Manual Servicio Case 580 Super K Construction King

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SECTION INDEX - GENERAL
Section Title
Loctite Product Chart
Torque Specifications .
Fluids and Lubricants .
CASE CORPORATION
Rae 8-17141
Section Number
1001
..1002
Copyright 1992 J I Case Company
Printed in U.SA
August. 1992
1001
STANDARD TORQUE SPECIFICATIONS
TABLE OF CONTENTS
Torque Specifications - Decimal
Hardware 1001-2
Torque Specifications - Steel Hydraullc
Fittings 1001-4
Torque Specifications - Metric Hardware ...1001-3 Torque Specifications - O-ring Face
Seal Fittings..... ....................1001-5
CASE CORPORATION Bur 8-71600
Printed in U.S.A.
Issued May 1988
1001-2
TORQUE SPECIFICATIONS - DECIMAL HARDWARE
Use the torques in this chart when special tor-
ques are not given. These torques apply to fasten-
ars with both UNC and UNF threads as received
from suppliers. dry. or when lubricated with engine
oil Not applicable if special graphites, rnotydisul-
fide greases. or other extreme pressure lubricants
are used.
8113608
1001-3
TORQUE SPECIFICATIONS - METRIC HARDWARE
Use the following toques when special torques
are not given.
These values apply to fasteners with coarse
threads as received from supplier. plated or un-
plated. or when lubricated with engine oil. These
values do not apply if graphite or molydisulfide
grease or oil if used.
811359A
1001-4
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
Tube OD Thread Pound- Newton
Hose ID Size Feet metres
37 Degree Flare Fittings
1/4 in 7/16-20 6-12 8-16
6.4 mm
5/16 in 1/2-20 8-16 11-21
7.9 mm
3/8 in 9/16-18 10-25 14-33
9.5 mm
1/2 in 3/4-16 15-42 20-56
12.7 mm
5/8 in 7/8-14 25-58 34-78
15.9 mm
3/4 in 1-1/16-12 40-80 54-108
19.0 mm
l/8.in 1-3/16-12 60-100 81-135
22.2 mm
1.0 in 1-5/16-12 75-117 102-158
25.4 mm
1-1/4 in 1-5/8-12 125-165 169-223
31.8 mm
1-1/2 in 1-7/8-12 210-250 285-338
38.1 mm
Split Flange Mounting Bolts
Pound- Newton
Size Feet metres
5/16-18 15-20 20-27
3/8-16 20-25 26-33
7/16-14 35-45 47-61
1/2-13 55-65 74-88
5/8-11 140-150 190-203
Tube OD Thread Pound- Newton
Hose ID Size Feet metres
Straight Threads with O-ring
1/4 in 7/16-20 12-19 16-25
6.4 mm
5/16 in 1/2-20 16-25 22-23
7.9 mm
3/8 in 9/16-18 25-40 34-54
9.5 mm
1/2 in 3/4-16 42-67 57-90
12.7 mm
5/8 in 7/8-14 58-92 79-124
15.9 mm
3/4 in 1-1/16-12 80-128 108-174
19.0 mm
7/8 in 1-3/16-12 100-160 136-216
22.2 mm
1.0 in 1-5/16-12 117-187 159-253
25.4 mm
1-1/4 in 1-5/8-12 165-264 224-357
31.8 mm
1-1/2 in 1-7/8-12 250-400 339-542
38.1 mm
8113618
1001-5
TORQUE SPECIFICATIONS - O-RING FACE SEAL FITTING
Nom.
SAE
Dash Thread Pound- Newton Thread Pound- Newton
Size Tube 00 Size Feet Metres Size Feet Metres
O-ring Face Seal End O-ring Boss End
Fitting or Locknut
-4 1/4 In 9/16-18 10-12 14-16 7/16-20 17-20 23-27
6.4 mm
-6 3/8 in 11/16-16 18-20 24-27 9/16-18 25-30 33-40
95 mm
-8 1/2 in 13/16-16 32-40 43-54 3/4-16 45-50 61-68
12.7 mm
-10 5/8 in 1-14 46-56 60-75 7/8-14 60-65 81-88
I
15.9 mm
I
-12 3/4 in 1-3/16-12 65-80 90-110 1-1/16-12 85-90 115-122
19.0 mm
I
-14 7/8 in
I
1-3/16-12 65-80 90-110 1-3/16-12 95-100 129-136
22.2 mm
-16 1.0 in 1-7/16-12 92-105 125-140 1-5/16-12 115-125 156-169
25.4 mm
-20 1-1/4 in 1-11/16-12 125-140 170-190 1-5/8-12 150-160 203-217
31.8 mm
-24 1-1/2 in 2-12 150-180 200-254 1-7/8-12 190-200 258-271
38.1 mm
8871553
CASE CORPORATION
Section
1002
FLUIDS AND LUBRICANTS
Bur 8-12271 Printed in U.S.A.
Issued March 1991
1002-2
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS ...
.......................................2
ENGINE OIL RECOMMENDATIONS . . 3
DIESEL FUEL .
.. .4
CAPACITIES AND LUBRICANTS
Engine Oil
Capacity with Filter Change 11.6 U.S. quarts (11 litres)
Type of oil. See Engine Oil Recommendations on page 3
Engine Cooling System
Capacity without heater 17.2 U.S. quarts (16.3 litres)
Capacity with heater.. ... 17.9 U.S quarts (16.9 litres)
Type of coolant. Ethylene glycol and water mixed for lowest ambient temperature
At least SO/50 mix
Fuel Tank
Capacity 25 U.S. gallons (94.6 litres)
Capacity with auxiliary tank.................................. . 33 U.S. gallons (124.9 litres)
Type of fuel See Diesel fuel specifications on page 4
Hydraulic System
Hydraulic reservoir refill capacity 21.5 US. gallons (81.4 litres)
Type of oil Case TCH Fluid
Transmission
Capacity 47.6 U.S. quarts (45 litres)
Total System Capacity 57.1 U.S. quarts (54 litres)
Type of oiL............. Case Hy-Trans Plus (MS 1207)
Front Axle - Four Wheel Drive
Capacity of center bowl 7.4 quarts (7 Iitres)
Capacity of planetary (each) 1.1 U.S. quarts (1 litre)
Type of oil..... .. CaselH 135-H EP gear lube
Brake Reservoir
Type of fluid Case TCH Fluid
Conversion Formulas
Imperial quart = litres x 0.879877
Imperial gallon =litres x 0.219969
Bur 8-12271 Issued 3-91 Printed in U.S.A.
1002-3
ENGINE OIL RECOMMENDATIONS
Case IH No.1 Engine Oil is recommended for use inyour Case IH Engine. Case IH
Engine Oil will lubricate your engine correctly under all operating conditions. If Case
IH No.1 Multi-Viscosity Engine Oil is not available, Case IH No.1 Single Grade Engine
Oil can be used
If Case IH No.1 Multi-Viscosity or Single
Grade Engine Oil is not available, use
only oil meeting API engine oil service ca-
tergory CE.
654L9
See the chart below for recommended viscosity at ambient air temperature ranges.
NOTE: Do not put Performance Additives or other oil additive products in the engine
crankcase. The oil intervals given in this manual are according to tests with Case IH
lubricants.
AMBIENT AIR TEMPERATURE RANGES
Temperature Fahrenheit
, I I
I I I I I I
I
I
MUL TI-GRADE OIL
I I
.

I I I I I I I I
.

I

SINGLE GRADE OIL
.

I I
I I I I I I I I I I I I
737L9
-34' _29'-23' -18' -12' -7" _1' 4' 10' 16" 21' 27" 32' 38' 43' -49'
Temperature Celsius
1002-4
DIESEL FUEL
Use NO.2 diesel fuel in the engine of
this machine. The use of other fuels can
cause the loss of engine power and high
fuel consumption.
Invery cold temperatures, a mixture of
NO.1and NO.2 diesel fuels is tempora-
rily permitted. See the following Note.
NOTE: See your fuel dealer for
winter fuel requirements in your area. If
the temperature of the fuel is below the
cloud point (wax appearance point), wax
crystals in the fuel will cause the engine
to lose power or not start.
The diesel fuel used in this machine
must meet the specifications inthe chart
below or Specification 0975-81 of the
American Society for Testing and Mate-
rials.
Fuel Storage
Ifyou keep fuel in storage for a period
of time, you can get foreign material or
water in the fuel storage tank. Many
engine problems are caused by water in
the fuel.
Keep the fuel storage tank outside
and keep the fuel as cool as possible.
Remove water from the storage con-
tainer at regular periods of time.
Specifications for Acceptable NO.2 Diesel Fuel
API gravity, minimum .. 34
Flash point, minimum. .. 140F (60C)
Cloud point (wax appearance point), maximum .. -5F (-20C) See Note above
Pour point. maximum -15F (-26C) See Note above
Distillation temperature. 90% point... 540 to 640F (282 to 338C)
Viscosity, at 100F (88C)
Centistokes . 2.0 to 43
Saybolt Seconds Universal................. .. 32 to 40
Cetane number, minimum 43 (45 to 55 for winter or high altitudes)
Water and sediment, by volume, maximum........................... .. 0.05 of 1%
Sulfur, by weight, maximum............... .. 0.5 of 1%
Copper strips corrosion, maximum .. No. 2
Ash, by weight, maximum................. .. 0.01 of 1%
Section
1024
SPECIFICATION DETAILS
IMPORTANT: This engine was made using the metric measurement system. All
measurements and checks must be made with metric tools to make sure of an
accurate reading when inspecting parts.
CASE CORPORATION
Rae 8-24162
Printed in U.S.A.
J une, 1983 (Revised J anuary, 1991)
1024-2
TABLE OF CONTENTS
RUN-IN INSTRUCTIONS. . 3
IDENTIFICATION MARKS
Crankshaft 4
Cylinder Block.... .. .4
Cylinder Head..... . ..4
ENGINE SPECIFICATION DETAILS
Cylinder Block... . .4
Service Cylinder Sleeve..... . 5
Piston....... . 5
Piston Pin 5
Piston Rings 6
Cylinder Head. .. ...................6
Lifters .. ... 6
Connecting Rod . 7
Crankshaft. 8
Camshaft 9
Turbocharger 9
Gear Train 9
Rocker Arm Assembly. ..............10
Intake Valve... .. 10
Exhaust Valve 10
Valve Springs.......... . 11
Valve Seat Installation Dimensions 11
SPECIAL TORQUES .. , 11-13
Rae 8-24162 Revised 1-91 Printed in U.S.A.
1024-3
RUN-IN INSTRUCTIONS
Engine Lubrication
Fill the engine crankcase with CO or CE service classification oil that has the correct viscosity rating for the ambient air
temperature. Install new oil filters, after the engine has been rebuilt.
Run-In Procedure for Rebuilt Engine
Step 1 Disconnect the wire to the electric shut-off on the injection pump so that the engine will not start Crank the
engine for 30 seconds until there is oil pressure, then reconnect the wire.
Step 2 Remove the air from the cooling system at the temperature sending unit.
Step 3 Run the engine at 1000 RPM minimum load for 5 minutes and check for oil leaks
Step 4 During the Run-In, continue to check the oil pressure, coolant level, and coolant temperature.
Run-In Procedure for Rebuilt Engines (With a Dynamometer)
The following procedure must be followed when using a PTOdynamometer to Run-In the engine. The dynamometer will
control the engine load at each speed and will remove stress on new parts during Run-In.
During the Run-In, continue to check the oil pressure, coolant level and coolant temperature.
STEP
1
2
3
TIME
5 Minutes
5 Minutes
5 Minutes
ENGINE SPEED
1000 RPM
1100 RPM
2200 RPM
DYNAMOMETER SCALE LOAD
50
1/2
Full
Run-In Procedure for Rebuilt Engines (Without a Dynamometer)
STEP
1
2
3
TIME
5 Minutes
5 Minutes
5 Minutes
ENGINE SPEED
1000 RPM
1100 RPM
2200 RPM
LOAD
No Load
Light Load
Light Load
Run-In Procedure (Agriculture Tractors)
For the first 8 hours of field operation stay one gear lower than normal. For the next 12 hours 00NOT "lug" the engine.
Prevent "lugging" by moving the lever to a lower gear. The engine must not be "lugged" below the rated engine RPM
during early hours of life.
Run-In Procedure (Construction Equipment)
For the first 8 hours, operate the engine at full throttle maintaining a normal load. Avoid converter or hydraulic stall. The
engine must not be "lugged" below the Rated Engine RPM (00 not stall the engine more than 10 seconds).
Rae 8-24162 Revised 1-91 Printedin USA
1024-4
Crankshaft
Letter N =Nitroc Hardened, crankshaft must be rehardened to a minimum hardness of 450 HV 0.2 rockwell any time
the crankshaft has been reconditioned.
Cylinder Block
LetterX =The cylinder block has been retaced and up to 0.25 mm has been removed. Use a thicker head gasket (DNa
notches).
Letter XX =The cylinder block has been refaced and up to 0.50 mm has been removed Use a thicker head gasket
(three notches).
Cylinder Head
Letter G = Thermostat passage in cylinder did not need to be machined
Letter M =Thermostat passage in cylinder head was machined.
Letter V =Valve seats have been machined.
LetterX = The cylinders inthe cylinder block have been bored oversize. Use a head gasket with oversize cylinder holes
(one notch)
LetterXX =The cylinder block has been refaced and up to 0.25 mm has been removed use athicker head gasket (DNa
notches) .
Letter XXX = The cylinder block has been refaced and up to 0.50 mm has been removed. Use a thicker head gasket
(three notches).
Numbers =RH rear corner of cylinder head indicates the amount of material removed from the cylinder head.
Cylinder Block
Metric Value
Type.. . Non-Sleeved
Material Cast Iron
10 of Cylinder... . 102.00 to 102.04 mm
Maximum Service Limit . 102.116 mm
Cylinder Out of Round (Maximum) 0.038 mm
Cylinder Taper (Maximum) 0.076 mm
0.5 mm Oversize Piston
Machine Cylinder Bore to 102.40 to 102.44 mm
Hone to (Finished Diameter) 102.50 to 102.54 mm
Warpage (Maximum).................................................................. 0.075 mm
Maximum Material Removal 0.50 mm
Rae 8-24162 Revised 1-91 Printed in U.SA
1024-5
Service Cylinder Sleeve
Type Dry, Can Be Replaced
Material Cast Iron
Machine Cylinder Block Bore to 104485 to 104.515 mm
Installation.................. . . Press Fit
Machine Sleeve Bore to:
Standard Size Piston (Finished Diameter) ................................10200 to 102.04 mm
Machine Cylinder Bore to 10240 to 10244 mm
Machine Cylinder Bore to.. .. 102.90 to 102.94 mm
Hone to (Finished Diameter) .. 103.00 to 103.04 mm
Piston
Type Cam Ground
Material................... ...Aluminum alloy
OD at 12 mm From the Bottom, 90 Degrees Piston Pin
Standard Size Piston 101.873 to 101.887 mm
Minimum Service Limit. 101.823 mm
0.5 mm Oversize Piston 102.373 to 102.387 mm
Minimum Service Limit 102.823 mm
ID of Piston Pin Bore 40.006 to 40.012 mm
Maximum Service Limit 40.025 mm
Width of 1st Ring Groove (Top) .2465 to 2.485 mm
Width of 2nd Ring Groove (Intermediate) 2.425 to 2445 mm
Width of 3rd Ring Groove (Oil Ring) 4.040 to 4.060 mm
Protrusion Above Cylinder Block (Maximum) 0.660 mm
Piston Pin
Type Full Float
OD of Pin 39.997 to 40.003 mm
1024-6
Piston Ri ngs
NO.1 Compression 4T-390 Engine Key Stone Type (Barrel Face)
End Gap in 102.02 10.... .. 0.4 to 0.70 mm
No.1. Compression 4-390 Engine Rectangular Type (Barrel Face)
End Gap in 102.02 10.................. . 0.25 to 0.55 mm
Maximum Service l.irnit.. 0.806 mm
Side Clearance 0.075 to 0.120 mm
Maximum Service Limit... 0.15 mm
NO.2 Compression. Rectangular Type (Tapper Face)
End Gap in 102.02 10. ................0.25 to 0.55 mm
NO.3 Oil Control Rings.. Two Piece
End Gap in 102.02 10 0.25 to 0.55 mm
Maximum Service Limit............................................... . 0.806 mm
Side Clearance. . 0 130 mm
Cylinder Head
Warpage (Maximum) 0.20 mm
Maximum Material Removal.......................... . 1.00 mm
Minimum Head Height .. 9375 mm
Engines Manufactured in U.S.A.:
Prior to Engine Serial Number 45511034 Injectior Nozzle 9 mm
Engine Serial Number 45511034 and After Injectior Nozzle 7 mm
Engines Manufactured in Darlington England:
Prior to Engine Serial Number 21092870 Injectior Nozzle 9 mm
Engine Serial Number 21092870 and After . Injector Nozzle 7 mm
Engines Manufactured in Neuss Germany:
Prior to Engine Serial Number 52107489 Injector Nozzle 9 mm
Engine Serial Number 52107489 and After Injector Nozzle 7 mm
Lifters
Material Hardened Iron
00 of Lifter 15.961 to 15.977 mm
Minimum Service Limit. . .. 15.960 mm
Bore Diameter in Block 16.000 to 16.030 mm
Maximum Service Limit. 16.055 mm
Rae 8-24162 Revised 1-91 Printed in USA.
1024-7
Connecting Rod
Bushing . Steel Backed Leaded Bronze
Bushing 10 Installed (Reamto Size)........................................................... ..40.053 to 40.067 mm
Bearing Liners...................... . Replaceable
J ournal 10 Without Bearing Liners 72.987 to 73.013 mm
Bearing Oil Clearance ..............0.038 to 0.116 mm
Maximum Service Limit..... . 0129 mm
Side Clearance...................................... . 0.100 to 0.300 mm
Maximum Service Limit ... 0330 mm
Connecting Rod Bend (Maximum)
Without Bushing. . .
With Bushing .
Connecting Rod Twist (Maximum)
Without Bushing. . ,..
With Bushing .
. 0.200 mm
0150 mm
. 0.500 mm
. 0.300 mm
1024-8
Crankshaft
Type Hardened Steel, Balanced
Main Bearing Liners...... .. . Replaceable
End Clearance, Center Main Bearing Cap 0.13 to 0.25 mm
Center Main Bearing Thrust Surface Thickness......... .. 2.50 mm
Connecting Rod J ournal
00, Standard . 68.987 to 69.013 mm
Maximum Service Lirnit.. . 68.962 mm
0.25 mm 00 Undersize, Grind to 68.737 to 68.763 mm
Maximum Service Limi!........................................................... .. 68.712 mm
0.50 mm 00 Undersize, Grind to...................................... . 68.487 to 68.513 mm
Maximum Service Limit.. 68.462 mm
Maximum Service Limi!............ . . 68.212 mm
1.00 mm 00 Undersize, Grind to..........................67.987 to 68.013 mm
Maximum Service Limi!..................................... . 67.962 mm
Connecting Rod J ournal Maximum Taper 0.013 mm
J ournals Out of Round Maximum....................................... . 0050 mm
Undersize Main Bearing Liners For Service . 0.25,0.50,0.75 and 1.00 mm
Main Bearing Oil Clearance 0.041 to 0.119 mm
Maximum Service Limit 0 140 mm
Main Bearing J ournal
00, Standard 82.987 to 83.013 mm
Maximum Service. Limi!..... . 82.962 mm
0.25 mm 00 Undersize, Grind to . 82.737 to 82.763 mm
0.75 mm 00 Undersize, Grind to .......................................................................82.237 to 82.263 mm
Main Bearing J ournal Bore 10 No Liners 87.982 to 88.018 mm
Main J ournal Width:
1st, 2nd, 3rd, 5th .. 37.424 to 37.576 mm
4th 37.475 to 37.525 mm
Connect Rod J ournals Width 38.950 to 39.050 mm
1024-9
Camshaft
Type Hardened Iron
Bushing (Front Only) 1, Replaceable
Bushing Lubrication:
Front Bushing Pressure Lubricated
Intermediate. Pressure Lubricated
Rear Pressure Lubricated
Oil Clearance 0.076 to 0.152 mm
IDof NO.1 Bushing, Installed 54.107 to 54.133 mm
Maximum Service Limit .. 54.146 mm
IDof NO.1 Oversize (57.24 mm 00) Service Bushing 54.089 to 54.139 mm
10 of NO.2, 3, 4 and 5 Service Bushing 54.089 to 54.139 mm
Width of No 1 Bushing 25.15 to 25.65 mm
Width of No.2, 3, 4 and 5 Service Bushing 1775 to 18.25 mm
Camshaft Bushing J ournal OD 53.987 to 54.013 mm
Camshaft Bore Diameter in Block
NO.1 Bushing 57.222 to 57.258 mm
NO.1. Oversize Bushing, Machine to 57. 722 to 57.758 mm
No.2, 3,4 and 5, Less Bushings 54.089 to 54139 mm
NO.2, 3,4 and 5 Oversize for Bushings, Machine to 57.222 to 57.258 mm
Camshaft Thrust Thickness 9.42 to 9.58 mm
Camshaft Thrust Clearance 0.130 to 0.340 mm
Camshaft Lobes:
Minimum Diameter at Peak Intake 47.265 mm
Minimum Diameter at Peak Exhaust 46.994 mm
Turbocharger
Horizontal Travel of Turbine Shaft 0.10 to 0.16 mm
Gear Train
Backlash:
Crankshaft Gear to Camshaft Gear 0.08 to 0.33 mm
Crankshaft Gear to Idler Gear 0.08 to 0.33 mm
Camshaft to Fuel Pump Gear 0.08 to 0.33 mm
Idler Gear to Oil Pump 0.08 to 0.33 mm
Camshaft to Auxiliary 0.08 to 0.33 mm
Maximum Service Limit (All Gears) 0.45 mm
1024-10
Rocker Arm Assembly
OD of Shaft . . 18.963 to 18.975 mm
Minimum Service Limit.............. . 18.938 mm
ID of Arm Bore.............................. .. 19.000 to 19.026 mm
Lubrication.. . Pressure From Oil Gallery
Shaft Oil Holes . Down
Intake Valve
Tappet Clearance (Cold) 0.254 mm
Face Angle 29 Degrees
Face Run-Out................. .. 0.038 mm
Valve Head Edge Thickness, Minimum........................... . 1.50 mm
Length 128.84 to 129.46 mm
OD of Stem . 7.960 to 7.980 mm
Minimum Service Limit . 7.940 mm
OD of Head 44870 to 45.130 mm
Seat Angle................................ . 30 Degrees
Seat Contact Width 1.32 to 1.92 mm
Seat Run-Out....... . 0.10 mm
Insert Height..................... .. 6.84 to 6.96 mm
OD of Insert......................... .. .47.063 to 47.089 mm
ID of Insert..................... Tapered
Valve Recession Below Head Surface 0.99 to 1.52 mm
Maximum Service Limit. .. 1.52 mm
IDof Valve Guide Bore 8.019 to 8.039 mm
Exhaust Valve
Face Run-Out. 0.038 mm
Valve Head Edge Thickness, Minimum......................................................................................................150 mm
OD of Head .41.870 to 42.130 mm
OD of Stem .. 7.960 to 7.980 mm
Length 128.74 to 129.36 mm
Insert Seat Angle.... .45 Degrees
Seat Contact Width .. 1.47 to 2.07 mm
Seat Run-Out. 0.10 mm
Insert Heigh!...... . 6.65 to 6.77 mm
OD of Insert........ . 43713 to 43.739 mm
ID of Insert... . Tapered
IDof Valve Guide Bore 8.019 to 8.039 mm
Rae 824162 Revised 1-91 Printed in U.S.A.
1024-11
Valve Springs
Free Length 55.63 mm
Total Coils. .. 7.25
Wire Diameter.......... .. . 4.830 to 4.930 mm
Compressed to 38.53 mm (Valve Open) 785 to 839 N
Maximum Service Limit . 765 N
Compressed to 49.25 mm (Valve Closed) 285 to 321 N
Minimum Service Limit 270 N
Valve Seat Installation Dimensions
Exhaust Seat
Diameter of Insert .43. 713 to 43.73 mm
Machine Insert Bore to...... . .. .....43.647 to 43663 mm
Depth of Bore. ..........1010 to .092 mm
Press FiL... ..0.05 to 0 102 mm
Intake Seat
Diameter of Insert 47.063 to 47.089 mm
Machine Bore to ..46.987 to 47.013 mm
Depth of Bore .. 10.30 to 10.50 mm
Press Fit....................... '''_ 0.05 to 0.102 mm
14 mm Valve Guide Installation Dimensions
Guide Diameter 14.026 to 14.038 mm
Machine Guide Bore to 13.987 to 14013 mm
Press Fit.. 013 to .051 mm
Installed Height (above top of valve guide boss on head) 11.25 to 11.75 mm
Guide Installed ID 819 to 8.39 mm
SPECIAL TORQUES
Metric Value
Aftercooler Bolts...... 21 to 27 Nm
Alternator Bracket Bolts (Lower) 21 to 27 Nm
Alternator Bracket Bolts (Upper) 21 to 27 Nm
Alternator Retaining Bolt 21 to 27 Nm
Balancer Counter Weight Bolts.................... .. 21 to 27 Nm
Balancer Mounting Bolts 167 to 183 Nm
Balancer Idler Gear .. 52 to 62 Nm
Belt Tensioner Bracket Bolts 21 to 27 Nm
Belt Tensioner Retaining Bolt. 39 to 47 Nm
Block Heater 11 to 13 Nm
1024-12
SPECIAL TORQUES (Cont'd)
Metric Valve
Camshaft Retaining Bolts 21 to 27 Nm
Coolant Inlet Bolts 39 to 47 Nm
Connecting Rod Bolts..................... 95 to 100 Nm
(Lubricate Threads with Engine Oil)
Cylinder Head Bolts 120 to 132 Nm
Engine Lift Bracket Bolts (Rear) 71 to 83 Nm
Exhaust Manifold Bolts 39 to 47 Nm
Fan Pulley Bracket Bolts .. __ .. 23 to 26 Nm
Fan Pulley Bolts 8.8..... ...__ __ __ 37 to 43 Nm
Fan Pulley Bolts 10.9.. " .__ 52 to 62 Nm
Flywheel Housing Bolts . 54 to 66 Nm
Flywheel Retaining Bolts 130 to 144 Nm
Flywheel Housing Cover Bolts __ 21 to 27 Nm
Fuel Filter Inlet Bolt 29 to 35 Nm
Fuel Air Removal Bolt........ .. 5 to 7 Nm
Fuel Filter Inlet NuL....... 29 to 35 Nm
Fuel Line Fitting (High Pressure) 22 to 28 Nm
Fuel Line Fitting (Low Pressure) 22 to 28 Nm
Fuel Shutoff Solenoid.. .. 15 Nm
Front Cover Bolts.... 21 to 27 Nm
Front Housing Bolts 21 to 27 Nm
Injection Pump Drive Gear Nut 59 to 71 Nm
Injection Pump Lock Bolt (Lock Position) 8 Nm
Injection Pump Lock Bolt (Unlock Position) 20 Nm
Injection Pump Retaining Nuts 21 to 27 Nm
Injection Pump Bracket Bolts 21 to 27 Nm
Injector Leak Off Bolt. . __ .. .. 5 to 7 Nm
Injector Retaining NuL... .. 55 to 65 Nm
Rae 8-24162 Revised 1-91 Printed in U.S.A
1024-13
SPECIAL TORQUES (Cont'd)
Metric Valve
Intake Manifold Bolts.. __ 21 to 27 Nm
Intake Manifold Plug __ __ 115 to 135 Nm
Lifter Cover Bolts.................. .. .. __ -- __ 21 to 27 Nm
Main Bearing Bolts............. ..__. __ __ __ __ __.__ 165 to 180 Nm
(Lubricate the Thread with Engine Oil)
Oil Fill Tube Bolts __ __ __ __ __ 39 to 47 Nm
Oil Pan Drain Plug..... __ ......68 to 82 Nm
Oil Pan Heater Plug 108 to 132 Nm
Oil Pan Retaining Bolts __ __ 21 to 27 Nm
Oil Pump Retaining Bolts. .. __.. ........21 to 27 Nm
Oil Inlet Tube Bolts __ .18 to 30 Nm
Oil Inlet Tube Brace.. ..21 to 27 Nm
Oil Filter Housing Bolts __ __ 21 to 27 Nm
Oil Relief Valve Plug __ __ __ __ __ __..__ __ __.__ __ __108 to 132 Nm
Primer Pump 21 to 27 Nm
Rear Seal Retaining Bolts __ 8 to 10 Nm
Rocker Arm Bolts __ __ __.21 to 27 Nm
Starter Retaining Bolts __ __ __ __ 39 to 47 Nm
Tachometer Drive Retaining Bolts .. __ __ 2 to 4 Nm
Thermostat Housing Bolts __..__ __ 21 to 27 Nm
Timing Pin Retaining Bolts __ ..__.__ __ 4 to 6 Nm
Thrust Bearing Screws (Torx Head) __ __ __ __ __ __ __...4 to 6 Nm
Turbocharger Mounting Bolts __ __ 30 to 34 Nm
Turbocharger Drain Tube Bolts 21 to 27 Nm
Turbine Housing Bolts 9 to 13 Nm
Center Housing to Back Plate Bolts __ __ 5 to 7 Nm
Compressor Housing Bolts __ 5 to 7 Nm
Compressor Lock Nut... 13 to 1.5Nm
Water Pump Mounting Bolts 21 to 27 Nm
Valve Cover Bolts.......................... 21 to 27 Nm
1024-14
NOTE: The J I Case Company reserves the right to make improvements in design or
changes in specifications at any time without incurring any obligation to install them
on units previously sold.
Rac 8-24162 Revised 1-91 Printed in U.S.A.
SECTION INDEX - ENGINE
Section Title Section Number
Engine Removal and Installation................................................. . 2001
Stall Tests. .. 2002
Detailed Engine Specifications. . 2402
Cylinder Head and Valve Train..... . 2415
Cylinder Block. . 2425
Lubrication System... .. 2445
Cooling System .. 2455
Turbocharger............. . ,..... ..2465
Turbocharger Failure Analysis 2565
CASE CORPORATION
Rae 8-17161
Printed in U.S.A
August. 1992
RADIATOR REMOVAL
2001-3
Put identification tags on all disconnected hoses
and wires. Close disconnected hoses and fittings with
caps and plugs.
NOTE: Cal/outs on the photographs are in the order
of the procedure.
STEP 1
Park the machine on a level surface. Raise the loader
and lock the support strut (1) to hold the loader.
STEP 2
Disconnect the overflow hose (2) from the radiator
neck.
Remove the coolant reservoir (3). (bolts, flat washers,
and self-locking nuts).
Disconnect the hood cable (4) from each side of the
shroud. (flatwashers, spacers, lock washers, and nuts)
Remove the hardware from the hood hinges (5). (bolts,
flatwashers, and lock washers).
Have another person help you remove the hood. The
weight of the hood is approximately 75 pounds (34 kg).
Bur 8-17560
NOTE: During instal/ation the hood must be adjusted.
Put the hood in position. Install the hardware in the hood
hinges. Do not tighten the hardware. Close the hood
and remove the plastic plugs for access to the hinge
hardware. Push the top of the hood to the rear as far as
possible and tighten the hinge hardware.
STEP 3
Slowly remove the radiator cap (6).
Install a hose on the drain valve (7) and drain the ra-
diator.
Disconnect the upper and lower radiator hoses (8).
Remove the hardware from the fan shroud (9). (bolts,
lock washers, and flat washers)
NOTE: During installation fill the radiator completely and
the coolant reservoir with apprOXimately 18U.S. quarts
(17 litres) of coolant. See Section 1002 for coolant
specifications. Start and run the engine until the coolant
is at operating temperature. Stop the engine and check
for leakage. When the coolant is cold, check the coolant
reservoir level.
Issued 3-91 Printed in U.S.A.
2001-4
STEP 4
Remove the strap (10) from the top of the radiator
shroud. (bolt, lock washer, and flat washer).
Remove the top cover (11). (bolts, lock washers, and
flat washers).
Remove the upper and lower foam baffles (12).
STEP 5
Disconnect the radiator brackets (13) from each side of
the radiator. (bolts, lock washers, and nuts)
Bur 8-17560
STEP 6
Remove the hardware (14) from each side of the
radiator shroud. (bolts, flat washers, and nuts).
Remove the radiator shroud. The weight of the radiator
shroud is approximately 50 pounds (23 kg).
NOTE: During installation, push the top of the shroud
toward the rear of the machine and tighten the bolts for
the radiator shroud to 270 to 324pound-feet (366to 439
Nm).
STEP 7
Remove the hardware that fastens the condenser and
oil cooler (15) to the radiator. (bolts, lock washers, and
flat washers).
Lift the radiator straight up and remove the radiator.
NOTE: Installation of the radiator is the reverse of
removal.
ENGINE REMOVAL
2001-5
Do steps 1 through 6 of radiator removal.
STEP 8
The hydraulic reservoir holds approximately 25 U.S.
gallons (95 litres) of oil. Drain the oil from the hydraulic
reservoir (16).
NOTE: During installation make sure the hydraulic re-
servoir is filled with oil. See Section 1002 for specifica-
tions.
STEP 9
Disconnect the hose (17) from the bottom of the torque
converter to drain the oil from the torque converter.
Bur 8-17560
STEP 10
Remove the battery cover (18) from the left step. (cap
screws and lock washers).
STEP 11
Disconnect the ground cable(s) (19) from the batt-
ery(s) .
STEP 12
~7
Remove the bottom cover (20). (bolts, lock washers,
and flat washers).
2002-4
CHECK SHEET
1. _ (22301<Y2280-s-pe-cified) rpm (rim!ri)hydrauiiC stall speed
2. _
(2200 to 2300 specified) rpm (rimin) torque converter stall speed
3. _
(1550 to 1750 specified) rpm (rimin) hydraulic and torque converter stall speed
rpm (r/rnin)
1. 2230 to 2280 Torque converter, transmission, hydraulic system and engine ere probably good.
2. 2200 to 2300
3. 1550 to 1750
1. Above 2280 Engine problem. Check engine speeds. See specifications in Section 9001, Check the
2. Above 2300 timing of the fuel injection pump according to instructions in Section 3412.
3. Above 1750
1. Below 2230 Engine problem. Check engine speeds according to instructions in Section 9001. Check
2. Below 2200 the timing of the fuel injection pump according to instructions in Section 3412. Replace
3. Below 1550 the fuel and air filters.
1. Below 2230 Hydraulic system problem (s). See Section 8002. Check the setting of the main relief
2. 2200 to 2300 valve, Check the output of the pumps.
3. Below 1550
1. Above 2280 Hydraulic system problem (s). See Section 8002. Check the setting of the main relief
2. 2200 to 2300 valve. Check the output of the hydraulic pumps. Check for leakage in the loader
3. Above 1750 control valve.
1. 2230 to 2280 Torque converter or transmission problems. See Section 6002 and check the
2. Above 2300 transmission and torque converter.
3. Above 1750
1. 2230 to 2280 Torque converter or transmission problems. See Section 6002 and check
2. Below 2200 the transmission and torque converter.
3. Below 1550
D" . 0 ~",.,,, .
SECTION INDEX - ENGINE
Section Title Section Number
Engine Removal and Installation . ................. 2001
Stall Tests 2002
Detailed Engine Specifications........ ...2402
Cylinder Head and Valve Train . ...... 2415
Cylinder Block . ..2425
Lubrication System . .................................................................................................................................... ....2445
Cooling System ..... .. ..... 2455
Turbocharger . ....... ....2465
Turbocharger Failure Analysis.. . . .. 2565
CASE CORPORATION
Rae 8-17161
Printed in U.S.A.
August. 1992
Section
2001
ENGINE REMOVAL AND INSTALLATION
CASE CORPORATION
Bur 8-17560
Printed in U.S.A.
Issued March 1991
2001-2
TABLE OF CONTENTS
SPECIAL TOOLS 2
RADIATOR REMOVAL 3
ENGINE REMOVAL 5
REMOVING AND INSTALLING THE TORQUE CONVERTER 11
INSTALLING THE FRONT ENGINE SUPPORT.. 14
SPECIAL TOOLS
In Europe:
Order special tools from one of the following ad-
dresses:
In the U.S.A. and Canada:
Service Tools
P.O. Box 314
Owatonna, Minnesota 55060
VL Churchill Ltd.
P.O. Box 3, Daventry
Northants, NN11 4NF
England
CAS-1690 Rotation Tool
This tool is first used on page 12.
CAS-2081 Alignment Tool
Bur 8-17560 Issued3-91 Printedin U.S.A.
RADIATOR REMOVAL
2001-3
Put identification tags on all disconnected hoses
and wires. Close disconnected hoses and fittings with
caps and plugs.
NOTE: Cal/outs on the photographs are in the order
of the procedure.
STEP 1
and lock the support strut (1) to hold the loader.
STEP 2
neck.
Remove the coolant reservoir (3). (bolts, flat washers,
and self-locking nuts).
Disconnect the hood cable (4) from each side of the
shroud. (flatwashers, spacers, lock washers, and nuts)
Remove the hardware from the hood hinges (5). (bolts,
flatwashers, and lock washers).
weight of the hood is approximately 75 pounds (34 kg).
Bur 8-17560
NOTE: During installation the hood must be adjusted.
STEP 3
Slowly remove the radiator cap (6).
diator.
Remove the hardware from the fan shroud (9). (bolts,
lock washers, and flat washers)
NOTE: During installation fill the radiator completely and
the coolant reservoir with approximately 18U. S. quarts
(17 litres) of coolant. See Section 1002 for coolant
specifications. Start and run the engine until the coolant
is at operating temperature. Stop the engine and check
for leakage. When the coolant is cold, check the coolant
reservoir level.
Issued3-91 PrintedinU.S.A.
2001-4
STEP 4
Remove the strap (10) from the top of the radiator
shroud. (bolt, lock washer, and flat washer).
Remove the top cover (11). (bolts, lock washers, and
flat washers).
STEP 5
Disconnect the radiator brackets (13) from each side of
the radiator. (bolts, lock washers, and nuts)
Bur 6-17560
STEP 6
Remove the hardware (14) from each side of the
radiator shroud. (bolts, flat washers, and nuts).
Remove the radiator shroud. The weight of the radiator
shroud is approximately 50 pounds (23 kg).
NOTE: During installation, push the top of the shroud
toward the rear of the machine and tighten the bolts for
the radiator shroud to 270 to 324pound-feet (366to 439
Nm).
STEP 7
Remove the hardware that fastens the condenser and
oil cooler (15) to the radiator. (bolts, lock washers, and
flat washers).
Lift the radiator straight up and remove the radiator.
NOTE: Installation of the radiator is the reverse of
removal.
ENGINE REMOVAL
2001-5
Do steps 1 through 6 of radiator removal.
STEP 8
The hydraulic reservoir holds approximately 25 U.S.
gallons (95 litres) of oil. Drain the oil from the hydraulic
reservoir (16).
servoir is filled with oil. See Section 1002 for specifica-
tions.
STEP 9
Disconnect the hose (17) from the bottom of the torque
converter to drain the oil from the torque converter.
Bur 8-17560
STEP 10
Remove the battery cover (18) from the left step. (cap
screws and lock washers).
STEP 11
Disconnect the ground cable(s) (19) from the batt-
ery(s).
STEP 12
Remove the bottom cover (20). (bolts, lock washers,
and flat washers).
2001-6
STEP 13
Disconnect the two hoses (21) from the RH side of the
oil cooler.
Disconnect thetwo tubes (22) fromthe LH side of the oil
cooler.
STEP 14
Remove the hardware (23) that fastens the condenser
to the oil cooler and radiator. (bolts, lock washers, and
flat washers - bottom three on each side).
Move the condenser (24) to the LH side out of the way.
Have another person help you remove the oil cooler
and radiator (25). The weight of the oil cooler and
radiator is approximately 50 pounds (23 kg).
Remove the fan shroud (26).
Bur 8-17560
STEP 15
Disconnect the two hoses (27) from the LH side of the
pump. Remove the bolts and lock washers that fasten
the flange (28) on the RH side of the pump.
Remove the pump (29). (Bolts, lock washers, and
hardened washers on the lower two bolts).
NOTE: During installation, remove and clean the
suction screen for the pump. Apply Molykote Type G to
the splines of the pump.
STEP 16
Disconnect the two connectors (30).
Remove the hardware (31) from the adjusting straps.
(bolts, lock washers, flat washers, and nut - front
hardware has a weld nut).
Cut tie strap (32).
STEP 17
Remove the hardware (33) that fastens the compressor
to the bracket. (long bolt, flat washer, lock washer, and
nut). Remove the belt (34) and laythe compressor over
the side of the frame.
NOTE: During installation, adjust the drive belt ac-
cording to instructions in Section 9003.
STEP 18
Close the fuel shut off valve (35).
Bur 8-17560
2001-7
STEP 19
Disconnect throttle rod (36).
Disconnect the wiring clamp (37).
Disconnect the wire from the oil pressure sender (38).
Disconnect the fuel shutoff wire (39).
If the machine has ether injection, disconnect the tube
(40) and the wire (41).
Disconnect the fuel lines (42).
STEP 20
Remove the hardware from the muffler (43). (bolts, lock
washers, flat washers, and nuts)
Loosen the nuts on the muffler clamp (44). Remove the
muffler.
Disconnect the wires from the air restriction switch (45).
Then cut the tie straps which fasten the wire to the fuel
lines and put the wire out of the way.
Loosen the clamp (46) and remove the hose from the
turbocharger.
Remove the hardware that fastens the firewall (47).
(cap screws and flat washers). Remove the firewall (47)
and the air cleaner assembly. If the machine has ether
injection, disconnect the wire from the harness.
2001-8
STEP 21
Remove harness clamp (48).
Disconnect the wire (49) from the temperature sender.
Cut the tie straps that fasten the harness to the fuel
lines.
STEP 22
Disconnect the wires from the alternator (52).
Loosen the clamp (53) and disconnect the heater hose.
Bur 8-17560
STEP 23
Disconnect the wires (54) from the starter.
Disconnect the ground strap (55). (bolt and lock
washer).
Remove the hardware (56) for the engine mount. (bolt,
flat washer, and nut).
NOTE: During installation, tighten the nut to 135to 165
pound-feet (183to 224Nm).
STEP 24
Connect the lifting eye (57) to the rear of the engine
head.
NOTE: During installation, remove the lifting eye and put
in tool box.
Loosen the clamp (58) and disconnect the heater hose.
Remove the clamp (59).
Remove the hardware (60) for the engine mount. (bolt,
flat washer, and nut)
NOTE: During installation, tighten the nut to 135to 165
STEP 25
Remove the clamp (61).
STEP 26
Disconnect the tube (62) from the top of the filter head.
Disconnect the wire (63) from the sender on the filter
head.
Bur 8-17560
2001-9
STEP 27
Disconnect the hose (64) from the torque converter.
Disconnect the drive shaft (65) from the torque con-
verter. (bolts and straps)
NOTE: During installation, tighten the bolts to 288to
348 pound-inches (33to 40 Nm).
Loosen the clamps (66) on the hose.
STEP 28
Remove the hardware (67) for the front engine mount.
(bolts, flat washers, and self-locking nuts)
NOTE: During installation, tighten self-locking nuts to
360 to 420 pound-inches (41 to 47Nm).
Issued3-91 Printedin U.S.A.
2001-10
STEP 29
Connect lifting equipment to the lifting eyes on the
engine. Carefully lift the engine slightly and move the
engine toward the front. Disconnect the hose (66)
shown instep 27. Make sure all hoses and wires areout
of the way. Remove the engine from the machine.
Bur 8-17560
NOTE: Installation of the engine is the reverse of
removal. Before starting the engine, do the following:
a. The turbocharger must be filled with oil. Discon-
nect the wire from the fuel shutoff solenoid. Actuate
the starter for 10 to 20 seconds to fill the turboch-
arger with oil. Connect the wire to the fuel shutoff
solenoid.
b. Check the oil level in the transaxle.
c. On machines with PTO, the torque converter
housing is filled with oil. To prevent leakage, the
starter and torque converter housing must be
sealed. Use Loctite 504 on the torque converter
housing and form-in-place gasket material on the
starter.
d. With PTO fill the torque converter housing with
approximately one U.S. quart (0.95 litres) of oil.
See Section 1002 for specifications.
2001-11
REMOVING AND INSTALLING THE TORQUE CONVERTER
NOTE: On machines with PTO, drain the oil from the
torque converter housing.
STEP 30
Remove the cap screws and lock washers that fasten
thetorque converter housing to the engine. Remove the
STEP 31
Remove the cap screws and hardened washers that
fasten the drive ring to the flywheel.
STEP 32
Remove the torque converter.
NOTE: If the torque converter or the drive ring is being
replaced, do the following steps.
Bur 8-17560
STEP 33
Install the drive ring and the CAS-2018 alignmenttool.
Install the drive ring to get the least amount of
movement between the alignment tool and the drive
ring.
STEP 34
Install four cap screws and hardened washers.
STEP 35
Tighten the four cap screws evenly to 456 to 504
pound-inches (52 to 57 Nm). Remove the CAS-2018
tool and install the remaining hardened washers and
cap screws. Tighten the cap screws to the same torque
value.
2001-12
STEP 36
Hold the torque converter in place and install the cap
screws and lock washers.
STEP 37
Use a dial indicator to check the position of the torque
converter.
STEP 38
Remove the plastic plug at the left front of the flywheel
housing.
Bur 8-17560
STEP 39
Install the CAS-1690 tool to rotate the flywheel.
STEP 40
Rotate the flywheel and read the dial indicator. The
torque converter must be centered within 0.004 inch
(0.1 mm) so that the full indicated movement of the dial
indicator is 0.008 inch (0.2 mm) or less.
STEP 41
When the torque converter is centered, tighten the cap
screws to 156 to 180 pound-inches (18 to 20 Nm).
STEP 42
Remove the CAS-1690 tool and install the plastic plug.
NOTE: On machines with PTa, Apply Loctite 504to the
edge of the flywheel housing.
STEP 43
Install the torque converter housing so that the filter
head is horizontal.
IMPORTANT: DO NOT use extra force to push the
torque converter housing into place. Rotate the drive
yoke to align the shafts with the torque converter and
slide the torque converter housing against the engine.
Bur 8-17560
2001-13
STEP 44
Install the cap screws and lock washers. Tighten the
cap screws to 456 to 540 pound-inches (52to 61 Nm).
2001-14
INSTALLING THE FRONT ENGINE SUPPORT
NOTE: If the front engine support was removed for
any reason, the front engine support must be aligned
with the crankshaft of the engine. If the front engine
support is not aligned with the crankshaft of the engine,
the pump can be damaged.
STEP 45
FRONT ENGINE SUPPORT
B892300J
Install a bushing in each top hole in the front engine
support. Install the front engine support with the
hardware shown.
STEP 46
Use a dial indicator to check the alignment of the front
engine support.
Bur 8-17560
STEP 47
Remove the plastic plug at the left front of the flywheel
housing.
STEP 48
Install the CAS-1690 tool to rotate the flywheel.
STEP 49
Rotate the flywheel and read the dial indicator. The front
engine support must be centered with the crankshaft
within 0.010 inch (0.25 mm).
STEP 50
When the front engine support is centered, tighten the
cap screws to 66 to 79 pound-feet (89 to 107 Nm).
Bur 8-17560
2001-15
STEP 51
Remove the CAS-1690 tool and install the plastic plug.
Issued 3-91 Printedin U.S.A.
2002
STALL TEST
TABLE OF CONTENTS
Specifications 2002-2 Procedure to Heat Hydraulic and
Torque Converter Oil 2002-3
General Information 2002-2
Test Procedure .2002-3
Preparing the Machine for the Stall Test.. 2002-2
Check Sheet 2002-4
CASE CORPORATION
Bur 8-12301
Printed in U.S.A.
Issued March 1991
2002-2
SPECIFICATIONS
The specifications are the same for the naturally aspirated and turbocharged engines.
Low idle 850 to 900 rpm (r/rnin)
Full throttle (no load) 2330 to 2380 rpm (r/rnin)
Hydraulic stall speed (loader only) 2230 to 2280 rpm (r/rnin)
Torque converter stall speed 2200 to 2300 rpm (r/rnin)
Combined stall speed 1550 to 1750 rpm (r/min)
GENERAL INFORMATION
Do the stall test to find the cause of poor perfor-
mance.
The engine is run at full throttle and the transmission
and hydraulic systems are engaged separately, and
then together.
Comparing the engine speeds from the stall test
with the check sheet on page 2002-4 will help to find the
cause of the problem. It can be necessary to check a
separate systemto find the exact cause of the problem.
Use a photo tachometer or other tachometer of
equal accuracy to get accurate results from the stall
test.
The engine, transmission and hydraulic system
must be at operating temperature before doing the stall
test. Heat the oil according to instructions in this
section.
PREPARING THE MACHINE FOR THE STALL TEST
1. SeeSection 9001 and check the full throttle and low
idle speeds.
2. Apply the parking brake.
3. Withthe engine running at low idle move the trans-
mission control lever to fourth gear and the direction
control lever to FORWARD.
Bur 8-12301
4. Slowly increase the engine speed to full throttle.
5. If the machine begins to move at any time,
decrease the engine speed to low idle and stop the
engine.
6. Adjust or repair the parking brake as required. See
Section 7002 or 9001 as required.
PROCEDURE TO HEAT TORQUE CONVERTER AND HYDRAULIC OIL
2002-3
2. Start and run the engine at low idle.
3. With the engine running at full throttle, hold the
loader control lever in ROLLBACK for 15 seconds.
4. Return the loader control lever to NEUTRAL for 15
seconds.
5. Repeat steps 3and 4until the temperature of the oil
is 125F (52C). The side of the reservoir will be very
warm at this temperature.
6. With the engine running at low idle, move the trans-
mission control to fourth gear and the direction control
lever to FORWARD.
7. Run the engine at full throttle for 15 seconds.
8. Decrease the engine speed to low idle and move
the direction control lever to NEUTRAL for 15 seconds
9. Repeat steps 6 through 8 until the pointer in the
gauge for transmission oil temperature is in the center
of the green zone or the lamps in the optional instru-
ment cluster are illuminated to the center of the green
zone of the gauge for transmission oil temperature.
TEST PROCEDURE
1. Prepare the machine for the stall test according to
instructions in this section.
2. Heat the oil according to instructions inthis section.
3. Apply the parking brake and start the engine.
4. With the engine running at full throttle, hold the
loader control lever in ROLLBACK and read the tachom-
eter. Write the reading on line 1 on the check sheet.
5. Decrease the engine speed to low idle.
6. Move the transmission control lever to fourth gear
and the direction control lever to FORWARD.
Bur 8-12301
7. Slow!y increase the engine speed to full throttle and
read the tachometer. Write the reading on line 2 on the
check sheet.
8. With the transmission control lever in fourth gear,
the direction control lever in FORWARD, and the engine
running at full throttle. hold the loader control lever in
ROLLBACK and read the tachometer. Write the reading
on line 3 on the check sheet.
9. Decrease the engine speed to low idle (two
minutes with turbocharger) and stop the engine.
10. See the check sheet to understand the results of
the stall test.
2002-4
CHECK SHEET
1. _
(2230 to 2280 specified) rpm (r/min) hydraulic stall speed
2. _
(2200 to 2300 specified) rpm (r/min) torque converter stall speed
3. _
(1550 to 1750 specified) rpm (r/min) hydraulic and torque converter stall speed
rpm (r/min)
1. 2230 to 2280 Torque converter, transmission, hydraulic system and engine are probably good.
2. 2200 to 2300
3. 1550 to 1750
1. Above 2280 Engine problem. Check engine speeds. See specifications in Section 9001. Check the
2. Above 2300 timing of the fuel injection pump according to instructions in Section 3412.
3. Above 1750
1. Below 2230 Engine problem. Check engine speeds according to instructions in Section 9001. Check
2. Below 2200 the timing of the fuel injection pump according to instructions in Section 3412. Replace
3. Below 1550 the fuel and air filters.
1. Below 2230 Hydraulic system problem(s). See Section 8002. Check the setting of the main relief
2. 2200 to 2300 valve. Check the output of the pumps.
3. Below 1550
1. Above 2280 Hydraulic system problem(s). See Section 8002. Check the setting of the main relief
2. 2200 to 2300 valve. Check the output of the hydraulic pumps. Check for leakage in the loader
3. Above 1750 control valve.
1. 2230 to 2280 Torque converter or transmission problems. See Section 6002 and check the
2. Above 2300 transmission and torque converter.
3. Above 1750
1. 2230 to 2280 Torque converter or transmission problems. See Section 6002 and check
2. Below 2200 the transmission and torque converter.
3. Below 1550
Section
2402
4-390 Diesel Engine
SPECIFICATION DETAILS
CASE CORPORATION
Rae 8-24163
Printed in U.S.A.
J une, 1983 (Revised February, 1992)
2402-2
TABLE OF CONTENTS
RUN-IN INSTRUCTIONS 3
Crankshaft 4
Cylinder Block 4
Cylinder Head .4
Cylinder Block .4
Service Cylinder Sleeve 5
Piston 5
Piston Pin 5
Piston Rings 6
Cylinder Head 6
Lifters 6
Connecting Rod 7
Crankshaft 8
Camshaft 9
Gear Train 9
Rocker Arm Assembly 10
Intake Valve 10
Exhaust Valve 10
Valve Springs 11
Valve Seat Installation Dimensions 11
SPECIAL TORQUES 11-13
Rae 8-24163
Turbocharger 9
Revised 2-92 Printed in U.S.A.
2402-3
RUN-IN INSTRUCTIONS
Engine Lubrication
Fill the 4-390 engine crankcase with CC/SF, CD/SF, CE/SF or CF-4 service classification oil. Use the correct viscosity
rating for the ambient air temperature. Install new oil filters after the engine is rebuilt.
Fill the 4T390 and the 4TA 390 engine crankcase with CE/SF or CF-4 service classification oil. Use the correct viscosity
rating for the ambient air temperature. Install new oil filters after the engine is rebuilt.
Run-In Procedure for Rebuilt Engine
Step 1 Disconnect the wire to the electric shut-off on the injection pump so that the engine will not start. Crank the
engine for 30 seconds until there is oil pressure, then reconnect the wire.
Step 2 Remove the air from the cooling system at the temperature sending unit.
Step 3 Run the engine at 1000 RPM minimum load for 5 minutes and check for oil leaks.
Step 4 During the Run-In, continue to check the oil pressure, coolant level, and coolant temperature.
Run-In Procedure for Rebuilt Engines (with a Dynamometer)
The following procedure must befollowed when using a PTO dynamometer to Run-In the engine. The dynamometer will
control the engine load at each speed and will remove stress on new parts during Run-In.
During the Run-In, continue to check the oil pressure, coolant level and coolant temperature
STEP
1
2
3
TIME
5 Minutes
5 Minutes
5 Minutes
ENGINE SPEED
1000 RPM
1100 RPM
2200 RPM
DYNAMOMETER SCALE LOAD
50
1/ 2
Full
Run-In Procedure for Rebuilt Engines (without a Dynamometer)
STEP
1
2
3
TIME
5 Minutes
5 Minutes
5 Minutes
ENGINE SPEED
1000 RPM
1100 RPM
2200 RPM
LOAD
No Load
Light Load
Light Load
Run-In Procedure (Agriculture Equipment)
For the first 8 hours of field operation stay one gear lower than normal. For the next 12 hours DO NOT "lug" the engine.
Prevent "lugging" by moving the lever to a lower gear. The engine must not be "lugged" below the rated engine RPM
during early hours of life.
Run-In Procedure (Construction Equipment)
For the first 8 hours, operate the engine at full throttle maintaining a normal load. Avoid converter or hydraulic stall. The
engine must not be "lugged" below the Rated Engine RPM (Do not stall the engine more than 10 seconds).
2402-4
Crankshaft
Letter N =Nitroc Hardened, crankshaft must be rehardened to a minimum hardness of 450 HV0.2 rockwell any time
the crankshaft has been reconditioned.
Cylinder Block
LetterX = The cylinder block has been refaced and up to 0.25 mm has been removed. Use athicker head gasket (two
notches).
Letter XX = The cylinder block has been refaced and up to 0.50 mm has been removed. Use a thicker head gasket
(three notches).
Cylinder Head
Letter G = Thermostat passage in cylinder did not need to be machined.
Letter M = Thermostat passage in cylinder head was machined.
LetterX =The cylinders inthe cylinder block have been bored oversize. Use a head gasket with oversize cylinder holes
(one notch). This gasket is used for standard replacement, 0.5 mm oversize and 1.0 mm oversize bore.
LetterXX =The cylinder block has been refaced and up to 0.25 mm has been removed use athicker head gasket (two
notches).
Letter XXX = The cylinder block has been refaced and up to 0.50 mm has been removed. Use a thicker head gasket
(three notches).
Numbers =RH rear corner of cylinder head indicates the amount of material removed from the cylinder head.
Cylinder Block
Metric Value
Type Non-Sleeved
Material Cast Iron
10 of Cylinder 102.00 to 102.04 mm
Cylinder Out of Round (Maximum) 0.038 mm
Cylinder Taper (Maximum) 0.076 mm
Machine Cylinder Bore to... .. 102.90 to 102.94 mm
Warpage (Maximum) 0.075 mm
Maximum Material Removal. 0.50 mm
2402-5
Service Cylinder Sl eeve
Type , Dry, Can Be Replaced
Material .. , , , Cast Iron
Machine Cylinder Block Bore to ,104.485 to 104.515 mm
Installation Press Fit
Machine Sleeve Bore to:
Standard Size Piston (Finished Diameter) 102.00 to 102,04 mm
Hone to (Finished Diameter) 102.50 to 10254 mm
Hone to (Finished Diameter) 103,00 to 103.04 mm
Piston
Type : Cam Ground
Material Aluminum Alloy
00 at 12 mm From the Bottom, 90 Degrees Piston Pin
Standard Size Piston ,101.873 to 101.887 mm
Minimum Service Limit. , , 101.823 mm
Minimum Service Limit. , 102.823 mm
10 of Piston Pin Bore .40.006 to 40.012 mm
Width of 1st Ring Groove (Top) 2.465 to 2.485 mm
Width of 2nd Ring Groove (Intermediate) 2.425 to 2.445 mm
Width of 3rd Ring Groove (Oil Ring) , 4.040 to 4.060 mm
Protrusion Above Cylinder Block (Minimum) 0.280 mm
Piston Pin
Type Full Float
00 of Pin , 39.997 to 40.003 mm
Rae 8-24163
Revised292 Printedin U.S.A.
2402-6
Piston Rings
NO.1 Compression 4T-390 Engine Key Stone Type (Barrel Face)
End Gap in 102.02 ID 0.4 to 0.70 mm
NO.1 Compression 4-390 Engine Rectangular Type (Barrel Face)
End Gap in 102.02 ID 0.25 to 0.55 mm
Maximum Service Limit....... .. 0.806 mm
Side Clearance.................... . 0.075 to 0.120 mm
NO.2 Compression Rectangular Type (Tapper Face)
End Gap in 102.021D 0.25 to 0.55 mm
Maximum Service Limit.. 015 mm
NO.3 Oil Control Rings Two Piece
End Gap in 102.02 ID 0.25 to 0.55 mm
Maximum Service Limit. . 0806 mm
Side Clearance 0.130 mm
Cylinder Head
Warpage (Maximum) . 0.20 mm
Maximum Material Removal.................. 1.00 mm
Minimum Head Height 93.75 mm
Engines Manufactured in U.S.A.:
Engines Manufactured in Darlington England:
Engines Manufactured in Neuss Germany:
Lifters
Material Hardened Iron
OD of Lifter 15.961 to 15.977 mm
Bore Diameter in Block 16.000 to 16.030 mm
2402-7
Connecting Rod
Bushing Steel Backed Leaded Bronze
Bushing ID Installed (Ream to Size) 40.053 to 40.067 mm
Bearing Liners Replaceable
Bearing Oil Clearance 0.038 to 0.116 mm
Connecting Rod Bend (Maximum)
Without Bushing 0200 mm
With Bushing 0150 mm
Connecting Rod Twist (Maximum)
Without Bushing 0500 mm
With Bushing 0.300 mm .
Connecting Rod Bolt Maximum 59.25
Rae 8-24163
2402-8
Crankshaft
Type............................. . Hardened Steel, Balanced
Main Bearing Liners...... . Replaceable
End Clearance, Center Main Bearing Cap . 013 to 0.25 mm
Center Main Bearing Thrust Surface Thickness.. . 2.50 mm
Connecting Rod J ournal
OD, Standard 68.987 to 69.013 mm
Maximum Service Limit.. . 68.962 mm
0.25 mm OD Undersize, Grind to......................................................... ..68.737 to 68.763 mm
Maximum Service Limit.... . 68.712 mm
0.50 mm OD Undersize, Grind to 68.487 to 68.513 mm
Maximum Service Limit........ .. 68.462 mm
1.00 mm OD Undersize, Grind to. .. . 67.987 to 68.013 mm
Maximum Service Limit.............................................. .. 67962 mm
Connecting Rod J ournal Maximum Taper.................................................. .. 0.013 mm
J ournals Out of Round Maximum 0.050 mm
Undersize Main Bearing Liners For Service 0.25,0.50, 0.75 and 1.00 mm
Main Bearing J ournal
OD, Standard 82.987 to 83.013 mm
Main J ournal Width:
tst, 2nd, 3rd, 5th.......................... . 37.424 to 37.576 mm
4th................................................... . 37.475 to 37.525 mm
Connect Rod J ournals Width 38.950 to 39.050 mm
Main Bearing Bolt Maximum Length 119.25 mm
Rae 8-24163
2402-9
Camshaft
Type................ . Hardened Iron
Bushing (Front Only) 1, Replaceable
Bushing Lubrication:
Front Bushing Pressure Lubricated
Intermediate Pressure Lubricated
Rear Pressure Lubricated
Oil Clearance 0.076 to 0.152 mm
10 of NO.1 Bushing, Installed 54.107 to 54.133 mm
10of NO.1 Oversize (57.24 mm 00) Service Bushing 54.089 to 54.139 mm
10 of No.2, 3, 4 and 5 Service Bushing 54.089 to 54.139 mm
Width of No. 1 Bushing 25.15 to 25.65 mm
Width of No.2, 3, 4 and 5 Service Bushing 17.75 to 18.25 mm
Camshaft Bushing J ournal 00 53.987 to 54.013 mm
Camshaft Bore Diameter in Block
NO.1 Bushing 57.222 to 57.258 mm
NO.1 Oversize Bushing, Machine to 57.722 to 57.758 mm
No.2, 3, 4 and 5, Less Bushings 54.089 to 54.139 mm
No.2, 3, 4 and 5 Oversize for Bushings, Machine to 57.222 to 57.258 mm
Camshaft Thrust Thickness 9.42 to 9.58 mm
Camshaft Lobes:
Minimum Diameter at Peak Intake 47.265 mm
Minimum Diameter at Peak Exhaust... 46.994 mm
Turbocharger
Horizontal Travel of Turbine Shaft 0.10 to 0.16 mm
Gear Train
Backlash:
Crankshaft Gear to Idler Gear 0.08 to 0.33 mm
Camshaft to Fuel Pump Gear 0.08 to 0.33 mm
Idler Gear to Oil Pump 0.08 to 0.33 mm
Camshaft to Auxiliary 0.08 to 0.33 mm
Maximum Service Limit (All Gears) 0.45 mm
Rae 8-24163
Revised2-92 Printedin U.S.A.
2402-10
Rocker Arm Assembly
00 of Shaft . 18.963 to 18.975 mm
Minimum Service Limit .. 18.938 mm
10 of Arm Bore 19.000 to 19.026 mm
Lubrication Pressure From Oil Gallery
Shaft Oil Holes Down
Intake Valve
Face Angle..................... . 29 Degrees
Face Run-Out.. 0.038 mm
Valve Head Edge Thickness, Minimum 1.50 mm
Length 128.84 to 129.46 mm
00of Stem 7.960 to 7.980 mm
Minimum Service Limit.. 7.940 mm
00 of Head .44.870 to 45.130 mm
Seat Angle 30 Degrees
Seat Run-Out... 0.10 mm
Insert Height 6.84 to 6.96 mm
00 of Insert .47.063 to 47.089 mm
10 of Insert Tapered
10 of Valve Guide Bore 8.019 to 8.039 mm
Exhaust Valve
Face Run-Out 0.038 mm
Valve Head Edge Thickness, Minimum 1.50 mm
00 of Head 41.870 to 42.130 mm
00 of Stem 7.960 to 7.980 mm
Length 128.74 to 129.36 mm
Insert Seat Angle 45 Degrees
Seat Run-Out. 0.10 mm
Insert Height 6.65 to 6.77 mm
00of Insert .43.713 to 43.739 mm
10 of Insert Tapered
Maximum Service Limit : 1.52 mm
10 of Valve Guide Bore 8.019 to 8.039 mm
2402-11
Valve Springs
Free Length , , ,' , ,.,.., , , , 55.63 mm
Total Coils ' ,' ' , ,' , , , 7.25
Wire Diameter, , , '.., , , , , , . , .4.830 to 4.930 mm
Compressed to 38.53 mm , (Valve Open) 785 to 839 N
Maximum Service Limit , , , , 765 N
Compressed to 49.25 mm , (Valve Closed) 285 to 321 N
Minimum Service Limit , , ' 270 N
Valve Seat Installation Dimensions
Exhaust Seat
Diameter of Insert .' ,..43.713 to 43.73 mm
Machine Insert Bore to , , .43.647 to 43,663 mm
Depth of Bore , , 10.10 to .092 mm
Press Fit.. 0.05 to 0.102 mm
Intake Seat
Diameter of Insert .47.063 to 47.089 mm
Machine Bore to .46.987 to 47.013 mm
Depth of Bore . 10.30 to 10.50 mm
Press Fit................. 0.05 to 0.102 mm
Valve Guide Installation Dimensions
Valve Guide 00 , , 11.150 to 11.163 mm
Machine Guide Bore to 11.112 to 11.138 mm
Press Fit... 0.012 to 0.051 mm
Installed Height (above top of valve guide boss on head) "'"'''''''''''' """"'"'''''''''''''''' """ " " " " 11.25 to 11.75 mm
Guide Installed 10 8.19 to 8.39 mm
Guide Diameter 14.026 to 14.038 mm
Machine Guide Bore to 13.987 to 14.013 mm
Press Fit. , 013 to 051 mm
Installed Height (above top of valve guide boss on head) 11.25 to 11.75 mm
Guige Installed 10 , 8.19 to 8.39 mm
Metric Value
Aftercooler Bolts , 21 to 27 Nm
SPECIAL TORQUES
Alternator Bracket Bolts (Lower) 21 to 27 Nm
Alternator Bracket Bolts (Upper) , , , 21 to 27 Nm
Alternator Retaining Bolt 21 to 27 Nm
Balancer Counter Weight Bolts 21 to 27 Nm
Balancer Mounting Bolts 167 to 183 Nm
Balancer Idler Gear 52 to 62 Nm
Rae 8-24163 Revised2-92 Printedin U.S.A,
2402-12
Metric Valve
Belt Tensioner Retaining Bolt .39 to 47 Nm
Block Heater 11 to 13 Nm
Camshaft Retaining Bolts...... 21 to 27 Nm
Coolant Inlet Bolts 39 to 47 Nm
Connecting Rod Bolts 60 Nm Plus 60 Degrees
(Lubricate Threads with Engine Oil)
Cylinder Head Torque
Short Bolts 90 Nm Plus 90 Degrees
Long Bolts 120 Nm Plus 90 Degrees
Engine lift Bracket Bolts (Rear) 71 to 83 Nm
Exhaust Manifold Bolts 39 to 47 Nm
Fan Pulley Bracket Bolts 23 to 26 Nm
Fan Pulley Bolts
Grade 8.8 Size M8 37 to 43 Nm
Flywheel Housing Bolts 54 to 66 Nm
Flywheel Retaining Bolts................ 130 to 144 Nm
Flywheel Housing Cover Bolts 21 to 27 Nm
Fuel Filter Inlet Bolt 29 to 35 Nm
Fuel Air Removal Bolt 5 to 7 Nm
Fuel Filter Inlet Nut 29 to 35 Nm
Fuel Line Fitting (High Pressure) 22 to 28 Nm
Fuel line Fitting (Low Pressure) 22 to 28 Nm
Fuel Shutoff Solenoid 15 Nm
Front Cover Bolts 21 to 27 Nm
Front Housing Bolts 21 to 27 Nm
Injection Pump Drive Gear Nut.. 59 to 71 Nm
Injection Pump Retaining Nuts 21 to 27 Nm
Injection Pump Bracket Bolts 21 to 27 Nm
Injector Leak Off Bolt 5 to 7 Nm
Injector Retaining Nut. 55 to 65 Nm
2402-13
Metric Valve
Intake Manifold Bolts 21 to 27 Nm
Intake Manifold Plug 115 to 135 Nm
Lifter Cover Bolts 21 to 27 Nm
Main Bearing Bolts 80 Nm Plus 60 Degrees
(Lubricate the Thread with Engine Oil)
Oil Fill Tube Bolts 39 to 47 Nm
Oil Pan Drain Plug 68 to 82 Nm
Oil Pan Heater Plug 108 to 132 Nm
Oil Pan Retaining Bolts 21 to 27 Nm
Oil Pump Retaining Bolts... . 21 to 27 Nm
Oil Inlet Tube Bolts 18 to 30 Nm
Oil Inlet Tube Brace 21 to 27 Nm
Oil Filter Housing Bolts 21 to 27 Nm
Oil Relief Valve Plug 108 to 132 Nm
Primer Pump 21 to 27 Nm
Rear Seal Retaining Bolts 8 to 10 Nm
Rocker Arm Bolts 21 to 27 Nm
Starter Retaining Bolts 39 to 47 Nm
Tachometer Drive Retaining Bolts 2 to 4 Nm
Thermostat Housing Bolts 21 to 27 Nm
Timing Pin Retaining Bolts 4 to 6 Nm
Thrust Bearing Screws (Torx Head) .4 to 6 Nm
Turbocharger Mounting Bolts 30 to 34 Nm
Turbocharger Drain Tube Bolts 21 to 27 Nm
Turbine Housing Bolts 9 to 13 Nm
Center Housing to Back Plate Bolts 5 to 7 Nm
Compressor Housing Bolts 5 to 7 Nm
Compressor Lock NuL 13 to 15 Nm
Water Pump Mounting Bolts 21 to 27 Nm
Valve Cover Bolts 21 to 27 Nm
2402-14
Section
2415
CYLINDER HEAD AND VALVE TRAIN
4-390 Diesel Engine
IMPORTANT: This engine was made using the metric measurement system. NI
CASE CORPORATION
Rae 8-24173
Printed in U.S.A.
J une, 1983 (Revised February. 1992)
2415-2
TABLE OF CONTENTS
IDENTIFICATION MARKS 2
SPECIFICATIONS 3
SPECIAL TORQUES 4
SPECIAL TOOLS 5
CHECKING AND RESURFACING THE CYLINDER HEAD 12,13
VALVE GUIDE REPLACEMENT
14 mm Replacement Valve Guides 14
11 mm Replacement Valve Guides 15
INSPECTION OF THE VALVES AND VALVE SEATS 16-18
VALVE SEAT INSTALLATION.......................................... 19
REFACING INTAKE AND EXHAUST VALVES AND VALVE SEATS 20-26
CYLINDER HEAD ASSEMBLy 27,28
ROCKER ARM DiSASSEMBLy .28,29
ROCKER ARM ASSEMBLy 29
CYLINDER HEAD INSTALLATION 30-34
LOCATING TOP CENTER 35
ADJ USTING THE ROCKER ARM TO VALVE CLEARANCE 35-39
THERMOSTAT SERViCE 39-40
letter G Thermostat passage in cylinder did not need to be machined.
letter M =Thermostat passage in cylinder head was machined.
CYLINDER HEAD REMOVAL 6-10
CYLINDER HEAD DiSASSEMBLy................. 11
letter X =The cylinders inthe cylinder block have been bored oversize. Use a head gasket with oversize cylinder holes
(one notch).
LetterXX = The cylinder block has been refaced and up to 0.25 mm has been removed. Use athicker head gasket (two
notches).
Letter XXX =The cylinder block has been refaced and up to 0.50 mm has been removed. Use a thicker head gasket
(three notches).
Numbers = RH rear corner of cylinder head indicates the amount of material removed from the cylinder head.
2415-3
SPECIFICATIONS
ENGINES MANUFACTURED IN USA
ENGINES MANUFACTURED IN DARLINGTON ENGLAND
Prior to Engine Serial Number 21092870..................... Injector Nozzle 9 mm
Engine Serial Number 21092870 and After Injectior Nozzle 7 mm
ENGINES MANUFACTURED IN NEUSS GERMANY
Prior to Engine Number 52107489 Injector Nozzle 9 mm
CYLINDER HEAD
Maximum Warpage 0.010 mm in any 50 mm diameter area or more than
0.075 mm overall end to end or side to side.
Maximum amount of material that can be removed during resurfacing 1.0 mm
Minimum total height of cylinder head 93.75 to 94.25 mm
CYLINDER HEAD MACHINING IDENTIFICATION MARKS
Total thickness of cylinder head material removed See Page 12
X on head indicates block resurfacing See Page 27
Von head indicates valves have been ground See Page 27
G on head indicates thermostat bore inspected See Page 40
M on head indicates thermostat bore machined See Page 40
14 MM REPLACEMENT VALVE GUIDE
Valve guide 00 14.026 to 14.038 mm
Bore cylinder head to 13.987 to 14.013 mm
Press fit 0.013 to 0.051 mm
Installed height above top of valve guide boss on cylinder head 11.25 to 11.75 mm
11 MM REPLACEMENT VALVE GUIDE
Installed height above top of valve guide boss on cylinder head 11.25 to 11.75 mm
EXHAUST VALVE INSERT
Diameter of insert .43.713 to 43.739 mm
Diameter of bore 43.647 to 43.663 mm
Depth of bore 10.10 to 10.30 mm
INTAKE VALVE INSERT
Diameter of insert .47.063 to 47.089 mm
Diameter of bore .46.987 to 47.013 mm
Depth of bore 10.30 to 10.50 mm
:
2415-4
SPECIAL TORQUES
Alternator bracket bolts 21 to 27 Nm
Belt tensioner bracket bolts (Allen head) 21 to 27 Nm
Belt tensioner bolt 39 to 47 Nm
Cylinder head bolts 120 to 132 Nm
Exhaust manifold bolts 39 to 47 Nm
Fan belt pulley bracket bolts 23 to 25 Nm
Fan belt pulley bolts
Grade 8.8 Size M8 26 to 31
Fuel filter housing nut 29 to 35 Nm
Injector leak off fitting 5 to 7 Nm
Injector cap nut 55 to 60 Nm
Intake manifold cover bolts 21 to 27 Nm
Lift bracket bolts (Rear) 71 to 83 Nm
Rocker arm bracket bolts 21 to 27 Nm
Thermostat housing bolts 21 to 27 Nm
Valve cover bolts 21 to 27 Nm
2415-5
SPECIAL TOOLS
B90288SJ
B9028B3J
CAS-1066A Head Bolt Wrench
This tool is first used on Page 36.
CAS-1694 Injector Bore Cleaner (For 9 mm injectors)
CAS-2155 Injector Bore Cleaner (For 7 mm injectors)
B902884J
CAS-2162 Torque Angle Gauge
This tool first used on Page 31.
CAS-1743 Valve Guide Reamer
Rae 8-24173
2415-6
STEP 1
CYLINDER HEAD REMOVAL
STEP 4
Lift the belt tensioner and remove the fan belt.
STEP 2
Remove the belt tensioner bolt and the belt tensioner.
STEP 3
Mc,iQ,I6~94g
Remove the fan hub bolts and the fan hub.
Rae 8-24173
'T68944
Remove the belt tensioner bolts and the bracket.
STEP 5
i1
Remove the fan hub bracket bolts and the bracket.
STEP 6
Remove the bolts that hold the alternator and remove
the alternator.
STEP 7
Remove the alternator bracket bolts and the bracket.
STEP 8
Remove the thermostat bolts and the housing as-
sembly.
STEP 9 4T-390 ENGiNE
To remove the turbocharger see section 2465 in the
service manual.
Rae 8-24173
2415-7
STEP 10
STEP 11
Disconnect and remove the fuel lines.
STEP 12
I,
Install protective covers on the injection pump outlet
lines and the injection lines.
2415-8
STEP 13 CAV INJECTION PUMP
Remove the leak off fitting and gasket.
STEP 14 BOSCH INJECTION PUMP
Remove the leak off fitting and gaskets.
STEP 15
15
Remove the leak off fittings, gaskets and the leak off
line.
Rae 8-24173
STEP 16
Loosen the nut on the injectors.
NOTE: The injector must not rotate in the bore of the
cylinder head. This will damage the cylinder head.
STEP 17
Remove the injectors from the cylinder head.
NOTE: Make sure the injector seal is removed from the
cylinder head.
STEP 18
Use a strap type wrench to remove the fuel filters.
NOTE: Some engines have asingle fuel filter.
STEP 19
. " .w N
T68983
Remove the fuel line fittings and the fuel line.
STEP 20
STEP 21 CAY INJECTION PUMP
Remove the inlet line.
Rae 8-24173
2415-9
Remove the inlet line.
STEP 23
:> .:,.;
T~8~9~j
Install a protective cover in the injection pump.
STEP 24
.~:..
. . ~~ .....-.:~
..------ ':T68994
Remove the valve bolts and the valve covers.
2415-10
STEP 25
.... ".--..... ",...., .
Remove the intake manifold cover bolts and the intake
manifold cover.
STEP 26
Remove the rocker arm bolts and the rocker arm as-
semblies.
STEP 27
Remove the push rods from the cylinder head.
Rae 8-24173
STEP 28
Remove the lift bracket bolts and the lift bracket.
STEP 29
Remove the cylinder head bolts and the cylinder head.
STEP 30
~A#W T68~
Cover the cylinder bores and pistons. Clean all foreign
material from the cylinder head mounting surface.
NOTE: The cylinders and pistons must be covered to
prevent damage to the pistons and cylinder walls.
2415-11
STEP 31
CYLINDER HEAD DISASSEMBLY
STEP 34
687~8'
Put the cylinder head on a clean work surface.
STEP 32
.../-)
.~~,~ . -"(. 6~Q7':l()
~ ...'.~:::w:..
Use a valve spring compressor to push down the valve
springs. Remove the valve keepers.
STEP 33
{" -. "t-
~ ~ . . . &
Remove the valve spring retainers and the valve spring.
Rae 8-24173
Remove the valve seals.
STEP 35
; ::
Remove the valves.
2415-12
STEP 36
CHECKING AND RESURFACING THE CYLINDER HEAD
STEP 38
.:.:.:
....pp
Clean the cylinder head completely. Remove carbon
and other deposits. Check for cracks and any other
damage to the head.
STEP 37
Check the cylinder head surface with a straight edge
and feeler gauge. Resurface the cylinder head if
warpage or erosion is more than 0.010 mm in any 50
mm diameter area or if there is more than 0.075 mm
overall end to end or side to side
Rae 8-24173
B902888J
Resurface the cylinder head inincrements necessary to
straighten the surface and maintain surface finish ac-
cording to the following specifications:
A = 10 mm total amount of material removed.
B = 93.75 mm minimum total height of the cylinder
head.
C = Surface finish1.5 to 3.2 micrometers.
D = Use this area to stamp the total thickness of
cylinder head material removed in rnrn.
"levised 2-92 Printed in U.S.A
STEP 39
B902889J
Measure the valve guide diameter at three depths with a
bore gauge.
Rae 8-24173
2415-13
STEP 40
".
Measure the bore gauge with a micrometer. If the
diameter of the valve guide at any depth is more than
8.089 mm, install anewvalve guide. See Page 14for 14
mmvalve guides and Page 15 for 11 mmvalve guides.
2415-14
VALVE GUIDE REPLACEMENT
14 mm Replacement Valve Guides
STEP 42
There are two different diameters of replacement valve
guides for your engine. You can get either 14 mm or 11
mm 00 replacement valve guides. Measure the re-
placement valve guides before you machine the
cylinder head.
Specifications
Installed height above top of valve guide boss
on cylinder head 11.25 to 11.75 mm
STEP 41
Drill the valve guide bores to 13.987 to 14.013 mm
diameter.
Rae 8-24173
B902891J
Make a bushing 16.038 mm 10 x 11.25 to 11.75 mm
long. Install the bushing over the newvalve guide. Press
the new valve guide into the cylinder head until the
press contacts the bushing.
STEP 43
Drill the new valve guides to a diameter of 8.0 mm.
Ream the new valve guides to a finished diameter of
8.019 to 8.039 rnrn.
Revised 2-92 Printed in U.SA
2415-15
11 mm Replacement Valve Guides
Specifications STEP 45
Valve guide 00 11.150to 11.163 mm
Installed height above top of valve guide
boss on cylinder head 1125 to 11.75 mm
STEP 44
DIAMETER OF
11.112 TO 11.138 mm
(\
Drill the valve guide bores to 11.112 to 11.138 mm
diameter.
Rae 8-24173
t
11.25 TO 11.75 mm
t
B902891J
Make a bushing 16.038 mm 10 x 11.25 to 11.75 mm
long Install the bushing over the newvalve guide. Press
the new valve guide into the cylinder head until the
press contacts the bushing.
STEP 46
Drill the valve guides to adiameter of 8.0 mm. Reamthe
new valve guides to a finished diameter of 8.019 to
8.039 mm.
2415-16
STEP 47
INSPECTION OF THE VALVES AND VALVE SEATS
STEP 48 (Cont'd)
STEP 48
Check the valves for the following conditions.
VALVE STEM WITH A NARROW NECK
j
8902893J
NOTE: REPLACE THE VALVE IF THIS CONDITION OCCURS.
This Condition Can Be Caused By:
1. Valve does not have lubrication.
2. Restriction in the water passages.
3. Operating the engine under continued overload at
too much engine RPM.
._-- GROOVE IN VALVE FACE
8902894J
NOTE: GRIND OR REPLACE VALVE IF THIS CONDITION
OCCURS.
This condition can be caused by foreign material
entering the engine through the intake system or not
giving service to the air intake system.
Rae 8-24173
I FINE PiniNG
8902895J
NOTE: THIS IS A NORMAL CONDITION.
Small amounts of very fine pitting can be found on the
surfaces of the valve face or seat after the valves are
cleaned. These are normal and will not change the
engine performance. This fine pitting is caused by
normal oxidation procedure and can occur on any
engine during the run-in period. It is not necessary to
grind valves or seats ifthis fine pitting is found. because
pitting will generally occur after the engine has run for
several hours.
8902896J
NOTE: GRIND OR REPLACE THE VALVE IF THIS CONDITION
OCCURS.
This condition is generally caused byworn valve guides
or bad seals on the valves. permitting oil to go by the
valves. Low operating temperature is a secondary
cause. Worn piston rings and cylinder walls will also
permit too much oil to reach the combustion chamber.
RUST OR PiniNG ON VALVE STEM
1
8902897J
NOTE: REPLACE VALVE IF THIS CONDITION OCCURS.
This condition can be caused by using bad quality
engine oil or fuel and by not correctly keeping the
engine in storage.
NOTE: THIS CONDITION CAN BE CAUSED BY USING BAD
QUALITY ENGINE OIL OR FUEL.
DEEP BURNED VALVE FACE
CONCAVE VALVE HEAD
These conditions are generally caused by running the
engine at very high engine temperatures, grinding the
valve face too thin or valve grinding that is not correct.
B902900J
Rae 8-24173
2415-17
STEP 49
INTAKE VALVES
7.960 TO7.980 mm
7.960 TO7.980 mm
B902901J
Check the intake valve stem diameter at three points
along the stem. If the stem diameter is less than 7.960
mm, the valve must be replaced.
EXHAUST VALVES
7.960 TO7.980 mm
B902902J
Check the exhaust valve stem diameter at two points as
shown. Ifthe stemdiameter is less that 7.960 mm or the
stem tip diameter is less than 7.960 mm, the valve must
be replaced.
STEP 48 (Cont'd)
/' 1. RUST OR PiniNG IN VALVE FACE
2425-18
STEP 50
VALVE WITHOUT REPLACEABLE SEATS
1.52 mm MAX.
B902903J
Put the valves inthe cylinder head and check to make
sure that the valve heads are recessed in the cylinder
head. Thevalves must not protrude from the head. Ifthe
valve head is recessed more than 1.52 mm below the
cylinder head surface, the valve must be replaced or a
valve insert must be installed to make sure that there is
equal compression ratios between cylinders.
2415-19
STEP 51
VALVE SEAT INSTALLATION
STEP 52
Machine the cylinder head to the following specifica-
tions for valve seats.
Exhaust Valve Seat Specifications:
Diameter of Valve Seat 43.713 to 43739 mm
Diameter of Bore 43.647 to 43.663 mm
Depth of Bore 10.10 to 10.30 mm
Press Fit 0.05 to 0.092 mm
Intake Valve Seat Specifications:
Diameter of Valve Seat 47.063 to 47.089 mm
Diameter of Bore 46.987 to 47.013 mm
Depth of Bore 10.30 to 10.50 mm
Press Fit 0.05 to 0.102 mm
1. VALVE SEAT BORE
/
B902904J
Rae 8-24173
Clean the recessed area in the cylinder head. Put the
newvalve seats in dry ice for a minimum of one hour to
shrink the valve seats for easy installation. Use a driver
and install the valve seats.
A
Always wear gloves to prevent frostbite to
your hands when handling frozen parts.
SM118A
STEP 53
Use a center punch and stake the valve seats in three
positions. Grind the valve seats to the correct angle.
Revised 2-92 Printed in U.S.A
2415-20
REFACING INTAKE AND EXHAUST VALVES AND VALVE SEATS
STEP 54
VALVE IDENTIFICATION
The 45 degree exhaust valves are smaller in diameter
than the intake valves.
The 30 degree intake valves are larger in diameter than
the exhaust valves.
Rae 8-24173
STEP 55
VALVE AND SEAT GRINDING ANGLES
44 DEGREE
ANGLE
30 DEGREE VALVE
45 DEGREE SEAT
30 DEGREE SEAT
B902905J
Ifdimension A and B is less than 1.5 mm the valve must
be replaced.
NOTE: Use aprecision seat grinder. Take very light cuts
with the grinding stones so just enough metal is
removed to end up with a good smooth seat finish.
2415-22
IF THE VALVE CONTACT AREA ON THE
SEAT LOOKS LIKE THIS (A SEAT THAT
HAS BEEN GROUND).
SEAT CONTACT AREA ON THE VALVE
TO LOW
SEAT LOOKS LIKE THIS.
_ USE A 45 DEGREE ST~
TO MAKE WIDER, THE
- USE A 45 DEGREE STl
CONTACT AREA.
TOO HIGH
Rae 8-24173
_ USE A 45 DEGREE 51
AND TO MAKE WIDER
_ THE VALVE MUST BE f
VALVE SEAT MUST Sf
CAUSE MORE GRIN[
CHANGE THE LOWER l
Revised 2-92
DIAGNOSIS OF DIFFERENTDYE PATTERNS
45 Degree Exhaust valves
INE TO LIFT THE - USE A 60 DEGREE STONE TO LIFT AND
NARROW THE LOWER CONTACT AREA.
- CHECK THAT THE VALVE HEAD IS NOT - IF THE VALVE HEAD IS RE-
RECESSED MORE THAN 1.52 mm. BE- CESSED MORE THAN 1.52 rnm,
LOW THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
- CHECK THAT THE VALVE HEAD IS NOT _ IF THE VALVE HEAD IS RE-
RECESSED MORE THAN 1.52 mmBELOW CESSED MORE THAN 1.52 mm,
THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STAU A VALVE SEAT.
ONE TO LOWER _ USE A 30 DEGREE STONE TO NARROW
THE CONTACT THE UPPER CONTACT AREA, IN-
CREASED BY THE 45 DEGREE STONE.
IEPLACEDAND A
!INSTALLED BE-
liNG WIU NOT
eONTACT POINT.
Printed in U.S.A.
_ CHECK THAT THE VALVE HEAD IS NOT _IF THE VALVE HEAD IS RE-
RECESSED MORE THAN 1.52 mm, BE- CESSED MORE THAN 1.52 mm,
LOW THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
STEP 56
Put a small amount of blue dye on the valve face. Install
the valve in the head and rotate the valve on the seat.
STEP 57
Remove the valve and look at the contact area on the
valve face and seat. The blue dye will be gone from the
valve face where the valve made contact with the seat.
Rae 8-24173
2415-21
STEP 58
30 DEGREE VALVES
45 DEGREE VALVES
B902906J
Correct refacing of valves and seats will give a dye
pattern as shown.
NOTE: If the dye pattern is other than the patterns
shown, check the diagnosis of different dyepatterns on
the following pages.
2415-24
SEAT LOOKS LIKE THIS (A SEAT THAT
HAS BEEN GROUND).
<,
TO HIGH.
_ USE A 30 DEGREE
WIDER AND TO LO'
AREA.
- THE VALVE MUST E
VALVE SEAT IN!
MORE GRINDING \
THE LOWER CONTI
IF THE VALVE CONTACT AREA ON THE _ USE A 30 DEGREE
SEAT LOOKS UKE THIS (A SEAT THAT WIDER THE CONTA
HAS BEEN GROUND).
<,
IF THE VALVE CONTACT AREA ON THE _ THE VALVE MUST e
SEAT LOOKS LIKE THIS. VALVE SEAT INS
MORE GRINDING \
THE LOWER CONTI
TO NARROW
Rae8-24173 Revised,
t STONE TO MAKE
~ER THE CONTACT
E REPLACED AND A
TALLED BECAUSE
"ILL NOT CHANGE
,CTPOINT.
_ USE A 15 DEGREE STONE TO LOWER _ CHECK THAT THE VALVE HEAD IS NOT
THE UPPER CONTACT AREA. RECESSED MORE THAN 152 mm BELOW
THE CYLINDER HEAD SURFACE.
_ IFTHE VALVE HEAD IS RECESSED MORE
THAN 1.52 mm. REPLACE THE VALVE
AND INSTALL A VALVE SEAT.
- IF THE VALVE HEAD IS RE-
CESSED MORE THAN 152 mm,
REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
STONE TO MAKE
cr AREA.
E REPLACED AND A
TALLED BECAUSE
VILL NOT CHANGE
,CTPOINT.
-92 Printedin U.SA
_ CHECK THAT THE VALVE HEAD IS NOT
RECESSED MORE THAN 152 mmBELOW
B902909J
TO NARROW
CONTACT AREA
IF THE VAlVE CONTACT AREA ON THE
VALVE SEAT LOOKS LIKE THIS.
2415-23
_ USE A 45 DEGREE STONE TO INCREASE - CHECK THAi
THE CONTACT AREA. RECESSED"
THE CYLINDI
-THE VALVE MUST BE RE-
PLACED AND A VALVE SEATlN-
STALLED BECAUSE MORE
GRINDING WILL NOT CHANGE
THE LOWER CONTACT AREA.
TO WIDE.
Rae 8-24173
CONTACT AREA
_ USE A 30 DEGREE STONE TO LOWER
THE UPPER CONTACT AREA.
- USE A 30 DEGREE STONE TO LOWER
THE UPPER CONTACT AREA.
_USEA60DE
LOWER CON
-USEA60DE
LOWER CON
THE VALVE HEAD IS NOT
ORE THAN 1.52 mm BELOW
:R HEAD SURFACE.
- CHECK THAT THE VALVE HEAD
IS NOT RECESSED MORE THAN
1.52 mm. REPLACE THE VALVE
AND INSTALL A VALVE SEAT.
iREE STONE TO LIFT THE
ACT AREA.
_ IF THE VALVE HEAD IS RE-
CESSED MORE THAN 1.52 mm.
STALL A VALVE SEAT.
_ CHECK THAT THE VALVE HEAD IS NOT _ IF THE VALVE HEAD IS RE-
RECESSED MORE THAN 1.52 mm BELOW CESSED MORE THAN 1.52 mm.
THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
B902908J
2415-26
TO WIOE
IF THE VALVE CONTACT AREA ON THE - USE A 15 DEGREE STOI
SEAT LOOKS LIKE THIS (A SEAT THAT THE UPPER CONTACT AI
HAS BEEN GROUND) .
.....
Rae 8-24173
- 1 DEGREE INTERFEREN(
Revised 2-92
"IE TO LOWER
~EA.
iE TO LOWER
lEA.
- USEA45 DEGREE OR 60 DEGREE STONE _ CHECK THAT THE VALVE HEAD IS NOT
TO LIFT THE LOWER CONTACT AREA. RECESSED MORE THAN 1.52 mm BELOW
- USEA45 DEGREE OR 60 DEGREE STONE _CHECK THAT THE VALVE HEAD IS NOT
TO LIFT THE LOWER CONTACT AREA. RECESSED MORE THAN 1.52 mm, BE-
LOW THE CYLINDER HEAD SURFACE.
_IF THE VALVE HEAD IS RE-
CESSED MORE THAN 1.52 mm
STALL A VALVE SEAT.
_IF THE VALVE HEAD IS RE-
CESSED MORE THAN 1.52 mm,
STALL A VALVE SEAT.
:E ANGLE
Printed in U.S.A.
_ CORRECT REFACING OF THE INTAKE
VALVE AND VALVE SEAT WILL GIVE A 1
DEGREE INTERFERENCE ANGLE. THIS
ANGLE IS IMPORTANT BECAUSE IT
GIVES ASSISTANCE IN CUTTING CAR-
BON AND TO SEAT THE VALVES.
B902911J
THIS IS THE CORRECT SEAT CONTACT-THE CORRECT EXHAUST VALVE CON-
AREA ON THE VAlVE. TACT AREA ON THE SEAT WILL GIVE A
SEAT WIDTH OF 1.47 TO 2.07 mm.
2415-25
-
_1 DEGREE IN
30 DEGREE INTAKE VALVES ONLY
IF THE VAlVE CONTACT AREA ON THE - USE A 30 DEGREE STONE TO LIFT AND
SEAT LOOKS LIKE THIS (A SEAT THAT TO MAKE WIDER THE CONTACT AREA.
HAS BEEN GROUND).
<,
SEAT CONTACT AREA ON THE VAlVE
TO LOW
IF THE VAlVE CONTACT AREA ON THE _ USE A 30 DEGREE STONE TO LIFT THE
SEAT lOOKS LIKE THIS. CONTACT AREA.
Rae 8-24173
- USEA45DEG
TO NARROl1
AREA INCRE.
STONE.
ERFERENCE ANGLE
-CORRECT REFACING OF EXHAUST
VALVES AND VALVE SEATS WILL GIVE A
1 DEGREE INTERFERENCE ANGLE. THIS
ANGLE IS IMPORTANT BECAUSE THE
ANGLE GIVES ASSISTANCE IN CUTTING
CARBON AND TO SEAT THE VALVES.
STALL A VALVE SEAT.
'OEOR 60 DEGREE STONE
THE LOWER CONTACT
ED BY THE 30 DEGREE
E OR 60 DEGREE STONE
'HE LOWER CONTACT
-CHECK THAT THE VALVE HEAD IS NOT
RECESSED MORE THAN 152 mm. BE-
LOW THE CYLINDER HEAD SURFACE.
_ CHECK THAT THE VALVE HEAD IS NOT
RECESSED MORE THAN 152 mmBELOW
STALL A VALVE SEAT.
_ IF THE VALVE HEAD IS RE
CESSED MORE THAN 152 mm
REPLACE THE VALVE AND'
STALL A VALVE SEAT.
B90291 OJ
2415-27
STEP 59
CYLINDER HEAD ASSEMBLY
STEP 62
904LO
If the cylinder head has been machined, mark the
amount removed on the RH rear corner of the cylinder
head.
IMPORTANT: Do not machine more than 1.00 mm
from the cylinder head. The head height must not be
less than 93.75 mm.
STEP 60
" " ' 36
Apply lubrication to the valves. Install the valves in the
cylinder head.
STEP 61
Install new valve seals.
Rae 8-24173
Install the valve spring the valve spring caps.
STEP 63
.
. :,. ,.,/.~,"
-';.;I:;~. . L:,,-,T687~n
- ~ '.. ~:~#,... ... z;.;."':~
Push down the valve springs with a spring compressor.
Install the valve keepers.
NOTE: Always install new valvekeepers when new caps
or valves are installed.
STEP 64
r ~: ....
Remove the spring compressor and hit the end of the
valve stems with a soft hammer to seat the valve
keepers.
2415-28
STEP 65
)1:68728
Clean the injector bores with a bore cleaner Early Pro-
duction engines have 9 mm injectors and late produc-
tion engines have 7 mm injectors. See the following il-
lustration.
Use a CAS-1694 injector bore cleaner for heads that
have 9 mm injectors.
Use a CAS-2155 injector bore cleaner for heads that
have 7 mm injectors.
7 mm Diameter Tip
8903013J
9 mm Diameter Tip
ROCKER ARM DISASSEMBLY
305L91
Remove the snap ring, washer and rocker armfrom the
shaft.
Rae 8-24173
STEP 67
Use a micrometer and measure the rocker arm shaft for
out of round. Measure in three different locations
around the shaft. If the rocker arm shaft is less than
18.938 mm in diameter the rocker arm shaft assembly
must be replaced.
STEP 68
Measure the rocker arm with a bore gauge inthree dif-
ferent locations around the bore.
2415-29
STEP 69
- :, w-
Use a micrometer to measure the bore gauge. If the
diameter of the bore is more than 19.05 rnrn, the rocker
arm must be replaced.
ROCKER ARM ASSEMBLY
5. ROCKER ARM
STEP 70
Install the rocker arms on the rocker arm shaft with the
adjusting screws on same end as the large hole in the
bracket.
Rae 8-24173
309L91
STEP 71
Install thewashers and the snap rings on the rocker arm
shaft.
2415-30
STEP 72
CYLINDER HEAD INSTALLATION
STEP 74
Use the correctr tap and clean all head bolts holes of
foreign material.
STEP 73
Insallthe correct head gasket on the engine block, see
below.
Head Gasket Application
No Notches - Replacement Gaskett
2 Notches - 0.25 mm Oversize Gasket
3 Notches - 0.50 mm Oversize Gasket
IMPORTANT: Oversize thickness gaskets are used
when the cylinder block has been machined.
Rae 8-24173
Install the cylinder head.
STEP 75
9171.91
Use the bolt length gauge to check the head bolt length.
Ifthe head bolt length is more than the maximum length
on the gauge the bolt must be replaced.
918L91
Check and replace all head bolts that have rust, pitting
narrowing and corrosion.
STEP 77
Put a small amount of engine oil on the head bolt
threads. Install the head bolts and washers. Tighten the
bolts a small amount.
NOTE: Do not torque the head bolts at this time.
STEP 78
Install the push rods and the rocker arm assembly.
Rae 8-24173
2415-31
STEP 79
B902915J
Tighten the cylinder head bolts to the correct torque,
following the torque sequence shown above.
Use the following steps to get the correct torque.
Step 1 - torque to 41 Nm
Step 2 - torque to 90 Nm
Step 3 - torque bolts 3, 6, 11 and 14 to 120 Nm
STEP 80
Install the torque angle and tighten each head bolt an
additional 90 degrees.
2415-32
STEP 81
T68834
Tighten the rocker shaft bracket bolt to atorque of 21 to
27 Nm.
STEP 82
Install the intake manifold gasket and the intake man-
ifold.
STEP 83
Put Loctite liquid teflon on the intake manifold bolts
Rae 8-24173
8902916J
Install the intake manifold bolts and tighten to a torque
of 21 to 27 Nm, following the torque sequence shown
above.
STEP 85
Install the rear lift bracket and tighten the bolts to a
torque of 71 to 83 Nm.
CAY INJECTION PUMP
Connect and tighten the inlet tube nuts.
Install the injection pump inlet tube.
Tighten the fuel outlet fitting to a torque of 29 to 35 Nm.
Rae 8-24173
2415-33
STEP 89
Install the inlet tube. Install a new o-ring on the filter
housing and install the filter housing.
NOTE: Some engines have single fuel filters.
STEP 90
Install the filter housing nut and tighten to atorque of 29
to 35 Nm.
STEP 91
T68983
Install the lift pump outlet tube.
Revised 2-92 Printedin USA
2415-34
STEP 92
Tighten the filter inlet fitting to a torque of 29 to 35 Nm.
STEP 93
For correct fuel filter installation see the fuel filter
section.
STEP 94
Install the thermostat inthe thermostat housing. The pin
in the thermostat must be at the top of the thermostat
housing.
NOTE: See page 39 to check the diameter of the ther-
mostat opening in cylinder head.
Rae 8-24173
STEP 95
Install the seal and the front lift bracket.
STEP 96
Install the thermostat housing assembly and bolts.
Tighten the bolts to a torque of 21 to 27 Nm.
STEP 97
B902917J
T69
Install the manifold bolts and gasket on the cylinder
head. Tighten the bolts to a torque of 39 to 47 Nm,
follow the torque sequence shown above.
2415-35
STEP 98
LOCATING TOP CENTER
STEP 99
ADJUSTING THE ROCKER ARM TO VALVE CLEARANCE
Cold Setting
STEP 101
\1
Install the engine rotating tool into the flywheel housing.
Rotate the engine four revolutions to make sure the
push rods are seated correctly.
STEP 100
:':".;;-'
f'~~~
Check and adjust the intake and exhaust valves as the
arrows show below.
4 3 2 1
E E
B902918J
Number one cylinder top center compression stroke.
Valve Clearance, Cold: Intake Valves - 0.254 mm
Exhaust Valves - 0.508 mm
Rae 8-24173
.,.'.,..'.'M,"'...,..,~'"'" .... .-.,...,,w,,.._ ... ,,, .w."_""..... ,... ,
While turning the engine, push the lock pin in. When the
lock pin moves intothe camshaft gear the engine will be
at top center.
Install the engine rotating tool. Move the engine a small
amount in each direction. Pull the lock pin out.
Revised2-92 Printed in U.S.A
2415-36
STEP 102
Turn the engine one complete revolution.
Check and adjust the intake and exhaust valves as the
arrows show below.
3 2
E
8902919J
Number four cylinder top center compression stroke.
Valve Clearance, Cold: Intake Valves - 0.254 mm
Exhaust Valves - 0.508 mm
8903013J
7 mm Diameter Tip 9 mm Diameter Tip
Before you order newinjectors or seals, you must deter-
mine which injectors were installed in your engine.
Rae 8-24173
STEP 104
Put new seals on the injectors and install the injectors.
STEP 105
Tighten the injector nut to a torque of 55 to 60 Nm.
STEP 106
Install the leak off line, fittings and gaskets Tighten the
fittings to a torque of 5 to 7 Nm.
STEP 107
Install the injector lines connect and tighten the injector
line nut to the injection pump and injectors.
STEP 108
Install the bracket and tighten.
STEP 109
Install the alternator bracket and tighten the bolts to a
Rae 8-24173
2415-37
STEP 110
Install the alternator and tighten the bolts.
STEP 111
Install the fan belt pulley bracket and tighten the bolts to
a torque of 23 to 25 Nm.
STEP 112
J >9l85
Install the belt tensioner bracket and tighten the Allen
head bolts to a torque of 21 to 27 Nm.
Revised2-92 Printed in U.SA
2415-38
Install the fan belt pulley and tighten the bolts to a
torque of:
Grade 10.9 Size MO 51 to 62 Nm
STEP 114
Install the belt tensioner and tighten the bolt to a torque
of 39 to 47 Nm.
