Académique Documents
Professionnel Documents
Culture Documents
http://BestManuals.net
Best.Manuals@yahoo.com
580 Super K Loader Backhoe
P.I.N. JJG0160001 and after
Service Manual
Table of Contents
Engines Tab 2
Section Index - Engine 8-17161
Engine Removal & Installation 2001 8-17560
Stall Tests 2002 8-12301
Detailed Engine Specifications 2402 8-24163
Cylinder Head & Valve Train 2415 8-24173
Cylinder Block 2425 8-24183
Lubrication System 2445 8-24193
Cooling System 2455 8-24203
Turbocharger 2465 8-25550
Turbocharger Failure Analysis 2565 9-78235
Electrical Tab 4
Section Index - Electrical 8-17200
Removal & Installation of Electrical Components 4001 8-17210
Specifications, Troubleshooting & Schematics 4002 8-17220
Batteries 4003 8-12350
Starter & Starter Selenoid 4004 8-11370
95 Ampere Alternator 4006 8-12381
65 Ampere Alternator 4007 8-15670
Instrument Cluster 4008 8-17230
Steering Tab 5
Section Index - Steering 8-17250
Removal & Installation of Steering Component 5001 8-17260
Specifications, Schematics & Troubleshooting 5002 8-17270
Steering Control Valve - Eaton 5004 8-12440
Steering Control Valve - Danfoss 5005 8-12450
Steering Cylinder 5006 8-17280
Front Axle - Two Wheel Drive 5007 8-12471
Front Axle - Four Wheel Drive 5008 8-17300
Description Section No Form No
Brakes Tab 7
Section Index - Brakes 8-17350
Parking Brake 7000 7-37040
Disc Brakes 7001 7-37050
Removal & Installation of Brake Components 7002 8-12540
Master Cylinder 7003 8-12570
Hydraulics TabS
Section Index - Hydraulics 8-12580
Removal & Installation of Hydraulic Components 8001 8-17580
Schematics, Specifications & Troubleshooting 8002 8-17530
Cleaning the Hydraulic System 8003 8-67390
Hydraulic Pump 8004 8-17400
Loader Control Valve 8005 8-17410
Cylinder 8006 8-17591
Backhoe Control Valve 8007 8-17430
Swing Sequence Valve 8008 8-12650
Three Point Hitch Control Valve 8009 8-67421
Double Selector Valve 8011 8-12670
TABLE OF CONTENTS
Printed in U.S.A.
CASE CORPORATION Bur 8-71600
Issued May 1988
1001-2
8113608
1001-3
811359A
1001-4
Nom.
SAE
Dash Thread Pound- Newton Thread Pound- Newton
Size Tube 00 Size Feet Metres Size Feet Metres
8871553
Section
1002
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS ... ....................................... 2
DIESEL FUEL . .. .4
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)
Brake Reservoir
Type of fluid Case TCH Fluid
Conversion Formulas
Imperial quart = litres x 0.879877
Imperial gallon = litres x 0.219969
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.
, 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
737L9
I I I I I I I I I I I I
-34' _29' -23' -18' -12' -7" _1' 4' 10' 16" 21' 27" 32' 38' 43' -49'
Temperature Celsius
DIESEL FUEL
Use NO.2 diesel fuel in the engine of Fuel Storage
this machine. The use of other fuels can
cause the loss of engine power and high If you keep fuel in storage for a period
fuel consumption. of time, you can get foreign material or
water in the fuel storage tank. Many
Invery cold temperatures, a mixture of engine problems are caused by water in
NO.1 and NO.2 diesel fuels is tempora- the fuel.
rily permitted. See the following Note.
Keep the fuel storage tank outside
NOTE: See your fuel dealer for and keep the fuel as cool as possible.
winter fuel requirements in your area. If Remove water from the storage con-
the temperature of the fuel is below the tainer at regular periods of time.
cloud point (wax appearance point), wax
crystals in the fuel will cause the engine
to lose power or not start.
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.
TABLE OF CONTENTS
RUN-IN INSTRUCTIONS. . 3
IDENTIFICATION MARKS
Crankshaft 4
Cylinder Block.... .. .4
Cylinder Head..... . ..4
Piston....... . 5
Piston Pin 5
Piston Rings 6
Lifters .. ... 6
Connecting Rod . 7
Crankshaft. 8
Camshaft 9
Turbocharger 9
Gear Train 9
Intake Valve... .. 10
Exhaust Valve 10
Valve Springs.......... . 11
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.
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.
The following procedure must be followed 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.
For the first 8 hours of field operation stay one gear lower than normal. For the next 12 hours 00 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.
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).
IDENTIFICATION MARKS
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
Letter X = 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.
Letter X = The cylinders in the cylinder block have been bored oversize. Use a head gasket with oversize cylinder holes
(one notch)
Letter XX = The cylinder block has been refaced and up to 0.25 mm has been removed use a thicker head gasket (DNa
notches) .
Letter XXX = The cylinder block has been ref aced 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.
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. 101.323 mm
1.0 mm Oversize Piston 102.873 to 102.887 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
Minimum Service Limit 39.990 mm
Piston Rings
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
Maximum Service Limit 0.806 mm
Side Clearance 0.075 to 0.120 mm
Maximum Service Limit . 0.15 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
Connecting Rod
Bushing . Steel Backed Leaded Bronze
Bushing 10 Installed (Ream to Size)........................................................... ..40.053 to 40.067 mm
Maximum Service Limit 40.092 mm
Bearing Liners...................... . Replaceable
Journal 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. . . . 0.200 mm
With Bushing . 0150 mm
Connecting Rod Twist (Maximum)
Without Bushing. . ,.. . 0.500 mm
With Bushing . . 0.300 mm
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 Journal
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 Limit........................................................... .. 68.712 mm
0.50 mm 00 Undersize, Grind to...................................... . 68.487 to 68.513 mm
Maximum Service Limit.. 68.462 mm
0.75 mm 00 Undersize, Grind to 68.237 to 68.263 mm
Maximum Service Limit............ . . 68.212 mm
1.00 mm 00 Undersize, Grind to....................... ...67.98 to 68.013 mm
Maximum Service Limit..................................... . 67.962 mm
Connecting Rod Journal Maximum Taper 0.013 mm
Journals 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 Journal
00, Standard 82.987 to 83.013 mm
Maximum Service. Limit..... . 82.962 mm
0.25 mm 00 Undersize, Grind to . 82.737 to 82.763 mm
Maximum Service Limit. 82.712 mm
0.50 mm 00 Undersize, Grind to 82.487 to 82.513 mm
Maximum Service Limit 82.462 mm
0.75 mm 00 Undersize, Grind to .......................................................................82.237 to 82.263 mm
Maximum Service Limit. 82.212 mm
1.00 mm 00 Undersize, Grind to 81.987 to 82.013 mm
Maximum Service Limit.. 81.962 mm
Main Bearing Journal Bore 10 No Liners 87.982 to 88.018 mm
Maximum Service Limit . 88.031 mm
Main Journal Width:
1st, 2nd, 3rd, 5th .. 37.424 to 37.576 mm
4th 37.475 to 37.525 mm
Connect Rod Journals Width 38.950 to 39.050 mm
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
ID of NO.1 Bushing, Installed 54.107 to 54.133 mm
Maximum Service Limit .. 54.146 mm
ID of NO.1 Oversize (57.24 mm 00) Service Bushing 54.089 to 54.139 mm
Maximum Service Limit 54.146 mm
10 of NO.2, 3, 4 and 5 Service Bushing 54.089 to 54.139 mm
Maximum Service Limit 54.146 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 Journal 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
Minimum Service Limit 9.34 mm
Camshaft Thrust Clearance 0.130 to 0.340 mm
Maximum Service Limit 0.470 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 0.1 0 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
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....... . 0.1 0 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
ID of Valve Guide Bore 8.019 to 8.039 mm
Maximum Service Limit 8.089 mm
Exhaust Valve
Tappet Clearance (Cold) 0.508 mm
Face Angle 44 Degrees
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
Minimum Service Limit 7.940 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
Valve Recession Below Head Surface 0.99 to 1.52 mm
Maximum Service Limit 1.52 mm
ID of Valve Guide Bore 8.019 to 8.039 mm
Maximum Service Limit 8.089 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
SPECIAL TORQUES
Metric Value
Aftercooler Bolts...... 21 to 27 Nm
Block Heater 11 to 13 Nm
Primer Pump 21 to 27 Nm
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.
Turbocharger............. ..2465
RADIATOR REMOVAL
Put identification tags on all disconnected hoses NOTE: During instal/ation the hood must be adjusted.
and wires. Close disconnected hoses and fittings with Put the hood in position. Install the hardware in the hood
caps and plugs. hinges. Do not tighten the hardware. Close the hood
and remove the plastic plugs for access to the hinge
NOTE: Cal/outs on the photographs are in the order hardware. Push the top of the hood to the rear as far as
of the procedure. possible and tighten the hinge hardware.
STEP 1
STEP 3
Install a hose on the drain valve (7) and drain the ra-
STEP 2 diator.
STEP 4 STEP 6
Remove the strap (10) from the top of the radiator Remove the hardware (14) from each side of the
shroud. (bolt, lock washer, and flat washer). radiator shroud. (bolts, flat washers, and nuts).
Remove the top cover (11). (bolts, lock washers, and Remove the radiator shroud. The weight of the radiator
flat washers). shroud is approximately 50 pounds (23 kg).
Remove the upper and lower foam baffles (12). 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 324 pound-feet (366 to 439
STEP 5 Nm).
STEP 7
ENGINE REMOVAL
Do steps 1 through 6 of radiator removal. STEP 10
STEP 8
Remove the battery cover (18) from the left step. (cap
screws and lock washers).
The hydraulic reservoir holds approximately 25 U.S.
gallons (95 litres) of oil. Drain the oil from the hydraulic
reservoir (16). STEP 11
STEP 9
STEP 12
~7
Remove the bottom cover (20). (bolts, lock washers,
and flat washers).
CHECK SHEET
1. _ (22301<Y2280-s-pe-cified) rpm (rim!ri)hydrauiiC 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
Turbocharger . 2465
TABLE OF CONTENTS
SPECIAL TOOLS 2
RADIATOR REMOVAL 3
ENGINE REMOVAL 5
SPECIAL TOOLS
Order special tools from one of the following ad-
dresses:
Service Tools
P.O. Box 314
Owatonna, Minnesota 55060
In Europe:
VL Churchill Ltd.
P.O. Box 3, Daventry
Northants, NN11 4NF CAS-1690 Rotation Tool
England This tool is first used on page 12.
RADIATOR REMOVAL
Put identification tags on all disconnected hoses NOTE: During installation the hood must be adjusted.
and wires. Close disconnected hoses and fittings with Put the hood in position. Install the hardware in the hood
caps and plugs. hinges. Do not tighten the hardware. Close the hood
and remove the plastic plugs for access to the hinge
NOTE: Cal/outs on the photographs are in the order hardware. Push the top of the hood to the rear as far as
of the procedure. possible and tighten the hinge hardware.
STEP 1
STEP 3
Install a hose on the drain valve (7) and drain the ra-
STEP 2 diator.
STEP 4 STEP 6
Remove the strap (10) from the top of the radiator Remove the hardware (14) from each side of the
shroud. (bolt, lock washer, and flat washer). radiator shroud. (bolts, flat washers, and nuts).
Remove the top cover (11). (bolts, lock washers, and Remove the radiator shroud. The weight of the radiator
flat washers). shroud is approximately 50 pounds (23 kg).
Remove the upper and lower foam baffles (12). 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 324 pound-feet (366 to 439
STEP 5 Nm).
STEP 7
ENGINE REMOVAL
Do steps 1 through 6 of radiator removal. STEP 10
STEP 8
Remove the battery cover (18) from the left step. (cap
screws and lock washers).
The hydraulic reservoir holds approximately 25 U.S.
gallons (95 litres) of oil. Drain the oil from the hydraulic
reservoir (16). STEP 11
STEP 9
STEP 12
STEP 13 STEP 15
Disconnect the two hoses (21) from the RH side of the Disconnect the two hoses (27) from the LH side of the
oil cooler. pump. Remove the bolts and lock washers that fasten
the flange (28) on the RH side of the pump.
Disconnect the two tubes (22) from the LH side of the oil
cooler. Remove the pump (29). (Bolts, lock washers, and
hardened washers on the lower two bolts).
STEP 16
STEP 17 STEP 19
Remove the hardware (33) that fastens the compressor Disconnect throttle rod (36).
to the bracket. (long bolt, flat washer, lock washer, and
nut). Remove the belt (34) and lay the compressor over Disconnect the wiring clamp (37).
the side of the frame.
Disconnect the wire from the oil pressure sender (38).
NOTE: During installation, adjust the drive belt ac-
cording to instructions in Section 9003. Disconnect the fuel shutoff wire (39).
STEP 20
Loosen the clamp (46) and remove the hose from the
turbocharger.
STEP 21 STEP 23
Remove harness clamp (48). Disconnect the wires (54) from the starter.
Disconnect the wire (49) from the temperature sender. Disconnect the ground strap (55). (bolt and lock
Cut the tie straps that fasten the harness to the fuel washer).
lines.
Remove the hardware (56) for the engine mount. (bolt,
flat washer, and nut).
STEP 22
NOTE: During installation, tighten the nut to 135 to 165
pound-feet (183 to 224 Nm).
STEP 24
STEP 25 STEP 27
Remove the clamp (61). Disconnect the hose (64) from the torque converter.
STEP 28
Disconnect the tube (62) from the top of the filter head.
STEP 30
STEP 36 STEP 39
Hold the torque converter in place and install the cap Install the CAS-1690 tool to rotate the flywheel.
screws and lock washers.
STEP 40
STEP 37
STEP 38
STEP 41
STEP 42 STEP 44
Remove the CAS-1690 tool and install the plastic plug. Install the cap screws and lock washers. Tighten the
cap screws to 456 to 540 pound-inches (52 to 61 Nm).
NOTE: On machines with PTa, Apply Loctite 504 to the
edge of the flywheel housing.
STEP 43
STEP 45
STEP 48
B892300J
STEP 46
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 STEP 51
When the front engine support is centered, tighten the Remove the CAS-1690 tool and install the plastic plug.
cap screws to 66 to 79 pound-feet (89 to 107 Nm).
TABLE OF CONTENTS
SPECIFICATIONS
The specifications are the same for the naturally aspirated and turbocharged engines.
GENERAL INFORMATION
Do the stall test to find the cause of poor perfor- Use a photo tachometer or other tachometer of
mance. equal accuracy to get accurate results from the stall
test.
The engine is run at full throttle and the transmission
and hydraulic systems are engaged separately, and The engine, transmission and hydraulic system
then together. must be at operating temperature before doing the stall
test. Heat the oil according to instructions in this
Comparing the engine speeds from the stall test section.
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 system to find the exact cause of the problem.
3. With the engine running at full throttle, hold the 7. Run the engine at full throttle for 15 seconds.
loader control lever in ROLLBACK for 15 seconds.
8. Decrease the engine speed to low idle and move
4. Return the loader control lever to NEUTRAL for 15 the direction control lever to NEUTRAL for 15 seconds
seconds.
9. Repeat steps 6 through 8 until the pointer in the
5. Repeat steps 3 and 4 until the temperature of the oil gauge for transmission oil temperature is in the center
is 125F (52C). The side of the reservoir will be very of the green zone or the lamps in the optional instru-
warm at this temperature. 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 7. Slow!y increase the engine speed to full throttle and
instructions in this section. read the tachometer. Write the reading on line 2 on the
check sheet.
2. Heat the oil according to instructions in this section.
8. With the transmission control lever in fourth gear,
3. Apply the parking brake and start the engine. the direction control lever in FORWARD, and the engine
running at full throttle. hold the loader control lever in
4. With the engine running at full throttle, hold the ROLLBACK and read the tachometer. Write the reading
loader control lever in ROLLBACK and read the tachom- on line 3 on the check sheet.
eter. Write the reading on line 1 on the check sheet.
9. Decrease the engine speed to low idle (two
5. Decrease the engine speed to low idle. minutes with turbocharger) and stop the engine.
6. Move the transmission control lever to fourth gear 10. See the check sheet to understand the results of
and the direction control lever to FORWARD. the stall test.
CHECK SHEET
1. _ (2230 to 2280 specified) rpm (r/min) hydraulic 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
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.
TABLE OF CONTENTS
RUN-IN INSTRUCTIONS 3
IDENTIFICATION MARKS
Crankshaft 4
Cylinder Block 4
Cylinder Head .4
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
Intake Valve 10
Exhaust Valve 10
Valve Springs 11
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.
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.
The following procedure must be followed 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
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).
IDENTIFICATION MARKS
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
Letter X = The cylinder block has been refaced and up to 0.25 mm has been removed. Use a thicker 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.
Letter V = Valve seats have been machined.
Letter X = The cylinders in the 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.
Letter XX = The cylinder block has been refaced and up to 0.25 mm has been removed use a thicker 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.
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
0.5 mm Oversize Piston 102.373 to 102.387 mm
Minimum Service Limit. 101.323 mm
1.0 mm Oversize Piston 102.873 to 102.887 mm
Minimum Service Limit. , 102.823 mm
10 of Piston Pin Bore .40.006 to 40.012 mm
Maximum Service Limit 40.025 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 (Maximum) 0.660 mm
Protrusion Above Cylinder Block (Minimum) 0.280 mm
Piston Pin
Type Full Float
00 of Pin , 39.997 to 40.003 mm
Minimum Service Limit 39.990 mm
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
Maximum Service Limit. 0.15 mm
NO.2 Compression Rectangular Type (Tapper Face)
End Gap in 102.021D 0.25 to 0.55 mm
Maximum Service Limit. 0.806 mm
Side Clearance 0.075 to 0.120 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.:
Prior to Engine Serial Number 45511034 Injector Nozzle 9 mm
Engine Serial Number 45511034 and After Injector Nozzle 7 mm
Engines Manufactured in Darlington England:
Prior to Engine Serial Number 21092870 Injector 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
OD 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
Connecting Rod
Bushing Steel Backed Leaded Bronze
Bushing ID Installed (Ream to Size) 40.053 to 40.067 mm
Maximum Service Limit 40.092 mm
Bearing Liners Replaceable
Journal 10 Without Bearing Liners 72.987 to 73.013 mm
Bearing Oil Clearance 0.038 to 0.116 mm
Maximum Service Limit 0.129 mm
Side Clearance 0.100 to 0.300 mm
Maximum Service Limit 0.330 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 .
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 Journal
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
0.75 mm OD Undersize, Grind to 68.237 to 68.263 mm
Maximum Service Limit.. 68.212 mm
1.00 mm OD Undersize, Grind to. .. . 67.987 to 68.013 mm
Maximum Service Limit.............................................. .. 67962 mm
Connecting Rod Journal Maximum Taper.................................................. .. 0.013 mm
Journals 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 Oil Clearance 0.041 to 0.119 mm
Maximum Service Limit 0.140 mm
Main Bearing Journal
OD, Standard 82.987 to 83.013 mm
Maximum Service Limit. 82.962 mm
0.25 mm OD Undersize, Grind to 82.737 to 82.763 mm
Maximum Service Limit. 82.712 mm
0.50 mm OD Undersize, Grind to 82.487 to 82.513 mm
Maximum Service Limit. 82.462 mm
0.75 mm OD Undersize, Grind to 82.237 to 82.263 mm
Maximum Service Limit. 82.212 mm
1.00 mm OD Undersize, Grind to 81.987 to 82.013 mm
Maximum Service Limit. 81.962 mm
Main Bearing Journal Bore 10 No Liners 87.982 to 88.018 mm
Maximum Service Limit 88.031 mm
Main Journal Width:
tst, 2nd, 3rd, 5th.......................... . 37.424 to 37.576 mm
4th................................................... . 37.475 to 37.525 mm
Connect Rod Journals Width 38.950 to 39.050 mm
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
Maximum Service Limit 54.146 mm
10 of NO.1 Oversize (57.24 mm 00) Service Bushing 54.089 to 54.139 mm
Maximum Service Limit 54.146 mm
10 of No.2, 3, 4 and 5 Service Bushing 54.089 to 54.139 mm
Maximum Service Limit 54.146 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 Journal 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
Minimum Service Limit 9.34 mm
Camshaft Thrust Clearance 0.130 to 0.340 mm
Maximum Service Limit 0.470 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
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
00 of 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 Contact Width 1.32 to 1.92 mm
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
Valve Recession Below Head Surface 0.99 to 1.52 mm
Maximum Service Limit . 1.52 mm
10 of Valve Guide Bore 8.019 to 8.039 mm
Maximum Service Limit 8.089 mm
Exhaust Valve
Tappet Clearance (Cold) 0.508 mm
Face Angle 44 Degrees
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
Minimum Service Limit 7.940 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 Height 6.65 to 6.77 mm
00 of Insert .43.713 to 43.739 mm
10 of Insert Tapered
Valve Recession Below Head Surface 0.99 to 1.52 mm
Maximum Service Limit : 1.52 mm
10 of Valve Guide Bore 8.019 to 8.039 mm
Maximum Service Limit 8.089 mm
Rae 8-24163 Revised 2-92 Printed in U.S.A.
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
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
Metric Valve
Belt Tensioner Retaining Bolt .39 to 47 Nm
Block Heater 11 to 13 Nm
Camshaft Retaining Bolts...... 21 to 27 Nm
Metric Valve
Intake Manifold Bolts 21 to 27 Nm
Primer Pump 21 to 27 Nm
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.
IMPORTANT: This engine was made using the metric measurement system. NI
measurements and checks must be made with metric tools to make sure of an
accurate reading when inspecting parts.
TABLE OF CONTENTS
IDENTIFICATION MARKS 2
SPECIFICATIONS 3
SPECIAL TORQUES 4
SPECIAL TOOLS 5
IDENTIFICATION MARKS
letter G Thermostat passage in cylinder did not need to be machined.
letter X = The cylinders in the cylinder block have been bored oversize. Use a head gasket with oversize cylinder holes
(one notch).
Letter XX = The cylinder block has been refaced and up to 0.25 mm has been removed. Use a thicker 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.
Rae 8-24173 Revised 2-92 Printed in U.SA
2415-3
SPECIFICATIONS
ENGINES MANUFACTURED IN USA
Prior to Engine Serial Number 45511034 Injector Nozzle 9 mm
Engine Serial Number 45511034 and After Injector Nozzle 7 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
SPECIAL TORQUES
Alternator bracket bolts 21 to 27 Nm
SPECIAL TOOLS
B90288SJ
CAS-1066A Head Bolt Wrench
B9028B3J
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)
This tool is first used on Page 28.
'T68944
Lift the belt tensioner and remove the fan belt. Remove the belt tensioner bolts and the bracket.
STEP 2 STEP 5
i1
Remove the belt tensioner bolt and the belt tensioner. Remove the fan hub bracket bolts and the bracket.
STEP 3 STEP 6
Mc,iQ,I6~94g
Remove the fan hub bolts and the fan hub. Remove the bolts that hold the alternator and remove
the alternator.
STEP 7 STEP 10
STEP 8 STEP 11
Remove the thermostat bolts and the housing as- Disconnect and remove the fuel lines.
sembly.
STEP 12
STEP 9 4T-390 ENGiNE
I,
Install protective covers on the injection pump outlet
To remove the turbocharger see section 2465 in the lines and the injection lines.
service manual.
Remove the leak off fitting and gasket. Loosen the nut on the injectors.
STEP 17
STEP 18
15
Remove the leak off fittings, gaskets and the leak off
line.
. " .w N
T68983
Remove the fuel line fittings and the fuel line. Remove the inlet line.
STEP 20 STEP 23
:>.:,.;
T~8~9~j
Install a protective cover in the injection pump.
.~:..
. . ~~ ....-.:~
.
..------ ':T68994
Remove the inlet line. Remove the valve bolts and the valve covers.
STEP 25 STEP 28
Remove the intake manifold cover bolts and the intake Remove the lift bracket bolts and the lift bracket.
manifold cover.
STEP 29
STEP 26
STEP 27
~A#W T68~
Cover the cylinder bores and pistons. Clean all foreign
material from the cylinder head mounting surface.
Remove the push rods from the cylinder head.
NOTE: The cylinders and pistons must be covered to
prevent damage to the pistons and cylinder walls.
687~8'
Put the cylinder head on a clean work surface. Remove the valve seals.
STEP 32 STEP 35
;::
.
.~~,~ ../-)
. -"(.
~
6~Q7':l()
...'.~:::w:..
Use a valve spring compressor to push down the valve
springs. Remove the valve keepers.
Remove the valves.
STEP 33
{" -. "t-
~ ~...&
Remove the valve spring retainers and the valve spring.
.:.:.:
....pp
Clean the cylinder head completely. Remove carbon
and other deposits. Check for cracks and any other
B902888J
damage to the head.
".
STEP 39 STEP 40
B902889J
Specifications
Valve guide 00 14.026 to 14.038 mm
Bore cylinder head to 13.987 to 14.013 mm
Installed height above top of valve guide boss
on cylinder head 11.25 to 11.75 mm
STEP 41
B902891J
STEP 43
STEP 44
t
11.25 TO 11.75 mm
(\
DIAMETER OF
11.112 TO 11.138 mm
B902891J
I FINE PiniNG
8902895J
j
8902896J
8902893J
NOTE: GRIND OR REPLACE THE VALVE IF THIS CONDITION
OCCURS.
NOTE: REPLACE THE VALVE IF THIS CONDITION OCCURS.
This condition is generally caused by worn valve guides
This Condition Can Be Caused By: or bad seals on the valves. permitting oil to go by the
1. Valve does not have lubrication. valves. Low operating temperature is a secondary
2. Restriction in the water passages. cause. Worn piston rings and cylinder walls will also
3. Operating the engine under continued overload at permit too much oil to reach the combustion chamber.
too much engine RPM.
RUST OR PiniNG ON VALVE STEM
1
._-- GROOVE IN VALVE FACE
8902894J 8902897J
NOTE: REPLACE VALVE IF THIS CONDITION OCCURS.
7.960 TO 7.980 mm
B902901J
EXHAUST VALVES
CONCAVE VALVE HEAD
7.960 TO 7.980 mm
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.
B902902J
STEP 50
B902903J
Machine the cylinder head to the following specifica- Clean the recessed area in the cylinder head. Put the
tions for valve seats. new valve seats in dry ice for a minimum of one hour to
shrink the valve seats for easy installation. Use a driver
Exhaust Valve Seat Specifications: and install the valve seats.
A
Always wear gloves to prevent frostbite to
Diameter of Bore 43.647 to 43.663 mm your hands when handling frozen parts.
Depth of Bore 10.10 to 10.30 mm SM118A
Press Fit 0.05 to 0.092 mm
B902904J
30 DEGREE VALVE
VALVE IDENTIFICATION
44 DEGREE
ANGLE
B902905J
STEP 56 STEP 58
30 DEGREE VALVES
45 DEGREE VALVES
_ USE A 45 DEGREE 51
AND TO MAKE WIDER
- 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.
INE TO LIFT THE - USE A 60 DEGREE STONE TO LIFT AND - CHECK THAT THE VALVE HEAD IS NOT _ IF THE VALVE HEAD IS RE-
NARROW THE LOWER CONTACT AREA. RECESSED MORE THAN 1.52 mm BELOW 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 _ CHECK THAT THE VALVE HEAD IS NOT _IF THE VALVE HEAD IS RE-
THE CONTACT THE UPPER CONTACT AREA, IN- RECESSED MORE THAN 1.52 mm, BE- CESSED MORE THAN 1.52 mm,
CREASED BY THE 45 DEGREE STONE. LOW THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
IEPLACED AND A
! INSTALLED BE-
liNG WIU NOT
eONTACT POINT.
Printed in U.S.A.
2415-23
IF THE VALVE CONTACT AREA ON THE - USE A 30 DEGREE STONE TO LOWER -USEA60DE
SEAT LOOKS LIKE THIS. THE UPPER CONTACT AREA. LOWER CON
CONTACT AREA
_ 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
2415-24
E REPLACED AND A
TALLED BECAUSE
VILL NOT CHANGE
,CTPOINT.
B902909J
_1 DEGREE IN
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.
IF THE VAlVE CONTACT AREA ON THE _ USE A 30 DEGREE STONE TO LIFT THE
SEAT lOOKS LIKE THIS. CONTACT AREA.
Rae 8-24173
Revised 2-92 Printed in U.S.A.
ERFERENCE ANGLE -CORRECT REFACING OF EXHAUST
- IF THE VALVE HEAD IS RE-
VALVES AND VALVE SEATS WILL GIVE A CESSED MORE THAN 1.52 mm
1 DEGREE INTERFERENCE ANGLE. THIS REPLACE THE VALVE AND IN-
ANGLE IS IMPORTANT BECAUSE THE STALL A VALVE SEAT.
ANGLE GIVES ASSISTANCE IN CUTTING
CARBON AND TO SEAT THE VALVES.
'OEOR 60 DEGREE STONE -CHECK THAT THE VALVE HEAD IS NOT - IF THE VALVE HEAD IS RE-
THE LOWER CONTACT RECESSED MORE THAN 152 mm. BE- CESSED MORE THAN 1.52 mm
ED BY THE 30 DEGREE LOW THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
B90291 OJ
2415-26
- 1 DEGREE INTERFEREN(
iE TO LOWER - USEA45 DEGREE OR 60 DEGREE STONE _CHECK THAT THE VALVE HEAD IS NOT _IF THE VALVE HEAD IS RE-
lEA. TO LIFT THE LOWER CONTACT AREA. 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.
B902911J
Printed in U.S.A.
2415-27
904LO
If the cylinder head has been machined, mark the Install the valve spring the valve spring caps.
amount removed on the RH rear corner of the cylinder
head.
STEP 63
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
-';.;I:;~.
. -
:,.
~
.
STEP 61
r ~: ....
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.
8903013J
305L91
Remove the snap ring, washer and rocker arm from the Use a micrometer and measure the rocker arm shaft for
shaft. 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.
Rae 8-24173 Revised 2-92 Printed in U.S.A.
2415-29
STEP 68 STEP-:,w-69
Measure the rocker arm with a bore gauge in three dif- Use a micrometer to measure the bore gauge. If the
ferent locations around the bore. diameter of the bore is more than 19.05 rnrn, the rocker
arm must be replaced.
5. ROCKER ARM
309L91
STEP 70 STEP 71
Install the rocker arms on the rocker arm shaft with the Install the washers and the snap rings on the rocker arm
adjusting screws on same end as the large hole in the shaft.
bracket.
Use the correctr tap and clean all head bolts holes of Install the cylinder head.
foreign material.
STEP 75
STEP 73
9171.91
Use the bolt length gauge to check the head bolt length.
Insallthe correct head gasket on the engine block, see If the head bolt length is more than the maximum length
below. on the gauge the bolt must be replaced.
IMPORTANT: Oversize thickness gaskets are used Check and replace all head bolts that have rust, pitting
when the cylinder block has been machined. narrowing and corrosion.
STEP 77 STEP 79
B902915J
STEP 78
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 push rods and the rocker arm assembly.
STEP 81
8902916J
T68834
Tighten the rocker shaft bracket bolt to a torque of 21 to
27 Nm.
STEP 82
STEP 85
STEP 83
Connect and tighten the inlet tube nuts. Install the inlet tube. Install a new o-ring on the filter
housing and install the filter housing.
STEP 87 BOSCH INJECTION PUMP NOTE: Some engines have single fuel filters.
STEP 90
STEP 91
T68983
Install the lift pump outlet tube.
STEP 92 STEP 95
Tighten the filter inlet fitting to a torque of 29 to 35 Nm. Install the seal and the front lift bracket.
STEP 96
STEP 93
STEP 94
B902917J
Install the engine rotating tool into the flywheel housing. While turning the engine, push the lock pin in. When the
Rotate the engine four revolutions to make sure the lock pin moves into the camshaft gear the engine will be
push rods are seated correctly. at top center.
f'~~~
4 3 2 1
E E
B902918J
Number one cylinder top center compression stroke. Install the engine rotating tool. Move the engine a small
amount in each direction. Pull the lock pin out.
Valve Clearance, Cold: Intake Valves - 0.254 mm
Turn the engine one complete revolution. Put new seals on the injectors and install the injectors.
3 2
E
8902919J
Number four cylinder top center compression stroke. Tighten the injector nut to a torque of 55 to 60 Nm.
8903013J Install the leak off line, fittings and gaskets Tighten the
fittings to a torque of 5 to 7 Nm.
7 mm Diameter Tip 9 mm Diameter Tip
Install the injector lines connect and tighten the injector Install the alternator and tighten the bolts.
line nut to the injection pump and injectors.
STEP 111
STEP 108
Install the fan belt pulley bracket and tighten the bolts to
Install the bracket and tighten. a torque of 23 to 25 Nm.
J>9l85
Install the alternator bracket and tighten the bolts to a Install the belt tensioner bracket and tighten the Allen
torque of 21 to 27 Nm. head bolts to a torque of 21 to 27 Nm.
STEP 116
Install the fan belt pulley and tighten the bolts to a To install the turbocharger, see section 2465 in the
torque of: service manual.
STEP 118
STEP 115
STEP 119
STEP 120
THERMOSTAT SERVICE
STEP 121 STEP 123
2. Old Thermostat
1. New Thermostat
B902920J
8902922J
A new thermostat has been released for use in your
engine. If you removed an old thermostat from your If the cylinder head coolant passage is smaller than the
engine, do the following steps to install a new ther- 10 of the template, the coolant passage will have to be
mostat. made larger. Mark the 10 of the template on the cylinder
head.
STEP 122
STEP 124
8902921J
8902923J
Install the template that comes with the new thermostat
kit. 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.
B902924J
Stamp the letter "G" for cylinder heads that were in-
spected and did not need to be machined.
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.
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.
TABLE OF CONTENTS
SPECIFICATIONS .. ..4-6
Special Torques ...........6
REPLACEMENT OF THE MAIN BEARINGS WITHOUT REMOVING THE CRANKSHAFT .... . 38-41
CRANKSHAFT RECONDITIONING
Grinding a Crankshaft . .. 47
CAMSHAFT
Removal 58-59
FLYWHEEL
Removal 66
Installation '" 67
58 mm Expansion Plugs 70
26 mm Expansion Plugs 71
Testing 77
Manometer Removal 78
SPECIFICATIONS
CYLINDER BLOCK
ID of Cylinder , , 102.00 to 102.04 mm
Maximum Amount of Material that can be Removed During Resurfacing , ." , 0.50 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
PISTON
OD 12 mm From the Bottom, 90 Degrees from Piston Pin 101.873 to 101.887 mm
Minimum Service Limit 101.823 mm
PISTONS RINGS
No. 1 Compression
End Gap in 102.0210 Cylinder 0.25 to 0.55 mm
No. 2 Compression
End Gap in 102.0210 Cylinder 0.25 to 0.55 mm
Maximum Service Limit 0.806 mm
Side Clearance 0.075 to 0.120 mm
Maximum Service Limit 0.15 mm
PISTON PIN
00 of Pin. . 39.997 to 40.003 mm
Minimum Service Limit 39.990 mm
CONNECTING ROD
Bushing 10 installed 40.053 to 40.067 mm
CAMSHAFT
10 of Bushing Installed 54.1 07 to 54.133 mm
Maximum Service Limit. 54.146 mm
10 of Camshaft Bore 54.089 to 54.139 mm
Maximum Service Limit...... 54.164 mm
00 of Each Carnshatt Bearing Surface...................................... .. 53.987 to 54.013 mm
Minimum Service Limit 53.962 mm
Camshaft Thrust Clearance 0.130 to 0.340 mm
Minimum Service Limit.................................................. . 0.4 70 mm
Cam Lobe Minimum Diameter At Peak
Intake 47.265 mm
Exhaust...................... . 46.994 mm
GEAR TRAIN BACKLASH
Crankshaft Gear to Camshaft Gear 0.08 to 0.33 mm
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 M8 26 to 31 Nm
Grade 10.9 Size M8 37 to 43 Nm
Grade 8.8 Size Size M10 51 to 62 Nm
Grade 10.9 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-1692A Manometer
First used on Page 76.
Lift the belt tensioner and remove the fan belt. Remove the front cover bolts and remove the front
cover.
STEP 2
STEP 5
STEP 6
Remove the seal and clean the seal surface with Loctite
safety solvent
STEP 7 STEP 10
~;
Install the guide bolts and a new front cover gasket. Tighten the front cover bolts to a torque of 24 Nm.
Remove the installation tool.
STEP 8
STEP 11
STEP 12
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.
STEP 13 STEP 16
Remove the protective sleeve. Install the crankshaft and the crankshaft pulley bolts.
Tighten the bolts to a torque of 120 to 130 Nm.
STEP 14
STEP 17
STEP 15
Remove the engine oil pan. See Section 2445 for oil pan Remove the bolts and the flywheel housing from the
removal. engine block.
STEP 20 STEP 23
STEP 24
STEP 21
Remove the seal and clean the seal surface with Loctite
Remove the biolts and the flywheel from the flywheel safety solvent.
housing.
STEP 13 STEP 16
Remove the protective sleeve. Install the crankshaft and the crankshaft pulley bolts.
Tighten the bolts to a torque of 120 to 130 Nm.
STEP 14
STEP 17
STEP 15
Remove the engine oil pan. See Section 2445 for oil pan Remove the bolts and the flywheel housing from the
removal. engine block.
STEP 20 STEP 23
Remove the bolts and the starter from the flywheel Remove the seal carrier from the crankshaft.
housing.
STEP 24
STEP 21
Remove the seal and clean the seal surface with Loctite
Remove the biolts and the flywheel from the flywheel safety solvent.
housing.
STEP 25 STEP 28
Clean the seal surface on the crankshaft with Loctite Install the seal installation tool into the seal carrier with
safety solvent. the small diameter toward the engine. This will center
the seal carrier to the crankshaft.
IMPORTANT: The crankshaft sealing surface must be
free of all oil and grease to prevent damage to the oil
seal. STEP 29
STEP 26
Install the guide bolts and a new seal carrier gasket. STEP 30
STEP 27
Install the seal carrier bolts and remove the guide bolts.
Do not tighten the seal carrier bolts.
STEP 31
Install the seal and protective sleeve over the crank- Push the seal into the seal carrier until the outside
shaft until the outside diameter of the seal makes diameter of the seal installation tool makes contact with
contact with the seal carrier. seal carrier. Remove the installation tool.
STEP 32 STEP 35
Remove the protective sleeve Install the flywheel housing and tighten the bolts to a
torque of 54 to 66 Nm.
STEP 33
STEP 36
STEP 37 STEP 38
Install the starter and tighten the bolts to a torque of 39 Install the engine oil pan. See Section 2445 for oil pan
to 47 Nm. installation.
STEP 39
Lift the belt tensioner and remove the fan belt.
STEP 40
STEP 41
Remove the oil seal and clean the seal surface with
Loctite safety solvent.
crankshaft pulley and
STEP 44 STEP 47
Put Loctite 277 on the outside diameter of the seal Clean the crankshaft with Loctite safety solvent.
surface and install the seal in the front cover.
NOTE: The seal surface must be free of all oil and
grease to prevent damage to the oil seal.
STEP 45
STEP 48
Put the seal installation tool on the oil seal. The small
diameter of the seal installation tool must be toward the
seal. Install the wear sleeve on the crankshaft with the flange
toward the engine.
STEP 46
,
STEP 49
STEP 50 STEP 53
..
s
Install the guide bolts and a new front cover gasket. Install the crankshaft pulley and tighten the bolts to a
torque of 120 to 130 Nm.
STEP 51
STEP 54
STEP 55
STEP 56 STEP 59
";:~';; ( '-;'
. Ttl8'147
.--.:.. . SM..
Remove the engine oil pan See Section 2445 in the Remove the the bolts and flywheel housing.
service manual for oil pan removal
STEP 60
STEP 57
Remove the bolts and the seal carrier from the cran-
Remove the bolts and the starter from the flywheel kshaft.
housing.
STEP 61
STEP 58
Remove the seal and clean the seal surface with Loctite
Remove bolts and the flywheel safety solvent.
STEP 62 STEP 65
Install the seal in the seal carrier. Put the wear sleeve on the crankshaft with the flange
toward the engine.
STEP 63
STEP 66
Install the seal installation tool. Push the seal into the
seal carrier until the outside diameter of the seal instal- Install the wear sleeve installation tool on the wear
lation tool makes contact with the seal carrier. sleeve.
STEP 64 STEP 67
Clean the crankshaft seal surface with Loctite safety Push the wear sleeve on the crankshaft until the flange
solvent. of the wear sleeve is even with the rear seal surface on
the crankshaft.
STEP 68 STEP 71
Clean the seal surface with Loctite safety solvent. Install the seal carrier bolts and tighten the bolts to a
torque of 8 to 10 Nm.
IMPORTANT: The crankshaft seal surface must be free
of all oil and grease to prevent damage to the seal.
STEP 72
STEP 69
STEP 73
STEP 70
STEP 74 STEP 75
Install the starter bolts and tighten the bolts to a torque Install the engine oil pan. See Section 2445 in the
of 39 to 47 Nm. service manual for oil pan installation.
Remove the manifolds and cylinder head from the Check the side clearance of the piston connecting
engine. See Section 2415 of the service manual for rods. Replace the connecting rods if the side clearance
removal. is more than 0.330 mm.
STEP 79
1. RIDGE
Remove the engine oil pan and inlet tube. See Section
2445 of the service manual for removal. 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.
Rae 8-24183 Revised 2-92 Printed in U.S.A.
2425-22
STEP 80
Install a ridge reamer and remove the ridge from the Remove the rod cap.
cylinder walls.
STEP 84
STEP 81
T68776
'{Ji/;;- - _;;>.,
Remove the pistons from the top of the engine block.
Put a mark on each rod cap for cylinder identification.
STEP 82
Normal Wear
T2320
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.
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.
T68779
Measure the cylinder wall bore for taper as follows:
2. Too much piston ring groove wear. 4. Measure the bore in the same position at the bottom
end of the travel zone.
3. Too much piston ring side clearance.
Compare the results of the measurements (1) and (3)
4. Washed away areas of the piston ring lands where with (2) and (4), to find out if the bore has taper. To
the aluminum will be gone. measure use a inside micrometer, bore gauge or taper
gauge. If the taper is more than 0.076 mm, bore the
5. Piston rings will have too much face contact and cylinder. See reconditioning the cylinder block.
wear which can be seen as a reduction in radial
width and increase in end gap.
T68Z~~
2. Measure the bore in the same position at the bottom Too much glaze (smooth surface) on cylinder walls of a
end of the ring travel. new engine or an engine with an overhaul is caused by
run-in procedure that is not correct.
3. Measure the bore at right angles to the crankshaft at
the top end of the ring travel. Glaze does not permit the piston rings to seat correctly
in the cylinder sleeves. This will cause too much oil con-
4. Measure the bore in the same position at the bottom sumption.
end of the ring travel.
Too much glaze on the cylinder walls can be prevented
Compare the measurements (1) and (3) to find the out- by giving your customer instructions in the correct run-
of-round wear at the top end of the bore. in procedure. See Section 2402 in the service manual
for the correct run-in procedure.
Compare the measurements (2) and (4) to find the out-
of-round wear at the bottom of the bore.
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.
STEP 90 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.
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 NOTE: Clean the cylinder walls until a clean white cloth
hone and the stones free of foreign material. keeps completely clean, one cleaning operation is not
enough.
Start the hone at the top of the cylinder bore and actuate
the hone up and down until the correct cross-hatch IMPORTANT: Do not use gasoline, diesel fuel or
pattern is reached. The correct cross-hatch pattern is kerosene to clean cylinders because these materials
45 to 60 degrees from horizontal. will not remove the abrasives from the sleeve surface.
STEP 92
STEP 93
STEP 95
For 1.0 mm oversize pistons, machine cylinder bores to Rough Honing - Use 80 to 150 grit stones to get a
102.90 to 102.94 mm. cross-hatch pattern of 45 to 60 degrees from
horizontal.
STEP 97
the sleeves into the bore until the sleeve contacts the
ridge at the bottom of the bore.
Bore each cylinder to a diameter of 104.485 to 104.515 Cut the top of the sleeve flush to 0.025 mm above the
mm down to the mark. Boring must be done in four cylinder block surface.
steps with the final step taking a maximum of 0.125
mm. Let the block cool before the final step to prevent
distortion.
Break the top edge of the sleeve with a coarse stone. Rough Honing - Use 80 to 150 grit stones to get a
cross-hatch pattern of 45 to 60 degrees from
horizontal.
3. RETAINING RING
364L91 T6881 0
Remove the retaining ring, piston pin and the con-
necting rod from the piston.
STEP 105
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
365L91 replaced.
STEP 107
NOTE: The oil ring is a two piece ring.
705L91
STEP 108
Measure the diameter of the piston pin. If the diameter Break an old piston ring in half and use the broken ring
is less than 39.990 mm the piston pin must be replaced. half to clean the piston ring grooves. Too much deposit
in the ring grooves can force the rings out and will cause
scoring.
STEP 109
STEP 112
STEP 113
STEP 114
nWPRlitt!,.
Clean the piston holes with a small drill or fine wire.
Put the piston rings in the cylinder and check end gap. Install the second compression ring. The piston ring
Replace the piston rings if the end gap is more than must be installed with the side marked TOP toward the
0806 mm. top of the piston to give good oil control.
. L.~";.<.;.>~>".d::,.s\ii/f~~~,2Mti
Install the oil ring. Install the spring first and the oil ring Install the first compression ring on the piston. The
second. piston ring must be installed with the side marked TOP
toward the top of the piston to give good oil control.
NOTE: The spring must be between the oil ring and the
piston. NOTE: The top piston ring on the 4T-390 engine is a
key stone type ring.
Rae 8-24183 Revised 2-92 Printed in U.S.A.
2425-34
1. SPECIAL LAP
B902937J
STEP 120
STEP 123
137L91
Rotate the piston rings so that the ring ends are sepa- T68788
rated by 120 degrees. Install a ring compressor on the piston.
PISTON PIN
364L91 T68789
Install the connecting rod, piston pin and retaining rings Caref:Jlly push the piston down into the cylinder.
in the piston.
IMPORTANT: Make sure the arrow or the word FRONT
is toward the front of the engine.
Measure the connecting rod journals on the crankshaft. Install the liners. The liner locks must be in alignment.
