4
M7 FRONT LOWER WIPER (OPT.) 18-2
M8 AIR SUSPENSION SEAT (OPT.) 18-4
M9 DEFROSTER FAN REAR (OPT.) 18-5
M10 DEFROSTER FAN L.H. WINDSHIELD (OPT.) 18-5
M10A DEFROSTER FAN R.H. DOOR (OPT.) 18-6
M11 DAMPER TO AIR CONDITIONER 19-5
MLS MIRROR LEFT SIDE DEFROSTER 20-4
M PT TIRES INFLATOR COMPRESSOR 22-5
MRS MIRROR RIGHT SIDE DEFROSTER 20-4
M.T. EVAPORATOR UNIT (OPT.) AIR CONDITIONER 19-4
PO1 POWER OUTLET 20-5
PRM A POWER RELAY MODULE A – ACC 4-5
PRM B POWER RELAY MODULE B – IGN 4-4
PRM C POWER RELAY MODULE C – ACC 4-3
R3 CIGARETTE LIGHTER 12 VOLTS 22-2
RWDR REAR WINDOW DEFROSTER 20-2
S1 ELECTRIC MASTER SWITCH 2-1 / 3-1
S2 IGNITION SWITCH 4-1
S3 WORK LIGHT BEFORE AND AFTER MOLD BOARD SWITCH 5-2
S4 FLOOD/HEAD LIGHTS, HORN AND TURN SIGNAL SWITCH 6-4
S5 WARNING FLASHER SWITCH 6-3
S6 REAR FLOOD LIGHTS SWITCH 7-5
S7 CAB HEAD & SNOW LIGHT SWITCH (OPT.) 8-1
S8 FRONT BLADE BOARD SWITCH (OPT.) 8-2
S9 BRAKE LIGHT SWITCH 8-4
S10 ENGINE OIL PRESSURE SENSOR AND SWITCH 9-12 / 9a-12
S11 ENGINE COOLANT TEMPERATURE SENSOR 9-2 / 9a-2
S12 KEY–PAD SWITCH 10-4
S14 FUEL SENSOR LEVEL 9-1 / 9a-1
S15 ENGINE COOLANT TEMPERATURE SWITCH 10-2
S16 AIR CLEANER SWITCH 10-4
S17 TRANSMISSION OIL FILTER RESTRICTION SWITCH 9a-11
S18 TRANSMISSION OIL PRESSURE SWITCH 9-10 / 9a-9
S20 HYDRAULIC OIL TEMPERATURE SWITCH 9-2 / 9a-2
S21 BRAKE LOW PRESSURE SWITCH 9-12 / 9a-12
S22a OUTPUT SPEED SENSOR ZF (B4) 21-5
S23 HYDRAULIC OIL FILTER RESTRICTION SWITCH 10-4
S24 DIFFERENTIAL LOCK SWITCH (OPT.) 11-2
S25 STARTING AID SWITCH (ETHER – ONLY FOR MECHANICAL ENGINE) (OPT.) 16-2
S26 SADDLE LOCK PIN SWITCH 11-6
S27 RIPPER OR SCARIFIER SWITCH (OPT.) 15-3
S28 MOLD BOARD FLOAT L.H. SWITCH (OPT.) 12-3
S29 MOLD BOARD FLOAT R.H. SWITCH (OPT.) 12-5
S30 LIFT SHOCK DAMPENER SWITCH (OPT.) 13-3
S31 FRONT BLADE BOARD FLOAT SWITCH (OPT.) 14-1
S32 LEFT CAB DOME LIGHT SWITCH (NEXT TO LEFT DOOR) 16-3
S33 RIGHT CAB DOME LIGHT SWITCH (ABOVE CONSOLE) 16-4
S34 STROBE LIGHT SWITCH (OPT.) 16-5
S35 FRONT WIPER, WASHER PUMP, TIMER SWITCH 17-1
S37 REAR WIPER SWITCH 17-5
S38 REAR WASHER PUMP SWITCH 18-1
S39 FRONT LOWER WIPER AND WASHER SWITCH (OPT.) 18-3
S40 DEFROSTERS FANS SWITCH (OPT.) 18-6
S40a REAR WINDOW AND MIRROR DEFROSTER SWITCH (OPT.) 18-6
S41 HIGH PRESSURE SWITCH TO AIR CONDITIONER SYSTEM (OPT.) 19-2
S42 3 SPEED SWITCH TO FANS AND AIR CONDITIONER SYSTEM (OPT.) 19-3

4002-6
S43 AIR CONDITIONER ON–OFF SWITCH (OPT.) 19-5
S44 MOTOR DAMPER SWITCH TO AIR CONDITIONER SYSTEM (OPT.) 19-4
S47 FUNK BUMP GEAR SELECTOR 25-3
S47a ZF BUMP GEAR SELECTOR 21-8
S48 PARKING BRAKE LEVER HAND SWITCH (FUNK) 21-3
S48a PARKING BRAKE PRESSURE SWITCH (ZF) 21-3
S49 COME–HOME SWITCH (FUNK) 25-10
S50 ENGINE SPEED MAGNETIC PICKUP SENSOR (FUNK) 25-11
S50a ENGINE SPEED MAGNETIC PICKUP SENSOR (ZF - B1) 21-4
S51 OUTPUT SPEED MAGNETIC PICKUP SENSOR (FUNK) 25-11
S51a TURBINE SPEED MAGNETIC PICKUP SENSOR (ZF - B2) 21-4
S52 CYLINDER SPEED MAGNETIC PICKUP SENSOR (FUNK) 25-12
S52a INTERNAL SPEED MAGNETIC PICKUP SENSOR (ZF - B3) 21-4
S53 TEMPERATURE SENSOR – TRANSMISSION FUNK 25-12
S53a TEMPERATURE SENSOR – TRANSMISSION ZF 21-12
S55 FAN DRIVE INVERTER SWITCH 11-3
S58 WATER IN FUEL SENSOR 23-1
S59 CAMSHAFT SENSOR 24-6
S60 RAIL PRESSURE SENSOR 24-6
S61 COOLANT TEMPERATURE SENSOR 24-6
S62 FUEL TEMPERATURE SENSOR 24-6
S63 CRANK SHAFT POSITION SENSOR 24-6
S64 ENGINE OIL PRESSURE/TEMPERATURE SENSOR 24-6
S65 BOOST TEMPERATURE/PRESSURE SENSOR 24-6
S66 TIRES INFLATOR SWITCH 22-6
S67 ON–OFF FAN DRIVE SWITCH (OPT.) 14-4
S68 WATER TEMPERATURE 87 C SWITCH TO ON–OFF FAN DRIVE (OPT.) 14-5
S78 PARKING BRAKE PANEL SWITCH (ZF) 21-6
S79 DECLUTCH SWITCH 21-3
S79a DECLUTCH PRESSURE SWITCH 21-3
S80 TRANSMISSION AUTO/MANUAL SWITCH 21-4
S81 LOCK–UP SWITCH 21-5
S82 TRANSMISSION OIL FILTER RESTRICTION SWITCH 21-7
S83 ENGINE LOAD SENSOR (B6) 21-8
S84 CONVERTER TEMPERATURE SENSOR (B15) 21-7
SP1 SPEAKER L.H. 22-4
SP2 SPEAKER R.H. 22-4
V2 VARISTOR FOR DIFFERENTIAL LOCK SOLENOID VALVE (OPT.) 11-1
V3 VARISTOR FOR STARTING AID SOLENOID VALVE (OPT.) 16-1
V4 VARISTOR FOR SADDLE LOCK PIN SOLENOID VALVE 11-5
V5 VARISTOR FOR RIPPER OR SCARIFIER SOLENOID VALVE LEFT (OPT.) 15-1
V7 VARISTOR FOR RIPPER OR SCARIFIER SOLENOID VALVE RIGHT (OPT.) 15-4
V9 VARISTOR FOR MOLD BOARD FLOAT SOLENOID VALVE L.H. (OPT.) 12-1
V10 VARISTOR FOR MOLD BOARD FLOAT SOLENOID VALVE L.H. (OPT.) 12-3
V11 VARISTOR FOR MOLD BOARD FLOAT SOLENOID VALVE R.H. (OPT.) 12-4
V12 VARISTOR FOR MOLD BOARD FLOAT SOLENOID VALVE R.H. (OPT.) 12-5
V13 VARISTOR FOR LEFT LIFT CYLINDER ANTI–SHOCK SOLENOID VALVE (OPT.) 13-1
V17 VARISTOR FOR RIGHT LIFT CYLINDER ANTI–SHOCK SOLENOID VALVE (OPT.) 13-5
V19 VARISTOR FOR FRONT BLADE BOARD FLOAT SOLENOID VALVE (OPT.) 14-1
V21 VARISTOR FOR MAGNETIC CLUTCH/COMPRESSOR (OPT.) 19-1
V27 VARISTOR FOR SOLENOID FAN DRIVE INVERTER (OPT.) 11-4
V28 VARISTOR FOR SOLENOID ON–OFF FAN DRIVE (OPT.) 14-5
X1 MAIN REAR HARNESS WITH LATERAL CONSOLE 70 WAY CONNECTOR
X1DB MAIN REAR HARNESS WITH LATERAL CONSOLE 1 WAY CONNECTOR EYELET – POWER
X4 MAIN REAR HARNESS WITH FUEL TANK 2 WAY CONNECTOR

