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Case 580 Super K

Backhoe • Loader • Tractor

Service Manual P.I.N. JJG0160001 and after v 9.0

http://BestManuals.net [email protected]

580 Super K Loader Backhoe P.I.N. JJG0160001 and after Service Manual

Table of Contents Description

General Loctite Product Chart Section Index - General Torque Specifications Fluids & Lubricants Engines Section Index - Engine Engine Removal & Installation Stall Tests Detailed Engine Specifications Cylinder Head & Valve Train Cylinder Block Lubrication System Cooling System Turbocharger Turbocharger Failure Analysis Fuel System Section Index - Fuel System Fuel System & Filters Fuel Inj ectors CAV Injection Pump (4-390) Bosch Injection Pump (4T-390) Electrical Section Index - Electrical Removal & Installation of Electrical Components Specifications, Troubleshooting & Schematics Batteries Starter & Starter Selenoid 95 Ampere Alternator 65 Ampere Alternator Instrument Cluster Steering Section Index - Steering Removal & Installation of Steering Component Specifications, Schematics & Troubleshooting Steering Control Valve - Eaton Steering Control Valve - Danfoss Steering Cylinder Front Axle - Two Wheel Drive Front Axle - Four Wheel Drive

Section No Tabl

10001 10002

Form No 8-98900 8-17141 8-71600 8-12271

Tab 2 2001 2002 2402 2415 2425 2445 2455 2465 2565

8-17161 8-17560 8-12301 8-24163 8-24173 8-24183 8-24193 8-24203 8-25550 9-78235

Tab 3 3410 3413 3414 3415

8-17190 8-24212 8-24233 7-37131 7-37141

Tab 4 4001 4002 4003 4004 4006 4007 4008

8-17200 8-17210 8-17220 8-12350 8-11370 8-12381 8-15670 8-17230

Tab 5 5001 5002 5004 5005 5006 5007 5008

8-17250 8-17260 8-17270 8-12440 8-12450 8-17280 8-12471 8-17300

Description

Power Train Section Index - Power Train Removal & Installation of Components Transmission Specifications & Schematic Wheels & Tires PTO Rear Axles & Planetaries Transfer Gearbox Differential & Differential Lock ForwardlReverse Valve Torque Converter Charging Pump, Output Shaft & Converter Housing Transmi ssi on Brakes Section Index - Brakes Parking Brake Disc Brakes Removal & Installation of Brake Components Master Cylinder

Section No

Form No

Tab 6 6001 6002 6003 6019 6201 6202 6203 6204

8-17570 8-12501 8-12512 8-12521 7-37060 7-36980 7-36990 7-37000 7-37010

6205 6206

7-37020 7-37030

Tab 7 7000 7001 7002 7003

Hydraulics Section Index - Hydraulics Removal & Installation of Hydraulic Components Schematics, Specifications & Troubleshooting Cleaning the Hydraulic System Hydraulic Pump Loader Control Valve Cylinder Backhoe Control Valve Swing Sequence Valve Three Point Hitch Control Valve Double Selector Valve

TabS

Mounted Equipment Section Index - Mounted Equipment Pedals & Levers Air Conditioning Troubleshooting & Pressure Checks Air Conditioning System Loader ROBS Cab & ROPS Canopy Backhoe Three Point Hitch Seat & Seat Belts Suspension Seat

Tab 9

8001 8002 8003 8004 8005 8006 8007 8008 8009 8011

8-17350 7-37040 7-37050 8-12540 8-12570

8-12580 8-17580 8-17530 8-67390 8-17400 8-17410 8-17591 8-17430 8-12650 8-67421 8-12670

9001

8-12680 8-17540

9002 9003 9004 9005 9006 9008 9009 9010

8-12700 8-12711 8-17630 8-17470 8-12741 8-12761 8-12770 8-12781

SECTION INDEX - GENERAL

Section Title

Section Number

Standard Torque Specifications ...............................................................................................................................1001 Fluids and Lubricants ..............................................................................................................................................1002 Detailed Engi ne Specifications ................................................................................................................................1024

CASE CORPORATION

Bur 8-16230

Printed in U.S.A. Issued August 1990

2

o o Ol CO Ol

s

cb

a:

1001 STANDARD TORQUE SPECIFICATIONS TABLE OF CONTENTS Torque Specifications Hardware

- Decimal

Torque Specifications

- Metric Hardware ...1001-3

CASE CORPORATION

Torque Specifications Fittings

- Steel Hydraullc

Torque Specifications Seal Fittings.....

- O-ring Face ....................1001-5

1001-2

Bur 8-71600

1001-4

Printed in U.S.A. Issued May 1988

1001-2

TORQUE SPECIFICATIONS - DECIMAL HARDWARE Use the torques in this chart when special torques are not given. These torques apply to fastenars with both UNC and UNF threads as received from suppliers. dry. or when lubricated with engine oil Not applicable if special graphites, rnotydisulfide greases. or other extreme pressure lubricants are used.

8113608

1001-3

TORQUE SPECIFICATIONS - METRIC HARDWARE Use the following are not given.

toques

when

special

torques

These values apply to fasteners with coarse threads as received from supplier. plated or unplated. or when lubricated with engine oil. These values do not apply if graphite or molydisulfide grease or oil if used.

811359A

1001-4

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS Tube OD Hose ID

Thread Size

PoundFeet

Newton metres

Tube OD Hose ID

Thread Size

PoundFeet

Newton metres

Straight Threads with O-ring

37 Degree Flare Fittings 1/4 in 6.4 mm

7/16-20

6-12

8-16

1/4 in 6.4 mm

7/16-20

12-19

16-25

5/16 in 7.9 mm

1/2-20

8-16

11-21

5/16 in 7.9 mm

1/2-20

16-25

22-23

3/8 in 9.5 mm

9/16-18

10-25

14-33

3/8 in 9.5 mm

9/16-18

25-40

34-54

1/2 in 12.7 mm

3/4-16

15-42

20-56

1/2 in 12.7 mm

3/4-16

42-67

57-90

5/8 in 15.9 mm

7/8-14

25-58

34-78

5/8 in 15.9 mm

7/8-14

58-92

79-124

3/4 in 19.0 mm

1-1/16-12

40-80

54-108

3/4 in 19.0 mm

1-1/16-12

80-128

108-174

l/8.in 22.2 mm

1-3/16-12

60-100

81-135

7/8 in 22.2 mm

1-3/16-12

100-160

136-216

1.0 in 25.4 mm

1-5/16-12

75-117

102-158

1.0 in 25.4 mm

1-5/16-12

117-187

159-253

1-1/4 in 31.8 mm

1-5/8-12

125-165

169-223

1-1/4 in 31.8 mm

1-5/8-12

165-264

224-357

1-1/2 in 38.1 mm

1-7/8-12

210-250

285-338

1-1/2 in 38.1 mm

1-7/8-12

250-400

339-542

Split Flange Mounting Bolts PoundFeet

Newton metres

5/16-18

15-20

20-27

3/8-16

20-25

26-33

7/16-14

35-45

47-61

1/2-13

55-65

74-88

5/8-11

140-150

190-203

Size

8113618

1001-5

TORQUE SPECIFICATIONS Nom. SAE Dash Size

Thread Size

Tube 00

PoundFeet

- O-RING FACE SEAL FITTING

Newton Metres

O-ring Face Seal End

Thread Size

PoundFeet

Newton Metres

O-ring Boss End Fitting or Locknut

-4

1/4 In 6.4 mm

9/16-18

10-12

14-16

7/16-20

17-20

23-27

-6

3/8 in 95 mm

11/16-16

18-20

24-27

9/16-18

25-30

33-40

-8

1/2 in 12.7 mm

13/16-16

32-40

43-54

3/4-16

45-50

61-68

5/8 in 15.9 mm

1-14

46-56

60-75

7/8-14

60-65

81-88

-12

3/4 in 19.0 mm

1-3/16-12

65-80

90-110

1-1/16-12

85-90

115-122

-14

7/8 in 22.2 mm

1-3/16-12

65-80

90-110

1-3/16-12

95-100

129-136

-16

1.0 in 25.4 mm

1-7/16-12

92-105

125-140

1-5/16-12

115-125

156-169

-20

1-1/4 in 31.8 mm

1-11/16-12

125-140

170-190

1-5/8-12

150-160

203-217

-24

1-1/2 in 38.1 mm

2-12

150-180

200-254

1-7/8-12

190-200

258-271

-10

I

I

I

I

8871553

Section

1002 FLUIDS AND LUBRICANTS

CASE CORPORATION

Bur 8-12271

Printed in U.S.A. Issued March 1991

1002-2

TABLE OF CONTENTS ....................................... 2

CAPACITIES AND LUBRICANTS ... ENGINE OIL RECOMMENDATIONS DIESEL FUEL

.

.

3

..

.

.4

CAPACITIES AND LUBRICANTS Engine Oil Capacity with Filter Change Type of oil.

11.6 U.S. quarts (11 litres) See Engine Oil Recommendations on page 3

Engine Cooling System Capacity without heater Capacity with heater.. Type of coolant.

17.2 U.S. quarts (16.3 litres) ... 17.9 U.S quarts (16.9 litres) Ethylene glycol and water mixed for lowest ambient temperature At least SO/50 mix

Fuel Tank Capacity Capacity with auxiliary tank.................................. Type of fuel Hydraulic System Hydraulic reservoir refill capacity Type of oil

25 U.S. gallons (94.6 litres) . 33 U.S. gallons (124.9 litres) See Diesel fuel specifications on page 4

21.5 US. gallons (81.4 litres) Case TCH Fluid

Transmission Capacity Total System Capacity Type of oiL.............

47.6 U.S. quarts (45 litres) 57.1 U.S. quarts (54 litres) Case Hy-Trans Plus (MS 1207)

Front Axle - Four Wheel Drive Capacity of center bowl Capacity of planetary (each) Type of oil..... ..

7.4 quarts (7 Iitres) 1.1 U.S. quarts (1 litre) CaselH 135-H EP gear lube

Brake Reservoir Type of fluid

Case TCH Fluid

Conversion Formulas Imperial quart = litres x 0.879877 Imperial gallon = litres x 0.219969

Bur 8-12271

Issued 3-91

Printed in U.S.A.

1002-3

ENGINE OIL RECOMMENDATIONS Case IH No.1 Engine Oil is recommended for use in your Case IH Engine. Case IH Engine Oil will lubricate your engine correctly under all operating conditions. If Case IH No.1 Multi-Viscosity Engine Oil is not available, Case IH No.1 Single Grade Engine Oil can be used If Case IH No.1 Multi-Viscosity or Single Grade Engine Oil is not available, use only oil meeting API engine oil service catergory CE.

654L9

See the chart below for recommended viscosity at ambient air temperature ranges. NOTE: Do not put Performance Additives or other oil additive products in the engine crankcase. The oil intervals given in this manual are according to tests with Case IH lubricants.

AMBIENT AIR TEMPERATURE Temperature

I

,

I

I

I

I

RANGES

Fahrenheit

I

I

I •

I

.

I

MUL TI-GRADE OIL I

I

.

I

I

•

I

••

SINGLE GRADE OIL

.

I

•

I

•

I

I

• I

I

-34' _29' -23' -18' -12' -7"

•

••

I

•• •

I

I

737L9 I

I

_1'

I

I

4'

Temperature

Bur 8-12271

I

•

I

10'

I 16" 21'

I

I 27" 32'

I

I

I

38' 43' -49'

Celsius

Issued 3-91

Printed in U.S.A.

1002-4

DIESEL FUEL Use NO.2 diesel fuel in the engine of this machine. The use of other fuels can cause the loss of engine power and high fuel consumption. Invery cold temperatures, a mixture of NO.1 and NO.2 diesel fuels is temporarily permitted. See the following Note. NOTE: See your fuel dealer for winter fuel requirements in your area. If the temperature of the fuel is below the cloud point (wax appearance point), wax crystals in the fuel will cause the engine to lose power or not start.

Fuel Storage If you keep fuel in storage for a period of time, you can get foreign material or water in the fuel storage tank. Many engine problems are caused by water in the fuel. Keep the fuel storage tank outside and keep the fuel as cool as possible. Remove water from the storage container at regular periods of time.

The diesel fuel used in this machine must meet the specifications in the chart below or Specification 0975-81 of the American Society for Testing and Materials.

Specifications for Acceptable NO.2 Diesel Fuel API gravity, minimum

..

Flash point, minimum.

..

Cloud point (wax appearance

point), maximum

..

Pour point. maximum Distillation temperature.

34 140°F (60°C)

-5°F (-20°C) See Note above -15°F (-26°C) See Note above

90% point...

540 to 640°F (282 to 338°C)

Viscosity, at 100°F (88°C) Centistokes Saybolt Seconds

. Universal.................

Cetane number, minimum

2.0 to 43

..

32 to 40 43 (45 to 55 for winter or high altitudes)

Water and sediment, by volume, maximum...........................

.. 0.05 of 1%

Sulfur, by weight, maximum...............

..

Copper strips corrosion, maximum Ash, by weight, maximum.................

Bur 8-12271

0.5 of 1% ..

..

No. 2

0.01 of 1%

Issued 3-91

Printed in U.S.A.

Section

1024 SPECIFICATION

DETAILS

IMPORTANT: This engine was made using the metric measurement system. All measurements and checks must be made with metric tools to make sure of an accurate reading when inspecting parts.

CASE CORPORATION

Rae 8-24162

Copyright

© 1991 J I Case Company Printed in U.S.A. June, 1983 (Revised January, 1991)

1024-2

TABLE OF CONTENTS RUN-IN INSTRUCTIONS.

.

3

IDENTIFICATION MARKS Crankshaft Cylinder Block.... .. Cylinder Head.....

4 .4 ..4

.

ENGINE SPECIFICATION DETAILS Cylinder Block... . Service Cylinder Sleeve.....

.4

.

5

Piston.......

.

5

Piston Pin

5

Piston Rings

6

Cylinder Head. Lifters

..

...................

6

...

6

..

Connecting Rod

.

7

Crankshaft.

8

Camshaft

9

Turbocharger

9

Gear Train

9 ..............

Rocker Arm Assembly. Intake Valve...

..

10

Exhaust Valve

10

Valve Springs..........

.

Valve Seat Installation Dimensions

11 11

SPECIAL TORQUES .. ,

Rae 8-24162

10

11-13

Revised 1-91

Printed in U.S.A.

1024-3

RUN-IN INSTRUCTIONS Engine Lubrication Fill the engine crankcase with CO or CE service classification oil that has the correct viscosity rating for the ambient air temperature. Install new oil filters, after the engine has been rebuilt.

Run-In Procedure for Rebuilt Engine Step 1

Disconnect the wire to the electric shut-off on the injection pump so that the engine will not start Crank the engine for 30 seconds until there is oil pressure, then reconnect the wire.

Step 2

Remove the air from the cooling system at the temperature sending unit.

Step 3

Run the engine at 1000 RPM minimum load for 5 minutes and check for oil leaks

Step 4

During the Run-In, continue to check the oil pressure, coolant level, and coolant temperature.

Run-In Procedure for Rebuilt Engines (With a Dynamometer) The following procedure must be followed when using a PTO dynamometer to Run-In the engine. The dynamometer will control the engine load at each speed and will remove stress on new parts during Run-In. During the Run-In, continue to check the oil pressure, coolant level and coolant temperature. STEP 1

2 3

TIME 5 Minutes 5 Minutes 5 Minutes

ENGINE 1000 1100 2200

SPEED RPM RPM RPM

DYNAMOMETER SCALE LOAD

50 1/2

Full

Run-In Procedure for Rebuilt Engines (Without a Dynamometer) STEP 1

2 3

TIME 5 Minutes 5 Minutes 5 Minutes

Run-In Procedure

ENGINE SPEED 1000 RPM 1100 RPM 2200 RPM

LOAD No Load Light Load Light Load

(Agriculture Tractors)

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.

Run-In Procedure

(Construction Equipment)

For the first 8 hours, operate the engine at full throttle maintaining a normal load. Avoid converter or hydraulic stall. The engine must not be "lugged" below the Rated Engine RPM (00 not stall the engine more than 10 seconds).

Rae 8-24162

Revised 1-91

Printed in USA

1024-4

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 (three notches).

Use a thicker head gasket

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 Numbers

=

=

The cylinder block has been ref aced and up to 0.50 mm has been removed. Use a thicker head gasket (three notches). RH rear corner of cylinder head indicates the amount of material removed from the cylinder head.

ENGINE SPECIFICATION DETAILS

Cylinder Block Type..

Metric Value Non-Sleeved

.

Material 10 of Cylinder...

Cast Iron .

Maximum Service Limit

102.00 to 102.04 mm .

102.116 mm

Cylinder Out of Round (Maximum)

0.038 mm

Cylinder Taper (Maximum)

0.076 mm

0.5 mm Oversize Piston Machine Cylinder Bore to

102.40 to 102.44 mm

Hone to (Finished Diameter)

102.50 to 102.54 mm

1.00 mm Oversize Piston Machine Cylinder Bore to

102.90 to 102.94 mm

Hone to (Finished Diameter)

103.00 to 103.04 mm

Warpage (Maximum)..................................................................

0.075 mm

Maximum Material Removal

Rae 8-24162

0.50 mm

Revised 1-91

Printed in U.SA

1024-5

Service Cylinder Sleeve Type

Dry, Can Be Replaced

Material

Cast Iron

Machine Cylinder Block Bore to

104485 to 104.515 mm

Installation..................

.

.

Press Fit

Machine Sleeve Bore to: Standard Size Piston (Finished Diameter)

................................10200

to 102.04 mm

0.5 mm Oversize Piston Machine Cylinder Bore to

10240 to 10244 mm

Hone to (Finished Diameter)

102.50 to 102.54 mm

1.0 mm Oversize Piston Machine Cylinder Bore to..

..

Hone to (Finished Diameter)

102.90 to 102.94 mm ..

103.00 to 103.04 mm

Piston Type

Cam Ground

Material...................

...Aluminum alloy

OD at 12 mm From the Bottom, 90 Degrees Piston Pin Standard Size Piston

101.873 to 101.887 mm

Minimum Service Limit. 0.5 mm Oversize Piston

101.823 mm 102.373 to 102.387 mm

Minimum Service Limit. 1.0 mm Oversize Piston

101.323 mm 102.873 to 102.887 mm

Minimum Service Limit ID of Piston Pin Bore

102.823 mm 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 OD of Pin

Full Float 39.997 to 40.003 mm

Minimum Service Limit

Rae 8-24162

39.990 mm

Revised 1-91

Printed in U.S.A.

1024-6

Piston Rings NO.1 Compression 4T-390 Engine End Gap in 102.02 10....

Key Stone Type (Barrel Face) ..

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...............................................

.

Side Clearance.

.

0.806 mm 0 130 mm

Cylinder Head Warpage (Maximum)

0.20 mm

Maximum Material Removal..........................

.

Minimum Head Height

..

1.00 mm 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 Minimum Service Limit. . Bore Diameter in Block

15.961 to 15.977 mm ..

15.960 mm 16.000 to 16.030 mm

Maximum Service Limit.

Rae 8-24162

16.055 mm

Revised 1-91

Printed in USA.

1024-7

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......................

.

Journal 10 Without Bearing Liners

Replaceable

72.987 to 73.013 mm

Bearing Oil Clearance

.

0.038

Maximum Service Limit.....

to 0.116 mm .

Side Clearance......................................

.

0129 mm

0.100 to 0.300 mm

Maximum Service Limit

... 0330 mm

Connecting Rod Bend (Maximum) Without Bushing. With Bushing

.

.

.

0.200 mm

.

0150 mm

Connecting Rod Twist (Maximum) Without Bushing. With Bushing

Rae 8-24162

.

,..

.

.

0.500 mm .

Revised 1-91

0.300 mm

Printed in U.SA

1024-8

Crankshaft Type

Hardened Steel, Balanced

Main Bearing Liners......

..

.

Replaceable

End Clearance, Center Main Bearing Cap

0.13 to 0.25 mm

Center Main Bearing Thrust Surface Thickness.........

..

2.50 mm

Connecting Rod Journal 00, Standard Maximum Service Lirnit..

.

68.987 to 69.013 mm

.

68.962 mm

0.25 mm 00 Undersize, Grind to

68.737 to 68.763 mm

Maximum Service Limit...........................................................

..

0.50 mm 00 Undersize, Grind to......................................

68.712 mm . 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............

.

1.00 mm 00 Undersize, Grind to.......................

.

...67.98

68.212 mm to 68.013 mm

Maximum Service Limit.....................................

.

67.962 mm 0.013 mm

Connecting Rod Journal Maximum Taper Journals Out of Round Maximum.......................................

.

Undersize Main Bearing Liners For Service

.

Main Bearing Oil Clearance

0.25,0.50,0.75

0050 mm

and 1.00 mm

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..... 0.25 mm 00 Undersize, Grind to

.

82.962 mm

.

82.737 to 82.763 mm 82.712 mm

Maximum Service Limit. 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 4th Connect Rod Journals Width

Rae 8-24162

..

37.424 to 37.576 mm 37.475 to 37.525 mm 38.950 to 39.050 mm

Revised 1-91

Printed in U.S.A.

1024-9

Camshaft Type

Hardened Iron

Bushing (Front Only)

1, Replaceable

Bushing Lubrication: Front Bushing

Pressure Lubricated

Intermediate.

Pressure Lubricated

Rear

Pressure Lubricated

Oil Clearance

0.076 to 0.152 mm

ID of NO.1 Bushing, Installed Maximum Service Limit ID of NO.1 Oversize (57.24 mm 00) Service Bushing

54.107 to 54.133 mm ..

54.146 mm 54.089 to 54.139 mm

Maximum Service Limit 10 of NO.2, 3, 4 and 5 Service Bushing

54.146 mm 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 Camshaft Thrust Clearance

9.34 mm 0.130 to 0.340 mm

Maximum Service Limit

0.470 mm

Camshaft Lobes: Minimum Diameter at Peak Intake

47.265

Minimum Diameter at Peak Exhaust

mm

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)

Rae 8-24162

0.45 mm

Revised 1-91

Printed in U.S.A.

1024-10

Rocker Arm Assembly OD of Shaft

.

.

18.963 to 18.975 mm

Minimum Service Limit..............

.

ID of Arm Bore..............................

..

18.938 mm 19.000 to 19.026 mm

Maximum Service Limit

19.051 mm

Lubrication..

.

Pressure From Oil Gallery

Shaft Oil Holes

.

Down

Intake Valve Tappet Clearance (Cold)

0.254 mm

Face Angle

29 Degrees

Face Run-Out.................

..

Valve Head Edge Thickness, Minimum...........................

0.038 mm

.

Length

1.50 mm 128.84 to 129.46 mm

OD of Stem

.

Minimum Service Limit

7.960 to 7.980 mm

.

7.940 mm

OD of Head

44870 to 45.130 mm

Seat Angle................................

.

Seat Contact Width

30 Degrees 1.32 to 1.92 mm

Seat Run-Out.......

.

Insert Height.....................

..

OD of Insert.........................

0.1 0 mm

6.84 to 6.96 mm ..

.47.063 to 47.089 mm

ID of Insert.....................

Tapered

Valve Recession Below Head Surface Maximum Service Limit.

0.99 to 1.52 mm

..

ID of Valve Guide Bore

1.52 mm 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 OD of Head 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. Insert Heigh!......

0.10 mm .

OD of Insert........

ID of Insert...

6.65 to 6.77 mm .

43713 to 43.739 mm

.

Tapered

Valve Recession Below Head Surface

0.99 to 1.52 mm

Maximum Service Limit ID of Valve Guide Bore

1.52 mm 8.019 to 8.039 mm

Maximum Service Limit Rae 8·24162

mm

.41.870 to 42.130 mm

8.089 mm Revised 1-91

Printed in U.S.A.

1024-11

Valve Springs Free Length Total Coils.

55.63 mm

7.25

..

Wire Diameter.......... ..

.

4.830 to 4.930 mm

Compressed to 38.53 mm

(Valve Open) 785 to 839 N

Maximum Service Limit

.

765 N

Compressed to 49.25 mm

(Valve Closed) 285 to 321 N

Minimum Service Limit

270 N

Valve Seat Installation Dimensions Exhaust Seat Diameter of Insert

.43. 713 to 43.73 mm

Machine Insert Bore to......

.

..

.....43.647

Depth of Bore.

to 43663 mm

..........1010

to .092 mm

..0.05 to 0 102 mm

Press Fit... Intake Seat Diameter of Insert

47.063 to 47.089 mm

Machine Bore to

..46.987 to 47.013 mm

Depth of Bore

..

Press Fit.......................

'''_

10.30 to 10.50 mm 0.05 to 0.102 mm

14 mm Valve Guide Installation Dimensions Guide Diameter

14.026 to 14.038 mm

Machine Guide Bore to

13.987 to 14013 mm

Press Fit..

013 to .051 mm

Installed Height (above top of valve guide boss on head)

11.25 to 11.75 mm

Guide Installed ID

819 to 8.39 mm

SPECIAL TORQUES Aftercooler Bolts......

Metric Value 21 to 27 Nm

Alternator Bracket Bolts (Lower)

21 to 27 Nm

Alternator Bracket Bolts (Upper)

21 to 27 Nm

Alternator Retaining Bolt

21 to 27 Nm

Balancer Counter Weight Bolts....................

.. 21 to 27 Nm

Balancer Mounting Bolts Balancer Idler Gear

167 to 183 Nm ..

52 to 62 Nm

Belt Tensioner Bracket Bolts

21 to 27 Nm

Belt Tensioner Retaining Bolt.

39 to 47 Nm

Block Heater

11 to 13 Nm

Rae 8-24162

Revised 1-91

Printed in U.S.A.

1024-12

SPECIAL TORQUES (Cont'd) Camshaft Retaining Bolts

Metric Valve 21 to 27 Nm

Coolant Inlet Bolts

39 to 47 Nm

Connecting Rod Bolts..................... (Lubricate Threads with Engine Oil)

95 to 100 Nm

Cylinder Head Bolts

120 to 132 Nm

Engine Lift Bracket Bolts (Rear)

71 to 83 Nm

Exhaust Manifold Bolts

39 to 47 Nm

Fan Pulley Bracket Bolts Fan Pulley Bolts 8.8.....

..

..

23 to 26 Nm

...

37 to 43 Nm

Fan Pulley Bolts 10.9.. .

52 to 62 Nm

Flywheel Housing Bolts

.

54 to 66 Nm

Flywheel Retaining Bolts

130 to 144 Nm

Flywheel Housing Cover Bolts

21 to 27 Nm

Fuel Filter Inlet Bolt

29 to 35 Nm

Fuel Air Removal Bolt........

..

5 to 7 Nm

Fuel Filter Inlet NuL.......

29 to 35 Nm

Fuel Line Fitting (High Pressure)

22 to 28 Nm

Fuel Line Fitting (Low Pressure)

22 to 28 Nm

Fuel Shutoff Solenoid..

..

15 Nm

Front Cover Bolts....

21 to 27 Nm

Front Housing Bolts

21 to 27 Nm

Injection Pump Drive Gear Nut

59 to 71 Nm

Injection Pump Lock Bolt (Lock Position)

8 Nm

Injection Pump Lock Bolt (Unlock Position)

20 Nm

Injection Pump Retaining Nuts

21 to 27 Nm

Injection Pump Bracket Bolts

21 to 27 Nm

Injector Leak Off Bolt. Injector Retaining NuL... Rae 8-24162

. ..

..

5 to 7 Nm

..

55 to 65 Nm Revised 1-91

Printed in U.S.A

1024-13

SPECIAL TORQUES (Cont'd) Metric Valve 21 to 27 Nm

Intake Manifold Bolts.. Intake Manifold Plug Lifter Cover Bolts

115 to 135 Nm ..

21 to 27 Nm

Main Bearing Bolts (Lubricate the Thread with Engine Oil)

165 to 180 Nm

Oil Fill Tube Bolts

39 to 47 Nm

Oil Pan Drain Plug

68

108 to 132 Nm

Oil Pan Heater Plug Oil Pan Retaining Bolts

21 to 27 Nm

Oil Pump Retaining Bolts. Oil Inlet Tube Bolts

to 82 Nm

21 .

to 27 Nm 18 to 30 Nm

Oil Inlet Tube Brace..

..21 to 27 Nm 21 to 27 Nm

Oil Filter Housing Bolts Oil Relief Valve Plug

108 to 132 Nm

Primer Pump

21 to 27 Nm

Rear Seal Retaining Bolts

8 to 10 Nm

Rocker Arm Bolts

21 to 27 Nm

Starter Retaining Bolts

39 to 47 Nm

Tachometer Drive Retaining Bolts ..

2 to 4 Nm

Thermostat Housing Bolts

21 to 27 Nm

Timing Pin Retaining Bolts

4 to 6 Nm

Thrust Bearing Screws (Torx Head)

..4 to 6 Nm

Turbocharger Mounting Bolts

30 to 34 Nm

Turbocharger Drain Tube Bolts

21 to 27 Nm

Turbine Housing Bolts

9 to 13 Nm

Center Housing to Back Plate Bolts

5 to 7 Nm

Compressor Housing Bolts

5 to 7 Nm

Compressor Lock Nut...

13 to 1.5 Nm

Water Pump Mounting Bolts

21 to 27 Nm

Valve Cover Bolts..........................

21 to 27 Nm

Rae 8-24162

Revised 1-91

Printed in U.S.A.

1024-14

NOTE: The J I Case Company reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

Rac 8-24162

Revised 1-91

Printed in U.S.A.

SECTION INDEX - ENGINE Section Title

Section Number

Engine Removal and Installation................................................. Stall Tests.

.

2001

..

2002

Detailed Engine Specifications.

.

Cylinder Head and Valve Train.....

.

Cylinder Block.

Cooling System

.. ..

2455 ..2465 2565

Failure Analysis

CASE CORPORATION

2425 2445

Turbocharger............. Turbocharger

2415 .

Lubrication System...

2402

Rae 8-17161

Printed in U.S.A August. 1992

2001-3

RADIATOR REMOVAL Put identification tags on all disconnected hoses and wires. Close disconnected hoses and fittings with caps and plugs. NOTE: Cal/outs on the photographs are in the order of the procedure.

STEP 1

NOTE: During instal/ation the hood must be adjusted. Put the hood in position. Install the hardware in the hood hinges. Do not tighten the hardware. Close the hood and remove the plastic plugs for access to the hinge hardware. Push the top of the hood to the rear as far as possible and tighten the hinge hardware.

STEP 3

Park the machine on a level surface. Raise the loader and lock the support strut (1) to hold the loader.

Slowly remove the radiator cap (6).

STEP 2

Install a hose on the drain valve (7) and drain the radiator. Disconnect the upper and lower radiator hoses (8). Remove the hardware from the fan shroud (9). (bolts, lock washers, and flat washers)

NOTE: During installation fill the radiator completely and the coolant reservoir with apprOXimately 18 U.S. quarts (17 litres) of coolant. See Section 1002 for coolant specifications. Start and run the engine until the coolant is at operating temperature. Stop the engine and check for leakage. When the coolant is cold, check the coolant reservoir level. Disconnect the overflow hose (2) from the radiator neck. Remove the coolant reservoir (3). (bolts, flat washers, and self-locking nuts). Disconnect the hood cable (4) from each side of the shroud. (flat washers, spacers, lock washers, and nuts) Remove the hardware from the hood hinges (5). (bolts, flatwashers, and lock washers). Have another person help you remove the hood. The weight of the hood is approximately 75 pounds (34 kg).

Bur 8-17560

Issued 3-91

Printed in U.S.A.

2001-4

STEP 4

STEP 6

Remove the strap (10) from the top of the radiator shroud. (bolt, lock washer, and flat washer).

Remove the hardware (14) from each side of the radiator shroud. (bolts, flat washers, and nuts).

Remove the top cover (11). (bolts, lock washers, and flat washers).

Remove the radiator shroud. The weight of the radiator 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 Nm).

STEP 5

STEP 7

Disconnect the radiator brackets (13) from each side of the radiator. (bolts, lock washers, and nuts) Remove the hardware that fastens the condenser and oil cooler (15) to the radiator. (bolts, lock washers, and flat washers). Lift the radiator straight up and remove the radiator. NOTE: Installation removal.

Bur 8-17560

of the radiator is the reverse of

Issued 3-91

Printed in U.S.A.

2001-5

ENGINE REMOVAL Do steps 1 through 6 of radiator removal.

STEP 10

STEP 8

The hydraulic reservoir holds approximately 25 U.S. gallons (95 litres) of oil. Drain the oil from the hydraulic reservoir (16).

Remove the battery cover (18) from the left step. (cap screws and lock washers).

STEP 11

NOTE: During installation make sure the hydraulic reservoir is filled with oil. See Section 1002 for specifications.

STEP 9

Disconnect the ground cable(s) (19) from the battery(s) .

STEP 12 Disconnect the hose (17) from the bottom of the torque converter to drain the oil from the torque converter.

~7

Remove the bottom cover (20). (bolts, lock washers, and flat washers).

Bur 8-17560

Issued 3-91

Printed in U.S.A.

2002-4

CHECK SHEET 1.

_

(22301.,

Put a mark on each rod cap for cylinder identification.

Remove the pistons from the top of the engine block.

STEP 82

Put an identification mark on each piston for assembly.

Rae 8-24183

Revised 2-92

Printed in USA

2425-23

CYLINDER

WALL INSPECTION

STEP 85

Inspect the cylinder walls for the following conditions

Scoring on Cylinder Walls

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 combustion pressure moving the top ring against the cylinder wall. Normal wear shows acceptable cylinder wall conditions and the cylinder need not be machined.

T10764

Worn Cylinder Wall

Scoring on cylinder walls is caused by metal moving from one location to a different location. This is shown by heavy vertical lines. The vertical lines are caused by metal coming in contact with the piston. The scoring can be in one specific area or it can occur the complete length of the piston movement. If this condition is present, the cylinder must be machined and the piston and rings replaced.

T2319 A smooth surface between the upper and lower limits of the ring movement area shows a worn cylinder wall because of normal wear and the cylinder must be machined.

Rae 8-24183

Revised 2-92

Printed in U.S.A.

2425-24

STEP 86

Dusted Cylinder

T68779 Measure the cylinder wall bore for taper as follows: T40178 Too much wear in the piston ring movement shows a dusting failure.

area

A dusting failure will cause the following: 1. Upper area of piston ring wall will show wear. 2. Too much piston ring groove wear.

1. Measure the bore parallel to the crankshaft at the top end of the ring travel zone. 2. Measure the bore in the same position at the bottom end of the ring travel zone. 3. Measure the bore at right angles to the crankshaft at the top end of the ring travel zone. 4. Measure the bore in the same position at the bottom end of the travel zone.

3. Too much piston ring side clearance. 4. Washed away areas of the piston ring lands where the aluminum will be gone. 5. Piston rings will have too much face contact and wear which can be seen as a reduction in radial width and increase in end gap.

Compare the results of the measurements (1) and (3) with (2) and (4), to find out if the bore has taper. To measure use a inside micrometer, bore gauge or taper gauge. If the taper is more than 0.076 mm, bore the cylinder. See reconditioning the cylinder block.

6. Chrome piston rings will show wear through the face. The chrome will be worn off the face and base iron can be seen. 7. The cylinder heads can have smooth intake parts and worn valve guides. All of these conditions are caused by dirt which is mixed with the intake air.

Rae 8-24183

Revised 2-92

Printed in U.S.A.

2425-25

STEP 87

STEP 89 IMPORTANT: Before removing glaze, cover the crankshaft journals with a clean cloth to prevent abrasives and dirt caused by the cylinder hone from falling on the crankshaft.

T68Z~~

Measure the cylinder wall bores for out-of-round as follows: 1. Measure the bore parallel to the crankshaft at the top end of the ring travel. 2. Measure the bore in the same position at the bottom end of the ring travel. 3. Measure the bore at right angles to the crankshaft at the top end of the ring travel. 4. Measure the bore in the same position at the bottom end of the ring travel. Compare the measurements (1) and (3) to find the outof-round wear at the top end of the bore.

If new rings are used. the glaze must be removed from the cylinder bore so that the piston rings can correctly seat against the cylinder wall during the run-in time. It is recommended that a qualified engine repair shop do this work. Removing glaze can be done by using a cylinder hone with 250 to 300 grit stone. Too much glaze (smooth surface) on cylinder walls of a new engine or an engine with an overhaul is caused by run-in procedure that is not correct. Glaze does not permit the piston rings to seat correctly in the cylinder sleeves. This will cause too much oil consumption. Too much glaze on the cylinder walls can be prevented by giving your customer instructions in the correct runin procedure. See Section 2402 in the service manual for the correct run-in procedure.

Compare the measurements (2) and (4) to find the outof-round wear at the bottom of the bore. If out-of-round is more than 0.038 mm, bore the cylinders. See reconditioning the cylinder block.

STEP 88

Measure the cylinder bores. See specifications on Page 4. If the cylinder bore is more than 102.116 mm, the cylinders must be bored. See reconditioning the cylinder block. Rae 8-24183

Revised 2-92

Printed in U.S.A

2425-26

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 hone and the stones free of foreign material. Start the hone at the top of the cylinder bore and actuate the hone up and down until the correct cross-hatch pattern is reached. The correct cross-hatch pattern is 45 to 60 degrees from horizontal.

NOTE: Clean the cylinder walls until a clean white cloth keeps completely clean, one cleaning operation is not enough. IMPORTANT: Do not use gasoline, diesel fuel or kerosene to clean cylinders because these materials will not remove the abrasives from the sleeve surface.

Use a 250 to 300 grit stone to reach the correct cylinder bore finish of 0.4 to 0.8 micrometers.

Rae 8-24183

Revised 2-92

Printed in U.S.A.

2425-27

RECONDITIONING THE ENGINE CYLINDER BLOCK Checking and Resurfacing the Cylinder Block STEP 92 Clean the cylinder block completely. Remove carbon and other deposits. Check for cracks and other damage

STEP 93 Check the cylinder block surface with a straight edge and feeler gauge. Resurface the cylinder block if warpage or erosion is more than 0.010 mm in any 50 mm diameter area or if there is more than 0.075 mm overall end to end or side to side.

B902936J

Resurface the cylinder block in increments necessary to straighten the surface and maintain the surface finish according to the following specifications: A

=

0.25 mm first refacing. 0.35 mm second refacing. 0.50 mm total amount of material that can be removed.

B

=

322.90 to 323.10 mm standard 322.65 to 322.85 mm first refacing 322.40 to 322.60 mm second refacing

C

=

Surface finish 1.5 to 3.2 micrometers

o = Use this area to stamp an "X" when the first refacing of 0.25 mm is done. Stamp a second "XX" when the second refacing 0.50 mm total is done. NOTE: When resurfacing the block it is always necessary to machine the block to the specified dimensions. There are two thicknesses of head gasket to make up for the material removed from the cylinder block. See page 2415-30 for selection of the correct head gasket.

Rae 8-24183

Revised 2-92

Printed in U.S.A.

2425-28

Reconditioning

the Cylinder Block for Oversize Pistons

NOTE: Some of the following photographs show a cylinder block that has been cut in half for photographic purposes.

STEP 96

STEP 95

For 0.5 mm oversize pistons, machine cylinder bores to 10240 to 102.44 mm. For 1.0 mm oversize pistons, machine cylinder bores to 102.90 to 102.94 mm.

Use a cylinder hone and hone the cylinder bores to the following specifications. Use a lubricant/coolant with the hone to keep the stones clean and cool. Rough Honing - Use 80 to 150 grit stones to get a cross-hatch pattern of 45 to 60 degrees from horizontal. 0.5 mm oversize piston - 102.475 to 102.695 mm 1.0 mm oversize piston - 102.975 to 103.195 mm Finish Honing - Use 250 to 300 grit stones to get a cross-hatch pattern of 45 to 60 degrees from horizontal. 0.5 mm oversize piston - 102.50 to 102.54 mm 1.0 mm oversize piston - 103.00 to 103.04 mm Finished cylinder bore must have a surface finish of 0.4 to 0.8 micrometers with a taper of less than 0.025 mm.

Rae 8-24183

Revised 2-92

Printed in U.S.A.

2425-29

Reconditioning the Cylinder Block for Sleeves NOTE: Some of the following photographs show a cylinder block that has been cut in half for photographic purposes.

STEP 99

STEP 97

Freeze the sleeves at -12 C for at least one hour. Push the sleeves into the bore until the sleeve contacts the ridge at the bottom of the bore. 0

Put a mark on the cylinder bores 6.36 mm up from the bottom.

L>.. ••

Always wear gloves to prevent frostbite to your hands when handling frozen parts. SM118A

STEP 98

STEP 100

Bore each cylinder to a diameter of 104.485 to 104.515 mm down to the mark. Boring must be done in four steps with the final step taking a maximum of 0.125 mm. Let the block cool before the final step to prevent distortion.

Cut the top of the sleeve flush to 0.025 mm above the cylinder block surface.

Rae 8-24183

Revised 2-92

Printed in U.S.A.

2425-30

STEP 101

Bore the sleeve to a diameter of 101.90 to 101.94 mm in two steps with the final step taking a maximum of 0.125 mm. Let the sleeve cool between steps to prevent distortion.

STEP 102 Break the top edge of the sleeve with a coarse stone.

STEP 103

Use a cylinder hone and hone the cylinder bores to the following specifications. Use a lubricant/coolant with the hone to keep the stones clean and cool. Rough Honing - Use 80 to 150 grit stones to get a cross-hatch pattern of 45 to 60 degrees from horizontal. Standard

piston - 101.975 to 102.015 mm

Finish Honing - Use 250 to 300 grit stones to get a cross-hatch pattern of 45 to 60 degrees from horizontal. Standard

piston - 102.00 to 102.04 mm

Finished cylinder bore must have a surface finish of 0.4 to 0.8 micrometers with a taper of less than 0.025 mm.

Rae 8-24183

Revised 2-92

Printed in U.S.A.

2425-31

PISTION AND CONNECTING ROD DISASSEMBLY AND INSTALLATION STEP 104

STEP 106

3. RETAINING

RING

T6881 0

364L91

Remove the retaining ring, piston pin and the connecting rod from the piston.

STEP 105

T68807

365L91

Measure the inside diameter of the connecting rod for wear and out-of-round. If the inside diameter is more than 40.092 mm the connecting rod bushing must be replaced.

STEP 107 NOTE: The oil ring is

a two piece ring.

705L91

To remove and install the connecting rod bushing use a CAS-10900 connecting rod pin bushing removal and installation tool.

Rae 8-24183

Revised 2-92

Printed in U.S.A.

2425-32

STEP 108

Measure the diameter of the piston pin. If the diameter is less than 39.990 mm the piston pin must be replaced.

STEP 109

Break an old piston ring in half and use the broken ring half to clean the piston ring grooves. Too much deposit in the ring grooves can force the rings out and will cause scoring.

STEP 112

Measure the piston pin bore. If the piston pin bore is more than 40.025 mm the piston must be replaced.

STEP 110

Check the side clearance of the oil ring in the piston. Insert a feeler gauge between the upper surface of a new ring and the piston lands to check the clearance. Replace the piston if side clearance is more than 0.13 rnrn.

STEP 113

Measure the diameter of the piston across the thrust face 12 mm from the bottom of the piston at right angles to the piston pin holes. Replace the piston if the diameter is less than 101823 rnrn.

Rae 8-24183

Check the side clearance of the first and second compression rings. Replace the piston if the side clearance is more than 0.15 rnrn. Revised 2-92

Printed in U.SA

2425-33

STEP 114

·nWPRlitt!,. Clean the piston holes with a small drill or fine wire.

PISTON AND CONNECTING ROD ASSEMBLY AND INSTALLATION STEP 115

STEP 117

Put the piston rings in the cylinder and check end gap. Replace the piston rings if the end gap is more than 0806 mm.

Install the second compression ring. The piston ring must be installed with the side marked TOP toward the top of the piston to give good oil control.

STEP 116

STEP 118

. L.~";.~>".d::,.s\ii/f~~~,§2Mti Install the oil ring. Install the spring first and the oil ring second.

NOTE: The spring must be between the oil ring and the piston. Rae 8-24183

Install the first compression ring on the piston. The piston ring must be installed with the side marked TOP toward the top of the piston to give good oil control. NOTE: The top piston ring on the 4T-390 engine is a key stone type ring. Revised 2-92

Printed in U.S.A.

2425-34

STEP 122

STEP 119 1. SPECIAL LAP

B902937J

The first compression ring. In a replacement set of rings, must have a special lap design on the surface that contacts the cylinder wall.

STEP 120

---,_

T6818-J,~

..-"'." ..."".. ,.... . ,:'.-.- .. Apply lubrication to the pistons, piston rings and cylinder walls, using clean engine oil.

STEP 123

137L91

T68788

Rotate the piston rings so that the ring ends are separated by 120 degrees.

Install a ring compressor

STEP 121

STEP 124

on the piston.

PISTON PIN

T68789

364L91

Install the connecting rod, piston pin and retaining rings in the piston.

Rae 8-24183

Caref:Jlly push the piston down into the cylinder. IMPORTANT: Make sure the arrow or the word FRONT is toward the front of the engine.

Revised 2-92

Printed in U.S.A

2425-35

STEP 125

STEP 127

Measure the connecting rod journals on the crankshaft. Each journal must be a minimum of 68.962 mm in diameter. Measure the front and rear of each journal, checking for taper. If the taper is more than 0.013 mm or the journal is less than 68.962 rnrn, reconditioning of the journals must be done.

Install the liners. The liner locks must be in alignment. NOTE: When installing the liners, make sure that the liner locks are in alignment. Use a sliding type movement when installing the liners. Never push on the center of the liner locks.

STEP 126

STEP 128

k •

,.

T68783 The connecting rod journals must be checked again, 90 degrees from the first measurements for outof-round. If out-of-round is more than 0.050 mm, reconditioning of the journals must be done.

Rae 8-24183

Clean the connecting rod journals and the rod bearing liners. Put a piece of plastigage on the crankshaft journal.

Revised 2-92

Printed in U.S.A.

3425-36

STEP 131

STEP 129

I"

---.:J Install the bearing caps.

NOTE: Make sure that the number on the bearing cap is the same as the number on the connecting rod.

Lubricate the connecting rod bolts with clean engine oil and tighten the bolts to a torque of 60 Nm.

STEP 132

STEP 130

-

1. MAXIMUM LENGTH

59.25 mm

7L92

Measure the length of the connecting rod bolts. If the bolt length is more than 59.25 mm the bolt must be replaced.

IMPORTANT: Each bolt length before installation.

must

Install the torque angle gauge. Position and lock the holding rod. Move-the pointer to 60 degrees. Tighten the bolt until the pointer is at 0 degrees.

STEP 133

be checked

Remove the bearing caps and check the clearance. The clearance must be between 0.038 mm to 0.129 mm. If the clearance is more than 0.129 rnrn, undersize bearing liners must be installed and reconditioning of the bearing journals must be done by grinding.

NOTE: A clearance of 0.038 mm to 0.116 mm is required when installing new bearing liners. Rae 8-24183

Revised 2-92

Printed in U.S.A.

2425-37

STEP 134

STEP 137

Apply lubrication to the bearing liners before installation, using clean engine oil.

Install the torque angle gauge. Position and lock the holding rod. Turn the pointer to 60 degrees. Tighten the bolt until the pointer is at 0 degrees.

STEP 135

_

STEP 138 1. MAXIMUM

59.25 mm

LENGTH

__

7L92

Measure the length of the connecting rod bolts. If the bolt length is more than 59.25 mm the bolt must be replaced. IMPORTANT: Each bolt before installation.

length

Install the engine oil inlet tube. See Section 2445 of the service manual for the inlet tube and the oil pan installation.

must be checked

STEP 139

STEP 136

r

'~;l! Lubricate the connecting rod bolts with clean engine oil and tighten the bolts to a torque of 60 Nm.

Rae 8-24183

L

Use a dial indicator to check piston protrusion. The piston protrusion must not be more than 0.660 mm plus any amount of material removed during resurfacing.

Revised 2-92

Printed in U.S.A.

2425-38

STEP 140

Install the cylinder head and manifold. See Section 2415 of the service manual.

REPLACEMENT OF THE MAIN BEARINGS WITHOUT REMOVING THE CRANKSHAFT STEP 141

STEP 143

Remove the engine oil pan and gasket. 2445 of the service manual.

Remove the bolts and main bearing cap.

STEP 142

NOTE: Remove only one cap at a time to prevent the crankshaft from moving.

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

STEP 148

STEP 145

~"

•

•

•

.T58~

'.

Put a new bearing liner on the crankshaft. Use a thin piece of plastic to push the bearing liner in position.

STEP 146

6L92

Measure the length of the main bearing bolts If the bolt length is more than 119.25 mm the bolt must be replaced. IMPORTANT: Each bolt length before installation.

must be checked

STEP 149

, I..

STEP 147

'."'."

;!:

~.

Install the bearing cap and tighten the mounting bolts to a torque of 80 Nm.

STEP 150

Put a new bearing liner in the bearing cap.

NOTE: Make sure the bearing liner locks are aligned when installing the liners. Slide the liner in position. Never push on the center of the liners. Install the torque angle gauge. Position and lock the holding rod. Turn the pointer to 50 degrees.Tighten the bolt until the pointer is at 0 degrees. Rae 8-24183

Revised 2-92 Printed in U.S.A

2425-40

STEP 153

STEP 151

.•..

•

..-

~

•

T688.

6L91

Remove the bearing cap and check the clearance Clearance must be 0.041 to 0.140 mm. New liners must be installed if the clearance is more than 0.140 mm.

Measure the length of the main bearing bolts. If the bolt length is more than 119.25 mm the bolt must be replaced.

NOTE: The crankshaft must be reconditioned if the clearance is more than 0. 119 mm with the new liners.

IMPORTANT: Each bolt before installation.

STEP 152

STEP 154

Add lubrication to the bearing liners bearing cap.

Add lubrication to the mounting bolts. Install the mounting bolts and tighten to a torque of 80 Nm.

length

must be checked

STEP 155

Install the torque angle gauge. Position and lock the holding rod. Turn the pointer to 60 degrees.Tighten the bolt until the pointer is at 0 degrees. Rae 8-24183

Revised 2-92

Printed in U.SA

2425-41

STEP 156

STEP 157

-~, e" ,.

!o_,~"~ __ "_",~__ .~.""~, ••••• """""",,,,-,,._,, • T7Sfr28· Remove the nut and washer from the injection pump shaft.

STEP 28

Loosen the lock bolt and remove the slotted tab.

STEP 26 Install the gear puller and tighten the bolts until the gear is loose on the injection pump.

Tighten the lock bolt to a torque of 27 to 33 Nm.

Rae 7-37141

Revised 2-92

Printed in U.S.A.

3415-10

Installation STEP 31

STEP 29

.....

",,_

.• _,,'0_.

~"~_'

8906

'_"""""_"'.

Install the slotted tab and tighten the lock bolt to a torque of 12 to 14 Nm.

LETIER

B

=

BOSCH PUMPS

Install the drive gear on the injection pump shaft. Make sure the correct letter on the drive gear and the mark on the camshaft are aligned. NOTE: The slot in the drive gear and the key on the pump shaft must be aligned.

STEP 33

STEP 30

. T78828 Install the washer and nut on the injection pump shaft.

Rae 7-37141

Pull the locking pin out of the camshaft gear.

Tighten the drive gear nut to a torque of 59 to 71 Nm.

Revised 2-92

Printed in U.S.A.

3415-11

STEP 34

INJECTION PUMP TIMING STEP 35

STEP 36

Make sure the locking pin is engaged in the camshaft gear.

TG3414

If the pump shaft is not in the locked position, rotate the shaft clockwise until the key in pump shaft and the slot in the drive gear are aligned.

Rae 7-37141

Revised 2-92

Printed in U.S.A.

3415-12

STEP 37

STEP 40

Install the injection pump into the drive gear Make sure the slot in the drive gear and the key on the pump shaft are aligned,

Install the slotted tab and tighten the lock bolt to a torque of 12 to 14 Nm.

STEP 38

STEP 41

Pull the locking pin out of the camshaft gear. Install the three nuts and the bracket bolt. Tighten the nuts and bracket bolt a small amount.

STEP 42

STEP 39

Tighten the drive gear nut to a torque of 59 to 71 Nm. Install the washer and nut on the injection pump shaft. Tighten the drive gear nut a small amount.

Rae 7-37141

Revised 2-92

Printed in U.S.A.

3415-13

STEP 43

STEP 45

Remove the plug from the rear of the injection pump.

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

Remove the caps from the injection pump. Pull the locking pin out of the camshaft gear.

Rae 7-37141

Revised 2-92

Printed in U.S.A.

3415-14

STEP 48

STEP 50

Push in on to the locking pin and turn the engine clockwise until the lock pin engages in the camshaft gear. The dial indicator must read 1.8 mm. If the reading is not correct continue to Step 51. If the reading is correct go to Step 53.

