Ce BD 011200

CEBM011200
Shop
Manual
830B
850B
870B
830C
850C
870C
MOTOR GRADER
830B 203163
830C 202753
850B 202575
SERIAL NUMBERS and UP
850C 202727
870B 202599
870C 202775
This material is proprietary to Komatsu America Corp/ and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
October 2003 Copyright 2003 Komatsu
Printed in USA DataKom Publishing Division
830B/C- 00-1
850B/C-870B/C
FOREWORD CONTENTS
12
CONTENTS 00
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 830B/C-850B/C-870B/C
PRODUCT PUBLICATIONS INFORMATION
Various product Parts and Service Publications are available to all KOMATSU construction equipment
owners, including operation and maintenance manuals, parts books and service manuals.
Special publications, such as service tool, air conditioning and turbocharger service manuals are also
available as well as selected Operation and Service manuals in foreign languages.
The Publications listed below are available for this particular machine(s).
DESCRIPTION FORM NUMBER
PARTS BOOK - PAPER:

Chassis and Engine 830B/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB002801
Chassis and Engine 850B/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BEPBG58612
Chassis and Engine 870B/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BEPBG78100
OPERATION AND MAINTENANCE MANUAL:

Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM009800
SHOP MANUAL
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM011200
Engine 114E-2 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM000601
Engine 102E-2 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEBM010016
SAFETY MANUAL
Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1085 960 R2
Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the
Komatsu America Corp. Extranet Literature Ordering System.
If the Extranet Literature Ordering System is not available at the distributor location, then the following
Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown
on the reverse side of this page. Komatsu America Corp. reserves the right to add a surcharge to all fax
orders.
830B/C-850B/C-870B/C Publinfok.fm 10/16/03

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM DataKom Publications and Training Division

AND RETURN TO 440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME
SHIP TO PURCHASE ORDER NO.
ATTN.
STREET ADDRESS ORDER DATE

TYPE or PRINT
ONLY CITY, STATE, ZIP CODE
COUNTRY
PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND
MACHINE SERIAL NUMBER MUST BE SHOWN.
QTY. PUBLICATION FORM NO. PARTS BOOK PUBLICATION MODEL NUMBER SERIAL NUMBER
P-Paper DESCRIPTION
➥
M-Microfiche
KDC91E 071403 CURRENT PRICES WILL BE CHARGED

FOREWORD SAFETY
12
SAFETY 00
SAFETY NOTICE 00
IMPORTANT SAFETY NOTICE 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise,
first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 00
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE
operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with
buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding
work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting.
Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct
places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK 00
1. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the
machine from moving.
2. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not
possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the
control levers and hang warning signs on them.
3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
830B/C-850B/C-870B/C 00-3
FOREWORD SAFETY
4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails,
ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the
handrails, ladders or steps, use a stand to provide safe footing.
PRECAUTIONS DURING WORK 00
1. When removing the oil filler cap, drain plug or

hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before
disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the
circuit.
2. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and
water to cool before carrying out any work on the oil or water circuits.
3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-)
terminal first.
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.
8. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing
electrical parts.
9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any
measurements.
14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
00-4 830B/C-850B/C-870B/C
FOREWORD GENERAL
12
GENERAL 00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this
section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
830B/C-850B/C-870B/C 00-5
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00
VOLUMES 00
REVISIONS 00
Shop manuals are issued as a guide to carrying out repairs.

Revised pages are shown at the LIST OF REVISED PAGES
They are divided as follows:
between the title page and SAFETY page.
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series SYMBOLS 00
Electrical volume: Each issued as one to cover all models So that the shop manual can be of ample practical use,
Attachment volume: Each issued as one to cover all models important places for safety and quality are marked with the
following symbols.
These various volumes are designed to avoid duplication of
information. Therefore to deal with all repairs for any model, Symbol Item Remarks
it is necessary that chassis, engine, electrical and attachment
be available. Special safety precautions are
Safety necessary when performing the
work.
DISTRIBUTION AND UPDATING 00
Special technical precautions or

Any additions, amendments or other changes will be sent to other precautions for preserving
★ Caution
your distributors. Get the most up-to-date information before standards are necessary when
you start any work. performing the work.
Weight of parts or systems.
FILING METHOD 00
Caution necessary when
Weight selecting hoisting wire or when
1. See the page number on the bottom of the page. File the working posture is important,
pages in correct order. etc.
2. Following examples show how to read the page number:
Example: Places that require special
Tightening
attention for tightening torque
torque
10 - 3 during assembly.
Places to be coated with
Item number (10. Structure and Function) Coat
adhesives and lubricants etc.
Consecutive page number for each item Places where oil, water or fuel
Oil, water
must be added, and the capacity.
3. Additional pages: Additional pages are indicated by a
hyphen (-) and numbered after the page number. File as Places where oil or water must
in the example. Drain be drained, and quantity to be
Example: drained.
10-4
10-4-1
Added pages
10-4-2
10-5
REVISED EDITION MARK 00
When a manual is revised, an edition mark (123…) is

recorded on the bottom outside corner of the pages.
00-6 830B/C-850B/C-870B/C
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00
HOISTING 00
can result. Hooks have maximum strength at the middle
portion.
WARNING! Heavy parts (25 kg or more)
must be lifted with a hoist etc. In
the DISASSEMBLY AND
ASSEMBLY section, every part
weighing 25 kg or more is
indicated clearly with the symbol
● If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made:
1. Check for removal of all bolts fastening the part to the 3. Do not sling a heavy load with one rope alone, but sling
relative parts. with two or more ropes symmetrically wound on to the
2. Check for existence of another part causing interface load.
with the part to be removed.
WARNING! Slinging with one rope may
WIRE ROPES 00 cause turning of the load during
hoisting, untwisting of the rope,
1. Use adequate ropes depending on the weight of parts to or slipping of the rope from its
be hoisted, referring to the table below: original winding position on the
load, which can result in a dan-
Wire ropes gerous accident
(Standard “Z” or “S” twist ropes without galvanizing)
4. Do not sling a heavy load with ropes forming a wide
Rope diameter Allowable load
hanging angle from the hook. When hoisting a load with
mm kN tons two or more ropes, the force subjected to each rope will
increase with the hanging angles. The table below
10 9.8 1.0
shows the variation of allowable load (kg) when
11.2 13.7 1.4 hoisting is made with two ropes, each of which is
allowed to sling up to 1000 kg vertically, at various
12.5 15.7 1.6
hanging angles. When two ropes sling a load vertically,
14 21.6 2.2 up to 2000 kg of total weight can be suspended. This
weight becomes 1000 kg when two ropes make a 120°
16 27.5 2.8
hanging angle. On the other hand, two ropes are subject
18 35.3 3.6 to an excessive force as large as 4000 kg if they sling a
2000 kg load at a lifting angle of 150°
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
★ The allowable load value is estimated to be 1/6 or 1/7 of

the breaking strength of the rope used.
2. Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident
830B/C-850B/C-870B/C 00-7
FOREWORD COATING MATERIALS
12
COATING MATERIALS 00
★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
● Used to prevent rubber gaskets, rubber cushions
LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out
● Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene
LT-1B 790-129-9050 ● Used for plastics (except polyethylene,
(2 pes.) container
polypropylene, tetrafluoroethylene, and vinyl
chloride), rubber, metal and non-metal.
● Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g ● Used for anti-loosening and sealant
container
purposes for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive ● Used as adhesive or sealant for metal, glass or
LT-3 Hardening Can
and hardening plastic.
agent:
agent)
500 g
Adhesives
Polyethylene
LT-4 790-129-9040 250 g ● Used as sealant for machined holes.
container
Holtz ● Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
● Quick hardening type adhesive.
Three bond Polyethylene ● Cure time: within 5 sec. to 3 min.
179-129-9140 2g
1735 container ● Used mainly for adhesion of metals, rubbers,
plastics and woods.
● Quick hardening type adhesive.
Aron-alpha Polyethylene ● Quick cure type (max. strength after 30 minutes).
790-129-9130 50 g
201 container ● Used mainly for adhesion of rubbers, plastics
and metals.
● Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc ● Used at joint portions subject to high tempera-
648-50 container
ture.
● Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
Features: Resistance to heat
Gasket sealant
●
● Used as sealant for flange surfaces and bolts at
high temperature locations; used to prevent
LG-3 790-129-9070 1 kg Can seizure.
● Used as sealant for heat resistant gasket for at
high temperature locations such as engine
pre-combustion chamber, exhaust pipe.
00-8 830B/C-850B/C-870B/C
FOREWORD COATING MATERIALS
Category Code Part No. Quantity Container Main applications, features

● Features: Resistance to water, oil
● Used as sealant for flange surface, thread.
● Also possible to use as sealant for flanges with
LG-4 790-129-9020 200 g Tube
large clearance.
● Used as sealant for mating surfaces of final drive
case, transmission case.
● Used as sealant for various threads, pipe joints,
Polyethylene con- flanges.
Gasket sealant
LG-5 790-129-9080 1 kg
tainer ● Used as sealant for tapered plugs, elbows, nip-
ples of hydraulic piping.
● Features: Silicon based, resistant to heat, cold.
LG-6 09940-00011 250 g Tube ● Used as sealant for flange surface, thread.
● Used as sealant for oil pan, final drive case, etc.
● Features: Silicon based, quick hardening type.
LG-7 09920-00150 150 g Tube ● Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Three bond ● Used as heat-resisting sealant for repairing
790-129-9090 100 g Tube
1211 engines.
● Used as lubricant for sliding parts (to prevent
LM-G 09940-00051 60 g Can
Molybdenum
squeaking).
disulphide
lubricant
● Used to prevent seizure or scuffing of the thread

LM-P 09940-00040 200 g Tube when press fitting or shrink fitting.
● Used as lubricant for linkage, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various ● General purpose type
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
● Used for normal temperature, light load bearing
G2-CA SYG2-400CA-A Various Various
Grease
at places in contact with water or steam.

SYG2-160CA
SYG2-160CNCA
disulphide lubricant
Molybdenum
400 g (10 per

SYG2-400M Belows type ● Used for places with heavy load.
case)
830B/C-850B/C-870B/C 00-9
FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE 00
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
Thread diameter of bolt Width across flats
mm mm Nm lbf ft
6 10 13.2 ± 1.4 9.2 ± 1.03
8 13 31.4 ± 2.9 23.1 ± 2.1
10 17 65.7 ± 6.8 48.4 ± 5.0
12 19 112 ± 9.8 82.6 ± 7.2
14 22 177 ± 19 130.5 ± 14.0
16 24 279 ± 29 205.7 ± 21.3
18 27 383 ± 39 282.4 ± 28.7
20 30 549 ± 58 404.9 ± 42.7
22 32 745 ± 78 549 ± 57.5
24 36 927 ± 98 683 ± 72.2
27 41 1320 ± 140 973.5 ± 103.2
30 46 1720 ± 190 1268.6 ± 140.1
33 50 2210 ± 240 1630.0 ± 177.0
36 55 2750 ± 290 2028.2 ± 213.8
39 60 3280 ± 340 2419.2 ± 250.7
Thread diameter of bolt Width across flats
mm mm Nm lbf ft
6 10 7.85 ± 1.95 5.7 ± 1.4
8 13 18.6 ± 4.9 13.7 ± 3.6
10 14 40.2 ± 5.9 29.6 ± 4.3
12 27 82.35 ± 7.85 60.7 ± 5.7
00-10 830B/C-850B/C-870B/C
FOREWORD STANDARD TIGHTENING TORQUE
12
TIGHTENING TORQUE OF HOSE NUTS 00
Use these torques for hose nuts.

Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm lbf ft
02 14 19 24.5 ± 4.9 18.0 ± 3.6
03 18 24 49 ± 19.6 36.1 ± 14.4
04 22 27 78.5 ± 19.6 57.8 ± 14.4
05 24 32 137.3 ± 29.4 101.2 ± 21.6
06 30 36 176.5 ± 29.4 130.1 ± 21.6
10 33 41 196.1 ± 49 144.6 ± 36.1
12 36 46 245.2 ± 49 180.8 ± 36.1
14 42 55 294.2 ± 49 216.9 ± 36.1
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 00
Use these torques for split flange bolts.

mm mm Nm lbf ft
10 14 65.7 ± 6.8 48.4 ± 5.0
12 17 112 ± 9.8 82.6 ± 7.2
16 22 279 ± 29 205.7 ± 21.3
TIGHTENING TORQUE FOR FLARED NUTS 00
Use these torques for flared part of nut.

mm mm Nm lbf ft
14 19 24.5 ± 4.9 18.0 ± 3.6
18 24 49 ± 19.6 36.1 ± 14.4
22 27 78.5 ± 19.6 57.8 ± 14.4
24 32 137.3 ± 29.4 101.2 ± 21.6
30 36 176.5 ± 29.4 130.1 ± 21.6
33 41 196.1 ± 49 144.6 ± 36.1
36 46 245.2 ± 49 180.8 ± 36.1
42 55 294.2 ± 9 216.9 ± 36.1
830B/C-850B/C-870B/C 00-11
FOREWORD ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE 00
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS 00
Copper wire
Nominal Cable O.D. Current
Number of Dia. Of strand Cross section Applicable circuit
number (mm) rating (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE 00
Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Code W B B R Y G L
Primary
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yellow & Green &
Color — Red & Black Blue & Red
Black Yellow Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yellow & Green & Blue &
Color — Black & Red
Blue Yellow Green Yellow Yellow
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
00-12 830B/C-850B/C-870B/C
FOREWORD CONVERSION TABLES
12
CONVERSION TABLES 00
METHOD OF USING THE CONVERSION TABLE 00
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.
EXAMPLE
● Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as 1, then draw a horizontal line from 1.
B. Locate the number 5 in the row across the top, take this as 2, then draw a perpendicular line down from 2.
C. Take the point where the two lines cross as 3. This point 3 gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.

A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to
55 mm.
B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
2
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
3
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
1
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
830B/C-850B/C-870B/C 00-13
12
Millimeters to Inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound 1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-14 830B/C-850B/C-870B/C
12
Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon 1 L = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
830B/C-850B/C-870B/C 00-15
12
kgm to ft. lb. 1 kgm = 7.233 ft. lb.

0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-16 830B/C-850B/C-870B/C
12
kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2

0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
830B/C-850B/C-870B/C 00-17
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees,
consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the
column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-18 830B/C-850B/C-870B/C
01 GENERAL
GENERAL ASSEMBLY DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2

830 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
850/870 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
FUEL, COOLANT, AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
ACCORDING TO AMBIENT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
ENGINE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5
NORMAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5
ARCTIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5
TRANSMISSION, TORQUE CONVERTER AND OIL COOLER, TANDEM DRIVE CASES,
FRONT-WHEEL-DRIVE GEAR CASE, IF EQUIPPED, AND HYDRAULIC SYSTEM OIL
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
REAR-DRIVE AXLE AND CIRCLE DRIVE BRAKE HOUSING OIL SPECIFICATIONS . . . . . . . . . . . 01-6
DIESEL FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
COOLANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
ANTIFREEZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
SUPPLEMENTAL COOLANT ADDITIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
MAINTENANCE OF SUPPLEMENTAL COOLANT ADDITIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
COOLANT TESTING FOR CONDITIONER CONCENTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
REPLENISHING COOLANT CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
SUPPLEMENTAL COOLANT ADDITIVE MAINTENANCE GUIDE . . . . . . . . . . . . . . . . . . . . . . . 01-10
COOLING SYSTEM TEST KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
CIRCLE DRIVE GEAR CASE OIL SPECIFICATIONS (HDTF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
830B/C-850B/C-870B/C 01-1
GENERAL GENERAL ASSEMBLY DRAWING
12
GENERAL ASSEMBLY DRAWING
830
850/870
01-2 830B/C-850B/C-870B/C
GENERAL FUEL, COOLANT, AND LUBRICANTS
12
FUEL, COOLANT, AND LUBRICANTS
ACCORDING TO AMBIENT TEMPERATURE
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS

It is not Komatsu’s policy to approve fuel, coolant and lubricants or to guarantee performance in service. The supplier is
responsible for the quality of the fuel, coolant, and lubricants. When in doubt, consult your Komatsu distributor. The specified
fuel, coolant, and lubricant recommended for this machine are as shown in the following table.
Other equipment may be needed when operating the machines at temperatures below -20° C (-4° F). Consult your Komatsu
distributor for your specific needs.
Remark
For axle oil, use only the following recommended oils.
SHELL: DONAX TT or TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON:TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBILE 424
It is possible to substitute engine oil SAE 30 API classification CD for axle oil. Although increased brake noise may result,
durability is not affected.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
NLGI: National Lubricating Grease Institute
830B/C-850B/C-870B/C 01-3
12
AMBIENT TEMPERATURE CAPACITY

FLUID
RESERVOIR -22 -4 14 32 50 68 86 104 122° F S6D102E-1 S6D114E-1
TYPE
-30 -20 -10 0 10 20 30 40 50° C ENGINE ENGINE
SAE 5W-30
Engine 16.4 liter 22.4 liter
Engine SAE 10W-30
Oil 4.33 gal 5.92 gal
SAE 15W-40
Trans- 26.5 liter 26.5 liter
Transmission mission DEXRON III/C-4
fluid 7.0 gal 7.0 gal
or Engine
Front-wheel-drive 7.57 liter 7.57 liter
oil SAE 10W
gear case 2.0 gal 2.0 gal
24.6 liter 24.6 liter

Rear axle
4.5 gal 4.5 gal
Hytran
Tandem drive cases Type 30.9 liter 30.9 liter
Fluid 8.7 gal 8.7 gal
Circle slip clutch 1.9 liter 1.9 liter

0.5 gal 0.5 gal
SAE 80W-90
Circle drive gear 2.83 liter 2.83 liter
Gear lube SAE 85W-140 or 80W-90
case 0.75 gal 0.75 gal
SAE 85W-140
Hydraulic system 98.4 liter 98.4 liter

without Trans- DEXRON III/C-4
All-Wheel-Drive mission 26.0 gal 26.0 gal
fluid or
Hydraulic system Engine SAE 5W-20 or SAE 5W-30 117.4 liter 117.4 liter
with 31.0 gal 31.0 gal
oil
All-Wheel-Drive SAE 10W
ASTM D975 No. 2

Diesel 346 liter 346 liter
Fuel tank ASTM D975
fuel 91.5 gal 91.5 gal
No. 1
Komatsu Super Grease or NLGI No. 2 Multipurpose lithium grease

All lube fittings Grease Fill as instructed
with 3 percent molybdenum disulfide
32.6 liter 32.0 liter

Cooling system Coolant See coolant specifications on page 01-7
8.6 gal 8.5 gal
01-4 830B/C-850B/C-870B/C
12
ENGINE OIL SPECIFICATIONS
NORMAL OPERATION
Oil performance recommendations are as follows:
The use of a quality engine lubricating oil combined with appropriate oil and filter change intervals are critical factors in
maintaining engine performance and durability.
SAE 15W-40 multiviscosity oil meeting the API performance classification of CF-4 or CF-4/SG is recommended.
CE or CE/SF oils may be used in areas where CF-4 or CF-4/SG oil is not yet available.
A sulfated ash limit of 1.0 mass percent is suggested for optimum valve and piston deposit and oil consumption control. The
sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85 mass percent has been placed on all engine
lubricating oils recommended for use in the engine. Higher ash oils can cause valve and/or piston damage and lead to
excessive oil consumption.
The API service symbol displays the following information. The upper half of the symbol displays the appropriate oil
categories; the lower half may contain words to describe oil energy conserving features. The center section identifies the SAE
oil viscosity grade.
Oil viscosity recommendations are as follows:
The use of a multigraded lubricating oil has been found to improve oil consumption control and improve engine cranking in
cold temperatures while maintaining lubrication at high operating temperatures.
While SAE 15W-40 multiviscosity oil is recommended for most operating climates, refer to the previous chart for oil viscosity
recommendations for extreme climates.
Single graded oils may be used if multigraded oil is not available. But be sure to use oil that matches the temperature shown in
the table.
Special “break-in” lubricating oils are not recommended for a new or rebuilt engine. Use the same type of oil during the
break-in as specified for normal operation.
Additional information regarding lubricating oil availability throughout the world is available in the “E.M.A. Lubricating Oils
Data Book for Automotive and Industrial Engines.” Order the data book from the Engine Manufacturers Association, 401
North Michigan Ave., Chicago, IL U.S.A. 60611. The telephone number is (312) 644-6610.
ARCTIC OPERATION
If an engine is operated in ambient temperatures consistently below -23° C (-10° F) and there are no provisions to keep the
engine warm when it is not in operation, use a synthetic API performance classification CE or CF-4 engine oil with adequate
low temperature properties such as SAE 5W-20 or 5W-30. The oil supplier must be responsible for meeting the performance
service specifications.
The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change intervals can decrease
engine life due to corrosion, deposits, and wear.
830B/C-850B/C-870B/C 01-5
12
TRANSMISSION,TORQUE CONVERTER AND OIL COOLER, TANDEM DRIVE
CASES, FRONT-WHEEL-DRIVE GEAR CASE, IF EQUIPPED, AND
HYDRAULIC SYSTEM OIL SPECIFICATIONS
Komatsu Heavy Duty Transmission Fluid, Dexron III/C4, engine oil with an API classification of CD/CC, CD or
MIL-L-2104D or E and meeting C-4 and TO-2, TO-4 and containing 0.10 percent zinc minimum is recommended.
REAR-DRIVE AXLE AND CIRCLE DRIVE BRAKE HOUSING OIL

SPECIFICATIONS
Komatsu Hydraulic Transmission Fluid or Hytran Fluid is recommended.
DIESEL FUEL SPECIFICATIONS
WARNING! Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion,
resulting in injury or death.
WARNING! Never remove the fuel tank filler cap or refill the fuel tank while the engine is hot or
running, or when the grader is indoors. Fumes are dangerous and a spark or flame could
result in a fire or explosion.
Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept clean and free of
dirt or water. Dirt or water in the system can cause severe damage to both the injection pump and nozzles.
At temperatures below -12° C (+10° F) the paraffin in ASTM Grade No. 2-D diesel fuel will change to wax particles and
clog the fuel filters. For best results, use grade No. 1-D diesel fuel in cold weather.
For normal service above -12° C (+10° F), the use of ASTM Grade No. 2-D diesel fuel with a minimum Cetane number of 40
is recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating conditions.
Fuels with Cetane numbers greater than 40 may be needed in high altitudes or extremely low ambient temperatures to prevent
misfires and excessive smoke.
At operating temperatures below -12° C (+10° F), use ASTM Grade No. 1-D diesel fuel. The use of lighter fuels can reduce
fuel economy.
Where a winterized blend of Grade No. 2-D and No. 1-D fuels is available, it may be substituted for Grade No. 1-D fuel. It is
the supplier's responsibility to provide the fuel for the anticipated ambient temperature.
Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected fuel temperature. Cloud
point is the temperature at which crystals begin to form in the fuel.
The viscosity of the fuel must be kept above 1.3 cSt to provide adequate fuel system lubrication.
Optionally, use the equivalent grades of recognized Federal Government specifications, the latest revisions of VV-F-800a.
01-6 830B/C-850B/C-870B/C
12
COOLANT SPECIFICATIONS
GENERAL
Selection and maintenance of the engine coolant is important to long engine life. The following information provides
recommendations for selecting the engine coolant and maintaining the coolant inhibitors.
Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additives.
Supplemental coolant additive recommendations are included in the section entitled “Inhibitors/Conditioners.” The coolant
mixture must be drained and replaced at the specified service interval shown in the maintenance schedule chart, or every two
years of operation, whichever comes first.
WATER
Use water which has a low mineral content. Water used in conjunction with antifreeze, coolant filters and inhibited water must
meet the following standards:
Total Hardness:
Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale deposits. Water containing dissolved
magnesium and calcium (the usual reason for water hardness) above the specified amount will cause scale deposits to develop
in the engine.
Chlorides:
Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.
Sulfates:
Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion.
Dissolved Solids:
Not to exceed 340 parts per million (20 grains/gallon maximum) to minimize sludge deposits, scale deposits, corrosion or a
combination of these.
If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To determine if local water
supplies meet these standards, water samples can be tested by water treatment laboratories. “Softened” water that is prepared
using common salt (sodium chloride) contains excessive amounts of chlorides and should not be used.
Never use water alone in the cooling system because corrosion will occur.
ANTIFREEZE
In climates where the temperature is above -37° C (-34° F), use a coolant mixture that contains 50 percent antifreeze.
Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and
by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze protection is
required. Never use more than 68 percent antifreeze under any condition.
An antifreeze concentration greater than 68% will adversely affect freeze protection and heat transfer rates. Antifreeze
concentrations between 68 and 100% actually have a higher freezing point than a 68% antifreeze concentration and should not
be used due to reduced heat transfer rates.
Low silicate ethylene glycol antifreeze is recommended. The antifreeze should contain no more than 0.1% anhydrous alkali
metasilicate. Low silicate antifreeze is recommended to avoid the formation of silica-gel (hydro-gel). This gel formation can
occur when the cooling system contains an over concentration of high silicate antifreeze and/or supplemental coolant additive.
DO NOT use methanol or alcohol as an antifreeze because of its low boiling point.
830B/C-850B/C-870B/C 01-7
12
Antifreeze may retain its freeze protection for more than one season but coolant conditioners must be added to maintain corro-
sion protection.
Antifreeze formulated with methoxy propanol or propylene glycol is not recommended for this system.
Do not mix types of antifreeze solutions. Mixed solutions make it impossible to determine the protection against
freezing. Antifreeze containing sealer or antileak additives should NOT be used in this system. Sealer or antileak
additives will cause plugging problems in the cooling system.
WARNING! Use extreme caution when adding coolant to a hot radiator. Wear gloves and goggles
and keep your face away from the radiator filler neck to avoid being burned.
Check the solution periodically and at normal operating temperature to be sure the cooling system has sufficient protection
against freezing.
An antifreeze concentration greater than 68 percent will adversely affect antifreeze protection and heat transfer rates. Although
an antifreeze concentration from 69 percent to 100 percent has a higher freezing point than one of 68 percent, the rate of heat
transfer is reduced. Thus, do not use a concentration greater than 68 percent. Also, never use a 100 percent concentration of
antifreeze because it will corrode and damage the cooling system.
The following table shows the approximate percentage of antifreeze solution required for various temperatures.
Percentage of Antifreeze
Approximate Freezing Point Specific Gravity at 16° C (60° F)
Concentration by Volume
0° C (+32° F) 0 1.000
-7° C (+20° F) 15 1.025
-12° C (+10° F) 25 1.040
-18° C (0° F) 33 1.053
-23° C (-10° F) 40 1.062
-29° C (-20° F) 45 1.070
-34° C (-30° F) 48 1.074
-40° C (-40° F) 53 1.080
-46° C (-50° F) 56 1.083
-51° C (-60° F) 59 1.088
-57° C (-70° F) 62 1.092
-62° C (-80° F) 65 1.095
-68° C (-90° F) 67 1.097
-69° C (-92° F) 68 1.098
In tropical climates where antifreeze availability may be limited, use a corrosion inhibitor DCA4, to protect the engine cooling
system.
01-8 830B/C-850B/C-870B/C
12
SUPPLEMENTAL COOLANT ADDITIVES
1. All cooling system inhibitors, including those in antifreeze solutions, become depleted through normal operation. If the
inhibitors in antifreeze are allowed to become depleted, the antifreeze becomes corrosive and attacks and coats the
metallic surfaces of the cooling system which reduces heat transfer. Cooling system conditioners that contain these
inhibitors must be added to maintain corrosion protection.
2. SOLUBLE OIL IS NOT RECOMMENDED for use in this engine as its use will reduce heat transfer.
3. There are no miracle additives that will increase heat transfer or prevent overheating. Conditioned water is still the best
coolant.
4. A corrosion inhibitor is recommended to inhibit corrosion in the cooling system for the following reasons:
• Improved compatibility with high silicate antifreezes to minimize hydro-gel formation if over concentration occurs.
• Provides engine protection in the following areas:
- Solder corrosion/bloom - Copper corrosion/erosion/stress cracking
- Oil fouling - Cylinder liner cavitation corrosion
- Aluminum cavitation corrosion - Seal and gasket degradation
MAINTENANCE OF SUPPLEMENTAL COOLANT ADDITIVES

Keeping the engine coolant properly inhibited will keep the engine and radiator free of rust, scale deposits and corrosion.
New machines are delivered with antifreeze protection. Service at regular scheduled intervals specified in with a service
DCA4 filter.
Each time the coolant is drained and replaced, the coolant must be recharged with DCA4. New coolant can be correctly
charged with supplemental coolant additives by using DCA4 filters or DCA4 concentrate listed in the table entitled, “DCA4
Unit Guide.”
If coolant is added between drain intervals, additional DCA4 will be required.
COOLANT TESTING FOR CONDITIONER CONCENTRATION

When the cooling system is maintained as recommended, the conditioner concentration should be satisfactory. The DCA4
concentration must not fall below 1.0 unit per 3.8 liters (1 US gal) or exceed 2 units per 3.8 liters (1 US gal) of coolant. The
only accurate method for testing chemical concentrations in coolant with mixed chemical compounds is a laboratory analysis.
Maintain the coolant inhibitor.
Inadequate concentration of the coolant additive can result in major corrosive damage to cooling system components.
Over concentration can cause gel formation that can plug coolant passages, causing overheating.
REPLENISHING COOLANT CONDITIONER

Install a “precharge” DCA4 filter when the coolant is changed or a significant (more than 50%) coolant loss occurs. Install a
service DCA4 filtrate every 250 hour inspection. When antifreeze is added, add coolant conditioner equal to 1.0 unit per 3.8
liters (1 US gal) of antifreeze.
Mixing of DCA4 and other supplemental coolant additives is not recommended because there is currently no test kit
available to measure the concentration levels of a mixed chemical solution.
830B/C-850B/C-870B/C 01-9
12
SUPPLEMENTAL COOLANT ADDITIVE MAINTENANCE GUIDE
Use supplemental coolant additives (corrosion inhibitors) to protect the engine cooling system from corrosion. Antifreeze
alone does not provide enough corrosion protection for a heavy duty diesel engine. Supplemental corrosion protection must
be supplied through periodic additions of supplemental coolant additives to the coolant.
To protect against corrosion, a new coolant charge must be brought up to 0.26 DCA4 unit per liter (one unit per U.S. gal) of
coolant (initial charge). Maintain the correct DCA4 concentration by changing the service coolant filter at each engine oil and
filter change interval.
Each time the coolant is drained and replaced, the coolant must be recharged with supplemental coolant additives. Use the
appropriate DCA4 spin-on filter listed in following table. The coolant mixture must be drained and replaced as defined under
“General”.
The amount of replacement inhibitor is determined by the length of the service interval and the cooling system capacity. Refer
to the DCA4 Unit Guide for the selection of the correct filter to replenish the DCA4.
If coolant is added between drain intervals, additional DCA4 will be required. Check the coolant DCA4 concentration level
anytime make-up coolant is added to the system. The DCA4 concentration must not fall below 0.13 units per liter or exceed
0.5 units per liter (0.5 units per U.S. gallon or exceed 2 units per U.S. gallon).
DCA4 Unit Guide
Fleet guard Part No. DCA4 Units
DCA4 Coolant Filter
WF-2070 2
WF-2071 4
WF-2072 6
WF-2073 8
WF-2074 12
WF-2075 15
WF-2076 23
WF-2077 0
DCA4 Liquid
DCA60L 4 (1 Pint)
DCA80L 1760 (55 US gal)
DCA4 Powder
DCA95 20
01-10 830B/C-850B/C-870B/C
DCA4 PreCharge and Service Filters
System Capacity PreCharge Filter Service Filter
Liters Gallons (See Remark 1) (See Remark 3)
19-29 5-7 WF-2072 WF-2070
30-41 8-10 WF-2073 WF-2071
42-60 11-15 WF-2074 WF-2071
61-79 16-20 WF-2075 WF-2071
80-117 21-30 WF-2076 WF-2072
118-190 31-50 (See Remark 2) WF-2073
Remark 1
After draining and replacing coolant, always precharge the cooling system to maintain the DCA4
concentration between 1.0 and 2.0 units per 3.8 liters (1 US gal).
When performing service that requires draining the cooling system, discard the coolant. Reusing old coolant can introduce
contaminates or over -concentrated chemicals, resulting in premature failure of the cooling system components.
Remark 2
To precharge cooling systems larger than 114 liters (30 gal), do the following:
• Install the appropriate service filter listed in the above table based on cooling system capacity.
Example: 95 gal (360 liters) cooling system capacity

-15 Units (1) WF-2075 Filter
80 Units
• The answer represents the additional units required to pre charge the cooling system. Four bottles of powder, part
number DCA95, will provide a sufficient amount of DCA4 units (80) to pre charge the example cooling system.
• Install the appropriate service filter at the next and subsequent maintenance intervals.
Remark 3
Change the coolant filter at every engine oil and filter change interval to protect the cooling system.
Maintain a nominal concentration of 1.0 DCA4 unit per 3.8 liters (1 US gal) of coolant in the system. Less than 0.5 unit per 3.8
liters (1 US gal) indicates an under-concentrated coolant solution. More than 2.0 units per 3.8 liters (1 US gal) indicates an
over-concentrated coolant solution.
To check the DCA4 concentration level, use the Fleet guard coolant test kit, CC2626. Instructions are included with the test
kit.
830B/C-850B/C-870B/C 01-11
SCA Unit Concentration Guide
Number of Solution A Drops to

Coolant Condition Action Required
Cause Color Change
Extremely under-concentrated: less Initially charge the system to a

0 to 10 Drops than 0.4 SCA units per 3.8 liters (1 US minimum of 1.0 SCA unit per 3.8
gal) liters (1 US gal)
Add SCA liquid units to maintain 1.0

Marginally under-concentrated: 0.45
SCA unit per 3.8 liters (1 US gal)
11 to 16 Drops to 0.8 SCA units per 3.8 liters (1 US
minimum or change the DCA4
gal)
coolant filter
Acceptable: 0.85 to 1.3 SCA units per

17 to 25 Drops NONE
3.8 liters (1 US gal)
Highly acceptable: 1.35 to 2.0 SCA

26 to 35 Drops NONE
units per 3.8 liters (1 US gal)
Marginally over-concentrated: 2.1 to

36 to 55 Drops Review maintenance practice
3.3 SCA units per 3.8 liters (1 US gal)
Drain 50% of the coolant and replace

with water antifreeze mixture. Retest
Over 55 Drops Extremely over-concentrated
the system for correct SCA unit
concentration.
COOLING SYSTEM TEST KIT

The Fleet Guard® Coolant Test Kit is used to check the concentration of
coolant additives in the cooling system, and may be purchased from your
Komatsu America International Company distributor.
Part Number: CC-2626
1. Test strip bottles
2. Solution #1 bottle
3. Small plastic container
4. Large plastic cup

5. Syringe
CIRCLE DRIVE GEAR CASE OIL SPECIFICATIONS (HDTF)

Transmission and/or hydraulic system fluid controlled friction characteristics 10W per HMS B21-0006.
01-12 830B/C-850B/C-870B/C
10 STRUCTURE AND FUNCTION
12
STEERING (ORBITROL) CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
TRANSMISSION POWER SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
TRANSMISSION SHIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
RECOMMENDED LUBRICANT AND FILTER CHANGE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
GENERAL LOCATION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
ALL-WHEEL-DRIVE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
ROTARY GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
EP2 HYDRAULIC CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
INTERPRETATION OF TYPE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
CIRCLE REVERSE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
CIRCLE REVERSE GEAR CASE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
CIRCLE REVERSE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
STEERING AND BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
STEERING AND BRAKE PUMP MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
STEERING AND BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
AWD HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
HYDRAULIC OIL SWIVEL BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
FOUR WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
CONTROL VALVE MANIFOLDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
OPTIONAL CONTROL LEVER (SCARIFIER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
OPTIONAL CONTROL LEVERS (AUXILIARY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
CONTROL VALVES - L.H. BANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
CONTROL VALVES - R.H. BANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
VALVE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
MAIN SYSTEM PUMP MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
MAIN SYSTEM PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
AWD HIC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48
SOLENOID VALVE CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
BRAKE SYSTEM ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
DRAWBAR LIFT AND DRAWBAR SIDE SHIFT ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
HYDRAULIC SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
STANDARD GRADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
MAIN HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
STEERING AND BRAKE HYDRAULIC CIRCUIT (INCLUDES LOCK PIN) . . . . . . . . . . . . . . . . . 10-57
STANDARD GRADER WITH ALL WHEEL DRIVE (AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
MAIN HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
ALL WHEEL DRIVE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
STEERING AND BRAKE HYDRAULIC CIRCUIT (INCLUDES LOCK PIN) . . . . . . . . . . . . . . . . . 10-59
MAIN HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
SPOOL VALVE POSITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
NEUTRAL (CENTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
PULLED (PRESSURIZED "B" PORT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
PUSHED (PRESSURIZED "A" PORT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-67
830B/C-850B/C-870B/C 10-1
MAIN SYSTEM CONTROL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-69
SCARIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-69
RIGHT AND LEFT BLADE LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
FLOAT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
BLADE SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
CIRCLE REVERSE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73
MOLDBOARD TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74
ARTICULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75
CIRCLE SIDE SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
LEANING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78
OPTIONAL FLOAT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-79
STEERING AND BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80
ALL-WHEEL-DRIVE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
NORMAL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
AGGRESSIVE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
HYDRAULIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87
ELECTRICAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90
AWD CONTROLLER PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92
LOCK/UNLOCK DIFFERENTIAL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
CIRCLE REVERSE SLIP CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96
CIRCLE REVERSE GEAR CASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98
WITHOUT SLIP CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98
WITH SLIP CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100
MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102
TANDEM CASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
NONPLANETARY FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
PLANETARY FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106
FINAL DRIVE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108
PART NUMBER TAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108
TANDEM CASE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
AWD GEARBOX ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
AWD GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110
FRONT AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112
NON ALL-WHEEL-DRIVE FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112
AWD FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114
FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116
FINAL DRIVE WITHOUT PLANETARY REDUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116
FINAL DRIVE WITH PLANETARY REDUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-118
NO-SPIN DIFFERENTIAL CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120
LOCK/UNLOCK DIFFERENTIAL CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-122
INPUT QUILL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
NO-SPIN DIFFERENTIAL BEARING QUILLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128
LOCK/UNLOCK DIFFERENTIAL BEARING QUILLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130
LOCK/UNLOCK DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
LOCK/UNLOCK DIFFERENTIAL CASE OIL LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
NO-SPIN DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
NO-SPIN DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
PLANETARY ASSEMBLY AND RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
NONPLANETARY FINAL DRIVE CROSS SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-142
PLANETARY REDUCTION FINAL DRIVE CROSS SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-143
MICO PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
MICO PARKING BRAKE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-145
PARKING BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
10-2 830B/C-850B/C-870B/C
MICO BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148
BRAKE PEDAL LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148
HYDRAULIC BRAKE LINES - WITHOUT AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150
HYDRAULIC BRAKE LINES - WITH AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-154
TILT STEERING CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-156
EXPLODED VIEW OF TILT STEERING CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
830B/C-850B/C-870B/C 10-3
STRUCTURE AND FUNCTION STEERING (ORBITROL) CONTROL VALVE
12
STEERING (ORBITROL) CONTROL VALVE
10-4 830B/C-850B/C-870B/C
STRUCTURE AND FUNCTION STEERING (ORBITROL) CONTROL VALVE
12
LEGEND FOR STEERING (ORBITROL) CONTROL UNIT
The exploded view on the previous page and this legend identify the parts and their orientation to each other while servicing
the steering (orbitrol) control unit. Some components mentioned in the service section of this book may be shown in this
illustration only.
1. SEAL 11. BUSHING, SEAL GLAND 21. KIT, CENTERING SPRING
2. O-RING 12. RACE, BEARING 22. PIN, CENTERING
3. RING, BACKUP 13. BEARING, NEEDLE THRUST 23. PLATE, SPACER
4. O-RING 14. SCREW, SET 24. DRIVE
5. SEAL, TEFLON 15. SEAL, CHECK BALL 25. GEROTER
6. O-RING 16. BALL, CHECK 26. SPACER
7. O-RING 17. RETAINER, CHECK BALL 27. CAP, END
8. O-RING 18. HOUSING, CONTROL 28. BOLT
9. WASHER, SEALING 19. SLEEVE, CONTROL
10. RING, RETAINING 20. SPOOL, CONTROL
830B/C-850B/C-870B/C 10-5
STRUCTURE AND FUNCTION TRANSMISSION POWER SHIFT
12
TRANSMISSION POWER SHIFT
This transmission has six speeds forward, and three in reverse.
The forward and reverse speeds are obtained through the use of electrically controlled solenoids and hydraulically actuated
multiple disc clutches. These clutches are power absorbing members that can be engaged at full engine power. Shifting under
full engine power makes this a full powershift for the forward and reverse motion in all speeds. The clutches in these units are
hydraulically applied and spring released. Because the clutches are hydraulically controlled, there is automatic compensation
for normal wear, which eliminates the need for adjustment. Each clutch uses a composition friction plate and a polished steel
reaction plate.
The power from the engine is transmitted to the transmission through a torque converter. The use of the torque converter has
two distinct advantages:
1. The converter is essentially a fluid drive, meaning no direct mechanical connection between the engine and transmission
assembly. This feature creates a very smooth and shock-free drive eliminating engine stalling.
2. The converter multiplies torque during heavy pull-down loads. When loads are light, the converter transmits the engine
power directly at almost engine speed, and there is no torque multiplication. The net result is an action like a transmission,
with infinitely variable and automatic speed ratios. The need for shifting gears, although present, is greatly reduced.
TRANSMISSION SHIFTER
For better quality and enhanced diagnostics, a new transmission shifter p/n
1439 905 H91 replaces transmission shifter p/n 1433 426 H92. The new
shifter uses a U-shift pattern, the industry standard.
The new shifter is different from the old shifter. The old shifter did not
control the parking brake while the new shifter controls the parking brake
circuit in the “Park” position. The new shifter also has on-board
diagnostics. A red LED is located on the right side of the shifter. The LED
flashes a code to indicate the type of problem.
When the LED flashes an error code, the transmission automatically shifts
to Neutral despite the gearshift remaining at the selected position. Thus, the
machine cannot move. Move the gearshift to the Neutral position to
coincide with the transmission being in neutral, and which also clears the
controller's memory. After clearing the controller's memory, the
transmission gears can once again be engaged. To determine if the problem
is a “glitch” or one-time occurrence, reposition the gearshift to the desired
gear range and continue with the operation. If the LED flashes again, count
the number of flashes because a problem exists. See the table in
Section 20-100 TROUBLESHOOTING - TRANSMISSION SHIFTER for
a diagnostic interpretation of the LED flash code, and make the needed
repairs. After repairing the problem, clear the controller's memory before
returning the machine to service.
10-6 830B/C-850B/C-870B/C
12
830B/C-850B/C-870B/C 10-7
12
OPERATION
Like all mechanical equipment, the transmission will need attention and servicing. Routine checks will help prevent down
time. The operator can aid in preventive maintenance by reporting weak or borderline malfunctions.
Because the unit operates "in" oil and "by" oil, most of the maintenance is concerned with oil replenishment and oil
cleanliness. The type of service and operating conditions will determine the maintenance interval. However, as previously
stated, it is especially important that the oil be kept clean.
1. Check the oil level daily, with the engine at idle speed, the transmission in neutral, and the transmission oil temperature
from 160° to 200° F (71° to 93° C) Clean the area around the dipstick before removing it.
WARNING! Assure that the transmission has been shifted to NEUTRAL, parking brake has been
applied, and moldboard is resting on ground. Do not risk severe personal injury or death.
2. The transmission should always be in the neutral position before starting the engine, or when the vehicle is parked and the
engine is running.
3. If the vehicle is to be towed, it will be necessary to run the engine at idle speed to lubricate the clutches.
4. If the engine cannot be run, towing must be limited to a speed of 3 mph (4.8 km/h) and a distance of 1 mile (1.6 km),
maximum total. If exceeding these conditions, disconnect the drive lines, making towing permissible at speeds not to
exceed the towing vehicle manufacture’s recommended speeds.
5. If the oil temperature gauge, which is the converter oil out temperature, rises to 250° F (121° C) or the warning light
comes on, stop the vehicle immediately. Shift to neutral and run the engine from 1000 to 1200 RPM. The temperature
should drop rapidly to the engine water temperature, or if an air to oil exchanger is used, the temperature should drop
rapidly to ambient air temperature across the heat exchanger. If the temperature does not drop, trouble is indicated. The
trouble should be determined before the vehicle is operated again. Overheating generally occurs due to working in too
high of a gear ratio.
6. Do not shut off the engine when the unit is overheating, if the cooling system is in working order.
7. When servicing the unit for the first time after vehicle installation and/or after repair, the unit is filled as follows:
• Fill the unit with 4 U.S. gallons (15.1 L) of the recommended lubricant.
• Start the engine and run at idle speed to let the converter and oil lines fill.
WARNING! Assure that transmission has been shifted to NEUTRAL, parking brake has been applied,
and moldboard is resting on the ground. Do not risk severe personal injury or death.
•With the engine at idle speed, finish filling the unit to the full level. The amount needed will vary with each
application.
Remark
The oil level is always checked with the engine running at idle speed, the transmission in neutral, and
transmission oil temperature from 160° to 200° F (71° to 93° C). In some applications that use an air-to-oil
heat exchanger, the transmission temperature will be below the temperature recommended for checking
oil level. Because oil expands as it heats up, check the oil level at the recommended temperature.
10-8 830B/C-850B/C-870B/C
12
8. Lubrication Recommendation
WARNING! Do not overfill the transmission.
Prevailing Ambient Temperature Oil Specifications
Above -10° F (-23° C) Hydraulic Transmission Fluid, type C-3 or C-4 (except Grade 30).
Below -10° F (-23° C) Hydraulic Transmission Fluid, type C-3 or C-4 (except Grade 30).
Auxiliary preheat required to raise the sump temperature to above -10° F (- 23° C).
Above 32° F (0° C) Hydraulic Transmission Fluid, type C-3 or C-3 Grade 30.
WARNING! Do not use any hydraulic transmission fluid that uses an "EP" (Extreme Pressure) additive.
RECOMMENDED LUBRICANT AND FILTER CHANGE INTERVALS

1. Recommendations utilizing the filter with the bypass indicator inoperative or not connected:
A. The lubricant and filter should be changed after the first 20 hours of transmission operation. After the initial lubricant
and filter change, it is recommended that the filter be changed every 200 hours of operation and the lubricant be
changed every 600 hours of operation.
2. The following recommendations apply if the bypass indicator is connected and operative:
A. The filter should be changed when the bypass indicator signals the vehicle operator.
B. The lubricant change interval shall be every other filter change but not to exceed 1200 hours.
Remark
In cold weather operation and/or initial startup (when the transmission oil is cold), the oil will have a higher
viscosity and bypass the filter intermittently. When this situation happens, the filter bypass indicator will be
activated.
Check the converter "out" oil temperature. If the temperature is in the normal working range, change the
filter. If the converter "out" oil temperature is below the normal working range, stop the machine and
increase oil temperature by stalling the converter while observing the bypass indicator. If this step disarms
the system, work the transmission in a higher gear to keep the converter "out" oil temperature in the
normal working range. If this step does not disarm the system, change the filter.
WARNING! When stalling the converter, make sure the transmission is in high gear, the vehicle
brakes set, and the immediate area is clear of personnel and obstructions. Do not exceed
30 seconds or 250° F (121° C) converter out oil temperature, whichever comes first, at
full governed engine RPM stall speed.
830B/C-850B/C-870B/C 10-9
12
Remark
The preceding lubricant change recommendations can be neglected if a lubricant analysis indicates that
the following limits are not exceeded.
Presence of Limit
Glycol (antifreeze) 0% by volume
Water (after transmission operation @ 150° - 250° F or 66° - 121° C) 0.05% by volume
Increased viscosity @ 100° F (38° C) Increase of 40% over new lubricant value
Total acid number (TAN) per ASTM D664 Increase of 3.0 over new lubricant value
Remark
The above recommendation is void if the oil shows signs of contamination or the effects of a high operating
temperature as evidenced by a strong burnt odor. If this condition is evident, the oil and filter should be
changed immediately.
3. When changing the oil, drain the dirty oil while the unit is warm. Examine the oil for contamination as described above.
4. Clean the suction screen thoroughly before reinstalling.
10-10 830B/C-850B/C-870B/C
12
GENERAL LOCATION OF COMPONENTS
830B/C-850B/C-870B/C 10-11
STRUCTURE AND FUNCTION ALL-WHEEL-DRIVE PUMP
12
ALL-WHEEL-DRIVE PUMP
The All-Wheel-Drive (AWD) pump is a piston-type pump mounted to the transmission and driven directly by the torque
converter. The pump directs pressurized oil to the all-wheel-drive motors, which drive the gearboxes.
10-12 830B/C-850B/C-870B/C
12
LEGEND FOR THE AWD PUMP
1. ROTARY GROUP 19. NUT, SEAL
2. SHAFT ASSEMBLY 20. VALVE, RELIEF
3. HOUSING ASSEMBLY 21. O-RING
4. STROKING PISTON ASSEMBLY 22. RING, BACKUP
5. PORT BLOCK ASSEMBLY 23. O-RING
6. EP2 CONTROL 24. NUT, JAM
7. COVER KIT, STROKING PISTON 25. VALVE, CHARGE PRESURE RELIEF
8. COVER KIT, STROKING PISTON 26. O-RING
9. PUMP ASSEMBLY, CHARGE 27. PLUG
10. ORIFICE, STROKING - 1.0 MM 28. PLUG
11. RING, RETAINING 29. O-RING
12. NUT, JAM 30. PIN, LOCATING
13. BOLT 31. PLUG
14. SEAL, SHAFT 32. O-RING
15. O-RING 33. PLUG
16. PLUG 34. PLUG
17. O-RING 35. O-RING
18. PIN, THREADED 36. ADAPTOR
830B/C-850B/C-870B/C 10-13
12
ROTARY GROUP
10-14 830B/C-850B/C-870B/C
12
LEGEND FOR THE ROTARY GROUP
Exploded view of parts shown on previous page.
1. BARREL 9. RACE, BEARING
2. LENS 10. BEARING SET, CRADLE
3. PISTON 11. WI RE
4. PLATE, RETAINING 12. LEVER
5. PLATE, SWASH 13. SHIM
6. BALL, RETAINING 14. SPRING
7. SPRING STACK, CUP 15. RING, RETAINING
8. SHIM, PRELOAD - 1.20 MM

SHIM, PRELOAD - 0.95 MM
830B/C-850B/C-870B/C 10-15
12
EP2 HYDRAULIC CONTROL
10-16 830B/C-850B/C-870B/C
12
LEGEND FOR THE EP2 HYDRAULIC CONTROL
1. MODULE, CONTROL 11. PIN, DOUBLE BREAK 21. SOLENOID, PROPORTIONAL
2. LEVER, FEEDBACK 12. O-RING 22. O-RING
3. SHIM 13. COVER 23. O-RING
4. NEEDLE ROLLER 14. SPRING, DRAW 24. O-RING
5. CONTROL PISTON WITH 15. GASKET 25. SPRING, CUP

CYLINDER PIN
6. ARM, LEVER 16. ASSEMBLY PIECE 26. CONNECTOR
7. PIN, ECCENTRIC 17. SCREW, SOCKET-HEAD 27. CONNECTOR
8. SHIM 18. SCREW, SOCKET-HEAD 28. PIN, CYLINDER
9. SCREW, SOCKET-HEAD 19. O-RING
10. SCREW, SOCKET-HEAD 20. O-RING
830B/C-850B/C-870B/C 10-17
12
INTERPRETATION OF TYPE CODES
10-18 830B/C-850B/C-870B/C
12
MEMORANDUM
830B/C-850B/C-870B/C 10-19
STRUCTURE AND FUNCTION CIRCLE REVERSE MOTOR
12
CIRCLE REVERSE MOTOR
The circle reverse motor mounts to the circle reverse gear case, which is located on the drawbar and moldboard assembly.
CIRCLE REVERSE GEAR CASE MOTOR
10-20 830B/C-850B/C-870B/C
12
LEGEND FOR CIRCLE REVERSE CASE MOTOR
the circle reverse motor. Some components mentioned in the service section of this book may be shown in this illustration
only.
1. HYDRAULIC MOTOR
2. BOLT
3. FLAT WASHER
4. GASKET
5. BOLT
6. WASHER
7. MOUNT PLATE
8. GASKET
9. COUPLING
10. CIRCLE REVERSE GEAR CASE ASSEMBLY
830B/C-850B/C-870B/C 10-21
12
10-22 830B/C-850B/C-870B/C
12
LEGEND FOR THE CIRCLE REVERSE MOTOR
the circle reverse motor. Some components mentioned in the service section of this book may be shown in this illustration
only.
1. BOLT 11. VANE
2. COVER, END1 12. ROTOR
3. SEAL, COMMUTATOR1 13. PLATE, WEAR
4. SEAL, RING 14. LINK, DRIVE
5. SEAL, INNER1 15. SHAFT, COUPLING
6. SEAL, DIRT/WATER1 16. HOUSING
7. WASHER, BACKUP 17. BEARING, NEEDLE
8. COMMUTATOR AND RING 18. WASHER, THRUST
9. MANIFOLD 19. BEARING, THRUST
10. STATOR 20. BEARING, NEEDLE
830B/C-850B/C-870B/C 10-23
STRUCTURE AND FUNCTION STEERING AND BRAKE PUMP
12
STEERING AND BRAKE PUMP
STEERING AND BRAKE PUMP MOUNT

The steering and brake pump is located on the left side of the engine and is mounted to the front gear housing.
LEGEND FOR STEERING AND BRAKE PUMP MOUNT
The exploded view and legend identify the parts and their orientation to each other while servicing the steering and brake
pump mount. Some components in the service section of this book may be shown in this illustration only.
1. NUT, HEX 5. SPACER
2. GEAR 6. WASHER, FLAT
3. HUB 7. BOLT
4. GASKET, ACCESSORY DRIVE 8. PUMP, STEERING & BRAKE HYDRAULIC
10-24 830B/C-850B/C-870B/C
12
MEMORANDUM
830B/C-850B/C-870B/C 10-25
12
10-26 830B/C-850B/C-870B/C
12
LEGEND FOR STEERING AND BRAKE PUMP
the steering and brake pump. Some components mentioned in the service section of this book may be shown in this illustration
only.
1. RING, RETAINING 15. KEY 29. PLATE ASSEMBLY, BACK
2. SEAL, SHAFT 16. SHAFT, DRIVE 30. BOLT
3. RING, RETAINING 17. HOUSING ASSEMBLY 31. BOLT, ALLEN HEAD
4. O-RING 18. BEARING, NEEDLE 32. PLUG
5. RING, RETAINING 19. RACE, INNER 33. PLUG
6. GASKET 20. COVER, TRUNNION 34. O-RING
21. SPRING, CAM PLATE 35. SPOOL, PRESSURE

7. GASKET, COMPENSATOR
CONTROL COMPENSATOR
8. O-RING 22. COLLAR, SPRING 36. CAP, SPRING PIVOT
37. SPRING, PRESSURE

9. O-RING 23. BUTTON, PIVOT
COMPENSATOR
10. O-RING 24. PIN, ROLL 38. O-RING
39. FOLLOWER, PRESSURE

11. O-RING 25. PLATE, CAM
SPRING
12. WASHER 26. KIT, ROTATING 40. O-RING
41. CAP, PRESSURE

13. WASHER, THRUST 27. PISTON, CONTROL
ADJUSTMENT
14. BEARING, THRUST 28. PIN, ROLL 42. HOUSING, COMPENSATOR
12
SPECIFICATIONS
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70422 RDU
Pump Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 CIR
Application Speed:
Rated Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2575 RPM
High Idle Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2835 RPM
Pressure Compensator Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1650 ± 25 PSI (116.0 ± 1.8 kg/cm2)
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clockwise (Right Hand)
Empty Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 lb (12.2 kg.)
830B/C-850B/C-870B/C 10-27
STRUCTURE AND FUNCTION AWD HYDRAULIC MOTOR
12
AWD HYDRAULIC MOTOR
An All-Wheel-Drive (AWD) motor is located on each of the AWD gearbox assemblies located on the front axle.
10-28 830B/C-850B/C-870B/C
12
LEGEND FOR ALL WHEEL DRIVE MOTOR
the all-wheel-drive motor. Some components mentioned in the service section of this book may be shown in this illustration
only.
1. BOLT 9. BLOCK, CYLINDER 17. SPRING
2. BLOCK, VALVE 10. KIT, PISTON SHOE 18. WASHER, THRUST
3. HOUSING 11. PLATE, SHOE 19. PIN
4. GASKET 12. WASHER, SPHERICAL 20. PLATE, SWASH
5. BEARING & RACE 13. PIN 21. SHAFT
6. PLATE, WAFER 14. RETAINER, PIN 22. BEARING & RACE
7. PIN 15. RING, RETAINING 23. RING, RETAINING
8. KIT, BEARING SPACER 16. WASHER 24. SEAL, SHAFT
OPERATION
An all-wheel-drive (AWD) motor is located on each front wheel, providing front-wheel-drive assist to the rear-wheel effort of
the grader. Each AWD motor is driven by a variable displacement pump at the rear of the machine. A switch on the instrument
console allows the operator to easily engage/disengage the AWD function. Refer to current Operator's Manual for operational
instructions.
Pressurized fluid enters the piston motor inlet, causing the motor shaft to rotate. As fluid moves into the inlet port, force is
applied to all pistons located within the kidney inlet slot. Each of these pistons exert an axial force against the swash plate
through the piston shoes. The swash plate angle converts the axial force into motion and the piston and shoe S/A's slide against
the swash plate in the direction of rotation. The angular force developed by this sliding motion is transmitted into the cylinder
block and subsequently to the motor shaft through a connecting spline. The pistons continue to move out of the cylinder block
until they approach the outlet kidney slot. At this time, pressure drops, and the motion of the pistons reverse. The fluid is
pushed out of the cylinder block into the outlet kidney slot. Because this motor is bidirectional, the function of the inlet and
outlet ports and kidney slots reverse, depending upon which port the pressurized fluid is received through.
830B/C-850B/C-870B/C 10-29
12
SPECIFICATIONS
Model MFE-19-2-30
MFE Fixed displacement motor
19 At 19.6 GPM (74.2 L /min) @ 1800 RPM
2 Output shaft #2 - S.A.E. B-B Splined
30 Position No.
10-30 830B/C-850B/C-870B/C
STRUCTURE AND FUNCTION HYDRAULIC OIL SWIVEL BLOCK
12
HYDRAULIC OIL SWIVEL BLOCK
FOUR WAY
Sealing rings are now used instead of O-rings in the two-way and four-way swivel blocks. The new style seal ring will fit in
the O-ring groove and is totally interchangeable with the O-ring. The seal ring consists of two parts: the outer ring and the
inner ring. The outer ring (lip) is made from a hard material and has a glossy finish. The inner ring (expander) is made from a
soft material and has a dull finish.The correct way to install the seal ring for the two or four-way swivel block. Use caution not
to overstretch the outer ring (lip) any more than needed.
830B/C-850B/C-870B/C 10-31
STRUCTURE AND FUNCTION CONTROL VALVE MANIFOLDS
12
CONTROL VALVE MANIFOLDS
A manually operated control valve controls the hydraulic cylinders while the vehicle is running. Combining several valves
form a valve bank or manifold. Two valve banks or manifolds exist below the cab floor: one on the left side of the steering
console and one on the right side.
10-32 830B/C-850B/C-870B/C
12
LEGEND FOR CONTROL VALVE MOUNT
the control valve mount. Some components mentioned in the service section of this book may be shown in this illustration
only.
1. FRAME, FRONT
2. VALVE, CONTROL - L.H.
3. BOLT
4. WASHER, FLAT
5. BOLT
6. VALVE, CONTROL - R.H.
7. NUT, HEX
830B/C-850B/C-870B/C 10-33
12
OPTIONAL CONTROL LEVER (SCARIFIER)
10-34 830B/C-850B/C-870B/C
12
LEGEND FOR OPTIONAL CONTROL LEVERS (SCARIFIER)
the optional control levers (scarifier). Some components mentioned in the service section of this book may be shown in this
illustration only.
1. KNOB, SCARIFIER
2. EPOXY, GENERAL PURPOSE - 1.2 OZ
3. LEVER ASSEMBLY
4. WASHER, BEARING
5. BOLT
6. WASHER, LOCK
7. END, ROD
8. NUT, JAM
9. ROD, LINK
10. BOOT
11. ADAPTOR, SWIVEL
830B/C-850B/C-870B/C 10-35
12
OPTIONAL CONTROL LEVERS (AUXILIARY)
10-36 830B/C-850B/C-870B/C
12
LEGEND FOR OPTIONAL CONTROL LEVERS (AUXILIARY)
the optional control levers (auxiliary). Some components mentioned in the service section of this book may be shown in this
illustration only.
1. KNOB, AUXILIARY
2. EPOXY, GENERAL PURPOSE - 1.2 OZ
3. LEVER ASSEMBLY
4. WASHER, BEARING
5. BOLT
6. WASHER, LOCK
7. END, ROD
8. NUT, JAM
9. ROD, LINK
10. BOOT
11. ADAPTOR, SWIVEL
12. LEVER, SCARIFIER
13. LEVER ASSEMBLY
830B/C-850B/C-870B/C 10-37
12
CONTROL VALVES - L.H. BANK
10-38 830B/C-850B/C-870B/C
12
LEGEND FOR CONTROL VALVE - L.H. BANK
the left control valve bank. Some components mentioned in the service section of this book may be shown in this illustration
only.
1. NUT, HEX 11. VALVE SECTION - MOLDBOARD SHIFT
2. ROD, TIE 12. O-RING
3. NUT, HEX 13. VALVE SECTION - CIRCLE REVERSE
5. OUTLET SECTION 15. VALVE SECTION - MOLDBOARD TILT
6. SHUTTLE 16. O-RING
7. VALVE SECTION - SCARIFIER 17. PLUG
9. VALVE SECTION - L.H. BLADE LIFT 19. INLET SECTION
830B/C-850B/C-870B/C 10-39
12
CONTROL VALVES - R.H. BANK
10-40 830B/C-850B/C-870B/C
12
LEGEND FOR CONTROL VALVE - R.H. BANK
the right control valve bank. Some components mentioned in the service section of this book may be shown in this illustration
only.
1. NUT, HEX 12. VALVE SECTION - DRAWBAR SIDE SHIFT
3. NUT, HEX 14. VALVE SECTION - LEANING WHEEL
5. PLUG, SHUT-OFF 16. VALVE SECTION - R.H. BLADE LIFT
7. INLET SECTION 18. OUTLET SECTION
8. O-RING 19. CARTRIDGE, MAIN RELIEF VALVE
10. VALVE SECTION - ARTICULATION 21. O-RING
11. O-RI NG
830B/C-850B/C-870B/C 10-41
12
VALVE SECTION
10-42 830B/C-850B/C-870B/C
12
LEGEND FOR VALVE SECTION
the valve section (circle reverse, scarifier, and ripper). Some components mentioned in the service section of this book may be
shown in this illustration only.
1. NUT, HEX 11. VALVE SECTION - MOLDBOARD SHIFT
3. NUT, HEX 13. VALVE SECTION - CIRCLE REVERSE
5. OUTLET SECTION 15. VALVE SECTION - MOLDBOARD TILT
7. VALVE SECTION - SCARIFIER 17. PLUG
9. VALVE SECTION - L.H. BLADE LIFT 19. INLET SECTION
830B/C-850B/C-870B/C 10-43
STRUCTURE AND FUNCTION MAIN SYSTEM PUMP MOUNT
12
MAIN SYSTEM PUMP MOUNT
The main system pump is located on the left rear of the transmission torque converter housing. Main pump flow is directed to
the two control valve manifolds. The articulated grader hydraulic system is a pressure-flow, load-sensing system.
WARNING! DO NOT attempt to increase the system pressure by adjusting the compensator
assembly.
10-44 830B/C-850B/C-870B/C
STRUCTURE AND FUNCTION MAIN SYSTEM PUMP MOUNT
12
LEGEND FOR HYDRAULIC PUMP MOUNT
the hydraulic pump mount. Some components mentioned in the service section of this book may be shown in this illustration
only.
1. PUMP, TRANSMISSION CHARGE
2. O-RING
3. SLEEVE
4. RING, RETAINING
5. PUMP, HYDRAULIC
6. WASHER, FLAT
7. BOLT
830B/C-850B/C-870B/C 10-45
STRUCTURE AND FUNCTION MAIN SYSTEM PUMP
12
MAIN SYSTEM PUMP
10-46 830B/C-850B/C-870B/C
STRUCTURE AND FUNCTION MAIN SYSTEM PUMP
12
LEGEND FOR MAIN SYSTEM PUMP
the pump. Some components mentioned in the service section of this book may be shown in this illustration only.
39. COMPENSATOR ASSEMBLY,

1. RETAINING RING 20. PISTON ASSEMBLY
PRESSURE
2. SHAFT SEAL 21. SPIDER 40. PLUG ASSEMBLY
3. WASHER 22. SPIDER PIVOT 41. O-RING
42. COMPENSATOR HOUSING,

4. RETAINING RING 23. PISTON BLOCK
PRESSURE-FLOW
43. SPOOL, PRESSURE

5. THRUST RACE 24. PIN KEEPER
COMPENSATOR
6. THRUST BEARING 25. PIN 44. SPRING PIVOT CAP
45. SPRING, PRESSURE

7. KEY 26. WASHER
COMPENSATOR
8. DRIVE SHAFT 27. SPRING 46. O-RING
9. HOUSING ASSEMBLY 28. RETAINING RING 47. PRESSURE ROD
10. NEEDLE BEARING 29. ROTATING KIT ASSEMBLY 48. O-RING
49. ADJUSTMENT CAP,

11. INNER RACE 30. CONTROL PISTON
PRESSURE
50. SPOOL, FLOW

12. O-RING 31. GASKET
COMPENSATOR
13. TRUNNION COVER 32. DOWEL PIN 51. & 51 A SPRING PIVOT
52. SPRING, FLOW

14. NOT USED 33. BACKPLATE ASSEMBLY
COMPENSATOR
15. CAM PLATE CONTROL

34. & 34A CAP SCREW 53. O-RING
SPRING
16. SPRING COLLAR 35. GASKET, COMPENSATOR 54. PRESSURE ROD
17. PIVOT BUTTON 36. O-RING 55. O-RING
37. COMPENSATOR ASSEMBLY,

18. ROLL PIN 56. ADJUSTMENT CAP, FLOW
PRESSURE
57. COMPENSATOR HOUSING,

19. CAM PLATE 38. ALLEN HEAD CAP SCREW
PRESSURE
830B/C-850B/C-870B/C 10-47
STRUCTURE AND FUNCTION AWD HIC VALVE
12
AWD HIC VALVE
The Hydraulic Integrated Circuit (HIC) valve is used in the all-wheel-drive system to control the oil flow from the all-wheel-
drive pump to the front axle gearbox assemblies.
When the grader is in the forward motion, the HIC valve allows oil to drive the motor located on each gearbox.
When the grader is in reverse, the HIC valve allows oil to drive the motor located on each gearbox. The reverse clutch pack
located within each gearbox engages. The oil recirculates from the outlet to the inlet of the motors when a reverse overrun
condition is induced by the tires driving the motor at a faster speed than the oil being supplied to it by the pump. The oil
recirculation prevents the motors from cavitating.
Remark
Making a turn while the grader is in reverse, the outside tire will turn faster than the inside one. The outside
tire’s faster rotation causes the motor to pump oil.
A flushing valve and a shuttle valve, located in the HIC valve, allow the flow of cool oil into the main loop of the AWD system
at all times, preventing excessive heat buildup.
10-48 830B/C-850B/C-870B/C
12
LEGEND FOR THE HIC VALVE
the HIC valve. Some components mentioned in the service section of this book may be shown in this illustration only.
1. BOLT 15. PLUG 29. POPPET
2. PLATE 16. BOLT 30. PLUG
3. PLUG 17. PLATE 31. O-RING
4. BACKUP RING 18. PLUG 32. SPRING
5. O-RING 19. BACKUP RING 33. SPOOL ASSEMBLY
6. SPRING 20. HONED ASSEMBLY 34. PLUG
7. ORIFICE PLATE 21. O-RING 35. SOLENOID CARTRIDGE
8. BACKUP RING 22. O-RING 36. SEQUENCE CARTRIDGE
9. O-RING 23. BODY 37. O-RING
10. MATCHED SUB ASSEMBLY 24. PLUG 38. O-RING
11. BACKUP RING 25. O-RING 39. O-RING
12. O-RING 26. SPRING 40. PLUG
13. SPRING 27. BACKUP RING
14. PLUG 28. BALL
830B/C-850B/C-870B/C 10-49
12
HIC valve
10-50 830B/C-850B/C-870B/C
12
HIC valve components
830B/C-850B/C-870B/C 10-51
12
SOLENOID VALVE CARTRIDGE
LEGEND
The exploded view and legend on this page identify the parts and their orientation to each other while servicing the solenoid
valve cartridge of the HIC valve assembly. Some components mentioned in the service section of this book may be shown in
this illustration only.
1. NUT 5. BACKUP RING
2. COIL - 32V 6. O-RING
3. CARTRIDGE, VALVE 7. FEMALE SHROUD AND MALE PIN
4. O-RING 8. FRONT AWD HARNESS
10-52 830B/C-850B/C-870B/C
STRUCTURE AND FUNCTION ACCUMULATOR
12
ACCUMULATOR
LEGEND
The exploded view and legend identify the parts and their orientation to each other while servicing the accumulator. Some
components mentioned in the service section of this book may be shown in this illustration only.
1. BODY 7. CAP, GAS END
2. RING, TEFLON 8. VALVE, GAS
3. V-RING 9. CAP, GAS VALVE
4. O-RING, END CAP 10. PROTECTOR, GAS VALVE
5. O-RING, GAS VALVE 11. SCREW
6. PISTON
830B/C-850B/C-870B/C 10-53
12
SPECIFICATIONS
Piston Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairable
Oil Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 in. 3 (0.95 L)
Operating Pressure Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,000 PSI (210.9 kgf/cm2)
Proof Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,500 PSI (316.3 kgf/cm2)
Burst Pressure Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,000 PSI (843.6 kgf/cm2)
Precharge Pressure (Nitrogen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NONE
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.19 in. (589.0 mm
O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.375 in. (60.325 mm)
Fluid Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -50 to 225° F (-45.5 to 107.2° C)
10-54 830B/C-850B/C-870B/C
12
BRAKE SYSTEM ACCUMULATORS
The hydraulic accumulator(s) is located between the under side of the cab and the frame.
The hydraulic accumulator, in this case, is a backup supply of pressurized hydraulic fluid for operating the wet brakes during
an emergency. When the unit is in normal operation, the accumulator is filled with oil from the steering and brake pump. The
steering and brake pump operates at 1650 PSI (16.0 kgf/cm2), which exceeds the 500 ±25 PSI (35.1 ±1.7 kgf/cm2) accumulator
precharge. The higher system pressure causes the piston within the accumulator to compress the precharge until it equals the
1650 PSI (16.0 kgf/cm2) system pressure, filling the accumulator with oil. The check valves isolate the accumulator(s),
brake(s), and brake valve from the drain and return lines. In the event that system pressure is not available from the steering
and brake pump, the check valves allow the hydraulic oil stored in the accumulator(s) to flow to the brakes.
Refer to "Hydraulic Troubleshooting and Adjustment" section for detailed hydraulic schematic of the brake circuit.
DRAWBAR LIFT AND DRAWBAR SIDE SHIFT ACCUMULATORS

When this accessory packaged is installed on a unit the accumulators will be installed as follows:
1. Two accumulators will be mounted to the top of the moldboard assembly to protect the circle shift cylinder. One will be
plumbed into the rod end supply line and the other will be connected to the base end supply line. The circle shift cylinder
is subjected to impact loading from both directions.
2. Two accumulators will be mounted to the main frame (one on each side) in front of the moldboard suspension group. The
right accumulator is plumbed into the base end of the right lift cylinder, and the left accumulator is connected to the base
end of the left lift cylinder. The lift cylinders require protection from impacts that would cause the cylinders to retract.
A piston-type hydraulic accumulator is available as an accessory on graders to help protect the moldboard assembly and
related components from impact loading in severe working conditions, or areas where extremely hard material many be
encountered.
830B/C-850B/C-870B/C 10-55
STRUCTURE AND FUNCTION HYDRAULIC SYSTEM OVERVIEW
12
HYDRAULIC SYSTEM OVERVIEW
The block flow diagrams on the following pages show the relationship between the different components of various hydraulic
system configurations. A brief description of each circuit will be given after each illustration. You will then be directed to the
detailed explanation of individual circuits.
STANDARD GRADER
The standard grader consists of two separate hydraulic circuits:
1. The main hydraulic circuit.
2. The steering and brake circuit (includes lock pin circuit).
10-56 830B/C-850B/C-870B/C
12
MAIN HYDRAULIC CIRCUIT
The main system pump is driven by the transmission.
The main system pump draws the oil from the hydraulic oil tank through a 100-mesh strainer located in the bottom of the tank.
It is a flow demand pump, controlled by a load sensing compensator. The compensator sensor line is connected to the two
control valve banks. The sensor lines are used to sense system pressure and control the swash plate angle of the main system
pump by means of the compensator assembly.
When demanded by a control function (i.e. moldboard tilt, lift cylinder, etc.) the main system pump flow is directed to the
control valve banks. It then can be directed by mechanically controlled valve spools to various functions. These functions will
be discussed later in their own sections.
Return oil from the control valve banks is routed through a junction block. The oil from the junction block is routed next to the
hydraulic oil filter and then to the hydraulic oil tank.
Remark
Some control valve functions have independent drain lines which are also connected to the junction block.
This description by no means describes the main hydraulic circuit. It is only intended to show the basic functional order of
components in the system. Refer to the appropriate section of this manual for a complete description and troubleshooting.
STEERING AND BRAKE HYDRAULIC CIRCUIT (INCLUDES LOCK PIN)

The steering and brake pump is driven by the engine.
The steering and brake pump is a flow-compensated pump, which responds to a drop in system pressure when flow is created
by the actuation of a function in the circuit. The pump draws oil from the hydraulic oil tank through a 100 mesh strainer
located in the bottom of the tank. This oil is then routed to either the orbitrol steering unit or the double check valve.
Turning the steering wheel creates a demand for oil and causes a pressure drop. The pump strokes up to maintain pressure. The
orbitrol unit directs the oil flow to the steering cylinder. Return oil from the cylinders, first passes back through the orbitrol
unit, then is routed to a relief valve, with a 150 PSI (10.5 kg/cm2) threshold, located at the junction block. This relief valve
maintains oil in the return line circuit.
Remark
Emergency steering is made possible by the relief valve because it blocks the oil flow from returning to the
tank.
Oil from the pump directed through the double-check valve supplies the normal wet brakes (located in rear axle), parking/
emergency brake, and lock pin cylinder (if equipped). The double-check valve splits the oil into two circuits. Each of these
circuits contains an accumulator to supply emergency operating fluid and pressure. One circuit supplies the left rear axle brake
(controlled by the brake valve). The other circuit supplies oil to the right brake circuit, plus oil to the parking/emergency brake
solenoid valve and lock pin solenoid valve (if equipped) located at the junction block.
830B/C-850B/C-870B/C 10-57
12
STANDARD GRADER WITH ALL WHEEL DRIVE (AWD)
The standard grader with all-wheel-drive (AWD) consists of three separate hydraulic circuits: 1. The main hydraulic circuit. 2.
The steering and brake circuit (includes lock pin circuit). 3. All-wheel-drive circuit.
10-58 830B/C-850B/C-870B/C
12
The transmission drives the main system pump.
The main system pump draws oil from the hydraulic oil tank through a 100 mesh strainer located in the bottom of the tank. A
flow demand pump is controlled by a load-sensing compensator. The compensator-sensor line is connected to the two control
valve banks. The sensor lines are used to sense system pressure and control the swash plate angle of the main system pump by
means of the compensator assembly.
When demanded by a control function (i.e. moldboard tilt, lift cylinder, etc.), the main system pump flow is directed to the
control valve banks. It then can be directed by mechanically controlled valve spools to various functions. These functions will
be discussed later in their own sections.
Return oil from the control valve banks is routed through a junction block. The oil from the junction block is routed to the
hydraulic oil filter and then to the hydraulic oil tank.
Remark
Some control valve functions have independent drain lines which are also connected to the junction block.
This description by no means describes the main hydraulic circuit. It is only intended to show the basic functional order of
components in the system. Refer to the appropriate section of this manual for a complete description and troubleshooting.
ALL WHEEL DRIVE CIRCUIT

The transmission drives the All-Wheel-Drive (AWD) charge and main pumps.
The AWD charge pump draws oil from the hydraulic oil tank through a 100 mesh strainer located in the bottom of the tank.
The charge pump flow is then routed through the AWD hydraulic oil filter, before entering the closed loop main pump portion
of the AWD system.
The main pump portion of the AWD system is controlled electronically by magnetic sensors and a control module. When the
system is turned ON the control module maintains a ratio between the magnetic sensor signals (impulses). When demanded by
the system the pump delivers oil flow to the AWD Hydraulic Integrated Circuit (HIC) valve. The HIC valve in turn controls
the flow of oil to and from the AWD motors and gearbox reverse clutch packs. The HIC valve also controls the oil for cooling
of the system, and reverse travel direction differential pressure in the motors. Oil return lines from the pump, HIC valve and
motors return the oil directly to the hydraulic oil tank.
This description by no means describes the AWD system. It is only intended to show the basic functional order of components
in the system. Refer to the appropriate section of this manual for a complete description and troubleshooting.
STEERING AND BRAKE HYDRAULIC CIRCUIT (INCLUDES LOCK PIN)

The engine drives the steering and brake pump.
The steering and brake pump is a flow compensated pump, which responds to a drop in system pressure when flow is created
by the actuation of a function in the circuit. The pump draws oil from the hydraulic oil tank through a 100 mesh strainer
located in the bottom of the tank. This oil is then routed to either the orbitrol steering unit or the double brake check valve.
Turning the steering wheel creates a demand for oil (a drop in pressure) and the pump strokes up to maintain pressure. The
orbitrol unit directs the flow of oil to the steering cylinder. Return oil from the cylinders, first passes back through the orbitrol
unit, then is routed to a relief valve, which has a 150 PSI (10.5 kg/cm2) threshold, located at the junction block. This relief
valve maintains oil pressure in the return line circuit.
Remark
Emergency steering is made possible because the relief valve blocks the oil flow from returning to the tank.
Oil from the pump flows through the double check valve to the normal wet brakes, parking/emergency brake, and lock pin
cylinder (if equipped). The double brake check valve splits the oil into two circuits. Each of these circuits contains an
accumulator to supply emergency operating fluid and pressure. One circuit supplies the left rear axle brake (controlled by the
brake valve). The other circuit supplies oil to the right brake circuit, plus oil to the parking/emergency brake solenoid valve
and lock pin solenoid valve (if equipped) located at the junction block.
830B/C-850B/C-870B/C 10-59
STRUCTURE AND FUNCTION MAIN HYDRAULIC CIRCUIT
12
This section discusses in detail the main hydraulic circuit that was discussed briefly in the overview.
All flow to the main system pump must pass through a 100 mesh strainer located at the bottom of the tank. The strainers are
serviceable items and must be cleaned whenever the hydraulic oil tank is drained during regular service intervals. Refer to the
Operation and Maintenance Manual for these intervals.
The main system pump is an axial piston, variable-displacement pump. The compensator assembly, which sits atop the pump,
receives pressure signals from the control valve banks. These signals determine pump output. In neutral, demand for oil flow is
near 0 GPM (0.0 L/min.) and the pump destrokes. This situation also occurs when the system goes into high-pressure standby.
However, when several functions are moving simultaneously, demand for oil flow is high and the pump may stroke at its
maximum angle.
Oil flow from the pump is directed to the right and left control valve banks. The control valve banks can control from nine to
14 functions. These valves are, closed-center, closed-port type, with spring centered, manually operated spools. When the
operator pulls a control lever, oil flows from port "A" of the control valve. Three flow rates are used: 5 GPM (18.9 L/min),
10 GPM (37.9 L/min.), and 20 GPM (75.7 L/min.).
The flow divider principle is used in this valve’s operation. The advantage of the flow divider principle over conventional
means of compensation is the ability to control multi-function operation when flow demand exceeds pump capacity. For
example, all operating circuits continue to function, regardless of the differences in their load and pump flow. The flow
relationships specified between functions will be maintained over the pump’s full flow range.
10-60 830B/C-850B/C-870B/C
12
The simplified schematic below illustrates the dynamic interrelationship of the load-sense shuttle (1), the compensator (2), the
directional spool or variable orifice (3), combined with a variable-volume, pressure-compensated, load-sense pump (4).
830B/C-850B/C-870B/C 10-61
12
After the spool is activated, the work-port load pressure is transmitted to the bridge (5). The load-sense shuttle (1) in turn
transmits the highest work-port pressure to the load sense port of the pump (4) and all the compensators (2) within the valve
assembly. The pump (4) responds to a load-sense signal with load-sense pressure plus pump margin or differential. It is this
pressure margin or differential that overcomes the compensators (2) and permits the flow to the bridge (5) and work port A or
B. This system establishes constant pressure differential across a variable orifice spool (3). At full stroke of the spool (3), the
maximum orifice can be determined, creating spool flow ranges (i.e. 5, 10, 20 GPM) at a predetermined pressure differential at
the spool (3). This working combination of components sets up the flow dividing principle on which the CompChek Valve
Technology is based.
10-62 830B/C-850B/C-870B/C
12
Two other components are found in the load-sensing circuit:
1. Pressure reducing valve; and
2. Relief valve
1. Load-sensing pressure reducing valve in the outboard end plate of the left valve bank. The load-sensing pressure reducing
valve is used to fill the load-sensing circuit to 140 PSI (9.8 kg/cm2) to ensure quick response when a valve is actuated.
This pressure is read at test port "2" with all controls in neutral.
2. Load-sensing relief valve in the outboard section of the right valve bank. The load-sensing relief valve limits the
maximum pressure in the load-sensing circuit to 2300 PSI (161.7 kg/cm2). This maximum can be read at test port "2"
when a control valve is stalled by bottoming a cylinder. With the pump compensator pressure differential at 220 PSI (15.5
kg/cm2), the pump outlet maximum pressure is 2520 PSI (177.2 kg/cm2). This pressure can be read at test port "1" when
test port "2" is at 2300 PSI (161.7 kg/cm2).
830B/C-850B/C-870B/C 10-63
12
All of the oil returning to the tank from the main system passes through the junction block and filter, including oil from the
circle motor drain and float valve drain circuits. Return flow from the control valve circuits and load-sensing drain also passes
through the filter. The filter element has a 10 rating of 6 to 15. A filter bypass valve opens if the element restricts the flow more
than about 44 ±4 PSI (3.1 ±0.3 kg/cm2). At 28 ± 4 PSI (2.0 ±0.3 kg/cm2) the warning lamp on the control console turns ON. If
the light comes ON when oil is at operating temperature, change the filter.
The figure below shows a typical left control valve section schematic. The right control valve schematic differs slightly in the
way that the shuttle ball is shown.
When looking at the individual main system control valve function circuits that follow, refer back to this illustration and
figures on the following three pages for clarification.
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12
SPOOL VALVE POSITIONS
Discussed in detail are the three spool-valve positions:
1. NEUTRAL (CENTER)
2. PULLED (PRESSURIZED "B" PORT)
3. PUSHED (PRESSURIZED "A" PORT)
NEUTRAL (CENTER)
When the control valve spool is in its neutral or center position, the oil flow to either the "A" or "B" ports is blocked. Also,
note that the valve spool blocks the oil flow at three points.
1. The center portion of the valve spool is closed, preventing oil from the pump to act upon the compensator.
2. Oil flow to or from the control valve function (i.e. cylinder) is blocked from the return oil passage or bridge passage at the
"A" port.
3. Oil flow to or from the control valve function (i.e. cylinder) is blocked from the return oil passage or bridge passage at the
"B" port.
These three blockages are why this type of control valve is called a closed-center, closed-port valve.
The pump compensator reduces pressure to 220 PSI (15.5 kg/cm2) above the load-sensing line pressure of 140 PSI
(9.8 kg/cm2). Thus, 360 PSI (25.3 kg/cm2) results at test port "2" when the system is at low-pressure standby.
830B/C-850B/C-870B/C 10-65
12
PULLED (PRESSURIZED "B" PORT)
Pulling the control lever and oil flows from the pump. The oil passes through the now-opened center portion of the valve
section and opens the compensator. With the compensator opened, oil passes through the bridge and flows out the now opened
"B" port. Simultaneously, the pressurized oil causes the load-sensing shuttle to shift. When the load-shift shuttle is shifted, the
140 PSI (9.8 kg/cm2) load-sensing line pressure is blocked off from all control valves downstream from the shuttle. The
shuttle senses system pressure.
The return oil from the control function is allowed to enter port "A" and passes over the now-opened valve spool and returns to
the tank.
Remark
Remember that when a valve section is in the right bank that the flow is out the opposite "A" port and the
return oil enters the "B" port.
10-66 830B/C-850B/C-870B/C
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PUSHED (PRESSURIZED "A" PORT)
Pushing the control lever allows oil to flow from the pump. The oil then passes through the now opened center portion of the
valve section and opens the compensator. With the compensator opened, oil passes through the bridge and flows out the now
opened "A" port. Simultaneously, the pressurized oil causes the load-sensing shuttle to shift.
When the load-shift shuttle shifts, the 140 PSI (9.8 kg/cm2) load-sensing line pressure is blocked off from all control valves
down stream from the shuttle. The shuttle senses system pressure.
The return oil from the control function is allowed to enter port "B" and passes over the now opened valve spool and returns to
the tank.
Remark
Remember that when a valve section is in the right bank, that the flow is out the opposite "B" port and the
return oil enters the "A" port.
830B/C-850B/C-870B/C 10-67
12
10-68 830B/C-850B/C-870B/C
12
MAIN SYSTEM CONTROL VALVES
SCARIFIER
The optional scarifier control uses the 20 GPM (75.7 L/min.) control valve. Also, a double pilot check valve with cross line
relief is used to protect the rod ends of the cylinders from damaging impacts when the control valve is in neutral.
DOUBLE PILOT CHECK VALVE
When the scarifier control lever is PUSHED, oil flow is routed to port
"VH" of the double-pilot check valve with cross line relief. Oil is allowed
to pass freely over the pilot check valve between ports "VH" and "CH." A
pilot line from port "VH" opens the pilot check valve located between ports
"CR" and "VR." This action allows the rod end oil being exhausted to pass
over this pilot check valve. Returning the control lever to the neutral
position causes spring pressure to close the pilot check valve poppets. This
action traps the oil, preventing the cylinders from drifting.
When the scarifier control lever is PULLED, oil flow is routed to port
"VR" of the double-pilot check valve with cross line relief. Oil is allowed
to pass freely over the pilot check valve between ports "VR" and "CR." A
pilot line from port "VR" opens the pilot check valve located between ports
"CH" and "VH" and allows the base end oil being exhausted to pass over
this pilot check valve. Returning the control lever to neutral causes the
spring pressure to close the pilot check valve poppet. The trapped oil
prevents the cylinders from drifting.
The two pilot-check valves operate at a 3:1 ratio. This ratio requires the
pilot pressure to be at least 1/3 of the exhaust oil pressure to open the check
valve. This situation causes a controlled flow and movement of the
cylinders, preventing them from free falling.
LEGEND
A. FLOATING BODY
B. CHECK POPPET ASSEMBLY
C. CHECK SEAT
D. CHECK SPRING
E. PISTON RETURN SPRING
F. PILOT PASSAGE
G. THREAD AND STATIC SEAL ASSEMBLY
A typical cutaway view of a pilot check valve is shown at the right. A pilot piston, upon receipt of a pressure signal, physically
forces the check poppet from its seat. This action allows oil to flow through the valve in either direction. The check poppet
assembly (B) closes and seals on seat (A), allowing free flow from port "2" to port "1". Pilot flow at port "3" through passage
(F) actuates the piston, forcing the piston to the right, opening the valve. Oil can now flow in either direction. When the pilot
pressure is released, spring (E) retracts the pilot piston while spring (D) forces the poppet to the closed position.
CROSSLINE RELIEF VALVE
If the control valve is in the neutral position and an outside force caused the scarifier cylinders to extend, pressure could
increase to 2700 PSI (189.8 kg/cm2). At that point, a cross line relief valve, which is located between ports "CR" and "CH,"
opens. The oil now circulates from the rod end to the base end of the cylinders. Oil circulation prevents the cylinders from
being damaged. However, oil cannot circulate from the base end to the rod end of the cylinder, preventing cylinder movement
when ripping materials.
830B/C-850B/C-870B/C 10-69
12
RIGHT AND LEFT BLADE LIFT
The blade lift circuits use 10 GPM (37.9 L/min.) control valves with dual counterbalance valves as a standard feature. These
holding valves eliminate blade drift and maintain smooth control while lowering the blade. A crossline relief valve with a 2700
PSI (189.8 kg/cm2) threshold. The relief valve is incorporated between the extended and retracted sides to prevent rod
extension overload damage to the cylinder when the control valve is in neutral.
Blade float valves, an option, are used primarily when plowing snow. These valves are electrically operated from switches on
the instrument console. Turning the switch on causes both solenoids to unblock both pilot checks. Oil now flows between the
rod and base end of the cylinder as the blade rises and falls to follow the contour of the road. Additional oil is available from
the tank return circuit to prevent cavitation in the cylinder.
Also available is an optional accumulator installed at the base end of the cylinder to cushion the blade lift assembly from
excessive shock loading when the control valve is in neutral. The accumulator is charged with nitrogen to 2500 PSI
(175.8 kg/cm2).
10-70 830B/C-850B/C-870B/C
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DUAL COUNTERBALANCE VALVE
Both the right and left blade lift circuits function in the same manner. Pushing a blade lift control lever lowers the blade
(cylinder extends). Oil now flows to port "VH" of the dual counterbalance valve with crossline relief. Oil is passes freely over
the check valve located between ports "VH" and "CH." A pilot line from port "VH," combined with a pilot line form port
"CR" opens the relief valve (3000 PSI or 210.9 kg/cm2 threshold), which is located between ports "CR" and "VR." The rod
end oil passes through the relief valve. Returning the control lever to neutral causes spring pressure to close the relief valve
and the oil is trapped, preventing the cylinder from drifting.
The counterbalance relief valves function at a 4.5:1 ratio. When pilot pressure from the inlet port multiplies by 4.5, and the
pilot pressure from the exhaust port equals 3000 PSI (210.9 kg/cm2) plus return oil back pressure, the relief valve will
compress the spring, opening the valve.
When (VH x 4.5) + CR = VR + 3000 PSI (210.9 kg/cm2), the cylinder will extend.
When (VR x 4.5) + CH = VH + 3000 PSI (210.9 kg/cm2), the cylinder will retract.
This 4.5:1 pilot ratio allows the system pressure, which has a maximum of 2300 PSI (161.7 kg/cm2), to open the relief valve,
which has a 3000 PSI (210.9 kg/cm2) threshold.
LEGEND
A. FLOATING BODY
C. CHECK SEAT/VALVE SPOOL ASSEMBLY
D. CHECK SPRING
E. MAJOR BIAS SPRING
F. PILOT PASSAGE
Remark
The valve action discussed is for lowering the
blade.
Positive internal piloting pressure from supply line "VH,"
opposite the controlled (counterbalanced) line "CR" is utilized with the load induced pressure from line "CR" pushing against
the check valve seat end of the spool, to open the valve. With the pilot assist feature, internal pilot pressure from supply line
"VH"
effectively reduces the pressure setting of the valve by allowing pilot pressure through pilot passage (F). This forces the check
seat and valve spool assembly (C) to the left against the major bias spring (E). The loaded machine member is restrained until
pressure is available from the opposite cylinder line "CR." That means the actuator cannot move faster than the speed resulting
from the pressurized supply (pump) fluid in line "VH." This action permits smooth, positive control of overrunning loads and
cushioned deceleration. This positive control of overrunning loads occurs due to the drop in pressure that takes place during
the overrun condition in the supply pilot line "VH." This action allows the major bias spring (E) to move the valve spool
assembly to the right closing the valve.
CROSSLINE RELIEF
If the control valve is in the NEUTRAL position and an outside force for some reason should cause the lift cylinders to extend
(causing oil pressure to rise), a 2700 PSI (189.8 kg/cm2) crossline relief valve is located between ports "CR" and "CH." This
valve will allow oil to circulate from the rod end to the base end of the cylinders. This circulation of oil prevents the cylinders
from being damaged. However, oil cannot circulate from the base end to the rod end of the cylinder, preventing cylinder
movement when grading.
830B/C-850B/C-870B/C 10-71
12
FLOAT VALVE
The float valve is activated by an electrical switch. Activating the float switches allows oil to circulate from the cylinder rod
end to the base end, and vice versa. However, deactivating the solenoid valve and the oil is only free to flow to and from the
dual counterbalance valve and the rod end and base end of the cylinder.
A spring-loaded spool in the solenoid valve controls the oil flow to the tank. When the float switch is off, the springloaded
spool keeps the pilot line pressure equal on both sides of the two poppet valves. This action prevents oil on the spring side of
the two poppets from flowing to the tank. However, when the float switch is on, the spool within the valve opens and the pilot
pressure exerted on the cylinder pilot lines opens the poppet valves. The pilot oil, on the spring side of the poppet valves, can
now return to the tank. The oil passes over the opposite check valve poppet to the other end of the cylinder. Lack of oil or
excess oil is allowed to flow to and from the tank, depending on which direction the cylinder is moving.
BLADE SHIFT
Oil flows to the blade shift cylinder must pass through the circle swivel
block. This rotary distribution block's stationary center pin is mounted
under the drawbar cover plate, and the outer housing rotates with the circle.
The lip seal replaces the previous O-ring for improved service life. The
blade shift control uses the 10 GPM (37.9 L/min.) control valve, without a
holding valve in the circuit.
Pushing the control lever oil flows through the swivel block to the rod end
of the cylinder, causing the moldboard to slide to the left.
Pulling the control lever directs the oil through the swivel block to the base
end of the cylinder, causing the moldboard to slide to the right.
10-72 830B/C-850B/C-870B/C
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The circle reverse motor control uses the 20 GPM (75.7 L/min.) control
valve to direct oil to the geroter-style motor. No holding valve is needed
because of the worm-gear type of reduction before the drive pinion. The
circle reverse motor has an independent drain line back to the hydraulic
junction block.
Pushing the control lever directs oil through the swivel block to the circle
reverse motor. This action causes the moldboard to move in a
counterclockwise direction.
Pulling the control lever directs oil through the swivel block to the circle
reverse motor. This action causes the moldboard to move in a clockwise
direction.
830B/C-850B/C-870B/C 10-73
12
MOLDBOARD TILT
Flow to the moldboard tilt cylinder must pass through the circle swivel block. This rotary distribution block's stationary center
pin is mounted under the drawbar cover plate, and the outer housing rotates with the circle. The new type lip seal replaces the
previous O-ring for improved service life. The moldboard tilt circuit in the left hand valve bank uses a 5 GPM (18.9 L/min.)
control valve and double-pilot check valve.
DOUBLE PILOT CHECK VALVE
Pushing the moldboard tilt control lever tilts the blade forward. Oil flows
through the swivel block to port "V2" of the double-pilot check valve. Oil
is allowed to pass freely over the pilot check valve between ports "V2" and
"C2." A pilot line from port "V2" opens the pilot check valve located
between ports "C1" and "V1." The rod end oil passes over this pilot check
valve. Returning the control lever to the neutral position causes spring
pressure to close the pilot check valve poppets and the oil is trapped,
preventing the cylinders from drifting.
Pulling the moldboard tilt control lever tilts the blade rearward. Oil flows
through the swivel block to port "V1" of the double-pilot check valve. Oil
is allowed to pass freely over the pilot check valve between ports "V1" and
"C1." A pilot line from port "V1" opens the pilot check valve located
between ports "C2" and "V2." This action allows the base end oil being
exhausted to pass over this pilot check valve. Returning the control lever to
the neutral position causes spring pressure to close the pilot check valve
poppets and the oil is trapped, preventing the cylinders from drifting.
The two pilot check valves operate at a 3:1 ratio. To open the check valve,
pilot pressure must be at least 1/3 of the exhaust oil pressure that is trying
to keep the valve closed. This action causes a controlled flow and
movement of the cylinders, preventing a free falling condition.
LEGEND
A typical cutaway view of a pilot check valve is shown at the right. The
check poppet (B) is normally closed against its seat (A). The pilot piston,
upon receipt of a pressure signal, forces the check poppet from its seat.
This action establishes flow through the valve in either direction. Oil now
flows freely from port "2" to port "1". Pilot flow at port "3" through
passage (F) actuates the piston, causing it to shift to the right.
This action opens the valve and oil flow in either direction. When the pilot
pressure is released, the spring (E) retracts the pilot piston while spring (D)
forces the poppet closed.
A. FLOATING BODY
C. CHECK SEAT
D. CHECK SPRING
F. PILOT PASSAGE
10-74 830B/C-850B/C-870B/C
12
ARTICULATION
The articulation control circuit uses a 10 GPM (37.9 L/min.) control valve and dual counterbalance holding valve without
crossline relief. This valve prevents the frame halves from drifting while still allowing smooth control when articulating the
grader.
When the articulation control lever is PUSHED to articulate the frame to the left, oil flow is routed to port "V2" of the dual
counterbalance valve. Oil is allowed to pass freely over the check valve located between ports "V2" and "C2." A pilot line
from port "V2", combined with a pilot line form port "C1" opens the 3000 PSI (210.9 kg/cm2) relief valve, located between
ports "C1" and "V1". This allows the oil being exhausted to pass through the relief valve. Returning the control lever to the
neutral position causes spring pressure to close the pilot check valve poppets and the oil is trapped, preventing the cylinders
from drifting.
When the articulation control lever is PULLED to articulate the frame to the right, oil flow is routed to port "V1" of the dual
counterbalance valve. Oil is allowed to pass freely over the check valve located between ports "V1" and "C1". A pilot line
from port "V1," combined with a pilot line form port "C2" opens the 3000 PSI (210.9 kg/cm2) relief valve, located between
ports "C2" and "V2". This action allows the oil being exhausted to pass through the relief valve. Returning the control lever to
the neutral position causes spring pressure to close the pilot check valve poppets and the oil is trapped, preventing the
cylinders from drifting.
The counterbalance relief valves function at a 4.5:1 ratio. When the pilot pressure from the inlet port is multiplied 4.5 times
and the pilot pressure from the exhaust port equals 3000 PSI (210.9 kg/cm2) plus return oil back pressure, the relief valve will
compress the spring, opening the valve.
When (V2 x 4.5) + C1 = V1 + 3000 PSI (210.9 kg/cm2), the cylinder will extend.
When (V1 x 4.5) + C2 = V2 + 3000 PSI (210.9 kg/cm2), the cylinder will retract.
The 4.5:1 pilot ratio allows the system pressure, which has a maximum of 2300 PSI (161.7 kg/cm2), to open the relief valve,
which has a threshold of 3000 PSI (210.9 kg/cm2).
LEGEND
A. FLOATING BODY
D. CHECK SPRING
F. PILOT PASSAGE
Remark
Valve action discussed is for a left turn.
A cutaway view of a counterbalance valve is shown at the right. Positive internal-piloting pressure is from supply line "V2",
opposite the controlled (counterbalanced) line "C1". Utilized with the load-induced pressure from line "C1", pressure against
the check valve seat end of the spool opens the valve. Internal pilot pressure from supply line "V2" reduces the valve’s
pressure setting by allowing pilot pressure through the pilot passage (F). This action forces the check seat and valve spool
assembly (C) against the major bias spring (E). The loaded machine member is restrained until pressure is available from the
opposite cylinder line "C1". That means the actuator cannot move faster than the speed resulting from the pressurized supply
(pump) fluid in line "V2". This action permits smooth, positive control of overrunning loads and cushioned deceleration. This
positive control of overrunning loads occurs due to the pressure drop that takes place during the overrun condition in the
supply pilot line "V2". This action allows the major bias spring (E) to move the valve spool assembly to the right, closing the
valve.
830B/C-850B/C-870B/C 10-75
12
CIRCLE SIDE SHIFT
The circle side shift circuit uses a 10 GPM (37.9 L/min.) control valve and dual counterbalance holding valve, without
crossline relief. This valve prevents the circle assembly from drifting while still allowing smooth control when shifting the
circle assembly. Accumulators are available as options to mount at both ends of this cylinder.
When the circle shift control lever is PUSHED to move the circle to the
left, oil flow is routed to port "V2" of the dual counterbalance valve. Oil is
allowed to pass freely over the check valve located between ports "V2" and
"C2." A pilot line from port "V2," combined with a pilot line form port
"C1" opens the 3000 PSI (210.9 kg/cm2) relief valve, located between ports
"C1" and "V1". This allows the oil being exhausted to pass through the
relief valve. When the control lever is returned to neutral, a spring closes
the relief valve and the oil is trapped, preventing the cylinders from
drifting.
Remark
When the grader has R.H. & L.H. blade suspension, port
"C2" is connected to the base end of the circle shift cylinder.
Port "C1" is connected to the rod end. However, when a
grader has R.H. bias blade suspension, port "C2" is
connected to the rod end of the circle shift cylinder. Port
"C1" is connected to the base end.
When the circle shift control lever is PULLED to move the circle to the
right, oil flow is routed to port "V1" of the dual counterbalance valve. Oil
is allowed to pass freely over the check valve located between ports "V1"
and "C1". A pilot line from port "V1", combined with a pilot line form port
"C2" opens the 3000 PSI (210.9 kg/cm2) relief valve, located between ports
"C2" and "V2". This allows the oil being exhausted to pass through the
relief valve. When the control lever is returned to neutral, a spring closes
the relief valve and the oil is trapped, preventing the cylinders from
drifting.
The counterbalance relief valves function at a 4.5:1 ratio. When pilot
pressure from the inlet port increases 4.5 times and the pilot pressure from
the exhaust port equals 3000 PSI (210.9 kg/cm2) plus return oil back
pressure, the relief valve will compress the spring, opening the valve.
When (V2 x 4.5) + C1 = V1 + 3000 PSI (210.9 kg/cm2), the cylinder will extend.
When (V1 x 4.5) + C2 = V2 + 3000 PSI (210.9 kg/cm2), the cylinder will retract.
This 4.5:1 pilot ratio allows the system pressure, which has a maximum of 2300 PSI (161.7 kg/cm2), to open the relief valve,
which has a threshold of 3000 PSI (210.9 kg/cm2).
10-76 830B/C-850B/C-870B/C
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LEGEND
A. FLOATING BODY
D. CHECK SPRING
F. PILOT PASSAGE
Remark
The valve action discussed is for moving the circle to the right.
At right, a cutaway view of a counterbalance valve. Positive internal-piloting pressure from supply line "V2", opposite the
controlled (counterbalanced) line "C1". Utilized with the load-induced pressure from line "C1", pressure against the check
valve seat end of the spool opens the valve. With the pilot-assist feature, internal pilot pressure from supply line "V2"
effectively reduces the pressure setting of the valve by allowing pilot pressure through pilot passage (F). This pressure forces
the check seat and valve spool assembly (C) against the major bias spring (E). The loaded machine member is restrained until
pressure is available from the opposite cylinder line "C1". That means the actuator cannot move faster than the speed resulting
from the pressurized supply (pump) fluid in line "V2". This action permits smooth, positive control of overrunning loads and
cushioned deceleration. This positive control of overrunning loads occurs due to a pressure drop that takes place during the
overrun condition in the supply pilot line "V2". This action allows the major bias spring (E) to move the valve spool assembly
to the right, closing the valve.
830B/C-850B/C-870B/C 10-77
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LEANING WHEEL
The leaning wheel control uses a 5 GPM (18.9 L/min.) control valve and a holding valve of the double pilot check
type, because no gravity load exists to control.
DOUBLE-PILOT CHECK VALVE
When the leaning wheel control lever is PUSHED to lean the wheels to the
left, oil flow is routed to port "V2" of the double-pilot check valve. Oil is
allowed to pass freely over the pilot check valve between ports "V2" and
"C2". A pilot line from port "V2" opens the pilot check valve located
between ports "C1" and "V1". This action allows the base end oil being
exhausted to pass over this pilot check valve. When the control lever is
returned to neutral, springs close the pilot check valve poppets and the oil
is trapped, preventing the cylinders from drifting.
When the leaning wheel control lever is PULLED to lean the wheels to the
right, oil flow is routed to port "V1" of the double-pilot check valve. Oil is
allowed to pass freely over the pilot check valve between ports "V1" and
"C1". A pilot line from port "V1" opens the pilot check valve located
between ports "C2" and "V2". This allows the rod end oil being exhausted
to pass over this pilot check valve. When the control lever is returned to the
neutral position, spring pressure closes the pilot check valve poppets and
the oil is trapped, preventing the cylinders from drifting.
The two pilot check valves operate at a 3:1 ratio. To open the check valve,
pilot pressure must be at least 1/3 of the exhaust oil pressure. The exhaust
oil pressure acts against the opposite side of the check valve, attempting to
keep it closed. This action causes a controlled flow and movement of the
cylinders, preventing a free falling condition.
LEGEND
A. FLOATING BODY
C. CHECK SEAT
D. CHECK SPRING
F. PILOT PASSAGE
A cutaway view of a pilot check valve is shown at right. The check poppet (B) closes and seals on seat (A). The pilot piston
forces the check poppet from its seated position. This action establishes flow through the valve in either direction. Oil flows
from port "2" to port "1". Pilot flow at port "3" through passage (F), actuates the piston, causing it to shift to the right. This
opens the valve to flow in either direction. When pilot pressure is released, spring (E) retracts the pilot piston. Spring (D)
forces the poppet closed.
10-78 830B/C-850B/C-870B/C
12
OPTIONAL FLOAT VALVE
The auxiliary float switch on the shift console electrically operates this valve. When switched ON, the solenoid valve unblocks
both pilot checks. Oil now flows between the rod and base end of the cylinder as the blade rises and falls, imitating the contour
of the road. Additional oil is available from the tank return circuit to prevent cavitation in the cylinder. This circuit can be used
for attachments, like V-plows and snow wings.
FLOAT VALVE FUNCTION
The float valve allows oil to circulate from the cylinder rod end to the
base end, and vice versa. This action takes place when the electric float
switch is actuated. When the electric solenoid valve is not actuated, oil
is only free to flow to and from the control valve ports.
Deactivating the solenoid valve closes a spring-loaded spool valve
within the solenoid valve. This action keeps oil on the spring side of
the two poppets from flowing to the tank. Thus, the pilot-line pressure
remains equal on both sides of the two poppet valves and they remain
closed.
Activating the solenoid valve opens the spool within the valve. This
action forces the pressurized pilot oil to overcome spring pressure,
opening the poppet valves. While some of the oil returns to the tank,
some of the oil flows over the opposite check valve poppet to the other
end of the cylinder.
Depending on which direction the cylinder is moving, oil can flow into
the tank or from the tank. Oil flows from the tank when there is a lack
of oil. However, excess oil is allowed to flow to the tank.
830B/C-850B/C-870B/C 10-79
STRUCTURE AND FUNCTION STEERING AND BRAKE CIRCUIT
12
STEERING AND BRAKE CIRCUIT
(INCLUDES LOCK PIN)
All oil that flows to the steering and brake pump must first pass through a 100-mesh strainer located at the bottom of the tank.
The strainers are serviceable items and must be cleaned whenever the hydraulic oil tank is drained during regular service
intervals. Refer to the Operation and Maintenance Manual for these intervals.
The steering and brake pump is an axial piston, variable-displacement pump used to create flow in the steering and brake
circuit. The flow created is dependant upon system requirements. The pump is set to maintain the circuit pressure at 1650 PSI
(116.0 kg/cm2). A pump-mounted flow compensator responds to a system pressure drop when flow is created by the actuation
of a function in the circuit. The oil is routed to either the orbitrol steering unit or the double-check valve.
10-80 830B/C-850B/C-870B/C
12
Turning the steering wheel creates a demand for oil (a pressure drop), and the pump strokes up to maintain pressure. The
orbitrol unit directs the oil flow to the steering cylinder. Return oil from the cylinder passes through the orbitrol unit before
being routed to a relief valve, which has a 150 PSI (10.5 kg/cm2) threshold, located at the junction block. This relief valve
maintains oil in the return line circuit.
Remark
Emergency steering is made possible by the relief valve, which has a 150 PSI (10.5 kg/cm2) threshold. In
an emergency, the relief valve blocks the oil flow from returning to the tank and the steering wheel can be
turned.
Oil from the pump directed through the double-check valve supplies the normal wet brakes (located in rear axle), parking/
emergency brake, and lock pin cylinder (if equipped). The double-check valve splits the oil into two circuits. Each circuit
contains an accumulator that supplies pressurized hydraulic oil for emergencies. The accumulators are precharged at 500 PSI
(35.2 kg/cm2). When the unit is running, the pump develops 1650 PSI (116.0 kg/cm2), which increases the 500 PSI
(35.2 kg/cm2) precharge to 1650 PSI (116.0 kg/cm2). The oil used in the circuit to pressurize the precharge gas is then available
to operate the system in an emergency.
Only one circuit supplies the left rear axle brake (controlled by the brake valve). The other circuit supplies oil to the right brake
circuit, plus oil to the parking/emergency brake solenoid valve and lock pin solenoid valve (if equipped) located at the junction
block.
A pressure switch is located in the Double Check Valve set at 1100 ±60 psi (77.33 ± 4.21 kg/cm2). this switch activates a warn-
ing light in the instrument panel and will activate when the system supply pressure drops below the pressure switch setting.
A second pressure switch is located in the Parking Brake Valve set at 1100 ±60 psi (77.33 ± 4.21 kg/cm2). This switch activates
a warning light in the instrument panel that will warn if the parking brake is applied. It also serves as an input to the transmis-
sion shifter. When the parking brake is applied the transmission will not go into gear or if the parking brake looses pressure the
transmission will shift to NEUTRAL.
Remember, any component in the circuit after the steering and brake pump retains static hydraulic pressure because of the
accumulators. Release the hydraulic pressure before servicing any of the below components:
1. Double-check valve
2. Junction block
3. Accumulators
4. Lock pin cylinder
5. Rear axle assembly
6. Parking brake
7. Rexroth brake valve
830B/C-850B/C-870B/C 10-81
12
10-82 830B/C-850B/C-870B/C
STRUCTURE AND FUNCTION ALL-WHEEL-DRIVE CIRCUIT
12
ALL-WHEEL-DRIVE CIRCUIT
All Wheel Drive (AWD) is the front-wheel-assist drive system for the graders. When it's switched on, all six wheels are
powered. This system uses a hydraulic pump and two motors to deliver engine power to special low-profile gearboxes in the
front wheels. The electrical system controls many factors, leaving the operator free to concentrate on grading.
AWD increases a grader's productivity to that of a larger size machine by increasing traction. It also improves front end
stability. You get all this, without increasing fuel consumption.
A three-position switch -- OFF, NORMAL MODE, AGGRESSIVE MODE -- on the shift console controls the AWD. Select
any mode, any time and in any gear. Pressing the brake pedal turns the system OFF. The AWD system resumes its assistance
automatically after removing your foot from the brake pedal. The inching pedal works in the same manner.
Shifting the transmission to neutral or applying the parking/emergency brake automatically turns the AWD off. If the parking
brake has not been applied, the AWD resumes operation when the gear shift lever is placed into gear. If the parking brake was
applied, an interlock system requires that the gear shift lever be returned to neutral before the parking/emergency brake can
again be released. Shift the transmission into gear to resume AWD operation.
830B/C-850B/C-870B/C 10-83
12
NORMAL MODE
Most grading situations can be handled in the more efficient NORMAL MODE. In this mode, the system is in a standby
condition:
The system waits for a speed differential between the front and rear wheels.
10-84 830B/C-850B/C-870B/C
12
If the rear wheels slip more than two percent (2%) for any reason, the system will already have power waiting at the front
wheels to help pull.
Two percent is not very much and the operator concentrating on the job will not notice the front wheel assist at this point. Until
the front wheels also lose traction, the operator may think the system is not working.
830B/C-850B/C-870B/C 10-85
12
AGGRESSIVE MODE
Operating in the AGGRESSIVE MODE helps stabilize the front end of the grader better against heavy side draft. In this mode,
the controller orders the system to drive the front wheels slightly faster than the rear wheels all the time.
10-86 830B/C-850B/C-870B/C
12
HYDRAULIC OPERATION
The diagram below shows the AWD System components positioned as they are on the grader. We'll examine each part and
discuss its role in the system. Then we'll look at the circuits that automatically control each part to make them work together as
a system.
830B/C-850B/C-870B/C 10-87
12
When the engine is running, the AWD system charge pump mounted on the rear of the main AWD pump is running. The
charge pump supplies oil to the AWD circuit. Supply oil from the tank first passes through a 100-mesh strainer. Pressurized oil
from port "G1" is then passes through a 10 micron filter with a bypass valve that limits restriction to about 40 PSI
(2.8 kg/cm2). Then it returns to the pump at port "G." Charge oil is now available to:
1. Replenish the main loop through the high pressure relief/makeup check valve cartridges.
2. Act as control oil to position the swash plate control cylinder; or
3. Be dumped as excess flow into the case drain circuit across a charge relief valve in the pump, which has a 350 PSI
(24.6 kg/cm2) threshold. However, because of another relief valve in the system, which has a 250 PSI (17.6 kg/cm2) threshold,
the flushing valve on the pump does not control the charge pressure, but acts as a backup.
WARNING! DO NOT OPERATE the pump with the port "G1" plugged. This external circuit is enabled
by a special fitting in port "G1" that blocks an internal passage to the charge relief valve.
Due to the flushing valve downstream in the Hydraulic Integrated Circuit (HIC), the charge pump flow is always entering the
main pump loop. This action occurs even when the system is not doing any work. When the system is doing work, one side of
the loop will be at a higher pressure than the other. This imbalance shifts the HIC shuttle valve to a position that:
1. Allows the working side of the loop to drive the wheel motors.
2. Allows the return side of the loop to dump hot return oil across the flushing valve into the cooling circuit.
3. Maintains a flow of cool replenishment oil into the pump at about 250 PSI (17.6 kg/cm2).
The cooling circuit oil flows from port "T" of the HIC valve to the bottom port of the cooler located in front of the engine
radiator. An external bypass circuit with a check valve, which has a 100 PSI (7.0 kg/cm2) threshold, protects the cooler from
pressure damage due to a cooler restriction or very cold oil. The oil flows from the cooler top tank to the bottom pump case
port "T1" to cool the pump. It then flows from the top pump case port "T2" to the hydraulic tank. A temperature switch located
in the hydraulic tank turns the indicator lamp on, which is located on the steering console (wire "35T/YELLOW") when the oil
temperature exceeds 190F (88° C).
The main loop is the part of the system that carries the oil from the pump output through the HIC to the motors. It hydraulically
transmits engine power to the front wheels. Pressures in the loop can range from the minimum charge pressure of about 250
PSI (17.6 kg/cm2) (to keep the system full of oil and prevent cavitation) to a sustained high pressure of 4400 PSI
(309.3 kg/cm2), which is the Pressure Override Valve (POV) setting. The POV controls system pressure by destroking the
pump swash plate when the system reaches this pressure.
If the high-pressure relief valves, which have a threshold of 4550 PSI (319.9 kg/cm2), in the pump were allowed to limit
maximum pressure during sustained maximum loads, overheating of these crossline reliefs could result. When conducting a
power or stall pressure check, the gauge may momentarily peak above 4800 PSI (337.4 kg/cm2). Once the POV responds and
controls the flow, the pressure will stabilize at 4400 PSI (309.3 kg/cm2).
When the system is driving forward, oil flows out of pump port "A" (left side). Oil then flows along the left side of the rear
frame to the articulation joint area. From there, oil flows along the right side of the front frame to the flange port on the back
side of the HIC. The flow divider/combiner valve in the HIC splits the pump flow equally and sends it out of HIC valve ports
"M1" and "M2" to the wheel motors. Exhaust oil from the wheel motors returns to HIC ports "A" and "B" and is combined.
Part of this flow, equal to charge pump flow, passes through the shuttle valve and flushing valve and into the cooling circuit.
The rest of this flow returns to the pump inlet at port "B," where it joins replenishment flow from the charge circuit.
When the system is driving in reverse, flow in the loop is out of pump port "B" (right side), along the right side of the rear
frame to the articulation joint area, then along the left side of the front frame to the flange port on the front side of the HIC. The
oil flows to each motor from HIC ports "A" and "B." Exhaust flow from the wheel motors equals the charge pump flow, which
passes through the shuttle valve and flushing valve and into the cooling circuit. The rest of this motor flow returns to the pump
inlet at port "A," where it joins replenishment flow from the charge circuit.
The system also requires a free-wheeling capability in both directions, which is necessary when the:
1. System is turned OFF.
2. Machine is moving faster than 12 mph.
3. Operating in the NORMAL MODE before the rear wheels slip.
10-88 830B/C-850B/C-870B/C
12
In the forward direction, this free-wheeling can be compared to the coasting action of a bicycle. This action is achieved by the
sprague clutch in the double-reduction wheel gearbox, which is the key to the efficient NORMAL MODE of operation. In this
mode, the system waits for rear wheel slip before powering the front wheels, just like pedaling while the bicycle is still
coasting. The sprague clutch also permits the differential action of the front wheels when in a turn.
In the reverse direction, the sprague clutch makes life more difficult. The motor can't drive the wheels because that's the
free-wheel direction of the sprague clutch. A hydraulic clutch pack in the wheel gearbox is actuated to provide a power path
around the sprague. This reverse clutch in each wheel is applied when the clutch valve in the bottom side of the HIC sees the
reverse drive flow from the pump. The clutch valve sends oil at flushing valve pressure, 250 PSI (17.6 kg/cm2), out port "C" to
both wheels.
Reverse overrun, which is the lock-up direction for the sprague clutch, is done hydraulically. A pair of pilot-to-close poppet
valves located in the bottom of the HIC will open. This action allows the motors to pump in a recirculation loop when they are
being driven during reverse overrun. This recirculation plus available makeup oil at charge pressure insures that the motors do
not cavitate as they pump.
When the reverse drive stops, the clutch valve shifts, relieves clutch pressure into a tank drain circuit. This action allows the
clutches to spring release. This drain circuit comes out at HIC port "D" and joins the motor case drains, and goes straight back
to the tank.
You will find another line coming from above the oil level of each wheel gearbox. These are gear case breather extension lines
and they each end with a breather cap fitting in a protected location in the frame behind the head block.
830B/C-850B/C-870B/C 10-89
12
ELECTRICAL OPERATION
The operator turns the system ON and selects the MODE of operation with the toggle switch on the shift console switch panel.
In the middle position, NORMAL MODE, this switch sends main power (at least 20 VDC required) to the controller on wire
"3 AWD." In the upper position, AGGRESSIVE MODE, this switch sends main power on wire "3 AWD" to turn on the
controller, and on wire "9 AWD" to actuate the AGGRESSIVE MODE. A green indicator lamp on the steering console lights
in either of these two modes to indicate that the system is ON.
The system controller is an encapsulated, microprocessor based, electronic module. It is located to the right of the operator's
seat, beneath the access cover. The controller receives or sends signals to manage the AWD system via three multi-pin
connectors.
The controller has a self-diagnostic system and a built-in test circuit that allows the operator to perform a dynamic system test
of the front and rear sensors. The self-diagnostic system indicates system status via a multicolored LED lamp mounted to the
case of the controller. The test circuit is actuated through the controller mounted push button. This test injects an artificial 3
MPH input command (rear wheel speed signal) to the controller. By observing the machine's response to this test, the operator
can verify that the system is responding normally.
The primary command to the controller is the rear wheel speed signal. This signal is generated by the rear speed sensor,
mounted in the transmission housing. This signal is compared electronically to the front wheel speed signal generated by the
front speed sensor (located in the right front wheel housing). These sensors produce digital pulses which are compared by the
controller to create an error signal. This error signal, via wire "1 AWD," controls the pump swash plate angle; thus pump flow,
and front wheel speed.
The pump receives direction information from the transmission shifter. Electronic circuitry, in the transmission adapter
harness, provides power to the proper pump solenoid. This harness provides power on wire "E AWD" when a reverse gear is
selected. It is connected to the pump reverse solenoid. When a forward gear is selected, this harness provides power on wires
"F AWD" and "D AWD." Wire "F AWD" supplies power to the pump forward solenoid. Wire "D AWD" controls the forward
relay which, in turn, controls the HIC solenoid valve. The forward and reverse control signals from the controller, wire
"1 AWD," are identical except when the machine is first shifted into reverse after applying the brake pedal. At that time, a
"reverse bump" signal is momentarily superimposed on the usual reverse signal.
This causes the front wheels momentarily to provide aggressive performance when reverse is first selected. The signal from
the reverse relay, wire "6 AWD," starts this feature from the controller.
To drive in the reverse direction, the clutch pack in each front wheel gearbox receives pressure from the HIC valve. This action
provides a power path around the Sprague clutch. When a forward gear is selected, the HIC solenoid valve must be energized.
This solenoid prevents the two pilot-to-close poppet valves in the HIC from opening.
Bypassing oil at the poppet valves would cause a loss of forward power. The front wheels can be driven in the forward
direction only if this solenoid is energized.
A disconnect signal is supplied to the controller, on wire "10 AWD." Wire "10 AWD" is connected to the AWD disable relay.
The disable relay can be activated by the brake pedal, inching pedal or parking brake switch. Any voltage on wire "10 AWD"
will signal the controller to cancel the drive signal to the pump. The AWD system will appear to shutoff when any of the
previous functions are applied.
10-90 830B/C-850B/C-870B/C
12
The controller also receives a reset signal on wire "12 AWD" from the shifter when neutral is selected. This signal clears all
speed data from the controller when in neutral. In neutral, power will be removed from both pump solenoids due to logic in the
transmission adapter harness. The neutral signal to the controller will assure that no drive signal is present when changing
from Neutral to Forward or Neutral to Reverse.
Each speed sensor requires a three conductor shielded cable. This cable carries a common ground wire "4 AWD," at least 8.5
VDC for sensor power on wire "5 AWD," and a signal to the controller on wire "7 AWD" from the front, and wire "8 AWD"
from the rear. The cable shield is grounded only at the controller.
Care must be taken to ensure that voltage polarity is not reversed or the sensor can be damaged. Consequently, DO NOT
conduct a continuity check of the sensor to determine if it is working. Follow the testing procedures in the troubleshooting
section.
830B/C-850B/C-870B/C 10-91
12
AWD CONTROLLER PROGRAMMING
The AWD controller is programmable. The programming is accomplished by means of wires that protrude from the backside.
The first controller is p/n 1259 559 H1 for units with S/N 100477 thru 199999. A second version, p/n 1259 559 H2, which is
used on units with S/N 199999 and up.
The controllers can be identified by the programming loops. One controller has just a black wire while the other controller has
a back wire and a white wire.
1. P/N 1259 559 H1 - A single black wire located near the lower left rear
corner.
P/N 1259 559 H1 - One wire loop is located on the back of the
controller. This wire allows the controller to be programmed for a
nonplanetary or planetary reduction final drive machine. Depending
on whether the wire is CUT or NOT CUT allows the controller to be
programmed to process different final reduction ratios. The following
table shows when the wire should be CUT or NOT CUT.
10-92 830B/C-850B/C-870B/C
12
2. P/N 1259 559 H2 - One black wire and one white wire located near the
lower left rear corner.
P/N 1259 559 H2 - Two wire loops (one black and one white) are
located on the back of the controller. Depending on how the
combination of wires are CUT or NOT CUT allows the controller to
be programmed to process different final reduction ratios. The
following table shows which wires should be CUT or NOT CUT.
830B/C-850B/C-870B/C 10-93
STRUCTURE AND FUNCTION LOCK/UNLOCK DIFFERENTIAL PUMP
12
LOCK/UNLOCK DIFFERENTIAL PUMP
The belt-driven rear axle lock/unlock differential pump is located under the front engine mount.
10-94 830B/C-850B/C-870B/C
STRUCTURE AND FUNCTION LOCK/UNLOCK DIFFERENTIAL PUMP
12
LEGEND
the lock/unlock differential pump. Some parts mentioned in the service section of this book may be shown in this illustration
only.
1. HOUSING, REAR 10. GASKET
2. BOLT 11. HOUSING, FRONT
3. PLUG 12. RING, RETAINING
4. BEARING, NEEDLE 13. BEARING, BALL
5. GEAR, DRIVE 14. SPACER
6. SHAFT ASSEMBLY, IDLER 15. SEAL, OIL