Each journal must be a minimum of 68.962 mm in
diameter. Measure the front and rear of each journal, NOTE: When installing the liners, make sure that the
checking for taper. If the taper is more than 0.013 mm or liner locks are in alignment. Use a sliding type
the journal is less than 68.962 rnrn, reconditioning of movement when installing the liners. Never push on the
the journals must be done. center of the liner locks.
T68783
The connecting rod journals must be checked again, Clean the connecting rod journals and the rod bearing
90 degrees from the first measurements for out- liners. Put a piece of plastigage on the crankshaft
of-round. If out-of-round is more than 0.050 mm, recon- journal.
ditioning of the journals must be done.
---.:J
Install the bearing caps. Lubricate the connecting rod bolts with clean engine oil
and tighten the bolts to a torque of 60 Nm.
NOTE: Make sure that the number on the bearing cap is
the same as the number on the connecting rod.
STEP 132
STEP 130
- 1. MAXIMUM LENGTH
59.25 mm -
Apply lubrication to the bearing liners before installa- Install the torque angle gauge. Position and lock the
tion, using clean engine oil. holding rod. Turn the pointer to 60 degrees. Tighten the
bolt until the pointer is at 0 degrees.
STEP 135
STEP 138
_ 1. MAXIMUM LENGTH __
59.25 mm
7L92
STEP 136
r
L
'~;l!
Use a dial indicator to check piston protrusion. The
piston protrusion must not be more than 0.660 mm plus
Lubricate the connecting rod bolts with clean engine oil any amount of material removed during resurfacing.
and tighten the bolts to a torque of 60 Nm.
STEP 140
Remove the engine oil pan and gasket. Remove the bolts and main bearing cap.
2445 of the service manual.
NOTE: Remove only one cap at a time to prevent the
crankshaft from moving.
STEP 142
STEP 144
\,
Remove the bolts from the oil inlet tube. See Section
2445 of the service manual for the oil inlet tube removal.
Rae 8-24183
2425-39
Put a new bearing liner on the crankshaft. Use a thin Measure the length of the main bearing bolts If the bolt
piece of plastic to push the bearing liner in position. length is more than 119.25 mm the bolt must be re-
placed.
STEP 149
I.. ,
STEP 147
'."'."
;!: ~.
Install the bearing cap and tighten the mounting bolts to
a torque of 80 Nm.
STEP 150
Remove the bearing cap and check the clearance Measure the length of the main bearing bolts. If the bolt
Clearance must be 0.041 to 0.140 mm. New liners must length is more than 119.25 mm the bolt must be re-
be installed if the clearance is more than 0.140 mm. placed.
NOTE: The crankshaft must be reconditioned if the IMPORTANT: Each bolt length must be checked
clearance is more than 0. 119 mm with the new liners. before installation.
Add lubrication to the bearing liners Add lubrication to the mounting bolts. Install the
bearing cap. mounting bolts and tighten to a torque of 80 Nm.
STEP 155
-~, e" ,.
!<?;&,17
Install a new oil inlet tube gasket. See Section 2445 of Install the oil pan. See Section 2445 of the service
the service manual for the installation of the oil inlet manual.
tube.
Remove the cylinder head. See Section 2415 of the Remove the oil pan. See Section 2445 in the service
service manual for cylinder head removal. manual for oil pan removal.
i
Remove the bolts and the crankshaft pulley. Remove the oil inlet tube bolts. See Section 2445 for the
oil inlet tube removal.
STEP 163
STEP 170
STEP 167
T69029
STEP 171
STEP 168
Remove the front housing Remove the bolts and the flywheel housing
Remove the bolts and the starter. Remove the bolts and the seal carrier.
Remove the bolts and the flywheel. Put a mark on each rod cap piston for assembly identifi-
cation
T68776
Remove the pistons and connecting rods.
Pull the gear off the crankshaft. Remove the pin or woodruff key from the crankshaft.
CRANKSHAFT INSPECTION
STEP 186 STEP 188
T69070
Measure the main bearing journals to see if the journals Measure the connecting rod journals. Measure the front
are worn. Measure the front and rear of each journal. If and rear of each journal. Grind the journals if the taper is
the diameter is less than 82.962 mm grind the crank- more than 0.013 mm or if the diameter is less than
shaft journals. 68.962 mm.
.,..,.. .....,
CRANKSHAFT RECONDITIONING
See crankshaft inspection on Page 46. If the crankshaft Grinding a Crankshaft
is worn or damaged, it is recommended that you have a
qualified engine shop regrind the crankshaft according Grind the crankshaft to the following specifications:
to the following instructions.
Crankshaft Rehardening
..,...
~,,~~_.>U"~_''',~''''','',,',.,.~ . '1'69075
Install the crankshaft gear pin or woodruff key. Heat the crankshaft gear for a minimum of 25 minutes
at 250F (121C). Use a bearing heater oven.
CRANKSHAFT INSTALLATION
STEP 194
Clean the oil spray nozzle with a small wire. If the nozzle
is damaged it must be replaced.
STEP 196
STEP 199
1. MAXIMUM LENGTH I ,
119.25 mm
Clean the main bearing journals and put a piece of plas- 6L92
tigage on the journals to check main bearing oil clear- Measure the length of the main bearing bolts. If the bolt
ance. length is more than 119.25 mm the bolt must be re-
placed.
I .
I
~ STEP 200
I.
; ':tJi
I
Install the liners in the 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.
Install the main bearing cap bolts and tighten to a
torque of 80 Nm.
Install the torque angle gauge. Position and lock the Add lubrication to the liner. Use clean engine oil.
holding rod. Turn the pointer to 60 degrees.Tighten the
bolt until the pointer is at 0 degrees.
STEP 205
1. MAXIMUM LENGTH
119.25mm
6L92
STEP 206
Install the torque angle gauge. Position and lock the Install a new front housing gasket.
holding rod. Turn the pointer to 60 degrees.Tighten the
bolt until the pointer is at 0 degrees.
STEP 208
STEP 211
Make sure the timing marks on the crankshaft and Put a dial indicator on the camshaft gear. Check the
camshaft are aligned. 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-
STEP
.~s-
213
. '.~ ~..:- placed .
STEP 216
STEP 214
T69027
Remove the pins from the lifters.
STEP 217
Install a new gasket on the lifter cover. Install the injection pump and the hand primer pump.
See Section 3414 for CAV injection pum p and Section
3415 for Bosch injection pump
STEP 219
STEP 222
STEP 223
T68788
Install the tachometer drive assembly, if equipped. Install a ring compressor on the piston.
STEP 228
- 1. MAXIMUM LENGTH _
59.25 mm
7L92
Install the bearing liners on the connecting rods and rod Measure the length of the connecting rod bolts If the
caps bolt length is more than 59.25 mm the bolt must be re-
placed.
IMPORTANT: Make sure the liner locks are aligned
when installing the liners. Use a sliding type movement IMPORTANT: Each bolt length must be checked
when installing the liners Never push on the center of before installation.
the liners.
---...:
Clean the connecting rod journals and the bearing Tighten the connecting rods to a torque of 60 Nm.
liners. Put a piece of plastigage on the crankshaft jour-
nals.
STEP 234
----.:J
Remove the bearing caps and check the clearance. Add lubrication to the rod bolts. Install the rod bolts and
The clearance must be 0.038 to 0.129 rnrn. If the clear- tighten to a torque of 60 Nm.
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 STEP 239
will give a clearance of 0.038 to 0.116 rnrn.
STEP 236
-- 1. MAXIMUM LENGTH
59.25 mm -
7L92 Install a new oil inlet tube gasket. See Section 2445 for
Measure the length of the connecting rod bolts. If the oil inlet tube installation.
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 Revised 2-92 Printed in U.S.A
2425-57
Install the engine oil pan. See Section 2445 for oil pan Install the crankshaft pulley and tighten the retaining
installation. bolts to a torque of 120 to 130 Nm.
STEP 245
STEP 243
CAMSHAFT
Removal
STEP 246 STEP 249
T69021
Lift the belt tensioner and remove the fan belt. 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
STEP 247 manual.
STEP 250
STEP 248 Remove the bolts, lifter cover and breather cover.
STEP 251
STEP 253
Remove the engine oil pan. See Section 2445 in the Measure the camshaft bores. Use a bore gauge. The
service manual. bores must be measured in two positions. Take a
second measurement 90 degrees from the first measu-
rement.
If the bushing diarneter is more than 54.146 mm, the If the intermediate or the rear bores are more than
front camshaft bushing must be replaced. 54146 mm, disassemble the engine block and line
bore the bores. See specifications for machining di-
mensions
T69053
Put a bushing puller in the engine block and pull the Install the bushing on the puller. Align the oil holes. Pull
bushing out of the cylinder block. Use tool CAS-14124. the bushing into the cylinder block until it is even with
the housing.
. c, '-1: .. 1.'
.lIIIIII:tk 'l~
Remove the pins from the lifters and remove the lifters. Measure the outside diameter of the valve lifter stem.
Replace the valve lifters if the outside diameter of the
NOTE: The crankshaft and pistons have been removed lifter stem is less than 15.961 rnrn.
for photographic purposes.
STEP 265
STEP 262
STEP 263
~
Install the lifters in the block and fasten in position with
the pins.
If the diameter ofthe lifter bore is more than 16.030 rnrn,
the engine block must be replaced.
T69065
Press the gear off the camshaft. Measure the front and rear of each bearing surface on
the camshaft. Use a micrometer.
STEP 268
STEP 270
T69064
Remove the shaft key.
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
T69064
Install the shaft key Install the camshaft gear on the camshaft with the lock
pin hole down.
Heat the camshaft gear a minimum of 45 minutes at a.
temperature of 250F (121C). Use a bearing heater
oven.
Camshaft Installation
STEP 273 STEP 275
Lubricate the camshaft bearing surface with clean Install the camshaft thrust plate.
engine oil.
STEP 276
STEP 274
Check the camshaft end clearance with a dial indicator. Install the oil breather cover, if equipped.
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 281
STEP 278
STEP 279
Install new seals on the lifter cover bolts and tighten the
bolts to a torque of 21 to 27 Nm.
T69027
Remove the pins from the lifters.
Install the cylinder head. See Section 2415 for cylinder See Section 3414 in the service manual to install the in-
head installation. jection pump fuel lines.
If the engine oil pan was removed, see Section 2445 in See Section 3415 in the service manual to install the in-
the service manual for installation. jection pump fuel lines.
STEP
.......
285 STEP 288
Install the front crankshaft pulley and tighten the bolts to See Section 3413 in the service manual to install the fuel
a torque of 120 to 130 Nm. injectors.
Install the fan pulley and bolts. Tighten the bolts to a Lift the belt tensioner and install the fan belt.
torque of:
Grade 8.8 Size M8 26 to 31
Grade 10.9 SiZe M8 37 to 43
Grade 8.8 Size M10 51 to 62
Grade 10.9 Size M10 51 to 62
FLYWHEEL
Removal
STEP 291
STEP. 292
,~.
STEP 294
Remove the ring gear from the flywheel, using a drift Install the flywheel Tighten the retaining bolts to a
hammer. Work around the circumference of the ring torque of 130 to 144 Nm.
gear.
STEP 293
....-.,
T69213
:.,.,.,.W""*"'v~,-;.':
883L91
STEP 298
883L91
Disassemble the tachometer drive. 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.
Remove the expansion plug from the cylinder block. Apply Loctite 277 to the sealing surface of the expan-
sion plug.
STEP 300
STEP 302
58 mm Expansion Plugs
STEP 303 STEP 306
""
2509"
Apply Loctite 277 to the sealing surface of the expan-
sion plug.
26 mm Expansion Plugs
STEP 307 STEP 310
893LO
l~.i,Q3
Remove the expansion plug from the cylinder block.
STEP 312
Install the expansion plug into the bore, until the top
edge of the expansion plug is even with the bottom
edge of the chamfer,
"~~~~
STEP 313
18 mm Expansion Plug
STEP 315 STEP 318
~cJi824a4ot ::.T8~
Put a small amount of grease in the expansion plug. Use Loctite safety solvent to clean the sealing surface
of all foreign material.
STEP 316
STEP 319
STEP 320
10 mm Expansion Plugs
STEP 321 STEP 322
Put a small amount of grease in the expansion plug. Drill a small hole in the center of the expansion plug.
Install a screw in the expansion plug and pull the expan- Apply Loctite 277 to the sealing surface of the expan-
sion plug out of the cylinder block. sion plug.
Remove the clamp and the breather hose. Turn each connector on the manometer one turn coun-
terclockwise.
STEP 331
Install the manometer. Push the button on the gauge and move the gauge up
or down, until the zero on the gauge and the liquid in the
tube are aligned.
Testing
NOTE: Do the following steps to get the correct man- MANOMETER READING
ometer readings.
Inches of
Step 1 - Warm the engine to operating temperature. Water Umin
Manometer Removal
Disconnect the tube from the connector. Remove the adapter from the breather tube.
Turn each connector on the manometer one turn clock- Install breather hose and the hose clamp.
wise.
STEP 336
~/
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.
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.
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TORQUES 3
OIL PUMP
Removal 4
Disassembly and Assembly 5
Installation 6-7
SPECIFICATIONS
Oil Pressure
New Engine at Low or 800 rpm 1.9 to 3.0 Bar 28 to 43 PSI
at 1700 rpm 2.8 to 3.4 Bar 40 to 50 PSI
at High Idle or 2400 rpm 3.0 to 3.7 Bar 43 to 54 PSI
Oil Pump Relief Valve Spring Specification (For 2 Hole Relief Valves)
Free Length 55.83 mm
Outside Diameter 14.02 mm
Assembled Height:
Compress to 44.98 mm 63 to 79 N
Spring Load Height:
Compress to 39.98 mm 95 to 113 N
Oil Pump Relief Valve Spring Specification (For 4 Hole Relief Valves)
Free Length 64.0 mm
Outside Diameter 14.7 mm
Assembled Height:
Compress to 44.5 mm 87 N
Spring Load Height:
Compress to 41.25 mm 104.7 N
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
OIL PUMP
Removal
STEP 1 STEP 4
Lift the belt tensioner pulley and remove the fan belt. Remove the crankshaft pulley bolts and the pulley.
STEP 2 STEP 5
::1[~~9~6
Remove the retaining bolts and fan belt pulley. Remove the front cover retaining bolts and remove the
front cover.
STEP 3
STEP 6
STEP 7 STEP 9
T68767 T68766
Put the oil pump on a clean work surface. 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.
STEP 8
Installation
NOTE: If a new oil pump is installed it is necessary to STEP 13
install a new four hole relief valve and spring.
STEP 11
STEP 12
STEP 15
STEP 16 STEP 18
T689-16
" .
Install the fan pulley and the retaining bolts. Tighten the fan pulley retaining bolts to a torque of:
Grade 8.8 Size M8 26 to 31 Nm
Grade 10.9 Size M8 37 to 43 Nm
STEP 17 Grade 8.8 Size M10 " 51 to 62 Nm
Grade 10.9 Size M10 51 to 62 Nm
Lift the fan belt tensioner pulley and install the fan belt.
Use a valve spring tester and check the valve spring for the following specifications:
1. PLUG 4. RELIEFVALVE
2. GASKET 5. OIL FILTER HOUSING
3. RELIEFVALVE SPRING
STEP 21 STEP 23
.'~
Remove the oil filter housing. Put the oil filter housing on a clean work surface and
remove the cold oil relief valve.
Installation
STEP 24 STEP 25
l
Remove the oil pan drain plug and drain the oil. Remove the oil inlet tube bolts.
NOTE: On Installation, tighten the oil pan drain plug to a NOTE: On Installation, tighten the oil inlet tube retaining
torque of 68 to 82 Nm. bolts to 21 to 27 Nm.
STEP 27 STEP 29
Remove the oil pan bolts. Clean all surfaces of foreign material.
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.
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.
TABLE OF CONTENTS
SAFETY RULES 3
SPECIAL TORQUES..... .. 3
SPECIFICATIONS . 3
WATER PUMP
Removal 4
Installation 4
THERMOSTAT
Removal............... .. 5
Installation .. . . 6,7
Installation 8,9
Installation . 10,11
BELT TENSIONER
Removal 11,12
Installation .. 12,13
THERMOSTAT SERVICE. 14
SAFETY RULES
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 Never put coolant in a hot engine. The engine block or
cap counterclockwise to the FIRST stop. This will cylinder head can get cracks because of the difference
permit a gradual release of pressure with little coolant in temperature between the metal and coolant.
loss.
How to Clean the Cooling System
Clean the cooling system a minimum of once each 3. Drain the radiator cleaner solution and flush the
year. In areas where the water has minerals, clean the system with clean water. Fill the system with
system more frequently. antifreeze and water and check the hoses, radiator
and water pump for leaks.
1. When the coolant is hot, open the radiator and
engine block drain valves. Close the valves after the NOTE: After the cooling system is completely filled, run
system is empty. the engine for approximately 20 minutes to remove air
from the cooling system. Check coolant level and add
2. Add a radiator cleaner and fill the system with clean coolant if necessary.
water. Use a good type of radiator cleaner. Follow
the instructions given with the radiator cleaner.
SPECIAL TORQUES
Water Pump Housing Bolts 21 to 27 Nm
Thermostat Housing Bolts 21 to 27 Nm
SPECIFICATIONS
Belt Tension
Spring Tension at 35 Degree Angle (Minimum) 24 Nm
WATER PUMP
Removal
STEP 1 STEP 2
T6'EJ9
Lift the belt tensioner pulley and remove the fan belt Remove the water pump bolts and the water pump.
Installation
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
THERMOSTAT
Removal
STEP 6 STEP 9
Lift the belt tensioner pulley and remove the fan belt. Remove the thermostat bearing bolts and the ther-
mostat housing assembly
STEP 7 STEP 10
410L91
Remove the alternator bolts and the alternator. Disassemble the thermostat housing.
STEP 11
STEP 8
155666
Remove the bracket bolts and the alternator bracket. 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 heat the water to a temperature
of 203F (95C), the thermostat should be fully open at
this temperature. The thermostat must be replaced if it
does not meet this specification.
Rae 8-24203 Revised 2-92 Printed in U.S.A.
2455-6
Installation
410L91
1. THERMOSTAT HOUSING 3. SEAL
2. THERMOSTAT 4. LIFTING BRACKET
STEP 14
SM4
Install the template (1) as shown 410L91
STEP 15
24551
STEP 16 STEP 18
Install the alternator bracket and tighten the retaining Lift the belt tensioner pulley and install the fan belt.
bolts to a torque of 21 to 27 Nm.
STEP 17
Lift the belt tensioner pulley and remove the fan belt. Remove the coolant inlet manifold.
STEP 20
Installation
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 STEP 26
Install the alternator. Lift the belt tensioner pulley and install the fan belt.
STEP 25
T68919
Lift the belt tensioner pulley and remove the fan belt. Remove the fan pulley bracket.
STEP 28
: 1-.
i;T6891'6
. ;'~-"~
...........
,'
Installation
STEP 30 STEP 31
T68918
Install the fan pulley bracket and tighten the bolts to a Install the fan pulley and retaining bolts,
torque of 23 to 25 Nrn.
STEP 32 STEP 33
Lift the belt tensioner pulley and install the fan belt. Tighten the fan pulley bolts to a torque of:
Grade 8.8 Size M8 26 to 31 Nm
Grade 10.9 Size M8 37 to 43 Nm
Grade 8.8 Size M10 51 to 62 Nm
Grade 10.9 Size M10 51 to 62 Nm
BELT TENSIONER
Removal
STEP 34
STEP 35
Lift the belt tensioner pulley and remove the fan belt.
SM5
",..;;
STEP 36 STEP 38
Remove the tensioner bolt and the belt tensioner. Remove the belt tensioner bolts and the bracket.
STEP 37
Installation
STEP 39 STEP 40
Install the tensioner bracket and tighten the Allen head Install the fan belt pulley and retaining bolts
bolts to a torque of 21 to 27 Nm.
STEP 41 STEP 43
Lift the belt tensioner pulley and install the fan belt.
THERMOSTAT SERVICE
STEP 44 STEP 47
2. OLD THERMOSTAT
1. NEW THERMOSTAT
309L91
312L91
A new thermostat has been released for use in your
engine. If you removed an old thermostat from your Remove the template. Use a shop cloth in the coolant
engine, do the following steps to install a new ther- passage to keep foreign material out of the engine. Use
mostat a rotary grinder to remove the material.
STEP 48
STEP 45
31391
STEP 46
314L91
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.
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 8-24203 Revised 2-92 Printed in U.S.A
Section
2465
TURBOCHARGER
Written In Clear
And
Simple
English
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TORQUES 3
SPECIAL TOOLS 3
Inspection 6
Disassembly 7-13
Assembly 15-22
Installation 23,24
SPECIFICATIONS
Metric Value
Turbine Wheel Horizontal Movement 0.10 to 0.16 mm
SPECIAL TORQUES
U.S. Value Metric Value
Turbine Housing Bolts 96 Ib inch 11 Nm
(1.1kgm)
SPECIAL TOOLS
x, .!I
Turbocharger with the air cleaner and the exhaust Disconnect the oil supply tube.
pipe removed.
STEP 5
STEP 2
STEP 3 STEP 6
Remove the air intake hose. Disconnect the oil drain tube.
STEP 7 STEP 10
Remove the nuts that hold the turbochargerto the Clean the mounting surface on the turbocharger
exhaust manifold. and the exhaust manifold.
STEP 8 STEP 11
Inspection
STEP 12 STEP 13
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.
Disassembly
STEP 14 STEP 17
Put a identification mark on the compressor hous- Remove the compressor housing clamp plates.
ing and back plate. This identification is to make
sure the parts are in the correct position at assem-
bly. STEP 18
STEP 15
STEP 16
STEP 20
Remove the retaining bolts from the lock plate. Put the turbine end of the center housing assembly
into the holding fixture.
STEP 21
STEP 24
STEP 25
'\
\
STEP 26 STEP 29
STEP 27
STEP 28
STEP 31 STEP 34
Make the tabs straight on the lock plate. Remove the center housing from the back plate.
STEP 32 STEP 35
Remove the retaining bolts from the center hous- Remove the oil baffle from the back plate.
ing.
STEP 36
STEP 33
STEP 37 STEP 40
Remove the oil slinger from the back plate. Remove the torx head screws from the center
housing.
STEP 38
STEP 41
STEP 39
STEP 42
STEP 43
Remove the outer bearing retaining ring. Turn the center housing over and remove the outer
bearing retaining ring.
STEP 44
STEP 47
STEP 45
STEP 48
STEP 49
Replace the turbocharger if the outlet openings Replace the turbocharger if the turbine wheel is
show warpage or cracks. damaged or if the turbine shaft has grooves or
scratches.
STEP 51
STEP 53
STEP 54 STEP 56
Inspect the compressor wheel for bent blades and Replace the turbocharger if the oil slinger shows
scratches. Replace the turbocharger if the wheel damage.
shows damage.
STEP 57
STEP 55
Assembly
STEP 58 STEP 61
Install a new inner bearing retaining ring. The Turn the center housing over and install a new
round edge of the retaining ring must be toward inner bearing retaining ring. The round edgeofthe
the top. retaining ring must be toward the top.
STEP 59 STEP 62
Install a new center housing bearing. Install a new bearing in the center housing.
STEP 60 STEP 63
Install a new outer bearing retaining ring with the Install a new outer bearing retaining ring with the
round edge down. round edge down.
STEP 64 STEP 67
Install the thrust collar with the large 00 down. Tighten the thrust bearing screws to a torque of 36
Ib inch (5 Nm)(O.5 kgm).
STEP 65
STEP 68
STEP 69
STEP 70 STEP 73
Carefully install the oil slinger in the back plate. Install new lock plates and new mounting bolts.
STEP 71
STEP 72
STEP 76 STEP 79
Install a new seal ring in the groove of the turbine Install the compressor wheel on the turbine shaft.
wheel.
STEP 80
STEP 77
STEP 78
STEP 81
STEP 82 STEP 84
STEP 83
STEP 86 STEP 89
Install the new turbine housing bolts and tighten to Install the compressor housing mounting plates.
a torque of 96 Ib inch (11 Nm)(1.1 kgm).
STEP 90
STEP 87
STEP 88
STEP 91
TUBINE SHAFT
CENTER HOUSING
Rae 8-25550
Issued 6-84 Printed in U.S.A.
2465-23
Installation
STEP 95
Install a new gasket on the exhaust manifold. Install a new gasket on the oil drain tube.
STEP 93 STEP 96
STEP 94 STEP 97
""~.
!I'"
Install the turbocharger mounting nuts and tighten Tighten the oil drain tube bolts to a torque of 181b
to a torque of 24 Ib ft (32 Nm)(3.2 kgm). ft (24 Nm)(2.4 kgm).
STEP 102
STEP 99
STEP 100
Coked (sludged) center housing failures are The bearing surfaces of this shaft were scored
generally caused by high exhaust temperatures due to dirty engine oil. Evidence of a contamina-
due to over-fueling, over-loading the engine, ted oil failure calls for careful, thorough exa-
dirty engine oil, or plugged oil return. Also mination of engine lube system.
examine bearings for sludge.
Scored Bearings
Scored Turbine Shaft
Erosion of compressor blades from ingestion Discoloration of the turbine shaft is due to
of dust. Blades on one wheel are thinned while overheating caused by oil starvation. Lack of
the other wheel is almost completely worn lubrication generally is a matter of improper
away. Fine erosion of the inlet edges of the start-up or shut-down practices.
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- Backing Plate Wheel Rub
age to the turbine wheel or bearings unless the
problem was so severe that the rotating unit
became unbalanced.
Blade edges of the compressor wheel lifted Engine bearing material imbedded in the
by improper removal of the compressor hous- bearing surfaces. Checkout the engine for
ing. Housing should not be pried off but lifted possible bearing failure.
straight off.
Bearing Failure
Turbtne Shaft & Bearings
Fine scratches on both bearing journals are Bearing damage and extreme shaft motion
evidence that abrasive material has contamina- caused by lack of lubrication or abrasives in
ted the lubricating oil. the oil may eventually cause the shaft to bend
or even break. When this type of damage is
evident. check the bearings.
FILTER REPLACEMENT
NOTE: Some engines have MO fuel filters while others STEP 2
have single fuel filters. See the following photographs.
STEP 3
STEP 4
NOTE: If the primer pump can not be actuated, rotate NOTE: If the primer pump can not be actuated, rotate
the engine until the primer pump can be actuated. the engine until the primer pump can be actuated.
1. Bleed Screw
2. Primer Pump
Put the 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.
.NOTE: If the primer pump can not be actuated, rotate NOTE: If the primer pump can not be actuated, rotate
the engine until the primer pump can be actuated. the engine until the primer pump can be actuated.
1. Bleed Screw
2. Primer Pump
Put the 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.
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.
J'
TABLE OF CONTENTS
SAFETY RULES 2
SPECiFiCATIONS..... .. 3
SPECIAL TOOLS 4
SPECIAL TORQUES 4
GENERAL INFORMATION 4
OPERATING PROCEDURES 5
INJECTORS
Removal 6,7
Installation .. .. . 7,8
TESTING INJECTORS 10
Checking Opening Pressure................................ 10
Checking Seat Leakage 11
Spray Pattern 11
INJECTOR
Disassembly 12
Cleaning and Inspection 13
Assembly 14-16
Adjustments 16
SAFETY RULES
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.
Rae 8-24233 Revised 2-92 Printed in U.S.A.
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
Bosch Injectors
PART NUMBER
Assembly Nozzle Spray Angle Number of Spray Nozzle Size Opening Pressure
(Case) (Robert Bosch) Orifices Orifice Size
CAY Injectors
PART NUMBER
Assembly Nozzle Spray Angle Number of Spray Nozzle Size Opening Pressure
(Case) (CAV) Orifices Orifice Size
J917661 ,
6801102 155 Degrees 4 0.29 mm 9mm 245 to 253 Bar
(3553 to 3669 PSI)
SPECIAL TOOLS
1. CAS-1066A WRENCH
SEE PAGE 7
SPECIAL TORQUES
GENERAL INFORMATION
The fuel injector sends a measured amount of fuel to INJECTOR VALVE - The valve controls the flow of the
the combustion chamber from the injection pump. fuel from the injector.
Each quantity of fuel must be sent to the combustion
chamber in the form of fine particles. This will make sure VALVE STOP - The valve stop has two dowel pins which
that there is complete combustion and efficient engine hold the valve tip to the body. This will make a spray
performance pattern that is correct. Both faces of the valve stop have
a fine surface finish. The valve stop controls the
IMPORTANT: The injector tip end and the injector valve distance that the valve will move.
are a matched assembly. The two parts are made
smooth to fit together with accuracy. The injector tip or OPENING PRESSURE CONTROLSPRING - The spring
the injector valve cannot be replaced separately for controls the fuel pressure that is necessary to lift the
service. If it is necessary to replace either the valve or tip, valve from the seat.
replace the complete tip assembly.
SHIMS - The shims push down on the spring to keep a
IMPORTANT: Do not mix tip assemblies and bodies given pressure on the valve.
while the injectors are being disassembled.
INJECTOR TIP - The valve and the valve seat are in the
INJECTOR BODY - The body holds the injector parts in injector tip. There are orifices in the injector tip that
the correct position in the cylinder head. The body has a atomize the fuel for better combustion and separate the
high pressure channel and a leak off channel. The lower fuel spray to mix the fuel spray with air.
face of the body has a finished surface and has two
holes in the surface for locating dowel pins. NOZZLE SEAL - The seal is under the cap nut and stops
engine compression leakage.
OPERATING PROCEDURES
The operation of the injector is easy and positive When the fuel delivery stops, the pressure against the
valve is decreased and the control spring immediately
A measured quantity of fuel under high pressure moves returns the valve to the seat. This removes the danger of
from the injection pump to the high pressure channel in leakage, after the measured amount of fuel has been
the injector body The fuel then moves through the valve released. The valve opens and closes vary rapidly with
stop channel and enters the pressure chamber which is a very clear noise.
around the valve in the injector tip.
A small amount of fuel leaks, during injection, through
When the pressure of the fuel against the valve is more the controlled clearance between the tip assembly and
than the set spring orifice, the valve is moved from the the injector body. This leakage adds lubrication to all
seat. This permits the fuel under high pressure to enter the moving parts in the injector. This fuel then moves
the injector tip. The fuel then moves through the spray through the leak off channel, leak off lines and returns to
orifices and to the combustion chamber. The fuel the fuel tank.
reaches the combustion chamber in an atomized
condition.
420L91
!~
Loosen the tube nut on the fuel line. This will release the Loosen the tube nut on the fuel inlet line for the injector
fuel and the injector will not work. If this injector is faulty, at the cylinder head. If the injector is faulty, there will not
there will not be any difference in the engine perfor- be any difference in the engine performance Connect
mance. Connect and tighten the tube nut of the fuel line. ano tighten the tube on the fuel inlet line.
Repeat this procedure for the remaining injectors. Repeat this procedure for the remaining injectors.
INJECTOR
Removal
STEP 3 STEP 4
STEP 5 STEP 7
Remove the leak off bolt. Remove the fuel injector from the engine. Remove and
discard the sealing washer.
STEP 6
STEP 8
Installation
STEP 9 STEP 10
.~
lJ69231
Use the injector bore cleaning tool, see Special Tools Install a new seal on the injector and install the injector
page for correct size cleaning tool, to clean the injector in the cylinder head bore. The ball in the injector must
bore. Use compressed air to clean the injector bore. align with the slot in the cylinder head bore.
STEP 11 STEP 13
T78866 ~
Use the special wrench to tighten the injector retaining Remove the cap. Connect and tighten the injection line
nut to a torque of 55 to 65 Nm. to the injector.
STEP 12
-H,~I7i~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.
2. Connect the correct connectors to the connection 4. To remove the air that is in the system, close the
tube pressure release valve and the gauge protection
valve, open the pump. Operate the pump rapidly to
remove the air from the system.
TESTING INJECTORS
1
The injector must be cleaned before testing the injector. Connect the injector to the nozzle tester. The nozzle tip
Wash the body, nozzle tip and the cap nut in a solvent to must be facing down.
remove external dirt, grease and carbon deposits from
the cap, body and outside diameter of the tip. When testing or adjusting fuel injectors, do
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.
NOTE: There must not be more than 10.34 Bar (150 3. Check for broken or weak opening pressure control
PSI) difference between any of the injectors that have springs.
been removed from the engine.
Spray Pattern
Close the pressure release valve and the gauge The injector will make a very clear noise when the test
protection valve. Open the pump valve and operate the stand is operated rapidly. This noise will not necessarily
tester at 60 strokes a minute, check the spray pattern. occur in the opeation of the injector in the engine. The
The nozzle must have a spray pattern that will atomize noise is an indication of good seat width and
the fuel. The nozzle must not have a solid spray pattern. 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.
INJECTOR
Disassembly
STEP 14 STEP 16
Put the injector in a soft faced vise with the two flat Remove the nozzle cap nut and disassemble the in-
surfaces towards the vise face. The tip of the injector jector.
must be up. Remove and discard the sealing washer
NOTE: The injector parts have tight tolerances. Dirt will
NOTE: Use a cleaning solution to remove carbon damage a smooth surface. Keep the work location and
deposits from the nozzle and holder assembly. tools clean. Disassemble and assemble all parts
carefully to prevent damage.
STEP 15
1. NOZZLE HOLDER
2. PRESSURE ADJUSTING SHIMS
3. OPENING PRESSURE CONTROL SPRING
4. SPRING SEAT
5. VALVE STOP
6. NOZZLE TIP ASSEMBLY
7. CAP NUT
421L91
STEP 17
"T69086
Install the opening pressure control spring into the
T69087 nozzle holder.
Install the pressure adjusting shims required to obtain
the correct opening pressure.
Rae 8-24233 Revised 2-92 Printed in U.S.A.
3413-15
STEP 19 STEP 22
T69085 T69083
Install the spring seat onto the pressure spring. The Align the dowel pins in the nozzle tip assembly with the
small diameter end of the spring seat must be toward dowel pins in the stop valve assembly. Install the nozzle
the pressure spring. tip assembly onto the stop valve assembly
,STEP
.
20 STEP 23
T69084 T69082
Install the valve stop assembly. Align the dowel pins in Add lubrication to the nozzle shoulder. Do not put
the valve stop with the dowel pin holes in the nozzle grease on the holder or on the threads of the cap nut.
holder. Install the cap nut over the end of the nozzle tip
assembly and turn the cap nut clockwise two or three
times
STEP 21
STEP 24
STEP 25
1. INLET
2. LEAK OFF
3. LEAK OFF CHANNEL
4. EDGE FILTER (IF EQUIPPED)
5. HIGH PRESSURE CHANNEL
6. INJECTOR BODY
7. OPENING PRESSURE CONTROL SPRING
8. CAP NUT
9. NOZZLE SEALING WASHER
10. SPRAY ORIFICE
11. INJECTOR TIP
12. INJECTOR VALVE
_21 13. VALVE STOP
Check the fuel injector on the test stand, refer to Pages 14. SPRING SEAT
9 and 11. 15. PRESSURE ADJUSTING SHIMS
420L91
Adjustments
STEP 26 STEP 27
_"". om T69087
Remove the fuel injector from the nozzle tester. Put the Add pressure adjusting shims to increase the opening
injector in a soft faced vise. The flats of the injector pressure. Remove pressure adjusting shims to
holder must be toward the face of the vise. The injector decrease opening pressure. Do this until the correct
tip must be facing up. Loosen the cap nut. To pressure is reached.
disassemble the injector, refer to Page 12.
IMPORTANT: The opening pressure is changed by
about 3.79 Bar (55 PSI) 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.
Rae 8-24233 Revised 2-92 Printed in U.S.A
3413-17
INJECTOR SLEEVE
Installation
This sleeve must be used to change the 9 mm injector bore in the cylinder head to a 7 mm injector bore to use the 7 mm
injectors.
STEP 28 STEP 30
T78866
Use the injector bore cleaning tool, See Special Tools Use the special wrench and tighten the injector re-
page for correct size cleaning tool, clean the injector taining nut to a torque of 55 to 65 Nm.
bore. Use compressed air to clean the injector bore.
STEP 31
STEP 29
.#
J78860
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
35L92
the leak off line.
.~
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.
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.
TABLE OF CONTENTS
SPECIAL TOOLS .... .2
PRIMER PUMP
Removal.. . 15
Installation 15
SPECIAL TOOLS
SPECIAL TORQUES
Injection Pump Mounting Bolts 21 to 27 Nm
TROUBLESHOOTING GUIDE
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.
Disconnect and install dust caps on the injection tubes Remove the tachometer drive assembly (if equipped).
and the fuel injection pump
STEP 5
STEP 2
STEP 3
STEP 6 STEP 8
STEP 9
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.
Install the gear puller, CAS 1691, and tighten the bolts
STEP 7 until the gear is loose on the pump shaft.
STEP 10
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.
Remove the retaining nuts and bracket bolts. Remove
NOTE: The slotted washer must be loose after the lock the injection pump and discard the gasket.
bolt had been tightened.
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.
Installation
STEP 11 STEP 14
Install a new gasket and install the injection pump Loosen the lock bolt on the injection pump, move the
slotted washer onto the lock bolt. Tighten the lock bolt
NOTE : Make sure the key in the injection pump shaft to a torque of 20 Nm.
and the slot in the drive gear are aligned.
NOTE : The slotted washer must not move after the
locking bolt has been dropped.
STEP 12
STEP 15
Install the nut and washer onto the injection pump shaft.
Tighten the nut to a torque of 59 to 71 Nm.
Pullout the lock pin from the camshaft gear.
STEP 13
STEP 16
Install the tachometer drive assembly (if equipped). Install the fuel inlet fitting with new sealing washers.
Tighten the fitting to a torque of 22 to 28 Nm.
NOTE: The nut on the injection pump and the tachom-
eter drive nut must be aligned.
STEP 19
STEP 17
~
Remove the caps. Install and tighten the tubes between
the fuel injectors and fuel injection pump.
Remove the dust caps. Connect and tighten the fuel
leak off tube.
STEP 21
STEP 25
STEP 22
STEP 23
STEP 26 STEP 28
t~ LOCK
927A
Loosen the lock bolt and move the slotted washer off Remove the gear from the injection
the shoulder of the lock bolt. Tighten the lock bolt to a Remove the puller from the gear.
torque of 7 Nm.
STEP 27
Install the gear puller and tighten the bolts until the gear
is loose on the injection pump shaft.
Installation
STEP 29 STEP 31
NOTE: The slotted washer must not move after the lock
bolt has been tightened.
STEP 32
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
STEP 33
T78828
Install the washer and nut onto the injection pump shaft
and tighten a small amount
STEP 35
I~
Clean the sealing surface of the crankshaft with Loctite Install the tachometer drive assembly (if equipped).
Solvent. Refer to Section 2425 to install the timing gear
front cover and oil seal.
STEP 36
TG3414
STEP 39 STEP 42
!~ UNLOCK
927.
J.
Install the injection pump shaft into the drive gear. Make Loosen the lock bolt on the injection pump. Move the
sure the slot in the drive gear and the key on the injec- slotted washer on the lock bolt. Tighten the lock bolt to a
tion pump are aligned. torque of 20 Nm.
NOTE: The slotted washer must not move after the lock
STEP 40 bolt has been tightened.
STEP 43
Install the nuts and bracket bolts that hold the injection
pump to the front cover.
STEP 44 STEP 46
STEP 47
STEP 48
STEP 49
STEP 51 STEP 52
Remove the fuel shutoff solenoid from the injection Disassemble the fuel shutoff solenoid. Check the
pump. plunger and solenoid for scoring.
STEP 53 STEP 54
Assemble the fuel shutoff solenoid. Install the fuel shutoff solenoid and tighten to a torque of
14 Nm.
Rae 7-37131 Revised 2-92 Printed in U.S.A.
3414-15
PRIMER PUMP
Removal
STEP 55 STEP 56
Disconnect and remove the fuel inlet line. Remove the primer pump bolts and the primer pump
from the cylinder block.
Installation
STEP 57 STEP 59
Install the primer pump and tighten the bolts that hold Tighten the inlet fitting to a torque of 22 to 28Nm.
the primer pump to the cylinder block.
STEP 58
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.
TABLE OF CONTENTS
SPECIAL TOOLS .2
PRIMER PUMP
Removal . ..................... . 17
Installation . 18
SPECIAL TOOLS
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
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.
TROUBLESHOOTING GUIDE
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.
Clean the area around the fuel injection pump. Discon- Remove the tachometer drive assembly (if equipped).
nect and remove the fuel injector tubes.
STEP 5
STEP 2
STEP 3
STEP 6 STEP 8
STEP 9
'{;T78798
Install the engine turn over tool, and push in on the
locking pin. Turn the engine over until the locking pin
engages in the camshaft gear.
Install the gear puller and tighten the bolts until the gear
STEP 7 is loose from the pump shaft.
STEP 10
Jt,
Loosen the pump shaft lock bolt and remove the slotted
tab.
Installation
STEP 11 STEP 14
Install a new gasket Install the injection pump Install Pull out the locking pin from the camshaft gear.
the injection pump washer and nut
NOTE: Make sure the key in the injection pump shaft STEP 15
and the slot in the drive gear are aligned.
STEP 12
STEP 13
STEP 17 STEP 19
Remove the caps Install the leak off fitting and new Remove the caps. Install and tighten the tubes between
sealing washers. Tighten the fitting to a torque of 13 to the fuel injectors and fuel injection pump.
17 Nm.
STEP 18
Lift the belt tensioner and remove the fan belt. Remove the crankshaft pulley retaining bolts and cran-
kshaft pulley.
STEP 22 STEP 24
,
I:
Remove the front cover bolts and the front cover.
STEP 23
Install the engine turn over toot and turn the engine over
until the locking pin engages the camshaft gear.
STEP 25 STEP 27
?,1t
STEP 28
STEP 26
Install the gear puller and tighten the bolts until the gear
is loose on the injection pump.
Installation
STEP 29 STEP 31
NOTE: The slot in the drive gear and the key on the Pull the locking pin out of the camshaft gear.
pump shaft must be aligned.
STEP 33
STEP 30
STEP 34
TG3414
STEP 37 STEP 40
Install the injection pump into the drive gear Make sure Install the slotted tab and tighten the lock bolt to a
the slot in the drive gear and the key on the pump shaft torque of 12 to 14 Nm.
are aligned,
STEP 41
STEP 38
STEP 39
STEP 43 STEP 45
STEP 46
\;:n~"
Install the engine turn over tool, push in on the locking
pin and turn the engine over until the locking pin
engages in the camshaft gear.
Install a dial indicator in the injector pump.
STEP 44
,STEP 47
STEP 48 STEP 50
STEP 51
STEP 49
Loosen the bracket bolt and the nuts that hold the injec-
tion pump to the front cover,
STEP 52
STEP 53 STEP 56
22
Tighten the bracket bolt and the nuts that hold the injec- Install the sealing washer and the leak off fitting. There
tion pump to the front cover to a torque of 21 to 27 Nrn. 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 54
STEP 57
STEP 58
STEP 59 STEP 60
Install the tachometer drive assembly (if equipped). Pull the locking pin out of the camshaft gear.
NOTE: The drive gear nut and the tachometer drive nut
must be aligned.
Remove the fuel shut-off solenoid from the injection Disassemble the fuel shut-off. Check the plunger
pump. solenoid for scoring. Clean the orifice hole with a small
piece of wire.
6
Assemble the fuel shut-off solenoid as shown. Install the fuel shut-off solenoid and tighten to a torque
of 43 Nm.
PRIMER PUMP
Removal
STEP 65 STEP 66
Remove the fuel inlet line. Remove the primer pump from the cylinder block.
Installation
STEP 67 STEP 68
Tighten the bolts that hold the primer pump to the Tighten the inlet fitting to a torque of 32 Nm.
cylinder block.
Remove the retaining ring from the locking pin housing. Remove the locking pin from the housjnq.
Installation
STEP 71 STEP 72
Install a new a-ring onto the locking pin. Install the lock pin. Install the retaining ring into the
locking pin housing.
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.
Batteries 4003
Bur 8-17200
CASE CORPORATION
Section
4001
TABLE OF CONTENTS
STARTER 3
Removal 3
Installation .4
ALTERNATOR 5
Removal 5
Installation 6
INSTRUMENT CLUSTER 8
Removal 8
Installation 8
Replacing a Bulb 8
Circuit Board 8
SPECIFICATIONS
Alternator pulley shaft nut 50 pound-feet (68 Nm)
STARTER
Removal 9. Open the hood.
1. Park the machine on a level surface and apply the 10. Disconnect the wires and cables from the terminals
parking brake. on the starter.
7. If the machine has only one battery. disconnect the 11. Remove the two cap screws and lock washers that
negative battery cable from the battery. fasten the starter to the flywheel housing.
8. If the machine has two batteries. remove the 12. Remove the starter.
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.
4. Close the hood. 8. Install the cap screws and lock washers that fasten
the battery cover to the machine.
ALTERNATOR
Removal 9. Open the hood.
1. Park the machine on a level surface and apply the 10. Install a 1/2 inch breaker bar in the bracket for the
parking brake. tension pulley.
7. If the machine has only one battery, disconnect the 11. Use the breaker bar to move the tension pulley just
negative battery cable from the battery. 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.
15. Remove the cap screw and lock washer that fasten 6. Tighten the nut to 50 pound-feet (68 Nm).
the link to the bottom of the altnerator.
7. Remove the alternator from the vise.
12. Install the lock washer and the nut on the B + ter-
minal.
16. Hold the alternator and remove the cap screw and
lock washer at the top of the alternator.
13. Connect the connectors to the alternator.
17. Remove the alternator from the mounting bracket.
14. Use the breaker bar to move the tension pulley just
far enough to install the drive belt. Install the drive belt
18. Fasten the pulley of the alternator in a vise that has
on the alternator.
soft jaws.
15. Remove the breaker bar.
19. Remove the nut and lock washer from the shaft of
the alternator.
16. Close the hood.
Installation
1. Install the fan on the shaft.
4. Start the lock washer and the nut onto the shaft.
18. If the machine has two batteries, remove the 19. Install the battery cover.
terminal nut from the terminal. Install the negative
battery cable on the terminal. Make sure the jumper 20. Install the cap screws and lock washers that fasten
cable is installed on the terminal. Install the terminal nut the battery cover to the machine.
on the terminal.