STEP 51

Install the engine turn over tool into the flywheel housing . Turn the engine counterclockwise until there is no movement in the dial indicator.

STEP 49 Loosen the bracket bolt and the nuts that hold the injection pump to the front cover,

STEP 52

Turn the dial indicator dial to zero.

Rotate the injection pump until the dial indicator reading is 1.8 mm. NOTE: If 1.8 mm can not be reached go to Step 44 in this Section. Rae 7-37141

Revised 2-92

Printed in U.S.A.

3415-15

STEP 53

STEP 56

22 Tighten the bracket bolt and the nuts that hold the injection pump to the front cover to a torque of 21 to 27 Nrn.

STEP 54

Install the sealing washer and the leak off fitting. There must be a sealing washer on each side of the leak off line. Tighten the leak off fitting to a torque of 13 to 17 Nm.

STEP 57

Remove the dial indicator from the injection pump.

STEP 55

Install the inlet line. Install a sealing washer on each side of the inlet line and tighten the inlet fitting to a torque of 22 to 28 Nm.

STEP 58

Install the injection pump plug and tighten to a torque of 23 Nm.

Connect and tighten the injector lines to the fuel injectors and the injection pump.

Rae 7-37141

Revised 2-92

Printed in U.S.A.

3415-16

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.

FUEL SHUT-OFF SOLENOID Removal and Disassembly STEP 61

STEP 62

Remove the fuel shut-off solenoid from the injection pump.

Disassemble the fuel shut-off. Check the plunger solenoid for scoring. Clean the orifice hole with a small piece of wire.

Rae 7-37141

Revised 2-92

Printed in U.S.A

3415-17

Assembly and Installation STEP 63

STEP 64

Assemble the fuel shut-off solenoid as shown.

Install the fuel shut-off solenoid and tighten to a torque of 43 Nm.

6

PRIMER PUMP Removal STEP 65

STEP 66

Remove the fuel inlet line.

Remove the primer pump from the cylinder block.

Rae 7-37141

Revised 2-92

Printed in U.S.A.

3415-18

Installation STEP 67

STEP 68

Tighten the bolts that hold the primer pump to the cylinder block.

Tighten the inlet fitting to a torque of 32 Nm.

TIMING LOCKING PIN Removal STEP 69

STEP 70

Remove the retaining ring from the locking pin housing.

Remove the locking pin from the housjnq.

Rae 7-37141

Revised 2-92

Printed in U.SA.

3415-19

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.

Rac 7-37141

Revised 2-92

Printed in U.S.A.

SECTION

INDEX - ELECTRICAL

Section Title

Section Number

Removal and Installation of Electrical Components

.4001

Electrical Specifications, Troubleshooting,

.4002

and Schematics

Batteries

4003

Starter and Starter Solenoid

.4004

95 Ampere Alternator

4006

65 Ampere Alternator

4007

Instrument Cluster

.4008

CASE CORPORATION

Bur 8-17200

Section 4001 REMOVAL AND INSTALLATION OF ELECTRICAL COMPONENTS

CASE CORPORATION

Bur 8-17210

Printed in U.S.A. Issued January 1991

4001-2

TABLE OF CONTENTS STARTER

3

Removal

3

Installation

.4

ALTERNATOR

5

Removal

5

Installation

6

DRIVE BELT REPLACEMENT

7

INSTRUMENT CLUSTER

8

Removal

8

Installation

8

Replacing a Bulb

8

Gauge, Voltmeter, or Tachometer Removal and Installation

8

Circuit Board

8

SPECIFICATIONS Alternator pulley shaft nut Crankshaft pulley cap screws

Bur 8-17210

50 pound-feet (68 Nm) 70 to 84 pound-feet (95 to 114 Nm)

Issued 1-91

Printed in U.S.A.

4001-3

STARTER Removal

9.

1. Park the machine on a level surface and apply the parking brake.

10. Disconnect the wires and cables from the terminals on the starter.

Open the hood.

2. Remove the pin that fastens the support strut to the loader frame. 3. Raise the loader frame until the support strut is against the end of the lift cylinder. 4. Stop the engine and install the pin in the support strut. 5. Remove the cap screws and lock washers that fasten the battery cover to the right side of the machine. 6.

Remove the battery cover.

7. If the machine has only one battery. disconnect the negative battery cable from the battery.

11. Remove the two cap screws and lock washers that fasten the starter to the flywheel housing.

8. If the machine has two batteries. remove the terminal nut. Remove the negative battery cable from the terminal and move the negative battery cable away from the battery. Make sure the jumper cable is installed on the terminal and start the terminal nut onto the terminal.

12. Remove the starter.

Bur 8-17210

Issued 1-91

Printed in U.S.A.

4001-4

Installation 1.

5. If the machine has only one battery, connect the negative battery cable to the battery.

Put the starter in place on the flywheel housing.

2. Install the cap screws and lock washers that fasten the starter to the flywheel housing. Make sure the ground cable is installed under the upper cap screw.

6. If the machine has two batteries, remove the terminal nut from the terminal. Install the negative battery cable on the terminal. Make sure the jumper cable is installed on the terminal. Install the terminal nut on the terminal. 3. Connect the wires and cables to the terminals on the starter.

7. 4.

Close the hood.

Bur 8-17210

Install the battery cover.

8. Install the cap screws and lock washers that fasten the battery cover to the machine.

Issued 1-91

Printedin U.S.A.

4001-5

ALTERNATOR Removal

9.

1. Park the machine on a level surface and apply the parking brake.

10. Install a 1/2 inch breaker bar in the bracket for the tension pulley.

Open the hood.

2. Remove the pin that fastens the support strut to the loader frame. 3. Raise the loader frame until the support strut is against the end of the lift cylinder. 4. Stop the engine and install the pin in the support strut. 5. Remove the cap screws and lock washers that fasten the battery cover to the right side of the machine. 6.

Remove the battery cover.

7. If the machine has only one battery, disconnect the negative battery cable from the battery.

11. Use the breaker bar to move the tension pulley just far enough to release the tension on the drive belt and remove the drive belt from the alternator. 12. Move the rubber boot out of the way and disconnect the cable from the alternator.

8. If the machine has two batteries, remove the terminal nut. Remove the negative battery cable from the terminal and move the 'negative battery cable away from the battery. Make sure the jumper cable is installed on the terminal and start the terminal nut onto the terminal.

Bur 8-17210

13. Disconnect the wire from the alternator. 14. Disconnect the connector from the alternator.

Issued 1-91

Printed in U.S.A.

4001-6 15. Remove the cap screw and lock washer that fasten the link to the bottom of the altnerator.

6.

Tighten the nut to 50 pound-feet (68 Nm).

7.

Remove the alternator from the vise.

8. Hold the alternator in alignment with the mounting bracket and install the cap screw and the flat washer at the top of the alternator. Do not tighten the cap screw. 9. Install the cap screw and lock washer that fasten the link to the bottom of the alternator. 10. Tighten both of the cap screws. 11. Install the wire on the B + terminal.

16. Hold the alternator and remove the cap screw and lock washer at the top of the alternator. 17. Remove the alternator from the mounting bracket. 18. Fasten the pulley of the alternator in a vise that has soft jaws. 19. Remove the nut and lock washer from the shaft of the alternator. 20. Remove the alternator from the vise. 21. Hit the face of the pulley with a soft hammer to loosen the tapered bushing in the pulley.

12. Install the lock washer and the nut on the B + terminal. 13. Connect the connectors to the alternator. 14. Use the breaker bar to move the tension pulley just far enough to install the drive belt. Install the drive belt on the alternator. 15. Remove the breaker bar. 16. Close the hood. 17. If the machine has only one battery, connect the negative battery cable to the battery.

22. Remove the tapered bushing and pulley from the shaft. 23. Remove the fan from the shaft.

Installation 1.

Install the fan on the shaft.

2.

Install the pulley on the shaft.

3.

Install the tapered bushing on the shaft.

4.

Start the lock washer and the nut onto the shaft.

5.

Fasten the pulley in a vise that has soft jaws.

Bur 8-17210

Issued 1-91

Printed in U.S.A.

4001-7 18. If the machine has two batteries, remove the terminal nut from the terminal. Install the negative battery cable on the terminal. Make sure the jumper cable is installed on the terminal. Install the terminal nut on the terminal.

19. Install the battery cover. 20. Install the cap screws and lock washers that fasten the battery cover to the machine.

DRIVE BELT REPLACEMENT 1. Park the machine on a level surface and apply the parking brake. 2. Remove the pin that fastens the support strut to the loader frame. 3. Raise the loader frame until the support strut is against the end of the lift cylinder.

9. Remove the four cap screws, flat washers, and lock washers that fasten the coupling to the pulley on the crankshaft. 10. Move the coupling toward the hydraulic pump. 11. Remove the old drive belt.

4.

Stop the engine.

12. Install the new drive belt on the pulley on the water 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.

7. Install a 1/2 inch breaker bar in the bracket for the tension pulley.

14. Install the cap screws, flat washers, and lock washers that fasten the coupling to the pulley on the crankshaft. Tighten the cap screws to 70 to 84 poundfeet (95 to 114 Nm).

8. Use the breaker bar to move the tension pulley just far enough to release the tension on the drive belt. Remove the drive belt from the alternator.

15. Use the breaker bar to move the tension pulley just far enough to install the drive belt. Install the drive belt on the alternator. 16. Remove the breaker bar. 17. Close the hood.

Bur 8-17210

Issued 1-91

Printed in U.S.A.

4001-8

INSTRUMENT CLUSTER Removal 1 . Remove the screws (16) that fasten the instrument cluster to the instrument console.

2. Pull the instrument cluster out of the instrument console. 3. Disconnect the connectors for the wiring harness from the instrument cluster 4.

Remove the instrument cluster from the machine.

Installation 1. Connect the connectors for the wiring harness to the instrument cluster. 2. Install the instrument cluster in the instrument console. 3. Install the screws (16) that fasten the instrument cluster to the instrument console.

Gauge, Voltmeter, or Tachometer Removal and Installation 1. Remove the instrument cluster from the instrument console. 2. Remove the four screws (10) that fasten the cover (17) and the retainer (18) to the body (11). 3.

Remove the cover (17).

4.

Remove the retainer (18).

5. Remove the screws (21) thatfasten the gauge (1,2, or 15), voltmeter (14) or the tachometer (13) to the body (11) . 6. Remove the gauge (1, 2, or 15), voltmeter (14), or tachometer (13) from the body (11). If you are removing a gauge (1,2, or 15) or voltmeter (14), you must pull the studs of the gauge (1, 2, or 15) or voltmeter (14) from the clips (4) in the body (11).

1. Remove the instrument cluster from the instrument console.

7. Install a new gauge (1, 2, or 15), voltmeter (14) or tachometer (13) in the body (11). If you are installing a gauge (1, 2, or 15) or voltmeter (14), make sure the studs of the gauge (1, 2, or 15) or voltmeter (14) are pushed into the clips (4) in the body (11).

2. Turn the socket (5) counterclockwise the socket (5).

8. Install the screws (21) that fasten the gauge (1,2, or 15), voltmeter (14), or tachometer (13) to the body (11).

Replacing a Bulb

and remove

3. Pull the bulb (3) from the socket (5) and install a new bulb (3). 4. Install the socket (5) and turn the socket (5) clockwise to hold the socket (5) in place. 5. Install the instrument console.

cluster in the instrument

9.

Install the retainer (18).

10. Install the cover (17). 11. Install the screws (10) that fasten the cover (17) and the retainer (18) to the body (11). 12. Install the instrument console.

cluster in the instrument

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.

Bur 8-17210

Issued 1-91

Printedin U.S.A.

4001-9

4.CUP

6. RUBBER BOOT

2. OIL TEMPERATURE GAUGE 1. WATER TEMPERATURE GAUGE

18. RETAINER

20. IDENTIFICATION

STRIP

17. COVER

B861764R

Bur 8-17210

Issued 1-91

Printed in U.S.A.

Section

4002 ELECTRICAL SPECIFICATIONS, TROUBLESHOOTING, AND SCHEMATICS

CASE CORPORATION

Bur 8-17220

Printed in U.S.A. Issued January 1991

4002-2

TABLE OF CONTENTS SPECIFICATIONS

3

Starting, Charging, and Instrument Cluster Circuits

.4

Warning Buzzer, Parking Brake, Backup Alarm, and Clutch Cutout..

12

Return-To-Dig, Cab Relay, Lamp Switches, Turn Signal and Flashers

20

Flood Lamp Switch, High Pressure Switch, and Air Conditioning Compressor Clutch

28

Cab Harness

32

Canopy Harness

50

Cab Harness (Continued)

42

USING BOOSTER BATIERIES TO START THE ENGINE

58

ALPHABETICAL INDEX OF COMPONENTS

59

Bur 8-17220

Issued 1-91

Printed in U.S.A.

4002-3

SPECIFICATIONS Electrical system, standard Electrical system, optional System voltage Batteries, standard Production battery J I Case part number Group size Reserve capacity Cold cranking capacity At OaF (-17°C) At -20°F (-29°C) Load for Capacity (Load) Test. Plates per cell Approximate weight with electrolyte Nonspill caps Replacement battery . J I Case part number Group size Reserve capacity Cold cranking capacity At OaF (-1JOC) At -20°F (-29°C) Load for Capacity (Load) Test Plates per cell Approximate weight with electrolyte Nonspill caps Batteries, optional Production battery J I Case part number Group size Reserve capacity Cold cranking capacity At OaF (-17°C) At -20°F (-29°C) Load for Capacity (Load) Test Plates per cell , , , , Approximate weight with electrolyte Nonspill caps Replacement battery J I Case part number Group size ,' Reserve capacity Cold cranking capacity At OaF (-1JOC) At -20°F (-29°C) Load for Capacity (Load) Test Plates per cell Approximate weight with electrolyte Nonspill caps Alternator Standard Optional Voltage regulator Starter

Bur 8-17220

One 12 volt battery, negative ground Two 12 volt batteries connected in parallel, negative ground Approximately 12 volts

0132475 29H 160 minutes 650 amperes 487 amperes 325 amperes 16 56 pounds (25.4 kg) Not required on this machine A180406 or BMF31 E 31 170 minutes

,

700 amperes 520 amperes 350 amperes 17 57 pounds (25.8 kg) Not required on this machine

0128393 or BMF28SW 28 110 minutes

,

" ..,

,

,

525 390 265 , ' ' , 44 pounds Not required on this

amperes amperes amperes ,..,.'.. 12 (19.9 kg) machine

.0127414 or BMF28S 28 110 minutes 525 amperes 390 amperes 265 amperes 12 29 pounds (13.2 kg) Not required on this machine

'

" ,

12 volts, 65 amperes 12 volts, 95 amperes solid state, not adjustable 12 volt, solenoid actuated

Issued 1-91

Printed in U.S.A.

4002-4

Starting, Charging, and Instrument Cluster Circuits REF

COLOR

FROM

TO

1A 1B 1C 1D 3 4 8 19B 21A 21 B 22

Red Red Red Red Red/lt Blue Orange/White Orange/Black Yellow/White Red/Black White/Red White White/Red

Starter Alternator Cab Relay Starter Relay Key Switch (Batt.) 10 Ampere Fuse Cab Relay Diode Instrument Cluster Starter Relay Starter Solenoid Alarm Harness Connector

23F

White/Orange

Battery Battery Starter Battery Cab Relay Key Switch (Ign.) Key Switch (Ace.) Key Switch (Momentary Grd.) 15 Ampere Fuse Key Switch (Start) Starter Relay Starter Relay and Neutral Start Switch 10 Ampere Fuse

28 30 31 P

Gray/Orange Black/Yellow Yellow/Black

Ether Injection Switch Neutral Starter Switch Instrument Cluster

31 S 31T 32F 32T 33 34 36F 36H 36P

Yellow/Red Yellow Orange/Blue Yellow/Green Purple Yellow/Ok Blue Yellow/Orange Yellow/Purple Yellow/Brown

Alternator Tach Output Coolant Temperature Sender Transmission Filter Switch Converter Temp Sender Master Cylinder Reservoir Alternator Fuel Level Sender Hydraulic Filter Switch Parking Brake Switch

38 41

Yellow/Blue Pink

Air Filter Switch Instrument Cluster

o

Bur 8-17220

WIRE GAUGE

Instrument Cluster and Alarm Harness Connector Ether Injection Solenoid Ground Instrument Cluster and Alarm Harness Connector Instrument Cluster Instrument Cluster Instrument Cluster Instrument Cluster Instrument Cluster Instrument Cluster Instrument Cluster Instrument Cluster Instrument Cluster and Alarm Harness Connector Instrument Cluster Driving Lamp Switch and Driving Lamps

Issued 1-91

Cable 8 12 12 12 14 16 14 14 16 12 16 16 16 12 18 18 18 18 18 18 18 18 18 18 18 12

Printed in U.S.A.

4002-5

Starting, Charging, and Instrument Cluster Circuits

NOTE: The battery must be at full charge and all connections clean and tight before testing. Use a multimeter for the tests.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 1A to ground

12 volts

Check wire 1A between the positive battery terminal and alternator.

Approximately 10 volts

Check the wire between the alternator and the instrument cluster. Check the instrument cluster on page 4002-9.

NOTE: Turn key switch to

ON.

Terminal for wire 34 to ground

NOTE: If the readings are good, see Section 4006 or 4007 and repair the alternator.

Check Points

Reading

Possible Cause of Bad Reading

Battery terminal of starter solenoid to ground

12 volts

Check the battery cable to the positive post of the battery.

NOTE: Put the transmission control lever in NEUTRAL. Have another person hold the key switch in the START position. Terminal for wire 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.

Bur 8-17220

Issued 1-91

Printed in U.S.A.

4002-6

Check Points

Reading

Possible Cause of Bad Reading

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 the IGN terminal of the key switch

Continuity

Bad key switch (4).

Check between the BAT terminal and the ACC terminal of the key switch

Continuity

Bad key switch (4).

NOTE: Have another person hold the key switch in the

START position.

Between the START terminal and the BAT terminal of the key switch

Continuity

Bad key switch (4).

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 1C to ground

12 volts

Check wire 1C between the starter relay (5) and battery.

NOTE: Put the transmission control lever in Terminal for wire 22 to ground

NEUTRAL

Continuity

NOTE: Put the transmission control lever in

Bad circuit between the starter relay (5) and the neutral start switch (6). Also check the neutral start switch (6).

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).

Terminal for wire 21 B to ground

12 volts

Bad starter relay (5).

Check Points

Reading

Possible Cause of Bad Reading

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).

Bur 8-17220

Issued 1-91

Printedin U.S.A.

4002-7

Check Points

Reading

Possible Cause of Bad Reading

NOTE: Disconnect the wires from the ether injection switch. Push down and hold the button. Check between the terminals of the ether injection switch.

Continuity

Bad ether injection switch.

NOTE: If the reading is good, check wire 21 A between the cold start button and the key switch (4). Also check ether injection solenoid (8).

Check Points

Reading

Possible Cause of Bad Reading

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. 12 volts

Terminal for wire 28 to ground

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.

Reading

Check Points

Possible Cause of Bad Reading

NOTE: Disconnect the wires from the ether injection temperature switch. Make sure the engine is cold. Check between the terminals of the ether injection temperature switch

Continuity

Bad ether injection temperature switch.

Check Points

Reading

Possible Cause of Bad Reading

12 volts

Check circuit between the fuel shutoff solenoid and the key switch (4). Check the key switch (4).

NOTE: Turn the key switch to Terminal for wire 3to ground

ON.

NOTE: If the reading is good, replace the fuel shutoff solenoid.

Bur 8-17220

Issued 1-91

Printed in U.SA

4002-8

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 30 to ground

Continuity

Bad ground circuit.

12 volts

Bad circuit between master cylinder reservoir level switch and instrument cluster (14). Also check the instrument cluster (14).

NOTE: Turn the key switch to

ON.

Terminal for wire 33 to ground

NOTE: If the readings are good, replace the master cylinder resetvoir level switch.

Check Points

Reading

Possible Cause of Bad Reading

Check between the housing of the coolant temperature sender and the engine block.

Continuity

Bad ground connection between the coolant temperature sender and the engine block.

12 volts

Check circuit between the coolant temperature sender and instrument cluster (14). Also check the instrument cluster (14).

NOTE: Turn the key switch to

ON.

Terminal for wire 31T to ground

NOTE: If the readings are good, replace the coolant temperature sender.

Check Points

Reading

Possible Cause of Bad Reading

Check between the housing of the converter temperature sender and the converter housing.

Continuity

Bad ground connection between the converter temperature sender and the converter housing.

12 volts

Check the circuit between the converter temperature sender and the instrument cluster (14). Also check the instrument cluster (14).

NOTE: Tum the key switch to

ON.

Terminal for wire 32T to ground

NOTE: If the readings are good, replace the converter temperature sender.

Bur 8-17220

Issued 1-91

Printed in U.S.A.

4002-9

NOTE: Disconnect the connector from the instrument cluster. Turn the key switch and driving lamp switch to ON. Apply the parking brake. Check Points

Reading

Possible Cause of Bad Reading

Terminal T1 in connector to terminal for wire 33 at the master cylinder reservoir level switch (11)

Continuity

Check the circuit between the connector and the master cylinder reservoir level switch (11). Also check the master cylinder reservoir level switch (11) .

Terminal T2 in connector to ground

12 volts

Check the circuit between the connector and the 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 for wire 34 at alternator (2)

Continuity

Check the circuit between the connector and the 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 for wire 38 at the air filter switch filter switch. See page 4002-19

Continuity

Check the circuit between the connector and air filter switch. Also check the air filter switch. See page 4002-19.

NOTE: Have another person hold the key switch in the momentary ground position, halfway between ON and START. Terminal T8 in connector to ground

Continuity

Check the circuit from the connector through the diode to the key switch (4). Also check the diode in the circuit. See page 4002-19.

Terminal T9 in connector to ground

12 volts

Check jumper wire from T2 to T9.

Terminal T10 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).

NOTE: Turn the key switch to

ON.

Continued on next page

Bur 8-17220

Issued 1-91

Printed in U.S.A.

4002-10 Check Points

Reading

Possible Cause of Bad Reading

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 T15 in connector to ground

Continuity

Bad ground circuit.

Terminal T18 in connector to terminal for wire 36H at the hydraulic filter switch. See page 4002-19.

Continuity

Check the circuit between the connector and the hydraulic filter switch. Also check the hydraulic filter switch. See page 4002-19.

NOTE: Have another person hold the key switch in the momentary ground position, halfway between Terminal T18 in connector to ground

Continuity

ON and START.

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.

NOTE: Disconnect the tachometer wires from the instrument cluster. Terminal for wire 31S to terminal for wire 31 S at the alternator (2)

Continuity

Check the circuit between the connector and the alternator (2). Also check the alternator (2).

Terminal for wire 10 to ground

Continuity

Check wire 10 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: Turn the key switch to

ON.

Terminal for wire 23F to ground

NOTE: Disconnect the wires for the transmission filter warning lamp from the instrument cluster. Terminal for wire 32F to terminal for wire 32F at the transmission filter switch

NOTE: Turn the key switch to

Continuity

Check the circuit between the connector and the transmission filter switch. Also check the transmission filter switch. See page 4002-19.

12 volts

Check the circuit between the connector and the key switch (4). Also check the 10 ampere fuse and the key switch (4).

ON.

Terminal for wire 23F to ground

NOTE: Have another person hold the key switch in the momentary ground position, halfway between Terminal for wire 32F to ground

Bur 8-17220

Continuity

ON and START.

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.

Issued 1-91

Printedin U.S.A.

CONNECTORS A.. B. C. AND 0 CONNECTOR G

Main chassis harness 10 side console harness

Main chassis harness IransaxJe harness

STARTING, CHARGING, AND INSTRUMENT CLUSTER

10

11 ill

4002-12

Warning Buzzer, Parking Brake, Backup Alarm, and Clutch Cutout REF

COLOR

FROM

TO

4 8 10A 12C 13B2 13B3 13B4 19E

Black Black Orange/Black YellowlWhite Black/Orange Red Orange/Black Orange/Black Orange/Black Red/Blue

Backup Alarm Pressure Switch Backup Alarm Key Switch (Ace.) Key Switch (Momentary Grd) Alarm Harness Connector Cab Relay Cab Relay Fuse Boom Lock Switch 15 Ampere Fuse

14 14 16 14 14 12 16 16 16 14

22

White/Red

22 23F

Blue White/Orange

Starter Relay and Neutral Start Switch Alarm Harness Connector 10 Ampere Fuse

Backup Alarm Chassis Ground Cab Relay Diodes Ground 5 Ampere Fuse 3 Ampere Fuse Boom Lock Switch Boom Lock Solenoid Clutch Cutout Switch, ReturnTo-O:- Magnetic Detent. and Return- To-Dig Harness Alarm Harness Connector

16 16

23F 23G 25 25

Red RedlWhite Orange/Blue White/Blue

Alarm Harness ':onnector Diode Clutch Cutout Switch Loader Handle Harness

25

Gray

30 30

BlackiYeliow Black

30 30B6 31 P

Black Black Yellow/Black

Transaxle Harness, Pin B of Connector G Clutch Cutout Solenoid Transaxle Harness, Pin C of Connector G Return-To-Dig Harness Boom Lock Solenoid Oil Pressure Switch

Parking Brake Relay Instrument Cluster and Alarm Harness Connector Diode Parking Brake Relay Loader Handle Harness Transaxle Harness, Pin B of Connector G Clutch Cutout Solenoid

31 P 32F 3QF

Green Orange/Blue

o o

36H

't'ellawlQrange YellowlPurpfe Yellow/Brown

Alarm Harness Connector Transmission Filter Switch Fuel Level Sender Hydraulic Filter Switch Parking Brake Switch

36P 37 37 38 39A 39A 39B 39B 41 51A 30

White YellowlWhite Brown Yellow/Blue PurplelYeliow Orange PurplelWhite Purple Pink RedlYeliow Black/Yellow

Alarm Harness Connector Engine Temperature Switch Alarm Harness Connector Air Filter Switch Warning Alarm (Positive) Alarm Harness Connector Warning Alarm (Negative) Alarm Harness Connector Light Switch 5 Ampere Fuse Parking Brake Switch

36P

Bur 8-17220

WIRE GAUGE

16

16 18 16 16 16

Ground Ground

12 16

Ground Ground Instrument Cluster and Alarm Harness Connector Diode Instrument Cluster Instrument Cluster Instrument Cluster Instrument Cluster and Alarm Harness Connector Parking Brake Relay Alarm Harness Connector Parking Brake Relay Instrument Cluster Alarm Harness Connector Parking Brake Relay Alarm Harness Connector Parking Brake Relay Driving Lamps Backup Alarm Pressure Switch Ground

16 16 18

Issued 1-91

18 18 18 18 18 18 18 18 18 18 18 18 18 12 14 12

Printedin U.SA

4002-13

Warning Buzzer, Parking Brake, Backup Alarm, Clutch Cutout NOTE: The batteries must be at full charge and all connections clean and tight before testing. Use a multimeter for the tests.

Check Points

NOTE: Turn tne key switch to

Possible Cause of Bad Reading

Reading ON. If the warning buzzer

does not sound, do the following checks.

Terminal for wire 39A to ground

12 Volts

Check the circuit between the warning buzzer and the key switch. Also check the 10 ampere fuse and the key switch. See page 4002-11.

Terminal for wire 39B to ground

Continuity

Check the circuit between the warning buzzer and the engine oil pressure switch (3). Also check the engine oil pressure switch (3). Check the diode in wire 31P.

NOTE: If the readings are good, replace the warning buzzer.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 10 to ground

Continuity

Bad ground circuit.

12 volts

Check the circuit between the engine temperature switch and the parking brake relay (6). Also check the parking brake relay (6).

NOTE: Turn the key switch to Terminal for wire 37 to ground

ON.

NOTE: If the readings are good, replace the engine temperature switch.

Bur 8-17220

Issued 1-91

Printed in U.S.A

4002-14

Check Points

Reading

Possible Cause of Bad Reading

Check between the housing of the oil pressure switch and the engine block

Continuity

Bad ground connection between the oil pressure switch and the engine block.

12 volts

Check the circuit between the engine oil pressure switch and the instrument cluster. Also check the instrument cluster. See page 4002-11 .

NOTE: Turn the key switch to

ON.

Terminal for wire 31 P to ground

NOTE: If the readings are good, replace the engine oil pressure switch.

Check Points

Reading

Possible Cause of Bad Reading

Check between the housing of the fuel level sender and the machine frame

Continuity

Bad ground connection between the fuel level sender and the machine frame.

12 volts

Check the circuit between the fuel level sender and the instrument cluster. Also check the instrument cluster. See page 4002-11.

NOTE: Turn the key switch to

ON.

Terminal for wire 36F to ground

NOTE: If the readings are good, replace the fuel level sender.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 30 to ground

Continuity

Bad ground connection.

12 volts

Check the circuit between the parking brake switch and the instrument cluster. Also check the instrument cluster. See page 4002-11 .

NOTE: Turn the key switch to

ON.

Terminal for wire 36P to ground

NOTE: If the readings are good, replace the parking brake switch.

Bur 8-17220

Issued 1-91

Printed in U.S.A.

4002-15

Check Points

Reading

NOTE: Make sure the transmission control lever is in Terminal for wire 22 to ground

Possible Cause of Bad Reading NEUTRAL.

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.

Check Points

Reading

Possible Cause of Bad Reading

Check between the housing of the transmission filter switch and the transmission housing

Continuity

Bad ground connection.

12 volts

Check the circuit between the transmission filter switch and the instrument cluster. Also check the instrument cluster. See page 4002-11 .

NOTE: Turn the key switch to

NOTE: Turn the key switch to

ON.

ON.

Terminal for wire 32F to ground

NOTE: If the readings are good, replace the transmission filter switch.

Check Points

Reading

Possible Cause of Bad Reading

Check between the housing of the hydraulic filter switch and the filter housing

Continuity

Bad ground connection.

12 volts

Check the circuit between the hydraulic filter switch and the instrument cluster. Also check the instrument cluster. See page 4002-11.

NOTE: Turn the key switch to

ON.

Terminal for wire 36H to ground

NOTE: If the readings are good, replace the hydraulic filter switch.

Bur 8-17220

Issued 1-91

Printed in U.S.A.

4002-16

Check Points

Reading

Possible Cause of Bad Reading

Terminai for wire 30 to ground

Continuity

Bad ground connection.

Terminal for wire 38 to ground

12 volts

Bad circuit between the air filter switch and the instrument cluster. Also check the instrument cluster. See page 4002-11 .

Check Points

Reading

Possible Cause of Bad Reading

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 400227.

NOTE: Turn the key switch to

NOTE: Turn the key switch to

ON.

ON.

Terminal for wire 51A to ground

NOTE: Start and run the engine at low idle. Have another person hold down both brake pedals and shift the transmission into REVERSE. Terminal for wire 0 to ground

12 volts

Bad backup alarm pressure switch.

Check Points

Reading

Possible Cause of Bad Reading

Negative terminal to ground

Continuity

Bad ground circuit.

NOTE: Start and run the engine at low idle. Have another person hold down both brake pedals and shift the transmission into REVERSE. Positive terminal to ground

12 volts

Check the circuit between the the backup alarm and the backup alarm pressure switch (10). Also check the backup alarm pressure switch (10).

NOTE: If the readings are good, replace the backup alarm.

Bur 8-17220

Issued 1-91

Printed in U.S.A.

4002-17

Check Points

Reading

Possible Cause of Bad Reading

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. Terminal for wire 19E to ground

NOTE: Push down and hold the clutch cutout switch. Terminal 25 to ground

12 volts

Bad clutch cutout switch.

Check Points

Reading

Possible Cause of Bad Reading

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.

Check Points

Reading

Possible Cause of Bad Reading

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.

12 volts

8ad boom lock switch.

NOTE: Turn the key switch to ON. Terminal for wire 1383 to ground

NOTE: Turn the boom lock switch ON. Terminal for wire 1384 to ground

Bur 8-17220

Issued 1-91

Printed in U.S.A.

4002-18

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 30B6 to ground

Continuity

Bad ground circuit.

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: Turn the key switch to ON. Terminal for wire 13B4 to ground

NOTE: If the readings are good, replace the boom lock solenoid.

Check Points NOTE: Turn the key switch to

Reading

Possible Cause of Bad Reading

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.

ON.

Terminal for wire 19E to ground

NOTE: Push down and hold the clutch cutout switch. Terminal 25 to ground

Bur 8·17220

12 volts

Bad clutch cutout switch.

Issued 1-91

Printed in U.S.A.

Bur 8·17220

Issued 1·91

Printedin USA

4002-20

RETURN-TO-DIG, CAB RELA.Y, LA.MP SWITCHES, TURN SIGNAL AND FLA.SHERS REF

COLOR

FROM

1B 10 4 10 12A 12B 12C 13B2 19A 19B

Red Red/Lt Blue Orange/Black Black/Orange Red/Black Red/Orange Red Orange/Black Red Red/Black

Starter Key Switch Key Switch Cab Relay Cab Relay Cab Relay Cab Relay Cab Relay 25 Ampere 15 Ampere

190

RedlYellow

15 Ampere Fuse

19E

Red/Blue

15 Ampere Fuse

19E

Red

Return-To-Dig Harness

30 30

Black/Yellow Black

42R 44 45L 45R 46 47L 47R 48 53

Ok BluelWhite Tan Ok BrownlYellow Ok Brown/Green Ok Brown Lt Brown/Yellow Lt Brown/Green Lt BrownlWhite Purple/Red

54 64A

Brown/Pink Orange/Blue

64B

Green/Red

Turn Signal Indicator Lamps Return-to-Dig Relay and Proximity Switch Driving Lamp Switch Stop Lamp Switch Turn Signal Switch Turn Signal Switch Flasher Switch Left Turn Signal Switch Right Turn Signal Switch Rotating Beacon Switch Return-To-Dig and Auxiliary Hydraulic Switch Return-To-Dig Relay Turn Signal Switch and Horn Button Horn Relay

Bur 8-17220

TO

(Batt.) (Ace.)

Fuse Fuse

WIRE GAUGE

Cab Relay Cab Relay Cab Relay Ground 25 Ampere Fuse 10 Ampere and 15 Ampere Fuse 5 Ampere Fuse 3 Ampere Fuse Driving Lamp Switch Stop, Flasher Switch, Turn Signal Switch and Horn Button, Instrument Cluster Rotating Beacon and Dipper Lamp Switch, Flasher Clutch Cutout Switch, ReturnTo-Dig Magnetic Detent, and Return-To-Dig Harness Return-To-Dig Relay and Proximity Switch Ground Ground

6 12 16 12 12 12 12 16 12 14

Rear Working Lamp Brake Lamps Left Turn Signal Lamps Right Turn Signal Lamps Flasher (T1 Terminal) Left Turn Signal Indicator Right Turn Signal Indicator Rotating Beacon Loader Valve

12 14 14 14 14 18 18 14 16

Proximity Switch Horn Relay

16 16

Horn

16

Issued 1-91

14 14

16 12

Printed in U.S.A.

4002-21

Return-To-Dig, Cab Relay, Lamp Switches, Turn Signals, and Flashers NOTE: The battery must be at full charge and all connections clean and tight before testing. Use tests.

Check Points NOTE: Turn the key switch to

a multimeter for the

Reading

Possible Cause of Bad Reading

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).

ON.

Terminal for wire 19E to ground

NOTE: Disconnect the connector from the proximity switch (3). Terminal for wire 54 to terminal for wire 54 in connector for proximity switch (3)

Continuity -

Check wire 54.

Terminal for wire 30 to ground

Continuity

Bad ground connection

Terminal for wire 53 to ground

Approximately 12 volts

Check the circuit between the return-to-dig relay and the magnetic detent (2). Also check the magnetic detent (2).

Check Points

Reading

Possible Cause of Bad Reading

NOTE: Disconnect the wires from the magnetic detent. Turn the key switch to

ON.

Terminal in harness for wire 19E to ground

12 volts

Check the circuit between the magnetic detent and the cab relay (7). Also check the 15 ampere fuse on page 4002-19 and the cab relay (7).

Between the terminals magnetic detent

Continuity

Bad magnetic detent.

of the

NOTE: Also check the return-to-dig relay (1) and the proximity switch (3).

Bur 8-17220

Issued 1-91

Printed in U.S.A.

4002-22

Check Points

Reading

Possible Cause of Bad Reading

NOTE: Disconnect the connector from the proximity switch. Terminal for wire 30 in connector to ground

Continuity

Bad ground circuit.

.Terminal for wire 19E in connector to ground

12 volts

Check the circuit between the proximity switch 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 12 volts

Check the circuit between the proximity switch and the return-to-dig relay (1). Also check the return-to-dig relay (1).

NOTE: Turn the key switch to

ON .

NOTE: If the readings are good, replace the proximity switch.

Check Points

Reading

Possible Cause of Bad, Reading

Ground terminal to ground

Continuity

Bad ground circuit.

NOTE: Turn the key switch to

ON.

Terminal for wire 64B to ground

Have another person hold down the horn button. 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).

NOTE: If the readings are good, install a new horn.

Bur 8-17220

Issued 1-91

Printed in U.S.A

4002-23

Check Points

NOTE: Turn the key switch to

Reading

Possible Cause of Bad Reading

12 volts

Check the circuit between the horn relay and the cab relay (7). Also check the 15 ampere fuse and the cab relay (7).

ON.

Both terminals for wire 19B to ground

NOTE: Push down and hold the horn button (5). 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).

NOTE: Push down and hold the horn button (5). Terminal for wire 64B to ground

12 volts

Bad horn relay.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 30 to ground

Continuity

Bad ground connection.

Terminal for wire 53 to ground

Approximately 10 volts

Check the circuit between the optional switch relay and the magnetic detent (2). Also check the magnetic detent (2).

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 10 to ground

Continuity

Check wire 10 to ground.

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, or 12C and ground

12 volts

Bad cab relay.

NOTE: Turn the key switch to

NOTE: Turn the key switch to

Bur 8-17220

ON.

ON.

Issued 1-91

Printed in U.S.A.

4002-24

Check Points NOTE: Turn the key switch to

Reading

Possible Cause of Bad Reading

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).

ON.

Terminal for wire 19A to ground

NOTE: Turn the driving lamp switch to ON. Terminal for wire 41 to ground

12 volts

Bad driving lamp switch.

Terminal for wire 42R to ground

12 volts

Bad driving lamp switch.

NOTE: If the readings are good but the illumination lamps in the instrument cluster still do not work, check the instrument cluster. See page 4002-11.

Check Points NOTE: Tum the key switch to

Reading

Possible Cause of Bad Reading

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).

ON.

Terminal for wire 19B to ground

NOTE: Have another person push down and hold the brake pedals. Terminal for wire 44 to ground

12 volts

Bad stop lamp switch.

Check Points

Reading

Possible Cause of Bad Reading

12 volts

Check the circuit between the flasher switch and the cab relay (7). Also check the 15 ampere fuse and the cab relay (7).

12 volts

Bad flasher switch.

NOTE: Turn the key switch to

ON.

Terminal for wire 19B to ground

NOTE: Turn the flasher switch Terminal for wire 46 to ground

Bur 8-17220

ON.

Issued 1-91

Printed in U.S.A.

4002-25

Check Points NOTE: Turn the key switch to

Reading

Possible Cause of Bad Reading

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).

ON.

Terminal for wire 190 to ground

NOTE: Turn the rotating beacon switch ON. Terminal for wire 48 to ground

12 volts

Bad rotating beacon switch.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire T3 to ground

Continuity

Bad ground connection.

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: Turn the key switch to Terminal T2 to ground

ON.

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 T5 to ground

Intermittent 12 volts

Bad flasher.

Terminal T7 to ground

Interm ittent 12 volts

Bad flasher.

Terminal T6 to ground

Interm ittent 12 volts

Bad flasher.

Terminal T3 to ground

Interm ittent 12 volts

Bad flasher.

Bur 8-17220

Issued 1-91

Printed in U.S.A.

4002-26

Check Points

NOTE: Turn the key switch to

Reading

Possible Cause of Bad Reading

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).

ON.

Terminal for wire 19B to ground

NOTE: Make sure the flasher switch is in the Terminal for wire 45R to ground

12 volts

NOTE: Make sure the flasher switch is in the Terminal for wire 45L to ground

OFF position. Move the turn signal switch for

Bad turn signal switch.

OFF position. Move the turn signal switch for

12 volts

a left turn.

a right turn.

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 30 to ground

NOTE: Turn the key switch to

Continuity

Bad ground connection.

Approximately 10 volts

Ch8Ck wire 64A between the horn button and the horn relay (5). Also check the horn relay (5).

ON.

Terminal for wire 64A to ground

NOTE: If the readings are good, install a new turn signal switch and horn button.

Check Points

Reading

Possible Cause of Bad Reading

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to

ON.

Move the turn signal switch (13) for

a left turn.

Terminal for wire 47L to ground

Intermittent 12 volts

Check the circuit between the left turn signal indicator lamp and the flasher (12). Also check the flasher (12).

Terminal for wire 30 to ground

Continuity

Bad ground circuit.

Check Points

Reading

Possible Cause of Bad Reading

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to

ON.

Move the turn signal switch (13) for

a right turn.

Terminal for wire 47R to ground

Intermittent 12 volts

Check the circuit between the right turn signal indicator lamp and the flasher (12). Also check the flasher (12).

Terminal for wire 30 to ground

Continuity

Bad ground circuit.

Bur 8-17220

Issued 1-91

Printedin U.S.A.

Bur 8-172~

Issued 1-91

Printed in U.S.A.

4002-28

FLOOD LAMP SWITCH, HIGH PRESSURE SWITCH, AND AIR CONDITIONING COMPRESSOR CLUTCH REF

COLOR

FROM

TO

10 12C

Red/Lt Blue Red

Cab Relay Cab Relay

19C 40A 40B 41 42C 42F 42R 44 45L 45R 48 49 60 60A

Red/White Black Blacx/white Pink Ok Blue/Orange Ok Blue Ok Blue/White Tan OK Brown/Yellow Ok Brown/Green Lt Brown/White Gray Orange/Brown Orange/Black

12 12 12 12 12 12 12 14 14 14 14 16 16 16

60B 61 63

Orange/Green Gray/White Orange/Purple

20 Ampere Fuse Lamps Lamps Light Switch Flood Light Switch Flood Light Switch Light Switch Brake Switch Left Turn Signal Switch Right Turn Signa! Switch Rotating Beacon Switch 10 Ampere Fuse Compressor Clutch Relay Compressor Clutch Relay and Low Pressure Switch Compressor Clutch Relay 15 Ampere Fuse 15 Ampere Fuse

10 Ampere Fuse 15 Ampere Fuse and 20 Ampere Fuse Flood Lamp Switch Ground Ground Driving Lamps Rear Flood Lamps Front Flood Lamps Rear Working Lamp Brake Lamps Left Turn Signal Lamps Right Turn Signal Lamps Rotating Beacon Dome Lamp High Pressure Switch High Pressure Switch Air Conditioning Compressor Clutch Blower Wipers

16 14 14

Bur 8-17220

WIRE GAUGE

Issued 1-91

12 12

Printed in U.S.A.

4002-29

Flood Lamp Switch, High Pressure Switch, and Air Conditioning Clutch Circuit Checks

Compressor

NOTE: The battery must be at full charge and al/ connections clean and tight before testing. Use a multimeter for the tests.

Check Points

Reading

NOTE: Put the key switch in the

to

ON position.

Possible Cause of Bad Reading

Turn the blower switch to HIGH and the air conditioning temperature switch

COLD.

12 volts

Terminal for wire 60 to ground

Bad circuit between the high pressure switch and the air conditioning temperature switch.

NOTE: Disconnect the wires from the high pressure switch. Between the terminals of the high pressure switch

o

Open

High charge in the air conditioning system. See Section 9002. Bad high pressure switch.

Air Conditioning Compressor Clutch

Check Points

Reading

Possible Cause of Bad Reading

Ground wire of the air conditioning clutch to ground

Continuity

Bad ground wire.

NOTE: Turn the key switch to COLD.

ON.

Turn the cab blower switch to HIGH and the air conditioning temperature switch to

12 volts

Terminal for 60B to ground

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.

Check Points NOTE: Turn the key switch to

Reading

Possible Cause of Bad Reading

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.

ON.

Terminal for wire 19C to ground

NOTE: Turn the flood lamp switch to ON. Terminal for wire 42F to ground

12 volts

Bad flood lamp switch.

Terminal for wire 42C to ground

12 volts

Bad flood lamp switch.

Bur 8-17220

Issued 1-91

Printed in U.S.A.

4002-30

This page left blank.

Bur 8- 7220

Issued 1-91

Printed in U.S.A.

CONNECTORS A, B

MAin chassis haroos harness.

FLOOD LAMP SWITCH, HIGH PRESSURE SWITCH, AIR CONDITIONING COMPRESSOR CLUTCH

Bur 8-17220

ISSUfld 1-91

t

4002-32

CAB HARNESS REF

COLOR

FROM

TO

40A 40B 41 42C 42F 42R 44 45L 45R 48 49 60 60A

Black Black/White Pink Ok Blue/Orange Ok Blue Ok BluelWhite Tan OK Brown/Yellow Ok Brown/Green Lt BrownlWhite Gray Orange/Brown Orange/Black

Ground Ground Driving Lamps Rear Flood Lamps Front Flood Lamps Rear Flood Lamp Brake Lamps Left Turn Signal Lamps Right Turn Signal Lamps Rotating Beacon Dome Lamp Switch High Pressure Switch High Pressure Switch

12 12 12 12 12 12 14 14 14 14 16 16 16

60B

Orange/Green

Lamps Lamps Light Switch Flood Light Switch Flood Light Switch Light Switch Brake Switch Left Turn Signal Switch Right Turn Signal Switch Rotating Beacon Switch 10 Ampere Fuse Compressor Clutch Relay Compressor Clutch Relay and Low Pressure Switch Compressor Clutch Relay

16

61 61B 63 63A 66 67 69 80 81 82 85

GraylWhite Gray/Black Orange/Purple Orange/Purple Green Red Yellow Black Gray White Orange/Green

15 Ampere Fuse Dome Lamp Switch 15 Ampere Fuse Front Wiper Switch Front Wiper Switch (Low) Front Wiper Switch (High) Front Wiper Switch (Park) Rear Wiper Motor (Ground) Rear Wiper Switch (Low) Rear Wiper Switch (High) Blower Switch

86 87 88

Lt Blue Blue Lt BluelWhite

Blower Switch (Low) Blower Switch (Medium) Blower Switch (High)

Air Conditioning Compressor Clutch Blower Switch Dome Lamps Wipers Front Wiper Motor Front Wiper Motor (Low) Front Wiper Motor (High) Front Wiper Motor (Park) Rear Wiper Park Switch Rear Wiper Motor (Low) Rear Wiper Motor (High) Air Conditioning Temperature Switch Resistor Board (Low) Resistor Board (Medium) Resistor Board (High)

Bur 8-17220

WIRE GAUGE

Issued 1-91

14 16 14 16 16 16 16 14 16 16 14 14 14 14

Printed in USA

4002-33

Cab Harness NOTE: The battery must be at full charge and all connections clean and tight before testing. Use tests.

Check Points

a multimetet for the

Reading

Possible Cause of Bad Reading

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: Tum the key switch to ON. Terminal for wire 49 to ground

NOTE: Put the dome lamp switch in the ON positior: Terminal for wire 61 B to ground

12 volts

Bad dome lamp switch.

Check Points

Reading

Possible Cause of Bad Reading

Bulb

Good

Bad bulb.

Terminal for wire 40A to ground

Continuity

Bad ground circuit.

NOTE: Turn the key switch to

ON.

Terminal for wire 61 B to ground

Bur 8-17220

Put the dome lamp switch (1) in the 12 volts

ON

position.

Check the circuit between the left dome lamp and the dome lamp switch (1). Also check the dome lamp switch (1).

Issued 1-91

Printed in U.S.A.

4002-34

Check Points

Reading

Possible Cause of Bad Reading

Bulb

Good

Bad bulb.

Terminal for wire 40A to ground

Continuity

Bad ground circuit.

NOTE: Turn the key switch to

ON.

Put the dome lamp switch (1) in the

ON

position.

Terminal for wire 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).

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 85 to ground

12 volts

Bad blower switch.

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.

12 volts

Bad blower switch.

NOTE: Turn the key switch to

ON.

Terminal for wire 61 to ground

NOTE: Turn the blower switch to

LOW.

Terminal for wire 86 to ground

NOTE: Turn the blower switch to

MEDIUM.

12 volts

Bad blower switch.

12 volts

Bad blower switch.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40A to ground

Continuity

Bad ground circuit.

Terminal for wire 87 to ground

NOTE: Turn the blower switch to Terminal for wire 88 to ground

NOTE: Turn the key switch to

NOTE: Turn the key switch to Terminal for wire 88 to ground

Bur 8·17220

HIGH.

ON.

ON.

Turn the blower switch to 12 volts

HIGH.

Bad circuit between the blower motor and the blower switch (4). Also check the blower switch (4).

Issued 1-91

Printedin U.S.A.

4002-35

Check Points

Reading

Possible Cause of Bad Reading

NOTE: Turn the key switch to ON. Blower switch to LOW. Terminal for wire 86 to ground

12 volts

Bad blower switch.

12 volts

Bad blower switch.

NOTE: Blower switch to MEDIUM. Terminal for wire 87 to ground

NOTE: Disconnect the connector from the resistor board. Between terminals 1 and 3 of the resistor board

3.8 ohms

Bad resistor board.

Check Points

Reading

Possible Cause of Bad Reading

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: Turn the key switch to Terminal for wire 63 to ground

ON.

NOTE: Turn the rear wiper switch to LOW. Terminal for wire 81 to ground

12 volts

Bad rear wiper switch.

NOTE: Turn the rear wiper switch to HIGH. Terminal for wire 82 to ground

Bur 8-17220

12 volts

Bad rear wiper switch.

Issued 1-91

Printed in U.S.A.

4002-36

Reading

Check Points

NOTE: Make sure the rear wiper is not in the Terminal for wire 80 to ground

NOTE: Turn the key switch to

Possible Cause of Bad Reading

PARK position.

Continuity

Check the rear wiper park switch (9). Bad ground circuit.

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.

ON.

Terminal for wire 63 to ground

NOTE: Turn the rear wiper switch to

HIGH.

12 volts

Terminal for wire 82 to ground

NOTE: Turn the rear wiper switch to

Check the circuit between the rear wiper motor and the rear wiper switch (7). Also check the rear wiper switch (7).

LOW.

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).

Check Points

Reading

Possible Cause of Bad Reading

NOTE: Disconnect the wires from the rear wiper park switch. Make sure the rear wiper is in the Between the terminals of the rear wiper park switch

NOTE: Move the wiper out of the Between the terminals of the rear wiper park switch

Bur 8-17220

Open,

PARK position.

Bad rear wiper park switch.

PARK position.

Continuity

Bad rear wiper park switch.

Issued 1-91

Printed in U.S.A.

4002-37

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40B to ground

Continuity

Bad ground circuit.

NOTE: Turn the key switch to ON. Turn the blower switch to ON and the air conditioning temperature switch to COLD. Terminal for wire 60 to ground

12 volts

Bad circuit between the compressor clutch relay and the air conditioning temperature switch (11). Also check the air conditioning temperature switch (11).

Terminal for wire 60A to ground

12 volts

Bad low pressure switch (13) or high pressure switch. Also check the low pressure switch (13) and the high pressure switch. See page 4002-31 for the high pressure switch.

Terminal for wire 60B to ground

12 volts

Bad compressor

Check Points

Reading

Possible Cause of Bad Reading

NOTE: Turn the key switch to

ON.

Terminal for wire 85 to ground

Turn the blower switch to 12 volts

clutch relay.

HIGH.

Bad circuit between the air conditioning temperature 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

Check Points

Reading

Possible Cause of Bad Reading

Bulb

Good

Bad bulb.

Terminal for wire 40B to ground

Continuity

Bad ground circuit.

Bur 8-17220

temperature switch.

Issued 1-91

Printed in U.S.A.

4002-38

Check Points

NOTE: Turn the key switch to

Reading ON.

Turn the blower switch to

Possible Cause of Bad Reading HIGH

and the air conditioning temperature switch to

cow.

Terminal for wire 60 to ground

12 volts

Bad circuit between the low pressure switch and the air conditioning thermostat switch.

NOTE: Disconnect the wires from the low pressure switch. Between the terminals of the low pressure switch

Open

Low charge in the air conditioning system. See Section 9002. Bad low pressure switch.

Check Points

Reading

Possible Cause of Bad Reading

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 69 to ground

12 volts

Bad front wiper switch.

NOTE: Turn the key switch to

ON.