SHAFT, IDLER
GEAR, DRIVE
PIN, DRIVE
RING, RETAINING
7. SHAFT, DRIVE 16. RING, RETAINING
8. KEY, WOODRUFF 17. KEY
9. PIN, SHEAR
830B/C-850B/C-870B/C 10-95
STRUCTURE AND FUNCTION CIRCLE REVERSE SLIP CLUTCH
12
CIRCLE REVERSE SLIP CLUTCH
10-96 830B/C-850B/C-870B/C
STRUCTURE AND FUNCTION CIRCLE REVERSE SLIP CLUTCH
12
LEGEND
the circle reverse slip clutch. Some components mentioned in the service section of this book may be shown in this illustration
only.
1. PINION SHAFT 9. FRICTION PLATE 17. CLUTCH HOUSING COVER
2. O-RING 10. BACKING PLATE 18. FLAT WASHER
3. V-RING 11. CLUCH HUB 19. BOLT
4. BEARING 12. PINION SHAFT WASHER 20. OIL DRAIN/FILL PLUG
5. OIL LEVEL PLUG 13. LOCKNUT 21. O-RING
6. CLUTCH HOUSING 14. BELLEVILLE SPRING 22. PLUG
7. BACK-UP RING 15. O-RING 23. REDUCER
8. SEPARATOR PLATE 16. SHIM: 0.005, 0.007, 0.020, 0.060 24. CHECK VALVE
830B/C-850B/C-870B/C 10-97
STRUCTURE AND FUNCTION CIRCLE REVERSE GEAR CASE
12
CIRCLE REVERSE GEAR CASE
WITHOUT SLIP CLUTCH
10-98 830B/C-850B/C-870B/C
12
LEGEND
The figure on the previous page and this legend identify the parts and their orientation for servicing. This illustration may be
the only place some parts are shown.
1. RETAINER, BEARING 8. CUP, BEARING 15. CASE, CIRCLE REVERSE

BOLT
WASHER, LOCK
2. SHIM: 0.003 in. (0.076 mm), 0.005 in. 9. CONE, BEARING 16. CUP, BEARING
(0.127 mm), 0.020 in. (0.508 mm).
3. NUT, LOCK 10. GEAR, CIRCLE 17. CONE, BEARING

REVERSE
4. PIPE PLUG, FLUSH 11. CONE, BEARING 18. WORM, CIRCLE REVERSE
5. COVER, CIRCLE REVERSE CASE 12. CUP, BEARING 19. SHIM: 0.003 in. (0.076 mm), 0.005 in.
BOLT (0.127 mm), 0.020 in. (0.508 mm).
WASHER, LOCK
6. O-RING 13. SEAL, OIL 20. CAP, END

BOLT
WASHER, LOCK
7. WASHER 14. SHAFT PINION 21. SEAL, OIL SLINGER
830B/C-850B/C-870B/C 10-99
12
WITH SLIP CLUTCH
10-100 830B/C-850B/C-870B/C
12
LEGEND
1. RETAINER, BEARING 8. CUP, BEARING 15. CASE, CIRCLE REVERSE

BOLT
WASHER, LOCK
2. SHIM: 0.003 in. (0.076 mm), 0.005 in. 9. CONE, BEARING 16. CUP, BEARING
(0.127 mm), 0.020 in. (0.508 mm).
3. NUT, LOCK 10. GEAR, CIRCLE 17. CONE, BEARING

REVERSE
4. PIPE PLUG, FLUSH 11. CONE, BEARING 18. WORM, CIRCLE REVERSE
5. COVER, CIRCLE REVERSE CASE 12. CUP, BEARING 19. SHIM: 0.003 in. (0.076 mm), 0.005 in.
BOLT (0.127 mm), 0.020 in. (0.508 mm).
WASHER, LOCK
6. O-RING 13. SEAL, OIL 20. CAP, END

BOLT
WASHER, LOCK
7. WASHER 14. CLUTCH ASSEMBLY
830B/C-850B/C-870B/C 10-101
12
MOTOR INSTALLATION
10-102 830B/C-850B/C-870B/C
12
LEGEND
1. HYDRAULIC MOTOR
2. BOLT
3. CIRCLE REVERSE GEAR CASE ASSEMBLY
4. GASKET
5. BOLT
6. WASHER
7. MOUNT PLATE
8. COUPLING
830B/C-850B/C-870B/C 10-103
STRUCTURE AND FUNCTION TANDEM CASE
12
TANDEM CASE
The tandem case is the final drive line reduction point. By means of double or single strand chains the tandem case transmits
power from the rear axle assembly output shafts to the tandem case axle and sprocket assemblies.
The tandem cases are allowed to pivot independently of each other on the rear axle. This allows the tires to remain in contact
with the ground on uneven train. Stop blocks are welded to the tandem case weldment to limit the total oscillation (pivoting)
action of each case.
LOCATION
The tandem cases are located at each end of the rear axle assembly.
DESCRIPTION
The service of the tandem case is the same whether the grader is equipped with a planetary or nonplanetary reduction axle. A
planetary axle uses a single-strand chain while a nonplanetary axle uses a double-strand chain.
NONPLANETARY FINAL DRIVE
10-104 830B/C-850B/C-870B/C
12
LEGEND - NONPLANETARY FINAL DRIVE
the tandem drive case. Some components mentioned in the service section of this book may be shown in this illustration only.
1. NUT, AXLE 12. WASHER, FLAT 23. BOLT
2. WASHER, LOCKING 13. HOUSING, TANDEM 24. BOLT
3. WASHER 14. GASKET, LIQUID - 300ML 25. WASHER, FLAT

CARTRIDGE
4. WHEEL 15. CUP, BEARING 26. COVER, ACCESS
5. KEY 16. CONE, BEARING 27. BREATHER VALVE ASSEMBLY
6. BOLT 17. SHAFT WELDMENT - REAR 28. BUSHING, REDUCER
7. WASHER, FLAT 18. SHAFT WELDMENT - FRONT 29. ADAPTER, PIPE
8. RETAINER, BEARING 19. CHAIN - DOUBLE STRAND 30. PLUG, MAGNETIC
9. SHIM - 0.030 in. - CORAL 20. LINK, CONNECTING 31. CASE, TANDEM - L.H.
SHIM - 0.015 in. - PINK LINK, ROLLER CASE, TANDEM - R.H.
SHIM - 0.005 in. - BLUE
SHIM - 0.003 in. - GREEN
SHIM - 0.002 in. - RED
10. SEAL, OIL 21. COVER, ACCESS 32. STEP - R.H. ONLY
11. BOLT 22. WASHER, FLAT 33. STEP - R.H. ONLY
830B/C-850B/C-870B/C 10-105
12
PLANETARY FINAL DRIVE
10-106 830B/C-850B/C-870B/C
12
LEGEND - PLANETARY FINAL DRIVE
the tandem drive case. Some components mentioned in the service section of this book may be shown in this illustration only.
1. NUT, AXLE 12. WASHER, FLAT 23. BOLT
2. WASHER, LOCKING 13. HOUSING, TANDEM 24. BOLT
3. WASHER 14. GASKET, LIQUID - 300ML 25. WASHER, FLAT

CARTRIDGE
4. WHEEL 15. CUP, BEARING 26. COVER, ACCESS
5. KEY 16. CONE, BEARING 27. BREATHER VALVE ASSEMBLY
6. BOLT 17. SHAFT WELDMENT - REAR 28. BUSHING, REDUCER
7. WASHER, FLAT 18. SHAFT WELDMENT - FRONT 29. ADAPTER, PIPE
8. RETAINER, BEARING 19. CHAIN - SINGLE STRAND 30. PLUG, MAGNETIC
9. SHIM - 0.030 in. - CORAL 20. LINK, CONNECTING 31. CASE, TANDEM - L.H.
SHIM - 0.015 in. - PINK CASE, TANDEM - R.H.
SHIM - 0.005 in. - BLUE
SHIM - 0.003 in. - GREEN
SHIM - 0.002 in. - RED
10. SEAL, OIL 21. COVER, ACCESS 32. STEP - R.H. ONLY
11. BOLT 22. WASHER, FLAT 33. STEP - R.H. ONLY
830B/C-850B/C-870B/C 10-107
12
FINAL DRIVE IDENTIFICATION
A final drive with or without planetary reduction, can be easily identified without removing any access covers or other
components by using one of two methods: part number or tandem case measurement.
PART NUMBER TAG

A part number tag is located on the front side of the right axle mount pad.
The part number stamped into this tag indicates the version of axle that is
installed.
P/N 1277 411 H91 = Nonplanetary Axle
P/N 1277 412 H91 = Planetary Axle
TANDEM CASE MEASUREMENT

The planetary and nonplanetary drives use different chains. A planetary
reduction axle uses a single strand chain. A nonplanetary axle uses a
double strand chain. The chain pitch of a planetary reduction final drive
will differ from that of a nonplanetary final drive. This difference causes the axles to be closer together or farther apart. For
that reason, the distance from the outside of the axle bearing housing to the end of the tandem case will be different.
Remark
The tandem case has the same overall length for a planetary or nonplanetary final drive.
Measure the distance from the outside of the axle bearing housing to the end of the tandem case.
Planetary Reduction Axle = 1.500 in. (38.100 mm)
Nonplanetary Axle = 2.000 in. (50.800 mm)
10-108 830B/C-850B/C-870B/C
STRUCTURE AND FUNCTION AWD GEARBOX ASSEMBLY
12
SPECIFICATIONS
Nonplanetary Reduction Tandem Case
Spiral Bevel Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3:1
Tandem Case Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0:1
Total Final Drive and Tandem Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.8:1
Centerline to Centerline of Axle and Sprockets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.9 in. (1, 548.4 mm)
Planetary Reduction Tandem Case
Spiral Bevel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ratio4.3:1
Planetary Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7:1
Total Final Drive Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2:1
Tandem Case Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1:1
Total Final Drive and Tandem Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.8:1
Centerline to Centerline of Axles and Sprockets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.9 in. (1,573.6 mm)
Also, the number of teeth in the tandem case vary, depending if a planetary or nonplanetary is used and the machine s/n.
Planetary Reduction Tandem Case Axle
S/N 100477 thru 199999 = 21 Teeth
S/N 200000 & Up = 22 Teeth
Nonplanetary Tandem Case Axle
S/N 100477 thru 199999 = 43 Teeth
S/N 200000 & Up = 45 Teeth
AWD GEARBOX ASSEMBLY

This machine uses a hydraulic system and tandem-drive system. With front-wheel assist, traction increases, which increases
productivity.
An electronic network compares rear wheel speed and controls a variable-displacement piston pump. Flow from this pump
drives a piston motor in each front wheel gearbox assembly.
This gearbox assembly is a compact, low-profile unit with double-reduction gearing, a one-way clutch for overrunning in the
forward direction, a hydraulic clutch pack for reverse drive, and a hydraulic check-valve motor circuit for reverse overrun.
This assembly has many critical areas such as bearing adjustments, bolt torques, machining tolerances and the most
important... CLEANLINESS! Castings must be thoroughly washed before reassembling. See "Cleaning and Inspection" for
complete instructions. Bolts and mating threads must be degreased and dried where thread lock compound is used. The
gearbox oil must be filtered to 10 microns.
830B/C-850B/C-870B/C 10-109
12
AWD GEARBOX
10-110 830B/C-850B/C-870B/C
12
LEGEND
the AWD gear box. Some components mentioned in the service section of this book may be shown in this illustration only.
1. BOLT 22. CUP, BEARING 43. BEARING, ROLLER 64. BEARING
2. MOTOR, AWD 23. BEARING 44. GASKET 65. CUP, BEARING
3. O-RING 24. SUPPORT, BEARING 45. BOLT 66. WHEEL, FRONT

DRIVE
4. DISC, SPRING 25. BOLT 46. WASHER, TRHUST 67. GEAR, RING
5. BOLT - L.H. 26. WASHER, LOCK 47. SPRING, CLUTCH 68. O-RING
6. NUT, JAM - L.H. 27. O-RING 48. SLEEVE, CLUTCH 69. HOUSING, AWD
PLANETARY
7. SEAL, FASTENER 28. SEAL, PISTON - I.D. 49. PLATE, SEPARATOR 70. PIN, ROLL
8. BOLT 29. SEAL, PISTON - O.D. 50. PLATE, FRICTION 71. PIN, PLANET
9. WSHER, LOCK 30. PISTON 51. HOUSING, REVERSE 72. O-RING

CLUTCH
10. WASHER, FLAT 31. BEARING, THRUST 52. BEARING, BALL 73. WASHER, THRUST
11. GUARD 32. BOLT 53. SPACER, BEARING 74. WASHER, THRUST
WELDMENT
12. SPACER 33. WASHER, LOCK 54. RING, SNAP 75. GEAR, PLANETARY
13. ARM WELDMANT, 34. PLUG, PIPE - R.H. 55. WASHER, SPECIAL 76. BEARING, NEEDLE
STEERING
14. BOLT 35. PLUG, PIPE - R.H. 56. GEAR, BULL 77. SPACER
15. BOLT 36. RING, RETAINING 57. CLUTCH, ONE-WAY 78. WASHER, LOCK
16. WASHER, FLAT 37. BEARING, BALL 58. RING, RETAINING 79. BOLT
17. BOLT 38. WASHER 59. BOLT 80. O-RING
18. CAP, BEARING 39. PIN, DOWEL 60. SHAFT, SUN GEAR 81. PLUG, MAGNETIC
DRIVE
19. SHIMS 40. HOUSING GEAR CASE 61. SCREW, SELF-LOCKING 82. SENSOR, R.H. ONLY
20. BOLT 41. RETAINER, WHEEL 62. SEAL, OIL
21. PLATE, BEARING 42. PINION, MOTOR 63. SHIM

RETAINER
830B/C-850B/C-870B/C 10-111
STRUCTURE AND FUNCTION FRONT AXLE ASSEMBLY
12
FRONT AXLE ASSEMBLY
The basic design of the front axle assembly is common to both the Non All-Wheel-Drive and the All-Wheel-Drive graders.
The only major difference is the axle spindle assembly area.
NON ALL-WHEEL-DRIVE FRONT AXLE
10-112 830B/C-850B/C-870B/C
12
LEGEND FOR NON ALL-WHEEL-DRIVE FRONT AXLE
the Non All-Wheel-Drive Front Axle Assembly. Some components mentioned in the service section of this book may be
shown in this illustration only.
1. AXLE WELDMENT FRONT 21. NUT, LOCK 41. NUT, SLOTTED 61. BOLT
2. CYLINDER, STEERING 22. NUT, LOCK 42. SOCKET ASSY. 62. WASHER, FLAT
3. CYLINDER LEANING 23. WASHER, FLAT 43. PIN, COTTER 63. BOLT
WHEEL
4. FITTING, GREASE 24. BEARING, 44. FITTING, GREASE 64. WASHER, FLAT
THRUST
5. SPINDLE WELDMENT - 25. SPACER 45. NUT, HEX - L.H. 65. BEARING
R.H.
6. SPINDLE WELDMENT - 26. BEARING 46. BOLT

L.H.
7. ROD ASSEMBLY, 27. O-RING 47. CLAMP, RIM

LEANING WHEEL
8. FITTING, GREASE 28. BUSHING 48. NUT, HEX
9. SHAFT, AXLE PIVOT 29. PIN, PIVOT 49. COLLAR
10. FITTING, GREASE 30. GASKET 50. SEAL
11. RING, RETAINING 31. COVER 51. BEARING
12. PLATE, COVER 32. WASHER, LOCK 52. CUP, BEARING
13. BUSHING 33. BOLT 53. WHEEL, FRONT

AXLE
14. BEARING, TRHUST 34. WASHER, FLAT 54. CUP, BEARING
15. PIN, KING 35. PIN, LEANING 55. BEARING

WHEEL
16. PIN, ROLL 36. WAHSER, FLAT 56. SHIMS
17. YOKE, STEERING - R.H. 37. PIN 57. RETAINER
18. YOKE, STEERING - L.H. 38. ROD, TIE 58. BOLT
19. STUD 39. NUT, JAM 59. GASKET
20. SPACER 40. SOCKET ASSY. 60. CAP, HUB
830B/C-850B/C-870B/C 10-113
12
AWD FRONT AXLE
10-114 830B/C-850B/C-870B/C
12
LEGEND FOR AWD (ALL-WHEEL-DRIVE) FRONT AXLE
the All-Wheel-Drive Front Axle Assembly. Some components mentioned in the service section of this book may be shown in
this illustration only.
1. GEARBOX - L.H. 20. FLAT WASHER 39. TIE ROD
2. HOSE GUARD 21. LEANING WHEEL PIN 40. HEX NUT
3. LEANING WHEEL ROD ASSEMBLY 22. FLAT WASHER 41. SOCKET ASSY.
4. BALL BUSHING 23. NUT, HEX 42. SLOTTED NUT & COTTER
PIN
5. U-BOLT 24. NUT, LOCK 43. FLAT WASHER
6. FRONT AXLE WELDMENT 25. WASHER, FLAT 44. GREASE FITTING
7. STUD 26. THRUST BEARING 45. SOCKET ASSY.
8. BEARING, THRUST 27. SPACER 46. GEARBOX - R.H.
9. PIN, COTTER 28. BUSHING 47. VALVE EXTENSION
10. AXLE PIVOT SHAFT 29. PIVOT PIN 48. RIBBED NECK BOLT
11. BUSHING 30. O-RING 49. RIM CLAMP
12. COVER PLATE 31. BUSHING 50. HEX NUT
13. RETAINING RING 32. GASKET 51. STEERING CYLINDER
14. GREASE FITTING 33. COVER 52. SPACER
15. PIN 34. LOCK WASHER 53. RETAINING RING
16. GREASE FITTING - 45° 35. BOLT 54. AXLE GUARD
17. LEANING WHEEL CYLINDER 36. STEERING YOKE 55. BUSHING
18. GREASE FITTING 37. ROLL PIN
19. LOCK NUT 38. PIN, KING
830B/C-850B/C-870B/C 10-115
STRUCTURE AND FUNCTION FINAL DRIVE ASSEMBLY
12
FINAL DRIVE ASSEMBLY
With planetary and nonplanetary reduction (no-spin and lock/unlock differential)
FINAL DRIVE WITHOUT PLANETARY REDUCTION
10-116 830B/C-850B/C-870B/C
12
LEGEND FOR FINAL DRIVE WITHOUT PLANETARY
the final drive without planetary. Some components mentioned in the service section of this book may be shown in this
illustration only.
1. BOLT 14. SEAL, GREASE 27. SLEEVE, OUTPUT SHAFT
2. WASHER, FLAT 15. BEARING 28. SHAFT, AXLE
3. DISK, BRAKE 16. BEARING, CUP 29. GEAR, BRAKE PLATE
4. BOLT 17. HOUSING, FINAL DRIVE - 30. RING, RETAINING

L.H.
5. WASHER, FLAT 18. BOLT 31. RING, RETAINING
6. BRACKET, PARKING BRAKE 19. WASHER, FLAT 32. SPROCKET, OUTPUT SHAFT
7. CALIPER ASSEMBLY, 20. FITTING, LUBE 33. SPACER, OUTPUT

PARKING BRAKE SPROCKET
8. GASKET, LIQUID 21. BEARING, CUP 34. DOWEL, LOCATING
9. CASE, DIFFERENTIAL 22. BEARING 35. BOLT
10. RING, RETAINING 23. SHIMS: 0.13 mm, 0.18 mm, 36. WASHER
0.50 mm
11. BEARING, SPHERICAL 24. RETAINER, BEARING 37. NUT, HEX

ROLLER
12. SEAL, OIL 25. O-RING 38. NUT, LOCK
13. SLEEVE, TANDEM 26. BOLT
830B/C-850B/C-870B/C 10-117
12
FINAL DRIVE WITH PLANETARY REDUCTION
10-118 830B/C-850B/C-870B/C
12
LEGEND FOR FINAL DRIVE WITH PLANETARY REDUCTION
the final drive with planetary. Some components mentioned in the service section of this book may be shown in this illustration
only.
1. BOLT 14. SEAL, GREASE 27. SPACER, PLANETARY
2. WASHER, FLAT 15. BEARING 28. SHAFT, AXLE TANDEM
3. DISK, BRAKE 16. BEARING, CUP 29. PLANETARY & RING GEAR
4. BOLT 17. HOUSING, FINAL DRIVE - 30. RING, RETAINING

L.H.
5. WASHER, FLAT 18. BOLT 31. SPROCKET, OUTPUT SHAFT
6. BRACKET, PARKING BRAKE 19. WASHER, FLAT 32. SPACER, OUTPUT

SPROCKET
7. CALIPER ASSEMBLY, 20. FITTING, LUBE 33. DOWEL, LOCATING

PARKING BRAKE
8. GASKET, LIQUID 21. BEARING, CUP 34. BOLT
9. CASE, DIFFERENTIAL 22. BEARING 35. WASHER
10. RING, RETAINING 23. SHIMS: 0.13 mm, 0.18 mm, 36. NUT, HEX
0.50 mm
11. BEARING, SPHERICAL 24. RETAINER, BEARING 37. NUT, LOCK

ROLLER
12. SEAL, OIL 25. O-RING
13. SLEEVE, TANDEM MOUNT 26. BOLT
830B/C-850B/C-870B/C 10-119
12
NO-SPIN DIFFERENTIAL CASE ASSEMBLY
10-120 830B/C-850B/C-870B/C
12
LEGEND FOR THE NO-SPIN DIFFERENTIAL CASE ASSEMBLY
the differential case assembly. Some components mentioned in the service section of this book may be shown in this
illustration only.
1. PLUG 12. O-RING 23. NUT, HEX
2. O-RING 13. PLUG 24. WASHER, FLAT
3. BOLT 14. O-RING 25. BOLT
26. DIFFERENTIAL BEARING

4. WASHER, FLAT 15. PLUG
QUILLS
5. PLUG 16. O-RING 27. BRAKES
6. O-RING 17. SCREW, BLEED 28. PLUG
7. INPUT QUILL ASSEMBLY 18. BUSHING, BLEEDER 29. O-RING
8. DIFFERENTIAL ASSEMBLY 19. O-RING 30. REDUCER
9. PIN, DOWEL 20. CASE 31. BREATHER
10. O-RING 21. PLUG
11. PLUG 22. O-RING
830B/C-850B/C-870B/C 10-121
12
LOCK/UNLOCK DIFFERENTIAL CASE ASSEMBLY
10-122 830B/C-850B/C-870B/C
12
LEGEND FOR THE LOCK/UNLOCK DIFFERENTIAL CASE ASSEMBLY
the differential case assembly. Some components mentioned in the service section of this book may be shown in this
illustration only.
1. PLUG 16. O-RING
2. O-RING 17. SCREW, BLEED
3. BOLT 18. BUSHING, BLEEDER
4. WAHER, FLAT 19. O-RING
5. O-RING 20. CASE
6. PLUG 21. PLUG
7. INPUT QUILL ASSEMBLY 22. O-RING
8. DIFFERENTIAL ASSEMBLY 23. NUT, HEX
9. PIN, DOWEL 24. WASHER, FLAT
10. O-RING 25. BOLT
11. REDUCER 26. DIFFERENTIAL BEARING QUILLS
12. BREATHER 27. BRAKES
13. PLUG 28. PLUG
15. PLUG
830B/C-850B/C-870B/C 10-123
12
INPUT QUILL ASSEMBLY
10-124 830B/C-850B/C-870B/C
12
LEGEND FOR INPUT QUILL ASSEMBLY
the input quill assembly. Some components mentioned in the service section of this book may be shown in this illustration
only.
1. BEARING, CONE 9. YOKE
2. BEARING, CUP 10. SEAL
3. SHIMS: 0.003 in (0.076 mm); 0.005 in (0.127 mm); 0.010 in (0.254 mm) 11. V-SEAL
4. COVER, DIFFERENTIAL CASE 12. O-RING
5. SHIMS 13. WASHER, SPECIAL
6. SPACER 14. NUT, CASTLE
7. BEARING, CUP 15. PIN, COTTER
8. BEARING, CONE
830B/C-850B/C-870B/C 10-125
12
BRAKES
10-126 830B/C-850B/C-870B/C
12
LEGEND FOR BRAKES
the brakes. Some components mentioned in the service section of this book may be shown in this illustration only.
1. PLATE, BACKING
2. DISC, FRICTION
3. PISTON
4. SEAL, OUTER PISTON
5. SEAL, INNER PISTON
Remark
The brake portion of the axle assembly has several versions of pistons, brake discs, and backing plates.
Always refer to the appropriate parts manual for serial number ranges and parts break down.
830B/C-850B/C-870B/C 10-127
12
NO-SPIN DIFFERENTIAL BEARING QUILLS
10-128 830B/C-850B/C-870B/C
12
LEGEND FOR NO-SPIN DIFFERENTIAL BEARING QUILLS
the differential bearing quills. Some components mentioned during the service procedure may be shown in this illustration
only.
1. QUILL
2. SHIMS: 0.003 in. (0.076 mm), 0.005 in. (0.127 mm), 0.010 in. (0.254 mm)
3. BEARING, CUP
4. BEARING
5. BEARING
6. BEARING, CUP
7. QUILL
830B/C-850B/C-870B/C 10-129
12
LOCK/UNLOCK DIFFERENTIAL BEARING QUILLS
10-130 830B/C-850B/C-870B/C
12
LEGEND FOR LOCK/UNLOCK DIFFERENTIAL BEARING QUILLS
1. BOLT
2. WASHER
3. QUILL
4. BALL
5. CUP, BEARING
6. SHIMS
7. NUT
8. BEARING
9. BEARING
10. CUP, BEARING
11. QUI LL
830B/C-850B/C-870B/C 10-131
12
LOCK/UNLOCK DIFFERENTIAL ASSEMBLY
10-132 830B/C-850B/C-870B/C
12
LEGEND FOR LOCK/UNLOCK DIFFERENTIAL ASSEMBLY
the lock/unlock differential assembly. Some components mentioned in the service section may be shown in this illustration
only.
1. BOLT 12. SEAL 23. RING, RETAINING
2. COVER 13. BUSHING 24. SHAFT, PIOION
3. PIN, SPRING 14. PACKING 25. GEAR, BEVEL
4. WASHER 15. BOLT 26. HOUSING
5. SPRING 16. WASHER 27. BALL
6. DISK 17. GEAR, BEVEL 28. BALL
7. PLATE, CLUTCH SEPARATOR 18. WASHER, THRUST 29. BOLT
8. PLATE, CLUTCH BACKING 19. WASHER, THRUST 30. RING
9. HOUSING ASSEMBLY 20. ROLLER, NEEDLE 31. GEAR SET, PINION & RING
10. PISTON 21. PINION
11. SEAL 22. WASHER, THRUST
830B/C-850B/C-870B/C 10-133
12
LOCK/UNLOCK DIFFERENTIAL CASE OIL LINE
10-134 830B/C-850B/C-870B/C
12
LEGEND FOR LOCK/UNLOCK DIFFERENTIAL CASE OIL LINE
The exploded view and this legend identify the parts and their orientation to each other while servicing the oil line. Some
components mentioned in the service section may be shown in this illustration only.
1. ADAPTOR
2. O-RING
3. OIL LINE
4. ADAPTOR
5. O-RING
830B/C-850B/C-870B/C 10-135
12
NO-SPIN DIFFERENTIAL ASSEMBLY
10-136 830B/C-850B/C-870B/C
12
LEGEND FOR NO-SPIN DIFFERENTIAL ASSEMBLY
the NO-SPIN differential assembly. Some components mentioned in the service section may be shown in this illustration only.
1. BOLT
2. WASHER, FLAT
3. HOUSING
4. SET, RING GEAR & PINION
5. NO-SPIN
6. COVER
7. BOLT
830B/C-850B/C-870B/C 10-137
12
NO-SPIN DIFFERENTIAL
10-138 830B/C-850B/C-870B/C
12
LEGEND FOR NO-SPIN DIFFERENTIAL
The exploded view and legend shown here are to help identify parts and their orientation to each other while servicing the
NO-SPIN differential. Some components mentioned in the service section of this book may be shown in this illustration only.
1. GEAR, SIDE
2. RETAINER, CAM SPRING
3. SPRING
4. CLUTCH ASSEMBLY
5. STOP
6. SPIDER ASSEMBLY
830B/C-850B/C-870B/C 10-139
12
PLANETARY ASSEMBLY AND RING GEAR
10-140 830B/C-850B/C-870B/C
12
LEGEND FOR PLANETARY ASSEMBLY AND RING GEAR
the planetary assembly and ring gear. Some components mentioned in the service section of this book may be shown in this
illustration only.
1. SHAFT, INPUT 9. SHAFT, PLANET
2. RING, RETAINING 10. WASHER, THRUST
3. GEAR, SUN 11. PINION, PLANET
4. PLATE, LOCK 12. BEARING, ROLLER
5. BOLT, SPECIAL 13. SPACER, BEARING
6. CARRIER, PLANET 14. WASHER, THRUST
7. RING, RETAINING 15. WASHER, RETAINING
8. GEAR, RING
830B/C-850B/C-870B/C 10-141
12
NONPLANETARY FINAL DRIVE CROSS SECTION
10-142 830B/C-850B/C-870B/C
12
PLANETARY REDUCTION FINAL DRIVE CROSS SECTION
830B/C-850B/C-870B/C 10-143
STRUCTURE AND FUNCTION MICO PARKING BRAKE
12
MICO PARKING BRAKE
OPERATION
The caliper slides freely on the pin, which is securely fastened to the mount bracket. Depending on the direction of the disc
rotation during brake application, the force transfers to the pin and mount bracket.
Applying the brake pedal causes the internal Belleville washers to push on the piston. The piston forces the brake pads against
the brake disc. When the pressure equalizes on both brake pads, the brake disc is prevented from rotating.
Releasing the brake pedal directs oil pressure against the caliper piston. The oil pressure compresses the Belleville springs,
retracting the brake pads from the disc. The brake disc is now free to rotate.
The brake circuit also has accumulators that provide back-up hydraulic oil pressure should the engine fail.
LEGEND FOR MICO PARKING BRAKE INSTALLATION
the parking brake caliper. Some components mentioned in the service section of this book may be shown in this illustration
only.
1. BOLT 7. BRACKET, PARKING BRAKE
2. WASHER, FLAT 8. CALIPER ASSEMBLY, PARKING BRAKE
3. DISK, PARKING BRAKE 9. BOLT
4. YOKE, INPUT 10. WASHER, FLAT
5. BOLT 11. NUT, HEX
6. WASHER, FLAT 12. NUT, LOCK
10-144 830B/C-850B/C-870B/C
12
MICO PARKING BRAKE INSTALLATION
830B/C-850B/C-870B/C 10-145
12
PARKING BRAKE CALIPER
10-146 830B/C-850B/C-870B/C
LEGEND FOR MICO PARKING BRAKE CALIPER
the parking brake caliper. Some components mentioned in the service section of this book may be shown in this illustration
only.
1. BOLT 10. SCREW, SET
2. WASHER, LOCK 11. NUT, JAM
3. COVER 12. PISTON
4. SEAL, WIPER 13. ROD, PUSH
5. RING, BACK-UP 14. PISTON
6. O-RING 15. HOUSING
7. O-RING 16. FITTING, BLEEDER
8. RING, BACK-UP 17. FITTING, GREASE
9. SPRING, BELLEVILLE
830B/C-850B/C-870B/C 10-147
STRUCTURE AND FUNCTION MICO BRAKE VALVE
12
MICO BRAKE VALVE
OPERATION
The dual-circuit power brake valve regulates brake line pressure in both brake line circuits in direct proportion to the force
applied. Should any hydraulic brake circuit fail, the remaining brake valve spool operation is unaffected and the operating
force remains unchanged.
BRAKE PEDAL LINKAGE
10-148 830B/C-850B/C-870B/C
12
LEGEND FOR BRAKE VALVE LINKAGE
The exploded view and this legend identify the parts and their orientation to each other while servicing the brake pedal
components. Some components mentioned in the service section may be shown in this illustration only.
1. PAD, PEDAL 8. WASHER, BEARING 15. PIN
2. PEDAL, 9. NUT, LOCK 16. CAM

ACCELERATOR
3. PEDAL, BRAKE 10. BUMPER 17. BOLT
4. PEDAL, 11. NUT, HEX 18. NUT, LOCK

DECELERATOR
5. BOOT 12. PEDAL WELDMENT, 19. PEDAL WELDMENT, ACCELERATOR/

BRAKE DECELERATOR
6. NUT, HEX 13. BEARING, TEFLON 20. SPRING, ACCELERATOR /

DECELERATOR RETURN
7. BOLT, SHOULDER 14. RING, RETAINING 21. PLATE WELDMENT, FLOOR
830B/C-850B/C-870B/C 10-149
12
HYDRAULIC BRAKE LINES - WITHOUT AWD
10-150 830B/C-850B/C-870B/C
12
LEGEND FOR HYDRAULIC BRAKE LINES - WITHOUT AWD
the hydraulic brake lines. Some components mentioned in the service section of this book may be shown in this illustration
only.
1. VALVE, BRAKE 9. CONNECTOR
3. ADAPTOR 11. AXLE, REAR
4. SWITCH, BRAKE PRESSURE 12. TEE
5. O-RING 13. ELBOW
6. ELBOW - 90° 14. COUPLING, QUICK-DISCONNECT
7. PLUG 15. CAP, DUST
8. HOSE
830B/C-850B/C-870B/C 10-151
12
HYDRAULIC BRAKE LINES - WITH AWD
10-152 830B/C-850B/C-870B/C
12
LEGEND FOR HYDRAULIC BRAKE LINES - WITH AWD
the hydraulic brake lines. Some components mentioned in the service section of this book may be shown in this illustration
only.
1. VALVE, BRAKE 8. CONNECTOR
2. O-RING 9. O-RING
3. ADAPTOR 10. AXLE, REAR
4. SWITCH, BRAKE PRESSURE 11. TEE
5. O-RING 12. ELBOW
6. ELBOW - 90° 13. COUPLING, QUICK-DISCONNECT
7. HOSE 14. CAP, DUST
830B/C-850B/C-870B/C 10-153
12
BRAKE VALVE
10-154 830B/C-850B/C-870B/C
12
LEGEND FOR BRAKE VALVE
the brake valve. Some components mentioned in the service section of this book may be shown in this illustration only.
1. BOLT, HEX SOCKET 9. SHIMS 17. O-RING
2. WASHER, FLAT 10. SPRING, REGULATOR 18. O-RING
3. VALVE 11. SPRI NG 19. PLUG
4. BODY, BRAKE VALVE 12. RETAINER 20. SPRING
5. SPOOL, BRAKE VALVE 13. SPRING 21. SPOOL
6. SPACER 14. TUBE, ACTUATOR 22. PLUG
7. RING, RETAINING 15. RING, QUAD
8. RETAINER ASSEMBLY, SPRING 16. BOOT
830B/C-850B/C-870B/C 10-155
STRUCTURE AND FUNCTION TILT STEERING CONSOLE
12
TILT STEERING CONSOLE
10-156 830B/C-850B/C-870B/C
12
LEGEND FOR TILT STEERING CONSOLE
The exploded view shown on the previous page and legend shown here are to help identify parts and their orientation to each
other while servicing the tilt steering console. Some components mentioned during service procedure may only be shown in
this illustration.
1. OVAL HEAD SCREW 24. CONSOLE COVER
2. STEERING CONSOLE INSTRUMENT PANEL 25. BOLT & FLAT WASHER
3. PAN HEAD SCREW 26. CABLE CLAMP
4. HARNESS SPACER 27. TIE STRAP
5. CABLE CLAMP 28. BOLT, FLAT WASHER & HEX NUT
6. BOLT & FLAT WASHER 29. REAR CHANNEL WELDMENT
7. MACHINE SCREW, LOCK WASHER & HEX NUT 30. CONSOLE LOCK
8. TURN SIGNAL FLASHER 31. FRONT CHANNEL WELDMENT
9. CONSOLE HEAD WELDMENT 32. BUTTON PLUG
10. HOUR METER 33. LOCK MOUNT PIN
11. WEATHER SEAL - 14.9 IN. 34. RETAINING RING
12. FLAT WASHER 35. OUTLINE RELAY
13. UTILITY KNOB 36. CABLE CLAMP
14. FLAT HEAD SCREW 37. BOLT & LOCK WASHER
15. LOCK CONTROL 38. BOLT & FLAT WASHER
16. SHOULDER BOLT 39. SET SCREW
17. BEARING WASHER 40. BEARING ASSEMBLY
18. BEARING 41. LOWER SHAFT
19. STEERING CONTROL ASSEMBLY 42. BOLT & LOCK WASHER
20. TURN SIGNAL LEVER & TURN SIGNAL

43. BASE GROMMENT
INDICATOR BULB - 24 VOLT
21. STEERING WHEEL 44. BASE WELDMENT
22. STEERING WHEEL NUT 45. LOCK MUNT PIN
23. HORN BUTTON
830B/C-850B/C-870B/C 10-157
12
EXPLODED VIEW OF TILT STEERING CONSOLE
10-158 830B/C-850B/C-870B/C
12
LEGEND FOR EXPLODED VIEW OF TILT STEERING CONSOLE
The exploded view shown on the previous page and legend shown here are to help identify parts and their orientation to each
other while servicing the tilt steering console. Some components mentioned during service procedure may only be shown in
this illustration.
1. STEERING MOUNT BRACKET WELDMENT 9. HEX NUT
2. BOLT 10. STEERING LOCK PLATE
3. FLAT WASHER 11. O-RING
4. SPACER 12. CONNECTOR
5. O-RING 13. CONNECTOR
6. ELBOW - 90° 14. U-BOLT
7. HOSE 15. STEERING (ORBITROL) CONTROL UNIT
8. FLAT WASHER 16. STEERING COLUMN
830B/C-850B/C-870B/C 10-159
12
MEMORANDUM
10-160 830B/C-850B/C-870B/C
20 TESTING, ADJUSTING AND
TROUBLESHOOTING
STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5

TABLE OF JUDGEMENT STANDARD VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5
ENGINE IN CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8
TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
TRANSMISSION POWER SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15
TRANSMISSION SHIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15
VOLTAGE AND ELECTRICAL POWER REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-17
CLUTCH SOLENOID VALVE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18
PRESSURE AND FLOW CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18
FLOW RATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18
SETTING THE CLUTCH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-19
FLYWHEEL DIMENSIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-19
FLYWHEEL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20
CHECKING FOR THE CORRECT PILOT SLEEVE LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21
AWD PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22
REXROTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22
DIAGNOSTIC PORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22
CIRCLE REVERSE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23
STEERING AND BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
STARTUP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
AWD HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
FOUR-WAY SWIVEL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
FRONT AXLE AND GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27
FRONT WHEEL ALIGNMENT AND TURNING RADIUS ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 20-27
HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29
PRESSURE TESTING HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29
BALL AND SOCKET SHIMMING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29
ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30
PRECHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30
PROCEDURE FOR ACCUMULATORS UP TO 3000 psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31
PROCEDURE FOR ACCUMULATORS UP TO 5000 psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32
HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
RELIEVING ACCUMULATOR PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34
SETTING RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34
GENERAL DIAGNOSIS PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-35
HEAT PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-35
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36
HYDRAULIC PRESSURE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36
QUICK-REFERENCE PRESSURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37
MAIN HYDRAULIC SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
TEST PORT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
PUMP OUTLET LINE PRESSURE (TEST PORT 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
LOAD SENSOR LINE PRESSURE (TEST PORT 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
830B/C-850B/C-870B/C 20-1
TESTING AND ADJUSTING
TEST PROCEDURE: LOW-PRESSURE STANDBY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39
TEST PROCEDURE: HIGH-PRESSURE STANDBY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
STEERING AND BRAKE SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41
STEERING AND BRAKE SYSTEM SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41
TEST PORT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41
PUMP PRESSURE (TEST PORT 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41
TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41
AWD SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
AWD SYSTEM FUNCTIONAL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43
AWD HYDRAULIC SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
AWD SYSTEM SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
TEST PORT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
ALL-WHEEL-DRIVE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-49
HYDRAULIC CENTERING ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52
MECHANICAL CENTERING ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-54
AWD HYDRAULIC SYSTEM FILTERING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
AWD ELECTRICAL SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-56
AWD ELECTRICAL TEST FORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
ELECTRONIC CONTROL MODULE TERMINAL IDENTIFICATION . . . . . . . . . . . . . . . . . . . 20-62
SENSOR TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63
SENSOR GAP ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63
E66442V AWD CONTROLLER DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
LOCK/UNLOCK DIFFERENTIAL RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-65
REAR AXLE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-65
FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
WITH NoSPIN AND LOCK/UNLOCK DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
NO SPIN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
STATIC METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
DYNAMIC METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
BRAKE DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-67
TANDEM CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-68
TANDEM CHAIN WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-68
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-68
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-68
SPROCKET WEAR (NON-PLANETARY ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70
SINGLE AND DOUBLE STRAND CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70
CIRCLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72
FOUR SHOES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72
VERTICAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-73
SHOE NUMBER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-73
SHOES NUMBER 2 THRU 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-73
PINION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-74
CIRCLE REVERSE SLIP CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-76
CIRCLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-76
SLIP CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-77
ENGINE AND TRANSMISSION GEAR RANGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-78
PARKING BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-79
PERROT PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-79
BRAKE PRESSURE WARNING SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-79
LOW BRAKE PRESSURE WARNING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80
PARKING BRAKE PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80
BLEEDING THE CALIPER’S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-81
20-2 830B/C-850B/C-870B/C
MICO PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-82
BRAKE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-83
MICO BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-83
BRAKE PEDAL BUMPER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-83
BRAKE PEDAL FREE HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-83
BRAKE PEDAL STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-84
PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-85
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101
PREDELIVERY PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-201
830B/C-850B/C-870B/C 20-3
12
MEMORANDUM
20-4 830B/C-850B/C-870B/C
TESTING AND ADJUSTING STANDARD VALUE TABLES
12
STANDARD VALUE TABLES
WARNING! Please observe all safety and precautionary standards as dictated by the environment
and work conditions under which the equipment will be inspected, reworked and
repaired. Consult the appropriate “Shop Manual” and your Komatsu district service
manager with any and all questions regarding safety, removal, installation and repair
instructions not contained in this publication.
1. Park the machine on a flat level surface.
2. Lower the work equipment to the ground. Turn the engine off and cycle the controls to remove any residual hydraulic
pressure from the work equipment circuits. Fully apply the parking brake.
3. Place chocks at the front and rear of all wheels to prevent the machine from moving.
4. Remove the key from the start switch and retain it until the repairs are complete. Place a tag on the steering wheel
advising: “This machine is being repaired. It should not be started or moved for any reason until the tag is removed
by the person doing the repairs”.
5. When working in groups, used agreed upon signals and do not allow unauthorized persons near the machine.
6. When checking the water level in the radiator, wait for the engine to cool. Do not remove the radiator cap while the water
is hot, boiling water may spurt out.
7. Stay clear of rotating parts and ensure no loose clothing or cords become wrapped in moving parts.
8. Prior to installing gauges, slowly loosen oil filler cap to release any hydraulic pressure in the tank. Then operate the
control levers to relieve pressure from the hydraulic lines.
9. Do not allow unauthorized persons near the machine while taking measurements.
10. Oil in the machine is hot, use care not to get burnt.
11. When measuring engine speed, one worker should take the readings while the other sits in the operator’s seat to operate
the controls. Always ensure the operation is safe.
12. Do not let unauthorized persons near the machine.
TABLE OF JUDGEMENT STANDARD VALUE

The following precautions are necessary when using the “Standard Value Tables” to make judgements during troubleshooting
or testing and adjustment.
1. The values in this table are based on the values of new machines leaving the plant, so they should be used as target values
when repairing or when estimating wear after a period of use.
2. Any standard values should be used as reference in combination with repair and operating records when making
troubleshooting judgements.
3.These standard value tables must not be used for standard values when judging claims. In addition, do not use these values
alone to make simple judgements.
★ The valves given in the “Testing and Adjusting” data are NOT for adjustment of the output. Do not use values as a guide
to change the setting of the fuel injection pump
830B/C-850B/C-870B/C 20-5
ENGINE IN CHASSIS
Machine model 830 a

Standard machine b
Engine SA6D102E-1 c
Permissible
Item Condition Unit Standard Value d
Value
High Idle 2750 ±50 2750 ±50 e
Engine Speed Low Idle rpm 900 ±100 900 ±100 f
Rated speed 2500 2500 g
Exhaust temperature
°C 479 479 h
(turbine inlet temperature)
Clean filter (At rated output) 305 --- i
Intake resistance mm H2O
Dirty filter (At rated output) 635 --- j
Sudden acceleration --- --- k
Exhaust gas color Bosch index
High idle --- --- l
Intake valve 0.01 --- m
Valve clearance (cold) in
Exhaust valve 0.02 --- n
Blow-by pressure (SAE At rated output
mmHG 76 337 o
15W-40 oil) Coolant temperature: operating range
Coolant temperature: operating range
Oil pressure (SAE 15W-40
At rated output (Min. 30 psi) psi 65 Max. 110 p
oil)
At low idle (Min. 10 psi)
Oil temperature Whole speed range (inside oil pan) Max. 127 Max. 127 q
Fuel injection timing Before Top Dead Center Degrees 14° --- r
Deflection when pressed with finger force
--- s
of approximately 59 N (6 kg)
Fan belt tension
New belt 150 --- t
lb
* When adjusting belt tension 60 - 120 --- u
* If tension is below Min, adjust to Max.
20-6 830B/C-850B/C-870B/C
12
a 850 870
b Standard machine VHP specification machine Standard machine
c S6D102E-1 SA6D114E-1 SA6D114E-1
Permissible Permissible Permissible
d Standard Value Standard Value Standard Value
Value Value Value
e 2750 ±50 2200 ±50 2200 ±50 2200 ±50 2200 ±50 2200 ±50
f 900 ±100 800 ±50 800 ±50 800 ±50 800 ±50 800 ±50
g 2500 1900 1900 1900 1900 1900
h 474 474 375 to 523 523 523 523
i
--- --- --- --- --- ---
j
k --- --- Max. 4.5 Max. 5.5 --- ---
l --- --- Max. 1.0 Max.2.0 --- ---
m 0.012 --- 0.012 --- 0.012 ---
n 0.022 --- 0.022 --- 0.022 ---
o 92 460 92 460 204 460
p Normal 75 psi Max. 125 psi Normal 75 psi Max. 125 psi Normal 75 psi Max. 125 psi
q Max. 127 Max. 127 Max. 127 Max. 127 Max. 127 Max. 127
r 16° --- 16° --- 16° ---
s ---
t 150 --- 150 --- 150 ---
u 60 - 120 --- 60 - 120 --- 60 - 120 ---
830B/C-850B/C-870B/C 20-7
CHASSIS
Item Condition Unit Standard Value Permissible Value
Inching (Declutching) Pedal

•Height of declutching Pedal mm 90 80 to 100
Height from the floor plate to the lower
(When not operating) (in.) (3.6) (3.2 to 3.9)
edge of the pedal
• Play 0 0 to 5 (0.196)
Amount of movement in the up/down
• Travel 55 to 75 45 to 85
direction
(2.17 to 2.952) (1.771 to 3.346)
Maximum value until just before the end
• Operating Force kg Max. 9 to 13 Min 6 to Max 16
of the stroke.
(lb) (19.84 to 28.66) (13.22 to 35.27)
Gear Shift Lever N ➞ 1st 33 23 to 43
(1.299) (0.944 to 1.629)
1st ➞ 2nd 33 23 to 43
(1.299) (0.944 to 1.629)
• Travel 2nd ➞ 3rd 33 23 to 43

(1.299) (0.944 to 1.629)
3rd ➞ 4th 33 23 to 43
mm (1.299) (0.944 to 1.629)
(in.)
4th ➞ 5th 34 24 to 44
(1.338) (0.944 to 1.732)
5th ➞ 6th 34 24 to 44
(1.338) (0.944 to 1.732)
6th ➞ 7th 34 24 to 44
(1.338) (0.944 to 1.732)
7th ➞ 8th 34 24 to 44
Engine stopped, maximum value just prior (1.338) (0.944 to 1.732)
to the end of the travel
kg Max. 5.0 Max. 7.0
Operating Force Engine stopped, travel at the lever tip (psi) (Max. 11.02) (Max. 15.43)
20-8 830B/C-850B/C-870B/C
Machine 830
Travel speed
--- ---
● Forward
1st 4.5 (2.8) 4.3 to 4.6 (2.7 to 2.9)
2nd 7.0 (4.4) 6.7 to 7.4 (6.7 to 4.6)
● Operate on a flat and dry road
3rd surface 10.7 (6.7) 10.2 to 11.2 (6.4 to 7.0)
4th ● Oil temperature and pressure in 16.0 (10.0) 15.2 to 16.8 (9.5 to 10.5)
km/h
operating range
5th (mph) 26.7 (16.6) 25.4 to 28.0 (15.8 to 17.4)
● Engine at rated rotation
6th ● No load 40.5 (25.2) 38.4 to 42.6 (23.9 to 26.5)
● Tire air pressure at rated pressure
● Reverse --- ---
1st 4.0 (2.5) 3.8 to 4.1 (2.4 to 2.6)
2nd 9.1 (5.7) 8.6 to 9.6 (5.4 to 6.0)
3rd 23.0 (14.3) 21.8 to 24.1 (13.6 to 15.0)
Machine 850 and 850DHP

Travel speed
--- ---
● Forward
1st 4.8 (3.0) 4.6 to 5.1 (2.9 to 3.2)
2nd 7.4 (4.6) 7.0 to 7.7 (4.4 to 4.8)
3rd surface 11.2 (7.0) 10.7 to 11.9 (6.7 to 7.4)
km/h
operating range
5th (mph) 28.3 (17.6) 26.8 to 29.7 (16.7 to 18.5)
6th ● No load 42.1 (26.2) 40.0 to 44.2 (24.9 to 27.5)
● Reverse --- ---
1st 4.1 (2.6) 4.0 to 4.3 (2.5 to 2.7)
2nd 9.6 (6.0) 9.1 to 10.1 (5.7 to 6.3
3rd 24.3 (15.1 23.0 to 25.5 (14.3 to 15.9)
830B/C-850B/C-870B/C 20-9
12
Machine 870
Travel speed
--- ---
● Forward
1st 4.8 (3.0) 4.6 to 5.1 (2.9 to 3.2)
2nd 7.4 (4.6) 7.0 to 7.7 (4.4 to 4.8)
3rd surface 11.4 (7.1) 10.7 to 12.0 (6.7 to 7.5)
km/h
operating range
5th (mph) 28.4 (17.7) 27.0 to 29.9 (16.8 to 18.6)
6th ● No load 42.9 (26.7) 40.8 to 45.0 (25.4 to 28.0)
● Reverse --- ---
1st 4.1 (2.6) 4.0 to 4.3 (2.5 to 2.7)
2nd 9.8 (6.1) 9.3 to 10.2 (5.8 to 6.4)
3rd 24.4 (15.2) 23.1 to 25.7 (14.4 to 16.0)
20-10 830B/C-850B/C-870B/C

Transmission Oil Pressure
Engine Speed: High Idle
• Pilot Pressure kg/cm2 14.5 (206.24) Max. 11 (156.46)
Transmission Temperature: 40° ±5° C
• Lubrication Oil Pressure (psi) 2.5 (35.56) Max. 1 (14.22)
(104° ±4° F)
• Modulating Pressure 25.5 (362.70) Max. 22 (312.91)
Heat Balance Oil and Water Levels are Normal
• Engine Cooling Water Air Temperature 46° C (115° F) Max. 102 (215.6) Max. 110 (230)
Temperature Performed at a Continuous Traction, F-2
°C (°F)
•Transmission Oil Temp. On a Concrete Road Surface Max. 120 (248) Max. 125 (257)
•Tandem Case Oil Temp. Measure with a thermistor Max. 120 (248) Max. 125 (257)
•Final Drive Oil Temp. Max. 120 (248) Max. 125 (257)
Travel 5.5 to 5.8 Max. 6.5

Steering Wheel Turning Turn
Angle 16 to 26 11 to 31
Leaning Lever mm (0.630 to 1.024) (0.433 to 1.220)
Travel at the tip of the lever (in.) 21 to 31 16 to 36
Articulation Lever (0.827 to 1.220) (0.630 to 1.417)
Operating Force
Steering Wheel Max. 3.0 (6.61) Max. 5.0 (11.02)
Engine Low Idle
(turning direction) kg (lb)
Leaning Lever Max. 2.75 (6.06) Max. 4.0 (8.82)
Maximum value just prior to end of Stroke
Articulation Lever Max. 2.75 (6.06) Max. 4.0 (8.82)
Wheels
Tire Runout Measure tire side surface of both front mm Max. 7 Max. 7
and rear wheels with a dial gauge. (in) (0.276) (0.276)
Tire Inflation Pressure Front Wheel See Operation & See Operation &
Rear Wheel Maintenance Maintenance
Manual Manual
Camber Level Paved Surface degree 0 Max. 0 ±0.5
Toe-in Std. mm 3.17 - 9.52 3.17 - 9.52

(in.) (0.125 - 0.375) (0.125 - 0.375)
Toe-in w/AWD mm 0 to 3 0 to 3
(in.) (0 to 0.118) (0 to 0.118)
Leaning Angle Relative to axle degree 16.9 ---
Slow engine rotation and with tires
Steering Wheel Play floating, measure at the outside mm 10 to 12 Max. 35
circumference of the steering wheel. (in.) (0.394 to 0.472) (1.378)
Brake Pedal
kg (lb) Max. 30 (66.14) Max. 50 (110.23)
Operating Force
Engine Speed: Low Idle
Road Surface: Flat, horizontal dry, paved
Speed when applying brakes: 35 km/h
Brake Performance m (ft) Max. 12 (39.37) Max. 14 (45.93)
(21.75 MPH)
Ability to hold in stopped condition on a
Parking Brake Switch
1/5 inclined paved surface.
Operating Force Engine Speed: stopped kg(lb) Max. 2 (1) Max. 2 (1)
830B/C-850B/C-870B/C 20-11
Permissible
Item Condition Unit Standard Value
Value
Control Levers
• Travel
Blade lifting right, left 16 to 26 11 to 31
(0.630 to 1.023) (0.433 to 1.220)
Blade side shifting 16 to 26 11 to 31
(0.630 to 1.023) (0.433 to 1.220)
Drawbar side shifting 16 to 26 11 to 31
mm (0.630 to 1.023) (0.433 to 1.220)
Engine stopped, travel at tip of the lever.
Circle rotation (in) 16 to 26 21 to 31
(0.630 to 1.023) (0.827 to 1.220)
Power Tilt 21 to 31 16 to 36
(0.827 to 1.220) (0.630 to 1.417
Scarifier (if equipped) 21 to 31 16 to 36
(0.827 to 1.220) (0.630 to 1.417)
Ripper (if equipped) 21 to 31 16 to 36
(0.827 to 1.220) (0.630 to 1.417)
• Operating Force
Blade lifting right, left Max. 2.3 (5.07) Max. 4.0 (8.82)
Blade side shifting Engine stopped, travel at center of lever Max. 2.3 (5.07) Max. 4.0 (8.82)
Drawbar side shifting grip kg Max. 2.3 (5.07) Max. 4.0 (8.82)
Circle rotation (lb) Max. 2.3 (5.07) Max. 4.0 (8.82)
Power Tilt Maximum value just prior to end of travel. Max. 1.9 (4.19) Max. 4.0 (8.82)
Scarifier (if equipped) Max. 1.9 (4.19) Max. 4.0 (8.82)
Ripper (if equipped) Max. 1.9 (4.19) Max. 4.0 (8.82)
Control Speed Oil temperature: 40° ±5° C (104° ±41° F)
1. Blade lifting speed With engine at rated speed, the speed to
Raising raise or lower the lower edge of the blade 135 (5.314) 121 (4.763)
Lowering 50 to 150 mm (1.968 to 5.905 inches) 135 (5.314) 121 (4.763)
above the ground.
Oil temperature: 40° ±5° C (104° ±41° F)
2. Speed of drawbar side With engine at rated speed and the
shift movement height of the lower edge of the blade is at
Right 100mm (3.937in), speed of left and right 135 (5.314) 121 (4.763)
Left side shifting by a level, circular movement mm/sec 135 (5.314) 121 (4.763)
of 200mm (7.874in) under standard posi- (in/sec)
tion.
3. Speed of blade side With engine at rated speed and the
shift movement height of the lower edge of the blade is at
Right 100mm (3.937in), speed of left and right 135 (5.314) 121 (4.763)
Left side shifting by a level, circular movement 135 (5.314) 121 (4.763)
of 200mm (7.874 in.) under standard
position.
degree/
4. Circle turning speed Angle speed with engine at maximum 8.0 7.0
sec
rotation speed
20-12 830B/C-850B/C-870B/C

5. Scarifier lifting speed Oil temperature: 40° ±5° C (104° ±41° F)
(if equipped) With engine at rated speed, the speed to
(raising) raise or lower the scarifier center tooth tip 135 (5.314) 121 (4.763)
(lowering) 50 to 150 mm (1.968 to 5.905 inches) 135 (5.314) 121 (4.763)
above the ground. mm/sec
6. Ripper lifting speed Oil temperature: 40° ±5° C (104° ±41°F) (in/sec))
(if equipped) With engine at rated speed, the speed to
120 (4.724) 108 (4.251)
(raising) raise or lower the ripper center tooth tip 50
108 (4.251) 97 (3.818)
(lowering) to 150 mm (1.968 to 5.905 inches) above
the ground.
Hydraulic Drift
When the blade is suspended symmetri-
1. Extension of blade cyl Max. 10 (0.394) Max.20 (0.787)
cally perpendicular to the machine, the
inder
amount the cylinder is extended.
2. Retraction of blade cyl When the blade is contacting the ground
Max. 30 (1.181) Max. 50 (1.969)
inder and the front wheels floating, the amount
the cylinder is retracted.
3. Extension of scarifier
When the scarifier is suspended, the Max. 10 (0.394) Max.20 (0.787)
cylinder (if equipped)
4. Retraction of scarifier When the scarifier center tooth is contact-
Max. 30 (1.181) Max. 50 (1.969)
cylinder (if equipped) ing the ground and the front wheels float- mm/10
ing, the amount the cylinder is retracted. min
Oil temperature: 40° ±5° C (104° ±41° F) (in/10
5. Extension of ripper min)
When the ripper is suspended, the Max. 10 (0.394) Max.20 (0.787)
6. Retraction of ripper When the ripper center tooth is contacting
Max. 30 (1.181) Max. 50 (1.969)
cylinder (if equipped) the ground and the front wheels floating,
the amount the cylinder is retracted.
7. Extension of front blade
When the blade is suspended, the amount Max. 10 (0.394) Max.20 (0.787)
the cylinder is extended.
When the front blade lower tooth is con-
8. Retraction of front blade
tacting the ground and the front wheels Max. 30 (1.181) Max. 50 (1.969)
floating, the amount the cylinder is
retracted.
Work equipment control
valve, main relief set 200 +5/-0
185 (2,631.32)
pressure (2,844.7 +71.1/-0)
R.H. Valve Oil temperature: 40° ±5° C (104° ±41° F) kg/cm 2
Engine speed: high idle (psi)

200 +5/-0
L.H. Valve (2,844.7 +71.1/-0) 185 (2,631.32)
830B/C-850B/C-870B/C 20-13
TOOL LIST
No. Test Item Tool Part Number Remarks
Digital display
1 Engine Speed Multi-tachometer 799-203-8000 L: 60 to 2,000 rpm
H: 80 to 19,999 rpm
Water, Oil and Intake -50 to 1,200° C
2 Digital Thermometer 790-101-6000
Temperature (-122 to 2192° F)
25, 60, 400, 600 kg/cm2
3 Lubricant Pressure Hydraulic Tester D 799-101-5000 (355.58, 853.40, 5689.34,
8534.01 psi)
795-502-1590 0 to 70 kg/cm2 (995.63 psi)
4 Compression Pressure Compression Gauge, adaptor
795-502-1360 Kit No. 795-502-1205
Blow-by Pressure Gauge 3822566
5 Blow-by Pressure 0 to 500 mmH2O
Manometer ST-1111-3
6 Valve Clearance Feeler Gauge 795-125-1360 IN 0.33, EX 71mm
Discoloration 0 to 70% with standard
7 Exhaust Gas Color Handy Smoke Checker 799-201-9000 color (Discoloration% X 1/10 = Bosch
Index)
25, 60, 400, 600 kg/cm2
8 Lubricant Pressure Hydraulic Tester D 799-101-5000 (355.58, 853.40, 5689.34,
8534.01 lb/in2)
9 Operating Force Push-pull Scale 79A-262-0020 0 to 25 kg (0 to 55.12 lb)
Brake Pedal Operating
10 Depression Meter 799-101-1001 0 to 110 kg (0 to 242.51 lb)
Force
Commercially
11 Brake Distance Tape Measure 30 mm
Available
Commercially
12 Brake Shoe Clearance Feeler Gauge 0.1 to 3.0 mm (0.002 to 0.118 in)
Available
Commercially
13 Pedal Travel Convex Scale 2 m (2.18 yd)
Available
Commercially
14 Operating Force Push-pull Scale 0 to 50 kg (110.23 lb)
Available
Nitrogen (N2)
15 Charging Tool 792-610-1700 ---
Accumulator gas charge
20-14 830B/C-850B/C-870B/C
TESTING AND ADJUSTING TRANSMISSION POWER SHIFT
12
When the LED flashes an error code, the transmission automatically shifts
to Neutral despite the gearshift remaining at the selected position. Thus, the
machine cannot move.
Move the gearshift to the Neutral position to coincide with the transmission
being in neutral, and which also clears the controller's memory. After
clearing the controller's memory, the transmission gears can once again be
engaged.
To determine if the problem is a "glitch" or one-time occurrence, reposition
the gearshift to the desired gear range and continue with the operation. If
the LED flashes again, count the number of flashes because a problem
exists. See the table Section 20-100 TRANSMISSION SHIFTER for a
diagnostic interpretation of the LED flash code, and make the needed
repairs. After repairing the problem, clear the controller's memory before
returning the machine to service.
PIN USAGE
PIN# USAGE OTHER NAME

1 Logic power Logic power (+BATT)
2 Logic ground Logic ground (-BATT)
3 Solenoid power Dirty power (+BATT)
4 Solenoid power
5 Solenoid ground Dirty ground (-BATT)
6 Solenoid ground
7 Solenoid S4 Drive S4
8 Not park
9 Not used
10 De-clutch pedal Communication input 3
11 Not used (CAN/H)
12 Variable horsepower Drive S8
14 Not used (J1708/A)
15 Not used (J1708/B)
16 Parking brake Communication input 1
17 Not used (CAN/L)
18 Reverse signal Communication output 1
19 Forward signal Communication output 2
24 Neutral START Drive S7
830B/C-850B/C-870B/C 20-15
12
Remark
Moving the shifter to park or pulling the park brake switch should apply the brake. Both are no required to be
in the park position. Illustrated below is the revised wiring to activate the parking brake function in the shifter.
20-16 830B/C-850B/C-870B/C
12
VOLTAGE AND ELECTRICAL POWER REQUIREMENTS
Throughout this procedure, it is assumed that all wires are in good condition. As tests are made, it is advisable to inspect the
wires for wear and/or abrasions that would short the circuit. Wires may have internal breaks, which can only be detected by
use of an ohmmeter or similar device. The electrical wires are numbered with bands at each end to help trace them. Ensure the
terminal ends are crimped solidly, screws are tight, and that contact surfaces are not corroded. Replace if necessary.
To troubleshoot the valve’s electrical circuit, the chart below shows when each solenoid is active and during which gear.
• Solenoid #1 is for 1st gear clutch.

• Solenoid #2 is for 2nd gear clutch.
• Solenoid #3 is for 3rd gear clutch.
• Solenoid #4 is for reverse gear clutch.
• Solenoid #5 is for high range clutch.
• Solenoid #6 is for low range clutch.
Remark
The engine must be running for the valves to be energized. Use a voltmeter to determine if the solenoid is
energized.
830B/C-850B/C-870B/C 20-17
12
CLUTCH SOLENOID VALVE REQUIREMENTS
1. Checks should be made at the valve. Nominal desired voltage is 24 volts; 23 to 26 volts allowable.
2. Current draw is 1 amp per solenoid, with a maximum of 1.12 amps.
3. Resistance is 24.0 ohms, ±3%.
PRESSURE AND FLOW CHECKS

Remark
All pressure and flow tests must be accomplished at 2000 rpm at a converter out temperature from 105° F
(41° C) to 125° F (52° C).
1. Port 1 is for clutch pressure, which should be from 240 to 260 psi (16.9
to 18.3 kg/cm2).
2. Port 2 is for pump pressure, which will be higher than clutch pressure,
but not to exceed clutch pressure by more than 15 psi (1.1 kg/cm2).
3. Port 3 is for converter in pressure, which is not to exceed 85 psi (6.0

kg/cm2) at operating temperature.
Remark
Pressures above 85 psi (6.0 kg/cm2) can be expected during
initial start-up and in cold weather operation until the trans-
mission is warmed up.
FLOW RATES
Pump output at 2000 rpm, 105° F (41° C) to 125° F (52° C): 19.6 GPM (74.2/min).
Converter output at 2000 rpm, 105° F (41° C) to 125° F (52° C): 17 GPM (64.4/min).
Converter output pressure at full throttle stall: Not less than 35 psi (2.5 kg/cm2) at temperatures from 180° F (82° C) to 200° F
(93° C).
WARNING! When stalling the converter, make sure the transmission is in high gear, the service and
parking brakes applied, and the immediate area is clear of personnel and obstructions.
Do not exceed 30 seconds or 250° F (121° C) converter out oil temperature, whichever
comes first, for a stall condition.
Remark
Full-throttle stall speeds will vary depending on the engine and torque converter being used. Refer to the
Predelivery Section for the stall speed.
Lube in pressure at 2,000 rpm, 105° F (41° C) to 125° F (52° C): Not less than 10 psi (0.7 kg/cm2) and not to exceed 25 psi (1.8
kg/cm2).
20-18 830B/C-850B/C-870B/C
12
SETTING THE CLUTCH PRESSURE
Initial assembly of the pressure regulator, install two 0.030 in. (0.762 mm)
shims (4).
To adjust the clutch pressure, remove the regulator cap (6) and the pressure
regulator (5). The shims (4) will be installed inside the valve body against
the spring retainer cap.
With the transmission in neutral, the engine speed at idle (750 rpm
minimum), and the converter output oil temperature from 105° F (41° C) to
125° F (52° C), the clutch pressure should be 200 psi (14.1 kg/cm2)
minimum. If the clutch pressure is below 200 psi (14.1 kg/cm2), add one
0.030 in. (0.762 mm) shim (4).
Advance the engine speed to 2000 rpm, with the same temperatures, and the clutch pressure from 240 to 260 psi (16.9 to 18.3
kg/cm2).
If the clutch pressure is below 240 psi (16.9 kg/cm2), add one or two 0.015 in. (0.381 mm) shims to achieve the 240 psi (16.9
kg/cm2) minimum pressure.
If the clutch pressure is above 260 psi (18.3 kg/cm2), remove one 0.030 in. (0.762 mm) shim and install one 0.015 in. (0.381
mm) shim.
Remark
A maximum of five shims may be used.
FLYWHEEL DIMENSIONAL CHECKS

Use this section when the following conditions occur:
• An oil leak coming from the weep hole in the transmission bell housing.*
• An oil leak coming from the drain hole (if any) in the engine flywheel housing.
• If the drive plate and/or converter have been changed to a different size or part number.
• If the engine flywheel, or flywheel housing, has changed.
• If the engine has been changed.
830B/C-850B/C-870B/C 20-19
12
FLYWHEEL DIMENSIONS
20-20 830B/C-850B/C-870B/C
12
1. Flywheels with dimension K must comply with dimensions S and T (as listed for each Funk converter size), and
dimensions L, R and U will have to clear the drive plate and converter assemblies.
2. Check the flywheel for the following dimensions:
A. Dimension C is (3.94 ±0.05 in.) from the flywheel housing mounting face to the pilot bore positive stop.
B. Dimension Z is (1.82 ±0.01 in.) from the flywheel housing mounting face to the pilot bore positive stop.
C. Dimension B is (2.12 in. reference) the flywheel offset.
D. Engines with dimensions C, Z, and B require a 0.56 in. thick housing adaptor.
3. Standard length pilot sleeves (dimension H) are set up for dimension Z.
A. Engines with dimension Z (2.83 ±0.01 in.) require a 0.56 in. longer standard sleeve.
B. The use of a flywheel with a shoulder as a positive stop will have to comply with dimension N (minimum) to clear the
shoulder on the sleeve, dimension J.
CHECKING FOR THE CORRECT PILOT SLEEVE LENGTH
1. Use dimension Z.
2. Place the pilot sleeve on the converter front cover pilot knob and push back to the front cover. Measure from the drive
plate face (that will be mounted up to the flywheel), out to the end of the sleeve, or to the positive stop shoulder.
3. The sleeve length (2) should be equal to or 0.10 in. (2.540 mm) longer than the pilot depth (1) ref. Z in the flywheel. The
shoulder length (2) should be equal to or 0.10 in. (2.540 mm) longer than the shoulder depth (1) in the flywheel to
properly locate the converter.
4. Check the diameter of the flywheel pilot bore (dimension M) and the converter pilot sleeve (dimension A) for a proper fit.
There should be 0.0005 in. (0.013 mm) to 0.003 in. (0.076 mm) diametric clearance. Flywheels that do not fit within this
tolerance will require a special sleeve to accurately pilot the converter assembly. If the above dimensions check out, the
assembly can continue.
5. Check the engine crankshaft end play. It should comply with the engine manufacturer's tolerance.
830B/C-850B/C-870B/C 20-21
TESTING AND ADJUSTING AWD PUMP
12
AWD PUMP
REXROTH
The All-Wheel-Drive (AWD) Pump is a piston-type pump mounted to the transmission and driven directly by the torque
converter. The pump provides oil pressure and flow to the AWD motors, which in turn drive the gearboxes.
DIAGNOSTIC PORTS
The diagnostic ports for the pump are shown at the right.
R = Case vent port

30 psiG (2.1 kg/cm2) max.
(7/16" - 20 UNF)
X1, X2 = Control-pressure gauge port (before control orifices)

(7/16" - 20 UNF)
X3, X4 = Control-pressure gauge ports (after control orifices)

(7/16" - 20 UNF)
T1, T2 = Case drain ports

(1-1/16" - 12 UNF)
MA, MB = High-pressure gauge ports

6000 psiG (421.8 kg/cm2) max.
(7/16" - 20 UNF)
20-22 830B/C-850B/C-870B/C
TESTING AND ADJUSTING CIRCLE REVERSE MOTOR
12
S = Charge pump suction port
14 inches Hg (at start-up)
(1-3/16" - 12 UNF)
The proportional electric control operates as follows:
When properly installed, the pump rotates in a clockwise direction when

viewed from the shaft end.
When solenoid A is actuated:

● Control pressure is at ports X1 and X3.
● Output flows from port B.
● Working pressure is at port MB.
When solenoid B is actuated:

● Control pressure is at ports X2 and X4.
● Output flows from port A.
● Working pressure is at port MA.
TESTS AND ADJUSTMENTS

After installing the motor, operate it to ensure that it drives the circle in the proper direction. If the motor rotates in the wrong
direction, the motor was not timed correctly during assembly. Or, the hydraulic hoses to the motor may be reversed.
830B/C-850B/C-870B/C 20-23
TESTING AND ADJUSTING STEERING AND BRAKE PUMP
12
SPECIFICATION
Pressure Compensator Setting (pump pressure).................................. 1,650 ±25 psi (116.0 1.8 kg/cm2)
PROCEDURE
1. Connect a 3,000 psi gauge to the steering and brake pump test port (1).
Remark
The pump at right is for machines with s/n of 203163 and up.
The pump below is for machines with s/n of 203162 and
down, unless the machine has been upgraded with the new
pump.
2. Start the engine. Move the engine speed control lever to adjust engine
speed to 1,000 ±25 rpm.
3. Have another person record the steering and brake pump pressure.
4. If the pump pressure is not to specification, adjust the relief valve (2).
20-24 830B/C-850B/C-870B/C
TESTING AND ADJUSTING STEERING AND BRAKE PUMP
12
STARTUP PROCEDURE
When initially starting a rebuilt load-sensing system, it is extremely important that the startup procedure be followed. It
prevents the chance of damaging the pump which might occur if the system was not properly purged with oil before startup.
1. After the pump has been properly installed onto the machine and all hydraulic connections have been made, check all
fittings to make sure that they are tight.
2. Fill the pump housing at least 1/2 full with system oil that has been filtered through a 10 micron filter.
3. Fill the reservoir with an approved oil that has been filtered through a 10 micron filter.
4. Turn off the fuel flow to the injectors and crank the engine for 15 seconds. This procedure enables the pump to pick-up oil
before startup. While the engine is turning over, disconnect the sensor line from the pump compensator and pull one of the
valve spools. This step allows the oil flow through the sensor line, removing any air in the sensor line. Reconnect the
sensor line after a steady flow of oil is coming from the line.
5. Replace the coil wire or restore the fuel flow to the injectors and start the engine. Run at low idle speed for one minute.
The pump should immediately pickup oil and go into low-pressure standby. If there is no indication of fill in 30 seconds,
stop the engine and determine the cause. After the pump stabilizes in low-pressure standby, operate the control valve and
steering, if the system is equipped. This step purges air from the system and fills the cylinders with oil. Continue operating
the system slowly with no load until it responds fully.
6. Check the fluid level at the reservoir. Refill, if necessary, to the proper level with an approved filtered oil.
7. The machine is now ready to be put into operation.
8. Short hour filter changes are recommended for the first two changes after placing the machine back into operation. The
first filter would be changed from 3 to 5 hours, and the second filter at approximately 50 hours. Routine scheduled filter
changes are recommended for the maximum life of the hydraulic system.
830B/C-850B/C-870B/C 20-25
TESTING AND ADJUSTING AWD HYDRAULIC MOTOR
12
AWD HYDRAULIC MOTOR
Check the hydraulic tank and fill as needed. Start the engine. Check for leaks and/or loose connectors. Perform operational
tests to ensure proper operation of the unit before returning it to full service.
1. A motor that runs excessively hot or noisy is a potential failure. Should a motor become noisy or overheat, turn the
machine off immediately. Find the cause and correct it.
2. Periodic inspection of the fluid condition and tube or piping connections can prevent time-consuming breakdowns. The
following should be checked regularly:
A. All hydraulic connections must be kept tight. A loose connection in a pressure line will permit the fluid to leak out.
The fluid level should never be so low that the inlet pipe opening in the reservoir is exposed. If that happens,
extensive damage to the pump and motor can result. In suction lines, loose connections allow air to be sucked into the
system, resulting in noisy and/or erratic operation and pump cavitation.
B. Clean fluid is the best insurance for long service life. Therefore, check the fluid in the reservoir periodically for dirt or
other contaminants. If the fluid becomes contaminated, drain the system and clean the reservoir before adding new
fluid.
C. Check the filter elements periodically. A clogged filter element results in a higher-pressure drop. This situation can
force particles through the filter that would ordinarily be trapped or can cause the by-pass to open, resulting in a
partial or complete loss of filtration.
D. Air bubbles in the reservoir can ruin the motor and other components. Bubbles indicate the source of the air leak.
3. No periodic adjustments are required, other than to maintain proper shaft alignment with the load.
FOUR-WAY SWIVEL BLOCK

After the installation of either the two-way or four-way swivel block is completed on your unit, follow the steps listed
below:
1. Check the hydraulic oil tank level to be sure that the oil level is between the ADD and FULL marks.
2. Start the grader.
3. Raise the moldboard off the blocking.
4. Operate the side-shift lever to check that the moldboard shifts in the proper direction (this step applies to both types of
swivel blocks). If the unit does not function correctly check all hoses and lines for proper locations.
5. The four-way swivel block is used with the powertilt moldboard. Operate the powertilt lever to see if the blade tilts in the
proper direction. If the unit does not function correctly, check all hoses and lines for proper location.
Remark
When performing steps 4 and 5, the operation may be sluggish until the air is expelled from the swivel block,
lines, and hoses. Full cycling of cylinders will help expel air.
20-26 830B/C-850B/C-870B/C
TESTING AND ADJUSTING FRONT AXLE AND GEARBOX
12
FRONT AXLE AND GEARBOX
FRONT WHEEL ALIGNMENT AND TURNING RADIUS ADJUSTMENT

The steering cylinders control how far the spindle assemblies are allowed to move. This movement in turn controls the turning
radius of the grader. Adjust the steering cylinders this way to obtain a proper turning radius in both directions.
1. Steering cylinders to be equal length.
A. Factory set at 24 in. overall (retracted)

All Wheel Drive, print # 158206
Standard Drive, print # 157537
B. Field check: Measurement from the hex end of the steering

cylinder piston rod, behind the locknut, to the center of the grease
fitting on the ball socket assembly must be 3 9/16 in.
i. Loosen the jamnut (1) on the ball socket assembly (2).
ii. The distance from the end of the piston rod (3) to the center
of the grease fitting on the ball socket assembly should measure 3.562 in. (90.475 mm). Turning the piston rod
adjusts the distance.
iii. After making the 3.562 in. (90.475 mm) adjustment, tighten the jamnut.
iv. Repeat steps 1.B.i. thru 1.B.iii. for the other steering cylinder.
PROCEDURE
1. Park the grader on a level concrete surface. Ensure that all tires are
properly inflated to the same psi. Tires must be the same brand and
size.
2. Using the steering wheel and leaning wheel cylinder control lever,
position front wheels to that they are in the straight ahead position and
that the camber angle "X" is the same on both sides.
3. Check and adjust, if necessary, the front wheel toe-in.

All Wheel Drive: 0.0 in. (0.000 mm)
Standard Drive: 0.125 in. (3.175 mm)
A. Measure the distance between the wheels of the grader on the

same horizontal centerline as the spindle axle. These
measurements must be taken at both the front and rear of the
wheels.
Remark
Because of tire variances, do not measure from tire to tire or
tire rim to tire rim because inaccurate
measurements can result.
B. STANDARD DRIVE AXLE ONLY: The measurement at the rear

of the wheels should be approximately 1/8 ±1/32 in. (0.125 ±0.03
in.) more than the front. If not, adjust the tie rod to obtain the
proper toe-in.
830B/C-850B/C-870B/C 20-27
TESTING AND ADJUSTING FRONT AXLE AND GEARBOX
12
C. ALL-WHEEL-DRIVE AXLE ONLY: On All-Wheel-Drive
(AWD) front axles, there MUST BE ZERO TOE-IN.
D. If the front wheels need alignment, loosen the jamnut (1) on both
ends of the tie rod (2) at the ball socket assembly (3).
E. The tie rod has R.H. threads on the right end and L.H. threads on
the left end. This thread combination allows the wheel alignment
to be adjusted by turning the tie rod.
F. After obtaining the proper alignment, tighten the jamnuts (1).
4. Synchronize the steering cylinders:
A. Disconnect the left steering cylinder ball stud assembly from the
left steering arm.
B. Steer machine right so rod end of disconnected left steering

cylinder is extended and both steering cylinders are being
bottomed by hydraulic pressure.
C. Make an alignment mark on the rod end of the left steering

cylinder and ball stud assembly, so that the number of adjustment
turns can be counted.
D. With steering pressure holding both cylinders bottomed, adjust the

left steering cylinder ball stud IN or OUT to seat it fully in the
steering arm.
Remark
Count the number of full and partial turns.
Remark
Record the direction (IN or OUT) for turning the ball stud.
E. Divide the number of turns by 2.

Remark
The result is the amount of turns both steering cylinders must
be adjusted from their original position. Direction of turns (IN
or OUT) from original position for each cylinder is the same,
as required to seat ball stud in steering arm in step 4.D. above.
F. Reset the left ball stud at 1/2 the number of turns it was moved in step 4.D. Reassemble into the steering arm.
G. Make an alignment mark at the rod end of the right steering cylinder and ball stud assembly, so that the number of
adjustment turns can be counted.
H. On the right steering cylinder, loosen the ball stud to steering cylinder rod lock nut. Adjust the ball stud position by
turning the cylinder rod the number of turns calculated in step 4.E. above.
Remark
Make sure that direction piston rod is turned results in correct direction of ball stud movement noted at Step
4.D.
20-28 830B/C-850B/C-870B/C
TESTING AND ADJUSTING HYDRAULIC CYLINDERS
12
5. Retighten all locknuts.
6. Measure from the grease fitting to the piston rod end on both cylinders to ensure the measurements are equal. This
measurement may vary from the initial 3 9/16 in. setting.
7. Secure the right and left ball stud assemblies into position. After installing the plain washer and slotted nut, torque to 170
lbf ft. (230.5 Nm). If necessary, increase the torque on the nut to install the cotter key.
HYDRAULIC CYLINDERS
PRESSURE TESTING HYDRAULIC CYLINDERS
WARNING! When a cylinder is in a test stand (off the grader), place the cylinder in a test cage. Wear
goggles when performing this pressure test.
When pressure testing fully assembled cylinders for hydraulic leaks, fully extend or retract the piston rod for this test. Using a
calibrated test stand, connect the supply hose to the cylinder port for the appropriate piston rod position. Normally when a
piston rod is extended, the supply hose is connected to the base end. When the rod is retracted, the supply hose is connected to
the rod end port. Apply a maximum of 2,640 psi to the cylinder. Observe the port opposite the supply hose for leakage past the
piston seals and the rod seals. Correct any leakage situations found during testing.
Remark
Refer to the "Special Torques" for the pressure values of the cylinders.
BALL AND SOCKET SHIMMING ADJUSTMENT

1. The ball and socket joints on the blade lift, circle shift, and moldboard tilt cylinders, and on the drawbar are adjustable for
wear.
2. To make adjustments of any ball and socket, remove the bolts or cap screws and hex nuts with washers. Remove the shims
to eliminate free play in the joints; they should never bind.
WARNING! When making any shim adjustments relating to the suspended components (moldoard,
scarifier, ripper, etc.), be sure that it is resting solidly on the ground before disconnecting
any supporting members.
The following list is the recommended play allowed for ball and socket assemblies:
CYLINDER RECOMMENDED GAP
Ripper 0.002 in. to 0.020 in. (0.051 mm to 0.508 mm)

Scarifier 0.002 in. to 0.020 in. (0.051 mm to 0.508 mm)
Drawbar Lift 0.002 in. to 0.020 in. (0.051 mm to 0.508 mm)
Drawbar Side Shift 0.002 in. to 0.020 in. (0.051 mm to 0.508 mm)
Moldboard Tilt 0.003 in. to 0.037 in. (0.076 mm to 0.940 mm)
830B/C-850B/C-870B/C 20-29
TESTING AND ADJUSTING ACCUMULATORS
12
ACCUMULATORS
PRECHARGE
PRESSURES
The following list is for pressures required during "Service Diagnosis" and "Tests and Adjustments" sections for accumulators.
P/N 1285 352 H91: 500 ±25 psi (3,447 ±172 kPa) @ 70° F (21° C)
P/N 1279 537 H1: 2400 psi (16,547 kPa) @ 70° F (21° C)
P/N 1233 789 H91: 2500 psi (17, 237 kPa) @ 70° F (21° C)
P/N 1436 523 H91: 400 psi (2,757.9 kPa) @ 70° F (21° C)
TESTS AND ADJUSTMENTS

Use an inert gas, like nitrogen, for precharging the accumulators.
If water-pumped nitrogen is not available, use oil-pumped nitrogen. The CGA standard for nitrogen gas bottles:
● Water-pumped nitrogen gas bottles have a right-hand thread for the gas valve. Charging and gauging assembly, Parker p/n
14459500000, is required for accumulators rated up to 3000 psi (20,684 kPa).
● Oil-pumped nitrogen gas bottles use a left-handed thread for the gas valve (Parker p/n 14459600000).
● Charging and gauging assembly, Parker part number 1449120000, is required for accumulators rated up to 5000 psi
(34,474 kPa).
If equipment other than the above is used, make sure it is compatible with the gas valve assembly. All components must be
rated for a pressure at least as high as the nitrogen source. It is strongly recommended that the nitrogen bottle used have a
high-pressure regulator.
Turn off the nitrogen supply before attaching a hose to the nitrogen bottle.
20-30 830B/C-850B/C-870B/C
12
PROCEDURE FOR ACCUMULATORS UP TO 3000 psi
If the accumulator has a gas valve for use up to 3000 psi (right), perform
the following steps:
1. Remove the gas valve guard and gas valve cap.
2. Back out (counterclockwise) the gas chuck "T" handle before

attaching the charging assembly to the accumulator gas valve.
3. Close the bleed valve.
4. Making sure not to loop or twist the hose, attach the swivel nut to the
gas valve. Tighten the nut from 10 to 15 lbf in. (1.13 to 1.69 Nm).
5. Turn the gas chuck "T" handle all the way down. This action will depress the core in the gas valve.
6. Crack open the nitrogen bottle valve and slowly fill the accumulator. Turn the valve off when the gauge indicates the
desired precharge pressure.
7. Let the precharge set from 10 to 15 minutes. This step allows the gas
temperature to stabilize. High pressure may rupture the rubber valve
seat. Thus, if the desired precharge is exceeded, close the valve.
Slowly open the bleed valve. Never depress the valve core with a
foreign object.
8. When finished precharging the accumulator, back out the "T" handle
from the gas chuck. Open the bleed valve.
9. Hold the gas valve while loosening the swivel nut. Remove the
assembly.
10. Replace the gas valve cap. Tighten it from 10 to 15 lbf in. (1.13 to 1.69
Nm). Replace the valve guard.
830B/C-850B/C-870B/C 20-31
12
PROCEDURE FOR ACCUMULATORS UP TO 5000 psi
If the accumulator has a gas valve for use up to 5000 psi (right), perform
the following steps:
2. Close the bleed valve. Making sure not to loop or twist the hose, attach
a swivel nut to the gas valve. Tighten the nut from 10 to 15 lbf in. (1.13
to 1.69 Nm).
3. Hold the gas valve at C with a wrench. With another wrench, unscrew
the hexnut at D. This step will open the poppet inside the gas valve.
Remark
Four turns will fully open the valve.
4. Crack open the nitrogen bottle valve. Slowly fill the accumulator.
Close the valve when the gauge indicates the desired precharge
pressure.
5. Let the precharge set from 10 to 15 minutes. This step will allow the
gas temperature to stabilize. If the desired precharge is exceeded, close
the valve. Slowly open the bleed valve until the desired pressure is
reached.
6. With a wrench, tighten the hexnut from 5 to 8 lbf ft. (6.8 to 10.8 Nm)
at D to close the internal poppet.
7. Hold the gas valve at C with a wrench while removing the swivel nut
assembly.
8. After completing the precharge, replace the gas cap and tighten it from 10 to 15 lbf in. (1.13 to 1.69 Nm). Install the gas
valve guard.
20-32 830B/C-850B/C-870B/C
TESTING AND ADJUSTING HYDRAULIC CIRCUITS
12
HYDRAULIC CIRCUITS
This section discusses troubleshooting for basic hydraulic circuits of the graders.
Make a copy of this section to kept in the service file for each unit. Recording the test values that will be helpful in future
servicing.
When possible, always test with all fluids and components at operating temperatures. Pressures will be higher if the oil is cold.
Certain abbreviations are contained in this section which may be unfamiliar to the reader. They are:
AWD = All Wheel Drive

β = Beta
CCW = Counterclockwise
CW = Clockwise
HIC = Hydraulic Integrated Circuit
L.H. = Left Hand
L.S. = Load Sense
POV = Pressure Override Valve
psi = Pounds Per Square Inch
psid = Pounds Per Square Inch Differential (difference between the two pressure gauge readings).
R.H. = Right Hand
kPa = Kilopascal (metric equivalent for psi)
The Operator's Manual and this shop manual are needed to perform a diagnosis.
Actual desired pressure values to be recorded in this manual may vary slightly to those values shown in the hydraulic schemat-
ics. When discussing a system, schematic values will be used. When testing a system, the actual desired values will be used.
The difference in values is due to inherent restrictions -- hose lengths, fittings, etc. -- in the system.
830B/C-850B/C-870B/C 20-33
12
RELIEVING ACCUMULATOR PRESSURE
The accumulator stores hydraulic pressure. Thus, the hydraulic oil in the lines is also pressurized. Always relieve the line
pressure BEFORE disconnecting any hydraulic hoses and fittings. Use the following procedure to relieve the pressure in the
lines safely.
1. Turn the engine off.
2. Tag the brake hose on each side of the final drive.
3. Disconnect the brake line (1) from the fitting (2) on each side of the
final drive (3).
4. Attach a 3 ft. (0.91 m) length of hose to the end of each brake line.
Place the other end of the hose into a 1 U.S. gallon (3.8 L) container.
5. Press the service brake pedal. This step releases the pressurized oil
stored in the accumulator.
6. Replace the O-rings (4) with new ones.
7. Reconnect the hoses (1) and the fittings (2). Refer to the appropriate
"Final Drive Assembly" section for bleeding the brakes.
SETTING RELIEF VALVES

The following pressure check procedures involve the adjustment of relief valves. To help maintain clarity in the procedures, all
relief valves can be adjusted this way, unless otherwise specified.
1. Cut the lock wire, or remove the cap and sealing washer, from the relief valve cartridge.
Remark
On some relief valves, this cap also acts as a locking nut or collar.
2. Loosen the locking nut or collar.
3. Insert an allen wrench or screwdriver into the adjustment screw.
4. Turn the adjustment screw to obtain the desired pressure.