4002-7
X6 MAIN REAR HARNESS WITH FRONT CONSOLE 70 WAY CONNECTOR
X7 MAIN REAR HARNESS WITH MAIN FRONT 20 WAY CONNECTOR
X7A MAIN REAR HARNESS WITH FRONT WIPER LOWER, RIPPER/SCARIFIER 6 WAY CONNECTOR
X7a BUMP GEAR SELECTOR ZF 4 WAY CONNECTOR PLUG
X7b BUMP GEAR SELECTOR ZF 4 WAY CONNECTOR RECEPTACLE
X8 MAIN REAR HARNESS WITH ON–OFF FAN DRIVE 2 WAY CONNECTOR
X9 MAIN REAR HARNESS WITH MAGNETIC CLUTCH AIR CONDITIONER, START AID AND ON–OFF FAN DRIVE 3 WAY CONNECTOR
X10 MECHANICAL ENGINE HARNESS WITH ELECTRICAL SHUT–OFF 3 WAY CONNECTOR
X11 MAIN REAR HARNESS WITH REAR LIGHTS AND BACK–UP ALARM 6 WAY CONNECTOR
X12 MAIN REAR HARNESS WITH REAR POSITION LIGHTS 2 WAY CONNECTOR
X13 MAIN REAR HARNESS WITH MECHANICAL ENGINE 20 WAY CONNECTOR – GRAY
X15 MAIN REAR HARNESS WITH AIR CONDITIONER PRESSURE SWITCH AND DIFF. LOCK 6 WAY CONNECTOR
X19 LATERAL CONSOLE HARNESS WITH RADIO POWER AND CAN BUS CAB 6 WAY CONNECTOR
X20 LATERAL CONSOLE HARNESS WITH CAB 20 WAY CONNECTOR – BLACK
X23S/T X23S WITH X23T NORMALY OPERATION FUNK TRANSMISSION AND
X23S WITH X23TA COME–HOME 20 WAY CONNECTOR – GRAY
X23SA/TA X23SA WITH X23TA NORMALY OPERATION FUNK TRANSMISSION AND
X23SA WITH X23T COME–HOME FUNK TRANSMISSION 20 WAY CONNECTOR – GRAY
X24 LATERAL HARNESS WITH AIR CONDITIONER SYSTEM (FANS SPEED) 6 WAY CONNECTOR
X24S DISCONNECTED TO X24T = MAINTENANCE (WELD) 20 WAY CONNECTOR – BLACK
X25
X26 LATERAL HARNESS WITH AIR CONDITIONER SYSTEM 6 WAY CONNECTOR
X27 LATERAL HARNESS WITH AIR CONDITIONER CONTROL 6 WAY CONNECTOR
X27A LATERAL HARNESS WITH AIR CONDITIONER SYSTEM 3 WAY CONNECTOR
X29 ELECTRONIC AND MECHANICAL ENGINE HARNESS WITH HYDRAULIC AND TRANSMISSION SWITCH 6 WAY CONNECTOR
X30 MAIN FRONT HARNESS WITH OPTIONAL LIFT SHOCK DAMPENER 2 WAY CONNECTOR
X31 MAIN FRONT HARNESS WITH OPTIONAL MOLD BOARD FLOAT R.H. AND R.L. 3 WAY CONNECTOR
X32 MAIN FRONT HARNESS WITH OPTIONAL FRONT BLADE BOARD FLOAT 2 WAY CONNECTOR
X36 LATERAL HARNESS 2 WAY CONNECTOR FOR CALIBRATION
X37 LATERAL HARNESS 2 WAY CONNECTOR JUMP FOR CALIBRATION
X38 LATERAL HARNESS 3 WAY CONNECTOR FOR COMPUTER DIAGNOSE FUNK TRANSMISSION
X39 HYDRAULIC SENSOR HARNESS WITH TRANSMISSION FILTER RESTRICTION 1 WAY CONNECTOR
X40 CAB HARNESS WITH REAR LEFT STROBE LIGHT 2 WAY CONNECTOR
X42 LATERAL HARNESS WITH AIR SUSPENSION SEAT OPTIONAL 2 WAY CONNECTOR
X47 MAIN REAR HARNESS WITH ELECTRONIC ENGINE 20 WAY CONNECTOR – GRAY
X52 POWER FOR CONVERTER DIRECT FROM BATTERY 1 WAY CONNECTOR
X53 POWER FOR CONVERTER AFTER IGNTION SWITCH: “IGN” 1 WAY CONNECTOR
X53a POWER FOR CONVERTER 1 WAY CONNECTOR
X64 LATERAL HARNESS – DIAGNOSE TOOL
X65 MAIN REAR HARNESS WITH BRAKE PARTS 5 WAY CONNECTOR MALE TERMINAL
X86 MAIN REAR HARNESS WITH BRAKE PARTS 5 WAY CONNECTOR FEMALE TERMINAL
X86 MAIN REAR HARNESS WITH FAN REVERSE SOLENOID 2 WAY CONNECTOR
X87 MAIN REAR HARNESS WITH PWM SOLENOID (REVERSE) 2 WAY CONNECTOR
XA POWER DERIVATION POINT ON REAR FRAME NEAR TO CAB FLOOR
XAE MAIN REAR HARNESS WITH ELECTRIC ACCELERATOR 6 WAY CONNECTOR
XAEB TRANSMISSION ZF TOOL 6 WAY CONNECTOR
XCAN MAIN REAR HARNESS WITH ENGINE 6 WAY CONNECTOR
XCV LATERAL HARNESS WITH VOLTAGE CONVERTER 24V TO 12 V 6 WAY CONNECTOR
XDIF DIFFERENTIAL LOCK JUMP (USE ONLY WITH ZF TRANSMISSION) 1 WAY CONNECTOR
XDV1 POWER DERIVATION 2 WAY CONNECTOR STUD
XEDC7(A) ENGINE SUPPLIER HARNESS WITH ENGINE EDC 16 WAY CONNECTOR
XEDC7(B) ELECTRONIC ENGINE HARNESS WITH ENGINE EDC 89 WAY CONNECTOR
XEDC7(C) ENGINE SUPPLIER HARNESS WITH ENGINE EDC 36 WAY CONNECTOR
XG1 ELECTRONIC ENGINE HARNESS WITH ENGINE BLOCK (GROUND) 1 WAY CONNECTOR
XJ6 MAIN REAR HARNESS WITH TRANSMISSION HARNESS 31 WAY CONNECTOR
XM LATERAL HARNESS – ENGINE SET–UP 2 WAY CONNECTOR
XME LATERAL HARNESS – ELECTRONIC ENGINE OPTION 2 WAY CONNECTOR
XMM LATERAL HARNESS – MECHANICAL ENGINE OPTION 2 WAY CONNECTOR
XMS MAIN REAR HARNESS WITH MASTER SWITCH 3 WAY CONNECTOR
XPB BRAKE PARTS HARNESS WITH PARKING BRAKE SWITCH 3 WAY CONNECTOR

4002-8
XPS HYDRAULIC SENSOR HARNESS WITH TRANSMISSION OIL PRESSURE SWITCH 2 WAY CONNECTOR
XT7 LATERAL HARNESS WITH TRANSMISSION VOLTAGE PROTECTION (TVP) 6 WAY CONNECTOR
XT9 LATERAL HARNESS WITH PARKING BRAKE SWITCH 3 WAY CONNECTOR
XT11 MAIN REAR HARNESS WITH INCH PEDAL 6 WAY CONNECTOR
XY7 MAIN REAR HARNESS WITH LOCK–UP SOLENOID 2 WAY CONNECTOR
XY7a BRAKE PARTS HARNESS WITH PARKING BRAKE SOLENOID 2 WAY CONNECTOR
XZF LATERAL HARNESS WITH TRANSMISSION ZF ECU 68 WAY CONNECTOR

4002-9
ELECTRIC DIAGRAMS
Diagram 1 – Sheet 2 (Models with Tier 0, Tier 1 e Tier 2 Engines)
FIGURA 1 84154234-2

4002-10
Diagram 2 – Sheet 3 (Models with Tier 3 Engines)
FIGURA 2 84154234-3

4002-11
Diagram 3 – Sheet 4
FIGURA 3 84154234-4

4002-12
FIGURA 4 84154234-5

4002-13
FIGURA 5 84154234-6

4002-14
FIGURA 6 84154234-7

4002-15
FIGURA 7 84154234-8

4002-16
Diagram 8 – Sheet 9 (Models with ZF Transmission)
FIGURA 8 84154234-9

4002-17
Diagram 9 – Sheet 9a (Models with FUNK Transmission)
FIGURA 9 84154234-9a

4002-18
FIGURA 10 84154234-10

4002-19
FIGURA 11 84154234-11

4002-20
FIGURA 12 84154234-12

4002-21
FIGURA 13 84154234-13

4002-22
FIGURA 14 84154234-14

4002-23
FIGURA 15 84154234-15

4002-24
FIGURA 16 84154234-16

4002-25
FIGURA 17 84154234-17

4002-26
FIGURA 18 84154234-18

4002-27
FIGURA 19 84154234-19

4002-28
FIGURA 20 84154234-20

4002-29
Diagram 21 – Sheet 21 (Models with ZF Transmission)
FIGURA 21 84154234-21

4002-30
FIGURA 22 84154234-22

4002-31
FIGURA 23 84154234-23

4002-32
FIGURA 24 84154234-24

4002-33
Diagram 25 – Sheet 25 (Models with FUNK Transmission)
FIGURA 25 84154234-25

4002-34
FIGURA 26 84154234-26

4002-35
FIGURA 27 84154234-31

4002-36
NOTES

Section
4003
4003
ELECTRICAL DIAGRAM
865B AWD / 885B AWD
Models
With ALL WHEEL DRIVE SYSTEM