NOTE: Turn the front wiper switch to Terminal for wire 66 to ground

NOTE: Turn the front wiper switch to Terminal for wire 67 to ground

Bur 8-17220

LOW.

12 volts

Bad front wiper switch.

HIGH.

12 volts

Bad front wiper switch.

Issued 1-91

Printedin U.S.A.

4002-39

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40A to ground

Continuity

Bad ground circuit.

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).

NOTE: Turn the key switch to ON.

NOTE: Turn the front wiper switch to Terminal for wire 67 to ground

NOTE: Turn the front wiper switch to

HIGH.

12 volts

Check the circuit between the front wiper motor and the front wiper switch (7). Also check the front wiper switch (7).

LOW.

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).

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40B to ground

Continuity

Bad ground circuit.

NOTE: Turn the key switch and rotating beacon switch to ON. Bulb

Good

Bad bulb.

Terminal for wire 48 to ground

12 volts

Circuit between the rotating beacon and the rotating beacon switch. Also check the rotating beacon switch. See page 4002-27.

NOTE: /f the readings are good, rep/ace the rotating beacon.

Bur 8-17220

Issued 1-91

Printed in U.S.A.

4002-40

This page left blank.

Bur 8-17220

Issued 1-91

Printed in U.S.A.

4002-41

(

CONNECTOR

Connects one harT1 harness.

CAB HARNESS

Bur 8-17220

Issued 1-91

Printed in U.SA

41'UVc:.-""tL

CAB HARNESS (Continued) REF

COLOR

FROM

TO

40A 40B 41

Black Black/white Pink

Lamps Lamps Driving Lamp Switch

41T 42C 42F 42R 44 45L 45R

Pink Dk Blue/Orange Dk Blue Dk BluelWhite Tan DK Brown/Yellc': Dk Brown/Gree

Rear Light Harness Flood Lamp Switch Flood Lamp Switch Driving Lamp Switch Stop Lamp Switch Turn Signal Switch Turn Signal Switch

Ground Ground Driving Lamps and Rear Light Harness Tail Lamps Rear Flood Lamps Front Flood Lamps Rear Work Lamps Brake Lamps Left Turn Signal Lamps Right Turn Signal Lamps

Bur 8-17220

WIRE GAUGE

Issued1-91

12 12 12 16 12 12 12 14 14 14

Printedin USA

4002-43

Cab Harness (Continued) NOTE: The battery must be at full charge and a/l connections clean and tight before testing. Use a multimeter for the tests.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40B to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Tum the key switch to

ON.

Turn the driving lamp switch to

ON.

Terminal for wire 42R to ground

12 volts

Bad circuit between the rear LH work lamp and the driVing lamp switch. Also check the driving lamp switch. See page 4002-27.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40B to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Tum the key switch to

ON.

Turn the flood lamp switch to

ON.

Terminal for wire 42C to ground

12 volts

Bad circuit between the rear LH flood lamp and the flood lamp switch. Also check the flood lamp switch. See page 4002-31.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40B to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Tum the key switch to

ON.

Terminal for wire 42C to ground

Bur 8-17220

Turn the flood lamp switch to 12 volts

ON.

Bad circuit between the rear RH flood lamp and the flood lamp switch. Also check the flood lamp switch. See page 4002-31.

Issued 1-91

Printed in U.S.A.

4002-44

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40B to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to ON. Turn the driving lamp switch to ON. Terminal for wire 42R to ground

12 volts

Bad circuit between the rear RH work lamp and the drivinq lamp switch. Also check the driving lamp switch. See page 4002-27.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40A to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Tum the key switch to

ON. Make sure the flasher switch is OFF. Move the turn signal lever for

a

left turn.

Terminal for wire 45L to ground

Intermittent 12 volts

Bad circuit between the front left turn signal and flasher lamp and turn signal switch. Also check the turn signal switch. See page 4002-27.

Check Points

Reading

Possible Cause of Bad Reading

Terminal 40A to ground

Continuity

Bad ground connection.

Bulb

Good

Bad bulb.

NOTE: Turn the key switcr: to ON. Turn the driving lamp switch to ON. Terminal for wire 41 to ground

Bur 8-17220

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.

Issued 1-91

Printed in U.S.A.

4002-45

Check Points

Reading

Possible Cause of Bad Reading

Terminal 40A to ground

Continuity

Bad ground connection.

Bulb

Good

Bad bulb.

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.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40A to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

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.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40A to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to

ON.

Terminal for wire 42F to ground

Bur 8-17220

Turn the flood lamp switch to 12 volts

ON.

Bad circuit between the front RH flood lamp and the flood lamp switch. Also check the flood lamp switch. See page 4002-31.

Issued 1-91

Printed in U.S.A.

4002-46

Check Points

Reading

Possible Cause of Bad Reading

Terminal 40A to ground

Continuity

Bad ground connection.

Bulb

Good

Bad bulb.

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.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40A to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to

ON.

Make sure the flasher switch is

OFF.

Move the turn signal lever for a right turn.

Terminal for wire 45R to ground

Intermittent 12 volts

Bad circuit between the front RH turn signal and flasher lamp and turn signal switch. Also check the turn signal switch. See page 4002-27.

Check Points

Reading

Possible Cause of Bad Reading

Terminal 40A to ground

Continuity

Bad ground connection.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to Terminal for wire 41 to ground

Bur 8-17220

ON.

Turn the driving lamp switch to 12 volts

ON.

Bad circuit between the front RH marker lamp and the driving lamp switch. Also check the driving lamp switch. See page 4002-27.

Issued 1-91

Printed in U.S.A.

4002-47

Check Points

Reading

Possible Cause of Bad Reading

Terminal 40B to ground

Continuity

Bad ground connection.

Bulb

Good

Bad bulb.

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.

Check Points

Reading

Possible Cause of Bad Reading

Terminal 40B to ground

Continuity

Bad ground connection.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to ON. Have another person push down and hold the brake pedals. Terminal for wire 44 to ground

12 volts

Bad circuit between the LH brake lamp and the stop lamp switch. Also check the stop lamp switch. See page 4002-27.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40B to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to ON. Make sure the flasher switch is OFF. Move the turn signal lever for Terminal for wire 45L to ground

Bur 8-17220

Intermittent 12 volts

a left turn.

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.

Issued 1-91

Printed in U.S.A.

4002-48

Check Points

Reading

Possible Cause of Bad Reading

Terminal 40B to ground

Continuity

Bad ground connection.

Bulb

Good

Bad bulb.

NOTE: Tum the key switch to ON. Tum the driving lamp switch to ON. Terminal for wire 41T to ground

12 volts

Bad circuit between the RH tail lamp and the driving lamp switch. Also check the driving lamp switch. See page 4002-27.

Check Points

Reading

Possible Cause of Bad Reading

Terminal 40B to ground

Continuity

Bad ground connection.

Bulb

Good

Bad bulb.

NOTE: Tum the key switch to

ON.

Have another person push down and hold the brake pedals.

Terminal for wire 44 to ground

12 volts

Bad circuit between the RH brake lamp and the stop lamp switch. Also check the stop lamp switch. See page 4002-27.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40A to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Tum the key switch to ON. Make sure the flasher switch is OFF. Move the tum signal lever for a right tum. Terminal for wire 45R to ground

Bur 8-17220

Intermittent 12 volts

Bad circuit between the rear RH turn signal and flasher lamp and the turn signal switch. Also check the turn signal switch. See page 4002-27.

Issued 1-91

Printedin U.S.A.

4002-4

CAB HARNESS (COnt\nued)

I

~

Issued 1-91

BUr 8-17220

Printed In

u.s.~

4002-50

CANOPY HARNESS REF

COLOR

FROM

TO

40A

Black

Lamps

Ground

40B

BlacklVYhite

Lamps

Ground

12

41

Pink

Driving Lamp Switch

Driving Lamps and Rear Light Harness

12

42C

Ok Blue/Orange

Flood Light Switch

Rear Flood Lamps

12

42F

Ok Blue

Flood Light Switch

Front Flood Lamps

12

42R

Ok BluelWhite

Driving Lamp Switch

Rear Work Lamps

12

44

Tan

Stop Lamp Switch

Brake Lamps

14

45L

OK Brown/Yellow

Turn Signal Switch

Left Turn Signal Lamps

14

45R

Ok Brown/Green

Turn Signal Switch

Right Turn Signal Lamps

14

48

Lt BrownlWhite

Rotating Beacon Switch

Rotating Beacon

14

Bur 8-17220

WIRE GAUGE 12

Issued 1-91

Printed in U.S.A.

4002-51

NOTE: The batteries must be at full charge and all connections clean and tight before testing. Use a multimeter for the tests.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40B to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to

ON.

Turn the driving lamp switch to

ON.

Terminal for wire 42R to ground

12 volts

Bad circuit between the rear LH work lamp and the driving lamp switch. Also check the driving lamp switch. See page 4002-27.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40B to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

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.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40B to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to

ON.

Terminal for wire 42C to ground

Bur 8-17220

Turn the flood lamp switch to 12 volts

ON.

Bad circuit between the rear RH flood lamp and the flood lamp switch. Also check the flood lamp switch. See page 4002-31.

Issued 1-91

Printed in U.S.A.

4002-52

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40B to giOund

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to

ON.

Turn the driving lamp switch to

ON.

Terminal for wire 42R to ground

12 volts

Bad circuit between the rear RH work lamp and the driving lamp switch. Also check the driving lamp switch. See page 4002-27.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40A to ground

Continuity

Bad ground circuit

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to

ON.

Make sure the flasher switch is

OFF.

Move the turn signal fever for a left turn.

Terminal for wire 45L to ground

Intermittent 12 volts

Bad circuit between the front LH turn signal and flasher lamp and turn signal switch. Also check the turn signal switch. See page 4002-27.

Check Points

Reading

Possible Cause of Bad Reading

Terminal 40A to ground

Continuity

Bad ground connection.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to Terminal for wire 41 to ground

Bur 8-17220

ON.

Turn the driving lamp switch to 12 volts

ON.

Bad circuit between the front LH driving lamp and the driving lamp switch. Also check the driving lamp switch. See page 4002-27.

Issued 1-91

Printed in U.S.A.

4002-53

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40A to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

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.

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40A to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

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.

Check Points

Reading

Possible Cause of Bad Reading

Terminal 40A to ground

Continuity

Bad ground connection.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to Terminal for wire 41 to ground

Bur 8-17220

ON.

Turn the driving lamp switch to 12 volts

ON.

Bad circuit between the front RH driving lamp and the driving lamp switch. Also check the driving lamp switch. See page 4002-27.

Issued 1-91

Printed in U.S.A.

4002-54

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40A to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to ON. Make sure the flasher switch is OFF. Move the tum signal lever for

a right turn.

Terminal for wire 45R to ground

Intermittent 12 volts

Bad circuit between the front RH turn signal and flasher lamp and the turn signal switch. Also check the turn signal switch. See page 4002-27.

Check Points

Reading

Possible Cause of Bad Reading

Terminal 40B to ground

Continuity

Bad ground connection.

Bulb

Good

Bad bulb.

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.

Check Points

Reading

Possible Cause of Bad Reading

Terminal 40B to ground

Continuity

Bad ground connection.

Bulb

Good

Bad bulb.

NOTE: Tum the key switch to ON. Have another person push down and hold the brake pedals. Terminal for wire 44 to ground

Bur 8-17220

12 volts

Bad circuit between the LH brake lamp and the stop lamp switch. Also check the stop lamp switch. See page 4002-27.

Issued 1-91

Printedin U.S.A.

4002-55

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40B to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to ON. Make sure the flasher switch is OFF. Move the turn signal 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.

Check Points

Reading

Possible Cause of Bad Reading

Terminal 40B to ground

Continuity

Bad ground connection.

Bulb

Good

Bad bulb.

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.

Check Points

Reading

Possible Cause of Bad Reading.

Terminal 40B to ground

Continuity

Bad ground connection.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to ON. Have another person push down and hold the brake pedals. Terminal for wire 44 to ground

Bur 8-17220

12 volts

Bad circuit between the RH brake lamp and the stop lamp switch. Also check the stop lamp switch. See page 4002-27.

Issued 1-91

Printed in U.S.A

4002-56

Check Points

Reading

Possible Cause of Bad Reading

Terminal for wire 40A to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to ON. Make sure the flasher switch is OFF. Move the turn signal lever for a right turn. Terminal for wire 45R to ground

Interm ittent 12 volts

Bad circuit between the rear RH turn signal and flasher lamp and the turn signal switch. Also check the turn signal switch. See page 4002-27.

Check Points

Reading

Possible Cause of Bad Reading

Continuity

Bad ground circuit.

Terminal ground

for

ground

wire

to

NOTE: Turn the key switch and rotating beacon switch to ON. Bulb

Good

Bad bulb.

Terminal for wire 48 to ground

12 volts

Circuit between the rotating beacon and the rotating beacon switch. Also check the rotating beacon switch. See page 4002-27.

NOTE: If the readings are good, replace the rotating beacon.

Bur 8-17220

Issued 1-91

Printed in U.S.A.

4002-57

4002-58

USING BOOSTER BATIERIES TO START THE ENGINE 1. Sit in the operators seat and have the other person make the connections. 2. If using another machine for power, make sure the two machines do not touch. 3. Connect the positive (+) positive (+) battery terminal.

Single Battery

jumper cable to the

4. Connect the negative (-) jumper cable to a good ground away from the battery. 5. Start the engine and have the other person disconnect the negative (-) jumper cable first and the positive ( +) jumper cable last.

Dual Battery

Two persons are required for this procedure. Make sure the person making the connections is wearing face protection. Use a 12 volt booster battery.

Bur 8-17220

Issued 1-91

Printed in U.S.A.

4002-59

ALPHABETICAL INDEX OF COMPONENTS A

K

Air Conditioning Compressor Clutch Air Conditioning Indicator Lamp Air Conditioning Temperature Switch Air Filter Switch Alternator

29 37 37 16 5

Key Switch L LH Brake Lamp with Cab LH Brake Lamp with Canopy LH Tail Lamp with Cab LH Tail Lamp with Canopy Left Dome Lamp Left Turn Signal Indicator Lamp Loader Valve Return-Te-Dig Magnetic Detent.. Low Pressure Switch

B Backup Alarm and Pressure Switch Batteries Blower Motor and Blower Switch Blower Resistor Board Boom Lock Solenoid Boom Lock Switch

16 5 34 35 18 17

Cab Relay Clutch Cutout Solenoid Clutch Cutout Switch - Loader Handle Clutch Cutout Switch - Shift Handle Compressor Clutch Relay Converter Temperature Sender Coolant Temperature Sender

M

Dome Lamp Switch Driving Lamp Switch

Neutral Start Switch

a

•

with Cab with Canopy

with Cab with Canopy

24 29 .45 52 45 53 44 44 52 46 53 .45 53 46 .46 54 39 38 14 7

H 29 .22 22 23 15

15 14 22

R

14 13 7 7 7

F

RH Brake Lamp with Cab RH Brake Lamp with Canopy RH Tail Lamp with Cab RH Tail Lamp with Canopy Rear LH Flood Lamp with Cab Rear LH Flood Lamp with Canopy Rear LH Turn Signal and Flasher Lamp Rear LH Turn Signal and Flasher Lamp Rear LH Work Lamp with Cab Rear LH Work Lamp with Canopy Rear RH Flood Lamp with Cab Rear RH Flood Lamp with Canopy Rear RH Turn Signal and Flasher Lamp Rear RH Turn Signal and Flasher Lamp Rear RH Work Lamp with Cab Rear RH Work Lamp with Canopy Rear Wiper Motor and Park Switch Rear Wiper Switch Return- To-Dip Relay Right Dome Lamp Right Tum Signal Indicator Lamp Rotating Beacon with Canopy Rotating Beacon with Cab Rotating Beacon Switch

with Cab with Canopy

with Cab with Canopy

Bur 8-17220

48 55 48 55 .43 51 .47 55 43 51 .43 51 .48 56 44 52 36 35 21 34 26 56 39 25

S Starter Relay Starter and Solenoid Stop Lamp Switch

6 5 24

T Transmission Filter Switch Turn Signal Switch

15 .25 W

Warning Buzzer Instrument Cluster

23

P Parking Brake Relay Parking Brake Switch Proximity Switch

E

:

6

Optional Switch for Hand Held Hydraulic Attachments

33 24

Engine Oil Pressure Switch Engine Temperature Switch Ether Injection Solenoid Ether Injection Switch Ether Injection Temperature Switch

8

N

23 17 18 17 37 8 8

o

High Pressure Switch Horn Horn Button Horn Relay Hydraulic Filter Switch

.47 54 .47 54 33 26 21 38

Master Cylinder Reservoir Level Switch

C

Flasher Switch Flood Lamp Switch Front LH Driving Lamp with Cab Front LH Driving Lamp with Canopy Front LH Flood Lamp with Cab Front LH Flood Lamp with Canopy Front LH Marker Lamp Front LH Tum Signal and Flasher Lamp Front LH Tum Signal and Flasher Lamp Front RH Driving Lamp with Cab Front RH Driving Lamp with Canopy Front RH Flood Lamp with Cab Front RH Flood Lamp with Canopy Front RH Marker Lamp Front RH Turn Signal and Flasher Lamp Front RH Tum Signal and Flasher Lamp Front Wiper Motor Front Wiper Switch Fuel Level Sender Fuel Shutoff Solenoid

6

13

9 Issued 1-91

Printed in U.S.A.

Section

4003 BATTERY(S)

CASE CORPORATION

Bur 8-12350

Printed in U.S.A. Issued November 1989

4003-2

TABLE OF CONTENTS SPECIFICATIONS

See Section 4001

BOOSTER BATIERIES....

See Section 4001

SAFETY RULES SPECIAL TOOLS

:.

..

3

.

3

MAINTENANCE..

..4

Electrolyte Level

.4

Inspecting and Cleaning the Battery

.4

NONSPILL CAPS..

.

5

BATIERY TEST Visual Checks...............

6 .

6

Specific Gravity Check.

6

Capacity (Load) Test..

7

CHARGING A BATIERY.

8

PREPARING A DRY CHARGED BATIERY FOR USE.......

Bur 8-12350

.

9

Issued 11-89

Printed in U.S.A.

4003-3

SAFETY RULES

SPECIAL TOOLS '",-Order special tools from either of the following com-

"parses; "-'";:.,.;"V;:; ..,;-;::.:J::-.·;·.·

B523935M

;-;-.

Remove the O-ring and backup ring from the bottom of the gland. Discard the O-ring and backup ring.

STEP 28

STEP 26

-..._._.-

8523820M

.. ,~._

...

~~

...~?Bs47C ..•...

:.~-;':;::.,

.

.;...:

:

.

..:.

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.

Bur 8-12440

~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. 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.

Bur 8-12440

Issued 10-89

Printed in U.sA

5004-9

INSPECTION Clean all parts in cleaning solvent. Put the parts on paper towels until the parts are dry. Do not use cloths to wipe the parts dry. Check all machined surfaces for wear or damage If there are rough places on the ends of the stator and rotor, or on the machined surfaces on the body, end plate, or spacer plate, make the surfaces smooth by using 600 grit emery cloth. Put the emery cloth on a surface that is flat. The surface must be as flat as a piece of glass. If the emery cloth is new, move a piece of steel across the emery cloth six times to remove the sharp pieces of grit. Move the rotor, stator, body, end plate, or spacer across the emery cloth six times. Then check to see if the rough places have been removed. Use this method until all rough places have been removed. Make sure that the part is kept flat on the emery cloth as the part is moved across the emery cloth. Clean the parts in cleaning solvent to remove any grit on the parts.

STEP 32

Inspect the check valve in the inlet port of the body. Push the check valve in to see if the spring works correctly. If the check valve is worn or damaged, use a complete new steering control valve.

STEP 31

81758A88J

Inspect the Allen head plug, seat, steel ball, and retainer for damage or wear. Use new parts as required.

B1757A88J

STEP 34

If the spool, sleeve, or the bore in the body of the steering control valve is damaged or worn, use a complete new steering control valve. The spool, sleeve, or body of the steering control valve are not available separately

81759A88J

Inspect the washers and bearing for damage or wear. Use new parts as required.

Bur 8·12440

Issued 10-89

Printed in U.S.A.

5004-10

STEP 35

STEP 37

B1760A88J

Inspect the gland for damage or wear. Use a new gland as required. 8877703M Inspect the springs, pins, and balls for damage or wear. Use new parts as required

STEP 36

88473288M Use a feeler gauge to measure the clearance between the rotor and stator. If the clearance is more than 0.005 inch (0.13 mm), a new metering gear set must be used.

Bur 8-12440

Issued 10-89

Printed in U.S.A.

5004-11

2. END PLATE

6. STATOR

9. O-RING

8. METERING GEAR SET

27. WASHER

8871959J

Bur 8-12440

Issued 10-89

Printed in U.S.A.

5004-12

ASSEMBLY STEP 41

STEP 38

1. LARGE O-RING

852384 1M

'~~;*a8M Install a new O-ring in the bore for the gland. Lubricate the O-ring with petroleum jelly.

STEP 39

Install new O-rings on the seat for the check valve, Lubricate the O-rings with petroleum jelly, The large O-ring must be installed on the end of the seat that has threads,

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 steering control valve until the gland stops moving.

STEP 40

Use a screwdriver and punch to start the end of the retaining ring into the groove in the body. Push the retaining ring into the groove in the body. Bur 8-12440

~,_ B§J3622M Install the retainer in the bore for the check valve, Make sure the retainer is flat in the bottom of the bore,

STEP 43

Install the steel ball in the bore for the check valve,

Issued 10-89

Printed in U,S.A.

5004-13

STEP 44

STEP 47

_~ _,__~ __ ,__ ~.~_,~_~~_,__ ._~,

Install the seat for the check valve in the bore. The end of the seat with threads must be up.

..

-.---··W·~__

sse. . ,~

Install the backup ring in the bottom of the gland. Use petroleum jelly to hold the backup ring in place

STEP 45

Apply a small amount of 242 Loctite on the threads of the Allen head plug.

STEP 46

STEP 49

___

,~,___

p1888M

Install and tighten the Allen head plug to 100 poundinches (11 Nm).

Bur 8-12440

.,_." .",.~ •.•"."..,~.'-"'-""""-"W'W"-"' ..~,... 1588M Install the seal in the gland with the lip for the seal toward the outside of the body. Drive the seal into the gland until the seal stops moving.

Issued 10-89

Printed in U.S.A.

5004-14

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 position. 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 51

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 installed straight into the sleeve. Turn the spool in both directions as the spool is pushed into the sleeve.

Bur 8-12440

Assemble the centering springs in sets of three. Put the two sets of centering springs in the end of the tool with the notched corners toward the sleeve. Use your thumb and finger to compress the centering springs. Issued 10-89

Printed in U.S.A

5004-15

STEP 56

STEP 59

B523919M Push the centering springs into the spool. Move the tool as necessary to put the centering springs in position.

Install a new spacer on the spool.

STEP 60

STEP 57

8523721M

8523728M Put clean oil on the outside of the sleeve and spool.

Install the pin in the sleeve through the spool.

STEP 58

STEP 61

8523731M Install the washer, bearing, and the other washer on the spool.

Bur 8-12440

Put clean oil on the bore in the body of the steering control valve.

Issued 10-89

Printed in U.S.A.

5004-16

STEP 65

STEP 62

B877701M The sleeve and spool must be installed straight into the body of the steering control valve

Install the pins in the ports.

STEP 66

STEP 63

The pin can move out of the sleeve and spool. If the pin moves out of the sleeve and spool, the pin can keep the sleeve and spool from being pushed into the body. Hold the sleeve and spool in position in the body. Put the end of the sleeve and spool on the bench. Lower the body onto the sleeve and spool as shown.

Install the springs in the pins.

STEP 67

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. Bur 8-12440

Issued 10-89

Printed in U.S.A.

5004-17

STEP 68

STEP 71

B473688M

B8480388M

Align the rotor and stator and push the rotor into the stator.

Install the spacer place on the stator. Turn the spacer plate to align the holes with the holes in the stator.

NOTE: The drive shaft must be in the rotor in the correct position. See step 69.

STEP 72

STEP 69

.24:lj2 Engage the teeth on the drive shaft in the teeth in the rotor so the slot in the end of the drive shaft is between two teeth on the rotor.

Put the body of the steering control valve in the vise. Apply petroleum jelly on the a-ring for the body of the steering control valve. Install the a-ring in the groove in the body.

STEP 73

STEP 70

B524117M Check the position of the slot in the drive shaft again and make sure the slot is in the correct position. Bur 8-12440

Lower the drive shaft into the spool and engage the pin with the slot in the drive shaft. DO NOT let the drive shaft come out of the rotor. Turn the stator and spacer plate to align these parts with the body. Issued 10-89

Printed in U.S.A.

5004-18

STEP 77

STEP 74

~.

~

B524128M

Install the spacer in the rotor on top of the drive shaft.

STEP 75

Install the end plate on the metering gear set. Align the holes in the end plate with the holes in the stator.

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 Put petroleum jelly on the O-ring for the end plate. Install the O-ring in the groove in the end plate.

Bur 8-12440

B8450288M Tighten the Ferry head screws to 100 to 150 poundinches (11 to 17 Nm) in the sequence shown.

Issued 10-89

Printed in U.S.A.

5004-19

STEP 80

Tighten the Ferry head screws to 225 to 275 poundinches (25 to 31 Nm) in the sequence shown in step 79

Bur 8-12440

Issued 10-89

Printed in U.S.A.

5004-20

A

A 1. INLET CHECK VALVE

2. DRIVE SHAFT

SECTION A-A

SECTION B-B Bur 8-12440

SECTION C-C Issued 10-89

8871967J

Printed in U.S.A.

Section

5005 STEERING CONTROL VALVE - DANFOSS

CASE CORPORATION

Bur 8-12450

Printed

in U.S.A.

Issued November 1989

5005-2

TABLE OF CONTENTS .

SPECiFiCATIONS .....

2

SPECIAL TOOL

...........2

DISASSEMBLY

....3

INSPECTION

.

.

ASSEMBLY

.

7 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 addresses: In the U.SA

and Canada

Service Tools P.O. Box 314 Owatonna, Minnesota 55060 In Europe VL Churchill Ltd. PO Box 3, Daventry Northants, NN11 4NF England

Bur 8-12450

B785606M CAS-1239 Centering Spring Tool This tool is first used on page 5005-11.

Issued 11-89

Printed in USA

5005-3

DISASSEMBL Y STEP 1

STEP 4

__

""""'""'............

870981 OM

Put the steering control valve in the vise so the end plate is up. Loosen the cap screws.

STEP 5

STEP 2

B709812M Remove the cap screws and flat washers screw has a guide pin.

STEP 3

Remove the end plate

Bur 8-12450

Remove and discard the O-ring from the stator

One cap

Remove the metering gear set and spacer from the body.

STEP 6

Remove the drive shaft.

Issued 11-89

Printed in U.sA

5005-4

STEP 7

STEP 10

i!t/ipI

C

···i>;

~?~

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 careful not to damage the spindle seal.

Install the outer wheel bearing.

STEP 82

STEP 85

Install the flat washer and nut Fill the groove in the hub seal with the wheel bearing grease specified on page 5007-2.

Bur 8-12471

Issued 1-91

Printed in U.S.A.

5007-20

STEP 86

STEP 89

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.

Install the wheel and wheel bolts. Do not use an impact wrench to install the wheel bolts.

STEP 87

STEP 90

Install the cotter pin.

Remove the support from under the front axle and lower 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 Bur 8-12471

Lubricate the bearings for the kingpin. Lubricate the tie rod ends. Issued 1-91

Printed in U.SA

5007-21

KINGPIN BEARINGS AND THRUST BEARINGS STEP 96

Drive the lock pin out of the spindle. Raise the front wheel and put an acceptable support under the front axle.

STEP 97

STEP 94

Loosen and remove the wheel bolts. wheel.

Remove the

Remove the snap ring. The O-ring used between the spacer and bearing will cause the snap ring to be difficult to remove.

STEP 98

STEP 95

Remove the spacer. Loosen and remove the nut and lock washer from the lock pin Bur 8-12471

Issued 1-91

Printed in USA.

5007-22

STEP 99

STEP 102

Remove the O-ring.

Remove the O-ring.

STEP 100

STEP 103

Remove the snap ring at the bottom of the kingpin.

Drive the kingpin out of the spindle.

STEP 101

STEP 104

Remove the spacer

Remove the spindle and thrust bearing and put the spindle out of the way.

Bur 8-12471

Issued 1-91

Printed in U.SA

5007-23

STEP 105

STEP 107

Remove the thrust washer.

Remove the seal.

STEP 106

STEP 108

Use an acceptable driver and drive the top bearing out of the boss.

Drive the bottom bearing out of the boss.

Bur 8-12471

Issued 1-91

Printed in U.S.A

5007-24

2. GREASE FITTING

B891545J

36. COTTER PIN

Bur 8-12471

Issued 1-91

Printed in U.S.A.

5007-25

Installation

STEP 112

STEP 109

Clean the bores for the bearings.

Install the seal on an acceptable driver so that the lip is toward the driver. The driver must have a larger diameter that the seal.

STEP 110

STEP 113

Put a bearing on a driver that has a pilot end. The number on one end of the bearing must be toward the driver. The tape on the driver is 1/4 inch from the bearing to help install the bearing to the correct depth.

Drive the seal into the boss until the driver touches the boss.

STEP 114

STEP 111

Put the bearing on the driver so that the end of the bearing with the number is toward the driver. Drive the bearing into the bottom boss until the tape is even with the top of the boss. Bur 8-12471

Issued 1-91

Printed in U.SA

5007-26

STEP 115

STEP 118

Drive the bearing into the boss until the bearing is even with the bottom of the boss.

Install the spindle.

STEP 116

STEP 119

Clean the bore in the spindle.

The case of the thrust bearing must be on top when the thrust bearing is installed.

STEP 117

STEP 120

Install the thrust washer.

Install the thrust bearing so that the case is on top.

Bur 8-12471

Issued 1-91

Printed in U.S.A

5007-27

STEP 121

STEP 124

Align the spindle, thrust washer and thrust bearing with the front axle. Start the kingpin into the spindle so that the notch for the lock pin is toward the outside.

Install the lock washer and nut. Do not tighten the nut at this time.

STEP 122

"

Use a soft hammer and drive the kingpin into the spindle.

STEP 123

Install the lock pin.

Bur 8-12471

STEP 125

Install a new O-ring in the bottom boss. Use grease to hold the O-ring.

STEP 126

Apply a small amount of grease to a spacer and install the spacer so that the grease fitting is toward the center of the machine.

Issued 1-91

Printed in U.S.A.

5007-28

STEP 127

STEP 130

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.

STEP 129

STEP 132

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.

Bur 8-12471

Issued 1-91

Printed in U.S.A.

5007-29

STEP 133

Tighten the nut on the lock pin.

STEP 134

Install the wheel and wheel bolts. Do not use an impact wrench to install the wheel bolts.

Remove the support from under the front axle and lower the wheel to the floor.

STEP 136

Tighten the wheel nuts to 115 to 150 pound-feet (156 to 203 Nm).

STEP 137

Lubricate the bearings for the kingpins.

Bur 8-12471

Issued 1-91

Printed in U.S.A.

5007-30

TOE-IN

Measuring Toe-In

7. The measurement at the rear of the tires must be 0 to 3/16 inch (0 to 5 mm) more than the measurement at the front of the tires.

1. Raise the front of the machine until the front wheels are free of the floor.

Adjustment

2. Hold a tool that has a sharp point against the center of the tire tread.

1. Loosen the lock nut at each end of the piston rod for the steering cylinder

3. Hold the tool in one place and rotate the wheel to make a fine line around the tire. Repeat this procedure for the other front wheel. 4.

2. Turn the piston rod as needed to increase or decrease the toe-in. 3. When the toe-in is correct, tighten the lock nut nearest the flat on the piston rod first to 150 to 200 pound-feet (203 to 271 Nm). Then tighten the other lock nut to 150 to 200 pound-feet (203 to 271 Nm).

Lower the front wheels to the floor.

5. Turn the steering wheel as needed to put the front wheels in the straight position. 6. Measure the distance between the marks at the front and rear of the tires.

..

B

A B861482R

1. 2. 3.

Bur 8-12471

Mark Around Center of Tire Steering Cylinder Loosen Lock Nuts and Turn Piston Rod as Required

Measurement B Must Be Equal To or Up To 3/16 Inch (5 mm) Less Than Measurement A

Issued 1-91

Printed in U.S.A.

Section 5008 FRONT AXLE - FOUR WHEEL DRIVE

CASE CORPORATION

Bur 8-17300

Printed in U.S.A. Issued January 1991

5008-2

TABLE OF CONTENTS SPECIFICATIONS SPECIAL TOOLS MEASURING TOE-I N . DISASSEMBLY OF PLANETARy INSPECTION OF PLANETARY PARTS ASSEMBLY OF PLANETARy REMOVAL AND DISASSEMBLY OF SWIVEL HOUSiNG REPLACING A UNIVERSAL JOINT ASSEMBLY AND INSTALLATION OF SWIVEL HOUSiNG REMOVAL OF DIFFERENTIAL CARRIER DISASSEMBLY OF DIFFERENTIAL CARRIER DISASSEMBLY OF DIFFERENTIAL INSPECTION OF DIFFERENTIAL PARTS ASSEMBLY OF DIFFERENTIAL ASSEMBLY OF DIFFERENTIAL CARRIER INSTALLATION OF DIFFERENTIAL CARRIER

3 3 4 5 9 11 16 19 24 28 30 33 34 36 39 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

Gear lubricant

.

.............................................................

Capacities Center bowl Planetary (each) Special torques Studs for wheels Wheel nuts Allen screws for planetary cover with 242 Loctite Allen screws for carrier Nut for ball joint Cap screws for king pin Cap screw for lock for adjusting ring Cap screws for bearing caps Cap screws for differential case with 271 Loctite Cap screws for bearing caps Cap screws for steering cylinder Cap screws for hub for ring gear

Bur 8-17300

(1.1 to 2.3 Nm)

CaselH Gear Lube (85W-140)

7.4 U.S. quarts (7 litres) 1.1 U.S. quart (1 litre)

52 pound-feet (70 200 to 240 pound-feet (270 to 325 300 pound-inches (34 59 pound-feet (80 125 to 135 pound-feet (169 to 180 101 pound-feet (137 84 pound-inches (9.5 115 pound-feet (156 52 pound-feet (70 74 pound-feet (100 66 to 79 pound-feet (90 to 107 184 pound-feet (299

Issued 1-91

Nm) Nm) Nm) Nm) Nm) Nm) Nm) Nm) Nm) Nm) Nm) Nm)

Printed in U.S.A.

5008-3

SPECIAL TOOLS The special tools shown on this page are required to disassemble and assemble the planetaries and differential. In the US. and Canada, order the tools from Service Tools P.O. Box 314 Owatonna, MN 55060 In Europe order the tools from B4097388M

VL Churchill Ltd P.O. Box 3, Daventry Northants NN11 4NF England

CAS-1840B Spanner Wrench. Shown in use in step 150.

B4086.290M B875432M 1. 2. 3. 4. 5. 6.

CAS-1839-1 Gauge Tube CAS-1839-2 Gauge Block CAS-1668 Metric Feeler Gauge CAS-1596A-3 Pilot CAS-1596A-4 Handle 7116-A9 Stud

CAS-2151 Wrench For Pinion Nut. Shown in use in step 156.

CAS-1839 Pinion Setting Kit. Shown in use during assembly of differential carrier beginning in step 188.

B4094788M Yoke to hold shaft. Order D149861 from J I Case. Not Shown in use in step 156.

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-4

B4094188M CAS-1842 Wheel Stud Shown in use in step 3.

Removal

and

B40974B8M

Installation.

CAS-2151 Wrench to loosen and tighten tie rods for steering cylinder. Shown in use in step 139.

, ...,:B4095oeaM

'B4t068ssM CAS-1980 V-Blade. Used to support coupling when replacing a universal joint. First used in step 74.

CAS-1 0468 Puller. Used to remove ball joint from swivel housing. Used in step 57.

MEASURING TOE-IN B

1

A B870171J

1. 2.

3.

Bur 8-17300

Mark Around Center of Tire Steering Cylinder Loosen Clamps and Tum Piston Rod as Required

Measurement B Must Be Equal To Or Up To 3/16 Inch (5 mm) Less Than Measurement A

Issued 1-91

Printed in U.S.A.

5008-5

DISASSEMBLY STEP 1

Raise the wheel(s) off the floor and use suitable supports to hold the machine in place

OF PLANETARY STEP 5

STEP 2

Remove the nuts and hardened washers and remove the wheel(s).

STEP 3

Use chisel to separate the carrier from the planetary housing.

STEP 6

Two flanged studs hold the carrier. Use tool CAS-1842 to remove the flanged studs.

STEP 4

Put a drain pan below the planetary and use two prybars to loosen the carrier.

STEP 7

Remove the two Allen head screws that hold the carrier.

Remove the carrier.

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-6

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

Remove the spacer and thrust washer.

STEP 10

Remove the ring gear.

STEP 13

Remove the cap screws. Use a puller bar, a 1/4 inch (6 mm) thick spacer between the axle shaft and puller bar, and 12 mm x 3 inch cap screws to remove the outer bearing from the swivel housing.

Bur 8·17300

Issued 1-91

Printed in U.S.A.

5008-7

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

Remove the retaining ring. Remove the snap rings.

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-8

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 careful not to lose the needles.

Remove the bearing cups and seal as required.

STEP 22

Remove the Allen head screws and remove the cover.

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-9

INSPECTION OF PLANETARY PARTS 1. Clean all parts in cleaning solvent. 2. Inspect the bearing cup and the rollers in the wheel bearings for flat areas, pitting, scoring and other damage. Also check the inner race for damage. If any of these defects are found, a new wheel bearing and bearing cup must be installed. 3. Inspect the pinion shafts for wear and damage.

Bur 8-17300

4. Inspect the teeth of the pinion gears, sun gear and ring gear for wear, pitting, scoring and other damage. Use new parts as required. 5. Inspect the needles for the pinion gears for flat areas, pitting, scoring and other damage. If any of these defects are found, also inspect the bore of the pinion gears and use new parts as required. 6. Inspect the splines on the axle shaft and sun gear for wear and damage.

Issued 1-91

Printed in U.S.A.

5008-10

1. 2. 3. 4. 5. 6. 7.

Me Shaft Seal Bearing Bearing Cup Planetary Housing Dowel Pin Stud

Bur 8-17300

8.

9. 10. 11. 12. 13. 14.

Retaining Ring Hub Ring Gear Bushing Cap Screw Washer Spacer

15. Sun Gear

16. 17. 18. 19. 20. 21.

Snap Ring Retainer Pinion Gear Needles Thrust Washer Thrust Button

22. Carrier 23. 24. 25. 26. 27.

Allen Head Screw Flanged Stud Plug Pinion Shaft Cover

Issued 1-91

Printed in U.S.A.

5008-11

ASSEMBLY STEP 25

OF PLANETARY 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

Drive or press new bearing cups into the planetary housing.

STEP 26

127M Apply petroleum jelly to one side and the bore of the pinion gears.

STEP 30

The words OIL SEAL on the seal must be to the inside.

STEP 27 Install a thrust washer.

Drive a new seal into the planetary housing. Be careful not to damage the seal.

Bur 8-17300

Issued 1-91

Printed in U.SA

5008-12

STEP 31

STEP 34

Install 30 needles in each pinion gear using petroleum jelly to hold the needles in place.

Make sure that the threads in the pinion shafts are free of lubricant.

STEP 32

STEP 35

Install the pinion gears so that the thrust washer is toward the carrier

Apply 242 Loctite to the threads in the pinion shafts.

STEP 33

Install the retainer and snap rings.

Bur 8-17300

STEP 36

Install the cover and Allen head screws and tighten the Allen head screws to 300 pound-inches (34 Nm).

Issued 1-91

Printed in U.S.A.

5008-13

STEP 37

STEP 40

Press bushings into the hub as required.

Install a bearing on the swivel housing.

STEP 38

STEP 41

Install the hub.

Lubricate the bearings with gear lubricant.

STEP 39

STEP 42

Install the retaining ring.

Install the planetary housing and the other bearing.

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-14

STEP 43

STEP 46

Align the large diameter bushing with the large hole in the swivel housing and install the ring gear.

Install the thrust washer and spacer.

STEP 44

STEP 47

Install the sun gear and snap ring. Install and tighten the cap screws evenly to pull the ring gear against the swivel housing.

STEP 48

STEP 45

Apply form-in-place housing.

gasket material to the planetary

Tighten the cap screws to 184 pound-feet (2'4-QNm).

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-15

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).

Install and tighten the Allen head screws to 59 poundfeet (80 Nm).

Bur 8-17300

Issued 1-91

Printed in U.SA

5008-16

REMOVAL AND DISASSEMBLY OF SWIVEL HOUSING STEP 54

Do the necessary steps under Disassembly of Planetary for access to the swivel housing,

STEP 58

STEP 55

···B90762tGM

Remove the nut and swivel housing, Slide the inner wheel bearing off the swivel housing,

remove the ball joint from the

STEP 59

STEP 56

Loosen the cap screws that hold the top king pin,

Remove the cotter pin and loosen but do not remove

the nut.

STEP 60

STEP 57

Remove the top king pin. Be careful not to damage the

shims,

Use the CAS-10468 puller to loosen the ball joint. Bur 8-17300

Issued 1-91

Printed in U,S.A.

5008-17

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

Use a suitable puller and remove the top and bottom bushings. Remove the swivel housing.

STEP 64

STEP 67

Use a suitable puller and remove the seal. Remove the axle shaft.

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-18

STEP 68

STEP 71

90763'1 OM Use a suitable puller and remove the bushing.

STEP 69

Use a suitable puller and remove the seal from the swivel housing

Use a hammer and a chisel that has a long taper to start the bushing off the bottom king pin.

STEP 72

Press the bottom king pin out of the bushing.

STEP 70

Support the swivel housing on a sleeve and press the bushing out of the swivel housing.

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-19

REPLACING A UNIVERSAL JOINT STEP 73

STEP 76

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

Use the CAS-1980 V-block to support the coupling. Adjust the Allen screws in the V-block to hold the coupling level and use additional support as required. Use a suitable driver and press the bottom bearing cap against the V-block.

STEP 77

Remove the long axle shaft (or short axle shaft) from the coupling.

STEP 78

STEP 75

Remove the coupling from the bearing cap. Fasten the bearing cap in a vise and drive the coupling off the bearing cap. Bur 8-17300

Issued 1-91

Printed in U .SA

5008-20

STEP 79

STEP 82

Use a suitable support and driver to press the bottom bearing cap out of the yoke as far as possible.

Remove the cross.

STEP 80

STEP 83

Use a suitable driver and press the bearing cap out of the yoke.

STEP 81

Press the other bearing cap out of the yoke as far as possible.

Bur 8-17300

STEP 84

Press a bearing cap into the yoke 1/4 inch (3 mm) from the top of the yoke.

Issued 1-91

Printed in U.S.A.

5008-21

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

Press the other bearing cap into the yoke 3/8 inch (9 mm) from the top of the yoke.

STEP 87

Carefully raise the cross into the bearing cap so that the cross is in both bearing caps.

Bur 8-17300

STEP 89

Use a suitable driver and press a bearing cap into the yoke so that a snap ring can be installed.

STEP 90

Install a snap ring.

Issued 1-91

Printed in U.S.A

5008-22

STEP 91

Repeat steps 89 and 90 for the other bearing cap.

STEP 95

STEP 92

Carefully raise the cross into the top bearing cap so that the cross is in both bearing caps. Use the V-block to support the coupling and press a bearing cap into the coupling even with the 00 of the coupling.

STEP 96

STEP 93

Hold the cross and press the bearing cap into the coupling so that a snap ring can be installed.

Carefully install the cross in the bearing cap.

STEP 97

Install a snap ring.

Use a suitable driver and press the other bearing cap into the coupling 1/4 inch (3 mm) from the top of the coupling. Bur 8-17300

STEP 98

Repeat steps 96 and 97 for the other bearing cap.

Issued 1-91

Printed in U.S.A.

5008-23

B902646J

1. 2. 3.

Bur 8-17300

Top fVng Pin Shim Seal

4. 5. 6.

One Piece Bushing Swivel Housing Bushing

7. 8. 9.

Seal Two Piece Bushing Bottom fVng Pin

Issued 1-91

Printed in U.SA

5008-24

ASSEMBLY AND INSTALLATION OF SWIVEL HOUSING STEP 99

STEP 102

Drive the bushing into the bore until the bushing is 5/16 inch (8 mm) beyond the end of the bore. Then install the seal

Use a suitable driver and drive the seal all the way into bore.

STEP 100

STEP 103

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 101

STEP 105

Repeat step 100 for the bottom bushing.

Install the swivel housing.

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-25

STEP 106

If the old swivel housing is being installed and no new bushings for the king pins were installed, do steps 107 through 109.

STEP 111

STEP 107

Install the top king pin without shims.

STEP 112

Install the top king pin, shims and cap screws and lock washers or self-locking cap screws.

STEP 108

Tighten the cap screws to 101 pound-feet (137 Nm).

Measure the the thickness of the shims removed with the top and bottom king pins and install these shims and two additional 0.014 inch (0.35 mm) shims on the bottom king pin.

STEP 113

Install the bottom king pin and shims.

STEP 109

Repeat steps 107 through 108 for the bottom king pin.

STEP 110

If a new swivel housing or new bushings for the king pins have been installed, do steps 111 through 124.

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-26

STEP 114

STEP 117

Add 0.012 inch (0.30 mm) to the reading in step 116. Then subtract this answer from the answer in step 112

STEP 118

Divide the answer for step 117 by 2. This is the thickness 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

Install and tighten the cap screws to 101 pound-feet (137 Nm).

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.

Use a dial indicator and check the free travel of the swivel housing. Record the reading.

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-27

STEP 122

STEP 125

Tighten the cap screws to 101 pound-feet (134 Nrn).

Install the ball joint and nut.

STEP 123

Install the top king pin, shims, cap screws and lock washers.

STEP 126

Tighten the nut to 125 to 135 pound-feet (169 to 180 Nm).

STEP 127

STEP 124

Tighten the cap screws to 101 pound-feet (134 Nm).

Install a new cotter pin. 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 128

Lubricate the king pins.

STEP 129

Bur 8-17300

Assemble the planetary according to instructions in this section. Issued 1-91

Printed in U.S.A.

5008-28

REMOVAL OF DIFFERENTIAL CARRIER STEP 130

Drain the lubricant from the center bowl.

STEP 134

STEP 131

Fasten suitable lifting equipment as shown and remove the cap screws for the top and bottom king pins.

Remove the cotter pin from the ball joint.

STEP 135

STEP 132

Remove the nut and ball joint.

Loosen but do not remove the nut.

STEP 136

STEP 133

Remove the king pins.

Use a suitable puller to loosen the ball joint.

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-29

STEP 137

STEP 142

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

Remove the cap screws. 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

Use suitable lifting equipment and remove the differential carrier.

Remove the cap screws. Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-30

DISASSEMBLY OF DIFFERENTIAL CARRIER STEP 145

STEP 148

Typical Illustration Fasten the differential carrier in a repair stand.

Remove the cap screw and lock that hold each adjusting ring.

STEP 146

STEP 149

Prevent the pinion shaft from turning and measure the backlash of the ring gear. Record the reading.

Remove the cap screws.

STEP 147

Make an identification mark on the bearing cap and leg on the ring gear side of the differential carrier.

Bur 8-17300

STEP 150

Loosen both adjusting rings

Issued 1-91

Printed in U.S.A.

5008-31

STEP 151

STEP 155

~,

Remove both bearing caps.

STEP 152

Remove the adjusting rings, bearing cups and differential.

STEP 153

If the bearing cups are to be used again, fasten an identification tag to one bearing cup for correct installation.

Use a narrow chisel to push the nut out of the pinion shaft.

STEP 156

Use the yoke and CAS-2151 tool to remove the pinion nut.

STEP 157

STEP 154

Remove the washer.

Remove the seal and cover. Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-32

STEP 158

STEP 161

Use a soft hammer and drive the pinion shaft out of the outer bearing.

Remove the shim.

STEP 159

Remove the flat washers and spacer. Discard the spacer. The spacer MUST NOT be used again.

STEP 162

Remove the bearing cups only if inspection indicates the need for new parts. A spacer is used between the differential carrier and the inner bearing cup. Do not lose the spacer.

STEP 160

Press the pinion shaft out of the inner bearing.

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-33

DISASSEMBLY

OF DIFFERENTIAL

STEP 163

STEP 166

Remove the cap screws.

Remove the thrust washer and side gear.

STEP 164

STEP 167

Remove the ring gear.

Remove the pinion shaft assembly and pin.

STEP 165

STEP 168

Separate the case halves.

Remove the side gear.

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-34

STEP 169

STEP 171

Remove the thrust washer.

Remove the bearing from either case half as shown.

STEP 170

Remove and install new bushings in the case halves as required.

INSPECTION OF DIFFERENTIAL PARTS 1. Clean all parts in cleaning solvent. 2. Inspect the bearing cup and the rollers in the bearings for flat areas, pitting, scoring and other damage. Also check the inner race for damage. If any of these defects are found, a new bearing and bearing cup must be installed.

4. Inspect the teeth of the pinion gears and pinion shaft, and side gears for the differential for pitting, scoring and other damage. Also inspect the thrust surfaces and the bore of each pinion gear. Check the splines in the side gears for wear. Use new parts as required. 5. Inspect the thrust washers for pitting, scoring and other damage. Use new parts as required.

3. Inspect the teeth on the pinion gear and ring gear for pitting, scoring and broken teeth. The ring gear and pinion gear must be replaced as a set.

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-35

6

15

B902647J

1. 2. 3. 4. 5. 6.

Cover Seal Pinion Nut Washer Bearing Flat Washer

Bur 8-17300

7. 8. 9. 10. 11.

Spacer Bearing Cup Differential Carrier Adjusting Ring Bearing Cap

12. 13. 14. 15. 16.

Lock Shim Pinion Gear Ring Gear Case Half

17. 18. 19. 20. 21.

Thrust Washer Side Gear Pinion Gear Pinion Shaft Dowel Pin

Issued 1-91

Printed in U.S.A.

5008-36

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.

STEP 174

STEP 177

Lubricate the thrust washers, pinion gears and pinion shaft with gear lubricant

Install the thrust washers and pinion gears on the pinion shaft.

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-37

STEP 178

STEP 181

Install the pin.

Install the other side gear.

STEP 179

STEP 182

Install the pinion shaft assembly.

Install the other thrust washer in the other case half.

STEP 180

STEP 183

7~18M Apply 271 Loctite to the threads in the case half.

Bur 8-17300

Assemble the case halves.

Issued 1-91

Printed in U.S.A.

5008-38

STEP 184

STEP 185

Make sure that the mounting surfaces for the ring gear are clean and install the ring gear.

Use the press to prevent the differential from turning and install and tighten the cap screws to 52 pound-feet (70 Nm).

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-39

ASSEMBLY

OF DIFFERENTIAL

STEP 186

CARRIER

STEP 189

.