STEP 115
Lift the belt tensioner and install the fan belt.
Rae 8-24173
STEP 116
To install the turbocharger, see section 2465 in the
service manual.
STEP 117
Start and operate the engine. Check engine oil
pressure indicator to make sure of correct engine oil
pressure. Check the rocker arms to make sure that the
arms are receiving oil.
STEP 118
Install new gaskets on the valve covers.
STEP 119
Install new a-rings on the valve cover bolts.
STEP 120
Install the valve cover bolts and tighten to a torque of 21
to 27 Nm.
2415-39
STEP 121
THERMOSTAT SERVICE
STEP 123
1. New Thermostat
2. Old Thermostat
B902920J
A new thermostat has been released for use in your
engine. If you removed an old thermostat from your
engine, do the following steps to install a new ther-
mostat.
STEP 122
8902921J
Install the template that comes withthe newthermostat
kit.
Rae 8-24173
8902922J
If the cylinder head coolant passage is smaller than the
10 of the template, the coolant passage will have to be
made larger. Mark the 10of the template on the cylinder
head.
STEP 124
8902923J
Remove the template. Use a shop cloth in the coolant
passage to keep metal shavings out of the engine. Use
a rotary grinder to remove the material.
Revised2-92 PrintedinU.S.A.
2415-40
STEP 125 STEP 126
B902924J
Remove any metal shavings from the cylinder head.
Install the seal and newthermostat. Tighten the bolts to
21 to27 Nm.
Mark the cylinder head on the intake side next to the
serial number as follows:
Stamp the letter "G" for cylinder heads that were in-
spected and did not need to be machined.
Stamp the letter "M" for cylinder heads that were
machined.
Section
2425
CYLINDER BLOCK
Crankshaft, Pistons, Rods, Sleeves, Camshaft,
Bearings, Seals and Flywheel
4-390 Diesel Engine
CASE CORPORATION
Rae 8-24183
Printed in U.S.A.
J une. 1983 (Revised February, 1992)
2425-2
TABLE OF CONTENTS
SPECIFICATIONS ..
Special Torques
..4-6
...........6
SPECIAL TOOLS ............ 7-8
FRONT Oil SEAL REPLACEMENT. 9-11
REAR Oil SEAL REPLACEMENT 12-15
FRONT OIL SEAL AND WEAR SLEEVE INSTALLATION . .... 15-17
REAR Oil SEAL AND WEAR SLEEVE INSTALLATION . . 18-21
REMOVAL OF PISTONS AND RODS . . 21-22
CYLINDER WALL INSPECTION 23-26
RECONDITIONING THE ENGINE CYLINDER BLOCK
Checking and Resurfacing the Cylinder Block. . 27
Reconditioning the Cylinder Block for Oversize Pistons . ....28
Reconditioning the Cylinder Block for Sleeves . ...29-30
PISTON AND CONNECTING ROD DISASSEMBLY AND INSPECTION . ... 31-33
PISTON AND CONNECTING ROD ASSEMBLY AND INSTALLATION . ... 33-38
REPLACEMENT OF THE MAIN BEARINGS WITHOUT REMOVING THE CRANKSHAFT .... . 38-41
CRANKSHAFT AND MAIN BEARINGS . . 41-45
CRANKSHAFT GEAR REMOVAL . . 46
CRANKSHAFT INSPECTION .46
CRANKSHAFT RECONDITIONING
Grinding a Crankshaft . .. 47
Crankshaft Rehardening . . .47
CRANKSHAFT GEAR INSTALLATION .48
CRANKSHAFT INSTALLATION 48-57
2425-3
CAMSHAFT
Removal 58-59
Camshaft Bore and Bushing Inspection 59-60
Camshaft Bushing Removal and Installation 60
Valve Lifter Inspection 61
Camshaft Disassembly and Inspection 62
Camshaft Gear Installation 63
Camshaft Installation 63-66
FLYWHEEL
Removal 66
Ring Gear Removal and Installation 67
Installation '" 67
TACHOMETER DRIVE, IF EQUIPPED
Removal and Disassembly 68
Assembly and Installation 68
EXPANSION PLUG REMOVAL AND INSTALLATION
60 mm Expansion Plugs 69
22.5 mm Expansion Plugs 72
18 mm Expansion Plugs 73-74
10 mm Expansion Plugs 74-75
CRANKCASE PRESSURE CHECK (BLOW BY)
Manometer Installation 76
Testing 77
Manometer Removal 78
2425-4
SPECIFICATIONS
CYLINDER BLOCK
ID of Cylinder , , 102.00 to 102.04 mm
Maximum Cylinder Out of Round............................... 0.038 mm
Maximum Cylinder Taper . , 0.076 mm
Maximum Warpage of Cylinder Block Surface ..More than 0,010 mm in any 50 mm diameter area or
more than 0.075 mm overall end to end or side to side
Maximum Amount of Material that can be Removed During Resurfacing , . " , 0.50 mm
Standard Piston Finish Housing of Cylinder Bore 102.00 to 102.116 mm
0.5 mm Oversize Piston Machine Cylinder Block Bore to 102.40 to 102.44 mm
0.5 mm Oversize Piston Finish Honing of Cylinder Block Bore , 102.50 to 102.54 mm
1.0 mm Oversize Piston Machine Cylinder Block Bore to 102.90 to 102.94 mm
1.0 mm Oversize Piston Finish Honing of Cylinder Block Bore 103.00 to 103.04 mm
CYLINDER SLEEVE
Machine Cylinder Block Bore to 104.485 to 104.515 mm
Machine Cylinder Sleeve Bore to 101.90 to 101.94 mm
Finish Honing Cylinder Sleeve to 102.00 to 102.04 mm
PISTON
OD 12 mm From the Bottom, 90 Degrees from Piston Pin 101.873 to 101.887 mm
Piston Clearance 0.113 to 0.293
ID of Piston Pin Bore 40.006 to 40.012 mm
PISTONS RINGS
No. 1 Compression
End Gap in 102.0210 Cylinder 0.25 to 0.55 mm
Side Clearance 0.075 to 0 120 mm
No. 2 Compression
NO.3 Oil Control Ring
Maximum Service Limit , 0806 mm
Rae 8-24183 Revised 2-92 Printed in U.S.A
2425-5
PISTON PIN
00of Pin. . 39.997 to 40.003 mm
CONNECTING ROD
Bushing 10 installed 40.053 to 40.067 mm
Bearing Oil Clearance 0.038 to 0.116 mm
Side Clearance 0 100 to 0.300 mm
Bolt (Maximum Length) 59.25 mm
CRANKSHAFT
End Clearance, Center Main Bearing Cap 0.041 to 0.119 mm
Center Main Bearing Thrust Surface Thickness 2.50 mm
Connecting Rod J ournal Standard 00 68.987 to 69.013 mm
Connecting Rod J ournal Maximum Taper 0.013 mm
Connecting Rod J ournal Out of Round Maximum 0.050 mm
Main Bearing J ournal Standard 00 82.987 to 83.013 mm
Maximum Service Limit. 88031 mm
Bolt (Maximum Length) 119.25 mm
2425-6
CAMSHAFT
10 of Bushing Installed 54.107 to 54.133 mm
10 of Camshaft Bore 54.089 to 54.139 mm
Maximum Service Limit...... 54.164 mm
00of Each Carnshatt Bearing Surface...................................... .. 53.987 to 54.013 mm
Minimum Service Limit.................................................. . 0.470 mm
Cam Lobe Minimum Diameter At Peak
Intake 47.265 mm
Exhaust...................... . 46.994 mm
GEAR TRAIN BACKLASH
Maximum Service Limit (All Gears) .. 0.45 mm
SPECIAL TORQUES
Belt tensioner bolt 39 to 47 Nm
Camshaft plate bolts 21 to 27 Nm
Connecting rod bolts 60 Nm Plus 60 Degrees
Crankshaft pulley bolts 120 to 130 Nm
Fan Pulley Bolts
Grade 8.8 Size Size M10 51 to 62 Nm
Flywheel bolts 130 to 144 Nm
Flywheel housing bolts 54 to 66 Nm
Front cover bolts 21 to 27 Nm
Front housing bolts 21 to 27 Nm
Fuel inlet bolts 29 to 35 Nm
Fuel inlet nut. 29 to 35 Nm
Fuel outlet bolt 29 to 35 Nm
Injection pump nut 55 to 65 Nm
Injection pump lock bolt 6 to 8 Nm
Injection pump mounting nuts 21 to 27 Nm
Injection pump bracket bolts 21 to 27 Nm
Main bearing bolts 80 Nm Plus 50 Degrees
Oil suction tube bolts 18 to 30 Nm
Seal carrier bolts 8 to 10 Nm
Starter retaining bolts 39 to 47 Nm
CAS-1690 Engine Rotating Tool
First used on Page 42.
Rae 8-24183
2425-7
CAS-1358 Ridge Reamer
2425-8
CAS-10900 Connecting Rod Pin Bushing
Removal and installation tool
Crankcase Pressure Check (Blow By)
CAS-1692A Manometer
2425-9
STEP 1
FRONT OIL SEAL REPLACEMENT
STEP 4
STEP 2
Remove the tachometer drive, if equipped.
STEP 3
Remove the bolts from the crankshaft pulley and
remove the crankshaft pulley.
Rae 8-24183
Remove the front cover bolts and remove the front
cover.
STEP 5
Clean the crankshaft seal surface with Loctite safety
solvent
IMPORTANT: The seal surface on the crankshaft must
be free of all oil and grease to prevent damage to the oil
seal.
STEP 6
Remove the seal and clean the seal surface with Loctite
safety solvent
2425-10
STEP 7
Install the guide bolts and a new front cover gasket.
STEP 8
Install the front cover bolts. Do not tighten the bolts.
STEP 9
Install the seal installation tool into the front cover with
the small diameter toward the engine. This will center
the front cover with the crankshaft.
Rae 8-24183
STEP 10
~;
Tighten the front cover bolts to a torque of 24 Nm.
Remove the installation tool.
STEP 11
Put Loctite 277 on the outside surface of the seal.
IMPORTANT: The crankshaft oil seal surface must not
have any oil, grease or foreign material on the sealing
surface.
STEP 12
Carefully install the protective sleeve and seal on the
crankshaft. Push the seal on the crankshaft until the
seal makes contact with the seal surface.
STEP 13
Remove the protective sleeve.
STEP 14
Install the installation tool and push the seal to the
correct depth. The seal will be atthe correct depth when
the outside diameter of the installation tool makes
contact with the front cover.
STEP 15
Remove the seal installation.
Rae 8-24183
2425-11
STEP 16
Install the crankshaft and the crankshaft pulley bolts.
STEP 17
Install the tachometer drive, if equipped.
STEP 18
2425-12
STEP 19
REAR OIL SEAL REPLACEMENT
STEP 22
Remove the engine oil pan. See Section 2445 for oil pan
removal.
STEP 20
Remove the bolts and the starter from the flywheel
housing.
STEP 21
Remove the biolts and the flywheel from the flywheel
housing.
Rae 8-24183
Remove the bolts and the flywheel housing from the
engine block.
STEP 23
STEP 24
safety solvent.
STEP 13
Remove the protective sleeve.
STEP 14
Install the installation tool and push the seal to the
correct depth. The seal will be atthe correct depth when
the outside diameter of the installation tool makes
contact with the front cover.
STEP 15
Remove the seal installation.
Rae 8-24183
2425-11
STEP 16
Install the crankshaft and the crankshaft pulley bolts.
STEP 17
Install the tachometer drive, if equipped.
STEP 18
2425-12
STEP 19
REAR OIL SEAL REPLACEMENT
STEP 22
Remove the engine oil pan. See Section 2445 for oil pan
removal.
STEP 20
housing.
STEP 21
Remove the biolts and the flywheel from the flywheel
housing.
Rae 8-24183
Remove the bolts and the flywheel housing from the
engine block.
STEP 23
Remove the seal carrier from the crankshaft.
STEP 24
safety solvent.
STEP 25
Clean the seal surface on the crankshaft with Loctite
safety solvent.
IMPORTANT: The crankshaft sealing surface must be
free of all oil and grease to prevent damage to the oil
seal.
STEP 26
Install the guide bolts and a new seal carrier gasket.
STEP 27
Install the seal carrier bolts and remove the guide bolts.
Do not tighten the seal carrier bolts.
Rae 8-24183
2425-13
STEP 28
Install the seal installation tool into the seal carrier with
the small diameter toward the engine. This will center
the seal carrier to the crankshaft.
STEP 29
Tighten the seal carrier bolts to a torque of 8to 10 Nm.
STEP 30
Remove the seal installation tool.
2425-14
STEP 31
Install the seal and protective sleeve over the crank-
shaft until the outside diameter of the seal makes
contact with the seal carrier.
STEP 32
Remove the protective sleeve
STEP 33
Install the seal installation tool with the small diameter
toward the seal.
Rae 8-24183
Push the seal into the seal carrier until the outside
diameter of the seal installation tool makes contact with
seal carrier. Remove the installation tool.
STEP 35
Install the flywheel housing and tighten the bolts to a
STEP 36
Install the flywheel retaining bolts and tighten the bolts

to a torque of 130 to 144 Nm.
STEP 37
Install the starter and tighten the bolts to a torque of 39
to 47Nm.
2425-15
STEP 38
Install the engine oil pan. See Section 2445 for oil pan
installation.
FRONT OIL SEAL AND WEAR SLEEVE INSTALLATION
Used when crankshaft flange is worn and standard seal does not stop oil flow.
STEP 39
STEP 40
Remove the tachometer drive, if equipped.
STEP 41
crankshaft pulley and
Rae 8-24183
Remove the bolts and the front cover.
STEP 43
Remove the oil seal and clean the seal surface with
Loctite safety solvent.
2425-16
STEP 44
Put Loctite 277 on the outside diameter of the seal
surface and install the seal in the front cover.
STEP 45
Put the seal installation tool on the oil seal. The small
diameter of the seal installation tool must be toward the
seal.
STEP 46
Pushthe seal into the cover until,the outside diameter of
the installation tool makes contact with the cover.
Rae 8-24183
STEP 47
Clean the crankshaft with Loctite safety solvent.
NOTE: The seal surface must be free of all oil and
grease to prevent damage to the oil seal.
STEP 48
Install the wear sleeve on the crankshaft with the flange
toward the engine.
STEP 49
,
Install the wear sleeve installation tool over the wear
sleeve. Push the wear sleeve on the crankshaft until the
flange makes contact with the face of the crankshaft
gear. Remove the installation tool.
STEP 50
Install the guide bolts and a new front cover gasket.
STEP 51
Carefully install the front cover.
Install the front cover bolts and tighten the bolts to a
Rae 8-24183
2425-17
STEP 53
.. s
Install the crankshaft pulley and tighten the bolts to a
STEP 54
Install the tachometer drive. if equipped.
STEP 55
2425-18
REAR Oil SEAL AND WEAR SLEEVE INSTALLATION
STEP 56
Used when the crankshaft flange is worn and standard seal does not stop oil flow.
STEP 59
";:~';; ( '-;'
. Ttl8'147
.--.:.. . SM ..
Remove the engine oil pan See Section 2445 in the
service manual for oil pan removal
STEP 57
housing.
STEP 58
Remove bolts and the flywheel
Rae 8-24183
Remove the the bolts and flywheel housing.
STEP 60
Remove the bolts and the seal carrier from the cran-
kshaft.
STEP 61
safety solvent.
STEP 62
Install the seal in the seal carrier.
STEP 63
Install the seal installation tool. Push the seal into the
seal carrier until the outside diameter of the seal instal-
lation tool makes contact with the seal carrier.
STEP 64
Clean the crankshaft seal surface with Loctite safety
solvent.
Rae 8-24183
2425-19
STEP 65
Put the wear sleeve on the crankshaft with the flange
toward the engine.
STEP 66
Install the wear sleeve installation tool on the wear
sleeve.
STEP 67
Push the wear sleeve on the crankshaft until the flange
of the wear sleeve is even with the rear seal surface on
the crankshaft.
IMPORTANT: The wear sleeve flange must be even
with the rear seal surface of the crankshaft.
2425-20
STEP 68
Clean the seal surface with Loctite safety solvent.
IMPORTANT: Thecrankshaft seal surface must be free
of all oil and grease to prevent damage to the seal.
STEP 69
Install the guide bolts and a new seal carrier gasket.
STEP 70
Carefully install the seal carrier.
Rae 8-24183
STEP 71
Install the seal carrier bolts and tighten the bolts to a
STEP 72
Install the flywheel housing and tighten the bolts to a
STEP 73
Install the flywheel and tighten to a torque of 130 to 144
Nm.
STEP 74
Install the starter bolts and tighten the bolts to a torque
of 39 to 47 Nm.
2425-21
STEP 75
STEP 76
REMOVAL OF PISTONS AND RODS
STEP 78
Remove the manifolds and cylinder head from the
engine. See Section 2415 of the service manual for
removal.
Remove the engine oil pan and inlet tube. See Section
2445 of the service manual for removal.
Rae 8-24183
Check the side clearance of the piston connecting
rods. Replace the connecting rods if the side clearance
is more than 0.330 mm.
STEP 79
1. RIDGE
Remove the carbon from the top of the cylinder walls.
Check the cylinder walls for a ridge at the top of the ring
movement zone. A ridge will cause damage to the
piston when the piston is removed. A ridge will have to
be removed with a ridge reamer.
Install the engine oil pan. See Section 2445 in the
service manual for oil pan installation.
2425-22
STEP 80
Install a ridge reamer and remove the ridge from the
cylinder walls.
STEP 81
'{ J i/;;- - _;;>.,
Put a mark on each rod cap for cylinder identification.
STEP 82
Put an identification mark on each piston for assembly.
Rae 8-24183
Remove the rod cap.
STEP 84
T68776
Remove the pistons from the top of the engine block.
Revised 2-92 Printed in USA
CYLINDER WALL INSPECTION
2425-23
STEP 85
Inspect the cylinder walls for the following conditions
Normal Wear
T10766
A smooth surface with some of the cross-hatch pattern
showing between the upper and lower limits of the ring
movement area shows normal wear. There will always
be a small amount of wear present because of com-
bustion pressure moving the top ring against the
cylinder wall.
Normal wear shows acceptable cylinder wall condi-
tions and the cylinder need not be machined.
Worn Cylinder Wall
T2319
A smooth surface between the upper and lower limits of
the ring movement area shows a worn cylinder wall
because of normal wear and the cylinder must be
machined.
Rae 8-24183
Scoring on Cylinder Walls
T2320
T10764
Scoring on cylinder walls is caused by metal moving
from one location to a different location. This is shown
by heavy vertical lines. The vertical lines are caused by
metal coming in contact with the piston. The scoring
can be inone specific area or it can occur the complete
length of the piston movement. If this condition is
present, the cylinder must be machined and the piston
and rings replaced.
2425-24
Dusted Cylinder
T40178
Too much wear in the piston ring movement area
shows a dusting failure.
A dusting failure will cause the following:
1. Upper area of piston ring wall will show wear.
2. Too much piston ring groove wear.
3. Too much piston ring side clearance.
4. Washed away areas of the piston ring lands where
the aluminum will be gone.
5. Piston rings will have too much face contact and
wear which can be seen as a reduction in radial
width and increase in end gap.
6. Chrome piston rings will show wear through the face.
The chrome will be worn off the face and base iron
can be seen.
7. The cylinder heads can have smooth intake parts
and worn valve guides.
All of these conditions are caused by dirt which is
mixed with the intake air.
Rae 8-24183
STEP 86
T68779
Measure the cylinder wall bore for taper as follows:
1. Measure the bore parallel to the crankshaft at the top
end of the ring travel zone.
2. Measure the bore inthe same position at the bottom
end of the ring travel zone.
3. Measure the bore at right angles to the crankshaft at
the top end of the ring travel zone.
end of the travel zone.
Compare the results of the measurements (1) and (3)
with (2) and (4), to find out if the bore has taper. To
measure use a inside micrometer, bore gauge or taper
gauge. If the taper is more than 0.076 mm, bore the
cylinder. See reconditioning the cylinder block.
STEP 87
T68Z~~
Measure the cylinder wall bores for out-of-round as
follows:
1. Measure the bore parallel to the crankshaft at thetop
end of the ring travel.
3. Measure the bore at right angles to the crankshaft at
the top end of the ring travel.
Compare the measurements (1) and (3) to find the out-
of-round wear at the top end of the bore.
Compare the measurements (2) and (4) to find the out-
of-round wear at the bottom of the bore.
If out-of-round is more than 0.038 mm, bore the cylin-
ders. See reconditioning the cylinder block.
STEP 88
Measure the cylinder bores. See specifications on
Page 4. If the cylinder bore is more than 102.116 mm,
the cylinders must be bored. See reconditioning the
cylinder block.
Rae 8-24183
2425-25
STEP 89
IMPORTANT: Before removing glaze, cover the cran-
kshaft journals with aclean cloth to prevent abrasives
and dirt caused by the cylinder hone from falling on the
crankshaft.
If new rings are used. the glaze must be removed from
the cylinder bore so that the piston rings can correctly
seat against the cylinder wall during the run-in time. Itis
recommended that a qualified engine repair shop do
this work.
Removing glaze can be done by using a cylinder hone
with 250 to 300 grit stone.
Too much glaze (smooth surface) on cylinder walls of a
new engine or an engine with an overhaul is caused by
run-in procedure that is not correct.
Glaze does not permit the piston rings to seat correctly
inthe cylinder sleeves. This will cause too much oil con-
sumption.
Too much glaze on the cylinder walls can be prevented
by giving your customer instructions in the correct run-
in procedure. See Section 2402 in the service manual
for the correct run-in procedure.
2425-26
STEP 90
Use a 3/8 inch or 1/2 inch drill to power the cylinder
hone. Use a lubricant/coolant with the hone to keep the
hone and the stones free of foreign material.
Startthe hone atthe top of the cylinder bore and actuate
the hone up and down until the correct cross-hatch
pattern is reached. The correct cross-hatch pattern is
45 to 60 degrees from horizontal.
Use a 250 to 300 grit stone to reach the correct cylinder
bore finish of 0.4 to 0.8 micrometers.
Rae 8-24183
STEP 91
T10765
After removing the glaze. clean the cylinder walls with a
clean cloth. warm water and a mild detergent soap.
After cleaning the cylinder walls. clean the cylinder walls
again with clean engine oil.
NOTE: Clean the cylinder walls until aclean white cloth
keeps completely clean, one cleaning operation is not
enough.
IMPORTANT: Do not use gasoline, diesel fuel or
kerosene to clean cylinders because these materials
will not remove the abrasives from the sleeve surface.
2425-27
RECONDITIONING THE ENGINE CYLINDER BLOCK
Checking and Resurfacing the Cylinder Block
STEP 92
Clean the cylinder block completely. Remove carbon
and other deposits. Check for cracks and other
damage
STEP 93
Check the cylinder block surface with a straight edge
and feeler gauge. Resurface the cylinder block if
warpage or erosion is more than 0.010 mm in any 50
mm diameter area or if there is more than 0.075 mm
overall end to end or side to side.
Rae 8-24183
B902936J
Resurface the cylinder block in increments necessary
to straighten the surface and maintain the surface finish
according to the following specifications:
A = 0.25 mm first refacing.
0.35 mm second refacing.
0.50 mm total amount of material that can be
removed.
B =322.90 to 323.10 mm standard
322.65 to 322.85 mm first refacing
322.40 to 322.60 mm second refacing
C = Surface finish 1.5 to 3.2 micrometers
o = Use this area to stamp an "X" when the first
refacing of 0.25 mm is done. Stamp a second "XX"
when the second refacing 0.50 mm total is done.
NOTE: When resurfacing the block it is always neces-
sary to machine the block to the specified dimensions.
There are twothicknesses of head gasket to make up for
the material removed from the cylinder block. See page
2415-30 for selection of the correct head gasket.
2425-28
Reconditioning the Cylinder Block for Oversize Pistons
STEP 96
NOTE: Some of the following photographs show a
cylinder block that has been cut in half for photographic
purposes.
STEP 95
For 0.5 mmoversize pistons, machine cylinder bores to
10240 to 102.44 mm.
For 1.0 mmoversize pistons, machine cylinder bores to
102.90 to 102.94 mm.
Rae 8-24183
Use a cylinder hone and hone the cylinder bores to the
following specifications. Use a lubricant/coolant with
the hone to keep the stones clean and cool.
Rough Honing - Use 80 to 150 grit stones to get a
cross-hatch pattern of 45 to 60 degrees from
horizontal.
0.5 mm oversize piston - 102.475 to 102.695 mm
Finish Honing - Use 250 to 300 grit stones to get a
horizontal.
Finished cylinder bore must have a surface finish of 0.4
to 0.8 micrometers with a taper of less than 0.025 mm.
2425-29
Reconditioning the Cylinder Block for Sleeves
NOTE: Some of the following photographs show a STEP 99
cylinder block that has been cut in half for photographic
purposes.
STEP 97
Put a mark on the cylinder bores 6.36 mm up from the
bottom.
STEP 98
Bore each cylinder to a diameter of 104.485 to 104.515
mm down to the mark. Boring must be done in four
steps with the final step taking a maximum of 0.125
mm. Let the block cool before the final step to prevent
distortion.
Rae 8-24183
Freeze the sleeves at -12
0
C for at least one hour. Push
the sleeves into the bore until the sleeve contacts the
ridge at the bottom of the bore.
L>.. Always wear gloves to prevent frostbite to
your hands when handling frozen parts.
SM118A
STEP 100
Cut the top of the sleeve flush to 0.025 mm above the
cylinder block surface.
2425-30
STEP 101
Borethe sleeve to a diameter of 101.90 to 101.94 mm in
two steps with the final step taking a maximum of 0.125
mm. Let the sleeve cool between steps to prevent dis-
tortion.
STEP 102
Break the top edge of the sleeve with a coarse stone.
Rae 8-24183
STEP 103
Use a cylinder hone and hone the cylinder bores to the
following specifications. Use a lubricant/coolant with
the hone to keep the stones clean and cool.
Rough Honing - Use 80 to 150 grit stones to get a
horizontal.
Standard piston - 101.975 to 102.015 mm
Finish Honing - Use 250 to 300 grit stones to get a
horizontal.
Standard piston - 102.00 to 102.04 mm
Finished cylinder bore must have a surface finish of 0.4
to 0.8 micrometers with a taper of less than 0.025 mm.
2425-31
STEP 104
PISTION AND CONNECTING ROD DISASSEMBLY AND INSTALLATION
STEP 106
3. RETAINING RING
364L 91
Remove the retaining ring, piston pin and the con-
necting rod from the piston.
STEP 105
365L 91
NOTE: The oil ring is atwo piece ring.
Rae 8-24183
T6881 0
T68807
Measure the inside diameter of the connecting rod for
wear and out-of-round. If the inside diameter is more
than 40.092 mm the connecting rod bushing must be
replaced.
STEP 107
705L 91
To remove and install the connecting rod bushing use a
CAS-10900 connecting rod pin bushing removal and
installation tool.
2425-32
STEP 108
Measure the diameter of the piston pin. If the diameter
is less than 39.990 mmthe piston pin must be replaced.
STEP 109
Measure the piston pin bore. If the piston pin bore is
more than 40.025 mm the piston must be replaced.
STEP 110
Measure the diameter of the piston across the thrust
face 12mmfromthe bottom of the piston at right angles
to the piston pin holes. Replace the piston if the
diameter is less than 101823 rnrn.
Rae8-24183
Break an old piston ring in half and use the broken ring
half to clean the piston ring grooves. Too much deposit
inthe ring grooves can force the rings out and will cause
scoring.
STEP 112
Check the side clearance of the oil ring in the piston.
Insert a feeler gauge between the upper surface of a
new ring and the piston lands to check the clearance.
Replace the piston if side clearance is more than 0.13
rnrn.
STEP 113
Check the side clearance of the first and second com-
pression rings. Replace the piston if the side clearance
is more than 0.15 rnrn.
Revised 2-92 Printedin U.SA
STEP 114
2425-33
STEP 115
PISTON AND CONNECTING ROD ASSEMBLY AND INSTALLATION
STEP 117
Put the piston rings inthe cylinder and check end gap.
Replace the piston rings if the end gap is more than
0806 mm.
STEP 116
. L.~"; .<.; .> ~> ".d::,.s\ii/f~~~,2Mti
Install the oil ring. Install the spring first and the oil ring
second.
NOTE: The spring must bebetween the oil ring and the
piston.
Rae 8-24183
Install the second compression ring. The piston ring
must be installed with the side marked TOP toward the
top of the piston to give good oil control.
STEP 118
Install the first compression ring on the piston. The
piston ring must be installed with the side marked TOP
toward the top of the piston to give good oil control.
NOTE: The top piston ring on the 4T-390 engine is a
key stone type ring.
nWPRlitt!,.
Clean the piston holes with a small drill or fine wire.
2425-34
STEP 119
1. SPECIAL LAP
B902937J
The first compression ring. In a replacement set of
rings, must have a special lap design on the surface
that contacts the cylinder wall.
STEP 120
137L91
Rotate the piston rings so that the ring ends are sepa-
rated by 120 degrees.
STEP 121
PISTON PIN
364L91
Install the connecting rod, piston pin and retaining rings
in the piston.
Rae 8-24183
STEP 122
T6818- J, ~
---,_..-"'."..."".. ,.... . ,:'.-.- ..
Apply lubrication to the pistons, piston rings and
cylinder walls, using clean engine oil.
STEP 123
T68788
Install a ring compressor on the piston.
STEP 124
T68789
Caref:J lly push the piston down into the cylinder.
IMPORTANT: Make sure the arrow or the word FRONT
is toward the front of the engine.
STEP 125
Measure the connecting rodjournals on the crankshaft.
Each journal must be a minimum of 68.962 mm in
diameter. Measure the front and rear of each journal,
checking for taper. Ifthetaper is more than 0.013 mmor
the journal is less than 68.962 rnrn, reconditioning of
the journals must be done.
STEP 126
k ,.
T68783
The connecting rod journals must be checked again,
90 degrees from the first measurements for out-
of-round. Ifout-of-round is more than 0.050 mm, recon-
ditioning of the journals must be done.
Rae 8-24183
2425-35
STEP 127
Install the liners. The liner locks must be in alignment.
NOTE: When installing the liners, make sure that the
liner locks are in alignment. Use a sliding type
movement when installing the liners. Never push on the
center of the liner locks.
STEP 128
Clean the connecting rod journals and the rod bearing
liners. Put a piece of plastigage on the crankshaft
journal.
3425-36
STEP 129
Install the bearing caps.
NOTE: Make sure that the number on the bearing cap is
the same as the number on the connecting rod.
STEP 130
-
1. MAXIMUM LENGTH
59.25 mm
-
7L92
Measure the length of the connecting rod bolts. If the
bolt length is more than 59.25 mm the bolt must be re-
placed.
IMPORTANT: Each bolt length must be checked
before installation.
Rae 8-24183
STEP 131
I "
---.:J
Lubricate the connecting rod bolts with clean engine oil
and tighten the bolts to a torque of 60 Nm.
STEP 132
Install the torque angle gauge. Position and lock the
holding rod. Move-the pointer to 60 degrees. Tighten
the bolt until the pointer is at 0 degrees.
STEP 133
Remove the bearing caps and check the clearance.
The clearance must be between 0.038 mm to 0.129
mm. If the clearance is more than 0.129 rnrn, undersize
bearing liners must be installed and reconditioning of
the bearing journals must be done by grinding.
NOTE: A clearance of 0.038 mm to 0.116 mm is
required when installing new bearing liners.
STEP 134
Apply lubrication to the bearing liners before installa-
tion, using clean engine oil.
STEP 135
_ 1. MAXIMUM LENGTH __
59.25 mm
7L92
placed.
STEP 136
r
Lubricate the connecting rod bolts with clean engine oil
and tighten the bolts to a torque of 60 Nm.
Rae 8-24183
2425-37
STEP 137
holding rod. Turnthe pointer to 60 degrees. Tighten the
bolt until the pointer is at 0 degrees.
STEP 138
Install the engine oil inlet tube. See Section 2445 of the
service manual for the inlet tube and the oil pan installa-
tion.
STEP 139
L
'~; l!
Use a dial indicator to check piston protrusion. The
piston protrusion must not be more than 0.660 mm plus
any amount of material removed during resurfacing.
2425-38
STEP 140
Install the cylinder head and manifold. See Section
2415 of the service manual.
REPLACEMENT OF THE MAIN BEARINGS WITHOUT
REMOVING THE CRANKSHAFT
STEP 141
Remove the engine oil pan and gasket.
2445 of the service manual.
STEP 142
\,
Remove the bolts from the oil inlet tube. See Section
2445 of the service manual for the oil inlet tube removal.
Rae 8-24183
STEP 143
Remove the bolts and main bearing cap.
NOTE: Remove only one cap at a time to prevent the
crankshaft from moving.
STEP 144
STEP 145
'. ~" .T58~
Put a new bearing liner on the crankshaft. Use a thin
piece of plastic to push the bearing liner in position.
STEP 146
STEP 147
I
,
'."'." ..
; !: ~.
Put a new bearing liner in the bearing cap.
NOTE: Make sure the bearing liner locks are aligned
when installing the liners. Slide the liner in position.
Never push on the center of the liners.
Rae 8-24183
2425-39
STEP 148
6L92
Measure the length of the main bearing bolts Ifthe bolt
length is more than 119.25 mm the bolt must be re-
placed.
STEP 149
Install the bearing cap and tighten the mounting bolts to
a torque of 80 Nm.
STEP 150
holding rod. Turnthe pointer to 50 degrees.Tighten the
2425-40
STEP 151
... ..- ~ T6 88.
Remove the bearing cap and check the clearance
Clearance must be 0.041 to 0.140 mm. New liners must
be installed if the clearance is more than 0.140 mm.
NOTE: The crankshaft must be reconditioned if the
clearance is more than 0. 119mm with the new liners.
STEP 152
Add lubrication to the bearing liners
bearing cap.
Rae 8-24183
STEP 153
6L91
Measure the length of the main bearing bolts. If the bolt
placed.
STEP 154
Add lubrication to the mounting bolts. Install the
mounting bolts and tighten to a torque of 80 Nm.
STEP 155
holding rod. Turn the pointer to 60 degrees.Tighten the
STEP 156
Install a new oil inlet tube gasket. See Section 2445 of
the service manual for the installation of the oil inlet
tube.
2425-41
STEP 157
-~, e" ,.
!< ? ; & ,17
Install the oil pan. See Section 2445 of the service
manual.
STEP 158
CRANKSHAFT AND MAIN BEARINGS
STEP 160
Remove the cylinder head. See Section 2415 of the
service manual for cylinder head removal.
STEP 159
Remove the bolts and the crankshaft pulley.
Rae 8-24183
Remove the oil pan. See Section 2445 in the service
manual for oil pan removal.
STEP 161
i
Remove the oil inlet tube bolts. See Section 2445 for the
oil inlet tube removal.
2425-42
STEP 162
Remove the tachometer, if equipped.
STEP 163
Remove the bolts and the front cover.

Rae 8-24183
STEP 164
Turn the engine over with a engine rotating tool and
push the lock into the camshaft gear.
Remove the injection pump and primer pump. See
Section 3415 in the service manual. .
STEP 167
STEP 168
T69027
Raise the lifters and install pins to hold up the lifters.
Rae 8-24183
2425-43
STEP 169
r /
Remove the bolts that hold the camshaft thrust plate.
STEP 170
T69029
STEP 171
Remove the camshaft.
2425-44
STEP 172
Remove the front housing
STEP 173
Remove the bolts and the starter.
STEP 174
Remove the bolts and the flywheel.
Rae 8-24183
STEP 175
Remove the bolts and the flywheel housing
STEP 176
Remove the bolts and the seal carrier.
STEP 177
Put a mark on each rod cap piston for assembly identifi-
cation
STEP 178
Remove the bolts and the connecting rod bearing
caps
STEP 179
T68776
Remove the pistons and connecting rods.
STEP 180
Rae 8-24183
2425-45
STEP 181
STEP 182
STEP 183
Remove the main bearing liners from the engine.
2425-46
STEP 184
CRANKSHAFT GEAR REMOVAL
STEP 185
Pull the gear off the crankshaft. Remove the pin or woodruff key from the crankshaft.
STEP 186
CRANKSHAFT INSPECTION
STEP 188
T69070
Measure the main bearing journals to see if the journals
areworn. Measure the front and rear of each journal. If
the diameter is less than 82.962 mm grind the crank-
shaft journals.
STEP 187
Measure the main bearing journals, again, 90 degrees
from the first measurements (Step 186) for out-
of-round. If the out-of-round is more than 0.050 mm,
grind the journals and use undersize liners.
Rae 8-24183
Measure the connecting rodjournals. Measure the front
and rear of each journal. Grind the journals ifthe taper is
more than 0.013 mm or if the diameter is less than
68.962 mm.
STEP 189
.,..,.. .....,
f0.~fJ ~':~.':
Check the connecting rod journals again, 90 degrees
from the first measurements (Step 188) for out-
of-round. Grind the journals ifout-of-round is more than
0.050 mm.
NOTE: /f the crankshaft is bent, rep/ace the crankshaft.
2425-47
CRANKSHAFT RECONDITIONING
Grinding a Crankshaft Seecrankshaft inspection on Page 46. Ifthe crankshaft
is worn or damaged, itis recommended that you have a
qualified engine shop regrind the crankshaft according
to the following instructions.
There are two hardening methods used to harden the
journals of the crankshaft. One hardening process is in-
duction hardening which hardens the journals to a
depth of 2.00 mm. Theother hardening process is deep
nitroc which is a gas nitriding process This hardening
process hardens the journals to a very shallow depth.
Any time you grind a journal on a crankshaft that has
been deep nitroc hardened, you must reharden the
crankshaft.
Crankshafts hardened by the deep nitroc process are
stamped with the letter "N" on the pulley end (nose) of
the crankshaft. Induction hardened crankshafts are not
identified.
Rae 8-24183
Grind the crankshaft to the following specifications:
B902940J
A =Main Bearing J ournals
Standard diameter 82.987 to 83.013 mm
0.25 mm undersize diameter 82.737 to 82.763 mm
B = Connecting Rod J ournals
Standard diameter 68.987 to 69.013 mm
C =1.23 to 1.27 mm radius smoothly blended to the
reground journal
Surface finish = 0.4 micrometers
Crankshaft Rehardening
Remember that any time you grind a crankshaft that
was hardened with the deep nitroc process, you must
reharden the crankshaft. Reharden the crankshaft to a
minimum hardness of 450 HV 0.2 Rockwell.
2425-48
STEP 190
CRANKSHAFT GEAR INSTALLATION
STEP 191
CRANKSHAFT INSTALLATION
STEP 193
.;.:-:.:,:.-
Install the crankshaft gear pin or woodruff key.
STEP 192
1. Late Production Oil Spray Nozzle
2. Early Production Oil Spray Nozzle
Clean the oil spray nozzle with a small wire. Ifthe nozzle
is damaged it must be replaced.
Rae 8-24183
..,... ~,,~~_.>U"~_''',~''''','',,',.,.~ . '1'69075
Heat the crankshaft gear for a minimum of 25 minutes
at 250F (121C). Use a bearing heater oven.
Install the heated gear on the crankshaft.
Install the bearing liners. The flanged bearing liner must
be installed on the second 'journal from the rear of the
block. The remainder of the bearing liners have no
flange.
STEP 194
Add lubrication to the bearing liners.
oil.
STEP 195
STEP 196
Clean the main bearing journals and put a piece of plas-
tigage on the journals to check main bearing oil clear-
ance.
STEP 197
I .
~
I
; ':tJ i
I.
I
Install the liners inthe bearing caps. Make sure the liner
locks are aligned. Use a sliding type movement when
installing the liners. Never push on the center of the
liners.
Rae 8-24183
2425-49
STEP 198
STEP 199
1. MAXIMUM LENGTH I ,
119.25 mm
6L92
placed.
STEP 200
Install the main bearing cap bolts and tighten to a
torque of 80 Nm.
2425-50
STEP 201
Remove the main bearing caps.
STEP 203
Check the main bearing oil clearance. Clearance must
be 0.041 to 0.140 mm. If the clearance is more than
0.140 mm, undersize bearing liners must be installed.
Install new undersize liners which will give a clearance
of 0.041 to 0.119 mm.
NOTE: If the clearance is more than O.140mm the cran-
kshaft must be reconditioned.
Rae 8-24183
STEP 204
Add lubrication to the liner. Use clean engine oil.
STEP 205
1. MAXIMUM LENGTH
119.25mm
6L92
placed.
STEP 206
Add lubrication to the cap bolts. Install the cap bolts
and tighten. Tighten to a torque of 80 Nm.
STEP 207
STEP 208
Put a dial indicator on the crankshaft gear. Check the
crankshaft end clearance. The end clearance must be
0.041 to 0.119 mm. If the clearance is more than 0.119
mm, replace all the main bearing liners or the crank-
shaft.
NOTE: To get an accurate reading, use a pry bar
between the crankshaft and the number two and
number four main bearing caps as shown above.
Rae 8-24183
2425-51
STEP 209
Install a new front housing gasket.
Install the front housing and tighten the bolts to atorque
of 21 to 27 Nm.
STEP 211
~
Add lubrication to the camshaft bearing journals. Use
clean engine oil.
2425-52
STEP 212
Make sure the timing marks on the crankshaft and
camshaft are aligned.
STEP 213
.~s- . '.~~..:-
Install the camshaft thrust plate behind the camshaft
gear.
STEP 214
Install the thrust plate bolts and tighten to a torque of 21
to 27Nm.
Rae 8-24183
STEP 215
Put a dial indicator on the camshaft gear. Check the
backlash between the camshaft gear and the crank-
shaft gear. Backlash must be 0.08 to 0.33 mm. If
backlash is more than 0.45 mm the gears must be re-
placed .
NOTE : Too much backlash can also be caused by worn
camshaft bushings.
STEP 216
T69027
Remove the pins from the lifters.
STEP 217
Install the breather cover.
STEP 218
Install a new gasket on the lifter cover.
STEP 219
Install new seals on the lifter cover bolts.
STEP 220
Install the lifter cover bolts and tighten to a torque of 21
to 27 Nm.
Rae 8-24183
2425-53
STEP 221
Install the injection pump and the hand primer pump.
See Section 3414 for CAV injection pump and Section
3415 for Bosch injection pump
STEP 222
Install a new front cover gasket.
STEP 223
Clean the crankshaft seal surface of all oil and grease
using Loctite safety solvent. See seal installation inthis
section for the front crankshaft.
2425-54
STEP 224
Install the tachometer drive assembly, if equipped.
STEP 225
Clean the rear crankshaft seal of all foreign material,
using Loctite safety solvent. See seal installation inthis
section for installing the rear crankshaft seal.
STEP 226
Add lubrication to the cylinder walls and piston rings.
Use clean engine oil.
Rae 8-24183
STEP 227
T68788
Install a ring compressor on the piston.
NOTE: Make sure the piston rings are in the grooves
before tightening the ring compressor. Tighten the ring
compressor, alittle at atime, making sure the rings are
free to be pushed in.
STEP 228
T68789
Carefully push the piston down into the block.
IMPORTANT: Make sure that the arrow or the word
FRONT is toward the front of the engine. Make sure the
correct connecting rod is in the correct cylinder.
Issued 2-92 Printed in U.S.A
STEP 229
Install the bearing liners on the connecting rods and rod
caps
IMPORTANT: Make sure the liner locks are aligned
when installing the liners. Use asliding type movement
when installing the liners Never push on the center of
the liners.
STEP 230
Clean the connecting rod journals and the bearing
liners. Put a piece of plastigage on the crankshaft jour-
nals.
Install the bearing caps.
NOTE: Make sure the number on the bearing cap is
equal to the number on the connecting rod.
Rae 8-24183
2425-55
STEP 232
- 1. MAXIMUM LENGTH _
59.25 mm
7L92
Measure the length of the connecting rod bolts If the
placed.
STEP 233
r
---...:
Tighten the connecting rods to a torque of 60 Nm.
STEP 234
2425-56
STEP 235
Remove the bearing caps and check the clearance.
The clearance must be 0.038 to 0.129 rnrn. If the clear-
ance is more than 0 129 rnrn, undersize bearing liners
must be installed and reconditioning of the bearing
journals must be done. Install new bearing liners which
will give a clearance of 0.038 to 0.116 rnrn.
STEP 236
Add lubrication to the bearing liners. Use clean engine
oil.
STEP 237
--
1. MAXIMUM LENGTH
59.25 mm
-
7L92
placed.
before installation
Rae 8-24183
STEP 238
r
----.:J
Add lubrication to the rod bolts. Install the rod bolts and
tighten to a torque of 60 Nm.
STEP 239
STEP 240
Install a new oil inlet tube gasket. See Section 2445 for
oil inlet tube installation.
STEP 241
Install the engine oil pan. See Section 2445 for oil pan
installation.
STEP 243
Install the flywheel and tighten the retaining bolts to a
Rae 8-24183
2425-57
STEP 244
Install the crankshaft pulley and tighten the retaining
bolts to a torque of 120 to 130 Nm.
STEP 245
Install the cylinder head. See Section 2415 for installing
the cylinder head.
2425-58
CAMSHAFT
Removal
STEP 249 STEP 246
STEP 247
Remove the fan pulley bolts and the fan pulley.
STEP 248
Remove the cylinder head. See Section 2415 for
cylinder head removal.
Rae8-24183
T69021
Disconnect the fuel lines and remove the injection
pump. See Section 3414 for CAV injection pumps and
Section 3415 for Bosch injection pumps in the service
manual.
STEP 250
Remove the bolts, lifter cover and breather cover.
STEP 251
Raise the lifters and install pins to hold up the lifters.
STEP 252
r/
Remove the bolts from the camshaft thrust plate.
STEP 253
Remove the camshaft thrust plate.
2425-59
STEP 254
.f) , '.. .T6~.Q~;
Remove the camshaft from the engine block.
STEP 255
Camshaft Bore and Bushing Inspection
STEP 256
Remove the engine oil pan. See Section 2445 in the
service manual.
Rae 8-24183
Measure the camshaft bores. Use a bore gauge. The
bores must be measured in two positions. Take a
second measurement 90 degrees from the first measu-
rement.
NOTE: The crankshaft and pistons have been removed
for photographic purposes. These parts do not have to
be removed to service the camshaft.
2425-60
STEP 257
If the bushing diarneter is more than 54.146 mm, the
front camshaft bushing must be replaced.
STEP 258
If the intermediate or the rear bores are more than
54146 mm, disassemble the engine block and line
bore the bores. See specifications for machining di-
mensions
Camshaft Bushing Removal and Installation
STEP 260
Put a bushing puller in the engine block and pull the
bushing out of the cylinder block. Use tool CAS-14124.
Rae 8-24183
T69053
Install the bushing on the puller. Align the oil holes. Pull
the bushing into the cylinder block until it is even with
the housing.
2425-61
. c, '-1: ..
.lIIIIII:tk 'l~
Remove the pins from the lifters and remove the lifters.
NOTE: The crankshaft and pistons have been removed
for photographic purposes.
STEP 262
T69055
Measure the lifter bores. Use an expandable bore
gauge.
STEP 263
Ifthe diameter ofthe lifter bore is more than 16.030 rnrn,
the engine block must be replaced.
Rae 8-24183
1.'
Measure the outside diameter of the valve lifter stem.
Replace the valve lifters if the outside diameter of the
lifter stem is less than 15.961 rnrn.
STEP 265
Put clean engine oil on the lifters before installation
~
Install the lifters in the block and fasten in position with
the pins.
Issued 2-92 Printed in U.SA
2425-62
STEP 267
Camshaft Disassembly and Inspection
STEP 269
Press the gear off the camshaft.
STEP 268
T69064
Remove the shaft key.
Rae 8-24183
T69065
Measure the front and rear of each bearing surface on
the camshaft. Use a micrometer.
STEP 270
T69066
Each bearing surface must be measured in four posi-
tions. Measure the front and rear bearing surfaces
again, 90 degrees from the first measurement
NOTE: Replace the camshaft if the outside diameter of
any bearing surface is less than 53.962 mm.
2425-63
STEP 271
Camshaft Gear Installation
STEP 272
T69064
Install the shaft key
Heat the camshaft gear a minimum of 45 minutes at a.
temperature of 250F (121C). Use a bearing heater
oven.
Install the camshaft gear on the camshaft with the lock
pin hole down.
STEP 273
Camshaft Installation
STEP 275
Lubricate the camshaft bearing surface with clean
engine oil.
STEP 274
Align the timing marks on the camshaft with the timing
mark on the crankshaft.
Rae 8-24183
Install the camshaft thrust plate.
STEP 276
Install the camshaft thrust plate bolts and tighten to a
2425-64
STEP 277
Check the camshaft end clearance with adial indicator.
The end clearance must not be more than 0.130 to
0.470 mm. If the clearance is more than 0.470 mm, the
camshaft thrust plate must be replaced.
STEP 278
Puta dial indicator on the camshaft gear and check the
gear backlash between the camshaft gear and the
crankshaft gear. Gear backlash must be 0.08 to 0.330
mm. The gears must be replaced if the clearance is
more than 0.45 mm.
NOTE: Too much gear clearance can also be caused
by worn camshaft bushings.
STEP 279
T69027
Remove the pins from the lifters.
Rae 8-24183
STEP 280
Install the oil breather cover, if equipped.
STEP 281
Install a new gasket on the lifter cover and install the
lifter cover.
STEP 282
Install newseals on the lifter cover bolts and tighten the
Revised 2-92 Primed in U.S.A.
STEP 283
Install the cylinder head. See Section 2415 for cylinder
head installation.
STEP 284
If the engine oil pan was removed, see Section 2445 in
the service manual for installation.
STEP 285
.......
Install the front crankshaft pulley and tighten the bolts to
Rae 8-24183
2425-65
See Section 3414 inthe service manual to install the in-
jection pump fuel lines.
See Section 3415 inthe service manual to install the in-
jection pump fuel lines.
STEP 288
See Section 3413 inthe service manual to install the fuel
injectors.
2425-66
STEP 289
Install the fan pulley and bolts. Tighten the bolts to a
torque of:
Grade 10.9 SiZe M8 37 to 43
STEP 290
FLYWHEEL
Removal
STEP 291
Remove the bolts and the flywheel from the engine.
Rae 8-24183 Issued 2-92 Printed in U.S.A.
2425-67
Ring Gear Removal and Installation
NOTE: If your flywheel has awelded ring gear, DO NOT try to remove the ring gear. Use acomplete new flywheel and ring
gear assembly.
STEP 292
,~. .
Remove the ring gear from the flywheel, using a drift
hammer. Work around the circumference of the ring
gear.
STEP 293
T69213
....-., :.,.,.,.W""*"'v~,-;.':
Heat the newring gear, 400
0
to 450F (204 to 232C), in
oil or inan oven. Do not use atorch to heat the ring gear.
Install the ring gear on the flywheel.
Rae 8-24183
STEP 294
Install the flywheel Tighten the retaining bolts to a
2425-68
TACHOMETER DRIVE, IF EQUIPPED
Removal and Disassembly
STEP 297 STEP 295
Remove the tachometer drive
883L91
Disassemble the tachometer drive.
::lac 8-24183
883L91
Assemble thet achometer drive.
STEP 298
Install the tachometer drive assembly. Rotate the tac-
hometer drive until the tachometer drive until the tac-
hometer drive is at the correct angle Tighten the cover
bolts.
Revised 2-92 Printed in U.$A.
2425-69
EXPANSION PLUG REMOVAL AND INSTALLATION
60 mm Expansion Plug, Camshaft
NOTE: The flywheel and flywheel housing must be removed to replace the camshaft expansion plug.
STEP 299
Remove the expansion plug from the cylinder block.
STEP 300
Use Loctite safety solvent to clean the sealing surface
of all foreign material.
Rae 8-24183
STEP 301
Apply Loctite 277 to the sealing surface of the expan-
sion plug.
STEP 302
Install the expansion plug into the cylinder block. Hit the
expansion plug inthe center to lock the expansion plug
in position.
2425-70
STEP 303
58 mm Expansion Plugs
STEP 306
STEP 304
Clean the sealing surface of all foreign material
STEP 305
""
2509"
sion plug.
Rae 8-24183
892LO
Install the expansion plug into the cylinder block, until
the top edge of the expansion plug is even with the
bottom edge of the chamfer.
2425-71
STEP 307
STEP 310
STEP 308
Clean the sealing surface of all foreign material.
STEP 309
sion plug.
Rae 8-24183
892LO
Install the expansion plug into the cylinder block until
2425-72
STEP 311
22.5 mm Expansion Plug
STEP 314
l~.i,Q3
STEP 312
"~~~~
Clean the expansion plug bore of all foreign material,
use Loctite safety solvent
STEP 313
sion plug.
Rae 8-24183
893LO
Install the expansion plug into the bore, until the top
edge of the expansion plug is even with the bottom
edge of the chamfer,
Revised 2-92 Printed in U,S.A
2525-73
STEP 315
18 mm Expansion Plug
STEP 318
~cJ i824a4ot
Put a small amount of grease in the expansion plug.
STEP 316
Drill a small hole in the center of the expansion plug.
STEP 317
Install ascrew inthe expansion plug and remove the ex-
pansion plug from the cylinder block.
Rae 8-24183
::.T8~
Use Loctite safety solvent to clean the sealing surface
of all foreign material.
STEP 319
sion plug.
Revised2-92 Printed in U.S.A
2425-74
STEP 320
STEP 322 STEP 321
Put a small amount of grease in the expansion plug.
Rae 8-24183
Drill a small hole in the center of the expansion plug.
STEP 323
Install a screw inthe expansion plug and pull the expan-
sion plug out of the cylinder block.
STEP 324
Rae 8-24183
2425-75
STEP 325
sion plug.
STEP 326
1. CHAMFER
3. EXPANSION PLUG
893LO
the top edge of the expansion plug is even to the
2425-76
CRANKCASE PRESSURE CHECK (BLOW BY)
Manometer Installation
STEP 330 STEP 327
Remove the clamp and the breather hose.
Install the breather adapter with the four cylinder orifice.
NOTE: Use the 0.221 inch for four cylinder engines.
STEP 329
, r~
Install the manometer.
Rae 8-24183
Turn each connector on the manometer one turn coun-
terclockwise.
STEP 331
Connect the tube from the breather adapter to one of
the connectors on the manometer.
STEP 332
Push the button on the gauge and move the gauge up
or down, until the zero on the gauge and the liquid inthe
tube are aligned.
Testing
NOTE: Do the following steps to get the correct man-
ometer readings.
Step 1 - Warm the engine to operating temperature.
Step 2 - Operate the engine at the rated speed.
Step 3- Use the hydraulics to apply a load to the engine
during the manometer test.
STEP 333
Take a manometer reading from the engine. Add the
number of lowered inches to the number of raised
inches for the correct manometer reading.
See example below.
LOWERED INCHES + 1.5
RAISED INCHES 1.5
TOTAL 3.0 INCHES
See the chart for manometer reading and crankcase
pressure (Blow By) limits.
Rae 8-24183
MANOMETER READING
Inches of
Water Umin
1 27
2 40
3 49
4 58
5 64
6 71
7
'."
76
~._~.
8 81
9 86
10 90
11 94
12 98
13 102
14 105
,15
109
16 112
17 115
18 118
19 121
20 124
2425-77
2425-78
Disconnect the tube from the connector. Remove the adapter from the breather tube.
STEP 335 STEP 338
Turn each connector on the manometer one turn clock-
wise.
STEP 336
~/
Remove the manometer.
Install breather hose and the hose clamp.
Rae 8-24183
Revisd 2-92 Printed in U.S.A.
Manometer Removal
Section
2445
LUBRICATION SYSTEM
Oil Pan, Oil Pump, Oil Cooler
and Oil Filter Housing
4-390 Diesel Engine
CASE CORPORATION
Rae 8-24193
Printed in U.S.A.
J une. 1983 (Revised February. 1992)
2445-2
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TORQUES 3
OIL PUMP
Removal 4
Disassembly and Assembly 5
Installation 6-7
OIL PRESSURE RELIEF VALVE 8
OIL FILTER HOUSING AND Oil COOLER
Removal 9
Installation _ 9
Oil PAN AND OIL INLET TUBE
Removal and Installation ; 10
SPECIFICATIONS
Oil Pressure
New Engine at Low or 800 rpm 1.9 to 3.0 Bar
at 1700 rpm 2.8 to 3.4 Bar
at High Idle or 2400 rpm 3.0 to 3.7 Bar
28 to 43 PSI
40 to 50 PSI
43 to 54 PSI
Used Engine low Idle (minimum) 0.7 Bar
High Idle (minimum) 2.1 Bar
10 PSI
30 PSI
Oil Pump Idler Gear to Crankshaft Gear Backlash 0.450 mm
Oil Pump Rotor Clearance 0.178 mm
Oil Pump Relief Valve Spring Specification (For 2 Hole Relief Valves)
Outside Diameter 14.02 mm
Assembled Height:
Compress to 44.98 mm 63 to 79 N
Spring Load Height:
Oil Pump Relief Valve Spring Specification (For 4 Hole Relief Valves)
Free Length 64.0 mm
Assembled Height:
Compress to 44.5 mm 87 N
Spring Load Height:
Compress to 41.25 mm 104.7 N
Rae8-24193 Revised2-92 Printed in U.S.A.
2445-3
SPECIAL TORQUES
Oil Pump Retaining Bolts.. 21 to 27 Nm
Front Cover Retaining Bolts 21 to 27 Nm
Crankshaft Pulley Retaining 80Its 120 to 130 Nm
Fan Pulley 8racket Retaining 80Its 23 to 25 Nm
Fan Pulley Bolts
Filter Housing Retaining Bolts 21 to 27 Nm
Oil Inlet Tube Retaining Bolts 18 to 30 Nm
Oil Pan Drain Plug 68 to 82 Nm
Rae 8-24193
2445-4
OIL PUMP
Removal
STEP 4 STEP 1
Lift the belt tensioner pulley and remove the fan belt.
STEP 2
::1[~~9~6
Remove the retaining bolts and fan belt pulley.
STEP 3
Remove the fan pulley bracket retaining bolts and fan
pulley bracket.
Rae 8-24193
Remove the crankshaft pulley bolts and the pulley.
STEP 5
Remove the front cover retaining bolts and remove the
front cover.
STEP 6
Remove the oil pump bolts and the oil pump.
Di sassembly and Assembly
2445-5
STEP 7
T68767
Put the oil pump on a clean work surface.
STEP 8
Remove the back cover plate.
Rae 8-24193
STEP 9
T68766
Measure the clearance between the lobe on the gear
and the lobe on the pump body. If the clearance is
more than 0.178 mm the pump must be replaced.
,>T68765
Install the back cover plate on the oil pump.
Revised 2-92 Printed in U.SA.
2445-6
Inst allat i on
NOTE: If anew oil pump is installed it is necessary to STEP 13
install a new four hole relief valve and spring.
STEP 11
Install the oil pump and tighten the bolts to a torque of
21 to 27 Nm. Follow the torque sequence above.
NOTE: To prevent damage to the oil pump DO NOT
tighten the bolts to more than 27 Nm.
STEP 12
Check the backlash between the oil pump idler gear
and the crankshaft. Put a dial indicator on the oil pump
idler gear. Ifthe backlash is more than 0.450 mmthe oil
pump must be replaced.
Rae 8-24193
Clean the seal surface on the crankshaft with Loctite
Safety Solvent. Refer to Section 2425 in the service
manual for front cover installation.
STEP 14
Install the tachometer drive assembly (if equipped).
STEP 15
Install the fan pulley bracket. Install and tighten the
retaining bolts to a torque of 23 to 25 Nm.
STEP 16
T689-16
" .
Install the fan pulley and the retaining bolts.
STEP 17
Lift the fan belt tensioner pulley and install the fan belt.
Rae 8-24193
2445-7
STEP 18
Tighten the fan pulley retaining bolts to a torque of:
Grade 8.8 Size M10 " 51 to 62 Nm
2445-8
OIL PRESSURE RELIEF VALVE SERVICE
STEP 19
Bottom Mounted Relief Valve
Use a valve spring tester and check the valve spring for the following specifications:
Top Mounted Relief Valve
1. PLUG 4. RELIEF VALVE
2. GASKET 5. OIL FILTER HOUSING
3. RELIEFVALVESPRING
Relief Valve Springs (For 2 Hole Relief Valves)
Assembled Height:
Spring Load Height:
Rae 8-24193
1. PLUG 4. RELIEFVALVE
2. GASKET 5. OIL FILTER HOUSING
3. RELIEFVALVE SPRING
Relief Valve Springs (For 4 Hole Relief Valves)
Free Length 64.0 mm
Assembled Height:
Compress to 44.5 mm 87 N
Spring Load Height:
Compress to 41.25 mm 104.7 N
Replace the valve spring if specifications are not met.
2445-9
OIL FILTER HOUSING AND OIL COOLER
Removal
STEP 22 STEP 20
Remove the oil filter.
STEP 21
Remove the oil filter housing.
Remove the oil cooler.
STEP 23
.'~
Put the oil filter housing on a clean work surface and
remove the cold oil relief valve.
STEP 24
Inst allat i on
STEP 25
Install two guide bolts 8M x 1.25 x 75 into the engine
block.
Rae 8-24193
Repeat Steps 20 through 24 inreverse order and install
the oil cooler and filter housing. Remove the two
alignment bolts.
NOTE: On Installation, install new gaskets to the oil
cooler and oil filter housing. Tighten the oil filter housing
retaining bolts to atorque of 21to 27 Nm.
Revised2-92 Printedin U.SA.
2445-10
OIL PAN AND OIL INLET TUBE
Removal and Inst allat i on
STEP 28 STEP 26
Remove the oil pan drain plug and drain the oil.
NOTE: On Installation, tighten the oil pan drain plug to a
torque of 68 to 82Nm.
STEP 27
Remove the oil pan bolts.
NOTE: On Installation, tighten the oil pan retaining bolts
to a torque of 21to 27 Nm.
l
Remove the oil inlet tube bolts.
NOTE: On Installation, tighten the oil inlet tube retaining
bolts to 21to 27 Nm.
STEP 29
Clean all surfaces of foreign material.
STEP 30
Repeat Steps 26 to 28 in reverse order to install the oil
inlet tube and oil pan.
NOTE: On Installation, install new gaskets to the oil pan
and oil inlet tube.
Sect i on
2455
COOLING SYSTEM
Thermost at , Wat er Pump, Fan Pulley
and Belt Tensi oner
4-390 Di esel Engi ne
CASE CORPORATION
Rae 8-24203
Printed in U.S.A.
J une. 1983 (Revised February, 1992)
2455-2
TABLE OF CONTENTS
SAFETY RULES 3
SPECIAL TORQUES..... .. 3
SPECIFICATIONS . 3
WATER PUMP
Removal 4
Installation 4
THERMOSTAT
Removal............... .. 5
Installation .. . . 6,7
COOLING INLET MANIFOLD
Removal...... .. 8
Installation 8,9
FAN PULLEY BRACKET
Removal.............. 10
Installation . 10,11
BELT TENSIONER
Removal 11,12
Installation .. 12,13
THERMOSTAT SERVICE. 14
SAFETY RULES
2455-3
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT
SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS
SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS
AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY
OR DEATH. M171B
Add coolant to the radiator only when the engine is stopped or slowly
h idling. To avoid being scalded when the pressure-type filler cap is being
removed, turn the cap slowly to the first stop position to relieve pressure
before removing the cap. M346
To remove the system pressure, slowly turn the radiator
cap counterclockwise to the FIRST stop. This will
permit a gradual release of pressure with little coolant
loss.
Never put coolant in a hot engine. The engine block or
cylinder head can get cracks because of the difference
in temperature between the metal and coolant.
How t o Clean t he Cooli ng Syst em
Clean the cooling system a minimum of once each
year. In areas where the water has minerals, clean the
system more frequently.
1. When the coolant is hot, open the radiator and
engine block drain valves. Close the valves after the
system is empty.
2. Add a radiator cleaner and fill the system with clean
water. Use a good type of radiator cleaner. Follow
the instructions given with the radiator cleaner.
3. Drain the radiator cleaner solution and flush the
system with clean water. Fill the system with
antifreeze and water and check the hoses, radiator
and water pump for leaks.
NOTE: After the cooling system is completely filled, run
the engine for approximately 20 minutes to remove air
from the cooling system. Check coolant level and add
coolant if necessary.
SPECIAL TORQUES
Water Pump Housing Bolts 21 to 27 Nm
Thermostat Housing Bolts 21 to 27 Nm
Inlet Manifold Bolts 39 to 47 Nm
Fan Pulley Bracket Bolts 23 to 25 Nm
Fan Pulley Bolts .
Grade 109 Size M8 37 to 43 Nm
Grade 10.9 Size M10.
......................................................................................................... 51 to 62 Nm
Belt Tensioner Bolt 39 to 47 Nm
SPECIFICATIONS
Belt Tension
Spring Tension at 35 Degree Angle (Minimum) 24 Nm
2455-4
WATER PUMP
Removal
STEP 2 STEP 1
Lift the belt tensioner pulley and remove the fan belt
T6 'EJ 9
Remove the water pump bolts and the water pump.
Inst allat i on
STEP 3 STEP 5
Install a new a-ring into the water pump housing. Lift the belt tensioner pulley and install the fan belt
STEP 4
Install the water pump and tighten the water pump
retaining bolts to a torque of 21 to 27 Nrn.
2455-5
THERMOSTAT
Removal
STEP 9 STEP 6
STEP 7
Remove the alternator bolts and the alternator.
STEP 8
Remove the bracket bolts and the alternator bracket.
Rae 8-24203
Remove the thermostat bearing bolts and the ther-
mostat housing assembly
STEP 10
410L91
Disassemble the thermostat housing.
STEP 11
155666
Check the thermostat for correct operation. Put the
thermostat in a container of hot water, approximately
175F (83C), at this temperature the thermostat should
start to open. Gradually heatthe water to atemperature
of 203F (95C), the thermostat should be fully open at
this temperature. The thermostat must be replaced if it
does not meet this specification.
2455-6
Inst allat i on
410L 91
1. THERMOSTAT HOUSING
2. THERMOSTAT
3. SEAL
4. LIFTING BRACKET
STEP 14
SM4
Install the template (1) as shown 410L 91
STEP 13
Assemble the thermostat housing.
NOTE: Make sure the stepped side of the seal is
towards the thermostat housing.
STEP 15
24551
Checkthe cylinder head coolant passage. Ifthe coolant
passage is smaller than the template, see Page XX.
Install the thermostat housing assembly Install and
tighten the bolts to a torque of 21 to 27 Nm.
Rae8-24203
STEP 16
Install the alternator bracket and tighten the retaining
STEP 17
Install the alternator and tighten the retaining bolts.
Rae 8-24203
2455-7
STEP 18
Lift the belt tensioner pulley and install the fan belt.
2455-8
COOLANT INLET MANIFOLD
Removal
STEP 21 STEP 19
STEP 20
Remove the alternator retaining bolts and remove the
alternator.
Remove the coolant inlet manifold.
Inst allat i on
STEP 22 STEP 23
Install a new a-ring and the coolant inlet manifold. Install the coolant inlet manifold retaining bolts and
tighten to a torque of 39 to 47 Nm.
STEP 24
Install the alternator.
STEP 25
Install and tighten the alternator retaining bolts.
Rae 8-24203
2455-9
STEP 26
2455-10
FAN PULLEY BRACKET
Removal
STEP 29 STEP 27
STEP 28
: 1-.
i;T6891'6
.;'~-"~ ........... ,'
Remove the fan pulley retaining bolts and fan pulley,
T68919
Remove the fan pulley bracket.
STEP 30
Inst allat i on
STEP 31
T68918
Install the fan pulley bracket and tighten the bolts to a
torque of 23 to 25 Nrn.
Rae 8-24203
Install the fan pulley and retaining bolts,
STEP 32
2455-11
STEP 33
Tighten the fan pulley bolts to a torque of:
BELT TENSIONER
Removal
STEP 35
STEP 34
Rae 8-24203
SM5
",..;;
Use a precision type torque wrench to lift the belt
tensionerto a45 degree angle. Lower the belt tensioner
to a 35 degree angle. The spring tension must not be
less than 24 Nm . If the spring tension is less than 24
Nm, the belt tensioner must be replaced.
2455-12
STEP 36
Remove the tensioner bolt and the belt tensioner.
STEP 37
Remove the retaining bolts and fan belt pulley.
STEP 38
Remove the belt tensioner bolts and the bracket.
STEP 39
Inst allat i on
STEP 40
Install the tensioner bracket and tighten the Allen head
Rae 8-24203
Install the fan belt pulley and retaining bolts
STEP 41
STEP 42
Rae8-24203
2455-13
STEP 43
Tighten the fan belt pulley retaining bolts to a torque of:
2455-14
STEP 44
THERMOSTAT SERVICE
STEP 47
1. NEW THERMOSTAT
2. OLD THERMOSTAT
309L91
A new thermostat has been released for use in your
engine. If you removed an old thermostat from your
engine, do the following steps to install a new ther-
mostat
STEP 45
311L91
Install the template that comes with the new thermostat
kit
STEP 46
312L91
Remove the template. Use a shop cloth in the coolant
passage to keep foreign material out of the engine. Use
a rotary grinder to remove the material.
STEP 48
31391
Remove all foreign material from the cylinder head.
Install the seal and newthermostat. Tighten the bolts to
STEP 49
314L91
Mark the cylinder head on the intake side next to the
serial number as follows:
Stamp the letter "Go for cylinder heads that were in-
spected and did not need to be machined.
Stamp the letter "M" for cylinder heads that were mach-
ined.
Rac 8-24203 Revised 2-92 Printed in U.S.A
Sect i on
2465
TURBOCHARGER
Written In Clear
And
Simple
English
IMPORTANT: This Turbocharger was made using the Metric Measurement
system. All measurements and checks must be made with metric tools to make
sure of an accurate reading when inspecting parts.
CASE CORPORATION Rae 8-25550 Printed in U.S.A.
J une, 1984
2465-2
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TORQUES 3
SPECIAL TOOLS 3
SERVICING THE TURBOCHARGER
Removal 4,5
Inspection 6
Disassembly 7-13
Inspection After Disassembly 13-14
Assembly 15-22
Installation 23,24
SPECIFICATIONS
Metric Value
Turbine Wheel Horizontal Movement 0.10 to 0.16 mm
Rae 8-25550
SPECIAL TORQUES
U.S. Value
Turbine Housing Bolts 96 Ib inch
Center Housing to Back Plate Bolts " 48 Ib inch
Compressor Housing Bolts , 48 Ib inch
Compressor Lock Nut 120 lb inch
Thrust Bearing Screws (Torx Head) 36 Ib inch
Turbocharger Mounting Nuts : 24 Ib ft
Drain Tube Bolts 18 Ib ft
SPECIAL TOOLS
2465-3
Metric Value
11 Nm
(1.1kgm)
6 Nm
(0.6 kgm)
6 Nm
(0.6 kgm)
14 Nm
(1.4 kgm)
5 Nm
(0.5 kgm)
32 Nm
(3.2 kgm)
24 Nm
(2.4 kgm)
CAS-10032 LB INCH TORQUE WRENCH
CAS-10033 LB FT TORQUE WRENCH
CAS-10066-1A DIAL INDICATOR
Rae 8-25550
2465-4
SERVICING THE TURBOCHARGER
Removal
STEP 4 STEP 1
Turbocharger with the air cleaner and the exhaust
pipe removed.
STEP 2
Loosen the air intake hose clamps.
STEP 3
Remove the air intake hose.
Rae 8-25550
x, .!I
Disconnect the oil supply tube.
STEP 5
Disconnect the oil supply tube clamp from the
turbocharger.
STEP 6
Disconnect the oil drain tube.
Issued6-84 Printed in U.S.A.
STEP 7
Remove the nuts that hold the turbochargerto the
exhaust manifold.
STEP 8
Remove the gasket.
Rae 8-25550
2465-5
STEP 10
Clean the mounting surface on the turbocharger
and the exhaust manifold.
STEP 11
J
,
Clean the mounting surface on the turbocharger
and the oil drain tube.
2465-6
Inspect i on
STEP12 STEP13
Put the turbocharger on a clean work surface. Use a dial indicator to check the horizontal move-
ment of the turbine wheel assembly. The horizon-
tal movement must not be more than 0.10 to 0.16
mm. The turbocharger must be rebuilt if the move-
ment is more than 0.16 mm or less than 0.10 mm.
2465-7
STEP 14
Di sassembly
STEP 17
Put a identification mark on the compressor hous-
ing and back plate. This identification is to make
sure the parts are in the correct position at assem-
bly.
STEP 15
Put a identification mark on the turbine housing
and the back plate. This identification is to make
sure the parts are in the correct position at assem-
bly.
STEP 16
Remove the retaining bolts from the compressor
housing.
Remove the compressor housing clamp plates.
STEP 18
Lift the assembly off the compressor housing.
STEP 19
Make the tabs straight on the lock plate.
2465-8
STEP 20
Remove the retaining bolts from the lock plate.
STEP 21
Remove the lock plates and clamp plates from the
turbine housing.
STEP 22
Lift the center housing assembly from the turbine
housing.
Rae 8-25550
.
Put the turbine end of the center housing assembly
into the holding fixture.
STEP 24
Use a double universal joint to remove the com-
pressor wheel lock nut. This procedure will pre-
vent the turbine shaft from bending.
STEP 25
'\
\
Remove the compressor wheel lock nut.
NOTE: The compressor wheel lock nut is left hand
thread.
STEP 26
Remove the compressor wheel.
STEP 27
Lift the center housing from the turbine shaft.
STEP 28
Remove the heat shield.
Rae 8-25550
2465-9
STEP 29
Remove the seal ring from the turbine shaft.
STEP 30
Turbocharger center housing.
2465-10
STEP 31
Make the tabs straight on the lock plate.
STEP 32
Remove the retaining bolts from the center hous-
ing.
STEP 33
Remove the lock plates from the center housing.
Rae 8-25550
STEP 34
Remove the center housing from the back plate.
STEP 35
Remove the oil baffle from the back plate.
STEP 36
Remove the seal from the back plate.
STEP 37
Remove the oil slinger from the back plate.
STEP 38
Remove the seal ring from the oil slinger.
STEP 39
Turbocharger center housing.
Rae 8-25550
2465-11
STEP 40
Remove the torx head screws from the center
housing.
STEP 41
Remove the thrust bearing.
STEP 42
Remove the thrust collar.
2465-12
STEP 43
Remove the outer bearing retaining ring.
STEP 44
Use a wire hook and pull the bearing from the
center housing.
STEP 45
Remove inner bearing retaining ring.
Rae 8-25550
Turn the center housing over and remove the outer
bearing retaining ring.
STEP 47
Use a wire hook and pull the bearing from the
center housing.
STEP 48
Remove the inner bearing retaining ring.
STEP 49
Center housing disassembled.
2465-13
STEP 50
Inspect i on Aft er Di sassembly
STEP 52
Replace the turbocharger if the outlet openings
show warpage or cracks.
STEP 51
Replace the turbocharger if the compressor hous-
ing shows damage caused by wheel friction.
Rae 8-25550
Replace the turbocharger if the turbine wheel is
damaged or if the turbine shaft has grooves or
scratches.
STEP 53
Replace the turbocharger if the back plate has
wheel friction wear.
2465-14
STEP 54
Inspect the compressor wheel for bent blades and
scratches. Replace the turbocharger if the wheel
shows damage.
STEP 55
Replace the turbocharger if the heat shield shows
damage.
Rae 8-25550
STEP 56
Replace the turbocharger if the oil slinger shows
damage.
STEP 57
Inspect the center housing bearing surfaces for
scoring or scratches. Replace the turbocharger if
there is damage.
2465-15
Assembly
NOTE: Lubricate a/l bearings, seals and the tur-
bine shaft with clean engine oil before assembly.
2465-16
STEP 58
Install a new inner bearing retaining ring. The
round edge of the retaining ring must be toward
the top.
STEP 59
Install a new center housing bearing.
STEP 60
Install a new outer bearing retaining ring with the
round edge down.
Rae 8-25550
STEP 61
Turn the center housing over and install a new
inner bearing retaining ring. The round edgeofthe
retaining ring must be toward the top.
STEP 62
Install a new bearing in the center housing.
STEP 63
Install a new outer bearing retaining ring with the
round edge down.
STEP 64
Install the thrust collar with the large 00 down.
STEP 65
Install a new thrust bearing on the center housing.
STEP 66
Install new torx head screws in the center housing.
Rae 8-25550
2465-17
STEP 67
Tighten the thrust bearing screws to atorque of 36
Ib inch (5 Nm)(O.5 kgm).
STEP 68
Install the oil baffle on the center housing with the
cup side down.
STEP 69
2465-18
STEP 70
Carefully install the oil slinger in the back plate.
STEP 71
STEP 72
Install the center housing on the back plate. Make
sure the mark on the back plate and the center
housing are aligned.
Rae 8-25550
STEP 73
Install new lock plates and new mounting bolts.
Tighten the back plate mounting bolts to a torque
of 48 Ib inch (6 Nm)(O.6 kgm).
Bend the tabs on the lock plate.
STEP 76
Install a new seal ring in the groove of the turbine
wheel.
STEP 77
Install the turbine wheel in the fixture and install
the heat shield on the turbine wheel.
STEP 78
Install the center housing on the turbine shaft. Be
careful not to damage the seal ring.
Rae 8-25550
2465-19
STEP 79
Install the compressor wheel on the turbine shaft.
STEP 80
Install a new compressor wheel lock nut.
NOTE: The compressor wheel lock nut is left hand
thread.
STEP 81
Use a double universal joint socket to tighten the
lock nut on the compressor wheel. This procedure
will stop the turbine shaft from bending.
2465-20
STEP 82
Tighten the lock nut to a torque of 120 Ib inch (14
Nm)(1.4 kgm).
STEP 83
Remove the center housing assembly from the fix-
ture.
Rae 8-25550
STEP 84
Carefully install the center housing on the turbine
housing. Make sure the mark on the turbine hous-
ing is in align with the mark on the center housing.
STEP 85
Install the clamp plates and the new lock plates.
STEP 86
Install the newturbine housing bolts andtighten to
a torque of 96 Ib inch (11 Nm)(1.1 kgm).
STEP 87
Bend the tabs on the lock plates.
STEP 88
Install the turbine housing assembly on the com-
pressor housing. Make sure the mark onthe center
housing is in align with the mark on the compres-
sor housing.
Rae 8-25550
2465-21
STEP 89
Install the compressor housing mounting plates.
STEP 90
Install new lock washers and bolts in the compres-
sor housing. Tighten the bolts to a torque of 48 Ib
inch (6 Nm)(O.6 kgm).
STEP 91
Turbocharger completely assembled.
2465-22
Rae 8-25550
TUBINE SHAFT
CENTER HOUSING
Issued 6-84
Printed in U.S.A.
2465-23
Inst allat i on
STEP 95
Install a new gasket on the exhaust manifold.
STEP 93
STEP 94
""~.
! I '"
Install the turbocharger mounting nuts andtighten
to a torque of 24 Ib ft (32 Nm)(3.2 kgm).
Rae 8-25550
Install a new gasket on the oil drain tube.
STEP 96
Install the oil drain tube bolts.
STEP 97
Tighten the oil drain tube bolts to atorque of 181b
ft (24 Nm)(2.4 kgm).
2465- 24
STEP 98
Install a tighten the bolt for the oil supply tube
clamp.
STEP 99
Connect and tighten the oil supply tube to the
turbocharger.
STEP 100
Install the air intake hose.
STEP 101
STEP 102
Turbocharger installed on engine.
NOTE: The J I Case Company reserves the right to make improvements in
design or changes in specifications at any time without incurring any obliga-
tion to install them on units previously sold.
Rac 8-25550 Issued 6-84 Printed in U.S.A.
J I Case
A Tenneco Company
Sect i on
2565
TURBOCHARGER FAILURE ANALYSIS
Rae 9-78235 Printed in USA
2565-2
CAUSES OF PREMATURE TURBOCHARGER FAILURE
Certainoperatingandmaintenance conditions
can arise whichcouldcause premature turbo-
charger failure. NOTE: The total solution to
theproblemisnot inrepairing the failure, but
indetermining thecause. Replacing adamaged
turbocharger withoutdetermining thecausewill
frequently result in a repeat failure.
Lack of Lubri cat i ng Oi l
This type of failure can occur when the a-
mount of oil being supplied to theturbocharger
is insufficient to lubricate or cool bearing
and journal surfaces.
Operating temperatures affect the volume
of oil required by the turbocharger. Asturbo-
charger speed or engine load increases, the
needfor lubricating oil increases. NOTE: I n-
sufficient oil for periods as short as five sec-
ondscan cause failure. This is why it is nec-
essary to prime the turbocharger as part of
the everyday operating procedure. I MPOR-
TANT: I t is very important that adequate
lubrication reaches the turbocharger bear-
ings and throughout the engine before opera-
ting the engine at rated speed.
Pri mi ng The Turbocharger
1. Place the transmission range shift lever in
"N" Neutral position.
2. Set the throttle lever not more than 1/3open
position (1000RPM).
3. Push inthefuel shutoff control. Press starter
buttonuntil engine starts. I MPORTANT: Do
not increase throttle or apply load until nor-
mal oil pressure shows on the engine oil
pressure gauge, assuring proper lubrication
to the turbocharger.
I MPORTANT: I n very cold weather, at oil
filter change or when the tractor has been
idle for several weeks or more, proceed as
followsto prime the turbocharger.
Pull out the fuel shutoff control, press the
start button and hold. Allow the engine to
crank until the engine oil pressure gauge
pointer reaches the green zone. Do not
exceed 30seconds cranking time.
Push in the fuel shutoff control and press
the start button. Run the engine (about 2min.
max.) at 1000RPM until normal engine oil
pressure shows on the engine oil pressure
gauge assuring proper lubrication to the tur-
bocharger.
4. I f theenginefires andstops, wait for thestar-
tingmotor tostopspinningbefore attempting
another start.
5. Donot use the starting motor longer than 30
seconds without interruption. Wait at least
3 minutes between crankings so batteries
can recuperate and the starting motor can
cool.
6. Shouldthe engine kill when operating under
load, immediately restart the engine to
prevent over-heating caused by stopping the
flow of oil for turbocharger, cooling and
lubrication.
Forei gn Mat eri al or Di rt i n t he
Lubri cat i ng Syst em.
Operating the engine with contaminated oil
will cause damage to the turbocharger bear-
ings if the particles are of sufficient quantity.
I f the particles are large enough, they can
clog the internal oil passages and starve the
bearings. This is another reason why it is im-
portant to change the engine crankcase oil and
oil filters at regular specified intervals.
Forei gn Mat eri al i n Exhaust or
Ai r Int ake Syst ems.
Therotating parts of theturbocharger can be
damaged byparticles introduced throughtheair
intake, whichmakes proper maintenance of the
air cleaner system very important.
Hi gh Exhaust Temperat ure
Excessive temperature intheexhaust system
will cause lubricating oil to coke in the center
housing drain annulus at the turbine end. Oil
leakage, carbon deposits and eventual damage
to the back of the turbine wheel will result.
Highexhaust temperature can also erode the
turbine housing creating pitting and deposits
on the turbine wheel.
Highexhaust temperature can be caused by
the turbocharger itself. Carbonbuild uponthe
turbine wheel, if severe, will slowthe rotating
assembly, reducing the amount of inlet air.
TURBOCHARGER FAILURE ANALYSIS
2565-3
NOTE: Following are discussion and examples
of damagedparts which aretypical turbocharger
failures. In analyzing turbocharger failure it is
important to recognize what caused the failure.
Replacing of the parts will, of course, repair
the damage but, unless you can correct the
causes, a reoccurance of these problems can be
expected.
Turbi ne Cont act Damage
Contact damage to the turbine usually means
there was bearing damage and/or shaft motion
caused by lack of lubricant or contaminated
oil. In this picture we see the turbine end
showing wheel rub from bearing failure as a
result of oil starvation.
Compressor Cont act Damage
Damage to bearings from contaminated lub-
ricant or from lack of lubricant will allow
motion of the shaft, permitting the compressor
wheel to contact the housing. Marking will be
visible on both the housing and the compres-
sor wheel. In these pictures we see the com-
pressor end showing wheel rub from bearing
failure as a result of oil starvation.
2565-4
Coked Cent er Housi ng
Coked (sludged) center housing failures are
generally caused by high exhaust temperatures
due to over-fueling, over-loading the engine,
dirty engine oil, or plugged oil return. Also
examine bearings for sludge.
Scored Turbi ne Shaft
The scoring of this shaft was caused by a
loose compressor wheel lock-nut.
Scored Beari ng Surface
The bearing surfaces of this shaft were scored
due to dirty engine oil. Evidence of a contamina-
ted oil failure calls for careful, thorough exa-
mination of engine lube system.
Scored Beari ngs
Scoring on the inside and outside surfaces
of the bearings is definitely attributed to
dirty engine oil.
Scored Thrust Collar
Scoring on the thrust collar caused by dirty
oil usually because engine oil and/or oil filters
were not changedat the recommended intervals.
Compressor Damage - Soft
Soft material getting into the inlet will dam-
age the compressor blades as shown. The
damage to this blade was caused by a shop
towel being left in the intake system.
2565-5
Compressor Damage - Hard
Hard material such as a nut. wire. wrench
or bolt getting into the inlet will damage the
compressor blades as shown. The compressor
housing will be marked by the bits of foreign
material. If damage to blades is so extensive
that wheel balance is destroyed. some wheel-
to-housing contact damage may also be pre-
sent.
2565-6
Compressor Blade Erosi on
Erosion of compressor blades from ingestion
of dust. Blades on one wheel are thinned while
the other wheel is almost completely worn
away. Fine erosion of the inlet edges of the
compressor wheel suggests sand or other fine
abrasive in the inlet system, entering through
a damaged air cleaner element or a leak in
inlet piping. There will generally be no dam-
ageto the turbine wheel or bearings unless the
problem was so severe that the rotating unit
became unbalanced.
Turbi ne Wheel Damage
Foreign material in the exhaust system will
cause chipped or broken turbine wheel blades.
Foreign material is usually something left by
accident in the exhaust manifold, or debris from
anenginecomponent suchasavalvewhich failed.
If damageis extreme, the turbine wheel balance
will bedestroyed and further damage will occur.
If you find this problem checkout the engine.
Turbi ne Shaft Di scolorat i on
Discoloration of the turbine shaft is due to
overheating caused by oil starvation. Lack of
lubrication generally is a matter of improper
start-up or shut-down practices.
Backi ng Plat e Wheel Rub
Wheel rub against the backing plate can be
caused by a bent shaft or improper assembly.
Blade Edges Li ft ed
Blade edges of the compressor wheel lifted
by improper removal of the compressor hous-
ing. Housing should not be pried off but lifted
straight off.
Turbtne Shaft & Beari ngs
Turbine shaft and bearings showing effect of
oil starvation.
2565-7
Beari ng Damage
Engine bearing material imbedded in the
bearing surfaces. Checkout the engine for
possible bearing failure.
Beari ng Fai lure
Bearing failures occur in two separate
areas. Scoring on the inside as well as the
outside is attributed to dirty oil. Abrasive
wear can also cause erosion around the oil
holes in the bearings. A good bearing is shown
in the lower right for comparison.
2565-8
Fi ne Scrat ches on Shaft
Fine scratches on both bearing journals are
evidence that abrasive material has contamina-
ted the lubricating oil.
Bent or Broken Shaft
Bearing damage and extreme shaft motion
caused by lack of lubrication or abrasives in
the oil may eventually cause the shaft to bend
or even break. When this type of damage is
evident. check the bearings.
NOTE: The J I Case Company reserves the right to make improvements
in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
SECTION INDEX - FUEL SYSTEM
Sect i on Ti t le Sect i on Number
Fuel System and Filters 3410
Fuel Injection Pump 3412
Fuel Injectors 3413
Pri nt ed i n U.S.A.
Issued J anuary 1991
CASE CORPORATION
Sect i on
3410
FUEL SYSTEM AND FILTERS
Rae 8-24212
Printed in U.S.A.
Issued March 1991
3410-2
FILTER REPLACEMENT
STEP 2 NOTE: Some engines have MO fuel filters while others
have single fuel filters. See the following photographs.
Case engine with two fuel filters
Case engine with single fuel filter
STEP 1
Use a strap or clamp wrench to remove the filter or
filters.
Rae 8-24212
Remove and discard the rubber seals from the filter
head.
STEP 3
Lubricate the new rubber seals with clean engine oil.
Install the rubber seals on the filter head.
STEP 4
Lubricate the gasket on the new filter with clean engine
oil. Turn the filter clockwise until the gasket makes
contact with the filter head. Use your hands to tighten
the filter an additional 1/2 to 3/4 of a turn.
BLEEDING AIR FROM THE FUEL SYSTEM
3410-3
STEP 5 4-390 ENGINE
1. Bleed Screw
2. Primer Pump
Make surethere isfuel inthe fuel tank. Loosen the bleed
screw and actuate the primer pump. Tighten the bleed
screw when clear fuel with no air bubbles flows from the
bleed screw.
NOTE: If the primer pump can not be actuated, rotate
the engine until the primer pump can be actuated.
STEP 6 4-390 ENGINE
1. Bleed Screw
2. Primer Pump
Put the key switch inthe ON position. Loosen the bleed
screw on the fuel injection pump. Actuate the primer
pump. Tighten the bleed screw when clear fuel with no
air bubbles flows from the bleed screw.
Rae 8-24212
STEP 7 4T-390 ENGINE
1. Bleed Screw
2. Primer Pump
Make sure there is fuel inthe fuel tank. Loosen the bleed
screw when clear fuel with no air bubbles flows fromthe
bleed screw.
3410-4
BLEEDING AIR FROM THE FUEL SYSTEM
STEP 5 4-390 ENGINE
1. Bleed Screw
2. Primer Pump
Make sure there isfuel inthe fuel tank. Loosen the bleed
screw and actuate the primer pump Tighten the bleed
screw when clear fuel with no air bubbles flows from the
bleed screw.
.NOTE: If the primer pump can not be actuated, rotate
STEP 6 4-390 ENGINE
1. Bleed Screw
2. Primer Pump
Putthe key switch in the ON position. Loosen the bleed
screw on the fuel injection pump. Actuate the primer
pump. Tighten the bleed screw when clear fuel with no
air bubbles flows from the bleed screw.
Rae 8-24212
STEP 7 4T-390 ENGINE
1. Bleed Screw
2. Primer Pump
Make sure there is fuel inthe fuel tank. Loosen the bleed
screw when clear fuel with no air bubbles flows fromthe
bleed screw.
Sect i on
3413
FUEL INJECTORS
J '
CASE CORPORATION
Rae 8-24233
Printed in U.S.A.
J une, 1983 (Revised February 1992)
3413-2
TABLE OF CONTENTS
SAFETY RULES 2
SPECiFiCATIONS..... .. 3
SPECIAL TOOLS 4
SPECIAL TORQUES 4
GENERAL INFORMATION 4
OPERATING PROCEDURES 5
LOCATING FAULTY INJ ECTORS
Locating Faulty Injectors at the Fuel Pump . 6
Locating Faulty Injectors at the Cylinder Head 6
INJ ECTORS
Removal 6,7
Installation .. .. . 7,8
FUEL INJ ECTOR TESTER. 9
Nozzle Tester Preparation 9
TESTING INJ ECTORS 10
Checking Opening Pressure................................ 10
Checking Seat Leakage 11
Spray Pattern 11
INJ ECTOR
Disassembly 12
Cleaning and Inspection 13
Assembly 14-16
Adjustments 16
INJ ECTOR SLEEVE (9 mm BORE TO 7 mm BORE)
Installation 17
SAFETY RULES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT
SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS
SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS
AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY
OR DEATH. M171B
When testing or adjusting diesel fuel injectors, do not place your hands,
arms, or any other part of your body into the fuel injector spray.
Fuel s'prayfrom an injector has sufficient velocity to penetrate the skin and
cause serious infection or other reactions. If injured by fuel penetration,
see your doctor immediately. SM127A
Wash the injured part with boric acid solution, support the injured finger or hand with a splint and sling so the injured part
will remain absolutely at rest until a physician can examine it.
3413-3
SPECIFICATIONS
Engines Manufactured in Darlington, England:
Prior to Engine Serial Number 21092870 use 9 mm Injector Nozzles
Engine Serial Number 21092870 and after use 7 mm Injector Nozzles
Engines Manufactured in North America:
Engines Manufactured in Neuss, Germany:
Bosch Inj ect ors
PART NUMBER
Assembly Nozzle Spray Angle Number of Spray Nozzle Size Opening Pressure
(Case) (Robert Bosch) Orifices Orifice Size
J 914472 0433171067 155 Degrees 4 0.28 mm 9mm 220 to 228 Bar
(3190 to 3307 PSI)
J 909476 0433171074 155 Degrees 4 0.29 mm 9 mm 245 to 253 Bar
(3553 to 3699 PSI)
J 919300 155 Degrees 4 0.28 mm 7mm 220 to 228 Bar
(3190 to 3307 PSI)
CAY Inj ect ors
PART NUMBER
Assembly Nozzle Spray Angle Number of Spray Nozzle Size Opening Pressure
(Case) (CAV) Orifices Orifice Size
J 917661 6801102 155 Degrees 4
0.29 mm
9mm 245 to253 Bar
,
(3553 to 3669 PSI)
(3553 to 3699 PSI)
(3553 to 3669 PSI)
Valve Leakage Rate ,,, , No Leakage Permissible
Slight Moistening of Nozzle Tip Permissible
Maximimum Opening Pressure Variation between each Cylinder 10.34 Bar 150 PSI
Rae 8-24233
3413-4
SPECIAL TOOLS
1. CAS-1066A WRENCH
SEE PAGE 7
2. CAS-1694 9 mm INJ ECTOR BORE CLEANING TOOL
3. CAS-2155 7 mm INJ ECTOR BORE CLEANING TOOL
SEE PAGE 7
SPECIAL TORQUES
Injector Retaining Nut 55 to 65 Nm
Leak Off Bolt : , 8 Nm
Nozzle Cap Nut 55 Nm
GENERAL INFORMATION
The fuel injector sends a measured amount of fuel to
the combustion chamber from the injection pump.
Each quantity of fuel must be sent to the combustion
chamber inthe formof fine particles. This will make sure
that there is complete combustion and efficient engine
performance
IMPORTANT: Theinjector tip end and the injector valve
are a matched assembly. The two parts are made
smooth to fit together with accuracy. The injector tip or
the injector valve cannot be replaced separately for
service. If it is necessary to replace either the valve or tip,
replace the complete tip assembly.
IMPORTANT: Do not mix tip assemblies and bodies
while the injectors are being disassembled.
INJ ECTOR BODY - The body holds the injector parts in
thecorrect position inthe cylinder head. The body has a
highpressure channel and a leak off channel. The lower
face of the body has a finished surface and has two
holes in the surface for locating dowel pins.
Rae8-24233
INJ ECTOR VALVE - The valve controls the flow of the
fuel from the injector.
VALVE STOP - The valve stop has two dowel pins which
hold the valve tip to the body. This will make a spray
pattern that is correct. Both faces of the valve stop have
a fine surface finish. The valve stop controls the
distance that the valve will move.
OPENING PRESSURE CONTROLSPRING - The spring
controls the fuel pressure that is necessary to lift the
valve from the seat.
SHIMS - The shims push down on the spring to keep a
given pressure on the valve.
INJ ECTOR TIP - The valve and the valve seat are inthe
injector tip. There are orifices in the injector tip that
atomize the fuel for better combustion and separate the
fuel spray to mix the fuel spray with air.
NOZZLE SEAL - The seal is under the cap nut and stops
engine compression leakage.
OPERATING PROCEDURES
3413-5
The operation of the injector is easy and positive
A measured quantity of fuel under high pressure moves
from the injection pump to the high pressure channel in
the injector body The fuel then moves through thevalve
stop channel and enters the pressure chamber which is
around the valve in the injector tip.
When the pressure of the fuel against the valve is more
than the set spring orifice, the valve is moved from the
seat. This permits the fuel under high pressure to enter
the injector tip. The fuel then moves through the spray
orifices and to the combustion chamber. The fuel
reaches the combustion chamber in an atomized
condition.
When the fuel delivery stops, the pressure against the
valve is decreased and the control spring immediately
returns the valve to the seat. This removes the danger of
leakage, after the measured amount of fuel has been
released. The valve opens and closes vary rapidly with
a very clear noise.
A small amount of fuel leaks, during injection, through
the controlled clearance between the tip assembly and
the injector body. This leakage adds lubrication to all
the moving parts in the injector. This fuel then moves
through the leak off channel, leak off lines and returns to
the fuel tank.
1. INLET
2. LEAK OFF
3. LEAK OFF CHANNEL
4. EDGE FILTER (IF EQUIPPED)
5. HIGH PRESSURE CHANNEL
6. INJ ECTOR BODY
7. OPENING PRESSURE CONTROL SPRING
8. CAP NUT
Rae 8-24233
420L91
9. NOZZLE SEALING WASHER
10. SPRAY ORIFICE
11. INJ ECTOR TIP
12. INJ ECTOR VALVE
13. VALVE STOP
14. SPRING SEAT
15. PRESSURE ADJ USTING SHIMS
3413-6
LOCATING FAULTY INJECTORS
If there is a loss of power during engine operation, the
injectors can be faulty. Refer to the following
procedures to locate the faulty injectors:
Locat i ng Fault y Inj ect ors
at t he Fuel Pump
Loosen the tube nut on the fuel line. This will release the
fuel and the injector will not work. Ifthis injector is faulty,
there will not be any difference in the engine perfor-
mance. Connect and tighten the tube nut of the fuel line.
Repeat this procedure for the remaining injectors.
Locat i ng Fault y Inj ect ors
at t he Cyli nder Head
STEP 2
! ~
Loosen the tube nut on the fuel inlet line for the injector
at the cylinder head. If the injector is faulty, there will not
be any difference in the engine performance Connect
ano tighten the tube on the fuel inlet line.
Repeat this procedure for the remaining injectors.
INJECTOR
Removal
STEP 3
Clean the area around the fuel injectors.
Rae 8-24233
STEP 4
STEP 5
Remove the leak off bolt.
STEP 6
Install the special wrench and a wrench on the flat
surface of the injector. Loosen the injector.
3413-7
STEP 7
Remove the fuel injector from the engine. Remove and
discard the sealing washer.
STEP 8
Repeat Steps 4 through 7to remove the remaining in-
jectors.
STEP 9
Inst allat i on
STEP 10
Use the injector bore cleaning tool, see Special Tools
page for correct size cleaning tool, to clean the injector
bore. Use compressed air to clean the injector bore.
Rae 8-24233
.~
lJ 69231
Install a new seal on the injector and install the injector
in the cylinder head bore. The ball in the injector must
align with the slot in the cylinder head bore.
NOTE: Use only a 7mmseal with a 7mminjector and a
9 mm seal with a 9 mm injector.
3413-8
STEP 11
T78866
Use the special wrench to tighten the injector retaining
nut to a torque of 55 to 65 Nm.
STEP 12
-H,~I 7i~60
Install the seal and the leak off screw and tighten the
leak off bolt to a torque of 8 Nm.
NOTE: Make sure the top of the gasket does not touch
the leak off line.
Rae 8-24233
STEP 13
~
Remove the cap. Connect and tighten the injection line
to the injector.
3413-9
FUEL INJECTOR TESTER
A Diesel Fuel Injection Nozzle Tester, OEM 1064, is
needed for checking and adjusting the injectors. The
following instructions will work for all models of testers
except for descriptions on adjustments to the tester
Operating instructions are given with the tester.
The tester is used to make the following checks
1. Check and adjust the injector opening pressure
2. Check the injector assembly for fuel leakage.
3. Check the injector for accurate spring pattern.
Fuel injectors must be checked on the tester when
making the following service operations
1. An injector that has been removed from the engine
for cleaning, must be checked on the tester before
the injector can be installed in the engine.
2. A new injector assembly must be checked on the
tester before the injector can be installed in the
engine.
3. All the injectors must be removed and checked on
the tester during an engine overhaul.
4. An injector must be removed and checked on the
tester before the injector is disassembled, if the
injector is the cause of engine performance that is
not acceptable.
Nozzle Test er Preparat i on
1. Fill the reservoir with clean fuel.
2. Connect the correct connectors to the connection
tube
Rae 8-24233
3. Connect the injector to the tester.
4. To remove the air that is in the system, close the
pressure release valve and the gauge protection
valve, open the pump. Operate the pump rapidly to
remove the air from the system.
3413-10
TESTING INJECTORS
The injector must be cleaned before testing the injector.
Washthe body, nozzle tip and the cap nut ina solvent to
remove external dirt, grease and carbon deposits from
the cap, body and outside diameter of the tip.
IMPORTANT: Do not permit the wire brush to contact
the tip (spray hole area) of the nozzle.
1
Connect the injector to the nozzle tester. The nozzle tip
must be facing down.
When testing or adjusting fuel injectors, do
I >.. not put your hands or arms in front of spray.
The spray will penetrate the skin causing
serious personal injury. SM126A
Fuel from the spray orifices can enter clothing and skin,
causing serious damage. The tip must always be put in
a container to contain the spray.
Checki ng Openi ng Pressure
Close the pressure release valve and the gauge
protection valve, operate the pump rapidly to flush the
injector. Open the gauge protection valve and raise the
pressure slowly until the injector valve opens (the
gauge reading will fall quickly at this point). Check the
opening pressure against the Specifications, refer to
Page 3.
NOTE: There must not be more than 10.34 Bar (150
PSI) difference between any of the injectors that have
been removed from the engine.
Rae 8-24233
Ifthe injectors do not meet the given opening pressure:
1. New injectors can be adjusted to the given opening
pressure. Refer to Page 16.
2. Injectors inuse must be disassembled and cleaned.
Refer to Page 12.
3. Check for broken or weak opening pressure control
springs.
3413-11
Checki ng Seat Leakage
protection valve. Open the pump valve and operate the
pump rapidly to flush the injector.
1. Dry the injector tip completely. Open the gauge
protection valve.
2. Lift the pressure at the injector to 6.9 Bar (100 PSI)
under the opening pressure.
3. Close the pump valve for five seconds and check
the nozzle tip (spray hole location). The nozzle leaks
if drops of fuel are seen on the nozzle tip. A small
amount of moisture on the nozzle tip is permitted
4. Open the pressure release valve and remove the
injector.
The following procedure must be followed if drops of
fuel are seen on the nozzle tip.
1. Disassemble and clean the injector, refer to Pages
12.
2. Assemble the injector, refer to Pages 14through 16
Spray Pat t ern
protection valve. Open the pump valve and operate the
tester at 60 strokes a minute, check the spray pattern.
The nozzle must have a spray pattern that will atomize
the fuel. The nozzle must not have a solid spray pattern.
SPRAY PATTERN THAT WILL ATOMIZE FUEL
SOLID TYPE SPRAY PATTERN
Rae 8-24233
The injector will make a very clear noise when the test
stand is operated rapidly. This noise will not necessarily
occur in the opeation of the injector in the engine. The
noise is an indication of good seat width and
interference angles This noise can change between
nozzles The noise in the nozzles must not be
compared for purpose of making nozzles acceptable
or not acceptable.
If this injector makes a solid type spray pattern, do the
following:
1. Check the orifices that are not open and check
orifices for scratches and heavy damage
2. Disassemble and clean the injector.
3. Check for pitting of the valve seat, wear of valve in-
terference angles, bent valve and distortion in the
body. Replace the complete injector assembly if
there is distortion in the body. Under other condi-
tions, replace the tip assembly only.