Remark
Turning the adjustment screw to the right (CW or IN) causes the pressure to increase. Turning the
adjustment screw to the left (CCW or OUT) causes the pressure to decrease. Any relief valves that differ
from this adjustment procedure will be noted.
5. After making the adjustment, install the locking nut or collar and cap with the sealing washer. Retest to ensure that the
value has not changed. Install the lock wire to maintain the setting.
20-34 830B/C-850B/C-870B/C
12
GENERAL DIAGNOSIS PROCEDURE
Effective troubleshooting requires a logical approach to problem solving. Use the following steps to isolate and identify the
problems:
1. Understand the hydraulic system. Look at the flow diagrams in this manual for an overview of the system to better
understand its intended operation. Read the Operator's Manual to gain an understanding of the operating controls on the
unit.
2. Know the problem. Talk to the operator or other service people involved who have seen the problem arise. Ask questions
based on your knowledge of the system. Find out the sequence of events leading to problem.
3. Observe and verify the situation. Operate the machine to see if it operates how you expect it. Use all functions of the
machine. Make note of the items that don't work or work improperly. Check out everything yourself: don't rely only on the
operator’s observations. Note the circumstances surrounding the problem (At what speed does the problem occur?; Is the
ambient temperature warm or cold?; Is the hydraulic fluid warm or cold?; etc.). Be sure to write down all observations.
4. Use common sense in troubleshooting the problem. Start the problem solving process with simple checks: look, listen, and
smell in detecting the problem. Is the fluid level correct? Is the fluid foamy, milky, too dirty, too thin, too thick, or does it
smell scorched? Are any parts overheated? Are the parts caked with dirt or mud? Is something jamming a mechanism on
the machine? Are the hoses, lines, or connectors leaking, cracked, or collapsed? Any unusual noises? If all hydraulic
functions are not working properly, the problem is most likely in a component common to all circuits. Consider that one
circuit may affect the operation of another circuit. Be sure to record all observations.
5. Evaluate the situation. Consider the information gained by studying the machine’s design and operation. Verify the
problem. Create a list of possible causes using the troubleshooting information in this manual.
6. Reach a conclusion. Verify that your conclusion is correct before doing any repair work!
HEAT PROBLEMS
Fluid temperature should never exceed 225° F (107.2° C). Many possible causes exist for overheated fluid. Try to pinpoint the
source of heat. Listen for noisy operation. Compare the temperatures of different system components in various circuits. An
overheated condition is usually caused by an unwanted restriction in the fluid flow (kinked or bent hose, for example), or over-
worked circuits. Some other causes of overheated fluid are:
● Improper operation of the equipment.
● Low reservoir level.
● Defective pumps, motors, valves, or cylinders.
● Plugged hydraulic oil cooler.
830B/C-850B/C-870B/C 20-35
12
SPECIAL TOOLS
The pinout test box (1), cover plate (2), and wiring harness (3) are used in
testing the AWD controller. The harness connects the pinout box to the
AWD controller’s existing harness. This will permit electrical readings to
be taken while the system is functioning. The cover plate fits onto the
pinout test box and correlates the wires in the system to the pinout test box.
The pinout test box, cover plate, and wiring harness installed testing the
AWD controller.
The part numbers for the tools are as follows:
Harness checker (pinout test box), p/n 799-601-2600
Adaptor cable and cover plate, p/n J38622.
Order these tools from your local distributor.
HYDRAULIC PRESSURE TESTS

Two trained and experienced service personnel are required to perform these services.
Determine if the grader is equipped with the optional All Wheel Drive (AWD). High-pressure tubes that run along the outside
of the cab and front frame member indicate that the grader is equipped with AWD.
Before performing the pressure tests, ensure that the engine and hydraulic system are at operating temperature (75° F to 100° F
or 24° C to 38° C). Also, ensure that all lubricants are at the proper level.
Adjust the throttle linkage properly to ensure that the various engine speeds can be obtained.
A Quick-Reference Pressure Chart with the hydraulic pressure values for standard and AWD graders can be found on the next
page.
20-36 830B/C-850B/C-870B/C
12
QUICK-REFERENCE PRESSURE CHART
STANDARD GRADER GRADER WITH AWD
MAIN HYDRAULIC SYSTEM

Load-sensor line
Low standby @
1000 rpm 120 to 160 PS1
2500 rpm 120 to 160 PS1
120 to 160 PS1
120 to 160 PS1
High standby @
1000 rpm 2,250 to 2,400 psi 2,250 to 2,400 psi
2500 rpm 2,250 to 2,400 psi 2,250 to 2,400 psi

Pump-outlet line
Low standby @
1000 rpm 340 to 400 psi 340 to 400 psi
2500 rpm 340 to 400 psi 340 to 400 psi
High standby @
1000 rpm 2,470 to 2,640 psi 2,470 to 2,640 psi
2500 rpm 2,470 to 2,640 psi 2,470 to 2,640 psi
STEERING AND
BRAKE SYSTEM
Pump @ 1000 rpm 1650 psi 1650 psi
AWD SYSTEM
Charge pump @ 1000 rpm 250 to 290 psi

Forward stall @ 1000 rpm 4,200 to 4,600 psi
Reverse stall @ 1000 rpm 4,200 to 4,600 psi
Actual desired pressure values in this manual may vary slightly to those values in the hydraulic schematics. When a system
is discussed, schematic values will be used. When a system is tested, the actual desired values will be used. The restrictions
in the system -- hose lengths, fittings, etc. -- cause the difference in values.

Load-Sensor Line
Low Standby= Load Sense Pressure Reducing Valve
High Standby = Load Sense Relief Valve
Pump-Outlet Line
Low Standby = Load Sense Pressure Reducing Valve + Flow Compensator Spool Setting
High Standby = Load Sense Relief Valve + Flow Compensator Spool Setting
STEERING AND BRAKE SYSTEM (WITH LOCK PIN)

Pump = Flow Compensator Relief Valve
ALL-WHEEL-DRIVE SYSTEM
Charge Pump = Flushing Valve
Forward Stall = Pressure Override Valve
Reverse Stall = Pressure Override Valve
Brake Booster = Flushing Valve + Brake Booster Relief Valve
830B/C-850B/C-870B/C 20-37
12
MAIN HYDRAULIC SYSTEM SPECIFICATIONS
Load-Sensor Line
Low Standby 120 to 160 psi @ 1,000 ±25 rpm
120 to 160 psi @ 2,500 ±25 rpm
High Standby 2250 to 2,400 psi @ 1000 ±25 rpm

2250 to 2,400 psi @ 2500 ±25 rpm
Pump-Outlet Line
340 to 400 psi @ 2,500 ±25 rpm
High Standby 2,470 to 2,640 psi @ 1,000 ±25 rpm

2,470 to 2,640 psi @ 2,500 ±25 rpm
Remark
Actual desired pressure values recorded in this manual may vary slightly to those values in the hydraulic
schematics. When discussing a system, schematic values will be used. However, when testing a system,
use the desired values. The inherent restrictions in the system — hose lengths, fittings, etc. — cause the dif-
ference in values.
TEST PORT LOCATIONS
PUMP OUTLET LINE PRESSURE (TEST PORT 1)

Located in the pump outlet elbow on the right rear side of the main system
pump when viewing from the rear of the grader. Remove the grill to gain
access to the test port.
LOAD SENSOR LINE PRESSURE (TEST PORT 2)

Located on the top right side of the main system pump when viewing from
the rear of the grader. Remove the grill to gain access to the test port.
20-38 830B/C-850B/C-870B/C
12
TEST PROCEDURE: LOW-PRESSURE STANDBY
1. Turn the engine off and apply the parking brake.
2. Connect a calibrated 600 psi gauge to the load sensor line pressure test
port (2).
3. Connect a calibrated 600 psi gauge to the pump outlet line pressure
test port (1).
4. Start the engine. Move the engine speed control lever to increase the
5. Leave all hydraulic control levers in their NEUTRAL (at rest) positions.
WARNING! DO NOT operate the control levers or the pressure gauge will be damaged.
6. Have another person record both the load sensor and pump outlet pressure readings.
A. Load-sensor line low standby must be from 120 to 160 psi @ 1,000 ±25 rpm.
Actual Reading____________
B. Pump-outlet low standby must be from 340 to 400 psi @ 1,000 ±25 rpm.
7. Move the engine speed control lever to increase the speed to 2,500 ±25 rpm.
A. Load-sensor line low standby must be from 120 to 160 psi @ 2500 ±25 rpm.
10. Turn the engine off after recording the pressure readings.
830B/C-850B/C-870B/C 20-39
12
TEST PROCEDURE: HIGH-PRESSURE STANDBY
2. Connect a calibrated 5,000 psi gauge to the load-sensor line pressure

test port (2).
3. Connect a calibrated 5,000 psi gauge to the pump outlet line pressure
test port (1).
5. Bottom the leaning wheel cylinder (moldboard tilt, moldboard shift or circle shift cylinders could be used) while holding
the control valve fully OPEN.
A. Load-sensor line, high standby must be from 2,250 to 2,400 psi @ 1000 ±25 rpm.
B. Pump-outlet high standby must be from 2,470 to 2,640 psi @ 1,000 ±25 rpm.
8. Bottom the leaning wheel cylinder (moldboard tilt, moldboard shift or circle shift cylinders could be used) while
holding the control valve fully OPEN.
A. Load-sensor line high standby must be from 2,250 to 2,400 psi @ 2,500 ±25 rpm.
Actual Reading________________
B. Pump-outlet high standby must be from 2470 to 2640 psi @ 2500 ±25 rpm.
20-40 830B/C-850B/C-870B/C
12
STEERING AND BRAKE SYSTEM PRESSURE TEST
STEERING AND BRAKE SYSTEM SPECIFICATION
Pump pressure........................................1,650 psi @ 1000 rpm
Remark
Actual desired pressure values recorded in this manual may vary slightly to those values shown in the
hydraulic schematics. When discussing a system, schematic values will be used. However, when testing a
system, use the desired values. The restrictions in the system — hose lengths, fittings, etc. — cause the dif-
ferent values.
TEST PORT LOCATION

PUMP PRESSURE (TEST PORT 1)
The pump mounts to the engine. The test port is located at the rear of the
pump.
TEST PROCEDURE
1. Connect a calibrated 3,000 psi gauge to the steering and brake pump
test port (1).
2. Start the engine. Move the engine speed control lever to increase the speed to 1,000 ±25 rpm.
3. Have another person record the steering and brake pump pressure reading. Steering and brake pump pressure reading must
be 1,650 psi @ 1,000 ±25 rpm.
Steering and brake pump pressure @ 1,000 ±25 rpm__________________
4. If needed, adjust the relief valve (2) to obtain the desired 1,650 psi.
830B/C-850B/C-870B/C 20-41
12
AWD SYSTEM TEST
Due to the way this system synchronizes the speed of the front wheels with the rear wheels, it is sometimes difficult for the
operator to tell if the system is operating properly. These test procedures will verify proper system operation. The
troubleshooting section of this program assumes that these test procedures are performed as follows.
1. Functional Test
2. Hydraulic Pressure Test
3. Electrical Test
Remark
Perform the tests in the order listed below.
The functional test and pressure test sections will make reference to a specific set of problems. These problems will in turn
give additional testing steps and refer to the electrical test procedure when appropriate.
It is very important during any troubleshooting to define the problem. This sounds too simple to consider, but failure to define
the actual problem usually leads to a frustrating dead end. Conducting the tests carefully will prevent assumptions which lead
to incorrect conclusions. It won't take long to do the test correctly, so start at the beginning and don't take shortcuts. The
following troubleshooting notes are important!
● The troubleshooting steps outlined assume that the system did work properly at one time, and that no components were
tampered with or were reassembled incorrectly.
● When troubleshooting intermittent or unspecified problems, check for good electrical connections. Check for proper
routing of all hydraulic lines and wiring.
● The voltages specified will be measured relative to the frame ground on the voltmeter's DC scale, except in a few cases
where a voltage between two points will be specified.
● The term "system voltage" will be used to indicate that battery or charging system voltage, if the engine is running, that is
expected at that point. The exact voltage will depend on the condition of the battery or the regulator setting but will
usually be between 22 and 30 VDC. The system should work, however, if supplied with at least 20 VDC.
● Always turn the power OFF before disconnecting a connector.
● Pressures specified will be with the oil warm, at least 75° F (24° C), and the engine at a low idle, unless otherwise stated
in the testing procedures.
If you suspect that the AWD system is not working, but ALL other grader functions are normal, MAKE SURE THAT:
● The console indicator lamp is ON when the mode switch on the shift console is in the NORMAL MODE or
AGGRESSIVE MODE.
● The foot brake is NOT APPLIED (brake lights are NOT lit).
● Inching pedal is NOT APPLIED and properly adjusted.
● Parking brake switch is NOT APPLIED and functioning properly.
Although the controller's built-in self-diagnostic system is the easiest of the
tests to perform, it is not the most complete. The AWD system controller is
located on the right side of the operator's seat, beneath the access cover.
The AWD controller conducts a self-test when first turned on, and then
monitors sensor signals of the AWD electrical system. The controller has a
test button (1) and a tricolor LED test lamp (2). The test lamp can emit the
following colors:
RED: A blinking RED light indicates that only one rear-wheel-sensor
signal is present. However, if the RED light is continuously on, the
controller has failed.
GREEN: A blinking GREEN light indicates that only one front wheel
sensor signal is present.
YELLOW: A blinking YELLOW light indicates that both front and rear wheel sensor signals are present.
20-42 830B/C-850B/C-870B/C
Stop the machine and turn on the AWD system to the NORMAL MODE or AGGRESSIVE MODE. The test lamp mounted on
the controller should momentarily blink red, then turn off. If this lamp stays red, or blinks slowly when the machine is stopped,
a failure in the controller is indicated.
Whenever the machine is moving with the system ON, the lamp should blink yellow. This indicates that both front and rear
speed signals are present at the controller (normal operation). The test lamp will blink green when only one front wheel signal
is detected. However, if only one rear wheel signal is detected, the red light will blink.
AWD SYSTEM FUNCTIONAL TEST
1. Check the hydraulic tank and wheel gearbox oil levels.
2. Turn the key switch ON, and move the AWD switch to the NORMAL MODE. Do NOT start the engine.
3. Check the controller test lamp.
A. If the lamp momentarily blinks red then goes off, the controller is OK.
B. If the lamp is continuously red, the controller has failed.
4. Start the engine. Shift the transmission into first gear forward, set the engine at 1/4 throttle, and raise the blade.
A. With the machine moving, check the controller test lamp.
i. If the lamp blinks yellow, sensor inputs are OK.
ii. If the lamp does not light, go to Problem 1 (page 20-103).
iii. If the lamp blinks red, go to Problem 3 (page 20-105).
B. Move the AWD switch to the AGGRESSIVE MODE while moving steadily.
i. If there is no hydraulic response, go to Problem 4 (page 20-105).
ii. If the system appears to lack power, go to Problem 5 (page 20-106).
5. Stop the machine. Move the AWD switch to the off position, shift the transmission into neutral, set the engine throttle to
low idle, and release the parking brake.
A. Position the moldboard crosswise on the ground. Using the moldboard lift cylinders, raise the front wheels off the
ground.
i. Both wheels should not creep or turn in either direction.
ii. If the wheels turn or creep, go to Problem 6 (page 20-106).
B. Apply the foot brake, and shift the transmission into sixth gear forward.
i. Both wheels should not creep or turn in forward direction.
ii. If the wheels turn or creep forward, go to Problem 6 (page 20-106).
830B/C-850B/C-870B/C 20-43
12
6. Move the AWD system switch to the NORMAL MODE, and release the foot brake.
A. Push the test button (1) on the controller.
i. Both wheels should turn forward (test lamp should show continuous green).
ii. If both wheels do not turn forward, go to Problem 8 (page 20-108).
B. Continue to push the test button (1) and apply the inching pedal.
i. Both wheels should stop.
ii. Release the inching pedal.
iii. Both wheels should start to turn forward.
iv. If the wheels do not stop and then start to turn forward, go to Problem 10 (page 20-109).
C. Continue to push the test button (1) and apply the parking brake.
ii. Release the parking brake. Both wheels should remain stopped.
iii. Shift the transmission back to neutral and then shift back into sixth gear forward.
iv. Both wheels should start to turn forward.
v. If the wheels do not stop and then start to turn forward, go to Problem 10 (page 20-109).
D. Continue to push the test button (1) and apply the foot brake.
ii. Release the foot brake.
iii. Both wheels should start to turn forward.
iv. If the wheels do not stop and then start to turn forward, go to Problem 10 (page 20-109).
E. Continue to push the test button (1) and release the foot brake. When the foot brake is released the wheels should turn
forward. Continue to push test button and shift transmission to neutral.
i. If the wheels do not stop when the transmission is shifted into neutral, go to Problem 10 (page 20-109).
F. Shift the transmission back into sixth gear forward. The wheels should again turn forward. With the wheels turning
forward release the test button (1). The wheels should slow to a stop when the test button is released.
i. If the wheels turn or creep forward, go to Problem 10 (page 20-109).
7. With the foot brake released, shift the transmission into third gear reverse.
Remark
Due to the "reverse bump" feature, the front wheels will turn in reverse for a few seconds and slow to a stop.
Wait for them to stop.
20-44 830B/C-850B/C-870B/C
12
A. Push the test button (1) on the controller.
i. Both wheels should turn in reverse.
ii. If both wheels do not turn in reverse, go to Problem 9 (page 20-109).
B. Continue to push the test button (1), and apply the inching pedal.
ii. Release the inching pedal.
iii. Both wheels should start to turn in reverse and not slow while test button is being held.
iv. If wheels do not stop and then start to turn in reverse, go to Problem 10 (page 20-109).
C. Continue to push the test button (1), and apply the parking brake.
ii. Release the parking brake. Both wheels should remain stopped.
iii. Shift the transmission back into neutral and then shift back into third gear reverse.
iv. Both wheels should start to turn in reverse and not slow while holding the test button.
v. If the wheels do not stop and then start to turn in reverse, go to Problem 10 (page 20-109).
D. Continue to push the test button (1) and apply the foot brake.
ii. Release the foot brake.
iii. Both wheels should start to turn in reverse and not slow while the test button is being held.
iv. If the wheels do not stop and then start to turn in reverse, go to Problem 10 (page 20-109).
E. Continue to push the test button (1) and release the foot brake.
i. When the foot brake is released, the wheels should turn in reverse. Continue to push the test button and shift the
transmission into neutral.
ii. If the wheels do not stop when shifting the transmission into neutral, go to Problem 10 (page 20-109).
F. Shift the transmission back into third gear reverse.
i. The wheels should again turn in reverse. With the wheels turning in reverse release the test button (1). The
wheels should slow to a stop when the test button is released.
ii. If the wheels turn or creep in reverse, go to Problem 10 (page 20-109).
830B/C-850B/C-870B/C 20-45
12
AWD HYDRAULIC SYSTEM PRESSURE TEST
AWD SYSTEM SPECIFICATION
Charge Pump Pressure 250 to 290 psi @ 1,000 rpm
Forward Stall Pressure 4,200 to 4,600 psi @ 1,000 rpm
Reverse Stall Pressure 4,200 to 4,600 psi @ 1,000 rpm
Remark
Actual desired pressure values recorded in this manual may vary slightly to those values shown in the
hydraulic schematics. When discussing a system, schematic values will be used. However, when testing a
system, use the desired values. The restrictions in the system — hose lengths, fittings, etc. — cause the
different values.
TEST PORT LOCATIONS
CHARGE PUMP PRESSURE
Located at the AWD filter.
REVERSE PRESSURE (TEST PORT 1)
Located on the left top side of the main frame in front of the operator's cab.
FORWARD PRESSURE (TEST PORT 2)
Located on the right top side of the main frame in front of the operator's
cab
WARNING! The system develops full force during this

test. Keep clear of the area in front of and
behind the machine.
20-46 830B/C-850B/C-870B/C
12
TEST PROCEDURE
1. Raise the moldboard so the front wheels are resting solidly on ground.
2. Connect a calibrated 5,000 psi pressure gauge to test port 1, and another calibrated 5,000 psi pressure gauge to test port 2.
Both test ports are located in the hydraulic lines along the frame to the front wheels.
3. Remove the AWD controller access cover.
4. Unplug the wire "10 AWD" from the brake light switch. This step
allows brake application, without turning the AWD system off.
5. Apply the foot brake, release the parking brake and move the AWD
switch to the OFF position. Start the engine. Move the engine speed
control lever to increase the speed to 1,000 ±25 rpm.
Remark
The pump has a Pressure Override Valve (POV) that varies
the swash-plate angle to limit the maximum pressure. This
valve prevents continuous dumping of excessive flow, at
maximum pressure, through the system relief valves in the
pump. This action eliminates unnecessary heating of the oil
and protects the pump when the wheels stall.
6. Move the AWD switch to the NORMAL mode. After shifting the transmission into the forward high (6th) gear, push the
test button on the controller.
A. The right hand gauge should register override pressure from 4,200 to 4,600 psi @ 1,000 ±25 rpm. Have another
person record the override pressure @ 1,000 ±25 rpm__________________
B. The left hand gauge should register charge pressure from 250 to 290 psi @ 1,000 ±25 rpm. Have another person
record the charge pump pressure @ 1,000 ±25 rpm____________________
7. After shifting the transmission into reverse third gear, push the test button.
A. The right gauge should register charge pressure from 250 to 290 psi @ 1,000 ±25 rpm. Have another person record
the charge pump pressure @ 1,000 ±25 rpm____________________
B. The left gauge should register override pressure from 4,200 to 4,600 psi @ 1,000 ±25 rpm. Have another person
record the override pressure @ 1,000 ±25 rpm__________________
8. Turn the engine off and apply the parking/emergency brake.
9. Reconnect the "10AWD" wire to the brake light switch.
10. Start the engine. Shift the transmission into first gear forward, set the engine at 1/4 throttle, raise the blade, and move the
AWD system switch to the NORMAL MODE. With the machine moving steadily on even ground, check the pressure at
the right pressure gauge. Now, move the AWD switch to the AGGRESSIVE MODE. Pressure should increase.
ADJUSTMENT
The AWD pump has several adjustment procedures. They must be followed to ensure that it will function properly in the
system. The "AWD Hydraulic System Pressure Tests" only measures pump pressure as it interacts with the entire system. The
actual AWD pump charge pressure setting cannot be tested unless the pump is isolated from the HIC valve. The HIC valve
contains the flushing valve that is set at a lower pressure than the charge pump relief valve. Also, the Pressure Override Valve
(POV) limits the maximum system pressure. The POV prevents the forward and reverse high-pressure relief valves from
830B/C-850B/C-870B/C 20-47
limiting the system pressure. The only way the pump and relief valves can be properly adjusted is to perform the following
procedures.
The pump must also be properly centered. That is, it must be able to return to a neutral position when the AWD system is
turned off. If the pump does not fully destroke to neutral (0° swash-plate angle), it will continue to create flow into the system.
This flow will continue to drive the AWD motors and gear boxes. The hydraulic and mechanical centering procedures are
dependent on each other. The centering procedure ensures a 0° swash-plate angle when the pump is in neutral.
The relief valves are normally factory set. They will only require adjustment when the pump has had major service involving
the relief valve cartridges. Adjust all relief valves BEFORE performing the hydraulic and mechanical centering procedures.
20-48 830B/C-850B/C-870B/C
12
LEGEND FOR ALL-WHEEL-DRIVE PUMP
1. PORT "S" (LOCATED ON OPPOSITE SIDE)

2. PORT "B"
3. CHARGE PRESSURE RELIEF VALVE
4. TEST PORT "MB" (LOCATED AT END OF PUMP)
5. PORT "FE"
6. FORWARD HIGH PRESSURE RELIEF VALVE, PORT "A"
7. TEST PORT "MA" (LOCATED ON END OF PUMP)
8. PORT "FA"
9. PORT "T2"
10. ECCENTRIC TIMING SCREW
11. MECHANICAL CENTERING ADJUSTING SCREW
12. HYDRAULIC CENTERING ADJUSTING SCREW
13. PORT "R"
14. PORT "X3"
15. PORT "X1"
16. SOLENOID "A"
17. PORTS "A1" AND "B1"
18. REVERSE HIGH-PRESSURE RELIEF VALVE, PORT "B"
19. PORT "T1"
20. PRESSURE OVERRIDE VALVE (POV) ADJUSTING SCREW
21. SOLENOID "B"
22. PORT "X3"
23. PORT "X4"
Remark
- IMPORTANT - The flushing valve contained in the HIC valve assembly is factory set and lock wired with a
lead seal. Do NOT adjust this cartridge.
RELIEF VALVES
During this adjustment procedure, test ports "MA" and "MB" located on the rear of the AWD pump are going to be used to
measure system pressure. These test ports are more convenient for the person adjusting the relief valves.
WARNING! When pressure testing and adjusting relief valve cartridges, two people are required.
Have one person in the cab at all times while the second person records and performs
the adjustment. Do not adjust the relief valves while the machine is running. Turn off the
engine and then turn the adjustment screws. The second person should stand to the side
of the machine and away from the tires in case it should move forward or reverse.
1. Turn the engine off and set the parking brake.
830B/C-850B/C-870B/C 20-49
12
2. Using the two split-flange plugs (P/N 603 517 C1) and
the two O-rings (P/N 343 906 R1), block the oil flow in
the high-pressure tubes leading to the HIC valve. The
split-flange connections are located just in front of the
forward and reverse test ports.
Remark
Blocking the high-pressure tubes prevents the
flushing valve from affecting the charge
pressure reading.
3. Connect two calibrated 600 psi (42.2 kg/cm2) gauges to

pressure test ports "MA" and "MB".
4. Start the engine and set the engine speed control lever
to 2,500 ±25 rpm.
5. Charge pressure must be from 330 to 370 psi (23.2 to

26.0 kg/cm2) @ 1,770 ±25 rpm. Record the charge
pressure readings.
____________ psi at test port MA
____________ psi at test port MB
6. If the readings are incorrect, turn the engine off and adjust the charge-pressure relief valve. Then restart the engine and
check the pressures again.
Remark
If the pressure readings are not within 5 psi (0.4 kg/cm2) of each other, the "Hydraulic Centering Procedure"
must be performed.
8. Turn the forward and reverse high-pressure relief valve adjustment screws out (CCW) until the spring tension is
completely relieved. Then turn both screws in (CW) one full turn.
9. Turn the Pressure Override Valve (POV) adjusting screw in (CW) until firm resistance is encountered.
WARNING! Do not force the POV adjustment screw beyond the firm resistance point. To do so could
damage the valve.
Remark
Turning the POV adjustment screw all the way in will set it to a higher pressure than that of the forward and
reverse high-pressure relief valves.
10. Connect two calibrated 10,000 psi (703.0 kg/cm2) pressure gauges to test ports MA and MB.
11. Unplug the connector containing wire "10 AWD" from the brake switch. This step must be done for the test so the brakes
can be applied, without shutting off power to the AWD system.
20-50 830B/C-850B/C-870B/C
12
WARNING! The system develops full force during this test. Keep clear of the area in front of and
behind the machine.
12. Apply the service brake, release the parking brake, and move the AWD system switch to the off position. Start the engine
and set the engine speed control to 1,000 ±25 rpm.
13. Move the AWD system switch to the NORMAL MODE, shift the transmission into sixth gear forward, increase the
engine setting to 2,500 ±25 rpm, and push the test button on the controller.
A. The MA gauge should register forward high-pressure relief valve reading. Adjust the forward high-pressure relief
valve adjustment screw until the reading is 4,550 psi (319.9 kg/cm2) higher @ 2,500 ±25 rpm than the charge pump
pressure reading from 330 to 370 psi (23.2 to 26.0 kg/cm2). Have another person record the forward high-pressure
relief valve reading.
_________ psi forward high-pressure relief valve (@ 2,500 ±25 rpm).
B. The MB gauge should show charge pressure from 330 to 370 psi (23.2 to 26.0 kg/cm2) @ 1,770 ±25 rpm. Have
another person record the charge pump reading.
_________ Charge pump pressure (@ 1770 ±25 rpm).
WARNING! Perform this step as quickly as possible to prevent the pump from overheating. Flow must
not be permitted to spill over the high-pressure relief valve for no longer than 10 seconds,
especially at higher pressures.
14. Set the engine throttle to 1,000 ±25 rpm.
15. Shift the transmission into third gear reverse, increase the engine speed to 2,500 ±25 rpm, and push the test button.
A. The MA gauge should show charge pressure from 330 to 370 psi (23.2 to 26.0 kg/cm2) @ 1,770 ±25 rpm. Have
another person record the charge pump reading.
_________ Charge pump pressure (@ 1,770 ±25 rpm).
B. The MB gauge should now show the reverse high-pressure relief valve reading. Adjust the reverse high-pressure
relief valve adjustment screw until the reading is 4,550 psi (319.9 kg/cm2) higher @ 2,500 + 25 rpm than the charge
pump pressure reading from 330 to 370 psi (23.2 to 26.0 kg/cm2). Have another person record the reverse
high-pressure relief valve reading.
_________ Reverse high-pressure relief valve (@ 2,500 ±25 rpm)
WARNING! Perform this step as quickly as possible to prevent the pump from overheating. Flow must
not be permitted to spill over the high-pressure relief valve for no longer than 10 seconds,
especially at the higher pressures.
16. Turn the engine and the AWD off.
17. Turn the POV adjustment screw all the way out (CCW).
830B/C-850B/C-870B/C 20-51
12
18. Start the engine, move the AWD switch to the NORMAL MODE, shift the transmission into sixth gear forward, increase
the engine speed to 2,500 ±25 rpm, and push the test button on the controller.
A. The right gauge should register pressure override. Adjust the POV adjustment screw until the reading is 4,400 psi
(309.3 kg/cm2) @ 2,500 ±25 rpm. Record the pressure override valve reading @ 2,500 ±25 rpm _________
B. The left gauge should register charge pressure from 330 to 370 psi (23.2 to 26.0 kg/cm2) @ 1,770 ±25 rpm. Have
another person record the charge pump pressure @ 1,770 ±25 rpm _________
Remark
After adjusting the POV, the pump does not have to be adjusted for the opposite direction.
19. Turn the engine and AWD off.
20. Remove the split-flange plugs.
21. Remove all gauges.
22. Reconnect the connector that was disconnected in step 11 before returning the machine to service.
HYDRAULIC CENTERING ADJUSTMENT PROCEDURE

After servicing or replacing the EL control module, you must center the module. Use the following procedure to ensure it is
hydraulically centered.
Two people are required to perform the following adjustment procedure. One person must remain in the cab at all times.
2. Remove both plug-in connectors from solenoids A and B.

Remark
Use a small screwdriver to remove the screw that secures the connectors to the solenoid valves. Having the
connectors unplugged will ensure there is no electrical signal at the solenoids.
3. Using the two split-flange plugs (P/N 603 517 C1) and two O-rings
(P/N 343 906 R1), block the oil flow in the high-pressure tubes leading
to the HIC valve. The split-flange connections are located just in front
of the forward and reverse test ports.
Remark
Blocking the high-pressure tubes eliminates the flushing
valve from affecting the charge pressure reading. This step
also causes the AWD pump flow to deadhead, equalizing
pressure and show charge pressure at test ports MA and MB.
4. Install two calibrated 600 psi (42.2 kg/cm2) gauges at test ports MA
and MB.
5. Start the engine and set the engine speed control lever to 2,500 + 25 rpm.
20-52 830B/C-850B/C-870B/C
12
6. Record the pressure readings at test ports MA and MB.
____________ psi @ test port MA
____________ psi @ test port MB

Remark
Switch the gauges to verify that the pressure readings do not vary.
7. If the readings are NOT within 5 psi (0.4 kg/cm2) of each other, loosen the jamnut on the hydraulic centering adjusting
screw. Turn the adjusting screw until the pressure readings are within 5 psi (0.4 kg/cm2) of each other. Tighten the jamnut.
WARNING! Turning the hydraulic centering adjustment screw too far from the center position can
cause system pressure that can damage the 600 psi (42.2 kg/cm2) gauges.
Remark
The adjustment screw is eccentric shaped. Therefore, turning it more than 90° in either direction will have no
further centering effect and may cause the control to bind, damaging it.
Remark
If hydraulic centering cannot bring pressure within 5 psi (0.4 kg/cm2) of each other, than mechanical
centering must be done.
Remark
If difficulties were encountered while obtaining a neutral
position of the EL control module, check that the ends of the
control feedback spring are correctly located. The spring ends
should be in the grooves near the end of the feedback lever
arm. See the appropriate All-Wheel-Drive pump section for
servicing procedures.
8. Turn the engine off and disconnect the hydraulic gauges from the test
ports. Plug the test ports.
9. Remove the split-flange plugs from the high-pressure tubes.
10. After the split flanges are connected, conduct the "Filtering Procedure
for AWD Hydraulic System."
830B/C-850B/C-870B/C 20-53
12
MECHANICAL CENTERING ADJUSTMENT PROCEDURE
Mechanical centering is only performed when the pump cannot be hydraulically centered. Mechanical centering should not
change once it is set. Hydraulic centering must be repeated afterwards.
1. Turn the engine off and set the parking brake.
2. With a high-pressure hose, connect test port "X3" to "X4".

Remark
Connecting test port "X3" to "X4" equalizes pressure on both sides of the control valve and control piston.
With this condition, the pump remains off stroke and the system pressure measured at test ports "MA" and
"MB" equals charge pressure.
3. Using the two split-flange plugs (P/N 603 517 C1) and two O-rings
(P/N 343 906 R1), block the oil flow in the high-pressure tubes leading
to the HIC valve. The split-flange connections are located just in front
of the forward and reverse test ports.
Remark
Blocking the high-pressure tubes prevents the flushing valve
from affecting the charge pressure reading. This will cause
the AWD pump flow to deadhead making pressure readings
equalize and show charge pressure at test ports MA and MB.
4. Install two calibrated 600 psi (42.2 kg/cm2) gauges at test port MA and
MB.
5. Start the engine and set the engine speed control lever to high idle.
6. Record the pressure readings at test ports MA and MB.
____________ psi @ Port MA
____________ psi @ Port MB
Remark
Switch the gauges and verify there is not any difference in their pressure readings.
7. If the readings are NOT within 7 psi (0.5 kg/cm2) of each other, loosen the jamnut on the mechanical centering adjusting
screw. Turn the adjusting screw until pressure readings are within 7 psi (0.5 kg/cm2) of each other. Carefully tighten the
jamnut.
8. Turn the engine off and disconnect the hydraulic gauges from the test ports. Plug the test ports.
9. Remove the high-pressure hose from between test port "X3" and "X4." Plug the test ports.
10. Remove the split-flange plugs from the high-pressure tubes.
11. Repeat the hydraulic centering procedure.
20-54 830B/C-850B/C-870B/C
12
AWD HYDRAULIC SYSTEM FILTERING PROCEDURE
Use the following procedure:
1. Disconnect the front wheel sensor, which is located on the right gearbox assembly.
2. Raise the front wheels off the ground.
3. Start the engine.
4. Arrange the electronic control box so that the test button can be easily pressed during the test.
5. Engage the AWD switch to the NORMAL MODE.
6. Press the test button.
7. Apply the foot brake.
8. Shift the transmission into forward high gear.
9. Accelerate the engine rpm gradually from low idle to high idle and hold for five (5) minutes.
10. After five (5) minutes, decelerate to low idle.
12. Shift the transmission into reverse high gear.
13. Accelerate the engine rpm gradually from low idle to high idle and hold for five (5) minutes.
14. After five (5) minutes, decelerate to low idle.
16. Release the test button, lower the front wheels, and reconnect the front sensor.
17. This action concludes the filtering procedure.
WARNING! Apply the foot brake whenever shifting the transmission from forward to reverse and vice
versa.
830B/C-850B/C-870B/C 20-55
12
AWD ELECTRICAL SYSTEM TESTS
wires for wear and/or abrasions that would short circuit. Wires may have internal breaks that can only be detected with the use
of an ohmmeter. When the possibility arises that a switch or other component is bad, check the wires for continuity. They are
numbered with bands at each end to help trace them. Replace, if necessary.
Remark
Be sure that the terminal ends are crimped solidly, screws are tight and that contact surfaces are not
corroded.
The system controller is an encapsulated, microprocessor based, electronic module. It is located to the right side of the opera-
tor's seat and beneath the access cover. The controller receives or sends signals to manage the AWD system via three multi-pin
connectors. Individual wires may be located by their position in these connectors. Each wire has been assigned a reference
number. Signal descriptions and voltages, for each combination of wire reference numbers, are shown in the following table.
An electrical system pinout test box, cover plate and wiring harness has been developed to test the AWD controller.
Remark
These voltage readings may vary slightly depending upon the supply voltage at wire "3 AWD." The alternator
output controls the supply voltage to this wire.
The table is classified in two test categories: static and outside. The static test is performed with the machine stationary.
Perform the outside test with adequate distance to operate the machine in excess of 12 MPH. Both tests yield the same basic
results. However, unless the unit is driven outside to test the sensor processing, the system cannot be fully tested.
Install pin out box for electrical test, see “SPECIAL TOOLS” on page 20-36
WIRE TO WIRE TEST TEST PROCEDURE VOLTAGE READING VOLTAGE READING

COMBINATION FOR WIRE TO WIRE WITH TEST BUTTON DURING OPERATION
COMBINATION (STATIC TEST) (OUTSIDE TEST)
1 AWD - 2 AWD Perform this test outside. With Will show about 20 VDC for a
the engine running, the parking minimum pump stroke signal to
Control signal to ground. brake released, the AWD sys- about 6VDC for a maximum
N/A
tem in the normal mode, and the stroke signal.
transmission in sixth gear for-
ward.
Perform this test inside or out- Voltage decreases from 20

side. With the engine running, VDC to 9.9 VDC.
the front wheels raised, the
parking brake released, the N/A
AWD system in the normal
mode, the transmission in sixth
gear forward, push the test but-
ton.
3 AWD - 1AWD Perform this test outside. With Will register about 6 VDC for
the engine running, the parking minimum pump stroke; 20
Power supply to control signal brake released, the AWD sys- VDC for a maximum stroke
N/A
for pump solenoid (EL mod- tem in the normal mode, and the signal
ule). transmission in sixth gear for-
ward.
NOTE: Power will turn off at Perform this test inside or out- Voltage will increase from 6.2
12 mph. side. With the engine running, VDC to 15.3 VDC.
parking brake released, the N/A
mode, the transmission in sixth
ton.
2 AWD On both front and rear har-

nesses, check the continuity
Ground between: N/A N/A
• 2 AWD and COM 4
• 2 AWD and ground
20-56 830B/C-850B/C-870B/C

3 AWD - 2 AWD 1. Perform this test inside or Main power from the AWD Main power from the AWD
outside. With the engine switch to ground should mea- switch to ground should mea-
running, the front wheels sure at least 20 VDC. sure at least 20 VDC.
Main power supply to ground.
This reading measures the raised, the parking brake
alternator output. released, the AWD system
in the normal mode.
2. Turn the AWD switch on.

The red light on the con-
troller should turn on
momentarily. If it does not,
check that the main power
switch is on.
5 AWD - 4 AWD Perform this test outside. With Minimum 8.5 VDC, but not to
(Front sensor cable) the engine running, the parking exceed 9.5 VDC
brake N/A
released, the AWD system in
Power "5AWD" to front sensor the normal mode, and the trans-
when measured to common "4 mission in sixth gear forward.
AWD"
Perform this test inside or out- Minimum 8.5 VDC, but not to
side. With the engine running, exceed 9.5 VDC
WARNING! parking brake released, the
AWD system in the normal N/A
Do not check the continuity of NOTE: Voltage should not
the sensor wires while attached mode, the transmission in sixth increase or decrease while
to the sensor or the sensor may gear forward, push the test but- pushing the test button or after
become damaged. ton. releasing it.
5 AWD - 4 AWD Perform this test outside. With Minimum 8.5 VDC, but not to
(Rear sensor cable) the engine running, the parking exceed 9.5 VDC
brake released, the AWD sys- N/A
tem in the normal mode, and the
Power "5AWD" to rear sensor transmission in sixth gear for-
when measured to common "4 ward.
AWD"
Perform this test inside or out- Minimum 8.5 VDC, but not to N/A
side. With the engine running, exceed 9.5 VDC
WARNING! parking brake released, the
Do not check the continuity of AWD system in the normal NOTE: Voltage should not
the sensor wires while attached mode, the transmission in sixth increase or decrease while
to the sensor or the sensor may gear forward, push the test but- pushing the test button or after
become damaged. ton. releasing it.
830B/C-850B/C-870B/C 20-57

6 AWD - 2 AWD 1. Perform this test outside Minimum 20 VDC when in

with the engine running gear and 0 (zero) VDC in neu-
and the parking brake tral.
"Reverse bump" signal from
the reverse relay to ground applied.
N/A
while the transmission is in
reverse. 2. Shift the transmission from
neutral to reverse to neu-
tral.
1. Perform this test outside or Minimum 20 VDC when in

inside with the engine run- gear and 0 (zero) VDC in neu-
ning, front wheels raised, tral.
parking brake released.
N/A
2. Shift the transmission into
neutral and then into
reverse and finally back
into neutral.
7 AWD - 4 AWD 1. Perform this test outside. 3.5 to 5.5 VDC

With the engine running,
Signal from the front sensor to the parking brake released,
the common ground wire when the AWD system in the
the right front wheel is turning. normal mode, and the
transmission in sixth gear
forward. N/A
WARNING!
2. Drive slowly and note the
Do not check the continuity of VDC. Increase the speed
the sensor wires while attached
to the sensor or the sensor may until 12 MPH is exceeded
become damaged. and verify that the signal is
cancelled.
Perform this test inside or out- 3.5 to 5.0 VDC

NOTE: Drive the unit to ensure side. With the engine running,
that signal cancels when speed the front wheels raised, the
exceeds 12 MPH. parking brake released, the
mode, the transmission in sixth N/A
NOTE: If a voltage reading of gear forward, push the test but-
8.5 VDC or higher is obtained, ton.
check that sensor hook-up is
not reversed.
20-58 830B/C-850B/C-870B/C

8 AWD - 4 AWD 1. Perform this test outside. 3.5 to 5.0 VDC

With the engine running,
Signal from the rear sensor the parking brake released,
measured to the common the AWD system in the
ground wire when the drive normal mode, and the
shaft is turning. transmission in sixth gear N/A
forward.
WARNING! 2. Drive slowly and note the

VDC. This signal will not
Do not check the continuity of
the sensor wires while attached cancel.
to the sensor or the sensor may
become damaged. Perform this test inside or out- 0 (zero) VDC
side. With the engine running,
parking brake released, the
mode, the transmission in sixth N/A
ton.
NOTE: The drive shaft is not

turning during the static test.
9 AWD - 2 AWD 1. Perform this test inside or Minimum of 20 VDC in the Minimum of 20 VDC in the
outside. With the engine aggressive mode and 0 (zero) aggressive mode and 0 (zero)
running and the parking VDC in the normal mode. VDC in the normal mode.
Power from the system switch
to ground. brake released.
2. Move the AWD system

switch from off to the
aggressive mode and then
finally to the normal mode.
830B/C-850B/C-870B/C 20-59

10 AWD - 2 AWD 1. Perform this test outside. Minimum of 20 VDC when

With the engine running, applying any of the listed func-
the parking brake released, tions. When the functions are
Disconnect the signal from the not applied, the applied volt-
AWD disable relay to ground. the AWD system in the age will return to 0 (zero)
normal mode, and the VDC.
NOTE: Activated when the
inching pedal, service brake, or forward. N/A
the parking brake are applied.
2. Actuate the following
functions:
• Inching pedal
• Service brake
• Parking brake
1. Perform this test inside or Minimum of 20 VDC when

outside. With the engine applying any of the listed func-
running, the front wheels tions. When the functions are
not applied, the applied volt-
raised, the parking brake age will return to 0 (zero)
released, the AWD system VDC.
in the normal mode, the
forward, push the test but- N/A
ton.
2. Actuate the following

functions:
• Inching pedal
• Service brake
• Parking brake
12 AWD - 2 AWD 1. Perform this test outside. Minimum of 20 VDC when in Minimum of 20 VDC when in
With the engine running, neutral and 0 VDC when in neutral and 0 VDC when in
the parking brake released, gear. gear.
Neutral signal from the shifter
to ground when the transmis- the AWD system in the
sion is in neutral. normal mode.
2. Shift the transmission from

neutral into forward and
then into reverse.
20-60 830B/C-850B/C-870B/C
12
AWD ELECTRICAL TEST FORM
Make a copy of this form for use in the field.
AWD SYSTEM TEST READING NOTES
1. PUMP POWER 24V AWD 1 & G
1. PUMP POWER 6 - 24V* AWD 3 & 1 * = Voltage increases as

speed increases, with a
24V maximum.
2. SYSTEM GROUND OHM TO COM 4 AND G
3. SYSTEM POWER 24V
6. REVERSE BUMP 24V
9. AGGRESSIVE 24V
10. BRAKE 24V
12. NEUTRAL 24V
FRONT HARNESS
4. FRONT SENSOR COM OHM AWD 4 TO AWD 2 AND G
5. FRONT SENSOR POWER 8.5V AWD 5 TO COM 4 (sensor voltage not to exceed 9.5V
or the sensor may be damaged).
7. FRONT SIGNAL 3.5V AWD 7 TO COM 4
G. SHIELD TIE GROUND OHM AWD 2 TO COM 4
REAR HARNESS
4. REAR SENSOR COM. OHM AWD 4 TO AWD 2 AND G
5. REAR SENSOR POWER 8.5V AWD 5 TO COM 4 (sensor voltage not to exceed 9.5V
or the sensor may be damaged).
8. REAR SENSOR SIGNAL 3.5V AWD 8 TO COM 4
G. SHIELD TIE GROUND OHM AWD 2 TO COM 4 AND G
830B/C-850B/C-870B/C 20-61
12
ELECTRONIC CONTROL MODULE TERMINAL IDENTIFICATION
20-62 830B/C-850B/C-870B/C
12
SENSOR TEST AND ADJUSTMENT
Remark
DO NOT test the sensor by checking for continuity. This digital magnetic sensor uses solid state components
that can be damaged by a reverse polarity voltage.
1. Remove the sensor from the gearbox or transmission housing, and connect it to a harness and controller known to be
"good." Move the AWD system switch to the NORMAL MODE.
A. Voltage between wires "4 AWD" and "5 AWD" should be at least 8.5 VDC, but not exceed 9.5 VDC.
B. Voltage between wires "4 AWD" and "7 AWD" (front) or "4 AWD" and "8 AWD" (rear) should be 0 (zero).
2. Move a wrench rapidly back and forth close to the front of the sensor and/or pull a small magnet rapidly away from the
front of the sensor.
A. Connect a voltmeter between wires "4 AWD" and "7 AWD" (front) or "4 AWD" and "8 AWD" (rear). The voltmeter
should show a deflection of several volts.
3. A preferred method is to hold the sensor in the magnetic field of a small transformer. The type used in a soldering gun or
calculator power supply works well. The magnetic field of the transformer fluctuates at 60 Hz and generates a 60 Hz sig-
nal from the sensor.
A. Connect a voltmeter between wires "4 AWD" and "7 AWD" (front) or "4 AWD" and "8 AWD" (rear). The voltmeter
should register 3.5 to 5 VDC.
B. Controller test lamp will blink green (front) or red (rear), depending upon which sensor is being checked.
SENSOR GAP ADJUSTMENT PROCEDURE
1. Rear Sensor (All-Wheel-Drive):
A. Turn the transmission output shaft until a tooth of the third gear
clutch pack aligns with the center of the sensor pickup mounting
hole.
B. Disconnect the electrical lead (1) from the sensor (2).
C. Loosen the jamnut (3).
D. Screw the rear sensor (2) in until it just touches the gear O.D.
E. Back out the sensor 3.6 turns to obtain a 0.200 in. (5.080 mm) gap.
Remark
Because this sensor uses a 5/8 in. bolt with 18 UNF threads, turning the sensor one full turn screws the
sensor in or out 0.055 in. (1.397 mm). Thus, backing the sensor out 3.63 turns yields the 0.200 in. gap.
F. After obtaining the desired gap, tighten the jamnut (3).
G. Reconnect the electrical lead (1) to the sensor (2).
H. Test the all-wheel-drive system to ensure that the rear sensor is properly adjusted and functioning.
830B/C-850B/C-870B/C 20-63
12
2. Front Sensor (All-Wheel-Drive):
A. For R.H. wheel assemblies, reinstall the sensor assembly. Using a

feeler gauge, obtain a 0.045 in. (1.143 mm) gap between the gear
tooth and the sensor pickup.
B. To measure the gap, remove the gearbox breather hose and fitting
from the gearbox.
C. After obtaining the specified gap, tighten the locknut, but DO

NOT exceed 36 lbf in. (0.4 kgm).
Remark
The front sensor uses a 3/8 in. diameter bolt with 24 UNF
threads. Thus, turning the sensor one full turn screws the sensor in or out 0.042 in. (1.067 mm).
D. After installing the front sensor, it may have to be adjusted inward to reduce the gap to prevent front-wheel creep.
Perform the "AWD System Functional Test" to determine if an additional adjustment is required ("AWD System
Functional Test," Steps 5.F, 6.F).
E66442V AWD CONTROLLER DIAGNOSTICS

LEGACY DIAGNOSTICS (For 1259559H3 and H4 Controllers)
Press the push-to-test button (1) on the AWD control box, the LED (2) will
turn “green” if pump is stroking greater than 75% of full displacement, but
will give no signal if the pump is stroking less than 75%.
LED flashes "red" once or twice when power is applied to the unit.
LED slowly blinks "red" if an internal failure prevents control box from
functioning.
LED blinks “red” when the AWD control and rear wheel pickup are
functioning.
LED blinks “green” if the AWD control and front wheel pickup are
functioning.
LED blinks “yellow” when the front and rear wheel pickups are
functioning together.
In this manner, a technician can determine if either wheel sensor is malfunctioning.
NEW DIAGNOSTIC SEQUENCES (For 1259559H4 Controller only)
These new diagnostics allow a technician to test input wiring and connections in the unit.
1. While the AWD control is functioning, press the push-to-test switch and apply power to thc AWD control.
2. Wait for the LED to turn yellow.
3. Release the push-to-test switch, the LED will slowly blink yellow.
The controller is now in test mode.
4. Apply the brake pedal, the LED should turn and remain red until the brake is released. When released, the LED should
slowly blink yellow again. If the LED does not signal as described check brake pressure, connections and wiring.
5. Select "aggressive" on the "normal/aggressive" selector. The LED should turn and remain green until the selector is put
back in the normal position. The LED should then slowly blink yellow again. If the LED does not signal as described
check the selector connections and wiring.
20-64 830B/C-850B/C-870B/C
TESTING AND ADJUSTING LOCK/UNLOCK DIFFERENTIAL RELIEF VALVE
6. Shift into neutral, the LED should turn and remain red until put back into original position. The LED should then slowly
blink yellow again. If the LED does not signal as described check the shifter connections and wiring.
7. Shift into reverse, the LED should turn and remain yellow until shifter is moved into back into previous position. The
LED should then slowly blink yellow again. If the LED does not signal as described check the shifter connections and
wiring.
8. Exit diagnostic mode by turning off the AWD control power. Wait at least 10 seconds before reapplying power.
LOCK/UNLOCK DIFFERENTIAL RELIEF VALVE

1. Connect a calibrated 3,000 psi (210.9 kg/cm2) gauge to the test port.
The test port is located atop of the rear axle.
2. Start the engine. Move the engine-speed control lever until the engine
speed reaches 1,000 rpm.
3. Adjust the relief valve (1) until the gauge registers 625 psi (43.9 kg/
cm2).
4. Move the engine-speed control lever until the engine speed reaches
2,500 rpm. The gauge should register 650 ±20 psi (45.6 ±1.4 kg/cm2).
5. Adjust the relief valve, if necessary.
REAR AXLE COOLING SYSTEM

There is no pressure adjustment for the rear axle cooling system.
830B/C-850B/C-870B/C 20-65
TESTING AND ADJUSTING FINAL DRIVE ASSEMBLY
12
WITH NoSPIN AND LOCK/UNLOCK DIFFERENTIAL

NO SPIN TEST
Two methods can be used to determine if the NoSPIN unit is operating properly: static and dynamic.
STATIC METHOD
The static method involves raising all four of the drive wheels off the ground by blocking the frame. Next, apply the parking
brake so the drive shaft will not turn.
Have an assistant on a drive wheel of the opposite tandem case. Start the test by rotating the drive wheels as far as possible in
the forward direction. Then with one person firmly holding the right wheel forward against the stop, rotate the left wheel
rearward. Listen for regular indexing or clicking sounds. See "Notes on Testing" below.
Remark
Ensure the right wheel is held firmly against the stop or the left wheel will not disengage.
Next, rotate both wheels rearward until they stop. With one person holding the right wheel firmly against the stop in the
rearward direction, rotate the left wheel forward. Listen for indexing or clicking sounds. Finally, repeat these tests. This time,
hold the left wheel against the stops and rotate the right wheel forward and rearward.
NOTES ON TESTING
If operating properly, rotating the wheel should cam out easily by hand and rotate freely in both directions until the direction of
rotation is reversed or pressure on the opposite wheel is relaxed.
With the standard NoSPIN, a prominent clicking or indexing noise is normal. The noise comes from the driven clutch
alternately engaging and disengaging from the spider while rotating.
With the silent-type NoSPIN, only a faint indexing noise — possibly none — will be heard, until the direction of rotation is
reversed. When reversed, the clutch will re-index and make a slight noise. If you do hear repeated loud indexing or clicking
sounds when checking a silent-type NoSPIN, one of the holdout ring and clutch assemblies may not be operating properly.
DYNAMIC METHOD
The dynamic method of testing the NoSPIN involves driving the machine. To determine that the NoSPIN is driving both
wheels, perform the driving test under stress. To get some torque load on the driving clutch teeth of the NoSPIN, drive up
against a solid obstruction in low gear while in loose dirt or gravel. Determine if both wheels spin, or not, in both directions.
Remark
Stall the machine by putting excessive downward pressure on the blade.
Another driving test is to check for proper camming action for both tandems in both directions. On a flat surface with good
traction conditions, drive the grader in a tight circle forward and rearward to the left and to the right to be sure that the outside
wheels are free and the outside tires do not scuff excessively. If the machine fails this test, find and correct the problem.
20-66 830B/C-850B/C-870B/C
TESTING AND ADJUSTING FINAL DRIVE ASSEMBLY
12
BRAKE DISC INSPECTION
Brake discs can be checked on each side for wear through external inspection holes.
Remark
These inspection holes double as oil level check holes. The one inspection hole may contain a 90° elbow for
maintaining the proper oil level. Remove this elbow to perform the inspection.
Every 3 Months or 500 Hours, inspect the brake linings (1). Remove the oil level elbow and inspection plug(s) from the
inspection holes. Using a flash light, check the condition of the brake lining material. If the brake facing material is worn so
that the oil grooves are no longer visible, replace the brakes.
830B/C-850B/C-870B/C 20-67
TESTING AND ADJUSTING TANDEM CASE
12
TANDEM CASE
TANDEM CHAIN WEAR LIMITS

Vertical chain deflection (sag) is a useful guide in determining the serviceable life of the tandem chains and sprockets. As wear
progresses, the chains become longer, resulting in increased deflection. This increased deflection indicates chain internal pin
and bushing wear as well as outer bushing and sprocket wear. If vertical deflection of the used chain exceeds the guideline,
chain elongation should be measured.
SPECIFICATIONS
CHAIN ELONGATION
CHAIN DEFLECTION
10 LINK MEASURE
New Wear Limit New Wear Limit
Planetary Single Strand Chain <1.5 in. 7.5 in. 20.00 in. 20.30 in.
Non-Planetary Double Strand Chain <1.5 in. 7.5 in. 12.50 in. 12.69 in.
PROCEDURE
1. Measuring Chain Deflection
A. Remove the access cover directly above the chain to be measured.
B. Use the blade to raise one tandem off the ground. Rotate the wheel
by hand to remove all chain slack from the bottom of the chain.
C. With all slack in the top section of the chain, pull the chain up
until all slack is removed, use a tape measure or mark a stick from
the chain to the top of the tandem case; then push chain down
until all slack is removed, use a tape measure or mark a stick from
the chain to the top of the tandem case. Subtract the two measurements or measure the difference between the marks
on the stick.
20-68 830B/C-850B/C-870B/C
12
2. Measuring Chain Elongation
A. Break chain.
B. Hold chain under tension, and measure the pin to pin centerline
dimension for a span of 10 links.
3. Measuring waist width of link plate "WHITNEY 160" chains.
A. Identify that the chain is a WHITNEY 160 chain by looking at the

chain side plate marking.
B. Identify the link chain roller side plates. The link stipulates are on
the inside.
C. Measure the waist width of a typical plate through all 4 cover

plates with a vernier caliper. If the waist width is under 1.496 in
(38 mm), this machine must have that tandem case chain changed.
See Section 30 - "TANDEM CASE" on page 30-334.
D. If the chain waist dimension is over 1.496 in (38 mm) the chain is
OK for continued use.
830B/C-850B/C-870B/C 20-69
SPROCKET WEAR (NON-PLANETARY ONLY)

During the normal service interval for the tandem case oil, the wheel axle
shaft sprockets should be examined for wear. Refer to graphic at right for
reference.
If the X dimension is more than twice the Y dimension then the sprocket
should be replaced. Check the sprockets at four places, 90° apart.
OIL
All machines should now be using HTF or EO all temperature ranges.
EO - API CE/CC or MIL-L-2104D with Sulfated Ash of 1.85% maximum and meeting NTC 400.
HTF - Hydraulic Transmission Fluid per HMS B06-0002. Komatsu P/N 1400102H91 (Order two 5 U.S. gallons
[18.0 buckets])
SINGLE AND DOUBLE STRAND CHAINS

ROAD TEST
After reinstalling the tandems and final drive, road test the grader to ensure that the tandems, final drive, and brakes are
functioning properly before returning the grader to service.
Drive the unit forward and backward approximately 20 ft. (6.1 m), applying the brakes to bring the unit to a hard stop. Perform
this step 10 times and recheck the 1950 lbf ft. (2643.8 Nm) torque applied to the axle nuts. Repeat this procedure until the axle
nut does not tighten any more. This procedure ensures that the tapered axle and wheel assembly are seated to each other prior
to bending the tab on the lock washer.
Recheck all oil levels.
WARNING! Retorque the axle nuts after several minutes of operation. Bend the lock washer tabs to
secure the nuts in position.
20-70 830B/C-850B/C-870B/C
12
MEMORANDUM
830B/C-850B/C-870B/C 20-71
TESTING AND ADJUSTING CIRCLE ADJUSTMENT
12
CIRCLE ADJUSTMENT
FOUR SHOES
This section is a guide for the proper adjustment of the drawbar and circle: the circle pinion gear and vertical mounting shoes.
Two major contact points exist on the mounting shoes:
● The top of the shoes provide a horizontal bearing surface for the circle (A).
● The edge of each shoe opposite the jack bolts provide a vertical bearing surface for the circle (B).
The clearance between the bottom of the drawbar and the top of the circle (C) must be a minimum of 0.031 in. (0.793 mm), but
not exceed 0.062 in. (1.588 mm). This clearance ensures the circle will not bind while rotating. Measure this clearance at areas
directly above the four shoes. The number of shims used with each vertical mounting bolt determines the overall clearance.
Align the shoes before tightening the vertical bolts. Improper shoe alignment at (B) will cause uneven wear. Each shoe should
be of equal distance from the vertical edge of the circle. The shoe clearance at (A) should be consistent throughout its length.
After completing the adjustments in this section, the gap running the length of each bearing surface (A and B) should be
consistent. The clearance at points A and C remain the same, depending on the blade position.
20-72 830B/C-850B/C-870B/C
12
VERTICAL ADJUSTMENT
WARNING! Do not remove all of the vertical bolts at the same time. If you do, the shoe, which is
heavy, will fall from the bolt and cause injury. Ensure that the moldboard is crosswise
under the grader.
SHOE NUMBER 1
Set the parking brake. With the moldboard set crosswise
under the grader and using the blade lift controls, apply a
slight downward pressure on the blade. With the moldboard
in this position, the minimum clearance between the bottom
of the moldboard plate and the top of the circle (C) should
be from 0.031 in. (7.925 mm) to 0.062 in. (1.575 mm). If
the clearance in this area is less than 0.031 in. (7.925 mm)
or exceeds 0.062 in. (1.575 mm), add or subtract shims
from each bolt. Each shim is 0.030 in. (7.925 mm) thick.
WARNING! Do not remove all of the vertical bolts at the same time. If you do, the shoe, which is
heavy, will fall from the bolt and cause injury. Ensure that the moldboard is crosswise
under the grader
SHOES NUMBER 2 THRU 4

Raise the moldboard 1.0 in. (25.4 mm) from the ground. After measuring the gap at each shoe (2, 3 and 4), apply a slight
downward pressure to the moldboard before adding or removing shims. When the blade is in the air, the circle tips or tilts
(usually) such that clearance exists at point C at shoes number 2 thru number 4, and at point A at shoe number 1.
Do not torque the vertical bolts at this time. It is necessary for the shoes to be moveable to perform the pinion adjustment.
830B/C-850B/C-870B/C 20-73
12
PINION ADJUSTMENT
With the moldboard crosswise under the grader, rotate the circle slightly until the pinion gear is in the position
.
With the pinion in this position, the tooth backlash should be 0.125 in. (3.175 mm) throughout 360° rotation.
20-74 830B/C-850B/C-870B/C
12
Remark
The circle may have to be rotated slightly to obtain the proper pinion gear alignment. At no time should the
pinion tooth top land touch the bottom land between any two teeth of the circle or vice versa. Due to
manufacturing processes, the chordal thickness of circle teeth may vary. When adjusting the backlash, allow
for this variance.
Make the adjustment as follows:
1. Loosen the vertical shoe mounting bolts.
2. Back out the jack bolts at shoes number 3 and 4.
3. Tighten the jack bolts at shoes number 1 and 2.
4. Increase the backlash beyond 0.125 in. (3.175 mm), then back out the jack bolts.
5. Have one person hold two 0.125 in. (3.175 mm) diameter rods between the top and bottom lands and a 0.125 in. (3.175
mm) backlash spacer between the faces of the teeth.
6. Tighten the jack bolts at shoes number 3 and 4 until the spacer and rods are pinched between the pinion gear and circle.
Then loosen the jack bolts one turn.
7. Tighten the jack bolts at shoes number 1 and 2 until the spacer and rods are free.
Remark
Tightening the jack bolts on shoe number 2 will tend to increase top and bottom land clearance, while shoe
#1 will tend to increase backlash.
8. Tighten the jack bolts at shoes number 3 and 4.
9. Once the circle is in position, tighten all vertical mounting bolts.
10. Torque the bolts to 455 lbf ft. (62.9 kg m).
11. Recheck the pinion clearance after the vertical bolts are tightened.
12. Perform the vertical adjustment one shoe at a time.

Remark
When tightening the jack bolts and jam nuts, make certain that the edge of the shoe against the vertical shoe
of the circle is making equal contact.
13. Have one person observe the pinion clearances while another rotates the moldboard 360° in both directions. Make any
necessary corrections.
830B/C-850B/C-870B/C 20-75
TESTING AND ADJUSTING CIRCLE REVERSE SLIP CLUTCH
12
CIRCLE ADJUSTMENT
Because of the lip located on the pinion gear, it cannot be
adjusted the same as a normal pinion gear. The lip prevents
measurement of the root and side gear tooth clearances. For
this reason, use a dial indicator to determine when the circle
gear teeth are bottomed into the pinion gear and then
backed out the specified distance.
Use the following procedure to adjust the pinion gear
clearance.
1. Measure the inside diameter of the circle gear teeth to

determine the smallest inside diameter. The smallest
diameter must be known so that as the circle is rotated
the tips of the circle gear teeth do not come into contact
with the roots of the pinion gear.
2. Rotate the circle so that the smallest inside diameter

aligns with the pinion gear. The centerline of a circle
gear tooth must align with the pinion gear’s centerline
(right).
3. Loosen the circle shoe vertical mounting bolts.
4. Loosen the jamnuts on all circle shoe jacking bolts.
5. Use the jacking bolts on circle shoes 3 and 4 to move

the circle so that the circle gear tooth bottoms into the
pinion gear.
6. Use a dial indicator (right) to determine when the circle

cannot be moved any farther with the jacking bolts.
Remark
Ensure that clearance exists between the circle
jacking bolts and circle shoes 1 and 2. If no
clearance exists, the circle may not be
bottomed into the pinion gear.
7. After bottoming the circle (it cannot be moved any

farther), loosen the jacking bolts on circle shoes 3 and
4 until 0.250 in. (6.350 mm) clearance exists.
8. Set the dial indicator to zero (0).
9. Use the jacking bolts on circle shoes 1 and 2 to move

the circle away from the pinion until 0.125 in. (3.175
mm) registers on the dial indicator.
10. Do not remove the dial indicator after obtaining the 0.125 in. (3.175 mm) reading. Keep the dial indicator set at its current
reading so that the circle maintains its position while adjusting the circle shoes.
20-76 830B/C-850B/C-870B/C
12
11. Make all final adjustments to the circle shoes detailed in section 20, “Circle Adjustment (Four Shoe).”
12. The circle must rotate freely after making all final adjustments.
SLIP CLUTCH ADJUSTMENT
WARNING! Use extreme caution when performing this test. Make sure that all equipment being used
to conduct test is in good condition. All equipment must be able to handle a load of at
least 25,000 lb (11,337.5 kg).
After installing the slip clutch on the grader, perform the following test to check the operation.
1. Position the circle (1) so that its centerline intersects with the frame’s
centerline (2).
2. Rotate the blade (3) so that it is 90° to the frame’s (2) centerline.
3. Sideshift the blade (3) so that the end of it is more than 8 ft. (2.44 m)
from the frame’s (2) centerline.
4. Attach one end of a spring scale (4) to the blade (3) 8 ft. (2.44 m) from
the frame’s (2) centerline. The spring scale must be 90° to the blade.
The scale must be large enough to handle a 25,000 lb (11,337.5 kg)
load.
5. Attach the other end of the spring scale to a solid object (5) capable of
holding this load. The grader must be on a surface that allows the
grader to have traction in third and fourth gears, without slipping the
wheels.
6. The circle slip clutch should slip with the grader moving in a forward direction, with a force of 11,325 lb (5,135.9 kg) reg-
istering at the spring scale (4). However, if the clutch:
● Slips before the scale registers 11,325 lb (5,135.9 kg), reduce the thickness of the slip clutch shim pack by 0.002 in. (0.050
mm). Hint: Replace a 0.007 in. (0.178 mm) shim with a 0.005 in.(0.127 mm) shim.
● Continues to hold past 11,325 lb (5,135.9 kg), increase the thickness of the slip clutch shim pack by 0.002 in. (0.050 mm).
Hint: Replace a 0.005 in. (0.127 mm) shim with a 0.007 in. (0.178 mm) shim.
Remark
Reducing the shim pack thickness increases spring pressure. However, increasing shim pack thickness
reduces spring pressure.
7. Repeat this test until the slip clutch operates properly.
830B/C-850B/C-870B/C 20-77
12
ENGINE AND TRANSMISSION GEAR RANGE TEST
After installing the slip clutch on the grader, perform the following test can
to check the operation.
1. Position the circle (1) so that its centerline intersects with the frame’s
centerline (2).
2. Rotate the blade (3) so that it is 90° to the frame’s (2) centerline.
3. Sideshift the blade (3) so that the end of it is more than 8 ft. (2.44 m)
from the frame’s (2) centerline.
4. Position the blade (3) against a solid object (4) that is 8 ft. (2.44 m)
from the frame’s (2) centerline. The object must be able to withstand a
load of 25,000 lb (11,337.5 kg). The grader must be on a surface that
allows the grader to have traction in third and fourth gears, without
slipping the wheels.
5. Use a calibrated tachometer to monitor engine speed (rpm).
6. The following table lists the variables for the slip clutch test:
MODEL TIRE SIZE TRANSMISSION GEAR ENGINE rpm
830 13:00 x 24 THIRD (FORWARD) 1370 ±75
FOURTH (FORWARD) 1730 ±75

850 14:00 x 24 or 17:50 x 25
THIRD (FORWARD) 1400 ±75
FOURTH (FORWARD) 1730 ±75

870 14:00 x 24 or 17:50 x 25
THIRD (FORWARD) 1400 ±75
DESIRED rpm: 0 rpm DESIRED rpm:

FULL THROTTLE
CIRCLE SLIP SHOULD HOLD
CIRCLE SLIP
CLUTCH SHOULD
SLIP
7. The circle slip clutch should slip with the grader moving in a forward direction at the specified rpm. However, if the
clutch:
● Slips before obtaining the specified engine rpm, reduce the slip clutch shim pack by 0.002 in. (0.050 mm).
● Continues to hold past the specified engine rpm, increase the slip clutch shim pack by 0.002 in. (0.050 mm).
Remark
Reducing the shim pack thickness increases spring pressure. However, increasing the shim pack thickness
reduces spring pressure.
8. Repeat this test until the slip clutch operates properly.
20-78 830B/C-850B/C-870B/C
TESTING AND ADJUSTING PARKING BRAKE CALIPER
12
PERROT PARKING BRAKE ADJUSTMENT
WARNING! For safe operation, it is imperative that the parking brake always be kept correctly
adjusted and in proper working order.
The parking brake assembly is mounted to the rear axle assembly. The parking brake is a spring-applied, hydraulically released
mechanism. Under normal conditions, no periodic service adjustment is required. When the brake is released, a 0.015 in.
(0.381 mm) to 0.125 in. (3.175 mm) gap is acceptable.
However, if the parking brake should need adjustment, use the following procedure:
1. Park the grader on a level surface. Rest the moldboard and all
accessories solidly on the ground.
2. Place blocking in front of and behind each tire.
3. Parking brake in the RELEASED position.
4. With one person in the cab, have a second person remove the rubber
boot (1) from the parking brake caliper (2).
5. With the caliper still pressurized, loosen the jamnut (3).
6. Turn the adjustment screw (4) clockwise (IN) until both brake pads (5
and 6) are in solid contact with the brake disc (7).
7. With both brake pads (5 and 6) in contact with the disc (7), turn the adjustment screw (4) OUT until the 0.030 in. (0.762
mm) clearance is obtained.
8. Tighten the jamnut (3).
9. Install the rubber boot (1) on the caliper (2).
BRAKE PRESSURE WARNING SWITCHES

There are two high pressure switches on the grader and are used in two different places, "Low Brake Pressure Warning
Switch" and "Parking Brake Pressure Switch". Testing is accomplished per the following conditions.
Condition #1 - If the warning buzzer sounds and the low brake pressure indicator is lit at the same time, then conduct
the following test procedure, “Low Brake Pressure Warning Switch.”
Condition #2 - If the transmission suddenly shifts into neutral while the transmission gear shift selector is still in a
gear position and the parking brake indicator light comes on, then conduct the following testing
procedure, “Parking Brake Pressure Switch.”
Remark
If the above problem occurs and it is inconvenient to troubleshoot the condition, disconnect the switch from
the harness and the grader can be temporarily operated.
Condition #3 - If the parking brake switch on the switch panel is applied, and the parking brake indicator light doesn't
come on, check bulb. If bulb is ok, conduct the following testing procedure, “Parking Brake
Pressure Switch.”
830B/C-850B/C-870B/C 20-79
LOW BRAKE PRESSURE WARNING SWITCH
1. Lower moldboard to the ground. Shutdown engine and set parking

brake. Block wheels to prevent machine from moving during test.
2. Disconnect Low Pressure Warning Switch (1) from the main wiring
harness (2) on the brake check valve block (3). Depress brake pedal
25-50 times to discharge accumulator charge pressure.
3. Connect a calibrated 2000 - 3000 psi (140.6 - 210.9 kg/cm2) gauge to

pressure test port (1, above graphic) on steering and brake pump.
4. With pressure gauge reading 0 psi, use a Volt-Ohm Meter and test
continuity across the pressure switch terminals. Switch must indicate a
closed circuit. If switch shows an open circuit at 0 PSI, replace switch.
5. Have another person start machine and set engine RPM to 1000 ±25
RPM.
A. Pressure gauge should read 1650 psi (116.0 kg/cm2). If pressure is

less than 1600 psi (112.5 kg/cm2), readjust pump relief valve (2,
above graphic) as outlined in Shop Manual.
B. If pressure is 1650 PSI (116.0 kg/cm2), test switch for open circuit with Volt-Ohm Meter. If switch indicates a closed
circuit, replace switch.
PARKING BRAKE PRESSURE SWITCH
1. Lower moldboard to the ground. Shutdown engine and set parking

brake. Block wheels to prevent machine from moving during test.
2. Connect a calibrated 2000 - 3000 psi (140.6 - 210.9 kg/cm2) gauge to

pressure test port on bottom of junction block (4).
3. Disconnect High Pressure Warning Switch (5) from the main wiring
harness (6) on the junction block (4).
4. With pressure gauge reading 0 psi, use a Volt-Ohm Meter and test
continuity across the pressure switch terminals. Switch must indicate a
closed circuit. If switch shows an open circuit at 0 psi, replace switch.
5. Have another person start machine and set engine RPM to 1000 ±25
RPM.
20-80 830B/C-850B/C-870B/C
12
6. Release parking brake.
A. Pressure gauge should read 1650 psi (116.0 kg/cm2). If pressure is

less than 1600 psi (112.5 kg/cm2), readjust pump relief valve (2).
B. If pressure is 1650 psi (116.0 kg/cm2), test switch for open circuit
with Volt-Ohm Meter. If switch indicates a closed circuit, replace
switch.
BLEEDING THE CALIPER’S

1. Bleeding the caliper’s:
A. Attach a plastic line from bleed cock to a bucket.
B. Start engine and apply pressure by releasing the brake.
C. Monitor fluid from bleed cock. Close bleed cock when no air is seen in fluid.
D. Remove plastic line from bleed cock.
2. Adjusting caliper’s running clearance:
A. Start engine and apply pressure by releasing brake.
B. Insert a 0.012 in feeler gauge between brake pad and brake disc.
C. Tighten square head adjusting screw on caliper until feeler gauge resists movement.
D. Tighten jam nut on adjusting screw.
3. Fill front axle with oil to the proper level.
4. Check to ensure parking brake holds 4th gear stall torque. If brake does not hold, then burnish brakes.
Remark
To verify 4th gear stall, you must disconnect the parking brake pressure switch. Make sure that you
reconnect after this test.
5. Burnishing brakes
WARNING! Operator must wear seat belt during burnishing procedure to prevent serious injury
during sudden stops.
A. While operating the machine at 7 mph (3rd gear maximum speed and full throttle), apply the parking brake.
B. Repeat step 5A five times, leaving approximately 5 minutes between stops.
830B/C-850B/C-870B/C 20-81
12
MICO PARKING BRAKE ADJUSTMENT
1. Park the grader on a level surface. Rest the blade and all accessories
solidly on the ground.
4. With one person in the cab, have another person loosen the hexnut (1).
5. Turn the adjustment setscrew (2) clockwise (IN) until both brake pads
(3 and 4) are in solid contact with the brake disc.
6. With both brake pads (3 and 4) in contact with the disc, turn the
adjustment setscrew (2) OUT until 0.012 in. (0.305 mm) clearance is obtained.
7. Tighten the hexnut (1).
20-82 830B/C-850B/C-870B/C
TESTING AND ADJUSTING BRAKE VALVES
12
BRAKE VALVES
Adjust the service brakes to ensure that:
● Brake discs never drag after releasing the pedal.
● Full brake line pressure develops after pushing the pedal to the floorboard.
● Excess force is never applied to a bottomed piston in the brake valve.
MICO BRAKE VALVE

Three brake adjustments are as follows:
● Brake pedal bumper.
● Brake pedal free height.
● Brake pedal stop.
BRAKE PEDAL BUMPER ADJUSTMENT
This adjustment ensures that the brake valve (7) is not applied after
releasing the brake pedal (2). With the brake released, the brake valve
actuator (3) must protrude 1.50 in. (38.10 mm) from the face of the brake
mounting bracket (1). To adjust:
1. Loosen the locknut below the bumper (4).
2. To increase the distance at point A, screw the bumper (4) downward.
3. To reduce the distance at point A, screw the bumper (4) upward.
4. Tighten the jamnut below the bumper (4).

Remark
The brake valve actuator (3) will always contact the brake pedal assembly. The actuator is not retained
within the brake valve body. NO FREE PEDAL CLEARANCE EXISTS WITH THIS VALVE ARRANGEMENT.
BRAKE PEDAL FREE HEIGHT

This adjustment sets the brake pedal free height, which affects the other pedal adjustments.
1. Loosen the nut (6).
2. Turn the brake pedal rod up or down until the distance at point C is 3.9 in. (99.060 mm)
3. Tighten the nut (6).
830B/C-850B/C-870B/C 20-83
12
BRAKE PEDAL STOP
This adjustment ensures that the brake valve (7) fully opens, allowing full brake pressure; and the brake pedal (2) stops against
the pedal stop bolt (5), preventing the piston from bottoming out in the valve (7).
WARNING! Applying excessive force to the brake valve piston while it is already at full stroke could
damage the brake valve.
1. Loosen the jamnut (8).
2. Turn the pedal stop bolt (5) clockwise until it is against the jamnut (8).
3. Using hand pressure, depress the brake pedal (2) slowly until it stops.
Determine if clearance exists between the pedal (2) and the pedal stop
bolt (5). If clearance doesn’t exist, go to step 4; if clearance exists, go
to step 5.
4. If clearance doesn’t exist between the pedal stop bolt (5) and the brake
pedal (2):
A. Loosen the nut (6).
B. Turn the brake pedal rod upward to obtain clearance.
C. With hand pressure, depress the brake pedal again until it stops.
D. If clearance now exists between the pedal stop bolt (5) and the brake pedal (2), adjust the stop bolt (5) upward until it
contacts the brake pedal (2).
E. Then turn the stop bolt (5) one additional full turn upward.
F. Tighten the nut (6).
5. If clearance exists between the bottom of the brake pedal (2) and the pedal stop bolt (5):
A. Adjust the stop bolt (5) upward until it contacts the brake pedal (2).
B. Then turn the stop bolt (5) one additional full turn upward.
C. Align the brake pedal pad.
D. If the nut (6) was loosened in step A, tighten it.
E. With hand pressure, press the brake pedal (2) down again until it stops.
F. If clearance still exists between the brake pedal (2) and the stop bolt (5), repeat step 5.
6. Check the from the mount bracket (1) to the ridge of the rubber boot (point B). If the distance is not 0.95 in. (24.130 mm),
one of the three adjustments is inaccurate. Recheck all three adjustments.
20-84 830B/C-850B/C-870B/C
12
PRESSURE TEST
After completing the brake pedal adjustments, perform a hydraulic pressure check to assure that the adjustments are correct.
1. Connect a calibrated 2,000 psi (140.6 kg/cm2) gauge to the test port fitting.
3. With the engine running and the brake pedal (2) released, the gauge should register 0 psi (0.0 kg/cm2).
__________ psi with the Brake Pedal Released
4. Depress the brake pedal (2) against the pedal stop bolt (5). The gauge should register 1160 ±75 psi (81.5 ±5.3 kg/cm2).
__________ psi with the Brake Pedal Applied
6. If both pressure readings are correct, remove the pressure gauge. If the pressure readings do not meet specifications,
readjust the pedal linkage as done previously.
7. Connect a calibrated 50 psi (3.5 kg/cm2) gauge.
WARNING! Do not depress the brake pedal with the 50 psi (3.5 kg/cm2) gauge installed.
9. With the brake pedal (2) released, the pressure should register 0 psi (0.0 kg/cm2). However, if the pressure increases:
A. Loosen the jamnut at the rubber bumper (4).
B. Turn the bumper (4) CW to increase the 1.50 in (38.1 mm) Dimension until pressure equals 0.0 (0.0 kg/cm2), then
increase an additional 0.060 in (1.52 mm).
C. Tighten the jamnut.
__________ psi with Brake Pedal Released __________ psi with Brake Pedal Applied
10. Turn the engine off and make the adjustments.
11. Recheck the brake system until the proper readings are obtained.
830B/C-850B/C-870B/C 20-85
12
MEMORANDUM
20-86 830B/C-850B/C-870B/C
TROUBLESHOOTING
HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-103

PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-103
Problem 1. Test lamp does not light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-103
Problem 2. Test lamp blinks green when in reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-104
Problem 3. Test lamp blinks red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
Problem 4. No change between the normal mode and aggressive mode . . . . . . . . . . . . . . . . . . . . . . 20-105
Problem 5. System appears to lack power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
Problem 6. Wheels turn when in neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
Problem 7. Wheels don't turn either direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-107
Problem 8. Wheels do not turn forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-108
Problem 9. Wheels do not turn in reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-109
Problem 10. Wheels do not stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-109
RIGHT AND LEFT CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110
MOLDBOARD TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-112
BLADE SHIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-112
HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-112
CIRCLE REVERSE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-113
AWD PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-114
AWD HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-118
STEERING AND BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
CONTROL VALVE MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120
MAIN SYSTEM PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121
TRANSMISSION POWER SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-123
TRANSMISSION SHIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-123
TANDEM CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-127
SINGLE AND DOUBLE STRAND CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-127
FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-128
WITH NoSPIN AND LOCK/UNLOCK DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-128
PARKING BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-129
830B/C-850B/C-870B/C 20-101
TROUBLESHOOTING
12
MEMORANDUM
20-102 830B/C-850B/C-870B/C
TROUBLESHOOTING HYDRAULIC CIRCUITS
12
HYDRAULIC CIRCUITS
PROBLEMS
Problem 1. Test lamp does not light
("AWD System Functional Test" Step 3.A)
When the machine is moving and the AWD system is on in either the NORMAL MODE or AGGRESSIVE MODE, the
controller test lamp should blink yellow. If the test lamp is not blinking, the front and rear sensor signals are NOT detected by
the controller. Thus, the system will not operate in either forward or reverse.
If the test lamp blinks green when moving in reverse with the AWD system on, go to Problem 2.
Turn the key switch to the off position and then disconnect both 4-pin connectors from the controller.
Turn the key switch to the ON position, move the AWD switch to the NORMAL MODE, and continue with the following
checks.
830B/C-850B/C-870B/C 20-103
12
1. With the front and rear sensor harnesses disconnected from the controller, check the voltage from the power supply to the
sensors: wire "5 AWD" (Pin 3) to "4 AWD" (Pin 3) in connector SS4P (front); and wire "5 AWD" (Pin 4) to "4 AWD" (Pin
1) in connector SS4R (rear). Each test point should measure 8.5VDC.
A. If the voltage is below the minimum 8.5 VDC:
i. Check the ground connections.
ii. Check the wire and its connections for continuity.
B. If the voltage is above 9.5 VDC:
i. Replace the controller.
2. Disconnect the sensor from the harness and perform a continuity check of the harness.
A. If continuity exists:
i. Replace the sensor.
B. If continuity does not exist:
i. Repair the harness.
Problem 2. Test lamp blinks green when in reverse

("AWD System Functional Test" Step 3. A)
When the machine is moving (forward or reverse) with the AWD system in either the NORMAL MODE or AGGRESSIVE
MODE, the controller test lamp should blink yellow. If the yellow lamp is not blinking while moving forward but is blinking
green when moving in reverse, the rear sensor signal is not present at the controller. Thus, the system will not operate in either
forward or reverse. However, the system may appear to operate normally while pressing the button on the controller.
1. Check the rear wiring harness connections at the controller four-pin connector (containing wire "8 AWD"), and at the rear
sensor.
2. Check the rear sensor.
A. Rear sensor gap should be properly adjusted.
B. Substitute a good sensor, if available.
C. Test the sensor.

Remark
DO NOT test the sensor for continuity. Reverse polarity or excess voltage can damage the sensor.
3. Check the rear wiring harness.
A. Substitute a known good harness, if available.
B. Disconnect the rear sensor connection and test for 8-9 VDC between wires "5 AWD" (Pin A) and "4 AWD" (Pin B).
C. Disconnect the harness at both ends and check for continuity and shorts.
20-104 830B/C-850B/C-870B/C
12
Problem 3. Test lamp blinks red
When the machine is moving with the AWD system on in either the NORMAL MODE or AGGRESSIVE MODE, the
controller test lamp should blink yellow. If the lamp is blinking red, the front sensor signal is not present at the controller.
Thus, the system will operate very aggressively and require more engine power. Or if blinking yellow when moving in reverse,
it could indicate that the drive motor is not turning. Conduct Test Step 5. If the wheels turn, then continue with the following
checks:
1. Check the front wiring harness connections at the controller four-pin connector (containing wire "7 AWD"), and at front
sensor.
2. Check the front sensor.
A. Front sensor gap should be properly adjusted.
B. Substitute a known good sensor.

Remark
Do NOT test sensor for continuity. Reverse polarity or excess voltage can damage the sensor.
3. Check the front wiring harness.
A. Substitute a known good harness, if available.
B. Disconnect front sensor connector (at sensor), and test for 8-9 VDC between wires "5 AWD" (Pin A) and "4 AWD"
(Pin C).
C. Disconnect the harness at both ends and check for continuity and short circuits.
Problem 4. No change between the normal mode and aggressive mode

("AWD System Functional Test" Step 3.B)
When the machine is moving on level ground with the blade up and the AWD system in the NORMAL MODE, the system
requires little power. However, the AGGRESSIVE MODE requires more power to drive the front wheels faster than the rear.
Therefore, the operator should hear an increase in hydraulic system noise and may hear a change in engine rpm.
If no change exists from the NORMAL MODE to the AGGRESSIVE MODE, install a 6,000 psi (421.8 kg/cm2) gauge to the
right hand test port, in line on the front frame. The pressure reading should be higher in the AGGRESSIVE MODE than in the
NORMAL MODE. If not, continue with the following checks.
1. Measure the right front wheel loaded radius, hub center to ground. The measurement should be the same as an average of
the rear wheels.
2. Check for a minimum of 20 VDC at harness wire "9 AWD" (Pin 7) coming from mode switch with the key switch on and
the mode switch in the AGGRESSIVE MODE.
3. Conduct the checks outlined in "AWD System Functional Test" Step 5.A, 6.A, and Problem 7 (page 20-83).
4. Verify that all previous checks are normal before substituting a new controller.
830B/C-850B/C-870B/C 20-105
12
Problem 5. System appears to lack power
("AWD System Functional Test" Step 3.B)
If the system appears to lack power, it is important to remember that the wheels may stall at maximum power with good trac-
tion, rather than spin. This maximum power situation can occur in either the NORMAL MODE or AGGRESSIVE MODE.
Therefore, it must be verified by conducting the hydraulic system pressure tests.
1. If the charge pressure is low:
A. Check the charge relief/flushing valve in the HIC.
B. Check the charge relief valve at the pump.
C. Check the charge pump.
2. If the override pressure is low in FORWARD:
A. Check the solenoid valve in the HIC.
B. Check the pilot-to-close poppet checks in the HIC.
C. Check the left hand high-pressure relief valve at the pump.
3. If the override pressure is low in REVERSE:
A. Check the right hand high-pressure relief valve at pump.
4. If the override pressure is low in FORWARD and REVERSE:
A. Check the pressure override valve.
Problem 6. Wheels turn when in neutral

This step ensures that the pump is centered in neutral, and that no false signals are causing the pump to stroke. Note that the
AWD system switch is off during this step. If the pump is misadjusted toward the forward direction, it will not turn the wheels
until the HIC solenoid valve is energized by shifting to FORWARD in "AWD System Functional Test" Step 4.B. If either or
both wheels try to turn in either direction, continue with the following checks.
1. Remove the electrical connectors from the pump solenoids and re-test.
A. If the wheels don't turn now, check for voltage energizing one of the pump solenoids from wire "1 AWD," "E
AWD" or "F AWD."
B. If the wheels still turn, adjust the pump "EL module" or servo piston back to neutral. Perform the "Mechanical and
Hydraulic Centering Adjustment Procedures" portion of this manual.
20-106 830B/C-850B/C-870B/C
12
Problem 7. Wheels don't turn either direction
("AWD System Functional Test" Step 5.A, 6.A)
At this point in the test, the wheels are off the ground, the engine at idle, parking/emergency brake released, the service brake
released, the transmission in either sixth gear forward or third gear reverse, and the AWD switch in the NORMAL MODE.
Pushing the test button on the controller simulates a rear sensor signal in the controller. The front wheels should now turn
about 3 MPH and the test lamp should blink green. If they do not turn, continue with the following checks:
If the wheels turn while moving forward but not in reverse, go to Problem 8. If they turn in reverse but not forward, go to
Problem 9.
1. Check the foot brake and brake light, inching pedal, and parking brake circuits. Voltage thru wire "10 AWD" will cause
the system to cut off as if any one of these functions were applied.
2. Disconnect the large, 7-pin connector from the controller. Momentarily connect pin 2, (wire GRD AWD) to pin 3, (wire 1
AWD).
3. If the wheels turn, check the test setup and retest. If the results are the same, then replace the controller.
4. If the wheels don't turn, operate the pump solenoid manually by depressing the pin in the end of shell with the wheels off
the ground, the AWD switch off, and the transmission in neutral.
830B/C-850B/C-870B/C 20-107
12
5. If the wheels still don't turn, check the charge pressure. It should be a minimum of 250 psi (17.6 kg/cm2).
A. If the pressure is normal:
i. Check the main relief valves or pressure override valve (POV).
B. If the pressure is low:
i. Check the HIC charge relief/flushing valve.
ii. Check the charge pump.
iii. Check the charge relief valve in pump.
6. If the wheels turn when manually operating the solenoid, check the system voltage at the transmission harness from wire
"F AWD" (forward) or "E AWD" (reverse), through solenoids and connectors, and through the ballast resistor on wire "1
AWD" to the controller.
Problem 8. Wheels do not turn forward

At this point in the test, the wheels are off the ground, the engine at idle, the parking/emergency brake applied, the foot brake
released, the transmission in sixth gear forward, and the AWD switch in the NORMAL MODE. Pushing the test button on the
controller simulates the rear sensor signal in the controller. The front wheels should turn forward about 3 MPH and the test
lamp should blink green. The wheels should turn in reverse ("AWD System Functional Test" Step 6.A) but not in forward.
1. Measure the voltage across the solenoid coil studs. System voltage comes from the transmission, through the forward
relay terminals 3 and 5 on wire "D AWD."
A. Check the solenoid ground wire (in harness, grounded at cab floor).
B. Check the solenoid coil (resistance approximately 70 ohms).
2. Operate the pump solenoid manually by depressing the pin in end of shell.
A. If the wheels turn now, the problem is electrical.
i. Check for system voltage at the pump solenoid (wire "F AWD" from the transmission harness).
ii. Substitute the pump solenoid coil with a known good one.
B. If the wheels don't turn now, the problem is mechanical.
i. Substitute the HIC solenoid valve with a known good one.
ii. Inspect the pilot-to-close check valves in bottom side of the HIC.
20-108 830B/C-850B/C-870B/C
12
Problem 9. Wheels do not turn in reverse
At this point in the test, the wheels are off the ground, the engine at idle, the parking/emergency brake applied, the service
brake released, the transmission in third gear reverse, and the AWD switch in the NORMAL MODE. Pushing the test button
on the controller simulates a rear sensor signal in the controller. The front wheels should turn forward about 3 MPH and the
test lamp should blink green. If the wheels turn while in forward gear ("AWD System Functional Test" Step 5.A) but not in
reverse, continue with the following checks:
1. Operate the pump solenoid manually by depressing the pin in the shell end.
A. If the wheels turn now, the problem is electrical.
i. Check for system voltage at the pump solenoid (wire "E AWD" from transmission harness).
ii. Substitute a known good pump solenoid coil.
B. If the wheels don't turn now, the problem is mechanical.
i. Inspect the pilot-to-close check valves in the bottom side of the HIC.
ii. Check that the reverse clutch pressure at HIC port "C" is 250 psi (17.6 kg/cm2).
iii. Check the reverse clutch valve at the bottom of the HIC.
Problem 10. Wheels do not stop

("AWD System Functional Test" Step 5.B, 5.C, 5.D, 5.E, 5.F, 6.B, 6.C, 6.D,6.E, 6.F)
Any time the service brake is applied, the inching pedal is depressed, the parking brake is activated, or the transmission is
shifted into neutral, the drive signal is canceled and the wheels should stop. ("AWD System Functional Test," Steps 5.B, 5.C,
5.D, 6.B, 6.C, 6.D and 5.E, 6.E)
If the machine is slowed to a stop without applying the foot brake or shifting the transmission into neutral, the front wheels
should stop and not continue to drive the grader. If the front wheels continue to drive the grader, they can cause the engine to
lug. This condition is simulated at "AWD System Functional Test," Steps 5.F, 6.F.
If the wheels don't stop under any of the previously mentioned conditions, continue with the following checks:
Remark
The "Mechanical and Hydraulic Centering Adjustment Procedures" should have been conducted before
these checks.
1. Check for at least 20 VDC at wire "10 AWD" (pin 6 of the large controller connector). A minimum of 20 VDC must be
present when the foot brake is applied, the inching pedal is depressed, or the parking brake is applied. This condition is
tested during "AWD System Functional Test," Steps 5.B, 5.C, 5.D, 6.B, 6.C, 6.D.
2. Check for at least 20 VDC at wire "12 AWD" (pin 4 of the large controller connector). This condition is tested during
"AWD System Functional Test," Steps 5.E, 6.E.
3. Check that the front sensor is properly adjusted. ("AWD System Functional Test," Steps 5.F, 6.F)
830B/C-850B/C-870B/C 20-109
12
TROUBLESHOOTING
The following data is presented as an aid to locating the source of difficulty in a malfunctioning unit. It is necessary to consider
the torque converter, charge pump, transmission, oil cooler, and connecting lines as a complete system when running down the
source of trouble, since the proper operation of any unit therein depends greatly on the condition and operation of the others.
By studying the data in this section, it may be possible to correct any malfunction that may occur in the system.
wires for wear and/or abrasions which would short the circuit. Wires may have internal breaks which can only be detected by
use of an ohmmeter or similar device. When the possibility arises that a switch or other component is bad, check the wires for
continuity. They are numbered with bands at each end to help trace them. Replace if necessary.
Remark
Be sure that terminal ends are crimped solidly, screws are tight and that contact surfaces are not corroded.
RIGHT AND LEFT CONTROL VALVE

PROBLEM POSSIBLE CAUSE CORRECTION
One secondary function is defective while all Control linkage not allowing spool valve to Free the control linkage.
other functions are normal. move.
External linkage between the valve Damaged O-ring. Replace the O-ring.
sections
Improper tie rod torque. Check the torque on the tie rods.
Excessive work port leakage. Spool not fully centered. Check the linkage to ensure that the spools
are centered.
NOTE: In neutral, the valve’s load sense port
should register return line pressure. If not, the
spool may be uncentered.
Load sense seal between the inlet section and Inspect the seal.
the first spool section leaking.
Improper tie rod torque. Check the torque on the tie rods.
Spool flow too high or too low Spool not fully stroked (low flow). Check the linkage to ensure spools are cen-
tered.
Improper differential pressure between the Check the standby pressure and the load
inlet and load sense ports. sense plumbing.
Inadequate pump supply. Check the pump displacement.
NOTE: This symptom usually registers nor-

mal inlet/load pressures at the start of the
spool stroke. And the end of the spool stroke
results with decreasing pressures.
Inadequate pump supply. Low fluid level. Add fluid to the correct level.
Unable to operate two sections simulta- Loss of inlet/load sense differential pressure. This situation can occur when the pump com-
neously. pensator or relief setting is overloaded.
Ensure that the relief valve is set to 230 psi
(16.2 kg/cm2).
Fluctuating or unstable differential pressure Check the load-sense line between the valve
between the valve’s inlet and load-sense and pump for crimps or blockage.
ports.
Check the pump compensator.
Check that the supply flow maintains ade-
NOTE: Symptoms normally display them- quate pressure differential pressure.
selves in all sections within the valve stack, if
this cause is the problem.
Manual valve spool position changes Check the linkage for proper operation.
erratically.
20-110 830B/C-850B/C-870B/C

Excessive pressure in neutral. Load-sensing cartridge plugged. Inspect the cartridge for contamination.
Clean or replace the cartridge.
Spools not fully centered. Check the linkage to ensure that spools are
centered.
Both right and left control valve banks The screen located in the left control valve Clean the screen.
functions are sluggish. bank inlet section may be clogged.
NOTE: All sensor line pressure signals to

both control valves must pass through this
screen. If it is clogged, back pressure to the
pump compensator assembly will destroke
the main system pump, causing low flow.
All right control valve bank functions are The shutoff located in the outlet section of the Tighten the shutoff plug to 30 to 50 lbf ft.
sluggish. right control valve bank is not seated. (4.1 to 6.9 kg•m). This action ensures that the
plug is fully seated in the outlet section of the
right control valve bank.
NOTE: If this plug is loose, the system will
go into a condition where main system pres-
sure enters the sensor line portion of the cir-
cuit. This action will destroke the main
system pump, causing low flow.
All left control valve bank functions are The shutoff located in the outlet section of the Tighten the shutoff plug to 30 to 50 lbf ft.
sluggish. left control valve bank is not seated. (4.1 to 6.9 kg•m). This action ensures that the
plug is fully seated in the outlet section of the
left control valve bank.
NOTE: If this plug is loose, the system will
go into a condition where main system pres-
sure enters the sensor line portion of the cir-
cuit. This action will destroke the main
system pump, causing low flow.
830B/C-850B/C-870B/C 20-111
12
MOLDBOARD TILT CYLINDER
Actuating the blade shift cylinder moves the The seals in the swivel block allow the Replace the seals in the swivel block.
moldboard tilt cylinders. hydraulic oil to be redirected to the mold-
board circuit. However, the opposite could
happen, too.
Actuating the moldboard tilt cylinders causes Lack of lubricant on the ball caps, pivot Clean and lubricate as outlined in the Opera-
erratic or jerky movement. points, or both. tor’s Manual.
BLADE SHIFT CYLINDER

Actuating the moldboard tilt cylinders moves The seals in the swivel block allow the Replace the seals in the swivel block.
the blade shift cylinder. hydraulic oil to be redirected to the blade
shift circuit. However, the opposite could
happen, too.
Actuating the moldboard tilt cylinders causes Lack of lubricant on the ball caps, pivot Clean and lubricate as outlined in the Opera-
erratic or jerky movement. points, or both. tor’s Manual.
HYDRAULIC CYLINDERS
Excessive leakage from the cylinder fittings. Loose fittings. Tighten the fittings.
Damaged fittings. Replace the fittings.
Damaged hoses. Replace the hoses.
Excessive leakage around the cylinder rod. Damaged cylinder seal. Replace the rod seal.
Cylinder binds while extending or retracting. Bent cylinder rod. Replace the cylinder.
Cylinder slips while extending. Damaged piston seals. Replace the seals.
Inside of cylinder scored or damaged. Replace the cylinder.
20-112 830B/C-850B/C-870B/C
12
Circle needs lubrication or is out of Lubricate or adjust the circle. Refer to the
Circle lacks power or will not move while all adjustment. appropriate section for circle adjustment.
other functions are normal.
Circle reverse motor is defective. Repair or replace the circle reverse motor.
Check & replace damaged fittings or O-rings.
Hose fittings loose, worn or damaged Torque to manufactures specifications.
Oil seal rings deteriorated by excess heat Replace oil seal rings by dissembling unit
Loosen, then tighten single bolt to torque
Oil leakage Special bolt loose or its sealing area requirements
deteriorated by corrosion
Replace bolt
Internal shaft seal worn or damaged Replace seal
Worn coupling shaft and internal seal Replace coupling shaft and seal
Check for faulty relief valve and adjust or
replace as required
Lack of sufficient oil supply Check for and repair worn pump
Check for and use correct oil for temperature
of operation
Significant loss of speed under load High internal motor leakage Replace worn rotor set
Replace rotor set, drive link and coupling
Severely worn or damaged internal splines shaft
Locate excessive heat source (usually a
Excessive heat restriction) in the system and correct the
condition
Line blockage Locate blockage source and repair or replace
Disassemble unit, identify and remedy cause
Internal interference
Low mechanical efficiency or undue and repair, replacing parts as necessary
high pressure required to operate unit Lack of pumping pressure Check for and repair worn pump
Excessive binding or loading in system exter- Locate source and eliminate cause
nal to unit
830B/C-850B/C-870B/C 20-113
12
AWD PUMP
To aid in troubleshooting, refer to the diagnostic port connections for test gauge installation information. Procedure assumes
gauges are installed. This procedure was written to aid the troubleshooter in following a logical approach to a system fault.
1. TRANSMISSION DOES NOT DRIVE WITH THE PRIME MOVER RUNNING
No Fill reservoir
1.1 Is there oil in the reservoir?
Yes Proceed to step 1.2
No Engage clutch
1.2 Is engine clutch engaged?
No Correct the piping
1.3 Is the hydraulic piping in accordance with the hydraulic circuit?
No Fit pump having the correct direction of rotation
1.4 Is the pump direction of rotation correct?
No Proceed to step 1.6
1.5 Is there a broken pipe, loose fitting or burst hose?
Yes Repair the fault
No Check brake release circuit or mechanism
1.6 Are the brakes released?
Charge pump and relief valve:
1.7 Is there any charge pressure at port G?
Is the charge pressure at specification while the pump is running No Proceed to step 1.9
1.8
at normal operating speed? Yes Proceed to step 1.19
Can the charge pressure be adjusted at the charge No Proceed to step 1.10
1.9
pressure relief valve? (Refer to relief valve adjustment) Yes Adjust charge pressure to specification and proceed to step 1.19
Remark
If flushing valve is used in circuit, it should be set at 50 psi less than charge pump relief. Refer to data sheet on flushing
valve for information and setting procedure.
No Open valve
1.10 Is suction line shut-off valve open?
Is the charge pump suction pressure within No Proceed to step 1.12
1.11
recommended limits? (-3.2 psig or 6.5 in Hg vacuum) Yes Proceed to step 1.16
1.12 Is suction filter element plugged?
Yes Replace filter element
Does the reservoir design ensure that suction pipe is always No Correct the reservoir design
1.13
covered with oil? Yes Proceed to step 1.14
Run at lower speed and return to point 1.7 or rework suction
No
1.14 Is the suction pipe size adequate for the flow? piping
1.15 Is the reservoir air breather blocked or undersized?
Yes Clean or replace air breather
Remove charge pressure relief valve cartridge and inspect. Is it No Refit cartridge and proceed to step 1.17
1.16
damaged? Yes Fit a new cartridge and return to step 1.7
1.17 Remove and inspect charge pump assembly. Is it damaged? Repair or replace damaged components and return to step 1.7
Yes
Note: Replace charge pump as complete unit
Refit charge pump by rotating pump housing 180°, return to
No
step 1.7
1.18 Is the charge pump installed for correct direction of rotation?
With proper charge pressure and transmission still does not
Yes
operate, proceed to step 1.19
20-114 830B/C-850B/C-870B/C
Pump control:
Is control medium connected to pump control? HD - pilot Connect appropriate medium and check that control signal is
No
1.19 pressure, HW - mechanical cable or EL 12 or 24 volts DC actually being applied to the control valve
electrical current Yes Proceed to step 1.20
If variable displacement motors are installed, is maximum No Select maximum displacement
1.20
displacement selected? (If not done automatically) Yes Proceed to step 1.21
1.21 Actuate the control in both directions. Does pump stroke?
Yes Operate the transmission
Stroke the pump in both directions. Do the pressure at X3 and No Remove and replace control module. Repeat step 1.21
1.22
X4 alternate between 30 and 250 psi during cycle? Yes Proceed to step 1.23
Re pipe pump case drain line so that case pressure at port R is
No
1.23 Is the pressure at port R less than 21 psi? less than 21 psi. Return to step 1.21
Stroke pump in both directions. Does any pressure greater than Verify that loading of the pump will cause system pressure to
No
1.24 350 psi alternate between ports MA and MB? increase above charge pressure. Proceed to step 1.19
Replace high pressure relief valve cartridges and return to step
Is it possible to adjust high pressure relief valves using the 0 - No
1.21
1.25 10,000 psi gauges at MA and MB to monitor pressure? (Refer to
Adjust high pressure relief valves to required or designed
relief valve adjustment) Yes
pressure. Proceed to step 1.26
Check if motor sizing is adequate for application. Check for
No
1.26 Actuate control in both directions. Does transmission run? mechanical faults in the drive beyond the motor shaft.
Yes Operate the transmission
2. TRANSMISSION DRIVE IS SLUGGLISH OR ERRATIC
Is the control medium in good condition? Recife the control fault. HD - bleed pilot lines, HW - Lubricate
No
For example: Control medium is not in good condition if HD or free the cable or linkage, EL - check control current
2.1
control-air in pilot lines, HW control-sticking cable or linkage,
EL control-fluctuating control current.
No Check brake release circuit or mechanism
2.2 Are the brakes fully released?
Remove the plugs in ports X1 and X2 and remove control
Are the stroking time orifices correctly sized for the No orifices with screw drive. Try various sizes until desired pump
2.3
application? stroking rae is attained
Change spring to suit. AA4V pump - curve 05 or 06 of 4TH7
With HD control, is the control curve of remote pilot valve No
2.4 pilot operator
correctly matched to the pump?
Does the charge pressure fluctuate more than 30 psi when No Proceed to step 2.9
2.5
stroking the pump? Yes Proceed to step 2.6
If the charge pump output is used to operate auxiliary functions. No Proceed to step 2.8
2.6
Do these other functions cause fluctuations in charge pressure? Yes Proceed to step 2.7
Isolate the auxiliary function and run the transmission. Are the No Proceed to step 2.8
2.7
charge pressure fluctuations reduced or eliminated? Yes Operate transmission and return to step 2.1
Are there system pressure fluctuations which are synchronous No Proceed to step 2.9
2.8
with the charge pressure fluctuations? Yes Determine the cause of system pressure fluctuations.
Add motor stroking time adjustment valve tot he variable motor
If variable displacement motor is used, is motor stroking time No or modify the control circuit to provide desired stroking time.
2.9
correct for the application?
--- ---
830B/C-850B/C-870B/C 20-115
3. TRANSMISSION DRIVES IN ONE DIRECTION ONLY

With control lines switched, does pump drive in the opposite
3.1 Control signal from one side does not work properly. Repair as
direction only? Yes
necessary
With control lines still switched, does pump drive in initial
3.2 Problem is in one side of control module or the pump. Proceed
direction only? Yes
to step 3.3
No Correct control signal problem
3.3 Is there control pressure or current from both control lines?
Check flushing valve (if installed). Is shuttle spool stuck in one No (Not installed) Proceed to step 3.5
3.4
position? Yes Remove flushing; valve, clean or replace
Switch relief valves. Does transmission drive in the other No Proceed to step 3.6
3.5
direction only? Yes Repair or replace relief valve on non-driving side
Replace control module and reconnect control lines. Does pump No Replace or repair pump
3.6
operate properly? Yes Operate transmission
4. TRANSMISSION DRIVES IN THE WRONG DIRECTION
4.1 Pump with HD control Switch control lines on ports Y1 and Y2
4.2 Pump with EL control Switch electrical connectors on solenoids A & B
4.3 Pump with HW control Remark linkage or cable to give correct drive direction
5. PUMP DOES NOT FIND OR HOLD NEUTRAL
5.1 Does pump return to neutral with control lines removed? Check control for electrical signal problem (EL control) or back
Yes
pressure in the pilot lines (HD control)
Check mechanical centering of pump and control. Does pump No Repair or replace pump
5.2
return to neutral with control lines removed? Yes Replace control module if needed. Operate transmission
6. TRANSMISSION DRIVES AT A HIGH NOISE LEVEL
No Fill gear box with correct grade of oil to the prescribed level
6.1 Are the drive gear boxes filled with correct grade of oil?
No Install coupling per manufacturer’s instructions and tolerances
6.2 Is the drive coupling correctly installed and aligned?
6.3 Is rigid piping connected to the pump? Install short length of hose between pressure ports of the pump
Yes
and the system piping
Is the suction pressure at the charge pump inlet within No Return to step 1.7
6.4
recommended limits? Yes Proceed to step 6.5
Is there air in the hydraulic oil? This may be indicated by No Proceed to step 6.6
6.5
foaming or milky colored oil. Yes Deairate oil and inspect system for cause of air induction
Check motor sizing in relation to available oil flow from the
6.6 Is the hydraulic motor operating at excessive speed? Yes
pump
7. TRANSMISSION OPERATES AT A HIGHER THAN NORMAL TEMPERATURE
195° F is the upper limit. If temperature is close to 195° F, the
No
7.1 Is the operating temperature above 195° F? oil cooler may need to be cleaned
7.2 Is the hydraulic motor stalling intermittently? Hydraulic oil is being heated through system relief valves. Shut
Yes
down system and rectify cause of the motor stall
Does temperature remain above 195° F after cleaning oil No Operate transmission. Check oil cooler
7.3
cooler? Yes Proceed to step 7.4
20-116 830B/C-850B/C-870B/C
Check differential pressure across oil cooler as compared to the No Proceed to step 7.
manufacturer’s specs at charge pump flow.
7.4
Is ∆ P higher than it should be? Yes Check piping from oil cooler to the reservoir
Note: Max. pressure is 30 psi
Disconnect pump case drain from oil cooler and check flow No Refer to charge pump remove and inspection procedure
7.5
from charge pump. Is flow normal? Yes Check oil cooler location
8. PUMP DOES NOT DEVELOP MAXIMUM HORSEPOWER (FLOW & PRESSURE)
No Return to 1.9
8.1 Is the charge pressure at least 320 psi measured at port G?
Yes Proceed to 8.2
Check sizing of return lines from T port of pump and the cooler
No
8.2 Is the case pressure less than 30 psi? sizing related to flow
Yes Proceed to 8.3
Are the high pressure relief valves adjusted to t he required No Adjust or replace relief valve cartridge
pressure so that they do not by-pass?
8.3
Note: If pressure override valve is fitted to the pump, check that Yes Replace the pump
pressure setting is sufficient for the application.
830B/C-850B/C-870B/C 20-117
12
AWD HYDRAULIC MOTOR
Fill the tank with the recommended oil, but
do not overfill the tank or damage results.
Low oil level in the hydraulic oil tank. Please refer to the Operator’s Manual for the
specified oil and filling procedure.
Open the hydraulic oil tank and operate the
system until purged.
Air in the system. Bleed the hydraulic lines at the highest point
Excessive noise. downstream of the pump while the system is
pressurized.
Vacuum condition. Check the suction lines and fittings for leaks.
Drain the system and refill with the correct
Thick oil. viscosity oil.
Run the hydraulic system until the unit is
Cold weather. warm to the touch and the noise disappears.
Internal leakage. Return the grader to the shop for repairs.
Overheating. Heat exchanger not functioning. Repair or replace the heat exchanger.
Fluid level low. Add the specified oil.
One or both relief-replenishing valves are Replace one or both valves as needed.
stuck open.
No system pressure.
Internal fluid loss, slippage, or cylinder block Return the grader to the shop for repairs.
lift (motor overspeed).
• Ruptured hydraulic hose(s). Check all external connections, tubing, and
Fluid loss. • Loose fitting(s). hoses. Tighten the connections and replace
the defective gasket(s) or seal(s).
• Leaking gasket(s) or seal(s).
Miscellaneous. Drive mechanism broken or disconnected. Locate and repair.
20-118 830B/C-850B/C-870B/C
12
Oil too viscous. Change oil to proper viscosity.
Suction strainer or filter plugged. Clean or replace.
Noisy pump caused by cavitation.
Clean the line and check for proper size and
Suction line plugged, too small, or too long. length.
Oil supply low. Fill the reservoir.
Air leaking into the suction line. Tighten the fittings.
Noisy pump caused by aeration.
Drain the reservoir and fill with nonfoaming
Oil foams. type oil.
Drain the system and refill it with the proper
Oil too thin. viscosity oil.
Disconnect the case, drain the line. Measure
Hydraulic system overheating. the leakage volume while pressurizing the
Excessive internal leakage. hydraulic system. The case drain flow should
not exceed 3 G.P.M. If it does, repair the
pump.
Aerated oil. Tighten the hydraulic fittings.
the leakage volume while pressurizing the
pump.
Disassemble the compensator. Inspect if the
System not developing adequate pressure. Compensator spool stuck open. spool is stuck open. Clean or replace the
compensator assembly.
Compensator spring weak or broken. spring is weak or broken. Replace the spring,
if needed.
Check the signal line connections. Check the
No flow compensator signal. signal line for obstructions or damage.
the leakage volume while pressurizing the
pump.
Compensator spool stuck open. spool is stuck open. Clean or replace the
Insufficient system flow. compensator assembly.
Compensator spring weak or broken. spring is weak or broken. Replace the spring,
if needed.
Pump cavitation. Change the oil to the proper viscosity.
Check the signal line connections. Check the
No flow compensation signal. signal line for obstructions or damage.
830B/C-850B/C-870B/C 20-119
12
Damaged O-ring. Replace the O-ring.
External leakage between the sections.
Improper tie rod torque. Check the torque on the tie rod nuts.
Spool not fully centered.
Check linkage to ensure that spools are
NOTE: In neutral the load-sense port of a centered in neutral.
valve should register return line pressure. If it
does not, it may indicate that a spool is
uncentered.
Excessive work port leakage. Excessive spool to bore clearance. Replace the spool.
Insufficient oil viscosity used during high oil
temperature.
Reduce the work load and change the oil with
the proper viscosity oil.
NOTE: Spool leakage is directly proportional
to the oil viscosity.
Relief valve or pump controller pressure
levels set too low. Check the pressure levels.
Relief valve not seating. Inspect the relief valve for contamination.
Check the load-sense line for crimping or
blockage.
Unable to build pressure at the work port. Load-sense signal to the pump too low.
Check the load-sense bleed cartridge in the
valve or pump for excessive draining.
Load-sense seal between the inlet section and Inspect the seal.
the first spool section leaking.
Improper tie rod torque. Check to ensure the correct torque.
Check the linkage to ensure the spools are
Spool not fully stroked (low flow). centered in neutral.
Improper differential pressure between the Check the standby-pressure setting and
inlet and load-sense ports. load-sense plumbing.
Supply from the pump not adequate to obtain
Spool flow too high or too low. flow.
NOTE: This cause will usually indicate itself Check the pump displacement.
by exhibiting normal inlet/load-sense
differential pressures at the start of the spool
stroke, with falling differential pressures at
the end of the spool stroke.
Supply from the pump inadequate to obtain Low fluid level. Fill the fluid to the correct level.
flow.
This situation can occur when the pump
compensator or relief setting is overloaded.
This problem can be remedied by the
Unable to operate two sections Loss of inlet/load-sense differential pressure. installation of a load-sense relief valve in the
simultaneously. valve or hydraulic system. This valve is set to
about 200 psi (14.1 kg/cm2) below the
maximum system pressure.
Fluctuating or unstable differential pressure Check the load-sense line between the valve
between the valve’s inlet and load-sense port. and pump for crimps or blockage.
Check the load-sensor pump controller.
NOTE: If this is the possible cause, Check supply flow for adequate
Erratic work port flow. symptoms will generally exhibit themselves
in all sections within the valve stack. maintained differential pressure.
Spool position changing erratically
Check the linkage for proper operation.
- manual valves.
Inspect the cartridge for contamination,
Load-sensing cartridge plugged. clean, inspect, and replace, if necessary
Excessive pressure in neutral.
Check the linkage to make sure the spools are
Spools not fully centered. centered.
20-120 830B/C-850B/C-870B/C
MAIN SYSTEM PUMP

Drain the oil and fill the system with the
Oil too viscous. proper viscosity oil.
Noisy pump caused by cavitation. Suction strainer or filter plugged. Clean the strainer and replace the filter.
Suction line plugged or collapsed. Clean or replace the line.
Air leaking into the suction line. Tighten the fittings.
Noisy pump caused by aeration.
Drain the reservoir and fill it with nonfoam-
Foaming oil. ing-type oil.
Oil viscosity insufficient. proper viscosity oil.
Disconnect the case drain line. Measure the
Hydraulic system overheating. leakage volume while pressurizing the
Excessive internal leakage. hydraulic system. Case drain flow should not
exceed 3.2 GPM (22.7 LPM). If excessive,
remove the pump and repair it.
Oil aerated. Tighten the fittings.
leakage volume while pressurizing the
Disassemble the compensator and inspect for
System developing inadequate pressure. Compensator spool stuck open. a stuck spool. Clean or replace the compensa-
tor assembly.
Compensator spring weak or broken. a weak or broken spring. Replace the spring,
if needed.
Check the signal line connections. Check for
Loss of compensator signal. line obstruction and damage.
leakage volume while pressurizing the
Compensator spool stuck open. a stuck spool. Clean or replace the compensa-
tor assembly.
System developing inadequate flow. Compensator spring weak or broken. a weak or broken spring. Replace the spring,
if needed.
proper viscosity oil.
Pump cavitation. Clean or replace the filtering screen on the
inlet line inside the tank.
Clean or replace the inlet line.
Check the signal line connections. Check for
Loss of flow compensator signal. line obstruction and damage.
830B/C-850B/C-870B/C 20-121
12

No flow in all functions No oil in the system. Add oil.
Low or no sensor line signal to the pump Unplug the sensor line.
compensator.
Defective pump compensator assembly. Repair or replace the compensator.
Defective main system pump. Repair or replace the pump.
All secondary functions slow or inoperable. Hydraulic oil tank level low. Add oil.
Low or no signal to the pump compensator Unplug the load sensor line.
Defective pump compensator. Repair or replace the compensator.
Defective pump. Repair or replace the pump.
20-122 830B/C-850B/C-870B/C
TROUBLESHOOTING TRANSMISSION POWER SHIFT
12
When the LED flashes an error code, the transmission automatically shifts to Neutral despite the gearshift remaining at the
selected position. Thus, the machine cannot move. Move the gearshift to the Neutral position to coincide with the transmission
being in neutral, and which also clears the controller's memory. After clearing the controller's memory, the transmission gears
can once again be engaged. To determine if the problem is a “glitch” or one-time occurrence, reposition the gearshift to the
desired gear range and continue with the operation. If the LED flashes again, count the number of flashes because a problem
exists. See the following table for a diagnostic interpretation of the LED flash code, and make the needed repairs. After
repairing the problem, clear the controller's memory before returning the machine to service.
Time needed in park
Error
Description LED response or Neutral to clear Action
code
the error code
A Hall sensor may have failed or a 1 flash, 2 second pause
1 1.5 seconds Replace the shifter
magnet may have fallen out. before LED flashes again.
Using an allen wrench, loosen the
24-pin connector at the shifter. Turn
the ignition switch on. Using a
voltmeter, probe the wiring harness
One of the output lines to the battery 2 flashes, 2 second pause
2 2.5 seconds pins and determine if there is a posi-
has shorted. before LED flashes again.
tive voltage on pins 7, 8, 12, 13, 18,
19, 20, 21, 22, 23 or 24.
Determine cause of positive voltage
and correct.
Remove the shifter connector using a
hex allen wrench. With a volt meter
probe the wiring harness pins and
One of the output lines to ground has 3 flashes, 2 second pause
3 1.5 seconds determine if there is a short to ground
shorted. before LED flashes again.
on pin's 7, 8, 12, 13, 18, 19, 20, 21,
22, 23 or 24. Determine the cause of
the short circuit and correct.
The signal to the processor is lost.
Return the gearshift to Neutral. If the
There is an unknown source for the 4 flashes, 2 second pause
4 4.5 seconds source does not clear, replace the
interrupt. If the problem does not clear, before LED flashes again.
shifter.
the unit is nonfunctional.
The unit has failed if this condition
Stays on continuously. No
5 cannot be cleared by powering the Will not clear Replace the shifter
flashes or pauses.
system off and on.
830B/C-850B/C-870B/C 20-123
12
The following data is presented as an aid to locating the source of difficulty in a malfunctioning unit. It is necessary to consider
the torque converter, charge pump, transmission, oil cooler, and connecting lines as a complete system when running down the
source of trouble, since the proper operation of any unit therein depends greatly on the condition and operation of the others.
By studying the data in this section, it may be possible to correct any malfunction that may occur in the system.
wires for wear and/or abrasions which would short the circuit. Wires may have internal breaks which can only be detected by
use of an ohmmeter or similar device. When the possibility arises that a switch or other component is bad, check the wires for
continuity. They are numbered with bands at each end to help trace them. Replace if necessary.
Remark
Be sure that terminal ends are crimped solidly, screws are tight and that contact surfaces are not corroded.