4003-2
TABLE OF CONTENTS
COMPONENTS LIST.....................................................................................................................................................................3
ELECTRIC DIAGRAMS..................................................................................................................................................................8
Diagram 2 – Sheet 4................................................................................................................................................................9
Diagram 3 – Sheet 5..............................................................................................................................................................10
Diagram 4 – Sheet 6..............................................................................................................................................................11
Diagram 5 – Sheet 7..............................................................................................................................................................12
Diagram 6 – Sheet 8..............................................................................................................................................................13
Diagram 7 – Sheet 9a (Models with FUNK Transmission)....................................................................................................14
Diagram 8 – Sheet 10............................................................................................................................................................15
Diagram 9 – Sheet 11............................................................................................................................................................16
Diagram 10 – Sheet 12..........................................................................................................................................................17
Diagram 11 – Sheet 13..........................................................................................................................................................18
Diagram 12 – Sheet 14..........................................................................................................................................................19
Diagram 13 – Sheet 15..........................................................................................................................................................20
Diagram 14 – Sheet 16..........................................................................................................................................................21
Diagram 15 – Sheet 17..........................................................................................................................................................22
Diagram 16 – Sheet 18..........................................................................................................................................................23
Diagram 17 – Sheet 19..........................................................................................................................................................24
Diagram 18 – Sheet 20..........................................................................................................................................................25
Diagram 19 – Sheet 22..........................................................................................................................................................26
Diagram 20 – Sheet 23..........................................................................................................................................................27
Diagram 21 – Sheet 24..........................................................................................................................................................28
Diagram 22 – Sheet 25 (Models with FUNK Transmission)..................................................................................................29
Diagram 23 – Sheet 26..........................................................................................................................................................30
Diagram 24 – Sheet 31..........................................................................................................................................................31

4003-3
COMPONENTS LIST
AIC ADV. INSTRUMENT CLUSTER 9a-6
AT AERIAL, ANTENNA FOR RADIO 22-3
CB1 CIRCUIT BREAKER 105 AMP 2-3/3-4
D6 DIODE, PARKING BRAKE SIGNAL TO START RELAY (ZF) 21-7
D8 DIODE TO ON–OFF FAN DRIVE SYSTEM – (OPT.) 14-4
D12 DIODE TO ELECTRIC MASTER SWITCH (ACC) 5-3
D13 DIODE TO ELECTRIC MASTER SWITCH (IGN) 5-3
DB1 DIODE BOX FOR TURN SIGNAL 3-6
DB2 DIODE BOX FOR WIPERS AND DEFROSTER FANS 17-4
DMC.H DIODE BOX FOR COME-HOME 25-8
DR DIODE AND RESISTOR BOX FOR PARKING BRAKE SIGNAL AND AWD 21-1/25-7
ECA FUSE BOX ON LATERAL CONSOLE 32 and 33
ECB FUSE AND RELAY BOX ON LATERAL CONSOLE 32 and 33
ECC FUSE AND RELAY BOX ON LATERAL CONSOLE 32 and 33
ECD FUSE AND RELAY BOX ON LATERAL CONSOLE 32 and 33
ECE FUSE AND RELAY BOX ON FRONT CONSOLE 34
EDC7 ENGINE DATA CONTROL ON LATERAL CONSOLE 23 and 24
EM ELECTRIC MAGNETIC CLUTCH FOR A/C 19-1
EV2 DIFFERENTIAL LOCK SOLENOID VALVE - (OPT.) 1-11
EV3 STARTING AID SOLENOID VALVE (ETHER) – MECHANICAL ENGINE ONLY - (OPT.) 16-2
EV4 SADDLE LOCK PIN SOLENOID VALVE 5-11
EV27 FAN DRIVE INVERTER SOLENOID VALVE (OPT.) 4-11
EV28 SOLENOID ON–OFF FAN DRIVE (OPT.) 14-6
EVTA PROPORTIONAL SOLENOID VALVE A – SPEED 25-9
EVTB PROPORTIONAL SOLENOID VALVE B – SPEED 25-10
EVTC PROPORTIONAL SOLENOID VALVE C – SPEED 25-10
EVTD PROPORTIONAL SOLENOID VALVE D – SPEED 25-11
EV- MLE PROPORTIONAL SOLENOID VALVE HYDR. MOTOR LEFT 21-10
EV–MRI PROPORTIONAL SOLENOID VALVE HYDR. MOTOR RIGHT 21-11
EV–MS PILOT SOLENOID VALVE HYDR. PUMP 21-12
EV–MY PROPORTIONAL SOLENOID VALVE PUMP REVERSE 21-11
EV–MZ PROPORTIONAL SOLENOID VALVE PUMP FORWARD 21-12
FGH MEGA FUSE 125.0 AMP – GRID HEATER 23-4
FH FUEL FILTER HEATER 6-3
G1 BATTERY 12V – 1010 CCA 1-3
G2 BATTERY 12V – 1010 CCA 1-3

4003-4
G3 ALTERNATOR 28 VOLTS 90 AMP 2-3
GH GRID HEATER 23-3
H1 RIGHT WORK LIGHT BEFORE MOLD BOARD 2-5
H2 LEFT WORK LIGHT BEFORE MOLD BOARD 3-5
H3 RIGHT WORK LIGHT AFTER MOLD BOARD 3-5
H4 LEFT WORK LIGHT AFTER MOLD BOARD 4-5
H5 FRONT POSITION LIGHT L.H. 2-6
H6 REAR POSITION LIGHT R.H. 2-6
H7 RIGHT SNOW WORK LIGHT 5-5
H8 LEFT SNOW WORK LIGHT 6-5
H9 FRONT TURN SIGNAL LIGHT R.H. CAB. – RESERVE 5-6
H10 REAR TURN SIGNAL LIGHT R.H. 5-6
H11 FRONT TURN SIGNAL LIGHT R.H. 5-6
H12 FRONT TURN SIGNAL LIGHT L.H. 4-6
H13 REAR TURN SIGNAL LIGHT L.H. 4-6
H14 FRONT TURN SIGNAL LIGHT L.H. CAB. – RESERVE 4-6
H16 LEFT HEAD LIGHT (HIGH BEAM) 1-7
H17 RIGHT HEAD LIGHT (HIGH BEAM) 2-7
H18 LEFT HEAD LIGHT (LOW BEAM) 2-7
H19 RIGHT HEAD LIGHT (LOW BEAM) 3-7
H20 FRONT POSITION LIGHT R.H. 3-7
H21 REAR POSITION LIGHT L.H. 3-7
H22 LICENSE PLATE LIGHT (OPT.) 4-7
H27 REAR FLOOD LIGHT R.H. (CAB) 6-7
H28 REAR FLOOD LIGHT L.H. (CAB) 6-7
H29 CAB HEAD LIGHT L.H. (OPT.) 1-8
H30 CAB HEAD LIGHT R.H. (OPT.) 2-8
H31 FRONT BLADE BOARD LIGHT L.H. (OPT.) 2-8
H32 FRONT BLADE BOARD LIGHT R.H. (OPT.) 3-8
H33 BRAKE LIGHT L.H. 4-8
H34 BRAKE LIGHT R.H. 4-8
H40 FRONT RIGHT STROBE LIGHT (OPT.) 16-6
HA1 HORN 1-6
HA2 BUZZER (AIC) 9a-3
HA3 BACK–UP ALARM (OPT.) 5-8
J1-J2-J3 FUNK ECU CONNECTORS 25
J4 FUNK BUMP GEAR SELECTOR CONNECTOR 25-3
J6 TRANSMISSION FUNK CONNECTOR 25-8
K15 FLASHER RELAY 3-6
K C1 CONVERTER VOLTAGE 24 TO 12 VOLTS FOR RADIO AND CIGARETTE LIGHTER 22-1
K ECU ELECTRONIC CONTROL UNIT – FUNK TRANSMISSION 25
K EHC AWD SYSTEM ELECTRONIC MODULE 21
KFH FUEL FILTER & WATER SEPARATOR HEATER RELAY 5-3
K IP INCH PEDAL – FUNK TRANSMISSION 25-1
K PT AUXILIARY MAGNETIC SWITCH TO TIRES INFLATOR 22-6
KR RADIO 22-4
KRD REAR WINDOW & SIDE MIRRORS DEFROSTER RELAY 20-2
KSR STARTER RELAY 4-3
K TVP TRANSIENT VOLTAGE PROTECTION – FUNK TRANSMISSION 25-1
M1 ENGINE START 3-3
M2 FRONT WIPER 17-3
M3 FRONT WASHER PUMP 17-4
M4 REAR WIPER 17-6
M5 REAR WASHER PUMP 18-1
M6 FRONT LOWER WASHER PUMP (OPT.) 18-4
M7 FRONT LOWER WIPER (OPT.) 18-2
M8 AIR SUSPENSION SEAT (OPT.) 18-4
M9 DEFROSTER FAN REAR (OPT.) 18-5