Revised 2-92 Printed in U.S A
3413-12
INJECTOR
Di sassembly
STEP 16 STEP 14
Put the injector in a soft faced vise with the two flat
surfaces towards the vise face. The tip of the injector
must be up. Remove and discard the sealing washer
NOTE: Use a cleaning solution to remove carbon
deposits from the nozzle and holder assembly.
STEP 15
Use a small amount of force to turn the cap nut.
IMPORTANT: The nozzle is held in position with the cap
nut. To prevent damage to the dowel pins. valve stop
and holder body pressure face, the nozzle must not turn
with the cap nut. Wet the nozzle and holder assembly in
cleaning solution until the nozzle is free in the cap nut.
replace the valve stop assembly if there is damage to
the dowel pins or valve stop.
Rae 8-24233
Remove the nozzle cap nut and disassemble the in-
jector.
NOTE: The injector parts have tight tolerances. Dirt will
damage asmooth surface. Keep the work location and
tools clean. Disassemble and assemble all parts
carefully to prevent damage.
3413-13
Cleani ng and Inspect i on
1. All parts must be put in a solvent to loosen the
carbon deposits.
2. Use the Nozzle Cleaning Kit, OEM 1068, to clean the
injectors A brass wire brush must be used to clean
the outside of the tip body. Use cleaning wires to
remove the carbon from the spray orifices. Use
cleaning wires that are0.0127 to 0.0254 mm smaller
in diameter than the spray orifice. Put the cleaning
wire in a pin vise, the end of the wire must extend
o 79 mm past the tip of the pin vise. A longer length
of pinwill hitthe opposite side of the sac hole and will
break.
3 Use a stone to remove sharp edges from the end of
the wire. A small flat on one side of the wire will make
it easier to cut the carbon from the orifice. Put the
cleaning wire in the spray orifice and turn the wire
until the wire is free Wash the body with clean
solvent and look at the tip. The nozzle tip must be
replaced if the orifice inthe tip shows damage at the
edges. Damage to the orifice will change the spray
pattern.
Rae 8-24233
4. Clean all channels with compressed air Direct the
air through both ends of the nozzle tip assembly. All
Carbon deposits must be removed.
8
5. Make sure that the nozzle valve slides freely in the
nozzle body.
6. Carefully clean the nozzle valve and the inside
diameter of the body to remove all dirt, varnish and
other foreign deposits.
7. The injector valve must be cleaned with a brush to
remove deposits from the seat location. Varnish
must be removed with a solvent and a cleaning pad
made of felt. Do not put the valve in a motor driven
lathe to clean the valve. This method can remove too
much material from the valve which can change
valve lift. Look at the valve for pitting or damage
which can cause leakage
8. Replace all parts that show damage.
3413-14
NOTE: Clean all parts in clean diesel fuel before as-
sembly.
STEP 17
T69087
Install the pressure adjusting shims required to obtain
the correct opening pressure.
Rae8-24233
1. NOZZLE HOLDER
4. SPRING SEAT
5. VALVE STOP
6. NOZZLE TIP ASSEMBLY
7. CAP NUT
421L91
STEP 18
"T69086
Install the opening pressure control spring into the
nozzle holder.
STEP 19
T69085
Install the spring seat onto the pressure spring. The
small diameter end of the spring seat must be toward
the pressure spring.
STEP 20
,.
T69084
Install the valve stop assembly. Align the dowel pins in
the valve stop with the dowel pin holes in the nozzle
holder.
STEP 21
Put a small amount of clean fuel on the nozzle valve and
slide the nozzle valve up and down a number of times in
the nozzle tip to make sure that there is free movement.
Rae 8-24233
3413- 15
STEP 22
T69083
Align the dowel pins in the nozzle tip assembly with the
dowel pins inthe stop valve assembly. Install the nozzle
tip assembly onto the stop valve assembly
STEP 23
T69082
Add lubrication to the nozzle shoulder. Do not put
grease on the holder or on the threads of the cap nut.
Install the cap nut over the end of the nozzle tip
assembly and turn the cap nut clockwise two or three
times
STEP 24
T69080
Put the injector in a soft vise with the tip of the injector
up. The flat surface of the injector must be toward the
face of the vise. Tighten the nut to a torque of 55 Nm.
3413-16
STEP 25
_21
Check the fuel injector on the test stand, refer to Pages
9 and 11.
1. INLET
2. LEAK OFF
3. LEAK OFF CHANNEL
4. EDGE FILTER (IF EQUIPPED)
5. HIGH PRESSURE CHANNEL
6. INJ ECTOR BODY
8. CAP NUT
9. NOZZLE SEALING WASHER
10. SPRAY ORIFICE
11. INJ ECTOR TIP
12. INJ ECTOR VALVE
13. VALVE STOP
14. SPRING SEAT
420L91
STEP 26
Adj ust ment s
STEP 27
Remove the fuel injector from the nozzle tester. Put the
injector in a soft faced vise. The flats of the injector
holder must be toward the face of the vise. The injector
tip must be facing up. Loosen the cap nut. To
disassemble the injector, refer to Page 12.
Rae 8-24233
_"". om T69087
Add pressure adjusting shims to increase the opening
pressure. Remove pressure adjusting shims to
decrease opening pressure. Do this until the correct
pressure is reached.
IMPORTANT: The opening pressure is changed by
about 3.79 Bar (55PSI) for each 0.0254 mm of shim
thickness that is added or removed.
STEP 39
Assemble the fuel injector. Refer to Pages 14 through
16.
3413-17
INJECTOR SLEEVE
Inst allat i on
This sleeve must be used to change the 9 mm injector bore inthe cylinder head to a 7mm injector bore to use the 7mm
injectors.
STEP 28
Use the injector bore cleaning tool, See Special Tools
page for correct size cleaning tool, clean the injector
bore. Use compressed air to clean the injector bore.
STEP 29
35L92
Install the sleeve on the injector.
IMPORTANT: Do not install a sealing washer on the
injector when sleeve is used.
Rae 8-24233
STEP 30
T78866
Use the special wrench and tighten the injector re-
taining nut to a torque of 55 to 65 Nm.
STEP 31
.#
J 78860
Install the seal and the leak off screw and tighten the
leak off bolt to a torque of 8 Nm.
NOTE: Make sure the top of the gasket does not touch
the leak off line.
STEP 32
.~
Remove the dust cap. Connect and tighten the injection
line to the injector.
3413-18
Sect i on
3414
CAV FUEL INJECTION PUMP
Pump Dri ve Gear, Fuel Shut Off
Pri mer Pump and Pump Ti mi ng
CASE CORPORATION
Rae 7-37131
Printed in U.S.A.
February, 1991 (Revised February, 1992)
3414-2
TABLE OF CONTENTS
SPECIAL TOOLS .... .2
SPECIAL TORQUES . . ... 2
TROUBLESHOOTING GUIDE .... 3
FUEL INJ ECTION PUMP
Removal .
Installation .
. 4,5
. ... 6,7
INJ ECTION PUMP GEAR
Removal.
Installation
8,9
................................................................................................................................. 10,11
FUEL INJ ECTION PUMP TIMING ... 11-14
FUEL SHUT-OFF SOLENOID
Assembly and Installation
................... 14
............. 14
PRIMER PUMP
Removal.. . 15
Installation 15
SPECIAL TOOLS
CAS-1690 ENGINE TURN OVER TOOL
FIRST USED ON PAGE 5
CAS-1691 A GEAR PULLER
FIRST USED ON PAGE 5
SPECIAL TORQUES
Injection Pump Mounting Bolts 21 to 27 Nm
Injection Pump Nut 59 to 71 Nm
Fuel Line Inlet Bolt 22 to 28 Nm
Fuel Shutoff Solenoid 14 Nm
Leak Off Fitting 13 to 17 Nm
3414-3
TROUBLESHOOTING GUIDE
NOTE: It isassumed that the engine isin good working order and properly tuned, and that the electrical system has been
checked and repaired as necessary.
Rae 7-37131
CAUSE AND REMEDY
Incorrect fuel in the fuel tank:
Drain tank, flush system and fill with correct fuel
Fuel tank empty or fuel tank vent blocked: .
Fill tank and bleed system, check tank vent (Refer to Section 3410)
Air in the fuel system:
Bleed fuel system, eliminate air leaks (Refer to Section 3410)
Pump rear support bracket loose:
Replace as necessary
, Voltage supply malfunction, stop solenoid defective:
Correct electrical faults, replace solenoid (Refer to Section 3414)
Fuel filter blocked:
Replace fuel filter (Refer to Section 3410)
Fuel supply lines blocked or resticted:
Check all fuel supply lines, flush or replace
Loose connection, injection lines leaking or broken:
Tighten the connection, eliminate the leak
Paraffin deposit in fuel filter:
Replace filter, use Diesel Fuel no.1 (Refer to Operators Manual)
Fuel injection pump timing incorrect:
Adjust timing
Injection nozzle faulty:
Repair or replace (Refer to Section 3413)
Engine air filter blocked:
Replace air filter element
Injection sequence does not correspond to firing order:
Install fuel injection lines in the correct order (Refer to Section 3414
Overflow fitting interchanged with inlet fitting:
Install fittings in correct positions (Refer to Section 3414)
Cold-start device malfunction (if equipped):
Check cold-start mechanism (if equipped)
Low or uneven engine compression:
Repair as necessary (Refer to Section 2425)
Fuel injection pump defective or cannot be adjusted:
Replace (Refer to Section 3414)
3414-4
-
FUEL INJECTION PUMP
Removal
STEP 4 STEP 1
Disconnect and install dust caps on the injection tubes
and the fuel injection pump
STEP 2
Disconnect and install caps on the fuel inlet tubes and
the injection pump. Remove the tube.
STEP 3
Disconnect and install a dust cap on the fuel leak off
tube and the injection pump
Rae 7-37131
Remove the tachometer drive assembly (if equipped).
STEP 5
Remove the nut and washer from the injection pump
drive shaft.
STEP 6
Install the engine turn over tool, CAS 1690, and push in
on the lock pin. Turn the engine over until the lock pin
engages in the camshaft gear.
STEP 7
2
._..~ .......... ' _~.v,_, ,".-.y _ ..... -.""",... ~"'".-...c"""' .,...; .
Loosen the pump shaft lock bolt and move the slotted
washer off the lock bolt shoulder. Tighten the lock bolt
to a torque of 7 Nm.
NOTE: The slotted washer must be loose after the lock
bolt had been tightened.
Rae 7-37131
3414-5
STEP 8
Loosen the injection pump retaining nuts and bracket
bolts.
STEP 9
Install the gear puller, CAS 1691, and tighten the bolts
until the gear is loose on the pump shaft.
STEP 10
Remove the retaining nuts and bracket bolts. Remove
the injection pump and discard the gasket.
NOTE: Care must be taken when removing the pump
from the gear not to lose the key from the pump shaft. If
the key is not on the shaft, it is necessary to remove the
timing cover.
3414-6
STEP 11
Inst allat i on
STEP 14
j
Install a new gasket and install the injection pump
NOTE : Make sure the key in the injection pump shaft
and the slot in the drive gear are aligned.
STEP 12
Install the nut and washer onto the injection pump shaft.
Tighten the nut to a torque of 59 to 71 Nm.
STEP 13
Align the marks on the injection pump flange and front
housing. Install the pump retaining nuts and bracket
bolts. Tighten the nuts and bolt to a torque of 21 to 27
Nm
Rae 7-37131
Loosen the lock bolt on the injection pump, move the
slotted washer onto the lock bolt. Tighten the lock bolt
to a torque of 20 Nm.
NOTE : The slotted washer must not move after the
locking bolt has been dropped.
STEP 15
Pullout the lock pin from the camshaft gear.
STEP 16
NOTE: The nut on the injection pump and the tachom-
eter drive nut must be aligned.
STEP 17
Remove the dust caps. Connect and tighten the fuel
leak off tube.
Rae 7-37131
3414-7
Install the fuel inlet fitting with new sealing washers.
Tighten the fitting to a torque of 22 to 28 Nm.
STEP 19
~
Remove the caps. Install and tighten the tubes between
the fuel injectors and fuel injection pump.
3414-8
INJECTION PUMP GEAR
Removal
STEP 24 STEP 20
STEP 21
Remove the crankshaft pulley retaining bolts and cran-
kshaft pulley.
STEP 22
STEP 23
Remove the timing gear cover retaining bolts. Remove
the timing gear cover. Remove and discard the gasket.
Rae 7-37131
Remove the nut from the injection pump drive shaft
STEP 25
Remove the plug from the flywheel housing and install
the engine turn over tool. Turn the engine over until the
lock pin engages in the camshaft gear.
STEP 26
t~
LOCK
927A
Loosen the lock bolt and move the slotted washer off
the shoulder of the lock bolt. Tighten the lock bolt to a
torque of 7 Nm.
NOTE: The slotted washer mustl be loose after the lock
bolt has been tightened.
STEP 27
Install the gear puller and tighten the bolts until the gear
is loose on the injection pump shaft.
Rae 7-37131
STEP 28
3414-9
Remove the gear from the injection
Remove the puller from the gear.
3414-10
STEP 29
Inst allat i on
STEP 31
T83414
LETIER A =CAV PUMP
Install the drive gear onto the injection pump drive shaft.
Make sure the correct letter on the drive gear and the
mark on the camshaft are aligned.
STEP 30
T78828
Install the washer and nut onto the injection pump shaft
and tighten a small amount
Rae 7-37131
Loosen the pump shaft lock bolt, move the slotted
washer onto the lock bolt Tighten the lock bolt to a
torque of 20 Nm.
NOTE: The slotted washer must not move after the lock
STEP 32
Pull out the lock pin from the camshaft gear.
STEP 33
Tighten the drive gear retaining nut to a torque of 59 to
71 Nm
I~
Clean the sealing surface of the crankshaft with Loctite
Solvent. Refer to Section 2425 to install the timing gear
front cover and oil seal.
3414-11
STEP 35
STEP 36
STEP 37
INJECTION PUMP TIMING
STEP 38
Make sure the lock pin is engaged inthe camshaft gear.
Rae 7-37131
TG3414
Ifthe pump shaft is not inthe locked position, rotate the
shaft clockwise until the key on the shaft and the slot in
the drive gear are aligned.
3414-12
STEP 39
J .
Install the injection pump shaft intothe drive gear. Make
sure the slot in the drive gear and the key on the injec-
tion pump are aligned.
STEP 40
Install the nuts and bracket bolts that hold the injection
pump to the front cover.
STEP 41
Tighten the drive gear nut a small amount.
Rae 7-37131
STEP 42
!~
UNLOCK
927.
Loosen the lock bolt on the injection pump. Move the
slotted washer on the lock bolt. Tighten the lock bolt to a
torque of 20 Nm.
NOTE: The slotted washer must not move after the lock
STEP 43
Tighten the drive gear nut to a torque of 59 to 71 Nm.
STEP 44
Install the engine turn over tool, CAS 1691, push in on
the lock pin and turn the engine over until the lock pin
STEP 45
Rotate the pump until the mark on the injection pump
flange and the mark on the front cover are aligned.
Rae 7-37131
3414-13
STEP 46
Tighten the injection pump mounting bolts and bracket
STEP 47
Pullout the lock pin from the camshaft gear.
STEP 48
Connect and tighten the fuel leak off tube.
3414-14
STEP 49
Install the fuel inlet line, fitting and sealing washers
FUEL SHUTOFF SOLENOID
Removal and Di sassembly
STEP 51
Remove the fuel shutoff solenoid from the injection
pump.
STEP 52
Disassemble the fuel shutoff solenoid. Check the
plunger and solenoid for scoring.
Assembly and Inst allat i on
STEP 53
Assemble the fuel shutoff solenoid.
Rae 7-37131
STEP 54
Install the fuel shutoff solenoid and tighten to atorque of
14 Nm.
3414-15
PRIMER PUMP
Removal
STEP 56 STEP 55
Disconnect and remove the fuel inlet line. Remove the primer pump bolts and the primer pump
from the cylinder block.
STEP 57
Inst allat i on
STEP 59
Install the primer pump and tighten the bolts that hold
the primer pump to the cylinder block.
STEP 58
Connect and tighten the fuel inlet line to the primer
pump.
Tighten the inlet fitting to a torque of 22 to 28Nm.
NOTE: The J I Case Company reserves the right 10 make improvements in design or
Sect i on
3415
BOSCH FUEL INJECTION PUMP
Pump Dri ve Gear, Fuel Shut off Solenoi d,
Pri mer Pump and Pump Ti mi ng
CASE CORPORATION
Rae 7-37141
Printed in U.S.A.
February, 1991 (Revised February, 1992)
3415-2
TABLE OF CONTENTS
SPECIAL TOOLS .2
SPECIAL TORQUES .............................. 2
TROUBLESHOOTING GUIDE ................. 3
FUEL INJ ECTION PUMP
Removal .
Installation .
4-5
. 6-7
INJ ECTION PUMP GEAR
Removal .
Installation ..
. ..... 9
10-11
INJ ECTION PUMP TIMING .. 11
.................................................................................................. 16
17
PRIMER PUMP
Removal .
Installation .
..................... . 17
18
TIMING LOCKING PIN
Removal .
Installation.... .
18
. 19
SPECIAL TOOLS
CAS-1690 ENGINE TURNOVER TOOL
CAS-1691 A GEAR PULLER
SPECIAL TORQUES
Injection Pump Mounting Bolts........... . 21 to 27 Nm
Injection Pump Nut . 59 to 71 Nm
Fuel Line Inlet Bolt 22 to 28 Nm
Fuel Shut-off Solenoid 43 Nm
Leak Off Fitting .. 13 to 17 Nm
Injection Pump Lock Bolt, Lock Position 27 to 33 Nm
Injection Pump Lock Bolt, Unlock Position 12 to 14 Nm
Rac 7-37141 Revised 2-92 Printed in U.sA
TROUBLESHOOTING GUIDE
3415-3
NOTE: It is assumed that the engine is in good working order and properly tuned, and that the electrical system has been
checked and repaired as necessary.
Rae 7-37141
CAUSE AND REMEDY
Incorrect fuel in the fuel tank:
Drain tank, flush system and fill with correct fuel
Fuel tank empty or fuel tank vent blocked:
Fill tank and bleed system, check tank vent (Refer to Section 3410)
Air in the fuel system:
Bleed fuel system, eliminate air leaks (Refer to Section 3410)
Pump rear support bracket loose:
Replace as necessary
Voltage supply malfunction, stop solenoid defective:
Correct electrical fauIts, replace solenoid (Refer to Section 3414)
Fuel filter blocked:
Replace fuel filter (Refer to Section 3410)
Fuel supply lines blocked or resticted:
Check all fuel supply lines, flush or replace
Loose connection, injection lines leaking or broken:
Tighten the connection, eliminate the leak
Paraffin deposit in fuel filter:
Replace filter, use Diesel Fuel no.1 (Refer to Operators Manual)
Fuel injection pump timing incorrect:
Adjust timing
Injection nozzle faulty:
Repair or replace (Refer to Section 34"13)
Engine air filter blocked:
Replace air filter element
Injection sequence does not correspond to firing order:
Install fuel injection lines in the correct order (Refer to Section 3414)
Overflow fitting interchanged with inlet fitting:
Install fittings in correct positions (Refer to Section 3414)
Cold-start device malfunction (if equipped):
Check cold-start mechanism (if equipped)
Low or uneven engine compression:
Repair as necessary (Refer to Section 2425)
Fuel injection pump defective or cannot be adjusted:
Replace (Refer to Section 3414)
3415-4
FUEL INJECTION PUMP
Removal
STEP 4 STEP 1
Clean the area around the fuel injection pump. Discon-
nect and remove the fuel injector tubes.
STEP 2
Disconnect and remove the fuel inlet tube.
STEP 3
Remove the leak off fitting. Remove and discard the
scaling washers.
Rae 7-37141
STEP 5
drive shaft.
STEP 6
'{;T78798
Install the engine turn over tool, and push in on the
locking pin. Turn the engine over until the locking pin
STEP 7
J t,
Loosen the pump shaft lock bolt and remove the slotted
tab.
Rae 7-37141
3415-5
STEP 8
Tighten the pump shaft lock bolt to a torque of 27 to 33
Nm.
STEP 9
is loose from the pump shaft.
STEP 10
Remove the pump retaining nuts and bolt and remove
the pump.
IMPORTANT: Care must be taken when removing the
pump from the gear not to lose the key from the pump
shaft. If the key is not on the shaft, it is necessary to
remove the timing cover.
3415-6
STEP 11
Inst al l at i on
STEP 14
Install a new gasket Install the injection pump Install
the injection pump washer and nut
NOTE: Make sure the key in the injection pump shaft
and the slot in the drive gear are aligned.
STEP 12
Align the marks on the injection pump flange and front
housing. Install the pump retaining nuts and bolt. Install
the bolt into pump mounting bracket Tighten the nuts
and bolts to a torque of 21 to 27 Nm.
STEP 13
',,;;1.
Install the slotted tab and tighten the lock bolt to a
Rae 7-37141
Pull out the locking pin from the camshaft gear.
STEP 15
Install the nut and washer on the injection pump shaft.
Tighten the nut to a torque of 59 to 71 Nm.
STEP 16
NOTE: The nut on the injection pump and the tachom-
eter drive nut must be aligned.
STEP 17
Remove the caps Install the leak off fitting and new
sealing washers. Tighten the fitting to a torque of 13 to
17 Nm.
STEP 18
Install the fuel inlet fitting with new sealing washers.
3415-7
STEP 19
Remove the caps. Install and tighten the tubes between
the fuel injectors and fuel injection pump.
INJECTION PUMP GEAR'
Removal
STEP 21 STEP 20
Rae 7-37141
Remove the crankshaft pulley retaining bolts and cran-
kshaft pulley.
3415-8
STEP 22
Remove the front cover bolts and the front cover.
STEP 23
Loosen the nut on the injection pump shaft.
Rae 7-37141
STEP 24
I
,
:
Install the engine turn over toot and turn the engine over
until the locking pin engages the camshaft gear.
STEP 25
?,1t
Loosen the lock bolt and remove the slotted tab.
STEP 26
Tighten the lock bolt to a torque of 27 to 33 Nm.
Rae 7-37141
3415-9
STEP 27
_'.>o_,~"~__ "_",~__ .~.""~, """""",,,,-,,. _,, T7Sfr28
shaft.
STEP 28
is loose on the injection pump.
3415-10
STEP 29
Inst al l at i on
STEP 31
LETIER B = BOSCH PUMPS
Install the drive gear on the injection pump shaft. Make
sure the correct letter on the drive gear and the mark on
the camshaft are aligned.
NOTE: The slot in the drive gear and the key on the
pump shaft must be aligned.
STEP 30
. T78828
Install the washer and nut on the injection pump shaft.
Rae 7-37141
..... ",,_ ._,,'0_. ~"~_' '_"""""_"'. 8906
Pull the locking pin out of the camshaft gear.
STEP 33
STEP 34
3415-11
STEP 35
INJECTION PUMP TIMING
STEP 36
Make sure the locking pin is engaged in the camshaft
gear.
Rae 7-37141
TG3414
If the pump shaft is not inthe locked position, rotate the
shaft clockwise until the key in pump shaft and the slot
in the drive gear are aligned.
3415-12
STEP 37
Install the injection pump into the drive gear Make sure
the slot inthe drive gear and the key on the pump shaft
are aligned,
STEP 38
Install the three nuts and the bracket bolt. Tighten the
nuts and bracket bolt a small amount.
STEP 39
Install the washer and nut on the injection pump shaft.
Tighten the drive gear nut a small amount.
Rae 7-37141
STEP 40
STEP 41
STEP 42
STEP 43
\; "
:n~
Install the engine turn over tool, push in on the locking
pin and turn the engine over until the locking pin
STEP 44
Remove the caps from the injection pump.
Rae 7-37141
3415-13
STEP 45
Remove the plug from the rear of the injection pump.
STEP 46
Install a dial indicator in the injector pump.
STEP 47
,
Revised2-92 Printed in U.S.A.
3415-14
STEP 48
Install the engine turn over tool into the flywheel
housing .Turn theengine counterclockwise until there is
no movement in the dial indicator.
STEP 49
Turn the dial indicator dial to zero.
Rae 7-37141
STEP 50
Push in on to the locking pin and turn the engine clock-
wise until the lock pin engages in the camshaft gear.
The dial indicator must read 1.8 mm. If the reading is
not correct continue to Step 51. If the reading is correct
go to Step 53.
STEP 51
Loosen the bracket bolt and the nuts that hold the injec-
tion pump to the front cover,
STEP 52
Rotate the injection pump until the dial indicator reading
is 1.8 mm.
NOTE: If 1.8mmcan not be reached go to Step 44in
this Section.
STEP 53
22
Tighten the bracket bolt and the nuts that hold the injec-
tion pump to the front cover to a torque of 21 to 27 Nrn.
STEP 54
Remove the dial indicator from the injection pump.
STEP 55
Install the injection pump plug and tighten to a torque of
23 Nm.
Rae 7-37141
3415-15
STEP 56
Install the sealing washer and the leak off fitting. There
must be a sealing washer on each side of the leak off
line. Tighten the leak off fitting to a torque of 13 to 17
Nm.
STEP 57
Install the inlet line. Install a sealing washer on each side
of the inlet line and tighten the inlet fitting to a torque of
22 to 28 Nm.
STEP 58
Connect and tighten the injector lines to the fuel injec-
tors and the injection pump.
3415-16
STEP 59
NOTE: The drive gear nut and the tachometer drive nut
must be aligned.
STEP 60
Removal and Di sassembl y
STEP 62 STEP 61
Remove the fuel shut-off solenoid from the injection
pump.
Rae 7-37141
Disassemble the fuel shut-off. Check the plunger
solenoid for scoring. Clean the orifice hole with a small
piece of wire.
3415-17
STEP 63
Assembl y and Inst al l at i on
STEP 64
Assemble the fuel shut-off solenoid as shown.
6
Install the fuel shut-off solenoid and tighten to a torque
of 43 Nm.
PRIMER PUMP
STEP 65
Removal
STEP 66
Remove the fuel inlet line.
Rae 7-37141
Remove the primer pump from the cylinder block.
3415-18
Inst al l at i on
STEP 67
Tighten the bolts that hold the primer pump to the
cylinder block.
STEP 68
Tighten the inlet fitting to a torque of 32 Nm.
TIMING LOCKING PIN
Removal
STEP 70 STEP 69
Remove the retaining ring from the locking pin housing.
Rae 7-37141
Remove the locking pin from the housjnq.
Revised 2-92 Printedin U.SA.
3415-19
STEP 71
Inst al l at i on
STEP 72
Install a new a-ring onto the locking pin. Install the lock pin. Install the retaining ring into the
locking pin housing.
SECTION INDEX - ELECTRICAL
Sect i on Ti t l e Sect i on Number
Removal and Installation of Electrical Components .4001
Electrical Specifications, Troubleshooting, and Schematics .4002
Batteries 4003
Starter and Starter Solenoid .4004
95 Ampere Alternator 4006
65 Ampere Alternator 4007
Instrument Cluster .4008
CASE CORPORATION
Bur 8-17200 Pri nt ed i n U.S.A.
CASE CORPORATION
Sect i on
4001
REMOVAL AND INSTALLATION
OF ELECTRICAL COMPONENTS
Bur 8-17210
Printed in U.S.A.
4001-2
TABLE OF CONTENTS
STARTER 3
Removal 3
Installation .4
ALTERNATOR 5
Removal 5
Installation 6
DRIVE BELT REPLACEMENT 7
INSTRUMENT CLUSTER 8
Removal 8
Installation 8
Replacing a Bulb 8
Gauge, Voltmeter, or Tachometer Removal and Installation 8
Circuit Board 8
SPECIFICATIONS
Alternator pulley shaft nut 50 pound-feet (68 Nm)
Crankshaft pulley cap screws 70 to 84 pound-feet (95 to 114 Nm)
Bur 8-17210
Removal
STARTER
4001-3
1. Park the machine on a level surface and apply the
parking brake.
2. Remove the pin that fastens the support strut to the
loader frame.
3. Raise the loader frame until the support strut is
against the end of the lift cylinder.
4. Stop the engine and install the pin in the support
strut.
5. Remove the cap screws and lock washers that
fasten the battery cover to the right side of the machine.
6. Remove the battery cover.
7. Ifthe machine has only one battery. disconnect the
negative battery cable from the battery.
8. If the machine has two batteries. remove the
terminal nut. Remove the negative battery cable from
the terminal and move the negative battery cable away
from the battery. Make sure the jumper cable is in-
stalled on the terminal and start the terminal nut onto
the terminal.
Bur 8-17210
9. Open the hood.
10. Disconnect the wires and cables fromthe terminals
on the starter.
11. Remove the two cap screws and lock washers that
fasten the starter to the flywheel housing.
12. Remove the starter.
4001-4
Inst al l at i on
1. Put the starter in place on the flywheel housing.
2. Install the cap screws and lock washers that fasten
the starter to the flywheel housing. Make sure the
ground cable is installed under the upper cap screw.
3. Connect the wires and cables to the terminals on
the starter.
4. Close the hood.
Bur 8-17210
5. If the machine has only one battery, connect the
negative battery cable to the battery.
6. If the machine has two batteries, remove the
terminal nut from the terminal. Install the negative
battery cable on the terminal. Make sure the jumper
cable is installed on the terminal. Install the terminal nut
on the terminal.
7. Install the battery cover.
the battery cover to the machine.
Removal
ALTERNATOR
4001-5
parking brake.
2. Remove the pinthat fastens the support strut to the
loader frame.
4. Stop the engine and install the pin in the support
strut.
5. Remove the cap screws and lock washers that
fasten the battery cover to the right side of the machine.
6. Remove the battery cover.
7. Ifthe machine has only one battery, disconnect the
negative battery cable from the battery.
terminal nut. Remove the negative battery cable from
the terminal and move the 'negative battery cable away
from the battery. Make sure the jumper cable is in-
stalled on the terminal and start the terminal nut onto
the terminal.
Bur 8-17210
9. Open the hood.
10. Install a 1/2 inch breaker bar inthe bracket for the
tension pulley.
11. Use the breaker bar to move the tension pulley just
far enough to release the tension on the drive belt and
remove the drive belt from the alternator.
12. Move the rubber boot out of the way and discon-
nect the cable from the alternator.
13. Disconnect the wire from the alternator.
14. Disconnect the connector from the alternator.
4001-6
15. Remove the cap screw and lock washer that fasten
the link to the bottom of the altnerator.
16. Hold the alternator and remove the cap screw and
lock washer at the top of the alternator.
17. Remove the alternator from the mounting bracket.
18. Fasten the pulley of the alternator in a vise that has
soft jaws.
19. Remove the nut and lock washer from the shaft of
the alternator.
20. Remove the alternator from the vise.
21. Hit the face of the pulley with a soft hammer to
loosen the tapered bushing in the pulley.
22. Remove the tapered bushing and pulley from the
shaft.
23. Remove the fan from the shaft.
Inst al l at i on
1. Install the fan on the shaft.
2. Install the pulley on the shaft.
3. Install the tapered bushing on the shaft.
4. Start the lock washer and the nut onto the shaft.
5. Fasten the pulley in a vise that has soft jaws.
Bur 8-17210
6. Tighten the nut to 50 pound-feet (68 Nm).
7. Remove the alternator from the vise.
8. Hold the alternator in alignment with the mounting
bracket and install the cap screw and the flat washer at
the top of the alternator. Do not tighten the cap screw.
9. Install the cap screw and lock washer that fasten
the link to the bottom of the alternator.
10. Tighten both of the cap screws.
11. Install the wire on the B+terminal.
12. Install the lock washer and the nut on the B+ter-
minal.
13. Connect the connectors to the alternator.
far enough to install the drive belt. Install the drive belt
on the alternator.
15. Remove the breaker bar.
16. Close the hood.
17. If the machine has only one battery, connect the
negative battery cable to the battery.
terminal nut from the terminal. Install the negative
battery cable on the terminal. Make sure the jumper
cable is installed on the terminal. Install the terminal nut
on the terminal.
4001-7
19. Install the battery cover.
the battery cover to the machine.
DRIVE BELT REPLACEMENT
parking brake.
2. Remove the pinthat fastens the support strut to the
loader frame.
4. Stop the engine.
5. Install the pin in the support strut.
6. Open the hood.
7. Install a 1/2 inch breaker bar inthe bracket for the
tension pulley.
far enough to release the tension on the drive belt.
Remove the drive belt from the alternator.
Bur 8-17210
9. Remove the four cap screws, flat washers, and lock
washers that fasten the coupling to the pulley on the
crankshaft.
10. Move the coupling toward the hydraulic pump.
11. Remove the old drive belt.
12. Install the new drive belt on the pulley on the water
pump and the pulley on the crankshaft.
13. Align the coupling with the pulley on the crankshaft.
14. Install the cap screws, flat washers, and lock
washers that fasten the coupling to the pulley on the
crankshaft. Tighten the cap screws to 70 to 84 pound-
feet (95 to 114 Nm).
far enough to install the drive belt. Install the drive belt
on the alternator.
16. Remove the breaker bar.
17. Close the hood.
4001-8
INSTRUMENT CLUSTER
Gauge, Vol t met er, or Tachomet er
Removal and Inst al l at i on
Removal
1. Remove the screws (16) that fasten the instrument
cluster to the instrument console.
2. Pull the instrument cluster out of the instrument
console.
3. Disconnect the connectors for the wiring harness
from the instrument cluster
4. Remove the instrument cluster from the machine.
Inst al l at i on
1. Connect the connectors for the wiring harness to
the instrument cluster.
2. Install the instrument cluster in the instrument
console.
3. Install the screws (16) that fasten the instrument
cluster to the instrument console.
Repl aci ng a Bul b
1. Remove the instrument cluster from the instrument
console.
2. Turn the socket (5) counterclockwise and remove
the socket (5).
3. Pull the bulb (3) from the socket (5) and install a
new bulb (3).
4. Install the socket (5) and turn the socket (5) clock-
wise to hold the socket (5) in place.
console.
Bur 8-17210
console.
2. Remove the four screws (10) that fasten the cover
(17) and the retainer (18) to the body (11).
3. Remove the cover (17).
4. Remove the retainer (18).
5. Remove the screws (21) thatfasten the gauge (1,2,
or 15), voltmeter (14) or the tachometer (13) to the body
(11) .
6. Remove the gauge (1, 2, or 15), voltmeter (14), or
tachometer (13) from the body (11). Ifyou are removing
a gauge (1,2, or 15) or voltmeter (14), you must pull the
studs of the gauge (1, 2, or 15) or voltmeter (14) from
the clips (4) in the body (11).
7. Install a new gauge (1, 2, or 15), voltmeter (14) or
tachometer (13) in the body (11). If you are installing a
gauge (1, 2, or 15) or voltmeter (14), make sure the
studs of the gauge (1, 2, or 15) or voltmeter (14) are
pushed into the clips (4) in the body (11).
8. Install the screws (21) that fasten the gauge (1,2, or
15), voltmeter (14), or tachometer (13) to the body (11).
9. Install the retainer (18).
10. Install the cover (17).
11. Install the screws (10) that fasten the cover (17)
and the retainer (18) to the body (11).
console.
Ci rcui t Board
The circuit board does not normally cause any
problems. Use an ohmmeter to check the continuity of
the strips. Ifthere is no continuity inanyone of the strips,
the circuit board must be replaced.
4001-9
4.CUP
6. RUBBER
BOOT
2. OIL
TEMPERATURE
GAUGE
1. WATER
TEMPERATURE
GAUGE
18. RETAINER
20. IDENTIFICATION STRIP
17. COVER
B861764R
Bur 8-17210
Sect i on
4002
ELECTRICAL SPECIFICATIONS, TROUBLESHOOTING,
AND SCHEMATICS
CASE CORPORATION
Bur 8-17220
Printed in U.S.A.
4002-2
TABLE OF CONTENTS
SPECIFICATIONS 3
Starting, Charging, and Instrument Cluster Circuits .4
Warning Buzzer, Parking Brake, Backup Alarm, and Clutch Cutout.. 12
Return-To-Dig, Cab Relay, Lamp Switches, Turn Signal and Flashers 20
Flood Lamp Switch, High Pressure Switch, and Air Conditioning Compressor Clutch 28
Cab Harness 32
Canopy Harness 50
Cab Harness (Continued) 42
USING BOOSTER BATIERIES TO START THE ENGINE 58
ALPHABETICAL INDEX OF COMPONENTS 59
Bur 8-17220
4002-3
SPECIFICATIONS
Electrical system, standard One 12 volt battery, negative ground
Electrical system, optional Two 12 volt batteries connected in parallel, negative ground
System voltage Approximately 12 volts
Batteries, standard
Production battery
J I Case part number 0132475
Group size 29H
Reserve capacity 160 minutes
Cold cranking capacity
At OaF (-17C) 650 amperes
At -20F (-29C) 487 amperes
Load for Capacity (Load) Test. 325 amperes
Plates per cell 16
Approximate weight with electrolyte 56 pounds (25.4 kg)
Nonspill caps Not required on this machine
Replacement battery .
J I Case part number A180406 or BMF31E
Group size 31
Reserve capacity , 170 minutes
At OaF (-1J OC) 700 amperes
Load for Capacity (Load) Test 350 amperes
Plates per cell 17
Batteries, optional
Production battery
J I Case part number 0128393 or BMF28SW
Group size 28
At OaF (-17C) 525 amperes
Plates per cell , , , , , ".., , , ' ' , ,..,.'..12
Approximate weight with electrolyte , 44 pounds (19.9 kg)
Replacement battery
J I Case part number .0127414 or BMF28S
Group size ,' 28
At OaF(-1J OC) 525 amperes
Plates per cell ' 12
Alternator
Standard 12 volts, 65 amperes
Optional " 12 volts, 95 amperes
Voltage regulator solid state, not adjustable
Starter , 12 volt, solenoid actuated
4002-4
St art i ng, Chargi ng, and Inst rument Cl ust er Ci rcui t s
REF COLOR FROM TO WIRE GAUGE
o Red Battery Starter Cable
1A Red Battery Alternator 8
1B Red Starter Cab Relay 12
1C Red Battery Starter Relay 12
1D Red/lt Blue Cab Relay Key Switch (Batt.) 12
3 Orange/White Key Switch (Ign.) 10 Ampere Fuse 14
4 Orange/Black Key Switch (Ace.) Cab Relay 16
8 Yellow/White Key Switch (Momentary Grd.) Diode 14
19B Red/Black 15 Ampere Fuse Instrument Cluster 14
21A White/Red Key Switch (Start) Starter Relay 16
21B White Starter Relay Starter Solenoid 12
22 White/Red Starter Relay and Neutral Alarm Harness Connector 16
Start Switch
23F White/Orange 10 Ampere Fuse Instrument Cluster and 16
Alarm Harness Connector
28 Gray/Orange Ether Injection Switch Ether Injection Solenoid 16
30 Black/Yellow Neutral Starter Switch Ground 12
31P Yellow/Black Instrument Cluster Instrument Cluster and 18
Alarm Harness Connector
31S Yellow/Red Alternator Tach Output Instrument Cluster 18
31T Yellow Coolant Temperature Sender Instrument Cluster 18
32F Orange/Blue Transmission Filter Switch Instrument Cluster 18
32T Yellow/Green Converter Temp Sender Instrument Cluster 18
33 Purple Master Cylinder Reservoir Instrument Cluster 18
34 Yellow/Ok Blue Alternator Instrument Cluster 18
36F Yellow/Orange Fuel Level Sender Instrument Cluster 18
36H Yellow/Purple Hydraulic Filter Switch Instrument Cluster 18
36P Yellow/Brown Parking Brake Switch Instrument Cluster and Alarm 18
Harness Connector
38 Yellow/Blue Air Filter Switch Instrument Cluster 18
41 Pink Instrument Cluster Driving Lamp Switch and Driving 12
Lamps
4002-5
St art i ng, Chargi ng, and Inst rument Cl ust er Ci rcui t s
NOTE: The battery must be at full charge and all connections clean and tight before testing. Use amultimeter for the
tests.
Check Points Reading Possible Cause of Bad Reading
Terminal for wire 1A to ground 12 volts Check wire 1A between the positive battery
terminal and alternator.
NOTE: Turn key switch to ON.
Terminal for wire 34 to ground Approximately
10 volts
Check the wire between the alternator and the in-
strument cluster. Check the instrument cluster on
page 4002-9.
NOTE: If the readings are good, see Section 4006 or 4007 and repair the alternator.
Battery terminal of starter solenoid to 12 volts
ground
Check the battery cable to the positive post of the
battery.
NOTE: Put the transmission control lever in NEUTRAL. Have another person hold the key switch in the START position.
Terminal for wire 21B to ground 12 volts Check the starter relay (5), neutral start switch (6),
and the key switch (4).
NOTE: If the readings are good, see Section 4004 and check the starter.
4002-6
Terminal for wire 1D to ground 12 volts Bad circuit between the key switch (4) and the cab
relay. See page 4002-27.
NOTE: Disconnect the connector from the key switch. Turn the key switch to the ON position.
Check between the BAT terminal and Continuity
the IGN terminal of the key switch
Bad key switch (4).
Check between the BAT terminal and Continuity
the ACC terminal of the key switch
Bad key switch (4).
NOTE: Have another person hold the key switch in the START position.
Between the STARTterminal and the Continuity
BAT terminal of the key switch
Bad key switch (4).
Terminal for wire 1C to ground 12 volts Check wire 1C between the starter relay (5) and
battery.
NOTE: Put the transmission control lever in NEUTRAL
Terminal for wire 22 to ground Continuity Bad circuit between the starter relay (5) and the
neutral start switch (6). Also check the neutral
start switch (6).
Terminal for wire 21A to ground 12 volts Check wire 21A between the starter relay (5) and
the key switch (4). Also check the key switch (4).
Terminal for wire 21B to ground 12 volts Bad starter relay (5).
Terminal for wire 22 to ground 12 volts Bad circuit between the neutral start switch (6)
and the starter relay (5). Check the starter relay
(5).
Terminal for wire 30 to ground 12 volts Bad neutral start switch (6).
Bur 8-17220 Issued1-91 PrintedinU.S.A.
4002-7
NOTE: Disconnect the wires from the ether injection switch. Push down and hold the button.
Check between the terminals of the Continuity
ether injection switch.
Bad ether injection switch.
NOTE: If the reading is good, check wire 21 A between the cold start button and the key switch (4). Also check ether
injection solenoid (8).
Ground terminal to ground Continuity Engine temperature too warm. Let the engine
cool. Check the ether injection temperature
switch (9).
NOTE: Disconnect wire 3from the fuel shutoff solenoid (10). Have another person hold the key switch in the START
position and push in and hold the ether injection switch.
Terminal for wire 28 to ground 12 volts Bad circuit between the ether injection solenoid
and the ether injection switch (7). Also check the
ether injection switch (7).
NOTE: If the readings are good, replace the ether injection solenoid.
NOTE: Disconnect the wires from the ether injection temperature switch. Make sure the engine is cold.
Check between the terminals of the Continuity
ether injection temperature switch
Bad ether injection temperature switch.
NOTE: Turn the key switch to ON.
Terminal for wire 3to ground 12 volts Check circuit between the fuel shutoff solenoid
and the key switch (4). Check the key switch (4).
NOTE: If the reading is good, replace the fuel shutoff solenoid.
Bur 8-17220 Issued 1-91 Printed in U.SA
4002-8
Terminal for wire 30 to ground Continuity Bad ground circuit.
Terminal for wire 33 to ground 12 volts Bad circuit between master cylinder reservoir
level switch and instrument cluster (14). Also
check the instrument cluster (14).
NOTE: If the readings are good, replace the master cylinder resetvoir level switch.
Check between the housing of the Continuity
coolant temperature sender and the
engine block.
Bad ground connection between the coolant tem-
perature sender and the engine block.
Terminal for wire 31T to ground 12 volts Check circuit between the coolant temperature
sender and instrument cluster (14). Also check
the instrument cluster (14).
NOTE: If the readings are good, replace the coolant temperature sender.
Check between the housing of the Continuity
converter temperature sender and
the converter housing.
Bad ground connection between the converter
temperature sender and the converter housing.
NOTE: Tum the key switch to ON.
Terminal for wire 32T to ground 12 volts Check the circuit between the converter tempera-
ture sender and the instrument cluster (14). Also
check the instrument cluster (14).
NOTE: If the readings are good, replace the converter temperature sender.
4002-9
NOTE: Disconnect the connector from the instrument cluster. Turn the key switch and driving lamp switch to ON. Apply
the parking brake.
Terminal T1 in connector to terminal Continuity
for wire 33 at the master cylinder re-
servoir level switch (11)
Check the circuit between the connector and the
master cylinder reservoir level switch (11). Also
check the master cylinder reservoir level switch
(11) .
Terminal T2 in connector to ground 12 volts Check the circuit between the connector and the
keyswitch (4). Also check the 10ampere fuse and
the key switch (4).
Terminal T3 in connector to ground Continuity Check the circuit between the connector and the
parking brake switch. Also check the parking
brake switch. See page 4002-19.
cab relay. Also check the 15ampere fuse and cab
relay. See page 4002-27.
for wire 34 at alternator (2)
alternator (2). Also check the alternator (2).
oil pressure switch. Also check the oil pressure
switch. See page 4002-19.
for wire 38 at the air filter switch filter
switch. See page 4002-19
Check the circuit between the connector and air
filter switch. Also check the air filter switch. See
page 4002-19.
NOTE: Have another person hold the key switch in the momentary ground position, halfway between ON and START.
Terminal T8 in connector to ground Continuity Check the circuit from the connector through the
diode to the key switch (4). Also check the diode
in the circuit. See page 4002-19.
Terminal T9 in connector to ground 12 volts Check jumper wire from T2 to T9.
Terminal T10 inconnector to ground Continuity Check the circuit between the connector and the
coolant temperature sender (12). Also check the
coolant temperature sender (12).
Terminal T11 inconnector to ground Continuity Check the circuit between the connector and the
converter temperature sender (13). Also check
the converter temperature sender (13).
Continued on next page
4002-10
driving lamp switch. Also check the driving lamp
fuel level sender. Also check the fuel level sender.
See page 4002-19.
Terminal T15 in connector to ground Continuity Bad ground circuit.
Terminal T18 inconnector to terminal Continuity
for wire 36H at the hydraulic filter
hydraulic filter switch. Also check the hydraulic
filter switch. See page 4002-19.
Terminal T18 in connector to ground Continuity Check the circuit from the connector through the
in the circuit and the key switch (4). See page
4002-19 for the diode.
NOTE: Disconnect the tachometer wires from the instrument cluster.
Terminal for wire 31S to terminal for Continuity
wire 31S at the alternator (2)
alternator (2). Also check the alternator (2).
Terminal for wire 10 to ground Continuity Check wire 10 to ground.
Terminal for wire 23F to ground 12 volts Check the circuit between the connector and the
keyswitch (4). Also check the 10 ampere fuse and
the key switch (4).
NOTE: Disconnect the wires for the transmission filter warning lamp from the instrument cluster.
Terminal for wire 32F to terminal for Continuity
wire 32F at the transmission filter
switch
transmission filter switch. Also check the trans-
mission filter switch. See page 4002-19.
Terminal for wire 23F to ground 12 volts Check the circuit between the connector and the
keyswitch (4). Also check the 10 ampere fuse and
the key switch (4).
Terminal for wire 32F to ground Continuity Check the circuit from the connector through the
in the circuit and the key switch (4). See page
4002-19 for the diode.
Bur 8-17220
CONNECTORS A.. B. C. AND 0
CONNECTOR G
Main chassis harness 10side console
harness
Main chassis harness 10
IransaxJ e harness
STARTING, CHARGING, AND INSTRUMENT CLUSTER
" ;"
" , 1 1
1 1 i l l
4002-12
Warni ng Buzzer, Parki ng Brake, Backup Al arm, and Cl ut ch Cut out
o Black Backup Alarm Pressure Switch Backup Alarm 14
o Black Backup Alarm Chassis Ground 14
4 Orange/Black Key Switch (Ace.) Cab Relay 16
8 YellowlWhite Key Switch (Momentary Grd) Diodes 14
10A Black/Orange Alarm Harness Connector Ground 14
12C Red Cab Relay 5 Ampere Fuse 12
13B2 Orange/Black Cab Relay 3 Ampere Fuse 16
13B3 Orange/Black Fuse Boom Lock Switch 16
13B4 Orange/Black Boom Lock Switch Boom Lock Solenoid 16
19E Red/Blue 15 Ampere Fuse Clutch Cutout Switch, Return- 14
To-O: - Magnetic Detent. and
Return-To-Dig Harness
22 White/Red Starter Relay and Neutral Start Alarm Harness Connector 16
Switch
22 Blue Alarm Harness Connector Parking Brake Relay 16
23F White/Orange 10 Ampere Fuse Instrument Cluster and Alarm 16
Harness Connector
23F Red Alarm Harness ': onnector Diode 16
23G RedlWhite Diode Parking Brake Relay 18
25 Orange/Blue Clutch Cutout Switch Loader Handle Harness 16
25 White/Blue Loader Handle Harness Transaxle Harness, Pin B of Con- 16
nector G
25 Gray Transaxle Harness, Pin B of Con- Clutch Cutout Solenoid 16
nector G
30 BlackiYeliow Clutch Cutout Solenoid Ground 12
30 Black Transaxle Harness, Pin C of Con- Ground 16
nector G
30 Black Return-To-Dig Harness Ground 16
30B6 Black Boom Lock Solenoid Ground 16
31P Yellow/Black Oil Pressure Switch Instrument Cluster and Alarm 18
Harness Connector
31P Green Alarm Harness Connector Diode 18
32F Orange/Blue Transmission Filter Switch Instrument Cluster 18
3QF 't 'el l awl Qrange Fuel Level Sender Instrument Cluster 18
36H Yel l owl Purpfe Hydraulic Filter Switch Instrument Cluster 18
36P Yellow/Brown Parking Brake Switch Instrument Cluster and Alarm 18
Harness Connector
36P White Alarm Harness Connector Parking Brake Relay 18
37 YellowlWhite Engine Temperature Switch Alarm Harness Connector 18
37 Brown Alarm Harness Connector Parking Brake Relay 18
38 Yellow/Blue Air Filter Switch Instrument Cluster 18
39A PurplelYeliow Warning Alarm (Positive) Alarm Harness Connector 18
39A Orange Alarm Harness Connector Parking Brake Relay 18
39B PurplelWhite Warning Alarm (Negative) Alarm Harness Connector 18
39B Purple Alarm Harness Connector Parking Brake Relay 18
41 Pink Light Switch Driving Lamps 12
51A RedlYeliow 5 Ampere Fuse Backup Alarm Pressure Switch 14
30 Black/Yellow Parking Brake Switch Ground 12
Bur 8-17220 Issued1-91 PrintedinU.SA
4002-13
Warni ng Buzzer, Parki ng Brake, Backup Al arm, Cl ut ch Cut out
NOTE: Thebatteries must be at full charge and all connections clean and tight before testing. Use amultimeter for the
tests.
NOTE: Turn tne key switch to ON. If the warning buzzer does not sound, do the following checks.
Terminal for wire 39A to ground 12 Volts Check the circuit between the warning buzzer and
the key switch. Also check the 10 ampere fuse
and the key switch. See page 4002-11.
Terminal for wire 39B to ground Continuity Check the circuit between the warning buzzer and
the engine oil pressure switch (3). Also check the
engine oil pressure switch (3). Check the diode in
wire 31P.
NOTE: If the readings are good, replace the warning buzzer.
Terminal for wire 10 to ground Continuity Bad ground circuit.
Terminal for wire 37 to ground 12 volts Check the circuit between the engine temperature
switch and the parking brake relay (6). Also check
the parking brake relay (6).
NOTE: If the readings are good, replace the engine temperature switch.
Bur 8-17220
4002-14
Check Points
Check between the housing of the
oil pressure switch and the engine
block
Terminal for wire 31P to ground
Reading Possible Cause of Bad Reading
Continuity Bad ground connection between the oil pressure
switch and the engine block.
12 volts Check the circuit between the engine oil pressure
switch and the instrument cluster. Also check the
instrument cluster. See page 4002-11 .
NOTE: If the readings are good, replace the engine oil pressure switch.
Check Points
fuel level sender and the machine
frame
Terminal for wire 36F to ground
Continuity Bad ground connection between the fuel level
sender and the machine frame.
12 volts Check the circuit between the fuel level sender
and the instrument cluster. Also check the instru-
ment cluster. See page 4002-11.
NOTE: If the readings are good, replace the fuel level sender.
Check Points
Terminal for wire 30 to ground
Continuity Bad ground connection.
12 volts Check the circuit between the parking brake
NOTE: If the readings are good, replace the parking brake switch.
Check Points
4002-15
NOTE: Make sure the transmission control lever is in NEUTRAL.
Terminal for wire 39B to ground
Check Points
transmission filter switch and the
transmission housing
Continuity Bad circuit between parking brake relay and the
neutral start switch. Also check the neutral start
switch. See page 4002-11 .
12 volts Check the circuit between the parking brake relay
and the key switch. Also check the 10 ampere
fuse and the key switch. See page 4002-11 .
12 volts Check wire 39B to the warning buzzer (1). Also
check the warning buzzer (1).
12 volts Bad parking brake relay.
12 volts Check the circuit between the transmission filter
NOTE: If the readings are good, replace the transmission filter switch.
Check Points
hydraulic filter switch and the filter
housing
Terminal for wire 36H to ground
12 volts Check the circuit between the hydraulic filter
instrument cluster. See page 4002-11.
NOTE: If the readings are good, replace the hydraulic filter switch.
4002-16
Terminai for wire 30 to ground Continuity Bad ground connection.
Terminal for wire 38 to ground 12 volts Bad circuit between the air filter switch and the in-
strument cluster. Also check the instrument
cluster. See page 4002-11 .
Terminal for wire 51A to ground 12 volts Check the circuit between the backup alarm
pressure switch and the cab relay. Also check the
5ampere fuse and the cab relay. See page 4002-
27.
NOTE: Start and run the engine at low idle. Have another person hold down both brake pedals and shift the trans-
mission into REVERSE.
Terminal for wire 0 to ground 12 volts Bad backup alarm pressure switch.
Negative terminal to ground Continuity Bad ground circuit.
NOTE: Start and run the engine at low idle. Have another person hold down both brake pedals and shift the trans-
mission into REVERSE.
Positive terminal to ground 12 volts Check the circuit between the the backup alarm
and the backup alarm pressure switch (10). Also
check the backup alarm pressure switch (10).
NOTE: If the readings are good, replace the backup alarm.
4002-17
Terminal for wire 19E to ground 12 volts Check the circuit between the clutch cutout switch
and the cab relay. Also check the 15ampere fuse
and the cab relay. See page 4002-27.
NOTE: Push down and hold the clutch cutout switch.
Terminal 25 to ground 12 volts Bad clutch cutout switch.
NOTE: Turn the key switch to ON. Have another person push down and hold a clutch cutout switch.
Terminal for wire 25 to ground 12 volts Check the circuits between the clutch cutout
solenoid and the clutch cutout switch (12). Also
check the clutch cutout switch (12).
Terminal for wire 30 to ground Continuity Check the ground circuit 30.
NOTE: If the readings are good, replace the clutch cutout solenoid.
Terminal for wire 1383 to ground 12 volts Check the circuit between the boom lock switch
and the cab relay. Also check the 3 ampere fuse
and the cab relay. See page 4002-27 for the cab
relay.
NOTE: Turn the boom lock switch ON.
Terminal for wire 1384 to ground 12 volts 8ad boom lock switch.
4002-18
Terminal for wire 30B6 to ground Continuity Bad ground circuit.
Terminal for wire 13B4 to ground 12 volts Check the circuit between the boom lock solenoid
valve and the boom lock switch (14). Also check
the boom lock switch (14).
NOTE: If the readings are good, replace the boom lock solenoid.
Terminal for wire 19E to ground 12 volts Check the circuit between the clutch cutout switch
and the cab relay. See page 4002-27.
NOTE: Push down and hold the clutch cutout switch.
Terminal 25 to ground 12 volts Bad clutch cutout switch.
Bur 817220 Issued 1-91 Printedin U.S.A.
Bur 817220
Issued191 PrintedinUSA
Bur 8-17220
4002-20
RETURN-TO-DIG, CAB RELA.Y, LA.MP SWITCHES,
TURN SIGNAL AND FLA.SHERS
1B Red Starter Cab Relay 6
10 Red/Lt Blue Key Switch (Batt.) Cab Relay 12
4
Orange/Black Key Switch (Ace.) Cab Relay 16
10 Black/Orange Cab Relay Ground 12
12A Red/Black Cab Relay 25 Ampere Fuse 12
12B Red/Orange Cab Relay 10 Ampere and 15 Ampere Fuse 12
12C Red Cab Relay 5 Ampere Fuse 12
13B2 Orange/Black Cab Relay 3 Ampere Fuse 16
19A Red 25 Ampere Fuse Driving Lamp Switch 12
19B Red/Black 15 Ampere Fuse Stop, Flasher Switch, Turn Signal 14
Switch and Horn Button,
Instrument Cluster
190 RedlYellow 15 Ampere Fuse Rotating Beacon and Dipper 14
Lamp Switch, Flasher
19E Red/Blue 15 Ampere Fuse Clutch Cutout Switch, Return- 14
To-Dig Magnetic Detent, and
Return-To-Dig Harness
19E Red Return-To-Dig Harness Return-To-Dig Relay and Proxi- 16
mity Switch
30 Black/Yellow Turn Signal Indicator Lamps Ground 12
30 Black Return-to-Dig Relay and Proximity Ground
Switch
42R Ok BluelWhite Driving Lamp Switch Rear Working Lamp 12
44 Tan Stop Lamp Switch Brake Lamps 14
45L Ok BrownlYellow Turn Signal Switch Left Turn Signal Lamps 14
45R Ok Brown/Green Turn Signal Switch Right Turn Signal Lamps 14
46 Ok Brown Flasher Switch Flasher (T1 Terminal) 14
47L Lt Brown/Yellow Left Turn Signal Switch Left Turn Signal Indicator 18
47R Lt Brown/Green Right Turn Signal Switch Right Turn Signal Indicator 18
48 Lt BrownlWhite Rotating Beacon Switch Rotating Beacon 14
53 Purple/Red Return-To-Dig and Auxiliary Loader Valve 16
Hydraulic Switch
54 Brown/Pink Return-To-Dig Relay Proximity Switch 16
64A Orange/Blue Turn Signal Switch and Horn Relay 16
Horn Button
64B Green/Red Horn Relay Horn 16
4002-21
Ret urn-To-Di g, Cab Rel ay, Lamp Swi t ches, Turn Si gnal s, and Fl ashers
NOTE: The battery must be at full charge and all connections clean and tight before testing. Use amultimeter for the
tests.
Terminal for wire 19E to ground 12 volts Check the circuit between the return-to-dig relay
and the cab relay (7). Also check the 15 ampere
fuse on page 4002-19 and the cab relay (7).
NOTE: Disconnect the connector from the proximity switch (3).
Terminal for wire 54 to terminal for
wire 54 in connector for proximity
switch (3)
Continuity - Check wire 54.
Terminal for wire 30 to ground Continuity Bad ground connection
Terminal for wire 53 to ground Approximately
12 volts
Check the circuit between the return-to-dig relay
and the magnetic detent (2). Also check the
magnetic detent (2).
NOTE: Disconnect the wires from the magnetic detent. Turn the key switch to ON.
Terminal inharness for wire 19E to
ground
12 volts Check the circuit between the magnetic detent
Between the terminals of the
magnetic detent
Continuity Bad magnetic detent.
NOTE: Also check the return-to-dig relay (1) and the proximity switch (3).
4002-22
Check Points Reading
NOTE: Disconnect the connector from the proximity switch.
Terminal for wire 30 in connector
to ground
.Terminal for wire 19E inconnector
to ground
Terminal for wire 54 in connector
Continuity
12 volts
Approximately
12 volts
NOTE: If the readings are good, replace the proximity switch.
Check Points
Ground terminal to ground
Reading
Continuity
Possible Cause of Bad Reading
Bad ground circuit.
Check the circuit between the proximity switch
Check the circuit between the proximity switch
and the return-to-dig relay (1). Also check the
return-to-dig relay (1).
Possible Cause of Bad, Reading
NOTE: Turn the key switch to ON. Have another person hold down the horn button.
Bad ground circuit.
Terminal for wire 64B to ground 12 volts
NOTE: If the readings are good, install a new horn.
Bur 8-17220
Check the circuit between the horn and the horn
relay (5). Also check the horn relay (5) and the turn
signal switch and horn button (13).
Check Points
Both terminals for wire 19B to
ground
4002-23
12 volts Check the circuit between the horn relay and the
cab relay (7). Also check the 15 ampere fuse and
the cab relay (7).
Terminal for wire 64A to ground
NOTE: Push down and hold the horn button (5).
Continuity Check wire 64A between the horn relay and the
turn signal switch and horn button (13). Also
check the turn signal switch and horn button (13).
NOTE: Push down and hold the horn button (5).
Bad horn relay. 12 volts
Check Points
Check Points
Terminal for wire 13B2, 12A 12B,
or 12C and ground
Bur 8-17220
Approximately
10 volts
Check the circuit between the optional switch
relay and the magnetic detent (2). Also check the
magnetic detent (2).
Readi ng Possible Cause of Bad Reading
Continuity Check wire 10 to ground.
12 volts Check the circuit between the cab relay and the
key switch. Also check the key switch. See page
4002-11.
12 volts Check wire 1B between the cab relay and the
starter. Also check the starter. See page 4002-11.
12 volts Bad cab relay.
4002-24
Check Points
12 volts Check the circuit between the driving lamp switch
fuse and the cab relay (7).
NOTE: Turn the driving lamp switch to ON.
12 volts Bad driving lamp switch.
Terminal for wire 42R to ground 12 volts Bad driving lamp switch.
NOTE: If the readings are good but the illumination lamps in the instrument cluster still do not work, check the in-
strument cluster. Seepage 4002-11.
Check Points
12 volts Check the circuit between the stop lamp switch
NOTE: Have another person push down and hold the brake pedals.
12 volts Bad stop lamp switch.
Check Points
NOTE: Turn the flasher switch ON.
Bur 8-17220
12 volts Check the circuit between the flasher switch and
the cab relay (7). Also check the 15 ampere fuse
and the cab relay (7).
12 volts Bad flasher switch.
Check Points
4002-25
Reading
12 volts
NOTE: Turn the rotating beacon switch ON.
Check Points
Terminal for wire T3 to ground
Terminal T2 to ground
12 volts
Reading
Continuity
12 volts
Check the circuit between the rotating beacon
switch and the cab relay (7). Also check the 15
ampere fuse and the cab relay (7).
Bad rotating beacon switch.
Bad ground connection.
Check the circuit between the flasher and the cab
relay (7). Also check the 15 ampere fuse and the
cab relay (7).
NOTE: Make sure the turn signal switch is in the OFF position. Turn the flasher switch ON.
Bur 8-17220
12 volts
Intermittent
12 volts
Intermittent
12 volts
Intermittent
12 volts
Intermittent
12 volts
Check the circuit between the flasher and the
flasher switch (10). Also check the flasher switch
(10).
Bad flasher.
Bad flasher.
Bad flasher.
Bad flasher.
4002-26
Check Points
12 volts Check the circuit between the turn signal switch
Terminal for wire 45R to ground
NOTE: Make sure the flasher switch is in the OFF position. Move the turn signal switch for a left turn.
12 volts Bad turn signal switch.
NOTE: Make sure the flasher switch is in the OFF position. Move the turn signal switch for a right turn.
Terminal for wire 45L to ground 12 volts Bad turn signal switch.
NOTE: If the readings are good but the turn signals still do not work, check the flasher (12).
Continuity Bad ground connection. Terminal for wire 30 to ground
Terminal for wire 64A to ground Approximately
10 volts
Ch8Ckwire 64A between the horn button and the
horn relay (5). Also check the horn relay (5).
NOTE: If the readings are good, install anew turn signal switch and horn button.
Check Points
Bulb
Good Bad bulb.
Terminal for wire 47L to ground
NOTE: Turn the key switch to ON. Move the turn signal switch (13) for aleft turn.
Intermittent
12 volts
Check the circuit between the left turn signal indi-
cator lamp and the flasher (12). Also check the
flasher (12).
Continuity Bad ground circuit.
Check Points
Bulb
Good Bad bulb.
Terminal for wire 47R to ground
NOTE: Turn the key switch to ON. Move the turn signal switch (13) for a right turn.
Bur 8-17220
Intermittent
12 volts
Check the circuit between the right turn signal in-
dicator lamp and the flasher (12). Also check the
flasher (12).
Bur 8-172~ Issued 1-91 Printed in U.S.A.
4002-28
FLOOD LAMP SWITCH, HIGH PRESSURE SWITCH,
AND AIR CONDITIONING COMPRESSOR CLUTCH
10 Red/Lt Blue Cab Relay 10 Ampere Fuse 12
12C Red Cab Relay 15 Ampere Fuse and 20 Ampere 12
Fuse
19C Red/White 20 Ampere Fuse Flood Lamp Switch 12
40A Black Lamps Ground 12
40B Blacx/white Lamps Ground 12
42C Ok Blue/Orange Flood Light Switch Rear Flood Lamps 12
42F Ok Blue Flood Light Switch Front Flood Lamps 12
42R Ok Blue/White Light Switch Rear Working Lamp 12
44 Tan Brake Switch Brake Lamps 14
45L OK Brown/Yellow Left Turn Signal Switch Left Turn Signal Lamps 14
45R Ok Brown/Green Right Turn Signa! Switch Right Turn Signal Lamps 14
48 Lt Brown/White Rotating Beacon Switch Rotating Beacon 14
49 Gray 10 Ampere Fuse Dome Lamp 16
60 Orange/Brown Compressor Clutch Relay High Pressure Switch 16
60A Orange/Black Compressor Clutch Relay and High Pressure Switch 16
Low Pressure Switch
60B Orange/Green Compressor Clutch Relay Air Conditioning Compressor Clutch 16
61 Gray/White 15 Ampere Fuse Blower 14
63 Orange/Purple 15 Ampere Fuse Wipers 14
Bur 8-17220
4002-29
Fl ood Lamp Swi t ch, Hi gh Pressure Swi t ch, and Ai r Condi t i oni ng Compressor
Cl ut ch Ci rcui t Checks
NOTE: The battery must be at full charge and al/ connections clean and tight before testing. Use a multimeter for the
tests.
NOTE: Put the key switch in the ON position. Turn the blower switch to HIGH and the air conditioning temperature switch
to COLD.
Terminal for wire 60 to ground 12 volts Bad circuit between the high pressure switch and
the air conditioning temperature switch.
NOTE: Disconnect the wires from the high pressure switch.
Between the terminals of the high
pressure switch
Open High charge in the air conditioning system. See
Section 9002. Bad high pressure switch.
oAi r Condi t i oni ng Compressor Cl ut ch
Ground wire of the air con-
ditioning clutch to ground
Continuity Bad ground wire.
NOTE: Turn the key switch to ON. Turn the cab blower switch to HIGH and the air conditioning temperature switch to
COLD.
Terminal for 60B to ground 12 volts Check the circuit between the air conditioning
compressor clutch and the compressor clutch
relay. Also check the compressor clutch relay.
See page 4002-41 .
NOTE: If the readings are correct, replace the air conditioning compressor clutch.
Terminal for wire 19C to ground 12 volts Check the circuit between the flood lamp switch
relay.
NOTE: Turn the flood lamp switch to ON.
Terminal for wire 42F to ground 12 volts Bad flood lamp switch.
Terminal for wire 42C to ground
Bur 8-17220
12 volts Bad flood lamp switch.
4002-30
Thi s page l eft bl ank.
Bur 8- 7220 Issued 1-91 Printed in U.S.A.
CONNECTORS A, B
MAin chassis haroos
harness.
FLOOD LAMP SWITCH, HIGH PRESSURE SWITCH, t
AIR CONDITIONING COMPRESSOR CLUTCH
Bur 8-17220
ISSUfld 1-91
Bur 8-17220 Issued 1-91 Printedin USA
4002-32
CAB HARNESS
40B Black/White Lamps Ground 12
42R Ok BluelWhite Light Switch Rear Flood Lamp 12
44 Tan Brake Switch Brake Lamps 14
45L OK Brown/Yellow Left Turn Signal Switch Left Turn Signal Lamps 14
45R Ok Brown/Green Right Turn Signal Switch Right Turn Signal Lamps 14
49 Gray 10 Ampere Fuse Dome Lamp Switch 16
60 Orange/Brown Compressor Clutch Relay High Pressure Switch 16
60A Orange/Black Compressor Clutch Relay and High Pressure Switch 16
Low Pressure Switch
60B Orange/Green Compressor Clutch Relay Air Conditioning Compressor 16
Clutch
61 GraylWhite 15 Ampere Fuse Blower Switch 14
61B Gray/Black Dome Lamp Switch Dome Lamps 16
63 Orange/Purple 15 Ampere Fuse Wipers 14
63A Orange/Purple Front Wiper Switch Front Wiper Motor 16
66 Green Front Wiper Switch (Low) Front Wiper Motor (Low) 16
67 Red Front Wiper Switch (High) Front Wiper Motor (High) 16
69 Yellow Front Wiper Switch (Park) Front Wiper Motor (Park) 16
80 Black Rear Wiper Motor (Ground) Rear Wiper Park Switch 14
81 Gray Rear Wiper Switch (Low) Rear Wiper Motor (Low) 16
82 White Rear Wiper Switch (High) Rear Wiper Motor (High) 16
85 Orange/Green Blower Switch Air Conditioning Temperature 14
Switch
86 Lt Blue Blower Switch (Low) Resistor Board (Low) 14
87 Blue Blower Switch (Medium) Resistor Board (Medium) 14
88 Lt BluelWhite Blower Switch (High) Resistor Board (High) 14
4002-33
Cab Harness
NOTE: The battery must be at full charge and all connections clean and tight before testing. Use amultimetet for the
tests.
Terminal for wire 49 to ground 12 volts Check the circuit between the dome lamp switch
and the key switch. Also check the 10 ampere
fuse and the key switch. See page 4002-31 for the
10 ampere fuse and page 4002-11 for the key
switch.
NOTE: Put the dome lamp switch in the ON positior:
Terminal for wire 61B to ground 12 volts Bad dome lamp switch.
Bulb Good Bad bulb.
Terminal for wire 40A to ground Continuity Bad ground circuit.
NOTE: Turn the key switch to ON. Put the dome lamp switch (1) in the ON position.
Terminal for wire 61B to ground 12 volts Check the circuit between the left dome lamp and
the dome lamp switch (1). Also check the dome
lamp switch (1).
4002-34
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Put the dome lamp switch (1) in the ON position.
Terminal for wire 61B to ground 12 volts Check the circuit between the right dome lamp
and the dome lamp switch (1). Also check the
dome lamp switch (1).
Terminal for wire 85 to ground 12 volts Bad blower switch.
Terminal for wire 61 to ground 12 volts Bad circuit between the blower switch and the
cab relay. Also check the 15ampere fuse and the
cab relay. See page 4002-27 for the cab relay.
NOTE: Turn the blower switch to LOW.
NOTE: Turn the blower switch to MEDIUM.
NOTE: Turn the blower switch to HIGH.
NOTE: Turn the key switch to ON. Turn the blower switch to HIGH.
Terminal for wire 88 to ground 12 volts Bad circuit between the blower motor and the
blower switch (4). Also check the blower switch
(4).
Bur 817220
Check Points
4002-35
NOTE: Turn the key switch to ON. Blower switch to LOW.
NOTE: Blower switch to MEDIUM.
12 volts Bad blower switch.
NOTE: Disconnect the connector from the resistor board.
12 volts Bad blower switch.
Between terminals 1 and 3 of the
resistor board
Check Points
3.8 ohms Bad resistor board.
12 volts Check the circuit between the rear wiper switch
relay.
NOTE: Turn the rear wiper switch to LOW.
12 volts Bad rear wiper switch.
NOTE: Turn the rear wiper switch to HIGH.
Bur 8-17220
12 volts Bad rear wiper switch.
4002-36
NOTE: Make sure the rear wiper is not in the PARK position.
Terminal for wire 80 to ground Continuity Check the rear wiper park switch (9). Bad ground
circuit.
Terminal for wire 63 to ground 12 volts Check the circuit between the rear wiper motor
relay.
NOTE: Turn the rear wiper switch to HIGH.
and the rear wiper switch (7). Also check the rear
wiper switch (7).
NOTE: Turn the rear wiper switch to LOW.
and the rear wiper switch (7). Also check the rear
wiper switch (7).
NOTE: Disconnect the wires from the rear wiper park switch. Make sure the rear wiper is in the PARK position.
Between the terminals of the rear
wiper park switch
Open, Bad rear wiper park switch.
NOTE: Move the wiper out of the PARK position.
Between the terminals of the rear
wiper park switch
Continuity Bad rear wiper park switch.
4002-37
Terminal for wire 40B to ground Continuity Bad ground circuit.
NOTE: Turn the key switch to ON. Turn the blower switch to ON and the air conditioning temperature switch to COLD.
Terminal for wire 60 to ground 12 volts Bad circuit between the compressor clutch relay
and the air conditioning temperature switch (11).
Also check the air conditioning temperature
switch (11).
Terminal for wire 60A to ground 12 volts Bad low pressure switch (13) or high pressure
switch. Also check the low pressure switch (13)
and the high pressure switch. See page 4002-31
for the high pressure switch.
Terminal for wire 60B to ground 12 volts Bad compressor clutch relay.
NOTE: Turn the key switch to ON. Turn the blower switch to HIGH.
Terminal for wire 85 to ground 12 volts Bad circuit between the air conditioning tempera-
ture switch and the blower switch (4). Also check
the blower switch (4).
NOTE: Turn the air conditioning temperature switch all the way to COLD.
Terminal for wire 60 to ground 12 volts Bad air conditioning temperature switch.
Bulb Good Bad bulb.
Bur 8-17220 Issued 1-91 Printedin U.S.A.
4002-38
NOTE: Turn the key switch to ON. Turn the blower switch to HIGH and the air conditioning temperature switch to
cow.
Terminal for wire 60 to ground 12 volts Bad circuit between the low pressure switch and
the air conditioning thermostat switch.
NOTE: Disconnect the wires from the low pressure switch.
Between the terminals of the low
pressure switch
Open Low charge in the air conditioning system. See
Section 9002. Bad low pressure switch.
Terminal for wire 63 to ground 12 volts Check the circuit between the front wiper switch
and the cab relay. Also check the 15ampere fuse
relay.
Terminal for wire 69 to ground 12 volts Bad front wiper switch.
NOTE: Turn the front wiper switch to LOW.
NOTE: Turn the front wiper switch to HIGH.
Bur 8-17220
4002-39
Terminal for wire 63A to ground 12 volts Check the circuit between the front wiper motor
relay.
Terminal for wire 69 to ground 12 volts Check the circuit between the front wiper motor
and the front wiper switch (7). Also check the front
wiper switch (7).
NOTE: Turn the front wiper switch to HIGH.
and thefront wiper switch (7). Also check the front
wiper switch (7).
NOTE: Turn the front wiper switch to LOW.
and the front wiper switch (7). Also check the front
wiper switch (7).
NOTE: Turn the key switch and rotating beacon switch to ON.
Bulb Good Bad bulb.
Terminal for wire 48 to ground 12 volts Circuit between the rotating beacon and the
rotating beacon switch. Also check the rotating
beacon switch. See page 4002-27.
NOTE: /f the readings are good, rep/ace the rotating beacon.
4002-40
Thi s page l eft bl ank.
4002-41
(
CONNECTOR
Connects one harT1l
harness.
CAB HARNESS
Bur 8-17220
41'UVc:.-""tL
CAB HARNESS (Cont i nued)
40B Black/white Lamps Ground 12
41 Pink Driving Lamp Switch Driving Lamps and Rear Light 12
Harness
41T Pink Rear Light Harness Tail Lamps 16
42C Dk Blue/Orange Flood Lamp Switch Rear Flood Lamps 12
42F Dk Blue Flood Lamp Switch Front Flood Lamps 12
42R Dk BluelWhite Driving Lamp Switch Rear Work Lamps 12
45L DK Brown/Yellc': Turn Signal Switch Left Turn Signal Lamps 14
45R Dk Brown/Gree Turn Signal Switch Right Turn Signal Lamps 14
Bur 8-17220
Issued1-91 PrintedinUSA
4002-43
Cab Harness (Continued)
NOTE: The battery must be at full charge and a/l connections clean and tight before testing. Use a multimeter for the
tests.
Bulb Good Bad bulb.
NOTE: Tum the key switch to ON. Turn the driving lamp switch to ON.
Terminal for wire 42R to ground 12 volts Bad circuit between the rear LH work lamp and
the driVing lamp switch. Also check the driving
lamp switch. See page 4002-27.
Bulb Good Bad bulb.
NOTE: Tum the key switch to ON. Turn the flood lamp switch to ON.
Terminal for wire 42C to ground 12 volts Bad circuit between the rear LH flood lamp and
the flood lamp switch. Also check the flood lamp
Bulb Good Bad bulb.
NOTE: Tum the key switch to ON. Turn the flood lamp switch to ON.
Terminal for wire 42C to ground 12 volts Bad circuit between the rear RH flood lamp and
4002-44
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Turn the driving lamp switch to ON.
Terminal for wire 42R to ground 12 volts Bad circuit between the rear RH work lamp and
the drivinq lamp switch. Also check the driving
Bulb Good Bad bulb.
NOTE: Tum the key switch to ON. Make sure the flasher switch is OFF. Move the turn signal lever for a left turn.
Terminal for wire 45L to ground Intermittent
12 volts
Bad circuit between the front left turn signal and
flasher lamp and turn signal switch. Also check
the turn signal switch. See page 4002-27.
Terminal 40A to ground Continuity Bad ground connection.
Bulb Good Bad bulb.
NOTE: Turn the key switcr: to ON. Turn the driving lamp switch to ON.
Terminal for wire 41 to ground 12 volts Bad circuit between the front LH marker lamp and
the driving lamp switch. Also check the driving
Check Points
Terminal 40A to ground
Bulb
4002-45
Good Bad bulb.
Check Points
Bulb
12 volts Bad circuit between the front LH driving lamp and
Good Bad bulb.
NOTE: Turn the key switch to ON. Turn the flood lamp switch to ON.
12 volts Bad circuit between the front LH flood lamp and
Check Points
Bulb
Good Bad bulb.
Bur 8-17220
12 volts Bad circuit between the front RH flood lamp and
4002-46
Bulb Good Bad bulb.
Terminal for wire 41 to ground 12 volts Bad circuit between the front RHdriving lamp and
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Make sure the flasher switch is OFF. Move the turn signal lever for a right turn.
Terminal for wire 45R to ground Intermittent
12 volts
Bad circuit between the front RH turn signal and
Bulb Good Bad bulb.
Terminal for wire 41 to ground 12 volts Bad circuit between the front RHmarker lamp and
4002-47
Terminal 40B to ground Continuity Bad ground connection.
Bulb Good Bad bulb.
Terminal for wire 41T to ground 12 volts Bad circuit between the LH tail lamp and the
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Have another person push down and hold the brake pedals.
Terminal for wire 44 to ground 12 volts Bad circuit between the LH brake lamp and the
stop lamp switch. Also check the stop lamp
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Make sure the flasher switch is OFF. Move the turn signal lever for a left turn.
Terminal for wire 45L to ground Intermittent 12 volts Bad circuit between the rear LH turn signal and
flasher lamp and the turn signal switch. Also
check the turn signal switch. See page 4002-27.
4002-48
Bulb Good Bad bulb.
NOTE: Tum the key switch to ON. Tum the driving lamp switch to ON.
Terminal for wire 41T to ground 12 volts Bad circuit between the RH tail lamp and the
Bulb Good Bad bulb.
NOTE: Tum the key switch to ON. Have another person push down and hold the brake pedals.
Terminal for wire 44 to ground 12 volts Bad circuit between the RH brake lamp and the
Bulb Good Bad bulb.
NOTE: Tum the key switch to ON. Make sure the flasher switch is OFF. Move the tum signal lever for a right tum.
12 volts
Bad circuit between the rear RH turn signal and
~
I
4002-4
CAB HARNESS (COnt\nued)
Issued 1-91 Printed In u.s.~
BUr 8-17220
4002-50
CANOPY HARNESS
40B BlacklVYhite Lamps Ground 12
41 Pink Driving Lamp Switch Driving Lamps and Rear Light 12
Harness
42R Ok BluelWhite Driving Lamp Switch Rear Work Lamps 12
45L OK Brown/Yellow Turn Signal Switch Left Turn Signal Lamps 14
45R Ok Brown/Green Turn Signal Switch Right Turn Signal Lamps 14
Bur 8-17220
4002-51
NOTE: The batteries must be at full charge and all connections clean and tight before testing. Use a multimeter for the
tests.
Bulb Good Bad bulb.
Terminal for wire 42R to ground 12 volts Bad circuit between the rear LH work lamp and
Bulb Good Bad bulb.
Terminal for wire 42C to ground 12 volts Bad circuit between the rear LH flood lamp and
Bulb Good Bad bulb.
Terminal for wire 42C to ground 12 volts Bad circuit between the rear RH flood lamp and
4002-52
Terminal for wire 40B to giOund Continuity Bad ground circuit.
Bulb Good Bad bulb.
Terminal for wire 42R to ground 12 volts Bad circuit between the rear RH work lamp and
Terminal for wire 40A to ground Continuity Bad ground circuit
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Make sure the flasher switch is OFF. Move the turn signal fever for a left turn.
12 volts
Bad circuit between the front LH turn signal and
Bulb Good Bad bulb.
Terminal for wire 41 to ground 12 volts Bad circuit between the front LH driving lamp and
Check Points
Bulb
4002-53
Good Bad bulb.
12 volts Bad circuit between the front LH flood lamp and
Check Points
Bulb
Good Bad bulb.
Check Points
Terminal 40A to ground
Bulb
12 volts Bad circuit between the front RH flood lamp and
Good Bad bulb.
12 volts Bad circuit between the front RH driving lamp and
Bur 8-17220
4002-54
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Make sure the flasher switch is OFF. Move the tum signal lever for a right turn.
12 volts
Bad circuit between the front RH turn signal and
Bulb Good Bad bulb.
Terminal for wire 41 to ground 12 volts Bad circuit between the LH tail lamp and the
Bulb Good Bad bulb.
NOTE: Tum the key switch to ON. Have another person push down and hold the brake pedals.
Terminal for wire 44 to ground 12 volts Bad circuit between the LH brake lamp and the
4002-55
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Make sure the flasher switch is OFF. Move the turn signal lever for a left turn.
12 volts
Bad circuit between the rear LH turn signal and
Bulb Good Bad bulb.
Terminal for wire 41 to ground 12 volts Bad circuit between the RH tail lamp and the
Check Points Reading Possible Cause of Bad Reading.
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Have another person push down and hold the brake pedals.
Terminal for wire 44 to ground 12 volts Bad circuit between the RH brake lamp and the
Bur 8-17220 Issued 1-91 Printed in U.S.A
4002-56
Bulb Good Bad bulb.
NOTE: Turnthe key switch to ON. Make sure the flasher switch is OFF. Move the turn signal lever for a right turn.
12 volts
Bad circuit between the rear RH turn signal and
Terminal for ground wire to
ground
NOTE: Turn the key switch and rotating beacon switch to ON.
Bulb Good Bad bulb.
Terminal for wire 48 to ground 12 volts Circuit between the rotating beacon and the
rotating beacon switch. Also check the rotating
beacon switch. See page 4002-27.
NOTE: If the readings are good, replace the rotating beacon.
4002-57
4002-58
USING BOOSTER BATIERIES TO START THE ENGINE
Singl e Battery
Dual Battery
Two persons are required for this procedure. Make
sure the person making the connections is wearing
face protection. Use a 12 volt booster battery.
Bur 8-17220
1. Sit in the operators seat and have the other person
make the connections.
2. If using another machine for power, make sure the
two machines do not touch.
3. Connect the positive (+) jumper cable to the
positive (+) battery terminal.
4. Connect the negative (-) jumper cable to a good
ground away from the battery.
5. Start the engine and have the other person discon-
nect the negative (-) jumper cable first and the positive
(+) jumper cable last.
ALPHABETICAL INDEX OF COMPONENTS
4002-59
A
Air Conditioning Compressor Clutch 29
Air Conditioning Indicator Lamp 37
Air Conditioning Temperature Switch 37
Air Filter Switch 16
Alternator 5
B
Backup Alarm and Pressure Switch 16
Batteries 5
Blower Motor and Blower Switch 34
Blower Resistor Board 35
Boom Lock Solenoid 18
Boom Lock Switch 17
C
Cab Relay 23
Clutch Cutout Solenoid 17
Clutch Cutout Switch - Loader Handle 18
Clutch Cutout Switch - Shift Handle 17
Compressor Clutch Relay 37
Converter Temperature Sender 8
Coolant Temperature Sender 8
o
Dome Lamp Switch 33
Driving Lamp Switch 24
E
Engine Oil Pressure Switch 14
Engine Temperature Switch 13
Ether Injection Solenoid 7
Ether Injection Switch 7
Ether Injection Temperature Switch : 7
F
Flasher Switch 24
Flood Lamp Switch 29
Front LH Driving Lamp with Cab .45
Front LH Driving Lamp with Canopy 52
Front LH Flood Lamp with Cab 45
Front LH Flood Lamp with Canopy 53
Front LH Marker Lamp 44
Front LH Tum Signal and Flasher Lamp with Cab 44
Front LH Tum Signal and Flasher Lamp with Canopy 52
Front RH Driving Lamp with Cab 46
Front RH Driving Lamp with Canopy 53
Front RH Flood Lamp with Cab .45
Front RH Flood Lamp with Canopy 53
Front RH Marker Lamp 46
Front RH Turn Signal and Flasher Lamp with Cab .46
Front RH Tum Signal and Flasher Lamp with Canopy 54
Front Wiper Motor 39
Front Wiper Switch 38
Fuel Level Sender 14
Fuel Shutoff Solenoid 7
H
High Pressure Switch 29
Horn .22
Horn Button 22
Horn Relay 23
Hydraulic Filter Switch 15
Instrument Cluster 9
Bur 8-17220
K
Key Switch 6
L
LH Brake Lamp with Cab .47
LH Brake Lamp with Canopy 54
LH Tail Lamp with Cab .47
LH Tail Lamp with Canopy 54
Left Dome Lamp 33
Left Turn Signal Indicator Lamp 26
Loader Valve Return-Te-Dig Magnetic Detent.. 21
Low Pressure Switch 38
M
Master Cylinder Reservoir Level Switch 8
N
Neutral Start Switch 6
a
Optional Switch for Hand Held Hydraulic Attachments 23
P
Parking Brake Relay 15
Parking Brake Switch 14
Proximity Switch 22
R
RH Brake Lamp with Cab 48
RH Brake Lamp with Canopy 55
RH Tail Lamp with Cab 48
RH Tail Lamp with Canopy 55
Rear LH Flood Lamp with Cab .43
Rear LH Flood Lamp with Canopy 51
Rear LH Turn Signal and Flasher Lamp with Cab .47
Rear LH Turn Signal and Flasher Lamp with Canopy 55
Rear LH Work Lamp with Cab 43
Rear LH Work Lamp with Canopy 51
Rear RH Flood Lamp with Cab .43
Rear RH Flood Lamp with Canopy 51
Rear RH Turn Signal and Flasher Lamp with Cab .48
Rear RH Turn Signal and Flasher Lamp with Canopy 56
Rear RH Work Lamp with Cab 44
Rear RH Work Lamp with Canopy 52
Rear Wiper Motor and Park Switch 36
Rear Wiper Switch 35
Return- To-Dip Relay 21
Right Dome Lamp 34
Right Tum Signal Indicator Lamp 26
Rotating Beacon with Canopy 56
Rotating Beacon with Cab 39
Rotating Beacon Switch 25
S
Starter Relay 6
Starter and Solenoid 5
Stop Lamp Switch 24
T
Transmission Filter Switch 15
Turn Signal Switch .25
W
Warning Buzzer 13
Section
4003
BATIE RY (S)
CASE CORPORATION
Bur 8-12350
Printed in U.S.A.
Issued November 1989
4003-2
TABLE OF CONTENTS
SPECIFICATIONS See Section 4001
BOOSTER BATIERIES.... See Section 4001
SAFETY RULES :. .. 3
SPECIAL TOOLS . 3
MAINTENANCE.. ..4
Electrolyte Level .4
Inspecting and Cleaning the Battery .4
NONSPILL CAPS.. . 5
BATIERY TEST 6
Visual Checks............... . 6
Specific Gravity Check. 6
Capacity (Load) Test.. 7
CHARGING A BATIERY. 8
PREPARING A DRY CHARGED BATIERY FOR USE....... . 9
SAFETY RULES
4003-3
SPECIAL TOOLS
'",-Orderspecial tools from either of the following com-
"-
parses;
<,
In the U.S.A. and Canada
Service Tools
PO. Box 314
In Europe
VL Churchill ltd
Northants, NN11 4NF
England
Bur 8-12350
The CAS-10147 tester is used to do the Capacity
(Load) Test. This tool is first used on page 4003-7.
4003-4
MAINTENANCE
El ectrol yte Level
If the battery is a maintenance free battery, check
the level of the electrolyte every 1000 hours of operation
orsixmonths, whichever occurs first. For all other batte-
ries, check the level of the electrolyte every 250 hours of
operation.
NOTE: A maintenance free battery will have the
words Maintenance Free on the decal on the top of the
battery. If the center part of the decal has been removed
for access to the battery caps, it is possible that the
words Maintenance Free have been removed from the
decal.
Check the level of the electrolyte more often during
hot weather. The use of a large amount of water by the
battery can be caused by high battery temperature or a
voltage regulator setting that is too high. Keep the elec-
trolyte level above the top of the plates inthe battery at
all times to prevent damage to the battery.
NOTE: On maintenance free batteries it is neces-
saryto remove the center part of the decal for access to
the battery caps. Do not discard the center part of the
decaf. Install the center part of the decal after the battery
caps have been installed.
Ifthe level of the electrolyte is low, add distilled water
or other clean water until the electrolyte is just below the
cell opening. Do not add more water than is needed.
Too much water can cause bad performance, a short
service life, and corrosion around the battery.
Bur 8-12350
NOTE: Add water only. DO NOT add electrolyte.
Inspecting and Cl eaning a Battery
If damage causes an electrolyte leak, replace the
battery.
Ifthe battery inyour machine has nons pill caps, see
Nonspill Caps on page 4003-5 and check the condition
of the nonspill caps. See Specifications inSection 4002
to find if the battery inyour machine must have nonspill
caps.
Inspect the battery at regular intervals for dirt, corro-
sion, and damage. Electrolyte and dirt on the top of the
battery can cause the battery to discharge by making a
passage for the current to flow.
If the battery must be cleaned, remove the battery
from the battery carrier and clean the battery, cable ter-
minals, and the battery carrier. When available, use
Case Battery Saver and Cleaner according to the in-
structions on the container. Case Battery Saver and
Cleaner also helps prevent corrosion. If Case Battery
Saver and Cleaner is not available, use baking soda
and water as a cleaner. DO NOT permit any type of
cleaner to enter the cells of the battery.
Install the battery inthe machine and make sure the
fasteners are tight. Apply Case Battery Saver and
Cleaner or Urethane Seal Coat to the cable terminals to
prevent corrosion. See the Parts Counter Catalog. DO
NOT apply grease.
NONSPILL CAPS
4003-5
SeeSpecifications inSection 4002 to find if the batt-
ery(s) in your machine must have nonspill caps.
Do not operate the machine if the nonspill caps do
not work correctly or ifthe nonspill caps are not in place.
Nonspill caps prevent electrolyte leakage which can
cause personal injuryand damage to the machine if the
machine turns over in an accident.
B800305M
Bur 8-12350
The nonspill caps have a valve with a stem made of
lead and rubber. When the nonspill cap is turned
upside down, the weight of the lead holds the rubber
stem against the breather hole, preventing the loss of
electrolyte.
If the breather hole and valve are closed by foreign
material, pressure in the battery can become high
enough to break the case of the battery. Always check
the breather hole for foreign material when you check
the electrolyte level. If there is foreign material over the
breather hole, turn the nons pill cap upside down and
clean the nonspill cap. Move the nonspill cap up and
down rapidly. You must be able to hear the movement
of the valve. If you cannot hear the valve, wash the
nonspill cap and loosen the valve. Move the nonspill
cap up and down rapidly to remove the water.
When you remove a nonspill cap, check the condi-
tion of the rubber gasket. Ifthe rubber gasket is gone or
is damaged, install a new nonspill cap.
Missing or broken nonspill caps MUST be replaced
with new nonspill caps. DO NOT use any other type of
cap to replace nonspill caps.
When you install a new battery, the new battery
MUST have nonspill caps. You can use the nons pill
caps from the old battery ifthe nonspill caps are ingood
condition.
4003-6
NOTE: Tocorrectly test abattery, do each part of the
battery test until you know the condition of the battery.
Visual Checks
1. Make sure the cable connections are clean and
tight. Clean foreign material from the top of the battery.
2. Inspect the battery case, battery posts, and cables
for damage.
3. Check the electrolyte level See page 4003-4
4. If you added water to the battery, the battery must
be charged for 15 minutes at 15 to 25 amperes to mix
the water with the electrolyte.
Specific Gravity Check
A hydrometer is used to check the specific gravity
(weight) of the electrolyte. The specific gravity is an
indication of the level of charge for each celt.
Hydrometers are made to show the correct specific
gravity when the temperature of the electrolyte is 80F
(26.J OC).
When you check the specific gravity, you must know
the temperature of the electrolyte. If your hydrometer
does not have a thermometer, get a thermometer to
check the temperature of the electrolyte. The thermo-
meter must indicate a high temperature of at least
120F (52C).
1. Remove enough electrolyte from a cell so that the
float is free in the tube.
NOTE: If the specific gravity cannot be checked
without first adding water to the cell, the battery must be
charged for 15minutes at 15to 25amperes to mix the
water with the electrolyte. Then check the specific
gravity.
2. Read the float.
3. Read the thermometer Ifthe reading is above 80F
(26.J OC)add specific gravity points to the reading for
specific gravity. If the reading is below 80F (26SC)
subtract specific gravity points from the reading for
specific gravity. Seethe following illustration and add or
subtract specific gravity points as needed.
Bur 8-12350
BATTERY TEST
1. Temperature in O F 2. Temperature in C
Specific Gravity Chart
4. Make a record of the corrected specific gravity
reading for each cell.
5. If the difference between the high reading and the
low reading is .050 or more, charge the battery and
check the specific gravity again. If after charging, the
difference is still .050 or more, install a new battery.
6. The corrected specific gravity reading shows the
level of charge for the cell. The level of charge must be
at least 75% in each of the cells. In maintenance free
batteries the level of charge is at least 75% if the cor-
rected specific gravity reading is 1.240 or higher. In all
other batteries the level of charge is at least 75% if the
corrected specific gravity reading is 1.230 or higher.
low reading is less than .050, and the level of charge is
at least 75% in all of the cells, do the Capacity (Load)
Test.
low reading is less than .050, but the level of charge is
less than 75%inany of the cells, charge the battery and
check the specific gravity again. If after charging:
a The level of charge is less than 75% in any of
the cells, discard the battery.
b. The level of charge is at least 75% in all of the
cells, do the Capacity (Load) Test.
Capacity (Load) Test
This test can be done using a variable load tester
such as the Sun Electric VAT-33. Other test equipment
can be used. Connect the test equipment according to
the instructions of the manufacturer of the equipment.
1. The level of charge of the battery must be at least
75%. Do the Specific Gravity Check in this section
2. Prepare the tester (Sun Electric VAT-33 shown) for
the test.
a. Select the voltmeter range that will measure 1
to 18 volts.
b. Make sure the load control knob is in the OFF
position.
c. Select the ammeter range that will measure 0
to 1000 amperes.
d. Move the volt lead switch to the INT. position.
3. Connect the tester to the battery as shown.
1. Load Control Knob
B790499J
2. Ammeter Clamp
(Tip of Arrow Away
from Battery)
Bur 8-12350
4003-7
NOTE: Never apply a load for longer than 15seconds.
After each 15seconds, turn the load control knob to OFF
for at least one minute.
4. Apply a 15 ampere load to the battery for 15
seconds. Wait at least three minutes before applying
the load again.
5. Check and make a record of the temperature of the
electrolyte.
6. Find the correct load for this test inSpecifications in
Section 4002.
NOTE: The correct load is half of the cold cranking
amperes at O a F (-17"C).
7. Turn the load control knob until the ammeter indi-
cates the specified load Keep the load for 15 seconds
and read the voltmeter. Turn the load control knob to
OFF.
8. Compare the test reading and the temperature of
the electrolyte to the chart below.
Temperature of
electrolyte
Minimum Voltage
70F (21C) and above 9.6
60F (16C) . __ 9.5
50F (1OC) _ _ 9.4
40F (4C) 9.3
30F (-1C) 9.1
20F (-7C) 8.9
10F (-12C) 8.7
OaF(-18C) 8.5
a. If the test result is equal to or more than the
voltage shown, the battery is in good condition.
b. If the test result is less than the voltage shown,
discard the battery.
4003-8
CHARGING A BATTERY
Before you charge the battery, check the level of the
electrolyte.
It is difficult to give an exact charging rate because
of the following variable conditions: (1) temperature of
the electrolyte, (2) level of charge, and (3) condition of
the battery. Use the charging guide for the correct
charging rate and time.
See Specifications in Section 4002 for the reserve
capacity of the battery in this machine.
The charging rate must be decreased if:
1. Too much gas causes the electrolyte to flow from
the cells.
2. The temperature of the electrolyte rises above
125F (52C).
NOTE: For the best charge, use the slow charging
rates.
The battery is fully charged when, over a three hour
period at a lowcharging rate, no cell is giving too much
gas, and the specific gravity does not change.
CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES
Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See
Reserve Capacity under
Specifications
80 Minutes or Less
Slow Charge Fast Charge
10 Hours at 5 Amperes
2.5 Hours at 20 Amperes
Above 80 to 125 Minutes 15 Hours at 5 Amperes
*Initial rate for standard taper charger.
NOTE: A maintenance free battery will have the words
Maintenance Free on the decal on the top of the battery.
If the center part of the decal has been removed to get
Bur 8-12350
851285
access to the battery caps, it is possible the words
Maintenance Free will have been removed from the
decal.
Continued on next page
4003-9
CHARGING GUIDE FOR BATTERIES OTHER THAN
MAINTENANCE FREE BATTERIES
Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See
Reserve Capacity under
Specifications Slow Charge Fast Charge
80 Minutes or Less 10 Hours at 5 Amperes
Above 250 Minutes 24 Hours at 10 Amperes 6 Hours at 40 Amperes
*Initial rate for standard taper charger.
851286
PREPARING A DRY CHARGED BATTERY FOR USE
1. Remove the caps from the battery. 4. Connect a battery charger to the battery
2. Fill each cell to the top of the separators with elec-
trolyte. This will permit the volume of electrolyte to
increase when heated by charging the battery.
5. Charge the battery at 30 amperes until the specific
gravity is 1.250or more and the temperature of the elec-
trolyte is at least 60F (15'soC).
3. Install the caps on the battery. If the battery inyour
machine must have nonspill caps, install the nonspill
caps. See Specifications in Section 4002 to find if the
battery in your machine must have nons pill caps.
6. If necessary, fill each cell with electrolyte until the
electrolyte is just below split ring atthe bottom ofthe cell
opening.
Bur 8-12350
4004
STARTER AND STARTER SOLENOID
TABLE OF CONTENTS
Removal and Installation See Section 4001 Disassembly 4004-7
Specifications 4004-2 Inspection 4004-11
Lubrication 4004-2 Brushes and Brush Springs 4004-11
No-Load Test 4004-2 Brush Helder 4004-11
General Information 4004-2 Armature 4004-11
Test Equipment 4004-2 Field Coil Test... .4004-12
Test Procedure 4004-3 Assembly 4004-14
Understanding No-Load Test Results 4004-S Starter Solenoid Test 4004-20
CASE CORPORATION
Bur 8-11370
Printed in U.S.A.
Issued J une 1989
4004-2
SPECIFICATIONS
Case part number A170746
No-Load Test at 80F (26.7C)
Volts 11
Current draw 180 amperes maximum
Starter drive speed 3500 rpm (r/min) minimum
LUBRICATION
Interval When the starter is disassembled or each
time the engine is removed for repairs
Lubricant
Molykote-GN Use on shaft at pinion end of starter drive
Case multipurpose grease Use on bearings, gears,
idler gear shaft and spring.
General Information
NO-LOAD TEST
Test Equipment
1. The No-Load Test is done with the starter removed
from the engine.
The No-Load Test can be done using a Sun Electric
VAT-33 Tester, an equivalent tester, or separate pieces
of test equipment.
2. Check to see if you can pull the gear on the starter
drive out of the starter drive housing. A hand held tachometer is needed to measure the
speed of the armature shaft.
3. Check to see if the starter drive can be turned. Pull
the gear on the starter drive out of the starter drive
housing. Turn the gear to turn the starter drive and the
armature.
A remote starter button is needed to actuate the
starter.
4. If the starter drive cannot be turned, disassemble
the starter and make repairs as needed. Then do the
No-Load Test.
A fully charged 12 volt battery is needed to supply
the electricity to turn the starter.
Test Procedure
The illustrations in this procedure show the use of
the Sun Electric VAT-33 tester. Other test equipment
can be used. Connect the test equipment according to
this procedure and the manufacturer's instructions.
1. If the VAT-33 tester is being used:
a. Select the 0 to 100 ampere range.
b. Select the 18 to 40 volt range.
c. Move the volt lead switch to the EXT. position.
d. Turn the load control to the OFF position.
2. Fasten the starter in a vise or use another method
to prevent the starter from moving. This must be done
to prevent personal injury.
Bur 8-11370
4004-3
3. Connect the positive battery cable to the battery
terminal onthe starter solenoid and the negative battery
cable to the mounting flange of the starter.
1
3
2
B831430J
1. Positive Battery Cable
2. Battery Terminal
3. Negative Bettery Cable
4. Connect the positive load cable to the positive post
of the battery. Connect the negative load cable to the
negative post.
B831431J
1. Positive Load Cable
2. Negative Load Cable
4004-4
5. Connect the red voltmeter lead to the motor
terminal on the starter solenoid.
o
1
B831432J
1. Red Voltmeter Lead
2. Motor Terminal
6. Connect the black voltmeter lead to the mounting
flange on the starter.
1
B831433J
1. Black Voltmeter Lead
Bur 8-11370
7. Fasten the ammeter clamp around the positive
battery cable so that the tip of the arrow is toward the
?tarter.
o 0
o
B831434J
1. Ammeter Clamp
8. Connectthe leads from the remote starter button to
the Battery and Switch terminals.
B831435J
IMPORTANT: Steps 9, 10, and 11 must be done
rapidly. Do not load the battery for more than 15
seconds at one time. After the battery has been loaded
for 15seconds, let the starter cool for 60 seconds.
9. Actuate the remote starter button and turn the load
control until the voltmeter indicates 11 volts.
I
B831436J
1. Remote Starter Button
2. Load Control
3. Voltmeter
4. Ammeter
5. Hand Held Tachometer
10. Look at the ammeter and make a record of the
ammeter indication.
11. Use the hand held tachometer and check the
armature shaft speed. Make a record of armature shaft
speed.