3. Raise the loader frame until the support strut is 11. Remove the old drive belt.
against the end of the lift cylinder.
12. Install the new drive belt on the pulley on the water
4. Stop the engine. pump and the pulley on the crankshaft.
5. Install the pin in the support strut. 13. Align the coupling with the pulley on the crankshaft.
6. Open the hood. 14. Install the cap screws, flat washers, and lock
washers that fasten the coupling to the pulley on the
7. Install a 1/2 inch breaker bar in the bracket for the crankshaft. Tighten the cap screws to 70 to 84 pound-
tension pulley. feet (95 to 114 Nm).
8. Use the breaker bar to move the tension pulley just 15. Use the breaker bar to move the tension pulley just
far enough to release the tension on the drive belt. far enough to install the drive belt. Install the drive belt
Remove the drive belt from the alternator. on the alternator.
INSTRUMENT CLUSTER
Removal Gauge, Voltmeter, or Tachometer
Removal and Installation
1 . Remove the screws (16) that fasten the instrument
cluster to the instrument console.
1. Remove the instrument cluster from the instrument
console.
2. Pull the instrument cluster out of the instrument
console. 2. Remove the four screws (10) that fasten the cover
(17) and the retainer (18) to the body (11).
3. Disconnect the connectors for the wiring harness
from the instrument cluster 3. Remove the cover (17).
4. Remove the instrument cluster from the machine. 4. Remove the retainer (18).
2. Turn the socket (5) counterclockwise and remove 8. Install the screws (21) that fasten the gauge (1,2, or
the socket (5). 15), voltmeter (14), or tachometer (13) to the body (11).
3. Pull the bulb (3) from the socket (5) and install a 9. Install the retainer (18).
new bulb (3).
10. Install the cover (17).
4. Install the socket (5) and turn the socket (5) clock-
wise to hold the socket (5) in place. 11. Install the screws (10) that fasten the cover (17)
and the retainer (18) to the body (11).
5. Install the instrument cluster in the instrument
console. 12. Install the instrument cluster in the instrument
console.
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 in anyone of the strips,
the circuit board must be replaced.
6. RUBBER
4.CUP
BOOT
2. OIL
TEMPERATURE
GAUGE
1. WATER
TEMPERATURE
GAUGE
18. RETAINER
17. COVER
B861764R
Bur 8-17210
Issued 1-91 Printed in U.S.A.
Section
4002
TABLE OF CONTENTS
SPECIFICATIONS 3
Flood Lamp Switch, High Pressure Switch, and Air Conditioning Compressor Clutch 28
Cab Harness 32
Canopy Harness 50
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 BMF31 E
Group size 31
Reserve capacity , 170 minutes
Cold cranking capacity
At OaF (-1JOC) 700 amperes
At -20F (-29C) 520 amperes
Load for Capacity (Load) Test 350 amperes
Plates per cell 17
Approximate weight with electrolyte 57 pounds (25.8 kg)
Nonspill caps Not required on this machine
Batteries, optional
Production battery
J I Case part number 0128393 or BMF28SW
Group size 28
Reserve capacity 110 minutes
Cold cranking capacity
At OaF (-17C) 525 amperes
At -20F (-29C) 390 amperes
Load for Capacity (Load) Test 265 amperes
Plates per cell , , , , , " .., , , ' ' , ,..,.'.. 12
Approximate weight with electrolyte , 44 pounds (19.9 kg)
Nonspill caps Not required on this machine
Replacement battery
J I Case part number .0127414 or BMF28S
Group size ,' 28
Reserve capacity 110 minutes
Cold cranking capacity
At OaF (-1JOC) 525 amperes
At -20F (-29C) 390 amperes
Load for Capacity (Load) Test 265 amperes
Plates per cell ' 12
Approximate weight with electrolyte 29 pounds (13.2 kg)
Nonspill caps Not required on this machine
Alternator
Standard 12 volts, 65 amperes
Optional " 12 volts, 95 amperes
Voltage regulator solid state, not adjustable
Starter , 12 volt, solenoid actuated
NOTE: The battery must be at full charge and all connections clean and tight before testing. Use a multimeter for the
tests.
Terminal for wire 1A to ground 12 volts Check wire 1A between the positive battery
terminal and alternator.
Terminal for wire 34 to ground Approximately Check the wire between the alternator and the in-
10 volts 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 Check the battery cable to the positive post of the
ground battery.
NOTE: Put the transmission control lever in NEUTRAL. Have another person hold the key switch in the START position.
Terminal for wire 21 B 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.
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 Bad key switch (4).
the IGN terminal of the key switch
Check between the BAT terminal and Continuity Bad key switch (4).
the ACC terminal of the key switch
NOTE: Have another person hold the key switch in the START position.
Between the START terminal and the Continuity Bad key switch (4).
BAT terminal of the key switch
Terminal for wire 1C to ground 12 volts Check wire 1C between the starter relay (5) and
battery.
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).
NOTE: Put the transmission control lever in NEUTRAL. Have another person hold the key switch in the START position.
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).
NOTE: Put the transmission control lever in NEUTRAL. Have another person hold the key switch in the START position.
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).
NOTE: Disconnect the wires from the ether injection switch. Push down and hold the button.
Check between the terminals of the Continuity Bad ether injection switch.
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 3 from 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 Bad ether injection temperature switch.
ether injection temperature switch
Terminal for wire 3to ground 12 volts Check circuit between the fuel shutoff solenoid
and the key switch (4). Check the key switch (4).
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 Bad ground connection between the coolant tem-
coolant temperature sender and the perature sender and the engine block.
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 Bad ground connection between the converter
converter temperature sender and temperature sender and the converter housing.
the converter housing.
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.
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 Check the circuit between the connector and the
for wire 33 at the master cylinder re- master cylinder reservoir level switch (11). Also
servoir level switch (11) check the master cylinder reservoir level switch
(11) .
Terminal T2 in connector to ground 12 volts Check the circuit between the connector and the
key switch (4). Also check the 10 ampere 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.
Terminal T4 in connector to ground 12 volts Check the circuit between the connector and the
cab relay. Also check the 15 ampere fuse and cab
relay. See page 4002-27.
Terminal T5 in connector to terminal Continuity Check the circuit between the connector and the
for wire 34 at alternator (2) alternator (2). Also check the alternator (2).
Terminal T7 in connector to ground Continuity Check the circuit between the connector and the
oil pressure switch. Also check the oil pressure
switch. See page 4002-19.
Terminal T8 in connector to terminal Continuity Check the circuit between the connector and air
for wire 38 at the air filter switch filter filter switch. Also check the air filter switch. See
switch. See page 4002-19 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 T10 in connector to ground Continuity Check the circuit between the connector and the
coolant temperature sender (12). Also check the
coolant temperature sender (12).
Terminal T11 in connector to ground Continuity Check the circuit between the connector and the
converter temperature sender (13). Also check
the converter temperature sender (13).
Terminal T12 in connector to ground 12 volts Check the circuit between the connector and the
driving lamp switch. Also check the driving lamp
switch. See page 4002-27.
Terminal T14 in connector to ground Continuity Check the circuit between the connector and the
fuel level sender. Also check the fuel level sender.
See page 4002-19.
Terminal T18 in connector to terminal Continuity Check the circuit between the connector and the
for wire 36H at the hydraulic filter hydraulic filter switch. Also check the hydraulic
switch. See page 4002-19. 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 T18 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 and the key switch (4). See page
4002-19 for the diode.
Terminal for wire 31S to terminal for Continuity Check the circuit between the connector and the
wire 31 S at the alternator (2) alternator (2). Also check the alternator (2).
Terminal for wire 23F to ground 12 volts Check the circuit between the connector and the
key switch (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 Check the circuit between the connector and the
wire 32F at the transmission filter transmission filter switch. Also check the trans-
switch mission filter switch. See page 4002-19.
Terminal for wire 23F to ground 12 volts Check the circuit between the connector and the
key switch (4). Also check the 10 ampere fuse and
the key switch (4).
NOTE: Have another person hold the key switch in the momentary ground position, halfway between ON and START.
Terminal for wire 32F to ground Continuity Check the circuit from the connector through the
diode to the key switch (4). Also check the diode
in the circuit and the key switch (4). See page
4002-19 for the diode.
CONNECTOR G
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.
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.
Check between the housing of the Continuity Bad ground connection between the oil pressure
oil pressure switch and the engine switch and the engine block.
block
Terminal for wire 31 P to ground 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 between the housing of the Continuity Bad ground connection between the fuel level
fuel level sender and the machine sender and the machine frame.
frame
Terminal for wire 36F to ground 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.
Terminal for wire 36P to ground 12 volts Check the circuit between the parking brake
switch and the instrument cluster. Also check the
instrument cluster. See page 4002-11 .
NOTE: If the readings are good, replace the parking brake switch.
Terminal for wire 22 to ground Continuity Bad circuit between parking brake relay and the
neutral start switch. Also check the neutral start
switch. See page 4002-11 .
Terminal for wire 238 to ground 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 .
Terminal for wire 39B to ground 12 volts Check wire 39B to the warning buzzer (1). Also
check the warning buzzer (1).
Terminal for wire 36P to ground 12 volts Bad parking brake relay.
Terminal for wire 32F to ground 12 volts Check the circuit between the transmission filter
switch and the instrument cluster. Also check the
instrument cluster. See page 4002-11 .
NOTE: If the readings are good, replace the transmission filter switch.
Terminal for wire 36H to ground 12 volts Check the circuit between the hydraulic filter
switch and the instrument cluster. Also check the
instrument cluster. See page 4002-11.
NOTE: If the readings are good, replace the hydraulic filter switch.
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
5 ampere 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.
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).
Terminal for wire 19E to ground 12 volts Check the circuit between the clutch cutout switch
and the cab relay. Also check the 15 ampere fuse
and the cab relay. See page 4002-27.
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.
Terminal for wire 1384 to ground 12 volts 8ad boom lock switch.
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. Also check the 15 ampere fuse
and the cab relay. See page 4002-27.
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).
Terminal for wire 53 to ground Approximately Check the circuit between the return-to-dig relay
12 volts 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 in harness for wire 19E to 12 volts Check the circuit between the magnetic detent
ground and the cab relay (7). Also check the 15 ampere
fuse on page 4002-19 and the cab relay (7).
NOTE: Also check the return-to-dig relay (1) and the proximity switch (3).
.Terminal for wire 19E in connector 12 volts Check the circuit between the proximity switch
to ground and the cab relay (7). Also check the 15 ampere
fuse on page 4002-19 and the cab relay (7).
Terminal for wire 54 in connector Approximately Check the circuit between the proximity switch
12 volts and the return-to-dig relay (1). Also check the
return-to-dig relay (1).
NOTE: Turn the key switch to ON. Have another person hold down the horn button.
Terminal for wire 64B to ground 12 volts 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).
Both terminals for wire 19B to 12 volts Check the circuit between the horn relay and the
ground cab relay (7). Also check the 15 ampere fuse and
the cab relay (7).
Terminal for wire 64A to ground 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).
Terminal for wire 53 to ground Approximately Check the circuit between the optional switch
10 volts relay and the magnetic detent (2). Also check the
magnetic detent (2).
Terminal for wire 4 to ground 12 volts Check the circuit between the cab relay and the
key switch. Also check the key switch. See page
4002-11.
Terminal for wire 1B to ground 12 volts Check wire 1B between the cab relay and the
starter. Also check the starter. See page 4002-11.
Terminal for wire 13B2, 12A 12B, 12 volts Bad cab relay.
or 12C and ground
Terminal for wire 19A to ground 12 volts Check the circuit between the driving lamp switch
and the cab relay (7). Also check the 25 am pere
fuse and the cab relay (7).
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. See page 4002-11.
Terminal for wire 19B to ground 12 volts Check the circuit between the stop lamp switch
and the cab relay (7). Also check the 15 am pere
fuse and the cab relay (7).
NOTE: Have another person push down and hold the brake pedals.
Terminal for wire 19B to ground 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).
Terminal for wire 190 to ground 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).
Terminal T2 to ground 12 volts 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.
Terminal T1 to ground 12 volts Check the circuit between the flasher and the
flasher switch (10). Also check the flasher switch
(10).
Terminal for wire 19B to ground 12 volts Check the circuit between the turn signal switch
and the cab relay (7). Also check the 15 ampere
fuse and the cab relay (7).
NOTE: Make sure the flasher switch is in the OFF position. Move the turn signal switch for a left turn.
Terminal for wire 45R to ground 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).
Terminal for wire 64A to ground Approximately Ch8Ck wire 64A between the horn button and the
10 volts horn relay (5). Also check the horn relay (5).
NOTE: If the readings are good, install a new turn signal switch and horn button.
NOTE: Turn the key switch to ON. Move the turn signal switch (13) for a left turn.
Terminal for wire 47L to ground Intermittent Check the circuit between the left turn signal indi-
12 volts cator lamp and the flasher (12). Also check the
flasher (12).
NOTE: Turn the key switch to ON. Move the turn signal switch (13) for a right turn.
Terminal for wire 47R to ground Intermittent Check the circuit between the right turn signal in-
12 volts dicator lamp and the flasher (12). Also check the
flasher (12).
Flood Lamp Switch, High Pressure Switch, and Air Conditioning Compressor
Clutch Circuit 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.
Between the terminals of the high Open High charge in the air conditioning system. See
pressure switch Section 9002. Bad high pressure switch.
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
and the cab relay. Also check the 20 ampere fuse
and the cab relay. See page 4002-27 for the cab
relay.
Terminal for wire 42F to ground 12 volts Bad flood lamp switch.
Terminal for wire 42C to ground 12 volts Bad flood lamp switch.
Bur 8-17220 Issued 1-91 Printed in U.S.A.
4002-30
CAB HARNESS
Cab Harness
NOTE: The battery must be at full charge and all connections clean and tight before testing. Use a multimetet 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: Turn the key switch to ON. Put the dome lamp switch (1) in the ON position.
Terminal for wire 61 B 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).
NOTE: Turn the key switch to ON. Put the dome lamp switch (1) in the ON position.
Terminal for wire 61 B 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 61 to ground 12 volts Bad circuit between the blower switch and the
cab relay. Also check the 15 ampere fuse and the
cab relay. See page 4002-27 for the cab relay.
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).
Terminal for wire 63 to ground 12 volts Check the circuit between the rear wiper switch
and the cab relay. Also check the 15 ampere fuse
and the cab relay. See page 4002-27 for the cab
relay.
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
and the cab relay. Also check the 15 ampere fuse
and the cab relay. See page 4002-27 for the cab
relay.
NOTE: Turn the rear wiper switch to HIGH.
Terminal for wire 82 to ground 12 volts Check the circuit between the rear wiper motor
and the rear wiper switch (7). Also check the rear
wiper switch (7).
Terminal for wire 81 to ground 12 volts Check the circuit between the rear wiper motor
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 Open, Bad rear wiper park switch.
wiper park switch
Between the terminals of the rear Continuity Bad rear wiper park switch.
wiper park switch
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.
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.
Between the terminals of the low Open Low charge in the air conditioning system. See
pressure switch 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 15 ampere fuse
and the cab relay. See page 4002-27 for the cab
relay.
Terminal for wire 63A to ground 12 volts Check the circuit between the front wiper motor
and the cab relay. Also check the 15 ampere fuse
and the cab relay. See page 4002-27 for the cab
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).
Terminal for wire 67 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).
Terminal for wire 66 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 key switch and rotating beacon switch to ON.
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.
CONNECTOR
Connects one harT1
harness.
CAB HARNESS
NOTE: The battery must be at full charge and a/l connections clean and tight before testing. Use a multimeter for the
tests.
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.
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
switch. See page 4002-31.
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
the flood lamp switch. Also check the flood lamp
switch. See page 4002-31.
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
lamp switch. See page 4002-27.
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 Bad circuit between the front left turn signal and
12 volts flasher lamp and turn signal switch. Also check
the turn signal switch. See page 4002-27.
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
lamp switch. See page 4002-27.
NOTE: Turn the key switch to ON. Turn the driving lamp switch to ON.
Terminal for wire 41 to ground 12 volts Bad circuit between the front LH driving lamp and
the driving lamp switch. Also check the driving
lamp switch. See page 4002-27.
NOTE: Turn the key switch to ON. Turn the flood lamp switch to ON.
Terminal for wire 42F to ground 12 volts Bad circuit between the front LH flood lamp and
the flood lamp switch. Also check the flood lamp
switch. See page 4002-31.
NOTE: Turn the key switch to ON. Turn the flood lamp switch to ON.
Terminal for wire 42F to ground 12 volts Bad circuit between the front RH flood lamp and
the flood lamp switch. Also check the flood lamp
switch. See page 4002-31.
NOTE: Turn the key switch to ON. Turn the driving lamp switch to ON.
Terminal for wire 41 to ground 12 volts Bad circuit between the front RH driving lamp and
the driving lamp switch. Also check the driving
lamp switch. See page 4002-27.
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 Bad circuit between the front RH turn signal and
12 volts flasher lamp and turn signal switch. Also check
the turn signal switch. See page 4002-27.
NOTE: Turn the key switch to ON. Turn the driving lamp switch to ON.
Terminal for wire 41 to ground 12 volts Bad circuit between the front RH marker lamp and
the driving lamp switch. Also check the driving
lamp switch. See page 4002-27.
NOTE: Turn the key switch to ON. Turn the driving lamp switch to ON.
Terminal for wire 41T to ground 12 volts Bad circuit between the LH tail lamp and the
driving lamp switch. Also check the driving lamp
switch. See page 4002-27.
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
switch. See page 4002-27.
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.
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
driving lamp switch. Also check the driving lamp
switch. See page 4002-27.
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
stop lamp switch. Also check the stop lamp
switch. See page 4002-27.
NOTE: Tum the key switch to ON. Make sure the flasher switch is OFF. Move the tum signal lever for a right tum.
Terminal for wire 45R to ground Intermittent Bad circuit between the rear RH turn signal and
12 volts flasher lamp and the turn signal switch. Also
check the turn signal switch. See page 4002-27.
I
~
BUr 8-17220
4002-50
CANOPY HARNESS
NOTE: The batteries must be at full charge and all connections clean and tight before testing. Use a multimeter for the
tests.
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 LH work lamp and
the driving lamp switch. Also check the driving
lamp switch. See page 4002-27.
NOTE: Turn 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
switch. See page 4002-31.
NOTE: Turn 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
the flood lamp switch. Also check the flood lamp
switch. See page 4002-31.
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 driving lamp switch. Also check the driving
lamp switch. See page 4002-27.
NOTE: Turn the key switch to ON. Make sure the flasher switch is OFF. Move the turn signal fever for a left turn.
Terminal for wire 45L to ground Intermittent Bad circuit between the front LH turn signal and
12 volts flasher lamp and turn signal switch. Also check
the turn signal switch. See page 4002-27.
NOTE: Turn the key switch to ON. Turn the driving lamp switch to ON.
Terminal for wire 41 to ground 12 volts Bad circuit between the front LH driving lamp and
the driving lamp switch. Also check the driving
lamp switch. See page 4002-27.
NOTE: Turn the key switch to ON. Turn the flood lamp switch to ON.
Terminal for wire 42F to ground 12 volts Bad circuit between the front LH flood lamp and
the flood lamp switch. Also check the flood lamp
switch. See page 4002-31.
NOTE: Turn the key switch to ON. Turn the flood lamp switch to ON.
Terminal for wire 42F to ground 12 volts Bad circuit between the front RH flood lamp and
the flood lamp switch. Also check the flood lamp
switch. See page 4002-31.
NOTE: Turn the key switch to ON. Turn the driving lamp switch to ON.
Terminal for wire 41 to ground 12 volts Bad circuit between the front RH driving lamp and
the driving lamp switch. Also check the driving
lamp switch. See page 4002-27.
NOTE: Turn the key switch to ON. Make sure the flasher switch is OFF. Move the tum signal lever for a right turn.
Terminal for wire 45R to ground Intermittent Bad circuit between the front RH turn signal and
12 volts flasher lamp and the turn signal switch. Also
check the turn signal switch. See page 4002-27.
NOTE: Turn the key switch to ON. Turn the driving lamp switch to ON.
Terminal for wire 41 to ground 12 volts Bad circuit between the LH tail lamp and the
driving lamp switch. Also check the driving lamp
switch. See page 4002-27.
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
stop lamp switch. Also check the stop lamp
switch. See page 4002-27.
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 Bad circuit between the rear LH turn signal and
12 volts flasher lamp and the turn signal switch. Also
check the turn signal switch. See page 4002-27.
NOTE: Turn the key switch to ON. Turn the driving lamp switch to ON.
Terminal for wire 41 to ground 12 volts Bad circuit between the RH tail lamp and the
driving lamp switch. Also check the driving lamp
switch. See page 4002-27.
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
stop lamp switch. Also check the stop lamp
switch. See page 4002-27.
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 Interm ittent Bad circuit between the rear RH turn signal and
12 volts flasher lamp and the turn signal switch. Also
check the turn signal switch. See page 4002-27.
NOTE: Turn the key switch and rotating beacon switch to ON.
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.
Dual Battery
Instrument Cluster 9
BATTERY(S)
TABLE OF CONTENTS
SPECIFICATIONS See Section 4001
SAFETY RULES :. .. 3
SPECIAL TOOLS . 3
MAINTENANCE.. ..4
Electrolyte Level .4
NONSPILL CAPS.. . 5
BATIERY TEST 6
Visual Checks............... . 6
CHARGING A BATIERY. 8
SAFETY RULES
SPECIAL TOOLS
'",-Order special tools from either of the following com-
parses;
"-
<,
In Europe
VL Churchill ltd
P.O. Box 3, Daventry
Northants, NN11 4NF
England
The CAS-10147 tester is used to do the Capacity
(Load) Test. This tool is first used on page 4003-7.
MAINTENANCE
Electrolyte Level NOTE: Add water only. DO NOT add electrolyte.
If the battery is a maintenance free battery, check Inspecting and Cleaning a Battery
the level of the electrolyte every 1000 hours of operation
or six months, whichever occurs first. For all other batte- If damage causes an electrolyte leak, replace the
ries, check the level of the electrolyte every 250 hours of battery.
operation.
If the battery in your machine has nons pill caps, see
NOTE: A maintenance free battery will have the Nonspill Caps on page 4003-5 and check the condition
words Maintenance Free on the decal on the top of the of the nonspill caps. See Specifications in Section 4002
battery. If the center part of the decal has been removed to find if the battery in your machine must have nonspill
for access to the battery caps, it is possible that the caps.
words Maintenance Free have been removed from the
decal. Inspect the battery at regular intervals for dirt, corro-
sion, and damage. Electrolyte and dirt on the top of the
Check the level of the electrolyte more often during battery can cause the battery to discharge by making a
hot weather. The use of a large amount of water by the passage for the current to flow.
battery can be caused by high battery temperature or a
voltage regulator setting that is too high. Keep the elec- If the battery must be cleaned, remove the battery
trolyte level above the top of the plates in the battery at from the battery carrier and clean the battery, cable ter-
all times to prevent damage to the battery. minals, and the battery carrier. When available, use
Case Battery Saver and Cleaner according to the in-
NOTE: On maintenance free batteries it is neces- structions on the container. Case Battery Saver and
sary to remove the center part of the decal for access to Cleaner also helps prevent corrosion. If Case Battery
the battery caps. Do not discard the center part of the Saver and Cleaner is not available, use baking soda
decaf. Install the center part of the decal after the battery and water as a cleaner. DO NOT permit any type of
caps have been installed. cleaner to enter the cells of the battery.
Ifthe level of the electrolyte is low, add distilled water Install the battery in the machine and make sure the
or other clean water until the electrolyte is just below the fasteners are tight. Apply Case Battery Saver and
cell opening. Do not add more water than is needed. Cleaner or Urethane Seal Coat to the cable terminals to
Too much water can cause bad performance, a short prevent corrosion. See the Parts Counter Catalog. DO
service life, and corrosion around the battery. NOT apply grease.
NONSPILL CAPS
See Specifications in Section 4002 to find if the batt- The nonspill caps have a valve with a stem made of
ery(s) in your machine must have nonspill caps. lead and rubber. When the nons pill cap is turned
upside down, the weight of the lead holds the rubber
stem against the breather hole, preventing the loss of
electrolyte.
BATTERY TEST
NOTE: To correctly test a battery, 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.
A hydrometer is used to check the specific gravity 4. Make a record of the corrected specific gravity
(weight) of the electrolyte. The specific gravity is an reading for each cell.
indication of the level of charge for each celt.
5. If the difference between the high reading and the
Hydrometers are made to show the correct specific low reading is .050 or more, charge the battery and
gravity when the temperature of the electrolyte is 80F check the specific gravity again. If after charging, the
(26.JOC). difference is still .050 or more, install a new battery.
When you check the specific gravity, you must know 6. The corrected specific gravity reading shows the
the temperature of the electrolyte. If your hydrometer level of charge for the cell. The level of charge must be
does not have a thermometer, get a thermometer to at least 75% in each of the cells. In maintenance free
check the temperature of the electrolyte. The thermo- batteries the level of charge is at least 75% if the cor-
meter must indicate a high temperature of at least rected specific gravity reading is 1.240 or higher. In all
120F (52C). other batteries the level of charge is at least 75% if the
corrected specific gravity reading is 1.230 or higher.
1. Remove enough electrolyte from a cell so that the
float is free in the tube. 7. If the difference between the high reading and the
low reading is less than .050, and the level of charge is
NOTE: If the specific gravity cannot be checked at least 75% in all of the cells, do the Capacity (Load)
without first adding water to the cell, the battery must be Test.
charged for 15 minutes at 15 to 25 amperes to mix the
water with the electrolyte. Then check the specific 8. If the difference between the high reading and the
gravity. low reading is less than .050, but the level of charge is
less than 75% in any of the cells, charge the battery and
2. Read the float. check the specific gravity again. If after charging:
3. Read the thermometer If the reading is above 80F a The level of charge is less than 75% in any of
(26.JOC)add specific gravity points to the reading for the cells, discard the battery.
specific gravity. If the reading is below 80F (26SC)
subtract specific gravity points from the reading for b. The level of charge is at least 75% in all of the
specific gravity. See the following illustration and add or cells, do the Capacity (Load) Test.
subtract specific gravity points as needed.
Capacity (Load) Test NOTE: Never apply a load for longer than 15 seconds.
After each 15 seconds, turn the load control knob to OFF
This test can be done using a variable load tester for at least one minute.
such as the Sun Electric VAT-33. Other test equipment
can be used. Connect the test equipment according to 4. Apply a 15 ampere load to the battery for 15
the instructions of the manufacturer of the equipment. seconds. Wait at least three minutes before applying
the load again.
1. The level of charge of the battery must be at least
75%. Do the Specific Gravity Check in this section 5. Check and make a record of the temperature of the
electrolyte.
2. Prepare the tester (Sun Electric VAT-33 shown) for
the test. 6. Find the correct load for this test in Specifications in
Section 4002.
a. Select the voltmeter range that will measure 1
to 18 volts. NOTE: The correct load is half of the cold cranking
amperes at OaF (-17"C).
b. Make sure the load control knob is in the OFF
position. 7. Turn the load control knob until the ammeter indi-
cates the specified load Keep the load for 15 seconds
c. Select the ammeter range that will measure 0 and read the voltmeter. Turn the load control knob to
to 1000 amperes. OFF.
d. Move the volt lead switch to the INT. position. 8. Compare the test reading and the temperature of
the electrolyte to the chart below.
3. Connect the tester to the battery as shown.
Temperature of Minimum Voltage
electrolyte
B790499J
CHARGING A BATTERY
The charging rate must be decreased if:
851285
NOTE: A maintenance free battery will have the words access to the battery caps, it is possible the words
Maintenance Free on the decal on the top of the battery. Maintenance Free will have been removed from the
If the center part of the decal has been removed to get decal.
851286
2. Fill each cell to the top of the separators with elec- 5. Charge the battery at 30 amperes until the specific
trolyte. This will permit the volume of electrolyte to gravity is 1.250 or more and the temperature of the elec-
increase when heated by charging the battery. trolyte is at least 60F (15'soC).
3. Install the caps on the battery. If the battery in your 6. If necessary, fill each cell with electrolyte until the
machine must have nonspill caps, install the nonspill electrolyte is just below split ring at the bottom ofthe cell
caps. See Specifications in Section 4002 to find if the opening.
battery in your machine must have nons pill caps.
TABLE OF CONTENTS
SPECIFICATIONS
Case part number A 170746
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
NO-LOAD TEST
General Information Test Equipment
1. The No-Load Test is done with the starter removed The No-Load Test can be done using a Sun Electric
from the engine. 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 A remote starter button is needed to actuate the
housing. Turn the gear to turn the starter drive and the starter.
armature.
A fully charged 12 volt battery is needed to supply
4. If the starter drive cannot be turned, disassemble the electricity to turn the starter.
the starter and make repairs as needed. Then do the
No-Load Test.
B831430J
B831431J
5. Connect the red voltmeter lead to the motor 7. Fasten the ammeter clamp around the positive
terminal on the starter solenoid. battery cable so that the tip of the arrow is toward the
?tarter.
o
o 0
o
1
B831432J
B831434J
6. Connect the black voltmeter lead to the mounting
flange on the starter.
1. Ammeter Clamp
B831433J
B831435J
IMPORTANT: Steps 9, 10, and 11 must be done 2. Low armature shaft speed and high current draw
rapidly. Do not load the battery for more than 15 are indications of too much friction. Possible causes of
seconds at one time. After the battery has been loaded too much friction are:
for 15 seconds, let the starter cool for 60 seconds.
a. Tight, dirty, or worn bearings.
9. Actuate the remote starter button and turn the load
control until the voltmeter indicates 11 volts. b. A bent armature shaft.
I 12
3.. If the armature does not rotate and the current draw
is high, possible causes are:
c. Damaged bearings.
B831436J
a. An open field armature circuit. Disassemble
the starter and inspect the field coil connections.
1. Remote Starter Button
2. Load Control b. An open armature coil. Disassemble the
3. Voltmeter starter and check for burned commutator bars.
4. Ammeter Use an armature tester to test the armature. Use
5. Hand Held Tachometer the instructions included with the armature tester.
10. Look at the ammeter and make a record of the c. Brushes not making good contact with the
ammeter indication. commutator bars. Check for high insulation
between the commutator bars, broken brush
11. Use the hand held tachometer and check the springs, or worn brushes.
armature shaft speed. Make a record of armature shaft
speed. 5. Low armature shaft speed and low current draw are
indications of:
12. Release the remote starter button and turn the load
control to the OFF position. a. Dirt or corrosion on connections.
1. If the current draw and the armature shaft speed c. Dirty commutator bars.
are within the ranges under Specifications, the starter is
good. d. All causes in step 4.
6. High armature shaft speed and high current draw coil. Do the No-Load Test again to check for improve-
are indications of a short circuit in the field coil. It is diffi- ment in the operation of the starter.
cult to find a short circuit in a field coil. Install a new field
DISASSEMBLY
STEP 1 STEP 4
Pull back the boot on the motor terminal and loosen and Remove the cover.
remove the nut and lock washer.
STEP 5
STEP 2
STEP 6
STEP 7 STEP 10
Remove the field frame assembly. Remove the starter drive housing from the starter sole-
noid.
STEP 8
STEP 11
STEP 12
STEP 13 STEP 16
Remove the O-ring from the groove in the starter drive Remove the bearing cage.
housing.
STEP 17
STEP 14
STEP 18
STEP 15
STEP 19 STEP 21
STEP 20 STEP 22
,1.0M
Remove the cover. If necessry, remove the gasket from the cover.
INSPECTION
All parts except the starter drive must be cleaned Armature
using mineral spirits and a brush or cloth. Use a clean,
dry cloth to clean the starter drive. 1. Test the armature on an armature tester. Use the
equipment manufacturer's instructions.
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.
B610616M
ASSEMBLY
STEP 23 STEP 26
Install the plunger in the starter solenoid. Install and tighten the screws.
STEP 24 STEP 27
If necessary, install a new gasket in the cover. Install the bearings in the bearing cage.
STEP 25 STEP 28
Install the cover. Lubricate the bearings and teeth of the idler gear with
the grease specified on page 4004-2.
STEP 29 STEP 32
STEP 30 STEP 33
Install the bearing cage as shown. Install a new O-ring in the groove in the starter drive
housing. Lubricate the O-ring.
STEP 31
STEP 34
STEP 35 STEP 38
741M
Start the starter drive into the starter drive housing. Assemble the starter drive housing and starter sol-
enoid.
STEP 36
STEP 39
STEP 40
STEP 41 STEP 44
Fasten the starter solenoid in the vise and tighten the Use the springs to hold the brushes in the brush holder
screws that hold the starter drive housing. as shown.
STEP 42 STEP 45
STEP 43 STEP 46
Install the field frame assembly. Put the springs on top of the brushes connected to the
brush holder.
STEP 47 STEP 50
Install the brushes that are connected to the field coil. Install the cover and align the cover with the brush
holder.
STEP 48
STEP 51
Use a cap screw to align the brush holder with the field
frame assembly. Install the tighten the screws that hold the brush holder.
STEP 49 STEP 52
B330816M
Move the brush holder so that the brush holder is even Install a lock washer, flat washer, and O-ring on the cap
with the end of the armature. screws. Lubricate the O-rings.
STEP 53 STEP 54
Install and tighten the cap screws. 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.
1. 12 Volt Battery B831438R 8. If the pinion gear started to move toward the starter
2. Starter drive housing, the hold-in winding is damaged. The
3. Battery Terminal complete starter solenoid housing assembly must be
4. Switch Terminal replaced.
5. Motor Terminal
95 AMPERE ALTERNATOR
TABLE OF CONTENTS
SPECIFICATIONS 2
DiSASSEMBLy 3
INSPECTION OF BRUSHES 7
ASSEMBLY 15
SPECIFICATIONS
12 Volt Alternator
Manufacturer Robert Bosch
Special Torques
Nut that fastens the pulley to the rotor shaft 44 to 52 pound-feet (60 to 70 Nm)
DISASSEMBLY
STEP 1 STEP 4
STEP 2 STEP 5
STEP 3 STEP 6
STEP 7 STEP 10
Disconnect the lead for the capacitor. Loosen and remove the nut, flat washer, and fiber
washers from the B + terminal.
STEP 8
STEP 11
STEP 9
STEP 12
STEP 13 STEP 16
Remove the cover and rotor from the stator and Loosen and remove the screws that fasten the rectifier
housing. bridge to the housing.
STEP 14 STEP 17
Loosen and remove the screws that fasten the bearing Remove the housing.
retainer to the cover. The rotor now can be removed.
STEP 18
STEP 15
STEP 19 STEP 20
Remove the insulator from the 0 + terminal. Remove the shield from the housing.
INSPECTION OF BRUSHES
STEP 21 STEP 24
Use an ohmmeter and check the continuity from each To replace the brushes, use a soldering iron to remove
terminal and brush. If the reading is zero, replace the the original brushes. Install the springs and new
brush or voltage regulator and brush holder. 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
STEP 22 sleeve.
STEP 25
Touch the leads of the ohmmeter to the slip rings. The Use a dial indicator and measure the runout of each slip
reading must be 2.52 to 3.08 ohms. If the reading is not ring. If the runout is more than 0.002 inch (0.05 mm) a
as specified, a new rotor must be installed. new rotor must be used or use a lathe to remove
enough material until the runout is less than specified.
STEP 27
STEP 29
STEP 31
STEP 32
STEP 37
b. Remove the bearing retainer. e. Press the new front bearing onto the rotor shaft
until the front bearing stops moving.
d. Install the bearing retainer on the rotor shaft. g. Press the new rear bearing onto the other end of
the rotor shaft.
B891870J
ASSEMBLY
STEP 39 STEP 42
Install a new shield in the housing. Install the housing on the rectifier bridge.
STEP 40 STEP 43
Install the insulator on the 0 + terminal. Install and tighten the screws that fasten the rectifier
bridge to the housing.
STEP 41
STEP 44
STEP 45 STEP 48
Check for a short circuit between the terminal and the Install the rotor in the cover.
housing. If there is continuity, the insulator is bad.
STEP 49
STEP 46
STEP 50
STEP 47
STEP 51 STEP 54
Install and tighten the screws evenly that fasten the Install the voltage regulator and the brush holder. Be
housing, stator, and cover. careful not to damage the brushes.
STEP 52 STEP 55
Install the capacitor and tighten the screw. Install the screws and flat washers and tighten the
screws.
STEP 53
STEP 56
STEP 57 STEP 59
Fasten the pulley in a vise with soft jaws. Tighten the nut
Install the pulley and the tapered bushing. to 44 to 52 pound-feet (60 to 70 Nm)
STEP 58
Install the lock washer and start the nut onto the shaft.
TABLE OF CONTENTS
SPECiFiCATIONS 2
DISASSEMBLY 3
INSPECTION OF BRUSHES 8
ASSEMBLY 14
SPECIFICATIONS
Rated output. 14 volts at 65 amperes
DISASSEMBLY
STEP 1 STEP 4
Fasten the pulley in a vise that has soft jaws and loosen Remove the fan.
end remove the nut and lock washer.
STEP 5
STEP 2
M
.;:;::~..:.:: ....
STEP 6
STEP 3
STEP 7 STEP 10
Make an alignment mark on the front and rear hous- Remove the front housing and rotor from the rear
ings. housing.
STEP 8 STEP 11
Loosen and remove the screws that hold the front and Loosen and remove the screws that hold the retainer for
rear housings together. the rotor.
STEP 9 STEP 12
Hold the stator and hit the front housing with a soft Remove the rotor.
hammer to separate the front housing from the stator.
STEP 13 STEP 16
;1~~?07M
Use an acceptable puller and press the rotor out of the Loosen and remove the screw that holds the con-
spacer and bearing. denser.
STEP 14 STEP 17
Remove the retainer. Disconnect the lead from the condenser from the
terminal and remove the condenser.
STEP 15
STEP 18
STEP 19 STEP 22
Loosen and remove the nut, lock washer and flat Remove the insulators from the D + terminal.
washer from the B + terminal.
STEP 23
STEP 20
STEP 21 STEP 24
Loosen and remove the nut, lock washer and flat Carefully remove the stator and rectifier bridge from the
washer from the D + terminal. rear housing.
STEP 25 STEP 27
Turn the insulator off of the D + terminal. Use a screwdriver to start the cover for the slip rings out
of the rear housing.
STEP 26
STEP 28
INSPECTION OF BRUSHES
STEP 29 STEP 32
Use an ohmmeter and check the continuity from each To replace the brushes, use a soldering iron to remove
terminal and brush. If the reading is zero, replace the the original brushes. Install the springs and new
brush or voltage regulator and brush holder. 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
STEP 30 sleeve.
STEP 33
Touch the leads of the ohmmeter to the slip rings. The Use a dial indicator and measure the runout of each slip
reading must be 2.52 to 3.08 ohms. If the reading is not ring. If the runout is more than 0.002 inch (0.05 mm) a
as specified, a new rotor must be installed. new rotor must be used or use a lathe to remove
enough material until the runout is less than specified.
STEP 35
STEP 37
STEP 39
STEP 40
Touch the leads of the ohmmeter to a positive diode Touch the leads of the ohmmeter to a negative diode
and the heat sink as shown. Then reverse the leads. and the heat sink as shown. Then reverse the leads.
There must be a high reading and a low or zero reading. There must be a high reading and a low or zero reading.
Then test the other two positive diodes. If a positive Then test the other two negative diodes. If a negative
diode did not have readings as specified, the positive diode did not have readings as specified, the negative
diode is bad and a new rectifier bridge must be instal- diode is bad and a new rectifier bridge must be in-
led. stalled.
NOTE: If the tester you are using has a diode test func-
tion, use the tester according to the instructions of the
manufacturer to check the positive and negative
diodes.
ASSEMBLY
STEP 46 STEP 49
Align the boss on the cover with the notch in the rear Turn the insulator all the way onto the D + terminal.
housing.
STEP 50
STEP 47
STEP 51
STEP 48
STEP 52 STEP 55
Install and tighten the two screws that hold the rectifier Install the insulators on the B + terminal.
bridge.
STEP 56
STEP 53
STEP 54 STEP 57
Install the flat washer, lock washer and nut on the 0 + Install the lead from the condenser on the B + terminal.
terminal. Tighten the nut.
STEP 58 STEP 61
Install and tighten the screw that holds the condenser. Install the spacer with the smooth surface up.
STEP 59 STEP 62
Install the retainer with the smooth side up. Use an acceptable driver and press the bearing and
spacer all the way onto the shaft.
STEP 60
STEP 63
Install.the bearing.
Use an acceptable driver and press the other bearing
all the way onto the shaft.
STEP 64 STEP 67
.':1.~M
.-,-.'y~.-.";';"',;,.~"".M.-~..:
Install the rotor in the front housing. Install and tighten the screws that hold the alternator to-
gether.
STEP 65
STEP 68
Align the retainer with the front housing and install and
tighten the screws. Install the voltage regulator and brush holder.
STEP 66 STEP 69
Assemble the front and rear housings so that the align- Hold the voltage regulator and brush holder in place
ment marks are aligned. and install and tighten the screws.
STEP 70 STEP 72
STEP 71 STEP 73
Install the pulley and tapered bushing. Fasten the pulley in a vise that has soft jaws and tighten
the nut to 44 to 50 pound-feet (60 to 70 Nm).
INSTRUMENT CLUSTER
TABLE OF CONTENTS
INSTRUMENT CLUSTER 4
Replacing a Bulb .4
Circuit Board 4
Alternator 5
Voltmeter 6
B901651J
INSTRUMENT CLUSTER
4. Remove the instrument cluster from the machine. 4. Remove the screws that fasten the gauge or the tac-
hometer to the body.
5. Connect the connectors for the wiring harness to the
instrument cluster 5. Remove the gauge or the tachometer from the body.
If you are removing a gauge, you must pull the studs of
6. Install the instrument cluster in the instrument panel. the gauge from the clips in the body.
7. Install the screws that fasten the instrument cluster to 6. Install the new gauge or the new tachometer in the
the instrument panel. body. If you are installing agauge, make sure the studs
of the gauge are pushed into the clips in the body.
Replacing a Bulb
7. Install the screws that fasten the gauge or the tac-
1. Remove the instrument cluster from the instrument hometer to the body.
panel.
8. Install the retainer and the cover.
2. Turn the socket counterclockwise and remove the
socket.
9. Install the screws that fasten the cover and the re-
tainer to the body.
3. Pull the bulb from the socket and install the new bulb.
10. Install the instrument cluster in the instrument panel.
4. Install the socket and turn the socket clockwise to
hold the socket in place. Circuit Board
5. Install the instrument cluster in the instrument panel. The circuit board does not normally cause any
problems. Use an ohmmeter to check the continuity of
the strips. If there is no continuity in anyone of the strips,
the circuit board must be replaced.
2. If the warning lamp illuminates when the engine is b. A bad switch for the warning lamp.
running, the cause is probably the alternator or voltage
regulator. See Section 4002 and check the alternator c. A short circuit in the wire between the switch and
and the voltage regulator. the warning lamp.
1. If the gauge does not work correctly: a. A bad connection at the sender.
a. Disconnect the wire from the sender. b. A bad connection at the instrument cluster.
b. Turn the key switch to RUN c. Bad connection in the connectors in the wiring
harness.
c. Hold the wire against the frame or the engine to
make a good ground connection. d. A short circuit or an open circuit in the wires
between the instrument cluster and the sender.
d. Have another person look at the gauge. If you
are checking the water temperature gauge or the e. A bad sender.
oil temperature gauge, the needle must move all
the way to the top of the gauge. If you are checking f. A bad gauge.
the fuel level gauge, the needle must go all the way
to the bottom of the gauge. Voltmeter
e.lfthe needle moved, the sender is bad and must 1. Connect the positive lead of a test voltmeter to the
be replaced. If the needle did not move, the gauge positive post of the battery. Connect the negative lead
is bad or there is an open circuit in the wires of the test voltmeter to the negative post of the battery. If
between the sender and the gauge. the machine has two batteries, make sure the leads are
connected to the same battery.
f. Install the wire on the sender.
2. Start the engine and run the engine at 1500 rpm
g. See page 4 and remove the instrument cluster (r/min).
from the instrument console and disconnect the
wiring harness from the instrument cluster. 3. Read the test voltmeter.
h. See the wiring schematic in Section 4002 for the 4. Read the voltmeter for the machine and compare the
location of the terminal in the connector on the reading with the reading of the test voltmeter.
wiring harness. Connect one lead of an ohmmeter
to the terminal in the connector. Connect the other
lead of the ohmmeter to a good ground connec-
tion.
3. Remove the right side panel from the engine com- a. If the voltmeter indicated system voltage, do the
partment. next step.
4. Remove the connector from the W terminal of the al- b. If the voltmeter does not indicate system
ternator. voltage, repair or replace the wire between the
small connector and the ground connection near
5. Connect one of the leads of a voltmeter to the W the fuse blocks.
terminal in the alternator. Connect the other lead of the
voltmeter to a good ground connection on the engine. 12. Turn the key switch to the OFF position.
Adjust the voltmeter to indicate volts AC (alternating
current). 13 Connect one of the leads of an ohmmeter to the re-
maining terminal (yellow and red wire) in the small con-
6. Have another person start the engine while you look nector on the wiring harness.
at the voltmeter. The voltmeter must indicate a
minimum of six volts AC. Stop the engine. 14. Connect the other lead of the ohmmeter to the
terminal on the wire that was connected to the W
a. If the voltmeter indicated six volts or more, do the terminal of the alternator.
next step.
a. If the ohmmeter indicates continuity, the
b. If the voltmeter indicated less than six volts, see problem is in the tachometer, and the tachometer
Section 4006 or 4007 and replace the rectifier must be replaced.
bridge.
b. If the ohmmeter does not indicate continuity,
7. Remove the instrument cluster from the instrument see the wiring schematics in Section 4002 and
console. Make sure that the wiring harness is discon- check the continuity of wire 31S (yellow and red)
nected from the instrument cluster. through the main wiring harness and the side
console wiring harness. Repair or replace the wire
8. Turn the key switch to the RUN position. as necessary.
TABLE OF CONTENTS
SPECiFiCATIONS..... .. .. . 3
SPECIAL TOOLS 4
Removal.......... ..5
Installation........ . , ,. ... 8
STEERING COLUMN 10
Removal 10
Installation 14
Removal...... . 18
Installation... . 18
Removal.................................. ...20
Installation.... 21
Removal . .............. .. 24
Installation.. . ................ . 24
Removal . ............................ 26
Installation . .. 26
SPECIFICATIONS
Special torques
Nut for the steering wheel 384 to 444 pound-inches (43 to 50 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)
SPECIAL TOOLS
Order special tools from one of the following ad-
dresses:
Service Tools
P.O. Box 314
Owatonna, Minnesota 55060
VL Churchill Ltd
P.O. Box 3, Daventry
Northants, NN11 4NF
England B4095088M
CAS-10486 Puller
The tool shown is needed to remove the steering This tool is used to remove the ball joint for the steering
wheel. Make the tool in your shop. This tool is first used cylinder from the axle. This tool is first used on page 20.
on page 5.