4003-5
M10 DEFROSTER FAN L.H. WINDSHIELD (OPT.) 18-5
M10A DEFROSTER FAN R.H. DOOR (OPT.) 18-6
M11 DAMPER TO AIR CONDITIONER 19-5
MLS MIRROR LEFT SIDE DEFROSTER 20-4
M PT TIRES INFLATOR COMPRESSOR 22-5
MRS MIRROR RIGHT SIDE DEFROSTER 20-4
M.T. EVAPORATOR UNIT (OPT.) AIR CONDITIONER 19-4
PO1 POWER OUTLET 20-5
PRM A POWER RELAY MODULE A – ACC 5-4
PRM B POWER RELAY MODULE B – IGN 4-4
PRM C POWER RELAY MODULE C – ACC 3-4
R3 CIGARETTE LIGHTER 12 VOLTS 22-2
RWDR REAR WINDOW DEFROSTER 20-2
S1 ELECTRIC MASTER SWITCH 1-3
S2 IGNITION SWITCH 1-4
S3 WORK LIGHT BEFORE AND AFTER MOLD BOARD SWITCH 2-5
S4 FLOOD/HEAD LIGHTS, HORN AND TURN SIGNAL SWITCH 4-6
S5 WARNING FLASHER SWITCH 3-6
S6 REAR FLOOD LIGHTS SWITCH 5-7
S7 CAB HEAD & SNOW LIGHT SWITCH (OPT.) 1-8
S8 FRONT BLADE BOARD SWITCH (OPT.) 2-8
S9 BRAKE LIGHT SWITCH 4-8
S9a AWD BRAKE SWITCH 4-8
S12 KEY–PAD SWITCH 4-10
S14 FUEL SENSOR LEVEL 9a-1
S15 ENGINE COOLANT TEMPERATURE SWITCH 2-10
S16 AIR CLEANER SWITCH 4-10
S17 TRANSMISSION OIL FILTER RESTRICTION SWITCH 9a-11
S18 TRANSMISSION OIL PRESSURE SWITCH 9a-9
S20 HYDRAULIC OIL TEMPERATURE SWITCH 9a-2
S21 BRAKE LOW PRESSURE SWITCH 9a-12
S23 HYDRAULIC OIL FILTER RESTRICTION SWITCH 4-10
S24 DIFFERENTIAL LOCK SWITCH (OPT.) 2-11
S25 STARTING AID SWITCH (ETHER – ONLY FOR MECHANICAL ENGINE) (OPT.) 16-2
S26 SADDLE LOCK PIN SWITCH 6-11
S27 RIPPER OR SCARIFIER SWITCH (OPT.) 15-3
S28 MOLD BOARD FLOAT L.H. SWITCH (OPT.) 3-12
S29 MOLD BOARD FLOAT R.H. SWITCH (OPT.) 5-12
S30 LIFT SHOCK DAMPENER SWITCH (OPT.) 13-3
S31 FRONT BLADE BOARD FLOAT SWITCH (OPT.) 14-1
S32 LEFT CAB DOME LIGHT SWITCH (NEXT TO LEFT DOOR) 16-3
S33 RIGHT CAB DOME LIGHT SWITCH (ABOVE CONSOLE) 16-4
S34 STROBE LIGHT SWITCH (OPT.) 16-5
S35 FRONT WIPER, WASHER PUMP, TIMER SWITCH 17-1
S37 REAR WIPER SWITCH 17-5
S38 REAR WASHER PUMP SWITCH 18-1
S39 FRONT LOWER WIPER AND WASHER SWITCH (OPT.) 18-3
S40 DEFROSTERS FANS SWITCH (OPT.) 18-6
S40a REAR WINDOW AND MIRROR DEFROSTER SWITCH (OPT.) 18-6
S41 HIGH PRESSURE SWITCH TO AIR CONDITIONER SYSTEM (OPT.) 19-2
S42 3 SPEED SWITCH TO FANS AND AIR CONDITIONER SYSTEM (OPT.) 19-3
S43 AIR CONDITIONER ON–OFF SWITCH (OPT.) 19-5
S44 MOTOR DAMPER SWITCH TO AIR CONDITIONER SYSTEM (OPT.) 19-4
S47 FUNK BUMP GEAR SELECTOR 25-3
S49 COME–HOME SWITCH (FUNK) 25-10
S50 ENGINE SPEED MAGNETIC PICKUP SENSOR (FUNK) 25-11
S51 OUTPUT SPEED MAGNETIC PICKUP SENSOR (FUNK) 25-11
S52 CYLINDER SPEED MAGNETIC PICKUP SENSOR (FUNK) 25-12
S53 TEMPERATURE SENSOR – TRANSMISSION FUNK 25-12
S55 FAN DRIVE INVERTER SWITCH 3-11
S58 WATER IN FUEL SENSOR 23-1

4003-6
S59 CAMSHAFT SENSOR 24-6
S60 RAIL PRESSURE SENSOR 24-6
S61 COOLANT TEMPERATURE SENSOR 24-6
S62 FUEL TEMPERATURE SENSOR 24-6
S63 CRANKSHAFT POSITION SENSOR 24-6
S64 ENGINE OIL PRESSURE/TEMPERATURE SENSOR 24-6
S65 BOOST TEMPERATURE/PRESSURE SENSOR 24-6
S66 TIRES INFLATOR SWITCH 22-6
S67 ON–OFF FAN DRIVE SWITCH (OPT.) 14-4
S68 WATER TEMPERATURE 87 C SWITCH TO ON–OFF FAN DRIVE (OPT.) 14-5
S85 SPEED SENSOR LEFT - HYDRAULIC MOTOR - AWD 21-3
S86 SPEED SENSOR RIGHT - HYDRAULIC MOTOR - AWD 21-4
S87 ADDITIONAL MACHINE SPEED SENSOR - AWD 21-4
S88 PRESSURE SENSOR LINE A - AWD 21-5
S89 PRESSURE SENSOR LINE B - AWD 21-5
SDB ELECTRONIC SWITCH - AWD 21-6
SP1 SPEAKER L.H. 22-4
SP2 SPEAKER R.H. 22-4
V2 VARISTOR FOR DIFFERENTIAL LOCK SOLENOID VALVE (OPT.) 1-11
V3 VARISTOR FOR STARTING AID SOLENOID VALVE (OPT.) 16-1
V4 VARISTOR FOR SADDLE LOCK PIN SOLENOID VALVE 5-11
V9 VARISTOR FOR MOLD BOARD FLOAT SOLENOID VALVE L.H. (OPT.)
V10 VARISTOR FOR MOLD BOARD FLOAT SOLENOID VALVE L.H. (OPT.)
V11 VARISTOR FOR MOLD BOARD FLOAT SOLENOID VALVE R.H. (OPT.)
V12 VARISTOR FOR MOLD BOARD FLOAT SOLENOID VALVE R.H. (OPT.)
V21 VARISTOR FOR MAGNETIC CLUTCH/COMPRESSOR (OPT.) 19-1
V27 VARISTOR FOR SOLENOID FAN DRIVE INVERTER (OPT.) 4-11
V28 VARISTOR FOR SOLENOID ON–OFF FAN DRIVE (OPT.) 14-5
X1 MAIN REAR HARNESS WITH LATERAL CONSOLE 70 WAY
X1DB MAIN REAR HARNESS WITH LATERAL CONSOLE 1 WAY CONNECTOR EYELET – POWER
X4 MAIN REAR HARNESS WITH FUEL TANK 2 WAY CONNECTOR
X6 MAIN REAR HARNESS WITH FRONT CONSOLE 70 WAY CONNECTOR
X7 MAIN REAR HARNESS WITH MAIN FRONT 20 WAY CONNECTOR
X7A MAIN REAR HARNESS WITH FRONT WIPER LOWER, RIPPER/SCARIFIER 6 WAY CONNECTOR
X8 MAIN REAR HARNESS WITH ON–OFF FAN DRIVE 2 WAY CONNECTOR
X9 MAIN REAR HARNESS WITH MAGNETIC CLUTCH AIR CONDITIONER, START AID AND ON–OFF FAN DRIVE 3 WAY CONNECTOR
X10 MECHANICAL ENGINE HARNESS WITH ELECTRICAL SHUT–OFF 3 WAY CONNECTOR
X11 MAIN REAR HARNESS WITH REAR LIGHTS AND BACK–UP ALARM 6 WAY CONNECTOR
X12 MAIN REAR HARNESS WITH REAR POSITION LIGHTS 2 WAY CONNECTOR
X15 MAIN REAR HARNESS WITH AIR CONDITIONER PRESSURE SWITCH AND DIFF. LOCK 6 WAY CONNECTOR
X19 LATERAL CONSOLE HARNESS WITH RADIO POWER AND CAN BUS CAB 6 WAY CONNECTOR
X20 LATERAL CONSOLE HARNESS WITH CAB 20 WAY CONNECTOR – BLACK
X23S/T X23S WITH X23T NORMALY OPERATION FUNK TRANSMISSION AND X23S WITH X23TA COME–HOME 20 WAY CONNECTOR – GRAY
X23SA/TA X23SA WITH X23TA NORMALY OPERATION FUNK TRANSMISSION AND
X23SA WITH X23T COME–HOME FUNK TRANSMISSION 20 WAY CONNECTOR – GRAY
X24 LATERAL HARNESS WITH AIR CONDITIONER SYSTEM (FANS SPEED) 6 WAY CONNECTOR
X24S DISCONNECTED TO X24T = MAINTENANCE (WELD) 20 WAY CONNECTOR – BLACK
X26 LATERAL HARNESS WITH AIR CONDITIONER SYSTEM 6 WAY CONNECTOR
X27 LATERAL HARNESS WITH AIR CONDITIONER CONTROL 6 WAY CONNECTOR