12. Release the remote starter button and turn the load
control to the OFF position.
Understanding No-Load Test Resul ts
1. If the current draw and the armature shaft speed
arewithin the ranges under Specifications, the starter is
good.
Bur 8-11370
4004-5
2. Low armature shaft speed and high current draw
are indications of too much friction. Possible causes of
too much friction are:
a. Tight, dirty, or worn bearings.
b. A bent armature shaft.
c. Loose pole shoes (pole shoes make contact
with the armature).
d. A short circuit in the armature coil. Disas-
semble the starter. Use an armature tester to test
the armature. Use the instructions included with
the armature tester.
e. Damaged field coil. Do the test on page 4004-
12
3.. Ifthe armature does not rotate and the current draw
is high, possible causes are:
a. Field terminal making contact with the field
frame. Inspect the insulators for the field terminal
b. Damaged field coil. Do the tests on page
4004-12.
c. Damaged bearings.
4. Ifthe armature does not rotate and the current draw
is zero, possible causes are:
a. An open field armature circuit. Disassemble
the starter and inspect the field coil connections.
b. An open armature coil. Disassemble the
starter and check for burned commutator bars.
Use an armature tester to test the armature. Use
the instructions included with the armature tester.
c. Brushes not making good contact with the
commutator bars. Check for high insulation
between the commutator bars, broken brush
springs, or worn brushes.
5. Low armature shaft speed and lowcurrent draw are
indications of:
a. Dirt or corrosion on connections.
b. Damaged wiring.
c. Dirty commutator bars.
d. All causes in step 4.
4004-6
6. High armature shaft speed and high current draw
are indications of a short circuit inthe field coil. It is diffi-
cult to find a short circuit ina field coil. Install a new field
Bur 8-11370
coil. Do the No-Load Test again to check for improve-
ment in the operation of the starter.
4004-7
DISASSEMBLY
STEP 4 STEP 1
Pull back the boot onthe motor terminal and loosen and
remove the nut and lock washer.
STEP 2
Loosen and remove the screws that hold the cover.
STEP 3
Loosen and remove the cap screws.
Bur 8-11370
Remove the cover.
STEP 5
Hold the spring away from one of the brushes con-
nected to the field coil and remove the brush from the
brush holder. Repeat this step for the other brush con-
nected to the field coil.
STEP 6
Remove the brush holder.
4004-8
STEP 7
Remove the field frame assembly.
STEP 8
Remove the armature.
STEP 9
Fasten the starter solenoid in a vise and loosen and
remove the screws that hold the starter drive housing.
Bur 8-11370
STEP 10
Remove the starter drive housing from the starter sole-
noid.
STEP 11
Push down the starter drive housing as shown to loosen
and remove the starter drive.
STEP 12
Remove the steel ball from the starter drive. If ne-
cessary, use a magnet.
STEP 13
Remove the O-ring from the groove in the starter drive
housing.
STEP 14
Remove the spring.
STEP 15
Remove the idler gear.
Bur 8-11370
4004-9
STEP 16
Remove the bearing cage.
STEP 17
Remove the thrust washer.
STEP 18
Loosen and remove the screws that hold the cover.
4004-10
STEP 19
If necessary, use a hammer to loosen the cover.
STEP 20
Remove the cover.
Bur 8-11370
STEP 21
Remove the plunger.
STEP 22
,1.0M
If necessry, remove the gasket from the cover.
4004-11
INSPECTION
All parts except the starter drive must be cleaned
using mineral spirits and a brush or cloth. Use a clean,
dry cloth to clean the starter drive.
Brushes and Brush Springs
1. If the length of the brush fastened to the brush
holder is less than 7/16 inch (11 mm), a new brush
holder assembly must be used when the starter is as-
sembled.
2. If the length of a brush fastened to the field coil is
less than 7/16 inch (11 mm), a new field frame
assembly must be used when the starter is assembled.
3. Usea spring scale to check thetension of the brush
springs. Pull the brush spring up until the brush spring
is just above the brush holder. The scale indication
must be between 4 and 9 pounds (1.8 and 4.1 kg). If a
brush spring is not as specified, usea newbrush spring
when the starter is assembled.
Brush Hol der
1. Hold the leads of an ohmmeter against the frame
and the brush holders that have insulation between the
brush holder and frame.
2. If there was an indication of a complete circuit,
install a new brush holder.
Bur 8-11370
Armature
1. Test the armature on an armature tester. Use the
equipment manufacturer's instructions.
2. Put the armature on vee-blocks as shown and
check the runout of the armature with a dial indicator.
The runout must not be more than .002 inch (0.05 mm).
3. If -necessary, put the armature in a lathe and
remove enough material from the commutator to make
the runout less than .002 inch (0.05 mm).
4. Measure the diameter of the commutator. If the
diameter is less than 1.38 inch (35 mm), install a newar-
mature.
5. If the depth of the groove between the commutator
bars is less than .008 inch (0.2 mm), cut the insulation
between the commutator bars to a depth of 1/64 to 1/32
inch (0.5 to 0.8 mm). Use sandpaper to remove the
rough edges from the commutator bars.
6. Check the bearings on the armature for free rota-
tion, rough balls, and damage to the inner race or outer
race. If a bearing is to be replaced, use a press and ac-
ceptable tools to remove and install the bearings.
4004-12
Fiel d Coil Test
1. Hold the leads of an ohmmeter against one of the
brushes and the field frame. The needle of the
ohmmeter must not move.
2. Ifthe needle of the ohmmeter moved, install a new
field frame assembly.
Bur 8-11370
B610616M
3. Hold the leads of the ohmmeter against one of the
brushes and the end of the cable. The needle of the
ohmmeter must move.
4. Ifthe needle of the ohmmeter did not move, install a
new field frame assembly.
Bur 8-11370
4004-13
4004-14
ASSEMBLY
STEP 26 STEP 23
Install the plunger in the starter solenoid.
STEP 24
If necessary, install a new gasket in the cover.
STEP 25
Install the cover.
Bur 8-11370
Install and tighten the screws.
STEP 27
Install the bearings in the bearing cage.
STEP 28
Lubricate the bearings and teeth of the idler gear with
the grease specified on page 4004-2.
STEP 29
Install the thrust washer.
STEP 30
Install the bearing cage as shown.
STEP 31
Install the idler gear.
Bur 8-11370
4004-15
STEP 32
Install the spring.
STEP 33
Install a new O-ring in the groove in the starter drive
housing. Lubricate the O-ring.
STEP 34
Lubricate the open bearing on the starter drive with the
grease specified on page 4004-2.
4004-16
STEP 35
Start the starter drive into the starter drive housing.
STEP 36
Push down the starter drive housing to push the starter
drive all the way into the starter drive housing.
STEP 37
Put a small amount of grease in the hole in the starter
drive and install the steel ball in the hole.
Bur 8-11370
STEP 38
741M
Assemble the starter drive housing and starter sol-
enoid.
STEP 39
Install a lock washer, flat washer, and O-ring on the
screws that hold the starter drive housing. Lubricate the
O-rings.
STEP 40
Install the screws in the starter drive housing.
STEP 41
Fasten the starter solenoid in the vise and tighten the
screws that hold the starter drive housing.
STEP 42
Install the armature.
STEP 43
Install the field frame assembly.
Bur 8-11370
4004-17
STEP 44
Use the springs to hold the brushes inthe brush holder
as shown.
STEP 45
Install the brush holder.
STEP 46
Put the springs on top of the brushes connected to the
brush holder.
4004-18
STEP 47
Install the brushes that are connected to the field coil.
STEP 48
Use a cap screw to align the brush holder with the field
frame assembly.
STEP 49
Move the brush holder so that the brush holder is even
with the end of the armature.
Bur 8-11370
STEP 50
Install the cover and align the cover with the brush
holder.
STEP 51
Install the tighten the screws that hold the brush holder.
STEP 52
B330816M
Install a lock washer, flat washer, and O-ring on the cap
screws. Lubricate the O-rings.
STEP 53
Install and tighten the cap screws.
Bur 8-11370
4004-19
STEP 54
Install the cable, lock washer, and nut on the motor ter-
minal, and tighten the nut.
STEP 55
Pull the boot over the motor terminal.
4004-20
STARTER SOLENOID TEST
This test will check the condition of the pull-in
winding and the hold-in winding in the starter solenoid.
The jumper cable connected to the starter mounting
flange and the motor terminal must have a common
connection at the negative battery post.
Starter Sol enoid Test Procedure
1. Remove the rubber boot from the motor terminal.
Remove the nut and lock washer from the motor ter-
minal. Then remove the wire from the motor terminal.
2. Connect ajumper cable to the positive battery post
of a fully charged 12volt battery. Connect the other end
of the jumper cable to the battery terminal inthe starter
solenoid housing.
1. 12Volt Battery
2. Starter
3. Battery Terminal
4. Switch Terminal
5. Motor Terminal
B831438R
Bur 811370
3. Connect a jumper wire to the battery terminal and
the switch terminal inthe starter solenoid housing. The
jumper wire must be made from No. 10 or larger wire.
4. Connect the jumper cable with the common con-
nection to the starter mounting flange and the motor
terminal in the starter solenoid housing.
NOTE: Steps 5and 7must be done in a maximum of
15 seconds to prevent damage to the pull-in winding
and the hold-in winding.
5. Connect the jumper cable with the common con-
nection to the negative battey post. The pinion gear on
the starter drive must come all the way out rapidly and
with force.
6. Ifthe pinion gear did not come out rapidly and with
force, the pull-in winding is damaged. The complete
starter solenoid housing assembly must be replaced.
7. Disconnect the jumper cable from the motor
terminal inthe starter solenoid housing. The pinion gear
on the starter drive must not move toward the starter
drive housing.
8. Ifthe pinion gear started to move toward the starter
drive housing, the hold-in winding is damaged. The
complete starter solenoid housing assembly must be
replaced.
CASE CORPORATION
Section
4006
95 AMPERE ALTERNATOR
Bur 8-12381
Printed in U.S.A.
4006-2
TABLE OF CONTENTS
SPECIFICATIONS 2
DiSASSEMBLy 3
INSPECTION OF BRUSHES 7
INSPECTION AND TESTING OF ROTOR 8
INSPECTION AND TESTING OF STATOR 9
TESTING THE CONDENSER 10
TESTING THE RECTIFIER BRIDGE 11
INSPECTION AND REPLACEMENT OF BEARINGS 12
ASSEMBLY 15
SPECIFICATIONS
12 Volt Alternator
Manufacturer Robert Bosch
Robert Bosch part number 0 120 484 011
Case part number A187623
Output 14 volts at 95 amperes
Resistance of rotor winding 3.0 ohms
. Resistance of stator winding 0.05 to 0.06 ohms
Minimum brush length 0.55 inch (14 mm)
Special Torques
Nut that fastens the pulley to the rotor shaft 44 to 52 pound-feet (60 to 70 Nm)
4006-3
DISASSEMBLY
STEP 4 STEP 1
Fasten the pulley of the alternator in a vise that has soft
jaws. Loosen and remove the nut and lock washer.
STEP 2
Hit the face of the pulley with a soft hammer to loosen
the tapered bushing in the pulley.
STEP 3
Remove the tapered bushing and the pulley from the
shaft.
Bur 8-12381
Remove the fan from the shaft.
STEP 5
Loosen and remove the screws and flat washers that
fasten the voltage regulator and brush holder to the
housing.
STEP 6
Remove the voltage regulator and brush holder.
4006-4
STEP 7
Disconnect the lead for the capacitor.
STEP 8
Loosen and remove the screw and remove the capa-
citor.
STEP 9
Loosen and remove the nut, flat washer, and fiber
washers from the D+terminal.
Bur 8-12381
STEP 10
Loosen and remove the nut, flat washer, and fiber
washers from the B+terminal.
STEP 11
Make an alignment mark on the cover, the stator, and
the housing.
STEP 12
Loosen and remove the screws that fasten the cover,
stator, and housing together.
STEP 13
Remove the cover and rotor from the stator and
housing.
STEP 14
Loosen and remove the screws that fasten the bearing
retainer to the cover. The rotor now can be removed.
STEP 15
Remove the rotor from the cover.
Bur 8-12381
4006-5
STEP 16
Loosen and remove the screws that fasten the rectifier
bridge to the housing.
STEP 17
Remove the housing.
STEP 18
Remove the insulator from the B+terminal.
4006-6
STEP 19
Remove the insulator from the 0 +terminal.
Bur 8-12381
STEP 20
Remove the shield from the housing.
INSPECTION OF BRUSHES
4006-7
STEP 21
Use an ohmmeter and check the continuity from each
terminal and brush. If the reading is zero, replace the
brush or voltage regulator and brush holder.
STEP 22
Remove the shield.
STEP 23
Measure the length of each brush. If the length of one
brush is less than 0.55 inch (14 mm) replace both
brushes or the voltage regulator and brush holder.
Bur 8-12381
STEP 24
To replace the brushes, use a soldering iron to remove
the original brushes. Install the springs and new
brushes and use rosin core solder to solder the leads to
the terminals. Before soldering the terminal shown,
open the sleeve for the brush lead and then crimp the
sleeve.
STEP 25
Install the shield.
Issued 1-91 Printed i'1 U.S.A.
4006-8
INSPECTION AND TESTING OF ROTOR
STEP 28 STEP 26
Touch the leads of the ohmmeter to the slip rings. The
reading must be 2.52 to 3.08 ohms. Ifthe reading is not
as specified, a new rotor must be installed.
STEP 27
Touch the leads to each slip ring and the shaft. If a
reading shows continuity, a newrotor must be installed.
Bur 8-12381
Use a dial indicator and measure the runout of each slip
ring. If the runout is more than 0.002 inch (0.05 mm) a
new rotor must be used or use a lathe to remove
enough material until the runout is less than specified.
STEP 29
Measure the diameter of the slip ring. The diameter
must not be less than 1.055 inch (26.8 mm).
INSPECTION AND TESTING OF STATOR
4006-9
STEP 30
Look for burned insulation on the coils of the stator. This
is an indication of a short circuit. Install a new stator.
STEP 31
Touch the leads of the ohmmeter to each lead from the
stator and the common connection. The readings must
be 0.05 to 0.06 ohm. If the readings are not as speci-
fied, a new stator must be installed.
STEP 32
stator and the frame. If a reading shows continuity, a
new stator must be installed.
Bur 8-12381
STEP 33
Use a high watt soldering iron and rosin core soider to
solder the leads of the stator to the rectifier bridge.
4006-10
TESTING THE CONDENSER
STEP 35
Touch the terminal to the bracket to discharge the con-
denser.
STEP 34
Touch the leads of the ohmmeter to the condenser as
shown. The reading will increase and then return to zero
resistance as the condenser is charged. Ifthere is no in-
dication of resistance, a new condenser must be in-
stalled. The condenser is used to reduce radio noise.
TESTING THE RECTIFIER BRIDGE
4006-11
STEP 36
Touch the leads of the ohmmeter to a positive diode
and the heat sink as shown. Then reverse the leads.
There must be a high reading and a lowor zero reading.
Then test the other two positive diodes. If a positive
diode did not have readings as specified, the positive
diode is bad and a new rectifier bridge must be instal-
led.
STEP 37
Touch the leads of the ohmmeter to a negative diode
Then test the other two negative diodes. If a negative
diode did not have readings as specified, the negative
diode is bad and a new rectifier bridge must be in-
stalled.
Bur 8-12381
NOTE: If the tester you are using has adiode test func-
tion, use the tester according to the instructions of the
manufacturer to check the positive and negative
diodes.
4006-12
INSPECTION AND REPLACEMENT OF BEARINGS
STEP 38
Inspect the bearings on the rotor. If the bearings are
damaged, use the following procedure to replace the
bearings.
Bur 8-12381
a. Use a suitable support between the front bearing
and the bearing retainer on the rotor shaft and
press the rotor shaft out of the front bearing and the
spacer.
b. Remove the bearing retainer.
c. Use a suitable support between the rear bearing
and the slip ring on the other end of the rotor shaft
and press the rotor shaft out of the rear bearing.
d. Install the bearing retainer on the rotor shaft.
Bur 8-12381
4006-13
e. Press the new front bearing onto the rotor shaft
until the front bearing stops moving.
f. Press the spacer onto the rotor shaft until the
spacer stops moving.
g. Press the newrear bearing onto the other end of
the rotor shaft.
4006-14
B891870J
Bur 8-12381
ASSEMBLY
4006-15
STEP 39
Install a new shield in the housing.
STEP 40
Install the insulator on the 0 +terminal.
STEP 41
Install the insulator on the B+terminal.
Bur 8-12381
STEP 42
Install the housing on the rectifier bridge.
STEP 43
Install and tighten the screws that fasten the rectifier
bridge to the housing.
STEP 44
Install the fiber washers, flat washer, and nut onthe B+
terminal.
4006-16
STEP 45
Check for a short circuit between the terminal and the
housing. If there is continuity, the insulator is bad.
STEP 46
Install the fiber washers, flat washer, and nut on the D+
terminal.
STEP 47
Check for a short circuit between the terminal and the
housing. If there is continuity, the insulator is bad.
Bur 8-12381
STEP 48
Install the rotor in the cover.
STEP 49
Install and tighten the screws that fasten the bearing
retainer and rotor to the cover.
STEP 50
Make sure the marks are in alignment and install the
cover and rotor in the stator and housing.
STEP 51
Install and tighten the screws evenly that fasten the
housing, stator, and cover.
STEP 52
Install the capacitor and tighten the screw.
STEP 53
Connect the lead to the terminal.
Bur 8-12381
4006-17
STEP 54
Install the voltage regulator and the brush holder. Be
careful not to damage the brushes.
STEP 55
Install the screws and flat washers and tighten the
screws.
STEP 56
Install the fan.
4006-18
STEP 57
Install the pulley and the tapered bushing.
STEP 58
Install the lock washer and start the nut onto the shaft.
Bur 8-12381
STEP 59
Fasten the pulley in a vise with soft jaws. Tighten the nut
to 44 to 52 pound-feet (60 to 70 Nm)
CASE CORPORATION
Section
4007
65 AMP ALTERNATOR A 187873
Bur 8-15670
Printed in U.S.A.
Issued J uly 1990
4007-2
TABLE OF CONTENTS
SPECiFiCATIONS 2
DISASSEMBLY 3
INSPECTION OF BRUSHES 8
INSPECTION AND TESTING OF ROTOR 9
INSPECTION AND TESTING OF STATOR 10
TESTING THE CONDENSER 11
TESTING THE RECTIFIER BRIDGE 12
ASSEMBLY 14
SPECIFICATIONS
Rated output. 14 volts at 65 amperes
Resistance of rotor winding 2.52 to 3.08 ohms
Maximum runout for slip rings 0.002 inch (0.05 mm)
Minimum diameter of slip rings 1.055 inch (26.8 mm)
Resistance of stator coils 0.09 to 0.11 ohms
Minimum length of brushes 0.27 inch (7 mm)
Torque for nut for pulley 44 to 55 pound-feet (60 to 70 Nm)
4007-3
DISASSEMBLY
STEP 1
Fasten the pulley ina vise that has soft jaws and loosen
end remove the nut and lock washer.
STEP 2
Hit the pulley with a hammer to loosen the tapered
bushing.
STEP 3
Remove the pulley and tapered bushing.
Bur 8-15670
STEP 4
Remove the fan.
STEP 5
M
.;:;::~..:.:: ....
Hold the voltage regulator and brush holder and loosen
and remove the screws.
STEP 6
Remove the voltage regulator and brush holder.
4007-4
STEP 7
Make an alignment mark on the front and rear hous-
ings.
STEP 8
Loosen and remove the screws that hold the front and
rear housings together.
STEP 9
Hold the stator and hit the front housing with a soft
hammer to separate the front housing from the stator.
Bur 8-15670
STEP 10
Remove the front housing and rotor from the rear
housing.
STEP 11
Loosen and remove the screws that hold the retainer for
the rotor.
STEP 12
Remove the rotor.
STEP 13
Use an acceptable puller and press the rotor out of the
spacer and bearing.
STEP 14
Remove the retainer.
STEP 15
Usean acceptable puller and driver and press the rotor .
out of the other bearing.
Bur 8-15670
4007-5
STEP 16
;1~~?07M
Loosen and remove the screw that holds the con-
denser.
STEP 17
Disconnect the lead from the condenser from the
terminal and remove the condenser.
STEP 18
Loosen and remove the two screws that hold the recti-
fier bridge.
4007-6
STEP 19
Loosen and remove the nut, lock washer and flat
washer from the B+terminal.
STEP 20
Remove the insulators from the B+terminal.
STEP 21
Loosen and remove the nut, lock washer and flat
washer from the D+terminal.
Bur 8-15670
STEP 22
Remove the insulators from the D+terminal.
STEP 23
Use a screwdriver and separate the stator from the rear
housing.
STEP 24
Carefully remove the stator and rectifier bridge from the
rear housing.
STEP 25
Turn the insulator off of the D+terminal.
STEP 26
Remove the insulator for the B+terminal.
Bur 8-15670
4007-7
STEP 27
Use a screwdriver to start the cover for the slip rings out
of the rear housing.
STEP 28
Use an acceptable tool to remove the cover from the
rear housing.
4007-8
INSPECTION OF BRUSHES
STEP 32 STEP 29
Use an ohmmeter and check the continuity from each
terminal and brush. If the reading is zero, replace the
brush or voltage regulator and brush holder.
STEP 30
Remove the shield.
STEP 31
Measure the length of each brush. If the length of one
brush is less than 0.27 inch (7 mm) replace both
brushes or the voltage regulator and brush holder.
Bur 8-15670
To replace the brushes, use a soldering iron to remove
the original brushes. Install the springs and new
brushes and use rosin core solder to solder the leads to
the terminals. Before soldering the terminal shown,
open the sleeve for the brush lead and then crimp the
sleeve.
STEP 33
Install the shield.
4007-9
INSPECTION AND TESTING OF ROTOR
STEP 36 STEP 34
Touch the leads of the ohmmeter to the slip rings. The
reading must be 2.52 to 3.08 ohms. If the reading is not
as specified, a new rotor must be installed.
STEP 35
Touch the leads to each slip ring and the shaft. If a
reading shows continuity, a newrotor must be installed.
Bur 8-15670
Use a dial indicator and measure the runout of each slip
ring. If the runout is more than 0.002 inch (0.05 mm) a
new rotor must be used or use a lathe to remove
enough material until the runout is less than specified.
STEP 37
Measure the diameter of the slip ring. The diameter
must not be less than 1.055 inch (26.8 mm).
4007-10
INSPECTION AND TESTING OF STATOR
STEP 38
Look for burned insulation onthe coils of the stator. This
is an indication of a short circuit. Install a new stator.
STEP 39
stator and the common connection. The readings must
be 0.09 to 0.11 ohm. If the readings are not as speci-
fied, a new stator must be installed.
STEP 40
stator and the frame. If a reading shows continuity, a
new stator must be installed.
Bur 8-15670
STEP 41
Use a high watt soldering iron and rosin core solder to
solder the leads of the stator to the rectifier bridge.
4007-11
TESTING THE CONDENSER
STEP 43
Touch the terminal to the bracket to discharge the con-
denser.
STEP 42
Touch the leads of the ohmmeter to the condenser as
shown. The reading will increase and then return to zero
resistance as the condenser is charged. Ifthere is no in-
dication of resistance, a new condenser must be in-
stalled. The condenser is used to reduce radio noise.
Bur 8-15670
4007-12
TESTING THE RECTIFIER BRIDGE
STEP 44
Touch the leads of the ohmmeter to a positive diode
Then test the other two positive diodes. If a positive
diode did not have readings as specified, the positive
diode is bad and a new rectifier bridge must be instal-
led.
Bur 8-15670
STEP 45
Touch the leads of the ohmmeter to a negative diode
Then test the other two negative diodes. If a negative
diode did not have readings as specified, the negative
diode is bad and a new rectifier bridge must be in-
stalled.
NOTE: If the tester you are using has adiode test func-
tion, use the tester according to the instructions of the
manufacturer to check the positive and negative
diodes.
Bur8-15670 Issued7-90 PrintedinU.S.A.
4007-14
ASSEMBLY
STEP 49 STEP 46
Align the boss on the cover with the notch in the rear
housing.
STEP 47
Use an acceptable driver and a small hammer and ca-
refully drive the cover into the rear housing.
STEP 48
Install the insulator for the B+terminal.
Bur 8-15670
Turn the insulator all the way onto the D+terminal.
STEP 50
Install the stator and rectifier bridge assembly in the
rear housing.
STEP 51
Pull the D+terminal and insulator into alignment with
the rear housing.
STEP 52
Install and tighten the two screws that hold the rectifier
bridge.
STEP 53
Install the insulators on the 0 +terminal.
STEP 54
Install the flat washer, lock washer and nut on the 0 +
terminal. Tighten the nut.
Bur 8-15670
4007-15
STEP 55
Install the insulators on the B+terminal.
STEP 56
Install the flat washer, lock washer and nut on the B+
terminal. Tighten the nut.
STEP 57
Install the lead from the condenser on the B+terminal.
4007-16
STEP 58
Install and tighten the screw that holds the condenser.
STEP 59
Install the retainer with the smooth side up.
STEP 60
Install.the bearing.
Bur 8-15670
STEP 61
Install the spacer with the smooth surface up.
STEP 62
Use an acceptable driver and press the bearing and
spacer all the way onto the shaft.
STEP 63
Use an acceptable driver and press the other bearing
all the way onto the shaft.
STEP 64
Install the rotor in the front housing.
STEP 65
Align the retainer with the front housing and install and
tighten the screws.
STEP 66
Assemble the front and rear housings so that the align-
ment marks are aligned.
Bur 8-15670
4007-17
STEP 67
.':1.~M
.-,-.'y~.-.";';"',;,.~"".M.-~..:
Install and tighten the screws that hold the alternator to-
gether.
STEP 68
Install the voltage regulator and brush holder.
STEP 69
Hold the voltage regulator and brush holder in place
and install and tighten the screws.
4007-18
STEP 70
Install the fan.
STEP 71
Install the pulley and tapered bushing.
Bur 8-15670
STEP 72
Install the lock washer and nut.
STEP 73
Fasten the pulley ina vise that has soft jaws and tighten
the nut to 44 to 50 pound-feet (60 to 70 Nm).
CASE CORPORATION
Section
4008
INSTRUMENT CLUSTER
4008-2
TABLE OF CONTENTS
INSTRUMENT CLUSTER 4
Removal and Installation .4
Replacing a Bulb .4
Gauge or Tachometer Removal and Installation ..4
Circuit Board 4
CHECKING THE WARNING LAMPS 5
Engine Oil Pressure 5
Alternator 5
Hydraulic Filter and Air Filter 5
CHECKING THE GAUGES 6
Water Temperature, Oil Temperature, or Fuel Level 6
Voltmeter 6
CHECKING THE TACHOMETER 7
Bur 8-17230
4008-3
B901651J
1. Rubber Cover
2. Socket
3. Bulb No. 194
4. Bulb No. 168
5. Gasket
6. Body
7. Water Temperature Gauge
8. Fuel Level Gauge
9. Oil Temperature Gauge
10. Voltmeter
11. Tachometer
12. Gasket
13. Identification Strip
14. Cover
15. Retainer
Bur 8-17230
4008-4
INSTRUMENT CLUSTER
Gauqe or Tachometer
Removal and Instal l ation
Removal and Instal l ation
1. Remove the screws that fasten the instrument cluster
to the instrument panel.
2. Pull the instrument cluster out of the instrument
panel.
3. Disconnect the connectors for the wiring harness
from the instrument cluster.
4. Remove the instrument cluster from the machine.
5. Connect the connectors for the wiring harness to the
instrument cluster
6. Install the instrument cluster in the instrument panel.
7. Install the screws that fasten the instrument cluster to
the instrument panel.
Repl acing a Bul b
panel.
2. Turn the socket counterclockwise and remove the
socket.
3. Pull the bulb fromthe socket and install the new bulb.
4. Install the socket and turn the socket clockwise to
hold the socket in place.
5. Install the instrument cluster inthe instrument panel.
Bur 8-17230
1. R'emove the instrument cluster from the instrument
panel.
2. Remove the four screws that fasten the cover and the
retainer to the body.
3. Remove the cover and the retainer.
4. Remove the screws that fasten the gauge or the tac-
hometer to the body.
5. Remove the gauge or the tachometer from the body.
If you are removing a gauge, you must pull the studs of
the gauge from the clips in the body.
6. Install the new gauge or the new tachometer in the
body. Ifyou are installing agauge, make sure the studs
of the gauge are pushed into the clips in the body.
7. Install the screws that fasten the gauge or the tac-
hometer to the body.
8. Install the retainer and the cover.
9. Install the screws that fasten the cover and the re-
tainer to the body.
10. Install the instrument cluster inthe instrument panel.
Circuit Board
The circuit board does not normally cause any
problems. Use an ohmmeter to check the continuity of
the strips. Ifthere is no continuity inanyone of the strips,
the circuit board must be replaced.
4008-5
CHECKING THE WARNING LAMPS
Hydraul ic Fil ter and Air Fil ter Engine Oil Pressure
1. The warning lamp for engine oil pressure must illu-
minate when the key switch is in the RUN position and
the engine is not running. If the warning lamp does not
illuminate:
a. Check for a bad bulb.
b Check for corrosion or bad connections at the
socket in the instrument cluster and at the switch
for engine oil pressure.
c. Check the wire between the switch and the in-
strument cluster.
2. If the warning lamp illuminates when the engine is
running, the cause can be low engine oil pressure, or a
bad switch for the warning lamp.
Al ternator
1. The warning lamp for the alternator must illuminate
when the key switch is in the RUN position and the
engine is not running.lf the warning lamp does not illu-
minate:
a. Check for a bad bulb.
b. Check for corrosion or bad connections at the
socket in the instrument cluster and at the alter-
nator.
c. Check for a damaged wire between the alter-
nator and the instrument panel.
2. If the warning lamp illuminates when the engine is
running, the cause is probably the alternator or voltage
regulator. See Section 4002 and check the alternator
and the voltage regulator.
Bur 8-17230
1. Both warning lamps must illuminate when the key
switch is turned half the distance between RUN and ST.
If one of the warning lamps will not illuminate, check
for:
a. A bad bulb.
b. Dirty connection at the instrument cluster.
c. An open circuit in a diode or in the wire between
the diodes.
d. An open circuit inthe wire between a diode and
the instrument cluster.
If neither of the warning lamps illuminate, check for:
a. A damaged wire between the instrument cluster
and the IGN terminal of the key switch.
b. A damaged wire between the diodes and the
GRD terminal of the key switch.
c. A bad key switch.
2. Neither of the warning lamps must illuminate when
the engine is running.
Ifeither warning lamp illuminates when the engine is
running, the cause can be:
a. A dirty filter.
b. A bad switch for the warning lamp.
c. A short circuit inthe wire between the switch and
the warning lamp.
If both of the warning lamps illuminate when the
engine is running, the cause can be:
a. A bad key switch.
b. One of the warning lamps has illumninated for
one of the causes above, and the other warning
lamp has illuminated because of a bad diode.
4008-6
CHECKING THE GAUGES
Water Temperature, Oil Temperature,
or Fuel Level
1. If the gauge does not work correctly:
a. Disconnect the wire from the sender.
b. Turn the key switch to RUN
c. Hold the wire against the frame or the engine to
make a good ground connection.
d. Have another person look at the gauge. If you
are checking the water temperature gauge or the
oil temperature gauge, the needle must move all
the way to the top of the gauge. Ifyou are checking
the fuel level gauge, the needle must go all the way
to the bottom of the gauge.
e.lfthe needle moved, the sender is bad and must
be replaced. Ifthe needle did not move, the gauge
is bad or there is an open circuit in the wires
between the sender and the gauge.
f. Install the wire on the sender.
g. See page 4 and remove the instrument cluster
from the instrument console and disconnect the
wiring harness from the instrument cluster.
h. See the wiring schematic in Section 4002 for the
location of the terminal in the connector on the
wiring harness. Connect one lead of an ohmmeter
to the terminal inthe connector. Connect the other
lead of the ohmmeter to a good ground connec-
tion.
i. If the ohmmeter did not indicate continuity, there
is a short circuit inthe wires between the connector
and the sender. Repair or replace the wires. If the
ohmmeter indicated continuity, the wires are good
and the gauge must be replaced.
Bur 8-17230
2. Ifthe gauge only works part of the time, the cause can
be:
a. A bad connection at the sender.
b. A bad connection at the instrument cluster.
c. Bad connection in the connectors in the wiring
harness.
d. A short circuit or an open circuit in the wires
between the instrument cluster and the sender.
e. A bad sender.
f. A bad gauge.
Vol tmeter
1. Connect the positive lead of a test voltmeter to the
positive post of the battery. Connect the negative lead
of the test voltmeter to the negative post of the battery. If
the machine has two batteries, make sure the leads are
connected to the same battery.
2. Start the engine and run the engine at 1500 rpm
(r/min).
3. Read the test voltmeter.
4. Read the voltmeter for the machine and compare the
reading with the reading of the test voltmeter.
5. If the readings are within 1/2 volt, the voltmeter is
good.
CHECKING THE TACHOMETER
4008-7
1. Park the machine on a level surface and lower the
bucket to the floor.
2. Stop the engine and apply the parking brake.
3. Remove the right side panel from the engine com-
partment.
4. Remove the connector from the W terminal of the al-
ternator.
5. Connect one of the leads of a voltmeter to the W
terminal inthe alternator. Connect the other lead of the
voltmeter to a good ground connection on the engine.
Adjust the voltmeter to indicate volts AC (alternating
current).
6. Have another person start the engine while you look
at the voltmeter. The voltmeter must indicate a
minimum of six volts AC. Stop the engine.
a. Ifthe voltmeter indicated sixvolts or more, do the
next step.
b. If the voltmeter indicated less than sixvolts, see
Section 4006 or 4007 and replace the rectifier
bridge.
console. Make sure that the wiring harness is discon-
nected from the instrument cluster.
8. Turn the key switch to the RUN position.
9. Adjust the voltmeter to indicate volts DC (direct cur-
rent).
10. Connect the positive lead of the voltmeter to the
middle terminal (white and orange wire) of the small
connector of the wiring harness. Connect the negative
lead of the voltmeter to a good ground connection.
a. Ifthe voltmeter indicates system voltage, do the
next step.
b. If the voltmeter does not indicate system
voltage, repair or replace the wire between the
small connector and the fuse block.
Bur 8-17230
11. Keep the positive lead of the voltmeter connected to
the middle terminai of the small connector. Connect the
negative lead of the voltmeter to the lower terminal
(black and orange wire) of the small connector.
a. Ifthe voltmeter indicated system voltage, do the
next step.
b. If the voltmeter does not indicate system
voltage, repair or replace the wire between the
small connector and the ground connection near
the fuse blocks.
12. Turn the key switch to the OFF position.
13 Connect one of the leads of an ohmmeter to the re-
maining terminal (yellow and red wire) inthe small con-
nector on the wiring harness.
14. Connect the other lead of the ohmmeter to the
terminal on the wire that was connected to the W
terminal of the alternator.
a. If the ohmmeter indicates continuity, the
problem is in the tachometer, and the tachometer
must be replaced.
b. If the ohmmeter does not indicate continuity,
see the wiring schematics in Section 4002 and
check the continuity of wire 31S (yellow and red)
through the main wiring harness and the side
console wiring harness. Repair or replace the wire
as necessary.
SECTION INDEX - STEERING
Removal and Installation of Steering Components 5001
Specifications, Schematic. and Troubleshooting. . 5002
..............................5004 Steering Control Valve - Eaton
Steering Control Valve - Danfoss.
Front Axle - Four Wheel Drive. .
...5005
.5006
..5007
..5008
Steering Cylinder .
Front Axle - Two Wheel Drive , .
CASE CORPORATION
Bur 8-17250
CASE CORPORATION
Sect i on
5001
OF STEERING COMPONENTS
Bur 8-17260
Printed in U.S.A.
5001-2
TABLE OF CONTENTS
SPECiFiCATIONS..... .. .. . 3
SPECIAL TOOLS 4
STEERING CONTROL VALVE . 5
Removal.......... ..5
Installation........ . , ,. ... 8
STEERING COLUMN 10
Removal 10
Installation 14
STEERING CYLINDER, TVVOWHEEL DRIVE MACHINES 18
Removal...... . 18
Installation... . 18
STEERING CYLINDER, FOUR WHEEL DRIVE MACHINES 20
Removal.................................. ...20
Installation.... 21
FRONT AXLE - TVVOWHEEL DRiVE . ..24
Installation .
.............. .. 24
................ . 24
. 26
............................ 26
.. 26
Removal .
Installation.. .
FRONT AXLE - FOUR WHEEL DRiVE .
Removal .
5001-3
SPECIFICATIONS
Special torques
Nut for the steering wheel 384 to 444 pound-inches (43 to 50 Nm)
Cap screws that fasten the steering cylinder
to the two wheel drive axle . . 580 to 696 pound-feet (786 to 944 Nm)
Capscrews that fasten the steering cylinder to fhe four wheel drive axle 66 to 79 pound-feet (90 to 107 Nm)
Nuts for the bolts that fasten the guard for the drive shaft to the frame ... 100 to 150 pound-feet (136 to 203 Nm)
Cap screws that hold the front drive shaft 504 to 576 pound-inches (58 to 65 Nm)
Wheel bolts for the two wheel drive front axle 115 to 150 pound-feet (156 to 203 Nm)
Wheel nuts for the four wheel drive front axle 200 to 260 pound-feet (270 to 352 Nm)
Nut that fastens the ball joint to the arm of the swivel housing
on the four wheel drive axle 170 pound-feet (230 Nm)
Bur 8-17260
5001-4
SPECIAL TOOLS
dresses:
Service Tools
P.O. Box 314
VL Churchill Ltd
Northants, NN11 4NF
England
The tool shown is needed to remove the steering
wheel. Make the tool in your shop. This tool is first used
on page 5.
4
6 7 B902174J
Make from 1/4 in (6 mm) Cold Rolled Steel
1. 2 In (50mm)
2. 1In (25.4 mm)
3. 5/8In (19mm)
4. 3/8In (9.5mm)
5. 3/4In (19mm)
6. Two Holes, 7/32 In (5.5 mm)
7. Use No. 4 OrilJfor 1/4 - 24
Threads Metric Thread Optional
Two 10-32 x 1In Screws Required
Bur 8-17260
B4095088M
CAS-10486 Puller
This tool is used to remove the ball joint for the steering
cylinder from the axle. This tool is first used on page 20.
B4097488M
CAS-2151 Wrench
This tool is used to remove and install the tie rod This
tool is first used on page 20.
Removal
STEERING CONTROL VALVE
5001-5
See the illustration on page 7.
parking brake.
2. Lower the bucket to the floor and put the backhoe in
the transport position.
3. Remove the cover (1)fromthe steering wheel (2). The
cover (1) is held by the fit of an O-ring (3).
4. Loosen and remove the nut (4) that holds the steering
wheel (2) in place.
5 Use the puller shown on page 4 to loosen and
remove the steering wheel (2).
Bur 8-17260
6. Remove the three screws that hold the rear cover for
the steering column (5).
7. Remove the front and rear covers.
8. Disconnect the wiring for the turn signals.
5001-6
9. Open the access cover at the rear of the hood. This
will giveyou access to the hoses connected to the front
of the steering control valve (6).
J ill""'"
10. Loosen and remove the three cap screws that hold
the access panel shown. Remove the access panel.
Bur 8-17260
11. Clean the hose connections at the steering control
valve (6).
12. Put identification tags on the hoses to the steering
control valve (6).
13. Three of the hoses at the steering control valve (6)
do not have swivel fittings. Find the end of each of the
hoses without swivel fittings and disconnect each hose
from the tube fitting. Install a cap on each hose and a
plug in each tube.
14. Disconnect the other two hoses from the fittings in
the steering control valve (6). Install a cap on each
fitting and a plug in each hose.
15. Loosen and remove the two cap screws (7) and lock
washers that hold the steering control valve (6) to the
bracket (8) for the steering column (5).
16. Loosen the nuts and lock washers on the bolts (9)
that fasten the plate (10) to the bracket (8) for the
steering column (5).
17. Push the steering column (5) down enough for
clearance to remove the two cap screws (11) and lock
washers that fasten the steering column (5) to the
steering control valve (6).
18. Hold the steering control valve (6) and remove the
cap screws (11) and lock washers.
19 Remove the steering control valve (6) and the three
hoses through the access hole.
20. Loosen and remove the three hoses and two fittings
from the steering control valve (6).
Bur 8-17260
5001-7
2 STEERING WHEEL
6. STEERING CONTROL VALVE
B902295J
Steering Control Valve Installation
12. DIRECTION
CONTROL LEVER
5001-8
Inst al l at i on
1. Install the three hoses and two fittings inthe steering
control valve (6).
2. Hold the steering control valve (6) in alignment with
the steering column (5)
3 Install the two cap screws (11) and lock washers that
fasten the steering column (5) to the steering control
valve (6). Tighten the cap screws (11).
4. Push the steering control valve (6) up and align the
steering column (5) with the bracket (8).
5 Tighten the nuts and lock washers on the bolts (9)
6. Remove the caps from the two fittings inthe steering
control valve (6) and remove the plugs from the two
hoses Connect the hoses to the fittings
7. Remove the caps from the three hoses inthe steering
control valve (6) and remove the plugs from the tube fit-
tings. Connect the tube fittings to the hoses.
8. Connect the wiring for the turn signals.
Bur 8-17260
9. Install the front and rear covers.
10. Install and tighten the three screws that hold the rear
cover for the steering column (5).
11. Install the steering wheel (2) and install the nut (4).
Tighten the nut (4) to 384 to 444 pound-inches (43to 50
Nm).
12. Install the cover (1) in the center of the steering
wheel (2).
13. Start the engine and run the engine at low idle.
14. Turn the steering wheel all the way to the right and
left several times to remove any air from the steering
system.
15. Stop the engine and check for oil leaks.
16. Check the level of the oil inthe reservoir and add oil
as required.
17. Install the access panel.
18. Close the access cover at the rear of the hood.
Bur 8-17260
2. STEERING WHEEL
5001-9
~ 5. STEERING COLUMN
B902295J
5001-10
Removal
STEERING COLUMN
parking brake.
2. Lower the bucket to the floor and put the backhoe in
the transport position.
3. Remove the cover (1) from the steering wheel (2). The
cover (1) is held by the fit of an O-ring (3).
4. Loosen and remove the nut (4) that holds the steering
wheel (2) in place.
5 Use the puller shown on page 4 to loosen and
remove the steering wheel (2).
Bur 8-17260
6. Remove the three screws that hold the rear cover for
the steering column (5).
7. Remove the front and rear covers.
8. Disconnect the wiring for the turn signals.
Bur 8-17260
5001-11
2. STEERING WHEEL
.'" 5. STEERING COLUMN
-,
B902295J
5001-12
9. Loosen and remove the screws that hold the control
console.
10 Remove the control console
Bur 8-17260
11. Remove the bulbs for the turn signals and discon-
nect the wiring from the lamp and warning flasher swit-
ches.
12. Loosen and remove the two cap screws and locK
washers that fasten the steering column (5) to the
steering control valve.
13. Loosen and remove the nut (13) and lock washer
that fasten the power shuttle rod (14) for the power
shuttle to the sleeve (15). Move the power shuttle rod
(14) out of the way
14. Loosen the nut and bolt on the clamp (16) that holds
the roll pin (17) in the sleeve (15). Remove the clamp
(16).
15. Remove the roll pin (17) from the control rod (19)
and sleeve.
16. Remove the sleeve (15) from the control rod (19).
17. Loosen and remove the bolts (18), lock washers,
and nuts that fasten the bracket (8) for the steering
column (5) to the firewall.
18. Lift the bracket (8) for the steering column (5) and
pull the control rod (19) through the self-aligning
bearing at the left side of the firewall Remove the
bracket (8) and the control rod (19).
19. Loosen the nuts and lock washers on the bolts (9)
20. Remove the steering column (5) from the bracket
(8).
5001-13
NOTCH
B902308J
5001-14
Inst al l at i on
1. Install the steering column (5) through the bracket
(8)
2. Tighten the nuts and lock washers on the bolts (9)
3. Install the bracket (8) for the steering column (5) and
install the control rod (19) through the self-aligning
bearing at the left side of the firewall.
4. Install the bolts (18), lock washers, and nuts that
fasten the bracket (8) for the steering column (5) to the
firewall. Tighten the nuts.
5 Install the sleeve (15) on the end of the control rod
(19).
6. Align the hole inthe sleeve (15) with the hole in the
control rod (19) and install the roll pin (17)
7. Install the clamp (16) over the sleeve (15) and tighten
the clamp (16).
8. Connect the power shuttle rod (14) for the power
shuttle to the sleeve (15) on the control rod (19). Install
the lock washer and nut (13) and tighten the nut (13).
9. If adjustment of the power shuttle linkage is required,
see Shuttle Control Linkage Adjustment in Section
9001.
10 Install the two cap screws and lock washers that
fasten the steering column (5) to the steering control
valve. Tighten the cap screws.
Bur 8-17260
11. Install the bulbs for the turn signals and connect the
wiring for the lamp and warning flasher switches.
12. Install the control console.
13. Install the screws that hold the control console.
Tighten the screws.
5001-15
Bur 8-17260
B90230BJ
5001-16
14. Connect the wiring for the turn signals.
15. Install the front and rear covers.
Bur 8-17260
16. Install and tighten the three screws that hold the rear
cover for the steering column (5).
17. Install the steering wheel (2) and install the nut (4)
Tighten the nut (4) to 384 to 444 pound-inches (43to 50
Nm).
18. Install the cover (1) in the center of the steering
wheel (2).
Bur 8-17260
2. STEERING WHEEL
5001-17
5. STEERING COLUMN
B902295J
5001-18
Removal
STEERING CYLINDER, TWO WHEEL DRIVE MACHINES
Inst al l at i on
1. Clean the hose connections (1) at the steering
cylinder (2).
2. Put an identification tag on one of the hoses (1).
3. Disconnect the hoses (1) from the steering cylinder
(2),
4, Install a plug in each hose (1),
5. Loosen and remove the nuts (3), lock washers (4),
and bolts (5)for the pins (6)that fasten the steering links
(7) to the piston rod eyes of the steering cylinder (2),
6, Drive the pins (6) out of the steering links (7) and the
piston rod eyes, Do not damage the grease fittings (8)
in the pins (6).
7, Loosen and remove the cap screws (9) and
hardened washers (10) that fasten the steering cylinder
(2) to the axle (11). There are access holes for the cap
screws (9) at each side of the front of the axle (11).
8. Remove the steering cylinder (2),
Bur 8-17260
1, Install the steering cylinder (2) on the axle (11) and
install the cap screws (9) and hardened washers (10),
2, Tighten the cap screws (9) to 580 to 696 pound-feet
(786 to 944 Nrn).
3 Align the steering links (7) with the piston rod eyes
and install the pins (6),
4, Install the bolts (5), lock washers (4), and nuts (3),
Tighten the nuts (3),
5, Remove the plugs from the hoses (1) and connect
the hoses (1) to the steering cylinder (2),
6 Lubricate the pins (6) for the steering links (7) with the
grease specified in Section 1002,
7, Check and adjust toe-in according to instructions in
Section 5007,
Issued 1-91 Printed in U,SA
5001-19
2. STEERING
CYLINDER
7. STEERING LINK
8892200J
Bur 8-17260
5001-20
STEERING CYLINDER, FOUR WHEEL DRIVE MACHINES
STEP 6 Removal
NOTE: The following photographs show the steering
cylinder being removed from the axle with the axle
removed from the machine. It is not necessary to
remove the axle from the machine to remove the
steering cylinder.
STEP 1
Clean the hose connections at the steering cylinder.
STEP 2
Fasten an identification tag to one of the hoses to the
steering cylinder
STEP 3
Disconnect the hoses from the steering cylinder. Install
a plug in each hose and a cap on each fitting.
STEP 4
Removethe cotter pin from the ball joint and loosen the
nut several turns. Do not remove the nut at this time
STEP 5
Install the CAS-10486 puller as shown and tighten the
screw.
Bur 8-17260
Remove the nut and remove the ball joint from the arm.
STEP 7
Repeat steps 4, 5, and 6 for the other end of the axle
STEP 8
.:e9g
Install the CAS-2151 tool on the flats of the piston rod
and install a wrench on the tie rod. Prevent the piston
rod from turning and loosen the tie rod.
STEP 9
Remove the tie rod and ball joint assembly from the
piston rod.
STEP 10
Loosen and remove the cap screws and lock washers
that fasten the steering cylinder to the axle.
STEP 11
NOTE: The photograph shows a plug being removed
from the steering cylinder. A hose fitting will be installed
in your steering cylinder
Remove the hose fitting
STEP 12
Hit the steering cylinder with a soft hammer to drive the
steering cylinder out of the axle.
Bur 8-17260
5001-21
STEP 13
Remove the steering cylinder from the axle.
Inst al l at i on
STEP 14
Install the steering cylinder in the axle.
STEP 15
Install the cap screws and lock washers that fasten the
steering cylinder to the axle. Tighten the cap screws to
66 to 79 pound-feet (90 to 107 Nm).
5001-22
STEP 16
NOTE: The photograph shows aplug being installed in
the steering cylinder. A hose fitting will be installed in
your steering cylinder.
Install the hose fitting.
STEP 17
STEP 18
Install the CAS-2151 tool on the flats of the piston rod
and install a wrench on the tie rod. Prevent the piston
rod from turning and tighten the tie rod.
Bur 8-17260
STEP 19
B907621OM
Install the ball joint in the arm.
STEP 20
Install the nut on the ball joint and tighten the nut to 170
pound-feet (230 Nm).
STEP 21
Install a new cotter pin in the nut and ball joint.
STEP 22
Repeat steps 19, 20, and 21 for the other end of the
axle.
STEP 23
Connect the hoses to the fittings inthe steering cylinder
STEP 24
Start the engine and run the engine at low idle.
STEP 25
Turn the steering wheel all the way to the right and left
several times to remove any air from the steering
system.
Bur 8-17260
5001-23
STEP 26
Stop the engine and check for oil leaks.
STEP 27
Check the level of the oil in the reservoir and add oil as
required.
5001-24
Removal
FRONT AXLE - TWO WHEEL DRIVE MACHINES
1. Raise the front wheels above the floor and use
suitable stands to hold the machine in place.
2. Loosen and remove the wheel bolts and remove the
wheels.
3. Fastenan identification tag to one of the hoses forthe
steering cylinder.
4. Disconnect the hoses from the fittings inthe steering
cylinder. Install a plug in each hose and a cap on each
fitting.
5. Remove the snap ring (1) fromthe rear of the pivot pin
(2)
6. Remove the flat washers (3).
7. Loosen and remove the grease fitting (4) from the
end of the pivot pin (2).
8. Putafloor jack under the axle (5) to hold the axle (5) in
position.
9. Drive the pivot pin (2) out of the frame and through
the hole in the counterweight.
10 Spacers (6) are used at the front and rear of the axle
(5), between the axle (5) and the frame. Lower the axle
(5) and remove the spacers (6)
11. Remove the axle (5) from under the machine
Inst al l at i on
1. Raise the axle (5) into alignment with the machine.
other end of the pivot pin (2). Install the pivot pin (2)
through the counterweight with the tapered end of the
pivot pin (2) toward the rear of the machine.
3. Install a thick spacer (6) and a thin spacer (6)
between the front of the axle (5) and the frame. Use
spacer (6) to remove any end play.
Bur 8-17260
4. Start the pivot pin (2) into the frame, spacers (6) and
axle (5).
5. Drive the pivot pin (2) into the rear pivot of the axle (5)
but not through the rear pivot.
6 Install the thin spacer (6) between the rear of the axle
(5) and the frame. Use spacer (6) to remove any end
play.
7. Drive the pivot pin (2) through the rear pivot and the
frame.
8. Install the flat washers (3) and snap ring (1) on the
tapered end of the pivot pin (2).
9 Hit the pivot pin (2) to move the pivot pin (2) toward
the front of the machine as far as possible.
10. Check the end play between the frame and the snap
ring (1) on the pivot pin (2) at the front of the machine.
Use flat washers (3) as required to remove any end
play.
11. Install a grease fitting (4) ineach end of the pivot pin
(2). Tighten the grease fittings (4).
12. Loosen and remove the plugs from the hoses and
the caps from the fittings for the steering cylinder.
13. Connect the hoses to the steering cylinder.
14. Install the wheels and wheel bolts. DO NOT use an
impact wrench to tighten the wheel bolts.
15. Tighten the wheel bolts to 115 to 150 pound-feet
(156 to 203 Nm).
16 Remove the stands and lower the wheels to the
floor.
17. Lubricate the pivot pin (2) for the axle (5).
Issued 1-91 Printedin U.SA
5001-25
B902461J
5001-26
Removal
FRONT AXLE - FOUR WHEEL DRIVE MACHINES
Inst al l at i on
1. Loosen and remove the nuts. flat washers, and bolts
that fasten the bar (1) to the guard (2) for the drive shaft
(3). Remove the bar (1).
2. Put afloor jack under the guard (2) to hold the guard
(2) in position.
3. Loosen and remove the nuts and flat washers from
the bolts that fasten the guard (2) for the drive shaft (3)
to the frame. Do not remove the bolts at this time.
4. Lower the guard (2) and remove the guard (2) from
under the machine.
5. Loosen and remove the cap screws that fasten the
drive shaft (3) to the flange on the trans axle and remove
the drive shaft (3).
6. Raise the front wheels above the floor and use
suitable stands to hold the machine in place.
7. Install blocks between the axlestops and the frame to
prevent the axle (4) from tilting.
8. Loosen and remove the wheel nuts and hardened
washers and remove the wheels.
9. Fasten anidentification tag to one of the hoses for the
steering cylinder.
10. Disconnect the hoses from the fittings in the
steering cylinder. Install a plug ineach hose and a cap
on each fitting.
11. Remove the snap ring (5) from the rear of the pivot
pin (6).
12. Remove the flat washers (7).
end of the pivot pin (6).
14. Putafloor jack under the axle (4) to hold the axle (4)
in position.
15. Drive the pivot pin (6) out of the frame and through
the hole in the counterweight.
16. Spacers (9) are used at the front and rear of the axle
(4), between the axle (4) and the frame. Lower the axle
(4) and remove the spacers (9).
17. Remove the axle (4) from under the machine.
Bur 8-17260
1. Raise the axle (4) into alignment with the frame.
other end of the pivot pin (6). Install the pivot pin (6)
through the counterweight with the tapered end of the
pivot pin (6) toward the rear of the machine.
3. Install a thick spacer (9) and a thin spacer (9)
between the front of the axle (4) and the frame.
4. Start the pivot pin (6) into the frame, spacers (9) and
axle (4).
5 Drive the pivot pin (6) into the rear pivot of the axle (4)
but not through the rear pivot.
6. Install the thin spacer (9) between the rear of the axle
(4) and the frame. Use spacers (9) as required for
minimum end play between the frame and the axle (4).
7. Drive the pivot pin (6) through the rear pivot and the
frame.
8. Install the flat washers (7) and snap ring (5) on the
tapered end of the pivot pin (6).
9. Hit the pivot pin (6) to move the pivot pin (6) toward
the front of the machine as far as possible.
10. Check the end play between the frame and the snap
ring (5) on the pivot pin (6) at the front of the machine.
Use flat washers (7) as required to remove any end
play
11. Install a grease fitting (8) ineach end of the pivot pin
(6). Tighten the grease fittings (8).
12. Loosen and remove the plugs from the hoses and
the caps from the fittings for the steering cylinder.
13. Connect the hoses to the steering cylinder.
14. Install the wheels, hardened washers, and nuts. DO
NOT use an impact wrench to tighten the nuts.
15. Tighten the nuts to 200 to 260 pound-feet (270 to
352 Nm).
16. Remove the blocks from between the axle stops
and the frame.
17. Remove the stands and lower the wheels to the
floor.
5001-27
7. FLAT .. :.~
WASHER ~ " ., .i:\:
~"\ \.",." ...
C>~'~ .
8. GREASE FITTING t:1 5. SNAP
RING
8. GREASE
FITTING
~19
6. PIVOT PIN ~ 5. SNAP
_ ' ~ 1 RING
;\: 7. FLAT WASHER (USE
AS REQUIRED FOR
MINIMUM END PLAY)
TIGHTEN TO 200 TO 260
POUND-FEET (270 TO 352 Nm)
@@
"
\
\
\
\
\
\
\
\
\
\
\
9. SPACER ~
~~ 9. SPACER (USE AS REQUIRED
~ FOR MINIMUM END PLAY)
, ~
/~ TIGHTEN TO 504 TO 576
~ POUND-INCHES (58 TO 65 Nm)
B902368J
5001-28
18. Lubricate the pivot pin (6) for the axle (4).
19. Install the drive shaft (3) and the cap screws that
fasten the drive shaft (3) to the flange on the transaxle.
20. Tighten the cap screws to 504 to 576 pound-inches
(58 to 65 Nm).
21. Use a floor jack and install the guard (2) under the
drive shaft (3).
Bur 8-17260
22. Raise the guard (2) into alignment with the brackets
on the frame and install the bolts, flat washers, and
nuts. Remove the floor jack
23. Tighten the nuts to 100 to 150 pound-feet (136 to
203 Nm).
24. Install the bar (1) on the guard (2) and install the
bolts, flat washers, and nuts. Tighten the nuts.
5001-29
Bur 8-17260
8902368J
Sect i on
5002
SPECIFICATIONS, SCHEMATIC AND TROUBLESHOOTING
CASE CORPORATION
Bur 8-17270
Printed in U.S.A.
5002-2
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TOOL 2
TROUBLESHOOTING PROCEDURE 3
CHECKING THE PRESSURE SETTING OF THE RELIEF VALVE .4
ADJ USTING THE PRESSURE SETTING OF THE RELIEF VALVE ..4
CHECKING PISTON PACKING FOR THE STEERING CYLINDER 5
SCHEMATiC 9
SPECIFICATIONS
Location of relief valve In inlet section of loader control valve
Pressure setting 2450 to 2600 psi at full throttle
(16 893 to 17 927 kPa, 169 to 179 bar)
SPECIAL TOOL
In Europe order the tools from
Inthe U.S. a~d Canada, order the tools from
Service Tools
P.O. Box 314
Owatonna. MN 55060
VL Churchill Ltd
PO. Box 3, Daventry
Northants, NN11 4NF
England.
CAS-1804 or CAS-10111 Pressure Fitting Kit
TROUBLESHOOTING PROCEDURE
5002-3
Add oil specified in Section 1002.
See Section 8002 for troubleshooting instructions.
Connect the hoses according to the schematic.
Does the steering control valve return to NEUTRAL
when the steering wheel is not being turned?
Replace or repair the steering control valve ac-
cording to instructions in Section 5004 or 5005.
Troubleshooting complete.
Repair as required according to instructions in
Section 5006.
Replace or repair the pump according to in-
structions in Section 8004.
Check the machine for oil leaks and damaged or missing parts. Repair as required.
5002-4
CHECKING THE PRESSURE SETIING OF THE RELIEF VALVE
1. The oil must be at operating temperature. To heat the
oil, do steps 2 through 4.
2. Withthe engine running at full throttle, hold the loader
control lever in the ROLLBACK position for 15 seconds.
3. Returnthe loader control lever to the NEUTRAL position
for 15 seconds.
4. Repeat steps 2and 3until thetemperature of the oil is
125F (51C) or the side of the reservoir is very warm.
5. Connect a 5000 psi (34473 kPa, 345 bar) gauge to
the quick disconnect fitting inthe pressure linefrom the
pump. The quick disconnect fitting is located just
forward of the battery box at the leftside of the machine.
The hose for the gauge must be long enough 'to read
the gauge from the operators seat.
6. With the engine running at full throttle, turn and hold
the steering wheel all the way to the right or to the left
and read the gauge. Make a record of the reading.
7. Decrease the engine speed to low idle for two
minutes and stop the engine.
8. Ifthe reading was not between 2450 and 2600 psi (16
893 to 17927 kPa, 169 to 179 bar), adjust the setting of
the relief valve.
ADJUSTING THE PRESSURE SETIING OF THE RELIEF VALVE
1. The relief valve is located in the inlet section of the
loader control valve.
2. Loosen the lock nut on the adjusting screw and turn
the adjusting screw clockwise to increase the setting or
turn the adjusting screw counterclockwise to decrease
the setting.
3. Prevent the adjusting screw from turning and tighten
the lock nut.
4. Check the setting of the relief valve again.
CHECKING PISTON PACKING FOR THE STEERING CYLINDER
1.Apply the parking brake and lower the loader bucket
to the floor.
stop the engine.
3. Disconnect the hose at the left side of the steering
cylinder.
4. Install a plug in the hose. The thread size is 3/4-16.
Bur 8-17270
5. Start the engine and run the engine at full throttle.
continue to turn the steering wheel to the right while
another person checks for leakage at the open fitting.
7. If there is constant leakage, the piston packing is
damaged and must be repaired. See Section 5006 for
repair instructions.
5002-5
o STEERING CONTROL VALVE
Controls oil flow to the steering cylinder.
1. Inlet
2. Outlet
3. Pilot
4. Check Valve
5. Spool and Sleeve Assembly
6. Drive Unk
7. Gerotor
Controls the flow of oil to the steering cylinders.
Bur 8-17270
B891058J
5002-6
1. Inlet
2. To Steering Control Valve
3. Pilot Pressure Port
4. Relief Valve for
Steering System
5. Spring
6. Spool
Controls flow of oil and pressure for the steering system.
Bur 8-17270
B891059J
INLET SECTION OF LOADER CONTROL VALVE
AND FLOW CONTROL VALVE
6
5002-7
Bur 8-17270
1. Backhoe Section
2. Loader Section
3. Outlet
4. Inlet
5. Drive Shaft
6. Coupling
Generates oil flow for the complete hydraulic system.
B891060J
Issued191 Printedin U.S.A.
5002-8
1. Inlet
2. To Reservoir
3. To Oil Cooler
4. From Steering Control Valve
5. Filter
6. Bypass Valve
7. Switch
8. Check Valve
Cleans oil returning to the reservoir.
Bur 8-17270
B891061J
5002-9
DIRECTION OF FLOW
Shows direction of oil flow.
PILOT PRESSURE
Pressure used to control
another component.
CROSSOVER LINES
CONNECTING LINES
FILTER OR SCREEN
OIL COOLER
CHECK VALVE
DOUBLE ACTING CYLINDER
Sect i on
5004
STEERING CONTROL VALVE - EATON
CASE CORPORATION
Bur 8-12440
Printed in U.S.A.
Issued October 1989
5004-2
TABLE OF CONTENTS
SPECfFICATIONS . . 2
SPECIAL TOOlS . .. 2
DiSASSEMBly................................... . .. 3
INSPECTION.............. ..9
ASSEMBLY ... . 12
SPECIFICATIONS
Rotor and stator clearance . ....................................... 0.005 inch (0.13 mm)
Special Torques
Allen head plug .. ................................................. 100 pound-inches (11 Nm)
Ferry head screws ..225 to 275 pound-inches (25 to 31 Nm)
SPECIAL TOOLS
dresses:
In Europe
In the U.SA and Canada
Service Tools
PO. Box 314
Owatonna. Minnesota 55060
VL Churchill Ltd.
PO. Box 3. Daventry
Northants. NN11 4NF
England
B785606M
CAS-1239 Centering Spring Installation Tool
This tool is first used on page 5004-14.
Bur 812440 Issued 10-89 Printed in U.S.A.
5004-3
STEP 1
DISASSEMBLY
STEP 4
Putthe steering control valve inthevise so the end plate
is up. Use a punch and hammer and hit the Ferry head
screws to make the Ferry head screws easier to
remove.
Remove the end plate.
STEP 5
STEP 2
Lift the metering gear set, spacer, drive shaft, and
spacer plate as an assembly from the body.
Loosen the Ferry head screws.
STEP 6
STEP 3
Remove the Ferry head screws.
8523536M
Separate the metering gear set, spacer, drive shaft and
spacer plate.
Bur 8-12440 Issued 10-89 Printed inU.S.A.
5004-4
B8471788M
Remove the rotor from the stator
STEP 8
Remove and discard the O-ring from the stator.
STEP 9
B8472388M
Remove and discard the O-ring from the end plate.
Bur 8-12440
STEP 10
Remove and discard the O-ring from the body.
STEP 11
'B877704M
._;., ... >zfq". " " '? I T . ;;:~'. <,'- ,," .
Findthe anticavitation valves inthe body. Put identifica-
tion marks on the body for use during assembly.
STEP 12
......."'.. ".."'.~.. '0&'~~~.,,".", .. " . O _ . , . . . , , , . V... ... . ..... 77698M
Remove the springs, pins, and balls from the ports in
the body.
STEP 13
Remove the body of the steering control valve from the
vise. Push the spool and sleeve part of the way out of
the bottom of the body. Turn the sleeve and spool in
both directions and pull the sleeve and spool out of the
body. The pin inside of the sleeve and spool can keep
the sleeve and spool fromcoming out of the body. Ifthe
sleeve and spool cannot be pushed out of the body
easily, use a magnet to move the pin inside the spool
one way or the other.
STEP 14
Remove and discard the spacer from the spool.
STEP 15
8523921M
Remove the washer.
Bur 8-12440
5004-5
STEP 16
8523923M
Remove the bearing.
STEP 17
8523925M
Remove the other washer.
STEP 18
8523927M
Use a punch to push the pinout of the sleeve and spool.
5004-6
STEP 19
B523929M
Pull the spool straight out of the sleeve. Remove the
centering springs.
STEP 20
Push the centering springs out of the spool. There are
four centering springs and two spacers Do not lose
any of the centering springs.
STEP 21
Remove the seal from the gland.
Bur 8-12440
STEP 22
1888M
Remove the Allen head plug from the body of the
steering control valve.
STEP 23
Install a No. 8-32 screw inthe seat for the check valve.
STEP 24
Use pliers to pull the seat out of the body of the steering
control valve.
STEP 25
';;;:ijki0i.+iri,jwJ ~~&3817M
vise. Turn the body up and let the steel ball and retainer
fallout of the body
STEP 26
8523820M
B523822M
Remove and discard the O-rings from the seat.
Bur 8-12440
5004-7
B523935M
'" . " . ,. . " . : . . ~. >" -'" ;:. ,. ;" V ;:; . . ,;-;::. :J ::-. ;. ;-;-.
Remove the O-ring and backup ring from the bottom of
the gland. Discard the O-ring and backup ring.
STEP 28
... ~? Bs47C
-..._. _. - .. ,~._ ... ~~ :. ~-;':;::. , . . ;. . . : ..... : . . . :.
Putthe body inthe vise with the gland up. Move the end
of the retaining ring out of the goove in the body.
Remove the retaining ring.
STEP 29
~-
The gland inthe body of the steering control valve can
be difficult to remove. Remove the body of the steering
control valve from the vise. Put the body in a press with
the gland down. Put blocks under the body to hold the
body off the press table. Press the gland out of the
body.
5004-8
STEP 30
~.. B~it;88M
Remove and discard the O-ring from the bore for the
gland.
Bur 8-12440 Issued 10-89 Printed in U.sA
INSPECTION
5004-9
C lean all parts in cleaning solvent. Put the parts on
paper towels until the parts are dry. Do not use cloths to
wipe the parts dry.
C heck all machined surfaces for wear or damage If
there are rough places on the ends of the stator and
rotor, or on the machined surfaces on the body, end
plate, or spacer plate, make the surfaces smooth by
using 600 grit emery cloth. Put the emery cloth on a
surface that is flat. The surface must be as flat as a
piece of glass. Ifthe emery cloth is new, move a piece of
steel across the emery cloth six times to remove the
sharp pieces of grit. Move the rotor, stator, body, end
plate, or spacer across the emery cloth six times. Then
check to see if the rough places have been removed.
Use this method until all rough places have been
removed. Make sure that the part is kept flat on the
emery cloth as the part is moved across the emery
cloth. C leanthe parts in cleaning solvent to remove any
grit on the parts.
STEP 31
B1757A88J
If the spool, sleeve, or the bore in the body of the
steering control valve is damaged or worn, use a
complete newsteering control valve. The spool, sleeve,
or body of the steering control valve are not available
separately
Bur 812440
STEP 32
Inspect the check valve in the inlet port of the body.
Push the check valve in to see if the spring works cor-
rectly. If the check valve is worn or damaged, use a
complete new steering control valve.
81758A88J
Inspect the Allen head plug, seat, steel ball, and
retainer for damage orwear. Use new parts as required.
STEP 34
81759A88J
Inspect the washers and bearing for damage or wear.
Use new parts as required.
5004-10
STEP 35
8877703M
Inspect the springs, pins, and balls for damage or wear.
Use new parts as required
STEP 36
88473288M
Use a feeler gauge to measure the clearance between
the rotor and stator. Ifthe clearance is more than 0.005
inch (0.13 mm), a newmetering gear set must be used.
Bur 8-12440
STEP 37
B1760A88J
Inspect the gland for damage or wear. Use a newgland
as required.
5004-11
2. END PLATE
9. O-RING
6. STATOR
8. METERING GEAR SET
27. WASHER
8871959J
5004-12
ASSEMBLY
STEP 38
'~~;*a8M
Install a new O-ring inthe bore for the gland. Lubricate
the O-ring with petroleum jelly.
STEP 39
1588M
Put the body of the steering control valve in a vise with
the gland end up Drive the gland into the body of the
steering control valve until the gland stops moving.
STEP 40
Use a screwdriver and punch to start the end of the re-
taining ring into the groove in the body. Push the re-
taining ring into the groove in the body.
Bur 8-12440
STEP 41
1. LARGE
O-RING
852384 1M
Install newO-rings onthe seat for the check valve, Lub-
ricate the O-rings with petroleum jelly, The large O-ring
must be installed on the end of the seat that has
threads,
STEP 42
~,_ BJ3622M
Install the retainer inthe bore for the check valve, Make
sure the retainer is flat in the bottom of the bore,
STEP 43
Install the steel ball in the bore for the check valve,
Issued 10-89 Printed in U,S.A.
STEP 44
Install the seat for the check valve in the bore. The end
of the seat with threads must be up.
STEP 45
Apply a small amount of 242 Loctite on the threads of
the Allen head plug.
STEP 46
___ ,~,___ p1888M
Install and tighten the Allen head plug to 100 pound-
inches (11 Nm).
Bur 8-12440
5004-13
STEP 47
sse.
_~ __ ,_~ __ ,__ ~. ~_,~_~~_,__ . _~, . . -. ---W~__ . ,~
Install the backup ring in the bottom of the gland. Use
petroleum jelly to hold the backup ring in place
STEP 49
.,_." .",.~. ".".. ,~.'-"'-""""-"W'W"-"' .. ~,... 1588M
Install the seal in the gland with the lip for the seal
toward the outside of the body. Drive the seal into the
gland until the seal stops moving.
5004-14
STEP 50
8523633M
Put clean oil on the inside of the sleeve.
STEP 51
8523635M
Put clean oil on the outside of the spool.
STEP 52
23637M
Install the spool in the sleeve. The spool must be in-
stalled straight intothe sleeve. Turn the spool inboth di-
rections as the spool is pushed into the sleeve.
Bur 8-12440
STEP 53
Putthe spool and sleeve inavise with soft jaws. Tighten
the vise just enough to hold the spool and sleeve in po-
sition. Turn the sleeve and move the sleeve on the spool
until the slots in the sleeve and spool for the centering
springs are in alignment.
STEP 54
Install the tool shown on page 5004-2 through the slot
for the centering springs.
STEP 55
Assemble the centering springs in sets of three. Put the
two sets of centering springs in the end of the tool with
the notched corners toward the sleeve. Use your thumb
and finger to compress the centering springs.
STEP 56
Push the centering springs into the spool. Move the tool
as necessary to put the centering springs in position.
STEP 57
8523721M
Install the pin in the sleeve through the spool.
STEP 58
Install the washer, bearing, and the other washer on the
spool.
Bur 8-12440
5004-15
STEP 59
B523919M
Install a new spacer on the spool.
STEP 60
8523728M
Put clean oil on the outside of the sleeve and spool.
STEP 61
8523731M
Put clean oil on the bore in the body of the steering
control valve.
5004-16
STEP 62
The sleeve and spool must be installed straight into the
body of the steering control valve
STEP 63
The pin can move out of the sleeve and spool. Ifthe pin
moves out of the sleeve and spool, the pin can keep the
sleeve and spool from being pushed into the body.
Hold the sleeve and spool in position in the body. Put
theend of the sleeve and spool on the bench. Lower the
body onto the sleeve and spool as shown.
STEP 64
B877702M
Install the balls inthe ports inthe body that are marked
with identification marks.
Bur 8-12440
STEP 65
B877701M
Install the pins in the ports.
STEP 66
Install the springs in the pins.
STEP 67
B8472088M
Put petroleum jelly on the O-ring for the stator. Install the
O-ring in the groove in the stator.
STEP 68
B473688M
Align the rotor and stator and push the rotor into the
stator.
NOTE: The drive shaft must be in the rotor in the
correct position. See step 69.
STEP 69
. 24:lj2
Engage the teeth on the drive shaft in the teeth in the
rotor so the slot inthe end of the drive shaft is between
two teeth on the rotor.
STEP 70
B524117M
C heck the position of the slot in the drive shaft again
and make sure the slot is in the correct position.
Bur 8-12440
5004-17
STEP 71
B8480388M
Install the spacer place on the stator. Turn the spacer
plate to align the holes with the holes in the stator.
STEP 72
Put the body of the steering control valve in the vise.
Apply petroleum jelly on the a-ring for the body of the
steering control valve. Install the a-ring inthe groove in
the body.
STEP 73
Lower the drive shaft into the spool and engage the pin
with the slot inthe drive shaft. DO NOT letthe drive shaft
come out of the rotor. Turn the stator and spacer plate
to align these parts with the body.
5004-18
STEP 74
~. ~ B524128M
Install the spacer in the rotor on top of the drive shaft.
STEP 75
Putclean oil on the metering gear set, spacer plate, and
drive shaft assembly.
STEP 76
B8472388M
Putpetroleum jelly on the O-ring for the end plate. Install
the O-ring in the groove in the end plate.
Bur 8-12440
STEP 77
Install the end plate on the metering gear set. Align the
holes in the end plate with the holes in the stator.
STEP 78
Install the Ferry head screws.
STEP 79
B8450288M
Tighten the Ferry head screws to 100 to 150 pound-
inches (11 to 17 Nm) in the sequence shown.
5004-19
STEP 80
Tighten the Ferry head screws to 225 to 275 pound-
inches (25to 31 Nm) inthe sequence shown i n step 79
5004-20
A
A
1. INLET
CHECK VALVE
SECTION B-B
Bur 8-12440
SECTION A-A
2. DRIVE SHAFT
SECTION C-C
8871967J
Secti on
5005
STEERING CONTROL VALVE - DANFOSS
C ASE C ORPORATION Bur 8-12450 Printed in U.S.A.
5005-2
TABLE OF CONTENTS
SPEC iFiC ATIONS ..... . 2
SPEC IAL TOOL . . . . . . . . . . .2
DISASSEMBLY . . . .3
INSPEC TION . . 7
ASSEMBLY . 10
SPECIFICATIONS
Rotor and stator clearance .. ..0.005 inch (0.13 mm)
Special torques
C ap screws for fastening end plate. .. 212 to 319 pound-inches (24 to 36 Nm)
SPECIAL TOOL
dresses:
In Europe
Inthe U.SA and C anada
Service Tools
P.O. Box 314
VL C hurchill Ltd.
PO Box 3, Daventry
Northants, NN11 4NF
England
B785606M
CAS-1239 Centering Spring Tool
This tool is first used on page 5005-11.
Bur 8-12450 Issued 11-89 Printed in USA
DISASSEMBL Y
5005-3
STEP 1
__ """"'""'............ 870981 OM
Putthe steering control valve inthe vise so the end plate
is up. Loosen the cap screws.
STEP 2
B709812M
Remove the cap screws and flat washers One cap
screw has a guide pin.
STEP 3
Remove the end plate
Bur 8-12450
STEP 4
Remove and discard the O-ring from the stator
STEP 5
Remove the metering gear set and spacer from the
body.
STEP 6
Remove the drive shaft.
Issued 11-89 Printed in U.sA
5005-4
STEP 7
Remove the spacer plate.
STEP 8
B710010M
Separate the metering gear set and spacer.
STEP 9
Remove and discard the other O-ring from the stator.
Bur 8-12450
STEP 10
i!t/ipI
C
; i<.O!lIJIl9834M
Remove and discard the O-ring from the body.
STEP 11
Loosen the plug in the body.
STEP 12
Remove the plug.
STEP 13
B709912M
vise. Turn the body up and let the steel balls, plungers,
and springs fall out of the body.
STEP 14
B709916M
Push the spool and sleeve part of the way out of the
bottom of the body. Turn the sleeve and spool in both
directions and pull the sleeve and spool out of the body.
The pin inside the spool can move out of the sleeve and
spool and keep the sleeve and spool from coming out
of the body, If the sleeve and spool cannot be pushed
out of the body easily, use a magnet to move the pin
inside the spool one way or the other,
STEP 15
B709918M
Remove the washer.
Bur 8-12450
5005-5
STEP 16
B709920M
Remove the bearing,
B710116M
Remove the other washer.
STEP 18
B709926M
5505-6
STEP 19
B709928M
Use apunch to push the pin out of the sleeve and spool.
STEP 20
Pull the spool straight out of the sleeve. Turn the spool
in both directions as the spool is pulled out of the
sleeve.
STEP 21
B709932M
Push the centering springs out of the spool. There are
four centering springs. Do not lose any of the centering
springs.
Bur 8-12450
STEP 22
Use an acceptable tool through the bore of the body
and remove the inner seal. Discard the inner seal.
STEP 23
Remove the outer seal from the bore. Discard the outer
seal.
INSPECTION
5005-7
C lean all parts incleaning solvent. Put the parts on
paper towels until the parts are dry. Do not use cloths to
wipe the parts dry.
C heck all machined surfaces for wear or damage. If
there are rough places on the ends of the stator and
rotor, or on the machined surfaces on the body, end
plate, or spacer plate, make the surfaces smooth by
using 600 grit emery cloth. Put the emery cloth on a
surface that is flat The surface must be as flat as a
piece of glass. Ifthe emery cloth is new, move a piece of
steel across the emery cloth six times to remove the
sharp pieces of grit. Move the rotor, stator, body, end
plate, or spacer across the emery cloth six times. Then
check to see if the rough places have been removed.
Use this method until all rough places have been
removed. Make sure that the part is kept flat on the
emery cloth as the part is moved across the emery
cloth C leanthe parts incleaning solvent to remove any
grit on the parts.
STEP 24
B871978R
If the spool (2), sleeve (3), or bore inthe body (1) of the
steering control valve is damaged or worn, use a
complete new steering control valve. The spool (2),
sleeve (3), or body of the steering control valve are not
available separately
Bur 8-12450
STEP 25
t,./~710008M
Inspect the check valve in the inlet port of the body
Push the check valve in to see if the spring works cor-
rectly If the check valve is worn or damaged, use a
complete new steering control valve.
STEP 26
1. WASHER
C heck the washers (1) and bearing (2) for damage or
wear. Use new parts as needed.
STEP 27
3. BALL
3. BALL
1. SPRING
2. PLUNGER
B709912A
Inspect the springs (1), plungers (2), and bs.lls (3) for
damage or wear. Use new parts as needed.
Issued 11-89 Printed in USA
5005-8
8523912M
Use a feeler gauge to measure the clearance between
the rotor and stator. If clearance is more than 0.005 inch
(0.13 mm), a new metering gear set must be used.
5005-9
12. SPOOL
A
20. CENTERING
SPRINGS
17. O-RING
21. O-RING
B
B871956R
5005-10
ASSEMBLY
STEP 29
B710018M
Lubricate the inner seal with clean oil.
STEP 30
The inner seal is not difficult to install. Install the inner
seal through the opposite end of the bore shown in the
photograph. Use your fingers to seat the inner seal
against the body. Make sure the lips of the inner seal
are toward the inside of the body
STEP 31
G !;f ;j ~028M
Install the outer seal inthe body with the lips of the outer
seal toward the outside of the body.
Bur 8-12450
STEP 32
8710030M
Use an acceptable driver and hammer and drive the
outer seal against the seat in the bore.
STEP 33
B710034M
Put clean oil on the inside of the sleeve.
STEP 34
8710036M
Put clean oil on the outside of the spool.
STEP 35
B710102M
Install the spool in the sleeve. The spool must be in-
stalled straight into the sleeve. Turn the spool inboth di-
rections as the spool is pushed into the sleeve.
STEP 36
Putthe spool and sleeve inavise with soft jaws. Tighten
the vise just enough to hold the spool and sleeve in po-
sition.Turn thesleeve and move the sleeve on the spool
until the slots in the sleeve and spool for the centering
springs are in alignment.
STEP 37
Install the tool shown on page 5005-2 through the slot
for the centering springs.
Bur 8-12450
5005-11
STEP 38
1. FLAT SPRING 1. FLAT SPRING
< r
2. C URVED SPRINGS
B871957R
Install the centering springs as shown inthe illustration.
STEP 39
,. 1Ql2Q~_
Putthe two flat springs inthe slot of the tool with the two
curved springs between the flat springs.
STEP 40
Use your thumb and finger to compress the centering
springs. Push the centering springs into the spool.
Move the tool as necessary to put the centering springs
in position.
5005-12
STEP 41
8710118M
Install the retaining ring, The retaining ring must be able
to rotate free of the centering springs.
STEP 42
8710120M
Install the washer, bearing, and the other washer on the
spool. See step 43.
Thewasher with the chamfer must be installed nearest
the sleeve as shown in the illustration.
Bur 8-12450
STEP 44
Put clean oil on the outside of the sleeve and spool.
STEP 45
8710126M
;-.'-~':Z-~" -:>-;':'<~. " ~::<:$:~~~-" ~'
Install the pin in the sleeve and through the spool.
STEP 46
Put clean oil in the bore in the body.
STEP 47
B710128M
The sleeve and spool must be installed straight into the
body of the steering contro Ivalve. The pin can move out
of the sleeve and spool. If the pin moves out of the
sleeve and spool, the pin can keep the sleeve and
spool from being pushed into the body. Hold the sleeve
and spool in position in the body. Put the end of the
sleeve and spool onthe bench and lower the body onto
the sleeve and spool.
STEP 48
Put the body of the steering control valve in the vise.
Install the large steel ball.
STEP 49
Install the plug.
Bur 8-12450
5005-13
STEP 50
Tighten the plug
STEP 51
Install one of the small steel balls
STEP 52
Install the other small steel ball in the port shown.
5005-14
STEP 53
Install the spring and plunger.
STEP 54
Install the other spring and plunger.
STEP 55
Install the O-ring in the groove in the body.
Bur 8-12450
STEP 56
B710218M
Apply petroleum jelly on each O-ring for the stator
Install an O-ring inthe groove in each side of the stator.
STEP 57
B710220M
Align the rotor and stator and install the rotor in the
stator.
STEP 58
B710224M
The drive shaft must be installed in the rotor in the
correct position. Engage the teeth on the drive shaft
and the teeth in the rotor so the slot in the end of the
drive shaft is between the two teeth on the rotor.
STEP 59
8710228M
Install the spacer plate on the stator. Turn the spacer
plate to align the holes with the holes in the stator.
STEP 60
710212M
Hold the metering gear set, spacer plate, and drive
shaft as an assembly in position over the body of the
steering control valve. Turn the metering gear set,
spacer plate, and drive shaft assembly to put the slot in
the end of the drive shaft inalignment with the pin inside
the spool Lower the metering gear set, spacer plate,
and drive shaft assembly into position on the body.
Turn the metering gear set, spacer plate, and drive
shaft assembly a small amount in one direction or the
other until the slot inthe drive shaft is engaged with the
pin inside of the spool Turn the spacer plate and stator
to align the ho!es with the holes in the body.
Bur 8-12450
5005-15
STEP 61
'B710232M
Putclean oil on the metering gear set. spacer plate, and
drive shaft assembly.
STEP 62
Install the spacer in the rotor on top of the drive shaft.
STEP 63
709820M
Install the end plate. Align the holes inthe end plate with
the holes in the stator.
5005-16
STEP 64
B709816M
Install the cap screw with the guide pin in the hole
shown.
STEP 65
B709812M
Install the remaining cap screws and flat washers.
Bur 8-12450
STEP 66
Tighten the cap screws to 100 to 150 pound-inches (11
to 17 Nm) in the sequence shown.
STEP 67
to 36 Nm) in the sequence shown in step 66.
C ASE C ORPORATION
Secti on
5006
STEERING CYLINDER REPAIR
Bur 8-17280
Printed in U.S.A.
5006-2
TABLE OF CONTENTS
SPEC IFIC ATIONS 3
TWO WHEEL DRIVE STEERING C YLINDER .4
Disassembly 4
Inspection 4
Assembly 6
FOUR WHEEL DRIVE STEERING C yLINDER 8
Disassembly 8
Inspection 9
Assembly 9
5006-3
SPECIFICATIONS
Two wheel drive steering cylinder tie rod nuts 324 to 504 pound-inches (37 to 57 Nm).
5006-4
TWO WHEEL DRIVE STEERING CYLINDER
Di sassem bl y
1. C lean the outside of the steering cylinder (1).
2. Fasten the steering cylinder (1) in a vise or other
holding equipment. Be careful to prevent damage to
the tube (16)
3. One end of the piston rod (10) has two flat areas to
prevent the piston rod (10) from turning when the lock
nuts (3) for the rod eyes (2 and 17) are loosened. The
rod eye (2) at the end of the piston rod (10) that has two
flat areas has LH threads. Prevent the piston rod (10)
from turning, loosen the lock nut (3), and turn the rod
eye (2) out of the piston rod (10).
4. The rod eye (17) inthe other end of the piston rod has
RH threads. Prevent the piston rod (10) from turning,
loosen the lock nut (3) and turn the rod eye (17) out of
the piston rod (10).
5. Loosen and remove the nut (4) from each tie rod (5)
and remove the tie rods (5) that hold the steering
cylinder (1) together.
6. Pull one end of the piston rod ("10)straight out of the
tube (16) until the piston (11) contacts the gland (8)
7. Use a soft hammer to drive the gland (8) out of the
tube (16) and pull the piston rod (10) straight out of the
tube (16) to prevent damage to the tube (16).
8. Remove the gland (8) from the piston rod (10).
9. Use a soft hammer to drive the gland (8) out of the
other end of the tube (16). Remove the gland (8 or 19).
NOTE: The piston (11) cannot be removed from the
piston rod (10). If the piston (11) or the piston rod (10) is
damaged, the piston rod assembly (10 and 11) must be
replaced.
Bur 8-17280
10. Remove the wear ring (12) from the piston (11).
Remove the seal (13) and backup ring (15) from the
piston (11).
11. Remove the O-ring (9) and backup ring (14 ) from
the outside of each gland (8). Remove the wiper (6) and
seal (7) from the bore of each gland (8).
In specti on
1. Discard the parts removed from the piston (11) and
the glands (8).
2. C lean all parts in cleaning solvent.
3. Illuminate the inside of the tube (16). Inspect the
inside of the tube (16) for deep grooves and other
damage. Ifthere is damage to the tube (16), a newtube
(16) must be used.
4. C heck to be sure that the piston rod (10) is straight. If
the piston rod (10) is not straight, install a new piston
rod assembly (10 and 11).
5. Inspect the piston (11) for damage and wear. If the
piston (11) is damaged, or worn, a new piston rod
assembly (10 and 11) must be used.
6. Remove small scratches on the piston rod (10) and
inside the tube (16) with emery cloth of medium grit.
Use the emery cloth with a rotary motion.
7. Inspect both ends of the tube (16) for sharp edges
that will cut the gland O-rings (9) and remove the sharp
edges as necessary.
8. Inspect both glands (8) for rust. C lean and remove
rust as necessary.
Two Wheel Dri ve Steeri n g Cyl i n der - Expl oded Vi ew
Bur 8-17280 Issued 1-91 Printed i n U.S.A
5006-6
Assembl y
8. GLAND
8861554
Gland
1. Install a new seal (7) into the bore of each gland (8).
The lips of the seal (7) must be toward the inside of the
steering cylinder (1). The seal (7) can be difficult to
install. Do not damage the seal (7).
2. Install a new wiper (6) into the bore of each gland (8).
The lip of the wiper (6) must be toward the outside end
of the gland (8).
3. Install a new backup ring (14) inthe groove on each
gland (8).
4. Install a new O-ring (9) in the groove on each gland
(8). The O-ring (9) must be between the backup ring
(14) and the small end of the gland (8),
88861555
Piston
Bur 8-17280
5. Install a new wear ring (12) in the wide groove inthe
piston (11).
6. Install a new backup ring (15) inthe narrow grcAe in
the piston (11).
7. Install a new seal (13) on top of the backup ring (15).
8. Fasten the tube (16) in the vise or other holding
equipment. Be careful to prevent damage to the tube
(16).
9. Lubricate the bore of the tube (16) with clean oil.
10. Lubricate the O-ring (9 and 17) on both glands (8)
and the bore of both glands (8) with clean oil.
11. Remove any marks and sharp edges on the
chamfers at the end of the piston rod assembly (10 and
11). Make sure that the piston rod (10) is clean.
12. Lubricate the piston (11) with clean oil.
13. Install one of the glands (8) in the tube (16).
14. Push the other gland (8) onto the piston rod
assembly (10).
15. Push the piston rod assembly (10) straight into the
tube (16), and through the gland (16) at the other end of
the tube (16).
16. C arefully start the other gland (8) into the tube (16).
17. Make sure the ports in both glands (8) are installed
correctly and drive the gland (8) into the tube (16).
18. Install the tie rods (5) and nuts (4). Tighten the nuts
to 324 to 504 pound-inches (37 to 57 Nm).
19. The rod eye (2) for the end of the piston rod (10) that
has two flat areas has LH threads. Prevent the piston
rod (10) from turning, and turn the rod eye (2) into the
piston rod (10).
20. The rod eye (17) for the other end of the piston rod
(10) has RH threads. Prevent the piston rod from
turning, and turn the rod eye (17) into the piston rod
(10).
21. Do not tighten the lock nuts for the rod eyes (2 and
17) until after installation of the steering cylinder (1).
Two Wheel Drive Steering C ylinder - Exploded View
5006-8
FOUR WHEEL DRIVE STEERING CYLINDER
Di sassembl y 5. Remove the wiper (13), backup ring (12), and the
seal (11) from the closed end of the tube (10).
1. Fasten the tube (10) in avise or other holding equip-
ment. Do not damage the tube (10). 6. Fasten the piston rod assembly (7) in avise with soft
jaws
2. Separate the gland (5) from the tube (10).
3. Remove the gland (5) from the piston rod assembly
(7).
7. Remove the wear rings (9), seal (8), and the backup
ring (14) from the piston rod assembly (7)
4. Pull the piston rod assembly (7) straight out of the
tube (10) to prevent damage to the tube (10).
8. Remove the O-ring (6), wiper (2), backup ring (3),
and the seal (4) from the gland (5).
1. STEERING CYLINDER
7. PISTON ROD ASSEMBLY
8902049J
Four Wheel Drive Steering C ylinder - Exploded View
In specti on
1. Discard the parts that were removed from the gland,
piston rod assembly, and the tube (10).
2. C lean all parts in cleaning solvent.
3 Inspect the gland, piston rod assembly, and the tube
for damage and wear. These parts are not serviced se-
parately, if these parts need to be replaced. a new
steering cylinder must be used.
Assembl y
See the cross sectional view of the steering cylinder
on page 10.
1. Install a new seal (4) in the gland (5). The lip of the
seal (4) must be toward the inside of the gland (5).
2. Install a new backup ring (3) next to the gland (5).
3. Install a newwiper (2) inthe gland (5). The lip of the
wiper (2) must be toward the outside of the gland (5).
4. Install a newO-ring (6) inthe groove on the outside of
the gland (5).
5. Fasten the piston rod assembly (7) ina vise with soft
jaws.
Bur 8-17280
5006-9
6. Install a new backup ring (14) inthe center groove of
the piston rod assembly (7).
7. Install a new seal (8) on top of the backup ring (14) in
the center groove of the piston rod assembly (7).
8. Install a newwear ring (9) inthe groove on each side
of the seal (8).
9. Lubricate the seal (8) and wear rings (9) with clean oil.
Use a piston ring compression tool to hold the new
wear rings (9) in place.
10. Start the tube (10) onto the piston rod assembly (7).
Push the tube (10) onto the piston rod assembly (7) until
the compression tool is pushed off the piston rod
assembly (7). Be careful not to damage the wear rings
(9) and the seal (8).
11. Fasten the tube (10) inavise with soft jaws. Pushthe
piston rod assembly (7) all the way into the tube (10).
12. Lubricate the wiper (2), backup ring (3), seal (4),
and O-ring (6) on the gland (5) with clean oil.
13. Install the gland (5) on the piston rod assembly (7)
and push the gland (5) against the tube (10).
5006-10
5. GLAND
10. TUBE
Bur 8-17280
8. SEAL
Issued 1-91
B9020SOJ
Printed in U.S.A
Secti on
5007
FRONT AXLE, TWO WHEEL DRIVE.MACHINES
C ASE C ORPORATION Bur 8-12471 Printed in U.S.A.
5007-2
TABLE OF CONTENTS
SPEC IFIC ATIONS. 2
FRONT WHEEL BEARINGS 3
Removal and Disassembly . . .. . . .3
Inspection . . . . . . .5
Assembly and Installation . .. . . 7
Wheel Bearing Adjustment 10
SPLINDLE ................................ 11
Removal . ....11
Installation 16
KiNGPIN BEARINGS AND THRUST BEARINGS . . ...21
Removal . .....21
Installation. . 25
TOE-IN 30
Measuring Toe-In 30
Adjustment 30
SPECIFICATIONS
Service
Toe-In 0 to 3/16 inch (0 to 5 mm)
C lean and lubricate front wheel bearings After every 500 hours of operation
Wheel bearing grease Number 2 wheel bearing grease
Special Torques
Wheel bearing nut. . 75 to 85 pound-feet (101 to 115 Nm) with wheel turning.
Then loosen a maximum of 1/16 turn
Front wheel bolts 115 to 150 pound-feet (156 to 203 Nm)
Steering cylinder lock nuts 150 to 200 pound-feet (203 to 271 Nm)
FRONT WHEEL BEARINGS
5007-3
Removal an d Di sassembl y
STEP 1
r i ' ! ! Y
Raise the front wheel and put an acceptable support
under the front axle.
STEP 2
Loosen and remove the wheel bolts. Remove the
wheel.
STEP 3
Remove the cap
Bur 8-12471
STEP 4
Remove the cotter pin.
STEP 5
Remove the nut.
STEP 6
Pull the hub toward you to remove the outer wheel
bearing from the spindle. Itcan be necessary to hit the
hub with a soft hammer.
Issued 1-91 Printed in U.SA.
5007-4
STEP 7
Remove the flat washer and wheel bearing.
STEP 8
Remove the hub.
STEP 9
Use a chisel to move the spindle seal away from the
spindle.
Bur 8-12471
STEP 10
Use two prybars and remove the spindle seal.
STEP 11
Remove the dirt and grease from the spindle.
STEP 12
Put an acceptable driver on top of the wheel bearing.
STEP 13
Press the hub seal and wheel bearing out of the hub.
STEP 14
Use a hammer and punch and remove the outer
bearing cup from the hub only if inspection indicates
the need for a new bearing cup or wheel bearing.
Bur 8-12471
5007-5
STEP 15
Use a hammer and punch and remove the inner
bearing cup from the hub only if inspection indicates
the need for a new bearing cup or wheel bearing.
In specti on
1. C lean the wheel bearings in cleaning solvent to
remove all indications of grease from the wheel bear-
ings.
2. C heck the bearing cups for scoring, flat areas, and
pitting.
3. Inspect the rollers inthe wheel bearings for flat areas,
scoring and other damage. Also check the inner race
for wear and damage.
5007-6
Bur 8-12471
Assembl y an d In stal l ati on
STEP 16
B0213?9M
Fill each wheel bearing with the grease specified on
page 5007-2.
STEP 17
Start the outer bearing cup into the hub.
STEP 18
Use an acceptable driver and press the bearing cup all
the way into the hub.
Bur 8-12471
5007-7
STEP 19
Start the inner bearing cup into the hub.
STEP 20
Use an acceptable driver and press the bearing cup all
the way into the hub.
STEP 21
Put the other wheel bearing in the hub.
5007-8
STEP 22
3. HUB SEAL
4. SPINDLE SEAL B891546J
Thehub seal must be installed as shown in the illustra-
tion.
STEP 23
Putthe hub seal on an acceptable driver.
Bur 8-12471
STEP 24
Press the hub seal into the hub until the hub seal stops
moving. Be careful not to damage the hub seal by
using too much pressure.
STEP 25
Drive the newspindle seal all the way onto the spindle.
Be careful not to damage the spindle seal.
STEP 26
Fill the groove in the hub seal with wheel bearing
grease.
STEP 27
Install the hub onto the spindle.
STEP 28
Install the outer wheel bearing.
STEP 29
Install the flat washer and nut.
Bur 8-12471
5007-9
STEP 30
Tighten the nut to 75 to 85 pound-feet (101 to 115 Nm)
and turn the hub at the same time. Then loosen the nut
to the first cotter pin hole.
STEP 31
Install the cotter pin.
STEP 32
Install the cap
5007-10
STEP 33
Install the wheel and wheel bolts. Do not use an impact
wrench to install the wheel bolts.
STEP 34
1.......
t. ..
. !" >': : ; u
Remove the support from under the front axle and lower
the wheel to the floor.
STEP 35
Tightenthe wheel bolts to 115 to 150 pound-feet (156to
203 Nm).
Bur 8-12471
Wheel Bearing Adjustment
The following photographs show the hub with the
wheel off. It is not necessary to remove the wheel from
the hub to adjust the wheel bearing
STEP 36
Remove the cap .
STEP 37
Turn the wheel or hub and tighten the nut to 75 to 85
pound-feet (101 to 115 Nm). Then loosen the nut to the
first cotter pin hole.
STEP 38
Install a new cotter pin.
STEP 39
Install the cap
5007-11
SPINDLE
Removal
STEP 40
Raisethe front wheel off the floor and put an acceptable
support under the front axle.
STEP 41
wheel.
Bur 8-12471
STEP 42
Remove the cap.
STEP 43
Remove the cotter pin.
5007-12
STEP 44
Remove the nut.
STEP 45
Pull the hub toward you to remove the outer wheel
bearing from the spindle. It can be necessary to hit the
hub with a soft hammer.
STEP 46
Remove the flat washer and wheel bearing.
Bur 8-12471
STEP 47
Remove the hub.
STEP 48
Loosen the nut on the lock pin.
STEP 49
Remove the nut and lock washer.
STEP 50
Drive the lock pin out of the spindle.
STEP 51
Loosen the nuts on the bolts that hold the pivot pin for
the steering link.
STEP 52
Drive the pivot pin out of the steering link.
Bur 8-12471
5007-13
STEP 53
Remove the snap ring. The O-rings used between the
spacer and bearing will cause the snap ring to be diffi-
cult to remove.
STEP 54
Remove the spacer.
STEP 55
Remove the O-ring.
5007-14
STEP 56
Remove the snap ring at the bottom of the king pin
STEP 57
Remove the spacer.
STEP 58
Remove the O-ring.
Bur 8-12471
STEP 59
Drive the king pin toward the top to prevent damage to
the seal.
STEP 60
Remove the spindle and thrust bearing.
STEP 61
5007-15
---
8891545J
36. COlTER
PIN
Bur 8-12471
Issued 1-91
Printed in U.S.A.
5007-16
Installation
STEP 62
Put the thrust washer on the bottom boss.
STEP 63
Install the spindle.
STEP 64
The case of the thrust bearing must be on top when the
thrust bearing is installed.
Bur 8-12471
STEP 65
Install the thrust bearing. Remember, the case must be
on top.
STEP 66
Align the spindle, thrust bearing, and thrust washer with
the front axle. Install the kingpin so that the notch for the
lock is toward the outside.
STEP 67
Hold the spindle and push the kingpin into place.
STEP 68
Install the lock pin.
STEP 69
Install the lock washer and nut but do not tighten the nut
now.
STEP 70
Install a new O-ring in the bottom boss. Use grease to
hold the O-ring in place.
Bur 8-12471
5007-17
STEP 71
Apply a small amount of grease to a spacer and install
the spacer so that the grease fitting is toward the center
of the machine.
STEP 72
Install the snap ring. Hit the spacer and snap ring to
make sure that the snap ring is in the groove.
STEP 73
5007-18
STEP 74
Install the spacer so that the grease fitting is toward the
center of the machine.
STEP 75
Install the snap ring.
STEP 76
Hitthespacer and snap ring to make sure that the snap

ring is in the groove.
Bur 8-12471
STEP 77
Tighten the nut that holds the lock pin.
STEP 78
Align the steering linkwith the spindle and start the pivot
pin into the steering link.
STEP 79
Drive the pivot pin into the steering link.
STEP 80
.~ ... ~.-
,~ -.,; : ..: .>>;
~?~
Tighten the nuts on the bolts that hold the pivot pin.
STEP 81
Drive the spindle seal all the way onto the spindle Be
careful not to damage the spindle seal.
STEP 82
Fill the groove in the hub seal with the wheel bearing
grease specified on page 5007-2.
Bur 8-12471
5007-19
STEP 83
Install the hub onto the spindle.
STEP 84
Install the outer wheel bearing.
STEP 85
Install the flat washer and nut
5007-20
STEP 86
Tighten the nut to 75 to 85 pound-feet (101 to 115 Nm)
and turn the hub at the same time. Then loosen the nut
to the first cotter pin hole.
STEP 87
Install the cotter pin.
STEP 88
Install the cap.
Bur 8-12471
STEP 89
STEP 90
STEP 91
Tighten the wheel bolts to 115 to 150 pound-feet (156 to
203 Nm).
STEP 92
Lubricate the bearings for the kingpin. Lubricate the tie
rod ends.
5007-21
KINGPIN BEARINGS AND THRUST BEARINGS
STEP 96
Raise the front wheel and put an acceptable support
STEP 94
wheel.
STEP 95
Loosen and remove the nut and lock washer from the
lock pin
Bur 8-12471
Drive the lock pin out of the spindle.
STEP 97
Remove the snap ring. The O-ring used between the
spacer and bearing will cause the snap ring to be diffi-
cult to remove.
STEP 98
Remove the spacer.
Issued 1-91 Printedin USA.
5007-22
STEP 99
Remove the O-ring.
STEP 100
Remove the snap ring at the bottom of the kingpin.
STEP 101
Remove the spacer
Bur 8-12471
STEP 102
Remove the O-ring.
STEP 103
Drive the kingpin out of the spindle.
STEP 104
Remove the spindle and thrust bearing and put the
spindle out of the way.
STEP 105
STEP 106
Use an acceptable driver and drive the top bearing out
of the boss.
Bur 8-12471
5007-23
STEP 107
Remove the seal.
STEP 108
Drive the bottom bearing out of the boss.
5007-24
2. GREASE
FITTING
36. COTTER
PIN
Bur 8-12471
Issued 1-91
B891545J
Printed in U.S.A.
Installation
STEP 109
Clean the bores for the bearings.
STEP 110
Put a bearing on a driver that has a pilot end. The
number on one end of the bearing must be toward the
driver. The tape on the driver is 1/4 inch from the
bearing to help install the bearing to the correct depth.
STEP 111
Drive the bearing into the bottom boss until the tape is
even with the top of the boss.