4
6 7 B902174J B4097488M
CAS-2151 Wrench
Make from 1/4 in (6 mm) Cold Rolled Steel This tool is used to remove and install the tie rod This
1. 2 In (50 mm) tool is first used on page 20.
2. 1 In (25.4 mm)
3. 5/8 In (19 mm)
4. 3/8 In (9.5 mm)
5. 3/4 In (19 mm)
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 1 In Screws Required
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.
9. Open the access cover at the rear of the hood. This 11. Clean the hose connections at the steering control
will give you access to the hoses connected to the front valve (6).
of the steering control valve (6).
Jill""'" 12. Put identification tags on the hoses to the steering
control valve (6).
15. Loosen and remove the two cap screws (7) and lock
washers that hold the steering control valve (6) to the
10. Loosen and remove the three cap screws that hold bracket (8) for the steering column (5).
the access panel shown. Remove the access panel.
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).
18. Hold the steering control valve (6) and remove the
cap screws (11) and lock washers.
20. Loosen and remove the three hoses and two fittings
from the steering control valve (6).
2 STEERING WHEEL
12. DIRECTION
CONTROL LEVER
B902295J
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).
11. Install the steering wheel (2) and install the nut (4).
Tighten the nut (4) to 384 to 444 pound-inches (43 to 50
Nm).
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.
16. Check the level of the oil in the reservoir and add oil
as required.
2. STEERING WHEEL
~ 5. STEERING COLUMN
B902295J
STEERING COLUMN
Removal 6. Remove the three screws that hold the rear cover for
the steering column (5).
1. Park the machine on a level surface and apply the
parking brake.
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.
2. STEERING WHEEL
-,
.'" 5. STEERING COLUMN
B902295J
9. Loosen and remove the screws that hold the control 11. Remove the bulbs for the turn signals and discon-
console. nect the wiring from the lamp and warning flasher swit-
ches.
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).
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)
that fasten the plate (10) to the bracket (8) for the
steering column (5).
NOTCH
B902308J
Installation 11. Install the bulbs for the turn signals and connect the
wiring for the lamp and warning flasher switches.
1. Install the steering column (5) through the bracket
(8)
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.
5 Install the sleeve (15) on the end of the control rod 12. Install the control console.
(19).
6. Align the hole in the 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).
B90230BJ
14. Connect the wiring for the turn signals. 16. Install and tighten the three screws that hold the rear
cover for the steering column (5).
2. STEERING WHEEL
5. STEERING COLUMN
B902295J
2. Put an identification tag on one of the hoses (1). 2, Tighten the cap screws (9) to 580 to 696 pound-feet
(786 to 944 Nrn).
3. Disconnect the hoses (1) from the steering cylinder
(2), 3 Align the steering links (7) with the piston rod eyes
and install the pins (6),
4, Install a plug in each hose (1),
4, Install the bolts (5), lock washers (4), and nuts (3),
5. Loosen and remove the nuts (3), lock washers (4), Tighten the nuts (3),
and bolts (5) for the pins (6) that fasten the steering links
(7) to the piston rod eyes of the steering cylinder (2), 5, Remove the plugs from the hoses (1) and connect
the hoses (1) to 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) 6 Lubricate the pins (6) for the steering links (7) with the
in the pins (6). grease specified in Section 1002,
7, Loosen and remove the cap screws (9) and 7, Check and adjust toe-in according to instructions in
hardened washers (10) that fasten the steering cylinder Section 5007,
(2) to the axle (11). There are access holes for the cap
screws (9) at each side of the front of the axle (11).
2. STEERING
CYLINDER
7. STEERING LINK
8892200J
Bur 8-17260
5001-20
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
Remove the nut and remove the ball joint from the arm.
STEP 3
Disconnect the hoses from the steering cylinder. Install
a plug in each hose and a cap on each fitting.
STEP 7
Repeat steps 4, 5, and 6 for the other end of the axle
STEP 4
STEP 8
Remove the cotter pin from the ball joint and loosen the .:e9g
nut several turns. Do not remove the nut at this time 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 5
STEP 9
STEP 10 STEP 13
Loosen and remove the cap screws and lock washers Remove the steering cylinder from the axle.
that fasten the steering cylinder to the axle.
Installation
STEP 11
STEP 14
STEP 12
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).
Hit the steering cylinder with a soft hammer to drive the
steering cylinder out of the axle.
STEP 16 STEP 19
B907621OM
NOTE: The photograph shows a plug being installed in Install the ball joint in the arm.
the steering cylinder. A hose fitting will be installed in
your steering cylinder.
STEP 20
Install the hose fitting.
STEP 17
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
STEP 18 axle.
STEP 23 STEP 26
Connect the hoses to the fittings in the steering cylinder Stop the engine and check for oil leaks.
STEP 24 STEP 27
Start the engine and run the engine at low idle. Check the level of the oil in the reservoir and add oil as
required.
STEP 25
Turn the steering wheel all the way to the right and left
several times to remove any air from the steering
system.
B902461J
3. Loosen and remove the nuts and flat washers from 3. Install a thick spacer (9) and a thin spacer (9)
the bolts that fasten the guard (2) for the drive shaft (3) between the front of the axle (4) and the frame.
to the frame. Do not remove the bolts at this time.
4. Start the pivot pin (6) into the frame, spacers (9) and
4. Lower the guard (2) and remove the guard (2) from axle (4).
under the machine.
5 Drive the pivot pin (6) into the rear pivot of the axle (4)
5. Loosen and remove the cap screws that fasten the but not through the rear pivot.
drive shaft (3) to the flange on the trans axle and remove
the drive shaft (3). 6. Install the thin spacer (9) between the rear of the axle
(4) and the frame. Use spacers (9) as required for
6. Raise the front wheels above the floor and use minimum end play between the frame and the axle (4).
suitable stands to hold the machine in place.
7. Drive the pivot pin (6) through the rear pivot and the
7. Install blocks between the axle stops and the frame to frame.
prevent the axle (4) from tilting.
8. Install the flat washers (7) and snap ring (5) on the
8. Loosen and remove the wheel nuts and hardened tapered end of the pivot pin (6).
washers and remove the wheels.
9. Hit the pivot pin (6) to move the pivot pin (6) toward
9. Fasten an identification tag to one of the hoses for the the front of the machine as far as possible.
steering cylinder.
10. Check the end play between the frame and the snap
10. Disconnect the hoses from the fittings in the ring (5) on the pivot pin (6) at the front of the machine.
steering cylinder. Install a plug in each hose and a cap Use flat washers (7) as required to remove any end
on each fitting. play
11. Remove the snap ring (5) from the rear of the pivot 11. Install a grease fitting (8) in each end of the pivot pin
pin (6). (6). Tighten the grease fittings (8).
12. Remove the flat washers (7). 12. Loosen and remove the plugs from the hoses and
the caps from the fittings for the steering cylinder.
13. Loosen and remove the grease fitting (8) from the
end of the pivot pin (6). 13. Connect the hoses to the steering cylinder.
14. Put a floor jack under the axle (4) to hold the axle (4) 14. Install the wheels, hardened washers, and nuts. DO
in position. NOT use an impact wrench to tighten the nuts.
15. Drive the pivot pin (6) out of the frame and through 15. Tighten the nuts to 200 to 260 pound-feet (270 to
the hole in the counterweight. 352 Nm).
16. Spacers (9) are used at the front and rear of the axle 16. Remove the blocks from between the axle stops
(4), between the axle (4) and the frame. Lower the axle and the frame.
(4) and remove the spacers (9).
17. Remove the stands and lower the wheels to the
17. Remove the axle (4) from under the machine. floor.
8. GREASE
FITTING
~19
6. PIVOT PIN ~ 5. SNAP
_' ~ 1 RING
7. FLAT .. :.~
WASHER ~ " ., .i:\:
~"\ \.",." ...
"\
C>~'~ . \
8. GREASE FITTING t:1 5. SNAP \
\
RING
\
\
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
18. Lubricate the pivot pin (6) for the axle (4). 22. Raise the guard (2) into alignment with the brackets
on the frame and install the bolts, flat washers, and
19. Install the drive shaft (3) and the cap screws that nuts. Remove the floor jack
fasten the drive shaft (3) to the flange on the transaxle.
23. Tighten the nuts to 100 to 150 pound-feet (136 to
20. Tighten the cap screws to 504 to 576 pound-inches 203 Nm).
(58 to 65 Nm).
24. Install the bar (1) on the guard (2) and install the
21. Use a floor jack and install the guard (2) under the bolts, flat washers, and nuts. Tighten the nuts.
drive shaft (3).
8902368J
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TOOL 2
TROUBLESHOOTING PROCEDURE 3
SCHEMATiC 9
SPECIFICATIONS
Location of relief valve In inlet section of loader control valve
SPECIAL TOOL
In the 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.
TROUBLESHOOTING PROCEDURE
Check the machine for oil leaks and damaged or missing parts. Repair as required.
Troubleshooting complete.
Troubleshooting complete.
8. If the reading was not between 2450 and 2600 psi (16
893 to 17 927 kPa, 169 to 179 bar), adjust the setting of
the relief valve.
2. Loosen the lock nut on the adjusting screw and turn 4. Check the setting of the relief valve again.
the adjusting screw clockwise to increase the setting or
turn the adjusting screw counterclockwise to decrease
the setting.
3. Disconnect the hose at the left side of the steering 7. If there is constant leakage, the piston packing is
cylinder. damaged and must be repaired. See Section 5006 for
repair instructions.
4. Install a plug in the hose. The thread size is 3/4-16.
1. Inlet
2. Outlet
3. Pilot
4. Check Valve
5. Spool and Sleeve Assembly
6. Drive Unk
7. Gerotor
B891058J
1. Inlet
2. To Steering Control Valve
3. Pilot Pressure Port
4. Relief Valve for
Steering System
5. Spring
6. Spool
B891059J
1. Backhoe Section
2. Loader Section
3. Outlet
4. Inlet
5. Drive Shaft
6. Coupling
B891060J
1. Inlet
2. To Reservoir
3. To Oil Cooler
4. From Steering Control Valve
5. Filter
6. Bypass Valve
7. Switch
8. Check Valve
B891 061 J
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
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
SPECIAL TOOLS
Order special tools from one of the following ad-
dresses:
Service Tools
PO. Box 314
Owatonna. Minnesota 55060
In Europe
VL Churchill Ltd.
PO. Box 3. Daventry
B785606M
Northants. NN11 4NF
England CAS-1239 Centering Spring Installation Tool
This tool is first used on page 5004-14.
DISASSEMBLY
STEP 1 STEP 4
Put the steering control valve in the vise so the end plate Remove 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. STEP 5
STEP 2
STEP 3
8523536M
Separate the metering gear set, spacer, drive shaft and
spacer plate.
Remove the Ferry head screws.
STEP 10
B8471788M
Remove the rotor from the stator Remove and discard the O-ring from the body.
STEP 8 STEP 11
._;.,
...
>zfq". ""'?IT . ;;:~'.<,'- ,,".
'B877704M
Remove and discard the O-ring from the stator. Find the anticavitation valves in the body. Put identifica-
tion marks on the body for use during assembly.
STEP 9
STEP 12
B8472388M
Remove and discard the O-ring from the end plate. ......."'.." .."'.~..'0&'~~~.,,".",
..".O_. , ... ,,, . V... ... . ..... 77698M
Remove the springs, pins, and balls from the ports in
the body.
STEP 13 STEP 16
8523923M
Remove the body of the steering control valve from the Remove the bearing.
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 STEP 17
body. The pin inside of the sleeve and spool can 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 14
8523925M
Remove the other washer.
STEP 18
STEP 15
8523927M
Use a punch to push the pin out of the sleeve and spool.
8523921M
Remove the washer.
STEP 19 STEP 22
B523929M 1888M
Pull the spool straight out of the sleeve. Remove the Remove the Allen head plug from the body of the
centering springs. steering control valve.
STEP 20 STEP 23
Push the centering springs out of the spool. There are Install a No. 8-32 screw in the seat for the check valve.
four centering springs and two spacers Do not lose
any of the centering springs.
STEP 24
STEP 21
Use pliers to pull the seat out of the body of the steering
control valve.
Remove the seal from the gland.
STEP 25
STEP 28
STEP 26
8523820M Put the body in the 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
B523822M
Remove and discard the O-rings from the seat.
~-
The gland in the 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.
Bur 8-12440 Issued 10-89 Printed in U.S.A.
5004-8
STEP 30
~.. B~it;88M
Remove and discard the O-ring from the bore for the
gland.
INSPECTION
Clean all parts in cleaning solvent. Put the parts on STEP 32
paper towels until the parts are dry. Do not use cloths to
wipe the parts dry.
STEP 31
81758A88J
STEP 34
B1757A88J
81759A88J
STEP 35 STEP 37
B1760A88J
STEP 36
88473288M
Use a feeler gauge to measure the clearance between
the rotor and stator. If the clearance is more than 0.005
inch (0.13 mm), a new metering gear set must be used.
2. END PLATE
6. STATOR
9. O-RING
8. METERING GEAR SET
27. WASHER
8871959J
ASSEMBLY
STEP 38 STEP 41
1. LARGE
O-RING
'~~;*a8M 852384 1M
Install a new O-ring in the bore for the gland. Lubricate Install new O-rings on the seat for the check valve, Lub-
the O-ring with petroleum jelly. ricate the O-rings with petroleum jelly, The large O-ring
must be installed on the end of the seat that has
threads,
STEP 39
STEP 42
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 ~,_ BJ3622M
steering control valve until the gland stops moving. Install the retainer in the bore for the check valve, Make
sure the retainer is flat in the bottom of the bore,
STEP 40
STEP 43
STEP 44 STEP 47
_~
_,__~
__
,__
~.~_,~_~~_,__
._~, .. -.---W~__
sse.
. ,~
Install the seat for the check valve in the bore. The end Install the backup ring in the bottom of the gland. Use
of the seat with threads must be up. petroleum jelly to hold the backup ring in place
STEP 45
STEP 46 STEP 49
STEP 50 STEP 53
8523633M
Put clean oil on the inside of the sleeve. Put the spool and sleeve in a vise 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
STEP 51 until the slots in the sleeve and spool for the centering
springs are in alignment.
STEP 54
8523635M
Put clean oil on the outside of the spool.
STEP 52
Install the tool shown on page 5004-2 through the slot
for the centering springs.
STEP 55
23637M
Install the spool in the sleeve. The spool must be in-
stalled straight into the sleeve. Turn the spool in both di-
rections as the spool is pushed into the sleeve.
STEP 56 STEP 59
B523919M
Push the centering springs into the spool. Move the tool Install a new spacer on the spool.
as necessary to put the centering springs in position.
STEP 60
STEP 57
8523728M
8523721M Put clean oil on the outside of the sleeve and spool.
Install the pin in the sleeve through the spool.
STEP 61
STEP 58
8523731M
Put clean oil on the bore in the body of the steering
Install the washer, bearing, and the other washer on the control valve.
spool.
STEP 62 STEP 65
B877701M
The sleeve and spool must be installed straight into the Install the pins in the ports.
body of the steering control valve
STEP 66
STEP 63
STEP 64
B8472088M
Put petroleum jelly on the O-ring for the stator. Install the
O-ring in the groove in the stator.
B877702M
Install the balls in the ports in the body that are marked
with identification marks.
STEP 68 STEP 71
B473688M B8480388M
Align the rotor and stator and push the rotor into the Install the spacer place on the stator. Turn the spacer
stator. plate to align the holes with the holes in the stator.
STEP 69
STEP 70
Lower the drive shaft into the spool and engage the pin
B524117M with the slot in the drive shaft. DO NOT let the drive shaft
Check the position of the slot in the drive shaft again come out of the rotor. Turn the stator and spacer plate
and make sure the slot is in the correct position. to align these parts with the body.
STEP 74 STEP 77
~. ~ B524128M
Install the spacer in the rotor on top of the drive shaft. Install the end plate on the metering gear set. Align the
holes in the end plate with the holes in the stator.
STEP 75
STEP 78
Put clean oil on the metering gear set, spacer plate, and
drive shaft assembly. Install the Ferry head screws.
STEP 76 STEP 79
B8472388M B8450288M
Put petroleum jelly on the O-ring for the end plate. Install Tighten the Ferry head screws to 100 to 150 pound-
the O-ring in the groove in the end plate. inches (11 to 17 Nm) in the sequence shown.
STEP 80
1. INLET
CHECK VALVE
2. DRIVE SHAFT
SECTION A-A
8871967J
SECTION C-C
SECTION B-B
TABLE OF CONTENTS
SPECiFiCATIONS ..... . 2
DISASSEMBLY ....3
INSPECTION . . 7
ASSEMBLY . 10
SPECIFICATIONS
Rotor and stator clearance .. ..0.005 inch (0.13 mm)
Special torques
Cap screws for fastening end plate. .. 212 to 319 pound-inches (24 to 36 Nm)
SPECIAL TOOL
Order special tools from one of the following ad-
dresses:
Service Tools
P.O. Box 314
Owatonna, Minnesota 55060
In Europe
VL Churchill Ltd.
PO Box 3, Daventry
B785606M
Northants, NN11 4NF
England CAS-1239 Centering Spring Tool
This tool is first used on page 5005-11.
DISASSEMBL Y
STEP 1 STEP 4
__ """"'""'............ 870981 OM
Put the steering control valve in the vise so the end plate Remove and discard the O-ring from the stator
is up. Loosen the cap screws.
STEP 5
STEP 2
B709812M Remove the metering gear set and spacer from the
Remove the cap screws and flat washers One cap body.
screw has a guide pin.
STEP 6
STEP 3
STEP 7 STEP 10
i!t/ipI
C
; i<.O!lIJIl9834M
Remove the spacer plate. Remove and discard the O-ring from the body.
STEP 8 STEP 11
B710010M
Separate the metering gear set and spacer. Loosen the plug in the body.
STEP 9 STEP 12
Remove and discard the other O-ring from the stator. Remove the plug.
STEP 13 STEP 16
B709912M B709920M
Remove the body of the steering control valve from the Remove the bearing,
vise. Turn the body up and let the steel balls, plungers,
and springs fall out of the body.
STEP 14
B710116M
B709916M Remove the other washer.
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. STEP 18
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
B709926M
Remove the retaining ring.
B709918M
Remove the washer.
STEP 19 STEP 22
B709928M
Use a punch to push the pin out of the sleeve and spool. Use an acceptable tool through the bore of the body
and remove the inner seal. Discard the inner seal.
STEP 20
STEP 23
Pull the spool straight out of the sleeve. Turn the spool
in both directions as the spool is pulled out of the Remove the outer seal from the bore. Discard the outer
sleeve. seal.
STEP 21
B709932M
Push the centering springs out of the spool. There are
four centering springs. Do not lose any of the centering
springs.
INSPECTION
Clean all parts in cleaning solvent. Put the parts on STEP 25
paper towels until the parts are dry. Do not use cloths to
wipe the parts dry.
STEP 27
3. BALL 3. BALL
B871978R
If the spool (2), sleeve (3), or bore in the body (1) of the 1. SPRING
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 2. PLUNGER
available separately
B709912A
Inspect the springs (1), plungers (2), and bs.lls (3) for
damage or wear. Use new parts as needed.
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.
12. SPOOL
20. CENTERING
SPRINGS
17. O-RING
21. O-RING
B871956R
ASSEMBLY
STEP 29 STEP 32
B710018M 8710030M
Lubricate the inner seal with clean oil. Use an acceptable driver and hammer and drive the
outer seal against the seat in the bore.
STEP 30
STEP 33
The inner seal is not difficult to install. Install the inner B710034M
seal through the opposite end of the bore shown in the Put clean oil on the inside of the sleeve.
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 34
STEP 31
8710036M
Put clean oil on the outside of the spool.
G!;f;j ~028M
Install the outer seal in the body with the lips of the outer
seal toward the outside of the body.
STEP 35 STEP 38
<r
2. CURVED SPRINGS
B871957R
STEP 36
,.1Ql2Q~_
Put the two flat springs in the slot of the tool with the two
curved springs between the flat springs.
Put the spool and sleeve in a vise with soft jaws. Tighten
the vise just enough to hold the spool and sleeve in po- STEP 40
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 37
STEP 41 STEP 44
8710118M
Install the retaining ring, The retaining ring must be able Put clean oil on the outside of the sleeve and spool.
to rotate free of the centering springs.
STEP 45
STEP 42
;-.'-~':Z-~"-:>-;':'<~."~::<:$:~~~-"~'
8710126M
8710120M Install the pin in the sleeve and through the spool.
Install the washer, bearing, and the other washer on the
spool. See step 43.
STEP 46
STEP 47 STEP 50
B710128M
The sleeve and spool must be installed straight into the Tighten the plug
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 STEP 51
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 on the bench and lower the body onto
the sleeve and spool.
STEP 48
STEP 52
STEP 49
STEP 53 STEP 56
B710218M
Install the spring and plunger. Apply petroleum jelly on each O-ring for the stator
Install an O-ring in the groove in each side of the stator.
STEP 54
STEP 57
STEP 58
STEP 59 STEP 61
8710228M 'B710232M
Install the spacer plate on the stator. Turn the spacer Put clean oil on the metering gear set. spacer plate, and
plate to align the holes with the holes in the stator. drive shaft assembly.
STEP 60 STEP 62
710212M
Hold the metering gear set, spacer plate, and drive Install the spacer in the rotor on top of the drive shaft.
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 STEP 63
the end of the drive shaft in alignment 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.
709820M
Install the end plate. Align the holes in the end plate with
the holes in the stator.
STEP 64 STEP 66
B709816M
Install the cap screw with the guide pin in the hole Tighten the cap screws to 100 to 150 pound-inches (11
shown. to 17 Nm) in the sequence shown.
STEP 65 STEP 67
B709812M
Install the remaining cap screws and flat washers. Tighten the cap screws to 212 to 319 pound-inches (24
to 36 Nm) in the sequence shown in step 66.
5006
TABLE OF CONTENTS
SPECIFICATIONS 3
Disassembly 4
Inspection 4
Assembly 6
Disassembly 8
Inspection 9
Assembly 9
SPECIFICATIONS
Two wheel drive steering cylinder tie rod nuts 324 to 504 pound-inches (37 to 57 Nm).
2. Fasten the steering cylinder (1) in a vise or other 11 . Remove the O-ring (9) and backup ring (14 ) from
holding equipment. Be careful to prevent damage to the outside of each gland (8). Remove the wiper (6) and
the tube (16) seal (7) from the bore of each gland (8).
3. One end of the piston rod (10) has two flat areas to Inspection
prevent the piston rod (10) from turning when the lock
nuts (3) for the rod eyes (2 and 17) are loosened. The 1. Discard the parts removed from the piston (11) and
rod eye (2) at the end of the piston rod (10) that has two the glands (8).
flat areas has LH threads. Prevent the piston rod (10)
from turning, loosen the lock nut (3), and turn the rod 2. Clean all parts in cleaning solvent.
eye (2) out of the piston rod (10).
3. Illuminate the inside of the tube (16). Inspect the
4. The rod eye (17) in the other end of the piston rod has inside of the tube (16) for deep grooves and other
RH threads. Prevent the piston rod (10) from turning, damage. If there is damage to the tube (16), a new tube
loosen the lock nut (3) and turn the rod eye (17) out of (16) must be used.
the piston rod (10).
4. Check to be sure that the piston rod (10) is straight. If
5. Loosen and remove the nut (4) from each tie rod (5) the piston rod (10) is not straight, install a new piston
and remove the tie rods (5) that hold the steering rod assembly (10 and 11).
cylinder (1) together.
5. Inspect the piston (11) for damage and wear. If the
6. Pull one end of the piston rod ("10)straight out of the piston (11) is damaged, or worn, a new piston rod
tube (16) until the piston (11) contacts the gland (8) assembly (10 and 11) must be used.
7. Use a soft hammer to drive the gland (8) out of the 6. Remove small scratches on the piston rod (10) and
tube (16) and pull the piston rod (10) straight out of the inside the tube (16) with emery cloth of medium grit.
tube (16) to prevent damage to the tube (16). Use the emery cloth with a rotary motion.
8. Remove the gland (8) from the piston rod (10). 7. Inspect both ends of the tube (16) for sharp edges
that will cut the gland O-rings (9) and remove the sharp
9. Use a soft hammer to drive the gland (8) out of the edges as necessary.
other end of the tube (16). Remove the gland (8 or 19).
8. Inspect both glands (8) for rust. Clean and remove
NOTE: The piston (11) cannot be removed from the rust as necessary.
piston rod (10). If the piston (11) or the piston rod (10) is
damaged, the piston rod assembly (10 and 11) must be
replaced.
Assembly 5. Install a new wear ring (12) in the wide groove in the
piston (11).
15. Push the piston rod assembly (10) straight into the
2. Install a new wiper (6) into the bore of each gland (8).
tube (16), and through the gland (16) at the other end of
The lip of the wiper (6) must be toward the outside end
the tube (16).
of the gland (8).
16. Carefully start the other gland (8) into the tube (16).
3. Install a new backup ring (14) in the groove on each
gland (8).
17. Make sure the ports in both glands (8) are installed
correctly and drive the gland (8) into the tube (16).
4. Install a new O-ring (9) in the groove on each gland
(8). The O-ring (9) must be between the backup ring
18. Install the tie rods (5) and nuts (4). Tighten the nuts
(14) and the small end of the gland (8),
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).
88861555
Piston
1. STEERING CYLINDER
8902049J
3. Install a new wiper (2) in the gland (5). The lip of the 12. Lubricate the wiper (2), backup ring (3), seal (4),
wiper (2) must be toward the outside of the gland (5). and O-ring (6) on the gland (5) with clean oil.
4. Install a new O-ring (6) in the groove on the outside of 13. Install the gland (5) on the piston rod assembly (7)
the gland (5). and push the gland (5) against the tube (10).
5. GLAND
8. SEAL
10. TUBE
B9020SOJ
TABLE OF CONTENTS
SPECIFICATIONS. 2
Inspection . ......5
SPLINDLE ................................ 11
Removal . ....11
Installation 16
Removal . .....21
Installation. . 25
TOE-IN 30
Measuring Toe-In 30
Adjustment 30
SPECIFICATIONS
Service
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)
STEP 1
r i'!!Y
STEP 2
STEP 3
STEP 7 STEP 10
Remove the flat washer and wheel bearing. Use two prybars and remove the spindle seal.
STEP 8 STEP 11
Remove the hub. Remove the dirt and grease from the spindle.
STEP 9 STEP 12
Use a chisel to move the spindle seal away from the Put an acceptable driver on top of the wheel bearing.
spindle.
STEP 13 STEP 15
Press the hub seal and wheel bearing out of the hub. 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.
STEP 14
Inspection
1. Clean the wheel bearings in cleaning solvent to
remove all indications of grease from the wheel bear-
ings.
STEP 16
STEP 17
STEP 18
STEP 22 STEP 24
3. HUB SEAL
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
STEP 23
Drive the new spindle seal all the way onto the spindle.
Be careful not to damage the spindle seal.
STEP 26
STEP 27 STEP 30
Install the hub onto the spindle. 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 28
STEP 31
STEP 32
STEP 36
STEP 34
1 .......
t. ..
. !">'::;u Remove the cap .
STEP 37
Remove the support from under the front axle and lower
the wheel to the floor.
STEP 35
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
STEP 39
SPINDLE
Removal STEP 42
STEP 40
Raise the front wheel off the floor and put an acceptable
support under the front axle. STEP 43
STEP 41
STEP 44 STEP 47
STEP 45 STEP 48
Pull the hub toward you to remove the outer wheel Loosen the nut on the lock pin.
bearing from the spindle. It can be necessary to hit the
hub with a soft hammer.
STEP 49
STEP 46
STEP 50 STEP 53
Drive the lock pin out of the spindle. 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 51
STEP 54
Loosen the nuts on the bolts that hold the pivot pin for
the steering link.
Remove the spacer.
STEP 52
STEP 55
STEP 56 STEP 59
Remove the snap ring at the bottom of the king pin Drive the king pin toward the top to prevent damage to
the seal.
STEP 57
STEP 60
STEP 58
STEP 61
---
8891545J
36. COlTER
PIN
Installation STEP 65
STEP 62
STEP 63 STEP 66
Install the spindle. 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 64
STEP 67
STEP 68 STEP 71
Install the lock pin. 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 69
STEP 72
Install the lock washer and nut but do not tighten the nut
now.
Install the snap ring. Hit the spacer and snap ring to
make sure that the snap ring is in the groove.
STEP 70
STEP 73
STEP 74 STEP 77
Install the spacer so that the grease fitting is toward the Tighten the nut that holds the lock pin.
center of the machine.
STEP 78
STEP 75
Align the steering link with the spindle and start the pivot
Install the snap ring. pin into the steering link.
STEP 76 STEP 79
Hit the spacer and snap ring to make sure that the snap Drive the pivot pin into the steering link.
ring is in the groove.
STEP 80 STEP 83
.~
,~
... ~.-
-.,;:..:.>>;
~?~
Tighten the nuts on the bolts that hold the pivot pin. Install the hub onto the spindle.
STEP 81 STEP 84
Drive the spindle seal all the way onto the spindle Be Install the outer wheel bearing.
careful not to damage the spindle seal.
STEP 85
STEP 82
STEP 86 STEP 89
Tighten the nut to 75 to 85 pound-feet (101 to 115 Nm) Install the wheel and wheel bolts. Do not use an impact
and turn the hub at the same time. Then loosen the nut wrench to install the wheel bolts.
to the first cotter pin hole.
STEP 90
STEP 87
Remove the support from under the front axle and lower
Install the cotter pin. the wheel to the floor.
STEP 88 STEP 91
Install the cap. 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.
Bur 8-12471 Issued 1-91 Printed in U.SA
5007-21
STEP 94
STEP 95
Loosen and remove the nut and lock washer from the
lock pin
Remove the snap ring at the bottom of the kingpin. Drive the kingpin out of the spindle.
Remove the spacer Remove the spindle and thrust bearing and put the
spindle out of the way.
Use an acceptable driver and drive the top bearing out Drive the bottom bearing out of the boss.
of the boss.
2. GREASE
FITTING
B891545J
36. COTTER
PIN
STEP 109
Put a bearing on a driver that has a pilot end. The Drive the seal into the boss until the driver touches the
number on one end of the bearing must be toward the boss.
driver. The tape on the driver is 1/4 inch from the
bearing to help install the bearing to the correct depth.
STEP 114
STEP 111
Drive the bearing into the boss until the bearing is even Install the spindle.
with the bottom of the boss.
STEP 119
STEP 116
Install the thrust washer. Install the thrust bearing so that the case is on top.
Align the spindle, thrust washer and thrust bearing with Install the lock washer and nut. Do not tighten the nut at
the front axle. Start the kingpin into the spindle so that this time.
the notch for the lock pin is toward the outside.
STEP 125
STEP 122
"
Use a soft hammer and drive the kingpin into the
spindle.
Install a new O-ring in the bottom boss. Use grease to
hold the O-ring.
STEP 126
STEP 123
Install a snap ring. Install the spacer so that the grease fitting is toward the
center of the machine.
STEP 128
STEP 131
Hit the spacer and snap ring to make sure that the snap
ring is in the groove. Install the snap ring.
Install a new O-ring in the top boss. Hit the spacer and snap ring to make sure that the snap
ring is in the groove.
STEP 133
Tighten the nut on the lock pin. Remove the support from under the front axle and lower
the wheel to the floor.
STEP 134
STEP 136
STEP 137
Lubricate the bearings for the kingpins.
TOE-IN
4. Lower the front wheels to the floor. 3. When the toe-in is correct, tighten the lock nut
nearest the flat on the piston rod first to 150 to 200
5. Turn the steering wheel as needed to put the front pound-feet (203 to 271 Nm). Then tighten the other lock
wheels in the straight position. nut to 150 to 200 pound-feet (203 to 271 Nm).
B ..
B861482R
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 JOINT 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)
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
The special tools shown on this page are required to
disassemble and assemble the planetaries and dif-
ferential.
Service Tools
P.O. Box 314
Owatonna, MN 55060
B4086.290M
B875432M CAS-2151 Wrench For Pinion Nut. Shown in use in step
1. CAS-1839-1 Gauge Tube 156.
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
B4094788M
Yoke to hold shaft. Order D149861 from J I Case. Not
Shown in use in step 156.
B4094188M B40974B8M
CAS-1842 Wheel Stud Removal and Installation. CAS-2151 Wrench to loosen and tighten tie rods for
Shown in use in step 3. steering cylinder. Shown in use in step 139.
'B4t068ssM , ...,:B4095oeaM
CAS-1980 V-Blade. Used to support coupling when CAS-1 0468 Puller. Used to remove ball joint from swivel
replacing a universal joint. First used in step 74. housing. Used in step 57.
MEASURING TOE-IN
A
B870171J
DISASSEMBLY OF PLANETARY
STEP 1 STEP 5
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
STEP 6
STEP 4
STEP 7
Remove the two Allen head screws that hold the carrier.
STEP 8 STEP 11
Remove the snap ring and sun gear. Install the cap screws just removed in the threaded
holes in the hub and tighten the cap screws evenly until
the ring gear is free of the swivel housing.
STEP 9
STEP 12
STEP 13
STEP 14 STEP 17
Remove the planetary housing and wheel bearing. Remove the hub.
STEP 15 STEP 18
Slide the inner wheel bearing off the swivel housing. Press the bushings from the hub only if new bushing(s)
are needed or a new hub is being installed.
STEP 16
STEP 19
STEP 20 STEP 23
Remove the retainer. Press the pinion shafts out of the carrier.
STEP 21 STEP 24
Remove the pinion gears and thrust washers being Remove the bearing cups and seal as required.
careful not to lose the needles.
STEP 22
ASSEMBLY OF PLANETARY
STEP 25 STEP 28
Press the pinion shafts into the carrier until the inner end
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 29
STEP 26
127M
Apply petroleum jelly to one side and the bore of the
pinion gears.
STEP 30
STEP 27
STEP 31 STEP 34
Install 30 needles in each pinion gear using petroleum Make sure that the threads in the pinion shafts are free
jelly to hold the needles in place. of lubricant.
STEP 32 STEP 35
Install the pinion gears so that the thrust washer is Apply 242 Loctite to the threads in the pinion shafts.
toward the carrier
STEP 36
STEP 33
Install the cover and Allen head screws and tighten the
Install the retainer and snap rings. Allen head screws to 300 pound-inches (34 Nm).
STEP 37 STEP 40
Press bushings into the hub as required. Install a bearing on the swivel housing.
STEP 38 STEP 41
STEP 39 STEP 42
Install the retaining ring. Install the planetary housing and the other bearing.
STEP 43 STEP 46
Align the large diameter bushing with the large hole in Install the thrust washer and spacer.
the swivel housing and install the ring gear.
STEP 47
STEP 44
STEP 45
STEP 49 STEP 51
Install the carrier. Use tool CAS-1842 and install and tighten the studs to
52 pound-feet (70 Nm).
STEP 50
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).
STEP 55
B90762tGM
Remove the nut and remove the ball joint from the
swivel housing,
Slide the inner wheel bearing off the swivel housing, STEP 59
STEP 56
Loosen the cap screws that hold the top king pin,
Remove the cotter pin and loosen but do not remove STEP 60
the nut.
STEP 57
STEP 61 STEP 65
Remove the shims and keep for use during assembly. Remove the seal for each king pin.
STEP 62
Repeat steps 59 through 61 for the bottom king pin. STEP 66
STEP 63
STEP 67
STEP 64
STEP 68 STEP 71
90763'1 OM
Use a suitable puller and remove the bushing. Use a hammer and a chisel that has a long taper to start
the bushing off the bottom king pin.
STEP 69
STEP 72
STEP 70
Remove the four snap rings. Use the V-block to support the coupling and press the
other bearing cap against the V-block.
STEP 74
STEP 77
STEP 75
STEP 79 STEP 82
Use a suitable support and driver to press the bottom Remove the cross.
bearing cap out of the yoke as far as possible.
STEP 83
STEP 80
STEP 84
STEP 81
Press a bearing cap into the yoke 1/4 inch (3 mm) from
Press the other bearing cap out of the yoke as far as the top of the yoke.
possible.
STEP 85 STEP 88
Carefully install the cross in the bearing cap. Hold the cross and press the bearing caps into the
yoke.
STEP 86
STEP 89
Press the other bearing cap into the yoke 3/8 inch (9
mm) from the top of the yoke. Use a suitable driver and press a bearing cap into the
yoke so that a snap ring can be installed.
STEP 87
STEP 90
Carefully raise the cross into the bearing cap so that the
cross is in both bearing caps. Install a snap ring.
STEP 91 STEP 95
Repeat steps 89 and 90 for the other bearing cap.
STEP 92
Carefully raise the cross into the top bearing cap so that
the cross is in both bearing caps.
STEP 93
Hold the cross and press the bearing cap into the
coupling so that a snap ring can be installed.
STEP 98
Use a suitable driver and press the other bearing cap Repeat steps 96 and 97 for the other bearing cap.
into the coupling 1/4 inch (3 mm) from the top of the
coupling.
B902646J
Drive the bushing into the bore until the bushing is 5/16 Use a suitable driver and drive the seal all the way into
inch (8 mm) beyond the end of the bore. Then install the bore.
seal
STEP 103
STEP 100 Repeat step 102 for the bottom seal.
STEP 104
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. Install the axle shaft.
STEP 107
STEP 112
Measure the the thickness of the shims removed with
Install the top king pin, shims and cap screws and lock the top and bottom king pins and install these shims
washers or self-locking cap screws. and two additional 0.014 inch (0.35 mm) shims on the
bottom king pin.
STEP 108
STEP 113
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.
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
STEP 115
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
Tighten the cap screws.
STEP 116
Install the bottom king pin, and cap screws and lock
washers or self-locking cap scre.vs.
Tighten the cap screws to 101 pound-feet (134 Nrn). Install the ball joint and nut.
STEP 126
STEP 123
STEP 124
STEP 128
Lubricate the king pins.
STEP 129
Assemble the planetary according to instructions in this
section.
Bur 8-17300 Issued 1-91 Printed in U.S.A.
5008-28
STEP 131
Remove the cotter pin from the ball joint. STEP 135
STEP 132
STEP 133
Remove the planetary and axle assembly. Remove the steering cylinder.
STEP 138
Repeat steps 131 through 137 at the other side. STEP 143
STEP 139
Use tool CAS-2151 and loosen and remove the right tie
rod. STEP 144
STEP 140
Remove the fitting from the closed end of the steering
cylinder.
STEP 141
Typical Illustration Remove the cap screw and lock that hold each ad-
Fasten the differential carrier in a repair stand. justing ring.
Prevent the pinion shaft from turning and measure the Remove the cap screws.
backlash of the ring gear. Record the reading.
STEP 150
STEP 147
~,
Remove both bearing caps. Use a narrow chisel to push the nut out of the pinion
shaft.
STEP 152
STEP 156
STEP 153
If the bearing cups are to be used again, fasten an iden- STEP 157
tification tag to one bearing cup for correct installation.
STEP 154
Use a soft hammer and drive the pinion shaft out of the Remove the shim.
outer bearing.
STEP 162
STEP 159
STEP 160
DISASSEMBLY OF DIFFERENTIAL
STEP 163 STEP 166
Remove the cap screws. Remove the thrust washer and side gear.
Remove the ring gear. Remove the pinion shaft assembly and pin.
Remove the thrust washer. Remove the bearing from either case half as shown.
STEP 170
15
B902647J
ASSEMBLY OF DIFFERENTIAL
STEP 172 STEP 175
Press a new bearing onto each case half. Install a thrust washer in the case half with threaded
holes.
STEP 173
STEP 176
Make sure that the threads in the other case half are free
of lubricant Install a side gear.
Lubricate the thrust washers, pinion gears and pinion Install the thrust washers and pinion gears on the pinion
shaft with gear lubricant shaft.
Install the pinion shaft assembly. Install the other thrust washer in the other case half.
7~18M
Apply 271 Loctite to the threads in the case half. Assemble the case halves.
Make sure that the mounting surfaces for the ring gear Use the press to prevent the differential from turning
are clean and install the ring gear. and install and tighten the cap screws to 52 pound-feet
(70 Nm).
. .
~~~~~,M.
If new bearing cups are being installed in the differential Install the gauge block assembly, bearings and handle.
carrier, make sure that the spacer is installed in the bore Tighten the handle until the bearings become difficult to
for the inner bearing cup. turn.
Use a suitable driver and drive the bearing cup(s) into Install the gauge tube, bearing caps with marks aligned
the differential carrier. and the cap screws.
Use the metric feeler gauge and measure the space Remove the cap screws, bearing caps, gauge tube,
between the gauge block and the gauge tube. Write the handle, gauge block assembly and the bearings.
measurement on line b in step 194
STEP 196
STEP 193
Example
a. 109.75 mm a. 109.75 mm
b.+ mm b. + 0.45 mm
c. mm c. 110.20 mm
d. - mm d. -107.45 mm
e. mm e. 2.75 mm
use 2.70 mm
Use a suitable driver and press the inner bearing
thick shim
against the shim.
Install a new spacer and flat washers. The old spacer Install a new pinion nut.
MUST NOT be used again.
STEP 203
STEP 200
Use the yoke and the CAS-2151 wrench and tighten the
Install the pinion shaft and the outer bearing. pinion nut to 50 pound-feet (68 Nm).
STEP 205
Use a suitable driver and drive a new seal into the dif-
ferential carrier.
STEP 208
STEP 209
Install the bearing caps with the alignment marks Tighten both adjusting rings while making sure that
aligned and the cap screws. there is clearance (backlash) between the ring gear and
pinion gear.
STEP 212
STEP 215
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.
If there is not enough backlash, loosen the adjusting
STEP 219 ring on the 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
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. ''''';.;.'.''-" . ",1,
"'307tv1
~'"
STEP 220
, :
When the backlash is correct, tighten the cap screws to Install the lock, cap screw and lock washer that hold
115 pound-feet (156 Nm). each adjusting ring. Tighten the cap screws to 84
pound-inches (9 Nm).
STEP 227
STEP 229
s.~
Install and tighten the cap screws to 66 to 79 pound- Install the king pins, shims, cap screws and lock
feet (90 to 107 Nm). washers.
Install and tighten the tie rod. Install the ball joint and nut.
STEP 233
Tighten the nuts to 170 pound-feet (230 Nm). Install new cotter pins. If a notch in the 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.
PTO . .6019
Torque Converter Charging Pump, Output Shaft, And Converter Housing 6205
Transmission. . 6206
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TOOLS 2
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 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
Order special tools from one of the following ad-
dresses:
Service Tools
P.O. Box 314
Owatonna, Minnesota 55060
Vl Churchill Ltd
P.O. Box 3, Daventry
Northants, NN11 4NF
England B897521OM
CAS-2018 Alignment Tool
This tool is shown in use in step 19.
Bur 8-12501 Issued 3-91 Printed in U.S.A.
6001-3
STEP 2
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.
Drain the oil from the transaxle. The trans axle holds ap- STEP 6
proximately 47.6 U.S. quarts (45Iitres).lfequipped with
a PTa, drain the oil from the torque converter housing.
STEP 3
If the 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
STEP 7
STEP 8 STEP 11
Loosen and remove the cap screws that fasten the front
drive shaft to the flange on the transaxle. Remove the Loosen the clamps at each end of the hose on the
front drive shaft. suction tube and remove the suction tube.
STEP 9 STEP 12
If equipped with a PTO, loosen and remove the Ferry Loosen and remove the nut, lock washer, and wire from
head screws and clamps that fasten the drive shaft to the switch for the filter warning lamp.
the torque converter and remove the drive shaft.
STEP 13
STEP 10
STEP 14
Loosen and remove the cap screws and flat washers
that fasten the torque converter housing to the flywheel
housing.
STEP 15 STEP 17
Loosen and remove the torque converter housing.
STEP 16
STEP 18
If necessary, loosen and remove the cap screws, flat
Loosen the cap screws that hold the torque converter. washers, and the drive ring from the torque converter.
4. HARDENED WASHER
~..-..-
2. CAP SCREW ~
7. TORQUE
~ CONVERTER
2. CAP c? ~ 3. FLAT HOUSING
SCREW WASHER B891515J
STEP 19 STEP 22
Install the drive ring and the CAS-2018 alignment tool. Tighten the cap screws to 156 to 180 pound-inches (18
Install the drive ring to get the least amount of to 20 Nm).
movement between the alignment tool and the drive
ring. STEP 23
If equipped with a PTO, apply Loctite 515 all the way
STEP 20 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.
STEP 28
Install the wire, lock washer, and nut on the switch for
the filter warning lamp and tighten the nut.
STEP 29 STEP 31
1.7/8-14
THREAD
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).
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
If the machine has four wheel drive, do steps 34 through
STEP 30 38. If the 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).
STEP 35 STEP 38
Move the guard in position under the drive shaft. Install the bar on the guard for the drive shaft. Install the
bolts, flat washers, and nuts and tighten the nuts.
STEP 36
STEP 39
STEP 37 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.
Install the flat washers and nuts on the bolts. Tighten the
bolts to 100 to 150 pound-feet (136 to 203 Nm).
Raise the wheels off of the floor high enough to remove Loosen and remove the bolts, flat washers. and nuts
the transaxle from under the machine. Put suitable that fasten the bar to the guard for the drive shaft.
stands under the frame at the rear of the machine and Remove the bar.
under the front axle.
STEP 46
STEP 43
Loosen and remove the nuts and flat washers from the
Drain the oil from the transaxle. The trans axle holds ap- bolts that fasten the guard to the frame. Do not remove
proximately 47.6 U.S. quarts (45 litres). the bolts at this time.