4003-7
X27A LATERAL HARNESS WITH AIR CONDITIONER SYSTEM 3 WAY CONNECTOR
X29 ELECTRONIC AND MECHANICAL ENGINE HARNESS WITH HYDRAULIC AND TRANSMISSION SWITCH 6 WAY CONNECTOR
X30 MAIN FRONT HARNESS WITH OPTIONAL LIFT SHOCK DAMPENER 2 WAY CONNECTOR
X31 MAIN FRONT HARNESS WITH OPTIONAL MOLD BOARD FLOAT R.H. AND R.L. 3 WAY CONNECTOR
X32 MAIN FRONT HARNESS WITH OPTIONAL FRONT BLADE BOARD FLOAT 2 WAY CONNECTOR
X36 LATERAL HARNESS 2 WAY CONNECTOR FOR CALIBRATION
X37 LATERAL HARNESS 2 WAY CONNECTOR JUMP FOR CALIBRATION
X38 LATERAL HARNESS 3 WAY CONNECTOR FOR COMPUTER DIAGNOSE FUNK TRANSMISSION
X39 HYDRAULIC SENSOR HARNESS WITH TRANSMISSION FILTER RESTRICTION 1 WAY CONNECTOR
X40 CAB HARNESS WITH REAR LEFT STROBE LIGHT 2 WAY CONNECTOR
X42 LATERAL HARNESS WITH AIR SUSPENSION SEAT OPTIONAL 2 WAY CONNECTOR
X47 MAIN REAR HARNESS WITH ELECTRONIC ENGINE 20 WAY CONNECTOR – GRAY
X52 POWER FOR CONVERTER DIRECT FROM BATTERY 1 WAY CONNECTOR
X53 POWER FOR CONVERTER AFTER IGNTION SWITCH: “IGN” 1 WAY CONNECTOR
X53a POWER FOR CONVERTER 1 WAY CONNECTORELECTRONIC SWITCH AWD WITH MACHINE CODE CONNECTOR 4 WAY
X62
X63 MACHINE CODE CLASS 170HP - AWD
X63A MACHINE CODE CLASS 200HP - AWD
X64 LATERAL HARNESS – DIAGNOSE TOOL
X86 MAIN REAR HARNESS WITH FAN REVERSE SOLENOID 2 WAY CONNECTOR
X87 MAIN REAR HARNESS WITH PWM SOLENOID (REVERSE) 2 WAY CONNECTOR
XA POWER DERIVATION POINT ON REAR FRAME NEAR TO CAB FLOOR
XAE MAIN REAR HARNESS WITH ELECTRIC ACCELERATOR 6 WAY CONNECTOR
XCAN MAIN REAR HARNESS WITH ENGINE 6 WAY CONNECTOR
XCV LATERAL HARNESS WITH VOLTAGE CONVERTER 24V TO 12 V 6 WAY CONNECTOR
XDIF DIFFERENTIAL LOCK JUMP (USE ONLY WITH ZF TRANSMISSION) 1 WAY CONNECTOR
XDV1 POWER DERIVATION 2 WAY CONNECTOR STUD
XEDC7(A) ENGINE SUPPLIER HARNESS WITH ENGINE EDC 16 WAY CONNECTOR
XEDC7(B) ELECTRONIC ENGINE HARNESS WITH ENGINE EDC 89 WAY CONNECTOR
XEDC7(C) ENGINE SUPPLIER HARNESS WITH ENGINE EDC 36 WAY CONNECTOR
XJ6 MAIN REAR HARNESS WITH TRANSMISSION HARNESS 31 WAY CONNECTOR
XM LATERAL HARNESS – ENGINE SET–UP 2 WAY CONNECTOR
XME LATERAL HARNESS – ELECTRONIC ENGINE OPTION 2 WAY CONNECTOR
XMM LATERAL HARNESS – MECHANICAL ENGINE OPTION 2 WAY CONNECTOR
XMS MAIN REAR HARNESS WITH MASTER SWITCH 3 WAY CONNECTOR
XPB BRAKE PARTS HARNESS WITH PARKING BRAKE SWITCH 3 WAY CONNECTOR
XPS HYDRAULIC SENSOR HARNESS WITH TRANSMISSION OIL PRESSURE SWITCH 2 WAY CONNECTOR
XT7 LATERAL HARNESS WITH TRANSMISSION VOLTAGE PROTECTION (TVP) 6 WAY CONNECTOR
XT9 LATERAL HARNESS WITH PARKING BRAKE SWITCH 3 WAY CONNECTOR
XT11 MAIN REAR HARNESS WITH INCH PEDAL 6 WAY CONNECTOR

4003-8
ELECTRIC DIAGRAMS
FIGURE 1 84410029-3

4003-9
FIGURE 2 84410029-4

4003-10
FIGURE 3 84410029-5

4003-11
FIGURE 4 84410029-6

4003-12
FIGURE 5 84410029-7

4003-13
FIGURE 6 84410029-8

4003-14
Diagram 7 – Sheet 9a (Models with FUNK Transmission)
FIGURE 7 84410029-9a

4003-15
FIGURE 8 84410029-10

4003-16
FIGURE 9 84410029-11

4003-17
FIGURE 10 84410029-12

4003-18
FIGURE 11 84410029-13

4003-19
FIGURE 12 84410029-14

4003-20
FIGURE 13 84410029-15

4003-21
FIGURE 14 84410029-16

4003-22
FIGURE 15 84410029-17

4003-23
FIGURE 16 84410029-18

4003-24
FIGURE 17 84410029-19

4003-25
FIGURE 18 84410029-20

4003-26
FIGURE 19 84410029-22

4003-27
FIGURE 20 84410029-23

4003-28
FIGURE 21 84410029-24

4003-29
Diagram 22 – Sheet 25 (Models with FUNK Transmission)
FIGURE 22 84410029-25

4003-30
FIGURE 23 84410029-26

4003-31
FIGURE 24 84410029-31

4003-32
NOTES

Section
4004
BATTERY
4004

4004-2
TABLE OF CONTENTS
Battery Safety........................................................................................................................................................................3
SPECIAL TOOLS...........................................................................................................................................................................4
BATTERY SERVICE.......................................................................................................................................................................5
Battery Fluid Level...................................................................................................................................................................5
Battery Vents...........................................................................................................................................................................5
Cleaning the Batteries.............................................................................................................................................................5
Starting the Engine Using Booster Batteries...........................................................................................................6
Connecting Booster Batteries..................................................................................................................................................6
Disconnecting Booster Batteries.............................................................................................................................................6
BATTERY TEST.............................................................................................................................................................................7
Visual Checks..........................................................................................................................................................................7
Specific Gravity Check............................................................................................................................................................7
Table of Specific Gravity..........................................................................................................................................................7
Capacity (Load) Test................................................................................................................................................................8
CHARGING A BATTERY................................................................................................................................................................9
PREPARING A DRY CHARGED BATTERY FOR USE................................................................................................................10

4004-3
Battery Safety
WARNING: Never try to charge the battery if the electrolyte in the battery is frozen.
WARNING: Never cause sparks to occur or smoke near batteries that are charging or have been recently char-
ged.
WARNING: Disconnect the ground cable first when the battery cables are disconnected from the battery. Connect
the ground cable last when the battery cables are connected to the battery.
WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clo-
thing. Antidote: EXTERNAL - Flush with water. INTERNAL - Drink large quantities of water or milk. Follow with milk
of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and
get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, and cigarettes away. Ventilate
when charging or using in enclosed area. Always shield eyes when working near batteries. Keep out of reach of
children.
WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing.
Battery acid or battery explosion can cause serious injuries.
WARNING: When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2)
you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full
charge. If you do not follow these instructions, you or others in the area can be injured.
WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the follo-
wing:
1. When you disconnect the battery cables, always disconnect the negative (-) battery cable first.
2. When you connect the battery cables, always connect the negative (-) cable last.
3. Do not short circuit the battery posts with metal items.
4. Do not weld, grind, or smoke near a battery.
WARNING: Avoid water jets directly on electric/electronic components - alternator, starter motor, electronic center,
electric connectors and their wiring harnesses, fuses, relays, etc.

4004-4
SPECIAL TOOLS
Tool No. Specification Tool Illustration Tool
CAS-10147 Test Set

4004-5
BATTERY SERVICE
NOTE: The electrical system in this machine is 24 volts. Cleaning the Batteries
Each battery is 12 volts.
Check the batteries and battery compartment regularly for
Before you service components of the electrical system, dirt, corrosion and damage. Dirt mixed with electrolyte or
always disconnect the NEGATIVE (-) battery cable. moisture on the top of the batteries can cause a discharged
Do not run the engine with the battery cables disconnected condition in the batteries. Use one of the following methods
or with the alternator wires disconnected. to clean the batteries.
Before you use an electric welder, disconnect the alternator Clean the exterior of the batteries with bicarbonate of soda
wires, instrument cluster, transmission electronic control or ammonia and wash with water. Use a special product for
unit and turn the master disconnect switch to OFF. battery cleaning to avoid corrosion of the terminals.
Do not use a steam cleaner or cleaning solvent to clean

the alternator.
Battery Fluid Level

The batteries are “Maintenance Free” type and electrolyte
level check is not required. 1
Do not leave lamps switched on for long intervals of time
with the engine stopped or idling. Keep batteries clean,
specially on its top surface.
Make sure of that cable terminals are correctly fixed on the
battery poles. Always disconnect master switch before ser-
vicing batteries.
FIGURE 1 P1030806
IMPORTANT: If the temperature is equal or lower than 0°C
1. Battery (Right side)
and water has been added to a battery, proceed as follows:
connect a battery charging equipment or run the engine for
approximately two (2) hours. This procedure is necessary
in order to mix the added water with the electrolyte inside
the battery.
Battery Vents
2
Keep the battery vents clean, make sure the vents are not
restricted.
FIGURE 2 P1030806
2. Battery (Left side)

4004-6
Starting the Engine Using Booster Batteries

WARNING: Explosive gas is produced while batteries are in use or being charged. Keep open flames and/or sparks
away from the battery charging area. Charge the batteries in a well ventilated place. Park the machine on a dry firm,
surface. Do not park on metal surfaces. Take care to make correct connections. Never connect a positive terminal
(+) to a negative terminal (-).
IMPORTANT: The machine electrical system is 24 V with negative (-) ground. Use only booster batteries with same voltage.
Connecting Booster Batteries

Proceed in the following order:
•• Connect one terminal of the red cable (1) to the positive
(+) pole of machine batteries and the other terminal of
same cable to the positive (+) pole of booster batteries
(loaded).
•• Connect one terminal of the black cable (2) to the nega-
tive (-) pole of booster batteries and the other terminal of
same cable to ground (machine frame).
•• Start the engine.
IMPORTANT: The connection of booster batteries should
not be accomplished by non-authorized personnel.
FIGURE 3 S0001
Cable connection order:

A B C D B A
C
Cable disconnection order:
D C B A
batteries batteries
(loaded) (unloaded)
D
FIGURE 4 M0074
Disconnecting Booster Batteries

•• Disconnect the black cable (2) terminal from ground
(machine frame), then disconnect the other terminal of
same cable from the negative (-) pole of booster batte-
ries (loaded).
•• Disconnect the red cable (1) terminal from the positive
(+) pole of booster batteries, then disconnect the other
terminal of same cable from the positive (+) pole of ma-
chine batteries (unloaded).