Bur 8-12471
5007-25
STEP 112
Install the seal on an acceptable driver so that the lip is
toward the driver. The driver must have a larger
diameter that the seal.
STEP 113
Drive the seal into the boss until the driver touches the
boss.
STEP 114
Put the bearing on the driver so that the end of the
bearing with the number is toward the driver.
5007-26
STEP 115
Drive the bearing into the boss until the bearing is even
with the bottom of the boss.
STEP 116
Clean the bore in the spindle.
STEP 117
Bur 8-12471
STEP 118
Install the spindle.
STEP 119
The case of the thrust bearing must be on top when the
thrust bearing is installed.
STEP 120
Install the thrust bearing so that the case is on top.
STEP 121
Align the spindle, thrust washer and thrust bearing with
the front axle. Start the kingpin into the spindle so that
the notch for the lock pin is toward the outside.
STEP 122
"
Use a soft hammer and drive the kingpin into the
spindle.
STEP 123
Install the lock pin.
Bur 8-12471
5007-27
STEP 124
Install the lock washer and nut. Do not tighten the nut at
this time.
STEP 125
Install a new O-ring in the bottom boss. Use grease to
hold the O-ring.
STEP 126
Apply a small amount of grease to a spacer and install
the spacer so that the grease fitting is toward the center
of the machine.
5007-28
STEP 127
Install a snap ring.
STEP 128
Hitthe spacer and snap ring to make sure that the snap
STEP 129
Install a new O-ring in the top boss.
Bur 8-12471
STEP 130
Install the spacer so that the grease fitting is toward the
center of the machine.
STEP 131
STEP 132
Hit the spacer and snap ring to make sure that the snap
STEP 133
Tighten the nut on the lock pin.
STEP 134
Bur 8-12471
5007-29
STEP 136
Tighten the wheel nuts to 115 to 150 pound-feet (156to
203 Nm).
STEP 137
Lubricate the bearings for the kingpins.
5007-30
TOE-IN
Measuring Toe-In
1. Raisethe front of the machine until the front wheels
are free of the floor.
2. Holdatool that has a sharp point against the center
of the tire tread.
3. Hold the tool in one place and rotate the wheel to
make afine line around the tire. Repeat this procedure
for the other front wheel.
4. Lower the front wheels to the floor.
5. Turnthe steering wheel as needed to put the front
wheels in the straight position.
6. Measure the distance between the marks at the
front and rear of the tires.
1. Mark Around Center of Tire
2. Steering Cylinder
3. Loosen Lock Nuts and Turn
Piston Rod as Required
Bur 8-12471
7. The measurement at the rear of the tires must be 0
to 3/16 inch (0to 5 mm) more than the measurement at
the front of the tires.
Adjustment
1. Loosen the lock nut at each end of the piston rod for
the steering cylinder
2. Turn the piston rod as needed to increase or
decrease the toe-in.
3. When the toe-in is correct, tighten the lock nut
nearest the flat on the piston rod first to 150 to 200
pound-feet (203to 271 Nm). Then tighten the other lock
nut to 150 to 200 pound-feet (203 to 271 Nm).
B
..
A
B861482R
Measurement BMust BeEqual To or Up To 3/16
Inch (5mm) Less Than Measurement A
Section
5008
FRONT AXLE - FOUR WHEEL DRIVE
CASE CORPORATION
5008-2
TABLE OF CONTENTS
SPECIFICATIONS 3
SPECIAL TOOLS 3
MEASURING TOE-I N . 4
DISASSEMBLY OF PLANETARy 5
INSPECTION OF PLANETARY PARTS 9
ASSEMBLY OF PLANETARy 11
REMOVAL AND DISASSEMBLY OF SWIVEL HOUSiNG 16
REPLACING A UNIVERSAL J OINT 19
ASSEMBLY AND INSTALLATION OF SWIVEL HOUSiNG 24
REMOVAL OF DIFFERENTIAL CARRIER 28
DISASSEMBLY OF DIFFERENTIAL CARRIER 30
DISASSEMBLY OF DIFFERENTIAL 33
INSPECTION OF DIFFERENTIAL PARTS 34
ASSEMBLY OF DIFFERENTIAL 36
ASSEMBLY OF DIFFERENTIAL CARRIER 39
INSTALLATION OF DIFFERENTIAL CARRIER 45
SPECIFICATIONS
Backlash for ring gear 0.008 to 0.010 inch (0.20 to 0.25 mm)
Rotating torque for pinion shaft without seal 10 to 20 pound-inches (1.1 to 2.3 Nm)
Gear lubricant . ............................................................. CaselH Gear Lube (85W-140)
Capacities
Center bowl 7.4 U.S. quarts (7 litres)
Planetary (each) 1.1 U.S. quart (1 litre)
Special torques
Studs for wheels 52 pound-feet (70 Nm)
Wheel nuts 200 to 240 pound-feet (270 to 325 Nm)
Allen screws for planetary cover with 242 Loctite 300 pound-inches (34 Nm)
Allen screws for carrier 59 pound-feet (80 Nm)
Nut for ball joint 125 to 135 pound-feet (169 to 180 Nm)
Cap screws for king pin 101 pound-feet (137 Nm)
Cap screw for lock for adjusting ring 84 pound-inches (9.5 Nm)
Cap screws for bearing caps 115 pound-feet (156 Nm)
Cap screws for differential case with 271 Loctite 52 pound-feet (70 Nm)
Cap screws for bearing caps 74 pound-feet (100 Nm)
Cap screws for steering cylinder 66 to 79 pound-feet (90 to 107 Nm)
Cap screws for hub for ring gear 184 pound-feet (299 Nm)
SPECIAL TOOLS
5008-3
The special tools shown on this page arerequired to
disassemble and assemble the planetaries and dif-
ferential.
In the US. and Canada, order the tools from
Service Tools
P.O. Box 314
Owatonna, MN 55060
VL Churchill Ltd
Northants NN11 4NF
England
B875432M
1. CAS-1839-1 Gauge Tube
2. CAS-1839-2 Gauge Block
3. CAS-1668 Metric Feeler Gauge
4. CAS-1596A-3 Pilot
5. CAS-1596A-4 Handle
6. 7116-A9 Stud
CAS-1839 Pinion Setting Kit. Shown in use during
assembly of differential carrier beginning in step 188.
Bur 8-17300
B4097388M
CAS-1840B Spanner Wrench. Shown in use in step
150.
B4086.290M
CAS-2151 Wrench For Pinion Nut. Shown inuse instep
156.
B4094788M
Yoke to hold shaft. Order D149861 from J I Case. Not
Shown in use in step 156.
5008-4
B4094188M
CAS-1842 Wheel Stud Removal and Installation.
Shown in use in step 3.
' B4t068ssM
CAS-1980 V-Blade. Used to support coupling when
replacing a universal joint. First used in step 74.
B40974B8M
CAS-2151 Wrench to loosen and tighten tie rods for
steering cylinder. Shown in use in step 139.
, ...,: B4095oeaM
CAS-10468 Puller. Used to remove ball joint fromswivel
housing. Used in step 57.
MEASURING TOE-IN
B
1
A
B870171J
1. Mark Around Center of Tire
2. Steering Cylinder
3. Loosen Clamps and Tum Piston Rod as Required
Bur 8-17300
Measurement B Must Be Equal To Or Up To
3/16 Inch (5 mm) Less Than Measurement A
DISASSEMBLY OF PLANETARY
5008-5
STEP 1
Raise the wheel(s) off the floor and use suitable
supports to hold the machine in place
STEP 2
Remove the nuts and hardened washers and remove
the wheel(s).
STEP 3
Two flanged studs hold the carrier. Use tool CAS-1842
to remove the flanged studs.
STEP 4
Remove the two Allen head screws that hold the carrier.
Bur 8-17300
STEP 5
Use chisel to separate the carrier from the planetary
housing.
STEP 6
Put a drain pan below the planetary and use two
prybars to loosen the carrier.
STEP 7
Remove the carrier.
5008-6
STEP 8
Remove the snap ring and sun gear.
STEP 9
Remove the spacer and thrust washer.
STEP 10
Remove the cap screws.
Bur 817300
STEP 11
Install the cap screws just removed in the threaded
holes inthe hub and tighten the cap screws evenly until
the ring gear is free of the swivel housing.
STEP 12
Remove the ring gear.
STEP 13
Use a puller bar, a 1/4 inch (6 mm) thick spacer
between the axle shaft and puller bar, and 12 mm x 3
inch cap screws to remove the outer bearing from the
swivel housing.
STEP 14
Remove the planetary housing and wheel bearing.
STEP 15
Slide the inner wheel bearing off the swivel housing.
STEP 16
Bur 8-17300
5008-7
STEP 17
Remove the hub.
STEP 18
Press the bushings from the hub only if new bushing(s)
are needed or a new hub is being installed.
STEP 19
Remove the snap rings.
5008-8
STEP 20
STEP 21
Remove the pinion gears and thrust washers being
careful not to lose the needles.
STEP 22
Remove the Allen head screws and remove the cover.
Bur 8-17300
STEP 23
Press the pinion shafts out of the carrier.
STEP 24
Remove the bearing cups and seal as required.
5008-9
INSPECTION OF PLANETARY PARTS
1. Clean all parts in cleaning solvent.
2. Inspect the bearing cup and the rollers in the wheel
bearings for flat areas, pitting, scoring and other
damage. Also check the inner race for damage. Ifanyof
these defects are found, a new wheel bearing and
bearing cup must be installed.
3. Inspect the pinion shafts for wear and damage.
Bur 8-17300
4. Inspect the teeth of the pinion gears, sun gear and
ring gear for wear, pitting, scoring and other damage.
Use new parts as required.
5. Inspect the needles for the pinion gears for flat areas,
pitting, scoring and other damage. If any of these
defects are found, also inspect the bore of the pinion
gears and use new parts as required.
6. Inspect the splines on the axle shaft and sun gear for
wear and damage.
5008-10
1. Me Shaft 8. Retaining Ring 15. Sun Gear 22.Carrier
2. Seal 9. Hub 16. Snap Ring 23. Allen Head Screw
3. Bearing 10. Ring Gear 17. Retainer 24. Flanged Stud
4. Bearing Cup 11. Bushing 18. Pinion Gear 25. Plug
5. Planetary Housing 12. Cap Screw 19. Needles 26. Pinion Shaft
6. Dowel Pin 13. Washer 20. Thrust Washer 27. Cover
7. Stud 14. Spacer 21. Thrust Button
5008-11
ASSEMBLY OF PLANETARY
STEP 28
Press the pinion shafts into the carrier until the innerend
of the pinion shafts are 1.350 to 1.450 inch (34.3 to 36.8
mm) from the machined surface on the carrier.
STEP 25
Drive or press new bearing cups into the planetary
housing.
STEP 26
The words OIL SEAL on the seal must be to the inside.
STEP 27
Drive a newseal into the planetary housing. Be careful
not to damage the seal.
Bur 8-17300
STEP 29
127M
Apply petroleum jelly to one side and the bore of the
pinion gears.
STEP 30
Install a thrust washer.
5008-12
STEP 31
Install 30 needles in each pinion gear using petroleum
jelly to hold the needles in place.
STEP 32
Install the pinion gears so that the thrust washer is
toward the carrier
STEP 33
Install the retainer and snap rings.
Bur 8-17300
STEP 34
Make sure that the threads in the pinion shafts are free
of lubricant.
STEP 35
Apply 242 Loctite to the threads in the pinion shafts.
STEP 36
Install the cover and Allen head screws and tighten the
Allen head screws to 300 pound-inches (34 Nm).
STEP 37
Press bushings into the hub as required.
STEP 38
Install the hub.
STEP 39
Install the retaining ring.
Bur 8-17300
5008-13
STEP 40
Install a bearing on the swivel housing.
STEP 41
Lubricate the bearings with gear lubricant.
STEP 42
Install the planetary housing and the other bearing.
5008-14
STEP 43
Align the large diameter bushing with the large hole in
the swivel housing and install the ring gear.
STEP 44
Install and tighten the cap screws evenly to pull the ring
gear against the swivel housing.
STEP 45
Tighten the cap screws to 184 pound-feet (2'4-QNm).
Bur 8-17300
STEP 46
Install the thrust washer and spacer.
STEP 47
Install the sun gear and snap ring.
STEP 48
Apply form-in-place gasket material to the planetary
housing.
STEP 49
Install the carrier.
STEP 50
Install and tighten the Allen head screws to 59 pound-
feet (80 Nm).
Bur 8-17300
5008-15
STEP 51
Use tool CAS-1842 and install and tighten the studs to
52 pound-feet (70 Nm).
STEP 52
Fill the planetary(ies) with 1.1 U.S. quart (1 litre) of
CaselH Gear Lube.
STEP 53
Install the wheel(s), hardened washers and nuts.
Tighten the nuts to 200 to 240 pound-feet (270 to 325
Nm).
5008-16
REMOVAL AND DISASSEMBLY OF SWIVEL HOUSING
STEP 54
Do the necessary steps under Disassembly of Plane-
tary for access to the swivel housing,
STEP 55
Slide the inner wheel bearing off the swivel housing,
STEP 56
Remove the cotter pin and loosen but do not remove
the nut.
STEP 57
Use the CAS-10468 puller to loosen the ball joint.
Bur 8-17300
STEP 58
B90762tGM
Remove the nut and remove the ball joint from the
swivel housing,
STEP 59
Loosen the cap screws that hold the top king pin,
STEP 60
Remove the top king pin. Be careful not to damage the
shims,
STEP 61
Remove the shims and keep for use during assembly.
STEP 62
Repeat steps 59 through 61 for the bottom king pin.
STEP 63
Remove the swivel housing.
STEP 64
Remove the axle shaft.
Bur 8-17300
5008-17
STEP 65
Remove the seal for each king pin.
STEP 66
Use a suitable puller and remove the top and bottom
bushings.
STEP 67
Use a suitable puller and remove the seal.
5008-18
STEP 68
90763'1 OM
Use a suitable puller and remove the bushing.
STEP 69
Use a suitable puller and remove the seal from the
swivel housing
STEP 70
Support the swivel housing on a sleeve and press the
bushing out of the swivel housing.
Bur 8-17300
STEP 71
Use a hammer and a chisel that has a long taper to start
the bushing off the bottom king pin.
STEP 72
Press the bottom king pin out of the bushing.
5008-19
REPLACING A UNIVERSAL JOINT
STEP 76 STEP 73
Remove the four snap rings.
STEP 74
Use the CAS-1980 V-block to support the coupling.
Adjust the Allen screws in the V-block to hold the
coupling level and use additional support as required.
Use a suitable driver and press the bottom bearing cap
against the V-block.
STEP 75
Fasten the bearing cap ina vise and drive the coupling
off the bearing cap.
Bur 8-17300
Use the V-block to support the coupling and press the
other bearing cap against the V-block.
STEP 77
Remove the long axleshaft (or short axle shaft) from the
coupling.
STEP 78
Remove the coupling from the bearing cap.
5008-20
STEP 79
Use a suitable support and driver to press the bottom
bearing cap out of the yoke as far as possible.
STEP 80
STEP 81
Press the other bearing cap out of the yoke as far as
possible.
Bur 8-17300
STEP 82
Remove the cross.
STEP 83
Use a suitable driver and press the bearing cap out of
the yoke.
STEP 84
Press a bearing cap into the yoke 1/4 inch (3 mm) from
the top of the yoke.
STEP 85
Carefully install the cross in the bearing cap.
STEP 86
Press the other bearing cap into the yoke 3/8 inch (9
mm) from the top of the yoke.
STEP 87
Carefully raise the cross into the bearing cap so that the
cross is in both bearing caps.
Bur 8-17300
5008-21
STEP 88
Hold the cross and press the bearing caps into the
yoke.
STEP 89
Use a suitable driver and press a bearing cap into the
yoke so that a snap ring can be installed.
STEP 90
5008-22
STEP 91
Repeat steps 89 and 90 for the other bearing cap.
STEP 92
Use the V-block to support the coupling and press a
bearing cap into the coupling even with the 00of the
coupling.
STEP 93
Carefully install the cross in the bearing cap.
Use a suitable driver and press the other bearing cap
into the coupling 1/4 inch (3 mm) from the top of the
coupling.
Bur 8-17300
STEP 95
Carefully raise the cross into the top bearing cap so that
the cross is in both bearing caps.
STEP 96
Hold the cross and press the bearing cap into the
coupling so that a snap ring can be installed.
STEP 97
STEP 98
Bur 8-17300
5008-23
B902646J
1. Top fVng Pin
2. Shim
3. Seal
4. One Piece Bushing
5. Swivel Housing
6. Bushing
7. Seal
8. Two Piece Bushing
9. Bottom fVng Pin
5008-24
ASSEMBLY AND INSTALLATION OF SWIVEL HOUSING
STEP 102 STEP 99
Drivethe bushing into the bore until the bushing is 5/16
inch (8mm) beyond the end of the bore. Then install the
seal
STEP 100
Install the bushing for the top king pin on a driver that
has a pilot and drive the bushing all the way into the
bore.
STEP 101
Repeat step 100 for the bottom bushing.
Bur 8-17300
Use a suitable driver and drive the seal all the way into
bore.
STEP 103
Repeat step 102 for the bottom seal.
STEP 104
Install the axle shaft.
STEP 105
Install the swivel housing.
STEP 106
If the old swivel housing is being installed and no new
bushings for the king pins were installed, do steps 107
through 109.
STEP 107
Install the top king pin, shims and cap screws and lock
washers or self-locking cap screws.
STEP 108
Tighten the cap screws to 101 pound-feet (137 Nm).
STEP 109
Repeat steps 107 through 108 for the bottom king pin.
STEP 110
If a new swivel housing or new bushings for the king
pins have been installed, do steps 111 through 124.
Bur 8-17300
5008-25
STEP 111
Install the top king pin without shims.
STEP 112
Measure the the thickness of the shims removed with
the top and bottom king pins and install these shims
and two additional 0.014 inch (0.35 mm) shims on the
bottom king pin.
STEP 113
Install the bottom king pin and shims.
5008-26
STEP 114
Install and tighten the cap screws to 101 pound-feet
(137 Nm).
STEP 115
Tighten the cap screws.
STEP 116
Use a dial indicator and check the free travel of the
swivel housing. Record the reading.
Bur 8-17300
STEP 117
Add 0.012 inch (0.30 mm) to the reading in step 116.
Then subtract this answer from the answer in step 112
STEP 118
Divide the answer for step 117 by 2. This is the thick-
ness of the shims to be installed on each king pin. If the
shims cannot be divided equally, install the thickest
shim set on the top king pin.
STEP 119
Remove the cap screws that hold the top and bottom
king pins.
STEP 120
Install the correct thickness of shims on each king pin.
STEP 121
Install the bottom king pin, and cap screws and lock
washers or self-locking cap scre.vs.
STEP 122
Tighten the cap screws to 101 pound-feet (134 Nrn).
STEP 123
Install the top king pin, shims, cap screws and lock
washers.
STEP 124
Bur 8-17300
5008-27
STEP 125
Install the ball joint and nut.
STEP 126
Tighten the nut to 125 to 135 pound-feet (169 to 180
Nm).
STEP 127
Install a newcotter pin. Ifa notch inthe nut is not aligned
with the hole in the stud, tighten the nut to align the
nearest notch with the hole.
STEP 128
Lubricate the king pins.
STEP 129
Assemble the planetary according to instructions inthis
section.
5008-28
REMOVAL OF DIFFERENTIAL CARRIER
STEP 130
Drain the lubricant from the center bowl.
STEP 131
Remove the cotter pin from the ball joint.
STEP 132
Loosen but do not remove the nut.
STEP 133
Use a suitable puller to loosen the ball joint.
Bur 8-17300
STEP 134
Fasten suitable lifting equipment as shown and remove
the cap screws for the top and bottom king pins.
STEP 135
Remove the nut and ball joint.
STEP 136
Remove the king pins.
STEP 137
Remove the planetary and axle assembly.
STEP 138
Repeat steps 131 through 137 at the other side.
STEP 139
Use tool CAS-2151 and loosen and remove the right tie
rod.
STEP 140
Remove the fitting from the closed end of the steering
cylinder.
STEP 141
Bur 8-17300
5008-29
STEP 142
Remove the steering cylinder.
STEP 143
STEP 144
Use suitable l i f t i n g equipment and remove the differen-
tial carrier.
5008-30
DISASSEMBLY OF DIFFERENTIAL CARRIER
STEP 145
Typical Illustration
Fasten the differential carrier in a repair stand.
STEP 146
Prevent the pinion shaft from turning and measure the
backlash of the ring gear. Record the reading.
STEP 147
Make an identification mark on the bearing cap and leg
on the ring gear side of the differential carrier.
Bur 8-17300
STEP 148
Remove the cap screw and lock that hold each ad-
justing ring.
STEP 149
STEP 150
Loosen both adjusting rings
STEP 151
~,
Remove both bearing caps.
STEP 152
Remove the adjusting rings, bearing cups and differen-
tial.
STEP 153
Ifthe bearing cups areto be used again, fasten an iden-
tification tag to one bearing cup for correct installation.
STEP 154
Remove the seal and cover.
Bur 8-17300
5008-31
STEP 155
Use a narrow chisel to push the nut out of the pinion
shaft.
STEP 156
Use the yoke and CAS-2151 tool to remove the pinion
nut.
STEP 157
Remove the washer.
5008-32
STEP 158
Use a soft hammer and drive the pinion shaft out of the
outer bearing.
STEP 159
Remove the flat washers and spacer. Discard the
spacer. The spacer MUST NOT be used again.
STEP 160
Press the pinion shaft out of the inner bearing.
Bur 8-17300
STEP 161
Remove the shim.
STEP 162
Remove the bearing cups only if inspection indicates
the need for new parts. A spacer is used between the
differential carrier and the inner bearing cup. Do not
lose the spacer.
5008-33
DISASSEMBLY OF DIFFERENTIAL
STEP 166 STEP 163
STEP 164
Remove the ring gear.
STEP 165
Separate the case halves.
Bur 8-17300
Remove the thrust washer and side gear.
STEP 167
Remove the pinion shaft assembly and pin.
STEP 168
Remove the side gear.
5008-34
STEP 169
STEP 170
Remove and install new bushings inthe case halves as
required.
STEP 171
Remove the bearing from either case half as shown.
INSPECTION OF DIFFERENTIAL PARTS
1. Clean all parts in cleaning solvent.
2. Inspect the bearing cup and the rollers in the
bearings for flat areas, pitting, scoring and other
damage. Also check the inner race for damage. Ifany of
these defects are found, a new bearing and bearing
cup must be installed.
3. Inspect the teeth on the pinion gear and ring gear for
pitting, scoring and broken teeth. The ring gear and
pinion gear must be replaced as a set.
Bur 8-17300
4. Inspect the teeth of the pinion gears and pinion shaft,
and side gears for the differential for pitting, scoring
and other damage. Also inspect the thrust surfaces and
the bore of each pinion gear. Check the splines in the
side gears for wear. Use new parts as required.
5. Inspect the thrust washers for pitting, scoring and
other damage. Use new parts as required.
5008-35
6
15
B902647J
1. Cover
2. Seal
3. Pinion Nut
4. Washer
5. Bearing
6. Flat Washer
Bur 8-17300
7. Spacer
8. Bearing Cup
9. Differential Carrier
10. Adjusting Ring
11. Bearing Cap
12. Lock
13. Shim
14. Pinion Gear
15. Ring Gear
16. Case Half
17. Thrust Washer
18. Side Gear
19. Pinion Gear
20. Pinion Shaft
21. Dowel Pin
5008-36
ASSEMBLY OF DIFFERENTIAL
STEP 172
Press a new bearing onto each case half.
STEP 173
Make surethat the threads inthe other case half arefree
of lubricant
STEP 174
Lubricate the thrust washers, pinion gears and pinion
shaft with gear lubricant
Bur 8-17300
STEP 175
Install a thrust washer in the case half with threaded
holes.
STEP 176
Install a side gear.
STEP 177
Install the thrust washers and pinion gears on the pinion
shaft.
STEP 178
Install the pin.
STEP 179
Install the pinion shaft assembly.
STEP 180
7~18M
Apply 271 Loctite to the threads in the case half.
Bur 8-17300
5008-37
STEP 181
Install the other side gear.
STEP 182
Install the other thrust washer in the other case half.
STEP 183
Assemble the case halves.
5008-38
STEP 184
Make sure that the mounting surfaces for the ring gear
are clean and install the ring gear.
Bur 8-17300
STEP 185
Use the press to prevent the differential from turning
and install and tighten the cap screws to 52 pound-feet
(70 Nm).
5008-39
ASSEMBLY OF DIFFERENTIAL CARRIER
STEP 189 STEP 186
If new bearing cups are being installed inthe differential
carrier, make sure that the spacer is installed inthe bore
for the inner bearing cup.
STEP 187
Use a suitable driver and drive the bearing cup(s) into
the differential carrier.
STEP 188
Assemble the gauge block, pilot and stud from the
CAS-1839 pinion setting kit.
Bur 8-17300
. .
~~~~~,M.
Install the gauge block assembly, bearings and handle.
Tighten the handle until the bearings become difficult to
turn.
STEP 190
Install the gauge tube, bearing caps with marks aligned
and the cap screws.
STEP 191
5008-40
STEP 192
Use the metric feeler gauge and measure the space
between the gauge block and the gauge tube. Write the
measurement on line b in step 194
STEP 193
Write thenumber onthe end of the pinion shaft on line d
in step 194.
STEP 194
The number on line a does not change. Add line a and
line bandwrite the answer on line c. Subtract line dfrom
line c and write the answer on line e. Line e is the thick-
ness of the shim to be installed on the pinion shaft.
Example
a. 109.75 mm
b.+ mm
c. mm
d. - mm
e. mm
a. 109.75 mm
b. +0.45 mm
c. 110.20 mm
d. -107.45 mm
e. 2.75 mm
use 2.70 mm
thick shim
Bur 8-17300
STEP 195
Remove the cap screws, bearing caps, gauge tube,
handle, gauge block assembly and the bearings.
STEP 196
Install the shim with the thickness specified in step 194.
The chamfer on the IDof the shim must be towards the
pinion gear.
STEP 197
Use a suitable driver and press the inner bearing
against the shim.
STEP 198
Lubricate the bearings with gear lubricant.
STEP 199
Install a new spacer and flat washers. The old spacer
MUST NOT be used again.
STEP 200
Install the pinion shaft and the outer bearing.
Bur 8-17300
5008-41
STEP 201
Install the washer.
STEP 202
Install a new pinion nut.
STEP 203
Use the yoke and the CAS-2151 wrench and tighten the
pinion nut to 50 pound-feet (68 Nm).
5008-42
STEP 204
The pinion shaft and bearings will still be loose. Tighten
the pinion nut in SMALL amounts until the bearings
become seated.
IMPORTANT: If the pinion nut is tightened too much,
(rotating torque more than specified) anew spacer must
be installed on the pinion shaft.
STEP 205
Use a pound-inch torque wrench and check the
rotating torque of the pinion shaft. Use a 1-5/16 inch
socket 12 point socket and 1/8 inch (3 mm) cotter pin
as ashaft adapter. The rotating torque must be 15to 20
pound-inches (1.7 to 2.2 Nm). If the rotating torque is
less than specified, tighten the pinion nut a SMALL
amount and check the rotating torque again. Also see
IMPORTANT below step 204.
STEP 206
When the rotating torque is as specified, use a hammer
and punch and drive part of the pinion nut into the slot in
the pinion shaft.
Bur 8-17300
STEP 207
Use a suitable driver and drive a new seal into the dif-
ferential carrier.
STEP 208
Use a suitable driver and drive the cover onto the pinion
shaft
STEP 209
Install the differential carrier and lubricate the bearings
with gear lubricant. The ring gear must be next to the leg
with the identification mark.
STEP 210
Install the bearing cups.
STEP 211
Install the bearing caps with the alignment marks
aligned and the cap screws.
STEP 212
Tighten the cap screws to pull the bearing caps against
the differential carrier.
Bur 8-17300
5008-43
STEP 213
Install the adjusting rings.
STEP 214
Tighten both adjusting rings while making sure that
there is clearance (backlash) between the ring gear and
pinion gear.
STEP 215
Use a dial indicator and check for end play.
5008-44
STEP 216
If there is end play, tighten the adjusting ring on the
tooth side of the ring gear until there is no end play.
STEP 217
If there is no end play, loosen the adjusting ring on the
backface side of the ring gear to make sure that there is
clearance between the ring gear and pinion gear and
tighten the opposite adjusting ring until there is no end
play.
STEP 218
When there is no end play, tighten each adjusting ring
one notch.
STEP 219
Use the dial indicator and check the backlash for the
ring gear at 90 degree intervals. If the readings are not
equal, adjust the backlash at the position that had the
smallest reading.
STEP 220
Ifthe original ring gear and pinion gear are being used,
the backlash must be equal to the measurement made
during disassembly.
3TEP 221
If a new ring gear and pinion gear are being used. the
backlash must be 0.008 to 0.020 inch (0.15 to 0.25
mm).
Bur 8-17300
STEP 222
If there is not enough backlash, loosen the adjusting
ring onthe backface side of the ring gear one notch and
tighten the opposite adjusting ring one notch. Check
the backlash again. Continue with this step until the
backlash is correct.
STEP 223
' ' ' ' ' ; . ;. . ' ' ' - " . " , 1 ,
"'307tv1
, : ~'"
If there is too much backlash, loosen the adjusting ring
on the tooth side of the ring gear one notch and tighten
the opposite adjusting ring one notch. Check the
backlash again. Continue with this step until the
backlash is correct.
STEP 224
When the backlash is correct, tighten the cap screws to
115 pound-feet (156 Nm).
5008-45
STEP 225
Install the lock, cap screw and lock washer that hold
each adjusting ring. Tighten the cap screws to 84
pound-inches (9 Nm).
INSTALLATION OF DIFFERENTIAL CARRIER
STEP 228 STEP 226
Apply form-in-place gasket material.
STEP 227
Install the differential carrier.
Bur 8-17300
STEP 229
Install the steering cylinder.
5008-46
STEP 230
s.~
Install and tighten the cap screws to 66 to 79 pound-
feet (90 to 107 Nm).
STEP 231
Install and tighten the tie rod.
STEP 232
Install and tighten the fitting at the closed end of the
steering cylinder.
STEP 233
Installthe planetary and axle assembly. Itcan be neces-
sary to have another person turn the pinion shaft.
Bur 8-17300
STEP 234
Install the king pins, shims, cap screws and lock
washers.
STEP 235
Install the ball joint and nut.
STEP 236
STEP 237
Tighten the nuts to 170 pound-feet (230 Nm).
Bur 8-17300
5008-47
STEP 238
Install new cotter pins. Ifa notch inthe nut is not aligned
with the hole in the stud, tighten the nut to align the
nearest notch with the hole.
STEP 239
Fill the center bowl with 7.4 U.S quarts (7Iitres) of gear
lubricant.
STEP 240
Lubricate the king pins with molydisulfide grease.
SECTION INDEX - POWER TRAIN
Removal and Installation of Power Train Components . ...6001
Transmission Specifications and Schematic.... . 6002
Wheels and Tires .... . 6003
PTO . .6019
Rear Axles and Planetaries 6201
Transfer Gearbox 6202
Differential and Differential Lock . .....6203
Forward/Reverse Valve . ..6204
Torque Converter Charging Pump, Output Shaft, And Converter Housing 6205
Transmission. . 6206
CASE CORPORATION
Bur 8-17570
Printed in U.S.A.
CASE CORPORATION
Sect i on
6001
REMOVAL AND INSTALLATION OF
POWER TRAIN COMPONENTS
Bur 812501
Printed in U.S.A.
Issued March 1991
6001-2
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TOOLS 2
REMOVING THE TORQUE CONVERTER HOUSING AND TORQUE CONVERTER 3
INSTALLING THE TORQUE CONVERTER AND TORQUE CONVERTER HOUSING 6
REMOVING THE TRANSAXlE 9
INSTALLING THE TRANSAXlE 14
REPLACING A UNIVERSAL J OINT 18
SPECIFICATIONS
Special torques
Ferry head screws that hold the rear drive shaft 156 to 216 pound-inches (18 to 24 Nm)
Ferry head screws that hold the PTO drive shaft 156 to 216 pound-inches (18 to 24 Nm)
Cap screws that hold the front drive shaft 504 to 576 pound-inches (57 to 65 Nm)
Cap screws that fasten the torque converter
housing to the flywheel housing... . . . ....360 to 420 pound-inches (40 to 47 Nm)
Cap screws that fasten the drive ring to the torque converter .456 to 504 pound-inches (52 to 57 Nm)
Cap screws that fasten the drive ring to the flywheel 156 to 180 pound-inches (18 to 20 Nm)
Wheel nuts for the rear wheels 320 to 380 pound-feet (434 to 515 Nm)
Nuts for the bolts that fasten the transaxle to the frame 520 to 640 pound-feet (705 to 868 Nm)
Nuts for the bolts that fasten the guard for the drive shaft to the frame ... 100 to 150 pound-feet (136 to 203 Nm)
Oil refill capacity for the transaxle 47.6 U.S. quarts (45 litres)
SPECIAL TOOLS
dresses:
In the U.8A and Canada
Service Tools
P.O. Box 314
Vl Churchill Ltd
Northants, NN11 4NF
England
B897521OM
Bur 8-12501
CAS-2018 Alignment Tool
This tool is shown in use in step 19.
6001-3
REMOVING THE TORQUE CONVERTER HOUSING AND TORQUE CONVERTER
STEP 1
Parkthe machine on a level surface. Put the backhoe in
thetransport position and lower the loader bucket to the
floor.
STEP 2
Drain the oil fromthe transaxle. The transaxle holds ap-
proximately 47.6 U.S. quarts (45Iitres).lfequipped with
a PTa, drain the oil from the torque converter housing.
STEP 3
Ifthe machine has four wheel drive and a PTa, do steps
4 through 8. If the machine has a PTa only, do steps 4
through 7.
STEP 4
Loosen and remove the bolts, flat washers, and nuts
that fasten the bar to the guard for the drive shaft.
Remove the bar.
Bur 8-12501
STEP 5
Loosen and remove the nuts and flat washers from the
bolts that fasten the guard to the frame. Do not remove
the bolts at this time.
STEP 6
Put a floor jack under the guard.
STEP 7
Remove the bolts and lower the guard. Remove the
guard from under the machine.
6001-4
STEP 8
Loosen and remove the cap screws that fasten the front
drive shaft to the flange on the transaxle. Remove the
front drive shaft.
STEP 9
If equipped with a PTO, loosen and remove the Ferry
head screws and clamps that fasten the drive shaft to
the torque converter and remove the drive shaft.
STEP 10
Loosen and remove the Ferryhead screws and clamps
that fasten the rear drive shaft to the torque converter.
Remove the rear drive shaft
NOTE: If necessary, use a prybar to remove the rear
drive shaft. If the rear drive shaft cannot be removed with
aprybar, loosen the hardware that fastens the transaxle
to the frame and move the transaxle toward the rear of
the machine. Remove the rear drive shaft.
Bur 8-12501
STEP 11
Loosen the clamps at each end of the hose on the
suction tube and remove the suction tube.
STEP 12
Loosen and remove the nut, lock washer, and wire from
the switch for the filter warning lamp.
STEP 13
STEP 14
Loosen and remove the cap screws and flat washers
that fasten the torque converter housing to the flywheel
housing.
NOTE: If equipped with aPTO, instal! two 10mm - 1.5x
4 inch (100 mm) studs to hold the torque converter
housing while loosening the torque converter housing.
STEP 15
Loosen and remove the torque converter housing.
NOTE: The following photographs show removing the
torque converter with the engine removed. The pro-
cedure is the same with the engine in the machine.
STEP 16
Loosen the cap screws that hold the torque converter.
4. HARDENED WASHER ..-
~..-
2. CAP SCREW ~
~
2. CAP c?~3. FLAT
SCREW WASHER
7. TORQUE
CONVERTER
HOUSING
Bur 8-12501
6001-5
STEP 17
Hold the torque converter and remove the cap screws
and hardened washers and remove the torque con-
verter.
STEP 18
If necessary, loosen and remove the cap screws, flat
washers, and the drive ring from the torque converter.
B891515J
6001-6
INSTALLING THE TORQUE CONVERTER AND TORQUE CONVERTER HOUSING
STEP 19
Install the drive ring and the CAS-2018 alignment tool.
Install the drive ring to get the least amount of
movement between the alignment tool and the drive
ring.
STEP 20
Install four cap screws and flat washers and tighten the
cap screws to 456 to 504 pound-inches (52 to 57 Nm).
Then install and tighten the remainder of the cap
screws.
STEP 21
Hold the torque converter in place and install the cap
screws and hardened washers.
Bur 8-12501
STEP 22
to 20 Nm).
STEP 23
If equipped with a PTO, apply Loctite 515 all the way
around the edge of the flywheel housing.
STEP 24
Install a 10 mm - 1.5 x 4 inch (100 mm) stud in the
middle hole on each side of the flywheel housing.
STEP 25
Install the torque converter housing so that the suction
tube and filter are on the horizontal centerline.
STEP 26
Move the torque converter housing forward.
IMPORTANT: DO NOT use extra force to push the
torque converter housing into place. If the torque con-
verter housing does not easily slide into contact with the
flywheel housing, the parts are not correctly aligned.
STEP 27
Install the cap screws and lock washers that hold the
torque converter housing and tighten the cap screws to
360 to 420 pound-inches (40 to 47 Nm).
STEP 28
Install the wire, lock washer, and nut on the switch for
the filter warning lamp and tighten the nut.
STEP 29
1.7/8-14
THREAD
STEP 30
Install the suction tube and tighten each clamp on the
hose.
Bur 8-12501
6001-7
STEP 31
Install the rear drive shaft, clamps, and the Ferry head
screws. Tighten the Ferry head screws to 156 to 216
pound-inches (18 to 24 Nm).
NOTE: If the hardware for the transaxle was loosened to
remove the rear drive shaft, tighten the hardware ac-
cording to the torque specifications in step 69.
STEP 32
If equipped with a PTO, install the drive shaft, clamps,
and the Ferry head screws. Tighten the Ferry head
screws to 156 to 216 pound-inches (18 to 24 Nm).
STEP 33
Ifthe machine has four wheel drive, do steps 34through
38. Ifthe machine has a PTO but no four wheel drive, do
steps 35 through 38.
STEP 34
Install the front drive shaft and cap screws. Tighten the
cap screws to 504 to 576 pound-inches (57 to 65 Nm).
6001-8
STEP 35
Move the guard in position under the drive shaft.
STEP 36
Raisethe guard into alignment with the brackets on the
frame and install the bolts. Lower the floor jack and
remove the floor jack from under the machine.
STEP 37
Install theflatwashers and nuts onthe bolts. Tighten the
bolts to 100 to 150 pound-feet (136 to 203 Nm).
Bur 8-12501
STEP 38
Install the bar on the guard for the drive shaft. Install the
bolts, flat washers, and nuts and tighten the nuts.
STEP 39
Install and tighten the drain plug in the transaxle (and
the torque converter housing if equipped with PTO).
STEP 40
Fill the trans axle to the correct level. If the oil drained
from the transaxle is to be used again, the oil must be
filtered before being returned to the transaxle.
STEP 41
If equipped with a PTO, fill the torque converter to the
correct level.
REMOVING THE TRANSAXLE
6001-9
STEP 42
Raise the wheels off of the floor high enough to remove
the transaxle from under the machine. Put suitable
stands under the frame at the rear of the machine and
STEP 43
Drain the oil from the transaxle. The trans axle holds ap-
proximately 47.6 U.S. quarts (45 litres).
STEP 44
Ifthe machine has four wheel drive and a PTO, do steps
45 through 49. If the machine has a PTO only, do steps
45 through 48.
Bur 8-12501
STEP 45
Loosen and remove the bolts, flat washers. and nuts
that fasten the bar to the guard for the drive shaft.
Remove the bar.
STEP 46
Loosen and remove the nuts and flat washers from the
bolts that fasten the guard to the frame. Do not remove
the bolts at this time.
STEP 47
Put a floor jack under the guard.
6001-10
STEP 48
Remove the bolts and lower the guard. Remove the
guard from under the machine.
STEP 49
Loosen and remove the cap screws that fasten the front
drive shaft to the flange on the transaxle. Remove the
front drive shaft.
STEP 50
If equipped with a PTa, loosen and remove the Ferry
head screws and clamps that fasten the drive shaft to
the torque converter and remove the drive shaft.
STEP 51
Loosen and remove the Ferry head screws and clamps
that fasten the rear drive shaft to the torque converter.
Remove the rear drive shaft.
Bur 8-12501
NOTE: If necessary, use a prybar to remove the rear
drive shaft. If the rear drive shaft cannot be removed with
aprybar, loosen the hardware that fastens the transaxle
to the frame and move the transaxle toward the rear of
the machine. Remove the rear drive shaft.
STEP 52
Loosen and remove the wheel nuts and remove the rear
wheels.
STEP 53
If the machine has four wheel drive, disconnect the
control rod from the lever at the transaxle.
STEP 54
Loosen and remove the nuts from the bolts that fasten
the clamp and spacer for the parking brake cable to the
bracket on the transaxle. Remove the bolts, clamp, and
spacer.
STEP 55
Slide the boot up the parking brake cable. Loosen the
jam nut and turn the parking brake cable counterclock-
wise out of the transaxle.
STEP 56
Remove the cotter pins and clevis pins that fasten the
control rods to the levers on the transaxle.
IMPORTANT: Do not move the levers on the transaxle
while the control rods are disconnected. If you move the
levers, the detents can disengage which will require
transax/e disassembly to install the detents.
Bur 8-12501
6001-11
STEP 57
Loosen and remove the cap screws and flat washers
that fasten the guard for the hose on the suction tube
and remove the guard. Loosen each clamp on the hose
on the suction tube and slide the hose upward to dis-
connect the hose.
STEP 58
If the machine is equipped with a cab and has a
floormat, remove the floormat.
STEP 59
Remove the operators seat.
STEP 60
Loosen and remove the screws that hold the rear floor
plate and remove the rear floor plate.
STEP 61
Disconnect the control rod from the spring. Disconnect
the hose from the tee fitting. Install a plug in the hose
and a cap on the tee fitting. Disconnect the connector
for the wiring harness. Remove the cotter pin and clevis
pinthat fasten the power shuttle rod to the control valve.
6001-12
STEP 62
Disconnect the brake hose from each side of the trans-
axle. Install a plug in each hose and a cap on each
fitting. Disconnect the tube from the fitting at the top left
side of the transaxle. Install a plug inthe tube and a cap
on the fitting. Disconnect the spring from the lever at the
top right side of the transaxle so that the tube will be free
of the transax/e.
STEP 63
Disconnect the tube from the right side of the transaxle.
Install a plug in the tube and a cap on the fitting.
STEP 64
If used. loosen and remove the cap screws that fasten
the straps to the frame and remove the straps.
Bur 8-12501
STEP 65
Install a transmission jack under the transaxle.
STEP 66
Loosen and remove the nuts. hardened washers,
clamps. and bolts that fasten the transaxle to theframe.
STEP 67
Lower the transaxle and remove the transaxle from
under the machine.
6001-13
-
890240SJ
Bur 8-12501
6001-14
INSTALLING THE TRANSAXLE
STEP 71 STEP 68
Putthetrans axle under the machine and raise thetrans-
axle into position.
STEP 69
Install the bolts, clamps, hardened washers, and nuts
that fasten the transaxle to the frame. Tighten the nuts to
STEP 70
Lower and remove the transmission jack.
Bur 8-12501
-w,-
B9075614M
If used, install the straps and align the straps with the
blocks inthe frame. Install the cap screws that hold the
straps and tighten the cap screws.
STEP 72
Connect the tube to the right side of the transaxle.
STEP 73
Connect the brake hose to each side of the transaxle.
Connect the tube to the fitting at the top left side of the
transaxle. Connect the spring to the lever at the top right
side of the transaxle.
STEP 74
Connect the control rod to the spring, Connect the hose
to the tee fitling, Connect the connector for the wiring
harness, Install the clevis pin and cotter pin that fasten
the power shuttle rod to the control valve,
STEP 75
Install the rear floor plate. Install the screws that hold the
rear floor plate and tighten the screws,
STEP 76
Install the operators seat.
STEP 77
If the machine is equipped with a cab and has a
floormat, install the floormat.
STEP 78
Install the hose for the suction tube and tighten the
clamps on the hose, Install the guard and install the cap
screws and flat washers. Tighten the cap screws.
Bur 8-12501
6001-15
STEP 79
Install the clevis pins and cotter pins that fasten the
control rods to the levers on the transaxle.
STEP 80
Turn the jam nut onto the parking brake cable until the
jam nut is flush with the flats on the threads. Turn the
parking brake cable clockwise into the transaxle until
the jam nut contacts the transaxle. Prevent the parking
brake cable from turning and tighten the jam nut.
STEP 81
Install the boot over the jam nut and parking brake
cable. Install the bolts, clamp, spacer, and nuts that
fasten the parking brake cable to the bracket on the
transaxle. Tighten the nuts.
6001-16
STEP 82
Ifthe machine has four wheel drive, connect the control
rod to the lever at the transaxle.
STEP 83
Install the rear wheels and wheel nuts. Tighten the
wheel nuts to 320 to 380 pound-feet (434 to 515 Nm).
STEP 84
Install the rear drive shaft, clamps, and the Ferry head
screws. Tighten the Ferry head screws to 156 to 216
STEP 85
If equipped with a PTO, install the drive shaft, clamps,
and Fetty head screws that hold the drive shaft.
Bur 8-12501
STEP 86
Ifthe machine has four wheel drive and a PTO, do steps
87 through 91. Ifthe machine has a PTO only, do steps
88 through 91.
STEP 87
Install the front drive shaft and cap screws. Tighten the
cap screws to 504 to 576 pound-inches (57to 65 Nm).
STEP 88
Move the guard in position under the drive shaft.
STEP 89
Raise the guard into alignment with the brackets on the
frame and install the bolts. Lower the floor jack and
remove the floor jack from under the machine.
STEP 90
Install theflatwashers and nuts onthe bolts. Tighten the
bolts to 100 to 150 pound-feet (136 to 203 Nm).
STEP 91
Install the bar on the guard for the drive shaft. Install the
bolts, flat washers, and nuts and tighten the nuts.
Bur 8-12501
6001-17
STEP 92
Install and tighten the drain plug in the transaxle.
STEP 93
Fill the transaxle to the correct level. If the oil drained
from the transaxle is to be used again, the oil must be
filtered before being returned to the transaxle.
STEP 94
Remove the air from the brakes according to the in-
structions in Section 7002.
STEP 95
Adjust the shift linkage for the transmission and the
power shuttle according to the instructions in Section
9001.
6001-18
REPLACING A UNIVERSAL JOINT
STEP 99 NOTE: This procedure shows the removal of a uni-
versal joint for the rear drive shaft. The procedure is the
same for all drive shafts used on this machine.
STEP 96
Remove the snap rings.
STEP 97
Use an acceptable support and driver and press the
bearing caps out ofthe shaft Make sure that the grease
fitting is up as shown.
STEP 98
Remove the bearing cap. If necessary, use pliers to
remove the bearing cap.
Bur 8-12501
Remove the cross from the shaft
STEP 100
Repeat steps 97, 98, and 99 to remove the cross from
the yoke.
STEP 101
Start a bearing cap into the yoke. DO NOT press the
bearing cap all the way in.
STEP 102
Install the cross in the yoke.
STEP 103
Install the cross in the bearing cap. Be careful not to
move the needles.
STEP 104
Press the other bearing cap a short distance into the
yoke. Carefully raise the cross into the top bearing cap
and press the bearing cap into the yoke.
STEP 105
Usethe driver and press the bearing cap into the yoke
until the groove for the snap ring can be seen.
Bur 8-12501
6001-19
STEP 106
Install a snap ring in the groove.
STEP 107
Press the other bearing cap all the way into the yoke.
STEP 108
Issued 3-91 Printedin USA
6001-20
STEP 109
Start a bearing cap into the shaft. DO NOT press the
bearing cap all the way in.
STEP 110
Install the cross inthe shaft with the grease fitting up as
shown.
STEP 111
Install the cross inthe bearing cap being careful not to
move the needles.
Bur 8-12501
STEP 112
Press the other bearing cap a short distance into the
shaft. Carefully raise the cross into the bearing cap and
press the bearing cap into the shaft.
STEP 113
Use the driver and press the bearing cap into the shaft
until the groove for the snap ring can be seen.
STEP 114
STEP 115
Sect i on
6002
SPECIFICATIONS, SCHEMATIC AND TROUBLESHOOTING
CASE CORPORATION
Issued March 1991
6002-2
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TOOLS 3
SCHEMATIC OF TRANSMISSION HYDRAUliC SYSTEM 4
TROUBLESHOOTING 5
Problem: Machine Will Not Move 5
Problem: Loss of Power 6
Problem: Oil in Transmission Too Hot 7
Problem: Clutch Discs Wear Too Fast or Are Burned 7
Problem: Brake Discs Wear Too Fast 7
Problem: Pinion Shaft Failure 7
CHECKING CLUTCH PRESSURE 9
CHECKING OUTPUT OF CHARGING PUMP AND SETTING OF CHARGE PRESSURE REliEF VALVE 9
CHECKING CONVERTER IN PRESSURE AND FLOW 10
CHECKING CONVERTER OUT PRESSURE AND FLOW 11
CHECKING BRAKE COOLING FLOW 11
CHECKING LUBRICATION FLOW AND PRESSURE FOR CLUTCHES 12
CHECKING LUBRICATION FLOW FOR PINION SHAFT 12
SPECIFICATIONS
Output of charging pump 15 to 17 U.S. gpm at 80 to 140 psi at 2200 rpm
(57 to 64 Umin at 551 to 965 kPa, 5.5 to 9.6 bar at 2200 r/rnin)
Charge pump relief valve 350 to 430 psi at 2200 rpm
(2413 to 2965 kPa, 24 to 30 bar at 2200 r/rnin)
Neutral pressure 75 to 135 psi at 2200 rpm
(517 to 930 kPa, 5.2 to 9.3 bar at 2200 r/rnin)
Forward and reverse clutch 175 to 230 psi at 2200 rpm
(1082 to 1586 kPa, 11 to 16 bar at 2200 r/rnin)
Flow Specifications
Torque converter in 5 to 7 U.S. gpm at 50 to 100 psi at 2200 rpm
(19 to 26.5 Umin at 345 to 689 kPa, 3.4 to 7 bar at 2200 r/rnin)
Torque converter out... Within 1/2 U.S gpm of torque converter in at 30 to 80 psi
(1.9 Umin of torque converter in at 207 to 551 kPa, 2.1 to 5.5 bar at 2200 r/min)
Brake cooling 5 to 7 U.S. gpm at 10 to 30 psi
(19 to 26.5 Umin at 69 to 207, 0.7 to 2.1 bar at 2200 r/rrun)
Clutch lubrication 5 to 7 U.S. gpm at 45 to 90 psi at 2200 rpm
(19 to 26.5 Umin at 310 to 620 kPa, 3.1 to 6.2 bar at 2200 r/rnin)
SPECIAL TOOLS
6002-3
In the U.S. and Canada, order the tools from
Service Tools
P.O. Box 314
Owatonna, MN
55060
VL Churchill Ltd.
Northants NN11 4NF
England
CAS-10280 Flowmeter
B877168
CAS-1BOBor 10106 Flowmeter Fitting Kit
Bur 8-12512
B877558
CAS-1B04 or 10111 Pressure Fitting Kit
B4218289M
CAS-2026 Special Fitting Kit
6002-4
1
1. Clutch Lubrication Oil
2. Reverse Clutch
3. Forward CLutch
4. Spool
5. Modulator Valve
6. Accumulator
7. Clutch Cutout Valve
8. Dual Regulator Valve
9. Filter
10. Torque Converter
Relief Valve
11. Pressure Regulator Valve
12. Charging Pump
13. Torque Converter
14. Oil Cooler
Bur 8-12512
15. Brake Cooling Oil
16. PTO Control Valve
17. PTO Clutch
18. Pinion Lubricaion Oil
6002-5
TROUBLESHOOTING
Probl em: Machi n e Wi l l Not Move
Check the pressure for the forward and
reverse clutches.
The clutch cutout solenoid is not working
correctly. Repair as required.
The dual regulator valve in the transmis-
sion control valve is not working correctly.
Remove the parts and repair as required.
Check the output of charging pump and
the setting of the charge pressure relief
valve and repair as required.
The problem can be broken parts in the
transaxle. Repair as required.
The problem can also be caused by bad
seals for the clutch piston. bad sealing
rings on the shaft or a worn wear sleeve in
the bore for the shaft.
Bur 8-12512
Troubleshooting complete. Find cause of
loss of oil.
Check the setting of the torque converter
relief valve and repair as required.
There can be a problem inthe torque con-
verter housing or the torque converter.
Repair as required.
If the drive shaft turned with the direction
control lever in NEUTRAl but did not turn in
forward or reverse, the problem is in the
transaxle.
6002-6
Probl em: Loss of Power
Loss of power can be caused by a
damaged torque converter. Replace the
torque converter.
Loss of power can also be caused by worn
friction discs in the clutch. Disassemble
transmission and repair as required.
NOTE: If the pressure for the totwetd and
reverse clutches is equally lower than spe-
cified, the problem can be the clutch
cutout solenoid or the control valve. Repair
as required.
Bur 8-12512
Repair engine as required.
Loss of pressure can be caused by bad
seals inthe clutch, bad sealing rings on the
shaft or a worn wear sleeve inthe bore for
the shaft. It will be necessary to remove
and disassemble the transmission to find
the cause.
The dual regulator valve in the transmis-
sion control valve can also cause the
problem. Remove the parts and repair as
required.
If the pressure for the forward and reverse
clutches is less than before, the problem is
in the clutch for the PTO.
The loss of pressure can be caused by
bad seals in the clutch, bad sealing rings
on the shaft or a worn wear sleeve in the
rear bore for the shaft for the PTO. Itwill be
necessary to disassemble the PTO to find
the cause.
6002-7
Probl em: Oi l In Tran smi ssi on Too Hot
Check torque converter in pressure and
flow. Isthe pressure and flow as specified?
NO Remove and inspect the parts of the
~ torque converter relief valve for wear and
damage. Install new parts as required and
check the pressure again.
IMPORTANT: The torque converter relief
valve cannot be adjusted. DO NOT try to
adjust the torque converter relief valve.
Check the output of the charging pump
and repair as required.
NO There is a restriction in the cooling circuit.
-- - Clean the tubes, hoses and the oil cooler.
Probl em: Cl ut ch Di scs Wear Too Fast or are Burn ed
Check the outJ :M' of ttie charging pump
and repair as required.
Bur 8-12512
NO One problem can be worn sealing rings or wear sleeve
for the shaft. Disassemble the transmission and repair
as required.
Another problem can be a plugged orifice inthe lubrica-
tion passage in the housing below the transmission
control valve. See the following illustration.
B901668J
6002-8
Problem: Brakes Wear Too Fast
SeeChecking Torque Converter Out Flowand Pressure
and Brake Cooling Flow.
One side wears faster than the other.
Make sure that the orifice and spring are installed below
the elbow at the top left rear of the transmission
housing.
Problem: Pinion Shaft Failure
This problem will be found during repair of the trans-
axle. Check to make sure that the lubrication tubes are
not damaged and correctly installed. Also check to
make sure that the orifice inthe connector between the
tubes is open.
Bur 8-12512
6002-9
CHECKING CLUTCH PRESSURE
Equipment Required
CAS-10111 or CAS-1804 pressure fitting kit
Test Procedure
Parking brake applied.
Shift lever in NEUTRAL.
Oil at operating temperature.
400 psi (2758 kPa, 27 bar) gauge connected to
FORWARD port.
Engine running at 2200 rpm (r/min).
Move direction control lever to FORWARD.
Read gauge and record the reading.
See page 2 for the specification.
Repeat the procedure at the REVERSE port.
CHECKING OUTPUT OF CHARGING PUMP AND SETTING OF
CHARGE PRESSURE.RELIEF VALVE
Equipment Required
CAS-10106 or CAS-1808 flowmeter fitting kit.
CAS-10280 flowmeter.
Test Procedure
1MPO RT ANT: Dothis check quickly to prevent damage
to the torque converter. Oil flow to the torque converter is
stopped during this check.
Inlet of flowmeter connected to port 1.
Outlet of flowmeter connected to port 2.
Read the flow gauge and the pressure gauge and
record both readings.
All transmission controls in NEUTRAL.
Load valve for flowmeter open.
With the engine running at 2200 rpm (r/min), slowly
close load valve until the pressure stops increasing and
record the reading.
See page 2 for specifications.
6002-10
CHECKING CONVERTER IN PRESSURE AND FLOW
Equipment Required
Test Procedure
All transmission controls in NEUTRAL. Test point shown is early production. Tube replaced
with hose for late production.
See page 2 for the specifications.
Bur 8-12512
6002-11
CHECKING CONVERTER OUT PRESSURE AND FLOW
Equipment Required
Test Procedure
Parking brake applied. Bottom of torque converter housing
Engine running at 2200 rpm (r/rnin).
Read the flow gauge and record the reading.
See page 2 for the specification.
CHECKING BRAKE COOLING FLOW
Equipment Required
Test Procedure
6002-12
CHECKING LUBRICATION FLOW AND PRESSURE FOR CLUTCHES
Equipment Required
CAS-10111 or CAS-1804 pressure fitting kit
CAS-2026 special fitting kit
Test Procedure
Connect the inlet of the flowmeter to port 1.
Connect the outlet of the flowmeter to port 2.
Connect a 100 psi (670 kPa, 6.7 bar) gauge to port 3
Load valve for flowmeter open
Engine running at 2200 rpm (rzmin).
Read the flow gauge and record the reading.
Read the pressure gauge and record the reading
LUBRICATION FLOW FOR PINION SHAFT
An estimate of the lubrication flow can be made from
known flow readings as shown in the following
example. The specified flow is 1-1/2 to 2 U.S. gpm (5.7
to 7.6 Umin).
U.S. gpm Umin
flow for torque converter in 6.6 25
flow for clutch lubrication +5.8 +22
12.4 47
pump output
14.4
54.5
answer from above
-12.4
- 47.0
lubrication flow for pinion shaft 2.0 7.5
Bur 8-12512
Section
6003
WHEELS AND TIRES
CASE CORPORATION
Issued March 1991
6003-2
WHEEL BOLTS AND NUTS
Torque Specifications
Front wheel, two wheel drive 115 to 150 pound-feet (156 to 203 Nm)
Front wheel, four wheel drive 200 to 260 pound-feet (270 to 352 Nm)
Rear wheel mounting nuts 320 to 380 pound-feet (434 to 515 Nm)
IMPORTANT: The rear wheel mounting nuts on this machine are metric. Use only the mounting nuts shown in the parts
catalog for this machine.
General Information
Tighten the wheel bolts and nuts on a newmachine or whenever awheel has been removed and installed after every
two hours of operation until the wheel bolts stay tight.
TIRE PRESSURE
Front Tires
11L x 16,10 PR, F3 .48 psi (331 kPa, 3.3 bar)
12 x 16.5,6 PR, Lug 45 psi (310 kPa, 3.1 bar)
12 x 16.5,8 PR, Lug 55 psi (380 kPa, 3.8 bar)
Rear Tires
16.9 x 24,10 PR, R4 28 psi (193 kPa, 1.9 bar)
17.5L x 24,8 PR, R4 22 psi (152 kPa, 1.5 bar)
17.5L x 24,10 PRoR4 28 psi (193 kPa, 1.9 bar)
19.5L x 24,8 PR, R4 20 psi (140 kPa, 1.4 bar)
19.5L x 24,10 PR, R4 24 psi (165 kPa, 1.6 bar)
Bur 8-12521
Section
6019
HYDRAULIC PTa
CASE CORPORATION Don 7-37060
Printed in U.S.A.
December 1990
OUl~:h:~
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TORQUES 2
SPECIAL TOOLS 3
SHOP EQUIPMENT TOOLS 3
PTa HOUSING
Removal 4
Installation 5
PTa INPUT SHAFT (PRIMARY)
Removal and Disassembly 6
Assembly and Installation 6
PTO CLUTCH
Removal 7
Disassembly 8
Inspection , 9
Assembly 10
Cross Sectional Drawing of the PTa Clutch 13
Installation 14
PTO VALVE
Removal 14
Disassembly 15
Assembly 16
Cross Sectional Drawing of the PTa Valve 17
Installation 18
INPUT AND OUTPUT SHAFTS
Removal 19
Installation 21
SPECIFICATIONS
Lubrication Hy-Tran Plus (MS1207)
Input Shaft End Play 0.025 to 0.127 mm 0.001 to 0.005 inch
Output Shaft End Play.......... 0.025 to 0.127 mm 0.001 to 0.005 inch
Clutch Friction Plate Thickness 2.45 to 2.60 mm 0.096 to 0.102 inch
Clutch Separator Plate Thickness 2.11 to 2.31 mm 0.083 to 0.091 inch
SPECIAL TORQUES
PTO Housing Retaining Bolts 195 to 250 Nm
PTOValve Retaining Bolts 73 to 87 Nm
PTOClutch Hub Retaining Bolt 101 to 113 Nm
145 to 185 Ib ft
54 to 64 Ib ft
75 to 83 Ib ft
Don 7-37060 Issued 12-90 Printed in U.S.A
6019-3
SPECIAL TOOLS
1. CLUTCH SPRING COMPRESSOR
CAS 1992
First Used on Page 8
2. SEAL EXPANDER/PROTECTOR
CAS 2001
3. SEAL COMPRESSOR
CAS 2005-1
SHOP EQUIPMENT TOOLS
1. BUSHING DRIVER SET OEM 6506 4. PRIMER 'N' 8500637
2. TORQUE WRENCH OEM 6480 5. DIAL GAUGE OEM 1030-1
3. SEALANT B17555 LOCmE 515 6. IMPACT HAMMER OEM 4251
Don 7-37060 Issued 12-90 Printed in U.S.A.
6019-4
PTO HOUSING
Removal
STEP 1
Park the machine on level ground and apply the parking
brake.
STEP 2
Lower the bucket to ground level.
STEP 3
Install blocks in front and behind the rear wheels.
STEP 4
Install a container with a capacity of 60 litres under the
transmission and drain the oil.
STEP 5
029221
Remove the bolt from the clamp (1) disconnect the tube
to the valve and PTO housing. Cap the tube
connections to prevent foreign material from entering
the system.
NOTE: The transmission was removed for
photographic purposes only.
Don 7-37060
~. :".
~,
~
Install a hoist onto the PTO housing and remove the
housing bolts.
STEP 7
Install bolts into the two threaded holes. Tighten the
bolts to separate the PTO housing from the transaxle.
6019-5
Installation
STEP 11 STEP 8
Clean the faces on the transaxle and PTO housings.
STEP 9
029221
Remove the caps and install the PTO clutch supply
tube. Tighten the tube ends and mounting clamp (1).
800411 STEP 12
030227
Apply sealant 817555 to the face of the transaxle, and
Primer 'N' 8500637 to the face of the PTO housing.
Instali the PTOhousing and mounting bolts. Tighten the
bolts to a torque of 195 to 250 Nm (145 to 185 Ib ft).
Don 7-37060
Install Hy-Tran Plus transmission oil up to the full mark
on the dipstick.
STEP 13
Remove the blocks from the rear wheels.
6019-6
P.T.G. INPUT SHAFT (PRIMARY)
STEP 16 STEP 14
Remove the transmission end cover. Refer to Section
6206.
STEP 15
D30202
';;;~;~~
Remove the snap ring (1) on the inside of the housing.
Remove the shaft and bearing with a soft hammer.
NOTE: If the PTO housing has been removed it will not
be necessary to remove the end cover. Remove the
seal and outer bearing snap ring. Use a soft hammer
and drive the input shaft iotweto out of the end cover.
D30208
Remove the snap ring (1) and bearing (2) from the
shaft.
STEP 17
Remove and discard the oil seal from the housing.
STEP 18
Examine all parts and replace if necessary.
1. SHAFT
2. SNAP RING
3. BEARING
4. SEAL
Don 7-37060
INP580
STEP 19
030206
Install the new seal (1) with the bushing driver OEM
6506 until the faces on the seal and cover are level.
6019-7
STEP 20
Follow Steps 14 to 16 in reverse order and install the
primary input shaft.
PTO CLUTCH
Removal
STEP 24
STEP 21
Referto Steps 1to 7and remove the PTO housing from
the transaxle.
STEP 22
030215
Remove the three bolts (1) and shroud (2) from the
housing.
STEP 23
030217
Remove the hub (1), thrust bearing (2) and thrust
washer (3).
Don 7-37060
029626
Remove the bolt (1) and clutch assembly (2) from the
input shaft. Remove and discard the two rubber seals
(3) from the input shsft.
6019-8
Disassembly
STEP 28 STEP 25
029817
Remove the snap ring (1) backing plate (2) four clutch
plates (3) and four separate plates (4) inalternate order
from the housing.
STEP 26
Install the clutch assembly and special tool CAS 1992
(1) into a press and compress the spring. Remove the
snap ring (2).
STEP 27
Release the pressure and remove the retainer (1) and
spring (2).
Don 7-37060
C26827
Turn the clutch housing over, shock the housing against
a wooden block to remove the piston (1).
STEP 29
C26829
Remove and discard the o-rings and seals (1) from the
piston.
STEP 30
D30223
Remove the snap ring (1), brake plate (2), springs (3),
brake assembly (4) and inner brake plate (5) from the
clutch housing.
6019-9
STEP 31 STEP 32
Remove the three piston pins (1) and discard the
a-rings (2).
C27202
Remove the needle roller bearing (1) and clutch
assembly retaining washer (2) from the housing.
STEP 33
Inspection
STEP 35
Wash all the parts in cleaning solvent and dry using
compressed air. Replace any part that shows signs of
wear or damage.
808116
Inspect the friction plates for wear and damage.
Replace the friction plates if the thickness is less than
2.4 mm (0.094 inch).
STEP 34
B0611S
Inspect the steel separator plates for wear and
damage. Replace the plates ifthe thickness is less than
2.10 mm (0.082 inch).
Don 7-37060 Issued 12-90 Printed in U.S.! .
6019-10
Assembly
1. INPUT SHAFT
2. O-RING
3. PIN
4. SNAP RING
5. PLATE
6. BRAKE ASSEMBLY
7. SPRING
8. HOUSING
9. PISTON
10. SEAL
11. WASHER
12. BOLT
13. BACKING PLATE
14. FRICTION PLATE
15. SEPARATOR PLATE
16. RETAINER
17. NEEDLE ROLLER BEARING
18. THRUST WASHER
19. THRUST BEARING
20. HUB
21. INPUT SHAFT (PRIMARY)
STEP 36
60198
Install the washer (1) and needle bearing (2) into the
housing. Install the bearing until the outer face of the
bearing is 9.5 mm (0.37 inch) below the top face of the
housing (3).
STEP 37
Install new o-rings (1) onto the three piston brake pins
(2). Install the pins.
Don 7-37060
6019-11
STEP 38
. )
""'-
e/D3a223
Install the inner brake plate (1), brake assembly (2),
springs (3), outer plate (4) and snap ring (5).
STEP 39
C26829
Install the o-rings and seals (1) onto the clutch piston.
STEP 40
808132
Lubricate and install the piston into the housing. Push in
the piston equally from all sides until fully installed.
NOTE: 00not use adriver or press to install the piston
into the clutch housing.
6019-12
STEP 41
Install the clutch housing into a press. Install the piston
returnspring and retainer. Compress the spring with the
special tool CAS 1992 (1) and install the snap ring (2).
STEP 42
lnstaH the clutch plates into the housing in alternate
order. Start with a separator plate (1) and finish with a
friction plate 2. Install the backing plate (3) and snap
ring (4).
Don 7-37060
STEP 43
ll30221
Install new rubber seals (1) onto the input shaft.
NOTE: The larger diameter seal is installed first.
6019-13
Cross Secitonal Drawing of the PTO Clutch
1. HOUSING
2. BACKING PLATE
3. SNAP RING
4. NEEDLE ROLLER BEARING
5. RETAINER
6. SPRING
7. PISTON
8. SEAL
9. O-RING
10. PIN
11. BRAKE PLATE
12. BRAKE ASSEMBLY
13. SEPARATOR PLATE
14. FRICTION PLATE
Don 7-37060
e
6019A
6019-14
STEP 44
Installation
STEP 46
029626
Install the PTO clutch assembly (1), and retaining bolt
(2). Tighten the bolt to a torque of 101 to 113 Nm (75 to
83 Ib ft).
STEP 45
030217
Use petroleum jelly to install the thrust bearing (1) and
thrust washer (2) into the friction plate drive hub (3).
Install the hub into the PTO clutch.
IMPORTANT: Make sure the splines on the hub engage
with the splines on the friction plates.
Install the shroud (1) and retaining bolts (2). Tighten the
bolts.
STEP 47
Install the PTO housing. Refer to Steps 8 to 13.
PTa VALVE
Removal
STEP 49
.-......
STEP 48
Refer to Steps 1to 7 and remove the PTOhousing from
the transaxle
Don 7-37060
030229
Remove the bolts and valve assembly. Discard the
o-rings (1).
6019-15
Disassembly
STEP 53 STEP 50
Make a note of the number of threads visible on the
screw (1). Loosen the nut (2) and remove the screw,
nut, washer and seal. Remove and discard the seal.
STEP 51
808019
Remove the spring (1), detent (2) and ball (3) from the
valve body.
STEP 52
B08021
Remove the snap ring (1) retaining the end cap.
Don 7-37060
STEP 54
B08027
Remove the spool (1) from the valve body.
STEP 55
Wash all parts in cleaning solvent and dry using
compressed air
STEP 56
Replace any part that shows signs of wear or damage.
6019-16
Assembly
STEP 57
Follow Steps 50 to 54 in reverse order and assemble
the PTO valve.
NOTE: Apply petroleum jelly to retain the ball onto the
detent.
Don 7-37060
1.SCREW
2. NUT
3.WASHER
4.SEAL WASHER
5.SPRING
6.DETENT
7.BALL
8.VALVE BODY
9.END CAP
10.SNAP RING
11.RETURN SPRING
12.PRIMARY SPRING
13.WASHER
14.SECONDARY SPRING
15.WASHER
16. VALVE
17.SPOOL
61189
6019-17
Cross Sectional Drawing of the PTO Valve
1. SPOOL
2. VALVE BODY
3. BALL
4. VALVE
5. SECONDARY SPRING
6. RETURN SPRING
7. PRIMARY SPRING
8. SNAP RING
9. END CAP
10. DETENT GUIDE
11. DETENT SPRING
12. SCREW
13. NUT
14. WASHER
15. SEAL WASHER
PTOV580
6019-18
STEP 58
Installation
STEP 59
Install new o-rings (1) to thevalve body. Install thevalve
and tighten the retaining bolts to atorque of 73to 87 Nm
(54 to 64 Ib tt).
6019-19
INPUT AND OUTPUT SHAFTS
Removal
STEP 64 STEP 60
Remove the PTO housing from the transaxle. Refer to
Steps 1 to 7.
STEP 61
Remove the clutch and valve assemblies from the PTO
housing. Refer to Steps 22 and 49.
STEP 62
Remove the oil seal and snap ring from the rear of the
PTO housing. Discard the seal.
STEP 63
029630
Remove the snap ring (1) from the front bearing of the
output shaft.
Don 7-37060
029802
Support the gear and drive out the output shaft
rearwards with the bearing driver OEM 6506.
NOTE: The output shaft gear must be supported during
removal by an assistant to prevent damage to the PTO
gears.
STEP 65
Remove the front bearing cone (1), thrust washer (2)
and gear (3) from the housing. Drive out the front
bearing cup (4) from the housing.
6019-20
STEP 66
808425
Remove the snap ring from the housing and install the
impact hammer OEM 4251 (1). Remove the input shaft
and front bearing cone. Discard the two seals from the
input shaft.
Don 7-37060
STEP 67
029814
Examine the bearings, gears, snap rings, rear bearing
cup (1) and seal sleeve (2) for wear and damage.
Replace if necessary.
Installation
6019-21
1.BEARING CUP
2. BEARING CONE
3. SEALS
4. INPUT SHAFT
5.SNAP RING
6. a-RINGS
7. SPACER
8.GEAR
9.OUTPUT SHAFT
10. SEAL
1HS580
STEP 68
C21727
Use the special tool CAS 2001 to expand and install the
new seals (1) onto the input shaft.
IMPORTANT: Soak the seals in Hy-Tran Plus before
installation.
Don 7-37060
STEP 69
C21730
Install the special tool CAS 2005-3 to compress the
seals to the correct diameter.
IMPORTANT: The correct seal operating size can only
be obtained by using the special tools.
6019-22
STEP 70
Install the input shaft, front bearing cone and snap ring.
Install the inpact hammer and seat the bearing cone
against the snap ring (1).
STEP 71
Installthe dial gauge OEM 1030-1 and measure the end
play on the input shaft.
NOTE: Snap rings are available in sizes from 2.0to 2.36
mm (O.OBOta 0.093 inch)./nsta/I a snap ring which gives
an end play of O.025 ta 0.127 mm (0.001 to 0.005 inch).
STEP 72
029802
Install the gear and output shaft into the PTa housing.
Don 7-37060
STEP 73
D29636
Install the rear bearing cone and snap ring.
STEP 74
Install the thrust washer (1), front bearing cone (2),
bearing cup (3) and snap ring (4).
STEP 75
:':':.
D302t9
Use a soft hammer and drive the output shaft in both
directions to seat the bearing cups against the snap
rings. Install the dial gauge OEM 1030-1 and measure
the end play on the output shaft. If necessary replace
the snap ring with one of a different thickness until the
end play measures 0.025 to 0.127 mm (0.001 to 0.005
inch).
STEP 76
Install a new output shaft oil seal (1) until the seal face is
level with the face of the PTO housing.
Don 7-37060
6019-23
STEP 77
Install the clutch and PTO valve assemblies. Refer to
Steps 44 and 58.
STEP 78
Issued 12-90 Printed in USA.
CASE CORPORATION
Section
6201
REAR AXLES AND PLANETARIES
Don 7-36980
Printed in U.S.A.
December 1990
6201-2
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TORQUES 2
SPECIAL TOOLS 3
TOOLS TO BE MADE 4
SERVICING THE REAR AXLES AND PLANETARIES
Removal 5
Disassembly 6
Inspection 9
Assembly 10
Installation 15
SPECIFICATIONS
Lubrication
Transmission Oil. Hy-Tran Plus (MS 1207)
Axle Shaft Bearing Rolling Torque 3.4 to 5.7 Nm 30 to 50 Ib inches
SPECIAL TORQUES
Rear Axles To Transmission Case 326 to 353 Nm 240 to 260 Ib ft
6201-3
SPECIAL TOOLS
1. SEAL INSTALLATION TOOL FOR REAR AXLE
CAS 2007
2. lOCKNUT SOCKET FOR REAR AXLE SHAFT NUT
CAS 2006
1. TORQUE WRENCH
OEM 6475
2. SEALANT B500642 lOCTITE 324
ACTIVATOR B500622 lOCTITE 707
KIT PART NUMBER B500621
3.BEARING OVEN OEM 8014
5. ALIGNMENT STUD SET
CAS 1995
Don 7-36980
6201-4
TOOLS TO BE MADE
AXLE BEARING PRE-LOAD SETIING TOOL
A. 344mm (13.5 inch)
B. 382 mm (15.0 inch)
C. 40 mm (1.6 inch)
D. 5 mm (0.2 inch)
E. 20 mm (0.8 inch)
F. 14mm (0.6 inch)
7.36980 Issued 12-90 Printed in U.S.A.
6201-5
SERVICING THE REAR AXLES AND PLANETARIES
Removal
STEP 4 NOTE: The transaxle must be removed from the
machine to service the rear axles and planetaries.
STEP 1
Drainthe oil from the transmission into a container with
a capacity of 40 litres.
STEP 2
Remove two opposite retaining bolts from the rear axle
and install alignment studs CAS 1995.
STEP 3
Use suitable lifting equipment to support the rear axle.
Remove the remainder of the retaining bolts and
remove the rear axle from the transaxle housing.
Don 7-36980
C12345
Put the rear axle in a clean work area so that the
planetary gear end is facing upwards.
6201-6
Disassembly
STEP 8 STEP 5
, . ~
Remove the snap rings from the three planet gear pins,
STEP 6
C13206
Remove the steel plate.
STEP 7
C13208
Release the snap ring from the planet gear carrier-
Don 7-36980
Remove the planet gear carrier assembly from the axle
housing.
STEP 9
Use a suitable drift punch to move the tab on the lock
washer away from the ring nut.
STEP 10
....~.
Use the special tool CAS (2006) to loosen the ring nut.
Remove the ring nut.
STEP 11
~.-'.
Remove and discard the lock washer.
STEP 12
STEP 13
Ale.
Putthe rear axle ina horizontal position and remove the
inner bearing from the axle shaft.
Don 7-36980
6201-7
STEP 14
Use a lever to remove the shaft seal from the rear axle
case.
STEP 15
Remove the axle shaft from the rear axle case.
STEP 16
BOIl520
Install the puller, OEM 1108, and remove the bearing
from the axle shaft.
6201-8
STEP 17
Remove and discard the oil seal.
STEP 18
Mark the gears and pins for the correct assembly of the
planet gear carrier
STEP 19
Remove the gears and thrust washers from the planet
gear carrier.
NOTE: Remove the bottom thrust washer with the gears
to retain the loose bearing rollers.
Don 7-36980
STEP 20
Remove the '0' washer from the top of the planet gear.
NOTE: Keep the parts of the planet gear assemblies
together, so that they can be assembled as a set.
STEP 21
Remove the top rollers.
Remove the separator.
STEP 23
013
Remove the bottom rollers.
6201-9
STEP 24
014
Remove the planet gear from the bottom washer.
STEP 25
Inspection
STEP 28
Clean all parts in cleaning solvent and dry in
compressed air. DO NOT permit the bearings to rotate
when drying.
STEP 26
016
Check the planet gears for wear and cracks atthe tooth
root. Replace the planet gears in sets only.
STEP 27
Check the planet gear pins and the splines inthe carrier
for wear or damage and replace if necessary.
NOTE: The Flat side of the pin faces outvvard.
Don 7-36980
A35
Check the bearings for free, smooth action. Replace
the bearings if necessary, making sure that the new
bearing cups are against their shoulders in the axle
case.
STEP 29
A3S
h #
Check the ring gear and axle case for cracks or other
damage. Replace as necessary.
NOTE: The ring gear and axle housing cannot be
serviced separately.
6201-10
Assembly
Don 7-36980
EA2583
STEP 30
Clean the faces of the rear axle case and the trans axle
housing.
STEP 31
Lubricate the new oil seal (1), with clean transmission
oil. Install the seal onto the axle shaft so that the lip is
toward the flange (2), (groove inward).
STEP 32
Heat theouter axle shaft bearing inthe oven OEM 8014
to atemperature of 300F (150C). Install the bearing on
to the axle shaft so that it is against the shoulder (1).
Don 7-36980
6201-11
$TEP 33
3.BEARING 51252
Putthe axle case ina horizontal position. Install the axle
shaft, assembly and seal installer CAS 2007 into the
axle housing.
STEP 34
Install the inner bearing.
6201-12
STEP 35
AXLE HOUSING 51252A
Install the ring nut only at this stage and tighten until the
seal is fully installed. Remove the seal installation tool
CAS 2007. Remove the ring nut.
Don 7-36980
STEP 36
STEP 37
Install a new lock washer.
STEP 38
Install and tighten the ring nut until all end play is
removed. Lightly hit theflange end of the axle shaft with
a soft hammer to seat the bearings, while rotating the
axle shaft clockwise.
STEP 39
EC3227A
Use the Specia Iy made tool bolted across the
centerline of the axle, with the nut in the center. Use a
torque wrench to measure the rolling torque at the nut,
with the axle resting on the axle flange (measure the
rolling torque with no bearing preload). Make a note of
the rolling torque. Tighten the nut using the Special tool
(CAS 2006). While rotating the axle housing, preload
the bearings to 3.4 to 5.7 Nm (30to 50 Ib in) above the
measurement noted with no bearing preload. Loosen
the ring nut and hit the inner end of the axle shaft with a
soft hammer if the rolling torque is incorrect. Repeat the
setting procedure.
NOTE: When the bearing pre-load is correct, move a
tab on the lock washer into one of the slots in the ring
nut.
STEP 40
Lubricate the surface of the bottom washer with
petroleum jelly and install a planet gear on to the
washer.
Don 7-36980
6201-13
STEP 41
Lubricate the bearing rollers with petroleum jelly and
install the bottom set.
STEP 42
"
011
Install the separator.
STEP 43
Install the top set of bearing rollers.
6201-14
STEP 44
DB
Install the 'D' washer to the top of the planet gear.
Repeat the procedure for the remaining two planet
gears.
STEP 45
STEP 47
Install the planet gear carrier assembly into the axle
housing.
STEP 48
C13208
Install the snap ring onto the planet carrier.
C13222 Install the snap ring onto the axle shaft.
STEP 49
STEP 46
C1321B
Carefully install the planet gear assemblies onto the
planet gear carrier pins.
Don 7-36980
C13206
Install the steel Baffle plate.
Issued12-90 Printedin U.S.A
STEP 50
Install the snap rings into the grooves inthe planet gear
pins. Make sure that the eyes of the snap rings are
opposite the flat on the pins.
6201-15
Installation
STEP 52 STEP 51
712B9GA
aean the surface of the transaxle housing and apply
Sealant CAS 8500642 (Loctite 324).
IMPORTANT: Do not get sealant onto the brake
surfaces.
Don 7-36980
Clean the surface of the rear axle housing and apply
Activator CAS 8500622 (Loctite 707).
STEP 53'
Install the two alignment studs CAS 1995.
6201-16
STEP 54
Use suitable lifting equipment to install the rear axle
onto the transaxle housing.
STEP 55
Install the axle retaining bolts and washers then remove
the two alignment studs.
NOTE: After the rear axles are installed, the mounting
bolts must be fully tjghtened within 3to 5minutes.
Don 7-36980
STEP 56
Install the remaining two bolts and washers then evenly
tighten all the bolts to atorque of 326 to 353 Nm(240 to
260 Ib ft).
STEP 57
Install the transaxle into the machine.
STEP 58
Fill the transmission with Hy-Tran Plus oil upto the FULL
mark on the dipstick.
Section
6202
TRANSFER GEARBOX
CASE CORPORATION
Don 7-36990
Printed in U.S.A.
December 1990
6202-2
TABLE OF CONTENTS
SPECIAL TORQUES 2
TRANSFER GEARBOX
Removal 3
Disassembly 3
Inspection 6
Assembly 7
Installation 10
SPECIAL TORQUES
Transfer Gearbox to Parking Brake Housing 77 to 100 Nm 57 to 74 Ib ft
1. TORQUE WRENCH (OEM 6475) 2. SEALANT 817555 (LOCnTE 515)
+PRIMER 'N' 8500637
6202-3
SERVICING THE TRANSFER GEARBOX
Removal
NOTE: It is not necessary to remove the transaxle from
the machine to service the transfer gearbox. The
transaxle shown was removed for photographic
purposes only.
STEP 1
To prevent excessive loss of oil from the transaxle raise
the front of the machine and support on axle stands.
STEP 2
Remove the drive shaft. Refer to Section 6001.
STEP 3
Disconnect the linkage to the transfer gearbox.
STEP 4
Remove the transfer gearbox retaining bolts.
STEP 5
Remove the transfer gearbox.
Disassembly
STEP 7 STEP 6
Remove the plug.
Don 7-36990
Remove the spring and plunger.
6202-4
STEP 8
Remove and discard the o-ring from the detent plug.
STEP 9
Move the shift rod so the shift collar is clear of the yoke
splines and remove the collar.
STEP 10
Remove the two pads from the shift fork.
Don 7-36990
STEP 11
Remove the roll pins from the shift fork and rod.
STEP 12
Remove the shift fork and rod from the housing.
STEP 13
Remove and discard the shift rod seal
housing.
STEP 14
Remove the snap ring from the yoke.
STEP 15
Use a hydraulic press to remove the yoke from the
housing in the direction shown.
STEP 16
Remove the snap ring from the yoke.
STEP 17
Remove and discard the seal.
Don 7-36990
6202-5
STEP 18
Remove the bearing retainer snap ring from the
housing.
STEP 19
Use a hydraulic press to remove the bearing from the
housing.
6202-6
Inspection
STEP 23 STEP 20
Check the bearing for smooth operation and replace if
necessary.
STEP 21
Check theyoke andshift collar for wear or damage and
replace if necessary. Use a hone to remove any metal
protrusions. Make sure the collar slides easily onto the
yoke.
STEP 22
Check the shift fork and pads for wear or damage and
replace if necessary. Replace pads as a pair.
Don 7-36990
.~:
Clean the surfaces of the parking brake housing andthe
transfer gearbox housing.
6202-7
Assembly
3.SNAP RING
5.SHIFT ROD
6.HOUSING
8.SHIFT COLlAR
EA2S87
Don 7-36990 Issued 12-90 Printedin U.SA
6202-8
STEP 24
Install the new seal into the housing until both the seal
and housing faces are level.
STEP 25
Lubricate and install the yoke shaft into the housing.
STEP 26
Install the first snap ring onto the yoke shaft.
Don 7-36990
STEP 27
Use a hydraulic press to install the bearing.
STEP 28
Install the second snap ring.
Issued 12-90 Printed in U.S A
STEP 29
Install the bearing retainer snap ring.
STEP 30
Install a new shift rod seal (flat side outward) until it is
level with the housing.
STEP 31
Install the shift fork so the detent groove is aligned with
the hole in the housing.
Don 7-36990
6202-9
STEP 32
Install the shift rod.
STEP 33
Rotate the shift lever to the correct position. Align the
holes and install the roll pins.
STEP 34
Install the two pads into the shift fork.
6202-10
STEP 35
Install the shift collar onto the two pads with the flat side
of the collar faces inward. Align the splines and slide
the collar over the yoke.
STEP 36
Install the detent plunger and spring.
STEP 37
~::.
Install a new o-ring onto the plug.
STEP 38
Install and tighten the plug.
STEP 39
Check the movement of the shift collar by moving the
shift rod. Make sure the detent plunger holds the shift
fork in the engaged and disengaged positions. Rotate
the yoke and repeat the test.
Installation
STEP 41 STEP 40
70001
Clean the surfaces of the parking brake housing and
transfer gearbox housing. Apply CAS 817555 (Loctite
515) to the parking brake housing and Primer 'N'
8500637 to the transfer gearbox housing.
Don 7-36990
,-.
Install the transfer gearbox onto the park brake housing.
STEP 42
Install the five bolts and washers and evenly tighten to a
torque of 77 to 100 Nm (57 to 74 Ib ft).
Don 7-36990
6202-11
STEP 43
Install the drive shaft. Refer to Section 6202.
STEP 44
Connect the linkage to the transfer gearbox.
STEP 45
Remove the axle stands and lower the machine to the
ground.
STEP 46
Add oil of the correct type to the transmission until the
level reaches the full mark on the dipstick.
"
Section
6203
DIFFERENTIAL AND DIFFERENTIAL LOCK
Don 7-37000
Printed in U.S.A.
December 1990 CASE CORPORATION
6203-2
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TORQUES 2
SERVICING THE DIFFERENTIAL AND DIFFERENTIAL LOCK
Removal........ 4
Disassembly , , 6
Inspection....... 9
Assembly ,....................................................................................................................... 10
Installation.............................................................................................................................. 13
SPECIFICATIONS
Lubrication
Transmission OiL Hy-Tran Plus (MS 1207)
SPECIAL TORQUES
Rear Axles To Transmission Case 326 to 353 Nm
Differential Bearing Carrier Bolts 73 to 87 Nm
(Tighten While Rotating The Differential)
Differential Lock Cage To Carrier 73 to 87 Nm
Differential Carrier To Crown Wheel. 126 to 153 Nm
240 to 260 Ib ft
54 to 64 Ib ft
54 to 64 Ib ft
93 to 113 Ib ft
Don 7-37000 Issued12-90 Printedin U.S.A.
6203-3
1. TORQUE WRENCH (OEM 6475)
4. DEPTH GAUGE (OEM 1013)
2. SEALANT CAS B17555 (LOCTITE 515) AND
PRIMER 'N' B500637
5. BEARING OVEN (OEM 8014)
6. THREAD SEALANT
LOCTITE 680
3. DIAL GAUGE AND MAGNETIC BLOCK
(OEM 1030-1)
NOTE: Any reference to left or right hand is as seen from the operator's seat looking forward.
6203-4
SERVICING THE DIFFERENTIAL AND DIFFERENTIAL LOCK
STEP 1
Removal
STEP 4
Drain the oil from the transmission case. Remove the
transaxle from the machine. Refer to Section 6001.
STEP 2
Remove both rear axles. Refer to Section 6201.
STEP 3
Remove the brake backing plate, friction plate and
reaction pins from the left side of the transmission
housing. Refer to Section 7001 for the correct
procedure.
NOTE: Do not remove the brake piston.
Don 7-37000
Remove the sun shaft from the differential.
STEP 5
Remove the brake parts from the right hand side of the
transmission housing.
NOTE: 00not remove the brake piston.
STEP 6
Disconnect the return spring from the top of the
differential lock selector lever.
STEP 7
Use a punch to remove the pin from the differential lock
selector fork and lever.
STEP 8
Remove the differential lock lever from the transmission
housing.
STEP 9
Remove the sun shaft and differential lock selector
assembly.
Don 7-37000
6203-5
STEP 10
Remove the nuts, bolts, washers and setscrews from
the rear cover plate.
STEP 11
Remove the rear cover plate.
STEP 12
... .~
Use a block of wood to support the differential.
6203-6
STEP 13
Remove the four bolts and washers fromthe right hand
differential bearing carrier.
STEP 14
Remove the differential bearing carrier and shims from
the transmission case.
STEP 15
Repeat the procedure for the differential bearing carrier
on the left hand side.
STEP 16'
~?
Carefully remove the differential.
Disassembly
STEP 18 STEP 17
Put the differential assembly on a clean work surface.
Don 7-37000
Remove the bolts which hold the differential lock cage
to the differential carrier.
STEP 19
F21
..... ,;;;..;:.
Remove the differential lock cage.
STEP 20
Remove the side gear.
STEP 21
F25
Remove the crown wheel retaining bolts and washers.
Don 7-37000
6203-7
STEP 22
Install two 12mm bolts into the threaded holes in the
differential carrier. Evenly tighten the bolts to push the
crown wheel from the differential carrier.
STEP 23
F30
Remove the differential carrier.
STEP 24
F34
Use a suitable drift to remove the groove pin from the
planetary gear pin.
6203-8
STEP 25
.. d.,
Remove the planetary gear pin from the differential
carrier.
STEP 26
Remove the two planetary gears.
STEP 27
Remove the second side gear.
Don 7-37000
STEP 28
G16
Put the differential lock selector and sun shaft on a
clean work area.
STEP 29
Remove the selector fork and pads.
STEP 30
.G19
Remove the selector from the sun shaft.
6203-9
Inspection
STEP 34 STEP 31
when drying.
STEP 32
"G23
Check,the side gears, planet gears and pin for wear or
damage and replace as necessary.
STEP 33
G12A
Check the differential carrier and differential lock cage
for wear or damage and the bearing for free andsmooth
action and replace if necessary
Don 7-37000
G14
Check both differential bearing carriers for wear or
damage. If replacing the differential bearings, make
sure that the new bearing cups are correctly installed.
STEP 35
G9
The crown wheel and the pinion shaft are a matched
set. Replace both parts if there is any wear or damage.
Refer to Section 6206 for pinion shaft removal.
STEP 36
G2OA.
Check both sun shafts and the differential lock selector
for wear or damage and replace as necessary.
6203-10
EA2586B
STEP 37
Lubricate the differential lock selector with clean
transmission oil then slide it onto the inner splines on
the sun shaft. Make sure that the selector teeth are
away from the sun gear.
STEP 38
Install the two pads into the selector fork. Use
petroleum jelly to hold them in position.
STEP 39
Install thefork into the selector. The hole for the pin must
be at thetop when the fork is on the left hand side of the
selector, looking on the gear end of the sun shaft.
Don 7-37000
6203-11
STEP 40
Install the left hand side gear into the differential carrier.
STEP 41
Install the two planet gears.
STEP 42
,00
Push the planet gear pin through the differential carrier
and the planet gears. Make sure that the hole for the
grooved pin is vertical.
6203-12
STEP 43
G36
Install a new grooved pin into the differential carrier and
planet gear pin.
STEP 44
Install two guide studs into opposite holes inthe crown
wheel.
STEP 45
F3S
Heat the crown wheel in a bearing oven to a maximum
temperature of 302F (150C) and install the crown
wheel onto the differential carrier. When the parts are
cool, remove the guide studs.
hWARNING: Always wear heat protective
gloves when touching heated parts.
Don 7-37000
STEP 46
Apply (Loctite 680) to the threads and install the twelve
12mm bolts and new hardened washers into the
differential carrier and crown wheel.
STEP 47
F24
Evenly tighten the bolts to atorque of 126to 153Nm (93
to 113 Ib ft).
STEP 48
Install the right hand side gear and lubricate the gears
with clean transmission oil.
STEP 49
Install the differential lock cage onto the differential
carrier.
STEP 50
Install the six 10 mmbolts into the differential lock cage
and carrier.
6203-13
STEP 51
~':
Evenly tighten the bolts to atorque of 73to 87 Nm(54to
64 Ib ft). Lubricate the bearing with clean transmission
oil.
Installation
STEP 53 STEP 52
Remove the tube nut for the differential lock lever, from
the top of the transmission housing.
Don 7-37000
Install new inner and outer o-rings onto the tube nut.
6203-14
STEP 54
w~ : ,
",.
Install the tube nut into the transmission housing.
STEP 55
,
Install the differential into the transmission housing, so
thatthe crown wheel teeth arepointing to the right hand
side of the housing.
STEP 56
Install the right hand bearing carrier without shims.
NOTE: Make sure the hole for the differential lock
control rod is properly aligned.
Don 7-37000
STEP 57
Install the four 1Ommbolts and newhardened washers.
STEP 58
~
Evenlytighten the bolts to atorque of 73to 87 Nm(54to
64 Ib ft).
STEP 59
Install the left hand bearing carrier without shims.
STEP 60
Install two bolts and new hardened washers into
opposite holes then remove the wood block from under
the differential.
STEP 61
While rotating the differential, evenly tighten the bolts to
a torque of 20 Nm (180 in Ibs). Rotate the differential
and check the torque.
Loosen the two bolts and now torque to 5.6 Nm (50 in
Ibs.)
NOTE; The differential must be rotated while tightening
the bolts to make sure that the bearings are correctly
seated. Continue this procedure until there is no change
in bolt torque.
Don 7-37000
6203-15
STEP 62
Using a depth gauge, measure the distance from the
face of the carrier to the transxaxle mounting face,
through the measuring holes. If the difference in the
measurements is 0.13mm (0.005 in.) or less, take the
average of the two measurements. If the difference is
greater than 0.13mm, disassemble and check for
proper bearing seating. Subtract the carrier flange
thickness fromthis figure and add the aero-set constant
of 0.065mm (0.0026 in.) to the measured gap. This is
the shim pack required for the correct bearing preload.
STEP 63
Remove the two bolts, washers and the left hand
bearing carrier. Fit the total shim thickness onto the
bearing carrier and install the bearing carrier.
STEP 64
Install the bolts and washers onto the bearing carrier.
6203-16
STEP 65
While rotating the differential, evenly tighten the bolts to
a torque of 73 to 87 Nm (54 to 64 Ib ft). The bearings
are now correctly pre-loaded.
STEP 66
Use a dial gauge on the edge of a crown wheel tooth to
measure the amount of backlash between the crown
wheel and the pinion. This must be between 0.15 to
0.30 mm (0.006 to 0.012 inch). To change the amount
of backlash, move some of the shims from the left hand
bearing carrier to the right hand bearing carrier, without
changing the total shim pack thickness. For each 0.076
mm (0.003 inch) of shim thickness moved, the
backlash will change by approximately 0.05 mm (0.002
inch).
After moving the shims. rotate the differential and
evenly tighten the bearing carrier bolts to atorque of 73
to 87 Nm (54 to 64 Ib ft).
Check the ring gear to pinion shaft contact pattern.
Refer to Section 6206
Don 7-37000
STEP 67
Remove any old joint material from the rear cover plate
and the joint face of the transmission housing. Make
sure both faces are free of oil.
STEP 68
Apply a continuous bead of CAS 817555 (Loctite 515)
onto the joint face of the transmission housing. Apply
Primer 'N' 8500637 onto the mounting face of the
cover.
STEP 69
Install the rear cover plate onto the transmission
housing
STEP 70
Install the nuts, bolts, washers and setscrews and
evenlytighten to atorque of 221 to 250 Nm (160 to 185
Ib ft).
STEP 71
Install the sun shaft and differential lock selector
assembly into the right hand side of the differential.
Make sure that the selector fork is at the rear.
STEP 72
Install the selector lever through the tube nut and into
the selector fork. Becareful not to damage the a-ring in
the tube nut. The top of the selector lever must be
pointing outward from the transmission case.
Don 7-37000
6203-17
STEP 73
Install a new pin into the selector fork and lever.
STEP 74
Connect the return spring to the selector lever.
STEP 75
Install the right hand side disc brake parts. Refer to
Section 7001.
6203-18
STEP 76
Install the left hand sun shaft into the differential.
STEP 77
Install the left hand side disc brake parts.
Don 7-37000
STEP 78
Install the rear axles. Refer to Section 6201.
IMPORTANT: Use only the sealant kit 8500621 when
installing the rear axles.
CASE CORPORATION
Section
6204
FORWARD/REVERSE VALVE
Don 7-37010
Printed in U.S.A.
December 1990
6204-2
TABLE OF CONTENTS
SPECIFICATIONS _ 2
SPECIAL TORQUES 2
FORWARD/REVERSE VALVE
Disassembly 3
Inspection 5
Assembly 6
SPECIFICATIONS
Transmission Lubricating Oil Hy-Trans Plus (to MS 1207)
Spool Detent Spring Free Length 37.26 mm 1.467 inch
Regulator Spring Free Length 58.65 mm 2.309 inch
Modulation Spool Inner Spring Free Length 70.55 mm 2.777 inch
Modulation Spool Outer Spring Free Length 77.60 mm 3.055 inch
SPECIAL TORQUES
Forward/Reverse Spool Plug 31 to 34 Nm
Detent Plug 16 to 18 Nm
Accumulator Piston Plug 31 to 34 Nm
Pressure Regulator Piston Plug 42 to 45 Nm
Solenoid Valve 17 to 20 Nm
Coil Cover Nut.. 0.8 to 1.0 Nm
Neutral Start Switch 20 to 27 Nm
23 to 25 Ib ft
12 to 13 Ib ft
23 to 25 Ib ft
31 to 33 Ib ft
13to 15 Ib ft
0.5 to 0.75 Ib ft
15 to 20 Ib ft
1. TORQUE WRENCH
OEM 6479
Disassembly
STEP 4
".".".. --y".'
STEP 1
Remove the connecting wires and neutral start switch
(1) from the valve body. Discard the a-ring from the
switch.
STEP 2
Remove the allen plugs from the top of the valve body
and discard the a-rings.
STEP 3
Remove the nut (1), a-ring (2), cover (3) and a-ring (4)
from the solenoid valve. Discard the a-rings.
Don 7-37010
6204-3
Remove the solenoid valve (1) from the valve body and
discard the o-rings (2).
STEP 5
Remove the allen plug (1), pressure regulator piston (2),
spring (3), pin (4) and regulator spool (5). Discard the
a-ring (6).
IMPORTANT: Machines equipped with PTO have a
special hexagon plug (A) to keep the pressure regulator
piston activated for PTO operation with the transmission
control lever in neutral. Remove the plug and
components as in Step 5, discard the a-ring from the
plug.
6204-4
STEP 6
Remove the allen plug (1), accumulator piston (2),
secondary spring (3) and primary spring (4). Discard
the o-ring on the plug.
STEP 7
030111
Remove the allen plug from the opposite end of the
same bore and remove the modulation pressure
regulator spool (1) Discard the o-ring (2) from the plug.
STEP 8
Remove the allen plug (1), spring (2) and detent (3).
Discard the o-ring (4).
Don 7-37010
STEP 9
8
'~~7r
"i1Jons
Remove the allen plug (1) and forward/reverse spool
(2). Discard the ring (3) from the spool and o-ring from
the plug.
STEP 10
030117
Remove and discard the oil seal (1) from the bore of the
forward/reverse spool.
6204-5
STEP 11
Inspection
STEP 13
Clean all parts in cleaning solvent. Dry using
compressed air. DO NOT use cloths.
STEP 12
Inspect all the components for wear and replace if
necessary. Replace the valve assembly if there is any
damage to the surfaces of the bores and spools.
FRY OR
Make sure the oil restrictor (1) is clean. Remove
obstructions with compressed air or a soft wire.
Don 7-37010 Issued12-90 Printedin U.S.A
6204-6
Assembly
1. BODY
2. SWITCH
3. PLUG
4. O-RING
5. Oil RESTRICTOR
6. SOLENOID
7. REGULATO VAlVE ASSEMBLY
8. SPRING R PISTON
9. PIN
10. SPOOL
11. ACCUMU
12. MODULA~TOR PISTON
13 SE OR SPOOL
. LECTOR SPOOL
14. RING
15. DETENT
16. SEAL
STEP 14
Lubricate all components with clean Hy-Tran Plus.
STEP 15
030'17
Installl the newoil seal (1), into the valve body with the
flat side outwards. When fully installed, the outer face of
the seal must be 2.5 mm(O.10) inch below the face of
the valve body.
STEP 16
Don 7-37010
6204-7
STEP 17
Install the spool (1), into the position shown.
STEP 18
STEP 19
030111
Install a new a-ring (1) onto the plug. Install the
modulator pressure regulator spool (2), and plug.
Tighten the plug.
6204-8
STEP 20
000110
Install a new a-ring (1) onto the plug. Install the primary
spring (2), secondary spring (3) and accumulator
piston (4). Install and tighten the plug.
STEP 21
000119
Install a new o-ring (1) onto the plug. Install the
regulator spool (2), pin (3), spring (4) pressure regulator
piston (5). Install and tighten the plug.
STEP 22
030107
Install new a-rings (1) onto the solenoid valve 2. Install
and tighten the valve to a torque of 20 Nm (15 Ib ft).
Don 7-37010
STEP 23
000106
Install a newo-ring (1), cover (2), o-ring (3) and nut (4).
Tighten the nut to atorque of 0.8 to 1.0Nm(0.6to 0.71b
ft)
STEP 24
000105
Install newo-rings onto the plugs. Install and tighten the
plugs.
STEP 25
D30233
Install a new o-ring onto the neutral start switch. Install
and tighten to a torque of 20 to 27 Nm (15 to 20) Ib ft.
Install the wires and tighten the screws.
Section
6205
TORQUE CONVERTER CHARGING PUMP, OUTPUT SHAFT,
AND CONVERTER HOUSING
CASE CORPORATION
Don 7-37020
Printed in U.S.A.