Low oil level. Add oil to proper level.
*Pump gasket not sealing. Replace gasket.
*O-Ring on sump tube not sealing. Replace O-ring.
Erratic oil pressure.
*Oil passage cover plate leaking in front Replace seal, apply sealant per instructions in
cover. assembly manual.
Remove object and check for other contami-
Foreign object in suction port. nation.
* = Some indications of a suction leak are:

● Erratic oil pressure (rapid fluctuation of gauges).
● Pump and filter hoses jumping.
● Excessive air in the transmission oil.
● A long prime time (time elapsed from engine start to an indication of pump pressure).
Remark
To determine if a suction leak exists, fill the transmission with transmission fluid. Then start the engine to see
if there is an indication of erratic oil pressure. If none, a suction leak probably exists.
WARNING! Do not neglect to drain the transmission to the correct level after the test. Failure to do
so will result in poor performance and overheating.
20-124 830B/C-850B/C-870B/C
12
Excessive amount of regulator valve shims. Install the correct amount of shims.
Check the main regulator for contamination
Excessive oil pressure. Sticking main regulator valve. and clean the orifice.
Faulty spring. Change the spring.
Sticking main regulator valve. Clean the main regulator valve.
Oil pressure set too low. Add shims (5 maximum).
O-ring on charge pump mount defective. Replace the O-Ring.
Low oil pressure.
Charge pump defective. Replace the pump.
Internal disconnect seal damaged or installed Replace the seal and install correctly.
incorrectly.
Disassemble and clean the entire control
**Contaminated solenoid valve spool. valve. Replace the filter and transmission
fluid.
Low pressure in one gear but all right in **Broken wire to one solenoid, or dirty con- Repair the wire (see solenoid chart for
other gears. nection. electrical valves and locations).
**Broken seal ring on the input end of the Replace the seal ring.
clutch assembly.
**Clutch pack shaft piston seals leaking. Replace the seals.
WARNING! ** If a solenoid is removed from the valve, the solenoid has to be reinstalled in the same
location.
Remark
**Determining which clutch is defective is a process of elimination. For example, if the gear selected uses
solenoids 6 and 3, and low pressure is indicated, select another clutch that uses one of those solenoids. If
pressure is good, then the solenoid or clutch not selected is the one that is bad. To confirm that this is the
faulty circuit, select another clutch that uses this solenoid, to assure that the discrepancy is actually in this
solenoid or clutch.
EXAMPLE:
Clutch Selected Indication
Uses solenoids 6 & 3 Low pressure Solenoid or clutch 6 or 3 is defective.
Uses solenoids 5 & 3 Pressure O.K. Solenoid or clutch 6 probably defective.
Uses solenoids 6 & 2 Low pressure Confirms that the solenoid or clutch 6
is defective.
830B/C-850B/C-870B/C 20-125
12
Voltage to wrong solenoids on the
Check the wiring and connectors.
control valve - see schematic.
Check the wiring, controller and
Vehicle will not move, but all pressures are No voltage to all solenoids. connectors.
normal.
Voltage to all solenoids. Check the wiring and controller.
Inspect, clean and replace if
Solenoid valve spool stuck.
necessary. Replace the oil and filter.
Converter bypass valve defective. Replace the converter bypass valve.
Low or no converter pressure. Converter hub seal ring not sealing. Replace the seal ring.
Converter bypass valve plug left out. Install the plug.
Hose bends are too sharp. Reroute the hoses.
Filter or filter lines blow out. Defective hose. Replace the hose.
Main regulator valve struck. Clean the valve and change the filter and oil.
Contaminated solenoid valve spool. Clean the valve and replace the oil and filter.
Accumulator spring too strong. Replace the spring.
Clutch pressure does not return to
normal. Primary pump defective. Replace the primary pump.
Inspect the seal ring, piston seals and all
Excessive internal leakage to the clutch.
sealing surfaces.
Charge pump defective. Replace the pump.
Replace the bearings and inspect for defec-
Excessive noise. Excessive backlash in gear.
tive gears.
Auxiliary drive pump bad. Remove the pump and check for noise.
Establish the proper oil level. (Check the
Transmission overfilled with oil. front seal on auxiliary driven hydraulic
Blows oil out of breather or dipstick. pump if installed.)
Remove the transmission and install a new
Converter seal ring broken.
seal ring on the converter hub.
Converter stalling. Shift to a lower gear.
Establish the proper oil level. (Check front
Oil level to high. seal on auxiliary driven hydraulic pump if
installed.)
Transmission overheating. Engine overheating. Check the engine coolant.
Water line defective on heat exchanger. Replace the lines.
Heat exchanger dirty. Clean the heat exchanger.
Clutch slipping. Check the clutch pressure.
Converter sprag clutch damaged or installed Disassemble the converter and inspect. (See
Transmission pressure checks okay, but has wrong. assembly manual for correct installation.)
no power and possibly overheating.
Converter relief valve broken. Replace the relief valve.
Converter front cover seal leaking. Replace the seal.
Converter hub seal or O-ring damaged. Replace the seal.
Oil leaking from engine flywheel and/or Bearing retainer plate gasket leaking. Replace the gasket.
weep hole in transmission bell housing. Check the engine flywheel offset dimension
Converter not properly positioned within bell
and the converter pilot bushing length,
housing, causing converter and seal to leak.
against vehicle manufacture standards.
20-126 830B/C-850B/C-870B/C
TROUBLESHOOTING TANDEM CASE
12
TANDEM CASE

Sprockets misaligned. Misalignment causes Check the sprocket alignment.
abnormal loading and wear.
Find the cause of inadequate lubrication at
Inadequate lubrication. the pin/bushing contact areas.
Replace the worn bearings as soon as possi-
Worn bearings. ble. Worn bearings cause drive-system
Excessive noise. misalignment.
Worn chain or sprocket. Replace both the chain and the sprocket.
Chain travel obstructed. Remove the obstruction.
Chain joints tight. Replace the stiff links.
Heavy and pulsating load. Reduce the load.
Insufficient amount of oil. Increase the volume of oil
Chain drive running hot. Chain continually rubbing against an Remove the obstruction and prevent the chain
obstruction. from vibrating.
Worn chain or sprockets. Replace both the chain and sprockets.
Chain climbing or jumping sprocket teeth. Material build-up in the sprocket tooth Remove the material build-up.
pockets.
Worn chain or sprockets Replace the chain and sprockets if needed.
Chain stiffens, starts to whip.
One or more stiff chain joints Remove or repair stiff links.
If possible, eliminate the cause of pulsations.
Pulsating drive condition can also initiate link Check
Link plate fails. for excessive slack in the chain,
plate failure. indicating worn sprockets; replace, if worn.
Worn roller link Drive misalignment usually causes wear Check and correct, if needed, the sprocket
plates. pattern A. and shaft alignment.
The chain rubbing against the case or other Eliminate the source of rubbing. Remove the
obstruction usually causes wear pattern B. obstruction or control of slack strand.
830B/C-850B/C-870B/C 20-127
TROUBLESHOOTING FINAL DRIVE ASSEMBLY
12
WITH NoSPIN AND LOCK/UNLOCK DIFFERENTIAL

Insufficient amount of lubricant. Add lubricant as needed.
Loss of lubricant
Replace the lubricant with the correct type
Incorrect type of lubricant. and viscosity.
NOTE: If a sudden loss of lubricant in the A loose drain plug. Tighten or replace the plug.
differential is detected, check the oil level in
the tandem cases. If the oil level in the tan- Cracked case. Repair or replace the case.
dem case has risen above the normal level, Oil seal failure. Replace the seal(s).
the axle shaft seal has failed.
Incorrect bolt torque. Retorque the bolts.
Worn bearings. Replace the bearings.
Damaged or worn parts. Replace the parts as needed.
Excessive and continuous noise. Loss of lubricant. See above "Loss of Lubricant."
Damaged or worn final drive or planetary Replace the gears as needed.
pinion gear.
See "Pinion Gear Cone Point Adjustment"
Excessive noise only under load. Bevel pinion shaft adjustment too tight. and "Pinion Gear Endplay Adjustment" in
section 20.
Worn bearings. Replace the bearings.
Excessive noise only without a load. See "Pinion Gear Cone Point Adjustment"
Bevel pinion shaft adjustment too loose. and "Pinion Gear Endplay Adjustment" in
section 20.
See “Pinion Gear Cone Point Adjustment”
Bevel pinion shaft adjustment too tight. and “Pinion Gear Endplay Adjustment” in
section 20.
Loss of lubricant. See above "Loss of Lubricant."
Excessive heat only under load. Excessive amount of lubricant. Drain the excess lubricant.
Insufficient amount of lubricant. Add lubricant as needed.
Replace the lubricant with the correct type
Incorrect type of lubricant. and viscosity.
Oil level above the differential plug indicates Check the brake piston seals. Replace the inner and outer piston seals.
the hydraulic oil mixed in with axle lubricant.
Check the O-ring located between the differ- Replace the O-ring.
NOTE: Low brake pressure may also indicate ential case and cover.
that the seals are leaking.
Axle lubricant leaking from between the final Improper bolt torque. Tighten the bolts to the specified torque
drive housing, spacer and/or ring gear, and value.
the differential case. Insufficient sealer between the parts. Disassemble and reseal.
20-128 830B/C-850B/C-870B/C
TROUBLESHOOTING PARKING BRAKE CALIPER
12
Parking/emergency brake release valve was Open the parking/emergency brake release
left closed, preventing the hydraulic oil valve.
pressure from releasing the brake.
Check for electrical power to the brake
solenoid valve (located in the junction block).
NOTE: If power to the solenoid valve is not

detected, check the switch in the shift console
and shifter.
Check that the solenoid valve is not stuck.
Remove and clean.
Malfunctioning brake solenoid valve.
WARNING! Relieve the pressure in
the accumulators.
Parking/emergency brake does not release. Check the seals and replace, if necessary.
WARNING! Relieve the pressure in

the accumulators.
Hydraulic oil on the caliper indicates the

seals in the parking/emergency brake caliper Remove the caliper and replace the seals.
are leaking.
Air in the system. Bleed the hydraulic circuit.
Steering and brake system not developing
sufficient pressure. Check the steering and brake system
pressure. See the “Hydraulic
NOTE: This problem will also result in loss Troubleshooting” section for the test
of steering and/or sluggish steering and procedure.
inadequate service brakes.
Worn brake pads. Replace the brake pads.
Broken or cracked Belleville washers Replace the washers (springs).
Parking/emergency brake does not hold. (springs).
Oil on the pads. Replace the pads.
830B/C-850B/C-870B/C 20-129
TROUBLESHOOTING PARKING BRAKE CALIPER
12
MEMORANDUM
20-130 830B/C-850B/C-870B/C
PREDELIVERY PROCEDURES
12
PREDELIVERY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-203
CHECKS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-203
FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-203
AIR CLEANER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-203
AIR INDUCTION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-204
TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-204
SERVICE INDICATOR SAFETY FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-205
RADIATOR HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-206
FUEL LINES AND FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-207
WATER TRAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-207
TRANSMISSION FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-207
TRANSMISSION FILL PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-207
HYDRAULIC OIL TANK LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-207
HYDRAULIC OIL AND FUEL TANK FILL POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-208
TANDEM CASE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-208
TANDEM CASE BREATHER/FILL POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-208
CIRCLE REVERSE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-208
CIRCLE REVERSE FILL POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-209
REAR AXLE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-209
REAR AXLE OIL FILL POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-209
FUEL TANK DRAIN PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-209
GREASE ZERKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210
MOLDBOARD SLIDE RAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210
CONTROL LEVER LINKAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210
CONTROL VALVE LINKAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210
OIL LEVEL - AWD FRONT WHEEL GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-211
ENGINE OIL LEVEL AND FILL POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-211
BATTERY WATER LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-211
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-211
ENGINE SPEED TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-212
ENGINE SPEED CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-213
THROTTLE ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-214
HYDRAULIC PRESSURE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-217
QUICK-REFERENCE PRESSURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-218
MAIN HYDRAULIC SYSTEM SPECIFICATIONs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-219
TEST PORT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-219
PUMP-OUTLET LINE PRESSURE (TEST PORT 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-219
LOAD-SENSOR LINE PRESSURE (TEST PORT 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-219
TEST PROCEDURE: Low-Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220
TEST PROCEDURE: High-Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-221
STEERING AND BRAKE SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-222
STEERING AND BRAKE SYSTEM SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-222
TEST PORT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-222
PUMP PRESSURE (TEST PORT 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-222
TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-222
AWD HYDRAULIC SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-223
AWD SYSTEM SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-223
830B/C-850B/C-870B/C 20-201
TEST PORT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-223
CHARGE PUMP PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-223
REVERSE PRESSURE (TEST PORT 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-223
FORWARD PRESSURE (TEST PORT 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-223
TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-224
CLUTCH PACK PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-225
TIRES AND RIMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-226
TIRE INFLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-226
TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-226
RIM CENTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-226
CONTROL VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-228
CONTROL LEVERS - RIGHT BANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-228
CONTROL LEVERS - LEFT BANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-229
OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-231
LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-231
WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-231
YARD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-231
BRAKE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-232
MICO BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-232
BRAKE PEDAL BUMPER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-232
BRAKE PEDAL FREE HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-232
BRAKE PEDAL STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-233
PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-234
PARKING BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-235
PERROT PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-235
MICO PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-236
20-202 830B/C-850B/C-870B/C
TESTING AND ADJUSTING PREDELIVERY PROCEDURES
12
PREDELIVERY PROCEDURES
CHECKS AND ADJUSTMENTS

FAN BELT TENSION
WARNING! Keep clear of the engine fan and fan drive belts when the engine is running.
WARNING! When checking, adjusting, or replacing the drive belts, ensure the ignition switch is in the
OFF position to prevent accidental engine cranking. Also, ensure the controls are tagged.
New drive belts will stretch after the first few hours of operation. After running the engine a few minutes to seat the belt,
readjust the belt tension. After 1/2 hour of operation and then again after 10 hours of operation, readjust the belt tension. Check
the belt tension every 100 hours thereafter and adjust the belt, if necessary.
Replace badly worn, greasy, or cracked belt(s) immediately. Always replace both belts of a matched set if just one is needed.
Use a belt-tension gauge to check the drive-belt tension. Check the belt tension between the two pulleys farthest apart. Adjust
the drive-belt tension from 80 to 100 lbf (360 to 490 N). Tighten the mounting hardware. The drive-belt deflection can range
from 3/8 in. to 1/2 in. (9.5 to 12.7 mm). Recheck the belt tension. Repeat if necessary.
Remark
When adjusting the fan-belt tension, check if the fan blade is hitting the radiator shroud. If so, the radiator mounts or
the engine mounts require replacement.
AIR CLEANER SYSTEM

SERVICE: Clean the precleaner. Check the air restriction indicator (inset).
If it indicates a restriction, replace the element. To prevent dirt from
entering the engine, inspect the air cleaner hose, elbow, and piping
connections between the manifold and air cleaner. To eliminate undue
strain on the piping and connections, ensure that all components are
properly aligned. See that all joints between the air cleaner and engine
manifold are tight, including the flexible connections and manifold
gaskets. Ensure that the manifold stud bolts are torqued to specifications
(see Engine Manual for torque values).
830B/C-850B/C-870B/C 20-203
12
AIR INDUCTION PRESSURE CHECK
The most common cause of engine failure is dirt. Dirt can enter the induction system through areas other than an improperly
maintained air filter. An air induction leak on the suction side, no matter how small, can cause an engine failure. Thus, pressure
testing the air induction system cannot be emphasized enough with high-speed diesel engines.
Perform this test:

● During the predelivery of all new machines.
● Before removing, or after installing an engine.
● Whenever any part of the air induction system is removed or replaced.
● Every 1,000 hours of machine operation.
● When oil analysis reveals a high silicone content.
● When oil consumption is excessive.
● When loss of power is detected.
The tools needed to perform this test are:

● Manually regulated compressed air supply.
● 15 psi (1.1 kg/cm²) pressure gauge.
● Tube fittings.
● Duct tape.
● Paint brush.
● Soap solution.
WARNING! Never use ether to determine suction or pressure leaks.
TEST PROCEDURE
1. Remove the end cover from the air cleaner.
2. Remove both filter elements from the air cleaner.
3. Mask the entire perforated metal outside diameter of the safety (small) element with the duct tape. Seal must be airtight.
Reinstall the taped element only.
4. Remove the air cleaner filter service indicator at the air cleaner.
5. Install a tee and reinstall the indicator and the pressure gauge.
6. MACHINES WITHOUT ETHER START: Remove the 1/4 in. pipe plug from the left side of the cylinder head.
7. MACHINES WITH ETHER START: Disconnect the ether start tube from the left side of the cylinder head.
8. Connect the manually regulated compressed air supply to the engine cylinder head.
9. Introduce air into the system and adjust the regulator so that 3 psi (0.2 kg/cm²) registers at the pressure gauge. If the
specified pressure cannot be achieved, turn the engine over slightly to reach a point where minimal leakage occurs past the
engine valves.
20-204 830B/C-850B/C-870B/C
12
10. Coat the following areas with a soap solution and check for leaks (soap bubbles form at the leak point).
A. Air cleaner body surface around the outlet pipe to approximately the outside diameter of the safety (small) element.
B. Air cleaner outlet elbow to the air cleaner body junction.
C. Fitting connections from air cleaner outlet to service indicator, including the bottom of the indicator.
D. All clamped hose and gasket connections between the air cleaner outlet and the intake manifold, including
turbocharger connections.
E. Surface of all air induction piping and hoses between the air cleaner and intake manifold, including the manifold
gasket area.
F. The air compressor air inlet piping, including the fitting and the gasket.
11. No leakage is permitted between the air cleaner, turbocharger (suction side) and intake manifold (the entire air induction
system). If leakage at the joints is detected, tighten the hose clamps. If leakage persists, remove the parts to determine the
cause. Replace the parts as necessary, using new hoses, clamps, and torque values specified. Retest the corrected area.
12. Remove and unmask the taped element. Inspect the seals for damage.
13. Install both filter elements and the air cleaner end cover. Support the primary (large) filter element during installation to
assure centering of the seal surface to the air cleaner body.
14. Disconnect the compressed air supply.
15. Reinstall the pipe plug into the engine cylinder head or reconnect the ether start tube to the engine cylinder head.
16. Remove the test gauge and tee.
17. Reinstall the service indicator.

Remark
Any leak in the air induction system could allow dirt to enter the engine. Dirt entering an engine can cause worn or
broken piston rings (indicated by excessive blue smoke and/or high oil consumption) or turbocharger compressor
wheel pitting and erosion. If any leaks are found in the air intake system, check the internal condition of the engine by
performing an engine crankcase pressure check.
18. Press the reset button on the filter service indicator. Start the engine and run at full throttle. If the service indicator shows
an airflow restriction (the red signal band locked in position), turn the engine off. Determine where the restriction is
located within the air induction system. Correct the restriction.
19. If the air cleaner filter elements are plugged, but the service indicator did not show a restriction, check the operation of the
safety filter as described below.
SERVICE INDICATOR SAFETY FILTER

The safety filter within the indicator adapter prevents unfiltered air from entering the engine through the damaged indicator. If
a leak occurs, this filter will, with continued operation, plug up. Loss of indicator operation indicates a plugged filter. This
situation can be checked as follows:
830B/C-850B/C-870B/C 20-205
12
Remove the air precleaner hood. Start the engine and operate at low idle. Gradually seal the air intake opening with a flat piece
of cardboard until the opening is almost completely covered. If the red signal band of the indicator fails to rise and lock in
position:
1. The filter is plugged as a result of a leak in the indicator.
2. A leak exists in the air cleaner. Locate the leak and correct immediately.
Clean or replace the service indicator safety filter.
ASSEMBLY TIPS
1. Whenever air cleaner to turbocharger elbow is removed, install the protective shield on the turbocharger air inlet opening.
2. Service the indicator safety filter within indicator adapter as follows:
A. Remove the air cleaner filter service indicator.
B. Remove the service indicator adapter from the air cleaner outlet pipe.
C. Direct compressed air through the safety filter in the opposite direction of normal airflow until all foreign material is
removed.
WARNING! Do not exceed 30 psi (2.1 kg/cm²) at the air nozzle. Keep a reasonable distance between
the air nozzle and the filter. Wear goggles and side shields for your protection.
D. Install the service indicator adapter and service indicator on the air cleaner outlet pipe.
RADIATOR HOSES
To prevent loss of coolant and engine overheating, inspection the radiator hoses and clamps. Twisted, bent, or kinked radiator
hoses restrict coolant flow, causing the cooling system to overheat. Clamps must be seated and tightened to specification to
prevent pressure leaks.
20-206 830B/C-850B/C-870B/C
12
FUEL LINES AND FITTINGS
Check all fuel lines connections and fittings to ensure that they are properly aligned and tightened. Ensure that the fuel lines
are free of kinks and/or binding that would restrict fuel flow, resulting in a loss of power and performance. Refer to the
Operator’s Manual for the specified values for all fittings and connections.
WATER TRAP
SERVICE: Open the valve and drain the water from the trap. Close the
valve.
Remark
For servicing, see the “Engine Fuel System” section of the
Operator’s Manual.
TRANSMISSION FLUID LEVEL

SERVICE:Remove the transmission dipstick to check the transmission
fluid level. The fluid level should be to the FULL mark on the dipstick.
LUBRICANT: ATF
Remark
See the “Transmission Checks” section of the Operator’s Manual
for servicing.
TRANSMISSION FILL PLUG

SERVICE: Remove the plug and pour the fluid in. Use the transmission
dipstick to check the fluid level.
LUBRICANT: ATF
Remark
See the “Transmission Checks” section of the Operator’s Manual
for servicing.
HYDRAULIC OIL TANK LEVEL

SERVICE: Check the sight gauge on the tank. The tank is considered full
when the oil level is 1.0 in. below the HIGH mark on the tube.
LUBRICANT: ATF
Remark
See “Care of Hydraulic System” section of the Operator’s Manual
for servicing.
830B/C-850B/C-870B/C 20-207
12
HYDRAULIC OIL AND FUEL TANK FILL POINT
SERVICE: Remove the cap on top of the tank to pour the fluid in. Use the
sight gauge to determine the fluid level in the tank.
LUBRICANT: ATF
Remark
See the “Care of Hydraulic System” section of the Operator’s
Manual for servicing.
TANDEM CASE OIL LEVEL

SERVICE: After removing the plug, the fluid should be to the bottom of
the threads.
LUBRICANT: ATF
Remark
Oil must not have a contaminant level higher 1000 particles
larger than 10 micro meters per cubic centimeter based on ANSI
B93.28-1973 Calibration procedure.
TANDEM CASE BREATHER/FILL POINT

SERVICE: Remove the plug and pour the fluid in. See above to determine
when the case is full. Inspect the breather while removed and clean, if
needed.
LUBRICANT: ATF
Remark
See the Remark above.
CIRCLE REVERSE OIL LEVEL

SERVICE: After removing the plug, the oil should be to the bottom of the
threads.
LUBRICANT: GO
Remark
Oil must not have a contaminant level higher than 1000 particles
20-208 830B/C-850B/C-870B/C
12
CIRCLE REVERSE FILL POINT
SERVICE: Remove the plug atop the case and pour the fluid in. To deter-
mine when the case is full, see above.
LUBRICANT: GO
Remark
REAR AXLE OIL LEVEL

SERVICE: After removing the cap on top of the elbow, the fluid should be
to the top of the elbow.
LUBRICANT: HTF
Remark
See the Remake above.
REAR AXLE OIL FILL POINT

SERVICE: Remove the plug on the side of the case and pour the fluid in.
To determine when the case is full, see above.
LUBRICANT: HTF
Remark
See the Remark above.
FUEL TANK DRAIN PLUG

SERVICE: Unscrew the drain plug, which is located on the underside of
the fuel tank. Drain the sediment and water from the tank. Reinstall the
drain plug.
Remark
See the “Engine Fuel System” section of the Operator’s Manual
for servicing.
830B/C-850B/C-870B/C 20-209
12
GREASE ZERKS
SERVICE: Grease all zerks according to the lubrication chart on the frame
(right) or the Operator’s Manual to ensure that all points are sufficiently
lubricated.
LUBRICANT: MPG
MOLDBOARD SLIDE RAILS

SERVICE: After cleaning the rails, spray Drylube (p/n 1438 158 H1) on
them.
CONTROL LEVER LINKAGES

SERVICE: Lubricate.
LUBRICANT: EO
CONTROL VALVE LINKAGES

SERVICE: Lubricate.
LUBRICANT: EO
20-210 830B/C-850B/C-870B/C
12
OIL LEVEL - AWD FRONT WHEEL GEAR
SERVICE: With the words CHECK OIL LEVEL at the 6 o’clock position,
the bolt (arrow) will be at the 10 o’clock position. Unscrew the bolt
(arrow). Fluid should be to the bottom of the threads. If not, add the recom-
mended fluid through this bolt hole. Reinstall the bolt. Check the oil level
on both sides of the unit.
LUBRICANT: ATF
Remark
ENGINE OIL LEVEL AND FILL POINT

SERVICE: Check the oil level using the dipstick (A). If additional oil is
needed, remove the cap (B) and pour in the oil.
LUBRICANT: EO
Remark
See the “Engine Lubricating Oil System” section of the Opera-
tor’s Manual for servicing.
BATTERY WATER LEVEL

SERVICE: If the batteries are not maintenance free, check each cell. The
water level should be to the top of the ring in each cell.
FLUID: Distilled water.
NOTE: See the "Batteries" section of the Operator’s Manual for servicing.
ENGINE COOLANT
SERVICE: Check the coolant level and the freeze point of the coolant.
FLUID: COL
NOTE: See the "Engine Cooling System" section of the Operator’s Man-
ual for servicing.
830B/C-850B/C-870B/C 20-211
12
WARNING! Never remain in a stall condition for more than 30 seconds at a time. After performing a
stall test and before making any further tests, run the engine without a load for 5 minutes.
ENGINE SPEED TABLE

Perform all tests with the hydraulic oil at 160° F (71° C). All controls must be in NEUTRAL. If the unit has air conditioning
(A/C), turn the A/C on and set it for maximum cooling. Turn the All-Wheel-Drive (AWD) feature off. Set the parking brake.
The moldboard must be ON and IN the ground. If the rpm is not to specifications, adjust the throttle linkage to obtain the
desired the rpm; do not attempt to adjust the engine fuel pump (refer to the Engine Service Manual).
830B/C with S6D102E-1 (SINGLE HORSEPOWER)
SPEED MINIMUM rpm MAXIMUM rpm ACTUAL rpm

Low Idle 800 900 ____________
Low Idle (AWD) 900 950 ____________
High Idle 2600 2750 ____________
Stall Speed 1667 1818 ____________
Stall Speed (AWD)1638 1790 ____________

Low Idle 800 950 ____________
Low Idle (AWD) 900 950 ____________
High Idle 2600 2830 ____________
Stall Speed 1818 1966 ____________
Stall Speed (AWD)1794 1950 ____________
850B/C with S6D114E-1 (DUAL HORSEPOWER)

Low Idle 800 950 ____________
Low Idle (AWD) 900 950 ____________
High Idle 2600 2830 ____________
Stall Speed 1910 2057 ____________
Stall Speed (AWD)1885 2042 ____________

Low Idle 800 950 ____________
Low Idle (AWD) 900 950 ____________
High Idle 2600 2830 ____________
Stall Speed 1964 2107 ____________
Stall Speed (AWD)1944 2088 ____________
20-212 830B/C-850B/C-870B/C
12
ENGINE SPEED CHECK PROCEDURE
1. Set the parking/emergency brake.
2. Leave the transmission in NEUTRAL.
3. Move the engine speed control lever to the low idle (slow) position. Use a calibrated tachometer and record the low idle
rpm.
________________Low Idle rpm
4. Move the engine speed control lever rearward to the high idle (fast) position. Use a calibrated tachometer and record the
high idle rpm.
________________High Idle rpm
5. Return the engine speed control lever to the low idle position.
6. Position the moldboard crossways on and in the ground.
7. Firmly apply the service brake pedal.
8. Shift the transmission into high forward gear (6th gear).
9. Move the engine speed control lever slowly to the high idle (fast) position. Use a calibrated tachometer and record the stall
speed rpm.
________________Stall Speed rpm
WARNING! Never remain in a stall condition for more than 30 seconds at a time. Before making any
further tests, run the engine without a load for 5 minutes.
10. Return the engine speed control lever to the low idle position and shift the transmission into NEUTRAL.
12. Compare the recorded engine rpm values to those shown in the preceding tables for your unit. If the values are not within
range, perform the “Throttle Adjustment Procedure.”
830B/C-850B/C-870B/C 20-213
12
THROTTLE ADJUSTMENT PROCEDURE
Although the throttle adjustment procedure for all graders is basically the same, the linkage position varies. The position of the
throttle cable and the connecting rod (between the pedal weldment and bellcrank) on the 830 is slightly different from the
setup on the 850/870.
20-214 830B/C-850B/C-870B/C
12
WARNING! Overtravel of the throttle linkage in either direction can damage the fuel injection pump.
Use extreme care when making adjustments.
1. Disconnect the throttle cable (1) from the fuel injection pump control lever (2) at the engine.
2. Start the engine and manually actuate the fuel injection pump control lever (2) to ensure that the proper low and high idle
speeds are obtainable.
Remark
If the desired engine speeds cannot be obtained, see the appropriate “Engine Service Manual” for adjustments.
4. Disconnect the spring tube assembly (3) from the bellcrank (4).
830B/C-850B/C-870B/C 20-215
5. Adjust the accelerator/decelerator pedal weldment (5) so the throttle cable (1) travel at the engine matches that of the fuel
injection pump control lever (2). Use the two stop bolts (6 and 7) to adjust the amount of total travel. Make sure that the
fuel injection pump does not overtravel. Connect the throttle cable to the fuel injection pump control lever.
6. Reconnect the spring tube assembly (3) to the bellcrank (4). Adjust the length of the spring tube assembly (3) as follows:
With the engine speed control lever (8) in the low idle position, the stop screw (6) should fully contact the underside of the
floorboard. If the stop screw (6) does not touch the floorboard, the spring tube assembly (3), throttle cable (1), or both (1
and 3) are misadjusted. Now move the speed control lever (8) to the high idle position. With the lever (8) at the high idle
position, the stop screw (7) should fully contact the underside of the floorboard. If the stop screw (7) does not touch the
floorboard, the spring tube assembly (3), throttle cable (1), or both (1 and 3) are misadjusted.
20-216 830B/C-850B/C-870B/C
12
HYDRAULIC PRESSURE TESTS
Two trained and experienced service personnel are required to perform these services.
Determine if the grader is equipped with the optional All Wheel Drive (AWD). High-pressure tubes that run along the outside
of the cab and front frame indicate that the grader is equipped with AWD.
Before performing the pressure tests, ensure that the engine and hydraulic system are at operating temperature (75° F to 100° F
or 24° C to 38° C). Also, ensure that all lubricants are at the proper level.
Adjust the throttle linkage properly to ensure that the various engine speeds can be obtained.
A Quick-Reference Pressure Chart with the hydraulic pressure values for nonAWD and AWD graders can be found on the next
page.
830B/C-850B/C-870B/C 20-217
12
QUICK-REFERENCE PRESSURE CHART
STANDARD GRADER GRADER WITH AWD
Load-sensor line
Low standby @
1,000 rpm 120 to 160 PS1
2,500 rpm 120 to 160 PS1
120 to 160 PS1 120 to 160 PS1
High standby @
1,000 rpm 2250 to 2,400 psi 2,250 to 2,400 psi
2,500 rpm 2250 to 2,400 psi 2,250 to 2,400 psi
Pump-outlet line
Low standby @
1,000 rpm 340 to 400 psi 340 to 400 psi
2,500 rpm 340 to 400 psi 340 to 400 psi
High standby @
1,000 rpm 2,470 to 2,640 psi 2,470 to 2,640 psi
2,500 rpm 2,470 to 2,640 psi 2,470 to 2,640 psi
STEERING AND
BRAKE SYSTEM
Pump @ 1000 rpm 1,650 psi 1,650 psi
AWD SYSTEM
Charge pump @ 1,000 rpm 250 to 290 psi
Forward stall @ 1,000 rpm 4,200 to 4,600 psi
Reverse stall @ 1,000 rpm 4,200 to 4,600 psi
Actual desired pressure values in this manual may vary slightly to those values in the hydraulic schematics. When a system is discussed,
schematic values will be used. When a system is tested, the actual desired values will be used. The restrictions in the system -- hose lengths,
fittings, etc. -- cause the difference in values.

Load-Sensor Line
Low Standby = Load Sense Pressure Reducing Valve
High Standby = Load Sense Relief Valve
Pump-Outlet Line
Low Standby = Load Sense Pressure Reducing Valve + Flow Compensator Spool Setting
High Standby = Load Sense Relief Valve + Flow Compensator Spool Setting
STEERING AND BRAKE SYSTEM (WITH LOCK PIN)

Pump = Flow Compensator Relief Valve
ALL-WHEEL-DRIVE SYSTEM
Charge Pump = Flushing Valve
Forward Stall = Pressure Override Valve
Reverse Stall = Pressure Override Valve
Brake Booster = Flushing Valve + Brake Booster Relief Valve
20-218 830B/C-850B/C-870B/C
12
MAIN HYDRAULIC SYSTEM SPECIFICATIONs
Load-Sensor Line
120 to 160 psi @ 2,500 ±25 rpm

2,250 to 2,400 psi @ 2,500 ±25 rpm
Pump-Outlet Line
340 to 400 psi @ 2,500 ±25 rpm

2,470 to 2,640 psi @ 2,500 ±25 rpm
Remark
Actual desired pressure values recorded in this manual may vary slightly to those values in the hydraulic schematics.
When discussing a system, schematic values will be used. When testing a system, the desired values will be used. The
inherent restrictions in the system — hose lengths, fittings, etc. — cause the difference in values.
TEST PORT LOCATIONS
PUMP-OUTLET LINE PRESSURE (TEST PORT 1)

Located in the pump outlet elbow on the right rear side of the main system
pump when viewing from the rear of the grader. Remove the grill to gain
access to the test port.
LOAD-SENSOR LINE PRESSURE (TEST PORT 2)

Located on the top right side of the main system pump when viewing from
the rear of the grader. Remove the grill to gain access to the test port.
830B/C-850B/C-870B/C 20-219
12
TEST PROCEDURE: Low-Pressure Standby
2. Connect a calibrated 600 psi gauge to the load sensor line pressure test
port (2).
3. Connect a calibrated 600 psi gauge to the pump outlet line pressure
test port (1).
20-220 830B/C-850B/C-870B/C
12
TEST PROCEDURE: High-Pressure Standby
2. Connect a calibrated 5,000 psi gauge to the load sensor line pressure
test port (2).
3. Connect a calibrated 5,000 psi gauge to the pump outlet line pressure
test port (1).
5. Bottom the leaning wheel cylinder (moldboard tilt, moldboard shift or circle shift cylinders could be used) while holding
the control valve fully OPEN.
8. Bottom the leaning wheel cylinder (moldboard tilt, moldboard shift or circle shift cylinders could be used) while
holding the control valve fully OPEN.
830B/C-850B/C-870B/C 20-221
12
STEERING AND BRAKE SYSTEM PRESSURE TEST
STEERING AND BRAKE SYSTEM SPECIFICATION
Pump pressure.......................................1,650 psi @ 1,000 rpm
Remark
Actual desired pressure values recorded in this manual may vary slightly to those values shown in the hydraulic
schematics. When discussing a system, schematic values will be used. However, when testing a system, use the desired
values. The restrictions in the system — hose lengths, fittings, etc. — cause the different values.
TEST PORT LOCATION
PUMP PRESSURE (TEST PORT 1)

The pump mounts to the engine. The test port is located at
the rear of the pump.
TEST PROCEDURE
1. Connect a calibrated 3,000 psi gauge to the steering

and brake pump test port (1).
2. Start the engine. Move the engine speed control lever

to increase the speed to 1,000 ±25 rpm.
3. Have another person record the steering and brake

pump pressure reading. Steering and brake pump
pressure reading must be 1,650 psi @ 1,000 ±25 rpm.
Steering and brake pump pressure @ 1,000 ±25 rpm__________________
4. If needed, adjust the relief valve (2) to obtain the desired 1,650 psi.
20-222 830B/C-850B/C-870B/C
12
AWD HYDRAULIC SYSTEM PRESSURE TEST
AWD SYSTEM SPECIFICATION
Charge Pump Pressure 250 to 290 psi @ 1,000 rpm
Forward Stall Pressure 4,200 to 4,600 psi @ 1,000 rpm
Reverse Stall Pressure 4,200 to 4,600 psi @ 1,000 rpm
Remark
Actual desired pressure values recorded in this manual may vary slightly to those values shown in the hydraulic sche-
matics. When discussing a system, schematic values will be used. However, when testing a system, use the desired val-
ues. The restrictions in the system — hose lengths, fittings, etc. — cause the different values.
TEST PORT LOCATIONS
CHARGE PUMP PRESSURE

Located at the AWD filter.
REVERSE PRESSURE (TEST PORT 1)

Located on the left top side of the main frame in front of the operator's cab.
FORWARD PRESSURE (TEST PORT 2)

Located on the right top side of the main frame in front of the operator's
cab.
WARNING! The system develops full force during this

test. Keep clear of the area in front of and
behind the machine.
830B/C-850B/C-870B/C 20-223
12
TEST PROCEDURE
1. Raise the moldboard so the front wheels are resting solidly on ground.
2. Connect a calibrated 5,000 psi pressure gauge to test port 1, and another calibrated 5,000 psi pressure gauge to test port 2.
Both test ports are located in the hydraulic lines along the frame to the front wheels.
3. Remove the AWD controller access cover.
4. Unplug the wire “10 AWD” from the brake light switch. This step
allows brake application, without turning the AWD system off.
5. Apply the foot brake, release the parking brake and move the AWD
switch to the OFF position. Start the engine. Move the engine speed
control lever to increase the speed to 1,000 ±25 rpm.
Remark
The pump has a Pressure Override Valve (POV) that varies the
swash-plate angle to limit the maximum pressure. This valve pre-
vents continuous dumping of excessive flow, at maximum pres-
sure, through the system relief valves in the pump. This action
eliminates unnecessary heating of the oil and protects the pump
when the wheels stall.
6. Move the AWD switch to the NORMAL mode. After shifting the transmission into the forward high (6th) gear, push the
test button on the controller.
A. The right gauge should register override pressure from 4,200 to 4,600 psi @ 1,000 ±25 rpm. Have another person
record the override pressure @ 1,000 ±25 rpm__________________
B. The left gauge should register charge pressure from 250 to 290 psi @ 1,000 ±25 rpm. Have another person record the
charge pump pressure @ 1,000 ±25 rpm____________________
7. After shifting the transmission into reverse third gear, push the test button.
A. The right gauge should register charge pressure from 250 to 290 psi @ 1,000 ±25 rpm. Have another person record
the charge pump pressure @ 1,000 ±25 rpm____________________
B. The left gauge should register override pressure from 4200 to 4600 psi @ 1,000 ±25 rpm. Have another person record
the override pressure @ 1,000 ±25 rpm__________________
8. Turn the engine off and apply the parking/emergency brake.
9. Reconnect the "10AWD" wire to the brake light switch.
10. Start the engine. Shift the transmission into first gear forward, set the engine at 1/4 throttle, raise the blade, and move the
AWD system switch to the NORMAL MODE. With the machine moving steadily on even ground, check the pressure at
the right pressure gauge. Now, move the AWD switch to the AGGRESSIVE MODE. Pressure should increase.
20-224 830B/C-850B/C-870B/C
CLUTCH PACK PRESSURE CHECK

A grader’s transmission pressure test port is located on the transmission
control valve. Connect a calibrated 600 psi (4,137 kPa) gauge to this test
port to determine whether a clutch pack is malfunctioning. The gauge nee-
dle should remain in approximately the same position after each gear shift.
Remark
This test determines if the clutch pack seal rings and solenoid
valves function properly, or if a hydraulic oil leaks exist. Three
seal rings exist on each dual clutch pack shaft. Dual clutch packs
are grouped as follows: 1 & 5, 2 & 6, 3 & 4.
The seal rings on the dual clutch pack isolate the oil from each pack. Different combinations of clutch packs 1 thru 6 provide
the six forward speeds and three reverse speeds.
WARNING! Perform this test outside. Ensure that sufficient room exists in front of and behind the
grader should it move.
The following test procedure determines if the clutch packs are functioning correctly.
1. After placing the transmission gear range lever in NEUTRAL, engage the neutral lock.
2. After placing the moldboard in the ground crossways, release the parking/emergency brake.
3. Use the foot service brake to prevent the wheels from turning while performing the pressure checks.
4. Observe the gauge with the engine at low idle. A normal pressure reading is from 240 to 260 psi (1655 to 1793 kPa).
5. Move the gear range lever through all six forward and three reverse gear ranges.
6. Pressure should not vary more than 5 psi (34 kPa) between the clutch packs. If the readings vary more than 5 psi (34 kPa),
see the appropriate "Shop Manual" for further testing.
7. After checking the clutch packs, return the gear range lever to NEUTRAL and engage the neutral lock.TIRES AND RIMS
830B/C-850B/C-870B/C 20-225
12
TIRES AND RIMS
TIRE INFLATION
Take precautions when inflating the tires. Never inflate a flat tire without first inspecting the tire, rim, and wheel for damage.
Be sure all components are properly assembled. Never stand directly in front of a tire while inflating it because serious injury
could result, if the tire and mounting were to separate. Use a clip-on chuck with an air hose long enough to allow the person
inflating the tire to stand to the side. And when inflating or deflating unmounted tires, place the tire in a safety cage per
O.S.H.A. regulations. Inflate the tire to 5 psi and check that all components are properly seated. After inflating the tire to 5 psi
and visually inspecting all components, continue to inflate the tire to 50 psi. After inflating the tire to 50 psi, deflate the tire to
the recommended pressure.
TIRE PRESSURES
Several variables — tire size, rim size, tire construction — MUST be considered for the tire pressure.
TIRE SIZE TIRE CONSTRUCTION RIM SIZE PRESSURE

13:00 x 24 10 ply 8 in. rims 30 psi (207 kPa)
14:00 x R24 Radial 8 in. rims 55 psi (379 kPa)
Remark
Tire pressure may be increased 50 percent for work or travel on paved surfaces.
Remark
Because nitrogen (N) gas lacks moisture, nitrogen is recommended for tire inflation. However, air is acceptable if
nitrogen is unavailable.
RIM CENTERING
20-226 830B/C-850B/C-870B/C
Uncentered rims, the rim not centered to the wheel, may cause excessive grader bounce when travelling on smooth surfaces. A
visual inspection will reveal if the rims are uncentered.
To ensure that the rims are centered while changing the tires:
1. Have the tires off the ground.
2. Snugly tighten the rim clamps in place with the lug nuts, using the tightening patterns above for the front and rear wheels.
3. Torque all lug nuts to the final torque, using the tightening patterns above for the front and rear wheels.
830B/C-850B/C-870B/C 20-227
12
CONTROL VALVE OPERATION
The control valve levers are located on either side of the steering control panel. The standard grader is equipped with nine con-
trol valves: five in the left valve bank and four in the right valve bank. However, only eight are utilized for standard controls.
An additional five valves for the various options may be added: two to the left valve bank and three to the right valve bank.
Configuration of these valve bank arrangements may vary from the standard valve banks shown below.
Remark
Located on top the optional accessory control valve bank sections are flow-control adjustment valves. The valve (one
per section) is a tee-handle that can be turned to adjust the oil flow rate to the optional function.
CONTROL LEVERS - RIGHT BANK
1. Circle Shift
20-228 830B/C-850B/C-870B/C
Pulling this lever moves the moldboard to the right;
pushing this lever forces the moldboard to the left.
2. Articulation
Pulling this lever moves the rear module to the right,
assisting in right turns; pushing this lever forces the
rear module to the left, assisting in left turns.
3. Wheel Lean
Pulling this lever causes the front wheels to lean to the
right; pushing this lever causes the wheels to lean to the
left.
4. Right Blade Lift

Pulling this lever raises the right side of the blade;
pushing this lever lowers the right side of the blade.
CONTROL LEVERS - LEFT BANK
830B/C-850B/C-870B/C 20-229
1. Left Blade Lift
Pulling this lever raises the left side of the blade;
pushing this lever lowers the left side of the blade.
2. Optional - Scarifier or Ripper

Pulling this lever raises the scarifier or ripper; pushing
this lever lowers the ripper or scarifier.
3. Blade Shift
Pulling this lever forces the moldboard to the right;
pushing this lever moves the moldboard to the right.
4. Blade Tilt
Pulling this lever moves the top of the blade rearward;
pushing this lever moves the top of the blade forward.
5. Circle Rotation
Pulling this lever moves the circle clockwise; pushing
this lever moves the circle counterclockwise.
20-230 830B/C-850B/C-870B/C
12
OPTIONAL EQUIPMENT
LIGHTING
1. Single beam headlights
2. Hi-Lo beam headlights
3. Amber turn signals
4. Dome lights
5. Moldboard flood lights
6. Snow lights (work)
WARNING LIGHTS
1. Flashing light (blue or amber)
2. Amber revolving light
YARD TEST
Prior to starting each day’s work, perform the following checks:
1. Check that all gauges and indicator lights respond properly. Indicator lights should respond to the respective gauges.
2. Check that the lights, wipers, fan, heater, and other accessories operate properly.
3. Test the grader on a smooth road or a rough field in all forward and reverse speeds.
4. Check the antifreeze protection level when the operating temperature is 160° F (71.1° C).
5. Check for leaks before and after roading.
6. Be alert for any strange noises or vibrations. Find the cause of the noise or vibration and make the needed repairs, and then
retest.
830B/C-850B/C-870B/C 20-231
12
BRAKE VALVES
Adjust the service brakes to ensure that:
● Brake discs never drag after releasing the pedal.
● Full brake line pressure develops after pushing the pedal to the floorboard.
● Excess force is never applied to a bottomed piston in the brake valve.
MICO BRAKE VALVE

Three brake adjustments are as follows:
● Brake pedal bumper.
● Brake pedal free height.
● Brake pedal stop.
BRAKE PEDAL BUMPER ADJUSTMENT

This adjustment ensures that the brake valve (1) is not applied after
releasing the brake pedal (2). With the brake released, the brake valve
actuator (3) must protrude 1.50 in. (38.100 mm) from the brake mounting
bracket (7) face. To make adjustments:
1. Loosen the locknut below the bumper (4).
A. To increase the distance at point A, screw the bumper (4)

downward.
B. To reduce the distance at point A, screw the bumper (4) upward.
2. Tighten the jamnut below the bumper (4).

Remark
The brake valve actuator (3) will always contact the brake pedal assembly. The actuator is not retained within the
brake valve body. NO FREE PEDAL CLEARANCE EXISTS WITH THIS VALVE ARRANGEMENT.
BRAKE PEDAL FREE HEIGHT

This adjustment sets the brake pedal free height, which affects the other pedal adjustments.
1. Loosen the nut (6).
2. Turn the brake pedal rod up or down until the distance at point C is 3.9 in. (99.060 mm)
3. Tighten the nut (6).
20-232 830B/C-850B/C-870B/C
12
BRAKE PEDAL STOP
This adjustment ensures that the brake valve (7) fully opens, allowing full brake pressure; and the brake pedal (2) stops against
the pedal stop bolt (5), preventing the piston from bottoming out in the valve (7).
WARNING! Applying excessive force to the brake valve piston while it is already at full stroke could
damage the brake valve.
1. Loosen the jamnut (8).
2. Turn the pedal stop bolt (5) clockwise until it is against the jamnut
(8).
3. Using hand pressure, depress the brake pedal (2) slowly until it stops.
Determine if clearance exists between the pedal (2) and the pedal
stop bolt (5). If clearance doesn’t exist, go to step 4; if clearance
exists, go to step 5
4. If clearance doesn’t exist between the pedal stop bolt (5) and the
brake pedal (2):
A. Loosen the nut (6).
B. Turn the brake pedal rod upward to obtain clearance.
C. With hand pressure, depress the brake pedal again until it stops.
D. If clearance now exists between the pedal stop bolt (5) and the brake pedal (2), adjust the stop bolt (5) upward until it
contacts the brake pedal (2).
E. Then turn the stop bolt (5) one additional full turn upward.
F. Tighten the nut (6).
5. If clearance exists between the bottom of the brake pedal (2) and the pedal stop bolt (5):
A. Adjust the stop bolt (5) upward until it contacts the brake pedal (2).
B. Then turn the stop bolt (5) one additional full turn upward.
C. Align the brake pedal pad.
D. If the nut (6) was loosened in step A, tighten it.
E. With hand pressure, press the brake pedal (2) down again until it stops.
F. If clearance still exists between the brake pedal (2) and the stop bolt (5), repeat step 5.
6. Check the from the mounting bracket (1) to the ridge of the rubber boot (point B). If the distance is not 0.95 in. (24.130
mm), one of the three adjustments is inaccurate. Recheck all three adjustments.
830B/C-850B/C-870B/C 20-233
12
PRESSURE TEST
After completing the brake pedal adjustments, perform a hydraulic pressure check to assure that the adjustments are correct.
1. Connect a calibrated 2,000 psi (140.6 kg/cm²) gauge to the test port fitting.
3. With the engine running and the brake pedal (2) released, the gauge should register 0 psi (0 kg/cm²).
__________ psi with Brake Pedal Released
4. Press the brake pedal (2) against the pedal stop bolt (5). The gauge should register 1,160 ±75 psi (81.5 ±5.3 kg/cm²).
__________ psi with Brake Pedal Applied
6. If both pressure readings are correct, remove the pressure gauge. If the pressure readings do not meet specifications,
readjust the pedal linkage.
7. Remove the pressure gauge.
8. Connect a calibrated 50 psi (3.5 kg/cm²) gauge.
WARNING! Do not depress the brake pedal with the 50 psi (3.5 kg/cm²) gauge installed.
10. With the brake pedal (2) released, the gauge should register 0 psi (0 kg/cm²). However, if the pressure increases, turn the
engine off and:
A. Loosen the jamnut at the rubber bumper (4).
B. Turn the bumper (4) CW to increase the 1.50 in (38.1 mm) Dimension until pressure equals 0.0 (0.0 kg/cm2), then
increase an additional 0.060 in (1.52 mm).
C. Tighten the jamnut.
D. Restart the engine and recheck the pressure with the brake released.
__________ psi with Brake Pedal Released __________ psi with Brake Pedal Applied
20-234 830B/C-850B/C-870B/C
12
This section discusses the adjustments for both the Perrot and the Mico parking brakes.
PERROT PARKING BRAKE ADJUSTMENT

WARNING! For safe operation, it is imperative that the parking brake always be kept correctly
adjusted and in proper working order.
The parking brake assembly is mounted to the rear axle assembly. The parking brake is a spring-applied, hydraulically released
mechanism. With normal conditions, no periodic service adjustment is required. When the brake is released, a 0.015 in. (0.381
mm) to 0.125 in. (3.175 mm) gap is acceptable.
However, if the parking brake should need adjustment, use the following procedure:
1. Park the grader on a level surface. Rest the moldboard and all
accessories solidly on the ground.
4. With one person in the cab, have a second person remove the rubber
boot (1) from the parking brake caliper (2).
5. With the caliper still pressurized, loosen the jamnut (3).
6. Turn the adjustment screw (4) clockwise (IN) until both brake pads
(5 and 6) are in solid contact with the brake disc (7).
7. With both brake pads (5 and 6) in contact with the disc (7), turn the adjustment screw (4) OUT until the 0.030 in. (0.762
mm) clearance is obtained.
8. Tighten the jamnut (3).
9. Install the rubber boot (1) on the caliper (2).
830B/C-850B/C-870B/C 20-235
12
MICO PARKING BRAKE ADJUSTMENT
1. Park the grader on a level surface. Rest the blade and all accessories
solidly on the ground.
4. With one person in the cab, have another person loosen the hexnut
(1).
5. Turn the adjustment setscrew (2) clockwise (in) until both brake pads
(3 and 4) are in solid contact with the brake disc.
6. With both brake pads (3 and 4) in contact with the disc, turn the adjustment setscrew (2) counterclockwise (out) until
0.012 in. (0.305 mm) clearance exists between the pads (3 and 4) and the disc.
7. Tighten the hexnut (1).
20-236 830B/C-850B/C-870B/C
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9

PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
PRECAUTIONS WHEN CLEANING AND INSPECTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12
PRECAUTIONS WHEN COMPLETING THE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12
OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
SKETCHES OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
CHANNEL SUPPORT TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
CLUTCH PACK REMOVAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
CLUTCH SPRING COMPRESSION TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
CIRCLE REVERSE MOTOR (PARKER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
SPECIAL BEARING MANDREL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
CIRCLE REVERSE MOTOR (CHAR-LYNN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
ASSEMBLY BULLET TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
SEAL BULLET TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
SEAL INSTALLATION TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21
SHAFT BEARING REMOVAL / INSTALLATION TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21
HOUSING BEARING RACE REMOVAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
BEARING RACE INSTALLATION TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
SHAFT SEAL DRIVER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23
HYDRAULIC OIL SWIVEL BLOCK - 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
SWIVEL BLOCK SEAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
CIRCLE REVERSE SLIP CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
CIRCLE SLIP CLUTCH GAUGE TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
TANDEM CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
WHEEL KNOCKER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
AXLE LIFTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
AXLE ROLLING TORQUE TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27
SPREADER BAR AND CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27
AWD - GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
SEAL INSTALLATION TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
AWD - MOTOR (VICKERS-EATON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
SPECIAL SHAFT BEARING REMOVAL AND INSTALLATION TOOLS . . . . . . . . . . . . . . . . . . . 30-30
HOUSING BEARING RACE REMOVAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
SPECIAL BEARING RACE INSTALLATION TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
SHAFT SEAL DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
SPREADER BAR AND CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
DIFFERENTIAL BACKLASH TOOL (DR08-111) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33
ARTICULATION JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
830B/C-850B/C-870B/C 30-1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45
ENGINE HOOD, FRONT & REAR COWLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-48
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
FUEL TANK AND HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-54
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-55
TRANSMISSION SHIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56
TRANSMISSION POWER SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60
FRONT COVER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62
MAIN CASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64
TORQUE CONVERTER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-66
CLUTCH PACK 1 AND 5 DISASSEMBLY (FIRST STAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-68
CLUTCH PACK 2 AND 6 DISASSEMBLY (SECOND STAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70
CLUTCH PACK 3 AND 4 DISASSEMBLY (THIRD STAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-72
CONTROL VALVE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-74
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
FRONT COVER REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
TORQUE CONVERTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
CLUTCH PACK 1 AND 5 REASSEMBLY (FIRST STAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-82
CLUTCH PACK 2 AND 6 REASSEMBLY (SECOND STAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85
CLUTCH PACK 3 AND 4 REASSEMBLY (THIRD STAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-88
CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
MAIN CASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-93
TRANSMISSION/TORQUE CONVERTER REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96
INSTALLING THE CONVERTER INTO THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-99
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-99
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-101
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104
SERVICING THE MACHINE AFTER A TRANSMISSION OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . 30-108
STARTUP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-108
ALL WHEEL DRIVE (AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-108
ALL-WHEEL-DRIVE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109
SHAFT SEAL (IN-WARRANTY SERVICE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-111
CHARGE PUMP (IN-WARRANTY SERVICE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112
CONTROL PISTON COVER (IN-WARRANTY SERVICE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113
LEFT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113
RIGHT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114
REPLACING THE VALVES (IN-WARRANTY SERVICE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115
BOOST PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115
RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115
PRESSURE CUT-OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115
CONTROL DEVICE (IN-WARRANTY SERVICE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
REGULATOR VALVE (IN-WARRANTY SERVICE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-117
REBUILDING THE PUMP (OUT-OF-WARRANTY SERVICE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118
TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-135
TIGHTENING TORQUES FOR SHAFT BOLTS (METRIC ISO STANDARD THREAD) . . . . . . . 30-135
TIGHTENING TORQUES FOR LOCKING SCREWS VSTI (METRIC ISO FINE THREAD) . . . . 30-135
TIGHTENING TORQUE FOR SEAL LOCK NUTS VSTI (METRIC ISO STANDARD THREAD) 30-136
TIGHTENING TORQUES FOR CROSS-SLOTTED LENS HEAD SCREWS DIN 7985
(METRIC ISO STANDARD THREAD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-136
30-2 830B/C-850B/C-870B/C
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-137
CIRCLE REVERSE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-138
CHAR-LYNN (MACHINE S/N 202309 TO 203192) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-138
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-138
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-138
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-140
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-142
PARKER (MACHINE S/N 203193 AND UP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-144
EXPLODED ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-144
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-146
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-146
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-155
ONE PIECE STATOR CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-164
FINAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-165
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-165
STEERING (ORBITOL) VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-171
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-175
STEERING AND BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-176
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-176
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-177
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-180
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182
HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-183
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-183
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184
SPECIAL INSPECTION AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-188
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-190
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-193
4-WAY SWIVAL VALVE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-194
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-194
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-195
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-196
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-198
CONTROL VALVE MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-200
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-200
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
CONTROL VALVE BANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
VALVE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-204
VALVE SECTION IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-205
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206
VALVE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206
CONTROL VALVE BANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-207
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208
MAIN SYSTEM PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-210
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-210
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-211
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-217
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-223
HYDRAULIC INTEGRATED CIRCUIT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-224
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-224
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-225
HIC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-225
SOLENOID CARTRIDGE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-226
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-227
830B/C-850B/C-870B/C 30-3
SOLENOID CARTRIDGE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-227
HIC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-228
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-229
HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-230
BALL AND SOCKET SHIMMING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-230
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-231
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-231
STEERING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-232
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-232
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-233
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-234
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-235
LEANING WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-236
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-236
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-237
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-239
MOLDBOARD TILT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-241
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-242
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-243
MOLDBOARD SIDE SHIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-244
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-244
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-245
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-245
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-246
DRAWBAR SIDE SHIFT CYLINDER (R.H. BLADE SUSPENSION ONLY) . . . . . . . . . . . . . . . . . . . . 30-247
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-247
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-248
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-249
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-250
DRAWBAR SIDE SHIFT CYLINDER (R.H. & L.H. BIAS BLADE SUSPENSION) . . . . . . . . . . . . . . . 30-251
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-251
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-251
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-253
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-254
DRAWBAR LIFT CYLINDERS (R.H. BLADE SUSPENSION ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . 30-255
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-255
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-256
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-257
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-258
DRAWBAR LIFT CYLINDERS (R.H. & L.H. BIAS BLADE SUSPENSION ONLY) . . . . . . . . . . . . . . 30-259
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-259
TRUNNION BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-260
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-261
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-262
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-263
SCARIFIER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-265
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-265
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-266
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-267
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-268
LOCK PIN CYLINDER (R.H. & L.H. BIAS BLADE SUSPENSION ONLY) . . . . . . . . . . . . . . . . . . . . . 30-270
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-270
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-271
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-272
30-4 830B/C-850B/C-870B/C
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-273
ARTICULATION CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-274
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-274
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-275
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-276
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-277
ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-278
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-278
CHECKING THE PRECHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-278
ACCUMULATORS WITH PARKER VALVE P/N 5323640000. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-279
ACCUMULATORS WITH PARKER VALVE P/N 6124330000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-279
REMOVAL (BRAKE SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-280
REMOVAL (DRAWBAR LIFT AND DRAWBAR SIDE SHIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-281
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-282
REPAIR AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-283
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-283
INSTALLATION (BRAKE SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-284
INSTALLATION (DRAWBAR LIFT AND DRAWBAR SIDE SHIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . 30-284
LOCK/UNLOCK DIFFERENTIAL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-285
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-285
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-286
REPAIR AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-287
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-288
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-289
ADJUSTING DIFFERENTIAL PUMP BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-290
V-BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-290
OPTIONAL V-BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-290
CIRCLE REVERSE SLIP CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-291
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-291
GENERAL EXPLOSION VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-292
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-294
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-296
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-301
RETROFITTING A STANDARD CIRCLE GEAR CASE WITH A SLIP CLUTCH . . . . . . . . . . . . . . . . 30-302
CIRCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-302
RETROFITTING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-302
CIRCLE REVERSE GEAR CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-304
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-304
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-310
TANDEM CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-318
SINGLE AND DOUBLE STRAND CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-318
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-318
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-322
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-323
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-325
AWD - GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-328
TWO-PIECE SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-328
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-333
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-337
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-344
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-353
AWD MOTOR (VICKERS/EATON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-358
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-358
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-358
REMOVAL OF FRONT SHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-361
REPLACE ALL PARTS THAT DO NOT MEET THE FOLLOWING SPECIFICATIONS. . . . . . . . 30-361
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-362
830B/C-850B/C-870B/C 30-5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-365
FRONT AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-366
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-366
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-368
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-372
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-379
FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-382
NoSPIN AND LOCK/UNLOCK DIFFERENTIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-382
PARKING BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-382
FINAL DRIVE BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-382
ROAD TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-383
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-383
GENERAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-388
DISASSEMBLY OF THE PLANETARY CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-388
DISASSEMBLY OF THE NONPLANETARY CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-392
DISASSEMBLY OF THE DIFFERENTIAL BRAKE PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-395
DISASSEMBLY OF THE INPUT QUILL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-396
DISASSEMBLY OF THE DIFFERENTIAL CASE WITH NoSPIN DIFFERENTIAL . . . . . . . . . . . 30-398
DISASSEMBLY OF THE NoSPIN DIFFERENTIAL QUILLS . . . . . . . . . . . . . . . . . . . . . . . . . . 30-398
DISASSEMBLY OF RING GEAR AND NoSPIN DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . 30-398
DISASSEMBLY OF MISCELLANEOUS NoSPIN DIFFERENTIAL ITEMS . . . . . . . . . . . . . . 30-399
DISASSEMBLY OF DIFFERENTIAL CASE WITH LOCK/UNLOCK DIFFERENTIAL . . . . . . . . 30-400
DISASSEMBLY OF LOCK/UNLOCK DIFFERENTIAL QUILLS . . . . . . . . . . . . . . . . . . . . . . 30-400
DISASSEMBLY OF RING GEAR AND LOCK/UNLOCK DIFFERENTIAL . . . . . . . . . . . . . . 30-400
DISASSEMBLY OF DIFFERENTIAL PINIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-405
DISASSEMBLY OF MISCELLANEOUS LOCK/UNLOCK DIFFERENTIAL ITEMS . . . . . . 30-405
NoSPIN DIFFERENTIAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-406
LOCK/UNLOCK DIFFERENTIAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-406
PARKING BRAKE MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-407
DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-408
NoSPIN DIFFERENTIAL CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-409
ASSEMBLY OF MISCELLANEOUS ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-409
ASSEMBLY OF THE RING GEAR AND NoSPIN DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . 30-410
QUILL PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-411
LOCK/UNLOCK DIFFERENTIAL CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-413
ASSEMBLY OF MISCELLANEOUS ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-413
ASSEMBLY OF THE RING GEAR AND LOCK/UNLOCK DIFFERENTIAL . . . . . . . . . . . . . 30-414
LOCK/UNLOCK DIFFERENTIAL QUILL PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . 30-417
PINION GEAR ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-420
PINION GEAR CONE POINT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-420
PINION GEAR ENDPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-422
PINION GEAR BACKLASH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-423
RING GEAR AND PINION ROLLING PATTERN CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-424
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-426
ASSEMBLY OF THE DIFFERENTIAL BRAKE PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-428
NONPLANETARY CARRIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-430
PLANETARY CARRIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-437
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-442
REPLACING 6C FLANGE DRIVE SHAFT WITH 7C FLANGE DRIVE SHAFT . . . . . . . . . . . . . . 30-443
CIRCLE TOOTH REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-449
REBUILDING THE TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-449
MICO PARKING BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-450
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-450
BRAKE LINING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-452
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-452
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-456
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-459
30-6 830B/C-850B/C-870B/C
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-460
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-460
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-463
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-465
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-466
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-468
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-468
COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-470
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-471
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-473
LOWER SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-474
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-475
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-477
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-477
SEAT ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-478
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-479
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-479
TILT STEERING CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-480
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-480
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-488
AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-497
AIR CONDITIONING SYSTEM ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-497
AIR CONDITIONING SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-498
AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-499
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-499
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-499
COMPRESSOR CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-500
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-500
CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-500
CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-503
COMPRESSOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-504
RECEIVER/DRYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-505
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-505
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-505
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-505
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-506
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-506
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-506
AIR CONDITIONER/HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-507
ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-507
ASSEMBLY DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-508
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-510
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-510
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-511
AIR CONDITIONING SYSTEM CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-534
CHECKING COMPRESSOR OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-536
830B/C-850B/C-870B/C 30-7
12
MEMORANDUM
30-8 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
12
METHOD OF USING MANUAL
1. When removing or installing unit assemblies
A. When removing or installing a unit assembly, the order of work and techniques used are given for the removal
operation; the order of work for the installation operation is not given.
B. Any special techniques applying only to the installation procedure are marked , and the same mark is placed
after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to.
Example Explanation
(COMPONENT) REMOVAL Title of operation
WARNING!
Safety precautions to observe when performing an operation
1. XXX Text of or name of procedural step
A. Text of procedural step if 1 was procedural name
★ Technique or important point
Reference to a special technique during assembly or installation (note that

this symbol is right-aligned).
(COMPONENT) INSTALLATION Title of operation
• Installation is the reverse of removal. Overall directive
Special technique during assembly or installation (note that this symbol is

left-aligned).
(Component/assembly)
Specification
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as
PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when performing out
the operation.
3. Listing of special tools

For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure,
see the SPECIAL TOOL LIST later in this section.
830B/C-850B/C-870B/C 30-9
DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION
PRECAUTIONS DURING OPERATION

12
★ Be sure to follow the general precautions given below when carrying out removal or installation (disassembly or
assembly) of units.
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK

• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places before removal
to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the
connectors.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws alternately.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after
removal.
★ Precautions when handling piping during disassembling
• Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1. Hoses and tubes using sleeve nuts
Nominal Sleeve nut (elbow end) Use the two items

Plug (nut end)
number below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2. Split flange type hoses and tubes
Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
30-10 830B/C-850B/C-870B/C
3. If the part is not under hydraulic pressure, the following corks can be
used:
Dimensions
Nominal
Part Number
number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
PRECAUTIONS WHEN CLEANING AND INSPECTING

• All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or foreign
material enters the unit being assembled. Even minute particles can cause malfunction of close fitting parts, such as: thrust
bearing, matched parts, etc. Clean all metal parts thoroughly using a suitable cleaning fluid. It is recommended that parts
be immersed in cleaning fluid and moved up and down slowly until all oils, lubricants, and/or foreign materials are
dissolved and parts are thoroughly clean.
WARNING! When using solvent-type cleaners, exercise care to avoid inhalation of vapors, exposure
to skin, and creating fire hazards.
• For bearings that can be removed, soak them in a suitable cleaning fluid for a minute or two. Remove the bearings from
the cleaning fluid and strike them flat against a block of wood to dislodge solidified particles. Immerse the bearings again
in the cleaning fluid to flush out the particles. Repeat this step until the bearings are thoroughly clean. To dry the bearings,
use moisture-free compressed air. DO NOT spin an unlubricated bearing with the compressed air. A bearing may be
rotated slowly by hand to facilitate drying process.
• Carefully inspect all bearing rollers, cages, and cups for wear, chipping, or nicks. Do not replace a bearing cone or cup,
without replacing the mating cup or cone at the same time. After inspection, dip the bearings in lightweight oil and wrap
them in a clean, lintless cloth or paper to protect them until installation. For those bearings that must be inspected in place;
check them for: roughness during rotation, scoring, pitting, cracks or chipped races. If any of these defects are found,
replace the bearings. Also, inspect the bearing housing and shaft for grooves or galling, which would indicate the bearing
has been turning in its housing. Replace the shaft, the housing, or both, with a new bearing.
• It is more economical to replace the oil seals, O-rings, sealing rings, gaskets and snap rings when unit is disassembled
than waiting for premature failures; refer to the latest Parts Book for replacement items. Be extremely careful to avoid cut-
ting or scratching the seal during installation. Curling of a seal lip will seriously impair its efficiency. Apply a thin coat of
Loctite #120 to the outer diameter of the oil seal’s metal case. Do not get Loctite on the lip of the oil seal or that portion of
the seal will become brittle and leak. When replacing lip-type seals, ensure that the spring-loaded side is towards the oil.
• If available, use magnaflux, or a similar process, for checking for cracks that are undetected by the unaided eye. Examine
the teeth on all gears for wear, pitting, chipping, nicks, cracks or scoring. Replace all gears showing cracks or spots where
830B/C-850B/C-870B/C 30-11
case hardening has worn through. Small nicks may be removed with suitable hone. Inspect the shafts and quills to make
certain they are not sprung, bent, or splines twisted, and that shafts are true.
Remark
Spline wear is not considered detrimental, except where it affects the fit of the splined parts.
• Inspect the thrust washers for distortion, scores, burs, and wear. Replace any thrust washer, if defective or worn.
• Inspect the bores and bearing surfaces of the cast parts and machined surfaces for scratches, wear, grooves and dirt.
Remove any scratches and burrs with crocus cloth. Replace any parts that are grooved or worn.
• Check the sprockets for evidence of the chain climbing on the teeth. If an excessive amount of climbing is noticeable,
replace the sprockets.
• Thoroughly clean the interior and exterior of the housings, etc. Provided the cast parts do not have polished surfaces,
clean the cast parts in a hot tank using a mild alkali solution. Keep the parts in the solution until thoroughly heated and
cleaned. Rinse the parts with clean water to remove all traces of alkali. Cast parts can also be cleaned with a steam cleaner
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two or three
drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage,
then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press-fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.
• When using eye bolts, check that there is no deformation or deterioration, screw them fully, and align the direction of
the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
PRECAUTIONS WHEN COMPLETING THE OPERATIONS

• If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate
the coolant through the system. Then check the coolant level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to
circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair, bleed
air from the system after reassembling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related parts.
30-12 830B/C-850B/C-870B/C
12
OTHER PRECAUTIONS
• To maintain the performance of the machine and to prevent failures, it is particularly important to pay attention to the
degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or when replacing the filters,
check that the oil container and area around the filler of the hydraulic tank are clean.
• To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points when
disassembling or assembling.
• Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to be
disassembled.
• Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
• Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits or parts that
have failed.
• When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment completely.
• Do not use seal tape for the thread of the plug mounts or connections.
• If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and circuits to
remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, also carry
out thorough flushing of the hydraulic circuits.
• When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump piping, always bleed the
air before starting the engine to prevent seizure of the pump.
Remark
After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing
any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always
bleed the air as follows after completion of installation.
A. Run the engine at low idling, and extend and retract the steering, blade, and lift arm cylinders 4 - 5 times without
going to the end of this stroke. (Stop approximate 100 mm before the end of the stroke.)
★ If the engine is run at high speed from the start, or the cylinders are operated to the end of this stroke, the air
inside the cylinder will cause damage to the piston packing.
B. Operate the steering, blade, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the engine and bleed
the air from the plugs at the top of the hydraulic tank filter.
C. Raise the engine speed and repeat Step B to bleed the air. Repeat this procedure until no more air comes out from the
plugs.
D. After completing bleeding the air, tighten the plugs.
Plug: 11.3 ±1.5 Nm (8.33 ±1.10 lbf ft)
E. After repair or long storage, follow the same procedure.
830B/C-850B/C-870B/C 30-13
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
12
SPECIAL TOOL LIST
Nature of work Part Number Part Name Qty Remarks
Installation of cylinder head 790-331-1110 Wrench 1 For tightening cylinder head angle
Disassembly, assembly of transmission
799-301-1500 Leak tester 1 For checking operation of piston
assembly
Disassembly, assembly of final drive assembly 792-571-1600 Chain puller 1 For securing chain
790-502-1003 Repair stand 1
790-502-2000 Repair stand 1 Stand for disassembly cylinder
790-101-1102‘ Pump 1
790-330-1100 Wrench 1 Removal, installation of round head
790-302-1270 Socket (50 mm) 1 Leaning
Blade lift
790-102-1320 Socket (70 mm) 1 Drawbar shift Removal,
Blade shift installation of nylon
Power tilt nut
790-102-1330 Socket (75 mm) 1
Articulate
790-302-1340 Socket (80 mm) 1 Ripper
790-101-5021 Grip 1
Kit No. 790-201-1702
01010-50816 Bolt 1
790-201-1741 Push tool 1 Steering
790-201-1751 Push tool 1 Leaning
790-201-1781 Push tool 1 Drawbar shift
Blade lift Press fitting coiled
Blade shift bushing
790-201-1791 Push tool 1
Power tilt
Articulate
790-201-1811 Push tool 1 Ripper
Disassembly, assembly of hydraulic cylinder 790-101-5021 Grip 1
Kit No. 790-201-1500
01010-50816 Bolt 1
790-201-1550 Plate 1 Steering
790-201-1560 Plate 1 Leaning
790-201-1590 Plate 1 Drawbar shift
Blade lift
Press fitting dust seal
Blade shift
790-201-1610 Plate 1
Power tilt
Articulate
790-201-1620 Plate 1 Ripper
790-720-1000 Expander 1
796-720-1630 Ring 1
Steering
07281-00709 Clamp 1
796-720-1650 Ring 1
Leaning
07281-01029 Clamp 1
796-720-1650 Ring 1 Blade lift
Installation of piston
Blade shift
07281-01159 Clamp 1 ring
Drawbar shift
796-720-1670 Ring 1 Power tilt
07281-01279 Clamp 1 Articulate
796-720-1680 Ring 1
Ripper
07281-01589 Clamp 1
30-14 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Remark
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
TRANSMISSION
CHANNEL SUPPORT TOOL
When the transmission is in place, it supports the rear of the engine. But when the transmission is removed for repairs, the rear
of the engine needs support. Thus, the channel support tool (below) supports the engine after removing the transmission from
the grader.
830B/C-850B/C-870B/C 30-15
12
CLUTCH PACK REMOVAL TOOL
The clutch pack removal tool (below) removes the three clutch pack assemblies from the transmission. Because of the clutch
pack’s interlocking gear design, it is impossible to remove them individually. The tool slides in the oil passage lands on the
clutch pack support shaft. Do not confuse these lands with the seal ring grooves.
30-16 830B/C-850B/C-870B/C
12
CLUTCH SPRING COMPRESSION TOOL
The tool compresses the clutch spring to allow removal of the retaining ring in each clutch pack.
830B/C-850B/C-870B/C 30-17
12
CIRCLE REVERSE MOTOR (PARKER)
SPECIAL BEARING MANDREL TOOL
30-18 830B/C-850B/C-870B/C
12
CIRCLE REVERSE MOTOR (CHAR-LYNN)
ASSEMBLY BULLET TOOL
SEAL BULLET TOOL
830B/C-850B/C-870B/C 30-19
12
SEAL INSTALLATION TOOL
30-20 830B/C-850B/C-870B/C
12
HYDRAULIC MOTOR
SHAFT BEARING REMOVAL / INSTALLATION TOOL
830B/C-850B/C-870B/C 30-21
12
HOUSING BEARING RACE REMOVAL TOOL
BEARING RACE INSTALLATION TOOL
30-22 830B/C-850B/C-870B/C
12
SHAFT SEAL DRIVER TOOL
830B/C-850B/C-870B/C 30-23
12
HYDRAULIC OIL SWIVEL BLOCK - 4 WAY
SWIVEL BLOCK SEAL TOOL
Using a swivel-block seal tool to install a two-piece oil seal in a groove of

the swivel block pin. Use clean hydraulic oil to coat the seal and the outside
of the tool, allowing the seal to slide into position.
30-24 830B/C-850B/C-870B/C
12
CIRCLE SLIP CLUTCH GAUGE TOOL
The circle slip clutch gauge tool is used instead of the Belleville springs to determine the slip clutch shim pack thickness.
Remove the gauge after determining the shim pack thickness.
Circle Slip Clutch Gauge Tool (part number DR11-901). Refer to “Service Tools Catalog” 1128166R2, Section 11.
Orders for these tools should be placed with your distributor.
830B/C-850B/C-870B/C 30-25
12
TANDEM CASE
WHEEL KNOCKER TOOL
The wheel knocker frees the axle from the wheel.
Using tire tongs b, sling the tire. Install the wheel knocker tool c on the
axle e. Strike the tool b with the sledge hammer to separate the wheel d
from the taper of the axle.
AXLE LIFTING TOOL

The axle lifter tool removes the axle from the tandem case
Install the axle lifting tool b on the end of the axle c. Using a suitable
lifting device, lift the axle from the tandem case d.
30-26 830B/C-850B/C-870B/C
12
AXLE ROLLING TORQUE TOOL
The axle rolling torque tool obtains the proper preload on the tandem case
axle bearings.
Install the axle rolling torque tool b on the end of the axle c. Using a 0 to
100 lbf in (0 to 11.2 Nm) dial indicator or beam-type torque wrench,
measure the rolling torque.
Remark
Do not use a click-type torque wrench.
SPREADER BAR AND CHAINS

The spreader holds the chains apart while removing and installing the axle assembly. The manufacturing details for the
spreader are below.
830B/C-850B/C-870B/C 30-27
12
Two chains, each 17 ft (5.18 m) long with 3/8 in links are required.
Notch the spreader bar to receive the 3/8 in chain link. Both ends of the spreader must be moused (locked) to the chain, 6 ft
(1.83 m) from the lifting eye(s). The chains must have a minimum lifting capacity of 2 tons (1.81 metric tons).
Attach the spreader bar between the chains (right).
A piece of wire passed through the two drilled holes and twisted will hold the chain in position in spreader bar.
30-28 830B/C-850B/C-870B/C
12
AWD - GEARBOX ASSEMBLY
SEAL INSTALLATION TOOL
Use P/N DR08-106 (right) to install the two-piece seal. Refer to the
“Service Tools Catalog” 1128-166-R1, Section 8.
830B/C-850B/C-870B/C 30-29
12
AWD - MOTOR (VICKERS-EATON)
SPECIAL SHAFT BEARING REMOVAL AND INSTALLATION TOOLS
HOUSING BEARING RACE REMOVAL TOOL
30-30 830B/C-850B/C-870B/C
12
SPECIAL BEARING RACE INSTALLATION TOOL
SHAFT SEAL DRIVER
830B/C-850B/C-870B/C 30-31
12
SPREADER BAR AND CHAINS
The spreader holds the chains apart while removing and installing the axle assembly. The manufacturing details for the
spreader are below.
Two chains 17 ft (5.18 m) long with 0.375 in (9.525 mm) links are required. The chains must have a minimum lifting capacity
of 2 tons (1.81 metric tons).
Notch the spreader bar to receive a 0.375 in (9.525 mm) chain link. Both ends of the spreader must be moused (locked) to the
chain 6 ft (1.83 m) from the lifting eye(s). Attach the spreader bar between the chains (right). After passing a piece of wire
through the two drilled holes, twist the wire to hold the chain in position in the spreader bar.
30-32 830B/C-850B/C-870B/C
DIFFERENTIAL BACKLASH TOOL (DR08-111)

The differential backlash tool DR08-111 is designed to expand into the
splines of the No-Spin differential and have a bar rotate around its
centerline at the same distance of the ring gear O.D. This tool must be used.
There is no physical way to measure the backlash after installing the pinion
gear.
Install the backlash tool into the No-Spin to measure the backlash of the
ring gear. A dial indicator set at the same O.D. of the ring gear is used to
measure the backlash on the bar.
830B/C-850B/C-870B/C 30-33
12
MEMORANDUM
30-34 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY ARTICULATION JOINT
12
ARTICULATION JOINT
830B/C-850B/C-870B/C 30-35
12
Remark
Thoroughly clean the component to be serviced and the surrounding area. Cleaning helps prevent
contamination from entering the component or system being serviced.
REMOVAL
1. For adequate stability, position the motor grader moldboard crosswise under the machine.
2. Position the rear module straight ahead (centered), NOT articulated one way or the other.
3. For safety, lower the moldboard to the floor and position on suitable blocks.
4. Tag the ignition key and then remove it.
5. Remove the clamp b and exhaust stack c from the muffler d.
6. Remove the clamp b and air intake cap c from the air intake tube d.
7. With the sidehood b still supported, remove the gas spring door
cylinder c from the sidehood b and rear cowl d.
30-36 830B/C-850B/C-870B/C
12
8. Remove the 16 bolts and plain washers b that secure the hood top c
to the front and rear cowls.
9. Using a suitable lifting device, sling the hood top b as shown. Remove
the hood top from the grader.
Remark
Set the hood top on the front frame member in front of the lift
cylinders. Doing so helps prevent the sheet metal and hood
sides from warping.
Remark
If the unit is equipped with an air restriction indicator c,
disconnect the plastic tube leading to the indicator. The tube
is located inside the left hood top lip.
10. Remove the two bolts, lock washers, and plain washers from the
bottom b and top c of the front shell weldment d on each side.
11. Install a suitable lifting eye in the top/center shell. With the strap and
overhead hoist, remove the shell. Place the shell away from the work
area.
Remark
When removing the shell, do not damage the radiator
overflow tube on the right side of the machine. Also, do not
damage the rubber radiator strips. Pay particular attention to
these two areas.
12. Remove one bolt, lock washer, b and clamp c.
13. Remove the bolt, lock washer, and articulation indicator control rod
end d.
14. Disconnect the electrical connections of wire numbers 0 and 53A e at

the articulation sender.
830B/C-850B/C-870B/C 30-37
12
15. After removing the two bolts and lock washers b from the top and
bottom, lift off the plates c. Use a Port-a-power to remove the pins.
16. At the grill’s midpoint, remove the bolt and flat washers b. At the
lower corners, remove the two hexnuts and flat washers c that secure
the rear grill d to the rear cowl e.
17. Using a 10 ton (9.07 metric ton) overhead hoist, support the rear half
of the articulated frame. Apply moderate tension to the chain.
18. Remove the air baffle.

Remove the four bolts, lock washers, plain washers b, hose clamps
and plate c.
30-38 830B/C-850B/C-870B/C
12
19. Remove the two bolts, lock washers, and retainer plate top b and
bottom c.
20. Remove the plates and shims from the top articulation joint.
Remark
Repeat this step for the bottom articulation joint.
21. Place a suitable 10-ton jack b under the front module for support.
22. Using another hydraulic jack c, remove the bottom hinge pin.
23. Install a hydraulic jack between the remaining top articulation

assembly and the top of the bottom hinge pin assembly. Using the jack,
remove the top hinge pin.
830B/C-850B/C-870B/C 30-39
12
DISASSEMBLY
30-40 830B/C-850B/C-870B/C
12
1. Separate the front half of the grader from the rear half. Remove the six hex nuts, lock washers and bolts b, top bearing cap
c, shims d, seal e, and grease zerk f.
Remark
Block the tires so the unit does not coast forward during disassembly.
2. Remove the bearing cartridge g, bearings h, and seal i, using a hydraulic jack with spacers.
3. Remove the six spacers j and inspect them; replace with new ones, if necessary.
Remark
Two spacers exist in the top articulation joint and four in the bottom joint.
4. Remove the thrust washer 1) from under the bearing cartridge g.
5. Remove the bearing cup 1% and oil seal 1^ from the bearing
cartridge 1&.
6. Remove the oil seal 1* from the bearing cap 1(.
Remark
If bearing is to be cleaned and reused, keep all component parts together. The cups, cones and spacers are
a matched set. Do not intermix the parts.
830B/C-850B/C-870B/C 30-41
12
ASSEMBLY
30-42 830B/C-850B/C-870B/C
12
1. Shims d and 1# for both bearing caps c and retaining plates 1) are available in various sizes: 0.005 in (0.127 mm), 0.007
in (0.178 mm), and 0.020 in (0.508 mm).
2. Install all spacers j prior to the pins 1@ (two on top; four on bottom).
3. Two retaining plates 1) exist for each half of the articulation joint (top section and bottom section).
4. If the spacers were removed for inspection, reinstall them with the chamfered edge toward the inside of the web assembly.
Remark
See the articulation joint cross-section view for reference, “ARTICULATION JOINT” on page 30-35.
5. Hand pack each bearing assembly h with approved grease.

Remark
See the cross-section view of the articulation joint for proper installation of the oil seals e and i
“ARTICULATION JOINT” on page 30-35.
6. Install the seal i and the double-tapered roller bearing h into the bearing cartridge g.
Remark
Before installing the bearing, look for the engraved numbers along the outside diameter of the bearing cups
and cones. Match the bearing pieces with the numbers.
7. Install each bearing cap c for the bottom section and top section, without the shims d. Install the six bolts, lock
washers, and hexnuts b.
Bolts b of the bearing caps c: 15 lbf ft (20.3 Nm)
8. Strike the bearing cap c with a soft-faced mallet, until seated against the bearing h to ensure that the caps are drawn
down evenly.
9. Recheck the torque of the bolts b.
10. With a feeler gauge, measure the gap between the bearing cap c and the housing at two places, 180° apart.
11. Deduct 0.002 in (0.051 mm) from the reading and insert the shims to obtain the desired clearance.
12. After determining the proper shim pack thickness, remove the bearing caps c. Apply a liberal amount of liquid gasket
around the shim pack area because moisture tends to penetrate the shim pack area.
13. Reinstall the bolts, lock washers, and hexnuts b.
Bolts b: 55 lbf ft (74.5 Nm)
14. Install a grease zerk f.
15. Install the spacers j, top and bottom sections (top spacer - chamfer side down; bottom spacer - chamfer side up).
16. Install the retaining plates 1) with the lock washers and bolts 1!, but without the shims 1#.
Bolts 1!: 22 lbf ft (29.8 Nm)
17. With a feeler gauge, measure the gap between the plate and the top of the web at two places, 180° apart. Ensure that plate
deflection doesn’t exist because of the load applied by the bolts.
830B/C-850B/C-870B/C 30-43
12
18. After determining the proper shim pack thickness, remove the plate 1), and the lock washers and bolts 1!. Apply a
liberal amount of liquid gasket around both ends of the pins 1@, prior to reinstalling the shims d and retaining plates 1).
19. Position the front and rear modules of the grader together.
Remark
Do not forget to install the thrust washer 1$ prior to installing the hinge pin.
20. Install the hinge pins 1@ chamfered side down. Use a 10-ton (9.07 metric ton) jack from the underside, pushing up.
Remark
The upper hinge pin must be drawn up against the upper retaining plate. However, the lower hinge pin must
be drawn down toward the lowermost retaining plate.
Bolts 1!: 110 lbf ft (149.1 Nm)
21. Remove the 10-ton (9.07 metric ton) hydraulic jack(s).
Remark
TOP BEARING CAP: Locate the grease zerk 40° from the machine centerline.
BOTTOM BEARING CAP: Locate the grease zerk 30° from the machine centerline.
30-44 830B/C-850B/C-870B/C
12
INSTALLATION
1. Position the articulation cylinders in place. Drive the pin through the
anchor brackets and cylinder bores, with the chamfered side down.
Install the lock washers and bolts b.
Bolts: 23 lbf ft (31.1 Nm)
Pins are to be drawn up against the upper retaining plate c.
2. Install the bolt, lock washer, and articulation indicator control rod end
d.
3. Position the hoses through the clamp c and install the bolt and lock
washer b. Tighten the bolt.
4. Reconnect the electrical connections of wires 0 and 53A e.
5. Secure the rear grill d to the rear cowl e with the two flat washers and
hexnuts c at the lower corners and one flat washer and bolt b at the
midpoint.
6. Using the overhead hoist, position the front shell weldment d in place.
Remark
During installation, do not damage the rubber radiator
overflow tube and rubber strips on the sides of the radiator.
7. Install the two inboard bolts c lock washers and plain washers. Install
the two outboard bolts, lock washers and plain washers b. These are
on each side of the front shell weldment.
8. Torque the bolts according to the standard torque value table.
830B/C-850B/C-870B/C 30-45
12
9. Using a suitable lifting device, sling the hood top b as shown. Set the
hood top into position on the front and rear cowls.
Remark
be sure to reconnect the plastic tube leading to it located
inside the hood top lip by the left hood side.
10. Install the 16 bolts and plain washers b to secure the hood top c to the
front and rear cowls.
11. Check to ensure that the hood sides can be opened without dragging. If
the hood sides drag, remove the bolts and install washers under the
bolt heads. Reinstall the bolts and retorque them.
12. Support the hood side b while installing the door gas cylinder c
between the hood side and rear cowl d.
13. Secure the air intake cap c to the air intake tube d with the clamp b.
30-46 830B/C-850B/C-870B/C
12
14. Secure the exhaust stack c to the muffler d with the clamp b.
Remark
The exhaust stack must point towards the rear of the grader.
15. Start the engine and test the hydraulic articulation. Move the controls
until all functions operate normally. Recheck the hydraulic oil level
and refill as necessary.
830B/C-850B/C-870B/C 30-47
DISASSEMBLY AND ASSEMBLY ENGINE HOOD, FRONT & REAR COWLING
12
ENGINE HOOD, FRONT & REAR COWLING
REMOVAL
1. Thoroughly clean the component to be serviced and the surrounding area. Plug and/or cap all connections and ports that
are opened. These steps help prevent hydraulic system contamination.
2. Park the grader so that the hood top and transmission are within reach of a 2-ton lifting device. Position the moldboard
crossways under the grader so that the moldboard rests solidly on the ground. Turn the engine off and apply the parking
brake. Disconnect the negative (-) battery cables from the batteries to prevent the grader from accidentally starting.
3. Remove the bolt and flat washers b and the two hexnuts and flat
washers c, securing the rear grill d to the rear cowl e.
4. Drain the fuel tank. Drain the hydraulic oil tank. Remove the drain
plug b and attach a drain hose to the bottom of the hydraulic oil tank.
Fuel tank: 91.5 gal (346 L)
Hydraulic tank: 16 gal (60.6 L)
Remark
The hydraulic oil tank shown is an All-Wheel-Drive unit. On a
non-all wheel unit, the drain plug will be located where the
temperature sensor c is installed.
5. Reinstall the drain plug when finished draining the hydraulic oil tank.
6. Remove the clamp b and exhaust stack c from the muffler d.
30-48 830B/C-850B/C-870B/C
12
7. Remove the clamp b and air intake cap c from the air intake tube d.
8. Support the hood side b. Remove the door’s gas cylinder c from the
hood side and rear cowl d.
9. Remove the 16 bolts and flat washers b that secure the hood top c to
the front and rear cowls.
10. Using a suitable lifting device, sling the hood top b as shown. Remove
the hood top from the grader.
Remark
Set the hood top on the front frame member in front of lift
cylinders. This will help prevent the sheet metal and hood
sides from warping.
Remark
Disconnect the plastic tube leading to the air restriction
indicator c, if so equipped. The tube is located inside the left
hood top lip.
830B/C-850B/C-870B/C 30-49
12
11. Remove the three bolts, lock washers, and flat washers b that secure
the rear cowl c to the frame d on each side. Remove the two bolts,
lock washers, and flat washers that secure the rear cowl to the battery
tray e.
12. Remove the two bolts, lock washers, and flat washers that secure the
rear cowl to the engine panel on the other side.
13. Using a suitable lifting device, sling the rear cowl b through the fuel
tank and hydraulic oil tank access cover holes.
14. Disconnect the electrical connector c.
15. Lift the rear cowl b and move it slowly rearward to expose the wires
c to the fuel tank sending unit d. Tag and the wires before
disconnecting them.
16. After disconnecting the wires, remove the rear cowl.
30-50 830B/C-850B/C-870B/C
12
INSTALLATION
1. Secure the tank support c to the side frame d with the bolts, flat
washers, and hex nuts b.
2. Secure the tank support bracket c to the frame studs d with the flat
washers and hex nuts b on each side.
3. See “FUEL TANK AND HYDRAULIC TANK” on page 30-54 - INSTALLATION.
4. Sling the rear cowl through the fuel tank and hydraulic oil tank access
cover holes. Raise the rear cowl.
5. Connect the wires c to the fuel tank sending unit d.
6. Set the rear cowl b into position on the rear frame.
7. Reconnect the electrical connector c leading to the tail lights, fuel

tank sending unit, hydraulic oil filter indicator, back-up alarm and
hydraulic oil temperature sensor (and other accessories if applicable).
8. Ensure that all hoses and electrical connections have been made.
830B/C-850B/C-870B/C 30-51
12
9. Install the flat washers, lock washers, and bolts that secure the rear
cowl c to the battery tray e. Install the two flat washers, lock
washers, and bolts that secure the rear cowl to the engine panel on the
other side.
10. Secure the rear cowl to the frame d with the flat washers, lock
washers, and bolts b on each side.
11. Using a suitable lifting device, sling the hood top b in opposite
corners. Set the hood top into position on the front and rear cowls.
Remark
reconnect it to the plastic tube, which is located inside the left
side hood top lip.
12. Secure the hood top c to the front and rear cowls with the bolts b.
13. Check to ensure that the hood sides can be opened without dragging. If
the hood sides drag, remove the bolts and install washers under the
bolt heads. Reinstall the bolts and retorque them.
14. Support the side hood b and install the gas door prop c between the
hood side and rear cowl d.
30-52 830B/C-850B/C-870B/C
12
15. Secure the air intake cap c to the air intake tube d with the clamp b.
16. Secure the exhaust stack c to the muffler d with the clamp b.
Remark
The exhaust stack must point towards the rear of the grader.
17. Reconnect the (-) negative battery cables.
18. Secure the rear grill d to the rear cowl e with flat washers and nuts at
each lower corner c, and a bolt and flat washer in the center b.
830B/C-850B/C-870B/C 30-53
DISASSEMBLY AND ASSEMBLY FUEL TANK AND HYDRAULIC TANK
12
FUEL TANK AND HYDRAULIC TANK
REMOVAL
Remark
See “ENGINE HOOD, FRONT & REAR COWLING” on page
30-48 - REMOVAL.
1. Disconnect, plug and/or cap the fuel return line b and elbow c.
2. Close the fuel shut-off valve and disconnect the supply hose d. Drain
the fuel tank. Plug the supply hose. Cap the shut-off valve.
3. Drain the hydraulic tank. Tag and disconnect all hoses from the bottom
of the hydraulic oil tank b and hydraulic oil filter c.
Hydraulic oil tank: 16 gal (60.6 L)
4. Remove the two nuts and flat washers b that secure the tank support
bracket c to the frame studs d on each side.
5. Remove the two hexnuts, flat washers, and bolts b that secure the tank
support c to the side of the frame d.
30-54 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY FUEL TANK AND HYDRAULIC TANK
12
6. Disconnect the air restriction indicator tube b from the air cleaner
outlet c.
7. Remove the clamp d and pump hose e from the air cleaner outlet.
8. Using a suitable lifting device, sling the tank support and tanks b as
shown.
9. Check to ensure that all hoses are disconnected from the bottom of the
hydraulic oil tank and fuel tank.
10. Remove the tank assembly from the grader.
INSTALLATION
• Install in reverse order as REMOVAL.
• Ensure that all hoses and electrical connections have been made.
• Fill the hydraulic oil tank with hydraulic oil to the FULL mark on the sight gauge. After unit has run for a while, recheck
the level and add more oil, if needed.
Hydraulic oil tank: 16 gal (60.6 L)
• Fill the fuel tank.
Remark
Refer to the Operator's Manual for the proper hydraulic oil specifications and fill capacities.
Remark
To install the “ENGINE HOOD, FRONT & REAR COWLING” on page 30-48 - INSTALLATION.
830B/C-850B/C-870B/C 30-55
DISASSEMBLY AND ASSEMBLY TRANSMISSION SHIFTER
12
REMOVAL
1. Remove bolt (1), washer (2) and top console cover (4), along with lower front console cover (6).
2. Disconnect Deutsche electrical connector.