4004-7
BATTERY TEST
NOTE: To correctly test a battery, do each part of the bat-
tery test until you know the condition of the battery.
Visual Checks
1. Make sure the cable connections are clean and tight.
Clean foreign material from the top of the battery.
2. Inspect the battery , battery posts, and cables for da-
mage.
3. Check the electrolyte level.
4. If you added water to the battery, the battery must be
charged for 15 minutes at 15 to 25 amperes to mix the
water with the electrolyte.
Specific Gravity Check

A hydrometer is used to check the specific gravity (weight)
FIGURE 5 4004002A
of the electrolyte. The specific gravity is an indication of the
1. TemperaturE IN Farenheit
level of charge for each cell.
2. TemperaturE IN Celsius
Hydrometers are made to show the correct specific gravi ty
when the temperature of the electrolyte is 26.7°C (80°F).
Table of Specific Gravity
When you check the specific gravity, you must know the
1. Make a record of the corrected specific gravity reading
temperature of the electrolyte. If your hydrometer does not
for each cell.
have a thermometer, get a thermometer to check the tem-
perature of the electrolyte. The thermometer must indicate 2. If the difference between the high reading and the low
a high temperature of at least 52°C (120°F). reading is 0.050 or more, charge the battery and check
the specific gravity again. If after charging, the differen-
1. Remove enough electrolyte from a cell so that the float
ce is still 0.050 or more, install a new battery.
is free in the tube.
3. The corrected specific gravity reading shows the level
NOTE: If the specific gravity cannot be checked without
of charge for the cell. The level of charge must be at
first adding water to the cell, the battery must be tilted to
least 75% in each of the cells. In maintenance free bat-
the left and right to about a 30° angle to mix the water and
teries the level of charge is at least 75% if the corrected
acid. Next the battery must be charged for 15 minutes at 15
specific gravity reading is 1.240 or higher. In all other
to 25 amperes to further mix the water with the electrolyte.
batteries the level of charge is at least 75% if the cor-
Then check the specific gravity.
rected specific gravity reading is 1.230 or higher.
2. Read the float.
4. If the difference between the high reading and the low
3. Read the thermometer. If the reading is above 26.7°C reading is less than 0.050, and the level of charge is
(80°F) add specific gravity points to the reading for spe- at least 75% in all of the cells, do the Capacity (Load)
cific gravity. If the reading is below 26.7°C (80°F) sub- Test.
tract specific gravity points from the reading for specific
5. If the difference between the high reading and the low
gravity. See the following illustration and add or sub-
reading is less than 0.050, but the level of charge is less
tract specific gravity points as needed. than 75% in any of the cells, charge the battery and
check the specific gravity again. If after charging:
a. The level of charge is less than 75% in any of the
cells, discard the battery.
b. The level of charge is at least 75% in all of the cells,
do the Capacity (Load) Test.

4004-8
Capacity (Load) Test

This test can be done using a variable load tester such NOTE: Never apply a load for longer than 15 seconds. Af-
as the Sun Electric VAT-33. Other test equipment can be ter each 15 seconds, turn the load control knob to OFF for
used. Connect the test equipment according to the instruc- at least one minute.
tions of the manufacturer of the equipment.
4. Apply a 15 ampere load to the battery for 15 secon-
1. The level of charge of the battery must be at least 75%. ds. Wait at least three minutes before applying the load
Do the Specific Gravity Check in this section. again.
2. Prepare the tester (Sun Electric VAT-33 shown) for the 5. Check and make a record of the temperature of the
test. electrolyte.
a. Select the voltmeter range that will measure 1 to 6. Find the correct load for this test in Specifications.
18 volts.
b. Make sure the load control knob is in the OFF po- NOTE: The correct load is half of the cold cranking ampe-
sition. res at -17°C (0°F).
c. Select the ammeter range that will measure 0 to 7. Turn the load control knob until the ammeter indicates
1000 amperes. the specified load. Keep the load for 15 seconds and
d. Move the volt lead switch to the INT. position. read the voltmeter. Turn the load control knob to OFF.
3. Connect the tester to the battery as shown. 8. Compare the test reading and the temperature of the
electrolyte to the chart below.
Temperature of Electrolyte Minimum Voltage

21°C (70°F) and above 9.6
16°C (60°F) 9.5
10°C (50°F) 9.4
4°C (40°F) 9.3
-1°C (30°F) 9.1
-7°C (20°F) 8.9
-12°C (10°F) 8.7
-18°C (0°F) 8.5
a. If the test result is equal to or more than the vol tage

shown, the battery is in good condition.
b. If the test result is less than the voltage shown, dis-
card the battery.
FIGURE 6 4004003A
1. LOAD CONTROL KNOB
2. AMMETER CLAMP (TIP OF ARROW AWAY FROM BATTERY)

4004-9
CHARGING A BATTERY
Before you charge the battery, check the level of the elec- The charging rate must be decreased if:
trolyte.
1. Too much gas causes the electrolyte to flow from the
It is difficult to give an exact charging rate because of the cells.
following variable conditions.
2. The temperature of the electrolyte rises above 52°C
1. Temperature of the electrolyte, (125°F).
2. Level of charge, and NOTE: For the best charge, use the slow charging rates.
3. Condition of the battery. The battery is fully charged when, over a three hour period
at a low charging rate, no cell is giving too much gas, and
4. Use the charging guide for the correct charging rate
the specific gravity does not change.
and time.
See Specifications for the reserve capacity of the battery
in this machine.
CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES
Recommended Rate* and Time for Fully Discharged Battery

Battery Capacity –
Slow Charge Fast Charge
See Reserve Capacity under Specifications
10 Hours at 5 Amperes 2.5 Hours at 20 Amperes
80 Minutes or Less
Above 80 to 125 Minutes
7.5 Hours at 10 Amperes 1.5 Hours at 50 Amperes
20 Hours at 5 Amperes 5 Hours at 20 Amperes
*Initial rate for standard taper charger.
NOTE: Maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If the center part
of the decal has been removed to get access to the battery caps, it is possible the words Maintenance Free will have been
removed from the decal.
CHARGING GUIDE FOR BATTERIES OTHER THAN MAINTENANCE FREE BATTERIES
Recommended Rate* and Time for Fully Discharged Battery

Battery Capacity –
Slow Charge Fast Charge
See Reserve Capacity under Specifications
80 Minutes or Less
7.5 Hours at 10 Amperes 1.5 Hours at 50 Amperes
6 Hours at 40 Amperes
Above 250 Minutes 24 Hours at 10 Amperes
4 Hours at 60 Amperes
*Initial rate for standard taper charger

4004-10
PREPARING A DRY CHARGED BATTERY FOR USE

1. Remove the caps from the battery. 4. Connect a battery charger to the battery..
2. Fill each cell to the top of the separators with electrolyte. 5. Charge the battery at 30 amperes until the specif ic gra-
This will permit the volume of electrolyte to increase vity is 1.250 or more and the temperature of the elec-
when heated by charging the battery. trolyte is at least 15.5°C (60° F).
3. Install the caps on the battery. If the battery in your ma- 6. If necessary, fill each cell with electrolyte until the elec-
chine must have nonspill caps, install the nonspill caps. trolyte is just below split ring at the bottom of the cell
See Specifications to find if the battery in your machine opening.
must have nonspill caps.

SECTION INDEX
Steering
Steering Control Valve . .......................................................................................................................................................... 5003
Steering Priority Valve ............................................................................................................................................................ 5004

Section
5003
5003
STEERING CONTROL VALVE

5003-2
TABLE OF CONTENTS
SPECIFICATIONS..........................................................................................................................................................................3
SPECIAL TOOLS...........................................................................................................................................................................3
STEERING CONTROL VALVE.......................................................................................................................................................4
Disassembly............................................................................................................................................................................4
Section Drawing and Integral Valves.......................................................................................................................................7
Inspection................................................................................................................................................................................8
Assembly.................................................................................................................................................................................9
TROUBLESHOOTING.................................................................................................................................................................13

5003-3
SPECIFICATIONS
Manufacturer ........................................................................................................................................................................ Eaton
Special Torques – Cap screws for end cap ......................................................................................... 31 NM (275 pound-inches)
SPECIAL TOOLS
Tool No. Specification Tool Illustration Tool
600057 Spring installation
Order Special Tools from:

Eaton Corporation, Hydraulics Division, 15151 Highway 5, Eden Prairie, MN 55344

5003-4
STEERING CONTROL VALVE

Disassembly
1. Clean the port area of the steering control

valve housing before disconnecting the
hydraulic lines.
2. Drain the oil, and plug the ports. Clean
the exterior of the steering control valve
housing. Protect the machines surfaces
during repair.
3. Put the steering control valve in a vise so
that the end cap (2) is up, refer to Figure 1.
7. Remove housing from vise. Place housing

on a clean soft cloth to protect surface finish.
Use a thin bladed screwdriver to pry retaining
ring from housing, as shown in Fig. 1- A .
Figure 1. Steering control valve-end cap up
1. Vise
2. End cap
3. Anti-cavitation valves
4. Check valve
8. Rotate spool and sleeve until pin is horizontal.

4. Remove the seven cap screws (1), end cap Push spool and sleeve assembly forward
(2), O-ring (3), gerotor (4), O-ring (3), spacer with your thumbs just far enough to free
plate (5), and O-ring (3), refer to Figure 2. gland bushing from housing, see Fig. 1 - B.
Remove bushing
5. Remove the gerotor star from gerotor (4),
Figure 2.
6. Remove drive shaft (6), Figure 2.