December 1990
6205-2
TABLE OF CONTENTS
SPECIAL TORQUES 2
SERVICING THE CHARGING PUMP
Removal 3
Disassembly 4
Inspection 5
Assembly 6
Installation 8
SERVICING THE OUTPUT SHAFT
Removal 9
Inspection.................................... 10
Installation 11
SERVICING THE TORQUE CONVERTER HOUSiNG 13
SPECIAL TORQUES
Charging Pump Retaining Bolts 23 to 30 Nm 17 to 22 Ibs ft
Output Shaft Locknut 217 to 271 Nm 160 to 200 Ibs ft
SERVICING THE CHARGING PUMP
6205-3
Removal
STEP 4 STEP 1
Remove the torque converter housing from the
machine. Refer to Section 6200.
STEP 2
Remove the four retaining bolts and flat washers from
the charging pump.
STEP 3
Don 7-37020
Remove and discard the o-ring seal from the torque
converter housing.
6205-4
Disassembly
STEP 5
Loosen the internal hexagon screw that holds the stator
support to the pump body.
STEP 6
Remove the screw, lower the pump body and gears on
to the work bench, and remove the stator support.
STEP 7
Xll
For easy assembly, make a mark on the pump body,
driven gear and drive gear.
Don 7-37020
STEP 8
X13
Remove the drive gear.
STEP 9
Remove the driven gear.
STEP 10
Remove and discard the seal from the pump body.
6205-5
Inspection
STEP 12 STEP 11
X22
1. Clean all the parts in cleaning solvent and dry in
compressed air.
2. Only the seal and two bushings are available
separately as service parts. If there is damage to
any other part of the charging pump, you must
install a new assembly.
3. Check the two gears for wear and damage.
4. Check the body and converter support for pitting,
scoring, cracks and wear.
5. There is only a small amount of clearance
between the parts of the charging pump. It is
possible for the parts to look good but still be
worn enough for the charging pump to be
replaced. If troubleshooting shows that there is
not enough flow fromthe charging pump, install a
new assembly.
NOTE: Low charge pump pressure could be caused by
the charge regulator valve stuck open.
Don 7-37020
Ifa newconverter support bushing (1) is installed, make
sure that it fits against the internal shoulders (2) as
shown.
6205-6
Don 7-37020
Assembly
62056
STEP 13
Before assembly, lubricate all the parts with clean
transmission oil.
STEP 14
__ ~ ~9
Install a new seal into the body so that the flat face is
outward and level with the outer face of the body.
STEP 15
X18
Install the driven gear so that the marks align.
STEP 16
X14
Install the drive gear so that the small diameter is inward
and the marks align.
Don 7-37020
6205-7
STEP 17
Install the converter support through the body.
STEP 18
Install and tighten the internal hexagon head screw.
6205-8
Installation
STEP 21 STEP 19
Lubricate and install a new o-ring seal into the torque
converter housing.
STEP 20
Install the charging pump onto the torque converter
housing, making sure that the two oil holes align.
Don 7-37020
;, X1
Install the four retaining bolts and newflat washers and
evenly tighten to atorque of 23 to 30 Nm (17 to 22 Ibft).
STEP 22
Install the torque converter housing onto the machine.
Refer to Section 6200.
SERVICING THE OUTPUT SHAFT
6205-9
Removal
STEP 26 STEP 23
Refer to STEPS 1 through 4 to remove the charging
pump.
STEP 24
Hold the coupling ina vice and remove the locknut and
washer.
NOTE: The coupling is shown out of the vice for
photographic purposes. When removing or installing
the drive coupling nut, clamp the coupling in the vice
and not the input shaft. This will prevent possible
damage to the shaft and splines.
STEP 25
Remove the coupling from the ouput shaft.
Don 7-37020
Remove and discard the o-ring.
STEP 27
Remove and discard the oil seal from the outer face of
the torque converter housing.
STEP 28
Remove the output shaft bearing snap ring from the
STEP 29
Use a soft hammer to remove the output shaft and
bearing from the torque converter housing in the
direction shown.
6205-10
STEP 30
6205GR
Remove the bearing from the shaft.
STEP 31
Remove and discard the sealing ring from the groove in
the output shaft in the direction shown.
Inspection
STEP 33 STEP 32
1. Clean all the parts in cleaning solvent and dry
using compressed air.
2. Replace the output shaft if there is damage to the
sealing surfaces. Remove any metal protrusions
from the splines with a fine hone.
3. Check the bearing and wear sleeve inthe torque
converter housing for wear and replace if neces
sary.
Don 7-37020
~,
Check the wear sleeve for wear or damage and replace
if necessary. Use a suitable drift to remove the wear
sleeve inthe direction shown. Take care not to damage
the housing bore. When installing a new wear sleeve
make sure it is against the shoulder in the bore.
6205-11
Installati on
6205138
Don 7-37020
6205-12
STEP 34
Putthe new sealing ring into clean transmission oil for
several minutes before installing onto the output shaft
in the direction shown.
STEP 35
Install the bearing onto the output shaft.
STEP 36
6205GFW
Install the output shaft and bearing into the torque
coverter housing and install the snap ring.
Don 7-37020
STEP 37
Install a new oil seal into the torque coverter housing,
and lubricate with clean transmission oil.
STEP 38
Lubricate and install a new o-ring onto the output shaft.
STEP 39
Install the coupling.
STEP 40
Install the washer and lock nut. Hold the coupling in a
vise and tighten the lock nut to a torque of 217 to 271
Nm (160 to 200 Ibs ft).
6205-13
SERVICING THE TORQUE CONVERTER HOUSING
62115130
Don 7-37020
6205-14
STEP 41
1. Refer to Section 6200 to replace the torque
converter housing.
2. Refer to Maintenance Section to replace the oil
filter cartridge. Always replace the cartridge after
doing work on the torque converter housing,
charging pump or output shaft.
3. Refer to the following STEPS to service the
charging pump relief valve, torque converter relief
valve, oil restriction indicator and filter bypass
valve. The torque converter housing is shown
removed from the machine for photographic
purposes only.
STEP 42
Remove the plug for the charging pump relief valve.
STEP 43
Remove the spring.
Don 7-37020
STEP 44
Use a magnet to remove the steel ball.
STEP 45
Use a suitable wood or plastic dowel to remove the
relief valve cartridge.
NOTE: If there is any damage, anew cartridge must be
installed.
STEP 46
Replace the o-ring and lubricate with clean
transmission oil.
STEP 47
Install the relief valve cartridge into the bore.
STEP 48
Install the steel ball and spring.
STEP 49
Install a new a-ring on the plug. Install and tighten the
plug.
Don 7-37020
6205-15
STEP 50
Follow STEPS 42 through 49 to service the torque
converter relief valve.
STEP 51
Remove the filter bypass valve from the right hand side
of the torque converter housing. Parts for the relief
valve are not available. If there is any damage to the
seat area of the poppet, install a new assembly. Always
replace the a-ring on the plug.
STEP 52
Remove the restriciton indicator from the right hand
side of the torque converter housing. Always replace
both a-rings before installation.
Sect i on
6206
TRANSMISSION
CASE CORPORATION Don 737030
Printed in U.S.A.
December 1990
6206-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................... " 2
SPECIAL TORQUES _ _ 2
SPECIAL TOOLS 3
TRANSMISSION END COVER
Removal _ 5
Installation 35
SERVICING THE INTERMEDIATE SHAFT
Removal 7
Disassembly 8
Inspection 9
Assembly _ _ _.. 9
Installation 10
SERVICING THE SHUTTLE SHAFT
Removal _ _ _ 11
Disassembly _ 11
Inspection 14
Assembly _ 15
Installation 19
SERVICING THE PINION SHAFT
Disassembly _ 19
Inspection _ _-..- _ 25
Assembly _ - 26
Checking Ring Gear and Pinion Tooth Contact 37
SERVICING THE GEAR SHIFTERS
Removal _ 39
Disassembly 40
Inspection _.41
Assembly _ _ _ __ 42
Installation _ 43
Adjustment __ 44
REMOVAL AND INSTALLATION OF THE MAGNETIC SPEED SENSOR 44
INSTALLATION OF TRANSAXlE REAR COVER .45
SPECIFICATIONS
Lubricating Oil Hy-Tran Plus (MS 1207)
SPECIAL TORQUES
Transmission End Cover Bolt 195 to 250 Nm
Pinion Shaft End Bolt.. 251 to 280 Nm
Transmission Rear Cover Bolts 195 to 250 Nm
Gear Shift Rail Retaining Bolts .44 to 58 Nm
Don 7-37030
145 to 185 Ib ft
185 to 205 Ib ft
145 to 185 Ib ft
33 to 43 Ib ft
SPECIAL TOOLS
6206-3
The transmission tool kit (CAS 1989) contains the special tools required to service the trans axle assembly.
The following are the tools required to service the transmission Section.
1. PINION SHAFT PRELOAD SETIING WASHER
CAS 1998
2. SEAL COMPRESSOR SET
CAS 2005-1
3. CLUTCH PACK SPRING COMPRESSOR
CAS 1992
Don 7-37030
4. SEAL EXPANDER/PROTECTOR SHUTTLE SHAFT
CAS 1999
5. PINION SHAFT MASTER BEARING CONE
CAS 2019
6. TRANSMISSION BEARING RACE RETAINER
CAS 2008
6206-4
4. DIAL GAUGE WITH MAGNETIC BASE (OEM 1030)
2. SEALANT B17555 (LOCTITE 515)
AND PRIMER 'N' B500637
5. METRIC FEELER GAUGE (OEM 1024)
3. BEARING OVEN (OEM 8014)
6206-5
Removal
STEP 4 NOTE: To service the transmission the transaxle must
be removed from the machine, refer to Section 6001.
Drain the oil from the transmission into acontainer with a
capacity of 40 litres (42 US quarts).
STEP 1
Remove the rear cover and stand the transaxle on the
rear flange in the vertical position. This will reduce the
stress on the shafts and bearings.
STEP 2
C1Z301
Remove the transfer gearbox or end cover. Refer to
Section 6202.
STEP 3
Remove the parking brake housing and
assembly. Refer to Section 7000.
Don 7-37030
Remove the bolt, washer and shims from the pinion
shaft.
STEP 5
..,:. -.... - .;,
Remove the spacer and splined park brake hub.
Issued 12-90 Printedin U.S.A
6206- 6
STEP 6
...... ..,
Remove the two bolts and plate from the end of the gear
shift rail.
STEP 7
Remove the retaining bolts and washers from the
transmission end cover.
Don 7-37030
STEP 8
__ ~.~c
Remove the three blanking plugs from the end cover
and insert a 38 mm (1.5 inch) spacer into each hole.
Install and tighten the bolts evenly to separate the end
cover from the transmission housing.
STEP 9
" .- ~ :.:~.
Remove the bearing cone from the end of the pinion
shaft.
STEP 10
Use suitable lifting equipment and remove the
transmission end cover.
6206-7
SERVICING THE INTERMEDIATE SHAFT
Removal
STEP 11
Follow steps 1 to 10 to remove the transmission end
cover.
STEP 12
Remove the snap ring from the end of the pinion shaft.
NOTE: This will allow the synchromesh hub to move up
as the intermediate shaft is removed.
Don 7-37030
STEP 13
Remove the intermediate shaft from the transmission
housing.
6206-8
Di sassembl y
STEP 17
,
STEP 14
C124Q6
Mark the gears for easier assembly.
STEP 15
C1'22ll6
Use a press and remove the bearing cone (1), fourth
drive gear (2) and spacer(3).
STEP 16
Remove the third gear.
Don 7-37030
Remove the second gear and spacer.
STEP 18
Remove the second bearing cone and first gear.
6206- 9
Inspect i on
STEP 19
Clean all parts in cleaning solvent and dry using
while drying. Check all the parts for wear and damage
and replace if necessary.
Assembl y
9. 4TH GEAR
6. 2ND GEAR
4. 1ST GEAR
2. BEARING CONE
7. 3RD GEAR 8. SPACER
6. 2ND
GEAR
NOTE: If equipped the first and second gears and the
intermediate shaft are one piece.
Don 7-37030
6206-10
STEP 20
Put the gears and bearings into an oven (OEM 8014)
and heat to a temperature of 302F (150 C). Keep the
shaft as cool as possible.
NOTE: The tapped hole at the end of the intermediate
shaft must be at the fourth gear end.
STEP 21
i~!
1. SHOULDER
e
6007318
Install the parts onto the intermediate shaft infollowing
order. Gear (1), Bearing (2), Spacer (3), 2nd Gear (4),
3rd Gear (5), Spacer (6), 4th Gear (7) and Bearing (8).
IMPORTANT: After Assembly make sure both the
bearing cones are against the shoulders on the shaft.
Inst al l at i on
STEP 23 STEP 22
Install the intermediate shaft
housing.
the transmission
NOTE: Uft up the 3rd and 4th gear synchromesh hub to
allow installation of the intermediate shaft.
Don 7-37030 .
Make sure the synchromesh hub, needle bearing and
thrust washer is against the pinion shaft and install the
snap ring.
STEP 24
Follow STEPS 140 to 145to install the transmission end
cover.
STEP 25
Follow STEPS 146 to 151 and check the intermediate
shaft end play.
6206- 11
SERVICING THE SHUTTLE SHAFT
Removal
STEP 29 STEP 26
Follow STEPS 1to 10 to remove the transmission end
cover.
STEP 27
Follow STEPS 12 to 13 to remove the intermediate
shaft.
STEP 28
Usea puller and remove the bearing from the end of the
shuttle shaft. Remove the snap ring thrust washer and
bearing. Remove the forward gear.
Follow STEPS 71 to 87 to service the pinion shaft.
NOTE: The shuttle shaft cannot be removed with the
pinion shaft assembled.
STEP 30
Remove the shuttle shaft from the transmission.
Di sassembl y
STEP 32 STEP 31
N17
Remove the roller bearing (1), spacer (2) and second
roller bearing (3).
Don 7-37030
036
Remove the thrust bearing (1).
6206- 12
STEP 33
STEP 34
Remove the snap ring from the clutch plate carrier.
STEP 35
030
Remove the clutch backing plate.
Don 7-37030
STEP 36
Remove the 6 friction and 6 steel plates from the
forward clutch.
STEP 37
P16
Put the shuttle shaft in a press. Use the special tool
(CAS 1992) to push the piston return spring and washer
away from the snap ring. Remove the snap ring.
STEP 38
024
Remove the washer.
STEP 39
022
Remove the piston return spring.
STEP 40
021
Use compressed air through the following holes in the
reverse gear end of the shaft to remove the clutch
piston:
Outer hole - forward piston
Inner hole - reverse piston
Middle hole - for lubrication
NOTE: Do not use levers to remove the piston. The
piston can be easily damaged by levers.
Don 7-37030
6206- 13
STEP 41
011
Remove and discard the outer piston seal and a-ring.
STEP 42
010
Remove and discard the inner piston seal and a-ring.
STEP 43
016
Remove and discard the four sealing rings. Remove the
bearing cone (1), snap ring, thrust washer, thrust
bearing (2) and gear (3). Repeat STEPS 31 to 42 and
disassemble the reverse clutch.
6206-14
Inspect i on
STEP 48 STEP 44
Clean all the parts in cleaning solvent and dry in
compressed air.
STEP 45
02
Check the piston for wear or damage and replace if
necessary.
STEP 46
03
Check the friction plates for wear or damage and
replace if necessary.
STEP 47
05
Check the steel wear plates for wear or damage and
Don 7-37030
06
Check the backing plate for damage and replace if
necessary. Remove small scoring or grooves with a
hone or fine emery cloth.
STEP 49
08
Check the drive gear for damage and replace if
necessary. Look for cracks at the root of the teeth. Use
a hone to remove any small protrusions from the
splines.
STEP 50
Check the shuttle shaft and replace the assembly if
there is wear or damage.
6206-15
Assembl y
620619
6206- 16
NOTE: Before assembly, use compressed air to make
sure that all the oil holes are clear.
STEP 51
Lubricate all the parts with clean transmission oil before
assembly. Put the seal rings for the piston and shuttle
shaft in warm transmission oil for several minutes to
prevent damage during assembly.
STEP 52
010
Install a new o-ring (1) and then a newinner seal ring (2)
into the clutch piston.
STEP 53
011
Install a new o-ring (3) and then a newouter seal ring (4)
onto the clutch piston.
Don 7-37030
STEP 54
021
Carefully install the clutch piston onto the shuttle shaft
so that the grooved face of the piston is outward. If the
piston locks up during installation, remove with
compressed air and install again. Never use force to
correct wrong alignment of the piston.
STEP 55
022
Install the piston return spring.
STEP 56
024
Install the washer.
STEP 57
STEP 58
I P16
Put the shuttle shaft assembly into a press. Use the
special tool (CAS 1992) to push the piston return spring
and special washer below the snap ring groove. Install
the snap ring.
STEP 59
Install a steel clutch plate.
Don 7-37030
6206- 17
STEP 60
Install a friction clutch plate. Continue installing a steel
and then a friction clutch plate until there is a total of 12
plates in the clutch pack.
STEP 61
030
Install the backing plate so that the small diameter is
outward.
STEP 62
6206-18
STEP 63
Install a thrust washer (1) and thrust bearing (2).
IMPORTANT: Make sure the smooth side of the
bearing is outward.
STEP 64
Install a roller bearing (1), spacer (2) and second roller
bearing (3).
STEP 65
Repeat Steps 51 to 64 and assemble the reverse
clutch. Install the gear, thrust bearing, thrust washer,
snap ring and bearing cone.
Don 7-37030
STEP 66
Use the special plastic installation tool CAS 1999 (1) to
install the sealing rings (2).
NOTE: Put the sealing rings in clean transmission oil
STEP 67
Compress the seal ring by hand and then install the seal
compressor, CAS 2005-1.
NOTE: Only by using the seal compressor, CAS2005- 1,
can the seals be compressed to the correct working
size.
6206-19
Inst al l at i on
STEP 69 STEP 68
2. WEAR SLEEVE
62066
Check the wear sleeve in the transmission case for
damage or wear marks. If necessary, replace the wear
sleeve making sure that the oil holes arealigned with the
holes in the top of the transmission case.
Install the shuttle shaft.
NOTE: The second driven gear will have to be raised
slightly to allow the shuttle shaft to locate into the bore in
the transmission case.
STEP 70
Follow STEPS 126 to 135 on servicing the pinion shaft.
SERVICING THE PINION SHAFT
Di sassembl y
NOTE: To prevent damage to the pinion shaft and STEP 72
crown wheel, remove the axles, differential and ~<
lubrication tube. Support the pinion shaft before starting
disassembly.
STEP 71
;~
Remove the intermediate shaft. Refer to STEP 12.
Don 7-37030
Remove the baffle plate.
6206- 20
STEP 73
Remove the forward gear from the shuttle shaft.
STEP 74
Loosen the two gear shift lever pivot bushings (1).
STEP 75
:~~'
,.: J ",$ ..
Pull the gear shift rail up from its locating bore in the
transmission case. Rotate the assembly counter-
clockwise and lift the rail and shift forks clear of the
pinion shaft.
Don 7-37030
STEP 76
Remove the thrust washer (1) and needle bearing(2).
STEP 77
Remove the fourth driven gear.
STEP 78
Remove the washer.
STEP 79
Remove the synchromesh unit outer cup.
STEP 80
Remove the bearing.
STEP 81
Remove the synchromesh unit.
Don 7-37030
6206-21
STEP 82
Remove the hub.
STEP 83
Remove the needle bearing and synchromesh inner
cup.
6206-22
STEP 84
Remove the third driven gear.
STEP 85
Remove the needle bearing (1) and thrust washer (2).
STEP 86
>'
Remove the snap ring.
Don 7-37030
STEP 87
Remove the thrust washer (1) and needle bearing (2).
STEP 88
Remove the shuttle shaft.
NOTE: litt up the second driven gear toallow the shuttle
shaft to be lifted out of the transmission case.
STEP 89
Remove the second driven gear.
STEP 90
'.' ,
Remove the synchromesh assembly.
STEP 91
Remove the needle bearing.
STEP 92
Remove the synchromesh hub.
Don 7-37030
6206- 23
STEP 93
Remove the needle bearing and thrust washer.
STEP 94
t.. .~
Remove the first driven gear with spacer.
STEP 95
:S.
h
1:12121
Remove the two roller bearings.
6206-24
STEP 96
1
Remove the thrust washer, needle bearing and second
thrust washer.
STEP 97
Remove the pinion shaft support and the pinion shaft
from the differential housing.
Don 7-37030
STEP 98
Use a soft drift to remove the pinion bearing cup and
shims from the differential housing.
NOTE: Tie the shim pack together for easy assembly.
6206- 25
STEP 99
Inspect i on
STEP 102
Clean all the parts in cleaning solvent and dry using
while drying.
STEP 100
Q20
Check both pinion bearings for free, smooth action. If a
new pinion bearing cone is used, install a new bearing
cup into the transmission housing.
PIS
Check the operation of the synchromesh units and
replace as necessary.
IMPORTANT: The pinion shaft and crown wheel are a
matched setand cannot be replaced separately. If there
is damage to either part, install a new set.
STEP 101
PIS
Check all the gears, parking brake hub and
synchromesh hubs for wear and damage. Look for
cracks at the root of teeth and splines.
6206-26
Assembl y
STEP 103
NOTE1: During the manufacture of early built transaxles
the numbers stamped on the ring gears and pinion shaft
include the thickness of the pinion inner bearing cup.
The bearing cup width must be added to this number
when calculating the shim pack thickness.
NOTE 2: If the original ring gear and pinion shaft are to
be used, assemble the pinion shaft using the original
shim pack, removed during disassembly.
NOTE 3: If the ring gear and pinion shaft are to be
replaced and the mounting dimension is stamped on
the rear face of the housing, the pinion mounting
distance shim pack is calculated as follows:
1. Subtract the dimension etched on the ring gear from
the dimension etched on the transmission housing rear
face.
IMPORTANT: !fthere are no numbers stamped on the
transmission rear face, use the constant of 181.46 mm.
2. Then subtract the bearing growth dimension of 0.04
mm.
Example:
Differential Mounting dimension constant
or number stamped on housing 181.46 mm
Dimension Etched on Ring Gear 179.86 mm
Bearing Growth Constant 0.04 mm
Required Shim Pack 1.56 mm
Don 7-37030
6206-27
STEP 104
Install the shim pack and pinion bearing cup into the
transmission case from the differential side. Make sure
all the shims are against the shoulder.
STEP 105
Install the pinion shaft.
STEP 1106
. ,
~ ~
Pull the pinion shaft to seat on its bearing and support
the end with a block of wood.
6206-28
STEP 107
62067
If a new front pinion bearing was installed, replace the
bearing cup in the transmission end cover.
STEP 108
Install the end cover.
STEP 109
.~ - ,- - ..
Install the retaining bolts and tighten to a torque of 195
to 250 Nm (145 to 185 Ib ft).
Don 7-37030
STEP 110
Install the master bearing cone (CAS 2019) onto the
pinion shaft.
STEP 111
Install the splined parking hub and spacer.
STEP 112
Install the setting washer (CAS 1998) (1) and bolt. Do
not install any shims.
STEP 113
To correctly seat the bearings, rotate the shaft while
tightening the bolt.
STEP 114
Don 7-37030
6206-29
Using a depth gauge measure the distance from the
face of the setup washer to the end of the counters haft
(A) through both holes. If the difference in the two
measurements is 0.08mm (0.003 inch) or less take the
average of the two measurements. If the difference is
greater than 0.08 mm disassemble and check for
proper bearing seating, burrs or foreign material.
Subtract the setup washer thickness (8) and add the
aero-set constant of 0.17 mm (0.0067 inch) to the
measured gap. This is the shim pack thickness (C).
STEP 115
Rotatethe transmission housing onto its rearflange and
put a support under the pinion shaft.
STEP 116
Remove the bolt from the end of the pinion shaft.
Remove the setting washer, shims, spacer and brake
hub. Remove the master bearing and transmission end
cover. Fasten the shims together and store safely.
STEP 117
i
Install the thrust washer, needle bearing and second
thrust washer.
NOTE: The bevelled side of the 1st thrust washer must
be towards the pinion gear.
STEP 118
,
IB ~
in:C12121
Install the two roller bearings.
6206-30
STEP 119
Install the first driven gear and spacer with the splined
hub outward.
NOTE: When installed the spacer must be level with the
end of the first gear.
STEP 120
Install the thrust washer first and then the needle
bearing.
STEP 121
Install the synchromesh hub.
Don 7~3" 7030
STEP 122
Install the needle bearing.
STEP 123
Install the synchromesh assembly.
STEP 124
Install the second driven gear with the splined hub
inward.
STEP 125
Slightly raise the second gear (1) and Install the shuttle
shaft.
NOTE: When installing the shuttle shaft be sure not to
bind the shaft in the wear sleeve or damage to the seal
rings and wear sleeves will occur.
STEP 126
Install the needle bearing and thrust washer
STEP 127
Don 7-37030
6206- 31
STEP 128
Install the thrust washer (1) and needle bearing (2).
STEP 129
Install the third driven gear with the splined hub
outward.
STEP 130
Install the synchromesh inner cup (1) and needle
bearing (2).
6206-32
STEP 131
Install the hub (1) and synchromesh unit (2) onto the
pinion shaft.
Don 7-37030
STEP 132
Install the needle bearing (1) and the synchromesh
outer cup (2).
STEP 133
Install the washer onto the 3rd and 4th gear
synchromesh.
STEP 134
,.
Install the fourth driven gear with the splines facing
inward.
STEP 135
Install the needle bearing (1) and thrust washer (2).
STEP 136
Install the gear shift selector forks and shift rail. Push
the shift rail into its locating bore in the transmission
housing.
Don 7-37030
6206- 33
STEP 137
Install the shuttle shaft forward gear.
STEP 138
- . ,- ,'
Install the baffle plate (1) and intermediate shaft.
NOTE: Raise the third and fourth gear synchromesh
hub slightly, to allow easyinstallation of the intermediate
shaft.
STEP 139
elL
.,:..}
Make sure the third and fourth gear synchromesh hub,
needle bearing and thrust washer are properly seated.
6206-34
Don 7-37030
TRANSMISSION
~i
-..-
6206-35
Inst al l at i on
STEP 143 STEP 140
Clean the surfaces of the end cover and the
transmission case.
STEP 141
Mounting surfaces must be clean and free of oil. Apply
a continuous bead of 817555 (Loctite 515) onto the
mounting face of the end cover. Apply Primer 'N'
8500637 to the mounting face of the transaxle. Install
the cover and torque the bolts to 195to 250 Nm (145 to
185Ibft).
STEP 142
Install the shift rail retaining plate and two bolts and
tighten to a torque of 44 to 58 Nm (33 to 43 Ib ft).
Don 7-37030
Put the pinion shaft bearing into a bearing oven (OEM
8014) and heat to a temperature of 302F (150C).
Install the bearing and brake hub onto the pinion shaft.
NOTE: Wear heat protective gloves.
STEP 144
Install the spacer, new shim pack, as calculated in
STEP 114. Install the washer and bolt. Tigten the bolt to
a torque of 251 to 280 Nm (185 to 205 Ib ft).
STEP 145
Install the bearing cup and spacer onto the
intermediate shaft.
6206-36
STEP 146
,- ~.:;;~
Install the Special Tool CAS 2008 (1).
NOTE: No shims have been installed at this time.
STEP 147
Install a bolt (2) and jam nut and lock it onto the end of
the intermediate shaft.
STEP 148
'0"
Install a dial gauge and check the end play. End play
must be 0.03 to 0.13 mm (0.001 to 0.005 inch).
Don 7-37030
STEP 149
Use a micrometer to determine the required shim pack
thickness.
STEP 150
Install the shims, spacer and bearing race retaining tool
(CAS 2008). Check the end play and add or subtract
shims as required until the end play measures 0.03 to
0.13 mm (0.001 to 0.005 inch).
STEP 151
Install a 'C' clamp onto the end of the shuttle shaft and
repeat STEPS 145to 150 and adjust the end play on the
shuttle (input) shaft. The end play must be 0.03 to 0.13
mm (0.001 to 0.005 inch).
STEP 152
Refer to Step 180 and adjust the selector shaft pivot
bushes
STEP 153
Install the lubricating tube (1) against the pinion head
(2) and tighten the fitting.
6206-37
STEP 154
Refer to Section 6203 and install the differential
assembly.
NOTE: Make sure the lubrication tube is clear of the ring
gear. Adjust if necessary.
CHECKING FOR CORRECT PINION TO CROWN WHEEL TOOTH CONTACT
STEP 155
Put Prussian Blue or red lead on the crown wheel teeth.
on the convex side. Turn the pinion in the forward
direction (clockwise) while holding pressure against the
crown gear to cause a braking force. See the contact
patterns in the following illustrations.
Don 7-37030
NOTE: The contact patterns of the crown wheel teeth
that are shown are approximate shapes. The gear teeth
contact patterns can change from the illustrations, but
the same general shape must be seen. The tooth
contact pattern can change in aused gear set because
of wear of the parts. Try to get a contact pattern that is
similar to the illustrations to get the best results.
CORRECT TOOTH CONTACT PATTERN
RC627
Correct adjustment is made when the pattern and size
of thetooth contact area (both horizontal and vertical) is
as shown.
6206-38
STEP 155 (Cont i nued)
Pi ni on i n t oo far Cont act Pat t ern
RC625
Correct this type of pattern by removing shims from
under the pinion shaft inner bearing cone. Refer to Step
103.
Move the pinion shaft away from the
crown wheel to correct this pattern.
' l l 2. PINION SHAFT
Pi ni on out t oo far Cont act Pat t ern
RC625
Correct this type of pattern by adding shims under the
pinion shaft inner bearing cone. Refer to Step 103.
STEP 156
Referto Section 6203 and adjust the backlash between
the crown wheel and pinion gear.
NOTE : The backlash has only a small effect on the
contact pattern.
Don 7-37030
Move the piruon shaft towards the
crown wheel to correct this pattern.
6206-39
SERVICING THE GEAR SHIFTERS
Removal
STEP 160 STEP 157
Refer to STEPS 1to 13 to remove the transmission end
cover, and intermediate shaft.
NOTE: The gear shifters can be serviced with the
transmission gears installed. In this case the pivot
bushes have to be removed first before the gear
selector shafts.
STEP 158
." Z ; .
.;o':!llo.
Remove the oil baffle plate.
STEP 159
D29422
Mark the levers and shafts for easy assembly. Remove
the levers.
Don 7-37030
+ ""IT :
till
Loosen the two pivot bushes.
STEP 161
i~~~
Pull the gear shift rail up from its locating bore in the
transmission case. Rotate the assembly counter
clockwise and lift the rail and gear shifter forks clear of
the pinion shaft.
6206-40
STEP 162
Remove the pivot bushing from the transaxle and
discard the o-ring.
STEP 163
Remove the selector shaft from the transaxle and
discard the o-ring seal.
STEP 164
Repeat STEPS 162 and 163 to remove the second gear
pivot bushing and selector shaft.
STEP 165
Di sassembl y
STEP 166
Of;
Cover the detent holes on the the shift forks and
carefully pull the shift fork from the shift rail.
NOTE: Put marks on the two shift forks for easy
installation.
Don 7-37030
Remove the detent ball and spring.
6206-41
Inspect i on
STEP 169 STEP 167
Check the bushings (1) in the shift forks for wear or
damage and replace as necessary.
STEP 168
,..
Check the roller bearing (2) onthe shiftfork and replace
if necessary. Install a new snap ring to hold the roller in
position.
Don 7-37030
Q14
Check the detent grooves on the shift rail for wear or
damage and replace if necessary.
STEP 170
029420
Check the gear selector shafts, levers and pivot
bushing for wear or damage and replace if necessary.
6206- 42
Assembl y
1. BUSH
STEP 171
,;~.
Install a shift fork onto the shift rail as marked during
disassembly, and install the detent spring and ball.
NOTE: Always wear eye protection when installing
detent springs and balls.
Don 7-37030
STEP 172
Use a suitable tool to compress the detent spring, and
push the detent ball below the diameter of the shift rail.
Push the shift fork onto the shift rail.
NOTE: The threaded end of the shift rail is installed into
the transmission end cover.
STEP 173
Repeat STEPS 171 and 172 and install the second gear
shift fork.
6206-43
Inst al l at i on
STEP 177 STEP 174
Install a new a-ring (1). Install the selectors into the
transmission housing as marked on removal.
STEP 175
Install a new a-ring. Install the pivot bushings into the
transmission housing.
STEP 176
Install the gear shift forks and rail assembly. Locate the
shift forks over the two synchromesh units and push the
shift rail into its locating bore in the transmission
housing.
Don 7-37030
Install the levers as marked on removal until the
clamping bolt (1) is level with the groove (2) in the
selector shaft. Tighten the clamping bolts.
NOTE: If new selectors or levers are installed, first make
sure the transaxle is in the horizontal position. Install the
levers onto the selector shafts in the horizontal position
with the lever ends pointing towards the axle housing.
Remove the lever and turn in aclockwise direction one
spline. Install the lever and tighten the locking bolt.
NOTE: The pivot bushings end play can only be
adjusted after the transmission end cover has been
installed.
6206-44
STEP 178
Refer to STEPS 138and 139 and install the baffle plate
intermediate shaft, and snap ring.
STEP 179
Refer to STEPS 140 to 151 and install the transmission
end cover.
Adj ust ment
STEP 180
Install a dial gauge onto the the end of the gear selector
shafts. Loosen the pivot bushing lock nut (1) and adjust
the pivot bushing (2) until the selector shaft end play
measures 1.0 to 1.5 mm (0.040 to 0.060 inches).
Tighten the lock nut.
REMOVAL AND INSTALLATION OF THE MAGNETIC SPEED SENSOR
STEP 181
On some transmissions a magnetic speed sensor is
fitted inthe top of the transmission case above the ring
gear. Disconnect the electrical connectors.
STEP 182
Loosen the locknut and remove the speed sensor.
Don 7-37030
STEP 183
y ~~
Install the speed sensor by hand until itcontacts the ring
gear. Loosen the sensor 0.75 of one turn and tighten the
locking nut. Connect the electrical connections.
NOTE: If the rear cover had been removed. Adjust the
gap between the ring gear and speed sensor with a
feeler gauge OEM 1024until the gap measures 0.25 mm
(0.010 inch).
INSTALLATION OF TRANSAXLE REAR COVER
6206-45
STEP 184
Remove old sealant material and oil from the
transmission rear housing and cover.
STEP 185
Apply B17555 (Loctite 515) to the transmission rear
housing. Apply Primer 'N' B500637 to the transmission
rear cover.
. STEP 186
::w
Install the rear cover and tighten all the bolts to a torque
of 195 to 250 Nm (145 to 185 Ib ft).
Don 7-37030
STEP 187
Refer to Section 6201 and install the Rear Axles.
STEP 188
Refer to Section 7000 and install the Parking Brake and
Housing.
STEP 189
Refer to Section 6202 and install the Transfer Gearbox
or end cover.
STEP 190
Refer to Section 6200 and install the Transmission into
the machine. Add Hy-Tran Plus Transmission oil up to
the FULL mark on the dipstick.
STEP 191
Test machine for correct operation. Check and add
transmission oil if required.
SECTION INDEX - BRAKES
Parking Brake . . .7000
Disc Brakes 7001
Removal and Installation of Brake Components 7002
Master Cylinder '" 7003
Printed in U.S.A.
Sect i on
7000
PARKING BRAKE
CASE CORPORATION
Don 7-37040
Copyright 1990 J I case Company
Printed in U.S.A
December 1990
7000- 2
TABLE OF CONTENTS
SPECIFICATIONS , 2
SPECIAL TORQUES 2
SERVICING THE PARKING BRAKE
Removal .. . 3
Disassembly 4
Inspection 6
Assembly 7
Installation 10
SPECIFICATIONS
BRAKE FRICTION PLATE THICKNESS
New 5.5 to 6.3 mm
Wear Limit 4.2 to 4.8 mm
0.216 to 0.248 inch
0.165 to 0.189 inch
NOTE: This machine was designed using the metric measuring system. Afl checks and settings must be made using
metric tools.
SPECIAL TORQUES
Brake Housing Mounting Bolts 77 to 100 Nm
Transfer Gearbox - Cover Plate Mounting Bolts 77 to 100 Nm
57 to 74 Ib ft
57 to 74 Ib ft
2. GASKET ELIMINATOR 817555 (LOCTlTE 515)
+PRIMER 'N' 8500637
Don 7.37040 Issued 12-90 Printed in U.S.A.
7000-3
SERVICING THE PARKING BRAKE
Removal
STEP 6 NOTE: It is not necessary to remove the transaxle from
the machine to service the parking brake. The transaxle
shown was removed for photographic purposes only.
STEP 1
To prevent excessive loss of oil fromtransaxle raise the
front of the machine and support on axle stands.
STEP 2
Remove the input and front drive shafts (4 WD
Machines). Refer to Section 6001.
STEP 3
Disconnect the parking brake operating cable. Refer to
Section 9001.
STEP 4
Remove the five bolts that hold the transfer gearbox (4
WD Machines) or the cover plate to the parking brake
housing.
STEP 5
Remove the transfer gearbox or cover plate.
Don 7.37040
Remove the brake actuator tube nut from the brake
housing. Remove and discard the o-ring.
STEP 7
C1Z309
Remove the parking brake housing retaining bolts and
washers. .
STEP 8
Remove the housing and guide the actuator pin from
the brake housing.
7000- 4
Di sassembl y
STEP 12 STEP 9
",
Remove the steel wear plate.
STEP 10
Remove the friction disc.
STEP 11
Remove the brake actuator assembly.
Don 7.37040
Remove the friction disc.
STEP 13
Remove the wear plate.
STEP 14
Remove the three reaction pins.
STEP 15
.:y.;,:':'.: {(::.:: . ,.,/K9
nut from the bolt in the brake actuator
STEP 16
7000- 5
STEP 18
Separate the two actuator'pl~tes.
STEP 19
Remove the bolt.
KloRemovethefour steel balls.
K15
STEP 17
Disconnect the two springs from the actuator plate.
Don 7.37040 Issued 12-90 Printed in U.S.A.
7000-6
Inspect i on
STEP 22 STEP 20
Clean all parts with cleaning solvent and dry with
compressed air.
STEP 21
Check the two friction plates for wear or damage and
Don 7.37040
Check the wear'f6r~~~i,distortion a~d
cracks around locating lugs and replace if necessary.
STEP 23
.. .: .. T.. ./..; . ..(',. )r .1 ? 7
Check the steel balls and both actuator plates for wear
or damage. and replace if necessary.
Assembl y
9. PARKING BRAKE HOUSING
5. STEEL WEAR PLATE
a.SPRING .4
4. FRICTION PLATE 7. STEEL BAll 0
6. ACTUATOR PLATE
\
5. STEEL WEAR PLATE
\
4. FRICTION PLATE
Don 7-37040
7000-7
:. 1.01L SEAl
3. ACTUATOR PLATE
o
12. ACTUATOR PLATE
UNKAGE
EA2584
8. SPRING
10. REACTION PIN
" 2. TUBE NUT
11. O-RING
7000- 8
STEP 24
Install the top actuator plate onto the bottom plate.
STEP 26
Install the two springs.
Don 7.37040
STEP 27
Install the bolt through the actuator levers and plate.
Make sure the two bolt heads are on opposite sides of
the actuator plates.
STEP 28
Install and tighten the nut.
STEP 29
Install the reaction pins into the transmission end cover.
STEP 30
Install the wear plate onto the reaction pins.
STEP 31
Install the friction disc.
STEP 32
Install the actuator assembly.
Don 7.37040
7000-9
STEP 33
Install the second friction disc.
STEP 34
Install the second wear plate.
7000-10
Inst al l at i on
STEP 38
STEP 35
..... ,.......................... ,............... .:.;.;.:.:.:.:.:.: ...:.:.:.:.;.:.:.:.:.:.::::::::::.;
the input shaft seal in the parking brake
housing. Fitthe newseal so that the flat face is outward
and level with the outer face on the housing.
STEP 36
Clean the mounting surfaces on the transaxle and
parking brake housings. Apply a continuous bead of
B17555 (Loctite 515) onto the face of the transmission
end cover. Apply Primer 'N' to the face of the parking
brake housing.
STEP 37
" ::::::::::':::::::::::x:::::::::';':
Positionthe actuator pinand guide itthrough the hole in
the parking brake housing.
Don 7 .37 040
Guide the parking brake housing onto the brake
reaction pins. Install and tighten the bolts to a torque of
77 to 110 Nm (57 to 81 Ib ft).
STEP 39
Install a new o-ring and install and tighten the actuator
tube nut.
STEP 40
Clean the surfaces of the transfer gearbox
housing/cover plate. Apply a continous bead of
817555 (Loctite 515) onto the joint lace of the parking
brake housing. Apply Primer 'N' 8500637 to the face of
the transfer gearbox housing.
STEP 41
Install the transfer gearbox or end cover onto the
parking brake housing.
STEP 42
:.:.:.:~.:.:.:.:.:.:.:.'.'."" ...
Install and evenly tighten the five bolts and washers to
the correct torque.
Don 7.37040
7000-11
STEP 43
Connect and adjust the parking brake operating cable.
Refer to Section 9001.
STEP 44
Install the input and front drive shaft (4 WD
MACHINES). Refer to Section 6001.
STEP 45
Lower the machine to the ground.
STEP 46
Add oil of the correct type to the transmission until the
level reaches the full mark on the dipstick.
Sect i on
7001
DISC BRAKES
CASE CORPORATION
Don 7-37050
Printed in U.S.A.
December 1990
7001-2
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TORQUES 2
SERVICING THE DISC BRAKES
Removal 3
Inspection 5
Installation 6
SPECIFICATIONS
BRAKES FRICTION PLATE THICKNESS
New 6.25 to 6.40 mm
Wear Limit 475 to 4.90 mm
0.246 to 0.252 inches
0.187 to 0.193 inches
SPECIAL TORQUES
Rear Axle Retaining Bolts 326 to 353 Nm
240 to 260 Ib ft
3. SEALANT 8500642 LOCTITE 324
ACTIVATOR 8500622 LOCTITE 707
KIT PART NUM8ER 8500621
1. ALIGNMENT STUDS CAS 1995
Don 7-37050
Removal
7001- 3
NOTE: Any reference to left and right hand is as seen
from the operators seat looking forward.
NOTE: Servicing of the disc brakes can only be done
with the transaxfe removed from the machine. Refer to
Section 6001.
STEP 1
Remove two opposite retaining bolts from the rear axle
and install guide studs.
STEP 2
Use suitable lifting equipment to support the rear axle.
Remove the remaining retaining bolts, and remove the
rear axle assembly from the transaxle housing.
Don 7-37050
STEP 3
Remove the two guide studs.
STEP 4
STEP 5
Remove the friction plate.
7001- 4
STEP 6
Remove the sun shaft.
STEP 7
Remove the three reaction pins.
Don 7-37050
STEP 8
. .ii~13
Remove the brake piston (1) by injecting compressed
air through the brake hose port (2).
STEP 9
Remove and discard the inner and outer o-rings from
the grooves (1) on the piston.
Inspect i on
STEP 13
compressed air. Do not use cloths.
Check the brake piston for wear, pitting, or other
damage. Replace if necessary. Check the brake
cylinder bore in the transaxle housing.
C8
Check the friction plate for wear, scoring, warpage and
damage to the splined teeth and replace if necessary.
D30132
Check the brake backing plate for wear and damage
and replace if necessary. Remove small scoring or
grooves with a hone or fine grade emery cloth.
C14
Replace the three reaction pin springs if the plunger
movement is easy. A weak reaction plunger spring will
cause wear and warpage to the friction plates.
Inspect the two snap rings of each reaction pin for
tightness. If the snap rings are loose, the friction and
backing plates will not separate quickly when the brake
pedal is released. Check the eyes of the two snap rings
are 180
0
apart. Replace the snap rings if necessary.
7001- 6
1. TRANSMISSION HOUSING
2. PISTON SEALS
3. PISTON
4. FRICTION DISC
5. BACKING PLATE
6. REACTION PIN
Don 7-37050
Inst al l at i on
Issued 12-90
8902564
Printed in U.S.A.
STEP 14
Remove the old jointing material from the face of the
trans axle and axle case.
STEP 15
Lubricate the two new inner and outer piston o-rings
with petroleum jelly and install into the grooves (1) of the
brake piston.
Don 7-37050
7001- 7
STEP 16
.>.. )?~13
Evenly install the brake piston into the cylinder bore and
align the lugs with the reaction pin holes.
STEP 17
Lubricate and install the three reaction pins so the
plungers are outward and the snap rings are on the
outside of the lugs on the brake piston.
7001-8
STEP 18
Install the sun shaft.
4. STRAIGHT EDGE
Putastraight edge across the end of the plunger of the
reaction pin and measure the distance from the
machined surface of the transmission case to the end
of the plunger. The measurement must be 2 mm (0.079
inch). Adjust the position of the snap rings if the
distance is incorrect. Make sure the edges of the two
snap rings are 180
0
apart. Repeat the procedure for the
other two reaction pins.
STEP 20
Lubricate and install the friction plate.
Don 7-37050
STEP 21
....
Install the brake backing plate so the large side is
towards the friction plate.
STEP 22
\:::~:::'
Install the two guide studs into the transaxle housing.
STEP 23
71289GA
Make sure the joint faces are clean. Apply sealant
8500642 (Loctite 324) to the face on the transaxle.
STEP 24
Apply activator 8500622 (Loctite 707) to the face on the
axle housing.
STEP 25
Use suitable lifting equipment and install the rear axle
onto the transaxle housing.
STEP 26
Install some of the retaining bolts and washers before
removing the guide studs.
NOTE: When the axle and transmission housings are
joined, the mounting bolts must be fuJ lytorqued within 3
to 5minutes.
Don 7-37050
7001-9
STEP 27
.i:-;'- .r ;;;: ,-.-.- '.
Tighten all the bolts to 326 to 353 Nm(240to 260 Ibs ft).
STEP 28
Install the transaxle into the machine. Refer to Section
6001.
STEP 29
Fill the transmission with Hy-Tran Plus oil, to the FULL
IMPORTANT: If new brake friction discs and new
Hy-Tran Plus are installed in the transaxfe, a special
additive must be added to the transmission fluid. The
additive 8191443 soaks into the brake linings and
prevents excessive brake chatter. Add one quart of
additive to the transmission fluid while circulating the oil
at operating temperature. DO NOT add 8191443 to
machines that have factory fiJ Ifluid in the transaxfe.
STEP 30
Remove the air from the brake system. Refer to Secian
7002.
7001-10
STEP 29
Fill the transmission with Hy-Tran Plus oil, to the FULL
Don 7-37050
STEP 30
Remove the air from the brake system. Refer to Secian
7002.
Sect i on
7002
REMOVAL AND INSTALLATION OF BRAKE COMPONENTS
Issued November 1989 CASE CORPORATION
7002-2
TABLE OF CONTENTS
MASTER CYLINDER. . . 2
Installation .
Removal .
. 2
REMOVING AIR FROM THE BRAKE SySTEM .
PARKING BRAKE .
DISC BRAKE .
. 2
. .4
.See Section 7000
....See Section 7001
SPECIFICATIONS
Type of oil.. .. Case TCH Fluid
Capacity
Reservoir... . 16 fluid ounces (473 ml)
System.. '" 32 fluid ounces (946 ml)
Removal
MASTER CYLINDER
1. Park the machine on a level surface
2. Lower the loader bucket to the floor and stop the
engine.
4. Open the access cover above the master cylinder
(1) .
5. Remove any dirt from the master cylinder (1) and the
area around the master cylinder (1).
6. Remove the clevis pin (2) that fastens the clevis (3) on
the master cylinder (1) to the brake pedal
7. Disconnect the tube (4) for the master cylinder reser-
voir (5) from the master cylinder (1).
8. Drain the fluid from the master cylinder reservoir (5).
9 Disconnect the tubes (6 and 7) from the master
cylinder (1).
10. Loosen and remove the nuts (8). lock washers (9),
and bolts (10) that fasten the master cylinder (1) to the
frame.
Bur 8-12540
11. Remove the master cylinder (1) from the frame.
12 Install caps on the tubes (6 and 7).
Inst al l at i on
1. If a new master cylinder (1) is being installed, fill the
master cylinder with clean Case TCH fluid.
2. Hold the master cylinder (1) in alignment with the
holes in the frame and install the bolts (10), lock
washers (9), and nuts (8)that fasten the master cylinder
(1) to the frame.
3 Connect the tubes (4, 6and 7) to the master cylinder
(1)
4. Install the clevis pin (2) that fastens the clevis (3) to
the brake pedal.
5 See step 20 in Section 7003, page 7003-4, and
adjust the master cylinder (1).
6. Fill the master cylinder reservoir (5) with Case TCH
fluid until the fluid level is at the full mark.
7. See page 7002-4 and remove the air from the brake
system.
8. Check for leakage at the master cylinder (1).
7002-3
6. TUBE
4. TUBE
8891712J
Master Cylinder Installation
Bur 8-125
4
0
7002-4
REMOVING AIR FROM THE BRAKE SYSTEM
1. Two persons are required, one to actuate the master
cylinder and the other to open and close the airremoval
screw on the transaxle.
2. Move the brake pedal down and up several times to
increase the pressure in the brake system.
3. When the brake pedal feels " hard" , continue to push
against the pedal and have another person open the air
removal screw at the transaxle
Bur 8-12540
4 When the brake pedal touches the floor plate, hold
the brake pedal in place and have the other person
tighten the air removal screw.
5. Repeat steps 2, 3, and 4 until there are no bubbles in
the fluid coming from the air removal screw.
6. Fill the master cylinder reservoir with Case TCH fluid.
Sect i on
7003
MASTER CYLINDER
CASE CORPORATION
Bur 8-12570
Printed in U.S.A.
7003-2
TABLE OF CONTENTS
MASTER CYLINDER..
REMOVING AIR FROM THE BRAKE SYSTEM .. . .. See Section 7002
Removal and Installation
. 2
...... See Section 7002
Disassembly . . 2
Inspection . ....4
Assembly .
......4
SPECIFICATIONS
Type of oil....
Master cylinder
Girling part number
. Case TCH Fluid
...... A6315
Case part number.......... . 8143162
MASTER CYLINDER
Di sassembl y
1. Clean the outside of the master cylinder.
2 Fasten the body (6) of the master cylinder in the
vise.
3. Remove the flow valve adapter (1) from the master
cylinder.
4. Remove the flowvalve (3) fromthe master cylinder
5. Remove the ball (5) from the master cylinder.
6 Remove the gasket (2) from the flow valve adapter
(1) .
7. Remove the flow valve seal (4) from the flow valve
(3).
8 Loosen the lock nut. Remove the clevis and lock
nut from the push rod (15).
9. Remove the boot (18) from the body (6).
10. Remove the snap ring (17) from the body (6).
11. Remove the push rod (15) and washer (16) from
the body (6).
Bur 812570
12. Hit the open end of the master cylinder against a
piece of wood to move the piston assembly to the end
of the master cylinder.
13. Pull the piston assembly from the master cylinder
14. There is a small tab in the spring seat (12) that
holds the spring seat (12) on the piston (13). Use a
screwdriver to lift up the tab.
15. Remove the check valve assembly from the piston
(13).
16. Remove the seal (14) from the piston (13).
17. Disconnect the check valve seat (10) from the
spring seat (12).
18 Remove the spring (11) from the spring seat (12).
19. Remove the check valve seat (10) from the check
valve piston (8).
20 Remove the wave spring (9) from the check valve
piston (8).
21 Remove the check valve seal (7) from the check
valve piston (8)
Issued 1189 Primed in U.S.A
7003-3
B870122R
Mast er Cyl i nder
Bur 8-12570
Issued 11 -89 Printed in U.S.A
7003-4
Inspect i on
1. Inspect the bores inthe body (6) for scoring, pitting,
or other damage. If the bores in the body (6) are
damaged a new master cylinder must be used.
2. Check the tab in the spring seat (12). Push the tab
down a small amount so that the tab will engage the
end ofthe piston (8) to hold the check valve assembly in
place. If the tab is broken, use a new master cylinder.
3. Inspect the flow valve (3), ball (5), check valve
piston (8), piston (13), and the push rod (15) for
scoring, pitting, or other damage If the flow valve (3),
ball (5), check valve piston (8), piston (13) or the push
rod (15) are damaged a new master cylinder must be
used.
Assembl y
1. Install the check valve seal (7) on the check valve
piston (8).
2. Install the spring (11) on the spring seat (10).
3. Install the check valve assembly inthe spring (11).
Engage the stem of the check valve piston (8) in the
spring seat (12).
4. Install the check valve assembly on the piston (13).
Push the check valve assembly onto the piston (13)
until the tab in the spring seat (12) engages the end of
the piston (13).
5. Install the seal (14) on the piston (13)
6. Lubricate the bore of the body (6) with clean hyd-
raulic fluid.
7. Install the piston assembly into the bore of the body
(6).
8. Push the piston assembly into the bore until the
push rod (15) and washer (16) can be installed
9. Install the push rod (15) and washer (16).
10 Install the snap ring (17)
11. Install the boot (18).
12. Install the lock nut and clevis on the push rod (15).
Do not tighten the lock nut on the push rod at this time.
Bur 8-12570
13 Install the ball (5) in the body (6).
14. Lubricate the flow valve seal (4) and the flow valve
(3) with clean hydraulic oil. Install the flowvalve (3) inthe
bore in the master cylinder. The flow valve (3) must be
centered in the bore of the master cylinder.
15. Install a new gasket (2) on the flow valve adapter
(1) .
16. Carefully start the flow valve adapter (1) into the
bore in the master cylinder by hand If the flow valve
adapter (1) cannot be turned into the master cylinder
completely by hand remove the flow valve adapter (1)
from the master cylinder and make sure that the flow
valve (3) is in the center of the bore in the master
cylinder.
17. Repeat step 16 until the flow valve adapter (1) can
be turned completely into the master cylinder by hand.
18. Tighten the flow valve adapter (1) to 30 to 34
pound-feet (41 to 47 Nm)
19. See Section 7002 and install the master cylinder on
the machine.
20 Depress the brake pedal to stroke the piston (13) in
the master cylinder. Release the brake pedal and allow
the piston to return. Adjust the push rod to piston clear-
ance to .025 to 050 inch (0.6 to 1.3mm). Turn the clevis
clockwise to shorten or counterclockwise to lengthen.
Tighten the lock nut against the clevis. See the illustra-
tion below.
--->
B870123R
Issued11-89 Printedin USA
7003- 5
8870122R
Master Cylinder
Bur 8-12570 Issued 11-89 Printed in U:S.A.
SECTION INDEX - HYDRAULICS
Sect i on Ti t l e
Sect i on Number
Removal and Installation of Hydraulic Components 8001
Specifications, Schematics, and Troubleshooting 8002
Cleaning the Hydraulic System 8003
Hydraulic Pump 8004
Loader Control Valve 8005
Cylinders 8006
Backhoe Control Valve 8007
Swing Sequence Valve 8008
Three Point Hitch Control Valve 8009
Double Selector Valve 8011
CASE CORPORATION
Bur 8-12580
Printed in U.S.A.
CASE CORPORATION
Sect i on
8001
OF HYDRAULIC COMPONENTS
Issued March 1991
8001-2
TABLE OF CONTENTS
OIL COOLER .. . 3
...................... , : 3 Removal ,
Installation , , , , , .4
HYDRAULIC PUMP , 6
Removal 6
Installation 8
LOADER CONTROL VALVE ,... 10
Removal , ,." ,........................... . , , 10
Installation........ ... 10
BACKHOE CONTROL VALVE...... ... 11
Removal 11
Installation .
SWING SEQUENCE VALVE.
. 11
. 13
Removal , , 13
Installation 13
SWING SEQUENCE VALVE ADJ USTMENT................... . 14
THREE-POINT HITCH CONTROL VALVE.................... .15
Removal , , 15
Installation , , 15
Bur 8-17580
8001-3
Removal
STEP 1
OIL COOLER
STEP 3
and lock the support strut (1) to hold up the loader.
Remove the bolts, flat washers, spacers, lock washers,
and nuts which fasten the hood cables (1) to the sides
of the radiator shroud.
Remove the bolts, flat washers, and lock washers from
the hood hinges (2).
weight of the hood is approximately 100 pounds (45
kg).
Bur 8-17580
Remove the bolt, lock washer, and flat washer which
fasten the strap (1) to the top of the radiator shroud.
Remove the strap (1).
Remove the bolts, lock washers, and flat washers from
the top cover (2). Remove the top cover (2).
STEP 4
Remove the bolts, lock washers, and nuts which fasten
the mounting brackets (1) to each side of the oil cooler.
8001-4
STEP 5
Remove the bolts, flat washers, and nuts which fasten
the radiator shroud (1) to the machine frame. Remove
the radiator shroud (1), The weight of the radiator
shroud (1) is approximately 50 pounds (23 kg).
NOTE: During installation, tighten the bolts for the
radiator shroud (1)to 270 to 324pound-feet (366to 439
Nm).
STEP 6
.90[:~~;!ef
the bottom cover (1). Remove the bottom cover (1).
STEP 7
Connect a vacuum pump to the hydraulic reservoir
Start the vacuum pump.
Bur 8-17580
STEP 8
8907
Disconnect the two hoses (1) from the RH side of the oil
cooler. Put identification tags on the hoses (1). Discon-
nect the two tubes (2) from the LH side of the oil cooler.
Install caps on the fittings and plugs in the hoses and
tubes. Stop the vacuum pump.
STEP 9
" ';'!~~7'4703M'
Remove the bolts, lock washers, and flat washers
which fasten the condenser (1) and the oil cooler (2) to
the radiator (3). Move the condenser (1) to the LH side
out of the way. Remove the oil cooler (2).
Inst al l at i on
Installation of the oil cooler is the reverse of removal.
Bur 8-17580
8001- 5
1. OIL COOLER
2. FROM HYDRAULIC
OIL FILTER
3. TO HYDRAULIC
RESERVOIR
4. FROM TORQUE CONVERTER
B902372J
5. TO TRANSAXLE
8001- 6
HYDRAULIC PUMP
Removal
STEP 10
and lock the support strut (1) to hold up the loader.
STEP 11
,
neck.
Remove the bolts, flat washers, spacers, lock washers,
and nuts which fasten the hood cables (2) to the sides
of the radiator shroud.
Remove the bolts, flat washers, and lock washers from
the hood hinges (3).
weight of the hood is approximately 100 pounds (45
kg).
Bur 8-17580
STEP 12
Slowly remove the radiator cap (1)
diator.
which fasten the fan shroud (4) to the radiator.
NOTE: During installation fill the radiator and the coolant
reservoir with approximately 18US. quarts (17litres) of
coolant. See Section 1002 for coolant specifications.
Start and run the engine until the coolant is at operating
temperature. Stop the engine and check for leakage.
When the coolant is cold, check the coolant reservoir
level.
STEP 13
Remove the bolt, lock washer, and flat washer which
fasten the strap (1) to the top of the radiator shroud.
Remove the strap (1).
the top cover (2). Remove the top cover (2).
STEP 14
Removethe bolts, lock washers, and nuts which fasten
the mounting brackets (1) to each side of the oil cooler.
STEP 15
Remove the bolts, flat washers, and nuts which fasten
the radiator shroud (1) to the machine frame. Remove
the radiator shroud (1). The weight of the radiator
shroud (1) is approximately 50 pounds (23 kg).
NOTE: During installation, tighten the bolts for the
radiator shroud (1)to 270 to 324pound-feet (366to 439
Nm).
STEP 16
.,
,!~9071~e'M
Removethe bolts, lock washers, and flat washers from
the bottom cover (1). Remove the bottom cover (1).
Bur 8-17580
8001-7
STEP 17
The hydraulic reservoir holds approximately 25 U.S
gallons (95 litres) of oil. Remove the drain plug (1) and
drain the oil from the hydraulic reservoir.
setvou is filled with oil. SeeSection 1002for specifica-
tions.
STEP 18
., ..
B 90?~,~~Ji
Disconnect the two hoses (1) from the RHside of the oil
cooler. Put identification tags on the hoses (1). Discon-
nect the two tubes (2) from the LH side of the oil cooler.
Install caps on the fittings and plugs in the hoses and
tubes.
8001-8
STEP 19
which fasten the condenser (1) to the oil cooler (2) and
radiator (3). Move the condenser (1) to the LH side out
of the way. Have another person help you remove the
oil cooler (2) and radiator (3). The weight of the oil
cooler (2) and radiator (3) is approximately 50 pounds
(23 kg).
Remove the fan shroud (4).
Bur 8-17580
STEP 20
B9074717M
Disconnect the two hoses (1) from the LH side of the
hydraulic pump (2). Remove the bolts and lock
washers that fasten the flange (3) on the RH side of the
hydraulic pump (2)
Remove the bolts, lock washers, and hardened
washers (Thehardened washers are on the bottom two
bolts only.) which fasten the hydraulic pump (2) to the
front engine support. Remove the hydraulic pump (2).
Inst al l at i on
Installation of the hydraulic pump is the reverse of
removal.
NOTE: During installation, remove and clean the
suction screen for the hydraulic pump. Apply Molykote
Type G to the splines of the hydraulic pump.
8001- 9
4. SUCTION
SCREEN
B902373J
Bur 8-17580
Issued 3-91
Printed in U.S.A.
8001-10
Removal
LOADER CONTROL VALVE
Inst al l at i on
1. Park the machine on a level surface.
2 Apply the parking brake.
3. Lower the loader bucket to the floor.
4. Stop the engine.
5. Move the loader control lever in all directions to
release the pressure from the hydraulic circuits.
6 Remove the bolts, lock washers, and flat washers
which fasten the cover for the loader control valve to the
RH step frame. Remove the cover for the loader control
valve.
7. Find the wires for the return-to-dig switch on the
loader control valve. Disconnect the wires from the
return-to-dig switch.
8. Fasten identification tags to the loader linkage at the
9. Disconnect the linkage from the loader control valve.
10. Clean the loader control valve and the area around
the loader control valve. Fasten identification tags to the
tubes and hoses at the loader control valve.
11. Connect avacuum pump to the hydraulic reservoir.
12. Disconnect the tubes and hoses from the fittings in
the loader control valve. Install caps on the fittings and
plugs inthe hoses and tubes Stop the vacuum pump.
13. Connect suitable lifting equipment to the loader
control valve. The weights of loader control valves avail-
able on this machine are approximately 57 to 72
pounds (26 to 33 kg).
14. Loosen and remove the cap screws and lock
washers that fasten the loader control valve to the
mounting brackets.
15. Remove the loader control valve from the machine.
Bur 8-17580
1. Use suitable lifting equipment to put the loader
control valve in position on the machine.
the loader control valve to the mounting brackets.
3 Remove the lifting equipment from the loader control
valve.
4. Connect the vacuum pump to the hydraulic reservoir.
Start the vacuum pump
5. Connect the tubes and hoses to the fittings on the
6. Stop the vacuum pump.
7. Connect the linkage to the loader control valve.
8. Connect the wires to the return-to-dig switch on the
9. Start and runthe engine at low idle. Move the loader
control lever to raisethe loader completely. Continue to
hold the loader control lever in the RAISE position for 30
seconds.
10. Lower the loader bucket to the floor. Stop the
engine.
11. Check for oil leakage at the loader control valve.
12. Check the oil level inthe hydraulic reservoir. Add oil
as required. See Section 1002 for specifications.
13. Put the cover for the loader control valve in position
on the RH step frame. Install the bolts, lock washers,
and flat washers which fasten the cover to the RH step
frame.
Removal
BACKHOE CONTROL VALVE
8001-11
3. If the machine is equipped with an Extendahoe,
install the Extendahoe lock pin.
4. If the backhoe is not inthe transport position, put the
backhoe in the transport position.
5. Lower the stabilizers until the stabilizers just touch the
floor
7. Install the swing lock pin.
8. Move each backhoe control lever in both directions
until all hydraulic pressure has been removed from the
backhoe hydraulic circuits.
9. Clean the backhoe control valve and the area around
the backhoe control valve. Fasten identification tags to
the hoses and tubes at the backhoe control valve.
10. Connect avacuum pump to the hydraulic reservoir
Start the vacuum pump
11. Disconnect the hoses and tubes from the backhoe
control valve. Install caps on the fittings and plugs inthe
hoses and tubes.Stop the vacuum pump.
12. Disconnect the tube for the B port of the swing
section from the fitting in the swing sequence valve.
13. Fasten identification tags to the linkage for the
backhoe control valve.
14. Disconnect the linkage from the spools in the
15. The weights of backhoe control valves available on
this machine are approximately 115 to 130 pounds (52
to 59 kg). Have another person help with steps 16
through 18.
16. Hold the backhoe control valve in place and remove
the bolts, lock washers, and nuts that fasten the LH side
of the backhoe control valve to the mounting bracket.
17. Remove the cap screw, lock washer, and spacers
that fasten the RH side of the backhoe control valve to
the mounting bracket.
Bur 8-17580
18. Remove the backhoe control valve from the
machine.
Inst al l at i on
1. Ifthe fittings were removed from the backhoe control
valve, if a newbackhoe control valve is being used, or if
the dipper or boom section of the backhoe control valve
has been replaced, do the following steps:
a. Make sure that a restrictor is installed in the A
port of the dipper section of the backhoe control
valve. The restrictor must be installed so that the
large end of the restrictor is toward the inside of the
b. Install new O-rings on the fittings
c. Lubricate the O-rings with clean hydraulic oil.
d. Install the fittings in the backhoe control valve.
2 Put the backhoe control valve in position on the
mounting bracket. Make sure that the rubber mount is
in position in the mounting bracket.
3. Install the cap screw, lock washer, and spacers that
fasten the backhoe control valve to the mounting
bracket. Make sure that the spacers are in position
between the backhoe control valve and the mounting
bracket.
4. Connect the linkage to the spools in the backhoe
control valve.
5. Connect the vacuum pump to the hydraulic reservoir.
6. Connect the tube to the fitting inthe swing sequence
valve and to the B port in the swing section of the
7. Connect the remaining tubes and the hoses to the
fittings inthe backhoe control valve. Stop the vacuum
pump.
9. Slowly extend and retract each cylinder several times
to remove any air from the backhoe hydraulic circuits.
10. Stop the engine.
11. Check for oil leakage at the backhoe control valve.
12. Check the oil level inthe hydraulic reservoir. Add oil
8001-12
Bur 8-17580
8001-13
SWING SEQUENCE VALVE
Removal
3. If the backhoe is not inthe transport position, put the
backhoe in the transport position.
5. Install the swing lock pin.
6. Move the swing control pedals or levers inboth direc-
tions to remove any pressure in the swing hydraulic
circuit.
7. Clean the swing sequence valve and the area around
the swing sequence valve. Fasten identification tags to
the hoses and tubes for the swing sequence valve.
8. Disconnect the tube from the B port in the swing
section of the backhoe control valve and from the fitting
in the bottom of the swing sequence valve.
9 Install caps on the fittings in the backhoe control
valve and the swing sequence valve.
10. Disconnect the remaining tubes and hoses from the
swing sequence valve.
11. Use caps or plugs to close all openings in order to
keep dirt out of the hydraulic system.
12. Remove the cotter pin and clevis pin that fasten the
yoke on the linkage to the spool inthe swing sequence
valve.
13. Hold the swing sequence valve in position on the
mounting bracket. The weight of the swing sequence
valve is approximately 20 pounds (9 kg). Loosen and
remove the cap screws that fasten the swing sequence
valve to the mounting bracket.
Bur 8-17580
14 Remove the swing sequence valve from the
machine.
Inst al l at i on
1. Hold the swing sequence valve in position on the
mounting bracket. Install the cap screws that fasten the
swing sequence valve to the mounting bracket.
2. Turn the spool so that when the yoke is installed on
the spool, the holes will be aligned vertically. Put the
yoke in position on the spool. Install the clevis pin and
the cotter pin to fasten the yoke to the spool.
3. Connect the tube to the B port inthe swing section of
the backhoe control valve and to the fitting inthe bottom
of the swing sequence valve.
4. Connect the remaining tubes and the hoses to the
fittings in the swing sequence valve.
5. Remove the swing lock pin.
7. Slowly and completely swing the backhoe to the left
and then to the right several times to remove any air
from the swing hydraulic circuit.
8. Stop the engine.
9. Check for oil leakage at the swing sequence valve.
10. Check the oil level in the hydraulic reservoir. Add oil
11. See Swing Sequence Valve Adjustment on page 14.
Adjust the swing sequence valve as required.
8001-14
SWING SEQUENCE VALVE ADJUSTMENT
5. CAM
B902375J
NOTE: In the following instructions, " right' and " left" are
as seen from the backhoe operators seat.
1. Swing the swing tower completely to the right.
2. Loosen the jam nuts at the yoke and at the ball joint
on the control rod.
3. Turn the control rod clockwise or counterclockwise
until the cam follower will turn freely. The cam follower
must still touch the cam or be within 0.02 inch (0.5 mm)
from the cam.
4. After step 3has been completed, turn the control rod
clockwise 1/4 to 1/2 turn to shorten the control rod.
Bur 8-17580
5Make sure that the clevis pin that fastens the yoke on
the control rod to the spool eye inthe swing sequence
valve is in the vertical position. If the clevis pin is not
vertical after the jam nuts are tightened on the control
rod, the control rod or the spool can be damaged.
6 Tighten the jam nuts at the yoke and at the ball joint
on the control rod.
7. Start and run the engine at approximately 1/4throttle.
8. Swing the backhoe completely to the left and then to
the right. The amount of cushion should be equal on
both sides. See the illustration below for the correct
swing cushion adjustment. Shorten or lengthen the
control rod as required. The only adjustment available
is to divide the amount of cushion equally between
sides.
CORRECT AMOUNT OF CUSHION
LENGTHEN CONTROL ROD TO INCREASE THE
RIGHT CUSHION. (TURN COUNTERCLOCKWISE)
SHORTEN CONTROL ROD TO INCREASE
THE LEFT CUSHION. (TURN CLOCKWISE)
B870349J
THREE-POINT HITCH CONTROL VALVE
8001-15
Removal
3 Lower any rear attachments to the floor.
5. Move all control levers forthe three-point hitch in both
directions to remove any pressure in the hydraulic
circuit
6. Clean the three-point hitch control valve and the area
around the three-point hitch control valve.
7. Fasten identification tags to the hoses at the three-
point hitch control valve.
8. Disconnect the hoses from the fittings at the three-
9 Use caps or plugs to close all openings in order to
keep dirt out of the hydraulic system.
10. Disconnect the linkage from the spool eyes at the
three-point hitch control valve.
11. Hold the three-point hitch control valve inplace and
remove the bolts, lock washers, and nuts that fasten the
three-point hitch control valve to the mounting bracket.
Bur 8-17580
12. Remove the three-point hitch control valve from the
machine.
Inst al l at i on
1. Ifthe fittings were removed from the three-point hitch
control valve, or a new three-point hitch control valve is
being used, install newO-rings on the fittings, and lubri-
cate the O-rings with clean hydraulic oil. Install the
fittings in the three-point hitch control valve.
2. Put the three-point hitch control valve in place on the
mounting bracket. Install the bolts, lock washers, and
nuts that fasten the three-point hitch control valve to the
mounting bracket
3. Connect the linkage to the spool eyes in the three-
4. Connect the hoses to the fittings in the three-point
hitch control valve.
6. Move all control levers for the three-point hitch slowly
in both directions to remove any air from the hydraulic
circuits.
7. Lower any rear attachments to the floor. Stop the
engine.
8. Check for oil leakage at the three-point hitch control
valve.
9. Check the oil level in the hydraulic reservoir Add oil
8001-16
Bur 8- 17580
Sect i on
8002
HYDRAULIC SCHEMATICS, SPECIFICATIONS
AND TROUBLESHOOTING
CASE CORPORATION
Issued March 1991
8002-2
TABLE OF CONTENTS
SPECiFiCATIONS." , , , ,., ' , 3
SPECIAL TOOLS .., , , .4
TROUBLESHOOTING PROCEDURE FOR PROBLEM IN ALL CiRCUiTS 5
TROUBLESHOOTING PROCEDURE FOR PROBLEM IN A SINGLE CIRCUIT 6
MAIN RELIEF VALVE , 7
CHECKING OUTPUT OF PUMP WITH FLOWMETER 8
CIRCUIT RELIEF VALVES FOR LOADER AND BACKHOE CONTROL VALVES , , , 11
CIRCUIT RELIEF VALVE FOR THE THREE POINT HITCH CONTROL VALVE 12
ADJ USTING THE MAIN RELIEF VALVE OR A CIRCUIT RELIEF VALVE 12
CROSS-SECTION DRAWINGS
Pump 13
Loader Control Valve 14
Steering Control Valve ,15
Filter 16
Backhoe Control Valve , , 17
Three Point Hitch Control Valve 18
Swing Sequence Valve 19
LOADER BACKHOE SCHEMATiC 21
LOADER THREE POINT HITCH SCHEMATIC 22
Bur 8-17530
8002-3
SPECIFICATIONS
Output of Pump
Rear section (Loader and Steering) 24 U.S. gpm at 2000 psi at 2000 rpm
(90.8 Umin at 13 789 kPa, 138 bar at 2000 r/min)
Front section (Backhoe) 9 U.S. gpm at 2000 psi at 2000 rpm
(34 Umin at 13 789 kPa, 138 bar at 2000 r/rnin)
Main relief valve for Loader Backhoe 2500 to 2600 psi (17237 to 17 927 kPa, 172 to 179 bar)
Main relief valve for Three Point Hitch 2488 to 2588 psi (17 154 to 17 844 kPa, 171 to 178 bar)
Relief valve in piston of boom cylinder 4600 to 4800 psi (31 716 to 33095 kPa, 317 to 330 bar)
Circuit Relief Valves
Boom A port 2050 to 2250 psi (14 135 to 15574 kPa, 141 to 155 bar)
Boom B port 4000 to 4100 psi (27580 to 28 268 kPa, 276 to 283 bar)
Dipper and bucket A and B ports 2950 to 3150 psi (20340 to 21 719 kPa, 203 to 217 bar)
Swing A and B ports 2050 to 2250 psi (14135 to 15 514 kPa, 141 to 155 bar)
Swing sequence valve 4000 to 4100 psi (27580 to 28268 kPa, 276 to 283 bar)
Loader bucket A and B ports 2950 to 3150 psi (20340 to 21 719 kPa, 203 to 217 bar)
Three point hitch lift B port 2650 to 2750 psi (18271 to 18 960 kPa, 183 to 190 bar)
8002-4
SPECIAL TOOLS
dresses:
Service Tools
P.O. Box 314
In Europe:
VL Churchill Ltd.
Northants, NN11 4NF
England
OEM 1239 or CAS-10280 Flowmeter
CAS-1808 or CAS-10106 Flowmeter Fitting Kit
Bur 8-17530
CAS-1804 or CAS-10111 Pressure Fitting Kit
CAS-1205 Test Block
CAS-10090 Hand Pump
CAS-1913 Hand Pump
8002-5
TROUBLESHOOTING PROCEDURE FOR PROBLEM IN ALL CIRCUITS
Check the machine for leaks and repair as
required.
NOTE: The main relief valve controls the
pressure in the loader and backhoe cir-
cuits.
Do the flowmeter test according to instruc-
tions in this section.
Bur 8-17530
Adjust the main relief valve according to in-
structions in this section.
8002-6
TROUBLESHOOTING PROCEDURE FOR PROBLEM IN A SINGLE CIRCUIT
Check the machine for oil leaks and
missing or damaged parts.
Check the operation of the circuit that has
the problem. Does the cylinder(s) move in
both directions?
There is some wear or damage in the
control valve. Repair as required.
Bur 8-17530
Check the spool travel. See Section 8005
and 8007 as required for specifications for
spool travel. Is the spool travel correct?
YES
Adjust the linkage as required to meet the
specification for spool travel.
,
There can be internal wear or damage to
the control valve. Repair or replace as re-
quired.
Replace the O-ring.
Adjust the setting of the circuit relief valve
according to instructions in this section.
NOTE: Boom cylinder only. A check
valve isinstalled in the piston. The problem
in the boom circuit can be the check valve
and not the piston packing.
Repair or replace the cylinder as required.
Check the O-ring on the plug for the load
check valve in the loader or backhoe
control valve. Is the O-ring good?
Check the O-ring on the end of the circuit
relief valve or plug. Is the O-ring good?
If used, check setting of the circuit relief
valve. Is the setting correct?
Check the piston packing for the cylinder.
Is the piston packing good?
Replace the O-ring.
8002-7
MAIN RELIEF VALVE
Equipment Required 5. Continue to hold the loader control lever in the RAISE
position and read the pressure gauge. Stop the engine.
o to 3000 psi (20 684 kPa, 207 bar) pressure gauge.
Pressure Check
6. Compare the reading with the specification on page
3. If the reading is not correct, adjust the main relief
valve.
1. Parkthe machine on a level surface. Putthe backhoe
inthe transport position and lower the loader bucket to
the floor.
Adjusting Main Relief Valve
2. Heat the oil to operating temperature.
1. The main relief valve is in the outlet section of the
loader control valve. Loosen the lock nut on the main
relief valve. Turn the adjusting screw clockwise to
increase the pressure and counterclockwise to
decrease the pressure.
3. See the illustration. Connect the pressure gauge to
the quick disconnect fitting at Test Port 1.
4. Runthe engine at full throttle. Hold the loader control
lever inthe RAISE position until the loader stops moving.
2. Check the pressure again.
3. When the pressure is correct, tighten the lock nut.
3. HYDRAULIC PUMP
4. FROM RESERVOIR
B901795J
Bur 8-17530
8002-8
CHECKING OUTPUT OF PUMP WITH FLOWMETER
Equipment Required
CAS-10106 or CAS-1808 flowmeter fitting kit
OEM 1239 or CAS-10280 Flowmeter
Checking the Output of the
Loader (Rear) Section
1. Parkthe machine ona level surface. Put the backhoe
the floor. Stop the engine.
2. See the illustration. Connect the flowmeter into the
circuit.
3. Heat the oil to operating temperature by closing the
load valve on the flowmeter until the pressure gauge
reads 1000 psi (6895 kPa, 69 bar). Run the engine at
full throttle until the temperature is 125F (52C).
Bur 8-17530
4. Run the engine at 2000 rpm (r/min). Open the load
valve on the flowmeter. Read the flow gauge. Record
the flow reading.
5. Keep the engine running at 2000 rpm (r/rnin). Slowly
close the load valve until the pressure is 2000 psi (13
789 kPa, 138 bar). Read the flow gauge and record the
reading.
6. Decrease the engine speed to low idle and stop the
engine.
7. The pump efficiency is found by dividing the flow
reading at 2000 psi (13 789 kPa, 138 bar) by the flow
reading at 0 psi (0kPa, 0 bar). The answer multiplied by
100 is the percent efficiency of the pump. If the effi-
ciency is less than 70%, repair or replace the pump.
8002-9
1. CAP. 1-5/16-12
FLARE THREAD
3. HYDRAULIC PUMP
6. CONNECT FLOWMETER
OUTLET TO TUBE
1-5/16-12 FLARE THREAD
01
7. TO INLET OF
5. OEM 1239 OR
CAS-10280 FLOWMETER
B901796J
8002-10
Checking the Output of the Backhoe
or Three Point Hitch (Front) Section
1. Parkthe machine on a level surface. Put the backhoe
the floor. Stop the engine.
2. See the illustration. Connect the flowmeter into the
circuit.
3. Heat the oil to operating temperature by closing the
load valve on the flowmeter until the pressure gauge
reads 1000 psi (6895 kPa, 69 bar). Run the engine at
full throttle until the temperature is 125F (52C).
6. TO SWING SECTION OF
Bur 8-17530
4. Run the engine at 2000 rpm (r/min). Open the load
valve on the flowmeter. Read the flow gauge. Record
the ~Iowreading.
5. Keep the engine running at 2000 rpm (r/min). Slowly
close the load valve until the pressure is 2000 psi (13
789 kPa, 138 bar). Read the flow gauge and record the
reading.
6. Decrease the engine speed to low idle and stop the
engine.
7. The pump efficiency is found by dividing the flow
reading at 2000 psi (13 789 kPa, 138 bar) by the flow
reading at 0 psi (0kPa, 0bar). The answer multiplied by
100 is the percent efficiency of the pump. If the effi-
ciency is less than 70%, repair or replace the pump.
2. HYDRAULIC PUMP
3. FROM RESERVOIR
.!}~, .... -~..
_ '! . . . . . . : : : ': . - ~ 0
'! ) . . - ~
~ ~-
B901797J
4. OEM 1239 OR
CAS-10280 FLOWMETER
8002-11
CIRCUIT RELIEF VALVES FOR LOADER AND BACKHOE CONTROL VALVES
Equipment Required
CAS-10111 or CAS-1804 Pressure fitting kit
CAS-10095 Multigauge
CAS-10090 Hand Pump for circuit relief valves set
below 3500 psi (24 132 kPa, 241 bar)
CAS-1913 Hand pump for circuit relief valves above
3500 psi (24 132 kPa, 241 bar)
CAS-1205 Test block
Pressure Check
1. Connect the hand pump to the test block.
2. Install the circuit relief valve in the test block.
B901824J
Loader:
1. Bucket A and B Ports Circuit Relief Valve
2950 to 3150 psi (20 340 to 21 719 kPa,
203 to 217 bar)
Bur 8-17530
3. Actuate the handle on the hand pump and record the
highest pressure reading. Check the pressure setting
several times to be sure of your reading.
4. Compare the reading with the specifications on page
3.
5. Ifthe pressure setting is not correct, adjust the circuit
relief valve.
Adjusting the Circuit Relief Valves
1. Loosen the lock nut on the adjusting screw.
2. Turn the adjusting screw clockwise to increase the
pressure setting and counterclockwise to decrease the
pressure setting.
3. Check the pressure setting again. When the pressure
setting is correct, tighten the lock nut.
1 2 3 5
1 2 4 5
Backhoe:
1. Bucket A and B Ports. 2950 to 3150 psi
(20340 to 21 719 kPa, 203 to 217 bar)
2. Dipper A and B Ports. 2950 to 3150 psi
(20340 to 21 719 kPa, 203 to 217 bar)
3. Boom A Port. 2050 to 2250 psi
(14 135 to 15514 kPa, 141 to 155 bar)
4. Boom B Port. 4000 to 4100 psi
(27 580 to 28 269 kPa, 276 to 283 bar)
5. Swing A and B Ports. 2050 to 2250 psi
(14 135 to 15514 kPa, 141 to 155 bar)
8002-12
CIRCUIT RELIEF VALVE FOR THE THREE POINT HITCH CONTROL VALVE
Equipment Required
CAS-10111 or CAS-1804 Pressure fitting kit
CAS-10095 Multi gauge
CAS-10090 Hand pump
Pressure Check
Attachment on the floor.
Loosen filler cap on reservoir to relieve pressure in re-
servoir.
Disconnect hose from S-port of the lift section.
Connect the correct fitting fromthe pressure fitting kit to
the S-port.
Connect hand pump to fitting.
Actuate hand pump and read the gauge. check the
setting three times.
Record the average setting.
See page 8002-3 for specifications.
ADJUSTING THE MAIN RELIEF VALVE OR A CIRCUIT RELIEF VALVE
1. Loosen the lock nut on the adjusting screw. 3. Prevent the adjusting screw from turning and tighten
the lock nut.
2. Turn the adjusting screw clockwise to increase the
setting or turn the adjusting screw counterclockwise to
decrease the setting.
4. Check the setting again.
Bur B-17530 Issued3-91 Printedin U.S.A.
8002-13
6
Supplies oil flow for the complete hydraulic system.
Bur 8-17530
Controls flow of oil to the cylinders
movement of control levers.
1. Inlet
2. Outlet
4. From Steering Control Valve (I
5. To Bucket Cylinders
6. To Lift Cylinders
7. To Clam Cylinders
8 Main Relief Valve
9. Steering Relief Valve
10. Flow Control Valve
11. Circuit Relief Valve
12. Load Check Valve
13. Spool
14. Check Valve
I E
for the loader by
BUCKET SECTION
Jilot)
INLET SECTION
LIFT SECTlm
t LOADER CONTROL VALVE
Controls flow of oil to the cylinders for the loader by
1. Inlet
2. Outlet
4. From Steering Control Valve (Pilot)
5. To Bucket Cylinders
6. To Uft Cylinders
7. To Clam Cylinders
8. Main Relief Valve
9. Steering Relief Valve
10. Flow Control Valve
13. Spool
14. Check Valve
BUCKET SECTION
INLET SECTION
8002-14
LIFT SECTION
Bur 8-17530
CLAM SECTION
OUTLET SECTION
B891~
Issued3-91 Printedin U~
8002-15
1. Inlet
2. Outlet
3. Pilot
4. Check Valve
5. Spool and Sleeve Assembly
6. Drive Unk
7. Gerotor
Controls oil flow to the steering cylinder.
8891058J
8002-16
1. Inlet
2. To Resetvoi:
3. To Oil Cooler
4. From Steering Control Valve
5. Filter
6. Bypass Valve
7. Switch
8. Check Valve
Cleans oil returning to the reservoir.
Bur 8-17530
B891061J
1 2
1 4 L I
1 2
1 4
1 2
Bur 8-17530
8002-1
Controls flow of oil to cylinders for backhoe hy
control levers.
1. Inlet
2. Outlet
3. To Swing Cylinders
4. To Boom Cylinder
5. To Left Stabilizer Cylinder
6. To Right Stabilizer Cylinder
7 To Dipper Cylinder
B To Bucket Cylinder
9 To Extension Cylinder
10. Anticavitation Valve
13. Check Valve
14. Spool
15 Regeneration Valve
@
Issued3-91 Printedin U
7
1110Vnl110.111 of
INLET SECTION
. SA
SWING SECTION
BOOM SECTION
LEFT AND RIGHT
STABILIZER SECTIONS
DIPPER AND
BUCKET SECTION
EXTENSION SECTION
OUTLET SECTION
B891299A
1002-1"
V E
shoo by
led in U
9
o THREE POINT HITCH CaNT,
Controls flow of oil to cylinders for three c
1. inlet
2. Outlet
3. t Implement
4. t Tilt Cylinder
5. To Pitch Cylinder
6. To litt Cylinder
8. Circuit Relief - Anticavitation Valve
9. Load Check Valve
10. Spool
PI
Corrrols flow of oil to cylinders for three point hitch by
1. inlet
2. Outlet
3. t Implement
4. to Tilt Cylinder
5. To Pitch Cylinder
6. To Uft Cylinder
B. Circuit Relief - Anticavitation Valve
9. Load Check Valve
10. Spool
INLET-OUTLET AND
IMPLEMENT SECTIO~
8002-18
oint hitch by
INLET-OUTLET AND
IMPLEMENT SECTION
TILT AND PITCH SEC'
Bur 8-17530
~OL VALVE
8002-18
LIFT SECTION
TILT AND PITCH SECTIONS
--
8891 300
Bur 8-17530
Issued 3-9'
8002-19
Bur 8-17530
1. Spool
2. Check Valve
3. Orifice
Actuated by cam to slow the speed of the swing
motion of the backhoe.
C D
C D
B891 301 J
8002-20
This Page Left Blank
8002-2
DIRECTION OF FLOW
PILOT PRESSURE
Pressure used to control another component.
CROSSOVER LINES
CONNECTING LINES
FILTER OR SCREEN
OIL COOLER
CHECK VALVE
Permits oil flow in one direction only.
Loader Backhoe Schematic
Bur 8-17530
TEST PORT 2
TEST PORT 1
FILLER CAP
OIL COOLER
RESERVOIR
8002-21
inted in U.S.A.
STEERING CYLINDER
-
,
,
...
TEST PORT 2
TEST PORT 1
FILLER CAP
BUCKET LIFT
o FILTER
!
t
L
OIL coc
RESERVOIR
STEERINC
DIRECTION OF FLOW
PILOT PRESSURE
Pressure used to control another component.
CROSSOVER LINES
CONNECTING LINES
-0-
TEST PORT 2
FILTER OR SCREEN
OIL COOLER
CHECK VALVE
Permits oil flow in one direction only.
8891303
Loader Three Point Hitch Schematic
Bur 6-17530
Issued 3-91 Prinlr.din USA
8003
CLEANING THE HYDRAULIC SYSTEM
TABLE OF CONTENTS
Portable Filter 8003-2 Cleaning the Hydraulic System 8003-4
General Information 8003-3 Flushing Water From
the Hydraulic System 8003-6
Types of Contamination 8003-3
CASE CORPORATION
8-67390 Printed in U.S.A.
Issued March 1987
B003-2
PORTABLE FILTER
The Portable Filter and Fitting Kit are available
from Service Tools in the United States or from
J obborn Manfaucturing Co. in Canada. See Spe-
cial Tools in Section 1001 for correct address.
The part number of the Portable Filter is CAS-
10162A and for the Fitting Kit the part number is
CAS-1050B.
Fitting Kit
S06126
Portable Filter
806127
8003-3
GENERAL INFORMATION
Contamination in the hydraulic system is a
major cause of the malfunction of hydraulic com-
ponents. Contamination is any foreign material in
the hydraulic oil. Contamination can enter the hy-
draulic system in several ways.
1. When you drain the oil or disconnect any line.
2. When you disassemble a component.
3. From normal wear of the hydraulic compo-
nents.
4. From damaged or worn seals.
5. From a damaged component in the hydraulic
system.
All hydraul ic systems operate with some con-
tamination. The design of the components in this
hydraulic system permits efficient operation with a
small amount of contamination. An increase in this
amount of contamination will cause problems in
the hydraulic system. The following list includes
some of these problems.
1. Cylinder rod seals leak.
2. Control valve spools do not return to NEUTRAL.
3. Movement of control valve spools is difficult.
4. Hydraulic oil becomes too hot.
5. Pump gears, housing, and other parts wear
rapidly.
6. Relief valves or check valves held open by dirt.
7. Quick failure of components that have been
repaired.
8. Cycle times are slow; machine does not have
enough power.
If your machine has any of these problems,
check the hydraulic oil for contamination. See
Types of Contamination below. If you find contam-
ination, usethe Portable Filter to clean the hydrau-
lic system.
TYPES OF CONTAMINATION
There are two types of contamination, micro-
scopic and visible.
1. Microscopic contamination occurs when very
fine particles of foreign material are in suspension
inthe hydraulic oil. These particles are too small to
see or feel. Microscopic contamination can be
found by identification of the following problems
or by testi ng in a laboratory. Examples of the prob-
lems:
a. Cylinder rod seals leak.
b. Control valve spools do not return to NEU-
TRAL.
c. The hydraulic system has ahigh operating
temperature.
2. Visible contamination is foreign material that
can befound by sight, touch, or odor. Visible con-
tamination can cause a sudden failure of acompo-
nent. Examples of visible contamination.
a. Particles of metal or dirt in the oil.
b. Air in the oil.
c. The oil is dark and thick.
d. The oil has the odor of burned oil.
e. Water in the oil. See page 8003-6.
8003-4
CLEANING THE HYDRAULIC SYSTEM
1. Prepare the portable filter shown on page
8003-2 by doing the following steps:
a. Remove all the hydraulic oil from the inlet
and outlet hoses for the portable filter.
b. Remove the filter element from the porta-
ble filter.
c. Remove all hydraulic oil from the portable
filter.
d. Clean the inside of the housing forthe filter
element.
e. Install a new filter element.
2. You must know whether the contamination is
microscopic or visible. See Types of Contamina-
tion on page 8003-3.
3. If the contamination is microscopic:
a. Check the maintenance schedule for the
machine to learn if the hydraulic oil must be
changed. If needed, change the hydraulic oil.
See Section 8001. Change the hydraulic filter.
b. Do steps 6 through 38.
4. If the contamination is visible:
a. Change the hydraulic oil and hydraulic fil-
ter. See Section 8001. Remove and clean the
hydraulic pump suction screen.
b. Do steps 5 through 38.
5. Check the amount of contamination in the hy-
draulic system by doing the following steps.
a. Disassemble one cylinder in two different
circuits. Check for damage to seals, scoring of
the cylinder wall, etc. Repair the cylinders as
necessary.
b. If, in your judgment, the damage to the
cylinders was caused by severe contamination
and is not the result of normal wear, it is neces-
sary to remove, clean and repair valves, pump,
lines, cylinders, hydraulic reservoir, etc. inthe
hydraulic system.
6. Loosen and remove the filler cap from the
reservoir.
7. Connect avacuum pump to the filler cap open-
ing. Start the vacuum pump.
8. Loosen and remove the drain plug from the
reservoi r.
9. Seethe fitting kit shown on page8003-2. Install
the valve in the hole for the drain plug. Make sure
that the valve is closed.
10. Stop the vacuum pump.
11. Connect the inlet hose for the portable filter to
the valve that is installed in the hole for the drain
plug.
12. Disconnect the vacuum pump from the filler
cap opening on the hydraulic reservoir.
13. Install the outlet hose for the portable filter in
the hydraulic reservoir.
14. Open the valve that is installed in the hole for
the drain plug.
15. Move the switch for the portable filter to the ON
position. Start and run the engine at 1500 rpm
(r/min).
16. Run the portable filter for 10minutes.
17. Continue to run the portable filter.
18. Increase the engine speed to full throttle. Heat
the oil to operating temperature by doing the fol-
lowing steps:
a. Hold the bucket control lever in the ROLL-
BACK position for 15 seconds.
b. Return the bucketcontrolleverto NEUTRAL
for 30 seconds.
c. Repeat steps 18aand 18bunti I the oil inthe
hydraulic system is at operating temperature.
19. Continue to run the engine atfull throttle. Con-
tinue to run the portable filter.
20. Operate each hydraulic circuit to completely
extend and retract the cylinders. Continue to oper-
ate each hydraulic circuit two times, one after the
other, for 45 minutes.
21. Decrease the engi ne speed to low idle.
22. Continue to run the portable filter for 10 min-
utes.
23. Stop the portable filter.
25. Remove the hose from the hydraulic reservoir.
26. Close the valve that is installed in the hole for
the drain plug.
27. Disconnect the inlet hose for the portable fi Iter
from the valve.
28. Connect a vacuum pump to the fill cap open-
ing of the hydraulic reservoir.
29. Start the vacuum pump.
30. Remove the valve from the hole for the drain
plug.
8003-5
31. Install the drain plug.
32. Stop the vacuum pump. Disconnect the vacu-
um pump from the hydraulic reservoir.
33. Install the filler cap.
34. Remove the hydraulic filter element from the
machine.
35. Install a new hydraulic filter element on the
machine.
36. Check the oil level in the hydraulic reservoir.
Add oil as required. See Section 8001.
37. Start the engine. Check for oil leakage around
the new hydraulic filter. ~
8003-6
FLUSHING WATER FROM THE HYDRAULIC SYSTEM
1. Start and run the engine at 1500 rpm (r/rnin).
2. Completely retract the cylinders of all attach-
ments on the machine.
3. Any attachment or part of anattachment that is
raised must be supported to prevent the attach-
ment from falling.
4. Loosen and remove the filler cap from the
reservoir.
5. Drain the hydraulic oil from the reservoir.
a. The reservoir holds approximately 21U.S.
gallons (79.5 litres) of hydraulic oil.
b. Have available acceptable equipment to
drain the hydraulic oil.
c. Remove the drain plug from the bottom of
the reservoir.
6. Remove the hydraulic oil filter from the ma-
chine.
7. Install a newhydraulic oil filter on the machine.
8. Install the drain plug inthe bottom of the reser-
voir.
9. Fill the hydraulic reservoir with 21 U.S. gallons
(79.5 Iitres) of Case TCH Fluid.
10. Move each control lever in both directions to
release pressure in the circuits.
11. Disconnect the line from the rod end and
closed end of each cylinder.
12. Be sure all control levers are in the NEUTRAL
position.
IMPORTANT: Check the oil level in the hydraulic.
reservoir frequently while doing step 14.
14. Move each control lever in both directions un-
til oil begins to flow from the open line. Hold the
control lever in place until clean oil flows from the
open line.
16. Connect the line to the CLOSED end of each
cylinder.
18. Completely extend all cylinders. As the piston
rod comes out of the cylinder, oil will be pushed out
of the rod end of the cylinder.
19. Support the loader frame so that the loader
frame will stay in the RAISED position.
21. Connect the lines to the rod end of the cylin-
ders.
22. Fill the reservoir to the correct level.
23. Install the filler cap for the reservoir.
Section
8004
HYDRAULIC PUMP
CASE CORPORATION
8004-2
TABLE OF CONTENTS
SPECiFiCATIONS 2
DiSASSEMBLy . . 3
INSPECTION ...................... . .7
ASSEMBLY .. . 9
SPECIFICATIONS
Manufacturer Commercial Shearing
Rotation Counterclockwise as seen from shaft end
Wear specifications See Inspection
Special torques
Cap screws that hold the' sections together 250 pound-feet (339 Nm)
Weight 80 pounds (36 kg)
Bur 8-17400
DISASSEMBLY
8004-3
STEP 1
Clean the outside of the hydraulic pump. Fasten the
hydraulic pump inavisewith soft jaws. Make alignment
marks on each section of the hydraulic pump.
STEP 2
Loosen and remove the cap screws and flat washers.
STEP 3
Remove the end cover.
Bur 8-17400
STEP 4
Remove the quad ring.
STEP 5
Remove the thrust plate.
STEP 6
8004-4
STEP 7
STEP 8
!
Remove the other thrust plate.
STEP 9
Remove the gear housing.
STEP 1 0
Removethe quad ring from bottom of the gear housing.
Bur 8-17400
STEP 1 1
Remove the carrier.
STEP 1 2
Remove the quad ring.
STEP 1 3
Remove the thrust plate.
STEP 1 4
STEP 1 5
Remove the coupling.
STEP 1 6
A
Bur 8-17400
8004-5
STEP 1 7
Remove the other thrust plate.
STEP 1 8
Remove the gear housing.
STEP 1 9
Remove the quad ring from the bottom of the gear
housing.
STEP 2 0
l
Remove the snap ring from the drive end cover.
8004-6
STEP 2 1
Remove the bearing from the drive end cover.
STEP 2 2
Remove the seal.
Bur 8-17400
STEP 2 3
Remove the seal from the thrust plates.
INSPECTION
8004-7
Discard all seals and quad rings, Clean all parts in
cleaning solvent. Check all machined surfaces for
damage or wear,
STEP 2 4
Measure the amount of wear caused by the gear teeth
inthe gear housing. Ifthe wear is more than 0.005 inch
(0.13 mm), use a new gear housing.
STEP 2 5
Inspect the gears for wear and damage. If the gears
must be replaced, use a new hydraulic pump.
Bur 8-17400
STEP 2 6
852 501 8M
Measure the thickness of the thrust plates. If the thick-
ness of a thrust plate is less than 0.247 inch (6.27 mm),
install a new thrust plate.
STEP 2 7
1. BUSHING
Inspect the bushings inthe drive end cover, carrier, and
end cover. Ifthe bushings are worn or damaged, use a
new hydraulic pump.
8004-8
5. QUAD
RING
12. DRIVE GEAR
16. QUAD
RING
22. SEAL
13. QUAD
RING
31. DRIVE
END COVER
Bur 8-17400
6. END COVER
8. CAP SCREW
7. FLAT WASHER
28. DRIVEN GEAR
B901880J
8004-9
ASSEMBLY
STEP 31 STEP 2 8
Install new quad rings in the grooves in the gear hous-
ings. Use petroleum jelly to hold the quad rings inplace.
STEP 2 9
Install a new oil seal in the drive end cover.
STEP 30
Press the oil seal into the drive end cover.
Bur 8-17400
Press a new bearing into the drive end cover until the
snap ring can be installed in the groove.
STEP 32
STEP 33
Install new seals in each thrust plate.
8004-10
STEP 34
Fasten the drive end cover in the vise with soft jaws.
STEP 35
Install the gear housing.
STEP 36
Install the thrust plate with the seal down and the
grooves as shown above.
Bur 8-17400
STEP 37
Install the drive gear.
STEP 38
Install the coupling.
STEP 39
Install the driven gear.
STEP 4 0
Install the thrust plate with the seal up as shown above.
STEP 4 1
Install the carrier.
STEP 4 2
Install the gear housing.
Bur 8-17400
8004-11
STEP 4 3
Install the thrust plate with the seal down and the
grooves as shown above.
STEP 4 4
Install the drive gear
STEP 4 5
Install the driven gear.
8004-12
STEP 4 6
l
Install the thrust plate with the seal up as shown.
STEP 4 7
Install the end cover.
Bur 8-17400
STEP 4 8
Install the cap screws and flat washers. Tighten the cap
screws evenly to 250 pound-feet (339 Nm).
8004-13
3. OIL SEAL
6. DRIVE
5. QUAD GEAR
RING
12. QUAD RING
14. THRUST PLATE
13. DRIVE
GEAR
15. BUSHING
16. FLAT
WASHER
/
18. END
COVER
24. DRIVE
END COVER
23. GEAR
HOUSING
22. DOWEL
PIN
21. CARRIER
19. GEAR
HOUSING
8901881J
Bur 817400
CASE CORPORATION
Section
8005
Bur 817410
Printed in U.S.A.
8005-2
TABLE OF CONTENTS
SPECiFiCATIONS....... .. . 3
SPECIAL TOOLS.. . 4
SEPARATING THE VALVE SECTIONS 5
ASSEMBLING THE VALVE SECTIONS 6
OUTLET SECTION.. .. 7
Disassembly 7
Exploded View 8
Assembly 8
Cross Section........ . 9
INLET SECTION . 10
Disassembly.. . ,. . . 10
Inspection... . 11
Exploded View.. . 12
Assembly.... .. . . 13
Cross Section . . 14
BUCKET SECTION...... .15
Disassembly............ . .15
Exploded View....................................................................................... . 19
Inspection .. .. . 20
Assembly '" .20
Cross Section . .. .. " 25
LIFT SECTION 26
Disassembly 26
Exploded View. . 29
Inspection................ 30
Assembly 30
Cross Section 34
CLAM SECTION 35
Disassembly 35
Exploded View 37
Inspection 38
Assembly 38
Cross Section 41
CIRCUIT RELIEF VALVE 42
Dissasembly 42
Inspection . .......43
Assembly 43
8005-3
SPECIFICATIONS
Manufacturer . . . . . . J I Case
Pressure Settings . . See Section 8002
Ports and Spools
Spool travel, neutral to pressure 0.390 inch (9.9 mm)
Spool travel. neutral to float . . 0.680 inch (17.2 mm)
Spool moved into the body . ... pressure at A port
SpOOl moved out of the body .. ............ pressure at B port
Inlet. outlet, and power beyond ports 1-5/16-12, straight thread
Threads in steering pilot port . ...................................... 9/16 - 18, straight thread
Threads in steering outlet port . .. 3/4 - 16 straight thread
Threads in A and B ports . .. 7/8 - 14, straight thread
Special torque
Nuts that fasten the valve sections together 20 to 30 pound-feet (27 to 41 Nm)
Main relief valve 35 to 40 pound-feet (47 to 54 Nm)
Circuit relief valves.................... .. 65 to 85 pound-feet (88 to 155 Nm)
Plug for outlet section ............................................................ 30 to 40 pound-feet (41 to 54 Nm)
Spool cap or detent housing 20 to 30 pound-feet (27 to 41 Nm)
Allen head screws for bucket spool Tightenscrews evenly to 15 to 30 pound-inches
(2 to 3 Nm). Then tighten the Allen head screws
evenly to 50 to 60 pound-inches (6 to 7 Nm).
Circuit relief valve body 96 to 144 pound-inches (11 to 16 Nm)
Weight approximately 70 pounds (32 kg)
Bur 8-17410
8005-4
SPECIAL TOOLS
dresses:
Service Tools
PO. Box 314
In Europe:
VL Churchill Ltd
P.O. Box 3,Daventry
Northants, NN11 4NF
England
The spring compressing plate is used to compress the
centering springs for removal and installation. The part
number of the tool is CAS-1147-2. This tool is first used
on page 17.