Remark
The Deutsche connector has to be disconnected with a 5/32 Allen wrench.
3. Remove the four bolts (1) and washers (2), now lift out the transmission shifter.
INSTALLATION
1. Install in reverse order of removal.
30-56 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY TRANSMISSION POWER SHIFT
12
REMOVAL
1. Thoroughly clean the component to be serviced and the surrounding area. Plug and/or cap all connections and ports that
are opened. These steps help prevent hydraulic system contamination.
2. Park the grader so that the hood top and transmission are within reach of a 2-ton lifting device. Position the moldboard
crossways under the grader so that the moldboard rests solidly on the ground. Turn the engine off and apply the parking
brake. Disconnect the negative (-) battery cables from the batteries to prevent the grader from accidentally starting.
3. Open the drain plug (arrow) and drain the transmission fluid prior to
removing the transmission from the unit. Reinstall the drain plug.
Discard the used transmission fluid. The transmission holds 7 U.S.
gallons (26.5 L).
4. See “ENGINE HOOD, FRONT & REAR COWLING” on page 30-48

and “FUEL TANK AND HYDRAULIC TANK” on page 30-54 to
gain access to transmission power shift components.
5. Remove the flanged 12-point bolts b and the lock washers that secure
the drive shaft c to the transmission output yoke d.
6. Main system pump (standard)
A. Tag the hoses b thru d from the main system pump e. After
disconnecting the hoses, plug them to prevent contamination from
entering the system.
B. Remove the four bolts and lock washers f that secure the main
system pump to the transmission charge pump g. Support the
main system pump while removing it from the transmission
charge pump.
C. Tag the electrical connections h and i before disconnecting

them.
D. Tag the transmission charge pump hoses j and 1) before disconnecting them from the elbows.
830B/C-850B/C-870B/C 30-57
E. Remove the sleeve b and the O-ring c from the main system
pump d.
7. All-wheel-drive pump (optional)
A. Tag all hoses b from the all-wheel-drive pump c before

disconnecting them. Plug the hoses after disconnecting them from
the pump.
B. Remove the screw securing each electrical terminal d and e to

the control module f.
C. Support the pump and then remove the two bolts g and flat
washers, pump, and gasket from the transfer case h.
D. Disconnect the hose i between the transfer case and the elbow j.
Remark
The transfer case should be serviced at the same time as the
transmission. Refer to the “Transfer Case” section of this
manual. The removal of the transfer case is part of the
disassembly procedure.
8. All-wheel-drive rear sensor (optional)
A. Disconnect the electrical lead b from the rear sensor c.
B. Loosen the jamnut d and unscrew the sensor from the

transmission housing.
9. Remove the electrical lead b from the converter oil temperature

sending unit c.
10. Remove the converter oil in hose d and converter oil out hose e from
the tee.
30-58 830B/C-850B/C-870B/C
12
11. Using a suitable lifting device, sling the transmission b as shown.
12. Remove the engine flywheel housing access cover b from the
flywheel housing c.
13. Bar the engine crankshaft over to gain access to the drive plate
mounting bolts. Remove all eight bolts and flat washers.
14. Remove the two prevailing torque nuts, four flat washers, and two
bolts b from the transmission support c and frame d.
15. Loosen but DO NOT remove the four bolts that connect the front
engine support to the frame.
16. Raise the transmission just enough to allow the piece of the channel to
be placed under the engine flywheel housing and rest on frame support
for transmission mount. Lower transmission and allow flywheel
housing to rest on channel.
WARNING! Prior to separating the transmission from the flywheel housing, ensure that all hoses and
electrical leads are disconnected from it. Do not damage the sending units and solenoids
when removing the transmission. When raising the
transmission, be careful not to allow the engine fan blade to hit the radiator.
17. Remove the 11 bolts and flat washers that secure the transmission to the flywheel housing. Mark the location of the two
bolts that secure the transmission dipstick and ground strap. These two bolts are different lengths.
18. Carefully pull the transmission rearward, separating it from the flywheel housing.
19. At this point refer to “Servicing the Machine After Transmission Overhaul” section of this manual. Items mentioned in
this section can be performed simultaneously as the transmission disassembly and reassembly.
830B/C-850B/C-870B/C 30-59
12
DISASSEMBLY
1. With a 5/8 in Allen wrench, remove the drain plug b from the transmission case c and drain 27 U.S. quarts of C-3
transmission fluid from the case, if not drained during removal.
2. Remove the bolts d and e, hexnuts g and star washers f.Remove the charge pump h with gasket i and O-ring j.
3. Remove the retaining ring 1) and gear 1! from the charge pump housing.
4. With suitable bearing puller, remove the bearing 1@.
5. Because the charge pump internal parts are not serviced, disassembly would be of no use. Order a new charge pump if
found to be defective.
6. Remove the bolts 1# and 1$, flat washers 1%, valve body 1^, and gasket 1&.
30-60 830B/C-850B/C-870B/C
12
7. Remove the bolts 1*, ring 1(, drive plates 2), and converter drive-plate assembly 2!.
8. Remove the torque converter assembly 2@.
9. Remove the bolts 2$, 2%, 2^, 2&, 2* and 2( and gasket 3).
10. With a nylon strap, sling the front cover 2# and separate it from the transmission case c.
830B/C-850B/C-870B/C 30-61
12
FRONT COVER DISASSEMBLY
1. Remove the bolts b, bearing retainer c with oil seal d, plastic strip gasket e, and bearing f from the front cover g.
2. Remove the bolts that secure the bearing retainer h to the rear of the front cover.
3. Remove the impeller hub gear 2* and thrust washer 2( from the stator support hub splines.
4. Remove the bolts i, cover plate j, and stator support tube 1).
5. With a soft-face hammer, drive the input shaft 1! through the housing from the front to the back side. Remove the ball
bearing 1@, retaining ring 1#, and seal ring 1$.
6. Remove the cover 1% with O-ring 1^, bolt, retaining washer, roll pin, idler shaft 1&, bearing 1*, retaining ring 1(, auxiliary
pump gear 2), bearing 2! and retaining ring 2@.
7. Remove the lube tube 3) and elbow 3! from the front cover g, if necessary.
30-62 830B/C-850B/C-870B/C
12
8. Remove the bolts, oil passage cover 2#, and ring seal 2$.
9. Remove the ball bearings, pipe plug 2%, converter relief valve assembly 2^, and breather 2&.
10. If replacement is necessary, remove the sleeves 3@ from the front cover g.
Remark
When removing the sleeves, notice the tag location inside the lip that aligns with the index notch.
830B/C-850B/C-870B/C 30-63
12
MAIN CASE DISASSEMBLY
1. Using suitable blocking/cribbing, lay the main case assembly b on its back. Make certain it is adequately supported in
order that personal injury will not result.
2. Using the clutch pack removal tool, remove the three clutch pack
assemblies c,d, and e simultaneously.
3. With the use of a suitable bearing puller, remove the three inner
bearings f and two outer bearings g.
4. Remove the bolt h, washer i, O-ring 1), and yoke 1!.
5. Remove the bolts 1@, bearing retainer 1#, O-ring 1$, oil seal 1%, and
bearing cup 1^.
6. With a suitable puller, remove the bearing cone 1&.
7. Raise the main case from the blocking and set the case in an upright position.
30-64 830B/C-850B/C-870B/C
12
8. Remove the retaining ring 1* from the output shaft 1(.
9. Remove the bolts 2), bearing retainer 2!, shims 2@, O-ring 2#, and
bearing cup 2$.
10. Slide the output shaft through the output gear 2& and main case, with
the bearing cone 2*.
11. Remove the bolts 2% and seal washers j and oil baffle 2^.
Remark
Discard the seal washers j.
12. Remove the suction screen 2( and seal 3) from the transmission case
b.
13. Remove the bolt 3@, clamp 3#, and suction tube 3$ from the
transmission case b.
830B/C-850B/C-870B/C 30-65
12
TORQUE CONVERTER DISASSEMBLY
1. Remove the bolts b and locknuts c. Separate the front cover d from the impeller f.
2. Remove the O-ring 2$ from the impeller f.
3. Remove the needle bearing e from the front cover d.
4. Remove the thrust washer g and thrust bearing h from the turbine i.
5. Remove the turbine i, thrush washer 1#, thrust bearing j, and thrust washer 1) from the fixed-stator hub 1$.
6. Remove the stator and hub assembly from the impeller f and thrust bearing assembly 1*, 1&, 1^.
30-66 830B/C-850B/C-870B/C
12
7. Remove the internal retaining ring 1% and fixed-stator hub 1$ from the stator 1!. Remove the internal retaining ring 1@ from
the stator 1!.
8. Remove thrust washer 1^, thrust bearing 1&, and thrust washer 1* from the impeller f.
9. Remove the bolts 1(, seal washers 2) and impeller hub 2! from impeller f. Remove the O-ring 2@ and seal ring 2# from the
impeller hub.
830B/C-850B/C-870B/C 30-67
12
CLUTCH PACK 1 AND 5 DISASSEMBLY (FIRST STAGE)
DISASSEMBLE THE FIFTH CLUTCH PACK AS FOLLOWS:
1. Remove the seal rings b from the shaft of the clutch pack housing 1*.
2. Remove the inner bearing race c from the shaft of the clutch pack housing 1*.
3. Remove the retaining ring d and gear and hub assembly f from the clutch pack housing 1*. Remove the bearing e with
the gear and hub assembly f.
4. Using a suitable puller, remove the bearings e and g from the gear and hub assembly f.
5. Remove the retaining ring h and retainer i from the clutch pack housing 1*.
6. Remove the separator plates j and clutch plates 1).
30-68 830B/C-850B/C-870B/C
12
7. Using the clutch-spring compression tool and a suitable press, depress the retainer 1@ slightly so that the retaining ring 1!
can be removed.
8. Remove the tool, retainer 1@, spring 1#, and piston 1% from the clutch pack housing 1*.
9. Remove the O-ring 1$ from the piston’s 1% I.D.
10. Remove the back-up ring 1^ and lip seal 1& from the bore of the clutch pack housing 1*.
DISASSEMBLE THE FIRST CLUTCH PACK AS FOLLOWS:
1. Remove the inner bearing race 3% from the shaft of the clutch pack 1*.
2. Remove the retaining ring 3$ from the shaft of the clutch pack housing 1*.
3. Remove the gear and hub assembly 3! from the clutch pack housing 1*.
4. Using a suitable puller, remove the bearing 3# from the gear and hub assembly 3!.
5. Remove the retaining ring 3@ from the gear and hub assembly 3!.
6. Using a suitable puller, remove the bearing 3) from the clutch pack shaft 1* or gear and hub assembly 3!.
7. Remove the retaining ring 2( and retainer 2* from the clutch pack housing 1*.
8. Remove the separator plates 2^ and clutch plates 2& from the clutch pack housing 1*.
9. Using the clutch spring compression tool and suitable press, depress the retainer 2$ just enough to remove the retaining
ring 2% from the shaft of the clutch pack housing 1*.
10. Remove the tool, retainer 2$, spring 2#, and piston 2! from the clutch pack housing 1*.
11. Remove the O-ring 2@ from the piston’s 2! I.D.
12. Remove the back-up ring 2) and lip seal 1& from the clutch pack housing 1*.
830B/C-850B/C-870B/C 30-69
12
CLUTCH PACK 2 AND 6 DISASSEMBLY (SECOND STAGE)
DISASSEMBLE THE SIXTH CLUTCH PACK AS FOLLOWS:
1. Remove the seal rings b from the shaft of the clutch pack housing 2).
2. Remove the inner bearing race c from the shaft of the clutch pack housing 2).
3. Remove the retaining ring d and gear and hub assembly g from the clutch pack housing 2). Remove the bearing e with
the gear and hub assembly g.
4. Using a suitable puller, remove the bearings e and i from the gear and hub assembly g.
5. Remove the retaining rings f and h from the gear hub assembly g.
6. Remove the retaining rings j and retainer 1) from the clutch pack housing 2).
7. Remove the separator plates 1@ and clutch plates 1!.
30-70 830B/C-850B/C-870B/C
12
8. Using the clutch-spring compression tool and a suitable press, depress the retainer 1$ slightly so that the retaining ring 1#
can be removed.
9. Remove the tool, retainer 1$, spring 1%, and piston 1& from the clutch pack housing 2).
10. Remove the O-ring 1^ from the piston’s 1& I.D.
11. Remove the back-up ring 1* and lip seal 1( from the bore of the clutch pack housing 2).
DISASSEMBLE THE SECOND CLUTCH PACK AS FOLLOWS:
1. Remove the inner bearing race 3% from the shaft of the clutch pack 2).
2. Remove the retaining ring 3# from the shaft of the clutch pack housing 2).
Remark
The outer bearing race 3$ remains in the case while the inner bearing race is an integral part of the of the
gear and hub assembly 3#.
3. Using a suitable puller, remove the bearing 3@ from the shaft of the clutch pack housing 2)
4. Remove the retaining ring 3! and retainer 3) from the clutch pack housing 2).
5. Remove the separator plates 2) and clutch plates 2* from the clutch pack housing 1*.
6. Using the clutch-spring compression tool and a suitable press, depress the retainer 2^ slightly so that the retaining ring 2&
can be removed.
7. Remove the tool, retainer 2^, spring 2%, and piston 2# from the clutch pack housing 2).
8. Remove the O-ring 2@ from the piston’s 2! I.D.
9. Remove the back-up ring 2@ and lip seal 2! from the clutch pack housing 2).
830B/C-850B/C-870B/C 30-71
12
CLUTCH PACK 3 AND 4 DISASSEMBLY (THIRD STAGE)
DISASSEMBLE THE FOURTH CLUTCH PACK AS FOLLOWS:
1. Remove the seal rings b from the shaft of the clutch pack housing 2).
2. Remove the inner bearing race c from the shaft of the clutch pack housing 2).
3. Remove the retaining ring d and gear and hub assembly g from the clutch pack housing 2). Remove the bearing e with
the gear and hub assembly g.
4. Using a suitable puller, remove the bearings e and i from the gear and hub assembly g.
5. Remove the retaining rings f and h from the gear hub assembly g.
6. Remove the retaining rings j and retainer 1) from the clutch pack housing 2).
7. Remove the separator plates 1@ and clutch plates 1!.
30-72 830B/C-850B/C-870B/C
8. Using the clutch-spring compression tool and a suitable press, depress the retainer 1$ slightly so that the retaining ring 1#
can be removed.
9. Remove the tool, retainer 1$, spring 1%, and piston 1& from the clutch pack housing 2).
10. Remove the O-ring 1^ from the piston’s 1& I.D.
11. Remove the back-up ring 1* and lip seal 1( from the bore of the clutch pack housing 2).
DISASSEMBLE THE THIRD CLUTCH PACK AS FOLLOWS:
1. Remove the inner bearing race 3% from the shaft of the clutch pack 2).
2. Remove the retaining ring 3# from the shaft of the clutch pack housing 2).
3. Using a suitable puller, remove the inner bearing 3$ from the shaft of the clutch pack housing 3#.
4. Using a suitable puller, remove the bearing 3@ from the shaft of the clutch pack housing 2).
5. Remove the retaining ring 3! and retainer 3) from the clutch pack housing 2).
6. Remove the separator plates 2* and clutch plates 2( from the clutch pack housing 1*.
7. Using the clutch-spring compression tool and a suitable press, depress the retainer 2^ slightly so that the retaining ring 2&
can be removed.
8. Remove the tool, retainer 2^, spring 2%, and piston 2# from the clutch pack housing 2).
9. Remove the O-ring 2$ from the piston’s 2# I.D.
10. Remove the back-up ring 2@ and lip seal 2! from the clutch pack housing 2).
830B/C-850B/C-870B/C 30-73
12
CONTROL VALVE DISASSEMBLY
1. Remove the flanged nuts 2& and assemblies.
2. Remove pin & coil assembly 2^, core assembly 2$, O-ring 2%, solenoid spring 2#, plunger and spool assembly 1*.
3. Remove plug 1&, O-ring 1^, retaining ring 1%, orifice plate 1$, regulator spool assembly 1#, spring shim 1@.
4. Remove plug 1!, O-ring 1), dump valve spring j, plunger and spool assembly i, accumulator piston g, outer
accumulator spring f, inner accumulator spring e,
5. Remove pipe plugs 2*, orifice plugs 3$, bolts 3), then remove valve body b.
30-74 830B/C-850B/C-870B/C
12
MEMORANDUM
830B/C-850B/C-870B/C 30-75
12
REASSEMBLY
FRONT COVER REASSEMBLY
1. Press the three sleeves 3@ into the front cover g. The sleeve’s lip has a tang (white arrow in inset) that must align with the
hole (black arrows in inset) at each location.
2. Install the breather 2&, converter relief valve assembly 2^, pipe plug 2%, and the three ball bearings (used to support clutch
packs) in the front cover g.
Apply pipe thread sealant to the pipe plug 2%. Install the pipe plug slightly below flush with the front
cover.
3. Install the ring seal 2$ and oil passage cover 2# with the three bolts to the front cover g.
Coat the seal ring 2$ with seal lubricant. Apply Loctite Plastic Gasket under the bolt heads and Loctite
262 to the bolt threads.
Bolt: 9 lbf ft (12.2 Nm)
30-76 830B/C-850B/C-870B/C
12
4. Install the retaining ring 2@, bearing 2!, auxiliary pump gear 2), retaining ring 1(, bearing 1*, idler shaft 1&, retaining
washer, roll pin, bolt and cover 1% with O-ring 1^. Tighten the bolt to
Apply seal lubricant to the O-ring 1^. Apply Loctite 262 around the edge of the cover 1%. Apply Loctite
262 to the bolt threads.
5. Apply Teflon® paste to the elbow 3! and install it in the front cover g. Install the lube tube 3) in the front cover casting
hole and connect the other end to the elbow.
Remark
DO NOT use Teflon® tape because of the possibility of pieces of the tape plugging up the bearing lube hole
or orifices in the control valve.
6. Position the stator support tube 1) and cover plate j with six bolts i.
Apply Loctite 262 to the bolt threads.
7. Install the seal ring 1$, retaining ring 1#, and ball bearing 1@. With a soft face hammer, drive the input shaft 1! through the
housing from the back side to the front.
8. After installing the bolts that secure the bearing retainer h to the rear of the front cover g.
Apply Loctite 262 to threads of bolts.
9. Reposition the thrust washer 2( and impeller hub gear 2* on the stator support hub splines.
10. Install a new bearing f and oil seal d into the bearing retainer c.
11. Remove the old gasket material e.
12. To properly install a new Gortex gasket e:
A. Clean the mounting surface with Loctite safety solvent.
B. Peel the protective tape from the gasket.
C. Start the gasket behind a bolt hole.
D. Press the gasket to the surface.
E. End up by crossing over the start point behind the bolt hole location.
830B/C-850B/C-870B/C 30-77
12
13. Secure the retainer to the front cover with the bolts b.
Apply Loctite 262 to the oil seal d O.D. and bolt

threads.
30-78 830B/C-850B/C-870B/C
12
MEMORANDUM
830B/C-850B/C-870B/C 30-79
12
TORQUE CONVERTER ASSEMBLY
1. Install the seal ring 2# and O-ring 2@ onto the impeller hub 2!. Secure the hub to the impeller f with the seal washers 2)
and bolts 1(.
Apply Loctite 262 to the bolt threads.
Bolts: 21 to 25 lbf ft (28.4 to 33.8 Nm)
2. Install the thrust washer 1*, needle thrust bearing 1&, and thrust washer 1^ onto the impeller hub 2! inside the impeller f.
30-80 830B/C-850B/C-870B/C
12
3. Install the one-way (sprag) clutch 1$ in the stator 1!.
A. Position the stator 1! so that the front of it is facing up. The letter
“F” is cast into the front side of the stator.
B. Install the internal retaining ring 1% in the stator 1!.
C. Install a clutch retainer 1$A in the stator 1!.
D. Assemble the inner clutch race 1$B, sprag clutch 1$C, and outer
clutch race 1$D. Install the sprag clutch assembly 1$ into the stator
1!. The sprag cage flanges must be towards the “F” side of the
stator 1!.
E. Install the second clutch retainer 1$E in the stator 1!.
Install the remaining internal retaining ring 1@ to finish securing

F.
the free-wheeling stator hub components 1$ in stator. Position the
stator and hub assembly in the impeller f on the thrust bearing
assembly 1*, 1&, and 1^.
Remark
Ensure that the “F” stamped into the stator case is toward the front cover and not the impeller.
4. Install the thrust washer 1), thrust washer bearing j and thrust washer 1# in the free-wheeling stator hub 1$. Carefully
position the turbine i on the thrust bearing assembly in the impeller f.
5. Install the thrust bearing h and thrust washer g on the turbine i.

Remark
Only one thrust washer is used at this location.
6. Press the needle bearing e on the front cover d.

Remark
Install the bearing end 0.100 in (2.540 mm) above the face of the front cover.
7. Position the O-ring d on the impeller f.
8. Position the front cover d to the impeller f and install the bolts b and lock nuts c.
Bolt: 26 ± 2 lbf ft (35.2 ± 0.4 Nm)
830B/C-850B/C-870B/C 30-81
12
CLUTCH PACK 1 AND 5 REASSEMBLY (FIRST STAGE)
REASSEMBLE THE FIRST CLUTCH PACK AS FOLLOWS:
1. Install the back-up ring 2) and lip seal 1(, which are inside the clutch pack housing 1* bore near the bottom. Install the
back-up ring first, and the seal ring second. Install the seal ring under the back-up ring with its lip towards the bottom of
the clutch pack housing, away from the back-up ring.
2. Install the O-ring 2@ in the piston’s 2! inner diameter.
3. Lubricate the back-up ring 2) and lip seal 1( and O-ring 2@ inside the piston 2! with clean transmission fluid. Press the
piston 2! into the clutch pack housing 1*.
Remark
The webbed-grooved side of the piston 2! must be visible.
4. Position the spring 2# and retainer 2$ on the clutch shaft on top of the piston 2!.
30-82 830B/C-850B/C-870B/C
12
5. Using a suitable press and clutch spring compression tool, depress the retainer 2$ just enough to install the retaining ring 2%
on the clutch shaft. Ensure the fingers on the retainer 2$ are surrounding the retaining ring, and that the spring 2# is
centered under the retainer.
6. Beginning with a separator plate 2^, alternate installing the clutch plates 2& with the separator plates 2^.
Coat each plate with clean transmission fluid prior to

installation into the clutch pack.
7. Install the retainer 2* and retaining ring 2( in the clutch pack housing 1*. A minimum 0.050 in (1.270 mm) gap must exist
between the retainer and the last clutch plate. If a 0.050 in (1.270 mm) gap doesn’t exist, exchange the clutch and
separator plates with those of another clutch pack.
Remark
Separator plates have teeth on the O.D.; clutch plates have teeth on the I.D.
8. Install the retaining ring 3@ into the bore of the gear and hub assembly 3!.
9. Using a suitable adaptor, press the bearing 3# into the gear and hub assembly 3!. Only press on the outer race.
Remark
Do not press the bearing (33) into the gear and hub assembly 3!.
10. Align all clutch plate 2& teeth with a straight edge at three points, 120° apart from each other.
11. Using a suitable adaptor, press the gear and hub assembly 3! with the bearing 3) into the clutch pack housing 1*. Only
press on the inner bearing race. Align the hub splines with the clutch plate teeth. Do not damage the clutch plate teeth
when pressing the gear and hub assembly into position.
12. After seating the inner bearing race 3), place the shims (“A” arrows)
between the gear and clutch pack housing. The shims prevent bearing
damage while installing the bearing 3#.
13. Using a suitable adaptor, press the bearing 3# onto the clutch pack
housing 1* shaft gear 3!. Press on both the inner and outer races to
prevent bearing damage.
14. Install the retaining ring 3$ on the shaft of the clutch pack housing 1*.
15. Using a suitable adaptor, press the inner bearing race 3% onto the clutch
pack 1* shaft.
Remark
Ensure that the lip side of the bearing race presses against
the bearing seat (arrows). If not, the clutch pack cannot be
properly installed into the main case.
830B/C-850B/C-870B/C 30-83
12
REASSEMBLE THE FIFTH CLUTCH PACK AS FOLLOWS:
1. Install the back-up ring 1^ and lip seal 1& near the bottom inside of the clutch pack housing 1*. Install the back-up ring first.
Install the seal ring with its lip towards the bottom of the clutch pack housing, away from the back-up ring.
2. Install the O-ring 1$ in the I.D. of the piston 1%.
3. Lubricate the back-up ring 1^, lip seal 1&, and the O-ring 1$ in the piston 1% with clean transmission fluid. Press the piston
1% into the clutch pack housing 1*.
Remark
The webbed-grooved side of the piston 1% must be visible.
4. Position the spring 1# and retainer 1@ on the clutch shaft atop the piston 1%.
5. Using a suitable press and clutch spring compression tool, depress the retainer 1@ just enough to install the retaining ring 1!
on the clutch shaft. Ensure that the four fingers on the retainer 1@ are surrounding the retaining ring. Also ensure that the
spring 1# is centered under the retainer.
6. Beginning with a separator plate j, alternately install the clutch plates 1) and the separator plates j.
Remark
Coat each plate with clean transmission fluid prior to installing in the clutch pack.
7. Install the retainer i and retaining ring h in the clutch pack housing 1*. A minimum 0.050 in (1.270 mm) gap must exist
between the retainer and last clutch plate. If a 0.050 in (1.270 mm) gap doesn’t exist, exchange the clutch and separator
plates with those of another clutch pack.
Remark
8. Using a suitable adaptor, press the bearing g into the gear and hub assembly f. Only press on the outer bearing race.
Remark
Do not press the bearing e into the gear and hub assembly f at this time.
9. Align all clutch plate 1) teeth with a straight edge at three points, 120° apart from each other.
10. Using a suitable adaptor, press the gear and hub assembly f with the bearing g into the clutch pack housing 1*. Only
press on the inner bearing race. Align the hub splines with the clutch plate teeth. Do not damage the clutch plate teeth
11. After seating the bearing inner race g, place the shims (arrow “A”) between the gear and clutch pack housing. The shims
prevent bearing g damage during installation.
12. Using a suitable adaptor, press the bearing e on the clutch pack housing 1* shaft and gear f bore. Press on both the inner
and outer races to prevent bearing damage.
13. Install the retaining ring d on the shaft of the clutch pack housing 1*.
14. Using a suitable adaptor, press the inner bearing race c on the shaft of the clutch pack 1*.
Remark
Make sure that lip side on bearing race is pressed against the bearing seat. If not, the clutch pack cannot be
15. Install the seal rings b on the clutch pack housing 1* shaft.
Remark
Form the seal onto the shaft diameter and fit the ring seal into the groove. Exercise caution not to deform
the rings any more than necessary. Apply finger pressure to assure the seal ring is formed into the groove.
Lubricate the seal ring with oil before installation.
30-84 830B/C-850B/C-870B/C
12
CLUTCH PACK 2 AND 6 REASSEMBLY (SECOND STAGE)
REASSEMBLE THE SECOND CLUTCH PACK AS FOLLOWS:
1. Install the back-up ring 2@ first and then the and lip seal 2! in the groove near the bottom of the clutch pack housing 2).
Install the back-up ring first, and the seal ring second. Install the seal ring with its lip towards the bottom of the clutch
pack housing, away from the back-up ring.
2. Install the O-ring 2$ in the I.D. of the piston 2#.
3. Lubricate the back-up ring 2@, lip seal 2!, and O-ring 2$ with clean transmission fluid. Press the piston 2#) into the clutch
pack housing 2).
Remark
The webbed-grooved side of piston 2# must be visible.
4. Position the spring 2% and retainer 2^ on the clutch shaft atop the piston 2#.
830B/C-850B/C-870B/C 30-85
12
5. Using a suitable press and clutch spring compression tool, depress the retainer 2^ just enough to install the retaining ring 2&
on the clutch shaft. Ensure that the four fingers on the retainer 2^ are surrounding the retaining ring, and that the spring 2%
is centered under the retainer.
6. Beginning with a separator plate 2(, terminatively install the separator plates 2( and clutch plates 2*.

7. Install the retainer 3) and retaining ring 3! in the clutch pack housing 2). A minimum 0.050 in (1.270 mm) gap must exist
Remark
8. Using a suitable adaptor, press the bearing 3@ on the shaft of the clutch pack housing 2).
9. Align all clutch plate 2* teeth with a straight edge at three points, 120° apart from each other.
10. Using a suitable adaptor, press the gear and hub assembly 3# into the clutch pack housing 2). Align the hub splines with
the clutch plate teeth. Do not to damage the clutch plate teeth when pressing the gear and hub assembly into position.
11. Using a suitable adaptor, press the inner bearing race 3% on the shaft of
the clutch pack 2). Ensure that the lip side of the bearing race presses
against the bearing seat (arrows). If not, the clutch pack cannot be
12. Install the bearing 3$ in the main case.
REASSEMBLE THE SIXTH CLUTCH PACK AS FOLLOWS:
1. Install the back-up ring 1* first and then the lip seal 1( in the groove near the bottom of the clutch pack housing 2). The seal
ring must have its lip towards the bottom of the clutch pack housing, away from the back-up ring.
2. Install the O-ring 1^ in the I.D. of the piston 1&.
3. Lubricate the back-up ring 1*, lip seal 1(, and O-ring 1^ with clean transmission fluid.
4. Press the piston 1& into the clutch pack housing 2).
Remark
The webbed-grooved side of piston 1& must be visible.
5. Position the spring 1% and retainer 1% on the clutch shaft atop the piston 1&.
30-86 830B/C-850B/C-870B/C
12
6. Using a suitable press and clutch spring compression tool, depress the retainer 1$ just enough to install the retaining ring 1#
on the clutch shaft. Ensure that the four fingers on the retainer 1$ are surrounding the retaining ring, and that the spring 1%
7. Beginning with a separator plate 1@, alternate installing the separator plates 1@ and clutch plates 1!.

installation into clutch pack.
8. Install the retainer 1) and retaining ring j in the clutch pack housing 2). A minimum gap of 0.050 in (1.270 mm) must
exist between the retainer and the last clutch plate. If the 0.050 in (1.270 mm) gap doesn’t exist, exchange the clutch and
Remark
9. Install the retaining ringsf and h into the bore of the gear and hub assembly g.
10. Using a suitable adaptor, press the bearing i into the gear and hub assembly g. Press on the outer bearing race only.
Remark
Do not press the bearing e into the gear and hub assembly g at this time.
11. Align all clutch plate 1! teeth with a straight edge at three points, 120° apart from each other.
12. Using a suitable adaptor, press the gear and hub assembly g with bearing i into the clutch pack housing 2). Press only on
the inner bearing race. Align the hub splines with the clutch plate teeth. Do not damage the clutch plate teeth when
pressing the gear and hub assembly into position.
13. After seating the inner bearing race i, place the shims (arrows “A”)
damage during installation.
14. Using a suitable adaptor, press the bearing e into position on the shaft
of the clutch pack housing 2) and gear g. Press on both the inner and
outer races to prevent bearing damage.
15. Install the retaining ring d on the shaft of the clutch pack housing 2).
16. Using a suitable adaptor, press the inner bearing race c on the shaft of
the clutch pack 2).
Remark
Ensure that the lip side of the bearing race presses
against the bearing seat. If not, the clutch pack cannot be
17. Install the seal rings b on the shaft of the clutch pack housing 1*.
Remark
Form the seal onto the shaft diameter and fit the ring seal into the groove. Exercise caution not to deform
the rings any more than necessary. Apply finger pressure to the seal ring to assure that it fits securely in the
groove. Lubricate the seal ring with oil before installation.
830B/C-850B/C-870B/C 30-87
12
CLUTCH PACK 3 AND 4 REASSEMBLY (THIRD STAGE)
REASSEMBLE THE THIRD CLUTCH PACK AS FOLLOWS:
1. Install the back-up ring 2@ first and then the and lip seal 2! in the groove near the bottom of the clutch pack housing 2).
Install the seal ring with its lip towards the bottom of the clutch pack housing, away from the back-up ring.
2. Install the O-ring 2$ in the I.D. of the piston 2#.
3. Lubricate the back-up ring 2@, lip seal 2!, and O-ring 2$ with clean transmission fluid. Press the piston 2# into the clutch
pack housing 2).
Remark
The webbed-grooved side of the piston 2# must be visible.
4. Position the spring 2% and retainer 2^ on the clutch shaft on top of piston 2#.
30-88 830B/C-850B/C-870B/C
12
5. Using a suitable press and clutch spring compression tool, depress the retainer 2^ just enough to install the retaining ring 2&
on the clutch shaft. Ensure that the four fingers on the retainer 2^ are surrounding the retaining ring, and that the spring 2%
6. Beginning with a separator plate 2*, alternate installing the separator plates 2* and clutch plates 2(.

7. Install the retainer 3) and retaining ring 3! in the clutch pack housing 2). A minimum gap of 0.050 in (1.270 mm) gap
Remark
8. Using a suitable adaptor, press the bearing 3@ onto the shaft of the clutch pack housing 2).
9. Using a suitable adaptor, press the inner bearing race 3$ onto the gear and hub assembly 3#.
Remark
Install the outer race of the bearing 3$ in the main case.
10. Align all clutch plate 2( teeth with a straight edge at three points, 120° apart from each other.
11. Using a suitable adaptor, press the gear and hub assembly 3# into the clutch pack housing 2). Align the hub splines with
the clutch plate teeth. Use extreme care not to damage the clutch plate teeth when pressing the gear and hub assembly into
position.
12. Using a suitable adaptor, press the inner bearing race 3% onto the shaft of the clutch pack 2).
13. Ensure that lip side of the bearing race presses against the bearing seat.
If not, the clutch pack cannot be properly installed into the main case.
REASSEMBLE FOURTH CLUTCH PACK AS FOLLOWS:
1. Install the back-up ring 1* first and then the lip seal 1( in the groove near the bottom of the clutch pack housing 2). Install
the seal ring with its lip towards the bottom of the clutch pack housing, away from the back-up ring.
2. Install the O-ring 1^ in the I.D. of the piston 1&.
830B/C-850B/C-870B/C 30-89
12
3. Lubricate the back-up ring 1*, lip seal 1(, and O-ring 1^ with clean transmission fluid. Press the piston 1& into the clutch
pack housing 2).
Remark
The webbed-grooved side of piston 1& must be visible.
4. Position the spring 1% and retainer 1$ on the clutch shaft atop the piston 1&.
5. Using a suitable press and clutch spring compression tool, depress the retainer 1$ just enough to install the retaining ring 1#
on the clutch shaft. Ensure that the four fingers on the retainer 1$ are surrounding the retaining ring, and that the spring 1%
6. Beginning with a separator plate 1@, alternate installing the separator plates 1@ and clutch plates 1!.

installation into clutch pack
7. Install the retainer 1) and retaining ring j in the clutch pack housing 2). A minimum gap of 0.050 in (1.270 mm) must
exist between the retainer and the last clutch plate. If a 0.050 in (1.270 mm) gap doesn’t exist, exchange the clutch and
Remark
8. Install the retaining rings f and h into the gear and hub assembly g.
9. Using a suitable adaptor, press the bearing i into the gear and hub assembly g. Press only on the outer bearing race.
Remark
Do not press the bearing e into the gear and hub assembly g at this time.
10. Align all clutch plate 1! teeth with a straight edge at three points, 120° apart from each other.
11. Using a suitable adaptor, press gear and hub assembly g with bearing i into clutch pack housing (20). Press only on the
inner bearing race. Align the hub splines with the clutch plate teeth. Use extreme care not to damage clutch plates teeth
12. After seating the bearing inner race i, place the shims (arrows “A”)
i damage during installation.
13. Using a suitable adaptor, press the bearing e onto the clutch pack
housing 2) shaft and gear g. Press on the inner and outer races to pre-
vent bearing damage.
14. Install the retaining ring d onto the clutch pack housing 2) shaft.
30-90 830B/C-850B/C-870B/C
12
15. Using a suitable adaptor, press the inner bearing race c onto the clutch
pack 2) shaft.
Remark
Ensure that the lip side of the bearing race presses against
the bearing seat (arrows). If not, the clutch pack cannot be
16. Install the seal rings b onto the clutch pack housing 1* shaft.
Remark
Form the seal onto the shaft diameter and fit the ring seal
into the groove. Exercise caution not to deform the rings any
more than necessary. Apply finger pressure to the seal ring
to assure it is seated in the groove. Lubricate the seal ring
with oil before installation.
830B/C-850B/C-870B/C 30-91
12
CONTROL VALVE ASSEMBLY
1. Install pipe plugs 2*, orifice plugs 3$, bolts 3), then remove valve body b.
2. Install plug 1!, O-ring 1), dump valve spring j, plunger and spool assembly i, accumulator piston g, outer
accumulator spring f, inner accumulator spring e,
3. Install plug 1&, O-ring 1^, retaining ring 1%, orifice plate 1$, regulator spool assembly 1#, spring shim 1@.
4. Install pin & coil assembly 2^, core assembly 2$, O-ring 2%, solenoid spring 2#, plunger and spool assembly 1*.
5. Install the flanged nuts 2& and assemblies.
30-92 830B/C-850B/C-870B/C
12
MAIN CASE REASSEMBLY
1. Position the tube clamp 3@ on the tube 3#. Apply Loctite 601 to the bore
of the transmission case b mounting hole and O.D. of end of tube.
Place the tube into the bore. The tube must be flush to the surface of
the case, but not to exceed 0.060 in (1.524 mm) below the surface of
the case. The tube must not rotate with any hand pressure.
2. Apply Loctite 262 to the bolt threads 3!. Install the bolt 3! to secure the
tube 3# to the transmission case b.
3. Install the suction screen gasket 3) and suction screen 2( into the
transmission case b. Ensure that the screen is properly seated on the
tube 3#.
4. Install the oil baffle 2^ with two new seal washers j and bolts 2%.
830B/C-850B/C-870B/C 30-93
12
5. After installing the seal washers on the bolts.
Apply Loctite 262 to the bolt thread
6. Press the bearing cone 2* onto the output shaft 1(.
7. Position the output gear 2& in the baffle 2^, which is inside the main case b, and slide the output shaft 1( through the output
gear 2&.
8. Press the bearing cup 2$ into the bearing retainer 2!.
9. Install the 0.080 in (2.032 mm) shims 2@, bearing retainer 2!, and bolts 2).
Remark
Do not install the O-ring 2# at this time.
10. Install the retaining ring 1* on the output shaft 1( to secure the outer gear in place.
11. Press the bearing cup 1^ into the bearing retainer 1#.
Apply Loctite 262 to the O.D. of the seal 1%.
12. Install the oil seal 1% so that the lip points toward the transmission when pressed into the bearing retainer 1#.
13. Lay the housing onto the blocking. Using a suitable driver, install the bearing cone 1& onto the output shaft 1(.
14. Install the bearing retainer 1#, O-ring 1$, and bolts 1@.
Apply seal lubricant to the O-ring 1$
Loctite 262 to the bolt threads 1@
15. Install the output flange yoke 1!, O-ring 1), washer i, and bolt h.
30-94 830B/C-850B/C-870B/C
12
16. Output shaft shim pack procedure
A. With a dial indicator, check the end play of the output flange yoke 1!, and record this figure.
B. Remove the bearing retainer 2! and the 0.080 in (2.032 mm) shims (22) previously installed.
C. Subtract the end play measurement from the 0.080 in (2.032 mm). This figure will be the new desired shim pack
thickness.
Remark
The desired shim setting is 0.004 in (0.102 mm) preload to 0.004 in (0.102 mm) end play. Shims are
available in the following sizes: 0.005 in (0.127 mm), 0.007 in (0.178 mm), and 0.020 in (0.508 mm).
17. Install the shim pack 2@, O-ring 2#, retainer 2!, and bolts 2).
Apply seal lubricant to the O-ring 2#
Loctite 262 to the bolt threads 2)
18. Install the inner bearings f and two outer bearings g, using a suitable bearing driver.
19. With the use of the clutch pack removal tool, reinstall the clutch packs c, d, and e.
830B/C-850B/C-870B/C 30-95
12
TRANSMISSION/TORQUE CONVERTER REASSEMBLY
1. Position the main housing assembly in a horizontal position on cribbing and/or blocking. Install a new gasket 3) on the
housing c. Sling the front cover. With a suitable lifting device, position the front cover 2# over the clutch packs. Secure
the front cover to the housing with the bolts 2$, 2%, 2^, 2&, 2*, and 2(. Tighten the bolts to the torque values specified below:
Apply Loctite 262 to the bolt threads
Bolts: 2& 1/2 in - 13 x 3-1/4 in Grade 5, Qty. 1 - Torque to 75 lbf ft (101.6 Nm).
2* 1/2 in - 13 x 2-1/2 in Grade 5, Qty. 1 - Torque to 75 lbf ft (101.6 Nm).
2( 1/2 in - 13 x 1-1/2 in Grade 5, Qty. 3 - Torque to 75 lbf ft (101.6 Nm).
3) 1/2 in - 13 x 3 in Grade 8, Qty. 1 - Allen Head - Torque to 75 lbf ft (101.6 Nm).
3! 1/2 in - 13 x 2-1/2 in Grade 8, Qty. 3 - Allen Head - Torque to 75 lbf ft (101.6 Nm).
3@ 1/2 in - 13 x 2 in Grade 5, Qty. 1 - Torque to 75 lbf ft (101.6 Nm).
Remark
Ensure that these are located in the correct locations along the mounting flange, according to the flange’s
depth and bore.
30-96 830B/C-850B/C-870B/C
12
2. Install the torque converter assembly 2@.
3. Install the drive plate assembly 2!, drive plates 2), ring 1(, and bolts 1* on the torque converter 2@.
4. Install the gasket 1&, valve body 1^, bolts 1# and 1$, and flat washers 1%.
Remark
Starting with the center bolt, tighten the bolts in a circular pattern to ensure the gasket seats properly.
5. Install the bearing 1@, gear 1!, and retaining ring 1) onto the charge pump’s h drive shaft.
6. Position the gasket i and O-ring j onto the charge pump housing h.
Apply seal lubricant to the O-ring j and coat the gasket i

with a light film of grease.
7. Install the charge pump onto the transmission and use the star washers f and two 3/8 in-16 Grade 2 hexnuts g, and
one 3/8 in-16 x 3-1/4 in Grade 5 bolt d, one 3/8 in-16 x 5-1/4 in Grade 5 bolt e.
Bolts and hexnuts: 30 lbf ft (40.6 Nm)
8. Ensure the drain plug b is secure in the transmission case c.
9. Refer to the “Converter Assembly Installation Into Transmission if Separated From the Transmission” section of this
manual for installation instructions of the converter into the transmission.
830B/C-850B/C-870B/C 30-97
12
INSTALLING THE CONVERTER INTO THE TRANSMISSION
Place a light coat of grease on the converter impeller hub gear, and the converter hub seal ring. Also
apply a light coat of grease on the transmission input shaft splines, stator support tube splines, and the
converter hub oil seal.
1. Support the converter assembly so that it aligns with the transmission input shaft centerline. Carefully insert the converter
into the transmission, keeping the input shaft centered in the hub bore. Push the converter assembly in slowly to feel when
the splines and/or gear teeth begin to engage. If the converter assembly stops at this point, rock it back and forth and turn
the converter slightly to allow the splines and/or gears to align.
Remark
Never force the converter into the transmission, or damage will result.
2. When all the splines and teeth are aligned, the converter assembly will slide easily into place.
3. Install the pilot sleeve on the converter pilot knob.
Place a light coat of grease on the converter assembly

pilot sleeve I.D. and O.D.
4. A 3/8 in-24 thread stud (with a screwdriver slot) threaded into the drive plate, from the engine side, will help align the
drive plate to the flywheel.
30-98 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY TRANSFER CASE
12
TRANSFER CASE
DISASSEMBLY
1. Only three of the four bolts (not shown) that secure the transfer case b to the transmission are accessible from outside the
transfer case. One of the four bolts is longer than the others. Mark the location of this bolt for reassembly later. To gain
access to the fourth bolt, remove the output gear c. To remove the output gear assembly from the transfer case, remove
the retaining ring e and then slide the output gear assembly c out.
Remark
A 3/8 in-16 UNC tapped hole is provided in the bottom of the splined hole in the output gear c to help aid in
the removal of the gear assembly.
830B/C-850B/C-870B/C 30-99
12
2. After removing the four bolts, remove the O-ring located between the transfer case and transmission.
3. Remove the transfer case assembly from the transmission.
4. Remove the retaining ring d and ball bearing f from the output gear c, if necessary.
5. Remove the roller bearing g from the transfer case housing b, if necessary.
6. Remove the bolts 1$, retainer plate 1#, and shims 1@ from the end of the transfer case gear h.
7. Slide the transfer case gear 1! and bearing cone i off the splined end of the gear h.
Remark
Using a suitable puller, remove the bearing cone i from the gear 1!, if necessary.
8. Using a suitable puller, remove the bearing cup j from the transfer case housing b.
Remark
Keep the bearing cone i and cup j together so that the wear patterns will match during reassembly.
9. Remove the two retaining rings 1) and 1% from the transfer case housing b.
10. Pull the gear h, bearing cone 1&, and cup 1^ out of the transfer case b.
Remark
Using a suitable puller, remove the bearing cone 1& from the gear h, if necessary. Keep the bearing cone 1&
and cup 1^ together so the wear patterns will match after reassembly.
30-100 830B/C-850B/C-870B/C
12
ASSEMBLY
1. Using a suitable adapter, press bearing cone 1& onto the geared shaft h.
Lubricate the bearing cone with clean transmission fluid.
2. Position the geared shaft h and bearing 1& into the transfer case housing.
WARNING! Using excessive force to press bearing cup in will unseat or distort the retaining ring.
3. Press bearing cup 1^ into the housing slowly, until the groove for the retaining ring is visible.
4. Install retaining ring 1) into the groove diameter.
830B/C-850B/C-870B/C 30-101
5. Install another retaining ring 1) into the retaining groove at the top of the housing. Press bearing cup 1^ into the transfer
case housing.
Remark
Do not press hard enough to unseat or distort the retaining ring.
6. Press bearing cone 1& onto the hard turned diameter on gear 1! (The cone must seat against the face on the gear).
Lubricate the bearing cone with clean transmission fluid.
Place this subassembly onto the geared shaft and into the bearing cup.
Remark
The gear must slide freely over the splined shaft.
7. Install retainer plate 1# using three socket head bolts 1$.
A. Align the depth mic hole on the plate with the top of the shaft, this is important for measuring for the required shim
pack.
B. Preload the bearings
Torque each bolt to 25 lbf ft, rotating the gear while doing so.
C. Loosen the bolts and tap the shaft loose to re-set the torque.
Torque each bolt to 5 lbf ft rotating the gear while doing so.
D. Check the torque on each bolt again to ensure that the proper torque setting was achieved.
E. Measure the distance from the top of the retainer plate to the top of the geared shaft using depth micrometers and
record this dimension.
F. Remove the three bolts and subtract the thickness of the retaining plate from the measured reading.
G. This dimension plus.015 equals the shim pack that's required between the retaining plate and the geared shaft.
8. Add up the required shim pack using shims 1@ to achieve the required pack size.
A. Install the shim pack and the retaining plate.
Apply loctite #242 to the socket head bolts.
Torque each bolt to 44 lbf ft while rotating the gear in the process.
9. Check the torque again on each bolt to ensure that the proper torque setting was achieved.
10. Press roller bearing g into the transfer case housing.
11. Press bearing f onto output gear c and install retaining ring d.
12. Place the output gear into the transfer case housing and into the roller bearing.
13. After this has been completed install retaining ring e into the retaining groove.
30-102 830B/C-850B/C-870B/C
14. Install the ball bearing f and retaining ring d onto the output gear c, if removed during disassembly.
15. Apply a small amount of Loctite Plastic Gasket around each of the four transfer case mounting holes of the transmission.
The correct mounting hole is the center one of each set of three around the mounting flange.
16. Lubricate the new O-ring (not shown) between the transfer case and transmission. Position the O-ring in the groove of the
mounting flange of the transmission.
17. After aligning the mounting holes, slide the transfer case assembly into position.
Remark
Use care not to damage the O-ring.
18. Install the four bolts (not shown) that secure the transfer case assembly to the transmission.
Remark
The longest bolt is located at the 5 o'clock position.
19. After mounting the transfer case to the transmission, install the output gear c assembly in the transfer case. Install the
retaining ring e to hold the bearing f in place.
830B/C-850B/C-870B/C 30-103
12
INSTALLATION
1. Prior to installing the transmission in the grader, check the engine crankshaft end play and flywheel runout. Refer to the
appropriate engine service manual for your unit.
Remark
Place a locating dowel or 3.0 in (76.2 mm) long stud in a transmission drive plate assembly hole. When low-
ering the transmission, align the dowel or stud with one engine flywheel mounting hole and the engine fly-
wheel housing access hole. This step will aid the installation of the bolts into the drive plate assembly after
the transmission bolts up. Turn the flywheel to align the flywheel mounting hole with the access hole.
2. Place a nylon strap or chain around the transmission b and attach the
strap or chain to a suitable lifting device. Lower the transmission so
that it aligns with the engine crankshaft and engine flywheel housing.
Align the pilot sleeve with the flywheel pilot bore. Align the 3.0 in
(76.2 mm) stud with one of the thru holes in the flywheel.
3. Place O-ring in pilot sleeve groove.
4. Push the transmission up against the engine.
5. Install bolt (Hex 3/8-24X2.0 LG) (washer and rubber mount) b
WARNING! If the transmission does not seat against the flywheel housing, DO NOT PROCEED.
Forcing the transmission against engine with the assembly bolts could preload the engine
crankshaft and cause engine problems, transmission problems, or both at a later time.
Remove the transmission and check the previous assembly steps to determine the prob-
lem. Take the corrective action needed before proceeding.
6. While lowering the transmission, install one bolt through the left forward transmission/engine mounting hole. Installing
the bolt will be difficult after the transmission is in place.
7. Install the bolts c (M10X35 LG) (and lock washers) around the transmission housing.
Remark
Install the battery ground strap and electrical harness clamp under two of the top bolts. Secure the
transmission dipstick to the flywheel housing and transmission.
30-104 830B/C-850B/C-870B/C
12
Remark
If the transmission support c was removed from the
transmission, reinstall the support. Secure it to the
transmission with the flat washers and bolts e on each side.
8. Raise the transmission and engine assembly just enough to allow the
removal of the channel placed under the engine flywheel housing. The
channel was used as a rear support during transmission removal. When
raising the transmission and engine assembly, do not let the engine fan
blade hit the radiator.
9. Secure the transmission support to the frame d with the bolts, flat washers, and prevailing torque nuts b.
10. Tighten the front engine support to frame bolts.
Remark
Ensure that the engine fan blade can rotate, without hitting the fan shroud assembly.
11. Slowly bar the engine over and install the flat washers and bolts that
secure the drive plate to the engine flywheel. Tighten the drive plate
bolts AFTER installing all eight bolts, which prevents the drive plate
from binding or misalignment.
8 Bolts: 38 lbf ft (51.5 Nm)
Remark
Remove the alignment dowel or stud when encountered.
Install one regular mounting bolt prior to removing the dowel
or stud.
12. Install the engine flywheel housing access cover b on the flywheel
housing c. Use care when installing the self-tapping screws d so as not to cross thread the previously tapped threaded
holes.
13. Recheck the engine crankshaft end play and compare it with the end play reading prior to installing the transmission. No
end play could mean that the crankshaft has been preloaded while installing the transmission. DO NOT run the engine
until after determining the cause of the preload.
830B/C-850B/C-870B/C 30-105
12
14. After removing the plugs from the end of the converter oil hoses d and
e, connect them to the tee on the transmission.
15. Reconnect the electrical lead b to the converter oil temperature

sending unit c.
16. All-wheel-drive rear sensor (optional)
A. Turn the transmission output shaft until one tooth of the third gear
clutch pack is centered in the sensor pickup mounting hole.
B. Screw the rear sensor c in until it just touches the gear O.D.
Unscrew the sensor three to four turns to obtain a 0.200 in (5.080
mm) gap.
C. After obtaining the specified gap, tighten the jam nut d.
D. Connect the electrical lead b to the sensor.
E. Test the all-wheel-drive system to ensure that the rear sensor is

properly adjusted and functioning.
17. All-wheel-drive pump (optional)

Remark
Install the transfer case h prior to installing the all-wheel-
drive pump. Installation procedures for the transfer case is
part of the “Transfer Case Reassembly” procedure. See the
“Transfer Case” section of this manual.
A. Support the all-wheel-drive pump c, and position the gasket

against the transfer case. Install the flat washers and bolts g.
Install the screw to secure the terminals d and e to the control

module f.
B. Unplug and cap the hoses b and connect them to the pump as tagged during removal.
C. Add 1 U.S. quart (0.9 L) of clean transmission fluid in the transfer case through the side hose hole. This step ensures
that the bearings have lubricant on them when the engine is first started.
D. Connect the hose i between the transfer case h and elbow j.
30-106 830B/C-850B/C-870B/C
12
18. Main system pump (standard)
A. Install the new O-ring c onto the main system pump d.
B. Install the sleeve b onto the pump drive shaft

Remark
Insure retaining ring is in position inside of pump coupler.
19. Unplug and connect the transmission charge pump hoses j and 1) to
the elbows.
20. Connect the electrical connectors h and i as tagged during removal.
21. Support the pump e and align the sleeve b splines with the
transmission charge pump drive shaft. Slide the pump into position.
Secure the pump e to the charge pump g with the lock washers and
bolts f.
22. Unplug and connect the hoses b thru d to the main system pump.
23. Secure the drive shaft c to the transmission output yoke d with the
lock washers and 12-point bolts b.
24. See “FUEL TANK AND HYDRAULIC TANK” on page 30-54 -

INSTALLATION and “ENGINE HOOD, FRONT & REAR COWL-
ING” on page 30-48 - INSTALLATION for final machine assembly.
830B/C-850B/C-870B/C 30-107
12
SERVICING THE MACHINE AFTER A TRANSMISSION OVERHAUL
After installing the transmission in the machine, thoroughly clean the oil cooler and connecting hydraulic system.
1. Drain the entire system thoroughly.
2. Disconnect, remove, and clean all hydraulic lines.
3. Remove the oil filter element and thoroughly clean the filter housing assembly.
4. Install a new oil filter element.
5. “Back flush” the cooler with oil and compressed air because flushing in the direction of normal oil flow will not
adequately clean the cooler of all foreign material. If necessary, remove the cooler assembly from machine for cleaning.
Use oil, compressed air, and a steam cleaner. DO NOT use flushing compounds for cleaning purposes.
6. Reassemble all components and use only the oil recommended for lubrication in the Operator's Manual. Fill the
transmission through transmission fill plug until the oil level comes up to the LOW mark on the transmission dipstick.
7. Run the engine for two minutes at low idle to prime the transmission and hydraulic lines. Recheck the fluid level in
transmission with engine running at low idle. Add oil to bring the fluid to the LOW mark on the dipstick. Recheck oil
level when the oil reaches operating temperature from 160° to 200° F (71° to 93° C). Add oil to bring the oil level to the
FULL mark on the dipstick.
8. Recheck all drain plugs, lines, and connections, etc., for leaks and tighten where necessary.
STARTUP PROCEDURE
1. Turn the ignition key ON and start the engine. Run the engine for two minutes at low idle to prime transmission and
hydraulic lines.
2. Recheck the transmission fluid level with the engine running at a low idle.
3. Add oil to bring the oil level to the LOW mark on the dipstick.
4. Recheck the oil level when the oil operating temperature is from 160° to 200° F (71° to 93° C).
5. Add oil to bring the oil level to the FULL mark on the dipstick.
6. Test all transmission gears in both forward and reverse directions.
7. Observe the clutch pressure reading. Refer to the “Pressure and Flow Checks” section of this manual.
9. Recheck all drain plugs, lines, connections, and the transmission for signs of leaks.
ALL WHEEL DRIVE (AWD)

Test the all-wheel-drive system. Refer to the appropriate service manual for the AWD system.
1. Ensure that the AWD rear sensor is properly installed.
2. Ensure that the AWD pump is functioning properly.
30-108 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY ALL-WHEEL-DRIVE PUMP
12
Thoroughly clean the component to be serviced and the surrounding area. This step will help prevent contamination from
entering the component or system being serviced.
Through out this procedure, hydraulic hoses and lines will be disconnected. It is recommended to plug and/or cap all
connections and ports which are opened to prevent contamination from entering the hydraulic system or component.
REMOVAL
1. Turn the engine off and set the parking brake. Disconnect the negative
(-) battery cables from the batteries to prevent accidental starting of the
unit.
2. Remove the bolt and flat washers b and two hex nuts and flat washers
c that secure the rear grill d to the rear cowl e.
3. Remove the drain plug b and attach a drain hose to the bottom of the
hydraulic oil tank. Drain the tank. It holds about 16 U.S. gallons
(60.6 L).
Remark
The hydraulic oil tank shown is used on an all-wheel-drive
unit. On a non all-wheel unit, the drain plug will be located
where the temperature sensor c is installed.
4. Reinstall the drain plug after draining the tank.
5. Tag, disconnect, and plug the hoses b thru d from the bottom of the
hydraulic oil tank e.
6. Remove the cap f from the elbow. Drain 1 U.S. gallon (3.8 L) from
the hydraulic oil filter return line.
7. Remove the hydraulic oil filter g from the filter head h.
830B/C-850B/C-870B/C 30-109
12
8. Tag, disconnect and plug all hoses b from the all-wheel-drive pump
c.
9. Remove the screw securing each electrical terminal d and e to the

control module f.
10. Support the pump and remove the two bolts and washers g, pump and
gasket from the transfer case h.
30-110 830B/C-850B/C-870B/C
12
SHAFT SEAL (IN-WARRANTY SERVICE)
1. Protect the drive shaft.
2. Remove the retaining ring.
3. Screw in the sheet-metal screws into the holes fitted with rubber.
4. Pull out the shaft seal with the pliers.
5. Press in the shaft seal with the bushing to the stop.
6. Assemble the retaining ring.
830B/C-850B/C-870B/C 30-111
12
CHARGE PUMP (IN-WARRANTY SERVICE)
1. Mark the position and then remove the fixing screws.
2. Pry off the cover.
3. Pry off the cover.
4. Check the O-ring, groove, gliding surface, connection plate.
5. To assemble the pump, reverse the procedure.

See “TORQUE VALUES” on page 30-135 for bolt torque.
30-112 830B/C-850B/C-870B/C
12
CONTROL PISTON COVER (IN-WARRANTY SERVICE)
LEFT COVER
1. Mark the position.
1. Rotate the cover and release by tapping gently with a hammer.
2. Reverse the procedure for assembly. See “TORQUE VALUES” on

page 30-135 for bolt torque.
830B/C-850B/C-870B/C 30-113
12
RIGHT COVER
1. Mark the cover. Must be fixed. Loosen the controller nut while holding
the adjustment screw.
2. Remove the cover.
3. Lift off by turning the set screw.
4. Check the O-ring b, groove c, and housing d.
5. Reverse the procedure for assembly.
30-114 830B/C-850B/C-870B/C
12
REPLACING THE VALVES (IN-WARRANTY
SERVICE)
BOOST PRESSURE VALVE
1. Remove the valve completely. Do not change the adjustment screw

setting.
WARNING! Check the valve setting after installation.
RELIEF VALVE
1. Remove the valve completely. Control: O-ring, housing. Replace the

nut. Record and measure.
WARNING! After assembly, check the valve setting.
PRESSURE CUT-OFF VALVE
1. Unscrew the setting cartridge completely. Control:

O-ring, housing. Replace the nut. Record and measure.
WARNING! After assembly, check the valve setting.
830B/C-850B/C-870B/C 30-115
12
CONTROL DEVICE (IN-WARRANTY SERVICE)
1. Size 71: Sealing the control device as size 40 to 56 with flat seal.
2. Check: O-rings, gasket.
30-116 830B/C-850B/C-870B/C
12
REGULATOR VALVE (IN-WARRANTY SERVICE)
1. Inspect the orifice. No damage.
2. Cover the threads. Insert the O-ring.
830B/C-850B/C-870B/C 30-117
12
REBUILDING THE PUMP (OUT-OF-WARRANTY SERVICE)
If the pump requires rebuilding during the warranty time frame, return the
pump for an overhaul.
1. Remove the control device.
2. Remove the auxiliary pump. Mark the assembly position previously.
3. Mark the position of the index screw b. Record the setting measure.
Set the index screw to the disassembly position c.
4. Mark the position of the connection plate. Loosen the connection plate
fixation.
30-118 830B/C-850B/C-870B/C
12
5. Lift off the port plate and control plate.
6. Press the cylinder to the bottom b and then remove the fixed indexing
screw c.
7. Push off the hydraulic section of the rotary group.
8. Remove the retaining ring and radial seal ring.
830B/C-850B/C-870B/C 30-119
12
9. Remove the drive shaft with slide-hammer strokes.
10. Remove the swash plate/bearing cups.
11. Remove the joint pin.
12. Mark the position of the right control cover, note the measure of the
“zero position.” Loosen the nut.
30-120 830B/C-850B/C-870B/C
12
13. Remove the cover.
14. Mark the position of the left cover. Loosen the locking screw and
remove the cover.
15. Remove the positioning ring.
16. Fit the tool device and preload the spring.
830B/C-850B/C-870B/C 30-121
12
17. Remove the rings and then the safety ring.
18. Remove the piston with the retaining plate. Remove the retaining ball
with the spring cup assembly.
19. Remove the safety ring.
20. Disc 1, 2
30-122 830B/C-850B/C-870B/C
12
21. Check the cage set b and bearing cup set c.
22. Check the bearing surfaces b.
23. Check that the sliding surface is free from scoring.
24. Check that the return device is free of scoring.
830B/C-850B/C-870B/C 30-123
12
25. Check the splines for damage or fretting. Check the running surfaces.
Check if a groove was cut by the shaft seal.
26. Check that there are no scratches or metal deposits on sliding surface
b and that there is no axial play c, otherwise the pistons must be
replaced in sets.
27. Check the cylinder bores b and splines c.
28. Check that the cylinder surface b is free of scoring. Check that the
control plate c is without scoring.
30-124 830B/C-850B/C-870B/C
12
29. Check the positioning piston - cradle linkage. Check the Gliding stone
b, groove at the positioning piston c.
30. Install the snap rings.
31. Install the barguide ring.
32. Install the O-ring.
830B/C-850B/C-870B/C 30-125
12
33. Fit the seal ring into the assembly tool.
34. Press the seal ring into the kidney shape, using the assembly tool. The
deformation of the Turcon seal must be done with care so as not to
damage the sealing edges.
35. Position the seal ring into the housing and place the seal into the
groove. Release the tension and withdraw the assembly tool. Check
the position of the seal ring. If necessary, straighten using a finger.
36. Insert a guide thorn into the positioning piston.
30-126 830B/C-850B/C-870B/C
12
37. Grease slightly the guide thorn. Install the positioning piston with the
guide thorn.
38. Oil the positioning piston before inserting it into the housing.
39. Insert the bearing cup set.
40. Assemble the bearing, wire, gliding stone and articulation pin. Devices
used in assisting: clamp, rubber rings, grease.
830B/C-850B/C-870B/C 30-127
12
41. Insert completely the swivel cradle into the housing. Pay attention for
the correct seat of the swivel cradle in the housing.
WARNING! Remove the auxiliary device.
42. Swivel the swivel bearing by using the control piston. It should move
easily. Center by using a measuring device (dial gauge or depth
measurement). Check points 1 and 2. They should have the same
dimension.
WARNING! Check the location of the swivel

bearing in the bearing.
43. Fit the joint pin.
30-128 830B/C-850B/C-870B/C
12
44. Fit the holding device. Hold the swash plate in position using the set screw.
830B/C-850B/C-870B/C 30-129
12
45. Assemble the drive shaft with the bearings and radial seal rings.
46. Disc 1 and 2.
47. Oil the pistons and piston pads. Assemble the pistons with the
retaining plate.
30-130 830B/C-850B/C-870B/C
12
48. Remove the holding device. Fit the cylinder complete with pistons and
retaining device.
49. Assembly aid: Hold the pistons by using an O-ring.
50. Control plate counterclockwise rotation - indexed in the direction of

rotation.
WARNING! Noise grooves are machined in, based on

the direction of rotation.
830B/C-850B/C-870B/C 30-131
12
51. Control plate clockwise rotation - indexed in the direction of rotation.
WARNING! Noise grooves are machined in, based on

the direction of rotation.
52. Basic setting - index screw: 29 ± 0.75 mm
53. Press the cylinder to the bottom b. Screw in the index screw c.
Groove in the mounting position.
54. Insert the control plate - clockwise rotation.
30-132 830B/C-850B/C-870B/C
12
55. Insert the control plate - counterclockwise rotation.
56. Plate installed.
57. Assemble the connection plate.
WARNING! Spring preloaded. Insert the control plate

into the housing, guidance with two
locking screws crossing over. Finish the
assembly.
58. Locking screw. Observe the adjustment measurement.
830B/C-850B/C-870B/C 30-133
12
59. Assemble the cover and then adjust the zero position, according to the
measurement.
WARNING! Adjustment of the correct zero position to be

performed after the installation on the
machine or test bench.
60. Assemble the auxiliary pump. Take care of the direction of rotation.
61. Assemble the control device.
30-134 830B/C-850B/C-870B/C
12
TORQUE VALUES
TIGHTENING TORQUES FOR SHAFT BOLTS (METRIC ISO STANDARD THREAD)
Strength Classes
Thread
8.8 10.9 12.9
size
Tightening Torque (lbf ft)
M3 1.3 2 2.3
M4 3.1 4.5 5.3
M5 6.1 8.9 10.4
The values for tightening torques shown in this table M6 10.4 15.5 18
are valid only for shaft bolts with metric ISO-standard M8 25 37 43
threads and head support surface dimensions in accor- M10 51 75 87
dance with DIN 912, DIN 931 and DIN 933. These
values are also valid only for light or unoiled, M12 87 130 150
untreated surfaces as well as for use only with torque M14 140 205 240
indicating wrenches and force-limiting tools. M16 215 310 370
M18 300 430 510
M20 430 620 720
M22 580 830 970
M24 740 1060 1240
M27 1100 1550 1850
M30 1500 2100 2500
TIGHTENING TORQUES FOR LOCKING SCREWS VSTI (METRIC ISO FINE THREAD)
Thread size Designation Tightening Torque (lbf ft)
M8x1 VSTI 8 x 1 -ED/SA 4
M 10 x 1 VSTI 10 x 1 -ED 7
M 12 x 1.5 VSTI 12 x 1.5 -ED 15
M 14 x 1.5 VSTI 14 x 1.5 -ED 22
M 16 x 1.5 VSTI 16 x 1.5 -ED/SA 22
M 18 x 1.5 VSTI 18 x 1.5 -ED/SA 29
M 20 x 1.5 VSTI 20 x 1.5 -ED/SA 37
M 22 x 1.5 VSTI 22 x 1.5 -ED 44
M 26 x 1.5 VSTI 16 x 1.5 -ED/SA 51
M 27 x 2 VSTI 27 x 2 -ED 66
M 30 x 1.5 VSTI 30 x 1.5 -ED/SA 74
M 33 x 2 VSTI 33 x 2 -ED/SA 88
M 42 x 2 VSTI 42 x 2 -ED/SA 147
M 48 x 2 VSTI 48 x 2 -ED 220
830B/C-850B/C-870B/C 30-135
12
TIGHTENING TORQUE FOR SEAL LOCK NUTS VSTI (METRIC ISO STANDARD THREAD)
Strength Class
Thread
8.8 10.9 12.9
size
Tightening Torque (lbf ft)
The values for tightening torque shown in the table are M6 7.4 n/a n/a
valid only for seal lock nuts of the strength class 8.8 and M8 16.2 n/a n/a
with metric ISO standard thread. M 10 29.5 n/a n/a
M 12 50.9 n/a n/a
M 14 81.1 n/a n/a
M 16 125.3 n/a n/a
TIGHTENING TORQUES FOR CROSS-SLOTTED LENS HEAD SCREWS DIN 7985 (METRIC
ISO STANDARD THREAD)
Strength classes
Thread size 8.8 10.9 12.9
Tightening torques (lbf ft)
The values for tightening torques shown in the M3 0.8 n/a n/a
table are valid only for cross-slotted lens head
M4 2.1 n/a n/a
screws DIN 7985 of the strength class 8.8 and
with metric ISO standard thread. M5 4.4 n/a n/a
M6 7.4 n/a n/a
M8 18.4 n/a n/a
M 10 36.1 n/a n/a
30-136 830B/C-850B/C-870B/C
12
INSTALLATION
1. Support the all-wheel-drive pump c, and position the gasket and
pump against the transfer case h. Install the plain washers and bolts
g.
2. Install the screw to secure the terminals d and e to the control module
f.
3. Unplug the hoses b and reconnect them to the pump.
4. Connect the hoses b thru d to the bottom of the hydraulic oil tank e
as tagged during disassembly.
5. Install the hydraulic oil filter g onto the filter head h.
6. Ensure that the cap f is tight on the elbow.
7. Fill the hydraulic oil tank with hydraulic oil to the “FULL” mark on
the sight gauge. After the unit has run for a while, recheck the oil level
and add as necessary.
Remark
Refer to the Operator's Manual for the proper hydraulic oil
specifications and fill capacities.
8. Reconnect the negative (-) battery cables.
9. At this time, refer to the “Testing and Adjustments” section prior to installing the rear grill.
10. Secure the rear grill d to the rear cowl e with the flat washers and
bolts b and c.
830B/C-850B/C-870B/C 30-137
DISASSEMBLY AND ASSEMBLY CIRCLE REVERSE MOTOR
12
CHAR-LYNN (MACHINE S/N 202309 TO 203192)

The following is only one method of removing, disassembling, cleaning, inspecting, reassembling, and installing the circle
reverse motor.
REMOVAL
1. Remove the bolts and washers b that attach the circle reverse motor c
to the gear case mounting plate d.
2. Remove the motor c and O-ring from the gear case mounting plate d.
3. Tag and disconnect the hoses E and F from the elbows g and h. Plug
the hoses to prevent contamination from entering the hydraulic
system.
4. Remove the elbows g and h from the motor c, if necessary.
DISASSEMBLY
1. Clamp the motor in a vise so that the shaft is vertical and the end cap is
on top. Clamp the mounting flange with just enough force to hold the
motor securely in place. Protect the mounting flange with soft vise
jaws.
2. Remove the bolts b that secure the end cap c, geroler d, and spacer
plate e to the housing f.
3. Separate the end cap c, geroler d, and spacer plate e from the
housing f. Remove the O-rings g thru i.
Remark
Do not disassemble the geroler d.
4. Remove the drive j from the geroler d and the housing f.
5. Unclamp the motor and remove the output shaft b, thrust needle
bearing c, and thrust bearing race d from the housing e.
Remark
Keep the needle bearing and race together to maintain
proper orientation.
6. Clamp the housing e across the port area so the mounting flange is on
top. Use just enough force to hold the motor securely in place.
30-138 830B/C-850B/C-870B/C
7. Remove the bolts b that hold the mounting flange c to the motor
housing d.
Remark
Because Loctite was used on these bolts during assembly,
DO NOT exceed 500 lbf in (56.4 Nm) of torque to remove
them. If unable to break the bond the Loctite created, heat
the motor housing with a propane torch (A) where the bolt
threads into the motor housing. Turn the bolt while heating
the housing. Apply just enough heat to remove the bolt; do
not overheat the motor housing or mounting flange.
8. Remove the mounting flange c and O-ring e from the motor housing
d. The exclusion seal f, pressure seal g, and back-up ring h will
come off with the mounting flange.
9. Remove the exclusion seal b, pressure seal c, and backup ring d

from the mounting flange e. A seal removal tool may be fabricated by
bending and rounding the end of a small blade screwdriver (B).
WARNING! Do not damage the mounting flange

where the shaft passes through it.
830B/C-850B/C-870B/C 30-139
12
ASSEMBLY
During reassembly, lubricate the new seals with Vaseline. Lubricate the machined surfaces and bearings with clean hydraulic
fluid.
1. Remove all the old Loctite from the mounting flange bolts and their
threaded holes. Clean and dry the threads so that the new Loctite can
hold properly.
2. Lubricate and install the output shaft b, needle thrust bearing c, and
bearing race d into the housing e.
WARNING! Do not permit oil to get into the threaded

holes.
3. Lubricate the exclusion seal b and press it into its seat in the mounting
flange c.
4. Lubricate and install the back-up ring d and pressure seal e. Use the
two-piece seal installation tool to press the pressure seal into place.
Remark
Ensure that the exclusion seal and pressure seal are
undamaged and properly seated.
5. Apply 3 or 4 drops of Loctite #277 to the four threaded holes in the

motor housing b where the mounting flange c will be attached. Also,
coat the bolt threads with Loctite.
6. Install a protective sleeve or bullet (not shown) over the output shaft
d. Lubricate the inner edges of the exclusion and pressure seals.
Lubricate and install the O-ring e on the mounting flange c. Then
slide the mounting flange down over the shaft.
7. Remove the protective sleeve and install the bolts f. Tighten the bolts,
in a criss-cross pattern. Be sure the output shaft does not fall out of the
housing.
Bolts: 250 lbf in (28.2 Nm)
30-140 830B/C-850B/C-870B/C
12
Remark
Loctite must cure completely before the motor is put into service. Loctite curing time is 6 hours. Use of
Loctite Primer reduces the curing time to 15 minutes. Follow the instructions on the Loctite package.
8. Clamp the motor housing f in a vise so the output shaft is vertical and
pointed down. Clamp on mounting flange.
9. Pour clean hydraulic fluid into the motor housing f to provide start-up
lubrication.
10. Lubricate and install the seal i in the groove of the motor housing f.
11. Install the drive j into the shaft.

Remark
If the splined ends of the drive are different lengths, install
the longer end into the shaft.
12. Align the shaft’s timing dot b with any bolt hole c. Mark the outside
of the housing that aligns with the bolt hole. The bolt hole will be used
as a reference point for the timing process.
13. Install the spacer plate e, and note the position of the threaded hole in
the housing aligned with the timing dot b.
Remark
Ensure that the slots in the spacer plate provide passage for
hydraulic fluid as well as the bolts. If the spacer plate is
flipped, the motor will not operate.
14. Lubricate and install the O-ring seal h in the groove of the geroler d.
15. Install the geroler d on the drive j and the spacer plate e.
Remark
Align any star point f with the threaded hole noted for
location of the timing dot b. If a valley g is used, the motor
will function in reverse.
16. Rotate the geroler d to align the bolt holes.
17. Lubricate and install the O-ring g in the groove of the end cap c.
18. Fill the geroler with clean hydraulic oil.

Remark
The “S” is for standard timing and the “R” is for reverse timing.
19. Install the end cap c and bolts b. While tightening the bolts in a
criss-cross pattern, turn the output shaft. Turning it while torquing the
bolts ensures that all internal parts are aligned.
Bolts b: 300 lbf in (33.8 Nm)
830B/C-850B/C-870B/C 30-141
12
INSTALLATION
1. Install the O-ring (not shown) onto the circle reverse motor c
mounting flange.
2. Attach the circle reverse motor c to the gear case mounting plate d
with the washers and bolts b.
3. Reinstall the elbows g and h to the circle reverse motor c, if they

were removed.
4. Unplug the hoses e and f and connect them to the elbows g and h as
tagged during removal.
30-142 830B/C-850B/C-870B/C
12
MEMORANDUM
830B/C-850B/C-870B/C 30-143
12
PARKER (MACHINE S/N 203193 AND UP)
EXPLODED ASSEMBLY VIEW
30-144 830B/C-850B/C-870B/C
12
830B/C-850B/C-870B/C 30-145
12
REMOVAL
1. Bleed down hydraulic pressure, mark, disconnect and plug hoses b

and c.
2. Support circle reverse motor and disconnect the two mount bolts d.
Remark
If you need to reach the circle reverse worm gear, remove
the six bolts e on the cover after removing the circle revers
motor.
DISASSEMBLY
Remark
Refer to exploded views “EXPLODED ASSEMBLY VIEW” on
page 30-144 and page 30-145 for all call out references in
the following steps.
1. Place the Torqlink™ in a soft jawed vice, with coupling shaft 1@

pointed down and the vise jaws clamping firmly on the sides of the
housing 1* mounting flange or port bosses. Remove manifold port
O-rings 1*A if applicable.
WARNING! If the torqlink™ is not firmly held in the

vise, it could be dislodged during the
service procedures, causing injury.
2. Scribe an alignment mark down and across the Torqlink™ components

from end cover c to housing 1* to facilitate reassembly orientation
where required. Loosen two shuttle or relief valve plugs 2! for
disassembly later if included in end cover. 3/16 or 3/8 inch Allen
wrench or 1 inch hex socket required.
30-146 830B/C-850B/C-870B/C
12
3. Remove the five, six, or seven special ring head bolts b, bA, bB, or
bC using an appropriate 1/2 or 9/16 inch size socket. Inspect bolts for
damaged threads, or sealing rings, under the bolt head. Replace
damaged bolts.
4. Remove end cover assembly c and seal ring e. Discard seal ring.
Remark
Refer to the appropriate “alternate cover construction” on the
“EXPLODED ASSEMBLY VIEW” on page 30-144 to
determine the end cover construction being serviced.
5. If the end cover c is equipped with shuttle valve or relief valve 2$

components, remove the two previously loosened plugs 2! and O-rings
2@.
WARNING! Be ready to catch the shuttle valve or

relief valve components that will fall out of
the end cover valve cavity when the plugs
are removed.
Remark
O-ring 2@ is not included in seal kits but serviced separately if
required.
Remark
The insert and if included the orifice plug in the end cover
c must not be removed as they are serviced as an integral
part of the end cover.
830B/C-850B/C-870B/C 30-147
12
6. Thoroughly wash end cover c in proper solvent and blow dry. Be sure
the end cover valve apertures, including the internal orifice plug, are
free of contamination. Inspect end cover for cracks and the bolt head
recesses for good bolt head sealing surfaces. Replace end cover as nec-
essary.
Remark
A polished pattern (not scratches) on the cover from rotation
of the commutator f is normal. Discoloration would indicate
excess fluid temperature, thermal shock, or excess speed
and require system investigation for cause and close
inspection of end cover, commutator, manifold, and rotor set.
7. Remove commutator ring g.

Inspect commutator ring for cracks, or burrs.
8. Remove commutator f and seal ring d.

Remove seal ring from commutator, using an air hose to blow air into
ring groove until seal ring is lifted out and discard seal ring. Inspect
commutator for cracks or burrs, wear, scoring, spalling or brinelling. If
any of these conditions exist, replace commutator and commutator
ring as a matched set.
30-148 830B/C-850B/C-870B/C
12
9. Remove manifold h and inspect for cracks surface scoring, brinelling
or spalling. Replace manifold if any of these conditions exist. A
polished pattern on the ground surface from commutator or rotor
rotation is normal. Remove and discard the seal rings e that are on
both sides of the manifold.
Remark
The manifold is constructed of plates bonded together to
form an integral component not subject to further
disassembly for service. Compare configuration of both
sides of the manifold to ensure that same surface is
reassembled against the rotor set.
10. Remove rotor set i and wearplate j, together to retain the rotor set in
its assembled form, maintaining the same rotor vane iC to stator iB
contact surfaces.
The drive link 1) may come away from the coupling shaft 1@ with the
rotor set, and wearplate. You may have to shift the rotor set on the
wearplate to work the drive link out of the rotor iA and wearplate.
Inspect the rotor set in its assembled form for nicks, scoring, or
spalling on any surface and for broken or worn splines. If the rotor set
component requires replacement, the complete rotor set must be
replaced as it is a matched set. Inspect the wearplate for cracks,
brinelling, or scoring. Discard seal ring e that is between the rotor set
and wearplate.
Remark
The rotor set i components may become disassembled
during service procedures. Marking the surface of the rotor
and stator that is facing UP, with etching ink or grease pencil
before removal from Torqlink™ will ensure correct reassembly of rotor into stator and rotor set into
Torqlink™. Marking all rotor components and mating spline components for exact repositioning at assembly
will ensure maximum wear life and performance of rotor set and Torqlink™.
830B/C-850B/C-870B/C 30-149
12
Remark
Discard seal ring only if stator halves become disassembled
during the service procedures.
Remark
A polished pattern on the wear plate from rotor rotation is
normal.
11. Place rotor set i and wear plate j on a flat surface and center rotor
iA in stator iB such that two rotor lobes (180 degrees apart) and a
roller vane iC centerline are on the same stator centerline. Check the
rotor lobe to roller vane clearance with a feeler gage at this common
centerline. If there is more than 0.005 inches (0.13 mm) of clearance,
replace rotor set.
12. Remove drive link 1) from coupling shaft 1@ if it was not removed with
rotor set and wear plate. Inspect drive link for cracks and worn or
damaged splines. No perceptible lash (play) should be noted between
mating spline parts. Remove and discard seal ring e from housing 1*.
13. Remove thrust bearing 1! from top of coupling shaft 1@. Inspect for
wear, brinelling, corrosion and a full complement of retained rollers.
30-150 830B/C-850B/C-870B/C
12
14. Check exposed portion of coupling shaft 1@ to be sure you have
removed all signs of rust and corrosion which might prevent its
withdrawal through the seal and bearing. Crocus cloth or fine emery
paper may be used. Remove any key 1@A, nut 1@B, washer 1@C, bolt
1@D, lock washer 1@E, or retaining ring 1@F.
15. Remove coupling shaft 1@, by pushing on the output end of shaft.
Inspect coupling shaft bearing and seal surfaces for spalling, nicks,
grooves, severe wear or corrosion and discoloration. Inspect for
damaged or worn internal and external splines or keyway. Replace
coupling shaft if any of these conditions exist.
Remark
Minor shaft wear in seal area is permissible. If wear exceeds
0.020 inches (0.51 mm) diametrically, replace coupling shaft.
Remark
A slight “polish” is permissible in the shaft bearing areas.
Anything more would require coupling shaft replacement.
16. Remove and discard seal ring e from housing 1*.
17. Remove thrust bearing 1% and thrust washer 1$. Inspect for wear,
brinelling, corrosion and a full complement of retained rollers.
830B/C-850B/C-870B/C 30-151
12
18. Remove seal 1^ and back up washer 1& from housing 1*. Discard both.
Remove seal 1^, backup washer 1&, and backup washer 2% from
housing by working them around unseated thrust washers 1$ and thrust
bearing 1% and out of the housing. Discard seal and washers.
19. Remove housing 1* from vise, invert it and remove and discard seal 2).
A blind hole bearing or seal puller is required.
20. Inspect housing 1* assembly for cracks, the machined surfaces for
nicks, burrs, brinelling or corrosion. Remove burrs that can be
removed without changing dimensional characteristics. Inspect tapped
holes for thread damage. If the housing is defective in these areas,
discard the housing assembly.
30-152 830B/C-850B/C-870B/C
12
21. If the housing 1* assembly has passed inspection to this point, inspect
the housing bearings/bushings 1( and 1# and if they are captured in the
housing cavity the two thrust washers 1$ and thrust bearing 1%. The
bearing rollers must be firmly retained in the bearing cages, but must
rotate and orbit freely. All rollers and thrust washers must be free of
brinelling and corrosion.
A bearing, bushing, or thrust washer that does not pass inspection must
be replaced. If the housing has passed this inspection the disassembly
of the Torqlink™ is completed.
Remark
The depth or location of bearing/bushing 1# in relation to the
housing wear plate surface and the depth or location of
bearing/bushing 1( in relation to the beginning of bearing/
bushing counter bore should be measured and noted before
removing the bearings/bushings. This will facilitate the
correct reassembly of new bearings/bushings.
830B/C-850B/C-870B/C 30-153
12
22. If the bearings, bushing or thrust washers must be replaced use a
suitable size bearing puller to remove bearing/bushings 1( and 1# from
housing 1* without damaging the housing. Remove thrust washers 1$
and thrust bearing 1% if they were previously retained in the housing by
bearing 1#.
30-154 830B/C-850B/C-870B/C
12
ASSEMBLY
Remark
Refer to exploded views “EXPLODED ASSEMBLY VIEW” on page 30-144 and page 30-145 for all call out
references in the following steps.
Remark
Unless otherwise indicated, do not oil or grease parts before assembly.
Remark
Replace all seals and seal rings with new ones each time you reassemble the Torqlink™ unit. Lubricate all
seals and seal rings with SAE 10W40 oil or clean grease before assembly.
Remark
Individual seals and seal rings as well as a complete seal kit are available. The parts should be available
through most distributors. (Contact your local dealer for availability).
Remark
Wash all parts in clean petroleum-based solvents before assembly. Blow them dry with compressed air.
Remove any paint chips from mating surfaces of the end cover, commutator set, manifold rotor set, wear
plate and housing and from port and sealing areas.
WARNING! Since they are flammable, be extremely careful when using any solvent. Even a small
explosion or fire could cause injury or death.
WARNING! Wear eye protection and be sure to comply with osha or other maximum air pressure
requirements.
1. If the housing 1* bearing components were removed for

replacement, thoroughly coat and pack a new outer bearing/bushing 1(
with clean corrosion resistant grease recommended in the material
section. Press the new bearing/bushing into the counterbore at the
mounting flange end of the housing, using the appropriate sized
bearing mandrel “SPECIAL BEARING MANDREL TOOL” on page
30-18 which will control the bearing/ bushing depth.
Torqlink™ housings require the use of bearing mandrel “SPECIAL

BEARING MANDREL TOOL” on page 30-18 to press
bearing/bushing 1( into the housing to a required depth of 0.151/0.161
inches (3.84/4.09 mm) from the end of the bearing counterbore.
830B/C-850B/C-870B/C 30-155
12
Remark
Bearing mandrel must be pressed against the lettered end of
bearing shell. Take care that the housing bore is square with
the press base and the bearing/bushing is not cocked when
pressing a bearing/bushing into the housing.
WARNING! If the bearing mandrel specified in the “Tools and Materials Required for Servicing”
section is not available and alternate methods are used to press in bearing/bushing 1#
and 1( the bearing/bushing depths specified must be achieved to insure adequate
bearing support and correct relationship to adjacent components when assembled.
WARNING! Because the bearing/bushings 1# and 1( have a press fit into the housing they must be
discarded when removed. They must not be reused.
2. The inner housing bearing/bushing 1# can now be pressed into its

counterbore in housing 1* flush to 0.03 inch (0.76 mm) below the
housing wear plate contact face. Use the opposite end of the bearing
mandrel that was used to press in the outer bearing/bushing 1(.
Reference “SPECIAL BEARING MANDREL TOOL” on page 30-18.
3. Press a new dirt and water seal 2) into the housing 1* outer bearing
counterbore.
30-156 830B/C-850B/C-870B/C
12 The dirt and water seal 2) must be pressed in until its’ flange is flush
against the housing.
4. Place housing 1* assembly into a soft jawed vise with the coupling
shaft bore down, clamping against the mounting flange.
5. Assemble a new backup washer 1& and new seal 1^ with the seal lip
facing toward the inside, into their respective counterbores in
housing 1* if they were not assembled in step 2.
830B/C-850B/C-870B/C 30-157
12
6. Assemble thrust washer1$ then thrust bearing 1% that was removed
from the Torqlink™.
Remark
One thrust washer 1$ with thrust bearing 1%. The coupling
shaft will be seated directly against the thrust bearing.
7. Apply masking tape around splines or keyway on shaft 1@ to prevent

damage to seal.
8. Be sure that a generous amount of clean corrosion resistant grease has

been applied to the lower (outer) housing bearing/bushing 1(. Install
the coupling shaft 1@ into housing 1*, seating it against the thrust
bearing 1% in housings.
WARNING! The outer bearing 1( is not lubricated by

the system’s hydraulic fluid. Be sure it is
thoroughly packed with the recommended
grease.
Mobile Mobilith SHC ® 460 or a 102 Tube is included in

each seal kit.
The coupling shaft 1@ will be flush or just below the housing wear plate
surface when properly seated. The coupling shaft must rotate smoothly
on the thrust bearing package.
30-158 830B/C-850B/C-870B/C
12
9. Apply a small amount of clean grease to a new seal ring e and insert it
into the housing 1* seal ring groove.
Remark
One or two alignment studs screwed finger tight into housing
(18) bolt holes, approximately 180 degrees apart, will
facilitate the assembly and alignment of components as
required in the following procedures. The studs can be made
by cutting off the heads of either 3/8-24 UNF 2A or 5/16-24
UNF 2A bolts as required that are over 0.5 inch (12.7 mm)
longer than the bolts b, bA, bB, or bC.
10. Install drive link 1) the long splined end down into the coupling shaft
1@ and engage the drive link splines into mesh with the coupling shaft
splines.
Remark
Use any alignment marks put on the coupling shaft and drive
link before disassembly to assemble the drive link splines in
their original position in the mating coupling shaft splines.
11. Assemble wear plate j over the drive link 1) and alignment studs onto
the housing 1*.
12. Apply a small amount of clean grease to a new seal ring e and
assemble it into the seal ring groove on the wear plate side of the rotor
set stator iB.
830B/C-850B/C-870B/C 30-159
12
13. Install the assembled rotor set i onto wear plate j with rotor iA
counterbore and seal ring side down and the splines into mesh with the
drive link splines.
Remark
It may be necessary to turn one alignment stud out of the
housing 1* temporarily to assemble rotor set i or manifold h
over the drive link.
Remark
The rotor set rotor counterbore side must be down against
wear plate for drive link clearance and to maintain the
original rotor-drive link spline contact. A rotor set without a
counterbore and that was not etched before disassembly
can be reinstalled using the drive link spline pattern on the
rotor splines if apparent, to determine which side was
down.The rotor set seal ring groove faces toward the wear
plate j.
14. Apply clean grease to a new seal ring e and assemble it in the seal ring
groove in the rotor set contact side of manifold h.
Remark
The manifold h is made up of several plates bonded
together permanently to form an integral component. The
manifold surface that must contact the rotor set has it’s
series of irregular shaped cavities on the largest
circumference or circle around the inside diameter. The
polished impression left on the manifold by the rotor set is
another indication of which surface must contact the rotor
set.
15. Assemble the manifold h over the alignment studs and drive link 1)
and onto the rotor set. Be sure the correct manifold surface is against
the rotor set.
16. Apply grease to a new seal ring e and insert it in the seal ring groove
exposed on the manifold.
30-160 830B/C-850B/C-870B/C
12
17. Assemble the commutator ring g over alignment studs onto the
manifold.
18. Assemble a new seal ring d flat side up, into commutator f and
assemble commutator over the end of drive link 1) onto manifold h
with seal ring side up.
19. If shuttle valve components items 2!, 2@, 2#, 2$ were removed from the
end cover c turn a plug 2! with a new O-ring 2@, loosely into one end
of the valve cavity in the end cover. Insert a spring 2#, the valve 2$, and
the second spring 2# into the other end of the valve cavity. Turn the
second plug 2! with a new O-ring 2@ loosely into the end cover valve
cavity. 3/16 inch Allen wrench required.
830B/C-850B/C-870B/C 30-161
12
20. If relief valve components items 2!, 2@, 2$ were removed from the end
cover c assemble a new O-ring 2@ on the two plugs 2!. Assemble a two
piece relief valve 2$ in each of the plugs, with the large end of the
conical spring into the plug first and the small nut of the other valve
piece in the small end of the conical spring. Turn each of the plug and
relief valve assemblies into the end cover loosely to be torqued later.
3/8 inch Allen or 1 inch Hex socket required.
21. Assemble a new seal ring e into end cover c and assemble end cover
over the alignment studs and onto the commutator set. If the end cover
has only 5 bolt holes be sure the cover holes are aligned with the 5
threaded holes in housing 1*.
22. The correct 5 bolt end cover bolt hole relationship to housing port
bosses is shown at right.
Remark
If the end cover has a valve 2$ or has five bolt holes, use the
line you previously scribed on the cover to radially align the
end cover into its original position.
30-162 830B/C-850B/C-870B/C
12
23. Assemble the 5 or 7 special bolts b, bA, bB or bC) and screw in
finger tight. Remove and replace the two alignment studs with bolts
after the other bolts are in place. Alternately and progressively tighten
the bolts to pull the end cover and other components into place
Bolts: 22 - 26 lbf ft (30 - 35 Nm)
Remark
The special bolts required for use with the relief or shuttle
valve 2$ end cover assembly c are longer than the bolts
required with standard and cover assembly. Refer to the
service parts lists for correct service part number if
replacement is required.
24. Torque the two shuttle valve plug assemblies 2! in end cover assembly.
Plugs: 9 - 12 lbf ft (12 - 16 Nm) if cover is so equipped
Torque the two relief valve plug assemblies 2! in end cover assembly.
Plugs: 45 - 55 lbf ft (61 - 75 Nm) if cover is so equipped
830B/C-850B/C-870B/C 30-163
12
ONE PIECE STATOR CONSTRUCTION
A disassembled rotor iA stator iB and vanes iC that cannot be readily
assembled by hand can be assembled by the following procedures.
1. Place stator iB onto wear plate j with seal ring e side down, after
following assembly steps 1 through 13. Be sure the seal ring is in
place.
2. If assembly alignment studs are not being utilized, align stator bolt
holes with wear plate and housing bolt holes and turn two bolts b
finger tight into bolt holes approximately 180 degrees apart to retain
stator and wear plate stationary.
3. Assemble the rotor iA, counterbore down if applicable, into stator

iB, and onto wear plate j with rotor splines into mesh with drive link
1) splines.
Remark
If the manifold side of the rotor was etched during
disassembly, this side should be up. If the rotor is not etched
and does not have a counterbore, use the drive link spline
contact pattern apparent on the rotor splines to determine
the rotor side that must be against the wear plate.
4. Assemble six vanes iC, or as many vanes that will readily assemble
into the stator vane pockets.
WARNING! Excessive force used to push the rotor

vanes into place could shear off the
coating applied to the stator vane
pockets.
5. Grasp the output end of coupling shaft 1@ with locking pliers or other
appropriate turning device and rotate coupling shaft, drive link and
rotor to seat the rotor and the assembled vanes iC into stator iB,
creating the necessary clearance to assemble the seventh or full
complement of seven vanes. Assemble the seven vanes using
minimum force.
6. Remove the two assembled bolts b if used to retain stator and wear
plate.
Go to assembly procedure step #14, to continue assembly.
30-164 830B/C-850B/C-870B/C
12
FINAL CHECKS
• Pressurize the circle reverse motor with 100 p.s.i. dry air or nitrogen and submerge in solvent to check for external leaks.
• Check for rotation. Torque required to rotate coupling shaft should not be more than 50 lbf ft (68 Nm)
• Pressure port with “A” cast under it on housing 1* is for clockwise coupling shaft rotation as viewed from the output end
of coupling shaft. Pressure port with “B” cast under it is for counter clockwise coupling shaft rotation.
• Use test stand if available, to check operation of the circle reverse motor.
HYDRAULIC FLUID
Keep the hydraulic system filled with one of the following:

• 10W40 SE or SF manufacturers suggested oil.
• Hydraulic fluid as recommended by equipment manufacturer, but the viscosity should not drop below 50 SSU or contain
less than 0.125% zinc anti-wear additives.
WARNING! Do not mix oil types. Any mixture, or an unapproved oil, could deteriorate the seals.
Maintain the proper fluid level in the reservoir. When changing fluid, completely drain old
oil from the system. It is suggested also that you flush the system with clean oil.
FILTRATION
Recommended filtration 20-50 micron.

OIL TEMPERATURE
Maximum operating temperature 200° F (93.3° C).
INSTALLATION
Install in reverse order of removal.
Apply Loctite 262 to bolt threads
Two mount bolts e: 98 lbf ft (149.1 Nm)
Install a new motor gasket (not shown).
Apply Loctite 518 to cover plate
Apply Loctite 262 to bolt threads
Six cover mount bolts d: 45 lbf ft (61.0 Nm)
Remark
A coupling is located between the output shaft of the motor and circle reverse gear case worm gear.
830B/C-850B/C-870B/C 30-165
DISASSEMBLY AND ASSEMBLY STEERING (ORBITOL) VALVE
12
STEERING (ORBITOL) VALVE
REMOVAL
It is imperative that no contaminants enter the steering (orbitrol) unit after
removal. Thus, remove all connectors and elbows from the unit and plug
the ports in the unit housing. Plug the hoses and then tag them to identify
the port each hose connects to, ensuring proper installation during
reassembly.
The removal procedure for the orbitrol unit is covered in the “Thoroughly
clean the component to be serviced and the surrounding area. This will help
prevent contamination from entering the component or system being serviced.” on page 30-481. The upper portion of the
console must be disassembled to gain access to the unit.
DISASSEMBLY
1. Plug all the ports in the orbitrol unit to prevent internal contamination
during servicing.
2. Make alignment marks on the unit end cap, gerotor, spacer plate, and
housing. The marks will be used to properly align the parts during
reassembly.
3. Loosen and remove the seven end-cap mount bolts b and the cap c.
4. Remove the O-ring b from the end cap. Lift the gerotor b from the
star gear c.
5. Remove the O-ring b from the gerotor c.
30-166 830B/C-850B/C-870B/C
12
6. Lift the star gear b from the drive splines. Remove the gear and the
spacer c.
7. Pull the drive shaft b from the housing c and remove the spacer plate
d.
8. Remove the O-ring b from the housing c.
9. With a clean wood block to protect the housing end from the vise rail,
position the housing in the vise.
10. Remove the retaining ring b from the housing c.
830B/C-850B/C-870B/C 30-167
12
11. Pry the seal gland bushing b from the housing c.
12. Remove the upper seal b and the lower quad ring seal c from the seal
gland bushing d. Refer to the cleaning and inspection section for the
appropriate service.
13. Remove the upper thrust washer b, needle bearing, and lower thrust
washer from the centering spool splined end.
14. Pull the O-ring c from the housing.
15. Apply pressure to the splined end of the centering spool b, opposite
the end shown, and push it out of the housing c.
Remark
If the centering spool binds during removal from the housing,
internal damage will result and seriously impair the orbitrol
unit operation. Rotate the centering spool while removing it
from the housing will help eliminate binding.
30-168 830B/C-850B/C-870B/C
12
16. Using a suitable tool, remove the centering pin b from the control
parts assembly c.
17. Slide the spool b from the sleeve c.

Remark
Do not bind the spool inside the sleeve. Damage to the spool
or sleeve will impair the orbitrol unit operation. Rotating the
spool while removing it from the sleeve will help eliminate
binding.
18. Remove the six centering springs d from the spool.

Remark
Observe the position of the springs before removing them.
They must be reinstalled in the same position.
19. Remove the setscrew b from the housing c.
20. Check that the ball seat inside the housing is threaded in the top. Screw
a 1/8 in-24 machine screw into the ball seat and pull the seat b from
the housing c.
830B/C-850B/C-870B/C 30-169
12
21. Turn the housing upside down. The check ball b and check ball
retainer c will fall from the port.
22. Remove the O-ring seals d from the check ball seat e. Refer to the
cleaning and inspection section for the appropriate service.
30-170 830B/C-850B/C-870B/C
12
ASSEMBLY
1. Replace the O-ring seals d on the check ball seat e.
2. Install the check ball retainer c and check ball b into the housing.
WARNING! Ensure that the port check ball retainer c

rests flat in the bottom after installation.
3. Insert the check ball seat b into the housing c port.
4. After screwing the setscrew b into the housing c, tighten the

setscrew b.
5. Replace the centering springs d into the spool b. Install three springs
on each side, with the curved sides facing each other.
6. Lubricate the parts and slide the control spool b into the sleeve c.
Remark
Do not bind the spool in the sleeve while installing the spool.
Rotating the spool while installing it into the sleeve will help
eliminate binding.
830B/C-850B/C-870B/C 30-171
12
7. Insert the centering pin b through the control ports assembly c.
8. Insert the spool b into the bottom of the housing c.