.

~~~~~,M.

If new bearing cups are being installed in the differential carrier, make sure that the spacer is installed in the bore for the inner bearing cup.

Install the gauge block assembly, bearings and handle. Tighten the handle until the bearings become difficult to turn.

STEP 187

STEP 190

Use a suitable driver and drive the bearing cup(s) into the differential carrier.

Install the gauge tube, bearing caps with marks aligned and the cap screws.

STEP 188

STEP 191

Assemble the gauge block, pilot and stud from the CAS-1839 pinion setting kit.

Tighten the cap screws to 115 pound-feet (156 Nm).

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-40

STEP 192

STEP 195

Use the metric feeler gauge and measure the space between the gauge block and the gauge tube. Write the measurement on line b in step 194

Remove the cap screws, bearing caps, gauge tube, handle, gauge block assembly and the bearings.

STEP 196

STEP 193

Write the number on the end of the pinion shaft on line d in step 194.

Install the shim with the thickness specified in step 194. The chamfer on the ID of the shim must be towards the pinion gear.

STEP 194

STEP 197

The number on line a does not change. Add line a and line b and write the answer on line c. Subtract line d from line c and write the answer on line e. Line e is the thickness of the shim to be installed on the pinion shaft. Example a. 109.75 mm b.+ c. d. e.

mm mm mm mm

a. b. c. d. e.

109.75 mm + 0.45 mm 110.20 mm -107.45 mm 2.75 mm

use 2.70 mm thick shim

Bur 8-17300

Use a suitable driver and press the inner bearing against the shim.

Issued 1-91

Printed in U.S.A.

5008-41

STEP 198

STEP 201

Lubricate the bearings with gear lubricant.

Install the washer.

STEP 199

STEP 202

Install a new spacer and flat washers. The old spacer MUST NOT be used again.

Install a new pinion nut.

STEP 200

Install the pinion shaft and the outer bearing.

Bur 8-17300

STEP 203

Use the yoke and the CAS-2151 wrench and tighten the pinion nut to 50 pound-feet (68 Nm).

Issued 1-91

Printed in U.S.A.

5008-42

STEP 204

STEP 207

The pinion shaft and bearings will still be loose. Tighten the pinion nut in SMALL amounts until the bearings become seated. IMPORTANT: If the pinion nut is tightened too much, (rotating torque more than specified) a new spacer must be installed on the pinion shaft.

STEP 205

Use a suitable driver and drive a new seal into the differential carrier.

STEP 208

Use a pound-inch torque wrench and check the rotating torque of the pinion shaft. Use a 1-5/16 inch socket 12 point socket and 1/8 inch (3 mm) cotter pin as a shaft adapter. The rotating torque must be 15 to 20 pound-inches (1.7 to 2.2 Nm). If the rotating torque is less than specified, tighten the pinion nut a SMALL amount and check the rotating torque again. Also see IMPORTANT below step 204.

STEP 206

Use a suitable driver and drive the cover onto the pinion shaft

STEP 209

When the rotating torque is as specified, use a hammer and punch and drive part of the pinion nut into the slot in the pinion shaft.

Bur 8-17300

Install the differential carrier and lubricate the bearings with gear lubricant. The ring gear must be next to the leg with the identification mark.

Issued 1-91

Printed in U.S.A.

5008-43

STEP 210

STEP 213

Install the bearing cups.

Install the adjusting rings.

STEP 211

STEP 214

Install the bearing caps with the alignment aligned and the cap screws.

marks

STEP 212

Tighten the cap screws to pull the bearing caps against the differential carrier.

Bur 8-17300

Tighten both adjusting rings while making sure that there is clearance (backlash) between the ring gear and pinion gear.

STEP 215

Use a dial indicator and check for end play.

Issued 1-91

Printed in U.S.A.

5008-44

STEP 216

If there is end play, tighten the adjusting ring on the tooth side of the ring gear until there is no end play.

STEP 222

STEP 217

If there is no end play, loosen the adjusting ring on the backface side of the ring gear to make sure that there is clearance between the ring gear and pinion gear and tighten the opposite adjusting ring until there is no end play.

STEP 218

When there is no end play, tighten each adjusting ring one notch.

STEP 219

If there is not enough backlash, loosen the adjusting 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.

STEP 220

If the original ring gear and pinion gear are being used, the backlash must be equal to the measurement made during disassembly.

3TEP 221

''''';.;.'.''-" . ",1, "'307tv1 ,

:

~'"

If there is too much backlash, loosen the adjusting ring on the tooth side of the ring gear one notch and tighten the opposite adjusting ring one notch. Check the backlash again. Continue with this step until the backlash is correct.

If a new ring gear and pinion gear are being used. the backlash must be 0.008 to 0.020 inch (0.15 to 0.25 mm).

Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-45

STEP 224

STEP 225

When the backlash is correct, tighten the cap screws to 115 pound-feet (156 Nm).

Install the lock, cap screw and lock washer that hold each adjusting ring. Tighten the cap screws to 84 pound-inches (9 Nm).

INSTALLATION OF DIFFERENTIAL CARRIER STEP 226

STEP 228

Apply form-in-place gasket material.

STEP 227

Install the differential carrier.

Bur 8-17300

STEP 229

Install the steering cylinder.

Issued 1-91

Printed in U.S.A

5008-46

STEP 230

STEP 234

s.~ Install and tighten the cap screws to 66 to 79 poundfeet (90 to 107 Nm).

Install the king pins, shims, washers.

STEP 231

STEP 235

Install and tighten the tie rod.

Install the ball joint and nut.

STEP 232

STEP 236

Install and tighten the fitting at the closed end of the steering cylinder.

cap screws and lock

STEP 233

Tighten the cap screws to 101 pound-feet (134 Nm).

Install the planetary and axle assembly. It can be necessary to have another person turn the pinion shaft. Bur 8-17300

Issued 1-91

Printed in U.S.A.

5008-47

STEP 237

STEP 238

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.

Bur 8-17300

Issued 1-91

Printed in U.S.A.

SECTION INDEX - POWER TRAIN Section Title

Section Number

Removal and Installation of Power Train Components

.

Transmission Specifications and Schematic....

...6001

.

6002

Wheels and Tires ....

.

PTO

.

6003 .6019

Rear Axles and Planetaries

6201

Transfer Gearbox

6202

Differential and Differential Lock Forward/Reverse Valve

.

.....6203

.

..6204

Torque Converter Charging Pump, Output Shaft, And Converter Housing Transmission.

.

CASE CORPORATION

6205 6206

Bur 8-17570

Printed in U.S.A. Issued January 1991

Section

6001 REMOVAL AND INSTALLATION OF POWER TRAIN COMPONENTS

CASE CORPORATION

Bur 8·12501

Printed in U.S.A. Issued March 1991

6001-2

TABLE OF CONTENTS SPECIFICATIONS

2

SPECIAL TOOLS

2

REMOVING THE TORQUE CONVERTER HOUSING AND TORQUE CONVERTER

3

INSTALLING THE TORQUE CONVERTER AND TORQUE CONVERTER HOUSING

6

REMOVING THE TRANSAXlE

9

INSTALLING THE TRANSAXlE

14

REPLACING A UNIVERSAL JOINT

18

SPECIFICATIONS Special torques Ferry head screws that hold the rear drive shaft

156 to 216 pound-inches

(18 to 24 Nm)

Ferry head screws that hold the PTO drive shaft

156 to 216 pound-inches

(18 to 24 Nm)

Cap screws that hold the front drive shaft

504 to 576 pound-inches

(57 to 65 Nm)

. ....360 to 420 pound-inches

(40 to 47 Nm)

.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)

Cap screws that fasten the torque converter housing to the flywheel housing... .

.

Cap screws that fasten the drive ring to the torque converter

Oil refill capacity for the transaxle

47.6 U.S. quarts (45 litres)

SPECIAL TOOLS Order special tools from one of the following addresses: In the U.8A and Canada Service Tools P.O. Box 314 Owatonna, Minnesota 55060 Vl Churchill Ltd P.O. Box 3, Daventry Northants, NN11 4NF England

Bur 8-12501

B897521OM CAS-2018 Alignment Tool This tool is shown in use in step 19. Issued 3-91

Printed in U.S.A.

6001-3

REMOVING THE TORQUE CONVERTER HOUSING AND TORQUE CONVERTER STEP 1

Park the machine on a level surface. Put the backhoe in the transport position and lower the loader bucket to the floor.

STEP 5

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 approximately 47.6 U.S. quarts (45Iitres).lfequipped with a PTa, drain the oil from the torque converter housing.

STEP 6

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

Put a floor jack under the guard.

STEP 7

Loosen and remove the bolts, flat washers, and nuts that fasten the bar to the guard for the drive shaft. Remove the bar.

Remove the bolts and lower the guard. Remove the guard from under the machine.

Bur 8-12501

Issued 3-91

Printed in U.S.A.

6001-4

STEP 8

STEP 11

Loosen and remove the cap screws that fasten the front drive shaft to the flange on the transaxle. Remove the front drive shaft.

Loosen the clamps at each end of the hose on the suction tube and remove the suction tube.

STEP 9

STEP 12

If equipped with a PTO, loosen and remove the Ferry head screws and clamps that fasten the drive shaft to the torque converter and remove the drive shaft.

STEP 10

Loosen and remove the nut, lock washer, and wire from the switch for the filter warning lamp.

STEP 13

Loosen and remove the Ferry head screws and clamps that fasten the rear drive shaft to the torque converter. Remove the rear drive shaft NOTE: If necessary, use a prybar to remove the rear drive shaft. If the rear drive shaft cannot be removed with a prybar, loosen the hardware that fastens the transaxle to the frame and move the transaxle toward the rear of the machine. Remove the rear drive shaft.

STEP 14

Loosen and remove the cap screws and flat washers that fasten the torque converter housing to the flywheel housing. NOTE: If equipped with a PTO, instal! two 10 mm - 1.5 x 4 inch (100 mm) studs to hold the torque converter housing while loosening the torque converter housing. Bur 8-12501

Issued 3-91

Printed in U.S.A.

6001-5

STEP 15

Loosen and remove the torque converter housing.

STEP 17

NOTE: The following photographs show removing the torque converter with the engine removed. The procedure is the same with the engine in the machine.

STEP 16

Hold the torque converter and remove the cap screws and hardened washers and remove the torque converter.

STEP 18

Loosen the cap screws that hold the torque converter.

4. HARDENED WASHER

If necessary, loosen and remove the cap screws, flat washers, and the drive ring from the torque converter.

~..-..-

2. CAP SCREW ~

2. CAP SCREW

Bur 8-12501

~

c? ~ 3. FLAT

7. TORQUE CONVERTER HOUSING B891515J

WASHER

Issued 3-91

Printed in U.S.A.

6001-6

INSTALLING THE TORQUE CONVERTER AND TORQUE CONVERTER

HOUSING

STEP 19

STEP 22

Install the drive ring and the CAS-2018 alignment tool. Install the drive ring to get the least amount of movement between the alignment tool and the drive ring.

Tighten the cap screws to 156 to 180 pound-inches (18 to 20 Nm).

STEP 20

STEP 23

If equipped with a PTO, apply Loctite 515 all the way around the edge of the flywheel housing.

STEP 24

Install a 10 mm - 1.5 x 4 inch (100 mm) stud in the middle hole on each side of the flywheel housing.

STEP 25

Install the torque converter housing so that the suction tube and filter are on the horizontal centerline.

STEP 26

Move the torque converter housing forward.

Install four cap screws and flat washers and tighten the cap screws to 456 to 504 pound-inches (52 to 57 Nm). Then install and tighten the remainder of the cap screws.

STEP 21

IMPORTANT: DO NOT use extra force to push the torque converter housing into place. If the torque converter housing does not easily slide into contact with the flywheel housing, the parts are not correctly aligned.

STEP 27

Install the cap screws and lock washers that hold the torque converter housing and tighten the cap screws to 360 to 420 pound-inches (40 to 47 Nm).

STEP 28

Install the wire, lock washer, and nut on the switch for the filter warning lamp and tighten the nut.

Hold the torque converter in place and install the cap screws and hardened washers. Bur 8-12501

Issued 3-91

Printed in U.S.A.

6001-7

STEP 31

STEP 29

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). NOTE: If the hardware for the transaxle was loosened to remove the rear drive shaft, tighten the hardware according to the torque specifications in step 69.

STEP 32

If equipped with a PTO, install the drive shaft, clamps, and the Ferry head screws. Tighten the Ferry head screws to 156 to 216 pound-inches (18 to 24 Nm).

STEP 33

STEP 30

If the machine has four wheel drive, do steps 34 through 38. If the machine has a PTO but no four wheel drive, do steps 35 through 38.

STEP 34

Install the suction tube and tighten each clamp on the hose. Install the front drive shaft and cap screws. Tighten the cap screws to 504 to 576 pound-inches (57 to 65 Nm).

Bur 8-12501

Issued 3-91

Printed in U.S.A.

6001-8

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

Raise the guard into alignment with the brackets on the frame and install the bolts. Lower the floor jack and remove the floor jack from under the machine.

Install and tighten the drain plug in the transaxle (and the torque converter housing if equipped with PTO).

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).

Bur 8-12501

Issued 3-91

Printed in U.S.A.

6001-9

REMOVING

THE TRANSAXLE

STEP 42

STEP 45

Raise the wheels off of the floor high enough to remove the transaxle from under the machine. Put suitable stands under the frame at the rear of the machine and under the front axle.

Loosen and remove the bolts, flat washers. and nuts that fasten the bar to the guard for the drive shaft. Remove the bar.

STEP 43

STEP 46

Drain the oil from the transaxle. The trans axle holds approximately 47.6 U.S. quarts (45 litres).

Loosen and remove the nuts and flat washers from the bolts that fasten the guard to the frame. Do not remove the bolts at this time.

STEP 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.

Put a floor jack under the guard. Bur 8-12501

Issued 3-91

Printed in U.S.A.

6001-10

STEP 48

NOTE: If necessary, use a prybar to remove the rear drive shaft. If the rear drive shaft cannot be removed with a prybar, loosen the hardware that fastens the transaxle to the frame and move the transaxle toward the rear of the machine. Remove the rear drive shaft.

STEP 52

Remove the bolts and lower the guard. Remove the guard from under the machine.

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 the torque converter and remove the drive shaft.

If the machine has four wheel drive, disconnect the control rod from the lever at the transaxle.

STEP 51

STEP 54

Loosen and remove the Ferry head screws and clamps that fasten the rear drive shaft to the torque converter. Remove the rear drive shaft.

Loosen and remove the nuts from the bolts that fasten the clamp and spacer for the parking brake cable to the bracket on the transaxle. Remove the bolts, clamp, and spacer.

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 jam nut and turn the parking brake cable counterclockwise out of the transaxle.

Loosen and remove the cap screws and flat washers that fasten the guard for the hose on the suction tube and remove the guard. Loosen each clamp on the hose on the suction tube and slide the hose upward to disconnect 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.

IMPORTANT: Do not move the levers on the transaxle while the control rods are disconnected. If you move the levers, the detents can disengage which will require transax/e disassembly to install the detents.

Disconnect the control rod from the spring. Disconnect the hose from the tee fitting. Install a plug in the hose and a cap on the tee fitting. Disconnect the connector for the wiring harness. Remove the cotter pin and clevis pin that fasten the power shuttle rod to the control valve.

Bur 8-12501

Issued 3-91

Printed in U.S.A.

6001-12

STEP 62

STEP 65

Disconnect the brake hose from each side of the transaxle. 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 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.

Install a transmission

jack under the transaxle.

STEP 66

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

Loosen and remove the nuts. hardened washers, clamps. and bolts that fasten the transaxle to the frame.

STEP 67

If used. loosen and remove the cap screws that fasten the straps to the frame and remove the straps.

Lower the transaxle and remove the transaxle from under the machine.

Bur 8-12501

Issued 3-91

Printed in U.S.A.

6001-13

-

890240SJ

Bur 8-12501

Issued 3-91

Printed in U.S.A.

6001-14

INSTALLING THE TRANSAXLE STEP 68

STEP 71

·-······w·,·-·

B9075614M Put the trans axle under the machine and raise the transaxle into position.

STEP 69

If used, install the straps and align the straps with the blocks in the frame. Install the cap screws that hold the straps and tighten the cap screws.

STEP 72

Connect the tube to the right side of the transaxle.

STEP 73

Install the bolts, clamps, hardened washers, and nuts that fasten the transaxle to the frame. Tighten the nuts to 520 to 640 pound-feet (705 to 868 Nm).

STEP 70

Connect the brake hose to each side of the transaxle. Connect the tube to the fitting at the top left side of the transaxle. Connect the spring to the lever at the top right side of the transaxle.

Lower and remove the transmission jack.

Bur 8-12501

Issued 3-91

Printed in U.S.A.

6001-15

STEP 74

STEP 79

Connect the control rod to the spring, Connect the hose to the tee fitling, Connect the connector for the wiring harness, Install the clevis pin and cotter pin that fasten the power shuttle rod to the control valve,

Install the clevis pins and cotter pins that fasten the control rods to the levers on the transaxle.

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 floormat, install the floormat.

with a cab and has a

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. Bur 8-12501

Issued 3-91

Printed in U.S.A.

6001-16

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

If the machine has four wheel drive, connect the control rod to the lever at the transaxle.

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

Install the rear wheels and wheel nuts. Tighten the wheel nuts to 320 to 380 pound-feet (434 to 515 Nm).

STEP 84 Move the guard in position under the drive shaft.

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, and Fetty head screws that hold the drive shaft. Bur 8-12501

Raise the guard into alignment with the brackets on the frame and install the bolts. Lower the floor jack and remove the floor jack from under the machine. 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 bolts to 100 to 150 pound-feet (136 to 203 Nm).

Install and tighten the drain plug in the transaxle.

STEP 91

STEP 93

Fill the transaxle to the correct level. If the oil drained from the transaxle is to be used again, the oil must be filtered before being returned to the transaxle.

STEP 94

Remove the air from the brakes according to the instructions 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.

Bur 8-12501

Issued 3-91

Printed in U.S.A.

6001-18

REPLACING A UNIVERSAL JOINT NOTE: This procedure shows the removal of a universal joint for the rear drive shaft. The procedure is the same for all drive shafts used on this machine.

STEP 99

STEP 96

Remove the cross from the shaft

Remove the snap rings.

STEP 97

STEP 100

Repeat steps 97, 98, and 99 to remove the cross from the yoke.

STEP 101

Use an acceptable support and driver and press the bearing caps out ofthe shaft Make sure that the grease fitting is up as shown.

STEP 98

Start a bearing cap into the yoke. DO NOT press the bearing cap all the way in.

STEP 102

Remove the bearing cap. If necessary, use pliers to remove the bearing cap. Bur 8-12501

Install the cross in the yoke.

Issued 3-91

Printed in U.SA

6001-19

STEP 103

STEP 106

Install the cross in the bearing cap. Be careful not to move the needles.

Install a snap ring in the groove.

STEP 104

Press the other bearing cap a short distance into the yoke. Carefully raise the cross into the top bearing cap and press the bearing cap into the yoke.

STEP 107

Press the other bearing cap all the way into the yoke.

STEP 108

STEP 105

Install a snap ring.

Use the driver and press the bearing cap into the yoke until the groove for the snap ring can be seen.

Bur 8-12501

Issued 3-91

Printed in USA

6001-20

STEP 109

STEP 112

Start a bearing cap into the shaft. DO NOT press the bearing cap all the way in.

Press the other bearing cap a short distance into the shaft. Carefully raise the cross into the bearing cap and press the bearing cap into the shaft.

STEP 110

Install the cross in the shaft with the grease fitting up as shown.

STEP 111

Install the cross in the bearing cap being careful not to move the needles.

STEP 113

Use the driver and press the bearing cap into the shaft until the groove for the snap ring can be seen.

STEP 114

Install a snap ring.

STEP 115

Repeat steps 113 and 114 for the other bearing cap.

Bur 8-12501

Issued 3-91

Printed in U.S.A.

Section

6002 SPECIFICATIONS,

CASE CORPORATION

SCHEMATIC AND TROUBLESHOOTING

Bur 8-12512

Printed in U.S.A. Issued March 1991

6002-2

TABLE OF CONTENTS SPECIFICATIONS SPECIAL TOOLS SCHEMATIC OF TRANSMISSION HYDRAUliC SYSTEM TROUBLESHOOTING Problem: Machine Will Not Move Problem: Loss of Power Problem: Oil in Transmission Too Hot Problem: Clutch Discs Wear Too Fast or Are Burned Problem: Brake Discs Wear Too Fast Problem: Pinion Shaft Failure CHECKING CLUTCH PRESSURE CHECKING OUTPUT OF CHARGING PUMP AND SETTING OF CHARGE PRESSURE REliEF VALVE CHECKING CONVERTER IN PRESSURE AND FLOW CHECKING CONVERTER OUT PRESSURE AND FLOW CHECKING BRAKE COOLING FLOW CHECKING LUBRICATION FLOW AND PRESSURE FOR CLUTCHES CHECKING LUBRICATION FLOW FOR PINION SHAFT

2 3 4 5 5 6 7 7 7 7 9 9 10 11 11 12 12

SPECIFICATIONS Output of charging pump

15 to 17 U.S. gpm at 80 to 140 psi at 2200 rpm (57 to 64 Umin at 551 to 965 kPa, 5.5 to 9.6 bar at 2200 r/rnin)

Charge pump relief valve

350 to 430 psi at 2200 rpm (2413 to 2965 kPa, 24 to 30 bar at 2200 r/rnin)

Neutral pressure

Forward and reverse clutch

75 to 135 psi at 2200 rpm (517 to 930 kPa, 5.2 to 9.3 bar at 2200 r/rnin) 175 to 230 psi at 2200 rpm (1082 to 1586 kPa, 11 to 16 bar at 2200 r/rnin)

Flow Specifications Torque converter in

Torque converter out...

Brake cooling

Clutch lubrication

Bur 8-12512

5 to 7 U.S. gpm at 50 to 100 psi at 2200 rpm (19 to 26.5 Umin at 345 to 689 kPa, 3.4 to 7 bar at 2200 r/rnin) 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) 5 to 7 U.S. gpm at 10 to 30 psi (19 to 26.5 Umin at 69 to 207, 0.7 to 2.1 bar at 2200 r/rrun) 5 to 7 U.S. gpm at 45 to 90 psi at 2200 rpm (19 to 26.5 Umin at 310 to 620 kPa, 3.1 to 6.2 bar at 2200 r/rnin)

Issued 3-91

Printed in U.S.A.

6002-3

SPECIAL TOOLS In the U.S. and Canada, order the tools from Service Tools P.O. Box 314 Owatonna, MN 55060 In Europe order the tools from VL Churchill Ltd. P.O. Box 3, Daventry Northants NN11 4NF England

B877558 CAS-1B04 or 10111 Pressure Fitting Kit

B4218289M CAS-10280 Flowmeter

CAS-2026 Special Fitting Kit

B877168 CAS-1BOBor 10106 Flowmeter Fitting Kit

Bur 8-12512

Issued 3-91

Printed in U.S.A.

6002-4 1

1. Clutch Lubrication Oil 2. Reverse Clutch 3. Forward CLutch 4. Spool 5. Modulator Valve

Bur 8-12512

6. Accumulator 7. Clutch Cutout Valve 8. Dual Regulator Valve 9. Filter 10. Torque Converter Relief Valve

11. Pressure Regulator Valve 12. Charging Pump 13. Torque Converter 14. Oil Cooler

15. 16. 17. 18.

Brake Cooling Oil PTO Control Valve PTO Clutch Pinion Lubricaion Oil

Issued 3-91

Printed in U.S.A.

6002-5

TROUBLESHOOTING Problem: Machine Will Not Move Troubleshooting loss of oil.

complete. Find cause of

Troubleshooting

complete.

Check the setting of the torque converter relief valve and repair as required. There can be a problem in the torque converter housing or the torque converter. Repair as required. If the drive shaft turned with the direction control lever in NEUTRAl but did not turn in forward or reverse, the problem is in the transaxle.

Check the pressure for the forward and reverse clutches. The clutch cutout solenoid is not working correctly. Repair as required. The dual regulator valve in the transmission control valve is not working correctly. Remove the parts and repair as required.

Check the output of charging pump and the setting of the charge pressure relief valve and repair as required. The problem can be broken parts in the transaxle. Repair as required. The problem can also be caused by bad seals for the clutch piston. bad sealing rings on the shaft or a worn wear sleeve in the bore for the shaft.

Bur 8-12512

Issued 3-91

Printed in U.S.A.

6002-6

Problem: Loss of Power Repair engine as required.

Loss of pressure can be caused by bad seals in the clutch, bad sealing rings on the shaft or a worn wear sleeve in the bore for the shaft. It will be necessary to remove and disassemble the transmission to find the cause. The dual regulator valve in the transmission control valve can also cause the problem. Remove the parts and repair as required.

If the pressure for the forward and reverse clutches is less than before, the problem is in the clutch for the PTO. The loss of pressure can be caused by bad seals in the clutch, bad sealing rings on the shaft or a worn wear sleeve in the rear bore for the shaft for the PTO. It will be necessary to disassemble the PTO to find the cause.

Loss of power can be caused by a damaged torque converter. Replace the torque converter. Loss of power can also be caused by worn friction discs in the clutch. Disassemble transmission and repair as required.

NOTE: If the pressure for the totwetd and reverse clutches is equally lower than specified, the problem can be the clutch cutout solenoid or the control valve. Repair as required.

Bur 8-12512

Issued 3-91

Printed in U.S.A

6002-7

Problem: Oil In Transmission Too Hot Check torque converter in pressure and flow. Is the pressure and flow as specified?

NO ~

Remove and inspect the parts of the torque converter relief valve for wear and damage. Install new parts as required and check the pressure again. IMPORTANT: The torque converter relief valve cannot be adjusted. DO NOT try to adjust the torque converter relief valve. Check the output of the charging pump and repair as required.

NO --

•• -

There is a restriction in the cooling circuit. Clean the tubes, hoses and the oil cooler.

Problem: Clutch Discs Wear Too Fast or are Burned NO

One problem can be worn sealing rings or wear sleeve for the shaft. Disassemble the transmission and repair as required. Another problem can be a plugged orifice in the lubrication passage in the housing below the transmission control valve. See the following illustration.

Check the outJ:M' of ttie charging pump and repair as required.

B901668J

Bur 8-12512

Issued 3-91

Printed in U.S.A.

6002-8

Problem: Brakes Wear Too Fast See Checking Torque Converter Out Flow and Pressure and Brake Cooling Flow. One side wears faster than the other. Make sure that the orifice and spring are installed below the elbow at the top left rear of the transmission housing.

Problem: Pinion Shaft Failure This problem will be found during repair of the transaxle. Check to make sure that the lubrication tubes are not damaged and correctly installed. Also check to make sure that the orifice in the connector between the tubes is open.

Bur 8-12512

Issued 3-91

Printed in U.S.A.

6002-9

CHECKING CLUTCH PRESSURE Equipment Required CAS-10111 or CAS-1804 pressure fitting kit

Test Procedure Parking brake applied. Shift lever in

NEUTRAL.

Oil at operating temperature. 400 psi (2758 kPa, 27 bar) gauge FORWARD port.

connected

to

Engine running at 2200 rpm (r/min). Move direction control lever to

FORWARD.

Read gauge and record the reading. See page 2 for the specification. Repeat the procedure at the

REVERSE

port.

CHECKING OUTPUT OF CHARGING PUMP AND SETTING OF CHARGE PRESSURE.RELIEF VALVE Equipment Required CAS-10106 or CAS-1808 flowmeter fitting kit. CAS-2026 Special Fitting Kit 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. Inlet of flowmeter connected to port 1.

Engine running at 2200 rpm (r/min).

Outlet of flowmeter connected to port 2.

Read the flow gauge and the pressure gauge and record both readings.

All transmission controls in

NEUTRAL.

Parking brake applied. Load valve for flowmeter open. Oil at operating temperature.

Bur 8-12512

With the engine running at 2200 rpm (r/min), slowly close load valve until the pressure stops increasing and record the reading. See page 2 for specifications.

Issued 3-91

Printed in U.SA

6002-10

CHECKING CONVERTER IN PRESSURE AND FLOW Equipment Required CAS-1 01 06 or CAS-1808 flowmeter fitting kit. CAS-2026 Special Fitting Kit CAS-10280 flowmeter.

Test Procedure Inlet of flowmeter connected to port 1. Outlet of flowmeter connected to port 2. All transmission controls in

NEUTRAL.

Test point shown is early production. with hose for late production.

Tube replaced

Parking brake applied. Load valve for flowmeter open. Oil at operating temperature. Engine running at 2200 rpm (r/min). Read the flow gauge and the pressure gauge and record both readings. See page 2 for the specifications.

Bur 8-12512

Issued 3-91

Printed in U.S.A.

6002-11

CHECKING CONVERTER OUT PRESSURE AND FLOW Equipment Required CAS-2026 Special Fitting Kit CAS-10280 flowmeter.

Test Procedure Inlet of flowmeter connected to port 1. Outlet of flowmeter connected to port 2. All transmission controls in NEUTRAL. Parking brake applied.

Bottom of torque converter housing

Load valve for flowmeter open. Oil at operating temperature. Engine running at 2200 rpm (r/rnin). Read the flow gauge and record the reading. See page 2 for the specification.

CHECKING BRAKE COOLING FLOW Equipment Required CAS-2026 Special Fitting Kit CAS-10280 flowmeter.

Test Procedure Inlet of flowmeter connected to port 1. Outlet of flowmeter connected to port 2. All transmission controls in NEUTRAL. Parking brake applied. Load valve for flowmeter open. Read the flow gauge and the pressure gauge and record both readings. See page 2 for the specifications.

Bur 8-12512

Issued 3-91

Printed in U.S.A.

6002-12

CHECKING LUBRICATION FLOW AND PRESSURE FOR CLUTCHES

Equipment Required CAS-1 01 06 or CAS-1808 flowmeter fitting kit. CAS-10280 flowmeter. CAS-10111 or CAS-1804 pressure fitting kit CAS-2026 special fitting kit

Test Procedure Connect the inlet of the flowmeter to port 1. Connect the outlet of the flowmeter to port 2. Connect a 100 psi (670 kPa, 6.7 bar) gauge to port 3 All transmission controls in NEUTRAL. Parking brake applied. Load valve for flowmeter open Oil at operating temperature. Engine running at 2200 rpm (rzmin). Read the flow gauge and record the reading. Read the pressure gauge and record the reading See page 2 for the specifications.

LUBRICATION FLOW FOR PINION SHAFT An estimate of the lubrication flow can be made from known flow readings as shown in the following example. The specified flow is 1-1/2 to 2 U.S. gpm (5.7 to 7.6 Umin). U.S. gpm flow for torque converter in flow for clutch lubrication

pump output answer from above lubrication flow for pinion shaft

Bur 8-12512

6.6

Umin 25

+ 5.8

+ 22

12.4

47

14.4 -12.4

54.5 - 47.0

2.0

7.5

Issued 3-91

Printed in U.S.A.

Section

6003 WHEELS AND TIRES

CASE CORPORATION

Bur 8-12521

Printed in U.S.A. Issued March 1991

6003-2

WHEEL BOLTS AND NUTS Torque Specifications Front wheel, two wheel drive

115 to 150 pound-feet

(156 to 203 Nm)

Front wheel, four wheel drive

200 to 260 pound-feet

(270 to 352 Nm)

Rear wheel mounting nuts

320 to 380 pound-feet

(434 to 515 Nm)

IMPORTANT: The rear wheel mounting nuts on this machine are metric. Use only the mounting nuts shown in the parts catalog for this machine.

General Information Tighten the wheel bolts and nuts on a 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)

12 x 16.5,6

PR, Lug

45 psi (310 kPa, 3.1 bar)

12 x 16.5,8

PR, Lug

55 psi (380 kPa, 3.8 bar)

Rear Tires 16.9 x 24,10 PR, R4

28 psi (193 kPa, 1.9 bar)

17.5L x 24,8 PR, R4

22 psi (152 kPa, 1.5 bar)

17.5L x 24,10 PRoR4

28 psi (193 kPa, 1.9 bar)

19.5L x 24,8 PR, R4

20 psi (140 kPa, 1.4 bar)

19.5L x 24,10 PR, R4

24 psi (165 kPa, 1.6 bar)

Bur 8-12521

Issued 3-91

Printed in U.S.A.

Section

6019 HYDRAULIC PTO

CASE CORPORATION

J I Case Company Don 7-37060

Printed in U.S.A. December 1990

OUl ~:h:~

TABLE OF CONTENTS SPECIFICATIONS

2

SPECIAL TORQUES

2

SPECIAL TOOLS

3

SHOP EQUIPMENT TOOLS

3

PTa HOUSING Removal Installation

4 5

PTa INPUT SHAFT (PRIMARY) Removal and Disassembly Assembly and Installation

6 6

PTO CLUTCH Removal Disassembly Inspection Assembly Cross Sectional Drawing of the PTa Clutch Installation

7 8 ,9 10 13 14

PTO VALVE Removal Disassembly Assembly Cross Sectional Drawing of the PTa Valve Installation

14 15 16 17 18

INPUT AND OUTPUT SHAFTS Removal Installation

19 21

SPECIFICATIONS Lubrication Input Shaft End Play Output Shaft End Play.......... Clutch Friction Plate Thickness Clutch Separator Plate Thickness

mm mm mm mm

Hy-Tran Plus (MS1207) 0.001 to 0.005 inch 0.001 to 0.005 inch 0.096 to 0.102 inch 0.083 to 0.091 inch

195 to 250 Nm 73 to 87 Nm 101 to 113 Nm

145 to 185 Ib ft 54 to 64 Ib ft 75 to 83 Ib ft

0.025 to 0.127 0.025 to 0.127 2.45 to 2.60 2.11 to 2.31

SPECIAL TORQUES PTO Housing Retaining Bolts PTO Valve Retaining Bolts PTO Clutch Hub Retaining Bolt

Don 7-37060

Issued 12-90

Printed in U.S.A

6019-3

SPECIAL TOOLS

1. CLUTCH SPRING COMPRESSOR CAS 1992 First Used on Page 8

2. SEAL EXPANDER/PROTECTOR CAS 2001 First Used on Page 21

3. SEAL COMPRESSOR CAS 2005-1 First Used on Page 21

SHOP EQUIPMENT TOOLS

1. BUSHING

DRIVER SET OEM 6506

2. TORQUE WRENCH

OEM 6480

3. SEALANT B17555 LOCmE

Don 7-37060

515

4. PRIMER 'N' 8500637 5. DIAL GAUGE OEM 1030-1 6. IMPACT HAMMER OEM 4251

Issued 12-90

Printed in U.S.A.

6019-4

PTO HOUSING

Removal STEP 1 Park the machine on level ground and apply the parking brake.

STEP 2 Lower the bucket to ground level.

STEP 3

~.

:".

~,

~ Install a hoist onto the PTO housing and remove the housing bolts.

STEP 7

Install blocks in front and behind the rear wheels.

STEP 4 Install a container with a capacity of 60 litres under the transmission and drain the oil.

STEP 5

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. NOTE: The transmission photographic purposes only.

Don 7-37060

was

removed

for

Issued 12-90

Printed in U.S.A.

6019-5

Installation STEP 8

STEP 11

Clean the faces on the transaxle and PTO housings.

STEP 9

029221

Remove the caps and install the PTO clutch supply tube. Tighten the tube ends and mounting clamp (1). 800411

STEP 12 Install Hy-Tran Plus transmission oil up to the full mark on the dipstick.

STEP 13 Remove the blocks from the rear wheels.

030227

Apply sealant 817555 to the face of the transaxle, and Primer 'N' 8500637 to the face of the PTO housing.

Instali the PTO housing and mounting bolts. Tighten the bolts to a torque of 195 to 250 Nm (145 to 185 Ib ft).

Don 7-37060

Issued 12-90

Printed in U.S.A.

6019-6

P.T.G. INPUT SHAFT (PRIMARY) Removal and Disassembly STEP 14

STEP 16

Remove the transmission end cover. Refer to Section 6206.

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 the shaft and bearing with a soft hammer. NOTE: If the PTO housing has been removed it will not be necessary to remove the end cover. Remove the seal and outer bearing snap ring. Use a soft hammer and drive the input shaft iotweto out of the end cover.

Remove and discard the oil seal from the housing.

STEP 18 Examine all parts and replace if necessary.

Assembly and Installation

1. 2. 3. 4.

SHAFT SNAP RING BEARING SEAL

Don 7-37060

INP580

Issued 12-90

Printed in U.S.A.

6019-7

STEP 19

STEP 20 Follow Steps 14 to 16 in reverse order and install the primary input shaft.

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 24

STEP 21 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

Remove the hub (1), thrust bearing (2) and thrust washer (3). Don 7-37060

Issued 12-90

Printed in U.SA

6019-8

Disassembly STEP 28

STEP 25

029817

Remove the snap ring (1) backing plate (2) four clutch plates (3) and four separate plates (4) in alternate order from the housing.

STEP 26

C26827

Turn the clutch housing over, shock the housing against a wooden block to remove the piston (1).

STEP 29

C26829

Install the clutch assembly and special tool CAS 1992 (1) into a press and compress the spring. Remove the snap ring (2).

Remove and discard the o-rings and seals (1) from the piston.

STEP 30

STEP 27

D30223

Release the pressure and remove the retainer (1) and spring (2).

Don 7-37060

Remove the snap ring (1), brake plate (2), springs (3), brake assembly (4) and inner brake plate (5) from the clutch housing.

Issued 12-90

Printed in U.S.A.

6019-9

STEP 31

STEP 32

C27202

Remove the three piston pins (1) and discard a-rings (2).

the

Remove the needle roller bearing (1) and clutch assembly retaining washer (2) from the housing.

Inspection STEP 35

STEP 33

Wash all the parts in cleaning solvent and dry using compressed air. Replace any part that shows signs of wear or damage.

808116

Inspect the friction plates for wear and damage. Replace the friction plates if the thickness is less than 2.4 mm (0.094 inch).

STEP 34

B0611S

Inspect the steel separator plates for wear and damage. Replace the plates if the thickness is less than 2.10 mm (0.082 inch).

Don 7-37060

Issued 12-90

Printed in U.S.! .

6019-10

Assembly

1. INPUT SHAFT

6. BRAKE ASSEMBLY

11. WASHER

16. RETAINER

2. O-RING

7. SPRING

12. BOLT

17. NEEDLE ROLLER BEARING

3. PIN

8. HOUSING

13. BACKING PLATE

18. THRUST WASHER

4. SNAP RING

9. PISTON

14. FRICTION PLATE

19. THRUST BEARING

5. PLATE

10. SEAL

15. SEPARATOR PLATE

20. HUB 21. INPUT SHAFT (PRIMARY)

Don 7-37060

Issued 12-90

Printed in U.S.A.

6019-11

STEP 36

STEP 38

.

e/

""'-

)

D3a223

Install the inner brake plate (1), brake assembly (2), springs (3), outer plate (4) and snap ring (5).

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 housing (3).

Install the o-rings and seals (1) onto the clutch piston.

STEP 37

STEP 40

Install new o-rings (1) onto the three piston brake pins (2). Install the pins.

Lubricate and install the piston into the housing. Push in the piston equally from all sides until fully installed.

C26829

808132

NOTE: 00 not use a driver or press to install the piston into the clutch housing.

Don 7-37060

Issued 12-90

Printed in U.S.A.

6019-12

STEP 41

STEP 43

Install the clutch housing into a press. Install the piston return spring and retainer. Compress the spring with the special tool CAS 1992 (1) and install the snap ring (2).

Install new rubber seals (1) onto the input shaft.

ll30221

NOTE: The larger diameter seal is installed first.

STEP 42

lnstaH the clutch plates into the housing in alternate order. Start with a separator plate (1) and finish with a friction plate 2. Install the backing plate (3) and snap ring (4).

Don 7-37060

Issued 12-90

Printed in U.S.A.

6019-13

Cross Secitonal Drawing of the PTO Clutch

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

Don 7-37060

Issued 12-90

Printed in U.S.A

6019-14

Installation STEP 44

STEP 46

029626

Install the PTO clutch assembly (1), and retaining bolt (2). Tighten the bolt to a torque of 101 to 113 Nm (75 to 83 Ib ft).

STEP 45

Install the shroud (1) and retaining bolts (2). Tighten the bolts.

STEP 47 Install the PTO housing. Refer to Steps 8 to 13.

030217

Use petroleum jelly to install the thrust bearing (1) and thrust washer (2) into the friction plate drive hub (3). Install the hub into the PTO clutch.

IMPORTANT: Make sure the splines on the hub engage with the splines on the friction plates.

PTa VALVE Removal STEP 48

STEP 49 .....•. .-

Refer to Steps 1 to 7 and remove the PTO housing from the transaxle

030229

Don 7-37060

Remove the bolts and valve assembly. Discard the o-rings (1). Issued 12-90

Printed in U.S.A.

6019-15

Disassembly STEP 50

STEP 53

Make a note of the number of threads visible on the screw (1). Loosen the nut (2) and remove the screw, nut, washer and seal. Remove and discard the seal.

STEP 54

STEP 51

808019

Remove the spring (1), detent (2) and ball (3) from the valve body.

STEP 52

B08027

Remove the spool (1) from the valve body.

STEP 55 Wash all parts in cleaning compressed air

solvent and dry using

STEP 56 Replace any part that shows signs of wear or damage.

B08021

Remove the snap ring (1) retaining the end cap.

Don 7-37060

Issued 12-90

Printed in U.S.A

6019-16

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 Follow Steps 50 to 54 in reverse order and assemble the PTO valve. NOTE: Apply petroleum jelly to retain the ball onto the detent.

Don 7-37060

Issued 12-90

Printed in U.S.A.

6019-17

Cross Sectional Drawing of the PTO Valve 1. SPOOL 2. VALVE BODY 3. BALL 4. VALVE 5. SECONDARY SPRING 6. RETURN SPRING 7. PRIMARY SPRING 8. SNAP RING 9. END CAP 10. DETENT GUIDE 11. DETENT SPRING 12. SCREW 13. NUT 14. WASHER 15. SEAL WASHER

PTOV580

Don 7-37060

Issued 12-90

Printed in U.S.A.

6019-18

Installation STEP 58

STEP 59 Install the PTO housing. Refer to Steps 8 to 13.

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).

Don 7-37060

Issued 12-90

Printed in U.S.A.

6019-19

INPUT AND OUTPUT SHAFTS Removal STEP 60

STEP 64

Remove the PTO housing from the transaxle. Refer to Steps 1 to 7.

STEP 61 Remove the clutch and valve assemblies from the PTO housing. Refer to Steps 22 and 49.

STEP 62 029802

Support the gear and drive out the output shaft rearwards with the bearing driver OEM 6506. NOTE: The output shaft gear must be supported during removal by an assistant to prevent damage to the PTO gears.

STEP 65 Remove the oil seal and snap ring from the rear of the PTO housing. Discard the seal.

STEP 63

Remove the front bearing cone (1), thrust washer (2) and gear (3) from the housing. Drive out the front bearing cup (4) from the housing.

029630

Remove the snap ring (1) from the front bearing of the output shaft.

Don 7-37060

Issued 12-90

Printed in U.SA

6019-20

STEP 67

STEP 66

029814

808425

Remove the snap ring from the housing and install the impact hammer OEM 4251 (1). Remove the input shaft and front bearing cone. Discard the two seals from the input shaft.

Don 7-37060

Examine the bearings, gears, snap rings, rear bearing cup (1) and seal sleeve (2) for wear and damage. Replace if necessary.

Issued 12-90

Printed in U .SA

6019-21

Installation

1. BEARING CUP

1HS580

2. BEARING CONE 3. SEALS 4. INPUT SHAFT 5. SNAP RING 6. a-RINGS 7. SPACER 8. GEAR 9. OUTPUT SHAFT 10. SEAL

STEP 69

STEP 68

C21727

C21730

Use the special tool CAS 2001 to expand and install the new seals (1) onto the input shaft.

Install the special tool CAS 2005-3 to compress the seals to the correct diameter.

seals in Hy-Tran Plus before

IMPORTANT: The correct seal operating size can only be obtained by using the special tools.

IMPORTANT: Soak the installation.

Don 7-37060

Issued 12-90

Printed in U.S.A.

6019-22

STEP 73

STEP 70

D29636

Install the input shaft, front bearing cone and snap ring. Install the inpact hammer and seat the bearing cone against the snap ring (1).

Install the rear bearing cone and snap ring.

STEP 74

STEP 71

Install the thrust washer (1), front bearing cone (2), bearing cup (3) and snap ring (4). Install the dial gauge OEM 1030-1 and measure the end play on the input shaft.

STEP 75 :':':.

NOTE: Snap rings are available in sizes from 2.0 to 2.36

mm (O.OBOta 0.093 inch)./nsta/I a snap ring which gives an end play of O.025 ta 0.127 mm (0.001 to 0.005 inch). STEP 72

D302t9

029802

Install the gear and output shaft into the PTa housing.

Don 7-37060

Use a soft hammer and drive the output shaft in both directions to seat the bearing cups against the snap rings. Install the dial gauge OEM 1030-1 and measure the end play on the output shaft. If necessary replace the snap ring with one of a different thickness until the end play measures 0.025 to 0.127 mm (0.001 to 0.005 inch).

Issued 12-90

Printed in U.S.A.

6019-23

STEP 76

STEP 77 Install the clutch and PTO valve assemblies. Refer to Steps 44 and 58.

STEP 78 Install the PTO housing. Refer to Steps 8 to 13.

Install a new output shaft oil seal (1) until the seal face is level with the face of the PTO housing.

Don 7-37060

Issued 12-90

Printed in USA.

Section

6201 REAR AXLES AND PLANETARIES

Copyright © 1990 J I Case Company

CASE CORPORATION

Don 7-36980

Printed in U.S.A. December 1990

6201-2

TABLE OF CONTENTS SPECIFICATIONS

2

SPECIAL TORQUES

2

SPECIAL TOOLS

3

SHOP EQUIPMENT TOOLS

3

TOOLS TO BE MADE

4

SERVICING THE REAR AXLES AND PLANETARIES Removal Disassembly Inspection Assembly Installation

5 6 9 10 15

SPECIFICATIONS Lubrication Transmission Oil. Axle Shaft Bearing Rolling Torque

3.4 to 5.7 Nm

Hy-Tran Plus (MS 1207) 30 to 50 Ib inches

SPECIAL TORQUES Rear Axles To Transmission Case

Don 7-36980

326 to 353 Nm

240 to 260 Ib ft

Issued 12-90

Printed in U.S.A.

6201-3

SPECIAL TOOLS

1. SEAL INSTALLATION TOOL FOR REAR AXLE CAS 2007

2. lOCKNUT

SOCKET FOR REAR AXLE SHAFT NUT CAS 2006

SHOP EQUIPMENT TOOLS

1. TORQUE WRENCH OEM 6475

2. SEALANT B500642 lOCTITE 324 ACTIVATOR B500622 lOCTITE 707 KIT PART NUMBER B500621 3.BEARING

OVEN OEM 8014

5. ALIGNMENT STUD SET CAS 1995 Don 7-36980

Issued 12-90

Printed in U.S.A.

6201-4

TOOLS TO BE MADE

AXLE BEARING PRE-LOAD SETIING TOOL

7.36980

A. 344mm (13.5 inch)

D. 5 mm (0.2 inch)

B. 382 mm (15.0 inch)

E. 20 mm (0.8 inch)

C. 40 mm (1.6 inch)

F. 14mm (0.6 inch)

Issued 12-90

Printed in U.S.A.

6201-5

SERVICING THE REAR AXLES AND PLANETARIES Removal NOTE: The transaxle must be removed from the machine to service the rear axles and planetaries.

STEP 4

STEP 1 Drain the oil from the transmission into a container with a capacity of 40 litres.

STEP 2

C12345

Put the rear axle in a clean work area so that the planetary gear end is facing upwards.

Remove two opposite retaining bolts from the rear axle and install alignment studs CAS 1995.

STEP 3

Use suitable lifting equipment to support the rear axle. Remove the remainder of the retaining bolts and remove the rear axle from the transaxle housing.

Don 7-36980

Issued 12-90

Printed in U.S.A.

6201-6

Disassembly STEP 5

STEP 8

,

.~

Remove the snap rings from the three planet gear pins,

STEP 6

Remove the planet gear carrier assembly from the axle housing.

STEP 9

C13206

Remove the steel plate. Use a suitable drift punch to move the tab on the lock washer away from the ring nut.

STEP 7

STEP 10

C13208

Release the snap ring from the planet gear carrier....~.

Use the special tool CAS (2006) to loosen the ring nut. Remove the ring nut.

Don 7-36980

Issued 12-90

Printed in U.S.A

6201-7

STEP 14

STEP 11

~.-'.

Use a lever to remove the shaft seal from the rear axle case.

Remove and discard the lock washer.

STEP 12

STEP 15

Remove the thrust washer.

Remove the axle shaft from the rear axle case.

STEP 13

STEP 16

Ale.

Put the rear axle in a horizontal position and remove the inner bearing from the axle shaft.

Don 7-36980

BOIl520

Install the puller, OEM 1108, and remove the bearing from the axle shaft.

Issued 12-90

Printed in U.S.A.

6201-8

STEP 17

STEP 20

Remove and discard the oil seal.

Remove the '0' washer from the top of the planet gear.

STEP 18

NOTE: Keep the parts of the planet gear assemblies together, so that they can be assembled as a set.

STEP 21

Mark the gears and pins for the correct assembly of the planet gear carrier

STEP 19

Remove the top rollers.

Remove the gears and thrust washers from the planet gear carrier. NOTE: Remove the bottom thrust washer with the gears to retain the loose bearing rollers.

Don 7-36980

Remove the separator.

Issued 12-90

Printed in U.SA

6201-9

STEP 24

STEP 23

013

Remove the bottom rollers.

STEP 25

014

Remove the planet gear from the bottom washer.

Inspection

Clean all parts in cleaning solvent and dry in compressed air. DO NOT permit the bearings to rotate when drying.

STEP 28

STEP 26

A35

Check the bearings for free, smooth action. Replace the bearings if necessary, making sure that the new bearing cups are against their shoulders in the axle case. 016

Check the planet gears for wear and cracks at the tooth root. Replace the planet gears in sets only.

STEP 29

STEP 27

h

#

A3S

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 serviced separately.

cannot be

NOTE: The Flat side of the pin faces outvvard. Don 7-36980

Issued 12-90

Printed in U.S.A.

6201-10

Assembly

EA2583

Don 7-36980

Issued 12-90

Printed in U.S.A.

6201-11

STEP 30

$TEP 33

Clean the faces of the rear axle case and the trans axle housing.

STEP 31

3. BEARING

Lubricate the new oil seal (1), with clean transmission oil. Install the seal onto the axle shaft so that the lip is toward the flange (2), (groove inward).

51252

Putthe axle case in a horizontal position. Install the axle shaft, assembly and seal installer CAS 2007 into the axle housing.

STEP 34

STEP 32

Install the inner bearing.

Heat the outer axle shaft bearing in the oven OEM 8014 to a temperature of 300°F (150°C). Install the bearing on to the axle shaft so that it is against the shoulder (1).

Don 7-36980

Issued 12-90

Printed in U.S.A.

6201-12

STEP 36

STEP 35

Install the thrust washer.

STEP 37

AXLE HOUSING

51252A

Install the ring nut only at this stage and tighten until the seal is fully installed. Remove the seal installation tool CAS 2007. Remove the ring nut.

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.

Don 7-36980

Issued 12-90

Printed in U.S.A.

6201-13

STEP 39

STEP 41

EC3227A

Use the Specia Iy made tool bolted across the centerline of the axle, with the nut in the center. Use a torque wrench to measure the rolling torque at the nut, with the axle resting on the axle flange (measure the rolling torque with no bearing preload). Make a note of the rolling torque. Tighten the nut using the Special tool (CAS 2006). While rotating the axle housing, preload the bearings to 3.4 to 5.7 Nm (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.

Lubricate the bearing rollers with petroleum jelly and install the bottom set.

"

STEP 42

NOTE: When the bearing pre-load is correct, move a tab on the lock washer into one of the slots in the ring nut.

STEP 40

011

Install the separator.

STEP 43

Lubricate the surface of the bottom washer with petroleum jelly and install a planet gear on to the washer.

Don 7-36980

Install the top set of bearing rollers.

Issued 12-90

Printed in U.S.A.

6201-14

STEP 44

STEP 47

DB

Install the 'D' washer to the top of the planet gear. Repeat the procedure for the remaining two planet gears.

STEP 45

Install the planet gear carrier assembly into the axle housing.

STEP 48

C13208 C13222

Install the snap ring onto the planet carrier.

Install the snap ring onto the axle shaft.

STEP 49

STEP 46

C13206 C1321B

Install the steel Baffle plate.

Carefully install the planet gear assemblies onto the planet gear carrier pins.

Don 7-36980

Issued 12-90

Printedin U.S.A

6201-15

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

712B9GA

aean the surface of the transaxle housing and apply Sealant CAS 8500642 (Loctite 324). IMPORTANT: surfaces.

Don 7-36980

Do not get sealant onto the brake

Clean the surface of the rear axle housing and apply Activator CAS 8500622 (Loctite 707).

STEP 53' Install the two alignment studs CAS 1995.

Issued 12-90

Printed in U.S.A.

6201-16

STEP 54

STEP 56

Use suitable lifting equipment to install the rear axle onto the transaxle housing.

Install the remaining two bolts and washers then evenly tighten all the bolts to a torque of 326 to 353 Nm (240 to 260 Ib ft).

STEP 57 Install the transaxle into the machine.

STEP 55

STEP 58 Fill the transmission with Hy-Tran Plus oil up to the FULL mark on the dipstick.

Install the axle retaining bolts and washers then remove the two alignment studs. NOTE: After the rear axles are installed, the mounting bolts must be fully tjghtened within 3 to 5 minutes.

Don 7-36980

Issued 12-90

Printed in U.S.A.

Section

6202 TRANSFER GEARBOX

Copyright

CASE CORPORATION

Don 7-36990

© 1990 J I Case Company Printed in U.S.A. December

1990

6202-2

TABLE OF CONTENTS SPECIAL TORQUES

2

SHOP EQUIPMENT TOOLS

2

TRANSFER GEARBOX Removal Disassembly Inspection Assembly Installation

3 3 6 7 10

SPECIAL TORQUES Transfer Gearbox to Parking Brake Housing

77 to 100 Nm

57 to 74 Ib ft

SHOP EQUIPMENT TOOLS

1. TORQUE WRENCH (OEM 6475)

Don 7-36990

2. SEALANT 817555 (LOCnTE 515) + PRIMER 'N' 8500637

Issued 12-90

Printed in U.S.A.

6202-3

SERVICING THE TRANSFER GEARBOX

Removal NOTE: It is not necessary to remove the transaxle from the machine to service the transfer gearbox. The transaxle shown was removed for photographic purposes only.

STEP 5

STEP 1 To prevent excessive loss of oil from the transaxle raise the front of the machine and support on axle stands.

STEP 2 Remove the drive shaft. Refer to Section 6001.

STEP 3

Remove the transfer gearbox.

Disconnect the linkage to the transfer gearbox.

STEP 4

Remove the transfer gearbox retaining bolts.

Disassembly STEP 6

STEP 7

Remove the plug.

Remove the spring and plunger.

Don 7-36990

Issued 12-90

Printed in U.S.A.

6202-4

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 Remove the shift fork and rod from the housing.