5003-5
FIGURE 2. STEERING CONTROL VALVE - EXPLODED VIEW
1. CAP SCREW 13. NEEDLE THRUST BEARING

2. END CAP 14. BEARING RACE
3. O-RING 15. O-RING
4. GEROTOR 16. O-RING
5. SPACER PLATE 17. SEAL GLAND BUSHING
6. DRIVE SHAFT 18. RETAINING RING
7. STEERING CONTROL HOUSING 19. DUST SEAL
8. SLEEVE 20. BALL CHECK
9. SPOOL 21. ROLL PIN
10. SPACER 22. ROLL PIN
11. PIN 23. BALL CHECK
12. CENTERING SPRING
5003-6
12. Remove spool and sleeve assembly from 14
hole end of housing, see Fig. 5.
ATTENTION: Do not bind spool

and sleeve in housing. Rotate spool
and sleeve assembly slowly when
removing from housing.
13. Push pin from spool and sleeve assembly.
9. Remove quad ring seal from seal gland

bushing.
10. Use a thin bladed screwdriver to pry dust
seal from seal gland bushing. Do not damage
bushing.
14. Push spool partially from control end of

sleeve, then remove 6 centering springs
from spool carefully by hand, see Fig. 6
15. Push spool back through and out of sleeve,

see Fig. 6 Rotate spool slowly when removing
11. Remove 2 bearing races and the needle thrust from sleeve.
bearing from spool and sleeve assembly.
16. Remove o-ring from housing, see Fig. 7 and
two cylinder port shock valves (set screw,
o-ring, spring, and check ball)..

5003-7
Section Drawing and Integral Valves

NOTE: The steering control valve housing (7) Fig. 2 has internally two anti-cavitation valves (EE) and
one check valve (CC). Before removing these valves, verify their positions.
17. To disassemble these valves, insert soda straws (3) in each end of the threaded holes, refer to
Figure 3. Remove the steering control valve housing from the vise and tilt it until the port face (4) is
upward. Continue turning until the roll pins (2) and ball checks (1) slide through the straws (3).

5003-8
FIGURE 8. ANTI-CAVITATION VALVE - DISASSEMBLY
1. BALL CHECK 4. PORT FACE

2. ROLL PIN 5. ANTI-CAVITATION VALVES
3. SODA STRAW 6. CHECK VALVE
Inspection
1. Clean all parts in cleaning solvent and air dry 3. If the spool (9) and sleeve (8) or the bore
on paper towels. Do not use cloths to wipe in the housing of the steering control valve
parts dry, as it may leave lint on the parts. (7) is damaged or worn, use a new steering
control valve.
2. Check all machined surfaces for wear 4. Inspect the cap screws (1), pin (11), backup
or damage. If there are rough places on washer (15), seal ring (16), O-ring (17),
the ends of the gerotor star or gerotor (4), needle thrust bearing (13) and bearing race
steering control valve housing (7), end cap (14). Use new parts as required.
(2), or spacer plate (5), use 600 grit emery
cloth to smooth the surfaces, refer to Figure 5. If your steering control valve has anti-
2. Place the emery cloth on a flat surface. If cavitation and check valves, inspect the
the emery cloth is new, rub a piece of steel balls checks (20), (23) and roll pins(21),
across the emery cloth six times to remove (22) for damage or wear. Use new parts as
the sharp pieces of grit. Make sure that the required.
part is held flat on the emery cloth. Rub each
part across the cloth six times. Check to see
if the rough places are removed. Use this
method until all rough places are removed.
Clean the parts in cleaning solvent to remove
any grit.

5003-9
Assembly
NOTE: Use new seals (3), (16), and (19) when
reassembling the steering control valve.
IMPORTANT: Lubricate all new seals

(with exception of new quad seal)
with clean petroleum jelly such as
Vaseline.
Do not use excessive lubricant on
seals for meter section. Refer to parts
listings covering your steering control
unit when ordering replacement parts. 2. Assemble spool and sleeve carefully so
A good service policy is to replace all
that the spring slots line up at the same
old seals with new seals.
end. Rotate spool while sliding parts
together. Some spool and sleeve sets have
1. Use a soda straw (3) as a guide tool, refer identification marks, align these marks as
to Figure 9. Drop the straw (3) into the anti- shown in Fig.10. Test for free rotation. Spool
cavitation valves (5) and check valve (6) to should rotate smoothly in sleeve with finger
the bottom of the bore. Drop the ball check tip force applied at splined end.
(2) through the straw (3). Pull the straw
(3) out and use the same procedure in the
others ball seat.
3. Bring spring slots of both parts in line and

stand parts on end of bench. Insert spring
installation tool through spring slots of both
parts. Tool is available as part no. 600057.
Position 3 pairs of centering springs (or 2
sets of 3 each) on bench so that extended
edge is down and arched center section is
together. In this position, insert one end of
entire spring set into springinstallation tool,
FIGURE 9. CHECK AND ANTI-CAVITATION see Fig. 11.
VALVES ASSEMBLY
4. Compress extended end of centering spring
1. ROLL PIN set and push into spool sleeve assembly with
2. BALL CHECK drawing installation tool at the same time.
3. SODA STRAW
4. PORT FACE 5. Center the spring set in the parts so that they
5. ANTI-CAVITATION VALVES push down evenly and flush with the upper
6. CHECK VALVE surface of the spool and sleeve.

5003-10
7. Install pin through spool and sleeve assembly

until pin becomes flush at both sides of
sleeve.
10. Install 2 bearing races and the needle thrust

bearing in the order shown in Fig. 14.
11. Install dust seal in seal gland bushing, flat

or smooth side of dust seal must face down
toward bushing, see Fig.16.
12. Install dry quad ring seal in seal gland

bushing, Smooth seal in place with your
finger. Do not use any seal that falls freely
into pocket of bushing , see Fig. 19.
8. Position the spool and sleeve assembly so
that the splined end of the spool enters the
14 hole end of housing first, see Fig. 13.
ATTENTION: Be extremely careful

that the parts do not tilt out of position
while inserting. Push parts gently into
place with slight rotating action, keep
pin nearly horizontal. Bring the spool
assembly entirely within the housing
bore until the parts are flush at the
meter end or 14 hole end of housing.
Do not pull the spool assembly beyond
this point to prevent the cross pin from
dropping into the discharge groove of
the housing. With the spool assembly
in this flush position, check for free
rotation within the housing by turning
with light finger tip force at the splined
end.
9. Place housing on clean, lint free cloth. Install

seal in housing, see Fig. 14.

5003-11
13. Install seal gland bushing over the spool end 15. Clamp housing in vise, as shown in Fig. 17.
with a twisting motion. Tap the bushing in Clamp lightly on edges of mounting area. Do
place with a rubber hammer. Make sure the not over tighten jaws.
bushing is flush against the bearing race.
Note: Check to insure that the spool and sleeve
are flush or slightly below the 14 hole surface of
the housing.
ATTENTION: Clean the upper surface

of the housing by wiping with the
palm of clean hand. Clean each of
the flat surfaces of the meter section
parts in a similar way when ready for
reassembly. Do not use cloth or paper
to clean surfaces.
14. Install retaining ring (see Fig. 15-16) in

housing. After installing ring, tap on ring
end to pry with screwdriver around entire
circumference of ring to property seat ring
in groove.
16. Install seal in housing, see Fig. 18.
17. Install spacer plate. AIign bolts holes in

spacer plate with tapped holes in housing.

5003-12
18. Rotate spool and sleeve assembly until pin
is parallel with port face, see Fig. 19. Install
drive, make sure you engage drive with pin,
To assure proper alignment, mark drive as
shown in Fig. 21 (ref. B). Note relationship
between slotted end of drive to splined end
of drive when marking.
21. Install drive spacer when used, in meter see

Fig. 22
22. Install seal in end cap.

19. Install seal in meter.
23. Install end cap on gerotor, align holes.
24. Install 7 dry cap screws in end cap. Pretighten

screws to 17 N.m (150 lb.in), then torque
screws to 31 N.m (275 lb.in) in the sequence
show in Fig. 23.
20. With seat side of meter toward spacer plate,

align star valleys (ref. A) on drive (ref. B).
Note the parallel relationship of reference
lines A, B, C, and D - Fig. 21. Align bolt holes
without disengaging meter from drive.

5003-13
TROUBLESHOOTING
Must steering problems can be corrected if the problem is properly defined. The entire steering system
should be evaluated before removing any components. The steering control unit is generally not the
cause of most steering problems. The following is a list of steering problems along with possible causes
and suggested corrections.
Problem Possible Cause Correction

1. Slow steering, hard steering, Worn or malfunctioning pump. Replace pump.
or loss of power assist.
Stuck flow divider piston. Replace flow divider.
Worn pump compensator Replace pump and compensator.

allowing the system pressure to
be less than specified.
Replace the relief valve.
Malfunctioning relief valve
allowing the system pressure to
be less than specified.
Reduce Load.
Overloaded steer axle.
Correct
If load sensing system:
1. Leaking or kinked load
sensing signal line. Check spring and sticking piston.
2. Malfunctioning priority valve. Check damping orifices in both
ends of main bore.
Check system pressure at SCU
inlet for proper system pressure.
If not correct replace priority
valve relief cartridge.
2. Wander – Vehicle will not Air in the system due to low level Correct.
stay in a straight line. of oil, cavitating pump, leaky
fitting, pinched hose, etc.
Worn mechanical linkage. Repair or replace.

Bending of linkage or cylinder Repair or replace.
rod. Repair or replace.
Loose cylinder piston. Repair or replace the accessory
Leaky crossover relief or valve.
anticavitation valve in cylinder Replace the steering control
lines. unit.
Severe wear in steering control
unit.
3. Drift – Vehicle veers slowly in Single rod end cylinder slowly ex- A small rate of extension may
one direction. tends without turning the steering be normal on a closed center
wheel. system.
Worn or damaged steering link- Replace linkage and align front

age. end.

5003-14

4. Slip – A slow movement of Leakage of cylinder piston seals Replace seals or accessory
steering wheel fails to cause or accessory valve between valve.
any movement of steered cylinder lines or ports.
wheels.
Worn steering control unit meter. Replace steering control unit.
5. Temporary hard steering or Thermal Shock* Check unit for proper operation
hang-up. and cause of thermal shock.
6. Erratic steering. Air in system due to low level of Correct condition and add fluid.
oil, cavitating pump, leaky fitting,
pinched hose, etc.
Loose cylinder piston. Replace cylinder.
*Thermal shock damage. Replace steering control unit.
Sticking flow control spool. Replace flow control valve.