Remark
If the spool binds while installing it in the housing, the orbitrol
unit operation would be seriously impaired. Rotating the
spool while installing it into the housing will help eliminate
binding.
9. Insert the O-ring seal c into the housing. Install the lower thrust
washer, needle bearing, and upper thrust washer b.
10. Replace the upper b and lower c quad ring seals in the seal gland
bushing d.
30-172 830B/C-850B/C-870B/C
12
11. Install the seal gland bushing b into the housing c.
12. Reinsert the seal gland retaining ring b into the housing c.
13. Replace the O-ring b in the housing end c.
14. Align the marks while installing the spacer plate d. Insert the drive
shaft b into the housing c.
Remark
The slot on the drive shaft must fit over the centering pin
when installed.
830B/C-850B/C-870B/C 30-173
12
15. Set the spacer c on the drive shaft. Install the star gear b on the drive
spline.
16. Replace the O-ring b on the gerotor c.
17. Align the marks while installing the gerotor b, with the O-ring down
and over the star gear c.
18. Replace the O-ring b on the end cap.
30-174 830B/C-850B/C-870B/C
12
19. Align the marks while installing the end cap c. Secure the end cap
with seven bolts b and torque them.
End cap bolts: 15 lbf ft (20.3 Nm)
INSTALLATION
Before installation, clean the connectors or elbows. Remove the plugs from the orbitrol unit and install the connectors or
elbows. Make certain that the hoses are connected to the proper unit ports.
The installation procedure for the steering (orbitrol) unit is covered in the “TILT STEERING CONSOLE” on page 30-481.
The upper portion of the console must be disassembled to gain access to the unit.
830B/C-850B/C-870B/C 30-175
DISASSEMBLY AND ASSEMBLY STEERING AND BRAKE PUMP
12
The following is only one method of removing, disassembling, cleaning, inspecting, reassembling, and installing the steering
and brake pump.
REMOVAL
1. Tag and disconnect the hoses b thru d from the fittings.
Remark
Remove the fittings and plug the ports and hoses to prevent
dirt from entering the pump and hydraulic system.
2. Remove the flat washers e, pump f, spacer and gasket from the
engine.
3. Remove the hexnut b, gear c, and hub d from the pump shaft.
30-176 830B/C-850B/C-870B/C
12
DISASSEMBLY
Remark
Removing the adjusting screw covers from the cap may void the warranty of this assembly.
1. Clamp the end of the drive shaft in a protected jaw vise with the pump body pointed up.
2. Remove the Allen head screws 3! securing the compensator 4@ to the bookplate 2(.
3. Remove the compensator assembly 4@, O-ring i, and gasket h.
4. Remove the bolts 3) from the backplate of the pump.
830B/C-850B/C-870B/C 30-177
12
5. Place a screwdriver in the slots between the housing and loosen the back plate. Remove the bookplate 2( and gasket g
from the housing.
6. Remove the control piston 2& remaining on the back plate or in the housing. Also, remove the plugs 3@ from the back plate
2(.
7. To remove the rotating assembly 2^ from the housing, remove the pump from the vise and slide the rotating assembly off
the shaft.
WARNING! Pistons may not come out with the piston block.
Remark
For steps 8 thru 10E, refer to the illustration below. For steps 11 thru 20, please refer to the illustration on
the previous page.
8. Remove the pistons b, spider c, and spider pivot d from the piston block e.
9. The piston block assembly e need not be disassembled unless the internal pins g or spring i are damaged.
10. Compress the spring i BEFORE removing the snap ring j, if the
spring must be removed from the piston block. Use the following
procedure:
A. Place one flat washer on the 3/8 in x 3-1/4 in large bolt and then
place it through the center of the piston block e.
B. Place the other washer on the bolt and let it rest on the three pins.
C. Screw the nut on and compress the spring inside the piston block.
D. Using a pair of snap-rings pliers, remove the internal snap ring j.
E. Remove the bolt and two washers h, three pins g, and internal pin keeper f.
FOR THE FOLLOWING STEPS, REFER TO THE ILLUSTRATION ON THE PREVIOUS PAGE.
11. To free the shaft seal and shaft, remove the retaining ring b.
12. Remove the shaft 1^ from the housing 1& by tapping the back plate end of the shaft with a wooden or plastic mallet.
13. Remove the shaft seal c, washer 1@, two retaining rings d, two thrust washers 1#, and bearing 1$ from the shaft.
14. To remove the camplate 2% from the housing, remove the two internal retaining rings f from the sides of the housing.
Remove the two covers 2), two O-rings e, two inner races 1(, and bearings 1*. Move the camplate to one side to remove it.
The two camplate pivot bearings are a loose slip fit in the housing. Do not be concerned if they are loose.
15. Remove the spring collar 2@ and spring 2!. Do not remove the button 2# and roll pin 2$ unless they are worn or loose.
30-178 830B/C-850B/C-870B/C
12
16. Disassemble the pressure-flow compensator assembly 4@ for cleaning and inspection.
Remark
Removing the adjusting-screw covers from the cap may void the warranty of this assembly.
17. Remove the pressure-adjustment cap 4! from the compensator housing 4@. Pull the pressure-spring follower 3( from the
cap 4!.
18. Remove the spring 3& and spring pivot 3^ from the compensator housing.
19. Remove the plug 3# and pressure-compensator spool 3% from the compensator housing 4@.
20. Replace the shaft seal, O-rings, and gaskets with new ones.
830B/C-850B/C-870B/C 30-179
12
ASSEMBLY
1. Lubricate all critical moving parts before reassembly.
2. Install the camplate control spring 2! and spring collar 2@ in the housing 1&.
3. Insert the camplate 2% into the housing 1&. Insert the needle bearings 1* and bearing inner race 1( over the camplate arms
and slide them into the housing 1&. The numbered end of the bearing should face outward and the chamfered I.D. of the
race should face inward.
30-180 830B/C-850B/C-870B/C
12
4. Install the new O-ring e around the O.D. of the camplate pivot bearing 1*. Install the trunnion covers 2) and secure them
with the retaining rings f.
5. Install the retaining ring d on the shaft 1^. Install the thrust washer 1#, thrust bearing 1$, and second thrust washer 1#.
Secure with the second retaining ring d.
6. Install the shaft 1^ into the housing 1& and then the washer 1@ and shaft seal c. Secure with the retaining ring b. Make sure
the retaining ring is seated in the groove.
FOR STEPS 7 THRU 9, PLEASE REFER TO THE ILLUSTRATION AT THE RIGHT.
7. If the piston block assembly was disassembled, compress the pin

keeper f and install it in the splined area of the piston block. Install
the three pins g with the head end to the inside of the block and install
them in special grooves of piston block spline.
8. Install the washer h, spring i, and second washer h in the piston

block. Use two 3/8 in I.D. washers and 3/8” x 3-1/4” large bolt to com-
press the spring. Secure with the retaining ring j. Remove the 3/8 in x
3-1/4 in large bolt and two washers.
9. Install the pivot d, spider c, and piston assemblies b in the piston

block. Install this assembly in the housing assembly. The piston shoes
must contact the camplate. Be sure all the parts are in their proper
position.
FOR THE FOLLOWING STEPS, PLEASE REFER TO THE ILLUSTRATION ON THE PREVIOUS PAGE.
10. Clamp this assembly in a protected jaw vise with the open end of the housing 1& up.
11. Install the new gasket g.
12. Install the control piston 2&, and plugs 3@ with new O-ring j onto the backplate 2(. Note the roll pin 2* locations.
13. Install the backplate 2( and bolts 3).
Bolts 3): 27 to 31 lbf ft (36.6 to 42.0 Nm)
14. Place the new O-ring j on the plug 3#. Install the plug assembly 3#, pressure-compensator spool 3%, spring pivot 3^, spring
3&, pressure-spring follower 3( with the new O-ring 1), pressure-adjustment cap 4! new O-ring 1! into the compensator
housing 4@.
Plug 3#: 6 to 8 lbf ft (8.1 to 10.8 Nm)
Pressure adjustment cap 4!: 35 to 40 lbf ft (47.4 to 54.2 Nm)
15. Install the new gasket h and new O-ring i.
16. Install the compensator assembly 4@ and secure it with the Allen head bolts 3!.
Allen head bolts 3!: 10 to 12 lbf ft (13.5 to 16.2 Nm)
17. Plug the ports to preserve cleanliness until installation on the vehicle. (Refer to the “Start-Up Procedures.”)
830B/C-850B/C-870B/C 30-181
12
INSTALLATION
1. Install the hub d, gear c, and nut b onto the pump shaft.
Nut b from 137 to 167 lbf ft (185.7 to 226.4 Nm)
2. Secure the gasket, spacer, and pump f to the engine with the two flat
washers and bolts e.
3. Install the fittings b thru d and connect the hoses to them as tagged
during removal.
4. After installing the pump, perform the “Start-Up Procedure.” Also,

refer to the “Hydraulic Troubleshooting and Adjustment'' section for
the compensator assembly setting.
30-182 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY HYDRAULIC MOTOR
12
HYDRAULIC MOTOR
The following is one method of removing, disassembling, cleaning, inspecting, reassembling, and installing the hydraulic
motor.
Thoroughly clean the component to be serviced and the surrounding area. This action will help prevent contamination from
REMOVAL
1. Make an alignment mark and remove the hoses b and c leading to the
motor d.
2. Disconnect the drain hose e.
3. Plug and cap all hoses and connectors.
4. Using a suitable lifting device and sling, remove the bolts, lock
washers f, and motor from the AWD gearbox assembly.
5. Remove the O-ring (not shown) from the motor.

Remark
A spring disc exists between the motor and gearbox. Do not misplace it.
830B/C-850B/C-870B/C 30-183
12
DISASSEMBLY
1. Make an alignment mark across the top of the valve block c and housing d. Remove the four bolts b from the valve
block. Remove the valve block from the housing and set aside the valve block for later inspection. Discard the gasket e.
2. Remove the (lift) tapered roller bearing f from the shaft 2!.
3. Lift and remove the wafer plate g.

Remark
The plate may resist removal because vacuum formed between the plate and cylinder block. The bronze
face of the wafer plate faces the cylinder block.
30-184 830B/C-850B/C-870B/C
12
4. Hold a hand over the open end of the housing d and turn the entire unit upside down. Catch the rotating group as an
assembly.
Remark
The rotating group contains items j thru 1*, and 2) thru 2@.
5. Lift and remove the drive shaft 2! with the tapered roller bearing 2@ still assembled from the rotating group.
6. Remove the swash plate 2).
7. Lift and remove the shoe plate 1! with the nine piston and shoe assemblies 1) in place.
8. Remove the spherical washer 1@.
9. Remove the three pins 1# and pin retainer 1$, if they did not fall out while removing the drive shaft 2! and bearing 2@
assembly.
10. Place the plain washer b under the head of the long bolt c, and insert
the threaded end through the center of the cylinder block. Ensure the
bolt extends approximately 1.5 in (38.1 mm) beyond the edges of the
cylinder block. Also, ensure that the bolt has enough threads to allow
about 1.0 in (25.4 mm) of spring e expansion after removing the
retaining ring. With the plain washer f and nut g installed, turn the
nut g until the spring is depressed enough to remove the retaining
ring. Slowly loosen the nut g to relieve spring tension. Remove the
nut from the bolt and remove the washer, spring, and thrust washer.
11. Remove the retainer ring.
12. Using an arbor press, remove the shaft seal out of the housing. Use a
short piece of 1.5 in (38.1 mm) heavy-wall tubing as a press tool.
13. Do not remove the alignment pins unless they are damaged.
The following steps may not be necessary after inspecting the components.
14. If the drive shaft bearing f is defective, remove the bearing race from
the valve block.
830B/C-850B/C-870B/C 30-185
12
15. Inspect the shaft for broken splines, burrs, and wear in the area of the
shaft seal(s). Replace the shaft, if wear exceeds 0.005 in (0.127 mm)
T.I.R. Inspect the front bearing for scuffing, peeling, or spalling of the
rollers and/or roughness when turned in the race. DO NOT remove the
bearing from the shaft if the bearing is functional. If the front shaft
bearing or shaft is defective, perform the following steps in the order
indicated.
A. Pull the shaft and bearing from the housing.
B. Remove the drive-shaft bearing as follows:
i. Install a 9.0 in (228.6 mm) piece of 1.5 in (38.1 mm)

heavy-wall tubing over the drive shaft. The end of the tubing
rests against the inner race of the tapered roller bearing and
extend out beyond the end of the shaft.
ii. Place the shaft and bearing and the tubing into the arbor press
with the drive splines up.
iii. Press the drive shaft through the bearing. Considerable force is required to remove the bearing from the shaft.
DO NOT remove the bearing race, unless the bearing is defective.
C. Remove the retaining ring.
D. Using an arbor press, press the shaft seal out of the housing. Use a short piece of 1.5 in (38.1 mm) heavy wall tubing.
An arbor press is also required to remove the bearing race, if replacement is needed.
30-186 830B/C-850B/C-870B/C
12
MEMORANDUM
830B/C-850B/C-870B/C 30-187
12
SPECIAL INSPECTION AREAS
1. Check the bearing spacer i for burrs. Remove any small burrs with an India Stone.
2. Inspect the cylinder block face j for wear, scratches and/or erosion between cylinders. Check the spring, washers, and
retaining ring located within the cylinder block.
3. Using the piston and shoe subassemblies 1), check each cylinder block bore for excessive wear. The piston should have a
very close fit and slide easily in and out of the bore. No binding should exist. If binding is evident, lubricate with clean
hydraulic fluid and try again. Even minor fluid contamination could cause the piston to seize in the cylinder bore.
4. Inspect each piston and shoe assembly 1) for a maximum end play of 0.005 in (0.127 mm) between the piston and shoe.
30-188 830B/C-850B/C-870B/C
12
5. The face thickness dimension of each shoe must be within 0.001 in (0.025 mm) of each other.
6. Inspect the shoe plate 1! for excessive wear and cracking in the area of spherical washer 1@. If heavy wear or cracks exist,
replace the shoe plate and spherical washer at the same time.
7. Check the spherical washer 1@ for burrs, wear, and possible scratches due to pin 1# breakage. Replace if wear is excessive.
8. Inspect the pins 1# for equal length, excessive wear, and possible bending. Replace all pins simultaneously if one is
defective.
9. The pin retainer 1$ may develop burrs. Remove all burrs with an India Stone.
10. Inspect the bronze face of the wafer plate g for excessive wear, scratches, and possible fractures. If the wafer plate is
fractured, make sure the new plate rests flat against the valve block at assembly and that wafer plate pin h does not extend
too far and hold the wafer plate away from the valve block.
11. Inspect the swash plate 2) for scratches, wear, and possible cracks. Replace if defective.
12. Inspect the housing d for cracks, cross threads, and wear. Check the retaining ring groove for wear and the proper depth.
Check the gasket mounting face for deep scratches or damage that could cause leakage past the gasket. Clean up burrs and
small scratches with an India Stone.
13. Inspect the valve block c for burrs, nicks, plugged body passages, flatness of the pump wafer plate and erosion. Repair or
replace the valve block, if defective.
14. Check the flatness of the valve block face in the areas around the locating pins 1( and bolt openings. Use an Arkansas
Stone to remove any burrs or raised metal in these areas.
830B/C-850B/C-870B/C 30-189
12
ASSEMBLY
A sectional view of the drive motor is presented below for general reference while performing the reassembly procedures.
Remark
Dip or coat all parts with the same hydraulic fluid used in the drive system before and during assembly of
the motor.
1. If the bearing race was removed from the block, install a new bearing
race. Use the “Special Bearing Race Installation Tool.”
2. If the new shaft bearings, shaft, valve block or housing are being
replaced, perform a complete shaft bearing preload adjustment. If the
same parts are returned to service, omit the preload adjustment.
3. If the shaft bearing requires replacement, install a new bearing race

into the housing. Use the “Special Bearing Race Installation Tool” to
press the bearing race in place. Make sure the bearing race is oriented
properly to accept the roller bearing before pressing it into the
housing. The bearing race must be bottomed against the shoulder of
the housing at completion of the press.
30-190 830B/C-850B/C-870B/C
12
4. Install the shaft into the front shaft bearing:
A. Place a short piece of 1.5 in (38.1 mm) heavy wall tubing 6.0 in
(152.4 mm) long over the drive spline of the shaft (tubing ends
must be square within 0.005 in (0.127 mm). The tubing must be
long enough to make contact with the inner race of the front
bearing.
B. Press the shaft through the bearing with an arbor press until the
bearing bottoms against the shoulder of the shaft.
C. Remove the short piece of the tubing and turn the shaft bearing in
its race with the end of the shaft. The bearing rollers must turn
free and smooth.
5. If the shaft bearings, shaft, valve block and housing were not replaced,
use the bearing spacer removed during the disassembly procedure to
preload the shaft bearings and perform step 7. If the preload
adjustment is necessary, perform steps 6 and 7.
6. Shaft bearing spacer procedure:
A. Obtain a shaft bearing spacer kit. Find the thickest spacer and measure it. Record this measurement as “A.” Install the
thickest bearing spacer over the shaft with the chamfer facing into the housing (toward the shoulder on the shaft).
B. Slide the bearing onto the shaft and up against the spacer. The small diameter of the tapered roller bearing must face
out of the housing.
C. Install the valve block against the housing without the gasket and rotating group. Turn the shaft to seat the bearings
then torque the valve block attaching bolts to 5 lbf in (0.1 kgm). Retorque the bolts while turning the shaft. The
bearings are seated when the shaft does not free up while turning. Check the opening between the valve block and
housing to be sure it is as even as possible.
D. Use a feeler gauge to measure the opening between valve bock c and housing d. Four measurements should be
obtained 90° apart from each other around the unit. A tapered feeler gauge is especially useful for this purpose.
Average the four readings by adding them together and dividing by four. Record the average gap as "B." Calculate the
thickness of the shaft bearing spacer as follows:
EXAMPLE:
+ 0.150 in (3.810 mm) A is the measured thickness of the bearing spacer.
- 0.027 in (0.686 mm) B is the average gap.
+ 0.003 ±0.001 in (0.076 ±0.025 mm) Preload setting.
+ 0.020 in (0.508 mm) Compressed thickness of gasket.
_______________________________
= 0.146 ±0.001 in (3.708 ±0.025 mm) Required bearing spacer thickness to provide the 0.003 ±0.001 in
(0.076 ±0.025 mm) preload.
830B/C-850B/C-870B/C 30-191
12
ACTUAL MEASUREMENTS:
+ _______________ A is the measured thickness of the bearing spacer.
- _______________ B is the average gap.
+ 0.003 ±0.001 in (0.076 ±0.025 mm) Preload setting.
+ 0.020 in (0.508 mm) Compressed thickness of the gasket.
= _______________ ± 0.001 in (3.708 ±0.025 mm) Required bearing spacer thickness to provide 0.003 ±0.001 in
(0.076 ±0.025 mm) preload.
E. Remove the four mounting bolts and valve block from the housing. The garter spring will face into the motor.
F. Remove the bearing and bearing spacer.
7. Locate a bearing spacer with the required thickness and place it with the shaft bearing. Use the original spacer if the
preload is not performed. Set aside for the final assembly.
8. Assemble the spring, two washers, and retaining ring into the cylinder block. Set the cylinder block assembly
subassembly on a flat surface. Use Kraft paper between the block and surface to prevent scratching the block face.
9. Install the pin retainer into the cylinder block. Position the pin retainer about 0.250 in (6.350 mm) below the surface, and
orient the open end of the pin retainer away from the large spline openings.
10. Slide the three pins into the cylinder block subassembly until they bottom against the pin washer.
11. Place the spherical washer atop the three pins. Install the shoe plate with nine piston and shoe subassemblies over the
spherical washer and into the cylinder block subassembly. Wobble the shoe plate to make sure that each piston is free
within its bore in the cylinder block. Coat all parts with clean hydraulic fluid.
12. Install the swash plate over the shaft into the housing. Set the housing on its side and hold the shaft end so the drive shaft
is horizontal. Slide the rotating group into the housing. Rotate the drive shaft, if necessary, to match the shaft splines to the
cylinder block and spherical washer.
13. Install the bearing spacer with the chamfer toward the shoulder of the drive shaft.
14. Install the tapered roller bearing over the shaft and against the spacer. The small diameter of the tapered roller bearing
must face toward the valve block.
15. Install two housing pins and place a new gasket over them.
16. Assemble the wafer plate locating pin into the valve block.
17. Assemble the wafer plate over the bearing race and locating pin with wear surface away from the valve block. Make sure
wafer plate is flat against valve block. Check the height of the pin to ensure that it does not hold the wafer plate away from
the valve block.
18. After assembling the valve block to the housing, torque the four bolts in a criss-cross pattern.
30-192 830B/C-850B/C-870B/C
12
19. Tape the splined end of the drive shaft with plastic tape to prevent cutting the new shaft seal. Start taping the shaft close to
the housing and work toward the end of the shaft. Install a new shaft seal, with the garter spring inward, over the shaft and
press evenly into the housing. Use the “Shaft Seal Driver.” Position the seal 0.020 in (0.508 mm) below the retaining ring
groove. Install the retaining ring into the housing.
Remark
If pressed too deep into the housing bore, the shaft seal will contact the tapered roller bearing and be
damaged.
INSTALLATION
1. After aligning the mounting holes, insert and engage the wheel motor
d with the O-ring (not shown), drive shaft, and the motor.
Remark
A spring disc exists between the motor and gearbox. Make
sure it is properly positioned.
2. Secure the motor in place with the two lock washers and bolts f.
Remark
Make sure that the motors are properly positioned. Install “Port A” to the top side for right gearbox. Install
the “Port B” to the top side for the left gearbox.
3. Check the identification tags/markings made during removal. Remove all caps/plugs and quickly reconnect the three
hoses b, c, and e.
830B/C-850B/C-870B/C 30-193
DISASSEMBLY AND ASSEMBLY 4-WAY SWIVAL VALVE BLOCK
12
4-WAY SWIVAL VALVE BLOCK
REMOVAL
1. Park the grader on level ground with the transmission in neutral and
the parking brake set. Position the moldboard with the powertilt in the
full vertical position, lower onto the blocking and bleed hydraulic
pressure off.
2. Disconnect the hose b from the elbow c. Cap the hose and elbow. Tag
the hose for reassembly. Repeat this procedure for the other hoses d
thru f.
3. Disconnect the hoses b and c from the connectors d and e. Cap the
hoses and connectors. Tag the hoses for reassembly.
4. Sling the swivel valve f and then remove the cotter pin g and pin h
from the lever and swivel valve mount i.
5. Make an alignment mark across the swivel valve i and circle

assembly j. Remove the nuts, washers, bolts 1), and swivel valve f
from the circle assembly j.
30-194 830B/C-850B/C-870B/C
12
DISASSEMBLY
SWIVEL BLOCK, FOUR-WAY
1. CONNECTOR & O-RING
2. ELBOW & O-RING
3. PLUG & O-RING
4. PIN, SWIVEL
5. BODY, SWIVEL
6. SEAL
7. COVER
8. BOLT
9. WASHER
10. SHIM, 0.005 THICK
11. CONNECTOR, STRAIGHT & O-RING
12. O-RING
Remark
Due to the number of units using this swivel block, some units use different elbows and connectors from
what is shown.
1. Remove the five seal rings G and two plugs d from the pin e. Replace the O-rings on the plugs, if necessary.
2. Remove O-rings 1@.
830B/C-850B/C-870B/C 30-195
12
ASSEMBLY
SWIVEL BLOCK, FOUR-WAY
1. CONNECTOR & O-RING
2. ELBOW & O-RING
3. PLUG & O-RING
4. PIN, SWIVEL
5. BODY, SWIVEL
6. SEAL
7. COVER
8. BOLT
9. WASHER
11. CONNECTOR, STRAIGHT & O-RING
12. O-RING
Remark
Due to the number of units using this swivel block, some units use different elbows and connectors from
what is shown.
1. Coat the seal rings g with hydraulic oil to help ease installation of the seal rings.
2. Coat top and bottom of pin and bottom of housing with grease.
3. Using the swivel-block seal tool, install the five seal rings G into the pin’s grooves.
Remark
See the “Special Tool” section of this manual for
manufacturing instructions of the seal tool.
4. Install two plugs d in the pin e. Replace the O-rings on the plugs, if necessary.
5. Install O-rings 1@.
6. Slide the body f onto the pin assembly e.

Remark
Apply a coating of hydraulic oil on the pin.
30-196 830B/C-850B/C-870B/C
12
7. Install the three bolts i and washers j with cover h onto the body f.
DETERMINING SHIM PACK
A. Install pin in valve body after installing seals on pin.
B. Assemble bottom cover to pin with three bolts and washers.
1st bolt torque: 5 - 10 lbf ft (6.7 - 13.5 Nm)
This is to draw shoulder of pin tight against swivel valve body
C. Disassemble bottom cover from pin.
D. Measure the distance between the bottom of the valve body and
bottom of the pin.
E. Add 0.003 to 0.005 inches to the above measurement to obtain the

required clearance between the pin, cover and valve housing.
F. Select the necessary shims to obtain the required clearance

determined in step E.
G. Reassemble the bottom cover to the pin with the required shim
pack. The machines surface of the cover should be against the
shims.
Final torque of bolts: 70 lbf ft (94.9 Nm)
7. Install the rest of the connectors, elbows and O-rings.
Remark
After assembly is complete, the 4-way swivel valve block should be tested on a hydraulic stand.
Requirements are each hose to be tested to 2500 psi and hold that pressure for 30 seconds ±50 psi.
830B/C-850B/C-870B/C 30-197
12
INSTALLATION
1. Center the swivel block against the circle assembly j and align the
alignment marks made earlier. Install the bolts, washers, and nuts 1).
2. Position the swivel block f against the swivel block mount i. Install
the pin h and cotter (2 EA 1/8 by 1 in) pins g.
3. Remove the caps and connect the hoses b and c to the connectors d
and e.
4. Remove the caps from the elbow c and hose b. Connect the line b to
the elbow c. Repeat this procedure for the other hoses d thru f.
30-198 830B/C-850B/C-870B/C
12
MEMORANDUM
830B/C-850B/C-870B/C 30-199
DISASSEMBLY AND ASSEMBLY CONTROL VALVE MANIFOLDS
12
Thoroughly clean the component to be serviced and the surrounding area. This will help prevent contamination from entering
the component or system being serviced.
The right and left control valve manifolds are similar in design to each other. For that reason, removing the right manifold is
the only one shown.
Disconnecting the main supply and return hoses from the manifold(s) drains the hydraulic oil tank.
When servicing the manifolds, do not interchange the valve spools and the housings. Also, do not rearrange the order in which
the valve sections are positioned. Although the valve sections appear the same, the spools within the valve differ from each
other.
Always refer to the most recent Parts Book when ordering replacement parts.
If servicing one manifold, it is advisable to service the other one at the same time.
REMOVAL
1. Prior to servicing the control valves, rest all components on the ground
(i.e. moldboard, scarifier, ripper, etc.). The area that you will be
working in is a confine space and limited access (See graphic at right.)
To obtain more room, begin by removing the cab steps.
30-200 830B/C-850B/C-870B/C
2. Remove the hexnuts, flat washers, and bolts c and d that secure the step assembly b to the frame.
3. Remove the bolts and flat washers b that secure the cover assembly c
to the cab deck.
4. Slide the cover assembly b up the control lever rods c. Use the
locking pliers to prevent the cover assembly from falling.
830B/C-850B/C-870B/C 30-201
5. Loosen the jamnut b and unscrew the swivel adaptor c from the
control lever rod d. Repeat the procedure for the remaining control
lever rods.
6. Tag and disconnect all hoses to the control valve. Cap the hoses and
fittings to prevent contamination form entering the hydraulic system.
The hydraulic oil tank will drain when the main supply and return
hoses are disconnected from the manifold. The hydraulic oil system
holds about 30 U.S. gallons.
7. Install the two 5/16 in - 24 UNF lifting eyes b in outside swivel adapt-
ers c. Attach a sling to the lifting eyes. Have one person hold the sling
while the other removes the three bolts holding the control valve to the
mounting bracket. Once the control valve is free, use the sling to lower
the valve to the ground.
8. Remove the swivel adapters and spacers from the control valve spools.
9. Tag and then remove all fittings from the control valve. Plug the control valve ports.
30-202 830B/C-850B/C-870B/C
12
DISASSEMBLY
CONTROL VALVE BANK
Both the left and right hand banks are disassembled using the following method. Care should be taken throughout these
procedures to protect the valve assemblies from dirt entering the hydraulic system.
Remark
Mark the valve sections for later reassembly.
830B/C-850B/C-870B/C 30-203
12
VALVE, CONTROL - R.H. - 4 VALVE BANK.

1. NUT, HEX 8. O-RING 15. O-RING
2. ROD, TIE 9. SHUTTLE 16. VALVE SECTION - R.H. BLADE LIFT
3. NUT, HEX 10. VALVE SECTION - ARTICULATION 17. O-RING
4. ROD, TIE 11. O-RING 18. OUTLET SECTION
5. PLUG, SHUT-OFF 12. VALVE SECTION - DRAWBAR SIDE SHIFT 19. CARTRIDGE, MAIN RELIEF VALVE
6. O-RING 13. O-RING 20. O-RING
7. INLET SECTION 14. VALVE SECTION - LEANING WHEEL 21. O-RING
1. Remove the hexnuts b from the tie rods c.
2. Remove the hexnuts d from the tie rod e.
3. Leave the tie rods c and e in position while removing the valve sections.
4. Remove the outlet section 1*.
5. Remove the valve sections 1^, 1$, 1@, and 1) and inlet section h.
6. Remove and discard the O-rings 1&, 1%, 1#, 1!, and i between the sections.
7. Remove the shuttle j from each valve section.
8. Remove the main relief valve cartridge 1( from the outlet section 1*.
9. Remove and discard the O-rings 2) and 2! from the main relief valve cartridge 1(.
10. Remove the shut-off plug f from the inlet section h.
11. Remove and discard the O-ring g from the shut-off plug f.
30-204 830B/C-850B/C-870B/C
VALVE SECTION
WARNING! Socket head screws b are under spring pressure; care should be taken when removing
the spool cap c.
1. Remove the two socket head screws b from the spool cap c.
2. Remove the two screws 1# and plate 1@.
3. Remove the spool end d, spring seat e, spring g, flat washer f, other spring seat e, and O-ring h.
830B/C-850B/C-870B/C 30-205
12
4. Remove the one wiper i and O-ring j from each end of the spool 1).
5. Remove the spool 1) from the valve body 1!.
6. Remove the spring 1% and compensator spool 1$ from the valve body 1!.
Remark
All valve sections are disassembled using the above procedure. The spring 1% and compensator spool 1$
are installed on the opposite sides for right and left valve bank sections. Do not intermix the right and left
sections.
VALVE SECTION IDENTIFICATION

Although the valve sections have similar construction, they
can have different flow rates. To determine the flow rate of a
specific valve section, each has been marked with or without
grooves at the end of the valve spool.
NO GROOVE = 10 GPM
(37.9 L /min) FLOW RATE
ONE GROOVE = 5 GPM

(18.9 L/min) FLOW RATE
TWO GROOVES = 20 GPM

(75.7 L /min) FLOW RATE
THREE GROOVES = 20 GPM

(75.7 L/min) FLOW RATE WITH
ANTI-CAVITATION FEATURE
30-206 830B/C-850B/C-870B/C
12
ASSEMBLY
VALVE SECTION
1. Install the O-ring j, wiper i, and cap 1@ with bolts 1# on the valve section body 1!.
2. Install the spool 1), O-ring j, and wiper i in the valve section body 1!.
3. Assemble the O-ring h, spring seat e, flat washer f, spring g, spring seat e, and bolt d on the end of the spool 1).
4. Secure the spool assembly in the body with the cap c and bolts b.
5. Install the O-ring 1^.

Remark
The O-ring 1^ can be installed between the valve sections later, if desired.
6. Install the compensator spool 1$ and spring 1% in the body 1!.
830B/C-850B/C-870B/C 30-207
CONTROL VALVE BANK
1. Install the O-ring 2! and O-ring 2# in the inlet section 2).
2. Align the marks made on the control valve during disassembly.
3. Install the shuttle j in each valve section.
4. Install the O-rings i, 1!, 1#, 1%, 1&).
5. Install the tie rods c and e and secure with the nuts b and d and washers c.
Nuts b: 17.5 ±1.5 lbf ft (23.7 ±2.0 Nm)
Nuts d to 33 ±3 lbf ft (44.7 ±4.0 Nm)
30-208 830B/C-850B/C-870B/C
6. Install the O-ring g and shut-off plug f.
7. Install the O-rings 2) and 2! on the main relief valve cartridge 1(.
8. Install the main relief valve cartridge 1( in the outlet section 1*.
Cartridge: 25 ±2.5 lbf ft (33 q13.38 Nm)
INSTALLATION
1. Reinstall all fittings on the manifold as tagged during removal.
2. Install the spacers and swivel adapters c on each control valve spool.
Attach the two 5/16 in - 24 UNF lifting eyes b to the outside swivel
adapters. Attach a sling to the lifting eyes and raise the manifold up
into position. Secure the manifold to the mounting bracket with the
bolts and related hardware.
3. Reconnect all hoses to the manifold as tagged during removal.
4. Screw the swivel adaptor c onto the control lever rod d and tighten
the jamnut c. Repeat the procedure for the remaining control lever
rods.
Remark
Make sure that the control lever knobs align.
5. Remove the locking pliers and slide the cover assembly b down the
control lever rods c.
830B/C-850B/C-870B/C 30-209
12
6. Secure the cover assembly c to the cab deck with the flat washers and
bolts b.
7. Attach the step assembly b to the frame with the bolts d and flat
washers c.
8. Fill the hydraulic oil tank to the specified level with the approved oil.
Refer to the Operator's Manual for the oil specification.
30-210 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY MAIN SYSTEM PUMP
12
MAIN SYSTEM PUMP
Thoroughly clean the component to be serviced and the surrounding area.
This step will help prevent contamination from entering the component or
system being serviced.
REMOVAL
1. Remove the flat washers and bolt b and the flat washers and hexnuts
c that secure the rear grill d to the rear cowl e.
2. Drain the hydraulic oil tank. Remove the drain plug b and attach a
drain hose to the bottom of the hydraulic oil tank. The hydraulic oil
tank holds about 16 U.S. gallons (60.6 L).
Remark
The hydraulic oil tank shown is on an all-wheel-drive grader.
On a non AWD unit, the drain plug will be located in place of
the temperature sensor c.
3. Reinstall the drain plug after draining the hydraulic oil tank.
4. Tag and disconnect the hoses b from the bottom of the hydraulic oil
tank.
5. Remove the split flanges c and d that secure the suction hose elbow
e and pump outlet hose elbow f to the pump g.
6. Disconnect the sensor hose h from the tee. Remove the tee and fitting
from the pump g.
7. Disconnect the pump case drain hose i from the elbow. Remove the
elbow from the pump g.
8. Cap all the hoses and pump ports to prevent contamination from
entering the pump g or hydraulic oil system.
9. Remove the bolts and flat washers j that secure the pump g to the
transmission charge pump.
10. Support the pump g while removing it from the transmission charge
pump.
11. Remove the sleeve b and retaining ring from the pump drive shaft c.
12. Remove the O-ring d from the pump e.
830B/C-850B/C-870B/C 30-211
12
DISASSEMBLY
1. Using the wooden blocks, clamp the pump drive shaft in the vise with
the body up.
2. Remove the bolts b, compensator c, gasket, and the O-ring from the
pump.
3. Remove the pressure-adjustment cap b, pressure rod c, spring-pivot

cap d, pressure-compensator spring e, spring-pivot cap f and
pressure-compensator spool g from the compensator housing h.
Remark
Use extreme care not to disturb the adjustment screw and
jamnut on the adjustment cap b.
4. Remove the O-ring j from the pressure-adjustment cap b.
5. Remove the O-ring 1) from the pressure rod c.
6. Remove the plug i from the compensator housing h.
7. Remove the O-ring 1! from the plug i.
8. Remove the flow-adjustment cap b, pressure rod 1#, spring pivot cap 1$, flow-compensator spring 1%, spring-pivot cap 1^
and pressure-compensator spool 1& from the compensator housing h.
Remark
Use extreme care not to disturb the adjustment screw and jamnut on the adjustment cap b.
9. Remove the O-ring 1* from the flow-adjustment cap b.
10. Remove the O-ring 1( from the pressure rod c.
11. Remove the plug 2) from the compensator housing h.
12. Remove the O-ring 2! from the plug i.
13. Remove the short bolts b and long bolts c from the back plate
assembly d.
30-212 830B/C-850B/C-870B/C
12
14. Using a soft-face hammer, tap the back-plate assembly b and remove
it from the housing assembly c.
15. Remove the gasket b from the back plate d.
16. Slide the control piston c off the guide pin.
17. Remove the needle bearing e from the back plate, if replacement is
necessary.
18. Set the housing c on the table. Slide the piston block assembly b off
the drive shaft d.
19. Remove the pistons b and spider c from the piston block d.
830B/C-850B/C-870B/C 30-213
12
20. Remove the spider pivot b from the piston block c.
21. To remove the piston block spring, use two 1/2 in flat washers with 1-5/8 in O.D., a 5/8 in flat washer with 1-3/4 in O.D.,
a 1/2 in x 4-1/2 in long bolt and one 1/2 in hexnut.
22. Place a 1/2 in flat washer over the 1/2 in bolt. Place this assembly through the center of the piston block.
23. Place the 5/8 in flat washer over the bolt and let it rest on three pins.
24. Place the other 1/2 in flat washer on the bolt. Screw the nut onto the bolt and compress the spring inside the piston block.
25. Remove the internal retaining ring b from the piston block.
26. Expand the spring by removing the nut and flat washers.
27. Remove the spring, washer, three pins, and pin keeper from the block.
28. Remove the retaining ring b from the front of the housing c.
29. Remove the drive shaft d by tapping on the other end from inside the
housing with a soft-face hammer.
30. Remove the needle bearing (not shown) from the housing after
removing the drive shaft, if replacement is necessary.
30-214 830B/C-850B/C-870B/C
12
31. Remove the shaft seal b and washer c from the drive shaft d.
32. Remove the retaining ring b from the drive shaft c.
33. Remove the thrust bearing races b, thrust bearing c, and retaining
ring d from the drive shaft e.
Remark
Make sure that the bearing surface of the thrust bearing race
faces the thrust bearing. Wear patterns must match during
reassembly.
34. Remove the retaining ring b and cover c from each side of the
housing d.
830B/C-850B/C-870B/C 30-215
12
35. Remove the O-ring b from each side of the housing c.
36. Remove the trunnion bearing b and trunnion race c from each cam
plate journal d.
Remark
Keep the trunnion bearing and matching race together. Wear
patterns must match during reassembly.
37. Slide the cam plate b to one side of the housing c.
38. Turn the cam plate and remove it from the housing.
39. Do not remove the button pivot b and spring pin c from the cam plate
d, unless they are worn or loose.
30-216 830B/C-850B/C-870B/C
12
40. Remove the spring collar b and spring c from the housing d.
830B/C-850B/C-870B/C 30-217
12
ASSEMBLY
1. Install the spring c and spring collar b in the housing d.
2. Install the button pivot b and spring pin c on the cam plate d, if
removed.
3. Install the cam plate b into the housing c.

Remark
Make sure the pivot button b seats properly against the
spring collar b.
4. Install the trunnion bearing b with the numbered end inward and the
trunnion race c on the cam plate journals d.
Remark
The numbered end of the race should face outward and the
chamfered I.D. inward.
30-218 830B/C-850B/C-870B/C
12
5. Install the O-ring b on each side of the housing c.
6. Install the cover c and retaining ring b on each side of the housing d.
7. Install the retaining ring d, thrust bearing races b, and thrust bearing
c on the drive shaft e.
8. Install the retaining ring b on the drive shaft c.
830B/C-850B/C-870B/C 30-219
12
9. Install the washer c and shaft seal b onto the drive shaft d.
Remark
Use care not to cut the shaft seal lips on the drive shaft
splines. Wrap masking tape over the splines to help prevent
damage to the seal.
10. Install the needle bearing (not shown) in the housing c, if removed
during disassembly.
11. After inserting the drive shaft assembly d into the housing c, install
the retaining ring b.
12. Install the pin keeper, three pins, washers, and spring in the bore of the
piston block.
13. Use a 1/2 in x 4-1/2 in bolt with three flat washers to compress the
spring. Install the internal retaining ring b.
14. Remove the 1/2 in x 4-1/2 in bolt and washers.
15. Set the spider pivot b on the piston block c.
30-220 830B/C-850B/C-870B/C
12
16. Install the spider c and pistons b in the piston block d.
17. Coat the piston shoes with clean hydraulic oil.
18. After aligning the splines, slide the piston block assembly b onto the
drive shaft d into the housing c.
WARNING! The piston shoes must contact the cam

plate. Be sure all parts are in their proper
position.
19. Install the needle bearing e in the back plate d.
20. Position the gasket b on the back plate.
21. Coat the inside of the control piston c with clean hydraulic oil. Slide
the piston on the guide pin.
22. With the housing e lying on its side, align the dowel pins and position
the back plate assembly d against the housing.
Remark
Make sure the gasket remains in position.
23. Turn the assembly up on end and clamp the drive shaft in the
soft-jawed vice.
24. Secure the back plate d to the housing with the short bolts b and long
bolts c.
Bolts: 35 - 40 lbf ft (47.4 - 54.2 Nm)
830B/C-850B/C-870B/C 30-221
12
25. Install the O-ring 2! onto the plug i.
26. Install the plug 2) in the compensator housing h.
Plug: 6 - 8 lbf ft (8.1 - 10.8 Nm)
27. Install the O-ring 1( onto the pressure rod c.
28. Install the O-ring 1* on the flow-adjustment cap b.
29. Install the pressure compensator spool 1&, spring pivot cap 1^,
flow-compensator spring 1%, spring-pivot cap 1$, pressure rod 1#), and
flow-adjustment cap b in the compensator housing h.
Flow adjustment cap: 10 - 12 lbf ft (13.5 - 16.2 Nm)
Remark
30. Install the O-ring 1! on the plug i.
31. Install the plug i in the compensator housing h.
Plug: 6 - 8 lbf ft (8.1 - 10.8 Nm)
32. Install the O-ring 1) on the pressure rod c.
33. Install the O-ring j on the pressure-adjustment cap b.
34. Install the pressure-compensator spool g, spring-pivot cap f, pressure-compensator spring e, spring-pivot cap d,
pressure rod c, and pressure-adjustment cap b into the compensator housing h.
Pressure-adjustment cap:
60 - 70 lbf ft (81.3 - 94.9 Nm)
Remark
35. Install the gasket b on the housing and the and O-ring c into the bore
of the housing.
30-222 830B/C-850B/C-870B/C
12
36. Install the compensator c.
37. Screw in the bolts b.
Bolts: 12 - 14 lbf ft (16.2 - 18.9 Nm)
38. Remove the pump from the vise.
830B/C-850B/C-870B/C 30-223
12
INSTALLATION
1. Install the retaining ring (not shown) and sleeve b on the pump drive
shaft c.
2. Install a new O-ring d on the pump e.
3. Support the pump g. After aligning the sleeve b splines with the
transmission charge pump drive shaft, slide the pump into position.
Install the flat washers and bolts j to secure the pump to the charge
pump.
4. Install the pump case drain elbow in the pump g. Connect the case
drain hose i to the elbow.
5. Install the sensor port fitting and tee on the pump. Connect the sensor
hose h to the tee.
6. Attach the suction hose elbow e and pump outlet hose elbow f to the
pump with the split flanges c and d.
7. Connect the hoses b to the bottom of the hydraulic oil tank as tagged during disassembly.
8. Fill the hydraulic oil tank to the proper level.
9. Start the engine and check for hydraulic oil leaks. Correct any leaks found.
10. Secure the rear grill d to the rear cowl e with the flat washers and
hexnuts c, and a washer and a bolt b.
30-224 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY HYDRAULIC INTEGRATED CIRCUIT VALVE
12
HYDRAULIC INTEGRATED CIRCUIT VALVE
REMOVAL
1. Tag and disconnect the electrical leads from the solenoid valve b on
the HIC valve.
Remark
After removing the hoses, cap them and the ports to prevent
contamination from entering the hydraulic system.
2. Tag and disconnect the hoses c, d, e, and a split-flange connection f

on the front side of the HIC valve.
3. Tag and disconnect the hoses g and h from the left side of the HIC
valve.
4. Tag and disconnect the hoses i and j from the right side of the HIC
valve.
5. Disconnect the split flange connection 1) from the back side of the HIC valve.
6. Remove the bolts and washers 1! and then the HIC valve from the
mounting bracket 1@.
7. Note the location and positions of all connectors and fittings, and then
remove them from the HIC valve.
830B/C-850B/C-870B/C 30-225
12
DISASSEMBLY
HIC VALVE
1. From only one side of the block 2#, remove the bolts b, plate c and plug d. Repeat the procedure for the other side.
2. Remove the backup rings e and O-rings f from the plugs d.
3. Remove the springs g from the bores of the block.
4. Remove the matched subassemblies 1).
5. Remove the orifice plate h from the end of each subassembly 1).
6. Remove the O-rings j and backup rings i from the subassemblies 1).
7. Remove the spring 1#, O-rings 1@, and backup rings 1! from the subassemblies 1).
8. Remove the screws 1^, plate 1&, and plug 1* from the side of the block 2#.
30-226 830B/C-850B/C-870B/C
12
9. Remove the backup ring 1( and O-ring j from the plug 1*. Remove the honed assembly 2) from the block.
10. Remove the O-rings j, 1@, 2!, and 2@ from the honed assembly 2).
11. Remove the plugs 2$ from the block 2#.
12. Remove the O-rings 2% from the plug 2$.
13. Remove the springs 2^, backup rings 2&, balls 2*, and poppets 2( from the block 2#.
14. Remove the plug 3) from the body 2#.
15. Remove the O-ring 3! from the plug 3).
16. Remove the spring 3@ and spool assembly 3# from the block 2#.
17. Remove the sequence cartridge 3^ from the body 2#.
18. Remove the O-rings 3& from the sequence cartridge 3^.
19. Remove the plugs 1$, 1%, 3$, and 3* from the body 2#.
20. Remove the solenoid cartridge 3%.
SOLENOID CARTRIDGE DISASSEMBLY
1. Remove the nut b, ID plate c, shell d, and plate e from the valve
cartridge g.
2. Remove the coil f from the valve cartridge.
3. Remove the O-rings h and j and backup ring i from the valve
cartridge g.
830B/C-850B/C-870B/C 30-227
12
ASSEMBLY
SOLENOID CARTRIDGE REASSEMBLY
1. Install the O-ring h, backup ring i, and O-ring j onto valve cartridge
g. Do NOT install the backup ring i and O-ring j in the groove at
the valve spool tip.
2. Install the coil f onto the valve cartridge.
3. Install the plate e, shell d, ID plate c, and nut b onto the valve
cartridge g.
30-228 830B/C-850B/C-870B/C
12
HIC VALVE
1. Coat all components with clean hydraulic oil prior to installation.
2. Install the solenoid cartridge 3% in the block 2#.
3. Install the plugs 1$, 1%, 3$, and 3* into the body 2#.
4. Install the O-rings 3& onto the sequence cartridge 3^.
5. Install the sequence cartridge 3^ into the body 2#.
6. Install the spool assembly 3# and spring 3@ in the block 2#.
7. Install the O-ring 3! onto the plug 3).
8. Install the plug 3) into the body 2#.
9. Install the poppets 2(, balls 2*, backup rings 2&, and springs 2^ into the block 2#.
830B/C-850B/C-870B/C 30-229
12
10. Install the O-rings 2% onto the plug 2$.
11. Install the plugs 2$ into the block 2#.
12. Install the O-rings j, 1@, 2!, and 2@ onto the honed assembly 2).
13. Install the honed assembly 2) into the block 2#.
14. Install the backup ring 1( and O-ring j onto the plug 1*.
15. Install the plug 1* in the block 2#.
16. Secure the plate 1& to the block 2# with the screws 1^.
17. Install the O-rings 1@, backup rings 1!, and spring 1# onto the subassemblies 1).
18. Install the O-rings j and backup rings i onto the subassemblies 1).
19. Install an orifice plate h in each end of the subassemblies 1).
20. Install the matched subassemblies 1) into the block 2#.
21. Install the backup rings e and O-rings f onto the plugs d.
22. Install the springs g, plugs d, plates c, and bolts b into the block 2#.
INSTALLATION
1. Install all connectors and fittings in the HIC valve at the positions
noted during the removal procedure.
2. Attach the HIC valve to the mounting bracket 1@ with the bolts and
washers 1!.
3. Connect the split flange and tube 1) to the back side of the HIC valve.
4. Connect the hoses i and j to the right side of the HIC valve as tagged
during the removal procedure.
5. Connect the split flange connection f to the front side of the HIC
valve as tagged during the removal procedure.
6. Connect the hoses g and h to the left side of the HIC valve as tagged
during the removal procedure.
7. Connect the hoses c thru e to the front side of the HIC valve as
tagged during the removal procedure.
8. Connect the two electrical leads to the solenoid valve b on the HIC
valve as tagged during the removal procedure.
30-230 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDERS
12
HYDRAULIC CYLINDERS
This section details the removal, disassembly, reassembly, and installation of the following cylinders:
• Steering.
• Leaning Wheel.
• Moldboard Tilt.
• Moldboard Side Shift.
• Drawbar Side Shift (R.H. Blade Suspension).
• Drawbar Side Shift (R.H. & L.H. Blade Suspension).
• Drawbar Lift (R.H. Blade Suspension).
• Drawbar Lift (R.H. & L.H. Blade Suspension).
• Scarifier.
• Lock Pin (R.H. & L.H. Blade Suspension).
• Articulation.
BALL AND SOCKET SHIMMING ADJUSTMENT
1. The ball and socket joints on blade lift, circle shift and moldboard tilt
cylinders, and drawbar ball and socket joints are adjustable for wear.
2. To make adjustments of any ball and socket, remove bolts or cap

screws and hex nuts with washers. Remove shims to eliminate free
play in joints. Joints should never bind, but must work freely.
WARNING! When making any shim adjustments

relating to suspended components
(moldboard, scarifier, ripper, etc.) be sure
that it is resting solidly on the ground
before disconnecting any supporting
members.
The following is a list of recommended free play for bail and socket assemblies:
CYLINDER RECOMMENDED GAP
Ripper 0.002 - 0.020 in (0.051 - 0.508 mm)
Scarifier 0.002 - 0.020 in (0.051 - 0.508 mm)
Drawbar Lift 0.002 - 0.020 in (0.051 - 0.508 mm)
Drawbar Side Shift 0.002 - 0.020 in (0.051 - 0.508 mm)
Moldboard Tilt 0.003 - 0.037 in (0.076 - 0.940 mm)
830B/C-850B/C-870B/C 30-231
12
SPECIAL TORQUES
The following is a comprehensive listing of special torques used during overhaul of this component.
CYLINDER NAME PISTON ROD NUT TORQUE VALUE CYLINDER TEST PRESSURE
Steering 180 Ibf ft (244.0 Nm) (Wet)
Leaning Wheel 400 Ibf ft (542.3 Nm) (Wet)
Moldboard Tilt 180 Ibf ft (244.0 Nm)
Moldboard Side Shift 400 Ibf ft (542.3 Nm) (Wet)
Drawbar Side Shift 400 Ibf ft (542.3 Nm) (Wet)
3000 psi (210.9 kgf/cm2)
Drawbar Lift 400 Ibf ft (542.3 Nm) (Wet)
Scarifier 285 Ibf ft (386.4 Nm)
Lock Pin None
Articulation Cylinder 400 Ibf ft (542.3 Nm) (Wet)
Ripper 500 Ibf ft (677.9 Nm) (Wet)
CLEANING AND INSPECTION

Clean all parts to permit an effective inspection. During assembly, it is very important that no dirt or foreign material enters the
unit being assembled. Even minute particles can cause malfunction of close fitting parts, such as bearings, etc.
1. Clean all metal parts thoroughly using a suitable cleaning fluid. It is recommended that the parts be immersed in cleaning
fluid and moved up and down slowly until all oils, lubricants, and/or foreign materials are dissolved and the parts are
thoroughly clean.
WARNING! When using solvent-type cleaners, exercise care to avoid inhaling vapors, exposure to
skin, and creating fire hazards.
2. Replace all oil seals, O-rings, sealing rings, gaskets, and snap rings after disassembling the unit. Refer to the latest Parts
Book for replacement items. Be extremely careful when installing seals to avoid cutting them. Curling of any seal’s lip
will seriously impair its efficiency. Apply a thin coat of Loctite #120 to the outer diameter of the oil seal’s metal casing to
assure an oil tight fit into the retainer. Do not get Loctite on the seal’s lips or the seal will become brittle and leak.
3. When replacing lip-type seals, make sure the seal’s spring is towards the oil side.
4. If available, use magna-flux or a similar process for checking for cracks that are not visible to the unaided eye. Examine
the teeth on all gears carefully for wear, pits, chips, nicks, cracks, or scores. Replace all gears having cracks, or spots
where the case hardening has worn through. Remove small nicks with s suitable hone. Inspect the shafts and quills to
make certain they are not sprung, bent, or the splines twisted and that the shafts are true.
Remark
Spline wear is not considered detrimental except where it affects the fit of the splined parts.
5. Inspect the thrust washers for distortion, scores, burrs, and wear. Replace the thrust washer, if defective or worn.
6. Inspect the bores and bearing surfaces of cast parts and machined surfaces for scratches, wear, grooves, and dirt. Remove
any scratches and burrs with a crocus cloth. Remove foreign matter. Replace any parts that are deeply grooved or
scratched. Repair, if possible, or replace cracked housings or other cast parts that are cracked.
7. Inspect the cylinder weldments, piston rods, pistons, etc., to be certain they are thoroughly cleaned and that mating
failures. If available, use magna-flux process for checking for cracks that are not visible to the unaided eye.
30-232 830B/C-850B/C-870B/C
12
STEERING CYLINDERS
REMOVAL
1. Loosen the jamnut b on the rod end c.
2. Remove the cotter pin, slotted nut, and plain washer d from the rod
end c.
3. Remove the rod end c from the axle e and piston rod f.
Remark
Measure the amount of exposed thread on the rod end for
reassembly.
4. Disconnect the hose b and tee c from the fittings d and e. Remove
fittings from cylinder. Plug the hose, tee, and cylinder.
5. Remove the self-locking nut and bolt f, spacers g, and cylinder h

from the axle weldment i.
830B/C-850B/C-870B/C 30-233
12
DISASSEMBLY
1. Remove the plugs from the cylinder ports and drain the cylinder of oil.
2. Using a spanner wrench, remove the clamp ring 1# from the cylinder weldment c.
3. Remove the piston rod assembly 1^ with the cylinder head 1$ from the cylinder weldment c.
4. Remove the piston wear ring e, piston sealing ring g, and O-ring f from the piston h.
5. Remove the self-locking nut d, piston h, and O-ring i from the piston rod 1^.
6. Slide the cylinder head 1$ off the piston rod 1^.
7. Remove the O-ring 1!, back-up ring 1@, retainer ring j, rod seal 1) and rod wiper 1% from the cylinder head 1$.
8. Using an adaptor and arbor press, remove the ball bushing b from the cylinder weldment c.
30-234 830B/C-850B/C-870B/C
12
ASSEMBLY
1. Clean the bushing bore of the cylinder weldment c and O.D. of the ball bushing b, following manufacturers instructions.
Using an adaptor and arbor press, install the ball bushing into the cylinder weldment with the bearing fracture orientation
as shown. Install retaining ring.
2. Using a suitable adaptor and arbor press, install rod seal 1) and rod wiper 1% inside cylinder head 1$. Secure the rod seal in
place with the retainer ring j. Install the O-ring 1! and back-up ring 1@ on the outside of the cylinder head.
Remark
When installing the back-up ring, be sure that the cupped side of the ring is against the O-ring. Install the
rod wiper with the cup side facing out.
3. Slide the cylinder head 1$ onto the piston rod 1$. Install the O-ring i, piston h, and self-locking nut d on the end of the
piston rod.
Nut, hex: Lubricated, 180 lbf ft (244 Nm)
4. Install the O-ring f, piston sealing ring g, and piston wear ring e onto the piston h.
Remark
When installing the sealing ring, be sure that the cupped side of the ring is against the O-ring.
830B/C-850B/C-870B/C 30-235
12
5. Coat the outside of the piston h and cylinder head 1$ with hydraulic oil. Slide the piston rod assembly 1^ into the cylinder
weldment c. Using a spanner wrench, secure the cylinder head in place with the clamp ring 1#.
WARNING! Install the piston straight into the cylinder weldment. Avoid scratching or binding the
piston.
6. Until the hose, line, and connectors are ready to be connected, install a
plug in each cylinder port to prevent contamination of the cylinder.
INSTALLATION
1. Position the cylinder h and spacers g in the axle weldment i. Secure

in place with the bolt and self-locking nut f.
Self-locking nut: 150 lbf ft (203.3 Nm)
2. Install the fittings d and e in the cylinder h. Connect the hose b and
tee c to the fittings.
3. Screw the rod end c with the jamnut b into the piston rod f.
Remark
After tightening the jamnut, be sure the amount of exposed
threads equals that measured during disassembly.
Remark
Clean the mating taper surfaces. They should be cleaned
and free of ALL foreign material (i.e. grease, dirt, paint etc.)
4. Position the rod end c in the axle e and tighten the ball socket
assembly. Install the plain washer and slotted nut d. If necessary,
Slotted nut: 170 lbf ft (230.5 Nm)
increase the torque on the nut to install the cotter pin.
5. Recheck the length of exposed threads and tighten the jamnut b.

Remark
The turning radius and wheel alignment must be checked. Refer to the “Front Wheel Alignment & Turning
Radius Adjustment” on page 20-25 of this manual.
30-236 830B/C-850B/C-870B/C
12
LEANING WHEEL CYLINDER
REMOVAL
1. Using the lift cylinders, raise the front end of the grader. Position the
blocking under the front axle weldment on each side. Rest the front
axle weldment solidly on blocking. This step prevents the axle from
pivoting after removing the leaning wheel cylinder.
2. Disconnect hoses b and c from the fittings d and e. Remove the

fittings from the cylinder f. Plug the hoses and ports.
3. Remove the cotter pin g and pin h to release the cylinder f from the
axle weldment i.
4. Remove the self-locking nut b and plain washer c from the tie rod
stud d. Remove the cylinder e.
830B/C-850B/C-870B/C 30-237
12
DISASSEMBLY
2. Using a spanner wrench, remove the clamp ring g from the cylinder weldment c.
Remark
The clamp ring will not slip off the piston rod assembly at this time.
3. Remove the piston rod assembly f with the cylinder head h from the cylinder weldment c.
WARNING! Remove the piston straight out from the cylinder weldment. Avoid scratching or binding
the piston.
4. Remove the piston wear ring 1$, piston sealing ring 1@, and O-ring 1# from the piston e.
5. Remove the self-locking nut d and piston e from the piston rod f.
6. Slide the cylinder head h off the piston rod 1%. Remove the clamp ring g.
7. Remove the O-ring 1), back-up ring j, rod seal 1!, and rod wiper i from the cylinder head h.
8. Remove the bushings b from the piston rod f and cylinder weldment c.
30-238 830B/C-850B/C-870B/C
12
ASSEMBLY
1. Install the bushings b in the piston rod f and cylinder weldment c.
2. Using an adaptor and arbor press, install the rod seal 1! and rod wiper
i inside the cylinder head h. Install the O-ring 1) and back-up ring j
on the outside of the cylinder head.
Remark
When installing the back-up ring, be sure that the cupped
side of the ring is against the O-ring. Install the rod wiper with
the cup side facing out.
3. Position the piston rod f through the clamp ring g. Slide the cylinder
head h onto the piston rod. Install the piston e, and self-locking nut d on the end of the piston rod.
4. Install the O-ring 1#, piston sealing ring 1@, and piston wear ring 1$ on the piston e.
Remark
When installing the seal ring, be sure that the cupped side of the ring is against the O-ring.
5. Coat the outside of the piston e and cylinder head h with multi-purpose Lithium grease. Slide the piston rod assembly f
into the cylinder weldment c. Using a spanner wrench, secure the cylinder head in place with the clamp ring g.
piston.
6. Until the hose, line, and connectors are ready to be connected, install a plug in each cylinder port to prevent contamination
of the cylinder.
830B/C-850B/C-870B/C 30-239
12
INSTALLATION
1. Position the piston rod e on the tie rod stud d. Install the plain washer
c and self-locking nut b to secure the piston rod on the stud.
2. Align the cylinder f with the axle weldment i and install the pin h
and cotter pin g.
3. Install the fittings d and e in the cylinder f. Connect the hoses b and
c to the fittings.
4. Remove the blocking from under the axle weldment after installing the
leaning wheel cylinder.
30-240 830B/C-850B/C-870B/C
12
MOLDBOARD TILT CYLINDERS
REMOVAL
1. Position the moldboard b on the blocking. If possible, fully extend the tilt cylinder c.
2. Tag and disconnect the hoses d and e from the elbows f and g. Remove the elbows from the cylinder, noting the
positions. Plug the hoses and cylinder ports.
3. Remove the hexnuts, lock washers, bolts h, ball cap i, and shims j from the piston rod end.
4. Remove the bolts and lock washers 1), ball cap 1!, and shims 1@ from the cylinder base end. Remove the cylinder from the
ball studs 1#.
830B/C-850B/C-870B/C 30-241
12
DISASSEMBLY
2. Using a spanner wrench, remove the clamp ring 1& from the cylinder weldment b.
Remark
★ Remove the piston rod assembly 1* with the cylinder head 1% from the cylinder weldment b.
the piston. Use care not to scratch the piston rod with the clamp ring.
3. Remove the piston wear ring g, piston sealing ring h, and O-ring i from the piston j.
4. Remove the self-locking nut f, piston j, and O-ring 1) from the piston rod 1*.
5. Slide the cylinder head 1% off the piston rod 1*. Remove the clamp ring 1&.
6. Remove the O-ring 1#, back-up ring 1$, retainer ring 1!, rod seal 1@, and rod wiper 1^ from cylinder head 1%.
30-242 830B/C-850B/C-870B/C
12
ASSEMBLY
1. Using an adaptor and arbor press, install the rod seal 1@, retaining ring j and rod wiper 1^ inside the cylinder head 1%.
Secure the rod seal in place with the retainer ring 1!. Install the O-ring 1# and back-up ring 1$ on the outside of the cylinder
head.
Remark
2. Position the piston rod 1* through the clamp ring 1&. Slide the cylinder head 1% onto the piston rod. Install the O-ring 1),
piston j, and self-locking nut f on the end of the piston rod.
Self-locking nut: 180 lbf ft (244 Nm)
3. Install the O-ring i, piston sealing ring h, and piston wear ring g on the piston j.
Remark
4. Coat the outside of the piston j and cylinder head 1% with hydraulic oil. Slide the piston rod assembly 1* into the cylinder
weldment b. Using a spanner wrench, secure the cylinder head in place with the clamp ring 1&.
piston.
of the cylinder.
830B/C-850B/C-870B/C 30-243
12
INSTALLATION
1. Coat the ball studs 1# with grease.

2. Position the base end of the cylinder c against the ball stud. Secure the cylinder in place by installing shims 1@, ball cap
1!, lock washers and bolts 1).
Remark
See “BALL AND SOCKET SHIMMING ADJUSTMENT” on page 30-231 of this manual.
3. Position the rod end of the cylinder c against the ball stud. Secure the cylinder in place by installing shims j, ball cap i,
bolts, lock washers and hexnuts h.
4. Unplug the hoses d and e and cylinder ports. Install elbows f and g in cylinder c as noted at disassembly. Connect the
hoses to the elbows as tagged.
5. Remove the blocking from under the moldboard b.
30-244 830B/C-850B/C-870B/C
MOLDBOARD SIDE SHIFT CYLINDER

REMOVAL
1. Fully extend the moldboard side shift cylinder, if possible. Rest the
moldboard b solidly on the blocking.
Remark
If the cylinder cannot be extended, disconnect the rod end of
the cylinder. After disconnecting the hoses, manually push
the moldboard to the right. Then, rest the moldboard on the
blocking.
2. Remove the self-locking nut and bolt c from the moldboard c and rod
end d.
3. After disconnecting the rod end d of the cylinder from the moldboard
b, retract the cylinder so that just 18 in (457 mm) remains extended.
Remark
If the cylinder cannot be retracted hydraulically, then it must
be retracted manually after disconnections the hoses.
4. Disconnect the hoses b from the fitting c. Remove the fitting from
the rod end cylinder port d. Plug the hose and cylinder port.
5. Disconnect the hose b from the fitting c. Remove the fitting from the
base end cylinder port d. Plug the hose and cylinder port.
Remark
If the cylinder could not be retracted manually, push it in
before plugging the ports in steps 4 and 5.
6. Remove the self-locking nut and bolt b from the base end of the
cylinder c and moldboard d. Remove the cylinder from the circle
assembly.
830B/C-850B/C-870B/C 30-245
12
DISASSEMBLY
2. Using a spanner wrench, remove the clamp ring 1# from the cylinder
weldment b.
Remark
The clamp ring will not slip off the piston rod assembly at this
time.
3. Remove the piston rod assembly i with the cylinder head 1$ from the
cylinder weldment b.
WARNING! Remove the piston straight out from the

cylinder weldment. Avoid scratching or
binding the piston. Use care not to scratch
the piston rod with the clamp ring.
4. Remove the piston wear ring d, piston sealing ring f, and O-ring g from the piston e.
5. Remove the self-locking nut c, piston e, and O-ring h from the piston rod i.
6. Slide the cylinder head 1$ off the piston rod i. Remove the clamp ring j.
7. Remove the O-ring 1!, back-up ring 1@, retaining ring j, rod seal 1), and rod wiper 1% from the cylinder head 1$.
ASSEMBLY
1. Using an adaptor and an arbor press, install the rod seal 1), retaining ring j, and rod wiper 1% inside the cylinder head 1$.
Install the O-ring 1! and back-up ring 1@ on the outside of the cylinder head.
Remark
2. Position the piston rod i through the clamp ring 1#. Slide the cylinder head 1$ onto the piston rod. Install an O-ring h,
piston e, and self-locking nut c on the end of the piston rod.
3. Install the O-ring g, piston-sealing ring f, and piston-wear ring d on the piston e.
Remark
4. Coat the outside of the piston e and cylinder head 1$ with hydraulic oil. Slide the piston rod assembly i into the cylinder
weldment b.
5. Using a spanner wrench, secure the cylinder head in place with the clamp ring 1#.
of the cylinder.
30-246 830B/C-850B/C-870B/C
12
INSTALLATION
1. Position the base end of the cylinder c in the moldboard d as shown.

Make sure that the ports are pointing upward. Install the bolt and self-
locking nut b to secure the base end in place.
2. Install the fitting c in the cylinder port d. Connect the hose b to the
fitting.
3. Install the fitting c in the cylinder port d. Connect the hose b to the
fitting.
4. Extend the piston rod d and align it with the moldboard b. Install the
bolt and self-locking nut c to secure the piston rod to the moldboard.
830B/C-850B/C-870B/C 30-247
12
DRAWBAR SIDE SHIFT CYLINDER (R.H.
BLADE SUSPENSION ONLY)
REMOVAL
1. Rest the moldboard solidly on the blocking. Remove the two hexnuts,
lock washers, and bolts b, ball cap c, and shims d from the piston rod
e.
2. Disconnect the hoses b and c from the cylinder port fittings d.

Remove the fittings from the ports. Plug the hoses and ports.
3. Using a suitable lifting device, sling the cylinder e as shown. Remove

the hexnut, lock washer, and bolt f from the cylinder. Remove the
expansion plugs g from the top and bottom of the yoke h.
4. Using a suitable driver, remove the pin from the yoke h to release the
cylinder e.
30-248 830B/C-850B/C-870B/C
12
DISASSEMBLY
2. Using a spanner wrench, remove the clamp ring 1@ from the cylinder weldment b.
Remark
3. Remove the piston rod assembly 1$ with the cylinder head i from the cylinder weldment b.
the piston. Use care not to scratch piston rod with clamp ring.
4. Remove the self-locking nut c, piston g, cylinder head i from the piston rod 1$. Remove the clamp ring 1@.
5. Remove the rod wiper 1#, back-up ring 1!, and O-ring 1) from the cylinder head i.
6. Remove the O-ring h, piston ring f, O-ring e, and wear ring d from the piston g.
7. Remove the retaining ring 1%, rod seal j from the cylinder head i.
830B/C-850B/C-870B/C 30-249
12
ASSEMBLY
1. Using an adaptor and arbor press, install the rod wiper 1# in the cylinder head i.
2. Install the wear ring d, piston ring f, and O-rings e, h in the piston g.
3. Install the O-ring 1), back-up ring 1!, and rod seal j and retaining ring 1% in the cylinder head i.
Remark
4. Install the clamp ring 1@, cylinder head i, piston g, and self-locking nut c on the rod 1$.
5. Coat the outside of the piston g and cylinder head i with hydraulic oil. Slide the piston rod assembly 1$ into the cylinder
weldment b. Using a spanner wrench, secure the cylinder head in place with the clamp ring 1@.
piston.
of the cylinder.
30-250 830B/C-850B/C-870B/C
12
INSTALLATION
1. Position the piston rod e against the ball stud. Install the shims d, ball
cap c, bolts, lock washers, and hexnuts b.
Remark
See “BALL AND SOCKET SHIMMING ADJUSTMENT” on
page 30-231 of this manual.
2. Using a suitable lifting device, sling the cylinder e as shown. Position

the cylinder in the yoke h as shown.
3. Using a suitable driver, install the pin (not shown) to secure the
cylinder e in the yoke h.
Remark
Be sure to align the groove in the pin with the bolt hole in the
cylinder.
4. Install the bolt, lock washer, and hexnut f in the cylinder e.
5. Install the expansion plugs g on the top and bottom of the yoke h.
6. Install the fittings d in the cylinder ports.
7. Reconnect the hoses b and c to the fittings d.
830B/C-850B/C-870B/C 30-251
12
DRAWBAR SIDE SHIFT CYLINDER (R.H. & L.H. BIAS BLADE SUSPENSION)
REMOVAL
WARNING! If grader is equipped with blade accumulator option, BE SURE to DEPRESSERIZE
trapped oil before starting.
1. After positioning the moldboard on the ground, sling the drawbar side
shift cylinder b as shown.
2. Disconnect and remove the hoses c and d and connectors e and f

from the cylinder. Cap the cylinder and hoses.
3. Remove the hexnuts, lock washers, bolts g, ball cap h, and shims i
from the cylinder. Repeat this procedure for the other end of the cylin-
der.
DISASSEMBLY
Remark
30-252 830B/C-850B/C-870B/C
12
3. Remove the piston rod assembly 1$ with the cylinder head i from the cylinder weldment b.
4. Remove the self-locking nut c, piston g, and cylinder head i from the piston rod 1$. Remove the clamp ring 1@.
5. Remove the rod wiper 1#, back-up ring 1!, and O-ring 1) from the cylinder head i.
6. Remove the O-ring h, piston ring f, O-ring e, and wear ring d from the piston g.
7. Remove the retainer ring 1% and rod seal j from the cylinder head 1^.
830B/C-850B/C-870B/C 30-253
12
ASSEMBLY
1. Using an adaptor and arbor press, install the rod wiper 1# in the cylinder head i.
2. Install the wear ring d, piston ring f, O-rings e and h in the piston g.
3. Install the O-ring 1), back-up ring 1!, retainer ring 1% and rod seal j in the cylinder head i.
Remark
4. Install the clamp ring 1@, cylinder head i, piston g, and self-locking nut c onto the rod 1$.
WARNING! Self-locking nut: 400 lbf ft (542.3 Nm)
5. After coating the outside of the piston g and cylinder head i with hydraulic oil, slide the piston rod assembly 1$ into the
cylinder weldment b. Using a spanner wrench, secure the cylinder head in place with the clamp ring 1@.
piston.
of the cylinder.
30-254 830B/C-850B/C-870B/C
12
INSTALLATION
1. Using a suitable lifting device, sling the cylinder b as shown. Position

the cylinder against the ball studs.
2. Position the shims i and ball cap h against the cylinder and install the
bolts, lock washers, and hex nuts g. Repeat this procedure for the
other end of the cylinder.
Remark
3. Uncap the cylinder and hoses c and d. Reconnect the connectors e

and f and hoses to the cylinder.
830B/C-850B/C-870B/C 30-255
12
DRAWBAR LIFT CYLINDERS (R.H. BLADE
SUSPENSION ONLY)
REMOVAL
WARNING! If grader is equipped with accumulator
option, BE SURE to DEPRESSERIZE
trapped oil before starting.
1. Position the moldboard solidly on the blocking.
2. Disconnect the hose b from the fitting c. Cap the hose and fitting.
3. Disconnect the hose d from the tube e. Plug the hose.
4. Disconnect the tube from the fitting f. Cap the fitting. Remove the
hexnut, lock washer, clamp g, and tube from the stud.
5. Remove the hexnuts, lock washers, bolts b, ball cap c, and shims d
from the piston rod e and ball stud.
6. Using a suitable lifting device, sling the cylinder b as shown. Make

sure the sling is under the stud c.
Remark
Match mark yoke(s) and cap(s) for assembly.
7. Remove the bolts d and yoke cap e from each side of the yoke f.
8. Remove the cylinder from the yoke. Remove the bushings g from the
cylinder.
30-256 830B/C-850B/C-870B/C
12
DISASSEMBLY
2. Using a spanner wrench, remove the clamp ring 1@ from the cylinder weldment b
Remark
3. Remove the piston rod assembly 1% with cylinder head 1# from the cylinder weldment b.
4. Remove the piston wear ring e, piston sealing ring g, and O-ring f from the piston d.
5. Remove the self-locking nut c, piston d, and O-ring h from the piston rod 1%.
6. Slide the cylinder head 1# off the piston rod 1%. Remove the clamp ring 1@.
7. Remove the O-ring 1), back-up ring 1!, retaining ring 1^, rod seal j, and rod wiper 1$ from the cylinder head 1#.
830B/C-850B/C-870B/C 30-257
12
ASSEMBLY
1. Using an adaptor and arbor press, install the rod seal j, retaining ring 1^, and rod wiper 1$ inside the cylinder head 1#.
Install O-ring 1) and backup ring 1! on the outside of the cylinder head.
Remark
When installing the backup ring, be sure that the cupped side of the ring is against the O-ring. Install the rod
wiper with the cup side facing out.
2. Position the piston rod 1% through the clamp ring 1@. Slide the cylinder head 1# onto the piston rod. Install the O-ring h,
piston d, and self-locking nut c on the end of the piston rod.
3. Install the O-ring f, piston sealing ring g, and piston wear ring e
Remark
4. Coat the outside of the piston d and cylinder head 1# with hydraulic oil. Slide the piston rod assembly 1% into the
cylinder weldment b. Using a spanner wrench, secure the cylinder head in place with the clamp ring 1@.
piston.
of the cylinder.
30-258 830B/C-850B/C-870B/C
12
INSTALLATION
1. Thoroughly grease the inside of the bushings g and position both of

them on the cylinder b.
2. Using a suitable lifting device, sling cylinder as shown. Make sure

sling is positioned below stud c on the side of the cylinder.
3. Position the cylinder b with the bushings g in the yoke f.
4. Secure the yoke cap e with lock washers and bolts d on each side of
the yoke.
5. Coat the ball stud with grease. Position piston the rod e against the
ball stud. Position the shims d and ball cap c against the piston rod.
6. Secure the caps and shims in place with the bolts, lock washers, hex-
nuts b.
Remark
7. Remove the sling.
8. Secure the tube e to the stud with a clamp, lock washer and hexnut g.
Uncap the fitting f and connect the tube to it.
9. Unplug the hose d and connect it to the tube e.
10. Uncap the hose b and fitting c and reconnect them.
830B/C-850B/C-870B/C 30-259
12
DRAWBAR LIFT CYLINDERS (R.H. & L.H.
BIAS BLADE SUSPENSION ONLY)
REMOVAL
1. Rest the moldboard solidly on the ground.
2. Disconnect the tube b from the rod end port connector c of the
cylinder. Remove the connector from the cylinder, if replacement is
necessary.
3. Remove the hexnut, plain washer, tube, and tube clamp b from the
cylinder stud c.
4. Using a suitable lifting device, sling the cylinder b as shown.
5. Disconnect the hose and/or fitting c from the base end port connector.
Remove the connector from the port, if replacement is necessary.
6. Remove the hexnuts, lock washers, bolts b, ball cap c, and shims
from the piston rod.
30-260 830B/C-850B/C-870B/C
12
7. Remove the lock washers, bolts b, trunnion caps c, and cylinder d
from the yoke e.
Remark
Match mark yoke and cap(s) for assembly.
Remark
The caps and yoke are machined as a set and must be
returned to the same position when reassembling.
8. Remove the trunnion bearings f from the cylinder trunnion pivots.

Remark
Remove the grease fitting(s) from the bearing(s), if
replacement is necessary.
TRUNNION BUSHING REPLACEMENT
1. Using a suitable lifting device, sling the lift cylinder.
2. match mark the lift cylinder yoke caps c.

Remark
The caps and yoke are machined as a set and must be
returned to the same position when reassembling.
3. Remove the four bolts from the mounting of the two yoke caps b.
4. Pull bushing off trunnion.
5. Clean and inspect trunnion shafts. The diameter of the shaft should be
2.249/2.250 in (57.12/57.15 mm).
830B/C-850B/C-870B/C 30-261
12
6. Thoroughly grease the inside of the new trunnion bushing with NLGI
#2 multipurpose lithium grease with 3% minimum molybdenum
disulfide.
7. Remove and replace the two bushings from the lift cylinder trunnion
f.
8. Position the cylinder in the yoke e and secure in place with the two
trunnion caps d, in the same position and orientation as originally
marked, with the lockwasher and bolts b.
9. Install grease fitting.
10. Remove the sling from the cylinder and repeat for the opposite lift cylinder.
DISASSEMBLY
Remark
3. Remove the piston rod assembly 1% with the cylinder head 1# from the cylinder weldment b.
4. Remove the piston wear ring e, piston sealing ring g, and O-ring f from the piston d.
30-262 830B/C-850B/C-870B/C
5. Remove the self-locking nut c, piston d, and O-ring h from the piston rod 1%.
6. Slide the cylinder head 1# off the piston rod 1%. Remove the clamp ring 1@.
7. Remove the O-ring 1), back-up ring 1!, retaining ring 1^, rod seal j, and rod wiper 1$ from the cylinder head 1#.
ASSEMBLY
1. Using an adaptor and arbor press, install the rod seal j and rod wiper 1$, retaining ring 1^,inside the cylinder head 1#.
2. Install the O-ring 1) and backup ring 1! on the outside of the cylinder head.
Remark
When installing a backup ring, be sure that the cupped side of the ring is against the O-ring. Install the
3. Position the piston rod 1% through the clamp ring 1@. Slide the cylinder head 1# onto the piston rod.
4. Install the O-ring h, piston d, and self-locking nut c on the end of the piston rod.
5. Install the O-ring f, piston sealing ring g, and piston wear ring e
Remark
6. Coat the outside of the piston d and cylinder head 1# with hydraulic oil. Slide the piston rod assembly 1% into the cylinder
weldment b.
piston.
7. Using a spanner wrench, secure the cylinder head in place with the clamp ring 1@. (Use match cap and yoke.)
of the cylinder.
830B/C-850B/C-870B/C 30-263
INSTALLATION
1. Using a suitable lifting device, sling the cylinder d.
2. Thoroughly grease the inside of the trunnion bearings f and position

both of them on the cylinder trunnion pivots.
Remark
Insure caps are positioned on the trier where previously
marked.
3. Position the cylinder in the yoke e and secure in place with the two
trunnion caps d, lock washers, and bolts b.
4. Coat the ball stud with grease. Position the piston rod against the ball
stud. Position the shims and ball cap c against the piston rod.
5. Install the bolts, lock washers, and hexnuts b to secure the caps c and
shims in place.
Remark
6. Install a new base end port connector in the cylinder b, if removed

during removal. Connect the hose and/or fitting c to the base end
connector.
7. Remove the sling from the cylinder.
8. Install the new rod end port connector c in the cylinder, if removed.
Connect the tube b to the connector.
30-264 830B/C-850B/C-870B/C
12
9. Secure the tube to the cylinder stud c with the tube clamp, plain
washer, and hexnut b.
830B/C-850B/C-870B/C 30-265
12
SCARIFIER CYLINDERS
REMOVAL
1. Rest the scarifier on the ground or the blocking.
2. Sling the cylinder as shown in the photo at right and below.
3. Tag and disconnect the hoses b and c from the tube d and elbow e.
Remove the elbow from the base end port of the cylinder, if
4. Remove the hexnut, plain washer, tube, and tube clamp f from the
cylinder stud g.
5. Remove the hexnuts, lock washers, bolts h, ball cap i, and shims
from the base end of the cylinder.
6. Disconnect the tube b from the elbow c at the rod end of the cylinder
d. Remove the elbow from the rod end port, if replacement is
necessary.
7. Remove the hexnuts, lock washers, bolts b, ball cap c, and shims
from the piston rod.
30-266 830B/C-850B/C-870B/C
12
DISASSEMBLY
2. Using a suitable spanner wrench, remove the clamp ring c from the cylinder 1$.
Remark
3. Remove the piston assembly from the cylinder.
4. Remove the self-locking nut 1#, seal retainer j, piston 1@, O-ring 1), seal retainer j, and cylinder head b from piston rod
b. Remove the clamp ring c.
5. Remove the rod wiper d and O-ring i and back-up ring h from the cylinder head e.
6. Remove the piston seals 1! from the piston 1@.
7. Pull the piston seals apart for inspection.
8. Remove the retaining ring 1%, rod packing f from the cylinder head e.
830B/C-850B/C-870B/C 30-267
12
ASSEMBLY
1. Install the rod packing f and retaining ring 1% into the cylinder head e.
2. Assemble the piston seals 1! and seal retainer j for installation on the piston.
3. Install the piston seals 1!, seal retainer j, and O-ring 1) on the piston 1@.
Remark
Be sure that the seal lips are pointing towards the middle of the piston.
4. Install the O-ring i and back-up ring h on the cylinder head e.
Remark
When installing the back-up ring, be sure that the cupped side of the ring is against the O-ring.
5. Install the rod wiper d in the cylinder head.
Remark
Install the rod wiper with the cup side facing out.
6. Position the clamp ring c and slide the cylinder head e, seal retainer j, O-ring 1), piston 1@ and seal retainer j on the
piston rod b.
7. Install the self-locking nut 1# onto the piston rod.
8. Slide the piston rod assembly b into the cylinder 1$.
piston.
9. Using a spanner wrench, screw the clamp ring onto the cylinder.
of the cylinder.
30-268 830B/C-850B/C-870B/C
12
INSTALLATION
1. Sling the upper and lower section of the cylinder as shown.
2. After coating the ball stud with grease, position the piston rod against
the ball stud.
3. Position the shims and ball cap c against the piston rod.
4. Install the bolts, lock washers and hex nuts b to secure the caps and
shims in place.
Remark
5. Install a new elbow c onto the rod end port of the cylinder d, if
removed.
6. Connect the tube b to the elbow.
830B/C-850B/C-870B/C 30-269
12
7. Secure the tube d to the cylinder stud g with the tube clamp, washer,
and hexnut f.
8. Coat the ball stud with grease. Position the base end of the cylinder
against the ball stud. Position the shims and ball cap i against the base
end.
9. Install the bolts, lock washers, and hexnuts h to secure the caps and
shims in place.
Remark
10. Install the elbow e in the base end port of the cylinder.
11. Connect the hoses b and c to the tube and elbow as tagged during removal.
30-270 830B/C-850B/C-870B/C
12
LOCK PIN CYLINDER (R.H. & L.H. BIAS BLADE SUSPENSION ONLY)
REMOVAL
WARNING! Before disconnecting the hoses from the lock pin cylinder, be sure to the
relieve pressure in the hydraulic circuit maintained by the accumulator.
1. Position the moldboard on the ground to relieve the weight on the lock
pin cylinder b.
2. Relieve the pressure in the lock pin circuit in the following manner:
A. Turn off the engine.
B. Tag and disconnect the brake hose b from the fitting c on each
side of the final drive d.
WARNING! Because of the accumulator in the brake

system, do not depress the brake pedal
after disconnecting the brake hose.
C. Attach a 3 ft (0.91 m) length of hose to each end of the discon-

nected brake hose. Place the open end of the hoses in a 1 U.S.
gallon (3.8 L) container.
D. With the hoses in the container, depress the foot brake pedal several times. This action will release the hydraulic fluid
from each accumulator.
E. Reconnect the hose b to the fitting c on each side of the final drive d. Refer to the appropriate “Final Drive
Assembly” shop manual section for the brake bleeding procedure after completing the cylinder installation.
3. Tag and disconnect the hoses c and d from the fittings e and f. Remove the fittings from the cylinder.
4. Remove the bolts and washers g and cylinder from the link weldment h.
830B/C-850B/C-870B/C 30-271
12
DISASSEMBLY
2. Remove retaining ring j from the groove.
3. Pry the cylinder head 1) from the cylinder weldment b.
4. Remove the rod seal g from the cylinder head 1).
5. Remove the O-ring h, back-up ring i, and rod wiper 1! from the cylinder head 1).
6. After applying compressed air through the bottom cylinder port, remove the piston rod 1@.
7. Remove the wear ring c, O-ring d, and seal e from the piston weldment 1@.
30-272 830B/C-850B/C-870B/C
12
ASSEMBLY
1. Install the piston seal e, O-ring d, and wear ring c on the piston weldment 1@.
2. After applying a thin coat of hydraulic oil to the piston weldment 1@, insert it into the cylinder weldment b.
3. Install the rod wiper 1!, back-up ring i, and O-ring h onto the cylinder head 1).
Remark
4. Install the rod seal g and retaining ring f in the cylinder head 1).
5. Install the retaining ring j onto the cylinder head 1).
6. After compressing the ring j, slide the cylinder head assembly 1) into the cylinder weldment until the ring j seats in the
groove.
piston.
of the cylinder.
830B/C-850B/C-870B/C 30-273
12
INSTALLATION
1. After positioning the cylinder b against the link weldment h, install

the bolts and washers g.
2. Uncap the hoses c and d and cylinder ports.
3. Install the fittings e and f and reconnect the hoses as tagged during
removal.
4. Because the accumulators were discharged during the removal

procedure, refer to the appropriate “Final Drive Assembly” section for
the brake bleeding procedure.
WARNING! Bleed the hydraulic brake system for

proper braking.
30-274 830B/C-850B/C-870B/C
12
ARTICULATION CYLINDERS
WARNING! Make sure that the articulation lock pin is

installed before any work is done.
REMOVAL
1. Disconnect the hoses b, c, d from the fitting e and tee f.
2. Remove the fitting e and tee f from the cylinder g. Plug the hoses
and cylinder ports.
3. Remove the bolts h and retaining plate i from each end of a cylinder.
Remark
Remove the bolt, washer, and retainer plate i from the bottom of each end.
4. Use a port-a-power to press out the retaining pin, which is located between the retaining plates.
5. Remove the cylinder.
830B/C-850B/C-870B/C 30-275
12
DISASSEMBLY
2. Using a spanner wrench, remove the clamp ring 1^ from the cylinder weldment b.
Remark
3. Remove the piston rod assembly 1& with the head and bushing assembly 1# from the cylinder weldment b.
4. Remove the piston wear ring e, piston sealing ring f, and O-ring g from the piston h.
5. Remove the self-locking nut d, piston h, and O-ring i from the piston rod 1&.
6. Slide the head and bushing assembly 1# off the piston rod 1&. Remove the clamp ring 1^.
7. Remove the retaining ring j, O-ring 1), back-up ring 1!, rod seal 1@, bushing 1^, and rod wiper 1% from the head and
bushing assembly 1#.
8. Using a suitable adaptor and arbor press, remove the rod wipers 1* and bushing c.
30-276 830B/C-850B/C-870B/C
12
ASSEMBLY
1. Using an adaptor and arbor press, install the new bushing 1* and rod wipers c.
Remark
Install the rod wipers with the cup side facing out. Install the rod wipers with the cup side facing out.
2. Using a suitable adaptor and arbor press, install the rod seal 1@, bushing 1$, and rod wiper 1% inside the head and bushing
assembly 1#. Install the O-ring 1), back-up ring 1!, and retaining ring j on the outside of the assembly.
Remark
3. Position the piston rod 1& through the clamp ring 1^. Slide the head and bushing assembly 1# onto the piston rod. Install the
O-ring i, piston h, and self-locking nut d on the end of piston rod.
4. Install the O-ring g, piston sealing ring f, and piston wear ring e on the piston h.
5. Coat the outside of the piston h and cylinder head 1# with hydraulic oil. Slide the piston rod assembly 1& into the cylinder
weldment b. Using a spanner wrench, secure the head in place with the clamp ring 1^.
piston.
of the cylinder.
830B/C-850B/C-870B/C 30-277
12
INSTALLATION
1. Position the articulation cylinder g on the machine. Use a

port-a-power to press the retaining pins into place.
Remark
Be sure that the end of pin with the two tapped holes is f
acing up and that they are at 90°or parallel to the retaining
plate stop.
2. Install the retaining plate i, washers, bolts h.
3. Tighten all the bolts.
4. Remove the plugs from the cylinder ports and install the fitting e and tee f.
5. Remove the plugs from the hoses b thru d and reconnect them to the fitting e and tee f.
30-278 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY ACCUMULATORS
12
ACCUMULATORS
MAINTENANCE
Occasional replacement of the V-O-Ring seal on the piston is generally the only maintenance required. Replacement of other
seals on the end caps and gas valve is recommended.
Periodic check of the precharge pressure will detect whether the V-O-Ring wear is sufficient to begin reducing sealing perfor-
mance. The precharge pressure will rise if the oil gathers in the gas side. The precharge pressure will fall if the gas leaks into
the oil side or out past the gas end seals. After installation, check weekly and, thereafter, once a month.
CHECKING THE PRECHARGE

Using the appropriate valve in the hydraulic system, discharge all oil from
the accumulator and allow the piston to bottom against the hydraulic end
cap. See “Removal (Brake System).”
For accumulators rated at 3,000 psi (210.9 kgf/cm2) or less, use the gauge
assembly shown at the right, Parker part number 0851220000.
For accumulators rated over 3000 psi (210.9 kgf/cm2) and up to 5000 psi
(351.5 kgf/cm2), use the assembly shown at the right, Parker part number
1449610000.
830B/C-850B/C-870B/C 30-279
12
ACCUMULATORS WITH PARKER VALVE P/N
5323640000.
This valve is shown at right. Use the following procedure:
2. Back out the gas chuck “T” handle all the way (counterclockwise)
before attaching the charging assembly to the accumulator gas valve.
4. Attach the swivel nut to the gas valve and tighten the nut.
Nut: 10 to 15 lbf in (1.13 to 1.69 Nm)
5. Turn the gas chuck “T” handle all the way down. This action will depress the core in the gas valve.
6. To remove the gaging assembly, turn the “T” handle all the way out on the gas chuck, then open the bleed valve.
7. While holding the gas valve, loosen the swivel nut and remove the assembly.
8. Install the gas valve cap and tighten, then install the valve guard.
Cap: 10 to 15 lbf in (1.13 to 1.69 Nm)
ACCUMULATORS WITH PARKER VALVE P/N

6124330000
This valve is shown at right. Use the following procedure:
3. Attach the swivel nut to the gas valve and tighten.
Swivel nut: 10 to 15 lbf in (1.1 to 1.6 Nm)
4. Hold hexnut “C” with one wrench while unscrewing hexnut “D” with a second wrench. Turn hexnut “D” from 2 to 3
times. This action will open the poppet inside the gas valve. Read the
precharge.
5. With a wrench, tighten hexnut “D” to close the internal poppet.
Nut: 5 to 8 lbf ft (6.8 to 10.8 Nm)
6. Hold hexnut “C” with a wrench and remove the swivel nut assembly.
7. Install the gas cap and tighten it, then install the gas valve guard.
Cap: 10 to 15 lbf in (1.1 to 1.6 Nm)
30-280 830B/C-850B/C-870B/C
12
REMOVAL (BRAKE SYSTEM)
Prior to disconnecting the hoses and lines from the hydraulic (wet) brake system, be sure to relieve the pressure in the circuit
maintained by the accumulator.
1. Park the grader on a level surface and lower all mounted equipment.
2. Place the blocking in front of and behind each tire.
3. Relieve the pressure in the brake circuit as follows:

system, do not depress the brake pedal
after disconnecting until brake line is
placed in a container. Cap the hoses to
prevent the accidental discharge of
hydraulic fluid from the accumulator.
C. Attach a 3 ft (0.91 m) length of hose to each brake hose. Place the

open end of the hoses in a gallon (3.8 L) container.
D. With the hoses in the container, depress the brake pedal several times. This action will release the hydraulic fluid
E. Reconnect the hose b to the fitting c on each side of the final drive d.
4. Relieve the precharge pressure:
A. Accumulators with a Parker valve P/N 5323640000, attach the gauges, Parker P/N 0851220000, following the
“Precharging Checking Procedure” steps 1 thru 5. Then open the bleed valve until all the gas precharge is relieved
from the accumulator. Then remove the gauges and gas valve.
B. Accumulators with a Parker valve P/N 6124330000, remove the gas valve guard and gas valve cap. Then hold hexnut
“C” with one wrench while unscrewing hexnut “D” with a second wrench. Wait until the entire gas precharge is
relieved from the accumulator. Remove the gas valve.
5. Tag and disconnect the hoses b from the fittings c. Cap the hoses and
fittings to prevent contamination from entering the hydraulic system
and accumulators e and g.
6. After loosening the clamps f and h, slide the accumulators e and g

out.
7. Remove the fittings c and O-rings d from the end of the accumulators
e and g, if replacement is necessary.
830B/C-850B/C-870B/C 30-281
12
REMOVAL (DRAWBAR LIFT AND DRAWBAR SIDE SHIFT)
Prior to disconnecting the hoses and lines from the hydraulic (wet) brake system, be sure to relieve the pressure stored in the
circuit by the accumulator.
1. Park the grader on a level surface and lower all mounted equipment. Make sure there is not excessive unit down pressure
on the implement to be serviced. Down pressure will create as static pressurization in the hydraulic lines.
3. Turn off the engine.
4. Operate the appropriate control lever for the function being serviced.
5. Tag and disconnect the hoses b from the fittings c. Cap the hoses and
fittings to prevent contamination from entering the hydraulic system
and accumulators e and g.
6. After loosening the clamps f and h, slide the accumulators e and g

out.
7. Remove the fittings c and O-rings d from the end of the accumulators
e and g, if replacement is necessary.
30-282 830B/C-850B/C-870B/C
12
DISASSEMBLY
1. Lay the accumulator horizontal and hold it down with a strap wrench or in a vise.
2. To remove the gas cap h, install three pins into the holes at the end of the cap. Insert a long bar between two pins, using
them as fulcrum points, and apply force to the bar to unthread the cap h from the body b.
3. Remove the O-ring e from the gas cap h.
4. Remove the piston g from the body b by pushing from the hydraulic end with a bar.
WARNING! Never try to remove the piston by applying compressed air at the opposite end.
5. To remove the Teflon rings c and V-O-ring d from the piston g, lift the seal with a small, smooth screwdriver. Move the
tool around the piston several times while using the other hand to work the ring off the piston.
830B/C-850B/C-870B/C 30-283
12
REPAIR AND REPLACEMENT
Minor nicks, scratches or light scoring of the body bore can be removed by using a crocus cloth. Dress the bore until all imper-
fections have been removed. Replace the Teflon wear rings, V-O-rings, O-rings and their respective back-up washers, if the
original assembly contained them.
ASSEMBLY
1. Coat all internal parts with clean hydraulic fluid before reassembly.
2. Install new V-O-ring d and Teflon rings c on the piston g.
3. Install the piston g, with the hollow side toward the gas end, into the bore of the body b. Do not let the V-O-ring d drag
on the threads. The piston must go into the bore squarely (not cocked) and slowly.
Remark
The V-O-ring will compress as it rides up the chamfer if done slowly, but the ring may be damaged if it is
forced quickly. The piston should fit snugly. Use the hammer and wood block to tap the piston into place
until the piston head is 2 in (50.8 mm) below the opening of the honed bore. Keep force against the piston
while tapping the V-O-ring through the bore chamfer. If the force is not kept against the piston, it will bounce
back, damaging the O-ring. Cover the port opening to keep out dirt.
30-284 830B/C-850B/C-870B/C
12
4. After installing a new O-ring e onto the cap h, install the cap h into the body b.
Remark
Exercise care not to drag the O-ring over the threads. The end cap will stop against the chamfer leading
into the honed bore (extreme tightness not required; O-ring sealing is not dependent upon the cap tight-
ness). The cap should be flush with the end of the body, within 0.062 in (1.575 mm) to 0.093 in (2.362 mm)
above or below.
5. Install the gas valve i after replacing the O-ring f.
INSTALLATION (BRAKE SYSTEM)

1. Precharge the accumulator (400 psi [28.1 kgf/cm2])prior to installation on the machine.
2. Install new O-rings d and fittings c in the end of the accumulators e

and g.
3. Slide the accumulators e and g into the clamps f and h. Tighten the
clamps after making the hydraulic hose connections.
4. Uncap the fittings c and hoses b. Connect the hoses to the fittings as
5. After installing the accumulator, refer to the “Final Drive” section for
the brake system bleeding procedure.
INSTALLATION (DRAWBAR LIFT AND DRAWBAR SIDE SHIFT)

1. Precharge the accumulator prior to installation on the machine.
2. Install the new O-rings d and fittings c in the end of the accumulators
e and g.
3. Slide the accumulators e and g into the clamps f and h. Tighten the
clamps after making the hydraulic hose connections.
4. Uncap the fittings c and hoses b. Connect the hoses to the fittings as
830B/C-850B/C-870B/C 30-285
DISASSEMBLY AND ASSEMBLY LOCK/UNLOCK DIFFERENTIAL PUMP
12
LOCK/UNLOCK DIFFERENTIAL PUMP
REMOVAL
1. Tag and disconnect all hoses from the pump, control valve, and relief
valve.
2. Disconnect the electrical connection to the solenoid.
3. Remove the adjustment bolt b and hardware.
4. Loosen the pivot mounting bolt (not shown) and remove the drive belt
c from the pulley d.
5. Remove the pivot mounting bolt and hardware.
6. Remove the pump mounting bracket e from the engine support f.
7. Using a suitable puller, remove the pulley assembly b from the pump
drive shaft c. Remove the key (not shown) from the shaft
8. Remove the bolts d that hold the pulley bushing e to the pulley.
9. Remove the elbows b and tee c from the pump e.
10. Remove the bolts d and pump e from the mounting bracket f.
11. Remove the bolts g, control valve, and relief valve h from the
mounting bracket f.
Remark
Not used on no-spin differential axles.
30-286 830B/C-850B/C-870B/C
12
DISASSEMBLY
1. Make an alignment mark across the rear housing b and front housing 1!.
2. Remove the bolts c, rear housing b, and gasket 1) from the front housing 1!.
Remark
Record the gasket color removed. Use the same color gasket during assembly.
3. Remove the needle bearings e from the rear housing b, if replacement is necessary.
4. Remove the shaft assembly g from the front housing 1!. The shaft assembly is comprised of a drive gear, idler shaft, drive
pin, and retaining ring. Replace the parts as needed.
830B/C-850B/C-870B/C 30-287
12
5. Remove the drive gear f and woodruff key i from the drive shaft h.
6. Remove the retaining ring 1^ from the front housing 1!.
7. Using an arbor press, press on the rear housing end of the drive shaft. Remove the oil seal 1%, spacer 1$, and drive shaft
assembly from the front housing. Remove the retaining rings 1@ and ball bearing 1# from the drive shaft h, if replacement
is necessary.
8. Remove the needle bearings e from the front housing 1!, if replacement is necessary.
REPAIR AND REPLACEMENT

Minor nicks, scratches, or light scoring of the body bore can be removed by using a crocus cloth. Dress the bore until all
imperfections have been removed. Replace the Teflon wear rings, V-O-rings, O-rings, and their respective back-up washers, if
the original assembly contained them.
30-288 830B/C-850B/C-870B/C
12
REASSEMBLY
1. Install the needle bearings e in the front housing 1!.
2. Install the ball bearing 1# on the drive shaft h. Hold the bearing in place with the retaining rings 1@.
3. Press the bearing 1# with the shaft h into the front housing 1!.
4. Install the spacer 1$, oil seal 1%, and retaining ring 1^ in the front housing 1!.
5. Install the woodruff key i and drive gear f onto the drive shaft h.
6. Assemble the idler gear drive shaft g. The shaft assembly consists of a drive gear, idler shaft, drive pin, and retaining ring.
7. Install the needle bearings e in the rear housing b.
830B/C-850B/C-870B/C 30-289
8. Align the alignment marks, position the proper colored gasket 1) and rear housing b onto the front housing 1!. After
installing the bolts c tighten them.
Bolt: 9.5 to 12.5 lbf ft (12.8 to 16.9 Nm)
Remark
The new gasket must be the same color as the one removed during disassembly.
INSTALLATION
1. Attach the control and relief valve h to the mounting bracket f with
flat washers and bolts g. (If equipped)
2. Attach the pump e to the mounting bracket f with the flat washers
and bolts d.
3. Install the elbows b and tee c onto the pump e. Position the elbows
and tee as shown.
4. Using the bolts d, attach the pulley bushing e to the pulley b.
5. Tighten the bolts to.
6. Press the pulley assembly b with the key (not shown) onto the pump
drive shaft c.
7. Loosen the pivot mounting bolt (not shown) and remove the drive belt
c from the pulley d.
8. Attach the pump mounting bracket e to the engine support f with the
pivot mounting bolt (not shown), adjustment bolt b, and hardware.
Only finger tighten the bolts at this time.
9. Position the drive belt c onto the pulley d. Pivot the mounting bracket
to apply tension to the drive belt.
Remark
Belt deflection should be from 0.25 to 0.375 in (6.35 to 9.52 mm)
10. Tag and connect all hoses from the pump and control and relief valve (If equipped) as tagged during the removal
procedure.
11. Connect the electrical connection to the solenoid.
30-290 830B/C-850B/C-870B/C
ADJUSTING DIFFERENTIAL PUMP BELT TENSION

A belt tension gauge is available from your dealer, P/N BT-3373-BF. To
use gauge, depress ball b fully so that the hook c will engage the belt.
Release the ball and read direct tension units on dial face across from
indicating bar on belt gauge body d.
Remark
Release ball with a quick motion. DO NOT let the ball snap
back quickly when the gauge is off the belt. The will result in
damage to the gauge.
V-BELT ADJUSTMENT
Adjust V-belt tension 15 to 20 lb. using belt tension gauge. Check pulley
alignment and adjust to no more than 0.060 in misalignment per 1 in span
between pulleys.
OPTIONAL V-BELT ADJUSTMENT

Maximum deflection at A should be 0.25 in After “run-in,” maximum
deflection should be 0.25 in to 0.38 in
830B/C-850B/C-870B/C 30-291
DISASSEMBLY AND ASSEMBLY CIRCLE REVERSE SLIP CLUTCH
12
Thoroughly clean the component to be repaired and the surrounding area. This step will help prevent contamination from
entering the component or system being repaired.
REMOVAL
1. Before removing the circle slip clutch from the grader, loosen the
circle shoes and move the circle away from the pinion gear. Unless the
circle is moved, a small lip by the root of the pinion gear prevents it
from being removed.
2. Position a floor jack under the circle slip clutch assembly to prevent it
from falling.
3. Remove the bolts and lock washers b, bearing retainer c, and shims
from the circle reverse gear case cover d.
Remark
Keep the shim pack together for reassembly.
4. Remove the locknut and washer b from the pinion shaft c.
5. Slowly lower the floor jack and remove the circle slip clutch assembly
out of the circle reverse gear case.
30-292 830B/C-850B/C-870B/C
12
GENERAL EXPLOSION VIEW
830B/C-850B/C-870B/C 30-293
12
1. PINION SHAFT 9. FRICTION PLATE 17. CLUTCH HOUSING COVER

2. O-RING 10. BACKING PLATE 18. FLAT WASHER
3. V-RING 11. CLUTCH HUB 19. BOLT
4. BEARING 12. PINION SHAFT WASHER 20. OIL DRAIN/FILL PLUG
5. OIL LEVEL PLUG 13. LOCK NUT 21. O-RING
6. CLUTCH HOUSING 14. BELLEVILLE SPRING 22. PLUG
7. BACK-UP RING 15. O-RING 23. REDUCER
8. SEPARATOR PLATE 16. SHIM - 0.005 24. CHECK VALVE
SHIM - 0.007
SHIM - 0.020
SHIM - 0.060
30-294 830B/C-850B/C-870B/C
12
DISASSEMBLY
1. Remove the plug b from the clutch housing cover c.
2. Remove the O-ring (not shown) from the plug b.
3. Remove the bolts and flat washers d, clutch housing cover c, and
split shims (not shown) from the clutch housing e.
Remark
Keep each split shim pack half together.
4. Remove the O-ring b from the clutch housing cover c.
5. Remove the two Belleville springs b and backing plate c from the
slip clutch.
6. Remove the eight separator plates b and seven friction plates from the
clutch housing c.
830B/C-850B/C-870B/C 30-295
12
7. Remove the back-up ring b from the clutch housing c.
8. Remove the V-ring 1) from the clutch housing c.
9. Remove the check valve j and reducer i from the end of the pinion
shaft e, if replacement is necessary.
10. Remove the locknut h, pinion shaft washer g, and clutch hub f from
the pinion shaft e.
11. Remove the pinion shaft e from the clutch housing c.
12. Remove the O-ring d from the clutch housing c.
13. Press the self-lubricated bearing b out of the clutch housing c.
30-296 830B/C-850B/C-870B/C
12
ASSEMBLY
WARNING! Prior to build up of the circle reverse slip clutch, soak the friction plates in
hydraulic-transmission fluid for a minimum of 30 minutes. This step allows any expansion
of the plates to occur prior to the assembly, ensuring proper shimming of the slip clutch
assembly.
Remark
Friction plates must be replaced when clutch friction material is worn to less than 0.082 in thickness.
1. Press the self-lubricated bearing b from the chamfered end into the
bore of the clutch housing c until even with the chamfer at point A.
2. Install the new O-ring d into the groove of the clutch housing c. Coat
the O-ring and self-lubricated bearing with oil to help aid installation
of the pinion shaft.
3. Install the pinion shaft e into the clutch housing c.
4. Install the clutch hub f, pinion shaft washer g, and locknut h onto
the pinion shaft e. Tighten the locknut.
Locknut: 155 ±20 lbf ft (210.1 ±27.1 Nm).
5. Install the reducer i and check valve j into the end of the pinion shaft
e.
6. Install the new V-ring 1) on the clutch housing c, with the lip on the
V-ring pointing away from the housing.
7. Position the new back-up ring b in the clutch housing c.
830B/C-850B/C-870B/C 30-297
12
8. Before build up of the circle reverse slip clutch, soak the friction plates
b in hydraulic-transmission fluid at least 30 minutes. This step allows
expansion of the plates to occur before assembly, ensuring proper
shimming of the slip clutch.
9. Install a separator plate b into the clutch housing c.

Remark
Separator plates have external teeth that engage the clutch
housing. A total of eight plates are used.
10. Install a friction plate b onto the clutch hub c.