STEP 44 STEP 47
If the 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.
STEP 52
STEP 49
Loosen and remove the wheel nuts and remove the rear
wheels.
STEP 53
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 If the machine has four wheel drive, disconnect the
the torque converter and remove the drive shaft. control rod from the lever at the transaxle.
STEP 51 STEP 54
Loosen and remove the Ferry head screws and clamps Loosen and remove the nuts from the bolts that fasten
that fasten the rear drive shaft to the torque converter. the clamp and spacer for the parking brake cable to the
Remove the rear drive shaft. bracket on the transaxle. Remove the bolts, clamp, and
spacer.
Bur 8-12501 Issued 3-91 Printed in U.S.A.
6001-11
STEP 55 STEP 57
Slide the boot up the parking brake cable. Loosen the Loosen and remove the cap screws and flat washers
jam nut and turn the parking brake cable counterclock- that fasten the guard for the hose on the suction tube
wise out of the transaxle. 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 56
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
Remove the cotter pins and clevis pins that fasten the
control rods to the levers on the transaxle.
STEP 62 STEP 65
Disconnect the brake hose from each side of the trans- Install a transmission jack under the transaxle.
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 in the tube and a cap STEP 66
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
STEP 67
890240SJ
Bur 8-12501
Issued 3-91 Printed in U.S.A.
6001-14
-w,-
B9075614M
Put the trans axle under the machine and raise the trans- If used, install the straps and align the straps with the
axle into position. blocks in the frame. Install the cap screws that hold the
straps and tighten the cap screws.
STEP 69
STEP 72
Connect the tube to the right side of the transaxle.
STEP 73
STEP 74 STEP 79
Connect the control rod to the spring, Connect the hose Install the clevis pins and cotter pins that fasten the
to the tee fitling, Connect the connector for the wiring control rods to the levers on the transaxle.
harness, Install the clevis pin and cotter pin that fasten
the power shuttle rod to the control valve,
STEP 80
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
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 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.
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.
STEP 82 STEP 86
If the machine has four wheel drive and a PTO, do steps
87 through 91. If the machine has a PTO only, do steps
88 through 91.
STEP 87
STEP 83
Install the front drive shaft and cap screws. Tighten the
cap screws to 504 to 576 pound-inches (57 to 65 Nm).
STEP 88
STEP 84
STEP 89
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).
STEP 85
If equipped with a PTO, install the drive shaft, clamps, Raise the guard into alignment with the brackets on the
and Fetty head screws that hold the drive shaft. frame and install the bolts. Lower the floor jack and
remove the floor jack from under the machine.
Bur 8-12501 Issued 3-91 Printed in U.S.A.
6001-17
STEP 90 STEP 92
Install the flat washers and nuts on the bolts. Tighten the Install and tighten the drain plug in the transaxle.
bolts to 100 to 150 pound-feet (136 to 203 Nm).
STEP 93
STEP 91 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.
Install the bar on the guard for the drive shaft. Install the
bolts, flat washers, and nuts and tighten the nuts.
STEP 96
STEP 100
Remove the snap rings. Repeat steps 97, 98, and 99 to remove the cross from
the yoke.
STEP 97
STEP 101
STEP 102
Install the cross in the bearing cap. Be careful not to Install a snap ring in the groove.
move the needles.
STEP 107
STEP 104
Press the other bearing cap all the way into the yoke.
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 108
STEP 105
Use the driver and press the bearing cap into the yoke
until the groove for the snap ring can be seen.
Start a bearing cap into the shaft. DO NOT press the Press the other bearing cap a short distance into the
bearing cap all the way in. shaft. Carefully raise the cross into the bearing cap and
press the bearing cap into the shaft.
STEP 110
STEP 113
STEP 111
STEP 114
STEP 115
Repeat steps 113 and 114 for the other bearing cap.
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)
Flow Specifications
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)
SPECIAL TOOLS
In the U.S. and Canada, order the tools from
Service Tools
P.O. Box 314
Owatonna, MN
55060
VL Churchill Ltd.
P.O. Box 3, Daventry
Northants NN11 4NF
B877558
England
CAS-1B04 or 10111 Pressure Fitting Kit
B4218289M
CAS-10280 Flowmeter CAS-2026 Special Fitting Kit
B877168
CAS-1BOBor 10106 Flowmeter Fitting Kit
1. Clutch Lubrication Oil 6. Accumulator 11. Pressure Regulator Valve 15. Brake Cooling Oil
2. Reverse Clutch 7. Clutch Cutout Valve 12. Charging Pump 16. PTO Control Valve
3. Forward CLutch 8. Dual Regulator Valve 13. Torque Converter 17. PTO Clutch
4. Spool 9. Filter 14. Oil Cooler 18. Pinion Lubricaion Oil
5. Modulator Valve 10. Torque Converter
Relief Valve
TROUBLESHOOTING
Problem: Machine Will Not Move
Troubleshooting complete.
B901668J
Make sure that the orifice and spring are installed below
the elbow at the top left rear of the transmission
housing.
Test Procedure
Parking brake applied.
CAS-10280 flowmeter.
Test Procedure
1MPO RT ANT: Do this check quickly to prevent damage
to the torque converter. Oil flow to the torque converter is
stopped during this check.
Outlet of flowmeter connected to port 2. Read the flow gauge and the pressure gauge and
record both readings.
All transmission controls in NEUTRAL.
With the engine running at 2200 rpm (r/min), slowly
Parking brake applied. close load valve until the pressure stops increasing and
record the reading.
Load valve for flowmeter open.
See page 2 for specifications.
Oil at operating temperature.
CAS-10280 flowmeter.
Test Procedure
Inlet of flowmeter connected to port 1.
All transmission controls in NEUTRAL. Test point shown is early production. Tube replaced
with hose for late production.
Parking brake applied.
CAS-10280 flowmeter.
Test Procedure
Inlet of flowmeter connected to port 1.
CAS-10280 flowmeter.
Test Procedure
Inlet of flowmeter connected to port 1.
CAS-10280 flowmeter.
Test Procedure
Connect the inlet of the flowmeter to port 1.
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 new machine or whenever a wheel 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)
Rear Tires
16.9 x 24,10 PR, R4 28 psi (193 kPa, 1.9 bar)
J I Case Company
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
PTa HOUSING
Removal 4
Installation 5
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
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 145 to 185 Ib ft
PTO Valve Retaining Bolts 73 to 87 Nm 54 to 64 Ib ft
PTO Clutch Hub Retaining Bolt 101 to 113 Nm 75 to 83 Ib ft
SPECIAL TOOLS
3. SEAL COMPRESSOR
CAS 2005-1
First Used on Page 21
PTO HOUSING
Removal
STEP 1
STEP 2
STEP 3
~. :".
~,
~
Install a hoist onto the PTO housing and remove the
housing bolts.
STEP 7
STEP 4
STEP 5
Install bolts into the two threaded holes. Tighten the
bolts to separate the PTO housing from the transaxle.
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.
Installation
STEP 8 STEP 11
STEP 9
029221
800411 STEP 12
STEP 13
030227
STEP 15
D30208
Remove the snap ring (1) and bearing (2) from the
shaft.
STEP 17
D30202
';;;~;~~
Remove the snap ring (1) on the inside of the housing. Remove and discard the oil seal from the housing.
Remove the shaft and bearing with a soft hammer.
STEP 18
NOTE: If the PTO housing has been removed it will not
be necessary to remove the end cover. Remove the Examine all parts and replace if necessary.
seal and outer bearing snap ring. Use a soft hammer
and drive the input shaft iotweto out of the end cover.
1. SHAFT
2. SNAP RING INP580
3. BEARING
4. SEAL
STEP 19 STEP 20
030206
Install the new seal (1) with the bushing driver OEM
6506 until the faces on the seal and cover are level.
PTO CLUTCH
Removal
STEP 21 STEP 24
Refer to Steps 1 to 7 and remove the PTO housing from
the transaxle.
STEP 22
029626
030215
Remove the three bolts (1) and shroud (2) from the
housing.
STEP 23
Remove the bolt (1) and clutch assembly (2) from the
input shaft. Remove and discard the two rubber seals
(3) from the input shsft.
030217
Disassembly
STEP 25 STEP 28
029817 C26827
Remove the snap ring (1) backing plate (2) four clutch Turn the clutch housing over, shock the housing against
plates (3) and four separate plates (4) in alternate order a wooden block to remove the piston (1).
from the housing.
STEP 29
STEP 26
C26829
Remove and discard the o-rings and seals (1) from the
Install the clutch assembly and special tool CAS 1992 piston.
(1) into a press and compress the spring. Remove the
snap ring (2). STEP 30
STEP 27
D30223
Remove the snap ring (1), brake plate (2), springs (3),
brake assembly (4) and inner brake plate (5) from the
Release the pressure and remove the retainer (1) and clutch housing.
spring (2).
STEP 31 STEP 32
C27202
Remove the three piston pins (1) and discard the Remove the needle roller bearing (1) and clutch
a-rings (2). assembly retaining washer (2) from the housing.
Inspection
STEP 33 STEP 35
808116
STEP 34
B0611S
Assembly
STEP 36 STEP 38
. )
""'-
e/ D3a223
STEP 39
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 C26829
housing (3). Install the o-rings and seals (1) onto the clutch piston.
STEP 37 STEP 40
808132
Install new o-rings (1) onto the three piston brake pins Lubricate and install the piston into the housing. Push in
(2). Install the pins. the piston equally from all sides until fully installed.
STEP 41 STEP 43
ll30221
Install the clutch housing into a press. Install the piston Install new rubber seals (1) onto the input shaft.
return spring and retainer. Compress the spring with the
special tool CAS 1992 (1) and install the snap ring (2). NOTE: The larger diameter seal is installed first.
STEP 42
e 6019A
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
Installation
STEP 44 STEP 46
029626
Install the PTO clutch assembly (1), and retaining bolt Install the shroud (1) and retaining bolts (2). Tighten the
(2). Tighten the bolt to a torque of 101 to 113 Nm (75 to bolts.
83 Ib ft).
STEP 47
STEP 45
Install the PTO housing. Refer to Steps 8 to 13.
030217
PTa VALVE
Removal
STEP 48 STEP
......
.-
49
Refer to Steps 1 to 7 and remove the PTO housing from
the transaxle
030229
Disassembly
STEP 50 STEP 53
STEP 51 STEP 54
808019 B08027
Remove the spring (1), detent (2) and ball (3) from the Remove the spool (1) from the valve body.
valve body.
STEP 55
STEP 52
Wash all parts in cleaning solvent and dry using
compressed air
STEP 56
B08021
Assembly
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
STEP 57
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
Installation
STEP 58 STEP 59
Install new o-rings (1) to the valve body. Install the valve
and tighten the retaining bolts to a torque of 73 to 87 Nm
(54 to 64 Ib tt).
STEP 61
STEP 62
029802
STEP 65
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.
STEP 66 STEP 67
029814
808425
Remove the snap ring from the housing and install the Examine the bearings, gears, snap rings, rear bearing
impact hammer OEM 4251 (1). Remove the input shaft cup (1) and seal sleeve (2) for wear and damage.
and front bearing cone. Discard the two seals from the Replace if necessary.
input shaft.
Installation
STEP 68 STEP 69
C21727 C21730
Use the special tool CAS 2001 to expand and install the Install the special tool CAS 2005-3 to compress the
new seals (1) onto the input shaft. seals to the correct diameter.
IMPORTANT: Soak the seals in Hy-Tran Plus before IMPORTANT: The correct seal operating size can only
installation. be obtained by using the special tools.
STEP 70 STEP 73
D29636
Install the input shaft, front bearing cone and snap ring. Install the rear bearing cone and snap ring.
Install the inpact hammer and seat the bearing cone
against the snap ring (1). STEP 74
STEP 71
STEP 72
D302t9
STEP 76 STEP 77
STEP 78
Install a new output shaft oil seal (1) until the seal face is
level with the face of the PTO housing.
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TORQUES 2
SPECIAL TOOLS 3
TOOLS TO BE MADE 4
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
SPECIAL TOOLS
1. SEAL INSTALLATION TOOL FOR REAR AXLE 2. lOCKNUT SOCKET FOR REAR AXLE SHAFT NUT
CAS 2007 CAS 2006
1. TORQUE WRENCH
OEM 6475
TOOLS TO BE MADE
STEP 1
STEP 2
C12345
STEP 3
Disassembly
STEP 5 STEP 8
, .~
Remove the snap rings from the three planet gear pins, Remove the planet gear carrier assembly from the axle
housing.
STEP 6
STEP 9
C13206
STEP 10
C13208
Use the special tool CAS (2006) to loosen the ring nut.
Remove the ring nut.
STEP 11 STEP 14
~.-'.
Remove and discard the lock washer. Use a lever to remove the shaft seal from the rear axle
case.
STEP 12
STEP 15
Ale.
BOIl520
Put the rear axle in a horizontal position and remove the
inner bearing from the axle shaft. Install the puller, OEM 1108, and remove the bearing
from the axle shaft.
STEP 17 STEP 20
Remove and discard the oil seal. Remove the '0' washer from the top of the planet gear.
STEP 21
Mark the gears and pins for the correct assembly of the
planet gear carrier
STEP 23 STEP 24
013 014
Remove the bottom rollers. Remove the planet gear from the bottom washer.
Inspection
STEP 25
STEP 28
Clean all parts in cleaning solvent and dry in
compressed air. DO NOT permit the bearings to rotate
when drying.
STEP 26
A35
Check the planet gears for wear and cracks at the tooth STEP 29
root. Replace the planet gears in sets only.
STEP 27
A3S
h #
Check the ring gear and axle case for cracks or other
damage. Replace as necessary.
Check the planet gear pins and the splines in the carrier
for wear or damage and replace if necessary. NOTE: The ring gear and axle housing cannot be
serviced separately.
NOTE: The Flat side of the pin faces outvvard.
Don 7-36980 Issued 12-90 Printed in U.S.A.
6201-10
Assembly
EA2583
STEP 30 $TEP 33
Clean the faces of the rear axle case and the trans axle
housing.
STEP 31
3. BEARING 51252
STEP 32
Heat the outer axle shaft bearing in the oven OEM 8014
to a temperature of 300F (150C). Install the bearing on
to the axle shaft so that it is against the shoulder (1).
STEP 35 STEP 36
STEP 37
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.
Install a new lock washer.
STEP 38
Install and tighten the ring nut until all end play is
removed. Lightly hit the flange end of the axle shaft with
a soft hammer to seat the bearings, while rotating the
axle shaft clockwise.
STEP 39 STEP 41
EC3227A
Use the Specia Iy made tool bolted across the Lubricate the bearing rollers with petroleum jelly and
centerline of the axle, with the nut in the center. Use a install the bottom set.
torque wrench to measure the rolling torque at the nut,
"
with the axle resting on the axle flange (measure the STEP 42
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 (30 to 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.
STEP 43
STEP 44 STEP 47
DB
Install the 'D' washer to the top of the planet gear. Install the planet gear carrier assembly into the axle
Repeat the procedure for the remaining two planet housing.
gears.
STEP 48
STEP 45
C13208
C13206
C1321B
Install the steel Baffle plate.
Carefully install the planet gear assemblies onto the
planet gear carrier pins.
STEP 50
Install the snap rings into the grooves in the planet gear
pins. Make sure that the eyes of the snap rings are
opposite the flat on the pins.
Installation
STEP 51 STEP 52
IMPORTANT: Do not get sealant onto the brake Install the two alignment studs CAS 1995.
surfaces.
STEP 54 STEP 56
Use suitable lifting equipment to install the rear axle Install the remaining two bolts and washers then evenly
onto the transaxle housing. tighten all the bolts to a torque of 326 to 353 Nm (240 to
260 Ib ft).
STEP 57
STEP 58
STEP 55
Fill the transmission with Hy-Tran Plus oil up to the FULL
mark on the dipstick.
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
STEP 1
STEP 2
STEP 4
Disassembly
STEP 6 STEP 7
STEP 8 STEP 11
Remove and discard the o-ring from the detent plug. Remove the roll pins from the shift fork and rod.
STEP 9 STEP 12
STEP 13
Move the shift rod so the shift collar is clear of the yoke
splines and remove the collar.
STEP 10
Remove and discard the shift rod seal
housing.
STEP 14
STEP 15 STEP 18
Use a hydraulic press to remove the yoke from the Remove the bearing retainer snap ring from the
housing in the direction shown. housing.
STEP 16 STEP 19
Remove the snap ring from the yoke. Use a hydraulic press to remove the bearing from the
housing.
STEP 17
Inspection
STEP 20 STEP 23
STEP 21
Check the yoke and shift 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.
Assembly
3. SNAP RING
5. SHIFT ROD
6. HOUSING
8. SHIFT COLlAR
EA2S87
STEP 24 STEP 27
Install the new seal into the housing until both the seal
and housing faces are level.
STEP 25
STEP 28
Lubricate and install the yoke shaft into the housing.
STEP 26
STEP 29 STEP 32
Install the bearing retainer snap ring. Install the shift rod.
STEP 30 STEP 33
Install a new shift rod seal (flat side outward) until it is Rotate the shift lever to the correct position. Align the
level with the housing. holes and install the roll pins.
STEP 31 STEP 34
Install the shift fork so the detent groove is aligned with Install the two pads into the shift fork.
the hole in the housing.
STEP 35 STEP 37
~::.
Install the shift collar onto the two pads with the flat side Install a new o-ring onto the plug.
of the collar faces inward. Align the splines and slide
the collar over the yoke. STEP 38
STEP 36
Installation
STEP 40 STEP 41
70001
STEP 42 STEP 43
STEP 44
STEP 45
STEP 46
Install the five bolts and washers and evenly tighten to a
torque of 77 to 100 Nm (57 to 74 Ib ft). Add oil of the correct type to the transmission until the
level reaches the full mark on the dipstick.
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TORQUES 2
SPECIFICATIONS
Lubrication
Transmission OiL Hy-Tran Plus (MS 1207)
SPECIAL TORQUES
Rear Axles To Transmission Case 326 to 353 Nm 240 to 260 Ib ft
Differential Bearing Carrier Bolts 73 to 87 Nm 54 to 64 Ib ft
(Tighten While Rotating The Differential)
Differential Lock Cage To Carrier 73 to 87 Nm 54 to 64 Ib ft
Differential Carrier To Crown Wheel. 126 to 153 Nm 93 to 113 Ib ft
6. THREAD SEALANT
LOCTITE 680
NOTE: Any reference to left or right hand is as seen from the operator's seat looking forward.
Removal
STEP 1 STEP 4
STEP 2
STEP 5
STEP 3
Remove the brake parts from the right hand side of the
transmission housing.
STEP 7 STEP 10
Use a punch to remove the pin from the differential lock Remove the nuts, bolts, washers and setscrews from
selector fork and lever. the rear cover plate.
STEP 8 STEP 11
Remove the differential lock lever from the transmission Remove the rear cover plate.
housing.
STEP 12
STEP 9
... .~
STEP 13 STEP 15
Remove the four bolts and washers from the right hand Repeat the procedure for the differential bearing carrier
differential bearing carrier. on the left hand side.
Remove the differential bearing carrier and shims from Carefully remove the differential.
the transmission case.
Disassembly
STEP 17 STEP 18
Put the differential assembly on a clean work surface. Remove the bolts which hold the differential lock cage
to the differential carrier.
STEP 19 STEP 22
..... ,;;;..;:.
F21
Remove the differential lock cage. Install two 12mm bolts into the threaded holes in the
differential carrier. Evenly tighten the bolts to push the
STEP 20 crown wheel from the differential carrier.
STEP 23
STEP 24
F25
STEP 25 STEP 28
..d., G16
Remove the planetary gear pin from the differential Put the differential lock selector and sun shaft on a
carrier. clean work area.
STEP 26 STEP 29
Remove the two planetary gears. Remove the selector fork and pads.
STEP 27 STEP 30
.G19
Remove the second side gear. Remove the selector from the sun shaft.
Inspection
STEP 31 STEP 34
STEP 32
G14
STEP 35
"G23
STEP 33
G9
STEP 36
G12A
G2OA.
EA2586B
STEP 37 STEP 40
Lubricate the differential lock selector with clean Install the left hand side gear into the differential carrier.
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 41
STEP 38
Install the two pads into the selector fork. Use STEP 42
petroleum jelly to hold them in position.
STEP 39
,00
STEP 43 STEP 46
G36
Install a new grooved pin into the differential carrier and Apply (Loctite 680) to the threads and install the twelve
planet gear pin. 12mm bolts and new hardened washers into the
differential carrier and crown wheel.
STEP 44
STEP 47
Install two guide studs into opposite holes in the crown F24
F3S
Heat the crown wheel in a bearing oven to a maximum
temperature of 302F (150C) and install the crown Install the right hand side gear and lubricate the gears
wheel onto the differential carrier. When the parts are with clean transmission oil.
cool, remove the guide studs.
STEP 49 STEP 51
~':
Install the differential lock cage onto the differential Evenly tighten the bolts to a torque of 73 to 87 Nm (54 to
carrier. 64 Ib ft). Lubricate the bearing with clean transmission
oil.
STEP 50
Installation
STEP 52 STEP 53
Remove the tube nut for the differential lock lever, from Install new inner and outer o-rings onto the tube nut.
the top of the transmission housing.
STEP 54 STEP 57
w~:,
",.
Install the tube nut into the transmission housing. Install the four 1Omm bolts and new hardened washers.
STEP
, 55 STEP 58
~
Install the differential into the transmission housing, so Evenly tighten the bolts to a torque of 73 to 87 Nm (54 to
thatthe crown wheel teeth are pointing to the right hand 64 Ib ft).
side of the housing.
STEP 59
STEP 56
STEP 60 STEP 62
Install two bolts and new hardened washers into Using a depth gauge, measure the distance from the
opposite holes then remove the wood block from under face of the carrier to the transxaxle mounting face,
the differential. through the measuring holes. If the difference in the
measurements is 0.13mm (0.005 in.) or less, take the
STEP 61 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 from this 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
STEP 64
STEP 65 STEP 67
While rotating the differential, evenly tighten the bolts to Remove any old joint material from the rear cover plate
a torque of 73 to 87 Nm (54 to 64 Ib ft). The bearings and the joint face of the transmission housing. Make
are now correctly pre-loaded. sure both faces are free of oil.
STEP 66 STEP 68
Use a dial gauge on the edge of a crown wheel tooth to Apply a continuous bead of CAS 817555 (Loctite 515)
measure the amount of backlash between the crown onto the joint face of the transmission housing. Apply
wheel and the pinion. This must be between 0.15 to Primer 'N' 8500637 onto the mounting face of the
0.30 mm (0.006 to 0.012 inch). To change the amount cover.
of backlash, move some of the shims from the left hand
bearing carrier to the right hand bearing carrier, without STEP 69
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 a torque of 73
to 87 Nm (54 to 64 Ib ft).
Check the ring gear to pinion shaft contact pattern.
Refer to Section 6206
STEP 70 STEP 73
Install the nuts, bolts, washers and setscrews and Install a new pin into the selector fork and lever.
evenly tighten to a torque of 221 to 250 Nm (160 to 185
Ib ft). STEP 74
STEP 71
STEP 72
Install the selector lever through the tube nut and into
the selector fork. Be careful not to damage the a-ring in
the tube nut. The top of the selector lever must be
pointing outward from the transmission case.
STEP 76 STEP 78
Install the left hand sun shaft into the differential. Install the rear axles. Refer to Section 6201.
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 23 to 25 Ib ft
Detent Plug 16 to 18 Nm 12 to 13 Ib ft
Accumulator Piston Plug 31 to 34 Nm 23 to 25 Ib ft
Pressure Regulator Piston Plug 42 to 45 Nm 31 to 33 Ib ft
Solenoid Valve 17 to 20 Nm 13 to 15 Ib ft
Coil Cover Nut.. 0.8 to 1.0 Nm 0.5 to 0.75 Ib ft
Neutral Start Switch 20 to 27 Nm 15 to 20 Ib ft
Disassembly
STEP 1 STEP 4".".".. --y".'
Remove the connecting wires and neutral start switch Remove the solenoid valve (1) from the valve body and
(1) from the valve body. Discard the a-ring from the discard the o-rings (2).
switch.
STEP 5
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) IMPORTANT: Machines equipped with PTO have a
from the solenoid valve. Discard the a-rings. 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.
STEP 6 STEP 9
(2). Discard the ring (3) from the spool and o-ring from
the o-ring on the plug. the plug.
STEP 7 STEP 10
030111 030117
Remove the allen plug from the opposite end of the Remove and discard the oil seal (1) from the bore of the
same bore and remove the modulation pressure forward/reverse spool.
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).
Inspection
STEP 11 STEP 13
STEP 12
FRYOR
Assembly
1. BODY 9. PIN
2. SWITCH 10. SPOOL
3. PLUG 11. ACCUMU
12. MODULA~TOR PISTON
4. O-RING
13 SE OR SPOOL
5. Oil RESTRICTOR . LECTOR SPOOL
6. SOLENOID 14. RING
7. REGULATO VAlVE ASSEMBLY
15. DETENT
8. SPRING R PISTON
16. SEAL
STEP 14 STEP 17
STEP 15
STEP 18
030'17
Installl the new oil 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
STEP 19
030111
STEP 20 STEP 23
000110 000106
Install a new a-ring (1) onto the plug. Install the primary Install a new o-ring (1), cover (2), o-ring (3) and nut (4).
spring (2), secondary spring (3) and accumulator Tighten the nut to a torque of 0.8 to 1.0 Nm (0.6 to 0.71b
piston (4). Install and tighten the plug. ft)
STEP 21 STEP 24
000119 000105
Install a new o-ring (1) onto the plug. Install the Install new o-rings onto the plugs. Install and tighten the
regulator spool (2), pin (3), spring (4) pressure regulator plugs.
piston (5). Install and tighten the plug.
STEP 25
STEP 22
D30233
030107 Install a new o-ring onto the neutral start switch. Install
Install new a-rings (1) onto the solenoid valve 2. Install and tighten to a torque of 20 to 27 Nm (15 to 20) Ib ft.
and tighten the valve to a torque of 20 Nm (15 Ib ft). Install the wires and tighten the screws.
TABLE OF CONTENTS
SPECIAL TORQUES 2
SPECIAL TORQUES
Charging Pump Retaining Bolts 23 to 30 Nm 17 to 22 Ibs ft
STEP 2
STEP 3
Disassembly
STEP 5 STEP 8
X13
Loosen the internal hexagon screw that holds the stator Remove the drive gear.
support to the pump body.
STEP 9
STEP 6
STEP 7
Inspection
STEP 11 STEP 12
X22
1. Clean all the parts in cleaning solvent and dry in If a new converter support bushing (1) is installed, make
compressed air. sure that it fits against the internal shoulders (2) as
2. Only the seal and two bushings are available shown.
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 from the charging pump, install a
new assembly.
Assembly
62056
STEP 13 STEP 17
STEP 14
STEP 18
__ ~ ~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
STEP 16
X14
Installation
STEP 19 STEP 21
;, X1
Lubricate and install a new o-ring seal into the torque Install the four retaining bolts and new flat washers and
converter housing. evenly tighten to a torque of 23 to 30 Nm (17 to 22 Ib ft).
STEP 20 STEP 22
Removal
STEP 23 STEP 26
STEP 24
STEP 27
Remove and discard the oil seal from the outer face of
Hold the coupling in a vice and remove the locknut and the torque converter housing.
washer.
STEP 28
NOTE: The coupling is shown out of the vice for
photographic purposes. When removing or installing Remove the output shaft bearing snap ring from the
the drive coupling nut, clamp the coupling in the vice torque converter housing.
and not the input shaft. This will prevent possible
damage to the shaft and splines. STEP 29
STEP 25
STEP 30 STEP 31
6205GR
Remove the bearing from the shaft. Remove and discard the sealing ring from the groove in
the output shaft in the direction shown.
Inspection
STEP 32 STEP 33
~,
Check the wear sleeve for wear or damage and replace
if necessary. Use a suitable drift to remove the wear
sleeve in the 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.
Installati on
6205138
STEP 34 STEP 37
STEP 38
Put the new sealing ring into clean transmission oil for
several minutes before installing onto the output shaft
in the direction shown.
STEP 35
Lubricate and install a new o-ring onto the output shaft.
STEP 39
STEP 36
Install the coupling.
STEP 40
6205GFW
Install the output shaft and bearing into the torque Install the washer and lock nut. Hold the coupling in a
coverter housing and install the snap ring. vise and tighten the lock nut to a torque of 217 to 271
Nm (160 to 200 Ibs ft).
62115130
STEP 41 STEP 44
STEP 46
STEP 47 STEP 50
Install the relief valve cartridge into the bore. Follow STEPS 42 through 49 to service the torque
converter relief valve.
STEP 48
STEP 51
STEP 52
TABLE OF CONTENTS
SPECIFICATIONS ........................................................................................................................................................ 2
SPECIFICATIONS
Lubricating Oil ...........................................................................................................................Hy-Tran Plus (MS 1207)
SPECIAL TORQUES
Transmission End Cover BoiL .......................................................... 195 to 250 Nm 145 to 185 Ib ft
Pinion Shaft End Bolt.. ....................................................................... 251 to 280 Nm 185 to 205 Ib ft
Transmission Rear Cover Bolts ......................................................... 195 to 250 Nm 145 to 185 Ib ft
Gear Shift Rail Retaining Bolts ............................................................... 44 to 58 Nm 33 to 43 Ib ft
Don 7-37030 Printed in U.S.A.
6206-3
SPECIAL TOOLS
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.
STEP 1
STEP 2
STEP 5
C1Z301
STEP 3
STEP 6 STEP 8
...... ..,
Remove the two bolts and plate from the end of the gear
shift rail.
STEP 7
__ ~.~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
Remove the retaining bolts and washers from the cover from the transmission housing.
transmission end cover.
STEP 9
".- ~ :.:~.
STEP 10
STEP 12
Remove the snap ring from the end of the pinion shaft.
Disassembly
STEP 14 STEP
, 17
C124Q6
Mark the gears for easier assembly. Remove the second gear and spacer.
STEP 15 STEP 18
C1'22ll6
Use a press and remove the bearing cone (1), fourth Remove the second bearing cone and first gear.
drive gear (2) and spacer(3).
STEP 16
Inspection
STEP 19
Assembly
9. 4TH GEAR
6. 2ND GEAR
4. 1ST GEAR
2. BEARING CONE
6. 2ND
GEAR
STEP 20 STEP 21
6007318
Installati on
STEP 22 STEP 23
Install the intermediate shaft the transmission Make sure the synchromesh hub, needle bearing and
housing. thrust washer is against the pinion shaft and install the
snap ring.
NOTE: Uft up the 3rd and 4th gear synchromesh hub to
allow installation of the intermediate shaft. STEP 24
STEP 25
STEP 27
STEP 28
STEP 30
Use a puller and remove the bearing from the end of the
shuttle shaft. Remove the snap ring thrust washer and
bearing. Remove the forward gear.
Disassembly
STEP 31 STEP 32
N17 036
Remove the roller bearing (1), spacer (2) and second Remove the thrust bearing (1).
roller bearing (3).
STEP 33 STEP 36
Remove the thrust washer. Remove the 6 friction and 6 steel plates from the
forward clutch.
STEP 34
STEP 37
Remove the snap ring from the clutch plate carrier. P16
STEP 38
030
024
STEP 39 STEP 41
022 011
Remove the piston return spring. Remove and discard the outer piston seal and a-ring.
STEP 40 STEP 42
010
STEP 43
021
piston: Remove and discard the four sealing rings. Remove the
bearing cone (1), snap ring, thrust washer, thrust
Outer hole - forward piston bearing (2) and gear (3). Repeat STEPS 31 to 42 and
Inner hole - reverse piston disassemble the reverse clutch.
Middle hole - for lubrication
Inspection
STEP 44 STEP 48
STEP 45
06
02 STEP 49
Check the piston for wear or damage and replace if
necessary.
STEP 46
08
STEP 47
Assembly
620619
STEP 51
STEP 52
021
STEP 55
010
Install a new o-ring (1) and then a new inner seal ring (2)
into the clutch piston.
STEP 53
022
STEP 56
011
Install a new o-ring (3) and then a new outer seal ring (4)
onto the clutch piston.
024
STEP 57 STEP 60
Install the snap ring. Install a friction clutch plate. Continue installing a steel
and then a friction clutch plate until there is a total of 12
STEP 58 plates in the clutch pack.
STEP 61
I P16
and special washer below the snap ring groove. Install Install the backing plate so that the small diameter is
the snap ring. outward.
STEP 59 STEP 62
STEP 63 STEP 66
Install a thrust washer (1) and thrust bearing (2). Use the special plastic installation tool CAS 1999 (1) to
install the sealing rings (2).
IMPORTANT: Make sure the smooth side of the
bearing is outward. NOTE: Put the sealing rings in clean transmission oil
before installation.
STEP 64
STEP 67
Installation
STEP 68 STEP 69
2. WEAR SLEEVE
STEP 71
;~
STEP 73 STEP 76
Remove the forward gear from the shuttle shaft. Remove the thrust washer (1) and needle bearing(2).
STEP 74 STEP 77
Loosen the two gear shift lever pivot bushings (1). Remove the fourth driven gear.
STEP 75 STEP 78
:~~'
,.:J ",$ ..
Pull the gear shift rail up from its locating bore in the Remove the washer.
transmission case. Rotate the assembly counter-
clockwise and lift the rail and shift forks clear of the
pinion shaft.
STEP 79 STEP 82
STEP 80 STEP 83
Remove the bearing. Remove the needle bearing and synchromesh inner
cup.
STEP 81
STEP 84 STEP 87
Remove the third driven gear. Remove the thrust washer (1) and needle bearing (2).
STEP 85 STEP 88
Remove the needle bearing (1) and thrust washer (2). Remove the shuttle shaft.
STEP 86 NOTE: litt up the second driven gear to allow the shuttle
shaft to be lifted out of the transmission case.
STEP 89
>'
STEP 90 STEP 93
'.' ,
Remove the synchromesh assembly. Remove the needle bearing and thrust washer.
STEP 91 STEP 94
t.. .~
Remove the needle bearing. Remove the first driven gear with spacer.
STEP 92 STEP 95
:S.
h
1:12121
Remove the synchromesh hub. Remove the two roller bearings.
STEP 96 STEP 98
1
Remove the thrust washer, needle bearing and second Use a soft drift to remove the pinion bearing cup and
thrust washer. shims from the differential housing.
STEP 97 NOTE: Tie the shim pack together for easy assembly.
Inspection
STEP 99 STEP 102
STEP 100
Q20
STEP 101
PIS
Assembly
STEP 105
STEP 1106
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 Issued 12-90 Printed in U.S.A
6206-28
62067
If a new front pinion bearing was installed, replace the Install the master bearing cone (CAS 2019) onto the
bearing cup in the transmission end cover. pinion shaft.
Install the end cover. Install the splined parking hub and spacer.
STEP 112
STEP 109
.~ -,--.. Install the setting washer (CAS 1998) (1) and bolt. Do
Install the retaining bolts and tighten to a torque of 195 not install any shims.
to 250 Nm (145 to 185 Ib ft).
STEP 113 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
STEP 117
i
Install the thrust washer, needle bearing and second
thrust washer.
STEP 118
,
IB~
in:C12121
Install the first driven gear and spacer with the splined Install the needle bearing.
hub outward.
STEP 123
NOTE: When installed the spacer must be level with the
end of the first gear.
STEP 120
STEP 124
STEP 121
Slightly raise the second gear (1) and Install the shuttle Install the thrust washer (1) and needle bearing (2).
shaft.
STEP 129
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
STEP 130
STEP 127
Install the hub (1) and synchromesh unit (2) onto the Install the needle bearing (1) and the synchromesh
pinion shaft. outer cup (2).
STEP 133
,.
Install the fourth driven gear with the splines facing Install the shuttle shaft forward gear.
inward.
STEP 138
STEP 135
-. ,-,'
Install the baffle plate (1) and intermediate shaft.
Install the needle bearing (1) and thrust washer (2).
NOTE: Raise the third and fourth gear synchromesh
STEP 136 hub slightly, to allow easy installation of the intermediate
shaft.
STEP 139
Install the gear shift selector forks and shift rail. Push
the shift rail into its locating bore in the transmission
housing. .,:..} elL
Make sure the third and fourth gear synchromesh hub,
needle bearing and thrust washer are properly seated.
Install the snap ring.
TRANSMISSION
-..-
~i
Clean the surfaces of the end cover and the Put the pinion shaft bearing into a bearing oven (OEM
transmission case. 8014) and heat to a temperature of 302F (150C).
Install the bearing and brake hub onto the pinion shaft.
STEP 141
NOTE: Wear heat protective gloves.
STEP 144
Install the shift rail retaining plate and two bolts and Install the bearing cup and spacer onto the
tighten to a torque of 44 to 58 Nm (33 to 43 Ib ft). intermediate shaft.
Don 7-37030 Issued 12-90 Printed in U.S.A.
6206-36
,- ~.:;;~
Install the Special Tool CAS 2008 (1). Use a micrometer to determine the required shim pack
thickness.
NOTE: No shims have been installed at this time.
STEP 150
STEP 147
Install a 'C' clamp onto the end of the shuttle shaft and
repeat STEPS 145 to 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
'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).
RC627
RC625
RC625
STEP 156
STEP 158
+ ""IT :
till
Loosen the two pivot bushes.
STEP 161
."Z;.
.;o':!llo.
STEP 159
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.
D29422
Remove the pivot bushing from the transaxle and Remove the selector shaft from the transaxle and
discard the o-ring. discard the o-ring seal.
STEP 164
Disassembly
STEP 165 STEP 166
Of;
Cover the detent holes on the the shift forks and Remove the detent ball and spring.
carefully pull the shift fork from the shift rail.
Inspection
STEP 167 STEP 169
Q14
Check the bushings (1) in the shift forks for wear or Check the detent grooves on the shift rail for wear or
damage and replace as necessary. damage and replace if necessary.
STEP
,..
168 STEP 170
029420
Check the roller bearing (2) on the shift fork and replace Check the gear selector shafts, levers and pivot
if necessary. Install a new snap ring to hold the roller in bushing for wear or damage and replace if necessary.
position.
Assembly
1. BUSH
,;~.
Install a shift fork onto the shift rail as marked during Use a suitable tool to compress the detent spring, and
disassembly, and install the detent spring and ball. push the detent ball below the diameter of the shift rail.
Push the shift fork onto the shift rail.
NOTE: Always wear eye protection when installing
detent springs and balls. 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.
Don 7-37030 Issued 12-90 Printed in U.S.A.
6206-43
Installation
STEP 174 STEP 177
STEP 175
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.
Refer to STEPS 138 and 139 and install the baffle plate Refer to STEPS 140 to 151 and install the transmission
intermediate shaft, and snap ring. end cover.
Adjustment
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.
STEP 182
y ~~
Remove old sealant material and oil from the Refer to Section 6201 and install the Rear Axles.
transmission rear housing and cover.
STEP 188
STEP 185
Refer to Section 7000 and install the Parking Brake and
Housing.
STEP 189
STEP 190
::w
Install the rear cover and tighten all the bolts to a torque
of 195 to 250 Nm (145 to 185 Ib ft).
TABLE OF CONTENTS
SPECIFICATIONS , 2
SPECIAL TORQUES 2
SPECIFICATIONS
BRAKE FRICTION PLATE THICKNESS
New 5.5 to 6.3 mm 0.216 to 0.248 inch
Wear Limit 4.2 to 4.8 mm 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 57 to 74 Ib ft
Transfer Gearbox - Cover Plate Mounting Bolts 77 to 100 Nm 57 to 74 Ib ft
STEP 1
STEP 2
STEP 3 Remove the brake actuator tube nut from the brake
housing. Remove and discard the o-ring.
Disconnect the parking brake operating cable. Refer to
Section 9001. STEP 7
STEP 4
C1Z309
Remove the five bolts that hold the transfer gearbox (4 STEP 8
WD Machines) or the cover plate to the parking brake
housing.
STEP 5
Disassembly
STEP 9 STEP 12
",
STEP 10 STEP 13
STEP 11 STEP 14
Remove the brake actuator assembly. Remove the three reaction pins.
STEP 15 STEP 18
STEP 19
STEP 16
K15
STEP 17
Inspection
STEP 20 STEP 22
STEP 21
STEP 23
Assembly
11. O-RING
a.SPRING .4
6. ACTUATOR PLATE
\
8. SPRING 12. ACTUATOR PLATE
\ UNKAGE
4. FRICTION PLATE
EA2584
STEP 24 STEP 27
STEP 28
STEP 29
STEP 30 STEP 33
Install the wear plate onto the reaction pins. Install the second friction disc.
STEP 31 STEP 34
STEP 32
Installation
STEP 35 STEP 38
the input shaft seal in the parking brake Guide the parking brake housing onto the brake
housing. Fit the new seal so that the flat face is outward reaction pins. Install and tighten the bolts to a torque of
and level with the outer face on the housing. 77 to 110 Nm (57 to 81 Ib ft).
STEP 36 STEP 39
STEP 37
STEP 40
STEP 41 STEP 43
STEP 44
STEP 45
:.:.:.:~.:.:.:.:.:.:.:.'.'."" ...
DISC BRAKES
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TORQUES 2
SPECIFICATIONS
BRAKES FRICTION PLATE THICKNESS
New 6.25 to 6.40 mm 0.246 to 0.252 inches
Wear Limit 475 to 4.90 mm 0.187 to 0.193 inches
SPECIAL TORQUES
Rear Axle Retaining Bolts 326 to 353 Nm 240 to 260 Ib ft
Removal
NOTE: Any reference to left and right hand is as seen STEP 3
from the operators seat looking forward.
STEP 1
STEP 4
STEP 2
STEP 5
STEP 6 STEP 8
..ii~13
Remove the sun shaft. Remove the brake piston (1) by injecting compressed
air through the brake hose port (2).
STEP 7
STEP 9
C14
D30132
Installation
8902564
1. TRANSMISSION HOUSING
2. PISTON SEALS
3. PISTON
4. FRICTION DISC
5. BACKING PLATE
6. REACTION PIN
STEP 14 STEP 16
.>.. )?~13
Remove the old jointing material from the face of the Evenly install the brake piston into the cylinder bore and
trans axle and axle case. align the lugs with the reaction pin holes.
STEP 15 STEP 17
Lubricate the two new inner and outer piston o-rings Lubricate and install the three reaction pins so the
with petroleum jelly and install into the grooves (1) of the plungers are outward and the snap rings are on the
brake piston. outside of the lugs on the brake piston.
STEP 18 STEP 21
....
Install the sun shaft. Install the brake backing plate so the large side is
towards the friction plate.
STEP 22
4. STRAIGHT EDGE
Put a straight edge across the end of the plunger of the \:::~:::'
reaction pin and measure the distance from the Install the two guide studs into the trans axle housing.
machined surface of the transmission case to the end
of the plunger. The measurement must be 2 mm (0.079 STEP 23
inch). Adjust the position of the snap rings if the
distance is incorrect. Make sure the edges of the two
snap rings are 180 apart. Repeat the procedure for the
0
STEP 20
71289GA
STEP 24 STEP 27
Apply activator 8500622 (Loctite 707) to the face on the Tighten all the bolts to 326 to 353 Nm (240 to 260 Ibs ft).
axle housing.
STEP 28
STEP 25
Install the transaxle into the machine. Refer to Section
6001.
STEP 29
STEP 29 STEP 30
Fill the transmission with Hy-Tran Plus oil, to the FULL Remove the air from the brake system. Refer to Secian
mark on the dipstick. 7002.
TABLE OF CONTENTS
MASTER CYLINDER. . . 2
Removal . . 2
Installation . . 2
SPECIFICATIONS
Type of oil.. .. Case TCH Fluid
Capacity
Reservoir... . 16 fluid ounces (473 ml)
System.. '" 32 fluid ounces (946 ml)
MASTER CYLINDER
Removal 11. Remove the master cylinder (1) from the frame.
1. Park the machine on a level surface 12 Install caps on the tubes (6 and 7).
2. Lower the loader bucket to the floor and stop the Installation
engine.
1. If a new master cylinder (1) is being installed, fill the
3. Apply the parking brake. master cylinder with clean Case TCH fluid.
4. Open the access cover above the master cylinder 2. Hold the master cylinder (1) in alignment with the
(1) . holes in the frame and install the bolts (10), lock
washers (9), and nuts (8) that fasten the master cylinder
5. Remove any dirt from the master cylinder (1) and the (1) to the frame.
area around the master cylinder (1).
3 Connect the tubes (4, 6 and 7) to the master cylinder
6. Remove the clevis pin (2) that fastens the clevis (3) on (1 )
the master cylinder (1) to the brake pedal
4. Install the clevis pin (2) that fastens the clevis (3) to
7. Disconnect the tube (4) for the master cylinder reser- the brake pedal.
voir (5) from the master cylinder (1).
5 See step 20 in Section 7003, page 7003-4, and
8. Drain the fluid from the master cylinder reservoir (5). adjust the master cylinder (1).
9 Disconnect the tubes (6 and 7) from the master 6. Fill the master cylinder reservoir (5) with Case TCH
cylinder (1). fluid until the fluid level is at the full mark.
10. Loosen and remove the nuts (8). lock washers (9), 7. See page 7002-4 and remove the air from the brake
and bolts (10) that fasten the master cylinder (1) to the system.
frame.
8. Check for leakage at the master cylinder (1).
6. TUBE
4. TUBE
8891712J
Bur 8-12540
7002-4
2. Move the brake pedal down and up several times to 5. Repeat steps 2, 3, and 4 until there are no bubbles in
increase the pressure in the brake system. the fluid coming from the air removal screw.
3. When the brake pedal feels "hard", continue to push 6. Fill the master cylinder reservoir with Case TCH fluid.
against the pedal and have another person open the air
removal screw at the transaxle
MASTER CYLINDER
TABLE OF CONTENTS
REMOVING AIR FROM THE BRAKE SYSTEM .. . .. See Section 7002
MASTER CYLINDER.. . 2
Disassem bly . . 2
Inspection . ... .4
Assembly . ......4
SPECIFICATIONS
Type of oil.... . Case TCH Fluid
Master cylinder
MASTER CYLINDER
Disassembly 12. Hit the open end of the master cylinder against a
piece of wood to move the piston assembly to the end
1. Clean the outside of the master cylinder. of the master cylinder.
2 Fasten the body (6) of the master cylinder in the 13. Pull the piston assembly from the master cylinder
vise.