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 housing.

the shift rod seal

STEP 14

Remove the two pads from the shift fork.

Remove the snap ring from the yoke.

Don 7-36990

Issued 12-90

Printed in U.S.A.

6202-5

STEP 15

STEP 18

Use a hydraulic press to remove the yoke from the housing in the direction shown.

Remove the bearing 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

retainer

snap

ring from the

Remove and discard the seal.

Don 7-36990

Issued 12-90

Printed in U.S.A.

6202-6

Inspection STEP 20

STEP 23

Check the bearing for smooth operation and replace if necessary.

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 .~:

Clean the surfaces of the parking brake housing and the transfer gearbox housing.

Check the shift fork and pads for wear or damage and replace if necessary. Replace pads as a pair.

Don 7-36990

Issued 12-90

Printed in U.S.A.

6202-7

Assembly

3. SNAP RING

5. SHIFT ROD 6. HOUSING

8. SHIFT COLlAR Don 7-36990

EA2S87

Issued 12-90

Printed in U.SA

6202-8

STEP 24

STEP 27

Install the new seal into the housing until both the seal and housing faces are level.

STEP 25

Use a hydraulic press to install the bearing.

STEP 28 Lubricate and install the yoke shaft into the housing.

STEP 26

Install the second snap ring.

Install the first snap ring onto the yoke shaft.

Don 7-36990

Issued 12-90

Printed in U.S A

6202-9

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 level with the housing.

Rotate the shift lever to the correct position. Align the holes and install the roll pins.

STEP 31

STEP 34

Install the shift fork so the detent groove is aligned with the hole in the housing.

Install the two pads into the shift fork.

Don 7-36990

Issued 12-90

Printed in U.S.A.

6202-10

STEP 37

STEP 35

~::.

Install the shift collar onto the two pads with the flat side of the collar faces inward. Align the splines and slide the collar over the yoke.

Install a new o-ring onto the plug.

STEP 38

STEP 36

Install and tighten the plug.

STEP 39

Install the detent plunger and spring.

Check the movement of the shift collar by moving the shift rod. Make sure the detent plunger holds the shift fork in the engaged and disengaged positions. Rotate the yoke and repeat the test.

Installation STEP 41

STEP 40

70001

Clean the surfaces of the parking brake housing and transfer gearbox housing. Apply CAS 817555 (Loctite 515) to the parking brake housing and Primer 'N' 8500637 to the transfer gearbox housing. Don 7-36990

,-.

Install the transfer gearbox onto the park brake housing. Issued 12-90

Printedin U.S.A.

6202-11

STEP 42

STEP 43 Install the drive shaft. Refer to Section 6202.

STEP 44 Connect the linkage to the transfer gearbox.

STEP 45 Remove the axle stands and lower the machine to the ground.

Install the five bolts and washers and evenly tighten to a torque of 77 to 100 Nm (57 to 74 Ib ft).

Don 7-36990

STEP 46 Add oil of the correct type to the transmission until the level reaches the full mark on the dipstick.

Issued 12-90

Printed in U.S.A.

"

Section

6203 DIFFERENTIAL AND DIFFERENTIAL LOCK

Copyright Don 7-37000

CASE CORPORATION

© 1990 J I Case Company Printed in U.S.A. December 1990

6203-2

TABLE OF CONTENTS SPECIFICATIONS

2

SPECIAL TORQUES

2

SHOP EQUIPMENT TOOLS

3

SERVICING THE DIFFERENTIAL AND DIFFERENTIAL LOCK Removal........ Disassembly , , Inspection....... Assembly ,....................................................................................................................... Installation..............................................................................................................................

4 6 9 10 13

SPECIFICATIONS Lubrication Transmission OiL

Hy-Tran Plus (MS 1207)

SPECIAL TORQUES Rear Axles To Transmission Case Differential Bearing Carrier Bolts (Tighten While Rotating The Differential) Differential Lock Cage To Carrier Differential Carrier To Crown Wheel.

Don 7-37000

326 to 353 Nm 73 to 87 Nm

240 to 260 Ib ft 54 to 64 Ib ft

73 to 87 Nm 126 to 153 Nm

54 to 64 Ib ft 93 to 113 Ib ft

Issued 12-90

Printed in U.S.A.

6203-3

SHOP EQUIPMENT TOOLS

1. TORQUE WRENCH (OEM 6475) 4. DEPTH GAUGE (OEM 1013)

2. SEALANT CAS B17555 (LOCTITE 515) AND PRIMER 'N' B500637

5. BEARING OVEN (OEM 8014)

6. THREAD SEALANT LOCTITE 680

3. DIAL GAUGE AND MAGNETIC BLOCK (OEM 1030-1)

NOTE: Any reference to left or right hand is as seen from the operator's seat looking forward. Don 7-37000

Issued 12-90

Printed in U.S.A.

6203-4

SERVICING THE DIFFERENTIAL AND DIFFERENTIAL LOCK Removal STEP 1

STEP 4

Drain the oil from the transmission case. Remove the transaxle from the machine. Refer to Section 6001.

STEP 2

Remove the sun shaft from the differential.

STEP 5 Remove both rear axles. Refer to Section 6201.

STEP 3

Remove the brake parts from the right hand side of the transmission housing. NOTE: 00 not remove the brake piston. Remove the brake backing plate, friction plate and reaction pins from the left side of the transmission housing. Refer to Section 7001 for the correct procedure.

STEP 6

NOTE: Do not remove the brake piston.

Disconnect the return spring differential lock selector lever.

Don 7-37000

from the top of the

Issued 12-90

Printed in U.S.A.

6203-5

STEP 7

STEP 10

Use a punch to remove the pin from the differential lock selector fork and lever.

Remove the nuts, bolts, washers and setscrews from the rear cover plate.

STEP 8

STEP 11

Remove the differential lock lever from the transmission housing.

Remove the rear cover plate.

STEP 9

STEP 12

..•.

.~

Use a block of wood to support the differential. Remove the sun shaft and differential lock selector assembly.

Don 7-37000

Issued 12-90

Printed in U.S.A.

6203-6

STEP 13

STEP 15

Remove the four bolts and washers from the right hand differential bearing carrier.

Repeat the procedure for the differential bearing carrier on the left hand side.

STEP 14

STEP 16'

Remove the differential bearing carrier and shims from the transmission case.

Carefully remove the differential.

~?

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.

Don 7-37000

Issued 12-90

Printed in U.S.A.

6203-7

STEP 22

STEP 19

..... ,;;;..;:.

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 crown wheel from the differential carrier.

STEP 20

STEP 23

Remove the side gear. F30

STEP 21

Remove the differential carrier.

STEP 24

F25

Remove the crown wheel retaining bolts and washers. F34

Use a suitable drift to remove the groove pin from the planetary gear pin.

Don 7-37000

Issued 12-90

Printed in U.S.A.

6203-8

STEP 25

STEP 28

..d.,

G16

Remove the planetary gear pin from the differential carrier.

Put the differential lock selector and sun shaft on a clean work area.

STEP 26

STEP 29

Remove the two planetary gears.

Remove the selector fork and pads.

STEP 27

STEP 30

Remove the second side gear.

Remove the selector from the sun shaft.

·.G19

Don 7-37000

Issued 12-90

Printed in U.S.A.

6203-9

Inspection STEP 31

STEP 34

Clean all parts in cleaning solvent and dry in compressed air. DO NOT permit the bearings to rotate when drying.

STEP 32

G14

Check both differential bearing carriers for wear or damage. If replacing the differential bearings, make sure that the new bearing cups are correctly installed.

STEP 35 "G23

Check,the side gears, planet gears and pin for wear or damage and replace as necessary.

STEP 33

G9

The crown wheel and the pinion shaft are a matched set. Replace both parts if there is any wear or damage. Refer to Section 6206 for pinion shaft removal.

STEP 36 G12A

Check the differential carrier and differential lock cage for wear or damage and the bearing for free and smooth action and replace if necessary

G2OA.

Check both sun shafts and the differential lock selector for wear or damage and replace as necessary.

Don 7-37000

Issued 12-90

Printed in U.S.A.

6203-10

EA2586B

Don 7-37000

Issued 12-90

Printed in U.S.A.

6203-11

STEP 37

STEP 40

Lubricate the differential lock selector with clean transmission oil then slide it onto the inner splines on the sun shaft. Make sure that the selector teeth are away from the sun gear.

Install the left hand side gear into the differential carrier.

STEP 41

STEP 38

Install the two planet gears. Install the two pads into the selector petroleum jelly to hold them in position.

fork.

Use

STEP 42

STEP 39

,00

Push the planet gear pin through the differential carrier and the planet gears. Make sure that the hole for the grooved pin is vertical. Install the fork into the selector. The hole for the pin must be at the top when the fork is on the left hand side of the selector, looking on the gear end of the sun shaft.

Don 7-37000

Issued 12-90

Printed in U.S.A.

6203-12

STEP 43

STEP 46

G36

Install a new grooved pin into the differential carrier and planet gear pin.

STEP 44

Apply (Loctite 680) to the threads and install the twelve 12mm bolts and new hardened washers into the differential carrier and crown wheel.

STEP 47

Install two guide studs into opposite holes in the crown wheel.

STEP 45

F24

Evenly tighten the bolts to a torque of 126 to 153 Nm (93 to 113 Ib ft).

STEP 48

F3S

Heat the crown wheel in a bearing oven to a maximum temperature of 302°F (150°C) and install the crown wheel onto the differential carrier. When the parts are cool, remove the guide studs.

h •••

Install the right hand side gear and lubricate the gears with clean transmission oil.

WARNING: Always wear heat protective gloves when touching heated parts.

Don 7-37000

Issued 12-90

Printed in U.S.A.

6203-13

STEP 49

STEP 51

Install the differential lock cage onto the differential carrier.

Evenly tighten the bolts to a torque of 73 to 87 Nm (54 to 64 Ib ft). Lubricate the bearing with clean transmission

STEP 50

~':

oil.

Install the six 10 mm bolts into the differential lock cage and carrier.

Installation STEP 52

STEP 53

Remove the tube nut for the differential lock lever, from the top of the transmission housing.

Install new inner and outer o-rings onto the tube nut.

Don 7-37000

Issued 12-90

Printed in U.S.A.

6203-14

STEP 54 w~:,

STEP 57

",.

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 thatthe crown wheel teeth are pointing to the right hand side of the housing.

STEP 56

Install the right hand bearing carrier without shims.

~ Evenly tighten the bolts to a torque of 73 to 87 Nm (54 to

64 Ib ft).

STEP 59

Install the left hand bearing carrier without shims.

NOTE: Make sure the hole for the differential lock control rod is properly aligned.

Don 7-37000

Issued 12-90

Printed in U.S.A.

6203-15

STEP 60

STEP 62

Install two bolts and new hardened washers into opposite holes then remove the wood block from under the differential.

Using a depth gauge, measure the distance from the face of the carrier to the transxaxle mounting face, through the measuring holes. If the difference in the measurements is 0.13mm (0.005 in.) or less, take the average of the two measurements. If the difference is greater than 0.13mm, disassemble and check for proper bearing seating. Subtract the carrier flange thickness 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 61

STEP 63

While rotating the differential, evenly tighten the bolts to a torque of 20 Nm (180 in Ibs). Rotate the differential and check the torque. Loosen the two bolts and now torque to 5.6 Nm (50 in Ibs.)

NOTE; The differential must be rotated while tightening the bolts to make sure that the bearings are correctly seated. Continue this procedure until there is no change in bolt torque.

Remove the two bolts, washers and the left hand bearing carrier. Fit the total shim thickness onto the bearing carrier and install the bearing carrier.

STEP 64

Install the bolts and washers onto the bearing carrier. Don 7-37000

Issued 12-90

Printed in U.S.A

6203-16

STEP 65

STEP 67

While rotating the differential, evenly tighten the bolts to a torque of 73 to 87 Nm (54 to 64 Ib ft). The bearings are now correctly pre-loaded.

Remove any old joint material from the rear cover plate and the joint face of the transmission housing. Make sure both faces are free of oil.

STEP 66

STEP 68

Use a dial gauge on the edge of a crown wheel tooth to measure the amount of backlash between the crown wheel and the pinion. This must be between 0.15 to 0.30 mm (0.006 to 0.012 inch). To change the amount of backlash, move some of the shims from the left hand bearing carrier to the right hand bearing carrier, without changing the total shim pack thickness. For each 0.076 mm (0.003 inch) of shim thickness moved, the backlash will change by approximately 0.05 mm (0.002 inch). After moving the shims. rotate the differential and evenly tighten the bearing carrier bolts to 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

Apply a continuous bead of CAS 817555 (Loctite 515) onto the joint face of the transmission housing. Apply Primer 'N' 8500637 onto the mounting face of the cover.

STEP 69

Install the rear cover plate onto the transmission housing

Don 7-37000

Issued 12-90

Printed in U.S.A.

6203-17

STEP 70

STEP 73

Install the nuts, bolts, washers and setscrews and evenly tighten to a torque of 221 to 250 Nm (160 to 185 Ib ft).

Install a new pin into the selector fork and lever.

STEP 74

STEP 71

Connect the return spring to the selector lever. Install the sun shaft and differential lock selector assembly into the right hand side of the differential. Make sure that the selector fork is at the rear.

STEP 75

STEP 72

Install the right hand side disc brake parts. Refer to Section 7001.

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.

Don 7-37000

Issued 12-90

Printed in U.S.A.

6203-18

STEP 76

STEP 78

Install the left hand sun shaft into the differential.

Install the rear axles. Refer to Section 6201.

STEP 77

IMPORTANT: Use only the sealant kit 8500621 when installing the rear axles.

Install the left hand side disc brake parts.

Don 7-37000

Issued 12-90

Printed in U.S.A.

Section 6204 FORWARD / REVERSE VALVE

CASE CORPORATION

Don 7-37010

Copyright

© 1990 J I Case Company Printed in U.S.A. December 1990

6204-2

TABLE OF CONTENTS SPECIFICATIONS _

2

SPECIAL TORQUES

2

SHOP EQUIPMENT TOOLS

2

FORWARD/REVERSE VALVE Disassembly Inspection Assembly

3 5 6

SPECIFICATIONS Transmission Lubricating Oil Spool Detent Spring Free Length Regulator Spring Free Length Modulation Spool Inner Spring Free Length Modulation Spool Outer Spring Free Length

37.26 58.65 70.55 77.60

mm mm mm mm

Hy-Trans Plus (to MS 1207) 1.467 inch 2.309 inch 2.777 inch 3.055 inch

SPECIAL TORQUES Forward/Reverse Spool Plug Detent Plug Accumulator Piston Plug Pressure Regulator Piston Plug Solenoid Valve Coil Cover Nut.. Neutral Start Switch

31 to 34 16 to 18 31 to 34 42 to 45 17 to 20 0.8 to 1.0 20 to 27

23 to 25 12 to 13 23 to 25 31 to 33 13 to 15 0.5 to 0.75 15 to 20

Nm Nm Nm Nm Nm Nm Nm

Ib ft Ib ft Ib ft Ib ft Ib ft Ib ft Ib ft

SHOP EQUIPMENT TOOLS 1. TORQUE WRENCH OEM 6479

Don 7-37010

Issued 12-90

Printed in U.S.A.

6204-3

Disassembly STEP 1

STEP 4

Remove the connecting wires and neutral start switch (1) from the valve body. Discard the a-ring from the switch.

Remove the solenoid valve (1) from the valve body and discard the o-rings (2).

STEP 2

".".".. --y".'

•

STEP 5

Remove the allen plugs from the top of the valve body and discard the a-rings.

STEP 3

Remove the allen plug (1), pressure regulator piston (2), spring (3), pin (4) and regulator spool (5). Discard the a-ring (6). Remove the nut (1), a-ring (2), cover (3) and a-ring (4) from the solenoid valve. Discard the a-rings.

Don 7-37010

IMPORTANT: Machines equipped with PTO have a special hexagon plug (A) to keep the pressure regulator piston activated for PTO operation with the transmission control lever in neutral. Remove the plug and components as in Step 5, discard the a-ring from the plug. Issued 12-90

Printed in U.S.A

6204-4

STEP 6

STEP 9

8

'~~7r

"i1Jons

Remove the allen plug (1), accumulator piston (2), secondary spring (3) and primary spring (4). Discard the o-ring on the plug.

Remove the allen plug (1) and forward/reverse spool (2). Discard the ring (3) from the spool and o-ring from the plug.

STEP 7

STEP 10

030111

Remove the allen plug from the opposite end of the same bore and remove the modulation pressure regulator spool (1) Discard the o-ring (2) from the plug.

030117

Remove and discard the oil seal (1) from the bore of the forward/reverse spool.

STEP 8

Remove the allen plug (1), spring (2) and detent (3). Discard the o-ring (4).

Don 7-37010

Issued 12-90

Printed in U.S.A

6204-5

Inspection STEP 11 Clean all parts in cleaning solvent. compressed air. DO NOT use cloths.

STEP 13 Dry

using

STEP 12 Inspect all the components for wear and replace if necessary. Replace the valve assembly if there is any damage to the surfaces of the bores and spools.

FRYOR

Make sure the oil restrictor obstructions with compressed

Don 7-37010

(1) is clean. Remove air or a soft wire.

Issued 12-90

Printedin U.S.A

6204-6

Assembly

1. BODY

9. PIN

2. SWITCH

10. SPOOL

3. PLUG

11. ACCUMU 12. MODULA~TOR PISTON 13 SE OR SPOOL . LECTOR SPOOL

4. O-RING 5. Oil RESTRICTOR 6. SOLENOID 7. REGULATO VAlVE ASSEMBLY 8. SPRING

Don 7-37010

R PISTON

14. RING 15. DETENT 16. SEAL

Issued 12-90

Printed in U.S.A

6204-7

STEP 14

STEP 17

Lubricate all components with clean Hy-Tran Plus.

STEP 15

Install the spool (1), into the position shown.

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

Install a new a-ring (1) onto the plug. Install the modulator pressure regulator spool (2), and plug. Tighten the plug.

Don 7-37010

Issued 12-90

Printed in U.S.A

6204-8

STEP 20

STEP 23

000110

000106

Install a new a-ring (1) onto the plug. Install the primary spring (2), secondary spring (3) and accumulator piston (4). Install and tighten the plug.

Install a new o-ring (1), cover (2), o-ring (3) and nut (4). Tighten the nut to a torque of 0.8 to 1.0 Nm (0.6 to 0.71b

STEP 21

STEP 24

ft)

000105

000119

Install a new o-ring (1) onto the plug. Install the regulator spool (2), pin (3), spring (4) pressure regulator piston (5). Install and tighten the plug.

STEP 22

Install new o-rings onto the plugs. Install and tighten the plugs.

STEP 25

D30233 030107

Install new a-rings (1) onto the solenoid valve 2. Install and tighten the valve to a torque of 20 Nm (15 Ib ft).

Don 7-37010

Install a new o-ring onto the neutral start switch. Install and tighten to a torque of 20 to 27 Nm (15 to 20) Ib ft. Install the wires and tighten the screws.

Issued 12-90

Printed in U.S.A

Section 6205 TORQUE CONVERTER CHARGING PUMP, OUTPUT SHAFT, AND CONVERTER HOUSING

Copyright © 1990 J I Case Company

CASE CORPORATION

Don 7-37020

Printed in U.S.A. December 1990

6205-2

TABLE OF CONTENTS SPECIAL TORQUES

2

SHOP EQUIPMENT TOOLS

2

SERVICING THE CHARGING PUMP Removal Disassembly Inspection Assembly Installation

3 4 5 6 8

SERVICING THE OUTPUT SHAFT Removal Inspection.................................... Installation

9 10 11

SERVICING THE TORQUE CONVERTER HOUSiNG

13

SPECIAL TORQUES Charging Pump Retaining Bolts Output Shaft Locknut

23 to 30 Nm

17 to 22 Ibs ft

217 to 271 Nm

160 to 200 Ibs ft

SHOP EQUIPMENT TOOLS

1. TORQUE WRENCH

Don 7-37020

(OEM 6475)

Issued 12-90

Printed in U.S.A.

6205-3

SERVICING THE CHARGING PUMP Removal STEP 4

STEP 1 Remove the torque converter machine. Refer to Section 6200.

housing

from

the

STEP 2

Remove and discard the o-ring seal from the torque converter housing.

Remove the four retaining bolts and flat washers from the charging pump.

STEP 3

Don 7-37020

Issued 12-90

Printed in U.S.A.

6205-4

Disassembly STEP 5

STEP 8

X13

Loosen the internal hexagon screw that holds the stator support to the pump body.

STEP 6

Remove the drive gear.

STEP 9

Remove the driven gear. Remove the screw, lower the pump body and gears on to the work bench, and remove the stator support.

STEP 10

STEP 7

Xll

Remove and discard the seal from the pump body.

For easy assembly, make a mark on the pump body, driven gear and drive gear.

Don 7-37020

Issued 12-90

Printed in U.S.A.

6205-5

Inspection STEP 11

STEP 12

X22

1. Clean all the parts in cleaning solvent and dry in compressed air. 2. Only the seal and two bushings are available separately as service parts. If there is damage to any other part of the charging pump, you must install a new assembly. 3. Check the two gears for wear and damage. 4. Check the body and converter support for pitting, scoring, cracks and wear. 5. There is only a small amount of clearance between the parts of the charging pump. It is possible for the parts to look good but still be worn enough for the charging pump to be replaced. If troubleshooting shows that there is not enough flow from the charging pump, install a new assembly.

If a new converter support bushing (1) is installed, make sure that it fits against the internal shoulders (2) as shown.

NOTE: Low charge pump pressure could be caused by the charge regulator valve stuck open.

Don 7-37020

Issued 12-90

Printed in U.S.A.

6205-6

Assembly

62056

Don 7-37020

Issued 12-90

Printed in U.S.A.

6205-7

STEP 13 Before assembly, transmission oil.

STEP 17 lubricate all the parts with clean

STEP 14

Install the converter support through the body.

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

Install and tighten the internal hexagon head screw.

X18

Install the driven gear so that the marks align.

STEP 16

X14

Install the drive gear so that the small diameter is inward and the marks align.

Don 7-37020

Issued 12-90

Printed in U.S.A.

6205-8

Installation STEP 19

STEP 21

;,

X1

Lubricate and install a new o-ring seal into the torque converter housing.

Install the four retaining bolts and new flat washers and evenly tighten to a torque of 23 to 30 Nm (17 to 22 Ib ft).

STEP 20

STEP 22 Install the torque converter housing onto the machine. Refer to Section 6200.

Install the charging pump onto the torque converter housing, making sure that the two oil holes align.

Don 7-37020

Issued 12-90

Printed in U.S.A.

6205-9

SERVICING THE OUTPUT SHAFT Removal STEP 23

STEP 26

Refer to STEPS 1 through 4 to remove the charging pump.

STEP 24

Remove and discard the o-ring.

STEP 27 Hold the coupling in a vice and remove the locknut and washer.

NOTE: The coupling

is shown out of the vice for

photographic purposes. When removing or installing the drive coupling nut, clamp the coupling in the vice and not the input shaft. This will prevent possible damage to the shaft and splines.

Remove and discard the oil seal from the outer face of the torque converter housing.

STEP 28 Remove the output shaft bearing snap ring from the torque converter housing.

STEP 29

STEP 25

Remove the coupling from the ouput shaft. Use a soft hammer to remove the output shaft and bearing from the torque converter housing in the direction shown.

Don 7-37020

Issued 12-90

Printed in U.S.A.

6205-10

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

1. Clean all the parts in cleaning solvent and dry using compressed air. 2. Replace the output shaft if there is damage to the sealing surfaces. Remove any metal protrusions from the splines with a fine hone. 3. Check the bearing and wear sleeve in the torque converter housing for wear and replace if neces sary.

•

~,

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.

Don 7-37020

Issued 12-90

Printed in U.S.A.

6205-11

Installati on

6205138

Don 7-37020

Issued 12-90

Printed in U.S.A.

6205-12

STEP 34

STEP 37 Install a new oil seal into the torque coverter housing, and lubricate with clean transmission oil.

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

Install the bearing onto the output shaft.

STEP 36

Install the coupling.

STEP 40

6205GFW

Install the output shaft and bearing into the torque coverter housing and install the snap ring.

Don 7-37020

Install the washer and lock nut. Hold the coupling in a vise and tighten the lock nut to a torque of 217 to 271 Nm (160 to 200 Ibs ft).

Issued 12-90

Printed in U.S.A.

6205-13

SERVICING THE TORQUE CONVERTER HOUSING

62115130

Don 7-37020

Issued 12-90

Printed in U.S.A.

6205-14

STEP 41 1. Refer to Section 6200 to replace the torque converter housing. 2. Refer to Maintenance Section to replace the oil filter cartridge. Always replace the cartridge after doing work on the torque converter housing, charging pump or output shaft. 3. Refer to the following STEPS to service the charging pump relief valve, torque converter relief valve, oil restriction indicator and filter bypass valve. The torque converter housing is shown removed from the machine for photographic purposes only.

STEP 42

STEP 44

Use a magnet to remove the steel ball.

STEP 45

Remove the plug for the charging pump relief valve.

STEP 43

Use a suitable wood or plastic dowel to remove the relief valve cartridge.

NOTE: If there is any damage, installed.

a new cartridge must be

STEP 46

Remove the spring.

Replace the o-ring transmission oil.

Don 7-37020

and

lubricate

Issued 12-90

with

clean

Printed in U.S.A.

6205-15

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

Install the steel ball and spring.

STEP 49

Remove the filter bypass valve from the right hand side of the torque converter housing. Parts for the relief valve are not available. If there is any damage to the seat area of the poppet, install a new assembly. Always replace the a-ring on the plug.

STEP 52

Install a new a-ring on the plug. Install and tighten the plug.

Remove the restriciton indicator from the right hand side of the torque converter housing. Always replace both a-rings before installation.

Don 7-37020

Issued 12-90

Printed in U.S.A.

Section

6206 TRANSMISSION

Copyright

CASE CORPORATION

Don 7·37030

© 1990 J I Case Company Printed in U.S.A. December

1990

6206-2

TABLE OF CONTENTS SPECIFICATIONS ........................................................................................................................................................ 2 SPECIAL TORQUES .................................................................................................................................................... 2 SPECIAL TOOLS ......................................................................................................................................................... 3 SHOP EQUIPMENT TOOLS ........................................................................................................................................ 4 TRANSMISSION END COVER Removal .................................................................................................................................................................. 5 Installation ............................................................................................................................................................. 35 SERVICING THE INTERMEDIATE SHAFT Removal .................................................................................................................................................................. 7 Disassembly ........................................................................................................................................................... 8 Inspection ............................................................................................................................................................... 9 Assembly ................................................................................................................................................................ 9 Installation ............................................................................................................................................................. 10 SERVICING THE SHUTTLE SHAFT Removal ................................................................................................................................................................ Disassembly ......................................................................................................................................................... Inspection ............................................................................................................................................................. Assembly .............................................................................................................................................................. Installation .............................................................................................................................................................

11 11 14 15 19

SERVICING THE PINION SHAFT Disassembly ............................................................................................................................................................ 19 Inspection ............................................................................................................................................................. 25 Assembly .............................................................................................................................................................. 26 Checking Ring Gear and Pinion Tooth Contact .................................................................................................. 37 SERVICING THE GEAR SHIFTERS Removal ................................................................................................................................................................ Disassembly ......................................................................................................................................................... Inspection ............................................................................................................................................................. Assembly .............................................................................................................................................................. Installation ............................................................................................................................................................. Adjustment ...........................................................................................................................................................

39 40 41 42 43

44

REMOVAL AND INSTALLATION OF THE MAGNETIC SPEED SENSOR .................................................................. .44 INSTALLATION OF TRANSAXLE REAR COVER .........................................................................................................45

SPECIFICATIONS Lubricating Oil ...........................................................................................................................Hy-Tran Plus (MS 1207)

SPECIAL TORQUES Transmission End Cover BoiL .......................................................... 195 to 250 Pinion Shaft End Bolt.. ....................................................................... 251 to 280 Transmission Rear Cover Bolts ......................................................... 195 to 250 Gear Shift Rail Retaining Bolts ............................................................... 44 to 58 Don 7-37030

Nm Nm Nm Nm

145 to 185 185 to 205 145 to 185 33 to 43

Ib Ib Ib Ib

ft ft ft ft

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.

1. PINION SHAFT PRELOAD SETIING WASHER CAS 1998

2. SEAL COMPRESSOR CAS 2005-1

3. CLUTCH

Don 7-37030

SET

PACK SPRING COMPRESSOR CAS 1992

4. SEAL EXPANDER/PROTECTOR CAS 1999

SHUTTLE SHAFT

5. PINION SHAFT MASTER BEARING CONE CAS 2019

6. TRANSMISSION

BEARING RACE RETAINER CAS 2008

Issued 12-90

Printed in U.SA

6206-4

SHOP EQUIPMENT TOOLS

1. TORQUE WRENCH (OEM 6475)

4. DIAL GAUGE WITH MAGNETIC BASE (OEM 1030)

2. SEALANT B17555 (LOCTITE 515) AND PRIMER 'N' B500637

5. METRIC FEELER GAUGE (OEM 1024)

3. BEARING OVEN (OEM 8014)

Don 7-37030

Issued 12-90

Printed in U.S.A.

6206-5

TRANSMISSION END COVER

Removal NOTE: To service the transmission the transaxle must be removed from the machine, refer to Section 6001. Drain the oil from the transmission into a container with a capacity of 40 litres (42 US quarts).

STEP 4

STEP 1 Remove the rear cover and stand the transaxle on the rear flange in the vertical position. This will reduce the stress on the shafts and bearings.

STEP 2 Remove the bolt, washer and shims from the pinion shaft.

STEP 5

C1Z301

Remove the transfer gearbox or end cover. Refer to Section 6202.

STEP 3

Remove the parking brake housing assembly. Refer to Section 7000.

and ..,:.

-.... -.;,

Remove the spacer and splined park brake hub.

Don 7-37030

Issued 12-90

Printed in U.S.A

6206-6

STEP 6

STEP 8

...... ..,

Remove the two bolts and plate from the end of the gear shift rail.

STEP 7

__

Remove the retaining bolts and washers transmission end cover.

from the

·~.~c

Remove the three blanking plugs from the end cover and insert a 38 mm (1.5 inch) spacer into each hole. Install and tighten the bolts evenly to separate the end cover from the transmission housing.

STEP 9

".-

~

:.:~.

Remove the bearing cone from the end of the pinion shaft.

Don 7-37030

Issued 12-90

Printed in U.S.A.

6206-7

STEP 10

Use suitable lifting equipment transmission end cover.

and

remove

the

SERVICING THE INTERMEDIATE SHAFT Removal STEP 11 Follow steps 1 to 10 to remove the transmission cover.

STEP 13 end

STEP 12

Remove the intermediate shaft from the transmission housing.

Remove the snap ring from the end of the pinion shaft.

NOTE: This will allow the synchromesh hub to move up as the intermediate shaft is removed.

Don 7-37030

Issued 12-90

Printed in U.S.A

6206-8

Disassembly STEP 17 ,

STEP 14

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 drive gear (2) and spacer(3).

Remove the second bearing cone and first gear.

STEP 16

Remove the third gear.

Don 7-37030

Issued 12-90

Printed in U.S.A

6206-9

Inspection STEP 19 Clean all parts in cleaning solvent and dry using compressed air. DO NOT permit the bearings to rotate while drying. Check all the parts for wear and damage and replace if necessary.

Assembly

9. 4TH GEAR

6. 2ND GEAR

4. 1ST GEAR

2. BEARING CONE

7. 3RD GEAR

8. SPACER

6. 2ND GEAR

NOTE: If equipped the first and second gears and the intermediate shaft are one piece. Don 7-37030

Issued 12-90

Printed in U.S.A

6206-10

STEP 20

STEP 21

Put the gears and bearings into an oven (OEM 8014) and heat to a temperature of 302°F (150° C). Keep the shaft as cool as possible.

NOTE: The tapped hole at the end of the intermediate shaft must be at the fourth gear end.

i~! e

1. SHOULDER

6007318

Install the parts onto the intermediate shaft in following order. Gear (1), Bearing (2), Spacer (3), 2nd Gear (4), 3rd Gear (5), Spacer (6), 4th Gear (7) and Bearing (8). IMPORTANT: After Assembly make sure both the bearing cones are against the shoulders on the shaft.

Installati on STEP 23

STEP 22

Install the intermediate shaft housing.

the transmission

NOTE: Uft up the 3rd and 4th gear synchromesh hub to allow installation of the intermediate shaft.

Make sure the synchromesh hub, needle bearing and thrust washer is against the pinion shaft and install the snap ring.

STEP 24 Follow STEPS 140 to 145 to install the transmission end cover.

STEP 25 Follow STEPS 146 to 151 and check the intermediate shaft end play.

Don 7-37030 .

Issued 12-90

Printed in U.S.A.

6206-11

SERVICING THE SHUTTLE SHAFT Removal STEP 26

STEP 29

Follow STEPS 1 to 10 to remove the transmission end cover.

STEP 27 Follow STEPS 12 to 13 to remove the intermediate shaft.

STEP 28

Follow STEPS 71 to 87 to service the pinion shaft. NOTE: The shuttle shaft cannot be removed with the pinion shaft assembled.

STEP 30 Remove the shuttle shaft from the transmission.

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 32

STEP 31

036

N17

Remove the roller bearing (1), spacer (2) and second roller bearing (3).

Don 7-37030

Remove the thrust bearing (1).

Issued 12-90

Printed in U.S.A.

6206-12

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

Put the shuttle shaft in a press. Use the special tool (CAS 1992) to push the piston return spring and washer away from the snap ring. Remove the snap ring.

STEP 35

STEP 38

030

Remove the clutch backing plate. 024

Remove the washer.

Don 7-37030

Issued 12-90

Printed in U.S.A

6206-13

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

Remove and discard the inner piston seal and a-ring.

STEP 43

021

Use compressed air through the following holes in the reverse gear end of the shaft to remove the clutch piston: Outer hole - forward piston Inner hole - reverse piston Middle hole - for lubrication

016

Remove and discard the four sealing rings. Remove the bearing cone (1), snap ring, thrust washer, thrust bearing (2) and gear (3). Repeat STEPS 31 to 42 and disassemble the reverse clutch.

NOTE: Do not use levers to remove the piston. The piston can be easily damaged by levers.

Don 7-37030

Issued 12-90

Printed in U.S.A.

6206-14

Inspection STEP 48

STEP 44 Clean all the parts in cleaning solvent and dry in compressed air.

STEP 45

06

Check the backing plate for damage and replace if necessary. Remove small scoring or grooves with a hone or fine emery cloth. 02

Check the piston for wear or damage and replace if necessary.

STEP 49

STEP 46

08

··03

Check the friction plates for wear or damage and replace if necessary.

Check the drive gear for damage and replace if necessary. Look for cracks at the root of the teeth. Use a hone to remove any small protrusions from the splines.

STEP 50

STEP 47

05

Check the shuttle shaft and replace the assembly if there is wear or damage.

Check the steel wear plates for wear or damage and replace if necessary. Don 7-37030

Issued 12-90

Printed in U.S.A

6206-15

Assembly

620619

Don 7-37030

Issued 12-90

Printed in U.S.A

6206-16 NOTE: Before assembly, use compressed air to make sure that all the oil holes are clear.

STEP 54

STEP 51 Lubricate all the parts with clean transmission oil before assembly. Put the seal rings for the piston and shuttle shaft in warm transmission oil for several minutes to prevent damage during assembly.

STEP 52 021

Carefully install the clutch piston onto the shuttle shaft so that the grooved face of the piston is outward. If the piston locks up during installation, remove with compressed air and install again. Never use force to correct wrong alignment of the piston.

STEP 55 010

Install a new o-ring (1) and then a new inner seal ring (2) into the clutch piston.

STEP 53

022

Install the piston return spring.

STEP 56

011

Install a new o-ring (3) and then a new outer seal ring (4) onto the clutch piston.

024

Install the washer.

Don 7-37030

Issued 12-90

Printed in U.S.A

6206-17

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 plates in the clutch pack.

STEP 58

STEP 61

I

P16

Put the shuttle shaft assembly into a press. Use the special tool (CAS 1992) to push the piston return spring and special washer below the snap ring groove. Install the snap ring.

Install the backing plate so that the small diameter is outward.

STEP 59

STEP 62

Install a steel clutch plate.

Install the snap ring.

Don 7-37030

030

Issued 12-90

Printed in U.S.A

6206-18

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.

STEP 64

Install a roller bearing (1), spacer (2) and second roller bearing (3).

STEP 65 Repeat Steps 51 to 64 and assemble the reverse clutch. Install the gear, thrust bearing, thrust washer, snap ring and bearing cone.

Don 7-37030

NOTE: Put the sealing rings in clean transmission oil before installation.

STEP 67

Compress the seal ring by hand and then install the seal compressor, CAS 2005-1. NOTE: Only by using the seal compressor, CAS 2005-1, can the seals be compressed to the correct working size.

Issued 12-90

Printed in U.S.A.

6206-19

Installation STEP 68

STEP 69

2. WEAR SLEEVE

Install the shuttle shaft. 62066

Check the wear sleeve in the transmission case for damage or wear marks. If necessary, replace the wear sleeve making sure that the oil holes are aligned with the holes in the top of the transmission case.

NOTE: The second driven gear will have to be raised slightly to allow the shuttle shaft to locate into the bore in the transmission case.

STEP 70 Follow STEPS 126 to 135 on servicing the pinion shaft.

SERVICING THE PINION SHAFT Disassembly NOTE: To prevent damage to the pinion shaft and crown wheel, remove the axles, differential and lubrication tube. Support the pinion shaft before starting disassembly.

STEP 72 ~


Install the push rod (15) and washer (16).

10 Install the snap ring (17) B870123R

11. Install the boot (18). 12. Install the lock nut and clevis on the push rod (15). Do not tighten the lock nut on the push rod at this time.

Bur 8-12570

Issued 11-89

Printed in USA

7003-5

8870122R

Master Cylinder

Bur 8-12570

Issued 11-89

Printed in U:S.A.

SECTION INDEX - HYDRAULICS Section Title

Section Number

Removal and Installation of Hydraulic Components

8001

Specifications, Schematics, and Troubleshooting

8002

Cleaning the Hydraulic System

8003

Hydraulic Pump

8004

Loader Control Valve

8005

Cylinders

8006

Backhoe Control Valve

8007

Swing Sequence Valve

8008

Three Point Hitch Control Valve

8009

Double Selector Valve

8011

CASE CORPORATION Bur 8-12580

Printed

in U.S.A.

Issued November 1989

Section

8001 REMOVAL AND INSTALLATION OF HYDRAULIC COMPONENTS

CASE CORPORATION Bur 8-17580

Printed in U.S.A. Issued March 1991

8001-2

TABLE OF CONTENTS OIL COOLER

..

Removal

.

...................... ,

,

Installation HYDRAULIC

,

,

3

:

,

,

PUMP

3

,

.4

,

6

Removal

6

Installation

8

LOADER CONTROL

VALVE

Removal

,... ,

,."

,...........................

10

.

,

,

10

Installation........ BACKHOE

CONTROL

... 10 VALVE......

... 11

11

Removal Installation

.

.

SWING SEQUENCE

.

VALVE.

Removal

,

13

SWING SEQUENCE

Removal Installation

Bur 8-17580

13 13

,

Installation

THREE-POINT

11

VALVE ADJUSTMENT...................

HITCH CONTROL

.

14

VALVE....................

.15

,

, ,

15 ,

15

Issued 3-91

Printed in U.S.A.

8001-3

OIL COOLER Removal

STEP 3

STEP 1

Park the machine on a level surface. Raise the loader and lock the support strut (1) to hold up the loader.

Remove the bolt, lock washer, and flat washer which fasten the strap (1) to the top of the radiator shroud. Remove the strap (1). Remove the bolts, lock washers, and flat washers from the top cover (2). Remove the top cover (2). Remove the upper and lower foam baffles (3).

STEP 4

Remove the bolts, flat washers, spacers, lock washers, and nuts which fasten the hood cables (1) to the sides of the radiator shroud. Remove the bolts, flat washers, and lock washers from the hood hinges (2).

Remove the bolts, lock washers, and nuts which fasten the mounting brackets (1) to each side of the oil cooler.

Have another person help you remove the hood. The weight of the hood is approximately 100 pounds (45 kg). NOTE: During installation the hood must be adjusted. Put the hood in position. Install the hardware in the hood hinges. Do not tighten the hardware. Close the hood and remove the plastic plugs for access to the hinge hardware. Push the top of the hood to the rear as far as possible and tighten the hinge hardware.

Bur 8-17580

Issued 1-91

Printed in U.S.A.

8001-4

STEP 5

STEP 8

Remove the bolts, flat washers, and nuts which fasten the radiator shroud (1) to the machine frame. Remove the radiator shroud (1), The weight of the radiator shroud (1) is approximately 50 pounds (23 kg).

Disconnect the two hoses (1) from the RH side of the oil cooler. Put identification tags on the hoses (1). Disconnect the two tubes (2) from the LH side of the oil cooler. Install caps on the fittings and plugs in the hoses and tubes. Stop the vacuum pump.

8907

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' .90[:~~;!ef Remove the bolts, lock washers, and flat washers the bottom cover (1). Remove the bottom cover

STEP 7

Connect a vacuum pump Start the vacuum pump.

Bur 8-17580

from (1).

Remove the bolts, lock washers, and flat washers which fasten the condenser (1) and the oil cooler (2) to the radiator (3). Move the condenser (1) to the LH side out of the way. Remove the oil cooler (2).

Installation to the hydraulic

reservoir

Installation

of the oil cooler is the reverse of removal.

Issued 3-91

Printed in U.S.A

8001-5

1. OIL COOLER

2. FROM HYDRAULIC OIL FILTER

3. TO HYDRAULIC RESERVOIR

4. FROM TORQUE CONVERTER

B902372J

5. TO TRANSAXLE

Bur 8-17580 Issued 3-91

Printed in U.S.A.

8001-6

HYDRAULIC PUMP Removal

STEP 12

STEP 10

Slowly remove the radiator cap (1) Park the machine on a level surface. Raise the loader and lock the support strut (1) to hold up the loader.

,

STEP 11

Install a hose on the drain valve (2) and drain the radiator. Disconnect the upper and lower radiator hoses (3). Remove the bolts, lock washers, and flat washers which fasten the fan shroud (4) to the radiator. NOTE: During installation fill the radiator and the coolant reservoir with approximately 18 US. quarts (17 litres) of coolant. See Section 1002 for coolant specifications. Start and run the engine until the coolant is at operating temperature. Stop the engine and check for leakage. When the coolant is cold, check the coolant reservoir level.

STEP 13 Disconnect the overflow hose (1) from the radiator neck. Remove the bolts, flat washers, spacers, lock washers, and nuts which fasten the hood cables (2) to the sides of the radiator shroud. Remove the bolts, flat washers, and lock washers from the hood hinges (3). Have another person help you remove the hood. The weight of the hood is approximately 100 pounds (45 kg).

NOTE: During installation the hood must be adjusted. Put the hood in position. Install the hardware in the hood hinges. Do not tighten the hardware. Close the hood and remove the plastic plugs for access to the hinge hardware. Push the top of the hood to the rear as far as possible and tighten the hinge hardware.

Remove the bolt, lock washer, and flat washer which fasten the strap (1) to the top of the radiator shroud. Remove the strap (1). Remove the bolts, lock washers, and flat washers from the top cover (2). Remove the top cover (2). Remove the upper and lower foam baffles (3).

Bur 8-17580

Issued 3-91

Printed in U.SA

8001-7

STEP 14

STEP 17

Remove the bolts, lock washers, and nuts which fasten the mounting brackets (1) to each side of the oil cooler.

The hydraulic reservoir holds approximately 25 U.S gallons (95 litres) of oil. Remove the drain plug (1) and drain the oil from the hydraulic reservoir.

STEP 15

NOTE: During installation make sure the hydraulic re-

setvou is filled with oil. See Section 1002 for specifications.

STEP 18

Remove the bolts, flat washers, and nuts which fasten the radiator shroud (1) to the machine frame. Remove the radiator shroud (1). The weight of the radiator shroud (1) is approximately 50 pounds (23 kg). NOTE: During installation, tighten the bolts for the radiator shroud (1) to 270 to 324 pound-feet (366 to 439 Nm).

STEP 16

., ..

B90?~,~~Ji

Disconnect the two hoses (1) from the RH side of the oil cooler. Put identification tags on the hoses (1). Disconnect the two tubes (2) from the LH side of the oil cooler. Install caps on the fittings and plugs in the hoses and tubes.

.,

,!~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 which fasten the condenser (1) to the oil cooler (2) and radiator (3). Move the condenser (1) to the LH side out of the way. Have another person help you remove the oil cooler (2) and radiator (3). The weight of the oil cooler (2) and radiator (3) is approximately 50 pounds (23 kg). Remove the fan shroud (4).

Disconnect the two hoses (1) from the LH side of the hydraulic pump (2). Remove the bolts and lock washers that fasten the flange (3) on the RH side of the hydraulic pump (2) Remove the bolts, lock washers, and hardened washers (The hardened washers are on the bottom two bolts only.) which fasten the hydraulic pump (2) to the front engine support. Remove the hydraulic pump (2).

Installation Installation of the hydraulic pump is the reverse of removal. NOTE: During installation, remove and clean the suction screen for the hydraulic pump. Apply Molykote Type G to the splines of the hydraulic pump.

Bur 8-17580

Issued 3-91

Printed in U.S.A.

8001-9

4. SUCTION

SCREEN B902373J

Bur 8-17580

Issued 3-91

Printed in U.S.A.

8001-10

LOADER CONTROL VALVE Removal

Installation

1. Park the machine on a level surface.

1. Use suitable lifting equipment to put the loader control valve in position on the machine.

2 Apply the parking brake.

2. Install the cap screws and lock washers that fasten the loader control valve to the mounting brackets.

3. Lower the loader bucket to the floor. 4. Stop the engine. 5. Move the loader control lever in all directions release the pressure from the hydraulic circuits.

to

6 Remove the bolts, lock washers, and flat washers which fasten the cover for the loader control valve to the RH step frame. Remove the cover for the loader control valve. 7. Find the wires for the return-to-dig switch on the loader control valve. Disconnect the wires from the return-to-dig switch. 8. Fasten identification tags to the loader linkage at the loader control valve. 9. Disconnect the linkage from the loader control valve. 10. Clean the loader control valve and the area around the loader control valve. Fasten identification tags to the tubes and hoses at the loader control valve. 11. Connect a vacuum pump to the hydraulic reservoir. Start the vacuum pump. 12. Disconnect the tubes and hoses from the fittings in the loader control valve. Install caps on the fittings and plugs in the hoses and tubes Stop the vacuum pump. 13. Connect suitable lifting equipment to the loader control valve. The weights of loader control valves available on this machine are approximately 57 to 72 pounds (26 to 33 kg).

3 Remove the lifting equipment from the loader control valve. 4. Connect the vacuum pump to the hydraulic reservoir. Start the vacuum pump 5. Connect the tubes and hoses to the fittings on the loader control valve. 6. Stop the vacuum pump. 7. Connect the linkage to the loader control valve. 8. Connect the wires to the return-to-dig switch on the loader control valve. 9. Start and run the engine at low idle. Move the loader control lever to raise the loader completely. Continue to hold the loader control lever in the RAISE position for 30 seconds. 10. Lower the loader bucket to the floor. Stop the engine. 11. Check for oil leakage at the loader control valve. 12. Check the oil level in the hydraulic reservoir. Add oil as required. See Section 1002 for specifications. 13. Put the cover for the loader control valve in position on the RH step frame. Install the bolts, lock washers, and flat washers which fasten the cover to the RH step frame.

14. Loosen and remove the cap screws and lock washers that fasten the loader control valve to the mounting brackets. 15. Remove the loader control valve from the machine.

Bur 8-17580

Issued 3-91

Printed in U.S.A.

8001-11

BACKHOE CONTROL VALVE

Removal

18. Remove the backhoe machine.

1. Park the machine on a level surface.

control

valve from

the

Installation

2. Lower the loader bucket to the floor. 3. If the machine is equipped with an Extendahoe, install the Extendahoe lock pin. 4. If the backhoe is not in the transport position, put the backhoe in the transport position. 5. Lower the stabilizers until the stabilizers just touch the floor

1. If the fittings were removed from the backhoe control valve, if a new backhoe control valve is being used, or if the dipper or boom section of the backhoe control valve has been replaced, do the following steps: a. Make sure that a restrictor is installed in the A port of the dipper section of the backhoe control valve. The restrictor must be installed so that the large end of the restrictor is toward the inside of the backhoe control valve.

6. Stop the engine and apply the parking brake. b. Install new O-rings on the fittings

7. Install the swing lock pin. 8. Move each backhoe control lever in both directions until all hydraulic pressure has been removed from the backhoe hydraulic circuits. 9. Clean the backhoe control valve and the area around the backhoe control valve. Fasten identification tags to the hoses and tubes at the backhoe control valve. 10. Connect a vacuum pump to the hydraulic reservoir Start the vacuum pump 11 . Disconnect the hoses and tubes from the backhoe control valve. Install caps on the fittings and plugs in the hoses and tubes.Stop the vacuum pump. 12. Disconnect the tube for the B port of the swing section from the fitting in the swing sequence valve. 13. Fasten identification tags to the linkage for the backhoe control valve. 14. Disconnect the linkage from the spools backhoe control valve.

in the

15. The weights of backhoe control valves available on this machine are approximately 115 to 130 pounds (52 to 59 kg). Have another person help with steps 16 through 18. 16. Hold the backhoe control valve in place and remove the bolts, lock washers, and nuts that fasten the LH side of the backhoe control valve to the mounting bracket. 17. Remove the cap screw, lock washer, and spacers that fasten the RH side of the backhoe control valve to the mounting bracket.