Remark
Friction plates have internal teeth that engage the clutch
hub. A total of seven plates are used.
11. Continue to alternate the installation of the separator and friction

plates. The last plate installed must be a separator plate b with
external teeth.
30-298 830B/C-850B/C-870B/C
12
12. Install the backing plate b atop the separator plate c.
Remark
Make sure that the backing plate is centered in the clutch
housing.
13. Position the “Circle Slip Clutch Gauge Tool” b atop the backing plate.
Remark
Refer to the Special Tools section of this manual for
manufacturing details of the Circle Slip Clutch Gauge Tool.
This tool must be used to obtain the proper shimming of the
clutch housing. The tool is ground to the compressed
thickness of the two Belleville springs when installed.
14. Set the clutch housing cover b on the clutch housing c. Align the
fluid drain plug d and fluid level check plug e 30° apart from each
other as shown.
Remark
Do not install the O-ring on the clutch housing cover at this
time.
15. Install the four bolts b equally spaced apart from each other. Tighten
the bolts.
Bolt: 120 lbf in (13.5 Nm)
830B/C-850B/C-870B/C 30-299
12
16. Using a feeler gauge b, measure the gap between the cover c and the
housing d beside each bolt e.
17. Average the four readings together.
18. Make a shim pack ± 0.002 in (0.051mm) of the average reading.
19. Remove the four bolts e previously installed and the clutch housing
cover c from the clutch housing d.
20. Remove the “Circle Slip Clutch Gauge Tool” b from the clutch
housing d.
WARNING! Do not leave the “Circle Slip Clutch

Gauge Tool” in the clutch pack assembly.
21. Coat the new O-ring b with clean oil and position it in the O-ring
groove of the clutch housing cover c.
22. With the “Circle Slip Clutch Gauge Tool” b removed, install the two
Belleville springs b on the backing plate c. Coat the Belleville
springs and mating surface of the backing plate with 3% molybdenum
disulfide grease. The O.D. of the Belleville springs must contact the
backing plate.
23. The shims used under the clutch housing cover are a split-shim design
b. Keep the thickest shims to the outside of the pack. Make sure that
both halves of the shim pack are the same thickness and have the same
number of half shims.
30-300 830B/C-850B/C-870B/C
12
24. Install the clutch housing cover b with the new O-ring on the clutch
housing c with the bolts and washers d. DO NOT TIGHTEN THE
BOLTS AT THIS TIME.
25. Slide the split-shim pack e into position.
26. Torque the bolts b.
Bolt: 40 - 46 lbf ft (54.2 - 62.3 Nm)
27. With a feeler gauge, check the gap at point A. If a 0.010 in (0.254 mm)
gap does not exist, add the separator plate, P/N 1208 675 H1, under the
backing plate. If a 0.010 in (0.254 mm) gap cannot be obtained, the
friction and separator plates must be replaced with new ones. Be sure
to remove the separator plate, P/N 1208 675 H1, from under the back-
ing plate.
28. Fill the circle-slip clutch assembly with hydraulic-transmission fluid.
29. Install the plug b with a new O-ring on the clutch housing cover c.
830B/C-850B/C-870B/C 30-301
12
INSTALLATION
Remark
The illustrations shown were taken during factory assembly.
A floor jack can be used to raise the assembled circle slip
clutch into position from the bottom side of the circle.
1. The lip at point A exists on the pinion gear portion of the slip clutch
housing b. Therefore, loosen, but do not remove, the circle shoe
mounting hardware of all four circle shoes c so that the circle d can
be moved away from the pinion gear e.
2. Position the clutch housing subassembly b into the circle gear case.
3. Install the washer and locknut b on the pinion shaft c. Tighten the
locknut.
Locknut: 950 - 1,050 lbf ft (1,288.0 - 1,423.6 Nm)
4. Fill the bearing retainer b with molybdenum disulfide grease. After

installing the retainer, the grease will ensure that the top bearing in the
circle reverse gear case is lubricated.
5. Secure the shims and bearing retainer c to the circle reverse gear case
d with the lock washers and bolts b.
Remark
Use the same amount of shims as removed during
disassembly. If necessary, refer to the “CIRCLE REVERSE
GEAR CASE” on page 30-305 for the shimming procedure.
6. Verify clutch setting as per procedure in testing and adjusting section.
30-302 830B/C-850B/C-870B/C
12
RETROFITTING A STANDARD CIRCLE GEAR CASE WITH A SLIP CLUTCH
FOR CIRCLE P/N 1430 851 H92
CIRCLE IDENTIFICATION
Not all circles can be retrofitted with a circle-slip clutch. The knee brace of the circle must provide clearance for the slip-clutch
housing. Some circles allow for the slip-clutch housing clearance by moving the knee braces back. An old style configuration
b and the new style circle c are shown below. Note that the knee braces d on the circle c protrude beyond the circumference
of the circle at point “A.” IF THE CIRCLE’S KNEE BRACES DOES NOT PROTRUDE, THE CIRCLE CANNOT BE
EQUIPPED WITH A SLIP CLUTCH.
RETROFITTING INSTRUCTIONS
1. Remove the bolts b, bearing retainer c, and shims (not shown) from
the circle reverse gear case cover d.
830B/C-850B/C-870B/C 30-303
12
2. Remove the locknut and washer b from the pinion shaft/gear c.
3. Using a pry bar, remove the pinion shaft/gear b and oil singular seal
(not shown) from the circle gear case.
Remark
The oil seal should remain in the bore of the gear case.
4. Proceed with the “Reassembly” and “Installation” steps outlined

earlier within this section.
30-304 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY CIRCLE REVERSE GEAR CASE
12
CIRCLE REVERSE GEAR CASE
DISASSEMBLY
This circle reverse gear case shown in this procedure has been removed from the grader for photographic purposes. To replace
the bottom seal, the gear case housing need not be removed from the grader. Should the gear case housing require removal,
remove the grader’s circle before removing the gear case because the three bolts are covered by the circle.
1. Remove the bolts b, circle reverse motor c, and motor gasket (not
shown) from the mounting plate d. Discard the gasket.
Remark
Move the motor out of the way. Wire or strap the motor to the
grader drawbar.
2. Remove the bolts e, mounting plate d, and mounting plate gasket

(not shown) from the circle reverse gear case f. Discard the gasket.
3. The circle reverse worm b is coupled to the hydraulic motor shaft with
a splined coupling c. Remove this coupling.
4. Remove the fill plug b atop the gear case c.
830B/C-850B/C-870B/C 30-305
12
5. Remove the fluid level check plug b at the side of the gear case c.
Remove drain plug d and drain oil. Dispose of oil in proper manner.
6. To aid in the reassembly of the gear case, center punch the caps, the
cover, and the gear case to mark their locations.
7. Remove the bolts and washers b from the bearing retainer c.
8. Remove the bearing retainer b and shims c. Use extreme care not to
damage the shims because they will be used during reassembly to
preload the bearings.
30-306 830B/C-850B/C-870B/C
12
9. Remove the bolts b from the circle reverse case cover c.
10. Remove the circle reverse case cover b and cover the gasket c from
the circle reverse case d. Use care not to damage cover gasket.
Bearing cup will also be removed with cover. Discard the gasket.
11. Inspect the bearing cup e. Remove and replace the cup, if necessary.
12. Remove the pinion shaft lock nut b and flat washer c from the pinion
shaft d.
Remark
On some gear cases, the pinion gear may be part of a circle
slip clutch. Refer to the “CIRCLE REVERSE SLIP CLUTCH”
on page 30-292 for servicing.
13. Using a soft face hammer, remove the pinion shaft b from the circle
reverse case c.
Remark
The oil slinger seal is removed with the shaft. Oil will drain
from the case at this time.
WARNING! If the circle reverse case is attached to

the grader, support the pinion shaft from
the underside as the shaft is driven out.
830B/C-850B/C-870B/C 30-307
12
14. Inspect the pinion shaft b. Inspect the splines, teeth, oil seal, sealing
surface, and oil slinger seal. If any portion of the pinion is damaged or
unserviceable, replace the pinion shaft.
15. Remove the oil slinger seal c from the pinion shaft b.
16. Remove the circle reverse gear b from the circle reverse case c.
17. Inspect the circle reverse gear b and bearings c and d. If the gear or
bearings are damaged, replace them. Use care in replacing the
bearings. Use a suitable puller to remove the bearings and cups.
Remark
If a cup or bearing is replaced, the companion cup or bearing
must also be replaced. The bearings must be seated tightly
against the shoulders on the gear.
18. Remove the bolts b, end cap c, and shim pack from the circle reverse
case d.
Remark
Use care not to damage the shims.
30-308 830B/C-850B/C-870B/C
12
19. With a suitable press (or puller), pressing from the motor flange end,
press the circle reverse worm b from the circle reverse case c.
20. Remove the bearing cup b from the cap end c and inspect the bearing
for damage.
21. Remove the circle reverse worm b with the bearings c and d.
22. Using a suitable puller, remove the bearings c and d from the circle
reverse worm b, if replacement is warranted.
Remark
Also make sure that the circle reverse worm is not worn and
that the circle reverse gear is in a serviceable condition.
23. If the bearings on the circle reverse worm were replaced in step 22,
replace this cup b also. Using a suitable puller, remove the bearing
cup b from the flange end of the case c.
830B/C-850B/C-870B/C 30-309
12
24. If the bearings were replaced in step 17, replace this cup b also. Using
a suitable puller, remove the lower bearing cup b from the circle
reverse case c.
Remark
Remove the pinion shaft seal d from the circle reverse case
c.
30-310 830B/C-850B/C-870B/C
12
ASSEMBLY
1. Using an arbor press and suitable adaptor, press the bearing cup b into
the circle reverse case c.
2. Apply a light coating of a non hardening sealant on the pinion shaft

seal’s d outer diameter. Install the pinion shaft seal d with the seal’s
lip facing the inside of the circle reverse case c.
the flange end of the circle reverse case c.
Remark
Bearing may be heated to 250° F (121° C) in oil to ease
assembly.
4. Using an arbor press and suitable adaptor, install the two bearing cones
b and c on the circle reverse worm d.
Remark
Make sure that bearings are properly seated.
5. Install the circle reverse worm assembly in the circle reverse case e.
Be certain that the bearing cup in the flange end of the case is fully
seated prior to installing the circle reverse worm. Install it in the case
with the splined end of the worm toward the flange of the case.
6. Install the bearing cup b in the cap end of the circle reverse worm
housing c.
830B/C-850B/C-870B/C 30-311
12
7. Adjust the circle reverse worm preload using the following procedure:
A. Worm shaft
i. Assemble the worm shaft section without shims under the

endcap b.
ii. Install the two bolts d 180° apart. Both bolts should be
without flat washers and without shims.
iii. Tighten the bolts.
Bolt: 40 - 50 lbf ft (54.2 - 67.7 Nm)
Remark
Rotate the circle reverse worm occasionally to assure proper seating of the bearings.
iv. Completely loosen the two bolts d.
v. Re-tighten the bolts d.
Remark
vi. Insert a feeler gauge between the end cap b and the circle reverse case c, next to both torqued bolts d. Average
the two readings.
vii. Add 0.018 in (0.457 mm) to the average gap reading to obtain the shim pack thickness. This step will establish a
0.000 in to 0.002 in (0.000 to 0.051 mm) preload.
________________ First gap reading

+ ________________ Second gap reading
= ________________ Total gap reading ÷ 2 = ________________ Average reading
+ 0.018 in Constant
= ________________ Shim pack thickness
viii. Remove the cap b and place the shim pack in place.
All bolts: 32 lbf ft (43.3 Nm)
Remark
Reference rolling torque to be 35 - 50 in lb.
30-312 830B/C-850B/C-870B/C
12
B. Worm gear
i. Assemble the worm shaft section without shims under the

endcap b.
ii. Install the two bolts d 180° apart. Both bolts should be
without flat washers and without shims.
iii. Tighten the bolts.
Bolt: 40 - 50 lbf ft (54.2 - 67.7 Nm)
Remark
iv. Completely loosen the two bolts d.
v. Re-tighten the bolts d.
Remark
vi. Insert a feeler gauge between the end cap b and the circle reverse case c, next to both torqued bolts d. Average
the two readings.
vii. Add 0.07 in (1.1778 mm) to the average gap reading to obtain the shim pack thickness.
viii. Remove the cap b and place the shim pack in place.
All bolts: 32 lbf ft (43.3 Nm)
830B/C-850B/C-870B/C 30-313
12
C. Remove the two bolts d and end cap b from the circle reverse
case c.
D. Place the shim pack in position.
E. Install the end cap b and six bolts with washers c. Tighten the
bolts.
8. Using an arbor press and suitable adaptor, press the bearings c and d
onto the circle reverse gear b.
Remark
Make sure that the bearings are fully seated.
Remark
Bearing may be heated to 250° F (121° C) in oil to ease
assembly.
9. Insert the circle reverse gear b in the circle reverse case c with the
longer shoulder to the bottom of the case. The bearing d is mounted
on the long shoulder.
Remark
The circle reverse gear should engage the circle reverse
worm as the circle reverse gear is inserted in the circle
reverse case.
10. Install the oil slinger seal c on the pinion shaft b, making certain it is
properly seated on the shaft. The flat side of the slinger installs
towards the oil seal.
30-314 830B/C-850B/C-870B/C
12
11. Insert the pinion shaft b into the bottom of the circle reverse case c
through circle reverse gear d. Apply a light coat of grease to the lower
seal prior to installing the pinion shaft. Be certain that during this
installation the lower seal and oil slinger are not damaged.
12. Install the flat washer c on the pinion shaft d.
13. Install the pinion shaft locknut b on the pinion shaft c. Tighten the
pinion shaft locknut.
Pinion shaft locknut:

950 to 1050 lbf ft (1288.0 to 1423.6 Nm)
the circle reverse case cover c.
15. Apply a light coat of non hardening sealant on the inside O.D. of the
circle reverse case cover c and install the new O-ring d in groove on
the cover.
16. Position the circle reverse case cover b on the circle reverse case c so
that the fill plug hole e is directly across from the worm side of the
case. Apply Loctite 262 only to the two bolts marked A and B in thru
holes nearest worm shaft. Install balance of fore bolts and washers.
Install the washers and bolts d. Using a criss-cross pattern, tighten the
bolts.
830B/C-850B/C-870B/C 30-315
12
17. Adjust the circle reverse gear preload using the following procedure:
A. Place the bearing retainer c onto the circle reverse case cover d.
Install the two bolts b 180° apart, but without the flat washers and
without the shims.
B. Tighten the bolts b.
Bolt: 40 - 50 lbf ft (54.2 - 67.7 Nm)
Remark
Rotate the circle reverse worm occasionally to assure proper
seating of the circle reverse gear bearings.
C. Completely loosen the two bolts b.
D. Tighten the bolts b.
Remark
Rotate the circle reverse worm occasionally to assure proper seating of the circle reverse gear bearings.
18. Insert a feeler gauge between the bearing retainer b and circle reverse case cover c, next to both torqued bolts b.
Average the two readings.
A. Add 0.007 in (0.178 mm) to the average gap reading to obtain the shim pack thickness. This step will establish a
0.006 in to 0.008 in (0.152 to 0.203 mm) preload.
________________ First gap reading

+ ________________ Second gap reading
= ________________ Total gap reading ÷ 2 = ________________ Average reading
+ 0.007 in Constant
= ________________ Shim pack thickness
19. Remove the two bolts b and bearing retainer c from the circle reverse case cover d.
20. Prior to installation on the circle reverse case cover, fill the bearing
retainer b with multipurpose grease. This grease will ensure that the
top bearing is sufficiently lubricated during operation.
21. Place the shim pack c on the bearing retainer b.
30-316 830B/C-850B/C-870B/C
12
22. Install the bearing retainer b and shims to the circle reverse case cover
c with six washers and bolts d.
23. Install the circle reverse worm to the motor coupling b on the worm.
24. Secure the new mounting plate gasket (not shown) and mounting plate
d to the circle reverse case f with the washers and bolts e.
25. Secure the new motor gasket (not shown) and circle reverse motor c
to the mounting plate d with the flat washers and bolts b.
Remark
Apply Loctite #518 to the threads of the bolts to prevent oil
leaks.
26. Add the specified gear oil through the fill plug hole c atop the circle
reverse case until oil comes out of the oil level check hole b on the
side of the circle reverse case.
Remark
Refer to the Operation and Maintenance Manual for the
proper oil specification.
27. The breather installs in the case where the plug c is shown. Prior to
installation, clean the breather.
830B/C-850B/C-870B/C 30-317
12
28. Install the fill plug b atop the circle reverse case c.
30-318 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY TANDEM CASE
12
TANDEM CASE
REMOVAL
Thoroughly clean the component to be serviced and the surrounding area before starting the removal procedure. This step will
help prevent contamination from entering the component or system being serviced.
1. Park the grader where both tandems and all four rear tires are within
reach of a 2 ton lifting device. Position the moldboard crossways
under grader resting solidly on ground.
2. Before shutting the engine down, release the parking brake.

At the junction block, turn the needle valve (arrow) to lock fluid in the
parking brake circuit to keep the brake released.
Remark
Do not forget to reopen the needle valve upon completion of
this work.
3. Place a 10 ton jack b under the rear of each tandem case c. Place a
support stand d under the rear of the frame e to support the unit
before removing the jacks.
Remark
With the heel of the moldboard positioned in front of the rear
tires, extend one lift cylinder at a time to raise the rear of the
frame. Place the blocking under the frame. DO NOT support
the grader with the moldboard.
4. Lockout the machine so it cannot be started. Shut down engine.

Disconnect (-) negative battery cables from batteries to prevent
accidental starting of machine.
5. Remove the axle nut b, and washer c from the axle d.

Remark
If the grader is equipped with wheel weights, remove them to
help gain access to the lock washer and axle nut.
830B/C-850B/C-870B/C 30-319
12
Using tire tongs b, sling the tire. Install the wheel knocker tool c on the
axle e. Strike the tool with the sledge hammer to separate the wheel d
from the taper of the axle.
Remark
Make sure that the wheel knocker tool seats against the end
of the axle while hitting the tool with a hammer. If the
knocker is not tight, the axle threads will absorb the impact,
possibly damaging them. Placing a small washer between
the end of the axle and knocker tool will help ensure that the
knocker seats against the axle.
The tire must have solid contact with the ground. Pivoting the tandem
case with a jack accomplishes this feat.
6. After separating the wheel from the tapered portion of the axle,
remove the wheel knocker tool, key, and tire from the axle.
7. Repeat this procedure for the remaining wheel and tire assemblies.
Mark all locations of the tires for later reassembly.
8. Place a jack and blocking b under the tandem case c. Remove the
drain plug d from side of case. Drain and discard the old oil. Reinstall
the drain plug.
Tandem case: 8.7 U.S. gallons (32.9 L)
9. Remove all four of the side access hole covers e and two top access covers f from the tandem case.
10. Reinstall the two washers b onto the axle c.
11. Install the two axle shaft nuts d and rotate the axle assembly until the
master link e is accessible through the side access hole.
Remark
Rotating the final drive input shaft moves the master link into
position.
30-320 830B/C-850B/C-870B/C
12
Two different types of chains are used in the tandem case. A nonplanetary
axle uses a double-strand chain (right) while a planetary reduction axle
uses a single-strand chain (below).
Remark
Assemble connecting link of each chain strand with cotter
pins toward sides of tandem case for planetary assembly
- OR -
toward center of tandem case for non-planetary assembly.
12. Remove the master link b from the chain c.
13. Remove the axle shaft nuts d and washers b from the axle.
830B/C-850B/C-870B/C 30-321
12
14. Position the two jacks under the tandem case so that it remains level.
15. Using a 2 ton (1, 814 kg) lifting device, sling the tandem case.
16. Remove the 24 bolts that secure the tandem to the final drive.
Remark
The seven bolts on top of the final drive cannot be removed
until the tandem case is separated from the final drive.
17. Repeat the removal steps for the tandem case on the opposite side.
30-322 830B/C-850B/C-870B/C
12
DISASSEMBLY
1. Remove the bolts g, hardened washers h, bearing retainer i, and shims j from the tandem housing 1#. Remove the oil
seal 1) from the retainer, if necessary.
2. Remove the prevailing-torque bolts 1!, hardened washers 1@, and tandem housing 1# from the tandem case weldment 3!.
Remove the outer bearing cup 1% from the tandem housing, if necessary.
3. Using the axle lifting tool, remove the axle and sprocket weldment 1& and 1* from the tandem case weldment 3!. Remove
the two bearings 1^ from the axle, if necessary.
4. Remove the inner bearing cup 1% from the tandem case weldment 3!, if necessary.
5. Repeat all disassembly steps for the remaining axles.
6. Remove the breather 2&, reducer bushing 2*, and pipe adapter 2( from each tandem case weldment 3!.
830B/C-850B/C-870B/C 30-323
12
ASSEMBLY
1. Clean all metal parts thoroughly using a suitable cleaning fluid. Its recommended that parts be immersed in cleaning fluid
and moved up and down slowly until all oils, lubricants and/or foreign materials are dissolved.
WARNING! Care should be exercised to avoid inhalation of vapors, exposure to skin and creating fire
hazards when using solvent type cleaners.
2. Inspect bores and bearing surfaces of cast parts and machines surfaces for scratches, wear, grooves and dirt. Remove
foreign matter. Replace any parts that are deeply grooved or scratched which affect their operation.
3. Freeze four of the bearing cups. Drive the inner bearing cup 1% in tandem case weldment 3! and insure that they are
completely seated.
4. Heat the bearings 1^ in hot oil (Maximum temperature 121 - 149° C [250 - 300° F]). After thoroughly heating the
bearings, install them on the axle and sprocket weldment 1& or 1*. When the bearings have cooled, use a suitable driver to
ensure that they are properly seated.
5. Using an axle lifting tool, position the axle and sprocket weldment 1& or 1* in the tandem case weldment 3!.
30-324 830B/C-850B/C-870B/C
6. Coat the mating surfaces of the tandem housing 1# and tandem case weldment 3! with Loctite 518. Secure the housing to
the case with the hardened washers 1@ and prevailing-torque bolts 1!.
Remark
Thoroughly clean the surface to be sealed with degreasing solvent. Apply primer “N” (spray
can-accelerator) liberally to one surface to shorten curing time. Apply gasket-sealant as required to the
other surface. Assemble without excessive lateral movement.
7. Install the outer bearing cup 1% in the tandem housing 1#, if removed during disassembly.
8. To obtain proper preload of bearings, wheel bearing retainer i in tandem housing 1# (Do not install oil seal).
A. Install two hardened washers h and bolts g 180° apart and torque evenly, while turning axle and sprocket in both
directions to be sure bearings are seated properly.
Bolts g: 30 lbf ft (40.6 Nm)
B. Back off bolts to 0 lbf ft, re-torque while rotating axle shaft.
Bolts g: 16.6 lbf ft (22.5 Nm)
C. Measure gap between housing and retainer at both bolts and average the two readings. Install shim pack, average plus
0.010 in
Remark
Shims come in 0.030 in (CORAL), 0.015 in (PINK), 0.005 in (BLUE), 0.003 in (GREEN), and 0.002 in (RED)
sizes. If a combination of these shims do not match the desired thickness, go to the closest, higher combi-
nation.
9. Install axle rolling torque tool on end of axle shaft. Using a dial indicator torque wrench measure the rolling torque.
Rolling torque must be: 30 - 40 lbf ft (3.4 - 4.5 Nm)
Remark
Do not use a click-type torque wrench for rolling torque.
10. If the rolling torque is not within limits, add or subtract the shims to the shim pack to obtain the proper rolling torque.
11. Remove the bolts g, hardened washers h, and retainer i from the housing 1# after determining the shim pack value.
12. Install oil seal 1) into retainer i. Position shim pack j (Determined in Step 8) and wheel bearing retainer i on tandem
housing 1#. Install six hardened washers h and bolts g.
13. Repeat the bearing setting process above for each of the three remaining wheels.
14. Coat the pipe adapter threads with Loctite 592. Install the pipe adapter 2(, reducer bushing 2*, and breather 2& in each
tandem case weldment 3!.
830B/C-850B/C-870B/C 30-325
12
INSTALLATION
1. Prepare the mating surfaces of the tandem case and final drive with Loctite 518.
Remark
Thoroughly clean surface to be sealed with degreasing solvent. Apply the primer “N” (spray can-accelera-
tor) liberally to one surface to shorten the curing time. Apply gasket-sealant as required to the other surface.
Assemble without excessive lateral movement.
2. Apply Loctite 518 to all bolt threads.
3. Install seven bolts with two hardened washers each bolt, that secure the final drive and tandem case together, into the tan-
dem mounting sleeve. With the seven bolts in a row, rotate the sleeve until they are located at the top of the sleeve under
the frame.
4. Using a 2-ton lifting device, sling the tandem case.
5. Position the tandem case against the final drive assembly, aligning the
sleeve with the case. Install two hardened washers per bolt that secure
the tandem to the final drive.
24 Bolts: 175 - 180 lbf ft (237 - 244 Nm)
WARNING! Position the jacks under the tandem case

to prevent it from rocking.
6. To install the chains, lower them over the axle sprockets and then bring
them up over the final drive sprockets.
30-326 830B/C-850B/C-870B/C
12
7. Place the two washers b on the axle c.
8. Install the two axle nuts d and rotate the axle assembly until the
master link can be installed through the side access hole.
9. Draw both ends of the chain together using the chain puller.
Remark
Rotating the final drive input shaft positions the chain so that
the master link may be installed through side access hole.
10. Install the master link b in the chain c with the cotter pin side towards
the center of the tandem case.
11. Two different types of chains are used in the tandem case. A
nonplanetary axle uses a double-strand chain (right) while a planetary
reduction axle uses a single-strand chain (below).
830B/C-850B/C-870B/C 30-327
12
12. Remove the nuts d and washers b from the axle c.
13. Install all four of the side access hole covers e and the two top access
hole covers f on the tandem case.
Remark
Seal the access covers with Loctite 518.
14. Ensure the drain plug d is securely in place and fill the tandem case c
with oil. Refer to the “Operator's Manual” for the specified lubricant.
Tandem case: 8.7 U.S. gallons (32.9 L)
Remark
Apply Loctite 592 to the drain plug and oil level plug.
15. Leave the jack and blocking b under the tandem case.
16. Using tire tongs, sling the tire. Position the wheel b on the axle c.
17. Align the keyways and install the key.
18. Install the washer d, and axle nut e on the axle.
Axle nut: 1950 lbf ft (2643.8 Nm)
19. At the junction block, turn the needle valve (arrow) to UN-lock fluid
in the parking brake circuit.
20. The unit must be roaded, then the nuts must be torqued again to ensure
proper seating of the tapers.
21. Remove the blocking from under unit once the remaining tandem and
tires are installed.
22. Road test the machine at this time.
30-328 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY AWD - GEARBOX ASSEMBLY
12
AWD - GEARBOX ASSEMBLY
TWO-PIECE SEAL INSTALLATION

Incorrect assembly of a two-piece seal can result in the toric ring to slip at just one location. This situation causes the ring to
twist, resulting in uneven pressure that causes galling, scoring, and leakage. A cocked seal results in the seal wobbling,
allowing dirt to enter.
1. Use tri-chloroethane and a clean cloth to remove any oil, dust, or debris from the toric rubber rings c, tramps e, h, and
lips d, i of the rings b and housings g.
Remark
IMPORTANT: Never permit oil to get onto the toric rings or ramps before both seal rings are put together in
their final assembled position.
WARNING! When using tri-chloroethane, avoid: prolonged contact with the skin, inhaling the vapors,
using near an open flame, welding operations, or other heated surfaces exceeding 900°
F (482.2° C).
830B/C-850B/C-870B/C 30-329
12
2. Place the toric ring c on the seal ring b, at the bottom of seal ring ramp h and against the lip i.
Remark
Make sure that the toric ring c is not twisted and that it is positioned squarely on the seal ring b. Be careful
when you work on the rubber toric ring. Nicks, cuts, and scratches can cause leaks.
3. Place the seal installation tool j, “Special Tool Number DR08-106”, onto the seal ring b with the toric ring c. Lower the
rings into a container with tri-chloroethane until all surfaces of the toric ring c are wet.
Remark
Do not use stanosol, or any other liquid that leaves an oil film or that does not evaporate quickly.
30-330 830B/C-850B/C-870B/C
12
4. With all surfaces of the toric rings c still wet, use the installation tool j to position the seal ring b and the toric ring c
squarely against the housing f. Use sudden and even pressure to pop (push) the toric ring c under the retaining lip d of
the housing f.
5. Check the assembled height (A) in at least four places 90° apart. The differences in height around the ring must not exceed
0.039 in (0.9906 mm).
830B/C-850B/C-870B/C 30-331
12
6. If small adjustments are necessary, do not push directly on the seal ring b; use the installation tool j instead.
7. The toric ring c can twist if it is not wet all around during installation, of if there are burs or fins on the retaining lip d of
the housing f.
Remark
Misalignments, twists, and bulges of the toric ring will cause seal failures. If the correct installation is not
obvious, remove the seal from housing and repeat the installation steps.
Remark
IMPORTANT: The toric rings c must never slip on the ramps of either seal rings b or seal ring housings f.
To prevent slippage, wait a minimum of two minutes to let the tri-chloroethane evaporate before further
assembly. Once correctly in place, the toric ring must roll on the ramps only.
8. Wipe the seal faces g of the seal rings b clean. Use a lintless cloth or paper towel. No particles of any kind are
permissible on the sealing surfaces. Even a small piece from a paper towel can prevent a proper seal, causing leakage.
30-332 830B/C-850B/C-870B/C
12
9. Put a thin film of clean oil on the seal faces g. Be careful not to get any oil on the rubber toric rings.
10. Make sure both housings f are in correct alignment and are
concentric. Move the parts slowly and carefully toward each other.
Remark
Do not slam the seals together. High impact can scratch or
damage the seal components. Once in place, fasten all parts
tightly.
11. Thoroughly clean the component to be serviced and the surrounding

area to prevent contamination from entering the component or system
being serviced.
830B/C-850B/C-870B/C 30-333
12
REMOVAL
1. With the parking brake set, moldboard centered crosswise under the
machine and transmission in neutral, raise the front end of the machine
using the blade lift cylinders.
2. Place suitable blocking/cribbing b underneath the axle assembly c

and lower the machine onto the blocking.
WARNING! Use extreme caution when positioning the

blocking under the axle assembly.
3. Using tire tongs and a suitable lifting device, remove all lug nuts b
and rim clamps c. Remove the tire and rim assembly d from the axle.
4. After removing the two bolts b, one of them is hidden, remove the
cover c. The front wheel speed sensor cover, sensor and hose d can
now be accessed. Remove the hose d.
5. Unplug the electrical connection from the sensor.
6. Loosen the locknut and remove the sensor assembly.
30-334 830B/C-850B/C-870B/C
12
7. Tag, remove, and plug the hoses b to the wheel motor c and hose d
from the elbow.
8. Tag, remove, and then plug the hose b.
9. Remove the cotter pins b, slotted nuts c, and washers from the tie rod
d and steering cylinder rod end e.
10. Remove the retaining ring b and cover plate c from the top and
bottom of the spindle assembly.
Remark
Remove the grease fitting from the cover plate, if necessary.
830B/C-850B/C-870B/C 30-335
12
11. Drive the roll pin b into the center of the spindle pin c until the roll
pin hits the arm d.
12. Support the gearbox assembly with a suitable lifting device and sling
d.
13. Drive the spindle pin b through the steering yoke c and gearbox
assembly e.
14. Remove the gearbox assembly from the spindle yoke and prepare it for
disassembly.
Remark
A thrust washer exists between the gearbox assembly arms
and the steering yoke at the top and bottom.
15. After removing the spindle pin out of the steering yoke and gearbox, punch the roll pin b out from the spindle pin.
16. Remove the bushing (not shown) from the steering yoke, if replacement is necessary.
Remark
While removing the bushing, notice which side of the bushing is worn. That way, when the new bushing is
installed the split can be properly located.
17. Remove the bolts b and steering arm weldment c.
30-336 830B/C-850B/C-870B/C
12
18. Remove the four bolts b and motor guard weldment c.
19. After removing the motor guard weldment, remove the four spacers d.
20. Remove the two bolts b and then the motor c. Ensure that the motor’s
O-ring and disc spring underneath are removed with the motor.
Remark
See the “AWD MOTOR (VICKERS/EATON)” on page 30-359
servicing.
830B/C-850B/C-870B/C 30-337
12
DISASSEMBLY
1. Remove the plug b with the O-ring c from the planetary carrier and
drain 1 U.S. gallon (3.78 L) of oil from the assembly. Remove the
eight bolts d and planetary housing e.
2. Remove the O-ring b from the planetary housing c.
3. To remove the planet gear b, drive the roll pin c planet pin d past the
flange. Remove the pin with O-ring e, planetary gear b, two thrust
washers f, and two special shaped thrust washers g.
Remark
Be careful care when handling any gear. Two rows of 22
needle bearings h and a spacer i exist in each gear. Do not
lose any of the needle bearings.
4. Remove the four bolts and lock washers b from the bearing cap c.
30-338 830B/C-850B/C-870B/C
12
5. Remove the four bolts b from the bearing support c.
6. Insert two screwdrivers into the slots in the cap b and pry off the cap.
Remove the shims and O-ring from inside the cap.
7. Remove the three socket head bolts b and cap c with the shims d.
8. Using the appropriate puller, remove the bearing support assembly b.

Remark
Care should be taken that the bearing is not dropped,
damaged, or lost.
830B/C-850B/C-870B/C 30-339
12
9. Remove the bearing cups b, bearings c, and O-ring d from the
bearing support e.
Remark
These are slip-fit bearings and should not require a puller.
10. Insert a drift punch through hole A in the bearing support b. Hammer
the drift punch to drive the piston c out. Remove the I.D. seal d and
O.D. seal e from the piston.
11. Remove the thrust bearing b from the housing c.
12. Remove the lock washers and bolts b and c from the gear housing.
30-340 830B/C-850B/C-870B/C
12
13. Remove the two remaining bolts b. Remove the lock washers and
reinstall the bolts 180° apart. Engage enough threads [approximately
0.375 in (9.52 mm)] to prevent thread damage. Sling the housing and
raise it about 1.500 in to 2 in (38.1 mm to 50.8 mm) above the work
surface. Strike the bolt heads alternately until the gear housing is freed.
Remove the gear housing d from the wheel retainer e.
Remark
Do not damage the threads in the gear housing.
14. Remove the gasket b.
15. Remove the motor pinion b, ball bearing c, and retaining ring d from
the gear housing e.
16. Remove the retaining ring b from the pinion c. Press the pinion from
the bearing d.
830B/C-850B/C-870B/C 30-341
12
17. Clutch pack and bull gear
A. Remove three socket head bolts b and thrust washer c.
WARNING! The thrust washer is under spring load.
B. Remove the 12 clutch springs b from the reverse clutch housing.
C. Remove the clutch sleeve b from inside the reverse clutch

housing.
D. Remove the 12 separator plates and 11 friction plates b.

Remark
There are two missing teeth in each friction plate, not
necessarily 180° apart. These must be in line throughout the
installation.
30-342 830B/C-850B/C-870B/C
12
E. Remove the bull gear assembly b from the housing.
F. Remove the six socket head bolts b that secure the bull gear c to
the clutch housing.
G. Remove the reverse clutch housing b from the bull gear c.

Remark
It may be necessary to leave the two bolts b in the housing
180° apart and tap off the reverse clutch housing.
H. Invert the assembly and remove the retaining ring. Press the sun
gear shaft b from the bull gear c.
Remark
The arrow points in the direction that the sun gear shaft must
be pressed off the bull gear.
830B/C-850B/C-870B/C 30-343
12
I. Remove the one-way clutch b from the bull gear c.
Remark
Remove the outer ball bearing d as the procedure
progresses. Do not damage the bearing.
J. Slide the bearing spacer e to one side of the gear hub. Press
against the spacer and remove the bearing f. Remove the
retaining ring g. Press the bearing d and special washer h from
the bull gear.
18. Ring gear and wheel bearing group
A. Remove the roller bearing b from the retainer housing d.

Remove the eight bolts c and retainer housing from the front
drive wheel e.
B. Remove the seal b from the retainer housing.

Remark
If the unit is equipped with a two-piece face seal, remove the
second seal from the front-drive wheel. See “TWO-PIECE
SEAL INSTALLATION” on page 30-329 for proper
installation.
C. Remove the shims b, bearing cups c, bearings d, and ring gear

e from the wheel.
30-344 830B/C-850B/C-870B/C
12
ASSEMBLY
Remark
- IMPORTANT - Before reassembling the gearbox, immerse the clutch plates in CLEAN gearbox oil. Soak
the plates for at least 30 minutes prior to installing them in the clutch pack.
Remark
Thoroughly clean the wheel, ring gear, and gearbox housing with solvent and blow dry before assembling
the gearbox. It is extremely important that no contaminants be allowed to enter this unit.
1. Install the seal b in the retainer housing.

Remark
See “TWO-PIECE SEAL INSTALLATION” on page 30-329
for installation instructions.
2. Install the two ring gear bearing cups B and c in the wheel d with the
proper driver.
Remark
The bearing cups must be fully seated in order to properly
adjust the preload on the bearings when the gear case half is
installed.
3. Install one outer bearing on the shoulder of the ring gear b. With the
ring gear setting on the table, lower the front drive wheel c into the
piston on the bearing and ring gear. Position the inner bearing d on the
ring gear. Make sure that the bearings are well lubricated with clean oil
so that they will adjust accurately.
4. A preload from 0.002 in to 0.004 in (0.0508 mm to 0.1016 mm) must

exist on the wheel bearings. A shim pack between the ring gear and the
retainer housing controls the preload. To determine the size of the shim
pack, measure the gap between the ring gear and the retainer housing
as follows.
830B/C-850B/C-870B/C 30-345
12
A. Install the retainer housing b without the seal or shims. Install the
two bolts c in the holes adjacent to the depth micrometer
measurement holes. Rotate the wheel while tightening the bolts
evenly.
B. Measure the depth from the retainer housing to the face of the ring
gear with a depth micrometer through the two holes provided in
the retainer housing. Record the average of these two
measurements as measurement A.
C. Remove the retainer housing and measure the thickness of the

housing next to the two depth measurement holes. Record the
average of these two measurements as measurement B.
D. Subtract measurement B from measurement A. Record this answer as measurement C.
E. Add 0.014 in (0.3556 mm) to measurement C, which is the shim pack size needed to achieve the desired preload on
the wheel bearings.
___________ Measurement A
- ___________ Measurement B
= ___________ Measurement C
+ 0.014 in Constant
= ___________ Shim Pack Thickness
F. Assemble the shim pack using 0.020 in, 0.007 in, and 0.005 in (0.508 mm, 0.1778 mm, and 0.127 mm) shims as nec-
essary.
30-346 830B/C-850B/C-870B/C
12
5. Install the two-piece seal on the gear case inner half.
Remark
See “TWO-PIECE SEAL INSTALLATION” on page 30-329 for installation instructions.
6. Install the retainer housing with the shim pack.
7. Apply one drop of Loctite #242 to the threads of each bolt. Install the bolts and torque while rotating the assembly.
8. Place the new gasket b on the retainer housing c over the alignment
dowel pins.
9. Clutch pack and bull gear group
A. After pressing one roller bearing b onto the shaft, install the
special washer c.
B. Install the shaft d into the bull gear.
C. After installing the retaining ring e and spacer f, press the

second bearing g on.
D. Install the one-way clutch b.

Remark
One lip exists on the outside of the clutch. The lip will be
installed away from the planetary gears for the right gear
case and toward the planetary gears for the left gear case.
A simple way to tell if the one-way clutch is installed

properly, is to turn the sun shaft in the direction it is
allowed to turn. On a right gearbox, the sun gear will turn in a
clockwise direction. On a left gearbox, the sun gear will turn
in a counterclockwise direction.
830B/C-850B/C-870B/C 30-347
12
E. Install the retaining ring b.
F. Position the reverse clutch housing b against the bull gear c.
Remark
Coat the threads of the bolts with Loctite #242 compound
before installation. Make sure the threads are clean and free
of previous compound and oil before applying new.
G. Invert the assembly and attach the reverse-clutch housing to the

bull gear b with six socket head bolts c. Tighten the bolts.
H. Install the motor pinion b in the retainer housing c.

Remark
Make sure the pinion is seated in the retainer housing.
30-348 830B/C-850B/C-870B/C
12
Install the bull gear assembly b into the planetary assembly in the
I.
wheel. Install the clutch sleeve c.
Remark
IMPORTANT: Immerse the friction plates in the gearbox oil
for 30 minutes prior to installing them in the clutch pack.
J. Install the clutch sleeve.
K. Install the separator plates d alternating with the friction plates e

into the reverse clutch housing.
Remark
Install the separator plate d first, then the friction plate e,
alternating between the two plate types. If done properly, a
separator plate is the last one installed. Each friction plate has two missing teeth, not necessarily 180°
apart. These gaps should be aligned throughout installation. Additional gearbox oil on the plates while
installing them helps prevent them from being damaged.
Remark
Coat the threads of the bolts with Loctite #242 compound before installation. Make sure the threads are
clean and free of previous compound and oil before applying new.
L. Install the 12 clutch springs b, thrust plate c, and three socket

head bolts d. Tighten the bolts.
M. Install the gear case housing b over the gasket, using the
alignment dowel pins for proper alignment.
N. Install the lock washers and four bolts c. Tighten the bolts.
830B/C-850B/C-870B/C 30-349
12
O. Press the bearing b onto the pinion c and into the gear housing d
simultaneously.
P. Install the retaining ring e.
Q. Install the disc spring b over the pinion assembly c.
R. Install the I.D. piston seal b and O.D. piston seal c on the reverse
clutch piston d.
S. After lubricating the piston seals, push the piston b into the
bearing support c until the outer seal clears the lip. Install the
O-ring seal d on the bearing support outer lip O.D.
30-350 830B/C-850B/C-870B/C
12
T. Install the two bearing cups b into the bearing support c.
U. After applying a light coat of petroleum jelly to the bottom side of

the reverse clutch piston b, install the thrust bearing c.
V. Carefully place the bearing support b on the assembly, making

sure the thrust bearing stays in place. Position the housing so that
the hydraulic port c is opposite the motor mount d.
Remark
Coat the threads of the bolts with Loctite #242 compound
before installation. Make sure the threads are clean and free
of previous compound and oil before applying new.
W. Install the cap b with the three socket head bolts c. Alternately
tighten the socket head bolts.
Socket head bolts: 35 lbf ft (47.5 Nm)
Remark
These bolts seat the bearings while torquing the bolts.
830B/C-850B/C-870B/C 30-351
12
X. Install the lock washers and four bearing retainer bolts b. Tighten
the bolts b.
Bolts b:24 lbf ft (32.5 Nm)
Y. Install the bearing cap b with the O-ring, but WITHOUT the
shims and WITHOUT the bolts.
Z. Measure the gap between the cap and the bearing support. Add
shims totalling 0.002 in (0.0508 mm) to the value. Bearing end
play should now be from 0.000 in to 0.003 in (0.000 mm to
0.0762 mm).
Remark
Shims range in sizes of 0.005 in, 0.007 in, and 0.020 in
(0.127 mm, 0.1778 mm, and 0.508 mm).
AA. After establishing the shim pack, insert the shims and cap with the
four bolts and lock washers. Tighten the bolts.
AB. Right hand (RH) wheel assembly reinstall the sensor assembly
with seal washer. Using a feeler gauge, obtain a 0.040 in to 0.050
in (1.016 mm to 1.270 mm) gap between the gear teeth and the
sensor pickup. Rotate gear to find high spot. Reconnect the sen-
sor’s electrical connection.
WARNING! DO NOT tighten the locknut more than

36 lbf in (4.06 Nm).
Remark
Refer to the “Troubleshooting and Adjustment Section” for
your unit for the proper final adjustment.
AC. Install in left hand (LH) wheel assembly reinstall bolt, nut and
seal washer.
30-352 830B/C-850B/C-870B/C
12
10. Planetary gear assembly
A. Using a liberal amount of grease to hold the needle bearings in

place, install the two rows of 22 needle bearings h and a spacer i
in each planet gear b.
B. Place the O-ring e on the planet gear pin d. Place the following
parts in the carrier in the following order: special washer g,
wave-thrust washer f, planet gear b, wave-thrust washer f, and
special washer g.
C. When positioning the parts in the carrier, note the position of the
special-shaped washer b.
D. Insert the planet gear pin from the face of the carrier.
E. With a screwdriver inserted through the slot, turn the planet gear
pin until the hole aligns with the hole in the carrier flange. Insert
the roll pin.
F. Install the O-ring b on the planet carrier c.
G. Install the carrier assembly into the gear box. Install the lock
washers and eight bolts d. Tighten the bolts.
830B/C-850B/C-870B/C 30-353
12
INSTALLATION
1. Make sure the motor disc spring is over the pinion bearing. Install the
pinion bearing and motor c and sensor guard (RH side only) with the
O-ring using two bolts b and lock washers. Tighten the bolts.
Remark
Make sure the motors are properly positioned. Install “Port
A” to the top side for the right gearbox. Install the “Port B” to
the top side for left gearbox.
30-354 830B/C-850B/C-870B/C
12
2. Install the motor guard weldment c over the spacers d using four
bolts and lock washers b. Tighten the bolt.
3. Install the steering arm weldment c for a right or left assembly. After
applying Loctite #242 to the bolt threads (use only one drop per bolt)
to the three 5/8 in -11 x 4-1/2 in grade 8 bolts, one 5/8 in-11 x 1-1/2 in
grade 8 bolt b secure the weldment in place with the bolts. Tighten the
bolts.
4. Using a suitable lifting device and sling d, position the gearbox

assembly e into place.
Remark
Place a thrust washer between the gearbox assembly arms
and steering yoke at the top and bottom.
5. Align the holes between the thrust washers, gearbox assembly and
steering yoke. Drive the spindle pin b in until the roll pin hole aligns
with roll pin hole in the gearbox assembly arm.
Remark
Once center pin is installed, remove sling d.
6. Drive the roll pin b into the spindle pin c until the roll pin is flush
with gearbox assembly arm d.
830B/C-850B/C-870B/C 30-355
12
7. Install the cover plate c and retaining ring b in top and bottom of
spindle assembly.
Remark
Install the new grease fitting in the cover, if removed at
disassembly.
8. Install the tie rod d and steering cylinder rod end e, with flat washers,
slotted nuts c, and cotter pin b. Tighten the slotted nut. If necessary,
increase the torque on the nut to install the cotter pin.
Remark
Place a flat washer under the slotted nut. Install a flat
washer, if one was not present at disassembly.
9. Remove the plugs and install the hose b to the position tagged during
removal.
10. Remove the plugs and install the hose d into the position tagged
during removal.
30-356 830B/C-850B/C-870B/C
12
11. Remove the plugs and install the hoses b and d to the wheel motor c
in the positions tagged during removal.
12. Using tire tongs and a suitable lifting device, install the tire and rim
assembly d, rim clamps c, and lug nuts b. Tighten the lug nuts.
Nuts: 115 lbf ft (155.9 Nm).
13. Inspect AWD case breather vent position is mounted vertically.
Remark
Adding a clamp to the tie plate in the head block and
clamping the AWD vent hoses will prevent the breathers
from coming in contact with water which may collect inside
the head block. This will eliminate entry of water into the
AWD gear cases.
A. Remove two bolts and washers holding front cover plate and
remove front cover plate.
B. Drill a 0.375 in to 0.437 in hole in the tie plate as indicated to the

right.
830B/C-850B/C-870B/C 30-357
12
C. On the back side of tie plate b install a clamp c around vent
hoses d with a bolt, flat washer and nut.
Insure that the breather vents e are vertical as illustrated to the
right nd cannot fall.
D. Re-install tie plate onto AWD.
14. With the parking brake set, moldboard centered crosswise under the
machine, transmission in neutral, raise the front end of the machine
using the blade lift cylinders.
15. Remove the blocking/cribbing b underneath the axle assembly c and

lower the machine to the ground. Recheck the lug nut torque.
WARNING! Use extreme care when removing the

blocking from under the axle.
Remark
Fill the gearbox with 1 U.S. gallon (3.78 L) of oil. Refer to the
Operator's manual for the specified oil.
30-358 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY AWD MOTOR (VICKERS/EATON)
12
AWD MOTOR (VICKERS/EATON)
REMOVAL
Match mark and remove hoses to whee1 motor. Remove drain hose. After removing hoses, cap and p1ug connections. Support
motor whi1e removing two bolts with 1ock washers. Remove motor. Disengage motor drive shaft by pu11ing motor straight
out. Place on work bench and prepare for disassemb1y.
DISASSEMBLY
For purposes of parts identification within the following procedures, numbers in text are cross-referenced to matching call outs
in diagram.
WARNING! Use care not to scratch or damage any machined surfaces while performing the following
procedures.
1. Match mark valve block c to housing d. Remove four bolts b from va1ve block. Remove valve block from housing and
set aside for inspection. Remove and discard gasket e.
2. Remove (1ift) tapered roller bearing f from shaft 2!. Set aside for inspection.
3. Lift and remove wafer p1ate f. P1ate may resist removal due to vacuum formed between plate and cy1inder b1ock j.
Remark
Bronze face of wafer plate faces cy1inder b1ock.
A1so, remove bearing spacer i.
830B/C-850B/C-870B/C 30-359
12
4. Ho1d hand over open end of housing d and turn entire unit upside down. Catch rotating group as an assembly and gent1y
s1ide housing up and off of rotating group assemb1y. P1ace rotating group assemb1y on clean work surface.
Remark
Rotating group consists of cylinder block, shoe plate, shoe pistons, swash plate, drive shaft, etc. - except for
item 1( - items j through 2@.
5. Lift and remove drive shaft 2! with tapered bearing 2@ still assemb1ed from rotating group. Set aside for inspection.
6. Remove swash p1ate 2) and set aside for inspection. Lift shoe plate 1! with nine piston and shoe assemblies 1) in p1ace
and set aside for inspection. Remove spherica1 washer 1@.
7. The three pins 1# and pin retainer 1$ sometimes fall out when the shaft 2! and bearing 2@ assemb1y is removed (Step 5). If
not, remove the pins and retainer now.
WARNING! Wear safety glasses while removing retaining ring in following procedure.
8. Place plain washer b under head of 1ong bolt c and insert threaded
end through center of cylinder block d. Be sure bolt extends
approximately 1-1/2 inches (38.1 mm) beyond edges of cylinder block
and has enough threads to al1ow for approximately 1 inch (25.4 mm)
of spring e expansion when retaining ring 1% (previous graphic) is
removed. Place plain washer f and nut g on threaded end of bolt and
tighten nut until spring is depressed enough to allow remova1 of
retaining ring. Slow1y loosen nut to relieve tension on spring. Remove
nut from bolt and remove washer 1^, spring 1&, and thrust washer 1*,
(1^, 1& and 1* previous graphic).
9. Remove retainer ring 2# (previous page) and arbor press shaft sea1 2$ out of housing d. Use a short piece of l-1/2 inch
(38.l mm) heavy wall tubing as a press tool.
10. Alignment pins h and j need not be removed unless damaged.
30-360 830B/C-850B/C-870B/C
12
11. If it is found that the drive shaft bearing f is defective, remove
bearing race from valve block.
in diagram.
830B/C-850B/C-870B/C 30-361
12
REMOVAL OF FRONT SHAFT BEARING
The following steps, concerning removal of the front shaft bearing, may
not be required. Inspect shaft for broken splines, burrs and wear in the area
of shaft sea1(s). Rep1ace shaft if wear exceeds 0.005 T.I.R. Inspect the
front bearing for scuffing, peeling or spalling of the rollers and/or
roughness when turned in the race. DO NOT remove the bearing from the
shaft if the bearing is functional. If the front shaft bearing or shaft is
defective, perform the fol1owing steps in the order indicated. See
“SPECIAL SHAFT BEARING REMOVAL AND INSTALLATION
TOOLS” on page 30-30 specia1 remova1 tool dimensions and refer to
graphic at right during the shaft bearing removal.
1. Pull shaft 2! and bearing from housing d.
2. Remove drive shaft bearing as follows:
A. Install a nine inch (228.6 mm) piece of 1-1/2 inch (38.1 mm)
heavy wall tubing over drive shaft 2!. The end of the tubing will
rest against the inner race of tapered roller bearing 2@ and extend out beyond the end of the shaft.
B. P1ace the shaft and bearing with tubing into an arbor press with drive spline up.
C. Press the drive shaft through the bearing. A 0.001 inch (0.0254 mm) press exists between the shaft and bearing so
considerab1e force is required to remove the bearing from the shaft. DO NOT remove the bearing race unless bearing
2@ was found to be defective. For bearing race removal, use specia1 too1 shown “HOUSING BEARING RACE
REMOVAL TOOL” on page 30-30.
3. Remove retaining ring 2# and use arbor press to press shaft seal 2$ out of the housing. Use a short piece of l-l/2 inch (38.1
mm) heavy wall tubing as a tool. A1so, use arbor press to remove bearing race, if required.
REPLACE ALL PARTS THAT DO NOT MEET THE FOLLOWING SPECIFICATIONS.
1. Check bearing spacer i for burrs. Remove smal1 burrs with an India stone.
2. Inspect cy1inder block face j for wear, scratches and/or erosion between cy1inders. Check the spring, washers and
retaining ring located within the cylinder block.
3. Check each cylinder block bore for excessive wear. Use the piston and shoe subassemblies 1) for this purpose. The piston
should be a very close fit and slide easily in and out of the bore. No bind can be tolerated. If binding is evident, lubricate
with clean hydraulic f1uid and try again. Even minor contamination of the fluid could cause the piston to freeze up in the
cy1inder bore.
4. Inspect each piston and shoe subassembly 1) for maximum end play of 0.005 inch (0.127 mm) between the piston and
shoe.
5. The face thickness dimension of each shoe must be within 0.00l inch (0.0254 mm) of each other.
6. Inspect shoe plate 1! for excessive wear and cracking in the area of spherical washer 1@. If heavy wear or cracks are found,
replace the shoe plate and spherical washer at the same time.
7. Check spherical washer 1@ for burrs, wear and possible scratches due to pin 1# breakage or contamination. Replace if wear
is excessive.
30-362 830B/C-850B/C-870B/C
8. Inspect pins 1# for equal length, excessive wear and possible bending. Rep1ace all pins simultaneously if one is
defective.
9. The pin retainer 1$ may develop burrs. Remove all burrs with an India stone.
10. Inspect the bronze face of wafer p1ate g for excessive wear, scratches and possible fractures. If the wafer plate is frac-
tured, make sure the new plate rests flat against the valve block at assembly and that wafer plate pin h does not extend too
far and hold the wafer plate away from the valve block.
11. Inspect swash plate 2) for scratches, wear and possible cracks. Replace if defective.
12. Inspect housing d for cracks, cross threads and wear. Check retaining ring groove for wear and the proper depth. Check
gasket mounting face for deep scratches or damage that could cause leakage past the gasket. Clean up burrs and small
scratches with an India stone.
13. Inspect the valve block c for burrs, nicks, p1ugged body passages, flatness of the pump wafer plate area and erosion.
Repair or replace the valve block if defective.
14. Check f1atness of the valve block face in the areas around 1ocating pins 1( and bolt openings. Use an Arkansas stone to
remove burrs or raised meta1 in these areas.
ASSEMBLY
in diagram.
830B/C-850B/C-870B/C 30-363
12
A sectional view of the drive motor is presented below for general reference while performing reassembly procedures.
Remark
Dip or coat all parts with the same hydraulic fluid used in the drive system before and during assembly of
the motor.
1. If the bearing race was removed from block c, install a new bearing
race as shown at right. Use tool “SPECIAL BEARING RACE
INSTALLATION TOOL” on page 30-31.
2. If new shaft bearings f or 2@, shaft 2!, valve block c or housing d are
being replaced, a complete shaft bearing preload adjustment must be
performed. If the same parts are returned to service, the preload
adjustment can be omitted.
3. If the shaft bearing 2@ requires replacement, instal1 a new bearing race

into housing d. Use too1 “SPECIAL BEARING RACE INSTALLA-
TION TOOL” on page 30-31 to press bearing race in place. Make sure
the bearing race is oriented properly to accept the ro11er bearing
before pressing into the housing. The race must be bottomed against
the shoulder of the housing at comp1etion of press.
30-364 830B/C-850B/C-870B/C
12
4. Install shaft (21) into front shaft bearing (22) as follows:
Use a short piece of l-l/2 inch (38.1 mm) heavy wall tubing
(approximately 6 inches [l52.4 mm] long), over the drive spline of the
shaft (tubing ends must be square within 0.005 inch [0.127 mm]). The
tubing must be long enough to make contact with the inner race of the
front bearing. Press the shaft through the bearing with an arbor press
until the bearing bottoms against the shoulder of the shaft.
5. Remove the short piece of tubing and turn shaft bearing 2@ in its race
with the end of the shaft. The bearing rollers must turn free and
smooth.
6. If the shaft bearings, shaft, valve b1ock or housing were not replaced,
use the bearing spacer removed during the disassembly procedure to
preload the shaft bearings and perform Step 13. If preload adjustment
is necessary, perform Steps 7 through 13.
7. Obtain a shaft bearing spacer kit and install the thickest bearing spacer
i over shaft 2! with the chamfer facing into the housing (toward the
shoulder on the shaft).
8. Slide bearing f on the shaft and up against spacer i. The small diameter of the tapered roller bearing must face out of the
housing.
9. Install valve block c to housing d without gasket e and rotating group. Turn shaft 2! to seat the bearings then torque the
valve block attaching screws b to 5 lbf in (0.56 Nm). Retorque screws whi1e turning shaft. The bearings are seated when
shaft does not free up while turning. Check the opening between the valve block and housing to be as even as possible.
10. Use a feeler gauge to measure the opening between va1ve block c and housing d. Four measurements should be obtained
equidistant around the unit. A tapered fee1er gauge is especially useful for this purpose. Average the four readings by
adding them together and dividing by four (4). Calculate thickness of the shaft bearing spacer as follows:
+0.150 in (3.81 mm) Measured thickness of bearing spacer

-0.027 in (0.686 mm) Average gap
-0.903 ±0.001 in (0.0762 ±0.0254 mm) Preload setting
+0.020 in (0.508 mm) Compressed thickness of gasket
0.146 ±0.001 in (3.71 ±0.0254 mm) Required bearing spacer thickness to provide 0.003 ±0.001
inch (0.0762 ±0.0254 mm) preload
11. Remove four mounting screws b and remove valve block c from housing d. Garter spring will face into the motor.
12. Remove bearing f and bearing spacer i.
13. Locate a bearing spacer with ca1culated dimensions and place with shaft bearing f. Use the original spacer if preload is
not performed. Set aside for final assembly.
14. Assemble spring 1&, two washers 1^ & 1* and retaining ring 1% into the cylinder block j. See reverse disassembly
procedures. Set the cylinder block subassembly on a flat surface. Use Kraft paper between the block and surface to
prevent scratching the cylinder block face.
15. Install pin retainer 1$ into the cy1inder block j. Position the pin retainer approximate1y 1/4 inch (6.35 mm) be1ow the
surface, and orient the open end of the pin retainer to be away from the 1arge spline openings.
830B/C-850B/C-870B/C 30-365
16. Slide three pins 1# into cylinder block subassembly until they bottom against pin washer 1*.
17. Place spherica1 washer 1@ on top of the three pins. Install the shoe p1ate 1! with nine piston and shoe subassemblies 1)
over the spherical washer and into the cylinder block subassemb1y. Wobble the shoe p1ate to make sure that each piston is
free within its bore in the cylinder block. (F1ood all parts with clean hydraulic fluid.)
18. Install swash plate 2) over shaft 2! into housing 2!. Set housing d on its side and ho1d the shaft end so drive shaft 2! is
horizontal. Slide the rotating group into the housing. Rotate drive shaft 2!, if necessary, to match the shaft sp1ines to
cylinder block j and spherical washer 1@.
19. Install bearing spacer i with chamfer toward the shoulder of drive shaft 2!.
20. Install tapered roller bearing f over the shaft and against the spacer. The small diameter of the tapered roller bearing must
face toward valve block c.
21. Install two c housing pins 1( and place a new gasket 1(, over them.
22. Assemble wafer plate locating pin 1& into valve block c.
23. Assemble wafer plate g over the bearing race and locating pin h with wear surface away from valve block c. Make sure
wafer plate is flat against valve block c. Check height of pin to be sure that it does not hold the wafer plate away from the
valve block.
24. Assemble valve block to housing with four attaching screws b.
Cross torque the screws: 42 - 45 lbf ft (57 - 61 Nm).
Be careful not to cut rear shaft seal 2% on through shaft models. (Tape shaft apline with plastic tape.)
25. Tape the spline end of drive shaft 2! with plastic tape to prevent cutting new shaft seal 2$. Start taping the shaft close to the
housing and work toward the end of the shaft. Install a new shaft seal 2$, garter spring inward, in position over the shaft
and press evenly into the housing. Use shaft seal driver shown “SHAFT SEAL DRIVER” on page 30-31. The seal must
be positioned just below (approximately 0.020 inch [0.508 mm]) the retaining ring groove. Install retaining ring 2# into the
housing. Use internal Truarc pliers to install retaining ring.
Remark
Shaft seal will contact the tapered roller bearing and be damaged if pressed too deep into the housing bore.
INSTALLATION
Align mounting holes, insert and engage wheel motor drive shaft and install motor with 0-ring using two lock washers and
bolts (5).
Bolts: 58 lbf ft (79 Nm)
Remark
Make sure that motors are properly oriented. Install Port A to the top side for R.H. gearbox. Install Port B to
the top side for L.H. gearbox.
Check identification tags/markings made during removal. Remove all caps/plugs and quickly reconnect the three hoses.
30-366 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
12
FRONT AXLE ASSEMBLY
This step will help prevent contamination from entering the component or
REMOVAL
1. Remove the grease zerk b from the bottom of the drawbar ball joint
socket c.
2. Remove both ends of the tie rod assembly b by removing the cotter
pin c, slotted nut d, and flat washer. Move the tie rod assembly out of
the work area.
Remark
On some axle assemblies, a flat washer may not exist under
the slotted nut.
3. With the parking brake set, use the moldboard to raise the front tires
clear of the ground.
4. Have another person position suitable blocking b under the drawbar

ball joint cand relieve the tension on the hydraulic lift cylinders.
WARNING! Use extreme care when placing blocking

under the frame.
5. Remove the six lug nuts b, rim clamps c, and front tires on each side
of the axle assembly.
830B/C-850B/C-870B/C 30-367
12
6. After tagging the hoses b to the steering cylinders c, remove and cap
the fittings and hoses.
7. After tagging the hoses b to the leaning wheel cylinder c, remove and
cap the fittings and hoses.
WARNING! The front axle wheels may lean to one

side after disconnecting the hoses from
the cylinder.
8. All-Wheel-Drive Axle only:

Refer to the “AWD - GEARBOX ASSEMBLY” on page 30-329. This manual will show additional hoses and sensors that
must be tagged and disconnected prior to removal of the axle assembly from the unit.
9. Using a suitable lifting device, sling the axle assembly b.
10. Match mark the pivot cap with the frame and bracket.
Remove the eight bolts with flat washers b and two pivot caps c.
Remark
When removing the rear pivot cap, remove the locating pin
(not shown).
11. Lower the axle assembly and remove it from the machine. Place the
axle on a work bench and/or table and prepare it for disassembly.
30-368 830B/C-850B/C-870B/C
12
DISASSEMBLY
1. NON ALL-WHEEL-DRIVE AXLE ONLY: Remove four bolts and
lock washers b and hubcap c.
2. NON ALL-WHEEL-DRIVE AXLE ONLY: Remove the lock wire

b, two drilled head bolts c, retainer plate d with shims, bearing e,
and wheel.
3. NON ALL-WHEEL-DRIVE AXLE ONLY: Using a suitable puller,

remove the tapered bearing cone b.
4. Remove the seal c behind the bearing.

Remark
On later model graders the seal c is installed on a collar.
Remove the seal and collar.
5. ALL-WHEEL-DRIVE AXLE ONLY: Refer to “AWD - GEARBOX ASSEMBLY” on page 30-329 for removal and
disassembly of the All-Wheel-Drive gearbox.
6. Remove the self-locking nut b, flat washer c, and mounting leaning

wheel cylinder d from the steering yoke e.
7. Supported by the sling and overhead hoist, remove the self-locking nut
f, flat washer g, and rod assembly h. Support the opposite side of the
spindle assembly when removing the rod.
8. Press the bushing i out of each end of the rod h, if replacement is

necessary.
830B/C-850B/C-870B/C 30-369
12
9. Remove the cotter pin b, pin c and leaning wheel cylinder d.
Remove the base end from the mounts, then the rod end.
Remark
Refer to the appropriate Shop Manual section for servicing
the leaning wheel cylinder.
10. Remove the cotter pin b, slotted nut c, flat washer and steering
cylinder socket assembly d from the spindle weldment.
Remark
On some axle assemblies, there may not be a flat washer
under the slotted nut.
11. Remove the grease zerk b, retaining ring c, and cover plate d from
the top and bottom of the steering yoke.
12. Unless replacing the two thrust washers e, it is not necessary to

disassemble this area further.
Remark
A roll pin b is installed through the top spindle pin hole,
which can be tapped, with a drift punch into the pin c of the
spindle weldment. This pin is 0.375 in (9.525 mm) diameter.
13. Drive the pin c out of the steering yoke and spindle weldment d.
After removing the pin c, drive the roll pin b out.
Remark
Do not damage the tapped hole for the grease fitting in the
pin c. Support the spindle in order to prevent injury after the
pin falls from the spindle assembly.
30-370 830B/C-850B/C-870B/C
12
14. Remove the spindle weldment and two thrust washers e top and bottom.
15. Remove the bushings (not shown) from the steering yoke, if replacement is necessary.
Remark
After removing the bushing, notice which side of the bushing is worn. That way, when installing the new
bushing the split can be located properly.
16. Remove the four bolts and lock washers b, cover c, and gasket.
17. Support the yoke i with the overhead hoist and strap.
18. Remove the self-locking nut b and flat washer c. After driving the
pivot pin g from the yoke, remove the two thrust bearing assembly.
Remark
The insert shows how stack-up is to be removed from
the rear axle weldment arm.
19. Press the leaning wheel pin h out of the yoke i, if replacement is
necessary.
Remark
The leaning wheel pin is tapered. Be sure to press on the
small end.
830B/C-850B/C-870B/C 30-371
12
Remark
An O-ring is located on the pivot pin, inside the front arm bushing.
20. Remove the two bushings b, one from each arm, and one spacer c from the rear axle weldment arm.
Remark
The spacer c sets inside the bore of the bushing.
Remark
After removing the bushing, notice which side of the bushing is worn. That way, when installing the new
bushing the split can be located properly.
21. Tag and remove the hoses b from the steering cylinders
c. Remove the locknut d, stud e, and two spacers f
from the base end of each steering cylinder. Remove the
steering cylinders.
22. Remove the two retaining rings g, grease zerks h, and

cover plates i.
23. After driving the pivot pin j from the weldment 1),
remove the two thrust washers 1!.
Remark
Do not damage the grease fitting threads in the
pivot pin.
24. Remove the two bushings from the axle weldment, if

Remark
When removing the bushing, notice which side
of the bushing is worn. That way, when installing the new bushing the split can be located properly.
30-372 830B/C-850B/C-870B/C
12
ASSEMBLY
1. Lubricate and install the two new bushings in the axle
weldment.
Remark
Install the bushings with the split 45° to the hor-
izontal and vertical center lines. Locate the split
on a non load carrying side of the bushing.
2. Start the pivot pin j through the axle weldment 1) and

position the two new thrust washers 1! over the pin. The
lips of these two seals must face each other toward the
inside of the axle weldment.
Remark
When installing the pivot pin make sure that the
locating hole (for locating pin) is positioned on
the bottom side. This hole must align with the
hole in the rear retainer cap.
3. After driving the pin into both the front and rear bores of the axle
weldment, install the front and rear cover plates i. Install the retaining
rings g and grease zerks h.
4. Position the steering cylinders c in place. Install the spacers f, studs

e, and locknuts d. Tighten the locknuts
Locknuts: 150lbf ft (203.3 Nm)
Remark
There should be zero clearance between flange and spacer
after torquing.
5. Install the hoses b and tighten the fittings.
6. Lubricate and install two new bushings b, one in each axle weldment
arm.
7. Install one spacer c in the rear arm only.

Remark
Install the bushings with the split 45° to the horizontal and
vertical center lines. Locate the split on the non load carrying
side of the bushing.
830B/C-850B/C-870B/C 30-373
12
8. Press the leaning wheel pin h into the yoke i.
9. Start the pivot pin g through the arm and yoke. Seat the O-ring (not
shown) inside the front arm bushing. See the cross section below.
10. Position thrust bearing a assembly on the pivot pin (see inset).Install
the flat washer c and self-locking nut b. Tighten the nut to seat the
pin against the taper.
11. Install the flat washer c and self locking nut b.

Tighten the nut to seat the pin against the taper.
12. Install the cover c with a new gasket, lock washers, and bolts b.
13. Lubricate and install the two new bushings (not shown) in the steering
yoke. Install the bushings with the split 45° to the horizontal and
vertical center lines. Locate the split on the non load carrying side of
bushing. Support the spindle to prevent injury from occurring.
30-374 830B/C-850B/C-870B/C
12
14. Position the two thrust washers e (one on top and one under the
spindle) and spindle d into the steering yoke.
15. Align the holes between the thrust washers, spindle, and steering yoke.
16. Drive the center pin c in until the roll pin hole in the center pin aligns
with the roll pin hole in the spindle d.
17. Drive the roll pin b in until flush.
18. Install the cover plate d, retaining ring c, and grease fitting b in the
top and bottom of the steering yoke.
19. Install the steering cylinder socket assembly through the hole in the
spindle weldment.
20. Install the flat washer and slotted nut. Tighten the slotted nut.
If necessary, increase the torque on the nut to install the cotter pin b.
Remark
A hardened washer must be used under the slotted nut.
Install a flat washer if one was not present at disassembly.
21. Install the leaning wheel cylinder d rod end first, then the base end.
22. Install the pin c and cotter pin b to secure the base end of the cylinder
in position.
830B/C-850B/C-870B/C 30-375
12
23. Press the ball bushing in each end of the rod h.
24. Install the flat washer i, rod assembly h, two flat washers g, and
self-locking nut f onto the steering yoke e.
Remark
Additional flat washers g may be needed.
25. Install the flat washer c, self-locking nut b, and leaning wheel
cylinder rod end d to the steering yoke.
26. NON ALL-WHEEL-DRIVE AXLE ONLY: Hand pack the bearings

b and d with grease.
Remark
For grease specifications, refer to the Operator’s Manual for
your unit.
27. Install the collar f onto the spindle g. Seat the collar against the
shoulder.
28. Install the seal e onto the collar f as shown. Note the direction of the
seal lip.
29. Install the bearing cup in the wheel c.
30. Install the bearing d after placing the wheel c on the spindle g.
31. Using a suitable lifting device, position the wheel c on the spindle
assembly g and install the bearing d on the spindle.
Remark
Prior to installing the bearing d, pack the cavity between the
bearings with grease. Wipe the excess grease from the end
of the spindle after installing the bearing d.
30-376 830B/C-850B/C-870B/C
12
32. NON ALL-WHEEL-DRIVE AXLE ONLY: Install the retainer i
without the shims.
33. Lubricate and then install the two drilled head bolts h. Torque the
bolts while rotating the wheel to assure that the bearings are fully
seated.
34. Back out the two drilled head bolts h. Tap the wheel hub with the
hammer to ensure that the bearing d moves outward slightly to
remove the preload. Retorque the bolts while rotating the wheel.
35. NON ALL-WHEEL-DRIVE AXLE ONLY: Using a depth

micrometer j, measure distance A from the retainer plate i outside
surface to the end of the spindle g. Record this measurement in the
following step.
830B/C-850B/C-870B/C 30-377
12
36. NON ALL-WHEEL-DRIVE AXLE ONLY: Remove the two drilled
head bolts h and the retainer plate i.
37. Using a micrometer, measure the thickness B of the retainer plate i.

Record this measurement.
38. Subtract measurement B from A. Subtract 0.003 in (0.076 mm) from

the difference to obtain the required shim pack j thickness. The shim
pack causes a 0.003 in (0.076 mm) preload on the bearings.
_________________ Measurement A
- _________________ Measurement B
= _________________ Difference of A and B
0.003 in Preload measurement
= _________________ Required shim pack thickness
39. NON ALL-WHEEL-DRIVE AXLE ONLY: Position the shims j

and retainer plate i on the spindle.
40. Install the two lubricated, drilled head bolts h. Tighten the bolts.
41. After installing the bolts, lock wire them into position.
30-378 830B/C-850B/C-870B/C
12
42. NON ALL-WHEEL-DRIVE AXLE ONLY: Install the gasket and
hub cap 1) with the four lock washers and bolts 1!. Tighten the bolts.
43. ALL-WHEEL-DRIVE GEARBOX ONLY: Refer to “AWD -

GEARBOX ASSEMBLY” on page 30-329 for reassembly.
830B/C-850B/C-870B/C 30-379
12
INSTALLATION
1. Sling the front axle assembly b with chains to the overhead hoist. Lift
the axle into place under the grader frame.
2. Position axle pivot pin 0.94 in from rear surface. Install the locating pin (not shown), and front and rear pivot caps c with
the flat washers and eight bolts b.
3. Snug the bolts in sequence to obtain equal separation of the bolting

surfaces.
4. Reinstall the hoses b to the leaning wheel cylinder c.
5. ALL-WHEEL-DRIVE AXLE ONLY: Refer to “AWD - GEARBOX

ASSEMBLY” on page 30-329. This manual will show additional
hoses and sensors that must be connected.
30-380 830B/C-850B/C-870B/C
12
6. Reinstall the hoses b to the steering cylinders c.
7. Install the tire and rim assembly with the six rim clamps c and lug
nuts b. Tighten the lug nuts.
Remark
Make sure that the rim is properly centered. Refer to the
Operator’s Manual for “Rim Centering.”
8. With the parking brake set, use the moldboard to raise the front tires
clear of the ground.
9. Have another person remove the blocking b from under the drawbar
ball joint c.
WARNING! Use extreme care when removing the

blocking from under the frame.
10. Install the tie rod assembly b with the flat washer, slotted nut d and
cotter pin c. Tighten the slotted nut. If necessary, increase the torque
on the nut to install the cotter pin.
Remark
Use a flat washer under the slotted nut. Install a flat washer if
one was not present at disassembly.
830B/C-850B/C-870B/C 30-381
12
11. Install the grease zerk b into the bottom of the drawbar ball joint
socket c.
Remark
See the “FRONT WHEEL ALIGNMENT AND TURNING RADIUS ADJUSTMENT” on page 20-25 of this
manual for adjustment of the steering cylinders. See sections for the “AWD - GEARBOX ASSEMBLY” on
page 30-329 and for the “AWD MOTOR (VICKERS/EATON)” on page 30-359.
30-382 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
12
NoSPIN AND LOCK/UNLOCK DIFFERENTIALS

PARKING BRAKE BLEEDING
1. Place blocking in front of and behind each tire to prevent accidental movement of the grader.
2. Attach a clear plastic tube to the parking brake caliper bleeder screw. Place the other end of tube into a container with
clean hydraulic oil.
3. Close the bleeder screw.
4. Start the engine and allow the unit to run to ensure that the hydraulic accumulators are filled with hydraulic oil.
5. With the accumulators filled, release and apply the parking brake switch several times.
7. With the engine off, open the caliper bleeder screw. Turn the ignition key ON, but do not start the engine.
8. Move the parking brake switch to the released position. This action will cause hydraulic oil in the accumulator to
purge air from the parking brake system.
9. Close the bleeder screw.
10. Repeat steps 4 thru 8 as many times as necessary so that no air bubbles appear in the plastic tube or container.
FINAL DRIVE BRAKE BLEEDING
1. Place blocking in front of and behind each tire to prevent accidental movement of the grader.
2. Attach a clear plastic tube to each final drive wet brake bleeder screw. Place the other end of the tube into a container with
clean hydraulic oil.
Remark
The bleeder screws are located on top of the final drive.
3. Close the bleeder screws.
4. Start the engine and allow the unit to run to ensure that the hydraulic accumulators are filled with hydraulic oil.
5. With the accumulators filled, release and apply the service brake several times.
7. With the engine off, open the final drive bleeder screws.
8. Apply the foot brake. This action will cause hydraulic oil in the accumulators to purge air from the final drive brake sys-
tem.
9. With the foot brake still applied, close the bleeder screw.
10. Repeat Steps 4 thru 8 as many times as necessary so no air bubbles appear in the plastic tubes or container.
830B/C-850B/C-870B/C 30-383
12
ROAD TESTING
After reinstalling the tandems and final drive and bleeding the brake lines, road test the grader. This will ensure that tandems,
final drive and brakes are functioning properly, before returning the unit to service.
1. Start the engine and pump brakes for several minutes with the transmission in NEUTRAL. Look for signs of hydraulic oil
leaks. Correct any leaks, if found.
2. The brake pedal should have a solid feel. If the pedal feels spongy, bleed the brake system again.
3. Test the brakes at low travel speed. Increase the speed slowly in 1 to 2 mph increments, but come to a complete stop
between each speed increase. Test the brakes in forward and reverse.
4. Test the parking brake as outlined in “Parking Brake Adjustment” section of this manual.
5. Again look for signs of oil leaks, and correct if necessary.
6. Recheck all oil levels.
Thoroughly clean the component to be serviced and the surrounding area. This action will help prevent contamination from
REMOVAL
1. Park the grader where both tandems and all four rear tires are within
reach of a 2-ton lifting device. Position the moldboard crossways
under the grader so that the moldboard rests solidly on the ground.
Turn the engine off.
2. Remove the transmission guard b from the frame (if equipped).

Position a floor jack under the guard. Remove the hexnuts e, flat
washers d, and bolts c on each side, and the bolts f, hexnuts, flat
washers on the rear.
WARNING! Be sure that transmission guard is

adequately supported.
3. Remove the parking brake caliper.
A. Start the engine and release the parking brake.
B. With the operator in the cab have another person turn the parking
brake release valve (arrow) fully CW to close it. This action will
hydraulically lock the parking brake caliper in the released
position.
C. Turn the engine off.
30-384 830B/C-850B/C-870B/C
12
4. Mico parking brake caliper removal.
A. Remove the hexnuts, flat washers and bolts b that secure the
caliper mount assembly c to the parking brake bracket d.
WARNING! Do not place your fingers between the

brake pads.
B. With the caliper mount assembly c and caliper e removed from

the parking brake bracket d, tie them up and out of the way of the
final drive.
Remark
If the caliper cannot be hydraulically released, tag and
disconnect the hose from the caliper. Leave the caliper on
the mounting bracket until it is removed from under the unit.
It will be easier to remove the caliper when it is out from
under the unit. Refer to the “Operation and Maintenance
Manual” for a manual release procedure.
C. Tag and disconnect the brake hose b from the fitting c on each
side of the final drive d. Plug the hoses to prevent contamination
from entering the hydraulic system.

system, do not depress the foot brake
after disconnecting the brake hose. Cap
the hoses to prevent the accidental
discharge of the hydraulic fluid from the
accumulator.
D. Remove the fittings c and h from the final drive d and f,

parking brake j. Replace the O-ring e, i, 1@, 1(, and 2)
on each fitting, if necessary. Plug the brake ports to prevent
contamination from entering the brake portion of the final drive.
Remark
Tag and disconnect the supply and return lines.
Plug and cap the hoses and fittings.
830B/C-850B/C-870B/C 30-385
12
E. Disconnect the negative (-) battery cables from the batteries to
prevent accidental starting of the unit.
F. Drain the tandem cases and final drive. Refer to the “Operation
and Maintenance Manual” for capacities.
G. Place a 10-ton jack b under the rear of each tandem case c. Place
adequate blocking or support stand d under the rear of the frame
e to support the unit after removing the jacks.
H. Remove the jacks.

Remark
With the heel of the moldboard positioned in front of the rear
tires, extend one lift cylinder at a time. This action will raise the rear of the frame so that blocking can be
placed under the frame. DO NOT support the grader with the moldboard.
I. Using a suitable lifting device and tire tongs, remove the lug nuts,
wheel clamps b, and tire from the wheel.
J. Repeat procedure for remaining tandem tires.
K. Place the jack(s) and blocking b under the tandem case c. If not
previously done, remove the drain plug d from the side of the
case and drain the old oil. Reinstall the drain plug.
Each tandem: 8.7 U.S. gallons (32.9 L)
L. Remove all side access hole covers e and the top access covers f
from the tandem case.
M. Rotate the final drive input shaft until the master link b is
accessible through the side access hole.
Remark
Release the parking brake caliper to rotate the shaft. See
steps 3B and 3A. If the input shaft will not move the chain,
turn the wheel until the master link is in position.
N. Remove the master link from the chain c.
30-386 830B/C-850B/C-870B/C
12
Two different types of chains exist. A double-strand chain (right) is used
with a nonplanetary axle. However, a single-strand chain (below right) is
used with a planetary reduction axle.
O. Position the two jacks under the tandem case b so it will remain
level.
P. Using a 2-ton (1,814 kg) lifting device, sling the tandem case b.
Q. Remove the bolts and washers that secure the tandem case b to
the final drive.
Remark
The bolts on top of the final drive cannot be removed until
the tandem case is separated from the final drive.
R. Repeat the previous steps for the remaining tandem case.
830B/C-850B/C-870B/C 30-387
12
S.
If not previously done, remove the drain plug from the final drive
assembly b and discard the old oil. Reinstall the drain plug.
Remark
Refer to the “Operation and Maintenance Manual” for the oil
capacity of final drive assembly.
T.
Using a suitable lifting device and spreader, sling the final drive
assembly b. Position a jack under the brake disc c to prevent the
final drive from tipping as it is lowered away from frame d.
Remark
See “Special Tools” for manufacturing details of the spreader
bar and chains.
U. Disconnect the drive shaft e from the input yoke f.
V. Remove the bolts g that secure the final drive to the frame. Lower the final drive to the ground and slide it out from
under the unit.
30-388 830B/C-850B/C-870B/C
12
GENERAL DISASSEMBLY
After removing the final drive assembly from the grader, disassembly
differs according to whether the final drive has planetary or nonplanetary
reduction, and a NoSPIN or a lock/unlock differential.
DISASSEMBLY OF THE PLANETARY CARRIER
1. Using a suitable lifting device, position and secure differential case b

with the final drive c on an adequate table or stand.
2. Using a suitable lifting device, sling the final drive assembly c.

Remove the bolts, flat washers, and final drive from the differential
case b.
3. Remove the locating dowels d from the differential case b.
4. Remove the friction disc d from the backing plate b and sun gear e.
5. Remove the backing plate b from the dowels c.

Remark
A factory rollover stand (shown in the background) was
used during this service procedure.
6. Remove the three brake backing dowels e from the ring gear f.
7. Remove the sun gear b with the input shaft c from the carrier d.
8. Slide the input shaft d out of the sun gear c.
9. Remove the retaining ring b from the sun gear c, if replacement is

necessary.
830B/C-850B/C-870B/C 30-389
12
10. Remove the triangular lock plate b from the carrier c and bolt d.
11. After installing a piece of bar stock b to hold the planet carrier c and
ring gear d in position, turn the assembly over.
12. Remove the retaining ring d and output shaft sprocket b from the axle
c.
13. Remove the output sprocket spacer e from the axle f.
14. Remove the retaining ring d that secures the spherical roller bearing b
in the tandem mounting sleeve c.
30-390 830B/C-850B/C-870B/C
12
15. Remove the bolt b, retaining washer c, and brass thrust washer (not
shown) from the carrier d and axle shaft.
16. Using a suitable lifting device, install an eye bolt b into the axle shaft.
Lift the axle shaft and carrier assembly c from the final drive
assembly d.
17. Remove the ring gear e and locating dowels (not shown) from the
final drive assembly d.
18. Remove the spherical roller bearing b from the tandem mounting
sleeve c.
19. Remove the carrier assembly c and planetary spacer b from the axle
shaft d.
20. Pry the retaining ring b out of the groove in the end of the pinion shaft
h. Press the shaft out of the carrier c and planetary gear f.
21. Slide the thrust washers g and planetary gear f out of the carrier c.
22. Remove the bearing rollers e and bearing spacer d from the planetary
gear f.
23. Repeat the steps 20 thru 22 for the remaining two planetary gears.
830B/C-850B/C-870B/C 30-391
12
24. Remove the bolts b, retainer plate c, and shims (not shown) from the
tandem mounting sleeve d.
25. Remove the bearing cone d from the tandem mounting sleeve b.
26. Using a suitable lifting device, sling the final drive housing c.
Remove the housing from the tandem mounting sleeve b.
27. Remove the oil seal b from the tandem mounting sleeve c.
28. Remove the bearing cup f from the inboard end of the final drive
housing e.
29. Remove the grease seal d, bearing cone c, and bearing cup b from
the outboard end of the final drive housing e.
30. Remove the grease fitting g from the final drive housing e, if
30-392 830B/C-850B/C-870B/C
12
DISASSEMBLY OF THE NONPLANETARY CARRIER
1. Using a suitable lifting device, position and secure the differential case
b with the final drive c on an adequate table or stand.
2. Using a suitable lifting device, sling the final drive assembly c.

Remove the bolts, flat washers, and final drive from the differential
case b.
3. Remove the locating dowels d from the differential case b.
4. Remove the friction disc and brake plate gear assembly d from the
backing plate b and axle shaft e.
5. Remove the backing plate b from the dowels c.

Remark
A factory rollover stand (shown in background) was used
during this service procedure.
6. Remove the retaining ring b and friction disc d from the brake plate
gear c. Remove the remaining retaining ring e from gear, if
7. Remove the three brake backing plate dowels b thru d and spacer e
from final drive housing f.
Remark
On later built axles, the spacer e is cast as an integral part of
the housing f. The one-piece spacer/housing and the
separate spacer and housing are available from the parts
department. In the event that a one-piece spacer/housing in
not available, a separate housing and spacer may be
substituted, along with two additional locating dowels.
830B/C-850B/C-870B/C 30-393
12
8. Remove the locating dowels b from the final drive housing c.
9. Remove the retaining ring d and axle assembly b from the tandem
mounting sleeve c.
10. Remove the retaining ring h, sprockets e and f, output sprocket

spacer d, spherical roller bearing c, and output shaft sleeve b from
the axle shaft g.
11. Remove the bolts b, retainer plate c, and shims (not shown) that hold
the tandem mounting sleeve in the final drive housing d.
30-394 830B/C-850B/C-870B/C
12
12. Remove the bearing d from the tandem mounting sleeve b.
13. Using a suitable lifting device, sling the final drive housing c.
Remove the housing from the tandem mounting sleeve b.
14. Remove the oil seal b from the tandem mounting sleeve c.
15. Remove the bearing cup f from the inboard end of the final drive
housing e.
16. Remove the grease seal d, bearing cone c, and bearing cup b from
outboard end of final drive housing e.
17. Remove the grease fitting g from the final drive housing e, if
830B/C-850B/C-870B/C 30-395
12
DISASSEMBLY OF THE DIFFERENTIAL BRAKE PISTONS
1. Remove the piston b and three dowels c from each side of the differential case d.
2. Remove the inner seal e and outer seal f from each side of the differential case d.
30-396 830B/C-850B/C-870B/C
12
DISASSEMBLY OF THE INPUT QUILL ASSEMBLY
1. If the parking brake caliper b has not been removed, refer to the “Operation and Maintenance Manual” for the manual
release method. Remove the spacers c, support bar d, and spring e from the parking brake bracket f.
Remark
See the Parrot parking brake caliper or the Mico parking brake caliper in the REMOVAL section for
additional information.
830B/C-850B/C-870B/C 30-397
12
2. Remove the bolts d and flat washers e that secure the differential case
cover 1$ to the differential case.
3. Two jacking holes A exist in the differential case cover 1$ to help

break it free from the case. One hole is located on each side of the
cover on the horizontal centerline of the input yoke. Remove the cover
and the two O-rings 1) from the case.
4. Remove the bolts 1! and brake disk 1@ from the yoke 1#, if disk
5. Remove the cotter pin g, castle nut h, special washer i, and O-ring j
from the pinion gear 1).
6. Remove the yoke 1# from the pinion gear 1).
7. Remove the V-seal 1% from the yoke 1#.
8. Using an arbor press and suitable adaptor, press the pinion gear 1) out of the bearing cone 1&.
9. Remove the washer 1( and pinion end play shims 2) from the pinion gear 1).
Remark
Set the pinion end play shims 2) aside so they can be used as a starting point for the pinion end play shim
pack thickness at reassembly.
10. Remove the seal 1^, bearing cone 1&, and bearing cup 1* from the differential case cover 1$.
11. Remove the cone point shims 2! and bearing cup 2@ from the differential case cover 1$.
12. Remove the bearing cone 2# from the pinion gear 1), if replacement of either part is necessary.
Remark
The pinion gear and ring gear are a matched set. Always replace as a set.
13. Remove the bolts 2$, parking brake bracket f, and brake bracket spacer 2% from the differential case cover 1$. However,
differentials with mounting bracket P/N 1430 033 H1, the bracket is held on with only five bolts and flat washers while
the spacer 2% has been eliminated.
30-398 830B/C-850B/C-870B/C
12
DISASSEMBLY OF THE DIFFERENTIAL CASE WITH
NoSPIN DIFFERENTIAL
DISASSEMBLY OF THE NoSPIN DIFFERENTIAL QUILLS
1. It is possible to install the ring gear and differential assembly b in the

case backwards. Thus, mark the position of the ring gear on the
differential case for reassembly.
2. Using a suitable lifting device, sling the ring gear and differential
assembly b.
3. Remove the bolts c, bearing quills d and e, and shims f and g from
the case.
Remark
One nut and flat washer h exist on the inside of the case for each quill. It is located at the bolt hole closest
to the case opening.
4. Remove the bearing cups i and j from the quills d and e, if replacement of either part is necessary.
DISASSEMBLY OF RING GEAR AND NoSPIN DIFFERENTIAL
1. Insert a 5/16 in diameter threaded rod 18 in long b through the

differential assembly. Install a 3.0 in (76.2 mm) O.D. washer on each
end of threaded rod with appropriate hexnuts c. Tighten the hexnuts
and washers against housing d and cover e. This rod will retain
spring pressure exerted by NoSPIN springs.
2. Make a diagonal mark across the housing e, differential spider f, and

cover d. This alignment mark will ensure that the differential is
properly reassembled.
3. Remove the bolts g holding the housing and cover together.
4. After removing the bolts, slowly unscrew the hexnuts on the threaded
rod to allow the housing and cover to separate. This step will allow the NoSPIN springs to expand.
5. Remove the threaded rod and NoSPIN parts b thru g in the order shown from between the housing and the cover.
6. Using a suitable puller, remove the bearings h and i from the housing e and cover d.
7. Remove the ring gear bolts j and ring gear 1) from the housing.
Remark
Secure the bolts in position with 3M 2158 epoxy. The pinion gear and ring gear are a matched set. Always
replace as a set.
830B/C-850B/C-870B/C 30-399
12
DISASSEMBLY OF MISCELLANEOUS NoSPIN DIFFERENTIAL ITEMS
1. Remove the alignment dowels j from the differential case 2), if replacement is necessary.
2. Remove the plugs b, g, 1!, 1#, 1%, 2!, and 2* from the differential case 2) and cover h. Remove the O-rings from the plugs,
if replacement is necessary.
3. Remove the breather 3! and reducer 3) from the differential case 2).
4. Remove the bleeder screw 1&, bleeder bushing 1*, and O-ring 1( from the differential case 2).
30-400 830B/C-850B/C-870B/C
12
DISASSEMBLY OF DIFFERENTIAL CASE WITH LOCK/UNLOCK DIFFERENTIAL
DISASSEMBLY OF LOCK/UNLOCK DIFFERENTIAL QUILLS
1. Remove the fittings b and c to remove the differential lock oil line d
from the adaptors e and f.
Remark
Inspect the O-rings and replace, if necessary.
2. It is possible to install the ring gear and differential assembly b in the

case backwards. Thus, mark the position of the ring gear on the
differential case for reassembly.
assembly b.
4. Remove the washers and bolts c, bearing quills d and e, and shims f
and g from the case.
Remark
One nut and flat washer h exist on the inside of the case for
each quill. The nut is located at the bolt hole closest to the
case opening.
5. Remove the bearing cups i and j from the quills d and e, if replacement of either part is necessary.
DISASSEMBLY OF RING GEAR AND LOCK/UNLOCK DIFFERENTIAL
1. Place one alignment mark at a 45° angle across the end of one pinion
shaft and another alignment mark at a 90° angle across the end of the
other pinion shaft. Ensure that each alignment mark continues across
the lock/unlock differential housing halves. This step will ensure that
the shafts are installed in the same location at reassembly.
2. Remove the bolts b that hold the lock/unlock differential housing

halves c and d together.
830B/C-850B/C-870B/C 30-401
12
3. Remove the thrust washer b from the bevel gear c.
4. Remove the bevel gear b from the pinion set c.
5. Remove the pinion set c as a unit and carefully set aside.
6. Remove the inside bevel gear b and thrust washer c from the ring
gear side of the differential housing d.
7. Remove the pinion thrust washer b, bearing thrust washer c, pinion

gear d, roller bearings e, bearing thrust washer f, and retaining ring
g from each end of both pinion shafts h.
Remark
Install the same parts on the same pinion shaft end they
were removed from.
30-402 830B/C-850B/C-870B/C
12
8. Remove the bolts b and cover c from the ring gear half of the
differential assembly d.
9. Using a suitable puller remove bearing cone e from the cover c, if

10. Remove the ring gear bolts f and ring gear g from the housing.
Remark
Secure the bolts in position with 3M 2158 epoxy.
Remark
The pinion and ring gear are a matched set. Always replace
as a set.
11. Remove the four disk plates, three clutch separator plates, and clutch
backing plate b from the housing c.
12. Remove the three return springs d from the housing c.
13. Remove the three pins b from the cover c, if replacement is

necessary.
14. Test the springs d for the proper free length and compressed force.
Replace the springs as a set if one or more of them do not meet the
following specifications.
Free Length:
1.6 in (40.64 mm) (approximate)
Test Length:
1.1 in (27.94 mm) at 23 to 28 lbf (102 to 125 N)
15. Using a rubber-tipped nozzle air hose, blow the differential lock piston
b from the housing c.
830B/C-850B/C-870B/C 30-403
12
16. Remove the seals b and c from the piston bore.
17. Using a suitable puller, remove the bearing b from the housing c.
18. Unlock and remove the two sealing rings b from the housing c.
30-404 830B/C-850B/C-870B/C
12
19. Open the rings slightly to remove.
830B/C-850B/C-870B/C 30-405
12
DISASSEMBLY OF DIFFERENTIAL PINIONS
DISASSEMBLY OF MISCELLANEOUS LOCK/UNLOCK DIFFERENTIAL ITEMS
1. Remove the alignment dowels j from the differential case 2), if replacement is necessary.
2. Remove the plugs b, g, 1!, 1#, 1%, 2!, and 2* from the differential case 2) and cover h. Remove the O-rings from the plugs,
3. Remove the breather 3! and reducer 3) from the differential case 2).
4. Remove the bleeder screw 1&, bleeder bushing 1*, and O-ring 1( from the differential case 2).
30-406 830B/C-850B/C-870B/C
12
NoSPIN DIFFERENTIAL INSPECTION
1. Inspect the splines on the side gears and clutches. Remove any burs or small chips with an abrasive stone or electric bur
grinder. If any splines are broken, replace the NoSPIN. Check the side gear hubs for fractures, and replace if needed.
2. Examine the differential sub case. Replace the case, if the trunnion holes or the thrust surfaces on the inside ends of the
differential sub case are worn or scored. Examine the threads of all bolts and nuts and replace those that are stripped or
damaged.
3. Examine the bearings and ring gear for wear or damage, and replace if needed.
4. Check the thrust and bearing surfaces of the sub case for metal particles or wear and replace if necessary.
5. Check each clutch and holdout ring assembly for correct indexing of holdout ring to cam ring. Be sure that the holdout
ring rotates on the clutch with only a little resistance.
6. Check the holdout rings in the NoSPIN for cracks, chips, or excessive tooth wear. If wear is evident, replace the assembly.
7. Check the center cam for free movement. It must be free to rotate within the limits of the key in the spider. It is not
necessary to remove the center cam from the spider because these parts are serviced only as an assembly. If either part is
excessively worn or damaged, replace the complete spider-center cam assembly.
8. Inspect the clutch teeth on the spider and the driven clutches. Very slight chips can be touched up with an abrasive stone.
If excessively chipped or rounded, replace the NoSPIN. Check the tooth protruding radially inward from the spider for
signs of improper alignment with the gap in either holdout ring.
9. Assemblies must not be excessively chipped. A smooth wear pattern up to 50 percent of the cam face width is acceptable.
10. Check the side gear spline fit on its mating axle shaft. Be sure the splines do not bind. Also check the internal side gear
splines for wear or chipping.
11. Check the spring load with the valve spring tester at 0.900 in (22.86 mm) operating height. If the reading is less than 115
lbf in (12.9 Nm) ± 10 percent, replace the NoSPIN.
LOCK/UNLOCK DIFFERENTIAL INSPECTION
1. Inspect the disks b. Replace if:
A. Peening is evident or the splines have backlash.
B. Warping or coning exceeds 0.010 in (0.25 mm).
C. Friction material is burned, flaked, or pitted.
2. Inspect the separator plates c. Replace if:
A. Scored or galled.
B. Tangs are worn or damaged.
C. Coning warpage exceeds 0.010 in (0.25 mm).
830B/C-850B/C-870B/C 30-407
12
3. Inspect the piston inlet seal b. Replace if necessary. Hold in place with
petroleum jelly.
4. Inspect the piston b for nicks or scratches, and replace if necessary.
5. Inspect the sealing rings for scratches or grooves. Inspect the locks on
the ends of rings. Inspect the sealing ring grooves for wear or damage.
Replace the rings as necessary. Make sure the sealing ring ends are
correctly locked together.
6. Inspect the sealing ring patterns in the quill for skips, nicks, or
scratches.
PARKING BRAKE MOUNTING BRACKET

If the mounting bracket, P/N 1283 956 H1, or spacer, P/N 1283 955 H1, are damaged in any way, replace them with the
mounting bracket, P/N 1430 033 H1. The mounting bracket, P/N 1430 033 H1, incorporates the spacer into its design.
30-408 830B/C-850B/C-870B/C
12
DIFFERENTIAL ASSEMBLY
Refer to the appropriate reassembly procedure, depending on whether the LOCK/UNLOCK or NoSPIN differential is used.
830B/C-850B/C-870B/C 30-409
12
NoSPIN DIFFERENTIAL CASE ASSEMBLY
ASSEMBLY OF MISCELLANEOUS ITEMS
1. Install the alignment dowels j in the differential case 2), if removed during the disassembly.
2. Install the plugs b, g, 1!, 1#, 1%, 2!, and 2* with new O-rings in the differential case 2) and cover h.
3. Install the reducer 3) and breather 3! in the differential case 2).
4. Install the new O-ring 1(, bleeder bushing 1*, and bleeder screw 1& in the differential case 2).
30-410 830B/C-850B/C-870B/C
12
ASSEMBLY OF THE RING GEAR AND NoSPIN DIFFERENTIAL
1. If the ring gear 1) is reused, clean the ring gear bolts j and the bolt
holes in the ring gear.
Remark
DO NOT use a petroleum base solvent to degrease the bolts
and ring gear. USE lacquer thinner or chloroethane.
2. Using the hot air method, heat the ring gear 1) to a maximum of 300° F
(149° C). Install the gear on the housing e after aligning the bolt
holes.
3. Apply 3M 2158 epoxy to the lower 0.75 in (19.050 mm) of the bolt
threads.
4. Secure the ring gear 1) to the housing e with the flat washers and bolts j. Tighten the bolts.
5. Install the bearing cones h and i on the housing e and cover d.
6. Pass the 5/16 in threaded rod that is 18 in long b through the housing e.
7. Install the NoSPIN parts b thru g (below) in the order shown onto the rod (note the differential spider alignment marks).
830B/C-850B/C-870B/C 30-411
12
8. When the NoSPIN parts are in position on the threaded rod, position
the cover d on the rod. Use a 3 in O.D. washer and the appropriate
hexnut c on each end of the rod to draw the differential assembly parts
together.
9. Align the cover d with the alignment mark on the differential spider f
to the alignment mark on the housing e.
10. Install the bolts g to secure the housing and cover together. Tighten
the bolts.
11. After installing the bolts g, remove the threaded rod from the differential.
QUILL PRELOAD ADJUSTMENT
1. Install the bearing cups i and j in the quills d and e, if replacement is

necessary.
assembly b.
3. It is possible to install the ring gear and differential assembly in the

case backwards. Thus, note the marked position of the ring gear on the
differential case lower ring gear and differential assembly b in the
case.
4. Install the bearing quills d and e without the shims f and g into case. Install the flat washers and bolts c. Tighten the
bolts holding the quill e. Only finger tighten the bolts on the quill d.
Quill e: 66 lbf ft (89.4 Nm)
Remark
Do not install the one bolt, flat washer, and nut in the unthreaded hole of each quill. The unthreaded bolt
hole is closest to the case opening.
30-412 830B/C-850B/C-870B/C
12
5. Turn the differential case b with the centerline of the differential
assembly c and quills in a vertical position. The ring gear side of the
case must be facing down.
6. Add shims under the quill d until an end play reading can be taken.
Tighten the bolts holding the quill d.
Quill d: 66 lbf ft (89.4 Nm)
Using a dial indicator, measure the end play of the differential

assembly. Use a pry bar to lift the assembly to make the measurement.
Record this measurement. Add from 0.002 to 0.004 in (0.051 to
0.1016 mm) to the end play reading. Subtract the combined end play
and preload tolerance from the shim pack to obtain the proper preload.
______________ Endplay Measurement
+ 0.002 to 0.004 in Preload Tolerance
= _____________ Combined Endplay and Preload
_____________ Shim Pack Thickness Installed to Obtain Endplay Reading
- ______________ Combined Endplay and Preload
= _____________ Final Shim Pack Thickness
7. Add the appropriate shim pack f under the quill to obtain from 0.002 to 0.005 in (0.051 to 0.127 mm) preload on the
bearings. Tighten the bolts.
Remark
Add the shims to this side. Thus, after installing the pinion gear, move the shims f from this side to the
other side [shims g] to adjust the backlash. This step will prevent the pinion gear from jamming into the ring
gear.
8. Double check the shim pack preload by taking a rolling torque. The
rolling torque must be from.
Rolling torque: 2.1 to 7.8 lbf ft (2.8 to 10.5 Nm)
9. Add shims to decrease the rolling torque. Remove the shims to

increase the rolling torque.
Remark
When the “Backlash Adjustment” is made, shims will have to
be adjusted from one side to the other.
10. Coat both sides of six ring gear teeth with “Prussian Blue” or “Never-
Seize” compound. Do this step at three locations 120° away from each other. Perform this step to check the rolling pattern.
830B/C-850B/C-870B/C 30-413
12
LOCK/UNLOCK DIFFERENTIAL CASE ASSEMBLY
ASSEMBLY OF MISCELLANEOUS ITEMS
1. Install the alignment dowels j in the differential case 2), if removed during disassembly.
2. Install the plugs b, g, 1%, 2!, and 2* using new O-rings in the differential case 2) and cover h.
3. Install the reducer 3) and breather 3! in the differential case 2).
4. Install the new O-ring 1(, bleeder bushing 1*, and bleeder screw 1& in the differential case 2).
30-414 830B/C-850B/C-870B/C
12
ASSEMBLY OF THE RING GEAR AND LOCK/UNLOCK DIFFERENTIAL
1. Install the two sealing rings b on the differential housing c. Open the
rings slightly to install. Make sure the rings are locked once in the
grooves.
Remark
Be sure a gap exists between the locks on the ends of the
sealing rings. Install new rings if a gap doesn’t exist. Ensure
that a gap exists with the new rings.
2. Using a suitable adaptor, press the bearing cone b onto the differential
housing c.
3. Install the seals b and c into the piston bore of the differential
housing (ring gear half).
4. Install the piston b into the piston bore of the differential housing c.
WARNING! Do not damage the seals while installing

the piston.
830B/C-850B/C-870B/C 30-415
12
5. Install the three pins b in the differential piston housing cover c, if
removed during disassembly.
Remark
The spring d will fit over the pins when assembled into the
housing.
6. Install the clutch backing plate, four disk plates, and three clutch
separator plates b into the housing c.
Remark
Alternate installing the separator plates with the disk plates.
Align the internal teeth of the plates with a straight edge.
7. Place the three springs d into position in the housing c.
8. Using a suitable adaptor, press the bearing cone e onto the cover c.
9. Aligning the splines, position the cover c into the differential housing
d. Install the bolts b to hold the cover in place.
10. If the ring gear g is reused, clean the ring gear bolts f and the bolt
holes in the ring gear.
Remark
Do not use a petroleum-base solvent to degrease the bolts
and ring gear. Instead, use lacquer thinner or chloroethane.
11. Using the hot air method, heat the ring gear g to a maximum of 300° F
(149° C).
12. After aligning the bolt holes, install the gear on the housing d.
13. Apply 3M #2158 epoxy to the lower 0.75 in (19.050 mm) of the bolt
threads.
14. Secure the ring gear g to the housing d using flat washers and bolts
f. Tighten the bolts.
15. Install the bevel gear thrust washer c and bevel gear b in the ring gear
side of the differential housing d.
30-416 830B/C-850B/C-870B/C
12
16. Install the roller bearings b in the pinion gear c.
Remark
Replace the roller bearings b as a set. Use petroleum jelly to
hold the bearings in place.
17. Install the retaining ring g, bearing thrust washer f, pinion gear d,
with roller bearings e, bearing thrust washer c and pinion thrust
washer b on the end of each pinion shaft h.
18. Install the pinion shaft assembly b on the bevel gear. Align the marks
made during disassembly.
19. Align the tangs c with the differential housing slots d on each pinion.
20. Install the bevel gear b on the pinion gear set c.
21. Install the thrust washer d on the bevel gear b.
830B/C-850B/C-870B/C 30-417
12
22. After aligning the alignment marks, position the differential housing c
on the housing d.
23. Install the bolts b to hold the housing halves together. Tighten the
bolts.
LOCK/UNLOCK DIFFERENTIAL QUILL PRELOAD

ADJUSTMENT
1. Assemble and test the quill.
WARNING! Inspect for leakage when replacing the

bearing quill.
A. Remove the old sealant material from the quill bore. Clean the
outside diameter and bearing quill bore using chloroethane,
lacquer thinner, or equivalent. Avoid handling the cleaned
surfaces.
B. Following manufactures directions, apply Loctite #12017 to the

quill bore where the drilled holes break into the bore. Apply a
curing primer to the bearing cup b. Allow three minutes for the
primer to dry.
C. Install the bearing cup b tight against the quill shoulder. Allow 30
minutes for the plastic gasket to cure before testing.
D. Check for leakage around the pressure (inlet) passage behind the
bearing cup. Block the passage using a piece of large O-ring c
that is held in place with a pair of locking pliers. Do not damage the surface d with the locking pliers. Apply a
generous amount of clean hydraulic oil around the bearing cup. Use an Air Test Plug and 14.5 psi (1 kg/cm2)
minimum pressure to check for air leakage. If leakage is present, replace the bearing cup and/or quill.
2. Install the bearing cup j in the quill e, if replacement is necessary.
assembly b.
4. It is possible to install ring gear and differential assembly in the case

backwards. Thus, note the marked position of the ring gear on the
differential case lower ring gear and differential assembly b into the
case.
5. Install the bearing quills d and e without shims f and g into case.
Install flat washers and bolts c. Tighten the bolts holding quill e.
Only finger tighten the bolts on the quill d.
Quill e to 66 lbf ft (89.4 Nm)
Remark
Do not install the one bolt, flat washer, and nut in the unthreaded hole for each quill. The unthreaded bolt
hole is closest to the case opening. Make sure that the oil line port in the quill d is in the proper position for
installation of the oil line.
30-418 830B/C-850B/C-870B/C
12
6. Install the adaptors e and f with new O-rings.
7. Connect the fittings b and c to hold the line d in position.