14. There is a small tab in the spring seat (12) that
3. Remove the flow valve adapter (1) from the master holds the spring seat (12) on the piston (13). Use a
cylinder. screwdriver to lift up the tab.
4. Remove the flow valve (3) from the master cylinder 15. Remove the check valve assembly from the piston
(13).
5. Remove the ball (5) from the master cylinder.
16. Remove the seal (14) from the piston (13).
6 Remove the gasket (2) from the flow valve adapter
(1) . 17. Disconnect the check valve seat (10) from the
spring seat (12).
7. Remove the flow valve seal (4) from the flow valve
(3). 18 Remove the spring (11) from the spring seat (12).
8 Loosen the lock nut. Remove the clevis and lock 19. Remove the check valve seat (10) from the check
nut from the push rod (15). valve piston (8).
9. Remove the boot (18) from the body (6). 20 Remove the wave spring (9) from the check valve
piston (8).
10. Remove the snap ring (17) from the body (6).
21 Remove the check valve seal (7) from the check
11. Remove the push rod (15) and washer (16) from valve piston (8)
the body (6).
B870122R
Master Cylinder
1. Inspect the bores in the body (6) for scoring, pitting, 14. Lubricate the flow valve seal (4) and the flow valve
or other damage. If the bores in the body (6) are (3) with clean hydraulic oil. Install the flow valve (3) in the
damaged a new master cylinder must be used. bore in the master cylinder. The flow valve (3) must be
centered in the bore of the master cylinder.
2. Check the tab in the spring seat (12). Push the tab
down a small amount so that the tab will engage the 15. Install a new gasket (2) on the flow valve adapter
end ofthe piston (8) to hold the check valve assembly in (1) .
place. If the tab is broken, use a new master cylinder.
16. Carefully start the flow valve adapter (1) into the
3. Inspect the flow valve (3), ball (5), check valve bore in the master cylinder by hand If the flow valve
piston (8), piston (13), and the push rod (15) for adapter (1) cannot be turned into the master cylinder
scoring, pitting, or other damage If the flow valve (3), completely by hand remove the flow valve adapter (1)
ball (5), check valve piston (8), piston (13) or the push from the master cylinder and make sure that the flow
rod (15) are damaged a new master cylinder must be valve (3) is in the center of the bore in the master
used. cylinder.
Assembly 17. Repeat step 16 until the flow valve adapter (1) can
be turned completely into the master cylinder by hand.
1. Install the check valve seal (7) on the check valve
piston (8). 18. Tighten the flow valve adapter (1) to 30 to 34
pound-feet (41 to 47 Nm)
2. Install the spring (11) on the spring seat (10).
19. See Section 7002 and install the master cylinder on
3. Install the check valve assembly in the spring (11). the machine.
Engage the stem of the check valve piston (8) in the
spring seat (12). 20 Depress the brake pedal to stroke the piston (13) in
the master cylinder. Release the brake pedal and allow
4. Install the check valve assembly on the piston (13). the piston to return. Adjust the push rod to piston clear-
Push the check valve assembly onto the piston (13) ance to .025 to 050 inch (0.6 to 1.3 mm). Turn the clevis
until the tab in the spring seat (12) engages the end of clockwise to shorten or counterclockwise to lengthen.
the piston (13). Tighten the lock nut against the clevis. See the illustra-
tion below.
5. Install the seal (14) on the piston (13)
8. Push the piston assembly into the bore until the --->
push rod (15) and washer (16) can be installed
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.
8870122R
Master Cylinder
Cylinders 8006
CASE CORPORATION
CASE CORPORATION
TABLE OF CONTENTS
OIL COOLER .. . 3
Removal , ......................
, : 3
Installation , , , , , .4
HYDRAULIC PUMP , 6
Removal 6
Installation 8
Installation........ ... 10
Removal 11
Installation . . 11
Removal , , 13
Installation 13
Removal , , 15
Installation , , 15
OIL COOLER
Removal STEP 3
STEP 1
STEP 4
Remove the bolts, flat washers, and lock washers from Remove the bolts, lock washers, and nuts which fasten
the hood hinges (2). the mounting brackets (1) to each side of the oil cooler.
STEP 5 STEP 8
8907
Remove the bolts, flat washers, and nuts which fasten Disconnect the two hoses (1) from the RH side of the oil
the radiator shroud (1) to the machine frame. Remove cooler. Put identification tags on the hoses (1). Discon-
the radiator shroud (1), The weight of the radiator nect the two tubes (2) from the LH side of the oil cooler.
shroud (1) is approximately 50 pounds (23 kg). Install caps on the fittings and plugs in the hoses and
tubes. Stop the vacuum pump.
NOTE: During installation, tighten the bolts for the
radiator shroud (1) to 270 to 324 pound-feet (366 to 439
Nm). STEP 9
STEP 6
"';'!~~7'4703M'
Remove the bolts, lock washers, and flat washers
which fasten the condenser (1) and the oil cooler (2) to
.90[:~~;!ef the radiator (3). Move the condenser (1) to the LH side
Remove the bolts, lock washers, and flat washers from out of the way. Remove the oil cooler (2).
the bottom cover (1). Remove the bottom cover (1).
Installation
STEP 7
Connect a vacuum pump to the hydraulic reservoir Installation of the oil cooler is the reverse of removal.
Start the vacuum pump.
1. OIL COOLER
2. FROM HYDRAULIC
OIL FILTER
3. TO HYDRAULIC
RESERVOIR
B902372J
5. TO TRANSAXLE
Bur 8-17580
HYDRAULIC PUMP
Removal STEP 12
STEP 10
Park the machine on a level surface. Raise the loader Install a hose on the drain valve (2) and drain the ra-
,
and lock the support strut (1) to hold up the loader. diator.
STEP 13
Disconnect the overflow hose (1) from the radiator
neck.
STEP 14 STEP 17
Remove the bolts, lock washers, and nuts which fasten The hydraulic reservoir holds approximately 25 U.S
the mounting brackets (1) to each side of the oil cooler. gallons (95 litres) of oil. Remove the drain plug (1) and
drain the oil from the hydraulic reservoir.
STEP 18
.,
,!~9071~e'M
Remove the bolts, lock washers, and flat washers from
the bottom cover (1). Remove the bottom cover (1).
Bur 8-17580 Issued 3-91 Printed in U.S.A
8001-8
STEP 19 STEP 20
B9074717M
Remove the bolts, lock washers, and flat washers Disconnect the two hoses (1) from the LH side of the
which fasten the condenser (1) to the oil cooler (2) and hydraulic pump (2). Remove the bolts and lock
radiator (3). Move the condenser (1) to the LH side out washers that fasten the flange (3) on the RH side of the
of the way. Have another person help you remove the hydraulic pump (2)
oil cooler (2) and radiator (3). The weight of the oil
cooler (2) and radiator (3) is approximately 50 pounds Remove the bolts, lock washers, and hardened
(23 kg). washers (The hardened washers are on the bottom two
bolts only.) which fasten the hydraulic pump (2) to the
Remove the fan shroud (4). front engine support. Remove the hydraulic pump (2).
Installation
Installation of the hydraulic pump is the reverse of
removal.
4. SUCTION
SCREEN
B902373J
4. Stop the engine. 3 Remove the lifting equipment from the loader control
valve.
5. Move the loader control lever in all directions to
release the pressure from the hydraulic circuits. 4. Connect the vacuum pump to the hydraulic reservoir.
Start the vacuum pump
6 Remove the bolts, lock washers, and flat washers
which fasten the cover for the loader control valve to the 5. Connect the tubes and hoses to the fittings on the
RH step frame. Remove the cover for the loader control loader control valve.
valve.
6. Stop the vacuum pump.
7. Find the wires for the return-to-dig switch on the
loader control valve. Disconnect the wires from the 7. Connect the linkage to the loader control valve.
return-to-dig switch.
8. Connect the wires to the return-to-dig switch on the
8. Fasten identification tags to the loader linkage at the loader control valve.
loader control valve.
9. Start and run the engine at low idle. Move the loader
9. Disconnect the linkage from the loader control valve. control lever to raise the loader completely. Continue to
hold the loader control lever in the RAISE position for 30
10. Clean the loader control valve and the area around seconds.
the loader control valve. Fasten identification tags to the
tubes and hoses at the loader control valve. 10. Lower the loader bucket to the floor. Stop the
engine.
11. Connect a vacuum pump to the hydraulic reservoir.
Start the vacuum pump. 11. Check for oil leakage at the loader control valve.
12. Disconnect the tubes and hoses from the fittings in 12. Check the oil level in the hydraulic reservoir. Add oil
the loader control valve. Install caps on the fittings and as required. See Section 1002 for specifications.
plugs in the hoses and tubes Stop the vacuum pump.
13. Put the cover for the loader control valve in position
13. Connect suitable lifting equipment to the loader on the RH step frame. Install the bolts, lock washers,
control valve. The weights of loader control valves avail- and flat washers which fasten the cover to the RH step
able on this machine are approximately 57 to 72 frame.
pounds (26 to 33 kg).
16. Hold the backhoe control valve in place and remove 9. Slowly extend and retract each cylinder several times
the bolts, lock washers, and nuts that fasten the LH side to remove any air from the backhoe hydraulic circuits.
of the backhoe control valve to the mounting bracket.
10. Stop the engine.
17. Remove the cap screw, lock washer, and spacers
that fasten the RH side of the backhoe control valve to 11. Check for oil leakage at the backhoe control valve.
the mounting bracket.
12. Check the oil level in the hydraulic reservoir. Add oil
as required. See Section 1002 for specifications.
Bur 8-17580 Issued 3-91 Printed in U.S.A
8001-12
4. Stop the engine and apply the parking brake. 2. Turn the spool so that when the yoke is installed on
the spool, the holes will be aligned vertically. Put the
5. Install the swing lock pin. yoke in position on the spool. Install the clevis pin and
the cotter pin to fasten the yoke to the spool.
6. Move the swing control pedals or levers in both direc-
tions to remove any pressure in the swing hydraulic 3. Connect the tube to the B port in the swing section of
circuit. the backhoe control valve and to the fitting in the bottom
of the swing sequence valve.
7. Clean the swing sequence valve and the area around
the swing sequence valve. Fasten identification tags to 4. Connect the remaining tubes and the hoses to the
the hoses and tubes for the swing sequence valve. fittings in the swing sequence valve.
8. Disconnect the tube from the B port in the swing 5. Remove the swing lock pin.
section of the backhoe control valve and from the fitting
in the bottom of the swing sequence valve. 6. Start and run the engine at low idle.
9 Install caps on the fittings in the backhoe control 7. Slowly and completely swing the backhoe to the left
valve and the swing sequence valve. and then to the right several times to remove any air
from the swing hydraulic circuit.
10. Disconnect the remaining tubes and hoses from the
swing sequence valve. 8. Stop the engine.
11. Use caps or plugs to close all openings in order to 9. Check for oil leakage at the swing sequence valve.
keep dirt out of the hydraulic system.
10. Check the oil level in the hydraulic reservoir. Add oil
12. Remove the cotter pin and clevis pin that fasten the as required. See Section 1002 for specifications.
yoke on the linkage to the spool in the swing sequence
valve. 11. See Swing Sequence Valve Adjustment on page 14.
Adjust the swing sequence valve as required.
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.
6 Tighten the jam nuts at the yoke and at the ball joint
on the control rod.
5. CAM
B902375J
2. Loosen the jam nuts at the yoke and at the ball joint LENGTHEN CONTROL ROD TO INCREASE THE
on the control rod. RIGHT CUSHION. (TURN COUNTERCLOCKWISE)
TABLE OF CONTENTS
SPECiFiCATIONS." , , , ,., ' , 3
CIRCUIT RELIEF VALVE FOR THE THREE POINT HITCH CONTROL VALVE 12
CROSS-SECTION DRAWINGS
Pump 13
Filter 16
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)
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)
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)
SPECIAL TOOLS
Order special tools from one of the following ad-
dresses:
Service Tools
P.O. Box 314
Owatonna, Minnesota 55060
In Europe:
VL Churchill Ltd.
P.O. Box 3, Daventry CAS-1804 or CAS-10111 Pressure Fitting Kit
Northants, NN11 4NF This tool is first used on page 7.
England
Troubleshooting complete.
Troubleshooting complete.
Troubleshooting complete.
Troubleshooting complete.
Check the operation of the circuit that has Check the spool travel. See Section 8005
the problem. Does the cylinder(s) move in and 8007 as required for specifications for
both directions? spool travel. Is the spool travel correct?
YES
Adjust the linkage as required to meet the
, specification for spool travel.
Check the O-ring on the end of the circuit Replace the O-ring.
relief valve or plug. Is the O-ring good?
If used, check setting of the circuit relief Adjust the setting of the circuit relief valve
valve. Is the setting correct? according to instructions in this section.
Check the piston packing for the cylinder. NOTE: Boom cylinder only. A check
Is the piston packing good? valve is installed in the piston. The problem
in the boom circuit can be the check valve
and not the piston packing.
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.
6. Compare the reading with the specification on page
Pressure Check 3. If the reading is not correct, adjust the main relief
valve.
1. Park the machine on a level surface. Put the backhoe
in the transport position and lower the loader bucket to Adjusting Main Relief Valve
the floor.
1. The main relief valve is in the outlet section of the
2. Heat the oil to operating temperature. loader control valve. Loosen the lock nut on the main
relief valve. Turn the adjusting screw clockwise to
3. See the illustration. Connect the pressure gauge to increase the pressure and counterclockwise to
the quick disconnect fitting at Test Port 1. decrease the pressure.
4. Run the engine at full throttle. Hold the loader control 2. Check the pressure again.
lever in the RAISE position until the loader stops moving.
3. When the pressure is correct, tighten the lock nut.
3. HYDRAULIC PUMP
4. FROM RESERVOIR
B901795J
OEM 1239 or CAS-10280 Flowmeter 5. Keep the engine running at 2000 rpm (r/rnin). Slowly
close the load valve until the pressure is 2000 psi (13
Checking the Output of the 789 kPa, 138 bar). Read the flow gauge and record the
Loader (Rear) Section reading.
1. Park the machine on a level surface. Put the backhoe 6. Decrease the engine speed to low idle and stop the
in the transport position and lower the loader bucket to engine.
the floor. Stop the engine.
7. The pump efficiency is found by dividing the flow
2. See the illustration. Connect the flowmeter into the reading at 2000 psi (13 789 kPa, 138 bar) by the flow
circuit. reading at 0 psi (0 kPa, 0 bar). The answer multiplied by
100 is the percent efficiency of the pump. If the effi-
3. Heat the oil to operating temperature by closing the ciency is less than 70%, repair or replace the pump.
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).
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
LOADER CONTROL VALVE
5. OEM 1239 OR
CAS-10280 FLOWMETER
B901796J
Checking the Output of the Backhoe 4. Run the engine at 2000 rpm (r/min). Open the load
or Three Point Hitch (Front) Section valve on the flowmeter. Read the flow gauge. Record
the ~Iow reading.
1. Park the machine on a level surface. Put the backhoe
in the transport position and lower the loader bucket to 5. Keep the engine running at 2000 rpm (r/min). Slowly
the floor. Stop the engine. close the load valve until the pressure is 2000 psi (13
789 kPa, 138 bar). Read the flow gauge and record the
2. See the illustration. Connect the flowmeter into the reading.
circuit.
6. Decrease the engine speed to low idle and stop the
3. Heat the oil to operating temperature by closing the engine.
load valve on the flowmeter until the pressure gauge
reads 1000 psi (6895 kPa, 69 bar). Run the engine at 7. The pump efficiency is found by dividing the flow
full throttle until the temperature is 125F (52C). reading at 2000 psi (13 789 kPa, 138 bar) by the flow
reading at 0 psi (0 kPa, 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.
2. HYDRAULIC PUMP
3. FROM RESERVOIR
6. TO SWING SECTION OF
.!}~, .... -~..
BACKHOE CONTROL VALVE _'!. ..... :: :':.- ~ 0
'!) . . - ~
~ ~-
B901797J
4. OEM 1239 OR
CAS-10280 FLOWMETER
2. Install the circuit relief valve in the test block. 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)
B901824J 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
Loader: (14 135 to 15514 kPa, 141 to 155 bar)
1. Bucket A and B Ports Circuit Relief Valve 4. Boom B Port. 4000 to 4100 psi
2950 to 3150 psi (20 340 to 21 719 kPa, (27 580 to 28 269 kPa, 276 to 283 bar)
203 to 217 bar) 5. Swing A and B Ports. 2050 to 2250 psi
(14 135 to 15514 kPa, 141 to 155 bar)
CIRCUIT RELIEF VALVE FOR THE THREE POINT HITCH CONTROL VALVE
Equipment Required
CAS-10111 or CAS-1804 Pressure fitting kit
Pressure Check
Attachment on the floor.
1. Inlet
2. Outlet
3. To Steering Control Valve
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
IE
for the loader by
BUCKET SECTION
LIFT SECTlm
Jilot)
INLET SECTION
t LOADER CONTROL VALVE
Controls flow of oil to the cylinders for the loader by
movement of control levers.
8002-14
B891~
Bur 8-17530
Issued 3-91 Printed in U~
8002-15
1. Inlet
2. Outlet
3. Pilot
4. Check Valve
5. Spool and Sleeve Assembly
6. Drive Unk
7. Gerotor
8891058J
1. Inlet
2. To Resetvoi:
3. To Oil Cooler
4. From Steering Control Valve
5. Filter
6. Bypass Valve
7. Switch
8. Check Valve
B891 061 J
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
12 10. Anticavitation Valve
11. Circuit Relief Valve
12. Load Check Valve
13. Check Valve
14. Spool
15 Regeneration Valve
14 L I
12
14
@
12
Bur 8-17530
Issued 3-91 Printed in U
7
1110Vnl110.111 of
INLET SECTION
.SA
1002-1"
VE
shoo by
DIPPER AND
BUCKET SECTION EXTENSION SECTION
OUTLET SECTION
B891299A
led in U
o THREE POINT HITCH CaNT,
1. inlet
2. Outlet
3. t Implement
9
4. t Tilt Cylinder
5. To Pitch Cylinder
6. To litt Cylinder
7. Main Relief Valve
8. Circuit Relief - Anticavitation Valve
9. Load Check Valve
10. Spool
Corrrols flow of oil to cylinders for three point hitch by
movement of control levers.
1. inlet
2. Outlet
3. t Implement
4. to Tilt Cylinder
5. To Pitch Cylinder INLET-OUTLET AND
6. To Uft Cylinder IMPLEMENT SECTIO~
7. Main Relief Valve
B. Circuit Relief - Anticavitation Valve
9. Load Check Valve
10. Spool
PI
8002-18
~OL VALVE
oint hitch by
INLET-OUTLET AND
IMPLEMENT SECTION
TILT AND PITCH SEC'
Bur 8-17530
8002-18
LIFT SECTION
8891300
Bur 8-17530
Issued 3-9'
8002-19
1. Spool
2. Check Valve
3. Orifice
4. Circuit Relief Valve
CD
CD
B891301J
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
Permits oil flow in one direction only.
TEST PORT 1
FILLER CAP
OIL COOLER
RESERVOIR
8002-21
STEERING CYLINDER
BUCKET LIFT
,-
,...
TEST PORT 2
TEST PORT 1
o
!
t
FILTER L
FILLER CAP
OIL coc
RESERVOIR
inted in U.S.A.
STEERINC
DIRECTION OF FLOW
Shows direction of oil flow.
PILOT PRESSURE
Pressure used to control another component.
CROSSOVER LINES
CONNECTING LINES
OIL COOLER
CHECK VALVE
Permits oil flow in one direction only.
Bur 6-17530
Issued 3-91 Prinlr.d in USA
8003
CLEANING THE HYDRAULIC SYSTEM
TABLE OF CONTENTS
CASE CORPORATION
PORTABLE FILTER
The Portable Filter and Fitting Kit are available
from Service Tools in the United States or from
Jobborn Manfaucturing Co. in Canada. See Spe-
cial Tools in Section 1001 for correct address.
S06126
Fitting Kit
806127
Portable Filter
8003-3
GENERAL INFORMATION
Contamination in the hydraulic system is a 1. Cylinder rod seals leak.
major cause of the malfunction of hydraulic com-
ponents. Contamination is any foreign material in 2. Control valve spools do not return to NEUTRAL.
the hydraulic oil. Contamination can enter the hy-
draulic system in several ways. 3. Movement of control valve spools is difficult.
1. When you drain the oil or disconnect any line. 4. Hydraulic oil becomes too hot.
2. When you disassemble a component. 5. Pump gears, housing, and other parts wear
rapidly.
3. From normal wear of the hydraulic compo-
nents. 6. Relief valves or check valves held open by dirt.
4. From damaged or worn seals. 7. Quick failure of components that have been
repaired.
5. From a damaged component in the hydraulic
system. 8. Cycle times are slow; machine does not have
enough power.
All hydraul ic systems operate with some con-
tamination. The design of the components in this If your machine has any of these problems,
hydraulic system permits efficient operation with a check the hydraulic oil for contamination. See
small amount of contamination. An increase in this Types of Contamination below. If you find contam-
amount of contamination will cause problems in ination, use the Portable Filter to clean the hydrau-
the hydraulic system. The following list includes lic system.
some of these problems.
TYPES OF CONTAMINATION
There are two types of contamination, micro- 2. Visible contamination is foreign material that
scopic and visible. can be found by sight, touch, or odor. Visible con-
tamination can cause a sudden failure of a compo-
1. Microscopic contamination occurs when very nent. Examples of visible contamination.
fine particles of foreign material are in suspension
in the hydraulic oil. These particles are too small to a. Particles of metal or dirt in the oil.
see or feel. Microscopic contamination can be
found by identification of the following problems b. Air in the oil.
or by testi ng in a laboratory. Examples of the prob-
lems: c. The oil is dark and thick.
a. Cylinder rod seals leak. d. The oil has the odor of burned oil.
b. Control valve spools do not return to NEU- e. Water in the oil. See page 8003-6.
TRAL.
a. Remove all the hydraulic oil from the inlet 9. See the fitting kit shown on page 8003-2. Install
and outlet hoses for the portable filter. the valve in the hole for the drain plug. Make sure
that the valve is closed.
b. Remove the filter element from the porta-
ble filter. 10. Stop the vacuum pump.
c. Remove all hydraulic oil from the portable 11. Connect the inlet hose for the portable filter to
filter. the valve that is installed in the hole for the drain
plug.
d. Clean the inside of the housing forthe filter
element. 12. Disconnect the vacuum pump from the filler
cap opening on the hydraulic reservoir.
e. Install a new filter element.
13. Install the outlet hose for the portable filter in
2. You must know whether the contamination is the hydraulic reservoir.
microscopic or visible. See Types of Contamina-
tion on page 8003-3. 14. Open the valve that is installed in the hole for
the drain plug.
3. If the contamination is microscopic:
15. Move the switch for the portable filter to the ON
a. Check the maintenance schedule for the position. Start and run the engine at 1500 rpm
machine to learn if the hydraulic oil must be (r/min).
changed. If needed, change the hydraulic oil.
See Section 8001. Change the hydraulic filter. 16. Run the portable filter for 10 minutes.
4. If the contamination is visible: 18. Increase the engine speed to full throttle. Heat
the oil to operating temperature by doing the fol-
a. Change the hydraulic oil and hydraulic fil- lowing steps:
ter. See Section 8001. Remove and clean the
hydraulic pump suction screen. a. Hold the bucket control lever in the ROLL-
BACK position for 15 seconds.
b. Do steps 5 through 38.
b. Return the bucketcontrolleverto NEUTRAL
5. Check the amount of contamination in the hy- for 30 seconds.
draulic system by doing the following steps.
c. Repeat steps 18a and 18b unti I the oil in the
a. Disassemble one cylinder in two different hydraulic system is at operating temperature.
circuits. Check for damage to seals, scoring of
the cylinder wall, etc. Repair the cylinders as 19. Continue to run the engine at full throttle. Con-
necessary. tinue to run the portable filter.
b. If, in your judgment, the damage to the 20. Operate each hydraulic circuit to completely
cylinders was caused by severe contamination extend and retract the cylinders. Continue to oper-
and is not the result of normal wear, it is neces- ate each hydraulic circuit two times, one after the
sary to remove, clean and repair valves, pump, other, for 45 minutes.
lines, cylinders, hydraulic reservoir, etc. in the
hydraulic system. 21. Decrease the engi ne speed to low idle.
22. Continue to run the portable filter for 10 min- 31. Install the drain plug.
utes.
32. Stop the vacuum pump. Disconnect the vacu-
23. Stop the portable filter. um pump from the hydraulic reservoir.
25. Remove the hose from the hydraulic reservoir. 34. Remove the hydraulic filter element from the
machine.
26. Close the valve that is installed in the hole for
the drain plug. 35. Install a new hydraulic filter element on the
machine.
27. Disconnect the inlet hose for the portable fi Iter
from the valve. 36. Check the oil level in the hydraulic reservoir.
Add oil as required. See Section 8001.
28. Connect a vacuum pump to the fill cap open-
ing of the hydraulic reservoir. 37. Start the engine. Check for oil leakage around
the new hydraulic filter. ~
29. Start the vacuum pump.
38. Stop the engine.
30. Remove the valve from the hole for the drain
plug.
8003-6
13. Start the engine and run the engine at low idle.
HYDRAULIC PUMP
CASE CORPORATION
TABLE OF CONTENTS
SPECiFiCATIONS 2
DiSASSEMBLy . . 3
INSPECTION ...................... . .7
ASSEMBLY .. . 9
SPECIFICATIONS
Manufacturer Commercial Shearing
Special torques
Cap screws that hold the' sections together 250 pound-feet (339 Nm)
DISASSEMBLY
STEP 1 STEP 4
Clean the outside of the hydraulic pump. Fasten the Remove the quad ring.
hydraulic pump in a vise with soft jaws. Make alignment
marks on each section of the hydraulic pump.
STEP 5
STEP 2
STEP 3
STEP 7 STEP 11
STEP 8 STEP 12
!
Remove the other thrust plate. Remove the quad ring.
STEP 9 STEP 13
STEP 10
Remove the quad ring from bottom of the gear housing.
STEP 14 STEP 17
STEP 15 STEP 18
STEP 16 STEP 19
Remove the quad ring from the bottom of the gear
housing.
STEP 20
A
Remove the drive gear.
l
Remove the snap ring from the drive end cover.
STEP 21 STEP 23
Remove the bearing from the drive end cover. Remove the seal from the thrust plates.
STEP 22
INSPECTION
Discard all seals and quad rings, Clean all parts in STEP 26
cleaning solvent. Check all machined surfaces for
damage or wear,
STEP 24
8525018M
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 25
8. CAP SCREW
6. END COVER
5. QUAD
RING
7. FLAT WASHER
16. QUAD
12. DRIVE GEAR
RING
13. QUAD
RING
ASSEMBLY
STEP 28 STEP 31
Install new quad rings in the grooves in the gear hous- Press a new bearing into the drive end cover until the
ings. Use petroleum jelly to hold the quad rings in place. snap ring can be installed in the groove.
STEP 29 STEP 32
Install a new oil seal in the drive end cover. Install the snap ring.
STEP 30 STEP 33
Press the oil seal into the drive end cover. Install new seals in each thrust plate.
STEP 34 STEP 37
Fasten the drive end cover in the vise with soft jaws. Install the drive gear.
STEP 35 STEP 38
STEP 36 STEP 39
Install the thrust plate with the seal down and the Install the driven gear.
grooves as shown above.
STEP 40 STEP 43
Install the thrust plate with the seal up as shown above. Install the thrust plate with the seal down and the
grooves as shown above.
STEP 41
STEP 44
STEP 42
STEP 45
STEP 46 STEP 48
l
Install the thrust plate with the seal up as shown. Install the cap screws and flat washers. Tighten the cap
screws evenly to 250 pound-feet (339 Nm).
STEP 47
15. BUSHING
16. FLAT
WASHER
24. DRIVE
END COVER
18. END
23. GEAR 21. CARRIER
22. DOWEL COVER
HOUSING PIN
19. GEAR
8901881J
HOUSING
CASE CORPORATION
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
SPECIFICATIONS
Manufacturer . ..... J I Case
Special torque
Nuts that fasten the valve sections together 20 to 30 pound-feet (27 to 41 Nm)
SPECIAL TOOLS
Order special tools from one of the following ad-
dresses:
Service Tools
PO. Box 314
Owatonna, Minnesota 55060
In Europe:
VL Churchill Ltd
P.O. Box 3,Daventry
Northants, NN11 4NF
England
B861843J
Clean the outside of the loader control valve. Write a Remove the shims.
number on each section of the loader control valve.
STEP 5
STEP 2
STEP 3
STEP 8
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 9
OUTLET SECTION
Disassembly STEP 15
STEP 12
STEP 13
STEP 17
Loosen the plug in the other end of the outlet section. Do not disassemble the main relief valve. None of the
internal parts of the main relief valve are available for
service.
STEP 14
STEP 19
STEP 20
6. MAIN
RELIEF
VALVE
Install a new O-ring on the plug. Lubricate the O-ring
B870012J
with clean hydraulic oil. Install the plug. Tighten the plug
Outlet Section
to 30 to 40 pound-feet (41 to 54 Nm).
Assembly
STEP 18 STEP 21
5. OUTLET SECTION
2. O-RING
3. SPRING
B861799J
Outlet Section
INLET SECTION
Disassembly STEP 25
STEP 22
Loosen and remove the plug from the other end of the
inlet section.
Fasten the inlet section in the vise with soft jaws.
Loosen the steering relief valve.
STEP 26
STEP 23
STEP 24
Fasten the steering relief valve in the vise with soft jaws.
Prevent the adjusting screw from turning and loosen the
Remove the spring. lock nut. Make a count of the number of turns needed to
remove the adjusting screw from the body.
STEP 28 Inspection
STEP 29
4. a-RING
B628924M
.~ ..'
Remove the steering relief valve from the vise and 4. a-RING
separate the parts. B628928M
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.
4. BODY
6. O-RING
B870013J
Inlet Section
Assembly STEP 35
STEP 32
STEP 36
STEP 33
STEP 34
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
B861798J
Inlet Section
BUCKET SECTION
Disassembly STEP 42
STEP 39
STEP 40
STEP 41
STEP 45 STEP 48
STEP 46
STEP 49
STEP 50
STEP 51 STEP 54
8415238M
See Special Tools in this section. Install the spring com- Loosen and remove the circuit relief valve from the
pressing plates to compress the centering spring. body.
STEP 52 STEP 55
B415240M
Loosen and remove the stud. See Special Tools in this section. Use the tool to pull the
load check plug, spring, and poppet from the body.
STEP 53
STEP 56
Repeat steps 54 and 55 to remove the other circuit relief
valve.
STEP 57
'i8415242M
Release the spring tension and separate the centering
spring and spring seats.
STEP 58 STEP 59
See page 42 for disassembly, inspection, and
assembly of the circuit relief valves.
B901919J
Bucket Section
Bur 8-17410
Issued 1-91 Printed in U.S.A.
8005-20
Inspection STEP 63
STEP 60
B9073305M
Replace the O-ring and backup rings on the load check
B415232J plug.
Remove and discard the O-ring from the terminal.
STEP 64
STEP 61 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 a soldering 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.
B9073309M
Inspect the poppet. spring, and load check plug. Use
new parts as necessary.
Install a new O-ring in the groove of the spool bore.
STEP 69 STEP 72
B415242M
Use the tool to install the load check plug, spring, and Assemble the spring and spring seats. Use the spring
poppet. The groove in the load check plug must be compressing plates to compress the spring.
toward the spool bore.
STEP 73
STEP 70
B415243M
Install the spring and spring seats on the spool.
Lubricate the O-rings and backup ring on the circuit
relief valve. Install the circuit relief valve.
STEP 74
STEP 71
B415201M
Apply 242 Loctite to the threads of the stud. Install the
628630M stud in the spool.
Tighten the circuit relief valve to 65 to 85 pound-feet (88
to 155 Nrn).
STEP 75 STEP 78
B415238M "'B415202M
Remove the spring compressing plates. Push the parts against the detent housing.
STEP 76 STEP 79
Install the detent housing. Lubricate the spool, spool bore. and the O-rings with
clean hydraulic oil. Install the spool into the bore.
STEP 77
STEP 80
B4t5235M
Install the O-rings, spring washers, and retainer.
Install the coil and terminal on the stud.
STEP 81 STEP 84
Install the detent washer. Hold the washer in place and install the snap ring.
STEP 82 STEP 85
Install the spring. Install a new O-ring on the terminal. Install the gasket.
Put the terminal in the cap.
STEP 83
STEP 86
STEP 87 STEP 89
Tighten the Allen head screws evenly to 15 to 30 pound- Use a hollow sleeve and a hammer to push the wiper
inches (2 to 3 Nm). Then tighten the Allen screws to 50 into the body.
to 60 pound-inches (6 to 7 Nrn).
STEP 90
STEP 88
22. SPOOL
18. CIRCUIT
RELIEF
VALVE
24. BODY
26. A PORT
27. B PORT
6. SPRING
B901920J
LIFT SECTION
Disassembly STEP 94
STEP 91
Fasten the lift section in the vise with soft jaws. Loosen
and remove the plug. STEP 96
IIi
... :,(,=;::: ...."
STEP 93
B415424M
Loosen and remove the detent housing. See page 4 for the spring compressing plates Fasten
the spring compressing plates to compress the cen-
tering spring.
STEP 98
STEP 101
STEP 102
B415422M
Remove the O-ring and retainer from the spool.
B415428M
Remove the centering spring and spring seats from the
spool.
B415430M
Release the tension on the centering spring and Remove the wiper from the spool bore.
separate the centering spring and spring seats.
STEP 107
STEP 104
STEP 108
STEP 105 Repeat steps 104 and 105 to remove the other plug
load check plug, spring, and poppet.
Lift Section
Bur 8-17410 Issued 1-91 Printed in U.SA
8005-30
Assembly
STEP 114
B9073309M
Inspect the load check poppet, spring, and load check
plug. If any of the parts are damaged, replace the parts
as necessary.
STEP 115
B9073305M
Replace the O-ring and backup rings on the load check
plug. ~1' . ,,;,41?414t'lt
Use the tool shown on page 4 to install the load check
STEP 111 plug, spring, and load check poppet. The groove in the
Inspect the spool and spool bore for wear and damage. loade check plug must be in alignment with the work
If either part is worn or damaged, use a complete new port.
lift section
STEP 116
STEP 112
B415420M
Replace the O-rings and backup ring on the plug.
B41~5430M B415424M
Assemble the centering spring and spring seats. Use Remove the spring compressing plates.
the spring compressing plates shown on page 4 to
compress the centering spring.
STEP 121
STEP 118
STEP 119
Install the detent housing. Install the eight steel balls. Put the steel balls evenly
around the spacer.
STEP 124
STEP 127
STEP 125
STEP 128
Install the detent spring. Use a hollow sleeve and a hammer to push the wiper
into the body.
STEP 130
STEP 133
STEP 131
1. SPOOL
12. PLUG
13. a-RING
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
B901922J
Bur 8-17410 Lift Section Issued 1-91 Printed in U.S.A
8005-35
CLAM SECTION
Disassembly STEP 137
STEP 134
STEP 135
STEP 136
Remove the spring and spring seats from the spool. Use a prybar to remove the wiper from the other end of
Release the spring tension and separate the spring, the spool bore.
spring seats, and washer.
STEP 144
STEP 141
STEP 145
STEP 142 Do step 141 and 142 to remove the other plug, load
check plug, spring, and poppet.
B901923J
Clam Spool
Bur 8-17410
Issued 1-91 Printed in U.S.A.
8005-38
Inspection Assembly
STEP 146 STEP 150
B9073309M
Inspect the load check poppet, spring, and load check Install a new O-ring in the groove of the spool bore.
plug. Use new parts as necessary.
STEP 151
STEP 147
B415420M
Replace the O-rings and backup ring on the plug.
M
STEP 149
Lubricate the O-rings and backup ring on the plug.
Inspect the spool bore for wear and damage. If the
Install the plug. Tighten the plug to 65 to 85 pound-feet
spool or spool bore is damaged, use a complete new
(88 to 155 Nm).
clam section.
Bur 8-17410 Issued 1-91 Printed in U.S.A.
8005-39
i ' ,-:'B628624M
Assemble the spring, spring seats, and washer. Use Tighten the cap screw
the spring compressing plates shown in Special Tools
to compress the spring.
STEP 157
STEP 154
';':'~~~M
Release the tension of the spring and remove the spring
B628539M compressing plates.
Apply 242 Loctite to the threads of the cap screw.
STEP 158
STEP 155
5M
Lubricate a new wiper. Install the wiper with the lips up.
STEP 163
STEP 160
STEP 161
\OO28844M
Tighten the spool cap to 20 to 30 pound-feet (27 to 41
Nm).
., 15. PLUG
14. WIPER
2. O-RING
2. O-RING
16. A PORT
13. BODY
17. B PORT
5. WASHER
6. SPRING
7. CAP SCREW
~
8. SPOOL CAP
B901924J
Clam Spool
STEP 164
B628606M
Remove the relief valve from the vise. Separate the
parts of the relief valve.
B870017J
Inspection Assembly
STEP167 STEP169
Inspect the parts of the relief valve. All of the repair parts
in the relief valve are available in a kit. If any of the parts
are damaged, replace all the parts in the kit.
STEP 168
B628606M
Lubricate the O-rings on the parts of the relief valve
Assemble the parts into the body.
B628734M
Replace the O-rings and backup ring on the parts of the
relief valve.
Bur 8-17410 Issued 1-91 Printed in U.S.A.
8005-44
2. ADJUSTING SCREW
12M
Fasten the poppet seat in the vise with soft jaws.
Tighten the body to 96 to 144 pound-inches (11 to 16
Nrn).
6. SPRING
STEP 171
4. D-RING
6. SPRING
8. POPPET
SEAT
7. POPPET
Install the adjusting screw and lock nut in the body.
TABLE OF CONTENTS
Assembly............ 4 Inspection 16
Inspection. .. . 8 Disassembly......... .. 20
Assembly. . 8 Inspection. .. 20
Assembly 20
CASE CORPORATION
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)
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)
Loader cylinders
Bucket cylinder . ... 40 pounds (19 kg)
Lift cylinder.................. . ... 60 pounds (27 kg)
Clam cylinder.................. . ... 33 pounds (15 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)
SPECIAL TOOLS
Order special tools from one of the following ad- The tool shown is used to install the seal in the
dresses: glands of the cylinders. This tool is first used on page
8006-4
In the U.S.A. and Canada
Service Tools
PO Box 314
Owatonna, Minnesota 55060
In Europe
VL Churchill Ltd
P.O. Box 3, Daventry
Northants, NN11 4NF
England
B786441M
8795329M
3. Use the gland wrench shown on page 8006-3 to 7. Inspect the gland (3) for rust and clean and remove
loosen and remove the gland (3) from the tube (1). rust as required.
4. Pull the piston rod (6) straight out of the tube (1) to 8 Inspect the gland end of the tube (1) for share
prevent damage to the tube (1). edges that will cut the gland O-ring (12). remove as re-
quired.
5. Fasten the piston rod eye (5) in a vise and put a
support below the piston rod (6) near the piston (4). Use 9. Inspect the piston (4) for damage and wear If the
a shop cloth between the support and the piston rod (6) piston (4) is damaged or worn. a new piston (4) must be
to prevent damage to the piston rod (6). used.
7. Remove the piston (4) from the piston rod (6). 1. Install the bushing (17) in the gland (3).
8. Remove the gland (3) from the piston rod (6). 2. Install the wide seal (15) in the gland. The wide seal
(15) is to be installed so that the Iips of the wi de seal (15)
9. Remove the seal (9), backup ring (10), and wear are toward the small end of the gland (3). The wide seal
ring (11) from the piston (4). (15) can be difficult to install. Use the tool shown on
page 8006-3
10. Remove the O-ring (12), backup ring (13), wiper
(14), wide seal (15), narrow seal (16), and bushing (17) 3. Install a new wiper (14) in the gland (3). The lips of
from the gland (3). the wiper (14) must be toward the large end of the gland
(3).
Inspection
4. Install the narrow seal (16) in the gland (3) The side
1. Clean the piston (4), gland (3), piston rod (6), tube of the narrow seal (16) with the groove must be toward
(1), hardened washer (8), and cap screw (7) in cleaning the small end of the gland (3).
solvent.
5. Install a new backup ring (13) in the groove on the
2. Discard the parts that were removed from the outside of the gland (3). If both sides of the backup ring
piston (4) and the gland (3). (13) are not flat, the side that is not flat must be toward
the small end of the gland (3)_
3. Illuminate the inside of the tube (1). Inspect the
inside of the tube (1) for deep grooves and other 6. Install the O-ring (12) next to the backup ring (13) in
damage. If there is damage to the tube (1), a new tube the groove on the outside of the gland (3). The O-ring
(1) must be used. (12) must be toward the small end of the gland (3).
7. Fasten the piston rod eye (5) in the vise. 18 Install a new seal (9) on top of the backup ring (10)
on the outside of the piston (4)
8. Remove any marks and sharp edges on the chamfer
at the end of the piston rod (6). 19. Fasten the tube (1) in a vise or other holding equip-
ment. Be careful to prevent damage to the tube (1)
9 Lubricate the bore of the gland (3) with clean oil.
20 Lubricate the inside of tne tube (1) and tne ois.on (4)
10 Push the gland (3) onto the piston rod (6). If neces- with clean oil.
sary, use a soft hammer to drive the gland (3) onto
the piston rod (6). 21 Push the piston (4) straiqh: in.o .ne lube (1)
11. Put a support below and near the end of the piston 22 When the piston (4) is in he smooth oar: 0' the tube
rod (6). Use a shop cloth between the support and (1). start the gland (3) in:o 'he .ube (1\
the piston rod (6) to prevent damage to the piston
(4). 23 Lubricate the O-ring (12) or, .he gland (3) \VI:hclean
oil
12. Put the piston (4) on the end of the piston rod (6)
24. Tighten the gland (3) :0 10010 400 oounc-tee: (135
13. Put the hardened washer (8) on the cap screw (7). to 542 Nm) If the lock screw (2) holes becorre
aligned In this torcue range. Install .he lock screw
14. Clean the threads on the end of the piston rod and (2). Tighten the lock screw (2) :0 20 occno-vicnes
the threads of the cap screw using Loctite cleaning (2.3 Nm) Ii :he lock scre\' (2) holes are no: alignec
solvent. Allow to dry. Apply Loctite 242 to the piston do steps 25 through 27
rod threads 1/4 inch from the open end of the piston
rod so that there is 1/2 inch of Loctite 242 on the 25. Tighten the gland (3) to 100;0400 ocund-teet 1135
piston rod threads. DO NOT apply Loctite to the first to 542 Nm)
1/4 inch of the piston rod threads.
26. Use a No 26 drill and drill a hole half in the gland(3)
15. Install the cap screw (7). Tighten the cap screw (7) and half in the tube (1). Drill to a deeth of 7'16 irch
to the torque value on page 8006-2 for the cylinder (11 mm) Do not drill in line with a hole in he gland
that is being repaired A torque multiplier can be (3) for the gland wrench
used to help tighten the cap screw.
27. Install the lock screw (2). Tighten the lock screw (2)
16. Install a new wear ring (11) in the end groove on the to 20 pound-inches (23 Nm)
outside of the piston (4).
If the hoses were removed with the cylinder. install new
17. Install a new backup ring (10) in the center groove a-rings. if equipped on the hose fittings Lubricate the
on the outside of the piston (4). a-rings with clean oil. Install the hoses
12. a-RING
1. TUBE BB91512J
8. HARDENED
WASHER
7. CAP SCREW
BOOM CYLINDER
Disassembly 3 Illuminate the inside of the tube (1). Inspect the inside
of the tube (1) for deep grooves and other damage. If
Clean the outside of the cylinder. If the hoses were there is damage to the tube (1), a new tube (1) must be
removed with the cylinder, remove the hoses from the used.
cylinder.
4. Check to be sure that the piston rod (6) is straight If
1. Fasten the tube (1) in a vise or other holding equip- the piston rod (6) is not straight, install a new piston rod
ment. Be careful to prevent damage to the tube (1). (6).
2. Loosen and remove the lock screw (2) from the gland 5. Remove small scratches on the piston rod (6) or
(3) and tube (1). inside the tube (1) with emery cloth of medium grit. Use
the emery cloth with a rotary motion
3. Use the gland wrench shown on page 8090-3 to
loosen and remove the gland (3) from the tube (1). 6 Inspect the bushing (20) and seal (21). if equipped in
the piston rod eye (5) and the closed end of the tube (1).
4. Pull the piston rod (6) straight out of the tube (1) to and replace as required.
prevent damage to the tube (1).
7. Inspect the gland (3) for rust and clean and remove
5. Fasten the piston rod eye (5) in a vise and put a rust as required.
support below the piston rod (6) near the piston (4). Use
a shop cloth between the support and the piston rod (6) 8 Inspectthe gland end of the tube (1) for sharp edges
to prevent damage to the piston rod (6). that will cut the gland O-ring (14) and remove as re-
quired.
6. Loosen and remove the cap screw (7) and hardened
washer (8) that holds the piston (4). Use the torque mul- 9. Inspect the piston (4) for damage and wear If the
tiplier shown on page 8090-3 for cap screws that have a piston (4) is damaged orworn. a new piston (4) must be
high torque value. used.
7. Remove the piston (4) from the piston rod (6). Assembly
8. Remove the gland (3) from the piston rod (6). NOTE: If a new gland (3) is being instal/ed, put the
part number of the cylinder on the new gland (3).
NOTE: If the boom cylinder is being disassembled for
repair because of poor performance and the seals (10) 1. Install the bushing (16) in the gland (3).
on the piston (4) are good, replace the check valve (12)
and the O-ring (13). If the seals (10) are damaged, do 2. Install the narrow seal (17) in the gland (3). The side
the next step. of the narrow seal (17) with the groove must be toward
the small end of the gland (3).
9. Remove the wear ring (9), seals (10), and the backup
rings (11) from the piston (4) 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
10. Remove the O-ring (14), backup ring (15), wiper seal (18) are toward the small end of the gland (3) The
(19), wide seal (18), narrow seal (17), and bushing (16) wide seal (18) can be difficult to install. Use the tool
from the gland (3). shown on page 8009-3.