c. Lubricate the O-rings with clean hydraulic oil. d. Install the fittings in the backhoe control valve. 2 Put the backhoe control valve in position on the mounting bracket. Make sure that the rubber mount is in position in the mounting bracket. 3. Install the cap screw, lock washer, and spacers that fasten the backhoe control valve to the mounting bracket. Make sure that the spacers are in position between the backhoe control valve and the mounting bracket. 4. Connect the linkage to the spools in the backhoe control valve. 5. Connect the vacuum pump to the hydraulic reservoir. Start the vacuum pump. 6. Connect the tube to the fitting in the swing sequence valve and to the B port in the swing section of the backhoe control valve. 7. Connect the remaining tubes and the hoses to the fittings in the backhoe control valve. Stop the vacuum pump. 8. Start the engine and run the engine at low idle. 9. Slowly extend and retract each cylinder several times to remove any air from the backhoe hydraulic circuits. 10. Stop the engine. 11. Check for oil leakage at the backhoe control valve. 12. Check the oil level 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

Bur 8-17580

Issued 3-91

Printed in U.S.A

8001-13

SWING SEQUENCE VALVE Removal 1. Park the machine on a level surface. 2. Lower the loader bucket to the floor. 3. If the backhoe is not in the transport position, put the backhoe in the transport position. 4. Stop the engine and apply the parking brake. 5. Install the swing lock pin. 6. Move the swing control pedals or levers in both directions to remove any pressure in the swing hydraulic circuit. 7. Clean the swing sequence valve and the area around the swing sequence valve. Fasten identification tags to the hoses and tubes for the swing sequence valve.

14 Remove the swing machine.

sequence

valve from the

Installation 1. Hold the swing sequence valve in position on the mounting bracket. Install the cap screws that fasten the swing sequence valve to the mounting bracket. 2. Turn the spool so that when the yoke is installed on the spool, the holes will be aligned vertically. Put the yoke in position on the spool. Install the clevis pin and the cotter pin to fasten the yoke to the spool. 3. Connect the tube to the B port in the swing section of the backhoe control valve and to the fitting in the bottom of the swing sequence valve. 4. Connect the remaining tubes and the hoses to the fittings in the swing sequence valve.

8. Disconnect the tube from the B port in the swing section of the backhoe control valve and from the fitting in the bottom of the swing sequence valve.

5. Remove the swing lock pin.

9 Install caps on the fittings in the backhoe control valve and the swing sequence valve.

7. Slowly and completely swing the backhoe to the left and then to the right several times to remove any air from the swing hydraulic circuit.

10. Disconnect the remaining tubes and hoses from the swing sequence valve. 11. Use caps or plugs to close all openings in order to keep dirt out of the hydraulic system. 12. Remove the cotter pin and clevis pin that fasten the yoke on the linkage to the spool in the swing sequence valve.

6. Start and run the engine at low idle.

8. Stop the engine. 9. Check for oil leakage at the swing sequence valve. 10. Check the oil level in the hydraulic reservoir. Add oil as required. See Section 1002 for specifications. 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.

Bur 8-17580

Issued 3-91

Printed in U.SA

8001-14

SWING SEQUENCE VALVE ADJUSTMENT 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. 7. Start and run the engine at approximately 1/4 throttle. 8. Swing the backhoe completely to the left and then to the right. The amount of cushion should be equal on both sides. See the illustration below for the correct swing cushion adjustment. Shorten or lengthen the control rod as required. The only adjustment available is to divide the amount of cushion equally between sides.

CORRECT AMOUNT OF CUSHION

5. CAM

B902375J

NOTE: In the following instructions, "right' and "left" are as seen from the backhoe operators seat. 1. Swing the swing tower completely to the right. 2. Loosen the jam nuts at the yoke and at the ball joint on the control rod.

LENGTHEN CONTROL ROD TO INCREASE THE RIGHT CUSHION. (TURN COUNTERCLOCKWISE)

3. Turn the control rod clockwise or counterclockwise until the cam follower will turn freely. The cam follower must still touch the cam or be within 0.02 inch (0.5 mm) from the cam. 4. After step 3 has been completed, turn the control rod clockwise 1/4 to 1/2 turn to shorten the control rod.

SHORTEN CONTROL ROD TO INCREASE THE LEFT CUSHION. (TURN CLOCKWISE) B870349J

Bur 8-17580

Issued 3-91

Printed in U.S.A.

8001-15

THREE-POINT HITCH CONTROL VALVE Removal 1. Park the machine on a level surface. 2. Lower the loader bucket to the floor. 3 Lower any rear attachments to the floor. 4. Stop the engine and apply the parking brake. 5. Move all control levers forthe three-point hitch in both directions to remove any pressure in the hydraulic circuit 6. Clean the three-point hitch control valve and the area around the three-point hitch control valve. 7. Fasten identification tags to the hoses at the threepoint hitch control valve. 8. Disconnect the hoses from the fittings at the threepoint hitch control valve. 9 Use caps or plugs to close all openings in order to keep dirt out of the hydraulic system. 10. Disconnect the linkage from the spool eyes at the three-point hitch control valve. 11 . Hold the three-point hitch control valve in place and remove the bolts, lock washers, and nuts that fasten the three-point hitch control valve to the mounting bracket.

12. Remove the three-point hitch control valve from the machine.

Installation 1. If the fittings were removed from the three-point hitch control valve, or a new three-point hitch control valve is being used, install new O-rings on the fittings, and lubricate the O-rings with clean hydraulic oil. Install the fittings in the three-point hitch control valve. 2. Put the three-point hitch control valve in place on the mounting bracket. Install the bolts, lock washers, and nuts that fasten the three-point hitch control valve to the mounting bracket 3. Connect the linkage to the spool eyes in the threepoint hitch control valve. 4. Connect the hoses to the fittings in the three-point hitch control valve. 5. Start and run the engine at low idle. 6. Move all control levers for the three-point hitch slowly in both directions to remove any air from the hydraulic circuits. 7. Lower any rear attachments to the floor. Stop the engine. 8. Check for oil leakage at the three-point hitch control valve. 9. Check the oil level in the hydraulic reservoir Add oil as required. See Section 1002 for specifications.

Bur 8-17580

Issued 3-91

Printed in U.S.A

8001-16

Bur 8-17580

Issued 3-91

Printed in U.S.A.

Section 8002 HYDRAULIC SCHEMATICS, SPECIFICATIONS AND TROUBLESHOOTING

CASE CORPORATION

Bur 8-17530

Printed in U.S.A. Issued March 1991

8002-2

TABLE OF CONTENTS SPECiFiCATIONS."

,

SPECIAL TOOLS ..,

,

,

,

,.,

'

,

3

,

.4

TROUBLESHOOTING PROCEDURE FOR PROBLEM IN ALL CiRCUiTS

5

TROUBLESHOOTING PROCEDURE FOR PROBLEM IN A SINGLE CIRCUIT

6

MAIN RELIEF VALVE

,

CHECKING OUTPUT OF PUMP WITH FLOWMETER CIRCUIT RELIEF VALVES FOR LOADER AND BACKHOE CONTROL VALVES

7 8

,

, ,

11

CIRCUIT RELIEF VALVE FOR THE THREE POINT HITCH CONTROL VALVE

12

ADJUSTING THE MAIN RELIEF VALVE OR A CIRCUIT RELIEF VALVE

12

CROSS-SECTION DRAWINGS Pump

13

Loader Control Valve

14

Steering Control Valve

,15

Filter

16

Backhoe Control Valve

,

,

17

Three Point Hitch Control Valve

18

Swing Sequence Valve

19

LOADER BACKHOE SCHEMATiC

21

LOADER THREE POINT HITCH SCHEMATIC

22

Bur 8-17530

Issued 3-91

Printed in U.S.A.

8002-3

SPECIFICATIONS Output of Pump Rear section (Loader and Steering)

Front section (Backhoe)

24 U.S. gpm at 2000 psi at 2000 rpm (90.8 Umin at 13 789 kPa, 138 bar at 2000 r/min) 9 U.S. gpm at 2000 psi at 2000 rpm (34 Umin at 13 789 kPa, 138 bar at 2000 r/rnin)

Main relief valve for Loader Backhoe

2500 to 2600 psi (17237 to 17 927 kPa, 172 to 179 bar)

Main relief valve for Three Point Hitch

2488 to 2588 psi (17 154 to 17 844 kPa, 171 to 178 bar)

Relief valve in piston of boom cylinder

4600 to 4800 psi (31 716 to 33095 kPa, 317 to 330 bar)

Circuit Relief Valves Boom A port

2050 to 2250 psi (14 135 to 15574 kPa, 141 to 155 bar)

Boom B port

4000 to 4100 psi (27580 to 28 268 kPa, 276 to 283 bar)

Dipper and bucket A and B ports

2950 to 3150 psi (20340 to 21 719 kPa, 203 to 217 bar)

Swing A and B ports

2050 to 2250 psi (14135 to 15 514 kPa, 141 to 155 bar)

Swing sequence valve

4000 to 4100 psi (27580 to 28268 kPa, 276 to 283 bar)

Loader bucket A and B ports

2950 to 3150 psi (20340 to 21 719 kPa, 203 to 217 bar)

Three point hitch lift B port

2650 to 2750 psi (18271 to 18 960 kPa, 183 to 190 bar)

Bur 8-17530

Issued 3-91

Printed in U.S.A.

8002-4

SPECIAL TOOLS Order special tools from one of the following addresses: In the U.S.A. and Canada: Service Tools P.O. Box 314 Owatonna, Minnesota 55060 In Europe: VL Churchill Ltd. P.O. Box 3, Daventry Northants, NN11 4NF England

CAS-1804 or CAS-10111 Pressure Fitting Kit This tool is first used on page 7.

CAS-1205 Test Block This tool is first used on page 11. OEM 1239 or CAS-10280 Flowmeter This tool is first used on page 8.

CAS-10090 Hand Pump This tool is first used on page 11.

CAS-1808 or CAS-1 0106 Flowmeter Fitting Kit This tool is first used on page 8.

CAS-1913 Hand Pump This tool is first used on page 11. Bur 8-17530

Issued 3-91

Printed in U.S.A.

8002-5

TROUBLESHOOTING PROCEDURE FOR PROBLEM IN ALL CIRCUITS Check the machine for leaks and repair as required.

Troubleshooting

NOTE: The main relief valve controls the pressure in the loader and backhoe cir-

cuits.

complete.

Adjust the main relief valve according to instructions in this section.

Troubleshooting

complete.

Troubleshooting

complete.

Troubleshooting

Do the flowmeter test according to instructions in this section.

Bur 8-17530

Troubleshooting

complete.

complete.

Issued 3-91

Printed in U.S.A.

8002-6

TROUBLESHOOTING PROCEDURE FOR PROBLEM IN A SINGLE CIRCUIT Check the machine for oil leaks and missing or damaged parts.

Check the operation of the circuit that has the problem. Does the cylinder(s) move in both directions?

Check the spool travel. See Section 8005 and 8007 as required for specifications for spool travel. Is the spool travel correct?

YES

, Check the O-ring on the plug for the load check valve in the loader or backhoe control valve. Is the O-ring good?

Adjust the linkage as required to meet the specification for spool travel.

There can be internal wear or damage to the control valve. Repair or replace as required.

Replace the O-ring.

Check the O-ring on the end of the circuit relief valve or plug. Is the O-ring good?

Replace the O-ring.

If used, check setting of the circuit relief valve. Is the setting correct?

Adjust the setting of the circuit relief valve according to instructions in this section.

Check the piston packing for the cylinder. Is the piston packing good?

NOTE: Boom cylinder only. A check valve is installed in the piston. The problem in the boom circuit can be the check valve and not the piston packing.

Repair or replace the cylinder as required.

There is some wear or damage control valve. Repair as required.

Bur 8-17530

in the

Issued 3-91

Printed in U.S.A.

8002-7

MAIN RELIEF VALVE Equipment Required

o to 3000

psi (20 684 kPa, 207 bar) pressure gauge.

5. Continue to hold the loader control lever in the RAISE position and read the pressure gauge. Stop the engine.

Pressure Check

6. Compare the reading with the specification on page 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 the floor.

Adjusting Main Relief Valve

2. Heat the oil to operating temperature. 3. See the illustration. Connect the pressure gauge to the quick disconnect fitting at Test Port 1. 4. Run the engine at full throttle. Hold the loader control lever in the RAISE position until the loader stops moving.

1. The main relief valve is in the outlet section of the loader control valve. Loosen the lock nut on the main relief valve. Turn the adjusting screw clockwise to increase the pressure and counterclockwise to decrease the pressure. 2. Check the pressure again. 3. When the pressure is correct, tighten the lock nut.

3. HYDRAULIC

PUMP

4. FROM RESERVOIR B901795J

Bur 8-17530

Issued 3-91

Printed in U.S.A.

8002-8

CHECKING

OUTPUT OF PUMP WITH FLOWMETER

Equipment Required CAS-10106 or CAS-1808 flowmeter fitting kit OEM 1239 or CAS-10280 Flowmeter

Checking the Output of the Loader (Rear) Section 1. Park the machine on a level surface. Put the backhoe in the transport position and lower the loader bucket to the floor. Stop the engine. 2. See the illustration. Connect the flowmeter into the circuit. 3. Heat the oil to operating temperature by closing the load valve on the flowmeter until the pressure gauge reads 1000 psi (6895 kPa, 69 bar). Run the engine at full throttle until the temperature is 125°F (52°C).

Bur 8-17530

4. Run the engine at 2000 rpm (r/min). Open the load valve on the flowmeter. Read the flow gauge. Record the flow reading. 5. Keep the engine running at 2000 rpm (r/rnin). Slowly close the load valve until the pressure is 2000 psi (13 789 kPa, 138 bar). Read the flow gauge and record the reading. 6. Decrease the engine speed to low idle and stop the engine. 7. The pump efficiency is found by dividing the flow reading at 2000 psi (13 789 kPa, 138 bar) by the flow reading at 0 psi (0 kPa, 0 bar). The answer multiplied by 100 is the percent efficiency of the pump. If the efficiency is less than 70%, repair or replace the pump.

Issued 3-91

Printed in U.S.A.

8002-9

1. CAP. 1-5/16-12 FLARE THREAD 3. HYDRAULIC PUMP

6. CONNECT FLOWMETER OUTLET TO TUBE 1-5/16-12 FLARE THREAD ••

01

7. TO INLET OF LOADER CONTROL VALVE 5. OEM 1239 OR CAS-10280 FLOWMETER

B901796J

Bur 8-17530

Issued 3-91

Printed in U.S.A.

8002-10

Checking the Output of the Backhoe or Three Point Hitch (Front) Section 1. Park the machine on a level surface. Put the backhoe in the transport position and lower the loader bucket to the floor. Stop the engine. 2. See the illustration. Connect the flowmeter into the circuit. 3. Heat the oil to operating temperature by closing the load valve on the flowmeter until the pressure gauge reads 1000 psi (6895 kPa, 69 bar). Run the engine at full throttle until the temperature is 125°F (52°C).

4. Run the engine at 2000 rpm (r/min). Open the load valve on the flowmeter. Read the flow gauge. Record the ~Iow reading. 5. Keep the engine running at 2000 rpm (r/min). Slowly close the load valve until the pressure is 2000 psi (13 789 kPa, 138 bar). Read the flow gauge and record the reading. 6. Decrease the engine speed to low idle and stop the engine. 7. The pump efficiency is found by dividing the flow reading at 2000 psi (13 789 kPa, 138 bar) by the flow reading at 0 psi (0 kPa, 0 bar). The answer multiplied by 100 is the percent efficiency of the pump. If the efficiency 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

Bur 8-17530

Issued 3-91

Printed in U.S.A.

8002-11

CIRCUIT RELIEF VALVES FOR LOADER AND BACKHOE CONTROL VALVES Equipment Required CAS-10111 or CAS-1804 Pressure fitting kit

3. Actuate the handle on the hand pump and record the highest pressure reading. Check the pressure setting several times to be sure of your reading.

CAS-10095 Multigauge

4. Compare the reading with the specifications on page 3.

CAS-10090 Hand Pump for circuit relief valves set below 3500 psi (24 132 kPa, 241 bar)

5. If the pressure setting is not correct, adjust the circuit relief valve.

CAS-1913 Hand pump for circuit relief valves above 3500 psi (24 132 kPa, 241 bar)

Adjusting the Circuit Relief Valves

CAS-1205 Test block

1. Loosen the lock nut on the adjusting screw.

Pressure Check

2. Turn the adjusting screw clockwise to increase the pressure setting and counterclockwise to decrease the pressure setting.

1. Connect the hand pump to the test block. 2. Install the circuit relief valve in the test block.

B901824J

Loader: 1. Bucket A and B Ports Circuit Relief Valve 2950 to 3150 psi (20 340 to 21 719 kPa, 203 to 217 bar)

Bur 8-17530

3. Check the pressure setting again. When the pressure setting is correct, tighten the lock nut.

1

2

3

5

1

2

4

5

Backhoe: 1. Bucket A and B Ports. 2950 to 3150 psi (20340 to 21 719 kPa, 203 to 217 bar) 2. Dipper A and B Ports. 2950 to 3150 psi (20340 to 21 719 kPa, 203 to 217 bar) 3. Boom A Port. 2050 to 2250 psi (14 135 to 15514 kPa, 141 to 155 bar) 4. Boom B Port. 4000 to 4100 psi (27 580 to 28 269 kPa, 276 to 283 bar) 5. Swing A and B Ports. 2050 to 2250 psi (14 135 to 15514 kPa, 141 to 155 bar)

Issued 3-91

Printed in U.S.A.

8002-12

CIRCUIT RELIEF VALVE FOR THE THREE POINT HITCH CONTROL VALVE

Equipment Required CAS-10111 or CAS-1804 Pressure fitting kit CAS-10095 Multi gauge CAS-10090 Hand pump

Pressure Check Attachment on the floor. Loosen filler cap on reservoir to relieve pressure in reservoir. Disconnect hose from S-port of the lift section. Connect the correct fitting from the pressure fitting kit to the S-port. Connect hand pump to fitting. Actuate hand pump and read the gauge. check the setting three times. Record the average setting. See page 8002-3 for specifications.

ADJUSTING THE MAIN RELIEF VALVE OR A CIRCUIT RELIEF VALVE 1. Loosen the lock nut on the adjusting screw. 2. Turn the adjusting screw clockwise to increase the setting or turn the adjusting screw counterclockwise to decrease the setting.

Bur B-17530

3. Prevent the adjusting screw from turning and tighten the lock nut. 4. Check the setting again.

Issued 3-91

Printed in U.S.A.

8002-13

6

Supplies oil flow for the complete hydraulic system.

Bur 8-17530

Issued 3-91

Printed in U.S.A.

Controls flow of oil to the cylinders movement of control levers. 1. 2. 3. 4. 5. 6. 7. 8 9. 10. 11. 12. 13. 14.

Inlet Outlet To Steering Control Valve From Steering Control Valve (I To Bucket Cylinders To Lift Cylinders To Clam Cylinders Main Relief Valve Steering Relief Valve Flow Control Valve Circuit Relief Valve Load Check Valve Spool Check Valve

IE for the loader by

BUCKET SECTION Jilot)

INLET SECTION

LIFT SECTlm

t

LOADER CONTROL VALVE Controls flow of oil to the cylinders for the loader by movement of control levers. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Inlet Outlet To Steering Control Valve From Steering Control Valve (Pilot) To Bucket Cylinders To Uft Cylinders To Clam Cylinders Main Relief Valve Steering Relief Valve Flow Control Valve Circuit Relief Valve Load Check Valve Spool Check Valve

BUCKET SECTION

INLET SECTION

®

8002-14

LIFT SECTION

CLAM SECTION

OUTLET SECTION

B891~

Bur 8-17530

Issued 3-91

Printed in U~

8002-15

1. 2. 3. 4. 5. 6. 7.

Inlet Outlet Pilot Check Valve Spool and Sleeve Assembly Drive Unk Gerotor

Controls oil flow to the steering cylinder.

8891058J

Bur 8-17530

Issued 3-91

Printed in U.S.A.

8002-16

1. 2. 3. 4. 5. 6. 7. 8.

Inlet To Resetvoi: To Oil Cooler From Steering Control Valve Filter Bypass Valve Switch Check Valve

Cleans oil returning to the reservoir.

B891 061 J

Bur 8-17530

Issued 3-91

Printed in U.S.A.

8002-1·

Controls flow of oil to cylinders for backhoe hy control levers. 1. Inlet 2. Outlet 3. To Swing Cylinders 4. To Boom Cylinder 5. To Left Stabilizer Cylinder 6. To Right Stabilizer Cylinder 7 To Dipper Cylinder B To Bucket Cylinder 9 To Extension Cylinder 10. Anticavitation Valve 11. Circuit Relief Valve 12. Load Check Valve 13. Check Valve 14. Spool 15 Regeneration Valve

12

14

L

I

12

14

@

12

Bur 8-17530

Issued 3-91

Printed in U

7

1110Vnl110.111 of

SWING SECTION

INLET SECTION

.SA

BOOM SECTION

LEFT AND RIGHT STABILIZER SECTIONS

1002-1"

VE shoo by

DIPPER AND BUCKET SECTION

EXTENSION

SECTION

OUTLET SECTION

B891299A

led in U

o

THREE POINT HITCH CaNT, Controls flow of oil to cylinders for three movement of control levers. 1. 2. 3.

9

inlet Outlet Implement 4. 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

t» t»

c

Corrrols flow of oil to cylinders for three point hitch by movement of control levers. 1. 2. 3. 4. 5. 6. 7. B. 9. 10.

PI

inlet Outlet Implement to Tilt Cylinder To Pitch Cylinder To Uft Cylinder Main Relief Valve Circuit Relief - Anticavitation Valve Load Check Valve Spool

t»

INLET-OUTLET AND IMPLEMENT SECTIO~

8002-18

~OL VALVE oint hitch by

INLET-OUTLET AND IMPLEMENT SECTION

TILT AND PITCH SEC'

Bur 8-17530

8002-18

--

LIFT SECTION TILT AND PITCH SECTIONS

8891300

Bur 8-17530 Issued 3-9'

8002-19

1. 2. 3. 4.

Spool Check Valve Orifice Circuit Relief Valve

Actuated by cam to slow the speed of the swing motion of the backhoe.

CD CD

B891301J

Bur 8-17530

Issued 3-91

Printed in U.S.A.

8002-20

This Page Left Blank

Bur 8-17530

Issued 3-91

Printed in U.S.A.

8002-2

DIRECTION

OF FLOW

Shows direction of oil flow.

PILOT PRESSURE

Pressure used to control another component.

CROSSOVER

CONNECTING

LINES

LINES

FILTER OR SCREEN

OIL COOLER

CHECK VALVE

Permits oil flow in one direction only.

DOUBLE ACTING CYLINDER

Loader Backhoe Schematic Bur 8-17530

Issued 3-91

Printed in U.S.A

TEST PORT 2

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

RESERVOIR

inted in U.S.A.

coc

STEERINC

DIRECTION OF FLOW Shows direction of oil flow.

PILOT PRESSURE Pressure used to control another component.

CROSSOVER LINES

CONNECTING

LINES

-0FILTER OR SCREEN

OIL COOLER

CHECK VALVE Permits oil flow in one direction only.

DOUBLE ACTING CYLINDER

TEST PORT 2

8891303

Loader Three Point Hitch Schematic Bur 6-17530

Issued 3-91

Prinlr.d in USA

8003 CLEANING THE HYDRAULIC SYSTEM TABLE OF CONTENTS Portable Filter

8003-2

Cleaning the Hydraulic System

8003-4

General Information

8003-3

8003-6

Types of Contamination

8003-3

Flushing Water From the Hydraulic System

CASE CORPORATION 8-67390

Printed in U.S.A. Issued March 1987

B003-2

PORTABLE FILTER The Portable Filter and Fitting Kit are available from Service Tools in the United States or from Jobborn Manfaucturing Co. in Canada. See Special Tools in Section 1001 for correct address. The part number of the Portable Filter is CAS10162A and for the Fitting Kit the part number is CAS-1050B.

Fitting

Portable Filter

806127

Kit

S06126

8003-3

GENERAL INFORMATION Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways.

1.

Cylinder rod seals leak.

2.

Control valve spools do not return to

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 nents. 4.

compo-

6.

From damaged or worn seals.

5. From a damaged component system.

in the hydraulic

NEUTRAL.

Relief valves or check valves held open by dirt.

7. Quick failure of components repaired.

that have been

8. Cycle times are slow; machine does not have enough power.

All hydraul ic systems operate with some contamination. The design of the components in this hydraulic system permits efficient operation with a small amount of contamination. An increase in this amount of contamination will cause problems in the hydraulic system. The following list includes some of these problems.

If your machine has any of these problems, check the hydraulic oil for contamination. See Types of Contamination below. If you find contamination, use the Portable Filter to clean the hydraulic system.

TYPES OF CONTAMINATION There are two types of contamination, scopic and visible.

micro-

1. Microscopic contamination occurs when very fine particles of foreign material are in suspension in the hydraulic oil. These particles are too small to see or feel. Microscopic contamination can be found by identification of the following problems or by testi ng in a laboratory. Examples of the problems: a.

Cylinder rod seals leak.

b.

Control valve spools do not return to

NEU-

TRAL.

c. The hydraulic system has a high operating temperature.

2. Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause a sudden failure of a component. Examples of visible contamination. a.

Particles of metal or dirt in the oil.

b.

Air in the oil.

c.

The oil is dark and thick.

d.

The oil has the odor of burned oil.

e.

Water in the oil. See page 8003-6.

8003-4

CLEANING THE HYDRAULIC

SYSTEM

1. Prepare the portable filter shown on page 8003-2 by doing the following steps:

8. Loosen and remove the drain plug from the reservoi r.

a. Remove all the hydraulic oil from the inlet and outlet hoses for the portable filter.

9. See the fitting kit shown on page 8003-2. Install the valve in the hole for the drain plug. Make sure that the valve is closed.

b. Remove the filter element from the portable filter. c. Remove all hydraulic oil from the portable filter. d. Clean the inside of the housing forthe filter element. e.

Install a new filter element.

2. You must know whether the contamination is microscopic or visible. See Types of Contamination on page 8003-3. 3.

If the contamination

is microscopic:

a. Check the maintenance schedule for the machine to learn if the hydraulic oil must be changed. If needed, change the hydraulic oil. See Section 8001. Change the hydraulic filter. b. 4.

Do steps 6 th rough 38.

If the contamination

is visible:

a. Change the hydraulic oil and hydraulic filter. See Section 8001. Remove and clean the hydraulic pump suction screen. b.

Do steps 5 through 38.

5. Check the amount of contamination in the hydraulic system by doing the following steps. a. Disassemble one cylinder in two different circuits. Check for damage to seals, scoring of the cylinder wall, etc. Repair the cylinders as necessary. b. If, in your judgment, the damage to the cylinders was caused by severe contamination and is not the result of normal wear, it is necessary to remove, clean and repair valves, pump, lines, cylinders, hydraulic reservoir, etc. in the hydraulic system. 6. Loosen and remove the filler cap from the reservoir. 7. Connect a vacuum pump to the filler cap opening. Start the vacuum pump.

10. Stop the vacuum pump. 11. Connect the inlet hose for the portable filter to the valve that is installed in the hole for the drain plug. 12. Disconnect the vacuum pump from the filler cap opening on the hydraulic reservoir. 13. Install the outlet hose for the portable filter in the hydraulic reservoir. 14. Open the valve that is installed in the hole for the drain plug. 15. Move the switch for the portable filter to the ON position. Start and run the engine at 1500 rpm (r/min). 16. Run the portable filter for 10 minutes. 17. Continue to run the portable filter. 18. Increase the engine speed to full throttle. Heat the oil to operating temperature by doing the following steps: a.

Hold the bucket control lever in the position for 15 seconds.

ROLL-

BACK

b. Return the bucketcontrolleverto for 30 seconds.

NEUTRAL

c. Repeat steps 18a and 18b unti I the oil in the hydraulic system is at operating temperature. 19. Continue to run the engine at full throttle. Continue to run the portable filter. 20. Operate each hydraulic circuit to completely extend and retract the cylinders. Continue to operate each hydraulic circuit two times, one after the other, for 45 minutes. 21. Decrease the engi ne speed to low idle.

8003-5 22. Continue to run the portable filter for 10 minutes.

31. Install the drain plug.

23. Stop the portable filter.

32. Stop the vacuum pump. Disconnect the vacuum pump from the hydraulic reservoir.

24. Stop the engine.

33. Install the filler cap.

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. 27. Disconnect the inlet hose for the portable fi Iter from the valve. 28. Connect a vacuum pump to the fill cap opening of the hydraulic reservoir.

35. Install a new hydraulic machine.

36. Check the oil level in the hydraulic reservoir. Add oil as required. See Section 8001. 37. Start the engine. Check for oil leakage around the new hydraulic filter. ~

29. Start the vacuum pump. 38. Stop the engine. 30. Remove the valve from the hole for the drain plug.

filter element on the

8003-6

FLUSHING WATER FROM THE HYDRAULIC SYSTEM 1.

Start and run the engine at 1500 rpm (r/rnin).

2. Completely retract the cylinders ments on the machine.

of all attach-

11. Disconnect the line from the rod end and closed end of each cylinder. 12. Be sure all control levers are in the position.

NEUTRAL

13. Start the engine and run the engine at low idle. IMPORTANT: Check the oil level in the hydraulic. reservoir frequently while doing step 14. 3. Any attachment or part of an attachment that is raised must be supported to prevent the attachment from falling. 4. Loosen and remove the filler reservoir. 5.

cap from the

15. Stop the engine.

Drain the hydraulic oil from the reservoir. a. The reservoir holds approximately gallons (79.5 litres) of hydraulic oil. b. Have available acceptable drain the hydraulic oil.

21 U.S.

equipment

7.

16. Connect the line to the cylinder.

CLOSED

end of each

17. Start the engine and run the engine at low idle. to

c. Remove the drain plug from the bottom of the reservoir. 6. Remove the hydraulic chine.

14. Move each control lever in both directions until oil begins to flow from the open line. Hold the control lever in place until clean oil flows from the open line.

oil filter from the ma-

Install a new hydraulic oil filter on the machine.

8. Install the drain plug in the bottom of the reservoir. 9. Fill the hydraulic reservoir with 21 U.S. gallons (79.5 Iitres) of Case TCH Fluid. 10. Move each control lever in both directions to release pressure in the circuits.

18. Completely extend all cylinders. As the piston rod comes out of the cylinder, oil will be pushed out of the rod end of the cylinder. 19. Support the loader frame so that the loader frame will stay in the RAISED position. 20. Stop the engine. 21. Connect the lines to the rod end of the cylinders. 22. Fill the reservoir to the correct level. 23. Install the filler cap for the reservoir.

Section

8004 HYDRAULIC PUMP

CASE CORPORATION Bur 8-17400

Printed in U.S.A. Issued January 1991

8004-2

TABLE OF CONTENTS SPECiFiCATIONS

2

DiSASSEMBLy

.

.

3 ......................

INSPECTION .

ASSEMBLY ..

. .7 9

SPECIFICATIONS Manufacturer Rotation

Commercial Shearing Counterclockwise

as seen from shaft end

Wear specifications Special torques Cap screws that hold the' sections together Weight

Bur 8-17400

See Inspection

250 pound-feet (339 Nm) 80 pounds (36 kg)

Issued 1-91

Printed in U.S.A.

8004-3

DISASSEMBLY STEP 1

STEP 4

Clean the outside of the hydraulic pump. Fasten the hydraulic pump in a vise with soft jaws. Make alignment marks on each section of the hydraulic pump.

Remove the quad ring.

STEP 5

STEP 2

Remove the thrust plate. Loosen and remove the cap screws and flat washers.

STEP 6

STEP 3

Remove the driven gear. Remove the end cover.

Bur 8-17400

Issued 1-91

Printed in U.S.A.

8004-4

STEP 7

STEP 11

Remove the drive gear.

Remove the carrier.

STEP 8

STEP 12

!

Remove the other thrust plate.

Remove the quad ring.

STEP 9

STEP 13

Remove the gear housing.

Remove the thrust plate.

STEP 10

Remove the quad ring from bottom of the gear housing.

Bur 8-17400

Issued 1-91

Printed in U.S.A.

8004-5

STEP 14

STEP 17

Remove the driven gear.

Remove the other thrust plate.

STEP 15

STEP 18

Remove the coupling.

Remove the gear housing.

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.

Bur 8-17400

Issued 1-91

Printed in U.S.A.

8004-6

STEP 21

STEP 23

Remove the bearing from the drive end cover.

Remove the seal from the thrust plates.

STEP 22

Remove the seal.

Bur 8-17400

Issued 1-91

Printed in U.S.A

8004-7

INSPECTION Discard all seals and quad rings, Clean all parts in cleaning solvent. Check all machined surfaces for damage or wear,

STEP 26

STEP 24

8525018M Measure the thickness of the thrust plates. If the thickness of a thrust plate is less than 0.247 inch (6.27 mm), install a new thrust plate. Measure the amount of wear caused by the gear teeth in the gear housing. If the wear is more than 0.005 inch (0.13 mm), use a new gear housing.

STEP 27 1. BUSHING

STEP 25

Inspect the bushings in the drive end cover, carrier, and end cover. If the bushings are worn or damaged, use a new hydraulic pump. Inspect the gears for wear and damage. If the gears must be replaced, use a new hydraulic pump.

Bur 8-17400

Issued 1-91

Printed in U.S.A

8004-8 8. CAP SCREW

6. END COVER

5. QUAD RING

7. FLAT WASHER

12. DRIVE GEAR

16. QUAD RING

28. DRIVEN GEAR 22. SEAL

13. QUAD RING

B901880J

31. DRIVE END COVER

Bur 8-17400

Issued 1-91

Printed in U.S.A.

8004-9

ASSEMBLY STEP 28

STEP 31

Install new quad rings in the grooves in the gear housings. Use petroleum jelly to hold the quad rings in place.

Press a new bearing into the drive end cover until the 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.

Bur 8-17400

Issued 1-91

Printed in U.S.A.

8004-10

STEP 34

STEP 37

Fasten the drive end cover in the vise with soft jaws.

Install the drive gear.

STEP 35

STEP 38

Install the gear housing.

Install the coupling.

STEP 36

STEP 39

Install the thrust plate with the seal down and the grooves as shown above.

Install the driven gear.

Bur 8-17400

Issued 1-91

Printed in U.S.A.

8004-11

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

Install the carrier.

STEP 42

Install the gear housing.

Bur 8-17400

STEP 44

Install the drive gear

STEP 45

Install the driven gear.

Issued 1-91

Printed in U.S.A.

8004-12

STEP 46

l

Install the thrust plate with the seal up as shown.

STEP 48

Install the cap screws and flat washers. Tighten the cap screws evenly to 250 pound-feet (339 Nm).

STEP 47

Install the end cover.

Bur 8-17400

Issued 1-91

Printed in U.S.A

8004-13 12. QUAD RING 6. DRIVE 3. OIL SEAL

14. THRUST PLATE

5. QUAD GEAR RING

13. DRIVE GEAR 15. BUSHING 16. FLAT WASHER

/

24. DRIVE END COVER 23. GEAR HOUSING

22. DOWEL PIN

18. END COVER

21. CARRIER 19. GEAR HOUSING

Bur 8·17400

Issued 1-91

8901881J

Printed in U.S.A

Section

8005 LOADER CONTROL VALVE

CASE CORPORATION Bur 8·17410

Printed in U.S.A. Issued January 1991

8005-2

TABLE OF CONTENTS SPECiFiCATIONS....... SPECIAL TOOLS.. SEPARATING THE VALVE SECTIONS ASSEMBLING THE VALVE SECTIONS OUTLET SECTION.. .. Disassembly Exploded View Assembly Cross Section........ INLET SECTION Disassembly.. . ,. Inspection... . Exploded View.. Assembly.... .. Cross Section . BUCKET SECTION...... Disassembly............ Exploded View....................................................................................... Inspection .. .. Assembly Cross Section . .. .. " LIFT SECTION Disassembly Exploded View. Inspection................ Assembly Cross Section CLAM SECTION Disassembly Exploded View Inspection Assembly Cross Section CIRCUIT RELIEF VALVE Dissasembly Inspection . Assembly

Bur 8-17410

..

.

.

. .

. .

.

.

. .

. . . '"

.

3 4 5 6 7 7 8 8 9 10 10 11 12 13 14 .15 .15 19 20 .20 25 26 26 29 30 30 34 35 35 37 38 38 41

42 .......43

Issued 1-91

42 43

Printed in U.S.A.

8005-3

SPECIFICATIONS Manufacturer

.

Pressure Settings

.

.....

J I Case

.

See Section 8002

Ports and Spools Spool travel, neutral to pressure

0.390 inch (9.9 mm)

Spool travel. neutral to float

.

Spool moved into the body

.

0.680 inch (17.2 mm)

.

... pressure at A port

SpOOl moved out of the body ..

............

Inlet. outlet, and power beyond ports Threads in steering pilot port

1-5/16-12, straight thread .

......................................

Threads in steering outlet port

.

Threads in A and B ports

.

..

Spool cap or detent housing Allen head screws for bucket spool

Circuit relief valve body Weight

Bur 8-17410

3/4 - 16 straight thread 7/8 - 14, straight thread

20 to 30 pound-feet (27 to 41 Nm)

Main relief valve

Plug for outlet section

9/16 - 18, straight thread ..

Special torque Nuts that fasten the valve sections together

Circuit relief valves....................

pressure at B port

35 to 40 pound-feet (47 to 54 Nm) ..

65 to 85 pound-feet (88 to 155 Nm) ............................................................

30 to 40 pound-feet (41 to 54 Nm) 20 to 30 pound-feet (27 to 41 Nm)

Tightenscrews evenly to 15 to 30 pound-inches (2 to 3 Nm). Then tighten the Allen head screws evenly to 50 to 60 pound-inches (6 to 7 Nm). 96 to 144 pound-inches

(11 to 16 Nm)

approximately 70 pounds (32 kg)

Issued 1-91

Printed in U.S.A.

8005-4

SPECIAL TOOLS Order special tools from one of the following addresses: 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

B861843J

1.3/8-16 NC X 3 Inches (76 mm) Or Longer Hex Bolt 2. Grind Two Sides Evenly To 15/32 Inch (11.9 mm) 3. Grind To 1/8 Inch (3.2 mm) 4. 5/8 Inch (10.1 mm) The tool above is used to remove and install the load check plugs. This tool is first used on page 17.

The spring compressing plate is used to compress the centering springs for removal and installation. The part number of the tool is CAS-114 7-2. This tool is first used on page 17.

Bur 8-17410

Issued 1-91

Printed in U.S.A

8005-5

SEPARATING THE VALVE SECTIONS STEP 1

STEP 4

Clean the outside of the loader control valve. Write a number on each section of the loader control valve.

Remove the shims.

STEP 2

Loosen and remove the nuts that fasten the sections together.

STEP 5

Remove the remainder of the sections and shims.

STEP 6

STEP 3

Remove the studs from the outlet section. Remove the inlet section

Bur 8·17410

Issued 1-91

Printed in U.SA

8005-6

ASSEMBLING THE VALVE SECTIONS STEP 7

Inspect the O-rings in the valve sections. Replace the O-rings as necessary Use petroleum jelly to hold the O-rings in place as the valve sections are assembled

STEP 10

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.

Install the studs in the outlet section.

STEP 11

STEP 9

Install the shims.

Bur 8-17410

Install the nuts on the studs. Make sure the valve is on a flat surface. Tighten the nuts to 20 to 30 pound-feet (27 to 41 Nm).

Issued 1-91

Printed in USA

8005-7

OUTLET SECTION Disassembly

STEP 15

STEP 12

Remove the spring. Fasten the outlet section in the vise with soft jaws. Loosen and remove the main relief valve.

STEP 16

STEP 13

Remove the poppet.

Loosen the plug in the other end of the outlet section.

STEP 14

STEP 17

Do not disassemble the main relief valve. None of the internal parts of the main relief valve are available for service.

Remove the plug

Bur 8-17410

Issued 1-91

Printed in U.SA

8005-8

STEP 19

Install the spring.

STEP 20

6. MAIN

RELIEF VALVE

B870012J

Outlet Section

Install a new O-ring on the plug. Lubricate the O-ring with clean hydraulic oil. Install the plug. Tighten the plug to 30 to 40 pound-feet (41 to 54 Nm).

Assembly STEP 18

Install the poppet.

Bur 8-17410

STEP 21

Install new O-rings and a new backup ring on the main relief valve. Lubricate the O-rings and backup ring with clean hydraulic oil. Install the main relief valve. Tighten the main relief valve to 35 to 40 pound-feet (47 to 54 Nm). Issued 1-91

Printed in U.sA

8005-9

5. OUTLET SECTION

6. MAIN RELIEF VALVE

2. O-RING

3. SPRING

B861799J

Outlet Section

Bur 8-17410

Issued 1-91

Printed in U.S.A

8005-10

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

Remove the spool. Remove the steering relief valve.

STEP 27

STEP 24

Remove the spring.

Bur 8-17410

Fasten the steering relief valve in the vise with soft jaws. Prevent the adjusting screw from turning and loosen the lock nut. Make a count of the number of turns needed to remove the adjusting screw from the body. Issued 1-91

Printed in U.S.A.

8005-11

Inspection

STEP 28

STEP 29

4. a-RING

B628924M

.~

Remove the steering relief valve from the vise and separate the parts.

..'

4. a-RING

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 necessary.

Bur 8-17410

Issued 1-91

Printed in USA

8005-12

4. BODY

6. O-RING

B870013J

Inlet Section

Bur 8-17410

Issued 1-91

Printed in U.S.A.

8005-13

Assembly

STEP 35

STEP 32

.·B628924M Lubricate the new O-ring on the adjusting screw. Assemble the parts of the steering relief valve.

STEP 33

Fasten the body in the vise with soft jaws. Tighten the adjusting screw the same number of turns as in step 27 under Disassembly. Tighten the lock nut.

Install a new O-ring on the plug. Lubricate the O-ring on the plug. Lubricate the O-ring with clean hydraulic oil. Install the plug in the inlet section

STEP 36

Install the spring in the other end of the inlet section

STEP 37

STEP 34

Lubricate the new O-ring and backup ring on the steering relief valve. Install the steering relief valve. Install the spool.

Bur 8-17410

Issued 1-91

Printed in U.SA

8005-14

STEP 38

"""

~,

,,~§?44M

Tighten the steering relief valve to 65 to 85 pound-feet (88 to 155 Nm). 3. INLET SECTION 4. SPOOL

5. PLUG

B861798J

Inlet Section

Bur 8-17410

Issued 1-91

Printed in U.S.A.

8005-15

BUCKET SECTION Disassembly

STEP 42

STEP 39

Remove the cap and gasket. Remove the O-rings from the bucket section.

STEP 43

STEP 40

Remove the snap ring. Fasten the bucket section in the vise with soft jaws. Loosen the Allen head screws.

STEP 44

STEP 41

Remove the washer.

Hold the cap in place and remove the Allen head screws. Bur 8-17410

Issued 1-91

Printed in U.S.A

8005-16

STEP 45

STEP 48

Remove the spring.

Pull the spool from the body.

STEP 46

Remove the detent washer.

STEP 47

STEP 49

.:~~,S23~M Remove the O-ring, retainer, spring washers, and other O-ring from the spool.

STEP 50

Remove the coil and terminal. Remove the detent housing.

Bur 8-17410

Issued 1-91

Printed in U.S.A.

8005-17

STEP 54

STEP 51

8415238M See Special Tools in this section. Install the spring compressing plates to compress the centering spring.

Loosen and remove the circuit relief valve from the 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.

Use a prybar to remove the wiper. Bur 8-17410

Issued 1-91

Printed in U,S.A

8005-18

STEP 58

STEP 59

inspection, See page 42 for disassembly, assembly of the circuit relief valves.

and

Remove the O-ring from the spool bore.

Bur 8-17410

Issued 1-91

Printed in U.S.A.

8005-19

B901919J

Bucket Section Bur 8-17410

Issued 1-91

Printed in U.S.A.

8005-20

Inspection

STEP 63

STEP 60

B9073305M B415232J Remove and discard the O-ring from the terminal.

Replace the O-ring and backup rings on the load check plug.

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.

Inspect the rubber plug in the cap. Replace the rubber plug as necessary.

Assembly STEP 67

See page 42 for disassembly. inspection. assembly of the circuit relief valves.

STEP 62

and

STEP 68

B9073309M Inspect the poppet. spring, and load check plug. Use new parts as necessary.

Bur 8-17410

Install a new O-ring in the groove of the spool bore.

Issued 1-91

Printed in U.S.A.

8005-21

STEP 69

STEP 72

Use the tool to install the load check plug, spring, and poppet. The groove in the load check plug must be toward the spool bore.

Assemble the spring and spring seats. Use the spring compressing plates to compress the spring.

B415242M

STEP 73

STEP 70

B415243M Lubricate the O-rings and backup ring on the circuit relief valve. Install the circuit relief valve.

Install the spring and spring seats on the spool.

STEP 74

STEP 71

B415201M 628630M Tighten the circuit relief valve to 65 to 85 pound-feet (88 to 155 Nrn).

Bur 8-17410

Apply 242 Loctite to the threads of the stud. Install the stud in the spool.

Issued 1-91

Printed in U.SA

8005-22

STEP 78

STEP 75

B415238M Remove the spring compressing

"'B415202M Push the parts against the detent housing.

plates.

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.

Bur 8-17410

Install the coil and terminal on the stud.

Issued 1-91

Printed in U.S.A.

8005-23

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

15113M

Install the washer.

Align the gasket and cap with the detent housing. Install the Allen head screws and lock washers.

Bur 8-17410

Issued 1-91

Printed in U.8A

8005-24

STEP 87

STEP 89

Tighten the Allen head screws evenly to 15 to 30 poundinches (2 to 3 Nm). Then tighten the Allen screws to 50 to 60 pound-inches (6 to 7 Nrn).

Use a hollow sleeve and a hammer to push the wiper into the body.

STEP 88

Lubricate the wiper with clean hydraulic oil. Install the wiper with the lip up.

Bur 8-17410

STEP 90

Install new O-rings in the bucket section.

Issued 1-91

Printed in U.S.A.

8005-25

22. SPOOL

18. CIRCUIT RELIEF VALVE

24. BODY

26. A PORT

27. B PORT

6. SPRING

B901920J

Bur 8-17410

Bucket Section

Issued 1-91

Printed in U.S.A

8005-26

LIFT SECTION Disassembly

STEP 94

STEP 91

Remove the ball retainer. Remove and discard the O-rings from the body.

STEP 92

STEP 95

II

Remove the eight steel balls. Fasten the lift section in the vise with soft jaws. Loosen and remove the plug.

STEP 93

STEP 96

IIi ... :,(,=;::: ...."

Remove the spacer.

Remove the detent spring.

Bur 8-17410

Issued 1-91

Printed in U.S.A

8005-27

STEP 97

STEP 100

Loosen and remove the detent housing.

See page 4 for the spring compressing plates Fasten the spring compressing plates to compress the centering spring.

B415424M

STEP 98

STEP 101

Pull the spool from the body.

B415426M Loosen and remove the stud.

STEP 99

STEP 102

B415422M Remove the O-ring and retainer from the spool.

B415428M Remove the centering spring and spring seats from the spool.

Bur 8-17410

Issued 1-91

Printed in U.S.A

8005-28

STEP 103

STEP 106

B415430M Release the tension on the centering spring separate the centering spring and spring seats.

and

STEP 104

Remove the wiper from the spool bore.

STEP 107

Remove the O-ring from the spool bore. Loosen and remove the plug from the body.

STEP 105

STEP 108

Repeat steps 104 and 105 to remove the other plug load check plug, spring, and poppet.

Use the tool shown on page 4 to pull the load check plug, spring, and poppet from the body.

Bur 8-17410

Issued 1-91

Printed in U.SA

8005-29

Lift Section Bur 8-17410

Issued 1-91

Printed in U.SA

8005-30

Inspection

STEP 113

Inspect the stud, spacer, steel balls, and ball retainer for damage and wear. Install new parts as necessary.

STEP 109

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 110

Install a new O-ring in the spool bore.

STEP 115

B9073305M Replace the O-ring and backup rings on the load check plug.

STEP 111

Inspect the spool and spool bore for wear and damage. If either part is worn or damaged, use a complete new lift section

STEP 112

~1'

.

,,;,§41?414t'lt

Use the tool shown on page 4 to install the load check plug, spring, and load check poppet. The groove in the loade check plug must be in alignment with the work port.

STEP 116

B415420M Replace the O-rings and backup ring on the plug. Bur 8-17410

Issued 1-91

Printed in U.SA.

8005-31

STEP 120

STEP 117

B41~5430M Assemble the centering spring and spring seats. Use the spring compressing plates shown on page 4 to compress the centering spring.

B415424M Remove the spring compressing

plates.

STEP 121

STEP 118

Install the retainer and a new O-ring on the spool. Install the centering spring and spring seats on the spool.

STEP 122

STEP 119

B4t5426M

Lubricate the spool, spool bore, and the O-rings with clean hydraulic oil. Install the spool into the spool bore.

Apply 242 Loctite (blue) to the threads of stud. Install the stud in spool. Tighten the stud.

Bur 8-17410

Issued 1-91

Printed in U.S.A.

8005-32

STEP 123

STEP 126

Install the detent housing.

Install the eight steel balls. Put the steel balls evenly around the spacer.

STEP 124

Apply No. 2 molydisu\fide grease to the groove in the spacer.

STEP 125

Install the spacer so that the groove in the spacer is up.

Bur 8-17410

STEP 127

Apply No.2 molydisulfide grease to the flat side of the ball retainer.

STEP 128

Install the ball retainer with the flat side down.

Issued 1-91

Printed in U.S.A.

8005-33

STEP 129

STEP 132

Install the detent spring.

Use a hollow sleeve and a hammer to push the wiper into the body.

STEP 130

Install the plug.

STEP 133

Install new O-rings in the body,

STEP 131

Lubricate the new wiper with clean hydraulic oil. Install the wiper with the lip of the wiper up.

Bur 8-17410

Issued 1-91

Printed in U,S,A.

8005-34

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 Bur 8-17410

Lift Section

B901922J Issued 1-91

Printed in U.S.A

8005-35

CLAM SECTION Disassembly

STEP 137

STEP 134

Remove the O-ring and retainer from the spool. Remove the O-rings from the clam section

STEP 138

STEP 135

Use the spring compressing plates shown in Special Tools to compress the spring. Fasten the clam section in the vise with soft jaws. Loosen and remove the spool cap.

STEP 139

STEP 136

Loosen and remove the cap screw. Pull the spool from the body.

Bur 8-17410

Issued 1-91

Printed in U.S.A.

8005-36

STEP 140

STEP 143

Remove the spring and spring seats from the spool. Release the spring tension and separate the spring, spring seats, and washer.

Use a prybar to remove the wiper from the other end of the spool bore.

STEP 141

STEP 144

Remove the O-ring from the spool bore. Loosen and remove the plug.

STEP 142

STEP 145

Do step 141 and 142 to remove the other plug, load check plug, spring, and poppet.

Use the tool shown in Special Tools to pull the load check plug, spring, and poppet from the body.

Bur 8-17410

Issued 1-91

Printed in U.S.A.

8005-37

Bur 8-17410

B901923J

Clam Spool 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 plug. Use new parts as necessary.

Install a new O-ring in the groove of the spool bore.

STEP 151

STEP 147

B9073305M Replace the O-ring and backup rings on the load check plug.

Lubricate the O-ring and backup rings on the load check plug. Use the tool to install the load check plug, spring, and poppet. The groove in the load check plug must be toward the spool bore.

STEP 148 STEP 152

B415420M Replace the O-rings and backup ring on the plug.

STEP 149

Inspect the spool bore for wear and damage. If the spool or spool bore is damaged, use a complete new clam section. Bur 8-17410

M Lubricate the O-rings and backup ring on the plug. Install the plug. Tighten the plug to 65 to 85 pound-feet (88 to 155 Nm). Issued 1-91

Printed in U.S.A.

8005-39

STEP 153

STEP 156

i '

,-:'B628624M

Assemble the spring, spring seats, and washer. Use the spring compressing plates shown in Special Tools to compress the spring.

Tighten the cap screw

STEP 157

STEP 154

';':'~~~M B628539M Apply 242 Loctite to the threads of the cap screw.

STEP 158

STEP 155

B628622M Install the cap screw to fasten the spring to the spool.

Bur 8-17410

Release the tension of the spring and remove the spring compressing plates.

Install the retainer and a new O-ring on the spool.

Issued 1-91

Printed in U.S.A.

8005-40

STEP 159

STEP 162

5M Lubricate a new wiper. Install the wiper with the lips up.

STEP 163

STEP 160

Use a hollow sleeve and a hammer to push the wiper into the bore.

Install the spool cap.

STEP 161

\OO28844M Tighten the spool cap to 20 to 30 pound-feet (27 to 41 Nm).

Bur 8-17410

Issued 1-91

Printed in U.S.A

8005-41

., 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

Bur 8-17410

Issued 1-91

Printed in U.S.A.

8005-42

CIRCUIT RELIEF VALVE Disassembly

STEP 165

STEP 164

Fasten the circuit relief valve in the vise with soft jaws. Loosen the lock nut. Loosen and remove the adjusting screw and lock nut. NOTE: If you disassemble more than one relief valve, keep the parts for each relief valve together. This procedure will prevent mixing the parts during assembly.

Move the circuit relief valve in the vise. Fasten the poppet seat in the vise. Loosen the body from the poppet seat.

STEP 166

B628606M Remove the relief valve from the vise. Separate the parts of the relief valve.

Bur 8-17410

Issued 1-91

Printed in U.S.A.

8005-43

B870017J

Circuit Relief Valve

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

STEP 170

STEP 172

See the procedure in Section 8002. Check and adjust the pressure setting of the relief valve in a test block before the relief valve is installed. 2. ADJUSTING SCREW

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.

Bur 8-17410

Issued 1-91

Printed in U.S.A.

8006 CYLINDERS

TABLE OF CONTENTS Specifications

2

Special Tools....

3

Loader Bucket and Lift. Backhoe Extension, Bucket. Swing, Clam. Stabilizer and Dipper Cylinders. .

4 ..4

.. ..

... 4

Assembly............ Boom Cylinder.

.

Disassembly. Inspection.

. ..

Assembly.

12

Disassembly........

12

Inspection

Disassembly.. Inspection

Lift Cylinder for the Three-Point Hitch

Assembly.

.. 8

Assembly.

.

.

Disassembly... Inspection

.

12 12

Tilt Cylinder for the Three-Point Hitch

4

... 8

..

16 ..

16 16

.

16

Pitch Cylinder for the Three-Point Hitch

8

Disassembly.........

8

Inspection. Assembly

20 ..

..

20 20 20

CASE CORPORATION Rae 8-17591

Copyright © 1992 J I Case Company Printed in U.S.A. Issued March. 1991 (Revised August. 1992)

8006-2

SPECIFICATIONS Torque specifications

for piston cap screw with 242 Loctite on the threads

Loader cylinders Bucket cylinder Lift cylinder Clam cylinder......

..

269 to 339 pound-feet (365 to 460 Nm) 269 to 339 pound-feet (365 to 460 Nm) ..661 to 819 pound-feet (895 to 1110 Nm)

Three-point hitch cylinders Lift cylinder Tilt cylinder.............................................. Pitch cylinder

.

Backhoe cylinders Extension cylinder..................... Bucket cylinder Swing cylinder Stabilizer cylinder................ Boom cylinder Dipper cylinder.......................... Torque for all glands

200 to 220 pound-feet (271 to 298 Nm) 200 to 220 pound-feet (271 to 298 Nm) 169 to 192 pound-feet (230 to 260 Nm)