7. Spongy ”or soft steering. Air in hydraulic system. Most Bleed air out of system. Placing
likely air trapped in cylinders or ports on top of the cylinder will
lines. help prevent air trapping.
Add fluid and check for leaks.

Low fluid level.
8. Free Wheeling-Steering wheel Steering column upper shaft is Tighten steering wheel nut.
turns freely with no feeling of loose or damaged.
pressure and no action on
steered wheels. Lower splines of column may be Repair or replace column.
disengaged or broken.
Steering control unit meter has Usually starting engine will cure
a lack of oil. This can happen problem.
on start-up. after repair, or long
periods of non use.
No flow to steering unit can be

caused by:
1. Low fluid level. Add fluid and check for leaks.
2. Ruptured hose. Replace hose.
3. Internal steering control unit Replace the unit.
damage due to thermal shock
*.
9. Free Wheeling-Steering wheel Leaking crossover relief or Repair or replace the accessory
turns with slight resistance but anticavitation valve in cylinder valve.
results in little or no steered lines.
wheel action. Determine cause. Correct and
Piston seal blown out. replace seal.
*Thermal shock - A condition caused when the hydraulic system is operated for some time without turning the steering wheel
so that fluid in the reservoir and system is hot and the steering control unit is relatively cool (more than 50oF temperature
differential). When the steering wheel is turned quickly the result is temporary seizure and possible damage to internal parts
of the steering control unit. The temporary seizure may be followed by total free wheeling.

5003-15

10. Excessive free play at Loose steering wheel nut. Repair or replace steering wheel
steering wheel. Steering column shaft worn or connection or column.
damaged. There should be very
little free play in the unit itself.
11. Excessive free play at Broken or worn Iinkage between Check for loose fitting bearings
steered wheels. cylinder and steered wheels. and anchor points in steering
Iinkage between cylinder and
steered wheels.
Leaky cylinder seals. Replace cylinder seals.

12. Binding or poor centering of Binding or misalignment in steer- AIign column pilot and spline to
steering wheel. ing column or splined input con- steering control unit.
nection.
Revise circuit return line.
High back pressure in tank line
can cause slow return to center.
Should not exceed 300 psi.
Clean the unit and filter the oil.
Large particles can cause binding If another component has failed
between the spool and sleeve. generating contaminants, flush
the system while bypassing the
steering control unit.
13. Steering unit locks up. Large particles in meter section. Clean the unit.
Insufficient hydraulic power (units Check hydraulic power supply.

over 15 in3).
Severe wear and/or broken pin. Replace the unit.
*Thermal shock. Replace the unit.

14. Steering wheel oscillates or Parts assembled wrong. Correct timing.
turns by itself. Steering unit improperly timed.
Lines connected to wrong ports. Reconnect lines correctly.

15. Steered wheels turn in Lines connected to wrong Reconnect lines correctly.
wrong direction when opera- cylinder ports.
tor activates steering wheel
16. Steering wheel kicks at start No inlet check valve on steering Install a check valve.
of steering. control unit.

5003-16
NOTES

Section
5004
STEERING PRIORITY VALVE
5004

5004-2
TABLE OF CONTENTS
SPECIAL TORQUES......................................................................................................................................................................3
STEERING PRIORITY VALVE.......................................................................................................................................................4
Disassembly............................................................................................................................................................................4
Cleaning and Inspection..........................................................................................................................................................5
Assembly.................................................................................................................................................................................5

5004-3
SPECIAL TORQUES
Spool Orifice Screws ................................................................................................................... 7.3 to 9.6 Nm (65 to 85 lb-inch).

Plugs and Relief Valve ................................................................................................................. 33.9 to 54.2 Nm (25 to 40 lb-ft).
Adapter . ...................................................................................................................................... 8.1 to 9.5 Nm (72 to 84 lb-inch).

5004-4
STEERING PRIORITY VALVE

Disassembly
STEP 1
Put the steering priority valve in a soft jawed STEP 4
vise. Remove spring (5).
STEP 2 STEP 5
Remove relief valve (1). Remove and discard Remove spool (6).
O-ring (2) from relief valve.
STEP6
STEP 3 Remove plug (7). Remove and discard O-ring
Remove plug (3). Remove and discard O-ring (8) from plug.
(4) from plug.
1. Relief Valve 6. Spool

2. O-Ring 7. Plug
3. Plug 8. O-Ring
4. O-Ring 9. Housing
5. Spring

5004-5
Cleaning and Inspection Assembly

STEP 7
STEP 11
Clean all parts in cleaning solvent. Immerse
Install new O-ring (10) on plug (9). Install plug
housing (9) in cleaning solvent and agitate
and O-ring. Tighten plug to a torque of 33.9 to
cleaning solvent.
54.2 Nm (25 to 40 lb-ft).
WEAR EYE PROTECTION WHEN USING
COMPRESSED AIR. Use compressed air to STEP 12
remove foreign matter from interior of valve Install spool (8) and spring (7).
housing and to ensure that all orifices and bores STEP 13
are clear. Install new O-ring (4) on plug (3). Install plug and
STEP 8 O-ring. Tighten plug to a torque of 33.9 to 54.2
Inspect spool (6) and housing bores for deep Nm (25 to 40 lb-ft).
scratches, gouges, and other damage. Replace STEP 14
steering priority valve if any of these conditions Install new O-ring (2) on relief valve (1). Install
are seen. relief valve and O-ring. Tighten relief valve to a
STEP 9 torque of 33.9 to 54.2 Nm (25 to 40 lb-ft).
Check that orifice screws in each end of spool (6)
are free and clear of foreign matter. WEAR EYE
PROTECTION WHEN USING COMPRESSED
AIR. If necessary, remove ori fice screws and
use compressed air to remove foreign matter
from interior of spool (6) and orifice screws.
Install orifice screws in spool (6) ends. Tighten
screws to a torque of 7.3 to 9.6 Nm (65 to 85 lb-
inch).Aperte os parafusos com um torque de 7,3
a 9,6 N.m (65 a 85 lbf.pol).
STEP 10
Check spring (5) for cracks, breaks, or signs of
permanent set. Replace if any of these conditions
are seen.

5004-6
NOTES

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1 - GENERAL

845B / 845B DHP

Printed in U.S.A. Part number 84559573

Standard Torque Especifications ............................................................................................................................................ 1001

Fluids and Lubricants ............................................................................................................................................................. 1002

Metric Conversion Chart . ....................................................................................................................................................... 1003

Service Tools .......................................................................................................................................................................... 1005

Copyright © 2011 CNH America LLC.

STANDARD TORQUE ESPECIFICATIONS

Copyright © 2011 CNH America LLC.

6-46530 ENG Issued 07-11 Printed in Brazil

Size (inch) Pound-Inches N.m Size (inch) Pound-Inches N.m

7/16 54 - 64 73 - 87 7/16 70 - 84 95 - 114

1/2 80 - 96 109 - 130 1/2 110 - 132 149 - 179

6-46530 ENG Issued 07-11 Printed in Brazil

Size (inch) Pound-Inches N.m Size (inch) Pound-Inches N.m

Grade 12.9 Bolts, Nuts and Studs

Usually the torque values specified for grade 10.9 faste-

6-46530 ENG Issued 07-11 Printed in Brazil

Steel Hydraulic Fittings

37 Degree Flare Fitting Straight Threads with O-ring

Split Flange Mounting Bolts

6-46530 ENG Issued 07-11 Printed in Brazil

Steel Hydraulic Fittings

O-ring Boss End

6-46530 ENG Issued 07-11 Printed in Brazil

Copyright © 2011 CNH America LLC.

6-46540 ENG Issued 07-11 Printed in Brazil

FLUIDS AND LUBRICANTS

6-46540 ENG Issued 07-11 Printed in Brazil

6-46540 ENG Issued 07-11 Printed in Brazil

865B AWD / 885B AWD Models Equipped with Tier 3 Engines

6-46540 ENG Issued 07-11 Printed in Brazil

Recomendações de Viscosidade do Óleo e Fluidos

SAE 20W-50 TROPIC

SAE 15W-40 ALL SEASONS

SAE 10W-30 WINTER

SAE 5W-30 ARCTIC

SAE 0W-30 ARCTIC

-40º -30º -20º -10º 0º 10º 20º 30º 40º 50º

Hydraulic / Brake / Transmission System – Temperature Ranges

AKCELA AW HYDRAULIC FLUID 68 HV

CASE AKCELA Hy-Tran Ultra

CASE AKCELA Hy-Tran Ultra SSL

-40º -30º -20º -10º 0º 10º 20º 30º 40º 50º

6-46540 ENG Issued 07-11 Printed in Brazil

Specifications for Acceptable No. 2 Diesel Fuel

6-46540 ENG Issued 07-11 Printed in Brazil

Lubrication & Maintenance Chart

6-46540 ENG Issued 07-11 Printed in Brazil

500 hours Transmission Oil and Oil Filter

NOTE: See “FLUIDS AND LUBRICANTS” table on previous pages

6-46540 ENG Issued 07-11 Printed in Brazil

6-46540 ENG Issued 07-11 Printed in Brazil

6-46540 ENG Issued 07-11 Printed in Brazil

865B AWD / 885B AWD Models Equipped with Tier 3 Engines

6-46540 ENG Issued 07-11 Printed in Brazil

6-46540 ENG Issued 07-11 Printed in Brazil

6-46540 ENG Issued 07-11 Printed in Brazil

Copyright © 2011 CNH America LLC.

6-46550 ENG Issued 07-11 Printed in Brazil

sq. meter 10.76391 square foot

newton 3.596942 ounce force

millimeter 0.039370 inch