Remark
Do not tighten the fittings until the quills are properly
shimmed. This step will ensure stress is not placed on the
connections. Tighten the fittings during the “FINAL ASSEM-
BLY” on page 30-427 of the Differential Case.”
8. Turn the differential case b with the centerline of the differential

assembly c and quills in a vertical position. Position the ring gear side
of the case down.
9. Add shims under the quill d until an end play reading can be taken.
Tighten the bolts holding the quill d. Using a dial indicator, measure
the end play of the differential assembly. Use a pry bar to lift assembly
to make measurement. Record this measurement. Add from 0.002 to
0.004 in (0.051 to 0.1016 mm) to the end play reading. Subtract the
combined end play and preload tolerance from the shim pack to obtain
the proper preload.
Quill d: 66 lbf ft (89.4 Nm)
______________ Endplay Measurement
+ 0.002 to 0.004 in Preload Tolerance
= _____________ Combined Endplay and Preload
_____________ Shim Pack Thickness Installed to Obtain Endplay Reading
- _____________ Combined Endplay and Preload
= _____________ Final Shim Pack Thickness
10. Add the appropriate shim pack under the quill d to obtain the desired 0.002 to 0.005 in (0.051 to 0.127 mm) preload on
the bearings. Tighten the bolts.
Remark
The shims are added to this side. Thus, moving the shims f from this side to the other side [shims g]
adjusts the backlash after installing the pinion gear. This step prevents the pinion gear from jamming into
the ring gear.
830B/C-850B/C-870B/C 30-419
12
11. Double check the shim pack preload by taking a rolling torque.
Rolling torque must be: 2.1 to 7.8 lbf ft (2.8 to 10.5 Nm).
12. Add shims to decrease the rolling torque. Remove the shims to
increase the rolling torque.
Remark
When the “Backlash Adjustment” is made, shims will have to
be adjusted from one side to the other.
13. Coat both sides of six ring gear teeth with “Prussian Blue” or “Never-
Seize” compound. Do this at three locations 120° away from each
other. Perform this step to check the rolling pattern.
30-420 830B/C-850B/C-870B/C
12
PINION GEAR ADJUSTMENTS
The pinion gear requires three adjustment checks: the pinion gear cone, the pinion gear end play, and the pinion gear backlash.
Each adjustment is performed in the same manner for both the NoSPIN and LOCK/UNLOCK differential.
PINION GEAR CONE POINT ADJUSTMENT
1. Press the bearing cup i into the differential case cover 1$.
830B/C-850B/C-870B/C 30-421
12
2. Press the bearing cup 1* into the differential case cover 1$.
3. Install the Mico braking brake bracket.
A. Installing the Mico parking brake bracket:
i. Clean mounting surface of bracket and differential case cover.
ii. Apply Loctite #12017 to the mounting area of the bracket on differential case cover 1$.
iii. After aligning the holes, position the bracket to the cover at
45° from the centerline. Install the five flat washers and bolts.
Tighten the bolts.
The spacer 2% is not required with this mounting bracket.
4. Using a suitable adaptor and arbor press, install the bearing 2# onto the
pinion gear 1).
5. Subtract the number etched at the pinion gear end from 8.331 in
(211.607 mm). This step determines the required cone point shim pack
thickness to obtain a proper cone point adjustment.
Remark
The number at the pinion end is in inches.
8.331 in Constant (1400 Series)
- _________ Number on Pinion Gear End
= __________ Required Cone Point Shim Pack
6. Install the required cone point shim pack 2!, bearing cup 2@, and pinion
gear 1) with the bearing cone 2# in the differential case cover 1$.
30-422 830B/C-850B/C-870B/C
12
PINION GEAR ENDPLAY ADJUSTMENT
1. Install the bearing 1&, yoke 1#, special washer i, and castle nut h on the pinion gear 1). While rotating the pinion gear 1),
tighten the castle nut. This step ensures that all bearing components are seated.
Castle nut: 445 lbf ft (603.3 Nm)
Remark
The O-ring j and seals 1% and 1^ are not installed until after determining the pinion gear end play.
2. Remove the castle nut h, special washer i, and yoke 1# from the pinion gear 1). Press the pinion gear from the bearing 1&.
3. Install the same amount of pinion end play shims 2) removed during
disassembly, washer 1(, bearing 1&, yoke 1#, special washer i and
castle nut h. Again, tighten the castle nut. Then loosen it and then
tighten it.
Castle nut: 445 lbf ft (603.3 Nm)

Loosen it to below: 200 lbf ft (271.1 Nm)
Final: 225 to 300 lbf ft (305.0 to 406.7 Nm)
4. Turn the pinion gear 1) using a force from 2 to 4 lbf ft (2.7 to 5.4 Nm).
5. Check the end play. Using a dial indicator apply 23 to 68 lb (10.4 to

30.8 kg) of force to the pinion gear. Endplay reading must be from
0.000 to 0.003 in (0.000 to 0.076 mm). Adjust the pinion end play shims 2), as necessary to obtain the specified end play.
When the proper bearing setting is reached, tighten the castle nut so the cotter pin g can be installed. Use a different
special washer i, if necessary to meet the torque.
Torque: 225 to 300 lbf ft (305.0 to 406.7 Nm)
Remark
Each time the castle nut and components are removed to adjust the pinion end play shim pack for the
proper end play, tighten the castle nut to 445 lbf ft (603.3 Nm). Then loosen it to below 200 lbf ft (271.1 Nm),
and then tighten it from 225 to 300 lbf ft (305.0 to 406.7 Nm).
6. With the proper end play established, make an alignment mark across the castle nut h, yoke 1#, and pinion gear 1).
830B/C-850B/C-870B/C 30-423
12
PINION GEAR BACKLASH ADJUSTMENT
1. Coat both sides of six ring gear teeth with “Prussian Blue” or “Never-Seize” compound. Do this at three locations 120°
away from each other. Perform this step to check the rolling pattern.
2. Install new alignment dowels in the differential case b, if replacement

is necessary.
3. Secure the input quill assembly c to the case b with fourteen flat
washers and bolts d. Tighten the bolts.
DO NOT APPLY SEALANT AT THIS TIME.
4. Install the differential backlash tool DR08-111 e into the splines.

Remark
See “Special Tools” for backlash tool DR08-111.
5. Using a dial indicator, measure the backlash at 8.250 in (209.550 mm) from the centerline of the differential case.
Measure the backlash at three points, 120° away from each other. Average the results.
Remark
Hold the input yoke stationary while moving the bar to measure the backlash.
______________ Reading #1
+ ______________ Reading #2
+ ______________ Reading #3
= ______________ ÷ 3 = ______________ Average Backlash Reading
6. Adjust the quill shims f to obtain a backlash from 0.007 to 0.015 in (0.178 to 0.381 mm).
Remark
For every 0.001 in (0.025 mm) of backlash adjustment needed, move 0.001 in (0.025 mm) of shims from
one side to the other. Set the differential case on its side when moving the shims. This step prevents the
ring gear and differential from cocking in the quills. Shims are a one-piece construction. Remove the quill to
remove and install shims.
7. Tighten the differential quill bolts.
Quill bolts: 66 lbf ft (89.4 Nm)
30-424 830B/C-850B/C-870B/C
12
RING GEAR AND PINION ROLLING PATTERN CHECK
This procedure determines whether the pinion and ring gear teeth are meshing properly.
1. While one person is turning the input yoke, a second person inserts an axle shaft into the splines and creates resistance,
loading the ring gear. With the ring gear “loaded,” rotate the ring gear one revolution of the coated teeth.
2. Turn the input yoke in the opposite direction (and load the ring gear in the opposite direction) while rotating the ring gear
one revolution.
3. This procedure should wipe the coating off the ring gear teeth c that
contact the pinion gear teeth b.
4. The tooth bearing pattern d must start at a point e 0.120 to 0.520 in

(3.048 to 13.208 mm) from the toe end of the pinion.
5. Measure the length of the tooth pattern f. It must be a minimum of

1.300 in (33.020 mm).
6. Adjust the cone point shim pack to obtain the correct tooth pattern.
7. If the rolling pattern is not acceptable, determine whether to add or

subtract cone point shims. Then adjust the pinion end play and
backlash.
8. If the rolling pattern is acceptable, clean the ring and pinion gear teeth. Then proceed to the “FINAL ASSEMBLY” on
830B/C-850B/C-870B/C 30-425
12
MEMORANDUM
30-426 830B/C-850B/C-870B/C
12
FINAL ASSEMBLY
After adjusting the cone point, pinion end play, and backlash, assemble the differential case.
1. Remove the differential case cover (input quill) from the differential case.
Remark
Now, install one bolt, flat washer, and nut in the unthreaded hole (bolt hole closest to the case opening) of
the case of each quill.
Remark
A = Position lower elbow to ensure suction hose does not rub against rib on housing cover.
B = Assemble oil return fitting into elbow so that it is 0.12 in width slot is positioned to discharge at
approximately 45° angle. Reference view D-D.
WARNING! A tube breather 3) must be installed into internal pipe port, with the breather slots
parallel to the differential quill boars or a loss of all oil in final drive will occur.
2. With the end play established, make an alignment mark across the castle nut b, yoke c, and pinion gear end.
3. After aligning the marks, install the yoke c, O-ring, washer, and castle nut b. Tighten the castle nut.
Castle nut: 225 to 300 lbf ft (305.0 to 406.7 Nm)
830B/C-850B/C-870B/C 30-427
Install the cotter pin to secure the nut b into position.
4. LOCK/UNLOCK DIFFERENTIAL ONLY - Tighten the fittings of the oil supply line.
5. Position the two O-rings 1) in the grooves of the differential case face.
6. Apply Loctite #515 to the face of the differential case. Position the differential case cover h into position. Install the flat
washers and bolts d. Tighten the bolts.
Remark
For step 7, below, use the drawing on this page.
7. Position the brake disk d onto the yoke e. Install the washers g onto the bolts f. Slide the bolts f through the bolt holes
in the disk d and screw them into the yoke e. Torque the bolts.
30-428 830B/C-850B/C-870B/C
12
ASSEMBLY OF THE DIFFERENTIAL BRAKE PISTONS
Remark
The brake portion of the axle assembly has several different brake discs and backing plates. Always refer to
the appropriate parts manual for the serial number ranges and parts break down. Coat all components with
clean hydraulic oil before installation.
1. Inspect backing plate b and replace if surface is pitted, galled or scratched.
2. Inspect brake disk c for damage or facing is worn to bottom of grooves. Replace brake piston d is pitted, galled or
scratched.
3. Thoroughly oil packings and bore to ease piston installation.
830B/C-850B/C-870B/C 30-429
12
4. Install new packings, inner brake packing f, outer brake packings e.
5. Install brake piston d.

Remark
Make sure brake piston d is completely installed in the bore.
6. Install sun pinion shaft (B) into brake disk (C) as shown.
7. Install brake disk and sun pinion shaft as a unit into the differential
housing.
A = Brake piston
B = Sun pinion shaft
C = Brake Disk
8. Install backing plate (A), making sure that the long dowel pin (B) is
located in slot (C) in the piston lug.
9. Install axle housing assemblies.
10. Connect a 600 psi (42.2 kg/cm2) air gauge and a shutoff valve to the brake line port in the differential cover.
11. Apply 100 psi (7.0 kg/cm2) of air pressure to the brake piston. Close the valve.
12. The pressure gauge should remain at 100 psi (7.0 kg/cm2). If it does not, check the piston seals and/or O-ring (located
between the cover and case).
30-430 830B/C-850B/C-870B/C
12
NONPLANETARY CARRIER ASSEMBLY
1. Install the bearing cup b, bearing c, and grease seal d in the outboard
end of the final drive housing e.
Remark
The lip of the grease seal must point out.
2. Install the bearing cup f in the inboard end of the final drive housing
e.
3. Install the grease fitting g in the side of the final drive housing e.
Remark
Use a rollover stand during this procedure. The stand allows
access to both ends of the final drive assembly.
4. Install the oil seal b in the flanged end of the tandem mounting sleeve
c.
Remark
The lip of the oil seal must point in.
5. Position the tandem mounting sleeve b with the flanged end down.
6. Using a suitable lifting device, lower the final drive housing c onto
the tandem mounting sleeve b.
7. Install the bearing cone d on the tandem mounting sleeve b.
8. Install the two studs b as guide pins, and position the bearing retainer
c (without O-ring) on the end of the tandem mounting sleeve.
9. Install the bolts d 90° to each other, finger tight.
10. Slowly and in even increments, tighten the four bolts d, while rotating
the final drive housing e.
Bolts d: 22.5 Nm (200 lbf in)
11. Loosen the bolts to 0.0 Nm (0 lbf in), and then tighten them again,
while rotating the housing.
Bolts: 14.6 Nm (130 lbf in)
Remark
Rotating the housing will ensure that all bearing components
are properly seated.
830B/C-850B/C-870B/C 30-431
12
12. Using a depth micrometer b, measure from the outside face of the
bearing retainer plate c to the end of the tandem mounting sleeve.
Take a measurement at two places 180° apart. Average the readings.
________ Depth - 1st Micrometer Reading
+ ________ Depth - 2nd Micrometer Reading
= ________ ÷ 2 = ________ Average Depth
13. Remove the bearing retainer c and measure its thickness in locations
of depth micrometer readings. Average these two readings. Subtract the average thickness of the bearing retainer from the
average depth to obtain the required shim pack thickness.
________ Thickness - 1st Micrometer Reading
+ ________ Thickness - 2nd Micrometer Reading
= ________ ÷ 2
= ________ Average Depth
- ________ Average Thickness
= ________ Required Shim Pack Thickness
14. Using a grease gun, pack the inner bearing b with grease before
installing the shims c and bearing retainer. Be careful not to get any
grease into the retainer plate mounting holes.
15. Install the required shim pack c.
30-432 830B/C-850B/C-870B/C
12
16. Install the O-ring on the O.D. of the bearing retainer b.
17. Install the retainer plate b on the alignment studs c.
18. Apply Loctite #242 to the bolt b threads. After screwing the bolts b
in, tighten them to the values listed below. Remove the alignment
studs.
A. If 16 bolts (P/N 24540R1) are used, tighten them to
16 Bolts: 40 to 45 lbf ft (54.2 to 61.0 Nm)
B. If 18 bolts (P/N 31148R1) are used, tighten them to
18 Bolts: 50 lbf ft (67.7 Nm)
19. Pump the tandem sleeve assembly c full of grease. Slowly rotate the
final drive housing while filling. Continue to fill with grease until it
passes the grease seal at the tandem sleeve flange d.
Remark
Refer to the “Operation and Maintenance Manual” for the
proper grease specification.
20. Install the output shaft sleeve b, spherical roller bearing c, output
sprocket spacer, with the small O.D. towards the sprockets d and two
output shaft sprockets e and f on the axle shaft g. Install the
retaining ring h to secure the components to the shaft.
Remark
The boss end of the two sprockets must face each other.
Remark
Apply moly-lithium based grease to the splines of the axle
shaft and output shaft sprockets.
21. Install the axle assembly b in the tandem mounting sleeve c. Secure it
in place with the retaining ring d.
830B/C-850B/C-870B/C 30-433
12
22. Install the locating dowels b into the final drive housing c.
23. Coat the final drive housing c flange with Loctite #518 Master
Gasket.
24. Identify the brake backing plate, brake disk, and piston to be installed.
Several different brake assemblies exist. These assemblies must be
identified for proper brake assembly and operation. If the axle
assembly has already been serviced, the new parts may already be in
place. Use the following table along with the latest parts manual to
identify the parts.
INTERNAL WET BRAKE AXLE PART NUMBER BRAKE PISTON, DISK, AND
VERSION NONPLANETARY PLANETARY BACKING PLATE
1431 168 H91 1431 169 H91

VERSION #1
Version #2 brake If parts from version
Versions #3 and #4 parts parts may be used to #2 are used to service
cannot be used to service service this axle. this axle, use
version #1 and #2. backing plate P/N
1431 599 H91.
Versions #1 and #2 use
dowel pins to prevent the
piston and backing plate 1277 411 H91 1277 412 H91
from rotating.
Version #2 brake If parts from version
parts may be used to #2 are used to service The brake piston b has three dowel holes.
service this axle. this axle, use
backing plate P/N The brake disk c has slots.
1431 599 H91.
The backing plate d has three lugs on the
circumference. The plate is also
counterbored for planetary gear clearance.
VERSION #2
Versions #3 and #4 parts

cannot be used to service
versions #1 and #2.
1277 411 H92 1277 412 H92
dowel pins to prevent the The brake piston b has three dowel holes.
piston and backing plate
from rotating. The brake disk c has no slots.
The backing plate d has three slotted lugs

on the circumference.
30-434 830B/C-850B/C-870B/C
INTERNAL WET BRAKE AXLE PART NUMBER BRAKE PISTON, DISK, AND
VERSION NONPLANETARY PLANETARY BACKING PLATE
1431 781 H91 & H92 1431 782 H91 & H92
VERSION #3
If parts from version
Versions #1 and #2 parts #2 are used to service
cannot be used to service this axle, use
versions #3 and #4. backing plate P/N
1431 599 H91.
Versions #3 and #4 use lugs
on the circumference of the
piston and backing plate to
prevent them from rotating. 1432 004 H91 & H92 1432 005 H91 & H92
The brake piston b has three dowel holes.
The brake disk c has no slots.
The backing plate d has two lugs on the

circumference and no dowel pins.
1431 781 H93 and up 1431 782 H93 and up
VERSION #4
Versions #1 and #2 parts

cannot be used to service
versions #3 and #4.

dowel pins to prevent the 1432 004 H93 and up 1432 005 H93 and up
The brake piston b has one lug.
piston and backing plate
from rotating. The brake disk c has no slots.
The backing plate d has two lugs on the

circumference and two dowel pins.
830B/C-850B/C-870B/C 30-435
12
25. Note the position of the three brake backing plate dowels b thru d in
the spacer e in relationship to the final drive mounting pads, and
install spacer on final drive housing f.
Remark
Position of the brake backing plate dowels is critical. If they
are not properly positioned, the final drive assembly will not
align with the differential case. The reliefs in the differential
case are designed to accept the backing plate.
Remark
On later built axles, the spacer e is cast as an integral part of
the housing f. The one-piece spacer/housing and the
separate spacer and housing are available from the parts
department. In the event that a one-piece spacer/housing in
not available a separate housing and spacer may be substituted, along with an additional two locating
dowels.
26. Install the backing plate dowels b thru d in the spacer e.
27. Install a retaining ring b in one groove of the brake plate gear c.
Position the friction disc d on the brake plate gear and install the other
retaining ring e in the second groove.
28. The backing plate may or may not have dowel pins pressed into it. If it
does have dowel pins, press them out of the backing plate as shown.
A. Long dowel (dimension X) must protrude 0.925 ± 0.039 in

(23.5 ±1 mm).
B. Short dowel (dimension Y) must protrude 0.236 ± 0.039 in

(6 ±1 mm).
Remark
Several different brakes pistons, brake discs, and backing
plates exist. Always refer to the appropriate parts manual for
the serial number ranges and parts break down.
29. Set the backing plate b into position on the dowels c.
30. Position the friction disc and brake plate gear assembly d on the
backing plate b and axle shaft e.
30-436 830B/C-850B/C-870B/C
12
31. Install the locating dowels b in the differential case c.
32. Apply Loctite #518 Master Gasket to the flange.
33. After slinging the final drive assembly b, position it against the
differential case c. Secure the tandem sleeve assembly into position
with the bolts.
830B/C-850B/C-870B/C 30-437
12
PLANETARY CARRIER ASSEMBLY
1. The final drive tandem sleeve reassembly portion of this section is the
same as the nonplanetary carrier for steps up to and including step 19.
After completing step 19 in the nonplanetary carrier reassembly
section, continue with step 2 below.
2. Install the locating dowels b in the final drive housing c.
3. Coat the final drive housing c flange with Loctite #518 Master
Gasket.
Remark
A rollover stand is used during this service procedure to
allow access to both ends of the final drive assembly.
4. Note the position of the three brake backing plate dowel pin holes b
thru d in the ring gear e in relationship to the final drive mounting
pads f. Install the ring gear on the flange g.
Remark
Position of the brake backing plate dowels is critical.
Improperly positioned dowels cause the final drive assembly
not to align properly to the differential case. Reliefs in the
differential case are designed to accept the backing plate.
5. Inspect planet pinion components

Inspect OD of pinion shaft (A) and ID of pinion (B) for pits or
scratches.
Inspect washers (C) for wear and galling.
Remark
Some washers (C) are triangular shape.
6. Inspect inside of carrier for wear caused by planet pinion thrust

washers.
WEAR SPECIFICATIONS
Wear Pattern Disposition
Not uniform Replace carrier
Uniform and DOES NOT exceed thickness
Reuse carrier
of washer
Uniform and DOES exceed thickness of
Add additional thrust washers
washer
Remark
Make sure there is clearance between thrust washers and
pinions after assembly when adding thrust washers.
30-438 830B/C-850B/C-870B/C
12
7. Install the retaining ring b on the planet carrier c.
8. After installing the roller bearings e in the pinion gear f, install the
bearing spacer d on the pinion gear f.
Remark
A light coating of grease in the bore of the pinion gear will
hold the roller bearings in position.
9. Place a thrust washer g on each side of the pinion gear f. Slide the
thrust washers and gear assembly into the carrier c.
10. Install the planet shaft h into the carrier and planet gear assembly with
the retaining groove towards the retaining ring. Engage the retaining
ring in the planet shaft groove.
11. Install NEW thrust washer and carrier retaining washer, step side
toward axle, before the last planet pinion assembly is installed.
12. Install thrust washers using petroleum jelly to hold washers in

position. Check for thrust washer clearance after installing.
Install planet pinion assembly.
WARNING! Make sure there is clearance between

thrust washers and pinions after
assembly.
13. Repeat steps 6 thru 8 for the remaining planet gears.

Remark
To aid assembly, slide the retaining ring opening around the
carrier while installing each shaft.
14. Install the planetary spacer b and carrier assembly c on the axle shaft
d.
830B/C-850B/C-870B/C 30-439
12
15. Position a thin sheet of plastic b inside the tandem mounting sleeve c
to protect the oil seal when installing the axle shaft. Coat the plastic
sheet with clean oil to help aid installation.
16. Using a lifting eye and sling, lower the planetary carrier and tandem
axle assembly b into the final drive assembly c. Engage the planet
gears d with the ring gear e.
17. Carefully remove the plastic sheet b from between the axle shaft and
oil seal. DO NOT CURL THE SEAL LIP.
18. Install a thin brass thrust washer (not shown), retaining washer b, and
bolt c to secure the carrier d to the axle shaft. Place a brass bar e
between the planet gear teeth and ring gear as shown. Tighten bolt c.
Bolt c: 600 to 650 lbf ft (813.4 to 881.2 Nm)
19. Install a piece of bar stock b to hold the planet carrier c and ring gear
d in position. Then turn the assembly over.
30-440 830B/C-850B/C-870B/C
12
20. Install the spherical roller bearing b in the tandem mounting sleeve c.
Secure it in position with the retaining ring d.
21. Install the output sprocket spacer e on the axle f.
22. Install the output shaft sprocket b on the axle c. Secure the sprocket
in place with the retaining ring d.
Remark
Apply a moly-lithium based grease to the splines of the axle
shaft and output shaft sprocket.
23. Turn the final drive assembly back over and remove the bar stock used
to retain the carrier b and ring gear c.
24. After installing the triangular lock plate d, bolt e it into position.
25. Install the retaining ring b in the sun gear c.
26. Slide the input shaft d into the sun gear c.
830B/C-850B/C-870B/C 30-441
12
27. Install the sun gear b with the input shaft c in the carrier d.
28. Install the three brake backing dowels e in the ring gear f.
Remark
The position of the brake backing plate dowels is critical.
Improperly positioned dowels cause the final drive assembly
not to bolt up properly to the differential case. Reliefs in the
differential case are designed to accept the backing plate.
29. Install the backing plate b in position on the dowels c.
30. Place the friction disc d on the backing plate b and then the sun gear
e.
31. Install the locating dowels b in the differential case c. Coat the flange
with Loctite #518 Master Gasket.
32. After slinging the final drive assembly b, position it against the
differential case c. Secure the tandem sleeve assembly with the bolts.
33. Pump grease into tandem bearing cavity until grease surges from
between final drive housing and tandem sleeve. Rotate sleeve 180°
and repeat.
30-442 830B/C-850B/C-870B/C
12
INSTALLATION
1. Position the final drive assembly b under the grader. Using a suitable
lifting device and spreader, sling the final drive assembly as shown.
Position a jack under the brake disc c to prevent final drive from
tipping as it is raised against the frame d.
Remark
See the “Special Tools” for manufacturing details of the
spreader bar and chains.
2. Secure the final drive to the frame with the bolts g.
Bolts g: 580 lbf ft (786.3 Nm)
3. Connect the drive shaft e to the input yoke f.

6C drive shaft connect with 7/16 inch bolts.
6C bolts: 45 - 50 lbf ft (61.0 - 67.7 Nm)
7C drive shaft connect with 1/2 inch bolts.
7C bolts: 70 - 80 lbf ft (94.9 - 108.4 Nm)
Remark
Graders S/N 203511 thru 203542 were manufactured with either 6C or 7C drive shafts. To identify which
drive shaft your machine has, measure the circumference around the barrel of the drive shaft: 6C = 9.5 in;
7C = 11 in.
Remark
Parts have been made available to upgrade from 6C drive shaft to a 7C drive shaft. Kit 1438 019 H91 has
all parts needed for the upgrade. Following is the procedure.
830B/C-850B/C-870B/C 30-443
12
REPLACING 6C FLANGE DRIVE SHAFT WITH 7C FLANGE DRIVE SHAFT
A. To replace drive shaft, remove eight ferry head bolts and lock washers B securing drive shaft C to input yoke of
differential D and transmission output yoke E.
B. To replace output yoke of transmission, remove bolt f, washer g, O-ring h, yoke e and oil seal i. Discard O-ring,
yoke and oil seal.
C. Install new oil seal i, new yoke e, and a new O-ring. Reuse washer g and bolt f.
Bolt: 170lbf ft (230.4 Nm)
D. Remove parking brake caliper b from bracket c by following

removal instructions “MICO PARKING BRAKE CALIPER” on
page 30-451.
30-444 830B/C-850B/C-870B/C
12
E. Remove parking brake disk b from differential input yoke c by
removing eight bolts d and washers e.
F. Remove yoke c from differential by removing cotter pin f, castle

nut g, special washer h, and O-ring i.
G. Remove v-seal j from yoke c and seal 1) from differential case

cover 1!.
H. Install new seal b into differential case cover c; install new

v-seal d onto new yoke e; seals are included in yoke kit.
I. Install yoke assembly d and e onto pinion shaft in differential

case cover c.
J. Install new O-ring f, special washer g, and castle nut;
Castle nut: 1st tighten to 445 lbf ft (603.3 Nm)

2nd loosen to 200 lbf ft (271.1 Nm)
3rd final tighten to 300 lbf ft (406.7 Nm)
K. Install cotter pin i.

Remark
If pinion gear end play adjustment is necessary, follow procedure in “PINION GEAR ADJUSTMENTS” on
page 30-421.
L. Install parking brake disk j to yoke e with new hardware: eight bolts 1), sixteen washers 1!, and eight lock nuts 1@.
Bolts: 20 lbf ft (67.7 Nm) in a star crossing pattern.
M. Install parking brake caliper b to parking brake bracket c by

following installation instructions in “MICO PARKING BRAKE
CALIPER” on page 30-451 - INSTALLATION.
830B/C-850B/C-870B/C 30-445
12
N. Install new 7C drive shaft b to transmission output yoke c and
differential input yoke d with hex head bolts e and washers
supplied with drive shaft.
O. Grease all three grease fittings every 250 hours with Komatsu
Supergrease or equivalent.
4. Check the drain plug to ensure that it is properly installed. Remove fill
plug and add oil to proper level. Refer to “Operation and Maintenance
Manual” for proper lubricant and capacity.
5. Install the new O-ring e on each fitting c, if replacement was

necessary.
6. Install a fitting c in each side of the final drive d. Unplug and connect
the brake hoses b to the fittings as tagged during removal.
Remark
If the unit is equipped with a lock/unlock differential,
reconnect the supply and return lines. Plug and cap the
hoses and fittings.
7. Install the parking brake caliper. Refer to “MICO PARKING BRAKE CALIPER” on page 30-451 - INSTALLATION.
A. Refer to the “PARKING BRAKE TESTING ADJUSTMENT”

Section 20 of this manual for the proper adjustment procedure.
Remark
If the hose leading to the parking brake caliper was
disconnected, bleed the caliper. See the “PARKING BRAKE
BLEEDING” on page 30-383.
8. Turn the parking brake release valve b fully CCW to open it.
9. Disconnect the port-a-power or other auxiliary pumping device from

the quick-connect fitting c.
10. Prepare the mating surfaces of the tandem case b and final drive with
Loctite #518 Master Gasket.
Remark
Thoroughly clean the surface to be sealed with degreasing
solvent. Apply primer “N” (spray can-accelerator) liberally to
one surface to shorten the curing time. Apply gasket-sealant
as required to the other surface. Assemble without excessive
lateral movement.
11. Using a 2-ton (1.8 metric ton) lifting device, sling the tandem case.
30-446 830B/C-850B/C-870B/C
12
12. Position the tandem case against the final drive assembly, aligning the tandem mounting sleeve with the tandem case.
Install the remaining washers and bolts to secure the tandem to the final drive.
WARNING! Position the jacks under the tandem case to prevent rocking.
13. Use bolts (P/N 24875R1, 5/8-11 x 2") and flat washers (P/N 25547R1), two per bolt (See above). Apply Loctite 277 to all
bolt threads and install seven bolts with washers into tandem mounting sleeve. With seven bolts in a row, rotate tandem
mounting sleeve until they are located at the top of sleeve under frame.
14. Position tandem case against final drive assembly, aligning tandem mounting sleeve with tandem case. Install remaining
seventeen bolts with double washers to secure tandem to final drive.
Twenty-four bolts: 175 - 180 lbf ft (237.2 - 244.0 Nm)

Check torque twice.
15. If removed, install the chains into the tandem case see “TANDM CASE - INSTALLATION” on page 30-341.
16. Install all side-access covers e and the top access covers f on the
tandem case.
Remark
Seal the access covers with Loctite #518 Master Gasket.
17. Be sure the drain plug d is securely in place. Fill the tandem case c.
Each tandem case: 8.7 gal (32.9 L)
Refer to the “Operation and Maintenance Manual” for the specified

lubricant.
Remark
Apply Loctite #592 to the drain plug and oil level plug.
830B/C-850B/C-870B/C 30-447
12
18. Leave the jack and blocking b under the tandem case.
19. Using a suitable lifting device and tire tongs, position the tire on the
wheel. Secure the tire to the wheel with the eight wheel clamps and lug
nuts b.
Lug nuts: 115 lbf ft (155.9 Nm)
Remark
If the wheel has been removed, after reinstallation torque
wheel nut to:
Wheel Nut: 1950 lbf ft (2643.8 Nm)
20. Repeat the above procedure for the remaining tires.
WARNING! Make sure the tires are properly centered.

Refer to the Rim Centering section of the
“Operation and Maintenance Manual” for
instructions.
Remark
The unit must be roaded, then the nuts must be torqued again to ensure proper seating of tapers.
21. Remove the blocking from under the unit once the remaining tandem
and tires are installed.
22. Position the transmission guard b on a floor jack. Raise it into

position. Secure the guard to the frame with the bolts c, lock washers
d, and hex nuts e on each side. Complete the task by installing the
bolts f, lock washers, and hexnuts on the rear.
23. Remove the jack.
24. Fill the tandem cases and final drive with appropriate lubricants. Refer
to the “Operation and Maintenance Manual” for lubricants and
capacities.
30-448 830B/C-850B/C-870B/C
12
25. At the junction block, turn the needle valve (arrow) to UNLOCK the
locked fluid in the parking circuit that was used to keep the brake
released.
26. Perform “Road Testing” at this time, refer to “ROAD TESTING” on

page 30-384.
27. Re-torque all axle nuts.
Re-torque axle nuts: 1950 lbf ft (2643.8 Nm)
830B/C-850B/C-870B/C 30-449
DISASSEMBLY AND ASSEMBLY CIRCLE TOOTH REBUILD
12
CIRCLE TOOTH REBUILD
REBUILDING THE TEETH

It may become necessary to rebuild the circle teeth due to excessive circle-to-shoe play. Excess play can be caused by breaking
a tooth or hitting an object that is firmly planted in the roadbed, like a manhole cover. Rebuilding the circle teeth is less
expensive than circle replacement, unless the circle is out of round. An out-of-round circle is indicated by premature shoe wear
or repeated tooth breakage.
Only the working area of the circle, which is about 50 percent of the circle,
has heat-treated teeth. Heat-treated circle teeth are induction hardened to
0.25 in (6.350 mm) deep.
To repair a circle tooth:
1. Remove the circle from the drawbar.
2. Clean the area to be repaired by grinding until a good base is reached.
3. Build-up the tooth by welding to within 0.187 in (4.76 mm) of the

original tooth profile, using E-7018 electrodes or equivalent. A profile
gauge can be made from an adjacent tooth.
4. Build-up the remaining 0.187 in (4.76 mm) of the tooth using a hard-
surfacing electrode E-19141 or equivalent
(RC40-50). This tooth should be built up oversize.
5. Reduce the tooth to size by grinding. Check the tooth size using the
profile gauge.
ALL electrodes must kept dry in a sealed container or rod oven. An E-7018 electrode must not be exposed to the air for more
than four e hours. Perform all welding procedures at temperatures of 70° F (21° C) or above.
30-450 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY MICO PARKING BRAKE CALIPER
12
MICO PARKING BRAKE CALIPER
REMOVAL
3. Release the parking/emergency brake, using one of the following methods.
A. Method One: Use this procedure when the engine and all hydraulic systems are operative, and the brake pads need
replacement.
i. Set the parking/emergency brake.
ii. Place blocks in front of and behind each tire to prevent the grader from moving after releasing the
parking/emergency brake.
iii. Start the engine and release the parking/emergency brake.
iv. With the parking/emergency brake released, turn the parking/

emergency brake release valve b fully CW to close it and
hold the caliper in the released position.
v. After releasing the emergency/parking brake, turn off the

engine.
B. Method Two: Use this procedure when the engine and parking/
emergency are inoperative (emergency/parking brake caliper
requires a port-a-power for hydraulic release).
ii. Place blocks in front of and behind each tire to prevent the grader from moving after releasing the
parking/emergency brake.
iii. Turn the parking/emergency brake release valve b fully CW to close it.
iv. Attach a port-a-power or other pumping device to the quick-connect fitting c. Pump hydraulic fluid into the sys-
tem through the quick-connect fitting until the caliper releases. After releasing the caliper, remove the port-a-
power or other pumping device.
830B/C-850B/C-870B/C 30-451
12
C. Method Three: Use this procedure when the emergency/parking
caliper is unable to be released hydraulically.
ii. Place blocks in front of and behind each tire to prevent the
grader from moving after releasing the parking/emergency
brake.
iii. Loosen the hexnut b and turn the adjustment setscrew c

counterclockwise (out) until the brake pads d, e are clear of
the brake disc.
4. Remove the four hexnuts, eight flat washers, and four bolts b that
secure the caliper mount assembly c to the parking brake bracket d.

caliper brake pads.
5. Remove the caliper mount assembly c and caliper e from the parking
brake bracket d.
6. Turn the parking/emergency brake release valve b fully CCW to open

it. This step allows the caliper to return to the applied position,
relieving all hydraulic pressure.
7. Disconnect the hose from the fitting f. Plug the hose to prevent
contamination from entering the hydraulic system.
8. Remove the fitting f and O-ring from the caliper e. Plug the port in
the caliper to prevent contamination from entering it.
30-452 830B/C-850B/C-870B/C
12
BRAKE LINING REPLACEMENT
1. Place the caliper b in a soft jawed vise with the disc clearance slot
facing up.
Remark
Clamp the caliper machined surface sides.
2. Remove the two pan head screws c. Using a thin blade, pry the lining
d from the housing. Remove the lining through the disc clearance slot.
3. Loosen the locknut e on the adjustment screw f.
4. Force the lining assembly g from the housing bore by advancing the
adjusting screw f. Remove the lining assembly through the disc
clearance slot.
5. Install the new lining assembly g by inserting it into the housing bore through the disc clearance slot.
6. Install the two bushings h into the new lining pad d. Then install the pad into the housing through the disc clearance slot.
Align the holes in the brake lining with the holes in the housing. Secure the brake lining to the housing using the two pan
head screws c.
DISASSEMBLY
1. Remove the caliper b from the pin c.
2. Remove the hexnut d and lock washer e that secure the pin to the
mounting bracket f, if replacement of the pin or bracket is necessary.
Seal g must only have mineral-based hydraulic oil.
830B/C-850B/C-870B/C 30-453
12
MEMORANDUM
30-454 830B/C-850B/C-870B/C
12
3. After loosening the locknut 2* on the adjustment screw 2(, remove the adjustment screw from the piston 2$.
830B/C-850B/C-870B/C 30-455
12
Parking Brake Caliper Assembly

1. Mount bracket assembly 9. Drive screw 17. Piston 25. Belleville spring washers
2. Seal 10. Name plate 18. O-ring 26. Push rod
3. Housing 11. Bleeder screw 19. Back-up ring 27. Seal
4. Zerk fitting, 1/4 in taper 12. Screw 20. O-ring 28. Nut, 7/16 in -14
5. Gasket 13. Bushing 21. Back-up ring 29. Setscrew
6. Cover 14. Lining 22. O-ring
7. Washer, lock 3/8 in 15. Screw 23. Piston
8. Screw, cap 3/8in -16 16. Lining 24. Piston
4. Place the caliper in a soft jawed vise with the end cap g in a vertical position.
Remark
Clamping should be done at the sides of the caliper on the machined surfaces.
5. Remove the four bolts i and lock washers h that secure the end cap g to the housing d.
WARNING! Loosen the assembly bolts evenly in a criss-cross pattern until the spring preload is
released.
6. Remove the seal 2& from the end cap g.
7. Remove the Belleville springs 1%.

Remark
Take notice as to the stacking sequence of the Belleville springs.
8. Remove the piston 2$ from the housing bore d. Then remove the O-ring 2@ and back-up ring 2! from the piston. The push
rod 2^ should come out with the piston.
9. Remove the piston 1& from the housing bore d. Then remove the screws 1%, lining 1^, O-rings 1* and back-up rings 1( and
2! from the piston.
30-456 830B/C-850B/C-870B/C
12
ASSEMBLY
830B/C-850B/C-870B/C 30-457
12

8. Screw, cap 3/8in -16 16. Lining 24. Piston
1. Using clean system fluid, lubricate all O-rings and back-up rings with mineral-based hydraulic oil in the seal kit.
2. Install the new wiper seal 2&, O-rings 2) and 2@,and back-up rings 1( and 2! from the seal kit. Make sure the back-up rings
are installed in the proper position in the grooves.
Remark
When installing the back-up rings, it is essential the surfaces of the diagonal splice match with each other
after the back-up ring is installed in the groove.
3. Lubricate the housing bore d and pistons 2# and 2$ with the clean system fluid.
4. Install the piston 2# into the housing bore d.

Remark
When inserting the piston, be careful not to pinch the O-ring on the inlet ports.
5. Ensure the push rod 2^ is in the piston bore 2$. Then install the piston assembly 1& into the housing bore d.
6. Fully lubricate the threads of the adjustment screw 2( and locknut 2* with a heavy, waterproof grease. Then install the
adjusting screw locknut assembly into the end of the piston 2$.
7. Install the Belleville springs 2% over the piston end 2$ as shown at right.
Remark
The spring nearest the end cap should contact the end cap
on its outside diameter.
8. Install the end cap g with lock washers h and assembly bolts i.
Bolts i: 22 to 27 lbf ft (29.8 to 36.6 Nm)
Tighten the assembly bolts from evenly and in a criss-cross pattern.
30-458 830B/C-850B/C-870B/C
12
9. Install the lockers e and hexnut d to secure the pin c to the mounting
bracket f, if replacement of the pin or bracket is necessary.
10. Slide the caliper b on the pin c.

Remark
Coat the pin with grease.

8. Cap screw 3/8 in -16 16. Lining 24. Piston
830B/C-850B/C-870B/C 30-459
12
INSTALLATION
1. Install the O-ring and fitting f in the caliper e.
2. Connect the hose to the fitting f.
3. Start the engine and release the parking/emergency brake.
4. With the parking/emergency brake released, turn the

parking/emergency brake release valve b fully CW to close it. This
step holds the caliper in the released position.
5. With the caliper released, turn off the engine.
6. Install the four bolts, eight flat washers, and four hexnuts b that secure
the caliper mount assembly c to the parking brake bracket d.

caliper brake pads.
7. Turn the parking/emergency brake release valve b fully CCW to open

it, allowing the caliper to return to the applied position. This action
should relieve all hydraulic pressure.
8. Bleed and adjust the caliper.
30-460 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
12
BRAKE VALVE
REMOVAL
WARNING! Prior to disconnecting the hoses and lines from the hydraulic (wet) brake system, be sure
to relieve the pressure in the circuit stored in the accumulator.
3. Disconnect the negative (-) battery cables from the batteries because pressure switches mounted to the brake valve have
power to them even when the ignition key is turned off.
4. Relieve the pressure in the brake circuit in the following manner:

system, do not depress the foot brake
when the brake hose is disconnected.
Hoses must be capped to prevent
accidental discharge of hydraulic fluid
from the accumulator.
C. Attach a 3 ft (0.91 m) length of hose to each brake hose. Place the

open end of the hoses in a container.
Spillage: 1 U.S. gallon (3.8 L)
D. With the hoses in the container, depress the foot brake pedal several times. This action will release hydraulic fluid
E. Reconnect the hose b to the fitting c on each side of the final drive d.
5. Remove the right side step to help aid access to the brake valve.
830B/C-850B/C-870B/C 30-461
12
WARNING! Wires leading to the pressure switches mounted to the brake valve are live (hot) at all
times, even when the ignition key is turned OFF.
6. Tag and disconnect the electrical leads from the brake pressure switches e.
7. Tag and disconnect all hoses from the brake valve. Plug the hoses to prevent contamination from entering the hydraulic
system.
30-462 830B/C-850B/C-870B/C
12
8. Remove the two bolts d and flat washers e that secure the brake valve c to the mounting bracket.
9. Remove the tube, brake pressure switches, and fittings from the brake valve. Plug the brake valve ports to prevent
contamination from entering the valve.
830B/C-850B/C-870B/C 30-463
12
DISASSEMBLY
Items b thru 1$, and 1( thru 2@ are not serviceable. A seal kit is available to replace most of the O-rings and seals.
1. Remove the two bolts b and flat washers c that secure the brake valve bodies d and e together.
2. Separate the brake valve bodies d and e from each other and remove the O-ring 1&.
3. Pressing on the end of the brake valve spool 2! will indicate if the spring 2) is broken or that the spool is not free to move
in the body.
30-464 830B/C-850B/C-870B/C
12
4. Remove the dust cover 1^ from the brake valve body e and actuator tube 1$.
5. Remove the actuator tube 1$ and shaft seal 1% from the brake valve body e.
830B/C-850B/C-870B/C 30-465
12
ASSEMBLY
1. Using a suitable adaptor, press the shaft seal 1% flush into the end of the brake valve body e.
2. Slide the items f thru 1# into body e.
3. Install the dust cover 1^ on the brake valve body e and actuator tube 1$.
30-466 830B/C-850B/C-870B/C
12
4. Install the O-ring 1& on the end of the brake valve body e.
5. Place the plug 2@ into body e. Secure the brake valve bodies together with the two flat washers c and bolts b.
INSTALLATION
1. Install the fittings, brake pressure switches, and tubes on the brake valve.
2. Secure the brake valve c to the mounting bracket with two flat washers e and bolts d.
830B/C-850B/C-870B/C 30-467
12
3. Reconnect all hoses to the brake valve.
4. Reconnect the electrical leads to the brake pressure switches e.
5. Reinstall the right step that was removed to access the brake valve.
6. Reconnect the negative (-) battery cables to the batteries.
7. After installing the brake valve, bleed the system. See the Final Drive Brake Bleeding section of this manual.
8. Adjust the brake pedal linkage. See the Brake Pedal Adjustment section of this manual.
9. Remove the blocking from in front of and behind each tire.
30-468 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY SEAT
SEAT
GENERAL SPECIFICATIONS
Weight adjustment spring:
Free length 9.250 - 10.250 in (235 - 260 mm)
Test length 5.000 in (127 mm)
Test load:
At 5 in (127 mm) 170 - 240 lb (77 - 108 kg)
At 2.5 in (63.5 mm) 300 - 350 lb (136 - 158 kg)
Shock absorber pull rate 5000 lb (2267 kg)
Ride indicator projection 0.375 in (9.52 mm)
Lubricants and Sealants
Lubricating grease Moly-Coat #47
Suspension boot adhesive #110 Techno Adhesive
Lever cap adhesive #110 Techno Adhesive
830B/C-850B/C-870B/C 30-469
12
MEMORANDUM
30-470 830B/C-850B/C-870B/C
12
COMPLETE ASSEMBLY
830B/C-850B/C-870B/C 30-471
12
LEGEND FOR COMPLETE SEAT ASSEMBLY
1. Lower suspension 16. Tilt latch

2. Seat cushion 17. Tension spring
3. Backrest cushion assembly 18. Tilt latch cap
4. Tilt plate, recess screw, flat washer & lock nut 19. Flat washer
5. Tilt back bolt & flat washer 20. Lock nut
6. Bolt spacer 21. Spacer bar
7. Mounting bolt 22. Shoulder bolt
8. Bracket spacer 23. Lock nut
9. Armrest - LH, mounting screw & self-tapping screw 24. Flat washer - outer
10. Armrest - RH, mounting screw & self-tapping screw 25. Flat washer - inner
11. Armrest - LH cover 26. Vertical limit cable
12. Armrest - RH cover 27. Retainer bolt
13. Spring washer 28. Flat washer
14. Bracket - LH 29. Lock nut
15. Bracket - RH 30. Retaining spring
DISASSEMBLY
1. On each side, remove lock nut 2(, flat washer 2*, limit cable 2^ and retainer bolt 2& from lower suspension b.
2. Remove springs 3) (not shown), located between tilt plate e and spacer bar 2!. From each side, remove tilt back bolt f
and flat washer, then lift backrest cushion out of side brackets 1$ and 1%. If needed, further disassembly of backrest cushion
can be done by removing hardware and separating tilt plates from cushion.
3. Remove arm rest covers 1! and 1@ from armrests j and 1). Remove self-tapping screw, mounting screw, spring washer 1#
and armrest from each side bracket.
4. Remove lock nut 2#, shoulder bolt 2@, inner flat washer 2%, limit cable 2^, and outer flat washer 2$ from each side, that
secure spacer bar 2! from between side brackets. Remove mounting bolt h and mounting spacer i from each side, and
remove seat cushion c from side brackets.
5. Flip seat cushion over. Remove springs 1& from tilt latch 1^ and cushion frame. Pop tilt latch out of cushion. Do not
remove latch cap 1* unless replacement is necessary.
6. Remove four lock nuts 2) and flat washers 1( holding side brackets to lower suspension assembly.
7. A seat cover attachment is available for covering cushions in lieu of cushion replacement.
30-472 830B/C-850B/C-870B/C
12
830B/C-850B/C-870B/C 30-473
12
ASSEMBLY
1. Secure side brackets 1$ and 1% to lower suspension assembly b with four flat washer 1( and lock nuts 2).
Lock nuts: 25 ± 5 lbf ft (33.89 ± 6.7 Nm)
2. If removed, glue new latch cap 1* to tilt latch 1^ with adhesive. Position one end of tilt latch into seat cushion c, then pop
other side in Install springs 1& between latch and cushion frame.
3. Position seat cushion c and two mounting spacers i (one spacer on each side of cushion), between side brackets, and
secure in position with mounting bolts h.
Bolts: 8 - 12 lbf ft (10.84 - 16.26 Nm)
4. Slide outer flat washer 2$, one end of vertical limit cable 2^ and inner flat washer 2% on shoulder bolt 2@. Secure spacer bar
2! to side bracket 1$ with shoulder bolt assembly just made and lock nut 2#. Tighten lock nut.
Lock nut: 75 lbf ft (101.68 Nm)
Repeat procedure to secure spacer bar to other side bracket.
5. Install spring washer 1#, armrest j or 1), two mounting screw and self-tapping screw on side bracket. Tighten
mounting screws.
Screws: 9 ± 3 lbf ft (12.20 ± 4.06 Nm)
Repeat procedure for other armrest. Install armrest covers 1! and 1@ in end of armrest.
6. If removed, secure tilt plates e to backrest cushion d with appropriate mounting hardware. Position backrest cushion
between side brackets and secure in place with two flat washers and tilt back bolts f. Tighten tilt back bolts.
Tilt back bolts: 32 - 37 lbf ft (43.38 - 50.16 Nm)
7. Secure remaining end of each vertical limit cable to lower suspension assembly with retainer bolt 2&, flat washer 2* and
lock nut 2( on each side. Cable end is located between flat washer and lower suspension assembly. Tighten lock nut.
Lock nut: 32 ± 5 lbf ft (43.38 ± 6.77 Nm)
30-474 830B/C-850B/C-870B/C
12
LOWER SUSPENSION
830B/C-850B/C-870B/C 30-475
12
LEGEND FOR LOWER SUSPENSION OF SEAT
1. Seat adjuster 17. Slider bumper, 1.161 in (29.489 mm)

2. Roll pin 18. Slider bumper, 1.562 in (39.675 mm)
3. Spring pad 19. Slider bumper, 2.160 in (54.864 mm)
4. Weight adjustment spring 20. Slider bumper, 2.562 in (65.075 mm)
5. Spring washer 21. Shock absorber
6. Vertical gear and shaft 22. Shock absorber bushing
7. Roll pin 23. Shoulder bolt
8. Horizontal gear and shaft 24. Lock nut
9. Shaft bracket 25. Slide bumper
10. Suspension arm 26. Ride indicator
11. Weight adjustment knob 27. Mounting shaft
12. Instruction decal 28. Lock nut
13. Tube bushing 29. Roll pin
14. Suspension boot 30. Carriage bolt
15. Push-on fastener 31. Lock nut
16. Thrust washer 32. Upper housing
DISASSEMBLY
1. Remove fasteners 1% from instruction plate 1@ and suspension boot 1$. Remove plate from boot. Carefully remove boot,
upper front corners are adhered to upper housing 3@, from assembly. Remove roll pin c from ride indicator 2^. Unsnap
indicator from suspension arm 1).
2. Position assembly in press so that weight adjustment spring e is centered. Using adjustment lever 1!, raise assembly to its
highest point. Apply press to assembly.
3. Remove absorber shoulder bolt 2# lower bushing 2@ and lock nut 2$. Slowly raise press to allow spring to come to its full
height, 9.250 in (235 mm) to 10.250 in (260 mm). Remove assembly from press.
4. Remove upper and lower mounting shafts 2& and lock nuts 2* from assembly and separate components. Do not remove
spring pad d unless replacement is necessary.
5. Remove roll pin 2( and separate parts f, g and 1^. Remove bushings 1# and slider bumpers 1& thru 2) from suspension arm
1). Remove upper bushing 2@ from shock absorber 2!.
6. Remove roll pin h and slide weight adjustment knob 1! off shaft. Remove horizontal gear and shaft from bracket j.
Remove hardware 3) and 3! and bracket from housing. Remove slide bumpers 2% from housing.
30-476 830B/C-850B/C-870B/C
12
830B/C-850B/C-870B/C 30-477
12
INSPECTION AND REPAIR
1. Discard parts h, 1#, 1%, 1& thru 2), 2@, 2% and 2( and replace with new. If spring pad d was removed, discard and replace
with new.
2. Check the weight adjustment spring against those listed in “General Specifications.''
3. Shock absorber should withstand a pull test of 5000 lb (2267.5 kg), if not replace.
4. Check remaining parts for wear, cracks and damage and replace as necessary.
ASSEMBLY
1. Install new slide bumpers 2% into housing 3@. Install bracket j to housing with hardware 3) and 3! and torque nuts.
Nuts: 8 - 15 lbf ft (10.84 - 20.33 Nm)
Insert horizontal gear and shaft i through bracket and install knob 1! and secure with roll pin h.
2. Install new bushings 1# and bumpers 1& thru 2) into suspension arm 1). Install new bushings 2@ into shock absorber 2!. Coat
threads of spring washer f with fresh grease and thread vertical gear and shaft g all the way into washer and secure with
roll pin 2(. Lightly coat thrust washer 1^ and top of gear with fresh grease.
3. If removed, adhesive glue spring pad d to seat adjuster b. Position seat adjuster in press. Place weight adjustment spring
e on pad and center adjuster in press. Install suspension arm 1) into adjuster and connect with lower mounting shaft and
lock nut 2*. Torque nut.
Nut: 20 - 25 lbf ft (27.11 - 33.89 Nm)
Install shock absorber 2! into adjuster with shoulder bolt 2# and lock nut 2$. Torque nut.
Nut: 10 - 15 lbf ft (13.55 - 20.33 Nm)
Position vertical gear assembly on top of spring.
4. Position upper housing 3@ inserting sliding bumpers 1* and 2) in housing and meshing horizontal gear with vertical gear.
Slowly compress assembly until rear upper arm of suspension and shock absorber top mount align with mounting holes of
upper housing. Install upper mounting shaft 2& and secure with lock nut 2*. Torque nut.
Nut: 20 - 25 lbf ft (27.11 - 33.89 Nm)
5. Snap ride indicator 2^ onto front lower arm of suspension in line with hole in seat adjuster. Install roll pin c onto indicator
so it projects 0.38 in (9.652 mm) from front face of seat adjuster.
6. Glue top front corners of suspension boot 1$ to upper housing and secure with push-in fasteners 1%. Install instruction plate
1@ with two fasteners 1% through boot to seat adjuster.
30-478 830B/C-850B/C-870B/C
12
SEAT ADJUSTER
830B/C-850B/C-870B/C 30-479
12
LEGEND SEAT ADJUSTER
1. Slide track 8. Actuator lever

2. Lower housing 9. Push-on nut
3. Left side latch 10. Stop bolt
4. Right side latch 11. Stop bolt spacer
5. Latch rod 12. Actuator lever cap
6. Tension spring 13. Slide bearing
7. Latch link
DISASSEMBLY
1. Remove stop bolt 1) and spacer 1! from lower housing c. Unhook tension springs g from latches d and e and housing
and remove. Slide housing off track b.
2. Remove push-on nut j from actuator lever i and remove with latch link h. Do not remove lever cap 1@ from lever unless
3. Remove push-on nuts j from left and right side latches d and e. Remove latches with latch rod f and separate parts.
Remove push-on nuts j from bearing studs and remove bearings.
ASSEMBLY
1. Position slide bearings, dust seal side down, on studs and secure with push-on nuts j. Connect rod f to latches d and e
and mount to housing with nuts j.
2. If removed, install cap 1@ with adhesive to lever i. Position lever on housing and secure with push-on nuts. Connect link
h between lever and right side latch. Slide housing into track. Install tension springs g to housing and latches. Install stop
bolt 1) and spacer 1! to housing and torque.
Bolt: 50 - 55 lbf ft (67.79 - 74.57 Nm)
30-480 830B/C-850B/C-870B/C
DISASSEMBLY AND ASSEMBLY TILT STEERING CONSOLE
12
TILT STEERING CONSOLE
This will help prevent contamination from entering the component or
DISASSEMBLY
1. Remove access cover b from rear channel weldment c.
2. Remove bolt, flat washer and nylon bearing washer d from each end
of cross shaft. Loosen two set screws that secure lever cross shaft in
rear channel weldment.
3. Slide cross shaft out of levers e and console head and rear channel weldment
4. Tag and disconnect hoses b from steering (orbitrol) unit c. Plug hoses
to prevent contamination from entering hydraulic system
5. Disconnect sensor line hose to steering (orbitrol) unit, if applicable.
6. Turn horn button assembly b 120° in either direction and remove it

from steering wheel c.
7. Remove insulated spring retainer b, spring c, spring contact retainer

d and horn button retainer e from horn button f.
830B/C-850B/C-870B/C 30-481
12
8. Remove three screws b and ground contact plate c from steering
wheel d.
9. Remove nut b and steering wheel c from steering unit.
10. Remove harness clamp b holding harness c to rear channel

weldment d.
11. Loosen set screw b securing front channel weldment c to shaft d

located in base assembly e.
30-482 830B/C-850B/C-870B/C
12
12. Through holes “A”, loosen set screws that secure rear channel
weldment b to lower shaft c in base d.
13. Loosen set screws holding shafts c and e in bushing assemblies f

and g.
14. Remove shaft c and rear channel weldment from base.
15. Leave shaft e installed until later.
16. Remove turn signal switch b from steering unit column c.
17. Remove two pan head screws d and four oval head screws e and
instrument panel f from console head g.
18. Remove harness clamp b and harness spacer c from each side of
console head d.
19. Tag and disconnect all electrical leads from terminals and connectors.
Remark
To identify all electrical connections at this time which must
be disconnected is impractical for this shop manual to cover.
Connections vary greatly bases on gauges, switches and
accessories used with each grader. All electrical leads are
identified with a number band on the end of each wire. Refer
to the electrical schematic to determine appropriate
connections and hookups.
20. Remove retaining rings and lock mount pins b and console lock rods
c from base d.
830B/C-850B/C-870B/C 30-483
12
21. Remove retaining rings and lock mount pins b, and console lock rods
c from front channel weldment d.
22. Open slot with screw driver in release lever b and remove cable end c
and clip d from lock rod assembly e.
23. Repeat procedure for remaining lock rod assembly.
24. Remove clip b from end of each release cable c. Discard clip.
25. Remove turn signal flasher b, hour meter c and lock control
assembly d.
30-484 830B/C-850B/C-870B/C
26. Loosen jam nuts b and heavy flat washer c from side of console head.
27. Loosen hex nut b on short leg of U-bolt.
28. Remove shoulder bolt b and nylon bearing washer c from each side
of console head d. A piece of bar stock can be used on each side, to
help support steering assembly in console head.
29. Using a pry bar, remove nylon bearing washers b from between
steering assembly c and console head d.
830B/C-850B/C-870B/C 30-485
30. Remove knob b and heavy flat washer c from long leg of U-bolt.
31. Remove two support rods, steering assembly d and console head e
from front channel weldment.
32. Remove sensor line hose b from elbow c.
33. Remove heavy flat washer d and two hex nuts e from long leg of
U-bolt f.
34. Remove two hex nuts and flat washers g, steering lock plate h and
U-bolt from steering unit i.
35. Remove four bolts and flat washers b, mount bracket c, four
spacers d and column e from steering unit f.
Remark
Refer to appropriate section for serving the steering unit
“STEERING (ORBITOL) VALVE” on page 30-166.
36. Remove four connectors b from steering unit c.
37. Remove elbow d if equipped.
30-486 830B/C-850B/C-870B/C
12
38. Remove six split bearings b and weather seal c from console head d,
39. Remove relay b from front channel weldment c.
40. Remove lower shaft b and front channel weldment c from base d.
41. Remove split bearing b from each ear of front channel weldment c, if
830B/C-850B/C-870B/C 30-487
12
42. Remove three bolts and lock washers b and bearing assembly c from
base weldment d. Repeat procedure for three remaining bearing
assemblies.
30-488 830B/C-850B/C-870B/C
12
ASSEMBLY
1. Install four bearing assemblies c on base weldment d, with three lock
washers and bolts b.
Remark
Each bearing assembly consists of two bearing holders and
bearing.
2. Install one split bearing b in each ear of front channel weldment c.
3. Position front channel weldment c in base d and install lower shaft

b.
4. Secure outline relay b to front channel weldment c with two lock

washers, machine screws and nuts.
830B/C-850B/C-870B/C 30-489
12
5. Install six split bearing b in console head weldment d.
Remark
Install one split bearing in the end of each lever pivot (this
will use four). Install one in each side of console head in
steering unit pivot bosses.
6. Install weather seal c on console head.
7. Install four connectors b in steering unit c.

Remark
If grader IS NOT equipped with emergency brake and
auxiliary steering, install sensor line elbow d in side of
steering unit.
8. Position column e, four spacers d and mount bracket c on

steering unit f. Secure in place with four flat washers and bolts b.
Remark
Refer to “STEERING (ORBITOL) VALVE” on page 30-166
for service.
9. Position U-bolt f and steering lock plate h on steering unit i with

short leg on side with connectors. Install two flat washers and hex nuts
g on U-bolt. Leave hex nut on short leg flush with end of leg.
10. Install two hex nuts e and one heavy flat washer d on long leg. These
will be used as part of the tilt locking mechanism.
11. Install sensor line hose b on elbow c, if equipped.
30-490 830B/C-850B/C-870B/C
12
12. Using two pieces of bar stock as locating rods, position steering
assembly d in console head e.
13. Install remaining heavy flat washer c and knob b on long leg of
U-bolt.
14. Using a pry bar, position approximately three nylon bearing washers b
between steering assembly c and head d.
Use bar stock to help maintain alignment of all mount bolts.
15. Install one nylon bearing washer c and shoulder bolt b on each side
of console head d to secure steering assembly in position.
16. Tighten hex nut b on short leg of U-bolt c.

Remark
Short leg of U-bolt must not touch the inside of the console
head when steering unit is pivoted.
830B/C-850B/C-870B/C 30-491
12
17. Using hex nuts b as jam nuts, position heavy flat washer c against
inside of console head. Use jam nuts to maintain washer in this
position.
18. Check holding ability of tilt knob from preventing steering assembly
from pivoting. Adjust jam nuts if necessary.
19. Install turn signal flasher b and hour meter c.
20. Install lock control assembly d. Route release cable over steering
assembly as shown.
21. Install a clamp b on end of each control lock release cable c. Be sure
that long side of clip is towards cable sheath, as shown.
22. Attach cable end c and new clamp d to console lock rod assembly e.
23. Once cable end is seated in slot of release lever b, with a hammer,
peen the slot closed to prevent the cable from becoming disengaged.
24. Repeat procedure for remaining lock rod assembly.
30-492 830B/C-850B/C-870B/C
12
25. Secure console lock rods c in front channel weldment d with lock
mount pins and retaining rings b. Take note of the position of the
release cables.
26. Secure other ends of console lock rods c to base d with lock mount
pins and retaining rings b.
27. Secure harness spacer c and harness clamp b to console head d on

each side, to hold harness in position.
28. Connect all electrical leads as tagged during removal to appropriate

terminals and connectors.
Remark
To identify all electrical connections at this time which must
be made is impractical for this shop manual to cover.
Connections vary greatly based on gauges, switches and
accessories used with each grader. All electrical leads are
identified with a number band on the end of each wire. Refer
to the electrical diagram to determine appropriate
connections and hook-ups.
29. Attached steering console instrument panel f to console head g with

two pan head screws d and four oval head screws e.
30. Clamp turn signal switch b to steering unit column c.
830B/C-850B/C-870B/C 30-493
12
31. Position rear channel weldment b in base d. Align holes between
channel and base and install lower shaft c. Locate ends of shafts c
and e even with bushings f and g and tighten set screws.
32. Center rear channel in base and through holes “A” tighten set screws
to hold channel in position on shaft.
33. Center front channel weldment c with rear channel weldment and
base e. Tighten set screws b to secure front channel weldment to
shaft d.
34. Secure harness c to rear channel weldment d with harness clamp b.
35. Install steering wheel c and nut b on steering unit.
30-494 830B/C-850B/C-870B/C
12
36. Install ground contact plate c in steering wheel d with three screws
b.
37. Position horn button retainer e, spring contact retainer d, spring c

and insulated spring retainer b in horn button cover f.
38. Install horn button cover assembly b in steering wheel c. Turn

assembly 120° in either direction to lock assembly in wheel.
39. Connect four hydraulic hoses b to steering unit c as tagged during

removal.
40. Connect sensor line hose, if applicable.
830B/C-850B/C-870B/C 30-495
12
41. Install upper lever cross shaft and levers e.
Remark
A nylon bearing washer must be between each lever.
42. Tighten set screws to secure lever cross shaft to rear channel weldment
c. Install a nylon bearing washer, flat washer and bolt d on each end
of lever cross shaft.
43. Install access cover b on rear channel weldment.
30-496 830B/C-850B/C-870B/C
12
MEMORANDUM
830B/C-850B/C-870B/C 30-497
DISASSEMBLY AND ASSEMBLY AIR CONDITIONING
12
AIR CONDITIONING
AIR CONDITIONING SYSTEM ELECTRICAL DIAGRAM
30-498 830B/C-850B/C-870B/C
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AIR CONDITIONING SYSTEM DIAGRAM
1. Air conditioning under seat box 7. Tie strap 14. Hose clamp
2. Suction hose - A/C box (out) to
8. A/C hose clamp 15. A/C hose clamp
compressor (suction) (See Note 1)
3. A/C compressor 9. Condenser 16. Heater hose clamp
4. A/C compressor belt 10. Condenser hose to dryer (See Note 2) 17. Protective sleeves (20 in long)
5. Compressor hose to condenser (See
11. Hose clamp 18. Heater hose
Note 2)
6. Protective sleeve 12. Dryer/Receiver 19. A/C controls
13. Hose, dryer to A/C box (in) (See Note 1)
Note 1: Provide in evaporator hose kit.
Note 2: Provided in condenser hose kit.
830B/C-850B/C-870B/C 30-499
12
AIR CONDITIONING COMPRESSOR
REMOVAL
WARNING! ALWAYS wear eye and hand protection when working on Air Conditioning System. Liquid
A/C refrigerant can cause frostbite and/or blindness.
WARNING! AVOID breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes,
nose, and/or throat.
1. Disconnect electrical connections.
2. Evacuate R-134a from system.
3. Remove suction hose b and discharge hose c from compressor d,

then cap hoses and compressor ports to prevent dirt and moisture from
entering system.
4. Loosen one adjusting bolt e and two mounting bolts f, push on

compressor and remove belt g.
5. Remove mounting bolts e and f, then remove compressor d.
INSTALLATION
• Install compressor in reverse order of removal.
• Check pulley alignment and adjust to a maximum misalignment of 0.06 in.
• Charge system with R-134a gas see “AIR CONDITIONING SYSTEM CHARGING PROCEDURE” on page 30-535.
• Check compressor oil level, see “CHECKING COMPRESSOR OIL LEVEL” on page 30-537.
30-500 830B/C-850B/C-870B/C
12
COMPRESSOR CLUTCH SERVICE
GENERAL
All clutch service operations should be performed on the bench. The clutch includes a visible counterweight on the front plate
to improve dynamic balance.
24 Volt clutch replacement parts - P/N 1437 236 H91:
1. Accessory kit - nut, key, shims, snap rings, coil lead wire clamp with screw.
2. Rotor pulley & armature assembly with bearings.
3. Field coil.
CLUTCH REMOVAL
1. Insert the two pins of the front plate spanner into any two threaded
holes of the clutch front plate. Hold clutch plate stationary. Remove
hex nut with 3/4 in (19mm) socket.
2. Remove clutch front plate using puller. Align puller center bolt to
compressor shaft. Thumb tighten the three puller bolts into the
threaded holes.
Turn center bolt clockwise with 3/4 in (19mm) socket until front plate
is loosened.
830B/C-850B/C-870B/C 30-501
12
3. Remove shaft key by lightly tapping it loose with a slotted screw
driver and hammer.
4. Remove the internal bearing snap ring by using internal snap ring
pliers.
5. Remove the external front housing snap ring by using external snap
ring pliers.
Remark
On some later model clutches this step is not necessary as
the snap ring is below the bearing.
6. Remove rotor pulley assembly:

• Insert the lip of the jaws into the snap ring groove. (Snap ring
removed in Step 4.)
• Place rotor puller shaft protector (Puller set) over the exposed
shaft.
30-502 830B/C-850B/C-870B/C
12 • Align thumb head bolts to puller jaws and finger tighten.
• Turn puller center bolt clockwise using 3/4 in socket until rotor
pulley is free.
7. Remove field coil:

• Loosen coil lead wire from clip on top of compressor front
housing. (Earlier models do not use this clip.)
• Using external snap ring pliers, remove snap ring and field coil.
830B/C-850B/C-870B/C 30-503
12
CLUTCH INSTALLATION
1. Install field coil. Reverse the procedure outlined in Step 7 before.
2. Replace rotor pulley.

• Support the compressor on the four mounting ears at the
compressor rear. If using a vise, clamp only on the mounting
ears. . . never on the compressor body.
• Align rotor assembly squarely on the front housing hub.
• Using Rotor Installer Set, place the ring part of the set into the
bearing cavity. Make certain the outer edge rests firmly on the
rotor bearing inner race.
• Place the tool set driver into the ring as shown.
• With a hammer, tap the end of the driver while guiding the rotor to
prevent binding. Tap until the rotor bottoms against the
compressor front housing hub. Listen for a distinct change of
sound during the tapping process.
3. Reinstall internal bearing snap ring with pliers.
4. Reinstall external front housing snap ring with pliers.
30-504 830B/C-850B/C-870B/C
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5. Replace front plate assembly:
• Check that original clutch shims are in place on compressor shaft.
• Replace compressor shaft key.
• Align front plate keyway to compressor shaft key.
• Using Shaft Protector, tap front plate to shaft until it has bottomed
to the clutch shims. Note distinct sound change.
6. Replace shaft hex nut.
25 - 30 lbf ft (33.8 - 40.6 Nm)
7. Check air gap with feeler gauge. Standard is 0.016 in to 0.031 in. If air
gap is not consistent around the circumference, lightly pry up on the
counter-weighted front plate at the low spots. Lightly tap down at the
high spots.
Remark
The air gap is determined by the spacer shims. When
reinstalling or installing a new clutch assembly, try the
original shims first.
If the air gap does not meet the specification in Step 7, add or subtract
shims by repeating Steps 5 and 6.
COMPRESSOR BELT TENSION
1. Adjust initial belt tension to 121 ±5 lbf (538.2 ±22.2 N) using tension
gauge.
2. Check pulley alignment and adjust to no more than 0.060 in

misalignment per 1 ft span between pulleys. Maximum deflection at
“A” should be 0.25 in.
3. After “run-in”, with the belt hot, retention if below 50 lb (222 N).
Retention the belt to 90 lb if it is cold.
Remark
Be extremely careful not to break seal or damage
compressor housing when using a pry tool.
Remark
After putting compressor back into system, see “AIR CONDITIONING SYSTEM CHARGING PROCE-
DURE” on page 30-535.
830B/C-850B/C-870B/C 30-505
12
RECEIVER/DRYER
SERVICE
The service indicator, located on top of receiver/dryer, is a 0.25 in (7 mm)
diameter sight glass. The sight glass should be blue. Pink indicates
receiver/dryer should be replaced.
REMOVAL
1. Remove radiator grille, see “ENGINE HOOD, FRONT & REAR

COWLING” on page 30-48 - REMOVAL in this section.
2. Evacuate R-134a from system.
3. Remove receiver/dryer b and bracket c, by removing three bolts d

from hood. To separate receiver/dryer b from bracket c remove one
bolt e.
4. Disconnect condenser to dryer hose f and dryer to A/C box hose g.

Cap hoses to prevent dirt and moisture from entering system.
INSTALLATION
• Install receiver/dryer in reverse order of removal.
• Mount receiver/dryer with flow arrow on body in direction shown.
• Charge system with R-134a gas, see “AIR CONDITIONING SYS-
TEM CHARGING PROCEDURE” on page 30-535.
30-506 830B/C-850B/C-870B/C
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CONDENSER
REMOVAL
1. Remove radiator grille, see “ENGINE HOOD, FRONT & REAR

COWLING” on page 30-48 - REMOVAL in this section.
2. Evacuate R134a from system.
3. Disconnect compressor discharge to condenser hose b and condenser

to receiver/dryer hose c. Cap hoses and condenser ports to prevent
dirt and moisture from entering system.
4. Remove four mounting bolts d and take condenser e out of machine.
INSTALLATION
• Install condenser in reverse order of removal.
• Charge system with R-134a gas, see “AIR CONDITIONING SYS-
TEM CHARGING PROCEDURE” on page 30-535.
• Use caution not to damage any fins on condenser.
830B/C-850B/C-870B/C 30-507
12
AIR CONDITIONER/HEATER UNIT
ELECTRICAL DIAGRAM
30-508 830B/C-850B/C-870B/C
12
ASSEMBLY DIAGRAM
830B/C-850B/C-870B/C 30-509
12
1. Core gasket 16. Lock washer - internal tooth 31. Tor head bolt
2. Heater core 17. Water valve cable 32. Blower assembly
3. Flat washer 18. Jam nut 33. A/C connector tube
4. Bolt 19. Heater - A/C Control knob 34. Low pressure switch
5. Hose clamp 20. Temperature decal 35. A/C connector tube
6. Heater valve 21. Master switch 36. High pressure switch
7. Name plate decal 22. Fan switch 37. O-ring
8. R134a caution decal 23. Centering washer 38. O-ring
9. A/C box case 24. Resistor mounting (rubber) washer 39. Expansion valve
10. Drain tube 25. Resistor 40. O-ring
11. Heater/evaporator decal 26. Bolt 41. Evaporator coil
12. Lock washer 27. Bolt with lock washer
13. Jam nut 28. Freeze control switch
14. Barb fitting 29. Relay
15. O-ring 30. Grommet (rubber)
30-510 830B/C-850B/C-870B/C
12
REMOVAL
WARNING! AVOID breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate
eyes, nose, and/or throat
1. Evacuate R134a from system.
2. Remove operator’s seat fastened by two bolts b to cables at rear cab

wall, and four bolts and washers c that mount seat to A/C case top.
3. Remove eight 3/8 in flat head screws and eight 3/8-16 hex head screws
to remove the A/C box cover.
4. Disconnect heater and A/C hoses and electrical connections (not

shown).
5. Remove eight bolts that secure A/C / heater box to the cab floor plate
(not shown).
6. Remove air conditioner/heater box.
INSTALLATION
• Install air conditioner/heater box in reverse order of removal.
• Use new gaskets on the bottom of box, on floor plate and A/C duct.
• Make sure that the top box coil gasket is installed flat, across the whole top of the box.
• Charge system with R-134a gas, see “AIR CONDITIONING SYSTEM CHARGING PROCEDURE” on page 30-535.
• Use caution not to damage lunch box and cup holder tray when reinstalling.
830B/C-850B/C-870B/C 30-511
12
ASSEMBLY
Remark
Komatsu highly recommends replacement of old O-rings and
gaskets with new O-rings and gaskets when reassembling
Air Conditioner/Heater unit.
1. Place unit case weldment on blocks in work area, clean and visually
inspect and repair any damage before beginning any work.
2. Clean weld nut threads with a 1/4-20 tap.
3. Remove paint, oil, or grease from four screw holes in case for diffusers
with a 1/8 in drill bit.
4. Attach case bottom gasket with adhesive. Apply pressure to entire

surface of gasket to ensure adhesive bonds to case.
30-512 830B/C-850B/C-870B/C
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5. Remove jam nut that comes supplied with water valve cable.
6. Install switch on water valve cable. Cable must be positioned inside

bracket as shown.
7. Thread one 7/16 in jam nut onto water valve cable.
71 lbf in (8 Nm)
8. Attach rocker gasket to rocker blower switch.
830B/C-850B/C-870B/C 30-513
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9. Install rocker blower switch to switch plate.
10. Attach rocker gasket to rocker master switch.
11. Install rocker master switch to switch plate.
12. Install switch assembly with water valve cable to case.
30-514 830B/C-850B/C-870B/C
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13. Connect wire harness to rocker switches.
• Wire harness with red wires (A) connects to rocker master switch.
• Wire harness leads with yellow wires (B) connects to rocker
blower switch.
14. Make sure corner tab on harness plugs are matched with hole in rocker
switches. Push plugs in as far as possible.
15. Insert wire harness through grommet hole.
16. Run main harness through case.
830B/C-850B/C-870B/C 30-515
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17. Harness to extend a minimum 8 inches (200 mm) outside of case.
18. Attach heater block-off gasket to case bottom gasket. Apply pressure
to entire surface to ensure adhesive bonds to case bottom gasket.
19. Place drip tray on table, clean grease, oil, dirt, old silicone, and repair
any damage.
20. Seal all 4 corners of drip tray using silicone gun with black silicone
(Komatsu part #1232 251 H1). Using your finger, smooth silicone
fully in each corner to completely seal corner gaps.
30-516 830B/C-850B/C-870B/C
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21. Attach drain pan gasket to bottom of drip tray. Apply pressure to entire
surface of gasket to ensure adhesive to drip tray.
22. Place drip tray inside case, on top of gasket.
23. Place evaporator coil on table. Inspect for flat spots, if any found
straighten using appropriate size fin comb.
24. Wrap both ends of evaporator coil u-bends with insulation tape.
Remark
This type of insulation tape must not be stretched before
attaching or it will shrink, causing it to return to it’s original
size and shape.
830B/C-850B/C-870B/C 30-517
12
25. Place heater core on table. Inspect for flat spots, if any found
straighten using appropriate size fin comb. Then place heater core on
top of evaporator coil.
26. Secure coils together with four flat washers (M6) and four hex head
bolts (M6 X 16 mm).
9 lbf ft (12 Nm) with 10 mm socket
27. Remove protective caps from evaporator coil tube outlets. Lightly coat
two #8 O-rings with refrigeration oil and place on tube outlets, one
O-ring for each tube outlet.
28. Install expansion valve (R134a) to evaporator tube outlets.
12 lbf ft (16.27 Nm) with 3/4 in crows foot
30-518 830B/C-850B/C-870B/C
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29. Remove cap from A/C connector tube, and lightly coat #6 green
O-ring with refrigeration oil, then install on tube fitting.
Remark
O-rings must be kept in sealed container until time of
installation.
30. Inspect A/C connector tube fitting for O-ring. Lightly coat O-ring with
refrigeration oil.
31. Remove caps from A/C connector tube, and lightly coat #10 O-ring
with refrigeration oil, then install on tube fitting.
Remark
O-rings must be kept in sealed container until time of
installation.
32. Inspect A/C connector tube fitting for O-ring. Lightly coat O-ring with
refrigeration oil.
830B/C-850B/C-870B/C 30-519
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33. Install both A/C tube connectors and to expansion valve.
• Install A/C connector tube to small port opening in expansion
valve.
12 lbf ft (16 Nm) with 5/8 in crows foot
• Install A/C connector tube to large port opening in expansion

valve.
30 lbf ft (41 Nm) with 7/8 in crows foot
34. Clean weldnut threads with M6 tap, and install right side weldment
inside case on side shown.
35. Install 24 volt relay to right side weldment with one M6 hex screw and
M6 flat washer.
36. Install freeze control switch to right side weldment with two #8- 32
hex screws and two #8 spring lock washers. Freeze control switch
must be positioned as shown.
10.5 lbf in (1.18 Nm) with 1/4 in socket
30-520 830B/C-850B/C-870B/C
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37. Secure right side weldment to case with four M6 tor head screws.
45 lbf in (5 Nm) with Apex 49TX3 tor head bit
38. Clean weldnut threads with M6 tap, and install left side weldment
inside case on side shown.
39. Secure left side weldment to case with four M6 tor head screws.
5 lbf in (5 Nm) with Apex 49TX3 tor head bit
40. Attach cable block-off gasket to right side weldment. Apply pressure
to entire surface of gasket to ensure adhesive bonds to right side
weldment.
830B/C-850B/C-870B/C 30-521
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41. Install two coil retaining angles to case with four M6 hex screws and
four M6 flat washers.
42. Install coils inside case.
43. Slide evaporator coil end plates between slots in both coil retainer
angles. Push coils all the way down until they are resting on drip tray
and core gasket.
44. Insert heater coil tube (A) outlet and both A/C connector tubes (B and
C) through openings in case bottom
30-522 830B/C-850B/C-870B/C
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45. Wrap expansion valve with insulation tape.
Remark
This type of insulation tape must not be stretched before
attaching or it will shrink, causing it to return to it’s original
size and shape.
46. Insert water valve tube assembly tube outlet through opening in case
bottom.
47. Loosen cable clip screw on water valve using 5/16 in nut driver. Install
eyelet from water valve cable to water valve stem. Place cable clip
over cable, push cable all the way over as far as possible and secure
screw in cable clip. Then install compression clip to water valve stem
using pliers.
48. Install Heater-A/C control knob to water valve cable. Use control knob
to open and close cable to make sure cable works properly.
830B/C-850B/C-870B/C 30-523
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49. Install two Oetiker hose clamps (with bump side up) on 4 in
(101.6 mm) blue stripe hose, placing one end of hose on water valve
tube outlet. Place opposite end to heater coil tube outlet.
50. Tighten hose clamps using hose clamp crimper.
51. With a tape measure determine correct location of thermostat probe.

• 120 mm (4.72 in) From end plate.
• 20 mm (0.79 in) From inside edge of evaporator coil.
52. Measure capillary tube starting from tip @ 130 mm (5.12 in) and bend
at that point. Insert capillary tube all the way down to bend, in location
determined in step 51. Carefully roll capillary tube and lay flat against
top of coil.
Remark
If capillary tube is bent too sharp, tube may break causing it
to fail.
30-524 830B/C-850B/C-870B/C
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53. Attach core gasket to top of evaporator coil.
54. Install high pressure switch (A) to A/C connector tube.
45 lbf in (5 Nm) with 9/16 in crows foot
55. Install low pressure switch (B) to A/C connector tube.
71 lbf in (8 Nm) with 5/8 in crows foot
56. Connect matching harness leads to freeze control terminals.
57. Connect matching harness leads to relay.
830B/C-850B/C-870B/C 30-525
12
58. Connect matching harness plugs to high and low pressure switches.
Listen for “click” sound to verify high and low switches are properly
connected.
59. Place one M6 flat washer on long hex screw. Run long hex screw
through resistor bracket on case. Place one rubber resistor washer and
one indented centering washer on hex screw.
60. Place resistor inside bracket and run long hex screw through resistor.
Place second indented centering washer and second rubber resistor
washer on opposite end of resistor.
61. Thread end of long screw in weldnut on end of resistor bracket.

Tighten screw with 7/16 in deep well socket until resistor is snug
between rubber washers, but can still be turned by hand.
62. Attach wire leads to resistor terminals as shown.

Top Gray
Middle Green
Bottom Blue
63. Install four louvers to case with eight flat Phillips head screws.
10.5 lbf in (1.19 Nm)
30-526 830B/C-850B/C-870B/C
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64. Install one grommet around wire harness and in grommet hole.
65. Stand case up, with back side facing front.
66. Attach heater evaporator decal to case bottom.
67. Blue side of decal is positioned next to evaporator tubes and red side
positioned next to heater tube outlets.
830B/C-850B/C-870B/C 30-527
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68. Install 5/8 in internal tooth lock washer on small evaporator tube
outlet.
69. Install 7/8 in internal tooth lock washers on remaining three tube
outlets.
70. Install one 5/8 in hex jam nut on small evaporator tube outlet.
12 lbf ft (16 Nm) with 15/16 in crows foot.
71. Install three 7/8 in hex jam nut on remaining three tube outlets.
12 lbf ft (16 Nm) with 1 1/8 in crows foot.
72. Remove protective caps from two 5/8 in barb fittings.
73. Lightly coat and install two #10 O-rings, one for each barb fitting.
Remark
All O-rings must be kept in sealed container until time of
installation.
74. Install both barb fittings to heater tube outlets, position as shown, and
hand tighten.
30-528 830B/C-850B/C-870B/C
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75. Install two drain tubes in drain holes in case bottom.
76. Attach one 24 in (610 mm) piece of seal to one outlet plate. Seal must
be attached to side of plate shown. Repeat this step for second outlet
plate.
77. Install both outlet plates, one on each side of case.
78. Secure out plates to case with 1/4-20 hex screws and M6 flat washers.
45 lbf in (5 Nm) with 7/16” socket.
79. Attach one R134a caution decal to side of case as shown.
830B/C-850B/C-870B/C 30-529
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80. Place 24 volt motor on table, then cut motor leads to 12 in (304.8 mm)
length using wire cutter.
81. Remove approximately ½ in (12.7 mm) of plastic coating from ends of

motor leads using a wire stripper, then install two pin terminals to end
of motor leads. Secure pin terminals to motor leads using crimper.
82. Install motor lead terminals to motor plug. Orange lead must be
inserted in plug hole #1, and black ground motor lead must be inserted
in plug hole #2.
83. Install motor plug wedge inside motor plug using screwdriver.
30-530 830B/C-850B/C-870B/C
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84. Install motor mounting gasket on motor.
85. Install mounting bracket, secure with two flat washers and two 10-32
hex nuts.
20 lbf in (2.25 Nm) with 3/8 in socket.
86. Install orifice ring on motor bracket. Orifice ring must be positioned as
shown.
87. Install blower wheel to motor shaft. Push blower wheel all the way
down until it bottoms out on motor shaft.
830B/C-850B/C-870B/C 30-531
12
88. Install compression clip to blower wheel hub using pliers. Spin blower
wheel to ensure wheel will not rub.
89. Install motor assembly inside blower weldment. Motor lead must be
positioned as shown.
90. Install second motor mounting bracket on top of motor. Secure motor
and bracket to blower with three M6 flat washers and three M6 nylon
locknuts.
40 lbf in (4.5 Nm) with 7/16” socket.
91. Install two blower assemblies to case. Slide blower weldment behind
angles on right and left side weldments.
30-532 830B/C-850B/C-870B/C
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92. Connect motor plugs to matching harness plugs. Listen for “click”
sound to make sure plugs have been properly connected.
93. Secure water valve cable and motor leads to A/C connector tube with
two tie straps. Trim ties using bar-loc installation tool.
94. Clean four weldnut threads on cover using 1/4-20 tap.
95. Attach top coil gasket to cover. Apply pressure to entire surface of
gasket to ensure adhesive bonds to cover.
830B/C-850B/C-870B/C 30-533
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96. Install cover to case and install four 1/4-20 hex screws with four M6
flat washers.
45 lbf in (5 Nm) with 7/16 in socket.
97. Secure cover to case with eight 3/8 in flat head screws and eight 3/8-16
hex screws.
9 lbf ft (12 Nm) with 9/16 in socket.
98. Attach combo decal to cover, position decal as shown.
30-534 830B/C-850B/C-870B/C
12
AIR CONDITIONING SYSTEM CHARGING PROCEDURE
WARNING! DO NOT pressure or leak test Air Conditioning System with compressed air. Some
mixtures of air and refrigerant are explosive.
WARNING! DO NOT remove protective caps from compressor, air conditioner/heater box,
condenser, receiver/dryer connections, and hose ends until connections are made to
prevent dirt and moisture contamination. Moisture in the Air Conditioning System can
cause major damage.
Equipment and Supplies Required
• R-134a Gauge Set and Vacuum Pump

Equipment • Electronic Leak Detector
• Small Graduated Cylinder
• R-134a Refrigerant
Remark
Supplies
Komatsu highly recommends the use of brand names.
• Sanden SP-20 compressor oil.
1. Connect R-134a manifold gauge set to A/C system. Connect vacuum pump to gauge set. Air conditioner system must be
evacuated to 29.2 inches HG for at least 45 minutes before charging to ensure removal of any moisture in the system. 15
minutes into evacuation, close valves and not vacuum pressure. If after 15 minutes, the pressure hasn’t changed, evacuate
the system for 30 more minutes. If the pressure has changed, system has a leak.
Remark
Warmer ambient conditions require longer evacuation times.
2. After the system has been evacuated for a minimum of 45 minutes, close both high and low manifold gauge valves and
disconnect vacuum pump.
3. Connect yellow hose to refrigerant canister. Open valve on canister. Loosen fitting at manifold gauge set to purge air from
yellow line, then retighten.
4. Place canister on a scale and record weight.
5. Open valves on gauge set to allow refrigerant into system.
6. Monitor refrigerant charge on scale. Charge system to 3 lb 12 oz of R-134a refrigerant. When correct weight has been
obtained, close valve on canister, then close manifold valve.
Remark
Follow handling procedures and check MSDS.
7. Perform a preliminary electrical check. Turn ignition key to “ON” position, DO NOT start engine. Check for proper fan
operation in “Heat” and “A/C mode”. Check for clutch engagement in A/C mode.
8. When refrigerant flow stops, close the high side valve and start engine and run at idle. Set air conditioner controls to high
fan and coldest thermostat setting.
830B/C-850B/C-870B/C 30-535
12
Remark
Prior to operating, use electronic leak detector to check for leaks at the following locations:
• O-Ring Connections
• Hose Clamps
• Receiver Dryer
• Sight Glass
• Moisture Indicator
• Ports
• High Pressure Pop Off Valve
• Compressor Front Seal
• Compressor Rear Gasket
9. After checking items in step 8, an easy check of evaporator unit is to test for refrigerant at the condensate tubes.
Remark
Water may give a false indication of a refrigerant leak.
10. Shut engine down, and remove gauge set. Charging is complete.
30-536 830B/C-850B/C-870B/C
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CHECKING COMPRESSOR OIL LEVEL
1. It is not necessary to check the oil level as a routine maintenance. However, there are circumstances which warrant this
inspection:
• Whenever a system component has been replaced.
• An oil leak is suspected.
• Whenever it is specified as a diagnostic procedure.
2. If an inspection is warranted, after repairs have been made precede with the following procedures.
Remark
A standard rule is if a major component is replaced, such as a evaporator, condenser, or dryer, add 1 fl. oz.
(25 ml) of Sanden SP20 (R-134a compatible) refrigerant oil.
3. Run compressor for 10 minutes with engine at idle speed.
4. Recover all refrigerant from system. Be careful not to loose oil.
5. Determine the compressor mounting angle.

• Position angle gauge across flat surfaces of two front mounting ears.
• Center bubble.
• Read mounting angle to the closest degree. (This will be important in step 9).
6. Remove oil filler plug. To determine if compressor is mounted right or left. Rotate counterweight located on front clutch
until it is at the angle shown relative to oil filler hole.
7. Insert dipstick to its stop position. The stop is the angle near top of dipstick.
• Point of angle must be to left if mounting angle is to right.
• Point of angle must be to right if mounting angle is to left.
• Seat and O-Ring must be clean.
8. Remove dipstick. Count increments of oil.
9. If the increments read on dipstick do not match table, add or subtract oil to mid-range value. For example, if mounting
angle is 10, add oil in 1 fl. oz. (29.6 ml) increments until 7 is read on dipstick.
Remark
Follow handling procedures and check MSDS.
10. Replace oil fill plug. First check that sealing ring is not twisted or damaged.
14.5 ± 3.59 lbf ft (19.6 ± 4.88 Nm)
Remark
DO NOT over tighten oil filler plug to stop a leak. If plug leaks, replace O-ring with new.
830B/C-850B/C-870B/C 30-537
12
MEMORANDUM
30-538 830B/C-850B/C-870B/C
40 MAINTENANCE STANDARD
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-2

NO SPIN DIFFERENTIAL CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3
NO SPIN DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4
FINAL DRIVE AND TANDEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-5
TANDEM DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-6
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-7
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-8
LEANING WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-9
MOLDBOARD TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10
MOLDBOARD SIDE SHIFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11
DRAWBAR SIDE SHIFT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-12
DRAWBAR LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-13
SCARIFIER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-14
ARTICULATION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-15
RIPPER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-16
LUG NUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-17
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-18
POWER TILT MOLDBOARD CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-19
FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20
DRAWBAR AND CIRCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21
DRAWBAR LIFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22
ENGINE AND TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23
DRIVE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-24
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-25
CAB MOUNT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-26
830B/C-850B/C-870B/C 40-1
MAINTENANCE STANDARD FINAL DRIVE
12
FINAL DRIVE
TORQUE TORQUE
NUMBER BOLT DESCRIPTION
Nm lbf ft
1 Parking brake disc to yoke 60.8 - 67.7 45 - 50
2 Parking brake mounting bracket to differential case 60.8 - 67.7 45 - 50
Tandem sleeve retainer to tandem sleeve
3 16 bolts per side 53.9 - 60.8 40 - 45
18 bolts per side 67.7 50
4 Tandem sleeve to differential case 264 195
40-2 830B/C-850B/C-870B/C
MAINTENANCE STANDARD NO SPIN DIFFERENTIAL CASE ASSEMBLY
12
NO SPIN DIFFERENTIAL CASE ASSEMBLY
TORQUE TORQUE
NUMBER BOLT/NUT DESCRIPTION
Nm lbf ft
1 Castlenut to pinion gear 305 - 407 225 - 300
2 Differential bearing quills to differential case 89.2 66
3 Input quill cover to differential case 310 228
830B/C-850B/C-870B/C 40-3
MAINTENANCE STANDARD NO SPIN DIFFERENTIAL ASSEMBLY
12
NO SPIN DIFFERENTIAL ASSEMBLY
TORQUE TORQUE
Nm lbf ft
1 Housing to ring gear 298.1 220
2 Differential cover to housing 115.7 85
40-4 830B/C-850B/C-870B/C
MAINTENANCE STANDARD FINAL DRIVE AND TANDEMS
12
FINAL DRIVE AND TANDEMS
TORQUE TORQUE
Nm lbf ft
1 Final drive to frame 786.5 580
2 Final drive to tandem case 203 (dry) 150 (dry)
830B/C-850B/C-870B/C 40-5
MAINTENANCE STANDARD TANDEM DRIVE
12
TANDEM DRIVE
TORQUE TORQUE
NUMBER BOLT/NUT DESCRIPTION
Nm lbf ft
1 Axle nut to axle shaft weldment 2,643.8 1,950
2 Wheel bearing retainer to bearing housing 94.9 70
3 Bearing housing to tandem case 94.9 70
40-6 830B/C-850B/C-870B/C
MAINTENANCE STANDARD BRAKE VALVE
12
BRAKE VALVE
TORQUE TORQUE
Nm lbf ft
1 Brake valve body connecting bolts 33.9 25
830B/C-850B/C-870B/C 40-7
MAINTENANCE STANDARD STEERING CYLINDER
12
STEERING CYLINDER
TORQUE TORQUE
NUMBER DESCRIPTION
Nm lbf ft
1 Rod nut 244.0 180
40-8 830B/C-850B/C-870B/C
MAINTENANCE STANDARD LEANING WHEEL CYLINDER
12
LEANING WHEEL CYLINDER
TORQUE TORQUE
NUMBER DESCRIPTION
Nm lbf ft
1 Rod nut 542.3 400
830B/C-850B/C-870B/C 40-9
MAINTENANCE STANDARD MOLDBOARD TILT CYLINDER
12
MOLDBOARD TILT CYLINDER
TORQUE TORQUE
NUMBER DESCRIPTION
Nm lbf ft
1 Rod nut 244.0 180
40-10 830B/C-850B/C-870B/C
MAINTENANCE STANDARD MOLDBOARD SIDE SHIFT
12
MOLDBOARD SIDE SHIFT
TORQUE TORQUE
NUMBER DESCRIPTION
Nm lbf ft
1 Rod nut 542.3 400
830B/C-850B/C-870B/C 40-11
MAINTENANCE STANDARD DRAWBAR SIDE SHIFT CYLINDER
12
DRAWBAR SIDE SHIFT CYLINDER
TORQUE TORQUE
NUMBER DESCRIPTION
Nm lbf ft
1 Rod nut 542.3 400
40-12 830B/C-850B/C-870B/C
MAINTENANCE STANDARD DRAWBAR LIFT CYLINDER
12
DRAWBAR LIFT CYLINDER
TORQUE TORQUE
NUMBER DESCRIPTION
Nm lbf ft
1 Rod nut 542.3 400
830B/C-850B/C-870B/C 40-13
MAINTENANCE STANDARD SCARIFIER CYLINDER
12
SCARIFIER CYLINDER
TORQUE TORQUE
NUMBER DESCRIPTION
Nm lbf ft
1 Rod nut 386.4 285
40-14 830B/C-850B/C-870B/C
MAINTENANCE STANDARD ARTICULATION CYLINDER
12
ARTICULATION CYLINDER
TORQUE TORQUE
NUMBER DESCRIPTION
Nm lbf ft
1 Rod nut 542.3 400
830B/C-850B/C-870B/C 40-15
MAINTENANCE STANDARD RIPPER CYLINDER
12
RIPPER CYLINDER
TORQUE TORQUE
NUMBER DESCRIPTION
Nm lbf ft
1 Rod nut 677.9 500
40-16 830B/C-850B/C-870B/C
MAINTENANCE STANDARD LUG NUTS
12
LUG NUTS
TORQUE TORQUE
NUMBER DESCRIPTION
Nm lbf ft
Front axle lug nuts/non- AWD 155.9 115
1
Front axle lug nuts/AWD 149 110
2 Rear axle lug nuts 155.9 115
830B/C-850B/C-870B/C 40-17
MAINTENANCE STANDARD FRONT AXLE
12
FRONT AXLE
TORQUE TORQUE
NUMBER DESCRIPTION
Nm lbf ft
1 Planetary carrier to gear box bolts (AWD units only) 155.9 115
2 Socket assembly - end nut 230.5 170
3 Steering cylinder - rod end 230.5 170
4 Steering cylinder - base end 174.5 129
5 Nut: Steering yoke to axle, tie bar, leaning wheel cylinder 669.8 494
40-18 830B/C-850B/C-870B/C
MAINTENANCE STANDARD POWER TILT MOLDBOARD CARRIER
12
POWER TILT MOLDBOARD CARRIER
TORQUE TORQUE
NUMBER DESCRIPTION
Nm lbf ft
1 Moldboard shift cylinder bolt 467.8 345
2 Moldboard tilt pivot locknut 183.4 135
3 Upper slide rail wear pad bolts 454.0 335
4 Moldboard pivot locknut 407.0 300
830B/C-850B/C-870B/C 40-19
MAINTENANCE STANDARD FRAME
12
FRAME
TORQUE TORQUE
NUMBER DESCRIPTION
Nm lbf ft
1 Frame pivot pin caps to front axle 379.5 280
2 Articulation cylinders to frame 38.2 28
3 Articulation joint to frame 190.2 140
40-20 830B/C-850B/C-870B/C
MAINTENANCE STANDARD DRAWBAR AND CIRCLE
12
DRAWBAR AND CIRCLE
TORQUE TORQUE
NUMBER DESCRIPTION
Nm lbf ft
1 Drawbar to frame 528.6 390
2 Circle shoe bolts 616.8 455
830B/C-850B/C-870B/C 40-21
MAINTENANCE STANDARD DRAWBAR LIFT
12
DRAWBAR LIFT
TORQUE TORQUE
NUMBER DESCRIPTION
Nm lbf ft
1 Lift cylinder to yoke 190.2 140
2 Yoke to suspension arm 110.8 82
3 Lock pin cylinder to link 133.4 98
4 Suspension arm to frame 325.6 240
5 Suspension arm to link 325.6 240
40-22 830B/C-850B/C-870B/C
MAINTENANCE STANDARD ENGINE AND TRANSMISSION
12
ENGINE AND TRANSMISSION
TORQUE TORQUE
Nm lbf ft
1 Transmission mounting bracket to frame 216.7 160
2 Transmission to mounting bracket (patch bolt and flat washer) 325.6 240
3 Engine support to frame 216.7 160
4 S6D114E-1 engine to engine support 108.8 80
5 S6D102E-1 engine to engine support 190.2 140
830B/C-850B/C-870B/C 40-23
MAINTENANCE STANDARD DRIVE LINE
12
DRIVE LINE
TORQUE TORQUE
Nm lbf ft
1 Flywheel to converter drive plate 51.5 38
2 Drive shaft to output and input yokes 108.5 80
3 Transmission output yoke retainer to output shaft 230.5 170
4 Transmission housing to engine 55.6 41
5 Ring to converter 42.0 31
40-24 830B/C-850B/C-870B/C
MAINTENANCE STANDARD ALTERNATOR
12
ALTERNATOR
TORQUE TORQUE
NUMBER DESCRIPTION
Nm lbf ft
1 Alternator pulley nut 95.1 - 108.8 70 - 80
830B/C-850B/C-870B/C 40-25
MAINTENANCE STANDARD CAB MOUNT
12
CAB MOUNT
TORQUE TORQUE
NUMBER DESCRIPTION
Nm lbf ft
1 Cab mount bolts (ALL six) 271.1 200
40-26 830B/C-850B/C-870B/C
90 OTHERS
ORIGINAL ELECTRICAL DIAGRAM (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3

REVISED ELECTRICAL DIAGRAM (Sheet 1 Part 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
REVISED ELECTRICAL DIAGRAM (Sheet 1 Part 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
REVISED ELECTRICAL DIAGRAM (Sheet 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
800 TRANSMISSION WITH AWD DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15
HYDRAULIC CIRCUIT DIAGRAM (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17
HYDRAULIC CIRCUIT DIAGRAM (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19
Remark
The following items are incorporated into the production graders at the Serial Numbers (S/N)
specified. The referenced Parts and Service News (P&SN) numbers could be referenced for
earlier machines that were modified. Use the REVISED ELECTRICAL DIAGRAM foldouts 5, 6
and 7.
1. S/N 202844 and UP - P&SN AA97032

Provide time delay switch to prevent indication of low transmission oil pressure signal when shifting
transmission.
2. S/N 202844 and UP - P&SN AA98025

Add flasher to differential oil filter warning circuit to distinguish warning light meaning from transmission filter
warning. One light serves two functions; a continuous light indicates change transmission filter and a flashing
warning light means change differential filter.
3. S/N 203241 and UP - P&SN AA97179

Add diode to AC compressor clutch to prevent surges from affecting other components.
4. S/N 203474 and UP - P&SN AA97185B

Starting circuit change to assure starter disengagement.
5. S/N 203918 and UP - P7SN AA99121A

Heater source change from Eagle to Bergstrom.
6. S/N 210242 and UP - AA02003 - Komatsu brand GD530B & C, GD650B & C and GD670B & C
S/N 210514 and UP - AA01211 - Galion brand 830B & C, 850B & C and 870B & C
Parking brake circuit change with “U” gate shifter. Engages parking brake when shifter handle placed in park.
7. S/N 210655 and UP - AA01001A

Change engine oil pressure switch and add Hour meter circuit.
8. S/N 210877 and UP - P&SN AA02067

Addition of brake light relay.
830B/C-850B/C-870B/C 90-1
OTHERS
12
MEMORANDUM
90-2 830B/C-850B/C-870B/C
OTHERS FOLDOUT 1
12
ORIGINAL ELECTRICAL DIAGRAM (Sheet 1 of 3)
830B/C-850B/C-870B/C 90-3
OTHERS MEMORANDUM
MEMORANDUM
90-4 830B/C-850B/C-870B/C
OTHERS FOLDOUT 2
12
830B/C-850B/C-870B/C 90-5
OTHERS MEMORANDUM
12
MEMORANDUM
90-6 830B/C-850B/C-870B/C
OTHERS FOLDOUT 3
12
830B/C-850B/C-870B/C 90-7
OTHERS MEMORANDUM
12
MEMORANDUM
90-8 830B/C-850B/C-870B/C
OTHERS FOLDOUT 4
12
REVISED ELECTRICAL DIAGRAM (Sheet 1 Part 1 of 2)
830B/C-850B/C-870B/C 90-9
OTHERS MEMORANDUM
MEMORANDUM
90-10 830B/C-850B/C-870B/C
OTHERS FOLDOUT 5
12
REVISED ELECTRICAL DIAGRAM (Sheet 1 Part 2 of 2)
830B/C-850B/C-870B/C 90-11
OTHERS MEMORANDUM
MEMORANDUM
90-12 830B/C-850B/C-870B/C
OTHERS FOLDOUT 7
12
REVISED ELECTRICAL DIAGRAM (Sheet 2)
830B/C-850B/C-870B/C 90-13
OTHERS MEMORANDUM
12
MEMORANDUM
90-14 830B/C-850B/C-870B/C
OTHERS FOLDOUT 9
12
800 TRANSMISSION WITH AWD DIAGRAM
830B/C-850B/C-870B/C 90-15
OTHERS MEMORANDUM
12
MEMORANDUM
90-16 830B/C-850B/C-870B/C
OTHERS FOLDOUT 8
12
HYDRAULIC CIRCUIT DIAGRAM (Sheet 1 of 2)
830B/C-850B/C-870B/C 90-17
OTHERS MEMORANDUM
12
MEMORANDUM
90-18 830B/C-850B/C-870B/C
OTHERS FOLDOUT 9
12
HYDRAULIC CIRCUIT DIAGRAM (Sheet 2 of 2)
830B/C-850B/C-870B/C 90-19
OTHERS MEMORANDUM
12
MEMORANDUM
90-20 830B/C-850B/C-870B/C
Komatsu America Corp.
Data Kom Publications & Training PROPOSAL FOR MANUAL OR CSS REVISION
440 North Fairway Drive
Vernon Hills, Il. 60061-8112 U.S.A.
Attn: Service Publications
Fax No. (847)-970-4186
DATE: FOR INTERNAL USE ONLY -- No.PMR
NAME OF COMPANY: CITY:

PROPOSER
STATE OR PROVINCE:
DEPARTMENT: COUNTRY:
NAME: FAX:
MANUAL DESCRIPTION: CSS PROGRAM - e.g: Lookup, Parts or Service
MANUAL OR CSS CD NO: CSS PROGRAM RELEASE VERSION:
MANUAL OR CSS CD ISSUE DATE: CSS BOOK PUBLISHER:
BOOK DESCRIPTION
MACHINE MODEL & S/N:
MANUAL SECTION/PAGE NUMBERS OR CSS REFERENCE & PAGE NUMBERS
PROBLEM:
Attach photos or sketches.

If more space is needed, use another sheet.
FOR INTERNAL USE ONLY
CORRECTIVE ACTION:
PROPFREV.FM 100903

Ce BD 011200

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CEBM011200

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

DESCRIPTION FORM NUMBER

PARTS BOOK - PAPER:

OPERATION AND MAINTENANCE MANUAL:

Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1085 960 R2

830B/C-850B/C-870B/C Publinfok.fm 10/16/03

COMPLETE FORM DataKom Publications and Training Division

STREET ADDRESS ORDER DATE

PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE

KDC91E 071403 CURRENT PRICES WILL BE CHARGED

IMPORTANT SAFETY NOTICE 00

PREPARATIONS FOR WORK 00

PRECAUTIONS DURING WORK 00

1. When removing the oil filler cap, drain plug or

STRUCTURE AND FUNCTION

TESTING, ADJUSTING AND TROUBLESHOOTING

DISASSEMBLY AND ASSEMBLY

Shop manuals are issued as a guide to carrying out repairs.

Special technical precautions or

REVISED EDITION MARK 00

When a manual is revised, an edition mark (123…) is

● If a part cannot be smoothly removed from the machine

★ The allowable load value is estimated to be 1/6 or 1/7 of

Category Code Part No. Quantity Container Main applications, features

● Used to prevent seizure or scuffing of the thread

at places in contact with water or steam.

400 g (10 per

STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 00

Thread diameter of bolt Width across flats

Thread diameter of bolt Width across flats

Use these torques for hose nuts.

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 00

Use these torques for split flange bolts.

TIGHTENING TORQUE FOR FLARED NUTS 00

Use these torques for flared part of nut.

Thread diameter Width across flat Tightening torque

CLASSIFICATION BY COLOR AND CODE 00

METHOD OF USING THE CONVERSION TABLE 00

2. Convert 550 mm into inches.

B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.

Millimeters to Inches 1 mm = 0.03937 in

Kilogram to Pound 1 kg = 2.2046 lb

Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal

Liter to U.K. Gallon 1 L = 0.21997 U.K. Gal

kgm to ft. lb. 1 kgm = 7.233 ft. lb.

kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

GENERAL ASSEMBLY DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2

ACCORDING TO AMBIENT TEMPERATURE

PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS

ASTM: American Society of Testing and Material

AMBIENT TEMPERATURE CAPACITY

24.6 liter 24.6 liter

Circle slip clutch 1.9 liter 1.9 liter