269 to 339 pound-feet (365 to 460 ..661 to 819 pound-feet (895 to 1110 .. 325 to 365 pound-feet (440 to 495 . 661 to 819 pound-feet (895 to 1110 ..1314 to 1609 pound-feet (1780 to 2180 , 2443 to 2841 pound-feet (3310 to 3850

.

.

Nm) Nm) Nm) Nm) Nm) Nm)

........ 100 to 400 pound-feet (135 to 542 Nm)

Cylinder weights (approximate) Loader cylinders Bucket cylinder Lift cylinder.................. Clam cylinder.................. Three-point hitch cylinders Lift cylinder...... Tilt cylinder. Pitch cylinder .. Backhoe cylinders Extension cylinder Bucket cylinder Swing cylinder Stabilizer cylinder......................... Boom cylinder.......................... Dipper cylinder

Rae 8-17591

.

... 40 pounds (19 kg) ... 60 pounds (27 kg) ... 33 pounds (15 kg)

. .

.

. .

.

..

.......... 29 pounds (13 kg) ..23 pounds (10.4 kg) 30 pounds (13.6 kg)

.

82 98 70 99 170 155

Revised 8-92

pounds pounds pounds pounds pounds pounds

(37 (45 (32 (45 (77 (70

kg) kg) kg) kg) kg) kg)

Printed in USA

8006-3

SPECIAL TOOLS Order special tools from one of the following addresses: In the U.S.A. and Canada

The tool shown is used to install the seal in the glands of the cylinders. This tool is first used on page 8006-4

Service Tools PO Box 314 Owatonna, Minnesota 55060 In Europe VL Churchill Ltd P.O. Box 3, Daventry Northants, NN11 4NF England This tool is used to remove and install the gland on Case cylinders. The part number on the gland wrench is CAS-1 456 This tool is first used on page 8006-4

B505802M 1. 2. 3.

CAS-1659 For One Inch (25 mm) Rods CAS-1660 For 1-1/4 and 1-1/2 Inch (32 and 38 mm) Rods CAS-1758 For 2 Inch (50 mm) Rods

The torque multiplier is used to loosen and tighten the piston cap screw. Use the torque multiplier according to the instructions of the manufacturer. The part number of the torque multiplier is CAS-1 039. This tool is first used on page 8006-4.

B786441M

8795329M

gae 8-17591

Revised 8-92

Printed in U.S.A

8006-4

LOADER BUCKET AND LIFT, BACKHOE EXTENSION, BUCKET, SWING, CLAM, STABILIZER, AND DIPPER CYLINDERS Disassembly Clean the outside of the cylinder. If the hoses were removed with the cylinder, remove the hoses from the cylinder. 1. Fasten the tube (1) in a vise or other holding equipment. Be careful to prevent damage to the tube (1).

4. Check to be sure that the piston rod (6) is straight. If the piston rod (6) is not straight, install a new piston rod (6) 5. Remove small scratches on the piston rod (6) or inside the tube (1) with emery cloth of medium grit. Use the emery cloth with a rotary motion.

2 Loosen and remove the lock screw (2) from the gland (3) and tube (1).

6. Inspect the bushing (18) and seal (19). if equipped. in the piston rod eye (5) and the closed end of the tube (1), replace as required

3. Use the gland wrench shown on page 8006-3 to loosen and remove the gland (3) from the tube (1).

7. Inspect the gland (3) for rust and clean and remove rust as required.

4. Pull the piston rod (6) straight out of the tube (1) to prevent damage to the tube (1).

8 Inspect the gland end of the tube (1) for share edges that will cut the gland O-ring (12). remove as required.

5. Fasten the piston rod eye (5) in a vise and put a support below the piston rod (6) near the piston (4). Use a shop cloth between the support and the piston rod (6) to prevent damage to the piston rod (6).

9. Inspect the piston (4) for damage and wear If the piston (4) is damaged or worn. a new piston (4) must be used.

Assembly

6. Loosen and remove the cap screw (7) and hardened washer (8) that holds the piston (4). Use the torque multiplier shown on page 8006-3 for cap screws that have a high torque value.

NOTE: If a new gland (3) is being installed, put the part number of the cylinder on the new gland (3)

7.

Remove the piston (4) from the piston rod (6).

1.

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) are toward the small end of the gland (3). The wide seal (15) can be difficult to install. Use the tool shown on page 8006-3

9. Remove the seal (9), backup ring (10), and wear ring (11) from the piston (4). 10. Remove the O-ring (12), backup ring (13), wiper (14), wide seal (15), narrow seal (16), and bushing (17) from the gland (3).

Inspection 1. Clean the piston (4), gland (3), piston rod (6), tube (1), hardened washer (8), and cap screw (7) in cleaning solvent. 2. Discard the parts that were removed from the piston (4) and the gland (3). 3. Illuminate the inside of the tube (1). Inspect the inside of the tube (1) for deep grooves and other damage. If there is damage to the tube (1), a new tube (1) must be used.

Rae 8-17591

Install the bushing (17) in the gland (3).

3. Install a new wiper (14) in the gland (3). The lips of the wiper (14) must be toward the large end of the gland (3). 4. Install the narrow seal (16) in the gland (3) The side of the narrow seal (16) with the groove must be toward the small end of the gland (3). 5. Install a new backup ring (13) in the groove on the outside of the gland (3). If both sides of the backup ring (13) are not flat, the side that is not flat must be toward the small end of the gland (3)_ 6. Install the O-ring (12) next to the backup ring (13) in the groove on the outside of the gland (3). The O-ring (12) must be toward the small end of the gland (3).

Revised 8-92

Printed in U.SA

8006-5

,=lac: 8-1759 i

Revised 8-92

Printed in U.S.A

8006-6 7. Fasten the piston rod eye (5) in the vise. 8. Remove any marks and sharp edges on the chamfer at the end of the piston rod (6).

18 Install a new seal (9) on top of the backup ring (10) on the outside of the piston (4) 19. Fasten the tube (1) in a vise or other holding equipment. Be careful to prevent damage to the tube (1)

9 Lubricate the bore of the gland (3) with clean oil. 10 Push the gland (3) onto the piston rod (6). If necessary, use a soft hammer to drive the gland (3) onto the piston rod (6). 11. Put a support below and near the end of the piston rod (6). Use a shop cloth between the support and the piston rod (6) to prevent damage to the piston (4).

12. Put the piston (4) on the end of the piston rod (6) 13. Put the hardened washer (8) on the cap screw (7). 14. Clean the threads on the end of the piston rod and the threads of the cap screw using Loctite cleaning solvent. Allow to dry. Apply Loctite 242 to the piston 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 piston rod threads. DO NOT apply Loctite to the first 1/4 inch of the piston rod threads. 15. Install the cap screw (7). Tighten the cap screw (7) to the torque value on page 8006-2 for the cylinder that is being repaired A torque multiplier can be used to help tighten the cap screw. 16. Install a new wear ring (11) in the end groove on the outside of the piston (4). 17. Install a new backup ring (10) in the center groove on the outside of the piston (4).

Rae 8-17591

20 Lubricate the inside of tne tube (1) and tne ois.on (4) with clean oil. 21 Push the piston (4) straiqh: in.o .ne lube (1) 22 When the piston (4) is in he smooth oar: (1). start the gland (3) in:o 'he .ube (1\

0'

the tube

23 Lubricate the O-ring (12) or, .he gland (3) \VI:hclean oil 24. Tighten the gland (3) :0 10010 400 oounc-tee: (135 to 542 Nm) If the lock screw (2) holes becorre aligned In this torcue range. Install .he lock screw (2). Tighten the lock screw (2) :0 20 occno-vicnes (2.3 Nm) Ii :he lock scre\' (2) holes are no: alignec do steps 25 through 27 25. Tighten the gland (3) to 100;0400 to 542 Nm)

ocund-teet 1135

26. Use a No 26 drill and drill a hole half in the gland(3) and half in the tube (1). Drill to a deeth of 7'16 irch (11 mm) Do not drill in line with a hole in he gland (3) for the gland wrench 27. Install the lock screw (2). Tighten the lock screw (2) to 20 pound-inches (23 Nm) If the hoses were removed with the cylinder. install new a-rings. if equipped on the hose fittings Lubricate the a-rings with clean oil. Install the hoses

Revised 8-92

Printed in U.SA

8006-7 12. a-RING 13. BACKUP RING

5. PISTON ROD EYE 16. NARROW SEAL

17. BUSHING

Rod End of Cylinder

1. TUBE

BB91512J

8. HARDENED WASHER 7. CAP SCREW

Closed End of Cylinder

Rac 8·,7591

Revised 8-92

Printed in USA.

8006-8

BOOM CYLINDER Disassembly Clean the outside of the cylinder. If the hoses were removed with the cylinder, remove the hoses from the cylinder. 1. Fasten the tube (1) in a vise or other holding equipment. Be careful to prevent damage to the tube (1). 2. Loosen and remove the lock screw (2) from the gland (3) and tube (1). 3. Use the gland wrench shown on page 8090-3 to loosen and remove the gland (3) from the tube (1). 4. Pull the piston rod (6) straight out of the tube (1) to prevent damage to the tube (1). 5. Fasten the piston rod eye (5) in a vise and put a support below the piston rod (6) near the piston (4). Use a shop cloth between the support and the piston rod (6) to prevent damage to the piston rod (6).

3 Illuminate the inside of the tube (1). Inspect the inside

of the tube (1) for deep grooves and other damage. If there is damage to the tube (1), a new tube (1) must be used. 4. Check to be sure that the piston rod (6) is straight If the piston rod (6) is not straight, install a new piston rod (6).

5. Remove small scratches on the piston rod (6) or inside the tube (1) with emery cloth of medium grit. Use the emery cloth with a rotary motion 6 Inspect the bushing (20) and seal (21). if equipped in the piston rod eye (5) and the closed end of the tube (1). and replace as required. 7. Inspect the gland (3) for rust and clean and remove rust as required. 8 Inspectthe gland end of the tube (1) for sharp edges that will cut the gland O-ring (14) and remove as required.

6. Loosen and remove the cap screw (7) and hardened washer (8) that holds the piston (4). Use the torque multiplier shown on page 8090-3 for cap screws that have a high torque value.

9. Inspect the piston (4) for damage and wear If the piston (4) is damaged orworn. a new piston (4) must be 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) on the piston (4) are good, replace the check valve (12) and the O-ring (13). If the seals (10) are damaged, do the next step. 9. Remove the wear ring (9), seals (10), and the backup rings (11) from the piston (4) 10. Remove the O-ring (14), backup ring (15), wiper (19), wide seal (18), narrow seal (17), and bushing (16) from the gland (3).

Inspection 1. Clean the piston (4), gland (3), piston rod (6), tube (1), hardened washer (8) and cap screw (7) in cleaning solvent. 2. Discard the parts that were removed from the piston (4) and the gland (3).

Rae 8-17591

1. Install the bushing (16) in the gland (3). 2. Install the narrow seal (17) in the gland (3). The side of the narrow seal (17) with the groove must be toward the small end of the gland (3). 3. Install the wide seal (18) in the gland (3). The wide seal (18) is to be installed so that the lips of the wide seal (18) are toward the small end of the gland (3) The wide seal (18) can be difficult to install. Use the tool shown on page 8009-3. 4. Install a new wiper (19) in the gland (3) The lips of the wiper (19) must be toward the outside of the gland (3). 5 Install a new backup ring (15) in the groove on the 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 the small end of the gland (3).

Revised 8-92

Printed in US.A

8006-9

Rae 8-17591

Revised 8-92

Printed in U.S.A.

8006-10 6. Install the a-ring (14) next to the backup ring (15) in the groove on the outside of the gland (3). The a-ring (14) must be toward the small end of the gland (3).

17 Install a new backup ring (11) in each groove on the outside ends of the piston (4)

7 Fasten the piston rod eye (5) in the vise.

18 Install a new seal (10) over each backup ring (11) on the outside ends 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 equipment. Be careful to prevent damage to the tube (1).

9. Lubricate the bore of the gland (3) and the piston rod (6) with clean oil

20 Lubricate the inside of the tube (1) and the piston (4) with clean oil

10 Push the gland (3) onto the piston rod (6). If necessary, use a soft hammer to drive the gland (3) onto the piston rod (6).

21. Push the piston (4) straiqrn 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 the piston rod (6) to prevent damage to the piston (4) 12. Put the piston (4) on the end of the piston rod (6) 13. Put the hardened washer (8) on the cap screw (7). 14. Clean the threads on the end of the piston rod and the threads of the cap screw using Loctite cleaning solvent. Allow to dry. Apply Loctite 242 to the piston 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 piston rod threads. DO NOT apply Loctite to the first 1/4 inch of the piston rod threads. 15. Install the cap screw (7). Tighten the cap screw (7) to the torque value on page 8006-2 for the cylinder that is being repaired A torque multiplier can be used to help tighten the cap screw (7). 16. Install a new wear ring (9) in the groove in the center of the piston (4)

Rae 8-17591

22. When the piston (4) is in the smooth par; of the tube (1) start the gland (3) into the tube (1) 23. Lubricate the a-ring (14) on the gland (3) with clean oil.

24 Tighten the gland (3) to 100 to 400 pound-feet (135 to 542 Nm) If the lock screw (2) holes become aligned in this torque range install the lock screw (2) Tighten the lock screw (2) to 20 pound- inches (23 Nm) If the lock screw (2) holes are not aligned do steps 25 through 27 25. Tighten the gland (3) to 100 to 400 pound-feet (135 to 542 Nm). 26. Use a No. 26 drill and drill a hole half in the gland (3) and half in the tube (1). Drill to a depth of 7/16 inch (11 mm). Do not drill in line with a hole in the gland (3) for the gland wrench 27. Install the lock screw (2) Tighten the lock screw (2) to 20 pound-inches (23 Nm) 28. If the hoses were removed with the cylinder, install new a-rings. if equipped, on the hose fittings. Lub-icate the a-rings with clean oil. Install the hoses.

Revised 8-92

Printed in U.sA

8006-11

5. PISTON ROD EYE

1. TUBE 21. SEAL

B891539J

Closed End of Cylinder

Rae 8-17591

Revised 8-92

Printed in USA.

8006-12

LIFT CYLINDER FOR THREE-POINT HITCH Disassembly Clean the outside of the cylinder. If the hoses were removed with the cylinder, remove the hoses from the cylinder. 1. Fasten the tube (1) in a vise or other holding equipment. Be careful to prevent damage to the tube (1).

4. Check to be sure that the piston rod (6) is straight. If the piston rod (6) is not straight. install a new piston rod (6).

5. Remove small scratches on the piston rod (6) or inside the tube (1) with emery cloth of medium grit. Use the emery cloth with a rotary motion.

2. Loosen and remove the lock screw (2) from the gland (3) and tube (1).

6. Inspect the bushing (18) and seal (19), if equipped. in the piston rod eye (5) and the closed end of the tube (1). Replace as required.

3. Use the gland wrench shown on page 8006-3 to loosen and remove the gland (3) from the tube (1).

7. Inspect the gland (3) for rust and clean and remove rust as required.

4. Pull the piston rod (6) straight out of the tube (1) to prevent damage to the tube (1).

8. Inspect the gland end of the tube (1) for sharp edges that will cut the gland O-ring (12). Remove as required.

5. Fasten the piston rod eye (5) in a vise and put a support below the piston rod (6) near the piston (4). Use a shop cloth between the support and the piston rod (6) to prevent damage to the piston rod (6).

9. Inspect the piston (4) for damage and wear. If the piston (4) is damaged or worn. a new piston (4) must be used.

Assembly

6. Loosen and remove the cap screw (7) and hardened washer (8) that holds the piston (4). Use the torque multiplier shown on page 8006-3 for cap screws that have a high torque value.

NOTE: If a new gland (3) is being installed, put the part number of the cylinder on the new gland (3).

7.

Remove the piston (4) from the piston rod (6).

1.

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) are toward the small end of the gland (3). The wide seal (15) can be difficult to install Use the tool shown on page 8006-3.

9. Remove the seal (9), backup ring (10), and wear ring (11) from the piston (4) 10. Remove the O-ring (12), backup ring (13), wiper (14), wide seal (15), narrow seal (16), and bushing (17) from the gland (3).

1. Clean the piston (4), gland (3), piston rod (6). tube (1), hardened washer (8), and cap screw (7) in cleaning solvent. from the

3. Illuminate the inside of the tube (1). Inspect the inside of the tube (1) for deep grooves and other damage. If there is damage to the tube (1), a new tube (1) must be used.

Rae 8-17591

3. Install a new wiper (14) in the gland (3) The lips of the wiper (14) must be toward the large end of the gland (3)

Inspection

2. Discard the parts that were removed piston (4) and the gland (3).

Install the bushing (17) in the gland (3).

4. Install the narrow seal (16) in the gland (3). The side of the narrow seal (16) with the groove must be toward the small end of the gland (3). 5. Install a new backup ring (13) in the groove on the outside of the gland (3). If both sides of the backup ring (13) are not flat, the side that is not flat must be toward the small end of the gland (3). 6. Install the O-ring (12) next to the backup ring (13) in the groove on the outside of the gland (3). The O-ring (12) must be toward the small end of the gland (3).

Revised 8-92

Printed in U.SA

8006-13

5. PISTON ROD EYE

19. GREASE

rrrnso

1. TUBE

B891624J

Rae 8·17591

Revised 8-92

Printed in U.S.A.

8006-14 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) 9. Lubricate the bore of the gland (3) with clean oil 10. Push the gland (3) on to the piston rod (6). If neces-

sary, use a soft hammer to drive the gland (3) onto the piston rod (6). 11. Put a support below and near the end of the piston

rod (6). Use a shop cloth between the support and the piston rod (6) to prevent damage to the piston

19 Fasten the tube (1) In a vise or other holding equipment. Be careful to prevent damage to the tube (1)

20. Lubricate the inside of the tube (1) and the piston (4) with clean oil 21 Push the piston (4) s raiqh: into the tube (1).

22 When the piston (4) is In the smooth cart of the tube (1) start the gland (3) into the tube (1) 23. Lubricate the a-ring (12) on the gland (3) with clean ali

(4).

12 Put the piston (4) on the end of the piston rod (6) 13. Put the hardened washer (8) on the cap screw (7). 14. Clean the threads on the end of the piston rod and

the threads of the cap screw using l.octite cleaning solvent Allow to dry. Apply Loctite 242 to the piston 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 piston rod threads DO NOT apply Loctite to the first 1/4 inch of the piston rod threads

15. Install the cap screw (7) Tighten the cap screw (7) to the TOrque value on page 8006-2 for the cylinder that is being repaired A toraue multiplier can be used to help .ighten the cap screw. 16 Install a new wear ring (11) in the end groove a

the

outside of the piston (4) 17. Install a new backup ring (10) in the center groove

on the outside of the piston (4)

Rac 8-17591

24 Tighten the glar:d (3) ;0 100 to 400 pound-feet (135 IO 542 NIT,) I' the lock screw (2) holes oecorr-e aligned in tt"',istoroue range install the lock screw (2). Tighten the lock screw (2) :0 20 pound-Inches (23 Nm) I' tne lock screw (2) holes are no: aligned do stecs 25 :hroLgh 27 2S

7ighten

the gland (3) to 100 to 400 pound-tee: (135

to 542 Nrn)

26 Use a No. 26 drill and drill a hole half in the gland (3) and hal' in the tube (1) Drill to a death a' 7/16 inch (11 rr:r-) Do no: drill in line with a hole in the gland f3) 'or the glar.c wrencr; 27 l"1s:al,the lock screw (2) Tighten the lock screw (2) :020 cound-inches (2.3 Nm). Ii the hoses were removed with the cylinder. install new a-rings. ii equipped on the hose fittings. Lubricate the O-rings with clean 0'1. Install the hoses

RCVlscC

8-92

p"..,:::::: ,~ :.; s ,'".

8006-15 12. O-RING

3

6. PISTON ROD

18. BUSHING 17. BUSHING

15. WIDE SEAL

16. NARROW SEAL

Rod End of Cylinder

19. GREASE FinING

4.

18. BUSHING

8.HARDENED WASHER

7. CAP SCREW

S8S1S25J

Closed End of Cylinder

Rae 8-17591

Revised 8-92

Printed in U .SA

8006-16

TILT CYLINDER FOR THE THREE-POINT HITCH Disassembly

4. Check to be sure that the piston rod (6) is straight. If the piston rod (6) is not straight. install a new piston rod

Clean the outside of the cylinder. If the hoses were removed with the cylinder, remove the hoses from the cylinder.

(6).

1. Fasten the tube (1) in a vise or other holding equipment. Be careful to prevent damage to the tube (1).

5. Remove small scratches on the piston rod (6) or inside the tube (1) with emery cloth of medium grit. Use the emery cloth with a rotary motion.

2. Loosen and remove the lock screw (2) from the gland (3) and tube (1).

6 Inspect the bushing (17) and seal, if equipped, in the piston rod eye (5) and the closed end of the tube (1). Replace as required.

3 Use the gland wrench shown on page 8006-3 to loosen and remove the gland (3) from the tube (1)

7. Inspect the gland (3) for rust and clean and remove rust as required.

4. Pull the piston rod (6) straight out of the tube (1) to prevent damage to the tube (1).

8 Inspect the gland end of the tube (1) for sharp edges that will cut the gland O-ring (12). Remove as required.

5. Fasten the piston rod eye (5) in a vise and put a support below the piston rod (6) near the piston (4). Use a shop cloth between the support and the piston rod (6) to prevent damage to the piston rod (6). 6. Loosen and remove the cap screw (7) and hardened washer (8) that holds the piston (4). Use the torque multiplier shown on page 8006-3 for cap screws that have a high torque value 7.

Remove the piston (4) from the piston rod (6).

8.

Remove the gland (3) from the piston rod (6)

9. Remove the seal (9), backup ring (10). and wear ring (11) from the piston (4). 10 Remove the O-ring (12), backup ring (13), wiper (14), wide seal (15), narrow seal (16), and bushing (17) from the gland (3).

Inspection 1. Clean the piston (4), gland (3), piston rod (6), tube (1), hardened washer (8), and cap screw (7) in cleaning solvent. 2. Discard the parts that were removed from the piston (4) and the gland (3). 3 Illuminate the inside of the tube (1). Inspect the inside of the tube (1) for deep grooves and other damage. If there is damage to the tube (1), a new tube (1) must be used.

=lac 8-17591

9. Inspect the piston (4) for damage and wear. If he piston (4) is damaged or worn. a new piston (4) must be used.

Assembly NOTE: If a new gland (3) is being installed, put the part number of the cylinder on the new gland (3). 1. Install the wide seal (15) in the gland. The wide seal (15) is to be installed sothatthe lips of the wide seal (15) are toward the small end o' the gland (3). The wide seal (15) can be difficult to install. Use the tool shown on page 8006-3 2. Install a new wiper (14) in the gland (3). The lips of the wiper (14) must be toward the large end of the gland (3) . 3. Install the narrow seal (16) in the gland (3). The side of the narrow seal (16) with the groove must be toward the small end of the gland (3). 4 Install a new backup ring (13) in the groove on the outside of the gland (3). If both sides of the backup ring (13) are not flat, the side that is not flat must be toward the small end of the gland (3). 5. Install the O-ring (12) next to the backup ring (13) in the groove on the outside of the gland (3). The O-ring (12) must be toward the small end of the gland (3). 6.

Fasten the piston rod eye (5) in the vise

ReVised 8-92

Pwlted In US.A

8006-17 19 GREASE FITTING

~

Rae 8-17591

Revised 8-92

Printed in U.S.A

8006-18 7 Remove any marks and sharp edges on the chamfer at the end of the piston rod (6)

18. Fasten the tube (1) in a vise or other holding equipment. 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 necessary, use a soft hammer to drive the gland (3) onto the piston rod (6). 10 Put a support below and near the end of the piston rod (6). Use a shop cloth between the support and the piston rod (6) to prevent damage to the piston (4). 11. Put the piston (4) on the end of the piston rod (6) 12 Put the hardened washer (8) on the cap screw (7). 13. Clean the threads on the end of the piston rod and the threads of the cap screw usmq Loctite cleaning solvent. Allow to dry Apply Loctite 242 to the piston 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 piston rod threads. DO NOT apply Loctite to the first 1/4 inch of the piston rod threads. 14. Install the cap screw (7) Tighten the cap screw (7) to the torque value on page 8006-2 for the cylinder that is being repaired A torque multiplier can be used to help tighten the cap screw. When a torque multiplier IS used. a chain must be used to hold the piston rod (6) in position Use a shop cloth and a metal protector between the piston rod (6) and the chain

20 Push the piston (4) straight into the tube (1) 21. When the piston (4) is in the smooth part of the tube (1), start the gland (3) into the tube (1) 22 Lubricate the O-ring (12) on the gland (3) with clean oil 23 Tighten the gland (3) to 100 to 400 pound-feet (135 to 542 Nm) If the lock screw (2) holes become aligned in this torque range install the lock screw (2). Tighten the lock screw (2) to 20 pound-Inches (2.3 Nm) If the lock screw (2) holes are not aligned. do steps 24 through 26 24. Tighten the gland (3) to 100 tc 400 oounc-tee: (135 to 542 Nrn). 25 Use a No. 26 drill and drill a hole hal' In the gland (3) and half in the tube (1) Drill to a death of 7/16 inch (11 mm). Do not drill in line With a hole in the gland (3) for the gland wrench 26 Install the lock screw (2) Tighten the lock screw (2) to 20 pound-Inches (23 Nm) If the hoses were removed With the cylinder. install new 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) 16. Install a new backup ring (10) in the center 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)

Rae 8-17591

=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

ADJUSTMENT OF DRIVE BELT Check the tension of the drive belt after every 250 hours of operation. If a new drive belt is installed, check the tension of the drive belt after the first 20 hours of operation. The correct tension for a new drive belt is 65 to 75 pounds (29 to 34 kg) measured with a belt tension gauge. The correct tension for a drive belt used more than 20 hours is 55 to 65 pounds (20 to 23 kg) measured with a belt tension gauge.

To adjust the tension of the drive belt: 1. Loosen slightly the nuts on the bolts that hold the compressor. 2. Use a prybar near the front of the compressor to tighten the drive belt, then tighten the nuts. 3. Use a belt tension gauge and check the tension of the drive belt. 4.

Repeat steps 1, 2, and 3 as required.

LUBRICATION OF COMPRESSOR General Information Because the air conditioning system is a closed system, the compressor will not need regular oil level checks or oil changes.

1. Connect the hoses from the R-12 refrigerant recovery/recycling system to the manifold. Make sure that both valves in the gauge manifold are closed.

An oil change is necessary only when the air conditioning system has contamination from a leak or a component failure.

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.

Oil Level Check The level of the oil must be checked whenever a new receiver-drier, condenser, or evaporator has been installed. B891255J

2. Connect the hose from the high pressure gauge to the high pressure port. 3. Connect the hose from the low pressure gauge to the low pressure port. 4. Start the engine and 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. 5. Bur

8-12711

Stop the engine. Issued 1-91

Printed in U.SA

9003-6 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.

6. Connect the hose from the low pressure gauge to the low pressure port.

B840536J

1. Point Must Be Toward Left Side Of Machine. Stop On Dipstick Must Touch The Compressor

7. Connect the charge-discharge hose (yellow) to the fitting on the side of the R-12 refrigerant recovery/recycling system. 8. Put the angle gauge from the tool kit shown on page 9003-2 on the front or rear mounting flange. Adjust the level on the angle gauge until the bubble is between the marks. Tighten the wing nut.

12. Read the degrees on the angle gauge and the notches in the dipstick. 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. Angle Gauge Reading 0

Oil Level Notches 2-4

10

4-5

70

5-6

14. Charge the air conditioning system according to instructions in this section.

9.

Loosen and remove the filler plug.

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.

Bur 8-12711

Issued 1-91

Printed in U.S.A.

9003-7

Oil Level for a New Compressor 1. Drain the oil from the old compressor into a measuring container. 2. Drain the oil from the new compressor CLEAN measuring container.

Bur 8-12711

into a

3. Fill the new compressor with the new oil equal to the amount drained from the old compressor plus 1 U.S. fluid ounce (30 mL) of new oil. 4.

Install and tighten the filler plug.

5. No oil level check will be needed after the compressor has been installed.

Issued 1-91

Printed in U.S.A.

9003-8

DISCHARGING THE AIR CONDITIONING SYSTEM The air conditioning system must be discharged before beginning the removal of any component of the air conditioning system.

5. Loosen and remove the cap from the low pressure port. 6. Connect the hose from the low pressure gauge to the low pressure port. 7. Connect the charge-discharge hose (yellow) to the fitting on the side of the R-12 refrigerant recovery/recycling system. 8. Use the R-12 refrigerant recovery/recycling system according th the instructions of the manufacturer. 9. Open the valve for the low pressure gauge a small amount to slowly release the refrigerant 10 Open the valve for the high pressure gauge a small amount to release the refrigerant. 11. When the low pressure gauge and high pressure gauge indicate zero, the air conditioning system is discharged.

1. Connect the hoses from the R-12 refrigerant recovery/recycling system to the gauge manifold.

LOW PRESSURE GAUGE

HIGH PRESSURE GAUGE

2. Make sure that each valve in the gauge manifold is closed. CHARGEDISCHARGE ~HOSE

\ tt ,

HIGH

PRESSURE .I-../PORT Will

B891255J

3. Loosen and remove the cap from the high pressure port 4. Connect the hose from the high pressure gauge to the high pressure port.

Bur 8·12711

Issued 1-91

Printed in U.S.A

9003-9

REMOVING AIR AND MOISTURE FROM THE AIR CONDITIONING SYSTEM When the air conditioning system has been discharged and opened for service, air enters the air conditioning system before the openings can be closed. The air carries moisture which can cause damage to the air conditioning system. It is necessary to remove the air and moisture before the air conditioning system is charged with new refrigerant.

b. Connect the hose from the low pressure gauge to the low pressure port. 2. Make sure that the valves in the gauge manifold are open.

Replace the receiver-drier before removing the air and moisture if: a. The air conditioning system has been opened before. b. The receiver-drier has been used for more than two seasons. c. The reason for service is too much air and moisture in the air conditioning system. d. Disassembly of the compressor shows particles of the drying material inside the compressor. NOTE: Make sure the hoses from the R-12 refrigerant recoverylrecycling system are connected to the gauge manifold. 1. If the hoses from the gauge manifold have been disconnected from the compressor: LOW PRESSURE

HIGH PRESSURE

GAUGE

GAUGE

3. Connect the charge-discharge hose from the gauge manifold to the vacuum pump. 4. Run the vacuum pump for a minimum of 30 minutes. The low pressure gauge must indicate a vacuum of 28 to 29 inches of mercury (95 to 100 kPa) within five minutes. If the vacuum is not as specified, there is a leak in the air conditioning system or the vacuum pump is not working correctly. NOTE: The vacuum indication will be one inch of mercury (3.3 kPa) less for every 1000 feet (305 meters) above sea level. 5.

To check for a leak in the air conditioning system: a. Close the valves for the low pressure and high pressure gauges. b.

HIGH

Stop the vacuum pump.

c. If the reading of the low pressure gauge increases more than one inch of mercury (3.3 kPa) in four minutes, there is a leak in the air conditioning system. d. Check all connections in the air conditioning system.

B891255J

a. Connect the hose from the high pressure gauge to the high pressure port. Bur 8-12711

6. Before disconnecting the vacuum pump, make sure that the valves for the low pressure and high pressure gauges have been closed.

Issued 1-91

Printed in U.S.A.

9003-10

CHARGING THE AIR CONDITIONING SYSTEM General Information Charge the air conditioning system only when there is no indication of leaks,

LOW

HIGH

PRESSURE GAUGE

PRESSURE GAUGE

If the air conditioning system has been discharged, air and moisture must be removed from the air conditioning system according to instructions in this section before the air conditioning system can be charged. If refrigerant is being added to a charged air conditioning system, removal of air and moisture is not necessary, HIGH

The correct amount of R12 refrigerant for the air conditioning system is 80 ounces (2.26 Kg). Using more refrigerant than required will damage the compressor, Use the procedure that follows to correctly charge the air conditioning system.

B891255J

Charging Procedure 1, If the air conditioning system is to receive a complete charge of refrigerant, remove air and moisture from the air conditioning system according to instructions in this section, Then continue the procedure at step 3. NOTE: Make sure the hoses from the R-12 refrigerant recovery/recycling system are connected to the gauge manifold. 2,

If you are only adding refrigerant:

b. Loosen and remove the cap from the high pressure port. c. Connect the hose from the high pressure gauge to the high pressure port. d. Loosen and remove the cap from the low pressure port. e, Connect the hose from the low pressure gauge to the low pressure port.

a. Make sure the valves in the gauge manifold are closed,

Bur 8-12711

Issued 1-91

Printed in U,S,A,

9003-11 6. Open the control valve a small amount to remove the air from the charge-discharge hose. Then tighten the connection at the gauge manifold. 7. Open the control valve on the container several turns. 8. Slowly open the valve for the low pressure gauge to prevent the pressure from going above 40 psi (276 kPa, 2.8 bar). At a higher pressure the refrigerant will become liquid and damage the compressor. 9. Start the engine and run the engine at 1500 rpm (r/min). 3. Install the control valve on the container frigerant.

of re-

10. Turn the air conditioning control to the COLD position. 11. Turn the knob for the blower to the HI position. 12. Continue to charge the air conditioning system until 80 ounces (2.26 kg) of refrigerant is in the air conditioning system or until there are no air bubbles in the sight glass on the top of the receiver-drier. 13. When changing containers of refrigerant: a.

Close the valve for the low pressure gauge.

b.

Close the control valve on the container

c. Remove the control valve from the empty container. 4. Connect the charge-discharge hose from the gauge manifold to the control valve.

d.

Install the control valve on the new container.

14. Open the valve for the low pressure gauge and the control valve on the container of refrigerant. 15. Read the low pressure gauge and the high pressure gauge. The air conditioning system is correctly charged when: a. The indication of the low pressure gauge is 7 to 30 psi (48 to 207 kPa, 0.48 to 2.1 bar). b. The indication of the high pressure gauge is the same as in the temperature-pressure chart that follows on the next page.

5. Loosen the connection of the charge-discharge hose and the gauge manifold.

Bur 8-12711

Issued 1-91

Printed in U.S.A

9003-12 Ambient Temperature*

High Pressure Indication

80°F (26.7°C)

150 to 170 psi (1034 to 1172 kPa, 10.3 to 11.7 bar)

90°F (32ZC)

175 to 185 psi (1206 to 1275 kPa, 12.1 to 12.7 bar)

95°F (35°C)

100°F (37.8°C)

16. If the high pressure reading is too high: a. Close the control valve for the refrigerant container. b. Disconnect the charge-discharge the control valve.

c. Slowly open the valve for the high pressure gauge to decrease the high pressure to the correct value.

195 to 205 psi (1344 to 1413 kPa, 13.4 to 14.1 bar) 210 to 230 psi (1447 to 1585 kPa, 14.4 to 15.8 bar)

105°F (40.rC)

230 to 250 psi (1585 to 1723 kPa, 15.8 to 17.2 bar)

110°F (43°C)

250 to 270 psi (1723 to 1861 kPa, 17.2 to 18.6 bar)

hose from

d. Close the valve for the high pressure gauge when the reading is correct. 17. After the air conditioning system has the correct charge, stop the engine.

*The temperature of the air around the machine.

18. Disconnect pressure ports.

the hoses from the low and high

19. Install the cap on the low and high pressure ports.

REMOVING THE COMPRESSOR 1. Discharge the air conditioning system according to instructions in this section. 2.

Disconnect the hoses from the compressor.

3.

Install a plug in each hose.

4.

Disconnect the wire from the wiring harness.

6.

Remove the bolt and flat washer.

7. Loosen and remove the nut, lock washer and flat washers from the bolt that holds the compressor. 8. Hold the compressor and remove the bolt and remove the compressor from the machine.

5. Loosen and remove the nut and lock washer from the .bolt at the top of the adjustment strap.

Bur 8-12711

Issued 1-91

Printed in U.S.A

9003-13

Bur 8·12711

Issued 1-91

Printed in USA

9003-14

REPLACING THE COIL OR CLUTCH ASSEMBLY NOTE: Special tools are from kit CAS-10747 shown on page 9003-4.

STEP 4

STEP 1

Remove the shield from the bore of the pulley.

Fasten the compressor in a vise. Loosen and remove the three cap screws and lock washers from the cover on the clutch. Remove the cover. Loosen and remove the nut that holds the clutch plate.

STEP 5

STEP 2

Remove the large snap ring.

STEP 6 Install the puller for the clutch plate.

STEP 3

Remove the small snap ring.

Remove the clutch plate. Bur 8-12711

Issued 1-91

Printed in U.S.A.

9003-15

STEP 7

STEP 10

Install the jaws of the puller on the pulley.

Remove the pulley.

STEP 8

STEP 11

Install the separator.

Remove the separator.

STEP 9

STEP 12

Install the handle.

Loosen the screw that holds the clamp for the wire.

Bur 8-12711

Issued 1-91

Printed in U.S.A.

9003-16

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 bottom of the coil engages the hole in the front of the compressor.

Install the wire behind the clamp and tighten the screw.

Bur 8-12711

Issued 1-91

Printed in U.S.A.

9003-17

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.

Bur 8-12711

~-

Issued 1-91

Printed in U.S.A.

9003-18

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

Drive the clutch plate all the way onto the shaft.

STEP 27

STEP 29

If the gap is more than .032 inch (0.81 mm) or less than .016 inch (0.41 mm), remove the clutch plate and add or remove shims as required to get the correct gap.

STEP 30

Install the cover on the clutch.

Install and tighten the nut to 300 to 360 pound-inches (34 to 40 Nm).

Bur 8-12711

Issued 1-91

Printed in U.S.A.

9003-19

REPLACING THE SEAL STEP 31

STEP 34

Fasten the compressor in a vise. Remove the cover from the clutch. Loosen and remove the nut that holds the clutch plate.

Drive the bottom of the Woodruff key into the keyway.

STEP 35

STEP 32

Use a pair of wire cutters to remove the Woodruff key. Install the puller for the clutch plate.

STEP 36

STEP 33

Remove the shims for the clutch plate. Remove the clutch plate.

Bur 8-12711

Issued 1-91

Printed in U.S.A.

9003-20

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

Remove the snap ring that holds the seal seat.

STEP 39

STEP 41

Install the seal tool and engage the notches in the seal tool with the tabs on the seal.

STEP 42

Remove the seal seat. Remove the seal.

Bur 8-12711

Issued 1-91

Printed in U.S.A.

9003-21

STEP 43

STEP 46

Install the protector on the shaft.

Lubricate the protector with refrigeration oil and install the seal.

STEP 44

STEP 47

Carefully remove the seal from the container.

Mt.

NOTE: DO NOT touch the sealing surface of the carbon ring. Body salts and acids will damage the sealing surface.

STEP 48

Install the new a-ring in the bottom groove in the bore for the seal.

STEP 45

Carefully remove the seal seat from the container. Install the seal on the seal tool.

Bur 8-12711

NOTE: DO NOT touch the sealing surface of the seal seat. Body salts and acids will damage the sealing surface.

Issued 1-91

Printed in U.S.A.

9003-22

STEP 49

STEP 52

Lubricate the sealing surface of the seal seat with refrigeration oil and install the seal seat.

Drive the felt seal into the bore until the metal is even with the top of the bore.

STEP 50

STEP 53

Instail the snap ring so that the chamfer on the ID will be 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.

Bur 8-12711

B414508M

Issued 1-91

Printed in U.S.A.

9003-23

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.

Bur 8-12711

Issued 1-91

Printed in U.S.A

9003-24

REPLACING THE VALVE PLATE AND GASKETS STEP 59

Remove the dirt and grease from the compressor.

STEP 63

STEP 60

Remove the gasket from the valve plate.

Fasten the compressor in a vise and loosen and remove the cap screws that hold the end cap.

STEP 64

STEP 61

Loosen the valve plate.

Hit the end cap to loosen the end cap.

STEP 65

STEP 62

Remove the valve plate.

Remove the end cap. Bur 8-12711

Issued 1-91

Printed in U.S.A.

9003-25

STEP 66

STEP 69

If the gaskets are being replaced, remove the other gasket from the valve plate. Be careful not to damage the valves.

Install the end cap.

STEP 70

STEP 67

.:.....

4a43M· •.

: •...•••

:

->;., •.•••

Install the new gaskets on the valve plate. The gaskets will only fit one way.

STEP 68

Install and tighten every other cap screw to 264 to 300 pound-inches (30 to 34 Nm) until all cap screws have been tightened.

STEP 71

Loosen and remove the filler plug and drain the oil into a measuring container.

STEP 72

Fill the compressor with the same amount of NEW refrigeration oil.

STEP 73

Install and tighten the filler plug.

Install the valve plate.

Bur

8-12711

Issued 1-19

Printed in U.S.A.

9003-26

B1245A88J

Bur 8-12711

Issued 1-91

Printed in U.S.A.

9003-27

INSTALLING

THE COMPRESSOR

'I . Align the compressor with the mounting bracket and install the bolt and flat washer.

6. Adjustthe drive belt according to instructions in this section.

2. Install the flat washer, lock washer and nut on the bolt.

7.

Loosen and remove the plugs from the hoses.

8.

Connect the hoses to the compressor

9.

Connect the wiring to the wiring harness

3.

Install the drive belt on the pulley.

4. Align the adjusting strap with the compressor and install the bolt and flat washer. 5.

Install the lock washer and nut on the bolt.

Bur 8-12711

10. Charge the air conditioning system according to instructions in this section.

Issued 1-91

Printed in U.S.A.

9003-28

REPLACING THE AIR CONDITIONING CONTROL 1. Remove the evaporator according to instructions in this section.

6. Route the tube for the new air conditioning the same way as the original.

2. Loosen and remove the nut that holds the air conditioning control.

7.

3. Remove the air conditioning mounting plate. 4. Disconnect control. 5.

control from the

the wiring from the air conditioning

Completely remove the air conditioning control.

Connect the wiring to the air conditioning

8. Install the air conditioning plate.

control

control.

control in the mounting

9. Install and tighten the nut that holds the air conditioning control. 10. Install the evaporator according this section.

to instructions

in

REPLACING THE EXPANSION VALVE 1. Discharge the air conditioning system according to instructions in this section.

8. Disengage the vertical cover from the frame beginning at the top and remove the vertical cover.

2.

9. Disengage the left vertical cover beginning at the top and remove the vertical cover.

Turn the temperature control to HOT.

3. Drain one U.S. gallon (4 litres) of coolant from the radiator. 4. Remove the knobs from the switches, air conditioning control and temperature control. 5. Loosen and remove the screws that hold the control panel.

NOTE:

The front headliner MUST be removed first.

10. Hold the front headliner in place and loosen and remove the screws at the front of the front headliner and the screws on each side including the screw at the junction of the front and rear headliners. 11. Lower the front headliner onto the control.

6. Disengage the control panel from the vertical cover and disconnect the wiring from the cab lamp switch. 7. Loosen and remove the screws that hold the bottom of the vertical cover.

Bur 8-12711

12. Loosen the clamp on the front drain hoses. 13. Remove the hoses from the drain pan.

Issued 1-91

Printed in U.S.A.

9003-29 14. Loosen and remove the screw from the left and right rear sides of the rear headliner.

23. Install new insulation tape around the expansion valve.

15. Hold the rear headliner in place and loosen and remove the screws from the left and right sides of the rear headliner.

24. Carefully raise the rear headliner and engage the rear headliner with the slot at the rear of the roof.

16 Carefully lower the rear headliner behind the seat. 17. Remove the insulation from the expansion valve.

25. Hold the rear headliner in place and install a screw in the center hole on the right and left sides of the rear headliner. 26. Install and tighten the screw at the left and right rear sides of the rear headliner. 27. Connect the front drain hoses to the drain pan. 28. Tighten the clamp on each hose. 29. Carefully raise the front headliner and engage the front headliner with the rear headliner. 30. Install and tighten the screws atthe front of the front headliner. 31. Install and tighten the screws on the right sides of the front and rear headliners. 32. Install the left vertical cover.

8891257J

18. Loosen completely the connections at the rear of the expansion valve 19. Loosen completely the connections at the front of the expansion valve and remove the expansion valve. 20. Install new O-rings on the fittings on the tubes and the fittings on the evaporator. 21. Lubricate the O-rings with refrigeration oil. 22. Install the expansion valve and tighten the connections with force equal to 240 to 300 pound-inches (27 to 34 Nm).

Bur 8-12711

33. Install the right vertical cover. 34. Install and tighten the screw at the bottom of the right vertical cover. 35. Connect the wires to the cab lamp switch in the control panel and engage the control panel with the right vertical cover. 36. Install and tighten the screws that hold the control panel. 37. Install the knobs for the switches and the air conditioning and temperature controls. 38. Charge the air conditioning system according to instructions in this section.

Issued 1-91

Printed in U.S.A.

9003-30

REPLACING THE EVAPORATOR 1. Discharge the air conditioning system according to instructions in this section.

19. Remove the insulation for the connections to the expansion valve and evaporator.

2.

20. Disconnect the tubes from the expansion valve and evaporator .

Turn the temperature control to HOT.

3. Drain one U.S. gallon (4 litres) of coolant from the radiator. 4. Remove the knobs from the switches, ditioning control and temperature control. 5. Loosen and remove the screws control panel.

air con-

21. Loosen the cap screws that hold the evaporator. 22. Carefully remove the evaporator and remove the temperature sensor and tube for the air conditioning control from the evaporator.

that hold the

6. Disengage the control panel from the right vertical cover. 7. Loosen and remove the screws that hold the bottom of the right vertical cover. 8. Disengage the vertical cover from the frame beginning at the top and remove the vertical cover. 9. Disengage the left vertical cover beginning at the top and remove the vertical cover. IMPORTANT: first.

The front headliner must be removed

10. Hold the front headliner in place and loosen and remove the screws at the front of the headliner and the screws on each side including the screw at the junction of the front and rear headliners. 11. Lower the front headliner onto the control console. 12. Loosen the clamp on the front drain hoses. 13. Remove the front drain hoses from the drain pan. 14. Loosen and remove the screw from the left and right rear sides of the rear headliner. 15. Hold the rear headliner in place and loosen and remove the screws from the lett and right sides of the rear headliner. 16. Carefully lower the rear headliner behind the seat. 17. Loosen both clamps on the hoses connected to the heater.

B861647M

23. Remove any remaining insulation from the expansion valve and the connections to the evaporator. 24. Remove the clamp that holds the temperature sensor. 25. Disconnect the expansion valve and equalizer tube from the evaporator. 26. Connect the expansion valve to the new evaporator. 27. Connect the equalizer tube to the outlet tube of the evaporator. 28. Apply a small amount of grease between the temperature sensor and the outlet tube. 29. Install the clamp sensor.

that holds

the temperature

30. Apply new insulation tapes to the tubes at each end of the evaporator, the inlet and outlet tubes, and the expansion valve and the equalizer tubes.

18. Slide the hoses to the rear.

Bur 8-12711

Issued 1-91

Printed in U.S.A.

9003-31

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 evaporator as shown.

40. Install and tighten the screw at the left and right rear sides of the rear headliner. 41. Connect the front drain hoses to the drain pan. 42. Tighten the clamp on each hose. 43. Carefully raise the front headliner into position and engage the front headliner with the rear headliner. 44. Install and tighten the screws at the front of the front headliner. 45. Install and tighten the screws on the right and left sides of the front and rear headliners. 46. Install the left vertical cover.

32. Install the evaporator.

47. Install the right vertical cover.

33. Install and tighten the cap screws that hold the evaporator

48. Install and tighten the screws at the bottom of the right vertical cover.

34. Connect the tubes to the expansion valve and evaporator.

49. Connect the wires to the cab lamp switch and 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. 37. Tighten the clamps for both hoses.

51. Install the knobs for the switches and the air conditioning and temperature controls.

38. Carefully raise the rear headliner and engage the rear headliner with the slot at the rear of the roof.

52. Fill the radiator to the correct level.

39. Hold the rear headliner in place and install a screw in the center hole on the right and left sides of the rear headliner.

Bur 8-12711

53. Charge the air conditioning system according to instructions in this section.

Issued 1-91

Printed in U.S.A.

9003-33

Bur 8-12711 B891258J

ISsued 1-91

Printed in U.SA

9003-34

REPLACING THE CONDENSER 1. Discharge the air conditioning system according to instructions in this section. 2.

Have another person hold the hood in position.

3. Make an alignment mark at the top and rear of each pivot bracket for the hood. 4. Loosen and remove the nut, lock washer, spacer, flat washer and bolt that fasten each cable to the radiator shroud. 5. Loosen and remove the front and rear cap screws that hold each pivot bracket. 6.

Remove the hood from the machine.

7. Put blocks between the radiator and pump to hold the radiator in place with the radiator shroud or mounting brackets removed. 8. Loosen and remove the self-locking nut, bolt and flat washer from each oil cooler mount.

21. Tighten the cap screws. 22. Install the mounting brackets and bolts and lock washers and nuts. 23. Tighten the nuts. 24. Loosen and remove the plug from each hose. 25. Connect the hoses to the condenser. 26. Install the guard and cap screws. 27. Tighten the cap screws. 28. Install the radiator shroud. 29. Install the bolts and flat washers, and nuts that hold the radiator shroud. 30. Install the bracket and cap screw at the top of the radiator. 31. Tighten the cap screw.

9. Loosen and remove the cap screw and bracket at the top of the radiator. 10. Loosen and remove the nuts and bolts that hold the radiator shroud. 11. Remove the radiator shroud.

32. Have another person push and hold the top of the radiator shroud all the way to the rear. 33. Tighten the nuts. 34. Install a bolt and flat washer and self-locking nut in each oil cooler mount.

12. Loosen and remove the cap screws that hold the guard at the bottom of the condenser.

35. Tighten the self-locking

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. 16. Loosen and remove the nuts and lock washers from the bolts that hold the mounting brackets. 17. Remove the mounting brackets and the bolts. 18. Loosen and remove all but the top cap screws that hold the condenser. 19. Hold the condenser in place and remove the top cap screws and remove the condenser. 20 Hold the condenser in place and install the flat washers, lock washers and cap screws.

Bur

8-12711

nuts.

38. Install the hood. 39. Install the cap screws that hold the pivot brackets. 40. Align each pivot bracket with the alignment marks and tighten the cap screws. 41. Close the hood. The top rear of the hood must be even with the frame. 42. If the top of the hood is too high, check to see if the sides of the hood are touching the frame. To correct this problem, move the pivot brackets forward.