Bur 8-17410
B861843J
1.3/8-16 NC X 3Inches (76mm) Or Longer Hex Bolt
2. Grind Two Sides Evenly To 15/32 Inch (11.9 mm)
3. Grind To 1/8 Inch (3. 2 mm)
4. 5/8 Inch (10.1 mm)
The tool above is used to remove and install the load
check plugs. This tool is first used on page 17.
SEPARATING THE VALVE SECTIONS
8005-5
STEP 1
Clean the outside of the loader control valve. Write a
number on each section of the loader control valve.
STEP 2
Loosen and remove the nuts that fasten the sections to-
gether.
STEP 3
Remove the inlet section
Bur 817410
STEP 4
Remove the shims.
STEP 5
Remove the remainder of the sections and shims.
STEP 6
Remove the studs from the outlet section.
8005-6
ASSEMBLING THE VALVE SECTIONS
STEP 7
Inspect the O-rings in the valve sections. Replace the
O-rings as necessary Use petroleum jelly to hold the
O-rings in place as the valve sections are assembled
STEP 8
Install the studs in the outlet section.
STEP 9
Install the shims.
Bur 8-17410
STEP 1 0
B9073913M
Install the valve sections according to the sequence of
the numbers you wrote on the valve sections. Install the
shims between each section as shown in step 9.
STEP 1 1
Install the nuts on the studs. Make sure the valve is on a
flat surface. Tighten the nuts to 20 to 30 pound-feet (27
to 4 1 Nm).
8005-7
Disassembly
STEP 1 2
OUTLET SECTION
STEP 1 5
Fasten the outlet section in the vise with soft jaws.
Loosen and remove the main relief valve.
STEP 1 3
Loosen the plug in the other end of the outlet section.
STEP 1 4
Remove the plug
Bur 8-17410
Remove the spring.
STEP 1 6
Remove the poppet.
STEP 1 7
Do not disassemble the main relief valve. None of the
internal parts of the main relief valve are available for
service.
8005-8
6. MAIN
REL I EF
V A L V E
B870012J
Outlet Section
Assembly
STEP 1 8
Install the poppet.
Bur 8-17410
STEP 1 9
Install the spring.
STEP 2 0
Install a new O-ring on the plug. Lubricate the O-ring
with clean hydraulic oil. Install the plug. Tighten the plug
to 30 to 40 pound-feet (41 to 54 Nm).
STEP 2 1
Install new O-rings and a new backup ring on the main
relief valve. Lubricate the O-rings and backup ring with
clean hydraulic oil. Install the main relief valve. Tighten
the main relief valve to 35 to 40 pound-feet (47 to 54
Nm).
Issued 1-91 Printed in U.sA
8005-9
5. OUTLET SECTION
6. MAIN RELIEF VALVE
2. O-RING
3. SPRING
B861 799J
Outlet Section
Bur 8-17410
8005-10
INLET SECTION
STEP 2 5 Disassembly
STEP 2 2
Fasten the inlet section in the vise with soft jaws.
Loosen the steering relief valve.
STEP 2 3
Remove the steering relief valve.
STEP 2 4
Remove the spring.
Bur 8-17410
Loosen and remove the plug from the other end of the
inlet section.
STEP 2 6
Remove the spool.
STEP 2 7
Fasten the steering relief valve inthe vise with soft jaws.
Prevent the adjusting screwfrom turning and loosen the
lock nut. Make a count of the number of turns needed to
remove the adjusting screw from the body.
STEP 2 8
B62 892 4 M
Remove the steering relief valve from the vise and
separate the parts.
Bur 8-17410
8005-11
Inspection
STEP 2 9
4. a-RING
.~ ..'
4. a-RING
B62 892 8M
Inspect the seat in the end of the body If the seat is
damaged, use a press to replace the seat. Replace the
O-rings and backup ring on the body and adjusting
screw.
STEP 30
Inspect the orifice in the orifice plug. Make sure the
orifice is clean.
STEP 31
Inspect the spool and spring. Use new parts as neces-
sary.
8005-12
4. BODY
6. O-RING
B870013J
Inlet Section
Bur 8-17410
Assembly
STEP 32
.B62 892 4 M
Lubricate the new O-ring on the adjusting screw.
Assemble the parts of the steering relief valve.
STEP 33
Fasten the body in the vise with soft jaws. Tighten the
adjusting screw the same number of turns as instep 27
under Disassembly. Tighten the lock nut.
STEP 34
Install the spool.
Bur 8-17410
8005-13
STEP 35
Install a newO-ring on the plug. Lubricate the O-ring on
the plug. Lubricate the O-ring with clean hydraulic oil.
Install the plug in the inlet section
STEP 36
Install the spring in the other end of the inlet section
STEP 37
Lubricate the new O-ring and backup ring on the
steering relief valve. Install the steering relief valve.
8005-14
STEP 38
""" ~, ,,~?44M
Tighten the steering relief valve to 65 to 85 pound-feet
(88 to 155 Nm).
3. INLET SECTION
4. SPOOL
5. PLUG
B861 798J
Inlet Section
Bur 8-17410
BUCKET SECTION
8005-15
Disassembly
STEP 39
Remove the O-rings from the bucket section.
STEP 4 0
Fasten the bucket section in the vise with soft jaws.
Loosen the Allen head screws.
STEP 4 1
Hold the cap in place and remove the Allen head
screws.
Bur 8-17410
STEP 4 2
Remove the cap and gasket.
STEP 4 3
Remove the snap ring.
STEP 4 4
Remove the washer.
8005-16
STEP 4 5
Remove the spring.
STEP 4 6
Remove the detent washer.
STEP 4 7
Remove the coil and terminal.
Bur 8-17410
STEP 4 8
Pull the spool from the body.
STEP 4 9
.:~~,S23~M
Remove the O-ring, retainer, spring washers, and other
O-ring from the spool.
STEP 50
Remove the detent housing.
STEP 51
84 1 52 38M
See Special Tools inthis section. Install the spring com-
pressing plates to compress the centering spring.
STEP 52
B4 1 52 4 0M
Loosen and remove the stud.
STEP 53
'i84 1 52 4 2 M
Release the spring tension and separate the centering
spring and spring seats.
Bur 8-17410
8005-17
STEP 54
Loosen and remove the circuit relief valve from the
body.
STEP 55
See Special Tools inthis section. Use the tool to pull the
load check plug, spring, and poppet from the body.
STEP 56
Repeat steps 54 and 55to remove the other circuit relief
valve.
STEP 57
Use a prybar to remove the wiper.
Issued 1-91 Printed in U,S.A
8005-18
STEP 58
Remove the O-ring from the spool bore.
Bur 8-17410
STEP 59
See page 42 for disassembly, inspection, and
assembly of the circuit relief valves.
Bur 8-17410
8005-19
Bucket Section
B901919J
8005-20
Inspection
STEP 60
B4 1 52 32 J
Remove and discard the O-ring from the terminal.
STEP 61
Inspect the rubber plug in the cap. Replace the rubber
plug as necessary.
STEP 62
B9073309M
Inspect the poppet. spring, and load check plug. Use
new parts as necessary.
Bur 8-17410
STEP 63
B9073305M
Replace the O-ring and backup rings on the load check
plug.
STEP 64
Inspect the spool and spool bore for wear and damage.
If either part is worn or damaged. use a complete new
bucket section.
STEP 65
Use an ohmmeter to check the coil and terminal for
continuity and for a short circuit. If the terminal is
damaged. use asoldering iron to replace the terminal. If
the coil is damaged, remove the terminal from the old
coil and install the terminal on the new coil.
STEP 66
Discard the O-rings and gasket.
Assembly
STEP 67
See page 42 for disassembly. inspection. and
assembly of the circuit relief valves.
STEP 68
Install a new O-ring in the groove of the spool bore.
STEP 69
Use the tool to install the load check plug, spring, and
poppet. The groove in the load check plug must be
toward the spool bore.
STEP 70
Lubricate the O-rings and backup ring on the circuit
relief valve. Install the circuit relief valve.
STEP 71
62 8630M
Tighten the circuit relief valve to 65 to 85 pound-feet (88
to 155 Nrn).
Bur 8-17410
8005-21
STEP 72
B4 1 52 4 2 M
Assemble the spring and spring seats. Use the spring
compressing plates to compress the spring.
STEP 73
B4 1 52 4 3M
Install the spring and spring seats on the spool.
STEP 74
B4 1 52 01 M
Apply 242 Loctite to the threads of the stud. Install the
stud in the spool.
8005-22
STEP 75
B4 1 52 38M
Remove the spring compressing plates.
STEP 76
Install the detent housing.
STEP 77
B4 t52 35M
Install the O-rings, spring washers, and retainer.
Bur 8-17410
STEP 78
"'B415202M
Push the parts against the detent housing.
STEP 79
Lubricate the spool, spool bore. and the O-rings with
clean hydraulic oil. Install the spool into the bore.
STEP 80
Install the coil and terminal on the stud.
STEP 81
Install the detent washer.
STEP 82
Install the spring.
STEP 83
Install the washer.
Bur 8-17410
8005-23
STEP 84
Hold the washer in place and install the snap ring.
STEP 85
Install a new O-ring on the terminal. Install the gasket.
Put the terminal in the cap.
STEP 86
1 51 1 3M
Align the gasket and cap with the detent housing. Install
the Allen head screws and lock washers.
Issued 1-91 Printed in U.8A
8005-24
STEP 87
Tighten the Allen head screws evenly to 15to 30 pound-
inches (2to 3 Nm). Then tighten the Allen screws to 50
to 60 pound-inches (6 to 7 Nrn).
STEP 88
Lubricate the wiper with clean hydraulic oil. Install the
wiper with the lip up.
Bur 8-17410
STEP 89
Use a hollow sleeve and a hammer to push the wiper
into the body.
STEP 90
Install new O-rings in the bucket section.
Bur 8-17410
8005-25
22. SPOOL
18. CIRCUIT
RELIEF
VALVE
24. BODY
26. A PORT
27. B PORT
6. SPRING
B901920J
Bucket Section
8005-26
Disassembly
STEP 91
LIFT SECTION
STEP 94
Remove and discard the O-rings from the body.
STEP 92
Fasten the lift section inthe vise with soft jaws. Loosen
and remove the plug.
STEP 93
Remove the detent spring.
Bur 8-17410
Remove the ball retainer.
STEP 95
II
Remove the eight steel balls.
STEP 96
IIi
... :,(,= ;::: ...."
Remove the spacer.
STEP 97
Loosen and remove the detent housing.
STEP 98
STEP 99
B4 1 54 2 2 M
Remove the O-ring and retainer from the spool.
Bur 8-17410
8005-27
STEP 1 00
B4 1 54 2 4 M
See page 4 for the spring compressing plates Fasten
the spring compressing plates to compress the cen-
tering spring.
STEP 1 01
B4 1 54 2 6M
Loosen and remove the stud.
STEP 1 02
B4 1 54 2 8M
Remove the centering spring and spring seats from the
spool.
8005-28
STEP 1 03
B4 1 54 30M
Release the tension on the centering spring and
separate the centering spring and spring seats.
STEP 1 04
Loosen and remove the plug from the body.
STEP 1 05
Use the tool shown on page 4 to pull the load check
plug, spring, and poppet from the body.
Bur 8-17410
STEP 1 06
Remove the wiper from the spool bore.
STEP 1 07
STEP 1 08
Repeat steps 104 and 105 to remove the other plug
load check plug, spring, and poppet.
Lift Section
8005-29
8005-30
Inspection
STEP 1 09
B9073309M
Inspect the load check poppet, spring, and load check
plug. If any of the parts are damaged, replace the parts
as necessary.
STEP 1 1 0
B9073305M
Replace the O-ring and backup rings on the load check
plug.
STEP 1 1 1
Inspect the spool and spool bore for wear and damage.
If either part is worn or damaged, use a complete new
lift section
STEP 1 1 2
B4 1 54 2 0M
Replace the O-rings and backup ring on the plug.
Bur 8-17410
STEP 1 1 3
Inspect the stud, spacer, steel balls, and ball retainer
for damage and wear. Install new parts as necessary.
Assembly
STEP 1 1 4
Install a new O-ring in the spool bore.
STEP 1 1 5
~1' . ,,;,41?4
1 4 t
'lt
Use the tool shown on page 4 to install the load check
plug, spring, and load check poppet. The groove inthe
loade check plug must be in alignment with the work
port.
STEP 1 1 6
STEP 1 1 7
B41~5430M
Assemble the centering spring and spring seats. Use
the spring compressing plates shown on page 4 to
compress the centering spring.
STEP 1 1 8
Install the centering spring and spring seats on the
spool.
STEP 1 1 9
B4 t54 2 6M
Apply 242 Loctite (blue) to the threads of stud. Install
the stud in spool. Tighten the stud.
Bur 8-17410
8005-31
STEP 1 2 0
B4 1 54 2 4 M
Remove the spring compressing plates.
STEP 1 2 1
Install the retainer and a new O-ring on the spool.
STEP 1 2 2
Lubricate the spool, spool bore, and the O-rings with
clean hydraulic oil. Install the spool into the spool bore.
8005-32
STEP 1 2 3
Install the detent housing.
STEP 1 2 4
Apply No. 2 molydisu\fide grease to the groove in the
spacer.
STEP 1 2 5
Install the spacer so that the groove inthe spacer is up.
Bur 8-17410
STEP 1 2 6
Install the eight steel balls. Put the steel balls evenly
around the spacer.
STEP 1 2 7
Apply No.2 molydisulfide grease to the flat side of the
ball retainer.
STEP 1 2 8
Install the ball retainer with the flat side down.
STEP 1 2 9
Install the detent spring.
STEP 1 30
Install the plug.
STEP 1 31
Lubricate the new wiper with clean hydraulic oil. Install
the wiper with the lip of the wiper up.
Bur 8-17410
8005-33
STEP 1 32
into the body.
STEP 1 33
Install new O-rings in the body,
Issued 1-91 Printed in U,S,A.
8005-34
13. a-RING
1. SPOOL
12. PLUG
20. A PORT
18. BODY
21. B PORT
13. O-RING
17. RETAINER
3. SPRING
5. STUD
7. SPACER
6. DETENT
HOUSING
3. SPRING
10. PLUG
Bur 8-17410
Lift Section
B901922J
8005-35
Disassembly
STEP 1 34
CLAM SECTION
STEP 1 37
Remove the O-rings from the clam section
STEP 1 35
Fasten the clam section in the vise with soft jaws.
Loosen and remove the spool cap.
STEP 1 36
Bur 8-17410
STEP 1 38
Use the spring compressing plates shown in Special
Tools to compress the spring.
STEP 1 39
Loosen and remove the cap screw.
8005-36
STEP 1 4 0
Remove the spring and spring seats from the spool.
Release the spring tension and separate the spring,
spring seats, and washer.
STEP 1 4 1
Loosen and remove the plug.
STEP 1 4 2
Use the tool shown in Special Tools to pull the load
check plug, spring, and poppet from the body.
Bur 8-17410
STEP 1 4 3
Use a prybar to remove the wiper from the other end of
the spool bore.
STEP 1 4 4
STEP 1 4 5
Do step 141 and 142 to remove the other plug, load
check plug, spring, and poppet.
8005-37
Bur 8-17410
Clam Spool
B901 92 3J
8005-38
Inspection
STEP 1 4 6
B9073309M
Inspect the load check poppet, spring, and load check
plug. Use new parts as necessary.
STEP 1 4 7
B9073305M
Replacethe O-ring and backup rings on the load check
plug.
STEP 1 4 8
B4 1 54 2 0M
Replace the O-rings and backup ring on the plug.
STEP 1 4 9
Inspect the spool bore for wear and damage. If the
spool or spool bore is damaged, use a complete new
clam section.
Bur 8-17410
Assembly
STEP 1 50
Install a new O-ring in the groove of the spool bore.
STEP 1 51
Lubricate the O-ring and backup rings on the load
check plug. Use the tool to install the load check plug,
spring, and poppet. The groove in the load check plug
must be toward the spool bore.
STEP 1 52
M
Lubricate the O-rings and backup ring on the plug.
Install the plug. Tighten the plug to 65 to 85 pound-feet
(88 to 155 Nm).
STEP 1 53
i ' ,-:'B62 862 4 M
Assemble the spring, spring seats, and washer. Use
the spring compressing plates shown in Special Tools
to compress the spring.
STEP 1 54
B62 8539M
Apply 242 Loctite to the threads of the cap screw.
STEP 1 55
B62 862 2 M
Install the cap screw to fasten the spring to the spool.
Bur 8-17410
8005-39
STEP 1 56
Tighten the cap screw
STEP 1 57
';':'~~~M
Release the tension of the spring and remove the spring
compressing plates.
STEP 1 58
Install the retainer and a new O-ring on the spool.
8005-40
STEP 1 59
STEP 1 60
Install the spool cap.
STEP 1 61
\OO2 884 4 M
Tighten the spool cap to 20 to 30 pound-feet (27 to 41
Nm).
Bur 8-17410
STEP 1 62
5M
Lubricate a newwiper. Install the wiper with the lips up.
STEP 1 63
into the bore.
Bur 8-17410
14. WIPER
., 15. PLUG
2. O-RING
2. O-RING
16. A PORT
13. BODY
17. B PORT
6. SPRING
5. WASHER
7. CAP SCREW
~
8. SPOOL CAP
Clam Spool
8005-41
B901924J
8005-42
CIRCUIT RELIEF VALVE
Disassembly
STEP 1 64
Fasten the circuit relief valve in the vise with soft jaws.
Loosen the lock nut. Loosen and remove the adjusting
screw and lock nut.
NOTE: If you disassemble more than one relief valve,
keep the parts for each relief valve together. This pro-
cedure will prevent mixing the parts during assembly.
Bur 8-17410
STEP 1 65
Move the circuit relief valve in the vise. Fasten the
poppet seat in the vise. Loosen the body from the
poppet seat.
STEP 1 66
B62 8606M
Remove the relief valve from the vise. Separate the
parts of the relief valve.
Circuit Relief Valve
Inspection Assembly
STEP167 STEP169
Inspect the parts of the relief valve. All of the repair parts
inthe relief valve are available in a kit. If any of the parts
are damaged, replace all the parts in the kit.
STEP 1 68
B62 8606M
Lubricate the O-rings on the parts of the relief valve
Assemble the parts into the body.
B870017J
8005-43
B62 8734 M
Replace the O-rings and backup ring on the parts of the
relief valve.
8005-44
STEP 170
12M
Fasten the poppet seat in the vise wi t h soft jaws.
Tighten the body to 96 to 144 pound-inches (11 to 16
Nrn).
STEP 171
Install the adjusting screw and lock nut in the body.
Bur 8-17410
STEP 172
See the procedure in Section 8002. Check and adjust
the pressure setting of the relief valve in a test block
before the relief valve is installed.
2. ADJUSTING SCREW
6. SPRING
4. D-RING
6. SPRING
8. POPPET
SEAT
7. POPPET
8006
CYLINDERS
TABLE OF CONTENTS
Specifications 2 Lift Cylinder for the Three-Point Hitch 12
Special Tools.... 3 Disassembly........ 12
Loader Bucket and Lift. Backhoe Extension, Inspection .. 12
Bucket. Swing, Clam. Stabilizer and
Dipper Cylinders. . 4 Assembly. . 12
Disassembly.. ..4 Tilt Cylinder for the Three-Point Hitch 16
Inspection .. .. ... 4 Disassembly... .. 16
Assembly............ 4 Inspection 16
Boom Cylinder. . . . 8 Assembly. . 16
Disassembly. . ... 8 Pitch Cylinder for the Three-Point Hitch 20
Inspection. .. . 8 Disassembly......... .. 20
Assembly. . 8 Inspection. .. 20
Assembly 20
CASE CORPORATION
Rae 8-17591
Printed in U.S.A.
Issued March. 1991 (Revised August. 1992)
8006-2
SPECIFICATIONS
Torque specifications for piston cap screw with 242 Loctite on the threads
Loader cylinders
Bucket cylinder .. 269 to 339 pound-feet (365 to 460 Nm)
Lift cylinder 269 to 339 pound-feet (365 to 460 Nm)
Clam cylinder...... ..661 to 819 pound-feet (895 to 1110 Nm)
Three-point hitch cylinders
Lift cylinder . 200 to 220 pound-feet (271 to 298 Nm)
Tilt cylinder.............................................. 200 to 220 pound-feet (271 to 298 Nm)
Pitch cylinder 169 to 192 pound-feet (230 to 260 Nm)
Backhoe cylinders
Extension cylinder..................... 269 to 339 pound-feet (365 to 460 Nm)
Bucket cylinder ..661 to 819 pound-feet (895 to 1110 Nm)
Swing cylinder .. 325 to 365 pound-feet (440 to 495 Nm)
Stabilizer cylinder................ . 661 to 819 pound-feet (895 to 1110 Nm)
Boom cylinder ..1314 to 1609 pound-feet (1780 to 2180 Nm)
Dipper cylinder.......................... . , 2443 to 2841 pound-feet (3310 to 3850 Nm)
Torque for all glands . ........ 100 to 400 pound-feet (135 to 542 Nm)
Cylinder weights (approximate)
Loader cylinders
Bucket cylinder .
Lift cylinder.................. .
Clam cylinder.................. .
... 40 pounds (19 kg)
... 60 pounds (27 kg)
... 33 pounds (15 kg)
Three-point hitch cylinders
Lift cylinder...... .
Tilt cylinder. .
Pitch cylinder .. . .
.......... 29 pounds (13 kg)
..23 pounds (10.4 kg)
.. 30 pounds (13.6 kg)
Backhoe cylinders
Extension cylinder 82 pounds (37 kg)
Bucket cylinder . 98 pounds (45 kg)
Swing cylinder 70 pounds (32 kg)
Stabilizer cylinder......................... 99 pounds (45 kg)
Boom cylinder.......................... 170 pounds (77 kg)
Dipper cylinder 155 pounds (70 kg)
Rae 8-17591
SPECIAL TOOLS
8006-3
dresses:
Service Tools
PO Box 314
In Europe
VL Churchill Ltd
Northants, NN11 4NF
England
This tool is used to remove and install the gland on
Case cylinders. The part number on the gland wrench is
CAS-1456 This tool is first used on page 8006-4
B786441M
gae 8-17591
The tool shown is used to install the seal in the
glands of the cylinders. This tool is first used on page
8006-4
B505802M
1. CAS-1659 For One Inch (25 mm) Rods
2. CAS-1660 For 1-1/4and 1-1/2 Inch
(32 and 38mm) Rods
3. CAS-1758 For 2 Inch (50 mm) Rods
The torque multiplier is used to loosen and tighten
the piston cap screw. Use the torque multiplier ac-
cording to the instructions of the manufacturer. The part
number of the torque multiplier is CAS-1039. This tool is
first used on page 8006-4.
8795329M
8006-4
LOADER BUCKET AND LIFT, BACKHOE EXTENSION, BUCKET, SWING,
CLAM, STABILIZER, AND DIPPER CYLINDERS
Di sassembly
Clean the outside of the cylinder. If the hoses were
removed with the cylinder, remove the hoses from the
cylinder.
1. Fasten the tube (1) ina vise or other holding equip-
ment. Be careful to prevent damage to the tube (1).
2 Loosen and remove the lock screw (2) from the
gland (3) and tube (1).
3. Use the gland wrench shown on page 8006-3 to
loosen and remove the gland (3) from the tube (1).
4. Pull the piston rod (6) straight out of the tube (1) to
prevent damage to the tube (1).
5. Fasten the piston rod eye (5) in a vise and put a
support below the piston rod (6) near the piston (4). Use
ashop cloth between the support and the piston rod (6)
to prevent damage to the piston rod (6).
6. Loosen and remove the cap screw (7) and
hardened washer (8) that holds the piston (4). Use the
torque multiplier shown on page 8006-3 for cap screws
that have a high torque value.
7. Remove the piston (4) from the piston rod (6).
9. Remove the seal (9), backup ring (10), and wear
ring (11) from the piston (4).
10. Remove the O-ring (12), backup ring (13), wiper
(14), wide seal (15), narrow seal (16), and bushing (17)
from the gland (3).
Inspect i on
1. Clean the piston (4), gland (3), piston rod (6), tube
(1), hardened washer (8), and cap screw (7) incleaning
solvent.
2. Discard the parts that were removed from the
piston (4) and the gland (3).
damage. If there is damage to the tube (1), a new tube
(1) must be used.
Rae 8-17591
4. Check to be sure that the piston rod (6) is straight. If
the piston rod (6) is not straight, install a new piston rod
(6)
5. Remove small scratches on the piston rod (6) or
inside the tube (1) with emery cloth of medium grit. Use
the emery cloth with a rotary motion.
6. Inspect the bushing (18) and seal (19). if equipped.
inthe piston rod eye (5) and the closed end of the tube
(1), replace as required
7. Inspect the gland (3) for rust and clean and remove
rust as required.
8 Inspect the gland end of the tube (1) for share
edges that will cut the gland O-ring (12). remove as re-
quired.
9. Inspect the piston (4) for damage and wear If the
piston (4) is damaged or worn. a new piston (4) must be
used.
Assembly
NOTE: If anew gland (3) is being installed, put the
part number of the cylinder on the new gland (3)
1. Install the bushing (17) in the gland (3).
2. Install the wide seal (15) inthe gland. The wide seal
(15) is to be installed so that the Iips of the wi de seal (15)
are toward the small end of the gland (3). The wide seal
(15) can be difficult to install. Use the tool shown on
page 8006-3
3. Install a new wiper (14) in the gland (3). The lips of
the wiper (14) must be toward the large end of the gland
(3).
4. Install the narrow seal (16) inthe gland (3) The side
of the narrow seal (16) with the groove must be toward
the small end of the gland (3).
5. Install a new backup ring (13) in the groove on the
outside of the gland (3). If both sides of the backup ring
(13) are not flat, the side that is not flat must be toward
the small end of the gland (3)_
6. Install the O-ring (12) next to the backup ring (13) in
the groove on the outside of the gland (3). The O-ring
(12) must be toward the small end of the gland (3).
8006-5
,=lac: 8-1759 i
Revised 8-92
Printed i n U.S.A
8006-6
7. Fasten the piston rod eye (5) in the vise.
8. Remove any marks and sharp edges on the chamfer
at the end of the piston rod (6).
9 Lubricate the bore of the gland (3) with clean oil.
10 Push the gland (3) onto the piston rod (6). If neces-
sary, use a soft hammer to drive the gland (3) onto
the piston rod (6).
11. Put a support below and near the end of the piston
rod (6). Use a shop cloth between the support and
the piston rod (6) to prevent damage to the piston
(4).
12. Put the piston (4) on the end of the piston rod (6)
13. Put the hardened washer (8) on the cap screw (7).
14. Clean the threads on the end of the piston rod and
the threads of the cap screw using Loctite cleaning
solvent. Allow to dry. Apply Loctite 242 to the piston
rodthreads 1/4 inch from the open end of the piston
rod so that there is 1/2 inch of Loctite 242 on the
piston rod threads. DO NOT apply Loctite to the first
1/4 inch of the piston rod threads.
15. Install the cap screw (7). Tighten the cap screw (7)
to the torque value on page 8006-2 for the cylinder
that is being repaired A torque multiplier can be
used to help tighten the cap screw.
16. Install a newwear ring (11) inthe end groove on the
outside of the piston (4).
17. Install a new backup ring (10) in the center groove
on the outside of the piston (4).
Rae 8-17591
18 Install a new seal (9) on top of the backup ring (10)
on the outside of the piston (4)
19. Fasten the tube (1) in a vise or other holding equip-
ment. Be careful to prevent damage to the tube (1)
20 Lubricate the inside of tne tube (1) and tne ois.on (4)
with clean oil.
21 Push the piston (4) straiqh: in.o .ne lube (1)
22 When thepiston (4) is in he smooth oar: 0'the tube
(1). start the gland (3) in:o 'he .ube (1\
23 Lubricate the O-ring (12) or, .he gland (3) \VI:hclean
oil
24. Tighten the gland (3) :0 10010 400 oounc-tee: (135
to 542 Nm) If the lock screw (2) holes becorre
aligned In this torcue range. Install .he lock screw
(2). Tighten the lock screw (2) :0 20 occno-vicnes
(2.3 Nm) Ii:he lock scre\' (2) holes are no: alignec
do steps 25 through 27
25. Tighten the gland (3) to 100;0400 ocund-teet 1135
to 542 Nm)
26. Use a No 26 drill and drill a hole half inthe gland(3)
and half in the tube (1). Drill to a deeth of 7'16 irch
(11 mm) Do not drill in line with a hole in he gland
(3) for the gland wrench
27. Install the lock screw (2). Tighten the lock screw (2)
to 20 pound-inches (23 Nm)
If the hoses were removed with the cylinder. install new
a-rings. if equipped on the hose fittings Lubricate the
a-rings with clean oil. Install the hoses
8006-7
12. a-RING
13. BACKUP RING
5. PISTON ROD EYE
16. NARROW SEAL 17. BUSHING
Rod End of Cylinder
1. TUBE
BB91512J
8. HARDENED
WASHER
7. CAP SCREW
Closed End of Cylinder
Revised 8-92 Printed in USA.
Rac 8,7591
8006-8
BOOM CYLINDER
Di sassembly
cylinder.
2. Loosen and remove the lock screw (2) from the gland
(3) and tube (1).
6. Loosen and remove the cap screw (7) and hardened
washer (8)that holds the piston (4). Use the torque mul-
tiplier shown on page 8090-3 for cap screws that have a
high torque value.
NOTE: If the boom cylinder isbeing disassembled for
repair because of poor performance and the seals (10)
on the piston (4) are good, replace the check valve (12)
and the O-ring (13). If the seals (10) are damaged, do
the next step.
9. Remove the wear ring (9), seals (10), and the backup
rings (11) from the piston (4)
from the gland (3).
Inspect i on
(1), hardened washer (8) and cap screw (7) incleaning
solvent.
2. Discard the parts that were removed from the piston
(4) and the gland (3).
Rae 8-17591
3 Illuminate the inside of the tube (1). Inspect the inside
of the tube (1) for deep grooves and other damage. If
there is damage to the tube (1), a new tube (1) must be
used.
4. Check to be sure that the piston rod (6) is straight If
the piston rod (6) is not straight, install a new piston rod
(6).
the emery cloth with a rotary motion
6 Inspect the bushing (20) and seal (21). if equipped in
the piston rod eye (5) and the closed end of the tube (1).
and replace as required.
rust as required.
8 Inspectthe gland end of the tube (1) for sharp edges
that will cut the gland O-ring (14) and remove as re-
quired.
9. Inspect the piston (4) for damage and wear If the
piston (4) is damaged orworn. a new piston (4) must be
used.
Assembly
NOTE: If a new gland (3) is being instal/ed, put the
part number of the cylinder on the new gland (3).
2. Install the narrow seal (17) in the gland (3). The side
3. Install the wide seal (18) in the gland (3). The wide
seal (18) is to be installed so that the lips of the wide
seal (18) are toward the small end of the gland (3) The
wide seal (18) can be difficult to install. Use the tool
shown on page 8009-3.
4. Install a newwiper (19) inthe gland (3) The lips of the
wiper (19) must be toward the outside of the gland (3).
5 Install a new backup ring (15) in the groove on the
Revised 8-92 Printed in US.A
8006-9
Rae 8-17591
8006-10
6. Install the a-ring (14) next to the backup ring (15) in
the groove on the outside of the gland (3). The a-ring
7 Fasten the piston rod eye (5) in the vise.
at the end of the piston rod (6)
9. Lubricate the bore of the gland (3) and the piston rod
(6) with clean oil
10 Pushthe gland (3) onto the piston rod (6). If neces-
the piston rod (6).
(4)
the threads of the cap screw using Loctite cleaning
solvent. Allow to dry. Apply Loctite 242 to the piston
rodthreads 1/4inch from the open end of the piston
piston rod threads. DO NOT apply Loctite to the first
used to help tighten the cap screw (7).
16. Install a newwear ring (9) inthe groove inthe center
of the piston (4)
Rae 8-17591
17 Install a new backup ring (11) in each groove on the
outside ends of the piston (4)
18 Install a newseal (10) over each backup ring (11) on
the outside ends of the piston (4)
19 Fasten the tube (1) in a vise or other holding equip-
20 Lubricate the inside of the tube (1) and the piston (4)
with clean oil
21. Push the piston (4) straiqrn into the tube (1)
22. When the piston (4) is in the smooth par; of the tube
(1) start the gland (3) into the tube (1)
23. Lubricate the a-ring (14) on the gland (3) with clean
oil.
24 Tighten the gland (3) to 100 to 400 pound-feet (135
to 542 Nm) If the lock screw (2) holes become
aligned in this torque range install the lock screw
(2) Tighten the lock screw (2) to 20 pound- inches
(23 Nm) If the lock screw (2) holes are not aligned
25. Tighten the gland (3) to 100 to 400 pound-feet (135
to 542 Nm).
26. Use a No. 26 drill and drill a hole half in the gland (3)
and half in the tube (1). Drill to a depth of 7/16 inch
(11 mm). Do not drill in line with a hole in the gland
27. Install the lock screw (2) Tighten the lock screw (2)
to 20 pound-inches (23 Nm)
28. If the hoses were removed with the cylinder, install
newa-rings. if equipped, on the hose fittings. Lub-i-
cate the a-rings with clean oil. Install the hoses.
Revised 8-92 Printed in U.sA
8006-11
5. PISTON ROD EYE
1. TUBE
21. SEAL
B891539J
Rae 8-17591
Revised 8-92 Printed in USA.
8006-12
LIFT CYLINDER FOR THREE-POINT HITCH
Di sassembly
cylinder.
2. Loosen and remove the lock screw (2) from the
support belowthe piston rod (6) near the piston (4). Use
a shop cloth between the support and the piston rod (6)
9. Remove the seal (9), backup ring (10), and wear
ring (11) from the piston (4)
from the gland (3).
Inspect i on
1. Clean the piston (4), gland (3), piston rod (6). tube
(1), hardened washer (8), and cap screw (7) in cleaning
solvent.
(1) must be used.
Rae 8-17591
the piston rod (6) is not straight. install a new piston rod
(6).
6. Inspect the bushing (18) and seal (19), if equipped.
inthe piston rod eye (5) and the closed end of the tube
(1). Replace as required.
rust as required.
8. Inspect the gland end of the tube (1) for sharp
edges that will cut the gland O-ring (12). Remove as re-
quired.
used.
Assembly
(15) isto be installed so that the lips of the wide seal (15)
(15) can be difficult to install Use the tool shown on
page 8006-3.
3. Install a new wiper (14) in the gland (3) The lips of
(3)
4. Install the narrow seal (16) inthe gland (3). The side
8006-13
5. PISTON ROD EYE
19. GREASE
rrrnso
1. TUBE
B891624J
Rae 817591 Revised 8-92 Printed in U.S.A.
8006-14
9. Lubricate the bore of the gland (3) with clean oil
10. Push the gland (3) on to the piston rod (6). If neces-
the piston rod (6).
(4).
12 Put the piston (4) on the end of the piston rod (6)
the threads of the cap screw using l.octite cleaning
solvent Allow to dry. Apply Loctite 242 to the piston
rod threads 1/4inch from the open end of the piston
piston rod threads DO NOT apply Loctite to the first
1/4inch of the piston rod threads
15. Install the cap screw (7) Tighten the cap screw (7)
to the TOrquevalue on page 8006-2 for the cylinder
that is being repaired A toraue multiplier can be
used to help .ighten the cap screw.
16 Install a new wear ring (11) inthe end groove a the
outside of the piston (4)
Rac 8-17591
19 Fasten the tube (1) Ina vise or other holding equip-
20. Lubricate the inside of the tube (1) and the piston (4)
with clean oil
21 Push the piston (4) s raiqh: into the tube (1).
22 When the piston (4) is Inthe smooth cart of the tube
(1) start the gland (3) into the tube (1)
23. Lubricate the a-ring (12) on the gland (3) with clean
ali
24 Tighten the glar:d (3) ;0100 to 400 pound-feet (135
IO 542 NIT,) I' the lock screw (2) holes oecorr-e
aligned in tt"',istoroue range install the lock screw
(2). Tighten the lock screw (2) :020 pound-Inches
(23 Nm) I' tne lock screw (2) holes are no: aligned
do stecs 25 :hroLgh 27
2S 7
i
ghten the gland (3) to 100 to 400 pound-tee: (135
to 542 Nrn)
26 Use a No. 26 drill and drill a hole half inthe gland (3)
and hal' in the tube (1) Drill to a death a'7/16 inch
(11 rr:r-) Do no: drill in line with a hole in the gland
f3) 'or the glar.c wrencr;
27 l"1s:al,the lock screw (2) Tighten the lock screw (2)
:020 cound-inches (2.3 Nm).
Ii the hoses were removed with the cylinder. install new
a-rings. ii equipped on the hose fittings. Lubricate the
O-rings with clean 0'1. Install the hoses
RCVlscC 8-92 p"..,:::::: ,~ :.; s,'".
8006-15
12. O-RING
3
6. PISTON ROD
18. BUSHING
17. BUSHING 15. WIDE
SEAL
16. NARROW
SEAL
Rod End of Cylinder
4.
19. GREASE
Fi nING
18. BUSHING
8. HARDENED
WASHER
7. CAP SCREW
S8S1S25J
Rae 8-17591 Revised 8-92
Printed in U.SA
8006-16
TILT CYLINDER FOR THE THREE-POINT HITCH
Di sassembly
cylinder.
1. Fasten the tube (1) ina vise or other holding equip-
2. Loosen and remove the lock screw (2) from the
3 Use the gland wrench shown on page 8006-3 to
loosen and remove the gland (3) from the tube (1)
support below thepiston rod (6)near the piston (4). Use
that have a high torque value
8. Remove the gland (3) from the piston rod (6)
9. Remove the seal (9), backup ring (10). and wear
10 Remove the O-ring (12), backup ring (13), wiper
from the gland (3).
Inspect i on
solvent.
3 Illuminate the inside of the tube (1). Inspect the
(1) must be used.
=lac 8-17591
(6).
6 Inspect the bushing (17) and seal, if equipped, in
Replace as required.
rust as required.
8 Inspect the gland end of the tube (1) for sharp
edges that will cut the gland O-ring (12). Remove as re-
quired.
9. Inspect the piston (4) for damage and wear. If he
used.
Assembly
(15) is to be installed sothatthe lips of the wide seal (15)
are toward the small end o' the gland (3). The wide seal
page 8006-3
2. Install a new wiper (14) inthe gland (3). The lips of
(3) .
3. Install the narrow seal (16) inthe gland (3). The side
4 Install a new backup ring (13) in the groove on the
6. Fasten the piston rod eye (5) in the vise
ReVised 8-92 Pwlted In US.A
8006-17
19 GREASE FITTING
~
Rae 8-17591
Revised 8-92
Printed in U.S.A
8006-18
7 Remove any marks and sharp edges on the chamfer
9. Push the gland (3) on to the piston rod (6) If neces-
the piston rod (6).
10 Put a support below and near the end of the piston
(4).
12 Put the hardened washer (8) on the cap screw (7).
the threads of the cap screw usmq Loctite cleaning
solvent. Allow to dry Apply Loctite 242 to the piston
rod threads 1/4inch from theopen end of the piston
piston rod threads. DO NOTapply Loctite to the first
14. Install the cap screw (7) Tighten the cap screw (7)
used to help tighten the cap screw. When a torque
multiplier IS used. a chain must be used to hold the
piston rod (6) in position Use a shop cloth and a
metal protector between the piston rod (6) and the
chain
15. Install a newwear ring (11) In.beend groove on the
17. Install a new seal (9) on too of the backuo ring (10)
Rae 8-17591
19 Lubricate the piston (4) and the inside of the tube (1)
with clean oil.
20 Push the piston (4) straight into the tube (1)
21. When the piston (4) is in the smooth part of the tube
(1), start the gland (3) into the tube (1)
22 Lubricate the O-ring (12) on the gland (3) with clean
oil
23 Tighten the gland (3) to 100 to 400 pound-feet (135
to 542 Nm) If the lock screw (2) holes become
aligned in this torque range install the lock screw
(2). Tighten the lock screw (2) to 20 pound-Inches
(2.3 Nm) Ifthe lock screw (2) holes are not aligned.
24. Tighten the gland (3) to 100 tc 400 oounc-tee: (135
to 542 Nrn).
25 Use a No. 26 drill and drill a hole hal' Inthe gland (3)
and half inthe tube (1) Drill to a death of 7/16 inch
(11 mm). Do not drill in line Witha hole in the gland
26 Install the lock screw (2) Tighten the lock screw (2)
to 20 pound-Inches (23 Nm)
If the hoses were removed Withthe cylinder. install new
O-rings If equipped on the hose :ittings. Lubricate the
O-rings with clean oil Install the hoses
=<CVISCC 8-92 P~IC"tCC '" U S c ;
8006-19
5. PISTON ROD EYE
18. SNAP
RING
15. WIDE
SEAL
16. NARROW
SEAL
6. PISTON
ROD
Rod End of Cylinder
9. SEAL
8. HARDENED
WASHER
7. CAP SCREW
17. BUSHING
Rae 8-17591
8006-20
PITCH CYLINDER FOR THE THREE-POINT HITCH
Di sassembly
cylinder.
2 Loosen and remove the lock screw (2) from the
3 Use the gland wrench shown on page 8006-3 to
loosen and remove the gland (3) from the tube (1)
5 Fasten the piston rod eye (5) in a vise and put a
a shop cloth between the support and the piston rod (6)
7. Remove the piston (4) 'rom the piston rod (6).
8 Remove the gland (3) from the piston rod (6)
9 Remove the seal (9), backup ring (10). and wear
10 Remove the O-ring (12). backup ring (13). wiper
(14), wide seal (15). narrow seal (16), and bushing (17)
from the gland (3).
Inspect i on
solvent.
3. Illuminate the inside of the tube (1) Inspect the
(1) must be used.
Bur 8-15790
(6).
6 Inspect the bushing (18) and seal, if equipped, in
Replace as required.
7 Inspect the gland (3)for rust and clean and remove
rust as required.
8. Inspect the gland end of the tube (1) for share
edges that will cut the gland O-ring (12). remove as re-
quired.
piston (4) is damaged or worn. a new piston (4) rnus: be
used
Assembly
NOTE: If anew g/e.nd (3) is beif'Q ir.sralled. put the
pan number of the cylinder on the new gland (3).
1. Install the bushing (17) in .he gland (3).
2. lnstall the wide seal (15) inthe gland. The wide seal
(15) isto be installed so that the lips of the wide seal (i5)
page 8006-3
3. Install a new wiper (14) in the gland (3). The lips of
(3)
4. Install the narrow seal (16) inthe gland (3) The side
(12) must be toward the small end of the gland (3)
.~CVISCC 8-92 "'~;ri[CC !n USA
8006-21
Rae 8-17591
B891629J
19. SNAP
RING
8006-22
at the end of the piston rod (6).
10 Push the gland (3) onto the piston rod (6). If neces-
the piston rod (6).
(4).
13 Put the hardened washer (8) on the cap screw (7).
the threads of the cap screw usmq Lac ire cleaning
solvent. Allow to dry Apply Loctite 242 to the piston
rod threads 1/4inch from :he open end of the piston
rod so tha there is 1/2 inch of Loctue 242 on the
piston rod threads 00 NOT apoly Loctite to the first
1/4inch of the piston rod threads
that is being repaired. A torque rnultiolier can be
used to help tighten the cao screw.
16. Install a new wear ring (11) in the end groove on the
~ac 8-17591
on the outside of the piston (4).
19 Fasten the tube (1) in a vise or other holding equip-
ment Be careful to orevent damage to the tube (1).
20. Lubricate the inside of the tube (1) and the piston (4)
with clean oil
21 Push the piston (4) straight 1"1(0 tre tube (1)
22. When the cis.on (4) is in the srnoo.n pan of the tube
(1) star; the gland (3) into the tube (1)
23 Lubricate the O-ring (12) on the giand (3\ with clean
oil.
24 Tighten the gland (3) to 100 :0 400 ;:::OLnc-'eet :135
to 542 Nm) I: the lock screw '2: holes become
aligned in 'his toroue range ins.ar me lock screw
(2). 7ighten the icck screw :2) :020 co.r.o-mches
(23 NI) I': 2 lee- screw ~2:'"'ces are no: alqnec.
do s.eos 25 throL.:gh 2
7
25 7ighte the glanc (3) :0 1oo .c 400 ooi.r-o-reet :135
:0542 Nm)
26 Use a a 26 dr:1 and cr'll a "',012 1"2:' " Te gl2.rC (3)
and :,alf!'l :,2 t\.:Oe:1. Orl:l:O 2. deo:'" of 7 16 Ir,c~,
(11 rnrn) 00 no: drl;i -n line V/!;i" 2 :,0:0 ir the giand
(3) for t e glanc \'/re'lC';
27 Install the lac" screw (2) ilgr,:er :"Ie lccx screw (2)
to 20 oound-mcr-es 123 N'T
Ii the hoses were .err.oveo wi.h the cyunoer. instau new
O-rrngs I: ecuipped on :he hose :::;ings L.;brlca:c .no
0-,1ngs witr clear. cil. I::stall 'he hoses
Rcv!scc 8-92
8006-23
13
6. PISTON ROD
5. PISTON ROD EYE
15. WIDE
SEAL
17. BUSHING
Rod End of Cylinder
1. TUBE
4. PISTON
20. GREASE
FITTING
Bur 8-17590
Revised 8-92
Printed in U.S.A.
CASE CORPORATION
Sect i on
8007
Bur 8-17430
Printed in U.S.A.
8007-2
TABLE OF CONTENTS
SPECiFiCATIONS.... . 3
SPECIAL TOOLS.. .4
EXPLODED VIEW OF BACKHOE CONTROL VALVE.......... . 5
SEPARATING THE VALVE SECTIONS................................................................................. . 6
ASSEMBLING THE VALVE SECTIONS. . 7
INLET SECTION .. 8
Disassembly. 8
Assembly. .. 10
OUTLET SECTION......... 12
Disassembly............... . .............................12
Assembly........... ...14
SWING AND BOOM SECTION . ..16
Disassembly............. . 16
Assembly............................. .. . 22
STABILIZER SECTION . . 28
Disassembly 28
Assembly..... .. . 32
BUCKET, DIPPER, AND EXTENDABLE DIPPER SECTIONS..................... 37
Disassembly............................................................................. . 37
Assembly 41
CIRCUIT RELIEF VALVE 46
Disassembly .46
Inspection .... . 47
Assembly 48
INSPECTION 49
8007-3
SPECIFICATIONS
Manufacturer , .J I Case
Pressure settings , ,................... ,See Section 8002
Ports and Spools
Spool travel, neutral to pressure , , 0.45 inch (11.5 mm)
Spool moved into the body pressure at A port
Spool moved out of the body . .. pressure at B port
Threads in inlet and outlet ports , 1-5/16 - 12, straight thread
Threads in inlet and swing section port , . ........ ,.. 7/8 - 14, straight thread
Threads in A and B ports of stabilizer 3/4 - 16, straight thread
Threads in A and B ports of other sections 1-1/16 - 12, straight thread
Special torques
Nuts that fasten the valve sections together 20 to 30 pound-feet (27 to 41 Nm)
Circuit relief valves for swing, boom, stabilizer, and dipper sections
or plugs for load check valves 65 to 80 pound-feet (88 to 108 Nm)
Circuit relief valves for bucket or extendable dipper sections 65 to 85 pound-feet
(88 to 155 Nm)
Spool cap 20 to 30 pound-feet (27 to 41 Nm)
Weight , approximately 130 pounds (59 kg)
Bur 8-17430
8007-4
SPECIAL TOOLS
dresses:
Inthe U.S.A and Canada
Service Tools
P.O. Box 314
In Europe
VL Churchill Ltd.
Northants, NN11 4NF
England
The spring compressing plate is used to compress
the centering springs for removal and installation. The
part number of the tool is CAS-147-2. This tool is first
used on page 16.
Bur 8-17430
BB61843J
1. 3/8-16NC X 3Inches (76mm)
Or Longer Hex Bolt
2. Grind Two Sides Evenly
To 15/32 Inch (11.9 mm)
3. Grind To 1/8Inch (3.2 mm)
4. 5/8Inch (10.1 mm)
The tool above is used to remove and install the
load check plugs. The tool is first used on page 17.
8007-5
B870187J
Exploded View of Backhoe Control Valve
Bur 8-17430
8007-6
STEP 4 STEP 1
Clean the backhoe control valve and put the valve on a
clean bench. Write numbers on each section of the
valve.
STEP 2
Loosen and remove the nuts from the studs.
STEP 3
B630304M
Remove the inlet section.
Bur 8-17430
Remove the shims.
STEP 5
Remove the remainder of the sections and shims.
STEP 6
~.'
Remove the studs from the outlet section.
8007-7
STEP 7
Install new O-rings in each section.
STEP 8
Install the studs in the outlet section.
STEP 9
Install the shims on the studs.
Bur 8-17430
STEP 10
Use the numbers on each valve section as a guide and
install the valve sections and shims.
STEP 11
0044M
-,..-,.;,..,,;,., ,._,
Install the nuts. Tighten the nuts to 20 to 30 pound-feet
(27 to 41 Nm).
8007-8
INLET SECTION
Di sassembly
STEP 12
Fasten the inlet sections inavise with soft jaws. Loosen
the plug.
STEP 13
Remove the plug
Bur 8-17430
STEP 14
Remove the spring.
STEP 15
Remove the poppet.
STEP 16
See Inspection on page 49 and inspect the parts of the
inlet section.
Bur 8-17430
8007-9
B870188J
8007-10
Assembly
STEP 17
Install the poppet.
STEP 18
Install the spring.
Bur 8-17430
STEP 19
; B630320M
with clean hydraulic oil. Install the plug.
3. SPRING
Inlet Section
Bur 8-17430
8007-11
6. BODY
B861844J
8007-12
OUTLET SECTION
Di sassembly
STEP 20
Fasten the outlet section in the vise with soft jaws.
STEP 21
Remove the spring.
STEP 22
Remove the spool.
Bur 8-17430
STEP 23
Remove the piston.
STEP .24
1. OUTLET SECTION
Remove the O-ring from the bore for the spool.
STEP 25
See page 49 and inspect the parts of the outlet section.
7. PLUG
Outlet Section
Bur 8-17430
Issued 1-91
8007-13
B870189J
Printeo in U.S.A.
8007-14
Assembly
STEP 26
See the illustration on page 12 and install a new O-ring
in the bore for the spool.
STEP 27
Install the piston.
STEP 28
Bur 8-17430
STEP 29
Install the spring.
STEP 30
0414M
8007-15
3. PISTON
5. O-RING
B871846J
6. SPRING
Outlet Section
Bur 8-17430
8007-16
Di sassembly
STEP 31
SWING AND BOOM SECTION
STEP 34
Fasten the section inthe vise with soft jaws. Loosen and
remove the cap.
STEP 32
Pull the spool, retainer, and O-ring from the body.
STEP 33
Bur 8-17430
'B62~2M
Use the spring compressing plates shown on page 4to
compress the spring.
STEP 35
Remove the snap ring from the spool.
STEP 36
Release the spring tension and separate the spring
seats and spring.
STEP 37
Loosen the circuit relief valve.
STEP 38
Remove the circuit relief valve.
STEP 39
Use the tool shown on page 4to remove the load check
plug, spring and poppet.
Bur 817430
8007-17
STEP 40
Repeat steps 37,38, and 39 to remove the circuit relief
valve from the A port.
STEP 41
Removethewiperfrom theA portend of the spool bore.
STEP 42
Remove the a-ring from the bore.
NOTE: Steps 43through 46are for the swing section
only. The boom section does not have this check valve
assembly.
STEP 43
Loosen the check valve body in the swing section.
Issued 191 Printed in U.S.A.
8007-18
STEP 44
Remove the check valve body.
STEP 45
Remove the spring.
STEP 46
Remove the plunger.
Bur 8-17430
STEP 47
Loosen the plug.
STEP 48
Remove the plug.
STEP 49
Remove the spring and poppet.
STEP 50
Repeat steps 47,48, and 49 to remove the other plug,
spring, and poppet.
STEP 51
See page 46 for the disassembly and assembly of the
circuit relief valves.
Bur 8-17430
8007-19
STEP 52
See page 49 and inspect the parts of the swing section.
8007-20
Bur 8-17430
22. SPOOL
20. BODY
16. CAP
B901902J
Swing Section
/'
Bur 8-17430
Boom Section
8007-21
22. SPOOL
20. BODY
B901903J
8007-22
Assembly
STEP 53
8630614M
':"-'.";'. ;..... ,
Install the poppet and spring in the body.
STEP 54
0512M
STEP 55
Repeat steps 53 and 54 to install the other poppet,
spring, and plug.
NOTE: Steps 56through 59are for the swing section
only. The boom section does not have this check valve
assembly.
Bur 8-17430
STEP 56
Install the plunger in the body.
STEP 57
Install the spring.
STEP 58
Install a new O-ring and backup ring on the check valve
body.
STEP 59
Lubricate the O-ring and backup ring with clean oil.
Install the check valve body
STEP 60
Install a new O-ring inthe A port end of the spool bore.
STEP 61
Bur 8-17430
8007-23
STEP 62
STEP 63
check plug. Install the poppet, spring, and load check
plug. Make sure that the groove in the load check plug
is toward the spool bore.
STEP 64
Lubricate the O-rings and backup rings on the circuit
8007-24
STEP 65
to 108 Nm).
STEP 66
Repeat steps 61 through 65 to install the other load
check plug and circuit relief valve.
STEP 67
Assemble the spring seats and spring. Use the spring
STEP 68
B629344M
Install the spring and spring seats on the spool. Install
the snap ring.
Bur 8-17430
STEP 69
Release the spring tension and remove the spring com-
pressing plates.
STEP 70
Lubricate the O-ring with clean oil. Carefully install the
retainer and O-ring. Do not cut the O-ring on the spool.
STEP 71
Lubricate the spool and spool bore with clean oil. Install
the spool.
STEP 72
Install the cap.
STEP 73
Tighten the cap to 20 to 30 pound-feet (27 to 41 Nm).
Bur 8-17430
8007-25
STEP 74
Move the body in the vise so that the spool eye is up.
Lubricate the wiper with clean oil. Install the wiper with
the lip up.
STEP 75
~t2M
into the body.
8007-26
4. a-RING
23. A PORT
20. BODY
24. B PORT
4. a-RING
19. RETAINER
22. SPOOL
11. CIRCUIT RELIEF VALVE
4. a-RING
18. SPRING SEAT
6. SPRING 13. POPPET
Bur 8-17430
16. CAP
17. SNAP RING
B901904J
Swing Section
8007-27
6. SPRING
17. SNAP RING
22. SPOOL
4. a-RING
23. A PORT
6. SPRING
13. POPPET
20. BODY
24. B PORT
4. O-RING
19. RETAINER
14. PLUG
13. POPPET
B90190SJ
Boom Section
Bur 8-17430
8007-28
Di sassembly
STEP 76
STABILIZER SECTION
STEP 79
Fasten the section inthe vise with soft jaws. Loosen and
remove the cap.
STEP 77
Pull the spool, retainer, and O-ring from the body.
STEP 78
Bur 8-17430
B629342M
STEP 80
STEP 81
seats and spring.
STEP 82
Loosen the plug.
STEP 83
Remove the plug.
STEP 84
Loosen the check valve in the other end of the body.
Bur 8-17430
8007-29
STEP 85
Remove the check valve.
STEP 86
Remove the spool from the body.
STEP 87
Remove the wiper from the spool bore.
8007-30
STEP 88
Remove the O-ring from the bore.
STEP 89
Fasten the check valve inthe vise with soft jaws. Loosen
and remove the plug.
Bur 8-17430
STEP 90
Remove the spring.
STEP 91
Remove the plunger.
STEP 92
See page 49 and inspect the parts of the stabilizer
section.
Bur 8-17430
Stabilizer Section
8007-31
8007-32
Assembly
STEP 93
',B631008M
Install newO-rings (1) and backup rings (2) onthe body
of the check valve, Install a new O-ring on the plug.
STEP 94
Fasten the body of the check valve in the vise with soft
jaws. Install the plunger.
STEP 95
Install the spring.
Bur 8-17430
STEP 96,
Lubricate the O-ring on the plug. Install the plug in the
body.
STEP 97
Install a new O-ring in the A port end of the spool bore.
STEP 98
Lubricate the spool with clean oil. Install the spool inthe
body.
STEP 99
:'j!;, 'i
Lubricate the O-rings and backup rings on the check
valve. Install the check valve
STEP 100
Tighten the check valve to 65 to 80 pound-feet (88 to
108 Nrn).
STEP 101
Install new O-rings and a backup ring on the plug,
Bur 8-17430
8007-33
STEP 102
- J ,OM
Lubricate the O-rings and backup ring on the plug.
Install the plug,
STEP 103
STEP 104
9302M
8007-34
STEP 105
the snap ring.
STEP 106
pressing plates.
STEP 107
Lubricate the O-ring with clean oil. Carefully install the
retainer and O-ring. Do not cut the O-ring on the spool.
Bur 8-17430
STEP 108
the spool.
STEP 109
Install the cap.
STEP 110
Tighten the cap to 20 to 30 pound-feet (27 to 41 Nm).
STEP 111
.M
the lip up.
STEP 112
into the body.
Bur 8-17430
8007-35
1. PLUG
2. a-RING
3. SPRING
5. BODY
8861849J
Check Valve
8007-36
12. RETAINER
15. SPOOL
17. A PORT
2. O-RING
18. B PORT
3. SPRING
11. SPRING SEAT
B861850J
9. CAP
10. SNAP
RING
Stabilizer Section
Bur 8-17430
8007-37
BUCKET, DIPPER, AND EXTENDABLE DIPPER SECTIONS
Di sassembly
NOTE: The bucket and dipper sections have circuit
relief valves at the A port and B port. The extendable
dipper section has plugs in place of the circuit relief
valves. The following photographs show the dipper
section.
STEP 113
Fasten the section inthevise with soft jaws. Loosen and
remove the cap.
STEP 114
Pull the spool, retainer, and O-ring from the body
STEP 115
Bur 8-17430
STEP 116
B629342M
STEP 117
'B629344M
STEP 118
seats and spring.
8007-38
STEP 119
Loosen the circuit relief valve.
STEP 120
STEP 121
Usethe tool shown on page 4to remove the load check
plug, spring, and poppet.
STEP 122
Repeat steps 119. 120. and 121 to remove the circuit
relief valve, load check plug, spring. and poppet from
the A port.
Bur 8-17430
STEP 123
Remove the wiper from the A port end of the spool bore.
STEP 124
Remove the O-ring from the bore.
STEP 125
See page 46 for the disassembly and assembly of the
circuit relief valves.
STEP 126
See page 49 and inspect the parts of the section.
8007-39
8901906J
Bur 8-17430
Bucket and Dipper Section
8007-40
Bur 8-17430
Extendable Dipper Section
B901907J
Assembly
STEP 127
Install a new O-ring inthe A port end of the spool bore.
STEP 128
Install a new O-ring and new backup rings on the load
check plug.
STEP 129
Install the spring and poppet on the load check plug.
Bur 8-17430
8007-41
STEP 130
check plug. Install the poppet, spring, and load check
plug. Make sure that the groove inthe load check plug
is toward the spool bore.
STEP 131
Lubricate the O-rings and backup rings on the circuit
STEP 132
0802 1 \ 1
to 155Nm).
8007-42
STEP 133
Repeat steps 128 through 132 to install the other load
check plug and circuit relief valve.
STEP 134
STEP 135
the snap ring.
STEP 136
pressing plates.
Bur 8-17430
STEP 137
Lubricate the a-ring with clean oil. Carefully install the
retainer and a-ring. Do not cut the a-ring on the spool.
STEP 138
the spool.
STEP 139
Install the cap.
STEP 140
STEP 141
the lip up.
Bur 8-17430
8007-43
STEP 142
into the body.
8007-44
13. CAP
19. SPOOL
4. O-RING
20. A PORT
12. POPPET
17. BODY
21. B PORT
4. O-RING
16. RETAINER
15. SPRING SEAT
6. SPRING j.!;,
14. SNAP RING
6901908.1
15. SPRING SEAT
Bucket and Dipper Section
Bur 8-17430 Issued 1-91 Printed in U.SA.
8007-45
13. SPOOL
1. PLUG
2. a-RING
14. A PORT
15. B PORT
1. PLUG
7. CAP
B901909J
9. SPRING SEAT
Extendable Dipper Section
Bur 8-17430
8007-46
Di sassembly
STEP 143
CIRCUIT RELIEF VALVE
STEP 145
Fasten the circuit relief valve in the vise with soft jaws.
Loosen the lock nut. Loosen and remove the adjusting
screw and lock nut.
NOTE: If you disassemble more than one circuit relief
valve, keep the parts for each relief valve together. This
procedure will prevent mixing the parts during as-
sembly.
STEP 144
Move the circuit relief valve in the vise. Fasten the
poppet seat in the vise. Loosen the body from the
poppet seat.
Bur 817430
B628730M
Remove the circuit relief valve from the vise. Separate
the parts of the circuit relief valve. Some circuit relief
valves have a spring and pin and some circuit relief
valves have two springs.
3. BODY
Inspect i on
STEP 146
Inspect the parts of the circuit relief valve. All of the
repair parts are available in a kit. If any of the parts are
damaged, replace all the parts in the kit.
Bur 8-17430
8007-47
STEP 147
"""W,s.B628734M
Replace the O-rings and backup ring onthe parts of the
circuit relief valve.
8007-48
Assembly
STEP 148
B628606M
B628730M
Lubricate the O-rings on the parts of the relief valve.
Assemble the parts into the body.
STEP 149
Fasten the poppet seat in the vise with soft jaws.
Tighten the body to 96 to 144 pound-inches (11 to 16
Nm).
Bur 8-17430
STEP 150
STEP 151
the pressure setting of the circuit relief valve before the
relief valve is installed in the section.
8007-49
INSPECTION
STEP 152
Discard all O-rings. backup rings, and wipers.
STEP 153
Clean all parts in cleaning solvent.
STEP 154
B861853J
Inspect the seat inside the inlet section. If the seat is
damaged, use a 21/32 inch (17mm) diameter drill and
drill the seat to a depth of 11/32 inch (8.7 mm). A thin
shell of the seat will stay inthe inlet section. Remove this
thin shell. Remove all metal chips from the inlet section
Bur 8-17430
STEP 155
Inspect the spools and spool bores. Use a newsection
if the spool or bore is damaged.
STEP 156
Inspect the poppets. Use new parts as necessary
STEP 157
Inspect all machined surfaces.
CASE CORPORATION
Sect i on
8008
SWING SEQUENCE VALVE
Issued in November 1989
8008-2
TABLE OF CONTENTS
SPECIFICATIONS. . 2
DISASSEMBLY ................. 3
INSPECTION . . 7
EXPLODED VIEW OF SWING SEQUENCE VALVE........ . ...... 8
ASSEMBLY . . 9
CROSS SECTION VIEW OF SWING SEQUENCE VALVE . . 14
SPECIFICATIONS
Manufacturer . . J I Case
Pressure settings . ..... ..See Section 8002
Ports..... 7/8 - 14, straight thread
Special Torques
Relief valves ... .. 65 to 85 pound-feet (88 to 155 Nm)
Spool cap . ..20 to 30 pound-feet (27 to 41 Nm)
Relief valve body .. .. 8 to 12 pound-feet (11 to 16 Nm)
Weight . .. approximately 20 pounds (9 kg)
DISASSEMBL Y
8008-3
Clean the outside of the swing sequence valve
Fasten the swing sequence valve in the vise with soft
jaws.
STEP 1
B629022M
Loosen thespool cap The springs will push against the
spool cap as the spool cap is loosened.
STEP 2
Remove the spool cap.
STEP 3
Pull the spool tram the body.
Bur 8-12650
STEP 4
Loosen one of the relief valves.
STEP 5
Remove the relief valve.
STEP 6
B629130M
Fasten an identification tag to the relief valve.
8008-4
STEP 7
Loosen and remove the other relief valve.
STEP 8
B629130M
Fasten an identification tag to the relief valve.
STEP 9
Remove the wiper from the other end of the body.
Bur 8-12650
STEP 10
Remove the O-ring from the body.
STEP 11
Loosen the plug.
STEP 12
Remove the plug from the body.
STEP 13
Loosen the plug inside the bore.
STEP 14
Remove the plug.
STEP 15
Remove the plunger fromthe opposite end of the body.
Bur 8-12650
8008-5
STEP 16
Remove the spring.
STEP 17
8629142M
STEP 18
Remove the springs from the spool.
8008-6
B629101M
Loosen and remove the Allen head screw and spring
seat from the spool.
STEP 20
Fasten the relief valve inthe vise with soft jaws. Loosen
the lock nut from the adjusting screw. Remove the
adjusting screw and lock nut.
NOTE: If you disassemble more than one relief valve,
keep the parts for each relief valve together. This
procedure will prevent mixing the parts during
assembly.
Bur 8-12650
STEP 21
Loosen the vise. Fasten the poppet seat in the vise.
Loosen the body from the poppet seat.
STEP 22
B628606M
Remove the relief valve from the vise. Separate the
parts of the relief valve.
INSPECTION
1. Replace the O-ring on the plug.
B629140M
2. Inspect theparts of the relief valves. All repair parts in
the relief valves are available in a kit. If any of the parts
are damaged, replace all the parts in the kit.
Bur 8-12650
8008-7
3. Replace the O-rings and backup ring on the parts of
the relief valves.
2. a-RING
B628734M
4. Inspect the springs. If the springs are damaged,
install new springs.
5. Inspect the spool and spool bore. If the parts are
damaged or worn, use a new swing sequence valve.
6. Inspect the plunger. If the plunger is damaged or
worn, install a new plunger.
Issued 1189 Printed in U.S.A
8008-8
12. O-RING
13. PLUNGER
20. SPOOL
19. WIPER
B891691J
Swing Sequence Valve
Bur 8-12650
8008-9
ASSEMBLY
STEP 26
the pressure setting of each relief valve in a test block
before the relief valve is installed inthe swing sequence
valve.
STEP 23
B628606M
Lubricate the O-rings on the parts of the relief valve.
Assemble the parts in the body.
STEP 24
,,\~BB28602M
Fasten the poppet seat in the vise with soft jaws.
Tighten the body to 8 to 12 pound-feet (11 to 16 Nm).
STEP 25
Bur 8-12650
STEP 27
Fasten the body in the vise with soft jaws. Install the
spring and plunger in the body.
STEP 28
Lubricate the O-ring on the plug with clean hydraulic oil.
Install the plug in the bore for the relief valve.
STEP 29
Tighten the plug to 15 to 20 pound-feet (20 to 27 Nm).
8008-10
STEP 30
Lubricate the O-ring on the plug with clean hydraulic oil.
Install the plug.
STEP 31
Tighten the plug to 60 to 70 pound-feet (81 to 95 Nm).
STEP 32
Install a new O-ring in the spool bore.
Bur 8-12650
STEP 33
8629036M
Lubricate the O-rings and backup ring on one of the
relief valves with clean hydraulic oil. Install the relief
valve.
STEP 34
038M
Tighten the relief valve to 65 to 85 pound-feet (88to 155
Nm).
STEP 35
Lubricate the O-rings and backup ring on the other
relief valve with clean hydraulic oil. Install the relief
valve.
STEP 36
M
Tighten the relief valve to 65 to 85 pound-feet (88to 155
Nm).
STEP 37
Fasten the body in the vise with soft jaws as shown
above.
STEP 38
.-.....
Lubricate the spool with clean hydraulic oil. Install the
spool in the body.
Bur 8-12650
8008-11
STEP 39
M
Move the body inthe vise so that a rod can be installed
through the hole in the end of the spool. Fasten the
body inthe vise with the end of the spool incontact with
the vise.
STEP 40
Install a new O-ring on the spool.
STEP 41
Install the retainer. Make sure the shoulder on the
retainer is down.
8008-12
STEP 42
Install the three springs on the spool.
STEP 43
8629242M
Install the spring seat on the springs. Push down on the
spring seat to compress the springs. Install the Allen
head screw.
STEP 44
Install the spool cap. Do not tighten the spool cap atthis
time.
Bur 8-12650
STEP 45
Move the swing sequence valve in the vise so that the
spool is not incontact the the vise. Remove the rod from
the end of the spool.
STEP 46
~
_<6#$
.. ::.,:~-'.:/~..:~~"'~"
\;"
Tighten the spool cap. The spool cap must be
tightened to a torque of 20 to 30 pound-feet (27 to 41
Nm).
STEP 47
Install a new wiper on the spool. The lips of the wiper
must be up
STEP 48
,70128M
into the body until the top of the wiper is even with the
surface of the housing.
Bur 8-12650
4. SPRING
1. ADJ USTING
SCREW
j
2. BODY
3. SPRING
OR
PIN
5. POPPET
SEAT
13. POPPET
12. O-RING
Relief Valve
8008-13
8. O-RING
10. O-RING
11. BACKUP
RING
B861803M
_ 9. O-RING
8008-14
Bur 8-12650
15.
B891692J
1. O-RING
6. PLUG
8. SPRING
9. PLUNGER
14 SPRINGS
10. RELIEF
VALVE
Cross Section Valve -
. S quence SWing e
8009
THREE-POINT HITCH CONTROL VALVE
TABLE OF CONTENTS
Speci fi cat i ons 8009-2 Exploded View 8009-18
Speci al Tools 8009-2 Assembly 8009-19
Separat i ng t he Valve Sect i ons 8009-3 Inlet /Out let and Auxi li ary Sect i on 8009-22
Assembli ng t he Valve Sect i ons 8009-5 Disassembly 8009-22
Li ft Sect i on 8009-6 Exploded View 8009-26
Disassembly 8009-6 Assembly 8009-27
Exploded View 8009-10 Inspect i on 8009-30
Assem bly 8009-11 Reli ef Valves 8009-31
Ti lt and Pi t ch Sect i ons 8009-15
Disassembly 8009-31
Disassembly 8009-15
Inspection 8009-32
Assembly 8009-32
CASE CORPORATION
Bu r 8-67421 Printed in U.S.A.
Issued February 1968
8009-2
SPECIFICATIONS
Manufacturer Rexroth
Weight " " 20 pounds (9 kg)
Special Torques
Detent stud 17 to 21 pound-feet (23 to 28 N m, 2 to 3 kg/m)
Self-locking nuts on suds that
hold sections together 17 to 21 pound-feet (23 to 28 N rn, 2 to 3 kg/m)
Plugs and relief valves 50 to 60 pound-feet (60 to 80 N m, 7 to 8 kg/m)
Allen screws for spool caps
and retainers 60 to 80 pound-inches (7 to 9 N m, 0.7 to 0.9 kg/m)
SPECIAL TOOLS
786802
The spring compressing plates are used to
compress the centering springs for removal and
installation. The part number of the tool is CAS-
1147-2. See Section 1001 for information about
ordering the special tool.
8009-3
STEP 1
Clean the outside of the three-point control valve.
STEP 2
721802
Write numbers on each section.
STEP 3
72 1 804
Loosen the studs that fasten the valve sections
together.
STEP 4
721806
Remove the studs and self-locking nuts.
721606
Remove the lift section.
STEP 6
,2 1 81 0
Remove the pitch section.
STEP 7
Remove the tilt section.
8009-4
INLET/OUTLET /
AND AUXILIARY
SECTION
Three Point Hitch Control Valve
8871897
8009-5
STEP 8
i216'~
Replace the O-rings in each section of the control
valve.
STEP 9
721816
Remove the self-locking nuts from the studs. In-
stall the studs in the inlet/outlet and auxiliary sec-
tion.
STEP 10
721818
Install the tilt section.
STEP 11
721820
Install the pitch section.
STEP 12
721822
Install the li ft section.
STEP 13
Make sure that the control valve is on aflat surface.
Install the self-locking nuts. Tighten the self-lock-
ing nuts to 17 to 21 pound-feet (23to 28N m, 2 to 3
kg/m).
8009-6
LIFT SECTION
Di sassembly
STEP 14
721826
Fasten the lift section in the vise with soft jaws.
Loosen the Allen head screws.
STEP 15
Remove the Allen head screws and spool cap.
STEP 16
721830
There is a spring and detent balls inside the detent
sleeve. Use a punch to compress the spring and
remove the detent sleeve.
STEP 17
721832
Remove the large steel ball.
STEP 18
Remove the three small steel balls.
STEP 19
721836
Remove the spring.
STEP 20
721902
STEP 21
Pull the spool and detent housing from the body.
STEP 22
721906
Loosen the plug in the body.
8009-7
STEP 23
Remove the plug.
STEP 24
721910
Loosen the Allen head screws in the retainer.
STEP 25
i2 1 g1 2
Remove the Allen headscrews, retainer, and wiper.
8009-8
STEP 26
721914
Remove the O-ring.
STEP 27
Loosen the circuit relief valve from the body.
STEP 28
721926
STEP 29
721928
Loosen the plug for the load check valve. It can be
necessary to loosen the fitti ng to get access to the
plug.
Remove the plug.
STEP 31
72 1 934
Remove the spring.
STEP 32
Remove the poppet.
STEP 33
700840
Remove the sleeve, O-ring, and detent housing
from the spool.
STEP 34
700844
Install the spring compressing plates shown on
page 8009-2.
8009-9
STEP 35
i00802
Loosen and remove the detent stud from the spool.
STEP 36
700838
seats from the spring.
8009-1 0
Li ft Section
-SPOOL
8871898
Assembly
STEP 37
See page 8009-30. Inspect the parts of the lift sec-
tion.
STEP 38
700338
Assemble the spring seats and spring. Use the tool
shown on page 8009-2 to compress the spring.
STEP 39
7008:2
Install the spring seats and spring on the spool.
Tighten the detent stud to 17to 21 pound-feet (23
to 28 N rn, 2 to 3 kg/m).
STEP 40
700844
Remove the tool from the spool.
8009-11
STEP 41
700804
Install the detent housing on the spool. Lubricate
the a-ring with clean oil. Carefully install the 0-
ring into the detent housing.
STEP 42
700806
Install the sleeve into the detent housing.
Install the poppet in the body.
8009-12
STEP 44
Install the spring inthe poppet.
STEP 45
721930
Lubricate thea-ring withclean oil. Install the plug.
STEP 46
721928
Tighten the plug.
-,
721926
Lubricate the a-rings and backup ring onthe cir-
cuit relief valve. Install thecircuit relief valve.
STEP 48
Lubricate thea-rings andbackup ring onthe plug.
Install the plug.
STEP 49
72200.
Tighten the plug to 50 to 60 pound-feet (68 to 80
Nm,7 to 8 kg/m).
STEP 50
721904
Lubricate the spool andO-ring onthe detent hous-
ing with clean oil. Install thespool anddetent hous-
ing in the body.
STEP 51
721902
Install the retainer.
STEP 52
721836
Install the spring.
8009-13
STEP 53
7?2006
Install thethree steel balls inthe holes inthedetent
stud. Apply petroleum jelly tothesteel balls tohold
the steel balls in position.
STEP 54
721632
Install the large steel ball in the end of the detent
stud.
STEP 55
721830
Useapunch to push inthe steel ball and install the
detent sleeve. Make sure the large steel ball is
pushed past the small steel balls.
8009-14
STEP 56
721828
STEP 57
722010
Tighten the Allen head screws to 60 to 80 pound-
inches (7 to 9 Nrn,0.7 to 0.9 kg/m).
STEP 58
7220'"
Lubricate the O-ring with clean oil. Install the 0-
ring onthe spool.
STEP 59
7220'6
Install the wiper onthe spool.
STEP 60
7220' 8
Install the retainer. Tighten the Allen head screws
to 60 to 80 pound-inches (7 to 9 Nm, 0.7 to 0.9
kg/m).
8009-15
Disassembly
STEP 61
TILT AND PITCH SECTIONS
STEP 64
722022
Fasten the section inthe vise with soft jaws. Loos-
en the Allen head screws in the spool cap.
STEP 62
Remove the Allen head screws and spool cap.
STEP 63
722026
Pull the spool, O-ring, and wiper from the body.
722028
Loosen the plug from the body.
STEP 65
722030
Remove the plug.
STEP 66
722032
Loosen the Allen head screws from the retainer.
8009-16
STEP 67
722034
Remove the Allen head screws, retainer, andwiper.
STEP 68
722036
Remove the O-ring.
722037
STEP 70
722106
Loosen the plug for the load check valve.
-~
Remove the plug.
STEP 72
722"0
Remove the spring from the body.
STEP 73
72211 4
Remove the poppet.
STEP 74
700828
Remove the O-ring, wiper, and retainer from the
spool.
STEP 75
700832
Usethetool shown onpage8009-2 tocompress the
spring.
8009-17
STEP 76
70083"
Loosen and remove the Allen head screw from the
spool.
STEP 77
700638
Release the spring tension and separate thespring
seats and spring.
8009-18
6871899
Tilt and PitchSections
Assembly
See page 8009-30. Inspect the parts of the tilt
or pitch section.
STEP 78
iOO838
Assemble the spring seats and spring. Usethe tool
STEP 79
700834
Install the spring and spring seats on the spool.
STEP 80
700832
Remove the tool from the spool.
8009-19
STEP 81
700826
Lubricate the O-ring and spool with clean oil. In-
stall the retainer. Carefully install the wiper and 0-
ring. Push the retainer, wiper, and O-ring against
the spring seat.
STEP 82
72211~
Install the poppet inthe body.
STEP 83
i22"O
Install the spring.
8009-20
STEP 84
722108
Lubricate theO-ring with clean oil. Install theplug.
STEP 85
Tighten the plug.
STEP 86
722037
Lubricatethe O-rings and backup ring ontheplug.
Install the plug inthe body. Tighten the plug to50
to 60 pound-feet (68to 80 Nm,7to 8 kg/m).
722030
Lubricate the O-rings andbackup ring onthe plug.
Install the plug inthe body. Tighten the plug to 50
to 60 pound-feet (68 to 80 Nrn,7 to 8 kg/m).
STEP 88
722116
Lubricate the spool and O-ring with clean oil. In-
stall the spool inthe body.
STEP 89
722118
STEP 90
722120
Tighten the Allen headscrews to 60to 80 pound-
inches (7 to9 Nm,0.7to 0.9 kg/m).
STEP 91
ring on the spool.
Install the wiper onthe spool.
8009-22
INLET/OUTLET AND AUXiliARY SECTION
Disassembly
STEP 95
722130
Fastenthe section inthe vise with soft jaws. Loos-
entheAllen head screws in the spool cap.
STEP 96
722134
Removethe Allen head screws and spool cap.
STEP 97
722136
Pull the spool, O-ring, and wiper from the body.
722302
Loosen the plug from the body.
STEP 99
~.~
1~~,-
'...,
722306
Remove the plug.
STEP 100
72230e
Loosen the relief valve.
STEP 101
722310
Remove the relief valve.
722312
Loosen the Allen head screw from the retainer.
STEP 103
722314
Remove the Allen headscrews, retainer, and wiper.
8009-23
STEP 104
i22316
Remove the O-ring.
722318
Loosen the plug.
STEP 106
722322
Remove the plug.
8009-24
STEP 107
72232'
Loosen the plug for the load check valve.
STEP 108
722326
Remove the plug.
STEP 109
722328
Removethe spring from the body.
STEP 110
722330
Remove the poppet.
'STEP 111
700825
Remove the O-ring, wiper, and retainer from the
spool.
700832
Usethe tool shown on page 8009-2 tocompress the
spring.
STEP 113
700834
Loosen and remove the Allen head screw from the
spool.
STEP 114
8009-25
700838
seats and spring.
8009-26
-SPOOL
Inlet/Outlet and Auxiliary Sections
8871900
Assembly
SeepageBOOS-3D. Inspect theparts of the inlet!
outlet and auxiliary section.
STEP 115
;00838
Assemble thespring seats and spring. Use the tool
STEP 116
70083'
Install the spring andspring seats on the spool.
STEP 117
700832
Remove thetool fromthe spool.
8009-27
STEP 118
700828
Lubricate the a-ring and spool with clean oil. In-
stall the retainer. Carefully install thewiper and 0-
ring. Push the retainer, wiper, and a-ring against
the spring seat.
Install the poppet inthe body.
STEP 120
722328
Install the spring.
8009-28
STEP 121
722326
Lubricate the a-ring with clean oil. Install the plug.
STEP 122
Tighten the plug.
722320
Lubricate the a-rings and backup ring onthe plug.
to 60 pound-feet (68 to 80 Nm,7 to 8 kg/m).
STEP 124
722310
Lubricate thea-rings andbackup ring onthe relief
valve. Install the relief valveinthe body. Tighten the
retiet valvetoso toso pound-feet (68t080 Nm,7to
8 kg/m).
STEP 125
722304
Lubricate thea-rings andbackup ring onthe plug.
to 60 pound-feet (68to 80 Nrn,7 to 8 kg/m).
STEP 126
722136
Lubricate the spool and O-ring with clean oil. In-
stall the spool inthe body.
STEP 127
72213~
STEP 128
722132
Tighten the Allen head screws to 60 to 80 pound-
inches (7 to 9 Nm,0.7 to 0.9 kg/m).
STEP 129
722332
ring on the spool.
8009-29
STEP 130
Install the wiper on the spool.
STEP 131
tnstau the retainer and Allen head screws. Tighten
the Allen head screws to 60 to 80 pound-inches (7
to 9 Nm,0.7 to 0.9 kg/m).
8009-30
INSPECTION
Discard all O-rings, backup rings, and wipers.
Clean all parts in cleaning solvent. Inspect the
spools and spool bores for wear anddamage. Usea
new valve section if the spools or spool bores are
damaged.
STEP 132
700842
Install anewO-ring inthe detent housing for the lift
spool.
STEP 133
O-RINGS
700824
Install new O-rings and backup ring on the plugs.
STEP 134
700826
Install anewO-ring onthe plug for the load check
valves.
8009-31
RELIEF VALVES
Disassembly
STEP 135
700506
Fasten the relief valve in the vise with soft jaws.
Remove the cover.
STEP 136
700510
Loosen the lock nut.
STEP 137
i00512
Remove the adjusting screw and lock nut. Make a
count of the number of turns needed to remove the
adjusting screw. Record this count.
STEP 138
;01518
Loosen the body from the housing.
STEP 139
701520
Remove the body.
STEP 140
701616
Separate the parts of the relief valve.
8009-32
Inspection
Remove and discard the O-rings and backup
rings. Inspect the seal on the bottom of the adjust-
ing nut. Replace the adjusting nut if the seat is
damaged.
STEP 141
BODY
PLUNGER
701616
Inspect the parts ofthe relief valve. The spri ngs, 0-
rings, and backup rings areavailable for service. If
anyof the other parts are damaged, usea newrelief
valve.
STEP 142
O-RINGS
701610
Install new O-rings and backup ring on the hous-
ing.
STEP 143
O-RINGS
i01614
Install new O-rings and backup ring on the body.
Assembly
STEP 144
701520
Install the piston, plunger, spring, and body in the
housing.
STEP 145
701518
Tighten the body.
STEP 146
700512
Install the poppet, spring, adjusting screw, and
lock nut in the body.
STEP 147
700510
Turn the adjusting screw into the body the same
number of turns needed to remove the adjusting
screw.
8009-33
STEP 148
700506
Tighten the lock nut and install the cover.
After the three point hitch control valve is as-
sembled and installed, seeSection 8002andcheck
the pressure setti ng of the relief valves.
CASE CORPORATION
Section
8011
DOUBLE SELECTOR VALVE
8011-2
TABLE OF CONTENTS
SPECiFiCATIONS 2
DOUBLE SELECTOR VALVE 3
Disassembly 3
Inspection , , 4
Assembly 6
SPECIFICATIONS
Special torques
Retainer. 108 to 132 pound-inches (12 to 15 Nm)
Allen head screws 108 to 132 pound-inches (12 to 15 Nm)
Bur 8-12670 Issued 11-89 Printedin U.SA
Disassembly
STEP 1
DOUBLE SELECTOR VALVE
8011-3
B8971702M
Fasten the body of the double selector valve in avise.
Loosen and remove the Allen Head screws that fasten
the cap to the body.
STEP 2
Remove the cap from the body.
STEP 3
,__ B897171OM
Hold the spool in place and loosen the retainer.
Bur 8-12670
STEP 4
Remove the retainer and sleeve assembly from the
spool.
STEP 5
Remove the plate from the body.
STEP 6
Remove the double selector valve from the vise.
Remove the spool from the body.
8011-4
STEP 7
Remove anddiscard the seal fromeach end of the bore
of the body.
STEP 8
Push the retainer, balls, and spring from the sleeve.
Bur 8-12670
Inspection
STEP 9
B8971728M
Inspect the spool for damage or wear. If the spool is
damaged orworn anewdouble selector valve must be
used.
STEP 10
Inspect thespool bore inthe body for damage or wear.
If the spool bore is damaged or worn a new double
selector valve must be used.
STEP 11
Inspect the sleeve, balls, spring, and retainer for
damage or wear. Use new parts as required.
STEP 12
Inspect the cap, plate, and knob for damage or wear.
Use new parts as required
2. CAP
7. SPOOL
10. BODY
Double Selector Valve - Exploded View
Bur 8-12670
8011-5
Issued 1189 Printedin U.S.A.
8011-6
Assembly
STEP 13
B8971734M
Putthespring andballs intheretainer as shown inthe il-
lustration on page 5. Push the retainer assembly into
the sleeve.
STEP 14
Install newseals inthe bore of the body. Lubricate the
seals with clean hydraulic oil.
STEP 15
Lubricate the spool with clean hydraulic oil. Install the
spool inthe body.
Bur 8-12670
STEP 16
STEP 17
Apply 271 Loctite to the threads in the spool.
STEP 18
B8971720M
._----""'.{.~."-.~ ..,.~~
Keep the spool from turning and install and tighten the
retainer assembly to 108to 132 pound-inches (12 to 15
Nm).
STEP 19
Install the cap
Bur 8-12670
8011-7
STEP 20
88971704
Install and tighten the Allen head screws to 108 to 132
pound-inches (12 to 15 Nm)
8011-8
3. SLEEVE
7. SPOOL
10. BODY
11. KNOB
8891755
Double Selector Valve - Cross Section
Bur 8-12670
SECTION INDEX - MOUNTED EQUIPMENT
Section Title
Section Number
Pedals and Levers 9001
Air Conditioning Troubleshooting and Pressure Checks . .9002
Air Conditioning System _ _ . ....9003
Loader . _.9004
ROPS Cab and ROPS Canopy . .9005
Backhoe - Integral .9006
Backhoe - Demountable. ...9007
Three Point Hitch..... 9008
Seat and Seat Belts ..................................... . ..9009
Suspension Seat ... . _ 9010
CASE CORPORATION
Bur 8-12680
Printed in U.S.A.
Section
9001
PEDALS AND LEVERS
CASE CORPORATION
Issued March 1991
9001-2
TABLE OF CONTENTS
SPECiFiCATIONS , ' , , 3
SPECIAL TOOLS 4
ADJ USTMENT FOR RETURN-TO-DIG , " , , ,5
ADJ USTMENT OF ANTI ROLLBACK .. 6
THROTILE LINKAGE ADJ USTMENT... . 8
THROTILE LEVER ADJ USTMENT , 8
BRAKE PEDAL ADJ USTMENT.. _ 10
Checking Brake Pedal Height , ' , , ' 10
Brake Pedal Height Adjustment , 10
Free Travel Adjustment., , , , 10
Brake Switch Adjustment ,..10
PARKING BRAKE ADJ USTMENT , , , 12
SHUTILE CONTROL LINKAGE ADJ USTMENT 14
SHIFT LINKAGE ADJ USTMENT FOR TRANSAXLE 15
DIFFERENT\AllOCK PEDAL ADJ USTMENT , 16
SHIFT LINKAGE FOR TRANSFER CASE 17
LOADER LIFT CONTROL INSTALLATION 18
LOADER BUCKET CONTROL INSTALLATION 19
CLAM CONTROL INSTALLATION 20
ADJ USTMENT OF THE BACKHOE CONTROL LEVERS 21
ADJ USTMENT OF THE SWING SEQUENCE VALVE L1NKAGE.. 24
BOOM LATCH INSTALLATION .., ' , 25
THREE POINT HITCH CONTROL LEVER INSTALLATION (IF EQUIPPED) 26
ADJ USTMENT OF THE HOOD SEE SECTION 2001
9001-3
SPECIFICATIONS
Clearance between the switch and the inner bucket
link for return-to-dig..................................... . 0012 to 0.027 (0.3 to 0.7 mm)
Center to center length of the yoke and rollback rod
for antirollback adjustment... . . 14 inches (355 mm)
Number of teeth on the flywheel. . . 159
Engine speeds
Low idle ,.. . ...............................................850 to 900 rpm (r/min)
High idle (no load) . . 2330 to 2380 rpm (r/min)
Low idle and high idle override. .. 1/16 to 1/8 inch (1.5 to 3.0 mm)
Brake pedal height . .. 7-1/4 to 7-1/2 inches (185 to 190 mm)
Brake pedal free travel . .. " 0.06 to 0.18 inch (1.5 to 4.6 mm)
Angle of backhoe control levers .71 to 73 degrees
Maximum clearance of cam follower for the swing sequence valve 0.02 inch (0.5 mm)
Alignment of cam follower on cam for the swing sequence valve must be centered within 0.08 inch (2 mm)
Special torques
Nut that fastens clamp for shuttle control linkage 156 to 180 pound-inches (18 to 20 Nm)
Screw that fastens boot for the shift control lever 12 to 24 pound-inches (1.4 to 2.7 Nm)
Cap screw that fastens the bumper to the swing tower 274 to 318 pound-inches (31 to 36 Nm)
9001-4
SPECIAL TOOLS
dresses:
Inthe U.S.A. and Canada
Service Tools
P.O. Box 314
In Europe
VL Churchill Ltd.
Northants, NN11 4NF
England
CAS-10ll8
Bur 817540
The special tool shown is usedto check the engine
rpm (r/rnin).
The tool must be programmed for the number of
teeth on the flywheel. The580 Super K loader backhoe
has 159 teeth on the flywheel.
Install the magnetic sensor intothethreaded hole in
the flywheel housing. Turn the magnetic sensor clock-
wise until thesensor contacts theflywheel,thenturnthe
sensor counterclockwise 1/2 to3/4 of aturn andtighten
the lock nut. This tool is first used on page 8.
ADJUSTMENT FOR RETURN-TO-DIG
9001-5
1. Parkthe machine on a level surface and apply the
parking brake.
2. Lower the loader frame and put the bucket flat on
the floor or in the correct digging position.
3. Stop the engine.
4. Clean the switch so the LED at the wire end of the
switch can be seen,
5, Move the inner RH bucket link all the way to the
right.
6. There must be 0.012 to 0027 inches (0.3 to 0.7
mm) clearance between the switch and the inner
bucket link.
7 Turn the key switch to the ON position.
8. Loosen thenuts for theswitch, andmove the switch
all the way forward in the mounting slot.
Bur 8-17540
9. Slowly move the switch rearward until the LED illu-
minates.
10. Hold the switch inposition and tighten the nuts for
the switch.
11. Startthe engine. Raisethe loader frame all theway
and dump the bucket completely.
12. Increase the engine speed to full throttle.
13. Putthe loader control lever inthe RETURN-TO-DIG po-
sition. The loader frame will lower to the floor and the
bucket will roll back,
14. Check the position of the bucket on the floor,
15. Ifthe bucket is not inthe correct position, do steps
16 through 19.
16. Loosen the nuts for the switch.
17. Move the switch rearward if the bucket did not roll
back far enough.
18. Move the switch forward if the bucket rolled back
too far,
19. Repeat steps 11through 18until the bucket returns
to the correct position.
Issued3-91 Printed in U.S,A.
9001-6
ADJUSTMENT OF ANTI ROLLBACK
1. Check toseethat the yoke (1) androllback rod (2)are
adjusted to a length of 14 inches (355 mm) from the
center of the hole inthe endof the rollback rod(2) tothe
center of the clevis pin in the yoke (1).
2. Raise the loader frame until the pivot pin for the
bucket is 45 inches (1143 mm) from the floor.
3. Roll the bucket all the way back.
4. Check to seethat the rollback rod(2) andtherollback
pivot block (3) areengaged completely without anyfree
travel inthe pivot joints. Adjust the length of theyoke (1)
and the rollback rod (2) as required.
Bur B-17540
5. Raise the loader frame all the way.
6. Look at the side cutting edge of the bucket.
7. The side cutting edge must be approximately level.
8. Ifthe side cutting edge is not inthespecified position,
increase the length between the yoke (1) and the
rollback rod (2) to increase the amount of rollback.
Shorten the length between the yoke (1) and the
rollback rod (2) to decrease the amount of rollback.
Issued 3-91 Printed inU.S.A.
2. ROLLBACK ROD
Bur 8-17540
9001-7
B902737J
Issued 3-91
Printed in U.S.A.
9001-8
THROTTLE LINKAGE ADJUSTMENT
1. Disconnect the throttle rod (1) fromthe lever (2) on
the fuel injection pump.
2. Use a photo tachometer or other tachometer of
equal accuracy and check the engine speeds If the
engine speeds arenot equal tothe specifications inthis
section, adjust the engine speeds as required. See
Special Tools inthis section.
NOTE: Adjustment of high idle must be done by an
authorized Case service person.
3. Connect the throttle rod (1) to the lever (2) on the
fuel injection pump.
4, Make surethat the throttle lever (3) is inthe lowidle
position.
5. Check the position of the lever (2) on the fuel injec-
tion pump. Adjust the clevis (4) at the cross shaft (5)
until there is1/16to 1/8 inch (1.5to 3.0 mm) of override
as shown.
6. Have another person push the accelerator pedal
(6) down until the accelerator pedal (6) is against the
stop bolt (7).
7. Check the position of the lever (2) onthe fuel injec-
tion pump. Adjust the stop bolt (7) sothere is 1/16to 1/8
inch (1.5 to 3.0 mm) of override as shown.
8. Release the accelerator pedal (6).
9. Move the throttle lever (3) to thefull throttle position.
The accelerator pedal (6) must be against the stop bolt
(7) before the throttle lever (3) reaches the end of the
slot inthe mounting bracket (8). Adjust the cable (9) at
the throttle lever (3) as required.
10. Check to see that the high and low idle engine
speeds are as specified in this section.
THROTTLE LEVER ADJUSTMENT
Move the throttle lever (3) to the high idle position
and then to the low idle position. The throttle lever (3)
must move smoothly and hold the setting for thethrottle
lever (3) when the throttle lever (3) is released. If the
throttle lever (3) does not move smoothly or hold the
Bur 8-17540
setting after the throttle lever (3) has been released, the
throttle lever (3) must be adjusted. Loosen or tighten
the nut (10) as necessary until the throttle lever (3)
works correctly.
Issued 3-91 Printed inU.S.A.
9001-9
A
A
3. THROTTLE
LEVER
B902738J
Bur 8-17540
9001-10
BRAKE PEDAL ADJ USTMENT
Checking Brake Pedal Height
1. Remove the rubber pads (1 and 2) fromthe brake
pedals (3 and 4).
2. Disengage the brake pedal lock (5) if the brake
pedal lock (5) is engaged.
3. If equipped with a floormat, remove the floormat
from the floor plate.
4. Measure the distance fromthefloor platetothe rear
edge of each brake pedal (3 and 4) as shown. The
brake pedals (3 and 4) must be 7-1/4 to 7-1/2 inches
(185 to 190 mm) above the floor plate with the brake
pedals (3 and 4) in the released position.
Brake Pedal Height Adjustment
1. Loosen the lock nuts (6) on the stop bolt (7).
2. Turn the stop bolt (7) clockwise or counterclock-
wise as required until the rearedge of each brake pedal
(3 or 4) is 7-1/4 to 7-1/2 inches (185to 190 mm) above
the floor plate.
3. Tighten the lock nuts (6) on the stop bolt (7).
4. Repeat steps 1through 3for the other brake pedal
(3 or 4).
Bur 8-17540
Free Travel Adjustment
NOTE: Free travel is the distance which the brake
pedal can move before the push rod makes contact with
the outer piston in the master cylinders.
1. Measure the free travel at the rear edge of each
brake pedal (3and4) as shown. The freetravel must be
0.06 to 0.18 inch (1.5 to 4.6 rnrn).
2. To increase or decrease the free travel, loosen the
lock nut (8) at each clevis (9) and turn the push rod as
necessary to get thecorrect free travel. Tighten the lock
nut (8).
Brake Switch Adjustment
1. Loosen the lock nut (10) for the cap screw (11) that
actuates the brake switch (12). Adjust the cap screw
(11) so the brake switch (12) is not damaged with the
brake pedal (3 and 4) inthe released position. Tighten
the lock nut (10).
2. Thebrake switch (12) must actuate when the brake
pedal (3 or 4) is applied.
9001-12
PARKING BRAKE ADJUSTMENT
The parking brake must prevent the machine from
moving forward with the transmission inthird gear and
the engine running at 1500 rpm (r/rnin).
Toadjust the parking brake, do the following steps.
1. Release the parking brake.
2. Turnthe knob onthe parking brake lever clockwise
several turns to increase the tension. Turn the knob
counterclockwise several turns to decrease the
tension.
Bur 817540
3. Check the adjustment by trying to move the
machine with the parking brake applied.
4. Repeat steps 1,2, and 3 until the parking brake is
adjusted correctly.
NOTE: If you can not get the correct adjustment by
turning the knob, adjust the parking brake cable at the
transaxle. See page 13.
5. If the parking brake will not prevent the machine
from moving, the problem can be in the cable or the
parking brake mechanism. Repair the cable or the
parking brake mechanism as required.
NOTE: If your parking brake is equipped with a
parking brake switch, the parking brake switch cannot
be adjusted.
9001-13
1. BOOT. USED ON
TWO WHEEL DRIVE
MACHINES
NOTE: To adjust the parking brake cable, loosen
the lock nut and turn the end of the parking brake
cable as necessary to loosen or tighten the parking
brake cable.
B902739J
Parking Brake Cable Installation
Bur 8-17540 Issued3-91 Printedin U.S.A
9001-14
SHUTILE CONTROL LINKAGE ADJUSTMENT
1. Removethecotter pin(6)and pin(5) that fasten the
control rod (3) to the control spool on the transaxle.
2. Makesurethat thepinintheshuttle control lever (1)
is in the NEUTRAL position between the tabs on the
detent plate (2).
3. Adjust the length of the control rod (3) at the yoke
(4) as required until the control rod (3) can be con-
nected to the control spool on the transaxle with the
control lever inthe NEUTRAL position.
4. Put the control rod (3) in position on the control
spool. Install the pin (5) and cotter pin (6) that fasten the
control rod (3) to the control spool on the transaxle.
NOTE: SHUTTLE CONTROL LEVERAD-
JUSTMENT: Put the Shuttle Control Lever
(1) in the NEUTRAL position between the
tabs on the Detent Plate (2). Lock in place
with the Locking Co/lars (7) on the Control
Link (8).
Bur 817540
3. CONTROL ROD
B902740J
9001-15
SHIFT LINKAGE ADJUSTMENT FOR TRANSAXLE
NOTE: With the shift plates (1) and the transmission
in neutral detent, adjust the yokes (2) on the shift
rods (3) so the yokes (2) can be installed on the
levers (4) at the transmission without moving the
levers (4).
5. SHIFT LEVER
3. FIRST AND SECOND
GEAR SHIFT ROD
3. THIRD AND FOURTH
GEAR SHIFT ROD
6902741J
Bur 8-17540
9001-16
DIFFERENTIAL LOCK PEDAL ADJUSTMENT
1. Make sure that the stop onthe pedal (1) is against
the bottom of the floor plate.
2. Adjust the ball joint (2)onthe control rod (3) until all
free travel is removed fromthe pedal (i), then tighten
the ball joint (2) one additional turn.
3. CONTROL ROD
2. BALL J OINT .
Bur 8-17540
B902764J
9001-17
'<;
Bur 8-17540
Shift Linkage for Transfer Case
8902743J
9001-18
B902744J
Loader Lift Control Installation
9001-19
\
\
\
,
,
,
Loader Bucket Control Installation
9001-20
I
I
I
B902746J
Clam Control Installation
9001-21
ADJUSTMENT OF THE BACKHOE CONTROL LEVERS
1. All control levers (1) must be in alignment and
centered inthe slots inthe control tower (2).
2. All control levers (1) must be within 71 to 73
degrees fromthe floor plate as seen fromthe right side
of the backhoe. See the illustration below.
1. CONTROL LEVERS
2. CONTROL TOWER
71 TO 73 DEGREES
@
@
FLOOR PLATE RIGHT SIDE SHOWN B891234J
9001-22
1. EXTENDAHOE
(IF USED)
3. BOOM 4. DIPPER
5. BUCKET
6. RH STABILIZER
8. LH SWING
B902747J
Backhoe Controls with Foot Swing
9001-23
4. BOOM AND SWING
6. SWING
5 BOOM
11. EXTENDAHOE CONTROL
PIVOT (MOUNTED ON RH
SIDE OF BACKHOE
CONTROL TOWER)
I
3. DIPPER
NOTE: These parts
rotated 180 degrees.
10. EXTENDAHOE CONTROL
PEDAL (IF EQl!J IPPED)
B902748J
Backhoe Controls with Hand Swing
Bur 8-17540
9001-24
ADJISTMENT OF THE SWING SEQUENCE VALVE LINKAGE
Bur 8-17540
4. CAM
FOLLOWER
5. CAM
8902375J
NOTE: In the following instructions, "right" and "left"
are as seen from the backhoe operators seat.
1. Swing the swing tower completely to the right.
2. Loosen the jam nuts at the yoke and at the ball joint
on the control rod.
3. Turn the control rod clockwise or counterclockwise
until the cam follower will turn freely. The cam follower
must still touch the camor be within 0.02 inch (0.5mm)
from the cam.
4. After step 3 has been completed, turn the control rod
clockwise (looking atthe control rodfromtherear of the
tractor) 1/4 to 1/2 turn to shorten the control rod.
5. Make sure that the clevis pin that fastens theyoke on
the control rod to the spool eye inthe swing sequence
valve is in the vertical position. If the clevis pin is not
vertical after the jam nuts are tightened on the control
rod, the control rod or the spool can be damaged.
6. Tighten the jam nuts at the yoke and at the ball joint
on the control rod.
7. Start and runthe engine at approximately 1/4 throttle.
8. Swing the backhoe completely to the left and then to
the right. The amount of cushion should be equal on
both sides. If necessary, shorten the control rod to
increase left cushion or lengthen the control rod to
increase right cushion. The only adjustment available is
todivide the amount of cushion equally between sides.
Bur 8-17540
9001-25
B902765J
Boom Latch Installation
9001-26
B902411J
Three Point Hitch Control Lever Installation (If Equipped)
Bur 8-17540
9002
AIR CONDITIONING TROUBLESHOOTING
AND PRESSURE CHECKS
TABLE OF CONTENTS
Safety Rules 9002-2 Troubleshooting 9002-5
Special Tools 9002-2 System Checks 9002-7
Illustration 9002-3 Pressure Testing 9002-13
Operation 9002-4
CASE CORPORATION
Bur 8-12700
Printed in U.S.A.
9002-2
SAFETY RULES
SPECIAL TOOLS
Order special tools from one of the following
addresses:
Inthe U.S.A. and Canada
Service Tools
P.O. Box 314
In Europe
VL Churchill Ltd
Northants, NN114 NF
England
The tool shown below is used to check for leaks in
the air conditioning system. The part number is CAS-
10028. This tool is first used on page 9002-12.
131238
The tools shown below are used to service the air
conditioning system. Thetools are available separately
or in a kit. The part number of the kit is CAS-10023.