Inspection 4. Install a new wiper (19) in the gland (3) The lips of the
wiper (19) must be toward the outside of the gland (3).
1. Clean the piston (4), gland (3), piston rod (6), tube
(1), hardened washer (8) and cap screw (7) in cleaning 5 Install a new backup ring (15) in the groove on the
solvent. outside of the gland (3). If both sides of the backup ring
(15) are not flat, the side that is not flat must be toward
2. Discard the parts that were removed from the piston the small end of the gland (3).
(4) and the gland (3).
6. Install the a-ring (14) next to the backup ring (15) in 17 Install a new backup ring (11) in each groove on the
the groove on the outside of the gland (3). The a-ring outside ends of the piston (4)
(14) must be toward the small end of the gland (3).
18 Install a new seal (10) over each backup ring (11) on
7 Fasten the piston rod eye (5) in the vise. the outside ends of the piston (4)
8. Remove any marks and sharp edges on the chamfer 19 Fasten the tube (1) in a vise or other holding equip-
at the end of the piston rod (6) ment. Be careful to prevent damage to the tube (1).
9. Lubricate the bore of the gland (3) and the piston rod 20 Lubricate the inside of the tube (1) and the piston (4)
(6) with clean oil with clean oil
10 Push the gland (3) onto the piston rod (6). If neces- 21. Push the piston (4) straiqrn into the tube (1)
sary, use a soft hammer to drive the gland (3) onto
the piston rod (6). 22. When the piston (4) is in the smooth par; of the tube
(1) start the gland (3) into the tube (1)
11. Put a support below and near the end of the piston
rod (6). Use a shop cloth between the support and 23. Lubricate the a-ring (14) on the gland (3) with clean
the piston rod (6) to prevent damage to the piston oil.
(4)
24 Tighten the gland (3) to 100 to 400 pound-feet (135
12. Put the piston (4) on the end of the piston rod (6) to 542 Nm) If the lock screw (2) holes become
aligned in this torque range install the lock screw
13. Put the hardened washer (8) on the cap screw (7). (2) Tighten the lock screw (2) to 20 pound- inches
(23 Nm) If the lock screw (2) holes are not aligned
14. Clean the threads on the end of the piston rod and do steps 25 through 27
the threads of the cap screw using Loctite cleaning
solvent. Allow to dry. Apply Loctite 242 to the piston 25. Tighten the gland (3) to 100 to 400 pound-feet (135
rod threads 1/4 inch from the open end of the piston to 542 Nm).
rod so that there is 1/2 inch of Loctite 242 on the
piston rod threads. DO NOT apply Loctite to the first 26. Use a No. 26 drill and drill a hole half in the gland (3)
1/4 inch of the piston rod threads. 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
15. Install the cap screw (7). Tighten the cap screw (7) (3) for the gland wrench
to the torque value on page 8006-2 for the cylinder
that is being repaired A torque multiplier can be 27. Install the lock screw (2) Tighten the lock screw (2)
used to help tighten the cap screw (7). to 20 pound-inches (23 Nm)
16. Install a new wear ring (9) in the groove in the center 28. If the hoses were removed with the cylinder, install
of the piston (4) new a-rings. if equipped, on the hose fittings. Lub-i-
cate the a-rings with clean oil. Install the hoses.
1. TUBE
21. SEAL
B891539J
3. Use the gland wrench shown on page 8006-3 to 7. Inspect the gland (3) for rust and clean and remove
loosen and remove the gland (3) from the tube (1). rust as required.
4. Pull the piston rod (6) straight out of the tube (1) to 8. Inspect the gland end of the tube (1) for sharp
prevent damage to the tube (1). edges that will cut the gland O-ring (12). Remove as re-
quired.
5. Fasten the piston rod eye (5) in a vise and put a
support below the piston rod (6) near the piston (4). Use 9. Inspect the piston (4) for damage and wear. If the
a shop cloth between the support and the piston rod (6) piston (4) is damaged or worn. a new piston (4) must be
to prevent damage to the piston rod (6). used.
7. Remove the piston (4) from the piston rod (6). 1. Install the bushing (17) in the gland (3).
8. Remove the gland (3) from the piston rod (6). 2. Install the wide seal (15) in the gland. The wide seal
(15) is to be installed so that the lips of the wide seal (15)
9. Remove the seal (9), backup ring (10), and wear are toward the small end of the gland (3). The wide seal
ring (11) from the piston (4) (15) can be difficult to install Use the tool shown on
page 8006-3.
10. Remove the O-ring (12), backup ring (13), wiper
(14), wide seal (15), narrow seal (16), and bushing (17) 3. Install a new wiper (14) in the gland (3) The lips of
from the gland (3). the wiper (14) must be toward the large end of the gland
(3)
Inspection
4. Install the narrow seal (16) in the gland (3). The side
1. Clean the piston (4), gland (3), piston rod (6). tube of the narrow seal (16) with the groove must be toward
(1), hardened washer (8), and cap screw (7) in cleaning the small end of the gland (3).
solvent.
5. Install a new backup ring (13) in the groove on the
2. Discard the parts that were removed from the outside of the gland (3). If both sides of the backup ring
piston (4) and the gland (3). (13) are not flat, the side that is not flat must be toward
the small end of the gland (3).
3. Illuminate the inside of the tube (1). Inspect the
inside of the tube (1) for deep grooves and other 6. Install the O-ring (12) next to the backup ring (13) in
damage. If there is damage to the tube (1), a new tube the groove on the outside of the gland (3). The O-ring
(1) must be used. (12) must be toward the small end of the gland (3).
19. GREASE
rrrnso
1. TUBE
B891624J
7. Fasten the piston rod eye (5) in the vise. 18 Install a new seal (9) on top of the backup ring (10)
on the outside of the piston (4)
8. Remove any marks and sharp edges on the chamfer
at the end of the piston rod (6) 19 Fasten the tube (1) In a vise or other holding equip-
ment. Be careful to prevent damage to the tube (1)
9. Lubricate the bore of the gland (3) with clean oil
20. Lubricate the inside of the tube (1) and the piston (4)
10. Push the gland (3) on to the piston rod (6). If neces- with clean oil
sary, use a soft hammer to drive the gland (3) onto
the piston rod (6). 21 Push the piston (4) s raiqh: into the tube (1).
11. Put a support below and near the end of the piston 22 When the piston (4) is In the smooth cart of the tube
rod (6). Use a shop cloth between the support and (1) start the gland (3) into the tube (1)
the piston rod (6) to prevent damage to the piston
(4). 23. Lubricate the a-ring (12) on the gland (3) with clean
ali
12 Put the piston (4) on the end of the piston rod (6)
24 Tighten the glar:d (3) ;0 100 to 400 pound-feet (135
13. Put the hardened washer (8) on the cap screw (7). IO 542 NIT,) I' the lock screw (2) holes oecorr-e
aligned in tt"',istoroue range install the lock screw
14. Clean the threads on the end of the piston rod and (2). Tighten the lock screw (2) :0 20 pound-Inches
the threads of the cap screw using l.octite cleaning (23 Nm) I' tne lock screw (2) holes are no: aligned
solvent Allow to dry. Apply Loctite 242 to the piston do stecs 25 :hroLgh 27
rod threads 1/4 inch from the open end of the piston
rod so that there is 1/2 inch of Loctite 242 on the 2S 7ighten the gland (3) to 100 to 400 pound-tee: (135
piston rod threads DO NOT apply Loctite to the first to 542 Nrn)
1/4 inch of the piston rod threads
26 Use a No. 26 drill and drill a hole half in the gland (3)
15. Install the cap screw (7) Tighten the cap screw (7) and hal' in the tube (1) Drill to a death a' 7/16 inch
to the TOrque value on page 8006-2 for the cylinder (11 rr:r-) Do no: drill in line with a hole in the gland
that is being repaired A toraue multiplier can be f3) 'or the glar.c wrencr;
used to help .ighten the cap screw.
27 l"1s:al,the lock screw (2) Tighten the lock screw (2)
16 Install a new wear ring (11) in the end groove a the :020 cound-inches (2.3 Nm).
outside of the piston (4)
Ii the hoses were removed with the cylinder. install new
17. Install a new backup ring (10) in the center groove a-rings. ii equipped on the hose fittings. Lubricate the
on the outside of the piston (4) O-rings with clean 0'1. Install the hoses
12. O-RING
6. PISTON ROD
18. BUSHING
19. GREASE
4. FinING
18. BUSHING
S8S1S25J
8.HARDENED 7. CAP SCREW
WASHER
3 Use the gland wrench shown on page 8006-3 to 7. Inspect the gland (3) for rust and clean and remove
loosen and remove the gland (3) from the tube (1) rust as required.
4. Pull the piston rod (6) straight out of the tube (1) to 8 Inspect the gland end of the tube (1) for sharp
prevent damage to the tube (1). edges that will cut the gland O-ring (12). Remove as re-
quired.
5. Fasten the piston rod eye (5) in a vise and put a
support below the piston rod (6) near the piston (4). Use 9. Inspect the piston (4) for damage and wear. If he
a shop cloth between the support and the piston rod (6) piston (4) is damaged or worn. a new piston (4) must be
to prevent damage to the piston rod (6). used.
7. Remove the piston (4) from the piston rod (6). 1. Install the wide seal (15) in the gland. The wide seal
(15) is to be installed sothatthe lips of the wide seal (15)
8. Remove the gland (3) from the piston rod (6) are toward the small end o' the gland (3). The wide seal
(15) can be difficult to install. Use the tool shown on
9. Remove the seal (9), backup ring (10). and wear page 8006-3
ring (11) from the piston (4).
2. Install a new wiper (14) in the gland (3). The lips of
10 Remove the O-ring (12), backup ring (13), wiper the wiper (14) must be toward the large end of the gland
(14), wide seal (15), narrow seal (16), and bushing (17) (3) .
from the gland (3).
3. Install the narrow seal (16) in the gland (3). The side
Inspection of the narrow seal (16) with the groove must be toward
the small end of the gland (3).
1. Clean the piston (4), gland (3), piston rod (6), tube
(1), hardened washer (8), and cap screw (7) in cleaning 4 Install a new backup ring (13) in the groove on the
solvent. 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
2. Discard the parts that were removed from the the small end of the gland (3).
piston (4) and the gland (3).
5. Install the O-ring (12) next to the backup ring (13) in
3 Illuminate the inside of the tube (1). Inspect the the groove on the outside of the gland (3). The O-ring
inside of the tube (1) for deep grooves and other (12) must be toward the small end of the gland (3).
damage. If there is damage to the tube (1), a new tube
(1) must be used. 6. Fasten the piston rod eye (5) in the vise
19 GREASE FITTING
~
7 Remove any marks and sharp edges on the chamfer 18. Fasten the tube (1) in a vise or other holding equip-
at the end of the piston rod (6) ment. Be careful to prevent damage to the tube (1)
8. Lubricate the bore of the gland (3) with clean oil 19 Lubricate the piston (4) and the inside of the tube (1)
with clean oil.
9. Push the gland (3) on to the piston rod (6) If neces-
sary, use a soft hammer to drive the gland (3) onto 20 Push the piston (4) straight into the tube (1)
the piston rod (6).
21. When the piston (4) is in the smooth part of the tube
10 Put a support below and near the end of the piston (1), start the gland (3) into the tube (1)
rod (6). Use a shop cloth between the support and
the piston rod (6) to prevent damage to the piston 22 Lubricate the O-ring (12) on the gland (3) with clean
(4). oil
11. Put the piston (4) on the end of the piston rod (6) 23 Tighten the gland (3) to 100 to 400 pound-feet (135
to 542 Nm) If the lock screw (2) holes become
12 Put the hardened washer (8) on the cap screw (7). aligned in this torque range install the lock screw
(2). Tighten the lock screw (2) to 20 pound-Inches
13. Clean the threads on the end of the piston rod and (2.3 Nm) If the lock screw (2) holes are not aligned.
the threads of the cap screw usmq Loctite cleaning do steps 24 through 26
solvent. Allow to dry Apply Loctite 242 to the piston
rod threads 1/4 inch from the open end of the piston 24. Tighten the gland (3) to 100 tc 400 oounc-tee: (135
rod so that there is 1/2 inch of Loctite 242 on the to 542 Nrn).
piston rod threads. DO NOT apply Loctite to the first
1/4 inch of the piston rod threads. 25 Use a No. 26 drill and drill a hole hal' In the gland (3)
and half in the tube (1) Drill to a death of 7/16 inch
14. Install the cap screw (7) Tighten the cap screw (7) (11 mm). Do not drill in line With a hole in the gland
to the torque value on page 8006-2 for the cylinder (3) for the gland wrench
that is being repaired A torque multiplier can be
used to help tighten the cap screw. When a torque 26 Install the lock screw (2) Tighten the lock screw (2)
multiplier IS used. a chain must be used to hold the to 20 pound-Inches (23 Nm)
piston rod (6) in position Use a shop cloth and a
metal protector between the piston rod (6) and the If the hoses were removed With the cylinder. install new
chain O-rings If equipped on the hose :ittings. Lubricate the
O-rings with clean oil Install the hoses
15. Install a new wear ring (11) In .be end groove on the
outside of the piston (4)
17. Install a new seal (9) on too of the backuo ring (10)
on the outside of the piston (4)
6. PISTON
15. WIDE 16. NARROW ROD
18. SNAP
SEAL SEAL
RING
9. SEAL
3 Use the gland wrench shown on page 8006-3 to 7 Inspect the gland (3) for rust and clean and remove
loosen and remove the gland (3) from the tube (1) rust as required.
4. Pull the piston rod (6) straight out of the tube (1) to 8. Inspect the gland end of the tube (1) for share
prevent damage to the tube (1). edges that will cut the gland O-ring (12). remove as re-
quired.
5 Fasten the piston rod eye (5) in a vise and put a
support below the piston rod (6) near the piston (4). Use 9. Inspect the piston (4) for damage and wear. If the
a shop cloth between the support and the piston rod (6) piston (4) is damaged or worn. a new piston (4) rnus: be
to prevent damage to the piston rod (6). used
7. Remove the piston (4) 'rom the piston rod (6). 1. Install the bushing (17) in .he gland (3).
8 Remove the gland (3) from the piston rod (6) 2. lnstall the wide seal (15) in the gland. The wide seal
(15) is to be installed so that the lips of the wide seal (i5)
9 Remove the seal (9), backup ring (10). and wear are toward the small end of the gland (3). The wide seal
ring (11) from the piston (4). (15) can be difficult to install. Use the tool shown on
page 8006-3
10 Remove the O-ring (12). backup ring (13). wiper
(14), wide seal (15). narrow seal (16), and bushing (17) 3. Install a new wiper (14) in the gland (3). The lips of
from the gland (3). the wiper (14) must be toward the large end of the gland
(3)
Inspection
4. Install the narrow seal (16) in the gland (3) The side
1. Clean the piston (4), gland (3), piston rod (6), tube of the narrow seal (16) with the groove must be toward
(1), hardened washer (8), and cap screw (7) in cleaning the small end of the gland (3).
solvent.
5. Install a new backup ring (13) in the groove on the
2. Discard the parts that were removed from the outside of the gland (3). If both sides of the backup ring
piston (4) and the gland (3). (13) are not flat, the side that is not flat must be toward
the small end of the gland (3).
3. Illuminate the inside of the tube (1) Inspect the
inside of the tube (1) for deep grooves and other 6. Install the O-ring (12) next to the backup ring (13) in
damage. If there is damage to the tube (1), a new tube the groove on the outside of the gland (3). The O-ring
(1) must be used. (12) must be toward the small end of the gland (3)
19. SNAP
RING
B891629J
7. Fasten the piston rod eye (5) in the vise. 18 Install a new seal (9) on top of the backup ring (10)
on the outside of the piston (4).
8. Remove any marks and sharp edges on the chamfer
at the end of the piston rod (6). 19 Fasten the tube (1) in a vise or other holding equip-
ment Be careful to orevent damage to the tube (1).
9. Lubricate the bore of the gland (3) with clean oil
20. Lubricate the inside of the tube (1) and the piston (4)
10 Push the gland (3) onto the piston rod (6). If neces- with clean oil
sary, use a soft hammer to drive the gland (3) onto
the piston rod (6). 21 Push the piston (4) straight 1"1(0 tre tube (1)
11. Put a support below and near the end of the piston 22. When the cis.on (4) is in the srnoo.n pan of the tube
rod (6). Use a shop cloth between the support and (1) star; the gland (3) into the tube (1)
the piston rod (6) to prevent damage to the piston
(4). 23 Lubricate the O-ring (12) on the giand (3\ with clean
oil.
12. Put the piston (4) on the end of the piston rod (6)
24 Tighten the gland (3) to 100 :0 400 ;:::OLnc-'eet : 135
13 Put the hardened washer (8) on the cap screw (7). to 542 Nm) I: the lock screw '2: holes become
aligned in 'his toroue range ins.ar me lock screw
14. Clean the threads on the end of the piston rod and (2). 7ighten the icck screw :2) :0 20 co.r.o-mches
the threads of the cap screw usmq Lac ire cleaning (23 NI) I': 2 lee- screw ~2:'"'ces are no: alqnec.
solvent. Allow to dry Apply Loctite 242 to the piston do s.eos 25 throL.:gh 27
rod threads 1/4 inch from :he open end of the piston
rod so tha there is 1/2 inch of Loctue 242 on the 25 7ighte the glanc (3) :0 1 oo .c 400 ooi.r-o-reet : 135
piston rod threads 00 NOT apoly Loctite to the first :0 542 Nm)
1/4 inch of the piston rod threads
26 Use a a 26 dr:1 and cr'll a "',012 1"2:' " Te gl2.rC (3)
15. Install the cap screw (7). Tighten the cap screw (7) and :,alf!'l :,2 t\.:Oe:1. Orl:l:O 2. deo:'" of 7 16 Ir,c~,
to the torque value on page 8006-2 for the cylinder (11 rnrn) 00 no: drl;i -n line V/!;i" 2 :,0:0 ir the giand
that is being repaired. A torque rnultiolier can be (3) for t e glanc \'/re'lC';
used to help tighten the cao screw.
27 Install the lac" screw (2) ilgr,:er :"Ie lccx screw (2)
16. Install a new wear ring (11) in the end groove on the to 20 oound-mcr-es 123 N'T
outside of the piston (4)
Ii the hoses were .err.oveo wi.h the cyunoer. instau new
17. Install a new backup ring (10) in the center groove O-rrngs I: ecuipped on :he hose :::;ings L.;brlca:c .no
on the outside of the piston (4) 0-,1ngs witr clear. cil. I::stall 'he hoses
13
6. PISTON ROD
20. GREASE
4. PISTON FITTING
1. TUBE
CASE CORPORATION
TABLE OF CONTENTS
SPECiFiCATIONS.... . 3
SPECIAL TOOLS.. .4
INLET SECTION .. 8
Disassembly. 8
Assembly. .. 10
OUTLET SECTION......... 12
Disassembly............... . .............................12
Assembly........... ...14
Disassembly............. . 16
Assembly............................. .. . 22
STABILIZER SECTION . . 28
Disassembly 28
Assembly..... .. . 32
Disassembly............................................................................. . 37
Assembly 41
Disassembly .46
Inspection .... . 47
Assembly 48
INSPECTION 49
SPECIFICATIONS
Manufacturer , . J I Case
Threads in inlet and swing section port , . ........ ,.. 7/8 - 14, 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)
SPECIAL TOOLS
Order special tools from one of the following ad-
dresses:
Service Tools
P.O. Box 314
Owatonna, Minnesota 55060
In Europe
VL Churchill Ltd.
P.O. Box 3, Daventry
Northants, NN11 4NF
BB61843J
England
B870187J
Bur 8-17430
Issued 1-91 Printed in U.S.A.
8007-6
Clean the backhoe control valve and put the valve on a Remove the shims.
clean bench. Write numbers on each section of the
valve.
STEP 5
STEP 2
STEP 3
Install new O-rings in each section. Use the numbers on each valve section as a guide and
install the valve sections and shims.
STEP 8
STEP 11
INLET SECTION
Disassembly STEP 14
STEP 12
STEP 13
B870188J
Assembly STEP 19
STEP 17
;B630320M
Install a new O-ring on the plug. Lubricate the O-ring
with clean hydraulic oil. Install the plug.
Install the poppet.
STEP 18
6. BODY
B861844J
3. SPRING
Inlet Section
OUTLET SECTION
Disassembly STEP 23
STEP 20
Fasten the outlet section in the vise with soft jaws.
Loosen and remove the plug.
STEP 21
STEP .24
1. OUTLET SECTION
STEP 22
STEP 25
See page 49 and inspect the parts of the outlet section.
B870189J
7. PLUG
Outlet Section
Assembly STEP 29
STEP 26
See the illustration on page 12 and install a new O-ring
in the bore for the spool.
STEP 27
STEP 30
STEP 28
0414M
Install a new O-ring on the plug. Lubricate the O-ring
with clean hydraulic oil. Install the plug.
3. PISTON
5. O-RING
B871846J
6. SPRING
Outlet Section
STEP 31
'B62~2M
Use the spring compressing plates shown on page 4 to
compress the spring.
Fasten the section in the vise with soft jaws. Loosen and
remove the cap.
STEP 35
STEP 32
STEP 33
STEP 37 STEP 40
Repeat steps 37,38, and 39 to remove the circuit relief
valve from the A port.
STEP 41
STEP 38
Removethewiperfrom theA portend of the spool bore.
STEP 42
STEP 39
Remove the a-ring from the bore.
STEP 43
STEP 44 STEP 47
STEP 45 STEP 48
STEP 46 STEP 49
STEP 50 STEP 52
Repeat steps 47,48, and 49 to remove the other plug, See page 49 and inspect the parts of the swing section.
spring, and poppet.
STEP 51
See page 46 for the disassembly and assembly of the
circuit relief valves.
22. SPOOL
20. BODY
16. CAP
B901902J
Swing Section
Bur 8-17430 Issued 1-91 Printed in U.S.A.
8007-21
22. SPOOL
/'
20. BODY
B901903J
Boom Section
Bur 8-17430 Issued 1-91 Printed in U.S.A.
8007-22
Assembly STEP 56
STEP 53
STEP 54
STEP 55
Repeat steps 53 and 54 to install the other poppet,
spring, and plug.
STEP 59 STEP 62
STEP 63
STEP 60
STEP 64
STEP 65 STEP 69
Tighten the circuit relief valve to 65 to 80 pound-feet (88 Release the spring tension and remove the spring com-
to 108 Nm). pressing plates.
STEP 66 STEP 70
Repeat steps 61 through 65 to install the other load
check plug and circuit relief valve.
STEP 67
STEP 71
Assemble the spring seats and spring. Use the spring
compressing plates to compress the spring.
STEP 68
Lubricate the spool and spool bore with clean oil. Install
the spool.
B629344M
Install the spring and spring seats on the spool. Install
the snap ring.
Bur 8-17430 Issued 1-91 Printed in U.S.A.
8007-25
STEP 72 STEP 74
Install the cap. 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 73
STEP 75
4. a-RING
23. A PORT
20. BODY
24. B PORT
4. a-RING
4. a-RING
19. RETAINER
Swing Section
Bur 8-17430 Issued 1-91 Printed in U.S.A
8007-27
4. a-RING
23. A PORT
6. SPRING
13. POPPET
20. BODY
24. B PORT
B90190SJ
Boom Section
Bur 8-17430 Issued 1-91 Printed in U.S.A.
8007-28
STABILIZER SECTION
Disassembly STEP 79
STEP 76
B629342M
Use the spring compressing plates shown on page 4 to
compress the spring.
Fasten the section in the vise with soft jaws. Loosen and
remove the cap.
STEP 80
STEP 77
STEP 78
STEP 82 STEP 85
STEP 83 STEP 86
STEP 84 STEP 87
Loosen the check valve in the other end of the body. Remove the wiper from the spool bore.
STEP 88 STEP 90
STEP 89 STEP 91
Fasten the check valve in the vise with soft jaws. Loosen Remove the plunger.
and remove the plug.
STEP 92
See page 49 and inspect the parts of the stabilizer
section.
Stabilizer Section
Bur 8-17430 Issued 1-91 Printed in U.S.A.
8007-32
STEP 93
STEP 94
Fasten the body of the check valve in the vise with soft
jaws. Install the plunger. STEP 98
STEP 95
Lubricate the spool with clean oil. Install the spool in the
body.
STEP 104
STEP 101
9302M
Assemble the spring seats and spring. Use the spring
Install new O-rings and a backup ring on the plug, compressing plates to compress the spring.
Install the spring and spring seats on the spool. Install Lubricate the spool and spool bore with clean oil. Install
the snap ring. the spool.
Release the spring tension and remove the spring com- Install the cap.
pressing plates.
STEP 110
STEP 107
2. a-RING
3. SPRING
.M
Move the body in the vise so that the spool eye is up.
5. BODY
Lubricate the wiper with clean oil. Install the wiper with
the lip up.
STEP 112
8861849J
Check Valve
15. SPOOL
17. A PORT
2. O-RING
18. B PORT
12. RETAINER
3. SPRING
B861850J
9. CAP
10. SNAP
RING
Stabilizer Section
STEP 113
B629342M
Use the spring compressing plates shown on page 4 to
compress the spring.
STEP 117
Fasten the section in the vise with soft jaws. Loosen and
remove the cap.
STEP 114
'B629344M
Remove the snap ring from the spool.
STEP 118
STEP 115
Loosen the circuit relief valve. Remove the wiper from the A port end of the spool bore.
Remove the circuit relief valve. Remove the O-ring from the bore.
STEP 126
See page 49 and inspect the parts of the section.
STEP 122
Repeat steps 119. 120. and 121 to remove the circuit
relief valve, load check plug, spring. and poppet from
the A port.
8901906J
B901907J
STEP 127
STEP 128
STEP 131
STEP 129
STEP 132
STEP 134
Assemble the spring seats and spring. Use the spring STEP 138
compressing plates to compress the spring.
STEP 135
Lubricate the spool and spool bore with clean oil. Install
the spool.
Install the spring and spring seats on the spool. Install STEP 139
the snap ring.
STEP 136
STEP 141
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.
19. SPOOL
4. O-RING
20. A PORT
12. POPPET
17. BODY
21. B PORT
4. O-RING
16. RETAINER
6. SPRING j.!;,
14. SNAP RING
10. CIRCUIT RELIEF VALVE
13. CAP
6901908.1
13. SPOOL
1. PLUG
2. a-RING
14. A PORT
15. B PORT
1. PLUG
7. CAP
B901909J
9. SPRING SEAT
STEP 143
Fasten the circuit relief valve in the vise with soft jaws.
Loosen the lock nut. Loosen and remove the adjusting
screw and lock nut.
STEP 144
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
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.
"""W,s.B628734M
Replace the O-rings and backup ring on the parts of the
circuit relief valve.
STEP 148
STEP 151
See the procedure in Section 8002. Check and adjust
the pressure setting of the circuit relief valve before the
relief valve is installed in the section.
B628730M
Lubricate the O-rings on the parts of the relief valve.
Assemble the parts into the body.
STEP 149
INSPECTION
STEP 152 STEP 155
Discard all O-rings. backup rings, and wipers. Inspect the spools and spool bores. Use a new section
if the spool or bore is damaged.
STEP 153
Clean all parts in cleaning solvent. STEP 156
Inspect the poppets. Use new parts as necessary
STEP 154
STEP 157
Inspect all machined surfaces.
B861853J
CASE CORPORATION
TABLE OF CONTENTS
SPECIFICATIONS. . 2
DISASSEMBLY ................. 3
INSPECTION . . 7
ASSEMBLY . . 9
SPECIFICATIONS
Manufacturer . . J I Case
Special Torques
Relief valves ... .. 65 to 85 pound-feet (88 to 155 Nm)
DISASSEMBL Y
Clean the outside of the swing sequence valve STEP 4
Fasten the swing sequence valve in the vise with soft
jaws.
STEP 1
B629022M
STEP 5
Loosen the spool cap The springs will push against the
spool cap as the spool cap is loosened.
STEP 2
STEP 6
Remove the spool cap.
STEP 3
B629130M
Fasten an identification tag to the relief valve.
STEP 7 STEP 10
Loosen and remove the other relief valve. Remove the O-ring from the body.
STEP 8 STEP 11
B629130M
Fasten an identification tag to the relief valve. Loosen the plug.
STEP 9 STEP 12
Remove the wiper from the other end of the body. Remove the plug from the body.
STEP 13 STEP 16
STEP 14 STEP 17
8629142M
Remove the plug. Remove the O-ring and retainer from the spool.
STEP 15 STEP 18
Remove the plunger from the opposite end of the body. Remove the springs from the spool.
STEP 21
B629101M
Loosen and remove the Allen head screw and spring Loosen the vise. Fasten the poppet seat in the vise.
seat from the spool. Loosen the body from the poppet seat.
STEP 20 STEP 22
B628606M
Fasten the relief valve in the vise with soft jaws. Loosen Remove the relief valve from the vise. Separate the
the lock nut from the adjusting screw. Remove the parts of the relief valve.
adjusting screw and lock nut.
INSPECTION
1. Replace the O-ring on the plug. 3. Replace the O-rings and backup ring on the parts of
the relief valves.
B629140M
2. a-RING
B628734M
2. Inspect the parts 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. 4. Inspect the springs. If the springs are damaged,
install new springs.
12. O-RING
20. SPOOL
B891691J
ASSEMBLY
STEP 23 STEP 26
See the procedure in Section 8002. Check and adjust
the pressure setting of each relief valve in a test block
before the relief valve is installed in the swing sequence
valve.
STEP 27
B628606M
Lubricate the O-rings on the parts of the relief valve.
Assemble the parts in the body.
STEP 24
Fasten the body in the vise with soft jaws. Install the
spring and plunger in the body.
STEP 28
,,\~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
Lubricate the O-ring on the plug with clean hydraulic oil.
Install the plug in the bore for the relief valve.
STEP 29
STEP 30 STEP 33
8629036M
Lubricate the O-ring on the plug with clean hydraulic oil. Lubricate the O-rings and backup ring on one of the
Install the plug. relief valves with clean hydraulic oil. Install the relief
valve.
STEP 31
STEP 34
STEP 35
STEP 36 STEP 39
M M
Tighten the relief valve to 65 to 85 pound-feet (88 to 155 Move the body in the vise so that a rod can be installed
Nm). through the hole in the end of the spool. Fasten the
body in the vise with the end of the spool in contact with
the vise.
STEP 37
STEP 40
STEP 38
STEP 41
.- .....
STEP 42 STEP 45
Install the three springs on the spool. Move the swing sequence valve in the vise so that the
spool is not in contact the the vise. Remove the rod from
the end of the spool.
STEP 43
STEP 46
_<6#$
.. ::.,:~-'.:/~..:~~"'~"
~
\;"
8629242M
Install the spring seat on the springs. Push down on the
spring seat to compress the springs. Install the Allen
head screw. Tighten the spool cap. The spool cap must be
tightened to a torque of 20 to 30 pound-feet (27 to 41
Nm).
STEP 44
STEP 47
Install the spool cap. Do not tighten the spool cap at this
time.
Install a new wiper on the spool. The lips of the wiper
must be up
STEP 48
1. ADJUSTING
SCREW
j
2. BODY
,70128M
Use a hollow sleeve and a hammer to push the wiper
into the body until the top of the wiper is even with the
surface of the housing.
3. SPRING 8. O-RING
OR
PIN
_ 9. O-RING
4. SPRING
5. POPPET
SEAT
10. O-RING
11. BACKUP
RING
13. POPPET
Relief Valve
1. O-RING
6. PLUG
8. SPRING
9. PLUNGER
15.
14 SPRINGS
10. RELIEF
VALVE
B891692J
.
SWing Se quence Valve - Cross Section
TABLE OF CONTENTS
Separating the Valve Sections 8009-3 Inlet/Outlet and Auxiliary Section 8009-22
Assembly 8009-32
CASE CORPORATION
SPECIFICATIONS
Manufacturer Rexroth
Special Torques
Detent stud 17 to 21 pound-feet (23 to 28 N m, 2 to 3 kg/m)
SPECIAL TOOLS
786802
STEP 2
721606
721802 STEP 6
Write numbers on each section.
STEP 3
,21810
721804 STEP 7
Loosen the studs that fasten the valve sections
together.
STEP 4
721806
INLET/OUTLET /
AND AUXILIARY
SECTION
8871897
i216'~ 721820
Replace the O-rings in each section of the control Install the pitch section.
valve.
STEP 12
STEP 9
721822
STEP 10
LIFT SECTION
Disassembly STEP 17
STEP 14
721832
Fasten the lift section in the vise with soft jaws. STEP 18
Loosen the Allen head screws.
STEP 15
STEP 19
Remove the Allen head screws and spool cap.
STEP 16
721836
721830
STEP 20 STEP 23
721902
STEP 21 STEP 24
721910
Pull the spool and detent housing from the body. Loosen the Allen head screws in the retainer.
STEP 22 STEP 25
721906 i21g12
Loosen the plug in the body. Remove the Allen head screws, retainer, and wiper.
8009-8
STEP 26 STEP 29
721914 721928
Remove the O-ring. Loosen the plug for the load check valve. It can be
necessary to loosen the fitti ng to get access to the
STEP 27 plug.
STEP 31
721926
STEP 32 STEP 35
i00802
Remove the poppet. Loosen and remove the detent stud from the spool.
STEP 33 STEP 36
700840 700838
Remove the sleeve, O-ring, and detent housing Release the spring tension and separate the spring
from the spool. seats from the spring.
STEP 34
700844
-SPOOL
8871898
Lift Section
8009-11
Assembly STEP 41
STEP 37
See page 8009-30. Inspect the parts of the lift sec-
tion.
STEP 38
700804
STEP 42
700338
STEP 39
700806
7008:2
STEP 40
700844
STEP 44
-,
721926
Install the spring in the poppet. Lubricate the a-rings and backup ring on the cir-
cuit relief valve. Install the circuit relief valve.
STEP 45
STEP 48
721930
STEP 49
721928
STEP 50 STEP 53
721904 7?2006
Lubricate the spool and O-ring on the detent hous- Install the three steel balls in the holes in the detent
ing with clean oil. Install the spool and detent hous- stud. Apply petroleum jelly to the steel balls to hold
ing in the body. the steel balls in position.
STEP 51 STEP 54
721902 721632
Install the retainer. Install the large steel ball in the end of the detent
stud.
STEP 52
STEP 55
721836
STEP 56 STEP 59
721828 7220'6
STEP 57 STEP 60
722010 7220' 8
Tighten the Allen head screws to 60 to 80 pound- Install the retainer. Tighten the Allen head screws
inches (7 to 9 N rn, 0.7 to 0.9 kg/m). to 60 to 80 pound-inches (7 to 9 Nm, 0.7 to 0.9
kg/m).
STEP 58
7220'"
STEP 61
722028
Fasten the section in the vise with soft jaws. Loos- STEP 65
en the Allen head screws in the spool cap.
STEP 62
722030
STEP 66
Remove the Allen head screws and spool cap.
STEP 63
722032
722026
STEP 67 STEP 70
722034 722106
Remove the Allen head screws, retainer, and wiper. Loosen the plug for the load check valve.
STEP 68
-~
722036
STEP 72
722037 722"0
Loosen and remove the plug. Remove the spring from the body.
8009-17
STEP 73 STEP 76
72211 4 70083"
Remove the poppet. Loosen and remove the Allen head screw from the
spool.
STEP 74
STEP 77
700828
700832
6871899
Assembly STEP 81
STEP 78
700826
Assemble the spring seats and spring. Use the tool STEP 82
to compress the spring.
STEP 79
72211~
700834 STEP 83
Install the spring and spring seats on the spool.
STEP 80
i22"O
700832
STEP 84
722108 722030
Lubricate the O-ring with clean oil. Install the plug. Lubricate the O-rings and backup ring on the plug.
Install the plug in the body. Tighten the plug to 50
STEP 85 to 60 pound-feet (68 to 80 N rn, 7 to 8 kg/m).
STEP 88
STEP 86 Lubricate the spool and O-ring with clean oil. In-
stall the spool in the body.
STEP 89
722037
722120
STEP 91
722302
Fasten the section in the vise with soft jaws. Loos- STEP 99
~.~
en the Allen head screws in the spool cap. 1~~,-
...
STEP 96
' ,
722306
STEP 97
72230e
722136
722310 i22316
722312 722318
Loosen the Allen head screw from the retainer. Loosen the plug.
722314 722322
Remove the Allen head screws, retainer, and wiper. Remove the plug.
8009-24
72232' 722330
Loosen the plug for the load check valve. Remove the poppet.
722326 700825
Remove the plug. Remove the O-ring, wiper, and retainer from the
spool.
STEP 109
722328
700834 700838
Loosen and remove the Allen head screw from the Release the spring tension and separate the spring
spool. seats and spring.
8009-26
-SPOOL
8871900
STEP 115
700828
STEP 116
STEP 117
722328
700832
722326 722310
Lubricate the a-ring with clean oil. Install the plug. Lubricate the a-rings and backup ring on the relief
valve. Install the relief valve in the body. Tighten the
STEP 122 retiet valve to so to so pound-feet (68 t080 N m, 7 to
8 kg/m).
STEP 125
722304
STEP 126
722320
722136
72213~
722132
Tighten the Allen head screws to 60 to 80 pound- tnstau the retainer and Allen head screws. Tighten
inches (7 to 9 N m, 0.7 to 0.9 kg/m). the Allen head screws to 60 to 80 pound-inches (7
to 9 N m, 0.7 to 0.9 kg/m).
STEP 129
722332
INSPECTION
Discard all O-rings, backup rings, and wipers. STEP 133
Clean all parts in cleaning solvent. Inspect the
spools and spool bores for wear and damage. Use a
new valve section if the spools or spool bores are
damaged.
STEP 132
O-RINGS
700824
STEP 134
700842
700826
RELIEF VALVES
Disassembly STEP 138
STEP 135
;01518
Fasten the relief valve in the vise with soft jaws. STEP 139
Remove the cover.
STEP 136
701520
STEP 137
701616
i00512
STEP 141
O-RINGS
i01614
BODY Assembly
701616
STEP 142
701520
STEP 145
O-RINGS
701610
701518
700512 700506
Install the poppet, spring, adjusting screw, and Tighten the lock nut and install the cover.
lock nut in the body.
After the three point hitch control valve is as-
STEP 147 sembled and installed, see Section 8002 and check
the pressure setti ng of the relief valves.
700510
CASE CORPORATION
TABLE OF CONTENTS
SPECiFiCATIONS 2
Disassembly 3
Inspection , , 4
Assembly 6
SPECIFICATIONS
Special torques
STEP 1
STEP 2
STEP 3
STEP 7 Inspection
STEP 9
Remove and discard the seal from each end of the bore
of the body. B8971728M
Inspect the spool for damage or wear. If the spool is
damaged or worn a new double selector valve must be
STEP 8 used.
STEP 10
Inspect the spool bore in the body for damage or wear.
If the spool bore is damaged or worn a new double
selector valve must be used.
STEP 11
STEP 12
Inspect the cap, plate, and knob for damage or wear.
Use new parts as required
2. CAP
7. SPOOL
10. BODY
Bur 8-12670
Issued 1189 Printed in U.S.A.
8011-6
Assembly STEP 16
STEP 13
B8971734M
Put the spring and balls in the retainer as shown in the il-
lustration on page 5. Push the retainer assembly into STEP 17
the sleeve.
STEP 14
STEP 18
Install new seals in the bore of the body. Lubricate the
seals with clean hydraulic oil.
STEP 15
._----""'.{.~."-.~
.. ~
,.~
B8971720M
Keep the spool from turning and install and tighten the
retainer assembly to 108 to 132 pound-inches (12 to 15
Nm).
STEP 19 STEP 20
88971704
Install the cap Install and tighten the Allen head screws to 108 to 132
pound-inches (12 to 15 Nm)
3. SLEEVE
7. SPOOL
10. BODY
11. KNOB
8891755
Loader . _.9004
CASE CORPORATION
CASE CORPORATION
TABLE OF CONTENTS
SPECiFiCATIONS , , , 3
SPECIAL TOOLS 4
SPECIFICATIONS
Clearance between the switch and the inner bucket
link for return-to-dig..................................... . 0012 to 0.027 (0.3 to 0.7 mm)
Engine speeds
Low idle and high idle override. .. 1/16 to 1/8 inch (1.5 to 3.0 mm)
Brake pedal free travel . .. " 0.06 to 0.18 inch (1.5 to 4.6 mm)
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)
SPECIAL TOOLS
Order special tools from one of the following ad- The special tool shown is used to check the engine
dresses: rpm (r/rnin).
In the U.S.A. and Canada The tool must be programmed for the number of
Service Tools teeth on the flywheel. The 580 Super K loader backhoe
P.O. Box 314 has 159 teeth on the flywheel.
Owatonna, Minnesota 55060
Install the magnetic sensor into the threaded hole in
In Europe the flywheel housing. Turn the magnetic sensor clock-
VL Churchill Ltd. wise until the sensor contacts the flywheel, then turn the
P.O. Box 3, Daventry sensor counterclockwise 1/2 to 3/4 of a turn and tighten
Northants, NN11 4NF the lock nut. This tool is first used on page 8.
England
CAS-10ll8
11. Start the engine. Raise the loader frame all the way
and dump the bucket completely.
8. Loosen the nuts for the switch, and move the switch 16. Loosen the nuts for the switch.
all the way forward in the mounting slot.
17. Move the switch rearward if the bucket did not roll
back far enough.
2. ROLLBACK ROD
B902737J
4, Make sure that the throttle lever (3) is in the low idle
position.
10. Check to see that the high and low idle engine
speeds are as specified in this section.
3. THROTTLE
LEVER
B902738J
The parking brake must prevent the machine from 3. Check the adjustment by trying to move the
moving forward with the transmission in third gear and machine with the parking brake applied.
the engine running at 1500 rpm (r/rnin).
1. BOOT. USED ON
TWO WHEEL DRIVE
MACHINES
B902739J
3. CONTROL ROD
B902740J
5. SHIFT LEVER
6902741J
3. CONTROL ROD
2. BALL JOINT .
B902764J
'<;
8902743J
Shift Linkage for Transfer Case
Bur 8-17540
B902744J
\
\
\
,
,,
I
I
I
B902746J
1. CONTROL LEVERS
2. CONTROL TOWER
71 TO 73 DEGREES
1. EXTENDAHOE
(IF USED)
3. BOOM 4. DIPPER
5. BUCKET
6. RH STABILIZER
8. LH SWING
B902747J
6. SWING
5 BOOM
I
NOTE: These parts
rotated 180 degrees.
B902748J
2. Loosen the jam nuts at the yoke and at the ball joint
on the control rod.
4. CAM
FOLLOWER 5. Make sure that the clevis pin that fastens the yoke on
the control rod to the spool eye in the 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.
5. CAM
7. Start and run the engine at approximately 1/4 throttle.
B902765J
B902411J
TABLE OF CONTENTS
Operation 9002-4
CASE CORPORATION
SAFETY RULES
SPECIAL TOOLS
Order special tools from one of the following The tools shown below are used to service the air
addresses: conditioning system. The tools are available separately
or in a kit. The part number of the kit is CAS-10023.
In the U.S.A. and Canada Parts from this kit are first used on page 9002-10.
Service Tools
P.O. Box 314
Owatonna, Minnesota 55060
In Europe
VL Churchill Ltd
P.O. Box 3, Daventry
Northants, NN114 NF
England
131238
9002-3
----------~-------
f
5
861485
::::::::::::::
Low Pressure Gas 1. Typical Expansion Valve
~,','>:
4. Compressor
High Pressure Gas 2. Temperature Sensor 5. Condenser
- - Low Pressure Liquid 3. Evaporator 6. Receiver-Drier
- High Pressure Liquid
9002-4
OPERATION
The air conditioning system includes five major corrosion of internal components of the air condi-
components: condenser, evaporator, compressor, tioning system. The receiver-drier is also a refriger-
expansion valve, and receiver-drier. These compo- ant reservoir for the air conditioning system.
nents are connected by tubes and hoses to operate
as a closed system. The air conditioning system is The refrigerant, still in a liquid from, flows to the
charged with R12 refrigerant. expansion valve. The expansion valve causes a re-
striction in the flow of refrigerant to the evaporator.
The compressor receives the refrigerant in gas Because of this restriction, the refrigerant flowing
form. The compressor then compresses the refriger- out of the expansion valve is under less pressure
ant and sends the refrigerant, still in gas form, to the than the refrigerant flowing in. As refrigerant flows
condenser. The condenser uses air flow from the through the evaporator, the refrigerant takes -heat
radiator fan to remove heat from the refrigerant. As from the air around the evaporator. The combination
heat is removed, the refrigerant changes into a liq- of increased heat and decreased pressure causes
uid. evaporation of the refrigerant. The evaporation
causes the air flowing over the evaporation coil to
The liquid refrigerant flows from the condenser become very cool. The cooled air is then used to
to the receiver-drier. The receiver-drier is a con- keep the operators cab cool.
tainer filled with a drying material which removes
moisture that has entered the air conditioning sys- The refrigerant, in a gas form again, flows back
tem. Moisture must be removed in order to prevent to the compressor, and the cycle is repeated.
9002-5
TROUBLESHOOTING
Problem
No Cooling
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.
SYSTEM CHECKS
9002-9
Air Louvers 1. Make sure ports are fully open for most effi-
cient air conditioning operation.
PRESSURE TESTING
Manifold Gauge Set indicate both psi (kPa) pressure and inches of mer-
cury.
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 During normal operation the low pressure
pressures of the system, the correct refrigerant gauge must always indicate from 7 to 30 psi (48 to
charge, system diagnosis, and operating efficiency. 207 kPa) after the system has run 10 to 15 minutes.
The manifold gauge set can read both the high (dis-
charge) and low (suction) sides at the same time, HIGH PRESSURE GAUGE - The high side
since pressures must be compared in order to make gauge is a pressure gauge used to indicate pres-
a diagnosis of system operation. sures in the high side of the system. The gauge must
indicate from 0 - 400 psi (0 - 2758 kPa) minimum.