Issued 1-91

Printed in U.S.A.

9003-35

3. O-RING

3. O-RING

3. O-RING

3. O-RING

B891259J

Bur 8-12711

Issued 1-91

Printed in U.S.A.

9003-36 43. If the top of the hood is too high and the sound of

metal hitting metal is heard at the front of the hood, the radiator shroud is not in the correct position. To correct this problem, the top of the radiator shroud must be moved farther to the rear.

Bur 8-12711

44. When the hood can be closed and is in the correct position, tighten the nuts on the bolts that hold the radiator shroud to 270 to 324 pound-feet (366 to 439 Nm). 45. Charge the air conditioning system according to instructions in this section.

Issued 1-91

Printed in U.S.A.

9003-37

3. O-RING

3. O-RING

3. O-RING

8891259J

Bur 8-12711

Issued 1-91

Printed in U.S.A.

9004 LOADER

TABLE OF CONTENTS REPLACEMENT OF CUTIING EDGE FOR STANDARD BUCKETS

2

EXPLODED VIEWS

REPLACEMENT OF CUTIING EDGE FOR CLAM BUCKET.

4

Lift Cylinder Hydraulic Installation

10

REPLACEMENT OF TOOTH SHANK

6

Bucket Cylinder Hydraulic Installation

11

REPLACEMENT OF TOOTH POINT

6

Antirollback Linkage

12

REMOVAL OF lOADER FRAME

7

Clam Cylinder Circuit...

13

INSTALLATION OF LOADER FRAME

8

Clam Cylinder Hydraulic Installation

14

Installation of Front Counterweight

15

Installation of Rear Counterweight

16

CASE CORPORATION Bur 8-17630

loader

Frame

9

Copyright © J I Case Company Printed in U.S.A. Issued March 1991

9004-2

REPLACEMENT OF CUTTING EDGE FOR STANDARD BUCKETS 1. If the bucket is not removed from the machine, raise the bucket to a suitable height and use suitable supports to hold the loader frame and bucket in place.

8. Put the cutting edge in place and use C-clamps to hold the cutting edge in place. See the illustration forthe correct position of the cutting edge.

2. If equipped with bucket teeth, use carbon arc rod to remove the bucket teeth. 3. Use carbon arc rod or an acetylene cutting torch to remove the welds that hold the cutting edge. Keep distortion to a minimum when removing the cutting edge. 4. When removing the bottom rear weld for the cutting edge DO NOT cut through the floor of the bucket. 5. If removing the cutting edge from a short lip bucket, remove the gusset from each side of the bucket.

B902762J

1. 2.

Short Up Bucket - 25-3/16 In (639 mm) Long Up Bucket - 27 In (687 mm)

9. Use E-7018 welding rod and weld the cutting edge to the bucket.

1. Gusset 6. If removing the cutting edge from a short lip bucket, cut through each corner of the cutting edge 1-13/16 (45 mm) to the rear from the front edge of the floor of the bucket. 7. Use a grinder to remove any welds or extra metal on the bucket that will prevent the new cutting edge from fitting correctly.

10. When welding the floor of the bucket the top of the cutting edge: a. Start at one end of the bucket and weld toward the center until one welding rod is used. b. Start at the center of the bucket and weld in both directions from center until one welding rod is used. c. Start at the other end of the bucket and weld toward the center until one welding rod is used. d. Continue to weld the cutting edge to the bucket using this method until welding is complete. 11. If replacing the cutting edge on a short lip bucket, weld the gussets in place at each side of the bucket. 12. If bucket teeth were removed from the old cutting edge, install the bucket teeth according to instructions in this section.

Bur 8-17630

Issued 3-91

Printed in U.SA

9004-3

Weld Specifications for Long Lip Bucket

1. 1/4 In (6 mm) Fillet 2. Fill Corners 3. Fill Groove 4. 3/16 In (5 mm) Fillet

Bur 8-17630

Weld Specifications for Short Lip Bucket

1. 1/4 In (6 mm) Fillet 2. Fill Corners 3. 3/16 In (5 mm) Fillet 4. 1/4 In (6 mm) Fillet 5-1/8 In (130 mm) Long on 9.8 In (250 mm) Center

Issued 3-91

Printed in U.S.A.

9004-4

REPLACEMENT OF CUTTING EDGE FOR CLAM BUCKET 1. If the bucket is not removed from the machine, raise the bucket to a suitable height and use suitable supports to hold the loader frame and bucket in place.

7. Put the cutting edge in place and use C-clamps to hold the cutting edge in place. See the illustration for the correct position of the cutting edge.

2. If equipped with bucket teeth, use carbon arc rod to remove the bucket teeth. 3. Use carbon arc rod or an acetylene cutting torch to remove the welds that hold the cutting edge. Keep distortion to a minimum when removing the cutting edge. 4. When removing the bottom rear weld for the cutting edge DO NOT cut through the floor of the bucket. 5. Cut through each corner of the bucket and cutting edge in the area shown.

B902018J

1. 11 Inches (279 mm) 8. Use E-7018 welding rod and weld the cutting edge to the bucket. 9. When welding the floor of the bucket the top of the cutting edge: 1. Cut Through Corner 6. Use a grinder to remove any welds or extra metal on the bucket that will prevent the new cutting edge from fitting correctly.

a. Start at one end of the bucket and weld toward the center until one welding rod is used. b. Start at the center of the bucket and weld in both directions from center until one welding rod is used. C. Start at the other end of the bucket and weld toward the center until one welding rod is used.

d. Continue to weld the cutting edge to the bucket using this method until welding is complete. 10. If bucket teeth were removed from the old cutting edge. install the bucket teeth according to instructions in this section.

Bur 8-17630

Issued 3-91

Printed in U.S.A.

9004-5

Weld Specifications for Clam Bucket

1. 1/4 Inch (6 mm) Fillet 2. Fill Corner 3. Fill Groove

Bur 8-17630

Issued 3-91

Printed in U.S.A.

9004-6

REPLACEMENT OF TOOTH SHANK 1. Use carbon arc rod or an acetylene cutting torch to remove the welds that hold the tooth shank in place.

4. See the following illustration for weld specifications and instructions.

2. Use a grinder to remove any welds or extra material that will prevent the tooth shank from fitting correctly. 3. See the following illustration for the correct location of the tooth shank on the cutting edge. 1 __

2_

B861656J

1. Short Up Bucket - 15-1/8 In (384 mm) Long Up Bucket - 8-1/4 In (208 mm) 2. Short Up Bucket - 14-9/16 In (370 mm) Long Up Bucket - 8 In (203 mm) 3. Put Tooth Shank as Close to Corner as Possible and Keep Corner of the Tooth Point Even With Outer Surface of Cutting Edge

B902019J

1. 3/8 Inch (10 mm) Fillet. Weld Around Each Corner 3/8 Inch (10 mm). Weld Two Times 2. 2-1/2 Inches (63 mm) 3. 3/8 Inch (10 mm) Fillet. Weld Both Sides and Rear of Tooth Shank Weld Two Times 4. 3/8 In (10 mm) Fillet. Two Times 5. Bent Area of Tooth Point

REPLACEMENT OF TOOTH POINT 1. Heat the part of the tooth point that has been pressed into the hole on each side of the tooth shank.

5. Heat the part of the tooth point that will be pressed into the hole on each side of the tooth shank.

2. Bend the tooth point out of the dent on each side of the tooth shank.

6. Have another person hold the tooth point against the tooth shank.

3. Use a pair of pliers to remove the tooth point from the tooth shank.

7. Use an suitable tool and drive the heated part of the tooth point into the dent on each side of the tooth shank.

4.

Install a new tooth point on the tooth shank.

Bur 8-17630

Issued 3-91

Printed in U.S.A.

9004-7

REMOVING THE LOADER FRAME 1. Raise the loader frame until the pivot pins for the piston rod eye ot the lift cylinders are above the hood. Stop the engine.

13. Remove the tie straps that fasten the wiring harness to the tubes on the loader frame. Put the wiring harness out of the way.

2. Fasten suitable lifting equipment to the loader frame to hold the loader frame in place.

14. Remove the cotter pin and flat washer that fasten 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. 4. Use suitable drivers and drive the pivot pins out of the loader frame. DO NOT remove the drivers now. 5. Disconnect the lifting equipment and lower the bucket to the floor. 6. Hold the right lift cylinder and remove the driver and lower the lift cylinder onto the front axle. 7. Hold the left lift cylinder and remove the driver and lower the lift cylinder onto the front axle. Flat washers are used between the strut and the loader frame; be careful not to lose the flat washers. It is not necessary to remove the strut. 8. Move the loader control lever to the right or left to relieve any pressure in the bucket circuit. 9. Disconnect the tubes to the bucket cylinders from the hoses on the right side of the loader frame. Fasten an identification tag to one of the hoses.

15. Remove the actuator rod. Be careful not to lose the spring or other flat washer. 16. If equipped with a clam bucket, move the clam control lever in either direction to relieve any pressure in the clam circuit. 17. Disconnect the tubes to the clam cylinders from the hoses on the left side of the machine. Fasten an identification tag to one hose. 18. Install a cap on each hose and a plug in each tube. 19. Remove the snap ring and flat washer from the right end of the pivot shaft. 20. Fasten suitable lifting equipment to the loader frame to hold the loader frame in place. 21. Use a suitable driver and drive the pivot shaft out of the loader frame.

10. Install a cap on each hose and a cap on each tube.

22. Belleville springs are used between the loader frame and the machine. Raise the loader frame and remove the Belleville springs.

11. Disconnect the wiring from the switch for returnto-dig.

23. Raise the loader frame until the loader frame is free of the machine.

12. Loosen and remove the bolt, flat washer and nut that holds the clamp for the wiring harness.

24. Carefully frame.

Bur 8-17630

move the machine

out of the loader

Issued 3-91

Printed in U.S.A.

9004-8

INSTALLATION OF LOADER FRAME 1.

Carefully move the machine into the loader frame.

2. Lower the loader frame into alignment frame.

with the

3. Install the Belleville springs between the frame and loader arm as shown.

1. BELLEVILLE SPRING. THIS SIDE TOWARD MACHINE

14. Connect the tubes to the bucket cylinders to the hoses on the right side of the machine. 15. Move the loader control lever to

FLOAT.

16. Remove the snap ring and flat washer from both pivot pins for the piston rod eyes of the lift cylinders. Then install the large snap ring on each pivot pin. 17. Start the pivot pin tor tne left piston rod eye into the loader frame and install the flat washer used between the strut and loader frame. 18. Start the pivot pin into the strut. 19. Align the piston rod with the strut and start the pivot pin into the piston rod eye.

B891353J

20. Drive the pivot pin into the piston rod eye.

4. Align the loader frame and Belleville springs with the frame.

21. Install the other flat washer between the strut and loader frame and drive the pivot pin all the way into the loader frame.

5. Start the pivot shaft into the loader frame from the left side of the machine.

22. Install the flat washer and snap ring on the pivot pin.

6. Drive the pivot shaft all the way into the loader frame.

23. Start the pivot pin for the other lift cylinder into the loader frame.

7.

24. Align the piston rod eye with the loader frame and drive the pivot pin all the way into the loader frame.

Install the flat washer and snap ring.

8. If equipped with a clam bucket, connect the hoses to the tubes on the left side of the machine. 9. Install the actuator rod and spring in the actuator tube for the antirollback mechanism. 10. Engage the actuator rod with the bellcrank and install the flat washer and cotter pin. 11. Connect the wiring harness to the switch for returnto-dig.

25. Install the flat washer and snap ring on the pivot pin. 26. Lubricate the pivot pins for the piston rod eyes of the lift cylinders and the pivot shaft. 27. With the engine running at low idle, extend and retract the bucket cylinders and clam cylinders, if equipped, three times to remove any air from the circuits.

12. Install the nut, bolt and flat washer that hold the clamp for the wiring harness for the switch. 13. Install tie straps to hold the wiring harness in place.

Bur 8-17630

Issued 3-91

Printed in U.S.A.

9004-9

Loader

Bur 8-17630

Frame

Issued 3-91

Printed in U.S.A.

9004-10

B902720J

Lift Cylinder Hydraulic Installation

Bur 8-17630

Issued 3-91

Printed in U.S.A.

9004-11

B902721J

Bur 8-17630

Bucket Cylinder Hydraulic Installation

Issued 3-91

Printed in U.S.A.

9004-12

B902719J

Antirollback Linkage

Bur 8-17630

Issued 3-91

Printed in U.S.A

9004-13

I· der Circuit Clam CYln

Bur 8-17630

Issued 3-91

Printed in U.S.A.

9004-~4

?rlllteO

_17630 Sur 8

. III

U.S.p..·

7. Tighten to 720 to 770 Pound-Feet (762 to 230 Nm)

Bur 8-17630

Issued 3-91

Printed in U.SA

9004-16

8861864J

1. Tighten to 360 to 439 Pound-Feet (488 to 596 Nm) NOTE: The weight of each counterweight is 1425 pounds (646 kg). Use acceptable lifting equipment to remove and install the countefINeights.

Bur 8-17630

Issued 3-91

Printed in U.S.A.

Section 9005 ROPS CAB AND ROPS CANOPY

CASE CORPORATION Bur 8-17470

Printed in U.S.A. Issued January 1991 .

9005-2

TABLE OF CONTENTS SPECIAL TOOL

.

TORQUE SPECiFiCATIONS

.

2

_

3

POSSIBLE DAMAGE TO THE ROPS CAB OR ROPS CANOPY

3

MAINTENANCE AND INSPECTION OF THE ROPS CAB OR ROPS CANOPY

3

IllUSTRATION

OF ROPS CANOPY INSTALLATION

.4

ILLUSTRATION OF SEAT INSTALLATION

5

REMOVAL AND INSTALLATION OF ROPS CAB

6

REMOVAL AND INSTALLATION OF ROPS CANOPY

14

REMOVAL AND INSTALLATION OF HEATER

_

15

REMOVAL AND INSTALLATION OF TEMPERATURE CONTROL

17

SPECIAL TOOL The tool shown is needed to remove the steering wheel. Make the tool in your shop. Shown in use in step 5.

6

7

4 8902174J

Make from 1/4 in (3 mm) Cold Rolled Steel 1. 2 In (50 mm) 2. 1 In (25 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 Np. 4 Drill for 1/4 - 24 Threads Metric Thread Optional Two 10-32 x 1 In Required

Bur 8-17470

Issued 1-91

Printed in U.S.A.

9005-3

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)

Nut tor steering wheel

384 to 444 pound-inches

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)

(43 to 50 Nm)

Seat and seat belt torques

See page 5

POSSIBLE DAMAGE TO THE ROPS CAB OR RaPS CANOPY If the machine has rolled over or the ROPS cab or ROPS canopy has been in some type of accident (such as hitting an overhead object during transport), you must replace the ROPS cab or ROPS canopy to get as much protection as you had originally.

After an accident, check for damage to the ROPS cab or ROPS canopy, the operators seat, the seat belt, and all accessories, wiring etc., in the ROPS cab or ROPS canopy. Before operating the machine again, all damaged parts must be replaced. Do not weld or try to straighten a ROPS cab or ROPS canopy.

MAINTENANCE AND INSPECTION OF THE RaPS CAB OR ROPS CANOPY After every 500 hours of operation or every six months, whichever comes first. do the following: See illustration on page 4. Check the torque on the ROPS cab or ROPS canopy mounting bolts. If necessary, tighten the cap screws and nuts to the correct torque. See illustration on page 5. Check the operators seat and the mounting parts for the seat belt. Make sure that all nuts and cap screws are tight. Replace parts that are worn or damaged.

Bur 8-17470

Issued 1-91

Printed in U.S.A.

9005-4

sur 8_17470

9005-5

@

,

B870363R

Bur 8-17470

Issued 1-91

Printed in U.S.A.

9005-6

REMOVAL AND INSTALLATION OF ROPS CAB STEP 1

If the machine has air conditioning. discharge the air conditioning system according to instructions in Section 9003.

STEP 5

NOTE: After installation, charge the air conditioning system according to instructions in Section 9003.

STEP 2

Turn the temperature control to HOT and drain two U.S. gallons (8 litres) of coolant from the radiator.

NOTE: After installation, return the coolant to the radiator.

STEP 3

Use the puller shown on page 2 to loosen and remove the steering wheel.

STEP 6

Remove the button.

STEP 4

Remove the three screws that hold the rear cover for the steering column.

STEP 7

Remove the nut.

NOTE: After installation, tighten the nut to 384 to 444 pound-inches (43 to 50 Nm).

~

Remove the front and rear covers.

Bur 8·17470

Issued 1-91

Printed in U.S.A.

9005-7

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

Remove the screws that hold the control console.

STEP 10

Remove the cap screws that hold the front of the ROPS cab.

STEP 13

Remove the control console. Remove the cap screws that hold the seat and remove the seat.

Bur 8-17470

Issued 1-91

Printed in U.S.A.

9005-8

STEP 14

STEP 17

Remove the self-locking nut and shoulder bolt that holds the cable for the left door.

Begin at the top and remove the vertical cover.

STEP 15

Remove the self-locking nut that holds rod for the door cylinder.

STEP 16

STEP 18

Remove the screws and the bottom cover.

STEP 19

Remove the screws that hold the guard for the instrument console and remove the guard.

STEP 20

Remove the two screws at the bottom of the vertical cover.

Bur 8-17470

Remove the screws that hold the instrument cluster.

Issued 1-91

Printed in U.S.A.

9005-9

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

Disconnect the wiring harness.

STEP 23

Remove the nut that holds the key switch. Remove the key switch from the panel.

Bur 8-17470

STEP 25

Remove the knobs.

STEP 26

Remove the screws that hold the cover.

Issued 1-91

Printed in U.S.A

9005-10

STEP 27

STEP 30

Disconnect the wiring from the cab lamp switch and lamp for air conditioning.

Disconnect the wiring from the switches.

STEP 28

NOTE: Top, five wire plug; bottom front, four wire plug; bottom rear, three wire plug. STEP 31

Remove the nut that holds the air conditioning control

STEP 29 STEP 32

Remove the screws that hold the switch panel. Remove the bottom vertical cover.

Bur 8-17470

Issued 1-91

Printed in U.S.A.

9005-11

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 instrument console.

Loosen the set screw that holds the handle.

STEP 35

Drive the knob off the lever.

Bur 8-17470

STEP 38

Slide the boot through the opening.

Issued 1-91

Printed in U.S.A.

9005-12

STEP 39

STEP 42

Remove the instrument console.

Disconnect the wiring harnesses.

STEP 40

STEP 43

Remove the cap screws that hold the support. There is a cap screw at the top of the support.

Remove the clevis and cotter pins that hold the shift 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.

Bur 8-17470

Issued 1-91

Printed in U.S.A.

9005-13

STEP 45

STEP 48

.~ ~~~

Disconnect the heater hoses and air conditioning hoses, if equipped. Install caps and plugs on the air conditioning hoses and tubes.

Remove the hardware at the side supports.

STEP 46

NOTE: During instal/ation, tighten the cap screws to 600 to 720 pound-feet (813 to 796 Nm).

1. Hardened Washer

STEP 49

Remove the cap screws all around the bottom.

STEP 47

Remove the plugs, cap screws and retainers.

STEP 50

1. Hardened Washer Remove the hardware at the front supports. NOTE: During instal/ation, tighten the nuts to 220 to 264 pound-feet (298 to 358 Nm). Bur 8-17470

Fasten suitable lifting equipment to the roof and carefully remove the ROPS cab.

STEP 51

Install the ROPS cab in the reverse of removal. Issued 1-91

Printed in U.S.A

9005-14

REMOVAL AND INSTALLATION OF ROPS CANOPY 1. Remove the hardware that holds the seat and remove the seat. NOTE: During instal/ation, tighten the cap screws to 80 to 96 pound-feet (109 to 130 Nm).

7. Remove the hardware at the front supports. NOTE: During installation, tighten the nuts to 220 to 264 pound-feet (298 to 358 Nm).

2. Do steps 20 to 25 and steps 35 to 45 under Removal and Installation of ROPS Cab. 3. Disconnect the wiring harness for the lamps. 4. Remove the hardware, reinforcement support for both fenders.

plate and

8. Remove the hardware at the side supports.

B902117J

5. Fasten suitable lifting equipment canopy.

to the ROPS

NOTE: During installation, tighten the cap screws to 600 to 720 pound-feet (813 to 796 Nm). 9. Carefully raise and remove the ROPS canopy. 10. Install the ROPS canopy in the reverse of removal.

6. Loosen and remove the hardware that fastens the floor plate to the front supports.

B902176J

Bur 8-17470

Issued 1-91

Printedin U.S.A

9005-15

REMOVAL AND INSTALLATION OF HEATER 1.Turn the temperature control to HOT and drain one U,S. gallon (4 litres) of coolant from the radiator, NOTE: During installation, return the coolant to the radiator. 2, Remove the knobs from the control panel. 3, Remove the screws that hold the control panel. Disconnect the wires from the switch for the cab lamp and the lamp for air conditioning, 4, Remove the screws at the bottom of the vertical cover and remove the vertical cover beginning at the top, 5, Remove the screws at the bottom of the left vertical cover and remove the left vertical cover beginning at the top, 6. Hold the front headliner in place and remove all screws that hold the front headliner,

8, If equipped with air conditioning, loosen the clamp on each front drain hose and remove the drain hoses from the drain pan, 9, Hold the rear headliner in place and remove all screws that hold the rear headliner. Lower the rear headliner behind the seat. 10, Disconnect the yellow wire from the wiring harness, 11 . Hold the blower assembly in place and remove the five cap screws that hold the blower mount and remove the blower assembly, 12, Loosen the clamps on the hoses at the heater and remove the hoses, 13, Hold the heater in place and remove the cap screws that hold the heater and remove the heater, 14, Install the heater in reverse of removal.

7, Lower the front headliner onto the control console,

Bur 8-17470

Issued 1-91

Printed in U,S.A

9005-76

"

Bur 8-17470

ISsued 1-91 Printed in U.SA

9005-17

REMOVAL AND INSTALLATION OF TEMPERATURE CONTROL

\\

B902178J

1. Temperature Control 1.Turn the temperature control to HOT and drain one U.S. gallon (4 litres) of coolant from the radiator. NOTE: During installation, return the coolant to the radiator. 2. Remove the knobs from the control panel. 3. Remove the screws that hold the control panel. Disconnect the wires from the switch for the cab lamp and the lamp for air conditioning. 4. Remove the screws at the bottom of the vertical cover and remove the vertical cover beginning at the top.

8. Disconnect the wiring from the switches. NOTE: Top, five wire plug; bottom front, four wire plug; bottom rear, three wire plug. 9. Loosen the top clamp and remove the hose from the temperature control. 10. Remove the screws that hold the temperature control. NOTE: During installation, make sure that the two ground wires are installed with the bottom screw.

5. Remove the screws that hold the switch panel.

11. Loosen the bottom clamp and remove the temperature control.

6. Remove the nut that holds the air conditioning control.

NOTE: During installation, make sure that the temperature control is aligned with the control panel.

7. Remove the screws that hold the switch mount.

12. Install the temperature removal.

Bur 8-17470

control in the reverse of

Issued 1-91

Printed in U.S.A.

Section

9006 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"

,

,

,

,

INSTALLATION OF SWING TOWER REMOVAL OF BOOM

,.,

INSTALLATION OF BOOM REMOVAL OF DiPPER

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INSTALLATION OF DIPPER EXTENSiON

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EXPLODED VIEWS Stabilizer Installation .,., , , , '., Stabilizer Cylinder Hydraulic Installation ,.., ,.., , Swing Tower and Swing Cylinder Installation , , , Sequence Valve Linkage .." , " .., , , , Swing Cylinder Hydraulic Installation , , , ', ,.." Boom latch Installation , Boom and Dipper Installation ,., ,., ', Boom Cylinder Hydraulic Installation , , Dipper Cylinder Hydraulic Installation , Quick Coupler and Bucket Installation , , ", , Bucket Cylinder Hydraulic Installation Without Extendable Dipper Extendable Dipper Installation , , " " Extension Cylinder Hydraulic Installation, , , , , , Bucket Cylinder Hydraulic Installation With Extendable Dipper Auxiliary Hydraulic Installation With Extendable Dipper ,

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REPLACING WEAR PLATES FOR DIPPER WITH EXTENDABLE DiPPER.,

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CUTIING EDGES Universal and Heavy Duty Buckets .., High Capacity Buckets " Standard Duty Trenching Buckets

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REMOVAL OF DIPPER EXTENSION,.,

Bur 8-12741

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INSTALLATION OF DIPPER

BUCKET TEETH Replacing a Tooth Point..; , , Replacing a Tooth Shank, ,.,..,,.."

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Issued 3-91

12 , 12

14 15 16 17 18 19 20 21 22 23 24 25 26 .27 28

Printed in U.S,A

9006-3

REMOVAL OF SWING TOWER 1. Remove all dirt from the hose connections backhoe control valve.

at the

2. Start the engine and run the engine at 1000 rpm (r/min).

18. Loosen and remove the cap screws, hardened washers and spacers that hold the pivot pins for the boom. 19 Remove the pivot pins for the boom.

position until

NOTE: Flat washers are installed between the boom and swing tower to center the boom in the swing tower.

4. Extend the dipper and boom as far as possible in the space that is available and lower the bucket to the floor.

20. Carefully move the machine away from the boom.

3. Hold the bucket control lever in the the bucket stops moving.

LOAD

5 Fasten suitable lifting equipment to the boom and dipper pivot area to prevent the boom and dipper from falling when the boom is free of the swing tower. 6. Move the control levers for the backhoe in either direction to relieve any pressure in the circuits. 7. Disconnect the hoses from the backhoe control valve one at a time and fasten an identification tag to each hose. 8. Install a cap on each fitting and a plug in each hose. 9 Loosen and remove the self-locking nuts and flat washers that hold the vertical clamps near the center of the swing tower.

21. Remove the snap ring and flat washer(s) from one end of the pivot pins for the piston rod eyes of the swing cylinders. 22. Use a hammer or hydraulic ram and a suitable driver and remove the pivot pins from the swing tower. 23. Remove a snap ring and flat washer(s) from one end of the pivot pin for the boom latch. 24. Loosen the set screw in the boom latch and drive the pivot pin out of the swing tower and remove the driver. 25. Move the boom latch out of the way

10. Remove the bolts and the clamps.

26. Loosen and remove the self-locking nut and flat washer from the bolt that holds the cam on the top pivot pin for the swing tower.

11. Loosen and remove the self-locking nuts, flat washers, bolts and the horizontal clamp at the rear of the swing tower.

27. Remove the bolt and flat washers used as spacers Record the amount of flat washers used for use during installation.

12. Write a number on each clamp ring so that the hoses will be installed in the correct notch during installation.

28. Remove the snap ring and flat washer from the bottom of the the bottom pivot pin for the swing tower.

13. Fasten suitable lifting equipment to the boom cylinder to hold the boom cylinder while the pivot pin is being removed.

29. Fasten suitable lifting equipment to the swing tower. 30. Use a hammer or hydraulic ram and a suitable driver and remove the bottom pivot pin.

14. Remove the snap ring and flat washer(s) from one end of the pivot pin for the boom cylinder.

31. Remove the snap ring and flat washer that hold the top pivot pin for the swing tower.

15. Drive the pivot pin out of the swing tower and remove the driver.

32 Drive the top pivot pin out of the swing tower.

16. Lower the boom cylinder until the boom cylinder touches the boom and remove the lifting equipment. 17. Use other suitable lifting equipment to hold the boom when the pivot pins for the boom are removed.

Bur 8-12741

33. Remove the swing tower from the frame. 34. Remove the thrust washer from the swing tower or the bottom support for the swing tower.

Issued 3-91

Printed in U.S.A

9006-4

INSTALLATION OF SWING TOWER 1. Installation of the swing tower is the reverse of removal. 2. The bottom pivot pin for the swing tower must be installed so that the grease fitting is on top.

Bur 8-12741

3. Lubricate all pivot pins with molydisulfide grease. 4. With the engine running at 1000 rpm (r/rnin), slowly operate the bucket, dipper, extension, if equipped, and boom cylinders through four complete cycles to remove any air from the circuits.

Issued 3-91

Printed in U.S.A.

9006-5

REMOVAL OF BOOM 1. With the engine running at low idle, hold the bucket control lever in the LOAD position until the bucket stops moving.

17. Remove the snap ring and flat washer from one end of the pivot pin for the piston rod eye of the boom cylinder.

2. Put the boom and dipper in a suitable position for removal of these parts with the bucket on the floor.

18. Drive the pivot pin out of the boom.

3. With the engine stopped, move the dipper control lever in either direction to relieve any pressure in the circuits.

19. Move the boom cylinder toward the machine and use a chain to hold the boom cylinder out of the way. 20. Disconnect the hoses from the dipper cylinder from the tubes inside the boom.

4. Fasten suitable lifting equipment to the dipper cylinder to hold the dipper cylinder for removal of the pivot pin for the piston rod eye.

21 . Install and tighten a plug in each tube and a cap on each hose.

5 Remove the snap ring and flat washer that hold the pivot pin for the piston rod eye of the dipper cylinder.

22. Fasten lifting equipment to the dipper cylinder for removal of the dipper cylinder.

6. Drive the pivot pin out of the dipper and remove the driver.

23. Remove the snap ring and flat washer from one end of the pivot pin for the dipper cylinder.

7. Raise the dipper cylinder for access to the hoses inside the boom

24. Drive the pivot pin out of the boom and remove the driver.

8. Disconnect the hoses from the bucket cylinder at the tubes inside the boom and fasten an identification tag to one hose.

25. Remove the dipper cylinder.

9. Install and tighten a plug in each tube and a cap on each hose. 10. If equipped with an extendable dipper, disconnect the hoses from the extension cylinder and the tubes inside the boom and fasten an identification tag to one hose. 11. Install a plug in each tube and a cap on each hose. 12. Fasten the lifting equipment to the dipper. 13. Loosen and remove the self-locking nut and hardened washer that hold the pivot pin for the dipper.

26. Lower the boom to the floor and use the lifting equipment to hold the boom when the pivot pins for the boom are removed. 27. Disconnect the hoses at the bottom of the boom from the tubes inside the boom one at a time and fasten an identification tag to each hose. 28. Install and tighten a plug in each tube and a cap on each hose. 29. Loosen and remove the cap screw, hardened washer and spacer that hold each pivot pin for the boom. 30. Remove the pivot pins for the boom.

14. Drive the pivot pin out of the dipper and remove the driver.

NOTE: Flat washers are installed between the boom 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.

Bur 8-12741

Issued 3-91

Printed in U.S.A.

9006-6

INSTALLATION 1. Install new seals at all pivot points.

OF BOOM 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. 3. For original or new booms, measure the distance between the ears of the boom at the dipper pivot point and record the measurement. Before installing the selflocking nut, install flat washers on the pivot pin that will pull the ears of the boom together 1/16 to 1/8 inch (1 to 3 mm).

5. Lubricate the pivot pins with molydisulfide

grease.

6. With the engine running at 1000 rpm (r/rnin), slowly operate the bucket, dipper, and extension, if equipped, cylinders through four complete cycles to remove any air from the circuits.

REMOVAL OF DIPPER 1. With the engine running at 1000 rpm (r/rnin) use the backhoe controls as required so that the bucket teeth are just off the floor and below the pivot pin for the bucket. 2. Remove the Klik pin from the pivot pin for the bucket. 3. Remove

the pivot pin for the bucket.

11. Raise the dipper cylinder for access to the hose connections inside the boom. 12. Disconnect the hoses from the bucket cylinder at the tubes inside the boom and fasten an identification tag to one hose. 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. 5. Move the bucket out of the way. 6. Retract the bucket cylinder and put the boom and dipper in a suitable position for removal of the dipper.

14. If equipped with an extendable dipper, disconnect the hoses from the extension cylinder at the tubes inside the boom and fasten an identification tag to one hose. 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 both directions to relieve any pressure in the circuits.

16. Fasten the lifting equipment to the dipper to hold and remove the dipper.

8. Fasten cylinder.

17. Loosen and remove the self-locking nut and hardened washer(s) from the pivot pin for the dipper.

suitable

lifting equipment

to the dipper

9. Remove a snap ring and flat washer from one end of the pivot pin for the piston rod eye of the dipper cylinder.

18. Drive the pivot pin out of the dipper. 19. Remove the dipper.

10. Drive the pivot pin out of the dipper.

Bur 8-12741

Issued 3-91

Printed in U.S.A.

9006-7

INSTALLATION OF DIPPER 1. Install new seals in the bores for the pivot pin for the dipper.

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

3. Before installing the dipper, measure the distance between the ears of the boom at the dipper pivot and record the measurement. Before installing the selflocking nut, install flat washers on the pivot pin so that the ears of the boom will be pulled together 1/16 to 1/8 inch (1 to 3 mm) when the self-locking nut is tightened.

6. With the engine running at 1000 rpm (r/min), slowly operate the bucket cylinder and the extension cylinder, if equipped, through four complete cycles to remove any air from the circuits.

grease.

REMOVAL OF DIPPER EXTENSION 1. With the engine running at 1000 rpm (rim in) use the backhoe controls as required so that the bucket teeth are just off the floor and below the pivot pin for the bucket. 2. Remove the Klik pin from the pivot pin for the bucket. 3. Remove the pivot pin for the bucket.

10. Drive the pivot pin out of the guide links. 11. Slowly remove the driver and lower a guide link and then the coupler and the other guide link. 12. Remove the snap ring and flat washer from each end of the pivot pin for the guide links and the piston rod eye of the extension cylinder.

4. Use the boom,

dipper and bucket controls as required to disengage the coupler from the bucket.

13. Remove the guide link and flat washer from each 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 feet (1 m) above the floor. 7. Completely retract the bucket cylinder and stop the engine. 8. Put a block under the bucket cylinder to hold the bucket cylinder when the pivot pin for the piston rod eye is removed. 9. Remove a snap ring and flat washer from one end of the pivot pin for the piston rod eye of the bucket cylinder.

Bur 8-12741

NOTE: The weight of the dipper extension and the coupler is approximately 395 pounds (179 kg). The length of the dipper extension is approximately 5-112 feet (1.7 my. 15. Fasten suitable lifting equipment to the dipper extension approximately two feet (0.6 m) from the bucket end of the dipper extension to hold and remove the dipper extension. 16. Install a bar through the hole for the pivot pin for the bucket and loosen the lifting equipment and pull the dipper extension off the dipper. Repeat this step until the dipper extension is free of the dipper. Be careful because the dipper extension can be out of balance on the lifting equipment.

Issued 3-91

Printed in U.S.A.

9006-8

INSTALLATION OF DIPPER EXTENSION 1. Installation is the reverse of removal.

3. Lubricate the pivot pins with molydisulfide grease.

2. After the dipper extension has been pushed onto the dipper, use the transport lock pin to hold the dipper extension in place.

REPLACING THE WEAR PLATES FOR DIPPER WITH EXTENDABLE DIPPER 1. Remove the dipper extension according to instructions in this section. 2. Loosen and remove the cap screws, flat washers, side wear plates only, retainers, wear plate(s) and shim(s). 3. Remove the grease from the sides and bottom of the dipper. 4. Select shims for the bottom wear plate so that the bottom wear plate will be even with or up to 0.030 inch (0.8 mm) beyond rails on the dipper. 5. Install the shim(s), wear plates, retainers and cap screws. Tighten the cap screws to 480 to 540 poundinches (54 to 61 Nm). 6. Select shim(s) for the top wear plate so that the distance from the bottom of the bottom wear plate and the top of the top wear plate is 9-3/16 inch (233 mm).

Bur 8-12741

7. Install the shim(s), wear plates, retainers and cap screws. Tighten the cap screws to 480 to 540 poundinches (54 to 61 Nm). 8. Select shim(s) for the side wear plates so that the side wear plates will be even with or or up to 0.030 inch (0.8 mm) beyond the rails on the dipper. 9. Install the shim(s), wear plates, retainers, flat washers and cap screws. Tighten the cap screws to 480 to 540 pound-inches (54 to 61 Nm). 10. Apply dipper.

molydisulfide

grease to the rails on the

11 . Remove the grease from the inside of the dipper extension. 12. Install the dipper extension according to instructions in this section.

Issued 3-91

Printed in U.SA

9006-9

CUTTING EDGES Universal and Heavy Duty Buckets Replacing Bottom Cutting Edge

6. See the following illustration and install the corner bucket teeth and weld the bucket teeth in place. Use E7018 welding rod.

1. Remove the bucket teeth. Use carbon arc rod or an acetylene cutting torch to remove the welds IMPORTANT: When removing the bottom weld at the rear of the bottom cutting edge, DO NO T cut through the bottom of the bucket. 2, Use carbon arc rod or an acetylene cutting torch to remove the welds that hold the bottom cutting edge. 3. Use a grinder and remove any welds still on the bucket and any extra metal so that the new bottom cutting edge will fit the bucket. 4. Hold the new bottom cutting edge in place and make several tack welds to hold the bottom cutting edge. 5. See the following illustration for the weld locations and specifications. DO NOT make any welds on the inside of the bucket except the bottom of the bucket to the bottom cutting edge. Use E7018 welding rod and weld the bottom cutting edge in place. \

B861750R

1. 2. 3. 4.

5.

6.

1/2 Inch (14 mm) 7/8 Inch (20 mm) No Weld No Weld, Top Only First Weld. 7/16 Inch (10 mm) Flare Bevel Weld Second Weld. 7/16 Inch (10 mm) Fillet Weld. Bottom All Around 5/16 Inch (8 mm) Fillet. Weld Two Times 5/16 Inch (8 mm) Fillet. Weld Two Times

7. Weld the remaining bucket teeth to the bottom cutting edge according to the instructions in this section. B892350J

1. 2. 3. 4. 5. 6.

Universal Bucket - 5 79 Inches (147 mm) Heavy Duty Bucket - 5-15/16 Inches (151 mm) Universal Bucket - 1.73 Inch (44 mm) Heavy Duty Bucket - 1-7/8 Inch (47 mm) 7/16 Inch (10 mm) Fillet Top and Bottom Fill Groove Return Wear Plates and Bottom Cutting Edge 1/4 Inch (6 mm) Fillet All Around. Two Pass 1/4 Inch (6 mm) Weld To Fill Void.

Bur 8-12741

Replacing Side Cutting Edge 1. Use carbon arc rod or an acetylene cutting torch to remove the welds that hold the side cutting edge. 2. Use a grinder and remove any welds still on the bucket and any extra metal so that the new side cutting edge will fit the bucket. 3. Use E7018 welding rod and weld the side cutting edge to the bucket with a 1/4 inch (6 mm) fillet all around the side cutting edge.

Issued 3-91

Printed in U.S ,A.

9006-10

High Capacity Buckets

8. Fill the corners cut through during removal.

Replacing Bottom Cutting Edge

Replacing Side Cutting Edge

1. Remove the bucket teeth. Use carbon arc rod or an acetylene cutting torch to remove the welds.

1. Remove all welds that hold the side cutting edge in place. Use carbon arc rod or an acetylene cutting torch to remove the welds.

2. Remove all welds that hold the bottom cutting edge in place. Use carbon arc rod or an acetylene cutting torch to remove welds. 3. Cut through each corner of the bottom cutting edge and bucket. 4. Remove the cutting edge from the bucket.

2. Remove the side cutting edge from the bucket. 3. Use a grinder to remove any welds still on the bucket and any extra metal so that the new side cutting edge will fit 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 will fit the bucket.

5. Use E7018 welding rod and weld the side cutting 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 Cclamps to hold the bottom cutting edge in place. 7. See the following illustration for weld locations and specifications. Use E7018 welding rod and weld the bottom cutting edge to the bucket.

B902037J

1. 2. 3. 4. 5.

1-7/8 Inch (48 mm) 1/4 Inch (6 mm) Fillet 1/4 Inch (6 mm) Fillet. Weld Two Times Groove Weld. Weld Two Times 1-7/16 Inch (37 mm)

Bur 8-12741

Issued 3-91

Printed in U.SA

9006-11

Standard Duty Trenching Buckets

8. Fill the corners cut through during removal.

Replacing Bottom Cutting Edge

Replacing Side Cutting Edge

1. Remove the bucket teeth. Use carbon arc rod or an acetylene cutting torch to remove the welds.

1. Remove the welds that hold the side cutting edge. Use carbon arc rod or an acetylene cutting torch

IMPORTANT: When removing the bottom weld at the rear of the bottom cutting edge, do not cut through the bottom of the bucket.

2. Remove the side cutting edge.

2. Use carbon arc rod or an acetylene cutting torch to remove the welds that hold the bottom cutting edge. 3. Cut through each corner of the bucket to the rear of the bottom cutting edge. 4. Remove the bottom cutting edge from the bucket. 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.

3. Use a grinder to remove any welds still on the bucket and any extra metal so that the new side cutting edge will fit the bucket. 4. Use C-clamps to hold the side cutting edge on the bucket. 5. Use E7018 welding rod and weld the side cutting edge to the bucket with a 3/16 inch (5 mm) fillet weld all around the side cutting edge.

6. Use C-c1amps to hold the bottom cutting edge on the bucket. 7. See the following illustration for weld locations and specifications. Use E7018 welding rod and weld the bottom cutting edge to the bucket.

1. 2. 3. 4.

1-7/16 Inches (36.5 mm) 3/16 Inch (5 mm) Fillet Fill Groove 1-3/16 Inches (30 mm)

BurB-12741

B902089J

Issued 3-91

Printed in U.S.A.

9006-12

BUCKET TEETH Replacing a Tooth Point 1. Use a hammer and punch to remove the flex pin from the tooth point.

5. Universal and heavy duty buckets only. See the following illustration for the weld specifications for the corner bucket teeth. Use E7018 welding rod and weld 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.

Replacing a Tooth Shank 1. Use carbon arc rod or an acetylene cutting torch to remove the welds that hold the tooth shank. 2. Use a grinder to remove any welds or extra metal that will prevent the new tooth shank from fitting correctly. 3. If a new cutting edge has been installed, see the illustrations on the following page for correct location of the bucket teeth. 4. See the following illustration for weld specifications for all bucket teeth except the corner bucket teeth for the universal and heavy duty buckets. Use E7018 welding rod to weld the tooth shanks in place.

B861750R

1. 11/16 Inch (17 mm) 2. 7/8 Inch (20 mm) No Weld 3. 4. 5.

6.

No Weld, Top Only First Weld. 7/16 Inch (10 mm) Flare Bevel Weld. Second Weld. 7/16 Inch (10 mm) Fillet Weld. Bottom All Around 5/16 Inch (8 mm) Fillet. Weld Two Times 5/16 Inch (8 mm) Fillet. Weld Two Times

B861752R

1. 7/8 Inch (20 mm) No Weld 2. No Weld 3. 5/16 Inch (8 mm) Fillet Both Sides. Weld Two Times

Bur 8-12741

Issued 3-91

Printed in U.S.A.

9006-13

B872455J

1. 2.

3.

4.

Center Tooth 0.50 In (12.7 mm) 18 In (457 mm) Bucket 24 In (610 mm) Bucket 30 In (762 mm) Bucket 36 In (914 mm) Bucket 18 In (457 mm) Bucket 36 In (914 mm) Bucket

5. - 5.18 In (131.5 mm) - 7.13 In (181 mm) - 8.86 In (225.1 mm) - 7.64 In (194 mm) - 10.83 In (275 mm) - 11.57 In (294 mm)

16 In (406 mm) Bucket - 7.0 In (177.9 mm) 24 In (610 mm) Bucket - 10.98 In (279 mm) 30 In (762 mm) Bucket - 14.0 In (355.7 mm) 36 In (914 mm) Bucket - 22.44 In (570 mm) 6. 36 In (914 mm) Bucket - 17.0 In (432 mm) 7. 24 In (610 mm) Bucket - 16.34 In (415 mm) 30 In (762 mm) Bucket - 20.65 In (524.4 mm) 36 In (914 mm) Bucket - 27.83 In (707 mm)

Tooth Location for Standard Duty Trenching Buckets

Tooth Location for High Capacity Buckets

4

1 1. 2.

3.

4.

Centerline Center Tooth 24 In (610 mm) Bucket - 4.3 In (109 mm) 30 In (762 mm) Bucket - 6.8 In (173 mm) Put Tooth Shank as Near Corner as Possible and Keep Tooth Point 0.5 In (12.7 mm) Outside of Cutting Edge

Bur 8-12741

1

B90203BJ

1. 2.

3. 4. 5.

B902038J

Centerline Center Tooth 18 In (457 mm) Bucket - 3.56 In (90 mm) 24 In (610 mm) Bucket - 5.4 In (137 mm) Put Tooth Shank as Near Corner as Possible and Keep Tooth Point 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

Issued 3-91

Printed in USA

9006-14

.......... , .

8902834J

Bur 8-12741

Issued 3-91

Printed in U.S.A.

9006-15

B902704J

Stabilizer Cylinder Hydraulic Installation

Bur 8-12741

Issued 3-91

Printed in U.S.A.

9006-16

e

B902B35J

1. Use Flat Washers As Required For 0.6 To 0.18 Inch (1.5 To 4.5 mm) Clearance Between the Top Pivot Pin and the Boom Latch with the Backhoe in Transport Position.

Bur 8-12741

Issued 3-91

Printed in U.S.A.

9006-17

Bur 8-12741

Issued 3-91

Printed in U.S.A.

9006-18

B902B36J

Bur 8-12741

Issued 3-91

Printed in U.S.A.

9006-19

•

B892343J

1. Tighten to 264 To 305 Pound-Inches (31 to 36 Nm) After Putting Backhoe in Transport Position Three Times

Bur 8-12741

Issued 3-91

Printed in U.S.A.

9006-20

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 Issued 3-91

Printed in U.S.A.

9006-21

Bur 8-12741

Issued 3-91

Printed in U.SA

9006-22

Dipper Cylinder Hydraulic Installation

Bur 8-12741

Issued 3-91

Printed in U.S.A.

9006-23

B902839J

Bur 8-12741

Issued 3-91

Printed in U.S.A

9006-24

\\'.' o

6902958.1

ut

BuCKet cylinder \-IydrauliC Installation Witoo

8dendable Dipper ISsued 3-91

Bur 8_12741

printed in U.S.A

9006-25

1.

Wear Plate

2.

8902713J

Shim

Bur 8-12741

ISSued3-91

Printed in U.S.A.

9006-26

~B I I I

Extension Cylinder Hydraulic . Installation

Bur 8-12741

Issued 3-91

Printed in U.S A

9006-27

Bur 8-12741 Issued 3-91

Printed in U.S.A.

9006-28

B902B40J

1. To Extension Cylinder

Issued 3-91

Bur B-12741

Printed in U.S.A

Section

9008 THREE-POINT HITCH

© 1996 Case Corporation

Bur 8-12761

Printed in U.S.A. Issued March 1991

9008-2

TABLE OF CONTENTS REMOVING THE THREE POINT HITCH

3

INSTALLING THE THREE POINT HITCH

3

EXPLODED VIEWS Three Point Hitch

.4

Cylinder Hydraulic Installation

5

Three Point Hitch Control Valve and Control lever Installation

6

Bur 8-12761

Issued 3-91

Printed in U.S.A

9008-3

REMOVING THE THREE-POINT HITCH 1. The attachment can stay on the three-point hitch. Lower the attachment to the floor. 2. Move the control levers in either direction to relieve any pressure in the circuits. 3. Disconnect all hoses from the three-point hitch control valve one at a time and and fasten an identification tag to each hose. 4. Install caps on the fittings and plugs in the hoses. 5. For machines with a ROPS cab, loosen and remove the nuts, lock washers, flat washers and bolts that hold the top closure panel. 6. Remove the top closure panel. 7. For machines with a ROPS canopy, loosen and remove the nuts, lock washers and bolts that hold the cover and remove the cover. 8. Fasten acceptable lifting equipment to the mounting bracket for the control levers and the three point hitch control valve.

9. Loosen and remove the nuts, lock washers and bolts that hold the mounting bracket and remove the mounting bracket assembly. 10. Raise the rear wheels off the floor and use acceptable supports to hold the machine in place. 11. Loosen and remove the wheel nuts and the wheels. 12. Fasten acceptable lifting equipment to the threepoint hitch to hold the three-point hitch in place when the bolts are removed. 13. Loosen and remove the nuts, hardened washers and bolts that hold the three-point hitch.

IMPORTANT: Before the engine can be started, the inlet and outlet hoses must be connected together. To connect the hoses together, use tube union 218-854. 14. Move the machine away from the three-point hitch.

IMPORTANT: If the three-point hitch is not to be installed again, the rear counterweight or backhoe must be installed before the machine can be used.

INSTALLING THE THREE-POINT HITCH 1. Move the machine into alignment with the three-point hitch.

8. Install the cover or top closure panel and the bolts, flat washers, lock washers and nuts. Tighten the nuts.

2. Install the hardened washers hardened washers and nuts.

and bolts and the

9. Connect the hoses to the three-point hitch control valve.

3. Tighten the nuts to 380 to 455 pound-feet (515 to 615 N m).

10. With the engine running at low idle, operate each 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. 5. Tighten the wheel nuts to 320 to 380 pound-feet (435 to 515 N m).

11. Stop the engine and check for oil leaks. 12. Check the level of the oil in the reservoir and add oil as required

6. Lower the wheels to the floor. 7. Align the mounting bracket assembly with the threepoint hitch and install the bolts, lock washers and nuts. Tighten the nuts.

Bur 8-12761

Issued 3-91

Printed in U.S.A.

9008-4

Bur 8-12761

Issued 3-91

. Printed in U.S.A

9008-5

B902761J

Bur 8-12761

Issued 3-91

Printed in U.S.A.

9008-6

Bur 8-12761

Issued 3-91

Printed in U.S.A.

Section

9009 SEAT AND SEAT BELT

© 1996 Case Corporation

Bur 8-12770

Printed in U.S.A. Issued November 1989

9009-2

TABLE OF CONTENTS ...

STANDARD SEAT INSTALLATION EXPLODED VIEW OF STANDARD SEAT. SUSPENSION SEAT INSTALLATION EXPLODED VIEW OF SEAT SUPPORT ....

Bur 8-12770

..

3 4

. .................. .

Issued 11-89

.

5 6

Printed in USA

9009-3

B891367J

1. 2. 3.

Tighten to 80 to 96 Pound-Feet (109 to 130 Nm) Tighten to 54 to 64 Pound-Feet (73 to 87 Nm) Tighten to 17 to 21 Pound-Feet (23 to 28 Nm) Standard Seat Installation

Bur 8-12770

lssuec 11-89

Printed in USA

9009-4

5. BACK CUSHION

B870238R

Standard Seat

Bur 8·12770

Issued 11·89

Printed in U.S.A.

9009-5

""

2

B891368J

1. 2. 3.

Tighten to 80 to 96 Pound-Feet (109 to 130 Nm) Tighten to 54 to 64 Pound-Feet (73 to 87 Nm) Tighten to 17 to 21 Pound-Feet (23 to 28 Nm) Suspension Seat Installation

Bur 8-12770

Issued 11-89

Printed in U.S.A.

9009-6

2. SWIVEL LEVER

7. HEIGHT ADJUSTER

B

5. SLIDE TUBE BELLOWS

4. SHAFT

B891369J

Seat Support

Bur 8-12770

Issued 11-89

Printed in U.S.A.

Section 9010 SUSPENSION SEAT

CASE CORPORA nON

Bur 8-12781

Printed in U.S.A. Issued January 1991

9010-2

TABLE OF CONTENTS DiSASSEMBLY

3

ASSEMBLY

7

Bur 8-12781

Issued 1-91

Printed in U.S.A.

9010-3

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 knob.

Remove the shaft.

STEP 3

STEP 6

Loosen and remove the cap screws that hold the seat. Use a prybar and remove the cover.

Bur 8-12781

Issued 1-91

Printed in U.S.A.

9010-4

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 absorber and remove the pivot pin.

STEP 9

Remove an E-ring from the pivot pin that holds the shock absorber and remove the pivot pin and the shock absorber.

Bur 8-12781

Remove the springs.

STEP 12

The adjuster rod is threaded into the bottom of the spring seat. Install the punch through the hole in the adjuster rod and turn the adjuster rod out of the spring seat.

Issued 1-91

Printed in USA

9010-5

STEP 13

Remove the spring seat.

STEP 17

STEP 14

Loosen and remove the cap screws that hold the base.

Remove the springs.

STEP 18

STEP 15

Remove the cotter pins and pivot pins that fasten the housing to the base.

STEP 16

Remove the base.

Remove the housing.

Bur 8-12781

Issued 1-91

Printed in U.SA

9010-6

2. SHOCK ABSORBER

4. ADJUSTER SPRING

f

11. COTTER PIN

B870242R

Bur 8-12781

Issued 1-91

Printed in U.S.A.

9010-7

ASSEMBLY STEP 19

STEP 23

Install the base.

Install the springs.

STEP 20

STEP 24

Install the spring seat.

STEP 25

Install and tighten th~ cap screws.

STEP 21

Turn the adjuster rod into the spring seat.

STEP 26

Install the housing

STEP 22

Install the pivot pins and cotter pins that hold the housing. Bur 8-12781

Install the springs. Issued 1-91

Printed in U.S.A.

9010-8

STEP 27

STEP 30

Install and tighten the self-locking nut on the bottom of the adjuster rod.

Install the seat.

STEP 28

STEP 31

Install and tighten the cap screws that hold the seat. Install the shock absorber, pivot pin and E-ring ..

STEP 29

STEP 32

Raise the boot and install the shaft. Align the piston rod eye with the brackets and install the pivot pin and E-ring.

Bur 8·12781

Issued 1-91

Printed in U.S.A.

9010-9

STEP 33

STEP 35

Install the C-c1ip.

Align the knob with the adjuster rod and drive the pin into the knob.

STEP 34

Install the cover.

Bur 8-12781

STEP 36

Fasten the boot to the slide.

Issued 1-91

Printed in U.S.A.

9010-10

2. SEAT BACKREST

3. SEAT CUSHION

r

14. LH COVER

10. BOOT

Bur 8-12781

Issued 1-91

Printed in U.S.A.