Parts from this kit are first used on page 9002-10.
9002-3
3
2
- - - - - - - - - - ~ - - - - - - -
f
4
5
861485
:::::::::::::: Low Pressure Gas
~,','>:High Pressure Gas
- - Low Pressure Liquid
- High Pressure Liquid
1. Typical Expansion Valve
2. Temperature Sensor
3. Evaporator
4. Compressor
5. Condenser
6. Receiver-Drier
9002-4
OPERATION
The air conditioning system includes five major
components: condenser, evaporator, compressor,
expansion valve, and receiver-drier. These compo-
nents are connected by tubes and hoses to operate
as a closed system. The air conditioning system is
charged with R12 refrigerant.
The compressor receives the refrigerant in gas
form. Thecompressor then compresses therefriger-
ant and sends the refrigerant, still ingas form, to the
condenser. The condenser uses air flow from the
radiator fan to remove heatfrom the refrigerant. As
heat is removed, the refrigerant changes into a liq-
uid.
The liquid refrigerant flows from the condenser
to the receiver-drier. The receiver-drier is a con-
tainer filled with a drying material which removes
moisture that has entered the air conditioning sys-
tem. Moisture must be removed in order to prevent
corrosion of internal components of the air condi-
tioning system. The receiver-drier is also arefriger-
ant reservoir for the air conditioning system.
The refrigerant, still inaliquid from, flows to the
expansion valve. The expansion valve causes a re-
striction in the flow of refrigerant to the evaporator.
Because of this restriction, the refrigerant flowing
out of the expansion valve is under less pressure
than the refrigerant flowing in. As refrigerant flows
through the evaporator, the refrigerant takes -heat
from the air around the evaporator. Thecombination
of increased heat and decreased pressure causes
evaporation of the refrigerant. The evaporation
causes the air flowing over the evaporation coil to
become very cool. The cooled air is then used to
keep the operators cab cool.
The refrigerant, in a gas form again, flows back
to the compressor, and the cycle is repeated.
9002-5
TROUBLESHOOTING
Problem
No Cooling
COMPRESSOR DOES NOT RUN
MECHANICAL
See mechanical Compressor Check, page 9002-
7.
ELECTRICAL
See Blower and Compressor Clutch Check, page
9002-8.
REFRIGERATION
See Visual and Leak Check, page 9002-11.
INTERNAL SYSTEM PRCJ BLEM
See Pressure Testing page, 9002-13.
ICOMPRES~OR RUNS I
9002-6
9002-7
SYSTEM CHECKS
9002-9
Blower and Compressor Clutch Check (Continued)
9002-10
Cab Temperature Check
Air Louvers
1. Make sure ports are fully open for most effi-
cient air conditioning operation.
2. Check blower; blower must be operating.
Air Conditioning
1. Feel the air conditioning hoses. The high
pressure hose (small line) must be warmer
than the low pressure hose (large line).
2. If no temperature difference, the system is
low on refrigerant, there is a restriction in
system, or compressor is not operating cor-
rectly.
Duct Temperature
1. Put a thermometer in the air duct and run
compressor for five minutes to maketemper-
ature stable.
2. Duct temperature must be below 50F(10C)
if systemis operating at maximum efficiency.
NOTE: Ambient temperature must be 70 -
90F (21 - 32C).
3. If temperature is above 50F (10C), system
is low on refrigerant, there is restriction in
system, or compressor has malfunction.
9002-12
9002-13
PRESSURE TESTING
Manifold Gauge Set
The manifold gauge set is the most important
tool used to service the air conditioning system. The
manifold gauge set is used to learn the high and low
pressures of the system, the correct refrigerant
charge, system diagnosis, and operating efficiency.
The manifold gauge set can read both the high (dis-
charge) and low (suction) sides at the same time,
since pressures must be compared in order to make
a diagnosis of system operation.
LOW PRESSURE GAUGE - The low pressure
gauge is a compound gauge. All air conditioning
systems can, under some conditions, change from a
pressure into a vacuum on the low side. For this
reason, it is necessary that agauge be used that will
Pressure - Temperature Chart
indicate both psi (kPa) pressure and inches of mer-
cury.
During normal operation the low pressure
gauge must always indicate from 7 to 30 psi (48 to
207 kPa) after the system has run 10 to 15minutes.
HIGH PRESSURE GAUGE - The high side
gauge is a pressure gauge used to indicate pres-
sures inthe high side of the system. The gauge must
indicate from 0 - 400 psi (0 - 2758 kPa) minimum.
During normal operation, the high pressure
gauge will normally indicate from 120 to 270 psi (827
to 1861 kPa), including correction for ambient air
temperatures, see pressure - temperature chart.
Pressure- Temperature Chart
I
Normal High Pressure Reading Ambient Temperature
150 - 170 psi 80 F (26.7 C)
(1034 - 1172 kPa)
175-185 psi
I
90 F (32.2C)
(1206 -1275 kPa)
195 - 205 psi 95 F (35C)
(1344 - 1413 kPa)
210 - 230 psi 100 F (37.8C)
(1447 - 1585 kPa)
230 - 250 psi 105 F (40.7C)
(1585 - 1723 kPa)
250 - 270 psi 110F (43C)
(1723 - 1861 kPa)
NOTE: Ambient temperature is the tempera-
ture of the air around the machine. Connect the
manifold gauge set according to the instructions in
Section 9003, page 9003-7 to do the following pres-
sure tests.
9002-14
Problem - No Cooling
1. LOW PRESSURE GAUGE READING IN A VACUUM
2. HIGH PRESSURE GAUGE READING BELOW PRESSURE-
TEMPERATURE CHART
Indications of Low Refrigerant Charge
a. Sight glass clear - no bubbles
1. Test system for leaks. see page 9002-12. It
can be necessary to add some refrigerant
charge, see Section 9003.
b. Discharge air from evaporator warm.
2. Discharge system of refrigerant, see Section
9003.
3. Repair system leaks as necessary. See Air
and Moisture Removal in Section 9003.
4. Check compressor oil level, see Section
9003.
5. Remove air and moisture from the system,
see Section 9003.
6. Charge systemwith newrefrigerant, see Sec-
tion 9003.
9002-15
Problem - No Cooling
1. LOW PRESSURE GAUGE READING ABOVE 30 PSI (207 kPaj
2. HIGH PRESSURE GAUGE READING ABOVE PRESSURE-
TEMPERATURE CHART
Indications of Air in System
a. Bubbles in sight glass. 1. Discharge refrigerant from system, SeeSec-
tion 9003.
b. Discharge air fromevaporator warm.
2. Replace receiver-drier if drying material is
full of moisture and removal procedure can-
not remove moisture from receiver-drier.
seeSection 9003.
4. Charge systemwith newrefrigerant, seeSec-
tion 9003.
Indications of a Problem
in Condenser Operation
a. Bubbles insight glass at intervals.
1. Inspect for loose or worn compressor belt
and fan belts.
b. Line between condenser and evaporator
inlet very hot.
c. Discharge air fromevaporator warm.
2. Inspect condenser and radiator for restric-
tions in air passages.
(Continued on next page)
9002-16
Indications of a Problem in Condenser Operation (Continued)
in Expansion Valve Operation
a. Discharge air from evaporator warm.
b. Much condensation on suction hose at
compressor.
c. Much condensation on evaporator out-
let.
-
3. Check system for too much refrigerant.
a. Discharge refrigerant until bubbles can
be seen in sight glass and gauge pres-
sure is below normal.
b. Add refrigerant until bubbles cannot be
seen in sight glass and gauges indicate
normal pressures, seeSection 9003.
4. Remove and inspect condenser for restric-
tion caused by oil.
a. Use compressed air to remove oil from
condenser.
b. Replace receiver-drier.
c. Remove air andmoisture andcharge sys-
tem, see Section 9003.
1. Remove cab trim panels and headliners, see
Section 9003. Inspect temperature sensing
contact to evaporator outlet for looseness or
corrosion.
2. Clean contact surface between temperature
sensing bulb and evaporator outlet, see Sec-
tion 9003.
3. Fasten temperature sensing bulb to evapora-
tor outlet and tighten.
4. Fill the area between temperature sensing
bulb and evaporator outlet with lithium base
grease to make a better conductor.
9002-17
Indications of a Problem in
Expansion Valve Operation (Continued)
5. Install the insulation putty inthe original po-
sition.
6. Discharge the system and remove expansion
valve, see Section 9003.
7. Test expansion valve and replace or adjust as
necessary, see Section 9003.
8. Replace expansion valve, remove air and
moisture, and charge system, see Section
9003.
9002-18
Problem - Not Enough Cooling
1. LOW PRESSURE GAUGE READING NORMAL.
7 TO 30 PSI (48 TO 207 kPa)
2. HIGH PRESSURE GAUGE READING NORMAL.
ACCORDING TO PRESSURE-TEMPERATURE CHART
I
Indications of Air In System
a. Sight glass free of bubbles or bubbles
can be seen only at intervals.
-
1. Test system for leaks, see page 9002-12.
Possible leak has let air enter; check com-
pressor seal carefully, see Section 9003.
b. Suction line warmto your hand.
c. Evaporator discharge air only a little
cool.
2. Discharge systemof refrigerant. SeeSection
9003.
3. Repair system leaks as necessary, see Dis-
charging the System in Section 9003.
4. Replace receiver-drier if drying material is
full of moisture and removal procedure can-
not remove moisture from receiver-drier.
5. Check compressor oil level, see Section
9003.
9002-19
Indications of Air in System (Continued)
see Section 9003.
tion 9003.
1. LOW PRESSURE GAUGE READING BELOW 7 PSI (48 kPaj
TEMPERATURE CHART
Indications of Low Refrigerant Charge 1. Test system for leaks. System has a loss of
refrigerant.
a. Bubbles in sight glass.
b. Discharge air from evaporator only alit-
tle cool.
NOTE: Normally. the system will have a
loss of 1/2 to 1 ounce (14.7 - 29.5 ml) of
refrigerant between seasons.
a. If leak is found, do Step 2.
b. If no leak is found, do Step 6.
2. Discharge systemof refrigerant. See Section
9003.
9002-20
Indications of Low Refrigerant Charge (Continued)
Indications of High Pressure Restriction
a. Discharge air fromevaporator only alittle
cool.
b. Condensation or frost on receiver-drier.
c. Liquid line to receiver-drier cool, with
frost or condensation.
a. Discharge air fromevaporator only alittle
cool.
b. Condensation or frost on expansion
valve inlet.
c. Inlet end of expansion valve is warm.
3. Repair system leaks as necessary. See Dis-
charging the System in Section 9003.
4. Check compressor oil level. See Section
9003.
see Section 9003.
6. Charge systemwith new refrigerant, seeSec-
tion 9003.
1. Discharge the system.
2. Remove and replace part which has restric-
tion.
see Section 9003.
4. Charge systemwith new refrigerant, seeSec-
tion 9003.
1. Expansion valve inlet which has condensa-
tion or frost is anindication of arestriction in
the expansion valve.
a. Discharge the system. SeeSection 9003.
b. Remove expansion valve andclean or re-
place. See Section 9003.
c. Remove air and moisture and charge sys-
tem. See Section 9003.
9002-21
in Expansion Valve Operation (Continued)
2. Inlet end of expansion valve is warm, indicat-
ing expansion valve is not completely open.
a. Discharge system. Test expansion valve
and adjust or replace. SeeSection 9003.
b. Install expansion valve, remove air and
moisture. and charge system, see Sec-
tion 9003.
c. Clean contact surface between tempera-
ture sensing and evaporator outlet. See
Section 9003.
d. Fill the area between temperature sens-
ing bulb and evaporator outlet with lith-
ium base grease to make a better con-
ductor.
e. Install the insulation putty inthe original
position.
9002-22
1. LOW PRESSURE GAUGE READING ABOVE 30 PSI (207 kPaj
TEMPERATURE CHART
I
Indications of a Problem 1. Separate the compressor from the system.
in Compressor Operation See Section 9003.
a. System is fully charged; no bubbles in
sight glass.

2. Internal leak in compressor is indicated. Re-
b. Evaporator discharge air only a little move compressor from machine. Possible
cool.
causes are:
a. Leakage at valves.
b. Leakage at head gasket
c. Pistons, rings, or cylinders havewear
or scoring.
3. Check and make a record of compressor oil
level before doing service work. SeeSection
9003.
4. Repair or replace compressor as necessary.
See Section 9003.
I
9002-23
in Compressor Operation (Continued)
5. Replace receiver-drier if:
a. The system has been opened for repairs
two times.
b. Receiver-drier operated two or more sea-
sons.
c. Disassembly of compressor showed fine
particles of drying material (normally
yellow or brown particles).
6. Fill compressor with newrefrigeration oil ac-
cording to instructions in Section 9003. In-
stall compressor in machine.
7. Remove air ana moisture from the system,
see Section 9003. Charge system.
8. Operate system and check refrigerant
charge. See Section 9003.
9002-24
1. LOW PRESSURE GAUGE READING ABOVE 30 PSI (207 kPa)
TEMPERATURE CHART
in Condenser Operation
1. Inspect for looseor worn fanandcompressor
belts.
a. Bubbles in sight glass at intervals.
b. Liquid line very hot.
c. Discharge air from evaporator warm.
2. Inspect condenser and radiator for restric-
tions inair passages.
3. Check systemfor too much refrigerant.
a. Remove refrigerant until there are
bubbles in sight glass and gauge pres-
sure is below normal.
b. Addrefrigerant until there arenobubbles
in sight glass and gauge pressures are
normal. SeeSection 9003.
c. If there is still a problem, do step 4.
in Condenser Operation (Continued)
Indications of Air in System
a. Bubbles in sight glass.
b. Discharge air from evaporator warm.
9002-25
4. Remove and inspect condenser for restric-

tions caused by oil.
a. Discharge system, see Section 9003.
b. Use compressed air to remove oil from
condenser.
c. Replace the receiver-drier.
d. Remove air and moisture from the sys-
tem and charge system, see Section
9003.
1. Discharge refrigerant from system, see Sec-
tion 9003.
-
2. Replace receiver-drier ifdrying material isfull of
moisture and removal procedure cannot re-
move moisture from receiver-drier.
see Section 9003.
4. Charge system with new refrigerant. See
Section 9003.
9002-26
Problem - Erratic Cooling
1. LOW PRESSURE GAUGE READING NORMAL.
7 TO 30 PSI (48 TO 207 kPa)
2. HIGH PRESSURE GAUGE READING NORMAL.
ACCORDING TO PRESSURE-TEMPERATURE CHART
Moisture in the System
a. Cooling is acceptable during cool part of
day, but not acceptable during hot part of
day.
1. Discharge system of refrigerant. If too much
moisture enters the orifice of the expansion
valve, the freezinq of this moisture can stop
refrigerant flow. See Section 9003.
2. Replace receiver-drier. Drying material isfull
of moisture.
3. Remove air and moisture from the system.
SeeSection 9003.
NOTE: Vacuum pump must run for at least
2 to 3 hours to remove a large amount of
moisture.
tion 9003.
9002-27
Problem - Erratic Cooling
1. LOW PRESSURE GAUGE READING BELOW 7 PSI (48 kPa)
TEMPERATURE CHART
a. Discharge air from evaporator only alittle
cool.
1. Expansion valve inlet which has condensa-
tion or frost is anindication of arestriction in
the expansion valve.
a. Discharge the system. SeeSection 9003.
b. Condensation or frost on expansion
valve inlet. b. Remove expansion valve and clean or re-
place. See Section 9003.
c. Inlet end of expansion valve is warm.
c. Remove air andmoisture andcharge sys-
tem. See Section 9003.
2. Inlet end of expansion valve iswarm, indicat-
ing expansion valve is not completely open.
a. Discharge system. Test expansion valve
and adjust or replace. SeeSection 9003.
b. Install expansion valve, remove air and
moisture. and charge system. See Sec-
tion 9003.
c. Clean contact surface between tempera-
ture sensing bulb and evaporator outlet.
See Section 9003.
9002-28
Indications of a Problemin
Expansion Valve Operation (Continued)
d. Continue performance test for possible
other problems.
e. Fastentemperature sensing bulb to eva-
porator outlet and tighten securely.
f. Fill theareabetween temperaturesensing
bulb and evaporator outlet with lithium
basegrease to make a better conductor.
g. Install the insulation putty inthe original
position.
Problem - Noise in System
1. LOW PRESSURE GAUGE READING NORMAL, 7 TO 30 PSI
(48 TO 207 kPa)
TEMPERATURE CHART
I
Indications of Too Much
Refrigerant in System
a. Sight glass clear.
1. Remove refrigerant from the system until
-
bubbles show in the sight glass and gauge
b. Discharge air fromevaporator cool.
readings are below normal.
c. Compressor makes noise.
2. Add new refrigerant until bubbles do not
show and gauge readings are normal. See
Section 9003.
CASE CORPORATION
Section
9003
AIR CONDITIONING SYSTEM
9003-2
TABLE OF CONTENTS
SPECIFICATIONS 3
SPECIAL TOOLS 3
ADJ USTMENT OF DRIVE BELT 5
LUBRICATION OF COMPRESSOR 5
General Information 5
Lubricant 5
Oil Level Check .
Oil Level for a New Compressor .
.. 5
. 7
DISCHARGING THE AIR CONDITIONING SYSTEM 8
REMOVING AIR AND MOISTURE FROM THE AIR CONDITIONING SySTEM 9
CHARGING THE AIR CONDITIONING SySTEM 10
REMOVING THE COMPRESSOR 12
REPLACING THE COIL OR CLUTCH ASSEMBLY 14
REPLACING THE SEAL 19
REPLACING THE VALVE PLATE AND GASKETS 24
INSTALLING THE COMPRESSOR 27
REPLACING THE AIR CONDITIONING CONTROL 28
REPLACING THE EXPANSION VALVE 28
REPLACING THE EVAPORATOR 30
REPLACING THE CONDENSER 34
Bur 8-12711
9003-3
SPECIFICATIONS
Compressor Manufacturer Sanyo-Sanden Corporation
Lubricant. Suniso-5GS or equivalent
Coil
Resistance 2.B to 3.3 ohms at BOF(27C)
Current draw 3.6 to 4.2 amperes at 12 volts
Torque
Cap screws for end cap 264 to 300 pound-inches (30 to 34 Nm)
Nut for clutch plate 300 to 360 pound-inches (34 to 40 Nrn.)
Refrigerant , , , , , , R-12 refrigerant
System capacity ' 80 U.S. ounces (2.26 kg)
SPECIAL TOOLS
The tools shown are required to service the air con-
ditioning system (finding leaks, charging the air con-
ditioning system, checking the charge of the air con-
ditioning system, and repairing the compressor).
It is a scientifically proven fact that one of the con-
tributing factors to thedepletion of theozone layer is the
use of CFCs.
Inthe U.S.A. and Canada, order the tools from:
Service Tools
P.O. Box 314
Owatonna, MN 55060
Youwill sean addition to the equipment required to
service the air conditioning system. This new piece of
equipment is an R-12 refrigerant recovery/recycling
system. This equipment will permit you to discharge an
air conditioning system without allowing the refrigerant
to escape into the atmosphere and help to cause the
depletion of the ozone layer This piece of equipment
will also permit the recycling of the refrigerant for future
use.
In Europe order the tools from:
VL Churchill ltd
Northants NN11 4NF
England
Introduction
These special tools arerequired to safely discharge
and charge the air conditioning system.
The use of chlorofluorocarbons (CFCs) such as R-
12 refrigerant used inmobile air conditioning systems
has become a worldwide concern. The concern is
about the depletion of the earth's ozone layer. The
ozone layer is a shield that protects man, beast, and
fieldfrom the harmful effects of ultraviolet rays from the
sun. Ultraviolet rays are believed to be a cause of skin
cancer and could also destroy the earth's entire food
chain,
9003-4
B4041990E
OEM-1396 Refrigerant/Recovery/Recycling
>B131238M
...... .
The leak detector shown is used to find leaks inthe
air conditioning system. The part number of the
detector is CAS-10028. Not shown in use.
Bur 8-12711
The tool shown is a vacuum pump that is used to
remove air and moisture from the air conditioning
system. The part number of the vacuum pump is CAS-
10027. Not shown in use
~t.1)'i$~~;;;"::7~., ..
C D ...-~a3M
1. CAS-10023-1 Gauge Manifold
2. CAS-10023-2 Goggles
3. CAS-10023-4 Thermometer
4. CAS-10023-5 Control Valve
NOTE: The other parts shown are not required.
The tools shown above are used to charge and
check the charge of the air conditioning system. The
tools are available as a kit or separately. The part
number of the kit is CAS-10023. Some parts shown in
use.
B414636M
The tool kit shown above is needed to replace the
seal, coil, or complete clutch assembly. Not all tools in
the kit are required for the compressor used on this
machine. The part number of the kit is CAS-10747.
ADJUSTMENT OF DRIVE BELT
9003-5
Check the tension of the drive belt after every 250
hours of operation. Ifanewdrive belt is installed, check
the tension of the drive belt after the first 20 hours of
operation.
The correct tension for a new drive belt is 65 to 75
pounds (29 to 34 kg) measured with a belt tension
gauge.
The correct tension for adrive belt used more than
20hours is55to65pounds (20to23 kg) measured with
a belt tension gauge.
To adjust the tension of the drive belt:
1. Loosen slightly the nuts on the bolts that hold the
compressor.
2. Use a prybar near the front of the compressor to
tighten the drive belt, then tighten the nuts.
3. Usea belt tension gauge and check the tension of
the drive belt.
4. Repeat steps 1, 2, and 3 as required.
General Information
LUBRICATION OF COMPRESSOR
Because the air conditioning system is a closed
system, the compressor will not need regular oil level
checks or oil changes.
An oil change is necessary only when the air con-
ditioning system has contamination from a leak or a
component failure.
Lubricant
Thecompressor uses refrigeration oil. Refrigeration
oil is a special oil that has most of the moisture
removed. Use Suniso-5GS, Texaco No. 768, Capella
WF100,or anequivalent refrigeration oil when you add
or change oll.
Oil Level Check
Thelevel of theoil must bechecked whenever anew
receiver-drier, condenser, or evaporator has been in-
stalled.
B ur 8-12711
1. Connect the hoses from the R-12 refrigerant re-
covery/recycling system to the manifold. Make sure
that both valves inthe gauge manifold are closed.
B891255J
2. Connect the hose from the high pressure gauge to
the high pressure port.
3. Connect the hose from the low pressure gauge to
the low pressure port.
4. Start the engine and runthe engine at lowidlewith
the air conditioning control set for maximum cooling
and the blower at high speed. Run the engine for 10
minutes.
5. Stop the engine.
9003-6
7. Connect the charge-discharge hose (yellow) to the
fitting onthe side of the R-12 refrigerant recovery/recy-
cling system.
8. Put the angle gauge from the tool kit shown on
page 9003-2 on the front or rear mounting flange.
Adjust the level onthe angle gauge until the bubble is
between the marks. Tighten the wing nut.
9. Loosen and remove the filler plug.
10. Look into the fill hole and check to see if a piston
rodandthe plate are inthe position shown above, next
column. Ifthe parts are not inthe correct position, use a
socket wrench andturn the shaft to put the parts inthe
position shown. This is important to correctly install the
dipstick.
Bur 8-12711
1. PISTON ROD
B840535J
11. Install the dipstick sothat the point onthe stop near
the handle is toward the left. The stop must touch the
compressor as shown.
B840536J
1. Point Must Be Toward Left
Side Of Machine. Stop On
Dipstick Must Touch
The Compressor
12. Read the degrees on the angle gauge and the
notches inthe dipstick.
13. Compare the readings withthe chart and add oil as
required. Add oil in amounts less than 1 U.S. fluid
ounce (30 mL) and check the level again. The oil must
be that which is specified on page 9003-3.
Angle Gauge Oil Level
Reading Notches
0 2-4
10 4-5
70 5-6
14. Charge the airconditioning systemaccording to in-
Oil Level for a New Compressor
1. Drainthe oil fromthe old compressor into a mea-
suring container.
2. Drain the oil from the new compressor into a
CLEAN measuring container.
Bur 8-12711
9003-7
3. Fill the new compressor with the newoil equal to
the amount drained from the old compressor plus 1
U.S. fluid ounce (30 mL) of new oil.
4. Install and tighten the filler plug.
5. No oil level check will be needed after the com-
pressor has been installed.
9003-8
DISCHARGING THE AIR CONDITIONING SYSTEM
The air conditioning system must be discharged
before beginning the removal of any component of the
air conditioning system.
1. Connect the hoses from the R-12 refrigerant re-
covery/recycling system to the gauge manifold.
2. Make sure that each valve in the gauge manifold is
closed.
3. Loosenand remove the cap fromthe high pressure
port
4. Connect the hose fromthe high pressure gauge to
the high pressure port.
B ur 812711
5. Loosen andremove the cap from the lowpressure
port.
7. Connect thecharge-discharge hose (yellow) to the
fitting onthe side of the R-12 refrigerant recovery/recy-
cling system.
8. Usethe R-12 refrigerant recovery/recycling system
according th the instructions of the manufacturer.
9. Open the valvefor the low pressure gauge asmall
amount to slowly release the refrigerant
10 Open thevalvefor the high pressure gauge asmall
amount to release the refrigerant.
11. When the lowpressure gauge and high pressure
gauge indicate zero,the air conditioning system is dis-
charged.
LOW
PRESSURE
GAUGE
HIGH
PRESSURE
GAUGE
CHARGE-
DISCHARGE
~HOSE
, HIGH
\ tt PRESSURE
.I-../PORT
Will
B 891255J
REMOVING AIR AND MOISTURE FROM THE AIR CONDITIONING SYSTEM
9003-9
When the air conditioning system has been dis-
charged and opened for service, air enters the air con-
ditioning system before the openings can be closed.
The air carries moisture which can cause damage to
the air conditioning system. It is necessary to remove
the air and moisture before the air conditioning system
is charged with new refrigerant.
Replace the receiver-drier before removing the air
and moisture if:
a. The air conditioning system has been opened
before.
b. Thereceiver-drier has been used for more than
two seasons.
c. The reason for service is too much air and
moisture in the air conditioning system.
d. Disassembly of the compressor shows parti-
cles of the drying material inside the compressor.
NOTE: Make sure the hoses from the R-12 refrigerant
recoverylrecycling system are connected to the gauge
manifold.
1. If the hoses from the gauge manifold have been
disconnected from the compressor:
LOW
PRESSURE
GAUGE
HIGH
PRESSURE
GAUGE
HIGH
B891255J
a. Connect the hose from the high pressure
gauge to the high pressure port.
Bur 8-12711
b. Connect thehosefromthe lowpressure gauge
to the low pressure port.
2. Makesurethatthevalves inthegauge manifold are
open.
3. Connect the charge-discharge hose from the
gauge manifold to the vacuum pump.
4. Run the vacuum pump for a minimum of 30
minutes. The low pressure gauge must indicate a
vacuum of 28 to 29 inches of mercury (95to 100 kPa)
within five minutes. If the vacuum is not as specified,
there is a leak in the air conditioning system or the
vacuum pump is not working correctly.
NOTE: The vacuum indication will be one inch of
mercury (3.3kPa) less for every 1000feet (305meters)
above sea level.
5. To check for a leak inthe air conditioning system:
a. Close thevalves for the lowpressure and high
pressure gauges.
b. Stop the vacuum pump.
c. If the reading of the low pressure gauge in-
creases more than one inch of mercury (3.3 kPa) in
four minutes, there is a leak inthe air conditioning
system.
d. Check all connections in the air conditioning
system.
6. Before disconnecting the vacuum pump, make
sure that the valves for the low pressure and high
pressure gauges have been closed.
9003-10
CHARGING THE AIR CONDITIONING SYSTEM
General Information
Charge the air conditioning system only when there
is no indication of leaks,
Ifthe air conditioning system has been discharged,
air and moisture must be removed from the air con-
ditioning system according to instructions in this
section before the air conditioning system can be
charged.
If refrigerant is being added to a charged air con-
ditioning system, removal of air and moisture is not ne-
cessary,
The correct amount of R12 refrigerant for the air
conditioning system is 80 ounces (2.26 Kg). Using
more refrigerant than required will damage the com-
pressor,
Use the procedure that follows to correctly charge
the air conditioning system.
Charging Pr o c ed u r e
1, If the air conditioning system is to receive a
complete charge of refrigerant, remove air and
moisture fromthe air conditioning system according to
instructions in this section, Then continue the pro-
cedure at step 3.
NOTE: Make sure the hoses from the R-12 refrigerant
recovery/recycling system are connected to the gauge
manifold.
2, If you are only adding refrigerant:
a. Makesurethevalves inthe gauge manifold are
closed,
Bur 8-12711
LOW
PRESSURE
GAUGE
HIGH
PRESSURE
GAUGE
HIGH
B891255J
b. Loosen and remove the cap from the high
pressure port.
c. Connect the hose from the high pressure
gauge to the high pressure port.
d. Loosen and remove the cap from the low
pressure port.
e, Connect the hose fromthe lowpressure gauge
to the low pressure port.
Issued 1-91 Printed in U,S,A,
3. Install the control valve on the container of re-
frigerant.
4. Connect the charge-discharge hose from the
gauge manifold to the control valve.
5. Loosen the connection of the charge-discharge
hose and the gauge manifold.
Bur 8-12711
9003-11
6. Open the control valve a small amount to remove
the air from the charge-discharge hose. Then tighten
the connection at the gauge manifold.
7. Open the control valve on the container several
turns.
8. Slowly open thevalve for the lowpressure gauge to
prevent the pressure fromgoing above 40 psi (276kPa,
2.8 bar). At a higher pressure the refrigerant will
become liquid and damage the compressor.
(r/min).
10. Turn the air conditioning control to the COLD posi-
tion.
11. Turn the knob for the blower to the HI position.
12. Continue to charge the air conditioning system
until 80 ounces (2.26 kg) of refrigerant is inthe air con-
ditioning system or until there are no air bubbles inthe
sight glass on the top of the receiver-drier.
13. When changing containers of refrigerant:
a. Close the valve for the low pressure gauge.
b. Close the control valve on the container
c. Remove the control valve fromthe empty con-
tainer.
d. Install the control valve on the newcontainer.
14. Open the valve for the lowpressure gauge and the
control valve on the container of refrigerant.
15. Read the low pressure gauge and the high
pressure gauge. The air conditioning system is cor-
rectly charged when:
a. The indication of the lowpressure gauge is 7to
30 psi (48 to 207 kPa, 0.48 to 2.1 bar).
b. The indication of the high pressure gauge is
the same as inthe temperature-pressure chart that
follows on the next page.
9003-12
Ambient Temperature* High Pressure Indication
80F (26.7C) 150 to 170 psi
(1034 to 1172 kPa,
10.3 to 11.7 bar)
90F (32ZC) 175 to 185 psi
(1206 to 1275 kPa,
12.1 to 12.7 bar)
95F (35C) 195 to 205 psi
(1344 to 1413 kPa,
13.4 to 14.1 bar)
100F (37.8C) 210 to 230 psi
(1447 to 1585 kPa,
14.4 to 15.8 bar)
105F (40.rC) 230 to 250 psi
(1585 to 1723 kPa,
15.8 to 17.2 bar)
110F (43C) 250 to 270 psi
(1723 to 1861 kPa,
17.2 to 18.6 bar)
*The temperature of the air around the machine.
16. If the high pressure reading is too high:
a. Close the control valve for the refrigerant con-
tainer.
b. Disconnect the charge-discharge hose from
the control valve.
c. Slowly open the valve for the high pressure
gauge to decrease the high pressure tothecorrect
value.
d. Close the valve for the high pressure gauge
when the reading is correct.
17. After the air conditioning system has the correct
charge, stop the engine.
18. Disconnect the hoses from the low and high
pressure ports.
19. Install the cap onthe lowand high pressure ports.
REMOVING THE COMPRESSOR
1. Discharge theair conditioning system according to
instructions inthis section.
2. Disconnect the hoses from the compressor.
3. Install a plug in each hose.
4. Disconnect the wire from the wiring harness.
5. Loosen and remove the nut and lock washer from
the.bolt at the top of the adjustment strap.
Bur 8-12711
6. Remove the bolt and flat washer.
7. Loosen and remove the nut, lock washer and flat
washers from the bolt that holds the compressor.
8. Hold the compressor and remove the bolt and
remove the compressor fromthe machine.
9003-13
B ur 812711
Issued 1-91 Printedin USA
9003-14
REPLACING THE COIL OR CLUTCH ASSEMBLY
NOTE: Special tools are from kit CAS-10747
shown on page 9003-4.
STEP 1
Fasten the compressor in a vise. Loosen and remove
the three cap screws and lock washers from the cover
on the clutch. Remove the cover. Loosen and remove
the nut that holds the clutch plate.
STEP 2
Install the puller for the clutch plate.
STEP 3
Remove the clutch plate.
B ur 8-12711
STEP 4
Remove the shield from the bore of the pulley.
STEP 5
Remove the large snap ring.
STEP 6
Remove the small snap ring.
STEP 7
Install the jaws of the puller on the pulley.
STEP 8
Install the separator.
STEP 9
Install the handle.
Bur 8-12711
9003-15
STEP 10
Remove the pulley.
STEP 11
Remove the separator.
STEP 12
Loosen the screw that holds the clamp for the wire.
9003-16
STEP 13
Remove the snap ring that holds the coil.
STEP 14
Remove the coil.
STEP 15
When you install the coil, make sure that the boss onthe
bottom of the coil engages the hole in the front of the
compressor.
Bur 8-12711
STEP 16
Install the coil.
STEP 17
Install the snap ring that holds the coil.
STEP 18
Install the wire behind the clamp and tighten the screw.
STEP 19
Install the pulley.
STEP 20
Assemble the two parts of the driver as shown.
STEP 21
Drive the pulley all the way onto the compressor.
Bur 8-12711
9003-17
STEP 22
~-
Install the snap ring that holds the pulley.
STEP 23
Install the large snap ring.
STEP 24
Start the shield into the pulley.
9003-18
STEP 25
Drive the shield into the pulley.
STEP 26
Drive the clutch plate all the way onto the shaft.
STEP 27
Install and tighten the nut to 300 to 360 pound-inches
(34 to 40 Nm).
B ur 8-12711
STEP 28
If a new clutch assembly has been installed check the
gap between the clutch plate and pulley.
STEP 29
If the gap is more than .032 inch (0.81 mm) or less than
.016 inch (0.41 mm), remove the clutch plate and add
or remove shims as required to get the correct gap.
STEP 30
Install the cover on the clutch.
9003-19
REPLACING THE SEAL
STEP 34 STEP 31
Fasten the compressor in a vise. Remove the cover
from the clutch. Loosen and remove the nut that holds
the clutch plate.
STEP 32
Install the puller for the clutch plate.
STEP 33
Remove the clutch plate.
Bur 8-12711
Drive the bottom of the Woodruff key into the keyway.
STEP 35
Use a pair of wire cutters to remove the Woodruff key.
STEP 36
Remove the shims for the clutch plate.
9003-20
STEP 37
Use a pair of snap ring pliers and remove the felt seal.
STEP 38
Remove the snap ring that holds the seal seat.
STEP 39
Remove the seal seat.
Bur 8-12711
STEP 40
Remove the O-ring from the groove. Be careful not to
make a scratch in the groove.
STEP 41
Install the seal tool and engage the notches inthe seal
tool with the tabs on the seal.
STEP 42
Remove the seal.
STEP 43
Install the protector on the shaft.
STEP 44
Carefully remove the seal from the container.
NOTE: DO NOT touch the sealing surface of the
carbon ring. Body salts and acids will damage the
sealing surface.
STEP 45
Install the seal on the seal tool.
Bur 8-12711
9003-21
STEP 46
Lubricate the protector with refrigeration oil and install
the seal.
STEP 47
Mt.
Install the new a-ring in the bottom groove in the bore
for the seal.
STEP 48
Carefully remove the seal seat from the container.
NOTE: DO NOT touch the sealing surface of the seal
seat. Body salts and acids will damage the sealing
surface.
9003-22
STEP 49
Lubricate the sealing surface of the seal seat with refri-
geration oil and install the seal seat.
STEP 50
Instail the snap ring sothat the chamfer on the IDwill be
on top.
STEP 51
Install the new felt seal.
Bur 8-12711
STEP 52
Drive the felt seal into the bore until the metal is even
with the top of the bore.
STEP 53
B414508M
Remove the protector.
STEP 54
Install the Woodruff key. If pliers are used as shown, use
a piece of metal as a protector between the pliers and
shaft to prevent damage to the shaft.
STEP 55
Install the same shims that were removed.
STEP 56
Drive the clutch plate all the way onto the shaft.
B ur 8-12711
9003-23
STEP 57
Install and tighten the nut to 300 to 360 pound-inches
(34 to 40 Nm).
STEP 58
Install the cover on the clutch.
9003-24
REPLACING THE VALVE PLATE AND GASKETS
STEP 59
Remove the dirt and grease from the compressor.
STEP 60
Fasten the compressor in a vise and loosen and
remove the cap screws that hold the end cap.
STEP 61
Hit the end cap to loosen the end cap.
STEP 62
Remove the end cap.
B ur 8-12711
STEP 63
Remove the gasket from the valve plate.
STEP 64
Loosen the valve plate.
STEP 65
Remove the valve plate.
STEP 66
If the gaskets are being replaced, remove the other
gasket from the valve plate. Be careful not to damage
the valves.
STEP 67
.:..... :
4a 43M
. : ... ->;., .
Install the new gaskets on the valve plate. The gaskets
will only fit one way.
STEP 68
Install the valve plate.
B ur 8-12711
9003-25
STEP 69
Install the end cap.
STEP 70
Install and tighten every other cap screw to 264 to 300
pound-inches (30 to 34 Nm) until all cap screws have
been tightened.
STEP 71
Loosen and remove the filler plug and drain the oil into a
measuring container.
STEP 72
Fill the compressor with the same amount of NEWrefri-
geration oil.
STEP 73
Install and tighten the filler plug.
B1245A88J
Bur 8-12711
9003-26
INSTALLING THE COMPRESSOR
9003-27
'I . Align the compressor with the mounting bracket
and install the bolt and flat washer.
2. Install the flat washer, lock washer and nut on the
bolt.
3. Install the drive belt on the pulley.
4. Align the adjusting strap with the compressor and
install the bolt and flat washer.
5. Install the lock washer and nut on the bolt.
Bur 8-12711
6. Adjustthe drive belt according to instructions inthis
section.
7. Loosen and remove the plugs from the hoses.
8. Connect the hoses to the compressor
9. Connect the wiring to the wiring harness
10. Charge the airconditioning system according to in-
9003-28
REPLACING THE AIR CONDITIONING CONTROL
1. Remove the evaporator according to instructions in
this section.
2. Loosen and remove the nut that holds the air con-
ditioning control.
3. Remove the air conditioning control from the
mounting plate.
4. Disconnect the wiring from the air conditioning
control.
5. Completely remove the air conditioning control.
6. Route the tube for the new air conditioning control
the same way as the original.
7. Connect the wiring to the air conditioning control.
8. Install the air conditioning control in the mounting
plate.
9. Install and tighten the nut that holds the air con-
ditioning control.
10. Install the evaporator according to instructions in
this section.
REPLACING THE EXPANSION VALVE
1. Discharge the air conditioning systemaccording to
2. Turn the temperature control to HOT.
3. Drain one U.S. gallon (4 litres) of coolant from the
radiator.
4. Remove the knobs from the switches, air con-
ditioning control and temperature control.
5. Loosen and remove the screws that hold the
control panel.
6. Disengage the control panel from the vertical cover
and disconnect the wiring from the cab lamp switch.
bottom of the vertical cover.
Bur 8-12711
8. Disengage the vertical cover from the frame begin-
ning at the top and remove the vertical cover.
9. Disengage the left vertical cover beginning at the
top and remove the vertical cover.
NOTE: The front headliner MUST be removed first.
10. Hold the front headliner in place and loosen and
remove the screws at the front of the front headliner and
the screws on each side including the screw at the
junction of the front and rear headliners.
11. Lower the front headliner onto the control.
12. Loosen the clamp on the front drain hoses.
13. Remove the hoses from the drain pan.
14. Loosen and remove the screw from the left and
right rear sides of the rear headliner.
15. Hold the rear headliner in place and loosen and
remove the screws from the left and right sides of the
rear headliner.
16 Carefully lower the rear headliner behind the seat.
17. Remove the insulation from the expansion valve.
8891257J
18. Loosen completely the connections at the rear of
the expansion valve
19. Loosen completely the connections at the front of
the expansion valve and remove the expansion valve.
20. Install new O-rings on the fittings on the tubes and
the fittings on the evaporator.
21. Lubricate the O-rings with refrigeration oil.
22. Install the expansion valve and tighten the connec-
tions withforce equal to 240 to 300 pound-inches (27to
34 Nm).
Bur 8-12711
9003-29
23. Install new insulation tape around the expansion
valve.
24. Carefully raise the rear headliner and engage the
rear headliner with the slot at the rear of the roof.
25. Hold the rear headliner in place and install a screw
in the center hole on the right and left sides of the rear
headliner.
26. Install and tighten the screw atthe left and right rear
sides of the rear headliner.
27. Connect the front drain hoses to the drain pan.
28. Tighten the clamp on each hose.
29. Carefully raise the front headliner and engage the
front headliner with the rear headliner.
30. Install and tighten the screws atthe front of thefront
headliner.
31. Install and tighten the screws on the right sides of
the front and rear headliners.
32. Install the left vertical cover.
33. Install the right vertical cover.
34. Install and tighten the screw at the bottom of the
right vertical cover.
35. Connect the wires to the cab lamp switch in the
control panel and engage the control panel with the
36. Install and tighten the screws that hold the control
panel.
37. Install the knobs for the switches and the air con-
ditioning and temperature controls.
38. Charge the air conditioning system according to in-
9003-30
REPLACING THE EVAPORATOR
1. Discharge the air conditioning system according to
2. Turn the temperature control to HOT.
3. Drain one U.S. gallon (4 litres) of coolant from the
radiator.
4. Remove the knobs from the switches, air con-
ditioning control and temperature control.
control panel.
6. Disengage the control panel from the right vertical
cover.
bottom of the right vertical cover.
8. Disengage the vertical cover from the frame begin-
ning at the top and remove the vertical cover.
9. Disengage the left vertical cover beginning at the
top and remove the vertical cover.
IMPORTANT: The front headliner must be removed
first.
10. Hold the front headliner in place and loosen and
remove the screws at the front of the headliner and the
screws on each side including the screw at the junction
of the front and rear headliners.
11. Lower the front headliner onto the control console.
12. Loosen the clamp on the front drain hoses.
13. Remove the front drain hoses from the drain pan.
14. Loosen and remove the screw from the left and
right rear sides of the rear headliner.
15. Hold the rear headliner in place and loosen and
remove the screws from the lett and right sides of the
rear headliner.
16. Carefully lower the rear headliner behind the seat.
17. Loosen both clamps on the hoses connected to
the heater.
18. Slide the hoses to the rear.
B ur 8-12711
19. Remove the insulation for the connections to the
expansion valve and evaporator.
20. Disconnect the tubes fromthe expansion valve and
evaporator .
21. Loosen the cap screws that hold the evaporator.
22. Carefully remove the evaporator and remove the
temperature sensor and tube for the air conditioning
control from the evaporator.
B861647M
23. Remove any remaining insulation from the expan-
sion valve and the connections to the evaporator.
24. Remove the clamp that holds the temperature
sensor.
25. Disconnect the expansion valve and equalizer tube
from the evaporator.
26. Connect the expansion valve to the new evapo-
rator.
27. Connect the equalizer tube to the outlet tube of the
evaporator.
28. Apply a small amount of grease between the tem-
perature sensor and the outlet tube.
29. Install the clamp that holds the temperature
sensor.
30. Apply newinsulation tapes to the tubes at each end
of the evaporator, the inlet and outlet tubes, and the ex-
pansion valve and the equalizer tubes.
Bur 8-12711
9003-31
1. HEATER
~.
- - - ~.
8891258J
Issued 1-91
Printed in U.S.A.
9003-32
31. Install the temperature sensor and tube in the eva-
porator as shown.
32. Install the evaporator.
33. Install and tighten the cap screws that hold the eva-
porator
34. Connect the tubes to the expansion valve and eva-
porator.
35. Apply new insulation tape to the connections.
36. Slide the hoses onto the tubes from the heater.
37. Tighten the clamps for both hoses.
38. Carefully raise the rear headliner and engage the
rear headliner with the slot at the rear of the roof.
39. Holdthe rear headliner in place and install a screw
inthe center hole on the right and left sides of the rear
headliner.
Bur 8-12711
40. Install and tighten the screw at the left and right rear
sides of the rear headliner.
41. Connect the front drain hoses to the drain pan.
42. Tighten the clamp on each hose.
43. Carefully raise the front headliner into position and
engage the front headliner with the rear headliner.
44. Install and tighten the screws at the front of the front
headliner.
45. Install and tighten the screws on the right and left
sides of the front and rear headliners.
46. Install the left vertical cover.
47. Install the right vertical cover.
48. Install and tighten the screws at the bottom of the
49. Connect the wires to the cab lamp switch and
engage the control panel with the right vertical cover.
50. Install and tighten the screws that hold the control
panel.
51. Install the knobs for the switches and the air con-
ditioning and temperature controls.
52. Fill the radiator to the correct level.
Bur 8-12711
9003-33
B891258J
ISsued 1-91
Printed in U.SA
9003-34
REPLACING THE CONDENSER
1. Discharge the air conditioning system according to
2. Have another person hold the hood in position.
3. Make analignment mark atthe top and rear of each
pivot bracket for the hood.
4. Loosen and remove the nut, lock washer, spacer,
flat washer and bolt that fasten each cable to the
radiator shroud.
5. Loosen and remove the front and rear cap screws
that hold each pivot bracket.
6. Remove the hood from the machine.
7. Put blocks between the radiator and pump to hold
the radiator in place with the radiator shroud or
mounting brackets removed.
8. Loosen and remove the self-locking nut, bolt and
flat washer from each oil cooler mount.
9. Loosen and remove the cap screw and bracket at
the top of the radiator.
10. Loosen and remove the nuts and bolts that hold the
radiator shroud.
11. Remove the radiator shroud.
12. Loosen and remove the cap screws that hold the
guard at the bottom of the condenser.
13. Remove the guard.
14. Disconnect the hoses from the condenser.
15. Install and tighten a plug in each hose.
16. Loosen and remove the nuts and lock washers
from the bolts that hold the mounting brackets.
17. Remove the mounting brackets and the bolts.
18. Loosen and remove all but the top cap screws that
hold the condenser.
19. Hold the condenser in place and remove the top
cap screws and remove the condenser.
20 Hold the condenser in place and install the flat
washers, lock washers and cap screws.
B ur 8-12711
21. Tighten the cap screws.
22. Install the mounting brackets and bolts and lock
washers and nuts.
23. Tighten the nuts.
24. Loosen and remove the plug from each hose.
25. Connect the hoses to the condenser.
26. Install the guard and cap screws.
27. Tighten the cap screws.
28. Install the radiator shroud.
29. Install the bolts and flat washers, and nuts that hold
the radiator shroud.
30. Install the bracket and cap screw at the top of the
radiator.
31. Tighten the cap screw.
32. Have another person push and hold the top of the
radiator shroud all the way to the rear.
33. Tighten the nuts.
34. Install a bolt and flat washer and self-locking nut in
each oil cooler mount.
35. Tighten the self-locking nuts.
36. Remove the blocks from below the radiator.
37. Make sure that the pivot brackets are all the way on
the pivots for the hood.
38. Install the hood.
39. Install the cap screws that hold the pivot brackets.
40. Align each pivot bracket with the alignment marks
and tighten the cap screws.
41. Close the hood. The top rear of the hood must be
even with the frame.
42. If the top of the hood is too high, check to see if the
sides of the hood are touching the frame. To correct this
problem, move the pivot brackets forward.
3. O-RING
3. O-RING
3. O-RING
Bur 8-12711
9003-35
3. O-RING
B891259J
9003-36
43. If the top of the hood is too high and the sound of
metal hitting metal is heard at the front of the hood, the
radiator shroud is not inthe correct position. To correct
this problem, the top of the radiator shroud must be
moved farther to the rear.
Bur 8-12711
44. When the hood can be closed and is inthe correct
position, tighten the nuts on the bolts that hold the
radiator shroud to 270 to 324 pound-feet (366 to 439
Nm).
3. O-RING
9003-37
3. O-RING
3. O-RING
B ur 8-12711
8891259J
Issued 1-91
Printed in U.S.A.
9004
LOADER
TABLE OF CONTENTS
REPLACEMENT OF CUTIING EDGE FOR
STANDARD BUCKETS 2
EXPLODED VIEWS
loader Frame 9
REPLACEMENT OF CUTIING EDGE FOR
CLAM BUCKET. 4 Lift Cylinder Hydraulic Installation 10
REPLACEMENT OF TOOTH SHANK 6 Bucket Cylinder Hydraulic Installation 11
REPLACEMENT OF TOOTH POINT 6 Antirollback Linkage 12
REMOVAL OF lOADER FRAME 7 Clam Cylinder Circuit... 13
INSTALLATION OF LOADER FRAME 8 Clam Cylinder Hydraulic Installation 14
Installation of Front Counterweight 15
Installation of Rear Counterweight 16
CASE CORPORATION
Bur 8-17630
Copyright J I Case Company
Printed in U.S.A.
Issued March 1991
9004-2
REPLACEMENT OF CUTTING EDGE FOR STANDARD BUCKETS
1. Ifthe bucket is not removed from the machine, raise
the bucket to a suitable height and use suitable
supports to hold the loader frame and bucket in place.
2. If equipped with bucket teeth, use carbon arc rod to
remove the bucket teeth.
3. Use carbon arc rod or an acetylene cutting torch to
remove the welds that hold the cutting edge. Keep dis-
tortion to a minimum when removing the cutting edge.
4. When removing the bottom rear weld for the cutting
edge DO NOT cut through the floor of the bucket.
5. If removing the cutting edge from a short lip bucket,
remove the gusset from each side of the bucket.
1. Gusset
6. If removing the cutting edge from a short lip bucket,
cut through each corner of the cutting edge 1-13/16 (45
mm) to the rear from the front edge of the floor of the
bucket.
7. Use a grinder to remove any welds or extra metal on
the bucket that will prevent the new cutting edge from
fitting correctly.
Bur 8-17630
8. Put the cutting edge in place and use C-clamps to
hold the cutting edge inplace. See the illustration forthe
correct position of the cutting edge.
B902762J
1. Short Up Bucket - 25-3/16 In (639mm)
2. Long Up Bucket - 27 In (687mm)
9. Use E-7018 welding rod and weld the cutting edge to
the bucket.
10. When welding the floor of the bucket the top of the
cutting edge:
a. Start at one end of the bucket and weld toward
the center until one welding rod is used.
b. Start at the center of the bucket and weld inboth
directions from center until one welding rod is
used.
c. Start at the other end of the bucket and weld
toward the center until one welding rod is used.
d. Continue to weld the cutting edge to the bucket
using this method until welding is complete.
11. If replacing the cutting edge on a short lip bucket,
weld the gussets in place at each side of the bucket.
12. If bucket teeth were removed from the old cutting
edge, install the bucket teeth according to instructions
in this section.
Wel d Speci f i ca t i ons f or
Long Li p Bucket
1. 1/4 In (6 mm) Fillet
2. Fill Corners
3. Fill Groove
4. 3/16 In (5mm) Fillet
Bur 8-17630
9004-3
Wel d Speci f i ca t i ons f or
Short Li p Bucket
1. 1/4 In (6 mm) Fillet
2. Fill Corners
3. 3/16 In (5mm) Fillet
4. 1/4 In (6 mm) Fillet 5-1/8 In (130 mm) Long
on 9.8 In (250 mm) Center
9004-4
REPLACEMENT OF CUTTING EDGE FOR CLAM BUCKET
1. Ifthe bucket is not removed from the machine, raise
the bucket to a suitable height and use suitable
supports to hold the loader frame and bucket in place.
2. If equipped with bucket teeth, use carbon arc rod to
remove the bucket teeth.
remove the welds that hold the cutting edge. Keep dis-
tortion to a minimum when removing the cutting edge.
4. When removing the bottom rear weld for the cutting
edge DO NOT cut through the floor of the bucket.
5. Cut through each corner of the bucket and cutting
edge in the area shown.
1. Cut Through Corner
6. Use a grinder to remove any welds or extra metal on
the bucket that will prevent the new cutting edge from
fitting correctly.
Bur 8-17630
7. Put the cutting edge in place and use C-clamps to
hold the cutting edge inplace. Seethe illustration for the
correct position of the cutting edge.
B902018J
1. 11 Inches (279 mm)
8. Use E-7018welding rod and weld the cutting edge to
the bucket.
9. When welding the floor of the bucket the top of the
cutting edge:
a. Start at one end of the bucket and weld toward
the center until one welding rod is used.
b. Start at the center of the bucket and weld inboth
directions from center until one welding rod is
used.
C. Start at the other end of the bucket and weld
toward the center until one welding rod is used.
d. Continue to weld the cutting edge to the bucket
using this method until welding is complete.
10. If bucket teeth were removed from the old cutting
edge. install the bucket teeth according to instructions
in this section.
Wel d Speci f i ca t i ons f or Cl a m Bucket
Bur 8-17630
9004-5
1. 1/4Inch (6mm) Fillet
2. Fill Corner
3. Fill Groove
9004-6
REPLACEMENT OF TOOTH SHANK
remove the welds that hold the tooth shank in place.
2. Use a grinder to remove any welds or extra material
that will prevent the tooth shank from fitting correctly.
3. See the following illustration for the correct location
of the tooth shank on the cutting edge.
1__ 2_
B 861656J
1. Short Up Bucket - 15-1/8In (384mm)
Long Up Bucket - 8-1/4 In (208 mm)
2. Short Up Bucket - 14-9/16 In (370mm)
Long Up Bucket - 8In (203 mm)
3. Put Tooth Shank as Close to Corner as Possible
and Keep Corner of the Tooth Point Even With Outer
Surface of Cutting Edge
4. See the following illustration for weld specifications
and instructions.
B902019J
1. 3/8Inch (10 mm) Fillet. Weld Around Each Corner
3/8 Inch (10 mm). Weld Two Times
2. 2-1/2 Inches (63 mm)
3. 3/8 Inch (10 mm) Fillet. Weld Both Sides and Rear
of Tooth Shank Weld Two Times
4. 3/8In (10 mm) Fillet. Two Times
5. Bent Area of Tooth Point
REPLACEMENT OF TOOTH POINT
1. Heat the part of the tooth point that has been
pressed into the hole on each side of the tooth shank.
2. Bend the tooth point out of the dent on each side of
the tooth shank.
3. Use a pair of pliers to remove the tooth point from
the tooth shank.
4. Install a newtooth point on the tooth shank.
Bur 8-17630
5. Heat the part of the tooth point that will be pressed
into the hole on each side of the tooth shank.
6. Have another person hold the tooth point against
the tooth shank.
7. Use an suitable tool and drive the heated part of the
tooth point into the dent on each side of the tooth shank.
REMOVING THE LOADER FRAME
9004-7
1. Raise the loader frame until the pivot pins for the
piston rod eye ot the lift cylinders are above the hood.
Stop the engine.
2. Fasten suitable lifting equipment to the loader
frame to hold the loader frame in place.
3. Remove theouter snap ring that hold the pivot pins
for the piston rod eyes ot the lift cylinders.
4. Use suitable drivers and drive the pivot pins out of
the loader frame. DO NOT remove the drivers now.
5. Disconnect the lifting equipment and lower the
bucket to the floor.
6. Hold the right liftcylinder and remove the driver and
lower the lift cylinder onto the front axle.
7. Hold the left lift cylinder and remove the driver and
lower the lift cylinder onto the front axle. Flat washers
are used between the strut and the loader frame; be
careful not to lose the flat washers. Itis not necessary to
remove the strut.
8. Move the loader control lever to the right or left to
relieve any pressure in the bucket circuit.
9. Disconnect the tubes to the bucket cylinders from
the hoses on the right side of the loader frame. Fasten
an identification tag to one of the hoses.
10. Install a cap on each hose and acap on each tube.
11. Disconnect the wiring from the switch for return-
to-dig.
12. Loosen and remove the bolt, flat washer and nut
that holds the clamp for the wiring harness.
Bur 8-17630
13. Remove the tie straps that fasten the wiring
harness to the tubes on the loader frame. Putthe wiring
harness out of the way.
14. Remove the cotter pin and flat washer that fasten
the actuator rod for antirollback to the bellcrank for the
right bucket cylinder.
15. Remove the actuator rod. Be careful not to lose the
spring or other flat washer.
16. If equipped with a clam bucket, move the clam
control lever ineither direction to relieve any pressure in
the clam circuit.
17. Disconnect the tubes to the clam cylinders fromthe
hoses on the left side of the machine. Fasten an identi-
fication tag to one hose.
18. Install a cap on each hose and a plug ineach tube.
19. Remove the snap ring and flat washer from the
right end of the pivot shaft.
20. Fasten suitable lifting equipment to the loader
frame to hold the loader frame in place.
21. Use a suitable driver and drive the pivot shaft out of
the loader frame.
22. Belleville springs are used between the loader
frame and the machine. Raise the loader frame and
remove the Belleville springs.
23. Raise the loader frame until the loader frame is free
of the machine.
24. Carefully move the machine out of the loader
frame.
9004-8
INSTALLATION OF LOADER FRAME
1. Carefully move the machine into the loader frame.
2. Lower the loader frame into alignment with the
frame.
3. Install the Belleville springs between the frame and
loader arm as shown.
1. BELLEVILLE SPRING.
THIS SIDE TOWARD MACHINE
B891353J
4. Align the loader frame and Belleville springs with
the frame.
5. Start the pivot shaft into the loader frame from the
left side of the machine.
6. Drive the pivot shaft all the way into the loader
frame.
7. Install the flat washer and snap ring.
8. Ifequipped with a clam bucket, connect the hoses
to the tubes on the left side of the machine.
9. Install the actuator rod and spring in the actuator
tube for the antirollback mechanism.
10. Engage the actuator rod with the bellcrank and
install the flat washer and cotter pin.
11. Connect the wiring harness to the switch for return-
to-dig.
12. Install the nut, bolt and flat washer that hold the
clamp for the wiring harness for the switch.
13. Install tie straps to hold the wiring harness in place.
Bur 8-17630
14. Connect the tubes to the bucket cylinders to the
hoses on the right side of the machine.
15. Move the loader control lever to FLOAT.
16. Remove the snap ring and flat washer from both
pivot pins for the piston rod eyes of the lift cylinders.
Then install the large snap ring on each pivot pin.
17. Start the pivot pintor tne left piston rod eye into the
loader frame and install the flat washer used between
the strut and loader frame.
18. Start the pivot pin into the strut.
19. Align the piston rod with the strut and start the pivot
pin into the piston rod eye.
20. Drive the pivot pin into the piston rod eye.
21. Install the other flat washer between the strut and
loader frame and drive the pivot pin all the way into the
loader frame.
22. Install the flat washer and snap ring on the pivot
pin.
23. Start the pivot pin for the other lift cylinder into the
loader frame.
24. Align the piston rod eye with the loader frame and
drive the pivot pin all the way into the loader frame.
25. Install the flat washer and snap ring on the pivot
pin.
26. Lubricate the pivot pins for the piston rod eyes of
the lift cylinders and the pivot shaft.
27. With the engine running at low idle, extend and
retract the bucket cylinders and clam cylinders, if
equipped, three times to remove any air from the cir-
cuits.
9004-9
Loa der Fra me
Bur 8-17630 3-91 Printed in U.S.A. Issued
9004-10
B 902720J
Lift Cylinder Hydra ul i c Installation
9004-11
B902721J
Bur 8-17630
Bucket Cylinder Hydraulic Installation
9004-12
Antirollback Linkage
Bur 8-17630
B902719J
9004-13
I der Circuit Clam CYln
Bur 8-17630 Printed in U.S.A. Issued 3-91
9004-~4
. III U.S.p..
?rl llteO
8
_17630
Sur
7. Tighten to 720to 770
Pound-Feet (762to 230 Nm)
Bur 8-17630
9004-16
8861864J
1. Tighten to 360 to 439 Pound-Feet (488 to 596 Nm)
NOTE: The weight of each counterweight is 1425 pounds (646 kg). Use acceptable
lifting equipment to remove and install the countefINeights.
Bur 8-17630
CASE CORPORATION
Sect i on
9005
ROPS CAB AND ROPS CANOPY
Issued J anuary 1991 .
9005-2
TABLE OF CONTENTS
SPECIAL TOOL . . 2
TORQUE SPECiFiCATIONS _ 3
POSSIBLE DAMAGE TO THE ROPS CAB OR ROPS CANOPY 3
MAINTENANCE AND INSPECTION OF THE ROPS CAB OR ROPS CANOPY 3
IllUSTRATION OF ROPS CANOPY INSTALLATION .4
ILLUSTRATION OF SEAT INSTALLATION 5
REMOVAL AND INSTALLATION OF ROPS CAB 6
REMOVAL AND INSTALLATION OF ROPS CANOPY 14
REMOVAL AND INSTALLATION OF HEATER _ 15
REMOVAL AND INSTALLATION OF TEMPERATURE CONTROL 17
SPECIAL TOOL
The tool shown is needed to remove the steering
wheel. Make the tool in your shop. Shown inuse instep
5.
4
6 7 8902174J
Make from 1/4in (3 mm) Cold Rolled Steel
1. 2 In (50mm)
2. 1In (25mm)
3. 5/8In (19mm)
4. 3/8In (9.5mm)
5. 3/4In (19mm)
6. Two Holes, 7/32 In (5.5 mm)
7. Use Np. 4 Drill for 1/4 - 24
Threads Metric Thread Optional
Two 10-32 x 1 In Required
TORQUE SPECIFICATIONS
9005-3
Bolts tor front support of ROPS cab and canopy 220 to 264 pound-feet (298 to 358 Nm)
Cap screws for rear support of ROPS cab and canopy 600 to 720 pound-feet (813 to 976 Nm)
Nut tor steering wheel 384 to 444 pound-inches (43 to 50 Nm)
Bolt for rear POD mount 220 to 264 pound-feet (298 to 358 Nm)
Bolt for front center POD mount... 220 to 264 pound-feet (298 to 358 Nm)
Seat and seat belt torques See page 5
POSSIBLE DAMAGE TO THE ROPS CAB OR Ra PS CANOPY
If the machine has rolled over or the ROPS cab or
ROPScanopy has been insome type of accident (such
as hitting an overhead object during transport), you
must replace the ROPS cab or ROPS canopy to get as
much protection as you had originally.
After an accident, check for damage to the ROPS
cab or ROPS canopy, the operators seat, the seat belt,
and all accessories, wiring etc., in the ROPS cab or
ROPS canopy. Before operating the machine again, all
damaged parts must be replaced.
Do not weld or tryto straighten a ROPS cab or ROPS
canopy.
MAINTENANCE AND INSPECTION OF THE Ra PS CAB OR ROPS CANOPY
After every 500 hours of operation or every six
months, whichever comes first. do the following:
See illustration on page 4. Check the torque on the
ROPS cab or ROPS canopy mounting bolts. If neces-
sary, tighten the cap screws and nuts to the correct
torque.
See illustration on page 5. Check the operators seat
and the mounting parts for the seat belt. Make sure that
all nuts and cap screws aretight. Replace parts that are
worn or damaged.
9005-4
sur 8_17
470
9005-5
@
,
B870363R
9005-6
REMOVAL AND INSTALLATION OF ROPS CAB
STEP 1
If the machine has air conditioning. discharge the air
conditioning system according to instructions in
Section 9003.
NOTE: After installation, charge the air conditioning
system according to instructions in Section 9003.
STEP 2
Turnthe temperature control to HOT and drain two U.S.
gallons (8 litres) of coolant from the radiator.
NOTE: After installation, return the coolant to the ra-
diator.
STEP 3
Remove the button.
STEP 4
Remove the nut.
NOTE: After installation, tighten the nut to 384 to 444
Bur 817470
STEP 5
Use the puller shown on page 2 to loosen and remove
the steering wheel.
STEP 6
Remove the three screws that hold the rear cover for the
steering column.
STEP 7
~
Remove the front and rear covers.
STEP 8
Disconnect the wiring for the turn signals.
STEP 9
Remove the screws that hold the control console.
STEP 10
Remove the control console.
Bur 8-17470
9005-7
STEP 11
Remove the bulbs for the turn signals and disconnect
the wiring from the lamp and warning flasher switches.
STEP 12
Remove the cap screws that hold the front of the ROPS
cab.
STEP 13
Remove the cap screws that hold the seat and remove
the seat.
9005-8
STEP 14
Remove the self-locking nut and shoulder bolt that
holds the cable for the left door.
STEP 15
Remove the self-locking nut that holds rod for the door
cylinder.
STEP 16
Remove the two screws at the bottom of the vertical
cover.
Bur 8-17470
STEP 17
Begin at the top and remove the vertical cover.
STEP 18
Remove the screws and the bottom cover.
STEP 19
Remove the screws that hold the guard for the instru-
ment console and remove the guard.
STEP 20
Remove the screws that hold the instrument cluster.
STEP 21
Disconnect the wiring and front lamp.
STEP 22
Disconnect the wiring harness.
STEP 23
Remove the nut that holds the key switch. Remove the
key switch from the panel.
Bur 8-17470
9005-9
STEP 24
Remove the collar from the cold start switch, if
equipped. Remove the cold start switch fromthe panel.
STEP 25
Remove the knobs.
STEP 26
Remove the screws that hold the cover.
9005-10
STEP 27
Disconnect the wiring from the cab lamp switch and
lamp for air conditioning.
STEP 28
Remove the nut that holds the air conditioning control
STEP 29
Remove the screws that hold the switch panel.
Bur 8-17470
STEP 30
Disconnect the wiring from the switches.
NOTE: Top, five wire plug; bottom front, four wire plug;
bottom rear, three wire plug.
STEP 31
STEP 32
Remove the bottom vertical cover.
STEP 33
Beginning at the bottom, remove the top vertical cover.
STEP 34
Remove the cap screws and flat washers that hold the
instrument console.
STEP 35
Drive the knob off the lever.
Bur 8-17470
9005-11
STEP 36
Remove the screws that hold the boot.
STEP 37
Loosen the set screw that holds the handle.
STEP 38
Slide the boot through the opening.
9005-12
STEP 39
Remove the instrument console.
STEP 40
Remove the cap screws that hold the support. There is
a cap screw at the top of the support.
STEP 41
Remove the nut, lock washer and bolt.
Bur 8-17470
STEP 42
Disconnect the wiring harnesses.
STEP 43
Remove the clevis and cotter pins that hold the shift
linkage.
STEP 44
Remove the hardware that holds the clamp, ROPS cab
only, and move the support out of the way.
STEP 45
.~
~~~
Disconnect the heater hoses and air conditioning
hoses, if equipped. Install caps and plugs on the air
conditioning hoses and tubes.
STEP 46
Remove the cap screws all around the bottom.
STEP 47
1. Hardened Washer
Remove the hardware at the front supports.
NOTE: During instal/ation, tighten the nuts to 220 to 264
pound-feet (298 to 358 Nm).
Bur 8-17470
9005-13
STEP 48
1. Hardened Washer
Remove the hardware at the side supports.
NOTE: During instal/ation, tighten the cap screws to
STEP 49
Remove the plugs, cap screws and retainers.
STEP 50
Fasten suitable lifting equipment to the roof and care-
fully remove the ROPS cab.
STEP 51
Install the ROPS cab in the reverse of removal.
9005-14
REMOVAL AND INSTALLATION OF ROPS CANOPY
1. Remove the hardware that holds the seat and
remove the seat.
NOTE: During instal/ation, tighten the cap screws to 80
to 96pound-feet (109to 130Nm).
2. Do steps 20 to 25and steps 35 to 45 under Removal
and Installation of ROPS Cab.
3. Disconnect the wiring harness for the lamps.
4. Remove the hardware, reinforcement plate and
support for both fenders.
B 902117J
5. Fasten suitable lifting equipment to the ROPS
canopy.
6. Loosen and remove the hardware that fastens the
floor plate to the front supports.
B 902176J
Bur 8-17470
7. Remove the hardware at the front supports.
NOTE: During installation, tighten the nuts to 220to 264
8. Remove the hardware at the side supports.
NOTE: During installation, tighten the cap screws to
9. Carefully raise and remove the ROPS canopy.
10. Install the ROPS canopy in the reverse of removal.
9005-15
REMOVAL AND INSTALLATION OF HEATER
1.Turn the temperature control to HOT and drain one
U,S. gallon (4 litres) of coolant from the radiator,
NOTE: During installation, return the coolant to the ra-
diator.
2, Remove the knobs from the control panel.
3, Remove the screws that hold the control panel. Dis-
connect thewires from the switch for the cab lamp and
the lamp for air conditioning,
4, Remove the screws atthe bottom of the vertical cover
and remove the vertical cover beginning at the top,
5, Remove the screws at the bottom of the left vertical
cover and remove the leftvertical cover beginning atthe
top,
6. Hold the front headliner in place and remove all
screws that hold the front headliner,
7, Lower the front headliner onto the control console,
Bur 8-17470
8, If equipped with air conditioning, loosen the clamp
on each front drain hose and remove the drain hoses
from the drain pan,
9, Hold the rear headliner in place and remove all
screws that hold the rear headliner. Lower the rear
headliner behind the seat.
10, Disconnect the yellow wire from the wiring harness,
11. Hold the blower assembly inplace and remove the
five cap screws that hold the blower mount and remove
the blower assembly,
12, Loosen the clamps on the hoses at the heater and
remove the hoses,
13, Hold the heater inplace and remove the cap screws
that hold the heater and remove the heater,
14, Install the heater in reverse of removal.
Issued 1-91 Printed in U,S.A
9005-76
"
Bur 8-17470
ISsued 1-91
Printed in U.SA
REMOVAL AND INSTALLATION OF TEMPERATURE CONTROL
9005-17
\
\
B902178J
1. Temperature Control
1.Turn the temperature control to HOT and drain one
U.S. gallon (4 litres) of coolant from the radiator.
NOTE: During installation, return the coolant to the ra-
diator.
2. Remove the knobs from the control panel.
3. Remove the screws that hold the control panel. Dis-
connect the wires from the switch for the cab lamp and
the lamp for air conditioning.
4. Remove the screws atthe bottom of the vertical cover
and remove the vertical cover beginning at the top.
5. Remove the screws that hold the switch panel.
6. Remove the nut that holds the air conditioning
control.
7. Remove the screws that hold the switch mount.
Bur 8-17470
8. Disconnect the wiring from the switches.
NOTE: Top, five wire plug; bottom front, four wire plug;
bottom rear, three wire plug.
9. Loosen the top clamp and remove the hose from the
temperature control.
10. Remove the screws that hold the temperature
control.
NOTE: During installation, make sure that the two
ground wires are installed with the bottom screw.
11. Loosen the bottom clamp and remove the tempera-
ture control.
NOTE: During installation, make sure that the tempera-
ture control is aligned with the control panel.
12. Install the temperature control in the reverse of
removal.
Sect i on
9006
BACKHOE
CASE CORPORATION
Bur 8-12741
Printed in U.S.A.
Issued March 1991
9006-2
TABLE OF CONTENTS
REMOVAL OF SWING TOWER" , , , , , , , , , , " ,.3
INSTALLATION OF SWING TOWER " ,.., , , '' , , ,., ,..', 4
REMOVAL OF BOOM ,., '., ,'..,..' , ' ', ",., " , " , ,.., ,., 5
INSTALLATION OF BOOM , , , ,.., ",., , ,." ,..,., ',., ' , 6
REMOVAL OF DiPPER ".,., .." , , , , , "." ..,."" , 6
INSTALLATION OF DIPPER , , 7
REMOVAL OF DIPPER EXTENSION,., , ", , , " " , 7
INSTALLATION OF DIPPER EXTENSiON , , , 8
REPLACING WEAR PLATES FOR DIPPER WITH EXTENDABLE DiPPER., ,.., , ,., , 8
CUTIING EDGES
Universal and Heavy Duty Buckets .., ', ,..'",' "." , "..""""'''' .,., ,"""" ,.', " , , '"..,..9
High Capacity Buckets " " , ,., , ".., , " "", ..,."., ' , ,10
Standard Duty Trenching Buckets ,..,..,'., ,,' ," , ' ,., , ", ,." , 11
BUCKET TEETH
Replacing a Tooth Point..; , , , ' , , , ', 12
Replacing a Tooth Shank, ,.,..,,.." ' ' ', ,., , , " ,' ,..,' '..,.",..,..' , ,.' , , 12
EXPLODED VIEWS
Stabilizer Installation .,., , , , '., 14
Stabilizer Cylinder Hydraulic Installation ,.., ,.., , , 15
Swing Tower and Swing Cylinder Installation , , , 16
Sequence Valve Linkage .." , ".., , , , , 17
Swing Cylinder Hydraulic Installation , , , ', ,.." , , 18
Boom latch Installation , , 19
Boom and Dipper Installation ,., ,., ', 20
Boom Cylinder Hydraulic Installation , , , ' 21
Dipper Cylinder Hydraulic Installation , 22
Quick Coupler and Bucket Installation , , ", , ,., , , 23
Bucket Cylinder Hydraulic Installation Without Extendable Dipper 24
Extendable Dipper Installation , , " " , 25
Extension Cylinder Hydraulic Installation, , , , , , , , 26
Bucket Cylinder Hydraulic Installation With Extendable Dipper , , .27
Auxiliary Hydraulic Installation With Extendable Dipper , 28
Bur 8-12741
Issued 3-91 Printed in U.S,A
9006-3
REMOVAL OF SWING TOWER
1. Remove all dirt from the hose connections at the
(r/min).
3. Hold the bucket control lever inthe LOAD position until
the bucket stops moving.
4. Extend the dipper and boom as far as possible inthe
space that is available and lower the bucket to the floor.
5 Fasten suitable lifting equipment to the boom and
dipper pivot area to prevent the boom and dipper from
falling when the boom is free of the swing tower.
6. Move the control levers for the backhoe in either di-
rection to relieve any pressure in the circuits.
7. Disconnect the hoses from the backhoe control valve
one at a time and fasten an identification tag to each
hose.
8. Install a cap on each fitting and a plug in each hose.
9 Loosen and remove the self-locking nuts and flat
washers that hold the vertical clamps near the center of
the swing tower.
10. Remove the bolts and the clamps.
11. Loosen and remove the self-locking nuts, flat
washers, bolts and the horizontal clamp at the rear of
the swing tower.
12. Write a number on each clamp ring so that the
hoses will be installed inthe correct notch during instal-
lation.
13. Fasten suitable lifting equipment to the boom
cylinder to hold the boom cylinder while the pivot pin is
being removed.
14. Remove the snap ring and flat washer(s) from one
end of the pivot pin for the boom cylinder.
15. Drive the pivot pin out of the swing tower and
remove the driver.
16. Lower the boom cylinder until the boom cylinder
touches the boom and remove the lifting equipment.
17. Use other suitable lifting equipment to hold the
boom when the pivot pins for the boom are removed.
Bur 8-12741
18. Loosen and remove the cap screws, hardened
washers and spacers that hold the pivot pins for the
boom.
19 Remove the pivot pins for the boom.
NOTE: Flat washers are installed between the boom
and swing tower to center the boom in the swing tower.
20. Carefully move the machine away from the boom.
21. Remove the snap ring and flat washer(s) from one
end of the pivot pins for the piston rod eyes of the swing
cylinders.
22. Use a hammer or hydraulic ram and a suitable
driver and remove the pivot pins from the swing tower.
23. Remove a snap ring and flat washer(s) from one
end of the pivot pin for the boom latch.
24. Loosen the set screw in the boom latch and drive
the pivot pin out of the swing tower and remove the
driver.
25. Move the boom latch out of the way
26. Loosen and remove the self-locking nut and flat
washer from the bolt that holds the cam on the top pivot
pin for the swing tower.
27. Remove the bolt and flat washers used as spacers
Record the amount of flat washers used for use during
installation.
28. Remove the snap ring and flat washer from the
bottom of the the bottom pivot pin for the swing tower.
29. Fasten suitable lifting equipment to the swing tower.
30. Use a hammer or hydraulic ram and a suitable
driver and remove the bottom pivot pin.
31. Remove the snap ring and flat washer that hold the
top pivot pin for the swing tower.
32 Drive the top pivot pin out of the swing tower.
33. Remove the swing tower from the frame.
34. Remove the thrust washer from the swing tower or
the bottom support for the swing tower.
9006-4
INSTALLATION OF SWING TOWER
1. Installation of the swing tower is the reverse of
removal.
2. The bottom pivot pin for the swing tower must be in-
stalled so that the grease fitting is on top.
Bur 8-12741
3. Lubricate all pivot pins with molydisulfide grease.
4. With the engine running at 1000 rpm (r/rnin), slowly
operate the bucket, dipper, extension, if equipped, and
boom cylinders through four complete cycles to
remove any air from the circuits.
9006-5
REMOVAL OF BOOM
1. With the engine running at low idle, hold the bucket
control lever inthe LOAD position until the bucket stops
moving.
2. Put the boom and dipper in a suitable position for
removal of these parts with the bucket on the floor.
3. With the engine stopped, move the dipper control
lever ineither direction to relieve any pressure inthe cir-
cuits.
4. Fasten suitable lifting equipment to the dipper
cylinder to hold the dipper cylinder for removal of the
pivot pin for the piston rod eye.
5 Remove the snap ring and flat washer that hold the
pivot pin for the piston rod eye of the dipper cylinder.
6. Drive the pivot pin out of the dipper and remove the
driver.
7. Raise the dipper cylinder for access to the hoses
inside the boom
8. Disconnect the hoses from the bucket cylinder at the
tubes inside the boom and fasten an identification tag
to one hose.
9. Install and tighten a plug in each tube and a cap on
each hose.
10. If equipped with an extendable dipper, disconnect
the hoses from the extension cylinder and the tubes
inside the boom and fasten an identification tag to one
hose.
11. Install a plug ineach tube and a cap on each hose.
12. Fasten the lifting equipment to the dipper.
13. Loosen and remove the self-locking nut and
hardened washer that hold the pivot pin for the dipper.
14. Drive the pivot pin out of the dipper and remove the
driver.
15. Move the dipper out of the way.
16. Fasten the lifting equipment to the boom.
Bur 8-12741
17. Remove the snap ringand flat washer fromone end
of the pivot pin for the piston rod eye of the boom
cylinder.
18. Drive the pivot pin out of the boom.
19. Move the boom cylinder toward the machine and
use a chain to hold the boom cylinder out of the way.
20. Disconnect the hoses from the dipper cylinder from
the tubes inside the boom.
each hose.
22. Fasten lifting equipment to the dipper cylinder for
removal of the dipper cylinder.
23. Remove the snap ring and flat washer fromone end
of the pivot pin for the dipper cylinder.
24. Drive the pivot pin out of the boom and remove the
driver.
25. Remove the dipper cylinder.
26. Lower the boom to the floor and use the lifting
equipment to hold the boom when the pivot pins for the
boom are removed.
27. Disconnect the hoses at the bottom of the boom
from the tubes inside the boom one at a time and fasten
an identification tag to each hose.
each hose.
29. Loosen and remove the cap screw, hardened
washer and spacer that hold each pivot pin for the
boom.
30. Remove the pivot pins for the boom.
NOTE: Flat washers are installed between the boom
and swing tower to center the boom in the swing tower.
31. Remove the boom and check for flat washers being
used between the swing tower and the boom.
9006-6
INSTALLATION OF BOOM
1. Install new seals at all pivot points.
2. Installation is the reverse of removal.
3. For original or new booms, measure the distance
between the ears of the boom at the dipper pivot point
and record the measurement. Before installing the self-
locking nut, install flat washers on the pivot pin that will
pull the ears of the boom together 1/16 to 1/8 inch (1to
3mm).
4. Tighten the self-locking nut for the pivot pin for the
dipper to 500 to 550 pound-feet (678 to 746 Nm).
5. Lubricate the pivot pins with molydisulfide grease.
6. With the engine running at 1000 rpm (r/rnin), slowly
operate the bucket, dipper, and extension, if equipped,
cylinders through four complete cycles to remove any
air from the circuits.
REMOVAL OF DIPPER
1. With the engine running at 1000 rpm (r/rnin) use the
backhoe controls as required so that the bucket teeth
are just off the floor and below the pivot pin for the
bucket.
2. Remove the Klik pin from the pivot pin for the bucket.
3. Remove the pivot pin for the bucket.
4. Use the boom, dipper and bucket controls as
required to disengage the coupler from the bucket.
5. Move the bucket out of the way.
6. Retract the bucket cylinder and put the boom and
dipper in a suitable position for removal of the dipper.
7. With the engine stopped, move the bucket control
lever and the extension control lever, if equipped, in
both directions to relieve any pressure in the circuits.
8. Fasten suitable lifting equipment to the dipper
cylinder.
9. Remove a snap ring and flat washer from one end of
thepivot pin for the piston rod eye of the dipper cylinder.
10. Drive the pivot pin out of the dipper.
Bur 8-12741
11. Raise the dipper cylinder for access to the hose
connections inside the boom.
12. Disconnect the hoses from the bucket cylinder at
the tubes inside the boom and fasten an identification
tag to one hose.
each hose.
14. If equipped with an extendable dipper, disconnect
the hoses from the extension cylinder at the tubes
inside the boom and fasten an identification tag to one
hose.
each hose. Thread size is 1-1/16-12.
16. Fasten the lifting equipment to the dipper to hold
and remove the dipper.
17. Loosen and remove the self-locking nut and
hardened washer(s) from the pivot pin for the dipper.
18. Drive the pivot pin out of the dipper.
19. Remove the dipper.
INSTALLATION OF DIPPER
9006-7
1. Install new seals inthe bores for the pivot pin for the
dipper.
3. Before installing the dipper, measure the distance
between the ears of the boom at the dipper pivot and
record the measurement. Before installing the self-
locking nut, install flat washers on the pivot pin so that
the ears of the boom will be pulled together 1/16 to 1/8
inch (1to 3 mm) when the self-locking nut is tightened.
4. Tighten the self-locking nut for the pivot pin for the
dipper to 500 to 550 pound-feet (678 to 746 Nm).
6. With the engine running at 1000 rpm (r/min), slowly
operate the bucket cylinder and the extension cylinder,
if equipped, through four complete cycles to remove
any air from the circuits.
REMOVAL OF DIPPER EXTENSION
1. With the engine running at 1000 rpm (rim in) use the
backhoe controls as required so that the bucket teeth
are just off the floor and below the pivot pin for the
bucket.
2. Remove the Klik pin from the pivot pin for the bucket.
3. Remove the pivot pin for the bucket.
4. Use the boom, dipper and bucket controls as
required to disengage the coupler from the bucket.
5. Move the bucket out of the way.
6. Completely extend the dipper and raise or lower the
boom so that the end of the dipper is approximately 3
feet (1 m) above the floor.
7. Completely retract the bucket cylinder and stop the
engine.
8. Put a block under the bucket cylinder to hold the
bucket cylinder when the pivot pin for the piston rod eye
is removed.
9. Remove a snap ring and flat washer from one end of
the pivot pin for the piston rod eye of the bucket
cylinder.
Bur 8-12741
10. Drive the pivot pin out of the guide links.
11. Slowly remove the driver and lower a guide link and
then the coupler and the other guide link.
12. Remove the snap ring and flat washer from each
endof the pivot pin for the guide links and the piston rod
eye of the extension cylinder.
13. Remove the guide link and flat washer from each
end of the pivot pin.
14. Drive the pivot pin out of the dipper extension and
remove the driver.
NOTE: The weight of the dipper extension and the
coupler is approximately 395 pounds (179 kg). The
length of the dipper extension is approximately 5-112
feet (1.7 my.
15. Fasten suitable lifting equipment to the dipper ex-
tension approximately two feet (0.6 m) from the bucket
end of the dipper extension to hold and remove the
dipper extension.
16. Install a bar through the hole for the pivot pin for the
bucket and loosen the lifting equipment and pull the
dipper extension off the dipper. Repeat this step until
the dipper extension is free of the dipper. Be careful
because the dipper extension can be out of balance on
the lifting equipment.
9006-8
INSTALLATION OF DIPPER EXTENSION
2. After the dipper extension has been pushed onto the
dipper, use the transport lock pin to hold the dipper ex-
tension in place.
REPLACING THE WEAR PLATES FOR DIPPER WITH EXTENDABLE DIPPER
1. Remove the dipper extension according to instruc-
2. Loosen and remove the cap screws, flat washers,
side wear plates only, retainers, wear plate(s) and
shim(s).
3. Remove the grease fromthe sides and bottom of the
dipper.
4. Select shims for the bottom wear plate so that the
bottom wear plate will be even with or up to 0.030 inch
(0.8 mm) beyond rails on the dipper.
5. Install the shim(s), wear plates, retainers and cap
screws. Tighten the cap screws to 480 to 540 pound-
inches (54 to 61 Nm).
6. Select shim(s) for the top wear plate so that the
distance from the bottom of the bottom wear plate and
the top of the top wear plate is 9-3/16 inch (233 mm).
Bur 8-12741
7. Install the shim(s), wear plates, retainers and cap
screws. Tighten the cap screws to 480 to 540 pound-
inches (54 to 61 Nm).
8. Select shim(s) for the side wear plates so that the
side wear plates will be even with or or up to 0.030 inch
(0.8 mm) beyond the rails on the dipper.
9. Install the shim(s), wear plates, retainers, flat
washers and cap screws. Tighten the cap screws to
480 to 540 pound-inches (54 to 61 Nm).
10. Apply molydisulfide grease to the rails on the
dipper.
11. Remove the grease from the inside of the dipper ex-
tension.
12. Install the dipper extension according to instruc-
9006-9
CUTTING EDGES
Uni versa l a nd Hea vy Dut y Bucket s
Repl a ci ng Bot t om Cut t i ng Edge
1. Remove the bucket teeth. Use carbon arc rod or an
acetylene cutting torch to remove the welds
IMPORTANT: When removing the bottom weld at the
rear of the bottom cutting edge, DO NOTcut through the
bottom of the bucket.
2, Use carbon arc rod or an acetylene cutting torch to
remove the welds that hold the bottom cutting edge.
3. Use a grinder and remove any welds still on the
bucket and any extra metal so that the new bottom
cutting edge will fit the bucket.
4. Hold the newbottom cutting edge in place and make
several tack welds to hold the bottom cutting edge.
5. See the following illustration for the weld locations
and specifications. DO NOT make any welds on the
inside of the bucket except the bottom of the bucket to
the bottom cutting edge. Use E7018 welding rod and
weld the bottom cutting edge in place.
\
B892350J
1. Universal Bucket - 5 79 Inches (147 mm)
Heavy Duty Bucket - 5-15/16 Inches (151 mm)
2. Universal Bucket - 1.73 Inch (44 mm)
Heavy Duty Bucket - 1-7/8 Inch (47mm)
3. 7/16Inch (10 mm) Fillet Top and Bottom
4. Fill Groove Return Wear Plates and
Bottom Cutting Edge
5. 1/4Inch (6mm) Fillet All Around.
6. Two Pass 1/4 Inch (6 mm) Weld To Fill Void.
Bur 8-12741
6. See the following illustration and install the corner
bucket teeth and weld the bucket teeth in place. Use
E7018 welding rod.
B861750R
1. 1/2Inch (14mm)
2. 7/8Inch (20 mm) No Weld
3. No Weld, Top Only
4. First Weld. 7/16 Inch (10 mm) Flare
Bevel Weld
Second Weld. 7/16 Inch (10 mm)
Fillet Weld.
5. Bottom All Around 5/16 Inch (8mm)
Fillet. Weld Two Times
6. 5/16Inch (8mm) Fillet. Weld Two Times
7. Weld the remaining bucket teeth to the bottom
cutting edge according to the instructions in this
section.
Repl a ci ng Si de Cut t i ng Edge
remove the welds that hold the side cutting edge.
2. Use a grinder and remove any welds still on the
bucket and any extra metal so that the newside cutting
edge will fit the bucket.
3. Use E7018 welding rod and weld the side cutting
edge to the bucket with a 1/4 inch (6 mm) fillet all
around the side cutting edge.
Issued 3-91 Printed in U.S,A.
9006-10
Hi gh Ca pa ci t y Bucket s
acetylene cutting torch to remove the welds.
2. Remove all welds that hold the bottom cutting edge
in place. Use carbon arc rod or an acetylene cutting
torch to remove welds.
3. Cut through each corner of the bottom cutting edge
and bucket.
4. Remove the cutting edge from the bucket.
5. Use a grinder to remove anywelds still on the bucket.
Remove any extra metal so that the new cutting edge
will fit the bucket.
6 Putthe new bottom cutting edge in place and use C-
clamps to hold the bottom cutting edge in place.
7. See the following illustration for weld locations and
specifications. Use E7018 welding rod and weld the
bottom cutting edge to the bucket.
B902037J
1. 1-7/8Inch (48mm)
2. 1/4Inch (6mm) Fillet
4. Groove Weld. Weld Two Times
5. 1-7/16 Inch (37mm)
Bur 8-12741
8. Fill the corners cut through during removal.
1. Remove all welds that hold the side cutting edge in
place. Use carbon arc rod or an acetylene cutting torch
to remove the welds.
2. Remove the side cutting edge from the bucket.
3. Use a grinder to remove any welds still on the bucket
and any extra metal so that the new side cutting edge
4. Put the side cutting edge inplace and use a C-c1amp
to hold the side cutting edge in place.
edge to the bucket with a 3/16 inch (5mm) fillet weld all
St a nda rd Dut y Trenchi ng Bucket s
acetylene cutting torch to remove the welds.
IMPORTANT: When removing the bottom weld at the
rear of the bottom cutting edge, do not cut through the
bottom of the bucket.
remove the welds that hold the bottom cutting edge.
3. Cut through each corner of the bucket to the rear of
the bottom cutting edge.
4. Remove the bottom cutting edge from the bucket.
and any extra metal so that the new bottom cutting
edge will fit the bucket.
6. Use C-c1amps to hold the bottom cutting edge on the
bucket.
7. See the following illustration for weld locations and
specifications. Use E7018 welding rod and weld the
bottom cutting edge to the bucket.
1. 1-7/16 Inches (36.5 mm)
2. 3/16 Inch (5 mm) Fillet
3. Fill Groove
4. 1-3/16 Inches (30 mm)
B902089J
BurB-12741
9006-11
8. Fill the corners cut through during removal.
1. Remove the welds that hold the side cutting edge.
Use carbon arc rod or an acetylene cutting torch
2. Remove the side cutting edge.
and any extra metal so that the new side cutting edge
4. Use C-clamps to hold the side cutting edge on the
bucket.
edge to the bucket with a 3/16 inch (5 mm) fillet weld all
9006-12
BUCKET TEETH
Repl a ci ng a Toot h Poi nt
1. Use a hammer and punch to remove the flexpin from
the tooth point.
2. Install the flex pin so that the shoulders aretoward the
cutting edge.
3. Install a newtooth point and drive a new flex pin into
the tooth point.
Repl a ci ng a Toot h Sha nk
remove the welds that hold the tooth shank.
2. Use a grinder to remove anywelds or extra metal that
will prevent the new tooth shank from fitting correctly.
3. Ifa new cutting edge has been installed, seethe illus-
trations on the following page for correct location of the
bucket teeth.
4. See the following illustration for weld specifications
for all bucket teeth except the corner bucket teeth for
the universal and heavy duty buckets. Use E7018
welding rod to weld the tooth shanks in place.
B861752R
1. 7/8 Inch (20 mm) No Weld
2. No Weld
3. 5/16Inch (8mm) Fillet Both Sides.
Weld Two Times
Bur 8-12741
5. Universal and heavy duty buckets only. See the fol-
lowing illustration for the weld specifications for the
corner bucket teeth. Use E7018 welding rod and weld
the tooth shanks in place.
B861750R
1. 11/16Inch (17mm)
2. 7/8Inch (20mm) No Weld
3. No Weld, Top Only
4. First Weld. 7/16 Inch (10 mm) Flare Bevel Weld.
Second Weld. 7/16 Inch (10 mm) Fillet Weld.
5. Bottom All Around 5/16 Inch (8mm) Fillet.
Weld Two Times
9006-13
1. Center Tooth
2. 0.50 In (12.7mm)
3. 18In (457mm) Bucket - 5.18In (131.5mm)
24 In (610 mm) Bucket - 7.13In (181mm)
30 In (762mm) Bucket - 8.86 In (225.1mm)
36 In (914mm) Bucket - 7.64In (194mm)
4. 18In (457mm) Bucket - 10.83 In (275mm)
36In (914mm) Bucket - 11.57In (294mm)
Toot h Loca t i on f or Hi gh
Ca pa ci t y Bucket s
4
1
B90203BJ
1. Centerline
2. Center Tooth
3. 24 In (610 mm) Bucket - 4.3 In (109 mm)
30 In (762mm) Bucket - 6.8In (173mm)
4. Put Tooth Shank as Near Corner as
Possible and Keep Tooth Point
0.5 In (12.7mm) Outside of Cutting Edge
Bur 8-12741
B872455J
5. 16In (406 mm) Bucket - 7.0 In (177.9 mm)
24 In (610 mm) Bucket - 10.98 In (279mm)
30 In (762mm) Bucket - 14.0 In (355.7mm)
36 In (914mm) Bucket - 22.44 In (570 mm)
6. 36 In (914mm) Bucket - 17.0 In (432mm)
7. 24 In (610mm) Bucket - 16.34In (415mm)
30 In (762mm) Bucket - 20.65 In (524.4mm)
36 In (914mm) Bucket - 27.83 In (707mm)
Toot h Loca t i on f or St a nda rd Dut y
Trenchi ng Bucket s
1
B902038J
1. Centerline
2. Center Tooth
3. 18In (457mm) Bucket - 3.56 In (90 mm)
4. 24 In (610 mm) Bucket - 5.4 In (137mm)
5. Put Tooth Shank as Near Corner as
Possible and Keep Tooth Point
0.5 In (12.7mm) Outside of Cutting Edge,
All Buckets Except 12in (305 mm) Bucket
Which Is Even with Outside of Cutting Edge
Issued3-91 Printedin USA
9006-14
.......... , .
8902834J
Bur 8-12741
Issued 3-91
Printed in U.S.A.
9006-15
B902704J
St a bi l i zer Cyl i nder Hydra ul i c Inst a l l a t i on
Bur 8-12741 Issued 3-91
Printed in U.S.A.
9006-16
e
B902B35J
1. Use Flat Washers As Required For 0.6 To 0.18 Inch (1.5 To 4.5 mm) Clearance Between the Top Pivot
Pin and the Boom Latch with the Backhoe in Transport Position.
Bur 8-12741
9006-17
Issued 3-91 Printed i n U.S.A.
9006-18
B902B36J
Bur 8-12741 Issued 3-91 Pri nt ed in U.S.A.
9006-
19
tTighten to 26
4
To 305 pound-Inches (3
1
to 36 Nm)
After putting Backhoe in Transport POSItionThree Times
Issued 3-9" \ pri nt ed i n U.S.A.
sur B-" \274" \
9006-20
1. See Installation of Dipper, Step 3.
2. Shim. Use as Required to Keep Boom Centered
in Swing Tower and Reduce Clearance.
B902837J
Bur 8-12741
9006-21
Bur 8-12741
9006-22
Dipper Cylinder Hydraulic Installation
Bur 8-12741
9006-23
B902839J
Bur 8-12741
9006-
24
\ \
'.'
o
6902958.1
BuCKetcylinder \ -IydrauliC Installation Witoo
ut
8dendable Dipper
ISsued3-91 printed in U.S.A
Bur 8_127
41
9006-25
1. Wear Plate
2. Shim
8902713J
Bur 8-12741
ISSued3-91 Printedin U.S.A.
9006-26
B870384R
Extension Cylinder HydrauliC Installation
Issued 3-91
Printed in U.S.A.
Bur 8-12741
9006-27
Bur 8-12741
Issued 3-91
Printed in U.S.A.
9006-28
Bur B-127
41
1. To Extension Cylinder
B902B40J
Issued 3-91
Printed in U.S.A
Sect i on
9008
THREE-POINT HITCH
1996 Case Corporation Bur 8-12761 Printed in U.S.A.
Issued March 1991
9008-2
TABLE OF CONTENTS
REMOVING THE THREE POINT HITCH 3
INSTALLING THE THREE POINT HITCH 3
EXPLODED VIEWS
Three Point Hitch .4
Cylinder Hydraulic Installation 5
Three Point Hitch Control Valve and Control lever Installation 6
Bur 8-12761
REMOVING THE THREE-POINT HITCH
9008-3
1. The attachment can stay on the three-point hitch.
Lower the attachment to the floor.
2. Move the control levers in either direction to relieve
any pressure in the circuits.
3. Disconnect all hoses from the three-point hitch
control valve one at atime and and fasten an identifica-
tion tag to each hose.
4. Install caps on the fittings and plugs in the hoses.
5. For machines with a ROPS cab, loosen and remove
the nuts, lock washers, flat washers and bolts that hold
the top closure panel.
6. Remove the top closure panel.
7. For machines with a ROPS canopy, loosen and
remove the nuts, lock washers and bolts that hold the
cover and remove the cover.
8. Fasten acceptable lifting equipment to the mounting
bracket for the control levers and the three point hitch
control valve.
9. Loosen and remove the nuts, lock washers and bolts
that hold the mounting bracket and remove the
mounting bracket assembly.
10. Raise the rear wheels off the floor and use accept-
able supports to hold the machine in place.
11. Loosen and remove the wheel nuts and the wheels.
12. Fasten acceptable lifting equipment to the three-
point hitch to hold the three-point hitch in place when
the bolts are removed.
13. Loosen and remove the nuts, hardened washers
and bolts that hold the three-point hitch.
IMPORTANT: Before the engine can be started, the
inlet and outlet hoses must be connected together. To
connect the hoses together, use tube union 218-854.
14. Move the machine away from the three-point hitch.
IMPORTANT: If the three-point hitch is not to be in-
stalled again, the rear counterweight or backhoe must
be installed before the machine can be used.
INSTALLING THE THREE-POINT HITCH
1. Move the machine into alignment with the three-point
hitch.
2. Install the hardened washers and bolts and the
hardened washers and nuts.
3. Tighten the nuts to 380 to 455 pound-feet (515to 615
N m).
4. Install the rear wheels and the wheel nuts. Do not use
an impact wrench to install the wheel nuts.
5. Tighten the wheel nuts to 320 to 380 pound-feet (435
to 515 N m).
6. Lower the wheels to the floor.
7. Align the mounting bracket assembly with the three-
point hitch and install the bolts, lock washers and nuts.
Tighten the nuts.
Bur 8-12761
8. Install the cover or top closure panel and the bolts,
flat washers, lock washers and nuts. Tighten the nuts.
9. Connect the hoses to the three-point hitch control
valve.
10. With the engine running at low idle, operate each
cylinder through three complete cycles to remove any
air from the circuits.
11. Stop the engine and check for oil leaks.
12. Check the level of the oil inthe reservoir and add oil
as required
9008-4
Bur 8-12761
Issued 3-91 .
Printed in U.S.A
9008-5
B902761J
Bur 8-12761
Issued 3-91 Printed i n U.S.A.
9008-6
Sect i on
9009
SEAT AND SEAT BELT
1996 Case Corporation Bur 8-12770 Printed in U.S.A.
9009-2
TABLE OF CONTENTS
STANDARD SEAT INSTALLATION
EXPLODED VIEW OF STANDARD SEAT. .. .
SUSPENSION SEAT INSTALLATION
EXPLODED VIEW OF SEAT SUPPORT ....
... 3
4
.................. . 5
. 6
Bur 8-12770
9009-3
Standard Seat Installation
Bur 8-12770
B891367J
lssuec 11-89 Printed in USA
Bur 8-12770
9009-4
s. BACK
CUSHION
1. CLIP
4. SHEll
Stand
ard S
eat
8870238R
ISsued
11-89
Printed
In U.SA
Bur 8-12770
9009-5
"
"
2
B891368J
Suspension Seat Installation
9009-6
B
2. SWIVEL LEVER
7. HEIGHT ADJUSTER
4. SHAFT
5. SLIDE TUBE BELLOWS
B891369J
Seat Support
Sect i on
9010
SUSPENSION SEAT
CASE CORPORA nON
Bur 8-12781
Printed in U.S.A.
9010-2
TABLE OF CONTENTS
DiSASSEMBLy _ _.._.._ _.__ ._._ 3
ASSEMBLy _ _ _ 7
9010-3
DISASSEMBLY
STEP 4 STEP 1
Remove the fasteners that hold the boot to the slide.
STEP 2
Drive the pin out of the knob and the adjuster rod and
remove the knob.
STEP 3
Use a prybar and remove the cover.
Bur 8-12781
Remove a C-clip from the shaft for the arm.
STEP 5
Remove the shaft.
STEP 6
Loosen and remove the cap screws that hold the seat.
9010-4
STEP 7
Remove the seat.
STEP 8
Remove an E-ring from the pivot pin for the shock ab-
sorber and remove the pivot pin.
STEP 9
Remove an E-ring from the pivot pin that holds the
shock absorber and remove the pivot pin and the shock
absorber.
Bur 8-12781
STEP 10
Make sure the tension of the springs has been released
and loosen and remove the self-locking nut from the
bottom of the adjuster rod.
STEP 11
Remove the springs.
STEP 12
The adjuster rod is threaded into the bottom of the
spring seat. Install the punch through the hole in the
adjuster rod and turn the adjuster rod out of the spring
seat.
STEP 13
Remove the spring seat.
STEP 14
Remove the springs.
STEP 15
Remove the cotter pins and pivot pins that fasten the
housing to the base.
STEP 16
Remove the housing.
Bur 8-12781
9010-5
STEP 17
Loosen and remove the cap screws that hold the base.
STEP 18
Remove the base.
9010-6
2. SHOCK ABSORBER
4. ADJUSTER SPRING
f 11. COTTER PIN
B870242R
Bur 8-12781
9010-7
ASSEMBLY
STEP 23 STEP 19
Install the base.
STEP 20
Install and tighten th~cap screws.
STEP 21
Install the housing
STEP 22
Install the pivot pins and cotter pins that hold the
housing.
Bur 8-12781
Install the springs.
STEP 24
Install the spring seat.
STEP 25
Turn the adjuster rod into the spring seat.
STEP 26
Install the springs.
9010-8
STEP 27
Install and tighten the self-locking nut on the bottom of
the adjuster rod.
STEP 28
Install the shock absorber, pivot pin and E-ring..
STEP 29
Align the piston rodeyewith the brackets and install the
pivot pin and E-ring.
Bur 812781
STEP 30
Install the seat.
STEP 31
Install and tighten the cap screws that hold the seat.
STEP 32
Raise the boot and install the shaft.
STEP 33
Install the C-c1ip.
STEP 34
Install the cover.
Bur 8-12781
9010-9
STEP 35
Align the knob with the adjuster rod and drive the pin
into the knob.
STEP 36
Fasten the boot to the slide.
9010-10
2. SEAT BACKREST
3. SEAT CUSHION
r
14. LH COVER
10. BOOT
Bur 8-12781

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Install the flywheel retaining bolts and tighten the bolts

Remove the bolts and the front cover.

Hitthespacer and snap ring to make sure that the snap

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