LOW PRESSURE GAUGE - The low pressure
gauge is a compound gauge. All air conditioning During normal operation, the high pressure
systems can, under some conditions, change from a gauge will normally indicate from 120 to 270 psi (827
pressure into a vacuum on the low side. For this to 1861 kPa), including correction for ambient air
reason, it is necessary that a gauge be used that will temperatures, see pressure - temperature chart.
Problem - No Cooling
Problem - No Cooling
Indications of a Problem
in Condenser Operation
1. Inspect for loose or worn compressor belt
a. Bubbles in sight glass at intervals. and fan belts.
3.
-
Check system for too much refrigerant.
b. Replace receiver-drier.
Indications of a Problem
in Expansion Valve Operation
1. Remove cab trim panels and headliners, see
a. Discharge air from evaporator warm. Section 9003. Inspect temperature sensing
contact to evaporator outlet for looseness or
b. Much condensation on suction hose at corrosion.
compressor.
Indications of a Problem in
Expansion Valve Operation (Continued)
-
a. Sight glass free of bubbles or bubbles 1. Test system for leaks, see page 9002-12.
can be seen only at intervals. Possible leak has let air enter; check com-
pressor seal carefully, see Section 9003.
b. Suction line warm to your hand.
Indications of Low Refrigerant Charge 1. Test system for leaks. System has a loss of
refrigerant.
a. Bubbles in sight glass.
NOTE: Normally. the system will have a
b. Discharge air from evaporator only a lit- loss of 1/2 to 1 ounce (14.7 - 29.5 ml) of
tle cool. refrigerant between seasons.
c. Inlet end of expansion valve is warm. c. Remove air and moisture and charge sys-
tem. See Section 9003.
Indications of a Problem
in Expansion Valve Operation (Continued)
a. Leakage at valves.
(Continued
I
on next page)
9002-23
Indications of a Problem
in Compressor Operation (Continued)
Indications of a Problem
in Condenser Operation
1. Inspect for loose or worn fan and compressor
belts.
a. Bubbles in sight glass at intervals.
Indications of a Problem
in Condenser Operation (Continued)
4. Remove and inspect condenser for restric-
tions caused by oil.
-
Indications of Air in System
1. Discharge refrigerant from system, see Sec-
a. Bubbles in sight glass. tion 9003.
Indications of a Problem
in Expansion Valve Operation 1. Expansion valve inlet which has condensa-
tion or frost is an indication of a restriction in
a. Discharge air from evaporator only a little the expansion valve.
cool.
a. Discharge the system. See Section 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 and moisture and charge sys-
tem. See Section 9003.
Indications of a Problem in
Expansion Valve Operation (Continued)
TEMPERATURE CHART
I
Indications of Too Much
-
Refrigerant in System
CASE CORPORATION
TABLE OF CONTENTS
SPECIFICATIONS 3
SPECIAL TOOLS 3
LUBRICATION OF COMPRESSOR 5
General Information 5
Lubricant 5
SPECIFICATIONS
Compressor Manufacturer Sanyo-Sanden Corporation
Coil
Resistance 2.B to 3.3 ohms at BOF (27C)
Torque
Cap screws for end cap 264 to 300 pound-inches (30 to 34 Nm)
SPECIAL TOOLS
The tools shown are required to service the air con- It is a scientifically proven fact that one of the con-
ditioning system (finding leaks, charging the air con- tributing factors to the depletion of the ozone layer is the
ditioning system, checking the charge of the air con- use of CFCs.
ditioning system, and repairing the compressor).
You will se an addition to the equipment required to
In the U.S.A. and Canada, order the tools from: service the air conditioning system. This new piece of
Service Tools equipment is an R-12 refrigerant recovery/recycling
P.O. Box 314 system. This equipment will permit you to discharge an
Owatonna, MN 55060 air conditioning system without allowing the refrigerant
to escape into the atmosphere and help to cause the
In Europe order the tools from: depletion of the ozone layer This piece of equipment
VL Churchill ltd will also permit the recycling of the refrigerant for future
P.O. Box 3, Daventry use.
Northants NN11 4NF
England These special tools are required to safely discharge
and charge the air conditioning system.
Introduction
The use of chlorofluorocarbons (CFCs) such as R-
12 refrigerant used in mobile 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
field from 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,
B4041990E
CD ...-~a3M
OEM-1396 Refrigerant/Recovery/Recycling ~t.1)'i$~~;;;"::7~., ..
>B131238M
...... .
The leak detector shown is used to find leaks in the
air conditioning system. The part number of the
detector is CAS-10028. Not 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.
Bur 8-12711 Issued 1-91 Printed in U.S.A.
9003-5
The correct tension for a new drive belt is 65 to 75 2. Use a prybar near the front of the compressor to
pounds (29 to 34 kg) measured with a belt tension tighten the drive belt, then tighten the nuts.
gauge.
3. Use a belt tension gauge and check the tension of
The correct tension for a drive belt used more than the drive belt.
20 hours is 55 to 65 pounds (20 to 23 kg) measured with
a belt tension gauge. 4. Repeat steps 1, 2, and 3 as required.
LUBRICATION OF COMPRESSOR
General Information 1. Connect the hoses from the R-12 refrigerant re-
covery/recycling system to the manifold. Make sure
Because the air conditioning system is a closed that both valves in the gauge manifold are closed.
system, the compressor will not need regular oil level
checks or oil changes.
Lubricant
The compressor 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 an equivalent refrigeration oil when you add
or change oll.
B891255J
4. Start the engine and run the engine at low idle with
the air conditioning control set for maximum cooling
and the blower at high speed. Run the engine for 10
minutes.
1. PISTON ROD
B840535J
11. Install the dipstick so that the point on the stop near
the handle is toward the left. The stop must touch the
compressor as shown.
8. Put the angle gauge from the tool kit shown on 12. Read the degrees on the angle gauge and the
page 9003-2 on the front or rear mounting flange. notches in the dipstick.
Adjust the level on the angle gauge until the bubble is
between the marks. Tighten the wing nut. 13. Compare the readings with the 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.
10. Look into the fill hole and check to see if a piston
rod and the plate are in the position shown above, next
column. If the parts are not in the correct position, use a
socket wrench and turn the shaft to put the parts in the
position shown. This is important to correctly install the
dipstick.
Oil Level for a New Compressor 3. Fill the new compressor with the new oil equal to
the amount drained from the old compressor plus 1
1. Drain the oil from the old compressor into a mea- U.S. fluid ounce (30 mL) of new oil.
suring container.
4. Install and tighten the filler plug.
2. Drain the oil from the new compressor into a
CLEAN measuring container. 5. No oil level check will be needed after the com-
pressor has been installed.
LOW HIGH
PRESSURE PRESSURE
GAUGE GAUGE
1. Connect the hoses from the R-12 refrigerant re-
covery/recycling system to the gauge manifold.
\ tt
, HIGH
PRESSURE
.I-../PORT
Will
B891255J
Charging Procedure
b. Loosen and remove the cap from the high
1, If the air conditioning system is to receive a pressure port.
complete charge of refrigerant, remove air and
moisture from the air conditioning system according to c. Connect the hose from the high pressure
instructions in this section, Then continue the pro- gauge to the high pressure port.
cedure at step 3.
d. Loosen and remove the cap from the low
NOTE: Make sure the hoses from the R-12 refrigerant pressure port.
recovery/recycling system are connected to the gauge
manifold. e, Connect the hose from the low pressure gauge
to the low pressure port.
2, If you are only adding refrigerant:
4. Connect the charge-discharge hose from the d. Install the control valve on the new container.
gauge manifold to the control valve.
14. Open the valve for the low pressure gauge and the
control valve on the container of refrigerant.
Ambient Temperature* High Pressure Indication 16. If the high pressure reading is too high:
19. Install the cap on the low and high pressure ports.
3. Install a plug in each hose. 8. Hold the compressor and remove the bolt and
remove the compressor from the machine.
4. Disconnect the wire from the wiring harness.
STEP 1
STEP 2
STEP 6
STEP 3
STEP 7 STEP 10
Install the jaws of the puller on the pulley. Remove the pulley.
STEP 8 STEP 11
STEP 9 STEP 12
Install the handle. Loosen the screw that holds the clamp for the wire.
STEP 13 STEP 16
Remove the snap ring that holds the coil. Install the coil.
STEP 14 STEP 17
Remove the coil. Install the snap ring that holds the coil.
STEP 15 STEP 18
When you install the coil, make sure that the boss on the Install the wire behind the clamp and tighten the screw.
bottom of the coil engages the hole in the front of the
compressor.
STEP 19 STEP 22
~-
Install the pulley. Install the snap ring that holds the pulley.
STEP 20 STEP 23
Assemble the two parts of the driver as shown. Install the large snap ring.
STEP 21 STEP 24
Drive the pulley all the way onto the compressor. Start the shield into the pulley.
STEP 25 STEP 28
Drive the shield into the pulley. If a new clutch assembly has been installed check the
gap between the clutch plate and pulley.
STEP 26
STEP 29
Drive the clutch plate all the way onto the shaft.
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
STEP 27 or remove shims as required to get the correct gap.
STEP 30
Install the cover on the clutch.
Fasten the compressor in a vise. Remove the cover Drive the bottom of the Woodruff key into the keyway.
from the clutch. Loosen and remove the nut that holds
the clutch plate.
STEP 35
STEP 32
STEP 33
STEP 37 STEP 40
Use a pair of snap ring pliers and remove the felt seal. Remove the O-ring from the groove. Be careful not to
make a scratch in the groove.
STEP 38
STEP 41
STEP 42
STEP 43 STEP 46
Install the protector on the shaft. Lubricate the protector with refrigeration oil and install
the seal.
STEP 44
STEP 47
STEP 45
Install the seal on the seal tool. NOTE: DO NOT touch the sealing surface of the seal
seat. Body salts and acids will damage the sealing
surface.
STEP 49 STEP 52
Lubricate the sealing surface of the seal seat with refri- Drive the felt seal into the bore until the metal is even
geration oil and install the seal seat. with the top of the bore.
STEP 50 STEP 53
Instail the snap ring so that the chamfer on the ID will be B414508M
on top. Remove the protector.
STEP 51 STEP 54
Install the new felt seal. 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 STEP 57
Install the same shims that were removed. Install and tighten the nut to 300 to 360 pound-inches
(34 to 40 Nm).
STEP 56
STEP 58
Install the cover on the clutch.
Drive the clutch plate all the way onto the shaft.
STEP 60
STEP 61
STEP 65
Hit the end cap to loosen the end cap.
STEP 62
STEP 66 STEP 69
If the gaskets are being replaced, remove the other Install the end cap.
gasket from the valve plate. Be careful not to damage
the valves.
STEP 70
STEP 67
.:.....
4a43M
:
STEP 71
STEP 68 Loosen and remove the filler plug and drain the oil into a
measuring container.
STEP 72
Fill the compressor with the same amount of NEW refri-
geration oil.
STEP 73
Install and tighten the filler plug.
B1245A88J
'I . Align the compressor with the mounting bracket 6. Adjustthe drive belt according to instructions in this
and install the bolt and flat washer. section.
2. Install the flat washer, lock washer and nut on the 7. Loosen and remove the plugs from the hoses.
bolt.
8. Connect the hoses to the compressor
3. Install the drive belt on the pulley.
9. Connect the wiring to the wiring harness
4. Align the adjusting strap with the compressor and
install the bolt and flat washer. 10. Charge the air conditioning system according to in-
structions in this section.
5. Install the lock washer and nut on the bolt.
2. Loosen and remove the nut that holds the air con- 7. Connect the wiring to the air conditioning control.
ditioning control.
8. Install the air conditioning control in the mounting
3. Remove the air conditioning control from the plate.
mounting plate.
9. Install and tighten the nut that holds the air con-
4. Disconnect the wiring from the air conditioning ditioning control.
control.
10. Install the evaporator according to instructions in
5. Completely remove the air conditioning control. this section.
2. Turn the temperature control to HOT. 9. Disengage the left vertical cover beginning at the
top and remove the vertical cover.
3. Drain one U.S. gallon (4 litres) of coolant from the
radiator. NOTE: The front headliner MUST be removed first.
4. Remove the knobs from the switches, air con- 10. Hold the front headliner in place and loosen and
ditioning control and temperature control. remove the screws at the front of the front headliner and
the screws on each side including the screw at the
5. Loosen and remove the screws that hold the junction of the front and rear headliners.
control panel.
11. Lower the front headliner onto the control.
6. Disengage the control panel from the vertical cover
and disconnect the wiring from the cab lamp switch. 12. Loosen the clamp on the front drain hoses.
7. Loosen and remove the screws that hold the 13. Remove the hoses from the drain pan.
bottom of the vertical cover.
14. Loosen and remove the screw from the left and 23. Install new insulation tape around the expansion
right rear sides of the rear headliner. valve.
15. Hold the rear headliner in place and loosen and 24. Carefully raise the rear headliner and engage the
remove the screws from the left and right sides of the rear headliner with the slot at the rear of the roof.
rear headliner.
25. Hold the rear headliner in place and install a screw
16 Carefully lower the rear headliner behind the seat. in the center hole on the right and left sides of the rear
headliner.
17. Remove the insulation from the expansion valve.
26. Install and tighten the screw at the left and right rear
sides of the rear headliner.
30. Install and tighten the screws atthe front of the front
headliner.
22. Install the expansion valve and tighten the connec- 37. Install the knobs for the switches and the air con-
tions with force equal to 240 to 300 pound-inches (27 to ditioning and temperature controls.
34 Nm).
38. Charge the air conditioning system according to in-
structions in this section.
2. Turn the temperature control to HOT. 20. Disconnect the tubes from the expansion valve and
evaporator .
3. Drain one U.S. gallon (4 litres) of coolant from the
radiator. 21. Loosen the cap screws that hold the evaporator.
4. Remove the knobs from the switches, air con- 22. Carefully remove the evaporator and remove the
ditioning control and temperature control. temperature sensor and tube for the air conditioning
control from the evaporator.
5. Loosen and remove the screws that hold the
control panel.
12. Loosen the clamp on the front drain hoses. 26. Connect the expansion valve to the new evapo-
rator.
13. Remove the front drain hoses from the drain pan.
27. Connect the equalizer tube to the outlet tube of the
14. Loosen and remove the screw from the left and evaporator.
right rear sides of the rear headliner.
28. Apply a small amount of grease between the tem-
15. Hold the rear headliner in place and loosen and perature sensor and the outlet tube.
remove the screws from the lett and right sides of the
rear headliner. 29. Install the clamp that holds the temperature
sensor.
16. Carefully lower the rear headliner behind the seat.
30. Apply new insulation tapes to the tubes at each end
17. Loosen both clamps on the hoses connected to of the evaporator, the inlet and outlet tubes, and the ex-
the heater. pansion valve and the equalizer tubes.
1. HEATER
- ~.
- -~.
Bur 8-12711
8891258J
Issued 1-91
Printed in U.S.A.
9003-32
31. Install the temperature sensor and tube in the eva- 40. Install and tighten the screw at the left and right rear
porator as shown. sides of 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.
32. Install the evaporator. 47. Install the right vertical cover.
33. Install and tighten the cap screws that hold the eva- 48. Install and tighten the screws at the bottom of the
porator right vertical cover.
34. Connect the tubes to the expansion valve and eva- 49. Connect the wires to the cab lamp switch and
porator. engage the control panel with the right vertical cover.
35. Apply new insulation tape to the connections. 50. Install and tighten the screws that hold the control
panel.
36. Slide the hoses onto the tubes from the heater.
51. Install the knobs for the switches and the air con-
37. Tighten the clamps for both hoses. ditioning and temperature controls.
38. Carefully raise the rear headliner and engage the 52. Fill the radiator to the correct level.
rear headliner with the slot at the rear of the roof.
53. Charge the air conditioning system according to in-
39. Hold the rear headliner in place and install a screw structions in this section.
in the center hole on the right and left sides of the rear
headliner.
Bur 8-12711
B891258J
ISsued 1-91
Printed in U.SA
9003-34
3. Make an alignment mark at the top and rear of each 23. Tighten the nuts.
pivot bracket for the hood.
24. Loosen and remove the plug from each hose.
4. Loosen and remove the nut, lock washer, spacer,
flat washer and bolt that fasten each cable to the 25. Connect the hoses to the condenser.
radiator shroud.
26. Install the guard and cap screws.
5. Loosen and remove the front and rear cap screws
that hold each pivot bracket. 27. Tighten the cap screws.
6. Remove the hood from the machine. 28. Install the radiator shroud.
7. Put blocks between the radiator and pump to hold 29. Install the bolts and flat washers, and nuts that hold
the radiator in place with the radiator shroud or the radiator shroud.
mounting brackets removed.
30. Install the bracket and cap screw at the top of the
8. Loosen and remove the self-locking nut, bolt and radiator.
flat washer from each oil cooler mount.
31. Tighten the cap screw.
9. Loosen and remove the cap screw and bracket at
the top of the radiator. 32. Have another person push and hold the top of the
radiator shroud all the way to the rear.
10. Loosen and remove the nuts and bolts that hold the
radiator shroud. 33. Tighten the nuts.
11. Remove the radiator shroud. 34. Install a bolt and flat washer and self-locking nut in
each oil cooler mount.
12. Loosen and remove the cap screws that hold the
guard at the bottom of the condenser. 35. Tighten the self-locking nuts.
13. Remove the guard. 36. Remove the blocks from below the radiator.
14. Disconnect the hoses from the condenser. 37. Make sure that the pivot brackets are all the way on
the pivots for the hood.
15. Install and tighten a plug in each hose.
38. Install the hood.
16. Loosen and remove the nuts and lock washers
from the bolts that hold the mounting brackets. 39. Install the cap screws that hold the pivot brackets.
17. Remove the mounting brackets and the bolts. 40. Align each pivot bracket with the alignment marks
and tighten the cap screws.
18. Loosen and remove all but the top cap screws that
hold the condenser. 41. Close the hood. The top rear of the hood must be
even with the frame.
19. Hold the condenser in place and remove the top
cap screws and remove the condenser. 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
20 Hold the condenser in place and install the flat problem, move the pivot brackets forward.
washers, lock washers and cap screws.
3. O-RING
3. O-RING
3. O-RING
3. O-RING
B891259J
43. If the top of the hood is too high and the sound of 44. When the hood can be closed and is in the correct
metal hitting metal is heard at the front of the hood, the position, tighten the nuts on the bolts that hold the
radiator shroud is not in the correct position. To correct radiator shroud to 270 to 324 pound-feet (366 to 439
this problem, the top of the radiator shroud must be Nm).
moved farther to the rear.
45. Charge the air conditioning system according to in-
structions in this section.
3. O-RING
3. O-RING
3. O-RING
8891259J
TABLE OF CONTENTS
CASE CORPORATION
Copyright J I Case Company
Bur 8-17630 Printed in U.S.A.
Issued March 1991
9004-2
B902762J
1. Gusset 10. When welding the floor of the bucket the top of the
6. If removing the cutting edge from a short lip bucket, cutting edge:
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 a. Start at one end of the bucket and weld toward
bucket. the center until one welding rod is used.
7. Use a grinder to remove any welds or extra metal on
the bucket that will prevent the new cutting edge from b. Start at the center of the bucket and weld in both
fitting correctly. directions from center until one welding rod is
used.
B902018J
1. 11 Inches (279 mm)
1 __ 2_
B861656J B902019J
1. Short Up Bucket - 15-1/8 In (384 mm) 1. 3/8 Inch (10 mm) Fillet. Weld Around Each Corner
Long Up Bucket - 8-1/4 In (208 mm) 3/8 Inch (10 mm). Weld Two Times
2. Short Up Bucket - 14-9/16 In (370 mm) 2. 2-1/2 Inches (63 mm)
Long Up Bucket - 8 In (203 mm) 3. 3/8 Inch (10 mm) Fillet. Weld Both Sides and Rear
3. Put Tooth Shank as Close to Corner as Possible of Tooth Shank Weld Two Times
and Keep Corner of the Tooth Point Even With Outer 4. 3/8 In (10 mm) Fillet. Two Times
Surface of Cutting Edge 5. Bent Area of Tooth Point
2. Bend the tooth point out of the dent on each side of 6. Have another person hold the tooth point against
the tooth shank. the tooth shank.
3. Use a pair of pliers to remove the tooth point from 7. Use an suitable tool and drive the heated part of the
the tooth shank. tooth point into the dent on each side of the tooth shank.
2. Fasten suitable lifting equipment to the loader 14. Remove the cotter pin and flat washer that fasten
frame to hold the loader frame in place. the actuator rod for antirollback to the bellcrank for the
right bucket cylinder.
3. Remove the outer snap ring that hold the pivot pins
for the piston rod eyes ot the lift cylinders. 15. Remove the actuator rod. Be careful not to lose the
spring or other flat washer.
4. Use suitable drivers and drive the pivot pins out of
the loader frame. DO NOT remove the drivers now. 16. If equipped with a clam bucket, move the clam
control lever in either direction to relieve any pressure in
5. Disconnect the lifting equipment and lower the the clam circuit.
bucket to the floor.
17. Disconnect the tubes to the clam cylinders from the
6. Hold the right lift cylinder and remove the driver and hoses on the left side of the machine. Fasten an identi-
lower the lift cylinder onto the front axle. fication tag to one hose.
7. Hold the left lift cylinder and remove the driver and 18. Install a cap on each hose and a plug in each tube.
lower the lift cylinder onto the front axle. Flat washers
are used between the strut and the loader frame; be 19. Remove the snap ring and flat washer from the
careful not to lose the flat washers. It is not necessary to right end of the pivot shaft.
remove the strut.
20. Fasten suitable lifting equipment to the loader
8. Move the loader control lever to the right or left to frame to hold the loader frame in place.
relieve any pressure in the bucket circuit.
21. Use a suitable driver and drive the pivot shaft out of
9. Disconnect the tubes to the bucket cylinders from the loader frame.
the hoses on the right side of the loader frame. Fasten
an identification tag to one of the hoses. 22. Belleville springs are used between the loader
frame and the machine. Raise the loader frame and
10. Install a cap on each hose and a cap on each tube. remove the Belleville springs.
11. Disconnect the wiring from the switch for return- 23. Raise the loader frame until the loader frame is free
to-dig. of the machine.
12. Loosen and remove the bolt, flat washer and nut 24. Carefully move the machine out of the loader
that holds the clamp for the wiring harness. frame.
3. Install the Belleville springs between the frame and 16. Remove the snap ring and flat washer from both
loader arm as shown. 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 pin tor tne left piston rod eye into the
loader frame and install the flat washer used between
1. BELLEVILLE SPRING. the strut and loader frame.
THIS SIDE TOWARD MACHINE
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.
B891353J 20. Drive the pivot pin into the piston rod eye.
21. Install the other flat washer between the strut and
4. Align the loader frame and Belleville springs with loader frame and drive the pivot pin all the way into the
the frame. loader frame.
5. Start the pivot shaft into the loader frame from the 22. Install the flat washer and snap ring on the pivot
left side of the machine. pin.
6. Drive the pivot shaft all the way into the loader 23. Start the pivot pin for the other lift cylinder into the
frame. loader frame.
7. Install the flat washer and snap ring. 24. Align the piston rod eye with the loader frame and
drive the pivot pin all the way into the loader frame.
8. If equipped with a clam bucket, connect the hoses
to the tubes on the left side of the machine. 25. Install the flat washer and snap ring on the pivot
pin.
9. Install the actuator rod and spring in the actuator
tube for the antirollback mechanism. 26. Lubricate the pivot pins for the piston rod eyes of
the lift cylinders and the pivot shaft.
10. Engage the actuator rod with the bellcrank and
install the flat washer and cotter pin. 27. With the engine running at low idle, extend and
retract the bucket cylinders and clam cylinders, if
11. Connect the wiring harness to the switch for return- equipped, three times to remove any air from the cir-
to-dig. cuits.
12. Install the nut, bolt and flat washer that hold the
clamp for the wiring harness for the switch.
Loader Frame
B902720J
B902721J
B902719J
Antirollback Linkage
I der Circuit
Clam CYln
. III U.S.p..
?rlllteO
_17630
Sur 8
7. Tighten to 720 to 770
Pound-Feet (762 to 230 Nm)
Bur 8-17630
8861864J
NOTE: The weight of each counterweight is 1425 pounds (646 kg). Use acceptable
lifting equipment to remove and install the countefINeights.
CASE CORPORATION
TABLE OF CONTENTS
SPECIAL TOOL . . 2
TORQUE SPECiFiCATIONS _ 3
SPECIAL TOOL
The tool shown is needed to remove the steering
wheel. Make the tool in your shop. Shown in use in step
5.
4
6 7 8902174J
TORQUE SPECIFICATIONS
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)
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)
sur 8_17470
9005-5
@
,
B870363R
STEP 2
Turn the temperature control to HOT and drain two U.S.
gallons (8 litres) of coolant from the radiator.
STEP 6
STEP 4 Remove the three screws that hold the rear cover for the
steering column.
STEP 7
STEP 8 STEP 11
Disconnect the wiring for the turn signals. Remove the bulbs for the turn signals and disconnect
the wiring from the lamp and warning flasher switches.
STEP 9
STEP 12
STEP 13
Remove the cap screws that hold the seat and remove
the seat.
STEP 14 STEP 17
Remove the self-locking nut and shoulder bolt that Begin at the top and remove the vertical cover.
holds the cable for the left door.
STEP 18
STEP 15
STEP 20
STEP 21 STEP 24
Disconnect the wiring and front lamp. Remove the collar from the cold start switch, if
equipped. Remove the cold start switch from the panel.
STEP 22
STEP 25
STEP 23
STEP 26
Remove the nut that holds the key switch. Remove the
key switch from the panel. Remove the screws that hold the cover.
STEP 27 STEP 30
Disconnect the wiring from the cab lamp switch and Disconnect the wiring from the switches.
lamp for air conditioning.
NOTE: Top, five wire plug; bottom front, four wire plug;
bottom rear, three wire plug.
STEP 28
STEP 31
STEP 29
STEP 32
STEP 33 STEP 36
Beginning at the bottom, remove the top vertical cover. Remove the screws that hold the boot.
STEP 34 STEP 37
Remove the cap screws and flat washers that hold the Loosen the set screw that holds the handle.
instrument console.
STEP 38
STEP 35
STEP 39 STEP 42
STEP 40 STEP 43
Remove the cap screws that hold the support. There is Remove the clevis and cotter pins that hold the shift
a cap screw at the top of the support. linkage.
STEP 41 STEP 44
Remove the nut, lock washer and bolt. Remove the hardware that holds the clamp, ROPS cab
only, and move the support out of the way.
STEP 45 STEP 48
.~
~~~
Disconnect the heater hoses and air conditioning 1. Hardened Washer
hoses, if equipped. Install caps and plugs on the air
conditioning hoses and tubes. Remove the hardware at the side supports.
STEP 49
1. Hardened Washer
Fasten suitable lifting equipment to the roof and care-
Remove the hardware at the front supports. fully remove the ROPS cab.
B902176J
3, Remove the screws that hold the control panel. Dis- 10, Disconnect the yellow wire from the wiring harness,
connect the wires from the switch for the cab lamp and
the lamp for air conditioning, 11 . Hold the blower assembly in place and remove the
five cap screws that hold the blower mount and remove
4, Remove the screws at the bottom of the vertical cover the blower assembly,
and remove the vertical cover beginning at the top,
12, Loosen the clamps on the hoses at the heater and
5, Remove the screws at the bottom of the left vertical remove the hoses,
cover and remove the left vertical cover beginning at the
top, 13, Hold the heater in place and remove the cap screws
that hold the heater and remove the heater,
6. Hold the front headliner in place and remove all
screws that hold the front headliner, 14, Install the heater in reverse of removal.
"
Bur 8-17470
ISsued 1-91
Printed in U.SA
9005-17
\\
B902178J
1. Temperature Control
1.Turn the temperature control to HOT and drain one 8. Disconnect the wiring from the switches.
U.S. gallon (4 litres) of coolant from the radiator.
NOTE: Top, five wire plug; bottom front, four wire plug;
NOTE: During installation, return the coolant to the ra- bottom rear, three wire plug.
diator.
9. Loosen the top clamp and remove the hose from the
2. Remove the knobs from the control panel. temperature control.
3. Remove the screws that hold the control panel. Dis- 10. Remove the screws that hold the temperature
connect the wires from the switch for the cab lamp and control.
the lamp for air conditioning.
NOTE: During installation, make sure that the two
4. Remove the screws at the bottom of the vertical cover ground wires are installed with the bottom screw.
and remove the vertical cover beginning at the top.
11. Loosen the bottom clamp and remove the tempera-
5. Remove the screws that hold the switch panel. ture control.
6. Remove the nut that holds the air conditioning NOTE: During installation, make sure that the tempera-
control. ture control is aligned with the control panel.
7. Remove the screws that hold the switch mount. 12. Install the temperature control in the reverse of
removal.
BACKHOE
CASE CORPORATION
Copyright 1991 J I Case Company
Bur 8-12741 Printed in U.S.A.
Issued March 1991
9006-2
TABLE OF CONTENTS
REMOVAL OF SWING TOWER" , , , , , , , , , , " ,.3
REMOVAL OF BOOM ,., '., ,' ..,..' , ' ', ",., " , " , ,.., ,., 5
INSTALLATION OF DIPPER , , 7
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
3. Hold the bucket control lever in the LOAD position until NOTE: Flat washers are installed between the boom
the bucket stops moving. and swing tower to center the boom in the swing tower.
4. Extend the dipper and boom as far as possible in the 20. Carefully move the machine away from the boom.
space that is available and lower the bucket to the floor.
21. Remove the snap ring and flat washer(s) from one
5 Fasten suitable lifting equipment to the boom and end of the pivot pins for the piston rod eyes of the swing
dipper pivot area to prevent the boom and dipper from cylinders.
falling when the boom is free of the swing tower.
22. Use a hammer or hydraulic ram and a suitable
6. Move the control levers for the backhoe in either di- driver and remove the pivot pins from the swing tower.
rection to relieve any pressure in the circuits.
23. Remove a snap ring and flat washer(s) from one
7. Disconnect the hoses from the backhoe control valve end of the pivot pin for the boom latch.
one at a time and fasten an identification tag to each
hose. 24. Loosen the set screw in the boom latch and drive
the pivot pin out of the swing tower and remove the
8. Install a cap on each fitting and a plug in each hose. driver.
9 Loosen and remove the self-locking nuts and flat 25. Move the boom latch out of the way
washers that hold the vertical clamps near the center of
the swing tower. 26. Loosen and remove the self-locking nut and flat
washer from the bolt that holds the cam on the top pivot
10. Remove the bolts and the clamps. pin for the swing tower.
11. Loosen and remove the self-locking nuts, flat 27. Remove the bolt and flat washers used as spacers
washers, bolts and the horizontal clamp at the rear of Record the amount of flat washers used for use during
the swing tower. installation.
12. Write a number on each clamp ring so that the 28. Remove the snap ring and flat washer from the
hoses will be installed in the correct notch during instal- bottom of the the bottom pivot pin for the swing tower.
lation.
29. Fasten suitable lifting equipment to the swing tower.
13. Fasten suitable lifting equipment to the boom
cylinder to hold the boom cylinder while the pivot pin is 30. Use a hammer or hydraulic ram and a suitable
being removed. driver and remove the bottom pivot pin.
14. Remove the snap ring and flat washer(s) from one 31. Remove the snap ring and flat washer that hold the
end of the pivot pin for the boom cylinder. top pivot pin for the swing tower.
15. Drive the pivot pin out of the swing tower and 32 Drive the top pivot pin out of the swing tower.
remove the driver.
33. Remove the swing tower from the frame.
16. Lower the boom cylinder until the boom cylinder
touches the boom and remove the lifting equipment. 34. Remove the thrust washer from the swing tower or
the bottom support for the swing tower.
17. Use other suitable lifting equipment to hold the
boom when the pivot pins for the boom are removed.
REMOVAL OF BOOM
1. With the engine running at low idle, hold the bucket 17. Remove the snap ring and flat washer from one end
control lever in the LOAD position until the bucket stops of the pivot pin for the piston rod eye of the boom
moving. cylinder.
2. Put the boom and dipper in a suitable position for 18. Drive the pivot pin out of the boom.
removal of these parts with the bucket on the floor.
19. Move the boom cylinder toward the machine and
3. With the engine stopped, move the dipper control use a chain to hold the boom cylinder out of the way.
lever in either direction to relieve any pressure in the cir-
cuits. 20. Disconnect the hoses from the dipper cylinder from
the tubes inside the boom.
4. Fasten suitable lifting equipment to the dipper
cylinder to hold the dipper cylinder for removal of the 21 . Install and tighten a plug in each tube and a cap on
pivot pin for the piston rod eye. each hose.
5 Remove the snap ring and flat washer that hold the 22. Fasten lifting equipment to the dipper cylinder for
pivot pin for the piston rod eye of the dipper cylinder. removal of the dipper cylinder.
6. Drive the pivot pin out of the dipper and remove the 23. Remove the snap ring and flat washer from one end
driver. of the pivot pin for the dipper cylinder.
7. Raise the dipper cylinder for access to the hoses 24. Drive the pivot pin out of the boom and remove the
inside the boom driver.
8. Disconnect the hoses from the bucket cylinder at the 25. Remove the dipper cylinder.
tubes inside the boom and fasten an identification tag
to one hose. 26. Lower the boom to the floor and use the lifting
equipment to hold the boom when the pivot pins for the
9. Install and tighten a plug in each tube and a cap on boom are removed.
each hose.
27. Disconnect the hoses at the bottom of the boom
10. If equipped with an extendable dipper, disconnect from the tubes inside the boom one at a time and fasten
the hoses from the extension cylinder and the tubes an identification tag to each hose.
inside the boom and fasten an identification tag to one
hose. 28. Install and tighten a plug in each tube and a cap on
each hose.
11. Install a plug in each tube and a cap on each hose.
29. Loosen and remove the cap screw, hardened
12. Fasten the lifting equipment to the dipper. washer and spacer that hold each pivot pin for the
boom.
13. Loosen and remove the self-locking nut and
hardened washer that hold the pivot pin for the dipper. 30. Remove the pivot pins for the boom.
14. Drive the pivot pin out of the dipper and remove the NOTE: Flat washers are installed between the boom
driver. and swing tower to center the boom in the swing tower.
15. Move the dipper out of the way. 31. Remove the boom and check for flat washers being
used between the swing tower and the boom.
16. Fasten the lifting equipment to the boom.
INSTALLATION OF BOOM
1. Install new seals at all pivot points. 4. Tighten the self-locking nut for the pivot pin for the
dipper to 500 to 550 pound-feet (678 to 746 Nm).
2. Installation is the reverse of removal.
5. Lubricate the pivot pins with molydisulfide grease.
3. For original or new booms, measure the distance
between the ears of the boom at the dipper pivot point 6. With the engine running at 1000 rpm (r/rnin), slowly
and record the measurement. Before installing the self- operate the bucket, dipper, and extension, if equipped,
locking nut, install flat washers on the pivot pin that will cylinders through four complete cycles to remove any
pull the ears of the boom together 1/16 to 1/8 inch (1 to air from the circuits.
3 mm).
REMOVAL OF DIPPER
1. With the engine running at 1000 rpm (r/rnin) use the 11. Raise the dipper cylinder for access to the hose
backhoe controls as required so that the bucket teeth connections inside the boom.
are just off the floor and below the pivot pin for the
bucket. 12. Disconnect the hoses from the bucket cylinder at
the tubes inside the boom and fasten an identification
2. Remove the Klik pin from the pivot pin for the bucket. tag to one hose.
3. Remove the pivot pin for the bucket. 13. Install and tighten a plug in each tube and a cap on
each hose.
4. Use the boom, dipper and bucket controls as
required to disengage the coupler from the bucket. 14. If equipped with an extendable dipper, disconnect
the hoses from the extension cylinder at the tubes
5. Move the bucket out of the way. inside the boom and fasten an identification tag to one
hose.
6. Retract the bucket cylinder and put the boom and
dipper in a suitable position for removal of the dipper. 15. Install and tighten a plug in each tube and a cap on
each hose. Thread size is 1-1/16-12.
7. With the engine stopped, move the bucket control
lever and the extension control lever, if equipped, in 16. Fasten the lifting equipment to the dipper to hold
both directions to relieve any pressure in the circuits. and remove the dipper.
8. Fasten suitable lifting equipment to the dipper 17. Loosen and remove the self-locking nut and
cylinder. hardened washer(s) from the pivot pin for the dipper.
9. Remove a snap ring and flat washer from one end of 18. Drive the pivot pin out of the dipper.
the pivot pin for the piston rod eye of the dipper cylinder.
19. Remove the dipper.
10. Drive the pivot pin out of the dipper.
INSTALLATION OF DIPPER
1. Install new seals in the bores for the pivot pin for the 4. Tighten the self-locking nut for the pivot pin for the
dipper. dipper to 500 to 550 pound-feet (678 to 746 Nm).
2. Installation is the reverse of removal. 5. Lubricate the pivot pins with molydisulfide grease.
3. Before installing the dipper, measure the distance 6. With the engine running at 1000 rpm (r/min), slowly
between the ears of the boom at the dipper pivot and operate the bucket cylinder and the extension cylinder,
record the measurement. Before installing the self- if equipped, through four complete cycles to remove
locking nut, install flat washers on the pivot pin so that any air from the circuits.
the ears of the boom will be pulled together 1/16 to 1/8
inch (1 to 3 mm) when the self-locking nut is tightened.
2. Remove the Klik pin from the pivot pin for the bucket. 12. Remove the snap ring and flat washer from each
end of the pivot pin for the guide links and the piston rod
3. Remove the pivot pin for the bucket. eye of the extension cylinder.
4. Use the boom, dipper and bucket controls as 13. Remove the guide link and flat washer from each
required to disengage the coupler from the bucket. end of the pivot pin.
5. Move the bucket out of the way. 14. Drive the pivot pin out of the dipper extension and
remove the driver.
6. Completely extend the dipper and raise or lower the
boom so that the end of the dipper is approximately 3 NOTE: The weight of the dipper extension and the
feet (1 m) above the floor. coupler is approximately 395 pounds (179 kg). The
length of the dipper extension is approximately 5-112
7. Completely retract the bucket cylinder and stop the feet (1.7 my.
engine.
15. Fasten suitable lifting equipment to the dipper ex-
8. Put a block under the bucket cylinder to hold the tension approximately two feet (0.6 m) from the bucket
bucket cylinder when the pivot pin for the piston rod eye end of the dipper extension to hold and remove the
is removed. dipper extension.
9. Remove a snap ring and flat washer from one end of 16. Install a bar through the hole for the pivot pin for the
the pivot pin for the piston rod eye of the bucket bucket and loosen the lifting equipment and pull the
cylinder. 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.
6. Select shim(s) for the top wear plate so that the 12. Install the dipper extension according to instruc-
distance from the bottom of the bottom wear plate and tions in this section.
the top of the top wear plate is 9-3/16 inch (233 mm).
CUTTING EDGES
Universal and Heavy Duty Buckets 6. See the following illustration and install the corner
bucket teeth and weld the bucket teeth in place. Use
Replacing Bottom Cutting Edge E7018 welding rod.
High Capacity Buckets 8. Fill the corners cut through during removal.
1. Remove the bucket teeth. Use carbon arc rod or an 1. Remove all welds that hold the side cutting edge in
acetylene cutting torch to remove the welds. place. Use carbon arc rod or an 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 2. Remove the side cutting edge from the bucket.
torch to remove welds.
3. Use a grinder to remove any welds still on the bucket
3. Cut through each corner of the bottom cutting edge and any extra metal so that the new side cutting edge
and bucket. will fit the bucket.
4. Remove the cutting edge from the bucket. 4. Put the side cutting edge in place and use a C-c1amp
to hold the side cutting edge in place.
5. Use a grinder to remove any welds still on the bucket.
Remove any extra metal so that the new cutting edge 5. Use E7018 welding rod and weld the side cutting
will fit the bucket. edge to the bucket with a 3/16 inch (5 mm) fillet weld all
around the side cutting edge.
6 Put the new bottom cutting edge in place and use C-
clamps to hold the bottom cutting edge in place.
B902037J
Standard Duty Trenching Buckets 8. Fill the corners cut through during removal.
1. Remove the bucket teeth. Use carbon arc rod or an 1. Remove the welds that hold the side cutting edge.
acetylene cutting torch to remove the welds. Use carbon arc rod or an acetylene cutting torch
IMPORTANT: When removing the bottom weld at the 2. Remove the side cutting edge.
rear of the bottom cutting edge, do not cut through the
bottom of 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
2. Use carbon arc rod or an acetylene cutting torch to will fit the bucket.
remove the welds that hold the bottom cutting edge.
4. Use C-clamps to hold the side cutting edge on the
3. Cut through each corner of the bucket to the rear of bucket.
the bottom cutting edge.
5. Use E7018 welding rod and weld the side cutting
4. Remove the bottom cutting edge from the bucket. edge to the bucket with a 3/16 inch (5 mm) fillet weld all
around the side cutting edge.
5. Use a grinder to remove any welds still on the bucket
and any extra metal so that the new bottom cutting
edge will fit the bucket.
BUCKET TEETH
Replacing a Tooth Point 5. Universal and heavy duty buckets only. See the fol-
lowing illustration for the weld specifications for the
1. Use a hammer and punch to remove the flex pin from corner bucket teeth. Use E7018 welding rod and weld
the tooth point. the tooth shanks in place.
2. Install the flex pin so that the shoulders are toward the
cutting edge.
3. Install a new tooth point and drive a new flex pin into
the tooth point.
B861752R
B872455J
1 B90203BJ 1 B902038J
1. Centerline 1. Centerline
2. Center Tooth 2. Center Tooth
3. 24 In (610 mm) Bucket - 4.3 In (109 mm) 3. 18 In (457 mm) Bucket - 3.56 In (90 mm)
30 In (762 mm) Bucket - 6.8 In (173 mm) 4. 24 In (610 mm) Bucket - 5.4 In (137 mm)
4. Put Tooth Shank as Near Corner as 5. Put Tooth Shank as Near Corner as
Possible and Keep Tooth Point Possible and Keep Tooth Point
0.5 In (12.7 mm) Outside of Cutting Edge 0.5 In (12.7 mm) Outside of Cutting Edge,
All Buckets Except 12 in (305 mm) Bucket
Which Is Even with Outside of Cutting Edge
.......... , .
8902834J
B902704J
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.
B902B36J
1. Tighten to 264 To 305 Pound-Inches (31 to 36 Nm)
B892343J
B902837J
1. See Installation of Dipper, Step 3.
2. Shim. Use as Required to Keep Boom Centered
in Swing Tower and Reduce Clearance.
Bur 8-12741
B902839J
\\'.'
6902958.1
ut
BuCKet cylinder \-IydrauliC Installation Witoo 8dendable Dipper
Bur 8_12741
9006-25
Bur 8-12741
~B
I I
I
Bur 8-12741
B902B40J
1. To Extension Cylinder
Printed in U.S.A
Issued 3-91
Bur B-12741
Section
9008
THREE-POINT HITCH
TABLE OF CONTENTS
REMOVING THE THREE POINT HITCH 3
EXPLODED VIEWS
6. Remove the top closure panel. IMPORTANT: Before the engine can be started, the
inlet and outlet hoses must be connected together. To
7. For machines with a ROPS canopy, loosen and connect the hoses together, use tube union 218-854.
remove the nuts, lock washers and bolts that hold the
cover and remove the cover. 14. Move the machine away from the three-point hitch.
8. Fasten acceptable lifting equipment to the mounting IMPORTANT: If the three-point hitch is not to be in-
bracket for the control levers and the three point hitch stalled again, the rear counterweight or backhoe must
control valve. be installed before the machine can be used.
2. Install the hardened washers and bolts and the 9. Connect the hoses to the three-point hitch control
hardened washers and nuts. valve.
3. Tighten the nuts to 380 to 455 pound-feet (515 to 615 10. With the engine running at low idle, operate each
N m). cylinder through three complete cycles to remove any
air from the circuits.
4. Install the rear wheels and the wheel nuts. Do not use
an impact wrench to install the wheel nuts. 11. Stop the engine and check for oil leaks.
5. Tighten the wheel nuts to 320 to 380 pound-feet (435 12. Check the level of the oil in the reservoir and add oil
to 515 N m). as required
Bur 8-12761
Issued 3-91 .
Printed in U.S.A
9008-5
B902761J
TABLE OF CONTENTS
STANDARD SEAT INSTALLATION ... 3
B891367J
5. BACK
CUSHION
B870238R
Standard Seat
""
B891368J
2. SWIVEL LEVER
7. HEIGHT ADJUSTER
B891369J
Seat Support
SUSPENSION SEAT
TABLE OF CONTENTS
DiSASSEMBLY 3
ASSEMBLY 7
DISASSEMBLY
STEP 1 STEP 4
Remove the fasteners that hold the boot to the slide. Remove a C-clip from the shaft for the arm.
STEP 2 STEP 5
Drive the pin out of the knob and the adjuster rod and Remove the shaft.
remove the knob.
STEP 6
STEP 3
Loosen and remove the cap screws that hold the seat.
Use a prybar and remove the cover.
STEP 7 STEP 10
Remove the seat. 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 8
STEP 11
Remove an E-ring from the pivot pin for the shock ab-
sorber and remove the pivot pin.
Remove the springs.
STEP 9
STEP 12
STEP 13 STEP 17
Remove the spring seat.
STEP 14
Loosen and remove the cap screws that hold the base.
STEP 18
Remove the springs.
STEP 15
Remove the cotter pins and pivot pins that fasten the
housing to the base.
STEP 16
2. SHOCK ABSORBER
4. ADJUSTER SPRING
B870242R
ASSEMBLY
STEP 19 STEP 23
STEP 20 STEP 24
Install the spring seat.
STEP 25
STEP 21
Turn the adjuster rod into the spring seat.
STEP 26
STEP 22
Install the pivot pins and cotter pins that hold the Install the springs.
housing.
STEP 27 STEP 30
Install and tighten the self-locking nut on the bottom of Install the seat.
the adjuster rod.
STEP 31
STEP 28
Install and tighten the cap screws that hold the seat.
Install the shock absorber, pivot pin and E-ring ..
STEP 32
STEP 29
STEP 33 STEP 35
Install the C-c1ip. Align the knob with the adjuster rod and drive the pin
into the knob.
STEP 34
STEP 36
2. SEAT BACKREST
3. SEAT CUSHION
14. LH COVER
10. BOOT